Toyota - Camry - Workshop Manual - 2007 - 2007

SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–1 AIRBAG SYSTEM PRECAUTION CAUTION: • The vehicle is equipped with a Supplemental Restraint System (SRS). It consists of a driver airbag, front passenger airbag, driver side knee airbag, side airbag, curtain shield airbag, and front seat belt pretensioner. Failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if a mistake is made in servicing the SRS, it is possible that the SRS may fail to operate when required. Before performing servicing (including removal or installation of parts, inspection or replacement), be sure to read the following items carefully, then follow the correct procedures indicated in the repair manual. • Wait at least 90 seconds after the ignition switch is turned off and the negative (-) terminal cable is disconnected from the battery before starting the operation. (The SRS is equipped with a backup power source, so if work is started within 90 seconds after disconnecting the negative (-) terminal cable from the battery, the SRS may be deployed.) • Do not expose the steering pad, front passenger airbag assembly, driver side knee airbag assembly, center airbag sensor assembly, front airbag sensor, front seat inner belt assembly, seat position airbag sensor, occupant classification ECU, front seat side airbag assembly, side airbag sensor, curtain shield airbag assembly, rear airbag sensor, or front seat outer belt assembly directly to hot air or flames. NOTICE: • Malfunction symptoms of the SRS are difficult to confirm, so DTCs are the most important source of information when troubleshooting. When troubleshooting the SRS, always inspect DTCs before disconnecting the battery. • Even in the case of a minor collision when the SRS does not deploy, the steering pad, front passenger airbag assembly, driver side knee airbag assembly, center airbag sensor assembly, front airbag sensor, front seat inner belt assembly, seat position airbag sensor, occupant classification ECU, front seat side airbag assembly, side airbag sensor, curtain shield airbag assembly, rear airbag sensor, or front seat outer belt assembly should be inspected. • Before repair work, remove the airbag sensor if any kind of shock is likely to occur to the airbag sensor during the operation. • Never use SRS parts from another vehicle. When replacing parts, replace them with new ones. RS RS–2 RS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM • Never disassemble or repair any of the following parts in order to reuse them. If any of these parts have been dropped, or a defect is found (e.g. cracks, dents or any other defects) in any of the housings, brackets or connectors, then replace the part with a new one. (a)Steering Pad (b)Front Passenger Airbag Assembly (c)Driver Side Knee Airbag Assembly (d)Front Seat Side Airbag Assembly (e)Curtain Shield Airbag Assembly (f) Center Airbag Sensor Assembly (g)Front Airbag Sensor (h)Front Seat Inner Belt Assembly (i) Seat Position Airbag Sensor (j) Occupant Classification ECU (k)Side Airbag Sensor (l) Rear Airbag Sensor (m)Front Seat Outer Belt Assembly • Use an volt/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting the electrical circuits. • Information labels are attached near the SRS components. Follow the instructions in the caution. • After work on the SRS is completed, perform the SRS warning light check (See page RS-32). • When the negative (-) terminal cable is disconnected from the battery, the memory will be cleared. Because of this, be sure to make a record of the contents memorized in each system before starting work. When work is finished, adjust each system as it was before. Never attempt to avoid erasing vehicle system memories by using a backup power supply from outside the vehicle. • If the vehicle is equipped with a mobile communication system, refer to the precaution in the INTRODUCTION section. HINT: In the airbag system, the center airbag sensor assembly, front airbag sensor LH and RH, side airbag sensor LH and RH, and rear airbag sensor LH and RH are collectively referred to as the airbag sensors. 1. HANDLING PRECAUTIONS FOR AIRBAG SENSORS (a) Before starting the following operations, wait for at least 90 seconds after disconnecting the negative () terminal cable from the battery: (1) Replacement of the airbag sensors. (2) Adjustment of the front/rear doors of the vehicle equipped with the side airbag and curtain shield airbag (fitting adjustment). (b) When connecting or disconnecting the airbag sensor connectors, ensure that each sensor is installed in the vehicle. (c) Do not use the airbag sensors which have been dropped during the operation or transportation. (d) Do not disassemble the airbag sensors. RS–3 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 2. 3. Expression Ignition Switch off Ignition Switch on (IG) Ignition Switch on (ACC) Engine Start INSPECTION PROCEDURE FOR VEHICLE INVOLVED IN ACCIDENT (a) When the airbag has not deployed, confirm the DTCs by checking the SRS warning light. If there is any malfunction in the SRS airbag system, perform troubleshooting. (b) When any of the airbags have deployed, replace the airbag sensors and check the installation condition. EXPRESSIONS OF IGNITION SWITCH The type of ignition switch used on this model differs according to the specifications of the vehicle. The expressions listed in the table below are used in this section. Switch Type Ignition Switch (position) Engine Switch (condition) LOCK Off ON On (IG) ACC On (ACC) START Start RS RS–4 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 4. SRS CONNECTORS (a) SRS connectors are located as shown in the following illustration. Driver Side: Center Airbag Sensor Assembly Combination Meter Assembly (SRS Warning Light) 1 2 3 4 3 4 13 Driver Side Knee Airbag Assembly (Driver Side Knee Airbag Squib) 14 5 7 Steering Pad (Driver Side Squib) Spiral Cable 8 6 17 16 Front Airbag Sensor LH 15 18 19 Side Airbag Sensor LH 20 RS 21 Rear Airbag Sensor LH 22 Front Seat Side Airbag Assembly LH (Driver Side - Side Squib) 23 24 Curtain Shield Airbag Assembly LH (Driver Side Curtain Shield Squib) 25 26 Front Seat Outer Belt Assembly LH (Driver Side Front Pretensioner Squib) 27 28 Front Seat Inner Belt Assembly LH (Driver Side Seat Belt Buckle Switch) / Seat Position Airbag Sensor 29 30 C123769E01 RS–5 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM Passenger Side: Center Airbag Sensor Assembly 1 2 3 4 3 4 33 31 32 Occupant Classification ECU 34 23 Front Seat Side Airbag Assembly RH (Front Passenger Side - Side Squib) 24 25 Curtain Shield Airbag Assembly RH (Front Passenger Side Curtain Shield Squib) 26 29 Front Seat Outer Belt Assembly RH (Front Passenger Side Front Pretensioner Squib) 30 19 RS Side Airbag Sensor RH 20 21 Rear Airbag Sensor RH 22 11 9 10 Front Passenger Airbag Assembly (Front Passenger Side Squib) 12 17 15 16 Front Airbag Sensor RH 18 35 Clock Assembly (Passenger Airbag ON/OFF Indicator) 36 C123770E01 No. Item Application (1) Terminal Twin-Lock Mechanism Connectors 5, 6, 9, 10, 15, 16, 20, 22, 23, 24, 31, 32 (2) Activation Prevention Mechanism Connectors 2, 4, 5, 10, 11, 13, 23, 25, 27 (3) Half Connection Prevention Mechanism Connectors 5, 6, 9, 16, 20, 22, 24 RS–6 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM No. Item (4) Connector 18 (5) Connector Lock Mechanism (1) Connectors 8, 12, 14, 26, 28 (6) Connector Lock Mechanism (2) Connector 2, 4 (7) Improper Connection Prevention Lock Mechanism Connector 1, 3 Spacer Housing Female Male Z005953E02 RS Application Connector Position Assurance Mechanism (b) All connectors in the SRS, except the seat position airbag sensor connector, are colored yellow to distinguish them from other connectors. These connectors have special functions, and are specially designed for the SRS. All SRS connectors use durable gold-plated terminals, and are placed in the locations shown on the previous page to ensure high reliability. (1) Terminal twin-lock mechanism: All connectors with a terminal twin-lock mechanism have a two-piece component consisting of a housing and a spacer. This design enables the terminal to be locked securely by two locking devices (the retainer and the lance) to prevent terminals from coming out. RS–7 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM (2) Activation prevention mechanism: All connectors with an activation prevention mechanism contain a short spring plate. When these connectors are disconnected, the short spring plate creates a short circuit by automatically connecting the positive (+) and negative (-) terminals of the squib. ●When Connector is Connected ●When Connector is Disconnected Short Spring Plate Short Spring Plate Housing Terminal Contacting Male Terminal Short Spring Plate ON Housing Squib Squib RS Closed Circuit Connectors Short Spring Plate H045309E03 (3) Half connection prevention mechanism: If the connector is not completely connected, the connector is disconnected due to the spring operation so that no continuity exists. Locking Part Stopper Locking Arm Spring Slider Stopper Rebound by Slider (Spring) H040180E07 RS–8 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM (4) Connector position assurance mechanism: Only when the housing lock (white part) is completely engaged, the CPA (yellow part) slides, which completes the connector engagement. Housing Lock (White Part) CPA (Yellow Part) H043306E02 (5) Connector lock mechanism (1): Locking the connector lock button connects the connector securely. Lock Button Claw Groove RS H040181E04 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–9 (6) Connector lock mechanism (2): Both the primary lock with holder lances and the secondary lock with retainer prevent the connectors from becoming disconnected. Holder Lance Retainer Retainer H043918E01 (7) Improper connection prevention lock mechanism: When connecting the holder, the lever is pushed into the end by rotating around the A axis to lock the holder securely. A A Lever H043245E01 RS RS–10 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 5. Lock Button (Yellow part) DISCONNECTION OF CONNECTORS FOR STEERING PAD, FRONT PASSENGER AIRBAG ASSEMBLY (SQUIB SIDE), DRIVER SIDE KNEE AIRBAG ASSEMBLY, CURTAIN SHIELD AIRBAG ASSEMBLY, AND FRONT SEAT OUTER BELT ASSEMBLY HINT: Tape up the screwdriver tip before use. (a) Release the lock button (yellow part) of the connector using a screwdriver. (b) Insert the screwdriver tip between the connector and the base, and then raise the connector. Lock Button (Yellow part) Tape Mark RS C C123672E01 6. CONNECTION OF CONNECTORS FOR STEERING PAD, FRONT PASSENGER AIRBAG ASSEMBLY (SQUIB SIDE), DRIVER SIDE KNEE AIRBAG ASSEMBLY, CURTAIN SHIELD AIRBAG ASSEMBLY, AND FRONT SEAT OUTER BELT ASSEMBLY (a) Connect the connector. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–11 (b) Push down securely on the lock button (yellow part) of the connector. (When locking, a click sound can be heard.) Lock Button (Yellow part) H043151E04 7. DISCONNECTION OF CONNECTOR FOR SPIRAL CABLE (INSTRUMENT PANEL WIRE SIDE) AND FRONT PASSENGER AIRBAG ASSEMBLY (INSTRUMENT PANEL WIRE SIDE) (a) Place a finger on the slider, slide the slider to release the lock, and then disconnect the connector. RS Slider Slider Disconnection is completed H001586E02 RS–12 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 8. CONNECTION OF CONNECTOR FOR SPIRAL CABLE (INSTRUMENT PANEL WIRE SIDE) AND FRONT PASSENGER AIRBAG ASSEMBLY (INSTRUMENT PANEL WIRE SIDE) (a) Connect the connector as shown in the illustration. (When locking, make sure that the slider returns to its original position and a click sound can be heard.) HINT: When connecting, the slider will slide. Be sure not to touch the slider while connecting, as it may result in an insecure fit. Slider Slider Connection is completed H043731E02 9. RS Slider DISCONNECTION OF CONNECTORS FOR FRONT SEAT SIDE AIRBAG ASSEMBLY (a) Place a finger on the slider, slide the slider to release the lock, and then disconnect the connector. Slider Disconnection is completed H001584E03 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–13 10. CONNECTION OF CONNECTORS FOR FRONT SEAT SIDE AIRBAG ASSEMBLY (a) Connect the connector as shown in the illustration. (When locking, make sure that the slider returns to its original position and a click sound can be heard.) HINT: When connecting, the slider will slide. Be sure not to touch the slider while connecting, as it may result in an insecure fit. Slider Slider Connection is completed H043169E02 11. DISCONNECTION OF CONNECTOR FOR CENTER AIRBAG SENSOR ASSEMBLY (a) Pull the lever by pushing part A as shown in the illustration and disconnect the holder (with connectors). A Holder (with connectors) Disconnection is completed H045112E01 HINT: Perform the following procedures when replacing the holder. RS RS–14 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM (b) Remove the holder. (1) Using a screwdriver, unlock the retainer. Retainer H043188E01 (2) Release the fitting lance and remove the holder. RS Lances H043189E01 H043190E01 (c) Install the holder. (1) Install the connectors to the holder. (When locking, a click sound can be heard.) HINT: The retainer is locked when the holder is connected. 12. CONNECTION OF CONNECTOR FOR CENTER AIRBAG SENSOR ASSEMBLY (a) Firmly insert the holder (with connectors) into the center airbag sensor assembly until it cannot be pushed any further. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–15 (b) Push the lever to connect the holder (with connectors). (When locking, a click sound can be heard.) HINT: The holder slides into the center airbag sensor assembly when it is being connected. Be sure not to hold the holder while connecting, as it may result in an insecure fit. Holder (with connectors) Lever Connection is completed H045113E01 13. DISCONNECTION OF CONNECTOR FOR FRONT AIRBAG SENSOR (a) Push down the housing lock (white part) and slide the CPA (yellow part). (At this time, the connector cannot be disconnected yet.) (b) Push down the housing lock (white part) again and disconnect the connector. HINT: Do not push down the A part shown in the illustration when disconnecting. RS RS–16 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM A Housing Lock (White Part) Connector lock is released CPA (Yellow Part) H043302E02 (c) After disconnecting the connector, check that the position of the housing lock (white part) is as shown in the illustration. RS H043303E02 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–17 14. CONNECTION OF CONNECTOR FOR FRONT AIRBAG SENSOR (a) Before connecting the connectors, check that the position of the housing lock (white part) is as shown in the illustration. H043304E01 (b) Be sure to engage the connectors until they are locked. (When locking, make sure that a click sound can be heard.) HINT: When connecting them, the housing lock (white part) slides. Be sure not to hold the housing lock (white part) and A part, as it may result in an insecure fit. A Housing Lock (White Part) CPA (Yellow Part) Connection is completed H043305E02 RS RS–18 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM Outer H002763E02 15. DISCONNECTION OF CONNECTORS FOR SIDE AIRBAG SENSOR AND REAR AIRBAG SENSOR (a) While holding the sides of the outer connector locking sleeve, slide the outer in the direction shown by the arrow. (b) When the connector lock is released, the connectors are disconnected. HINT: Be sure to hold both outer flank sides. Holding the top and bottom will make disconnection difficult. Connector lock is released Disconnection is completed H002764E02 RS 16. CONNECTION OF CONNECTORS FOR SIDE AIRBAG SENSOR AND REAR AIRBAG SENSOR (a) Connect the connector as shown in the illustration (When locking, make sure that the outer returns to its original position and a click sound can be heard). HINT: When connecting, the outer will slide. Be sure not to hold the outer while connecting, as it may result in an insecure fit. Outer Outer Connection is completed H002768E02 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–19 PARTS LOCATION FRONT SEAT SIDE AIRBAG ASSEMBLY LH REAR AIRBAG SENSOR RH REAR AIRBAG SENSOR LH FRONT SEAT SIDE AIRBAG ASSEMBLY RH SIDE AIRBAG SENSOR RH RS SIDE AIRBAG SENSOR LH SEAT POSITION SENSOR FRONT SEAT INNER BELT ASSEMBLY LH OCCUPANT CLASSIFICATION ECU FRONT AIRBAG SENSOR LH FRONT AIRBAG SENSOR RH C123718E02 RS–20 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM COMBINATION METER ASSEMBLY: CLOCK ASSEMBLY: SRS WARNING LIGHT PASSENGER AIRBAG ON/OFF INDICATOR CURTAIN SHIELD AIRBAG ASSEMBLY LH FRONT PASSENGER AIRBAG ASSEMBLY CURTAIN SHIELD AIRBAG ASSEMBLY RH FRONT SEAT OUTER BELT ASSEMBLY RH RS DRIVER SIDE KNEE AIRBAG ASSEMBLY SPIRAL CABLE STEERING PAD CENTER AIRBAG SENSOR ASSEMBLY FRONT SEAT OUTER BELT ASSEMBLY LH C123719E01 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–21 SYSTEM DIAGRAM Front Airbag Sensor LH Front Airbag Sensor RH Side Airbag Sensor LH Side Airbag Sensor RH Rear Airbag Sensor LH Rear Airbag Sensor RH Steering Pad (Driver Side Squib) Front Passenger Airbag Assembly (Front Passenger Side Squib) Driver Side Knee Airbag Assembly (Driver Side Knee Airbag Squib) Front Seat Side Airbag Assembly LH (Driver Side - Side Squib) Front Seat Side Airbag Assembly RH (Front Passenger Side - Side Squib) Curtain Shield Airbag Assembly LH (Driver Side Curtain Shield Squib) RS Seat Position Airbag Sensor Front Seat Inner Belt Assembly LH (Driver Side Seat Belt Buckle Switch LH) Occupant Classification ECU Curtain Shield Airbag Assembly RH (Front Passenger Side Curtain Shield Squib) Front Seat Outer Belt Assembly LH (Driver Side Front Pretensioner Squib) Front Seat Outer Belt Assembly RH (Front Passenger Side Front Pretensioner Squib) Clock Assembly (Passenger Airbag ON/OFF Indicator) : CAN C123736E01 RS–22 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM ECM Main Body ECU Combination Meter Assembly DLC3 : CAN C123737E01 Transmitting ECU (Transmitter) Receiving ECU Center Airbag Sensor Assembly ECM Center Airbag Sensor Assembly Main Body ECU Signals Crash detection signal Driver seat buckle switch signal • RS • Center Airbag Sensor Assembly Combination Meter Assembly • • • Combination Meter Assembly ECM Center Airbag Sensor Assembly Center Airbag Sensor Assembly Communication method SRS warning light ON demand signal SRS warning light blink demand signal Passenger seat occupant detection signal Passenger seat buckle switch signal Diagnosis signal (DTC) • • Vehicle speed signal Meter diagnoses polling signal • • Engine speed signal Accelerator opening angle information Accelerator opening angle signal Shift position signal Test mode signal Stop signal • • • • CAN SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–23 SYSTEM DESCRIPTION 1. 2. GENERAL (a) In conjunction with impact absorbing structure for a front collision, the SRS (Supplemental Restraint System) driver airbag, front passenger airbag, and driver side knee airbag were designed to supplement seat belts in the event of a front collision in order to help reduce shock to the head and chest of the driver and front passenger and knee of the driver. This system is a 3-sensor type airbag system to detect the impact during a front collision using the center airbag sensor assembly and front airbag sensors. It also operates the airbag system and seat belt pretensioner. (b) In order to detect the extent of the collision during the initial stages of the collision in further details, the front airbag sensors have been changed from mechanical type to electrical type deceleration sensors. Accordingly, the deployment of the driver airbag and front passenger airbag is controlled in two stages according to the severity of the impact. (c) In conjunction with impact absorbing structure for a side collision, the side airbag and curtain shield airbag were designed to help reduce shock to the driver, front passenger, and rear outer passengers in the event of a side collision. (d) The curtain shield airbag that helps reduce shock to the front and rear seat occupants with a single curtain shield airbag has been adopted. In conjunction with this system, the side airbag sensors have been installed at the bottom of the center pillars and the rear airbag sensors have been installed at the bottom of the rear pillars. (e) In this system, a front side collision is detected by the side airbag sensor in order to simultaneously deploy the side and curtain shield airbags. A rear side collision is detected by the rear airbag sensor and the center airbag sensor assembly in order to deploy the curtain shield airbag. (f) The center airbag sensor assembly sends the airbag deployment signal to the ECM through CAN (Controller Area Network) to operate the fuel pump control. CONSTRUCTION AND OPERATION (a) FRONT AIRBAG SENSOR (1) The front airbag sensors are installed on the right and left radiator supports respectively. (2) The front airbag sensor consists of the deceleration sensor. RS RS–24 RS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM (3) The deceleration sensor is built into the front airbag sensor, and the distortion that is created in the sensor is converted into an electric signal based on the vehicle deceleration rate during a frontal collision. Accordingly, the extent of the initial collision can be detected in detail. (b) SIDE AIRBAG SENSOR (1) The side airbag sensors are installed on the bottom of the right and left center pillars respectively. (2) The side airbag sensor consists of the deceleration sensor and ignition control circuit. (3) The deceleration sensor is built into the side airbag sensor, and the distortion that is created in the sensor is converted into an electric signal based on the vehicle deceleration rate during a front side collision. Accordingly, the extent of the initial collision can be detected in detail. (c) REAR AIRBAG SENSOR (1) The rear airbag sensors are installed on the right and left rear pillars respectively. (2) The rear airbag sensor consists of the deceleration sensor and ignition control circuit. (3) The deceleration sensor is built into the rear airbag sensor, and the distortion that is created in the sensor is converted into an electric signal based on the vehicle deceleration rate during a rear side collision. Accordingly, the extent of the initial collision can be detected in detail. (d) CENTER AIRBAG SENSOR ASSEMBLY (1) General • The center airbag sensor assembly is installed on the center floor under the instrument panel. • The center airbag sensor assembly consists of the deceleration sensor, safing sensor, electronic safing sensor, ignition control circuit, and diagnostic circuit. • The center airbag sensor assembly receives signals from the deceleration sensor and safing sensor built into the center airbag sensor assembly and front airbag sensor. Then the center airbag sensor assembly determines whether the driver airbag, front passenger airbag, driver side knee airbag, and front seat belt pretensioners should be activated, and diagnoses system malfunctions. • The center airbag sensor assembly causes the front seat side airbag assembly and the curtain shield airbag assembly to deploy when receiving signals from the side airbag sensor. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM (2) (3) (4) (5) (6) RS–25 • The center airbag sensor assembly receives signals from the deceleration sensor and the electronic safing sensor built into the center airbag sensor assembly and the rear airbag sensor, and determines whether the curtain shield airbag should be activated, and diagnoses system malfunctions. • The center airbag sensor assembly sends the airbag deployment signal to the ECM through CAN to operate the fuel pump control. Deceleration sensor and ignition control circuit • The deceleration sensor is built into the center airbag sensor assembly. • The ignition control circuit performs calculations based on the signal output from the deceleration sensors of the center airbag sensor assembly and front airbag sensor. If the calculated values are greater than the specified values, it activates ignition operation. Safing sensor • The safing sensor is built into the center airbag sensor assembly. During a front collision, the sensor turns on and outputs an ON signal to the center airbag sensor assembly if a deceleration rate sent to the safing sensor is greater than the specified value. Electronic safing sensor • The electronic safing sensor is built into the center airbag sensor assembly. During a side collision, the sensor turns on and outputs an ON signal to the center airbag sensor assembly if a deceleration rate sent to the electronic safing sensor is greater than the specified value. Backup power source • The backup power source consists of a power supply capacitor and a DC-DC converter. When the power system does not function during a collision, the power supply capacitor discharges and supplies electric power to the system. The DC-DC converter operates as a boosting transformer when the battery voltage falls below a predetermined level. Diagnostic circuit • This circuit constantly diagnoses system malfunctions. When a malfunction is detected, it turns on the SRS warning light on the combination meter assembly to inform the driver. RS RS–26 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM (7) Memory circuit • When a malfunction is detected in the diagnostic circuit, it is coded and stored in the memory circuit. (e) SRS WARNING LIGHT (1) The SRS warning light is located on the combination meter assembly. It comes on to inform the driver of system trouble when a malfunction is detected in self-diagnosis of the center airbag sensor assembly. Under normal operating conditions when the ignition switch is turned on (IG), it comes on for approximately 6 seconds and then goes off. RS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 3. RS–27 DEPLOYMENT CONDITION When the vehicle collides and the shock is greater than the specified value, the SRS is activated automatically. The center airbag sensor assembly includes the safing sensor and deceleration sensor. The safing sensor is designed to turn on at a smaller deceleration rate than the deceleration sensor. (a) The center airbag sensor assembly determines whether ignition is necessary based on signals from the deceleration sensor and the front airbag sensor (*1). If the safing sensor turns on simultaneously, current flows to the squibs to deploy the SRS as shown in the illustration below. Center Airbag Sensor Assembly Steering Pad Safing Sensor ON Front Passenger Airbag Assembly AND Deceleration Sensor ON Driver Side Knee Airbag Assembly Front Seat Outer Belt Assembly Center Airbag Sensor Assembly RS Steering Pad Safing Sensor ON Front Passenger Airbag Assembly AND Driver Side Knee Airbag Assembly Deceleration Sensor ON AND Front Seat Outer Belt Assembly Front Airbag Sensor (*1) C C109526E05 HINT: *1: In case of front collision, the ignition signal could be output with the deceleration sensor ON signal even without a signal from the front airbag sensor. RS–28 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM (b) The center airbag sensor assembly determines whether ignition is necessary based on signals from the side airbag sensor. If the safing sensor turns on simultaneously, current flows to the squib to deploy the SRS as shown in the illustration below. Center Airbag Sensor Assembly Safing Sensor Front Seat Side Airbag Assembly AND Curtain Shield Airbag Assembly Side Airbag Sensor C C109527E12 (c) The center airbag sensor assembly determines whether ignition is necessary based on signals from the rear airbag sensor. If the safing sensor turns on simultaneously, current flows to the squib to deploy the SRS as shown in the illustration below (*1). RS Front Seat Side Airbag Assembly Deployment Safing Sensor OR Center Airbag Sensor Assembly Curtain Shield Airbag Assembly AND Rear Airbag Sensor (*1) C C109528E03 HINT: *1: If the front seat side airbag assembly deploys, the curtain shield airbag assembly will also deploy, regardless of whether the signal is output from the rear airbag sensor. RS–29 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING The intelligent tester can be used in steps 3, 5, 7, 9, and 10. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS (a) Confirm problem symptoms (See page IN-45). NEXT 3 CHECK CAN COMMUNICATION SYSTEM (a) Check for DTC outputs. HINT: The center airbag sensor assembly is connected to the CAN communication system. Therefore, before starting troubleshooting, make sure to check that there is no trouble in the CAN communication system. Result Result Proceed To CAN communication DTC is not output. A CAN communication DTC is output. B B INSPECT CAN COMMUNICATION CIRCUIT A 4 WARNING LIGHT CHECK NEXT 5 CHECK DTC (Present and Past DTCs) (a) Check for DTC outputs. Result Result A DTC is not output. B B A Proceed To DTC is output. PROBLEM SYMPTOMS TABLE RS RS–30 6 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC CHART NEXT 7 CIRCUIT INSPECTION NEXT 8 REPAIR NEXT 9 CLEAR DTC (Present and Past DTCs) NEXT 10 CHECK DTC (Present and Past DTCs) (a) Check for DTC outputs. Result Result RS DTC is not output. A DTC is output. B B A 11 NEXT END CONFIRMATION TEST Proceed To Go to step 6 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–31 PROBLEM SYMPTOMS TABLE HINT: Proceed to the troubleshooting for each circuit in the table below. AIRBAG SYSTEM: Symptom Suspected area See page The SRS warning light goes off after the primary check, but then comes on. SRS Warning Light Remains ON RS-222 With the ignition switch on (IG), the SRS warning light sometimes comes on after approximately 6 seconds. SRS Warning Light Remains ON RS-222 The SRS warning light always comes on even when DTC is not output. SRS Warning Light Remains ON RS-222 With the ignition switch on (IG), the SRS warning light does not come on. SRS Warning Light does not Come On RS-228 Although an SRS warning light operates normally, DTC or a normal system code is not displayed. Diagnosis Circuit RS-231 Although terminals TC and CG of DLC3 are not connected, DTC or a normal system code is displayed. Diagnosis Circuit RS-231 RS RS–32 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM TERMINALS OF ECU 1. CENTER AIRBAG SENSOR ASSEMBLY E30 N1 O1 C123353E04 Terminal No. RS Terminal Symbol Destination E30-1 P2+ Front passenger airbag assembly (Front passenger side squib 2nd step) E30-2 P2- Front passenger airbag assembly (Front passenger side squib 2nd step) E30-3 P- Front passenger airbag assembly (Front passenger side squib) E30-4 P+ Front passenger airbag assembly (Front passenger side squib) E30-5 D+ Steering pad (Driver side squib) E30-6 D- Steering pad (Driver side squib) E30-7 D2- Steering pad (Driver side squib 2nd step) E30-8 D2+ Steering pad (Driver side squib 2nd step) E30-9 DK+ Driver side knee airbag assembly (Driver side knee airbag squib) E30-10 DK- Driver side knee airbag assembly (Driver side knee airbag squib) E30-13 CANH E30-16 SIL E30-17 P-AB CAN Communication line DLC3 Clock assembly (Passenger airbag ON/OFF indicator) E30-21 IG2 E30-22 CANL IGN fuse E30-23 PAON E30-25 E1 Ground E30-26 E2 Ground E30-27 -SR Front airbag sensor RH CAN Communication line Clock assembly (Passenger airbag ON/OFF indicator) E30-28 -SL Front airbag sensor LH E30-29 +SR Front airbag sensor RH E30-30 +SL Front airbag sensor LH N1-1 PD- Front seat outer belt assembly LH (Driver side front pretensioner squib) N1-2 PD+ Front seat outer belt assembly LH (Driver side front pretensioner squib) N1-6 ICD- Curtain shield airbag assembly LH (Driver side curtain shield squib) RS–33 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM Terminal No. Terminal Symbol Destination N1-7 ICD+ Curtain shield airbag assembly LH (Driver side curtain shield squib) N1-8 BBD+ Side airbag sensor LH N1-9 SFD+ Front seat side airbag assembly LH (Driver side - side squib) N1-10 SFD- Front seat side airbag assembly LH (Driver side - side squib) N1-11 DBE+ Front seat inner belt assembly LH (Driver side seat belt buckle switch) N1-12 DBE- Front seat inner belt assembly LH (Driver side seat belt buckle switch) N1-13 DSP- Seat position airbag sensor N1-14 DSP+ Seat position airbag sensor N1-15 BBD- Side airbag sensor LH O1-4 PP+ Front seat outer belt assembly RH (Front passenger side front pretensioner squib) O1-5 PP- Front seat outer belt assembly RH (Front passenger side front pretensioner squib) O1-6 SFP- Front seat side airbag assembly RH (Front passenger side - side squib) O1-7 SFP+ Front seat side airbag assembly RH (Front passenger side - side squib) O1-8 BBP+ Side airbag sensor RH O1-9 ICP+ Curtain shield airbag assembly RH (Front passenger side curtain shield squib) O1-10 ICP- Curtain shield airbag assembly RH (Front passenger side curtain shield squib) O1-11 BBP- Side airbag sensor RH O1-12 FSP+ Occupant classification ECU O1-13 FSP- Occupant classification ECU RS DIAGNOSIS SYSTEM 1. CG SG CANH SIL CANL CHECK DLC3 (a) The ECU uses ISO 15765-4 for communication. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. BAT H100769E16 Symbols (Terminal No.) Terminal Description Condition Specified condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 10 to 14 V CANH (6) - CANL (14) CAN bus line Ignition switch off (*) 54 to 69 Ω CANH (6) - BAT (16) HIGH-level CAN bus line Ignition switch off (*) 6 kΩ or higher CANH (6) - CG (4) HIGH-level CAN bus line Ignition switch off (*) 200 Ω or higher CANL (14) - BAT (16) LOW-level CAN bus line Ignition switch off (*) 6 kΩ or higher CANL (14) - CG (4) LOW-level CAN bus line Ignition switch off (*) 200 Ω or higher RS–34 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 2. RS NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches, or the doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: If the display shows a communication error message when connecting the cable of the intelligent tester to the DLC3, turning the ignition switch on (IG) and operating the intelligent tester, there is a problem on the vehicle side or tester side. • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 on the original vehicle. • If communication is still not possible when the tester is connected to another vehicle, the problem is probably in the tester itself. Consult the Service Department listed in the tester's instruction manual. SYMPTOM SIMULATION HINT: The most difficult case in troubleshooting is when no symptoms occur. In such cases, a thorough customer problem analysis must be carried out. Then the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be reproduced. No matter how experienced or skilled a technician may be, if he proceeds to troubleshoot without confirming the problem symptoms, he will likely overlook something important and make a wrong guess at some points in the repair operation. This leads to a standstill in troubleshooting. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM Vibrate Slightly Shake Slightly 3. Vibrate Slightly D025083E05 RS–35 (a) Vibration method: When vibration seems to be the major cause. HINT: Perform the simulation method only during the primary check period (for approximately 6 seconds after the ignition switch is turned on (IG)). (1) Slightly vibrate the part of the sensor considered to be the problem cause with your fingers and check whether the malfunction occurs. HINT: Shaking the relays too strongly may result in open relays. (2) Slightly shake the connector vertically and horizontally. (3) Slightly shake the wire harness vertically and horizontally. The connector joint and fulcrum of the vibration are the major areas to be checked thoroughly. FUNCTION OF SRS WARNING LIGHT (a) Primary check. (1) Turn the ignition switch off. Wait for at least 2 seconds, then turn the ignition switch on (IG). The SRS warning light comes on for approximately 6 seconds and the diagnosis of the airbag system (including the seat belt pretensioners) is performed. HINT: If trouble is detected during the primary check, the SRS warning light remains on even after the primary check period (for approximately 6 seconds) has elapsed. (b) Constant check. (1) After the primary check, the center airbag sensor assembly constantly monitors the airbag system for trouble. HINT: If trouble is detected during the constant check, the center airbag sensor assembly functions as follows: • The SRS warning light comes on. • The SRS warning light goes off, and then comes on. This blinking pattern indicates a source voltage drop. The SRS warning light goes off 10 seconds after the source voltage returns to normal. (c) Review. (1) When the airbag system is normal: The SRS warning light comes on only during the primary check period (for approximately 6 seconds after the ignition switch is turned on (IG)). (2) When the airbag system has trouble: • The SRS warning light remains on even after the primary check period has elapsed. RS RS–36 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM • The SRS warning light goes off after the primary check, but comes on again during the constant check. • The SRS warning light does not come on when turning the ignition switch from off to on (IG). HINT: The center airbag sensor assembly keeps the SRS warning light on if the airbag has been deployed. 4. C093955E02 5. RS Condition SRS WARNING LIGHT CHECK (a) Turn the ignition switch on (IG), and check that the SRS warning light comes on for approximately 6 seconds (primary check). (b) Check that the SRS warning light goes off approximately 6 seconds after the ignition switch is turned on (IG) (constant check). HINT: When any of the following symptoms occur, refer to "Problem Symptoms Table" (See page RS-30). • The SRS warning light comes on occasionally, after the primary check period has elapsed. • The SRS warning light comes on, but a DTC is not output. • The ignition switch is turned from off to on (IG), but the SRS warning light does not come on. FUNCTION OF PASSENGER AIRBAG ON/OFF INDICATOR (a) Initial check (1) Turn the ignition switch on (IG). (2) The passenger airbag ON/OFF indicator comes on for approximately 4 seconds, then goes off for approximately 2 seconds. (3) Approximately 6 seconds after the ignition switch is turned on (IG), the passenger airbag ON/OFF indicator will be ON/OFF depending on the conditions listed below. "ON" indicator "OFF" indicator Vacant OFF OFF Adult is seated. (Above 36 kg (79.37 lb)) ON OFF Child is seated. (Less than 36 kg (79.37 lb)) OFF ON Child restraint system is set. (*) OFF ON Front passenger occupant classification failure OFF ON *: Child restraint system (less than 7 kg (15.43 lb)) and passenger side buckle switch is ON, then 7 to 36 kg (15.43 to 79.37 lb) is set. HINT: • The passenger airbag ON/OFF indicator is based on the timing chart below in order to check the indicator light circuit. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–37 • When the front passenger occupant classification system has trouble, both the SRS warning light and the passenger airbag ON/OFF indicator ("OFF") come on. In this case, check the DTCs in "AIRBAG SYSTEM" first. Then troubleshoot the occupant classification system if DTC B1650/32 is detected, and troubleshoot the passenger airbag ON/OFF indicator if DTC B1660/43 is detected. ON Ignition Switch OFF Passenger Airbag ON/OFF Indicator (”ON”) Passenger Airbag ON/OFF Indicator (”OFF”) 4 sec. 2 sec. 4 sec. 2 sec. ON OFF ON OFF ON/OFF condition depends on the front passenger detection results. RS C123768E01 6. C123721 7. PASSENGER AIRBAG ON/OFF INDICATOR CHECK (a) Turn the ignition switch on (IG). (b) Check that the passenger airbag ON/OFF indicator ("ON" and "OFF") comes on for approximately 4 seconds, then goes off for approximately 2 seconds. HINT: Refer to the table in the previous step regarding the passenger airbag ON/OFF indicator when the ignition switch is turned on (IG) and approximately 6 seconds pass. ACTIVATION PREVENTION MECHANISM (a) FUNCTION OF ACTIVATION PREVENTION MECHANISM (1) An activation prevention mechanism is built into the connector (on the center airbag sensor assembly side) of the airbag system squib circuit to prevent accidental airbag activation. (2) This mechanism closes the circuit when the connector is disconnected by bringing the short spring into contact with the terminals and shutting off external electricity to prevent accidental airbag activation. RS–38 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM (b) RELEASE METHOD OF ACTIVATION PREVENTION MECHANISM (1) To release the activation prevention mechanism, insert a piece of paper with the same thickness as the male terminal (approximately 0.5 mm (0.020 in.)) between the terminals and the short spring to break the connection. (2) Refer to the following illustrations concerning connectors utilizing the activation prevention mechanism and its release method. CAUTION: Never release the activation prevention mechanism on the squib connector even when inspecting with the squib disconnected. NOTICE: • Do not release the activation prevention mechanism unless specially directed by the troubleshooting procedure. • To prevent the terminal and the short spring from being damaged, always use a piece of paper with the same thickness as the male terminal. RS RS–39 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM Driver Side: Center Airbag Sensor Assembly Combination Meter Assembly (SRS Warning Light) 1 2 3 4 3 4 13 Driver Side Knee Airbag Assembly (Driver Side Knee Airbag Squib) 14 5 7 Steering Pad (Driver Side Squib) Spiral Cable 8 6 17 16 Front Airbag Sensor LH 15 18 19 Side Airbag Sensor LH 20 21 Rear Airbag Sensor LH RS 22 Front Seat Side Airbag Assembly LH (Driver Side - Side Squib) 23 24 Curtain Shield Airbag Assembly LH (Driver Side Curtain Shield Squib) 25 26 Front Seat Outer Belt Assembly LH (Driver Side Front Pretensioner Squib) 27 28 Front Seat Inner Belt Assembly LH (Driver Side Seat Belt Buckle Switch) / Seat Position Airbag Sensor 29 30 C123769E01 RS–40 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM Passenger Side: Center Airbag Sensor Assembly 1 2 3 4 3 4 33 31 32 Occupant Classification ECU 34 23 Front Seat Side Airbag Assembly RH (Front Passenger Side - Side Squib) 24 25 Curtain Shield Airbag Assembly RH (Front Passenger Side Curtain Shield Squib) 26 29 Front Seat Outer Belt Assembly RH (Front Passenger Side Front Pretensioner Squib) 30 19 RS Side Airbag Sensor RH 20 21 Rear Airbag Sensor RH 22 11 9 10 Front Passenger Airbag Assembly (Front Passenger Side Squib) 12 17 15 16 Front Airbag Sensor RH 18 35 Clock Assembly (Passenger Airbag ON/OFF Indicator) 36 C123770E01 RS–41 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM Center Airbag Sensor Assembly Connector 2 4 4 Short Spring Short Spring Short Spring After Release Before Release Paper Paper Short Spring Short Spring Connector 5 Before Release After Release Paper Paper Short Spring Connector 10 Short Spring Before Release After Release Paper Connector 23 Paper Short Spring Short Spring Before Release RS Short Spring Paper Short Spring Short Spring After Release Paper Short Spring Short Spring C114854E04 RS–42 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC CHECK / CLEAR 1. CG 1 2 3 4 5 6 7 8 9 10 111213 141516 TC A082779E07 Normal System Code (without Past Trouble Code): 0.25 sec. ON OFF RS 0.25 sec. Normal System Code (with Past Trouble Code): 0.75 sec. ON OFF 0.25 sec. Trouble Code (Example Codes 11 and 31): 0.5 sec. 2.5 sec. 4.0 sec. ON OFF 1.5 sec. DTC 11 0.5 sec. Repeat DTC 31 H013050E17 DTC CHECK (USING SST CHECK WIRE) (a) Check the DTCs (Present trouble code). (1) Turn the ignition switch on (IG), and wait for approximately 60 seconds. (2) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 NOTICE: Connect the terminals to the correct positions to avoid a malfunction. (b) Check the DTCs (Past trouble code). (1) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 NOTICE: Connect the terminals to the correct positions to avoid a malfunction. (2) Turn the ignition switch on (IG), and wait for approximately 60 seconds. (c) Read the DTCs. (1) Read the blinking patterns of the DTCs. As examples, the blinking patterns for the normal system code and trouble codes 11 and 31 are shown in the illustration. • Normal system code indication (without past trouble code) The light blinks twice per second. • Normal system code indication (with past trouble code) When the past trouble code is stored in the center airbag sensor assembly, the light blinks only once per second. • Trouble code indication The first blinks indicates the first DTC. The second blinks occurs after a 1.5-second pause. If there are more than 1 code, there will be a 2.5second pause between each code. After all codes are shown, there will be a 4.0-second pause, and then they will all be repeated. HINT: • If 2 or more malfunctions are found, the indication begins with the smaller numbered code. • If DTCs are indicated without connecting the terminals, proceed to "Diagnosis Circuit" (See page RS-231). SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 2. RS–43 DTC CLEAR (USING SST CHECK WIRE) (a) Clear the DTCs. (1) When the ignition switch is turned off, the DTCs are cleared. HINT: Depending on the DTC, the code may not be cleared by turning off the ignition switch. In this case, proceed to the next procedure. (2) Using SST, connect terminals TC and CG of the DLC3, and then turn the ignition switch on (IG). SST 09843-18040 (3) Disconnect terminal TC of the DLC3 within 3 to 10 seconds after the DTCs are output, and check if the SRS warning light comes on after 3 seconds. (4) Within 2 to 4 seconds after the SRS warning light comes on, connect terminals TC and CG of the DLC3. (5) The SRS warning light should go off within 2 to 4 seconds after connecting terminals TC and CG of the DLC3. Then, disconnect terminal TC within 2 to 4 seconds after the SRS warning light goes off. (6) The SRS warning light comes on again within 2 to 4 seconds after disconnecting terminal TC. Then, reconnect terminals TC and CG within 2 to 4 seconds after the SRS warning light comes on. RS RS–44 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM (7) Check if the SRS warning light goes off within 2 to 4 seconds after connecting terminals TC and CG of the DLC3. Also check if the normal system code is output within 1 second after the SRS warning light goes off. If DTCs are not cleared, repeat this procedure until the codes are cleared. ON (IG) Ignition Switch Off Open DLC3 (TC and CG) Short 0.5 sec. 0.5 sec. 0.25 sec. 0.25 sec. SRS Warning Light (*) ON T1: 0 to ∞ sec. OFF T2: approx. 6 sec. 1.5 sec. T3: 3 to 5 sec. T4: 3 to 10 sec. T1 T2 T3 T4 T5 T6 T5 T6 T5 T6 T5 T7 T5: 2 to 4 sec. RS T6: 1 to 5 sec. T7: within 1 sec. *: The past trouble code in the illustration shows DTC 21 as an example. C C123780E02 3. DLC3 Intelligent Tester C131977E01 DTC CHECK (a) Check the DTCs. (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch on (IG). (3) Check the DTCs by following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. (b) Clear the DTCs. (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch on (IG). (3) Clear the DTCs by following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–45 CHECK MODE PROCEDURE 1. DLC3 Intelligent Tester C131977E01 CHECK MODE (SIGNAL CHECK): DTC CHECK (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Select "SIGNAL CHECK", and proceed with checking using the intelligent tester. NOTICE: Select "SIGNAL CHECK" from the "DTC CHECK" screen displayed on the intelligent tester to clear the output DTCs (both present and past). HINT: • DTCs can be detected more sensitively in check mode than in normal diagnosis mode. • Perform check mode inspection when a malfunction in each squib circuit is suspected even after the normal system code is output through normal diagnosis mode inspection. RS RS–46 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DATA LIST / ACTIVE TEST HINT: By accessing the DATA LIST displayed on the intelligent tester, you can perform such functions as reading the values of switches and sensors without removing any parts. Reading the DATA LIST as the first step in troubleshooting is one method to save labor time. 1. DATA LIST FOR CENTER AIRBAG SENSOR ASSEMBLY (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Turn the tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/ MOBD / SRS AIRBAG / DATA LIST. (e) Check the values by referring to the table below. DLC3 Intelligent Tester C131977E01 Item RS Measurement Item/ Range (Display) Normal Condition Diagnostic Note FORWARD/BKWARD - D SEAT POSITION Driver Seat Position/ FORWARD: Seat position is forward BKWARD: Seat position is backward FAIL: Failure detected PASSENGER CLASS Passenger Classification/ NG: Data is not determined OFF: Vacant CHILD: Child (less than 36 kg (79.37 lb)) is seated AF05: Adult (36 to 54 kg (79.37 to 119.05 lb) is seated AM50: Adult (more than 54 kg (119.05 lb)) is seated FAIL: A failure is detected OFF/CHILD/AF05/AM50 - PASSENGER DETECT Passenger Detection/ NG: Data is not determined NONE: No passenger DETECT: A passenger is seated FAIL: Failure detected NONE/DETECT - D BUCKLE SW Driver Buckle SW/ UNSET: The seat belt is not fastened SET: The seat belt is fastened NG: Data is not determined UNSET/SET - P BUCKLE SW Passenger Buckle SW/ UNSET: The seat belt is not fastened SET: The seat belt is fastened NG: Data is not determined UNSET/SET - RS–47 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM Item Measurement Item/ Range (Display) DISPLAY TYPE Display Type Information/ LR: The display is indicated by LH/RH DP: The display is indicated by Driver/Passenger PAST CODES Number of Past DTC/ Min.: 0, Max.: 255 Normal Condition Diagnostic Note DP - 0 - RS RS–48 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DIAGNOSTIC TROUBLE CODE CHART If a trouble code is displayed during the DTC check, check the circuit listed for the code in the table below (refer to the appropriate page). HINT: • When the SRS warning light remains on and the DTC output is the normal system code, a voltage source drop is likely to occur. This malfunction is not stored in the memory by the center airbag sensor assembly. If the power source voltage returns to normal, the SRS warning light will automatically go off. • When 2 or more codes are indicated, the code with the lower number appears first. • If a code is not listed on the display chart, the center airbag sensor assembly may have failed. • In the case of any malfunction concerning an open circuit, short to ground, or short to B+ due to a squib, other trouble codes may not be detected. In this case, repair the malfunction currently indicated and then perform malfunction diagnosis again. • Mark in the check mode column: *1: DTC is not corresponding to the check mode. *2: DTC is corresponding to the check mode. AIRBAG SYSTEM: DTC No. RS Detection Item Trouble Area Check Mode See page B1000/31 Center Airbag Sensor Assembly Malfunction Center airbag sensor assembly *1 RS-51 B1603/83 Front Satellite Sensor Bus RH Initialization Incomplete 1. Instrument panel wire 2. Engine room main wire 3. Front airbag sensor RH 4. Center airbag sensor assembly *1 RS-52 B1608/84 Front Satellite Sensor Bus LH Initialization Incomplete 1. Instrument panel wire 2. Engine room main wire 3. Front airbag sensor LH 4. Center airbag sensor assembly *1 RS-62 B1610/13 Front Airbag Sensor RH Malfunction 1. Front airbag sensor RH 2. Center airbag sensor assembly *1 RS-72 B1612/83 Lost Communication with Front Airbag Sensor RH 1. Instrument panel wire 2. Engine room main wire 3. Front airbag sensor RH 4. Center airbag sensor assembly *1 RS-52 B1613/83 Front Airbag Sensor RH Initialization Incomplete 1. Instrument panel wire 2. Engine room main wire 3. Front airbag sensor RH 4. Center airbag sensor assembly *1 RS-52 B1615/14 Front Airbag Sensor LH Malfunction 1. Front airbag sensor LH 2. Center airbag sensor assembly *1 RS-74 B1617/84 Lost Communication with Front Airbag Sensor LH 1. Instrument panel wire 2. Engine room main wire 3. Front airbag sensor LH 4. Center airbag sensor assembly *1 RS-62 RS–49 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC No. Detection Item Trouble Area Check Mode See page *1 RS-62 B1618/84 Front Airbag Sensor LH Initialization Incomplete 1. Instrument panel wire 2. Engine room main wire 3. Front airbag sensor LH 4. Center airbag sensor assembly B1620/21 Driver Side - Side Airbag Sensor Malfunction 1. Side airbag sensor LH 2. Center airbag sensor assembly *1 RS-76 B1622/81 Lost Communication with Driver Side - Side Airbag Sensor Assembly 1. Floor wire 2. Side airbag sensor LH 3. Rear airbag sensor LH 4. Center airbag sensor assembly *1 RS-80 B1623/81 Driver Side - Side Airbag Sensor Assembly Initialization Incomplete 1. Floor wire 2. Side airbag sensor LH 3. Rear airbag sensor LH 4. Center airbag sensor assembly *1 RS-80 B1625/22 Front Passenger Side Side Airbag Sensor Malfunction 1. Side airbag sensor RH 2. Center airbag sensor assembly *1 RS-96 B1627/82 Lost Communication with Front Passenger Side Side Airbag Sensor Assembly 1. Floor wire No. 2 2. Side airbag sensor RH 3. Rear airbag sensor RH 4. Center airbag sensor assembly *1 RS-100 B1628/82 Front Passenger Side Side Airbag Sensor Assembly Initialization Incomplete 1. Floor wire No. 2 2. Side airbag sensor RH 3. Rear airbag sensor RH 4. Center airbag sensor assembly *1 RS-100 B1630/23 Driver Side Rear Airbag Sensor Malfunction 1. Rear airbag sensor LH 2. Center airbag sensor assembly *1 RS-116 B1632/81 Lost Communication with Driver Side Rear Airbag Sensor 1. Floor wire 2. Side airbag sensor LH 3. Rear airbag sensor LH 4. Center airbag sensor assembly *1 RS-80 B1633/81 Driver Side Rear Airbag Sensor Initialization Incomplete 1. Floor wire 2. Side airbag sensor LH 3. Rear airbag sensor LH 4. Center airbag sensor assembly *1 RS-80 B1635/24 Front Passenger Side Rear Airbag Sensor Malfunction 1. Rear airbag sensor RH 2. Center airbag sensor assembly *1 RS-120 B1637/82 Lost Communication with Passenger Side Rear Airbag Sensor 1. Floor wire No. 2 2. Side airbag sensor RH 3. Rear airbag sensor RH 4. Center airbag sensor assembly *1 RS-100 B1638/82 Passenger Side Rear Airbag Sensor Initialization Incomplete 1. Floor wire No. 2 2. Side airbag sensor RH 3. Rear airbag sensor RH 4. Center airbag sensor assembly *1 RS-100 B1642/81 Lost Communication with Driver Side Satellite Sensor Bus 1. Floor wire 2. Side airbag sensor LH 3. Rear airbag sensor LH 4. Center airbag sensor assembly *1 RS-80 RS RS–50 DTC No. RS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM Detection Item Trouble Area Check Mode See page *1 RS-80 B1643/81 Driver Side Satellite Sensor Bus Initialization Incomplete 1. Floor wire 2. Side airbag sensor LH 3. Rear airbag sensor LH 4. Center airbag sensor assembly B1647/82 Lost Communication with Front Passenger Side Satellite Sensor Bus 1. Floor wire No. 2 2. Side airbag sensor RH 3. Rear airbag sensor RH 4. Center airbag sensor assembly *1 RS-100 B1648/82 Front Passenger Side Satellite Sensor Bus Initialization Incomplete 1. Floor wire No. 2 2. Side airbag sensor RH 3. Rear airbag sensor RH 4. Center airbag sensor assembly *1 RS-100 B1650/32 Occupant Classification System Malfunction 1. Floor wire No. 2 2. Occupant classification system 3. Front seat wire RH 4. Center airbag sensor assembly *1 RS-124 B1653/35 Seat Position Airbag Sensor Circuit Malfunction 1. Floor wire 2. Seat position airbag sensor 3. Center airbag sensor assembly *1 RS-136 B1655/37 Driver Side Seat Belt Buckle Switch Circuit Malfunction 1. Floor wire 2. Front seat inner belt assembly LH 3. Center airbag sensor assembly *1 RS-142 B1660/43 Passenger Airbag ON / OFF Indicator Circuit Malfunction 1. Instrument panel wire 2. Instrument panel wire No. 2 3. Clock assembly 4. Center airbag sensor assembly *1 RS-148 B1800/51 Short in Driver Side Squib Circuit 1. Instrument panel wire 2. Spiral cable 3. Steering pad 4. Center airbag sensor assembly *2 RS-159 B1801/51 Open in Driver Side Squib Circuit Same as DTC B1800/51 *2 RS-159 B1802/51 Short to GND in Driver Side Squib Circuit Same as DTC B1800/51 *2 RS-159 B1803/51 Short to B+ in Driver Side Squib Circuit Same as DTC B1800/51 *2 RS-159 B1805/52 Short in Front Passenger Side Squib Circuit 1. Instrument panel wire 2. Instrument panel wire assembly 3. Front passenger airbag assembly 4. Center airbag sensor assembly *2 RS-166 B1806/52 Open in Front Passenger Side Squib Circuit Same as DTC B1805/52 *2 RS-166 B1807/52 Short to GND in Front Passenger Side Squib Circuit Same as DTC B1805/52 *2 RS-166 B1808/52 Short to B+ in Front Passenger Side Squib Circuit Same as DTC B1805/52 *2 RS-166 RS–51 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC No. Detection Item Trouble Area Check Mode See page *2 RS-173 B1810/53 Short in Driver Side Squib 2nd Step Circuit 1. Instrument panel wire 2. Spiral cable 3. Steering pad 4. Center airbag sensor assembly B1811/53 Open in Driver Side Squib 2nd Step Circuit Same as DTC B1810/53 *2 RS-173 B1812/53 Short to GND in Driver Side Squib 2nd Step Circuit Same as DTC B1810/53 *2 RS-173 B1813/53 Short to B+ in Driver Side Squib 2nd Step Circuit Same as DTC B1810/53 *2 RS-173 B1815/54 Short in Front Passenger Side Squib 2nd Step Circuit 1. Instrument panel wire 2. Instrument panel wire assembly 3. Front passenger airbag assembly 4. Center airbag sensor assembly *2 RS-180 B1816/54 Open in Front Passenger Side Squib 2nd Step Circuit Same as DTC B1815/54 *2 RS-180 B1817/54 Short to GND in Front Passenger Side Squib 2nd Step Circuit Same as DTC B1815/54 *2 RS-180 B1818/54 Short to B+ in Front Passenger Side Squib 2nd Step Circuit Same as DTC B1815/54 *2 RS-180 B1820/55 Short in Driver Side - Side Squib Circuit 1. Floor wire 2. Front seat side airbag assembly LH 3. Center airbag sensor assembly *2 RS-187 B1821/55 Open in Driver Side - Side Squib Circuit Same as DTC B1820/55 *2 RS-187 B1822/55 Short to GND in Driver Side - Side Squib Circuit Same as DTC B1820/55 *2 RS-187 B1823/55 Short to B+ in Driver Side Side Squib Circuit Same as DTC B1820/55 *2 RS-187 B1825/56 Short in Front Passenger Side - Side Squib Circuit 1. Floor wire No. 2 2. Front seat side airbag assembly RH 3. Center airbag sensor assembly *2 RS-192 B1826/56 Open in Front Passenger Side - Side Squib Circuit Same as DTC B1825/56 *2 RS-192 B1827/56 Short to GND in Front Passenger Side - Side Squib Circuit Same as DTC B1825/56 *2 RS-192 B1828/56 Short to B+ in Front Passenger Side - Side Squib Circuit Same as DTC B1825/56 *2 RS-192 B1830/57 Short in Driver Side Curtain Shield Squib Circuit 1. Floor wire 2. Curtain shield airbag assembly LH 3. Center airbag sensor assembly *2 RS-197 B1831/57 Open in Driver Side Curtain Shield Squib Circuit Same as DTC B1830/57 *2 RS-197 RS RS–52 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC No. Detection Item B1832/57 Short to GND in Driver Side Curtain Shield Squib Circuit B1833/57 Check Mode See page Same as DTC B1830/57 *2 RS-197 Short to B+ in Driver Side Curtain Shield Squib Circuit Same as DTC B1830/57 *2 RS-197 B1835/58 Short in Front Passenger Side Curtain Shield Squib Circuit 1. Floor wire No. 2 2. Curtain shield airbag assembly RH 3. Center airbag sensor assembly *2 RS-202 B1836/58 Open in Front Passenger Side Curtain Shield Squib Circuit Same as DTC B1835/58 *2 RS-202 B1837/58 Short to GND in Front Passenger Side Curtain Shield Squib Circuit Same as DTC B1835/58 *2 RS-202 B1838/58 Short to B+ in Front Passenger Side Curtain Shield Squib Circuit Same as DTC B1835/58 *2 RS-202 B1860/64 Short in Driver Side Knee Airbag Squib Circuit 1. Instrument panel wire 2. Driver side knee airbag assembly 3. Center airbag sensor assembly *2 RS-207 B1861/64 Open in Driver Side Knee Airbag Squib Circuit Same as DTC B1860/64 *2 RS-207 B1862/64 Short to GND in Driver Side Knee Airbag Squib Circuit Same as DTC B1860/64 *2 RS-207 B1863/64 Short to B+ in Driver Side Knee Airbag Squib Circuit Same as DTC B1860/64 *2 RS-207 B1900/73 Short in Driver Side Front Pretensioner Squib Circuit 1. Floor wire 2. Front seat outer belt assembly LH 3. Center airbag sensor assembly *2 RS-212 B1901/73 Open in Driver Side Front Pretensioner Squib Circuit Same as DTC B1900/73 *2 RS-212 B1902/73 Short to GND in Driver Side Front Pretensioner Squib Circuit Same as DTC B1900/73 *2 RS-212 B1903/73 Short to B+ in Driver Side Front Pretensioner Squib Circuit Same as DTC B1900/73 *2 RS-212 B1905/74 Short in Front Passenger Side Front Pretensioner Squib Circuit 1. Floor wire No. 2 2. Front seat outer belt assembly RH 3. Center airbag sensor assembly *2 RS-217 B1906/74 Open in Front Passenger Side Front Pretensioner Squib Circuit Same as DTC B1905/74 *2 RS-217 B1907/74 Short to GND in Front Passenger Side Front Pretensioner Squib Circuit Same as DTC B1905/74 *2 RS-217 B1908/74 Short to B+ in Front Passenger Side Front Pretensioner Squib Circuit Same as DTC B1905/74 *2 RS-217 RS Trouble Area SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC RS–53 B1000/31 Center Airbag Sensor Assembly Malfunction DESCRIPTION The center airbag sensor assembly consists of the airbag sensor, the safing sensor, the drive circuit, the diagnosis circuit, the ignition control, etc. If the center airbag sensor assembly receives signals from the airbag sensor, it determines whether the SRS should be activated. DTC B1000/31 is recorded when a malfunction is detected in the center airbag sensor assembly. DTC No. DTC Detecting Condition B1000/31 Trouble Area Center airbag sensor assembly malfunction Center airbag sensor assembly HINT: When a trouble code is displayed simultaneously with B1000/31, repair the malfunction indicated by this code (except B1000/31) first. INSPECTION PROCEDURE 1 CHECK CENTER AIRBAG SENSOR ASSEMBLY DLC3 CG DTC 31 TC H041086E03 (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (d) Turn the ignition switch on (IG), and wait for at least 60 seconds. (e) Clear the DTCs stored in the memory (See page RS-41). (f) Turn the ignition switch off. (g) Turn the ignition switch on (IG), and wait for at least 60 seconds. (h) Check the DTCs (See page RS-41). OK: DTC B1000/31 is not output. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-441) OK USE SIMULATION METHOD TO CHECK (See page RS-32) RS RS–54 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1603/83 Front Satellite Sensor Bus RH Initialization Incomplete DTC B1612/83 Lost Communication with Front Airbag Sensor RH DTC B1613/83 Front Airbag Sensor RH Initialization Incomplete DESCRIPTION The front airbag sensor RH circuit consists of the center airbag sensor assembly and front airbag sensor RH. The front airbag sensor RH detect impacts to the vehicle and send signals to the center airbag sensor assembly to determine if the airbag should be deployed. DTC B1603/83, B1612/83, or B1613/83 is recorded when a malfunction is detected in the front airbag sensor RH circuit. DTC No. DTC Detecting Condition • B1603/83 B1612/83 B1613/83 RS • • The airbag sensor assembly center receives a line short circuit signal, an open circuit signal, a short circuit to ground signal or a short circuit to B+ signal in the front airbag sensor RH circuit for 2 seconds. Front airbag sensor RH malfunction Center airbag sensor assembly malfunction Trouble Area • • • • Instrument panel wire Engine room main wire Front airbag sensor RH Center airbag sensor assembly SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–55 WIRING DIAGRAM A28 Front Airbag Sensor RH +SR -SR 2 1 Center Airbag Sensor Assembly 2 AE4 29 E30 +SR 1 AE4 27 E30 -SR RS H002750E34 RS–56 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM INSPECTION PROCEDURE 1 CHECK DTC DC Front Airbag Sensor RH Center Airbag Sensor Assembly (a) Turn the ignition switch on (IG), and wait for at least 60 seconds. (b) Turn the ignition switch off. HINT: If a communication error occurs, DTCs for both the LH and RH sides will be stored simultaneously. To identify the malfunctioning area, turn the ignition switch off and then on (IG) again. (c) Turn the ignition switch on (IG), and wait for at least 60 seconds. (d) Check the DTCs (See page RS-41). Result DTC 83 Result DLC3 DTC 84 CG Proceed to DTC B1603, B1613, or 83 is output. A DTC B1618/84 is output. B DTC B1603, B1613, or 83 and B1618/84 are not output. C HINT: • DTCs indicating communication errors will be changed to DTCs indicating errors in initialization by turning the ignition switch off and then on (IG) again. • Codes other than DTC B1603, B1613, or 83 and B1618/84 may be output at this time, but they are not related to this check. TC C123723E01 RS B GO TO DTC B1618/84 C USE SIMULATION METHOD TO CHECK (See page RS-32) A 2 CHECK CONNECTION OF CONNECTORS (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the center airbag sensor assembly and the front airbag sensor RH. OK: The connectors are properly connected. NG OK CONNECT CONNECTORS PROPERLY SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 3 RS–57 CHECK CONNECTORS (a) Disconnect the connectors from the center airbag sensor assembly and front airbag sensor RH. (b) Check that the connectors (on the center airbag sensor assembly side and front airbag sensor RH side) are not damaged. OK: The connectors are not deformed or damaged. NG REPAIR OR REPLACE WIRE HARNESS OK 4 CHECK FRONT AIRBAG SENSOR RH CIRCUIT (OPEN) A F E Front Airbag Sensor RH DC B Center Airbag Sensor Assembly Connector E Connector B -SR +SR 10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11 30 29 28 27 26 25 24 23 22 21 +SR -SR Service Wire C C114792E04 OK Tester Connection Condition Specified Condition A28-2 (+SR) - A28-1 (SR) Always Below 1 Ω NG E30 A28 (a) Using a service wire, connect terminals 29 (+SR) and 27 (-SR) of connector B. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (b) Measure the resistance according to the value(s) in the table below. Standard resistance RS Go to step 9 RS–58 5 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FRONT AIRBAG SENSOR RH CIRCUIT (SHORT) A F E Front Airbag Sensor RH (a) Disconnect the service wire from connector B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance DC B Center Airbag Sensor Assembly Tester Connection Condition Specified Condition A28-2 (+SR) - A28-1 (SR) Always 1 MΩ or higher NG Go to step 10 Connector E A28 -SR +SR C C114791E05 OK RS 6 CHECK FRONT AIRBAG SENSOR RH CIRCUIT (SHORT TO B+) A F E Front Airbag Sensor RH (a) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage DC B Center Airbag Sensor Assembly Tester Connection Condition Specified Condition A28-2 (+SR) - Body ground Ignition switch on (IG) Below 1 V A28-1 (-SR) - Body ground Ignition switch on (IG) Below 1 V Connector E NG A28 -SR C +SR C114791E05 OK Go to step 11 RS–59 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 7 CHECK FRONT AIRBAG SENSOR RH CIRCUIT (SHORT TO GROUND) (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Measure the resistance according to the value(s) in the table below. Standard resistance A F E Front Airbag Sensor RH DC B Center Airbag Sensor Assembly Tester Connection Condition Specified Condition A28-2 (+SR) - Body ground Always 1 MΩ or higher A28-1 (-SR) - Body ground Always 1 MΩ or higher Connector E NG A28 -SR Go to step 12 +SR C C114791E05 OK 8 RS CHECK FRONT AIRBAG SENSOR RH DC Front Airbag Sensor LH Center Airbag Sensor Assembly DTC 83 DLC3 Result DTC 84 CG (a) Connect the connectors to the center airbag sensor assembly. (b) Interchange the front airbag sensor LH with RH and connect the connectors to them. (c) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (d) Turn the ignition switch on (IG), and wait for at least 60 seconds. (e) Clear the DTCs stored in the memory (See page RS-41). (f) Turn the ignition switch off. (g) Turn the ignition switch on (IG), and wait for at least 60 seconds. (h) Check the DTCs (See page RS-41). Result TC C123723E03 Proceed to DTC B1603, B1612, B1613, or 83 is output. A DTC B1608, B1617, B1618, or 84 is output. B DTC B1603, B1612, B1613, or 83 and B1608, B1617, B1618, or 84 are not output. C HINT: Codes other than DTC B1603, B1612, B1613, or 83 and B1608, B1617, B1618, or 84 may be output at this time, but they are not related to this check. RS–60 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM A REPLACE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-441) B REPLACE FRONT AIRBAG SENSOR RH (See page RS-446) C USE SIMULATION METHOD TO CHECK (See page RS-32) 9 CHECK INSTRUMENT PANEL WIRE (OPEN) Engine Room Main Wire Instrument Panel Wire F A E DC B Front Airbag Sensor RH Center Airbag Sensor Assembly Connector C -SR Tester Connection Condition Specified Condition AE4-2 (+SR) - AE4-1 (SR) Always Below 1 Ω Connector B AE4 RS (a) Disconnect the instrument panel wire connector from the engine room main wire. HINT: The service wire has already been inserted into connector B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance +SR NG E30 10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11 30 29 28 27 26 25 24 23 22 21 +SR Service Wire -SR C123715E01 OK REPAIR OR REPLACE ENGINE ROOM MAIN WIRE REPAIR OR REPLACE INSTRUMENT PANEL WIRE SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 10 RS–61 CHECK INSTRUMENT PANEL WIRE (SHORT) Engine Room Main Wire Instrument Panel Wire F A E DC B Front Airbag Sensor RH Center Airbag Sensor Assembly (a) Disconnect the instrument panel wire connector from the engine room main wire. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition AE4-2 (+SR) - AE4-1 (SR) Always 1 MΩ or higher NG Connector C REPAIR OR REPLACE INSTRUMENT PANEL WIRE AE4 -SR +SR C123716E01 OK REPAIR OR REPLACE ENGINE ROOM MAIN WIRE RS RS–62 11 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK INSTRUMENT PANEL WIRE (SHORT TO B+) Engine Room Main Wire Instrument Panel Wire F A E DC B Front Airbag Sensor RH Center Airbag Sensor Assembly Connector C AE4 -SR +SR (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the instrument panel wire connector from the engine room main wire. (d) Connect the negative (-) terminal cable to battery, and wait for at least 2 seconds. (e) Turn the ignition switch on (IG). (f) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition AE4-2 (+SR) - Body ground Ignition switch on (IG) Below 1 V AE4-1 (-SR) - Body ground Ignition switch on (IG) Below 1 V NG C123716E01 OK RS REPAIR OR REPLACE ENGINE ROOM MAIN WIRE REPAIR OR REPLACE INSTRUMENT PANEL WIRE SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 12 RS–63 CHECK INSTRUMENT PANEL WIRE (SHORT TO GROUND) Engine Room Main Wire Instrument Panel Wire F A E DC B Front Airbag Sensor RH Center Airbag Sensor Assembly Connector C (a) Disconnect the instrument panel wire connector from the engine room main wire. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition AE4-2 (+SR) - Body ground Always 1 MΩ or higher AE4-1 (-SR) - Body ground Always 1 MΩ or higher NG AE4 -SR REPAIR OR REPLACE INSTRUMENT PANEL WIRE +SR C123716E01 OK REPAIR OR REPLACE ENGINE ROOM MAIN WIRE RS RS–64 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1608/84 Front Satellite Sensor Bus LH Initialization Incomplete DTC B1617/84 Lost Communication with Front Airbag Sensor LH DTC B1618/84 Front Airbag Sensor LH Initialization Incomplete DESCRIPTION The front airbag sensor LH circuit consists of the center airbag sensor assembly and front airbag sensor LH. The front airbag sensor LH detects impacts to the vehicle and sends signals to the center airbag sensor assembly to determine if the airbag should be deployed. DTC B1608/84, B1617/84, or B1618/84 is recorded when a malfunction is detected in the front airbag sensor RH circuit. DTC No. DTC Detecting Condition • B1608/84 B1617/84 B1618/84 RS • • The center airbag sensor assembly receives a line short circuit signal, an open circuit signal, a short circuit to ground signal or a short circuit to B+ signal in the front airbag sensor LH circuit for 2 seconds. Front airbag sensor LH malfunction Center airbag sensor assembly malfunction Trouble Area • • • • Instrument panel wire Engine room main wire Front airbag sensor LH Center airbag sensor assembly SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–65 WIRING DIAGRAM A13 Front Airbag Sensor LH +SL -SL 2 1 Center Airbag Sensor Assembly 3 AE4 30 E30 +SL 4 AE4 28 E30 -SL RS H002750E35 RS–66 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM INSPECTION PROCEDURE 1 CHECK DTC DC Front Airbag Sensor LH Center Airbag Sensor Assembly (a) Turn the ignition switch on (IG), and wait for at least 60 seconds. (b) Turn the ignition switch off. HINT: If a communication error occurs, DTCs for both the LH and RH sides will be stored simultaneously. To identify the malfunctioning area, turn the ignition switch off and then on (IG) again. (c) Turn the ignition switch on (IG), and wait for at least 60 seconds. (d) Check the DTCs (See page RS-41). Result DTC 83 Result DLC3 DTC 84 CG Proceed to DTC B1608, B1618, or 84 is output. A DTC B1613/83 is output. B DTC B1608, B1618, or 84 and B1613/83 are not output. C HINT: • DTCs indicating communication errors will be changed to DTCs indicating errors in initialization by turning the ignition switch off and then on (IG) again. • Codes other than DTC B1608, B1618, or 84 and B1613/83 may be output at this time, but they are not related to this check. TC C123723E02 RS B GO TO DTC B1613/83 C USE SIMULATION METHOD TO CHECK (See page RS-32) A 2 CHECK CONNECTION OF CONNECTORS (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the center airbag sensor assembly and the front airbag sensor LH. OK: The connectors are properly connected. NG OK CONNECT CONNECTORS PROPERLY SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 3 RS–67 CHECK CONNECTORS (a) Disconnect the connectors from the center airbag sensor assembly and front airbag sensor LH. (b) Check that the connectors (on the center airbag sensor assembly side and front airbag sensor LH side) are not damaged. OK: The connectors are not deformed or damaged. NG REPAIR OR REPLACE WIRE HARNESS OK 4 CHECK FRONT AIRBAG SENSOR LH (OPEN) A F E DC B Front Airbag Sensor LH Center Airbag Sensor Assembly Connector E Connector B Condition Specified Condition Always Below 1 Ω NG +SL 10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11 30 29 28 27 26 25 24 23 22 21 +SL -SL Service Wire C114801E03 OK Tester Connection A13-2 (+SL) - A13-1 (SL) RS E30 A13 -SL (a) Using a service wire, connect terminals 30 (+SL) and 28 (-SL) of connector B. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Go to step 9 RS–68 5 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FRONT AIRBAG SENSOR LH (SHORT) (a) Disconnect the service wire from connector B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance A F E DC Front Airbag Sensor LH B Center Airbag Sensor Assembly Tester Connection Condition Specified Condition A13-2 (+SL) - A13-1 (SL) Always 1 MΩ or higher NG Go to step 10 Connector E A13 -SL +SL C C114791E06 OK RS 6 CHECK FRONT AIRBAG SENSOR LH (SHORT TO B+) (a) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage A F E DC Front Airbag Sensor LH B Center Airbag Sensor Assembly Tester Connection Condition Specified Condition A13-2 (+SL) - Body ground Ignition switch on (IG) Below 1 V A13-1 (-SL) - Body ground Ignition switch on (IG) Below 1 V Connector E NG A13 -SL C +SL C114791E06 OK Go to step 11 RS–69 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 7 CHECK FRONT AIRBAG SENSOR LH (SHORT TO GROUND) (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Measure the resistance according to the value(s) in the table below. Standard resistance A F E DC Front Airbag Sensor LH B Center Airbag Sensor Assembly Tester Connection Condition Specified Condition A13-2 (+SL) - Body ground Always 1 MΩ or higher A13-1 (-SL) - Body ground Always 1 MΩ or higher Connector E NG A13 -SL Go to step 12 +SL C C114791E06 OK 8 RS CHECK FRONT AIRBAG SENSOR LH DC Front Airbag Sensor RH Center Airbag Sensor Assembly DTC 83 DLC3 Result DTC 84 CG (a) Connect the connectors to the center airbag sensor assembly. (b) Interchange the front airbag sensor RH with LH and connect the connectors to them. (c) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (d) Turn the ignition switch on (IG), and wait for at least 60 seconds. (e) Clear the DTCs stored in the memory (See page RS-41). (f) Turn the ignition switch off. (g) Turn the ignition switch on (IG), and wait for at least 60 seconds. (h) Check the DTCs (See page RS-41). Result TC C123723E05 Proceed to DTC B1608, B1617, B1618, or 84 is output. A DTC B1603, B1612, B1613, or 83 is output. B DTC B1603, B1612, B1613, or 83 and B1608, B1617, B1618, or 84 are not output. C HINT: Codes other than DTC B1608, B1617, B1618, or 84 and B1603, B1612, B1613, or 83 may be output at this time, but they are not related to this check. RS–70 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM A REPLACE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-441) B REPLACE FRONT AIRBAG SENSOR LH (See page RS-446) C USE SIMULATION METHOD TO CHECK (See page RS-32) 9 CHECK INSTRUMENT PANEL WIRE (OPEN) Engine Room Main Wire Instrument Panel Wire F A E D C B Front Airbag Sensor LH Center Airbag Sensor Assembly Connector C Connector B AE4 E30 RS (a) Disconnect the instrument panel wire connector from the engine room main wire. HINT: The service wire has already been inserted into connector B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition AE4-3 (+SL) - AE4-4 (SL) Always Below 1 Ω NG 10 9 8 7 6 5 4 3 2 1 +SL -SL 20 19 18 17 16 15 14 13 12 11 30 29 28 27 26 25 24 23 22 21 +SL -SL Service Wire C123717E01 OK REPAIR OR REPLACE ENGINE ROOM MAIN WIRE REPAIR OR REPLACE INSTRUMENT PANEL WIRE SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 10 RS–71 CHECK INSTRUMENT PANEL WIRE (SHORT) Engine Room Main Wire Instrument Panel Wire F A E DC B Front Airbag Sensor LH Center Airbag Sensor Assembly (a) Disconnect the instrument panel wire connector from the engine room main wire. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition AE4-3 (+SL) - AE4-4 (SL) Always 1 MΩ or higher NG Connector C REPAIR OR REPLACE INSTRUMENT PANEL WIRE AE4 +SL -SL C123716E02 OK REPAIR OR REPLACE ENGINE ROOM MAIN WIRE RS RS–72 11 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK INSTRUMENT PANEL WIRE (SHORT TO B+) Engine Room Main Wire Instrument Panel Wire F A E DC B Front Airbag Sensor LH Center Airbag Sensor Assembly Connector C AE4 +SL (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the instrument panel wire connector from the engine room main wire. (d) Connect the negative (-) terminal cable to battery, and wait for at least 2 seconds. (e) Turn the ignition switch on (IG). (f) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition AE4-3 (+SL) - Body ground Ignition switch on (IG) Below 1 V AE4-4 (-SL) - Body ground Ignition switch on (IG) Below 1 V NG -SL C123716E02 OK RS REPAIR OR REPLACE ENGINE ROOM MAIN WIRE REPAIR OR REPLACE INSTRUMENT PANEL WIRE SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 12 RS–73 CHECK INSTRUMENT PANEL WIRE (SHORT TO GROUND) Engine Room Main Wire Instrument Panel Wire F A E DC B Front Airbag Sensor LH Center Airbag Sensor Assembly Connector C (a) Disconnect the instrument panel wire connector from the engine room main wire. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition AE4-3 (+SL) - Body ground Always 1 MΩ or higher AE4-4 (-SL) - Body ground Always 1 MΩ or higher NG AE4 +SL REPAIR OR REPLACE INSTRUMENT PANEL WIRE -SL C123716E02 OK REPAIR OR REPLACE ENGINE ROOM MAIN WIRE RS RS–74 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1610/13 Front Airbag Sensor RH Malfunction DESCRIPTION The front airbag sensor RH consists of the diagnostic circuit, the frontal deceleration sensor, etc. If the center airbag sensor assembly receives signals from the frontal deceleration sensor, it determines whether the SRS should be activated. DTC B1610/13 is recorded when a malfunction is detected in the front airbag sensor RH circuit. DTC No. B1610/13 DTC Detection Condition • • Front airbag sensor RH malfunction Center airbag sensor assembly malfunction Trouble Area • • Front airbag sensor RH Center airbag sensor assembly WIRING DIAGRAM Center Airbag Sensor Assembly A14 Front Airbag Sensor RH +SR 2 RS -SR 1 2 IA1 29 I34 +SR 1 IA1 27 I34 -SR H016901E08 RS–75 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM INSPECTION PROCEDURE 1 CHECK FRONT AIRBAG SENSOR RH DC Front Airbag Sensor LH Center Airbag Sensor Assembly DTC 13 DLC3 (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Interchange the front airbag sensor LH with RH and connect the connectors to them. (d) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (e) Turn the ignition switch on (IG), and wait for at least 60 seconds. (f) Clear the DTCs stored in the memory (See page RS-41). (g) Turn the ignition switch off. (h) Turn the ignition switch on (IG), and wait for at least 60 seconds. (i) Check the DTCs (See page RS-41). Result Result DTC 14 DTC B1610/13 is output. CG C TC Proceed to A DTC B1615/14 is output. B DTC B1610/13 and B1615/14 are not output. C HINT: Codes other than DTC B1610/13 and B1615/14 may be output at this time, but they are not related to this check. C114793E01 A REPLACE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-441) B REPLACE FRONT AIRBAG SENSOR RH (See page RS-446) C USE SIMULATION METHOD TO CHECK (See page RS-32) RS RS–76 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1615/14 Front Airbag Sensor LH Malfunction DESCRIPTION The front airbag sensor LH consists of the diagnostic circuit and the frontal deceleration sensor, etc. If the center airbag sensor assembly receives signals from the frontal deceleration sensor, it determines whether the SRS should be activated. DTC B1615/14 is recorded when a malfunction is detected in the front airbag sensor LH circuit. DTC No. B1615/14 DTC Detection Condition • • Front airbag sensor LH malfunction Center airbag sensor assembly malfunction Trouble Area • • Front airbag sensor LH Center airbag sensor assembly WIRING DIAGRAM Center Airbag Sensor Assembly A1 Front Airbag Sensor LH +SL 2 RS -SL 1 2 IA2 30 I34 +SL 1 IA2 28 I34 -SL H016901E09 RS–77 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM INSPECTION PROCEDURE 1 CHECK FRONT AIRBAG SENSOR LH DC Front Airbag Sensor RH Center Airbag Sensor Assembly DTC 13 DLC3 (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Interchange the front airbag sensor RH with LH and connect the connectors to them. (d) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (e) Turn the ignition switch on (IG), and wait for at least 60 seconds. (f) Clear the DTCs stored in the memory (See page RS-41). (g) Turn the ignition switch off. (h) Turn the ignition switch on (IG), and wait for at least 60 seconds. (i) Check the DTCs (See page RS-41). Result Result DTC 14 DTC B1615/14 is output. CG C TC Proceed to A DTC B1610/13 is output. B DTC B1610/13 and B1615/14 are not output. C HINT: Codes other than DTC B1610/13 and B1615/14 may be output at this time, but they are not related to this check. C114793E02 A REPLACE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-441) B REPLACE FRONT AIRBAG SENSOR LH (See page RS-446) C USE SIMULATION METHOD TO CHECK (See page RS-32) RS RS–78 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1620/21 Driver Side - Side Airbag Sensor Malfunction DESCRIPTION The side airbag sensor LH consists of the safing sensor, the diagnostic circuit, the lateral deceleration sensor, etc. If the center airbag sensor assembly receives signals from the lateral deceleration sensor, it determines whether the SRS should be activated. DTC B1620/21 is recorded when a malfunction is detected in the driver side - side airbag sensor circuit. DTC No. B1620/21 DTC Detection Condition • • Trouble Area Side airbag sensor LH malfunction Center airbag sensor assembly malfunction • • Side airbag sensor LH Center airbag sensor assembly WIRING DIAGRAM N7 Side Airbag Sensor LH Center Airbag Sensor Assembly 8 BBL+ BBL- N1 BBD+ 4 15 N1 BBD- 3 RS N12 Rear Airbag Sensor LH BCL+ BCL- 1 2 2 1 BCL+ BCL- H045218E08 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–79 INSPECTION PROCEDURE 1 CHECK DTC Side Airbag Sensor LH DLC3 Center Airbag Sensor Assembly DTC 21 (a) Turn the ignition switch on (IG), and wait for at least 60 seconds. (b) Clear the DTCs stored in the memory (See page RS-41). (c) Turn the ignition switch off. (d) Turn the ignition switch on (IG), and wait for at least 60 seconds. (e) Check the DTCs (See page RS-41). OK: DTC B1620/21 is not output. HINT: Codes other than DTC B1620/21 may be output at this time, but they are not related to this check. OK CG TC USE SIMULATION METHOD TO CHECK (See page RS-32) C123684E02 NG 2 CONFIRM PART NUMBER OF SIDE AIRBAG SENSOR (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Check that the part number of the side airbag sensor LH is equal to the number of the other side. OK: Those numbers are the same. NG OK Go to step 4 RS RS–80 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 3 CHECK SIDE AIRBAG SENSOR LH Side Airbag Sensor RH Center Airbag Sensor Assembly DTC 21 DLC3 (a) Interchange the side airbag sensor RH with LH and connect the connectors to them. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch on (IG), and wait for at least 60 seconds. (d) Clear the DTCs stored in the memory (See page RS-41). (e) Turn the ignition switch off. (f) Turn the ignition switch on (IG), and wait for at least 60 seconds. (g) Check the DTCs (See page RS-41). Result DTC 22 CG Result TC C123685E02 Proceed to DTC B1620/21 is output. A DTC B1625/22 is output. B DTC B1620/21 and B1625/22 are not output. C HINT: Codes other than DTC B1620/21 and B1625/22 may be output at this time, but they are not related to this check. (h) Turn the ignition switch off. (i) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (j) Return the side airbag sensor RH and LH to their original positions and connect the connectors to them. RS A B Go to step 5 REPLACE SIDE AIRBAG SENSOR LH (See page RS-449) C USE SIMULATION METHOD TO CHECK (See page RS-32) 4 REPLACE SIDE AIRBAG SENSOR LH (a) Replace the side airbag sensor LH (See page RS-449). HINT: Perform inspection using parts from a normal vehicle if possible. NEXT SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 5 RS–81 CHECK CENTER AIRBAG SENSOR ASSEMBLY (a) (b) Side Airbag Sensor LH Center Airbag Sensor Assembly (c) (d) (e) (f) DLC3 CG TC DTC 21 C123684E02 Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch on (IG), and wait for at least 60 seconds. Clear the DTCs stored in the memory (See page RS-41). Turn the ignition switch off. Turn the ignition switch on (IG), and wait for at least 60 seconds. Check the DTCs (See page RS-41). OK: DTC B1620/21 is not output. HINT: Codes other than DTC B1620/21 may be output at this time, but they are not related to this check. NG REPLACE CENTER AIRBAG SENOR ASSEMBLY (See page RS-441) OK USE SIMULATION METHOD TO CHECK (See page RS-32) RS RS–82 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1622/81 Lost Communication with Driver Side - Side Airbag Sensor Assembly DTC B1623/81 Driver Side - Side Airbag Sensor Assembly Initialization Incomplete DTC B1632/81 Lost Communication with Driver Side Rear Airbag Sensor DTC B1633/81 Driver Side Rear Airbag Sensor Initialization Incomplete DTC B1642/81 Lost Communication with Driver Side Satellite Sensor Bus DTC B1643/81 Driver Side Satellite Sensor Bus Initialization Incomplete DESCRIPTION RS The circuit for the side collision sensor LH (to determine deployment of the front seat side airbag assembly LH and curtain shield airbag assembly LH) is composed of the center airbag sensor assembly, side airbag sensor LH, and rear airbag sensor LH. The side airbag sensor LH and rear airbag sensor LH detect impacts to the vehicle and send signals to the center airbag sensor assembly to determine if the airbag should be deployed. DTC B1622/81, B1623/81, B1632/81, B1633/81, B1642/81, or B1643/81 is recorded when a malfunction is detected in the circuit for the side collision sensor LH (to determine deployment of the front seat side airbag assembly LH and curtain shield airbag assembly LH). DTC No. DTC Detecting Condition • 1622/81 1623/81 1632/81 1633/81 1642/81 1643/81 • • • The center airbag sensor assembly receives a line short circuit signal, an open circuit signal, a short circuit to ground signal or a short circuit to B+ signal in the circuit for the side collision sensor LH (to determine deployment of the front seat side airbag assembly LH and curtain shield airbag assembly LH) for 2 seconds. Side airbag sensor LH malfunction Rear airbag sensor LH malfunction Center airbag sensor assembly malfunction Trouble Area • • • • Floor wire Side airbag sensor LH Rear airbag sensor LH Center airbag sensor assembly SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–83 WIRING DIAGRAM N7 Side Airbag Sensor LH BBL+ BBL- Center Airbag Sensor Assembly 8 N1 BBD+ 4 15 N1 BBD- 3 N12 Rear Airbag Sensor LH BCL+ BCL- 1 2 2 1 BCL+ BCL- RS H045218E08 RS–84 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM INSPECTION PROCEDURE 1 CHECK PRESENT DTC Side Airbag Sensor LH Center Airbag Sensor Assembly DTC 81 DLC3 DTC 82 (a) Turn the ignition switch on (IG), and wait for at least 60 seconds. (b) Turn the ignition switch off. HINT: If a communication error occurs, DTCs for both the LH and RH sides will be stored simultaneously. To identify the malfunctioning area, turn the ignition switch off and then on (IG) again. (c) Turn the ignition switch on (IG), and wait for at least 60 seconds. (d) Check the present DTCs (See page RS-41). Result Result CG TC C123724E01 Proceed to Present DTC B1623, B1633, B1643, or 81 is output. A Present DTC B1628, B1638, B1648, or 82 is output. B Present DTC B1623, B1633, B1643, or 81 and B1628, B1638, B1648, or 82 are not output. C HINT: • DTCs indicating communication errors will be changed to DTCs indicating errors in initialization by turning the ignition switch off and then on (IG) again. • Codes other than present DTC B1623, B1633, B1643, or 81 and B1628, B1638, B1648, or 82 may be output at this time, but they are not related to this check. RS B REPAIR CIRCUITS INDICATED BY OUTPUT DTCS C USE SIMULATION METHOD TO CHECK (See page RS-32) A 2 CHECK PAST DTC (a) Check the past DTCs (See page RS-41). Result Result • • Past DTC B1632, B1642, or 81 is output. Past DTC B1622, B1632, B1642, or 81 is not output. Past DTC B1622 is output. Proceed to A B HINT: Codes other than past DTC B1622, B1632, B1642, or 81 may be output at this time, but they are not related to this check. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM B RS–85 Go to step 20 A 3 CHECK CONNECTION OF CONNECTORS (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the center airbag sensor assembly and the side airbag sensor LH. OK: The connectors are properly connected. NG CONNECT CONNECTORS PROPERLY OK 4 CHECK CONNECTORS (a) Disconnect the connectors from the center airbag sensor assembly and side airbag sensor LH. (b) Check that the connectors (on the center airbag sensor assembly side and side airbag sensor LH side) are not damaged. OK: The connectors are not deformed or damaged. NG OK REPAIR OR REPLACE FLOOR WIRE RS RS–86 5 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FLOOR WIRE (OPEN) Floor Wire A D C B Side Airbag Sensor LH Center Airbag Sensor Assembly Connector C Connector B N7 (a) Using a service wire, connect terminals 8 (BBD+) and 15 (BBD-) of connector B. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Condition Specified condition N7-4 (BBL+) - N7-3 (BBL-) Always Below 1 Ω N1 NG REPAIR OR REPLACE FLOOR WIRE 5 4 3 2 1 10 9 8 7 6 4 3 2 1 15 14 13 12 11 BBL- BBD- BBL+ BBD+ Service Wire C C114840E07 OK RS 6 CHECK FLOOR WIRE (SHORT) (a) Disconnect the service wire from connector B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Floor Wire A D C B Side Airbag Sensor LH Center Airbag Sensor Assembly Tester connection Condition Specified condition N7-4 (BBL+) - N7-3 (BBL-) Always 1 MΩ or higher NG Connector C N7 4 3 2 1 BBL+ C BBLC114841E06 OK REPAIR OR REPLACE FLOOR WIRE RS–87 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 7 CHECK FLOOR WIRE (SHORT TO B+) (a) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Floor Wire A D C B Side Airbag Sensor LH Center Airbag Sensor Assembly Connector C Tester connection Condition Specified condition N7-4 (BBL+) - Body ground Ignition switch on (IG) Below 1 V N7-3 (BBL-) - Body ground Ignition switch on (IG) Below 1 V NG N7 REPAIR OR REPLACE FLOOR WIRE 4 3 2 1 BBL+ BBL- C C114841E06 OK 8 (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Floor Wire A D C B Side Airbag Sensor LH Center Airbag Sensor Assembly Connector C 4 3 2 1 BBL+ BBLC114841E06 OK Tester connection Condition Specified condition N7-4 (BBL+) - Body ground Always 1 MΩ or higher N7-3 (BBL-) - Body ground Always 1 MΩ or higher NG N7 C RS CHECK FLOOR WIRE (SHORT TO GROUND) REPAIR OR REPLACE FLOOR WIRE RS–88 9 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CONFIRM PART NUMBER OF SIDE AIRBAG SENSOR (a) Check that the part number of the side airbag sensor LH is equal to the number of the other side. OK: Those numbers are the same. (b) Connect the connectors to the center airbag sensor assembly and the side airbag sensor LH. NG Go to step 11 OK 10 CHECK SIDE AIRBAG SENSOR LH Side Airbag Sensor RH Center Airbag Sensor Assembly DTC 81 DLC3 DTC 82 RS CG (a) Interchange the side airbag sensor RH with LH and connect the connectors to them. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch on (IG), and wait for at least 60 seconds. (d) Clear the DTCs stored in the the memory (See page RS41). (e) Turn the ignition switch off. (f) Turn the ignition switch on (IG), and wait for at least 60 seconds. (g) Check the DTCs (See page RS-41). Result Result TC C123724E02 Proceed to DTC B1623, B1633, B1643, or 81 is output. A DTC B1628, B1638, B1648, or 82 is output. B DTC B1623, B1633, B1643, or 81 and B1628, B1638, B1648, or 82 are not output. C (h) Turn the ignition switch off. (i) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (j) Return the side airbag sensor RH and LH to their original positions and connect the connectors to them. B REPLACE SIDE AIRBAG SENSOR LH (See page RS-449) C USE SIMULATION METHOD TO CHECK (See page RS-32) A 11 CHECK CONNECTION OF CONNECTOR (a) Check that the connector is properly connected to the rear airbag sensor LH. RS–89 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM OK: The connector is properly connected. NG CONNECT CONNECTOR PROPERLY OK 12 CHECK CONNECTOR (a) Disconnect the connectors from the side airbag sensor LH and rear airbag sensor LH. (b) Check that the connector (on the rear airbag sensor LH side) is not damaged. OK: The connector is not deformed or damaged. NG REPAIR OR REPLACE FLOOR WIRE OK 13 CHECK FLOOR WIRE (OPEN) Floor Wire D A C B Rear Airbag Sensor LH Side Airbag Sensor LH Connector C Connector B N12 N7 BCL+ Service Wire BCL- BCL+ C123725E01 OK Tester connection Condition Specified condition N7-1 (BCL+) - N7-2 (BCL-) Always Below 1 Ω NG 4 3 2 1 BCL- (a) Using a service wire, connect terminals 2 (BCL+) and 1 (BCL-) of connector C. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (b) Measure the resistance according to the value(s) in the table below. Standard resistance REPAIR OR REPLACE FLOOR WIRE RS RS–90 14 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FLOOR WIRE (SHORT) (a) Disconnect the service wire from connector C. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Floor Wire A D C B Side Airbag Sensor LH Rear Airbag Sensor LH Tester connection Condition Specified condition N7-1 (BCL+) - N7-2 (BCL-) Always 1 MΩ or higher NG REPAIR OR REPLACE FLOOR WIRE Connector B N7 4 3 2 1 BCL- BCL+ C C114843E11 OK RS 15 CHECK FLOOR WIRE (SHORT TO B+) (a) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Floor Wire A D C B Side Airbag Sensor LH Rear Airbag Sensor LH Tester connection Condition Specified condition N7-1 (BCL+) - Body ground Ignition switch on (IG) Below 1 V N7-2 (BCL-) - Body ground Ignition switch on (IG) Below 1 V Connector B NG N7 4 3 2 1 BCLC BCL+ C114843E11 OK REPAIR OR REPLACE FLOOR WIRE RS–91 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 16 CHECK FLOOR WIRE (SHORT TO GROUND) (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Floor Wire A D C B Side Airbag Sensor LH Rear Airbag Sensor LH Tester connection Condition Specified condition N7-1 (BCL+) - Body ground Always 1 MΩ or higher N7-2 (BCL-) - Body ground Always 1 MΩ or higher Connector B NG N7 REPAIR OR REPLACE FLOOR WIRE 4 3 2 1 BCLC BCL+ C114843E11 OK 17 CONFIRM PART NUMBER OF REAR AIRBAG SENSOR (a) Check that the part number of the rear airbag sensor LH is equal to the number of the other side. OK: Those numbers are the same. (b) Connect the connectors to the side airbag sensor LH and the rear airbag sensor LH. NG OK Go to step 19 RS RS–92 18 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK REAR AIRBAG SENSOR LH Rear Airbag Sensor RH Side Airbag Sensor LH DTC 81 DLC3 DTC 82 (a) Interchange the rear airbag sensor RH with LH and connect the connectors to them. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch on (IG), and wait for at least 60 seconds. (d) Clear the DTCs stored in the memory (See page RS-41). (e) Turn the ignition switch off. (f) Turn the ignition switch on (IG), and wait for at least 60 seconds. (g) Check the DTCs (See page RS-41). Result Result CG TC C123751E01 Proceed to DTC B1623, B1633, B1643, or 81 is output. A DTC B1628, B1638, B1648, or 82 is output. B DTC B1623, B1633, B1643, or 81 and B1628, B1638, B1648, or 82 are not output. C HINT: Codes other than DTC B1623, B1633, B1643, or 81 and B1628, B1638, B1648, or 82 may be output at this time, but they are not related to this check. (h) Turn the ignition switch off. (i) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (j) Return the rear airbag sensor RH and LH to their original positions and connect the connectors to them. RS B REPLACE REAR AIRBAG SENSOR LH (See page RS-455) C USE SIMULATION METHOD TO CHECK (See page RS-32) A 19 CHECK CENTER AIRBAG SENSOR ASSEMBLY (a) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (b) Turn the ignition switch on (IG), and wait for at least 60 seconds. (c) Clear the DTCs stored in the memory (See page RS-41). (d) Turn the ignition switch off. (e) Turn the ignition switch on (IG), and wait for at least 60 seconds. (f) Check the DTCs (See page RS-41). OK: DTC B1623, B1633, B1643, or 81 is not output. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–93 HINT: Codes other than DTC B1623, B1633, B1643, or 81 may be output at this time, but they are not related to this check. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-441) OK USE SIMULATION METHOD TO CHECK (See page RS-32) 20 CHECK CONNECTION OF CONNECTORS (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the center airbag sensor assembly and the side airbag sensor LH. OK: The connectors are properly connected. NG CONNECT CONNECTORS PROPERLY OK 21 RS CHECK CONNECTORS (a) Disconnect the connectors from the center airbag sensor assembly and side airbag sensor LH. (b) Check that the connectors (on the center airbag sensor assembly side and side airbag sensor LH side) are not damaged. OK: The connectors are not deformed or damaged. NG OK REPAIR OR REPLACE FLOOR WIRE RS–94 22 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FLOOR WIRE (OPEN) Floor Wire A D C B Side Airbag Sensor LH Center Airbag Sensor Assembly Connector C Connector B N7 (a) Using a service wire, connect terminals 8 (BBD+) and 15 (BBD-) of connector B. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Condition Specified condition N7-4 (BBL+) - N7-3 (BBL-) Always Below 1 Ω N1 NG REPAIR OR REPLACE FLOOR WIRE 5 4 3 2 1 10 9 8 7 6 4 3 2 1 15 14 13 12 11 BBL- BBD- BBL+ BBD+ Service Wire C C114840E07 OK RS 23 CHECK FLOOR WIRE (SHORT) (a) Disconnect the service wire from connector B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Floor Wire A D C B Side Airbag Sensor LH Center Airbag Sensor Assembly Tester connection Condition Specified condition N7-4 (BBL+) - N7-3 (BBL-) Always 1 MΩ or higher NG Connector C N7 4 3 2 1 BBL+ C BBLC114841E06 OK REPAIR OR REPLACE FLOOR WIRE RS–95 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 24 CHECK FLOOR WIRE (SHORT TO B+) (a) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Floor Wire A D C B Side Airbag Sensor LH Center Airbag Sensor Assembly Connector C Tester connection Condition Specified condition N7-4 (BBL+) - Body ground Ignition switch on (IG) Below 1 V N7-3 (BBL-) - Body ground Ignition switch on (IG) Below 1 V NG N7 REPAIR OR REPLACE FLOOR WIRE 4 3 2 1 BBL+ BBL- C C114841E06 OK 25 (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Floor Wire A D C B Side Airbag Sensor LH Center Airbag Sensor Assembly Connector C 4 3 2 1 BBL+ BBLC114841E06 OK Tester connection Condition Specified condition N7-4 (BBL+) - Body ground Always 1 MΩ or higher N7-3 (BBL-) - Body ground Always 1 MΩ or higher NG N7 C RS CHECK FLOOR WIRE (SHORT TO GROUND) REPAIR OR REPLACE FLOOR WIRE RS–96 26 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CONFIRM PART NUMBER OF SIDE AIRBAG SENSOR (a) Check that the part number of the side airbag sensor LH is equal to the number of the other side. OK: Those numbers are the same. (b) Connect the connectors to the center airbag sensor assembly and the side airbag sensor LH. NG Go to step 28 OK 27 CHECK SIDE AIRBAG SENSOR LH Side Airbag Sensor RH Center Airbag Sensor Assembly DTC 81 DLC3 DTC 82 RS (a) Interchange the side airbag sensor RH with LH and connect the connectors to them. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch on (IG), and wait for at least 60 seconds. (d) Clear the DTCs stored in the memory (See page RS-41). (e) Turn the ignition switch off. (f) Turn the ignition switch on (IG), and wait for at least 60 seconds. (g) Check the DTCs (See page RS-41). Result Result CG TC C123724E02 Proceed to DTC B1623, B1633, B1643, or 81 is output. A DTC B1628, B1638, B1648, or 82 is output. B DTC B1623, B1633, B1643, or 81 and B1628, B1638, B1648, or 82 are not output. C (h) Turn the ignition switch off. (i) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (j) Return the side airbag sensor RH and LH to their original positions and connect the connectors to them. B REPLACE SIDE AIRBAG SENSOR LH (See page RS-449) C USE SIMULATION METHOD TO CHECK (See page RS-32) A 28 CHECK CENTER AIRBAG SENSOR ASSEMBLY (a) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (b) Turn the ignition switch on (IG), and wait for at least 60 seconds. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–97 (c) Clear the DTCs stored in the memory (See page RS-41). (d) Turn the ignition switch off. (e) Turn the ignition switch on (IG), and wait for at least 60 seconds. (f) Check the DTCs (See page RS-41). OK: DTC B1623, B1633, B1643, or 81 is not output. HINT: Codes other than DTC B1623, B1633, B1643, or 81 may be output at this time, but they are not related to this check. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-441) OK USE SIMULATION METHOD TO CHECK (See page RS-32) RS RS–98 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1625/22 Front Passenger Side - Side Airbag Sensor Malfunction DESCRIPTION The side airbag sensor RH consists of the safing sensor, the diagnostic circuit, the lateral deceleration sensor, etc. If the center airbag sensor assembly receives signals from the lateral deceleration sensor, it determines whether the SRS should be activated. DTC B1625/22 is recorded when a malfunction is detected in the front passenger side - side airbag sensor circuit. DTC No. B1625/22 DTC Detection Condition • • Trouble Area Side airbag sensor RH malfunction Center airbag sensor assembly malfunction • • Side airbag sensor RH Center airbag sensor assembly WIRING DIAGRAM O7 Side Airbag Sensor RH Center Airbag Sensor Assembly 8 BBR+ RS BBR- O1 BBP+ 4 11 O1 BBP- 3 O9 Rear Airbag Sensor RH BCR+ BCR- 1 2 2 1 BCR+ BCR- H045218E09 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–99 INSPECTION PROCEDURE 1 CHECK DTC Side Airbag Sensor RH DLC3 Center Airbag Sensor Assembly DTC 22 (a) Turn the ignition switch on (IG), and wait for at least 60 seconds. (b) Clear the DTCs stored in the memory (See page RS-41). (c) Turn the ignition switch off. (d) Turn the ignition switch on (IG), and wait for at least 60 seconds. (e) Check the DTCs (See page RS-41). OK: DTC B1625/22 is not output. HINT: Codes other than DTC B1625/22 may be output at this time, but they are not related to this check. OK CG TC USE SIMULATION METHOD TO CHECK (See page RS-32) C123698E02 NG 2 CONFIRM PART NUMBER OF SIDE AIRBAG SENSOR (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Check that the part number of the side airbag sensor RH is equal to the number of the other side. OK: Those numbers are the same. NG OK Go to step 4 RS RS–100 3 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK SIDE AIRBAG SENSOR RH Side Airbag Sensor LH Center Airbag Sensor Assembly DTC 21 DLC3 DTC 22 CG (a) Connect the connectors to the center airbag sensor assembly. (b) Interchange the side airbag sensor LH with RH and connect the connectors to them. (c) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (d) Turn the ignition switch on (IG), and wait for at least 60 seconds. (e) Clear the DTCs stored in the memory (See page RS-41). (f) Turn the ignition switch off. (g) Turn the ignition switch on (IG), and wait for at least 60 seconds. (h) Check the DTCs (See page RS-41). Result TC Result C123699E02 Proceed to DTC B1625/22 is output. A DTC B1620/21 is output. B DTC B1620/21 and B1625/22 are not output. C HINT: Codes other than DTC B1620/21 and B1625/22 may be output at this time, but they are not related to this check. (i) Turn the ignition switch off. (j) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (k) Return the side airbag sensor LH and RH to their original positions and connect the connectors to them. RS A B Go to step 5 REPLACE SIDE AIRBAG SENSOR RH (See page RS-449) C USE SIMULATION METHOD TO CHECK (See page RS-32) 4 REPLACE SIDE AIRBAG SENSOR RH (a) Replace the side airbag sensor RH (See page RS-449). HINT: Perform inspection using parts from a normal vehicle if possible. NEXT SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 5 RS–101 CHECK CENTER AIRBAG SENSOR ASSEMBLY Side Airbag Sensor RH DLC3 CG TC Center Airbag Sensor Assembly DTC 22 C123698E02 (a) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (b) Turn the ignition switch on (IG), and wait for at least 60 seconds. (c) Clear the DTCs stored in the memory (See page RS-41). (d) Turn the ignition switch off. (e) Turn the ignition switch on (IG), and wait for at least 60 seconds. (f) Check the DTCs (See page RS-41). OK: DTC B1625/22 is not output. HINT: Codes other than DTC B1625/22 may be output at this time, but they are not related to this check. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-441) OK USE SIMULATION METHOD TO CHECK (See page RS-32) RS RS–102 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1627/82 Lost Communication with Front Passenger Side - Side Airbag Sensor Assembly DTC B1628/82 Front Passenger Side - Side Airbag Sensor Assembly Initialization Incomplete DTC B1637/82 Lost Communication with Passenger Side Rear Airbag Sensor DTC B1638/82 Passenger Side Rear Airbag Sensor Initialization Incomplete DTC B1647/82 Lost Communication with Front Passenger Side Satellite Sensor Bus DTC B1648/82 Front Passenger Side Satellite Sensor Bus Initialization Incomplete DESCRIPTION RS The circuit for the side collision sensor RH (to determine deployment of the front seat side airbag assembly RH and curtain shield airbag assembly RH) is composed of the center airbag sensor assembly, side airbag sensor RH, and rear airbag sensor RH. The side airbag sensor RH and rear airbag sensor RH detect impacts to the vehicle and send signals to the center airbag sensor assembly to determine if the airbag should be deployed. DTC B1627/82, B1628/82, B1637/82, B1638/82, B1647/82, or B1648/82 is recorded when a malfunction is detected in the circuit for the side collision sensor RH. DTC No. DTC Detecting Condition • B1627/82 B1628/82 B1637/82 B1638/82 B1647/82 B1648/82 • • • The center airbag sensor assembly receives a line short circuit signal, an open circuit signal, a short circuit to ground signal or a short circuit to B+ signal in the circuit for the side collision sensor RH (to determine deployment of the front seat side airbag assembly RH and curtain shield airbag assembly RH) for 2 seconds. Side airbag sensor RH malfunction Rear airbag sensor RH malfunction Center airbag sensor assembly malfunction Trouble Area • • • • Floor wire No. 2 Side airbag sensor RH Rear airbag sensor RH Center airbag sensor assembly SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–103 WIRING DIAGRAM O7 Side Airbag Sensor RH BBR+ BBR- Center Airbag Sensor Assembly 8 O1 BBP+ 4 11 O1 BBP- 3 O9 Rear Airbag Sensor RH BCR+ BCR- 1 2 2 1 BCR+ BCR- RS H045218E09 RS–104 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM INSPECTION PROCEDURE 1 CHECK DTC Side Airbag Sensor RH Center Airbag Sensor Assembly DTC 81 DLC3 DTC 82 (a) Turn the ignition switch on (IG), and wait for at least 60 seconds. (b) Turn the ignition switch off. HINT: If a communication error occurs, DTCs for both the LH and RH sides will be stored simultaneously. To identify the malfunctioning area, turn the ignition switch off and then on (IG) again. (c) Turn the ignition switch on (IG), and wait for at least 60 seconds. (d) Check the present DTCs (See page RS-41). Result Result CG TC C123752E01 Proceed to Present DTC B1628, B1638, B1648, or 82 is output. A Present DTC B1623, B1633 B1643, or 81 is output. B Present DTC B1623, B1633, B1643, or 81 and B1628, B1638, B1648, or 82 are not output. C HINT: • DTCs indicating communication errors will be changed to DTCs indicating errors in initialization by turning the ignition switch off and then on (IG) again. • Codes other than present DTC B1623, B1633, B1643, or 81 and B1628, B1638, B1648, or 82 may be output at this time, but they are not related to this check. RS B REPAIR CIRCUITS INDICATED BY OUTPUT DTCS C USE SIMULATION METHOD TO CHECK (See page RS-32) A 2 CHECK PAST DTC (a) Check the past DTCs (See page RS-41). Result Result • • Past DTC B1637, B1647, or 82 is output. Past DTC B1627, B1637, B1647, or 82 is not output. Past DTC B1627 is output. Proceed to A B HINT: Codes other than past DTC B1627, B1637, B1647, or 82 may be output at this time, but they are not related to this check. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM B RS–105 Go to step 20 A 3 CHECK CONNECTION OF CONNECTORS (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the center airbag sensor assembly and the side airbag sensor RH. OK: The connectors are properly connected. NG CONNECT CONNECTORS PROPERLY OK 4 CHECK CONNECTORS (a) Disconnect the connectors from the center airbag sensor assembly and side airbag sensor RH. (b) Check that the connectors (on the center airbag sensor assembly side and side airbag sensor RH side) are not damaged. OK: The connectors are not deformed or damaged. NG OK REPAIR OR REPLACE FLOOR WIRE NO. 2 RS RS–106 5 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FLOOR WIRE NO. 2 (OPEN) Floor Wire No. 2 A D C B Side Airbag Sensor RH Center Airbag Sensor Assembly Connector B (a) Using a service wire, connect terminals 8 (BBP+) and 11 (BBP-) of connector B. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Condition Specified condition O7-4 (BBR+) - O7-3 (BBR-) Always Below 1 Ω Connector C O1 O7 NG REPAIR OR REPLACE FLOOR WIRE NO. 2 5 4 3 2 1 10 9 8 7 6 4 3 2 1 15 14 13 12 11 BBR+ BBP+ BBR- BBP- Service Wire C114846E06 OK RS 6 CHECK FLOOR WIRE NO. 2 (SHORT) (a) Disconnect the service wire from connector B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Floor Wire No. 2 A D C B Side Airbag Sensor RH Center Airbag Sensor Assembly Tester connection Condition Specified condition O7-4 (BBR+) - O7-3 (BBR-) Always 1 MΩ or higher NG Connector C O7 4 3 2 1 BBR+ C BBRC114847E07 OK REPAIR OR REPLACE FLOOR WIRE NO. 2 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 7 RS–107 CHECK FLOOR WIRE NO. 2 (SHORT TO B+) Floor Wire No. 2 A D C B Side Airbag Sensor RH Center Airbag Sensor Assembly (a) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Tester connection Condition Specified condition O7-4 (BBR+) - Body ground Ignition switch on (IG) Below 1 V O7-3 (BBR-) - Body ground Ignition switch on (IG) Below 1 V Connector C NG O7 REPAIR OR REPLACE FLOOR WIRE NO. 2 4 3 2 1 BBR+ BBR- C C114847E07 OK 8 RS CHECK FLOOR WIRE NO. 2 (SHORT TO GROUND) Floor Wire No. 2 A D C B Side Airbag Sensor RH Center Airbag Sensor Assembly (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Condition Specified condition O7-4 (BBR+) - Body ground Always 1 MΩ or higher O7-3 (BBR-) - Body ground Always 1 MΩ or higher Connector C NG O7 4 3 2 1 BBR+ C BBRC114847E07 OK REPAIR OR REPLACE FLOOR WIRE NO. 2 RS–108 9 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CONFIRM PART NUMBER OF SIDE AIRBAG SENSOR (a) Check that the part number of the side airbag sensor RH is equal to the number of the other side. OK: Those numbers are the same. (b) Connect the connectors to the center airbag sensor assembly and the side airbag sensor RH. NG Go to step 11 OK 10 CHECK SIDE AIRBAG SENSOR RH Side Airbag Sensor LH Center Airbag Sensor Assembly DTC 81 DLC3 DTC 82 RS (a) Interchange the side airbag sensor LH with RH and connect the connectors to them. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch on (IG), and wait for at least 60 seconds. (d) Clear the DTCs stored in the memory (See page RS-41). (e) Turn the ignition switch off. (f) Turn the ignition switch on (IG), and wait for at least 60 seconds. (g) Check the DTCs (See page RS-41). Result Result CG TC C123752E02 Proceed to DTC B1628, B1638, B1648, or 82 is output. A DTC B1623, B1633, B1643, or 81 is output. B DTC B1623, B1633, B1643, or 81 and B1628, B1638, B1648, or 82 are not output. C (h) Turn the ignition switch off. (i) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (j) Return the side airbag sensor LH and RH to their original positions and connect the connectors to them. B REPLACE SIDE AIRBAG SENSOR RH (See page RS-449) C USE SIMULATION METHOD TO CHECK (See page RS-32) A 11 CHECK CONNECTION OF CONNECTOR (a) Check that the connector is properly connected to the rear airbag sensor RH. OK: The connector is properly connected. RS–109 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM NG CONNECT CONNECTOR PROPERLY OK 12 CHECK CONNECTOR (a) Disconnect the connectors from the side airbag sensor RH and rear airbag sensor RH. (b) Check that the connector (on the rear airbag sensor RH side) is not damaged. OK: The connector is not deformed or damaged. NG REPAIR OR REPLACE FLOOR WIRE NO. 2 OK 13 CHECK FLOOR WIRE NO. 2 (OPEN) Floor Wire No. 2 D A C Rear Airbag Sensor RH B Side Airbag Sensor RH Connector C Connector B O9 O7 BCR+ Service Wire BCR- BCR+ C123725E02 OK Tester connection Condition Specified condition O7-2 (BCR-) - O7-1 (BCR+) Always Below 1 Ω NG 4 3 2 1 BCR- (a) Using a service wire, connect terminals 2 (BCR+) and 1 (BCR-) of connector C. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (b) Measure the resistance according to the value(s) in the table below. Standard resistance REPAIR OR REPLACE FLOOR WIRE NO. 2 RS RS–110 14 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FLOOR WIRE NO. 2 (SHORT) Floor Wire No. 2 A D C B Side Airbag Sensor RH Rear Airbag Sensor RH (a) Disconnect the service wire from connector C. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Condition Specified condition O7-1 (BCR+) - O7-2 (BCR-) Always 1 MΩ or higher NG REPAIR OR REPLACE FLOOR WIRE NO. 2 Connector B O7 4 3 2 1 BCR- BCR+ C C114843E12 OK RS 15 CHECK FLOOR WIRE NO. 2 (SHORT TO B+) Floor Wire No. 2 A D C B Side Airbag Sensor RH Rear Airbag Sensor RH (a) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Tester connection Condition Specified condition O7-1 (BCR+) - Body ground Ignition switch on (IG) Below 1 V O7-2 (BCR-) - Body ground Ignition switch on (IG) Below 1 V Connector B NG O7 4 3 2 1 BCRC BCR+ C114843E12 OK REPAIR OR REPLACE FLOOR WIRE NO. 2 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 16 RS–111 CHECK FLOOR WIRE NO. 2 (SHORT TO GROUND) Floor Wire No. 2 A D C B Side Airbag Sensor RH Rear Airbag Sensor RH (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Condition Specified condition O7-1 (BCR+) - Body ground Always 1 MΩ or higher O7-2 (BCR-) - Body ground Always 1 MΩ or higher Connector B NG O7 REPAIR OR REPLACE FLOOR WIRE NO. 2 4 3 2 1 BCRC BCR+ C114843E12 OK 17 CONFIRM PART NUMBER OF REAR AIRBAG SENSOR (a) Check that the part number of the rear airbag sensor RH is equal to the number of the other side. OK: Those numbers are the same. (b) Connect the connectors to the side airbag sensor RH and the rear airbag sensor RH. NG OK Go to step 19 RS RS–112 18 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK REAR AIRBAG SENSOR RH Rear Airbag Sensor LH Side Airbag Sensor RH DTC 81 DLC3 DTC 82 (a) Interchange the side airbag sensor LH with RH and connect the connectors to them. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch on (IG), and wait for at least 60 seconds. (d) Clear the DTCs stored in the memory (See page RS-41). (e) Turn the ignition switch off. (f) Turn the ignition switch on (IG), and wait for at least 60 seconds. (g) Check the DTCs (See page RS-41). Result Result CG TC C123751E02 Proceed to DTC B1628, B1638, B1648, or 82 is output. A DTC B1623, B1633, B1643, or 81 is output. B DTC B1623, B1633, B1643, or 81 and B1628, B1638, B1648, or 82 are not output. C HINT: Codes other than DTC B1623, B1633, B1643, or 81 and B1628, B1638, B1648, or 82 may be output at this time, but they are not related to this check. (h) Turn the ignition switch off. (i) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (j) Return the rear airbag sensor LH and RH to their original positions and connect the connectors to them. RS B REPLACE REAR AIRBAG SENSOR RH (See page RS-455) C USE SIMULATION METHOD TO CHECK (See page RS-32) A 19 CHECK CENTER AIRBAG SENSOR ASSEMBLY (a) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (b) Turn the ignition switch on (IG), and wait for at least 60 seconds. (c) Clear the DTCs stored in the memory (See page RS-41). (d) Turn the ignition switch off. (e) Turn the ignition switch on (IG), and wait for at least 60 seconds. (f) Check the DTCs (See page RS-41). OK: DTC B1628, B1638, B1648, or 82 is not output. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–113 HINT: Codes other than DTC B1628, B1638, B1648, or 82 may be output at this time, but they are not related to this check. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-441) OK USE SIMULATION METHOD TO CHECK (See page RS-32) 20 CHECK CONNECTION OF CONNECTORS (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the center airbag sensor assembly and the side airbag sensor RH. OK: The connectors are properly connected. NG CONNECT CONNECTORS PROPERLY OK 21 RS CHECK CONNECTORS (a) Disconnect the connectors from the center airbag sensor assembly and side airbag sensor RH. (b) Check that the connectors (on the center airbag sensor assembly side and side airbag sensor RH side) are not damaged. OK: The connectors are not deformed or damaged. NG OK REPAIR OR REPLACE FLOOR WIRE NO. 2 RS–114 22 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FLOOR WIRE NO. 2 (OPEN) Floor Wire No. 2 A D C B Side Airbag Sensor RH Center Airbag Sensor Assembly Connector B (a) Using a service wire, connect terminals 8 (BBP+) and 11 (BBP-) of connector B. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Condition Specified condition O7-4 (BBR+) - O7-3 (BBR-) Always Below 1 Ω Connector C O1 O7 NG REPAIR OR REPLACE FLOOR WIRE NO. 2 5 4 3 2 1 10 9 8 7 6 4 3 2 1 15 14 13 12 11 BBR+ BBP+ BBR- BBP- Service Wire C114846E06 OK RS 23 CHECK FLOOR WIRE NO. 2 (SHORT) (a) Disconnect the service wire from connector B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Floor Wire No. 2 A D C B Side Airbag Sensor RH Center Airbag Sensor Assembly Tester connection Condition Specified condition O7-4 (BBR+) - O7-3 (BBR-) Always 1 MΩ or higher NG Connector C O7 4 3 2 1 BBR+ C BBRC114847E07 OK REPAIR OR REPLACE FLOOR WIRE NO. 2 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 24 RS–115 CHECK FLOOR WIRE NO. 2 (SHORT TO B+) Floor Wire No. 2 A D C B Side Airbag Sensor RH Center Airbag Sensor Assembly (a) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Tester connection Condition Specified condition O7-4 (BBR+) - Body ground Ignition switch on (IG) Below 1 V O7-3 (BBR-) - Body ground Ignition switch on (IG) Below 1 V Connector C NG O7 REPAIR OR REPLACE FLOOR WIRE NO. 2 4 3 2 1 BBR+ BBR- C C114847E07 OK 25 RS CHECK FLOOR WIRE NO. 2 (SHORT TO GROUND) Floor Wire No. 2 A D C B Side Airbag Sensor RH Center Airbag Sensor Assembly (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Condition Specified condition O7-4 (BBR+) - Body ground Always 1 MΩ or higher O7-3 (BBR-) - Body ground Always 1 MΩ or higher Connector C NG O7 4 3 2 1 BBR+ C BBRC114847E07 OK REPAIR OR REPLACE FLOOR WIRE NO. 2 RS–116 26 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CONFIRM PART NUMBER OF SIDE AIRBAG SENSOR (a) Check that the part number of the side airbag sensor RH is equal to the number of the other side. OK: Those numbers are the same. (b) Connect the connectors to the center airbag sensor assembly and the side airbag sensor RH. NG Go to step 28 OK 27 CHECK SIDE AIRBAG SENSOR RH Side Airbag Sensor LH Center Airbag Sensor Assembly DTC 81 DLC3 DTC 82 RS (a) Interchange the side airbag sensor LH with RH and connect the connectors to them. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch on (IG), and wait for at least 60 seconds. (d) Clear the DTCs stored in the memory (See page RS-41). (e) Turn the ignition switch off. (f) Turn the ignition switch on (IG), and wait for at least 60 seconds. (g) Check the DTCs (See page RS-41). Result Result CG TC C123752E02 Proceed to DTC B1628, B1638, B1648, or 82 is output. A DTC B1623, B1633, B1643, or 81 is output. B DTC B1623, B1633, B1643, or 81 and B1628, B1638, B1648, or 82 are not output. C (h) Turn the ignition switch off. (i) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (j) Return the side airbag sensor LH and RH to their original positions and connect the connectors to them. B REPLACE SIDE AIRBAG SENSOR RH (See page RS-449) C USE SIMULATION METHOD TO CHECK (See page RS-32) A 28 CHECK CENTER AIRBAG SENSOR ASSEMBLY (a) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (b) Turn the ignition switch on (IG), and wait for at least 60 seconds. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–117 (c) Clear the DTCs stored in the memory (See page RS-41). (d) Turn the ignition switch off. (e) Turn the ignition switch on (IG), and wait for at least 60 seconds. (f) Check the DTCs (See page RS-41). OK: DTC B1628, B1638, B1648, or 82 is not output. HINT: Codes other than DTC B1628, B1638, B1648, or 82 may be output at this time, but they are not related to this check. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-441) OK USE SIMULATION METHOD TO CHECK (See page RS-32) RS RS–118 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1630/23 Driver Side Rear Airbag Sensor Malfunction DESCRIPTION The rear airbag sensor LH consists of the safing sensor, the diagnostic circuit, the lateral deceleration sensor, etc. If the center airbag sensor assembly receives signals from the lateral deceleration sensor, it determines whether the SRS should be activated. DTC B1630/23 is recorded when a malfunction is detected in the driver side rear airbag sensor circuit. DTC No. B1630/23 DTC Detection Condition • • Trouble Area Rear airbag sensor LH malfunction Center airbag sensor assembly malfunction • • Rear airbag sensor LH Center airbag sensor assembly WIRING DIAGRAM N7 Side Airbag Sensor LH Center Airbag Sensor Assembly 8 BBL+ BBL- N1 BBD+ 4 15 N1 BBD- 3 RS N12 Rear Airbag Sensor LH BCL+ BCL- 1 2 2 1 BCL+ BCL- H045218E08 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–119 INSPECTION PROCEDURE 1 CHECK DTC Rear Airbag Sensor LH DLC3 CG TC (a) Turn the ignition switch on (IG), and wait for at least 60 seconds. (b) Clear the DTCs stored in the memory (See page RS-41). (c) Turn the ignition switch off. (d) Turn the ignition switch on (IG), and wait for at least 60 seconds. (e) Check the DTCs (See page RS-41). OK: DTC B1630/23 is not output. Side Airbag Sensor LH OK DTC 23 USE SIMULATION METHOD TO CHECK (See page RS-32) C123700E02 NG 2 CONFIRM PART NUMBER OF REAR AIRBAG SENSOR (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Check that the part number of the rear airbag sensor LH is equal to the number of the other side. OK: Those numbers are the same. NG OK Go to step 4 RS RS–120 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 3 CHECK REAR AIRBAG SENSOR LH Rear Airbag Sensor RH (a) Interchange the rear airbag sensor RH with LH and connect the connectors to them. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch on (IG), and wait for at least 60 seconds. (d) Clear the DTCs stored in the memory (See page RS-41). (e) Turn the ignition switch off. (f) Turn the ignition switch on (IG), and wait for at least 60 seconds. (g) Check the DTCs (See page RS-41). Result Side Airbag Sensor LH DTC 23 DLC3 DTC 24 CG C Result TC C114844E05 Proceed to DTC B1630/23 is output. A DTC B1635/24 is output. B DTC B1630/23 and B1635/24 are not output. C HINT: Codes other than DTC B1630/23 and B1635/24 may be output at this time, but they are not related to this check. (h) Turn the ignition switch off. (i) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (j) Return the rear airbag sensor RH and LH to their original positions and connect the connectors to them. RS A B Go to step 5 REPLACE REAR AIRBAG SENSOR LH (See page RS-455) C USE SIMULATION METHOD TO CHECK (See page RS-32) 4 REPLACE REAR AIRBAG SENSOR LH (a) Replace the rear airbag sensor LH (See page RS-455). HINT: Perform inspection using parts from a normal vehicle if possible. NEXT SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 5 RS–121 CHECK CENTER AIRBAG SENSOR ASSEMBLY Rear Airbag Sensor LH DLC3 CG TC (a) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (b) Turn the ignition switch on (IG), and wait for at least 60 seconds. (c) Clear the DTCs stored in the memory (See page RS-41). (d) Turn the ignition switch off. (e) Turn the ignition switch on (IG), and wait for at least 60 seconds. (f) Check the DTCs (See page RS-41). OK: DTC B1630/23 is not output. HINT: Codes other than DTC B1630/23 and B1635/24 may be output at this time, but they are not related to this check. Side Airbag Sensor LH DTC 23 C123700E02 NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-441) OK USE SIMULATION METHOD TO CHECK (See page RS-32) RS RS–122 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1635/24 Front Passenger Side Rear Airbag Sensor Malfunction DESCRIPTION The rear airbag sensor RH consists of the safing sensor, the diagnostic circuit, the lateral deceleration sensor, etc. If the center airbag sensor assembly receives signals from the lateral deceleration sensor, it determines whether the SRS should be activated. DTC B1635/24 is recorded when a malfunction is detected in the front passenger side rear airbag sensor circuit. DTC No. B1635/24 DTC Detection Condition • • Trouble Area Rear airbag sensor RH malfunction Center airbag sensor assembly malfunction • • Rear airbag sensor RH Center airbag sensor assembly WIRING DIAGRAM O7 Side Airbag Sensor RH Center Airbag Sensor Assembly 8 BBR+ RS BBR- O1 BBP+ 4 11 O1 BBP- 3 O9 Rear Airbag Sensor RH BCR+ BCR- 1 2 2 1 BCR+ BCR- H045218E09 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–123 INSPECTION PROCEDURE 1 CHECK DTC Rear Airbag Sensor RH DLC3 (a) Turn the ignition switch on (IG), and wait for at least 60 seconds. (b) Clear the DTCs stored in the memory (See page RS-41). (c) Turn the ignition switch off. (d) Turn the ignition switch on (IG), and wait for at least 60 seconds. (e) Check the DTCs (See page RS-41). OK: DTC B1635/24 is not output. HINT: Codes other than DTC B1635/24 may be output at this time, but they are not related to this check. Side Airbag Sensor RH DTC 24 OK CG TC USE SIMULATION METHOD TO CHECK (See page RS-32) C123701E02 NG 2 CONFIRM PART NUMBER OF REAR AIRBAG SENSOR (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Check that the part number of the rear airbag sensor RH is equal to the number of the other side. OK: Those numbers are the same. NG OK Go to step 4 RS RS–124 3 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK REAR AIRBAG SENSOR RH Rear Airbag Sensor LH (a) Interchange the rear airbag sensor LH with RH and connect the connectors to them. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch on (IG), and wait for at least 60 seconds. (d) Clear the DTCs stored in the memory (See page RS-41). (e) Turn the ignition switch off. (f) Turn the ignition switch on (IG), and wait for at least 60 seconds. (g) Check the DTCs (See page RS-41). Result Side Airbag Sensor RH DTC 23 DLC3 DTC 24 CG C Result TC C114844E06 Proceed to DTC B1635/24 is output. A DTC B1630/23 is output. B DTC B1630/23 and B1635/24 are not output. C HINT: Codes other than DTC B1630/23 and B1635/24 may be output at this time, but they are not related to this check. (h) Turn the ignition switch off. (i) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (j) Return the rear airbag sensor LH and RH to their original positions and connect the connectors to them. RS A B Go to step 5 REPLACE REAR AIRBAG SENSOR RH (See page RS-455) C USE SIMULATION METHOD TO CHECK (See page RS-32) 4 REPLACE REAR AIRBAG SENSOR RH (a) Replace the rear airbag sensor RH (See page RS-455). HINT: Perform inspection using parts from a normal vehicle if possible. NEXT SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 5 RS–125 CHECK CENTER AIRBAG SENSOR ASSEMBLY Rear Airbag Sensor RH DLC3 CG TC (a) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (b) Turn the ignition switch on (IG), and wait for at least 60 seconds. (c) Clear the DTCs stored in the memory (See page RS-41). (d) Turn the ignition switch off. (e) Turn the ignition switch on (IG), and wait for at least 60 seconds. (f) Check the DTCs (See page RS-41). OK: DTC B1635/24 is not output. HINT: Codes other than DTC B1635/24 may be output at this time, but they are not related to this check. Side Airbag Sensor RH DTC 24 C123701E02 NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-441) OK USE SIMULATION METHOD TO CHECK (See page RS-32) RS RS–126 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1650/32 Occupant Classification System Malfunction DESCRIPTION The occupant classification system circuit consists of the center airbag sensor assembly and the occupant classification system. If the center airbag sensor assembly receives signals from the occupant classification ECU, it determines whether the front passenger airbag assembly, the front seat side airbag assembly RH and front seat outer belt assembly should be operated. DTC B1650/32 is recorded when a malfunction is detected in the occupant classification system circuit. DTC No. DTC Detecting Condition • • B1650/32 • Occupant classification system malfunction The center airbag sensor assembly receives a line short circuit signal, an open circuit signal, a short circuit to ground signal or a short circuit to B+ signal in the occupant classification system circuit for 2 seconds. Center airbag sensor assembly malfunction Trouble Area • • • • Floor wire No. 2 Occupant classification system Front seat wire RH (for Power Seat) Center airbag sensor assembly WIRING DIAGRAM Occupant Classification ECU RS 8 8 FSR+ T10 O4 (*1) (*2) Center Airbag Sensor Assembly (*1) 1 OT1 (*1) 12 O1 FSP+ (*1) 13 O1 FSP- (*2) FSR- 4 4 T10 O4 (*1) (*2) (*1) 4 OT1 (*2) *1: for Power Seat *2: for Manual Seat H045471E04 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–127 INSPECTION PROCEDURE 1 CHECK DTC (OCCUPANT CLASSIFICATION ECU) (a) Turn the ignition switch on (IG), and wait for at least 10 seconds. (b) Using the intelligent tester, check the DTCs of the occupant classification ECU (See page RS-251). OK: DTC is not output. NG GO TO OCCUPANT CLASSIFICATION SYSTEM OK 2 CHECK DTC (CENTER AIRBAG SENSOR ASSEMBLY) for Manual Seat: Center Airbag Occupant Classification Sensor Assembly ECU for Power Seat: (a) Turn the ignition switch on (IG), and wait for at least 60 seconds. (b) Clear the DTCs stored in the memory (See page RS-41). (c) Turn the ignition switch off. (d) Turn the ignition switch on (IG), and wait for at least 60 seconds. (e) Check the DTCs (See page RS-41). OK: DTC B1650/32 is not output. HINT: Codes other than DTC B1650/32 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK (See page RS-32) Center Airbag Occupant Classification Sensor Assembly ECU DLC3 CG DTC 32 TC C131555E02 NG 3 CHECK CONNECTION OF CONNECTORS (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. RS RS–128 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM (c) Check that the connectors are properly connected to the center airbag sensor assembly and the occupant classification ECU. OK: The connectors are properly connected. NG CONNECT CONNECTORS PROPERLY OK 4 CHECK CONNECTORS (a) Disconnect the connectors from the center airbag sensor assembly and the occupant classification ECU. (b) Check that the connectors (on the center airbag sensor assembly side and occupant classification ECU side) are not damaged. OK: The connectors are not deformed or damaged. NG REPAIR OR REPLACE WIRE HARNESS OK 5 CHECK VEHICLE TYPE (a) Check the front passenger side seat type. Result RS Result for Manual seat A for Power seat B B A Proceed to Go to step 10 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 6 RS–129 CHECK FLOOR WIRE NO. 2 (OPEN) Floor Wire No. 2 D C Occupant Classification ECU A B Center Airbag Sensor Assembly (a) Using a service wire, connect terminals 12 (FSP+) and 13 (FSP-) of connector B. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Terminal Connection Condition Specified Condition O4-8 (FSR+) - O4-4 (FSR-) Always Below 1 Ω Connector B Connector C NG O1 REPAIR OR REPLACE FLOOR WIRE NO. 2 O4 FSR- 5 4 3 2 1 10 9 8 7 6 15 14 13 12 11 FSP+ FSP- FSR+ Service Wire C C123687E02 OK 7 RS CHECK FLOOR WIRE NO. 2 (SHORT) (a) Disconnect the service wire from connector B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Floor Wire No. 2 A D C Occupant Classification ECU B Center Airbag Sensor Assembly O4 FSR- FSR+ C123686E03 OK Condition Specified Condition O4-8 (FSR+) - O4-4 (FSR-) Always 1 MΩ or higher NG Connector C C Terminal Connection REPAIR OR REPLACE FLOOR WIRE NO. 2 RS–130 8 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FLOOR WIRE NO. 2 (SHORT TO B+) Floor Wire No. 2 D C Occupant Classification ECU A B Center Airbag Sensor Assembly (a) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition O4-8 (FSR+) - Body ground Ignition switch ON Below 1 V O4-4 (FSR-) - Body ground Ignition switch ON Below 1 V NG Connector C REPAIR OR REPLACE FLOOR WIRE NO. 2 O4 FSR- FSR+ C C123686E03 OK RS 9 CHECK FLOOR WIRE NO. 2 (SHORT TO GROUND) (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Floor Wire No. 2 A D C Occupant Classification ECU B Center Airbag Sensor Assembly Condition Specified Condition Always 1 MΩ or higher O4-4 (FSR-) - Body ground Always 1 MΩ or higher HINT: After replacing the center airbag sensor assembly, check for DTCs of the center airbag sensor assembly. If the DTC B1650/32 is detected, replace the occupant classification ECU (See page RS-469) and perform "zero point calibration" and "sensitivity check" of the occupant classification system (See page RS-242). Connector C O4 FSR- NG FSR+ C Tester Connection O4-8 (FSR+) - Body ground C123686E03 REPAIR OR REPLACE FLOOR WIRE NO. 2 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–131 OK REPLACE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-441) 10 CHECK OCCUPANT CLASSIFICATION SYSTEM CIRCUIT (OPEN) E Occupant Classification ECU DC B Center Airbag Sensor Assembly Connector B Connector E (a) Using a service wire, connect terminals 12 (FSP+) and 13 (FSP-) of connector B. NOTICE: Do not forcibly insert a service wire into the terminal of the connector when connecting. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition T10-8 (FSR+) - T10-4 (FSR-) Always Below 1 Ω NG O1 Go to step 14 T10 FSR5 4 3 2 1 10 9 8 7 6 15 14 13 12 11 FSR+ FSP- FSP+ Service Wire C123726E01 OK RS RS–132 11 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK OCCUPANT CLASSIFICATION SYSTEM CIRCUIT (SHORT) (a) Disconnect the service wire from connector B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance F A E DC Occupant Classification ECU B Center Airbag Sensor Assembly Tester Connection Condition Specified Condition T10-8 (FSR+) - T10-4 (FSR-) Always 1 MΩ or higher NG Go to step 15 Connector E T10 FSR- FSR+ C C110462E29 OK RS 12 CHECK OCCUPANT CLASSIFICATION SYSTEM CIRCUIT (SHORT TO B+) F E DC Occupant Classification ECU A B Center Airbag Sensor Assembly (a) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition T10-8 (FSR+) - Body ground Ignition switch on (IG) Below 1 V T10-4 (FSR-) - Body ground Ignition switch on (IG) Below 1 V NG Connector E T10 FSR+ C OK FSR- C110462E29 Go to step 16 RS–133 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 13 CHECK OCCUPANT CLASSIFICATION SYSTEM CIRCUIT (SHORT TO GROUND) F A E DC Occupant Classification ECU B Center Airbag Sensor Assembly FSR+ C Tester Connection Condition Specified Condition T10-8 (FSR+) - Body ground Always 1 MΩ or higher T10-4 (FSR-) - Body ground Always 1 MΩ or higher HINT: After replacing the center airbag sensor assembly, check for DTCs of the center airbag sensor assembly. If the DTC B1650/32 is detected, replace the occupant classification ECU (See page RS-469) and perform "zero point calibration" and "sensitivity check" of the occupant classification system (See page RS-242). Connector E T10 (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Measure the resistance according to the value(s) in the table below. Standard resistance FSR- NG Go to step 17 C110462E29 OK REPLACE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-441) RS RS–134 14 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FLOOR WIRE NO. 2 (OPEN) Front Seat Wire RH Floor Wire No. 2 A B Center Airbag Sensor Assembly F E D C Occupant Classification ECU (a) Disconnect the front seat wire RH connector from the floor wire No. 2. HINT: The service wire has already been inserted into connector B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition OT1-1 (FSR+) - OT1-4 (FSR-) Always Below 1 Ω Connector B Connector C FSR+ NG O1 OT1 5 4 3 2 1 10 9 8 7 6 15 14 13 12 11 FSR- FSPService Wire FSP+ C123727E01 OK RS REPAIR OR REPLACE FRONT SEAT WIRE RH REPAIR OR REPLACE FLOOR WIRE NO. 2 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 15 RS–135 CHECK FLOOR WIRE NO. 2 (SHORT) (a) Disconnect the front seat wire RH connector from the floor wire No. 2. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Front Seat Wire RH F A E Occupant Classification ECU D C B Center Airbag Sensor Assembly Tester Connection Condition Specified Condition OT1-1 (FSR+) - OT1-4 (FSR-) Always 1 MΩ or higher NG REPAIR OR REPLACE FLOOR WIRE NO. 2 Floor Wire No. 2 Connector C OT1 FSR+ FSRC C110464E18 OK REPAIR OR REPLACE FRONT SEAT WIRE RH RS RS–136 16 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FLOOR WIRE NO. 2 (SHORT TO B+) Front Seat Wire RH F A E Occupant Classification ECU D C B Center Airbag Sensor Assembly Floor Wire No. 2 Connector C OT1 FSR+ Tester Connection Condition Specified Condition OT1-1 (FSR+) - Body ground Ignition switch on (IG) Below 1 V OT1-4 (FSR-) - Body ground Ignition switch on (IG) Below 1 V NG FSRC (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the front seat wire RH connector from the floor wire No. 2. (d) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (e) Turn the ignition switch on (IG). (f) Measure the voltage according to the value(s) in the table below. Standard voltage C110464E18 OK RS REPAIR OR REPLACE FRONT SEAT WIRE RH REPAIR OR REPLACE FLOOR WIRE NO. 2 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 17 RS–137 CHECK FLOOR WIRE NO. 2 (SHORT TO GROUND) (a) Disconnect the front seat wire RH connector from the floor wire No. 2. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Front Seat Wire RH F A E Occupant Classification ECU D C B Center Airbag Sensor Assembly Floor Wire No. 2 Tester Connection Condition Specified Condition OT1-1 (FSR+) - Body ground Always 1 MΩ or higher OT1-4 (FSR-) - Body ground Always 1 MΩ or higher NG REPAIR OR REPLACE FLOOR WIRE NO. 2 Connector C OT1 FSR+ FSRC C110464E18 OK REPAIR OR REPLACE FRONT SEAT WIRE RH RS RS–138 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC Seat Position Airbag Sensor Circuit Malfunction B1653/35 DESCRIPTION The seat position airbag sensor circuit consists of the center airbag sensor assembly and the seat position airbag sensor. DTC B1653/35 is recorded when a malfunction is detected in the seat position airbag sensor circuit. DTC No. DTC Detecting Condition • B1653/35 • • The center airbag sensor assembly receives a line short circuit signal, an open circuit signal, a short circuit to ground signal or a short circuit to B+ signal in the seat position airbag sensor circuit for 2 seconds. Seat position airbag sensor malfunction Center airbag sensor assembly malfunction Trouble Area • • • Floor wire Seat position airbag sensor Center airbag sensor assembly WIRING DIAGRAM Center Airbag Sensor Assembly N3 Front Seat Inner Belt Assembly LH Seat Position Airbag Sensor RS LSP+ 14 N1 DSP+ 2 LSP4 C 13 N1 DSP- C123731E01 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–139 INSPECTION PROCEDURE 1 CHECK DTC Seat Position Airbag Sensor Center Airbag Sensor Assembly DLC3 (a) Turn the ignition switch on (IG), and wait for at least 60 seconds. (b) Clear the DTCs stored in the memory (See page RS-41). (c) Turn the ignition switch off. (d) Turn the ignition switch on (IG), and wait for at least 60 seconds. (e) Check the DTCs (See page RS-41). OK: DTC B1653/35 is not output. HINT: Codes other than DTC B1653/35 may be output at this time, but they are not related to this check. OK CG TC DTC 35 C USE SIMULATION METHOD TO CHECK (See page RS-32) C114797E01 NG 2 CHECK CONNECTION OF CONNECTORS (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the center airbag sensor assembly and the seat position airbag sensor. OK: The connectors are properly connected. NG CONNECT CONNECTORS PROPERLY, THEN GO TO STEP 1 OK 3 CHECK CONNECTORS (a) Disconnect the connectors from the center airbag sensor assembly and the seat position airbag sensor. (b) Check that the connectors (on the center airbag sensor assembly side and seat position airbag sensor side) are not damaged. OK: The connectors are not deformed or damaged. NG OK REPAIR OR REPLACE FLOOR WIRE RS RS–140 4 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FLOOR WIRE (OPEN) Floor Wire A D C B Seat Position Airbag Sensor Center Airbag Sensor Assembly Connector C Connector B LSP+ 1 2 Tester Connection Condition Specified Condition N3-2 (LSP+) - N3-4 (LSP-) Always Below 1 Ω NG N1 N3 (a) Using a service wire, connect terminals 14 (DSP+) and 13 (DSP-) of connector B. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (b) Measure the resistance according to the value(s) in the table below. Standard resistance REPAIR OR REPLACE FLOOR WIRE 5 4 3 2 1 10 9 8 7 6 3 4 LSP- 15 14 13 12 11 DSP+ DSP- Service Wire C C114798E05 OK RS 5 CHECK FLOOR WIRE (SHORT) (a) Disconnect the service wire from connector B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Floor Wire A D C B Seat Position Airbag Sensor Center Airbag Sensor Assembly Connector C N3 1 2 LSP+ 3 4 LSPC C114799E08 OK Tester Connection Condition Specified Condition N3-2 (LSP+) - N3-4 (LSP-) Always 1 MΩ or higher NG REPAIR OR REPLACE FLOOR WIRE RS–141 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 6 CHECK FLOOR WIRE (SHORT TO B+) (a) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Floor Wire A D C B Seat Position Airbag Sensor Center Airbag Sensor Assembly Tester Connection Condition Specified Condition N3-2 (LSP+) - Body ground Ignition switch on (IG) Below 1 V N3-4 (LSP-) - Body ground Ignition switch on (IG) Below 1 V NG REPAIR OR REPLACE FLOOR WIRE Connector C N3 LSP+ 1 2 3 4 LSPC C114799E08 OK 7 (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Floor Wire A D C B Seat Position Airbag Sensor Center Airbag Sensor Assembly Tester Connection Condition Specified Condition N3-2 (LSP+) - Body ground Always 1 MΩ or higher N3-4 (LSP-) - Body ground Always 1 MΩ or higher NG Connector C N3 1 2 LSP+ 3 4 LSPC C114799E08 OK RS CHECK FLOOR WIRE (SHORT TO GROUND) REPAIR OR REPLACE FLOOR WIRE RS–142 8 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK SEAT POSITION AIRBAG SENSOR Seat Position Airbag Sensor Center Airbag Sensor Assembly DLC3 CG C TC DTC 35 C114797E01 (a) Connect the connectors to the center airbag sensor assembly and the seat position airbag sensor. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch on (IG), and wait for at least 60 seconds. (d) Clear the DTCs stored in the memory (See page RS-41). (e) Turn the ignition switch off. (f) Turn the ignition switch on (IG), and wait for at least 60 seconds. (g) Check the DTCs (See page RS-41). OK: DTC B1653/35 is not output. HINT: Codes other than DTC B1653/35 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK (See page RS-32) NG 9 REPLACE SEAT POSITION AIRBAG SENSOR (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Replace the seat position airbag sensor (See page RS460). HINT: Perform inspection using parts from a normal vehicle if possible. RS NEXT SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 10 RS–143 CHECK CENTER AIRBAG SENSOR ASSEMBLY Seat Position Airbag Sensor Center Airbag Sensor Assembly DLC3 CG C TC DTC 35 C114797E01 (a) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (b) Turn the ignition switch on (IG), and wait for at least 60 seconds. (c) Clear the DTCs stored in the memory (See page RS-41). (d) Turn the ignition switch off. (e) Turn the ignition switch on (IG), and wait for at least 60 seconds. (f) Check the DTCs (See page RS-41). OK: DTC B1653/35 is not output. HINT: Codes other than DTC B1653/35 may be output at this time, but they are not related to this check. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-441) OK END RS RS–144 DTC SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM Driver Side Seat Belt Buckle Switch Circuit Malfunction B1655/37 DESCRIPTION The driver side seat belt buckle switch circuit consists of the center airbag sensor assembly and the front seat inner belt assembly LH. DTC B1655/37 is recorded when a malfunction is detected in the driver side seat belt buckle switch circuit. DTC No. DTC Detection Condition • B1655/37 • • The center airbag sensor assembly receives a line short circuit signal, an open circuit signal, a short circuit to ground signal or a short circuit to B+ signal in the driver side seat belt buckle switch circuit for 2 seconds. Front seat inner belt assembly LH malfunction Center airbag sensor assembly malfunction Trouble Area • • • Floor wire Front seat inner belt assembly LH (Driver side seat belt buckle switch) Center airbag sensor assembly WIRING DIAGRAM N3 Front Seat Inner Belt Assembly LH LBE+ RS 1 Center Airbag Sensor Assembly 11 N1 DBE+ 12 LBE- 3 N1 DBE- H043715E15 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–145 INSPECTION PROCEDURE 1 CHECK DTC Front Seat Inner Belt Assembly LH DLC3 Center Airbag Sensor Assembly DTC 37 (a) Turn the ignition switch on (IG), and wait for at least 60 seconds. (b) Clear the DTCs stored in the memory (See page RS-41). (c) Turn the ignition switch off. (d) Turn the ignition switch on (IG), and wait for at least 60 seconds. (e) Check the DTCs (See page RS-44). OK: DTC B1655/37 is not output. HINT: Codes other than DTC B1655/37 may be output at this time, but they are not related to this check. Ok C CG TC USE SIMULATION METHOD TO CHECK (See page RS-32) C126754E01 NG 2 CHECK CONNECTION OF CONNECTORS (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the center airbag sensor assembly and front seat inner belt assembly LH. OK: The connectors are properly connected. NG CONNECT CONNECTORS PROPERLY, THEN GO TO STEP 1 OK 3 CHECK CONNECTORS (a) Disconnect the connectors from the center airbag sensor assembly and the front seat inner belt assembly LH. (b) Check that the connectors (on the center airbag sensor assembly side and front seat inner belt assembly LH side) are not damaged. OK: The connectors are not deformed or damaged. NG OK REPAIR OR REPLACE FLOOR WIRE RS RS–146 4 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FLOOR WIRE (OPEN) Floor Wire A D C B Front Seat Inner Belt Assembly LH Center Airbag Sensor Assembly Connector C Connector B N3 DBE+ N1 (a) Using a service wire, connect terminals 11 (DBE+) and 12 (DBE-) of connector B. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition N3-1 (LBE+) - N3-3 (LBE-) Always Below 1 Ω NG REPAIR OR REPLACE FLOOR WIRE 5 4 3 2 1 1 2 10 9 8 7 6 3 4 15 14 13 12 11 LBE+ LBE- DBE- Service Wire C C114803E04 OK RS 5 CHECK FLOOR WIRE (SHORT) (a) Disconnect the service wire from connector B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Floor Wire A D C B Front Seat Inner Belt Assembly LH Center Airbag Sensor Assembly Connector C N3 LBE+ LBEC 1 2 3 4 C114799E09 OK Tester Connection Condition Specified Condition N3-1 (LBE+) - N3-3 (LBE-) Always 1 MΩ or higher NG REPAIR OR REPLACE FLOOR WIRE RS–147 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 6 CHECK FLOOR WIRE (SHORT TO B+) (a) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Floor Wire A D C B Front Seat Inner Belt Assembly LH Center Airbag Sensor Assembly Connector C Tester Connection Condition Specified Condition N3-1 (LBE+) - Body ground Ignition switch on (IG) Below 1 V N3-3 (LBE-) - Body ground Ignition switch on (IG) Below 1 V NG REPAIR OR REPLACE FLOOR WIRE N3 LBE+ 1 2 3 4 LBEC C114799E09 OK 7 (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Floor Wire A D C B Front Seat Inner Belt Assembly LH Center Airbag Sensor Assembly Connector C LBE+ LBE- 1 2 3 4 C114799E09 OK Tester Connection Condition Specified Condition N3-1 (LBE+) - Body ground Always 1 MΩ or higher N3-3 (LBE-) - Body ground Always 1 MΩ or higher NG N3 C RS CHECK FLOOR WIRE (SHORT TO GROUND) REPAIR OR REPLACE FLOOR WIRE RS–148 8 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FRONT SEAT INNER BELT ASSEMBLY LH Front Seat Inner Belt Assembly LH DLC3 C CG TC Center Airbag Sensor Assembly DTC 37 C126754E01 (a) Connect the connector to the center airbag sensor assembly and the front seat inner belt assembly LH. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch on (IG), and wait for at least 60 seconds. (d) Clear the DTCs stored in the memory (See page RS-41). (e) Turn the ignition switch off. (f) Turn the ignition switch on (IG), and wait for at least 60 seconds. (g) Check the DTCs (See page RS-41). OK: DTC B1655/37 is not output. HINT: Codes other than DTC B1655/37 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK (See page RS-32) NG 9 REPLACE FRONT SEAT INNER BELT ASSEMBLY LH (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Replace the front seat inner belt assembly LH (See page SB-15). HINT: Perform inspection using parts from a normal vehicle if possible. RS NEXT SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 10 CHECK CENTER AIRBAG SENSOR ASSEMBLY Front Seat Inner Belt Assembly LH DLC3 C RS–149 CG TC Center Airbag Sensor Assembly DTC 37 C126754E01 (a) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (b) Turn the ignition switch on (IG), and wait for at least 60 seconds. (c) Clear the DTCs stored in the memory (See page RS-41). (d) Turn the ignition switch off. (e) Turn the ignition switch on (IG), and wait for at least 60 seconds. (f) Check the DTCs (See page RS-41). OK: DTC B1655/37 is not output. HINT: Codes other than DTC B1655/37 may be output at this time, but they are not related to this check. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-441) OK END RS RS–150 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1660/43 Passenger Airbag ON / OFF Indicator Circuit Malfunction DESCRIPTION The passenger airbag ON/OFF indicator circuit consists of the center airbag sensor assembly and the clock assembly. The passenger airbag ON/OFF indicator indicates the operation condition of the front passenger airbag assembly and the front seat side airbag assembly RH. DTC B1660/43 is recorded when a malfunction is detected in the passenger airbag ON/OFF indicator circuit. DTC No. DTC Detecting Condition • B1660/43 • • The center airbag sensor assembly receives an open circuit signal, a short circuit to ground signal or a short circuit to B+ signal in the passenger airbag ON/OFF indicator circuit for 2 seconds. Passenger airbag ON/OFF indicator malfunction Center airbag sensor assembly malfunction Trouble Area • • • • Instrument panel wire Instrument panel wire No. 2 Clock assembly Center airbag sensor assembly WIRING DIAGRAM F3 Clock Assembly RS PAON P-AB IG Center Airbag Sensor Assembly 23 E30 PAON 13 17 E30 P-AB 14 25 E30 E1 3 From GAUGE No. 2 Fuse C 26 E30 E2 C123657E02 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–151 INSPECTION PROCEDURE 1 CHECK PASSENGER AIRBAG ON/OFF INDICATOR CONDITION (a) Turn the ignition switch on (IG). (b) Check the passenger airbag ON/OFF indicator operation. HINT: Refer to the normal condition of the passenger airbag ON/OFF indicator (See page RS-32). ON Ignition Switch OFF Passenger Airbag ON/OFF Indicator (”ON”) Passenger Airbag ON/OFF Indicator (”OFF”) 4 sec. 2 sec. 4 sec. 2 sec. ON OFF ON OFF RS ON/OFF condition depends on the front passenger detection results. C123768E01 Result ON/OFF Indicator Illumination Proceed to Always ON A OFF B B Go to step 10 A 2 CHECK CONNECTION OF CONNECTORS (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the center airbag sensor assembly and the clock assembly. OK: The connectors are properly connected. NG CONNECT CONNECTORS PROPERLY, THEN GO TO STEP 1 RS–152 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM OK 3 CHECK CONNECTORS (a) Disconnect the connectors from the center airbag sensor assembly and the clock assembly. (b) Check that the connectors (on the center airbag sensor assembly side and clock assembly side) are not damaged. OK: The connectors are not deformed or damaged. NG REPAIR OR REPLACE WIRE HARNESS OK 4 CHECK PASSENGER AIRBAG ON/OFF INDICATOR (a) Connect the connector to the clock assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch on (IG). (d) Check the passenger airbag ON/OFF indicator operation. OK: The passenger airbag ON/OFF indicator does not come on. RS NG Go to step 6 OK 5 CHECK CENTER AIRBAG SENSOR ASSEMBLY Clock Assembly Center Airbag Sensor Assembly DLC3 DTC 43 CG TC C123656E01 (a) Connect the connector to the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch on (IG), and wait for at least 60 seconds. (d) Clear the DTCs stored in the memory (See page RS-41). (e) Turn the ignition switch off. (f) Turn the ignition switch on (IG), and wait for at least 60 seconds. (g) Check for DTCs (See page RS-41). OK: DTC B1660/43 is not output. HINT: Codes other than DTC B1660/43 may be output at this time, but they are not related to this check. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-441) SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–153 OK USE SIMULATION METHOD TO CHECK (See page RS-32) 6 CHECK PASSENGER AIRBAG ON/OFF INDICATOR CIRCUIT (OPEN) D A C B Clock Assembly Center Airbag Sensor Assembly Connector C Connector B F3 E30 (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connector from the clock assembly. (d) Using a service wire, connect terminals 23 (PAON) and 17 (P-AB) of connector B. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (e) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition F3-13 (PAON) - F3-14 (PAB) Always Below 1 Ω 1 2 3 4 5 6 7 8 9 10 11 121314151617181920 PAON NG P-AB P-AB PAON Service Wire C C123728E01 OK REPAIR OR REPLACE WIRE HARNESS RS RS–154 7 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK PASSENGER AIRBAG ON/OFF INDICATOR CIRCUIT (SHORT) (a) Disconnect the service wire from connector B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance D A C B Clock Assembly Center Airbag Sensor Assembly Tester Connection Condition Specified Condition F3-13 (PAON) - F3-14 (PAB) Always 1 MΩ or higher NG REPAIR OR REPLACE WIRE HARNESS Connector C F3 1 2 3 4 5 6 7 8 9 10 11 121314151617181920 P-AB PAON C C123729E01 OK RS 8 CHECK PASSENGER AIRBAG ON/OFF INDICATOR CIRCUIT (SHORT TO GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance D A C B Clock Assembly Center Airbag Sensor Assembly Tester Connection Condition Specified Condition F3-13 (PAON) - Body ground Always 1 MΩ or higher F3-14 (P-AB) - Body ground Always 1 MΩ or higher NG Connector C F3 1 2 3 4 5 6 7 8 9 10 11 121314151617181920 PAON C P-AB C123729E01 OK REPAIR OR REPLACE WIRE HARNESS RS–155 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 9 CHECK PASSENGER AIRBAG ON/OFF INDICATOR CIRCUIT (SHORT TO B+) D (a) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage A C B Clock Assembly Center Airbag Sensor Assembly Tester Connection Condition Specified Condition F3-13 (PAON) - Body ground Ignition switch on (IG) Below 1 V F3-14 (P-AB) - Body ground Ignition switch on (IG) Below 1 V Connector C NG F3 REPAIR OR REPLACE WIRE HARNESS 1 2 3 4 5 6 7 8 9 10 11 121314151617181920 PAON P-AB C C123729E01 OK RS REPLACE CLOCK ASSEMBLY (See page OT-4) 10 CHECK CONNECTION OF CONNECTORS (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the center airbag sensor assembly and the clock assembly. OK: The connectors are properly connected. NG CONNECT CONNECTORS PROPERLY OK 11 CHECK CONNECTORS (a) Disconnect the connectors from the center airbag sensor assembly and the clock assembly. (b) Check that the connectors (on the center airbag sensor assembly side and clock assembly side) are not damaged. RS–156 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM OK: The connectors are not deformed or damaged. NG REPAIR OR REPLACE WIRE HARNESS OK 12 CHECK PASSENGER AIRBAG ON/OFF INDICATOR CIRCUIT (OPEN) D A C B Clock Assembly Center Airbag Sensor Assembly Connector C Connector B F3 E30 1 2 3 4 5 6 7 8 9 10 RS P-AB P-AB PAON Service Wire C C123728E01 OK Tester Connection Condition Specified Condition F3-13 (PAON) - F3-14 (P-AB) Always Below 1 Ω NG 11 121314151617181920 PAON (a) Using a service wire, connect terminals 23 (PAON) and 17 (P-AB) of connector B. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (b) Measure the resistance according to the value(s) in the table below. Standard resistance REPAIR OR REPLACE WIRE HARNESS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 13 RS–157 CHECK PASSENGER AIRBAG ON/OFF INDICATOR CIRCUIT (SHORT) (a) Disconnect the service wire from connector B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance D A C B Clock Assembly Center Airbag Sensor Assembly Tester Connection Condition Specified Condition F3-13 (PAON) - F3-14 (P-AB) Always 1 MΩ or higher NG REPAIR OR REPLACE WIRE HARNESS Connector C F3 1 2 3 4 5 6 7 8 9 10 11 121314151617181920 P-AB PAON C C123729E01 OK 14 CHECK PASSENGER AIRBAG ON/OFF INDICATOR CIRCUIT (SHORT TO GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance D A C B Clock Assembly Center Airbag Sensor Assembly Tester Connection Condition Specified Condition F3-13 (PAON) - Body ground Always 1 MΩ or higher F3-14 (P-AB) - Body ground Always 1 MΩ or higher NG Connector C F3 1 2 3 4 5 6 7 8 9 10 11 121314151617181920 PAON C P-AB C123729E01 OK REPAIR OR REPLACE WIRE HARNESS RS RS–158 15 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK PASSENGER AIRBAG ON/OFF INDICATOR CIRCUIT (SHORT TO B+) D (a) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage A C B Clock Assembly Center Airbag Sensor Assembly Tester Connection Condition Specified Condition F3-13 (PAON) - Body ground Ignition switch on (IG) Below 1 V F3-14 (P-AB) - Body ground Ignition switch on (IG) Below 1 V Connector C NG F3 REPAIR OR REPLACE WIRE HARNESS 1 2 3 4 5 6 7 8 9 10 11 121314151617181920 P-AB PAON C C123729E01 OK RS 16 CHECK CLOCK ASSEMBLY (SOURCE VOLTAGE) (a) Connect the connectors to the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch on (IG). (d) Measure the voltage according to the value(s) in the table below. Standard voltage Clock Assembly Side: F3 IG Condition Specified Condition F3-3 (IG) -Body ground Ignition switch on (IG) 10 to 14 V NG E128063E04 OK Tester Connection REPAIR OR REPLACE WIRE HARNESS (CLOCK ASSEMBLY - BATTERY) OR BATTERY RS–159 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 17 CHECK PASSENGER AIRBAG ON / OFF INDICATOR Center Airbag Sensor Assembly Side: E30 P-AB C (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Connect the connector to the clock assembly. (d) Disconnect the connectors from the center airbag sensor assembly. (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch on (IG). (g) Check the indicator according to the conditions in the table below. Result PAON C123661E03 Tester Connection Condition Passenger airbag ON/ OFF indicator E30-23 (PAON) - Body ground Ignition switch on (IG) "ON" comes on E30-17 (P-AB) - Body ground Ignition switch on (IG) "OFF" comes on NG REPLACE CLOCK ASSEMBLY (See page OT4) OK 18 CHECK CENTER AIRBAG SENSOR ASSEMBLY Clock Assembly Center Airbag Sensor Assembly DLC3 DTC 43 CG TC C123656E01 (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Connect the connectors to the center airbag sensor assembly. (d) Connect the negative (-) terminal cable to the battery and wait for at least 2 seconds. (e) Turn the ignition switch on (IG), and wait for at least 60 seconds. (f) Clear the DTCs stored in the memory (See page RS-41). (g) Turn the ignition switch off. (h) Turn the ignition switch on (IG), and wait for at least 60 seconds. (i) Check for DTCs (See page RS-41). OK: DTC B1660/43 is not output. HINT: Codes other than DTC B1660/43 may be output at this time, but they are not related to this check. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-441) RS RS–160 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM OK USE SIMULATION METHOD TO CHECK (See page RS-32) RS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1800/51 Short in Driver Side Squib Circuit DTC B1801/51 Open in Driver Side Squib Circuit DTC B1802/51 Short to GND in Driver Side Squib Circuit DTC B1803/51 Short to B+ in Driver Side Squib Circuit RS–161 DESCRIPTION The driver side squib circuit consists of the center airbag sensor assembly, the spiral cable and the steering pad. The circuit instructs the SRS to deploy when deployment conditions are met. These DTCs are recorded when a malfunction is detected in the driver side squib circuit. DTC No. DTC Detecting Condition • B1800/51 • • • • B1801/51 • • • • B1802/51 • • • • B1803/51 • • • Trouble Area The center airbag sensor assembly receives a line short circuit signal 5 times in the driver side squib circuit during primary check. Driver side squib malfunction Spiral cable malfunction Center airbag sensor assembly malfunction • • • • Instrument panel wire Spiral cable Steering pad (Driver side squib) Center airbag sensor assembly The center airbag sensor assembly receives an open circuit signal in the driver side squib circuit for 2 seconds. Driver side squib malfunction Spiral cable malfunction Center airbag sensor assembly malfunction • • • • Instrument panel wire Spiral cable Steering pad (Driver side squib) Center airbag sensor assembly The center airbag sensor assembly receives a short circuit to ground signal in the driver side squib circuit for 0.5 seconds. Driver side squib malfunction Spiral cable malfunction Center airbag sensor assembly malfunction • • • • Instrument panel wire Spiral cable Steering pad (Driver side squib) Center airbag sensor assembly The center airbag sensor assembly receives a short circuit to B+ signal in the driver side squib circuit for 0.5 seconds. Driver side squib malfunction Spiral cable malfunction Center airbag sensor assembly malfunction • • • • Instrument panel wire Spiral cable Steering pad (Driver side squib) Center airbag sensor assembly RS RS–162 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM WIRING DIAGRAM Center Airbag Sensor Assembly Driver Side Squib D+ 1 D2 5 E30 D+ 6 E30 D- E16 Spiral Cable RS H001451E44 INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-44). • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-44). SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 1 RS–163 CHECK STEERING PAD (DRIVER SIDE SQUIB) DC F E Spiral Cable Driver Side Squib Center Airbag Sensor Assembly Connector E SST Color: Orange DLC3 CG TC DTC 51 C C114804E01 (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the steering pad. (d) Connect the white wire side of SST (resistance 2.1 Ω) to connector E (orange connector). CAUTION: Never connect the tester to the steering pad (driver side squib) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: • Do not forcibly insert the SST into the terminals of the connector when connecting. • Insert straight the SST into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch on (IG), and wait for at least 60 seconds. (g) Clear the DTCs stored in the memory (See page RS-41). (h) Turn the ignition switch off. (i) Turn the ignition switch on (IG), and wait for at least 60 seconds. (j) Check the DTCs (See page RS-41). OK: DTC B1800, B1801, B1802, B1803, or 51 is not output. HINT: Codes other than DTC B1800, B1801, B1802, B1803, and 51 may be output at this time, but they are not related to this check. OK REPLACE STEERING PAD NG 2 CHECK CONNECTOR (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the SST from connector E. (d) Check that the spiral cable connectors (on the steering pad side) are not damaged. OK: The lock button is not disengaged, or the claw of the lock is not deformed or damaged. NG REPLACE SPIRAL CABLE (See page RS363) RS RS–164 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM OK 3 CHECK DRIVER SIDE SQUIB CIRCUIT Driver Side Squib A DC F E B Spiral Cable Center Airbag Sensor Assembly Connector E D- Tester Connection Condition Specified Condition D+ - Body ground Ignition switch on (IG) Below 1 V D- - Body ground Ignition switch on (IG) Below 1 V (c) Check for an open in the circuit. (1) Turn the ignition switch off. (2) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (3) Measure the resistance according to the value(s) in the table below. Standard resistance D+ Color: Orange C (a) Disconnect the connectors from the center airbag sensor assembly. (b) Check for a short to B+ in the circuit. (1) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (2) Turn the ignition switch on (IG). (3) Measure the voltage according to the value(s) in the table below. Standard voltage C114805E01 Tester Connection Condition Specified Condition D+ - D- Always Below 1 Ω (d) Check for a short to ground in the circuit. (1) Measure the resistance according to the value(s) in the table below. Standard resistance RS Tester Connection Condition Specified Condition D+ - Body ground Always 1 MΩ or higher D- - Body ground Always 1 MΩ or higher (e) Check for a short in the circuit. (1) Release the activation prevention mechanism built into connector B (See page RS-32). (2) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition D+ - D- Always 1 MΩ or higher NG OK Go to step 5 RS–165 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 4 CHECK CENTER AIRBAG SENSOR ASSEMBLY DC FE Spiral Cable Center Airbag Sensor Assembly Driver Side Squib DLC3 CG C DTC 51 TC C114806E01 (a) Connect the connectors to the steering pad and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch on (IG), and wait for at least 60 seconds. (d) Clear the DTCs stored in the memory (See page RS-41). (e) Turn the ignition switch off. (f) Turn the ignition switch on (IG), and wait for at least 60 seconds. (g) Check the DTCs (See page RS-41). OK: DTC B1800, B1801, B1802, B1803, or 51 is not output. HINT: Codes other than DTC B1800, B1801, B1802, B1803, and 51 may be output at this time, but they are not related to this check. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-441) OK USE SIMULATION METHOD TO CHECK (See page RS-32) 5 CHECK INSTRUMENT PANEL WIRE Instrument Panel Wire A D C F E B Spiral Cable Driver Side Squib Center Airbag Sensor Assembly Connector C E16 DD+ C RS (a) Restore the released activation prevention mechanism of connector B to the original condition. (b) Disconnect the instrument panel wire connector from the spiral cable. (c) Check for a short to B+ in the circuit. (1) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (2) Turn the ignition switch on (IG). (3) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition E16-1 (D+) - Body ground Ignition switch on (IG) Below 1 V E16-2 (D-) - Body ground Ignition switch on (IG) Below 1 V (d) Check for an open in the circuit. (1) Turn the ignition switch off. (2) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. C114807E17 RS–166 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM (3) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition E16-1 (D+) - E16-2 (D-) Always Below 1 Ω (e) Check for a short to ground in the circuit. (1) Measure the resistance according to the value(s) in the table below. Standard resistance (f) Tester Connection Condition Specified Condition E16-1 (D+) - Body ground Always 1 MΩ or higher E16-2 (D-) - Body ground Always 1 MΩ or higher Check for a short in the circuit. (1) Release the activation prevention mechanism built into connector B (See page RS-32). (2) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition E16-1 (D+) - E16-2 (D-) Always 1 MΩ or higher NG REPAIR OR REPLACE INSTRUMENT PANEL WIRE OK RS 6 CHECK SPIRAL CABLE (a) Check for a short to B+ in the circuit. (1) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (2) Turn the ignition switch on (IG). (3) Measure the voltage according to the value(s) in the table below. Standard voltage Instrument Panel Wire A D C F E B Spiral Cable Driver Side Squib Center Airbag Sensor Assembly D+ Color: Orange C Condition Specified Condition D+ - Body ground Ignition switch on (IG) Below 1 V D- - Body ground Ignition switch on (IG) Below 1 V (b) Check for an open in the circuit. (1) Turn the ignition switch off. (2) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (3) Measure the resistance according to the value(s) in the table below. Standard resistance Connector E D- Tester Connection Tester Connection Condition Specified Condition D+ - D- Always Below 1 Ω C114808E01 (c) Check for a short to ground in the circuit. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–167 (1) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition D+ - Body ground Always 1 MΩ or higher D- - Body ground Always 1 MΩ or higher (d) Check for a short in the circuit. (1) Release the activation prevention mechanism built into connector D (See page RS-32). (2) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition D+ - D- Always 1 MΩ or higher NG REPLACE SPIRAL CABLE (See page RS363) OK USE SIMULATION METHOD TO CHECK (See page RS-32) RS RS–168 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1805/52 Short in Front Passenger Side Squib Circuit DTC B1806/52 Open in Front Passenger Side Squib Circuit DTC B1807/52 Short to GND in Front Passenger Side Squib Circuit DTC B1808/52 Short to B+ in Front Passenger Side Squib Circuit DESCRIPTION The front passenger side squib circuit consists of the center airbag sensor assembly and the front passenger airbag assembly. The circuit instructs the SRS to deploy when deployment conditions are met. These DTCs are recorded when a malfunction is detected in the front passenger side squib circuit. DTC No. DTC Detection Condition • B1805/52 • • • B1806/52 • • RS • B1807/52 • • • B1808/52 • • Trouble Area The center airbag sensor assembly receives a line short circuit signal 5 times in the front passenger side squib circuit during primary check. Front passenger side squib malfunction Center airbag sensor assembly malfunction • • • The center airbag sensor assembly receives an open circuit signal in the front passenger side squib circuit for 2 seconds. Front passenger side squib malfunction Center airbag sensor assembly malfunction • • • The center airbag sensor assembly receives a short circuit to ground signal in the front passenger side squib circuit for 0.5 seconds. Front passenger side squib malfunction Center airbag sensor assembly malfunction • • • The center airbag sensor assembly receives a short circuit to B+ signal in the front passenger side squib circuit for 0.5 seconds. Front passenger side squib malfunction Center airbag sensor assembly malfunction • • • • • • • Instrument panel wire Instrument panel wire assembly Front passenger airbag assembly (Front passenger side squib) Center airbag sensor assembly Instrument panel wire Instrument panel wire assembly Front passenger airbag assembly (Front passenger side squib) Center airbag sensor assembly Instrument panel wire Instrument panel wire assembly Front passenger airbag assembly (Front passenger side squib) Center airbag sensor assembly Instrument panel wire Instrument panel wire assembly Front passenger airbag assembly (Front passenger side squib) Center airbag sensor assembly SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–169 WIRING DIAGRAM c2 Front Passenger Side Squib P+ 1 P2 Center Airbag Sensor Assembly 1 Ec1 4 E30 P+ 2 Ec1 3 E30 P- RS H044548E17 INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting "check mode" (signal check) with the intelligent tester (See page RS-44). • After selecting "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-44). RS–170 1 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FRONT PASSENGER AIRBAG ASSEMBLY (FRONT PASSENGER SIDE SQUIB) F E DC Front Passenger Side Squib Center Airbag Sensor Assembly Connector E c2 SST Color: Orange DLC3 RS CG DTC 52 TC C C114809E05 (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the front passenger airbag assembly. (d) Connect the white wire side of SST (resistance 2.1 Ω) to connector E (orange connector). CAUTION: Never connect the tester to the front passenger airbag assembly (front passenger side squib) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: • Do not forcibly insert the SST into the terminals of the connector when connecting. • Insert straight the SST into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch on (IG), and wait for at least 60 seconds. (g) Clear the DTCs stored in the memory (See page RS-41). (h) Turn the ignition switch off. (i) Turn the ignition switch on (IG), and wait for at least 60 seconds. (j) Check the DTCs (See page RS-41). OK: DTC B1805, B1806, B1807, B1808, or 52 is not output. HINT: Codes other than DTC B1805, B1806, B1807, B1808, and 52 may be output at this time, but they are not related to this check. OK REPLACE FRONT PASSENGER AIRBAG ASSEMBLY (See page RS-392) NG 2 CHECK CONNECTOR (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the SST from connector E. (d) Check that the instrument panel wire assembly connectors (on the front passenger airbag assembly side) are not damaged. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–171 OK: The lock button is not disengaged, or the claw of the lock is not deformed or damaged. NG REPAIR OR REPLACE INSTRUMENT PANEL WIRE ASSEMBLY OK 3 CHECK FRONT PASSENGER SIDE SQUIB CIRCUIT Front Passenger Side Squib F E DC Center Airbag Sensor Assembly Connector E c2 P+ PColor: Orange C C114810E04 (a) Disconnect the connectors from the center airbag sensor assembly. (b) Check for a short to B+ in the circuit. (1) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (2) Turn the ignition switch on (IG). (3) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition c2-1 (P+) - Body ground Ignition switch on (IG) Below 1 V c2-2 (P-) - Body ground Ignition switch on (IG) Below 1 V (c) Check for an open in the circuit. (1) Turn the ignition switch off. (2) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (3) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition c2-1 (P+) - c2-2 (P-) Always Below 1 Ω (d) Check for a short to ground in the circuit. (1) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition c2-1 (P+) - Body ground Always 1 MΩ or higher c2-2 (P-) - Body ground Always 1 MΩ or higher (e) Check for a short in the circuit. (1) Release the activation prevention mechanism built into connector B (See page RS-32). (2) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition c2-1 (P+) - c2-2 (P-) Always 1 MΩ or higher NG Go to step 5 RS RS–172 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM OK 4 CHECK CENTER AIRBAG SENSOR ASSEMBLY FE DC Front Passenger Side Squib Center Airbag Sensor Assembly DLC3 C CG TC DTC 52 C114811E01 (a) Connect the connectors to the front passenger airbag assembly and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch on (IG), and wait for at least 60 seconds. (d) Clear the DTCs stored in the memory (See page RS-41). (e) Turn the ignition switch off. (f) Turn the ignition switch on (IG), and wait for at least 60 seconds. (g) Check the DTCs (See page RS-41). OK: DTC B1805, B1806, B1807, B1808, or 52 is not output. HINT: Codes other than DTC B1805, B1806, B1807, B1808, and 52 may be output at this time, but they are not related to this check. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-441) OK RS USE SIMULATION METHOD TO CHECK (See page RS-32) SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 5 CHECK INSTRUMENT PANEL WIRE Instrument Panel Wire Assembly A F E D C Front Passenger Side Squib B Center Airbag Sensor Assembly Instrument Panel Wire Connector C Ec1 PP+ C RS–173 C114812E07 (a) Restore the released activation prevention mechanism of connector B to the original condition. (b) Disconnect the instrument panel wire connector from the instrument panel wire assembly. (c) Check for a short to B+ in the circuit. (1) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (2) Turn the ignition switch on (IG). (3) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition Ec1-1 (P+) - Body ground Ignition switch on (IG) Below 1 V Ec1-2 (P-) - Body ground Ignition switch on (IG) Below 1 V (d) Check for an open in the circuit. (1) Turn the ignition switch off. (2) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (3) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition Ec1-1 (P+) - Ec1-2 (P-) Always Below 1 Ω (e) Check for a short to ground in the circuit. (1) Measure the resistance according to the value(s) in the table below. Standard resistance (f) Tester Connection Condition Specified Condition Ec1-1 (P+) - Body ground Always 1 MΩ or higher Ec1-2 (P-) - Body ground Always 1 MΩ or higher Check for a short in the circuit. (1) Release the activation prevention mechanism built into connector B (See page RS-32). (2) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition Ec1-1 (P+) - Ec1-2 (P-) Always 1 MΩ or higher NG OK REPAIR OR REPLACE INSTRUMENT PANEL WIRE RS RS–174 6 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK INSTRUMENT PANEL WIRE ASSEMBLY Instrument Panel Wire A F E D C B Front Passenger Side Squib Instrument Panel Wire Assembly Center Airbag Sensor Assembly Connector E c2 P+ PColor: Orange C (a) Check for a short to B+ in the circuit. (1) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (2) Turn the ignition switch on (IG). (3) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition c2-1 (P+) - Body ground Ignition switch on (IG) Below 1 V c2-2 (P-) - Body ground Ignition switch on (IG) Below 1 V (b) Check for a open in the circuit. (1) Turn the ignition switch off. (2) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (3) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition c2-1 (P+) - c2-2 (P-) Always Below 1 Ω C114813E04 (c) Check for a short to ground in the circuit. (1) Measure the resistance according to the value(s) in the table below. Standard resistance RS Tester Connection Condition Specified Condition c2-1 (P+) - Body ground Always 1 MΩ or higher c2-2 (P-) - Body ground Always 1 MΩ or higher (d) Check for a short in the circuit. (1) Release the activation prevention mechanism built into connector D (See page RS-32). (2) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition c2-1 (P+) - c2-2 (P-) Always 1 MΩ or higher NG REPAIR OR REPLACE INSTRUMENT PANEL WIRE ASSEMBLY OK USE SIMULATION METHOD TO CHECK (See page RS-32) SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–175 DTC B1810/53 Short in Driver Side Squib 2nd Step Circuit DTC B1811/53 Open in Driver Side Squib 2nd Step Circuit DTC B1812/53 Short to GND in Driver Side Squib 2nd Step Circuit DTC B1813/53 Short to B+ in Driver Side Squib 2nd Step Circuit DESCRIPTION The driver side squib 2nd step circuit consists of the center airbag sensor assembly, the spiral cable, and the steering pad. The circuit instructs the SRS to deploy when deployment conditions are met. These DTCs are recorded when a malfunction is detected in the driver side squib 2nd step circuit. DTC No. DTC Detecting Condition • B1810/53 • • • • B1811/53 • • • • B1812/53 • • • • B1813/53 • • • Trouble Area The center airbag sensor assembly receives a line short circuit signal 5 times in the driver side squib 2nd step circuit during primary check. Driver side squib 2nd step malfunction Spiral cable malfunction Center airbag sensor assembly malfunction • • • • Instrument panel wire Spiral cable Steering pad (Driver side squib 2nd step) Center airbag sensor assembly The center airbag sensor assembly receives an open circuit signal in the driver side squib 2nd step circuit for 2 seconds. Driver side squib 2nd step malfunction Spiral cable malfunction Center airbag sensor assembly malfunction • • • • Instrument panel wire Spiral cable Steering pad (Driver side squib 2nd step) Center airbag sensor assembly The center airbag sensor assembly receives a short circuit to ground signal in the driver side 2nd step circuit for 0.5 seconds. Driver side squib 2nd step malfunction Spiral cable malfunction Center airbag sensor assembly malfunction • • • • Instrument panel wire Spiral cable Steering pad (Driver side squib 2nd step) Center airbag sensor assembly The center airbag sensor assembly receives a short circuit to B+ signal in the driver side squib 2nd step circuit for 0.5 seconds. Driver side squib 2nd step malfunction Spiral cable malfunction Center airbag sensor assembly malfunction • • • • Instrument panel wire Spiral cable Steering pad (Driver side squib 2nd step) Center airbag sensor assembly RS RS–176 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM WIRING DIAGRAM Center Airbag Sensor Assembly Driver Side Squib 2nd Step D2+ 4 D23 8 E30 D2+ 7 E30 D2- E16 Spiral Cable RS H001451E45 INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting "check mode" (signal check) with the intelligent tester (See page RS-44). • After selecting "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-44). SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 1 RS–177 CHECK STEERING PAD (DRIVER SIDE SQUIB 2ND STEP) F E DC Spiral Cable Driver Side Squib 2nd Step Center Airbag Sensor Assembly Connector E SST Color: Black DLC3 CG DTC 53 TC C C114814E01 (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the steering pad. (d) Connect the white wire side of SST (resistance 2.1 Ω) to connector E (black connector). CAUTION: Never connect the tester to the steering pad (driver side squib 2nd step) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: • Do not forcibly insert the SST into the terminals of the connector when connecting. • Insert straight the SST into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch on (IG), and wait for at least 60 seconds. (g) Clear the DTCs stored in the memory (See page RS-41). (h) Turn the ignition switch off. (i) Turn the ignition switch on (IG), and wait for at least 60 seconds. (j) Check the DTCs (See page RS-41). OK: DTC B1810, B1811, B1812, B1813, or 53 is not output. HINT: Codes other than DTC B1810, B1811, B1812, B1813, and 53 may be output at this time, but they are not related to this check. OK REPLACE STEERING PAD (See page RS349) NG 2 CHECK CONNECTOR (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the SST from connector E. (d) Check that the spiral cable connectors (on the steering pad side) are not damaged. OK: The lock button is not disengaged, or the claw of the lock is not deformed or damaged. RS RS–178 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM NG REPLACE SPIRAL CABLE (See page RS363) OK 3 CHECK DRIVER SIDE SQUIB 2ND STEP CIRCUIT Driver Side Squib 2nd Step A F E DC Spiral Cable B Center Airbag Sensor Assembly Connector E D2- C Tester Connection Condition Specified Condition D2+ - Body ground Ignition switch on (IG) Below 1 V D2- - Body ground Ignition switch on (IG) Below 1 V (c) Check for an open in the circuit. (1) Turn the ignition switch off. (2) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (3) Measure the resistance according to the value(s) in the table below. Standard resistance D2+ Color: Black RS (a) Disconnect the connectors from the center airbag sensor assembly. (b) Check for a short to B+ in the circuit. (1) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (2) Turn the ignition switch on (IG). (3) Measure the voltage according to the value(s) in the table below. Standard voltage C114815E01 Tester Connection Condition Specified Condition D2+ - D2- Always Below 1 Ω (d) Check for a short to ground in the circuit. (1) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition D2+ - Body ground Always 1 MΩ or higher D2- - Body ground Always 1 MΩ or higher (e) Check for a short in the circuit. (1) Release the activation prevention mechanism built into connector B (See page RS-32). (2) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition D2+ - D2- Always 1 MΩ or higher NG OK Go to step 5 RS–179 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 4 CHECK CENTER AIRBAG SENSOR ASSEMBLY FE DC Spiral Cable Driver Side Squib 2nd Step Center Airbag Sensor Assembly DTC 53 DLC3 C CG TC C114816E01 (a) Connect the connectors to the steering pad and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch on (IG), and wait for at least 60 seconds. (d) Clear the DTCs stored in the memory (See page RS-41). (e) Turn the ignition switch off. (f) Turn the ignition switch on (IG), and wait for at least 60 seconds. (g) Check the DTCs (See page RS-41). OK: DTC B1810, B1811, B1812, B1813, or 53 is not output. HINT: Codes other than DTC B1810, B1811, B1812, B1813, and 53 may be output at this time, but they are not related to this check. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-441) OK USE SIMULATION METHOD TO CHECK (See page RS-32) 5 CHECK INSTRUMENT PANEL WIRE Instrument Panel Wire A D C F E B Spiral Cable Driver Side Squib 2nd Step Center Airbag Sensor Assembly Connector C E16 D2- D2+ C RS (a) Check for a short to B+ in the circuit. (1) Restore the released activation prevention mechanism of connector B to the original condition. (2) Disconnect the instrument panel wire connector from the spiral cable. (3) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (4) Turn the ignition switch on (IG). (5) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition E16-4 (D2+) - Body ground Ignition switch on (IG) Below 1 V E16-3 (D2-) - Body ground Ignition switch on (IG) Below 1 V (b) Check for an open in the circuit. (1) Turn the ignition switch off. (2) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. C114807E16 RS–180 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM (3) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition E16-4 (D2+) - E16-3 (D2) Always Below 1 Ω (c) Check for a short to ground in the circuit. (1) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition E16-4 (D2+) - Body ground Always 1 MΩ or higher E16-3 (D2-) - Body ground Always 1 MΩ or higher (d) Check for a short in the circuit. (1) Release the activation prevention mechanism built into connector B (See page RS-32). (2) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition E16-4 (D2+) - E16-3 (D2) Always 1 MΩ or higher NG RS OK REPAIR OR REPLACE INSTRUMENT PANEL WIRE ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 6 RS–181 CHECK SPIRAL CABLE Driver Side Squib 2nd Step Instrument Panel Wire A F E DC Spiral Cable B Center Airbag Sensor Assembly D2+ Color: Black C Tester Connection Condition Specified Condition D2+ - Body ground Ignition switch on (IG) Below 1 V D2- - Body ground Ignition switch on (IG) Below 1 V (b) Check for an open in the circuit. (1) Turn the ignition switch off. (2) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (3) Measure the resistance according to the value(s) in the table below. Standard resistance Connector E D2- (a) Check for a short to B+ in the circuit. (1) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (2) Turn the ignition switch on (IG). (3) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition D2+ - D2- Always Below 1 Ω C114817E01 (c) Check for a short to ground in the circuit. (1) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition D2+ - Body ground Always 1 MΩ or higher D2- - Body ground Always 1 MΩ or higher (d) Check for a short in the circuit. (1) Release the activation prevention mechanism built into connector D (See page RS-32). (2) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition D2+ - D2- Always 1 MΩ or higher NG REPLACE SPIRAL CABLE (See page RS363) OK USE SIMULATION METHOD TO CHECK (See page RS-32) RS RS–182 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1815/54 Short in Front Passenger Side Squib 2nd Step Circuit DTC B1816/54 Open in Front Passenger Side Squib 2nd Step Circuit DTC B1817/54 Short to GND in Front Passenger Side Squib 2nd Step Circuit DTC B1818/54 Short to B+ in Front Passenger Side Squib 2nd Step Circuit DESCRIPTION The front passenger side squib 2nd step circuit consists of the center airbag sensor assembly and the front passenger airbag assembly. The circuit instructs the SRS to deploy when deployment conditions are met. These DTCs are recorded when a malfunction is detected in the front passenger side squib 2nd step circuit. DTC No. DTC Detecting Condition • B1815/54 • • RS • B1816/54 • • • B1817/54 • • • B1818/54 • • Trouble Area The center airbag sensor assembly receives a line short circuit signal 5 times in the front passenger side squib 2nd step circuit during primary check. Front passenger side squib 2nd step malfunction Center airbag sensor assembly malfunction • • • The center airbag sensor assembly receives an open circuit signal in the front passenger side squib 2nd step circuit for 2 seconds. Front passenger side squib 2nd step malfunction Center airbag sensor assembly malfunction • • • The center airbag sensor assembly receives a short circuit to ground signal in the front passenger side squib 2nd step circuit for 0.5 seconds. Front passenger side squib 2nd step malfunction Center airbag sensor assembly malfunction • • • The center airbag sensor assembly receives a short circuit to B+ signal in the front passenger side squib 2nd step circuit for 0.5 seconds. Front passenger side squib 2nd step malfunction Center airbag sensor assembly malfunction • • • • • • • Instrument panel wire Instrument panel wire assembly Front passenger airbag assembly (Front passenger side squib 2nd step) Center airbag sensor assembly Instrument panel wire Instrument panel wire assembly Front passenger airbag assembly (Front passenger side squib 2nd step) Center airbag sensor assembly Instrument panel wire Instrument panel wire assembly Front passenger airbag assembly (Front passenger side squib 2nd step) Center airbag sensor assembly Instrument panel wire Instrument panel wire assembly Front passenger airbag assembly (Front passenger side squib 2nd step) Center airbag sensor assembly SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–183 WIRING DIAGRAM c1 Front Passenger Side Squib 2nd Step P2+ 1 P22 Center Airbag Sensor Assembly 3 Ec1 1 E30 P2+ 4 Ec1 2 E30 P2- RS H044548E18 INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting "check mode" (signal check) with the intelligent tester (See page RS-44). • After selecting "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-44). RS–184 1 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FRONT PASSENGER AIRBAG ASSEMBLY (FRONT PASSENGER SIDE SQUIB 2ND STEP) F E DC Front Passenger Side Squib 2nd Step Center Airbag Sensor Assembly Connector E c1 SST Color: Black DLC3 RS CG DTC 53 TC C C114820E06 (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the front passenger airbag assembly. (d) Connect the white wire side of SST (resistance 2.1 Ω) to connector E (black connector). CAUTION: Never connect the tester to the front passenger airbag assembly (front passenger side squib 2nd step) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: • Do not forcibly insert the SST into the terminals of the connector when connecting. • Insert straight the SST into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch on (IG), and wait for at least 60 seconds. (g) Clear the DTCs stored in the memory (See page RS-41). (h) Turn the ignition switch off. (i) Turn the ignition switch on (IG), and wait for at least 60 seconds. (j) Check the DTCs (See page RS-41). OK: DTC B1815, B1816, B1817, B1818, or 54 is not output. HINT: Codes other than DTC B1815, B1816, B1817, B1818, and 54 may be output at this time, but they are not related to this check. OK REPLACE FRONT PASSENGER AIRBAG ASSEMBLY (See page RS-392) NG 2 CHECK CONNECTOR (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the SST from connector E. (d) Check that the instrument panel wire assembly connectors (on the front passenger airbag assembly side) are not damaged. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–185 OK: The lock button is not disengaged, or the claw of the lock is not damaged or deformed. NG REPAIR OR REPLACE INSTRUMENT PANEL WIRE ASSEMBLY OK 3 CHECK FRONT PASSENGER SIDE SQUIB 2ND STEP CIRCUIT A F E DC B Front Passenger Side Squib 2nd Step P2- Center Airbag Sensor Assembly Tester Connection Condition Specified Condition Connector E c1-1 (P2+) - Body ground Ignition switch on (IG) Below 1 V c1 c1-2 (P2-) - Body ground Ignition switch on (IG) Below 1 V P2+ Color: Black C (a) Disconnect the connectors from the center airbag sensor assembly. (b) Check for a short to B+ in the circuit. (1) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (2) Turn the ignition switch on (IG). (3) Measure the voltage according to the value(s) in the table below. Standard voltage C114821E05 (c) Check for an open in the circuit. (1) Turn the ignition switch off. (2) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (3) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition c1-1 (P2+) - c1-2 (P2-) Always Below 1 Ω (d) Check for a short to ground in the circuit. (1) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition c1-1 (P2+) - Body ground Always 1 MΩ or higher c1-2 (P2-) - Body ground Always 1 MΩ or higher (e) Check for a short in the circuit. (1) Release the activation prevention mechanism built into connector B (See page RS-32). (2) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition c1-1 (P2+) - c1-2 (P2-) Always 1 MΩ or higher RS RS–186 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM NG Go to step 5 OK 4 CHECK CENTER AIRBAG SENSOR ASSEMBLY Front Passenger Side Squib 2nd Step FE DC Center Airbag Sensor Assembly DLC3 C CG TC DTC 54 C114822E01 (a) Connect the connectors to the front passenger airbag assembly and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch on (IG), and wait for at least 60 seconds. (d) Clear the DTCs stored in the memory (See page RS-41). (e) Turn the ignition switch off. (f) Turn the ignition switch on (IG), and wait for at least 60 seconds. (g) Check the DTCs (See page RS-41). OK: DTC B1815, B1816, B1817, B1818, or 54 is not output. HINT: Codes other than DTC B1815, B1816, B1817, B1818, and 54 may be output at this time, but they are not related to this check. NG RS REPLACE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-441) OK USE SIMULATION METHOD TO CHECK (See page RS-32) SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 5 CHECK INSTRUMENT PANEL WIRE Instrument Panel Wire Assembly A F E D C B Front Passenger Side Squib 2nd Step Center Airbag Sensor Assembly Instrument Panel Wire Connector C Ec1 P2+ P2- C RS–187 C114812E08 (a) Check for a short to B+ in the circuit. (1) Restore the released activation prevention mechanism of connector B to the original condition. (2) Disconnect the instrument panel wire connector from the instrument panel wire assembly. (3) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (4) Turn the ignition switch on (IG). (5) Measure the voltage according to the value(s) in the table below. Standard voltage Tester connection Condition Specified condition Ec1-3 (P2+) - Body ground Ignition switch on (IG) Below 1 V Ec1-4 (P2-) - Body ground Ignition switch on (IG) Below 1 V (b) Check for an open in the circuit. (1) Turn the ignition switch off. (2) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (3) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition Ec1-3 (P2+) - Ec1-4 (P2) Always Below 1 Ω (c) Check for a short to ground in the circuit. (1) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition Ec1-3 (P2+) - Body ground Always 1 MΩ or higher Ec1-4 (P2-) - Body ground Always 1 MΩ or higher (d) Check for a short in the circuit. (1) Release the activation prevention mechanism built into connector B (See page RS-32). (2) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition Ec1-3 (P2+) - Ec1-4 (P2) Always 1 MΩ or higher NG OK REPAIR OR REPLACE INSTRUMENT PANEL WIRE RS RS–188 6 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK INSTRUMENT PANEL WIRE ASSEMBLY Instrument Panel Wire Assembly A F E D C Front Passenger Side Squib 2nd Step B Center Airbag Sensor Assembly Instrument Panel Wire Connector E c1 P2- P2+ Color: Black C C114823E04 (a) Check for a short to B+ in the circuit. (1) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (2) Turn the ignition switch on (IG). (3) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition c1-1 (P2+) - Body ground Ignition switch on (IG) Below 1 V c1-2 (P2-) - Body ground Ignition switch on (IG) Below 1 V (b) Check for an open in the circuit. (1) Turn the ignition switch off. (2) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (3) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition c1-1 (P2+) - c1-2 (P2-) Always Below 1 Ω (c) Check for a short to ground in the circuit. (1) Measure the resistance according to the value(s) in the table below. Standard resistance RS Tester Connection Condition Specified Condition c1-1 (P2+) - Body ground Always 1 MΩ or higher c1-2 (P2-) - Body ground Always 1 MΩ or higher (d) Check for a short in the circuit. (1) Release the activation prevention mechanism built into connector D (See page RS-32). (2) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition c1-1 (P2+) - c1-2 (P2-) Always 1 MΩ or higher NG REPAIR OR REPLACE INSTRUMENT PANEL WIRE ASSEMBLY OK USE SIMULATION METHOD TO CHECK (See page RS-32) SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–189 DTC B1820/55 Short in Front Driver Side - Side Squib Circuit DTC B1821/55 Open in Front Driver Side - Side Squib Circuit DTC B1822/55 Short to GND in Front Driver Side - Side Squib Circuit DTC B1823/55 Short to B+ in Front Driver Side - Side Squib Circuit DESCRIPTION The driver side - side squib circuit consists of the center airbag sensor assembly and the front seat side airbag assembly LH. This circuit instructs the SRS to deploy when deployment conditions are met. These DTCs are recorded when a malfunction is detected in the driver side - side squib circuit. DTC No. DTC Detection Condition • B1820/55 • • • B1821/55 • • • B1822/55 • • • B1823/55 • • The center airbag sensor assembly receives a line short circuit signal 5 times in the driver side - side squib circuit during primary check. Driver side - side squib malfunction Center airbag sensor assembly malfunction The center airbag sensor assembly receives an open circuit signal in the driver side - side squib circuit for 2 seconds. Driver side - side squib malfunction Center airbag sensor assembly malfunction The center airbag sensor assembly receives a short circuit to ground signal in the driver side - side squib circuit for 0.5 seconds. Driver side - side squib malfunction Center airbag sensor assembly malfunction The center airbag sensor assembly receives a short circuit to B+ signal in the driver side - side squib circuit for 0.5 seconds. Driver side - side squib malfunction Center airbag sensor assembly malfunction Trouble Area • • • • • • • • • • • • Floor wire Front seat side airbag assembly LH (Driver side side squib) Center airbag sensor assembly Floor wire Front seat side airbag assembly LH (Driver side side squib) Center airbag sensor assembly Floor wire Front seat side airbag assembly LH (Driver side side squib) Center airbag sensor assembly Floor wire Front seat side airbag assembly LH (Driver side side squib) Center airbag sensor assembly RS RS–190 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM WIRING DIAGRAM Center Airbag Sensor Assembly Z1 Driver Side - Side Spuib SFL+ 2 SFL1 9 N1 SFD+ 10 N1 SFD- NZ2 Wire Harness RS H001451E50 INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting "check mode" (signal check) with the intelligent tester (See page RS-44). • After selecting "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-44). SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 1 RS–191 CHECK FRONT SEAT SIDE AIRBAG ASSEMBLY LH (DRIVER SIDE - SIDE SQUIB) D C Driver Side - Side Squib Center Airbag Sensor Assembly Connector C NZ2 SST DLC3 CG C DTC 55 TC C114824E08 (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connector from the front seat side airbag assembly LH. (d) Connect the black wire side of SST (resistance 2.1 Ω) to connector C. CAUTION: Never connect the tester to the front seat side airbag assembly LH (driver side - side squib) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: • Do not forcibly insert the SST into the terminals of the connector when connecting. • Insert straight the SST into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch on (IG), and wait for at least 60 seconds. (g) Clear the DTCs stored in the memory (See page RS-41). (h) Turn the ignition switch off. (i) Turn the ignition switch on (IG), and wait for at least 60 seconds. (j) Check the DTCs (See page RS-41). OK: DTC B1820, B1821, B1822, B1823, or 55 is not output. HINT: Codes other than DTC B1820, B1821, B1822, B1823, and 55 may be output at this time, but they are not related to this check. OK NG REPLACE FRONT SEAT ASSEMBLY LH RS RS–192 2 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FLOOR WIRE (DRIVER SIDE - SIDE SQUIB CIRCUIT) Floor Wire A D C B Driver Side - Side Squib Connector C SFLC Center Airbag Sensor Assembly NZ2 1 2 SFL+ (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the SST from connector C. (d) Disconnect the connectors from the center airbag sensor assembly. (e) Check for a short to B+ in the circuit. (1) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (2) Turn the ignition switch on (IG). (3) Measure the voltage according to the value(s) in the table below. Standard voltage C114825E06 (f) RS Tester Connection Condition Specified Condition NZ2-2 (SFL+) - Body ground Ignition switch on (IG) Below 1 V NZ2-1 (SFL-) - Body ground Ignition switch on (IG) Below 1 V Check for an open in the circuit. (1) Turn the ignition switch off. (2) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (3) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition NZ2-2 (SFL+) - NZ2-1 (SFL-) Always Below 1 Ω (g) Check for a short to ground in the circuit. (1) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition NZ2-2 (SFL+) - Body ground Always 1 MΩ or higher NZ2-1 (SFL-) - Body ground Always 1 MΩ or higher (h) Check for a short in the circuit. (1) Release the activation prevention mechanism built into connector B (See page RS-32). (2) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition NZ2-2 (SFL+) - NZ2-1 (SFL-) Always 1 MΩ or higher NG REPAIR OR REPLACE FLOOR WIRE SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–193 OK 3 CHECK CENTER AIRBAG SENSOR ASSEMBLY Driver Side - Side Squib DC Center Airbag Sensor Assembly DLC3 C CG TC DTC 56 C114826E01 (a) Connect the connectors to the front seat side airbag assembly LH and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch on (IG), and wait for at least 60 seconds. (d) Clear the DTCs stored in the memory (See page RS-41). (e) Turn the ignition switch off. (f) Turn the ignition switch on (IG), and wait for at least 60 seconds. (g) Check the DTCs (See page RS-41). OK: DTC B1820, B1821, B1822, B1823, or 55 is not output. HINT: Codes other than DTC B1820, B1821, B1822, B1823, and 55 may be output at this time, but they are not related to this check. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-441) OK USE SIMULATION METHOD TO CHECK (See page RS-32) RS RS–194 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1825/56 Short in Front Passenger Side - Side Squib Circuit DTC B1826/56 Open in Front Passenger Side - Side Squib Circuit DTC B1827/56 Short to GND in Front Passenger Side - Side Squib Circuit DTC B1828/56 Short to B+ in Front Passenger Side - Side Squib Circuit DESCRIPTION The front passenger side - side squib circuit consists of the center airbag sensor assembly and the front seat side airbag assembly RH. The circuit instructs the SRS to deploy when deployment conditions are met. These DTCs are recorded when a malfunction is detected in the front passenger side - side squib circuit. DTC No. DTC Detection Condition • B1825/56 • • • RS B1826/56 • • • B1827/56 • • • B1828/56 • • The center airbag sensor assembly receives a line short circuit signal 5 times in the front passenger side - side squib circuit during primary check. Front passenger side - side squib malfunction Center airbag sensor assembly malfunction The center airbag sensor assembly receives an open circuit signal in the front passenger side - side squib circuit for 2 seconds. Front passenger side - side squib malfunction Center airbag sensor assembly malfunction The center airbag sensor assembly receives a short circuit to ground signal in the front passenger side - side squib circuit for 0.5 seconds. Front passenger side - side squib malfunction Center airbag sensor assembly malfunction The center airbag sensor assembly receives a short circuit to B+ signal in the front passenger side - side squib circuit for 0.5 seconds. Front passenger side - side squib malfunction Center airbag sensor assembly malfunction Trouble Area • • • • • • • • • • • • Floor wire No. 2 Front seat side airbag assembly RH (Front passenger side - side squib) Center airbag sensor assembly Floor wire No. 2 Front seat side airbag assembly RH (Front passenger side - side squib) Center airbag sensor assembly Floor wire No. 2 Front seat side airbag assembly RH (Front passenger side - side squib) Center airbag sensor assembly Floor wire No. 2 Front seat side airbag assembly RH (Front passenger side - side squib) Center airbag sensor assembly SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–195 WIRING DIAGRAM Center Airbag Sensor Assembly Y1 Front Passenger Side - Side Squib SFR+ 2 SFR1 7 O1 SFP+ 6 O1 SFP- OY2 Wire Harness RS H001451E51 INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting "check mode" (signal check) with the intelligent tester (See page RS-44). • After selecting "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-44). RS–196 1 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FRONT SEAT SIDE AIRBAG ASSEMBLY RH (FRONT PASSENGER SIDE - SIDE SQUIB) D C Front Passenger Side - Side Squib Center Airbag Sensor Assembly Connector C OY2 1 2 DLC3 RS CG SST DTC 56 TC C114818E06 (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connector from the front seat side airbag assembly RH. (d) Connect the black wire side of SST (resistance 2.1 Ω) to connector C. CAUTION: Never connect the tester to the front seat side airbag assembly RH (front passenger side - side squib) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: • Do not forcibly insert the SST into the terminals of the connector when connecting. • Insert straight the SST into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch on (IG), and wait for at least 60 seconds. (g) Clear the DTCs stored in the memory (See page RS-41). (h) Turn the ignition switch off. (i) Turn the ignition switch on (IG), and wait for at least 60 seconds. (j) Check the DTCs (See page RS-41). OK: DTC B1825, B1826, B1827, B1828, or 56 is not output. HINT: Codes other than DTC B1825, B1826, B1827, B1828, and 56 may be output at this time, but they are not related to this check. OK NG REPLACE FRONT SEAT ASSEMBLY RH RS–197 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 2 CHECK FLOOR WIRE NO. 2 (FRONT PASSENGER SIDE - SIDE SQUIB CIRCUIT) Floor Wire No. 2 A D C B Center Airbag Front Passenger Sensor Assembly Side - Side Squib Connector C OY2 SFRC 1 2 (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the SST from connector C. (d) Disconnect the connectors from the center airbag sensor assembly. (e) Check for a short to B+ in the circuit. (1) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (2) Turn the ignition switch on (IG). (3) Measure the voltage according to the value(s) in the table below. Standard voltage SFR+ C110406E22 (f) Tester connection Condition Specified condition OY2-2 (SFR+) - Body ground Ignition switch on (IG) Below 1 V OY2-1 (SFR-) - Body ground Ignition switch on (IG) Below 1 V Check for an open in the circuit. (1) Turn the ignition switch off. (2) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (3) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition OY2-2 (SFR+) - OY2-1 (SFR-) Always Below 1 Ω (g) Check for a short to ground in the circuit. (1) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition OY2-2 (SFR+) - Body ground Always 1 MΩ or higher OY2-1 (SFR-) - Body ground Always 1 MΩ or higher (h) Check for a short in the circuit. (1) Release the activation prevention mechanism built into connector B (See page RS-32). (2) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition OY2-2 (SFR+) - OY2-1 (SFR-) Always 1 MΩ or higher NG REPAIR OR REPLACE FLOOR WIRE NO. 2 RS RS–198 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM OK 3 CHECK CENTER AIRBAG SENSOR ASSEMBLY D C Front Passenger Side - Side Squib DLC3 CG Center Airbag Sensor Assembly DTC 56 TC C114819E01 (a) Connect the connectors to the front seat side airbag assembly RH and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch on (IG), and wait for at least 60 seconds. (d) Clear the DTCs stored in the memory (See page RS-41). (e) Turn the ignition switch off. (f) Turn the ignition switch on (IG), and wait for at least 60 seconds. (g) Check the DTCs (See page RS-41). OK: DTC B1825, B1826, B1827, B1828, or 56 is not output. HINT: Codes other than DTC B1825, B1826, B1827, B1828, and 56 may be output at this time, but they are not related to this check. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-441) OK RS USE SIMULATION METHOD TO CHECK (See page RS-32) SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–199 DTC B1830/57 Short in Driver Side Curtain Shield Squib Circuit DTC B1831/57 Open in Driver Side Curtain Shield Squib Circuit DTC B1832/57 Short to GND in Driver Side Curtain Shield Squib Circuit DTC B1833/57 Short to B+ in Driver Side Curtain Shield Squib Circuit DESCRIPTION The driver side curtain shield squib circuit consists of the center airbag sensor assembly and the curtain shield airbag assembly LH. The circuit instructs the SRS to deploy when deployment conditions are met. These DTCs are recorded when a malfunction is detected in the driver side curtain shield squib circuit. DTC No. DTC Detection Condition • B1830/57 • • • B1831/57 • • • B1832/57 • • • B1833/57 • • The center airbag sensor assembly receives a line short circuit signal 5 times in the driver side curtain shield squib circuit during primary check. Driver side curtain shield squib malfunction Center airbag sensor assembly malfunction The center airbag sensor assembly receives an open circuit signal in the driver side curtain shield squib circuit for 2 seconds. Driver side curtain shield squib malfunction Center airbag sensor assembly malfunction The center airbag sensor assembly receives a short circuit to ground signal in the driver side curtain shield squib circuit for 0.5 seconds. Driver side curtain shield squib malfunction Center airbag sensor assembly malfunction The center airbag sensor assembly receives a short circuit to B+ signal in the driver side curtain shield squib circuit for 0.5 seconds. Driver side curtain shield squib malfunction Center airbag sensor assembly malfunction Trouble Area • • • • • • • • • • • • Floor wire Curtain shield airbag assembly LH (Driver side curtain shield squib) Center airbag sensor assembly Floor wire Curtain shield airbag assembly LH (Driver side curtain shield squib) Center airbag sensor assembly Floor wire Curtain shield airbag assembly LH (Driver side curtain shield squib) Center airbag sensor assembly Floor wire Curtain shield airbag assembly LH (Driver side curtain shield squib) Center airbag sensor assembly RS RS–200 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM WIRING DIAGRAM Center Airbag Sensor Assembly N21 Driver Side Curtain Shield Squib ICL+ 1 ICL- 2 7 N1 ICD+ 6 N1 ICD- RS C124552E39 INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting "check mode" (signal check) with the intelligent tester (See page RS-44). • After selecting "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-44). SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 1 RS–201 CHECK CURTAIN SHIELD AIRBAG ASSEMBLY LH (DRIVER SIDE CURTAIN SHIELD SQUIB) D C Driver Side Curtain Shield Squib Center Airbag Sensor Assembly Connector C N21 DLC3 CG SST DTC 57 TC C C123742E01 (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connector from the curtain shield airbag assembly LH. (d) Connect the white wire side of SST (resistance 2.1 Ω) to connector C. CAUTION: Never connect the tester to the curtain shield airbag assembly LH (driver side curtain shield squib) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: • Do not forcibly insert the SST into the terminals of the connector when connecting. • Insert straight the SST into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch on (IG), and wait for at least 60 seconds. (g) Clear the DTCs stored in the memory (See page RS-41). (h) Turn the ignition switch off. (i) Turn the ignition switch on (IG), and wait for at least 60 seconds. (j) Check the DTCs (See page RS-41). OK: DTC B1830, B1831, B1832, B1833, or 57 is not output. HINT: Codes other than DTC B1830, B1831, B1832, B1833, and 57 may be output at this time, but they are not related to this check. OK REPLACE CURTAIN SHIELD AIRBAG ASSEMBLY LH (See page RS-416) NG 2 CHECK CONNECTOR (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the SST from connector C. (d) Check that the floor wire connector (on the curtain shield airbag assembly LH side) is not damaged. RS RS–202 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM OK: The lock button is not disengaged, or the claw of the lock is not deformed or damaged. NG REPAIR OR REPLACE FLOOR WIRE OK 3 CHECK FLOOR WIRE (DRIVER SIDE CURTAIN SHIELD SQUIB CIRCUIT) Floor Wire A D C Driver Side Curtain Shield Squib B Center Airbag Sensor Assembly Connector C N21 ICL+ ICL- RS C C123744E01 (a) Disconnect the connectors from the center airbag sensor assembly. (b) Check for a short to B+ in the circuit. (1) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (2) Turn the ignition switch on (IG). (3) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition N21-1 (ICL+) - Body ground Ignition switch on (IG) Below 1 V N21-2 (ICL-) - Body ground Ignition switch on (IG) Below 1 V (c) Check for an open in the circuit. (1) Turn the ignition switch off. (2) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (3) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition N21-1 (ICL+) - N21-2 (ICL-) Always Below 1 Ω (d) Check for a short to ground in the circuit. (1) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition N21-1 (ICL+) - Body ground Always 1 MΩ or higher N21-2 (ICL-) - Body ground Always 1 MΩ or higher (e) Check for a short in the circuit. (1) Release the activation prevention mechanism built into connector B (See page RS-32). (2) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition N21-1 (ICL+) - N21-2 (ICL-) Always 1 MΩ or higher SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM NG RS–203 REPAIR OR REPLACE FLOOR WIRE OK 4 CHECK CENTER AIRBAG SENSOR ASSEMBLY DC Driver Side Curtain Shield Squib DLC3 CG C Center Airbag Sensor Assembly DTC 57 TC C111695E02 (a) Connect the connectors to the curtain shield airbag assembly LH and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch on (IG), and wait for at least 60 seconds. (d) Clear the DTCs stored in the memory (See page RS-41). (e) Turn the ignition switch off. (f) Turn the ignition switch on (IG), and wait for at least 60 seconds. (g) Check the DTCs (See page RS-41). OK: DTC B1830, B1831, B1832, B1833, or 57 is not output. HINT: Codes other than DTC B1830, B1831, B1832, B1833, and 57 may be output at this time, but they are not related to this check. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-441) OK USE SIMULATION METHOD TO CHECK (See page RS-32) RS RS–204 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1835/58 Short in Front Passenger Side Curtain Shield Squib Circuit DTC B1836/58 Open in Front Passenger Side Curtain Shield Squib Circuit DTC B1837/58 Short to GND in Front Passenger Side Curtain Shield Squib Circuit DTC B1838/58 Short to B+ in Front Passenger Side Curtain Shield Squib Circuit DESCRIPTION The front passenger side curtain shield squib circuit consists of the center airbag sensor assembly and the curtain shield airbag assembly RH. The circuit instructs the SRS to deploy when deployment conditions are met. These DTCs are recorded when a malfunction is detected in the front passenger side curtain shield squib circuit. DTC No. DTC Detection Condition • B1835/58 • • RS • B1836/58 • • • B1837/58 • • • B1838/58 • • The center airbag sensor assembly receives a line short circuit signal 5 times in the front passenger side curtain shield squib circuit during primary check. Front passenger side curtain shield squib malfunction Center airbag sensor assembly malfunction The center airbag sensor assembly receives an open circuit signal in the front passenger side curtain shield squib circuit for 2 seconds. Front passenger side curtain shield squib malfunction Center airbag sensor assembly malfunction The center airbag sensor assembly receives a short circuit to ground signal in the front passenger side curtain shield squib circuit for 0.5 seconds. Front passenger side curtain shield squib malfunction Center airbag sensor assembly malfunction The center airbag sensor assembly receives a short circuit to B+ signal in the front passenger side curtain shield squib circuit for 0.5 seconds. Front passenger side curtain shield squib malfunction Center airbag sensor assembly malfunction Trouble Area • • • • • • • • • • • • Floor wire No. 2 Curtain shield airbag assembly RH (Front passenger side curtain shield squib) Center airbag sensor assembly Floor wire No. 2 Curtain shield airbag assembly RH (Front passenger side curtain shield squib) Center airbag sensor assembly Floor wire No. 2 Curtain shield airbag assembly RH (Front passenger side curtain shield squib) Center airbag sensor assembly Floor wire No. 2 Curtain shield airbag assembly RH (Front passenger side curtain shield squib) Center airbag sensor assembly SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–205 WIRING DIAGRAM Center Airbag Sensor Assembly O16 Front Passenger Side Curtain Shield Squib ICR+ 1 ICR- 2 9 O1 ICP+ 10 O1 ICP- RS C124552E40 INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting "check mode" (signal check) with the intelligent tester (See page RS-44). • After selecting "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-44). RS–206 1 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK CURTAIN SHIELD AIRBAG ASSEMBLY RH (FRONT PASSENGER SIDE CURTAIN SHIELD SQUIB) D C Front Passenger Side Curtain Shield Squib Center Airbag Sensor Assembly Connector C O16 DLC3 RS CG SST DTC 58 TC C C123743E01 (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the curtain shield airbag assembly RH. (d) Connect the white wire side of SST (resistance 2.1 Ω) to connector C. CAUTION: Never connect the tester to the curtain shield airbag assembly RH (front passenger side curtain shield squib) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: • Do not forcibly insert the SST into the terminals of the connector when connecting. • Insert straight the SST into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch on (IG), and wait for at least 60 seconds. (g) Clear the DTCs stored in the memory (See page RS-41). (h) Turn the ignition switch off. (i) Turn the ignition switch on (IG), and wait for at least 60 seconds. (j) Check the DTCs (See page RS-41). OK: DTC B1835, B1836, B1837, B1838, or 58 is not output. HINT: Codes other than DTC B1835, B1836, B1837, B1838, and 58 may be output at this time, but they are not related to this check. OK REPLACE CURTAIN SHIELD AIRBAG ASSEMBLY RH (See page RS-416) NG 2 CHECK CONNECTOR (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the SST from connector C. (d) Check that the floor wire No. 2 connectors (on the curtain shield airbag assembly RH side) are not damaged. RS–207 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM OK: The lock button is not disengaged, or the claw of the lock is not deformed or damaged. NG REPAIR OR REPLACE FLOOR WIRE NO. 2 OK 3 CHECK FLOOR WIRE NO. 2 (FRONT PASSENGER SIDE CURTAIN SHIELD SQUIB CIRCUIT) Floor Wire No. 2 A D C Front Passenger Side Curtain Shield Squib B Center Airbag Sensor Assembly Connector C O16 ICR+ C ICR- C123745E01 (a) Disconnect the connectors from the center airbag sensor assembly. (b) Check for a short to B+ in the circuit. (1) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (2) Turn the ignition switch on (IG). (3) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition O16-1 (ICR+) - Body ground Ignition switch on (IG) Below 1 V O16-2 (ICR-) - Body ground Ignition switch on (IG) Below 1 V (c) Check for an open in the circuit. (1) Turn the ignition switch off. (2) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (3) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition O16-1 (ICR+) - O16-2 (ICR-) Always Below 1 Ω (d) Check for a short to ground in the circuit. (1) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition O16-1 (ICR+) - Body ground Always 1 MΩ or higher O16-2 (ICR-) - Body ground Always 1 MΩ or higher (e) Check for a short in the circuit. (1) Release the activation prevention mechanism built into connector B (See page RS-32). (2) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition O16-1 (ICR+) - O16-2 (ICR-) Always 1 MΩ or higher RS RS–208 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM NG REPAIR OR REPLACE FLOOR WIRE NO. 2 OK 4 CHECK CENTER AIRBAG SENSOR ASSEMBLY DC Front Passenger Side Curtain Shield Squib DLC3 C CG TC Center Airbag Sensor Assembly DTC 58 C114828E01 (a) Connect the connectors to the curtain shield airbag assembly RH and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch on (IG), and wait for at least 60 seconds. (d) Clear the DTCs stored in the memory (See page RS-41). (e) Turn the ignition switch off. (f) Turn the ignition switch on (IG), and wait for at least 60 seconds. (g) Check the DTCs (See page RS-41). OK: DTC B1835, B1836, B1837, B1838, or 58 is not output. HINT: Codes other than DTC B1835, B1836, B1837, B1838, and 58 may be output at this time, but they are not related to this check. NG RS REPLACE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-441) OK USE SIMULATION METHOD TO CHECK (See page RS-32) SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–209 DTC B1860/64 Short in Driver Side Knee Airbag Squib Circuit DTC B1861/64 Open in Driver Side Knee Airbag Squib Circuit DTC B1862/64 Short to GND in Driver Side Knee Airbag Squib Circuit DTC B1863/64 Short to B+ in Driver Side Knee Airbag Squib Circuit DESCRIPTION The driver side knee airbag squib circuit consists of the center airbag sensor assembly and the driver side knee airbag assembly. This circuit instructs the SRS to deploy when deployment conditions are met. These DTCs are recorded when a malfunction is detected in the driver side knee airbag squib circuit. DTC No. DTC Detecting Condition • B1860/64 • • • B1861/64 • • • B1862/64 • • • B1863/64 • • The center airbag sensor assembly receives a line short circuit signal 5 times in the driver side knee airbag squib circuit during primary check. Driver side knee airbag squib malfunction Center airbag sensor assembly malfunction The center airbag sensor assembly receives an open circuit signal in the driver side knee airbag squib circuit for 2 seconds. Driver side knee airbag squib malfunction Center airbag sensor assembly malfunction he airbag sensor assembly center receives a short circuit to ground signal in the knee airbag (D side) squib circuit for 0.5 seconds. Driver side knee airbag squib malfunction Center airbag sensor assembly malfunction The airbag sensor assembly center receives a short circuit to B+ signal in the knee airbag (D side) squib circuit for 0.5 seconds. Driver side knee airbag squib malfunction Center airbag sensor assembly malfunction Trouble Area • • • • • • • • • • • • Instrument panel wire Driver side knee airbag assembly (Driver side knee airbag squib) Center airbag sensor assembly Instrument panel wire Driver side knee airbag assembly (Driver side knee airbag squib) Center airbag sensor assembly Instrument panel wire Driver side knee airbag assembly (Driver side knee airbag squib) Center airbag sensor assembly Instrument panel wire Driver side knee airbag assembly (Driver side knee airbag squib) Center airbag sensor assembly RS RS–210 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM WIRING DIAGRAM Center Airbag Sensor Assembly E54 Driver Side Knee Airbag Squib DK+ 1 DK- 2 9 E30 DK+ 10 E30 DK- RS C124552E41 INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting "check mode" (signal check) with the intelligent tester (See page RS-44). • After selecting "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-44). SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 1 RS–211 CHECK DRIVER SIDE KNEE AIRBAG ASSEMBLY (DRIVER SIDE KNEE AIRBAG SQUIB) D C Driver Side Knee Airbag Squib Center Airbag Sensor Assembly Connector C E54 SST DLC3 CG DTC 64 TC C123732E01 (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connector from the driver side knee airbag assembly. (d) Connect the white wire side of SST (resistance 2.1 Ω) to connector C. CAUTION: Never connect the tester to the driver side knee airbag assembly (driver side knee airbag squib) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: • Do not forcibly insert the SST into the terminals of the connector when connecting. • Insert straight the SST into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch on (IG), and wait for at least 60 seconds. (g) Clear the DTCs stored in the memory (See page RS-41). (h) Turn the ignition switch off. (i) Turn the ignition switch on (IG), and wait for at least 60 seconds. (j) Check the DTCs (See page RS-41). OK: DTC B1860, B1861, B1862, B1863, or 64 is not output. HINT: Codes other than DTC B1860, B1861, B1862, B1863, and 64 may be output at this time, but they are not related to this check. OK REPLACE DRIVER SIDE KNEE AIRBAG ASSEMBLY (See page RS-369) NG 2 CHECK CONNECTOR (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the SST from connector C. (d) Check that the instrument panel wire connector (on the driver side knee airbag assembly side) is not damaged. OK: The lock button is not disengaged, or the claw of the lock is not deformed or damaged. RS RS–212 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM NG REPAIR OR REPLACE INSTRUMENT PANEL WIRE OK 3 CHECK INSTRUMENT PANEL WIRE (DRIVER SIDE KNEE AIRBAG SQUIB CIRCUIT) Instrument Panel Wire A D C Driver Side Knee Airbag Squib B Center Airbag Sensor Assembly Connector C (a) Disconnect the connectors from the center airbag sensor assembly. (b) Check for a short to B+ in the circuit. (1) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (2) Turn the ignition switch on (IG). (3) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition E54-1 (DK+) - Body ground Ignition switch on (IG) Below 1 V E54-2 (DK-) - Body ground Ignition switch on (IG) Below 1 V E54 DK+ RS DK- C123733E01 (c) Check for an open in the circuit. (1) Turn the ignition switch off. (2) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (3) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition E54-1 (DK+) - E54-2 (DK-) Always Below 1 Ω (d) Check for a short to ground in the circuit. (1) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition E54-1 (DK+) - Body ground Always 1 MΩ or higher E54-2 (DK-) - Body ground Always 1 MΩ or higher (e) Check for a short in the circuit. (1) Release the activation prevention mechanism built into connector B (See page RS-32). (2) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition E54-1 (DK+) - E54-2 (DK-) Always 1 MΩ or higher SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM NG RS–213 REPAIR OR REPLACE INSTRUMENT PANEL WIRE OK 4 CHECK CENTER AIRBAG SENSOR ASSEMBLY DC Driver Side Knee Airbag Squib Center Airbag Sensor Assembly DLC3 CG TC DTC 64 C114833E01 (a) Connect the connectors to the driver side knee airbag assembly and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch on (IG), and wait for at least 60 seconds. (d) Clear the stored DTCs in the memory (See page RS-41). (e) Turn the ignition switch off. (f) Turn the ignition switch on (IG), and wait for at least 60 seconds. (g) Check the DTCs (See page RS-41). OK: DTC B1860, B1861, B1862, B1863, or 64 is not output. HINT: Codes other than DTC B1860, B1861, B1862, B1863, and 64 may be output at this time, but they are not related to this check. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-441) OK USE SIMULATION METHOD TO CHECK (See page RS-32) RS RS–214 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1900/73 Short in Driver Side Front Pretensioner Squib Circuit DTC B1901/73 Open in Driver Side Front Pretensioner Squib Circuit DTC B1902/73 Short to GND in Driver Side Front Pretensioner Squib Circuit DTC B1903/73 Short to B+ in Driver Side Front Pretensioner Squib Circuit DESCRIPTION The driver side front pretensioner squib circuit consists of the center airbag sensor assembly and the front seat outer belt assembly LH. This circuit instructs the SRS to deploy when deployment conditions are met. These DTCs are recorded when a malfunction is detected in the front pretensioner squib circuit. DTC No. DTC Detection Condition • B1900/73 • • • RS B1901/73 • • • B1902/73 • • • B1903/73 • • The center airbag sensor assembly receives a line short circuit signal 5 times in the driver side front pretensioner squib circuit during primary check. Driver side front pretensioner squib malfunction Center airbag sensor assembly malfunction The center airbag sensor assembly receives an open circuit signal in the driver side front pretensioner squib circuit for 2 seconds. Driver side front pretensioner squib malfunction Center airbag sensor assembly malfunction The center airbag sensor assembly receives a short circuit to ground signal in the driver side front pretensioner squib circuit for 0.5 seconds. Driver side front pretensioner squib malfunction Center airbag sensor assembly malfunction The center airbag sensor assembly receives a short circuit to B+ signal in the driver side front pretensioner squib circuit for 0.5 seconds. Driver side front pretensioner squib malfunction Center airbag sensor assembly malfunction Trouble Area • • • • • • • • • • • • Floor wire Front seat outer belt assembly LH (Driver side front pretensioner squib) Center airbag sensor assembly Floor wire Front seat outer belt assembly LH (Driver side front pretensioner squib) Center airbag sensor assembly Floor wire Front seat outer belt assembly LH (Driver side front pretensioner squib) Center airbag sensor assembly Floor wire Front seat outer belt assembly LH (Driver side front pretensioner squib) Center airbag sensor assembly SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–215 WIRING DIAGRAM Center Airbag Sensor Assembly N8 Driver Side Front Pretensioner Squib L+ 1 L- 2 2 N1 PD+ 1 N1 PD- RS C124552E42 INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting "check mode" (signal check) with the intelligent tester (See page RS-44). • After selecting "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-44). RS–216 1 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FRONT SEAT OUTER BELT ASSEMBLY LH (DRIVER SIDE FRONT PRETENSIONER SQUIB) D C Driver Side Front Pretensioner Squib Center Airbag Sensor Assembly Connector C N8 DLC3 RS CG SST DTC 73 TC C C114829E06 (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the front seat outer belt assembly LH. (d) Connect the white wire side of SST (resistance 2.1 Ω) to connector C. CAUTION: Never connect the tester to the front seat outer belt assembly LH (driver side front pretensioner squib) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: • Do not forcibly insert the SST into the terminals of the connector when connecting. • Insert straight the SST into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch on (IG), and wait for at least 60 seconds. (g) Clear the DTCs stored in the memory (See page RS-41). (h) Turn the ignition switch off. (i) Turn the ignition switch on (IG), and wait for at least 60 seconds. (j) Check the DTCs (See page RS-41). OK: DTC B1900, B1901, B1902, B1903, or 73 is not output. HINT: Codes other than DTC B1900, B1901, B1902, B1903, and 73 may be output at this time, but they are not related to this check. OK REPLACE FRONT SEAT OUTER BELT ASSEMBLY LH (See page SB-20) NG 2 CHECK CONNECTOR (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the SST from connector C. (d) Check that the floor wire connector (on the front seat outer belt assembly LH side) is not damaged. RS–217 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM OK: The lock button is not disengaged, or the claw of the lock is not deformed or damaged. NG REPAIR OR REPLACE FLOOR WIRE OK 3 CHECK FLOOR WIRE (DRIVER SIDE FRONT PRETENSIONER SQUIB CIRCUIT) Floor Wire A D C B Driver Side Front Center Airbag Pretensioner Squib Sensor Assembly Connector C C Tester connection Condition Specified condition N8-1 (L+) - Body ground Ignition switch on (IG) Below 1 V N8-2 (L-) - Body ground Ignition switch on (IG) Below 1 V (c) Check for an open in the circuit. (1) Turn the ignition switch off. (2) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (3) Measure the resistance according to the value(s) in the table below. Standard resistance N8 L+ (a) Disconnect the connectors from the center airbag sensor assembly. (b) Check for a short to B+ in the circuit. (1) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (2) Turn the ignition switch on (IG). (3) Measure the voltage according to the value(s) in the table below. Standard voltage L- C114830E08 Tester Connection Condition Specified Condition N8-1 (L+) - N8-2 (L-) Always Below 1 Ω (d) Check for a short to ground in the circuit. (1) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition N8-1 (L+) - Body ground Always 1 MΩ or higher N8-2 (L-) - Body ground Always 1 MΩ or higher (e) Check for a short in the circuit. (1) Release the activation prevention mechanism built into connector B (See page RS-32). (2) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition N8-1 (L+) - N8-2 (L-) Always 1 MΩ or higher NG REPAIR OR REPLACE FLOOR WIRE RS RS–218 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM OK 4 CHECK CENTER AIRBAG SENSOR ASSEMBLY Driver Side Front Pretensioner Squib DC Center Airbag Sensor Assembly DLC3 C CG DTC 73 TC C114831E01 (a) Connect the connectors to the front seat outer belt assembly LH and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch on (IG), and wait for at least 60 seconds. (d) Clear the DTCs stored in the memory (See page RS-41). (e) Turn the ignition switch off. (f) Turn the ignition switch on (IG), and wait for at least 60 seconds. (g) Check the DTCs (See page RS-41). OK: DTC B1900, B1901, B1902, B1903, or 73 is not output. HINT: Codes other than DTC B1900, B1901, B1902, B1903, or 73 may be output at this time, but they are not related to this check. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-441) OK RS USE SIMULATION METHOD TO CHECK (See page RS-32) SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–219 DTC B1905/74 Short in Front Passenger Side Pretensioner Squib Circuit DTC B1906/74 Open in Front Passenger Side Pretensioner Squib Circuit DTC B1907/74 Short to GND in Front Passenger Side Pretensioner Squib Circuit DTC B1908/74 Short to B+ in Front Passenger Side Front Pretensioner Squib Circuit DESCRIPTION The front passenger side front pretensioner squib circuit consists of the center airbag sensor assembly and the front seat outer belt assembly RH. This circuit instructs the SRS to deploy when deployment conditions are met. These DTCs are recorded when a malfunction is detected in the front passenger side front pretensioner squib circuit. DTC No. DTC Detection Condition • B1905/74 • • • B1906/74 • • • B1907/74 • • • B1908/74 • • The center airbag sensor assembly receives a line short circuit signal 5 times in the front passenger side front pretensioner squib circuit during primary check. Front passenger side front pretensioner squib malfunction Center airbag sensor assembly malfunction The center airbag sensor assembly receives an open circuit signal in the front passenger side front pretensioner squib circuit for 2 seconds. Front passenger side front pretensioner squib malfunction Center airbag sensor assembly malfunction The center airbag sensor assembly receives a short circuit to ground signal in the front passenger side front pretensioner squib circuit for 0.5 seconds. Front passenger side front pretensioner squib malfunction Center airbag sensor assembly malfunction The center airbag sensor assembly receives a short circuit to B+ signal in the front passenger side front pretensioner squib circuit for 0.5 seconds. Front passenger side front pretensioner squib malfunction Center airbag sensor assembly malfunction Trouble Area • • • Floor wire No. 2 Front seat outer belt assembly RH (Front passenger side front pretensioner squib) Center airbag sensor assembly RS • • • • • • • • • Floor wire No. 2 Front seat outer belt assembly RH (Front passenger side front pretensioner squib) Center airbag sensor assembly Floor wire No. 2 Front seat outer belt assembly RH (Front passenger side front pretensioner squib) Center airbag sensor assembly Floor wire No. 2 Front seat outer belt assembly RH (Front passenger side front pretensioner squib) Center airbag sensor assembly RS–220 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM WIRING DIAGRAM Center Airbag Sensor Assembly O8 Front Passenger Side Front Pretensioner Squib R+ 1 R- 2 4 O1 PP+ 5 O1 PP- RS C124552E43 INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting "check mode" (signal check) with the intelligent tester (See page RS-44). • After selecting "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-44). SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 1 CHECK FRONT SEAT OUTER BELT ASSEMBLY RH (FRONT PASSENGER SIDE FRONT PRETENSIONER SQUIB) D C Front Passenger Side Front Pretensioner Squib Center Airbag Sensor Assembly Connector C O8 DLC3 CG RS–221 SST DTC 74 TC C C109514E16 (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the front seat outer belt assembly RH. (d) Connect the white wire side of SST (resistance 2.1 Ω) to connector C. CAUTION: Never connect the tester to the front seat outer belt assembly RH (front passenger side front pretensioner squib) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: • Do not forcibly insert the SST into the terminals of the connector when connecting. • Insert straight the SST into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch on (IG), and wait for at least 60 seconds. (g) Clear the DTCs stored in the memory (See page RS-41). (h) Turn the ignition switch off. (i) Turn the ignition switch on (IG), and wait for at least 60 seconds. (j) Check the DTCs (See page RS-41). OK: DTC B1905, B1906, B1907, B1908, or 74 is not output. HINT: Codes other than DTC B1905, B1906, B1907, B1908, and 74 may be output at this time, but they are not related to this check. OK REPLACE FRONT SEAT OUTER BELT ASSEMBLY RH NG 2 CHECK CONNECTOR (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the SST from connector C. (d) Check that the floor wire No. 2 connector (on the front seat outer belt assembly RH side) is not damaged. RS RS–222 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM OK: The lock button is not disengaged, or the claw of the lock is not deformed or damaged. NG REPAIR OR REPLACE FLOOR WIRE NO. 2 OK 3 CHECK FLOOR WIRE NO. 2 (FRONT PASSENGER SIDE FRONT PRETENSIONER SQUIB CIRCUIT) Floor Wire No. 2 A D C B Front Passenger Side Front Pretensioner Squib Center Airbag Sensor Assembly Connector C R+ Tester Connection Condition Specified Condition O8-1 (R+) - Body ground Ignition switch on (IG) Below 1 V O8-2 (R-) - Body ground Ignition switch on (IG) Below 1 V (c) Check for an open in the circuit. (1) Turn the ignition switch off. (2) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (3) Measure the resistance according to the value(s) in the table below. Standard resistance R- O8 RS C (a) Disconnect the connectors from the center airbag sensor assembly. (b) Check for a short to B+ in the circuit. (1) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (2) Turn the ignition switch on (IG). (3) Measure the voltage according to the value(s) in the table below. Standard voltage C114784E10 Tester Connection Condition Specified Condition O8-1 (R+) - O8-2 (R-) Always Below 1 Ω (d) Check for a short to ground in the circuit. (1) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition O8-1 (R+) - Body ground Always 1 MΩ or higher O8-2 (R-) - Body ground Always 1 MΩ or higher (e) Check for a short in the circuit. (1) Release the activation prevention mechanism built into connector B (See page RS-32). (2) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition O8-1 (R+) - O8-2 (R-) Always 1 MΩ or higher NG REPAIR OR REPLACE FLOOR WIRE NO. 2 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–223 OK 4 CHECK CENTER AIRBAG SENSOR ASSEMBLY Front Passenger Side Front Pretensioner Squib DC CG DLC3 TC C Center Airbag Sensor Assembly DTC 74 C114834E01 (a) Connect the connectors to the front seat outer belt assembly RH and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch on (IG), and wait for at least 60 seconds. (d) Clear the DTCs stored in the memory (See page RS-41). (e) Turn the ignition switch off. (f) Turn the ignition switch on (IG), and wait for at least 60 seconds. (g) Check the DTCs (See page RS-41). OK: DTC B1905, B1906, B1907, B1908, or 74 is not output. HINT: Codes other than DTC B1905, B1906, B1907, B1908, and 74 may be output at this time, but they are not related to this check. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-441) OK USE SIMULATION METHOD TO CHECK (See page RS-32) RS RS–224 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM SRS Warning Light Remains ON DESCRIPTION The SRS warning light is located on the combination meter assembly. When the SRS is normal, the SRS warning light comes on for approximately 6 seconds after the ignition switch is turned from off to on (IG), and then goes off automatically. If there is a malfunction in the SRS, the SRS warning light comes on to inform the driver of a problem. When terminals TC and CG of the DLC3 are connected, the DTC is displayed by blinking of the SRS warning light. The SRS is equipped with a voltage-increase circuit (DC-DC converter) in the center airbag sensor assembly in case the source voltage drops. When the battery voltage drops, the voltage-increase circuit (DC-DC converter) functions to increase the voltage of the SRS to normal voltage. A malfunction in this circuit is not recorded in the center airbag sensor assembly. The SRS warning light automatically goes off when the source voltage returns to normal. The signal to illuminate the SRS warning light is transmitted from the center airbag sensor assembly to the combination meter assembly through the CAN communication system. RS RS–225 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM WIRING DIAGRAM Center Airbag Sensor Assembly Combination Meter 21 E30 IG2 IGN GAUGE No. 2 From Battery DOME MPX-B 1 B F1 2 B2 F1 13 IG+ F1 Junction Connector 17 CANH F1 1 1 E43 E45 13 E30 CANH 18 CANL F1 2 E43 2 E45 27 E30 CANL 12 E2 F1 25 E30 E1 24 ES F1 26 E30 E2 DLC3 C RS Steering Angle Sensor 6 CANH E10 1 1 E62 E63 14 CANL E10 2 E62 2 E63 (*1) 10 E17 CANH (*1) 9 E17 CANL C123738E01 RS–226 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM Yaw Rate Sensor 3 CANH E34 (*3) 2 CANL E34 (*3) Main Body ECU 2 E65 (*4) 3 E65 (*4) (*1) 1 E46 1 E44 5 E8 CANH (*1) 2 E46 2 E44 6 E8 CANL Skid Control ECU with Actuator 26 CANH A25 1 E42 15 E8 CANN 2 E42 16 E8 CANP Certification ECU Junction Connector 15 CANL A25 4 E41 27 E58 CANH 10 E41 28 E58 CANL Skid Control ECU with Actuator A/C Amplifier 11 CANH A26 (*3) 25 CANL A26 (*3) RS 35 A60 (*4) 14 A60 (*4) (*2) (*1) 2 A40 1 E41 11 E38 CANH 8 A40 7 E41 12 E38 CANL (*2) (*1) Option Connector (Buffer) ECM 1 CAN+ E61 2 E41 1 A40 (*6) 41 A24 CANH 2 CAN- E61 8 E41 2 A40 (*6) 49 A24 CANL *1: with VSC Transmission Control ECU C ECM 6 CAN+ C56 (*5) 7 CAN- C56 (*5) *2: without VSC 2 C55 CAN+ *3: TMC Made 41 (*5) CANH A55 1 C55 CAN- 49 CANL A55 (*5) *4: TMMK Made *5: 2GR-FE *6: 2AZ-FE C123739E01 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–227 INSPECTION PROCEDURE 1 CHECK CAN COMMUNICATION SYSTEM (a) Check if a CAN communication DTC is output (See page CA-25). Result Condition Proceed To DTC is not output A DTC is output B B REPAIR CIRCUITS INDICATED BY OUTPUT DTCS A 2 CHECK BATTERY (a) Measure the voltage of the battery. Standard voltage: 11 to 14 V NG CHECK AND REPLACE BATTERY OR CHARGING SYSTEM OK RS 3 CHECK CONNECTORS (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the center airbag sensor assembly and combination meter assembly. OK: The connectors are properly connected. NG OK CONNECT CONNECTORS PROPERLY RS–228 4 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK WIRE HARNESS (SOURCE VOLTAGE OF CENTER AIRBAG SENSOR ASSEMBLY) E30 IG2 E2 E1 G027651E43 (a) Disconnect the connectors from the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch on (IG). (d) Operate all components of the electrical system (defogger, wipers, headlight, heater blower, etc.). (e) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition E30-21 (IG2) - Body ground Ignition switch on (IG) 10 to 14 V (f) Turn the ignition switch off. (g) Measure the resistance according to the value(s) in the table below. Standard resistance RS Tester Connection Condition Specified Condition E30-25 (E1) - Body ground Always Below 1 Ω E30-26 (E2) - Body ground Always Below 1 Ω NG REPAIR OR REPLACE WIRE HARNESS OK 5 CHECK WIRE HARNESS (SOURCE VOLTAGE OF COMBINATION METER) Combination Meter Assembly Side: F1 B2 E2 B ES IG+ E123360E02 (a) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (b) Disconnect the F1 connector from the combination meter assembly. (c) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (d) Turn the ignition switch on (IG). (e) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition F1-1 (B) - Body ground Always 10 to 14 V F1-2 (B2) - Body ground Ignition switch on (IG) 10 to 14 V F1-13 (IG+) - Body ground Ignition switch on (IG) 10 to 14 V (f) Turn the ignition switch off. (g) Measure the resistance according to the value(s) in the table below. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–229 Standard resistance Tester Connection Condition Specified Condition F1-12 (E2) - Body ground Always Below 1 Ω F1-24 (ES) - Body ground Always Below 1 Ω NG REPAIR OR REPLACE WIRE HARNESS OK 6 CHECK SRS WARNING LIGHT (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Connect the connector to the combination meter assembly. (d) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (e) Turn the ignition switch on (IG). (f) Check the SRS warning light condition. OK: After the primary check period, SRS warning light goes off for approximately 10 seconds, and remains on. HINT: The primary check period shows approximately 6 seconds after the ignition switch is turned on (IG). NG GO TO COMBINATION METER SYSTEM OK REPLACE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-441) RS RS–230 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM SRS Warning Light does not Come ON DESCRIPTION See page RS-222. WIRING DIAGRAM See page RS-223. INSPECTION PROCEDURE 1 CHECK BATTERY (a) Measure the voltage of the battery. Standard voltage: 11 to 14 V NG CHECK AND REPLACE BATTERY OR CHARGING SYSTEM OK 2 CHECK CONNECTOR (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the combination meter assembly. OK: The connectors are properly connected. RS NG OK CONNECT CONNECTOR PROPERLY RS–231 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 3 CHECK WIRE HARNESS (SOURCE VOLTAGE OF COMBINATION METER) Combination Meter Assembly Side: F1 B2 E2 B ES IG+ E123360E02 (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the F1 connector from the combination meter assembly. (d) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (e) Turn the ignition switch on (IG). (f) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition F1-1 (B) - Body ground Always 10 to 14 V F1-2 (B2) - Body ground Always 10 to 14 V F1-13 (IG+) - Body ground Ignition switch on (IG) 10 to 14 V (g) Turn the ignition switch off. (h) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition F1-12 (E2) - Body ground Always Below 1 Ω F1-24 (ES) - Body ground Always Below 1 Ω NG REPAIR OR REPLACE WIRE HARNESS OK 4 CHECK SRS WARNING LIGHT (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Connect the connector to the combination meter assembly. (d) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (e) Turn the ignition switch on (IG). (f) Check the SRS warning light condition. OK: After the primary check period, SRS warning light goes off for approximately 10 seconds, and remains on. HINT: The primary check period is approximately 6 seconds after the ignition switch is turned on (IG). RS RS–232 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM NG GO TO COMBINATION METER SYSTEM OK REPLACE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-441) RS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–233 Diagnosis Circuit DESCRIPTION DTC output mode is set by connecting terminals TC and CG of the DLC3. DTCs are displayed by blinking of the SRS warning light. HINT: • When each warning light stays blinking, a ground short in the wiring of terminal TC of the DLC3 or an internal ground short in each ECU is suspected. • A DTC output mode signal is transmitted through CAN communication system to each ECU including the center airbag sensor assembly. Thus when all systems do not enter DTC output mode, there may be an ECM malfunction. RS RS–234 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM WIRING DIAGRAM Center Airbag Sensor Assembly Certification ECU 28 CANL E58 27 CANH E58 Main Body ECU (*5) (*5) 15 E8 CANN CANL 6 E8 2 E44 2 E45 22 E30 CANL 16 E8 CANP 5 E8 1 E44 1 E45 13 E30 CANH E60 Tire Pressure Warning ECU TC 2 CANL E34 (*3) 3 CANH E34 (*3) 10 C56 Transmission Control ECU CANH E17 Steering Angle Sensor Yaw Rate Sensor 27 27 TC A55 A24 (*1) (*2) (*6) 2 E46 2 E63 (*6) 9 CANL (*6) 1 E46 1 E63 (*6) 10 CANH 13 TC CANL Combination Meter 14 4 CG 6 CANH 2 6 CAN+ C55 CAN+ (*1) CANH 1 CAN- 7 CAN(*1) C55 CANL 3 E65 (*4) 2 E65 (*4) E10 DLC3 ECM RS J/C 41 A55 2 E43 18 F1 CANL 1 E62 1 E43 17 F1 CANH 2 E42 (*1) 49 A55 1 E42 (*1) 41 CANH A24 49 CANL A24 2 E62 *1: 2GR-FE (*2) *2: 2AZ-FE *3: TMC Made (*2) *4: TMMK Made *5: with Smart Key System C C123740E01 RS–235 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM J/C (*1) (*1) (*2) (*2) 1 A40 10 E41 7 A40 4 E41 E61 Option Connector (Bus Buffer) A25 Skid Control ECU with Actuator CANH 26 CANL 15 (*7) (*7) 2 E41 1 CAN+ 8 E41 2 CAN- Skid Control ECU with Actuator A/C Amplifier 35 11 CANH A60 A26 (*4) (*3) 14 25 CANL A60 A26 (*4) (*3) (*6) (*6) 2 A40 1 E41 11 E38 CANH 8 A40 7 E41 12 E38 CANL RS *6: with VSC *7: without VSC C C123741E01 RS–236 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM INSPECTION PROCEDURE 1 CHECK CAN COMMUNICATION SYSTEM (a) Check if a CAN communication system DTC is output (See page CA-25). Result Condition Proceed to DTC is not output A DTC is output B B REPAIR CIRCUITS INDICATED BY OUTPUT DTCS A 2 CHECK WIRE HARNESS (DLC3 - ECM) (a) Turn the ignition switch off. (b) Disconnect the connector from ECM. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: for 2GR-FE DLC3: E10         RS Tester Connection Condition Specified Condition E10-13 (TC) - A55-27 (TC) Always Below 1 Ω Tester Connection Condition Specified Condition E10-13 (TC) - A24-27 (TC) Always Below 1 Ω         for 2AZ-FE TC ECM: NG A55 (*1) *1: 2GR-FE *2: 2AZ-FE TC A24 (*2) E126838E05 REPAIR OR REPLACE WIRE HARNESS (TC OF DLC3 - TC OF ECM) SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–237 OK 3 CHECK WIRE HARNESS (CG OF DLC3 - BODY GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance DLC3: E10 CG 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Tester Connection Condition Specified Condition E10-4 (CG) - Body ground Always Below 1 Ω NG REPAIR OR REPLACE WIRE HARNESS (CG OF DLC3 - BODY GROUND) C126742E26 OK 4 CHECK WIRE HARNESS (TC OF ECM - BODY GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: for 2GR-FE ECM: Tester Connection Condition Specified Condition A55-27 (TC) - Body ground Always 1 MΩ or higher RS for 2AZ-FE Tester Connection Condition Specified Condition A24-27 (TC) - Body ground Always 1 MΩ or higher NG REPAIR OR REPLACE WIRE HARNESS OR EACH ECU A55 (*1) A24 (*2) *1: 2GR-FE *2: 2AZ-FE TC E126835E04 OK REPLACE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-441) RS–236 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM OCCUPANT CLASSIFICATION SYSTEM PRECAUTION 1. 2. RS Switch Type Ignition Switch off Expression Ignition Switch on (IG) Ignition Switch on (ACC) Engine Start INSPECTION PROCEDURE FOR VEHICLE INVOLVED IN ACCIDENT (a) Perform zero point calibration and sensitivity check if any of the following conditions occur: • The occupant classification ECU is replaced. • Accessories (seatback tray and seat cover, etc.) are installed. • The front passenger seat is removed from the vehicle. • The passenger airbag ON/OFF indicator ("OFF") comes on when the front passenger seat is not occupied. • The vehicle is brought to the workshop for repair due to an accident or a collision. NOTICE: When an accident vehicle is brought into the workshop for repair, check the flatness of the body side that is equipped with the passenger seat. If the flatness is not within +- 3.0 mm (0.118 in.), adjust it to the specified range. EXPRESSIONS OF IGNITION SWITCH The type of ignition switch used on this model differs according to the specifications of the vehicle. The expressions listed in the table below are used in this section. Ignition Switch (position) Engine Switch (condition) LOCK Off ON On (IG) ACC On (ACC) START Start SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–237 PARTS LOCATION COMBINATION METER ASSEMBLY: CLOCK ASSEMBLY: SRS WARNING LIGHT PASSENGER AIRBAG ON/OFF INDICATOR OCCUPANT CLASSIFICATION ECU RS CENTER AIRBAG SENSOR ASSEMBLY FRONT OCCUPANT CLASSIFICATION SENSOR LH REAR OCCUPANT CLASSFICATION SENSOR RH FRONT SEAT INNER BELT ASSEMBLY RH REAR OCCUPANT CLASSFICATION SENSOR LH FRONT OCCUPANT CLASSIFICATION SENSOR RH C123720E01 RS–238 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM SYSTEM DIAGRAM Front Seat Inner Belt Assembly RH (Buckle Switch RH) Front Occupant Classification Sensor LH Occupant Classification ECU Front Occupant Classification Sensor RH Rear Occupant Classification Sensor LH Rear Occupant Classification Sensor RH DLC3 Center Airbag Sensor Assembly Clock Assembly (Passenger Airbag ON/OFF Indicator) RS C C110375E01 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–239 SYSTEM DESCRIPTION 1. DESCRIPTION OF OCCUPANT CLASSIFICATION SYSTEM (a) GENERAL DESCRIPTION. (1) In the occupant classification system, the occupant classification ECU calculates the weight of the occupant based on a signal from the occupant classification sensors. This system recognizes the occupant as a child if it detects a weight of less than 36 kg (79.37 lb), and disables the front passenger airbag and front passenger side-side airbag. (2) This system is mainly comprised of 4 occupant classification sensors that detect the load on the front passenger seat. The occupant classification ECU controls the system, and the passenger airbag ON/OFF indicator indicates the ON/OFF condition of the front passenger airbag and front passenger side-side airbag. (b) OCCUPANT CLASSIFICATION SENSOR. Rear Occupant Classification Sensor RH RS Rear Occupant Classification Sensor LH Front Occupant Classification Sensor LH Front Occupant Classification Sensor RH Occupant Classification ECU Occupant Load A Occupant Classification Sensor A A - A Cross Section C C110537E01 RS–240 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM (1) The occupant classification sensors are installed on 4 brackets connecting the seat rail and seat frame. Accordingly, when load is applied to the front passenger seat by an occupant sitting in it, the occupant classification sensors register a distortion. C123721 RS (c) DESCRIPTION FOR PASSENGER AIRBAG ON/ OFF INDICATOR. (1) The passenger airbag ON/OFF indicator is installed on the clock assembly. This indicator informs the driver whether the occupant classification ECU puts the front passenger airbag assembly into an active state or inactive state. (2) If a malfunction occurs in the occupant classification system, "OFF" indication of the passenger airbag ON/OFF indicator and the SRS warning light come on. RS–241 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING The intelligent tester can be used in steps 4, 6, 8, and 9. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS (a) Confirm problem symptoms (See page IN-28). NEXT 3 PASSENGER AIRBAG ON/OFF INDICATOR CHECK NEXT 4 DTCS CHECK (Present and Past DTCs) (a) Check for DTCs. Result Result A DTC is not output. B B A 5 DTCS CHART NEXT 6 CIRCUIT INSPECTION NEXT 7 NEXT REPAIR Proceed to DTC is output. GO TO PROBLEM SYMPTOMS TABLE RS RS–242 8 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CLEAR DTCS (Present and Past DTCs) (a) Clear DTCs. NEXT 9 DTCS CHECK (Present and Past DTCs) (a) Check for DTCs. Result Result Proceed to DTC is not output. A DTC is output. B B Go to step 5 A 10 SYMPTOM SIMULATION (a) Check the passenger airbag ON/OFF indicator condition. Result RS Result Proceed to Passenger airbag ON/OFF indicator operates normally. A Passenger airbag ON/OFF indicator ("OFF") and SRS warning light come on. B B A 11 NEXT END CONFIRMATION TEST Go to step 5 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–247 PROBLEM SYMPTOMS TABLE HINT: Proceed to the troubleshooting for each circuit in the table below. OCCUPANT CLASSIFICATION SYSTEM: Symptom The front passenger seat condition differs from the indication by the passenger airbag ON/OFF indicator (DTC is not output). Suspected area See page Trouble in Passenger Airbag ON/OFF Indicator RS-342 RS RS–248 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM TERMINALS OF ECU 1. OCCUPANT CLASSIFICATION ECU (for Power seat) T11 T10 6 543 21 87 6 543 21 87 12 1110 9 12 1110 9 H043128E06 RS Terminal No. (Symbols) Wiring Color Terminal Description Condition Specification T10-1 (+B) - T10-3 (GND) W - W-B Battery Always 10 to 14 V T10-2 (DIA) - T10-3 (GND) GR - W-B Diagnosis (DLC3) Ignition switch on (IG) Pulse generation T10-3 (GND) - Body ground W-B - Body ground Ground Always Below 1 V T10-4 (FSR-) - T10-3 (GND) Y - W-B Center airbag sensor assembly communication line (-) Always Below 1 V T10-5 (BGND) - T10-3 (GND) GR - W-B Passenger side buckle switch ground line Always Below 1 V T10-7 (IG) - T10-3 (GND) BR - W-B Power source (ECU-B Fuse) Ignition switch on (IG) 10 to 14 V T10-8 (FSR+) - T10-4 (FSR-) L-Y Center airbag sensor assembly communication line Ignition switch on (IG) Pulse generation T10-9 (BSW) - T10-5 (BGND) B - GR Passenger side buckle switch line Always Below 1 V T11-1 (SGD1) - T10-3 (GND) G - W-B Front occupant classification sensor LH ground line Always Below 1 V T11-2 (SGD2) - T10-3 (GND) O - W-B Front occupant classification sensor RH ground line Always Below 1 V T11-3 (SGD3) - T10-3 (GND) W - W-B Rear occupant classification sensor LH ground line Always Below 1 V T11-4 (SGD4) - T10-3 (GND) BR - W-B Rear occupant classification sensor RH ground line Always Below 1 V GR - W Rear occupant classification sensor LH power supply line Ignition switch on (IG), a load is applied to rear occupant classification sensor LH 4.5 to 5.1 V V - BR Rear occupant classification sensor RH power supply line Ignition switch on (IG), a load is applied to rear occupant classification sensor RH 4.5 to 5.1 V P-G Front occupant classification sensor LH signal line Ignition switch on (IG), a load is applied to front occupant classification sensor LH 0.2 to 4.9 V L-O Front occupant classification sensor RH signal line Ignition switch on (IG), a load is applied to front occupant classification sensor RH 0.2 to 4.9 V T11-5 (SVC3) - T11-3 (SGD3) T11-6 (SVC4) - T11-4 (SGD4) T11-7 (SIG1) - T11-1 (SGD1) T11-8 (SIG2) - T11-2 (SGD2) SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM Terminal No. (Symbols) T11-9 (SIG3) - T11-3 (SGD3) T11-10 (SIG4) - T11-4 (SGD4) T11-11 (SVC1) - T11-1 (SGD1) T11-12 (SVC2) - T11-2 (SGD2) Wiring Color Terminal Description Condition RS–249 Specification Y-W Rear occupant classification sensor LH signal line Ignition switch on (IG), a load is applied to rear occupant classification sensor LH B - BR Rear occupant classification sensor RH signal line Ignition switch on (IG), a load is applied to rear occupant classification sensor RH 0.2 to 4.9 V R-G Front occupant classification sensor LH power supply line Ignition switch on (IG), a load is applied to front occupant classification sensor LH 4.5 to 5.1 V W-O Front occupant classification sensor RH power supply line Ignition switch on (IG), a load is applied to front occupant classification sensor RH 4.5 to 5.1 V 2. 0.2 to 4.9 V OCCUPANT CLASSIFICATION ECU (for Manual seat) d1 O4 6 54 3 21 121110 9 8 7 6 54 3 21 121110 9 8 7 C C110373E12 Terminal Description Condition Specification Always 10 to 14 V Ignition switch on (IG) Pulse generation Ground Always Below 1 V Always Below 1 V Terminal No. (Symbols) Wiring Color O4-1 (+B) - O4-3 (GND) LG - W-B Battery O4-2 (DIA) - O4-3 (GND) O - W-B Diagnosis (DLC3) O4-3 (GND) - Body ground W-B - Body ground O4-4 (FSR-) - O4-3 (GND) B-W Center airbag sensor assembly communication line (-) O4-5 (BGND) - O4-3 (GND) GR - W-B Passenger side buckle switch ground line Always Below 1 V O4-7 (IG) - O4-3 (GND) BR - W-B Power source (ECU-B Fuse) Ignition switch on (IG) 10 to 14 V O4-8 (FSR+) - O4-4 (FSR-) W-B Center airbag sensor assembly communication line Ignition switch on (IG) Pulse generation O4-9 (BSW) - O4-5 (BGND) P - GR Passenger side buckle switch line Always Below 1 V d1-1 (SGD1) - O4-3 (GND) G - W-B Front occupant classification sensor LH ground line Always Below 1 V d1-2 (SGD2) - O4-3 (GND) O - W-B Front occupant classification sensor RH ground line Always Below 1 V d1-3 (SGD3) - O4-3 (GND) W - W-B Rear occupant classification sensor LH ground line Always Below 1 V d1-4 (SGD4) - O4-3 (GND) BR - W-B Rear occupant classification sensor RH ground line Always Below 1 V RS SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–243 INITIALIZATION 1. ZERO POINT CALIBRATION NOTICE: Make sure that the front passenger seat is not occupied before performing the operation: HINT: Perform zero point calibration and sensitivity check if any of the following conditions occur. • The occupant classification ECU is replaced. • Accessories (seatback tray and seat cover, etc.) are installed. • The front passenger seat is removed from the vehicle. • The passenger airbag ON/OFF indicator ("OFF") comes on when the front passenger seat is not occupied. • The vehicle is brought to the workshop for repair due to an accident or a collision. (a) Zero point calibration and sensitivity check procedures. HINT: Make sure that zero point calibration has finished normally, and then perform the sensitivity check. (1) Adjust the seat position according to the table below. DLC3 Intelligent Tester C131977E01 Adjustment Component Position Slide Direction Rearmost position Reclining Angle Upright position Headrest Height Lowest position Lifter Height Lowest position (2) Connect the intelligent tester to the DLC3. (3) Turn the ignition switch on (IG). RS RS–244 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM (4) Perform the zero point calibration by following the prompts on the tester screen. ZERO POINT CALIBRATION PROCEDURE “1: DIAGNOSIS” - ”1: OBD/MOBD” - “MODEL YEAR” - “MODEL SELECTION” - “CAMRY” - Select the option parts” - “9: OCCUPANT DETECT” Refer to the following screen flow. Perform sensitity check. RS Perform DTC check. Sensor information is expressed as OK, MAX. or MIN. in [ ]. If MAX. or MIN. is displayed,, replace the front seat outer belt assembly. C C113452E20 HINT: Refer to the intelligent tester operator's manual for further details. SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM (5) (6) (7) (8) RS–245 OK: "COMPLETE" is displayed. Perform the sensitivity check by following the prompts on the tester screen. Confirm that the beginning sensor reading within standard value. Standard value: -3.2 to 3.2 kg (-7 to 7 lb) Place a 30 kg (66.14 lb) weight (eg. a 30 kg (66.14 lb) of lead mass) onto the front passenger seat. Confirm that the sensitivity is within the standard value. SENSITIVITY CHECK PROCEDURE “1: DIAGNOSIS” - “1: OBD/MOBD” - “MODEL YEAR” - “MODEL SELECTION = CAMRY” - Select the option parts - “9: OCCUPANT DETECT” - Refer to the following screen flow. RS *1: kg = lb Unit can be changed based on unit conversion setting. [System Selection Screen] “1: DIAGNOSIS” - “9: SETUP” - “4: UNIT CONVERSION” - “WEIGHT” (kg = lbs) C C113453E18 Standard value: 27 to 33 kg (59.52 to 72.75 lb) HINT: • When performing the sensitivity check, use a solid metal weight (the check result may not appear properly if the weight made from liquid is used). RS–246 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM • When the sensitivity deviates from the standard value, retighten the bolts of the front passenger seat without deforming the seat rail. After performing this procedure, if the sensitivity is not within the standard value, replace the front seat assembly RH. • When zero point calibration has not finished normally, replace the front seat assembly RH. RS RS–250 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM Terminal No. (Symbols) Wiring Color Terminal Description d1-5 (SVC3) - d1-3 (SGD3) GR - W Rear occupant classification sensor LH power supply line Ignition switch on (IG), a load is applied to rear occupant classification sensor LH 4.5 to 5.1 V d1-6 (SVC4) - d1-4 (SGD4) V - BR Rear occupant classification sensor RH power supply line Ignition switch on (IG), a load is applied to rear occupant classification sensor RH 4.5 to 5.1 V d1-7 (SIG1) - d1-1 (SGD1) SB - G Front occupant classification sensor LH signal line Ignition switch on (IG), a load is applied to front occupant classification sensor LH 0.2 to 4.9 V d1-8 (SIG2) - d1-2 (SGD2) L-O Front occupant classification sensor RH signal line Ignition switch on (IG), a load is applied to front occupant classification sensor RH 0.2 to 4.9 V d1-9 (SIG3) - d1-3 (SGD3) Y-W Rear occupant classification sensor LH signal line Ignition switch on (IG), a load is applied to rear occupant classification sensor LH 0.2 to 4.9 V d1-10 (SIG4) - d1-4 (SGD4) R - BR Rear occupant classification sensor RH signal line Ignition switch on (IG), a load is applied to rear occupant classification sensor RH 0.2 to 4.9 V d1-11 (SVC1) - d1-1 (SGD1) R-G Front occupant classification sensor LH power supply line Ignition switch on (IG), a load is applied to front occupant classification sensor LH 4.5 to 5.1 V d1-12 (SVC2) - d1-2 (SGD2) W-O Front occupant classification sensor RH power supply line Ignition switch on (IG), a load is applied to front occupant classification sensor RH 4.5 to 5.1 V Condition Specification DIAGNOSIS SYSTEM 1. CG SG CANH SIL RS CANL CHECK DLC3 (a) The ECU uses ISO 15765-4 for communication. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. BAT H100769E16 Symbols (Terminal No.) Terminal Description Condition Pulse condition SIL (7) - SG (5) Bus "+" Line During transmission Pulse generation CG (4) - Body ground Chassis Ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 10 to 14 V CANH (6) - CANL (14) CAN bus line Ignition switch off (*) 54 to 69 Ω CANH (6) - BAT (16) HIGH-level CAN bus line Ignition switch off (*) 6 kΩ or higher CANH (6) - CG (4) HIGH-level CAN bus line Ignition switch off (*) 200 Ω or higher CANL (14) - BAT (16) LOW-level CAN bus line Ignition switch off (*) 6 kΩ or higher CANL (14) - CG (4) LOW-level CAN bus line Ignition switch off (*) 200 Ω or higher NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches, or the door. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DLC3 Intelligent Tester C131977E01 HINT: If the display shows a communication error message when connecting the cable of the intelligent tester to the DLC3, turning the ignition switch on (IG) and operating the intelligent tester, there is a problem on the vehicle side or tester side. • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 on the original vehicle. • If communication is still not possible when the tester is connected to another vehicle, the problem is probably in the tester itself. Consult the Service Department listed in the tester's instruction manual. SYMPTOM SIMULATION HINT: The most difficult case in troubleshooting is when no symptoms occur. In such cases, a thorough customer problem analysis must be carried out. Then the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be simulated. No matter how experienced or skilled a technician may be, if he proceeds to troubleshoot without confirming the problem symptoms, he will likely overlook something important and make a wrong guess at some points in the repair operation. This leads to a standstill in troubleshooting. (a) Vibration method: When vibration seems to be the major cause. HINT: Perform the simulation method only during the primary check period (for approximately 6 seconds after the ignition switch is turned on (IG)). (1) Slightly vibrate the part of the sensor considered to be the problem cause with your fingers and check whether the malfunction occurs. HINT: Shaking the relays too strongly may result in open relays. (2) Slightly shake the connector vertically and horizontally. (3) Slightly shake the wire harness vertically and horizontally. The connector joint and fulcrum of the vibration are the major areas to be checked thoroughly. Vibrate Slightly Shake Slightly Vibrate Slightly 2. RS–251 D025083E05 RS RS–252 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 3. Condition RS (b) Simulation method for DTC B1794: Turn the ignition switch from the off to on (IG), hold it for 10 seconds, and back to off again 50 times in a row. HINT: DTC B1794 is output if the occupant classification ECU receives the ignition switch off-on (IG)-off signal 50 times in a row when a malfunction occurs in the power circuit for the occupant classification system. FUNCTION OF PASSENGER AIRBAG ON/OFF INDICATOR (a) Initial check. (1) Turn the ignition switch on (IG). (2) The passenger airbag ON/OFF indicator ("ON" and "OFF") comes on for approximately 4 seconds, then goes off for approximately 2 seconds. (3) Approximately 6 seconds after the ignition switch is turned to on (IG), the passenger airbag ON/OFF indicator will show ON or OFF depending on the conditions listed below. ON Indicator OFF Indicator Vacant OFF OFF Adult is seated. (Above 36 kg (79.37 lb)) ON OFF Child is seated. (Less than 36 kg (79.37 lb)) OFF ON Child restraint system is set. (*) OFF ON Front passenger occupant classification system failure OFF ON *: Child restraint system less than 7 kg (15.43 lb) and passenger side buckle switch is ON, then 7 to 36 kg (15.43 to 79.37 lb) is set. HINT: • The passenger airbag ON/OFF indicator is based on the timing chart below in order to check the indicator light circuit. • When the occupant classification system has trouble, both the SRS warning light and the passenger airbag ON/OFF indicator ("OFF") come on. In this case, check the DTCs in "AIRBAG SYSTEM" first. SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–253 ON Ignition Switch OFF Passenger Airbag ON/OFF Indicator (”ON”) Passenger Airbag ON/OFF Indicator (”OFF”) 4 Sec. 2 Sec. 4 Sec. 2 Sec. ON OFF ON OFF ON/OFF condition depends on the front passenger detection results. H043700E02 4. C123721 CHECK PASSENGER AIRBAG ON/OFF INDICATOR (a) Turn the ignition switch on (IG). (b) Check that the passenger airbag ON/OFF indicator ("ON" and "OFF") come on for approximately 4 seconds, then goes off for approximately 2 seconds. HINT: Refer to the table in step 3 regarding the passenger airbag ON/OFF indicator when the ignition switch is turned on (IG) and approximately 6 seconds pass. RS RS–254 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC CHECK / CLEAR 1. DLC3 Intelligent Tester C131977E01 RS DTC CHECK HINT: When DTC B1650/32 is detected as a result of troubleshooting for "AIRBAG SYSTEM", perform troubleshooting for the occupant classification system. (a) Check for DTCs. (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch on (IG). (3) Check the DTCs by following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. (b) Clear DTCs. (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch on (IG). (3) Clear the DTCs by following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–255 DATA LIST / ACTIVE TEST HINT: By accessing the DATA LIST displayed on the intelligent tester, you can perform such functions as reading the values of switches and sensors without removing any parts. Reading the DATA LIST is the first step in troubleshooting is one method to save labor time. 1. DATA LIST FOR OCCUPANT CLASSIFICATION ECU (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Turn the tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/ MOBD / OCCUPANT DETECT / DATA LIST. (e) Check the values by referring to the table below. DLC3 Intelligent Tester C131977E01 Item Measurement Item/ Range (Display) Normal Condition Diagnostic Note ON/OFF - IG SW Ignition switch condition/ ON: Ignition switch on (IG) OFF: Ignition switch off P BUCKLE SW Buckle switch (Passenger side)/ SET: The seat belt is fastened UNSET: The seat belt is not fastened NG: Data is not determined SET/UNSET - PASSENGER CLASS Passenger classification/ AM50: Adult (more than 54 kg (119.05 lb)) is seated AF05: Adult (36 to 54 kg (79.37 to 119.05 lb)) is seated CHILD: Child (less than 36 kg (79.37 lb)) is seated CRS: Child restraint system (less than 7 kg (15.43 lb)) and passenger side buckle switch is ON, then 7 to 36 kg (15.43 to 79.37 lb) is set OFF: Vacant AM50/AF05/CHILD/CRS/OFF - SENS RANGE INF Sensor range information/ OK: The value of a sensor is within the range NG: The value of a sensor is over the range OK - FL SENS RANGE Front left sensor range information/ OK: Sensor range is -17 to 27 kg (-37.48 to 59.52 lb) Min.: Less than -17 kg (-37.48 lb) Max.: More than 27 kg (59.52 lb) OK - RS RS–256 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM Measurement Item/ Range (Display) Normal Condition Diagnostic Note FR SENS RANGE Front right sensor range information/ OK: Sensor range is -17 to 27 kg (-37.48 to 59.52 lb) Min.: Less than -17 kg (-37.48 lb) Max.: More than 27 kg (59.52 lb) OK - RL SENS RANGE Rear left sensor range information/ OK: Sensor range is -17 to 37 kg (-37.48 to 81.57 lb) Min.: Less than -17 kg (-37.48 lb) Max.: More than 37 kg (81.57 lb) OK - RR SENS RANGE Rear right sensor range information/ OK: Sensor range is -17 to 37 kg (-37.48 to 81.57 lb) Min.: Less than -17 kg (-37.48 lb) Max.: More than 37 kg (81.57 lb) OK - FL SENS VOL Front left sensor voltage/ Min.: 0 V Max.: 19.8 V 0 to 4.7 V - FR SENS VOL Front right sensor voltage/ Min.: 0 V Max.: 19.8 V 0 to 4.7 V - RL SENS VOL Rear left sensor voltage/ Min.: 0 V Max.: 19.8 V 0 to 4.7 V - RR SENS VOL Rear right sensor voltage/ Min.: 0 V Max.: 19.8 V 0 to 4.7 V - FL SENS WEIGHT Front left sensor weight information/ Min.: -17 kg (-37.48 lb) Max.: 27 kg (59.52 lb) -17 to 27 kg (-37.48 to 59.52 lb) - FR SENS WEIGHT Front right sensor weight information/ Min.: -17 kg (-37.48 lb) Max.: 27 kg (59.52 lb) -17 to 27 kg (-37.48 to 59.52 lb) - RL SENS WEIGHT Rear left sensor weight information/ Min.: -17 kg (-37.48 lb) Max.: 37 kg (81.57 lb) -17 to 37 kg (-37.48 to 81.57 lb) - RR SENS WEIGHT Rear right sensor weight information/ Min.: -17 kg (-37.48 lb) Max.: 37 kg (81.57 lb) -17 to 37 kg (-37.48 to 81.57 lb) - TOTAL WEIGHT Total weight information/ Min.: -68 kg (-149.91 lb) Max.: 128 kg (282.19 lb) -68 to 128 kg (-149.91 to 282.19 lb) - #PRESENT CODES Number of present DTC recorded/ Min.: 0, Max.: 255 0 - #PAST CODES Number of past DTC recorded/ Min.: 0, Max.: 255 0 - Item RS SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–257 DIAGNOSTIC TROUBLE CODE CHART If a trouble code is displayed during the DTC check, check the circuit listed for the code in the table below (Proceed to the page listed for that circuit). OCCUPANT CLASSIFICATION SYSTEM: DTC No. Trouble Area See page Passenger Side Buckle Switch Circuit Malfunction 1. Front seat inner belt assembly RH 2. Occupant classification ECU 3. Floor wire No. 2 4. Front seat wire RH (for Power seat) RS-255 Front Occupant Classification Sensor LH Circuit Malfunction 1. Front seat assembly RH (Front occupant classification sensor LH) 2. Occupant classification ECU 3. Front seat wire RH RS-263 Front Occupant Classification Sensor RH Circuit Malfunction 1. Front seat assembly RH (Front occupant classification sensor RH) 2. Occupant classification ECU 3. Front seat wire RH RS-271 Rear Occupant Classification Sensor LH Circuit Malfunction 1. Front seat assembly RH (Rear occupant classification sensor LH) 2. Occupant classification ECU 3. Front seat wire RH RS-279 B1783 Rear Occupant Classification Sensor RH Circuit Malfunction 1. Front seat assembly RH (Rear occupant classification sensor RH) 2. Occupant classification ECU 3. Front seat wire RH RS-287 B1785 Front Occupant Classification Sensor LH Collision Detection 1. Front seat assembly RH (Front occupant classification sensor LH) 2. Occupant classification ECU RS-295 B1786 Front Occupant Classification Sensor RH Collision Detection 1. Front seat assembly RH (Front occupant classification sensor RH) 2. Occupant classification ECU RS-299 B1787 Rear Occupant Classification Sensor LH Collision Detection 1. Front seat assembly RH (Rear occupant classification sensor LH) 2. Occupant classification ECU RS-303 B1788 Rear Occupant Classification Sensor RH Collision Detection 1. Front seat assembly RH (Rear occupant classification sensor RH) 2. Occupant classification ECU RS-307 B1790 Center Airbag Sensor Assembly Communication Circuit Malfunction 1. Occupant classification ECU 2. Center airbag sensor assembly 3. Floor wire No. 2 4. Front seat wire RH (for Power seat) RS-311 B1793 Occupant Classification Sensor Power Supply Circuit Malfunction 1. Front seat assembly RH (Occupant classification sensors) 2. Front seat wire RH 3. Occupant classification ECU RS-325 Open in Occupant Classification ECU Battery Positive Line 1. Battery 2. ECU-B fuse 3. Floor wire No. 2 4. Front seat wire RH (for Power seat) 5. Occupant classification ECU RS-332 B1771 B1780 B1781 B1782 B1794 Detection Item RS RS–258 DTC No. RS SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM Detection Item Trouble Area See page RS-337 RS-340 B1795 Occupant Classification ECU Malfunction 1. Occupant classification ECU 2. Floor wire No. 2 3. Front seat wire RH (for Power seat) 4. Front seat inner belt assembly RH B1796 Sleep Operation Failure of Occupant Classification ECU Occupant classification ECU SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC RS–259 Passenger Side Buckle Switch Circuit Malfunction B1771 DESCRIPTION The passenger side buckle switch circuit consists of the occupant classification ECU and the front seat inner belt assembly RH. DTC B1771 is recorded when a malfunction is detected in the passenger side buckle switch circuit. Troubleshoot DTC B1771 first when the DTC B1771 and B1795 are output simultaneously. DTC No. DTC Detecting Condition • B1771 • • The occupant classification ECU receives a line short circuit signal, an open circuit signal, a short circuit to ground signal or a short circuit to B+ signal in the passenger side buckle switch circuit for 2 seconds. Passenger side buckle switch malfunction Occupant classification ECU malfunction Trouble Area • • • • Front seat inner belt assembly RH Floor wire No. 2 Front seat wire RH (for Power seat) Occupant classification ECU WIRING DIAGRAM T7 (*1) O3 (*2) Front Seat Inner Belt Assembly RH (Front Passenger’s Side) Occupant Classification ECU 9 9 T10 O4 BSW (*1) (*2) 2 RS 5 5 T10 O4 BGND (*1) (*2) 1 *1: for Power Seat *2: for Manual Seat H043685E02 INSPECTION PROCEDURE HINT: • If troubleshooting (wire harness inspection) is difficult to perform, remove the front passenger seat installation bolts to see the under surface of seat cushion. • In the above case, hold the seat so that it does not fall down. Holding the seat for a long period of time may cause a problem, such as seat rail deformation. Hold the seat only as necessary. RS–260 1 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK DTC (a) Turn the ignition switch on (IG). (b) Clear the DTCs stored in the center airbag sensor assembly (See page RS-41). (c) Clear the DTCs stored in the occupant classification ECU (See page RS-251). (d) Turn the ignition switch off. (e) Turn the ignition switch on (IG). (f) Check the DTCs (See page RS-251). OK: DTC B1771 is not output. HINT: Codes other than DTC B1771 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK (See page RS-248) NG 2 CHECK CONNECTION OF CONNECTORS (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. (c) Check that the connectors are properly connected to the occupant classification ECU and the front seat inner belt assembly RH. OK: The connectors are properly connected. RS NG OK CONNECT CONNECTORS PROPERLY, THEN GO TO STEP 1 RS–261 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 3 CHECK WIRE HARNESS (SHORT TO B+) A D C Front Seat Inner Belt Assembly RH B Occupant Classification ECU (a) Disconnect the connectors from the occupant classification ECU and the front seat inner belt assembly RH. (b) Connect the negative (-) terminal cable to the battery. (c) Turn the ignition switch on (IG). (d) Measure the voltage according to the value(s) in the table below. Standard voltage: for Power seat Tester connection Condition Specified condition T10-9 (BSW) - Body ground Ignition switch on (IG) Below 1 V T10-5 (BGND) - Body ground Ignition switch on (IG) Below 1 V Connector B for Manual seat BGND T10 (*1) *1: for Power Seat O4 (*2) *2: for Manual Seat BSW Tester connection Condition Specified condition O4-9 (BSW) - Body ground) Ignition switch on (IG) Below 1 V O4-5 (BGND) - Body ground Ignition switch on (IG) Below 1 V C123747E01 Result Result C Proceed to NG (for Power seat) A NG (for Manual seat) B OK C A REPAIR OR REPLACE FRONT SEAT WIRE RH B REPAIR OR REPLACE FLOOR WIRE NO. 2 RS RS–262 4 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK WIRE HARNESS (OPEN) A D C B Front Seat Inner Belt Assembly RH Occupant Classification ECU Connector C Connector B T10 (*1) T7 (*1) O3 (*2) O4 (*2) BSW 1 BGND Tester connection Condition Specified condition T10-9 (BSW) - T10-5 (BGND) Always Below 1 Ω Tester connection Condition Specified condition O4-9 (BSW) - O4-5 (BGND) Always Below 1 Ω for Manual seat 2 *1: for Power Seat Service Wire (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. (c) Using a service wire, connect terminals 2 and 1 of connector C. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (d) Measure the resistance according to the value(s) in the table below. Standard resistance: for Power seat *2: for Manual Seat C123748E01 Result RS C Result Proceed to NG (for Power seat) A NG (for Manual seat) B OK C A REPAIR OR REPLACE FRONT SEAT WIRE RH B REPAIR OR REPLACE FLOOR WIRE NO. 2 RS–263 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 5 CHECK WIRE HARNESS (SHORT) (a) Disconnect the service wire from connector C. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: for Power seat A D C Front Seat Inner Belt Assembly RH B Occupant Classification ECU Tester connection Condition Specified condition T10-9 (BSW) - T10-5 (BGND) Always 1 MΩ or Higher Tester connection Condition Specified condition O4-9 (BSW) - O4-5 (BGND) Always 1 MΩ or Higher for Manual seat Result Connector B Result BGND T10 (*1) *1: for Power Seat O4 (*2) *2: for Manual Seat BSW C C123747E01 Proceed to NG (for Power seat) A NG (for Manual seat) B OK C A REPAIR OR REPLACE FRONT SEAT WIRE RH B REPAIR OR REPLACE FLOOR WIRE NO. 2 RS RS–264 6 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK WIRE HARNESS (SHORT TO GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: for Power seat A D C Front Seat Inner Belt Assembly RH B Occupant Classification ECU Connector B Tester connection Condition Specified condition T10-9 (BSW) - Body ground Always 1 MΩ or Higher T10-5 (BGND) - Body ground Always 1 MΩ or Higher Tester connection Condition Specified condition O4-9 (BSW) - Body ground Always 1 MΩ or Higher O4-5 (BGND) - Body ground Always 1 MΩ or Higher for Manual seat BGND T10 (*1) *1: for Power Seat O4 (*2) *2: for Manual Seat BSW RS Result C123747E01 Result Proceed to NG (for Power seat) A NG (for Manual seat) B OK C A REPAIR OR REPLACE FRONT SEAT WIRE RH B REPAIR OR REPLACE FLOOR WIRE NO. 2 C 7 CHECK DTC (a) Connect the connectors to the occupant classification ECU and the front seat inner belt assembly RH. (b) Connect the negative (-) terminal cable to the battery. (c) Turn the ignition switch on (IG). (d) Clear the DTCs stored in the center airbag sensor assembly (See page RS-41). (e) Clear the DTCs stored in the occupant classification ECU (See page RS-251). (f) Turn the ignition switch off. (g) Turn the ignition switch on (IG). (h) Check the DTCs (See page RS-251). OK: DTC B1771 is not output. HINT: Codes other than DTC B1771 may be output at this time, but they are not related to this check. SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM OK RS–265 USE SIMULATION METHOD TO CHECK (See page RS-248) NG 8 REPLACE FRONT SEAT INNER BELT ASSEMBLY RH (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the front seat inner belt assembly RH (See page SB-15). HINT: Perform the inspection using parts from a normal vehicle if possible. (d) Connect the negative (-) terminal cable to the battery. (e) Turn the ignition switch on (IG). (f) Clear the DTCs stored in the center airbag sensor assembly (See page RS-41). (g) Clear the DTCs stored in the occupant classification ECU (See page RS-251). (h) Turn the ignition switch off. (i) Turn the ignition switch on (IG). (j) Check the DTCs (See page RS-251). OK: DTC B1771 is not output. HINT: Codes other than DTC B1771 may be output at this time, but they are not related to this check. OK END NG 9 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the occupant classification ECU (See page RS469). NEXT 10 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Using the intelligent tester, perform "zero point calibration" (See page RS-242). OK: "COMPLETED" is displayed. RS RS–266 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM NEXT 11 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "sensitivity check" (See page RS-242). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NEXT END RS SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC B1780 RS–267 Front Occupant Classification Sensor LH Circuit Malfunction DESCRIPTION The front occupant classification sensor LH circuit consists of the occupant classification ECU and the front occupant classification sensor LH. DTC B1780 is recorded when a malfunction is detected in the front occupant classification sensor LH circuit. DTC No. DTC Detecting Condition • B1780 • • The occupant classification ECU receives a line short circuit signal, an open circuit signal, a short circuit to ground signal or a short circuit to B+ signal in the front occupant classification sensor LH circuit for 2 seconds. Front occupant classification sensor LH malfunction Occupant classification ECU malfunction Trouble Area • • • Front seat assembly RH (Front occupant classification sensor LH) Front seat wire RH Occupant classification ECU WIRING DIAGRAM T14 (*1) d2 (*2) Front Occupant Classification Sensor LH SVC1 SIG1 SGD1 Occupant Classification ECU 11 11 T11 d1 SVC1 (*1) (*2) 1 RS 7 7 T11 d1 SIG1 (*1) (*2) 2 1 1 T11 d1 SGD1 (*1) (*2) 3 *1: for Power Seat *2: for Manual Seat H045935E07 RS–268 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM INSPECTION PROCEDURE HINT: • If troubleshooting (wire harness inspection) is difficult to perform, remove the front passenger seat installation bolts to see the under surface of seat cushion. • In the above case, hold the seat so that it does not fall down. Holding the seat for a long period of time may cause a problem, such as seat rail deformation. Hold the seat only as necessary. 1 CHECK DTC (a) Turn the ignition switch on (IG). (b) Clear the DTCs stored in the center airbag sensor assembly (See page RS-41). (c) Clear the DTCs stored in the occupant classification ECU (See page RS-251). (d) Turn the ignition switch off. (e) Turn the ignition switch on (IG). (f) Check the DTCs (See page RS-251). OK: DTC B1780 is not output. HINT: Codes other than DTC B1780 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK (See page RS-248) NG RS 2 CHECK CONNECTION OF CONNECTORS (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. (c) Check that the connectors are properly connected to the occupant classification ECU and the front occupant classification sensor LH. OK: The connectors are properly connected. NG OK CONNECT CONNECTORS PROPERLY, THEN GO TO STEP 1 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 3 RS–269 CHECK FRONT SEAT WIRE RH (SHORT TO B+) Front Seat Wire RH A D C Front Seat Inner Belt Assembly RH B Occupant Classification ECU Connector B SGD1 T11 (*1) d1 *1: for Power Seat *2: for Manual Seat (*2) SIG1 SVC1 (a) Disconnect the connectors from the occupant classification ECU and the front occupant classification sensor LH. (b) Connect the negative (-) terminal cable to the battery. (c) Turn the ignition switch on (IG). (d) Measure the voltage according to the value(s) in the table below. Standard voltage: for Power seat Tester connection Condition Specified condition T11-1 (SGD1) - Body ground Ignition switch on (IG) Below 1 V T11-7 (SIG1) - Body ground Ignition switch on (IG) Below 1 V T11-11 (SVC1) - Body ground Ignition switch on (IG) Below 1 V for Manual seat Tester connection Condition Specified condition d1-1 (SGD1) - Body ground Ignition switch on (IG) Below 1 V d1-7 (SIG1) - Body ground Ignition switch on (IG) Below 1 V d1-11 (SVC1) - Body ground Ignition switch on (IG) Below 1 V C138022E01 NG OK REPAIR OR REPLACE FRONT SEAT WIRE RH RS RS–270 4 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK FRONT SEAT WIRE RH (OPEN) Front Seat Wire RH D A C B Front Occupant Classification Sensor LH Connector C Occupant Classification ECU Connector B (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. (c) Using a service wire, connect terminals 1 (SVC1) and 3 (SGD1), and connect terminals 2 (SIG1) and 3 (SGD1) of connector C. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (d) Measure the resistance according to the value(s) in the table below. Standard resistance: for Power seat T14 (*1) Service Wire d1 (*2) SGD1 SVC1 T11 (*1) Tester connection Condition Specified condition d1 (*2) T11-7 (SIG1) - T11-1 (SGD1) Always Below 1 Ω T11-11 (SVC1) - T11-1 (SGD1) Always Below 1 Ω Tester connection Condition Specified condition d1-7 (SIG1) - d1-1 (SGD1) Always Below 1 Ω d1-11 (SVC1) - d1-1 (SGD1) Always Below 1 Ω SGD1 SIG1 *1: for Power Seat Service Wire C SIG1 SVC1 for Manual seat *2: for Manual Seat C111709E21 RS NG OK REPAIR OR REPLACE FRONT SEAT WIRE RH SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 5 RS–271 CHECK FRONT SEAT WIRE RH (SHORT) (a) Disconnect the service wire from connector C. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: for Power seat Front Seat Wire RH A D C Front Seat Inner Belt Assembly RH B Occupant Classification ECU Tester connection Condition Specified condition T11-7 (SIG1) - T11-1 (SGD1) Always 1 MΩ or Higher T11-11 (SVC1) - T11-1 (SGD1) Always 1 MΩ or Higher T11-7 (SIG1) - T11-11 (SVC1) Always 1 MΩ or Higher Tester connection Condition Specified condition d1-7 (SIG1) - d1-1 (SGD1) Always 1 MΩ or Higher d1-11 (SVC1) - d1-1 (SGD1) Always 1 MΩ or Higher d1-7 (SIG1) - d1-11 (SVC1) Always 1 MΩ or Higher for Manual seat Connector B SGD1 *1: for Power Seat *2: for Manual Seat T11 (*1) d1 (*2) SVC1 SIG1 C138022E01 NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK 6 RS CHECK FRONT SEAT WIRE RH (SHORT TO GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: for Power seat Front Seat Wire RH A D C Front Seat Inner Belt Assembly RH B Occupant Classification ECU Tester connection Condition Specified condition T11-1 (SGD1) - Body ground Always 1 MΩ or Higher T11-7 (SIG1) - Body ground Always 1 MΩ or Higher T11-11 (SVC1) - Body ground Always 1 MΩ or Higher for Manual seat Connector B SGD1 T11 (*1) d1 *1: for Power Seat *2: for Manual Seat (*2) SIG1 SVC1 C138022E01 Tester connection Condition Specified condition d1-1 (SGD1) - Body ground Always 1 MΩ or Higher d1-7 (SIG1) - Body ground Always 1 MΩ or Higher d1-11 (SVC1) - Body ground Always 1 MΩ or Higher RS–272 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK 7 CHECK DTC (a) Connect the connectors to the occupant classification ECU and the front occupant classification sensor LH. (b) Connect the negative (-) terminal cable to the battery. (c) Turn the ignition switch on (IG). (d) Clear the DTCs stored in the center airbag sensor assembly (See page RS-41). (e) Clear the DTCs stored in the occupant classification ECU (See page RS-251). (f) Turn the ignition switch off. (g) Turn the ignition switch on (IG). (h) Check the DTCs (See page RS-251). OK: DTC B1780 is not output. HINT: Codes other than DTC B1780 may be output at this time, but they are not related to this check. OK RS USE SIMULATION METHOD TO CHECK (See page RS-248) NG 8 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the occupant classification ECU (See page RS469). HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT 9 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Using the intelligent tester, perform "zero point calibration" (See page RS-242). OK: "COMPLETED" is displayed. NG Go to step 12 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–273 OK 10 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "sensitivity check" (See page RS-242). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 12 OK 11 CHECK DTC (a) Turn the ignition switch on (IG). (b) Clear the DTCs stored in the center airbag sensor assembly (See page RS-41). (c) Clear the DTCs stored in the occupant classification ECU (See page RS-251). (d) Turn the ignition switch off. (e) Turn the ignition switch on (IG). (f) Check the DTCs (See page RS-251). OK: DTC B1780 is not output. HINT: Codes other than DTC B1780 may be output at this time, but they are not related to this check. OK END NG 12 REPLACE FRONT SEAT ASSEMBLY RH (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the front seat assembly RH (See page SE-30 for power seat or SE-16 for manual seat). NEXT 13 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Using the intelligent tester, perform "zero point calibration" (See page RS-242). OK: "COMPLETED" is displayed. RS RS–274 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM NEXT 14 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "sensitivity check" (See page RS-242). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NEXT END RS SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC B1781 RS–275 Front Occupant Classification Sensor RH Circuit Malfunction DESCRIPTION The front occupant classification sensor RH circuit consists of the occupant classification ECU and the front occupant classification sensor RH. DTC B1781 is recorded when a malfunction is detected in the front occupant classification sensor RH circuit. DTC No. DTC Detecting Condition • B1781 • • The occupant classification ECU receives a line short circuit signal, an open circuit signal, a short circuit to ground signal or a short circuit to B+ signal in the front occupant classification sensor RH circuit for 2 seconds. Front occupant classification sensor RH malfunction Occupant classification ECU malfunction Trouble Area • • • Front seat assembly RH (Front occupant classification sensor RH) Front seat wire RH Occupant classification ECU WIRING DIAGRAM T16 (*1) d4 (*2) Front Occupant Classification Sensor RH SVC2 SIG2 SGD2 Occupant Classification ECU 12 12 T11 d1 SVC2 (*1) (*2) 1 RS 8 8 T11 d1 SIG2 (*1) (*2) 2 2 2 T11 d1 SGD2 (*1) (*2) 3 *1: for Power Seat *2: for Manual Seat H045935E08 RS–276 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM INSPECTION PROCEDURE HINT: • If troubleshooting (wire harness inspection) is difficult to perform, remove the front passenger seat installation bolts to see the under surface of seat cushion. • In the above case, hold the seat so that it does not fall down. Holding the seat for a long period of time may cause a problem, such as seat rail deformation. Hold the seat only as necessary. 1 CHECK DTC (a) Turn the ignition switch on (IG). (b) Clear the DTCs stored in the center airbag sensor assembly (See page RS-41). (c) Clear the DTCs stored in the occupant classification ECU (See page RS-251). (d) Turn the ignition switch off. (e) Turn the ignition switch on (IG). (f) Check the DTCs (See page RS-41). OK: DTC B1781 is not output. HINT: Codes other than DTC B1781 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK (See page RS-248) NG RS 2 CHECK CONNECTION OF CONNECTORS (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. (c) Check that the connectors are properly connected to the occupant classification ECU and the front occupant classification sensor RH. OK: The connectors are properly connected. NG OK CONNECT CONNECTORS PROPERLY, THEN GO TO STEP 1 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 3 RS–277 CHECK FRONT SEAT WIRE RH (SHORT TO B+) Front Seat Wire RH A D C Front Seat Inner Belt Assembly RH B Occupant Classification ECU Connector B SGD2 T11 (*1) d1 *1: for Power Seat *2: for Manual Seat (*2) SIG2 SVC2 (a) Disconnect the connectors from the occupant classification ECU and the front occupant classification sensor RH. (b) Connect the negative (-) terminal cable to the battery. (c) Turn the ignition switch on (IG). (d) Measure the voltage according to the value(s) in the table below. Standard voltage: for Power seat Tester connection Condition Specified condition T11-2 (SGD2) - Body ground Ignition switch on (IG) Below 1 V T11-8 (SIG2) - Body ground Ignition switch on (IG) Below 1 V T11-12 (SVC2) - Body ground Ignition switch on (IG) Below 1 V for Manual seat Tester connection Condition Specified condition d1-2 (SGD2) - Body ground Ignition switch on (IG) Below 1 V d1-8 (SIG2) - Body ground Ignition switch on (IG) Below 1 V d1-12 (SVC2) - Body ground Ignition switch on (IG) Below 1 V C138022E02 NG OK REPAIR OR REPLACE FRONT SEAT WIRE RH RS RS–278 4 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK FRONT SEAT WIRE RH (OPEN) Front Seat Wire RH D A C B Occupant Classification ECU Front Occupant Classification Sensor RH *1: for Power Seat *2: for Manual Seat Connector C Connector B T16 (*1) Service Wire d4 (*2) SGD2 SVC2 SIG2 C T11 (*1) Tester connection Condition Specified condition d1 (*2) T11-8 (SIG2) - T11-2 (SGD2) Always Below 1 Ω T11-12 (SVC2) - T11-2 (SGD2) Always Below 1 Ω Tester connection Condition Specified condition d1-8 (SIG2) - d1-2 (SGD2) Always Below 1 Ω d1-12 (SVC2) - d1-2 (SGD2) Always Below 1 Ω SGD2 SIG2 SVC2 Service Wire C110374E23 RS (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. (c) Using a service wire, connect terminals 1 (SVC2) and 3 (SGD2), and connect terminals 2 (SIG2) and 3 (SGD2) of connector C. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (d) Measure the resistance according to the value(s) in the table below. Standard resistance: for Power seat for Manual seat NG OK REPAIR OR REPLACE FRONT SEAT WIRE RH SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 5 RS–279 CHECK FRONT SEAT WIRE RH (SHORT) (a) Disconnect the service wire from connector C. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: for Power seat Front Seat Wire RH A D C Front Seat Inner Belt Assembly RH B Occupant Classification ECU Tester connection Condition Specified condition T11-8 (SIG2) - T11-2 (SGD2) Always 1 MΩ or Higher T11-12 (SVC2) - T11-2 (SGD2) Always 1 MΩ or Higher T11-8 (SIG2) - T11-12 (SVC2) Always 1 MΩ or Higher Tester connection Condition Specified condition d1-8 (SIG2) - d1-2 (SGD2) Always 1 MΩ or Higher d1-12 (SVC2) - d1-2 (SGD2) Always 1 MΩ or Higher d1-8 (SIG2) - d1-12 (SVC2) Always 1 MΩ or Higher for Manual seat Connector B SGD2 *1: for Power Seat *2: for Manual Seat T11 (*1) d1 (*2) SVC2 SIG2 C138022E02 NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK 6 RS CHECK FRONT SEAT WIRE RH (SHORT TO GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: for Power seat Front Seat Wire RH A D C Front Seat Inner Belt Assembly RH B Occupant Classification ECU Tester connection Condition Specified condition T11-2 (SGD2) - Body ground Always 1 MΩ or Higher T11-8 (SIG2) - Body ground Always 1 MΩ or Higher T11-12 (SVC2) - Body ground Always 1 MΩ or Higher for Manual seat Connector B SGD2 T11 (*1) d1 *1: for Power Seat *2: for Manual Seat (*2) SIG2 SVC2 C138022E02 Tester connection Condition Specified condition d1-2 (SGD2) - Body ground Always 1 MΩ or Higher d1-8 (SIG2) - Body ground Always 1 MΩ or Higher d1-12 (SVC2) - Body ground Always 1 MΩ or Higher RS–280 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK 7 CHECK DTC (a) Connect the connectors to the occupant classification ECU and the front occupant classification sensor RH. (b) Connect the negative (-) terminal cable to the battery. (c) Turn the ignition switch on (IG). (d) Clear the DTCs stored in the center airbag sensor assembly (See page RS-41). (e) Clear the DTCs stored in the occupant classification ECU (See page RS-251). (f) Turn the ignition switch off. (g) Turn the ignition switch on (IG). (h) Check the DTCs (See page RS-251). OK: DTC B1781 is not output. HINT: Codes other than DTC B1781 may be output at this time, but they are not related to this check. OK RS USE SIMULATION METHOD TO CHECK (See page RS-248) NG 8 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the occupant classification ECU (See page RS469). HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT 9 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Using the intelligent tester, perform "zero point calibration" (See page RS-242). OK: "COMPLETED" is displayed. NG Go to step 12 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–281 OK 10 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "sensitivity check" (See page RS-242). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 12 OK 11 CHECK DTC (a) Turn the ignition switch on (IG). (b) Clear the DTCs stored in the center airbag sensor assembly (See page RS-41). (c) Clear the DTCs stored in the occupant classification ECU (See page RS-251). (d) Turn the ignition switch off. (e) Turn the ignition switch on (IG). (f) Check the DTCs (See page RS-251). OK: DTC B1781 is not output. HINT: Codes other than DTC B1781 may be output at this time, but they are not related to this check. OK END NG 12 REPLACE FRONT SEAT ASSEMBLY RH (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the front seat assembly RH (See page SE-30 for power seat or SE-16 for manual seat). NEXT 13 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Using the intelligent tester, perform "zero point calibration" (See page RS-242). OK: "COMPLETED" is displayed. RS RS–282 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM NEXT 14 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "sensitivity check" (See page RS-242). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NEXT END RS SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC B1782 RS–283 Rear Occupant Classification Sensor LH Circuit Malfunction DESCRIPTION The rear occupant classification sensor LH circuit consists of the occupant classification ECU and the rear occupant classification sensor LH. DTC B1782 is recorded when a malfunction is detected in the rear occupant classification sensor LH circuit. DTC No. DTC Detecting Condition • B1782 • • The occupant classification ECU receives a line short circuit signal, an open circuit signal, a short circuit to ground signal or a short circuit to B+ signal in the rear occupant classification sensor LH circuit for 2 seconds. Rear occupant classification sensor LH malfunction Occupant classification ECU malfunction Trouble Area • • • Front seat assembly RH (Rear occupant classification sensor LH) Front seat wire RH Occupant classification ECU WIRING DIAGRAM T15 (*1) d3 (*2) Rear Occupant Classification Sensor LH SVC3 SIG3 SGD3 Occupant Classification ECU 5 5 T11 d1 SVC3 (*1) (*2) 1 RS 9 9 T11 d1 SIG3 (*1) (*2) 2 3 3 T11 d1 SGD3 (*1) (*2) 3 *1: for Power Seat *2: for Manual Seat H045935E09 RS–284 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM INSPECTION PROCEDURE HINT: • If troubleshooting (wire harness inspection) is difficult to perform, remove the front passenger seat installation bolts to see the under surface of seat cushion. • In the above case, hold the seat so that it does not fall down. Holding the seat for a long period of time may cause a problem, such as seat rail deformation. Hold the seat only as necessary. 1 CHECK DTC (a) Turn the ignition switch on (IG). (b) Clear the DTCs stored in the center airbag sensor assembly (See page RS-41). (c) Clear the DTCs stored in the occupant classification ECU (See page RS-251). (d) Turn the ignition switch off. (e) Turn the ignition switch on (IG). (f) Check the DTCs (See page RS-251). OK: DTC B1782 is not output. HINT: Codes other than DTC B1782 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK (See page RS-248) NG RS 2 CHECK CONNECTION OF CONNECTORS (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. (c) Check that the connectors are properly connected to the occupant classification ECU and the rear occupant classification sensor LH. OK: The connectors are properly connected. NG OK CONNECT CONNECTORS PROPERLY, THEN GO TO STEP 1 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 3 RS–285 CHECK FRONT SEAT WIRE RH (SHORT TO B+) Front Seat Wire RH A D C Front Seat Inner Belt Assembly RH B Occupant Classification ECU Connector B SGD3 T11 (*1) d1 (*2) SVC3 *1: for Power Seat *2: for Manual Seat SIG3 (a) Disconnect the connectors from the occupant classification ECU and the rear occupant classification sensor LH. (b) Connect the negative (-) terminal cable to the battery. (c) Turn the ignition switch on (IG). (d) Measure the voltage according to the value(s) in the table below. Standard voltage: for Power seat Tester connection Condition Specified condition T11-3 (SGD3) - Body ground Ignition switch on (IG) Below 1 V T11-5 (SVC3) - Body ground Ignition switch on (IG) Below 1 V T11-9 (SIG3) - Body ground Ignition switch on (IG) Below 1 V for Manual seat Tester connection Condition Specified condition d1-3 (SGD3) - Body ground Ignition switch on (IG) Below 1 V d1-9 (SIG3) - Body ground Ignition switch on (IG) Below 1 V d1-5 (SVC3) - Body ground Ignition switch on (IG) Below 1 V C138022E03 NG OK REPAIR OR REPLACE FRONT SEAT WIRE RH RS RS–286 4 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK FRONT SEAT WIRE RH (OPEN) Front Seat Wire RH D A C B Rear Occupant Classification Sensor LH Occupant Classification ECU *1: for Power Seat *2: for Manual Seat Connector C Connector B T15 (*1) Service Wire d3 T11 (*1) (*2) SGD3 SVC3 d1 (*2) SVC3 SGD3 SIG3 SIG3 C Tester connection Condition Specified condition T11-5 (SVC3) - T11-3 (SGD3) Always Below 1 Ω T11-9 (SIG3) - T11-3 (SGD3) Always Below 1 Ω Tester connection Condition Specified condition d1-9 (SIG3) - d1-3 (SGD3) Always Below 1 Ω d1-5 (SVC3) - d1-3 (SGD3) Always Below 1 Ω for Manual seat Service Wire C110374E24 RS (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. (c) Using a service wire, connect terminals 1 (SVC3) and 3 (SGD3), and connect terminals 2 (SIG3) and 3 (SGD3) of connector C. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (d) Measure the resistance according to the value(s) in the table below. Standard resistance: for Power seat NG OK REPAIR OR REPLACE FRONT SEAT WIRE RH SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 5 RS–287 CHECK FRONT SEAT WIRE RH (SHORT) (a) Disconnect the service wire from connector C. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: for Power seat Front Seat Wire RH A D C Front Seat Inner Belt Assembly RH B Tester connection Condition Specified condition T11-5 (SVC3) - T11-3 (SGD3) Always 1 MΩ or Higher T11-9 (SIG3) - T11-3 (SGD3) Always 1 MΩ or Higher T11-5 (SVC3) - T11-9 (SIG3) Always 1 MΩ or Higher Tester connection Condition Specified condition SVC3 d1-9 (SIG3) - d1-3 (SGD3) Always 1 MΩ or Higher *1: for Power Seat d1-5 (SVC3) - d1-3 (SGD3) Always 1 MΩ or Higher *2: for Manual Seat d1-9 (SIG3) - d1-5 (SVC3) Always 1 MΩ or Higher Occupant Classification ECU for Manual seat Connector B SGD3 T11 (*1) d1 (*2) SIG3 C138022E03 NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK 6 RS CHECK FRONT SEAT WIRE RH (SHORT TO GROUND) (a) Measure the resistance according to value(s) in the table below. Standard resistance: for Power seat Front Seat Wire RH A D C Front Seat Inner Belt Assembly RH B Occupant Classification ECU Tester connection Condition Specified condition T11-3 (SGD3) - Body ground Always 1 MΩ or Higher T11-5 (SVC3) - Body ground Always 1 MΩ or Higher T11-9 (SIG3) - Body ground Always 1 MΩ or Higher for Manual seat Connector B SGD3 T11 (*1) d1 (*2) SVC3 *1: for Power Seat *2: for Manual Seat SIG3 C138022E03 Tester connection Condition Specified condition d1-3 (SGD3) - Body ground Always 1 MΩ or Higher d1-9 (SIG3) - Body ground Always 1 MΩ or Higher d1-5 (SVC3) - Body ground Always 1 MΩ or Higher RS–288 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK 7 CHECK DTC (a) Connect the connectors to the occupant classification ECU and the rear occupant classification sensor LH. (b) Connect the negative (-) terminal cable to the battery. (c) Turn the ignition switch on (IG). (d) Clear the DTCs stored in the center airbag sensor assembly (See page RS-41). (e) Clear the DTCs stored in the occupant classification ECU (See page RS-251). (f) Turn the ignition switch off. (g) Turn the ignition switch on (IG). (h) Check the DTCs (See page RS-251). OK: DTC B1782 is not output. HINT: Codes other than DTC B1782 may be output at this time, but they are not related to this check. OK RS USE SIMULATION METHOD TO CHECK (See page RS-248) NG 8 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the occupant classification ECU (See page RS469). HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT 9 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Using the intelligent tester, perform "zero point calibration" (See page RS-242). OK: "COMPLETED" is displayed. NG Go to step 12 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–289 OK 10 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "sensitivity check" (See page RS-242). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 12 OK 11 CHECK DTC (a) Turn the ignition switch on (IG). (b) Clear the DTCs stored in the center airbag sensor assembly (See page RS-41). (c) Clear the DTCs stored in the occupant classification ECU (See page RS-251). (d) Turn the ignition switch off. (e) Turn the ignition switch on (IG). (f) Check the DTCs (See page RS-251). OK: DTC B1782 is not output. HINT: Codes other than DTC B1782 may be output at this time, but they are not related to this check. OK END NG 12 REPLACE FRONT SEAT ASSEMBLY RH (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the front seat assembly RH (See page SE-30 for power seat or SE-16 for manual seat). NEXT 13 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Using the intelligent tester, perform "zero point calibration" (See page RS-242). OK: "COMPLETED" is displayed. RS RS–290 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM NEXT 14 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "sensitivity check" (See page RS-242). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NEXT END RS SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC B1783 RS–291 Rear Occupant Classification Sensor RH Circuit Malfunction DESCRIPTION The rear occupant classification sensor RH circuit consists of the occupant classification ECU and the rear occupant classification sensor RH. DTC B1783 is recorded when a malfunction is detected in the rear occupant classification sensor RH circuit. DTC No. DTC Detecting Condition • B1783 • • The occupant classification ECU receives a line short circuit signal, an open circuit signal, a short circuit to ground signal or a short circuit to B+ signal in the rear occupant classification sensor RH circuit for 2 seconds. Rear occupant classification sensor RH malfunction. Occupant classification ECU malfunction. Trouble Area • • • Front seat assembly RH (Rear occupant classification sensor RH) Front seat wire RH Occupant classification ECU WIRING DIAGRAM T17 (*1) d5 (*2) Rear Occupant Classification Sensor RH SVC4 SIG4 SGD4 Occupant Classification ECU 6 6 T11 d1 SVC4 (*1) (*2) 1 RS 10 10 T11 d1 SIG4 (*1) (*2) 2 4 4 T11 d1 SGD4 (*1) (*2) 3 *1: for Power Seat *2: for Manual Seat H045935E10 RS–292 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM INSPECTION PROCEDURE HINT: • If troubleshooting (wire harness inspection) is difficult to perform, remove the front passenger seat installation bolts to see the under surface of seat cushion. • In the above case, hold the seat so that it does not fall down. Holding the seat for a long period of time may cause a problem, such as seat rail deformation. Hold the seat only as necessary. 1 CHECK DTC (a) Turn the ignition switch on (IG). (b) Clear the DTCs stored in the center airbag sensor assembly (See page RS-41). (c) Clear the DTCs stored in the occupant classification ECU (See page RS-251). (d) Turn the ignition switch off. (e) Turn the ignition switch on (IG). (f) Check the DTCs (See page RS-251). OK: DTC B1783 is not output. HINT: Codes other than DTC B1783 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK (See page RS-248) NG RS 2 CHECK CONNECTION OF CONNECTORS (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. (c) Check that the connectors are properly connected to the occupant classification ECU and the rear occupant classification sensor RH. OK: The connectors are properly connected. NG OK CONNECT CONNECTORS PROPERLY, THEN GO TO STEP 1 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 3 RS–293 CHECK FRONT SEAT WIRE RH (SHORT TO B+) Front Seat Wire RH A D C Front Seat Inner Belt Assembly RH B Occupant Classification ECU Connector B SGD4 T11 (*1) d1 *1: for Power Seat *2: for Manual Seat (*2) SIG4 SVC4 (a) Disconnect the connectors from the occupant classification ECU and the rear occupant classification sensor RH. (b) Connect the negative (-) terminal cable to the battery. (c) Turn the ignition switch on (IG). (d) Measure the voltage according to the value(s) in the table below. Standard voltage: for Power seat Tester connection Condition Specified condition T11-4 (SGD4) - Body ground Ignition switch on (IG) Below 1 V T11-6 (SVC4) - Body ground Ignition switch on (IG) Below 1 V T11-10 (SIG4) - Body ground Ignition switch on (IG) Below 1 V for Manual seat Tester connection Condition Specified condition d1-4 (SGD4) - Body ground Ignition switch on (IG) Below 1 V d1-10 (SIG4) - Body ground Ignition switch on (IG) Below 1 V d1-6 (SVC4) - Body ground Ignition switch on (IG) Below 1 V C138022E04 NG OK REPAIR OR REPLACE FRONT SEAT WIRE RH RS RS–294 4 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK FRONT SEAT WIRE RH (OPEN) Front Seat Wire RH D A C B Rear Occupant Classification Sensor RH Occupant Classification ECU *1: Power Seat *2: Manual Seat Connector C Connector B T17 (*1) Service Wire T11 (*1) d5 (*2) SGD4 SVC4 SVC4 SGD4 SIG4 C d1 (*2) SIG4 Service Wire C111709E22 (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. (c) for Power seat: Using a service wire, connect T17-1 (SVC4) and T17-3 (SGD4), and connect T17-2 (SIG4) and T17-3 (SGD4) of connector C. (d) for Manual seat: Using a service wire, connect d5-1 (SVC4) and d5-3 (SGD4), and connect d5-2 (SIG4) and d5-3 (SGD4) of connector C. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (e) Measure the resistance according to the value(s) in the table below. Standard resistance: for Power seat Tester connection Condition Specified condition T11-6 (SVC4) - T11-4 (SGD4) Always Below 1 Ω T11-10 (SIG4) - T11-4 (SGD4) Always Below 1 Ω for Manual seat RS Tester connection Condition Specified condition d1-10 (SIG4) - d1-4 (SGD4) Always Below 1 Ω d1-6 (SVC4) - d1-4 (SGD4) Always Below 1 Ω NG OK REPAIR OR REPLACE FRONT SEAT WIRE RH SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 5 RS–295 CHECK FRONT SEAT WIRE RH (SHORT) (a) Disconnect the service wire from connector C. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: for Power seat Front Seat Wire RH A D C Front Seat Inner Belt Assembly RH B Occupant Classification ECU Tester connection Condition Specified condition T11-6 (SVC4) - T11-4 (SGD4) Always 1 MΩ or Higher T11-10 (SIG4) - T11-4 (SGD4) Always 1 MΩ or Higher T11-6 (SVC4) - T11-10 (SIG4) Always 1 MΩ or Higher for Manual seat Connector B SGD4 *1: for Power Seat *2: for Manual Seat T11 (*1) d1 (*2) SVC4 SIG4 Tester connection Condition Specified condition d1-10 (SIG4) - d1-4 (SGD4) Always 1 MΩ or Higher d1-6 (SVC4) - d1-4 (SGD4) Always 1 MΩ or Higher d1-10 (SIG4) - d1-6 (SVC4) Always 1 MΩ or Higher C138022E04 NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK 6 RS CHECK FRONT SEAT WIRE RH (SHORT TO GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: for Power seat Front Seat Wire RH A D C Front Seat Inner Belt Assembly RH B Occupant Classification ECU Tester connection Condition Specified condition T11-4 (SGD4) - Body ground Always 1 MΩ or Higher T11-6 (SVC4) - Body ground Always 1 MΩ or Higher T11-10 (SIG4) - Body ground Always 1 MΩ or Higher for Manual seat Connector B SGD4 T11 (*1) d1 *1: for Power Seat *2: for Manual Seat (*2) SIG4 SVC4 C138022E04 Tester connection Condition Specified condition d1-4 (SGD4) - Body ground Always 1 MΩ or Higher d1-10 (SIG4) - Body ground Always 1 MΩ or Higher d1-6 (SVC4) - Body ground Always 1 MΩ or Higher RS–296 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK 7 CHECK DTC (a) Connect the connectors to the occupant classification ECU and the rear occupant classification sensor RH. (b) Connect the negative (-) terminal cable to the battery. (c) Turn the ignition switch on (IG). (d) Clear the DTCs stored in the center airbag sensor assembly (See page RS-41). (e) Clear the DTCs stored in the occupant classification ECU (See page RS-251). (f) Turn the ignition switch off. (g) Turn the ignition switch on (IG). (h) Check the DTCs (See page RS-251). OK: DTC B1783 is not output. HINT: Codes other than DTC B1783 may be output at this time, but they are not related to this check. OK RS USE SIMULATION METHOD TO CHECK (See page RS-248) NG 8 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the occupant classification ECU (See page RS469). HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT 9 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Using the intelligent tester, perform "zero point calibration" (See page RS-242). OK: "COMPLETED" is displayed. NG Go to step 12 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–297 OK 10 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "sensitivity check" (See page RS-242). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 12 OK 11 CHECK DTC (a) Turn the ignition switch on (IG). (b) Clear the DTCs stored in the center airbag sensor assembly (See page RS-41). (c) Clear the DTCs stored in the occupant classification ECU (See page RS-251). (d) Turn the ignition switch off. (e) Turn the ignition switch on (IG). (f) Check the DTCs (See page RS-251). OK: DTC B1783 is not output. HINT: Codes other than DTC B1783 may be output at this time, but they are not related to this check. OK END NG 12 REPLACE FRONT SEAT ASSEMBLY RH (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the front seat assembly RH (See page SE-30 for power seat or SE-16 for manual seat). NEXT 13 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Using the intelligent tester, perform "zero point calibration" (See page RS-242). OK: "COMPLETED" is displayed. RS RS–298 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM NEXT 14 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "sensitivity check" (See page RS-242). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NEXT END RS SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC RS–299 Front Occupant Classification Sensor LH Collision Detection B1785 DESCRIPTION DTC B1785 is output when the occupant classification ECU receives a collision detection signal sent by the front occupant classification sensor LH if an accident occurs. DTC B1785 is also output when the front seat assembly RH is subjected to a strong impact, even if an actual accident does not occur. However, when the occupant classification ECU outputs a collision detection signal, even if the vehicle is not in a collision, DTC B1785 can be cleared by "zero point calibration" and "sensitivity check". Therefore, if DTC B1785 is output, first perform "zero point calibration" and "sensitivity check". DTC No. B1785 DTC Detecting Condition • • • Front seat assembly RH malfunction Occupant classification ECU malfunction Front occupant classification sensor LH sensed large load Trouble Area • • Occupant classification ECU Front seat assembly RH (Front occupant classification sensor LH) WIRING DIAGRAM See page RS-263. INSPECTION PROCEDURE 1 PERFORM ZERO POINT CALIBRATION (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Using the intelligent tester, perform "zero point calibration" (See page RS-242). OK: "COMPLETED" is displayed. NG Go to step 4 OK 2 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "sensitivity check" (See page RS-242). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 4 OK 3 CHECK DTC (a) Turn the ignition switch on (IG). (b) Clear the DTCs stored in the center airbag sensor assembly (See page RS-41). RS RS–300 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM (c) Clear the DTCs stored in the occupant classification ECU (See page RS-251). (d) Turn the ignition switch off. (e) Turn the ignition switch on (IG). (f) Check the DTCs (See page RS-251). OK: DTC B1785 is not output. HINT: Codes other than DTC B1785 may be output at this time, but they are not related to this check. OK END NG 4 REPLACE FRONT SEAT ASSEMBLY RH (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the front seat assembly RH (See page SE-16 for power seat or SE-30 for manual seat). HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT RS 5 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Using the intelligent tester, perform "zero point calibration" (See page RS-242). OK: "COMPLETED" is displayed. NG Go to step 8 OK 6 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "sensitivity check" (See page RS-242). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG OK Go to step 8 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 7 RS–301 CHECK DTC (a) Turn the ignition switch on (IG). (b) Clear the DTCs stored in the center airbag sensor assembly (See page RS-41). (c) Clear the DTCs stored in the occupant classification ECU (See page RS-251). (d) Turn the ignition switch off. (e) Turn the ignition switch on (IG). (f) Check the DTCs (See page RS-251). OK: DTC B1785 is not output. HINT: Codes other than DTC B1785 may be output at this time, but they are not related to this check. OK END NG 8 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the occupant classification ECU (See page RS469). NEXT 9 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Using the intelligent tester, perform "zero point calibration" (See page RS-242). OK: "COMPLETED" is displayed. NEXT 10 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "sensitivity check" (See page RS-242). Standard value: 27 to 33 kg (59.52 to 72.75 lb) RS RS–302 NEXT END RS SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC RS–303 Front Occupant Classification Sensor RH Collision Detection B1786 DESCRIPTION DTC B1786 is output when the occupant classification ECU receives a collision detection signal sent by the front occupant classification sensor RH if an accident occurs. DTC B1786 is also output when the front seat assembly RH is subjected to a strong impact, even if an actual accident does not occur. However, when the occupant classification ECU outputs a collision detection signal, even if the vehicle is not in a collision, DTC B1786 can be cleared by "zero point calibration" and "sensitivity check". Therefore, if DTC B1786 is output, first perform "zero point calibration" and "sensitivity check". DTC No. B1786 DTC Detection Condition • • • Front seat assembly RH malfunction Occupant classification ECU malfunction Front occupant classification sensor RH sensed large load Trouble Area • • Occupant classification ECU Front seat assembly RH (Front occupant classification sensor RH) WIRING DIAGRAM See page RS-271. INSPECTION PROCEDURE 1 PERFORM ZERO POINT CALIBRATION (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Using the intelligent tester, perform "zero point calibration" (See page RS-242). OK: "COMPLETED" is displayed. NG Go to step 4 OK 2 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "sensitivity check" (See page RS-242). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 4 OK 3 CHECK DTC (a) Turn the ignition switch on (IG). (b) Clear the DTCs stored in the center airbag sensor assembly (See page RS-41). RS RS–304 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM (c) Clear the DTCs stored in the occupant classification ECU (See page RS-251). (d) Turn the ignition switch off. (e) Turn the ignition switch on (IG). (f) Check the DTCs (See page RS-251). OK: DTC B1786 is not output. HINT: Codes other than DTC B1786 may be output at this time, but they are not related to this check. OK END NG 4 REPLACE FRONT SEAT ASSEMBLY RH (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the front seat assembly RH (See page SE-30 for power seat or SE-16 for manual seat). HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT RS 5 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Using the intelligent tester, perform "zero point calibration" (See page RS-242). OK: "COMPLETED" is displayed. NG Go to step 8 OK 6 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "sensitivity check" (See page RS-242). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG OK Go to step 8 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 7 RS–305 CHECK DTC (a) Turn the ignition switch on (IG). (b) Clear the DTCs stored in the center airbag sensor assembly (See page RS-41). (c) Clear the DTCs stored in the occupant classification ECU (See page RS-251). (d) Turn the ignition switch off. (e) Turn the ignition switch on (IG). (f) Check the DTCs (See page RS-251). OK: DTC B1786 is not output. HINT: Codes other than DTC B1786 may be output at this time, but they are not related to this check. OK END NG 8 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the occupant classification ECU (See page RS469). NEXT 9 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Using the intelligent tester, perform "zero point calibration" (See page RS-242). OK: "COMPLETED" is displayed. NEXT 10 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "sensitivity check" (See page RS-242). Standard value: 27 to 33 kg (59.52 to 72.75 lb) RS RS–306 NEXT END RS SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC RS–307 Rear Occupant Classification Sensor LH Collision Detection B1787 DESCRIPTION DTC B1787 is output when the occupant classification ECU receives a collision detection signal sent by the rear occupant classification sensor LH if an accident occurs. DTC B1787 is also output when the front seat assembly RH is subjected to a strong impact, even if an actual accident does not occur. However, when the occupant classification ECU outputs a collision detection signal, even if the vehicle is not in a collision, DTC B1787 can be cleared by "zero point calibration" and "sensitivity check". Therefore, if DTC B1787 is output, first perform "zero point calibration" and "sensitivity check". DTC No. B1787 DTC Detecting Condition • • • Front seat assembly RH malfunction Occupant classification ECU malfunction Rear occupant classification sensor LH sensed large load Trouble Area • • Occupant classification ECU Front seat assembly RH (Rear occupant classification sensor LH) WIRING DIAGRAM See page RS-279. INSPECTION PROCEDURE 1 PERFORM ZERO POINT CALIBRATION (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Using the intelligent tester, perform "zero point calibration" (See page RS-242). OK: "COMPLETED" is displayed. NG Go to step 4 OK 2 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "sensitivity check" (See page RS-242). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 4 OK 3 CHECK DTC (a) Turn the ignition switch on (IG). (b) Clear the DTCs stored in the center airbag sensor assembly (See page RS-41). RS RS–308 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM (c) Clear the DTCs stored in the occupant classification ECU (See page RS-251). (d) Turn the ignition switch off. (e) Turn the ignition switch on (IG). (f) Check the DTCs (See page RS-251). OK: DTC B1787 is not output. HINT: Codes other than DTC B1787 may be output at this time, but they are not related to this check. OK END NG 4 REPLACE FRONT SEAT ASSEMBLY RH (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the front seat assembly RH (See page SE-30 for power seat or SE-16 for manual seat). HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT RS 5 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Using the intelligent tester, perform "zero point calibration" (See page RS-242). OK: "COMPLETED" is displayed. NG Go to step 8 OK 6 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "sensitivity check" (See page RS-242). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG OK Go to step 8 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 7 RS–309 CHECK DTC (a) Turn the ignition switch on (IG). (b) Clear the DTCs stored in the center airbag sensor assembly (See page RS-41). (c) Clear the DTCs stored in the occupant classification ECU (See page RS-251). (d) Turn the ignition switch off. (e) Turn the ignition switch on (IG). (f) Check the DTCs (See page RS-251). OK: DTC B1787 is not output. HINT: Codes other than DTC B1787 may be output at this time, but they are not related to this check. OK END NG 8 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the occupant classification ECU (See page RS469). NEXT 9 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Using the intelligent tester, perform "zero point calibration" (See page RS-242). OK: "COMPLETED" is displayed. NEXT 10 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "sensitivity check" (See page RS-242). Standard value: 27 to 33 kg (59.52 to 72.75 lb) RS RS–310 NEXT END RS SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC RS–311 Rear Occupant Classification Sensor RH Collision Detection B1788 DESCRIPTION DTC B1788 is output when the occupant classification ECU receives a collision detection signal sent by the rear occupant classification sensor RH if an accident occurs. DTC B1788 is also output when the front seat assembly RH is subjected to a strong impact, even if an actual accident does not occur. However, when the occupant classification ECU outputs a collision detection signal, even if the vehicle is not in a collision, DTC B1788 can be cleared by "zero point calibration" and "sensitivity check". Therefore, if DTC B1788 is output, first perform "zero point calibration" and "sensitivity check". DTC No. B1788 DTC Detection Condition • • • Front seat assembly RH malfunction Occupant classification ECU malfunction Rear occupant classification sensor RH sensed large load Trouble Area • • Occupant classification ECU Front seat assembly RH (Rear occupant classification sensor RH) WIRING DIAGRAM See page RS-287. INSPECTION PROCEDURE 1 PERFORM ZERO POINT CALIBRATION (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Using the intelligent tester, perform "zero point calibration" (See page RS-242). OK: "COMPLETED" is displayed. NG Go to step 4 OK 2 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "sensitivity check" (See page RS-242). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 4 OK 3 CHECK DTC (a) Turn the ignition switch on (IG). (b) Clear the DTCs stored in the center airbag sensor assembly (See page RS-41). RS RS–312 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM (c) Clear the DTCs stored in the occupant classification ECU (See page RS-251). (d) Turn the ignition switch off. (e) Turn the ignition switch on (IG). (f) Check the DTCs (See page RS-251). OK: DTC B1788 is not output. HINT: Codes other than DTC B1788 may be output at this time, but they are not related to this check. OK END NG 4 REPLACE FRONT SEAT ASSEMBLY RH (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the front seat assembly RH (See page SE-30 for power seat or SE-16 for manual seat). HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT RS 5 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Using the intelligent tester, perform "zero point calibration" (See page RS-242). OK: "COMPLETED" is displayed. NG Go to step 8 OK 6 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "sensitivity check" (See page RS-242). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG OK Go to step 8 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 7 RS–313 CHECK DTC (a) Turn the ignition switch on (IG). (b) Clear the DTCs stored in the center airbag sensor assembly (See page RS-41). (c) Clear the DTCs stored in the occupant classification ECU (See page RS-251). (d) Turn the ignition switch off. (e) Turn the ignition switch on (IG). (f) Check the DTCs (See page RS-251). OK: DTC B1788 is not output. HINT: Codes other than DTC B1788 may be output at this time, but they are not related to this check. OK END NG 8 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the occupant classification ECU (See page RS469). NEXT 9 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Using the intelligent tester, perform "zero point calibration" (See page RS-242). OK: "COMPLETED" is displayed. NEXT 10 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "sensitivity check" (See page RS-242). Standard value: 27 to 33 kg (59.52 to 72.75 lb) RS RS–314 NEXT END RS SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC B1790 RS–315 Center Airbag Sensor Assembly Communication Circuit Malfunction DESCRIPTION The center airbag sensor assembly communication circuit consists of the occupant classification ECU and the center airbag sensor assembly. DTC B1790 is recorded when a malfunction is detected in the center airbag sensor assembly communication circuit. DTC No. DTC Detecting Condition • B1790 • • The occupant classification ECU receives a line short circuit signal, an open circuit signal, a short circuit to ground signal or a short circuit to B+ signal in the center airbag sensor assembly communication circuit for 2 seconds. Center airbag sensor assembly malfunction Occupant classification ECU malfunction Trouble Area • • • • Occupant classification ECU Center airbag sensor assembly Floor wire No. 2 Front seat wire RH (for Power seat) WIRING DIAGRAM Occupant Classification ECU 8 8 FSR+ T10 O4 (*1) (*2) Center Airbag Sensor Assembly (*1) 1 OT1 (*1) 12 O1 FSP+ RS (*2) FSR- 4 4 T10 O4 (*1) (*2) (*1) 4 OT1 (*1) 13 O1 FSP- (*2) *1: for Power Seat *2: for Manual Seat H045471E04 RS–316 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM INSPECTION PROCEDURE HINT: • If troubleshooting (wire harness inspection) is difficult to perform, remove the front passenger seat installation bolts to see the under surface of seat cushion. • In the above case, hold the seat so that it does not fall down. Holding the seat for a long period of time may cause a problem, such as seat rail deformation. Hold the seat only as necessary. 1 CHECK DTC (a) Turn the ignition switch on (IG). (b) Clear the DTCs stored in the center airbag sensor assembly (See page RS-41). (c) Clear the DTCs stored in the occupant classification ECU (See page RS-251). (d) Turn the ignition switch off. (e) Turn the ignition switch on (IG). (f) Check the DTCs (See page RS-251). OK: DTC B1790 is not output. HINT: Codes other than DTC B1790 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK (See page RS-248) NG RS 2 CHECK CONNECTION OF CONNECTORS (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. (c) Check that the connectors are properly connected to the occupant classification ECU and the center airbag sensor assembly. OK: The connectors are properly connected. NG CONNECT CONNECTORS PROPERLY, THEN GO TO STEP 1 OK 3 CHECK VEHICLE CONDITION (a) Check the passenger seat type. Result: A: for Manual seat B: for Power seat SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM B RS–317 Go to step 13 A 4 CHECK FLOOR WIRE NO. 2 (SHORT TO B+) Floor Wire No. 2 A D C Occupant Classification ECU B Center Airbag Sensor Assembly (a) Disconnect the connector from the center airbag sensor assembly and occupant classification ECU. (b) Connect the negative (-) terminal cable to the battery. (c) Turn the ignition switch on (IG). (d) Measure the voltage according to the value (s) in the table below. Standard voltage Tester connection Condition Specified condition O4-8 (FSR+) - Body ground Ignition switch on (IG) Below 1 V O4-4 (FSR-) - Body ground Ignition switch on (IG) Below 1 V Connector C NG REPAIR OR REPLACE FLOOR WIRE NO. 2 O4 FSR- FSR+ C C123686E03 OK RS RS–318 5 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK FLOOR WIRE NO. 2 (OPEN) Floor Wire No. 2 D C Occupant Classification ECU A B Center Airbag Sensor Assembly Connector B Connector C O1 (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Using a service wire, connect terminals 12 (FSP+) and 13 (FSP-) of connector B. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (d) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Condition Specified condition O4-8 (FSR+) - O4-4 (FSR-) Always Below 1 Ω O4 FSR- 5 4 3 2 1 NG REPAIR OR REPLACE FLOOR WIRE NO. 2 10 9 8 7 6 15 14 13 12 11 FSP+ FSP- FSR+ Service Wire C C123687E02 OK RS 6 CHECK FLOOR WIRE NO. 2 (SHORT) (a) Disconnect the service wire from connector B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Floor Wire No. 2 A D C Occupant Classification ECU B Center Airbag Sensor Assembly O4 FSR- FSR+ C123686E03 OK Condition Specified condition O4-8 (FSR+) - O4-4 (FSR-) Always 1 MΩ or Higher NG Connector C C Tester connection REPAIR OR REPLACE FLOOR WIRE NO. 2 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 7 RS–319 CHECK FLOOR WIRE NO. 2 (SHORT TO GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Floor Wire No. 2 A D C Occupant Classification ECU B Center Airbag Sensor Assembly Tester connection Condition Specified condition O4-8 (FSR+) - Body ground Always 1 MΩ or Higher O4-4 (FSR-) - Body ground Always 1 MΩ or Higher NG REPAIR OR REPLACE FLOOR WIRE NO. 2 Connector C O4 FSR- FSR+ C C123686E03 OK 8 RS RECHECK DTC (a) Connect the connectors to the occupant classification ECU and the center airbag sensor assembly. (b) Connect the intelligent tester to the DLC3. (c) Connect the negative (-) terminal cable to the battery. (d) Turn the ignition switch on (IG). (e) Clear the DTCs stored in the center airbag sensor assembly (See page RS-251). (f) Clear the DTCs stored in the occupant classification ECU (See page RS-251). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor assembly. (g) Turn the ignition switch off. (h) Turn the ignition switch on (IG). (i) Using the intelligent tester, check the DTCs of the occupant classification ECU (See page RS-41). OK: DTC B1790 is not output. HINT: Codes other than DTC B1790 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK (See page RS-248) RS–320 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM NG 9 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Replace the occupant classification ECU (See page RS469). HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT 10 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Using the intelligent tester, perform "zero point calibration" (See page RS-242). OK: "COMPLETED" is displayed. NEXT RS 11 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "sensitivity check" (See page RS-242). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NEXT 12 RECHECK DTC (a) Turn the ignition switch on (IG). (b) Clear the DTCs stored in the center airbag sensor assembly (See page RS-251). (c) Clear the DTCs stored in the occupant classification ECU (See page RS-251). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor assembly. (d) Turn the ignition switch off. (e) Turn the ignition switch on (IG). (f) Using the intelligent tester, check the DTCs of the occupant classification ECU (See page RS-41). OK: DTC B1790 is not output. SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–321 HINT: Codes other than DTC B1790 may be output at this time, but they are not related to this check. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-441) OK END 13 CHECK OCCUPANT CLASSIFICATION SYSTEM CIRCUIT (TO B+) F A E DC Occupant Classification ECU B Center Airbag Sensor Assembly FSR+ C OK Tester connection Condition Specified condition T10-8 (FSR+) - Body ground Ignition switch on (IG) Below 1 V T10-4 (FSR-) - Body ground Ignition switch on (IG) Below 1 V NG Connector E T10 (a) Disconnect the connector from the center airbag sensor assembly and occupant classification ECU. (b) Connect the negative (-) terminal cable to the battery. (c) Turn the ignition switch on (IG). (d) Measure the voltage according to the value(s) in the table below. Standard voltage FSR- C110462E29 Go to step 22 RS RS–322 14 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK OCCUPANT CLASSIFICATION SYSTEM CIRCUIT (OPEN) E Occupant Classification ECU DC B Center Airbag Sensor Assembly Connector B Connector E O1 T10 (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. (c) Using a service wire, connect terminals 12 (FSP+) and 13 (FSP-) of connector B. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (d) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Condition Specified condition T10-8 (FSR+) - T10-4 (FSR-) Always Below 1 Ω FSR5 4 3 2 1 NG 10 9 8 7 6 Go to step 23 15 14 13 12 11 FSP- FSR+ FSP+ Service Wire C123726E01 OK RS 15 CHECK OCCUPANT CLASSIFICATION SYSTEM CIRCUIT (SHORT) (a) Disconnect the service wire from connector B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance F E DC Occupant Classification ECU A B Center Airbag Sensor Assembly T10 FSR+ OK Condition Specified condition T10-8 (FSR+) - T10-4 (FSR-) Always 1 MΩ or Higher NG Connector E C Tester connection FSR- C110462E29 Go to step 24 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 16 RS–323 CHECK OCCUPANT CLASSIFICATION SYSTEM CIRCUIT (TO GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance F A E DC Occupant Classification ECU B Center Airbag Sensor Assembly Tester connection Condition Specified condition T10-8 (FSR+) - Body ground Always 1 MΩ or Higher T10-4 (FSR-) - Body ground Always 1 MΩ or Higher NG Go to step 25 Connector E T10 FSR+ C FSR- C110462E29 OK 17 RS RECHECK DTC (a) Connect the connectors to the occupant classification ECU and the center airbag sensor assembly. (b) Connect the intelligent tester to the DLC3. (c) Connect the negative (-) terminal cable to the battery. (d) Turn the ignition switch on (IG). (e) Clear the DTCs stored in the center airbag sensor assembly (See page RS-251). (f) Clear the DTCs stored in the occupant classification ECU (See page RS-251). (g) Turn the ignition switch off. (h) Turn the ignition switch on (IG). (i) Using the intelligent tester, check the DTCs of the occupant classification ECU (See page RS-41). OK: DTC B1790 is not output. HINT: Codes other than DTC B1790 may be output at this time, but they are not related to this check. NG OK USE SIMULATION METHOD TO CHECK (See page RS-248) RS–324 18 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Replace the occupant classification ECU (See page RS469). HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT 19 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Using the intelligent tester, perform "zero point calibration" (See page RS-242). OK: "COMPLETED" is displayed. NEXT 20 PERFORM SENSITIVITY CHECK RS (a) Using the intelligent tester, perform "sensitivity check" (See page RS-242). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NEXT 21 RECHECK DTC (a) Turn the ignition switch on (IG). (b) Clear the DTCs stored in the center airbag sensor assembly (See page RS-251). (c) Clear the DTCs stored in the occupant classification ECU (See page RS-251). (d) Turn the ignition switch off. (e) Turn the ignition switch on (IG). (f) Using the intelligent tester, check the DTCs of the occupant classification ECU (See page RS-41). OK: DTC B1790 is not output. HINT: Codes other than DTC B1790 may be output at this time, but they are not related to this check. SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM NG RS–325 REPLACE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-441) OK END 22 CHECK FLOOR WIRE NO. 2 (TO B+) Front Seat Wire RH F A E Occupant Classification ECU D C B Center Airbag Sensor Assembly Floor Wire No. 2 Connector C OT1 (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the front seat wire RH connector from the floor wire No. 2. (d) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (e) Turn the ignition switch on (IG). (f) Measure the voltage according to the value(s) in the table below. Standard voltage Tester connection Condition Specified condition OT1-1 (FSR+) - Body ground Ignition switch on (IG) Below 1 V OT1-4 (FSR-) - Body ground Ignition switch on (IG) Below 1 V FSR+ NG FSRC C110464E18 OK REPAIR OR REPLACE FRONT SEAT WIRE RH REPAIR OR REPLACE FLOOR WIRE NO. 2 RS RS–326 23 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK FLOOR WIRE NO. 2 (OPEN) Front Seat Wire RH Floor Wire No. 2 A B Center Airbag Sensor Assembly F E D C Occupant Classification ECU (a) Disconnect the front seat wire RH connector from the floor wire No. 2. HINT: The service wire has already been inserted into connector B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Condition Specified condition OT1-1 (FSR+) - OT1-4 (FSR-) Always Below 1 Ω Connector B Connector C FSR+ NG O1 OT1 5 4 3 2 1 10 9 8 7 6 15 14 13 12 11 FSR- FSPService Wire FSP+ C123727E01 OK RS REPAIR OR REPLACE FRONT SEAT WIRE RH REPAIR OR REPLACE FLOOR WIRE NO. 2 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 24 RS–327 CHECK FLOOR WIRE NO. 2 (SHORT) (a) Disconnect the front seat wire RH connector from the floor wire No. 2. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Front Seat Wire RH F A E Occupant Classification ECU D C B Center Airbag Sensor Assembly Tester connection Condition Specified condition OT1-1 (FSR+) - OT1-4 (FSR-) Always 1 MΩ or Higher NG REPAIR OR REPLACE FLOOR WIRE NO. 2 Floor Wire No. 2 Connector C OT1 FSR+ FSRC C110464E18 OK REPAIR OR REPLACE FRONT SEAT WIRE RH RS RS–328 25 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK FLOOR WIRE NO. 2 (TO GROUND) (a) Disconnect the front seat wire RH connector from the floor wire No. 2. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Front Seat Wire RH F A E Occupant Classification ECU D C B Center Airbag Sensor Assembly Floor Wire No. 2 Tester connection Condition Specified condition OT1-1 (FSR+) - Body ground Always 1 MΩ or Higher OT1-4 (FSR-) - Body ground Always 1 MΩ or Higher NG Connector C OT1 FSR+ FSRC C110464E18 OK RS REPAIR OR REPLACE FRONT SEAT WIRE RH REPAIR OR REPLACE FLOOR WIRE NO. 2 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC B1793 RS–329 Occupant Classification Sensor Power Supply Circuit Malfunction DESCRIPTION The occupant classification sensor power supply circuit consists of the occupant classification ECU and the occupant classification sensors. DTC B1793 is recorded when a malfunction is detected in the occupant classification sensor power supply circuit. DTC No. DTC Detecting Condition • B1793 • The occupant classification ECU receives a line short circuit signal, an open circuit signal, a short circuit to ground signal or a short circuit to B+ signal in the occupant classification sensor power supply circuit for 2 seconds. Occupant classification ECU malfunction Trouble Area • • • Front seat assembly RH (Occupant classification sensors) Front seat wire RH Occupant classification ECU WIRING DIAGRAM T17 (*1) d5 (*2) Rear Occupant Classification Sensor RH Occupant Classification ECU SVC4 6 6 T11 d1 SVC4 (*1) (*2) SVC2 12 12 T11 d1 SVC2 (*1) (*2) SVC3 5 5 T11 d1 SVC3 (*1) (*2) SVC1 11 11 T11 d1 SVC1 (*1) (*2) 1 T16 (*1) d4 (*2) Front Occupant Classification Sensor RH RS 1 T15 (*1) d3 (*2) Rear Occupant Classification Sensor LH 1 T14 (*1) d2 (*2) Front Occupant Classification Sensor LH 1 *1: for Power Seat *2: for Manual Seat H045946E02 RS–330 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM INSPECTION PROCEDURE HINT: • If troubleshooting (wire harness inspection) is difficult to perform, remove the front passenger seat installation bolts to see the under surface of seat cushion. • In the above case, hold the seat so that it does not fall down. Holding the seat for a long period of time may cause a problem, such as seat rail deformation. Hold the seat only as necessary. 1 CHECK DTC (a) Turn the ignition switch on (IG). (b) Clear the DTCs stored in the center airbag sensor assembly (See page RS-41). (c) Clear the DTCs stored in the occupant classification ECU (See page RS-251). (d) Turn the ignition switch off. (e) Turn the ignition switch on (IG). (f) Check the DTCs (See page RS-251). OK: DTC B1793 is not output. HINT: Codes other than DTC B1793 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK (See page RS-248) NG RS 2 CHECK CONNECTION OF CONNECTORS (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the occupant classification ECU and the occupant classification sensors. OK: The connectors are properly connected. NG OK CONNECT CONNECTORS PROPERLY, THEN GO TO STEP 1 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 3 RS–331 CHECK FRONT SEAT WIRE RH (SHORT TO B+) T11 (*1) d1 (*2) SVC3 SVC4 SVC2 SVC1 *1: for Power Seat *2: for Manual Seat H043111E44 (a) Disconnect the connectors from the occupant classification ECU and the 4 occupant classification sensors. (b) Connect the negative (-) terminal cable to the battery. (c) Turn the ignition switch on (IG). (d) Measure the voltage according to the value(s) in the table below. Standard voltage: for Power seat Tester connection Condition Specified condition T11-5 (SVC3) - Body ground Ignition switch on (IG) Below 1 V T11-6 (SVC4) - Body ground Ignition switch on (IG) Below 1 V T11-11 (SVC1) - Body ground Ignition switch on (IG) Below 1 V T11-12 (SVC2) - Body ground Ignition switch on (IG) Below 1 V for Manual seat Tester connection Condition Specified condition d1-5 (SVC3) - Body ground Ignition switch on (IG) Below 1 V d1-6 (SVC4) - Body ground Ignition switch on (IG) Below 1 V d1-11 (SVC1) - Body ground Ignition switch on (IG) Below 1 V d1-12 (SVC2) - Body ground Ignition switch on (IG) Below 1 V NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK 4 CHECK FRONT SEAT WIRE RH (SHORT TO GROUND) T11 (*1) d1 (*2) (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: for Power seat SVC3 SVC4 SVC2 SVC1 *1: for Power Seat *2: for Manual Seat H043111E44 Tester connection Condition Specified condition T11-5 (SVC3) - Body ground Always 1 MΩ or Higher T11-6 (SVC4) - Body ground Always 1 MΩ or Higher T11-11 (SVC1) - Body ground Always 1 MΩ or Higher RS RS–332 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM Tester connection Condition Specified condition T11-12 (SVC2) - Body ground Always 1 MΩ or Higher for Manual seat Tester connection Condition Specified condition d1-5 (SVC3) - Body ground Always 1 MΩ or Higher d1-6 (SVC4) - Body ground Always 1 MΩ or Higher d1-11 (SVC1) - Body ground Always 1 MΩ or Higher d1-12 (SVC2) - Body ground Always 1 MΩ or Higher NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK 5 CHECK FRONT SEAT WIRE RH (OPEN) T11 (*1) d1 (*2) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: for Power seat SVC3 SVC4 SVC2 RS SVC1 *1: for Power Seat *2: for Manual Seat H043111E44 Tester connection Condition Specified condition T11-5 (SVC3) - T15-1 (SVC3) Always Below 1 Ω T11-6 (SVC4) - T17-1 (SVC4) Always Below 1 Ω T11-11 (SVC1) - T14-1 (SVC1) Always Below 1 Ω T11-12 (SVC2) - T16-1 (SVC2) Always Below 1 Ω Tester connection Condition Specified condition d1-5 (SVC3) - d3-1 (SVC3) Always Below 1 Ω d1-6 (SVC4) - d5-1 (SVC4) Always Below 1 Ω d1-11 (SVC1) - d2-1 (SVC1) Always Below 1 Ω d1-12 (SVC2) - d4-1 (SVC2) Always Below 1 Ω for Manual seat NG OK REPAIR OR REPLACE FRONT SEAT WIRE RH SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 6 RS–333 CHECK FRONT SEAT WIRE RH (SHORT) T11 (*1) d1 (*2) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: for Power seat SVC3 SVC4 SVC2 SVC1 *1: for Power Seat *2: for Manual Seat H043111E44 Tester connection Condition Specified condition T11-5 (SVC3) - T11-6 (SVC4) Always 1 MΩ or Higher T11-5 (SVC3) - T11-11 (SVC1) Always 1 MΩ or Higher T11-5 (SVC3) - T11-12 (SVC2) Always 1 MΩ or Higher T11-6 (SVC4) - T11-11 (SVC1) Always 1 MΩ or Higher T11-6 (SVC4) - T11-12 (SVC2) Always 1 MΩ or Higher T11-11 (SVC1) - T11-12 (SVC2) Always 1 MΩ or Higher Tester connection Condition Specified condition d1-5 (SVC3) - d1-6 (SVC4) Always 1 MΩ or Higher d1-5 (SVC3) - d1-11 (SVC1) Always 1 MΩ or Higher d1-5 (SVC3) - d1-12 (SVC2) Always 1 MΩ or Higher d1-6 (SVC4) - d1-11 (SVC1) Always 1 MΩ or Higher d1-6 (SVC4) - d1-12 (SVC2) Always 1 MΩ or Higher d1-11 (SVC1) - d1-12 (SVC2) Always 1 MΩ or Higher for Manual seat NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK 7 CHECK DTC (a) Connect the connectors to the occupant classification ECU and the 4 occupant classification sensors. (b) Connect the negative (-) terminal cable to the battery. (c) Turn the ignition switch on (IG). (d) Clear the DTCs stored in the center airbag sensor assembly (See page RS-41). (e) Clear the DTCs stored in the occupant classification ECU (See page RS-251). (f) Turn the ignition switch off. (g) Turn the ignition switch on (IG). (h) Check the DTCs (See page RS-251). RS RS–334 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM OK: DTC B1793 is not output. HINT: Codes other than DTC B1793 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK (See page RS-248) NG 8 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the occupant classification ECU (See page RS251). HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT 9 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) RS Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Using the intelligent tester, perform "zero point calibration" (See page RS-242). OK: "COMPLETED" is displayed. NG Go to step 12 OK 10 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "sensitivity check" (See page RS-242). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 12 OK 11 CHECK DTC (a) Turn the ignition switch on (IG). (b) Clear the DTCs stored in the center airbag sensor assembly (See page RS-41). SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–335 (c) Clear the DTCs stored in the occupant classification ECU (See page RS-251). (d) Turn the ignition switch off. (e) Turn the ignition switch on (IG). (f) Check the DTCs (See page RS-251). OK: DTC B1793 is not output. HINT: Codes other than DTC B1793 may be output at this time, but they are related to this check. OK END NG 12 REPLACE FRONT SEAT ASSEMBLY RH (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the front seat assembly RH (See page SE-30 for power seat or SE-16 for manual seat). NEXT 13 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Using the intelligent tester, perform "zero point calibration" (See page RS-242). OK: "COMPLETED" is displayed. NEXT 14 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "sensitivity check" (See page RS-242). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NEXT END RS RS–336 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC B1794 Open in Occupant Classification ECU Battery Positive Line DESCRIPTION This circuit consists of the occupant classification ECU and the power source circuit (battery, fuse, and wire harness). DTC B1794 is recorded when a malfunction is detected in the occupant classification ECU or the power source circuit. HINT: If DTC B1794 is output after switching the ignition switch off-on (IG)-off 50 times in a row when a malfunction occurs in the power circuit for the occupant classification system, the DTC is output again. This DTC is output when a malfunction is detected even after being cleared unless the normal system code is input. DTC No. DTC Detecting Condition • B1794 • RS The ignition switch is turned from off to on (IG), hold if for 10 seconds or more, and back to off again 50 times in a row when a malfunction occurs in the circuit for the occupant classification system. Occupant classification ECU malfunction Trouble Area • • • • • Battery ECU-B Fuse Floor wire No. 2 Front seat wire RH (for Power seat) Occupant classification ECU SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–337 WIRING DIAGRAM Occupant Classification ECU (*2) 3 5 (*1) EO2 2 EO2 OT1 6 OT1 (*1) 1 (*1) 1 T10 O4 (*1) (*2) 7 7 T10 O4 (*1) B+ IG (*1) (*2) (*2) IGN From Ignition Switch ECU-B No. 1 From Battery J/C 10 EO2 5 O20 3 T18 (*1) 3 3 T10 O4 GND (*1) (*2) (*2) 3 *1: for Power Seat O21 J/C RS *2: for Manual Seat C123750E01 INSPECTION PROCEDURE 1 CHECK BATTERY (a) Measure the voltage of the battery. Standard voltage: 11 to 14 V NG REPLACE BATTERY OK 2 CHECK FUSE (a) Check the ECU-B fuse. Standard resistance: Below 1 Ω RS–338 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM NG REPLACE FUSE OK 3 CHECK WIRE HARNESS (SOURCE VOLTAGE) T10 (*1) O4 (*2) GND +B *1: for Power Seat IG *2: for Manual Seat H043112E21 (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connector from the occupant classification ECU. (d) Connect the negative (-) terminal cable to the battery. (e) Turn the ignition switch on (IG). (f) Measure the voltage and resistance according to the value(s) in the table below. Standard voltage and resistance: for Power seat Tester connection Condition Specified condition T10-1 (+B) - Body ground Always 10 to 14 V T10-3 (GND) - Body ground Always Below 1 Ω T10-7 (IG) - Body ground Ignition switch on (IG) 10 to 14 V Tester connection Condition Specified condition O4-1 (+B) - Body ground Always 10 to 14 V O4-3 (GND) - Body ground Always Below 1 Ω O4-7 (IG) - Body ground Ignition switch on (IG) 10 to 14 V for Manual seat RS NG REPAIR OR REPLACE WIRE HARNESS OK 4 CHECK DTC (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. (c) Connect the connector to the occupant classification ECU. (d) Connect the intelligent tester to the DLC3. (e) Connect the negative (-) terminal cable to the battery. (f) Turn the ignition switch on (IG). (g) Clear the DTCs stored in the center airbag sensor assembly (See page RS-41). (h) Clear the DTCs stored in the occupant classification ECU (See page RS-251). SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–339 HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor assembly. (i) Turn the ignition switch off. (j) Turn the ignition switch on (IG), and wait for at least 10 seconds. (k) Using the intelligent tester, check the DTCs of the occupant classification ECU (See page RS-251). OK: B1794 is not output. HINT: Codes other than DTC B1794 may be output at this time, but they are not related to this check. NG USE SIMULATION METHOD TO CHECK (See page RS-248) OK 5 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Replace the occupant classification ECU (See page RS469). HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT 6 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Using the intelligent tester, perform the "zero point calibration" (See page RS-242). OK: "COMPLETED" is displayed. NEXT 7 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform the "sensitivity check" (See page RS-242). Standard value: 27 to 33 kg (59.52 to 72.75 lb) RS RS–340 NEXT END RS SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC B1795 RS–341 Occupant Classification ECU Malfunction DESCRIPTION DTC B1795 is recorded when a malfunction is detected in the occupant classification ECU. Troubleshoot the DTC B1771 first when the DTC B1771 and B1795 are output simultaneously. DTC No. DTC Detecting Condition • • B1795 • Trouble Area Occupant classification ECU circuit malfunction The occupant classification ECU receives a short circuit to ground signal in the passenger side buckle switch circuit for 2 seconds. Occupant classification ECU malfunction • • • • Front seat wire RH (for Power seat) Floor wire No. 2 Front seat inner belt assembly RH Occupant classification ECU INSPECTION PROCEDURE 1 CHECK DTC (a) Turn the ignition switch on (IG), and wait for at least 10 seconds. (b) Check the DTCs (See page RS-251). Result: A: DTC B1771 and B1795 are output. B: DTC B1795 is output. HINT: Codes other than DTC B1771 and B1795 may be output at this time, but they are not related to this check. A GO TO DTC B1771 B 2 CHECK FUSE (a) Check the ECU-B fuse. Resistance: Below 1 Ω NG OK REPLACE FUSE RS RS–342 3 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK WIRE HARNESS (SOURCE VOLTAGE) T10 (*1) O4 (*2) GND +B *1: for Power Seat IG *2: for Manual Seat H043112E21 (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. (c) Disconnect the connector from the occupant classification ECU. (d) Connect the negative (-) terminal cable to the battery. (e) Turn the ignition switch on (IG). (f) Measure the voltage according to the value(s) in the table below. Standard voltage: for Power seat Tester connection Condition Specified condition T10-1 (+B) - Body ground Always 10 to 14 V T10-7 (IG) - Body ground Ignition switch on (IG) 10 to 14 V Tester connection Condition Specified condition O4-1 (+B) - Body ground Always 10 to 14 V O4-7 (IG) - Body ground Ignition switch on (IG) 10 to 14 V for Manual seat (g) Turn the ignition switch off. (h) Measure the resistance according to the value(s) in the table below. Standard resistance: for Power seat RS Tester connection Condition Specified condition T10-3 (GND) - Body ground Always Below 1 Ω Tester connection Condition Specified condition O4-3 (GND) - Body ground Always Below 1 Ω for Manual seat NG REPAIR OR REPLACE WIRE HARNESS OK 4 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the occupant classification ECU (See page RS251). HINT: Perform the inspection using parts from a normal vehicle if possible. SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–343 NEXT 5 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Using the intelligent tester, perform "zero point calibration" (See page RS-242). OK: "COMPLETED" is displayed. NEXT 6 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "sensitivity check" (See page RS-242). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NEXT END RS RS–344 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC Sleep Operation Failure of Occupant Classification ECU B1796 DESCRIPTION During sleep mode, the occupant classification ECU reads the condition of each sensor while the ignition switch is off. In this mode, if occupant classification ECU detects an internal malfunction, DTC B1796 is output. DTC No. B1796 DTC Detecting Condition • Trouble Area Occupant classification ECU malfunction • Occupant classification ECU INSPECTION PROCEDURE 1 CHECK DTC (a) Turn the ignition switch on (IG). (b) Clear the DTCs stored in the memory (See page RS251). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor assembly. (c) Turn the ignition switch off, and wait for at least 10 seconds. (d) Turn the ignition switch on (IG). (e) Check the DTCs (See page RS-251). OK: DTC B1796 is not output. HINT: Codes other than DTC B1796 may be output at this time, but they are not related to this check. RS OK USE SIMULATION METHOD TO CHECK NG 2 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the occupant classification ECU (See page RS469). HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT 3 PERFORM ZERO POINT CALIBRATION (a) Connect the negative (-) terminal cable to the battery. (b) Connect the intelligent tester to the DLC3. SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–345 (c) Turn the ignition switch on (IG). (d) Using the intelligent tester, perform "zero point calibration" (See page RS-242). OK: "COMPLETED" is displayed. NEXT 4 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "sensitivity check" (See page RS-242). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NEXT END RS RS–346 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM Trouble in Passenger Airbag ON / OFF Indicator DESCRIPTION The occupant classification system detects the front passenger seat condition. It then informs a passenger of the front passenger airbag assembly and front seat side airbag assembly condition (activated/not activated) by the passenger airbag ON/OFF indicator. HINT: Approximately 6 seconds after the ignition switch is turned to the on (IG), the passenger airbag ON/OFF indicator will be ON/OFF depending on the conditions listed below. ON Indicator OFF Indicator Adult is seated. Front passenger seat condition ON OFF Child is seated. OFF ON Vacant OFF OFF Occupant classification system failure OFF ON INSPECTION PROCEDURE 1 CHECK SRS WARNING LIGHT (a) Turn the ignition switch on (IG), and check the SRS warning light condition. HINT: If this trouble occurs, the SRS warning light is off. If the light is on, a DTC is output. Troubleshoot for the output DTC. OK: After the primary check period, SRS warning light goes off. HINT: The primary check period is approximately 6 seconds after the ignition switch is turned on (IG). RS NG GO TO DTC CHART (See page RS-45) OK 2 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Turn the ignition switch off. Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Using the intelligent tester, perform "zero point calibration" (See page RS-242). OK: "COMPLETE" is displayed. NG OK Go to step 4 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 3 RS–347 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "sensitivity check" (See page RS-242). Standard value: 27 to 33 kg (59.52 to 72.75 lb) OK END NG 4 RETIGHTEN FRONT SEAT ASSEMBLY RH BOLT (a) Turn the ignition switch off. (b) Loosen the 4 installation bolts of the front seat assembly RH. (c) Tighten the 4 installation bolts of the front seat assembly RH to the specified torque. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) NEXT 5 PERFORM ZERO POINT CALIBRATION (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Using the intelligent tester, perform "zero point calibration" (See page RS-242). OK: "COMPLETE" is displayed. NG Go to step 7 OK 6 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "sensitivity check" (See page RS-242). Standard value: 27 to 33 kg (59.52 to 72.75 lb) OK END NG 7 CHECK CONNECTORS (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. RS RS–348 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM (c) Check that the connectors are properly connected to the occupant classification ECU and the 4 occupant classification sensors. OK: The connectors are properly connected. (d) Disconnect the connectors from the occupant classification ECU and the 4 occupant classification sensors. (e) Check that the connectors are not damaged or deformed. OK: The connectors are normal. NG REPAIR OR REPLACE CONNECTOR, THEN GO TO STEP 1 OK 8 CHECK DTC (a) Connect the connectors to the occupant classification ECU and the 4 occupant classification sensors. (b) Connect the negative (-) terminal cable to the battery. (c) Turn the ignition switch on (IG), and wait for at least 60 seconds. (d) Clear the DTCs stored in the center airbag sensor assembly (See page RS-41). (e) Clear the DTCs stored in the occupant classification ECU (See page RS-251). (f) Turn the ignition switch off. (g) Turn the ignition switch on (IG), and wait for at least 60 seconds. (h) Check the DTCs (See page RS-251). OK: DTC is not output. RS NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-441) OK 9 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the ignition switch off. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the occupant classification ECU (See page RS469). HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 10 RS–349 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Using the intelligent tester, perform "zero point calibration" (See page RS-242). OK: "COMPLETE" is displayed. NEXT 11 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "sensitivity check" (See page RS-242). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NEXT END RS RS–346 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD STEERING PAD SUPPLEMENTAL RESTRAINT SYSTEM RESTRAINTS COMPONENTS for 3 Spoke Type: STEERING PAD 8.8 (90, 78 in.*lbf) 8.8 (90, 78 in.*lbf) RS STEERING PAD NO. 3 LOWER STEERING WHEEL COVER NO. 2 LOWER STEERING WHEEL COVER N*m (kgf*cm, ft.*lbf) : Specified torque C133853E01 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD RS–347 ON-VEHICLE INSPECTION 1. INSPECT STEERING PAD (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (See page RS32). (b) With the steering pad installed on the vehicle, perform a visual check. If there are any defects as mentioned below, replace the steering pad with a new one: Cuts, minute cracks or marked discoloration on the steering pad top surface or in the grooved portion. for 4 Spoke Type: 2. INSPECT STEERING PAD (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check (See page RS32). for 3 Spoke Type: C133854E01 RS RS–348 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD (b) With the steering pad removed from the vehicle, perform a visual check. If there are any defects as mentioned below, replace the steering pad or steering wheel assembly with a new one: for 4 Spoke Type: for 3 Spoke Type: Horn Button Contact Plate Horn Button Contact Plate RS C133855E01 • Cuts, minute cracks or marked discoloration on the steering pad top surface or in the grooved portion. • Cracks or other damage to the connectors. • Deformation of the steering wheel assembly. • Deformation of the horn button contact plate of the steering pad. • There should be no interference between the steering pad and steering wheel assembly, and the clearance should be uniform all the way around when the new steering pad is installed on the steering wheel assembly. CAUTION: Be sure to follow the correct removal and installation procedures. SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD RS–349 REMOVAL 1. PRECAUTION CAUTION: Be sure to read "PRECAUTION" thoroughly before servicing (See page RS-1). 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment. 3. REMOVE NO. 3 LOWER STEERING WHEEL COVER (a) Using a screwdriver, remove the No. 3 lower steering wheel cover. HINT: Tape up the screwdriver tip before use. for 4 Spoke Type: for 3 Spoke Type: RS C133856E01 4. for 4 Spoke Type: REMOVE NO. 2 LOWER STEERING WHEEL COVER (a) Using a screwdriver, remove the No. 2 lower steering wheel cover. for 3 Spoke Type: C133857E01 HINT: Tape up the screwdriver tip before use. RS–350 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD 5. for 4 Spoke Type: REMOVE STEERING PAD (a) Using a "torx" socket wrench (T30), loosen the 2 "torx" screws until the groove along the screw circumference catches on the screw case. for 3 Spoke Type: “Torx” Screw Screw Case “Torx” Screw Screw Case C133858E01 RS C133859 (b) Pull out the steering pad from the steering wheel assembly and support the steering pad with one hand as shown in the illustration. NOTICE: When removing the steering pad, do not pull the airbag wire harness. (c) Disconnect the horn connector from the steering pad. (d) Disconnect the 2 airbag connectors and remove the steering pad. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. RS–362 SUPPLEMENTAL RESTRAINT SYSTEM – SPIRAL CABLE SPIRAL CABLE SUPPLEMENTAL RESTRAINT SYSTEM RESTRAINTS COMPONENTS for 3 Spoke Type: 50 (510, 37) STEERING PAD 8.8 (90, 78 in.*lbf) STEERING WHEEL ASSEMBLY STEERING COLUMN COVER STEERING WHEEL ASSEMBLY STEERING PAD 50 (510, 37) SPIRAL CABLE RS 8.8 (90, 78 in.*lbf) NO. 3 LOWER STEERING WHEEL COVER NO. 2 LOWER STEERING WHEEL COVER with VSC: SPIRAL CABLE SPIRAL CABLE WITH STEERING ANGLE SENSOR STEERING ANGLE SENSOR N*m (kgf*cm, ft.*lbf) : Specified torque C133868E01 SUPPLEMENTAL RESTRAINT SYSTEM – SPIRAL CABLE RS–363 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTICE: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment. 2. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 3. REMOVE NO. 3 LOWER STEERING WHEEL COVER (See page RS-349) 4. REMOVE NO. 2 LOWER STEERING WHEEL COVER (See page RS-349) 5. REMOVE STEERING PAD (See page RS-350) 6. REMOVE STEERING WHEEL ASSEMBLY (See page SR-38) 7. REMOVE STEERING COLUMN COVER (See page SR-39) 8. REMOVE SPIRAL CABLE (w/o VSC) (a) Disconnect the connectors from the spiral cable. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (b) Disengage the 3 claws and remove the spiral cable. RS C133869 RS–364 SUPPLEMENTAL RESTRAINT SYSTEM – SPIRAL CABLE 9. REMOVE SPIRAL CABLE WITH STEERING ANGLE SENSOR (w/ VSC) (a) Disconnect the connectors from the spiral cable with steering angle sensor. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (b) Disengage the 3 claws and remove the spiral cable with steering angle sensor. C133869 10. REMOVE SPIRAL CABLE (w/ VSC) (a) Disengage the 6 claws and remove the spiral cable from the steering angle sensor. Pin RS Pin C110478E02 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD RS–351 INSTALLATION 1. C133859 INSTALL STEERING PAD (a) Check that the ignition switch is off. (b) Check that the battery negative (-) terminal is disconnected. CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment. (c) Support the steering pad with one hand as shown in the illustration. (d) Connect the 2 airbag connectors to the steering pad. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (e) Connect the horn connector to the steering pad. (f) Confirm that the circumference groove of the "torx" screw fits in the screw case, and place the steering pad onto the steering wheel assembly. (g) Using a "torx" socket wrench (T30), tighten the 2 "torx" screws. Torque: 8.8 N*m (90 kgf*cm, 78 in.*lbf) for 4 Spoke Type: RS for 3 Spoke Type: C133860E01 RS–352 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD 2. for 4 Spoke Type: INSTALL NO. 3 LOWER STEERING WHEEL COVER (a) Install the No. 3 lower steering wheel cover. for 3 Spoke Type: C133905E01 3. for 4 Spoke Type: INSTALL NO. 2 LOWER STEERING WHEEL COVER (a) Install the No. 2 lower steering wheel cover. for 3 Spoke Type: RS C133906E01 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD for 4 Spoke Type: RS–353 5. INSPECT STEERING PAD (a) With the steering pad installed on the vehicle, perform a visual check. If there are any defects as mentioned below, replace the steering pad with a new one: Cuts, minute cracks or marked discoloration on the steering pad top surface or in the grooved portion. (b) Make sure that the horn sounds. HINT: If the horn does not sound, inspect the horn system (See page HO-2). 6. INSPECT SRS WARNING LIGHT (a) Inspect the SRS warning light (See page RS-32). for 3 Spoke Type: C133854E01 RS RS–354 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD DISPOSAL HINT: When scrapping a vehicle equipped with the SRS or disposing of the steering pad, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: • Never dispose of a steering pad that has an undeployed airbag. • The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents. • When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. • When deploying the airbag, perform the operation at least 10 m (33 ft) away from the steering pad. • The steering pad becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. • Use gloves and safety glasses when handling a steering pad with a deployed airbag. • Do not apply water, etc. to a steering pad with a deployed airbag. • Always wash your hands with water after completing the operation. 1. RS DISPOSE OF STEERING PAD (WHEN INSTALLED IN VEHICLE) HINT: Prepare a battery as the power source to deploy the airbag. (a) Check the function of the SST. SST 09082-00700 CAUTION: When deploying the airbag, always use the specified SST: SRS Airbag Deployment Tool SST C110371E01 Battery SST C110372E04 (1) Connect the SST to the battery. Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the negative (-) terminal. SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD SST C110475E01 RS–355 (2) Check the function of the SST. Press the SST activation switch, and check that the LED of the SST activation switch comes on. CAUTION: • Do not connect the SST connector (yellow colored one) to the airbag. • If the LED comes on when the activation switch is not being pressed, SST malfunction is possible, so replace the SST with a new one. (3) Disconnect the SST from the battery. (b) Precaution (See page RS-1). (c) Disconnect the cable from the negative battery terminal. CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment. (d) Remove the steering column cover (lower). (1) While turning the steering wheel assembly to the right and left, remove the 2 screws and steering column cover (lower). (e) Install the SST. CAUTION: Check that there is no looseness in the steering wheel assembly and steering pad. (1) Disconnect the airbag connector (yellow colored one) from the spiral cable. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. for 4 Spoke Type: for 3 Spoke Type: C133861E01 RS RS–356 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD (2) Connect the SST connector to the airbag connector of the spiral cable. SST 09082-00700, 09082-00780 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. for 4 Spoke Type: SST for 3 Spoke Type: SST C133862E01 Battery RS SST 10 m (33 ft) or more C110476E07 (f) (3) Move the SST at least 10 m (33 ft) away from the vehicle front side window. (4) Maintaining enough clearance for the SST wire harness in the front side window, close all doors and windows of the vehicle. NOTICE: Take care not to damage the SST wire harness. (5) Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the negative (-) terminal. Deploy the airbag. (1) Check that no one is inside the vehicle or within a 10 m (33 ft) radius of the vehicle. (2) Press the SST activation switch and deploy the airbag. CAUTION: • When deploying the airbag, make sure that no one is near the vehicle. • The steering pad becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. • Use gloves and safety glasses when handling a steering pad with a deployed airbag. • Do not apply water, etc. to a steering pad with a deployed airbag. • Always wash your hands with water after completing the operation. SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD RS–357 HINT: The airbag is deployed as the LED of the SST activation switch comes on. 2. DISPOSE OF STEERING PAD (WHEN NOT INSTALLED IN VEHICLE) NOTICE: • When disposing of the steering pad, never use the customer's vehicle to deploy the airbag. • Be sure to follow the procedure detailed below when deploying the airbag. HINT: Prepare a battery as the power source to deploy the airbag. (a) Check the function of the SST. SST 09082-00700 CAUTION: When deploying the airbag, always use the specified SST: SRS Airbag Deployment Tool SST C110371E01 Battery (1) Connect the SST to the battery. Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the negative (-) terminal. SST C110372E04 SST C110475E01 (2) Check the function of the SST. Press the SST activation switch, and check that the LED of the SST activation switch comes on. CAUTION: • Do not connect the SST connector (yellow colored one) to the airbag. • If the LED comes on when the activation switch is not being pressed, SST malfunction is possible, so replace the SST with a new one. (3) Disconnect the SST from the battery. (b) Remove the steering pad (See page RS-349). CAUTION: • When removing the steering pad, work must be started 90 seconds after the ignition switch is turned off and the negative (-) terminal cable is disconnected from the battery. RS RS–358 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD • When storing the steering pad, keep the airbag deployment side facing upward. Wire Harness Diameter Stripped Wire Harness Section B104882E02 (c) Using a service-purpose wire harness for the vehicle, tie down the steering pad to the disc wheel. Wire harness: Stripped wire harness section 1.25 mm2 or more (0.0019 in.2 or more) CAUTION: If the wire harness is too thin or an alternative object is used to tie down the steering pad, it may be snapped by the shock when the airbag is deployed. Always use a wire harness for vehicle use with an area of at least 1.25 mm2 (0.0019 in.2). HINT: To calculate the area of the stripped wire harness section: Area = 3.14 x (Diameter)2 divided by 4 (1) Install the 2 bolts with washers into the 2 bolt holes on the steering pad. Bolt: L: 35.0 mm (1.378 in.) M: 6.0 mm (0.236 in.) Pitch: 1.0 mm (0.039 in.) NOTICE: • Tighten the bolts by hand until they become difficult to turn. • Do not tighten the bolts excessively. for 4 Spoke Type: RS for 3 Spoke Type: L M C133863E01 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD RS–359 (2) After connecting the SST below to each other, connect them to the steering pad. SST 09082-00802 (09082-10801, 0908230801) (3) Using 3 wire harnesses, wind wire harness at least 2 times each around each of the bolts installed on the left and right sides of the steering pad. for 4 Spoke Type: SST for 3 Spoke Type: SST C133864E01 for 4 Spoke Type: for 3 Spoke Type: 2 times or more RS 2 times or more 2 times or more 2 times or more C133865E01 CAUTION: • Tightly wind the wire harness around the bolts so that there is no slack. • Make sure that the wire harness is tight. If there is slack in the wire harness, the steering pad may become loose due to the shock when the airbag is deployed. RS–360 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD (4) Face the airbag deployment side of the steering pad upward on top of a tire and wheel set. Separately tie the left and right sides of the steering pad to the disc wheel through the hub nut holes. Position the SST connector so that it hangs downward through the hub hole of the disc wheel. CAUTION: • Make sure that the wire harness is tight. If there is slack in the wire harness, the steering pad may become loose due to the shock when the airbag is deployed. • Always tie down the steering pad with the airbag deployment side facing upward. NOTICE: The disc wheel will be damaged by the airbag deployment, so use an extra disc wheel. for 4 Spoke Type: for 3 Spoke Type: C133866E01 (d) Install the SST. CAUTION: Place the disc wheel on level ground. (1) Connect the SST connector. SST 09082-00700 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the disc wheel. for 4 Spoke Type: SST RS for 3 Spoke Type: SST C133867E01 (2) Move the SST at least 10 m (33 ft) away from the airbag tied down to the disc wheel. SST 10 m (33 ft) or more C111070E01 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD Y Y X Weight Weight C111071E04 (e) Cover the steering pad (Using a cardboard box). (1) Cover the steering pad with the cardboard box. (2) Place weights on the cardboard box in 4 places totalling at least 190 N (19 kg, 43 lb). Cardboard box size: Must exceed the following dimensions X: 460 mm (18.11 in.) Y: 650 mm (25.59 in.) NOTICE: • When dimension Y of the cardboard box exceeds the diameter of the disc wheel with tire which the steering pad is tied to, X should be the following size. X = 460 mm (18.11 in.) + width of tire • If a cardboard box which is smaller than the specified size is used, the cardboard box will be broken by the shock from the airbag deployment. (f) Inner Diameter Width Tires (3 or more) C111105E05 RS–361 Cover the steering pad (Using tires). (1) Place at least 3 tires without disc wheels on the tire with disc wheel which the steering pad is tied to. (2) Place the tire with a disc wheel on top of them. Tire size: Must exceed the following dimensions Width: 185 mm (7.28 in.) Inner diameter: 360 mm (14.17 in.) CAUTION: Do not use tires with disc wheels except for on the top and bottom. NOTICE: • The tires may be damaged by the airbag deployment, so use an extra tire. • Do not place the SST connector under the tire because it could be damaged. (3) Tie the tires together with 2 wire harnesses. CAUTION: Make sure that the wire harness is tight. Looseness in the wire harness results in the tires coming free due to the shock when the airbag is deployed. C107322 RS RS–362 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD Using a cardboard box: Battery SST 10 m (33 ft) or more Steering Pad Using tires: (g) Deploy the airbag. (1) Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the negative (-) terminal. (2) Check that no one is within a 10 m (33 ft) radius of the disc wheel which the steering pad is tied to. (3) Press the SST activation switch and deploy the airbag. CAUTION: When deploying the airbag, make sure that no one is near the tire. HINT: The airbag is deployed as the LED of the SST activation switch comes on. Battery SST 10 m (33 ft) or more Steering Pad C111072E03 RS C051699E01 (h) Dispose of the steering pad. CAUTION: • The steering pad becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. • Use gloves and safety glasses when handling a steering pad with a deployed airbag. • Do not apply water, etc. to a steering pad with a deployed airbag. • Always wash your hands with water after completing the operation. (1) Remove the steering pad from the disc wheel. (2) Place the steering pad in a plastic bag, tie it tightly and dispose of it as other general part disposal. SUPPLEMENTAL RESTRAINT SYSTEM – SPIRAL CABLE RS–365 INSPECTION 1. (b) Inspect the spiral cable. (1) Measure the resistance according to the value(s) in the table below. Standard resistance Spiral Cable: k1 INSPECT SPIRAL CABLE (a) If there are any defects as mentioned below, replace the spiral cable with a new one: Scratches, cracks, dents or chips on the connector or the spiral cable. m1 Tester connection Condition Specified condition Center k1-1- m1-2 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right A B Center k1-1- J24-8 (HO) 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right Center k1-2- J24-9 (SUP) 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right Center k1-3- J24-10 (SDN) 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right Center k1-4- J24-11 (DIST) J24 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right J25 Center k1-5- J24-12 (IL+2) 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right Center C128776E01 k1-6- m1-4 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right Center k1-6- J24-2 (ECC) 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right Center k1-7- J24-3 (DISP) 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right Center k1-8- J24-4 (EAU) 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right Center k1-9- J24-5 (AU2) 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right Center k1-10- J24-6 (AU1) 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right Center m1-1- J24-7 (R/N) 2.5 rotations to the left 2.5 rotations to the right Below 1 Ω RS RS–366 SUPPLEMENTAL RESTRAINT SYSTEM – SPIRAL CABLE Tester connection Condition Specified condition Center m1-2- J24-8 (HO) 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right Center m1-3- J24-1 (CCS) 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right Center m1-4- J24-2 (ECC) 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right Center A-1 (D-) - J25-2 (D-) 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right Center A-2 (D+) - J25-1 (D+) 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right Center B-1 (D2-) - J25-3 (D2-) 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right Center B-2 (D2+) - J25-4 (D2+) 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right INSTALLATION Pin RS 1. INSTALL SPIRAL CABLE (w/ VSC) (a) Engage the 6 claws and install the spiral cable to the steering angle sensor. 2. INSTALL SPIRAL CABLE WITH STEERING ANGLE SENSOR (w/ VSC) (a) Check that the front wheels are facing straight ahead. (b) Set the turn signal switch to the neutral position. NOTICE: If it is not in the neutral position, the pin of the turn signal switch may be snapped. Pin C110515E02 (c) Engage the 3 claws and install the spiral cable with steering angle sensor. NOTICE: When replacing the spiral cable with a new one, remove the lock pin before installing the steering wheel assembly. (d) Connect the connectors to the spiral cable with steering angle sensor. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. C133870 3. INSTALL SPIRAL CABLE (w/o VSC) (a) Check that the front wheels are facing straight ahead. SUPPLEMENTAL RESTRAINT SYSTEM – SPIRAL CABLE RS–367 (b) Set the turn signal switch to the neutral position. NOTICE: If it is not in the neutral position, the pin of the turn signal switch may be snapped. (c) Engage the 3 claws and install the spiral cable. NOTICE: When replacing the spiral cable with a new one, remove the lock pin before installing the steering wheel assembly. (d) Connect the connectors to the spiral cable. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. C133870 4. INSTALL STEERING COLUMN COVER (See page SR50) 5. ADJUST SPIRAL CABLE (a) Check that the ignition switch is off. (b) Check that the battery negative (-) cable is disconnected. CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment. (c) Rotate the spiral cable counterclockwise slowly by hand until it feels firm. NOTICE: Do not turn the spiral cable by the airbag wire harness. C107193 (d) Rotate the spiral cable clockwise approximately 2.5 turns to align the marks. NOTICE: Do not turn the spiral cable by the airbag wire harness. HINT: The spiral cable will rotate approximately 2.5 turns to both the left and right from the center. Marks 6. INSTALL STEERING WHEEL ASSEMBLY (See page SR-51) 7. INSPECT STEERING WHEEL CENTER POINT 8. INSTALL STEERING PAD (See page RS-350) 9. INSTALL NO. 3 LOWER STEERING WHEEL COVER (See page RS-351) C107194E01 10. INSTALL NO. 2 LOWER STEERING WHEEL COVER (See page RS-352) RS RS–368 SUPPLEMENTAL RESTRAINT SYSTEM – SPIRAL CABLE 11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 12. INSPECT STEERING PAD (See page RS-352) 13. INSPECT SRS WARNING LIGHT (a) Inspect the SRS warning light (See page RS-32). RS RS–368 SUPPLEMENTAL RESTRAINT SYSTEM – DRIVER SIDE KNEE AIRBAG ASSEMBLY DRIVER SIDE KNEE AIRBAG ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM RESTRAINTS COMPONENTS DRIVER SIDE KNEE AIRBAG ASSEMBLY 10 (102, 7) LOWER INSTRUMENT PANEL FINISH PANEL LH RS COWL SIDE TRIM SUB-ASSEMBLY LH FRONT DOOR SCUFF PLATE LH N*m (kgf*cm, ft.*lbf) : Specified torque C133871E01 SUPPLEMENTAL RESTRAINT SYSTEM – DRIVER SIDE KNEE AIRBAG ASSEMBLY RS–369 ON-VEHICLE INSPECTION 1. INSPECT DRIVER SIDE KNEE AIRBAG ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (See page RS32). (b) With the driver side knee airbag assembly installed on the vehicle, perform a visual check. If there are any defects as mentioned below, replace the driver side knee airbag assembly with a new one: Cuts, minute cracks or marked discoloration on the driver side knee airbag assembly. 2. C133872 C133873 INSPECT DRIVER SIDE KNEE AIRBAG ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check (See page RS32). (b) With the driver side knee airbag assembly removed from the vehicle, perform a visual check. If there are any defects as mentioned below, replace the driver side knee airbag assembly with a new one: • Cuts, minute cracks or marked discoloration on the driver side knee airbag assembly. • Cracks or other damage to the connector. • Deformation or cracks on the instrument panel reinforcement. CAUTION: Be sure to follow the correct removal and installation procedures. RS RS–370 SUPPLEMENTAL RESTRAINT SYSTEM – DRIVER SIDE KNEE AIRBAG ASSEMBLY REMOVAL RS C133874 1. PRECAUTION CAUTION: Be sure to read "PRECAUTION" thoroughly before servicing (See page RS-1). 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTICE: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment. 3. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-24) 4. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-25) 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (See page IP-20) 6. REMOVE DRIVER SIDE KNEE AIRBAG ASSEMBLY (a) Remove the 4 bolts. (b) Disconnect the airbag connector. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. SUPPLEMENTAL RESTRAINT SYSTEM – DRIVER SIDE KNEE AIRBAG ASSEMBLY RS–371 (c) Disengage the 2 claws and remove the DLC3 connector. (d) Disengage the 2 hooks and remove the driver side knee airbag assembly. Hook Hook C133875E01 RS RS–372 SUPPLEMENTAL RESTRAINT SYSTEM – DRIVER SIDE KNEE AIRBAG ASSEMBLY INSTALLATION 1. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY (a) Check that the ignition switch is off. (b) Check that the battery negative (-) cable is disconnected. CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment. (c) Temporarily install the driver side knee airbag assembly with the 2 hooks. (d) Engage the 2 claws and install the DLC 3 connector. Hook Hook RS C133875E01 (e) Install the driver side knee airbag assembly with the 4 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) (f) Connect the driver side knee airbag connector. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. C133874 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (See page IP-58) 3. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-54) 4. INSTALL FRONT DOOR SCUFF PLATE LH (See page IR-54) 5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 6. INSPECT SRS WARNING LIGHT (a) Inspect the SRS warning light (See page RS-32). SUPPLEMENTAL RESTRAINT SYSTEM – DRIVER SIDE KNEE AIRBAG ASSEMBLY RS–373 DISPOSAL HINT: When scrapping a vehicle equipped with the SRS or disposing of the driver side knee airbag assembly, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: • Never dispose of a driver side knee airbag assembly that has an undeployed airbag. • The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents. • When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. • When deploying the airbag, perform the operation at least 10 m (33 ft) away from the driver side knee airbag assembly. • The driver side knee airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. • Use gloves and safety glasses when handling a driver side knee airbag assembly with a deployed airbag. • Do not apply water, etc. to a driver side knee airbag assembly with a deployed airbag. • Always wash your hands with water after completing the operation. 1. DISPOSE OF DRIVER SIDE KNEE AIRBAG ASSEMBLY (WHEN INSTALLED IN VEHICLE) HINT: Prepare a battery as the power source to deploy the airbag. (a) Check the function of the SST (See page RS-353). (b) Precaution (See page RS-1). (c) Disconnect the cable from the negative battery terminal. CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment. (d) Remove the driver side knee airbag assembly (See page RS-369). SST C110371E01 RS RS–374 SUPPLEMENTAL RESTRAINT SYSTEM – DRIVER SIDE KNEE AIRBAG ASSEMBLY (e) Install the SST. (1) Connect the SST connector to the driver side knee airbag assembly. SST 09082-00700, 09082-00770 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. (2) Install the driver side knee airbag assembly (See page RS-370). NOTICE: Take care not to damage the SST wire harness. SST C133876E01 Battery SST 10 m (33 ft) or more C110476E07 (f) RS 2. (3) Move the SST at least 10 m (33 ft) away from the vehicle front side window. (4) Maintaining enough clearance for the SST wire harness in the front side window, close all doors and windows of the vehicle. NOTICE: Take care not to damage the SST wire harness. (5) Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the battery negative (-) terminal. Deploy the airbag. (1) Check that no one is inside the vehicle or within a 10 m (33 ft) radius of the vehicle. (2) Press the SST activation switch and deploy the airbag. CAUTION: • When deploying the airbag, make sure that no one is near the vehicle. • The driver side knee airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. • Use gloves and safety glasses when handling a driver side knee airbag assembly with a deployed airbag. • Do not apply water, etc. to a driver side knee airbag assembly with a deployed airbag. • Always wash your hands with water after completing the operation. HINT: The airbag is deployed as the LED of the SST activation switch comes on. DISPOSE OF DRIVER SIDE KNEE AIRBAG ASSEMBLY (WHEN NOT INSTALLED IN VEHICLE) NOTICE: • When disposing of the driver side knee airbag assembly, never use the customer's vehicle to deploy the airbag. SUPPLEMENTAL RESTRAINT SYSTEM – DRIVER SIDE KNEE AIRBAG ASSEMBLY RS–375 • Be sure to follow the procedure detailed below when deploying the airbag. HINT: Prepare a battery as the power source to deploy the airbag. SST C110371E01 Wire Harness Diameter Stripped Wire Harness Section B104882E02 (a) Check the function of the SST (See page RS-355). (b) Remove the driver side knee airbag assembly (See page RS-369). CAUTION: • When removing the driver side knee airbag assembly, work must be started 90 seconds after the ignition switch is turned off and the negative (-) terminal cable is disconnected from the battery. • When storing the driver side knee airbag assembly, keep the airbag deployment side facing upward. (c) Using a service-purpose wire harness for the vehicle, tie down the driver side knee airbag assembly to the tire. Wire harness: Stripped wire harness section 1.25 mm2 or more (0.0019 in.2 or more) CAUTION: If the wire harness is too thin or an alternative object is used to tie down the driver side knee airbag assembly, it may be snapped by the shock when the airbag is deployed. Always use a wire harness for vehicle use with an area of at least 1.25 mm2 (0.0019 in.2). HINT: To calculate the area of the stripped wire harness section: Area = 3.14 x (Diameter)2 divided by 4 (1) Position the driver side knee airbag assembly inside the tire with the airbag deployment side facing inside. Tire size: Must exceed the following dimensions Width: 185 mm (7.28 in.) Inner diameter: 360 mm (14.17 in.) RS RS–376 SUPPLEMENTAL RESTRAINT SYSTEM – DRIVER SIDE KNEE AIRBAG ASSEMBLY Inner Diameter Width C133877E01 CAUTION: • Make sure that the wire harness is tight. If there is slack in the wire harness, the driver side knee airbag assembly may become loose due to the shock when the airbag is deployed. • Always tie down the driver side knee airbag assembly with the airbag deployment side facing inside the tire. NOTICE: The tire may be damaged by the airbag deployment, so use an extra tire. RS (d) Install the SST. (1) Connect the SST connector to the driver side knee airbag assembly. SST 09082-00770 SST C133878E01 SUPPLEMENTAL RESTRAINT SYSTEM – DRIVER SIDE KNEE AIRBAG ASSEMBLY Tire (2 or more) Tire (2 or more) C122412E01 RS–377 (e) Place the tires. (1) Place at least 2 tires under the tire which the driver side knee airbag assembly is tied to. (2) Place at least 2 tires over the tire which the driver side knee airbag assembly is tied to. The top tire should have the disc wheel installed. NOTICE: • The tire may be damaged by the airbag deployment, so use an extra tire. • Do not place the SST connector under the tire because it could be damaged. (3) Tie the tires together with 2 wire harnesses. CAUTION: Make sure that the wire harness is tight. Looseness in the wire harness results in the tires coming free due to the shock when the airbag is deployed. C107328 (f) Driver Side Knee Airbag Assembly SST Battery 10 m (33 ft) or more C122411E01 Install the SST. (1) Connect the SST connector. SST 09082-00700 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the tire. (2) Move the SST at least 10 m (33 ft) away from the airbag tied down to the tire. (g) Deploy the airbag. (1) Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the battery negative (-) terminal. (2) Check that no one is within a 10 m (33 ft) radius of the tire which the driver side knee airbag assembly is tied to. (3) Press the SST activation switch and deploy the airbag. CAUTION: When deploying the airbag, make sure that no one is near the tire. HINT: The airbag is deployed as the LED of the SST activation switch comes on. RS RS–378 SUPPLEMENTAL RESTRAINT SYSTEM – DRIVER SIDE KNEE AIRBAG ASSEMBLY C122413 RS (h) Dispose of the driver side knee airbag assembly. CAUTION: • The driver side knee airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. • Use gloves and safety glasses when handling a driver side knee airbag assembly with a deployed airbag. • Do not apply water, etc. to a driver side knee airbag assembly with a deployed airbag. • Always wash your hands with water after completing the operation. (1) Remove the driver side knee airbag assembly from the tire. (2) Place the driver side knee airbag assembly in a plastic bag, tie it tightly and dispose of it as other general part disposal. RS–378 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY FRONT PASSENGER AIRBAG ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM RESTRAINTS COMPONENTS for TMC Made: TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY 2.0 (20, 18 in.*lbf) RS STEERING COLUMN COVER 50 (510, 37) STEERING WHEEL ASSEMBLY LOWER NO. 2 STEERING WHEEL COVER LOWER NO. 3 STEERING WHEEL COVER 8.8 (90, 78 in.*lbf) STEERING PAD N*m (kgf*cm, ft.*lbf) : Specified torque B137279E01 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY RS–379 for TMMK Made: TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY 2.0 (20, 18 in.*lbf) STEERING COLUMN COVER for 4 Spoke Type: 50 (510, 37) STEERING WHEEL ASSEMBLY LOWER NO. 2 STEERING WHEEL COVER LOWER NO. 3 STEERING WHEEL COVER STEERING PAD RS 8.8 (90, 78 in.*lbf) for 3 Spoke Type: STEERING WHEEL ASSEMBLY 50 (510, 37) LOWER NO. 2 STEERING WHEEL COVER LOWER NO. 3 STEERING WHEEL COVER STEERING PAD 8.8 (90, 78 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque B137280E03 RS–380 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY for TMC Made: COMBINATION METER ASSEMBLY INSTRUMENT CLUSTER FINISH PANEL without Smart Key System: LOWER INSTRUMENT PANEL FINISH PANEL with Smart Key System: RS NO. 1 INSTRUMENT PANEL SUB-ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL COWL SIDE TRIM SUB-ASSEMBLY LH COWL SIDE TRIM CLIP LOWER INSTRUMENT PANEL FINISH PANEL LH FRONT DOOR SCUFF PLATE LH B137281E01 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY RS–381 for TMMK Made: COMBINATION METER ASSEMBLY INSTRUMENT CLUSTER FINISH PANEL without Smart Key System: LOWER INSTRUMENT PANEL FINISH PANEL with Smart Key System: RS NO. 1 INSTRUMENT PANEL SUB-ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL COWL SIDE TRIM SUB-ASSEMBLY LH COWL SIDE TRIM CLIP or

LOWER INSTRUMENT PANEL FINISH PANEL LH FRONT DOOR SCUFF PLATE LH B137281E03 RS–382 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY for TMC Made: LOWER INSTRUMENT PANEL SUB-ASSEMBLY or COWL SIDE TRIM SUB-ASSEMBLY RH COWL SIDE TRIM CLIP RS FRONT DOOR SCUFF PLATE RH INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY B137282E01 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY RS–383 for TMMK Made: LOWER INSTRUMENT PANEL SUB-ASSEMBLY or

COWL SIDE TRIM SUB-ASSEMBLY RH COWL SIDE TRIM CLIP RS FRONT DOOR SCUFF PLATE RH INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY B137282E03 RS–384 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH for Automatic Transaxle: SHIFT LEVER KNOB SUB-ASSEMBLY FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY UPPER CONSOLE REAR PANEL SUB-ASSEMBLY RS for Manual Transaxle: SHIFT LEVER KNOB SUB-ASSEMBLY UPPER CONSOLE PANEL UPPER CONSOLE REAR PANEL SUB-ASSEMBLY B137283E01 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY RS–385 for TMC Made: INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY without Navigation System: with Navigation System: RS RADIO RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY NAVIGATION RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY UPPER CONSOLE PANEL SUB-ASSEMBLY B137284E01 RS–386 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY for TMMK Made: INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY without Navigation System: with Navigation System: RS RADIO RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY NAVIGATION RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY UPPER CONSOLE PANEL SUB-ASSEMBLY B137284E03 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY RS–387 for TMC Made: FRONT PILLAR GARNISH CLIP FRONT PILLAR GARNISH CLIP FRONT PILLAR GARNISH RH FRONT PILLAR GARNISH LH INSTRUMENT PANEL NO. 3 REGISTER ASSEMBLY INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY NO. 1 CONSOLE BOX INSERT FRONT RS NO. 2 CONSOLE BOX INSERT FRONT CONSOLE BOX CARPET CONSOLE BOX ASSEMBLY CONSOLE BOX POCKET Non-reusable part B137285E01 RS–388 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY for TMMK Made: FRONT PILLAR GARNISH CLIP FRONT PILLAR GARNISH CLIP FRONT PILLAR GARNISH RH FRONT PILLAR GARNISH LH INSTRUMENT PANEL NO. 3 REGISTER ASSEMBLY INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY NO. 1 CONSOLE BOX INSERT FRONT or or RS NO. 2 CONSOLE BOX INSERT FRONT CONSOLE BOX CARPET CONSOLE BOX ASSEMBLY CONSOLE BOX POCKET Non-reusable part B137285E03 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY RS–389 for TMC Made: INSTRUMENT PANEL NO. 1 SPEAKER PANEL SUB-ASSEMBLY INSTRUMENT PANEL NO. 2 SPEAKER PANEL SUB-ASSEMBLY NO. 1 DEFROSTER NOZZLE GARNISH for RH Side: for LH Side: FRONT NO. 2 SPEAKER ASSEMBLY FRONT NO. 2 SPEAKER ASSEMBLY RS or or or 20 (204, 15) or INSTRUMENT PANEL SAFETY PAD ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B137286E01 RS–390 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY for TMMK Made: INSTRUMENT PANEL NO. 1 SPEAKER PANEL SUB-ASSEMBLY INSTRUMENT PANEL NO. 2 SPEAKER PANEL SUB-ASSEMBLY NO. 1 DEFROSTER NOZZLE GARNISH for RH Side: for LH Side: FRONT NO. 2 SPEAKER ASSEMBLY FRONT NO. 2 SPEAKER ASSEMBLY RS , or , or 20 (204, 15) INSTRUMENT PANEL SAFETY PAD ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B137286E03 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY RS–391 FRONT PASSENGER AIRBAG ASSEMBLY INSTRUMENT PANEL WIRE ASSEMBLY INSTRUMENT PANEL SAFETY PAD ASSEMBLY RS C132561E07 RS–392 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY ON-VEHICLE INSPECTION 1. INSPECT FRONT PASSENGER AIRBAG ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (See page RS32). (b) With the front passenger airbag assembly installed on the vehicle, perform a visual check. If there are any defects as mentioned below, replace the instrument panel with a new one: Cuts, minute cracks or marked discoloration on the instrument panel around the front passenger airbag assembly. 2. C132562 RS C132563 INSPECT FRONT PASSENGER AIRBAG ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check (See page RS32). (b) With the front passenger airbag assembly removed from the vehicle, perform a visual check. If there are any defects as mentioned below, replace the front passenger airbag assembly, instrument panel or instrument panel reinforcement with a new one: • Cuts, minute cracks or marked discoloration on the front passenger airbag assembly. • Cracks or other damage to the connectors. • Deformation or cracks on the instrument panel or instrument panel reinforcement. CAUTION: Be sure to follow the correct removal and installation procedures. SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY RS–393 REMOVAL 1. TABLE OF BOLT, SCREW AND NUT HINT: See page IP-1 2. PRECAUTION CAUTION: Be sure to read "PRECAUTION" thoroughly before servicing (See page RS-1). 3. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment. 5. REMOVE LOWER NO. 3 STEERING WHEEL COVER (See page RS-349) 6. REMOVE LOWER NO. 2 STEERING WHEEL COVER (See page RS-349) 7. REMOVE STEERING PAD (See page RS-350) 8. REMOVE STEERING WHEEL ASSEMBLY (See page SR-38) 9. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-24) 10. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-25) 11. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (See page IP-20) 12. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (See page IP-21) 13. REMOVE STEERING COLUMN COVER (for TMC Made) (See page IP-21) 14. REMOVE STEERING COLUMN COVER (for TMMK Made) (See page IP-21) 15. REMOVE TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY (See page SR-39) 16. REMOVE NO. 1 INSTRUMENT PANEL SUBASSEMBLY (See page IP-22) 17. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (w/o Smart Key System) (See page IP-22) 18. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (w/ Smart Key System) (See page IP-22) 19. REMOVE INSTRUMENT CLUSTER FINISH PANEL (See page IP-22) 20. REMOVE COMBINATION METER ASSEMBLY (for TMC Made) (See page IP-23) RS RS–394 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY 21. REMOVE COMBINATION METER ASSEMBLY (for TMMK Made) (See page IP-23) 22. REMOVE FRONT DOOR SCUFF PLATE RH (See page IR-26) 23. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH (See page IR-26) 24. REMOVE INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY (See page IP-23) 25. REMOVE LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMC Made) (See page IP-23) 26. REMOVE LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMMK Made) (See page IP-24) 27. DISCONNECT INSTRUMENT PANEL WIRE ASSEMBLY (a) Disconnect the connector. 28. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-24) 29. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) (See page IP-24) C132564 30. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-24) 31. REMOVE NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-25) RS 32. REMOVE FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-25) 33. REMOVE UPPER CONSOLE PANEL (for Manual Transaxle) (See page IP-25) 34. REMOVE UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Automatic Transaxle) (See page IP26) 35. REMOVE UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Manual Transaxle) (See page IP-26) 36. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMC Made) (See page IP-27) 37. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMMK Made) (See page IP-27) 38. REMOVE INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY (See page IP-27) 39. REMOVE RADIO RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY (w/o Navigation System) (See page AV-146) 40. REMOVE NAVIGATION RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY (w/ Navigation System) (See page NS-195) SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY RS–395 41. REMOVE CONSOLE BOX POCKET (See page NS195) 42. REMOVE CONSOLE BOX CARPET (See page IP-28) 43. REMOVE CONSOLE BOX ASSEMBLY (for TMC Made) (See page IP-28) 44. REMOVE CONSOLE BOX ASSEMBLY (for TMMK Made) (See page IP-29) 45. REMOVE NO. 2 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-29) 46. REMOVE NO. 2 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-30) 47. REMOVE NO. 1 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-30) 48. REMOVE NO. 1 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-30) 49. REMOVE FRONT PILLAR GARNISH LH (See page IR27) 50. REMOVE INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY (See page IP-31) 51. REMOVE INSTRUMENT PANEL NO. 1 SPEAKER PANEL SUB-ASSEMBLY (See page IP-31) 52. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (for LH Side) (See page AV-155) 53. REMOVE FRONT PILLAR GARNISH RH (See page IR27) 54. REMOVE INSTRUMENT PANEL NO. 3 REGISTER ASSEMBLY (See page IP-31) 55. REMOVE INSTRUMENT PANEL NO. 2 SPEAKER PANEL SUB-ASSEMBLY (See page IP-32) 56. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (for RH Side) (See page AV-156) 57. REMOVE NO. 1 DEFROSTER NOZZLE GARNISH (See page IP-32) 58. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY (for TMC Made) (See page IP-32) 59. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY (for TMMK Made) (See page IP-34) RS RS–396 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY 60. REMOVE FRONT PASSENGER AIRBAG ASSEMBLY (a) Remove the 2 screws. C132565 (b) Disengage the 10 hooks and remove the front passenger airbag assembly from the instrument panel. RS C132566 61. REMOVE INSTRUMENT PANEL WIRE ASSEMBLY (a) Disconnect the 2 connectors. (b) Remove the clamp and the instrument panel wire assembly from the front passenger airbag assembly. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. C132567 INSTALLATION 1. C132567 INSTALL INSTRUMENT PANEL WIRE ASSEMBLY (a) Connect the 2 connectors. (b) Install the clamp and the instrument panel wire assembly on the front passenger airbag assembly. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY 2. RS–397 INSTALL FRONT PASSENGER AIRBAG ASSEMBLY (a) Engage the 10 hooks and install the front passenger airbag assembly on the instrument panel. C132566 (b) Install the 2 screws. C132565 3. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY (for TMC Made) (See page IP-44) 4. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY (for TMMK Made) (See page IP-45) 5. INSTALL NO. 1 DEFROSTER NOZZLE GARNISH (See page IP-48) 6. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (for LH Side) (See page AV-156) 7. INSTALL INSTRUMENT PANEL NO. 1 SPEAKER PANEL SUB-ASSEMBLY (See page IP-48) 8. INSTALL INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY (See page IP-48) 9. INSTALL FRONT PILLAR GARNISH LH (See page IR51) 10. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (for RH Side) (See page AV-157) 11. INSTALL INSTRUMENT PANEL NO. 2 SPEAKER PANEL SUB-ASSEMBLY (See page IP-49) 12. INSTALL INSTRUMENT PANEL NO. 3 REGISTER ASSEMBLY (See page IP-49) 13. INSTALL FRONT PILLAR GARNISH RH (See page IR52) 14. INSTALL NO. 1 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-49) RS RS–398 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY 15. INSTALL NO. 1 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-50) 16. INSTALL NO. 2 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-50) 17. INSTALL NO. 2 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-50) 18. INSTALL CONSOLE BOX ASSEMBLY (for TMC Made) (See page IP-51) 19. INSTALL CONSOLE BOX ASSEMBLY (for TMMK Made) (See page IP-51) 20. INSTALL CONSOLE BOX CARPET (See page IP-51) 21. INSTALL CONSOLE BOX POCKET (See page IP-51) 22. INSTALL RADIO RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY (w/o Navigation System) (See page AV-147) 23. INSTALL NAVIGATION RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY (w/ Navigation System) (See page NS-196) 24. INSTALL INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY (See page IP-52) 25. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMC Made) (See page IP-52) RS 26. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMMK Made) (See page IP-52) 27. INSTALL UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Automatic Transaxle) (See page IP53) 28. INSTALL UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Manual Transaxle) (See page IP-53) 29. INSTALL FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-53) 30. INSTALL UPPER CONSOLE PANEL (for Manual Transaxle) (See page IP-54) 31. INSTALL NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-54) 32. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-55) 33. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-55) 34. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) (See page IP-55) SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY RS–399 35. CONNECT INSTRUMENT PANEL WIRE ASSEMBLY (a) Connect the connector. 36. INSTALL LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMC Made) (See page IP-55) 37. INSTALL LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMMK Made) (See page IP-56) 38. INSTALL INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY (See page IP-56) C132564 39. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH (See page IR-55) 40. INSTALL FRONT DOOR SCUFF PLATE RH (See page IR-55) 41. INSTALL COMBINATION METER ASSEMBLY (for TMC Made) (See page IP-56) 42. INSTALL COMBINATION METER ASSEMBLY (for TMMK Made) (See page IP-56) 43. INSTALL INSTRUMENT CLUSTER FINISH PANEL (See page IP-57) 44. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/o Smart Key System) (See page IP-57) 45. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/ Smart Key System) (See page IP-57) 46. INSTALL NO. 1 INSTRUMENT PANEL SUBASSEMBLY (See page IP-57) 47. INSTALL TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY (See page SR-50) 48. ADJUST SPIRAL CABLE SUB-ASSEMBLY (See page RS-367) 49. INSTALL STEERING COLUMN COVER (for TMC Made) (See page IP-58) 50. INSTALL STEERING COLUMN COVER (for TMMK Made) (See page IP-58) 51. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (See page IP-58) 52. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (See page IP-59) 53. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-54) 54. INSTALL FRONT DOOR SCUFF PLATE LH (See page IR-54) 55. INSTALL STEERING WHEEL ASSEMBLY (See page SR-51) 56. INSTALL STEERING PAD (See page RS-350) RS RS–400 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY 57. INSTALL LOWER NO. 3 STEERING WHEEL COVER (See page RS-351) 58. INSTALL LOWER NO. 2 STEERING WHEEL COVER (See page RS-352) 59. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 60. INSPECT STEERING PAD (See page RS-352) 61. INSPECT SRS WARNING LIGHT (a) Inspect the SRS warning light (See page RS-352). RS SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY RS–401 DISPOSAL HINT: When scrapping a vehicle equipped with the SRS or disposing of the front passenger airbag assembly, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of the TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: • Never dispose of a front passenger airbag assembly that has an undeployed airbag. • The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents. • When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. • When deploying the airbag, perform the operation at least 10 m (33 ft) away from the front passenger airbag assembly. • The front passenger airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. • Use gloves and safety glasses when handling a front passenger airbag assembly with a deployed airbag. • Do not apply water, etc. to a front passenger airbag assembly with a deployed airbag. • Always wash your hands with water after completing the operation. 1. SST C110371E01 DISPOSE OF FRONT PASSENGER AIRBAG ASSEMBLY (WHEN INSTALLED IN VEHICLE) HINT: Prepare a battery as the power source to deploy the airbag. (a) Check the function of the SST (See page RS-353 ). (b) Precaution (See page RS-1 ). (c) Disconnect the cable from the negative battery terminal. CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment. (d) Install the SST. (1) Remove the lower instrument panel subassembly (See page IP-23 ). RS RS–402 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY (2) Disconnect the connector. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. C132564 (3) Connect the SST connector to the instrument panel wire assembly. SST 09082-00700, 09082-00780 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. SST C132572E01 Battery SST RS 10 m (33 ft) or more C110476E07 (4) Move the SST at least 10 m (33 ft) away from the vehicle front side window. (5) Maintaining enough clearance for the SST wire harness in the front side window, close all doors and windows of the vehicle. NOTICE: Take care not to damage the SST wire harness. (6) Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the negative (-) terminal. (e) Deploy the airbag. (1) Check that no one is inside the vehicle or within a 10 m (33 ft) radius of the vehicle. (2) Press the SST activation switch and deploy the airbag. CAUTION: • When deploying the airbag, make sure that no one is near the vehicle. • The front passenger airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. • Use gloves and safety glasses when handling a front passenger airbag assembly with a deployed airbag. • Do not apply water, etc. to a front passenger airbag assembly with a deployed airbag. • Always wash your hands with water after completing the operation. SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY RS–403 HINT: The airbag is deployed as the LED of the SST activation switch comes on. 2. SST C110371E01 DISPOSE OF FRONT PASSENGER AIRBAG ASSEMBLY (WHEN NOT INSTALLED IN VEHICLE) NOTICE: • When disposing of the front passenger airbag assembly, never use the customer's vehicle to deploy the airbag. • Be sure to follow the procedure detailed below when deploying the airbag. HINT: Prepare a battery as the power source to deploy the airbag. (a) Check the function of the SST (See page RS-355 ). (b) Remove the front passenger airbag assembly (See page RS-392 ). CAUTION: • When removing the front passenger airbag assembly, work must be started 90 seconds after the ignition switch is turned off and the negative (-) terminal cable is disconnected from the battery. • When storing the front passenger airbag assembly, keep the airbag deployment side facing upward. (c) Install the SST. (1) After connecting the SST below to each other, connect them to the front passenger airbag assembly. SST 09082-00700, 09082-00802 (0908210801, 09082-30801) SST C132568E02 Wire Harness Diameter Stripped Wire Harness Section B104882E02 (d) Using a service-purpose wire harness for the vehicle, tie down the front passenger airbag assembly to the tire. Wire harness: Stripped wire harness section 1.25 mm2 or more (0.0019 in.2 or more) CAUTION: If the wire harness is too thin or an alternative object is used to tie down the front passenger airbag assembly, it may be snapped by the shock when the airbag is deployed. Always use a wire harness for vehicle use with an area of at least 1.25 mm2 (0.0019 in.2). HINT: To calculate the area of the stripped wire harness section: RS RS–404 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY Area = 3.14 x (Diameter)2 divided by 4 (1) Position the front passenger airbag assembly inside the tire with the airbag deployment side facing inside. Tire size: Must exceed the following dimensions Width: 185 mm (7.28 in.) Inner diameter: 360 mm (14.17 in.) Inner Diameter RS Width C132569E01 CAUTION: • Make sure that the wire harness is tight. If there is slack in the wire harness, the front passenger airbag assembly may become loose due to the shock when the airbag is deployed. • Always tie down the front passenger airbag assembly with the airbag deployment side facing inside the tire. NOTICE: The tire will be marked by the airbag deployment, so use an extra tire. SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY Tire (2 or more) Tire (2 or more) RS–405 (e) Place the tires. (1) Place at least 2 tires under the tire which the front passenger airbag assembly is tied to. (2) Place at least 2 tires over the tire which the front passenger airbag assembly is tied to. The top tire should have a disc wheel installed. NOTICE: Do not place the SST connector under the tire because it could be damaged. C132570E01 (3) Tie the tires together with 2 wire harnesses. CAUTION: Make sure that the wire harness is tight. Looseness in the wire harness results in the tires coming free due to the shock when the airbag is deployed. B105087 (f) Front Passenger Airbag Assembly Battery SST 10 m (33 ft) or more C132571E01 Install the SST. (1) Connect the SST connector. SST 09082-00700 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the tire. (2) Move the SST at least 10 m (33 ft) away from the airbag tied down to the tire. (g) Deploy the airbag. (1) Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the battery negative (-) terminal. (2) Check that no one is within a 10 m (33 ft) radius of the tire which the front passenger airbag assembly is tied to. (3) Press the SST activation switch and deploy the airbag. CAUTION: When deploying the airbag, make sure that no one is near the tire. HINT: The airbag is deployed as the LED of the SST activation switch comes on. RS RS–406 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY H041436 RS (h) Dispose of the front passenger airbag assembly. CAUTION: • The front passenger airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. • Use gloves and safety glasses when handling a front passenger airbag assembly with a deployed airbag. • Do not apply water, etc. to a front passenger airbag assembly with a deployed airbag. • Always wash your hands with water after completing the operation. (1) Remove the front passenger airbag assembly from the tire. (2) Place the front passenger airbag assembly in a plastic bag, tie it tightly and dispose of it as other general part disposal. RS–416 SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY ON-VEHICLE INSPECTION 1. INSPECT CURTAIN SHIELD AIRBAG ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (See page RS32). (b) With the curtain shield airbag assembly installed on the vehicle, perform a visual check. If there are any defects as mentioned below, replace the front pillar garnish or roof headlining assembly with a new one: Cuts, minute cracks or marked discoloration on the front pillar garnish or roof headlining assembly around the curtain shield airbag assembly. 2. C132557 RS C132558 INSPECT CURTAIN SHIELD AIRBAG ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check (See page RS32). (b) With the curtain shield airbag assembly removed from the vehicle, perform a visual check. If there are any defects as mentioned below, replace the curtain shield airbag assembly with a new one: • Cuts, minute cracks or marked discoloration on the curtain shield airbag assembly. • Cracks or other damage to the connectors. CAUTION: Be sure to follow the correct removal and installation procedures. SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY RS–417 REMOVAL HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. PRECAUTION CAUTION: Be sure to read "PRECAUTION" thoroughly before servicing (See page RS-1). 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTICE: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment. 3. REMOVE FRONT SEAT HEADREST ASSEMBLY (for Manual Seat) 4. REMOVE SEAT TRACK COVER LH (for Manual Seat) (See page SE-16) 5. REMOVE INNER SEAT TRACK BRACKET COVER LH (for Manual Seat) (See page SE-16) 6. REMOVE FRONT SEAT ASSEMBLY LH (for Manual Seat) (See page SE-16) 7. REMOVE FRONT SEAT HEADREST ASSEMBLY (for Manual Seat) 8. REMOVE SEAT TRACK COVER RH (for Manual Seat) HINT: Use the same procedures for the RH side and the LH side. 9. REMOVE INNER SEAT TRACK BRACKET COVER RH (for Manual Seat) HINT: Use the same procedures for the RH side and the LH side. 10. REMOVE FRONT SEAT ASSEMBLY RH (for Manual Seat) HINT: Use the same procedures for the RH side and the LH side. 11. REMOVE FRONT SEAT HEADREST ASSEMBLY (for Power Seat) 12. REMOVE SEAT TRACK COVER LH (for Power Seat) (See page SE-30) 13. REMOVE SEAT TRACK COVER RH (for Power Seat) (See page SE-30) 14. REMOVE FRONT SEAT ASSEMBLY LH (for Power Seat) (See page SE-30) 15. REMOVE FRONT SEAT HEADREST ASSEMBLY (for Power Seat) RS RS–418 SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY 16. REMOVE SEAT TRACK COVER RH (for Power Seat) HINT: Use the same procedures for the RH side and the LH side. 17. REMOVE SEAT TRACK COVER LH (for Power Seat) HINT: Use the same procedures for the RH side and the LH side. 18. REMOVE FRONT SEAT ASSEMBLY RH (for Power Seat) HINT: Use the same procedures for the RH side and the LH side. 19. REMOVE REAR DOOR SCUFF PLATE LH (See page IR-24) 20. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH 21. REMOVE REAR DOOR SCUFF PLATE RH (See page IR-24) 22. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH 23. REMOVE REAR SEAT CUSHION ASSEMBLY (See page SE-77) 24. REMOVE REAR SEAT HEADREST ASSEMBLY RS 25. REMOVE REAR CENTER SEAT HEADREST ASSEMBLY 26. REMOVE REAR SEAT BACK ASSEMBLY (for Fixed Seat Type) (See page SE-77) 27. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-47) 28. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) (See page SE-47) 29. REMOVE REAR SIDE SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-48) 30. REMOVE REAR SIDE SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) (See page SE-48) 31. REMOVE REAR SEAT BACK COVER (for Reclining Seat Type) (See page SE-63) 32. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Reclining Seat Type) (See page SE-63) 33. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Reclining Seat Type) (See page SE-64) SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY RS–419 34. REMOVE CENTER SEAT BACK ASSEMBLY (for Reclining Seat Type) (See page SE-64) 35. REMOVE RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY LH (for Reclining Seat Type) (See page SE-68) 36. REMOVE RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY RH (for Reclining Seat Type) HINT: Use the same procedures for the RH side and the LH side. 37. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG LH (See page ED-38) 38. REMOVE DOOR ASSIST GRIP COVER LH (See page ED-38) 39. REMOVE REAR DOOR TRIM BOARD SUBASSEMBLY LH (See page ED-39) 40. REMOVE REAR DOOR INNER GLASS WEATHERSTRIP LH (See page ED-40) 41. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-24) 42. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-25) 43. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH 44. REMOVE LAP BELT OUTER ANCHOR COVER (See page IR-25) 45. DISCONNECT FRONT SEAT OUTER BELT ASSEMBLY LH (See page IR-25) 46. REMOVE LOWER CENTER PILLAR GARNISH LH (See page IR-25) 47. REMOVE UPPER CENTER PILLAR GARNISH LH (See page IR-26) 48. REMOVE FRONT DOOR SCUFF PLATE RH (See page IR-26) 49. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH (See page IR-26) 50. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH 51. REMOVE LAP BELT OUTER ANCHOR COVER (See page IR-26) 52. DISCONNECT FRONT SEAT OUTER BELT ASSEMBLY RH (See page IR-26) 53. REMOVE LOWER CENTER PILLAR GARNISH RH (See page IR-26) RS RS–420 SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY 54. REMOVE UPPER CENTER PILLAR GARNISH RH (See page IR-26) 55. REMOVE ROOF SIDE INNER GARNISH LH (See page IR-26) 56. REMOVE ROOF SIDE INNER GARNISH RH (See page IR-26) 57. REMOVE FRONT PILLAR GARNISH LH (See page IR27) 58. REMOVE FRONT PILLAR GARNISH RH (See page IR27) 59. REMOVE ROOF CONSOLE BOX ASSEMBLY (See page IR-28) 60. REMOVE VISOR ASSEMBLY LH (See page IR-28) 61. REMOVE VISOR ASSEMBLY RH (See page IR-29) 62. REMOVE VISOR HOLDER (See page IR-29) 63. REMOVE FRONT ASSIST GRIP SUB-ASSEMBLY (See page IR-29) 64. REMOVE REAR ASSIST GRIP SUB-ASSEMBLY (See page IR-29) 65. REMOVE NO. 1 ROOM LIGHT ASSEMBLY (w/o Sliding Roof) (See page IR-30) 66. REMOVE SPOT LIGHT ASSEMBLY (w/ Sliding Roof) (See page IR-30) RS 67. REMOVE SUN ROOF OPENING TRIM MOULDING (w/ Sliding Roof) (See page IR-31) 68. REMOVE SUNSHADE TRIM HOLDER (w/ Rear Sunshade) (See page IR-31) 69. REMOVE ROOF HEADLINING ASSEMBLY (w/o Sliding Roof) (See page IR-31) 70. REMOVE ROOF HEADLINING ASSEMBLY (w/ Sliding Roof) (See page IR-32) 71. REMOVE CURTAIN SHIELD AIRBAG ASSEMBLY (a) Disconnect the connector. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. Pin Clip Airbag Body C141263E01 (b) Remove the 4 clips. (1) Using a clip remover, remove the pin. SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY (2) Using needle-nose pliers, remove the clip and curtain shield airbag from the body as shown in the illustration. (c) Remove the 5 bolts and curtain shield airbag assembly. Clip Airbag RS–421 Body C141264E03 C132575 (d) Remove the 4 clips and 4 spacers from the curtain shield airbag assembly. NOTICE: If clips and spacers are removed, always replace them with new ones even though they may not appear to be damaged. RS SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY RS–405 CURTAIN SHIELD AIRBAG ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM RESTRAINTS COMPONENTS for Manual Seat: FRONT SEAT HEADREST ASSEMBLY SEAT TRACK COVER RH 37 (377, 27) INNER SEAT TRACK BRACKET COVER RH 37 (377, 27) FRONT SEAT ASSEMBLY RH RS FRONT SEAT HEADREST ASSEMBLY INNER SEAT TRACK BRACKET COVER LH SEAT TRACK COVER LH 37 (377, 27) 37 (377, 27) FRONT SEAT ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque B132048E01 RS–406 SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY for Power Seat: FRONT SEAT HEADREST ASSEMBLY SEAT TRACK COVER RH INNER SEAT TRACK BRACKET COVER LH 37 (377, 27) 37 (377, 27) FRONT SEAT ASSEMBLY RH FRONT SEAT HEADREST ASSEMBLY RS INNER SEAT TRACK BRACKET COVER RH 37 (377, 27) SEAT TRACK COVER LH 37 (377, 27) FRONT SEAT ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque B132047E01 SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY RS–407 for Fixed Seat Type: REAR SEAT HEADREST ASSEMBLY REAR CENTER SEAT HEADREST ASSEMBLY REAR SEAT BACK ASSEMBLY RS 18 (184, 13) 18 (184, 13) REAR SEAT CUSHION ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B136589E02 RS–408 SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY for Fold Down Seat Type: REAR SEAT HEADREST ASSEMBLY REAR CENTER SEAT HEADREST ASSEMBLY 18 (184, 13) 18 (184, 13) 18 (184, 13) RS REAR SIDE SEAT BACK ASSEMBLY RH SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH 18 (184, 13) REAR SEAT CUSHION ASSEMBLY REAR SIDE SEAT BACK ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque B136564E02 SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY RS–409 for Reclining Seat Type: REAR SEAT HEADREST ASSEMBLY REAR CENTER SEAT HEADREST ASSEMBLY 18 (184, 13) SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH REAR SEAT BACK COVER CENTER SEAT BACK ASSEMBLY 18 (184, 13) 18 (184, 13) 18 (184, 13) REAR SEAT BACK COVER RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY RH 18 (184, 13) RS SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH 18 (184, 13) REAR SEAT CUSHION ASSEMBLY RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque B139577E01 RS–410 SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY NO. 1 DOOR SCUFF PLATE CLAMP REAR DOOR INNER GLASS WEATHERSTRIP LH REAR DOOR INSIDE HANDLE BEZEL PLUG LH RS DOOR ASSIST GRIP COVER LH REAR DOOR TRIM BOARD SUB-ASSEMBLY LH B139576E01 SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY RS–411 FRONT DOOR OPENING TRIM WEATHERSTRIP RH FRONT PILLAR GARNISH RH UPPER CENTER PILLAR GARNISH RH FRONT PILLAR GARNISH CLIP ROOF SIDE INNER GARNISH RH REAR DOOR OPENING TRIM WEATHERSTRIP RH RS REAR DOOR SCUFF PLATE RH FRONT SEAT OUTER BELT ASSEMBLY RH COWL SIDE TRIM CLIP FRONT DOOR SCUFF PLATE RH COWL SIDE TRIM SUB-ASSEMBLY RH 42 (428, 31) LAP BELT OUTER ANCHOR COVER LOWER CENTER PILLAR GARNISH RH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part B132050E02 RS–412 SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY UPPER CENTER PILLAR GARNISH LH FRONT PILLAR GARNISH LH FRONT PILLAR GARNISH CLIP REAR DOOR OPENING TRIM WEATHERSTRIP LH FRONT DOOR OPENING TRIM WEATHERSTRIP LH ROOF SIDE INNER GARNISH LH 42 (428, 31) RS LAP BELT OUTER ANCHOR COVER REAR DOOR SCUFF PLATE LH LOWER CENTER PILLAR GARNISH LH COWL SIDE TRIM CLIP FRONT SEAT OUTER BELT ASSEMBLY LH FRONT DOOR SCUFF PLATE LH COWL SIDE TRIM SUB-ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part B132049E02 SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY RS–413 without Sliding Roof: REAR ASSIST GRIP SUB-ASSEMBLY FRONT ASSIST GRIP SUB-ASSEMBLY ASSIST GRIP COVER ASSIST GRIP COVER ROOF HEADLINING ASSEMBLY REAR ASSIST GRIP SUB-ASSEMBLY RS NO. 1 ROOM LIGHT ASSEMBLY LENS COVER VISOR BRACKET COVER FRONT ASSIST GRIP SUB-ASSEMBLY ASSIST GRIP COVER VISOR ASSEMBLY RH VISOR HOLDER ASSIST GRIP COVER ROOF CONSOLE BOX ASSEMBLY VISOR ASSEMBLY LH VISOR HOLDER VISOR BRACKET COVER B132051E01 RS–414 SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY with Sliding Roof: FRONT ASSIST GRIP SUB-ASSEMBLY REAR ASSIST GRIP SUB-ASSEMBLY ASSIST GRIP COVER ASSIST GRIP COVER ROOF HEADLINING ASSEMBLY with Rear Sunshade: SUNSHADE TRIM HOLDER SPOT LIGHT ASSEMBLY RS VISOR BRACKET COVER REAR ASSIST GRIP SUB-ASSEMBLY VISOR ASSEMBLY RH ASSIST GRIP COVER ROOF CONSOLE BOX ASSEMBLY FRONT ASSIST GRIP SUB-ASSEMBLY ASSIST GRIP COVER VISOR HOLDER VISOR ASSEMBLY LH VISOR HOLDER VISOR BRACKET COVER SUN ROOF OPENING TRIM MOULDING B132052E01 SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY RS–415 SPACER SPACER RS CLIP CURTAIN SHIELD AIRBAG ASSEMBLY CLIP 11 (112, 8) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C140572E02 RS–422 SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY INSTALLATION HINT: • Use the same procedures for the RH side and the LH side. • The procedures listed below are for the LH side. 1. Body Clip Spacer Pin Airbag C141266E02 INSTALL CURTAIN SHIELD AIRBAG ASSEMBLY (a) Install a 4 new clips and 4 new spacers to the curtain shield airbag assembly as shown in the illustration. NOTICE: • Do not push in the pin. • Make sure that the clips are installed in the correct direction. • Make sure that the spacers are installed properly, in the correct direction, and that they are not damaged. (b) Install the curtain shield airbag assembly with the 5 new bolts. Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) RS C132575 NOTICE: Do not twist the curtain shield airbag assembly when installing it. Pin Clip Airbag Body C141265E01 (c) Install the 4 clips with the curtain shield airbag assembly to the body panel as shown in the illustration. NOTICE: Make sure that the pins of the clips are pushed in firmly. (d) Mark the clips. HINT: Mark the clips to make sure that they are not reused. (e) Connect the connector. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY RS–423 2. INSTALL ROOF HEADLINING ASSEMBLY (w/o Sliding Roof) (See page IR-45) 3. INSTALL ROOF HEADLINING ASSEMBLY (w/ Sliding Roof) (See page IR-46) 4. INSTALL SUNSHADE TRIM HOLDER (w/ Rear Sunshade) (See page IR-47) 5. INSTALL SUN ROOF OPENING TRIM MOULDING (w/ Sliding Roof) (See page IR-47) 6. INSTALL SPOT LIGHT ASSEMBLY (w/ Sliding Roof) (See page IR-48) 7. INSTALL NO. 1 ROOM LIGHT ASSEMBLY (w/o Sliding Roof) (See page IR-48) 8. INSTALL FRONT ASSIST GRIP SUB-ASSEMBLY (See page IR-49) 9. INSTALL REAR ASSIST GRIP SUB-ASSEMBLY (See page IR-49) 10. INSTALL VISOR HOLDER (See page IR-49) 11. INSTALL VISOR ASSEMBLY LH (See page IR-50) 12. INSTALL VISOR ASSEMBLY RH (See page IR-50) 13. INSTALL ROOF CONSOLE BOX ASSEMBLY (See page IR-50) 14. INSTALL FRONT PILLAR GARNISH LH (See page IR51) 15. INSTALL FRONT PILLAR GARNISH RH (See page IR52) 16. INSTALL ROOF SIDE INNER GARNISH LH (See page IR-52) 17. INSTALL ROOF SIDE INNER GARNISH RH (See page IR-52) 18. INSTALL UPPER CENTER PILLAR GARNISH LH (See page IR-53) 19. INSTALL LOWER CENTER PILLAR GARNISH LH (See page IR-53) 20. CONNECT FRONT SEAT OUTER BELT ASSEMBLY LH (See page IR-53) 21. INSTALL LAP BELT OUTER ANCHOR COVER (See page IR-53) 22. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH (See page IR-54) 23. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-54) 24. INSTALL FRONT DOOR SCUFF PLATE LH (See page IR-54) RS RS–424 SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY 25. INSTALL UPPER CENTER PILLAR GARNISH RH (See page IR-54) 26. INSTALL LOWER CENTER PILLAR GARNISH RH (See page IR-54) 27. CONNECT FRONT SEAT OUTER BELT ASSEMBLY RH (See page IR-54) 28. INSTALL LAP BELT OUTER ANCHOR COVER (See page IR-54) 29. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH (See page IR-55) 30. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH (See page IR-55) 31. INSTALL FRONT DOOR SCUFF PLATE RH (See page IR-55) 32. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP LH (See page ED-54) 33. INSTALL REAR DOOR TRIM BOARD SUBASSEMBLY LH (See page ED-55) 34. INSTALL DOOR ASSIST GRIP COVER LH (See page ED-56) 35. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG LH (See page ED-56) RS 36. INSTALL RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY LH (for Reclining Seat Type) (See page SE-69) 37. INSTALL RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY RH (for Reclining Seat Type) HINT: Use the same procedures for the RH side and the LH side. 38. INSTALL CENTER SEAT BACK ASSEMBLY (for Reclining Seat Type) (See page SE-71) 39. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Reclining Seat Type) (See page SE-72) 40. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Reclining Seat Type) (See page SE-71) 41. INSTALL REAR SEAT BACK COVER (for Reclining Seat Type) 42. INSTALL REAR SIDE SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-57) 43. INSTALL REAR SIDE SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY RS–425 44. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-57) 45. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) (See page SE-57) 46. INSTALL REAR SEAT BACK ASSEMBLY (for Fixed Seat Type) (See page SE-84) 47. INSTALL REAR CENTER SEAT HEADREST ASSEMBLY 48. INSTALL REAR SEAT HEADREST ASSEMBLY 49. INSTALL REAR SEAT CUSHION ASSEMBLY 50. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (See page IR-55) 51. INSTALL REAR DOOR SCUFF PLATE LH (See page IR-56) 52. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH (See page IR-56) 53. INSTALL REAR DOOR SCUFF PLATE RH (See page IR-56) 54. INSTALL FRONT SEAT ASSEMBLY LH (for Power Seat) (See page SE-41) 55. INSTALL SEAT TRACK COVER RH (for Power Seat) (See page SE-42) 56. INSTALL SEAT TRACK COVER LH (for Power Seat) (See page SE-42) 57. INSTALL FRONT SEAT HEADREST ASSEMBLY (for Power Seat) 58. INSTALL FRONT SEAT ASSEMBLY RH (for Power Seat) HINT: Use the same procedures for the RH side and the LH side. 59. INSTALL SEAT TRACK COVER LH (for Power Seat) HINT: Use the same procedures for the RH side and the LH side. 60. INSTALL SEAT TRACK COVER RH (for Power Seat) HINT: Use the same procedures for the RH side and the LH side. 61. INSTALL FRONT SEAT HEADREST ASSEMBLY (for Power Seat) 62. INSTALL FRONT SEAT ASSEMBLY LH (for Manual Seat) (See page SE-24) RS RS–426 SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY 63. INSTALL INNER SEAT TRACK BRACKET COVER LH (for Manual Seat) (See page SE-25) 64. INSTALL SEAT TRACK COVER LH (for Manual Seat) (See page SE-25) 65. INSTALL FRONT SEAT HEADREST ASSEMBLY (for Manual Seat) 66. INSTALL FRONT SEAT ASSEMBLY RH (for Manual Seat) HINT: Use the same procedures for the RH side and the LH side. 67. INSTALL INNER SEAT TRACK BRACKET COVER RH (for Manual Seat) HINT: Use the same procedures for the RH side and the LH side. 68. INSTALL SEAT TRACK COVER RH (for Manual Seat) HINT: Use the same procedures for the RH side and the LH side. 69. REMOVE FRONT SEAT HEADREST ASSEMBLY (for Manual Seat) 70. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL RS 71. PERFORM ZERO POINT CALIBRATION AND SENSITIVITY CHECK HINT: (See page RS-242) 72. INSPECT SRS WARNING LIGHT (a) Inspect the SRS warning light (See page RS-222). 73. INSPECT FRONT SEAT ASSEMBLY (for Power Seat) (See page SE-42) 74. INSPECT SLIDE ADJUSTER LOCK (for Manual Seat) SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY RS–427 DISPOSAL HINT: When scrapping a vehicle equipped with the SRS or disposing of the curtain shield airbag assembly, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: • Never dispose of a curtain shield airbag assembly that has an undeployed airbag. • The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents. • When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. • When deploying the airbag, perform the operation at least 10 m (33 ft) away from the curtain shield airbag assembly. • The curtain shield airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. • Use gloves and safety glasses when handling a curtain shield airbag assembly with a deployed airbag. • Do not apply water, etc. to a curtain shield airbag assembly with a deployed airbag. • Always wash your hands with water after completing the operation. 1. SST C110371E01 DISPOSE OF CURTAIN SHIELD AIRBAG ASSEMBLY (WHEN INSTALLED IN VEHICLE) HINT: Prepare a battery as the power source to deploy the airbag. (a) Check the function of the SST (See page RS-353). (b) Precaution (See page RS-1). (c) Disconnect the cable from the negative battery terminal. CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment. (d) Remove the roof headlining assembly (See page IR-22). (e) Install the SST. (1) Disconnect the connector from the curtain shield airbag assembly. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. RS RS–428 SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY (2) After connecting the SST below to each other, connect them to the curtain shield airbag assembly. SST 09082-00700, 09082-00802 (0908210801, 09082-20801) NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. SST SST C132560E01 Battery SST 10 m (33 ft) or more C110501E01 (f) RS 2. (3) Move the SST at least 10 m (33 ft) away from the vehicle rear side window. (4) Maintaining enough clearance for the SST wire harness in the rear side window, close all doors and windows of the vehicle. NOTICE: Take care not to damage the SST wire harness. (5) Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the battery negative (-) terminal. Deploy the airbag. (1) Check that no one is inside the vehicle or within a 10 m (33 ft) radius of the vehicle. (2) Press the SST activation switch and deploy the airbag. CAUTION: • When deploying the airbag, make sure that no one is near the vehicle. • The curtain shield airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. • Use gloves and safety glasses when handling a curtain shield airbag assembly with a deployed airbag. • Do not apply water, etc. to a curtain shield airbag assembly with a deployed airbag. • Always wash your hands with water after completing the operation. HINT: The airbag is deployed as the LED of the SST activation switch comes on. DISPOSE OF CURTAIN SHIELD AIRBAG ASSEMBLY (WHEN NOT INSTALLED IN VEHICLE) NOTICE: • When disposing of the curtain shield airbag assembly, never use the customer's vehicle to deploy the airbag. • Be sure to follow the procedure detailed below when deploying the airbag. SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY RS–429 HINT: Prepare a battery as the power source to deploy the airbag. (a) Check the function of the SST (See page RS-353). (b) Remove the curtain shield airbag assembly (See page RS-416). CAUTION: When removing the curtain shield airbag assembly, work must be started 90 seconds after the ignition switch is turned off and the negative (-) terminal cable is disconnected from the battery. SST C110371E01 (c) Cut off the deployment section of the curtain shield airbag assembly. C106890 Wire Harness Diameter Stripped Wire Harness Section B104882E02 (d) Using a service-purpose wire harness for the vehicle, tie down the curtain shield airbag assembly to the tire. Wire harness: Stripped wire harness section 1.25 mm2 or more (0.0019 in.2 or more) CAUTION: If the wire harness is too thin or an alternative object is used to tie down the curtain shield airbag assembly, it may be snapped by the shock when the airbag is deployed. Always use a wire harness for vehicle use with an area of at least 1.25 mm2 (0.0019 in.2). HINT: To calculate the area of the stripped wire harness section: Area = 3.14 x (Diameter)2 divided by 4 (1) Position the curtain shield airbag assembly inside the tire as shown in the illustration. Tire size: Must exceed the following dimensions Width: 185 mm (7.28 in.) Inner diameter: 360 mm (14.17 in.) Width Inner Diameter C106892E02 RS RS–430 SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY CAUTION: Make sure that the wire harness is tight. If there is slack in the wire harness, the curtain shield airbag assembly may become loose due to the shock when the airbag is deployed. NOTICE: The tire will be marked by the airbag deployment, so use an extra tire. SST C106891E01 Tire (2 or more) Tire RS (2 or more) (e) Install the SST. (1) After connecting the SST below to each other, connect them to the curtain shield airbag assembly. SST 09082-00802 (09082-10801, 0908220801) (f) Place the tires. CAUTION: Do not place the deployment direction of the curtain shield airbag assembly facing toward the ground. (1) Place at least 2 tires under the tire which the curtain shield airbag assembly is tied to. (2) Place at least 2 tires over the tire which the curtain shield airbag assembly is tied to. The top tire should have the disc wheel installed. NOTICE: Do not place the SST connector under the tire because it could be damaged. C106894E01 (3) Tie the tires together with 2 wire harnesses. CAUTION: Make sure that the wire harness is tight. Looseness in the wire harness results in the tires coming free due to the shock when the airbag is deployed. B105087 SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY Curtain Shield Airbag Assembly SST Battery 10 m (33 ft) or more C106893E06 (g) Install the SST. (1) Connect the SST connector. SST 09082-00700 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the tire. (2) Move the SST at least 10 m (33 ft) away from the airbag tied down to the tire. (h) Deploy the airbag. (1) Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the battery negative (-) terminal. (2) Check that no one is within a 10 m (33 ft) radius of the tire which the curtain shield airbag assembly is tied to. (3) Press the SST activation switch and deploy the airbag. CAUTION: When deploying the airbag, make sure that no one is near the tire. HINT: The airbag is deployed as the LED of the SST activation switch comes on. (i) C106889 RS–431 Dispose of the curtain shield airbag assembly. CAUTION: • The curtain shield airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. • Use gloves and safety glasses when handling a curtain shield airbag assembly with a deployed airbag. • Do not apply water, etc. to a curtain shield airbag assembly with a deployed airbag. • Always wash your hands with water after completing the operation. (1) Remove the curtain shield airbag assembly from the tire. (2) Place the curtain shield airbag assembly in a plastic bag, tie it tightly and dispose of it as other general part disposal. RS RS–432 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT SEAT SIDE AIRBAG ASSEMBLY FRONT SEAT SIDE AIRBAG ASSEMBLY ON-VEHICLE INSPECTION 1. FRONT SEAT SIDE AIRBAG ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (See page RS32). (b) With the front seat side airbag assembly installed on the vehicle, perform a visual check. If there are any defects as mentioned below, replace the front seat assembly with a new one: Cuts, minute cracks or marked discoloration on the front seatback assembly around the front seat side airbag assembly. 2. C133879 RS C133880 FRONT SEAT SIDE AIRBAG ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check (See page RS32). (b) With the front seat side airbag assembly removed from the vehicle, perform a visual check. If there are any defects as mentioned below, replace the front seat side airbag assembly with a new one: • Cuts, minute cracks or marked discoloration on the front seat side airbag assembly. • Cracks or other damage to the wire harness or connector. CAUTION: Be sure to follow the correct removal and installation procedures. SUPPLEMENTAL RESTRAINT SYSTEM – FRONT SEAT SIDE AIRBAG ASSEMBLY RS–433 DISPOSAL HINT: When scrapping a vehicle equipped with the SRS or disposing of the front seat side airbag assembly, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: • Never dispose of a front seat side airbag assembly that has an undeployed airbag. • The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents. • When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. • When deploying the airbag, perform the operation at least 10 m (33 ft) away from the front seat side airbag assembly. • The front seat side airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. • Use gloves and safety glasses when handling a front seat side airbag assembly with a deployed airbag. • Do not apply water, etc. to a front seat side airbag assembly with a deployed airbag. • Always wash your hands with water after completing the operation. 1. SST C110371E01 DISPOSE OF FRONT SEAT SIDE AIRBAG ASSEMBLY (WHEN INSTALLED IN VEHICLE) HINT: Prepare a battery as the power source to deploy the airbag. (a) Check the function of the SST (See page RS-353). (b) Precaution (See page RS-1). (c) Disconnect the cable from the negative battery terminal. CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment. (d) Remove the front seat assembly (See page SE-16 for Manual Seat, SE-30 for Power Seat). (e) Install the SST. (1) Disconnect the connector (yellow colored one) from the front seat side airbag assembly. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. RS RS–434 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT SEAT SIDE AIRBAG ASSEMBLY (2) Connect the SST connector to the front seat side airbag assembly connector. SST 09082-00700, 09082-00750 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. (3) Install the front seat assembly (See page SE24 for Manual Seat, SE-41 for Power Seat). SST C133881E01 Battery SST 10 m (33 ft) or more C110476E07 (f) RS 2. (4) Move the SST at least 10 m (33 ft) away from the vehicle front side window. (5) Maintaining enough clearance for the SST wire harness in the front side window, close all doors and windows of the vehicle. NOTICE: Take care not to damage the SST wire harness. (6) Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the battery negative (-) terminal. Deploy the airbag. (1) Check that no one is inside the vehicle or within a 10 m (33 ft) radius of the vehicle. (2) Press the SST activation switch and deploy the airbag. CAUTION: • When deploying the airbag, make sure that no one is near the vehicle. • The front seat side airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. • Use gloves and safety glasses when handling a front seat side airbag assembly with a deployed airbag. • Do not apply water, etc. to a front seat side airbag assembly with a deployed airbag. • Always wash your hands with water after completing the operation. HINT: The airbag is deployed as the LED of the SST activation switch comes on. DISPOSE OF FRONT SEAT SIDE AIRBAG ASSEMBLY (WHEN NOT INSTALLED IN VEHICLE) NOTICE: • When disposing of the front seat side airbag assembly, never use the customer's vehicle to deploy the airbag. • Be sure to follow the procedure detailed below when deploying the airbag. SUPPLEMENTAL RESTRAINT SYSTEM – FRONT SEAT SIDE AIRBAG ASSEMBLY RS–435 HINT: Prepare a battery as the power source to deploy the airbag. SST C110371E01 Wire Harness Diameter Stripped Wire Harness Section B104882E02 (a) Check the function of the SST (See page RS-355). (b) Remove the front seat side airbag assembly. (1) Remove the front seat assembly (See page SE-16 for Manual Seat, SE-30 for Power Seat). (2) Remove the 2 nuts and the front seat side airbag assembly from the seatback assembly (See page SE-17 for Manual Seat, SE-31 for Power Seat). CAUTION: • When removing the front seat side airbag assembly, work must be started 90 seconds after the ignition switch is turned off and the negative (-) terminal cable is disconnected from the battery. • When storing the front seat side airbag assembly, keep the airbag deployment side facing upward. (c) Using a service-purpose wire harness for the vehicle, tie down the front seat side airbag assembly to the tire. Wire harness: Stripped wire harness section 1.25 mm2 or more (0.0019 in.2 or more) HINT: To calculate the area of the stripped wire harness section: Area = 3.14 x (Diameter)2 divided by 4 CAUTION: If the wire harness is too thin or an alternative object is used to tie down the front seat side airbag assembly, it may be snapped by the shock when the airbag is deployed. Always use a wire harness for vehicle use with an area of at least 1.25 mm2 (0.0019 in.2). (1) Install the 2 nuts to the front seat side airbag assembly. C133882 RS RS–436 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT SEAT SIDE AIRBAG ASSEMBLY (2) Wind the wire harness around the stud bolts of the front seat side airbag assembly as shown in the illustration. C133896 Width Inner Diameter C C107072E03 RS (3) Position the front seat side airbag assembly inside the tire . Tire size: Must exceed the following dimensions Width: 185 mm (7.28 in.) Inner diameter: 360 mm (14.17 in.) CAUTION: • Make sure that the wire harness is tight. If there is slack in wire harness, the front seat side airbag assembly may become loose due to the shock when the airbag is deployed. • Always tie down the front seat side airbag assembly with the airbag deployment direction facing inside the tire. NOTICE: The tire will be marked by the airbag deployment, so use an extra tire. (d) Install the SST. (1) Connect the SST connector to the front seat side airbag assembly connector. SST 09082-00750 SST C C107073E01 Tire (2 or more) Tire (2 or more) C C107074E01 (e) Place the tires. (1) Place at least 2 tires under the tire which the front seat side airbag assembly is tied to. (2) Place at least 2 tires over the tire which the front seat side airbag assembly is tied to. The top tire should have the disc wheel installed. NOTICE: Do not place the SST connector under the tire because it could be damaged. SUPPLEMENTAL RESTRAINT SYSTEM – FRONT SEAT SIDE AIRBAG ASSEMBLY RS–437 (3) Tie the tires together with 2 wire harnesses. CAUTION: Make sure that the wire harness is tight. Looseness in the wire harness results in the tires coming free due to the shock when the airbag is deployed. B105087 (f) Front Seat Airbag Assembly Battery SST 10 m (33 ft) or more C C107075E01 H000544 Install the SST. (1) Connect the SST connector. SST 09082-00700 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the tire. (2) Move the SST at least 10 m (33 ft) away from the airbag tied down to the tire. (g) Deploy the airbag. (1) Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the battery negative (-) terminal. (2) Check that no one is within a 10 m (33 ft) radius of the tire which the front seat side airbag assembly is tied to. (3) Press the SST activation switch and deploy the airbag. CAUTION: When deploying the airbag, make sure that no one is near the tire. HINT: The airbag is deployed as the LED of the SST activation switch comes on. (h) Dispose of the front seat side airbag assembly. CAUTION: • The front seat side airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. • Use gloves and safety glasses when handling a front seat side airbag assembly with a deployed airbag. • Do not apply water, etc. to a front seat side airbag assembly with a deployed airbag. • Always wash your hands with water after completing the operation. (1) Remove the front seat side airbag assembly from the tire. RS RS–438 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT SEAT SIDE AIRBAG ASSEMBLY (2) Place the front seat side airbag assembly in a plastic bag, tie it tightly and dispose of it as other general part disposal. RS RS–438 SUPPLEMENTAL RESTRAINT SYSTEM – CENTER AIRBAG SENSOR ASSEMBLY CENTER AIRBAG SENSOR ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM RESTRAINTS COMPONENTS for Automatic Transaxle: SHIFT LEVER KNOB SUB-ASSEMBLY FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY UPPER CONSOLE REAR PANEL SUB-ASSEMBLY UPPER CONSOLE PANEL SUB-ASSEMBLY RS SHIFT LEVER KNOB SUB-ASSEMBLY UPPER CONSOLE PANEL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH UPPER CONSOLE REAR PANEL SUB-ASSEMBLY NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH C133911E01 SUPPLEMENTAL RESTRAINT SYSTEM – CENTER AIRBAG SENSOR ASSEMBLY RS–439 LOWER INSTRUMENT PANEL SUB-ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL LH INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY COWL SIDE TRIM SUB-ASSEMBLY RH RS COWL SIDE TRIM CLIP COWL SIDE TRIM SUB-ASSEMBLY LH FRONT DOOR SCUFF PLATE RH COWL SIDE TRIM CLIP FRONT DOOR SCUFF PLATE LH C142023E02 RS–440 SUPPLEMENTAL RESTRAINT SYSTEM – CENTER AIRBAG SENSOR ASSEMBLY CONSOLE BOX POCKET NO. 2 CONSOLE BOX INSERT FRONT NO. 1 CONSOLE BOX INSERT FRONT CONSOLE BOX CARPET 17.5 (179, 13) CENTER AIRBAG SENSOR ASSEMBLY CONSOLE BOX ASSEMBLY RS for Automatic Air Conditioning System: NO. 1 CONSOLE BOX DUCT CONSOLE BOX ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C133912E01 SUPPLEMENTAL RESTRAINT SYSTEM – CENTER AIRBAG SENSOR ASSEMBLY RS–441 ON-VEHICLE INSPECTION 1. INSPECT CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (See page RS32). 2. INSPECT CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check (See page RS32). 3. INSPECT CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the center airbag sensor assembly. CAUTION: Be sure to follow the correct removal and installation procedures. HINT: The center airbag sensor assembly should be replaced after any of the airbags has deployed, as it has been subjected to the impact. RS RS–442 SUPPLEMENTAL RESTRAINT SYSTEM – CENTER AIRBAG SENSOR ASSEMBLY REMOVAL RS 1. PRECAUTION CAUTION: Be sure to read "PRECAUTION" thoroughly before servicing (See page RS-1). 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment. 3. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-24) 4. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) (See page IP-24) 5. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-24) 6. REMOVE NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-25) 7. REMOVE FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-25) 8. REMOVE UPPER CONSOLE PANEL (for Manual Transaxle) (See page IP-25) 9. REMOVE UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Automatic Transaxle) (See page IP26) 10. REMOVE UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Manual Transaxle) (See page IP-26) 11. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (See page IP-27) 12. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-24) 13. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-25) 14. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (See page IP-20) 15. REMOVE FRONT DOOR SCUFF PLATE RH (See page IR-26) 16. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH (See page IR-26) 17. REMOVE INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY (See page IP-23) 18. REMOVE LOWER INSTRUMENT PANEL SUBASSEMBLY (See page IP-23) 19. REMOVE CONSOLE BOX POCKET (See page IP-28) SUPPLEMENTAL RESTRAINT SYSTEM – CENTER AIRBAG SENSOR ASSEMBLY RS–443 20. REMOVE CONSOLE BOX CARPET (See page IP-28) 21. REMOVE CONSOLE BOX ASSEMBLY (See page IP28) 22. REMOVE NO. 1 CONSOLE BOX INSERT FRONT (See page IP-30) 23. REMOVE NO. 2 CONSOLE BOX INSERT FRONT (See page IP-29) 24. REMOVE NO. 1 CONSOLE BOX DUCT (for Automatic Air Conditioning System) (See page AC-154) 25. REMOVE CENTER AIRBAG SENSOR ASSEMBLY (a) Turn back the carpet. (b) Disconnect the holder (with connectors). (c) Remove the 3 bolts and center airbag sensor assembly. C133884 RS RS–444 SUPPLEMENTAL RESTRAINT SYSTEM – CENTER AIRBAG SENSOR ASSEMBLY INSTALLATION 1. (c) Install the center airbag sensor assembly with the 3 bolts. Torque: 17.5 N*m (179 kgf*cm, 13 ft.*lbf) NOTICE: • If the center airbag sensor assembly has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. • When installing the center airbag sensor assembly, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the center airbag sensor assembly. (e) Connect the holder (with connectors). (f) Check that the water-proof sheet is properly set. Water-proof Sheet C133884E01 RS INSTALL CENTER AIRBAG SENSOR ASSEMBLY (a) Check that the ignition switch is off. (b) Check that the battery negative (-) cable is disconnected. CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment. 2. INSTALL NO. 1 CONSOLE BOX DUCT (for Automatic Air Conditioning System) (See page AC-177) 3. INSTALL NO. 2 CONSOLE BOX INSERT FRONT (See page IP-50) 4. INSTALL NO. 1 CONSOLE BOX INSERT FRONT (See page IP-49) 5. INSTALL CONSOLE BOX ASSEMBLY (See page IP51) 6. INSTALL CONSOLE BOX CARPET (See page IP-51) 7. INSTALL CONSOLE BOX POCKET (See page IP-51) 8. INSTALL LOWER INSTRUMENT PANEL SUBASSEMBLY (See page IP-55) 9. INSTALL INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY (See page IP-56) 10. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH (See page IR-55) 11. INSTALL FRONT DOOR SCUFF PLATE RH (See page IR-55) 12. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (See page IP-58) 13. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-54) SUPPLEMENTAL RESTRAINT SYSTEM – CENTER AIRBAG SENSOR ASSEMBLY RS–445 14. INSTALL FRONT DOOR SCUFF PLATE LH (See page IR-54) 15. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (See page IP-52) 16. INSTALL UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Manual Transaxle) (See page IP-53) 17. INSTALL UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Automatic Transaxle) (See page IP53) 18. INSTALL UPPER CONSOLE PANEL (for Manual Transaxle) (See page IP-54) 19. INSTALL FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-53) 20. INSTALL NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-54) 21. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-55) 22. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) (See page IP-55) 23. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-55) 24. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 25. INSPECT SRS WARNING LIGHT (a) Inspect the SRS warning light (See page RS-32). RS SUPPLEMENTAL RESTRAINT SYSTEM – FRONT AIRBAG SENSOR RS–445 FRONT AIRBAG SENSOR SUPPLEMENTAL RESTRAINT SYSTEM RESTRAINTS COMPONENTS ENGINE UNDER COVER RH RS FRONT AIRBAG SENSOR 17.5 (179, 13) ENGINE UNDER COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque C133885E01 RS–446 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT AIRBAG SENSOR ON-VEHICLE INSPECTION RS 1. INSPECT FRONT AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (See page RS32). 2. INSPECT FRONT AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check (See page RS32). (b) When the front bumper of the vehicle or its area is damaged, check if there is any damage to the front airbag sensor. If there are any defects as mentioned below, replace the front airbag sensor with a new one: • Cracks, dents or chips on the sensor housing. • Cracks or other damage to the connector. • Peeling off of the label or damage to the serial number. CAUTION: Be sure to follow the correct removal and installation procedures. 3. INSPECT FRONT AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the front airbag sensor. CAUTION: Be sure to follow the correct removal and installation procedures. HINT: The front airbag sensor on the impacted side should be replaced after the steering pad, front passenger airbag assembly or driver side knee airbag assembly has deployed. SUPPLEMENTAL RESTRAINT SYSTEM – FRONT AIRBAG SENSOR RS–447 REMOVAL HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. PRECAUTION CAUTION: Be sure to read "PRECAUTION" thoroughly before servicing (See page RS-1). 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment. 3. REMOVE ENGINE UNDER COVER RH 4. REMOVE ENGINE UNDER COVER LH 5. REMOVE FRONT AIRBAG SENSOR (a) Remove the bolt and front airbag sensor from the body. (b) Disconnect the connector from the front airbag sensor. RS C133886 RS–448 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT AIRBAG SENSOR INSTALLATION HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. INSTALL FRONT AIRBAG SENSOR (a) Check that the ignition switch is off. (b) Check that the battery negative (-) cable is disconnected. CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment. (c) Connect the connector. (d) Install the front airbag sensor with the bolt. Torque: 17.5 N*m (179 kgf*cm, 13 ft.*lbf) NOTICE: • If the front airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. • When installing the front airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (e) Check that there is no looseness in the installation parts of the front airbag sensor. RS C133886 2. INSTALL ENGINE UNDER COVER LH 3. INSTALL ENGINE UNDER COVER RH 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 5. INSPECT SRS WARNING LIGHT (a) Inspect the SRS warning light (See page RS-32). RS–448 SUPPLEMENTAL RESTRAINT SYSTEM – SIDE AIRBAG SENSOR SIDE AIRBAG SENSOR SUPPLEMENTAL RESTRAINT SYSTEM RESTRAINTS COMPONENTS REAR DOOR OPENING TRIM WEATHERSTRIP FRONT DOOR OPENING TRIM WEATHERSTRIP RS 9.0 (92, 80 in.*lbf) REAR DOOR SCUFF PLATE FRONT DOOR SCUFF PLATE LOWER CENTER PILLAR GARNISH SIDE AIRBAG SENSOR N*m (kgf*cm, ft.*lbf) : Specified torque C133887E01 SUPPLEMENTAL RESTRAINT SYSTEM – SIDE AIRBAG SENSOR RS–449 ON-VEHICLE INSPECTION 1. INSPECT SIDE AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (See page RS32). 2. INSPECT SIDE AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check (See page RS32). (b) When the center pillar of the vehicle or its area is damaged, check if there is any damage to the side airbag sensor. If there are any defects as mentioned below, replace the side airbag sensor with a new one: • Cracks, dents or chips on the sensor housing. • Cracks or other damage to the connector. • Peeling off of the label or damage to the serial number. CAUTION: Be sure to follow the correct removal and installation procedures. 3. INSPECT SIDE AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the side airbag sensor. CAUTION: Be sure to follow the correct removal and installation procedures. HINT: The side airbag sensor on the impacted side should be replaced after the front seat side airbag assembly and curtain shield airbag assembly have deployed. RS RS–450 SUPPLEMENTAL RESTRAINT SYSTEM – SIDE AIRBAG SENSOR REMOVAL HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. RS C133888 1. PRECAUTION CAUTION: Be sure to read "PRECAUTION" thoroughly before servicing (See page RS-1). 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTICE: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment. 3. REMOVE FRONT DOOR SCUFF PLATE (See page IR24) 4. REMOVE REAR DOOR SCUFF PLATE (See page IR24) 5. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP 6. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP 7. REMOVE LOWER CENTER PILLAR GARNISH (See page IR-25) 8. REMOVE SIDE AIRBAG SENSOR (a) Remove the bolt and side airbag sensor from the body. (b) Disconnect the connector from the side airbag sensor. SUPPLEMENTAL RESTRAINT SYSTEM – SIDE AIRBAG SENSOR RS–451 INSTALLATION HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. INSTALL SIDE AIRBAG SENSOR (a) Check that the ignition switch is off. (b) Check that the battery negative (-) cable is disconnected. CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment. (c) Install the side airbag sensor with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) NOTICE: • If the side airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. • When installing the side airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the side airbag sensor. (e) Connect the connector. C133888 2. INSTALL LOWER CENTER PILLAR GARNISH (See page IR-53) 3. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP 4. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP 5. INSTALL REAR DOOR SCUFF PLATE (See page IR56) 6. INSTALL FRONT DOOR SCUFF PLATE (See page IR54) 7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 8. INSPECT SRS WARNING LIGHT (a) Inspect the SRS warning light (See page RS-32). RS RS–452 SUPPLEMENTAL RESTRAINT SYSTEM – REAR AIRBAG SENSOR REAR AIRBAG SENSOR SUPPLEMENTAL RESTRAINT SYSTEM RESTRAINTS COMPONENTS for Fold Down Seat Type: ROOF SIDE INNER GARNISH REAR SIDE SEAT BACK ASSEMBLY 18 (184, 13) 9.0 (92, 80 in.*lbf) RS REAR AIRBAG SENSOR REAR SEAT CUSHION ASSEMBLY REAR DOOR OPENING TRIM WEATHERSTRIP REAR DOOR SCUFF PLATE N*m (kgf*cm, ft.*lbf) : Specified torque C133907E01 SUPPLEMENTAL RESTRAINT SYSTEM – REAR AIRBAG SENSOR RS–453 for Reclining Seat Type: RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY 18 (184, 13) 9.0 (92, 80 in.*lbf) REAR AIRBAG SENSOR RS BENCH TYPE REAR SEAT CUSHION ASSEMBLY REAR DOOR OPENING TRIM WEATHERSTRIP REAR DOOR SCUFF PLATE N*m (kgf*cm, ft.*lbf) : Specified torque C133909E01 RS–454 SUPPLEMENTAL RESTRAINT SYSTEM – REAR AIRBAG SENSOR for Fixed Seat Type: REAR SEAT HEADREST ASSEMBLY REAR SEAT HEADREST ASSEMBLY CENTER REAR SEATBACK ASSEMBLY 18 (184, 13 ) RS 9.0 (92, 80 in.*lbf) 18 (184, 13 ) REAR SEAT CUSHION ASSEMBLY REAR AIRBAG SENSOR N*m (kgf*cm, ft.*lbf) : Specified torque C133908E01 SUPPLEMENTAL RESTRAINT SYSTEM – REAR AIRBAG SENSOR RS–455 ON-VEHICLE INSPECTION 1. INSPECT REAR AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (See page RS32). 2. INSPECT REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check (See page RS32). (b) When the quarter panel of the vehicle or its area is damaged, check if there is any damage to the rear airbag sensor. If there are any defects as mentioned below, replace the rear airbag sensor with a new one: • Cracks, dents or chips on the sensor housing. • Cracks or other damage to the connector. • Peeling off of the label or damage to the serial number. CAUTION: Be sure to follow the correct removal and installation procedures. 3. INSPECT REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the rear airbag sensor. CAUTION: Be sure to follow the correct removal and installation procedures. HINT: The rear airbag sensor on the impacted side should be replaced after the curtain shield airbag assembly has deployed. RS RS–456 SUPPLEMENTAL RESTRAINT SYSTEM – REAR AIRBAG SENSOR REMOVAL HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. RS 1. PRECAUTION CAUTION: Be sure to read "PRECAUTION" thoroughly before servicing (See page RS-1). 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTICE: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment. 3. REMOVE REAR SEAT CUSHION ASSEMBLY (for Fold Down Seat Type) (See page SE-47) 4. REMOVE BENCH TYPE REAR SEAT CUSHION ASSEMBLY (for Reclining Seat Type) (See page SE62) 5. REMOVE REAR SEAT CUSHION ASSEMBLY (for Fixed Seat Type) (See page SE-77) 6. REMOVE REAR DOOR SCUFF PLATE (for Fold Down Seat Type) (See page IR-24) 7. REMOVE REAR DOOR SCUFF PLATE (for Reclining Seat Type) (See page IR-24) 8. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP (for Fold Down Seat Type) 9. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP (for Reclining Seat Type) 10. REMOVE ROOF SIDE INNER GARNISH (for Fold Down Seat Type) (See page IR-26) 11. REMOVE REAR SIDE SEAT BACK ASSEMBLY (for Fold Down Seat Type) (See page SE-48) 12. REMOVE RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY (for Reclining Seat Type) (See page SE-68) 13. REMOVE REAR SEAT HEADREST ASSEMBLY (for Fixed Seat Type) 14. REMOVE REAR SEAT HEADREST ASSEMBLY CENTER (for Fixed Seat Type) 15. REMOVE REAR SEATBACK ASSEMBLY (for Fixed Seat Type) (See page SE-77) SUPPLEMENTAL RESTRAINT SYSTEM – REAR AIRBAG SENSOR RS–457 16. REMOVE REAR AIRBAG SENSOR (a) Disconnect the connector. (b) Remove the bolt and rear airbag sensor. C133889 RS RS–458 SUPPLEMENTAL RESTRAINT SYSTEM – REAR AIRBAG SENSOR INSTALLATION 1. (c) Install the rear airbag sensor with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) NOTICE: • If the rear airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. • When installing the rear airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the rear airbag sensor. (e) Connect the connector. C133889 RS INSTALL REAR AIRBAG SENSOR (a) Check that the ignition switch is off. (b) Check that the battery negative (-) cable is disconnected. CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment. 2. INSTALL REAR SEATBACK ASSEMBLY (for Fixed Seat Type) (See page SE-84) 3. INSTALL REAR SEAT HEADREST ASSEMBLY CENTER (for Fixed Seat Type) 4. INSTALL REAR SEAT HEADREST ASSEMBLY (for Fixed Seat Type) 5. INSTALL RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY (for Reclining Seat Type) (See page SE-69) 6. INSTALL REAR SIDE SEAT BACK ASSEMBLY (for Fold Down Seat Type) (See page SE-57) 7. INSTALL ROOF SIDE INNER GARNISH (for Fold Down Seat Type) (See page IR-52) 8. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP (for Reclining Seat Type) 9. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP (for Fold Down Seat Type) 10. INSTALL REAR DOOR SCUFF PLATE (for Reclining Seat Type) (See page IR-56) 11. INSTALL REAR DOOR SCUFF PLATE (for Fold Down Seat Type) (See page IR-56) 12. INSTALL REAR SEAT CUSHION ASSEMBLY (for Fixed Seat Type) (See page SE-84) 13. INSTALL BENCH TYPE REAR SEAT CUSHION ASSEMBLY (for Reclining Seat Type) (See page SE73) SUPPLEMENTAL RESTRAINT SYSTEM – REAR AIRBAG SENSOR RS–459 14. INSTALL REAR SEAT CUSHION ASSEMBLY (for Fold Down Seat Type) (See page SE-58) 15. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 16. INSPECT SRS WARNING LIGHT (a) Inspect the SRS warning light (See page RS-32). RS RS–458 SUPPLEMENTAL RESTRAINT SYSTEM – SEAT POSITION SENSOR SEAT POSITION SENSOR SUPPLEMENTAL RESTRAINT SYSTEM RESTRAINTS COMPONENTS for Manual Seat: INNER SEAT TRACK BRACKET COVER LH 37 (377, 27) FRONT SEAT HEADREST ASSEMBLY FRONT SEAT ASSEMBLY LH 37 (377, 27) SEAT TRACK COVER LH RS FRONT SEAT CUSHION SHIELD 37 (377, 27) VERTICAL ADJUSTING HANDLE VERTICAL ADJUSTER COVER RECLINING ADJUSTER RELEASE HANDLE SEAT POSITION SENSOR 8.0 (82, 71 in.*lbf) SEAT SLIDE POSITION SENSOR PROTECTOR N*m (kgf*cm, ft.*lbf) : Specified torque C133899E01 RS–459 SUPPLEMENTAL RESTRAINT SYSTEM – SEAT POSITION SENSOR for Power Seat: SEAT TRACK COVER RH FRONT SEAT HEADREST ASSEMBLY 37 (377, 27) SEAT SLIDE POSITION SENSOR PROTECTOR 8.0 (82, 71 in.*lbf) SEAT POSITION SENSOR 37 (377, 27) 37 (377, 27) SEAT TRACK COVER LH FRONT SEAT ASSEMBLY LH 37 (377, 27) N*m (kgf*cm, ft.*lbf) : Specified torque C133890E01 RS RS–460 SUPPLEMENTAL RESTRAINT SYSTEM – SEAT POSITION SENSOR ON-VEHICLE INSPECTION RS 1. INSPECT SEAT POSITION SENSOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (See page RS32). 2. INSPECT SEAT POSITION SENSOR (VEHICLE INVOLVED IN COLLISION) (a) Perform a diagnostic system check (See page RS32). (b) Even if the airbag was not deployed, check if there is any damage to the seat position sensor. If there are any defects as mentioned below, replace the seat position sensor with a new one: • Cracks, dents or chips on the sensor housing. • Cracks or other damage to the connector. CAUTION: Be sure to follow the correct removal and installation procedures. SUPPLEMENTAL RESTRAINT SYSTEM – SEAT POSITION SENSOR RS–461 REMOVAL 1. PRECAUTION CAUTION: Be sure to read "PRECAUTION" thoroughly before servicing (See page RS-1). 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (for Manual Seat) NOTICE: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment. 3. REMOVE FRONT SEAT HEADREST ASSEMBLY (for Manual Seat) 4. REMOVE FRONT SEAT HEADREST ASSEMBLY (for Power Seat) 5. REMOVE SEAT TRACK COVER LH (for Manual Seat) (See page SE-16) 6. REMOVE SEAT TRACK COVER LH (for Power Seat) (See page SE-30) 7. REMOVE INNER SEAT TRACK BRACKET COVER LH (for Manual Seat) (See page SE-16) 8. REMOVE SEAT TRACK COVER RH (for Power Seat) (See page SE-30) 9. REMOVE FRONT SEAT ASSEMBLY LH (for Manual Seat) (See page SE-16) 10. REMOVE FRONT SEAT ASSEMBLY LH (for Power Seat) (See page SE-30) 11. REMOVE VERTICAL ADJUSTER COVER (for Manual Seat) (See page SE-17) 12. REMOVE VERTICAL ADJUSTING HANDLE (for Manual Seat) (See page SE-17) 13. REMOVE RECLINING ADJUSTER RELEASE HANDLE (for Manual Seat) (See page SE-18) 14. REMOVE FRONT SEAT CUSHION SHIELD (for Manual Seat) (See page SE-18) RS RS–462 SUPPLEMENTAL RESTRAINT SYSTEM – SEAT POSITION SENSOR 15. REMOVE SEAT POSITION SENSOR (for Manual Seat) (a) Disconnect the connector. (b) Using a "torx" socket wrench (T30), remove the "torx" screw and seat position sensor with the seat slide position sensor protector. C133900 (c) Remove the seat position sensor from the seat slide position sensor protector as shown in the illustration. RS C133901 16. REMOVE SEAT POSITION SENSOR (for Power Seat) (a) Disconnect the connector. (b) Using a "torx" socket wrench (T30), separate the "torx" screw and seat position sensor with the seat slide position sensor protector. C133891 SUPPLEMENTAL RESTRAINT SYSTEM – SEAT POSITION SENSOR RS–463 (c) Remove the seat position sensor from the seat slide position sensor protector as shown in the illustration. C133892 RS RS–464 SUPPLEMENTAL RESTRAINT SYSTEM – SEAT POSITION SENSOR INSTALLATION 1. INSTALL SEAT POSITION SENSOR (for Power Seat) (a) Check that the ignition switch is off. (b) Check that the negative battery (-) cable is disconnected. CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment. (c) Engage the pin and install the seat position sensor to the seat slide position sensor protector as shown in the illustration. RS C133893 Seat Position Sensor Feeler Gauge 1.5 mm (0.059 in.) Seat Rail C107067E03 (d) Using a feeler gauge 1.5 mm (0.059 in.), temporarily install the seat position sensor. NOTICE: • If the seat position sensor has been dropped, or there are any cracks, dents or other defects in the case or connector, replace the seat position sensor with a new one. • When installing the seat position sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. HINT: Be sure that a clearance between the seat position sensor and the seat rail is within 1.1 mm (0.043 in.) to 1.9 mm (0.075 in.). SUPPLEMENTAL RESTRAINT SYSTEM – SEAT POSITION SENSOR RS–465 (e) Using a "torx" socket wrench (T30), tighten the "torx" screw to install the seat position sensor. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (f) Make sure that a clearance between the seat position sensor and the seat rail is within 1.1 mm (0.043 in.) to 1.9 mm (0.075 in.). (g) Check that there is no looseness in the installation parts of the seat position sensor. (h) Connect the connector. 2. INSTALL SEAT POSITION SENSOR (for Manual Seat) (a) Check that the ignition switch is off. (b) Check that the negative battery (-) cable is disconnected. CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment. C133891 (c) Engage the pin and install the seat position sensor to the seat slide position sensor protector as shown in the illustration. RS C133902 Seat Position Sensor 1.5 mm (0.059 in.) Seat Rail C125585E04 (d) Using a feeler gauge 1.5 mm (0.059 in.), temporarily install the seat position sensor. NOTICE: • If the seat position sensor has been dropped, or there are any cracks, dents or other defects in the case or connector, replace the seat position sensor with a new one. RS–466 SUPPLEMENTAL RESTRAINT SYSTEM – SEAT POSITION SENSOR • When installing the seat position sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. HINT: Be sure that a clearance between the seat position sensor and the seat rail is within 1.1 mm (0.043 in.) to 1.9 mm (0.075 in.). (e) Using a "torx" socket wrench (T30), tighten the "torx" screw to install the seat position sensor. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (f) Make sure that a clearance between the seat position sensor and the seat rail is within 1.1 mm (0.043 in.) to 1.9 mm (0.075 in.). (g) Check that there is no looseness in the installation parts of the seat position sensor. (h) Connect the connector. RS 3. INSTALL FRONT SEAT CUSHION SHIELD (for Manual Seat) 4. INSTALL RECLINING ADJUSTER RELEASE HANDLE (for Manual Seat) 5. INSTALL VERTICAL ADJUSTING HANDLE (for Manual Seat) 6. INSTALL VERTICAL ADJUSTER COVER (for Manual Seat) 7. INSTALL FRONT SEAT ASSEMBLY LH (for Power Seat) (See page SE-41) 8. INSTALL FRONT SEAT ASSEMBLY LH (for Manual Seat) (See page SE-24) 9. INSTALL SEAT TRACK COVER RH (for Power Seat) (See page SE-42) C133900 10. INSTALL INNER SEAT TRACK BRACKET COVER LH (for Manual Seat) (See page SE-25) 11. INSTALL SEAT TRACK COVER LH (for Power Seat) (See page SE-42) 12. INSTALL SEAT TRACK COVER LH (for Manual Seat) (See page SE-25) 13. INSTALL FRONT SEAT HEADREST ASSEMBLY (for Power Seat) 14. INSTALL FRONT SEAT HEADREST ASSEMBLY (for Manual Seat) 15. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (for Manual Seat) 16. INSPECT POWER SEAT OPERATION (for Power Seat) 17. INSPECT SLIDE ADJUSTER LOCK (for Manual Seat) SUPPLEMENTAL RESTRAINT SYSTEM – SEAT POSITION SENSOR RS–467 18. INSPECT SEAT HEATER OPERATION (w/ Seat Heater System) (See page SE-42) 19. INSPECT SRS WARNING LIGHT (a) Inspect the SRS warning light (See page RS-32). RS SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION ECU RS–467 OCCUPANT CLASSIFICATION ECU SUPPLEMENTAL RESTRAINT SYSTEM RESTRAINTS COMPONENTS for Manual Seat: SEAT TRACK COVER RH FRONT SEAT HEADREST ASSEMBLY 37 (377, 27) FRONT SEAT ASSEMBLY RH 37 (377, 27) 37 (377, 27) RS INNER SEAT TRACK BRACKET COVER RH 37 (377, 27) OCCUPANT CLASSIFICATION ECU N*m (kgf*cm, ft.*lbf) : Specified torque C133894E01 RS–468 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION ECU for Power Seat: FRONT SEAT HEADREST ASSEMBLY SEAT TRACK COVER RH FRONT SEAT ASSEMBLY RH 37 (377, 27) RS 37 (377, 27) 37 (377, 27) 37 (377, 27) SEAT TRACK COVER LH OCCUPANT CLASSIFICATION ECU N*m (kgf*cm, ft.*lbf) : Specified torque C138924E01 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION ECU RS–469 ON-VEHICLE INSPECTION 1. INSPECT OCCUPANT CLASSIFICATION ECU (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (See page RS248). 2. INSPECT OCCUPANT CLASSIFICATION ECU (VEHICLE INVOLVED IN COLLISION) (a) Perform a diagnostic system check (See page RS248). (b) Even if the airbag was not deployed, check if there is any damage to the occupant classification ECU. If there are any defects as mentioned below, replace the occupant classification ECU with a new one: • Cracks, dents or chips on the case. • Cracks or other damage to the connector. CAUTION: Be sure to follow the correct removal and installation procedures. RS RS–470 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION ECU REMOVAL RS 1. PRECAUTION CAUTION: Be sure to read "PRECAUTION" thoroughly before servicing (See page RS-1). 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (for Manual Seat) CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment. 3. REMOVE FRONT SEAT HEADREST ASSEMBLY (for Manual Seat) 4. REMOVE FRONT SEAT HEADREST ASSEMBLY (for Power Seat) 5. REMOVE SEAT TRACK COVER RH (for Manual Seat) (See page SE-16) 6. REMOVE SEAT TRACK COVER RH (for Power Seat) (See page SE-30) 7. REMOVE INNER SEAT TRACK BRACKET COVER RH (for Manual Seat) (See page SE-16) 8. REMOVE SEAT TRACK COVER LH (for Power Seat) (See page SE-30) 9. REMOVE FRONT SEAT ASSEMBLY RH (for Manual Seat) (See page SE-16) 10. REMOVE FRONT SEAT ASSEMBLY RH (for Power Seat) (See page SE-30) 11. REMOVE OCCUPANT CLASSIFICATION ECU (a) Disconnect the connector from the occupant classification ECU. (b) Using a screwdriver, disengage the claw and remove the occupant classification ECU. C133895 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION ECU RS–471 INSTALLATION 1. INSTALL OCCUPANT CLASSIFICATION ECU (a) Check that the ignition switch is off. (b) Check that the negative battery (-) cable is disconnected. CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment. (c) Engage the claw. (d) Connect the connector and install the occupant classification ECU. NOTICE: • If the occupant classification ECU has been dropped, or there are any cracks, dents or other defects in the case or connector, replace the occupant classification ECU with a new one. • When installing the occupant classification ECU, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. 2. INSTALL FRONT SEAT ASSEMBLY RH (for Power Seat) (See page SE-41) 3. INSTALL FRONT SEAT ASSEMBLY RH (for Manual Seat) (See page SE-24) 4. INSTALL SEAT TRACK COVER LH (for Power Seat) (See page SE-25) 5. INSTALL INNER SEAT TRACK BRACKET COVER RH (for Manual Seat) (See page SE-25) 6. INSTALL SEAT TRACK COVER RH (for Power Seat) (See page SE-42) 7. INSTALL SEAT TRACK COVER RH (for Manual Seat) (See page SE-25) 8. INSTALL FRONT SEAT HEADREST ASSEMBLY (for Power Seat) 9. INSTALL FRONT SEAT HEADREST ASSEMBLY (for Manual Seat) C133903 10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (for Manual Seat) 11. PERFORM ZERO POINT CALIBRATION AND SENSITIVITY CHECK HINT: (See page RS-242) 12. INSPECT POWER SEAT OPERATION (for Power Seat) 13. INSPECT SLIDE ADJUSTER LOCK (for Manual Seat) RS RS–472 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION ECU 14. INSPECT SEAT HEATER OPERATION (w/ Seat Heater System) (See page SE-42) 15. INSPECT SRS WARNING LIGHT (a) Inspect the SRS warning light (See page RS-32). RS MX–1 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE SYSTEM MANUAL TRANSAXLE SYSTEM PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the ranked order of probability of each of the possible causes. Check each part in order. Replace parts as necessary. Manual transaxle system (MTM) Symptom Noise Oil leakage Hard to shift or will not shift Jumps out of gear Suspected area See page 1. Oil (Level low) MX-2 2. Oil (Wrong) MX-2 3. Gear (Worn or damaged) MX-54 - MX-79 - MX-89 4. Bearing (Worn or damaged) MX-40 - MX-79 - MX-89 1. Oil (Level too high) MX-2 2. Gasket (Damaged) MX-40 3. Oil seal (Worn or damaged) MX-5 - MX-99 4. O-Ring (Worn or damaged) MX-40 1. Control cable assembly MX-13 2. Synchronizer ring (Worn or damaged) MX-54 - MX-79 - MX-89 3. Shift key spring (Damaged) MX-40 - MX-77 - MX-87 1. Locking ball spring (Damaged) MX-40 2. Shift fork (Worn) MX-54 - MX-79 - MX-89 3. Gear (Worn or damaged) MX-54 - MX-79 - MX-89 4. Bearing (Worn or damaged) MX-40 - MX-79 - MX-89 MX MX–2 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE OIL MANUAL TRANSAXLE OIL ON-VEHICLE INSPECTION 1. 0 to 5 mm (0 to 0.20 in.) MX D025304E01 INSPECT MANUAL TRANSAXLE OIL (a) Stop the vehicle on a level surface. (b) Remove the transmission filler plug and gasket. (c) Check that the oil surface is within 5 mm (0.20 in.) of the bottom of the transmission filler plug opening. NOTICE: • Excessively large or small amounts of oil may cause trouble. • After replacing the oil, drive the vehicle and check the oil level again. HINT: Insert your finger into the filler plug hole. You should be able to just touch the surface of the oil if the oil is at the correct level. (d) Check for oil leakage if the oil level is low. (e) Install the transmission filler plug and a new gasket. Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) E351 MANUAL TRANSAXLE – DIFFERENTIAL OIL SEAL MX–3 DIFFERENTIAL OIL SEAL E351 MANUAL TRANSAXLE TRANSMISSION COMPONENTS DRIVE SHAFT BEARING BRACKET HOLE SNAP RING 64 (653, 47) x3 DRIVE SHAFT BEARING BRACKET MX 64 (653, 47) FRONT DRIVE SHAFT ASSEMBLY RH FRONT DRIVE INNER SHAFT OUTER LH SHAFT SNAP RING 32 (330, 24) DRIVE SHAFT BEARING BRACKET SETTING NO. 1 BOLT FRONT DRIVE SHAFT ASSEMBLY LH TIE ROD END SUB-ASSEMBLY FRONT SPEED SENSOR FRONT STABILIZER LINK ASSEMBLY 19 (192, 14) 8.0 (82, 71 in.*lbf) 74 (755, 55) 294 (3,000, 217) FRONT AXLE HUB NUT FRONT SUSPENSION LOWER NO. 1 ARM 49 (500, 36) COTTER PIN 75 (765, 55) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C135412E01 MX–4 E351 MANUAL TRANSAXLE – DIFFERENTIAL OIL SEAL MX MANUAL TRANSAXLE FRONT TRANSAXLE CASE COVER OIL SEAL Non-reusable part TRANSAXLE CASE OIL SEAL Apply MP grease C135407E01 E351 MANUAL TRANSAXLE – DIFFERENTIAL OIL SEAL MX–5 REMOVAL HINT: • Use the same procedures for the RH side (transaxle case oil seal) and LH side (transaxle case cover oil seal). • The procedures listed below are for the LH side (transaxle case cover oil seal). 1. DRAIN MANUAL TRANSAXLE OIL (a) Remove the filler plug and the gasket. (b) Remove the drain plug and gasket, and drain the manual transaxle oil. (c) Install a new gasket and the drain plug. Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) 2. REMOVE FRONT WHEELS 3. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH TMC made: (See page DS-7). TMMK made: (See page DS-25). 4. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH HINT: Use the same procedures described for the LH side. 5. REMOVE FRONT TRANSAXLE CASE COVER OIL SEAL (a) Using SST, remove the oil seal. SST 09308-00010 6. REMOVE TRANSAXLE CASE OIL SEAL (a) Using SST, remove the oil seal. SST 09308-00010 SST D026285E01 SST D025305E01 INSTALLATION 1. SST D025722E02 INSTALL FRONT TRANSAXLE CASE COVER OIL SEAL (a) Coat a new oil seal lip with MP grease. (b) Using SST and a hammer, install the oil seal. SST 09608-10010, 09950-70010 (09951-07200) Installation depth: -0.5 to 0.5 mm (-0.020 to 0.020 in.) NOTICE: Be careful not to damage the oil seal lip. MX MX–6 E351 MANUAL TRANSAXLE – DIFFERENTIAL OIL SEAL 2. INSTALL TRANSAXLE CASE OIL SEAL (a) Coat a new oil seal lip with MP grease. (b) Using SST and a hammer, install the oil seal. SST 09608-32010, 09950-70010 (09951-07200) Installation depth: 3.0 to 4.0 mm (0.1181 to 0.1575 in.) NOTICE: Be careful not to damage the oil seal lip. 3. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH TMC made: (See page DS-20). TMMK made: (See page DS-34). 4. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH HINT: Use the same procedures described for the LH side. 5. INSTALL FRONT WHEELS Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 6. ADD MANUAL TRANSAXLE OIL (a) Park the vehicle on a level place. (b) Remove the filler plug and gasket. (c) Check that the oil surface is within 5 mm (0.20 in.) below the lowest point of the filler plug opening. Oil grade: API GL-4 or GL-5 Viscosity: SAE 75W-90 NOTICE: • Problems may occur if the oil level is too high or too low. • After replacing the oil, drive the vehicle and check the oil level again. (d) Check for oil leakage if the oil level is low. (e) Install the filler plug and a new gasket. Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) 7. INSPECT MANUAL TRANSAXLE OIL 8. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT See page SP-4. 9. CHECK ABS SPEED SENSOR SIGNAL See page BC-11. SST MX D026133E04 0 to 5 mm (0 to 0.20 in.) D025304E01 E351 MANUAL TRANSAXLE – FLOOR SHIFT LEVER ASSEMBLY MX–7 FLOOR SHIFT LEVER ASSEMBLY E351 MANUAL TRANSAXLE TRANSMISSION COMPONENTS MX SHIFT LEVER KNOB SUB-ASSEMBLY NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH UPPER CONSOLE PANEL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH UPPER CONSOLE REAR PANEL SUB-ASSEMBLY CLIP 12 (122, 9) 12 (122, 9) CLIP 12 (122, 9) TRANSMISSION CONTROL CABLE ASSEMBLY FLOOR SHIFT LEVER ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C130477E01 MX–8 E351 MANUAL TRANSAXLE – FLOOR SHIFT LEVER ASSEMBLY REMOVAL MX 1. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-24) 2. REMOVE NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-25) 3. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (See page IP-24) 4. REMOVE UPPER CONSOLE PANEL (See page IP-25) 5. REMOVE UPPER CONSOLE REAR PANEL SUBASSEMBLY (See page IP-26) 6. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (a) Remove the 2 clips and disconnect the end of the transmission control cable. C132951 (b) Pull out the control cable assembly locks. Lock C135402E01 E351 MANUAL TRANSAXLE – FLOOR SHIFT LEVER ASSEMBLY MX–9 (c) Turn the adjust nut 180° clockwise. While holding the adjust nut, separate the control cable assembly. MX C132953 7. REMOVE FLOOR SHIFT LEVER ASSEMBLY (a) Remove the 4 bolts and shift lever assembly. C132955 INSTALLATION 1. INSTALL FLOOR SHIFT LEVER ASSEMBLY (a) Install the shift lever assembly with the 4 bolts. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 2. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (a) Connect the control cable to the shift lever retainer. NOTICE: • The projecting part of the cable outer should face upward when the shift cable is connected. • After installation, make sure that the cable outer lock is projecting from A as shown in the illustration. C132955 Projecting Part Lock A C132954E01 MX–10 E351 MANUAL TRANSAXLE – FLOOR SHIFT LEVER ASSEMBLY (b) Connect the end of the shift cable to the shift lever assembly with the clip. (c) Connect the end of the select cable to the shift lever assembly with a new clip. NOTICE: • The serrated part of the select cable point should face upward when the select cable point is connected. • The clip should be installed in the direction as shown in the illustration. Serrated Part Select Cable MX Shift Cable C132951E01 3. INSTALL UPPER CONSOLE REAR PANEL SUBASSEMBLY (See page IP-53) 4. INSTALL UPPER CONSOLE PANEL (See page IP-53) 5. INSTALL NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-54) 6. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-55) 7. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (See page IP-55) MX–11 E351 MANUAL TRANSAXLE – TRANSMISSION CONTROL CABLE TRANSMISSION CONTROL CABLE E351 MANUAL TRANSAXLE TRANSMISSION COMPONENTS NO. 1 ENGINE COVER SUB-ASSEMBLY MX 9.0 (92, 80 in.*lbf) 7.0 (71, 62 in.*lbf) 3.5 (36, 31 in.*lbf) AIR CLEANER CAP SUB-ASSEMBLY 5.0 (51, 44 in.*lbf) BATTERY BATTERY CLAMP SUB-ASSEMBLY BATTERY TRAY AIR CLEANER INLET ASSEMBLY AIR CLEANER CASE SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C138374E01 MX–12 E351 MANUAL TRANSAXLE – TRANSMISSION CONTROL CABLE SHIFT LEVER KNOB SUB-ASSEMBLY MX NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH 18 (180, 13) NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH 5.0 (51, 44 in.*lbf) CENTER AIRBAG SENSOR ASSEMBLY UPPER CONSOLE PANEL UPPER CONSOLE REAR PANEL SUB-ASSEMBLY 12 (122, 9) CLIP 12 (122, 9) CLIP WASHER CLIP 12 (122, 9) NO. 2 SHIFT CABLE GROMMET RETAINER CLIP WASHER CLIP CLIP FLOOR SHIFT LEVER ASSEMBLY TRANSMISSION CONTROL CABLE ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C135395E01 E351 MANUAL TRANSAXLE – TRANSMISSION CONTROL CABLE MX–13 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-24) 3. REMOVE NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-25) 4. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (See page IP-24) 5. REMOVE UPPER CONSOLE PANEL (See page IP-25) 6. REMOVE UPPER CONSOLE REAR PANEL SUBASSEMBLY (See page IP-53) 7. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (a) Remove the 2 clips and disconnect the end of the transmission control cable. C132951 (b) Pull out the control cable assembly locks. (c) Turn the adjust nut 180° clockwise. While holding the adjust nut, separate the control cable assembly. Lock 8. REMOVE INSTRUMENT PANEL SAFETY PAD SUBASSEMBLY See page IP-20. 9. REMOVE AIR CONDITIONER UNIT ASSEMBLY See page AC-151. 10. REMOVE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-442) 11. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (See page EM-94) 12. REMOVE AIR CLEANER INLET ASSEMBLY (See page EM-94) 13. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-416) C135402E01 14. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (See page EM-95) 15. REMOVE BATTERY (See page EM-95) MX MX–14 E351 MANUAL TRANSAXLE – TRANSMISSION CONTROL CABLE 16. REMOVE TRANSMISSION CONTROL CABLE ASSEMBLY (a) Remove the 2 clips and 2 washers and disconnect the 2 cables from the transaxle. (b) Remove the 2 clips and disconnect the 2 cables from the control cable bracket. MX C132952 (c) Remove the 2 bolts and control cable assembly. (d) Remove the No. 2 shift cable grommet retainer from the control cable assembly. C135401 INSTALLATION 1. C135401 INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (a) Install the No. 2 shift cable grommet retainer to the transmission control cable assembly. (b) Install the control cable assembly through the floor hole. (c) Install the control cable assembly with the 2 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) (d) Connect the ends of the 2 cables and install the 2 washers and 2 clips. (e) Install 2 new clips to the control cable bracket. C132952 E351 MANUAL TRANSAXLE – TRANSMISSION CONTROL CABLE 2. Projecting Part Lock A MX–15 INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (a) Connect the control cable to the shift lever retainer. NOTICE: • The projecting part of the cable outer should face upward when the shift cable is connected. • After installation, make sure that the cable outer lock is projecting from A as shown in the illustration. C132954E01 (b) Connect the end of the shift cable to the shift lever assembly with the clip. (c) Connect the end of the select cable to the shift lever assembly with a new clip. NOTICE: • The serrated part of the select cable point should face upward when the select cable point is connected. • The clip should be installed in the direction as shown in the illustration. Serrated Part Select Cable Shift Cable C132951E01 3. INSTALL CENTER AIRBAG SENSOR ASSEMBLY (See page RS-442) 4. INSTALL AIR CONDITIONER UNIT ASSEMBLY See page AC-173. 5. INSTALL INSTRUMENT PANEL SAFETY PAD SUBASSEMBLY See page IP-43. 6. INSTALL UPPER CONSOLE REAR PANEL SUBASSEMBLY (See page IP-53) 7. INSTALL UPPER CONSOLE PANEL (See page IP-54) 8. INSTALL NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-54) 9. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-55) 10. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (See page IP-55) 11. INSTALL BATTERY (See page EM-119) MX MX–16 E351 MANUAL TRANSAXLE – TRANSMISSION CONTROL CABLE 12. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (See page EM-120) 13. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See page ES-419) 14. INSTALL AIR CLEANER INLET ASSEMBLY (See page EM-120) 15. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (See page EM-121) MX 16. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page EM-120) MX–24 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE ASSEMBLY REMOVAL MX 1. DISCHARGE FUEL SYSTEM PRESSURE See page FU-1. 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 4. REMOVE FRONT WHEELS 5. REMOVE ENGINE UNDER COVER LH 6. REMOVE ENGINE UNDER COVER RH 7. REMOVE FRONT FENDER APRON SEAL RH 8. DRAIN ENGINE OIL (See page LU-4) 9. DRAIN ENGINE COOLANT (See page CO-5) 10. DRAIN MANUAL TRANSAXLE OIL (See page MX-5) 11. DRAIN BRAKE FLUID (See page BR-28) 12. REMOVE WINDSHIELD WIPER MOTOR ASSEMBLY See page WW-9. 13. REMOVE COWL TOP PANEL OUTER SUBASSEMBLY (See page ES-424) 14. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (See page EM-94) 15. REMOVE V-RIBBED BELT (See page EM-6) 16. REMOVE AIR CLEANER INLET ASSEMBLY (See page EM-94) 17. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-416) 18. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (See page EM-95) 19. REMOVE BATTERY (See page EM-95) 20. REMOVE NO. 2 ENGINE MOUNTING STAY RH (See page EM-95) 21. REMOVE ENGINE MOVING CONTROL ROD SUBASSEMBLY (See page EM-95) 22. REMOVE NO. 2 ENGINE MOUNTING BRACKET RH (See page EM-96) 23. DISCONNECT NO. 1 VACUUM HOSE CONNECTOR (See page EM-96) 24. DISCONNECT RADIATOR HOSE INLET (See page EM-96) 25. DISCONNECT RADIATOR HOSE OUTLET (See page EM-96) 26. DISCONNECT HEATER INLET WATER HOSE (See page EM-97) E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE ASSEMBLY MX–25 27. DISCONNECT HEATER OUTLET WATER HOSE (See page EM-97) 28. REMOVE ECM See page ES-432. 29. DISCONNECT ENGINE WIRE (See page EM-97) 30. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (See page EM-98) 31. DISCONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE (See page EM-98) 32. DISCONNECT RETURN TUBE SUB-ASSEMBLY (See page EM-99) 33. REMOVE CLUTCH ACCUMULATOR ASSEMBLY See page CL-15. 34. REMOVE CLUTCH RELEASE CYLINDER ASSEMBLY See page CL-23. 35. DISCONNECT FUEL TUBE SUB-ASSEMBLY (See page EM-99) 36. REMOVE GENERATOR ASSEMBLY (See page CH-11) 37. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (See page EM-99) 38. REMOVE FRONT EXHAUST PIPE ASSEMBLY See page EX-2. 39. REMOVE FRONT AXLE HUB NUT LH (See page DS7) 40. REMOVE FRONT AXLE HUB NUT RH HINT: Use the same procedures described for the LH side. 41. REMOVE FRONT STABILIZER LINK ASSEMBLY LH (See page DS-7) 42. REMOVE FRONT STABILIZER LINK ASSEMBLY RH HINT: Use the same procedures described for the LH side. 43. REMOVE FRONT SPEED SENSOR LH (See page DS7) 44. REMOVE FRONT SPEED SENSOR RH HINT: Use the same procedures described for the LH side. 45. DISCONNECT TIE ROD ASSEMBLY LH (See page DS-8) 46. DISCONNECT TIE ROD ASSEMBLY RH 47. DISCONNECT FRONT SUSPENSION LOWER NO. 1 ARM LH (See page DS-8) MX MX–26 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE ASSEMBLY 48. DISCONNECT FRONT SUSPENSION LOWER NO. 1 ARM RH HINT: Use the same procedures described for the LH side. 49. SEPARATE FRONT AXLE ASSEMBLY LH (See page DS-8) 50. SEPARATE FRONT AXLE ASSEMBLY RH HINT: Use the same procedures described for the LH side. MX 51. SEPARATE STEERING SLIDING YOKE (See page PS40) 52. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (See page EM-100) 53. REMOVE VANE PUMP ASSEMBLY (See page EM101) 54. REMOVE FRONT FRAME ASSEMBLY (See page EM101) 55. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (See page DS-9) 56. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (See page DS-9) 57. REMOVE STARTER ASSEMBLY (See page ST-5) 58. DISCONNECT WIRE HARNESS (a) Remove the bolt and separate the ground cable. (b) Disconnect the back-up light switch connector. (c) Disconnect the wire harness. 59. REMOVE MANUAL TRANSAXLE ASSEMBLY (a) Remove the 10 bolts. (b) Separate and remove the transaxle from the engine. D025747 60. REMOVE CLUTCH LINE (a) Remove the 2 bolts, clutch line and bracket. C132979 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE ASSEMBLY MX–17 MANUAL TRANSAXLE ASSEMBLY E351 MANUAL TRANSAXLE TRANSMISSION COMPONENTS FRONT WIPER ARM AND BLADE ASSEMBLY RH 20 (204, 15) MX FRONT FENDER TO COWL SIDE SEAL RH FRONT WIPER ARM AND BLADE ASSEMBLY LH COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 7.5 (77, 66 in.*lbf) 85 (867, 63) FRONT FENDER TO COWL SIDE SEAL LH 5.0 (51, 44 in.*lbf) WINDSHIELD WIPER LINK ASSEMBLY COWL TOP PANEL OUTER SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque A136912E01 MX–18 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE ASSEMBLY ENGINE MOVING CONTROL ROD SUB-ASSEMBLY NO. 2 ENGINE MOUNTING BRACKET RH 64 (653, 47) 9.0 (92, 80 in.*lbf) MX 52 (531, 38) 64 (653, 47) NO. 1 ENGINE COVER SUB-ASSEMBLY NO. 2 ENGINE MOUNTING STAY RH V-RIBBED BELT 9.8 (100, 87 in.*lbf) 52 (531, 38) 21 (214, 15) GENERATOR ASSEMBLY FRONT FENDER APRON SEAL RH N*m (kgf*cm, ft.*lbf) : Specified torque A134948E01 MX–19 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE ASSEMBLY AIR CLEANER CAP SUB-ASSEMBLY MX AIR CLEANER CASE SUB-ASSEMBLY 5.0 (51, 44 in.*lbf) 5.0 (51, 44 in.*lbf) 9.0 (92, 80 in.*lbf) 3.5 (36, 31 in.*lbf) AIR CLEANER INLET ASSEMBLY BATTERY BATTERY TRAY ENGINE UNDER COVER RH R/B COVER ENGINE UNDER COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque A134915E01 MX–20 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE ASSEMBLY MX TRANSMISSION CONTROL CABLE ASSEMBLY CLIP WASHER CLIP 25 (250, 18) CLIP WASHER NO. 1 VACUUM HOSE CONNECTOR COMPRESSOR AND MAGNETIC CLUTCH NO. 1 OIL RESERVOIR TO PUMP HOSE HEATER INLET WATER HOSE RETURN TUBE SUB-ASSEMBLY RADIATOR HOSE OUTLET RADIATOR HOSE INLET N*m (kgf*cm, ft.*lbf) : Specified torque HEATER OUTLET WATER HOSE Non-reusable part C138377E01 MX–21 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE ASSEMBLY TIE ROD ASSEMBLY LH STEERING SLIDING YOKE MX 35 (357, 26) 74 (755, 55) 49 (500, 36) COTTER PIN 8.0 (82, 71 in.*lbf) FRONT SPEED SENSOR LH DRIVE SHAFT ASSEMBLY LH 294 (3,000, 217) FRONT AXLE HUB NUT LH 75 (755, 55) FRONT SUSPENSION LOWER NO. 1 ARM LH EXHAUST PIPE GASKET 56 (571, 41) EXHAUST PIPE GASKET 62 (633, 46) FRONT EXHAUST PIPE NO. 1 SUPPORT BRACKET 33 (337, 24) 33 (337, 24) REAR EXHAUST PIPE NO. 1 SUPPORT BRACKET FRONT EXHAUST PIPE ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C143322E01 MX–22 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE ASSEMBLY VANE PUMP ASSEMBLY 43 (439, 32) NO. 2 ENGINE MOUNTING BRACKET REAR 54 (551, 40) MX 89 (910, 66) 95 (969, 70) 64 (653, 47) ENGINE MOUNTING BRACKET RH 87 (888, 64) 143 (1,459, 105) FRONT FRAME ASSEMBLY FRAME SIDE RAIL PLATE SUBASSEMBLY RH 32 (326, 24) FRAME SUSPENSION MEMBER BRACE REAR RH 85 (867, 63) FRAME SIDE RAIL PLATE SUB-ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque FRAME SUSPENSION MEMBER BRACE REAR LH 32 (326, 24) 85 (867, 63) A109017E03 MX–23 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE ASSEMBLY CLUTCH TUBE CLIP WIRE HARNESS 12 (122, 9) 12 (122, 9) BRACKET 15 (155, 11) 7.0 (71, 62 in.*lbf) 8.4 (86, 74 in.*lbf) MX 12 (120, 9) 15 (155, 11) BRACKET 8.4 (86, 74 in.*lbf) 64 (653, 47) 12 (120, 9) x3 CLUTCH LINE 46 (470, 34) 15 (155, 11) WIRE HARNESS CLAMP x2 12 (120, 9) 12 (120, 9) HEAT INSULATOR CLUTCH RELEASE CYLINDER ASSEMBLY CLUTCH ACCUMULATOR ASSEMBLY MANUAL TRANSAXLE ASSEMBLY 18 (184, 13) MANUAL TRANSMISSION CASE PROTECTOR x4 46 (470, 34) 44 (449, 32) ENGINE MOUNTING FRONT BRACKET 64 (653, 47) x2 STARTER ASSEMBLY 39 (398, 29) ENGINE MOUNTING INSULATOR LH HOLE SNAP RING FRONT DRIVE SHAFT ASSEMBLY RH SNAP RING 64 (653, 47) 64 (653, 47) FRONT DRIVE SHAFT ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C132978E01 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE ASSEMBLY MX–27 61. REMOVE WIRE HARNESS CLAMP (a) Remove the 2 bolts and wire harness clamps. MX C132983 62. REMOVE MANUAL TRANSMISSION CASE PROTECTOR (a) Remove the 2 bolts and manual transmission case protector. C132980 63. REMOVE ENGINE MOUNTING FRONT BRACKET (a) Remove the 3 bolts and engine mounting front bracket. C132981 64. REMOVE ENGINE MOUNTING INSULATOR LH (a) Remove the 4 bolts and engine mounting insulator LH. C132982 INSTALLATION B 1. A C D C132982E01 INSTALL ENGINE MOUNTING INSULATOR LH (a) Install the engine mounting insulator LH with the 4 bolts. Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) HINT: Tighten the bolts in order: A, B, C and D. MX–28 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE ASSEMBLY MX 2. INSTALL ENGINE MOUNTING FRONT BRACKET (a) Install the engine mounting front bracket with the 3 bolts. Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) 3. INSTALL MANUAL TRANSMISSION CASE PROTECTOR (a) Install the manual transmission case protector with the 2 bolts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 4. INSTALL WIRE HARNESS CLAMP (a) Install the 2 wire harness clamps with the 2 bolts. Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) 5. INSTALL CLUTCH LINE (a) Install the clutch line and bracket with the 2 bolts. Torque: Bolt A 12 N*m (122 kgf*cm, 9 ft.*lbf) Bolt B 7.0 N*m (71 kgf*cm, 62 in.*lbf) 6. INSTALL MANUAL TRANSAXLE ASSEMBLY (a) Align the input shaft with the clutch disc and install the transaxle to the engine. C132981 C132980 C132983 B A C132979E01 A B E D C D025747E04 (b) Install the 10 bolts. Torque: Bolt A 64 N*m (653 kgf*cm, 47 ft.*lbf) Bolt B 46 N*m (470 kgf*cm, 34 ft.*lbf) Bolt C 44 N*m (449 kgf*cm, 32 ft.*lbf) Bolt D 46 N*m (470 kgf*cm, 34 ft.*lbf) Bolt E 64 N*m (653 kgf*cm, 47 ft.*lbf) E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE ASSEMBLY MX–29 Bolt length: Bolt A: 60 mm (2.3622 in.) Bolt B: 60 mm (2.3622 in.) Bolt C: 32 mm (1.2598 in.) Bolt D: 65 mm (2.5591 in.) Bolt E: 74.5 mm (2.9331 in.) 7. CONNECT WIRE HARNESS (a) Install the wire harness. (b) Connect the back-up light switch connector. (c) Install the ground cable with the bolt. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 8. INSTALL STARTER ASSEMBLY (See page ST-13) 9. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (See page DS-20) 10. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (See page DS-21) 11. INSTALL FRONT FRAME ASSEMBLY (See page EM112) 12. INSTALL VANE PUMP ASSEMBLY (See page EM-113) 13. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (See page EM-114) 14. INSTALL STEERING SLIDING YOKE (See page PS65) 15. INSTALL FRONT AXLE ASSEMBLY LH (See page DS21) 16. INSTALL FRONT AXLE ASSEMBLY RH HINT: Use the same procedures described for the LH side. 17. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM LH (See page DS-21) 18. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM RH HINT: Use the same procedures described for the LH side. 19. INSTALL TIE ROD ASSEMBLY LH (See page DS-21) 20. INSTALL TIE ROD ASSEMBLY RH HINT: Use the same procedures described for the LH side. 21. INSTALL FRONT SPEED SENSOR LH (See page DS21) MX MX–30 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE ASSEMBLY 22. INSTALL FRONT SPEED SENSOR RH HINT: Use the same procedures described for the LH side. 23. INSTALL FRONT STABILIZER LINK ASSEMBLY LH (See page DS-22) 24. INSTALL FRONT STABILIZER LINK ASSEMBLY RH HINT: Use the same procedures described for the LH side. MX 25. INSTALL FRONT AXLE HUB NUT LH (See page DS-7) 26. INSTALL FRONT AXLE HUB NUT RH HINT: Use the same procedures described for the LH side. 27. INSTALL FRONT EXHAUST PIPE ASSEMBLY See page EX-3. 28. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (See page EM-115) 29. INSTALL GENERATOR ASSEMBLY (See page CH-19) 30. CONNECT FUEL TUBE SUB-ASSEMBLY (See page EM-115) 31. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY See page CL-25. 32. INSTALL CLUTCH ACCUMULATOR ASSEMBLY See page CL-29. 33. CONNECT RETURN TUBE SUB-ASSEMBLY (See page EM-116) 34. CONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE (See page EM-116) 35. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (See page EM-116) 36. CONNECT ENGINE WIRE (See page EM-117) 37. INSTALL ECM See page ES-433. 38. CONNECT HEATER INLET WATER HOSE (See page EM-117) 39. CONNECT HEATER OUTLET WATER HOSE (See page EM-118) 40. CONNECT OIL COOLER INLET HOSE (See page CO30) 41. CONNECT OIL COOLER OUTLET HOSE (See page CO-30) 42. CONNECT RADIATOR HOSE INLET (See page EM118) 43. CONNECT RADIATOR HOSE OUTLET (See page EM118) E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE ASSEMBLY MX–31 44. CONNECT NO. 1 VACUUM HOSE CONNECTOR (See page EM-118) 45. INSTALL NO. 2 ENGINE MOUNTING BRACKET RH (See page EM-118) 46. INSTALL ENGINE MOVING CONTROL ROD SUBASSEMBLY (See page EM-119) 47. INSTALL NO. 2 ENGINE MOUNTING STAY RH (See page EM-119) 48. INSTALL BATTERY (See page EM-119) 49. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (See page EM-120) 50. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-419) 51. INSTALL AIR CLEANER INLET ASSEMBLY (See page EM-120) 52. INSTALL V-RIBBED BELT (See page EM-6) 53. INSTALL COWL TOP PANEL OUTER SUBASSEMBLY (See page ES-426) 54. INSTALL WINDSHIELD WIPER LINK ASSEMBLY See page WW-13. 55. INSTALL FRONT WHEEL (See page EM-120) 56. ADD ENGINE OIL 57. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page EM-120) 58. BLEED CLUTCH LINE (See page CL-25) 59. ADD ENGINE COOLANT (See page CO-5) 60. ADD MANUAL TRANSAXLE OIL (See page MX-6) 61. ADD POWER STEERING FLUID 62. BLEED POWER STEERING FLUID (See page PS-7) 63. CHECK FOR FUEL LEAKS (See page FU-9) 64. CHECK FOR ENGINE OIL LEAKS 65. CHECK FOR ENGINE COOLANT LEAKS (See page CO-1) 66. CHECK FOR EXHAUST GAS LEAKS 67. ADJUST FRONT WHEEL ALIGNMENT See page SP-4. 68. CHECK IGNITION TIMING (See page EM-1) 69. CHECK ENGINE IDLE SPEED (See page EM-2) 70. INSPECT CO/HC (See page EM-3) 71. INSTALL FRONT FENDER APRON SEAL RH 72. INSTALL ENGINE UNDER COVER LH MX MX–32 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE ASSEMBLY 73. INSTALL ENGINE UNDER COVER RH 74. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (See page EM-121) 75. CHECK ABS SPEED SENSOR SIGNAL See page BC-11. MX MX–33 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MANUAL TRANSAXLE UNIT E351 MANUAL TRANSAXLE TRANSMISSION COMPONENTS 5.5 (56, 48 in.*lbf) CLUTCH RELEASE FORK SUB-ASSEMBLY 29 (296, 21) FRONT TRANSAXLE CASE OIL SEAL MX SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY O-RING MANUAL TRANSAXLE CASE RECEIVER CLUTCH RELEASE BEARING ASSEMBLY 47 (480, 35) RELEASE FORK SUPPORT 7.0 (71, 62 in.*lbf) MANUAL TRANSAXLE CASE CLUTCH RELEASE FORK BOOT TRANSMISSION MAGNET 17 (173, 13) CLUTCH RELEASE BEARING HUB CLIP OUTPUT SHAFT COVER NO. 1 CLUTCH TUBE BRACKET OUTPUT SHAFT FRONT BEARING FRONT TRANSAXLE CASE COVER OIL SEAL INPUT SHAFT FRONT BEARING N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Apply MP grease Precoated part C138366E01 MX–34 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT FRONT DIFFERENTIAL OIL BAFFLE MX OUTER RACE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING DIFFERENTIAL CASE ASSEMBLY FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING OUTER RACE FRONT DIFFERENTIAL CASE REAR SHIM TRANSMISSION CASE OIL SEAL Non-reusable part Apply MP grease C138367E01 MX–35 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT REVERSE SHIFT FORK SHIFT FORK SHAFT SHAFT SNAP RING SHIFT FORK SHAFT SHAFT SNAP RING MX NO. 1 GEAR SHIFT FORK SHAFT 24 (245, 18) SHIFT FORK SET BOLT 17 (173, 13) REVERSE SHIFT ARM BRACKET ASSEMBLY NO. 1 GEAR SHIFT FORK NO. 2 GEAR SHIFT FORK SHAFT SHIFT FORK SHAFT SHAFT SNAP RING SHIFT FORK SHAFT SHAFT SNAP RING NO. 1 GEAR SHIFT HEAD 24 (245, 18) REVERSE SHIFT FORK ROLLER SHIFT HEAD SET BOLT NO. 3 GEAR SHIFT FORK SHAFT NO. 3 GEAR SHIFT FORK 24 (245, 18) 24 (245, 18) SHIFT FORK SET BOLT SHIFT FORK SET BOLT NO. 2 GEAR SHIFT FORK N*m (kgf*cm, ft.*lbf) : Specified torque Precoated part C138368E01 MX–36 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT 20 (204, 15) CONTROL SHAFT COVER MX GASKET SHIFT AND SELECT LEVER SHAFT ASSEMBLY 6.4 (65, 57 in.*lbf) CONTROL SHIFT LEVER SPRING WASHER SHIFT OUTER LEVER LOCK PIN SHIFT AND SELECT LEVER BUSHING 20 (204, 15) SELECTING BELLCRANK ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Precoated part C135435E01 MX–37 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT 40 (408, 30) BACK-UP LIGHT SWITCH ASSEMBLY MX 29 (296, 21) SHIFT GATE PIN 29 (296, 21) 13 (133, 9.6) NO. 1 LOCK BALL ASSEMBLY GASKET REVERSE RESTRICT PIN PLUG MANUAL TRANSMISSION BREATHER PLUG TRANSMISSION OIL BAFFLE REVERSE RESTRICT PIN ASSEMBLY 17 (173, 13) MANUAL TRANSMISSION CASE 17 (173, 13) NO. 2 OIL RECEIVER PIPE x14 GASKET 17 (173, 13) NO. 1 OIL RECEIVER PIPE 29 (296, 21) GASKET 29 (296, 21) 49 (500, 36) 49 (500, 36) DRAIN PLUG SUB-ASSEMBLY x10 MANUAL TRANSMISSION FILLER PLUG MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Precoated part C135408E01 MX–38 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MX INPUT SHAFT ASSEMBLY OUTPUT SHAFT ASSEMBLY OUTPUT SHAFT REAR BEARING (OUTER RACE) OUTPUT SHAFT REAR BEARING SHIM REVERSE IDLER GEAR SUB-ASSEMBLY REVERSE IDLER GEAR SHAFT REVERSE IDLER THRUST WASHER 30 (306, 22) REVERSE IDLER GEAR SHAFT GASKET REVERSE IDLER GEAR SHAFT BOLT N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Precoated part C138369E01 MX–39 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MX 43 (438, 32) REAR BEARING RETAINER x7 5TH GEAR NEEDLE ROLLER BEARING INNER SHAFT REAR BEARING SHAFT SNAP RING 5TH GEAR 5TH DRIVEN GEAR 123 (1,254, 90) MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT NO. 3 SYNCHROMESH SHIFTING KEY SPRING NO. 5 SYNCHRONIZER RING INNER NO. 5 SYNCHRONIZER RING MIDDLE NO. 5 SYNCHRONIZER RING OUTER SYNCHRONIZER PULL RING SYNCHRONIZER PULL RING SNAP RING NO. 3 SYNCHROMESH SHIFTING KEY SPRING NO. 3 TRANSMISSION CLUTCH HUB NO. 3 TRANSMISSION HUB SLEEVE TRANSMISSION CLUTCH HUB NO. 3 SHAFT SNAP RING N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Precoated part C138370E01 MX–54 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT INSPECTION MX 1. INSPECT 5TH GEAR THRUST CLEARANCE (a) Using a dial indicator, inspect the 5th gear thrust clearance. Standard clearance: 0.10 to 0.65 mm (0.0039 to 0.0256 in.) If clearance is out of specification, replace the No. 3 transmission clutch hub, 5th gear, or input shaft rear radial ball bearing. 2. INSPECT 5TH GEAR RADIAL CLEARANCE (a) Using a dial indicator, inspect the 5th gear radial clearance. Standard clearance: 0.009 to 0.050 mm (0.0004 to 0.0020 in.) If clearance is out of specification, replace the 5th gear, 5th gear needle roller bearing, or input shaft. 3. INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY (a) Using a caliper gauge, measure the inside diameter of the reverse idler gear. Inside diameter: mm (in.) C069517 C069516 Standard inside diameter Maximum inside diameter 20.056 to 20.074 (0.7896 to 0.7903) 20.074 (0.7903) If the inside diameter exceeds the maximum, replace the reverse idler gear. C069503 (b) Using a micrometer, measure the outside diameter of the reverse idler gear shaft. Outside diameter: mm (in.) Standard outside diameter Minimum outside diameter 19.984 to 20.000 (0.7868 to 0.7874) 19.984 (0.7868) If the outside diameter is less than the minimum, replace the reverse idler gear shaft. C069505 4. C069509 INSPECT NO. 3 TRANSMISSION CLUTCH HUB (a) Inspect the sliding condition between the No. 3 transmission clutch hub and the No. 3 transmission hub sleeve. (b) Inspect the tip of the spline gear on the No. 3 transmission hub sleeve for wear. MX–55 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT 5. A INSPECT NO. 3 TRANSMISSION HUB SLEEVE (a) Using vernier calipers, measure the width of the No. 3 transmission hub sleeve groove and the thickness of the claw part on the No. 3 gear shift fork, and calculate the clearance. Standard clearance: 0.15 to 0.35 mm (0.0059 to 0.0138 in.) {A - B} If clearance is out of specification, replace the No. 3 transmission hub sleeve and No. 3 gear shift fork with new ones. Clearance= (A-B) B C070509E03 6. INSPECT 5TH GEAR (a) Using a caliper gauge, measure the inside diameter of the 5th gear. Inside diameter mm (in.) Standard inside diameter Maximum inside diameter 34.981 to 34.997 (1.3772 to 1.3778) 34.997 (1.3778) If the inside diameter exceeds the maximum, replace the 5th gear. C069768 7. INSPECT NO. 5 SYNCHRONIZER RING MIDDLE (a) Check that the No. 5 synchronizer ring middle rotates smoothly. C069510 (b) Check that the No. 5 synchronizer ring middle does not rotate while being pushed against the No. 3 clutch hub. C069511 MX MX–56 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT REASSEMBLY MX 1. INSTALL SYNCHRONIZER PULL RING (a) Install the No. 5 synchronizer middle ring, No. 5 synchronizer ring outer, and synchronizer pull ring to the No. 5 synchronizer ring inner. Using a screwdriver, fix them with the snap ring. 2. INSTALL NO. 3 SYNCHROMESH SHIFTING KEY SPRING (a) Install the No. 3 synchromesh shifting key spring to the No. 3 transmission clutch hub. NOTICE: Align the projection of the shifting key spring with the No. 3 hole of the clutch hub. (b) Install the synchronizer ring set and No. 3 synchromesh shifting key spring to the No. 3 transmission clutch hub. NOTICE: • Engage the shifting key spring claw to the center of the teeth of the synchronizer ring. • Align the projection of the shifting key spring with the hole of the No. 3 clutch hub. 3. INSTALL FRONT TRANSAXLE CASE COVER OIL SEAL (a) Using SST and a hammer, install a new front transaxle case cover oil seal. SST 09316-20011, 09950-60020 (09951-00910), 09950-70010 (09951-07150) Oil seal installation depth: - 0.5 to 0.5 mm (- 0.020 to 0.020 in.) (b) Coat the front transaxle case cover oil seal lip with MP grease. 4. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING (a) Using SST and a hammer, install the front differential case front tapered roller bearing (outer race) to the front transaxle case. SST 09950-60020 (09951-00910), 09950-70010 (09951-07100) C069514 C069515 SST C087990E03 SST C087991E02 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MX–57 (b) Using SST and a press, install the front differential case front tapered roller bearing (inner race) to the front differential case. SST 09950-70010 (09951-07100, 09951-07150), 09608-10010 SST MX C070823E02 5. SST INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING (a) Install the front differential case shim rear. (b) Using SST and a hammer, install the front differential case rear tapered roller bearing (outer race). SST 09950-60020 (09951-00890), 09950-70010 (09951-07100) C087992E02 (c) Using SST and a press, install the front differential case rear tapered roller bearing (inner race). SST 09631-12090, 09950-60010 (09951-00600), 09950-70010 (09951-07100) SST C090204E06 6. INSTALL TRANSMISSION CASE OIL SEAL (a) Using SST and a hammer, install a transmission case oil seal to the manual transmission case. SST 09608-32010, 09950-70010 (09951-07150) Oil seal installation depth: 3.0 to 4.0 mm (0.1181 to 0.1575 in.) (b) Coat the transmission case oil seal lip with MP grease. 7. INSTALL OUTPUT SHAFT REAR BEARING (a) Using SST and a hammer, install the output shaft rear bearing (outer race) to the manual transmission case. SST 09950-60020 (09951-00680), 09950-70010 (09951-07100) Clearance: 3.8 to 4.4 mm (0.150 to 0.173 in.) SST C087993E02 SST C087994E02 MX–58 MX E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT 8. INSTALL OUTPUT SHAFT COVER (a) Coat the output shaft cover with MP grease, and install it to the manual transaxle case. NOTICE: Align the projection of the output shaft with the transmission groove. 9. INSTALL OUTPUT SHAFT FRONT BEARING (a) Using SST and a hammer, install the output shaft front bearing (outer race). SST 09950-60020 (09951-00730), 09950-70010 (09951-07100) C069709 SST C087995E01 10. ADJUST OUTPUT SHAFT BEARING PRELOAD (a) Install the output shaft to the manual transaxle case. C083254 (b) Install the transmission case to the manual transaxle case with the 14 bolts. Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) C083227 (c) Install the 3 bolts to the manual transaxle case. Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) C083226 MX–59 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT (d) Install the output shaft rear bearing case shim to the output shaft. MX C083255 (e) Using a "TORX" socket wrench (T45), install the bearing retainer rear to the manual transmission case with the 7 screws. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) C083256 (f) Turn the output shaft in both directions to make sure that it starts to turn smoothly. (g) Using a socket wrench and torque wrench, inspect the preload. Preload: N*m (kgf*cm, in.*lbf) C069773 Bearing Preload New 0.8 to 1.6 (8.16 to 16.32, 7.1 to 14.2) Used 0.5 to 1.0 (5.10 to 10.20, 4.4 to 8.9) (h) If preload is out of specification, select a proper output shaft rear bearing shim and adjust it. HINT: The preload of all the output shaft rear bearing shim varies in torque from about 0.04 to 0.06 N*m (0.408 to 0.612 kgf*cm, 0.35 to 0.53 in.*lbf). Shim Part No. Thickness: mm (in.) Mark 90564-59001 1.30 (0.0512) 0 90564-59002 1.35 (0.0531) 1 90564-59003 1.40 (0.0551) 2 90564-59004 1.45 (0.0571) 3 90564-59005 1.50 (0.0591) 4 90564-59006 1.55 (0.0610) 5 90564-59007 1.60 (0.0630) 6 90564-59008 1.65 (0.0650) 7 90564-59009 1.70 (0.0669) 8 90564-59010 1.75 (0.0689) 9 90564-59011 1.80 (0.0709) A 90564-59012 1.85 (0.0728) B 90564-59013 1.90 (0.0748) C 90564-59014 1.95 (0.0768) D MX–60 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MX Part No. Thickness: mm (in.) Mark 90564-59015 2.00 (0.0787) E 90564-59016 2.05 (0.0807) F 90564-59017 2.10 (0.0827) G 90564-59018 2.15 (0.0846) H 90564-59019 2.20 (0.0866) J 90564-59020 2.25 (0.0886) K 90564-59021 2.30 (0.0906) L 90564-59022 2.35 (0.0925) M 90564-59023 2.40 (0.0945) N 90564-59024 2.45 (0.0965) P 90564-59025 2.50 (0.0984) Q (i) Remove the output shaft rear set nut from the output shaft. (j) Using a "TORX" socket wrench (T45), remove the 7 screws and bearing retainer rear from the manual transmission case. C083258 (k) Remove the output shaft rear bearing shim from the output shaft. C083255 (l) C083226 Remove the 3 bolts. E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MX–61 (m) Remove the 14 bolts and manual transmission case from the manual transaxle case. MX C083227 (n) Remove the output shaft assembly from the front manual transaxle case. C083254 11. ADJUST TAPERED ROLLER BEARING PRELOAD (a) Install the differential case assembly to the manual transaxle case. C083242 (b) Install the 14 bolts and manual transmission case to the manual transaxle case. Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) C083227 (c) Install the 3 bolts to the front manual transaxle case. Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) (d) Turn the differential case in both directions to make sure that it starts to turn smoothly. C083226 MX–62 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT (e) Using SST and a torque wrench, inspect preload. SST 09564-32011 Preload: N*m (kgf*cm, in.*lbf) SST MX Bearing Preload New 0.8 to 1.6 (8.16 to 16.32, 7.1 to 14.2) Used 0.5 to 1.0 (5.10 to 10.2, 4.4 to 8.9) If preload is out of specification, select a proper front differential case rear shim and adjust it. HINT: The preload of all the front differential case rear shims varies in torque from about 0.04 to 0.06 N*m (0.408 to 0.612 kgf*cm, 0.35 to 0.53 in.*lbf). Shim C087996E02 Part No. Thickness: mm (in.) Mark 90564-56055 2.00 (0.0787) 0 90564-56056 2.05 (0.0807) 1 90564-56057 2.10 (0.0827) 2 90564-56058 2.15 (0.0846) 3 90564-56059 2.20 (0.0866) 4 90564-56060 2.25 (0.0886) 5 90564-56061 2.30 (0.0906) 6 90564-56062 2.35 (0.0925) 7 90564-56063 2.40 (0.0945) 8 90564-56064 2.45 (0.0965) 9 90564-56065 2.50 (0.0984) A 90564-56066 2.55 (0.1004) B 90564-56067 2.60 (0.1024) C 90564-56068 2.65 (0.1043) D 90564-56069 2.70 (0.1063) E 90564-56070 2.75 (0.1083) F 90564-56071 2.80 (0.1102) G 90564-56072 2.85 (0.1122) H (f) C083226 Remove the 3 bolts. E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MX–63 (g) Remove the 14 bolts and manual transmission case from the manual transaxle case. MX C083227 (h) Remove the differential case assembly from the manual transaxle case. C083242 12. INSTALL FRONT TRANSAXLE CASE OIL SEAL (a) Using SST and a hammer, install a new front transaxle case oil seal to the manual transaxle case. SST 09950-60010 (09951-00420), 09950-70010 (09951-07150) (b) Coat the lip of the front transaxle case oil seal with MP grease. Clearance: 1.0 to 2.0 mm (0.0394 to 0.0787 in.) SST C087997E02 13. INSTALL INPUT SHAFT FRONT BEARING (a) Coat the input shaft front bearing with gear oil. (b) Using SST and a hammer, install the oil seal to the manual transaxle case. SST 09950-60010 (09951-00570), 09950-70010 (09951-07150) Clearance: 4.28 to 4.60 mm (0.1685 to 0.1811 in.) SST C087998E02 MX–64 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT 14. INSTALL MANUAL TRANSAXLE CASE RECEIVER (a) Install the manual transaxle case receiver to the manual transaxle case with the 3 bolts. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) MX C083243 15. INSTALL DIFFERENTIAL CASE ASSEMBLY (a) Coat the differential case tapered roller bearing with gear oil, and install the differential case assembly to the manual transaxle case. C083242 16. INSTALL OUTPUT SHAFT ASSEMBLY (a) Apply gear oil to each sliding part of the output shaft assembly. (b) Lift the differential case assembly with the output shaft assembly leaned, and install it to the manual transaxle case. C083241 17. INSTALL INPUT SHAFT ASSEMBLY (a) Apply gear oil to each sliding part of the input shaft assembly. (b) Install the input shaft assembly to the manual transaxle case while tilting the output shaft assembly. C083240 18. INSTALL NO. 2 GEAR SHIFT FORK (a) Coat the No. 2 gear shift fork with gear oil, and install it to the input shaft assembly. No. 2 Shift Fork C087999E04 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MX–65 19. INSTALL NO. 3 GEAR SHIFT FORK (a) Install the No. 3 gear shift fork to the No. 3 gear shift fork shaft. (b) Using a brass bar and hammer, install the 2 shift fork shaft snap rings to the gear shift fork shaft. MX C083257 (c) Apply gear oil to each sliding part of the No. 3 gear shift fork shaft, and install it to the manual transaxle case. No. 3 Shift Fork Shaft C088000E03 20. INSTALL NO. 1 GEAR SHIFT FORK (a) Apply gear oil to each sliding part of the No. 1 gear shift fork, and install it to the output shaft assembly. No. 1 Shift Fork C088001E03 21. INSTALL NO. 2 GEAR SHIFT FORK SHAFT (a) Install the No. 1 gear shift head to the No. 2 gear shift fork shaft. (b) Apply gear oil to each sliding part of the No. 2 gear shift fork shaft, and install it to the manual transaxle case. No. 2 Shift Fork Shaft No. 1 Shift Head C088002E05 (c) Install the shift fork set bolt and shift head set bolt to the No. 1 gear shift head. Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) C083234E03 MX–66 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT 22. INSTALL REVERSE SHIFT FORK ROLLER (a) Using a magnetic finger, install the reverse shift fork roller to the reverse shift fork. MX C083233 23. INSTALL NO. 1 GEAR SHIFT FORK SHAFT (a) Using a brass bar and hammer, install the shift fork shaft snap ring to the No. 1 shift fork shaft. C069752 (b) Install the No. 1 gear shift fork shaft to the manual transaxle case. No. 1 Shift Fork Shaft C088003E05 (c) Install the shift fork set bolt to the No. 1 gear shift fork. Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) C083231 24. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY (a) Install the reverse shift arm bracket assembly to the manual transaxle case with the 2 bolts. Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf) C083230 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MX–67 25. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY (a) Coat the reverse idler gear and reverse idler thrust washer with MP grease, and install them to the reverse idler gear shaft. MX C070512 (b) Install the reverse idler gear to the manual transaxle case. HINT: Align the mark of the reverse idler gear shaft with the hole of the bolt. Align the mark and hole. C069753E03 26. INSTALL TRANSMISSION MAGNET (a) Clean the transmission magnet and install it to the manual transaxle case. C083229 27. INSTALL NO. 1 OIL RECEIVER PIPE (a) Install the No. 1 oil receiver pipe to the manual transmission case with the bolt. Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf) NOTICE: Do not damage the pipe. C138375 28. INSTALL NO. 2 OIL RECEIVER PIPE (a) Install the No. 2 oil receiver pipe to the manual transmission case with the bolt. Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf) NOTICE: Do not damage the pipe. C138376 MX–68 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT 29. INSTALL REVERSE RESTRICT PIN ASSEMBLY (a) Install the transmission oil baffle and reverse restrict pin with the bolt. Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf) MX C135411 (b) Using a pin punch (φ 5 mm), install the slotted pin to the reverse restrict pin assembly. Clearance: 12.5 to 13.5 mm (0.492 to 0.531 in.) C069759 (c) Coat the reverse restrict pin plug with adhesive. Using a hexagon wrench (6 mm), install the manual transmission case. Torque: 13 N*m (133 kgf*cm, 9.6 ft.*lbf) Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent C135409 30. INSTALL MANUAL TRANSMISSION CASE (a) Apply a bead of FIPG to the manual transmission case as shown in the illustration. HINT: Install the manual transmission case within 10 minutes after applying FIPG. C069755 (b) Install the manual transmission case to the manual transaxle case with the 14 bolts. Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) C083227 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MX–69 (c) Coat the 3 bolts with adhesive. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent (d) Install the 3 bolts to the manual transaxle case. Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 31. INSTALL NO. 1 CLUTCH TUBE BRACKET (a) Install the clutch tube bracket with the bolt. Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf) C083226 32. INSTALL REVERSE IDLER GEAR SHAFT BOLT (a) Coat the bolt with adhesive. Install a new gasket to the manual transmission case with the bolt. Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent C083225 33. INSTALL SHIFT FORK SHAFT SHAFT SNAP RING (a) Using a brass bar and hammer, install the shift fork shaft snap ring to the No. 1 gear shift fork shaft. C069758 (b) Using a brass bar and hammer, install the shift fork shaft snap ring to the No. 2 gear shift fork shaft. C069757 34. INSTALL INPUT SHAFT REAR BEARING SHAFT SNAP RING (a) Using a snap ring expander, install the input shaft rear bearing shaft snap ring. C088004 MX MX–70 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT 35. INSTALL OUTPUT SHAFT REAR BEARING SHIM (a) Install the output shaft rear bearing shim to the output shaft. MX C069458 36. INSTALL REAR BEARING RETAINER (a) Coat the rear bearing retainer with sealant and install it with a "TORX" wrench (T45). (b) Install a new output rear set nut to the output shaft. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) C083259E02 SST 37. INSTALL 5TH DRIVEN GEAR (a) Using SST, install the 5th driven gear to the output shaft. SST 09309-12020 SST C095786E02 38. INSTALL 5TH GEAR NEEDLE ROLLER BEARING (a) Coat the 5th gear needle roller bearing with gear oil and install it to the input shaft. C069455 39. INSTALL 5TH GEAR (a) Coat the 5th gear with gear oil and install it to the input shaft. C069454 MX–71 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT 40. INSTALL NO. 3 TRANSMISSION CLUTCH HUB (a) Using SST, install the No. 3 transmission clutch hub to the input shaft. SST 09950-30012 (09951-03010, 09953-03010, 09954-03010) NOTICE: Align the projection of the synchronizer ring with the hole of the 5th gear. SST MX C088006E02 (b) Install the No. 3 transmission hub sleeve and No. 3 gear shift fork to the No. 3 transmission clutch hub. C069764 (c) Coat the shift fork set bolt with adhesive and install it to the No. 3 gear shift fork. Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent C083260 (d) Select a snap ring that will allow minimum axial play. Using a brass bar and a hammer, install the shaft snap ring. Clearance: 0.1 mm (0.004 in.) or less Snap ring Part No. Thickness: mm (in.) Mark 90520-27061 1.75 to 1.80 (0.0689 to 0.0709) a 90520-27062 1.80 to 1.85 (0.0709 to 0.0728) b 90520-27063 1.85 to 1.90 (0.0728 to 0.0748) c 90520-27064 1.90 to 1.95 (0.0748 to 0.0768) d 90520-27065 1.95 to 2.00 (0.0768 to 0.0787) e 90520-27066 2.00 to 2.05 (0.0787 to 0.0807) f 90520-27067 2.05 to 2.10 (0.0807 to 0.0827) g 90520-27068 2.10 to 2.15 (0.0827 to 0.0846) h C069763 MX–72 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT Part No. Thickness: mm (in.) Mark 90520-27069 2.15 to 2.20 (0.0846 to 0.0866) j 41. INSTALL MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT (a) Engage the 1st and 2nd gears simultaneously. MX C069266 (b) Install a new manual transmission output shaft rear set nut. Torque: 123 N*m (1,254 kgf*cm, 90 ft.*lbf) C090287 (c) Using a chisel and a hammer, stake the manual transmission output shaft rear set nut. (d) Disengage the gears. C069766 C069756 42. INSTALL MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY (a) Apply FIPG to the transaxle case cover subassembly as shown in the installation. FIPG: Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent NOTICE: Install the part within 10 minutes after applying the packing material (FIPG). E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MX–73 (b) Install the transmission case cover sub-assembly to the manual transaxle case with the 10 bolts. MX D031904 43. INSTALL DRAIN PLUG SUB-ASSEMBLY (a) Install the drain plug sub-assembly to the manual transmission case with a new gasket. Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) C087967 44. INSTALL MANUAL TRANSMISSION FILLER PLUG (a) Install the manual transmission filler plug to the transaxle case with a new gasket. Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) C070824E04 45. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY (a) Coat the shift and select lever shaft assembly with gear oil, and install it to the manual transmission case. C138371 46. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY (a) Install the back-up light switch assembly to the manual transmission case with a new gasket. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) C087966 MX–74 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT 47. INSTALL MANUAL TRANSMISSION BREATHER PLUG (a) Install the manual transmission breather plug to the manual transmission case. MX C138364 48. INSTALL SHIFT GATE PIN (a) Install the shift gate pin to the manual transmission case. Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) C138363 49. INSTALL NO. 1 LOCK BALL ASSEMBLY (a) Install the lock ball assembly No. 1 to the manual transmission case. Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) C138362 50. INSTALL CONTROL SHAFT COVER (a) Coat the 4 bolts with adhesive. Install a new gasket and the control shaft cover with the bolts. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent C092834 51. INSTALL CONTROL SHIFT LEVER (a) Install the control shift lever with the shift outer lever lock pin to the shift and select lever shaft. (b) Install the spring washer with the nut. Torque: 6.4 N*m (65 kgf*cm, 57 in.*lbf) C138360 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MX–75 52. INSTALL SELECTING BELLCRANK ASSEMBLY (a) Coat the 2 bolts with adhesive. Install the selecting bellcrank assembly to the manual transmission case with the bolts. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent C138359 53. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY (a) Install a new O-ring and the speedometer driven hole cover sub-assembly to the transmission case with the bolt. Torque: 5.5 N*m (56 kgf*cm, 48 in.*lbf) 54. INSTALL CLUTCH RELEASE FORK BOOT (a) Install the clutch release fork boot to the manual transaxle case. 55. INSTALL RELEASE FORK SUPPORT (a) Using a deep socket wrench, install the release fork support to the manual transaxle case. Torque: 47 N*m (480 kgf*cm, 36 ft.*lbf) C083809 56. INSTALL CLUTCH RELEASE BEARING ASSEMBLY (a) Coat the clutch release bearing assembly with release hub grease, and install it to the clutch release fork sub-assembly. Sealant: Part No. 08887-01806, Release Hub Grease or equivalent (b) Apply clutch spline grease to the input shaft spline. 57. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY (a) Install the clutch release fork sub-assembly to the input shaft. C069774 MX MX–40 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT DISASSEMBLY MX 1. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY (a) Remove the clutch release fork sub-assembly together with the clutch release bearing assembly from the manual transaxle case. 2. REMOVE CLUTCH RELEASE BEARING ASSEMBLY (a) Remove the clutch release bearing assembly and release bearing hub clip from the clutch release fork sub-assembly. 3. REMOVE RELEASE FORK SUPPORT (a) Remove the release fork support from the manual transaxle case. 4. REMOVE CLUTCH RELEASE FORK BOOT (a) Remove the clutch release fork boot from the manual transaxle case. 5. REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY (a) Remove the bolt and speedometer driven hole cover sub-assembly. (b) Remove the O-ring. 6. REMOVE SELECTING BELLCRANK ASSEMBLY (a) Remove the 2 bolts and selecting bellcrank assembly from the manual transmission case. 7. REMOVE CONTROL SHIFT LEVER (a) Remove the nut and spring washer. C069774 C083809 C138359 C138360 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MX–41 (b) Using a brass bar and hammer, remove the shift outer lever lock pin. (c) Remove the control shift lever. MX C138361 8. REMOVE CONTROL SHAFT COVER (a) Remove the 4 bolts and control shaft cover from the manual transmission case. 9. SECURE MANUAL TRANSAXLE ASSEMBLY (a) Place the manual transaxle assembly on wooden blocks. C092834 C087963 10. REMOVE NO. 1 LOCK BALL ASSEMBLY (a) Remove the No. 1 lock ball assembly from the manual transmission case. C138362 11. REMOVE SHIFT GATE PIN (a) Remove the shift gate pin from the manual transmission case. C138363 MX–42 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT 12. REMOVE MANUAL TRANSMISSION BREATHER PLUG (a) Remove the manual transmission breather plug. MX C138364 13. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY (a) Remove the shift and select lever shaft assembly from the manual transmission case. C138371 14. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY (a) Remove the back-up light switch assembly and gasket from the manual transmission case. C087966 15. REMOVE MANUAL TRANSMISSION FILLER PLUG (a) Remove the manual transmission filler plug and gasket from the manual transmission case. C070824 16. REMOVE DRAIN PLUG SUB-ASSEMBLY (a) Remove the drain plug sub-assembly and gasket from the manual transmission case. C087967 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MX–43 17. REMOVE MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY (a) Remove the 10 bolts and manual transmission case cover from the manual transmission case. MX D031904 18. REMOVE MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT (a) Engage the 1st and 2nd gears simultaneously. C069266 (b) Using SST and a hammer, unstake the manual transmission output shaft rear set nut. SST 09930-00010 SST C087968E02 (c) Using SST, remove the manual transmission output shaft rear set nut from the output shaft. SST 09229-55010 (d) Disengage the gears. SST C087969E02 19. REMOVE NO. 3 TRANSMISSION CLUTCH HUB (a) Using 2 screwdrivers and a hammer, remove the transmission clutch hub No. 3 shaft snap ring from the input shaft. HINT: Use a shop rag or a piece of cloth to keep the snap ring from flying. C069269 MX–44 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT (b) Remove the shift fork set bolt from the No. 3 gear shift fork. MX C069270 (c) Using SST, remove the No. 3 transmission clutch hub and No. 3 gear shift fork from the input shaft. SST 09950-30012 (09951-03010, 09953-03010, 09954-03010), 09950-50013 (0995704010), 09950-60010 (09951-00280) SST SST C069777E02 20. REMOVE 5TH GEAR (a) Remove the 5th gear from the input shaft. C069454 21. REMOVE 5TH GEAR NEEDLE ROLLER BEARING (a) Remove the 5th gear needle roller bearing from the input shaft. C069455 22. REMOVE 5TH DRIVEN GEAR (a) Using SST, remove the 5th driven gear from the output shaft. SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09957-04010), 09950-60010 (09951-00180, 09955-03011), 09950-50013 SST SST C069456E02 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MX–45 23. REMOVE REAR BEARING RETAINER (a) Using a "TORX" socket wrench (T45), remove the 7 "TORX" screws and rear bearing retainer from the manual transmission case. MX C069457E01 24. REMOVE OUTPUT SHAFT REAR BEARING SHIM (a) Remove the output shaft rear bearing shim from the output shaft. C069458 25. REMOVE INPUT SHAFT REAR BEARING SHAFT SNAP RING (a) Using a snap ring expander, remove the input shaft rear bearing shaft snap ring from the input shaft. C087970 26. REMOVE SHIFT FORK SHAFT SHAFT SNAP RING (a) Using 2 screwdrivers and a hammer, remove the shift fork shaft shaft snap ring from the No. 1 gear shift fork shaft. HINT: Use a shop rag or a piece of cloth to keep the snap ring from flying. C087971 (b) Using 2 screwdrivers and a hammer, remove the shift fork shaft shaft snap ring from the No. 2 gear shift fork shaft. HINT: Use a shop rag or a piece of cloth to keep the snap ring from flying. C069460 MX–46 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT 27. REMOVE REVERSE IDLER GEAR SHAFT BOLT (a) Remove the reverse idler gear shaft bolt and gasket. 28. REMOVE NO. 1 CLUTCH TUBE BRACKET (a) Remove the bolt and clutch tube bracket. MX C083225 29. REMOVE MANUAL TRANSMISSION CASE (a) Remove the 3 bolts from the manual transaxle case. C083226 (b) Remove the 14 bolts from the manual transmission case. (c) Tapping with a plastic hammer, remove the manual transmission case. C083227 30. REMOVE REVERSE RESTRICT PIN ASSEMBLY (a) Using a hexagon wrench (6 mm), remove the reverse restrict pin plug from the manual transmission case. C135409 (b) Using a pin punch (φ 5 mm) and hammer, remove the slotted pin. C135410 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MX–47 (c) Remove the bolt, transmission oil baffle and reverse restrict pin assembly. MX C135411 31. REMOVE NO. 2 OIL RECEIVER PIPE (a) Remove the bolt and No. 2 oil receiver pipe from the manual transmission case. NOTICE: Do not damage the pipe. C138376 32. REMOVE NO. 1 OIL RECEIVER PIPE (a) Remove the bolt and No. 1 oil receiver pipe from the manual transmission case. NOTICE: Do not damage the pipe. C138375 33. REMOVE TRANSMISSION MAGNET (a) Remove the transmission magnet from the manual transaxle case. C069468 34. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY (a) Remove the reverse idler gear sub-assembly from the manual transaxle case. C069470 MX–48 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT (b) Remove the reverse gear and reverse idler thrust washer from the reverse idler gear shaft. MX C070512 35. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY (a) Remove the 2 bolts and reverse shift arm bracket assembly from the manual transaxle case. C083230 36. REMOVE NO. 1 GEAR SHIFT FORK SHAFT (a) Remove the shift fork set bolt from the No. 1 gear shift fork. C083231 (b) Pull out the No. 1 gear shift fork shaft while the No. 3 gear shift fork shaft is pulled up. C087975 (c) Using 2 screwdrivers and a hammer, remove the shift fork shaft snap ring from the No. 1 gear shift fork shaft. HINT: Use a shop rag or a piece of cloth to keep the snap ring from flying. C069500 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MX–49 37. REMOVE REVERSE SHIFT FORK ROLLER (a) Using a magnetic finger, remove the reverse shift fork roller from the reverse shift fork. MX C083233 38. REMOVE NO. 2 GEAR SHIFT FORK SHAFT (a) Remove the shift fork set bolt and shift head set bolt from the No. 2 gear shift fork and No. 1 gear shift head. C083234 (b) Remove the No. 2 gear shift fork shaft and No. 1 gear shift head from the manual transaxle case. No. 2 Shift Fork Shaft No. 1 Shift Head C087976E07 39. REMOVE NO. 1 GEAR SHIFT FORK (a) Remove the No. 1 gear shift fork. No. 1 Shift Fork C087977E05 40. REMOVE NO. 3 GEAR SHIFT FORK SHAFT (a) Remove the No. 3 gear shift fork shaft from the manual transaxle case. Shift Fork Shaft No. 3 C087978E05 MX–50 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT (b) Using 2 screwdrivers and a hammer, remove the 2 shift fork shaft snap rings from the No. 3 gear shift fork shaft. (c) Remove the reverse shift fork from the No. 3 gear shift fork shaft. MX C083238 41. REMOVE NO. 2 GEAR SHIFT FORK (a) Remove the No. 2 gear shift fork from the input shaft assembly. No. 2 Shift Fork C087979E05 42. REMOVE INPUT SHAFT ASSEMBLY (a) Tilt the output shaft, then remove the input shaft from the manual transaxle case. C083240 43. REMOVE OUTPUT SHAFT ASSEMBLY (a) Lift the differential case assembly with the output shaft assembly leaned. (b) Remove the output shaft assembly from the manual transaxle case. C083241E03 44. REMOVE DIFFERENTIAL CASE ASSEMBLY (a) Remove the differential case assembly from the manual transaxle case. C083242 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MX–51 45. REMOVE MANUAL TRANSAXLE CASE RECEIVER (a) Remove the 3 bolts and manual transaxle case receiver from the manual transaxle case. MX C083243 46. REMOVE INPUT SHAFT FRONT BEARING (a) Using SST, remove the input shaft front bearing (outer race) from the manual transaxle case. SST 09612-65014 (09612-01040, 09612-01050) SST C087980E02 47. REMOVE FRONT TRANSAXLE CASE OIL SEAL (a) Using SST, remove the manual transaxle case oil seal from the manual transaxle case. SST 09612-65014 (09612-01040, 09612-01050) SST C087981E02 48. REMOVE OUTPUT SHAFT FRONT BEARING (a) Using SST, remove the output shaft front bearing (outer race) from the manual transaxle case. SST 09387-00041 (09387-02020, 09387-02010) SST C087982E02 49. REMOVE OUTPUT SHAFT COVER (a) Remove the output shaft cover from the manual transaxle case. C069483 MX–52 E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT 50. REMOVE OUTPUT SHAFT REAR BEARING (a) Using SST and a hammer, remove the output shaft rear bearing from the manual transmission case (outer race). SST 09950-60010 (09951-00680), 09950-70010 (09951-07100) SST MX C087983E02 51. REMOVE TRANSMISSION CASE OIL SEAL (a) Using SST, remove the transmission case oil seal from the manual transmission case. SST 09308-00010 SST C087984E02 52. REMOVE FRONT TRANSAXLE CASE COVER OIL SEAL (a) Using a screwdriver, remove the front transaxle case cover oil seal. HINT: Tape the screwdriver tip before use to avoid damage. D032768 53. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING (a) Using a brass bar and a hammer, remove the front differential case front tapered roller bearing (outer race) from the manual transaxle case. C069490 SST C070822E04 (b) Using SST, remove the front differential case front tapered roller bearing from the front differential case. SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00560) E351 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MX–53 54. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING (a) Using SST and a hammer, remove the front differential case rear tapered roller bearing (outer race) and front differential case rear shim from the manual transmission case. SST 09950-60020 (09951-00790), 09950-70010 (09951-07100) SST MX C087986E02 (b) Using SST, remove the front differential case rear tapered roller bearing (inner race) from the front differential case. SST 09950-60020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00490) SST C090344E04 No. 3 Hub Sleeve 55. REMOVE NO. 3 TRANSMISSION HUB SLEEVE (a) Remove the No. 3 transmission hub sleeve from the No. 3 transmission clutch hub. C087988E04 56. REMOVE NO. 3 SYNCHROMESH SHIFTING KEY SPRING (a) Remove the 2 No. 3 synchromesh shifting key springs from the No. 3 transmission clutch hub while pushing on the No. 3 synchromesh shifting key spring. C069507 57. REMOVE SYNCHRONIZER PULL RING (a) Using a screwdriver, remove the synchronizer pull ring snap ring. (b) Remove the synchronizer pull ring, No. 5 synchronizer outer ring, No. 5 synchronizer inner ring, and No. 5 synchronizer ring middle from the No. 5 synchronizer ring inner. C069508 MX–76 E351 MANUAL TRANSAXLE – INPUT SHAFT INPUT SHAFT E351 MANUAL TRANSAXLE TRANSMISSION COMPONENTS 2ND SYNCHRONIZER OUTER RING 4TH GEAR BEARING SPACER MX 4TH GEAR NEEDLE ROLLER BEARING 4TH GEAR INPUT SHAFT REAR RADIAL BALL BEARING INPUT SHAFT REAR BEARING SHAFT SNAP RING NO. 2 TRANSMISSION CLUTCH HUB 3RD GEAR NEEDLE ROLLER BEARING 3RD GEAR NO. 3 SYNCHRONIZER RING NO. 2 TRANSMISSION HUB SLEEVE NO. 2 SYNCHROMESH NO. 2 SYNCHROMESH SHIFTING KEY SHIFTING KEY SPRING CLUTCH HUB NO. 2 SETTING SHAFT SNAP RING INPUT SHAFT FRONT BEARING (INNER RACE) INPUT SHAFT C113288E07 E351 MANUAL TRANSAXLE – INPUT SHAFT MX–77 DISASSEMBLY 1. C070515 REMOVE 4TH GEAR (a) Hold the input shaft assembly in a vise using aluminum plates. (b) Using 2 screwdrivers and a hammer, remove the input shaft rear bearing shaft snap ring from the input shaft. HINT: Use a shop rag or a piece of cloth to keep the snap ring from flying. (c) Using SST and a press, remove the input shaft rear bearing and 4th gear. SST 09950-00020 NOTICE: Do not overtighten the SST. SST C092867E02 2. REMOVE 4TH GEAR NEEDLE ROLLER BEARING (a) Remove the 4th gear needle roller bearing from the input shaft. 3. REMOVE 2ND SYNCHRONIZER OUTER RING (a) Remove the 2nd synchronizer outer ring (No. 4 synchronizer ring) from the No. 2 transmission clutch hub. 4. REMOVE 4TH GEAR BEARING SPACER (a) Remove the 4th gear bearing spacer from the No. 2 transmission clutch hub. C069551 D031907 D031906 MX MX–78 E351 MANUAL TRANSAXLE – INPUT SHAFT 5. MX REMOVE 3RD GEAR (a) Using 2 screwdrivers and a hammer, remove the No. 2 clutch hub setting shaft snap ring from the input shaft. HINT: Use a shop rag or a piece of cloth to keep the snap ring from flying. C069615 (b) Using SST and a press, remove the No. 2 transmission clutch hub and 3rd gear from the input shaft. SST 09950-00020 NOTICE: Do not overtighten the SST. SST D031908E02 6. REMOVE 3RD GEAR NEEDLE ROLLER BEARING (a) Remove the 3rd gear needle roller bearing from the input shaft. 7. REMOVE NO. 3 SYNCHRONIZER RING (a) Remove the No. 3 synchronizer ring from the 3rd gear. 8. REMOVE NO. 2 TRANSMISSION HUB SLEEVE (a) Remove the No. 2 transmission hub sleeve, 3 No. 2 synchromesh shifting keys, and 3 No. 2 synchromesh shifting key springs from the No. 2 transmission clutch hub. HINT: Use a shop rag or a piece of cloth to keep the shifting keys and shifting key springs from flying. C069617 C069618 C069619 MX–79 E351 MANUAL TRANSAXLE – INPUT SHAFT 9. SST REMOVE INPUT SHAFT FRONT BEARING (a) Using SST and a press, remove the input shaft front bearing (inner race) from the input shaft. SST 09950-00020 NOTICE: Do not overtighten the SST. MX C092869E02 INSPECTION 1. INSPECT 4TH GEAR THRUST CLEARANCE (a) Using a feeler gauge, measure the 4th gear thrust clearance. Standard clearance: 0.10 to 0.57 mm (0.0039 to 0.0224 in.) If clearance is out of specification, replace the No. 2 transmission clutch hub, 4th gear, or input shaft rear radial ball bearing. 2. INSPECT 3RD GEAR THRUST CLEARANCE (a) Using a dial indicator, measure the 3rd gear thrust clearance. Standard clearance: 0.10 to 0.35 mm (0.0039 to 0.0138 in.) If clearance is out of specification, replace the No. 2 transmission clutch hub, 3rd gear, or input shaft. 3. INSPECT 4TH GEAR RADIAL CLEARANCE (a) Using a dial indicator, measure the 4th gear radial clearance. Standard clearance mm (in.) C069546 C069637 C069548 Standard clearance KOYO made 0.009 to 0.053 (0.0004 to 0.0021) NSK made 0.009 to 0.051 (0.0004 to 0.0020) If clearance is out of specification, replace the 4th gear, needle roller bearing, or input shaft. 4. C069549 Bearing INSPECT 3RD GEAR RADIAL CLEARANCE (a) Using a dial indicator, measure the 3rd gear radial clearance. Standard clearance mm (in.) Bearing Standard clearance KOYO made 0.009 to 0.053 (0.0004 to 0.0021) NSK made 0.009 to 0.051 (0.0004 to 0.0020) MX–80 E351 MANUAL TRANSAXLE – INPUT SHAFT If clearance is out of specification, replace the 3rd gear, needle roller bearing, or input shaft. 5. INSPECT INPUT SHAFT (a) Using a V-block and dial indicator, inspect the shaft for runout. Maximum runout: 0.03 mm (0.0012 in.) If runout exceeds the maximum, replace the input shaft. MX C069620 A B (b) Using a micrometer, measure the outside diameter of the input shaft journal surface. Outside diameter mm (in.) C C092870E02 Part Standard outside diameter Minimum outside diameter A 35.984 to 36.000 (1.4167 to 1.4173) 35.984 (1.4167) B 35.984 to 36.000 (1.4167 to 1.4173) 35.984 (1.4167) C 27.957 to 27.972 (1.1007 to 1.1013) 27.957 (1.1007) If the outside diameter is less than the minimum, replace the input shaft. 6. Standard inside diameter Maximum inside diameter 42.009 to 42.025 (1.6539 to 1.6545) 42.025 (1.6545) If the inside diameter exceeds the maximum, replace the 4th gear. C069622 7. C069622 INSPECT 4TH GEAR (a) Using a cylinder gauge, measure the inside diameter of the 4th gear. Inside diameter: mm (in.) INSPECT 3RD GEAR (a) Using a cylinder gauge, measure the inside diameter of the 3rd gear. Inside diameter: mm (in.) Standard inside diameter Maximum inside diameter 43.009 to 43.025 (1.6933 to 1.6939) 43.025 (1.6939) If the inside diameter exceeds the maximum, replace the 3rd gear. E351 MANUAL TRANSAXLE – INPUT SHAFT 8. MX–81 INSPECT 2ND SYNCHRONIZER OUTER RING (a) Coat the 4th gear cone with gear oil. Turn the 2nd synchronizer outer ring (No. 4 synchronizer ring) in one direction while pushing it against the 4th gear cone. Check that the ring locks. If the 2nd synchronizer outer ring does not lock, replace the ring or the 4th gear. MX C069623 (b) Using a feeler gauge, measure the clearance between the synchronizer outer ring (No. 4 synchronizer ring) back and 4th gear spline end. Standard clearance: 0.75 to 1.65 mm (0.0295 to 0.0650 in.) If clearance is out of specification, replace the synchronizer ring. C069624 9. INSPECT NO. 3 SYNCHRONIZER RING (a) Coat the 3rd gear cone with gear oil. Turn the synchronizer outer ring in one direction while pushing it against the 3rd gear cone. Check that the ring locks. If the synchronizer outer ring does not lock, replace the ring or the 3rd gear. C069625 (b) Using a feeler gauge, measure the clearance between the No. 3 synchronizer ring back and 3rd gear spline end. Standard clearance: 0.65 to 1.75 mm (0.0256 to 0.0689 in.) If clearance is out of specification, replace the No. 3 synchronizer ring. C069626 10. INSPECT NO. 2 TRANSMISSION HUB SLEEVE (a) Inspect the sliding condition between the No. 2 transmission hub sleeve and No. 2 transmission clutch hub. (b) Inspect the tip of the spline gear on the No. 2 transmission hub sleeve for wear. If any defects are found, replace the transmission hub sleeve or the transmission clutch hub. C067843 MX–82 E351 MANUAL TRANSAXLE – INPUT SHAFT (c) Using vernier calipers, measure the width of the No. 3 transmission hub sleeve groove and the thickness of the claw part on the No. 1 gear shift fork, and calculate the clearance. Standard clearance: 0.11 to 0.69 mm (0.0043 to 0.0272 in.) {A - B} If clearance is out of specification, replace the No. 2 transmission hub sleeve and No. 2 gear shift fork with new ones. A MX Clearance= (A-B) B C070506E02 REASSEMBLY 1. INSTALL INPUT SHAFT FRONT BEARING (a) Using SST and a press, install the input shaft front bearing (inner race). SST 09608-00071 2. INSTALL NO. 2 TRANSMISSION HUB SLEEVE (a) Coat the transmission No. 2 hub sleeve with gear oil. (b) Install the 3 synchromesh key springs with the No. 2 transmission hub sleeve. NOTICE: Install the No. 2 transmission clutch hub sleeve and the No. 2 transmission clutch hub in the correct direction. (c) Using a screwdriver, install the synchromesh shifting key to the input shaft. 3. INSTALL 3RD GEAR NEEDLE ROLLER BEARING (a) Coat the 3rd gear bearing with gear oil and install it to the input shaft. SST C092871E02 Same Direction 4th Gear Side 3rd Gear Side D031909E01 C069617 MX–83 E351 MANUAL TRANSAXLE – INPUT SHAFT 4. INSTALL 3RD GEAR (a) Coat the 3rd gear with gear oil and install it to the input shaft. MX C069629 5. INSTALL NO. 3 SYNCHRONIZER RING (a) Coat the No. 3 synchronizer ring with gear oil and install it to the 3rd gear. 6. INSTALL NO. 2 TRANSMISSION CLUTCH HUB (a) Using SST and a press, install the No. 2 transmission clutch hub to the input shaft. SST 09316-60011 (09316-00041) NOTICE: • Align the claw of the clutch hub No. 2 with the notch of the synchronizer ring No. 3. • Make sure that the 3rd gear can rotate. C069630 SST C092872E02 (b) Select a snap ring so that clearance between the No. 2 transmission clutch hub and the No. 2 clutch hub shaft snap ring will be within the specified range. Using a brass bar and a hammer, install the snap ring. Standard clearance: 0.1 mm or less (0.0039 in.) or less Snap ring thickness Part No. Thickness: mm (in.) Mark 90520-34003 2.30 to 2.35 (0.0906 to 0.0925) H 90520-34004 2.35 to 2.40 (0.0925 to 0.0945) J 90520-34005 2.40 to 2.45 (0.0945 to 0.0965) K 90520-34006 2.45 to 2.50 (0.0965 to 0.0984) L 90520-34007 2.50 to 2.55 (0.0984 to 0.1004) M 90520-34008 2.55 to 2.60 (0.1004 to 0.1024) N D031916 MX–84 E351 MANUAL TRANSAXLE – INPUT SHAFT Part No. Thickness: mm (in.) Mark 90520-34009 2.60 to 2.65 (0.1024 to 0.1043) P 7. INSTALL 4TH GEAR BEARING SPACER (a) Coat the 4th gear bearing spacer with gear oil and install it to the input shaft. 8. INSTALL 2ND SYNCHRONIZER OUTER RING (a) Coat the 2nd synchronizer outer ring (No. 4 synchronizer ring) with gear oil and install it to the No. 2 transmission clutch hub. NOTICE: Align the claw of the No. 2 clutch hub with the notch of the 2nd synchronizer outer ring (No. 4 synchronizer ring). 9. INSTALL 4TH GEAR NEEDLE ROLLER BEARING (a) Coat the 4th gear needle roller bearing with gear oil and install it to the input shaft. MX D031906 D031907 C069551 10. INSTALL 4TH GEAR (a) Coat the 4th gear with gear oil and install it to the input shaft. C069633 MX–85 E351 MANUAL TRANSAXLE – INPUT SHAFT 11. INSTALL INPUT SHAFT REAR RADIAL BALL BEARING (a) Using SST and a press, install the input shaft rear radial ball bearing to the input shaft. SST 09608-06041 NOTICE: • Install the bearing with its groove facing rearward. • Make sure that the 3rd gear rotates. SST MX C092857E01 (b) Select a snap ring so that the clearance between the input shaft radial ball rear bearing and the input shaft rear bearing snap ring will be within the specified range. Using a brass bar and a hammer, install the snap ring. Standard clearance: 0.1 mm (0.004 in.) or less Snap ring Part No. Thickness: mm (in.) Mark 90520-30008 2.35 to 2.40 (0.0925 to 0.0945) 1 90520-30009 2.40 to 2.45 (0.0945 to 0.0965) 2 90520-30010 2.45 to 2.50 (0.0965 to 0.0984) 3 90520-30011 2.50 to 2.55 (0.0984 to 0.1004) 4 90520-30012 2.55 to 2.60 (0.1004 to 0.1024) 5 90520-30013 2.60 to 2.65 (0.1024 to 0.1043) 6 90520-30021 2.65 to 2.70 (0.1043 to 0.1063) 7 90520-30022 2.70 to 2.75 (0.1063 to 0.1083) 8 C069635 MX–86 E351 MANUAL TRANSAXLE – OUTPUT SHAFT OUTPUT SHAFT E351 MANUAL TRANSAXLE TRANSMISSION COMPONENTS 2ND GEAR BEARING SPACER 2ND GEAR NEEDLE ROLLER BEARING MX 3RD DRIVEN GEAR 4TH DRIVEN GEAR 2ND GEAR BUSHING 2ND GEAR OUTPUT GEAR SPACER OUTPUT SHAFT REAR BEARING (INNER RACE) NO. 1 SYNCHROMESH SHIFTING KEY NO. 1 TRANSMISSION CLUTCH HUB NO. 1 SYNCHRONIZER RING SET REVERSE GEAR NO. 1 SYNCHROMESH SHIFTING KEY SPRING NO. 2 SYNCHRONIZER RING SET 2ND GEAR BUSHING BALL OUTPUT SHAFT FRONT BEARING OUTPUT SHAFT 1ST GEAR NEEDLE ROLLER BEARING 1ST GEAR C113289E05 E351 MANUAL TRANSAXLE – OUTPUT SHAFT MX–87 DISASSEMBLY SST 1. REMOVE 4TH DRIVEN GEAR (a) Using SST and a press, remove the output shaft rear bearing (inner race) and 4th driven gear. SST 09950-00020 MX C092858E02 2. REMOVE OUTPUT GEAR SPACER (a) Remove the output gear spacer from the output shaft. 3. REMOVE 2ND GEAR (a) Using SST and a press, remove the 3rd driven gear and 2nd gear from the output shaft. SST 09950-00020 4. REMOVE NO. 2 SYNCHRONIZER RING SET (a) Remove the No. 2 synchronizer ring set from the No. 1 transmission clutch hub. 5. REMOVE 2ND GEAR NEEDLE ROLLER BEARING (a) Remove the 2nd gear needle roller bearing from the output shaft. C069641 SST C092859E01 C069643 C069644 MX–88 MX E351 MANUAL TRANSAXLE – OUTPUT SHAFT 6. REMOVE 2ND GEAR BEARING SPACER (a) Remove the 2nd gear bearing spacer from the output shaft. 7. REMOVE 2ND GEAR BUSHING (a) Remove the 2nd gear bushing from the output shaft. 8. REMOVE 2ND GEAR BUSHING BALL (a) Using a magnetic finger, remove the 2nd gear bush ball from the output shaft. 9. REMOVE 1ST GEAR (a) Using SST and a press, remove the No. 1 transmission clutch hub and 1st gear from the output shaft. SST 09950-00020 C069645 C069646 C083814 SST C092860E02 10. REMOVE NO. 1 SYNCHRONIZER RING SET (a) Remove the No. 1 synchronizer ring set from the 1st gear. C069649 E351 MANUAL TRANSAXLE – OUTPUT SHAFT MX–89 11. REMOVE 1ST GEAR NEEDLE ROLLER BEARING (a) Remove the 1st gear needle roller bearing from the output shaft. MX C069650 12. REMOVE OUTPUT SHAFT FRONT BEARING (a) Using SST and a press, remove the output shaft front bearing (inner race) from the output shaft. SST 09950-00020, 09950-60010 (09951-00320), 09950-70010 (09951-07150) NOTICE: Do not overtighten the SST. SST C092861E02 13. REMOVE REVERSE GEAR (a) Remove the No. 1 transmission clutch hub, 3 No. 1 synchromesh shifting keys, and 3 No. 1 synchromesh shifting key springs from the reverse gear. C069652 INSPECTION 1. INSPECT 1ST GEAR THRUST CLEARANCE (a) Using a feeler gauge, measure the 1st gear thrust clearance. Standard clearance: 0.25 to 0.40 mm (0.0098 to 0.0157 in.) If clearance is out of specification, replace the 1st gear, thrust washer, 1st gear, or No. 1 transmission clutch hub. 2. INSPECT 2ND GEAR THRUST CLEARANCE (a) Using a dial indicator, measure the 2nd gear thrust clearance. Standard clearance: 0.10 to 0.35 mm (0.0039 to 0.0138 in.) If clearance is out of specification, replace the No. 1 transmission clutch hub, 2nd gear, or 3rd driven gear. C069636 C069637 MX–90 E351 MANUAL TRANSAXLE – OUTPUT SHAFT 3. MX C069638 INSPECT 1ST GEAR RADIAL CLEARANCE (a) Using a dial indicator, measure the 1st gear radial clearance. Standard clearance mm (in.) Bearing Standard clearance KOYO made 0.009 to 0.053 (0.0004 to 0.0021) NSK made 0.009 to 0.051 (0.0004 to 0.0020) If clearance is out of specification, replace the 1st gear and 1st gear needle roller bearing. 4. C069639 INSPECT 2ND GEAR RADIAL CLEARANCE (a) Using a dial indicator, measure the 2nd gear radial clearance. Standard clearance mm (in.) Bearing Standard clearance KOYO made 0.009 to 0.053 (0.0004 to 0.0021) NSK made 0.009 to 0.051 (0.0004 to 0.0020) If clearance is out of specification, replace the 2nd gear and 2nd gear needle roller bearing. 5. INSPECT OUTPUT SHAFT (a) Using a V-block and a dial indicator, inspect the shaft for runout. Maximum runout: 0.03 mm (0.0012 in.) If runout exceeds the maximum, replace the input shaft. C069653 A A (b) Using a micrometer, measure the outside diameter of the output shaft journal surface. Outside diameter mm (in.) B C091168E02 Part Standard outside diameter Minimum outside diameter A 37.610 to 37.626 (1.4807 to 1.4813) 37.610 (1.4807) B 34.502 to 34.512 (1.3583 to 1.3587) 34.502 (1.3583) If the outside diameter is less than the minimum, replace the input shaft. MX–91 E351 MANUAL TRANSAXLE – OUTPUT SHAFT 6. INSPECT 2ND GEAR (a) Using a cylinder gauge, measure the inside diameter of the 2nd gear. Inside diameter: mm (in.) Standard inside diameter Maximum inside diameter 50.009 to 50.025 (1.9689 to 1.9695) 50.025 (1.9695) If the inside diameter exceeds the maximum, replace the 2nd gear. C069655 7. INSPECT 1ST GEAR (a) Using a cylinder gauge, measure the inside diameter of the 1st gear. Inside diameter mm (in.) Standard inside diameter Maximum inside diameter 51.009 to 51.025 (2.0082 to 2.0089) 51.025 (2.0089) If the inside diameter exceeds the maximum, replace the 1st gear. C069655 8. INSPECT NO. 2 SYNCHRONIZER RING SET (a) Coat the 2nd gear cone with gear oil. Turn the No. 2 synchronizer ring set in one direction while pushing it against the No. 2 synchronizer ring. Check that the ring locks. If the No. 2 synchronizer ring set does not lock, replace the ring or 2nd gear. C069657 (b) Check the clearance between the No. 2 synchronizer ring and 2nd gear while pushing the 2nd gear against the No. 2 synchronizer ring. Standard clearance: 0.70 to 1.45 mm (0.0276 to 0.0571 in.) If clearance is out of specification, replace the No. 2 synchronizer ring set with a new one. C069656 9. C069658 INSPECT NO. 1 SYNCHRONIZER RING SET (a) Coat the 1st gear cone with gear oil. Turn the No. 1 synchronizer ring set in one direction while pushing it against the 1st gear cone. Check that the ring locks. If the No. 1 synchronizer ring set does not lock, replace the No. 1 synchronizer ring set with a new one. MX MX–92 E351 MANUAL TRANSAXLE – OUTPUT SHAFT (b) Check the clearance between the No. 1 synchronizer ring set and 1st gear while pushing the 1st gear against the cone of the No. 1 synchronizer ring set. Standard clearance: 0.70 to 1.45 mm (0.0276 to 0.0571 in.) If clearance is out of specification, replace the No. 1 synchronizer ring set with a new one. MX C069659 10. INSPECT REVERSE GEAR (a) Using vernier calipers, measure the width of the reverse gear groove and thickness of the claw part on the No. 1 gear shift fork, and calculate the clearance. Standard clearance: 0.15 to 0.35 mm (0.0059 to 0.0138 in.) {A - B} If clearance is out of specification, replace the reverse gear and No. 1 gear shift fork with new ones. A Clearance= (A - B) B C070507E02 11. INSPECT NO. 1 TRANSMISSION CLUTCH HUB (a) Check the sliding condition between the No. 1 transmission clutch hub and the reverse gear. (b) Check the tip of the spline gear on the sleeve of the reverse gear for wear. If any defects are found, replace the transmission hub sleeve or the transmission clutch hub. C069671 REASSEMBLY 1. C069672 INSTALL REVERSE GEAR (a) Coat the reverse gear with gear oil. (b) Install the 3 No. 1 synchromesh shifting key springs and No. 1 transmission clutch hub to the reverse gear. NOTICE: Assemble the reverse gear and the No. 1 transmission clutch hub in the correct direction. E351 MANUAL TRANSAXLE – OUTPUT SHAFT MX–93 (c) Using a screwdriver, install the 3 No. 1 synchromesh shifting keys to the reverse gear. 2. SST INSTALL OUTPUT SHAFT FRONT BEARING (a) Using SST and a press, install the output shaft front bearing (inner race) to the output shaft. SST 09950-60010 (09951-00430), 09950-70010 (09951-07150) MX C092874E02 3. INSTALL NO. 1 SYNCHRONIZER RING SET (a) Coat the No. 1 synchronizer ring set with gear oil and install it to the 1st gear. NOTICE: Align the No. 1 synchronizer ring set with the hole of the 1st gear. 4. INSTALL 1ST GEAR NEEDLE ROLLER BEARING (a) Coat the 1st gear needle roller bearing with gear oil and install it to the output shaft. 5. INSTALL 1ST GEAR (a) Coat the 1st gear with gear oil and install it to the output shaft. C069649 C069650 C069673 MX–94 E351 MANUAL TRANSAXLE – OUTPUT SHAFT 6. INSTALL NO. 1 TRANSMISSION CLUTCH HUB (a) Using SST and a press, install the No. 1 transmission clutch hub to the output shaft. SST 09316-60011 (09316-00031), 09950-60010 (09951-00320), 09950-70010 (09951-07100) NOTICE: • Align the No. 1 synchronizer ring with the No. 1 synchromesh shifting key. • Make sure that the 1st gear rotates. 7. INSTALL 2ND GEAR BUSHING BALL (a) Coat the gear bushing with MP grease, and install it to the output shaft. 8. INSTALL 2ND GEAR BUSHING (a) Coat the 2nd gear bushing with gear oil and install it to the output shaft. 9. INSTALL 2ND GEAR BEARING SPACER (a) Coat the 2nd gear bearing spacer with gear oil and install it to the output shaft. SST SST MX C092862E02 C083814 C069646 C069645 10. INSTALL 2ND GEAR NEEDLE ROLLER BEARING (a) Coat the 2nd gear needle roller bearing with gear oil and install it to the output shaft. C069644 E351 MANUAL TRANSAXLE – OUTPUT SHAFT MX–95 11. INSTALL NO. 2 SYNCHRONIZER RING SET (a) Coat the No. 2 synchronizer ring set with gear oil and install it to the No. 1 transmission clutch hub. NOTICE: Align the key groove on the No. 2 synchronizer ring set with the No. 1 synchromesh shifting key. MX C069643 12. INSTALL 2ND GEAR (a) Coat the 2nd gear with gear oil and install it to the output shaft. C069679 13. INSTALL 3RD DRIVEN GEAR (a) Using SST and a press, install the 3rd driven gear to the output shaft. SST 09608-00071, 09950-60010 (09951-00320), 09950-70010 (09951-07100) SST SST C092863E02 14. INSTALL OUTPUT GEAR SPACER (a) Install the output gear spacer to the output shaft. C069641 15. INSTALL 4TH DRIVEN GEAR (a) Using SST and a press, install the 4th driven gear to the output shaft. SST 09608-00071, 09950-60010 (09951-00320), 09950-70010 (09951-07100) SST SST C092864E03 MX–96 E351 MANUAL TRANSAXLE – OUTPUT SHAFT 16. INSTALL OUTPUT SHAFT FRONT BEARING (a) Using SST and a press, install the output shaft front bearing (inner race) to the output shaft. SST 09506-30012, 09950-60010 (09951-00320), 09950-70010 (09951-07100) SST SST MX C092865E02 E351 MANUAL TRANSAXLE – SHIFT AND SELECT LEVER SHAFT MX–97 SHIFT AND SELECT LEVER SHAFT E351 MANUAL TRANSAXLE TRANSMISSION COMPONENTS MX SELECTING BELLCRANK SUPPORT SUB-ASSEMBLY SELECTING BELLCRANK NO. 2 BUSHING SHIFT AND SELECT LEVER BUSHING NO. 2 SELECTING BELLCRANK NO. 2 SELECTING BELLCRANK DUST COVER SELECTING BELLCRANK NO. 2 BUSHING NO. 2 SELECTING BELLCRANK PLATE WASHER WAVE WASHER 12 (120, 9) NO. 1 SELECTING BELLCRANK DUST COVER N*m (kgf*cm, ft.*lbf) : Specified torque Apply MP grease C113290E07 MX–98 E351 MANUAL TRANSAXLE – SHIFT AND SELECT LEVER SHAFT SELECT SPRING NO. 1 SEAT SHAFT SNAP RING NO. 1 SELECT RETURN COMPRESSION SPRING SHIFT INTERLOCK PLATE SHIFT INTERLOCK PLATE COVER MX NO. 2 SELECT RETURN COMPRESSION SPRING NO. 1 SELECT SPRING SEAT SLOTTED PIN SLOTTED PIN NO. 2 SHIFT LEVER INNER NO. 2 SELECT SPRING SEAT NO. 1 SHIFT LEVER INNER SELECT SPRING NO. 2 SEAT SHAFT SNAP RING CONTROL SHAFT LEVER BOOT CONTROL SHAFT COVER CONTROL SHAFT COVER OIL SEAL SHIFT AND SELECT LEVER SHAFT Non-reusable part Apply MP grease C135404E01 E351 MANUAL TRANSAXLE – SHIFT AND SELECT LEVER SHAFT MX–99 DISASSEMBLY 1. REMOVE CONTROL SHIFT LEVER BUSHING (a) Remove the control shift lever bushing from the No. 2 selecting bellcrank. MX C069529 2. REMOVE NO. 1 SELECTING BELLCRANK DUST COVER (a) Remove the No. 1 selecting bellcrank dust cover from the No. 2 selecting bellcrank. 3. REMOVE SELECTING BELLCRANK SUPPORT SUBASSEMBLY (a) Remove the nut, wave washer, and selecting bellcrank No. 2 plate washer from the No. 2 selecting bellcrank. C069530 C069532 (b) Remove the selecting bellcrank support subassembly from the No. 2 selecting bellcrank. C069799 4. C069531 REMOVE NO. 2 SELECTING BELLCRANK DUST COVER (a) Remove the No. 2 selecting bellcrank dust cover from the No. 2 selecting bellcrank. MX–100 MX E351 MANUAL TRANSAXLE – SHIFT AND SELECT LEVER SHAFT 5. REMOVE SELECTING BELLCRANK NO. 2 BUSHING (a) Remove the selecting bellcrank bushing from the No. 2 selecting bellcrank. 6. REMOVE NO. 2 SHIFT LEVER INNER (a) Hold the shift and select lever in a vise using aluminum plates. NOTICE: Do not damage the shift and select lever shaft. (b) Using a pin punch (φ 5 mm), remove the 2 shift inner lever slotted pins. NOTICE: Do not damage the shift and select lever shaft. (c) Apply force to the No. 1 select return compression spring and No. 2 select return compression spring, then hold them in a vise using aluminum plates. C069798 C138351 (d) Using 2 screwdrivers and a hammer, remove the select spring No. 2 seat snap ring from the shift and select lever shaft. NOTICE: Do not damage the shift and select lever shaft. C069535 (e) Remove the No. 2 select spring seat, No. 2 select return compression spring, and No. 2 shift lever inner from the shift and select lever shaft. C135406 E351 MANUAL TRANSAXLE – SHIFT AND SELECT LEVER SHAFT 7. MX–101 REMOVE NO. 1 SELECT SPRING SEAT (a) Remove the shift inter lock plate, No. 1 select return compression spring and No. 1 select spring seat from the shift and select lever shaft. MX C069538 Shift Interlock Plate Cover 8. REMOVE SHIFT INTERLOCK PLATE COVER (a) Remove the shift interlock plate cover from the shift interlock plate. 9. REMOVE NO. 1 SHIFT LEVER INNER (a) Remove the No. 1 shift lever inner from the shift interlock plate. C091167E06 No. 1 Shift Lever Inner C091169E07 10. REMOVE SELECT SPRING NO. 1 SEAT SHAFT SNAP RING (a) Using 2 screwdrivers and a hammer, remove the select spring No. 1 seat shaft snap ring. NOTICE: Do not damage the shaft. C069539 11. REMOVE CONTROL SHAFT COVER OIL SEAL (a) Using a screwdriver, remove the control shaft cover oil seal from the control shaft cover. HINT: Tape the screwdriver tip before use to avoid damage. D032770 MX–102 E351 MANUAL TRANSAXLE – SHIFT AND SELECT LEVER SHAFT REASSEMBLY 1. INSTALL CONTROL SHAFT COVER OIL SEAL (a) Using SST and a hammer, install a new control shaft cover oil seal to the control shaft cover. SST 09950-60010 (09951-00280), 09950-70010 (09951-07100) Oil seal installation depth: 28.0 to 29.0 mm (1.1022 to 1.142 in.) 2. INSTALL SELECT SPRING NO. 1 SEAT SHAFT SNAP RING (a) Using a brass bar and a hammer, install the select spring No. 1 seat shaft snap ring. 3. INSTALL NO. 1 SHIFT LEVER INNER (a) Install the No. 1 shift lever inner to the shift interlock plate. 4. INSTALL SHIFT INTERLOCK PLATE COVER (a) Install the shift interlock plate cover to the shift interlock plate. 5. INSTALL NO. 1 SELECT SPRING SEAT (a) Install the No. 1 select spring seat, No. 1 select return compression spring, and shift interlock plate to the shift and select lever shaft. SST MX C092886E02 C069540 No. 1 Shift Lever Inner C091169E07 Shift Interlock Plate Cover C091167E06 C069538 E351 MANUAL TRANSAXLE – SHIFT AND SELECT LEVER SHAFT 6. MX–103 INSTALL NO. 2 SHIFT LEVER INNER (a) Install the No. 2 shift lever inner, No. 2 select return compression spring and No. 2 select return spring seat to the shift and select lever shaft. (b) Hold the shift and select lever in a vise using aluminum plates. (c) Using a brass bar and a hammer, install the select seat snap ring to the shift and select lever shaft. MX C135406 (d) Using a pin punch (φ 5 mm) and a hammer, install the 2 shift inner lever slotted pins to the shift and select lever shaft. Clearance A: 0.7 to 1.7 mm (0.0276 to 0.0669 in.) Clearance B: -0.4 to 0.5 mm (-0.0157 to 0.0197 in.) A B C135405E01 7. INSTALL SELECTING BELLCRANK NO. 2 BUSHING (a) Coat the 2 selecting bellcrank No. 2 bushings with MP grease and install them to the No. 2 selecting bellcrank. 8. INSTALL NO. 2 SELECTING BELLCRANK DUST COVER (a) Coat the No. 2 selecting bellcrank dust cover with MP grease and install it to the No. 2 selecting bellcrank. C069798 C069531 MX–104 E351 MANUAL TRANSAXLE – SHIFT AND SELECT LEVER SHAFT 9. MX INSTALL SELECTING BELLCRANK SUPPORT SUBASSEMBLY (a) Install the selecting bellcrank support sub-assembly to the No. 2 selecting bellcrank. C069799 (b) Install the No. 2 selecting bellcrank plate washer, washer, and nut. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) C069532 10. INSTALL NO. 1 SELECTING BELLCRANK DUST COVER (a) Install the No. 1 selecting bellcrank dust cover to the No. 2 selecting bellcrank. C069530 11. INSTALL CONTROL SHIFT LEVER BUSHING (a) Install the control shift lever bushing to the No. 2 selecting bellcrank. C069529 MX–105 E351 MANUAL TRANSAXLE – DIFFERENTIAL CASE DIFFERENTIAL CASE E351 MANUAL TRANSAXLE TRANSMISSION COMPONENTS FRONT DIFFERENTIAL PINION THRUST WASHER NO. 1 FRONT DIFFERENTIAL SIDE GEAR THRUST WASHER FRONT DIFFERENTIAL PINION FRONT DIFFERENTIAL SIDE GEAR NO. 1 FRONT DIFFERENTIAL SIDE GEAR THRUST WASHER FRONT DIFFERENTIAL RING GEAR NO. 1 FRONT DIFFERENTIAL PINION SHAFT FRONT DIFFERENTIAL PINION FRONT DIFFERENTIAL PINION THRUST WASHER FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN FRONT DIFFERENTIAL RING GEAR FRONT DIFFERENTIAL CASE 106 (1,080, 78) x16 SPEEDOMETER DRIVE GEAR N*m (kgf*cm, ft.*lbf) : Specified torque C109722E02 MX MX–106 E351 MANUAL TRANSAXLE – DIFFERENTIAL CASE DISASSEMBLY MX 1. REMOVE SPEEDOMETER DRIVE GEAR (a) Remove the speedometer drive gear from the front differential case assembly. 2. REMOVE FRONT DIFFERENTIAL RING GEAR (a) Put matchmarks on the front differential ring gear and the front differential case. C083559 Matchmarks C083560E01 (b) Remove the 16 bolts. (c) Using a plastic hammer, remove the front differential case. C083561 3. SST REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN (a) Using SST and a hammer, unstake the staked part of the front differential case. SST 09930-00010 C092887E01 (b) Using a pin punch and a hammer, remove the front differential pinion shaft straight pin from the front differential case. C083564 E351 MANUAL TRANSAXLE – DIFFERENTIAL CASE 4. MX–107 REMOVE NO. 1 FRONT DIFFERENTIAL PINION SHAFT (a) Remove the No. 1 front differential pinion shaft from the front differential case. MX C083565 5. REMOVE FRONT DIFFERENTIAL SIDE GEAR (a) Remove the 2 front differential pinions, 2 front differential pinion thrust washers, 2 front differential side gears, and 2 front differential side gear thrust washers from the front differential case. HINT: Remove the 2 pinion thrust washers and side gear thrust washers while turning the front differential pinion. C083566 INSPECTION 1. INSPECT FRONT DIFFERENTIAL SIDE GEAR BACKLASH (a) Hold the front differential pinion to the front differential case side. Using a dial indicator, measure the front differential side gear backlash. Standard backlash: 0.05 to 0.20 mm (0.002 to 0.0079 in.) If backlash is out of specification, install proper side gear thrust washers. 2. INSPECT FRONT DIFFERENTIAL PINION THRUST WASHER (a) Using a micrometer, measure the thickness of the front differential pinion thrust washer. Minimum thickness: 0.9 mm (0.035 in.) If the thickness is less than the minimum, replace the front differential pinion thrust washer. 3. INSPECT NO. 1 FRONT DIFFERENTIAL PINION SHAFT (a) Using a micrometer, measure the outside diameter of the No. 1 front differential pinion shaft. Minimum diameter: 17.975 mm (0.70768 in.) If the outer diameter is less than the minimum, replace the No. 1 front differential pinion shaft. C083562 C068517 C068518 MX–108 E351 MANUAL TRANSAXLE – DIFFERENTIAL CASE REASSEMBLY MX 1. INSTALL FRONT DIFFERENTIAL SIDE GEAR (a) Coat the rotating surface of the front differential side gear with gear oil. (b) Install the 2 front differential side gear thrust washers to the 2 front differential side gears. (c) Install the 2 front differential side gears, 2 front differential pinions, and 2 front differential side gear thrust washers to the front differential case. HINT: Install the 2 front differential pinions with the front differential washers while turning the front differential pinion. 2. REMOVE NO. 1 FRONT DIFFERENTIAL PINION SHAFT (a) Coat the rotating surface of the No. 1 front differential pinion shaft with gear oil. (b) Install the No. 1 front differential pinion shaft to the front differential case so that the hole for the front differential pinion shaft straight pin is aligned with the hole in the front differential case. 3. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN (a) Using a pin punch and a hammer, install the front differential pinion shaft straight pin to the front differential case. C083566 C083565 C083567 (b) Using a chisel and hammer, stake the front differential case hole. C083568 MX–109 E351 MANUAL TRANSAXLE – DIFFERENTIAL CASE 4. C083562 5. 90 to 100°C ADJUST FRONT DIFFERENTIAL SIDE GEAR BACKLASH (a) Hold the front differential pinion to the front differential case side. Using a dial indicator, measure the front differential side gear backlash. Standard backlash: 0.05 to 0.20 mm (0.002 to 0.0079 in.) (b) If backlash is out of specification, select another front differential side gear thrust washer and adjust backlash. Thrust washer Part No. Thickness: mm (in.) Mark 41361-28230 1.00 (0.0394) 1 41361-28240 1.10 (0.0433) 2 41361-28250 1.20 (0.0472) 3 41361-28260 1.30 (0.0512) 4 INSTALL FRONT DIFFERENTIAL RING GEAR (a) Using a heater, heat the front differential ring gear to 90 to 100°C (194.0 to 212.0°F). (b) Clean the surface that contacts the differential case. C092888E03 (c) Aligning the matchmarks, quickly install the front differential ring gear to the front differential case. Torque: 106 N*m (1,081 kgf*cm, 78 ft.*lbf) Matchmarks C070796E01 6. C070795 INSTALL SPEEDOMETER DRIVE GEAR (a) Install the speedometer drive gear to the front differential case. MX LU–1 2AZ-FE LUBRICATION – LUBRICATION SYSTEM LUBRICATION SYSTEM ON-VEHICLE INSPECTION 1. CHECK ENGINE OIL LEVEL (a) Warm up the engine, stop the engine and wait for 5 minutes. (b) Check that the engine oil level is between the L and F marks of the oil dipstick. If low, check for leakage and add oil up to the F mark. NOTICE: Do not add engine oil above the F mark. 2. CHECK ENGINE OIL QUALITY (a) Check the oil for deterioration, water intrusion, discoloration or thinning. If the quality is visibly poor, replace the oil. Oil grade: Use ILSAC multigrade engine oil. SAE 5W-20 and SAE 0W-20 engine oil may be used. However, SAE 0W-20 is the best choice for good fuel economy and good starting in cold weather. 3. CHECK OIL PRESSURE (a) Disconnect the oil pressure switch connector. Recommended Viscosity (SAE) 5W-20, 0W-20 °C -29 -18 °F -20 0 -7 20 4 40 16 60 27 38 80 100 A066623E18 (b) Using a 24 mm deep socket wrench, remove the oil pressure switch. A112272 (c) Install the oil pressure gauge. (d) Warm up the engine. (e) Measure the oil pressure. Standard oil pressure Oil Pressure Gauge A112273E01 Condition Specified Condition Idle 29 kPa (0.3 kgf/cm2, 4.3 psi) or more 3,000 rpm 170 to 300 kPa (1.7 to 3.1 kgf/cm2, 24 to 44 psi) LU LU–2 2AZ-FE LUBRICATION – LUBRICATION SYSTEM (f) Adhesive A085603E02 LU Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent (g) Using a 24 mm deep socket wrench, install the oil pressure switch. Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) NOTICE: Do not start the engine within 1 hour of installation. (h) Connect the oil pressure switch connector. (i) Check for engine oil leaks. 2AZ-FE LUBRICATION – OIL FILTER LU–3 OIL FILTER 2AZ-FE LUBRICATION ENGINE COMPONENTS 13 (133, 10) OIL FILTER SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A134971E01 LU LU–4 2AZ-FE LUBRICATION – OIL FILTER REPLACEMENT CAUTION: • Prolonged and repeated contact with engine oil will cause the loss of natural oils from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. • Precautions should be taken when replacing engine oil to minimize the risk of your skin making contact with used engine oil. Wear protective clothing and gloves. Wash your skin thoroughly with soap and water, or use a waterless hand cleaner to remove any used engine oil. Do not use gasoline, thinners or solvents. • For environmental protection, used oil and used oil filters must be disposed of at designated disposal sites. 1. DRAIN ENGINE OIL (a) Remove the oil filler cap. (b) Remove the oil drain plug and drain the oil into a container. 2. REMOVE OIL FILTER SUB-ASSEMBLY (a) Using SST, remove the oil filter. SST 09228-06501 3. INSTALL OIL FILTER SUB-ASSEMBLY (a) Check and clean the oil filter installation surface. (b) Apply clean engine oil to the gasket of a new oil filter. SST A136225E01 (c) Lightly screw the oil filter into place by hand. Tighten it until the gasket contacts the seat. (d) Using SST, tighten the oil filter. SST 09228-06501 (1) Depending on the work space available, choose from the following. 1. If enough space is available, use a torque wrench to tighten the oil filter. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) 2. If enough space is not available to use a torque wrench, tighten the oil filter a 3/4 turn by hand or use a common wrench. LU SST A136227E01 4. ADD ENGINE OIL (a) Clean and install the oil drain plug with a new gasket. Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) (b) Add new oil. Standard capacity Item Drain and refill with oil filter change Standard Condition 4.3 liters (4.5 US qts, 3.8 Imp. qts) LU–5 2AZ-FE LUBRICATION – OIL FILTER Item Standard Condition Drain and refill without oil filter change 4.1 liters (4.3 US qts, 3.6 Imp. qts) Dry fill 5.0 liters (5.3 US qts, 4.4 Imp. qts) (c) Install the oil filler cap. 5. CHECK FOR ENGINE OIL LEAKS LU LU–5 2AZ-FE LUBRICATION – OIL PUMP OIL PUMP 2AZ-FE LUBRICATION ENGINE COMPONENTS ENGINE MOVING CONTROL ROD SUB-ASSEMBLY 64 (653, 47) NO. 2 ENGINE MOUNTING BRACKET RH 9.0 (92, 80 in.*lbf) 52 (531, 38) 64 (653, 47) NO. 1 ENGINE COVER SUB-ASSEMBLY NO. 2 ENGINE MOUNTING STAY RH V-RIBBED BELT 9.8 (100, 87 in.*lbf) 52 (531, 38) 21 (214, 15) GENERATOR ASSEMBLY LU FRONT FENDER APRON SEAL RH N*m (kgf*cm, ft.*lbf) : Specified torque A134948E01 LU–6 2AZ-FE LUBRICATION – OIL PUMP 43 (439, 32) VANE PUMP ASSEMBLY FRONT EXHAUST PIPE ASSEMBLY EXHAUST PIPE GASKET 56 (571, 41) EXHAUST PIPE GASKET 62 (633, 46) LU REAR EXHAUST PIPE NO. 1 SUPPORT BRACKET FRONT EXHAUST PIPE NO. 1 SUPPORT BRACKET 33 (337, 24) 33 (337, 24) ENGINE UNDER COVER RH ENGINE UNDER COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A134947E01 LU–7 2AZ-FE LUBRICATION – OIL PUMP 9.0 (92, 80 in.*lbf) IGNITION COIL ASSEMBLY 14 (143, 10) 14 (143, 10) 11 (110, 8) x2 x6 11 (110, 8) CYLINDER HEAD COVER SUB-ASSEMBLY CYLINDER HEAD COVER GASKET CRANK POSITION SENSOR LU 9.0 (92, 80 in.*lbf) TMMK: 170 (1,733, 125) TMC: 180 (1,835, 133) OIL PAN SUB-ASSEMBLY CRANKSHAFT PULLEY 25 (255, 18) OIL PAN DRAIN PLUG GASKET 9.0 (92, 80 in.*lbf) x2 x12 9.0 (92, 80 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A134922E01 LU–8 2AZ-FE LUBRICATION – OIL PUMP CRANKSHAFT TIMING SPROCKET NO. 1 CHAIN VIBRATION DAMPER CHAIN SUB-ASSEMBLY NO. 2 CHAIN SUB-ASSEMBLY CHAIN TENSIONER SLIPPER OIL PUMP DRIVE SPROCKET 19 (194, 14) SPRING NO. 1 CRANKSHAFT POSITION SENSOR PLATE CHAIN TENSIONER PLATE GASKET 12 (122, 9.0) 9.0 (92, 80 in.*lbf) OIL PUMP DRIVEN SPROCKET TIMING CHAIN GUIDE OIL PUMP ASSEMBLY 30 (301, 22) 19 (194, 14) x3 11 (112, 8) 9.0 (92, 80 in.*lbf) 11 (112, 8) NO. 1 CHAIN TENSIONER ASSEMBLY GASKET LU 55 (561, 44) x4 22 (220, 16) STUD BOLT 60 (607, 44) 9.0 (92, 80 in.*lbf) V-RIBBED BELT TENSIONER ASSEMBLY x8 TIMING CHAIN CASE OIL SEAL TIMING CHAIN COVER SUB-ASSEMBLY 25 (255, 18) Non-reusable part N*m (kgf*cm, ft.*lbf) : Specified torque Apply MP grease A140756E01 LU–9 2AZ-FE LUBRICATION – OIL PUMP 8.8 (90, 78 in.*lbf) GASKET 8.8 (90, 78 in.*lbf) OIL PUMP STRAINER OIL PUMP COVER DRIVE ROTOR DRIVEN ROTOR 49 (500, 36) OIL PUMP RELIEF VALVE PLUG LU OIL PUMP ASSEMBLY OIL PUMP RELIEF VALVE OIL PUMP RELIEF VALVE SPRING Non-reusable part N*m (kgf*cm, ft.*lbf) : Specified torque A114157E07 LU–10 2AZ-FE LUBRICATION – OIL PUMP REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (See page EM-94) 3. REMOVE FRONT WHEEL RH 4. REMOVE ENGINE UNDER COVER LH 5. REMOVE ENGINE UNDER COVER RH 6. REMOVE FRONT FENDER APRON SEAL RH 7. DRAIN ENGINE OIL (See page LU-4) 8. REMOVE FRONT EXHAUST PIPE ASSEMBLY (See page EX-2) 9. REMOVE NO. 2 ENGINE MOUNTING STAY RH (See page EM-95) 10. REMOVE ENGINE MOVING CONTROL ROD SUBASSEMBLY (See page EM-95) 11. REMOVE NO. 2 ENGINE MOUNTING BRACKET RH (See page EM-96) 12. REMOVE V-RIBBED BELT (See page EM-6) 13. REMOVE GENERATOR ASSEMBLY (See page CH-11) 14. REMOVE VANE PUMP ASSEMBLY (See page EM101) 15. REMOVE IGNITION COIL ASSEMBLY (See page EM106) 16. DISCONNECT VENTILATION HOSE 17. DISCONNECT NO. 2 VENTILATION HOSE 18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (See page EM-21) LU 19. SET SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page EM-8) 20. REMOVE CRANKSHAFT PULLEY (See page EM-75) 21. REMOVE CRANK POSITION SENSOR (See page ES411) 22. REMOVE OIL PAN SUB-ASSEMBLY (See page EM22) 23. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY (See page EM-22) 24. INSTALL ENGINE HANGERS (See page EM-22) 25. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (See page EM-23) 26. REMOVE ENGINE MOUNTING INSULATOR (See page EM-23) 2AZ-FE LUBRICATION – OIL PUMP LU–11 27. REMOVE ENGINE MOUNTING BRACKET RH (See page EM-24) 28. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY (a) Using a E10 "torx" socket, remove the stud bolt for the drive belt tensioner from the cylinder block. (b) Remove the 12 bolts and 2 nuts. A128178 (c) Remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder block and cylinder head. HINT: Tape the screwdriver tip before use. LU A128179 LU–12 2AZ-FE LUBRICATION – OIL PUMP 29. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL (a) Using a screwdriver and a hammer, tap out the oil seal. HINT: Tape the screwdriver tip before use. 30. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE (See page EM-24) A128180 31. REMOVE CHAIN TENSIONER SLIPPER (See page EM-24) 32. REMOVE NO. 1 CHAIN VIBRATION DAMPER (See page EM-24) 33. REMOVE TIMING CHAIN GUIDE (See page EM-25) 34. REMOVE CHAIN SUB-ASSEMBLY (See page EM-25) 35. REMOVE CRANKSHAFT TIMING SPROCKET (See page EM-25) 36. REMOVE NO. 2 CHAIN SUB-ASSEMBLY (See page EM-25) 37. REMOVE OIL PUMP ASSEMBLY (a) Remove the 3 bolts, oil pump and gasket. B011673E01 DISASSEMBLY 1. REMOVE OIL PUMP STRAINER (a) Remove the 2 nuts, oil pump strainer and gasket. 2. REMOVE OIL PUMP RELIEF VALVE (a) Using a 27 mm socket wrench, remove the plug. (b) Remove the valve spring and relief valve. LU B011430E01 Relief Valve Plug Valve Spring A052074E02 2AZ-FE LUBRICATION – OIL PUMP 3. LU–13 REMOVE OIL PUMP COVER (a) Remove the 5 bolts and oil pump cover. (b) Remove the oil pump rotor. B011431E01 INSPECTION 1. INSPECT OIL JET (a) Check the oil jet for damage or clogging. If necessary, repair the cylinder block. 2. INSPECT OIL PUMP RELIEF VALVE (a) Check the relief valve. (1) Coat the valve with engine oil, and then check that the valve falls smoothly into the valve hole under its own weight. If the valve does not fall smoothly, replace the relief valve. If necessary, replace the oil pump assembly. 3. INSPECT OIL PUMP ROTOR (a) Install the oil pump rotor. (1) Coat the drive rotor and driven rotor with engine oil. (2) Place the drive and driven rotors into the oil pump with the marks facing the pump cover side. A126890 A114340 Mark B011423E04 B011420E02 (b) Check the side clearance. (1) Using a feeler gauge and precision straightedge, measure the clearance between the rotors and precision straightedge. Standard clearance: 0.030 to 0.085 mm (0.0012 to 0.0033 in.) Maximum clearance: 0.16 mm (0.0063 in.) If the side clearance is greater than the maximum, replace the oil pump assembly. LU LU–14 2AZ-FE LUBRICATION – OIL PUMP (c) Check the tip clearance. (1) Using a feeler gauge, measure the clearance between the drive and driven rotor tips. Standard clearance: 0.080 to 0.160 mm (0.0031 to 0.0063 in.) Maximum clearance: 0.35 mm (0.0138 in.) If the tip clearance is greater than the maximum, replace the oil pump assembly. Feeler Gauge A114223E01 (d) Check the body clearance. (1) Using a feeler gauge, measure the clearance between the driven rotor and pump body. Standard clearance: 0.100 to 0.170 mm (0.0039 to 0.0067 in.) Maximum clearance: 0.325 mm (0.0128 in.) If the body clearance is greater than the maximum, replace the oil pump assembly. B011422E01 4. INSPECT NO. 2 CHAIN SUB-ASSEMBLY (See page EM-138) 5. INSPECT OIL PUMP DRIVE SPROCKET (See page EM-138) 6. INSPECT OIL PUMP DRIVEN SPROCKET (See page EM-139) 7. INSPECT CHAIN TENSIONER PLATE (See page EM140) REASSEMBLY 1. INSTALL OIL PUMP COVER (a) Install the oil pump cover with the 5 bolts. Torque: 8.8 N*m (90 kgf*cm, 78 in.*lbf) 2. INSTALL OIL PUMP RELIEF VALVE (a) Coat the relief valve with engine oil. LU B011431E01 (b) Insert the relief valve and spring into the pump body hole. (c) Using a 27 mm socket wrench, install the plug. Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) Relief Valve Plug Valve Spring A052074E02 2AZ-FE LUBRICATION – OIL PUMP 3. LU–15 INSTALL OIL PUMP STRAINER (a) Install a new gasket and the oil strainer with the 2 nuts. Torque: 8.8 N*m (90 kgf*cm, 78 in.*lbf) B011430E01 INSTALLATION B011673E01 SST A128223E03 1. INSTALL OIL PUMP ASSEMBLY (a) Install a new gasket and the oil pump with the 3 bolts. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) 2. INSTALL NO. 2 CHAIN SUB-ASSEMBLY (See page EM-27) 3. INSTALL CRANKSHAFT TIMING SPROCKET (See page EM-28) 4. INSTALL NO. 1 CHAIN VIBRATION DAMPER (See page EM-28) 5. INSTALL CHAIN SUB-ASSEMBLY (See page EM-28) 6. INSTALL CHAIN TENSIONER SLIPPER (See page EM-29) 7. INSTALL TIMING CHAIN GUIDE (See page EM-30) 8. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE (See page EM-30) 9. INSTALL TIMING CHAIN CASE OIL SEAL (a) Using SST, tap in a new oil seal until its surface is flush with the timing chain cover edge. SST 09223-22010 (b) Apply a light coat of MP grease to the lip of the oil seal. NOTICE: Keep the gap between the timing chain cover edge and the oil seal free of foreign matter. 10. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block. LU LU–16 2AZ-FE LUBRICATION – OIL PUMP (b) Apply seal packing (diameter: 4.0 to 4.5 mm (0.157 to 0.177 in.)) as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent (c) Apply seal packing in a continuous bead as shown in the illustration. Seal Packing 4.0 to 4.5 mm (0.157 to 0.177 in.) A140776E01 A Seal Diameter: 4.0 (0.157) Seal Diameter: 4.0 (0.157) Seal Diameter: 2.5 to 3.0 (0.098 to 0.118) B A E Seal Diameter: 4.0 to 4.5 (0.157 to 0.177) D B LU Seal Diameter: 3.0 (0.118) 4.0 (0.157) C C Seal Diameter: 2.5 to 3.0 (0.098 to 0.118) 17.5 (0.689) 13.0 (0.512) E D Seal Diameter: 5.5 to 6.0 (0.217 to 0.236) Seal Diameter: 2.5 to 3.0 (0.098 to 0.118) : Seal Packing Seal Diameter: 4.5 to 5.0 (0.177 to 0.197) mm (in.) A132566E03 LU–17 2AZ-FE LUBRICATION – OIL PUMP Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent NOTICE: • Remove any oil from the contact surface. • Install the chain cover within 3 minutes after applying seal packing. • Do not start the engine for at least 2 hours after installing. NUT NUT C C C B B A B B B B B STUD BOLT (d) Install the timing chain cover with the 12 bolts and 2 nuts. Torque: Bolt A 9.0 N*m (92 kgf*cm, 80 in.*lbf) Bolt B 25 N*m (255 kgf*cm, 18 ft.*lbf) Bolt C 55 N*m (561 kgf*cm, 41 ft.*lbf) Nut 11 N*m (112 kgf*cm, 8 ft.*lbf) Bolt length Item Length Bolt A 30 mm (1.18 in.) length for 10 mm head Bolt B 30 mm (1.18 in.) length for 12 mm head Bolt C 40 mm (1.57 in.) length for 14 mm head (e) Using a E10 "torx" socket, install the stud bolt to the drive belt tensioner. Torque: 22 N*m (220 kgf*cm, 16 ft.*lbf) B A128178E01 11. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (See page EM-30) 12. INSTALL ENGINE MOUNTING BRACKET RH (See page EM-30) 13. INSTALL ENGINE MOUNTING INSULATOR (See page EM-30) 14. INSTALL OIL PAN SUB-ASSEMBLY (See page EM-31) 15. INSTALL CRANK POSITION SENSOR (See page ES411) 16. INSTALL CRANKSHAFT PULLEY (See page EM-76) 17. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (See page EM-32) 18. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (See page EM-33) 19. INSTALL NO. 2 VENTILATION HOSE 20. INSTALL VENTILATION HOSE 21. INSTALL IGNITION COIL ASSEMBLY (See page EM33) 22. INSTALL VANE PUMP ASSEMBLY (See page EM-113) 23. INSTALL GENERATOR ASSEMBLY (See page CH-19) LU LU–18 2AZ-FE LUBRICATION – OIL PUMP 24. INSTALL V-RIBBED BELT (See page EM-6) 25. INSTALL NO. 2 ENGINE MOUNTING BRACKET RH (See page EM-118) 26. INSTALL ENGINE MOVING CONTROL ROD SUBASSEMBLY (See page EM-119) 27. INSTALL NO. 2 ENGINE MOUNTING STAY RH (See page EM-119) 28. INSTALL FRONT EXHAUST PIPE ASSEMBLY (See page EX-3) 29. ADD ENGINE OIL 30. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page EM-120) 31. CHECK ENGINE OIL LEAKS 32. CHECK CHECK EXHAUST GAS LEAKS 33. CHECK IGNITION TIMING (See page EM-1) 34. INSTALL FRONT FENDER APRON SEAL RH 35. INSTALL ENGINE UNDER COVER LH 36. INSTALL ENGINE UNDER COVER RH 37. INSTALL FRONT WHEEL RH 38. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (See page EM-121) LU 2AZ-FE LUBRICATION – ENGINE OIL COOLER (w/ Oil Cooler) LU–19 ENGINE OIL COOLER (w/ Oil Cooler) 2AZ-FE LUBRICATION ENGINE COMPONENTS O-RING WATER BY-PASS HOSE ENGINE OIL COOLER PLATE WASHER 9.0 (92, 80 in.*lbf) LU 79 (800, 58) OIL COOLER UNION BOLT 13 (133, 10) OIL FILTER SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A124386E06 LU–20 2AZ-FE LUBRICATION – ENGINE OIL COOLER (w/ Oil Cooler) REMOVAL 1. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH 2. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH 3. REMOVE ENGINE UNDER COVER RH 4. REMOVE ENGINE UNDER COVER LH 5. DRAIN ENGINE COOLANT (See page CO-5) 6. DRAIN ENGINE OIL (See page LU-4) 7. REMOVE OIL FILTER SUB-ASSEMBLY (See page LU4) 8. REMOVE ENGINE OIL COOLER (a) Disconnect the 2 oil cooler hoses from the oil cooler. (b) Remove the oil cooler union bolt, plate washer, nut, oil cooler and O-ring. A114329 INSPECTION 1. A124388 LU INSPECT ENGINE OIL COOLER (a) Check the engine oil cooler for damage or clogging. If necessary, replace the oil cooler. 2AZ-FE LUBRICATION – ENGINE OIL COOLER (w/ Oil Cooler) LU–21 INSTALLATION 1. INSTALL ENGINE OIL COOLER (a) Clean the oil cooler contact surface. (b) Install a new O-ring to the oil cooler. New O-Ring A124389E01 (c) Apply a light coat of engine oil to the threads and under the head of the oil cooler union bolt. (d) Install the oil cooler with the plate washer, oil cooler union bolt and nut. Torque: for union bolt 79 N*m (800 kgf*cm, 58 ft.*lbf) for nut 9.0 N*m (92 kgf*cm, 80 in.*lbf) (e) Connect the 2 oil cooler hoses. A114329 2. INSTALL OIL FILTER SUB-ASSEMBLY (See page LU4) 3. ADD ENGINE OIL (See page LU-4) 4. ADD ENGINE COOLANT (See page CO-5) 5. CHECK FOR ENGINE OIL LEAKS 6. CHECK FOR ENGINE COOLANT LEAKS (See page CO-1) 7. CHECK ENGINE OIL LEVEL (See page LU-1) 8. INSTALL ENGINE UNDER COVER RH 9. INSTALL ENGINE UNDER COVER LH 10. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH 11. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH LU LI–1 LIGHTING – LIGHTING SYSTEM LIGHTING SYSTEM PRECAUTION 1. 2. 3. Switch Type Ignition switch off Expression Ignition switch on (IG) Ignition switch on (ACC) Engine start PRECAUTION FOR USING BATTERY DURING INSPECTION (a) While using the battery during inspection, do not bring the positive and negative tester probes too close to each other as a short circuit may occur. PRECAUTION FOR HEADLIGHT BULB REPLACEMENT (a) If even a thin film of oil is left on the surface of the halogen light, the bulb may be damaged because the light will burn at a higher temperature. (b) Handle any halogen light with great care. Dropping, hitting or damaging the bulb, in any way, may result in exploding and shattering because the internal pressure is high. (c) Always prepare a new bulb for immediate replacement. While replacing the bulb, the lens may attract dust and moisture if removed from the vehicle for too long. (d) Always use a bulb of the same wattage for replacement. (e) Firmly reinstall the socket after bulb replacement. The lens may become cloudy or the light cavity may fill with water through the gaps around the socket. EXPRESSIONS OF IGNITION SWITCH (a) The type of ignition switch used on this model differs according to the specifications of the vehicle. The expressions listed in the table below are used in this section. Ignition Switch (position) Engine Switch (condition) LOCK Off ON On (IG) ACC On (ACC) START Start LI LI–2 LIGHTING – LIGHTING SYSTEM PARTS LOCATION HEADLIGHT ASSEMBLY - LOW BEAM HEADLIGHT - HIGH BEAM HEADLIGHT - FRONT SIDE MARKER LIGHT - TURN SIGNAL AND PARKING LIGHT GENERATOR ENGINE ROOM J/B ASSEMBLY - POWER DISTRIBUTOR - H-LP (LL) FUSE - H-LR (RL) FUSE - H-LP (LH) FUSE - H-LP (RH) FUSE ECM ENGINE ROOM R/B - DOME FUSE - HAZ FUSE LI FOG LIGHT ASSEMBLY PARK / NEUTRAL POSITION SWITCH (FOR U250E A/T) PARK / NEUTRAL POSITION SWITCH (FOR U660E A/T) BACK-UP LIGHT SWITCH (FOR M/T) E121472E01 LI–3 LIGHTING – LIGHTING SYSTEM PERSONAL LIGHT ASSEMBLY (OVERHEAD J/B) WITHOUT SLIDING ROOF: - FRONT PERSONAL LIGHTS REAR ROOM LIGHT ASSEMBLY - INTERIOR LIGHT VANITY LIGHT PERSONAL LIGHT ASSEMBLY (OVERHEAD J/B) REAR ROOM LIGHT ASSEMBLY - REAR PERSONAL LIGHTS - FRONT PERSONAL LIGHTS REAR COMBINATION LIGHT ASSEMBLY - INTERIOR LIGHT - TAIL/STOP AND SIDE MARKER LIGHT - TURN SIGNAL LIGHT VANITY LIGHT REAR LIGHT ASSEMBLY - BACK-UP LIGHT - TAILLIGHT HIGH MOUNTED STOP LIGHT LI DOOR COURTESY LIGHT LUGGAGE ROOM LIGHT LICENSE PLATE LIGHT E121473E01 LI–4 LIGHTING – LIGHTING SYSTEM INSTRUMENT PANEL J/B HEADLIGHT DIMMER SWITCH (COMBINATION SWITCH) - MAIN BODY ECU - LIGHT CONTROL SWITCH - IG1 RELAY - DIMMER SWITCH - ACC RELAY - TURN SIGNAL SWITCH - TAIL RELAY - FOG LIGHT SWITCH - FOG RELAY - TAIL FUSE - AM1 FUSE TRANSPONDER KEY AMPRIFIER - STOP FUSE - IGNITION KEY CYLINDER LIGHT - FR FOG FUSE - GAUGE NO.1 FUSE AUTOMATIC LIGHT CONTROL SENSOR GLOVE BOX LIGHT LI HAZARD WARNING SWITCH PARKING BRAKE SWITCH TURN SIGNAL FLASHER ASSEMBLY DLC3 STOP LIGHT SWITCH E121474E01 LI–5 LIGHTING – LIGHTING SYSTEM DOOR LOCK ASSEMBLY (FRONT RH) DOOR LOCK ASSEMBLY (FRONT LH) - DOOR UNLOCK DETECTION SWITCH - DOOR UNLOCK DETECTION SWITCH DOOR LOCK ASSEMBLY (REAR RH) - DOOR UNLOCK DETECTION SWITCH MASTER SWITCH ASSEMBLY FRONT DOOR COURTESY SWITCH LI DOOR LOCK ASSEMBLY (REAR LH) - DOOR UNLOCK DETECTION SWITCH REAR DOOR COURTESY SWITCH LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY - BACK DOOR COURTESY SWITCH E121475E01 LI–6 LIGHTING – LIGHTING SYSTEM SYSTEM DIAGRAM Ignition Key Cylinder Light Headlight Dimmer Switch Assembly Interior Light Automatic Light Control Sensor Power Distributor - HEAD Relay Door Courtesy Switches - DRL Relay Door Unlock Detection Switches Low Beam Headlights High Beam Headlights Main Body ECU Parking Brake Switch Ignition Switch or Engine Switch TAIL Relay Taillights Parking Lights License Plate Lights LI ECM Side Marker Lights FOG Relay DLC3 Front Fog Lights : CAN E121511E01 LI–7 LIGHTING – LIGHTING SYSTEM SYSTEM DESCRIPTION 1. Input MANUAL LIGHT CONTROL SYSTEM This system functions if the lights such as the headlights and taillights come on by manual operation of the light control switch. (a) The main body ECU controls this system based on the signals listed below. Output Lights that illuminate Light control switch TAIL signal Taillight relay drive signal • • • • Light control switch HEAD signal Headlight relay drive signal Low beam headlights 2. Input • • Light control switch AUTO signal Automatic light control sensor signal Headlight relay drive signal Taillight relay drive signal 3. Input • • Door courtesy switch signal Ignition switch or engine switch signal AUTOMATIC LIGHT CONTROL SYSTEM When the light control switch is in the AUTO position, the automatic light control sensor detects ambient light, converts it into an electrical signal, and outputs it to the main body ECU. The main body ECU automatically turns the headlights and taillights on or off according to the signal. (a) The main body ECU controls this system based on the signals listed below. Output • • Lights that illuminate • • • • • Low beam headlights Taillights License plate lights Side marker lights Parking lights LIGHT AUTO TURN OFF SYSTEM When the headlights and taillights are on through the operation of the automatic light control system or through the light control switch, if the ignition switch is turned off and all doors are closed, this system continues to illuminate the headlights and taillights for approximately 30 seconds, and then turns off the headlights and taillights. However, if the ignition switch is turned off and all doors are locked, this system turns off the headlights and taillights immediately. (a) The main body ECU controls this system based on the signals listed below. Output • • • • Taillights License plate lights Side marker lights Parking lights Headlight relay OFF demand Taillight relay OFF demand DRL relay OFF demand FOG light relay OFF demand Lights that operate • • • • Low beam headlights Taillights, license plate lights, parking lights, and side marker lights High beam headlights Front fog lights LI LI–8 LIGHTING – LIGHTING SYSTEM 4. Items Conditions Ignition switch or engine switch On (IG) Engine Running Light control switch position OFF, TAIL or AUTO position (if headlight-on control is not being performed by the automatic light control) Parking brake switch Released (OFF) 5. Operation LI DAYTIME RUNNING LIGHT SYSTEM The daytime running light system is designed to automatically illuminate the headlights (dimmed HI beams), during the daytime to make the car more visible to other vehicle. (a) The main body ECU controls this system. The daytime running light system starts operating when all of the following conditions are met: ILLUMINATED ENTRY SYSTEM When a door is unlocked through a key or transmitter operation, or if a door is opened, the illuminated entry system turns on the interior light and the ignition key cylinder light. (a) The main body ECU controls this system. The operation and condition of the illuminated entry system are described below. Condition Fade in When any of the following conditions is met, the interior light and ignition key cylinder light fade in. • Any door is opened. • Any door is unlocked when the ignition switch is off and all doors are closed. • Ignition switch is turned from on (ACC) to off when all doors are closed. Fade out immediately When either of the following conditions is met, the interior light and ignition key cylinder light fade out immediately. • Ignition switch is turned from off to on (ACC or IG) when all doors are closed. • All doors are locked when the ignition switch is off. Illuminate for approximately 15 seconds, and then fade out All doors are closed when the ignition switch is off. Fade out (Battery saving) When the following conditions are met, the interior light and ignition key cylinder light fade out. • A key is not in the actuation area (with smart key system). • A key is not inserted in the ignition key cylinder (without smart key system). • There are no changes in the condition of the doors for 20 minutes. LIGHTING – LIGHTING SYSTEM 6. Power Distributor (Engine Room J/B) LI–9 POWER DISTRIBUTOR (a) The power distributor (engine room J/B assembly) is installed in the engine room R/B. (b) The HEAD relay and DRL relay are installed in the power distributor (engine room J/B assembly). (c) When a short circuit occurs between the power distributor (engine room J/B assembly) and high beam headlight bulbs, a fail-safe function operates. (d) When the fail-safe function operates, the power distributor stops the operation of the DRL relay. E121471E02 LI LI–10 LIGHTING – LIGHTING SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use the following procedures to troubleshoot the lighting system. • *: Use the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS CHECK AND SYMPTOM CHECK NEXT 3 INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT 4 INSPECT CAN COMMUNICATION SYSTEM* (a) Use the intelligent tester to check if the CAN communication system is functioning normally. Result Result Proceed to CAN communication system DTC is not output A CAN communication system DTC is output B LI B Go to step 8 A 5 CHECK FOR DTC* Result Result Proceed to DTC is not output A DTC is output B B A Go to step 8 LI–11 LIGHTING – LIGHTING SYSTEM 6 PROBLEM SYMPTOMS TABLE Result Result Proceed to Fault is not listed in problem symptoms table A Fault is listed in problem symptoms table B B Go to step 8 A 7 OVERALL ANALYSIS AND TROUBLESHOOTING* (a) Data List / Active Test (See page LI-21) (b) Terminals of ECU (See page LI-16) NEXT 8 ADJUST, REPAIR OR REPLACE NEXT 9 CONFIRMATION TEST NEXT END LI LI–12 LIGHTING – LIGHTING SYSTEM CUSTOMIZE PARAMETERS HINT: The followings are the possible items to be customized. NOTICE: • Before attempting to customize vehicle settings, confirm whether it is possible to make the change that the customer has requested. • Be sure to record the current value before customizing. • In case of performing the troubleshooting, pay attention because there is a possibility that the function has been disabled by customizing. (Example: In case of the symptom in which "The wireless operation does not function", check that the wireless operation has not been disabled by customizing, then perform the troubleshooting.) ILLUMINATED ENTRY: Display Default LIGHTING TIME 15 s Changes the lighting time of the interior light and ignition key cylinder light. 7.5 s / 15 s / 30 s I/L ON / UNLOCK ON Lights up the interior light and ignition key cylinder light when a door is unlocked. ON / OFF ON Lights up the interior light and ignition key cylinder light when the ignition switch is turned from on (ACC) to off ON / OFF I/L ON / ACC OFF Contents Setting LIGHT CONTROL: Display LI Default Contents Setting LIGHT OFF DELAY 30 s Keeps the headlights on for a certain period of time after turning the ignition switch off and closing all the doors with the headlights on. OFF / 30 s / 60 s / 90 s SENSITIVITY NORMAL Adjusts the sensitivity of the automatic light control system. *1 LIGHT 2 / LIGHT 1 / NORMAL / DARK 1 / DARK 2 DISP EX ON SEN NORMAL Changes the ambient brightness level required to dim the clock display illumination, etc. *1 LIGHT 2 / LIGHT 1 / NORMAL / DARK 1 / DARK 2 DISP EX OFF SEN NORMAL Changes the ambient brightness level required to cancel the dimming of the clock display illumination, etc. LIGHT 2 / LIGHT 1 / NORMAL / DARK 1 / DARK 2 HINT: Sensitivity adjustment can hardly be confirmed. Check by driving the customer's vehicle. Illustration *1 Ambient Brightness Level Setting Dark DARK2 Bright DARK1 NORMAL LIGHT1 LIGHT2 LI–13 LIGHTING – LIGHTING SYSTEM PROBLEM SYMPTOMS TABLE 1. Headlight system: Symptom One side LO-beam headlight does not illuminate Both left and right LO-beam headlights do not illuminate One side HI-beam headlight does not illuminate Both left and right HI-beam headlights do not illuminate "Flash" headlights do not illuminate LO-beam headlights or HI-beam headlights do not go off Suspected area See page 1. H-LP RL fuse or H-LP LL fuse - 2. Bulb - 3. Harness or connector - 4. Power distributor (Engine room J/B) - 1. H-LP RL fuse and H-LP LL fuse - 2. Bulb - 3. Light control switch circuit LI-48 4. Headlight relay circuit LI-35 5. Main body ECU (Instrument panel J/B) - 1. H-LP RH fuse or H-LP LH fuse - 2. Bulb - 3. Harness or connector - 4. Power distributor (Engine room J/B) - 1. H-LP RH fuse and H-LP LH fuse - 2. Bulb - 3. Light control switch circuit LI-48 4. Headlight (HI-BEAM) circuit LI-39 5. Main body ECU (Instrument panel J/B) - 1. Light control switch circuit LI-48 2. Main body ECU (Instrument panel J/B) - 1. Headlight dimmer switch assembly LI-120 2. Power distributor (Engine room J/B) - 3. Harness or connector - 4. Main body ECU (Instrument panel J/B) - 2. Daytime running light system: Symptom Day time running light system does not operate Suspected area See page 1. Light control switch circuit LI-48 2. Parking brake switch circuit LI-61 3. Power distributor (Engine room J/B) - 4. Main body ECU (Instrument panel J/B) - 5. ECM - LI 3. Taillight system: Symptom Front parking light does not illuminate Rear taillight does not illuminate License plate light does not illuminate Front side marker light does not illuminate Taillight system does not operate (Taillights, front side marker lights, parking lights, and license plate lights do not illuminate) Suspected area 1. Bulb See page - 2. Harness or connector - 1. Bulb - 2. Harness or connector - 1. Bulb - 2. Harness or connector - 1. Bulb - 2. Harness or connector - 1. TAIL fuse - 2. Taillight relay LI-141 3. Light control switch circuit LI-48 4. Taillight relay circuit LI-65 5. Main body ECU (Instrument panel J/B) - LI–14 LIGHTING – LIGHTING SYSTEM 4. Stop light system: Symptom Stop light system does not operate One side stop light does not illuminate Hi-mounted stop light does not illuminate Suspected area See page 1. Bulb - 2. Stop fuse - 3. Stop light switch LI-125 4. Harness or connector - 1. Bulb - 2. Harness or connector - 1. Bulb - 2. Harness or connector - 5. Front fog light system: Symptom One side fog light does not illuminate Both left and right fog lights do not illuminate (Taillight system is normal) Suspected area See page 1. Bulb - 2. Harness or connector - 1. FR FOG fuse - 2. FR FOG relay LI-142 3. Light control switch circuit LI-48 4. Front fog light circuit LI-44 5. Main body ECU (Instrument panel J/B) - 6. Turn signal and hazard warning system: Symptom Hazard warning lights do not operate (Turn signal lights are normal) Turn signal lights do not operate (Hazard warning lights are normal) LI "Hazard" and "Turn" do not operate Turn signal lights do not operate in one direction Only one bulb does not operate Suspected area See page 1. HAZ fuse - 2. Hazard warning signal switch LI-123 3. Clock assembly OT-4 4. Turn signal flasher assembly LI-138 5. Harness or connector - 1. GAUGE No. 1 fuse - 2. Headlight dimmer switch assembly (Turn signal switch) LI-120 3. Turn signal flasher assembly LI-138 4. Harness or connector - 1. HAZ fuse and GAUGE No. 1 fuse - 2. Bulb - 3. Turn signal flasher assembly LI-138 4. Hazard warning signal switch LI-123 5. Headlight dimmer switch assembly (Turn signal switch) LI-120 6. Clock assembly OT-4 7. Harness or connector - 1. Headlight dimmer switch assembly (Turn signal switch) LI-120 2. Turn signal flasher assembly LI-138 3. Harness or connector - 1. Bulb - 2. Harness or connector - 7. Buck-up light system: Symptom One side back-up light does not illuminate Suspected area See page 1. Bulb - 2. Harness or connector - LI–15 LIGHTING – LIGHTING SYSTEM Symptom Suspected area 1. Bulb Both left and right back-up lights do not illuminate See page - 2. GAUGE No. 1 fuse - 3. Buck-up light switch (for M/T) LI-127 4. Park/Neutral position switch (for U250E A/T) AX-129 5. Park/Neutral position switch (for U660E A/T) AX-175 6. Harness or connector - 8. Illuminated entry system: Symptom Only interior light does not illuminate Only ignition key cylinder light does not illuminate Interior light and ignition key cylinder light do not operate normally Suspected area See page 1. Bulb - 2. Personal light assembly (with sliding roof) LI-105 3. Rear room light assembly (without sliding roof) LI-108 4. Harness or connector - 1. Transponder key amplifier (Ignition key cylinder light) LI-113 2. Harness or connector - 1. DOME fuse - 2. Personal light assembly LI-105 3. Rear room light assembly LI-108 4. Transponder key amplifier LI-113 5. Door courtesy switch circuit LI-52 6. Door lock position switch circuit LI-55 7. Ignition switch circuit LI-28 8. Interior light circuit LI-57 9. Main body ECU (Instrument panel J/B) - 9. Vanity light system: Symptom Vanity light does not illuminate Suspected area See page 1. Bulb - 2. Vanity light assembly LI-116 3. Visor assembly (Vanity light switch) - 4. Harness or connector - 10. Luggage compartment light system: Symptom Luggage compartment light does not illuminate Suspected area See page 1. Luggage compartment light LI-111 2. Luggage compartment door lock assembly (Door courtesy switch) LI-132 3. Harness or connector - 11. Glove box light system: Symptom Glove box light does not illuminate Suspected area See page 1. Bulb - 2. Glove box light assembly LI-115 3. Harness or connector - 12. Door courtesy light system: Symptom Door courtesy light does not illuminate Suspected area See page 1. Door courtesy light LI-109 2. Front door courtesy switch LI-129 3. Harness or connector - LI LI–16 LIGHTING – LIGHTING SYSTEM 13. Personal light system: Symptom Front personal lights do not illuminate Rear personal lights do not illuminate Suspected area See page 1. Bulb - 2. Personal light assembly LI-105 3. Harness or connector - 1. Bulb - 2. Rear room light assembly LI-108 3. Harness or connector - 14. Automatic light control system: Symptom Automatic light control system does not operate normally Suspected area See page 1. Light control switch circuit LI-48 2. Automatic light control sensor circuit LI-23 3. Main body ECU (Instrument panel J/B) - 15. Light auto turn off system: Symptom Light auto turn off system does not operate normally Suspected area See page 1. Light control switch circuit LI-48 2. Door courtesy switch circuit LI-52 3. Main body ECU (Instrument panel J/B) - 16. Battery saving system: Symptom Battery saving function does not operate LI Suspected area See page 1. Door courtesy switch circuit LI-52 2. Main body ECU (Instrument panel J/B) - LI–17 LIGHTING – LIGHTING SYSTEM TERMINALS OF ECU 1. CHECK MAIN BODY ECU (INSTRUMENT PANEL J/B) Front Side: IK IJ IM IE IL IF IN IR IC ID IP IO IA IB Back Side: E7 E6 IG II E8 E9 IH LI E111961E05 (a) Disconnect the IA, ID, IF and IM J/B connectors. (b) Measure the voltage and resistance between the specified terminals of the wire harness side connectors and body ground. Standard voltage Symbols IA-1 - Body ground Wiring Color B - Body ground Terminal Description Battery power supply Condition Always Specified Condition 10 to 14 V LI–18 LIGHTING – LIGHTING SYSTEM Symbols ALTB (ID-16) - Body ground Wiring Color W - Body ground Terminal Description Generator power supply Condition Always Specified Condition 10 to 14 V Standard resistance Symbols Wiring Color Terminal Description Condition Specified Condition GND1 (IF-10) - Body ground W-B - Body ground Ground Always Below 1 Ω GND2 (IM-9) - Body ground W-B - Body ground Ground Always Below 1 Ω If the result is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the IA, ID, IF, and IM J/B connectors. (d) Measure the resistance and voltage between the specified terminals of the J/B connectors and body ground. Standard resistance Symbols CLTE (E6-18) - Body ground Wiring Color BR - Body ground Terminal Description Automatic light control ground Condition Specified Condition Below 1 Ω Always Standard voltage Symbols Terminal Description L - Body ground Parking brake switch input HRLY (ID-3) - Body ground P - Body ground Headlight relay drive output DRL (ID-9) - Body ground V - Body ground HU (IG-5) - Body ground LG - Body ground PKB (IC-14) - Body ground (*3) LI Wiring Color High beam headlights drive output Dimmer switch HIGH input Interior light and ignition key cylinder light drive output Condition Specified Condition Parking brake switch ON Below 1 V Parking brake switch OFF 10 to 14 V Light control switch in HEAD Below 1 V Light control switch not in HEAD 10 to 14 V Dimmer switch in HIGH or HIGH FLASH Below 1 V Dimmer switch in LOW 10 to 14 V Dimmer switch in HIGH or HIGH FLASH 10 to 14 V Dimmer switch in LOW Below 1 V Interior light and ignition key cylinder light ON Below 1 V Interior light and ignition key cylinder light OFF 10 to 14 V Parking brake switch ON Below 1 V Parking brake switch OFF (Released) 10 to 14 V ILE (II-10) - Body ground (*2) BR - Body ground PKB (IM-2) - Body ground (*4) Y - Body ground Parking brake switch input LCTY (IO-7) - Body ground LG - Body ground Rear left door courtesy switch input Rear left door open Below 1 V Rear left door closed 10 to 14 V LSR (IP-5) - Body ground (*2) GR - Body ground Rear left door lock position switch input Rear left door locked 10 to 14 V Rear left door unlocked Below 1 V LSWL (IP-5) - Body ground (*2) GR - Body ground Rear left door lock position switch input Rear left door locked 10 to 14 V Rear left door unlocked Below 1 V Light control switch in HEAD Below 1 V P - Body ground Light control switch HEAD input Light control switch not in HEAD 10 to 14 V HEAD (E6-17) - Body ground LI–19 LIGHTING – LIGHTING SYSTEM Symbols CLTS (E6-19) - Body ground CLTB (E6-20) - Body ground PCTY (E6-21) - Body ground LGCY (E6-25) - Body ground LSWP (E6-27) - Body ground Wiring Color Terminal Description G - Body ground Automatic light control sensor signal input B - Body ground Automatic light control sensor power supply output Y - Body ground Passenger side door courtesy switch input W - Body ground LG - Body ground Luggage courtesy switch input Passenger side door lock position switch input Front fog light switch input Condition Specified Condition Ignition switch off Below 1 V Automatic light control system operates Pulse generation (See waveform 1) Ignition switch off Below 1 V Ignition switch on (IG) and light control switch in AUTO 10 to 14 V Passenger side door open Below 1 V Passenger side door closed 10 to 14 V Luggage compartment door open Below 1 V Luggage compartment door closed 10 to 14 V Passenger side door locked 10 to 14 V Passenger side door unlocked Below 1 V Front fog light switch ON Below 1 V Front fog light switch OFF 10 to 14 V Rear right door locked 10 to 14 V Rear right door unlocked Below 1 V FFOG (E6-28) - Body ground V - Body ground LSWR (E6-5) - Body ground (*1) V - Body ground Rear right door lock position switch input RCTY (E6-5) - Body ground (*2) GR - Body ground Rear right door courtesy switch input Rear right door open Below 1 V Rear right door closed 10 to 14 V Rear right door courtesy switch input Rear right door open Below 1 V RCTY (E6-7) - Body ground (*1) GR - Body ground HF (E7-13) - Body ground R - Body ground SSW2 (E7-16) - Body ground (*1) V - Body ground SSW1 (E7-17) - Body ground (*1) L - Body ground A (E7-21) - Body ground ACCD (E7-22) - Body ground (*1) G - Body ground W - Body ground TAIL (E7-23) - Body ground B - Body ground DCTY (E7-24) - Body ground L - Body ground IG1D (E7-3) - Body ground (*1) P - Body ground Dimmer switch HIGH FLASH signal input Engine switch input Engine switch input Light control switch AUTO signal input Accessory relay drive output Rear right door closed 10 to 14 V Dimmer switch in HIGH FLASH position Below 1 V Dimmer switch not in HIGH FLASH position 10 to 14 V Engine switch not pushed 10 to 14 V Engine switch pushed Below 1 V Engine switch not pushed 10 to 14 V Engine switch pushed Below 1 V Light control switch in AUTO Below 1 V Light control switch not in AUTO 10 to 14 V Ignition switch on (ACC) Below 1 V Ignition switch off 10 to 14 V Light control switch in TAIL or HEAD Below 1 V Light control switch in neither TAIL nor HEAD 10 to 14 V Driver side door courtesy switch input Driver side door open Below 1 V Driver side door closed 10 to 14 V Ignition 1 relay drive output Ignition switch on (IG) Below 1 V Ignition switch off 10 to 14 V Light control switch TAIL signal input LI LI–20 LIGHTING – LIGHTING SYSTEM Symbols FFGO (E7-4) - Body ground Wiring Color Terminal Description Front fog light relay drive output R - Body ground Condition Specified Condition Light control switch in HEAD and front fog light switch ON Below 1 V Front fog light switch OFF 10 to 14 V Driver side door locked 10 to 14 V Driver side door unlocked Below 1 V Pulse generation LSWD (E7-9) - Body ground L - Body ground Driver side door lock position switch input CANH (E8-5) - Body ground R - Body ground Control system CAN communication Ignition switch on (IG) Ignition switch off Below 1 V Control system CAN communication Ignition switch on (IG) Pulse generation Ignition switch off Below 1 V CANL (E8-6) - Body ground W - Body ground If the result is not as specified, the main body ECU (Instrument panel J/B) may have a malfunction. HINT: *1: with smart key system *2: without smart key system *3: Pedal type parking brake *4: Lever type parking brake (1) Waveform 1 Item Tool setting A GND B113714E01 LI Contents 5 V/DIV., 5 ms./DIV. HINT: If the ambient light becomes brighter, width A becomes narrower. LI–21 LIGHTING – LIGHTING SYSTEM DIAGNOSIS SYSTEM 1. DESCRIPTION (a) Lighting system data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the intelligent tester to check for malfunctions and perform repairs. 2. CHECK DLC3 (a) The ECU uses ISO 15765-4 for communication. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. CG SG CANH SIL CANL BAT H100769E16 Symbols (Terminal No.) Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 11 to 14 V CANH (6) - CANL (14) CAN bus line Ignition switch off* 54 to 69 Ω CANH (6) - CG (4) HIGH-level CAN bus line Ignition switch off* 200 Ω or higher CANL (14) - CG (4) LOW-level CAN bus line Ignition switch off* 200 Ω or higher CANH (6) - BAT (16) HIGH-level CAN bus line Ignition switch off* 6 kΩ or higher CANL (14) - BAT (16) LOW-level CAN bus line Ignition switch off* 6 kΩ or higher NOTICE: *Before measuring the resistance, leave the vehicle as is for at least 1minute and do not operate the ignition switch, any other switches, or the doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. LI LI–22 LIGHTING – LIGHTING SYSTEM Intelligent Tester DLC3 CAN VIM C131977E10 3. DTC CHECK / CLEAR Intelligent Tester 1. 2. DLC3 CAN VIM C131977E10 LI (b) Connect the cable of the intelligent tester to the DLC3, turn the ignition switch on (IG) and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. HINT: • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. • If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. CHECK DTC (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Read the DTCs by following the directions on the tester screen. HINT: Please refer to the intelligent tester operator's manual for further details. CLEAR DTC (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Erase the DTCs by following the directions on the tester screen. HINT: Please refer to the intelligent tester operator's manual for further details. LI–23 LIGHTING – LIGHTING SYSTEM DATA LIST / ACTIVE TEST 1. READ DATA LIST HINT: Using the intelligent tester DATA LIST allows switch, actuator and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to save time. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Read the DATA LIST according to the display on the tester. MAIN BODY (MAIN BODY ECU): Item Measurement Item / Display (Range) Normal Condition Diagnostic Note ACC SW Ignition switch or engine switch ACC signal / ON or OFF ON: Ignition switch on (ACC or IG) OFF: Ignition switch off - IG SW Ignition switch or engine switch IG signal / ON or OFF ON: Ignition switch on (IG) OFF: Ignition switch off - D DOR CTY SW Driver side door courtesy switch signal / ON or OFF ON: Driver side door is open OFF: Driver side door is closed - P DOR CTY SW Passenger side door courtesy switch signal / ON or OFF ON: Front passenger side door is open OFF: Front passenger side door is closed - RR DOR CTY SW Rear right door courtesy switch signal / ON or OFF ON: Rear right door is open OFF: Rear right door is closed - RL DOR CTY SW Rear left door courtesy switch signal / ON or OFF ON: Rear left door is open OFF: Rear left door is closed - D LOCK POS SW Driver side door lock position switch signal / ON or OFF ON: Driver side door is unlocked OFF: Driver side door is locked - P LOCK POS SW Passenger side door lock position switch signal / ON or OFF ON: Front passenger side door is unlocked OFF: Front passenger side door is locked - RR LOCK POS SW (with Smart Key System) Rear right door lock position switch signal / ON or OFF ON: Rear right door is unlocked OFF: Rear right door is locked - RL. LOCK POS SW (with Smart Key System) Rear left door lock position switch signal / ON or OFF ON: Rear left door is unlocked OFF: Rear left door is locked - DIMMER SW Dimmer switch HIGH signal / ON or OFF ON: Dimmer switch in HIGH or HIGH FLASH OFF: Dimmer switch in LOW - HIGH FLASHER SW Dimmer switch HIGH FLASH signal / ON or OFF ON: Dimmer switch in HIGH FLASH OFF: Dimmer switch not in HIGH FLASH - F FOG LIGHT SW Fog light switch signal / ON or OFF ON: Fog light switch ON OFF: Fog light switch OFF - AUTO LIGHT SW Light control switch AUTO signal / ON or OFF ON: Light control switch in AUTO OFF: Light control switch not in AUTO - HEAD LIGHT SW Light control switch HEAD signal / ON or OFF ON: Light control switch in HEAD OFF: Light control switch not in HEAD - TAIL LIGHT SW Light control switch TAIL signal / ON or OFF ON: Light control switch in TAIL or HEAD OFF: Light control switch not in TAIL or HEAD - LI LI–24 LIGHTING – LIGHTING SYSTEM Measurement Item / Display (Range) Item ILLUMINATE RATE PARKING BRAKE SW Normal Condition Diagnostic Note Illumination rate information / 0 ms. to 99.99 ms. 0.8 ms. to 22.0 ms. (Value is output according to ambient illuminance) - Parking brake switch signal / ON or OFF ON: Parking brake switch is ON OFF: Parking brake switch is OFF - 2. PERFORM ACTIVE TEST HINT: Performing the intelligent tester ACTIVE TEST allows a relay, VSV, actuator, and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Perform the ACTIVE TEST according to the display on the tester. MAIN BODY (MAIN BODY ECU): Item F FOG LIGHT RLY HEAD LIGHT HEAD LIGHT (HI) TAIL LIGHT DIMMER SIG ILLUMI OUTPUT LI Test Details Diagnostic Note Front fog light relay ON / OFF - Headlight relay ON / OFF - High beam headlights ON / OFF - Taillight ON / OFF - Dimmer signal ON / OFF - Interior light and ignition key cylinder light ON / OFF (Interior light switch in DOOR position and all doors are closed) - LI–25 LIGHTING – LIGHTING SYSTEM DIAGNOSTIC TROUBLE CODE CHART LIGHTING SYSTEM: DTC No. B1244 Detection Item Light Sensor Circuit Malfunction Suspected Area 1. Automatic light control sensor 2. Harness or connector 3. Main body ECU (Instrument panel J/B) See page LI-23 LI LI–26 LIGHTING – LIGHTING SYSTEM DTC B1244 Light Sensor Circuit Malfunction DESCRIPTION The automatic light control sensor detects ambient light, converts it into an electrical signal, and outputs it to the main body ECU. The main body ECU turns on or off the headlights and taillights according to the signal. DTC No. B1244 DTC Detecting Condition • • Trouble Area Malfunction in automatic light control sensor Open or short in automatic light control sensor circuit • • • Automatic light control sensor Harness or connector Main body ECU (Instrument panel J/B) WIRING DIAGRAM E6 Main Body ECU E11 Automatic Light Control Sensor CLTB CLTS CLTE *1: Manual A/C 3 (*1) 6 (*2) 20 4 (*1) 5 (*2) 19 6 (*1) 3 (*2) 18 CLTB CLTS CLTE *2: Automatic A/C E124321E04 LI INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the intelligent tester main switch on. (c) Select the item below in the DATA LIST, and read the display on the intelligent tester. MAIN BODY (MAIN BODY ECU): Item ILLUMINATE RATE Measurement Item / Display (Range) Illumination rate information / 0 ms to 99.99 ms Normal Condition Diagnostic Note 0.8 ms to 22.0 ms (Value is output according to ambient illuminance) - OK: Normal condition listed above is displayed. LI–27 LIGHTING – LIGHTING SYSTEM OK REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY NG 2 CHECK VEHICLE CONDITION Result Vehicle Condition Proceed to Manual Air Conditioning System A Automatic Air Conditioning System B B Go to step 6 A 3 CHECK HARNESS AND CONNECTOR (MAIN BODY ECU - AUTOMATIC LIGHT CONTROL SENSOR) Wire Harness Side: Automatic Light Control Sensor E11 (a) Disconnect the E11 automatic light control sensor connector. (b) Disconnect the E6 main body ECU connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance CLTS CLTE CLTB Main Body ECU E6 NG CLTB CLTE Tester Connection Condition Specified Condition E6-18 (CLTE) - E11-6 (CLTE) Always Below 1 Ω E6-19 (CLTS) - E11-4 (CLTS) Always Below 1 Ω E6-20 (CLTB) - E11-3 (CLTB) Always Below 1 Ω E6-18 (CLTE) - Body ground Always 10 kΩ or higher E6-19 (CLTS) - Body ground Always 10 kΩ or higher E6-20 (CLTB) - Body ground Always 10 kΩ or higher REPAIR OR REPLACE HARNESS OR CONNECTOR CLTS E121476E03 OK 4 INSPECT MAIN BODY ECU (INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY) (a) Reconnect the main body ECU connector. LI LI–28 LIGHTING – LIGHTING SYSTEM (b) Measure the voltage and resistance according to the value(s) in the table below. Standard voltage Wire Harness Side: Automatic Light Control Sensor E11 CLTS CLTE CLTB Tester Connection Condition Specified Condition E11-3 (CLTB) - E11-6 (CLTE) Ignition switch off Below 1 V Ignition switch on (IG) 10 to 14 V Standard resistance B109993E15 Tester Connection Condition Specified Condition E11-6 (CLTE) - Body ground Always Below 1 Ω NG REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY OK 5 INSPECT AUTOMATIC LIGHT CONTROL SENSOR (a) Reconnect the automatic light control sensor connector. (b) Connect an oscilloscope to the automatic light control sensor connector. Automatic Light Control Sensor E11 CLTS CLTE E121468E03 (c) Check the waveform. OK A GND Tester Connection Tool Setting Condition Specified Condition E11-6 (CLTE) E11-4 (CLTS) 5 V/DIV., 5 ms./ DIV. Ignition switch on (IG), light control switch in AUTO Correct waveform is as shown LI B113714E01 HINT: If the ambient light becomes brighter, width A becomes narrower. NG REPLACE AUTOMATIC LIGHT CONTROL SENSOR OK REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY LI–29 LIGHTING – LIGHTING SYSTEM 6 CHECK HARNESS AND CONNECTOR (MAIN BODY ECU - AUTOMATIC LIGHT CONTROL SENSOR) Wire Harness Side: Automatic Light Control Sensor (a) Disconnect the E11 automatic light control sensor connector. (b) Disconnect the E6 main body ECU connector. Standard resistance E11 CLTE CLTS CLTB Main Body ECU Tester Connection Condition Specified Condition E6-18 (CLTE) - E11-3 (CLTE) Always Below 1 Ω E6-19 (CLTS) - E11-5 (CLTS) Always Below 1 Ω E6-20 (CLTB) - E11-6 (CLTB) Always Below 1 Ω E6-18 (CLTE) - Body ground Always 10 kΩ or higher E6-19 (CLTS) - Body ground Always 10 kΩ or higher E6-20 (CLTB) - Body ground Always 10 kΩ or higher E6 NG REPAIR OR REPLACE HARNESS OR CONNECTOR CLTB CLTE CLTS E121476E04 OK 7 INSPECT MAIN BODY ECU (INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY ) (a) Reconnect the main body ECU connector. (b) Measure the voltage and resistance according to the value(s) in the table below. Standard voltage Wire Harness Side: Automatic Light Control Sensor E11 CLTE CLTB B109993E16 Tester Connection Condition Specified Condition E11-6 (CLTB) - E11-3 (CLTE) Ignition switch off Below 1 V E11-6 (CLTB) - E11-3 (CLTE) Ignition switch on (IG) 10 to 14 V Standard resistance NG OK Tester Connection Condition Specified Condition E11-3 (CLTE) - Body ground Always Below 1 Ω REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY LI LI–30 LIGHTING – LIGHTING SYSTEM 8 INSPECT AUTOMATIC LIGHT CONTROL SENSOR (a) Reconnect the automatic light control sensor connector. (b) Connect an oscilloscope to the automatic light control sensor connector. Automatic Light Control Sensor E11 CLTE CLTS E121468E04 (c) Check the waveform. OK A GND B113714E01 Tester Connection Tool Setting Condition Specified Condition E11-3 (CLTE) E11-5 (CLTS) 5 V/DIV., 5 ms./ DIV. Ignition switch on (IG), light control switch in AUTO Correct waveform is as shown HINT: If the ambient light becomes brighter, width A becomes narrower. NG REPLACE AUTOMATIC LIGHT CONTROL SENSOR OK REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY LI LI–31 LIGHTING – LIGHTING SYSTEM Ignition Switch Circuit DESCRIPTION This circuit detects the state of the ignition switch or engine switch, and sends it to the main body ECU. WIRING DIAGRAM without Smart Key System: Main Body ECU Instrument Panel J/B ACC 1 IA 3 II ECU-ACC 5 3 2 1 22 ACC E23 Ignition Switch 2 1 ACC IG1 AM1 4 4 II 9 II ALT 10 IF IG1 AM1 ECU IG No. 1 5 3 2 1 15 IG FL MAIN Battery LI E121497E02 LI–32 LIGHTING – LIGHTING SYSTEM with Smart Key System: Main Body ECU Instrument Panel J/B ACC 1 IA 5 3 3 II 2 1 ECU-ACC 22 ACC 10 IF IG1 ALT 9 II 5 3 2 1 ECU-IG No. 1 AM2 15 IG 6 E7 AM1 22 E7 ACCD 3 E7 IG1D FL MAIN E52 Engine SW GND SS1 7 17 E7 SSW1 4 EOM SS2 2 16 E7 SSW2 5 Battery LI E121498E01 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the intelligent tester main switch on. LI–33 LIGHTING – LIGHTING SYSTEM (c) Select the items below in the DATA LIST, and read the display on the intelligent tester. MAIN BODY (MAIN BODY ECU): Measurement Item / Display (Range) Item Normal Condition Diagnostic Note ACC SW Ignition switch or engine switch ACC signal / ON or OFF ON: Ignition switch on (IG or ACC) OFF: Ignition switch off - IG SW Ignition switch or engine switch IG signal / ON or OFF ON: Ignition switch on (IG) OFF: Ignition switch off - OK: Normal conditions listed above are displayed. OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG 2 INSPECT ACC RELAY (a) Remove the ACC relay from the instrument panel J/B assembly. (b) Measure the resistance according to the value(s) in the table below. Standard resistance 3 3 5 1 2 Tester Connection Specified Condition 3-5 Below 1 Ω (When battery voltage is applied to terminals 1 and 2) 10 kΩ or higher 2 5 1 B087894E05 NG REPLACE ACC RELAY OK 3 INSPECT NO. 1 IGNITION RELAY (a) Remove the No. 1 ignition relay from the instrument panel J/B assembly. (b) Measure the resistance according to the value(s) in the table below. Standard resistance 3 3 5 1 2 Tester Connection Specified Condition 3-5 Below 1 Ω (When battery voltage is applied to terminals 1 and 2) 10 kΩ or higher 2 5 1 B087894E05 NG OK REPLACE NO. 1 IGNITION RELAY LI LI–34 LIGHTING – LIGHTING SYSTEM 4 CHECK HARNESS AND CONNECTOR (INSTRUMENT PANEL J/B ASSEMBLY - BATTERY AND GROUND) (a) Disconnect the IA instrument panel J/B assembly connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness Side: Instrument Panel J/B Assembly IA Tester Connection Condition Specified Condition IA-1 - Body ground Always 10 to 14 V E121505E01 (c) Disconnect the IF instrument panel J/B assembly connector. (d) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side: Instrument Panel J/B Assembly IF E121504E01 Tester Connection Condition Specified Condition IF-10 - Body ground Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 5 CHECK VEHICLE CONDITION (a) Check the vehicle condition. Result Condition Proceed to without Smart Key System A with Smart Key System B LI B A Go to step 8 LI–35 LIGHTING – LIGHTING SYSTEM 6 CHECK HARNESS AND CONNECTOR (INSTRUMENT PANEL J/B ASSEMBLY - IGNITION SWITCH) Wire Harness Side: Instrument Panel J/B Assembly II Ignition Switch IG1 Tester Connection Condition Specified Condition II-3 - E23-2 (ACC) Always Below 1 Ω II-4 - E23-4 (AM1) Always Below 1 Ω II-9 - E23-1 (IG1) Always Below 1 Ω II-3 - Body ground Always 10 kΩ or higher II-4 - Body ground Always 10 kΩ or higher II-9 - Body ground Always 10 kΩ or higher NG E23 ACC (a) Disconnect the E23 ignition switch connector. (b) Disconnect the II instrument panel J/B assembly connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance REPAIR OR REPLACE HARNESS OR CONNECTOR AM1 E121503E01 OK 7 INSPECT IGNITION SWITCH (a) Inspect the ignition switch (See page ST-155) OK: Ignition switch is normal. NG OK REPLACE INSTRUMENT PANEL J/B ASSEMBLY REPLACE IGNITION SWITCH LI LI–36 8 LIGHTING – LIGHTING SYSTEM CHECK HARNESS AND CONNECTOR (BATTERY - MAIN BODY ECU) (a) Disconnect the E7 main body ECU connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness Side: Main Body ECU AM1 E7 Tester Connection Condition Specified Condition E7-6 (AM1) - Body ground Always 10 to 14 V NG E121506E01 REPAIR OR REPLACE HARNESS OR CONNECTOR OK 9 CHECK HARNESS AND CONNECTOR (INSTRUMENT PANEL J/B ASSEMBLY - MAIN BODY ECU) Wire Harness Side: Instrument Panel J/B Assembly II Main Body ECU (a) Disconnect the E7 main body ECU connector. (b) Disconnect the II instrument panel J/B assembly connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition II-3 - E7-22 (ACCD) Always Below 1 Ω II-9 - E7-3 (IG1D) Always Below 1 Ω II-3 - Body ground Always 10 kΩ or higher II-9 - Body ground Always 10 kΩ or higher NG E7 LI E121484E02 OK REPAIR OR REPLACE HARNESS OR CONNECTOR LI–37 LIGHTING – LIGHTING SYSTEM 10 CHECK HARNESS AND CONNECTOR (ENGINE SWITCH - MAIN BODY ECU AND BODY GROUND) (a) Disconnect the E52 engine switch connector. (b) Disconnect the E7 main body ECU connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side: Engine Switch E52 SS2 SS1 Tester Connection Condition Specified Condition E52-7 (SS1) - E7-17 (SSW1) Always Below 1 Ω E52-2 (SS2) - E7-16 (SSW2) Always Below 1 Ω E52-5 (GND) - Body ground Always 10 kΩ or higher E52-4 (EOM) - Body ground Always 10 kΩ or higher Main Body ECU NG REPAIR OR REPLACE HARNESS OR CONNECTOR E7 SSW1 SSW2 E121502E01 OK 11 INSPECT ENGINE SWITCH (a) Inspect the engine switch (See page ST-153). OK: Engine switch is normal. NG OK REPLACE INSTRUMENT PANEL J/B ASSEMBLY REPLACE ENGINE SWITCH LI LI–38 LIGHTING – LIGHTING SYSTEM Headlight Relay Circuit DESCRIPTION The main body ECU receives a light control switch HEAD signal from the headlight dimmer switch assembly, and turns the low beam headlights on. The headlight relay is installed in the power distributor (engine room J/B assembly). WIRING DIAGRAM Main Body ECU Engine Room J/B 1 1G Instrument Panel J/B H-LP (LL) H-LP (LL) 9 1D 4 1B 3 ID 8 HRLY H-LP (RL) H-LP (RL) 5 1B A49 Headlight (RH Low) FL MAIN 1 2 A45 Headlight (LH Low) 1 LI 2 Battery E121488E01 INSPECTION PROCEDURE 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. LI–39 LIGHTING – LIGHTING SYSTEM (b) Turn the ignition switch on (IG) and turn the intelligent tester main switch on. (c) Select the item below in the ACTIVE TEST and then check that the relay operates. MAIN BODY (MAIN BODY ECU): Item Test Details HEAD RELAY Diagnostic Note Headlight Relay ON / OFF - OK: Headlight relay operates. (Low beam headlights illuminate.) OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG 2 INSPECT INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY (a) Measure the voltage according to the value(s) in the table below. Standard voltage Instrument Panel J/B Assembly ID Tester Connection Condition Specified Condition ID-3 (HRLY) - Body ground Light control switch OFF → HEAD 10 to 14 V → Below 1 V OK HRLY Go to step 6 E121528E01 NG 3 CHECK HARNESS AND CONNECTOR (BATTERY - ENGINE ROOM J/B ASSEMBLY) (a) Disconnect the 1G engine room J/B assembly connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness Side: Engine Room J/B Assembly 1 1G Tester Connector Condition Specified Condition 1G - Body ground Always 10 to 14 V NG B074501E17 REPAIR OR REPLACE HARNESS OR CONNECTOR OK 4 INSPECT ENGINE ROOM J/B BLOCK ASSEMBLY (a) Reconnect the 1G engine room J/B assembly connector. LI LI–40 LIGHTING – LIGHTING SYSTEM (b) Disconnect the 1D engine room J/B assembly connector. (c) Measure the voltage according to the value(s) in the table below. Standard voltage Engine Room J/B Assembly 1D Tester Connection Condition Specified Condition 1D-9 - Body ground Always 10 to 14 V NG E121531E01 REPLACE ENGINE ROOM JUNCTION BLOCK ASSEMBLY (POWER DISTRIBUTOR) OK 5 CHECK HARNESS AND CONNECTOR (ENGINE ROOM J/B ASSEMBLY - INSTRUMENT PANEL J/B ASSEMBLY) (a) Reconnect the 1D engine room J/B assembly connector. (b) Disconnect the ID instrument panel J/B assembly connector. (c) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness Side: Instrument Panel J/B Assembly ID Tester Connection Condition Specified Condition ID-3 (HRLY) - Body ground Always 10 to 14 V HRLY E121479E03 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY LI LI–41 LIGHTING – LIGHTING SYSTEM 6 INSPECT ENGINE ROOM JUNCTION BLOCK ASSEMBLY Power Distributer (Engine Room J/B) H-LP (RL) Terminal H-LP (LL) Terminal (a) Remove the H-LP (RL) fuse and H-LP (LL) fuse from the engine room J/B assembly. (b) Measure the voltage between the loading slot of each fuse and body ground. Standard voltage Tester Connection Condition Specified Condition H-LP (RL) Terminal Body ground Light control switch in HEAD 10 to 14 V H-LP (LL) Terminal Body ground Light control switch in HEAD 10 to 14 V NG REPLACE ENGINE ROOM JUNCTION BLOCK ASSEMBLY (POWER DISTRIBUTOR) E121533E01 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (FUSE - BODY GROUND) LI LI–42 LIGHTING – LIGHTING SYSTEM Headlight (HI-BEAM) Circuit DESCRIPTION The main body ECU receives dimmer switch HIGH signal and light control switch HEAD signal from the headlight dimmer switch assembly, and turns the high beam headlights on. HINT: When a short circuit occurs between the power distributor (engine room J/B assembly) and high beam headlight, the power distributor stops the DRL relay operation (Fail-safe function). WIRING DIAGRAM Main Body ECU Light Control Circuit Power Distributor (Engine Room J/B) Instrument Panel J/B 8 1D 9 ID 9 1D 3 ID 11 8 DRL HRLY 11 1E DRL H-LP (LH) 2 1B H-LP (RH) 3 1B 1 1G A29 Headlight (RH High) LI 2 FL MAIN 1 A8 Headlight (LH High) 2 1 Battery E121490E01 LI–43 LIGHTING – LIGHTING SYSTEM INSPECTION PROCEDURE 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the intelligent tester main switch on. (c) Select the item below in the ACTIVE TEST and then check that the relay operates. MAIN BODY (MAIN BODY ECU): Item Test Details HEAD LIGHT (HI) Diagnostic Note High beam headlights ON / OFF - OK: Relay operates. (High beam headlights illuminate.) OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG 2 INSPECT INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY (a) Measure the voltage according to the value(s) in the table below. Standard voltage Instrument Panel J/B Assembly ID HRLY Tester Connection Condition Specified Condition ID-3 (HRLY) - Body ground Light control switch OFF → HEAD 10 to 14 V → Below 1 V ID-9 (DRL) - Body ground Light control switch in HEAD, dimmer switch LOW → HIGH 10 to 14 V → Below 1 V DRL E121528E02 OK Go to step 6 NG 3 LI CHECK HARNESS AND CONNECTOR (ENGINE ROOM J/B ASSEMBLY - BATTERY AND BODY GROUND) (a) Disconnect the 1G engine room J/B assembly connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness Side: Engine Room J/B Assembly 1 1G B074501E17 Tester Connection Condition Specified Condition 1G-1 - Body ground Always 10 to 14 V LI–44 LIGHTING – LIGHTING SYSTEM (c) Disconnect the 1E engine room J/B assembly connector. (d) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side: Engine Room J/B Assembly 1E Tester Connection Condition Specified Condition 1E-11 - Body ground Always Below 1 Ω NG E121481E01 REPAIR OR REPLACE HARNESS OR CONNECTOR OK 4 INSPECT ENGINE ROOM JUNCTION BLOCK ASSEMBLY (a) Reconnect the 1G and 1E engine room J/B assembly connectors. (b) Disconnect the 1D engine room J/B assembly connector. (c) Measure the voltage according to the value(s) in the table below. Standard voltage Engine Room J/B Assembly 1D E121531E01 Tester Connection Condition Specified Condition 1D-8 - Body ground Always 10 to 14 V 1D-9 - Body ground Always 10 to 14 V NG REPLACE ENGINE ROOM JUNCTION BLOCK ASSEMBLY (POWER DISTRIBUTOR) OK 5 LI CHECK HARNESS AND CONNECTOR (ENGINE ROOM J/B ASSEMBLY - INSTRUMENT PANEL J/B ASSEMBLY) (a) Reconnect the 1D engine room J/B assembly connector. (b) Disconnect the ID instrument panel J/B connector. (c) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness Side: Instrument Panel J/B Assembly HRLY ID DRL Tester Connection Condition Specified Condition ID-3 (DRL) - Body ground Always 10 to 14 V ID-9 (HRLY) - Body ground Always 10 to 14 V E121479E02 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY LI–45 LIGHTING – LIGHTING SYSTEM 6 CHECK HARNESS AND CONNECTOR (SHORT IN RELAY-DRIVEN CIRCUIT) (a) Remove the H-LP (RH) fuse from the engine room J/B assembly. (b) Turn the light control switch to the HEAD position and turn the dimmer switch to the HIGH position. (c) Check if the high beam headlight LH illuminates. (d) Turn the dimmer switch to the LOW position. (e) Install the H-LP (RH) fuse and remove the H-LP (LH) fuse. (f) Turn the dimmer switch to the HIGH position. (g) Check if the high beam headlight RH illuminates. OK: Either high beam headlight LH or RH illuminates. Power Distributor (Engine Room J/B) H-LP(RH) H-LP(LH) OK REPAIR OR REPLACE HARNESS OR CONNECTOR (SHORT CIRCUIT BETWEEN FUSE AND BULB) E121471E01 NG 7 INSPECT ENGINE ROOM JUNCTION BLOCK ASSEMBLY (a) Remove the H-LP (RH) fuse and H-LP (LH) fuse from the engine room J/B assembly. (b) Measure the voltage between the loading slot of each fuse and body ground. Standard voltage H-LP (LH) Terminal H-LP (RH) Terminal E121532E01 Tester Connection Condition Specified Condition H-LP (RH) Terminal Body ground Light control switch in HEAD and dimmer switch in HIGH 10 to 14 V H-LP (LH) Terminal Body ground Light control switch in HEAD and dimmer switch in HIGH 10 to 14 V NG REPLACE ENGINE ROOM JUNCTION BLOCK ASSEMBLY (POWER DISTRIBUTOR) LI LI–46 LIGHTING – LIGHTING SYSTEM OK REPAIR OR REPLACE HARNESS OR CONNECTOR (OPEN CIRCUIT BETWEEN FUSE AND BODY GROUND) LI LIGHTING – LIGHTING SYSTEM LI–51 Light Control Switch Circuit DESCRIPTION This circuit detects the condition of the headlight dimmer switch assembly. LI LI–52 LIGHTING – LIGHTING SYSTEM WIRING DIAGRAM Main Body ECU 13 E7 HF Instrument Panel J/B 5 IG E21 Headlight Dimmer Switch Assembly 4 Fog SW 13 HU 28 E6 FFOG LFG BFG OFF ON 11 17 3 Dimmer SW HF HL HU ED Low High Flash 23 E7 TAIL 16 18 20 19 LI Light Control SW T H A EL 17 E6 HEAD 21 E7 A DRL-OFF (USA) OFF (*1) Auto Tail Head 12 *1: Except USA E121491E02 LI–53 LIGHTING – LIGHTING SYSTEM INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the intelligent tester main switch on. (c) Select the items below in the DATA LIST, and read the display on the intelligent tester. MAIN BODY (MAIN BODY ECU): Item Measurement Item / Display (Range) DIMMER SW Dimmer switch HIGH signal / ON or OFF ON: Dimmer switch in HIGH or FLASH OFF: Dimmer switch in neither HIGH nor FLASH - Dimmer switch FLASH signal / ON or OFF ON: Dimmer switch in FLASH OFF: Dimmer switch not in FLASH - F FOG LIGHT SW Front fog light switch signal / ON or OFF ON: Fog light switch ON OFF: Fog light switch OFF - AUTO LIGHT SW Light control switch AUTO signal / ON or OFF ON: Light control switch in AUTO OFF: Light control switch not in AUTO - HEAD LIGHT SW Light control switch HEAD signal / ON or OFF ON: Light control switch in HEAD OFF: Light control switch not in HEAD - TAIL LIGHT SW Light control switch TAIL signal / ON or OFF ON: Light control switch in TAIL or HEAD OFF: Light control switch in neither TAIL nor HEAD - HIGH FLASHER SW Normal Condition Diagnostic Note OK: Normal conditions listed above are displayed. OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG 2 INSPECT HEADLIGHT DIMMER SWITCH ASSEMBLY (a) Inspect the headlight dimmer switch assembly (See page LI-120). OK: Headlight dimmer switch assembly is normal. NG OK REPLACE HEADLIGHT DIMMER SWITCH ASSEMBLY LI LI–54 3 LIGHTING – LIGHTING SYSTEM CHECK HARNESS AND CONNECTOR (INSTRUMENT PANEL J/B ASSEMBLY - SWITCH ASSEMBLY) Wire Harness Side: Headlight Dimmer Switch Assembly BFG T LFG HU E21 H EL HL HF A Main Body ECU E7 HF A TAIL Main Body ECU E6 FFOG HEAD LI Instrument Panel J/B Assembly (a) Disconnect the E21 headlight dimmer switch assembly connector. (b) Disconnect the E6 and E7 main body ECU connectors. (c) Disconnect the IG instrument panel J/B connector. (d) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition E21-3 (LFG) - E21-16 (HL) Always Below 1 Ω E21-4 (BFG) - E6-28 (FFOG) Always Below 1 Ω E21-11 (HU) - IG-5 (HU) Always Below 1 Ω E21-17 (HF) - E7-13 (HF) Always Below 1 Ω E21-18 (T) - E7-23 (TAIL) Always Below 1 Ω E21-19 (A) - E7-21 (A) Always Below 1 Ω E21-20 (H) - E6-17 (HEAD) Always Below 1 Ω E21-3 (LFG) - Body ground Always 10 kΩ or higher E21-4 (BFG) - Body ground Always 10 kΩ or higher E21-11 (HU) - Body ground Always 10 kΩ or higher E21-17 (HF) - Body ground Always 10 kΩ or higher E21-18 (T) - Body ground Always 10 kΩ or higher E21-19 (A) - Body ground Always 10 kΩ or higher E21-20 (H) - Body ground Always 10 kΩ or higher E21-12 (EL) - Body ground Always Below 1 Ω NG HU REPAIR OR REPLACE HARNESS OR CONNECTOR IG E121507E02 OK REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY LI–47 LIGHTING – LIGHTING SYSTEM Front Fog Light Circuit DESCRIPTION The main body ECU controls the FOG relay when a signal is received from the headlight dimmer switch assembly. WIRING DIAGRAM Main Body ECU Instrument Panel Junction Block 7 TAIL 3 IL TAIL 2 1 3 5 FOG 4 IL 1 2 FR FOG 1 IA 5 3 4 E7 FFGO 8 II 5 ID 1 IC TRLY A1 Fog Light (Front LH) 2 1 A34 Fog Light (Front RH) 2 1 ALT FL MAIN LI Battery E121495E02 INSPECTION PROCEDURE 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. LI–48 LIGHTING – LIGHTING SYSTEM (b) Turn the ignition switch on (IG) and turn the intelligent tester main switch on. (c) Select the item below in the ACTIVE TEST and then check that the relay operates. MAIN BODY (MAIN BODY ECU): Item F FOG LIGHT RLY Test Details Diagnostic Note Front fog light relay ON / OFF - OK: Front fog light relay operates. (Front fog lights come on.) OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG 2 INSPECT FUSE (FR FOG) (a) Remove the FR FOG fuse from the instrument panel J/B assembly. (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω NG REPLACE FUSE OK 3 LI INSPECT FOG LIGHT RELAY 3 5 2 1 1 2 (a) Remove the front fog light relay from the instrument panel J/B assembly. (b) Measure the resistance according to the value(s) in the table below. Standard resistance 5 Tester Connection 3 3-5 Specified Condition 10 kΩ or higher Below 1 Ω (When battery voltage is applied to terminals 1 and 2) B060778E87 NG OK REPLACE FOG LIGHT RELAY LI–49 LIGHTING – LIGHTING SYSTEM 4 INSPECT INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY (a) Measure the voltage according to the value(s) in the table below. Standard voltage Instrument Panel J/B Assembly ID IC Tester Connection Condition Specified Condition IC-1 - Body ground Light control switch in HEAD, front fog light switch OFF → ON Below 1 V → 10 to 14 V ID-5 - Body ground Light control switch in HEAD, front fog light switch OFF → ON Below 1 V → 10 to 14 V E121539E01 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (INSTRUMENT PANEL J/B ASSEMBLY - BODY GROUND) NG 5 INSPECT INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY (a) Measure the voltage according to the value(s) in the table below. Standard voltage Instrument Panel J/B Assembly IL Tester Connection Condition Specified Condition IL-3 - Body ground Light control switch OFF → TAIL Below 1 V → 10 to 14 V NG REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY E121527E01 OK 6 CHECK HARNESS AND CONNECTOR (BETWEEN CONNECTOR IL-3 AND CONNECTOR IL-4) (a) Measure the voltage according to the value(s) in the table below. Standard voltage Instrument Panel J/B Assembly IL Tester Connection Condition Specified Condition IL-4 - Body ground Light control switch OFF → TAIL Below 1 V → 10 to 14 V NG E121527E01 OK REPAIR OR REPLACE HARNESS OR CONNECTOR LI LI–50 LIGHTING – LIGHTING SYSTEM 7 INSPECT INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY (a) Disconnect the II instrument panel J/B assembly connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Instrument Panel J/B Assembly II E121526E01 Tester Connection Condition Specified Condition II-8 - Body ground Light control switch OFF → TAIL Below 1 V → 10 to 14 V NG REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY OK 8 CHECK HARNESS AND CONNECTOR (BODY ECU - INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY) (a) Disconnect the E7 main body ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side: Instrument Panel J/B Assembly Tester Connection Condition Specified Condition E7-4 - II-8 Always Below 1 Ω II NG REPAIR OR REPLACE HARNESS OR CONNECTOR Main Body ECU LI FFGO E7 E121484E01 OK REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY LI–55 LIGHTING – LIGHTING SYSTEM Door Courtesy Switch Circuit DESCRIPTION The main body ECU detects the condition of the door courtesy switches. WIRING DIAGRAM *1: without Smart Key System *2: with Smart Key System Main Body ECU 24 E7 DCTY 21 E6 PCTY 7 (*2) RCTY 5 (*1) E6 Instrument Panel J/B 7 IO 1 M6 Door Courtesy Switch (Driver Side) 1 O6 Door Courtesy Switch (Front Passenger Side) 1 O10 Door Courtesy Switch (Rear RH) 1 17 LCTY N13 Door Courtesy Switch (Rear LH) C B110597E05 INSPECTION PROCEDURE 1 LI READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the intelligent tester main switch on. (c) Select the items below in the DATA LIST, and read the display on the intelligent tester. MAIN BODY (MAIN BODY ECU): Item Measurement Item / Display (Range) Normal Condition Diagnostic Note D DOR CTY SW Driver side door courtesy switch signal / ON or OFF ON: Driver side door is open OFF: Driver side door is closed - P DOR CTY SW Passenger side door courtesy switch signal / ON or OFF ON: Passenger side door is open OFF: Passenger side door is closed - RR DOR CTY SW Rear right door courtesy switch signal / ON or OFF ON: Rear right door is open OFF: Rear right door is closed - LI–56 LIGHTING – LIGHTING SYSTEM Measurement Item / Display (Range) Item RL DOR CTY SW Rear left door courtesy switch signal / ON or OFF Normal Condition Diagnostic Note ON: Rear left door is open OFF: Rear left door is closed - OK: Normal conditions listed above are displayed. OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG 2 INSPECT DOOR COURTESY SWITCH (a) Inspect the front door courtesy switch (See page LI-129). (b) Inspect the rear door courtesy switch (See page LI-131). OK: Door courtesy switches are normal. NG REPLACE DOOR COURTESY SWITCH OK 3 CHECK HARNESS AND CONNECTOR (MAIN BODY ECU - DOOR COURTESY SWITCH) Wire Harness Side: Main Body ECU RCTY (*1) RCTY (*2) E6 LI PCTY Switch (a) Check the harness and connector between the main body ECU and door courtesy switches (passenger side and rear RH). (1) Disconnect the E6 main body ECU connector. (2) Disconnect the O6 and O10 switch connectors. (3) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition E6-5 (*1) - O10-1 (Rear RH) Always Below 1 Ω E6-7 (*2) - O10-1 (Rear RH) Always Below 1 Ω E6-21 (PCTY) - O6-1 (Front passenger side) Always Below 1 Ω O10-1 (Rear RH) - Body ground Always 10 kΩ or higher O6-1 (Front passenger side) - Body ground Always 10 kΩ or higher HINT: *1: without Smart Key System *2: with Smart Key System O6 O10 E108574E07 LI–57 LIGHTING – LIGHTING SYSTEM (b) Check the harness and connector between the instrument panel J/B assembly and rear LH door courtesy switch. (1) Disconnect the IO instrument panel J/B assembly connector. (2) Disconnect the N13 switch connector. (3) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side: Instrument Panel J/B Assembly IO Tester Connection Condition Specified Condition IO-7 (LCTY) - N13-1 (Rear LH) Always Below 1 Ω IO-7 (LCTY) - Body ground Always 10 kΩ or higher Door Courtesy Switch N13 E121486E01 (c) Check the harness and connector between the main body ECU and driver side door courtesy switch. (1) Disconnect the E7 main body ECU connector. (2) Disconnect the M6 switch connector. (3) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side: Main Body ECU E7 DCTY Door Courtesy Switch Tester Connection Condition Specified Condition E7-24 (DCTY) - M6-1 (Driver side) Always Below 1 Ω E7-24 (DCTY) - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR LI M6 E121487E01 OK REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY LI–58 LIGHTING – LIGHTING SYSTEM Door LOCK Position Circuit DESCRIPTION The main body ECU receives each door lock position switch signal to control the illuminated entry system. WIRING DIAGRAM Main Body ECU Instrument Panel J/B K5 Door Lock Assembly (Rear LH) 9 5 IP 6 20 LSR (*1) LSWL (*2) J5 Door Lock Assembly (Rear RH) 9 6 (*2) 5 IL (*1) H8 Door Lock Assembly (Front Passenger’s Side) 8 LI 7 5 E6 LSWR 27 E6 LSWP 9 E7 LSWD I7 Door Lock Assembly (Driver’s Side) 7 8 *1: with Smart Key System *2: without Smart Key System E121496E02 LI–59 LIGHTING – LIGHTING SYSTEM INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the intelligent tester main switch on. (c) Select the items below in the DATA LIST, and read the display on the intelligent tester. MAIN BODY (MAIN BODY ECU): Item Measurement Item / Display (Range) Normal Condition Diagnostic Note D LOCK POS SW Driver side door lock position switch signal / ON or OFF ON: Driver side door is unlocked OFF: Driver side door is locked - P LOCK POS SW Passenger side door lock position switch signal / ON or OFF ON: Passenger side door is unlocked OFF: Passenger side door is locked - RR LOCK POS SW (with Smart Key System) Rear right door lock position switch signal / ON or OFF ON: Rear right door is unlocked OFF: Rear right door is locked - RL LOCK POS SW (with Smart Key System) Rear left door lock position switch signal / ON or OFF ON: Rear left door is unlocked OFF: Rear left door is locked - OK: Normal conditions listed above are displayed. NG GO TO POWER DOOR LOCK CONTROL SYSTEM OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE LI LI–60 LIGHTING – LIGHTING SYSTEM Interior Light Circuit DESCRIPTION The main body ECU controls the illuminated entry system (interior light and ignition key cylinder light). WIRING DIAGRAM Main Body ECU E25 Transpoder Key Amplifier Instrument Panel J/B Ignition Key Cylinder Light (*1) 2 ILL+ ILL- 6 (*1) 10 II 21 ILE Q9 Rear Room Light Assembly DOOR (*3) 1 2 OFF Interior Light ON 5 IR 3 Q6 Overhead J/B DOME (*2) LI (*3) CTY 7 B E (*2) 6 8 From Battery *1: without Smart Key System *2: with Sliding Roof *3: without Sliding Roof E121492E02 INSPECTION PROCEDURE 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn intelligent tester main switch on. LI–61 LIGHTING – LIGHTING SYSTEM (c) Select the item(s) below in the ACTIVE TEST, and check the operation. MAIN BODY (MAIN BODY ECU): Item INTERIOR LAMP Test Details Diagnostic Note Interior light and ignition key cylinder light ON / OFF (Interior light switch in DOOR position and all doors are closed). - OK: Each light illuminates. OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG 2 CHECK VEHICLE CONDITION (a) Check the vehicle condition. Result Condition Proceed to without Sliding Roof A with Sliding Roof B B Go to step 4 A LI LI–62 LIGHTING – LIGHTING SYSTEM 3 CHECK HARNESS AND CONNECTOR (LIGHT - BATTERY AND INSTRUMENT PANEL J/B ASSEMBLY) Wire Harness Side: Transponder Key Amplifier (*1) E25 (a) Disconnect the E25 transponder key amplifier connector (*1). (b) Disconnect the Q9 rear room light assembly connector. (c) Disconnect the IR and II instrument panel J/B assembly connectors. (d) Measure the voltage and resistance according to the value(s) in the table below. Standard voltage Tester Connection Rear Room Light Assembly Condition Specified Condition E25-2 - Body ground (*1) Always 10 to 14 V Q9-1 - Body ground Always 10 to 14 V Standard resistance Q9 Tester Connection Condition Specified Condition II-10 - E25-6 (*1) Always Below 1 Ω IR-5 - Q9-2 Always Below 1 Ω II-10 - Body ground Always 10 kΩ or higher IR-5 - Body ground Always 10 kΩ or higher Instrument Panel J/B Assembly HINT: *1: without Smart Key System IR NG Instrument Panel J/B Assembly REPAIR OR REPLACE HARNESS OR CONNECTOR II E121508E01 LI OK REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY LI–63 LIGHTING – LIGHTING SYSTEM 4 CHECK HARNESS AND CONNECTOR (LIGHT - BATTERY AND INSTRUMENT PANEL J/B ASSEMBLY) Wire Harness Side: Transponder Key Amplifier (*1) E25 Overhead J/B (a) Disconnect the E25 transponder key amplifier connector (*1). (b) Disconnect the Q6 overhead J/B connector. (c) Disconnect the IR and II instrument panel J/B assembly connectors. (d) Measure the voltage and resistance according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition E25-2 - Body ground (*1) Always 10 to 14 V Q6-7 - Body ground Always 10 to 14 V Tester Connection Condition Specified Condition II-10 - E25-6 (*1) Always Below 1 Ω Standard resistance Q6 Instrument Panel J/B Assembly IR Always Below 1 Ω Always 10 kΩ or higher IR-5 - Body ground Always 10 kΩ or higher HINT: *1: without Smart Key System NG Instrument Panel J/B Assembly IR-5 - Q6-6 II-10 - Body ground REPAIR OR REPLACE HARNESS OR CONNECTOR II E121509E01 OK REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY LI LI–64 LIGHTING – LIGHTING SYSTEM Parking Brake Switch Circuit DESCRIPTION The main body ECU receives a parking brake switch signal to control the daytime running light system. WIRING DIAGRAM Main Body ECU Instrument Panel J/B (*1) (*2) 1 2 IM 19 PKB 14 IC 1 E33 Parking Brake Switch A18 Parking Brake Switch *1: with Lever Type *2: with Pedal Type E121499E02 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch and turn the intelligent tester main switch on. (c) Select the item below in the DATA LIST, and read the display on the intelligent tester. LI MAIN BODY (MAIN BODY ECU): Item Measurement Item/ Display (Range) Normal Condition Diagnostic Note PARKING BRAKE SW Parking brake SW signal / ON or OFF ON: Parking brake switch is ON OFF: Parking brake switch is OFF - OK: Normal conditions listed above are displayed. OK NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE LI–65 LIGHTING – LIGHTING SYSTEM 2 INSPECT PARKING BRAKE SWITCH ASSEMBLY (a) Remove the parking brake switch assembly. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Parking Brake Switch Lever Type: Free Pushed in Tester Connection Condition Specified Condition 1 - Switch body Shaft is pushed in 10 kΩ or higher 1 - Switch body Shaft is not pushed in Below 1 Ω NG REPLACE PARKING BRAKE SWITCH ASSEMBLY Pedal Type: Free Pushed in C109430E04 OK 3 CHECK VEHICLE CONDITION (a) Check the vehicle condition. Result Condition Proceed to with Pedal Type Parking Brake A with Lever Type Parking Brake B B A Go to step 5 LI LI–66 4 LIGHTING – LIGHTING SYSTEM CHECK HARNESS AND CONNECTOR (SWITCH - INSTRUMENT PANEL J/B ASSEMBLY) (a) Disconnect the IC instrument panel J/B assembly connector. (b) Disconnect the A18 switch connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side: Instrument Panel J/B Assembly IC NG Parking Brake Switch Tester Connection Condition Specified Condition IC-14 - A18-1 Always Below 1 Ω IC-14 - Body ground Always 10 kΩ or higher REPAIR OR REPLACE HARNESS OR CONNECTOR A18 E121500E01 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE LI LI–67 LIGHTING – LIGHTING SYSTEM 5 CHECK HARNESS AND CONNECTOR (SWITCH - INSTRUMENT PANEL J/B ASSEMBLY) (a) Disconnect the IM instrument panel J/B assembly connector. (b) Disconnect the E33 switch connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side: Instrument Panel J/B Assembly IM NG Parking Brake Switch Tester Connection Condition Specified Condition IM-2 - E33-1 Always Below 1 Ω IM-2 - Body ground Always 10 kΩ or higher REPAIR OR REPLACE HARNESS OR CONNECTOR E33 E121501E01 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE LI LI–68 LIGHTING – LIGHTING SYSTEM Taillight Relay Circuit DESCRIPTION The main body ECU receives a light control switch TAIL signal from the headlight dimmer switch assembly, and turns the taillight relay on. WIRING DIAGRAM Main Body ECU Instrument Panel J/B 1 IA A46 Turn Signal and Parking Light (Front LH) 2 Parking 1 A47 Side Marker Light (Front LH) ALT 1 2 5 IC TAIL 1 2 5 3 7 TRLY TAIL 14 ID A50 Turn Signal and Parking Light (Front RH) FL MAIN 2 Parking 1 4 IC A51 Side Marker Light (Front RH) LI 1 Battery 6 ID 2 S11 Rear Combination Light (LH) 1 Tail 2 8 IP E121493E02 LI–69 LIGHTING – LIGHTING SYSTEM S12 Rear Combination Light (RH) 1 2 Tail 1 S4 License Plate Light (LH) 1 S2 Rear Combination Light (RH) 3 S3 Rear Combination Light (LH) 1 2 Tail Tail 3 S1 License Plate Light (RH) 1 2 E121494E01 INSPECTION PROCEDURE 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the intelligent tester main switch on. (c) Select the item below in the ACTIVE TEST and then check that the relay operates. MAIN BODY (MAIN BODY ECU): Item TAIL LIGHT Test Details Taillight relay ON / OFF Diagnostic Note - LI LI–70 LIGHTING – LIGHTING SYSTEM OK: Taillight relay operates. (Taillights illuminate.) OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG 2 INSPECT FUSE (TAIL) (a) Remove the TAIL fuse from the instrument panel J/B assembly. (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω NG REPLACE FUSE OK 3 INSPECT TAILLIGHT RELAY 1 4 3 2 5 1 4 (a) Remove the taillight relay from the instrument panel J/B assembly. (b) Measure the resistance according to the value(s) in the table below. Standard resistance 2 5 Tester Connection 3 3-5 Below 1 Ω (When battery voltage is applied to terminals 1 and 2) 3-4 10 kΩ or higher (When battery voltage is applied to terminals 1 and 2) 10 kΩ or higher Below 1 Ω A087121E11 NG LI OK Specified Condition REPLACE TAILLIGHT RELAY LI–71 LIGHTING – LIGHTING SYSTEM 4 INSPECT INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY (a) Measure the voltage according to the value(s) in the table below. Standard voltage Instrument Panel J/B Assembly ID IC Tester Connection Condition Specified Condition IC-4 - Body ground Light control switch OFF → TAIL Below 1 V → 10 to 14 V IC-5 - Body ground Light control switch OFF → TAIL Below 1 V → 10 to 14 V ID-6 - Body ground Light control switch OFF → TAIL Below 1 V → 10 to 14 V ID-14 - Body ground Light control switch OFF → TAIL Below 1 V → 10 to 14 V IP-8 - Body ground Light control switch OFF → TAIL Below 1 V → 10 to 14 V IP OK REPAIR OR REPLACE HARNESS OR CONNECTOR (INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY - BODY GROUND) E121540E01 NG 5 CHECK HARNESS AND CONNECTOR (BATTERY - INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY) Wire Harness Side: Instrument Panel J/B Assembly IA E121505E01 (a) Disconnect the IA instrument panel J/B assembly connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition IA-1 - Body ground Always 10 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY LI LI–69 LIGHTING – HEADLIGHT ASSEMBLY HEADLIGHT ASSEMBLY BODY ELECTRICAL LIGHTING COMPONENTS for 2GR-FE: COOL AIR INTAKE DUCT SEAL 3.6 (37, 32 in.*lbf) HEADLIGHT ASSEMBLY 3.6 (37, 32 in.*lbf) LI FRONT BUMPER ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque E128160E01 LI–70 LIGHTING – HEADLIGHT ASSEMBLY FRONT TURN SIGNAL LIGHT SOCKET NO. 1 HEADLIGHT BULB NO. 2 HEADLIGHT BULB FRONT TURN SIGNAL LIGHT BULB FRONT SIDE MARKER LIGHT BULB FRONT SIDE MARKER LIGHT SOCKET HEADLIGHT UNIT E128161E01 LI LIGHTING – HEADLIGHT ASSEMBLY LI–71 REMOVAL 1. REMOVE COOL AIR INTAKE DUCT SEAL (for 2GRFE) (See page ET-4) 2. REMOVE FRONT BUMPER ASSEMBLY (w/o Fog Light) (See page ET-5) 3. REMOVE FRONT BUMPER ASSEMBLY (w/ Fog Light) (See page ET-6) 4. REMOVE HEADLIGHT ASSEMBLY (a) Remove the bolt and 2 screws. (b) Disconnect the connectors and remove the headlight assembly. E128190 DISASSEMBLY 1. REMOVE NO. 2 HEADLIGHT BULB (a) Remove the No. 2 headlight bulb as shown in the illustration. 2. REMOVE NO. 1 HEADLIGHT BULB (a) Remove the No. 1 headlight bulb as shown in the illustration. E128191 LI E128193 3. E128195 REMOVE FRONT TURN SIGNAL LIGHT BULB (a) Turn the front turn signal light bulb and the front turn signal light socket in the direction indicated by the arrow and remove them as a unit. (b) Remove the front turn signal light bulb from the front turn signal light socket. LI–72 LIGHTING – HEADLIGHT ASSEMBLY 4. E128197 LI REMOVE FRONT SIDE MARKER LIGHT BULB (a) Turn the front side marker light bulb and the front side marker light socket in the direction indicated by the arrow and remove them as a unit. (b) Remove the front side marker light bulb from the front side marker light socket. LIGHTING – HEADLIGHT ASSEMBLY LI–73 ADJUSTMENT HINT: It is possible that a bulb is incorrectly installed, affecting headlight aim. Bulb installation should be considered prior to performing the adjustment procedure. 7.62 m (25 ft) or 3 m (9.84 ft) E128200E01 1. VEHICLE PREPARATION FOR HEADLIGHT AIM ADJUSTMENT (a) Prepare the vehicle according to the following conditions: • Ensure there is no damage or deformation to the body around the headlights. • Fill the fuel tank. • Make sure that the oil is filled to the specified level. • Make sure that the coolant is filled to the specified level. • Inflate the tires to the appropriate pressure. • Unload the trunk and vehicle, ensuring that the spare tire, tools, and jack are in their original positions. • Sit a person of average weight (68 kg, 150 lb) in the driver's seat. 2. PREPARATION FOR HEADLIGHT AIMING (Using a headlight aim test machine) (a) Adjust the headlight aim in accordance with the headlight aim test machine instructions. 3. PREPARATION FOR HEADLIGHT AIMING (for Using a Screen) (a) Prepare the vehicle: • Place the vehicle in a location that is dark enough to clearly observe the cutoff line. The cutoff line is a distinct line, below which light from the headlights can be observed and above which it cannot. • Place the vehicle at a 90° angle to the wall. • Create a 7.62 m (25 ft) distance between the vehicle (headlight bulb center) and the wall. • Make sure that the vehicle is on a level surface. • Bounce the vehicle up and down to settle the suspension. NOTICE: A distance of 7.62 m (25 ft) between the vehicle (headlight bulb center) and the wall is necessary for proper aim adjustment. If sufficient space is not available, secure a distance of exactly 3 m (9.84 ft) to allow for checking and adjustment of headlight aim. (The size of the target zone will change with the distance, so follow the instructions in the illustration.) (b) Prepare a piece of thick white paper (approximately 2 m (6.6 ft) (height) x 4 m (13.1 ft) (width)) to use as a screen. LI LI–74 LIGHTING – HEADLIGHT ASSEMBLY (c) Draw a vertical line down the center of the screen (V line). (d) Set the screen as shown in the illustration. Aligning distance is 3 m (9.84 ft): Aligning distance is 7.62 m (25 ft): V RH Line V RH Line 90° 90° V Line V Line V LH Line H Line V LH Line H Line 90° 7.62 m (25 ft) 90° 3 m (9.84 ft) E128201E01 HINT: • Stand the screen perpendicular to the ground. • Align the V line on the screen with the center of the vehicle. V LH Line V Line V RH Line H Line LI Ground I033423E15 (e) Draw base lines (H, V LH, and V RH lines) on the screen as shown in the illustration. HINT: • The base lines differ for "low-beam inspection" and "high-beam inspection". • Mark the headlight bulb center marks on the screen. If the center mark cannot be observed on the headlight, use the center of the headlight bulb or the manufacturer's name marked on the headlight as the center mark. (1) H Line (Headlight height): Draw a horizontal line across the screen so that it passes through the center marks. The H line should be at the same height as the headlight bulb center marks of the low-beam headlights. (2) V LH Line, V RH Line (Center mark position of left-hand (LH) and right-hand (RH) headlights): Draw two vertical lines so that they intersect the H line at each center mark (aligned with the center of the low-beam headlight bulbs). LI–75 LIGHTING – HEADLIGHT ASSEMBLY 4. HEADLIGHT AIMING INSPECTION (a) Cover the headlight or disconnect the connector of the headlight on the opposite side to prevent light from the headlight that is not being inspected from affecting the headlight aiming inspection. NOTICE: Do not keep the headlight covered for more than 3 minutes. The headlight lens is made of synthetic resin, which may melt or be damaged due to excessive heat. HINT: When checking the aim of the high-beam, cover the low-beam or disconnect the connector. (b) Start the engine. (c) Replacement text: Turn on the headlight and check if the cutoff line matches the preferred cutoff line in the following illustration. Aligning distance is 7.62 m (25 ft): Low Beam: 101.6 mm (4 in.) H Line V LH Line V RH Line 53 mm (2.08 in.) 101.6 mm (4 in.) 101.6 mm 101.6 mm (4 in.) Preferred Cutoff Line (4 in.) High Beam: V LH Line V RH Line 101.6 mm (4 in.) Alingning distance is 3 m (9.84 ft): Low Beam: 40 mm (1.57 in.) H Line V LH Line V RH Line 21 mm (0.82 in.) 40 mm (1.57 in.) Preferred Cutoff Line High Beam: 40 mm 40 mm (1.57 in.) (1.57 in.) V LH Line V RH Line 40 mm (1.57 in.) LI H Line H Line 101.6 mm (4 in.) 40 mm (1.57 in.) 101.6 mm 101.6 mm (4 in.) (4 in.) 40 mm 40 mm (1.57 in.) (1.57 in.) I041213E06 HINT: • Since the low-beam light and the high-beam light are a unit, if the aim on the low beam is correct, the high beam should also be correct. However, check both beams just to make sure. LI–76 LIGHTING – HEADLIGHT ASSEMBLY • If the alignment distance is 7.62 m (25 ft): The cutoff line should be within 101.6 mm (4 in.) above or below the H line as well as 101.6 mm (4 in.) left or right of the V line with low-beam (SAE J599). • If the alignment distance is 3 m (9.84 ft): The low beam cutoff line should be within 40 mm (1.57 in.) above or below the H line as well as 40 mm (1.57 in.) left or right of the V line (SAE J599). • If the alignment distance is 7.62 m (25 ft): The high beam center of intensity should be within 101.6 mm (4 in.) above or below the H line as well as 101.6 mm (4 in.) left or right of the V line (SAE J599). • If the alignment distance is 3 m (9.84 ft): The high beam center of intensity should be within 40 mm (1.57 in.) above or below the H line as well as 40 mm (1.57 in.) left or right of the V line (SAE J599). • If the alignment distance is 7.62 m (25 ft): The low beam cutoff line should be 53 mm (2.08 in.) below the H line (preferred cutoff line target). • If the alignment distance is 3 m (9.84 ft): The low beam cutoff line should be 21 mm (0.82 in.) below the H line (preferred cutoff line target). 5. LI Aiming Screw E128230E01 HEADLIGHT AIMING ADJUSTMENT (a) Adjust the aim vertically: Adjust the headlight aim into the specified range by turning aiming screw with a screwdriver. NOTICE: The final turn of the aiming screw should be made in the clockwise direction. If the screw is tightened excessively, loosen it and then retighten it, so that the final turn of the screw is in the clockwise direction. HINT: • The low-beam light and the high-beam light are a unit. Adjusting the aim on the low-beam to the correct position should also result in the highbeam adjustment being correct. • If it is not possible to correctly adjust headlight aim, check bulb, headlight unit, and headlight unit reflector installation. • The headlight aim moves up when turning the aiming screw clockwise, and moves down when turning the aiming screw counterclockwise. LIGHTING – HEADLIGHT ASSEMBLY LI–77 REASSEMBLY 1. INSTALL FRONT SIDE MARKER LIGHT BULB (a) Install the front side marker light bulb to the front side marker light socket. (b) Turn the front side marker light bulb and front side marker light socket in the direction indicated by the arrow and install them as a unit. 2. INSTALL FRONT TURN SIGNAL LIGHT BULB (a) Install the front turn signal light bulb to the front turn signal light socket. E128198 (b) Turn the front turn signal light bulb and front turn signal light socket in the direction indicated by the arrow and install them as a unit. E128196 3. INSTALL NO. 1 HEADLIGHT BULB (a) Install the No. 1 headlight bulb as shown in the illustration. 4. INSTALL NO. 2 HEADLIGHT BULB (a) Install the No. 2 headlight bulb as shown in the illustration. E128194 E128192 LI LI–78 LIGHTING – HEADLIGHT ASSEMBLY INSTALLATION 1. INSTALL HEADLIGHT ASSEMBLY (a) Connect the connectors. (b) Install the headlight assembly with the bolt and 2 screws. Torque: 3.6 N*m (37 kgf*cm, 32 in.*lbf) 2. INSTALL FRONT BUMPER ASSEMBLY (w/o Fog Light) (See page ET-13) 3. INSTALL FRONT BUMPER ASSEMBLY (w/ Fog Light) (See page ET-14) 4. INSTALL COOL AIR INTAKE DUCT SEAL (for 2GRFE) (See page ET-14) 5. VEHICLE PREPARATION FOR HEADLIGHT AIM ADJUSTMENT (See page LI-71) 6. PREPARATION FOR HEADLIGHT AIMING (Using a tester) (See page LI-72) 7. PREPARATION FOR HEADLIGHT AIMING (Using a screen) (See page LI-72) 8. HEADLIGHT AIMING INSPECTION (See page LI-74) 9. HEADLIGHT AIMING ADJUSTMENT (See page LI-75) E128190 10. VEHICLE PREPARATION FOR FOG LIGHT AIM (w/ Fog Light) (See page LI-79) 11. PREPARATION FOR FOG LIGHT AIMING (w/ Fog Light) (See page LI-80) 12. FOG LIGHT AIMING INSPECTION (w/ Fog Light) (See page LI-81) 13. FOG LIGHT AIMING ADJUSTMENT (w/ Fog Light) (See page LI-82) LI LI–78 LIGHTING – FOG LIGHT ASSEMBLY FOG LIGHT ASSEMBLY BODY ELECTRICAL LIGHTING COMPONENTS for 2GR-FE: COOL AIR INTAKE DUCT SEAL FRONT BUMPER ASSEMBLY 1.6 (16, 14 in.*lbf) FOG LIGHT ASSEMBLY LI FOG LIGHT BULB N*m (kgf*cm, ft.*lbf) : Specified torque E128163E01 LIGHTING – FOG LIGHT ASSEMBLY LI–79 REMOVAL 1. REMOVE COOL AIR INTAKE DUCT SEAL (for 2GRFE) (See page ET-4) 2. REMOVE FRONT BUMPER ASSEMBLY (See page ET-6) 3. REMOVE FOG LIGHT ASSEMBLY (a) Remove the screw and the fog light assembly. E128199 DISASSEMBLY 1. REMOVE FOG LIGHT BULB (a) Remove the fog light bulb as shown in the illustration. E123685 LI LI–80 LIGHTING – FOG LIGHT ASSEMBLY ADJUSTMENT HINT: It is possible that a bulb is incorrectly installed, affecting fog light aim. Bulb installation should be considered prior to performing the adjustment procedure. 7.62 m (25 ft) or 3 m (9.84 ft) LI E128202E01 1. VEHICLE PREPARATION FOR FOG LIGHT AIM (a) Prepare the vehicle according to the following conditions: • Ensure there is no damage or deformation to the body around the fog lights. • Fill the fuel tank. • Make sure that the oil is filled to the specified level. • Make sure that the coolant is filled to the specified level. • Inflate the tires to the appropriate pressure. • Unload the trunk and vehicle, ensuring that the spare tire, tools, and jack are in their original positions. • Sit a person of average weight (68 kg, 150 lb) in the driver's seat. • Vehicles with height adjustable suspension should set the vehicle height to the lowest setting prior to adjusting the fog light aim. 2. PREPARATION FOR FOG LIGHT AIMING (a) Prepare the vehicle: • Place the vehicle in a location that is dark enough to clearly observe the cutoff line. The cutoff line is a distinct line, below which light from the fog lights can be observed and above which it cannot. • Place the vehicle at a 90° angle to the wall. • Create a 7.62 m (25 ft) distance between the vehicle (fog light bulb center) and the wall. • Make sure that the vehicle is on a level surface. • Bounce the vehicle up and down to settle the suspension. NOTICE: A distance of 7.62 m (25 ft) between the vehicle (fog light bulb center) and the wall is necessary for proper aim adjustment. If unavailable, secure a distance of exactly 3 m (9.84 ft) for check and adjustment. (The target zone will change with the distance, so follow the instructions in the illustration.) (b) Prepare a piece of thick white paper (approximately 2 m (6.6 ft) (height) x 4 m (13.1 ft) (width)) to use as a screen. (c) Draw a vertical line down the center of the screen (V line). LI–81 LIGHTING – FOG LIGHT ASSEMBLY (d) Set the screen as shown in the illustration. Aligning distance is 3 m (9.84 ft): Aligning distance is 7.62 m (25 ft): V RH Line V RH Line 90° 90° V Line V Line V LH Line H Line V LH Line 90° H Line 7.62 m (25 ft) 90° 3 m (9.84 ft) E128203E01 HINT: • Stand the screen perpendicular to the ground. • Align the V line on the screen with the center of the vehicle. V LH Line V Line (e) Draw base lines (H, V LH, and V RH lines) on the screen as shown in the illustration. HINT: Mark the fog light bulb center marks on the screen. If the center mark cannot be observed on the fog light, use the center of the fog light bulb or the manufacturer's name marked on the fog light as the center mark. (1) H Line (Fog light height): Draw a horizontal line across the screen so that it passes through the center marks. The H line should be at the same height as the fog light bulb center marks of the low-beam fog lights. (2) V LH Line, V RH Line (Center mark position of left-hand (LH) and right-hand (RH) fog lights): Draw two vertical lines so that they intersect the H line at each center mark. V RH Line H Line Ground I033423E15 3. FOG LIGHT AIMING INSPECTION (a) Cover the fog light or disconnect the connector of the fog light on the opposite side to prevent light from the fog light that is not being inspected from affecting the fog light aiming inspection. NOTICE: Do not keep the fog light covered for more than 3 minutes. The fog light lens is made of synthetic resin, which may melt or be damaged due to excessive heat. LI LI–82 LIGHTING – FOG LIGHT ASSEMBLY (b) Start the engine. (c) Turn on the fog light and check if the cut off line falls within the specified area in the following illustration. Aligning distance is 3 m (9.84 ft): Aligning distance is 7.62 m (25 ft): V LH Line V RH Line V LH Line V RH Line 133 mm (5.24 in.) H Line 52 mm (2.05 in.) H Line I041221E02 4. Aiming Screw FOG LIGHT AIMING ADJUSTMENT (a) Adjust the aim vertically: Adjust the aim of each fog light to the specified range by turning each aiming screw with a screwdriver. NOTICE: The final turn of the aiming screw should be made in the clockwise direction. If the screw is tightened excessively, loosen it and then retighten it, so that the final turn of the screw is in the clockwise direction. HINT: If it is not possible to correctly adjust fog light aim, check bulb, fog light unit, and fog light unit reflector installation. E128204E01 REASSEMBLY LI 1. E123686 INSTALL FOG LIGHT BULB (a) Install the fog light bulb as shown in the illustration. LIGHTING – FOG LIGHT ASSEMBLY LI–83 INSTALLATION 1. INSTALL FOG LIGHT ASSEMBLY (a) Install the fog light assembly with the screw. Torque: 1.6 N*m (16 kgf*cm, 14 in.*lbf) 2. INSTALL FRONT BUMPER ASSEMBLY (See page ET14) 3. INSTALL COOL AIR INTAKE DUCT SEAL (for 2GRFE) (See page ET-14) 4. VEHICLE PREPARATION FOR FOG LIGHT AIM (See page LI-79) 5. PREPARATION FOR FOG LIGHT AIMING (See page LI-80) 6. FOG LIGHT AIMING INSPECTION (See page LI-81) 7. FOG LIGHT AIMING ADJUSTMENT (See page LI-82) E128199 LI LI–83 LIGHTING – REAR COMBINATION LIGHT ASSEMBLY REAR COMBINATION LIGHT ASSEMBLY BODY ELECTRICAL LIGHTING COMPONENTS REAR BUMPER ASSEMBLY with Rear Lower Spoiler: LI REAR BUMPER ASSEMBLY REAR FLOOR BOARD CLIP CLIP NUT B137224E01 LI–84 LIGHTING – REAR COMBINATION LIGHT ASSEMBLY LUGGAGE COMPARTMENT FLOOR MAT SPARE WHEEL COVER CLAMP SPARE WHEEL COVER ASSEMBLY NO. 1 LUGGAGE COMPARTMENT TRIM HOOK LUGGAGE COMPARTMENT SIDE TRAY ASSEMBLY 3.6 (37, 32 in.*lbf) NO. 1 LUGGAGE COMPARTMENT TRIM HOOK REAR FLOOR FINISH PLATE REAR COMBINATION LIGHT ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque LI E129958E01 LIGHTING – REAR COMBINATION LIGHT ASSEMBLY LI–85 REAR COMBINATION LIGHT GASKET REAR TURN SIGNAL LIGHT SOCKET TAIL AND STOP LIGHT SOCKET REAR TURN SIGNAL LIGHT BULB TAIL AND STOP LIGHT BULB REAR COMBINATION LIGHT LENS AND BODY REAR BUMPER RETAINER UPPER Non-reusable part E128165E01 LI LI–86 LIGHTING – REAR COMBINATION LIGHT ASSEMBLY LUGGAGE COMPARTMENT DOOR COVER 3.6 (37, 32 in.*lbf) 3.6 (37, 32 in.*lbf) REAR LIGHT ASSEMBLY REAR LIGHT GASKET REAR LIGHT SOCKET AND WIRE LI BACK UP LIGHT BULB TAIL LIGHT BULB REAR LIGHT LENS AND BODY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part E130211E01 LIGHTING – LICENSE PLATE LIGHT ASSEMBLY LI–93 LICENSE PLATE LIGHT ASSEMBLY BODY ELECTRICAL LIGHTING COMPONENTS LUGGAGE COMPARTMENT DOOR COVER LICENSE PLATE LIGHT ASSEMBLY LUGGAGE COMPARTMENT DOOR LOCK CYLINDER ASSEMBLY LUGGAGE COMPARTMENT DOOR OUTSIDE GARNISH LI LICENSE PLATE LIGHT SOCKET with Smart Key System: LICENSE PLATE LIGHT BULB LUGGAGE DOOR OPENING SWITCH ASSEMBLY LICENSE PLATE LIGHT LENS E128168E01 LI–94 LIGHTING – LICENSE PLATE LIGHT ASSEMBLY REMOVAL 1. REMOVE LUGGAGE COMPARTMENT DOOR COVER (See page ET-61) 2. REMOVE LUGGAGE DOOR OPENING SWITCH ASSEMBLY (w/ Smart Key System) (See page DL246) 3. REMOVE LUGGAGE COMPARTMENT DOOR LOCK CYLINDER ASSEMBLY (See page ET-61) 4. REMOVE LUGGAGE COMPARTMENT DOOR OUTSIDE GARNISH (See page ET-61) 5. REMOVE LICENSE PLATE LIGHT ASSEMBLY (a) Disconnect the connector. (b) Disengage the 2 claws and remove the license plate light assembly as shown in the illustration. (1) (2) E128223E01 DISASSEMBLY 1. E128224 LI REMOVE LICENSE PLATE LIGHT BULB (a) Turn the license plate light bulb and the license plate light socket in the direction indicated by the arrow and remove them as a unit. (b) Remove the license plate light bulb from the license plate light socket. LIGHTING – LICENSE PLATE LIGHT ASSEMBLY LI–95 REASSEMBLY 1. INSTALL LICENSE PLATE LIGHT BULB (a) Install the license plate light blub to the license plate light socket. (b) Turn the license plate light blub and the license plate light socket in the direction indicated by the arrow and install them as a unit. E128225 INSTALLATION E128223 1. INSTALL LICENSE PLATE LIGHT ASSEMBLY (a) Engage the 2 claws to install the license plate light assembly. (b) Connect the connector. 2. INSTALL LUGGAGE COMPARTMENT DOOR OUTSIDE GARNISH (See page ET-63) 3. INSTALL LUGGAGE COMPARTMENT DOOR LOCK CYLINDER ASSEMBLY (See page ET-64) 4. INSTALL LUGGAGE DOOR OPENING SWITCH ASSEMBLY (w/ Smart Key System) (See page DL246) 5. INSTALL LUGGAGE COMPARTMENT DOOR COVER (See page ET-64) LI LIGHTING – REAR COMBINATION LIGHT ASSEMBLY LI–87 REMOVAL 1. REMOVE REAR BUMPER ASSEMBLY (w/o Rear Lower Spoiler) (See page ET-17) 2. REMOVE REAR FLOOR BOARD (w/ Rear Lower Spoiler) (See page ET-18) 3. REMOVE REAR BUMPER ASSEMBLY (w/ Rear Lower Spoiler) (See page ET-18) 4. REMOVE LUGGAGE COMPARTMENT FLOOR MAT 5. REMOVE SPARE WHEEL COVER CLAMP 6. REMOVE SPARE WHEEL COVER ASSEMBLY 7. REMOVE LUGGAGE COMPARTMENT SIDE TRAY ASSEMBLY (See page ED-66) 8. REMOVE NO. 1 LUGGAGE COMPARTMENT TRIM HOOK (See page ED-66) 9. REMOVE REAR FLOOR FINISH PLATE (See page ED-66) 10. REMOVE REAR COMBINATION LIGHT ASSEMBLY (a) Disconnect the 2 connectors and clamp. Clamp E128226E01 (b) Remove the 3 nuts. (c) Disengage the clip and remove the rear combination light assembly. 11. REMOVE LUGGAGE COMPARTMENT DOOR COVER (See page ET-61) LI E128228 12. REMOVE REAR LIGHT ASSEMBLY (a) Disconnect the connector and clamp. Clamp E128231E01 LI–88 LIGHTING – REAR COMBINATION LIGHT ASSEMBLY (b) Remove the 3 nuts. (c) Disengage the pin and remove the rear light assembly. HINT: Be careful not to break the engaging portion of the pin when removing the rear light assembly. Pin E128227E01 DISASSEMBLY 1. REMOVE REAR COMBINATION LIGHT GASKET (a) Remove the rear combination light gasket. NOTICE: • Be sure to remove the all traces of the old gasket from the body. • Do not reuse the removed gasket. Be sure to install a new rear combination light gasket to prevent water ingress. 2. REMOVE TAIL AND STOP LIGHT BULB (a) Turn the tail and stop light bulb and the rear combination light socket in the direction indicated by the arrow and disconnect them as a unit. (b) Remove the tail and stop light bulb from the tail and stop light socket. 3. REMOVE REAR TURN SIGNAL LIGHT BULB (a) Turn the rear turn signal light bulb and the rear light socket and wire in the direction indicated by the arrow and disconnect them as a unit. (b) Remove the rear turn signal light bulb from the rear light socket and wire. 4. REMOVE REAR BUMPER RETAINER UPPER (a) Disengage the claw and remove the rear bumper retainer upper. E128217 E128220 LI E128218 E130242 LIGHTING – REAR COMBINATION LIGHT ASSEMBLY LI–89 5. REMOVE BACK UP LIGHT BULB (a) Turn the back up light bulb and the rear light socket and wire in the direction indicated by the arrow and remove them as a unit. (b) Remove the back up light bulb from the rear light socket and wire. 6. REMOVE TAIL LIGHT BULB (a) Turn the tail light bulb and the rear light socket and wire in the direction indicated by the arrow and remove them as a unit. (b) Remove the tail light bulb from the rear light socket and wire. 7. REMOVE REAR LIGHT GASKET (a) Remove the rear light gasket. NOTICE: • Be sure to remove all traces of the old gasket from the body. • Do not reuse the removed gasket. Be sure to install a new rear light gasket to prevent water ingress. E130212 E130214 E128212 REASSEMBLY 1. E128212E01 2. INSTALL REAR LIGHT GASKET (a) Remove the release paper from a new rear light gasket. NOTICE: • Be sure to remove all traces of the old gasket from the body. • Do not reuse the removed gasket. Be sure to install a new rear light gasket to prevent water ingress. (b) Align the rear light gasket with the 3 stud bolts and install the gasket as shown in the illustration. INSTALL TAIL LIGHT BULB (a) Install the tail light bulb to the rear light socket and wire. LI LI–90 LIGHTING – REAR COMBINATION LIGHT ASSEMBLY (b) Turn the tail light bulb and rear light socket and wire in the direction indicated by the arrow and install them as a unit. 3. INSTALL BACK UP LIGHT BULB (a) Install the back up light bulb to the rear light socket and wire. E130215 (b) Turn the back up light bulb and rear light socket and wire in the direction indicated by the arrow and install them as a unit. E130213 4. INSTALL REAR BUMPER RETAINER UPPER (a) Engage the claw and install the rear bumper retainer upper. 5. INSTALL REAR TURN SIGNAL LIGHT BULB (a) Install the rear turn signal light bulb to the rear turn signal light socket. E130242 (b) Turn the rear turn signal light bulb and rear turn signal light socket in the direction indicated by the arrow and install them as a unit. 6. LI INSTALL TAIL AND STOP LIGHT BULB (a) Install the tail and stop light bulb to the tail and stop light socket. E128219 (b) Turn the tail and stop light bulb and tail and stop light socket in the direction indicated by the arrow and install them as a unit. 7. E128221 INSTALL REAR COMBINATION LIGHT GASKET (a) Remove the release paper from a new rear combination light gasket. NOTICE: • Be sure to remove all traces of the old gasket from the body. LIGHTING – REAR COMBINATION LIGHT ASSEMBLY LI–91 • Do not reuse the removed gasket. Be sure to install a new rear combination light gasket to prevent water ingress. (b) Align the rear combination light gasket with the 3 stud bolts and install the gasket as shown in the illustration. E128217E01 INSTALLATION 1. INSTALL REAR LIGHT ASSEMBLY (a) Engage the pin and install the rear light assembly. (b) Install the 3 nuts. Torque: 3.6 N*m (37 kgf*cm, 32 in.*lbf) Pin E128227E01 (c) Connect the connector and clamp. Clamp 2. INSTALL LUGGAGE COMPARTMENT DOOR COVER (See page ET-64) 3. INSTALL REAR COMBINATION LIGHT ASSEMBLY (a) Engage the clip and install the rear combination light assembly. (b) Install the 3 nuts. Torque: 3.6 N*m (37 kgf*cm, 32 in.*lbf) E128231E01 E128229 LI LI–92 LIGHTING – REAR COMBINATION LIGHT ASSEMBLY (c) Connect the 2 connectors and clamp. Clamp E128226E01 4. INSTALL REAR FLOOR FINISH PLATE (See page ED72) 5. INSTALL NO. 1 LUGGAGE COMPARTMENT TRIM HOOK (See page ED-72) 6. INSTALL LUGGAGE COMPARTMENT SIDE TRAY ASSEMBLY (See page ED-72) 7. INSTALL SPARE WHEEL COVER ASSEMBLY 8. INSTALL SPARE WHEEL COVER CLAMP 9. INSTALL LUGGAGE COMPARTMENT FLOOR MAT 10. INSTALL REAR BUMPER ASSEMBLY (w/o Rear Lower Spoiler) (See page ET-23) 11. INSTALL REAR BUMPER ASSEMBLY (w/ Rear Lower Spoiler) (See page ET-24) 12. INSTALL REAR FLOOR BOARD (w/ Rear Lower Spoiler) (See page ET-24) LI LIGHTING – HIGH MOUNTED STOP LIGHT ASSEMBLY LI–101 REMOVAL 1. REMOVE REAR SEAT CUSHION ASSEMBLY (See page SE-77) 2. REMOVE REAR SEAT HEADREST ASSEMBLY 3. REMOVE REAR CENTER SEAT HEADREST ASSEMBLY 4. REMOVE REAR SEAT BACK ASSEMBLY (for Fixed Seat Type) (See page SE-77) 5. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-47) 6. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) (See page SE-47) 7. REMOVE REAR SIDE SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-48) 8. REMOVE REAR SIDE SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) (See page SE-48) 9. REMOVE REAR SEAT BACK COVER (for Reclining Seat Type) (See page SE-63) 10. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Reclining Seat Type) (See page SE-63) 11. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Reclining Seat Type) (See page SE-64) 12. REMOVE CENTER SEAT BACK ASSEMBLY (for Reclining Seat Type) (See page SE-64) 13. REMOVE REAR DOOR SCUFF PLATE LH (See page IR-24) 14. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH 15. REMOVE REAR DOOR SCUFF PLATE RH (See page IR-24) 16. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH 17. REMOVE RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY LH (for Reclining Seat Type) (See page SE-68) 18. REMOVE RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY RH (for Reclining Seat Type) 19. REMOVE CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH (See page SB-66) LI LI–102 LIGHTING – HIGH MOUNTED STOP LIGHT ASSEMBLY 20. DISCONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH (for TMC Made) (See page SB35) 21. DISCONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH (for TMMK Made) (See page SB-35) 22. REMOVE ROOF SIDE INNER GARNISH LH (See page IR-26) 23. REMOVE ROOF SIDE INNER GARNISH RH (See page IR-26) 24. DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) (See page SB-36) 25. DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) (See page SB-36) 26. REMOVE REAR SEAT SHOULDER BELT COVER (See page SB-36) 27. REMOVE REAR SEAT SHOULDER BELT HOLE COVER (See page SB-36) 28. REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY (See page SB-37) 29. REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY (for Reclining Seat Type) (See page SB-37) 30. REMOVE CENTER STOP LIGHT SET (a) Disconnect the connector. (b) Remove the 2 screws and the center stop light set. E128222 INSTALLATION LI E128222 1. INSTALL CENTER STOP LIGHT SET (a) Connect the connector. (b) Install the center stop light set with the 2 screws. Torque: 1.6 N*m (16 kgf*cm, 14 in.*lbf) 2. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY (See page SB-38) 3. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY (for Reclining Seat Type) (See page SB-39) 4. INSTALL REAR SEAT SHOULDER BELT HOLE COVER (See page SB-39) 5. INSTALL REAR SEAT SHOULDER BELT COVER (See page SB-39) LIGHTING – HIGH MOUNTED STOP LIGHT ASSEMBLY LI–103 6. CONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) (See page SB-39) 7. CONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) (See page SB-40) 8. INSTALL ROOF SIDE INNER GARNISH LH (See page IR-52) 9. INSTALL ROOF SIDE INNER GARNISH RH (See page IR-52) 10. INSTALL REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH (for TMC Made) (See page SB-40) 11. INSTALL REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH (for TMMK Made) (See page SB-40) 12. INSTALL CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH (See page SB-66) 13. INSTALL RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY LH (for Reclining Seat Type) (See page SE-69) 14. INSTALL RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY RH (for Reclining Seat Type) 15. CONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH 16. INSTALL REAR DOOR SCUFF PLATE LH (See page IR-56) 17. CONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH 18. INSTALL REAR DOOR SCUFF PLATE RH (See page IR-56) 19. INSTALL CENTER SEAT BACK ASSEMBLY (for Reclining Seat Type) (See page SE-71) 20. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Reclining Seat Type) (See page SE-72) 21. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Reclining Seat Type) (See page SE-71) 22. INSTALL REAR SEAT BACK COVER (for Reclining Seat Type) 23. INSTALL REAR SIDE SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-57) 24. INSTALL REAR SIDE SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) 25. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-57) LI LI–104 LIGHTING – HIGH MOUNTED STOP LIGHT ASSEMBLY 26. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) (See page SE-57) 27. INSTALL REAR SEAT BACK ASSEMBLY (for Fixed Seat Type) (See page SE-84) 28. INSTALL REAR CENTER SEAT HEADREST ASSEMBLY 29. INSTALL REAR SEAT HEADREST ASSEMBLY 30. INSTALL REAR SEAT CUSHION ASSEMBLY (See page SE-84) LI LI–96 LIGHTING – HIGH MOUNTED STOP LIGHT ASSEMBLY HIGH MOUNTED STOP LIGHT ASSEMBLY BODY ELECTRICAL LIGHTING COMPONENTS for Fixed Seat Type: REAR SEAT HEADREST ASSEMBLY REAR CENTER SEAT HEADREST ASSEMBLY REAR SEAT BACK ASSEMBLY 18 (184, 13) LI 18 (184, 13) REAR SEAT CUSHION ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B136589E02 LI–97 LIGHTING – HIGH MOUNTED STOP LIGHT ASSEMBLY for Fold Down Seat Type: REAR SEAT HEADREST ASSEMBLY REAR CENTER SEAT HEADREST ASSEMBLY 18 (184, 13) 18 (184, 13) 18 (184, 13) REAR SIDE SEAT BACK ASSEMBLY RH SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH LI 18 (184, 13) REAR SEAT CUSHION ASSEMBLY REAR SIDE SEAT BACK ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque B136564E02 LI–98 LIGHTING – HIGH MOUNTED STOP LIGHT ASSEMBLY for Reclining Seat Type: REAR SEAT HEADREST ASSEMBLY 18 (184, 13) REAR CENTER SEAT HEADREST ASSEMBLY CENTER SEAT BACK ASSEMBLY REAR SEAT BACK COVER 18 (184, 13) 18 (184, 13) 18 (184, 13) SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH REAR SEAT BACK COVER LI 18 (184, 13) SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH REAR SEAT CUSHION ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B139095E03 LIGHTING – HIGH MOUNTED STOP LIGHT ASSEMBLY LI–99 ROOF SIDE INNER GARNISH RH REAR DOOR OPENING TRIM WEATHERSTRIP RH for Reclining Seat Type: 18 (184, 13) RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY RH REAR DOOR SCUFF PLATE RH ROOF SIDE INNER GARNISH LH for Reclining Seat Type: REAR DOOR OPENING TRIM WEATHERSTRIP LH 18 (184, 13) LI RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY LH REAR DOOR SCUFF PLATE LH N*m (kgf*cm, ft.*lbf) : Specified torque B132018E01 LI–100 LIGHTING – HIGH MOUNTED STOP LIGHT ASSEMBLY for Reclining Seat Type: PACKAGE TRAY TRIM PANEL ASSEMBLY PACKAGE TRAY TRIM PANEL ASSEMBLY CENTER STOP LIGHT SET CENTER STOP LIGHT SET 1.6 (16, 14 in.*lbf) 1.6 (16, 14 in.*lbf) REAR SEAT SHOULDER BELT COVER REAR SEAT SHOULDER BELT HOLE COVER 18 (184, 13) CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH 42 (428, 31) REAR SEAT OUTER BELT ASSEMBLY 42 (428, 31) REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH 42 (428, 31) REAR SEAT SHOULDER BELT COVER LI for Fold Down Seat Type: REAR SEAT OUTER BELT ASSEMBLY 18 (184, 13) CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque E128169E01 LIGHTING – PERSONAL LIGHT ASSEMBLY LI–105 PERSONAL LIGHT ASSEMBLY BODY ELECTRICAL LIGHTING COMPONENTS ROOF CONSOLE BOX ASSEMBLY E128170E01 LI LI–106 LIGHTING – PERSONAL LIGHT ASSEMBLY REMOVAL 1. REMOVE ROOF CONSOLE BOX ASSEMBLY (See page IR-28) INSPECTION 1. 8 7 6 5 4 3 2 1 INSPECT ROOF CONSOLE BOX ASSEMBLY (with Sliding Roof) (a) Apply battery voltage to the roof console box assembly. (b) Check that the interior light and personal lights come on. OK Switch Condition Specified Condition Battery positive (+) → Terminal 7 Battery negative (-) → Terminal 6 Measurement Condition Interior light switch in DOOR Interior light comes on Battery positive (+) → Terminal 7 Battery negative (-) → Terminal 8 Interior light switch ON Interior light comes on Battery positive (+) → Terminal 7 Battery negative (-) → Terminal 8 Front RH personal light switch ON Front RH personal light comes on Battery positive (+) → Terminal 7 Battery negative (-) → Terminal 8 Front LH personal light switch ON Front LH personal light comes on E119968 If the result is not as specified, replace the roof console box assembly. 2. 8 7 6 5 4 3 2 1 E119968 LI INSPECT ROOF CONSOLE BOX ASSEMBLY (without Sliding Roof) (a) Apply battery voltage to the roof console box assembly. (b) Check that each personal light comes on. OK Measurement Condition Switch Condition Specified Condition Battery positive (+) → Terminal 7 Battery negative (-) → Terminal 8 Front RH personal light switch ON Front RH personal light comes on Battery positive (+) → Terminal 7 Battery negative (-) → Terminal 8 Front LH personal light switch ON Front LH personal light comes on If the result is not as specified, replace the roof console box assembly. LIGHTING – PERSONAL LIGHT ASSEMBLY LI–107 INSTALLATION 1. INSTALL ROOF CONSOLE BOX ASSEMBLY (See page IR-50) LI LIGHTING – REAR ROOM LIGHT ASSEMBLY LI–107 REAR ROOM LIGHT ASSEMBLY BODY ELECTRICAL LIGHTING COMPONENTS without Sliding Roof: NO. 1 ROOM LIGHT ASSEMBLY with Sliding Roof: LI SPOT LIGHT ASSEMBLY E128185E01 LI–108 LIGHTING – REAR ROOM LIGHT ASSEMBLY REMOVAL 1. REMOVE NO. 1 ROOM LIGHT ASSEMBLY (w/o Sliding Roof) (See page IR-30) 2. REMOVE SPOT LIGHT ASSEMBLY (w/ Sliding Roof) (See page IR-30) INSPECTION 1. INSPECT NO. 1 ROOM LIGHT ASSEMBLY (without Sliding Roof) (a) Apply battery voltage to the No. 1 room light assembly connector. (b) Check that the interior light comes on. OK Measurement Condition E116068 Switch Condition Specified Condition Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 2 DOOR Interior light comes on Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 3 ON Interior light comes on If the result is not as specified, replace the room light assembly. 2. Q10 Q11 E121513E01 LI INSPECT SPOT LIGHT ASSEMBLY (with Sliding Roof) (a) Apply battery voltage to the spot light assembly connector. (b) Check that the rear personal light comes on. OK Measurement Condition Switch Condition Battery positive (+) → Terminal Q10-2 Battery negative (-) → Terminal Q10-4 Pushed (ON) Rear RH personal light comes on Battery positive (+) → Terminal Q10-2 Battery negative (-) → Terminal Q10-3 Always Rear RH personal light comes on Battery positive (+) → Terminal Q11-2 Battery negative (-) → Terminal Q11-4 Pushed (ON) Rear LH personal light comes on Battery positive (+) → Terminal Q11-2 Battery negative (-) → Terminal Q11-5 Always Rear LH personal light comes on Specified Condition If the result is not as specified, replace the spot light assembly. LIGHTING – REAR ROOM LIGHT ASSEMBLY LI–109 INSTALLATION 1. INSTALL NO. 1 ROOM LIGHT ASSEMBLY (w/o Sliding Roof) (See page IR-48) 2. INSTALL SPOT LIGHT ASSEMBLY (w/ Sliding Roof) (See page IR-48) LI LIGHTING – DOOR COURTESY LIGHT LI–109 DOOR COURTESY LIGHT BODY ELECTRICAL LIGHTING COMPONENTS DOOR COURTESY LIGHT ASSEMBLY E128172E01 LI LI–110 LIGHTING – DOOR COURTESY LIGHT REMOVAL 1. REMOVE DOOR COURTESY LIGHT ASSEMBLY (See page ED-15) INSPECTION 1. INSPECT DOOR COURTESY LIGHT ASSEMBLY (a) Apply battery voltage to the door courtesy light assembly connector. (b) Check that the door courtesy light comes on. OK Measurement Condition B113722 Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 2 Specified Condition Door courtesy light comes on If the result is not as specified, replace the door courtesy light assembly. LI LIGHTING – DOOR COURTESY LIGHT LI–111 INSTALLATION 1. INSTALL DOOR COURTESY LIGHT ASSEMBLY (See page ED-34) LI LI–110 LIGHTING – LUGGAGE COMPARTMENT ROOM LIGHT LUGGAGE COMPARTMENT ROOM LIGHT BODY ELECTRICAL LIGHTING COMPONENTS NO. 1 LUGGAGE COMPARTMENT LIGHT ASSEMBLY E128173E01 REMOVAL LI 1. E128259 REMOVE NO. 1 LUGGAGE COMPARTMENT LIGHT ASSEMBLY (a) Disengage the 2 claws and disconnect the No. 1 luggage compartment light assembly. (b) Disconnect the connector and remove the No. 1 luggage compartment light assembly. LI–111 LIGHTING – LUGGAGE COMPARTMENT ROOM LIGHT INSPECTION 1. INSPECT NO. 1 LUGGAGE COMPARTMENT LIGHT ASSEMBLY (a) Apply battery voltage to the No. 1 luggage compartment light assembly connector. (b) Check that the No. 1 luggage compartment light comes on. OK Measurement Condition B113722 Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 2 Specified Condition Luggage compartment light comes on If the result is not as specified, replace the luggage compartment light assembly. INSTALLATION 1. INSTALL NO. 1 LUGGAGE COMPARTMENT LIGHT ASSEMBLY (a) Connect the connector. (b) Engage the 2 claws and install the No. 1 luggage compartment light assembly. E128259 LI LI–112 LIGHTING – IGNITION KEY CYLINDER LIGHT IGNITION KEY CYLINDER LIGHT BODY ELECTRICAL LIGHTING COMPONENTS TRANSPONDER KEY AMPLIFIER STEERING COLUMN COVER COWL SIDE TRIM SUB-ASSEMBLY LH LOWER INSTRUMENT PANEL FINISH PANEL LH COWL SIDE TRIM CLIP FRONT DOOR SCUFF PLATE LH E128182E01 LI LI–113 LIGHTING – IGNITION KEY CYLINDER LIGHT REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-26) 2. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-26) 3. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (See page IP-20) 4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (See page IP-21) 5. REMOVE STEERING COLUMN COVER (See page SR-39) 6. REMOVE TRANSPONDER KEY AMPLIFIER (See page SR-42) INSPECTION 1. ILL+ INSPECT TRANSPONDER KEY AMPLIFIER (a) Apply battery voltage to the transponder key amplifier connector. (b) Check that the ignition key cylinder light comes on. OK Measurement Condition ILLE074066E03 Battery positive (+) → Terminal 2 (ILL+) Battery negative (-) → Terminal 6 (ILL-) Specified Condition Ignition key cylinder light comes on If the result is not as specified, replace the transponder key amplifier. LI LI–114 LIGHTING – IGNITION KEY CYLINDER LIGHT INSTALLATION LI 1. INSTALL TRANSPONDER KEY AMPLIFIER (See page SR-46) 2. INSTALL STEERING COLUMN COVER (See page SR50) 3. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (See page IP-58) 4. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (See page IP-59) 5. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-54) 6. INSTALL FRONT DOOR SCUFF PLATE LH (See page IR-54) LI–114 LIGHTING – GLOVE BOX LIGHT GLOVE BOX LIGHT BODY ELECTRICAL LIGHTING COMPONENTS COWL SIDE TRIM SUB-ASSEMBLY RH COWL SIDE TRIM CLIP GLOVE BOX LIGHT ASSEMBLY FRONT DOOR SCUFF PLATE RH INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY LI LOWER INSTRUMENT PANEL SUB-ASSEMBLY E128174E01 LI–115 LIGHTING – GLOVE BOX LIGHT REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE RH (See page IR-26) 2. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH (See page IR-26) 3. REMOVE INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY (See page IP-23) 4. REMOVE LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMC Made) (See page IP-23) 5. REMOVE LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMMK Made) (See page IP-24) 6. REMOVE GLOVE BOX LIGHT ASSEMBLY (a) Disconnect the connector. (b) Disengage the 2 claws and remove the glove box light assembly. E128205 INSPECTION 1. INSPECT GLOVE BOX LIGHT ASSEMBLY (a) Apply battery voltage to the glove box light assembly connector. (b) Check that the glove box light comes on. OK Measurement Condition I044128 Battery positive (+) → Terminal 2 Battery negative (-) → Terminal 1 Switch Condition Glove box light switch ON Specified Condition Glove box light comes on If the result is not as specified, replace the glove box light assembly. INSTALLATION E128205 1. INSTALL GLOVE BOX LIGHT ASSEMBLY (a) Engage the 2 claws and install the glove box light assembly. (b) Connect the connector. 2. INSTALL LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMC Made) (See page IP-55) 3. INSTALL LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMMK Made) (See page IP-56) 4. INSTALL INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY (See page IP-56) 5. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH (See page IR-55) LI LI–116 LIGHTING – GLOVE BOX LIGHT 6. LI INSTALL FRONT DOOR SCUFF PLATE RH (See page IR-55) LI–116 LIGHTING – VANITY LIGHT VANITY LIGHT BODY ELECTRICAL LIGHTING COMPONENTS VANITY LIGHT ASSEMBLY E128175E01 LI LI–117 LIGHTING – VANITY LIGHT REMOVAL 1. REMOVE VANITY LIGHT ASSEMBLY (See page IR35) INSPECTION 1. INSPECT VANITY LIGHT ASSEMBLY (a) Apply battery voltage to the vanity light assembly connector. (b) Check that the vanity light comes on. OK Measurement Condition E121462 Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 2 Specified Condition Vanity light comes on If the result is not as specified, replace the vanity light assembly. LI LI–118 LIGHTING – VANITY LIGHT INSTALLATION 1. LI INSTALL VANITY LIGHT ASSEMBLY (See page IR-42) LI–118 LIGHTING – HEADLIGHT DIMMER SWITCH HEADLIGHT DIMMER SWITCH BODY ELECTRICAL LIGHTING COMPONENTS WINDSHIELD WIPER SWITCH ASSEMBLY SPIRAL CABLE WITH STEERING ANGLE SENSOR HEADLIGHT DIMMER SWITCH ASSEMBLY STEERING COLUMN COVER TMC made: STEERING WHEEL ASSEMBLY TMMK made: STEERING WHEEL ASSEMBLY 50 (510, 37) 50 (510, 37) LI 8.8 (90, 78 in.*lbf) NO. 2 LOWER STEERING WHEEL COVER NO. 3 LOWER STEERING WHEEL COVER STEERING PAD 8.8 (90, 78 in.*lbf) NO. 2 LOWER STEERING WHEEL COVER NO. 3 LOWER STEERING WHEEL COVER STEERING PAD N*m (kgf*cm, ft.*lbf) : Specified torque E128176E01 LIGHTING – HEADLIGHT DIMMER SWITCH LI–119 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment. (See page RS-1) 2. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 3. REMOVE NO. 2 LOWER STEERING WHEEL COVER (See page RS-349) 4. REMOVE NO. 3 LOWER STEERING WHEEL COVER (See page RS-349) 5. REMOVE STEERING PAD (See page RS-350) 6. REMOVE STEERING WHEEL ASSEMBLY (See page SR-38) 7. REMOVE STEERING COLUMN COVER (See page SR-39) 8. REMOVE SPIRAL CABLE WITH STEERING ANGLE SENSOR (See page RS-364) 9. REMOVE WINDSHIELD WIPER SWITCH ASSEMBLY (See page WW-21) 10. REMOVE HEADLIGHT DIMMER SWITCH ASSEMBLY (a) Disconnect the connector. (b) Disengage the clamp as shown in the illustration. Clamp E128206E01 (c) Disengage the claw and remove the headlight dimmer switch assembly as shown in the illustration. E128208 LI LI–120 LIGHTING – HEADLIGHT DIMMER SWITCH BFG INSPECTION LFG 1. HU H EL A T HF HL TL TR E068152E15 INSPECT HEADLIGHT DIMMER SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance: Light control switch Tester Connection Switch Condition Specified Condition 12 (EL) - 20 (H) - 18 (T) 19 (A) OFF 10 kΩ or higher 12 (EL) - 18 (T) TAIL Below 1 Ω 12 (EL) - 20 (H) - 18 (T) HEAD Below 1 Ω 12 (EL) - 19 (A) AUTO Below 1 Ω Tester Connection Switch Condition Specified Condition 17 (HF) - 12 (EL) FLASH Below 1 Ω Dimmer switch 16 (HL) - 12 (EL) LOW Below 1 Ω 11 (HU) - 12 (EL) HIGH Below 1 Ω Turn signal switch Tester Connection Switch Condition Specified Condition 13 (TR) - 12 (EL) - 15 (TL) OFF 10 kΩ or higher 13 (TR) - 12 (EL) RH Below 1 Ω 15 (TL) - 12 (EL) LH Below 1 Ω Tester Connection Switch Condition Specified Condition 3 (LFG) - 4 (BFG) OFF 10 kΩ or higher 3 (LFG) - 4 (BFG) ON Below 1 Ω Fog light switch If the result is not as specified, replace the headlight dimmer switch assembly. INSTALLATION 1. LI E130216 INSTALL HEADLIGHT DIMMER SWITCH ASSEMBLY (a) Engage the claw while loosening the clamp as shown in the illustration. LIGHTING – HEADLIGHT DIMMER SWITCH LI–121 (b) Install the headlight dimmer switch assembly with the clamp. (c) Connect the connector. Clamp 2. INSTALL WINDSHIELD WIPER SWITCH ASSEMBLY (See page WW-23) 3. INSTALL SPIRAL CABLE WITH STEERING ANGLE SENSOR (See page RS-366) 4. INSTALL STEERING COLUMN COVER (See page SR50) 5. INSTALL STEERING WHEEL ASSEMBLY (See page SR-51) 6. INSPECT STEERING WHEEL CENTER POINT 7. INSTALL STEERING PAD (See page RS-350) 8. INSTALL NO. 3 LOWER STEERING WHEEL COVER (See page RS-351) 9. INSTALL NO. 2 LOWER STEERING WHEEL COVER (See page RS-352) E128207E01 10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 11. INSPECT STEERING PAD (See page RS-352) 12. INSPECT SRS WARNING LIGHT (See page RS-32) LI LI–122 LIGHTING – HAZARD WARNING SWITCH HAZARD WARNING SWITCH BODY ELECTRICAL LIGHTING COMPONENTS HAZARD WARNING SIGNAL SWITCH ASSEMBLY INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY E128177E01 LI LI–123 LIGHTING – HAZARD WARNING SWITCH REMOVAL 1. REMOVE INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY (See page IP-27) 2. REMOVE HAZARD WARNING SIGNAL SWITCH ASSEMBLY (a) Disengage the 4 claws and remove the hazard warning signal switch assembly. E128236 INSPECTION 1. E121512 INSPECT HAZARD WARNING SIGNAL SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition 5-4 OFF 10 kΩ or higher 5-4 ON Below 1 Ω If the result is not as specified, replace the hazard warning signal switch assembly. (b) Apply battery voltage to the hazard warning signal switch assembly connector. OK Measurement Condition Specified Condition Battery positive (+) → Terminal 7 Battery negative (-) → Terminal 8 Illumination comes on If the result is not as specified, replace the hazard warning signal switch assembly. INSTALLATION E128236 1. INSTALL HAZARD WARNING SIGNAL SWITCH ASSEMBLY (a) Engage the 4 claws and install the hazard warning signal switch assembly. 2. INSTALL INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY (See page IP-52) LI LI–124 LIGHTING – STOP LIGHT SWITCH STOP LIGHT SWITCH BODY ELECTRICAL LIGHTING COMPONENTS with Smart Key System: LOWER INSTRUMENT PANEL FINISH PANEL COMBINATION METER ASSEMBLY without Smart Key System: INSTRUMENT CLUSTER FINISH PANEL NO. 1 INSTRUMENT PANEL SUB-ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL STOP LIGHT SWITCH ASSEMBLY LI LOWER INSTRUMENT PANEL FINISH PANEL LH DOWL SIDE TRIM CLIP COWL SIDE TRIM SUB-ASSEMBLY LH FRONT DOOR SCUFF PLATE LH E130341E01 LI–125 LIGHTING – STOP LIGHT SWITCH REMOVAL 2 1 4 3 Free Pushed in E065594E05 1. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-24) 2. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-25) 3. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (See page IP-20) 4. REMOVE NO. 1 INSTRUMENT PANEL SUBASSEMBLY (See page IP-22) 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (w/o Smart Key System) (See page IP-22) 6. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (w/ Smart Key System) (See page IP-22) 7. REMOVE INSTRUMENT CLUSTER FINISH PANEL (See page ME-65) 8. REMOVE COMBINATION METER ASSEMBLY (See page ME-65) 9. REMOVE STOP LIGHT SWITCH ASSEMBLY (See page BR-71) INSPECTION 1. INSPECT STOP LIGHT SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Switch Position Specified Condition 1-2 Switch pin free 10 kΩ or higher 3-4 Switch pin free Below 1 Ω 1-2 Switch pin pushed in Below 1 Ω 3-4 Switch pin pushed in 10 kΩ or higher If the result is not as specified, replace the stop light switch assembly. LI LI–126 LIGHTING – STOP LIGHT SWITCH INSTALLATION LI 1. INSTALL STOP LIGHT SWITCH ASSEMBLY (See page BR-72) 2. INSTALL COMBINATION METER ASSEMBLY (See page ME-67) 3. INSTALL INSTRUMENT CLUSTER FINISH PANEL (See page ME-68) 4. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/o Smart Key System) (See page IP-57) 5. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/ Smart Key System) (See page IP-57) 6. INSTALL NO. 1 INSTRUMENT PANEL SUBASSEMBLY (See page IP-57) 7. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (See page IP-55) 8. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-54) 9. INSTALL FRONT DOOR SCUFF PLATE LH (See page IR-54) LI–127 LIGHTING – BACK-UP LIGHT SWITCH BACK-UP LIGHT SWITCH INSPECTION 1. ON OFF  2  1 B113725E01 INSPECT BACK-UP LIGHT BULB (for Manual Transmission) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Switch Operation Specified Condition 1-2 Switch ON (Ball is not pressed) 10 kΩ or higher 1-2 Switch OFF (Ball is pressed) Below 1 Ω If the result is not as specified, replace the back-up light switch. LI LI–128 LIGHTING – FRONT DOOR COURTESY SWITCH FRONT DOOR COURTESY SWITCH BODY ELECTRICAL LIGHTING COMPONENTS FRONT DOOR COURTESY SWITCH ASSEMBLY 12 (122, 8.9) N*m (kgf*cm, ft.*lbf) : Specified torque E128179E01 REMOVAL LI 1. E128210 REMOVE FRONT DOOR COURTESY SWITCH ASSEMBLY (a) Using a "TORX" socket wrench (T30), remove the "TORX" bolt. (b) Disconnect the connector and remove the front door courtesy switch assembly. LIGHTING – FRONT DOOR COURTESY SWITCH LI–129 INSPECTION ON 1. OFF 1 INSPECT FRONT DOOR COURTESY LIGHT SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection 1 - Switch body E071371E02 Switch Operation Specified Condition Not pushed (ON) Below 1 Ω Pushed (OFF) 10 kΩ or higher If the result is not as specified, replace the front door courtesy light switch assembly. INSTALLATION 1. INSTALL FRONT DOOR COURTESY SWITCH ASSEMBLY (a) Connect the connector. (b) Using a "TORX" socket wrench (T30), install the front door courtesy switch assembly with the "TORX" bolt. Torque: 12 N*m (122 kgf*cm, 8.9 ft.*lbf) E128210 LI LI–130 LIGHTING – REAR DOOR COURTESY SWITCH REAR DOOR COURTESY SWITCH BODY ELECTRICAL LIGHTING COMPONENTS REAR DOOR COURTESY SWITCH ASSEMBLY 12 (122, 8.9) N*m (kgf*cm, ft.*lbf) : Specified torque E128180E01 REMOVAL LI 1. E128211 REMOVE REAR DOOR COURTESY SWITCH ASSEMBLY (a) Using a "TORX" socket wrench (T30), remove the "TORX" bolt. (b) Disconnect the connector and remove the rear door courtesy switch assembly. LIGHTING – REAR DOOR COURTESY SWITCH LI–131 INSPECTION ON 1. OFF 1 INSPECT REAR DOOR COURTESY LIGHT SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection 1 - Switch body E071371E02 Switch Operation Specified Condition Not pushed (ON) Below 1 Ω Pushed (OFF) 10 kΩ or higher If the result is not as specified, replace the rear door courtesy light switch assembly. INSTALLATION 1. INSTALL REAR DOOR COURTESY SWITCH ASSEMBLY (a) Connect the connector. (b) Using a "TORX" socket wrench (T30), install the rear door courtesy switch assembly with the "TORX" bolt. Torque: 12 N*m (122 kgf*cm, 8.9 ft.*lbf) E128211 LI LI–132 LIGHTING – BACK DOOR COURTESY SWITCH BACK DOOR COURTESY SWITCH BODY ELECTRICAL LIGHTING COMPONENTS LUGGAGE COMPARTMENT DOOR COVER 5.5 (56, 49 in.*lbf) LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B136883E01 LI LIGHTING – BACK DOOR COURTESY SWITCH LI–133 REMOVAL 1. REMOVE LUGGAGE COMPARTMENT DOOR COVER (See page ET-61) 2. REMOVE LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY (See page ED-63) INSPECTION 1. E119982 INSPECT LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition 1-2 Door is closed 10 kΩ or higher 1-2 Door is open Below 1 Ω If the result is not as specified, replace the luggage compartment door lock assembly. LI LI–134 LIGHTING – BACK DOOR COURTESY SWITCH INSTALLATION LI 1. INSTALL LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY (See page ED-64) 2. INSTALL LUGGAGE COMPARTMENT DOOR COVER (See page ET-64) LI–134 LIGHTING – AUTOMATIC LIGHT CONTROL SENSOR AUTOMATIC LIGHT CONTROL SENSOR BODY ELECTRICAL LIGHTING COMPONENTS AUTOMATIC LIGHT CONTROL SENSOR NO. 1 DEFROSTER NOZZLE GARNISH E128181E01 ON-VEHICLE INSPECTION Wire Harness Side: 1. Automatic Light Control Sensor LI E11 CLTB CLTE B109993E17 INSPECT AUTOMATIC LIGHT CONTROL SENSOR (for Manual Air Conditioning System) (a) Disconnect the E11 automatic light control sensor connector. (b) Measure the voltage and resistance according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition E11-3 (CLTB) - E11-6 (CLTE) Ignition switch off Below 1 V Ignition switch on (IG) 10 to 14 V Standard resistance Tester Connection Specified Condition E11-6 (CLTE) - Body ground Below 1 Ω If the result is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the automatic light control sensor connector. (d) Connect an oscilloscope to the automatic light control sensor connector. LI–135 LIGHTING – AUTOMATIC LIGHT CONTROL SENSOR (e) Check the waveform. OK GND A 2. Automatic Light Control Sensor E11 CLTE CLTB B109993E16 Tool Setting Condition Specified Condition E11-6 (CLTE) E11-4 (CLTS) 5 V/DIV., 5 ms./ DIV Ignition switch on (IG), light control switch in AUTO Correct waveform is as shown HINT: If the ambient light becomes brighter, width A becomes narrower. If the result is not as specified, replace the automatic light control sensor. B113714E01 Wire Harness Side: Tester Connection INSPECT AUTOMATIC LIGHT CONTROL SENSOR (for Automatic Air Conditioning System) (a) Disconnect the E11 automatic light control sensor connector. (b) Measure the voltage and resistance according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition E11-6 (CLTB) - E11-3 (CLTE) Ignition switch off Below 1 V Ignition switch on (IG) 10 to 14 V Standard resistance Tester Connection Specified Condition E11-3 (CLTE) - Body ground Below 1 Ω If the result is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the automatic light control sensor connector. (d) Connect an oscilloscope to the automatic light control sensor connector. (e) Check the waveform. OK A GND B113714E01 Tester Connection Tool Setting Condition Specified Condition E11-3 (CLTE) E11-5 (CLTS) 5 V/DIV., 5 ms./ DIV Ignition switch on (IG), light control switch in AUTO Correct waveform is as shown HINT: If the ambient light becomes brighter, width A becomes narrower. If the result is not as specified, replace the automatic light control sensor. LI LI–136 LIGHTING – AUTOMATIC LIGHT CONTROL SENSOR REMOVAL 1. REMOVE NO. 1 DEFROSTER NOZZLE GARNISH (See page IP-32) 2. REMOVE AUTOMATIC LIGHT CONTROL SENSOR (a) Disengage the 2 claws and remove the automatic light control sensor. E128234 INSTALLATION E128234 LI 1. INSTALL AUTOMATIC LIGHT CONTROL SENSOR (a) Engage the 2 claws and install the automatic light control sensor. 2. INSTALL NO. 1 DEFROSTER NOZZLE GARNISH (See page IP-48) LIGHTING – TURN SIGNAL FLASHER ASSEMBLY LI–137 TURN SIGNAL FLASHER ASSEMBLY BODY ELECTRICAL LIGHTING COMPONENTS with Smart Key System: NO. 1 INSTRUMENT PANEL SUB-ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL without Smart Key System: COWL SIDE TRIM SUB-ASSEMBLY LH LOWER INSTRUMENT PANEL FINISH PANEL COWL SIDE TRIM CLIP STEERING COLUMN COVER LI 2.0 (20, 18 in.*lbf) FRONT DOOR SCUFF PLATE LH LOWER INSTRUMENT PANEL FINISH PANEL LH N*m (kgf*cm, ft.*lbf) : Specified torque E127998E01 LI–138 LIGHTING – TURN SIGNAL FLASHER ASSEMBLY TURN SIGNAL FLASHER ASSEMBLY COMBINATION METER ASSEMBLY INSTRUMENT CLUSTER FINISH PANEL E128183E01 ON-VEHICLE INSPECTION Wire Harness Side: 1. LL LR IG E14 B EL ER E HAZ E068703E11 LI INSPECT TURN SIGNAL FLASHER ASSEMBLY (a) Disconnect the E14 turn signal flasher assembly connector. (b) Measure the voltage and resistance according the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition E14-1 (IG) - Body ground Ignition switch off Below 1 V E14-1 (IG) - Body ground Ignition switch on (IG) 10 to 14 V E14-4 (B) - Body ground Always 10 to 14 V Standard resistance Tester Connection Condition Specified Condition E14-5 (EL) - Body ground Turn signal switch OFF 10 kΩ or higher E14-5 (EL) - Body ground Turn signal switch in LH position Below 1 Ω E14-6 (ER) - Body ground Turn signal switch OFF 10 kΩ or higher E14-6 (ER) - Body ground Turn signal switch in RH position Below 1 Ω E14-7 (E) - Body ground Always Below 1 Ω E14-8 (HAZ) - Body ground Hazard warning switch OFF 10 kΩ or higher LIGHTING – TURN SIGNAL FLASHER ASSEMBLY LI–139 Tester Connection Condition Specified Condition E14-8 (HAZ) - Body ground Hazard warning switch ON Below 1 Ω If the result is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the turn signal flasher assembly connector. (d) Measure the voltage according to the valve(s) in the table below. Standard voltage Tester Connection Condition Specified Condition E14-2 (LR) - Body ground Hazard warning switch OFF Below 1 V E14-2 (LR) - Body ground Hazard warning switch ON 10 to 14 V (60 to 120 times per minute) E14-2 (LR) - Body ground Turn signal switch OFF Below 1 V E14-2 (LR) - Body ground Ignition switch on (IG) and turn signal switch in RH position 10 to 14 V (60 to 120 times per minute) E14-3 (LL)- Body ground Hazard warning switch OFF Below 1 V E14-3 (LL) - Body ground Hazard warning switch ON 10 to 14 V (60 to 120 times per minute) E14-3 (LL) - Body ground Turn signal switch OFF Below 1 V E14-3 (LL) - Body ground Ignition switch on (IG) and turn signal switch in LH position 10 to 14 V (60 to 120 times per minute) E14-5 (EL) - Body ground Ignition switch on (IG) and turn signal switch OFF 10 to 14 V E14-5 (EL) - Body ground Ignition switch on (IG) and turn signal switch in LH position Below 1 V E14-6 (ER) - Body ground Ignition switch on (IG) and turn signal switch OFF 10 to 14 V E14-6 (ER) - Body ground Ignition switch on (IG) and turn signal switch in RH position Below 1 V E14-8 (HAZ) - Body ground Hazard warning switch OFF 10 to 14 V E14-8 (HAZ) - Body ground Hazard warning switch ON Below 1 V If the result is not as specified, replace the turn signal flasher assembly. LI LI–140 LIGHTING – TURN SIGNAL FLASHER ASSEMBLY REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-24) 2. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-25) 3. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (See page IP-20) 4. REMOVE STEERING COLUMN COVER (See page SR-39) 5. REMOVE NO. 1 INSTRUMENT PANEL SUBASSEMBLY (See page IP-22) 6. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (w/o Smart Key System) (See page IP-22) 7. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (w/ Smart Key System) (See page IP-22) 8. REMOVE INSTRUMENT CLUSTER FINISH PANEL (See page ME-65) 9. REMOVE COMBINATION METER ASSEMBLY (See page ME-65) 10. REMOVE TURN SIGNAL FLASHER ASSEMBLY (a) Disconnect the connector. (b) Remove the clamp and the turn signal flasher assembly. Clamp E128235E01 INSTALLATION 1. INSTALL TURN SIGNAL FLASHER ASSEMBLY (a) Install the clamp and the turn signal flasher assembly. (b) Connect the connector. 2. INSTALL COMBINATION METER ASSEMBLY (See page ME-67) 3. INSTALL INSTRUMENT CLUSTER FINISH PANEL (See page ME-68) 4. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/o Smart Key System) (See page IP-57) 5. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/ Smart Key System) (See page IP-57) 6. INSTALL NO. 1 INSTRUMENT PANEL SUBASSEMBLY (See page IP-57) 7. INSTALL STEERING COLUMN COVER (See page SR50) LI Clamp E128235E01 LIGHTING – TURN SIGNAL FLASHER ASSEMBLY LI–141 8. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (See page IP-58) 9. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-54) 10. INSTALL FRONT DOOR SCUFF PLATE LH (See page IR-54) LI LI–141 LIGHTING – TAILLIGHT RELAY 1 4 4 TAILLIGHT RELAY 2 ON-VEHICLE INSPECTION 3 5 2 1 1. 5 3 A087121E11 INSPECT TAILLIGHT RELAY (a) Remove the taillight relay from the instrument panel J/B assembly. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition 3-5 Below 1 Ω (When battery voltage is applied to terminals 1 and 2) 10 kΩ or higher Below 1 Ω 3-4 10 kΩ or higher (When battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the taillight relay. LI LI–142 LIGHTING – FOG LIGHT RELAY FOG LIGHT RELAY 3 5 1 2 5 2 1 3 B060778E85 ON-VEHICLE INSPECTION 1. INSPECT FOG LIGHT RELAY (a) Remove the fog light relay from the instrument panel J/B assembly. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition 3-5 Below 1 Ω (When battery voltage is applied to terminals 1 and 2) 10 kΩ or higher If the result is not as specified, replace the fog light relay. LI ST–1 2AZ-FE STARTING – STARTING SYSTEM STARTING SYSTEM 2AZ-FE STARTING ENGINE PARTS LOCATION STARTER AT: PARK/NEUTRAL POSITION SWITCH ENGINE ROOM R/B ECM -STARTER RELAY -ST/AM2 FUSE -ALT FUSE INSTRUMENT PANEL J/B -AM1 FUSE ST MT: CLUTCH START SWITCH IGNITION SWITCH A135518E01 ST–2 2AZ-FE STARTING – STARTING SYSTEM SYSTEM DIAGRAM (*2) (*2) 4 C1 L B Park/Neutral P Position N Switch ECM (*2) 48 A24 STA A22 Clutch Start Switch E23 Ignition Switch (*1) 1 (*1) 2 ACC AM1 4 IG1 ST ST1 AM2 AM1 52 C24 NSW (*2) IG2 3 5 1 2 5 3 ST2 7 ALT ST/AM2 Starter FL MAIN ST Battery 1 D1 1 1 C29 C3 (*1) (*2) M *1: M/T *2: A/T A135060E01 ST–3 2AZ-FE STARTING – STARTER STARTER 2AZ-FE STARTING ENGINE COMPONENTS AIR CLEANER CAP SUB-ASSEMBLY AIR CLEANER FILTER ELEMENT 5.0 (51, 44 in.*lbf) STARTER ASSEMBLY for Manual Transaxle: x3 5.0 (51, 44 in.*lbf) 9.8 (100, 87 in.*lbf) 12 (120, 9) CLUTCH FLEXIBLE HOSE BRACKET x2 AIR CLEANER INLET ASSEMBLY AIR CLEANER CASE SUB-ASSEMBLY 37 (380, 28) ST N*m (kgf*cm, ft.*lbf) : Specified torque A133564E01 ST–4 2AZ-FE STARTING – STARTER STARTER ARMATURE ASSEMBLY STARTER COMMUTATOR END FRAME ASSEMBLY STARTER COMMUTATOR END FRAME COVER 6.0 (61, 53 in.*lbf) SNAP RING REPAIR SERVICE STARTER KIT WASHER -PLUNGER -RETURN SPRING 6.0 (61, 53 in.*lbf) -MAGNETIC SWITCH 7.5 (76, 66 in.*lbf) 10 (102, 7) ST MOTOR TERMINAL STARTER KIT PLANETARY GEAR N*m (kgf*cm, ft.*lbf) : Specified torque STARTER ARMATURE PLATE Non-reusable part STARTER YOKE ASSEMBLY Apply High-temperature grease A134900E01 2AZ-FE STARTING – STARTER ST–5 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE AIR CLEANER INLET ASSEMBLY (See page EM-94) 3. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-416) 4. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (See page EM-95) 5. REMOVE STARTER ASSEMBLY (for Manual Transaxle) (a) Disconnect the terminal 50 connector from the starter assembly. (b) Remove the nut and disconnect the wire harness from terminal 30. A133565 (c) Remove the 3 bolts, clutch flexible hose bracket and starter assembly. Bracket A133566E01 6. REMOVE STARTER ASSEMBLY (for Automatic Transaxle) (a) Disconnect the terminal 50 connector from the starter assembly. (b) Remove the nut and disconnect the wire harness from terminal 30. A134876 (c) Remove the 2 bolts and starter assembly. A134877 ST ST–6 2AZ-FE STARTING – STARTER DISASSEMBLY 1. REMOVE REPAIR SERVICE STARTER KIT (a) Remove the nut and disconnect the lead wire from terminal C. A079718E05 (b) Remove the 2 screws that hold the magnetic switch to the motor terminal starter kit. (c) Remove the repair service starter kit. (d) Remove the return spring and the plunger from the repair service starter kit. A079719E05 2. REMOVE STARTER YOKE ASSEMBLY (a) Remove the 2 through bolts and pull out the starter yoke assembly together with the starter commutator end frame assembly. A079720E05 (b) Remove the starter yoke assembly from the starter commutator end frame assembly. A079721E03 3. ST A079722E04 REMOVE STARTER ARMATURE PLATE (a) Remove the starter armature plate from the starter yoke assembly. 2AZ-FE STARTING – STARTER ST–7 4. REMOVE STARTER COMMUTATOR END FRAME COVER (a) Using a screwdriver, remove the starter commutator end frame cover. 5. REMOVE STARTER ARMATURE ASSEMBLY (a) Using snap ring pliers, remove the snap ring and plate washer. (b) Remove the starter armature assembly from the commutator end frame assembly. 6. REMOVE PLANETARY GEAR (a) Remove the 3 planetary gears from the motor terminal starter kit. A079723E03 Snap Ring Pliers A082440E07 A081167E03 ST ST–8 2AZ-FE STARTING – STARTER INSPECTION 1. INSPECT STARTER ASSEMBLY CAUTION: Make sure to complete each of the following tests within 5 seconds to prevent the coil from burning out. (a) Perform pull-in test: (1) Disconnect the lead wire from terminal C. Terminal C A133511E01 (2) Connect the battery to the magnetic switch as shown in the illustration. Check that the clutch pinion gear moves outward. If the clutch pinion gear does not move outward, replace the repair service starter kit. Terminal C Body Terminal 50 A133512E01 (b) Perform hold-in test: (1) Disconnect the negative (-) terminal lead from terminal C under the conditions for pull-in test. Check that the pinion gear remains out. If the clutch pinion gear moves inward, replace the repair service starter kit. Terminal C Body Terminal 50 A133513E01 Terminal C ST Body Terminal 50 A133514E01 (c) Inspect clutch pinion gear return: (1) Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear moves inward. If the clutch pinion gear does not move inward, replace the repair service starter kit. (d) Perform no-load performance test: (1) Connect the field coil wire to terminal C with the nut. Make sure that the lead is not grounded. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) (2) Clamp the starter in a vise. ST–9 2AZ-FE STARTING – STARTER (3) Connect the battery and an ammeter to the starter as shown in the illustration. (4) Check that the starter rotates smoothly and steadily with the clutch pinion gear extended. Check that the ammeter reads the specified current. Specified current Ammeter Terminal 30 Condition Specified condition at 11.5 V 90 A or less If the result is not as specified, overhaul the starter assembly. Body Terminal 50 A133510E01 2. INSPECT REPAIR SERVICE STARTER KIT (a) Check the plunger. (1) Push in the plunger and check that it returns quickly to its original position. If necessary, replace the repair service starter kit. A058586E04 (b) Inspect the resistance of the pull-in coil. (1) Using an ohmmeter, measure the resistance between terminals 50 and C. Standard resistance Terminal C Terminal 50 Tester connection Specified condition Terminal 50 - Terminal C Below 1 Ω If the resistance is not as specified, replace the repair service starter kit. Below 1 Ω A079725E08 (c) Inspect the resistance of the hold-in coil. (1) Using an ohmmeter, measure the resistance between terminal 50 and the switch body. Standard resistance Body Below 2 Ω Tester connection Specified condition Terminal 50 - Switch body Below 2 Ω If the resistance is not as specified, replace the repair service starter kit. Terminal 50 A079726E07 3. INSPECT STARTER ARMATURE ASSEMBLY (a) Check the commutator surface for dirt or burning. If the surface is dirty or burnt, smooth the surface with 400-grit sandpaper or leather. ST ST–10 2AZ-FE STARTING – STARTER (b) Inspect the resistance of the commutator. (1) Using an ohmmeter, measure the resistance between the segments of the commutator. Standard resistance Below 1 Ω Tester connection Specified condition Segment - Segment Below 1 Ω If the resistance is not as specified, replace the starter armature assembly. Segment A058372E04 (2) Using an ohmmeter, measure the resistance between the commutator and armature coil core. Standard resistance 10 kΩ or Higher Commutator Coil Core Tester connection Specified condition Commutator - Armature coil core 10 kΩ or higher If the resistance is not as specified, replace the starter armature assembly. A058373E04 (c) Using vernier calipers, measure the commutator depth. Specified depth: 3.1 mm (0.122 in.) Maximum depth: 3.8 mm (0.150 in.) If the depth is greater than the maximum, replace the starter armature assembly. Depth A058584E09 4. Length A076677E10 ST INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY (a) Check the brush length. (1) Using vernier calipers, measure the brush length. Specified length: 9.0 mm (0.354 in.) Maximum length: 4.0 mm (0.157 in.) If the length is less than the minimum, replace the starter commutator end frame assembly. (b) Check the resistance. (1) Using an ohmmeter, measure the resistance between the positive (+) and negative (-) brushes. Resistance: 10 kΩ or higher If the resistance is not as specified, repair or replace the starter commutator end frame assembly. 10 kΩ or Higher A079766E10 2AZ-FE STARTING – STARTER 5. Lock Free ST–11 INSPECT MOTOR TERMINAL STARTER KIT (a) Check the starter clutch. (1) Rotate the clutch pinion gear counterclockwise and check that it turns freely. Try to rotate the clutch pinion gear clockwise and check that it locks. If necessary, replace the motor terminal starter kit. A081655E05 REASSEMBLY 1. INSTALL PLANETARY GEAR (a) Apply high-temperature grease to the planetary gears and pin parts of the planetary shaft. (b) Install the 3 planetary gears to the motor terminal starter kit. 2. INSTALL STARTER ARMATURE ASSEMBLY (a) Apply high-temperature grease to the plate washer and the armature shaft. (b) Install the starter armature assembly to the starter commutator end frame assembly. (c) Using snap ring pliers, install the plate washer and a new snap ring. Apply Grease A081656E06 Snap Ring Pliers A082440E08 (d) Using vernier calipers, measure the snap ring. Maximum length: 5.0 mm (0.197 in.) If the length is greater than the maximum, replace the snap ring with a new one. Length A058810E14 3. A081178E03 INSTALL STARTER COMMUTATOR END FRAME COVER (a) Install the starter commutator end frame cover to the starter commutator end frame assembly. ST ST–12 Claw 2AZ-FE STARTING – STARTER 4. INSTALL STARTER ARMATURE PLATE (a) Align the claw of the armature plate with the groove inside the starter yoke assembly, and install the starter armature plate. 5. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY (a) Align the starter commutator end frame rubber with the groove of the starter yoke assembly. (b) Install the starter commutator end frame assembly to the starter yoke assembly. NOTICE: The magnet of the starter yoke assembly may attract the starter armature assembly when the starter commutator end frame assembly is installed, causing the magnet to break. 6. INSTALL STARTER YOKE ASSEMBLY (a) Align the claw of the starter yoke with the groove inside the motor terminal starter kit. Groove A073991E14 Rubber Groove A079727E08 Claw Groove A079728E07 (b) Install the starter yoke with the 2 through bolts. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) A079720E06 ST 7. A079729E03 INSTALL REPAIR SERVICE STARTER KIT (a) Apply high-temperature grease to the plunger and the hook. (b) Hang the plunger hook of the repair service starter kit to the drive lever hook. (c) Install the plunger and the return spring. 2AZ-FE STARTING – STARTER ST–13 (d) Install the repair service starter kit with the 2 screws. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) A079719E06 (e) Connect the lead wire to terminal C with the nut. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) A079718E06 INSTALLATION 1. B A A Bracket A133566E02 INSTALL STARTER ASSEMBLY (for Manual Transaxle) (a) Install the starter assembly and clutch flexible hose bracket with the 3 bolts. Torque: Bolt A 37 N*m (380 kgf*cm, 28 ft.*lbf) Bolt B 12 N*m (120 kgf*cm, 9 ft.*lbf) (b) Connect the wire harness to terminal 30 and install the nut. Then, attach the terminal cap. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) (c) Connect the terminal 50 connector to the starter assembly. A133565 2. A134877 INSTALL STARTER ASSEMBLY (for Automatic Transaxle) (a) Install the starter assembly with the 2 bolts. Torque: 37 N*m (380 kgf*cm, 28 ft.*lbf) ST ST–14 2AZ-FE STARTING – STARTER (b) Connect the wire harness to terminal 30 and install the nut. Then, attach the terminal cap. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) (c) Connect the terminal 50 connector to the starter assembly. 3. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (See page EM-120) 4. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See page ES-419) 5. INSTALL AIR CLEANER INLET ASSEMBLY (See page EM-120) 6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page EM-120) A134876 ST ST–14 2AZ-FE STARTING – STARTER RELAY STARTER RELAY ON-VEHICLE INSPECTION 1. INSPECT STARTER RELAY ASSEMBLY (a) Using an ohmmeter, measure the resistance between each terminal. Standard resistance Tester Connection E034090E03 Specified Condition 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the starter relay assembly. ST ST–15 2AZ-FE STARTING – IGNITION SWITCH IGNITION SWITCH LOCK ON-VEHICLE INSPECTION ACC 1. ON START AM1 ST1 ACC IG1 INSPECT IGNITION OR STARTER SWITCH ASSEMBLY (a) Check the resistance. (1) Using an ohmmeter, measure the resistance between the terminals. Standard resistance Condition Tester Connection Specified Condition LOCK Between all terminals 10 kΩ or higher ACC 2-4 Below 1 Ω ON 4 ST2 3 2 7 6 IG2 1 5 START AM2 1-2-4 5-6 1-3-4 5-6-7 Below 1 Ω Below 1 Ω If the result is not as specified, replace the ignition or starter switch. A119190E04 ST DS–1 DRIVE SHAFT – DRIVE SHAFT SYSTEM DRIVE SHAFT SYSTEM PROBLEM SYMPTOMS TABLE Use the table below to help find the cause of the problem. Check each part. If necessary, replace these parts. For TMC made Symptom Noise (Front drive shaft) Suspected area Inboard or outboard joint (Worn) See page DS-13 For TMMK made Symptom Noise (Front drive shaft) Suspected area Inboard or outboard joint (Worn) See page DS-29 DS DS–2 DRIVE SHAFT – FRONT DRIVE SHAFT (for TMC Made) FRONT DRIVE SHAFT (for TMC Made) DRIVE SHAFT LINE COMPONENTS FRONT DRIVE SHAFT ASSEMBLY RH BRACKET HOLE SNAP RING Manual Transaxle: FRONT DRIVE SHAFT LH HOLE SNAP RING DS 32 (330, 24) FRONT DRIVE SHAFT ASSEMBLY LH FRONT DRIVE SHAFT LH HOLE SNAP RING FRONT DRIVE SHAFT ASSEMBLY LH TIE ROD END SUB-ASSEMBLY FRONT STABILIZER LINK ASSEMBLY FRONT SPEED SENSOR 19 (192, 14) 74 (755, 55) 8.0 (82, 71 in.*lbf) FRONT FLEXIBLE HOSE FRONT AXLE ASSEMBLY 294 (3,000, 217) FRONT AXLE HUB NUT FRONT SUSPENSION LOWER NO. 1 ARM 49 (500, 36) COTTER PIN 75 (765, 55) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C136106E01 DS–3 DRIVE SHAFT – FRONT DRIVE SHAFT (for TMC Made) 2GR-FE LH SIDE: FRONT DRIVE SHAFT DUST COVER LH FRONT DRIVE INBOARD JOINT ASSEMBLY SHAFT SNAP RING DS NO. 2 FRONT AXLE INBOARD JOINT BOOT CLAMP FRONT AXLE INBOARD JOINT BOOT FRONT AXLE INBOARD JOINT BOOT CLAMP FRONT DRIVE SHAFT DAMPER CLAMP FRONT DRIVE SHAFT DAMPER LH FRONT AXLE OUTBOARD JOINT BOOT CLAMP FRONT AXLE OUTBOARD JOINT BOOT NO. 2 FRONT AXLE OUTBOARD JOINT BOOT CLAMP FRONT DRIVE OUTBOARD JOINT SHAFT ASSEMBLY Non-reusable part C136538E01 DS–4 DRIVE SHAFT – FRONT DRIVE SHAFT (for TMC Made) 2AZ-FE LH SIDE: FRONT DRIVE SHAFT DUST COVER LH FRONT DRIVE INBOARD JOINT ASSEMBLY NO. 2 FRONT AXLE INBOARD JOINT BOOT CLAMP SHAFT SNAP RING DS FRONT AXLE INBOARD JOINT BOOT FRONT AXLE INBOARD JOINT BOOT CLAMP FRONT DRIVE SHAFT DAMPER LH (Automatic Transaxle) SUPPLY PART: FRONT DRIVE SHAFT DAMPER CLAMP (Automatic Transaxle) FRONT AXLE OUTBOARD JOINT BOOT CLAMP FRONT AXLE OUTBOARD JOINT BOOT NO. 2 FRONT AXLE OUTBOARD JOINT BOOT CLAMP FRONT DRIVE SHAFT DAMPER CLAMP (Automatic Transaxle) FRONT DRIVE OUTBOARD JOINT SHAFT ASSEMBLY SUPPLY PARTS: FRONT AXLE OUTBOARD JOINT BOOT CLAMP NO. 2 FRONT AXLE OUTBOARD JOINT BOOT CLAMP Non-reusable part C141176E01 DS–5 DRIVE SHAFT – FRONT DRIVE SHAFT (for TMC Made) 2GR-FE RH SIDE: NO. 2 FRONT AXLE OUTBOARD JOINT BOOT CLAMP FRONT AXLE OUTBOARD JOINT BOOT FRONT AXLE OUTBOARD JOINT BOOT CLAMP FRONT DRIVE SHAFT DAMPER RH DS FRONT DRIVE SHAFT DAMPER CLAMP FRONT AXLE INBOARD JOINT BOOT CLAMP FRONT AXLE INBOARD JOINT BOOT FRONT DRIVE OUTBOARD JOINT SHAFT ASSEMBLY NO. 2 FRONT AXLE INBOARD JOINT BOOT CLAMP FRONT DRIVE INBOARD JOINT ASSEMBLY SHAFT SNAP RING FRONT DRIVE SHAFT DUST COVER FRONT DRIVE SHAFT BEARING DRIVE SHAFT HOLE SNAP RING FRONT DRIVE SHAFT DUST COVER RH Non-reusable part C136540E01 DS–6 DRIVE SHAFT – FRONT DRIVE SHAFT (for TMC Made) 2AZ-FE RH SIDE: FRONT DRIVE OUTBOARD JOINT SHAFT ASSEMBLY DS SUPPLY PARTS: NO. 2 FRONT AXLE OUTBOARD JOINT BOOT CLAMP FRONT AXLE OUTBOARD JOINT BOOT CLAMP NO. 2 FRONT AXLE OUTBOARD JOINT BOOT CLAMP FRONT AXLE OUTBOARD JOINT BOOT FRONT AXLE OUTBOARD JOINT BOOT CLAMP SUPPLY PART: FRONT DRIVE SHAFT DAMPER CLAMP FRONT DRIVE SHAFT DAMPER CLAMP FRONT AXLE INBOARD JOINT BOOT CLAMP FRONT DRIVE SHAFT DAMPER RH FRONT AXLE INBOARD JOINT BOOT FRONT DRIVE INBOARD JOINT ASSEMBLY SHAFT SNAP RING FRONT DRIVE SHAFT BEARING DRIVE SHAFT HOLE SNAP RING NO. 2 FRONT AXLE INBOARD JOINT BOOT CLAMP FRONT DRIVE SHAFT DUST COVER FRONT DRIVE SHAFT DUST COVER RH Non-reusable part C140766E01 DS–23 DRIVE SHAFT – FRONT DRIVE SHAFT (for TMMK Made) FRONT DRIVE SHAFT (for TMMK Made) DRIVE SHAFT LINE COMPONENTS FRONT DRIVE SHAFT ASSEMBLY RH BRACKET HOLE SNAP RING Manual Transaxle: FRONT DRIVE SHAFT LH HOLE SNAP RING DS 32 (330, 24) FRONT DRIVE SHAFT ASSEMBLY LH FRONT DRIVE SHAFT LH HOLE SNAP RING FRONT DRIVE SHAFT ASSEMBLY LH TIE ROD END SUB-ASSEMBLY FRONT STABILIZER LINK ASSEMBLY FRONT SPEED SENSOR 19 (192, 14) 74 (755, 55) 8.0 (82, 71 in.*lbf) FRONT FLEXIBLE HOSE FRONT AXLE ASSEMBLY 294 (3,000, 217) FRONT AXLE HUB NUT FRONT SUSPENSION LOWER NO. 1 ARM 49 (500, 36) COTTER PIN 75 (765, 55) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C136106E01 DS–24 DRIVE SHAFT – FRONT DRIVE SHAFT (for TMMK Made) LH SIDE: FRONT DRIVE SHAFT DUST COVER LH FRONT DRIVE INBOARD JOINT ASSEMBLY SHAFT SNAP RING DS NO. 2 FRONT AXLE INBOARD JOINT BOOT CLAMP Automatic Transaxle: FRONT AXLE INBOARD JOINT BOOT FRONT AXLE INBOARD JOINT BOOT CLAMP FRONT DRIVE SHAFT DAMPER CLAMP FRONT DRIVE SHAFT DAMPER LH FRONT AXLE OUTBOARD JOINT BOOT CLAMP FRONT AXLE OUTBOARD JOINT BOOT NO. 2 FRONT AXLE OUTBOARD JOINT BOOT CLAMP FRONT DRIVE OUTBOARD JOINT SHAFT ASSEMBLY Non-reusable part C136538E02 DS–25 DRIVE SHAFT – FRONT DRIVE SHAFT (for TMMK Made) RH SIDE: NO. 2 FRONT AXLE OUTBOARD JOINT BOOT CLAMP FRONT AXLE OUTBOARD JOINT BOOT FRONT AXLE OUTBOARD JOINT BOOT CLAMP FRONT DRIVE SHAFT DAMPER RH DS FRONT DRIVE SHAFT DAMPER CLAMP FRONT AXLE INBOARD JOINT BOOT CLAMP FRONT AXLE INBOARD JOINT BOOT FRONT DRIVE OUTBOARD JOINT SHAFT ASSEMBLY NO. 2 FRONT AXLE INBOARD JOINT BOOT CLAMP FRONT DRIVE INBOARD JOINT ASSEMBLY SHAFT SNAP RING FRONT DRIVE SHAFT DUST COVER FRONT DRIVE SHAFT BEARING DRIVE SHAFT HOLE SNAP RING FRONT DRIVE SHAFT DUST COVER RH Non-reusable part C136540E02 DRIVE SHAFT – FRONT DRIVE SHAFT (for TMC Made) DS–7 REMOVAL HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. DRAIN AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle) (a) for 2GR-FE: See page AX-207 (b) for 2AZ-FE: See page AX-162 2. DRAIN MANUAL TRANSAXLE OIL (for Manual Transaxle) (See page MX-5) 3. REMOVE FRONT WHEEL 4. REMOVE FRONT AXLE HUB NUT (a) Using SST and a hammer, release the staked part of the front axle hub nut. SST 09930-00010 NOTICE: Loosen the staked part of the nut completely, otherwise the thread of the drive shaft may be damaged. (b) While applying the brakes, remove the front axle hub nut. 5. SEPARATE FRONT STABILIZER LINK ASSEMBLY (a) Remove the nut and separate the front stabilizer link assembly. HINT: If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud. 6. SEPARATE FRONT SPEED SENSOR (a) Remove the bolt and clip, and separate the speed sensor wire and flexible hose from the shock absorber. SST C108168E02 C140591 C140592 DS DS–8 DRIVE SHAFT – FRONT DRIVE SHAFT (for TMC Made) (b) Remove the bolt and separate the speed sensor from the steering knuckle. NOTICE: • Prevent foreign matter from adhering to the speed sensor. • Be careful not to damage the speed sensor. C132782 DS 7. SEPARATE TIE ROD END SUB-ASSEMBLY (a) Remove the cotter pin and nut. (b) Using SST, separate the tie rod end sub-assembly from the steering knuckle. SST 09628-00011 NOTICE: • Make sure that the string of the SST is securely tied to the vehicle. • Be careful not to damage the ball joint dust cover. • Be careful not to damage the steering knuckle. • Be careful not to damage the front disc brake dust cover. 8. SEPARATE FRONT SUSPENSION LOWER NO. 1 ARM (a) Remove the bolt and 2 nuts, and separate the front suspension lower No. 1 arm from the lower ball joint. 9. SEPARATE FRONT AXLE ASSEMBLY (a) Put matchmarks on the front drive shaft assembly and the axle hub. (b) Using a plastic hammer, separate the front drive shaft assembly from the front axle assembly. NOTICE: Be careful not to damage the drive shaft boot and speed sensor rotor. Hold SST Turn C108515E02 F040142E01 Matchmarks D032030E06 DRIVE SHAFT – FRONT DRIVE SHAFT (for TMC Made) DS–9 10. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (a) Using SST, remove the front drive shaft assembly LH. SST 09520-01010, 09520-24010 (09520-32040) NOTICE: • Be careful not to damage the drive shaft dust cover, boot, and oil seal. • Be careful not to drop the drive shaft assembly. SST C083850E02 11. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (a) Using a screwdriver, remove the bearing bracket hole snap ring. (b) Remove the bolt and front drive shaft assembly RH from the drive shaft bearing bracket. NOTICE: Do not damage the boot and oil seal. C080304E03 12. SECURE FRONT AXLE HUB SUB-ASSEMBLY (a) Secure the front axle hub bearing. SST 09608-16042 (09608-02021, 09608-02041) NOTICE: The hub bearing may be damaged if it is subjected to the vehicle's full weight, such as moving the vehicle with the drive shaft removed. If it is necessary to place the vehicle's weight on the hub bearing, first support it with SST. SST F045045E03 13. INSPECT FRONT DRIVE SHAFT ASSEMBLY (See page DS-13) DISASSEMBLY 1. REMOVE FRONT DRIVE SHAFT LH HOLE SNAP RING (a) Using a screwdriver, remove the front drive shaft LH hole snap ring. 2. REMOVE NO. 2 FRONT AXLE INBOARD JOINT BOOT CLAMP (for 2GR-FE) (a) Using pliers, remove the No. 2 front axle inboard joint boot clamp as shown in the illustration. 3. REMOVE FRONT AXLE INBOARD JOINT BOOT CLAMP (for 2GR-FE) (a) Remove the front axle inboard joint boot clamp. HINT: Perform the same procedures as for the No. 2 front axle inboard joint boot clamp. C057543E04 C108564 DS DS–10 DRIVE SHAFT – FRONT DRIVE SHAFT (for TMC Made) 4. REMOVE NO. 2 FRONT AXLE INBOARD JOINT BOOT CLAMP (for 2AZ-FE) (a) For one touch type: (1) Using a screwdriver, remove the No. 2 front axle inboard joint boot clamp as shown in the illustration. (b) For claw engagement type: (1) Using needle-nose pliers, remove the No. 2 front axle inboard joint boot clamp as shown in the illustration. 5. REMOVE FRONT AXLE INBOARD JOINT BOOT CLAMP (for 2AZ-FE) (a) Remove the front axle inboard joint boot clamp. HINT: Perform the same procedures as for the No. 2 front axle inboard joint boot clamp. 6. SEPARATE FRONT AXLE INBOARD JOINT BOOT (a) Separate the front axle inboard joint boot from the inboard joint assembly. 7. REMOVE FRONT DRIVE INBOARD JOINT ASSEMBLY (a) Remove the grease from the inboard joint assembly. For One Touch Type: DS For Claw Engagement Type: Claws C132202E01 (b) Put matchmarks on the inboard joint assembly and outboard joint shaft. NOTICE: Do not use a punch for the marks. (c) Remove the inboard joint assembly from the outboard joint shaft. Matchmarks F045461E08 (d) Using a snap ring expander, remove the shaft snap ring. F045046 DRIVE SHAFT – FRONT DRIVE SHAFT (for TMC Made) DS–11 (e) Put matchmarks on the outboard joint shaft and tripod joint. NOTICE: Do not use a punch for the marks. (f) Using a brass bar and a hammer, remove the tripod joint from the outboard joint shaft. NOTICE: Do not tap the roller. Matchmarks 8. REMOVE FRONT AXLE INBOARD JOINT BOOT (a) Remove the inboard joint boot from the outboard joint shaft. 9. REMOVE FRONT DRIVE SHAFT DAMPER LH (for 2GR-FE) (a) Using pliers, remove the drive shaft damper clamp as shown in the illustration. (b) Remove the drive shaft damper. C141145E01 C108273 10. REMOVE FRONT DRIVE SHAFT DAMPER RH (for 2GR-FE) (a) Remove the front drive shaft damper RH. HINT: Perform the same procedures as for the front drive shaft damper LH. 11. REMOVE FRONT DRIVE SHAFT DAMPER LH (for 2AZ-FE Automatic Transaxle) (a) For one touch type: (1) Using a screwdriver, remove the drive shaft damper clamp as shown in the illustration. (b) For claw engagement type: (1) Using needle-nose pliers, remove the drive shaft damper clamp as shown in the illustration. (c) Remove the drive shaft damper. For One Touch Type: 12. REMOVE FRONT DRIVE SHAFT DAMPER RH (for 2AZ-FE) (a) Remove the front drive shaft damper RH. HINT: Perform the same procedures as for the front drive shaft damper LH. For Claw Engagement Type: Claws C135385E01 DS DS–12 DRIVE SHAFT – FRONT DRIVE SHAFT (for TMC Made) 13. REMOVE NO. 2 FRONT AXLE OUTBOARD JOINT BOOT CLAMP (for 2GR-FE) (a) Using pliers, remove the No. 2 front axle outboard joint boot clamp as shown in the illustration. C081167E02 14. REMOVE FRONT AXLE OUTBOARD JOINT BOOT CLAMP (for 2GR-FE) (a) Remove the front axle outboard joint boot clamp. HINT: Perform the same procedures as for the No. 2 front axle outboard joint boot clamp. 15. REMOVE NO. 2 FRONT AXLE OUTBOARD JOINT BOOT CLAMP (for 2AZ-FE) (a) Using a screwdriver, remove the No. 2 front axle outboard joint boot clamp as shown in the illustration. DS C063445 16. REMOVE FRONT AXLE OUTBOARD JOINT BOOT CLAMP (for 2AZ-FE) (a) Remove the front axle outboard joint boot clamp. HINT: Perform the same procedures as for the No. 2 front axle outboard joint boot clamp. 17. REMOVE FRONT AXLE OUTBOARD JOINT BOOT (a) Remove the outboard joint boot from the outboard joint shaft. (b) Remove the grease from the outboard joint. 18. REMOVE FRONT DRIVE SHAFT DUST COVER LH (a) Using SST and a press, remove the drive shaft dust cover LH. SST 09950-00020 NOTICE: Be careful not to drop the inboard joint assembly. SST F040647E07 19. REMOVE FRONT DRIVE SHAFT DUST COVER RH (a) Using a press, remove the drive shaft dust cover RH. C067101E02 DRIVE SHAFT – FRONT DRIVE SHAFT (for TMC Made) DS–13 20. REMOVE FRONT DRIVE SHAFT DUST COVER (a) Using SST and a press, remove the drive shaft dust cover. SST 09950-00020 SST F040208E03 21. REMOVE FRONT DRIVE SHAFT BEARING (a) Using a snap ring expander, remove the drive shaft hole snap ring. C092033E04 (b) Using SST and a press, remove the bearing. SST 09527-10011 (c) Remove the bearing bracket hole snap ring. NOTICE: Be careful not to drop the inboard joint assembly. SST F040210E04 INSPECTION 1. C091598E02 INSPECT FRONT DRIVE SHAFT ASSEMBLY (a) Check that there is no excessive play in the outboard joint. (b) Check that the inboard joint slides smoothly in the thrust direction. (c) Check that there is no excessive play in the radial directions of the inboard joint. (d) Check the boots for damage. REASSEMBLY 1. SST C092032E01 INSTALL FRONT DRIVE SHAFT BEARING (a) Install a new bearing bracket hole snap ring to the front drive shaft assembly RH. (b) Using SST and a steel plate, install a new front drive shaft bearing. SST 09527-30010, 09527-10011 NOTICE: Bearing should be completely installed. DS DS–14 DRIVE SHAFT – FRONT DRIVE SHAFT (for TMC Made) (c) Using a snap ring expander, install a new drive shaft hole snap ring. C092033E02 DS 2. INSTALL FRONT DRIVE SHAFT DUST COVER (a) Using SST and a press, install a new drive shaft dust cover. SST 09726-40010, 09527-10011 NOTICE: • The dust cover should be completely installed. • Be careful not to damage the dust deflector. 3. INSTALL FRONT DRIVE SHAFT DUST COVER RH (a) Using SST and a press, install a new drive shaft dust cover RH until distance (A) from the tip of the center drive shaft to the drive shaft dust cover RH meets the specification. SST 09527-10011 SST 26.6 to 27.6 mm (1.047 to 1.087 in.) F045047E03 SST (A) Engine type Distance (A) 2GR-FE 110.0 to 111.0 mm (4.3307 to 4.3701 in.) 2AZ-FE 91.0 to 92.0 mm (3.5827 to 3.6220 in.) C129109E01 NOTICE: • The dust cover should be completely installed. • Be careful not to damage the dust deflector. 4. SST F041033E03 INSTALL FRONT DRIVE SHAFT DUST COVER LH (a) Using SST and a press, install a new drive shaft dust cover LH. SST 09527-10011 NOTICE: • The dust cover should be completely installed. • Be careful not to damage the dust deflector. DS–15 DRIVE SHAFT – FRONT DRIVE SHAFT (for TMC Made) 5. Vinyl Tape W001994E04 6. Hold Turn SST C106162E04 INSTALL FRONT AXLE OUTBOARD JOINT BOOT (a) Hold the drive shaft lightly in a vise between aluminium plates. HINT: Before installing the boots, wrap the spline of the drive shaft with vinyl tape to prevent the boots from being damaged. (b) Temporarily install a new outboard joint boot to the drive shaft with the 2 clamps. (c) Pack the outboard joint shaft and boot with grease. Engine type Grease capacity 2GR-FE 164 to 184 g (5.8 to 6.5 oz.) 2AZ-FE 190 to 200 g (6.7 to 7.1 oz.) INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP (a) Hold the drive shaft lightly in a vise between aluminum plates. NOTICE: Do not overtighten the vise. (b) Install the 2 outboard joint boot clamps onto the boot. (c) Place SST onto the outboard joint boot clamp. SST 09521-24010 (d) Tighten the SST so that the outboard joint boot clamp is pinched. NOTICE: Do not overtighten the SST. (e) Using SST, measure the clearance of the outboard joint boot clamp. SST 09240-00020 Clearance: 0.5 to 1.5 mm (0.0197 to 0.0591 in.) NOTICE: If the measured value is greater than the specified value, retighten the clamp. SST 7. C106163E01 INSTALL NO. 2 FRONT AXLE OUTBOARD JOINT BOOT CLAMP (a) Install the No. 2 outboard joint boot clamp onto the boot. (b) Place SST onto the No. 2 outboard joint boot clamp. SST 09521-24010 (c) Tighten the SST so that the No. 2 outboard joint boot clamp is pinched. NOTICE: Do not overtighten the SST. Hold SST Turn R010425E04 DS DS–16 DRIVE SHAFT – FRONT DRIVE SHAFT (for TMC Made) (d) Using SST, measure the clearance of the No. 2 outboard joint boot clamp. SST 09240-00020 Clearance: 0.5 to 1.5 mm (0.0197 to 0.0591 in.) NOTICE: If the measured value is greater than the specified value, retighten the clamp. SST R010426E08 8. DS F040646E03 INSTALL FRONT DRIVE SHAFT DAMPER LH (for 2GR-FE) (a) Install the drive shaft damper to the drive shaft. (b) Make sure that the damper is on the shaft groove. (c) Set the distance as specified below. Distance: 228.0 to 232.0 mm (8.976 to 9.134 in.) (d) Install the drive shaft damper clamp onto the drive shaft damper. NOTICE: Be sure to install the clamp in the correct position. (e) Place SST onto the drive shaft damper clamp. SST 09521-24010 (f) Tighten the SST so that the clamp is pinched. NOTICE: Do not overtighten the SST. SST C108289E01 (g) Using SST, measure the clearance of the drive shaft damper clamp. SST 09240-00020 Clearance: 0.5 to 1.5 mm (0.0197 to 0.0591 in.) NOTICE: If the measured value is greater than the specified value, retighten the clamp. 9. C108290 INSTALL FRONT DRIVE SHAFT DAMPER RH (for 2GR-FE) (a) Install the front drive shaft damper RH. HINT: Perform the same procedures as for the front drive shaft damper LH. DRIVE SHAFT – FRONT DRIVE SHAFT (for TMC Made) DS–17 10. INSTALL FRONT DRIVE SHAFT DAMPER LH (for 2AZ-FE Automatic Transaxle) (a) Install the drive shaft damper to the drive shaft. (b) Make sure that the damper is on the shaft groove. (c) Set the distance as specified below. Distance: 222.0 to 226.0 mm (8.740 to 8.898 in.) F040646E03 (d) Using a screwdriver, install a new drive shaft damper clamp as shown in the illustration. F047132 11. INSTALL FRONT DRIVE SHAFT DAMPER RH (for 2AZ-FE) (a) Install the drive shaft damper to the drive shaft. (b) Make sure that the damper is on the shaft groove. (c) Set the distance as specified below. Distance: 223.4 to 227.4 mm (8.795 to 8.953 in.) F040646E03 (d) Using a screwdriver, install a new drive shaft damper clamp as shown in the illustration. F047132 Beveled side Matchmarks C067417E07 12. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY (a) Temporarily install a new inboard joint boot to the drive shaft with the 2 clamps. (b) Place the beveled side of the tripod joint axial spline toward the outboard joint shaft. (c) Align the matchmarks. (d) Using a brass bar and hammer, tap in the tripod joint to the outboard joint shaft. NOTICE: • Do not tap the roller. DS DS–18 DRIVE SHAFT – FRONT DRIVE SHAFT (for TMC Made) • Be sure to install the tripod joint assembly in the correct direction. (e) Using a snap ring expander, install a new shaft snap ring. (f) Coat the outboard joint shaft and boot with grease. DS Engine type Grease capacity 2GR-FE 155 to 175 g (5.5 to 6.2 oz.) 2AZ-FE 175 to 185 g (6.2 to 6.5 oz.) F045046 (g) Align the matchmarks and install the inboard joint assembly to the outboard joint shaft assembly. 13. INSTALL FRONT AXLE INBOARD JOINT BOOT (a) Install the inboard joint boot to the inboard joint assembly. Matchmarks F040222E04 (b) Check whether the drive shaft dimensions are within the following specifications. HINT: The following table shows dimension (A) of the drive shaft. Dimension (A) C104911 Engine Type LH RH 2GR-FE 585.5 to 589.5 mm (23.05 to 23.21 in.) 904.4 to 908.4 mm (35.61 to 35.76 in.) 2AZ-FE 592.2 to 602.2 mm (23.32 to 23.71 in.) 891.0 to 901.0 mm (35.08 to 35.47 in.) DRIVE SHAFT – FRONT DRIVE SHAFT (for TMC Made) Hold Turn SST D026925E03 DS–19 14. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP (for 2GR-FE) (a) Hold the drive shaft lightly in a vise between aluminum plates. NOTICE: Do not overtighten the vise. (b) Install the 2 inboard joint boot clamps onto the boot. (c) Place SST onto the inboard joint boot clamp. SST 09521-24010 (d) Tighten the SST so that the inboard joint boot clamp is pinched. NOTICE: Do not overtighten the SST. (e) Using SST, measure the clearance of the inboard joint boot clamp. SST 09240-00020 Clearance: 0.5 to 1.5 mm (0.0197 to 0.0591 in.) NOTICE: If the measured value is greater than the specified value, retighten the clamp. SST D026926E01 15. INSTALL NO. 2 FRONT AXLE INBOARD JOINT BOOT CLAMP (for 2GR-FE) (a) Hold the inboard joint shaft assembly in a vise between aluminium plates. NOTICE: Do not overtighten the vise. (b) Install the No. 2 front axle inboard joint boot clamp onto the boot. (c) Place SST onto the No. 2 front axle inboard joint boot clamp. SST 09521-24010 (d) Tighten the SST so that the No. 2 front axle inboard joint boot clamp is pinched. NOTICE: Do not overtighten the SST. Hold SST Turn C108292E04 (e) Using SST, measure the clearance of the No. 2 front axle inboard joint boot clamp. SST 09240-00020 Clearance: 0.5 to 1.5 mm (0.0197 to 0.0591 in.) NOTICE: If the measured value is greater than the specified value, retighten the clamp. SST C086270E07 DS DS–20 DRIVE SHAFT – FRONT DRIVE SHAFT (for TMC Made) 16. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP (for 2AZ-FE) (a) For one touch type: (1) Using a screwdriver, install the inboard joint boot clamp as shown in the illustration. (b) For claw engagement type: (1) Using needle nose pliers, install the inboard joint boot clamp as shown in the illustration. For One Touch Type: DS For Claw Engagement Type: Claws C137746E01 17. INSTALL NO. 2 FRONT AXLE INBOARD JOINT BOOT CLAMP (for 2AZ-FE) (a) For one touch type: (1) Using a screwdriver, install the No. 2 front axle inboard joint boot clamp as shown in the illustration. (b) For claw engagement type: (1) Using needle nose pliers, install the No. 2 front axle inboard joint boot clamp as shown in the illustration. For One Touch Type: For Claw Engagement Type: 18. INSTALL FRONT DRIVE SHAFT LH HOLE SNAP RING (a) Install a new hole snap ring. 19. INSPECT FRONT DRIVE SHAFT ASSEMBLY (See page DS-13) Claws C137749E01 INSTALLATION 1. C083851E03 INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (a) Coat the spline of the inboard joint shaft assembly with ATF. (b) Align the shaft splines and install the drive shaft assembly LH with a brass bar and hammer. NOTICE: • Set the shaft snap ring with the opening side facing down. DRIVE SHAFT – FRONT DRIVE SHAFT (for TMC Made) DS–21 • Be careful not to damage the drive shaft dust cover, boot, and oil seal. • Move the drive shaft assembly while keeping it level. 2. C080304E04 INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (a) Coat the spline of the inboard joint shaft assembly with ATF. (b) Install the front drive shaft the assembly RH. (c) Using a screwdriver, install a new bearing bracket hole snap ring. NOTICE: • Do not damage the boot and oil seal. • Move the drive shaft assembly while keeping it level. (d) Install a new bolt. Torque: 32 N*m (330 kgf*cm, 24 ft.*lbf) 3. INSTALL FRONT AXLE ASSEMBLY (a) Align the matchmarks and install the front drive shaft assembly to the front axle hub sub-assembly. NOTICE: Be careful not to damage the drive shaft boot and speed sensor rotor. 4. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM (a) Install the lower ball joint to the front suspension lower No. 1 arm with the bolt and 2 nuts. Torque: 75 N*m (765 kgf*cm, 55 ft.*lbf) 5. INSTALL TIE ROD END SUB-ASSEMBLY (a) Install the tie rod end sub-assembly to the steering knuckle with the nut. Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) (b) Install a new cotter pin. NOTICE: If the holes for the cotter pin are not aligned, tighten the nut up to 60° further. 6. INSTALL FRONT SPEED SENSOR (a) Install the front speed sensor to the steering knuckle with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) NOTICE: • Prevent foreign matter from adhering to the speed sensor. • Be careful not to damage the speed sensor. Matchmarks F047689E03 F040142E03 C132782 DS DS–22 DRIVE SHAFT – FRONT DRIVE SHAFT (for TMC Made) (b) Install the flexible hose and the speed sensor to the shock absorber with the bolt and set the sensor clip on the knuckle. Torque: 19 N*m (192 kgf*cm, 14 ft.*lbf) NOTICE: • Be careful not to damage the speed sensor. • Prevent foreign matter from adhering to the speed sensor. • Do not twist the sensor wire when installing the speed sensor. C140592 DS 7. INSTALL FRONT STABILIZER LINK ASSEMBLY (a) Install the stabilizer link assembly with the nut. Torque: 74 N*m (755 kgf*cm, 55 ft.*lbf) HINT: If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud. 8. INSTALL FRONT AXLE HUB NUT (a) Using a socket wrench (30 mm), install a new axle hub nut. Torque: 294 N*m (3,000 kgf*cm, 217 ft.*lbf) (b) Using a chisel and hammer, stake the front axle hub nut. 9. INSTALL FRONT WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) C140591 C068609E02 10. ADD AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle) (a) for 2GR-FE: See page AX-164 (b) for 2AZ-FE: See page AX-175 11. ADD MANUAL TRANSAXLE OIL (for Manual Transaxle) (See page MX-6) 12. INSPECT AUTOMATIC TRANSAXLE FLUID (for 2AZFE Automatic Transaxle) (See page AX-123) 13. INSPECT MANUAL TRANSAXLE OIL (for Manual Transaxle) (See page MX-2) 14. ADJUST FRONT WHEEL ALIGNMENT HINT: See page SP-4 15. CHECK ABS SPEED SENSOR SIGNAL (a) ABS: See page BC-11 (b) VSC (for BOSCH): See page BC-123 (c) VSC (for ADVICS): See page BC-290 DS–26 DRIVE SHAFT – FRONT DRIVE SHAFT (for TMMK Made) REMOVAL HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. DS 1. DRAIN AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle) (a) for 2GR-FE: See page AX-207 (b) for 2AZ-FE: See page AX-162 2. DRAIN MANUAL TRANSAXLE OIL (for Manual Transaxle) (See page MX-5) 3. REMOVE FRONT WHEEL 4. REMOVE FRONT AXLE HUB NUT (See page DS-7) 5. SEPARATE FRONT STABILIZER LINK ASSEMBLY (See page DS-7) 6. SEPARATE FRONT SPEED SENSOR (See page DS-7) 7. SEPARATE TIE ROD END SUB-ASSEMBLY (See page DS-8) 8. SEPARATE FRONT SUSPENSION LOWER NO. 1 ARM (See page DS-8) 9. SEPARATE FRONT AXLE ASSEMBLY (See page DS8) 10. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (See page DS-9) 11. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (See page DS-9) 12. SECURE FRONT AXLE HUB SUB-ASSEMBLY (See page DS-9) 13. INSPECT FRONT DRIVE SHAFT ASSEMBLY (See page DS-29) DISASSEMBLY 1. C057543E04 REMOVE FRONT DRIVE SHAFT LH HOLE SNAP RING (a) Using a screwdriver, remove the front drive shaft LH hole snap ring. DRIVE SHAFT – FRONT DRIVE SHAFT (for TMMK Made) DS–27 2. REMOVE NO. 2 FRONT AXLE INBOARD JOINT BOOT CLAMP (a) Using pliers, remove the No. 2 front axle inboard joint boot clamp as shown in the illustration. 3. REMOVE FRONT AXLE INBOARD JOINT BOOT CLAMP (a) Remove the front axle inboard joint boot clamp. HINT: Perform the same procedures as for the No. 2 front axle inboard joint boot clamp. 4. SEPARATE FRONT AXLE INBOARD JOINT BOOT (a) Separate the front axle inboard joint boot from the inboard joint assembly. 5. REMOVE FRONT DRIVE INBOARD JOINT ASSEMBLY (a) Remove the grease from the inboard joint assembly. C108564 (b) Put matchmarks on the inboard joint assembly and outboard joint shaft. NOTICE: Do not use a punch for the marks. (c) Remove the inboard joint assembly from the outboard joint shaft. Matchmarks F045461E08 (d) Using a snap ring expander, remove the shaft snap ring. F045046 (e) Put matchmarks on the outboard joint shaft and tripod joint. NOTICE: Do not use a punch for the marks. (f) Using a brass bar and a hammer, remove the tripod joint from the outboard joint shaft. NOTICE: Do not tap the roller. Matchmarks 6. C141145E01 REMOVE FRONT AXLE INBOARD JOINT BOOT (a) Remove the inboard joint boot from the outboard joint shaft. DS DS–28 DRIVE SHAFT – FRONT DRIVE SHAFT (for TMMK Made) 7. REMOVE FRONT DRIVE SHAFT DAMPER LH (a) Using pliers, remove the drive shaft damper clamp as shown in the illustration. (b) Remove the drive shaft damper. 8. REMOVE FRONT DRIVE SHAFT DAMPER RH (a) Remove the front drive shaft damper RH. HINT: Perform the same procedures as for the front drive shaft damper LH. 9. REMOVE NO. 2 FRONT AXLE OUTBOARD JOINT BOOT CLAMP (a) Using pliers, remove the No. 2 front axle outboard joint boot clamp as shown in the illustration. C108273 DS C081167E02 10. REMOVE FRONT AXLE OUTBOARD JOINT BOOT CLAMP (a) Remove the front axle outboard joint boot clamp. HINT: Perform the same procedures as for the No. 2 front axle outboard joint boot clamp. 11. REMOVE FRONT AXLE OUTBOARD JOINT BOOT (a) Remove the outboard joint boot from the outboard joint shaft. (b) Remove the grease from the outboard joint. 12. REMOVE FRONT DRIVE SHAFT DUST COVER LH (a) Using SST and a press, remove the drive shaft dust cover LH. SST 09950-00020 NOTICE: Be careful not to drop the inboard joint assembly. SST F040647E07 13. REMOVE FRONT DRIVE SHAFT DUST COVER RH (a) Using a press, remove the drive shaft dust cover RH. C067101E02 DRIVE SHAFT – FRONT DRIVE SHAFT (for TMMK Made) DS–29 14. REMOVE FRONT DRIVE SHAFT DUST COVER (a) Using SST and a press, remove the drive shaft dust cover. SST 09950-00020 SST F040208E03 15. REMOVE FRONT DRIVE SHAFT BEARING (a) Using a snap ring expander, remove the drive shaft hole snap ring. C092033E04 (b) Using SST and a press, remove the bearing. SST 09527-10011 (c) Remove the bearing bracket hole snap ring. NOTICE: Be careful not to drop the inboard joint assembly. SST F040210E04 INSPECTION 1. C091598E02 INSPECT FRONT DRIVE SHAFT ASSEMBLY (a) Check that there is no excessive play in the outboard joint. (b) Check that the inboard joint slides smoothly in the thrust direction. (c) Check that there is no excessive play in the radial directions of the inboard joint. (d) Check the boots for damage. REASSEMBLY 1. SST C092032E01 INSTALL FRONT DRIVE SHAFT BEARING (a) Install a new bearing bracket hole snap ring to the front drive shaft assembly RH. (b) Using SST and a steel plate, install a new front drive shaft bearing. SST 09527-30010, 09527-10011 NOTICE: Bearing should be completely installed. DS DS–30 DRIVE SHAFT – FRONT DRIVE SHAFT (for TMMK Made) (c) Using a snap ring expander, install a new drive shaft hole snap ring. C092033E02 DS 2. INSTALL FRONT DRIVE SHAFT DUST COVER (a) Using SST and a press, install a new drive shaft dust cover. SST 09726-40010, 09527-10011 NOTICE: • The dust cover should be completely installed. • Be careful not to damage the dust cover. 3. INSTALL FRONT DRIVE SHAFT DUST COVER RH (a) Using SST and a press, install a new drive shaft dust cover RH until distance (A) from the tip of the center drive shaft to the drive shaft dust cover RH meets the specification. SST 09527-10011 SST 26.6 to 27.6 mm (1.047 to 1.087 in.) F045047E03 SST (A) Engine type Distance (A) 2GR-FE 110.0 to 111.0 mm (4.3307 to 4.3701 in.) 2AZ-FE 91.0 to 92.0 mm (3.5827 to 3.6220 in.) C129109E01 NOTICE: • The dust cover should be completely installed. • Be careful not to damage the dust cover. 4. SST F041033E03 INSTALL FRONT DRIVE SHAFT DUST COVER LH (a) Using SST and a press, install a new drive shaft dust cover LH. SST 09527-10011 NOTICE: • The dust cover should be completely installed. • Be careful not to damage the dust cover. DS–31 DRIVE SHAFT – FRONT DRIVE SHAFT (for TMMK Made) 5. Vinyl Tape W001994E04 6. Hold Turn SST C106162E04 INSTALL FRONT AXLE OUTBOARD JOINT BOOT (a) Hold the drive shaft lightly in a vise between aluminium plates. HINT: Before installing the boots, wrap the spline of the drive shaft with vinyl tape to prevent the boots from being damaged. (b) Temporarily install a new outboard joint boot to the drive shaft with the 2 clamps. (c) Coat the outboard joint shaft and boot with grease. Engine type Grease capacity 2GR-FE 164 to 184 g (5.8 to 6.5 oz.) 2AZ-FE 100 to 120 g (3.5 to 4.2 oz.) INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP (a) Hold the drive shaft lightly in a vise between aluminum plates. NOTICE: Do not overtighten the vise. (b) Install the 2 outboard joint boot clamps onto the boot. (c) Place SST onto the outboard joint boot clamp. SST 09521-24010 (d) Tighten the SST so that the outboard joint boot clamp is pinched. NOTICE: Do not overtighten the SST. (e) Using SST, measure the clearance of the outboard joint boot clamp. SST 09240-00020 Clearance: 0.5 to 1.5 mm (0.0197 to 0.0591 in.) NOTICE: If the measured value is greater than the specified value, retighten the clamp. SST 7. C106163E01 INSTALL NO. 2 FRONT AXLE OUTBOARD JOINT BOOT CLAMP (a) Install the No. 2 outboard joint boot clamp onto the boot. (b) Place SST onto the No. 2 outboard joint boot clamp. SST 09521-24010 (c) Tighten the SST so that the No. 2 outboard joint boot clamp is pinched. NOTICE: Do not overtighten the SST. Hold SST Turn R010425E04 DS DS–32 DRIVE SHAFT – FRONT DRIVE SHAFT (for TMMK Made) (d) Using SST, measure the clearance of the No. 2 outboard joint boot clamp. SST 09240-00020 Clearance: 0.5 to 1.5 mm (0.0197 to 0.0591 in.) NOTICE: If the measured value is greater than the specified value, retighten the clamp. SST R010426E08 8. DS F040646E03 INSTALL FRONT DRIVE SHAFT DAMPER LH (a) Install the drive shaft damper to the drive shaft. (b) Make sure that the damper is on the shaft groove. (c) Set the distance as specified below. Distance: 228.0 to 232.0 mm (8.976 to 9.134 in.) (d) Install the drive shaft damper clamp onto the drive shaft damper. NOTICE: Be sure to install the clamp in the correct position. (e) Place SST onto the drive shaft damper clamp. SST 09521-24010 (f) Tighten the SST so that the clamp is pinched. NOTICE: Do not overtighten the SST. SST C108289E01 (g) Using SST, measure the clearance of the drive shaft damper clamp. SST 09240-00020 Clearance: 0.5 to 1.5 mm (0.0197 to 0.0591 in.) NOTICE: If the measured value is greater than the specified value, retighten the clamp. 9. C108290 INSTALL FRONT DRIVE SHAFT DAMPER RH (a) Install the front drive shaft damper RH. HINT: Perform the same procedures as for the front drive shaft damper LH. DS–33 DRIVE SHAFT – FRONT DRIVE SHAFT (for TMMK Made) Beveled side Matchmarks C067417E07 10. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY (a) Temporarily install a new inboard joint boot to the drive shaft with the 2 clamps. (b) Place the beveled side of the tripod joint axial spline toward the outboard joint shaft. (c) Align the matchmarks. (d) Using a brass bar and hammer, tap in the tripod joint to the outboard joint shaft. NOTICE: • Do not tap the roller. • Be sure to install the tripod joint assembly in the correct direction. (e) Using a snap ring expander, install a new shaft snap ring. (f) Coat the outboard joint shaft and boot with grease. Engine type Grease capacity 2GR-FE 155 to 175 g (5.5 to 6.2 oz.) 2AZ-FE 170 to 190 g (6.0 to 6.7 oz.) F045046 (g) Align the matchmarks and install the inboard joint assembly to the outboard joint shaft assembly. 11. INSTALL FRONT AXLE INBOARD JOINT BOOT (a) Install the inboard joint boot to the inboard joint assembly. Matchmarks F040222E04 DS DS–34 DRIVE SHAFT – FRONT DRIVE SHAFT (for TMMK Made) (b) Check whether the drive shaft dimensions are within the following specifications. HINT: The following table shows dimension (A) of the drive shaft. Dimension (A) Engine Type LH RH 2GR-FE 585.5 to 589.5 mm (23.05 to 23.21 in.) 904.4 to 908.4 mm (35.61 to 35.76 in.) 2AZ-FE 598.0 to 602.0 mm (23.54 to 23.70 in.) 897.0 to 901.0 mm (35.32 to 35.47 in.) DS C104911 Hold Turn SST D026925E03 12. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP (a) Hold the drive shaft lightly in a vise between aluminum plates. NOTICE: Do not overtighten the vise. (b) Install the 2 inboard joint boot clamps onto the boot. (c) Place SST onto the inboard joint boot clamp. SST 09521-24010 (d) Tighten the SST so that the inboard joint boot clamp is pinched. NOTICE: Do not overtighten the SST. (e) Using SST, measure the clearance of the inboard joint boot clamp. SST 09240-00020 Clearance: 0.5 to 1.5 mm (0.0197 to 0.0591 in.) NOTICE: If the measured value is greater than the specified value, retighten the clamp. SST D026926E01 13. INSTALL NO. 2 FRONT AXLE INBOARD JOINT BOOT CLAMP (a) Hold the inboard joint shaft assembly in a vise between aluminium plates. NOTICE: Do not overtighten the vise. (b) Install the No. 2 front axle inboard joint boot clamp onto the boot. DRIVE SHAFT – FRONT DRIVE SHAFT (for TMMK Made) DS–35 (c) Place SST onto the No. 2 front axle inboard joint boot clamp. SST 09521-24010 (d) Tighten the SST so that the No. 2 front axle inboard joint boot clamp is pinched. NOTICE: Do not overtighten the SST. Hold SST Turn C108292E04 (e) Using SST, measure the clearance of the No. 2 front axle inboard joint boot clamp. SST 09240-00020 Clearance: 0.5 to 1.5 mm (0.0197 to 0.0591 in.) NOTICE: If the measured value is greater than the specified value, retighten the clamp. SST C086270E07 14. INSTALL FRONT DRIVE SHAFT LH HOLE SNAP RING (a) Install a new hole snap ring. 15. INSPECT FRONT DRIVE SHAFT ASSEMBLY (See page DS-29) DS DS–36 DRIVE SHAFT – FRONT DRIVE SHAFT (for TMMK Made) INSTALLATION DS 1. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (See page DS-20) 2. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (See page DS-21) 3. INSTALL FRONT AXLE ASSEMBLY (See page DS-21) 4. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM (See page DS-21) 5. INSTALL TIE ROD END SUB-ASSEMBLY (See page DS-21) 6. INSTALL FRONT SPEED SENSOR (See page DS-21) 7. INSTALL FRONT STABILIZER LINK ASSEMBLY (See page DS-22) 8. INSTALL FRONT AXLE HUB NUT (See page DS-22) 9. INSTALL FRONT WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 10. ADD AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle) (a) for 2GR-FE: See page AX-164 (b) for 2AZ-FE: See page AX-175 11. ADD MANUAL TRANSAXLE OIL (for Manual Transaxle) (See page MX-6) 12. INSPECT AUTOMATIC TRANSAXLE FLUID (for 2AZFE Automatic Transaxle) (See page AX-123) 13. INSPECT MANUAL TRANSAXLE OIL (for Manual Transaxle) (See page MX-2) 14. ADJUST FRONT WHEEL ALIGNMENT HINT: See page SP-4 15. CHECK ABS SPEED SENSOR SIGNAL (a) ABS: See page BC-11 (b) VSC (for BOSCH): See page BC-290 (c) VSC (for ADVICS): See page BC-123 MAINTENANCE – OUTSIDE VEHICLE MA–1 OUTSIDE VEHICLE GENERAL MAINTENANCE Check the parts of the vehicle described below on a daily basis. Performing maintenance checks on the vehicle is the owner's responsibility. The owner may take the vehicle to a service center but it is recommended that the owner perform the checks. In most cases, special tools are not required. The procedures for general maintenance are as follows. 1. GENERAL NOTES • Maintenance requirements vary depending on the country. • Check the maintenance schedule in the owner's manual supplement. • Following the maintenance schedule is mandatory. • Determine the appropriate time to service the vehicle using either miles driven or time (months) elapsed, whichever reaches the specification first. • Failing to check each vehicle part could lead to poor engine performance and increase exhaust emissions. 2. TIRES (a) Check the tire pressure with a gauge. Make adjustments if necessary. (b) Check the surfaces of tires for cuts, damage or excessive wear. 3. WHEEL NUTS (a) Check for nuts that are loose or missing. Tighten them if necessary. 4. TIRE ROTATION Check the maintenance schedule in the owner's manual supplement. 5. WINDSHIELD WIPER BLADES (a) Check the blades for wear or cracks when they are unable to wipe the windshield clean. Replace them if necessary. 6. FLUID LEAKS (a) Check under the vehicle for leaking fuel, oil, water and other fluids. NOTICE: If you smell gasoline fumes or notice any leaks, locate the cause and repair it. 7. DOORS AND ENGINE HOOD (a) Check that all of the doors operate smoothly, and that all the latches lock securely. (b) When the primary latch is released, check that the engine hood secondary latch prevents the hood from opening. MA MA–2 MAINTENANCE – INSIDE VEHICLE INSIDE VEHICLE GENERAL MAINTENANCE Check the parts of the vehicle described below on a daily basis. Performing maintenance checks on the vehicle is the owner's responsibility. The owner may take the vehicle to a service center but it is recommended that the owner perform the checks. In most cases, special tools are not required. The procedures for general maintenance are as follows. MA 1. GENERAL NOTES • Maintenance requirements vary depending on the country. • Check the maintenance schedule in the owner's manual supplement. • Determine the appropriate time to service the vehicle using either miles driven or time (months) elapsed, whichever reaches the specification first. • Maintain similar intervals between periodic maintenance unless noted. • Failing to check each vehicle part could lead to poor engine performance and increase exhaust emissions. 2. LIGHTS (a) Check that the headlights, stop lights, taillights, turn signal lights, and other lights illuminate or blink. Also, check that they have enough brightness. 3. WARNING LIGHTS AND BUZZERS (a) Check that all the warning lights and buzzers are working. 4. HORNS (a) Check that the horn is working. 5. WINDSHIELD GLASS (a) Check for scratches, pits or abrasions. 6. WINDSHIELD WIPER AND WASHER (a) Check that the washers are aimed properly. Also, check that the washer fluid hits the center of the operating range of each wiper on the windshield. (b) Check that the wipers streak or not. Replace the wiper if necessary. 7. WINDSHIELD DEFROSTER (a) When the heater or air conditioner is on the defroster setting, check that air comes out of the defroster outlet. 8. REAR VIEW MIRROR (a) Check that the rear view mirror is securely mounted. 9. SUN VISORS (a) Check that the sun visors move freely and are securely mounted. MAINTENANCE – INSIDE VEHICLE MA–3 10. STEERING WHEEL (a) Check that the steering wheel has the proper free play. Also check for steering difficulty, unusual noises (See page SR-1). 11. SEATS (a) Check that the seat adjusters, seatback recliner and other front seat controls operate smoothly. (b) Check that all the latches lock securely in all positions. (c) Check that the locks hold securely in all positions. (d) Check that the headrests move up and down smoothly and that the locks hold securely in all latched positions. (e) When the rear seatbacks are folded down, check that the latches lock securely. 12. SEAT BELTS (a) Check that the seat belt system such as the buckles, retractors and anchors operate properly and smoothly. (b) Check that the belt webbing is not cut, frayed, worn or damaged. 13. ACCELERATOR PEDAL (a) Check that the pedal operates smoothly. In other words, check that the pedal does not have uneven pedal resistance or become stuck in certain positions. 14. CLUTCH PEDAL (a) Check that the pedal operates smoothly. (b) Check if the pedal has the proper free play (See page CL-5). 15. BRAKE PEDAL (a) Check that the pedal has the proper reserve distance and free play (See page BR-19). (b) Start the engine and check the brake booster function. 16. BRAKES (a) In a safe place, check that the vehicle remains straight when applying the brakes. 17. PARKING BRAKE (a) Check that the pedal or lever has the proper range of motion (See page PB-1). (b) On a low incline, check that the parking brake alone can stabilize the vehicle. 18. AUTOMATIC TRANSAXLE "PARK" MECHANISM (a) Check the lock release button of the shift lever for proper and smooth operation. (b) When the shift lever is in the P position and all brakes are released on a low incline, check that the vehicle is stable. MA MA–4 MAINTENANCE – UNDER HOOD UNDER HOOD GENERAL MAINTENANCE 1. GENERAL NOTES • Maintenance requirements vary depending on the country. • Check the maintenance schedule in the owner's manual supplement. • Following the maintenance schedule is mandatory. • Determine the appropriate time to service the vehicle using either miles driven or time elapsed, whichever reaches the specification first. • Maintain similar intervals between periodic maintenance unless noted. • Failing to check each vehicle part could lead to poor engine performance and increase exhaust emissions. 2. WINDSHIELD WASHER FLUID (a) Check that there is sufficient fluid in the tank. 3. ENGINE COOLANT LEVEL (a) Check that the coolant level is between the "FULL" and "LOW" lines on the see-through reservoir. 4. RADIATOR AND HOSES (a) Check that the front of the radiator is clean and free of leaves, dirt and bugs. (b) Check the hoses for cracks, kinks, rotting or loose connections. 5. BATTERY ELECTROLYTE LEVEL (a) Check that the electrolyte level of all the battery cells is between the upper and lower lines on the case. HINT: If the electrolyte level is difficult to see, lightly shake the vehicle. 6. BRAKE FLUID LEVEL (a) Check that the brake fluid levels are near the upper level line on the see-through reservoirs. 7. ENGINE DRIVE BELT (a) Check the drive belt for fraying, cracks, wear or oiliness. 8. POWER STEERING FLUID LEVEL (a) Check the fluid level in the fluid reservoir. HINT: If the fluid is hot, check that the fluid level is within the HOT range on the fluid reservoir. If the fluid is cold, check that the fluid level is within the COLD range. 9. ENGINE OIL LEVEL (a) Check that the level of engine oil is between "F" and "L" on the dipstick with the engine turned off. MA MAINTENANCE – UNDER HOOD MA–5 10. AUTOMATIC TRANSAXLE FLUID LEVEL (for U250E) (See page AX-123) 11. MANUAL TRANSAXLE OIL LEVEL (See page MX-2) 12. EXHAUST SYSTEM (a) Check for unusual exhaust sounds or abnormal exhaust fumes. Locate the cause and repair it. MA MA–6 MAINTENANCE – ENGINE ENGINE GENERAL MAINTENANCE HINT: Inspect these items on a cooled down engine. 1. INSPECT DRIVE BELT Type MA See procedures 2AZ-FE See page EM-6 2GR-FE See page EM-6 2. REPLACE ENGINE OIL AND OIL FILTER Type See procedures 2AZ-FE See page LU-1 2GR-FE See page LU-1 3. REPLACE ENGINE COOLANT Type See procedures 2AZ-FE See page CO-5 2GR-FE See page CO-5 4. INSPECT EXHAUST PIPES AND MOUNTINGS (a) Visually check the pipes, hangers and connections for severe corrosion, leaks or damage. 5. INSPECT SPARK PLUGS Type See procedures 2AZ-FE See page IG-5 2GR-FE See page IG-5 6. INSPECT BATTERY Type A054323 See procedures 2AZ-FE See page CH-4 2GR-FE See page CH-4 7. INSPECT AIR CLEANER FILTER (a) Remove the air filter. (b) Visually check that the air filter is not excessively damaged or oily. If necessary, replace the air filter. (c) Reinstall the air filter. 8. REPLACE AIR CLEANER FILTER (a) Replace the air filter with a new one. 9. INSPECT FUEL TANK CAP GASKET Type See procedures 2AZ-FE See page EC-5 2GR-FE See page EC-5 10. INSPECT FUEL LINES AND CONNECTIONS AND FUEL TANK VAPOR VENT SYSTEM HOSES AND FUEL TANK BANDS (a) Visually check the fuel lines for cracks, leakage, loose connections, deformation or tank band looseness. MA–7 MAINTENANCE – ENGINE 11. INSPECT CHARCOAL CANISTER Type See procedures 2AZ-FE See page EC-9 2GR-FE See page EC-9 MA MA–8 MAINTENANCE – BRAKE BRAKE GENERAL MAINTENANCE 1. INSPECT BRAKE LINE PIPES AND HOSES HINT: Work in a well-lighted area. Turn the front wheels fully to the right or left before beginning the inspection. (a) Using a mirror, check the entire circumference and length of the brake lines and hoses for: • Damage • Wear • Deformation • Cracks • Corrosion • Leaks • Bends • Twists (b) Check all the clamps for tightness and the connections for leakage. (c) Check that the hoses and lines are not near sharp edges, moving parts or the exhaust system. (d) Check that the lines are installed properly and pass through the center of the grommets. 2. INSPECT BRAKE PEDAL (See page BR-19) 3. INSPECT PARKING BRAKE (See page PB-1) 4. INSPECT BRAKE LININGS (a) Check the brake linings. Also check the brake linings of parking brake. 5. INSPECT FRONT BRAKE (a) Check the front brake pads and discs (See page BR-50). 6. INSPECT REAR BRAKE (a) Check the rear brake pads, discs linings and drums (See page BR-62). 7. INSPECT OR CHANGE BRAKE FLUID (See page BR-6) Fluid: SAE J1703 or FMVSS No. 116 DOT3 P009958E01 MA MA–9 MAINTENANCE – CHASSIS CHASSIS GENERAL MAINTENANCE 1. INSPECT STEERING LINKAGE & GEAR HOUSING (a) Check the steering wheel free play (See page SR1). (b) Check the steering linkage for looseness or damage. (1) Check that the tie rod ends do not have excessive play. (2) Check that the dust seals and boots are not damaged. (3) Check that the boot clamps are not loose. (4) Check that the steering gear housing is not damaged. (5) Check that the connector are properly connected to the steering gear housing. 2. INSPECT BALL JOINT AND DUST COVER (a) Inspect the ball joints for excessive looseness. (1) Jack up the front of the vehicle and place wooden blocks with a height of 180 to 200 mm (7.09 to 7.87 in.) under the front tires. (2) Lower the vehicle until the front coil spring has about half its ordinary load. Place stands under the vehicle for safety. (3) Check that the front wheels are pointing straight ahead. Use wheel chocks on all 4 wheels. (4) Using a lever, pry up the end of the lower arm. Check the amount of play. Maximum ball joint vertical play: 0 mm (0 in.) If there is any play, replace the ball joint. (b) Check the dust cover for damage. 3. INSPECT DRIVE SHAFT BOOTS (a) Check the drive shaft boots for loose clamps, grease leakage, kinks or damage. 4. CHECK AUTOMATIC TRANSAXLE FLUID (a) Visually check the transaxle for fluid leakage. If oil is leaking, find the cause and repair it. 5. CHECK MANUAL TRANSAXLE OIL (FLUID) (a) Visually check the transmission for oil (fluid) leakage. If oil is leaking, find the cause and repair it. 6. INSPECT FRONT AND REAR SUSPENSION Type See procedures Front Suspension See page SP-4 Rear Suspension See page SP-13 MA MA–10 MAINTENANCE – BODY BODY GENERAL MAINTENANCE 1. TIGHTEN BOLTS AND NUTS ON CHASSIS AND BODY (a) Where necessary, tighten all the parts of the chassis. • Front axle and suspension • Drive train • Rear axle and suspension • Brake system • Engine mounting, etc. (b) Where necessary, tighten all the parts of the body. • Seat belt system • Seat • Doors and hood • Body mountings • Fuel tank • Exhaust pipe system, etc. 2. REPLACE AIR CONDITIONING FILTER (a) Remove the glove compartment assembly. (b) Remove the filter case from the filter outlet. (c) Remove the filter from the filter case. (d) Replace the filter with a new one. (e) Installation is in the reverse order. 3. ROAD TEST (a) Check the engine and chassis for abnormal noises. (b) Check that the vehicle does not wander or pull to one side. (c) Check that the brakes work properly and do not drag. (d) Do setting of the parking brake shoes. 4. BODY INSPECTION (a) Check the body exterior for dents, scratches and rust. (b) Check the underbody for rust and damage. If necessary, replace or repair. 5. FINAL INSPECTION (a) Check the operation of the body parts. (1) Hood • Auxiliary catch operates properly. • Hood locks securely when closed. (2) Front and rear doors • Door locks operate properly. • Doors close properly. (3) Back door • Door lock operates properly. (4) Seats • Seat adjusts easily and locks securely in any position. • Front seatback locks securely in any position. MA MAINTENANCE – BODY MA–11 • Folding-down rear seatbacks lock securely. (5) Be sure to deliver a clean car. Especially check: • Steering wheel • Shift lever knob • All switch knobs • Door handles • Seats MA SUSPENSION – SUSPENSION SYSTEM SP–1 SUSPENSION SYSTEM SUSPENSION & AXLE PARTS LOCATION FRONT SHOCK ABSORBER SP FRONT LOWER BALL JOINT FRONT STABILIZER LINK ASSEMBLY C143401E01 SP–2 SUSPENSION – SUSPENSION SYSTEM SP REAR SHOCK ABSORBER REAR STABILIZER LINK ASSEMBLY C143402E01 SP–3 SUSPENSION – SUSPENSION SYSTEM PROBLEM SYMPTOMS TABLE SUSPENSION SYSTEM Symptom Bottoming Sways/pitches Front wheel shimmy Rear wheel shimmy Abnormal tire wear Suspected area See page 1. Vehicle (Overloaded) - 2. Spring (Weak) SP-18 3. Shock absorber (Worn) SP-18 1. Tire (Worn or improperly inflated) TW-3 2. Stabilizer bar (Bent or broken) SP-32 3. Shock absorber (Worn) SP-18 1. Tire (Worn or improperly inflated) TW-3 2. Wheel (Out of balance) TW-3 3. Shock absorber (Worn) SP-18 4. Wheel alignment (Incorrect) SP-4 5. Lower ball joint (Worn) SP-27 6. Hub bearing (Worn) AH-5 7. Steering gear (Out of adjustment or broken) PS-49 1. Tire (Worn or improperly inflated) TW-3 2. Wheel (Out of balance) TW-3 3. Shock absorber (Worn) SP-41 4. Wheel alignment (Incorrect) SP-13 5. Hub bearing (Worn) AH-14 1. Tire (Worn or improperly inflated) TW-3 2. Wheel alignment (Incorrect) TW-3 3. Shock absorber (Worn) SP-18 4. Suspension parts (Worn) - SP SP–4 SUSPENSION – FRONT WHEEL ALIGNMENT FRONT WHEEL ALIGNMENT ADJUSTMENT 1. INSPECT TIRES (See page TW-3) 2. MEASURE VEHICLE HEIGHT (a) Bounce the vehicle up and down at the corners to stabilize the suspension. Inspect the vehicle height. Vehicle height for USA and Canada: C D SP A B C132408E01 Model Front A - B Rear C - D ACV40L-CEAGKA 125 mm (4.92 in.) 54 mm (2.13 in.) GSV40L-CETGKA 126 mm (4.96 in.) 55 mm (2.17 in.) ACV40L-AEAGKA 125 mm (4.92 in.) 53 mm (2.09 in.) GSV40L-AETGKA 126 mm (4.96 in.) 54 mm (2.13 in.) ACV40L-CEANKA 125 mm (4.92 in.) 54 mm (2.13 in.) ACV40L-CEMNKA 125 mm (4.92 in.) 53 mm (2.09 in.) GSV40L-CETNKA 126 mm (4.96 in.) 55 mm (2.17 in.) ACV40L-AEANKA 125 mm (4.92 in.) 53 mm (2.09 in.) ACV40L-AEMNKA 125 mm (4.92 in.) 52 mm (2.05 in.) GSV40L-AETNKA 126 mm (4.96 in.) 54 mm (2.13 in.) ACV40L-CEASKA 128 mm (5.04 in.) 57 mm (2.24 in.) ACV40L-CEMSKA 127 mm (5.00 in.) 55 mm (2.17 in.) GSV40L-CETSKA 129 mm (5.08 in.) 58 mm (2.28 in.) for Mexico: Model Front A - B Rear C - D ACV40L-CEAGKA 115 mm (4.53 in.) 40 mm (1.57 in.) GSV40L-CETGKA 116 mm (4.57 in.) 41 mm (1.61 in.) ACV40L-CEANKA 115 mm (4.53 in.) 40 mm (1.57 in.) Measuring points: A: Ground clearance of front wheel center B: Ground clearance of lower suspension arm No. 2 bushing set bolt center C: Ground clearance of rear wheel center D: Ground clearance of strut rod set bolt center NOTICE: • Before inspecting the wheel alignment, adjust the vehicle height to the specified value. • Be sure to perform measurement on a level surface. • If it is necessary to go under the vehicle for measurement, confirm that the parking brake is applied and the vehicle is secured with chocks. 3. INSPECT TOE-IN (a) Bounce the vehicle up and down at the corners to stabilize the suspension. SP–5 SUSPENSION – FRONT WHEEL ALIGNMENT (b) Release the parking brake and move the shift lever to the neutral position. (c) Push the vehicle straight ahead approximately 5 m (16.4 ft). (*1) (d) Put tread center marks on the rearmost points of the front wheels and measure the distance between the marks (dimension B). (e) Slowly push the vehicle straight ahead to cause the front wheels to rotate 180° using the front tire valve as a reference point. HINT: Do not allow the wheels to rotate more than 180°. If the wheels rotate more than 180°, perform the procedure from *1 again. Dimension B Tread Center Marks C125225E02 Dimension A (f) A Front B Toe-in (total) - A - B: 0 +- 2 mm (0 +- 0.08 in.) HINT: If toe-in is not within the specified range, adjust it at the rack ends. C125226E03 4. C140712 Measure the distance between the tread center marks on the front side of the wheels. Toe-in ADJUST TOE-IN (a) Measure the thread lengths of the right and left rack ends. Standard: Difference in thread length between the right and left rack ends is 1.5 mm (0.06 in.) or less. (b) Remove the rack boot set clips. (c) Loosen the tie rod end lock nuts. (d) Adjust the rack ends if the difference in thread length between the right and left rack ends is not within the specified range. (1) Extend the shorter rack end if the measured toe-in deviates toward the outside. (2) Shorten the longer rack end if the measured toe-in deviates toward the inside. (e) Turn the right and left rack ends by equal amounts to adjust the toe-in. HINT: Try to adjust the toe-in to the center of the specified range. (f) Make sure that the lengths of the right and left rack ends are the same. (g) Tighten the tie rod end lock nuts. Torque: 74 N*m (755 kgf*cm, 55 ft.*lbf) SP SP–6 SUSPENSION – FRONT WHEEL ALIGNMENT NOTICE: Temporarily tighten the lock nut while holding the hexagonal part of the steering rack end so that the lock nut and the steering rack end do not turn together. Hold the flats on the tie rod end and tighten the lock nut. (h) Place the boots on the seats and install the clips. HINT: Make sure that the boots are not twisted. 5. SP A B B INSPECT WHEEL ANGLE (a) Put tread center marks on the rearmost points of the turning radius gauge. (b) Turn the steering wheel fully to the left and right and measure the turning angle. Wheel turning angle for USA and Canada: A Front A: Inside B: Outside C132439E01 Model Inside wheel Outside wheel reference ACV40L-CEAGKA 38°22' +-2° (38.37° +-2°) 33°33' (33.55°) GSV40L-CETGKA 38°22' +-2° (38.37° +-2°) 33°33' (33.55°) ACV40L-AEAGKA 38°22' +-2° (38.37° +-2°) 33°33' (33.55°) GSV40L-AETGKA 38°22' +-2° (38.37° +-2°) 33°33' (33.55°) ACV40L-CEANKA 38°22' +-2° (38.37° +-2°) 33°33' (33.55°) ACV40L-CEMNKA 38°22' +-2° (38.37° +-2°) 33°33' (33.55°) GSV40L-CETNKA 38°22' +-2° (38.37° +-2°) 33°33' (33.55°) ACV40L-AEANKA 38°22' +-2° (38.37° +-2°) 33°33' (33.55°) ACV40L-AEMNKA 38°22' +-2° (38.37° +-2°) 33°33' (33.55°) GSV40L-AETNKA 38°22' +-2° (38.37° +-2°) 33°33' (33.55°) ACV40L-CEASKA 38°42' +-2° (38.70° +-2°) 33°46' (33.77°) ACV40L-CEMSKA 38°42' +-2° (38.70° +-2°) 33°46' (33.77°) GSV40L-CETSKA 38°18' +-2° (38.30° +-2°) 33°32' (33.53°) for Mexico: Model Inside wheel Outside wheel reference ACV40L-CEAGKA 38°18' +-2° (38.30° +-2°) 33°41' (33.68°) GSV40L-CETGKA 38°18' +-2° (38.30° +-2°) 33°41' (33.68°) ACV40L-CEANKA 38°18' +-2° (38.30° +-2°) 33°41' (33.68°) If the right and left inside wheel angles differ from the specified value, check the right and left rack end lengths. 6. Alignment Tester Gauge C132440E01 INSPECT CAMBER, CASTER AND STEERING AXIS INCLINATION (a) Put the front wheel on the center of the alignment tester. (b) Remove the center ornament. (c) Set the camber-caster-king pin gauge and attachment at the center of the axle hub or drive shaft. SP–7 SUSPENSION – FRONT WHEEL ALIGNMENT (d) Inspect the camber, caster, and steering axis inclination. Camber for USA and Canada: Model Camber Right-left difference ACV40L-CEAGKA -0°40' +-45' (-0.67° +-0.75°) 45' (0.75°) or less GSV40L-CETGKA -0°40' +-45' (-0.67° +-0.75°) 45' (0.75°) or less ACV40L-AEAGKA -0°40' +-45' (-0.67° +-0.75°) 45' (0.75°) or less GSV40L-AETGKA -0°40' +-45' (-0.67° +-0.75°) 45' (0.75°) or less ACV40L-CEANKA -0°40' +-45' (-0.67° +-0.75°) 45' (0.75°) or less ACV40L-CEMNKA -0°40' +-45' (-0.67° +-0.75°) 45' (0.75°) or less GSV40L-CETNKA -0°40' +-45' (-0.67° +-0.75°) 45' (0.75°) or less ACV40L-AEANKA -0°40' +-45' (-0.67° +-0.75°) 45' (0.75°) or less ACV40L-AEMNKA -0°40' +-45' (-0.67° +-0.75°) 45' (0.75°) or less GSV40L-AETNKA -0°40' +-45' (-0.67° +-0.75°) 45' (0.75°) or less ACV40L-CEASKA -0°40' +-45' (-0.67° +-0.75°) 45' (0.75°) or less ACV40L-CEMSKA -0°40' +-45' (-0.67° +-0.75°) 45' (0.75°) or less GSV40L-CETSKA -0°40' +-45' (-0.67° +-0.75°) 45' (0.75°) or less for Mexico: Model Camber Right-left difference ACV40L-CEAGKA -0°35' +-45' (-0.58° +-0.75°) 45' (0.75°) or less GSV40L-CETGKA -0°35' +-45' (-0.58° +-0.75°) 45' (0.75°) or less ACV40L-CEANKA -0°35' +-45' (-0.58° +-0.75°) 45' (0.75°) or less Caster for USA and Canada: Model Caster Right-left difference ACV40L-CEAGKA 3°00' +-45' (3.00° +-0.75°) 45' (0.75°) or less GSV40L-CETGKA 2°55' +-45' (2.92° +-0.75°) 45' (0.75°) or less ACV40L-AEAGKA 2°55' +-45' (2.92° +-0.75°) 45' (0.75°) or less GSV40L-AETGKA 2°55' +-45' (2.92° +-0.75°) 45' (0.75°) or less ACV40L-CEANKA 3°00' +-45' (3.00° +-0.75°) 45' (0.75°) or less ACV40L-CEMNKA 2°55' +-45' (2.92° +-0.75°) 45' (0.75°) or less GSV40L-CETNKA 2°55' +-45' (2.92° +-0.75°) 45' (0.75°) or less ACV40L-AEANKA 2°55' +-45' (2.92° +-0.75°) 45' (0.75°) or less ACV40L-AEMNKA 2°55' +-45' (2.92° +-0.75°) 45' (0.75°) or less GSV40L-AETNKA 2°55' +-45' (2.92° +-0.75°) 45' (0.75°) or less ACV40L-CEASKA 3°00' +-45' (3.00° +-0.75°) 45' (0.75°) or less ACV40L-CEMSKA 2°55' +-45' (2.92° +-0.75°) 45' (0.75°) or less GSV40L-CETSKA 2°55' +-45' (2.92° +-0.75°) 45' (0.75°) or less for Mexico: Model Caster Right-left difference ACV40L-CEAGKA 2°45' +-45' (2.75° +-0.75°) 45' (0.75°) or less GSV40L-CETGKA 2°40' +-45' (2.67° +-0.75°) 45' (0.75°) or less ACV40L-CEANKA 2°45' +-45' (2.75° +-0.75°) 45' (0.75°) or less Steering axis inclination for USA and Canada: Model Steering axis inclination Right-left difference ACV40L-CEAGKA 12°15' +-45' (12.25° +-0.75°) 45' (0.75°) or less GSV40L-CETGKA 12°15' +-45' (12.25° +-0.75°) 45' (0.75°) or less SP SP–8 SUSPENSION – FRONT WHEEL ALIGNMENT Model Steering axis inclination Right-left difference ACV40L-AEAGKA 12°15' +-45' (12.25° +-0.75°) 45' (0.75°) or less GSV40L-AETGKA 12°15' +-45' (12.25° +-0.75°) 45' (0.75°) or less ACV40L-CEANKA 12°15' +-45' (12.25° +-0.75°) 45' (0.75°) or less ACV40L-CEMNKA 12°15' +-45' (12.25° +-0.75°) 45' (0.75°) or less GSV40L-CETNKA 12°15' +-45' (12.25° +-0.75°) 45' (0.75°) or less ACV40L-AEANKA 12°15' +-45' (12.25° +-0.75°) 45' (0.75°) or less ACV40L-AEMNKA 12°15' +-45' (12.25° +-0.75°) 45' (0.75°) or less GSV40L-AETNKA 12°15' +-45' (12.25° +-0.75°) 45' (0.75°) or less ACV40L-CEASKA 12°15' +-45' (12.25° +-0.75°) 45' (0.75°) or less ACV40L-CEMSKA 12°15' +-45' (12.25° +-0.75°) 45' (0.75°) or less GSV40L-CETSKA 12°15' +-45' (12.25° +-0.75°) 45' (0.75°) or less for Mexico: SP Model Steering axis inclination Right-left difference ACV40L-CEAGKA 12°00' +-45' (12.00° +-0.75°) 45' (0.75°) or less GSV40L-CETGKA 12°00' +-45' (12.00° +-0.75°) 45' (0.75°) or less ACV40L-CEANKA 12°00' +-45' (12.00° +-0.75°) 45' (0.75°) or less NOTICE: • Perform the inspection while the vehicle is unloaded. • The maximum tolerance of the right and left difference for the camber and caster is 45' (0.75°) or less. (e) Remove the camber-caster-king pin gauge and attachment. (f) Install the center ornament. (g) If the caster and steering axis inclination are not within the specified range after the camber has been correctly adjusted, recheck the suspension parts for damage and/or wear. 7. ADJUST CAMBER NOTICE: Inspect toe-in after the camber has been adjusted. (a) Remove the front wheel. (b) Remove the 2 nuts on the lower side of the front shock absorber. NOTICE: Keep the bolts inserted. (c) Clean the installation surfaces of the front shock absorber and the steering knuckle. (d) Temporarily install the 2 nuts (Step A). C132409 SUSPENSION – FRONT WHEEL ALIGNMENT - SP–9 (e) Fully push or pull the front axle hub in the direction of the required adjustment (Step B). (f) Tighten the nuts. Torque: 210 N*m (2,141 kgf*cm, 155 ft.*lbf) NOTICE: Keep the bolts from rotating when tightening the nuts. (g) Install the front wheel. Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) + C111319E01 1 2 C140710E01 (h) Check the camber. If the measured value is not within the specification, calculate the required adjustment amount using the formula below. Camber adjustment amount = center of the specified range center - measured value Check the combination of installed bolts. Select appropriate bolts from the table below to adjust the camber to the specified values. HINT: Try to adjust the camber to the center of the specified values. Move the axle toward (+) in step (B) Move the axle toward (-) in step (B) Refer to table (1) (Move the axle toward the positive side) Refer to table (2) (Move the axle toward the negative side) SP SP–10 SUSPENSION – FRONT WHEEL ALIGNMENT Table (1) (Move the axle toward the positive side) Installed Bolt 1 90105-17012 90105-17012 90105-17012 90105-17012 90105-17013 90105-17014 90105-17015 2 Adjusting Value 90105-17012 90105-17013 90105-17014 90105-17015 90105-17015 90105-17015 90105-17015 -1°30' to -1°15' (-1.50° to -1.25°) G -1°15' to -1°00' (-1.25° to -1°) SP G A G A B G A B C G A B C D G A B C D E F -1°00' to -0°45' (-1° to -0.75°) -0°45' to -0°30' (-0.75° to -0.5°) -0°30' to -0°15' (-0.5° to -0.25°) -0°15' to 0° (-0.25° to 0°) 0° to 0°15' (0° to 0.25°) A B C D E 0°15' to 0°30' (0.25° to 0.5°) B C D E F 0°30' to 0°45' (0.50° to 0.75°) C D E F 0°45' to 1°00' (0.75° to 1°) D E F 1°00' to 1°15' (1° to 1.25°) E F 1°15' to 1°30' (1.25° to 1.5°) F Selected Bolt Combination A B C D E F G 1 90105-17012 90105-17012 90105-17012 90105-17013 90105-17014 90105-17015 90105-17012 2 90105-17013 90105-17014 90105-17015 90105-17015 90105-17015 90105-17015 90105-17012 C138332E01 SP–11 SUSPENSION – FRONT WHEEL ALIGNMENT Table (2) (Move the axle toward the negative side) Installed Bolt 1 90105-17012 90105-17012 90105-17012 90105-17012 90105-17013 90105-17014 90105-17015 2 Adjusting Value 90105-17012 90105-17013 90105-17014 90105-17015 90105-17015 90105-17015 90105-17015 -1°30' to -1°15' (-1.50° to -1.25°) F -1°15' to -1°00' (-1.25° to -1°) E F -1°00' to -0°45' (-1° to -0.75°) D E F -0°45' to -0°30' (-0.75° to -0.5°) C D E F -0°30' to -0°15' (-0.5° to -0.25°) B C D E F -0°15' to 0° (-0.25° to 0°) A B C D E F G A B C D E G A B C D G A B C G A B G A 0° to 0°15' (0° to 0.25°) 0°15' to 0°30' (0.25° to 0.5°) SP 0°30' to 0°45' (0.50° to 0.75°) 0°45' to 1°00' (0.75° to 1°) 1°00' to 1°15' (1° to 1.25°) 1°15' to 1°30' (1.25° to 1.5°) G Selected Bolt Combination A B C D E F G 1 90105-17012 90105-17012 90105-17012 90105-17013 90105-17014 90105-17015 90105-17012 2 90105-17013 90105-17014 90105-17015 90105-17015 90105-17015 90105-17015 90105-17012 C138332E02 SP–12 SUSPENSION – FRONT WHEEL ALIGNMENT (i) SP The body and suspension may be damaged if the camber is not correctly adjusted according to the above table. NOTICE: Replace the nut with a new one when replacing the bolt. Repeat the steps mentioned above. In step (A), replace 1 or 2 selected bolts. HINT: Replace one bolt at a time when replacing 2 bolts. SP–13 SUSPENSION – REAR WHEEL ALIGNMENT REAR WHEEL ALIGNMENT ADJUSTMENT B A 1. INSPECT TIRES (See page TW-3) 2. MEASURE VEHICLE HEIGHT (See page SP-4) 3. INSPECT TOE-IN (a) Bounce the vehicle up and down at the corners to stabilize the suspension. Inspect the toe-in. Toe-in D Front C Toe-in (total) - A + B: C - D: 0° +- 24' (0° +- 0.4°) 4 +- 2 mm (0.16 +- 0.08 in.) If the toe-in is not within the specified range, inspect the suspension parts and replace them if necessary. C132438E01 4. ADJUST TOE-IN (a) Measure the lengths of the right and left rear No. 2 suspension arms. Difference in the length between the right and left rear No. 2 suspension arms: 1.5 mm (0.06 in.) or less If the left-right difference is larger than 1.5 mm (0.06 in.), adjust it by following the procedures below. C132497 (b) Loosen the lock nuts. (c) Turn the right and left adjusting tubes by an equal amount to adjust toe-in. HINT: • Try to adjust toe-in to the center of the specified range. • One turn of each adjusting tube will adjust toe-in by approximately 10.8 mm (0.425 in.). (d) Tighten the lock nuts. Torque: 56 N*m (571 kgf*cm, 41 ft.*lbf) C132498 5. INSPECT CAMBER Camber for USA and Canada: Model Camber Right-left difference ACV40L-CEAGKA -1°18' +-45' (-1.30° +-0.75°) 45' (0.75°) or less GSV40L-CETGKA -1°18' +-45' (-1.30° +-0.75°) 45' (0.75°) or less ACV40L-AEAGKA -1°15' +-45' (-1.25° +-0.75°) 45' (0.75°) or less GSV40L-AETGKA -1°15' +-45' (-1.25° +-0.75°) 45' (0.75°) or less ACV40L-CEANKA -1°18' +-45' (-1.30° +-0.75°) 45' (0.75°) or less ACV40L-CEMNKA -1°18' +-45' (-1.30° +-0.75°) 45' (0.75°) or less GSV40L-CETNKA -1°18' +-45' (-1.30° +-0.75°) 45' (0.75°) or less ACV40L-AEANKA -1°15' +-45' (-1.25° +-0.75°) 45' (0.75°) or less ACV40L-AEMNKA -1°15' +-45' (-1.25° +-0.75°) 45' (0.75°) or less GSV40L-AETNKA -1°15' +-45' (-1.25° +-0.75°) 45' (0.75°) or less SP SP–14 SUSPENSION – REAR WHEEL ALIGNMENT Model Camber Right-left difference ACV40L-CEASKA -1°18' +-45' (-1.30° +-0.75°) 45' (0.75°) or less ACV40L-CEMSKA -1°18' +-45' (-1.30° +-0.75°) 45' (0.75°) or less GSV40L-CETSKA -1°18' +-45' (-1.30° +-0.75°) 45' (0.75°) or less Model Camber Right-left difference ACV40L-CEAGKA -1°06' +-45' (-1.10° +-0.75°) 45' (0.75°) or less GSV40L-CETGKA -1°06' +-45' (-1.10° +-0.75°) 45' (0.75°) or less ACV40L-CEANKA -1°06' +-45' (-1.10° +-0.75°) 45' (0.75°) or less for Mexico: SP HINT: Camber is not adjustable. If the measurement is not within the specification range, inspect the suspension parts for damage and/or wear, and replace them if necessary. SP–15 SUSPENSION – FRONT SHOCK ABSORBER FRONT SHOCK ABSORBER SUSPENSION & AXLE COMPONENTS FRONT SUSPENSION SUPPORT SUB-ASSEMBLY 85 (867, 63) 70 (714, 52) FRONT SUSPENSION SUPPORT BEARING SP FRONT STABILIZER LINK ASSEMBLY FRONT COIL SPRING UPPER SEAT FRONT SHOCK ABSORBER WITH COIL SPRING FRONT COIL SPRING UPPER INSULATOR FRONT COIL SPRING 74 (755, 55) FRONT SPEED SENSOR FRONT SPRING BUMPER FRONT COIL SPRING LOWER INSULATOR 210 (2,141, 155) 19 (194, 14) FRONT FLEXIBLE HOSE FRONT SHOCK ABSORBER FRONT AXLE ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C132427E01 SP–16 SUSPENSION – FRONT SHOCK ABSORBER REMOVAL HINT: • Use the same procedures for the RH side and the LH side. • The procedures listed below are for the LH side. 1. REMOVE FRONT WHEEL 2. SEPARATE FRONT STABILIZER LINK ASSEMBLY (a) Support the front No. 1 suspension lower arm with a jack using a wooden block to avoid damage. SP Front Wooden Block Wooden Block C132410E01 (b) Remove the nut and separate the front stabilizer link assembly from the front shock absorber. HINT: If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud. C132411 SUSPENSION – FRONT SHOCK ABSORBER 3. SP–17 REMOVE FRONT SHOCK ABSORBER WITH COIL SPRING (a) Loosen the lock nut of the front shock absorber with coil spring. NOTICE: • Do not remove the lock nut. • Only loosen the nut when disassembling the front shock absorber with coil spring. C132412 (b) Remove the bolt and disconnect the front flexible hose and front speed sensor wire harness from the front shock absorber with coil spring. NOTICE: Be sure to remove the front speed sensor from the front shock absorber with coil spring. C132413 (c) Remove the 2 nuts on the lower side of the front shock absorber with coil spring. NOTICE: • When removing the nuts, keep the bolts from rotating. • Keep the bolts inserted to secure the front axle assembly. C132414 (d) Remove the 3 nuts on the upper side of the front shock absorber with coil spring. (e) Lower the front axle assembly, and remove the 2 bolts on the lower side of the front shock absorber. (f) Remove the front shock absorber with coil spring. NOTICE: Make sure that the front speed sensor is disconnected from the front shock absorber with coil spring. C132415 DISASSEMBLY 1. 28 mm (1.1 in.) C140711E01 FIX FRONT SHOCK ABSORBER WITH COIL SPRING (a) As shown in the illustration, secure the front shock absorber with coil spring in a vise using aluminum plates by clamping onto a double nutted bolt affixed to the bracket at the bottom of the absorber. SP SP–18 SUSPENSION – FRONT SHOCK ABSORBER 2. SST C132416E01 SP REMOVE FRONT SHOCK ABSORBER (a) Using SST, compress the front coil spring. SST 09727-30021 (09727-00010, 09727-00021, 09727-00031) NOTICE: Do not use an impact wrench. HINT: If the front coil spring is compressed at an angle, using 2 SST will make the work easier. (b) Remove the front suspension support subassembly, front suspension support bearing, front coil spring upper seat, front coil spring upper insulator, front coil spring, front spring bumper, and front coil spring lower insulator from the front shock absorber. INSPECTION 1. C132417 INSPECT FRONT SHOCK ABSORBER (a) Compress and extend the shock absorber rod 4 or more times. Standard: There is no abnormal resistance or sound and operation resistance is normal. HINT: If there is any abnormality, replace the front shock absorber with a new one. SUSPENSION – FRONT SHOCK ABSORBER SP–19 REASSEMBLY 1. INSTALL FRONT SHOCK ABSORBER (a) Install the front spring bumper to the piston rod. (b) Install the front coil spring lower insulator onto the front shock absorber. NOTICE: Align the 2 protrusions of the front coil spring lower insulator and the 2 holes in the front shock absorber. SP C132418 (c) Using SST, compress the front coil spring. SST 09727-30021 (09727-00010, 09727-00021, 09727-00031) NOTICE: Do not use an impact wrench. HINT: If the front coil spring is compressed at an angle, using 2 SST will make the work easier. SST C104393E01 (d) Install the front coil spring to the front shock absorber. NOTICE: The smaller diameter end of the front coil spring must face upward. HINT: Fit the lower end of the front coil spring into the gap of the insulator. C132419 SP–20 SUSPENSION – FRONT SHOCK ABSORBER (e) Install the front coil spring upper insulator as shown in the illustration. HINT: Any misalignment between the front shock absorber lower bracket and the matchmark must be +-5°. 5° 5° Outside SP C132420E01 (f) 5° 5° Outside Install the front coil spring upper seat with the mark facing to the outside of the vehicle. HINT: Any misalignment between the front shock absorber lower bracket and the matchmark must be +-5°. C132421E01 (g) Install a new front suspension support bearing as shown in the illustration. HINT: If there is foreign matter inside the front suspension support bearing, replace it with a new one. F040162 SUSPENSION – FRONT SHOCK ABSORBER SP–21 (h) Install the front suspension support sub-assembly. Temporarily tighten a new lock nut. NOTICE: Check that the flats on the piston rod and the flats on the front suspension support subassembly are aligned. Outside SP C132422E01 (i) Outside 10° +- 5° C132423E01 Remove the SST slowly in order to release the coil spring. NOTICE: Do not use an impact wrench. HINT: Any misalignment between the front shock absorber lower bracket and the arrows must be +-5°. SP–22 SUSPENSION – FRONT SHOCK ABSORBER INSTALLATION 1. INSTALL FRONT SHOCK ABSORBER WITH COIL SPRING (a) Install the front shock absorber with coil spring to the front axle assembly and insert the 2 bolts from the front side of the vehicle. (b) Slowly jack up the vehicle using a wooden block and install the front shock absorber with coil spring (upper side) to the vehicle. SP Front Wooden Block Wooden Block C132410E01 (c) Install the 3 nuts to the upper side of the front shock absorber with coil spring. Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) C132415 SUSPENSION – FRONT SHOCK ABSORBER SP–23 (d) Install the 2 nuts to the lower side of the front shock absorber with coil spring. Torque: 210 N*m (2,140 kgf*cm, 155 ft.*lbf) NOTICE: When installing the nuts, keep the bolts from rotating. C132414 (e) Install the front flexible hose and front speed sensor wire harness with the bolt. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) NOTICE: Do not twist the front speed sensor wire harness when installing it. C132413 (f) Fully tighten the lock nut. Torque: 70 N*m (714 kgf*cm, 52 ft.*lbf) C132412 C132411 A 2. INSTALL FRONT STABILIZER LINK ASSEMBLY (a) Install the front stabilizer link assembly with the nut. Torque: 74 N*m (755 kgf*cm, 55 ft.*lbf) HINT: If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud. 3. INSTALL FRONT WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 4. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page SP-4) DISPOSAL 25 mm (0.98 in.) 1. B C137486E01 DISPOSE OF FRONT SHOCK ABSORBER (a) Fully extend the shock absorber rod. (b) Using a drill, make a hole in the cylinder between A and B as shown in the illustration to discharge the gas inside. CAUTION: • Be careful when drilling because shards of metal may fly about. Always use the proper safety equipment. SP SP–24 SUSPENSION – FRONT SHOCK ABSORBER • The gas is colorless, odorless and nonpoisonous. SP SP–23 SUSPENSION – FRONT SUSPENSION LOWER NO. 1 ARM FRONT SUSPENSION LOWER NO. 1 ARM SUSPENSION & AXLE COMPONENTS Manual Transaxle: SP ENGINE MOUNTING INSULATOR ENGINE MOUNTING INSULATOR FRONT LOWER ARM BUSHING STOPPER 200 (2,040, 148) 200 (2,040, 148) 206 (2,100, 152) 87 (887, 64) N*m (kgf*cm, ft.*lbf) : Specified torque FRONT SUSPENSION LOWER NO. 1 ARM 75 (765, 55) C132435E01 SP–24 SUSPENSION – FRONT SUSPENSION LOWER NO. 1 ARM REMOVAL HINT: • Use the same procedures for the RH side and the LH side. • The procedures listed below are for the LH side. 1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE HINT: Refer to the instructions for installation of the engine assembly (See page EM-94 for 2AZ-FE, EM-23 for 2GRFE). 2. REMOVE ENGINE MOUNTING INSULATOR (a) Remove the 3 nuts and the engine mounting insulator. 3. REMOVE FRONT SUSPENSION LOWER NO. 1 ARM (a) Remove the 3 bolts and the nut on the front suspension lower No. 1 arm and remove it from the front frame assembly. (b) Remove the front lower arm bushing stopper. Automatic Transaxle: SP Manual Transaxle: C138032E01 C111327 SUSPENSION – FRONT SUSPENSION LOWER NO. 1 ARM SP–25 INSTALLATION 1. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM (a) Install the front lower arm bushing stopper. (b) Install the front suspension lower No. 1 arm to the front frame assembly with the 3 bolts and the nut, but do not tighten them yet. (c) Tighten the 3 bolts in numerical order shown in the illustration. Torque: 200 N*m (2,040 kgf*cm, 148 ft.*lbf) (bolt A) 206 N*m (2,100 kgf*cm, 152 ft.*lbf) (bolt B) A A B SP C111327E03 2. INSTALL ENGINE MOUNTING INSULATOR (a) Install the engine mounting insulator with the 3 nuts. Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) 3. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE HINT: Refer to the instructions for removal of the engine assembly (See page EM-107 for 2AZ-FE, EM-37 for 2GR-FE). Automatic Transaxle: Manual Transaxle: C138032E01 SP–26 SUSPENSION – FRONT LOWER BALL JOINT FRONT LOWER BALL JOINT SUSPENSION & AXLE COMPONENTS 210 (2,140, 155) 19 (194, 14) FRONT SPEED SENSOR SP 8.0 (82, 71 in.*lbf) FRONT AXLE ASSEMBLY TIE ROD END SUB-ASSEMBLY 107 (1,091, 79) FRONT DISC FRONT DISC BRAKE CALIPER ASSEMBLY 49 (500, 36) COTTER PIN 294 (3,000, 217) 75 (765, 55) FRONT AXLE HUB NUT FRONT SUSPENSION LOWER NO. 1 ARM N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C132429E01 SP–27 SUSPENSION – FRONT LOWER BALL JOINT FRONT WHEEL NO. 1 BEARING DUST DEFLECTOR FRONT AXLE HUB BEARING FRONT DISC BRAKE DUST COVER FRONT AXLE HUB HOLE SNAP RING SP 8.3 (85, 74 in.*lbf) COTTER PIN 123 (1,250, 91) 8.3 (85, 74 in.*lbf) FRONT LOWER BALL JOINT N*m (kgf*cm, ft.*lbf) : Specified torque FRONT AXLE HUB Non-reusable part C132430E01 SP–28 SUSPENSION – FRONT LOWER BALL JOINT REMOVAL HINT: • Use the same procedures for the RH side and the LH side. • The procedures listed below are for the LH side. 1. REMOVE FRONT WHEEL 2. REMOVE FRONT AXLE HUB NUT (See page DS-7) 3. SEPARATE FRONT SPEED SENSOR (See page DS-7) 4. SEPARATE FRONT DISC BRAKE CALIPER ASSEMBLY (See page AH-6) 5. REMOVE FRONT DISC (See page BR-49) 6. SEPARATE TIE ROD END SUB-ASSEMBLY (See page DS-8) 7. SEPARATE FRONT SUSPENSION LOWER NO. 1 ARM (See page DS-8) 8. REMOVE FRONT AXLE ASSEMBLY (See page DS-8) 9. REMOVE FRONT WHEEL NO. 1 BEARING DUST DEFLECTOR (See page AH-7) SP 10. REMOVE FRONT AXLE HUB HOLE SNAP RING (See page AH-7) 11. REMOVE FRONT AXLE HUB (See page AH-7) 12. REMOVE FRONT DISC BRAKE DUST COVER (See page AH-8) 13. REMOVE FRONT AXLE HUB BEARING (See page AH-8) 14. REMOVE FRONT LOWER BALL JOINT (a) Secure the steering knuckle in a vise using aluminum plates. (b) Remove the cotter pin and nut. (c) Using SST, remove the front lower ball joint. SST 09628-62011 NOTICE: • Do not damage the dust cover of the ball joint. • Do not damage the steering knuckle. SST C107301E01 SUSPENSION – FRONT LOWER BALL JOINT SP–29 INSPECTION 1. ZX01712 INSPECT FRONT LOWER BALL JOINT (a) Inspect the turning of the ball joint. (1) Secure the front lower ball joint assembly in a vise using aluminum plates. (2) Install the nut to the front lower ball joint assembly stud. (3) Using a torque wrench, turn the nut continuously at a rate of 3 to 5 seconds per turn and take the torque reading on the 5th turn. Torque: 1.0 to 3.4 N*m (10 to 35 kgf*cm, 9 to 30 in.*lbf) HINT: If the turning torque is not within the specified range, replace the front lower ball joint assembly with a new one. (b) Inspect the dust cover. (1) Check that the dust cover is not cracked and that there is no grease on it. SP SP–30 SUSPENSION – FRONT LOWER BALL JOINT INSTALLATION SP 1. INSTALL FRONT LOWER BALL JOINT (a) Install the front lower ball joint to the steering knuckle with the nut. Torque: 123 N*m (1,250 kgf*cm, 91 ft.*lbf) NOTICE: Prevent oil from adhering to the screw and tapered parts. (b) Install a new cotter pin. NOTICE: If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. 2. INSTALL FRONT AXLE HUB BEARING (See page AH9) 3. INSTALL FRONT DISC BRAKE DUST COVER (See page AH-9) 4. INSTALL FRONT AXLE HUB (See page AH-9) 5. INSTALL FRONT AXLE HUB HOLE SNAP RING (See page AH-9) 6. INSTALL FRONT WHEEL NO. 1 BEARING DUST DEFLECTOR (See page AH-10) 7. INSTALL FRONT AXLE ASSEMBLY (See page DS-21) 8. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM (See page DS-21) 9. CONNECT TIE ROD END SUB-ASSEMBLY (See page DS-21) 10. INSTALL FRONT DISC (See page BR-51) 11. INSTALL FRONT DISC BRAKE CALIPER ASSEMBLY (See page AH-10) 12. INSTALL FRONT SPEED SENSOR (See page DS-21) 13. INSTALL FRONT AXLE HUB NUT (See page AH-11) 14. SEPARATE FRONT DISC BRAKE CALIPER ASSEMBLY (See page AH-11) 15. REMOVE FRONT DISC (See page BR-49) 16. INSPECT FRONT AXLE HUB BEARING LOOSENESS (See page AH-5) 17. INSPECT FRONT AXLE HUB RUNOUT (See page AH6) 18. INSTALL FRONT DISC (See page BR-51) 19. INSTALL FRONT DISC BRAKE CALIPER ASSEMBLY (See page AH-10) 20. INSTALL FRONT AXLE HUB NUT (See page AH-11) 21. CHECK ABS SPEED SENSOR SIGNAL HINT: • ABS: See page BC-11 SUSPENSION – FRONT LOWER BALL JOINT SP–31 • VSC (for BOSCH): See page BC-290 • VSC (for ADVICS): See page BC-123 22. INSTALL FRONT WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 23. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page SP-4) SP SP–31 SUSPENSION – FRONT STABILIZER BAR FRONT STABILIZER BAR SUSPENSION & AXLE COMPONENTS 27 (275, 20) FRONT STABILIZER LINK ASSEMBLY RH 74 (755, 55) FRONT NO. 1 STABILIZER BAR BUSHING FRONT NO. 1 STABILIZER BRACKET RH 27 (275, 20) FRONT NO. 1 STABILIZER BRACKET LH SP FRONT NO. 1 STABILIZER BAR BUSHING 74 (755, 55) 74 (755, 55) FRONT STABILIZER BAR FRONT STABILIZER LINK ASSEMBLY LH 74 (755, 55) N*m (kgf*cm, ft.*lbf) : Specified torque C132428E01 SP–32 SUSPENSION – FRONT STABILIZER BAR REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 3. REMOVE FRONT WHEELS 4. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY (See page SR-42) 5. SEPARATE TIE ROD END SUB-ASSEMBLY (See page PS-40) 6. REMOVE FRONT STABILIZER LINK ASSEMBLY LH (a) Remove the 2 nuts and the front stabilizer link assembly LH. HINT: If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud. 7. REMOVE FRONT STABILIZER LINK ASSEMBLY RH (a) Remove the 2 nuts and the front stabilizer link assembly RH. HINT: If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud. 8. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE HINT: Refer to the instructions for removal of the engine assembly (See page EM-100 for 2AZ-FE, EM-29 for 2GR-FE). 9. REMOVE FRONT NO. 1 STABILIZER BRACKET LH (a) Remove the 2 bolts and the front No. 1 stabilizer bracket LH from the front frame assembly. SP C132425 C139012 C132433 SUSPENSION – FRONT STABILIZER BAR SP–33 10. REMOVE FRONT NO. 1 STABILIZER BRACKET RH (a) Remove the 2 bolts and the front No. 1 stabilizer bracket RH from the front frame assembly. 11. REMOVE FRONT NO. 1 STABILIZER BAR BUSHING (a) Remove the 2 front No. 1 stabilizer bar bushings from the front stabilizer bar. 12. REMOVE FRONT STABILIZER BAR C139011 INSPECTION 1. C066721 INSPECT FRONT STABILIZER LINK ASSEMBLY (a) Inspect the turning of the ball joint. (1) Secure the front stabilizer link assembly in a vise using aluminum plates. (2) Install the nut to the front stabilizer link assembly stud. (3) Using a torque wrench, turn the nut continuously at a rate of 3 to 5 seconds per turn and take the torque reading on the 5th turn. Torque: 0.05 to 2.0 N*m (0.5 to 20 kgf*cm, 0.4 to 18 in.*lbf) HINT: If the turning torque is not within the specified range, replace the front stabilizer link assembly with a new one. (b) Inspect the dust cover. (1) Check that the dust cover is not cracked and that there is no grease on it. for TMC made: INSTALLATION Outside 1. INSTALL FRONT NO. 1 STABILIZER BAR BUSHING (a) Install the 2 front stabilizer bar bushings No. 1 to the outside of the bushing stopper on the front stabilizer bar. NOTICE: Make sure that the cutout of the front stabilizer bar bushing No. 1 faces the rear side as shown in the illustration. 2. INSTALL FRONT NO. 1 STABILIZER BRACKET LH (a) Install the front No. 1 stabilizer bracket LH. 3. INSTALL FRONT NO. 1 STABILIZER BRACKET RH (a) Install the front No. 1 stabilizer bracket RH. Cutout Rear for TMMK made: Outside Cutout Rear C140709E01 SP SP–34 SUSPENSION – FRONT STABILIZER BAR 4. LH Side: INSTALL FRONT STABILIZER BAR (a) Install the front stabilizer bar with the 2 bolts. (LH Side) Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) C143302E01 (b) Install the front stabilizer bar with the 2 bolts. (RH Side) Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) RH Side: SP 5. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE HINT: Refer to the instructions for installation of the engine assembly (See page EM-107 for 2AZ-FE, EM-37 for 2GR-FE) 6. INSTALL FRONT STABILIZER LINK ASSEMBLY LH (a) Install the front stabilizer link assembly LH with the 2 nuts. Torque: 74 N*m (755 kgf*cm, 55 ft.*lbf) HINT: If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud. 7. INSTALL FRONT STABILIZER LINK ASSEMBLY RH (a) Install the front stabilizer link assembly RH with the 2 nuts. Torque: 74 N*m (755 kgf*cm, 55 ft.*lbf) HINT: If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud. 8. CONNECT TIE ROD END SUB-ASSEMBLY (See page PS-64) 9. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY (See page SR-47) C143303E01 C132425 C139012 10. PLACE FRONT WHEELS FACING STRAIGHT 11. INSTALL FRONT WHEELS Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 13. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page SP-4) SUSPENSION – REAR SHOCK ABSORBER SP–35 REAR SHOCK ABSORBER SUSPENSION & AXLE COMPONENTS for Fixed Type: REAR SEAT HEADREST ASSEMBLY REAR SEAT HEADREST ASSEMBLY SP REAR CENTER SEAT HEADREST ASSEMBLY 18 (184, 13) REAR SEAT BACK ASSEMBLY 18 (184, 13) REAR SEAT CUSHION ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C138582E01 SP–36 SUSPENSION – REAR SHOCK ABSORBER for Fold Down Seat Type: REAR SEAT HEADREST ASSEMBLY REAR SEAT HEADREST ASSEMBLY REAR SIDE SEAT BACK ASSEMBLY RH REAR CENTER SEAT HEADREST ASSEMBLY SP 18 (184, 13) 18 (184, 13) 18 (184, 13) SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH 18 (184, 13) REAR SEAT CUSHION ASSEMBLY REAR SIDE SEAT BACK ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque C138583E01 SP–37 SUSPENSION – REAR SHOCK ABSORBER for Reclining Seat Type: REAR SEAT HEADREST ASSEMBLY REAR SEAT HEADREST ASSEMBLY 18 (184, 13) SP REAR SEAT BACK COVER SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH 18 (184, 13) 18 (184, 13) SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH REAR SEAT BACK COVER 18 (184, 13) REAR SEAT CUSHION ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C138584E01 SP–38 SUSPENSION – REAR SHOCK ABSORBER 55 (561, 41) REAR SUSPENSION SUPPORT NO. 1 COVER REAR SHOCK ABSORBER COLLAR 39 (398, 29) SP REAR SHOCK ABSORBER WITH COIL SPRING 39 (398, 29) REAR SUSPENSION SUPPORT ASSEMBLY REAR NO. 1 SPRING BUMPER REAR STABILIZER LINK ASSEMBLY LH REAR BRAKE FLEXIBLE HOSE 39 (398, 29) REAR COIL SPRING REAR COIL SPRING LOEWR INSULATOR 19 (194, 14) 5.0 (51, 44 in.*lbf) REAR SPEED SENSOR 180 (1,840, 133) REAR SHOCK ABSORBER N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C132485E02 SUSPENSION – REAR SHOCK ABSORBER SP–39 REMOVAL 1. REMOVE REAR SEAT CUSHION ASSEMBLY (for Fixed Type) (See page SE-77) 2. REMOVE REAR SEAT HEADREST ASSEMBLY (for Fixed Type) 3. REMOVE REAR CENTER SEAT HEADREST ASSEMBLY (for Fixed Type) 4. REMOVE REAR SEAT BACK ASSEMBLY (for Fixed Type) (See page SE-77) 5. REMOVE REAR SEAT CUSHION ASSEMBLY (for Fold Down Seat Type) (See page SE-47) 6. REMOVE REAR SEAT HEADREST ASSEMBLY (for Fold Down Seat Type) 7. REMOVE REAR CENTER SEAT HEADREST ASSEMBLY (for Fold Down Seat Type) 8. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-47) 9. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) (See page SE-47) 10. REMOVE REAR SIDE SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-48) 11. REMOVE REAR SIDE SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) (See page SE-48) 12. REMOVE REAR SEAT CUSHION ASSEMBLY (for Reclining Seat Type) (See page SE-62) 13. REMOVE REAR SEAT HEADREST ASSEMBLY (for Reclining Seat Type) 14. REMOVE REAR SEAT BACK COVER (for Reclining Seat Type) (See page SE-63) 15. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Reclining Seat Type) (See page SE-63) 16. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Reclining Seat Type) (See page SE-64) 17. REMOVE REAR WHEEL SP SP–40 SUSPENSION – REAR SHOCK ABSORBER 18. SEPARATE REAR STABILIZER LINK ASSEMBLY LH (a) Remove the nut and separate the rear stabilizer link assembly from the front shock absorber LH. HINT: If the ball joint turns together with the nut, use a hexagon wrench (5 mm) to hold the stud. C132460 19. SEPARATE REAR SPEED SENSOR (a) Remove the 2 bolts, and disconnect the rear brake flexible hose and rear speed sensor from the rear shock absorber with coil spring and rear axle carrier. NOTICE: Be sure to remove the rear speed sensor from the rear shock absorber with coil spring. SP C132461 20. REMOVE REAR SUSPENSION SUPPORT NO. 1 COVER (a) Remove the 4 claws and the rear suspension support No. 1 cover. C132462 21. REMOVE REAR SHOCK ABSORBER WITH COIL SPRING (a) Loosen the lock nut of the rear shock absorber with coil spring. NOTICE: • Do not remove the lock nut. • Only loosen the nut when disassembling the rear shock absorber with coil spring. C132463 (b) Remove the 2 nuts and 2 bolts on the lower side of the rear shock absorber with coil spring. NOTICE: • When removing the nuts, keep the bolts from rotating. • Keep one bolt inserted to secure the hub and disc rotor. C132464 SUSPENSION – REAR SHOCK ABSORBER SP–41 (c) Remove the 3 nuts on the upper side of the rear shock absorber with coil spring. (d) Lower the rear axle carrier, and remove the 2 bolts on the lower side of the rear shock absorber with coil spring. NOTICE: Make sure that the rear speed sensor is disconnected from the rear shock absorber with coil spring. C132465 DISASSEMBLY 1. 28 mm (1.1 in.) FIX REAR SHOCK ABSORBER WITH COIL SPRING (a) As shown in the illustration, secure the rear shock absorber with coil spring in a vise using aluminum plates by closing the vise onto the double nutted bolt affixed to the bracket at the bottom of the absorber. C113438E01 2. C132466 REMOVE REAR SHOCK ABSORBER (a) Using SST, compress the rear coil spring. SST 09727-30021 (09727-00010, 09727-00021, 09727-00031) NOTICE: Do not use an impact wrench. HINT: If the front coil spring is compressed at an angle, using 2 SST will make the work easier. (b) Remove the nut, rear shock absorber collar and rear suspension support assembly. (c) Remove the rear coil spring, rear No. 1 spring bumper, and rear coil spring lower insulator. INSPECTION 1. C132467 INSPECT REAR SHOCK ABSORBER (a) Compress and extend the shock absorber rod 4 or more times. Standard: There is no abnormal resistance or sound and operation resistance is normal. HINT: If there is any abnormality, replace the rear shock absorber with a new one. SP SP–42 SUSPENSION – REAR SHOCK ABSORBER REASSEMBLY 1. INSTALL REAR SHOCK ABSORBER (a) Install the rear No. 1 spring bumper to the piston rod. (b) Install the rear coil spring lower insulator onto the rear shock absorber. Match C132468E01 SP (c) Using SST, compress the rear coil spring. SST 09727-30021 (09727-00010, 09727-00021, 09727-00031) NOTICE: Do not use an impact wrench. SST C104393E01 (d) Install the rear coil spring to the rear shock absorber. NOTICE: The smaller diameter end must face upward. HINT: • Fit the lower end of the rear coil spring into the gap of the lower seat. • If the front coil spring is compressed at an angle, using 2 SST will make the work easier. SST C132470E01 (e) Install the rear suspension support assembly. NOTICE: Align the notches of the piston rod and the rear suspension support assembly as shown in the illustration before installing the rear suspension support assembly. Match C132469E01 SUSPENSION – REAR SHOCK ABSORBER SP–43 (f) Align the notches of the shock absorber with the notch of the rear suspension support assembly so that the notches face the outside of the vehicle. (g) Install the rear shock absorber collar. (h) Loosely tighten a new lock nut to the rear suspension piston rod. Match Mark Outside SST Outside SP C132471E01 (i) C132472E01 Release the spring while adjusting the rear suspension support assembly to the position shown in the illustration, and remove the SST from the rear coil spring. NOTICE: Do not use an impact wrench. HINT: When lining up the rear suspension support assembly's stud bolts at the middle point between the two sides of the bracket, the maximum permissible degree of error is plus or minus 5°. SP–44 SUSPENSION – REAR SHOCK ABSORBER INSTALLATION 1. INSTALL REAR SHOCK ABSORBER WITH COIL SPRING (a) Install the rear shock absorber with coil spring to the rear axle carrier assembly and insert the 2 bolts from the rear of the vehicle. (b) Slowly jack up the vehicle using a wooden block and install the rear shock absorber with coil spring (upper side) to the vehicle. SP Wooden Block Wooden Block C132459E02 (c) Install the 3 nuts to the upper side of the rear shock absorber with coil spring. Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf) C132465 SUSPENSION – REAR SHOCK ABSORBER SP–45 (d) Install the 2 nuts and 2 bolts to the lower side of the rear shock absorber with coil spring. Torque: 180 N*m (1,840 kgf*cm, 133 ft.*lbf) NOTICE: When installing the nuts, keep the bolts from rotating. C132464 (e) Fully tighten the lock nut. Torque: 55 N*m (561 kgf*cm, 41 ft.*lbf) SP C132463 (B) 2. CONNECT REAR SPEED SENSOR (a) Install the rear brake flexible hose and rear speed sensor wire harness with the 2 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) (bolt A) 19 N*m (194 kgf*cm, 14 ft.*lbf) (bolt B) 3. INSTALL REAR STABILIZER LINK ASSEMBLY LH (a) Install the rear stabilizer link assembly LH to the rear shock absorber with the nut. Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf) HINT: If the ball joint turns together with the nut, use a hexagon wrench (5 mm) to hold the stud. 4. INSTALL REAR SUSPENSION SUPPORT NO. 1 COVER (a) Engage the 4 claws and install the rear suspension support No. 1 cover. 5. INSTALL REAR WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 6. INSTALL REAR SEAT BACK ASSEMBLY (for Fixed Type) (See page SE-84) (A) C132461E01 C132460 C132501 SP–46 SUSPENSION – REAR SHOCK ABSORBER 7. INSTALL REAR SEAT CUSHION ASSEMBLY (for Fixed Type) (See page SE-84) 8. INSTALL REAR CENTER SEAT HEADREST ASSEMBLY (for Fixed Type) 9. INSTALL REAR SEAT HEADREST ASSEMBLY (for Fixed Type) 10. INSTALL REAR SIDE SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) (See page SE-57) 11. INSTALL REAR SIDE SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-57) SP 12. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) (See page SE-57) 13. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-57) 14. INSTALL REAR SEAT CUSHION ASSEMBLY (for Fold Down Seat Type) (See page SE-58) 15. INSTALL REAR CENTER SEAT HEADREST ASSEMBLY (for Fold Down Seat Type) 16. INSTALL REAR SEAT HEADREST ASSEMBLY (for Fold Down Seat Type) 17. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Reclining Seat Type) (See page SE-71) 18. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Reclining Seat Type) (See page SE-71) 19. INSTALL REAR SEAT BACK COVER (for Reclining Seat Type) 20. INSTALL REAR SEAT CUSHION ASSEMBLY (for Reclining Seat Type) (See page SE-73) 21. INSTALL REAR SEAT HEADREST ASSEMBLY (for Reclining Seat Type) 22. CHECK ABS SPEED SENSOR SIGNAL ABS: See page BC-19 VSC (for BOSCH): BC-290 VSC (for ADVICS): BC-123 23. INSPECT AND ADJUST REAR WHEEL ALIGNMENT (See page SP-13) SUSPENSION – REAR SHOCK ABSORBER 40 mm (1.57 in.) A B C132473E01 SP–47 DISPOSAL 1. DISPOSE OF REAR SHOCK ABSORBER (a) Fully extend the shock absorber piston rod. (b) Using a drill, make a hole in the cylinder between A and B as shown in the illustration to discharge the gas inside. CAUTION: • Be careful when drilling because shards of metal may fly about. Always use the proper safety equipment. • The gas is colorless, odorless and nonpoisonous. SP SUSPENSION – REAR STRUT ROD SP–47 REAR STRUT ROD SUSPENSION & AXLE COMPONENTS for TMC made: REAR STRUT ROD SP 113 (1,152, 83) 113 (1,152, 83) PARKING BRAKE NO. 3 CABLE ASSEMBLY REAR STRUT ROD 6.0 (61, 53 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque C132486E01 SP–48 SUSPENSION – REAR STRUT ROD REMOVAL 1. REMOVE REAR WHEEL 2. SEPARATE PARKING BRAKE NO. 3 CABLE ASSEMBLY (a) Remove the bolt, and separate the parking brake No. 3 cable assembly. 3. REMOVE REAR STRUT ROD (a) Support the rear axle carrier with a jack. C132474 SP Wooden Block C132459E01 (b) Remove the bolt and nut, and disconnect the strut rod (front side). NOTICE: When removing the bolt, keep the nut from rotating. C132475 SUSPENSION – REAR STRUT ROD SP–49 (c) Remove the bolt, nut and strut rod from the rear axle carrier. NOTICE: When removing the bolt, keep the nut from rotating. C132476 INSTALLATION 1. TEMPORARILY TIGHTEN REAR STRUT ROD (a) Install the rear strut rod (rear side), bolt and nut, and temporarily tighten the bolt. NOTICE: When temporarily tightening the bolt, keep the nut from rotating. C132496 (b) Support the rear axle carrier. Wooden Block C132459E01 SP SP–50 SUSPENSION – REAR STRUT ROD (c) Connect the rear strut rod (inner side) with the bolt and nut. NOTICE: When temporarily tightening the bolt, keep the nut from rotating. C132476 2. STABILIZE SUSPENSION (a) Jack up the rear axle carrier, placing a wooden block to avoid damage. Apply load to the suspension so that the installed bolt of the rear suspension No. 1 arm (inner side of vehicle) is horizontally aligned with the center of the rear axle hub. 3. FULLY TIGHTEN REAR STRUT ROD (a) Fully tighten the bolt. Torque: 113 N*m (1,152 kgf*cm, 83 ft.*lbf) SP Wooden Block C108450E01 C132476 (b) Fully tighten the bolt. Torque: 113 N*m (1,152 kgf*cm, 83 ft.*lbf) C132475 SUSPENSION – REAR STRUT ROD SP–51 4. CONNECT PARKING BRAKE NO. 3 CABLE ASSEMBLY (a) Install the parking brake No. 3 cable assembly with the bolt. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 5. INSTALL REAR WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) C132474 SP SP–52 SUSPENSION – REAR NO. 1 SUSPENSION ARM REAR NO. 1 SUSPENSION ARM SUSPENSION & AXLE COMPONENTS for 2AZ-FE: GASKET 43 (438, 32) 43 (438, 32) SP EXHAUST PIPE SUPPORT NO. 4 43 (438, 32) CENTER EXHAUST PIPE ASSEMBLY GASKET 43 (438, 32) EXHAUST PIPE SUPPORT NO. 4 N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C138705E01 SP–53 SUSPENSION – REAR NO. 1 SUSPENSION ARM for 2GR-FE: EXHAUST PIPE SUPPORT NO. 4 43 (438, 32) 43 (438, 32) CENTER EXHAUST PIPE ASSEMBLY SP 19 (194, 14) EXHAUST PIPE DAMPER 56 (571, 41) EXHAUST PIPE SUPPORT NO. 4 EXHAUST PIPE SUPPORT NO. 4 56 (571, 41) EXHAUST PIPE ASSEMBLY TAIL 43 (438, 32) EXHAUST PIPE SUPPORT NO. 4 GASKET 43 (438, 32) N*m (kgf*cm, ft.*lbf) : Specified torque TAIL EXHAUST PIPE ASSEMBLY Non-reusable part C138704E02 SP–54 SUSPENSION – REAR NO. 1 SUSPENSION ARM REAR STABILIZER LINK ASSEMBLY RH REAR STABILIZER LINK ASSEMBLY LH SP REAR STABILIZER BUSHING 39 (398, 29) 39 (398, 29) REAR STABILIZER BAR REAR STABILIZER BUSHING 31 (316, 23) REAR STABILIZER BAR NO. 1 BRACKET 31 (316, 23) REAR STABILIZER BAR NO. 2 BRACKET N*m (kgf*cm, ft.*lbf) : Specified torque C132488E01 SP–55 SUSPENSION – REAR NO. 1 SUSPENSION ARM REAR SUSPENSION MEMBER SUB-ASSEMBLY SP 56 (571, 41 ) 38 (388, 28 ) REAR SUSPENSION MEMBER LOWER STOPPER LH 55 (561, 41 ) 100 (1,020, 74 ) 100 (1,020, 74 ) 56 (571, 41 ) REAR NO. 2 SUSPENSION ARM LH 100 (1,020, 74 ) 100 (1,020, 74 ) REAR NO. 1 SUSPENSION ARM LH 113 (1,152, 83) REAR STRUT ROD N*m (kgf*cm, ft.*lbf) : Specified torque C132490E01 SP–56 SUSPENSION – REAR NO. 1 SUSPENSION ARM REMOVAL NOTICE: Check if an old gasket still remains on the pipe. If so, remove it. Also, check if any bolts or nuts are rusted. If so, replace them. SP 1. REMOVE REAR WHEEL 2. REMOVE CENTER EXHAUST PIPE ASSEMBLY (for 2AZ-FE) (See page EX-2) 3. REMOVE TAIL EXHAUST PIPE ASSEMBLY (for 2GRFE) (See page EX-2) 4. REMOVE CENTER EXHAUST PIPE ASSEMBLY (for 2GR-FE) (See page EX-2) 5. SEPARATE REAR STABILIZER LINK ASSEMBLY LH (a) Remove the nut and separate the rear stabilizer link assembly LH (lower side) from the rear stabilizer bar. HINT: If the ball joint turns together with the nut, use a hexagon wrench (5 mm) to hold the stud. 6. SEPARATE REAR STABILIZER LINK ASSEMBLY RH HINT: Separate the RH side using the same procedures as for the LH side. 7. REMOVE REAR STABILIZER BAR NO. 2 BRACKET (See page SP-68) 8. REMOVE REAR STABILIZER BAR NO. 1 BRACKET (See page SP-68) 9. REMOVE REAR STABILIZER BAR C138763 10. REMOVE REAR STABILIZER BUSHING (See page SP-68) 11. SEPARATE REAR STRUT ROD (See page SP-48) 12. SEPARATE REAR NO. 2 SUSPENSION ARM LH (a) Remove the bolt, nut and separate the rear suspension No. 2 arm (outer side) from the rear axle carrier. NOTICE: When removing the bolt, keep the nut from rotating. C132478 13. SEPARATE REAR NO. 2 SUSPENSION ARM RH HINT: Separate the RH side using the same procedures as for the LH side. SUSPENSION – REAR NO. 1 SUSPENSION ARM SP–57 14. SEPARATE REAR NO. 1 SUSPENSION ARM LH (a) Remove the bolt, nut and the rear No. 1 suspension arm (outer side) from the rear axle carrier. NOTICE: When removing the bolt, keep the nut from rotating. C132479 15. SEPARATE REAR NO. 1 SUSPENSION ARM RH HINT: Separate the RH side using the same procedures as for the LH side. 16. REMOVE REAR SUSPENSION MEMBER LOWER STOPPER LH (a) Remove the 2 nuts and the rear suspension member lower stopper LH. C132500 17. REMOVE REAR SUSPENSION MEMBER LOWER STOPPER RH (a) Remove the 2 nuts and the rear suspension member lower stopper RH. C138862 18. REMOVE REAR SUSPENSION MEMBER SUBASSEMBLY (a) Support the rear suspension member with a jack. (b) Remove the 2 bolts, and the rear suspension member sub-assembly. C132502 19. REMOVE REAR NO. 1 SUSPENSION ARM LH (a) Remove the bolt and rear No. 1 suspension arm assembly LH. B053744E01 SP SP–58 SUSPENSION – REAR NO. 1 SUSPENSION ARM INSTALLATION 1. INSTALL REAR NO. 1 SUSPENSION ARM LH (a) Install the rear No. 1 suspension arm (inner side) with the bolt, and temporarily tighten the bolt. (1) Install the rear No. 1 suspension arm so that the bracket leans toward the front side of the vehicle as shown in the illustration. B053744E01 (2) Ensure that the paint mark faces the rear side of the vehicle. Paint Mark SP Front B073546E04 (b) Set the rear No.1 suspension arm in the position shown in the illustration, and fully tighten the bolt. Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf) C132503E01 2. INSTALL REAR SUSPENSION MEMBER SUBASSEMBLY (a) Raise the rear suspension member with a jack. (b) Install the rear suspension member with the 2 bolts. Torque: 56 N*m (571 kgf*cm, 41 ft.*lbf) 3. INSTALL REAR SUSPENSION MEMBER LOWER STOPPER LH (a) Install the rear suspension member lower stopper LH with the 2 nuts. Torque: Nut A 55 N*m (561 kgf*cm, 41 ft.*lbf) Nut B 38 N*m (388 kgf*cm, 28 ft.*lbf) C132502 A B C132500E01 SUSPENSION – REAR NO. 1 SUSPENSION ARM B SP–59 4. INSTALL REAR SUSPENSION MEMBER LOWER STOPPER RH (a) Install the rear suspension member lower stopper RH with the 2 nuts. Torque: Nut A 55 N*m (561 kgf*cm, 41 ft.*lbf) Nut B 38 N*m (388 kgf*cm, 28 ft.*lbf) 5. TEMPORARILY TIGHTEN REAR NO. 1 SUSPENSION ARM LH (a) Connect the rear No.1 suspension arm (outer side) to the rear axle carrier with the bolt and nut and temporarily tighten the bolt and nut. NOTICE: When temporarily tightening the bolt, keep the nut from rotating. HINT: Insert the bolt from the front of the vehicle and temporarily install the bolt. A C138862E01 C132479 6. TEMPORARILY TIGHTEN REAR NO. 1 SUSPENSION ARM RH HINT: Temporarily tighten the RH side using the same procedures as for the LH side. 7. TEMPORARILY TIGHTEN REAR NO. 2 SUSPENSION ARM LH (a) Connect the rear No. 2 suspension arm (outer side) to the rear axle carrier with the bolt and nut and temporarily tighten the bolt. NOTICE: When temporarily tightening the bolt, keep the nut from rotating. HINT: Insert the bolt from the rear of the vehicle and temporarily install the bolt. 8. TEMPORARILY TIGHTEN REAR NO. 2 SUSPENSION ARM RH HINT: Temporarily tighten the RH side using the same procedures as for the LH side. C132478 SP SP–60 SUSPENSION – REAR NO. 1 SUSPENSION ARM 9. C132496 TEMPORARILY TIGHTEN REAR STRUT ROD (a) Connect the strut rod assembly rear to the axle carrier with the bolt and nut and temporarily tighten the bolt. NOTICE: When temporarily tightening the bolt, keep the nut from rotating. HINT: Insert the bolt from the inside of the vehicle and temporarily install the bolt. 10. STABILIZE SUSPENSION (a) Jack up the rear axle carrier, placing a wooden block to avoid damage. Apply load to the suspension so that the installed bolt of the rear No. 1 suspension arm (inner side) is horizontally aligned with the center of the rear axle hub. SP Wooden Block C108450E01 11. FULLY TIGHTEN REAR NO. 1 SUSPENSION ARM LH (a) Fully tighten the bolt. Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf) 12. FULLY TIGHTEN REAR NO. 1 SUSPENSION ARM RH HINT: Fully tighten the RH side using the same procedures as for the LH side. C132483 13. FULLY TIGHTEN REAR NO. 2 SUSPENSION ARM LH (a) Fully tighten the bolt. Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf) 14. FULLY TIGHTEN REAR NO. 2 SUSPENSION ARM RH HINT: Fully tighten the RH side using the same procedures as for the LH side. C132492 15. FULLY TIGHTEN REAR STRUT ROD (See page SP50) SUSPENSION – REAR NO. 1 SUSPENSION ARM SP–61 16. INSTALL REAR STABILIZER BUSHING (See page SP69) 17. INSTALL REAR STABILIZER BAR NO. 2 BRACKET (See page SP-69) 18. INSTALL REAR STABILIZER BAR NO. 1 BRACKET (See page SP-69) 19. INSTALL REAR STABILIZER BAR 20. INSTALL REAR STABILIZER LINK ASSEMBLY LH (See page SP-70) 21. INSTALL REAR STABILIZER LINK ASSEMBLY RH (See page SP-70) 22. INSTALL CENTER EXHAUST PIPE ASSEMBLY (for 2AZ-FE) (See page EX-4) 23. INSTALL CENTER EXHAUST PIPE ASSEMBLY (for 2GR-FE) (See page EX-4) 24. INSTALL TAIL EXHAUST PIPE ASSEMBLY (for 2GRFE) (See page EX-5) 25. INSTALL REAR WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 26. CHECK FOR EXHAUST GAS LEAKAGE (See page EX-5) 27. INSPECT AND ADJUST REAR WHEEL ALIGNMENT (See page SP-13) SP SP–62 SUSPENSION – REAR NO. 2 SUSPENSION ARM REAR NO. 2 SUSPENSION ARM SUSPENSION & AXLE COMPONENTS REAR SUSPENSION MEMBER SUB-ASSEMBLY SP 56 (571, 41 ) 100 (1,020, 74 ) REAR NO. 2 SUSPENSION ARM N*m (kgf*cm, ft.*lbf) : Specified torque C132491E01 SUSPENSION – REAR NO. 2 SUSPENSION ARM SP–63 REMOVAL 1. REMOVE REAR WHEEL 2. REMOVE REAR NO. 2 SUSPENSION ARM (a) Remove the bolt, and disconnect the rear No. 2 suspension arm (inner side). C132489 (b) Remove the bolt, nut and the rear No. 2 suspension arm (outer side) from the rear axle carrier. NOTICE: When removing the bolt, keep the nut from rotating. C132484 INSTALLATION 1. Paint Mark TEMPORARILY TIGHTEN REAR NO. 2 SUSPENSION ARM (a) Install the rear No. 2 suspension arm (inner side) with the bolt, and temporarily tighten the bolt. HINT: Ensure that the paint mark faces to the rear of the vehicle. C132489E01 (b) Connect the rear No. 2 suspension arm (outer side) to the rear axle carrier with the bolt and nut, and temporarily tighten the bolt. NOTICE: When temporarily tightening the bolt, keep the nut from rotating. 2. C132484 STABILIZE SUSPENSION (See page SP-50) SP SP–64 SUSPENSION – REAR NO. 2 SUSPENSION ARM 3. FULLY TIGHTEN REAR NO. 2 SUSPENSION ARM (a) Fully tighten the bolt. Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf) Paint Mark C132489E01 (b) Fully tighten the bolt. Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf) 4. INSTALL REAR WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 5. INSPECT AND ADJUST REAR WHEEL ALIGNMENT (See page SP-13) SP C132484 SP–65 SUSPENSION – REAR STABILIZER BAR REAR STABILIZER BAR SUSPENSION & AXLE COMPONENTS for 2AZ-FE: GASKET 43 (438, 32) 43 (438, 32) SP EXHAUST PIPE SUPPORT NO. 4 43 (438, 32) CENTER EXHAUST PIPE ASSEMBLY GASKET 43 (438, 32) EXHAUST PIPE SUPPORT NO. 4 N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C138705E01 SP–66 SUSPENSION – REAR STABILIZER BAR for 2GR-FE: EXHAUST PIPE SUPPORT NO. 4 43 (438, 32) 43 (438, 32) CENTER EXHAUST PIPE ASSEMBLY SP 19 (194, 14) EXHAUST PIPE DAMPER 56 (571, 41) EXHAUST PIPE SUPPORT NO. 4 EXHAUST PIPE SUPPORT NO. 4 56 (571, 41) EXHAUST PIPE ASSEMBLY TAIL 43 (438, 32) EXHAUST PIPE SUPPORT NO. 4 GASKET 43 (438, 32) N*m (kgf*cm, ft.*lbf) : Specified torque TAIL EXHAUST PIPE ASSEMBLY Non-reusable part C138704E02 SP–67 SUSPENSION – REAR STABILIZER BAR REAR STABILIZER LINK ASSEMBLY RH 39 (398, 29) REAR STABILIZER LINK ASSEMBLY LH REAR STABILIZER BUSHING 39 (398, 29) SP 39 (398, 29) 39 (398, 29) REAR STABILIZER BAR REAR STABILIZER BUSHING REAR STABILIZER BAR NO. 1 BRACKET 31 (316, 23) 31 (316, 23) REAR STABILIZER BAR NO. 2 BRACKET N*m (kgf*cm, ft.*lbf) : Specified torque C137655E01 SP–68 SUSPENSION – REAR STABILIZER BAR REMOVAL NOTICE: Check if an old gasket still remains on the pipe. If so, remove it. Also, check if any bolts or nuts are rusted. If so, replace them. SP 1. REMOVE REAR WHEELS 2. REMOVE CENTER EXHAUST PIPE ASSEMBLY (for 2AZ-FE) (See page EX-2) 3. REMOVE TAIL EXHAUST PIPE ASSEMBLY (for 2GRFE) (See page EX-2) 4. REMOVE CENTER EXHAUST PIPE ASSEMBLY (for 2GR-FE) (See page EX-2) 5. REMOVE REAR STABILIZER LINK ASSEMBLY LH (a) Remove the 2 nuts and rear stabilizer link assembly LH. HINT: If the ball joint turns together with the nut, use a hexagon wrench (5 mm) to hold the stud. 6. REMOVE REAR STABILIZER LINK ASSEMBLY RH (a) Remove the 2 nuts and rear stabilizer link assembly RH. HINT: If the ball joint turns together with the nut, use a hexagon wrench (5 mm) to hold the stud. 7. REMOVE REAR STABILIZER BAR NO. 2 BRACKET (a) Remove the 2 bolts and rear stabilizer bar No. 2 bracket. C132493 C138761 C139014 SUSPENSION – REAR STABILIZER BAR SP–69 8. REMOVE REAR STABILIZER BAR NO. 1 BRACKET (a) Remove the 2 bolts and rear stabilizer bar No. 1 bracket. 9. REMOVE REAR STABILIZER BUSHING (a) Remove the 2 rear stabilizer bushings from the rear stabilizer bar. 10. REMOVE REAR STABILIZER BAR C139015 INSPECTION 1. C066721 INSPECT REAR STABILIZER LINK ASSEMBLY (a) Inspect the turning of the ball joint. (1) Secure the rear stabilizer link assembly in a vise using aluminum plates. (2) Install the nut to the rear stabilizer link assembly stud. (3) Using a torque wrench, turn the nut continuously at a rate of 3 to 5 seconds per turn and take the torque reading on the 5th turn. Torque: Turning torque 0.05 to 1.0 N*m (0.5 to 10 kgf*cm, 0.4 to 8.9 in.*lbf) HINT: If the turning torque is not within the specified range, replace the rear stabilizer link assembly with a new one. (b) Inspect the dust cover. (1) Check that the dust cover is not cracked and that there is no grease on it. INSTALLATION Outside Rear of Vehicle Stopper Ring 1. INSTALL REAR STABILIZER BUSHING (a) Install the 2 rear stabilizer bushings to the outside of the stopper ring on the stabilizer bar. 2. INSTALL REAR STABILIZER BAR NO. 2 BRACKET (a) Install the rear stabilizer bar No. 2 bracket. 3. INSTALL REAR STABILIZER BAR NO. 1 BRACKET (a) Install the rear stabilizer bar No. 1 bracket. 4. INSTALL REAR STABILIZER BAR (a) Install the rear stabilizer bar with the 2 bolts. (LH Side) Torque: 31 N*m (316 kgf*cm, 23 ft.*lbf) C132495E02 LH Side: C132494E01 SP SP–70 SUSPENSION – REAR STABILIZER BAR (b) Install the rear stabilizer bar with the 2 bolts. (RH Side) Torque: 31 N*m (316 kgf*cm, 23 ft.*lbf) RH Side: C138944E02 5. INSTALL REAR STABILIZER LINK ASSEMBLY LH (a) Install the rear stabilizer link assembly LH with the 2 nuts. Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf) HINT: If the ball joint turns together with the nut, use a hexagon wrench (5 mm) to hold the stud. 6. INSTALL REAR STABILIZER LINK ASSEMBLY RH (a) Install the rear stabilizer link assembly RH with the 2 nuts. Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf) HINT: If the ball joint turns together with the nut, use a hexagon wrench (5 mm) to hold the stud. 7. INSTALL CENTER EXHAUST PIPE ASSEMBLY (for 2AZ-FE) (See page EX-4) 8. INSTALL CENTER EXHAUST PIPE ASSEMBLY (for 2GR-FE) (See page EX-4) 9. INSTALL TAIL EXHAUST PIPE ASSEMBLY (for 2GRFE) (See page EX-5) SP C132493 C138761 10. INSTALL REAR WHEELS Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 11. INSPECT EXHAUST GAS LEAKAGE (See page EX-5) ME–1 METER – METER / GAUGE SYSTEM METER / GAUGE SYSTEM Negative (-) Terminal PRECAUTION 1. E110592E01 2. REMOVAL AND INSTALLATION OF THE BATTERY TERMINAL (a) Before performing electrical work, disconnect the battery negative (-) terminal in order to prevent a short in the system. (b) When disconnecting and reconnecting the battery cable, turn the ignition switch and lighting switches off and loosen the terminal nut completely. Perform these operations without prying on the terminal. EXPRESSIONS OF IGNITION SWITCH The type of ignition switch used on this model differs according to the specifications of the vehicle. The expressions listed in the table below are used in this section. Switch Type Ignition Switch (position) Engine Switch (condition) LOCK Off Ignition switch on (IG) ON On (IG) Ignition switch on (ACC) ACC On (ACC) START Start Expression Ignition switch off Engine start F053330E02 ME ME–2 METER – METER / GAUGE SYSTEM PARTS LOCATION SKID CONTROL ECU (ABS & TRACTION ACTUATOR ASSEMBLY) SLIDING ROOF CONTROL ECU (*1) ECM (2GR-FE) FUEL SENDER GAUGE ASSEMBLY ECM (2AZ-FE) ENGINE ROOM R/B AND ENGINE ROOM J/B ME COMBINATION METER ASSEMBLY - DOME FUSE - ECU-ACC FUSE *1: WITH SLIDING ROOF E128053E01 ME–3 METER – METER / GAUGE SYSTEM FOR 4 SPOKE MODEL: STEERING PAD SWITCH CLOCK ASSEMBLY NO. 3 J/B - FRONT PASSENGER SEAT BELT WARNING LIGHT TURN SIGNAL FLASHER CERTIFICATION ECU (*2) TIRE PRESSURE WARNING ECU (*3) ME A/C CONTROL AMPLIFIER DLC3 NO. 4 J/B INSTRUMENT PANEL J/B *2: WITH SMART KEY SYSTEM - MAIN BODY ECU CENTER AIRBAG SENSOR ASSEMBLY *3: WITH TIRE PRESSURE WARNING SYSTEM E128054E03 ME–4 METER – METER / GAUGE SYSTEM 2AZ-FE: ENGINE OIL PRESSURE SWITCH ENGINE COOLANT TEMPERATURE SENSOR 2GR-FE: ENGINE COOLANT TEMPERATURE SENSOR ENGINE OIL PRESSURE SWITCH ME E132655E01 ME–5 METER – METER / GAUGE SYSTEM SYSTEM DIAGRAM Fuel Sender Gauge Assembly Certification ECU Washer Level Warning Switch (*1 ) Engine Oil Pressure Switch Main Body ECU Combination Meter Assembly Skid Control ECU Turn Signal Flasher Steering Pad Switch Brake Fluid Level Warning Switch ECM Front Passenger Seat Belt Warning Light (Clock Assembly) Tire Pressure Warning ECU (*2) A/C Control Amplifier : CAN : Direct Line Cener Airbag Sensor Assembly ME *1: with Washer Level Warning Light Light Control Rheostat *2: with Tire Pressure Warning System E128116E02 ME–6 METER – METER / GAUGE SYSTEM INPUT AND OUTPUT SIGNALS OF THE COMBINATION METER ASSEMBLY: Sender Receiver • • • • ECM A/C Control Amplifier Center Airbag Sensor Assembly Main Body ECU Communication Signal Vehicle speed signal Certification ECU Combination Meter Assembly • • Main Body ECU A/C Control Amplifier Main Body ECU Communication Line CAN (CAN No. 1 Bus) CAN (CAN MS Bus) Rheostat duty signal Tail cancel signal CAN (CAN No. 1 Bus) Lounge illumination signal CAN (CAN No. 1 Bus) Vehicle specification signal (Destination/Handle code) CAN (CAN No. 1 Bus) Certification ECU Odometer signal CAN (CAN MS Bus) Clock assembly Passenger seat belt warning light signal Direct Line • • Center Airbag Sensor Assembly ECM Starter signal Test mode signal Cruise operation indicator Cruise control warning Charge light indicator TM oil temperature range ECM Combination Meter Assembly Engine coolant temperature signal CAN (CAN No. 1 Bus) Engine type information Shift position signal (*1) Reject buzzer signal Gear position signal Sports mode indicator (*1) Engine RPM data Illuminance data Auto dimmer signal ACC switch signal Key switch signal Each door courtesy switch signal Slide roof signal (*2) Main Body ECU Combination Meter Assembly Smart key signal (*3) CAN (CAN No. 1 Bus) Driver side seat belt switch signal Parking brake switch signal High beam indicator light signal Head (*4)/Tail (*5) indicator light signal ME Front fog indicator light signal • • Main Body ECU Certification ECU Combination Meter Assembly Hood courtesy switch signal CAN (CAN MS Bus) ME–7 METER – METER / GAUGE SYSTEM Sender Receiver Communication Signal Communication Line Meter buzzer request signal Each door open display signal Key lose warning signal (*3) Low key battery warning signal (*3) Certification ECU Combination Meter Assembly Shift position warning signal CAN (CAN MS Bus) Steeling lock abnormal warning (*3) Steeling lock unlock warning (*3) Immobiliser Key Identification Completion Vehicle speed signal Brake Warning light Control Flag Skid Control ECU Combination Meter Assembly ABS Warning Light signal CAN (CAN No. 1 Bus) Slip Indicator light signal (*6) VSC Warning light signal (*6) • • ECM Skid Control ECU Combination Meter Assembly Diagnosis signal CAN (CAN No. 1 Bus) A/C Control Amplifier Combination Meter Assembly Ambient temperature display signal CAN (CAN No. 1 Bus) Airbag warning light signal CAN (CAN No. 1 Bus) Center Airbag Sensor Assembly Combination Meter Assembly Front passenger seat condition signal Front passenger seat belt condition signal Direct Line Steering Pad Switch Combination Meter Assembly Steering pad switch operation signal Direct Line Oil Pressure Switch Combination Meter Assembly Engine oil pressure warning light signal Direct Line Fuel Sender Gauge Assembly Combination Meter Assembly Fuel level signal Direct Line Turn Signal flasher Combination Meter Assembly Turn LH/RH indicator light signal Direct Line Tire Pressure Warning ECU (*7) Combination Meter Assembly Tire pressure warning light signal Direct Line Washer Level Switch (*8) Combination Meter Assembly Washer fluid level warning light signal Direct Line Brake Fluid Level Warning Switch Combination Meter Assembly Brake fluid level warning light signal Direct Line *1: for Automatic Transaxle *2: with Sliding Roof *3: with Smart Key System *4: for U.S.A. *5: for Canada *6: with VSC *7: with Tire Pressure Warning System *8: with Washer Level Warning Light ME ME–8 METER – METER / GAUGE SYSTEM SYSTEM DESCRIPTION 1. METER GAUGE without Multi-information Display: Engine Coolant Temperature Receiver Gauge Fuel Receiver Gauge ODO/TRIP Display Tachometer A/T Shift Indicator Speedometer - ODO/TRIP Meter - Outside Temperature E128076E01 ME ME–9 METER – METER / GAUGE SYSTEM with Multi-information Display: Engine Coolant Temperature Receiver Gauge Fuel Receiver Gauge Multi-information Display Tachometer Master Caution Indicator Light A/T Shift Indicator Speedometer E128139E01 METER GAUGE: Item Detail Speedometer Indicates the vehicle speed receiving a signal from the skid Control ECU. (CAN (CAN No. 1 Bus)) Tachometer Indicates the engine speed based on a signal received from the ECM. (CAN (CAN No. 1 Bus)) Engine Coolant Temperature Receiver Gauge Indicates the engine coolant temperature based on a signal received from the ECM. (CAN (CAN No. 1 Bus)) Fuel Receiver Gauge Indicates the fuel level based on a signal the fuel sender gauge. (Direct Line) WARNING/INDICATOR: Item Detail TURN SIGNAL Receives a turn signal from the turn signal flasher. (Direct Line) BEAM Receives a beam signal from the main body ECU. (CAN (CAN No. 1 Bus)) CHARGE Receives a charge light signal from the alternator L terminal. (Direct Line) CHECK E/G Receives a check engine light signal from the ECM. (Direct Line) DOOR Open door indicator light comes on receiving a door condition signal from the main body ECU. (CAN (CAN MS Bus)) D-BELT Receives a driver side seat belt signal from the center airbag sensor assembly. (CAN (CAN No. 1 Bus)) P-BELT Receives a passenger side seat belt signal from the center airbag sensor assembly via the main body ECU (CAN) and transmits a passenger side seat belt condition signal to the clock assembly. (Direct Line) HEAD (*1) Receives a HEAD indicator light signal from main body ECU. (CAN (CAN No. 1 Bus)) TAIL (*2) Receives a TAIL indicator light signal from the main body ECU. (CAN (CAN No. 1 Bus)) A/T SHIFT Receives an A/T shift condition and A/T gear position signal from the park/neutral position switch and the ECM. (CAN (CAN No. 1 Bus)) FUEL Receives a fuel signal from the fuel sender gauge. (Direct Line) ABS Receives an ABS signal from the skid Control ECU. (CAN (CAN No. 1 Bus)) ME ME–10 METER – METER / GAUGE SYSTEM Item Detail SLIP (*3) Receives a SLIP signal from the skid Control ECU. (CAN (CAN No. 1 Bus)) VSC (*3) Receives a VSC signal from the skid Control ECU. (CAN (CAN No. 1 Bus)) BRAKE Receives a brake signal from the brake fluid level warning switch (Direct Line) and the skid Control ECU and main body ECU. (CAN (CAN No. 1 Bus)) CRUISE Receives a cruise signal from the ECM. (CAN (CAN No. 1 Bus)) AIRBAG Receives an airbag signal from the center airbag sensor assembly. (CAN (CAN No. 1 Bus)) Oil pressure Receives an oil pressure signal from the engine oil pressure switch. (Direct Line) Tire pressure (*4) Receives a tire pressure signal from the tire pressure warning ECU. (Direct Line) Washer (*5) Receives a washer signal from the washer level warning switch. (Direct Line) Maintenance required (*1) An oil change reminder light comes on/blinks to remind the driver to change the engine oil depending on the vehicle driving distance. *1: for U.S.A. *2: except for U.S.A. *3: with VSC *4: with Tire Pressure Warning System *5: with Washer Level Indicator HINT: • The multi-information display has been located in the center of the combination meter assembly. • The display shows a message or animation for each of the functions described in the table below. MULTI-INFORMATION DISPLAY: Item Door warning Detail When a door (driver/passenger/rear left/rear right/back/hood) of the vehicle is opened or closed, this item displays a warning message and animation to inform the driver of the condition of the door. • Maintenance required (*1) • • ODO/TRIP display • Outside temperature display This display switches between odometer, trip meter A, and trip meter B in accordance with the operation of the ODO/TRIP switch. It is possible to reset the trip display to keep pressing the trip reset knob for 0.8 second or more. Displays the outside temperature in accordance with the ambient temperature signal from the A/C control amplifier. • Average fuel consumption (after refueling) • ME A maintenance required will display the warning message to remind the driver to change the engine oil depending on the vehicle driving distance. Displays the mode while in the maintenance request reset mode. Displays the value that has been calculated by the meter CPU, which is based on the driven distance and the fuel consumption volume after the ignition switch is on (IG). The average fuel consumption exceeds 99.9 or more, the indication will be "99.9". Possible running distance Displays the value that has been calculated by the meter CPU, which is based on the the fuel consumption volume, fuel level, and vehicle speed. Cruising distance Displays the cruising distance after starting the engine. Average vehicle speed Displays the average vehicle speed after starting the engine. Warning message Illuminates or blinks the master warning light and displays a warning message for each type of system failure. DTC (Diagnostic Trouble Code) display (*3) Displays the DTCs pertaining to the VSC function. *1: for U.S.A. *2: Except for U.S.A. *3: with VSC ME–11 METER – METER / GAUGE SYSTEM 2. MULTI-INFORMATION DISPLAY Key is Not Inside The Vehicle. (*1) Display Off Key is Inside The Vehicle. (*1) Ignition Switch: off Warning: Occurs Warning Mode Warning: Repaired Ignition Switch: on (IG) Warning: Occurs Warning Mode Warning: Repaired Malfunction: Occurs Outside Temperature Display Cruise Information Display (*2) Diagnosis Mode Malfunction: Repaired Ignition Switch: off or on (ACC) Warning: Repaired Warning Mode Warning: Occurs ME Key is Not Inside The Vehicle. (*1) Ignition Switch: off *1: with Smart Key System Display Off *2: Keep pressing the MODE switch for about 1 second E128064E01 ME–12 METER – METER / GAUGE SYSTEM Warning Mode Key System (*1) (*2) * WATER TEMP (*2) * (*3) * * ME Master Caution Indicator Light Blinks *1: with Smart Key System Master Caution Indicator Light Comes On *2: Warning buzzer sounds when the indication appears. Master Caution Indicator Light Goes Off *3: When the vehicle speed is 5 km/h (3mph) or more, the waring buzzer sounds. E128065E01 ME–13 METER – METER / GAUGE SYSTEM (*4) * Oil Maintenance System (*5) Master Caution Indicator Light Blinks Master Caution Indicator Light Comes On Master Caution Indicator Light Goes Off *4: with VSC *5: for U.S.A. E132650E01 ME ME–14 METER – METER / GAUGE SYSTEM Key System (*1) OIL MAINTENANCE SYSTEM (*5) MAINT REQD MAINT REQD SOON *1: with Smart Key System *5: for U.S.A. E128066E01 3. ME DIAGNOSIS SYSTEM OK C E128079 HINT: • The multi-information display shows "DIAG" when turn the ignition switch on (IG) (See page BC-141 for Advics, BC-302 for Bosch). • Diagnosis information can be displayed on the multiinformation display after connecting a jumper wire between TC and CG of the DLC3 connector. METER – METER / GAUGE SYSTEM ME–15 HOW TO PROCEED WITH TROUBLESHOOTING 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS NEXT 3 CHECK CAN COMMUNICATION SYSTEM (a) Check for DTC output. HINT: See page CA-25. CAN DTC OUTPUT (PROCEED TO "CAN COMMUNICATION SYSTEM") NO CAN DTC (GO TO STEP 4) 4 PROBLEM SYMPTOM CONFIRMATION NEXT 5 PROBLEM SYMPTOMS TABLE HINT: See page ME-19. NEXT 6 CIRCUIT INSPECTION ME NEXT 7 NEXT REPAIR OR REPLACE ME–16 8 NEXT END ME METER – METER / GAUGE SYSTEM CONFIRMATION TEST ME–17 METER – METER / GAUGE SYSTEM CUSTOMIZE PARAMETERS 1. COMBINATION METER ASSEMBLY NOTICE: Be sure to record the current value before customizing. HINT: The following items can be customized using intelligent tester. METER: Display (Item) Default Contents Setting KEY REMND VOLUM LARGE Function to change the volume of the key remind warning buzzer KEY REMND SOUND NORMAL Function to change the cycle of the key remind warning buzzer FAST, NORMAL, SLOW SEAT-BELT WARN D/P ON Function to change the setting of the seat belt buzzer. D/P on, D ON, P on, D/P off 2. LARGE, MEDIUM, SMALL HINT: This setting is only valid for the buzzer which sounds at the 5 km/h (3 mph) or more. SEAT BELT BUZZER ON/OFF SETTING (Procedure "A") The seat belt buzzer ON/OFF setting, which is a setting of the buzzer function of the combination meter, can disable the driver and front passenger side seat belt buzzers. NOTICE: • These buzzers should be on for safe driving. Perform these procedures only if it is necessary to set the buzzer off (disabled). • When either the battery cable or the combination meter connector is disconnected, these buzzers are set on (enabled). • Odometer returns to 0 after starting this procedure, although it is not displayed. HINT: "b-oFF" indicates that the buzzer is OFF. "b-on" indicates that the buzzer is ON. The seat belt buzzer ON/OFF setting will be finished (the odometer will display "ODO") if the ODO/TRIP switch is not operated for 10 seconds or more. In this case, perform step 11 to check that the buzzer ON/OFF setting is complete. If it is not complete, start from step 1 again. (a) Driver and front passenger side seat belt buzzers (1) Turn the ignition switch on (IG). (2) Press the ODO/TRIP switch until the odometer displays "ODO". (3) Ignition switch off. (4) Turn the ignition switch on (IG). (5) Press the ODO/TRIP switch immediately (within 6 seconds) and hold it down for 10 seconds or more. (6) Continue holding down the ODO/TRIP switch and fasten the driver side seat belt. ME ME–18 METER – METER / GAUGE SYSTEM (7) Check that the odometer displays either "b-on" or "b-oFF". (8) Press the ODO/TRIP switch to change the display to "b-oFF". (9) Ignition switch off. (10)Turn the ignition switch on (IG). (11)Check that no buzzer sounds. (b) Front passenger side seat belt buzzer (1) Turn the ignition switch on (IG). (2) Press the ODO/TRIP switch until the odometer displays "ODO". (3) Ignition switch off. (4) Turn the ignition switch on (IG). (5) Sit in the front passenger seat. Press the ODO/ TRIP switch immediately (within 6 seconds) and hold it down for 10 seconds or more. (6) Sit in the front passenger seat. Continue holding down the ODO/TRIP switch and fasten the front passenger side seat belt. (7) Check that the odometer displays either "b-on" or "b-oFF". (8) Press the ODO/TRIP switch to change the display to "b-oFF". (9) Ignition switch off. (10)Turn the ignition switch on (IG). (11)Check that no buzzer sounds. ME ME–19 METER – METER / GAUGE SYSTEM INITIALIZATION 1. OIL MAINTENANCE INFORMATION MODE RESET OPERATION HINT: • The trip meter reset knob is located on the right side of the combination meter assembly. • This reset operation is required only for U.S.A.. (a) without multi-information display: (1) Turn the ignition switch on (IG). (2) Press the ODO/TRIP switch until the odometer appears. (3) Ignition switch off. (4) Turn the ignition switch on (IG). (5) Turn the ignition switch on (IG) while pressing and holding the trip meter reset knob. Hold the trip meter reset knob until the following conditions are met and 5 seconds have passed. without Multi-information display: Trip Meter Reset Knob Oil Change Reminder Light 5 Seconds Previous 4 Seconds Previous 1 Second Previous 3 Seconds Previous 2 Seconds Previous E128140E01 • When oil change reminder light turns off, the reset is complete. (b) with multi-information display: (1) Turn the ignition switch on (IG). (2) Press the ODO/TRIP switch until the odometer appears. (3) Ignition switch off. (4) Turn the ignition switch on (IG). ME ME–20 METER – METER / GAUGE SYSTEM (5) Turn the ignition switch on (IG) while pressing and holding the trip meter reset knob. Hold the trip meter reset knob until the following conditions are met and 5 seconds have passed. with Multi-information display: Trip Meter Reset Knob Master Caution Indicator light 5 Seconds Previous 4 Seconds Previous 1 Second Previous 3 Seconds Previous 2 Seconds Previous E128141E01 • The multi-information display shows "MAINT REQD RESET MODE". • The master caution indicator light illuminates. • When oil change reminder light turns off, the reset is complete. (6) When "MAINT REQD RESET MODE COMPLETE" disappears and the master caution indicator light turns off, the reset is complete. ME ME–21 METER – METER / GAUGE SYSTEM PROBLEM SYMPTOMS TABLE ENTIRE SYSTEM: Symptom Entire combination meter does not operate. Suspected area See page Power Source Circuit ME-42 Meter illumination is always dark. Meter Illumination Circuit ME-57 Meter illumination does not dim at night. Meter Illumination Circuit ME-59 METER GAUGES: Symptom Speedometer malfunction Suspected area See page Speedometer Circuit ME-44 Tachometer malfunction Tachometer Circuit ME-47 Fuel receiver gauge malfunction Fuel Receiver Gauge Circuit ME-50 Engine coolant temperature malfunction Engine Coolant Temperature Receiver Gauge Circuit ME-54 WARNING LIGHTS: Symptom Check engine warning light does not come on. Charge warning light does not come on. Brake warning light does not come on. Brake warning light does not go off. ABS warning light does not come on. Suspected area See page 1. MIL Circuit (for 2AZ-FE) ES-397 2. MIL Circuit (for 2GR-FE) ES-471 3. Wire Harness or Connector - 4. Combination Meter Assembly ME-63 1. Combination Meter (LED) ME-32 2. Wire Harness or Connector - 3. ECM (for 2AZ-FE) - 4. ECM (for 2GR-FE) - 5. Combination Meter Assembly ME-63 1. Combination Meter (LED) ME-32 2. Wire Harness or Connector - 3. Brake Warning Light Circuit (without VSC) BC-91 4. Brake Warning Light Circuit (with VSC, Bosch Made) BC-404 5 Brake Warning Light Circuit (with VSC, Advics Made) BC-91 6. Main Body ECU - 7. Parking Brake Switch - 8. Combination Meter Assembly ME-63 1. Combination Meter (LED) ME-63 2. Wire Harness or Connector - 3. Brake Warning Light Circuit (without VSC) BC-91 4. Brake Warning Light Circuit (with VSC, Bosch Made) BC-404 5. Brake Warning Light Circuit (with VSC, Advics Made) BC-252 6. Main Body ECU - 7. Parking Brake Switch - 8. Combination Meter Assembly ME-63 1. Combination Meter (LED) ME-32 2. Wire Harness or Connector - 3. ABS Warning Light Circuit (without VSC) BC-78 4. ABS Warning Light Circuit (with VSC, Bosch Made) BC-385 5. ABS Warning Light Circuit (with VSC, Advics Made) BC-233 6. Combination Meter Assembly ME-63 ME ME–22 METER – METER / GAUGE SYSTEM Symptom Suspected area 1. Combination Meter (LED) ABS warning light does not go off. Airbag warning light does not come on. Airbag warning light does not go off. Open door warning light does not come on. Fuel level warning light does not come on. Low oil pressure warning light does not come on. Driver seat belt warning light does not come on. Front passenger seat belt warning light does not come on. ME Tire pressure warning light does not come on. (with Tire Pressure Warning System) Washer level warning light does not come on (with washer level warning light). (with Washer Level Warning Light) See page ME-32 2. Wire Harness or Connector - 3. ABS Warning Light Circuit (without VSC) BC-78 4. ABS Warning Light Circuit (with VSC, Bosch Made) BC-385 5. ABS Warning Light Circuit (with VSC, Advics) BC-233 6. Combination Meter Assembly ME-63 1. Combination Meter (LED) ME-32 2. Airbag Warning Light Circuit RS-228 3. Wire Harness or Connector - 4. Combination Meter Assembly ME-63 1. Combination Meter (LED) ME-32 2. Airbag Warning Light Circuit RS-222 3. Wire Harness or Connector - 4. Combination Meter Assembly ME-63 1. Combination Meter (LED) ME-32 2. Wire Harness or Connector - 3. Door Courtesy Switch LI-129 4. Main Body ECU - 5. Combination Meter Assembly ME-63 1. Combination Meter (LED) ME-32 2. Wire Harness or Connector - 3. Fuel Sender Gauge Assembly (for 2AZ-FE) ME-71 4. Fuel Sender Gauge Assembly (for 2GR-FE) ME-74 5. Combination Meter Assembly ME-63 1. Combination Meter (LED) ME-32 2. Wire Harness or Connector - 3. Low Oil Pressure Switch ME-37 4. Combination Meter Assembly ME-63 1. Combination Meter (LED) ME-32 2. Wire Harness or Connector - 3. Driver Seat Belt Warning Light Circuit SB-9 4. Main Body ECU - 5. Center Airbag Sensor Assembly - 6. Combination Meter Assembly ME-63 1. Combination Meter (LED) ME-32 2. Wire Harness or Connector - 3. Front Passenger Seat Belt Warning Light Circuit SB-11 4. Combination Meter Assembly ME-63 5. Center Airbag Sensor Assembly - 6. Clock Assembly OT-4 1. Combination Meter (LED) ME-32 2. Wire Harness or Connector - 3. Tire Pressure Warning System TW-65 4. Combination Meter Assembly ME-63 1. Wire Harness or Connector - 2. Combination Meter Assembly - 3. Washer Level Switch - ME–23 METER – METER / GAUGE SYSTEM Symptom Suspected area 1. Combination Meter (LED) VSC warning light does not come on (without Multiinformation Display, with VSC). VSC warning light does not come on (without Multiinformation Display, with VSC). See page ME-32 2. Wire Harness or Connector - 3. VSC Indicator Light Circuit (with VSC, Bosch Made) BC-392 4. VSC Indicator Light Circuit (with VSC, Advics Made) BC-240 5. Combination Meter Assembly ME-63 1. Combination Meter (LED) ME-32 2. Wire Harness or Connector - 3. VSC Indicator Light Circuit (with VSC, Bosch Made) BC-392 4. VSC Indicator Light Circuit (with VSC, Advics Made) BC-240 5. Combination Meter Assembly ME-63 INDICATOR LIGHTS: Symptom Suspected area 1. Combination Meter (LED) Shift indicator light does not come on. (for 2AZ-FE, Automatic Transaxle) Shift indicator light does not come on. (for 2GR-FE, Automatic Transaxle, ) Turn indicator light does not come on. SLIP indicator light does not come on (with VSC). SLIP indicator light does not go off (with VSC). CRUISE indicator light does not come on. High beam indicator light does not come on. See page ME-32 2. Wire Harness or Connector - 3. Transmission Range Sensor Circuit AX-39 4. ECM ES-432 5. Combination Meter Assembly ME-63 1. Combination Meter (LED) ME-32 2. Wire Harness or Connector - 3. Park/Neutral Position Switch Circuit AX-158 4. Transmission Control Switch Circuit AX-154 5. ECM ES-518 6. Combination Meter Assembly ME-63 1. Wire Harness or Connector - 2. Turn Indicator Light Circuit LI-12 3. Combination Meter Assembly ME-63 1. Combination Meter (LED) ME-32 2. Wire Harness or Connector - 3. SLIP Indicator Light Circuit (with VSC, Bosch Made) BC-412 4. SLIP Indicator Light Circuit (with VSC, Advics Made) BC-259 5. Combination Meter Assembly ME-63 1. Combination Meter (LED) ME-32 2. Wire Harness or Connector - 3. SLIP Indicator Light Circuit (with VSC, Bosch Made) BC-412 4. SLIP Indicator Light Circuit (with VSC, Advics Made) BC-259 5. Combination Meter Assembly ME-63 1. Combination Meter (LED) ME-32 2. Wire Harness or Connector - 3. Cruise Main Indicator Light Circuit CC-34 4. Combination Meter Assembly ME-63 1. Wire Harness of Connector - 2. Headlight Dimmer Switch - 3. Main Body ECU - 4. Combination Meter Assembly ME-63 ME ME–24 METER – METER / GAUGE SYSTEM TERMINALS OF ECU 1. COMBINATION METER ASSEMBLY F1 F2 E123358E01 Symbols (Terminal No.) B (F2-1) - Body ground B (F2-2) - Body ground ME CHK (F2-4) - Body ground B/LE (F2-6) - Body ground Wiring Color G - Body ground L - Body ground R - Body ground LG - Body ground Terminal Description Turn indicator light signal Turn indicator light signal Malfunction indicator lamp signal Brake fluid level warning light signal Condition Specified Condition Turn the ignition switch on (IG), turn signal RH indicator light OFF Below 1 V Turn the ignition switch on (IG), turn signal RH indicator light ON 10 to 14 V Turn the ignition switch on (IG), turn signal LH indicator light OFF Below 1 V Turn the ignition switch on (IG), turn signal LH indicator light ON 10 to 14 V Turn the ignition switch on (IG), CHECK ENGINE warning light ON Below 3 V Turn the ignition switch on (IG), CHECK ENGINE warning light OFF 10 to 14 V Turn the ignition switch on (IG), BRAKE warning light OFF 10 to 14 V Turn the ignition switch on (IG), BRAKE warning light ON Below 1 V +S (F2-12) - Body ground V - Body ground Speed signal (Output) Turn the wheel slowly Pulse generation (See waveform 1) SI (F2-14) - Body ground V - Body ground Speed signal (Input) Turn the ignition switch on (IG), turn the wheel slowly Pulse generation (See waveform 1) ME–25 METER – METER / GAUGE SYSTEM Symbols (Terminal No.) FR (F2-15) - Body ground Wiring Color GR - Body ground Terminal Description Fuel signal Condition Specified Condition Turn the ignition switch on (IG), fuel level is FULL Below 1 V Turn the ignition switch on (IG), fuel level is EMPTY 3 to 7 V FE (F2-16) - Body ground P - Body ground Ground (Fuel ground) Always Below 1 V B2 (F1-1) - Body ground R - Body ground Battery Always 10 to 14 V B (F1-2) - Body ground V - Body ground Battery Always 10 to 14 V Turn the ignition switch on (IG), washer level warning light ON Below 1 V Turn the ignition switch on (IG), washer level warning light off 10 to 14 V Turn the ignition switch on (IG), tire pressure warning light ON 0.9 to 3.2 V Turn the ignition switch on (IG), tire pressure warning light off 3.2 V or higher Turn the ignition switch on (IG), engine oil pressure warning light OFF 10 to 14 V Turn the ignition switch on (IG), engine oil pressure warning light ON Below 1 V Sit on the front passenger seat, turn the ignition switch on (IG), front passenger seat belt warning light OFF 10 to 14 V Sit on the front passenger seat, turn the ignition switch on (IG), front passenger seat belt warning light Blinks 10 to 14 V ←→ Below 1 V 10 to 14 V ←→ Below 1 V WLVL (F1-5) (*1) - Body ground TIRE (F1-7) (*2) - Body ground S (F1-8) - Body ground P/SB (F1-9) - Body ground LG - Body ground L - Body ground O - Body ground P - Body ground Washer level warning switch signal Tire pressure warning light signal Engine oil pressure warning light signal Passenger seat belt warning light signal ILL- (F1-11) - Body ground BR - Body ground Illumination signal Turn the ignition switch on (IG) E2 (F1-12) - Body ground W-B - Body ground Ground (Power ground) Always IG+ (F1-13) - Body ground GR - Body ground Ignition switch signal CANH (F1-17) - Body ground B - Body ground CAN communication signal - - CANL (F1-18) - Body ground W - Body ground CAN communication signal - - DISP (F1-22) - Body ground CHG- (F1-23) - Body ground ES (F1-24) - Body ground V - Body ground L - Body ground BR - Body ground Steering pad switch signal Charge warning light signal Ground (Signal ground) Below 1 V Turn the ignition switch off Below 1 V Turn the ignition switch on (IG) 10 to 14 V Turn the ignition switch on (IG), DISP switch off 4 to 6 V Turn the ignition switch on (IG), DISP switch ON Below 1 V Turn the ignition switch on (IG), CHARGE warning light OFF 10 to 14 V Turn the ignition switch on (IG), CHARGE warning light ON Below 1 V Always Below 1 V *1: with Washer Level Warning Light *2: with Tire Pressure Warning System ME ME–26 METER – METER / GAUGE SYSTEM (a) Waveform 1 (Reference): Using oscilloscope: GND I043789E01 ME Item Condition Tool setting 5 V/DIV., 20 ms/DIV. Vehicle condition Driving at approx. 20 km/h (12 mph) ME–27 METER – METER / GAUGE SYSTEM 2. COMBINATION METER INNER CIRCUIT +B (DOME) F1-11(ILL-) F1-12 (E2) SPEED IG2 +B (DOME) TACHO FUEL F2-15 (FR) F1-22 (DISP) F2-16 (FE) TEMP IG+ F1-24 (ES) F1-23 (CHG-) F2-6 (B/LE) LCD ODO/TRIP CPU IG+ F2-14 (SI) BUZZER F2-12 (+S) F1-9 (P/SB) LCD ACC A/T RANGE F1-1 (B2) POWER SUPPLY CIRCUIT F1-2 (B) F1-13 (IG+) MPX+B F1-17 (CANH) F1-18 (CANL) E128088E01 ME ME–28 METER – METER / GAUGE SYSTEM TURN L TURN R F2-2 (B) F2-1 (B) IG+ D-BELT VSC (*1) ABS SLIP (*1) CRUISE DRIVE IC Fr FOG MASTER WARNING +B (DOME) DOOR HEAD (*3) / TAIL (*4) BEAM ME *1: with VSC *2: for Automatic Transaxle *3: for U.S.A. *4: for Canada E128089E01 ME–29 METER – METER / GAUGE SYSTEM IG+ BRAKE A/T P (*2) R (*2) N (*2) D (*2) DRIVE IC S (*2) 4 (*2) 3 (*2) 2 (*2) L (*2) AIRBAG F1-8 (S) OIL PRESSURE F1-5 (WLVL) (*5) WASHER LEVEL (*5) F2-4 (CHK) F1-7 (TIRE) (*6) CHECK ENGINE ACTIVE CIRCUIT TIRE PRESSURE (*6) IG+ *2: for Automatic Transaxle IG+ ILLUMINATION *5: with Washer Level Warning Light *6: with Tire Pressure Warning System IG+ LCD ILLUMINATION E128090E01 ME ME–30 METER – METER / GAUGE SYSTEM Terminal No. F2 F1 ME Wire harness side 1 Turn Signal Flasher (B) 2 Turn Signal Flasher (B) 3 - 4 ECM (CHK) 5 - 6 Brake Fluid Level Warning Switch (B/LE) 7 - 8 - 9 - 10 - 11 - 12 Each part that uses speed signal 13 - 14 Brake Actuator Assembly (*1) / ABS & Traction Actuator Assembly (*2) (SI) 15 Fuel Sender Gauge Assembly (FR) 16 Fuel Sender Gauge Assembly (FE) 1 MPX-B Fuse 2 DOME Fuse 3 - 4 - 5 Washer Level Warning Switch (*3) 6 - 7 Tire Pressure Warning ECU (*4) 8 Oil Pressure Warning Switch 9 Clock Assembly (P/SB) 10 - 11 PANEL Fuse 12 Ground (E2) 13 No. 2 GAUGE Fuse 14 - 15 - 16 - 17 CAN Communication Line (CAN H) 18 CAN Communication Line (CAN L) 19 - 20 - 21 - 22 Steering Pad Switch (DISP) 23 Alternator L Terminal 24 Ground (ES) *1: without VSC *2: with VSC *3: with Washer Level Warning Light *4: with Tire Pressure Warning System ME–31 METER – METER / GAUGE SYSTEM DIAGNOSIS SYSTEM 1. CG SG CANH SIL CANL BAT CHECK DLC3 (a) The ECU uses ISO 15765-4 for communication. The terminal arrangement of the DLC3 complies with SAE J1962 and matches ISO 15765-4 format. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace harness and connector. H100769E16 Symbols (Terminal No.) Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω CG (4) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 11 to 14 V CANH (6) - CANL (14) CAN bus line Ignition switch off 54 to 69 Ω CANH (6) - CG (4) HIGH-level CAN bus line Ignition switch off* 200 Ω or higher CANL (14) - CG (4) LOW-level CAN bus line Ignition switch off* 200 kΩ or higher CANH (6) - BAT (16) HIGH-level CAN bus line Ignition switch off* 6 kΩ or higher CANL (14) - CG (4) LOW-level CAN bus line Ignition switch off* 6 kΩ or higher NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: If the display shows an error message after having connected the cable of the intelligent tester to the DLC3, turn the ignition switch on (IG), and operated the tester, there is a problem on either the vehicle side or the tool side. • If communication is normal when the tool is connected to another vehicle, inspect the DLC3 on the original vehicle. • If communication is still impossible when the tool is connected to another vehicle, the problem is probably in the tool itself. Consult the Service Department listed in the tool's instruction manual. ME ME–32 METER – METER / GAUGE SYSTEM DTC CHECK / CLEAR 1. 2. DLC3 CAN VIM Intelligent Tester C131977E13 ME CHECK DTC (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the ignition switch on (IG) and turn the intelligent tester on. (c) Enter the following menus: DIAGNOSTICS / OBD/ MOBD / METER / DTC INFO / CURRENT CODES. (d) Check for DTCs. CLEAR DTC (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the ignition switch on (IG) and turn the intelligent tester on. (c) Enter the following menus: DIAGNOSTICS / OBD/ MOBD / METER / DTC INFO / CURRENT CODES. (d) Erase DTCs by pressing the YES button on the tester. ME–33 METER – METER / GAUGE SYSTEM FAIL-SAFE CHART ENGINE COOLANT TEMPERATURE GAUGE: Condition Engine coolant temperature data is interrupted for 3.1 seconds. Response Recovery The gauge needle indicates between / and C. Engine coolant temperature data is received. Response Recovery SHIFT INDICATOR: Condition Shift position data is interrupted for 3.1 seconds. All indicator light go off. Normal data is received. Gear position data is interrupted for 3 seconds. The gear position indicator light goes off. Normal data is received. ABS & BRAKE: Condition ABS & brake data is interrupted for 1 second. Response The warning light comes on. Recovery Normal data is received. DOOR: Condition Each door condition data is interrupted for 10 seconds. Response The data received most recently remains indicated. Recovery Normal data is received. DRIVER SIDE SEAT BELT: Condition Driver side front seat inner belt assembly data is interrupted for 10 seconds. Response The data received most recently remains indicated. Recovery Normal data is received. TIRE PRESSURE: Condition Tire pressure data is interrupted for 10 seconds. Response The tire pressure indicator light blinks for 60 to 64 seconds, then comes on. Recovery Normal data is received. OIL MAINTENANCE (*1): Condition The running distance after performing oil maintenance reminder light resetting procedure. Response Oil change reminder light comes on. Recovery Normal data is received. HEAD (*1)/TAIL (*2): Condition Regular data is interrupted for 10 seconds. Response The data received most recently remains indicated. Recovery Normal data is received. BEAM: Condition Regular data is interrupted for 10 seconds. Response The data received most recently remains indicated. Recovery Normal data is received. AIRBAG: Condition Response Recovery Airbag data is interrupted for 10 seconds. Turn the ignition switch on (IG), then the combination meter (meter CPU) can't detect the voltage of 9 V or more for 60 seconds. The warning light comes on. Normal data is received. FRONT PASSENGER SIDE SEAT BELT: Condition Regular data is interrupted for 10 seconds. Response The data received most recently remains indicated. Recovery Normal data is received. ME ME–34 METER – METER / GAUGE SYSTEM CRUISE: Condition Regular data is interrupted for 10 seconds. Response The data received most recently remains indicated. Recovery Normal data is received. CHARGE: Condition Regular data is interrupted. Response The warning light goes off. Recovery Normal data is received. MULTI-INFORMATION DISPLAY: Condition Cruise information data is interrupted for 60 seconds. Response The display becomes blank (only measurement units are displayed). *1: for U.S.A. *2: Except for U.S.A. ME Recovery Normal data is received. ME–35 METER – METER / GAUGE SYSTEM DATA LIST / ACTIVE TEST 1. DATA LIST According to the DATA LIST displayed by the intelligent tester, you can read the values of the switches, sensors, actuators and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten work time. (a) Warm up the engine. (b) Ignition switch off. (c) Connect the intelligent tester to the DLC3. (d) Turn the ignition switch on (IG). (e) Turn the tester ON. (f) Enter following menus: DIAGNOSIS / OBD/MOBD / METER / DATA LIST. (g) Check values by referring to the table below. METER: ITEM TAIL CANCEL SW Measurement Item/Range (Display) TAIL CANCEL switch is ON/OFF ODO/TRIP SW ODO/TRIP switch is ON/OFF P-BELT BUCKL SW Front passenger buckle switch is ON/OFF Normal Condition Diagnostic Note ON: Rheostat knob turns fully clockwise - OFF: Rheostat knob turns fully counterclockwise - ON: Switch is pushed - OFF: Switch is released - ON: Seat belt is fastened - OFF: Seat belt is unfastened - SPEED METER Vehicle speed/Min.: 0 km/h (0 mph), Max.: 255 km/h (158 mph) Almost same as actual vehicle speed (When driving) TACHO METER Engine speed/Min.: 0 rpm, Max.: 12,750 rpm Almost same at the meter rpm (When engine is running) COOLANT TEMP Engine coolant temperature 0°C (32°F) to 127.5°C (261.5°F) After warming up: 78°C (172.4°F) to 105°C (221°F) WASHER SW Washer level warning switch is ON/OFF If data received from the skid control ECU exceeds the range that can be displayed on the meter, the meter continues to display the maximum value of the range. If data received from the ECM exceeds the range that can be displayed on the meter, the meter continues to display the maximum value of the range. •If -40°C (-40°F): sensor circuit open •If 140°C (284°F) or more: sensor circuit shorted ON: Washer level is more than low - OFF: Washer level is less than low - ON: Mode switch is ON - MULTI DISP SW MODE switch in the steering pad is ON/OFF OFF: Mode switch is OFF - +B VOLTAGE VAL Battery voltage/Min.: 0 V, Max.: 25.5 V 10 to 14 V - OIL MAINTENANCE Oil maintenance warning value: Min.: 0, Max. 25500 The running distance after performing oil maintenance resetting procedure is displayed FUEL GAUGE Fuel input signal Min.: 0, Max. 255 If the value is 5,000 or more, perform oil maintenance resetting procedure after changing the oil. Fuel gauge indicates (F): 35 - Fuel gauge indicates (3/4): 85 - Fuel gauge indicates (1/2): 145 - Fuel gauge indicates (1/4): 186 - Fuel gauge indicates (E): 205 - ME ME–36 METER – METER / GAUGE SYSTEM ITEM Measurement Item/Range (Display) Normal Condition Diagnostic Note AMBIENT TEMP Outside temperature: Min.: -40°C (-40°F) to 87.5°C (189.5°F) Almost same as actual outside temperature The temperature displayed on the multi-information display is -22 to 122°C (-30 to 50 °F) RHEOSTAT Light Control Rheostat/Min.: 0, Max.: 100 Light control rheostat switch is Dark (0) → Bright (100) - KEY REMND SOUND The cycle of the key reminder warning buzzer is FAST, NORMAL, SLOW The customized setting of the cycle of the key reminder warning buzzer is displayed. - SEAT-BELT WARN The volume of the seat belt warning buzzer is D/P ON, D ON, P ON, D/P OFF The customized setting of the volume of the seat belt warning buzzer is displayed. - KEY REMND VOLUM The volume of the key reminder warning buzzer is LARGE, MEDIUM, SMALL The customized setting of the volume of the key reminder warning buzzer is displayed. - ABS/TRAC/VSC: ITEM Measurement Item/Range (Display) Normal Condition Diagnostic Note FR/FL/RR/RL WHEEL SPD Vehicle speed/Min.: 0 km/h (0 mph), Max.: 326 km/h (202 mph) Almost same as actual vehicle speed (When driving) - VEHICLE SPD Vehicle speed/Min.: 0 km/h (0 mph), Max.: 326 km/h (202 mph) Almost same as actual vehicle speed (When driving) - ENGINE: ITEM Measurement Item/Range (Display) Normal Condition ENGINE SPD Vehicle speed/Min.: 0 rpm, Max.: 16,383.75 rpm Almost same as actual vehicle speed (When driving) COOLANT TEMP Engine coolant temperature: Min.: -40°C (-40°F), Max.: 140°C (284°F) 80 to 100°C (176 to 212°F): After warming up 2. ME Diagnostic Note • • If -40°C (-40°F): sensor circuit open If 140°C (284°F) or more: sensor circuit shorted ACTIVE TEST Performing the ACTIVE TEST using the intelligent tester allows the meters, indicators and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one way to shorten labor time. It is possible to display the DATA LIST on the intelligent tester during the ACTIVE TEST. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Turn the tester ON. (d) Enter following menus: DIAGNOSIS / OBD/MOBD / METER / ACTIVE TEST. (e) From the display on the tester, performing the "ACTIVE TEST". METER: Item Test Details Diagnostic Note SPEED METER 0, 40 (24), 80 (48), 120 (72), 160 (96), 200 (120) km/h (mph) - TACHOMETER 0, 1,000, 2,000, 3,000, 4,000, 5,000, 6,000, 7,000 (rpm) - FUEL GAUGE EMPTY, 1/2, FULL - COOLANT TEMP LOW, NORM, HIGH - A/T INDIC (1) (*1) A/T shift indicator light L, 2, 3, 4, S, D, N, R, P is OFF/ON - A/T INDIC (2) (*1) A/T gear range indicator light is OFF/ON ME–37 METER – METER / GAUGE SYSTEM Item Test Details Diagnostic Note METER DISPLAY 1 All the dot in the multi-information display OFF/ON Confirm that the vehicle is stopped, engine idling METER DISPLAY 2 All the dot in the A/T shift indicator display OFF/ON Confirm that the vehicle is stopped, engine idling SRS WARN OPEN DOOR WARN SRS warning light is OFF/ON - Open door indicator is OFF/ON - P-BELT REMIND P-belt indicator is OFF/ON - D-BELT REMIND D-belt indicator is OFF/ON ABS WARN DISCHARGE WARN VSC WARN (*2) SLIP INDIC HIGH BEAM INDIC HEADLIGHT INDIC (*3) TAILLIGHT INDIC (*4) Confirm that the vehicle is stopped, engine idling ABS OFF indicator light is OFF/ON Charge warning light is OFF/ON - VSC warning light is OFF/ON - SLIP indicator is OFF/ON - Hi-beam indicator is OFF/ON - HEAD indicator is OFF/ON - TAIL indicator is OFF/ON - Fr FOG indicator light is OFF/ON Confirm that the vehicle is stopped, engine idling D DOOR OPEN D DOOR OPEN indicator light is OFF/ON Confirm that the vehicle is stopped, engine idling P DOOR OPEN P DOOR OPEN indicator light is OFF/ON Confirm that the vehicle is stopped, engine idling RR DOOR OPEN RR DOOR OPEN indicator light is OFF/ON Confirm that the vehicle is stopped, engine idling RL DOOR OPEN RL DOOR OPEN indicator light is OFF/ON Confirm that the vehicle is stopped, engine idling Luggage DOOR OPEN indicator light is OFF/ON Confirm that the vehicle is stopped, engine idling LOW WASHER warning light is OFF/ON Confirm that the vehicle is stopped, engine idling Fr FOG INDIC LUGG DOOR OPEN LOW WASHER WARN (*5) LOW FUEL WARN TIRE PRESS WARN (*6) ECB INDIC Fuel warning light is OFF/ON - TIRE PRESS warning is OFF/ON - BRAKE warning light is OFF/ON Confirm that the vehicle is stopped, engine idling CRUISE INDIC CRUISE indicator is OFF/ON BRAKE WARN BRAKE warning light is OFF/ON Confirm that the vehicle is stopped, engine idling MAINTENANCE indicator light is OFF/ON Confirm that the vehicle is stopped, engine idling MASTER WARNING light is OFF/ON Confirm that the vehicle is stopped, engine idling OIL MAINTENANCE (*3) MST WARN INDIC - *1: for Automatic Transaxle *2: without Multi-information Display, with VSC *3: for U.S.A. *4: for Canada *5: with Washer Level Warning Light *6: with Tire Pressure Warning System ME ME–38 METER – METER / GAUGE SYSTEM DIAGNOSTIC TROUBLE CODE CHART DTC No. ME Detection Item Trouble Area See page U0100 Lost Communication with ECM/ PCM "A" - ECM - CAN communication system ME-38 U0129 Lost Communication with Skid Control ECU - ABS and traction actuator assembly (Skid control ECU) - CAN communication system ME-40 ME–39 METER – METER / GAUGE SYSTEM ON-VEHICLE INSPECTION 1. INSPECT SPEEDOMETER (a) Check the operation. (1) Using a speedometer tester (calibrated chassis dynamometer), check the speedometer indication according to the table below. Reference: mph (U.S.A.) Chassis dynamometer indication Acceptable range 20 mph 20.0 to 23.0 mph 40 mph 40.0 to 43.5 mph 60 mph 60.0 to 64.0 mph 80 mph 80.0 to 84.5 mph 100 mph 100.0 to 105.0 mph 120 mph 120.0 to 125.5 mph 140 mph 140.0 to 146.0 mph 160 mph 160.0 to 166.5 mph Reference: km/h (Canada) Chassis dynamometer indication Acceptable range Data in ( ) is for reference 20 km/h (17.5 to 21.5 km/h) 40 km/h 38.0 to 42.0 km/h 60 km/h 58.0 to 63.0 km/h 80 km/h 78.0 to 84.0 km/h 100 km/h 98.5 to 104.5 km/h 120 km/h 119.0 to 125.0 km/h 140 km/h 139.0 to 146.0 km/h 160 km/h 159.0 to 167.0 km/h 180 km/h 179.0 to 188.0 km/h 200 km/h 199.0 to 209.0 km/h 220 km/h 219.0 to 230.0 km/h 240 km/h 239.0 to 251.0 km/h NOTICE: Tire wear as well as over or under inflation will cause errors. (2) Check the deviation from the acceptable range of the speedometer indication. Reference: Less than 0.5 km/h (0.3 mph) HINT: If the indication is not as specified, go to problem symptoms table (See page ME-19). 2. INSPECT TACHOMETER (a) Connect a tune-up tachometer, and start the engine. (b) Compare the test results with the tachometer indications. DC 13.5 V, at 25°C (77°F) Tune-up tachometer indication (rpm) Acceptable range Data in ( ) is for reference 700 630 to 770 1,000 (900 to 1,100) 2,000 (1,850 to 2,150) ME ME–40 METER – METER / GAUGE SYSTEM Acceptable range Data in ( ) is for reference Tune-up tachometer indication (rpm) 3,000 2,800 to 3,200 4,000 (3,800 to 4,200) 5,000 4,800 to 5,200 6,000 (5,750 to 6,250) 7,000 6,700 to 7,300 8,000 (7,700 to 8,300) HINT: If the indication is not as specified, go to the problem symptoms table (See page ME-19). 3. INSPECT ENGINE OIL PRESSURE SWITCH (a) Disconnect the connector from the engine oil pressure switch. (b) Turn the ignition switch on (IG). (c) Ground the terminal of the wire harness side connector, then check the low oil pressure warning light or message. OK Vehicle Specification with multi-information display without multiinformation display Condition Result Turn the ignition switch on (IG) and engine idling for 10 seconds or more Warning message is displayed. Turn the ignition switch on (IG) and engine off Oil pressure warning light comes on. Turn the ignition switch on (IG) and engine idling Oil pressure warning light goes off. HINT: If the warning light or message is not displayed, go to the problem symptoms table (See page ME-19). 4. ME E128092 INSPECT MULTI-INFORMATION DISPLAY (a) Ignition switch off. (b) Press the "DISP" button and hold it down. (c) Ignition switch on (IG). OK: All the dots in the multi-information display come on. HINT: This test is also available on "ACTIVE TEST" (See page ME-32). (d) Ignition switch off to finish this test mode. HINT: If the result is not as specified, replace the combination meter assembly. ME–41 METER – METER / GAUGE SYSTEM DTC U0100 Lost Communication with ECM/PCM "A" DESCRIPTION The combination meter assembly communicates with the ECM via the CAN communication lines (CAN No. 1 Bus). DTC No. DTC Detection Conditions U0100 When either of following conditions detected: 1. Vehicle speed 5 km/h (3.1 mph) or more and IG voltage 10.5 V or more 2. No communication with ECM continues for 3 seconds or more (No communication to ECM or skid control ECU continues for 60 seconds or more) Trouble Areas • • CAN communication system ECM WIRING DIAGRAM ECM Combination Meter Assembly CANH CANH CAN Line (CAN No. 1 Bus) CANL CAN Line (CAN No. 1 Bus) CANL E124226E06 INSPECTION PROCEDURE 1 CONFIRM DTC OUTPUT (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the tester on. Clear the stored DTCs by selecting the following menu items on the tester: DIAGNOSIS / OBD / MOBD / METER / DTC INFO / CLEAR CODES. (e) Drive the vehicle at more than 5 km/h (3.1 mph) for at least 60 seconds. (f) Stop the vehicle. (g) Check for DTCs (See page CA-25). ME ME–42 METER – METER / GAUGE SYSTEM Result B A GO TO CAN COMMUNICATION SYSTEM ME Result Proceed to DTC output A (See page CA-31) DTC not output B USE SIMULATION METHOD TO CHECK ME–43 METER – METER / GAUGE SYSTEM DTC U0129 Lost Communication with Skid Control ECU DESCRIPTION The combination meter assembly communicates with the ABS and traction actuator (skid control ECU) via the CAN communication lines (CAN No. 1 Bus). DTC No. DTC Detection Conditions U0129 When either of following conditions detected: 1. 15 seconds have elapsed since engine started and IG voltage 10.5 V or more 2. No communication with ABS and traction actuator (skid control ECU) continues for 3 seconds or more (No communication with ECM or skid control ECU continues for 60 seconds or more) Trouble Areas • • ABS and traction actuator assembly (Skid control ECU) CAN communication system WIRING DIAGRAM Skid Control ECU Combination Meter Assembly CANH CANL CAN Line (CAN No. 1 Bus) CAN Line (CAN No. 1 Bus) CANH CANL E124226E07 INSPECTION PROCEDURE 1 CONFIRM DTC OUTPUT (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the tester on. Clear the stored DTCs by selecting the following menu items on the tester: DIAGNOSIS / OBD / MOBD / METER / DTC INFO / CLEAR CODES. (e) Drive the vehicle at more than 5 km/h (3.1 mph) for at least 60 seconds. (f) Stop the vehicle. (g) Check for DTCs (See page CA-25). ME ME–44 METER – METER / GAUGE SYSTEM Result B A GO TO CAN COMMUNICATION SYSTEM ME Result Proceed to DTC output A (See page CA-31) DTC not output B USE SIMULATION METHOD TO CHECK ME–45 METER – METER / GAUGE SYSTEM Entire Combination Meter does not Operate DESCRIPTION This circuit is the power source circuit for the meter. This circuit provides two types of power sources; one is a constant power source mainly used as a backup power source, and the other is a power source mainly used for signal transmission. The constant power source is mainly used as a backup power source of the meter CPU, however, it is also used for communication. If a voltage of 12 V is not applied to terminal IG+ when turn the ignition switch on (IG), the indicator will not operate. WIRING DIAGRAM E23 Ignition Switch ST/AM2 5 6 DOME Combination Meter Assembly GAUGE No. 2 13 F1 2 F1 MPX-B to Battery IG+ B 1 F1 B2 12 F1 E2 24 F1 ES C E110182E09 ME ME–46 METER – METER / GAUGE SYSTEM INSPECTION PROCEDURE 1 INSPECT COMBINATION METER ASSEMBLY (a) Disconnect the F1 connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Combination Meter Assembly Wire Harness View: Tester Connection Condition Specified Condition F1-12 (E2) - Body ground Always Below 1 Ω F1-24 (ES) - Body ground Always Below 1 Ω F1 (c) Measure the voltage according to the value(s) in the table below. Standard voltage B E2 B2 ES IG+ E123360E01 Tester Connection Condition Specified Condition F1-13 (IG+) - Body ground Turn the ignition switch on (IG) 10 to 14 V F1-1 (B2) - Body ground Always 10 to 14 V F1-2 (B) - Body ground Always 10 to 14 V NG OK REPLACE COMBINATION METER ASSEMBLY ME REPAIR OR REPLACE HARNESS OR CONNECTOR ME–47 METER – METER / GAUGE SYSTEM Speedometer Malfunction DESCRIPTION The meter CPU receives vehicle speed signals from the skid control ECU via the CAN communication lines (CAN No. 1 Bus). The vehicle speed sensor detects the voltage that varies according to the vehicle speed. The skid control ECU supplies power to the vehicle speed sensor. The skid control ECU detects vehicle speed signals based on the pulses of the voltage. WIRING DIAGRAM Skid Control ECU Combination Meter Assembly CAN Communication Line (CAN No. 1 Bus) C E128084E02 INSPECTION PROCEDURE 1 CHECK CAN COMMUNICATION SYSTEM (a) Check if CAN communication DTC is output (See page CA-25). Result Result Proceed to CAN communication DTC is not output. A CAN communication DTC is output. B (See page CA-31) B GO TO CAN COMMUNICATION SYSTEM A 2 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). ME ME–48 METER – METER / GAUGE SYSTEM (c) Turn the tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / METER / ACTIVE TEST. (e) Check the values by referring to the values in the table below. METER: Item SPEED METER Test Details Diagnostic Note 0, 40, (24), 80 (48), 120 (72), 160 (96), 200 (120) km/h (mph) - OK: Needle indication is normal. NG REPLACE COMBINATION METER ASSEMBLY OK 3 READ VALUE OF INTELLIGENT TESTER (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / METER / DATA TEST. (e) Check the values by referring to the values in the table below. METER: Item SPEED METER Measurement Item/Range (Display) Vehicle speed/Min.: 0 km/h (0 mph), Max.: 255 km/h (158 mph) Normal Condition Almost same as actual speed (When driving) Diagnostic Note If data received from the skid control ECU exceeds the range that can be displayed on the meter, the meter continues to display the maximum value of the range. OK: Vehicle speed displayed on the tester is almost the same as the actual vehicle speed measured using a speedometer tester (calibrated chassis dynamometer). NG Go to step 4 OK ME REPLACE COMBINATION METER ASSEMBLY 4 READ VALUE OF INTELLIGENT TESTER (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / ABS/TRAC/VSC / DATA LIST. ME–49 METER – METER / GAUGE SYSTEM (e) Check the values by referring to the table below. ABS/TRAC/VSC: Item Measurement Item/Range (Display) (FL/FR/RL/RR) WHEEL SPD Vehicle speed/Min.: 0 km/h (0 mph), Max.: 326 km/h (202 mph) Normal Condition Almost same as actual speed (When driving) Diagnostic Note - OK: Vehicle speed displayed on the tester is almost the same as the actual vehicle speed. NG GO TO BRAKE CONTROL SYSTEM OK 5 REPLACE SKID CONTROL ECU (a) Replace the skid control ECU to a new or a normal one. OK: The operation of the speedometer returns to normal. NG REPLACE COMBINATION METER ASSEMBLY OK END ME ME–50 METER – METER / GAUGE SYSTEM Tachometer Malfunction DESCRIPTION The meter CPU receives engine revolution signals from the ECM via the CAN communication lines (CAN No. 1 Bus). The meter CPU displays engine revolution data that is calculated based on the data received from the ECM. WIRING DIAGRAM ECM Combination Meter Assembly CAN Communication Line (CAN No. 1 Bus) C E128084E03 INSPECTION PROCEDURE 1 CHECK CAN COMMUNICATION SYSTEM (a) Check if CAN communication DTC is output (See page CA-25). Result Result Proceed to CAN communication DTC is not output. ME A CAN communication DTC is output. B (See page CA-31) B GO TO CAN COMMUNICATION SYSTEM A 2 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Turn the tester ON. ME–51 METER – METER / GAUGE SYSTEM (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / METER / ACTIVE TEST. (e) Check the values by referring to the values in the table below. METER: Item TACHO METER Test Details Diagnostic Note 0, 1,000, 2,000, 3,000, 4,000, 5,000, 6,000, 7,000, (rpm) - OK: Needle indication is normal. NG REPLACE COMBINATION METER ASSEMBLY OK 3 READ VALUE OF INTELLIGENT TESTER (ENGINE SPEED SIGNAL) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / METER / DATA LIST. (e) Check the values by referring to the values in the table below. METER: Item TACHO METER Measurement Item/Range (Display) Engine speed/Min.: 0 rpm, Max.: 12,750 rpm Normal Condition Almost same as actual engine speed (When engine is running) Diagnostic Note If data received from the ECM exceeds the range that can be displayed on the meter, the meter continues to display the maximum value of the range. OK: Engine speed displayed on the tester is almost the same as the actual engine speed. NG Go to step 4 OK REPLACE COMBINATION METER ASSEMBLY ME 4 READ VALUE OF INTELLIGENT TESTER (ENGINE SPEED SIGNAL) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / ENGINE / DATA LIST. ME–52 METER – METER / GAUGE SYSTEM (e) Check the values by referring to the table below. ENGINE: Item Measurement Item/Range (Display) ENGINE SPD Engine speed/Min.: 0 rpm, Max.: 12,800 rpm Normal Condition Almost same as actual engine speed (When engine is running) Diagnostic Note - OK: Engine speed displayed on the tester is almost the same as the actual engine speed. NG GO TO SFI SYSTEM OK 5 REPLACE ECM (a) Replace the ECM to a new or a normal one. OK: The operation of the tachometer returns to normal. NG OK END ME REPLACE COMBINATION METER ASSEMBLY ME–53 METER – METER / GAUGE SYSTEM Fuel Receiver Gauge Malfunction DESCRIPTION The meter CPU uses the fuel sender gauge assembly to determine the level of the fuel in the fuel tank. The resistance of the fuel sender gauge will vary between approximately 15 Ω with the float at the full position, and 410 Ω with the float at the empty position. The meter outputs battery voltage through two 820 Ω resistors that are mounted in parallel inside the meter ECU. The meter CPU measures the voltage between the variable resistor in the fuel sender gauge and the two resistors mounted in parallel in the meter. Voltage measured at this point will vary as the float of the fuel sender gauge is moved. The highest voltage observed should be approximately half of battery voltage. HINT: The fuel level warning light will come on when the fuel level is below 10.5 liters. WIRING DIAGRAM Combination Meter Assembly 15 FR F2 2 N10 Fuel Sender Gauge Assembly 3 16 FE F2 ECM CAN Communication Line (CAN No. 1 Bus) - Vehicle Speed Signal - ST Signal E128091E01 INSPECTION PROCEDURE 1 CHECK CAN COMMUNICATION SYSTEM (a) Check if CAN communication DTC is output (See page CA-25). Result Result Proceed to CAN communication DTC is not output A CAN communication DTC is output B (See page CA-31) B A GO TO CAN COMMUNICATION SYSTEM ME ME–54 METER – METER / GAUGE SYSTEM 2 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the tester ON. Enter following menus: DIAGNOSIS / OBD/MOBD / METER / ACTIVE TEST. (e) Check the values by referring to the table below. METER: Item Test Details Diagnostic Note FUEL GAUGE EMPTY, 1/2, FULL - OK: Needle indication is normal. NG REPLACE COMBINATION METER ASSEMBLY OK 3 READ VALUE OF INTELLIGENT TESTER (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the tester ON. Enter following menus: DIAGNOSIS / OBD/MOBD / METER / DATA LIST. (e) Check the values by referring to the table below. METER: Item FUEL GAUGE Measurement Item/Range (Display) Fuel input signal Min.: 0, Max.: 255 Normal Condition Fuel gauge indicates (F): 35 Fuel gauge indicates (3/4): 85 Fuel gauge indicates (1/2): 145 Fuel gauge indicates (3/4): 186 Fuel gauge indicates (E): 205 Diagnostic Note - OK: Fuel value signal displayed on the tester is almost the same as needle indication. NG ME OK REPAIR OR REPLACE HARNESS OR CONNECTOR Go to step 4 ME–55 METER – METER / GAUGE SYSTEM 4 CHECK HARNESS AND CONNECTOR (COMBINATION METER - FUEL SENDER GAUGE ASSEMBLY) (a) Disconnect the F2 and N10 connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Combination Meter Assembly Wire Harness View: Tester Connection F2 FR FE Fuel Sender Gauge Assembly Wire Harness View: Condition Specified Condition F2-15 (FR) - N10-2 Always Below 1 Ω F2-16 (FE) - N10-3 Always Below 1 Ω N10-2 - Body ground Always 10 kΩ or higher F2-16 - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR N10 E128085E02 OK ME ME–56 5 METER – METER / GAUGE SYSTEM INSPECT FUEL SENDER GAUGE ASSEMBLY (a) (b) (c) (d) Fuel Sender Gauge Assembly (for 2GR-FE): F Fuel Sender Gauge Assembly Wire Harness View: FE Disconnect the fuel sender gauge connector. Remove the fuel sender gauge assembly. Check that the float moves smoothly between F and E. Measure the resistance between the terminals 2 (S) and 3 (FE) of connector according to the value(s) in the table below. Standard resistance Float Level Resistance (Ω) F 13.5 to 16.5 Between E and F 13.5 to 414.5 (Gradually changes) E 405.5 to 414.5 E NG REPLACE FUEL SENDER GAUGE ASSEMBLY S Fuel Sender Gauge Assembly (for 2AZ-FE): F E E128086E01 OK 6 REPLACE COMBINATION METER ASSEMBLY (a) Replace the combination meter assembly to a new one or a normal one. OK: The operation of the combination meter assembly returns to normal. ME NG OK END REPLACE ECM ME–57 METER – METER / GAUGE SYSTEM Engine Coolant Temperature Receiver Gauge Malfunction DESCRIPTION The meter CPU receives engine coolant temperature signals from the ECM via the CAN communication lines (CAN No. 1 Bus). The meter CPU displays engine coolant temperature that is calculated based on the data received from the ECM. WIRING DIAGRAM ECM Combination Meter Assembly CAN Communication Line (CAN No. 1 Bus) C4 E.F.I. Engine Coolant Temperature Sensor 97 THW C24 (*1) 96 ETHW C24 (*1) 79 C55 (*2) 78 C55 (*2) 2 1 *1: for 2AZ-FE *2: for 2GR-FE C E128087E02 INSPECTION PROCEDURE HINT: If there is an open or short in the engine coolant temperature sensor circuit, the ECM outputs the DTCs. Perform troubleshooting with the "SFI System" (See page ES-38 for 2AZ-FE, ES-63 for 2GR-FE). 1 CHECK CAN COMMUNICATION SYSTEM (a) Check if CAN communication DTC is output (See page CA-25). Result Result Proceed to CAN communication DTC is not output. A CAN communication DTC is output. B (See page CA-31) B A GO TO CAN COMMUNICATION SYSTEM ME ME–58 2 METER – METER / GAUGE SYSTEM PERFORM ACTIVE TEST BY INTELLIGENT TESTER (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / METER / ACTIVE TEST. (e) Check the values by referring to the values in the table below. METER: Item Test Details Diagnostic Note COOLANT TEMP LOW, NORMAL, HI - OK: Needle indication is normal. NG REPLACE COMBINATION METER ASSEMBLY OK 3 READ VALUE OF INTELLIGENT TESTER (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / METER / DATA LIST. METER: Item COOLANT TEMP Measurement Item/Range (Display) Normal Condition Engine coolant temperature: 0°C (-40°F) to 127.5°C (284°F) After warming up: 80 to 95°C (176 to 203°F) Diagnostic Note •If -40°C (-40°F): sensor circuit open •If 140°C (284°F) or more: sensor circuit shorted OK: Engine coolant temperature value displayed on the tester is almost the same as needle indication. NG ME Go to step 4 OK REPLACE COMBINATION METER ASSEMBLY 4 READ VALUE OF INTELLIGENT TESTER (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / ENGINE / DATA LIST. METER – METER / GAUGE SYSTEM ME–59 (e) Check the values by referring to the values in the table below. ENGINE: Item WATER TEMP Measurement Item/Range (Display) Normal Condition Engine coolant temperature: 40°C (-40°F) to 140°C (284°F) 80 to 100°C (176 to 212°F): After warming up Diagnostic Note •If -40°C (-40°F): sensor circuit open •If 140°C (284°F) or more: sensor circuit shorted OK: Engine coolant temperature value displayed on the tester is almost the same as needle indication. NG GO TO SFI SYSTEM OK 5 REPLACE COMBINATION METER ASSEMBLY (a) Replace the combination meter assembly to a new or a normal one. OK: The operation of the combination meter assembly returns to normal. NG GO TO SFI SYSTEM OK END ME ME–60 METER – METER / GAUGE SYSTEM Meter Illumination is Always Dark DESCRIPTION The meter CPU receives auto dimmer signals from the main body ECU via the CAN communication lines (CAN No. 1 Bus). When the meter CPU receives an auto dimmer signal, it dims the meter illumination. The main body ECU determines whether it is daytime, twilight, or nighttime based on the waveform transmitted from the automatic light control sensor. If the main body ECU determines that it is daytime, the ECU does not send auto dimmer signals. Therefore, the meter illumination (warning and indicator lights) will not dim even if the driver accidentally turns the light control switch to the TAIL or HEAD position in daytime. WIRING DIAGRAM Main Body ECU Combination Meter Assembly CAN Communication Line (CAN No. 1 Bus) Automatic Light Control Sensor 20 CLTB E6 3 6 E11 E11 CLTB (*1) (*2) 18 CLTE E6 6 3 E11 E11 CLTE (*1) (*2) 19 CLTS E6 4 5 E11 E11 CLTS (*1) (*2) *1: with Manual A/C *2: with Automatic A/C C E128112E02 INSPECTION PROCEDURE 1 ME CHECK CAN COMMUNICATION SYSTEM (a) Check if CAN communication DTC is output (See page CA-25). Result Result Proceed to CAN communication DTC is not output. A CAN communication DTC is output. B (See page CA-31) B A GO TO CAN COMMUNICATION SYSTEM ME–61 METER – METER / GAUGE SYSTEM 2 CHECK DTC (a) Check if DTC B1244 is output (See page LI-20). Result Result Proceed to B1244 is not output A B1244 is output B (See page LI-23) B GO TO LIGHTING SYSTEM A 3 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the tester ON. Enter the following menus: DIAGNOSIS / BODY / MAIN BODY / ACTIVE TEST. (e) Check the meter illumination. MAIN BODY: Item DIMMER SIG Test Details Diagnostic Note Auto dimmer signal ON/OFF - OK: The meter illumination is dimmed when the DIMMER SIG is ON. HINT: Refer to the sensitivity setting in the customization table of the automatic light control system. (See page LI-10) NG Go to step 4 OK CHECK LIGHTING SETTING 4 REPLACE COMBINATION METER ASSEMBLY (a) Replace the combination meter assembly to a new or a normal one. OK: The operation of the combination meter assembly returns to normal. NG OK END REPLACE MAIN BODY ECU ME ME–62 METER – METER / GAUGE SYSTEM Meter Illumination does not Dim at Night DESCRIPTION The meter CPU receives auto dimmer signals from the main body ECU via the CAN communication lines (CAN No. 1 Bus). When the meter CPU receives an auto dimmer signal, it dims the meter illumination. The main body ECU determines whether it is daytime, twilight, or nighttime based on the waveform transmitted from the automatic light control sensor. If the main body ECU determines that it is daytime, the ECU does not send auto dimmer signals. Therefore, the meter illumination (warning and indicator lights) will not dim even if the driver accidentally turns the light control switch to the TAIL or HEAD position in daytime. WIRING DIAGRAM Main Body ECU Combination Meter Assembly CAN Communication Line (CAN No. 1 Bus) Automatic Light Control Sensor 20 CLTB E6 3 6 E11 E11 CLTB (*1) (*2) 18 CLTE E6 6 3 E11 E11 CLTE (*1) (*2) 19 CLTS E6 4 5 E11 E11 CLTS (*1) (*2) *1: with Manual A/C *2: with Automatic A/C C E128112E02 INSPECTION PROCEDURE 1 ME CHECK CAN COMMUNICATION SYSTEM (a) Check if CAN communication DTC is output (See page CA-25). Result Result Proceed to CAN communication DTC is not output. A CAN communication DTC is output. B (See page CA-31) B A GO TO CAN COMMUNICATION SYSTEM ME–63 METER – METER / GAUGE SYSTEM 2 CHECK DTC (a) Check if DTC B1244 is output (See page LI-20). Result Result Proceed to B1244 is not output A B1244 is output B (See page LI-23) B GO TO LIGHTING SYSTEM A 3 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the tester ON. Enter the following menus: DIAGNOSIS / BODY / MAIN BODY / ACTIVE TEST. (e) Check the meter illumination. MAIN BODY: Item DIMMER SIG Test Details Diagnostic Note Auto dimmer signal ON/OFF - OK: The meter illumination is dimmed when the DIMMER SIG is ON. HINT: Refer to the sensitivity setting in the customization table of the automatic light control system. (See page LI-12) NG Go to step 4 OK CHECK LIGHTING SETTING 4 REPLACE COMBINATION METER ASSEMBLY (a) Replace the combination meter assembly to a new or a normal one. OK: The operation of the combination meter assembly returns to normal. NG OK END REPLACE MAIN BODY ECU RH ME METER – COMBINATION METER ME–61 COMBINATION METER BODY ELECTRICAL METER COMPONENTS with Smart Key System: NO. 1 INSTRUMENT PANEL SUB-ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL without Smart Key System: COWL SIDE TRIM SUB-ASSEMBLY LH LOWER INSTRUMENT PANEL FINISH PANEL COWL SIDE TRIM CLIP STEERING COLUMN COVER 2.0 (20, 18 in.*lbf) ME FRONT DOOR SCUFF PLATE LH LOWER INSTRUMENT PANEL FINISH PANEL LH N*m (kgf*cm, ft.*lbf) : Specified torque E127998E01 ME–62 METER – COMBINATION METER COMBINATION METER ASSEMBLY INSTRUMENT CLUSTER FINISH PANEL COMBINATION METER GLASS ME E127999E01 ME–70 METER – FUEL SENDER GAUGE ASSEMBLY (for 2AZ-FE) FUEL SENDER GAUGE ASSEMBLY (for 2AZ-FE) BODY ELECTRICAL METER COMPONENTS REAR SEAT CUSHION ASSEMBLY REAR FLOOR SERVICE HOLE COVER FUEL PUMP TUBE SUB-ASSEMBLY CLIP 5.9 (60, 52 in.*lbf) x8 FUEL TANK VENT TUBE SET PLATE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE GASKET ME FUEL SENDER GAUGE ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part E131811E01 METER – FUEL SENDER GAUGE ASSEMBLY (for 2AZ-FE) ME–71 REMOVAL 1. DISCHARGE FUEL SYSTEM PRESSURE HINT: (See page FU-1) 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment (See page RS-1). 3. REMOVE REAR SEAT CUSHION ASSEMBLY (for Fixed Seat Type) (See page SE-77) 4. REMOVE REAR SEAT CUSHION ASSEMBLY (for Fold Down Seat Type) (See page SE-47) 5. REMOVE REAR SEAT CUSHION ASSEMBLY (for Reclining Seat Type) (See page SE-62) 6. REMOVE REAR FLOOR SERVICE HOLE COVER (See page FU-23) 7. SEPARATE FUEL PUMP TUBE SUB-ASSEMBLY (See page FU-23) 8. REMOVE FUEL TANK VENT TUBE SET PLATE (See page FU-24) 9. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE (See page FU-24) 10. REMOVE FUEL SENDER GAUGE ASSEMBLY (See page FU-24) INSPECTION Fuel Sender Gauge Assembly: 1. F E Fuel Sender Gauge Assembly WIre Harness View: FE S INSPECT FUEL SENDER GAUGE ASSEMBLY (a) Remove the fuel sender gauge assembly. (b) Check that the float moves smoothly between F and E. (c) Measure the resistance between the terminals 2 (S) and 3 (FE) of connector according to the value(s) in the table below. Standard resistance Float Level Resistance (Ω) F 13.5 to 16.5 Between E and F 13.5 to 414.5 (Gradually changes) E 405.5 to 414.5 HINT: If the value is not as specified, replace the fuel sender gauge assembly. E132666E01 ME ME–72 METER – FUEL SENDER GAUGE ASSEMBLY (for 2AZ-FE) INSTALLATION 1. INSTALL FUEL SENDER GAUGE ASSEMBLY (See page FU-30) 2. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE (See page FU-30) 3. INSTALL FUEL TANK VENT TUBE SET PLATE (See page FU-31) 4. CONNECT FUEL PUMP TUBE SUB-ASSEMBLY (See page FU-31) 5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 6. CHECK FOR FUEL LEAKS (See page FU-8) 7. INSTALL REAR FLOOR SERVICE HOLE COVER (See page FU-31) 8. INSTALL REAR SEAT CUSHION ASSEMBLY (for Fixed Seat Type) (See page SE-84) 9. INSTALL REAR SEAT CUSHION ASSEMBLY (for Fold Down Seat Type) (See page SE-58) 10. INSTALL REAR SEAT CUSHION ASSEMBLY (for Reclining Seat Type) (See page SE-73) ME METER – COMBINATION METER ME–63 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment (See page RS-1). 2. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-24) 3. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-25) 4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (a) Remove the screw and the bolt. (b) Disconnect the hood lock control cable assembly. (c) Disengage the claw and the 9 clips. (d) Remove the air hose, disconnect the connector, and then remove the lower instrument panel finish panel LH. 5. REMOVE STEERING COLUMN COVER (a) Turn the steering wheel assembly to the right and remove the screw as shown in the illustration. B133980 E128001 ME ME–64 METER – COMBINATION METER (b) Turn the steering wheel assembly to the left and remove the screw as shown in the illustration. E128002 (c) Disengage the 2 claws and remove the steering column cover lower. E128003 (d) Disengage the claw and remove the steering column cover upper. ME E128005 6. REMOVE NO. 1 INSTRUMENT PANEL SUBASSEMBLY (See page IP-22) 7. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (w/o Smart Key System) (See page IP-22) 8. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (w/ Smart Key System) (See page IP-22) METER – COMBINATION METER 9. Guide ME–65 REMOVE INSTRUMENT CLUSTER FINISH PANEL (a) Remove the 2 clips. (b) Disengage the guide and the 4 claws, and then remove the instrument cluster finish panel. E128011E01 10. REMOVE COMBINATION METER ASSEMBLY (a) Remove the 4 screws. E128006 (b) Disconnect the 2 connectors. (c) Disengage the wire harness from the combination meter assembly. ME E128007 ME–66 METER – COMBINATION METER (d) Remove the combination meter assembly as shown in the illustration. E128009 DISASSEMBLY 1. REMOVE COMBINATION METER GLASS (a) Disengage the 6 claws and remove the combination meter glass. E128000 REASSEMBLY 1. E128000 ME INSTALL COMBINATION METER GLASS (a) Engage the 6 claws and install the combination meter glass. METER – COMBINATION METER ME–67 INSTALLATION 1. INSTALL COMBINATION METER ASSEMBLY (a) Connect the 2 connectors as shown in the illustration. (b) Secure the wire harness to the combination meter assembly. E128008 (c) Install the combination meter assembly as shown in the illustration. E128010 (d) Install the 4 screws. ME E128006 ME–68 Guide METER – COMBINATION METER 2. INSTALL INSTRUMENT CLUSTER FINISH PANEL (a) Engage the 4 claws and the guide. (b) Install the instrument cluster finish panel with the 2 clips. 3. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/o Smart Key System) (See page IP-57) 4. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/ Smart Key System) (See page IP-57) 5. INSTALL NO. 1 INSTRUMENT PANEL SUBASSEMBLY (See page IP-57) 6. INSTALL STEERING COLUMN COVER (a) Engage the claw and install the upper steering column cover. E128011E01 E128005 (b) Engage the 2 claws. (c) Install the lower steering column cover with the 2 screws. Torque: 2.0 N*m (20 kgf*cm, 18 in.*lbf) 7. ME E128004 INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (a) Install the air hose and connect the connector. METER – COMBINATION METER ME–69 (b) Engage the claw and the 9 clips. (c) Connect the hood lock control cable assembly. (d) Install the lower instrument panel finish panel LH with the screw and bolt. 8. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-54) 9. INSTALL FRONT DOOR SCUFF PLATE LH (See page IR-54) 10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL B133980 ME METER – FUEL SENDER GAUGE ASSEMBLY (for 2GR-FE) ME–73 FUEL SENDER GAUGE ASSEMBLY (for 2GR-FE) BODY ELECTRICAL METER COMPONENTS REAR SEAT CUSHION ASSEMBLY REAR FLOOR SERVICE HOLE COVER FUEL PUMP TUBE SUB-ASSEMBLY TUBE JOINT CLIP 5.9 (60, 52 in.*lbf) x8 FUEL TANK VENT TUBE SET PLATE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE GASKET ME FUEL SENDER GAUGE ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part E133616E01 ME–74 METER – FUEL SENDER GAUGE ASSEMBLY (for 2GR-FE) REMOVAL 1. DISCHARGE FUEL SYSTEM PRESSURE HINT: (See page FU-1) 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment (See page RS-1). 3. REMOVE REAR SEAT CUSHION ASSEMBLY (for Fixed Seat Type) (See page SE-77) 4. REMOVE REAR SEAT CUSHION ASSEMBLY (for Fold Down Seat Type) (See page SE-47) 5. REMOVE REAR SEAT CUSHION ASSEMBLY (for Reclining Seat Type) (See page SE-62) 6. REMOVE REAR FLOOR SERVICE HOLE COVER (See page FU-27) 7. SEPARATE FUEL PUMP TUBE SUB-ASSEMBLY (See page FU-27) 8. REMOVE FUEL TANK VENT TUBE SET PLATE (See page FU-28) 9. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE (See page FU-28) 10. REMOVE FUEL SENDER GAUGE ASSEMBLY (See page FU-28) INSPECTION Fuel Sender Gauge Assembly: 1. F E Fuel Sender Gauge Assembly Wire Harness VIew: Float Level ME FE INSPECT FUEL SENDER GAUGE ASSEMBLY (a) Remove the fuel sender gauge assembly. (b) Check that the float moves smoothly between F and E. (c) Measure the resistance between the terminals 2 (S) and 3 (FE) of connector according to the value(s) in the table below. Standard resistance S Resistance (Ω) F 13.5 to 16.5 Between E and F 13.5 to 414.5 (Gradually changes) E 405.5 to 414.5 HINT: If the value is not as specified, replace the fuel sender gauge assembly. E132667E01 METER – FUEL SENDER GAUGE ASSEMBLY (for 2GR-FE) ME–75 INSTALLATION 1. INSTALL FUEL SENDER GAUGE ASSEMBLY (See page FU-31) 2. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE (See page FU-32) 3. INSTALL FUEL TANK VENT TUBE SET PLATE (See page FU-32) 4. CONNECT FUEL PUMP TUBE SUB-ASSEMBLY (See page FU-33) 5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 6. CHECK FOR FUEL LEAKS (See page FU-8) 7. INSTALL REAR FLOOR SERVICE HOLE COVER (See page FU-33) 8. INSTALL REAR SEAT CUSHION ASSEMBLY (for Fixed Seat Type) (See page SE-84) 9. INSTALL REAR SEAT CUSHION ASSEMBLY (for Fold Down Seat Type) (See page SE-58) 10. INSTALL REAR SEAT CUSHION ASSEMBLY (for Reclining Seat Type) (See page SE-73) ME ME–76 METER – ENGINE OIL PRESSURE SWITCH ENGINE OIL PRESSURE SWITCH ON-VEHICLE INSPECTION 1. ME INSPECT ENGINE OIL PRESSURE SWITCH ASSEMBLY (a) Disconnect the connector from the oil pressure switch assembly. (b) With the switch still installed, measure the resistance between the terminal of the engine oil pressure switch and engine ground. Standard resistance: Engine stopped: Below 1 Ω Engine idling: 10 kΩ or higher HINT: If the value is not as specified, replace the engine oil pressure switch. ME–77 METER – STEERING PAD SWITCH STEERING PAD SWITCH BODY ELECTRICAL METER COMPONENTS for 4 Spoke: STEERING PAD 2.4 (24, 21 in.*lbf) NO. 3 LOWER STEERING WHEEL COVER STEERING PAD SWITCH LH 8.8 (90, 78 in.*lbf) NO. 2 LOWER STEERING WHEEL COVER STEERING PAD ME 2.4 (24, 21 in.*lbf) NO. 3 LOWER STEERING WHEEL COVER 8.8 (90, 78 in.*lbf) STEERING PAD SWITCH ASSEMBLY NO. 2 LOWER STEERING WHEEL COVER N*m (kgf*cm, ft.*lbf) : Specified torque E129172E02 ME–78 METER – STEERING PAD SWITCH for 3 Spoke: STEERING PAD 2.4 (24, 21 in.*lbf) STEERING PAD SWITCH LH NO. 3 LOWER STEERING WHEEL COVER NO. 2 LOWER STEERING WHEEL COVER 8.8 (90, 78 in.*lbf) STEERING PAD 2.4 (24, 21 in.*lbf) STEERING PAD SWITCH ASSEMBLY ME NO. 3 LOWER STEERING WHEEL COVER 8.8 (90, 78 in.*lbf) NO. 2 LOWER STEERING WHEEL COVER N*m (kgf*cm, ft.*lbf) : Specified torque E129201E02 METER – STEERING PAD SWITCH ME–79 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment (See page RS-1). 2. REMOVE LOWER NO. 3 STEERING WHEEL COVER (See page RS-349) 3. REMOVE LOWER NO. 2 STEERING WHEEL COVER (See page RS-349) 4. REMOVE STEERING PAD (See page RS-350) 5. REMOVE STEERING PAD SWITCH LH (for 4 Spoke) (a) Disconnect the pad switch connector from the spiral cable. (b) Remove the screw. (c) Disengage the 2 pins and remove the steering pad switch LH. 6. REMOVE STEERING PAD SWITCH ASSEMBLY (for 4 Spoke) (a) Disconnect the pad switch connector from the spiral cable. (b) Remove the screw. (c) Disengage the 2 pins and remove the steering pad switch. Pin E129186E01 Pin E129186E01 (d) Remove the screw. (e) Disengage the 2 pins and remove the steering pad switch assembly. ME Pin E129977E01 ME–80 Pin METER – STEERING PAD SWITCH 7. REMOVE STEERING PAD SWITCH LH (for 3 Spoke) (a) Disconnect the pad switch connector from the spiral cable and disengage the clamp. (b) Remove the screw. (c) Disengage the 2 pins and remove the steering pad switch LH. 8. REMOVE STEERING PAD SWITCH ASSEMBLY (for 3 Spoke) (a) Disconnect the pad switch connector from the spiral cable. (b) Disengage the clamp and remove the screw. (c) Disengage the 2 pins and remove the steering pad switch. Clamp E129202E02 Pin Clamp E129971E02 (d) Disengage the clamp and remove the screw. (e) Disengage the 2 pins and remove the steering pad switch assembly. Pin Clamp E129203E01 ME ME–81 METER – STEERING PAD SWITCH INSPECTION 1. INSPECT STEERING PAD SWITCH (a) Disconnect the steering pad switch connector. 4 Spoke Model: EAU DISP E128142E01 (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition DISP - EAU DISP switch is not pushed in. DISP - EAU DISP switch is pushed in. Specified Condition 10 kΩ or higher Below 1 Ω HINT: • This inspection is needed only for 4 spoke model steering pad switch. • If the value is not as specified, replace the steering pad switch. INSTALLATION 1. Pin E129977E01 INSTALL STEERING PAD SWITCH ASSEMBLY (for 4 Spoke) (a) Engage the 2 pins and install the steering pad switch assembly. (b) Install the screw. Torque: 2.4 N*m (24 kgf*cm, 21 in.*lbf) ME ME–82 METER – STEERING PAD SWITCH (c) Engage the 2 pins and install the steering pad switch assembly. (d) Install the screw. Torque: 2.4 N*m (24 kgf*cm, 21 in.*lbf) (e) Connect the connector to the spiral cable. Pin E129186E01 2. INSTALL STEERING PAD SWITCH LH (for 4 Spoke) (a) Engage the 2 pins and install the steering pad switch LH. (b) Install the screw. Torque: 2.4 N*m (24 kgf*cm, 21 in.*lbf) (c) Connect the connector to the spiral cable. 3. INSTALL STEERING PAD SWITCH ASSEMBLY (for 3 Spoke) (a) Engage the 2 pins and install the steering pad switch assembly. (b) Install the screw and engage the clamp. Torque: 2.4 N*m (24 kgf*cm, 21 in.*lbf) Pin E129186E01 Pin Clamp E129203E01 (c) Engage the 2 pins and install the steering pad switch assembly. (d) Install the screw and engage the clamp. Torque: 2.4 N*m (24 kgf*cm, 21 in.*lbf) (e) Connect the connector to the spiral cable. Pin Clamp E129971E02 ME Pin Clamp E129202E02 4. INSTALL STEERING PAD SWITCH LH (for 3 Spoke) (a) Engage the 2 pins and install the steering pad switch LH. (b) Install the screw and engage the clamp. Torque: 2.4 N*m (24 kgf*cm, 21 in.*lbf) (c) Connect the connector to the spiral cable. 5. INSTALL STEERING PAD (See page RS-350) 6. INSTALL LOWER NO. 3 STEERING WHEEL COVER (See page RS-351) METER – STEERING PAD SWITCH ME–83 7. INSTALL LOWER NO. 2 STEERING WHEEL COVER (See page RS-352) 8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 9. INSPECT SRS WARNING LIGHT (See page RS-352) ME LU–1 2GR-FE LUBRICATION – LUBRICATION SYSTEM LUBRICATION SYSTEM ON-VEHICLE INSPECTION 1. CHECK ENGINE OIL LEVEL (a) Warm up the engine, stop it and wait 5 minutes. The oil level should be between the dipstick's low level mark and full level mark. If low, check for leakage and add oil up to the full level mark. NOTICE: Do not fill above the full level mark. 2. CHECK ENGINE OIL QUALITY (a) Check the oil for deterioration, water contamination, discoloring or thinning. If the quality is visibly poor, replace the oil. Oil grade: Use ILSAC multigrade engine oil. SAE 5W-30 engine oil may be used. However, SAE 5W-30 is the best choice for good fuel economy and good starting in cold weather. 3. CHECK OIL PRESSURE (a) Remove the engine under cover LH. (b) Remove the engine under cover RH. (c) Disconnect the oil pressure switch connector. Recommended Viscosity (SAE) 5W-30 °C -29 -18 °F -20 0 -7 20 4 40 16 60 27 38 80 100 A066623E21 (d) Using a 24 mm deep socket wrench, remove the oil pressure switch. A127994 (e) Install the oil pressure gauge with adapter. (f) Warm up the engine. (g) Measure the oil pressure. Standard oil pressure A127995 Engine Condition Oil Pressure Idle 80 kPa (0.8 kgf*cm2, 11.6 psi) or more 6,000 rpm 380 kPa (3.9 kgf*cm2, 55.5 psi) or more If the oil pressure is not as specified, check the oil pump (See page LU-13). LU LU–2 2GR-FE LUBRICATION – LUBRICATION SYSTEM (h) Remove the oil pressure gauge. (i) Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent Adhesive A050082E14 (j) A127994 LU Using a 24 mm deep socket wrench, install the oil pressure switch. Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) NOTICE: Do not start the engine within 1 hour after installation. (k) Connect the oil pressure switch connector. (l) Check for engine oil leaks. (m) Remove the engine under cover RH. (n) Remove the engine under cover LH. 2GR-FE LUBRICATION – OIL FILTER LU–3 OIL FILTER 2GR-FE LUBRICATION ENGINE COMPONENTS OIL FILTER ELEMENT O-RING 25 (255, 18) OIL FILTER CAP ASSEMBLY 13 (127, 10) OIL FILTER DRAIN PLUG Non-reusable part N*m (kgf*cm, ft.*lbf) : Specified torque A133361E01 LU LU–4 2GR-FE LUBRICATION – OIL FILTER REPLACEMENT CAUTION: • Prolonged and repeated contact with engine oil will result in the removal of natural oils from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. • Precautions should be taken when replacing engine oil to minimize the risk of your skin making contact with used engine oil. Protective clothing and gloves that cannot be penetrated by oil should be worn. The skin should be washed with soap and water, or use water-less hand cleaner, to remove any used engine oil thoroughly. Do not use gasoline, thinners, or solvents. • In order to preserve the environment, used oil and used oil filters must be disposed of at designated disposal sites. Pipe 1. DRAIN ENGINE OIL (a) Remove the oil filler cap. (b) Remove the oil drain plug and drain the oil into a container. 2. REMOVE OIL FILTER ELEMENT (a) Connect the hose with an inside diameter of 15 mm (0.59 in.) to the pipe. Hose A127996E01 (b) Remove the oil filter drain plug from the oil filter cap. LU A127997 2GR-FE LUBRICATION – OIL FILTER LU–5 (c) Insert the pipe with the hose into the oil filter cap. NOTICE: Be sure to insert the pipe with the O-ring installed on the oil filter cap side. HINT: Place the hose end into a container before draining the oil from the hose. Cap O-Ring Pipe A127998E02 (d) Make sure that oil is completely drained, and remove the pipe and O-ring. HINT: Be sure to turn the pipe in the direction of the arrow to remove it. A127999 (e) Using SST, remove the oil filter cap. SST 09228-06501 SST A128000E01 (f) Oil Filter Element Oil Filter Cap Remove the oil filter element and O-ring from the oil filter cap. NOTICE: Do not use any tools to remove the O-ring in order to prevent the cap from being damaged. Be sure to remove it by hand. LU O-Ring A128001E01 Oil Filter Element Oil Filter Cap O-Ring A128001E02 3. INSTALL OIL FILTER ELEMENT (a) Clean the inside of the oil filter cap, threads, and Oring groove. (b) Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap. NOTICE: Make sure that the O-ring does not get twisted on the groove. (c) Install a new oil filter element to the oil filter cap. LU–6 2GR-FE LUBRICATION – OIL FILTER (d) Remove all dirt and foreign matter from the installation surface and the inside of the cap on the engine side. (e) Apply a light coat of engine oil to the O-ring again and install the oil filter cap. NOTICE: Make sure that the O-ring does not get caught between the parts. (f) Using SST, install the oil filter cap. SST 09228-06501 Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) NOTICE: Make sure that there is no clearance between the parts after tightening the oil filter cap. SST A128002E01 (g) Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap. NOTICE: Remove all dirt and foreign matter from the installation surface. (h) Install the oil filter drain plug to the oil filter cap. Torque: 13 N*m (127 kgf*cm, 10 ft.*lbf) NOTICE: Make sure that the O-ring does not get caught between the parts. O-Ring A128003E01 4. ADD ENGINE OIL (a) Clean and install the oil drain plug with a new gasket Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) (b) Add new oil. Standard capacity Item LU Standard Condition Drain and refill with oil filter change 6.1 liters (6.4 US qts, 5.4 lmp. qts) Drain and refill without oil filter change 5.7 liters (6.0 US qts, 5.0 lmp. qts) Dry fill 6.5 liters (6.9 US qts, 5.7 lmp. qts) (c) Install the oil filler cap. 5. CHECK FOR ENGINE OIL LEAKS (a) Start the engine. Check for engine oil leaks from the connected parts of the oil filter cap and oil filter drain plug. LU–7 2GR-FE LUBRICATION – OIL PUMP OIL PUMP 2GR-FE LUBRICATION ENGINE COMPONENTS OIL LEVEL GAUGE OIL STRAINER SUB-ASSEMBLY NO. 2 OIL LEVEL GAUGE GUIDE GASKET 10 (102, 7) 21 (214, 15) x2 10 (102, 7) 21 (214, 15) GASKET O-RING 21 (214, 15) NO. 1 OIL LEVEL GAUGE GUIDE OIL PAN SUB-ASSEMBLY x2 21 (214, 15) x14 10 (102, 7) 21 (214, 15) LU GASKET NO. 2 OIL PAN SUB-ASSEMBLY 40 (408, 30) OIL PAN DRAIN PLUG x2 10 (102, 7) N*m (kgf*cm, ft.*lbf) : Specified torque x16 10 (102, 7) Non-reusable part A141061E01 LU–8 2GR-FE LUBRICATION – OIL PUMP SEAL WASHER CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1) 10 (102, 7) 10 (102, 7) CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2) 21 (214, 15) x9 10 (102, 7) 10 (102, 7) SEAL WASHER x8 OIL CONTROL VALVE FILTER RH CYLINDER HEAD COVER GASKET 21 (214, 15) x3 GASKET GASKET GASKET CYLINDER HEAD COVER GASKET GASKET OIL PIPE GASKET GASKET NO. 1 OIL PIPE 65 (663, 48) UNION BOLT GASKET 10 (102, 7) GASKET O-RING 65 (663, 48) UNION BOLT OIL CONTROL VALVE FILTER LH LU O-RING WATER INLET HOUSING 10 (102, 7) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A140735E01 2GR-FE LUBRICATION – OIL PUMP TIMING CHAIN COVER SUB-ASSEMBLY LU–9 OIL PUMP GASKET 43 (438, 32) TIMING CHAIN CASE OIL SEAL 21 (214, 15) x22 250 (2,550, 184) CRANKSHAFT PULLEY N*m (kgf*cm, ft.*lbf) : Specified torque * 21 (214, 15) Non-reusable part * DO NOT apply oil A132051E03 LU LU–10 2GR-FE LUBRICATION – OIL PUMP TIMING CHAIN COVER SUB-ASSEMBLY OIL PUMP ROTOR SET DRIVEN ROTOR DRIVE ROTOR OIL PUMP COVER LU x3 OIL PUMP RELIEF VALVE x5 RELIEF VALVE SPRING 49 (500, 37) 9.1 (93, 81 in.*lbf) PLUG N*m (kgf*cm, ft.*lbf) : Specified torque A132054E05 2GR-FE LUBRICATION – OIL PUMP LU–11 REMOVAL 1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (See page EM-29) 2. SECURE ENGINE (See page EM-30) 3. REMOVE INTAKE AIR SURGE TANK ASSEMBLY (See page FU-13) 4. REMOVE IGNITION COIL ASSEMBLY (See page EM32) 5. REMOVE NO. 2 ENGINE MOUNTING STAY RH (See page EM-32) 6. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH (See page EM-32) 7. REMOVE OIL LEVEL GAUGE GUIDE SUBASSEMBLY (See page EM-33) 8. REMOVE NO. 2 MANIFOLD STAY (See page EM-33) 9. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR (See page EM-33) 10. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH (See page EM-33) 11. REMOVE ENGINE MOUNTING BRACKET RH (See page EM-33) 12. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (See page EM-34) 13. REMOVE NO. 2 TIMING GEAR COVER (See page EM34) 14. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY (See page EM-34) 15. REMOVE WATER PUMP PULLEY (See page CO-8) 16. REMOVE RADIO SETTING CONDENSER (See page EM-35) 17. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY (See page EM-35) 18. REMOVE NO. 1 OIL PIPE (See page EM-65) 19. REMOVE OIL PIPE (See page EM-65) 20. REMOVE CRANKSHAFT PULLEY (See page EM-67) 21. REMOVE NO. 1 ENGINE MOUNTING BRACKET FRONT LH (See page EM-68) 22. REMOVE WATER INLET HOUSING (See page EM-68) 23. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1) (See page EM-69) 24. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2) (See page EM-69) LU LU–12 2GR-FE LUBRICATION – OIL PUMP 25. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY (See page EM-70) 26. REMOVE OIL STRAINER SUB-ASSEMBLY (See page EM-70) 27. REMOVE OIL PAN SUB-ASSEMBLY (See page EM70) 28. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY (a) Remove the 23 bolts and 2 nuts as shown in the illustration. A128004 (b) Remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the cylinder head, cylinder block and chain cover. HINT: Tape the screwdriver tip before use. Protective Tape Protective Tape LU A129690E02 (c) Remove the gasket. A128006E01 2GR-FE LUBRICATION – OIL PUMP LU–13 29. REMOVE TIMING CHAIN CASE OIL SEAL (a) Using a screwdriver, pry out the oil seal. HINT: Tape the screwdriver tip before use. Protective Tape Wooden Block A128007E01 DISASSEMBLY 1. REMOVE OIL PUMP RELIEF VALVE (a) Using a 27 mm socket wrench, remove the relief valve plug. (b) Remove the valve spring and oil pump relief valve. 2. REMOVE OIL PUMP COVER (a) Remove the 8 bolts, oil pump cover and oil pump rotor set. A128008 A128009 INSPECTION 1. INSPECT OIL PUMP RELIEF VALVE (a) Coat the relief valve with engine oil and check that it falls smoothly into the valve hole under its own weight. If the valve does not fall smoothly, replace the relief valve. If necessary, replace the oil pump assembly. A094628 2. Mark A128010E01 INSPECT OIL PUMP ROTOR SET (a) Install the rotors to the timing chain cover with the rotors' marks facing outward. Check that the rotors revolve smoothly. LU LU–14 2GR-FE LUBRICATION – OIL PUMP (b) Check the tip clearance. (1) Using a feeler gauge, measure the clearance between the drive and driven rotors, as shown in the illustration. Tip clearance Standard Maximum 0.060 to 0.160 mm (0.0024 to 0.0063 in.) 0.16 mm (0.0063 in.) If the clearance is greater than the maximum, replace the drive and driven rotors. A128011 (c) Check the side clearance. (1) Using a feeler gauge and precision straightedge, measure the clearance between the rotors and precision straightedge, as shown in the illustration. Side clearance Standard Maximum 0.030 to 0.090 mm (0.0012 to 0.0035 in.) 0.090 mm (0.0035 in.) If the side clearance is greater than the maximum, replace the timing chain cover. A128012 (d) Check the body clearance. (1) Using a feeler gauge, measure the clearance between the timing chain cover and driven rotor, as shown in the illustration. Body clearance Standard Maximum 0.250 to 0.325 mm (0.0098 to 0.0128 in.) 0.325 mm (0.0128 in.) If the body clearance is greater than the maximum, replace the timing chain cover. A128013 REASSEMBLY Mark 1. LU INSTALL OIL PUMP COVER (a) Coat the drive and driven rotors with engine oil and place them into the timing chain cover with the marks facing outward (oil pump cover side). Check that the rotors revolve smoothly. A128010E02 (b) Install the oil pump cover with the 8 bolts. Torque: 9.1 N*m (93 kgf*cm, 81 in.*lbf) Bolt length A A A B B B B B A094627E02 Item Length Bolt A 22 mm (0.87 in.) Bolt B 40 mm (1.58 in.) LU–15 2GR-FE LUBRICATION – OIL PUMP 2. INSTALL OIL PUMP RELIEF VALVE (a) Coat the oil pump relief valve with engine oil. (b) Insert the relief valve and relief valve spring into the oil pump cover hole. (c) Using a 27 mm socket wrench, install the plug. Torque: 49 N*m (500 kgf*cm, 37 ft.*lbf) A128008 INSTALLATION 1. INSTALL TIMING CHAIN CASE OIL SEAL (a) Using SST, tap in a new oil seal until its surface is flush with the timing chain case edge. SST 09223-22010, 09506-35010 NOTICE: • Keep the lip free from foreign matter. • Do not tap on the oil seal at an angle. • Make sure that the oil seal edge does not stick out of the timing chain case. 2. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY (a) Apply seal packing in a continuous line to the engine unit as shown in the following illustration. SST A125109E04 C C C C C LU : Seal Packing 3.0 mm or more (0.118 in.) A132228E02 LU–16 2GR-FE LUBRICATION – OIL PUMP Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter: 3.0 mm (0.118 in.) NOTICE: • Be sure to clean and degrease the contact surfaces, especially the surfaces indicated by C in the illustration. • When the contact surfaces are wet, wipe them with oil-free cloth before applying seal packing. • Install the chain cover within 3 minutes. • Do not start the engine for at least 2 hours after installing. LU LU–17 2GR-FE LUBRICATION – OIL PUMP (b) Apply seal packing in a continuous line to the timing chain cover as shown in the following illustration. Be sure to apply seal packing C C 20 mm (0.787 in.) 20 mm (0.787 in.) A A B B Be sure to apply seal packing A-A 5.0 mm (0.197 in.) 3.0 to 4.0 mm (0.118 to 0.158 in.) B-B 1.0 to 2.0 mm (0.039 to 0.079 in.) C-C 2.0 to 3.0 mm (0.079 to 0.118 in.) Dashed line area (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent) Continuous line area (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent) LU Alternate long and short dashed line area (Seal packing: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or Equivalent) Diagonal line area (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent) A134901E01 Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Toyota Genuine Seal Packing Black 1282B, Three Bond 1282B or equivalent LU–18 2GR-FE LUBRICATION – OIL PUMP NOTICE: • When the contact surfaces are wet, wipe them with oil-free cloth before applying seal packing. • Install the chain cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing. • Do not start the engine for at least 2 hours after installing. Apply seal packing as follows Area Seal Packing Diameter Application Position from Inside Seal Line Continuous Line Area 4.5 mm or more (0.177 in.) 3.0 to 4.0 mm (0.118 to 0.158 in.) Alternate Long and short Dashed Line Area 3.5 mm or more (0.138 in.) 2.0 to 3.0 mm (0.079 to 0.118 in.) Dashed Line Area 3.5 mm or more (0.138 in.) 3.0 to 4.0 mm (0.118 to 0.158 in.) Diagonal Line Area 6.0 mm or more (0.236 in.) 5.0 mm (0.197 in.) (c) Install a new gasket. A128017E01 (d) Align the oil pump's drive rotor spline and the crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft. (e) Temporarily tighten the timing chain cover with the 23 bolts and 2 nuts. Crankshaft Drive Rotor Spline A132229E02 LU Area 4 C A C C C C C B B B C B C B B C Nut Area 4 Area 4 B B B B B Area 2 C Area 1 Area 1 Area 3 B Area 3 Nut A128019E02 LU–19 2GR-FE LUBRICATION – OIL PUMP Bolt length Item Length Bolt A 40 mm (1.57 in.) Bolt B 55 mm (2.17 in.) Bolt C 25 mm (0.98 in.) NOTICE: Make sure that there is no oil on the bolt threads. (f) Fully tighten the bolts in this order: Area 1 and Area 2. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) (g) Fully tighten the bolts and nuts in this order: Area 3. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) HINT: Tighten the bolts and nuts in the order of upper to lower as shown in the illustration. (h) Fully tighten the bolts in this order: Area 4. Torque: Bolt A 43 N*m (438 kgf*cm, 32 ft.*lbf) Except bolt A 21 N*m (214 kgf*cm, 15 ft.*lbf) HINT: Tighten the bolts in the order of lower to upper as shown in the illustration. 3. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2) (See page EM-150) 4. INSTALL WATER INLET HOUSING (See page EM-144) 5. REMOVE NO. 1 ENGINE MOUNTING BRACKET FRONT LH (See page EM-38) 6. INSTALL OIL PAN SUB-ASSEMBLY (See page EM147) 7. INSTALL OIL STRAINER SUB-ASSEMBLY (See page EM-148) 8. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY (See page EM-148) 9. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1) (See page EM-149) 10. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2) (See page EM-150) 11. INSTALL CRANKSHAFT PULLEY (See page EM-151) 12. INSTALL NO. 1 OIL PIPE (See page EM-153) 13. INSTALL OIL PIPE (See page EM-153) 14. INSTALL NO. 1 VACUUM SWITCHING VALVE (See page EC-14) 15. INSTALL RADIO SETTING CONDENSER (See page EM-38) 16. INSTALL WATER PUMP PULLEY (See page CO-10) LU LU–20 2GR-FE LUBRICATION – OIL PUMP 17. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY (See page EM-39) 18. INSTALL NO. 2 TIMING GEAR COVER (See page EM39) 19. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (See page EM-39) 20. INSTALL ENGINE MOUNTING BRACKET RH (See page EM-40) 21. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH (See page EM-40) 22. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR (See page EM-40) 23. INSTALL NO. 2 MANIFOLD STAY (See page EM-41) 24. INSTALL OIL LEVEL GAUGE GUIDE SUBASSEMBLY (See page EM-41) 25. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH (See page EM-41) 26. INSTALL NO. 2 ENGINE MOUNTING STAY RH (See page EM-42) 27. INSTALL IGNITION COIL ASSEMBLY (See page EM42) 28. INSTALL INTAKE AIR SURGE TANK ASSEMBLY (See page FU-18) 29. REMOVE ENGINE STAND 30. INSTALL DRIVE PLATE AND RING GEAR SUBASSEMBLY (See page EM-13) 31. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (See page AX-214) 32. INSTALL STARTER ASSEMBLY (See page ST-148) 33. INSTALL ENGINE WIRE LU 34. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (See page DS-21) 35. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (See page DS-20) 36. INSTALL FRONT FRAME ASSEMBLY (See page EM43) 37. INSTALL VANE PUMP ASSEMBLY (See page EM-44) 38. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (See page EM-44) GARAGE DOOR OPENER – GARAGE DOOR OPENER SYSTEM GD–1 GARAGE DOOR OPENER SYSTEM SYSTEM DIAGRAM Wiring Diagram Image Garage Door, Gate or Other Transmitter Code Based System Garage Door Opener LED Signal Garage Door Opener SW 3 SW 2 SW 1 1 2 Garage Door Opener Switch DOME Battery Battery B074550E01 1. DESCRIPTION (a) A maximum of three codes for transmitter code based systems such as garage doors, gates, and entry gates can be registered to the vehicle's garage door opener system. These stored codes can then be used to activate the transmitter controlled systems. It will not be necessary to keep the original handheld transmitters in the vehicle. GD GD–2 GARAGE DOOR OPENER – GARAGE DOOR OPENER SYSTEM REGISTRATION 1. GD RESISTER TRANSMITTER CODE HINT: • The vehicle's garage door opener system records transmitter codes for systems such as garage doors, gates, door locks, home lighting systems, security systems, or other transmitter-code based systems. • The garage door opener system is built into the roof console box assembly. If the roof console box assembly is replaced, transmitter codes previously registered in the garage door opener system must be re-registered. • Ensure that the customer is aware that existing codes may be cleared from the garage door opener system while performing diagnosis of the system. All remotes required to reprogram the system should be made available at the time of inspection or repair of the garage door opener system. (a) Re-registration of codes in the garage door opener system. (registration mode) NOTICE: • When programming a garage door opener system, you may operate a garage door or other device. To prevent injury, it is necessary to make sure that people and objects are out of the way of the garage door or other device. • Before beginning programming of the garage door opener system, turn off the engine and remove the key from the ignition key cylinder. • The garage door opener system cannot be used with openers that: (1) Were manufactured before April 1, 1982. (2) Do not meet Federal Safety Standards (for example, garage doors without a jam protection function). HINT: • 3 transmitter codes can be registered with the garage door opener system. It is possible to register one handheld transmitter code (original transmitter) for each of the three garage door opener system switches. • Disconnecting the vehicle's battery will not erase the transmitter codes registered in the garage door opener system. • An attempt to overwrite a previously registered code may fail. In this case, the previously registered handheld transmitter code will not be erased. • To successfully program the garage door opener system, it may be necessary to replace the handheld transmitter battery before programming. GARAGE DOOR OPENER – GARAGE DOOR OPENER SYSTEM LED GD–3 (1) Select one of the garage door opener system switches to program. (2) Press and hold the selected switch for 20 seconds. The garage door opener system will enter registration mode. Continue to hold this switch during steps 3 and 4. HINT: The garage door opener system LED should stay on while holding the selected switch for the 20 second period. After entering registration mode, the LED will flash approximately 1 time per second (1 Hz). This indicates that the garage door opener system has entered registration mode and is listening for a code from a handheld transmitter. These Switches E129941E01 Press Handheld Transmitter E129943E01 (3) After the garage door opener system has entered registration mode, bring the original handheld transmitter within 2 to 9 cm (1 to 3 in.) of the garage door opener system. Press and hold the switch on the handheld transmitter. If the flashing speed of the garage door indicator light changes from the slow speed to a faster speed, proceed to step 4. HINT: Some handheld transmitters stop transmitting after 1 to 2 seconds. In this case, continue to hold the selected garage door opener system switch while pressing the handheld transmitter switch for two seconds at a time. Repeat the cycle of pressing and releasing the transmitter switch while monitoring for a change of the flashing speed of the indicator LED. GD GD–4 GARAGE DOOR OPENER – GARAGE DOOR OPENER SYSTEM (4) When the indicator light begins to flash more rapidly, release both switches. This indicates that the garage door opener system has been successfully programmed. If the garage door opener system fails to program, review all hints before trying the programming process again. LED These Switches E129941E01 Press Handheld Transmitter E129943E01 GD HINT: • If transmitter registration fails: (1) The battery in the handheld transmitter may be weak or need to be replaced. (2) The handheld transmitter and opener device to be registered may not be compatible with the vehicle's garage door opener system. • After entering the garage door opener system registration mode, registration of the handheld transmitter code must be completed within 90 seconds. If 90 seconds have elapsed, the garage door opener system will enter low power mode. • For first time programming it may be necessary to press and hold the two outside switches until the indicator light begins to flash rapidly. The length of time that it is necessary to hold the switches for in this case should be approximately 20 seconds. • In some cases, the garage door indicator light may flash slowly (1 time per second (1 Hz)) as soon as the selected garage door opener system switch is pressed. This indicates that the system is ready or "listening" for a code from a handheld transmitter. Continue to hold the switch and proceed from step 3. GD–5 GARAGE DOOR OPENER – GARAGE DOOR OPENER SYSTEM PRESSED Garage Door Opener Switch RELEASED Registration Mode LED Operation ENTER 20 sec. EXIT ON OFF LED flashes at a cycle of 1 Hz Handheld Transmitter ON LED flashes at a cycle of 5.6 Hz OFF I003487E14 (b) Erasure of transmitter codes in the garage door opener system. (clear mode) HINT: All three codes registered in the garage door opener system will be erased. No option exists for erasing only one transmitter code. (1) Press and hold the left and right switches of the garage door opener system for 20 seconds. The LED will begin to flash approximately 5 times per second (5.6 Hz.) This indicates that the codes contained in the vehicle garage door opener system have been erased. Releasing the switches ends clear mode. HINT: • If the switches are released within 10 seconds after the transmitter codes have been erased, the system will enter registration mode immediately the next time a garage door opener system switch is pressed. • If the switches are held for 10 seconds or more after the transmitter codes have been erased, default codes will be set to the three switches of the garage door opener system. These default codes may in some cases be used for training an opener device that uses rolling codes. GD GD–6 GARAGE DOOR OPENER – GARAGE DOOR OPENER SYSTEM (c) Low power mode: (1) If the garage door opener switch is stuck or held for 100 seconds or more, the garage door opener will enter low power mode to economize on power consumption. When the garage door opener has entered low power mode, the LED turns off. When the garage door opener switch is released, low power mode will end. 2. Example: E129942E01 GD ROLLING CODE SYSTEMS (a) If the handheld transmitter for the opener device (customer's garage door) being programmed uses a rolling code, it may be necessary to "train" the garage door opener device. HINT: • "Train" refers to causing the opener device (customer's ceiling mounted garage door opener) to recognize a non-rolling code. • The steps required to "train" an opener device may vary depending on the model, type, age, and manufacturer of the device. (1) Locate the "training" button on the opener device. (2) Press the training button. (3) Within 30 seconds press and release the vehicle's programmed "HomeLink" switch twice. Some opener devices may require the vehicle's switch to be pressed three times. (4) The vehicle's garage door opener system should now operate the opener device. HINT: Opener device refers to a device such as a ceiling mounted garage door opener, which is located at the customer's residence. It is necessary to read the instructions for the customer's opener device, to allow the above procedure to be performed safely and successfully. The customer should be aware that performing this procedure will result in a lowered level of security for the customer's opener device. GARAGE DOOR OPENER – GARAGE DOOR OPENER SYSTEM GD–7 INSPECTION 1. INSPECT GARAGE DOOR OPENER (a) To inspect the garage door opener system, press each switch and check that the LED in the "HomeLink" logo illuminates as illustrated. If one or more of the switches do not cause the LED to illuminate, confirm that the fuse and the wiring to the garage door opener system unit is normal. If the fuse and wiring are normal, and the LED does not work, replace the garage door opener system unit located in the roof console box assembly. 2. INSPECT GARAGE DOOR OPENER REGISTRATION AND TRANSMITTIMG OPERATION HINT: Use the KENT-MOORE "HomeLink" tester, and the KENT-MOORE handheld transmitter for this test. First erase the customer's transmitter codes, and then register the tester's handheld transmitter code to the garage door opener system. LED These Switches E129941E01 (a) Check if the tester's handheld transmitter code was successfully registered. HINT: If the handheld transmitter's code cannot be registered, replace the garage door opener system unit. Press Handheld Transmitter E129943E01 (b) Press the garage door opener switch that was used to copy the signal from the handheld transmitter. Check if the "HomeLink" tester's green LED illuminates. HINT: If the green LED does not illuminate, replace the garage door opener system unit that is located in the dome light No. 1. (c) When the inspection is complete, re-register the customer's handheld transmitter codes. Press HomeLink Tester GD Green LED E129944E01 GD–8 GARAGE DOOR OPENER – GARAGE DOOR OPENER SWITCH GARAGE DOOR OPENER SWITCH BODY ELECTRICAL GARAGE DOOR OPENER COMPONENTS ROOF CONSOLE BOX ASSEMBLY E128170E01 REMOVAL 1. GD B136687 REMOVE ROOF CONSOLE BOX ASSEMBLY (a) Using a moulding remover, disengage the 2 clips and the 2 claws. (b) Disconnect the connectors and remove the roof console box assembly. GARAGE DOOR OPENER – GARAGE DOOR OPENER SWITCH GD–9 INSTALLATION 1. INSTALL ROOF CONSOLE BOX ASSEMBLY (a) Connect the connectors . (b) Engage the 2 claws and the 2 clips to install the roof console box assembly. B136688 GD STEERING COLUMN – STEERING SYSTEM SR–1 STEERING SYSTEM PRECAUTION 1. 2. HANDLING PRECAUTIONS FOR STEERING SYSTEM (a) Care must be taken when replacing parts. Incorrect replacement may affect the performance of the steering system and result in driving hazards. HANDLING PRECAUTIONS FOR SRS AIRBAG SYSTEM (a) The vehicle is equipped with SRS (Supplemental Restraint System) such as airbags. Failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing. This may cause a serious accident. Before servicing (including inspection, replacement, removal and installation of parts), be sure to read the precautionary notices for the Supplemental Restraint System (See page RS-1). SR SR–2 STEERING COLUMN – STEERING SYSTEM PROBLEM SYMPTOMS TABLE HINT: Use the table below to help determine the cause of the problem. The numbers indicate likely causes of the problem in descending order. Check each part in order. If necessary, repair or replace the faulty parts. STEERING SYSTEM Symptom Hard steering Poor return Suspected area TW-3 2. Front wheel alignment (Incorrect) SP-4 3. Steering system joints (Worn) SP-28 5. Steering column (Binding) SR-38 6. Power steering gear PS-40 1. Tires (Improperly inflated) TW-3 2. Front wheel alignment (Incorrect) Abnormal noise SP-4 3. Steering column (Binding) SR-38 4. Power steering gear PS-40 2. Suspension arm ball joints (Worn) SR - 4. Suspension arm ball joints (Worn) 1. Steering system joints (Worn) Excessive free play See page 1. Tires (Improperly inflated) 3. Intermediate shaft, universal joint, sliding yoke (Worn) SP-28 - 4. Front wheel bearing (Worn) AH-5 5. Power steering gear PS-40 1. Steering system joints (Worn) 2. Power steering gear PS-40 STEERING COLUMN – STEERING SYSTEM SR–3 ON-VEHICLE INSPECTION 1. Maximum Free Play 30 mm (1.18 in.) INSPECT STEERING WHEEL FREE PLAY (a) Stop the vehicle and align the tires facing straight ahead. (b) Gently turn the steering wheel right and left by hand, and check the steering wheel free play. Maximum free play: 30 mm (1.18 in.) HINT: If the free play exceeds the maximum, check the steering column, steering intermediate shaft, steering sliding yoke, or steering gear. C132537E01 SR SR–4 STEERING COLUMN – STEERING SYSTEM ADJUSTMENT 1. STEERING OFF CENTER ADJUSTMENT PROCEDURE HINT: This is the adjustment procedure for steering off center. (a) Inspect steering wheel off center. (1) Apply masking tape on the top center of the steering wheel and steering column upper cover. (2) Drive the vehicle in a straight line for 100 meters at a constant speed of 35 mph (56 km/ h), and hold the steering wheel to maintain the course. Steering Wheel Masking Tape Upper Steering Column Cover C132538E01 SR (3) Draw a line on the masking tape as shown in the illustration. (4) Turn the steering wheel to the center position. HINT: Look at the upper surface of the steering wheel, steering spoke, and SRS airbag line to find the center position. Upper Steering Column Cover Marked Line Steering Wheel C132539E01 STEERING COLUMN – STEERING SYSTEM SR–5 (5) Draw a new line on the masking tape on the steering wheel as shown in the illustration. (6) Measure the distance between the 2 lines on the masking tape on the steering wheel. (7) Convert the measured distance to steering angle. HINT: • Measured distance 1 mm (0.04 in.) = Steering angle of approximately 1 degree. • Make a note of the steering angle. Upper Steering Column Cover Marked Line Steering Wheel C132540E01 Marked Line C132045E02 C132541 (b) Adjust steering angle. (1) Draw a line on the RH and LH tie rod ends and rack ends respectively where it can be easily seen. (2) Using a paper gauge, measure the distance from the RH and LH tie rod ends to the rack end screws. HINT: • Measure both the RH and LH sides. • Make a note of the measured values. (3) Remove the RH and LH boot clips from the rack boots. (4) Loosen the RH and LH lock nuts. (5) Turn the RH and LH rack ends by the same amount (but in different directions) according to the steering angle. HINT: One 360 degree turn of the rack end (1.5 mm (0.059 in.) horizontal movement) equals to 12 degrees of steering angle. (6) Tighten the RH and LH lock nuts to the specified torque. Torque: 74 N*m (755 kgf*cm, 55 ft.*lbf) NOTICE: Make sure that the difference in length between the RH and LH tie rod ends and rack end screws is within 1.5 mm (0.059 in.). (7) Install the RH and LH boot clips. SR SR–4 STEERING COLUMN – ELECTRIC STEERING LOCK ELECTRIC STEERING LOCK PRECAUTION 1. SR PRECAUTIONS WHEN WORKING ON ELECTRIC STEERING LOCK (a) After replacing the steering lock actuator assembly (steering lock ECU), perform the key ID code registration. (b) If the steering lock actuator assembly is replaced, open and close the driver's door. The engine may not start until the driver's door is opened or closed. HINT: Opening and closing the driver's door causes the steering lock actuator assembly (steering lock ECU) to memorize the correct steering lock bar position. (c) If checking for DTCs of the smart access system with push-button start function or if checking the DATA LIST with the engine switch off, make sure that the driver's door is open. HINT: When the engine switch is off, the main body ECU may be in a sleep mode. If the main body ECU is in this sleep mode, it will not be possible for the intelligent tester to communicate with it. Opening and closing the driver's door will cause the ECU to exit the sleep mode. STEERING COLUMN – ELECTRIC STEERING LOCK SR–5 PARTS LOCATION STEERING COLUMN ASSEMBLY - STEERING LOCK ACTUATOR ASSEMBLY (STEERING LOCK ECU) ENGINE ROOM J/B AND R/B CERTIFICATION ECU - STR LOCK FUSE - D.C.C. FUSE SR ID CODE BOX - IG2 FUSE - AM2 FUSE - IG2 RELAY INSTRUMENT PANEL J/B - MAIN BODY ECU - IGN FUSE C113501E01 SR–6 STEERING COLUMN – ELECTRIC STEERING LOCK SYSTEM DIAGRAM Enigine Switch - Transponder Key Amplifier (with Key Coil) Certification ECU Main Body ECU ID Code Box Steering Lock ECU SR ECM LIN Communication Line B126245E02 Input and output signals of each ECU: Transmitting ECU (transmitter) Receiving ECU Signals Communication Method Main Body ECU Steering Lock ECU Power supply status (to steering lock motor) Steering Lock ECU • • • Certification ECU Main Body ECU ID Code Box Sleep available status LIN Steering Lock ECU • • • Certification ECU Main Body ECU ID Code Box Lock / Unlock sensor status LIN Steering Lock ECU • • • Certification ECU Main Body ECU ID Code Box Steering lock status LIN Steering Lock ECU • • • Certification ECU Main Body ECU ID Code Box Motor control status LIN Steering Lock ECU • • • Certification ECU Main Body ECU ID Code Box Diagnostic response status LIN Steering Lock ECU • • • Certification ECU Main Body ECU ID Code Box Lock / Unlock sensor malfunction LIN LIN SR–7 STEERING COLUMN – ELECTRIC STEERING LOCK Transmitting ECU (transmitter) Receiving ECU Signals Communication Method Steering Lock ECU • • • Certification ECU Main Body ECU ID Code Box Power supply malfunction (to steering lock motor) LIN Steering Lock ECU • • • Certification ECU Main Body ECU ID Code Box Motor driver malfunction LIN Steering Lock ECU • • • Certification ECU Main Body ECU ID Code Box Lock bar (stuck) status LIN Steering Lock ECU • • • Certification ECU Main Body ECU ID Code Box Push start status LIN Steering Lock ECU • • • Certification ECU Main Body ECU ID Code Box Lock / Unlock relay drive status LIN Steering Lock ECU • • • Certification ECU Main Body ECU ID Code Box Engine start control status LIN SR SR–8 STEERING COLUMN – ELECTRIC STEERING LOCK SYSTEM DESCRIPTION 1. 2. Item SR DESCRIPTION (a) The steering lock system locks or unlocks the steering lock by activating the steering lock bar with a motor. The steering lock ECU activates the motor based on signals from the certification ECU and main body ECU. (b) A LIN (Local Interconnect Network) is used for communication between different ECUs in this system. FUNCTIONS OF COMPONENTS (a) The steering lock ECU controls the system based on information from the following components. Function Steering lock actuator assembly Consists of a motor, lock bar, lock and unlock position sensors, etc. Activated by the steering lock ECU. Steering lock ECU Included in the steering lock actuator assembly. This ECU activates the steering lock motor based on permission signals from the main body ECU and certification ECU. Detects steering lock or unlock state and transmits this status to other ECUs. Main body ECU Permits the steering lock ECU to supply power to activate the motor. The main body ECU and certification ECU permit engine start after receiving an unlock signal from the steering lock ECU. Certification ECU Orders the steering lock ECU to lock / unlock the steering. The main body ECU and certification ECU permit engine start after receiving an unlock signal from the steering lock ECU. IG2 relay Controlled by the main body ECU. This ECU sends IG signals to the steering lock ECU. STEERING COLUMN – ELECTRIC STEERING LOCK SR–9 HOW TO PROCEED WITH TROUBLESHOOTING The intelligent tester can be used at steps 2, 6, 9 and 12. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CHECK AND CLEAR DTCS NEXT 3 PROBLEM SYMPTOM CONFIRMATION SYMPTOM DOES NOT OCCUR (Go to step 4) SYMPTOM OCCURS (Go to step 5) 4 SR SYMPTOM SIMULATION NEXT 5 CHECK CAN COMMUNICATION SYSTEM HINT: Check that there are no problems in the CAN communication system before troubleshooting the steering lock system. NEXT 6 DTC CHECK DTC IS NOT OUTPUT (Go to step 7) DTC IS OUTPUT (Go to step 8) 7 PROBLEM SYMPTOMS TABLE Go to step 9 SR–10 8 STEERING COLUMN – ELECTRIC STEERING LOCK DTC CHART NEXT 9 CIRCUIT INSPECTION NEXT 10 PROBLEM IDENTIFICATION NEXT 11 REPAIR OR REPLACEMENT NEXT SR 12 NEXT END CONFIRMATION TEST STEERING COLUMN – ELECTRIC STEERING LOCK SR–11 INITIALIZATION HINT: In vehicles equipped with the smart access system with pushbutton start function, the starting function may not operate after recharging or while jump-starting a discharged battery. This condition is most common if the battery voltage drops below 9 V. The following procedure has been developed to address this condition. 1. Engine Room J/B INITIALIZATION PROCEDURE (a) Confirm that the D.C.C. fuse is installed. HINT: If the D.C.C. fuse is not installed, install it at this time. (b) Move the shift lever to the P position. (c) Turn the engine switch off. (d) Open the driver's door. HINT: Opening the driver's door will start an initialization process between the steering lock ECU and the engine room J/B. (e) Depress the brake pedal. (f) Press the "START STOP" switch. SR D.C.C Fuse C113506E01 SR–12 STEERING COLUMN – ELECTRIC STEERING LOCK PROBLEM SYMPTOMS TABLE Inspect the suspected areas in numerical order by referring to the corresponding pages when any of the following symptoms occurs: ELECTRIC STEERING LOCK FUNCTION: Symptom Steering wheel cannot be unlocked (the engine cannot be started). Steering wheel cannot be unlocked (no steering unlock command). SR Steering wheel cannot be locked. Steering wheel cannot be locked (no steering lock command). Suspected area See page 1. Initialization SR-9 2. Check for DTCs in the smart access system with pushbutton start. ST-26 3. Check for DTCs in the engine immobiliser system. EI-24 4. Check that the LCK/UNLCK REC item in the DATA LIST of the certification ECU displays YES within 10 seconds after starting the engine. (If it displays NO, see "No steering unlock" command in this table.) SR-14 5. Check the input signal from the IGE terminal of the steering lock ECU. SR-24 6. Steering lock ECU power source circuit. SR-30 7. Replace the steering lock ECU. SR-42 1. Check that the S CODE MACH item in the DATA LIST of the certification ECU displays OK. (If it displays NG, replace the ID code box.) - 2. Check that the L CODE MACH item in the DATA LIST of the certification ECU displays OK. (If it displays NG, replace the ID code box.) - 3. Replace the certification ECU. - 1. Check for DTCs in the smart access system with pushbutton start. ST-26 2. Check for DTCs in the engine immobiliser system. EI-24 3. With the engine switch off and the shift in the P position, open and close the driver's door. After that, check that the LCK/UNLCK REC item in the DATA LIST of the certification ECU displays YES within 10 seconds. (If it displays NO, see "No steering lock" command in this table.) SR-14 4. Check the input signal from the IGE terminal of the steering lock ECU. SR-24 5. Steering lock ECU power source circuit. SR-30 6. Replace the steering lock ECU. SR-42 1. Courtesy light switch circuit LI-52 2. Check that the S CODE MACH item in the DATA LIST of the certification ECU displays OK. (If it displays NG, replace the ID code box.) - 3. Check that the L CODE MACH item in the DATA LIST of the certification ECU displays OK. (If it displays NG, replace the ID code box.) - 4. Replace the certification ECU. - SR–13 STEERING COLUMN – ELECTRIC STEERING LOCK SMART ACCESS SYSTEM WITH PUSH-BUTTON START FUNCTION: Symptom Engine does not start. Engine does not start due to the engine immobiliser. Suspected area See page 1. Initialization SR-9 2. Check for DTCs in the smart access system with pushbutton start. ST-26 3. Check for DTCs in the engine immobiliser system. EI-24 4. Check that the engine switch is turned on (IG). - 5. Check cranking operation. (If cranking operation is possible, see "Engine does not start due to the engine immobiliser" in this table.) - 6. Check SHIFT P SIG in the DATA LIST of the power source control ECU and confirm that the shift signal is normal. - 7. Check whether the steering wheel is locked or unlocked. (If it is locked, see "Steering wheel cannot be unlocked" in the steering lock function table.) - 8. Check the output from the SLP terminal of the steering lock ECU. SR-28 9. Check the output signal from the ST SW of the certification ECU (DTC B2275). ST-48 10. Replace the main body ECU. - 1. Check that the L CODE MACH item in the DATA LIST of the certification ECU displays OK. (If it displays NG, replace the ID code box.) - 2. Check that the ENG START REQ item in the DATA LIST of the certification ECU displays YES. (If it displays NO, replace the certification ECU.) - 3. Check that the S CODE MACH item in the DATA LIST of the certification ECU displays OK. (If it displays NG, replace the ID code box.) - 4. Replace the ID code box. - SR SR–14 STEERING COLUMN – ELECTRIC STEERING LOCK TERMINALS OF ECU E51 C106482E05 1. Terminal No. (Symbols) Terminal Description Condition Specified Condition E51-1 (GND) - Body ground W-B - Body ground Ground Always Below 1 V E51-2 (SGND) - Body ground W-B - Body ground Signal ground Always Below 1 V E51-3 (IGE) - E51-1 (GND) SR Wiring Color STEERING LOCK ACTUATOR ASSEMBLY (STEERING LOCK ECU) BR - W-B Power source for driving motor • • Motor is in operation Motor is not in operation • • Below 1 V 10 to 12 V • • Steering is locked Steering lock is released • • 10 to 14 V Below 1 V E51-4 (SLP1) - E51-2 (SGND) P - W-B Unlock position sensor output signal E51-5 (LIN) - E51-2 (SGND) O - W-B LIN communication bus Engine switch on (IG) Pulse generation E51-6 (IG2) - E51-1 (GND) B - W-B IG signal input Engine switch on (IG) 10 to 14 V E51-7 (B) - E51-1 (GND) P - W-B Power source Always 10 to 14 V SR–15 STEERING COLUMN – ELECTRIC STEERING LOCK DIAGNOSIS SYSTEM 1. DESCRIPTION (a) DIAGNOSTIC SYSTEM When troubleshooting a vehicle with a diagnostic system, the only difference from the usual troubleshooting procedure is connecting the intelligent tester to the vehicle and reading various data output from the vehicle's steering lock ECU. The steering lock ECU records DTCs when the computer detects a malfunction in the computer itself or in system circuits. To check the DTCs, connect the intelligent tester to the DLC3 on the vehicle. The intelligent tester enables the DTCs to be cleared, the indicators to be activated, and the DATA LIST to be checked. (b) The steering lock ECU diagnosis information cannot be read directly from the steering lock ECU by the tester. The diagnosis information from the steering lock ECU is transmitted to the tester via the certification ECU to the tester using the controller area network (CAN). 2. CHECK DLC3 (a) The certification ECU uses ISO 15765-4 for communication. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. CG SG CANH SIL CANL BAT H100769E16 Symbols (Terminal No.) Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 11 to 14 V CANH (6) - CANL (14) CAN bus line Engine Switch off* 54 to 69 Ω CANH (6) - CG (4) HIGH-level CAN bus line Engine Switch off* 200 Ω or higher CANL (14) - CG (4) LOW-level CAN bus line Engine Switch off* 200 Ω or higher CANH (6) - BAT (16) HIGH-level CAN bus line Engine Switch off* 6 kΩ or higher CANL (14) - BAT (16) LOW-level CAN bus line Engine Switch off* 6 kΩ or higher NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the engine switch, and other switches or the doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. SR SR–16 STEERING COLUMN – ELECTRIC STEERING LOCK (b) Connect the cable of the intelligent tester to the DLC3, turn the engine switch on (IG) and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. • If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. Intelligent Tester DLC3 CAN VIM C131977E05 3. Indicator Light WARNING FUNCTION OF ENGINE SWITCH INDICATOR (a) The steering lock ECU blinks the LED indicator of the engine switch when any of the following problems occurs in the system: SR B083100E01 Detection Item • Steering lock is still not released • • Malfunction in smart access system with push-button start • Indicator Light Blink Pattern Indication Status Blinks green at 1-second intervals Goes off 15 seconds after blinking starts The motor operates to release the steering lock, but the steering lock cannot be released (e.g. the lock bar is stuck in the steering column). Blinks amber at 2-second intervals Goes off 15 seconds after the engine switch is turned off while blinking 4. Detection Item • • There is a short in the devices activating the motor. There is a problem in the steering lock ECU or power source control ECU. Countermeasure Push the engine switch while turning the steering wheel left or right. Troubleshoot by following "HOW TO PROCEED WITH TROUBLESHOOTING" (See page SR-7). WARNING FUNCTION OF COMBINATION METER (a) The steering lock ECU displays a warning on the combination meter when any of the following problems occurs in the system. Display Steering lock is still not released "S/T is not Unlocked" • Goes off 15 seconds after blinking starts Malfunction in push start system "Check S/T Lock" • Goes off 15 seconds after the engine switch is turned off while blinking Indication Status The motor operates to release the steering lock, but the steering lock cannot be released (e.g. the lock bar is stuck in the steering column). • • There is a short in the devices activating the motor. There is a problem in the steering lock ECU or power source control ECU. Countermeasure Push the engine switch while turning the steering wheel left or right. Troubleshoot by following "HOW TO PROCEED WITH TROUBLESHOOTING" (See page SR-7). STEERING COLUMN – ELECTRIC STEERING LOCK SR–17 DTC CHECK / CLEAR Intelligent Tester 1. 2. DLC3 CAN VIM CHECK FOR DTCS (a) Prepare the intelligent tester. (b) Connect the intelligent tester to the DLC3 at the lower part of the instrument panel. (c) Turn the engine switch on (IG) and turn the intelligent tester on. (d) Use the intelligent tester to check for DTCs, and note or print the result (see the operator's manual for operating instructions). (e) Confirm the details of the DTCs (See page SR-15). CLEAR DTCS (a) Operate the intelligent tester to clear the DTCs (see the operator's manual for operating instructions). C131977E05 SR SR–18 STEERING COLUMN – ELECTRIC STEERING LOCK DATA LIST / ACTIVE TEST 1. DATA LIST HINT: By accessing the DATA LIST displayed on the intelligent tester, it is possible to perform such functions as reading the values of switches and sensors without removing any parts. Reading the DATA LIST is the first step in troubleshooting and is one method to save labor time. (a) Connect the intelligent tester to the DLC3. (b) Turn the engine switch on (IG) and turn the intelligent tester on. (c) Operate the intelligent tester according to the steps on the display and select DATA LIST. SMART ACCESS: Item SR Measurement Item / Range (Display) Normal Condition Diagnostic Note SLCK SLEEP COND Steering lock ECU sleep condition / YES or NO YES: Steering lock ECU sleep mode can be entered NO: Steering lock ECU sleep mode cannot be entered - SLCK START COND Steering lock ECU start signal / YES or NO YES: Steering lock ECU sent a start signal NO: Steering lock ECU did not send a start signal - ENG START COND Engine start condition / OK or NG OK: Engine is allowed to start NG: Engine is not allowed to start - SENSOR VALUE Sensor malfunction / NG (PAST) or OK NG (PAST): Sensor malfunction OK: No malfunction - PWR SUPPLY SHRT Short in ECU / NG (PAST) or OK NG (PAST): Short in ECU OK: No malfunction - PWR SUPPLY OPEN Open in ECU / NG (PAST) or OK NG (PAST): Open in ECU OK: No malfunction - MTR DRIVER SHRT Short in driver ECU / NG (PAST) or OK NG (PAST): Short in driver ECU OK: No malfunction - MTR DRIVER OPEN Open in driver ECU / NG (PAST) or OK NG (PAST): Open in driver ECU OK: No malfunction - LCK/UNLCK REC Steering lock command reception record / YES or NO YES: Steering lock / unlock signal received NO: Steering lock / unlock signal no received - LCK BAR STUCK Lock bar stuck malfunction / NG (PAST) or OK NG (PAST): Lock bar stuck malfunction OK: No malfunction - PUSH START ERR Push button start function malfunction / NG (PAST) or OK NG (PAST): Malfunction in push button start OK: No malfunction - IG2 IG2 voltage / ON or OFF ON: 10 to 14 V OFF: Below 1 V - IG (LIN) LIN bus IG status / ON or OFF ON: LIN bus IG ON status OFF: LIN bus IG OFF status - STEERING LOCK Steering lock condition / Set or Unset Set: Steering lock is set Unset: Steering lock is not set This status changes depending on the state of some sensors. STEERING UNLOCK Steering unlock condition / Set or Unset Set: Steering unlock is set Unset: Steering unlock is not set This status changes depending on the state of some sensors. SR–19 STEERING COLUMN – ELECTRIC STEERING LOCK 2. ACTIVE TEST HINT: Performing the ACTIVE TEST is one of the methods to save labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Connect the intelligent tester to the DLC3. (b) Turn the engine switch on (IG) and turn the intelligent tester on. (c) Following the display on the intelligent tester, perform the ACTIVE TEST. BODY: Item SECURITY INDIC Test Details Security Indicator / ON or OFF Diagnostic Note - SR SR–20 STEERING COLUMN – ELECTRIC STEERING LOCK DIAGNOSTIC TROUBLE CODE CHART If a trouble code is displayed during the DTC check, check the parts listed for that code in the table below and proceed to the appropriate page. HINT: The steering lock ECU does not store DTCs regarding the past problems. ELECTRIC STEERING LOCK: DTC No. Trouble Area See page B2781 Open / Short in Steering Lock ECU Steering lock actuator assembly (Steering lock ECU) SR-17 B2782 Power Source Control ECU Malfunction 1. Wire harness 2. Steering lock actuator assembly (Steering lock ECU) 3. Main body ECU SR-18 IG2 Signal Malfunction 1. IG2 relay 2. Wire harness 3. Main body ECU 4. Steering lock actuator assembly (Steering lock ECU) SR-21 B2788 SR Detection Item SR–21 STEERING COLUMN – ELECTRIC STEERING LOCK DTC B2781 Open / Short in Steering Lock ECU DESCRIPTION If the steering lock ECU determines that there is a malfunction inside the ECU, it outputs this DTC. The steering lock ECU diagnosis information cannot be read directly from the steering lock ECU by the tester. The diagnosis information from the steering lock ECU is transmitted to the tester via the certification ECU to the tester using the controller area network (CAN). DTC No. B2781 DTC Detecting Condition • • Steering lock motor drive circuit is defective. Both lock and unlock position sensors detect "ON". Trouble Area Steering lock actuator assembly (Steering lock ECU) INSPECTION PROCEDURE 1 REPLACE STEERING LOCK ACTUATOR ASSEMBLY (STEERING LOCK ECU) HINT: The steering lock ECU and steering lock actuator assembly are supplied as a unit. (a) Replace the steering lock actuator assembly (See page SR-42). NEXT END SR SR–22 STEERING COLUMN – ELECTRIC STEERING LOCK DTC B2782 Power Source Control ECU Malfunction DESCRIPTION The main body ECU (*) controls the power supply to activate the steering lock motor. This prevents the steering from being locked while the vehicle is moving. HINT: *: The power source control ECU is not a physical part. This code refers to the power source control function performed by the main body ECU. DTC No. DTC Detecting Condition B2782 Steering lock motor drive control circuit is defective. Trouble Area • • • Wire harness Steering lock actuator assembly (Steering lock ECU) Main body ECU WIRING DIAGRAM Steering Lock Actuator Assembly (Steering Lock ECU) Main Body ECU SR Steering Lock Motor Lock Position Sensor Unlock 3 Position IGE E51 Sensor 1 GND E51 19 E7 SLR+ C113485E03 INSPECTION PROCEDURE 1 INSPECT STEERING LOCK ACTUATOR ASSEMBLY (STEERING LOCK ECU) (a) Measure the voltage according to the value(s) in the table below. Standard voltage Steering Lock Actuator Assembly: E51 IGE GND C106483E22 Tester connection (Symbols) Condition E51-3 (IGE) - E51-1 (GND) The specified condition should be checked after performing the following: 1. Engine switch off 2. Turn the engine switch on (ACC or IG) Specified condition • • Motor activated: Below 1 V Motor not activated: 10 to 12 V SR–23 STEERING COLUMN – ELECTRIC STEERING LOCK Tester connection (Symbols) Condition E51-3 (IGE) - E51-1 (GND) The specified condition should be checked after performing the following: 1. Move the shift lever to the P position 2. Turn the engine switch off 3. Open the driver's door Specified condition • • Motor activated: Below 1 V Motor not activated: 10 to 12 V HINT: The steering lock ECU and steering lock actuator assembly are supplied as a unit. OK REPLACE STEERING LOCK ACTUATOR ASSEMBLY (STEERING LOCK ECU) NG 2 CHECK HARNESS AND CONNECTOR (STEERING LOCK ACTUATOR ASSEMBLY - BODY GROUND) (a) Disconnect the E51 connector from the steering lock actuator assembly. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Steering Lock Actuator Assembly: E51 GND Tester connection (Symbols) Condition Specified condition E51-1 (GND) - Body ground Always Below 1 Ω C106484E28 NG OK REPAIR OR REPLACE HARNESS OR CONNECTOR SR SR–24 3 STEERING COLUMN – ELECTRIC STEERING LOCK CHECK HARNESS AND CONNECTOR (STEERING LOCK ACTUATOR ASSEMBLY - MAIN BODY ECU) (a) Disconnect the E7 connector from the main body ECU. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Steering Lock Actuator Assembly: E51 IGE Main Body ECU: Condition Specified condition E51-3 (IGE) - E7-19 (SLR+) Always Below 1 Ω E51-3 (IGE) - Body ground Always 10 kΩ or higher NG E7 SR Tester connection (Symbols) SLR+ C113502E01 OK REPLACE MAIN BODY ECU REPAIR OR REPLACE HARNESS OR CONNECTOR SR–25 STEERING COLUMN – ELECTRIC STEERING LOCK DTC B2788 IG2 Signal Malfunction DESCRIPTION The steering lock ECU receives power from the IG2 relay. When the digital signal from the certification ECU and the voltage from the IG2 relay are received by the steering lock ECU, the steering will be unlocked. The steering lock ECU will not lock the steering when power from the IG2 relay is present (this prevents the steering from being locked while the vehicle is moving). DTC No. DTC Detecting Condition Different information is obtained from IG2 signals received directly from the IG2 circuit, and from IG2 signals sent via LIN communication for a period of 1 second. B2788 Trouble Area • • • • IG2 relay Wire harness Main body ECU Steering lock actuator assembly (Steering lock ECU) WIRING DIAGRAM Steering Lock Actuator Assembly (Steering Lock ECU) E50 ID Code Box 5 LIN1 SR E51 LIN 3 M+ Main Body ECU M- IG2 11 IG2D E6 6 AM1 E7 1 AM2 LK+ AM2 IG2 E6 IGN 6 E51 IG2 STR LOCK LK- 7 E51 B 1 FL MAIN ULK+ E51 GND ULK2 Battery E51 SGND C113505E02 SR–26 STEERING COLUMN – ELECTRIC STEERING LOCK INSPECTION PROCEDURE 1 INSPECT IG2 RELAY IG2 Relay: 3 (a) Remove the IG2 relay from the engine room R/B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance 1 2 5 5 1 Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (When battery voltage is applied to terminals 1 and 2) 2 3 B060778E17 NG REPLACE IG2 RELAY OK 2 SR CHECK HARNESS AND CONNECTOR (STEERING LOCK ACTUATOR ASSEMBLY - BODY GROUND) (a) Disconnect the E51 connector from the steering lock actuator assembly. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Steering Lock Actuator Assembly: GND E51 SGND C106484E29 Tester connection (Symbols) Condition Specified condition E51-1 (GND) - Body ground Always Below 1 Ω E51-2 (SGND) - Body ground Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 CHECK HARNESS AND CONNECTOR (STEERING LOCK ACTUATOR ASSEMBLY BATTERY) (a) Measure the voltage according to the value(s) in the table below. Standard voltage Steering Lock Actuator Assembly: GND E51 B IG2 SGND C106484E30 Tester connection (Symbols) Condition Specified condition E51-6 (IG2) - E51-1 (GND) Engine switch on (IG) 10 to 14 V E51-6 (IG2) - E51-2 (SGND) Engine switch on (IG) 10 to 14 V STEERING COLUMN – ELECTRIC STEERING LOCK SR–27 (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection (Symbols) Condition Specified condition *E51-6 (IG2) - E51-7 (B) Engine switch off 10 kΩ or higher *: This measurement is performed with the engine switch off to check for a short between IG2 and battery voltage. OK REPLACE STEERING LOCK ACTUATOR ASSEMBLY (STEERING LOCK ECU) NG REPAIR OR REPLACE HARNESS OR CONNECTOR (STEERING LOCK ACTUATOR ASSEMBLY BATTERY) SR SR–28 STEERING COLUMN – ELECTRIC STEERING LOCK Steering Lock Motor Drive Power Circuit DESCRIPTION The steering lock ECU is connected to the main body ECU and certification ECU. The steering lock ECU cannot activate the motor unless it receives permission signals from both ECUs. (The main body ECU permits the steering lock ECU to supply power to activate the motor.) WIRING DIAGRAM Steering Lock Actuator Assembly (Steering Lock ECU) Steering Lock Motor Lock Position Sensor SR Main Body ECU Unlock 3 Position IGE E51 Sensor 1 GND E51 19 E7 SLR+ C113485E03 INSPECTION PROCEDURE 1 CHECK VEHICLE CONDITION (a) Check the problem symptom of the steering lock system. Result Condition Proceed to Steering lock cannot be released A Steering cannot be locked B B Go to step 6 A 2 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Turn the engine switch on (IG), and turn the intelligent tester on. SR–29 STEERING COLUMN – ELECTRIC STEERING LOCK (c) Select the item below in the DATA LIST, and read its value displayed on the intelligent tester. SMART ACCESS Item Measurement Item / Range (Display) Steering lock command reception record / YES or NO LCK/UNLCK REC Normal Condition YES: Steering lock / unlock signal received NO: Steering lock / unlock signal not received (d) Check if steering unlock command signal has been received. OK: "YES" is displayed on the tester display. NG CHECK SMART ACCESS SYSTEM WITH PUSH-BUTTON START OK 3 INSPECT STEERING LOCK ACTUATOR ASSEMBLY (STEERING LOCK ECU) (a) Measure the voltage according to the value(s) in the table below. Standard voltage Steering Lock Actuator Assembly: E51 IGE GND Tester connection (Symbols) Condition E51-3 (IGE) - E51-1 (GND) 1. Engine switch off 2. Turn the engine switch on (ACC or IG) Specified condition • • Motor activated: Below 1 V Motor not activated: 10 to 12 V C106483E22 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG 4 CHECK HARNESS AND CONNECTOR (STEERING LOCK ACTUATOR ASSEMBLY - BODY GROUND) (a) Disconnect the E51 connector from the steering lock actuator assembly. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Steering Lock Actuator Assembly: E51 GND Tester connection (Symbols) Condition Specified condition E51-1 (GND) - Body ground Always Below 1 Ω C106484E28 NG OK REPAIR OR REPLACE HARNESS OR CONNECTOR SR SR–30 5 STEERING COLUMN – ELECTRIC STEERING LOCK CHECK HARNESS AND CONNECTOR (STEERING LOCK ACTUATOR ASSEMBLY - MAIN BODY ECU) (a) Disconnect the E7 connector from the main body ECU. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Steering Lock Actuator Assembly: E51 IGE Main Body ECU: Tester connection (Symbols) Condition Specified condition E51-3 (IGE) - E7-19 (SLR+) Always Below 1 Ω E51-3 (IGE) - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR E7 SR SLR+ C113502E01 OK REPLACE MAIN BODY ECU 6 INSPECT STEERING LOCK ACTUATOR ASSEMBLY (STEERING LOCK ECU) (a) Measure the voltage according to the value(s) in the table below. Standard voltage Steering Lock Actuator Assembly: E51 IGE GND C106483E22 Tester connection (Symbols) Condition E51-3 (IGE) - E51-1 (GND) The specified condition should be checked after performing the following: 1. Move the shift lever to the P position 2. Turn the engine switch off 3. Open the driver's door OK NG Specified condition • • Motor activated: Below 1 V Motor not activated: 10 to 12 V PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE SR–31 STEERING COLUMN – ELECTRIC STEERING LOCK 7 CHECK HARNESS AND CONNECTOR (STEERING LOCK ACTUATOR ASSEMBLY - MAIN BODY ECU) (a) Disconnect the E51 connector from the steering lock actuator assembly. (b) Disconnect the E7 connector from the main body ECU. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Steering Lock Actuator Assembly: E51 IGE Main Body ECU: Tester connection (Symbols) Condition Specified condition E51-3 (IGE) - E7-19 (SLR+) Always Below 1 Ω E51-3 (IGE) - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR E7 SR SLR+ C113502E01 OK REPLACE MAIN BODY ECU SR–32 STEERING COLUMN – ELECTRIC STEERING LOCK Unlock Position Sensor Signal Circuit DESCRIPTION The unlock position sensor is one of the components in the steering lock actuator. The sensor switch contact closes when the steering lock is released. The steering lock release signal is then sent to the main body ECU. Receiving the signal, the ECU permits engine start. (This prevents the engine from being started with the steering locked.) WIRING DIAGRAM Steering Lock Actuator Assembly (Steering Lock ECU) Steering Lock Motor SR Lock Position Sensor Main Body ECU Unlock 4 Position SLP1 E51 Sensor 2 SGND E51 18 E7 SLP C113485E04 INSPECTION PROCEDURE 1 INSPECT STEERING LOCK ACTUATOR ASSEMBLY (STEERING LOCK ECU) (a) Measure the voltage according to the value(s) in the table below. Standard voltage Steering Lock Actuator Assembly: SGND E51 SLP1 C106483E23 NG Tester connection (Symbols) Condition Specified condition E51-4 (SLP1) - E51-2 (SGND) 1. Engine switch off 2. Turn the engine switch on (ACC or IG) Below 1 V OK CHECK PUSH BUTTON START FUNCTION SR–33 STEERING COLUMN – ELECTRIC STEERING LOCK 2 CHECK HARNESS AND CONNECTOR (STEERING LOCK ACTUATOR ASSEMBLY - MAIN BODY ECU) (a) Disconnect the E51 connector from the steering lock actuator assembly. (b) Disconnect the E7 connector from the main body ECU. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Steering Lock Actuator Assembly: E51 SLP1 Main Body ECU: Tester connection (Symbols) Condition Specified condition E51-4 (SLP1) - E7-18 (SLP) Always Below 1 Ω E51-4 (SLP1) - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR E7 SLP SR C113502E02 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE SR–34 STEERING COLUMN – ELECTRIC STEERING LOCK Power Source Circuit DESCRIPTION This circuit supplies voltage from the battery to terminal B of the steering lock ECU. This circuit is used as power source for the steering lock CPU, motor, communication, and peripheral circuits. WIRING DIAGRAM Steering Lock Actuator Assembly (Steering Lock ECU) FL MAIN STR LOCK 7 M+ E51 B M- 2 SR LK+ E51 SGND LK- 1 ULK+ E51 GND Battery ULK- C113504E01 SR–35 STEERING COLUMN – ELECTRIC STEERING LOCK INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (STEERING LOCK ACTUATOR ASSEMBLY - BODY GROUND) (a) Disconnect the E51 connector from the steering lock actuator assembly. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Steering Lock Actuator Assembly: GND E51 SGND C106484E29 Tester connection (Symbols) Condition Specified condition E51-1 (GND) - Body ground Always Below 1 Ω E51-2 (SGND) - Body ground Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 2 CHECK HARNESS AND CONNECTOR (STEERING LOCK ACTUATOR ASSEMBLY BATTERY) (a) Measure the voltage according to the value(s) in the table below. Standard voltage Steering Lock Actuator Assembly: GND E51 B SGND Tester connection (Symbols) Condition Specified condition E51-7 (B) - E51-1 (GND) Always 10 to 14 V E51-7 (B) - E51-2 (SGND) Always 10 to 14 V C106484E31 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG REPAIR OR REPLACE HARNESS OR CONNECTOR (STEERING LOCK ACTUATOR ASSEMBLY BATTERY) SR SR–32 STEERING COLUMN – STEERING COLUMN ASSEMBLY STEERING COLUMN ASSEMBLY STEERING COLUMN COMPONENTS DRIVER SIDE KNEE AIRBAG ASSEMBLY SR 10 (102, 7) LOWER INSTRUMENT PANEL FINISH PANEL LH COWL SIDE TRIM SUB-ASSEMBLY LH FRONT DOOR SCUFF PLATE LH N*m (kgf*cm, ft.*lbf) : Specified torque C133871E03 SR–33 STEERING COLUMN – STEERING COLUMN ASSEMBLY without Cruise Control System: 50 (510, 37) STEERING WHEEL ASSEMBLY NO. 2 LOWER STEERING WHEEL COVER NO. 2 LOWER STEERING WHEEL COVER STEERING PAD NO. 3 LOWER STEERING WHEEL COVER SR STEERING COLUMN COVER TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY with Smart Key System: STEERING COLUMN COVER NO. 1 AIR DUCT STEERING COLUMN COVER N*m (kgf*cm, ft.*lbf) : Specified torque C133493E01 SR–34 STEERING COLUMN – STEERING COLUMN ASSEMBLY TMC Made: with Smart Key System: STEERING COLUMN ASSEMBLY 25 (255, 18) STEERING COLUMN ASSEMBLY SR STEERING INTERMEDIATE SHAFT ASSEMBLY 25 (255, 18) 35 (360, 26) CLAMP STEERING COLUMN HOLE SHIELD N*m (kgf*cm, ft.*lbf) : Specified torque C133496E01 STEERING COLUMN – STEERING COLUMN ASSEMBLY SR–35 TMMK Made: with Smart Key System: STEERING POST ASSEMBLY 21 (214, 16) STEERING POST ASSEMBLY SR 21 (214, 16) CLAMP 35 (360, 26) STEERING COLUMN HOLE SHIELD N*m (kgf*cm, ft.*lbf) : Specified torque C133497E01 SR–36 STEERING COLUMN – STEERING COLUMN ASSEMBLY TMC Made: Automatic Transaxle without Smart Key System: KEY INTERLOCK SOLENOID with Smart Key System: STEERING LOCK ACTUATOR ASSEMBLY TRANSPONDER KEY AMPLIFIER IGNITION SWITCH LOCK CYLINDER ASSEMBLY STEERING LOCK SUB-ASSEMBLY SR TAPERED-HEAD BOLT STEERING LOCK BRACKET IGNITION OR STARTER SWITCH ASSEMBLY UN-LOCK WARNING SWITCH ASSEMBLY Non-reusable part C133494E01 SR–37 STEERING COLUMN – STEERING COLUMN ASSEMBLY TMMK Made: Automatic Transaxle without Smart Key System: KEY INTERLOCK SOLENOID with Smart Key System: STEERING LOCK ACTUATOR ASSEMBLY TRANSPONDER KEY AMPLIFIER IGNITION SWITCH LOCK CYLINDER ASSEMBLY STEERING LOCK SUB-ASSEMBLY SR IGNITION OR STARTER SWITCH ASSEMBLY STEERING LOCK BRACKET UN-LOCK WARNING SWITCH ASSEMBLY TAPERED-HEAD BOLT Non-reusable part C133495E01 SR–38 STEERING COLUMN – STEERING COLUMN ASSEMBLY REMOVAL SR 1. PRECAUTION HINT: (See page RS-1) 2. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL HINT: (See page RS-1) 4. REMOVE FRONT WHEEL LH 5. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-24) 6. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-25) 7. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (See page IP-20) 8. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (See page IP-21) 9. REMOVE DRIVER SIDE KNEE AIRBAG ASSEMBLY (See page RS-370) 10. REMOVE NO. 2 LOWER STEERING WHEEL COVER (See page RS-349) 11. REMOVE NO. 3 LOWER STEERING WHEEL COVER (See page RS-349) 12. REMOVE STEERING PAD (See page RS-350) 13. REMOVE STEERING WHEEL ASSEMBLY (a) Remove the steering wheel assembly set nut. (b) Put matchmarks on the steering wheel assembly and the steering main shaft. (c) Disconnect the connectors from the spiral cable. Matchmarks SST Turn Hold C132542E01 (d) Using SST, remove the steering wheel assembly. SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05031) STEERING COLUMN – STEERING COLUMN ASSEMBLY SR–39 14. REMOVE STEERING COLUMN COVER (a) Remove the 2 screws. (b) Disengage the 2 claws to remove the steering column cover lower. C132544 (c) Disengage the claw to remove the steering column cover upper. 15. REMOVE TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY (a) Disconnect the connectors from the turn signal switch assembly with spiral cable sub-assembly. C132545 (b) Using pliers, grip the claws of the clip and remove the turn signal switch assembly with spiral cable sub-assembly. C132546 16. REMOVE NO. 1 AIR DUCT (a) Disengage the 2 claws and remove the No. 1 air duct. C132547 17. REMOVE STEERING COLUMN ASSEMBLY (for TMC Made) (a) Remove the clamp from the steering column hole shield. C133172 SR SR–40 STEERING COLUMN – STEERING COLUMN ASSEMBLY (b) Remove the bolt and slide the steering intermediate shaft assembly. NOTICE: Do not separate the steering intermediate shaft assembly from the power steering link assembly. Front of The Vehicle C132548E01 (c) Put matchmarks on the steering intermediate shaft assembly and the power steering link assembly. (d) Separate the steering intermediate shaft assembly from the power steering link assembly. (e) Disconnect the connectors and wire harness clamps from the steering column assembly. SR Matchmarks C132549E01 (f) C133173E01 Remove the bolt, 2 nuts, and the steering column assembly. STEERING COLUMN – STEERING COLUMN ASSEMBLY SR–41 18. REMOVE STEERING POST ASSEMBLY (for TMMK Made) (a) Remove the clamp from the steering column hole shield. C133172 (b) Remove the bolt and slide the steering sliding yoke. NOTICE: Do not separate the steering sliding yoke from the power steering link assembly. SR Front of The Vehicle C132548E01 (c) Put matchmarks on the steering sliding yoke and the power steering link assembly. (d) Separate the steering sliding yoke from the power steering link assembly. (e) Disconnect the connectors and wire harness clamps from the steering column assembly. Matchmarks C132549E01 SR–42 STEERING COLUMN – STEERING COLUMN ASSEMBLY (f) Remove the bolt, 2 nuts, and the steering post assembly. C133173E01 19. REMOVE STEERING INTERMEDIATE SHAFT ASSEMBLY (for TMC Made) (a) Put matchmarks on the steering intermediate shaft assembly and the steering column assembly. (b) Remove the bolt and the steering intermediate shaft assembly from the steering column assembly. SR Matchmarks C133503E01 STEERING COLUMN – STEERING COLUMN ASSEMBLY SR–43 DISASSEMBLY NOTICE: When using a vise, do not overtighten it. 1. REMOVE STEERING LOCK ACTUATOR ASSEMBLY (w/ Smart Key System) (a) Secure the steering column assembly in a vise. (b) Using a center punch, mark the center of the 2 tapered-head bolts. (c) Using a 3 to 4 mm (0.12 to 0.16 in.) drill, drill a hole in the 2 tapered-head bolts. (d) Using a screw extractor, remove the 2 tapered-head bolts, and then remove the steering lock actuator assembly and the steering lock bracket from the steering column assembly. 2. Screw Extractor REMOVE TRANSPONDER KEY AMPLIFIER (w/o Smart Key System) (a) Using a screwdriver, widen the claws hanging onto the upper bracket by approximately 1.0 mm (0.039 in.). C103930E01 (b) Pull out the transponder key amplifier with the claw open. NOTICE: Using excessive force may damage the case. 3. C115569 REMOVE STEERING COLUMN UPPER WITH SWITCH BRACKET ASSEMBLY (w/o Smart Key System) (a) Secure the steering column assembly in a vise. (b) Using a center punch, mark the center of the 2 tapered-head bolts. (c) Using a 3 to 4 mm (0.12 to 0.16 in.) drill, drill a hole in the 2 tapered-head bolts. (d) Using a screw extractor, remove the 2 tapered-head bolts, and then remove the steering column upper with switch bracket assembly and the steering lock bracket from the steering column assembly. 4. Screw Extractor C103929E01 REMOVE IGNITION SWITCH LOCK CYLINDER ASSEMBLY (w/o Smart Key System) (a) Turn the ignition switch lock cylinder assembly to the ACC position. SR SR–44 STEERING COLUMN – STEERING COLUMN ASSEMBLY (b) Push a screwdriver into the hole of the steering column upper with switch bracket assembly shown in the illustration and pull the ignition switch lock cylinder assembly until its claw contacts the stopper of the steering column upper with switch bracket assembly. NOTICE: Make sure to pull the ignition switch lock cylinder assembly until its claw contacts the stopper of the steering column bracket assembly upper. Failure to do so will affect later work operations. Screwdriver START ON ACC LOCK C105482E03 (c) Insert a screwdriver into the hole of the steering column upper with switch bracket assembly. Push the screwdriver downward as shown in the illustration to disengage the claw of the ignition switch lock cylinder assembly. Pull out the ignition switch lock cylinder assembly. SR Screwdriver C105483E03 5. REMOVE UN-LOCK WARNING SWITCH ASSEMBLY (w/o Smart Key System) (a) Remove the un-lock warning switch assembly by pushing up the center part and releasing the 2 claws. 6. REMOVE KEY INTERLOCK SOLENOID (for Automatic Transaxle without Smart Key System) (a) Remove the 2 screws and the key interlock solenoid from the steering lock sub-assembly. C104851E03 C104553 STEERING COLUMN – STEERING COLUMN ASSEMBLY 7. SR–45 REMOVE IGNITION OR STARTER SWITCH ASSEMBLY (w/o Smart Key System) (a) Disengage the 2 claws and remove the ignition or starter switch assembly from the steering lock subassembly. C104552E03 INSPECTION 1. INSPECT STEERING LOCK OPERATION (w/o Smart Key System) (a) Check that the steering lock mechanism is activated when the key is removed. C103934 START ON ACC LOCK C103935E02 (b) Check that the steering lock mechanism is deactivated when the key is inserted and turned to the ACC position. HINT: If there is any abnormality, replace the ignition switch lock cylinder assembly. SR SR–46 STEERING COLUMN – STEERING COLUMN ASSEMBLY REASSEMBLY 1. INSTALL STEERING LOCK ACTUATOR ASSEMBLY (w/ Smart Key System) (a) Temporarily install the steering lock actuator assembly and the steering lock bracket with 2 new tapered-head bolts. (b) Tighten the 2 tapered-head bolts until the bolt heads break off. C103937 2. INSTALL IGNITION OR STARTER SWITCH ASSEMBLY (w/o Smart Key System) (a) Engage the 2 claws to install the ignition or starter switch assembly to the steering lock sub-assembly. 3. INSTALL KEY INTERLOCK SOLENOID (for Automatic Transaxle without Smart Key System) (a) Install the key interlock solenoid to the steering lock sub-assembly with the 2 screws. 4. INSTALL UN-LOCK WARNING SWITCH ASSEMBLY (w/o Smart Key System) (a) Engage the 2 claws to install the un-lock warning switch assembly to the steering lock sub-assembly. 5. INSTALL IGNITION SWITCH LOCK CYLINDER ASSEMBLY (w/o Smart Key System) (a) Make sure that the ignition switch lock cylinder assembly is in the ACC position. SR C104552E03 C104553 C104837E02 STEERING COLUMN – STEERING COLUMN ASSEMBLY (b) Install the ignition switch lock cylinder assembly to the steering lock sub-assembly. (c) Make sure that the ignition switch lock cylinder assembly is securely installed. START ON ACC SR–47 6. INSPECT STEERING LOCK OPERATION (w/o Smart Key System) 7. INSTALL STEERING COLUMN UPPER WITH SWITCH BRACKET ASSEMBLY (w/o Smart Key System) (a) Temporarily install the steering column upper with switch bracket assembly and the steering lock bracket with 2 new tapered-head bolts. LOCK C103932E02 (b) Tighten the 2 tapered-head bolts until the bolt heads break off. 8. INSTALL TRANSPONDER KEY AMPLIFIER (w/o Smart Key System) (a) Align the transponder key amplifier with the installation position of the upper bracket with the amplifier inclined. C103936 (b) Push the transponder key amplifier up and install it to the upper bracket. NOTICE: Do not push the amplifier up with excessive force. C115570 SR SR–48 STEERING COLUMN – STEERING COLUMN ASSEMBLY INSTALLATION 1. INSTALL STEERING INTERMEDIATE SHAFT ASSEMBLY (for TMC Made) (a) Align the matchmarks on the steering intermediate shaft assembly and the steering column assembly. (b) Install the bolt. Torque: 35 N*m (360 kgf*cm, 26 ft.*lbf) Matchmarks C133503E01 2. SR INSTALL STEERING COLUMN ASSEMBLY (for TMC Made) (a) Install the steering column assembly with the bolt and 2 nuts. Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) (b) Connect the connectors and wire harness clamps to the steering column assembly. C133173E01 (c) Align the matchmarks on the steering intermediate shaft assembly and the power steering link assembly. Matchmarks C132549E01 STEERING COLUMN – STEERING COLUMN ASSEMBLY SR–49 (d) Install the bolt. Torque: 35 N*m (360 kgf*cm, 26 ft.*lbf) Front of The Vehicle C132548E01 (e) Install the clamp to the steering column hole shield. SR C133172 3. C133173E01 INSTALL STEERING POST ASSEMBLY (for TMMK Made) (a) Install the steering post assembly with the bolt and 2 nuts. Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf) (b) Connect the connectors and wire harness clamps to the steering post assembly. SR–50 STEERING COLUMN – STEERING COLUMN ASSEMBLY (c) Align the matchmarks on the steering sliding yoke and the power steering link assembly. Matchmarks C132549E01 (d) Install the bolt. Torque: 35 N*m (360 kgf*cm, 26 ft.*lbf) SR Front of The Vehicle C132548E01 (e) Install the clamp to the steering column hole shield. C133172 C132547 4. INSTALL NO. 1 AIR DUCT (a) Engage the 2 claws to install the No. 1 air duct. 5. PLACE FRONT WHEELS FACING STRAIGHT AHEAD STEERING COLUMN – STEERING COLUMN ASSEMBLY SR–51 6. INSTALL TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY (a) Install the turn signal switch assembly with spiral cable sub-assembly to the steering column assembly with the clamp. (b) Connect the connectors to the turn signal switch assembly with spiral cable sub-assembly. 7. INSTALL STEERING COLUMN COVER (a) Engage the claw to install the steering column cover upper. C132546 C132545 (b) Engage the 2 claws to install the steering column cover lower. (c) Install the 2 screws. 8. ADJUST SPIRAL CABLE SUB- ASSEMBLY (See page RS-367) 9. INSTALL STEERING WHEEL ASSEMBLY (a) Align the matchmarks on the steering wheel assembly and steering main shaft. (b) Install the steering wheel assembly set nut. Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf) (c) Connect the connectors to the spiral cable subassembly. C132544 Matchmarks 10. INSPECT STEERING WHEEL CENTER POINT 11. INSTALL STEERING PAD (See page RS-350) 12. INSPECT STEERING PAD (See page RS-352) 13. INSTALL NO. 2 LOWER STEERING WHEEL COVER (See page RS-352) C132543E01 14. INSTALL NO. 3 LOWER STEERING WHEEL COVER (See page RS-351) 15. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY (See page RS-370) 16. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (See page IP-58) SR SR–52 STEERING COLUMN – STEERING COLUMN ASSEMBLY 17. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (See page IP-59) 18. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-54) 19. INSTALL FRONT DOOR SCUFF PLATE LH (See page IR-54) 20. INSTALL FRONT WHEEL LH Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 21. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 22. INSPECT SRS WARNING LIGHT HINT: (See page RS-32) SR BC–1 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM ANTI-LOCK BRAKE SYSTEM PRECAUTION 1. Expression EXPRESSIONS OF IGNITION SWITCH The type of ignition switch used on this model differs according to the specifications of the vehicle. The expressions listed in the table below are used in this section. Switch Type Ignition Switch (Position) Engine Switch (Condition) Ignition switch off LOCK off Ignition switch on (IG) ON on (IG) Ignition switch on (ACC) ACC on (ACC) Engine start START start 2. 3. TROUBLESHOOTING PRECAUTION HINT: The anti-lock brake system includes the ABS and EBD. (a) When there is a malfunction in the terminal contact points or installation problems with parts, removing and installing the suspected problem parts may return the system to normal, either completely or temporarily. (b) In order to determine the malfunctioning area, be sure to check the conditions at the time the malfunction occurred, such as by the DTC output and the freeze frame data output, and record it before disconnecting each connector or removing and installing parts. (c) Be sure to remove and install the brake actuator and each individual sensor with the ignition switch off unless otherwise specified in the inspection procedure. (d) If the brake actuator or a sensor has been removed and installed, it is necessary to check the system for problems after the parts have been reassembled. Check for DTCs using the intelligent tester, also check that system functions and signals received by the ECU are normal using test mode. CAN COMMUNICATION SYSTEM PRECAUTION (a) The CAN communication system is used for data communication between each of the ECUs and sensors. If there is trouble in the CAN communication line, a DTC of the communication line is output. (b) If a DTC of the CAN communication line is output, repair the malfunction in the communication line and troubleshoot the anti-lock brake system. BC BC–2 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM (c) In order to enable CAN communication, a specific type of wiring is used for the CAN communication lines. The wiring used for each communication line is a twisted pair of wires that have an equal length. A bypass wire should not be used, because the data being transmitted will be corrupted. BC BC–3 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM PARTS LOCATION BRAKE MASTER CYLINDER ASSEMBLY - BRAKE FLUID LEVEL WARNING SWITCH BRAKE ACTUATOR SKID CONTROL SENSOR - SKID CONTROL ECU (REAR SPEED SENSOR) REAR SPEED SENSOR ROTOR FRONT SPEED SENSOR ROTOR FRONT SPEED SENSOR ECM (2GR-FE) BC FRONT SPEED SENSOR FRONT SPEED SENSOR ROTOR ECM (2AZ-FE) ENGINE ROOM R/B - FUSIBLE LINK (ABS NO. 1) - FUSIBLE LINK (ABS NO. 2) SKID CONTROL SENSOR (REAR SPEED SENSOR) REAR SPEED SENSOR ROTOR C131985E01 BC–4 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM STOP LIGHT SWITCH COMBINATION METER ASSEMBLY PARKING BRAKE SWITCH (AUTOMATIC TRANSAXLE) - ABS WARNING LIGHT - BRAKE WARNING LIGHT BC DLC3 INSTRUMENT PANEL J/B - ECU IG NO. 2 FUSE PARKING BRAKE SWITCH (MANUAL TRANSAXLE) C131984E01 BC–5 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM SYSTEM DIAGRAM Brake Actuator Assembly (Skid Control ECU with Actuator) Motor Relay Motor Solenoid Relay Solenoid Speed Sensor (On Each Wheel) BC Skid Control ECU Stop Light Switch Combination Meter Assembly Speedometer ABS Warning Light Parking Brake Switch BRAKE Warning Light ECM Main Body ECU CAN Communication System C131987E01 Transmitting ECU Skid control ECU Receiving ECU Combination meter Signals • • ABS warning light signal BRAKE warning light signal Communication method CAN communication system BC–6 BC BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM Transmitting ECU Receiving ECU Signals Communication method ECM Skid control ECU Shift position signal CAN communication system BC–7 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM SYSTEM DESCRIPTION 1. SYSTEM DESCRIPTION HINT: The skid control ECU is located within the brake actuator assembly. (a) ABS (Anti-lock Brake System) The ABS helps prevent the wheels from locking when the brakes are applied firmly or when braking on a slippery surface. Brake Actuator Assembly BC Pump Motor Each Speed Sensor Each Wheel Cylinder Skid Control ECU Solenoid Valves ABS Warning Light Combination Meter Assembly CAN Communication System Hydraulic Pressure C132003E01 BC–8 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM Operation description The skid control ECU detects wheel lock based on speed signals it receives from the wheel speed sensors. Based on this information, the skid control ECU controls the pump motor and solenoid valves. The pump motor and solenoid valves are used to prevent wheel lock by controlling the hydraulic pressure applied to the brakes at each wheel. The ABS warning light will come on when the system is malfunctioning. BC BC–9 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM (b) EBD (Electronic Brake force Distribution) The EBD control utilizes ABS, realizing proper brake force distribution between the front and rear wheels in accordance with driving conditions. In addition, when braking while cornering, it also controls the brake forces of the right and left wheels, helping to maintain vehicle behavior. Brake Actuator Assembly Pump Motor Each Speed Sensor Each Wheel Skid Control ECU BC Solenoid Valves BRAKE Warning Light ABS Warning Light Combination Meter Assembly CAN Communication System Hydraulic Pressure C132004E01 BC–10 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM 2. BC 3. 4. 5. Operation description The skid control ECU receives a speed signal from each wheel speed sensor, and uses these signals to detect locking of the wheels. The ECU uses this information in order to determine appropriate control of the solenoid valves. The solenoid valves control the hydraulic pressure applied to the brake cylinder at each wheel. In this way, the solenoid valves are used to control the brake power split between the front and rear, and left and right wheels. The ABS and BRAKE warning lights come on if there is a malfunction in the EBD system. ABS with EBD OPERATION (a) Based on the signals received from the 4 wheel speed sensors, the skid control ECU calculates the deceleration and speed of each wheel, while monitoring for wheel lock. If wheel lock is occurring, the ECU controls the solenoid valves in the brake actuator in order to adjust the hydraulic pressure applied to the brakes at each wheel. FAIL SAFE FUNCTION (a) When a failure occurs in the anti-lock brake system, the ABS warning light comes on and operation is prohibited. In addition, when a failure which disables EBD operation occurs, the brake warning light also comes on and operation is prohibited (See page BC-24). INITIAL CHECK (a) When the vehicle speed first becomes approximately 4 mph (6 km/h) or more after the ignition switch is turned on (IG), each solenoid valve and motor of the brake actuator is sequentially activated to perform an electrical check. During the initial check, the operating sound of solenoid valve and motor can be heard from the engine compartment, but this is not a malfunction. FUNCTION OF COMPONENTS Components Function • Brake actuator assembly • Composed of the holding solenoid valve, pressure reduction solenoid valve, pump motor, reservoir, etc., and adjusts the hydraulic pressure applied to each wheel cylinder. Houses the skid control ECU. Skid control ECU Processes the signals sent from each sensor to control ABS and EBD. Speed sensor Detects speed of each wheel and inputs the data into the skid control ECU. Master cylinder Generates pressure according to pedal effort. Stop light switch Illuminates the stop light when the brake pedal is depressed. (Sends a brake on signal to the skid control ECU) Solenoid relay • • Supplies power to each solenoid. Housed in the skid control ECU. Motor relay • • Supplies power to the pump motor. Housed in the skid control ECU. • Comes on to inform the driver that a malfunction in the ABS and EBD has occurred. Blinks to output DTC. ABS warning light • BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM Components Function • BRAKE warning light BC–11 • Comes on to inform the driver that the parking brake is on when the system is normal or the brake fluid level has decreased. Comes on to inform the driver that a malfunction in the EBD has occurred. BC BC–12 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS (a) Interview the customer to confirm the trouble. NEXT 3 CHECK CAN COMMUNICATION SYSTEM BC (a) Check for DTCs (See page BC-21). HINT: The skid control ECU is connected to the CAN communication system. Therefore, before starting troubleshooting, make sure to check that there is no trouble in the CAN communication system. Result Result Proceed to DTC is not output A DTC is output B B CHECK CAN COMMUNICATION CIRCUIT A 4 CHECK DTC AND FREEZE FRAME DATA (a) Check for DTCs and Freeze Frame Data (See page BC21 for DTC Check / Clear, BC-23 for Freeze Frame Data). (1) Record the DTCs and Freeze Frame Data. (b) Clear the DTCs. (c) Recheck for DTCs. (1) Reproduce the malfunction and check if the DTCs are output again. Result Result Proceed to DTC is output A DTC is not output (Problem symptom does not occur) B DTC is not output (Problem symptom occurs) C B GO TO STEP 9 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM C BC–13 GO TO STEP 10 A 5 DIAGNOSTIC TROUBLE CODE CHART (a) Go to "DIAGNOSTIC TROUBLE CODE CHART" (See page BC-27). NEXT 6 CIRCUIT INSPECTION NEXT 7 BC REPAIR OR REPLACE NEXT 8 CONFIRMATION TEST NEXT END 9 SYMPTOM SIMULATION NEXT 10 PROBLEM SYMPTOMS TABLE (a) Go to "PROBLEM SYMPTOMS TABLE" (See page BC16). NEXT 11 NEXT CIRCUIT INSPECTION BC–14 12 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM REPAIR OR REPLACE NEXT 13 CONFIRMATION TEST NEXT END TEST MODE PROCEDURE ABS Warning Light: BRAKE Warning Light: 1. BC USA: USA: Canada: Canada: C131966E01 WARNING LIGHT AND INDICATOR LIGHT INITIAL CHECK (a) Release the parking brake. NOTICE: Before releasing the parking brake, move the shift lever to the P position for safety (AT model) or set the chocks to hold the vehicle for safety (MT model). HINT: When the parking brake is applied or the level of the brake fluid is low, the BRAKE warning light comes on. (b) When the ignition switch is turned on (IG), check that the ABS warning light comes on for approximately 3 seconds. HINT: • If the skid control ECU stores any DTCs, the ABS and BRAKE warning lights come on. • If the indicator remains on or does not come on, proceed to troubleshooting for the light circuits listed below. Trouble Area See procedure ABS warning light (Remains on) BC-74 ABS warning light circuit (Does not come on) BC-78 BRAKE warning light (Remains on) BC-81 BRAKE warning light (Does not come on) BC-91 2. SENSOR SIGNAL CHECK USING TEST MODE (SIGNAL CHECK) (INTELLIGENT TESTER) HINT: If the ignition switch is turned from on (IG) to on (ACC) or off during Test Mode (signal check), DTCs recorded during the signal check function will be erased. BC–15 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM (a) Procedure to enter Test Mode. (1) Turn the ignition switch off. (2) Connect the intelligent tester to the DLC3. (3) Check that the steering wheel is centered and move the shift lever to the P position (for Automatic Transaxle) or apply the parking brake (Manual Transaxle). (4) Turn the ignition switch on (IG). DLC3 Intelligent Tester C131977E02 (5) Set the intelligent tester to Test Mode (select "SIGNAL CHECK"). HINT: Refer to the intelligent tester operator's manual for further details. C106533 (6) Check that the ABS warning light comes on for several seconds and then blinks in test mode. HINT: If the ABS warning light does not blink, inspect the ABS warning light circuit. TEST MODE: Blinking Pattern: 0.13 sec. 0.13 sec. Trouble Area ON ABS warning light (Does not come on) See procedure BC-78 (b) Check the sensor signal. (1) Drive the vehicle straight ahead. Accelerate the vehicle to a speed of 28 mph (45 km/h) or more for several seconds and check that the ABS warning light goes off when the brake pedal is depressed. HINT: • The sensor check may not be completed if wheel spin occurs, or if the steering wheel is turned during this check. • The ABS warning light goes off when the sensor signal check has been completed and the brake pedal is depressed. • The ABS warning light comes on immediately after a malfunction has been detected during the speed sensor signal check. OFF Display: USA: Canada: C132874E01 BC BC–16 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM BC 3. DLC3: (3) Using SST, connect terminals TS and CG of the DLC3. SST 09843-18040 (4) Turn the ignition switch on (IG). CG TS (c) Stop the vehicle. NOTICE: • The speed sensor check may not be completed if the speed sensor check is started while turning the steering wheel or spinning the wheels. • If the signal check has not been completed, the ABS warning light will blink while driving and the ABS system will not operate. (d) Read the DTC(s) by following the tester screen. NOTICE: • If only the DTCs are displayed, repair the malfunction area and clear the DTCs. • If the DTCs or Test Mode codes (DTC of signal check function) are displayed, repair the malfunction area, clear the DTCs and perform the Test Mode inspection. HINT: See the list of DTCs (See procedure "A"). SENSOR SIGNAL CHECK BY TEST MODE (SIGNAL CHECK) (SST CHECK WIRE) HINT: If the ignition switch is turned from on (IG) to on (ACC) or off during Test Mode (signal check), DTCs recorded during the signal check will be erased. (a) Procedure for Test Mode. (1) Turn the ignition switch off. (2) Check that the steering wheel is centered and move the shift lever to the P position (Automatic Transaxle) or apply the parking brake (Manual Transaxle). G022987E07 BC–17 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM (5) Check that the ABS warning light comes on for several seconds and then blinks in Test Mode. HINT: If the ABS warning light does not blink, inspect the TS and CG terminal circuit, and ABS warning light circuit. TEST MODE: Blinking Pattern: 0.13 sec. 0.13 sec. ON Trouble Area OFF Display: USA: Canada: C132874E01 DLC3: BC-97 ABS warning light circuit (Does not come on) BC-78 (b) Check the sensor signal. (1) Drive the vehicle straight ahead. Accelerate the vehicle to a speed of 28 mph (45 km/h) or more for several seconds and check that the ABS warning light goes off when the brake pedal is depressed. HINT: • The sensor check may not be completed if wheel spin occurs, or if the steering wheel is turned during this check. • The ABS warning light goes off when the sensor signal check has been completed and the brake pedal is depressed. • The ABS warning light comes on immediately after a malfunction has been detected during the speed sensor signal check. (c) Stop the vehicle. NOTICE: • The speed sensor check may not be completed if the speed sensor check is started while turning the steering wheel or spinning the wheels. • If the signal check has not been completed, the ABS warning light will blink while driving and the ABS system will not operate. (d) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 CG TS See procedure TS and CG terminal circuit TC G022988E01 BC BC–18 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM (e) Count the number of blinks of the ABS warning light. Blinking Pattern of Normal System Code: 0.25 sec. 0.25 sec. ON OFF Blinking Pattern of Trouble Code (Example Codes 71 and 72): 0.5 sec. 0.5 sec. BC 1.5 sec. 2.5 sec. 4 sec. Repeat ON OFF Code 71 Code 72 C132876E01 NOTICE: • If only the DTCs are displayed, repair the malfunction area and clear the DTCs. • If the DTCs or Test Mode codes (DTC of signal check function) are displayed, repair the malfunction area, clear the DTCs and perform the Test Mode inspection. HINT: • If more than 1 malfunction is detected at the same time, the lowest numbered code will be displayed first. • See the list of DTCs (See procedure "A"). (f) After performing the check, disconnect the SST from terminals TS and CG, and TC and CG of the DLC3, and turn the ignition switch off. (g) Turn the ignition switch on (IG) to cancel the test mode. HINT: • If the ignition switch is not turned on (IG) after the SST is removed from the DLC3, the previous Test Mode will continue. • If the ignition switch is turned on (IG) with terminals TS and CG shorted, the previous Test Mode will continue. BC–19 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM 4. DTC OF TEST MODE (SIGNAL CHECK) FUNCTION (Procedure "A") DTC of Test Mode (Signal Check): Code No. Diagnosis Trouble Area C1271/71 Low output signal of front speed sensor RH • • • Front speed sensor RH Sensor installation Speed sensor rotor C1272/72 Low output signal of front speed sensor LH • • • Front speed sensor LH Sensor installation Speed sensor rotor C1273/73 Low output signal of rear speed sensor RH • • • Rear speed sensor RH Sensor installation Speed sensor rotor C1274/74 Low output signal of rear speed sensor LH • • • Rear speed sensor LH Sensor installation Speed sensor rotor C1275/75 Abnormal change in output signal of front speed sensor RH • • • Front speed sensor RH Front speed sensor circuit RH Sensor installation C1276/76 Abnormal change in output signal of front speed sensor LH • • • Front speed sensor LH Front speed sensor circuit LH Sensor installation C1277/77 Abnormal change in output signal of rear speed sensor RH • • • Rear speed sensor RH Rear speed sensor circuit RH Sensor installation C1278/78 Abnormal change in output signal of rear speed sensor LH • • • Rear speed sensor LH Rear speed sensor circuit LH Sensor installation HINT: The codes in this table are output only in Test Mode (signal check). BC BC–20 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM PROBLEM SYMPTOMS TABLE If a normal code is displayed during the DTC check but the problem still occurs, check the circuits for each problem symptom in the order given in the table below and proceed to the relevant troubleshooting page. NOTICE: When replacing the skid control ECU, sensor, etc., turn the ignition switch off. HINT: • Inspect the fuses and relays before investigating the suspected areas as shown in the table below. • Inspect each malfunction circuit in numerical order for the corresponding symptoms. ANTI-LOCK BRAKE SYSTEM: Symptom BC ABS does not operate ABS does not operate efficiently ABS warning light malfunction (Remains on) ABS warning light malfunction (Does not come on) Brake warning light malfunction (Remains on) Brake warning light malfunction (Does not come on) ABS sensor DTC check cannot be done Suspected area See page 1. Check the DTC reconfirming that the normal system code is output BC-21 2. IG power source circuit BC-63 3. Front speed sensor circuit BC-30 4. Rear speed sensor circuit BC-38 5. Check the brake actuator assembly with the intelligent tester (Check brake actuator assembly operation using the active test function) If abnormal, check the hydraulic circuit for leakage BR-42 6. If the symptoms still occur even after the above circuits in suspected areas have been inspected and proved to be normal, replace the brake actuator assembly (skid control ECU) BC-432 1. Check the DTC reconfirming that the normal system code is output. BC-21 2. Front speed sensor circuit BC-30 3. Rear speed sensor circuit BC-38 4. Stop light switch circuit BC-67 5. Check the brake actuator assembly with the intelligent tester (Check brake actuator assembly operation using the active test function) BR-42 6. If the symptoms still occur even after the above circuits in suspected areas have been inspected and proved to be normal, replace the brake actuator assembly (skid control ECU) BC-432 1. ABS warning light circuit BC-74 2. Brake actuator assembly (skid control ECU) BC-432 1. ABS warning light circuit BC-78 1. Brake warning light circuit BC-81 2. Brake actuator assembly (skid control ECU) BC-432 1. Brake warning light circuit BC-91 2. Brake actuator assembly (skid control ECU) BC-432 1. Check the DTC again and make sure that the normal system code is output BC-21 2. TS and CG terminal circuit BC-97 3. TC and CG terminal circuit BC-94 4. If the symptoms still occur even after the above circuits in suspected areas have been inspected and proved to be normal, replace the brake actuator assembly (skid control ECU) BC-432 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM BC–21 TERMINALS OF ECU 1. TERMINALS OF ECU Skid Control ECU (Brake Actuator Assembly): C131974E01 Symbols (Terminal No.) Terminal Description GND2 (1) Actuator pump motor ground +BM (2) Motor relay power supply +BS (3) Solenoid valves power supply GND1 (4) Skid control ground FL+ (5) Front LH (+) wheel speed signal input FL- (6) Front LH (-) wheel speed signal input RL+ (7) Rear LH (+) wheel speed signal input RR- (8) Rear RH (-) wheel speed signal input FR- (9) Front RH (-) wheel speed signal input FR+ (10) Front RH (+) wheel speed signal input D/G (11) Diagnosis tester communication line CANL (15) CAN communication line L RL- (17) Rear LH (-) wheel speed signal input IG1 (18) ECU power supply RR+ (19) Rear RH (+) wheel speed signal input STP (20) Stop light switch input SP1 (23) Speed signal output for speedometer TS (25) Sensor check input CANH (26) CAN communication line H 2. TERMINAL INSPECTION (a) Disconnect the connector and measure the voltage or resistance on the wire harness side. HINT: Voltage cannot be measured with the connector connected to the skid control ECU as the connector is watertight. BC BC–22 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM Skid Control ECU (Harness Side Connector Front View): C131969E01 Symbols (Terminal No.) BC GND2 (1) - Body ground Wiring Color W-B - Body ground Terminal Description Condition Specified Condition Actuator pump motor ground Always Below 1 Ω +BM (2) - Body ground B - Body ground Motor relay power supply Always 10 to 14 V +BS (3) - Body ground L - Body ground Solenoid valves power supply Always 10 to 14 V Skid control ECU ground Always Below 1 Ω IG1 (18) - Body ground P - Body ground ECU power supply Ignition switch on (IG) 10 to 14 V STP (20) - Body ground P - Body ground Stop light switch input Stop light switch ON (Brake pedal depressed) 8 to 14 V STP (20) - Body ground P - Body ground Stop light switch input Stop light switch OFF (Brake pedal released) Below 3 V GND1 (4) - Body ground W-B - Body ground BC–23 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM DIAGNOSIS SYSTEM 1. CG (b) The vehicle's ECU uses the ISO 15765-4 for communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. HINT: Connect the cable of the intelligent tester to the DLC3, turn the ignition switch on (IG) and attempt to use the intelligent tester. If the screen displays a communication error message, a problem exists on either the vehicle side or the tester side. If the communication is normal when the tester is connected to another vehicle, inspect the DLC3 on the original vehicle. If the communication is still impossible when the tester is connected to another vehicle, the problem is probably in the tester itself. Consult the Service Department listed in the tester's instruction manual. SG CANH 1 2 3 4 5 6 7 8 9 10 11 1213141516 CANL BAT Symbols (Terminal No.) CG (4) - Body ground DIAGNOSIS SYSTEM (a) Inspect the battery voltage. Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge the battery before proceeding. A082779E65 Terminal Description Chassis ground Condition Specified Condition Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 9 to 14 V CANH (6) - CANL (14) HIGH-level CAN bus line Ignition switch OFF* 54 to 69 Ω CANH (6) - Battery positive HIGH-level CAN bus line Ignition switch OFF* 6 kΩ or higher CANH (6) - CG (4) HIGH-level CAN bus line Ignition switch OFF* 200 Ω or higher CANL (14) - Battery positive LOW-level CAN bus line Ignition switch OFF* 6 kΩ or higher CANL (14) - CG (4) LOW-level CAN bus line Ignition switch OFF* 200 Ω or higher 2. NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. DIAGNOSIS NOTICE: When releasing the parking brake, set chocks to hold the vehicle for safety. BC BC–24 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM (a) Release the parking brake. (b) Turn the ignition switch on (IG). (c) If the skid control ECU detects a malfunction, the ABS warning light and brake warning light will come on to warn the driver. The table below indicates which light will come on when there is a malfunction in a particular function. USA: USA: Canada: Canada: C131968E01 BC Item/Trouble Area ABS System EBD System Skid Control ECU ABS Warning light { { { Brake Warning light - { { 3. {: Light ON -: Light OFF • The DTCs are simultaneously stored in the memory. The DTCs can be read by connecting the SST (09843-18043) between the TC and CG terminals of the DLC3 and observing the blinking pattern of the ABS warning light, or by connecting an intelligent tester (See page BC21). • This system has a sensor signal check function (See page BC-11). WARNING LIGHT INITIAL CHECK NOTICE: When releasing the parking brake, set chocks to hold the vehicle for safety. HINT: When the parking brake is applied or the level of the brake fluid is low, the brake warning light comes on. (a) Release the parking brake. (b) Check that the ABS warning light and brake warning light come on when the ignition switch is turned on (IG) and go off in approximately 3 seconds. (c) If the warning lights do not come on or remain on, inspect the ABS warning light circuit and/or brake warning light circuit. Trouble Area USA: USA: Canada: Canada: C131968E01 See procedure ABS warning light circuit (Remains on) BC-74 ABS warning light circuit (Does not come on) BC-78 Brake warning light circuit (Remains on) BC-81 Brake warning light circuit (Does not come on) BC-91 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM 4. Shake Slightly DLC3: SYMPTOM SIMULATION HINT: The most difficult case in troubleshooting is when no symptoms occur. In such cases, a thorough customer problem analysis must be carried out. Then the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be reproduced. No matter how experienced or skilled a technician may be, if he proceeds to troubleshoot without confirming the problem symptoms, he will likely overlook something important and make a wrong guess at some points in the repair operation. This leads to a standstill in troubleshooting. (a) Vibration method: When vibration seems to be the major cause. HINT: Perform the simulation method only during the primary check period (for approximately 6 seconds after the ignition switch is turned on (IG)). (1) Slightly vibrate the part of the sensor considered to be the problem cause with your fingers and check whether the malfunction occurs. (2) Slightly shake the connector vertically and horizontally. HINT: Shaking the relays too strongly may result in open relays. (3) Slightly shake the wire harness vertically and horizontally. The connector joint and fulcrum of the vibration are the major areas to be checked thoroughly. Vibrate Slightly Vibrate Slightly BC–25 D025083E13 DTC CHECK / CLEAR CG TC 1. G022986E01 DTC CHECK / CLEAR (SST CHECK WIRE) (a) DTC check (1) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 (2) Turn the ignition switch on (IG). (3) Read the DTCs from the ABS warning light on the combination meter. HINT: If no code appears, inspect the TC and CG terminal circuit and the ABS warning light circuit. Trouble Area See procedure TC and CG terminal circuit BC-94 ABS warning light circuit (Remains on) BC-74 ABS warning light circuit (Does not come on) BC-78 BC BC–26 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM (4) As an example, refer to the chart below for the blinking patterns of the normal system code and trouble codes 11 and 21. Normal System Code: Trouble Code (Example Codes 11 and 21): 0.25 sec. 0.5 sec. 2.5 sec. 1.5 sec. 0.25 sec. 2 sec. 0.5 sec. 4 sec. 4 sec. ON ON OFF OFF Repeat Code 11 BC Code 21 I042843E01 (5) The codes are explained in the code table (See page BC-27). (6) After completing the check, disconnect terminals TC and CG of the DLC3, and turn off the display. If 2 or more DTCs are detected at the same time, the DTCs will be displayed in ascending order. DLC3: (b) DTC clear (1) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 (2) Turn the ignition switch on (IG). CG TC G022986E01 BR03890 (3) Clear the DTCs stored in the ECU by depressing the brake pedal 8 times or more within 5 seconds. (4) Check that the warning light indicates the normal system code. (5) Remove the SST from the terminals of the DLC3. HINT: Clearing the DTCs cannot be performed by disconnecting the battery terminal or the ECU-IG fuse. BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM 2. Intelligent Tester DLC3 CAN VIM C131977E05 3. BC–27 DTC CHECK/CLEAR (WHEN USING INTELLIGENT TESTER:) (a) DTC check (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch on (IG). (3) Read the DTCs by following the prompts on the tester screen. (b) DTC clear (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch on (IG). (3) Operate the intelligent tester to clear the codes. HINT: Refer to the intelligent tester operator's manual for further details. END OF DTC CHECK/CLEAR (a) Turn the ignition switch on (IG). (b) Check that the ABS warning light goes off within approximately 3 seconds. BC BC–28 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM FREEZE FRAME DATA 1. BC (c) (d) (e) (f) Intelligent Tester DLC3 FREEZE FRAME DATA (a) Whenever a DTC is detected or the ABS operates, the skid control ECU stores the current vehicle (sensor) status as Freeze Frame Data. (b) The skid control ECU stores the number of times (maximum: 31) the ignition switch has been turned from off to on (IG) since the last time the ABS was activated. HINT: • Freeze frame data at the time the ABS operates: The skid control ECU stores and updates data whenever the ABS system operates. When the skid control ECU stores data at the time a DTC is detected, the data stored during ABS operation is erased. • Freeze frame data at the time a DTC is detected: When the skid control ECU stores data at the time a DTC is detected, no updates will be performed until the data is cleared. Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Select "DTC INFO" on the tester display. On the DTC data display screen, select the DTC data display with "*". CAN VIM C131977E05 Intelligent Tester Display Measurement Item Reference Value TROUBLE CODE Freeze DTC min.: 0, max.: 65535 #DTC Number of trouble codes min.: 0, max.: 255 FREEZE TIME Elapsed time after freeze trigger Min.: 0 ms, Max.: 500 ms #IG ON Number of operations of ignition switch on (IG) after storing freeze frame data 0 to 31 STOP LAMP SW Stop light switch signal Stop light switch ON: ON, OFF: OFF PARKING BRAKE SW Parking brake condition ON: Parking brake on OFF: Parking brake off OPERATED SYSTEM Operated system ABS operated: ABS FR WHEEL SPD Front right wheel speed Min.: 0 MPH (0 km/h), Max.: 202 MPH (326 km/h) FL WHEEL SPD Front left wheel speed Min.: 0 MPH (0 km/h), Max.: 202 MPH (326 km/h) RR WHEEL SPD Rear right wheel speed Min.: 0 MPH (0 km/h), Max.: 202 MPH (326 km/h) BC–29 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM Intelligent Tester Display Measurement Item Reference Value RL WHEEL SPD Rear left wheel speed Min.: 0 MPH (0 km/h), Max.: 202 MPH (326 km/h) VEHICLE SPD Vehicle speed reading Speed indication on the meter SPD GRADE Vehicle speed grade Min.: -1.869 G, Max.: 1.869 G BC BC–30 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM FAIL-SAFE CHART 1. FAIL SAFE OPERATION If there is a problem with sensor signals or brake actuator systems, the skid control ECU will prohibit power supply to the brake actuator and terminate ABS control. ABS control will be prohibited, but EBD control continues as much as possible. If EBD control is impossible, the brake warning light will come on to warn the driver (See page BC-19). Malfunction Area Control Method ABS system Prohibits the ABS control EBD system Prohibits the ABS and EBD control HINT: If the ABS system has a malfunction, the brake system will operate normally without ABS control. BC BC–31 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM DATA LIST / ACTIVE TEST 1. DATA LIST HINT: According to the DATA LIST displayed by the intelligent tester, the value of the switch, sensor, actuator and other items can be read without removing any parts. Reading the DATA LIST as a first step in troubleshooting is one of the methods to save labor time. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) According to the display on the tester, read the "DATA LIST". Intelligent Tester BC DLC3 CAN VIM C131977E05 DATA LIST: Item Measurement Item / Range (Display) Normal Condition Diagnostic Note ABS MOT RELAY ABS motor relay / ON or OFF ON: During pump motor operation OFF: No pump motor operation - SOL RELAY Solenoid relay / ON or OFF ON: Solenoid relay ON OFF: Solenoid relay OFF - STOP LAMP SW Stop light switch / ON or OFF ON: Brake pedal depressed OFF: Brake pedal released - PARKING BRAKE SW Parking brake switch / ON or OFF ON: Parking brake applied OFF: Parking brake released - FR WHEEL SPD Wheel speed sensor (FR) reading / min.: 0 km/h (0 MPH), max.: 326 km/h (202 MPH) Actual wheel speed Speed indicated on speedometer FL WHEEL SPD Wheel speed sensor (FL) reading / min.: 0 km/h (0 MPH), max.: 326 km/h (202 MPH) Actual wheel speed Speed indicated on speedometer RR WHEEL SPD Wheel speed sensor (RR) reading / min.: 0 km/h (0 MPH), max.: 326 km/h (202 MPH) Actual wheel speed Speed indicated on speedometer RL WHEEL SPD Wheel speed sensor (RL) reading / min.: 0 km/h (0 MPH), max.: 326 km/h (202 MPH) Actual wheel speed Speed indicated on speedometer VEHICLE SPD Vehicle speed reading / min.: 0 km/h (0 MPH), max.: 326 km/h (202 MPH) Actual wheel speed Speed indicated on speedometer IG VOLTAGE ECU power supply voltage / NORMAL or TOO LOW NORMAL: 9.5 V or over TOO LOW: Below 9.5 V - SFRR ABS solenoid (SFRR) ON / OFF ON: Operates - SFRH ABS solenoid (SFRH) ON / OFF ON: Operates - SFLR ABS solenoid (SFLR) ON / OFF ON: Operates - BC–32 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM Item Measurement Item / Range (Display) Normal Condition Diagnostic Note SFLH ABS solenoid (SFLH) ON / OFF ON: Operates - SRRR ABS solenoid (SRRR (SRR)) ON / OFF ON: Operates - SRRH ABS solenoid (SRRH (SRH)) ON / OFF ON: Operates - SRLR ABS solenoid (SRLR) ON / OFF ON: Operates - SRLH ABS solenoid (SRLH) ON / OFF ON: Operates - TEST MODE Test mode / NORMAL or TEST NORMAL: Normal mode TEST: During test mode - #CODES Number of DTCs recorded / min.: 0, max.: 255 Min.: 0, max.: 19 - ABS WARN LAMP ABS warning light ON /OFF ON: ABS warning light ON OFF: ABS warning light off - BRAKE WARN LAMP Brake warning light ON / OFF ON: Brake warning light ON OFF: Brake warning light off - FR WHEEL ACCEL Front right wheel acceleration / Min.: -200.84 m/s, Max.: 199.27 m/s 0 m/s - FL WHEEL ACCEL Front left wheel acceleration / Min.: -200.84 m/s, Max.: 199.27 m/s 0 m/s - RR WHEEL ACCEL Rear right wheel acceleration / Min.: -200.84 m/s, Max.: 199.27 m/s 0 m/s - RL WHEEL ACCEL Rear left wheel acceleration / Min.: -200.84 m/s, Max.: 199.27 m/s 0 m/s - FR ABS STATUS Front right ABS control status / ON or OFF ON: During ABS control OFF: Not ABS control - FL ABS STATUS Front left ABS control status / ON or OFF ON: During ABS control OFF: Not ABS control - RR ABS STATUS Rear right ABS control status / ON or OFF ON: During ABS control OFF: Not ABS control - RL ABS STATUS Rear left ABS control status / ON or OFF ON: During ABS control OFF: Not ABS control - FR EBD STATUS Front right EBD control status / ON or OFF ON: During EBD control OFF: Not EBD control - FL EBD STATUS Front left EBD control status / ON or OFF ON: During EBD control OFF: Not EBD control - RR EBD STATUS Rear right EBD control status / ON or OFF ON: During EBD control OFF: Not EBD control - RL EBD STATUS Rear left EBD control status / ON or OFF ON: During EBD control OFF: Not EBD control - BC 2. ACTIVE TEST HINT: Performing the ACTIVE TEST using the intelligent tester allows the relay, actuator and other items to operate without removing any parts. Performing the ACTIVE TEST as a first step in troubleshooting is one of the methods to save labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). BC–33 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM (c) According to the display on the tester, perform the "ACTIVE TEST". ACTIVE TEST: Item Vehicle Condition / Test Details Diagnostic Note SFRR Turns ABS solenoid (SFRR) ON / OFF Operating sound of solenoid (clicking sound) can be heard SFRH Turns ABS solenoid (SFRH) ON / OFF Operating sound of solenoid (clicking sound) can be heard SFLR Turns ABS solenoid (SFLR) ON / OFF Operating sound of solenoid (clicking sound) can be heard SFLH Turns ABS solenoid (SFLH) ON / OFF Operating sound of solenoid (clicking sound) can be heard SRRR Turns ABS solenoid (SRRR) ON / OFF Operating sound of solenoid (clicking sound) can be heard SRRH Turns ABS solenoid (SRRH) ON / OFF Operating sound of solenoid (clicking sound) can be heard SRLR Turns ABS solenoid (SRLR) ON / OFF Operating sound of solenoid (clicking sound) can be heard SRLH Turns ABS solenoid (SRLH) ON / OFF Operating sound of solenoid (clicking sound) can be heard MOT RELAY Turns ABS motor relay ON / OFF Operating sound of motor can be heard ABS WRN LIGHT Turns ABS warning light ON / OFF Observe combination meter BRAKE WRN LIGHT Turns Brake warning light ON / OFF Observe combination meter BC BC–34 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM DIAGNOSTIC TROUBLE CODE CHART NOTICE: Turn the ignition switch off before removing parts. HINT: • If no abnormality is found when inspecting parts, inspect the skid control ECU and ground points for poor contact. • If a malfunction code is displayed during the DTC check, check the circuit indicated by the DTC. For details of each code, refer to the "See page" for respective "DTC No." in the DTC chart. • When 2 or more DTCs are detected, perform circuit inspection one by one until the problem is identified. ANTI-LOCK BRAKE SYSTEM: DTC No. Detection Item Trouble Area See page C0200/31 Right Front Wheel Speed Sensor Signal Malfunction 1. Front speed sensor RH 2. Front speed sensor RH circuit 3. Front speed sensor rotor RH 4. Sensor installation 5. Brake actuator assembly (skid control ECU) BC-30 C0205/32 Left Front Wheel Speed Sensor Signal Malfunction 1. Front speed sensor LH 2. Front speed sensor LH circuit 3. Front speed sensor rotor LH 4. Sensor installation 5. Brake actuator assembly (skid control ECU) BC-30 C0210/33 Right Rear Wheel Speed Sensor Signal Malfunction 1. Rear speed sensor RH 2. Rear speed sensor RH circuit 3. Rear speed sensor rotor RH 4. Sensor installation 5. Brake actuator assembly (skid control ECU) BC-38 C0215/34 Left Rear Wheel Speed Sensor Signal Malfunction 1. Rear speed sensor LH 2. Rear speed sensor LH circuit 3. Rear speed sensor rotor LH 4. Sensor installation 5. Brake actuator assembly (skid control ECU) BC-38 C0226/21 SFR Solenoid Circuit 1. SFRR or SFRH circuit 2. Brake actuator assembly BC-47 C0236/22 SFL Solenoid Circuit 1. SFLR or SFLH circuit 2. Brake actuator assembly BC-47 C0246/23 SRR Solenoid Circuit 1. SRRR or SRRH circuit 2. Brake actuator assembly BC-47 C0256/24 SRL Solenoid Circuit 1. SRLR or SRLH circuit 2. Brake actuator assembly BC-47 C0273/13 Open or Short Circuit in ABS Motor Relay Circuit 1. Brake actuator assembly (motor relay) 2. ABS No. 1 fuse (Fusible link) 3. Wire harness (+BM circuit) BC-49 C0278/11 Open or Short Circuit in ABS Solenoid Relay Circuit 1. Brake actuator assembly (solenoid relay) 2. ABS No. 2 fuse (Fusible link) 3. Wire harness (+BS circuit) BC-53 BC BC–35 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM Trouble Area See page C1237/37 DTC No. Speed Sensor Rotor Faulty Detection Item 1. Brake actuator assembly (skid control ECU) 2. Speed sensor rotor (Front) 3. Rear axle hub and bearing assembly 4. Speed sensor 5. Speed sensor circuit 6. Tire and wheel size 7. Tire deformation BC-56 C1241/41 Low Battery Positive Voltage or Abnormally High Battery Positive Voltage 1. Battery 2. Charging system 3. Power source circuit 4. Brake actuator assembly (Skid control ECU) BC-63 C1249/49 Open in Stop Light Switch Circuit 1. Stop light switch 2. Stop light switch circuit 3. Brake actuator assembly (Skid control ECU) BC-67 C1271/71 Low Output Signal of Front Speed Sensor RH (Test Mode DTC) 1. Front speed sensor RH 2. Sensor installation 3. Skid control rotor BC-30 C1272/72 Low Output Signal of Front Speed Sensor LH (Test Mode DTC) 1. Front speed sensor LH 2. Sensor installation 3. Skid control rotor BC-30 C1273/73 Low Output Signal of Rear Speed Sensor RH (Test Mode DTC) 1. Rear speed sensor RH 2. Sensor installation 3. Skid control rotor BC-38 C1274/74 Low Output Signal of Rear Speed Sensor LH (Test Mode DTC) 1. Rear speed sensor LH 2. Sensor installation 3. Skid control rotor BC-38 C1275/75 Abnormal Change in Output Signal of Front Speed Sensor RH (Test Mode DTC) 1. Front speed sensor RH 2. Front speed sensor circuit RH 3. Sensor installation BC-30 C1276/76 Abnormal Change in Output Signal of Front Speed Sensor LH (Test Mode DTC) 1. Front speed sensor LH 2. Front speed sensor circuit LH 3. Sensor installation BC-30 C1277/77 Abnormal Change in Output Signal of Rear Speed Sensor RH (Test Mode DTC) 1. Rear speed sensor RH 2. Sensor installation 3. Sensor rotor BC-38 C1278/78 Abnormal Change in Output Signal of Rear Speed Sensor LH (Test Mode DTC) 1. Rear speed sensor LH 2. Sensor installation 3. Sensor rotor BC-38 C1300/62 Skid Control ECU Malfunction Brake actuator assembly (skid control ECU) BC-72 C1330/35 Right Front Speed Sensor Circuit 1. Front speed sensor RH 2. Front speed sensor RH circuit 3. Sensor installation BC-30 C1331/36 Left Front Speed Sensor Circuit 1. Front speed sensor LH 2. Front speed sensor LH circuit 3. Sensor installation BC-30 C1332/38 Right Rear Speed Sensor Circuit 1. Rear speed sensor RH 2. Rear speed sensor RH circuit 3. Sensor installation BC-38 C1333/39 Left Rear Speed Sensor Circuit 1. Rear speed sensor LH 2. Rear speed sensor LH circuit 3. Sensor installation BC-38 U0073/94 Control Module Communication Bus OFF 1. Wire harness (CANL, CANH circuit) 2. Brake actuator assembly (skid control ECU) BC-73 BC BC–36 BC BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM DTC C0200/31 Right Front Wheel Speed Sensor Signal Malfunction DTC C0205/32 Left Front Wheel Speed Sensor Signal Malfunction DTC C1271/71 Low Output Signal of Front Speed Sensor RH (Test Mode DTC) DTC C1272/72 Low Output Signal of Front Speed Sensor LH (Test Mode DTC) DTC C1275/75 Abnormal Change in Output Signal of Front Speed Sensor RH (Test Mode DTC) DTC C1276/76 Abnormal Change in Output Signal of Front Speed Sensor LH (Test Mode DTC) DTC C1330/35 Right Front Speed Sensor Circuit DTC C1331/36 Left Front Speed Sensor Circuit DESCRIPTION The speed sensors detect wheel speed and transmit the signals to the skid control ECU. These signals are used for control of the ABS control system. Each of the front and rear rotors has 48 serrations. When the rotors rotate, the magnetic field generated by the permanent magnet in the speed sensor induces AC voltage. Since the frequency of this AC voltage changes in direct proportion to the speed of the rotor, the frequency is used by the ECU to detect the speed of each wheel. DTCs C1271/71 to C1276/76 can be deleted when the speed sensor sends a wheel speed signal or the test mode ends. DTCs C1271/71 to C1276/76 are output only in the test mode. Speed Sensor Rotor Coil N S Magnet To ECU Low speed High speed +V -V F000010E16 BC–37 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM DTC No. DTC Detecting Condition Trouble Area C0200/31 C0205/32 When either of the following is detected: • Vehicle speed is more than 25 mph (40 km/h), and pulses are not input for 0.03 sec. • When the vehicle speed has reached 8 mph (12 km/h) after the initial start or restart, a wheel speed of 0 mph (0 km/h) is detected. • • • • • Front speed sensor RH and/or LH Front speed sensor circuit RH and/or LH Front speed sensor rotor RH and/or LH Sensor installation Brake actuator assembly (skid control ECU) C1330/35 C1331/36 Abnormality in the resistance value of each speed sensor is detected. • • • Front speed sensor RH and/or LH Front speed sensor circuit RH and/or LH Sensor installation C1271/71 C1272/72 Detected only during test mode. • • • Front speed sensor Sensor installation Sensor rotor C1275/75 C1276/76 Detected only during test mode. • • • Front speed sensor Front speed sensor circuit Sensor installation HINT: DTC No. C0200/31 and C1330/35 are for the front speed sensor RH. DTC No. C0205/32 and C1331/36 are for the front speed sensor LH. BC WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) A14 ABS Speed Sensor Front LH A35 ABS Speed Sensor Front RH 1 2 1 2 5 A25 FL+ 6 A25 FL10 A25 FR+ 9 A25 FR- F040884E12 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). 1 READ VALUE OF INTELLIGENT TESTER (FRONT SPEED SENSOR) (a) Connect the intelligent tester to the DLC3. (b) Start the engine. BC–38 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM (c) Select "DATA LIST" and read the value displayed on the intelligent tester (See page BC-25). DATA LIST: ABS Measurement Item / Range (Display) Item Normal Condition FR WHEEL SPD Wheel speed sensor (FR) reading / min.: 0 MPH (0 km/h), max.: 202 MPH (326 km/h) Actual wheel speed FL WHEEL SPD Wheel speed sensor (FL) reading / min.: 0 MPH (0 km/h), max.: 202 MPH (326 km/h) Actual wheel speed (d) Check that there is no difference between the speed value output from the speed sensor displayed on the intelligent tester and the speed value displayed on the speedometer when driving the vehicle. OK: The speed value output from the speed sensor displayed on the intelligent tester is the same as the actual vehicle speed. NG BC Go to step 5 OK 2 PERFORM TEST MODE INSPECTION (SIGNAL CHECK) (a) Check if test mode (signal check) DTCs are detected (See page BC-11). Result Condition Proceed to Test mode (signal check) DTC is not output A Test mode (signal check) DTC is output B B A Go to step 5 BC–39 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM 3 INSPECT SPEED SENSOR SIGNAL WAVEFORM Front Speed Sensor (Wire Harness Side) Connector Front View: A14 A35 FRFLFL+ Normal Signal Waveform: FR+ GND 1 V/Division, 2 ms./Division C132005E01 (a) Lift up the vehicle. (b) Perform the inspection using an oscilloscope. (1) Disconnect the front speed sensor connector. (2) Connect the oscilloscope to terminals 1 and 2 of the front speed sensor. (3) Check that a waveform is output when the tires are rotated. OK: The same waveform is output from front wheels and there is no noise or interference in the waveform. HINT: • As vehicle speed (wheel rotation speed) increases, the width of the waveform narrows and the output voltage becomes greater. • When noise is identified in the waveform on the oscilloscope, the erratic signals are generated due to rotor scratches, looseness or foreign matter attached to the speed sensor. (c) Connect the connector. NG Go to step 11 OK 4 RECONFIRM DTC (a) Clear the DTCs (See page BC-21). (b) Drive the vehicle at a speed of approximately 25 mph (40 km/h) or more for 60 seconds or more. (c) Check if the same DTCs are recorded (See page BC21). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTCs (C0200/31, C0205/32, C1330/35 and C1331/36) are output A DTCs (C0200/31, C0205/32, C1330/35 and C1331/36) are output (When troubleshooting in accordance with the PROBLEM SYMPTOMS TABLE) B DTCs (C0200/31, C0205/32, C1330/35 and C1331/36) are not output (When troubleshooting in accordance with the DTC CHART) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page BC-16) C END BC BC–40 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM A 5 INSPECT FRONT SPEED SENSOR INSTALLATION (a) Check the front speed sensor installation. OK: The installation bolt is tightened properly. There is no clearance between the sensor and front steering knuckle. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) NOTICE: Check the speed sensor signal after replacement (See page BC-11). 8.0 N*m (82 kgf*cm, 71 in.*lbf) OK No clearance NG BR03795E21 BC NG REPLACE FRONT SPEED SENSOR (See page BC-438) OK 6 INSPECT FRONT SPEED SENSOR 2 (a) Make sure that there is no looseness at the locking part and the connecting part of the connectors. (b) Disconnect the front speed sensor connectors. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: LH 1 C093876E01 Tester Connection Specified Condition A14-1 (FL+) - A14-2 (FL-) 0.92 to 1.22 kΩ at 20 °C (68°F) A14-1 (FL+) - Body ground 10 kΩ or higher A14-2 (FL-) - Body ground 10 kΩ or higher Tester Connection Specified Condition A35-1 (FR+) - A35-2 (FR-) 0.92 to 1.22 kΩ at 20 °C(68°F) A35-1 (FR+) - Body ground 10 kΩ or higher A35-2 (FR-) - Body ground 10 kΩ or higher RH NOTICE: Check the speed sensor signal after replacement (See page BC-11). NG OK REPLACE FRONT SPEED SENSOR (See page BC-438) BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM 7 BC–41 CHECK HARNESS AND CONNECTOR (FRONT SPEED SENSOR TO SKID CONTROL ECU) Skid Control ECU (Wire Harness Side) Connector Front View: FL+ FL- FR- FR+ A25 Front Speed Sensor (Wire Harness Side) Connector Front View: A14 (a) Disconnect the skid control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: LH FL+ FR- FR+ C132908E02 Specified Condition A25-5 (FL+) - A14-1 (FL+) Below 1 Ω A25-6 (FL-) - A14-2 (FL-) Below 1 Ω A14-1 (FL+) - Body ground 10 kΩ or higher A14-2 (FL-) - Body ground 10 kΩ or higher Tester Connection Specified Condition A25-10 (FR+) - A35-1 (FR+) Below 1 Ω RH A35 FL- Tester Connection A25-9 (FR-) - A35-2 (FR-) Below 1 Ω A35-1 (FR+) - Body ground 10 kΩ or higher A35-2 (FR-) - Body ground 10 kΩ or higher (c) Connect the connectors. NG REPAIR OR REPLACE HARNESS OR CONNECTOR (FRONT SPEED SENSOR TO SKID CONTROL ECU) OK 8 INSPECT SPEED SENSOR SIGNAL WAVEFORM Front Speed Sensor (Wire Harness Side) Connector Front View: A14 A35 FRFLFL+ Normal Signal Waveform: FR+ GND 1 V/Division, 2 ms./Division C132005E01 (a) Lift up the vehicle. (b) Perform the inspection using an oscilloscope. (1) Disconnect the front speed sensor connector. (2) Connect the oscilloscope to terminals 1 and 2 of the front speed sensor. (3) Check that a waveform is output when the tires are rotated. OK: The same waveforms is output from front wheels and there is no noise or interference in the waveform. HINT: • As vehicle speed (wheel rotation speed) increases, the width of the waveform narrows and the output voltage becomes greater. • When noise is identified in the waveform on the oscilloscope, the erratic signals are generated due to rotor scratches, looseness or foreign matter attached to the speed sensor. (4) Connect the connector. NG Go to step 11 BC BC–42 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM OK 9 READ VALUE OF INTELLIGENT TESTER (FRONT SPEED SENSOR) (a) Connect the intelligent tester to the DLC3. (b) Start the engine. (c) Select "DATA LIST" and read the value displayed on the intelligent tester (See page BC-25). DATA LIST: ABS Measurement Item / Range (Display) Item Normal Condition FR WHEEL SPD Wheel speed sensor (FR) reading / min.: 0 MPH (0 km/h), max.: 202 MPH (326 km/h) Actual wheel speed FL WHEEL SPD Wheel speed sensor (FL) reading / min.: 0 MPH (0 km/h), max.: 202 MPH (326 km/h) Actual wheel speed (d) Check that there is no difference between the speed value output from the speed sensor displayed on the intelligent tester and the speed value displayed on the speedometer when driving the vehicle. OK: The speed value output from the speed sensor displayed on the intelligent tester is the same as the actual vehicle speed. HINT: If troubleshooting has been carried out according to the "PROBLEM SYMPTOMS TABLE", refer back to the table and proceed to the next step before replacing the part (See page BC-16). BC NG REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) OK 10 RECONFIRM DTC (a) Clear the DTCs (See page BC-21). (b) Drive the vehicle at a speed of approximately 25 mph (40 km/h) or more for 60 seconds or more. (c) Check if the same DTCs are recorded (See page BC21). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTCs (C0200/31, C0205/32, C1330/35 and C1331/36) are output A DTCs (C0200/31, C0205/32, C1330/35 and C1331/36) are not output B B END BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM BC–43 A 11 INSPECT SPEED SENSOR TIP (a) Remove the front speed sensor (See page BC-438). (b) Check the sensor tip. OK: No scratches or foreign matter on the sensor tip. NOTICE: Check the speed sensor signal after cleaning or replacement (See page BC-11). (c) Install the speed sensor. NG CLEAN OR REPLACE SPEED SENSOR OK CLEAN OR REPLACE SPEED SENSOR ROTOR BC BC–44 BC BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM DTC C0210/33 Right Rear Wheel Speed Sensor Signal Malfunction DTC C0215/34 Left Rear Wheel Speed Sensor Signal Malfunction DTC C1273/73 Low Output Signal of Rear Speed Sensor RH (Test Mode DTC) DTC C1274/74 Low Output Signal of Rear Speed Sensor LH (Test Mode DTC) DTC C1277/77 Abnormal Change in Output Signal of Rear Speed Sensor RH (Test Mode DTC) DTC C1278/78 Abnormal Change in Output Signal of Rear Speed Sensor LH (Test Mode DTC) DTC C1332/38 Right Rear Speed Sensor Circuit DTC C1333/39 Left Rear Speed Sensor Circuit DESCRIPTION Refer to DTCs C0200/31, C0205/32, C1330/35, and C1331/36 (See page BC-30). DTCs from C1273/73 to C1278/78 can be deleted when the speed sensor sends a vehicle speed signal or the test mode ends. DTCs from C1273/73 to C1278/78 are output only in the test mode. DTC No. DTC Detecting Condition C0210/33 C0215/34 When either of the following is detected: • Vehicle speed is more than 25 mph (40 km/h), and pulses are not input for 0.03 sec. • When the vehicle speed has reached 8 mph (12 km/h), after the initial start or restart a wheel speed of 0 mph (0 km/h) is detected. Trouble Area • • • • • Rear speed sensor RH and/or LH Rear speed sensor circuit RH and/or LH Rear speed sensor rotor RH and/or LH Sensor installation Brake actuator assembly (skid control ECU) C1332/38 C1333/39 Abnormality in the resistance value of each speed sensor is detected. • • • Rear speed sensor RH and/or LH Rear speed sensor circuit RH and/or LH Sensor installation C1273/73 C1274/74 Detected only during test mode. • • • Rear speed sensor Sensor installation Sensor rotor C1277/77 C1278/78 Detected only during test mode. • • • Rear speed sensor Sensor installation Sensor rotor HINT: DTC No. C0210/33 and C1332/38 are for the rear speed sensor RH. DTC No. C0215/34 and C1333/39 are for the rear speed sensor LH. BC–45 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) 2 g1 Speed Sensor Rear LH 7 A25 RL+ 1 2 17 A25 RL- f1 Speed Sensor Rear RH 8 A25 RR- 19 A25 RR+ 1 BC F040884E16 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). 1 READ VALUE OF INTELLIGENT TESTER (REAR SPEED SENSOR) (a) Connect the intelligent tester to the DLC3. (b) Start the engine. (c) Select "DATA LIST" and read the value displayed on the intelligent tester (See page BC-25). DATA LIST: ABS Item Measurement Item / Range (Display) Normal Condition RR WHEEL SPD Wheel speed sensor (RR) reading / min.: 0 MPH (0 km/h), max.: 202 MPH (326 km/h) Actual wheel speed RL WHEEL SPD Wheel speed sensor (RL) reading / min.: 0 MPH (0 km/h), max.: 202 MPH (326 km/h) Actual wheel speed (d) Check that there is no difference between the speed value output from the speed sensor displayed on the intelligent tester and the speed value displayed on the speedometer when driving the vehicle. OK: The speed value output from the speed sensor displayed on the intelligent tester is the same as the actual vehicle speed. NG OK Go to step 5 BC–46 2 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM PERFORM TEST MODE INSPECTION (SIGNAL CHECK) (a) Check if test mode (signal check) DTCs are detected (See page BC-11). Result Condition Proceed to Test mode (signal check) DTC is not output A Test mode (signal check) DTC is output B B Go to step 5 A 3 BC INSPECT SPEED SENSOR SIGNAL WAVEFORM Skid Control ECU (Harness Side Connector Front View): RL- RL+ RR- RR+ Normal Signal Waveform: GND (a) Lift up the vehicle. (b) Perform the inspection using an oscilloscope. (1) Disconnect the skid control ECU connector. (2) Connect the oscilloscope to terminals of the skid control ECU. (3) Check that a waveform is output when the tires are rotated. OK: The same waveform is output from rear wheels and there is no noise or interference in the waveform. HINT: • As vehicle speed (wheel rotation speed) increases, the width of the waveform narrows and the output voltage becomes greater. • When noise is identified in the waveform on the oscilloscope, the erratic signals are generated due to rotor scratches, looseness or foreign matter attached to the speed sensor. (4) Connect the connector. NG CLEAN OR REPLACE SPEED SENSOR AND SENSOR ROTOR 1 V/Division, 2 ms./Division C132907E02 OK 4 RECONFIRM DTC (a) Clear the DTCs (See page BC-21). (b) Drive the vehicle at a speed of approximately 25 mph (40 km/h) or more for 60 seconds or more. BC–47 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM (c) Check if the same DTCs are recorded (See page BC21). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTCs (C0210/33, C0215/34, C1332/38 and C1333/39) are output A DTCs (C0210/33, C0215/34, C1332/38 and C1333/39) are output (When troubleshooting in accordance with the PROBLEM SYMPTOMS TABLE) B DTCs (C0210/33, C0215/34, C1332/38 and C1333/39) are not output (When troubleshooting in accordance with the DTC CHART) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page BC-16) C END A 5 INSPECT SPEED SENSOR INSTALLATION (a) Check the rear speed sensor installation. OK: There is no clearance between the sensor and rear axle carrier. NOTICE: Check the speed sensor signal after replacement (See page BC-11). No Clearance OK NG NG F010178E07 OK REPLACE REAR SPEED SENSOR (See page BC-443) BC BC–48 6 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM INSPECT REAR SPEED SENSOR (a) Disconnect the rear speed sensor connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: LH Rear Speed Sensor: Tester Connection 2 g1-1 (RL+) - g1-2 (RL-) Below 2.2 kΩ g1-1 (RL+) - Body ground 10 kΩ or higher g1-2 (RL-) - Body ground 10 kΩ or higher Tester Connection Specified Condition RH 1 BC Specified Condition C113377E03 f1-1 (RR+) - f1-2 (RR-) Below 2.2 kΩ f1-1 (RR+) - Body ground 10 kΩ or higher f1-2 (RR-) - Body ground 10 kΩ or higher NOTICE: Check the speed sensor signal after replacement (See page BC-11). NG OK REPLACE REAR SPEED SENSOR (See page BC-443) BC–49 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM 7 CHECK HARNESS AND CONNECTOR (SKID CONTROL SENSOR WIRE TO SKID CONTROL ECU) Skid Control ECU (Wire Harness Side) Connector Front View: RL- RL+ RR- RR+ (a) Check harness and connector. (1) Disconnect the skid control ECU connector. (2) Disconnect the skid control sensor wire. (3) Measure the resistance according to the value(s) in the table below. Standard resistance: LH A25 Front Speed Sensor (Wire Harness Side) Connector Front View: Tester Connection Specified Condition A25-7 (RL+) - g1-1 (RL+) Below 1 Ω A25-17 (RL-) - g1-2 (RL-) Below 1 Ω g1-1 (RL+) - Body ground 10 kΩ or higher g1-2 (RL-) - Body ground 10 kΩ or higher RH Tester Connection Specified Condition A25-19 (RR+) - f1-1 (RR+) Below 1 Ω A25-8 (RR-) - f1-2 (RR-) Below 1 Ω 10 kΩ or higher 10 kΩ or higher g1 f1 f1-1 (RR+) - Body ground LH RH f1-2 (RR-) - Body ground NG RL- RL+ RR- RR+ REPAIR OR REPLACE HARNESS OR CONNECTOR (SKID CONTROL ECU TO SKID CONTROL SENSOR WIRE) C132909E03 OK 8 CHECK HARNESS AND CONNECTOR (SKID CONTROL SENSOR WIRE TO REAR SPEED SENSOR) Skid Control Sensor Wire: Vehicle Side Connector (a) Check harness and connector (skid control sensor wire). (1) Measure the resistance according to the value(s) in the table below. Standard resistance: LH Tester Connection g1 LH f1 RH A Specified Condition g1-1 - A-1 Below 1 Ω g1-1 - A-2 10 kΩ or higher g1-1 - Body ground 10 kΩ or higher g1-2 - A-2 Below 1 Ω g1-2 - A-1 10 kΩ or higher g1-2 - Body ground 10 kΩ or higher Tester Connection Specified Condition f1-1 - A-1 Below 1 Ω RH Sensor Side Connector C113396E04 BC BC–50 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM NG Tester Connection Specified Condition f1-1 - A-2 10 kΩ or higher f1-1 - Body ground 10 kΩ or higher f1-2 - A-2 Below 1 Ω f1-2 - A-1 10 kΩ or higher f1-2 - Body ground 10 kΩ or higher REPAIR OR REPLACE SKID CONTROL SENSOR WIRE OK 9 BC INSPECT SPEED SENSOR SIGNAL WAVEFORM Skid Control ECU (Harness Side Connector Front View): RL- RL+ RR- RR+ Normal Signal Waveform: GND (a) Lift up the vehicle. (b) Perform the inspection using the oscilloscope. (1) Disconnect the skid control ECU connector. (2) Connect the oscilloscope to terminals of the skid control ECU. (3) Check that a waveform is output when the tires are rotated. OK: The same waveforms is output from rear wheels and there is no noise or interference in the waveform. HINT: • As vehicle speed (wheel rotation speed) increases, the width of the waveform narrows and the output voltage becomes greater. • When noise is identified in the waveform on the oscilloscope, the erratic signals are generated due to rotor scratches, looseness or foreign matter attached to the speed sensor. (4) Connect the connectors. NG CLEAN OR REPLACE SPEED SENSOR AND SENSOR ROTOR 1 V/Division, 2 ms./Division C132907E02 OK 10 READ VALUE OF INTELLIGENT TESTER (REAR SPEED SENSOR) (a) Connect the intelligent tester to the DLC3. (b) Start the engine. BC–51 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM (c) Select "DATA LIST" and read the value displayed on the intelligent tester (See page BC-25). DATA LIST: ABS Measurement Item / Range (Display) Item Normal Condition RR WHEEL SPD Wheel speed sensor (RR) reading / min.: 0 MPH (0 km/h), max.: 202 MPH (326 km/h) Actual wheel speed RL WHEEL SPD Wheel speed sensor (RL) reading / min.: 0 MPH (0 km/h), max.: 202 MPH (326 km/h) Actual wheel speed (d) Check that there is no difference between the speed value output from the speed sensor displayed on the intelligent tester and the speed value displayed on the speedometer when driving the vehicle. OK: The speed value output from the speed sensor displayed on the intelligent tester is the same as the actual vehicle speed. HINT: • It is suspected that the DTCs were output due to a bad connection of the connector terminal. • If troubleshooting has been carried out according to the "PROBLEM SYMPTOMS TABLE", refer back to the table and proceed to the next step (See page BC16). NG REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) OK 11 RECONFIRM DTC (a) Clear the DTCs (See page BC-21). (b) Drive the vehicle at a speed of approximately 25 mph (40 km/h) or more for 60 seconds or more. (c) Check if the same DTCs are recorded (See page BC21). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTCs (C0210/33, C0215/34, C1332/38 and C1333/39) are output A DTCs (C0210/33, C0215/34, C1332/38 and C1333/39) are not output B B END A 12 INSPECT SPEED SENSOR ROTOR (a) Turn the ignition switch off. (b) Remove the rear axle (See page AH-15). BC BC–52 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM (c) Check the rotor. OK: No scratches, cracks, oil, or foreign matter on the rotors. NOTICE: Check the speed sensor signal after cleaning or replacement (See page BC-11). (d) Install the rear axle (See page AH-16). NG CLEAN OR REPLACE SPEED SENSOR ROTOR OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC BC–53 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM DTC C0226/21 SFR Solenoid Circuit DTC C0236/22 SFL Solenoid Circuit DTC C0246/23 SRR Solenoid Circuit DTC C0256/24 SRL Solenoid Circuit DESCRIPTION These solenoids turn on when signals are received from the ECU and they control the pressure acting on the wheel cylinders thus controlling braking force. DTC No. DTC Detecting Condition Trouble Area C0226/21 C0236/22 C0246/23 C0256/24 Solenoid valve signal does not match the check result. • • Each solenoid circuit Brake actuator assembly BC WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) ALT ABS No. 2 3 A25 +BS 4 FL MAIN A25 GND1 1 A25 GND2 Battery C131988E01 BC–54 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM INSPECTION PROCEDURE 1 RECONFIRM DTC HINT: These codes are detected when a problem is identified in the brake actuator assembly. The solenoid circuit is in the brake actuator assembly. Therefore, solenoid circuit inspection and solenoid unit inspection cannot be performed. Be sure to check if the DTC is output before replacing the brake actuator assembly. (a) Clear the DTC (See page BC-21). (b) Start the engine. (c) Drive the vehicle at a speed of 12 mph (20 km/h) or more for 30 seconds or more. (d) Check if the same DTC is recorded (See page BC-21). Result BC Condition Proceed to DTC is not output A DTC is output B HINT: • If the normal system code is output (the trouble code is not output), slightly jiggle the connectors, wire harness, and fuses of the brake actuator assembly. Make sure that no DTCs are output. • If any DTCs are output while jiggling a connector or wire harness of the brake actuator (skid control ECU), inspect and repair the connector or wire harness. • It is suspected that the DTCs were output due to a bad connection of the connector terminal. B A END REPAIR BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC–55 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM DTC Open or Short Circuit in ABS Motor Relay Circuit C0273/13 DESCRIPTION The ABS motor relay supplies power to the ABS pump motor. While the ABS is activated, the ECU turns the motor relay on and operates the ABS pump motor. If the voltage supplied to the motor relay (+BM) is below the DTCs detection threshold due to low voltage from the battery or alternator, the DTC may be stored. DTC No. DTC Detecting Condition C0273/13 When any of the following is detected: • When the motor relay is actuated, voltage is not supplied to the pump motor within 0.1 second. • When the motor relay is changed from ON to OFF, the remaining high voltage is more than 2 V for 1 second. • For 30 to 125 msec. after the motor relay is turned from ON to OFF, the remaining high voltage is out of range. The voltage is still out of range when the motor relay is turned from ON to OFF 3 times. Trouble Area • • • ABS No. 1 fuse (Fusible link) Wire harness (+BM circuit) Brake actuator assembly (motor relay) BC WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) ALT ABS No. 1 2 A25 +BM 4 FL MAIN A25 GND1 1 A25 GND2 Battery C131988E02 INSPECTION PROCEDURE HINT: • When C1241/41 is output together with C0273/13, inspect and repair the trouble areas indicated by C1241/41 (See page BC-63). BC–56 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM • Check the condition of each related circuit connector before troubleshooting (See page IN-40). 1 INSPECT FUSIBLE LINK (ABS NO. 1 FUSE) Engine Room R/B (a) Remove the fusible link from the engine room R/B. (b) Check if the fusible link is melted. OK: The fusible link is not melted. (c) Install the fusible link to the engine room R/B with the nut. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) Fusible Link NG REPLACE FUSIBLE LINK ABS No. 1 BC C136500E01 OK 2 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (ABS MOTOR RELAY) (a) Connect the intelligent tester to the DLC3. (b) Start the engine. (c) Select "ACTIVE TEST" on the intelligent tester (See page BC-25). ACTIVE TEST: ABS Item ABS MTR RELAY Measurement Item / Range (Display) Turns ABS motor relay ON / OFF Normal Condition Operating sound of motor is heard (d) Check the operating sound of the ABS motor relay when operating it with the intelligent tester. OK: The operating sound of the ABS motor relay should be heard. Result Result Proceed to The operating sound is not heard A The operating sound is heard B B A Go to step 5 BC–57 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM 3 INSPECT SKID CONTROL ECU CONNECTOR (+BM TERMINAL VOLTAGE) Skid Control ECU (Harness Side Connector Front View): A25 +BM (a) Disconnect the skid control ECU connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition A25-2 (+BM) Body ground Always 10 to 14 V NG C131970E02 REPAIR OR REPLACE HARNESS OR CONNECTOR (+BM CIRCUIT) OK 4 INSPECT SKID CONTROL ECU CONNECTOR (GND TERMINAL CONTINUITY) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU (Harness Side Connector Front View): GND2 BC GND1 Tester Connection Specified Condition A25-4 (GND1) - Body ground Below 1 Ω A25-1 (GND2) - Body ground Below 1 Ω (b) Connect the connector. C131970E03 NG REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) OK 5 RECONFIRM DTC HINT: This code is detected when a problem is identified in the brake actuator assembly. The ABS motor relay is in the brake actuator assembly. Therefore, ABS motor relay inspection and motor relay unit inspection cannot be performed. Be sure to check if the DTC is output before replacing the brake actuator assembly. (a) Clear the DTC (See page BC-21). (b) Start the engine. (c) Drive the vehicle at a speed of 12 mph (20 km/h) or more for 30 seconds or more. (d) Check if the same DTC is recorded (See page BC-21). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition DTC is not output Proceed to A BC–58 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM Condition Proceed to DTC is output B HINT: • If the normal system code is output (the trouble code is not output), slightly jiggle the connectors, wire harness, and fuses of the brake actuator assembly. Make sure that no DTCs are output. • If any DTCs are output while jiggling a connector or wire harness of the brake actuator (skid control ECU), inspect and repair the connector or wire harness. • It is suspected that the DTCs were output due to a bad connection of the connector terminal. B REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) A BC CHECK FOR INTERMITTENT PROBLEMS (SYMPTOM SIMULATION) (See page BC-19) BC–59 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM DTC Open or Short Circuit in ABS Solenoid Relay Circuit C0278/11 DESCRIPTION This relay supplies power to each ABS solenoid. If the ABS initial check is OK after the ignition switch is turned on (IG), the skid control ECU will turn the ABS solenoid relay on. DTC No. C0278/11 DTC Detecting Condition Trouble Area When any of the following is detected: • 3 or more solenoid valves are found faulty and simultaneously valve supply voltage is detected to be abnormal. • Solenoid valve relay is not switched off. • Valve relay is stuck open even through the valve relay supply voltage is high. • • • Wire harness (+BS circuit) ABS No. 2 fuse (Fusible link) Brake actuator assembly (Solenoid relay) WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) ALT ABS No. 2 3 A25 +BS 4 FL MAIN A25 GND1 1 A25 GND2 Battery C131988E01 INSPECTION PROCEDURE HINT: • When C1241/41 is output together with C0278/11, inspect and repair the trouble areas indicated by C1241/41 (See page BC-63). • Check the condition of each related circuit before troubleshooting (See page IN-40). BC BC–60 1 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM INSPECT FUSIBLE LINK (ABS NO. 2 FUSE) (a) Remove the fusible link from the engine room R/B. (b) Check if the fusible link is melted. OK: The fusible link is not melted. (c) Install the fusible link to the engine room R/B with the nut. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) Engine Room R/B ABS No. 2 BC NG REPLACE FUSIBLE LINK C136500E02 OK 2 INSPECT SKID CONTROL ECU CONNECTOR (+BS CIRCUIT) Skid Control ECU (Harness Side Connector Front View): +BS A25 (a) Disconnect the skid control ECU connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition A25-3 (+BS) Body ground Always 10 to 14 V NG C131970E10 REPAIR OR REPLACE HARNESS OR CONNECTOR (+BS CIRCUIT) OK 3 INSPECT SKID CONTROL ECU CONNECTOR (GND TERMINAL CONTINUITY) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU (Harness Side Connector Front View): GND2 GND1 A25 Tester Connection Specified Condition A25-4 (GND1) - Body ground Below 1 Ω A25-1 (GND2) - Body ground Below 1 Ω (b) Connect the connector. C131970E05 OK NG REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) BC–61 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM 4 RECONFIRM DTC HINT: This code is detected when a problem is identified in the brake actuator assembly. The solenoid circuit is in the brake actuator assembly. Therefore, solenoid circuit inspection and solenoid unit inspection cannot be performed. Be sure to check if the DTC is output before replacing the brake actuator assembly. (a) Clear the DTC (See page BC-21). (b) Start the engine. (c) Drive the vehicle at a speed of 12 mph (20 km/h) or more for 30 seconds or more. (d) Check if the same DTC is recorded (See page BC-21). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTC is not output A DTC is output B HINT: • If the normal system code is output (the trouble code is not output), slightly jiggle the connectors, wire harnesses, and fuses of the brake actuator assembly. Make sure that no DTCs are output. • If any DTCs are output while jiggling a connector or wire harness of the brake actuator (skid control ECU), inspect and repair the connector or wire harness. • It is suspected that the DTCs were output due to a bad connection of the connector terminal. B REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) A CHECK FOR INTERMITTENT PROBLEMS (SYMPTOM SIMULATION) (See page BC-19) BC BC–62 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM DTC C1237/37 Speed Sensor Rotor Faulty DESCRIPTION The skid control ECU measures the speed of each wheel by receiving signals from the speed sensor. These signals are used for recognizing that all 4 wheels are operating properly. Therefore, all wheel signals must be equal. DTC No. C1237/37 DTC Detecting Condition When any of the following is detected: • Wheel speed difference between the wheels. • Wheel sensor signal failure. • ABS control continues for 60 sec. or more. Trouble Area • • • • • • • Brake actuator assembly (skid control ECU) Speed sensor rotor (Front) Rear axle hub and bearing assembly Speed sensor Speed sensor circuit Tire and wheel size Tire deformation WIRING DIAGRAM BC Brake Actuator Assembly (Skid Control ECU) A14 ABS Speed Sensor Front LH A35 ABS Speed Sensor Front RH 1 2 1 2 5 A25 FL+ 6 A25 FL10 A25 FR+ 9 A25 FR- F040884E12 BC–63 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM Brake Actuator Assembly (Skid Control ECU) 2 g1 Speed Sensor Rear LH 7 A25 RL+ 1 2 17 A25 RL- f1 Speed Sensor Rear RH 8 A25 RR- 19 A25 RR+ 1 BC F040884E16 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). 1 CHECK TIRES (a) Check the size and condition of all 4 tires (See page TW3). HINT: This DTC is output when tire deformation or a difference in tire size is detected. OK: The diameters of all 4 tires and air pressure are the same. NG OK REPLACE TIRES SO THAT ALL 4 TIRES ARE THE SAME SIZE BC–64 2 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM INSPECT SPEED SENSOR AND SENSOR ROTOR SERRATIONS (a) Disconnect the skid control ECU connector. (b) Connect the oscilloscope to each speed sensor terminal of the skid control ECU connector. Terminals Skid Control ECU (Harness Side Connector Front View): FL+ FL- RL- RL+ RR- RR+ FR- FR+ C131970E06 Normal Signal Waveform: BC GND 1 V / Division, 2 ms. / Division C140980E01 Connector Circuit A25-5 (FL+) - A25-6 (FL-) Front left speed sensor A25-10 (FR+) - A25-9 (FR-) Front right speed sensor A25-7 (RL+) - A25-17 (RL-) Rear left speed sensor A25-19 (RR+) - A25-8 (RR-) Rear right speed sensor (c) Check that a waveform is output when the tires are rotated (by the sensor circuit). OK: A waveform as shown in the figure should be output. HINT: • Each sensor circuit outputs the same waveform without noise. • As vehicle speed (wheel rotation speed) increases, the width of the waveform narrows and the output voltage becomes greater. • When noise is identified in the waveform on the oscilloscope, the erratic signals are generated due to rotor scratches, looseness or foreign matter attached to the speed sensor. (d) Make sure that the waveform does not change while jiggling a connector or a wire harness. OK: The waveform does not change. HINT: If the waveform changes while jiggling a connector or a wire harness, there may be a malfunction in the connector or the wire harness. (e) Connect the connector. NG Go to step 4 OK 3 RECONFIRM DTC (a) Clear the DTC (See page BC-21). (b) Start the engine. (c) Drive the vehicle at a speed of 20 mph (32 km/h) or more for 60 seconds or more. (d) Check if the same DTC is recorded (See page BC-21). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. BC–65 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM Result Condition Proceed to DTC is not output A DTC is output B B REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) A CHECK FOR INTERMITTENT PROBLEMS (SYMPTOM SIMULATION) (See page BC-19) 4 CHECK SPEED SENSOR ROTOR (a) Check the speed sensor rotor. Front Speed Sensor Rotor: (See page DS-25) Rear Speed Sensor Rotor: (See page AH-15) OK: No scratches or foreign matter on the rotors. NOTICE: Check the speed sensor signal after the cleaning/ replacement (See page BC-11). NG CLEAN OR REPLACE SPEED SENSOR ROTOR OK 5 CHECK SPEED SENSOR TIP (a) Remove each speed sensor. (b) Check the speed sensor tip. OK: No scratches or foreign matter on the sensor tip. NOTICE: Check the speed sensor signal after the cleaning/ replacement (See page BC-11). (c) Install speed sensor. NG OK CLEAN OR REPLACE SPEED SENSOR BC BC–66 6 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM INSPECT EACH SPEED SENSOR (a) Disconnect each speed sensor connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: FRONT Front Speed Sensor: 1 BC 2 Rear Speed Sensor: Tester Connection Condition Specified Condition A14-1 (FL+) - A14-2 (FL) Always 1.4 to 1.8 kΩ at 20°C (68°F) A14-1 (FL+) - Body ground Always 10 kΩ or higher A14-2 (FL-) - Body ground Always 10 kΩ or higher A35-1 (FR+) - A35-2 (FR-) Always 1.4 to 1.8 kΩ at 20°C (68°F) A35-1 (FR+) - Body ground Always 10 kΩ or higher A35-2 (FR-) - Body ground Always 10 kΩ or higher REAR 1 2 Tester Connection Condition Specified Condition g1-1 (RL+) - g1-2 (RL-) Always Below 2.2 kΩ g1-1 (RL+) - Body ground Always 10 kΩ or higher g1-2 (RL-) - Body ground Always 10 kΩ or higher f1-1 (RR+) - f1-2 (RR-) Always Below 2.2 kΩ f1-1 (RR+) - Body ground Always 10 kΩ or higher f1-2 (RR-) - Body ground Always 10 kΩ or higher C136027E01 (c) Connect the connector. NOTICE: Check the speed sensor signal after replacement (See page BC-11). NG OK REPLACE EACH SPEED SENSOR BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM 7 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU TO EACH SPEED SENSOR) (a) Disconnect the skid control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: FRONT Skid Control ECU Harness Side Connector Front View: A25 BC–67 FL+ FL- RL+ RR- FR- RL- RR+ FR+ Front Speed Sensor Harness Side Connector Front View: A35 A14 FL- FR- FR+ FL+ Tester Connection Condition Specified Condition A25-5 (FL+) - A14-1 (FL+) Always Below 1 Ω A25-6 (FL-) - A14-2 (FL-) Always Below 1 Ω A25-10 (FR+) - A35-1 (FR+) Always Below 1 Ω A25-9 (FR-) - A35-2 (FR) Always Below 1 Ω A25-5 (FL+) - Body ground Always 10 kΩ or higher A25-6 (FL-) - Body ground Always 10 kΩ or higher A25-10 (FR+) - Body ground Always 10 kΩ or higher A25-9 (FR-) - Body ground Always 10 kΩ or higher Tester Connection Condition Specified Condition A25-7 (RL+) - g1-1 (RL+) Always Below 1 Ω A25-17 (RL-) - g1-2 (RL) Always Below 1 Ω A25-19 (RR+) - f1-1 (RR+) Always Below 1 Ω A25-8 (RR-) - f1-2 (RR-) Always Below 1 Ω A25-7 (RL+) - Body ground Always 10 kΩ or higher A25-17 (RL-) - Body ground Always 10 kΩ or higher A25-19 (RR+) - Body ground Always 10 kΩ or higher A25-8 (RR-) - Body ground Always 10 kΩ or higher REAR Rear Speed Sensor Harness Side Connector Front View: g1 f1 RR- RR+ RL- RL+ C136491E02 (c) Connect the connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR (SKID CONTROL ECU TO EACH SPEED SENSOR) OK 8 RECONFIRM DTC (a) Clear the DTC (See page BC-21). (b) Start the engine. BC BC–68 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM (c) Drive the vehicle at the speed of 20 mph (32 km/h) or more for at least 60 seconds. (d) Check if the same DTC is recorded (See page BC-21). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTC (C1237/37) is not output A DTC (C1237/37) is output B B REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) A BC CHECK FOR INTERMITTENT PROBLEMS (SYMPTOM SIMULATION) (See page BC-19) BC–69 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM DTC C1241/41 Low Battery Positive Voltage or Abnormally High Battery Positive Voltage DESCRIPTION If a malfunction is detected in the power supply circuit of the brake actuator assembly (skid control ECU), the skid control ECU (housed in the actuator assembly) stores this DTC and the fail-safe function prohibits ABS operation (See page BC-24). This DTC is output when the IG1 terminal voltage deviates from the normal condition due to a malfunction in the power supply or charging circuit such as the battery or alternator circuit, etc. This DTC is cancelled when the IG1 terminal voltage returns to normal (only when the voltage returns to normal from a voltage lower than the specified value). DTC No. DTC Detecting Condition C1241/41 With vehicle speed more than 4 mph (6 km/h), when any of the following is detected: • Battery voltage is 16.9 V or more. • Battery voltage is 9.4 V or less when ABS does not operate. • Battery voltage is 9.2 V or less when ABS operates. Trouble Area • • • • Battery Charging system Power source circuit Brake actuator assembly (Skid control ECU) BC BC–70 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) IG1 ECU IG No. 2 5 3 2 1 18 A25 IG1 E23 Ignition SW BC (*2) AM1 (*2) IG1 1 4 AM1 (*1) Main Body ECU ALT 6 E7 1 E6 (*1) AM2 AM1 IG1D 3 E7 AM2 4 FL MAIN A25 GND1 1 A25 Battery GND2 *1: with Smart Key System *2: without Smart Key System C136502E01 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). BC–71 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM 1 INSPECT FUSE (ECU-IG NO. 2 FUSE) (a) Remove the ECU-IG No. 2 fuse from the instrument panel J/B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Instrument Panel J/B: ECU-IG No. 2 Fuse Tester Connection Specified Condition ECU-IG No. 2 fuse Below 1 Ω (Continuity) (c) Install the fuse. C136048E01 NG REPLACE FUSE OK 2 INSPECT BATTERY BC (a) Check the battery voltage. Standard voltage: 11 to 14 V NG INSPECT CHARGING SYSTEM OK 3 INSPECT SKID CONTROL ECU CONNECTOR (IG1 TERMINAL VOLTAGE) Skid Control ECU (Harness Side Connector Front View): A25 IG1 OK C131970E07 (a) Disconnect the skid control ECU connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition A25-18 (IG1) Body ground Ignition switch on (IG) 10 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR (IG1 CIRCUIT) BC–72 4 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM INSPECT SKID CONTROL ECU CONNECTOR (GND TERMINAL CONTINUITY) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU (Harness Side Connector Front View): GND2 GND1 A25 Tester Connection Specified Condition A25-4 (GND1) - Body ground Below 1 Ω A25-1 (GND2) - Body ground Below 1 Ω (b) Connect the connector. C131970E05 NG REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) OK BC 5 RECONFIRM DTC (a) Clear the DTC (See page BC-21). (b) Turn the ignition switch on (IG). (c) Check if the same DTC is recorded (See page BC-21). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTC (C1241/41) is output A DTC (C1241/41) is output (When troubleshooting in accordance with the PROBLEM SYMPTOMS TABLE) B DTC (C1241/41) is not output (When troubleshooting in accordance with the DTC CHART) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page BC-16) C END A REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC–73 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM DTC C1249/49 Open in Stop Light Switch Circuit DESCRIPTION This circuit recognizes brake operation by sending a stop light signal to the skid control ECU. The skid control ECU has an open detection circuit, which outputs this DTC when detecting an open in the stop light signal input line (STP terminal) or the ground line of the stop light circuit with the stop light switch off (brake pedal not depressed). DTC No. C1249/49 DTC Detecting Condition Stop light switch circuit is open, and stop light switch voltage is 40% or more and less than 67% of the battery voltage. Trouble Area • • • Stop light switch Stop light switch circuit Brake actuator assembly (Skid Control ECU) BC BC–74 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) A19 Stop Light SW STOP 2 1 20 A25 STP N16 Center Stop Light 2 1 BC S12 Rear Combination Light (RH) Tail 3 ALT Stop FL MAIN Tail 2 Mutiplex Communication System (CAN) 2 Stop Battery 3 N15 Noise Filter (Dome and Stop) S11 Rear Combination Light (LH) C131990E01 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). BC–75 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM 1 CHECK STOP LIGHT SWITCH OPERATION (STOP LIGHT SWITCH CIRCUIT) (a) Check that the stop lights come on when the brake pedal is depressed and goes off when the brake pedal is released. OK Pedal Condition Illumination Condition Brake pedal depressed ON Brake pedal released OFF NG Go to step 5 OK 2 INSPECT SKID CONTROL ECU CONNECTOR (STP TERMINAL) Skid Control ECU (Harness Side Connector Front View): STP A25 (a) Disconnect the skid control ECU connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Switch Condition Specified Condition A25-20 (STP) - Body ground Brake pedal depressed 8 to 14 V A25-20 (STP) - Body ground Brake pedal released Below 4.0 V C131970E08 NG Go to step 7 OK 3 INSPECT SKID CONTROL ECU CONNECTOR (GND TERMINAL CONTINUITY) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU (Harness Side Connector Front View): GND2 GND1 A25 Tester Connection Specified Condition A25-4 (GND1) - Body ground Below 1 Ω A25-1 (GND2) - Body ground Below 1 Ω (b) Connect the connector. C131970E05 NG REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) OK 4 RECONFIRM DTC (a) Clear the DTC (See page BC-21). (b) Start the engine. BC BC–76 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM (c) Depress the brake pedal several times to test the stop light circuit. (d) Check if the same DTC is recorded (See page BC-21). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTC is not output A DTC is output (When troubleshooting in accordance with the DTC CHART) B DTC is output (When troubleshooting in accordance with the PROBLEM SYMPTOMS TABLE) C B REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) C PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page BC-16) BC A CHECK FOR INTERMITTENT PROBLEMS (SYMPTOM SIMULATION) (See page BC-19) 5 INSPECT STOP LIGHT SWITCH ASSEMBLY (POWER SOURCE TERMINAL VOLTAGE) Stop Light Switch (Wire Harness Side) Connector Front View: (a) Disconnect the stop light switch connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition A19-2 - Body ground Always 10 to 14 V A19 NG I042363E17 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (POWER SOURCE CIRCUIT) BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM 6 BC–77 INSPECT STOP LIGHT SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance Stop Light Switch Assembly Tester Connection Condition Specified Condition Switch pin free 1-2 Below 1 Ω Switch pin pushed in 1-2 10 kΩ or higher NG Free REPLACE STOP LIGHT SWITCH ASSEMBLY (See page BR-71) Pushed In BC C113379E01 OK 7 CHECK HARNESS AND CONNECTOR (STOP LIGHT SWITCH TO SKID CONTROL ECU) Skid Control ECU (Wire Harness Side) Connector Front View: STP A25 (a) Disconnect the stop light switch connector and skid control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition A25-20 (STP) - A19-1 (STP) Below 1 Ω (c) Connect the connector. Stop Light Switch (Wire Harness Side) Connector Front View: NG REPAIR OR REPLACE HARNESS OR CONNECTOR (STOP LIGHT SWITCH TO SKID CONTROL ECU) A19 STP C132984E02 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (STOP LIGHT CIRCUIT) BC–78 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM DTC C1300/62 Skid Control ECU Malfunction DESCRIPTION The skid control ECU outputs this DTC, if malfunctions are found in the circuit inside the computer by self diagnosis. DTC No. C1300/62 DTC Detecting Condition Internal failure of the skid control ECU control unit Trouble Area Brake actuator assembly (skid control ECU) INSPECTION PROCEDURE 1 REPLACE BRAKE ACTUATOR ASSEMBLY (a) Replace the brake actuator assembly (skid control ECU) (See page BC-432). HINT: This DTC is output when the skid control ECU detects a malfunction in the internal circuit. (b) Clear the DTC (See page BC-21). BC NEXT END BC–79 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM DTC U0073/94 Control Module Communication Bus OFF DESCRIPTION • The skid control ECU receives the signal sent from the ECM via the CAN communication system. • When DTCs indicating a CAN communication system malfunction are output, repair the CAN communication system before repairing each corresponding sensor. DTC No. U0073/94 DTC Detecting Condition When any of the following is detected: 1. The skid control ECU cannot send a signal (30 cycles). 2. The condition that bus OFF state occurs for 300 msec. Trouble Area • • Wire harness (CANL, CANH circuit) Brake actuator assembly (Skid control ECU) INSPECTION PROCEDURE Proceed to CAN communication system troubleshooting (See page CA-8). HINT: When DTCs indicating a CAN communication system malfunction are output, repair the CAN communication system before repairing each corresponding sensor. BC BC–80 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM ABS Warning Light Remains ON DESCRIPTION The skid control ECU sends the indicator signals to the combination meter assembly via the CAN communication system. If any of the following is detected, the ABS warning light remains on. • The skid control ECU connectors are disconnected from the skid control ECU. • There is a malfunction in the skid control ECU internal circuit. • There is an open in the wire harness between the combination meter and the skid control ECU. • The ABS and/or EBD is defective. HINT: The intelligent tester may not be used when the skid control ECU is abnormal. BC BC–81 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM WIRING DIAGRAM F1 Combination Meter Brake Actuator Assembly (Skid Control ECU) CANH 17 ABS IG+ DRIVER IC 26 A25 CANH 15 MICRO COMPUTER CANL 18 A25 CANL IG1 ECU IG No. 2 5 3 2 1 BC 18 A25 IG1 E23 Ignition SW (*2) AM1 (*2) IG1 4 AM1 1 Main Body ECU E7 (*1) (*1) 6 ALT AM1 IG1D 1 AM2 E6 3 E7 AM2 4 A25 GND1 FL MAIN 1 Battery *1: with Smart Key System A25 GND2 *2: without Smart Key System C136510E01 INSPECTION PROCEDURE HINT: Check the condition of each related circuit before troubleshooting (See page IN-40). BC–82 1 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM INSPECT CAN COMMUNICATION SYSTEM (a) Check if a CAN communication system DTC is output (See page BC-21). Result Condition Proceed to CAN communication system DTC is not output A CAN communication system DTC is output B B INSPECT CAN COMMUNICATION SYSTEM (See page CA-8) A 2 CHECK SKID CONTROL ECU CONNECTOR SECURELY CONNECTED BC (a) Check if the skid control ECU connector is connected. OK: The connector is securely connected. NG CONNECT CONNECTOR TO ECU CORRECTLY OK 3 CHECK BATTERY (a) Check the battery voltage. Standard voltage: 11 to 14 V NG INSPECT CHARGING SYSTEM OK 4 INSPECT SKID CONTROL ECU CONNECTOR (IG1 TERMINAL VOLTAGE) Skid Control ECU (Harness Side Connector Front View): A25 IG1 OK C131970E07 (a) Disconnect the skid control ECU connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition A25-18 (IG1) - Body ground Ignition switch on (IG) 10 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR (IG1 CIRCUIT) BC–83 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM 5 INSPECT SKID CONTROL ECU CONNECTOR (GND TERMINAL CONTINUITY) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU (Harness Side Connector Front View): GND2 GND1 A25 Tester Connection Specified Condition A25-4 (GND1) - Body ground Below 1 Ω A25-1 (GND2) - Body ground Below 1 Ω (b) Connect the connector. C131970E05 NG REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) OK 6 BC INSPECT COMBINATION METER ASSEMBLY (a) Connect the intelligent tester to the DLC3. (b) Select the "ACTIVE TEST" on the tester (See page BC25). ACTIVE TEST: ABS Item Vehicle Condition / Test Details Diagnostic Note ABS WRN LIGHT Turn ABS warning light ON / OFF Observe combination meter (c) Check the ABS warning light operation. OK: The ABS warning light turns on or off in accordance with the intelligent tester. Result Condition Proceed to OK A OK (When troubleshooting in accordance with the PROBLEM SYMPTOMS TABLE) B NG C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page BC-16) C REPLACE COMBINATION METER ASSEMBLY (See page ME-63) A REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC–84 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM ABS Warning Light does not Come ON WIRING DIAGRAM F1 Combination Meter Brake Actuator Assembly (Skid Control ECU) CANH 17 ABS IG+ DRIVER IC 26 A25 CANH 15 MICRO COMPUTER CANL 18 A25 CANL BC IG1 ECU IG No. 2 5 3 2 1 18 A25 IG1 E23 Ignition SW (*2) AM1 (*2) IG1 4 AM1 1 Main Body ECU E7 (*1) (*1) 6 ALT AM2 AM1 IG1D 1 E6 3 E7 AM2 4 A25 GND1 FL MAIN 1 Battery *1: with Smart Key System A25 GND2 *2: without Smart Key System C136510E01 BC–85 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). 1 INSPECT CAN COMMUNICATION SYSTEM (a) Check if a CAN communication system DTC is output (See page BC-21). Result Condition Proceed to CAN communication system DTC is not output A CAN communication system DTC is output B B REPAIR CAN COMMUNICATION SYSTEM (See page CA-8) A 2 BC INSPECT ABS WARNING LIGHT HINT: When disconnecting the skid control ECU connector, the ABS warning light comes on. (a) Turn the ignition switch off. (b) Disconnect the skid control ECU connector. (c) Turn the ignition switch on (IG). (d) Check that the ABS warning light comes on. OK: The ABS warning light comes on. (e) Connect the connector. NG Go to step 3 OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) 3 INSPECT COMBINATION METER ASSEMBLY (a) Connect the intelligent tester to the DLC3. (b) Select the "ACTIVE TEST" on the tester (See page BC25). ACTIVE TEST: METER Item Vehicle Condition / Test Details Diagnostic Note ABS WRN LIGHT Turn ABS warning light ON / OFF Observe combination meter (c) Check the ABS warning light operation. OK: The ABS warning light turns on or off in accordance with the intelligent tester. BC–86 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM NG REPLACE COMBINATION METER ASSEMBLY (See page ME-63) OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM BC–87 Brake Warning Light Remains ON DESCRIPTION The skid control ECU sends the indicator signals to the combination meter assembly via the CAN communication system. If any of the following is detected, the brake warning light remains on: • The skid control ECU connector is disconnected from the skid control ECU. • The brake fluid level is insufficient. • The parking brake is applied. • EBD operation is not possible. BC BC–88 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) Main Body ECU 5 CANH E8 6 CANL E8 Combination Meter CANH BC MICRO COMPUTER CANL 17 26 F1 A25 18 15 F1 A25 CANH CANL BRAKE DRIVER IC 6 F2 IG+ B/LE A16 Brake Fluid Level Warning SW 1 2 E33 (*1) A18 (*2) Parking Brake SW PKB 2 IM 14 IC (*1) (*2) 1 4 A25 GND1 1 A25 GND2 (*1): M/T (*2): A/T C136504E01 BC–89 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM IG1 18 ECU IG No. 2 5 3 2 1 A25 IG1 E23 Ignition SW (*2) AM1 (*2) 4 AM1 IG1 1 BC Main Body ECU ALT 6 E7 (*1) (*1) AM2 AM1 3 IG1D 1 E6 E7 AM2 FL MAIN Battery *1: with Smart Key System *2: without Smart Key System C136505E01 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). 1 CHECK DTC (a) Check if an ABS DTC is output (See page BC-21). Result Condition Proceed to CAN communication system DTC is not output A CAN communication system DTC is output B BC–90 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM B REPAIR CIRCUITS INDICATED BY OUTPUT DTCS (See page BC-27) A 2 INSPECT CAN COMMUNICATION SYSTEM (a) Check if a CAN communication system DTC is output (See page BC-21). Result Condition Proceed to DTC is not output A DTC is output B B BC REPAIR CAN COMMUNICATION SYSTEM (See page CA-8) A 3 CHECK IF SKID CONTROL ECU CONNECTOR SECURELY CONNECTED (a) Check if the skid control ECU connector is connected securely. OK: The connector should be securely connected. NG CONNECT CONNECTOR TO ECU CORRECTLY OK 4 CHECK BATTERY (a) Check the battery voltage. Standard voltage: 11 to 14 V NG OK INSPECT CHARGING SYSTEM BC–91 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM 5 INSPECT SKID CONTROL ECU CONNECTOR (IG1 TERMINAL VOLTAGE) Skid Control ECU (Harness Side Connector Front View): A25 IG1 C131970E07 (a) Disconnect the skid control ECU connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition A25-18 (IG1) - Body ground Ignition switch on (IG) 10 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR (IG1 CIRCUIT) OK 6 (a) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU (Harness Side Connector Front View): GND2 GND1 A25 NG C131970E05 OK BC INSPECT SKID CONTROL ECU CONNECTOR (GND TERMINAL CONTINUITY) Tester Connection Specified Condition A25-4 (GND1) - Body ground Below 1 Ω A25-1 (GND2) - Body ground Below 1 Ω REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) BC–92 7 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM INSPECT PARKING BRAKE SWITCH (a) Remove the parking brake switch. (b) Disconnect the parking brake switch connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Automatic Transaxle Parking Brake Switch: Automatic Transaxle: Free Pushed in Tester Connection Condition Specified Condition (A18-1) - Ground part Free Below 1 Ω (A18-1) - Ground part Pushed in 10 kΩ or higher Condition Specified Condition Manual Transaxle Tester Connection Manual Transaxle: Free BC Pushed in Free Below 1 Ω (E33-1) - Ground part Pushed in 10 kΩ or higher NG C109430E03 OK (E33-1) - Ground part REPLACE PARKING BRAKE SWITCH BC–93 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM 8 CHECK HARNESS AND CONNECTOR (MAIN BODY ECU TO PARKING BRAKE SWITCH) (a) Disconnect the main body ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: Automatic Transaxle Main Body ECU Wire Harness View: IC : Automatic Transaxle Tester Connection Specified Condition IC-14 - A18-1 (PKB) Below 1 Ω A18-1 (PKB) - Body ground 10 kΩ or higher Manual Transaxle IM : Manual Transaxle Specified Condition Below 1 Ω E33-1 (PKB) - Body ground 10 kΩ or higher (c) Connect the connector. NG Parking Brake Switch Harness Side Connector Front View: A18 : Automatic Transaxle E33 : Manual Transaxle C136418E03 OK Tester Connection IM-2 (PKB) - E33-1 (PKB) REPAIR OR REPLACE HARNESS OR CONNECTOR (MAIN BODY ECU TO PARKING BRAKE SWITCH) BC BC–94 9 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM INSPECT BRAKE FLUID LEVEL WARNING SWITCH ASSEMBLY Brake Fluid Level Warning Switch (a) Remove the reservoir tank cap. (b) Disconnect the brake fluid level warning switch connector. (c) Measure the resistance according to the value(s) in the table below. HINT: A float is located inside the reservoir. Its position can be changed by increasing or decreasing the level of brake fluid. Standard resistance A16 MAX Level MIN Level BC Tester Connection Condition Specified Condition (A16-1) - (A16-2) Float UP 10 kΩ or higher (No Continuity) (A16-1) - (A16-2) Float DOWN Below 1 Ω (Continuity) C139740E01 HINT: If there is no problem after finishing the above check, adjust the brake fluid level to the MAX level. NG OK REPLACE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY (BRAKE FLUID LEVEL WARNING SWITCH) BC–95 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM 10 CHECK HARNESS AND CONNECTOR (BRAKE FLUID LEVEL WARNING SWITCH TO COMBINATION METER) (a) Disconnect the combination meter assembly connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Combination Meter Wire Harness View: Tester Connection Specified Condition A16-1 - F2-6 (B/LE) Below 1 Ω F2-6 (B/LE) - Body ground 10 kΩ or higher A16-2 - Body ground Below 1 Ω (c) Connect the connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR (BRAKE FLUID LEVEL WARNING SWITCH TO COMBINATION METER) F2-6 (B/LE) Brake Fluid Level Warning Switch Harness Side Connector Front View: A16 C136033E01 OK 11 INSPECT COMBINATION METER ASSEMBLY (a) Connect the intelligent tester to the DLC3. (b) Select the "ACTIVE TEST" on the tester (See page BC25). ACTIVE TEST: ABS Item Vehicle Condition / Test Details Diagnostic Note BRAKE WARN LIGHT Turn brake warning light ON / OFF Observe combination meter (c) Check the ABS warning light operation. OK: The BRAKE warning light turns on or off in accordance with the intelligent tester. Result Condition Proceed to OK A OK (When troubleshooting in accordance with the PROBLEM SYMPTOMS TABLE) B NG C BC BC–96 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page BC-16) C REPLACE COMBINATION METER ASSEMBLY (See page ME-63) A REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC BC–97 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM Brake Warning Light does not Come ON WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) Main Body ECU 5 CANH E8 6 CANL E8 Combination Meter CANH MICRO COMPUTER CANL 17 26 F1 A25 18 15 F1 A25 BC CANH CANL BRAKE DRIVER IC 6 F2 IG+ B/LE A16 Brake Fluid Level Warning SW 1 2 E33 (*1) A18 (*2) Parking Brake SW PKB 2 IM 14 IC (*1) (*2) 1 4 A25 GND1 1 A25 GND2 (*1): M/T (*2): A/T C136504E01 BC–98 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM IG1 18 ECU IG No. 2 5 3 2 1 A25 IG1 E23 Ignition SW (*2) AM1 (*2) 4 AM1 IG1 1 BC Main Body ECU ALT 6 E7 (*1) (*1) AM2 AM1 IG1D 1 E6 3 E7 AM2 FL MAIN Battery *1: with Smart Key System *2: without Smart Key System C136505E01 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). 1 INSPECT CAN COMMUNICATION SYSTEM (a) Check if a CAN communication system DTC is output (See page BC-21). Result Condition Proceed to CAN communication system DTC is not output A CAN communication system DTC is output B BC–99 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM B REPAIR CAN COMMUNICATION SYSTEM (See page CA-8) A 2 INSPECT BRAKE WARNING LIGHT HINT: When disconnecting the skid control ECU connector, the brake warning light comes on. (a) Turn the ignition switch off. (b) Disconnect the skid control ECU connector. (c) Turn the ignition switch on (IG). (d) Check that the brake warning light comes on. OK: The brake warning light comes on. NG Go to step 3 BC OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) 3 INSPECT COMBINATION METER ASSEMBLY (a) Connect the intelligent tester to the DLC3. (b) Select the "ACTIVE TEST" on the tester (See page BC25). ACTIVE TEST: METER Item Vehicle Condition / Test Details Diagnostic Note BRAKE WARN LIGHT Turn brake warning light ON / OFF Observe combination meter (c) Check the ABS warning light operation. OK: The BRAKE warning light turns on or off in accordance with the intelligent tester. NG REPLACE COMBINATION METER ASSEMBLY (See page ME-63) OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC–100 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM TC and CG Terminal Circuit DESCRIPTION DTC output mode is set by connecting terminals TC and CG of the DLC3. DTCs are indicated by the blinking pattern of the ABS warning light. WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) ECM CANH BC CANL 41 41 A55 *1 A24 *2 49 A55 *1 49 A55 *2 26 A25 CANH 15 A25 CANL E10 DLC3 27 TC A55 *1 27 A24 *2 13 *1: 2GR-FE *2: 2AZ-FE 4 TC CG C136513E01 HINT: When warning lights continue to blink, a ground short in the wiring of terminal TC of the DLC3 or an internal ground short in one or more ECUs is suspected. INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). 1 CHECK CAN COMMUNICATION SYSTEM (a) Check if a CAN communication DTC is output (See page BC-21). Result Result Proceed to CAN communication system DTC is output A CAN communication system DTC is not output B BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM B BC–101 Go to step 2 A GO TO CAN COMMUNICATION SYSTEM (See page CA-8) 2 CHECK HARNESS AND CONNECTOR (ECM TO DLC3) (a) Disconnect the ECM connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance 2GR-FE DLC3: E10 Tester Connection Specified Condition A55-27 (TC) - E10-13 (TC) Below 1 Ω E10-13 (TC) - Body ground 10 kΩ or higher 2AZ-FE TC ECM Wire Harness View: Tester Connection Specified Condition A24-27 (TC) - E10-13 (TC) Below 1 Ω E10-13 (TC) - Body ground 10 kΩ or higher (c) Connect the connector. NG A55-27 (TC) (*1) A24-27 (TC) (*2) (*1): 2GR-FE (*2): 2AZ-FE C136035E02 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (TC TERMINAL CIRCUIT) BC BC–102 3 DLC3: BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM CHECK HARNESS AND CONNECTOR (DLC3 CG CIRCUIT) (a) Measure the resistance according to the value(s) in the table below. Standard resistance CG E10 NG Tester Connection Specified Condition E10-4 (CG) - Body ground Below 1 Ω REPAIR OR REPLACE HARNESS OR CONNECTOR (CG TERMINAL CIRCUIT) G022986E25 OK BC 4 REPAIR OR REPLACE HARNESS OR CONNECTOR (TC TERMINAL CIRCUIT) (a) Measure the resistance according to the value(s) in the table below. Standard resistance DLC3: E10 NG Tester Connection Specified Condition E10-13 (TC) - Body ground 10 kΩ or higher CHECK HARNESS AND CONNECTOR (TC TERMINAL CIRCUIT) G022986E26 OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC–103 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM TS and CG Terminal Circuit DESCRIPTION In the Test Mode (signal check), a malfunction of the speed sensor that cannot be detected when the vehicle is stopped can be detected while driving. Transition to the sensor check mode can be performed by connecting terminals TS and CG of the DLC3 and turning the ignition switch from off to on (IG). WIRING DIAGRAM A25 Brake Actuator Assembly E10 DLC3 TS CG (Skid Control ECU) 12 25 BC TS 4 C109400E11 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). BC–104 1 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU TO DLC3) (a) Disconnect the skid control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Contorl ECU (Harness Side Connector Front View): A25 Tester Connection Condition Specified Condition A25-25 (TS) - E10-12 (TS) Always Below 1 Ω (c) Connect the connector. NG TS DLC3: REPAIR OR REPLACE HARNESS OR CONNECTOR (SKID CONTROL ECU TO DLC3) BC E10 TS C133301E02 OK 2 DLC3: CHECK HARNESS AND CONNECTOR (DLC3 TO BODY GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance CG Tester Connection Condition Specified Condition E10-4 (CG) - Body ground Always Below 1 Ω E10 NG G022987E23 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (DLC3 TO BODY GROUND) BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM 3 BC–105 CHECK HARNESS AND CONNECTOR (DLC3 TO BODY GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance DLC3: Tester Connection Condition Specified Condition E10-12 (TS) - Body ground Always 10 kΩ or higher E10 NG TS REPAIR OR REPLACE HARNESS OR CONNECTOR (DLC3 TO BODY GROUND) G022987E24 OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC BC–100 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) PRECAUTION 1. Expression BC EXPRESSIONS OF IGNITION SWITCH The type of ignition switch used on this model differs according to the specifications of the vehicle. The expressions listed in the table below are used in this section. Switch Type Ignition Switch (Position) Engine Switch (Condition) Ignition switch off LOCK off Ignition switch on (IG) ON on (IG) Ignition switch on (ACC) ACC on (ACC) Engine start START start 2. 3. TROUBLESHOOTING PRECAUTIONS (a) When there is a malfunction with terminal contact points or part installation problems, removal and installation of the suspected problem parts may return the system to the normal condition either completely or temporarily. (b) In order to determine the malfunctioning area, be sure to check the conditions at the time the malfunction occurred, such as DTC output and the Freeze Frame Data, and record it before disconnecting each connector or removing and installing parts. (c) Since the system may be influenced by malfunctions in systems other than the brake control system, be sure to check for DTCs in other systems. HANDLING PRECAUTIONS (a) Do not remove or install VSC parts such as the steering angle sensor or yaw rate sensor (acceleration sensor included) except when required, as they cannot be adjusted correctly after removal or installation. (b) Be sure to perform preparation before work and confirmation after work is completed by following the direction in the repair manual when working on the VSC system. (c) Be sure to remove and install the ECU, actuator, each sensor, etc. with the ignition switch off unless it is not specified in the inspection procedure. (d) If the ECU, brake actuator, or a sensor has been removed and installed, it is necessary to check the system for problems after the parts have been reassembled. Check for DTCs using the intelligent tester, also check that system functions and signals received by the ECU are normal using Test Mode. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 4. 5. 6. BC–101 DTC PRECAUTION (a) Warnings for some DTCs cannot be cleared only by repairing the malfunctioning parts. If the warning is displayed after repair work, the DTC should be cleared after turning the ignition switch off. NOTICE: If a DTC for a malfunctioning part reappears after it was cleared, then it has been stored again. CHASSIS DYNAMOMETER PRECAUTION (a) Enter Test Mode to disable TRAC and VSC control when using a chassis dynamometer. HINT: The vehicle may move unexpectedly out of the dynamometer because of TRAC and VSC operations. NOTICE: • Make sure that the VSC warning light is blinking (for vehicles without the multi information display) or "CHECK VSC SYSTEM" is displayed on the multi information display (for vehicles with the multi information display) (Test Mode is achieved). • Secure the vehicle with the lock chain for safety. CAN COMMUNICATION SYSTEM PRECAUTIONS (a) The CAN communication system is used for the data communication between the skid control ECU, the steering angle sensor, the yaw rate sensor (acceleration sensor included) and other ECUs. If there is trouble in the CAN communication line, corresponding DTCs in the communication line are output. (b) If the DTC in the CAN communication line is output, repair the malfunction in the communication line and troubleshoot the VSC system while data communication is normal. (c) In order to enable CAN communication, a specific type of wiring is used for the CAN communication lines. The wiring used for each communication line is a twisted pair of wires that have an equal length. A bypass wire should not be used, because the data being transmitted will be corrupted. BC BC–102 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) PARTS LOCATION SKID CONTROL SENSOR (REAR SPEED SENSOR) BRAKE ACTUATOR - SKID CONTROL ECU ECM (*2) ECM (*1) BC BRAKE MASTER CYLINDER - BRAKE FLUID LEVEL WARNING SWITCH ENGINE ROOM R/B - ABS MOTOR RELAY FRONT SPEED SENSOR (VSC NO. 1 (FAIL SAFE) RELAY) (VSC NO. 2 RELAY) - ABS NO. 1 FUSE - ABS NO. 2 FUSE (*1): 2GR-FE (*2): 2AZ-FE C135800E01 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–103 COMBINATION METER - ABS WARNING LIGHT - BRAKE WARNING LIGHT - VSC WARNING LIGHT (*3) - MULTI INFORMATION DISPLAY (*4) - SLIP INDICATOR LIGHT - MASTER CAUTION INDICATOR LIGHT PARKING BRAKE SWITCH (*5) BC PARKING BRAKE SWITCH (*6) SKID CONTROL BUZZER DLC3 STEERING ANGLE SENSOR YAW RATE AND ACCELERATION SENSOR STOP LIGHT SWITCH MAIN BODY ECU (INSTRUMENT PANEL J/B) - ECU-IG NO. 2 FUSE - STOP FUSE (*3): Models without Multi Information Display (*5): A/T (*4): Models with Multi Information Display (*6): M/T C135801E04 BC–104 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) SYSTEM DIAGRAM Brake Actuator Assembly Speed Sensor (on Each Wheel) Master Cylinder Pressure Sensor Solenoid Relay BC Switching Solenoid Valve Stop Light Switch Control Solenoid Valve Skid Control ECU Pump Motor Stop Light VSC NO. 2 Relay Skid Control Buzzer VSC NO. 1 (Fail Safe) Relay C109461E02 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–105 Combination Meter Skid Control ECU Speedometer ABS Warning Light BRAKE Warning Light Steering Angle Sensor BC VSC Warning Light (*1) Multi Information Display (*2) Yaw Rate and Acceleration Sensor SLIP Indicator Light ECM Master Caution Indicator Light Main Body ECU DLC3 (*1): Models without Multi Information Display (*2): Models with Multi Information Display CAN Communication System C140724E01 BC–106 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) Transmitting ECU (transmitter) Receiving ECU ECM Skid control ECU Skid control ECU Yaw rate and acceleration sensor Skid control ECU Steering angle sensor Skid control ECU ECM Signals • • • • • • Combination meter BC CAN communication system Steering angle sensor request signal CAN communication system • • Wheel speed signal VSC data signal CAN communication system • • ABS warning light ON signal BRAKE warning light ON signal VSC warning light ON signal (*1) Multi information display ON signal (*2) SLIP indicator light ON signal Master caution indicator light ON signal Wheel speed signal CAN communication system • • • • Main body ECU Skid control ECU CAN communication system Yaw rate and acceleration request signal • Skid control ECU Shift position signal Throttle position signal Engine revolution signal Intake air temperature signal Engine torque request signal Accelerator pedal position signal Communication method Parking brake switch signal CAN communication system (*1): Models without multi information display (*2): Models with multi information display BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–107 SYSTEM DESCRIPTION 1. FUNCTION DESCRIPTION HINT: • The skid control ECU is located within the brake actuator assembly. • The yaw rate sensor and acceleration sensor are combined in a single unit. This unit communicates with the skid control ECU through CAN communication. (a) ABS (Anti-lock Brake System) The ABS helps prevent the wheels from locking when the brakes are applied firmly or when braking on a slippery surface. Brake Actuator Assembly BC Pump Motor Each Speed Sensor Each Wheel Cylinder Skid Control ECU Solenoid Valve Combination Meter ABS Warning Light : CAN Communication System : Hydraulic Pressure C109467E01 BC–108 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) (1) Operation description The skid control ECU detects wheel lock based on speed signals it receives from the wheel speed sensors. Based on this information, the skid control ECU controls the pump motor and solenoid valves. The pump motor and solenoid valves are used to prevent wheel lock by controlling the hydraulic pressure applied to the brakes at each wheel. The ABS warning light will come on when the system is malfunctioning. (b) EBD (Electronic Brake force Distribution) The EBD control utilizes ABS, and performs proper brake force distribution between the front and rear wheels in accordance with driving conditions. When braking while cornering, it also controls the brake forces of the right and left wheels, helping to maintain vehicle behavior. BC Brake Actuator Assembly Each Speed Sensor Skid Control ECU Solenoid Valves Each Wheel Cylinder Combination Meter BRAKE Warning Light : CAN Communication System : Hydraulic Pressure C109468E02 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–109 (1) Operation description The skid control ECU receives a speed signal from each wheel speed sensor, and uses these signals to detect locking of the wheels. The ECU uses this information in order to determine appropriate control of the solenoid valves. The solenoid valves control the hydraulic pressure applied to the brake cylinder at each wheel. In this way, the solenoid valves are used to control the brake power split between the front and rear, and left and right wheels. The BRAKE warning light will come on if there is a malfunction in the EBD system. BC BC–110 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) (c) BA (Brake Assist) The primary purpose of the brake assist system is to provide auxiliary brake force to assist the driver who cannot generate a large enough brake force during emergency braking, thus helping to maximize the brake performance of the vehicle. Brake Actuator Assembly Pump Motor Each Wheel Cylinder Each Speed Sensor Skid Control ECU Solenoid Valve BC Master Cylinder Pressure Sensor ECM Combination Meter ABS Warning Light : CAN Communication System : Hydraulic Pressure C109469E01 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–111 (1) Operation description The skid control ECU receives the speed signal from each speed sensor and the fluid pressure signal from the master cylinder pressure sensor to determine whether brake assist is necessary. If brake assist is necessary, the skid control ECU sends control signals to the pump motor and solenoid. The pump and the solenoid valve then control the pressure applied to each wheel cylinder. The ABS warning light comes on to indicate a malfunction in the BA system. BC BC–112 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) (d) TRAC (Traction Control) The TRAC system helps prevent the drive wheels from slipping when the driver depresses the accelerator pedal excessively when starting off or accelerating on a slippery surface. Brake Actuator Assembly Pump Motor Each Speed Sensor Skid Control ECU Each Wheel Cylinder Solenoid Valve BC Yaw Rate and Acceleration Sensor Combination Meter VSC Warning Light (*1) Steering Angle Sensor Multi Information Display (*2) ECM SLIP Indicator Light : CAN Communication System (*1): Models without Multi Information Display : Hydraulic Pressure (*2): Models with Multi Information Display C109470E03 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–113 (1) Operation description The skid control ECU detects wheelspin by receiving signals from each speed sensor and the ECM via CAN communication. The skid control ECU controls engine torque with the ECM via CAN communication and brake hydraulic pressure through the pump and solenoid valve. The SLIP indicator light blinks when the system is operating. When there is a malfunction in the TRAC system, both VSC warning light (models without multi information display) and SLIP indicator light will come on and the DTC will be displayed on the multi information display (models with multi information display). BC BC–114 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) (e) VSC (Vehicle Stability Control) The VSC system helps prevent the vehicle from slipping sideways as a result of strong front or rear wheel skid during cornering. Brake Actuator Assembly Pump Motor Each Speed Sensor Each Wheel Cylinder Skid Control ECU Solenoid Valves Skid Control Buzzer BC Yaw Rate and Acceleration Sensor Combination Meter VSC Warning Light (*1) Steering Angle Sensor Multi Information Display (*2) ECM SLIP Indicator Light : CAN Communication System (*1): Models without Multi Information Display : Hydraulic Pressure (*2): Models with Multi Information Display C109471E03 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 2. 3. BC–115 (1) Operation description The skid control ECU determines the vehicle operating conditions based on signals received from the wheel speed sensors, yaw rate and acceleration sensor, and steering angle sensor. The skid control ECU sends signals via CAN communication to the ECM in order to control engine torque. The skid control ECU controls brake hydraulic pressure using the pump and solenoid valves. The SLIP indicator light will blink, and the skid control buzzer will sound when the system is operating. If a malfunction occurs in the VSC system, both the VSC warning light (models without multi information display) and the SLIP indicator light will come on. In addition, the DTC will appear on the multi information display (models with multi information display). ABS with EBD, BA, TRAC and VSC OPERATION (a) The skid control ECU calculates vehicle stability tendency based on the signals from the speed sensor, yaw rate and acceleration sensor, and steering angle sensor. In addition, it evaluates the results of the calculations to determine whether any control actions (control of the engine output torque by electronic throttle control and of the wheel brake pressure by the brake actuator assembly) should be implemented. (b) The SLIP indicator blinks and the skid control buzzer sounds to inform the driver that the VSC system is operating. The SLIP indicator also blinks when traction control is operating, and the operation being performed is displayed. FAIL SAFE (a) When a failure occurs in the ABS with BA, TRAC and VSC systems, the ABS warning, VSC warning (models without multi information display), and SLIP indicator lights come on or the DTC will be displayed on the multi information display (models with multi information display) and ABS with BA, TRAC and VSC operations are prohibited. In addition, when there is a failure that disables the EBD operation, the BRAKE warning light also comes on and the EBD operation is prohibited. (b) If control is prohibited due to a malfunction during operation, control will be disabled gradually. This is to avoid sudden vehicle instability. BC BC–116 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 4. INITIAL CHECK (a) When the vehicle speed first becomes approximately 4 mph (6 km/h) or more after the ignition switch is turned on (IG), each solenoid valve and motor of the brake actuator is sequentially activated to perform an electrical check. During the initial check, the operating sound of solenoid valve and motor can be heard from the engine compartment, but this is not a malfunction. INSPECTION MODE (a) VSC operation can be disabled by operating the intelligent tester. HINT: Refer to the intelligent tester operator's manual for further details. FUNCTION OF COMPONENTS 5. 6. Components BC Speed sensor Function Detects the wheel speed and sends the signal to the skid control ECU. • Skid control ECU (housed in brake actuator assembly) • • • Consists of the master cylinder cut solenoid valve, retention solenoid valve, pressure reduction solenoid valve, pump motor, and reservoir, and adjusts the brake fluid pressure applied to each wheel cylinder. Houses the skid control ECU. • • Supplies power to each solenoid. Housed in the skid control ECU. Brake actuator assembly Solenoid relay Processes the signals sent from each sensor to control the ABS, BA, TRAC, and VSC. Sends and receives the control signals to or from the ECM, yaw rate and acceleration sensor, and steering angle sensor, etc. via CAN communication. Motor relay (VSC NO. 2 relay) Supplies power to the pump motor. Fail safe relay (VSC NO. 1 relay) Cuts off power to the motor when the pump motor circuit malfunctions. • • Steering angle sensor • • Installed in the combination switch. Detects the steering amount and direction and sends the signals to the skid control ECU via CAN communication. Has the magnetic resistance element which detects the rotation of the magnet housed in the detection gear in order to detect the changes of magnetic resistance and the steering amount and direction. • Acceleration sensor measures the capacity of the condenser that changes the distance between the electrodes depending on G force, which occurs when the vehicle is accelerated, and converts the measured value into electrical signals. Yaw rate sensor detects the vehicle's angular velocity (yaw rate) in the vertical direction based on the amount and direction of the piezoelectric ceramics deflection. Sends signals to the skid control ECU via CAN communication. Master cylinder pressure sensor • • Detects the fluid pressure in the master cylinder. Housed in the brake actuator assembly. Stop light switch Detects the brake operating conditions and inputs the results to the skid control ECU. ECM Controls the engine output when TRAC and VSC are operating with the skid control ECU via CAN communication. Yaw rate and acceleration sensor Skid control buzzer • Intermittently sounds to inform the driver that the VSC is operating. • ABS warning light • • BRAKE warning light • Comes on to inform the driver that a malfunction in the ABS or BA has occurred. Blinks to output DTC. Comes on to inform the driver that the parking brake is ON when the system is normal, or the brake fluid has decreased. Comes on to inform the driver that a malfunction in the EBD has occurred. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) Components BC–117 Function • VSC warning light (*1) • • Multi information display (*2) • Comes on to inform the driver that a malfunction in the VSC system has occurred. Blinks to output DTC. Displays to inform the driver that a malfunction in the VSC system has occurred. Displays to output DTC. SLIP indicator light Blinks to inform the driver that TRAC and VSC are operating. Master caution indicator light Comes on to inform the driver that a malfunction. (*1): Models without multi information display (*2): Models with multi information display BC BC–118 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) HOW TO PROCEED WITH TROUBLESHOOTING HINT: The intelligent tester can be used at steps 3, 7, and 10. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS (a) Interview the customer and confirm the trouble (See page IN-45). NEXT BC 3 CHECK DTC AND FREEZE FRAME DATA (a) Check and record a DTC and Freeze Frame Data. (b) Clear the DTC and Freeze Frame Data (See page BC141). (c) Reconfirm the DTC. (1) Reconfirm the DTC based on the recorded DTC and Freeze Frame Data (See page BC-141 for DTC Check/Clear, and BC-144 for Freeze Frame Data). HINT: If any of the DTCs U0100/65, U0123/62, U0124/95, and U0126/63 is output together with a CAN communication DTC, first check the appropriate sensor for a momentary open circuit (See page BC118). Result Condition Proceed to DTC is output A DTC is not output (Problem symptom does not occur) B DTC is not output (Problem symptom occurs) C B GO TO STEP 5 C GO TO STEP 6 A 4 DIAGNOSTIC TROUBLE CODE CHART (a) Proceed to Diagnostic Trouble Code Chart (See page BC-151). BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–119 NEXT GO TO STEP 7 5 SYMPTOM SIMULATION (a) Proceed to Diagnosis System (See page BC-138). NEXT 6 PROBLEM SYMPTOMS TABLE (a) Proceed to Problem Symptoms Table (See page BC134). NEXT 7 BC CIRCUIT INSPECTION NEXT 8 IDENTIFICATION OF PROBLEM NEXT 9 REPAIR OR REPLACEMENT NEXT 10 NEXT END CONFIRMATION TEST BC–120 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) CHECK FOR INTERMITTENT PROBLEMS 1. CHECK FOR INTERMITTENT PROBLEMS HINT: A momentary interruption (open circuit) in the connectors and/or wire harness between the sensors and ECUs can be detected using the ECU Data List function of the intelligent tester. (a) Turn the ignition switch off and connect the intelligent tester to the DLC3. BC DLC3 Intelligent Tester C131977E06 Harness Signal: OK Momentary interruption 1 sec. 1 sec. 1 sec. Intelligent Tester Display: ERROR NORMAL (b) Turn the ignition switch on (IG). Follow the directions on the intelligent tester to display the Data List and select areas where momentary interruption should be monitored. HINT: • A momentary interruption (open circuit) cannot be detected for 3 seconds after the ignition switch is turned on (IG) (initial check). • If the status remains on (ERROR displayed), check the continuity between the ECU and the sensors, or between ECUs. • The ERROR display on the intelligent tester remains on for 1 second after the harness signal changes from momentary interruption (open circuit) to normal condition. C106657E02 Item (Display) Measurement Item / Range (Display) Normal Condition Diagnostic Note FR SPD OPN FR speed sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - FL SPD OPN FL speed sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - RR SPD OPN RR speed sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - RL SPD OPN RL speed sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - EFI COM OPN EFI communication open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–121 Item (Display) Measurement Item / Range (Display) Normal Condition Diagnostic Note YAW RATE OPN Yaw rate sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - DECELERAT OPN Acceleration sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - STEERING OPN Steering angle sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - M/C OPN Master cylinder pressure sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - (c) While observing the screen, gently jiggle the connector or wire harness between the ECU and sensors, or between ECUs. Result: ERROR display does not change. HINT: The connector and/or wire harness will be in momentary interruption (open circuit) if the display changes. Repair or replace the connector and/or wire harness as one of them is faulty. F047126 BC BC–138 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) PROBLEM SYMPTOMS TABLE If there are no DTCs output and the problem still occurs, check the circuits for each problem symptom in the order given in the table below and proceed to the relevant troubleshooting page. HINT: • Inspect the fuse and relay before investigating the suspected areas as shown in the table below. • Inspect each malfunction circuit in numerical order for the corresponding symptom. Vehicle Stability Control System: Symptom BC ABS, BA and/or EBD does not operate ABS, BA and/or EBD does not operate efficiently ABS sensor DTC check cannot be done ABS warning light abnormal (Remains on) ABS warning light abnormal (Does not come on) BRAKE warning light abnormal (Remains on) BRAKE warning light abnormal (Does not come on) Suspected Area See page 1. Check the DTC again and make sure that the normal system code is output. BC-141 2. IG power source circuit BC-207 3. Front speed sensor circuit BC-156 4. Rear speed sensor circuit BC-164 5. Check the brake actuator assembly with the intelligent tester. (Check brake actuator assembly operation using the Active Test function.) If abnormal, check the hydraulic circuit for leakage. BC-425 6. If the symptoms still occur even after the above circuits in suspected areas have been inspected and proved to be normal, replace the brake actuator assembly (skid control ECU). BC-426 1. Check the DTC again and make sure that the normal system code is output. BC-141 2. Front speed sensor circuit BC-156 3. Rear speed sensor circuit BC-164 4. Stop light switch circuit BC-213 5. Check the brake actuator assembly with the intelligent tester. (Check brake actuator assembly operation using the Active Test function.) If abnormal, check the hydraulic circuit for leakage. BC-425 6. If the symptoms still occur even after the above circuits in suspected areas have been inspected and proved to be normal, replace the brake actuator assembly (skid control ECU). BC-426 1. Check the DTC again and make sure that the normal system code is output. BC-141 2. TC and CG terminal circuit BC-266 3. If the symptoms still occur even after the above circuit in suspected areas has been inspected and proved to be normal, replace the brake actuator assembly (skid control ECU). BC-426 1. ABS warning light circuit BC-229 2. Brake actuator assembly (Skid control ECU) BC-426 1. ABS warning light circuit BC-233 2. Brake actuator assembly (Skid control ECU) BC-426 1. BRAKE warning light circuit BC-244 2. Brake actuator assembly (Skid control ECU) BC-426 1. BRAKE warning light circuit BC-252 2. Brake actuator assembly (Skid control ECU) BC-426 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) Symptom Suspected Area VSC sensor DTC check cannot be done VSC warning light abnormal (Remains on) (*1) VSC warning light abnormal (Does not come on) (*1) Multi information display abnormal (Remains on) (*2) Multi information display abnormal (Does not come on) (*2) SLIP indicator light abnormal (Remains on) SLIP indicator light abnormal (Does not come on) Sensor check cannot be done Skid control buzzer abnormal See page 1. Check the DTC again and make sure that the normal system code is output. BC-141 2. IG power source circuit BC-207 3. Check the hydraulic circuit for leakage VSC and/or TRAC does not operate BC–139 - 4. Front speed sensor circuit BC-156 5. Rear speed sensor circuit BC-164 6. Yaw rate and acceleration sensor circuit BC-193 7. Steering angle sensor circuit BC-190 8. If the symptoms still occur even after the above circuits in suspected areas have been inspected and proved to be normal, replace the brake actuator assembly (skid control ECU). BC-426 1. Check the DTC again and make sure that the normal system code is output. BC-141 2. TC and CG terminal circuit BC-266 3. If the symptoms still occur even after the above circuit in suspected areas has been inspected and proved to be normal, replace the brake actuator assembly (skid control ECU). BC-426 1. VSC warning light circuit BC-236 2. Brake actuator assembly (Skid control ECU) BC-426 1. VSC warning light circuit BC-240 2. Brake actuator assembly (Skid control ECU) BC-426 1. VSC warning light circuit BC-236 2. Brake actuator assembly (Skid control ECU) BC-426 1. VSC warning light circuit BC-240 2. Brake actuator assembly (Skid control ECU) BC-426 1. SLIP indicator light circuit BC-255 2. Brake actuator assembly (Skid control ECU) BC-426 1. SLIP indicator light circuit BC-259 2. Brake actuator assembly (Skid control ECU) BC-426 1. TS and CG terminal circuit BC-269 2. Brake actuator assembly (Skid control ECU) BC-426 1. Skid control buzzer circuit BC-263 2. Brake actuator assembly (Skid control ECU) BC-426 (*1): Models without multi information display (*2): Models with multi information display BC BC–140 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) TERMINALS OF ECU 1. Terminal of ECU Skid Control ECU: F045080E06 BC Symbols (Terminal No.) Terminal Description GND2 (1) Pump motor ground BM (2) Motor relay input FR+ (3) Front wheel speed RH signal power supply output FL- (4) Front wheel speed LH signal input RR+ (5) Rear wheel speed RH signal power supply output RL- (6) Rear wheel speed LH signal input CANH (11) CAN communication line H SP1 (12) Speed signal output for combination meter D/G (13) Diagnosis tester communication line MRF (14) Fail safe motor relay output MR (15) Motor relay output FR- (17) Front wheel speed RH signal input FL+ (18) Front wheel speed LH signal power supply output RR- (19) Rear wheel speed RH signal input RL+ (20) Rear wheel speed LH signal power supply output TS (24) Test mode (signal check) input CANL (25) CAN communication line L STP (27) Stop light switch input BZ (30) Skid control buzzer output +BS (31) Solenoid relay power supply GND1 (32) Skid control ECU ground WFSE (42) WFSE input R+ (45) Power supply for motor relay IG1 (46) IG1 power supply BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 2. BC–141 Terminal Inspection (a) Disconnect the connector and measure the voltage or resistance on the wire harness side. Skid Control ECU Harness Side Connector Front View: A26 F049377E11 HINT: Voltage cannot be measured with the connector connected to the skid control ECU because the connector is watertight. Standard BC Symbols (Terminal No.) Wiring Color GND2 (A26-1) - Body ground W-B - Body ground STP (A26-27) - Body ground Terminal Description Condition Specified Condition Below 1 Ω Pump motor ground Ignition switch off P - Body ground Stop light switch input Stop light switch ON → OFF (Brake pedal depressed → released) 8 to 14 V → Below 1.5 V BZ (A26-30) - Body ground R - Body ground Buzzer output Ignition switch on (IG), when buzzer not sounding 6 to 10 V +BS (A26-31) - Body ground L - Body ground Solenoid relay power supply Always 10 to 14 V GND1 (A26-32) - Body ground W-B - Body ground Skid control ECU ground Always Below 1 Ω IG1 (A26-46) - Body ground P - Body ground IG1 power supply Ignition switch on (IG) 10 to 14 V BC–122 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) CALIBRATION 1. Replacing Parts / Operation DESCRIPTION • After replacing the VSC relevant components or performing "Front wheel alignment adjustment", clear and read the sensor calibration data. • Follow the chart to perform calibration. Necessary Operation Skid control ECU Yaw rate and acceleration sensor zero point calibration. Yaw rate and acceleration sensor 1. Clearing zero point calibration data. 2. Yaw rate and acceleration sensor zero point calibration. Front wheel alignment adjustment 1. Clearing zero point calibration data. 2. Yaw rate and acceleration sensor zero point calibration. 2. BC OBTAIN ZERO POINT OF YAW RATE AND ACCELERATION SENSOR (INTELLIGENT TESTER) NOTICE: • While obtaining the zero point, keep the vehicle stationary and do not vibrate, tilt, move, or shake it. (Do not start the engine.) • Be sure to perform this procedure on a level surface (with an inclination of less than 1 degree). (a) Clear the zero point calibration data. (1) Turn the ignition switch off. (2) Connect the intelligent tester to the DLC3. (3) Check that the steering wheel is centered and move the shift lever to the P position (A/T) or apply the parking brake (M/T). (4) Turn the ignition switch on (IG). DLC3 Intelligent Tester C131977E06 (5) Operate the intelligent tester to erase the codes (select "RESET MEMORY"). HINT: Refer to the intelligent tester operator's manual for further details. C106531 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–123 (6) Turn the ignition switch off. NOTICE: If the ignition switch is turned on (IG) for more than 15 seconds with the shift lever in the P position (A/T) or the parking brake applied (M/T) after zero point of the yaw rate and acceleration sensor has been cleared, only the zero point of the yaw rate sensor will be stored. If the vehicle is driven under these conditions, the skid control ECU will store the zero point calibration for the acceleration sensor as not being completed. The skid control ECU will then also indicate this as a malfunction of the VSC system using the indicator lights (models without multi information display) or multi information display (models with multi information display). (b) Perform zero point calibration of the yaw rate and acceleration sensor. (1) Turn the ignition switch off. (2) Check that the steering wheel is centered and move the shift lever to the P position (A/T) or apply the parking brake (M/T). NOTICE: DTCs C1210/36 and C1336/39 will be recorded if the shift lever is not in the P position (A/T) or the parking brake is not applied (M/T) (See page BC-188). (3) Connect the intelligent tester to the DLC3. (4) Turn the ignition switch on (IG). DLC3 Intelligent Tester C131977E06 BC BC–124 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) (5) Set the intelligent tester to Test Mode (select "TEST MODE"). HINT: Refer to the intelligent tester operator's manual for further details. (6) After the Test Mode has been entered, keep the vehicle stationary on a level surface for 2 seconds or more. C106532 TEST MODE Blinking Pattern: 0.13 sec. BC 0.13 sec. ON OFF Display: C135802E01 DLC3: CG TS G022987E07 3. (7) Check that the VSC warning light blinks (models without multi information display) or "CHECK VSC SYSTEM" is displayed on the multi information display (models with multi information display) (Test Mode). HINT: • The SLIP indicator light remains on during Test Mode because TRAC is prohibited. • If the VSC warning light does not blink (models without multi information display) or "CHECK VSC SYSTEM" is not displayed on the multi information display (models with multi information display), perform zero point calibration again. • The zero point calibration is performed only once after the system enters the Test Mode. • Calibration cannot be performed again until the stored data is cleared. (8) Turn the ignition switch off and disconnect the intelligent tester. OBTAIN ZERO POINT OF YAW RATE AND ACCELERATION SENSOR (SST CHECK WIRE) NOTICE: • While obtaining the zero point, keep the vehicle stationary and do not vibrate, tilt, move, or shake it. (Do not start the engine.) • Be sure to perform the procedure on a level surface (with an inclination of less than 1 degree). (a) Clear the zero point calibration data. (1) Turn the ignition switch off. (2) Check that the steering wheel is centered and move the shift lever to the P position (A/T) or apply the parking brake (M/T). (3) Turn the ignition switch on (IG). (4) The warning light and indicator light come on for 3 seconds to indicate that the initial check is completed. (5) Using SST, connect and disconnect terminals TS and CG of the DLC3 4 times or more within 8 seconds. SST 09843-18040 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–125 NOTICE: If the ignition switch is turned on (IG) for more than 15 seconds with the shift lever in the P position (A/T) or the parking brake applied (M/T) after zero point of the yaw rate and acceleration sensor has been cleared, only the zero point of the yaw rate sensor will be stored. If the vehicle is driven under these conditions, the skid control ECU will store the zero point calibration for the acceleration sensor as not being completed. The skid control ECU will then also indicate this as a malfunction of the VSC system using the indicator lights (models without multi information display) or multi information display (models with multi information display). (b) Perform zero point calibration of the yaw rate and acceleration sensor. (1) Turn the ignition switch off. (2) Check that the steering wheel is centered and move the shift lever to the P position (A/T) or apply the parking brake (M/T). NOTICE: DTCs C1210/36 and C1336/39 will be recorded if the shift lever is not in the P position (A/T) or the parking brake is not applied (M/T) (See page BC-188). DLC3: (3) Using SST, connect terminals TS and CG of the DLC3. SST 09843-18040 (4) Turn the ignition switch on (IG). (5) Keep the vehicle stationary on a level surface for 2 seconds or more. CG TS G022987E07 BC BC–126 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) (6) Check that the VSC warning light blinks (models without multi information display) or "CHECK VSC SYSTEM" is displayed on the multi information display (models with multi information display) (Test Mode). HINT: • The SLIP indicator light remains on during Test Mode because TRAC is prohibited. • If the VSC warning light does not blink (models without multi information display) or "CHECK VSC SYSTEM" is not displayed on the multi information display (models with multi information display), perform zero point calibration again. • The zero point calibration is performed only once after the system enters the Test Mode. • Calibration cannot be performed again until the stored data is cleared. (7) Turn the ignition switch off and disconnect the SST from the DLC3. TEST MODE Blinking Pattern: 0.13 sec. 0.13 sec. ON OFF Display: BC C135802E01 TEST MODE PROCEDURE ABS Warning Light: BRAKE Warning Light: VSC Warning Light (*1): SLIP Indicator Light: Master Caution Indicator Light: (*1): Models without Multi Information Display C140885E01 1. WARNING LIGHT AND INDICATOR LIGHT INITIAL CHECK (a) Release the parking brake. NOTICE: Before releasing the parking brake, move the shift lever to the P position for safety (A/T) or set the chocks to hold the vehicle for safety (M/T). HINT: When the parking brake is applied or the level of the brake fluid is low, the BRAKE warning light comes on. (b) When the ignition switch is turned on (IG), check that the ABS warning, BRAKE warning, SLIP indicator, and master caution indicator lights come on for approximately 3 seconds. Vehicles equipped with VSC, which are not equipped with a multi information display, the VSC warning light will illuminate instead of the master caution indicator light. HINT: If the ECU stores a DTC, the ABS warning, BRAKE warning, VSC warning and SLIP indicator lights will come on. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–127 If the vehicle is equipped with a multi information display, and the vehicle stores a DTC, the master caution indicator light will illuminate, and the multi information display will indicate the malfunction instead of the VSC warning light. In this case, the ABS warning, BRAKE warning, and SLIP indicator lights will also come on. If the indicator remains on or does not come on, proceed to troubleshooting for the light circuits listed below. Trouble Area ABS warning light circuit See procedure BC-229 or BC-233 BRAKE warning light circuit BC-244 or BC-252 VSC warning light circuit BC-236 or BC-240 SLIP indicator light circuit BC-255 or BC-259 2. SENSOR CHECK USING TEST MODE (SIGNAL CHECK) (INTELLIGENT TESTER) NOTICE: After replacement of the brake actuator assembly and/or yaw rate and acceleration sensor, perform zero point calibration of the yaw rate and acceleration sensor. HINT: • If the ignition switch is turned from on (IG) to on (ACC) or off during Test Mode (signal check), DTCs of the signal check function will be erased. • During Test Mode (signal check), the skid control ECU records all DTCs of the signal check function. By performing the Test Mode (signal check), the codes are erased if a normal condition is confirmed. The remaining codes are the codes where an abnormality was found. (a) Procedure to enter Test Mode. (1) Turn the ignition switch off. (2) Connect the intelligent tester to the DLC3. (3) Check that the steering wheel is centered and move the shift lever to the P position (A/T) or apply the parking brake (M/T). (4) Turn the ignition switch on (IG). DLC3 Intelligent Tester C131977E06 BC BC–128 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) (5) Set the intelligent tester to Test Mode (select "SIGNAL CHECK"). HINT: Refer to the intelligent tester operator's manual for further details. C106533 (6) Check that the ABS and VSC (models without multi information display) warning lights blink or "CHECK VSC SYSTEM" is displayed on the multi information display (models with multi information display) (Test Mode). HINT: • The SLIP indicator light remains on during Test Mode because TRAC is prohibited. • If the ABS and VSC (models without multi information display) warning lights do not blink or "CHECK VSC SYSTEM" is not displayed on the multi information display (models with multi information display), inspect the TS and CG terminal circuit, and ABS and VSC warning light circuits. TEST MODE Blinking Pattern: 0.13 sec. BC 0.13 sec. ON OFF Display: Trouble Area See procedure TS and CG terminal circuit BC-269 ABS warning light circuit BC-233 VSC warning light circuit BC-240 C135802E01 Blinking Pattern in TEST MODE: 0.13 sec. 0.13 sec. ON 3. OFF BR03904E16 4. (7) Check the ABS sensor. HINT: Check that the ABS warning light is blinking in Test Mode and perform the check. ACCELERATION SENSOR CHECK (INTELLIGENT TESTER) (a) Keep the vehicle stationary on a level surface for 1 second or more. HINT: Acceleration sensor check can be performed with the master cylinder pressure sensor check below. MASTER CYLINDER PRESSURE SENSOR CHECK (INTELLIGENT TESTER) (a) Leave the vehicle in a stationary condition and release the brake pedal for 1 second or more, and quickly and continuously depress the brake pedal with a force of 98 N (10 kgf, 22 lbf) or more for 1 second. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 5. BC–129 (b) Check that the ABS warning light stays on for 3 seconds. HINT: • Ensure that the ABS warning light comes on. • While the ABS warning light stays on, continue to depress the brake pedal with a force of 98 N (10 kgf, 22 lbf) or more. • The ABS warning light comes on for 3 seconds every time brake pedal operation above is performed. • If the check of the master cylinder pressure sensor is not completed, depressing the brake pedal causes further decrease in the negative pressure, making the sensor check difficult to be completed. • If the negative pressure is insufficient, the master cylinder pressure sensor check may not be completed. In this case, run the engine at idle to obtain sufficient negative pressure. • If the brake pedal is strongly depressed when the negative pressure is insufficient, the BRAKE warning light may come on in accordance with the booster pressure control. In this case, run the engine at idle to obtain sufficient negative pressure. SPEED SENSOR CHECK (INTELLIGENT TESTER) (a) Check the speed sensor signal. (1) Drive the vehicle straight ahead. Accelerate the vehicle to a speed of 28 mph (45 km/h) or more for several seconds and check that the ABS warning light goes off. HINT: The sensor check may not be completed if wheelspin occurs. (b) Stop the vehicle. NOTICE: • Before performing the speed sensor check, complete the acceleration sensor and master cylinder pressure sensor checks. • The speed sensor check may not be completed if the speed sensor check is started while turning the steering wheel or spinning the wheels. • After the ABS warning light goes off and if the vehicle speed exceeds 50 mph (80 km/h), a signal check code will be stored again. Accelerate or stop the vehicle before the speed reaches 50 mph (80 km/h). • If the signal check has not been completed, the ABS warning light blinks while driving and the ABS system does not operate. BC BC–130 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) HINT: When the sensor check has been completed, the ABS warning light goes off while driving and blinks in the Test Mode pattern while stationary. (c) Check the VSC sensor. Check that the VSC warning light (models without multi information display) blinks or "CHECK VSC SYSTEM" is displayed on the multi information display (models with multi information display), and perform the check. TEST MODE Blinking Pattern: 0.13 sec. 0.13 sec. ON OFF Display: BC C135802E01 6. Start Position Within +- 5 deg. End Position C137757E01 YAW RATE SENSOR CHECK (INTELLIGENT TESTER) (a) Check the output of the yaw rate sensor. (1) Keep the vehicle in a stationary condition on a level surface for 1 second or more. (2) Move the shift lever from P to the D position (A/ T) or release the parking brake (M/T) and drive the vehicle at a speed of approximately 3 mph (5 km/h), and turn the steering wheel either to the left or right 90° or more until the vehicle makes a 180° turn. (3) Stop the vehicle and move the shift lever to the P position (A/T) or apply the parking brake (M/T). Check that the skid control buzzer sounds for 3 seconds. HINT: • If the skid control buzzer sounds, the sensor check is completed normally. • If the skid control buzzer does not sound, check the skid control buzzer circuit (See page BC-263), then perform the sensor check again. • If the skid control buzzer still does not sound, there is a malfunction in the yaw rate sensor, so check the DTC. • Make a 180° turn. At the end of the turn, the direction of the vehicle should be within 180° +- 5° of its start position. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–131 • Do not spin the wheels. • Do not turn the ignition switch off while turning. • Do not move the shift lever to the P position (A/T) or do not apply the parking brake (M/T) while turning, but changing in the vehicle speed, stopping, or driving in reverse is possible. • Complete the turn within 20 seconds. 7. Blinking Pattern in TEST MODE: 0.13 sec. 0.13 sec. ON OFF BR03904E16 8. 9. END OF SENSOR CHECK (INTELLIGENT TESTER) (a) If the sensor check is completed, the ABS warning light blinks (Test Mode) when the vehicle stops and the ABS warning light is off while the vehicle is driving. NOTICE: • When the yaw rate sensor, acceleration sensor, speed sensor, and master cylinder pressure sensor checks are completed, the sensor check is completed. • If the sensor check is not completed, the ABS warning light blinks even while the vehicle is driving and the ABS does not operate. READ DTC OF SIGNAL CHECK FUNCTION (INTELLIGENT TESTER) (a) Read the DTC(s) by following the tester screen. NOTICE: • If only the DTCs are displayed, repair the malfunction area and clear the DTCs. • If the DTCs or Test Mode codes (DTC of signal check function) are displayed, repair the malfunction area, clear the DTCs and perform the Test Mode inspection. HINT: See the list of DTC (See procedure "A"). SENSOR CHECK USING TEST MODE (SIGNAL CHECK) (SST CHECK WIRE) NOTICE: After replacement of the brake actuator assembly and/or yaw rate and acceleration sensor, perform zero point calibration of the yaw rate and acceleration sensor. HINT: • If the ignition switch is turned from on (IG) to on (ACC) or off during Test Mode (signal check), DTCs of the signal check function will be erased. • During Test Mode (signal check), the skid control ECU records all DTCs of the signal check function. By performing the Test Mode (signal check), the codes are erased if a normal condition is confirmed. The remaining codes are the codes where an abnormality was found. (a) Procedure to enter Test Mode. (1) Turn the ignition switch off. BC BC–132 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) (2) Check that the steering wheel is centered and move the shift lever to the P position (A/T) or apply the parking brake (M/T). DLC3: (3) Using SST, connect terminals TS and CG of the DLC3. SST 09843-18040 (4) Turn the ignition switch on (IG). CG TS G022987E07 (5) Check that the ABS and VSC (models without multi information display) warning lights blink or "CHECK VSC SYSTEM" is displayed on the multi information display (models with multi information display) (Test Mode). HINT: • The SLIP indicator light remains on during Test Mode because TRAC is prohibited. • If the ABS and VSC (models without multi information display) warning lights do not blink or "CHECK VSC SYSTEM" is not displayed on the multi information display (models with multi information display), inspect the TS and CG terminal circuit, and ABS and VSC warning light circuits. TEST MODE Blinking Pattern: BC 0.13 sec. 0.13 sec. ON OFF Display: Trouble Area See procedure TS and CG terminal circuit BC-269 ABS warning light circuit BC-233 VSC warning light circuit BC-240 C135802E01 Blinking Pattern in TEST MODE: 0.13 sec. 0.13 sec. ON OFF BR03904E16 (6) Check the ABS sensor. HINT: Check that the ABS warning light is blinking in Test Mode and perform the check. 10. ACCELERATION SENSOR CHECK (SST CHECK WIRE) (a) Keep the vehicle stationary on a level surface for 1 second or more. HINT: Acceleration sensor check can be performed with the master cylinder pressure sensor check below. 11. MASTER CYLINDER PRESSURE SENSOR CHECK (SST CHECK WIRE) (a) Leave the vehicle in a stationary condition and release the brake pedal for 1 second or more, and quickly and continuously depress the brake pedal with a force of 98 N (10 kgf, 22 lbf) or more for 1 second. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–133 (b) Check that the ABS warning light stays on for 3 seconds. HINT: • Ensure that the ABS warning light comes on. • While the ABS warning light stays on, continue to depress the brake pedal with a force of 98 N (10 kgf, 22 lbf) or more. • The ABS warning light comes on for 3 seconds every time the brake pedal operation above is performed. • If the check of the master cylinder pressure sensor is not completed, depressing the brake pedal causes further decrease in the negative pressure, making the sensor check difficult to be completed. • If the negative pressure is insufficient, the master cylinder pressure sensor check may not be completed. In this case, run the engine at idle to obtain sufficient negative pressure. • If the brake pedal is strongly depressed when the negative pressure is insufficient, the BRAKE warning light may come on in accordance with the booster pressure control. In this case, run the engine at idle to obtain sufficient negative pressure. 12. SPEED SENSOR CHECK (SST CHECK WIRE) (a) Check the speed sensor signal. (1) Drive the vehicle straight ahead. Accelerate the vehicle to a speed of 28 mph (45 km/h) or more for several seconds and check that the ABS warning light goes off. HINT: The sensor check may not be completed if wheelspin occurs. (b) Stop the vehicle. NOTICE: • Before performing the speed sensor check, complete the acceleration sensor and master cylinder pressure sensor checks. • The speed sensor check may not be completed if the speed sensor check is started while turning the steering wheel or spinning the wheels. • After the ABS warning light goes off, if vehicle speed exceeds 50 mph (80 km/h), a signal check code will be stored again. Accelerate or stop the vehicle before the speed reaches 50 mph (80 km/h). • If the signal check has not been completed, the ABS warning light blinks while driving and the ABS system does not operate. BC BC–134 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) HINT: When the sensor check has been completed, the ABS warning light goes off while driving and blinks in the Test Mode pattern while stationary. (c) Check the VSC sensor. Check that the VSC warning light (models without multi information display) blinks or "CHECK VSC SYSTEM" is displayed on the multi information display (models with multi information display), and perform the check. TEST MODE Blinking Pattern: 0.13 sec. 0.13 sec. ON OFF Display: BC C135802E01 Start Position Within +- 5 deg. End Position C137757E01 13. YAW RATE SENSOR CHECK (SST CHECK WIRE) (a) Check the output of the yaw rate sensor. (1) Keep the vehicle stationary on a level surface for 1 second or more. (2) Move the shift lever from P to the D position (A/ T) or release the parking brake (M/T) and drive the vehicle at a vehicle speed of approximately 3 mph (5 km/h) and turn the steering wheel either to the left or right 90° or more and until the vehicle makes a 180° turn. (3) Stop the vehicle and move the shift lever to the P position (A/T) or apply the parking brake (M/T). Check that the skid control buzzer sounds for 3 seconds. HINT: • If the skid control buzzer sounds, the sensor check is completed normally. • If the skid control buzzer does not sound, check the skid control buzzer circuit (See page BC-263), then perform the sensor check again. • If the skid control buzzer still does not sound, there is a malfunction in the yaw rate sensor, so check the DTC. • Make a 180° turn. At the end of the turn, the direction of the vehicle should be within 180° +- 5° of its start position. • Do not spin the wheels. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–135 • Do not turn the ignition switch off while turning. • Do not move the shift lever to the P position (A/T) or do not apply the parking brake (M/T) while turning, but changing in the vehicle speed, stopping, or driving in reverse is possible. • Complete the turn within 20 seconds. Blinking Pattern in TEST MODE: 0.13 sec. 0.13 sec. ON OFF BR03904E16 DLC3: 15. READ DTC OF SIGNAL CHECK FUNCTION (SST CHECK WIRE) (a) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 CG TS 14. END OF SENSOR CHECK (SST CHECK WIRE) (a) If the sensor check is completed, the ABS warning light blinks (Test Mode) when the vehicle stops and the ABS warning light is off while the vehicle is driving. NOTICE: • When the yaw rate sensor, acceleration sensor, speed sensor, and master cylinder pressure sensor checks are completed, the sensor check is completed. • If the sensor check is not completed, the ABS warning light blinks even while the vehicle is driving and the ABS does not operate. TC G022988E01 BC BC–136 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) (b) Count the number of blinks of the ABS and VSC (models without multi information display) warning lights or read "DIAG VSC" on the multi information display (models with multi information display). Blinking Pattern in Normal System Code: 0.25 sec. Display of Normal System Code: 0.25 sec. ON OFF BC Blinking Pattern in Trouble Code (Example Codes 71 and 72): 0.5 sec. 0.5 sec. 2.5 sec. 1.5 sec. 4 sec. Repeat ON OFF Code 71 Code 72 Display of Trouble Code (Example Code 71): C135803E02 NOTICE: • If only the DTCs are displayed, repair the malfunction area and clear the DTCs. • If the DTCs or Test Mode codes (DTC of signal check function) are displayed, repair the malfunction area, clear the DTCs and perform the Test Mode inspection. HINT: • If more than 1 malfunction is detected at the same time, the lowest numbered code will be displayed first. • See the list of DTC (See procedure "A"). BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–137 (c) After performing the check, disconnect the SST from terminals TS and CG, and TC and CG of the DLC3 and turn the ignition switch off. (d) Turn the ignition switch on (IG). HINT: • If the ignition switch is not turned on (IG) after the SST is removed from the DLC3, the previous Test Mode will continue. • If the ignition switch is turned on (IG) with terminals TS and CG shorted, the previous Test Mode will continue. 16. DTC OF TEST MODE (SIGNAL CHECK) FUNCTION (Procedure "A") ABS sensor: Code No. Diagnosis Trouble Area C1271/71 Low output signal of front speed sensor RH • • • Front speed sensor RH Sensor installation Speed sensor rotor C1272/72 Low output signal of front speed sensor LH • • • Front speed sensor LH Sensor installation Speed sensor rotor C1273/73 Low output signal of rear speed sensor RH • • • Rear speed sensor RH Sensor installation Speed sensor rotor C1274/74 Low output signal of rear speed sensor LH • • • Rear speed sensor LH Sensor installation Speed sensor rotor C1275/75 Abnormal change in output signal of front speed sensor RH Speed sensor rotor C1276/76 Abnormal change in output signal of front speed sensor LH Speed sensor rotor C1277/77 Abnormal change in output signal of rear speed sensor RH Speed sensor rotor C1278/78 Abnormal change in output signal of rear speed sensor LH Speed sensor rotor C1279/79 Acceleration sensor output voltage malfunction • • Yaw rate and acceleration sensor Sensor installation C1281/81 Master cylinder pressure sensor output malfunction • • Stop light switch Master cylinder pressure sensor VSC sensor: Code No. C0371/71 Diagnosis Yaw rate sensor Trouble Area Yaw rate and acceleration sensor HINT: The codes in this table are output only in Test Mode (signal check). BC BC–142 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DIAGNOSIS SYSTEM 1. BC DLC3: CG SG CANH SIL CANL BAT G022986E35 DESCRIPTION When troubleshooting a vehicle with the diagnosis system, the only difference from the usual troubleshooting procedure is connecting the intelligent tester to the vehicle and reading various data output from the vehicle's skid control ECU. The skid control ECU records DTCs when the computer detects a malfunction in the computer itself or in its circuits. To check the DTCs, connect the intelligent tester to the DLC3 on the vehicle. The intelligent tester enables you to erase the DTCs, activate the various actuators, and check the Freeze Frame Data and Data List. (a) Check the battery voltage. Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge the battery before proceeding. (b) Check the DLC3. The ECU uses ISO 15765-4 for communication. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. Verify the conditions listed in the table below. Symbols (Terminal No.) Terminal Description Condition Specified condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 11 to 14 V CANH (6) - CANL (14) CAN bus line *Ignition switch off 54 to 69 Ω CANH (6) - CG (4) HIGH-level CAN bus line *Ignition switch off 200 Ω or higher CANL (14) - CG (4) LOW-level CAN bus line *Ignition switch off 200 Ω or higher CANH (6) - BAT (16) HIGH-level CAN bus line *Ignition switch off 6 kΩ or higher CANL (14) - BAT (16) LOW-level CAN bus line *Ignition switch off 6 kΩ or higher NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. HINT: Connect the cable of the intelligent tester to the DLC3, turn the ignition switch on (IG) and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. BC–143 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 on the original vehicle. • If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's operator's manual. 2. ABS Warning Light: BRAKE Warning Light: VSC Warning Light (*1): SLIP Indicator Light: DIAGNOSIS (a) If the skid control ECU detects a malfunction, the ABS, BRAKE, and VSC (models without multi information display) warning lights, and SLIP indicator light will come on and the multi information display (models with multi information display) shows warning messages in order to warn the driver. The table below indicates which lights will come on when there is a malfunction in a particular function. Master Caution Indicator Light: (*1): Models without Multi Information Display C140885E01 Item / Trouble Area ABS EBD BA TRAC VSC ABS warning light { { { - - BRAKE warning light - { - - - VSC warning light (*1) { { { { { Multi information display (*2) { { { { { SLIP indicator light { { { { { BC BC–144 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) {: Light ON -: Light OFF (*1): Models without multi information display (*2): Models with multi information display • The DTCs are simultaneously stored in the memory. The DTCs can be read by connecting the SST between terminals TC and CG of the DLC3 and observing the blinking pattern of the ABS and VSC (models without multi information display) warning lights, by reading the multi information display (models with multi information display), or by connecting the intelligent tester. • This system has a Test Mode (signal check) function (See page BC-123). The DTC can be read by connecting the intelligent tester and observing the blinking pattern of the ABS and VSC (models without multi information display) warning lights or by reading the multi information display (models with multi information display). BC 3. ABS Warning Light: BRAKE Warning Light: VSC Warning Light (*1): SLIP Indicator Light: Master Caution Indicator Light: WARNING LIGHT AND INDICATOR LIGHT CHECK (a) Release the parking brake. NOTICE: When releasing the parking brake, move the shift lever to the P position for safety (A/T) or set the chocks to hold the vehicle for safety (M/T). HINT: When the parking brake is applied or the level of the brake fluid is low, the BRAKE warning light comes on. (b) When the ignition switch is turned on (IG), check that the ABS, BRAKE and VSC (models without multi information display) warning lights, and SLIP, and master caution indicator lights come on for approximately 3 seconds. HINT: If the warning light and indicator light check result is not normal, proceed to troubleshooting for the ABS, BRAKE and VSC warning light circuits and SLIP indicator light circuit. If the indicator remains on, proceed to troubleshooting for the light circuit below. Trouble Area (*1): Models without Multi Information Display C140885E01 See procedure ABS warning light circuit BC-229 BRAKE warning light circuit BC-244 VSC warning light circuit BC-236 SLIP indicator light circuit BC-255 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 4. SYMPTOM SIMULATION HINT: The most difficult case in troubleshooting is when no symptoms occur. In such cases, a thorough customer problem analysis must be carried out. Then the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be reproduced. No matter how experienced or skilled a technician may be, if he proceeds to troubleshoot without confirming the problem symptoms, he will likely overlook something important and make a wrong guess at some points in the repair operation. This leads to a standstill in troubleshooting. (a) Vibration method: When vibration seems to be the major cause. HINT: Perform the simulation method only during the primary check period (for approximately 6 seconds after the ignition switch is on (IG)). (1) Slightly vibrate the part of the sensor considered to be the problem cause with your fingers and check whether the malfunction occurs. (2) Slightly shake the connector vertically and horizontally. HINT: Shaking the relays too strongly may result in open relays. (3) Slightly shake the wire harness vertically and horizontally. The connector joint and fulcrum of the vibration are the major areas to be checked thoroughly. Vibrate Slightly Shake Slightly Vibrate Slightly BC–145 D025083E14 DTC CHECK / CLEAR 1. DLC3 Intelligent Tester C131977E06 DTC CHECK/CLEAR (INTELLIGENT TESTER) (a) Check the DTC. (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch on (IG). (3) Read the DTCs following the prompts on the tester screen. (b) Clear the DTC. (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch on (IG). (3) Operate the intelligent tester to clear the codes. HINT: Refer to the intelligent tester operator's manual for further details. BC BC–146 DLC3: BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 2. CG TC G022986E01 DTC CHECK/CLEAR (SST CHECK WIRE) (a) Check the DTC. (1) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 (2) Turn the ignition switch on (IG). (3) Observe the blinking pattern of the ABS and VSC (models without multi information display) warning lights or read the multi information display (models with multi information display) in order to identify the DTC. HINT: If no code appears, inspect the TC and CG terminal circuit, and ABS and VSC warning light circuits. Trouble Area TC and CG terminal circuit BC See procedure BC-266 ABS warning light circuit BC-229 or BC-233 VSC warning light circuit BC-236 or BC-240 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–147 (4) As an example, the illustration below shows the blinking patterns of the normal system code and trouble codes 11 and 21 for ABS and VSC (models without multi information display) warning lights or display of the normal system code and trouble code 43 for the VSC on the multi information display (models with multi information display). Blinking Pattern in Normal System Code: Blinking Pattern in Trouble Code (Example Codes 11 and 21): 0.25 sec. 0.25 sec. 2 sec. ON ON 2.5 sec. 0.5 sec. 0.5 sec. 1.5 sec. 4 sec. 4 sec. Repeat BC OFF OFF Code 11 Code 21 Display of Trouble Code (Example Code 43): Display of Normal System Code: C135804E02 (5) The codes are explained in the code table (See page BC-151). (6) After completing the check, disconnect terminals TC and CG of the DLC3, and turn off the display. If 2 or more DTCs are detected at the same time, the DTCs will be displayed in ascending order. DLC3: (b) Clear the DTC. (1) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 (2) Turn the ignition switch on (IG). CG TC G022986E01 BC–148 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BR03890 3. BC (3) Clear the DTCs stored in the ECU by depressing the brake pedal 8 times or more within 5 seconds. (4) Check that the warning light or multi information display indicates the normal system code. (5) Remove the SST from the terminals of the DLC3. HINT: Clearing the DTCs cannot be performed by disconnecting the battery terminal or the ECU-IG NO. 2 fuse. END OF DTC CHECK/CLEAR (a) Turn the ignition switch on (IG). (b) Check that the ABS warning light goes off within approximately 3 seconds. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–149 FREEZE FRAME DATA 1. Item (Display) FREEZE FRAME DATA (a) Whenever an ABS DTC is detected, the skid control ECU stores the current vehicle (sensor) state as Freeze Frame Data. The skid control ECU stores the number of times (maximum: 31) the ignition switch has been turned from off to on (IG) since the last time the ABS was activated. HINT: • However, if the vehicle is stopped or at a low speed (4.3 mph (7 km/h) or less), or if a DTC is detected, the skid control ECU will stop counting the number. • Freeze Frame Data at the time the ABS operates: The skid control ECU stores and updates data whenever the ABS system operates. When the ECU stores data at the time a DTC is detected, the data stored during ABS operation is erased. • Freeze Frame Data at the time a DTC is detected: When the skid control ECU stores data at the time a DTC is detected, no updates will be performed until the data is cleared. (b) Connect the intelligent tester to the DLC3. (c) Turn the ignition switch on (IG). (d) On the tester display, select the Freeze Frame Data. Measurement Item Reference Value VEHICLE SPD Vehicle speed reading Min.: 0 mph (0 km/h), Max.: 202 mph (326.4 km/ h) STOP LAMP SW Stop light switch signal Stop light switch ON: ON, OFF: OFF #IG ON Number of operations of ignition switch on (IG) after storing Freeze Frame Data 0 to 31 MAS CYL PRESS 1 Master cylinder pressure sensor reading Brake pedal released: 0.3 to 0.5 V M/C PRESS GRADE Master cylinder pressure sensor change Min.: -30 MPa/s, Max.: 225 MPa/s YAW RATE Yaw rate sensor reading Min.: -128 deg/s, Max.: 127 deg/s STEERING SEN Steering angle sensor reading Left turn: Increase Right turn: Decrease FORWARD & REA G Forward and backward G Min.: -25.11 m/s2, Max.: 24.91 m/s2 SPD GRADE Vehicle speed grade Min.: -25.11 m/s2, Max.: 24.91 m/s2 BUZZER Skid control buzzer signal Skid control buzzer ON: ON, OFF: OFF ACCELERATOR % Accelerator opening angle % Min.: 0 %, Max.: 128 % PARKING BRAKE SW Parking brake switch signal Parking brake switch ON: ON, OFF: OFF ENGINE TORQUE Real engine torque Min.: -1,024 Nm, Max.: 1,023 Nm FR WHEEL SPD FR wheel speed Min.: 0 mph (0 km/h), Max.: 202 mph (326.4 km/ h) FL WHEEL SPD FL wheel speed Min.: 0 mph (0 km/h), Max.: 202 mph (326.4 km/ h) RR WHEEL SPD RR wheel speed Min.: 0 mph (0 km/h), Max.: 202 mph (326.4 km/ h) BC BC–150 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) Item (Display) Measurement Item Reference Value RL WHEEL SPD RL wheel speed Min.: 0 mph (0 km/h), Max.: 202 mph (326.4 km/ h) LATERAL G Lateral G Min.: -25.11 m/s2, Max.: 24.91 m/s2 Gear position information FAIL 1st 2nd 3rd 4th 5th 6th P, N R NOT R Shift lever position information FAIL 1st 2nd 3rd 4th 5th 6th/B D/M P, N R Operated system status ABS activated: ABS VSC activated: VSC TRAC activated: TRAC BA activated: BA Fail safe mode activated: FAIL No system activated: NON System prohibited: SYS GEAR POSITION LEVER POSITION BC OPERATED SYSTEM FREEZE TIME Elapsed time after freeze trigger Min.: 0 ms, Max.: 500 ms TROUBLE CODE Freeze frame DTC Displays to output DTC INSPECTION MODE Inspection mode OTHER: Normal, INSPECT: Service BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–151 FAIL-SAFE CHART 1. FAIL SAFE OPERATION • If there is a problem with sensor signals or actuator systems, the skid control ECU prohibits power supply to the brake actuator assembly and informs the ECM of VSC system failure. The brake actuator assembly turns off each solenoid and the ECM shuts off VSC control (traction control signal) from the skid control ECU accordingly, which turns out to be as if the ABS, TRAC and VSC systems were not installed. The ABS control will be prohibited, but EBD control continues as much as possible. If EBD control is impossible, the BRAKE warning light comes on to warn the driver (See page BC-138). • If system components have any malfunction before starting control, immediately stop the operation. If system components have any malfunction during control, gradually stop the control so as not to trigger a sudden change in vehicle conditions. If it is impossible to control the systems, the warning light comes on to inform the driver of termination of the systems (See page BC-138). HINT: If the hydraulic brake booster encounters a malfunction, brake performance is gradually lost and ABS, BA, TRAC and VSC systems are prohibited. ABS, EBD and BA system: Malfunction Area Control Method ABS system ABS, BA, TRAC and VSC control prohibited BA system ABS, BA, TRAC and VSC control prohibited EBD system ABS, EBD, BA, TRAC and VSC control prohibited HINT: A malfunction in either the ABS or BA system will result in an identical operation, with ABS, BA, TRAC and VSC system control prohibited. TRAC and VSC system: Malfunction Area Control Method Engine control system (TRAC and VSC systems) Before control: Disables control During control: Uses only the brakes to effect control Brake control system (VSC system) Before control: Disables control During control: Uses only the engine to effect control Brake control system (TRAC system) Before control: Disables control During control: Disables control (by gradually ending control) HINT: As for the TRAC and VSC systems, different systems prohibit different controls depending on a malfunctioning part. BC BC–152 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DATA LIST / ACTIVE TEST 1. Item (Display) BC DATA LIST HINT: With the intelligent tester connected to the DLC3 and the ignition switch on (IG), the ABS, TRAC and VSC Data List can be displayed. Follow the prompts on the tester screen to access the Data List. Measurement Item / Range (Display) Normal Condition Diagnostic Note ABS MTR RELAY ABS motor relay / ON or OFF ON: Motor relay ON OFF: Motor relay OFF - SOL RELAY Solenoid relay / ON or OFF ON: Solenoid relay ON OFF: Solenoid relay OFF - FAIL MTR RELAY Fail safe motor relay / ON or OFF ON: Motor relay ON OFF: Motor relay OFF - IDLE SW Main idle switch / ON or OFF ON: Accelerator pedal released OFF: Accelerator pedal depressed - STOP LAMP SW Stop light switch / ON or OFF ON: Brake pedal depressed OFF: Brake pedal released - PARKING BRAKE SW Parking brake switch / ON or OFF ON: Parking brake applied OFF: Parking brake released - ENG REVOLUTIONS Engine revolutions / min.: 0 r/min, max.: 65535 r/min - - GEAR POSITION Gear position information / P/N, R, 1st-6th, FAIL, NOT R - - LEVER POSITION Shift lever position information / P/N, R, D/M, 1st-6th/B, FAIL - - SHIFT INFO Shift information / ON or OFF ON: During gear change - FR WHEEL SPD FR wheel speed sensor reading / min.: 0 mph (0 km/h), max.: 202 mph (326 km/h) Actual wheel speed Similar speed as indicated on speedometer FL WHEEL SPD FL wheel speed sensor reading / min.: 0 mph (0 km/h), max.: 202 mph (326 km/h) Actual wheel speed Similar speed as indicated on speedometer RR WHEEL SPD RR wheel speed sensor reading / min.: 0 mph (0 km/h), max.: 202 mph (326 km/h) Actual wheel speed Similar speed as indicated on speedometer RL WHEEL SPD RL wheel speed sensor reading / min.: 0 mph (0 km/h), max.: 202 mph (326 km/h) Actual wheel speed Similar speed as indicated on speedometer DECELERAT SEN Acceleration sensor 1 reading / min.: -1.889 G, max.: 1.875 G Approximately 0+-0.13 G while stationary Reading changes when vehicle is bounced DECELERAT SEN 2 Acceleration sensor 2 reading / min.: -1.889 G, max.: 1.875 G Approximately 0+-0.13 G while stationary Reading changes when vehicle is bounced SFRR ABS solenoid (SFRR) / ON or OFF ON: Operates - SFRH ABS solenoid (SFRH) / ON or OFF ON: Operates - SFLR ABS solenoid (SFLR) / ON or OFF ON: Operates - SFLH ABS solenoid (SFLH) / ON or OFF ON: Operates - SRRR ABS solenoid (SRRR) / ON or OFF ON: Operates - SRRH ABS solenoid (SRRH) / ON or OFF ON: Operates - BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) Item (Display) Measurement Item / Range (Display) Normal Condition BC–153 Diagnostic Note SRLR ABS solenoid (SRLR) / ON or OFF ON: Operates - SRLH ABS solenoid (SRLH) / ON or OFF ON: Operates - SM1 Master cut solenoid (SM1) / ON or OFF ON: Operates - SM2 Master cut solenoid (SM2) / ON or OFF ON: Operates - VEHICLE SPD Maximum wheel speed sensor reading / min.: 0 mph (0 km/h), max.: 202 mph (326 km/h) Actual vehicle speed Speed indicated on speedometer YAW RATE SENS 1 Yaw rate sensor 1 / min.: -128 deg/s, max.: 127 deg/s Min.: -128 deg/s Max.: 127 deg/s - ZERO YAW RATE Memorized zero value / min.: 128 deg/s, max.: 127 deg/s Min.: -128 deg/s Max.: 127 deg/s - STEERING SEN Steering angle sensor / min.: 3,276.8 deg, max.: 3,276.7 deg Left turn: Increase Right turn: Decrease - MAS CYL PRESS 1 Master cylinder pressure sensor 1 reading / min.: 0 V, max.: 5 V When brake pedal is released: 0.3 to 0.5 V Reading increases when brake pedal is depressed ACCELERATOR % The difference of a present accelerator / min.: 0%, max.: 128% - - ENGINE TORQUE Real engine torque / min.: -1,024 N*m, max.: 1,023 N*m - - FR SPD OPN FR speed sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - FL SPD OPN FL speed sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - RR SPD OPN RR speed sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - RL SPD OPN RL speed sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - YAW RATE OPN Yaw rate sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - DECELERAT OPN Acceleration sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - STEERING OPN Steering angle sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - M/C OPN Master cylinder pressure sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - EFI COM OPN EFI communication open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - #DTC Number of DTC / min.: 0, max.: 255 - - ABS WARN LAMP ABS warning light / ON or OFF ON: Warning light ON OFF: Warning light OFF - BRAKE WARN LAMP BRAKE warning light / ON or OFF ON: Warning light ON OFF: Warning light OFF - SLIP INDI LAMP SLIP indicator light / ON or OFF ON: Indicator light ON OFF: Indicator light OFF - BUZZER Skid control buzzer / ON or OFF ON: Buzzer ON OFF: Buzzer OFF - VSC WARN LAMP VSC warning light (*1) or multi information display (*2) / ON or OFF ON: Indicator ON OFF: Indicator OFF - ZERO M/C SEN Memorized zero value / min.: 12.5 MPa, max.: 12.4 MPa Min.: -12.5 MPa Max.: 12.4 MPa - BC BC–154 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) Item (Display) FR WHEEL ACCEL FL WHEEL ACCEL RR WHEEL ACCEL RL WHEEL ACCEL ZERO DECELERAT ZERO DECELERAT 2 ZERO STEERING BC LATERAL G Measurement Item / Range (Display) Min.: -200.84 m/s2 FR wheel acceleration / min.: 2 Normal Condition 2 200.84 m/s , max.: 199.27 m/s Max.: 199.27 m/s2 FL wheel acceleration / min.: - Min.: -200.84 m/s2 200.84 m/s 2, max.: 199.27 m/s2 Min.: -200.84 m/s2 RR wheel acceleration / min.: m/s2 Max.: 199.27 m/s2 2 , max.: 199.27 m/s Max.: 199.27 m/s2 RL wheel acceleration / min.: - Min.: -200.84 m/s2 200.84 m/s2, max.: 199.27 m/s2 Max.: 199.27 m/s2 Memorized zero value / min.: - Min.: -25.11 m/s2 25.11 m/s2, max.: 24.91 m/s2 Max.: 24.91 m/s2 Memorized zero value / min.: - Min.: -25.11 m/s2 25.11 m/s2, max.: 24.91 m/s2 Max.: 24.91 m/s2 Memorized zero value / min.: 3,276.8 deg, max.: 3,276.7 deg Min.: -3,276.8 deg Max.: 3,276.7 deg Lateral G / min.: -25.11 m/s2, Min.: -25.11 m/s2 200.84 Diagnostic Note - - - - - - 2 Max.: 24.91 m/s2 Forward and rearward G / min.: - Min.: -25.11 m/s2 25.11 m/s2, max.: 24.91 m/s2 Max.: 24.91 m/s2 YAW RATE VALUE Yaw rate value / min.: -128 deg/s, max.: 127 deg/s Min.: -128 deg/s Max.: 127 deg/s - STEERING ANGLE Steering angle value / min.: 3,276.8 deg, max.: 3,276.7 deg Min.: -3,276.8 deg Max.: 3,276.7 deg - TRAC STATUS TRAC control status / ON or OFF ON: During the control - TRAC ENG STATUS TRAC engine control status / ON or OFF ON: During the control - TRAC BRK STATUS TRAC brake control status / ON or OFF ON: During the control - FR VSC STATUS FR wheel VSC control status / ON or OFF ON: During the control - FL VSC STATUS FL wheel VSC control status / ON or OFF ON: During the control - RR VSC STATUS RR wheel VSC control status / ON or OFF ON: During the control - RL VSC STATUS RL wheel VSC control status / ON or OFF ON: During the control - FR ABS STATUS FR wheel ABS control status / ON or OFF ON: During the control - FL ABS STATUS FL wheel ABS control status / ON or OFF ON: During the control - RR ABS STATUS RR wheel ABS control status / ON or OFF ON: During the control - RL ABS STATUS RL wheel ABS control status / ON or OFF ON: During the control - RR EBD STATUS RR wheel EBD control status / ON or OFF ON: During the control - RL EBD STATUS RL wheel EBD control status / ON or OFF ON: During the control - BA STATUS BA control status / ON or OFF ON: During the control - PBA STATUS PBA control status / ON or OFF ON: During the control - INSPECTION MODE Inspection mode / OTHER or INSPECT - - #IG ON2 Number of ignition switch on (IG) after entering the inspection mode / min.: 0, max.: 255 - - FORWARD&REA G max.: 24.91 m/s - BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) Item (Display) TROUBLE CODE Measurement Item / Range (Display) Normal Condition Freeze frame DTC / min.:0, max.: 65,535 - 2. Item (Display) BC–155 Diagnostic Note - (*1): Models without multi information display (*2): Models with multi information display ACTIVE TEST HINT: Performing the Active Test using the intelligent tester allows the relay, actuator, and other items to operate without removing any parts. Performing the Active Test as the first step in troubleshooting is one of the methods to save labor time. It is possible to display the Data List during the Active Test. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) On the tester display, select the Active Test. HINT: The ignition switch must be turned on (IG) to proceed to the Active Test using the intelligent tester. Vehicle Condition / Test Details Diagnostic Note SFRR Turns ABS solenoid (SFRR) ON / OFF Operating sound of solenoid (clicking sound) can be heard SFRH Turns ABS solenoid (SFRH) ON / OFF Operating sound of solenoid (clicking sound) can be heard SFLR Turns ABS solenoid (SFLR) ON / OFF Operating sound of solenoid (clicking sound) can be heard SFLH Turns ABS solenoid (SFLH) ON / OFF Operating sound of solenoid (clicking sound) can be heard SRRR Turns ABS solenoid (SRRR) ON / OFF Operating sound of solenoid (clicking sound) can be heard SRRH Turns ABS solenoid (SRRH) ON / OFF Operating sound of solenoid (clicking sound) can be heard SRLR Turns ABS solenoid (SRLR) ON / OFF Operating sound of solenoid (clicking sound) can be heard SRLH Turns ABS solenoid (SRLH) ON / OFF Operating sound of solenoid (clicking sound) can be heard SMF Turns master cut solenoid (SM1) ON / OFF Operating sound of solenoid (clicking sound) can be heard SMR Turns master cut solenoid (SM2) ON / OFF Operating sound of solenoid (clicking sound) can be heard SOL RELAY Turns ABS solenoid relay ON / OFF - MOTOR RELAY Turns ABS motor relay ON / OFF Operating sound of relay (clicking sound) and motor can be heard ABS WARN LAMP Turns ABS warning light ON / OFF Observe combination meter VSC WARN LAMP Turns VSC warning light (*1) or multi information display (*2) ON / OFF Observe combination meter SLIP INDI LAMP Turns SLIP indicator light ON / OFF Observe combination meter BRAKE WARN LAMP Turns BRAKE warning light ON / OFF Observe combination meter BUZZER Turns skid control buzzer ON / OFF Buzzer can be heard (*1): Models without multi information display (*2): Models with multi information display BC BC–156 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DIAGNOSTIC TROUBLE CODE CHART • If a trouble code is displayed during the DTC check, check the circuit indicated by the DTC. For details of each code, refer to the page for the respective "DTC No." in the DTC chart. • Inspect the fuse and relay before investigating the trouble areas as shown in the table below. DTC chart of ABS: DTC No. Trouble Area See page Front Speed Sensor RH Circuit 1. Front speed sensor RH 2. Speed sensor circuit 3. Speed sensor rotor 4. Sensor installation 5. Brake actuator assembly (Skid control ECU) BC-156 Front Speed Sensor LH Circuit 1. Front speed sensor LH 2. Speed sensor circuit 3. Speed sensor rotor 4. Sensor installation 5. Brake actuator assembly (Skid control ECU) BC-156 Rear Speed Sensor RH Circuit 1. Rear speed sensor RH 2. Speed sensor circuit 3. Speed sensor rotor 4. Sensor installation 5. Brake actuator assembly (Skid control ECU) BC-164 Rear Speed Sensor LH Circuit 1. Rear speed sensor LH 2. Speed sensor circuit 3. Speed sensor rotor 4. Sensor installation 5. Brake actuator assembly (Skid control ECU) BC-164 C0226/21 SFR Solenoid Circuit 1. Brake actuator assembly 2. SFRH or SFRR circuit BC-172 C0236/22 SFL Solenoid Circuit 1. Brake actuator assembly 2. SFLH or SFLR circuit BC-172 C0246/23 SRR Solenoid Circuit 1. Brake actuator assembly 2. SRRH or SRRR circuit BC-172 C0256/24 SRL Solenoid Circuit 1. Brake actuator assembly 2. SRLH or SRLR circuit BC-172 C0273/13 (*1) Open in ABS Motor Relay Circuit 1. ABS NO. 1 fuse 2. VSC NO. 2 relay 3. VSC NO. 2 relay circuit 4. Brake actuator assembly BC-175 C0274/14 Short to B+ in ABS Motor Relay Circuit 1. ABS NO. 1 fuse 2. VSC NO. 2 relay 3. VSC NO. 2 relay circuit 4. Brake actuator assembly BC-175 C0278/11 Open in ABS Solenoid Relay Circuit 1. ABS NO. 2 fuse 2. ABS solenoid relay 3. ABS solenoid relay circuit 4. Brake actuator assembly BC-181 C0279/12 Short to B+ in ABS Solenoid Relay Circuit Brake actuator assembly BC-181 C1225/25 SM Solenoid Circuit 1. Brake actuator assembly 2. SM1 or SM2 circuit BC-172 C1235/35 Foreign Object is Attached on Tip of Front Speed Sensor RH 1. Front speed sensor RH 2. Speed sensor rotor 3. Sensor installation 4. Brake actuator assembly (Skid control ECU) BC-197 C0200/31 (*1) C0205/32 (*1) Detection Item BC C0210/33 (*1) C0215/34 (*1) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DTC No. Detection Item Trouble Area See page C1236/36 Foreign Object is Attached on Tip of Front Speed Sensor LH 1. Front speed sensor LH 2. Speed sensor rotor 3. Sensor installation 4. Brake actuator assembly (Skid control ECU) BC-197 C1238/38 Foreign Object is Attached on Tip of Rear Speed Sensor RH 1. Rear speed sensor RH 2. Speed sensor rotor 3. Sensor installation 4. Brake actuator assembly (Skid control ECU) BC-197 Foreign Object is Attached on Tip of Rear Speed Sensor LH 1. Rear speed sensor LH 2. Speed sensor rotor 3. Sensor installation 4. Brake actuator assembly (Skid control ECU) BC-197 Low Battery Positive Voltage 1. ECU-IG NO. 2 fuse 2. Battery 3. Charging system 4. Power source circuit 5. Internal power supply circuit of the skid control ECU BC-207 Acceleration Sensor Stuck Malfunction 1. Yaw rate and acceleration sensor 2. Yaw rate and acceleration sensor circuit BC-193 Open or Short in Acceleration Sensor Circuit 1. Yaw rate and acceleration sensor 2. Yaw rate and acceleration sensor circuit BC-193 Acceleration Sensor Output Malfunction 1. Yaw rate and acceleration sensor 2. Yaw rate and acceleration sensor circuit BC-193 Master Cylinder Pressure Sensor Malfunction 1. Master cylinder pressure sensor 2. Master cylinder pressure sensor circuit 3. Stop light switch circuit 4. Brake actuator assembly BC-210 Open in Stop Light Switch Circuit 1. STOP fuse 2. Stop light switch 3. Stop light switch circuit 4. Brake actuator assembly (Skid control ECU) BC-213 Open in Pump Motor Circuit 1. Brake actuator assembly (GND circuit) 2. Brake actuator assembly (Motor circuit) BC-219 C1361/91 Short Circuit in ABS Motor Fail Safe Relay Circuit 1. ABS NO. 1 fuse 2. VSC NO. 1 (fail safe) relay 3. VSC NO. 1 (fail safe) relay circuit 4. Brake actuator assembly BC-175 C1381/97 Yaw Rate and / or Acceleration Sensor Power Supply Voltage Malfunction 1. Yaw rate and acceleration sensor 2. Yaw rate and acceleration sensor power source circuit BC-193 U0073/94 Control Module Communication Bus OFF CAN communication system BC-224 U0124/95 Lost Communication with Lateral Acceleration Sensor Module CAN communication system (Skid control ECU to yaw rate and acceleration sensor) BC-224 C1239/39 C1241/41 C1243/43 (*1) C1244/44 C1245/45 (*1) C1246/46 (*2) C1249/49 C1251/51 (*1) (*1, *2): BC–157 BC BC–158 BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) Even after the trouble areas are repaired, the ABS warning light will not go off unless the following operations are performed: • (*1): (a)Drive the vehicle at 12 mph (20 km/h) for 30 seconds or more and check that the ABS warning light goes off. (b)Clear the DTC. • (*2): (a)Keep the vehicle stationary for 5 seconds or more and depress the brake pedal lightly 2 or 3 times. (b)Drive the vehicle at the vehicle speed of 31 mph (50 km/h) and keep depressing the brake pedal strongly for approximately 3 seconds. (c) Repeat the above operation 3 times or more and check that the ABS warning light goes off. (d)Clear the DTC. HINT: In some cases, the intelligent tester cannot be used when the ABS warning light remains on. DTC chart of VSC: DTC No. 43 Detection Item Trouble Area See page ABS Control System Malfunction ABS control system BC-155 C1201/51 Engine Control System Malfunction Engine control system BC-186 C1203/53 ECM Communication Circuit Malfunction ECM BC-187 Zero Point Calibration of Yaw Rate Sensor Undone 1. Brake actuator assembly (Skid control ECU) 2. Yaw rate and acceleration sensor 3. Zero point calibration undone BC-188 C1231/31 Steering Angle Sensor Circuit Malfunction 1. Steering angle sensor 2. Steering angle sensor circuit 3. Steering angle sensor power supply 4. Brake actuator assembly (Skid control ECU) BC-190 C1232/32 Stuck in Acceleration Sensor 1. Yaw rate and acceleration sensor 2. Yaw rate and acceleration sensor circuit BC-193 C1234/34 Yaw Rate Sensor Malfunction 1. Yaw rate and acceleration sensor 2. Yaw rate and acceleration sensor circuit BC-193 C1290/66 Steering Angle Sensor Zero Point Malfunction 1. Yaw rate and acceleration sensor zero point calibration incomplete 2. Poor adjustment of the centered position of the steering wheel 3. Poor adjustment of front wheel alignment BC-222 C1336/39 Zero Point Calibration of Acceleration Sensor Undone 1. Brake actuator assembly (Skid control ECU) 2. Yaw rate and acceleration sensor 3. Zero point calibration undone BC-188 U0100/65 Lost Communication with ECM / PCM CAN communication system (Skid control ECU to ECM) BC-224 C1210/36 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DTC No. Detection Item Trouble Area See page BC-224 BC-224 U0123/62 Lost Communication with Yaw Rate Sensor Module CAN communication system (Skid control ECU to yaw rate and acceleration sensor) U0126/63 Lost Communication with Steering Angle Sensor Module CAN communication system (Skid control ECU to steering angle sensor) BC–159 HINT: In some cases, the intelligent tester cannot be used when the VSC warning light (models without multi information display) or multi information display (models with multi information display) remains on. Test Mode DTC of ABS: DTC No. Detection Item Trouble Area See page C1271/71 Low Output Signal of Front Speed Sensor RH (Test Mode DTC) 1. Front speed sensor RH 2. Sensor installation 3. Speed sensor rotor BC-156 C1272/72 Low Output Signal of Front Speed Sensor LH (Test Mode DTC) 1. Front speed sensor LH 2. Sensor installation 3. Speed sensor rotor BC-156 C1273/73 Low Output Signal of Rear Speed Sensor RH (Test Mode DTC) 1. Rear speed sensor RH 2. Sensor installation 3. Speed sensor rotor BC-164 C1274/74 Low Output Signal of Rear Speed Sensor LH (Test Mode DTC) 1. Rear speed sensor LH 2. Sensor installation 3. Speed sensor rotor BC-164 C1275/75 Abnormal Change in Output Signal of Front Speed Sensor RH (Test Mode DTC) Speed sensor rotor BC-197 C1276/76 Abnormal Change in Output Signal of Front Speed Sensor LH (Test Mode DTC) Speed sensor rotor BC-197 C1277/77 Abnormal Change in Output Signal of Rear Speed Sensor RH (Test Mode DTC) Speed sensor rotor BC-197 C1278/78 Abnormal Change in Output Signal of Rear Speed Sensor LH (Test Mode DTC) Speed sensor rotor BC-197 C1279/79 Acceleration Sensor Output Voltage Malfunction (Test Mode DTC) 1. Yaw rate and acceleration sensor 2. Sensor installation BC-193 C1281/81 Master Cylinder Pressure Sensor Output Malfunction (Test Mode DTC) 1. Stop light switch 2. Master cylinder pressure sensor BC-210 Test Mode DTC of VSC: DTC No. C0371/71 Detection Item Yaw Rate Sensor (Test Mode DTC) Trouble Area See page Yaw rate and acceleration sensor BC-193 BC BC–160 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DTC 43 ABS Control System Malfunction DESCRIPTION This DTC is output when the VSC system detects a malfunction in the ABS control system. DTC No. 43 DTC Detection Condition Malfunction in the ABS control system. Trouble Area ABS control system INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). 1 BC CHECK ABS CONTROL SYSTEM (a) Clear the DTC (See page BC-141). (b) Turn the ignition switch on (IG). (c) Check if the same DTC is recorded (See page BC-141). Result Condition Proceed to DTC (ABS control system DTC) is not output A DTC (ABS control system DTC) is output B B REPAIR CIRCUIT INDICATED BY OUTPUT DTC (See page BC-151) A 2 RECONFIRM DTC (a) Clear the DTC (See page BC-141). (b) Turn the ignition switch on (IG). (c) Check if the same DTC is recorded (See page BC-141). Result Condition Proceed to DTC (43) is not output A DTC (43) is output B B A USE SIMULATION METHOD TO CHECK REPLACE BRAKE ACTUATOR ASSEMBLY BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–161 DTC C0200/31 Front Speed Sensor RH Circuit DTC C0205/32 Front Speed Sensor LH Circuit DTC C1271/71 Low Output Signal of Front Speed Sensor RH (Test Mode DTC) DTC C1272/72 Low Output Signal of Front Speed Sensor LH (Test Mode DTC) DESCRIPTION The speed sensors detect wheel speed and transmit the signals to the ECU. These signals are used for control of the ABS control system. Each of the front and rear rotors have 48 serrations. When the rotors rotate, the magnetic field generated by the permanent magnet in the speed sensor induces an AC voltage. Since the frequency of this AC voltage changes in direct proportion to the speed of the rotor, the frequency is used by the ECU to detect the speed of each wheel. DTCs C1271/71 and C1272/72 can be deleted when the speed sensor sends a wheel speed signal or the Test Mode ends. DTCs C1271/71 and C1272/72 are output only in the Test Mode. Speed Sensor Rotor Coil N S Magnet To ECU Low speed High speed +V -V F000010E04 DTC No. DTC Detection Condition C0200/31 C0205/32 When any of the following is detected: 1. At a vehicle speed of 6 mph (10 km/h) or more, an open or short in the sensor signal circuit continues for 1 second or more. 2. Momentary interruption of the sensor signal from the abnormal wheel occurs 7 times or more. 3. An open in the speed sensor signal circuit continues for 0.5 seconds or more. HINT: • DTC C0200/31 is for the front speed sensor RH. • DTC C0205/32 is for the front speed sensor LH. Trouble Area • • • • • Front speed sensor RH/LH Speed sensor circuit Speed sensor rotor Sensor installation Brake actuator assembly (Skid control ECU) BC BC–162 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) WIRING DIAGRAM Brake Actuator Assembly - Skid Control ECU Front Speed Sensor RH 2 3 1 17 FR+ FR- Front Speed Sensor LH BC 2 18 1 4 FL+ FL- C132772E05 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). 1 CHECK HARNESS AND CONNECTOR (MOMENTARY INTERRUPTION) (a) Using the intelligent tester, check for any momentary interruption in the wire harness and connector corresponding to a DTC (See page BC-118). ABS / VSC: Item (Display) Measurement Item / Range (Display) Normal Condition FR SPD OPN FR speed sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal FL SPD OPN FL speed sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal Result Condition Proceed to There are no momentary interruptions A There are momentary interruptions B There is a constant open circuit C HINT: Perform the above inspection before removing the sensor and connector. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) B Go to step 11 C Go to step 5 BC–163 A 2 READ VALUE OF INTELLIGENT TESTER (FRONT SPEED SENSOR) (a) (b) (c) (d) Turn the ignition switch off. Connect the intelligent tester to the DLC3. Start the engine. Select the Data List mode on the intelligent tester. ABS / VSC: Item (Display) Measurement Item / Range (Display) Normal Condition FR WHEEL SPD FR wheel speed sensor reading / min.: 0 mph (0 km/ h), max.: 202 mph (326 km/h) Actual wheel speed FL WHEEL SPD FL wheel speed sensor reading /min.: 0 mph (0 km/h), max.: 202 mph (326 km/h) Actual wheel speed (e) Check that there is no difference between the speed value output from the speed sensor displayed on the intelligent tester and the speed value displayed on the speedometer when driving the vehicle. OK: The speed value output from the speed sensor displayed on the intelligent tester is the same as the actual vehicle speed. NG Go to step 5 OK 3 PERFORM TEST MODE (SIGNAL CHECK) (a) Perform sensor check in the Test Mode procedure (See page BC-123). OK: All Test Mode DTCs are erased. NG Go to step 5 OK 4 RECONFIRM DTC (a) (b) (c) (d) Turn the ignition switch off. Clear the DTC (See page BC-141). Start the engine. Drive the vehicle at the speed of 20 mph (32 km/h) or more for at least 60 seconds. (e) Check if the same DTC is recorded (See page BC-141). BC BC–164 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) Result Condition Proceed to DTCs (C0200/31 and/or C0205/32) are not output A DTCs (C0200/31 and/or C0205/32) are output B HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step (See page BC-134). B Go to step 7 A USE SIMULATION METHOD TO CHECK BC 5 CHECK FRONT SPEED SENSOR INSTALLATION (a) Turn the ignition switch off. (b) Check the speed sensor installation. OK: There is no clearance between the sensor and the front steering knuckle. The installation bolt is tightened properly. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) Front Speed Sensor: 8.0 N*m (82 kgf*cm, 71 in.*lbf) OK No clearance NG BR03795E52 NG INSTALL FRONT SPEED SENSOR CORRECTLY OK 6 CHECK FRONT SPEED SENSOR TIP (a) Remove the front speed sensor (See page BC-438). (b) Check the speed sensor tip. OK: No scratches or foreign matter on the sensor tip. NOTICE: Check the speed sensor signal after cleaning or replacement (See page BC-123). NG OK CLEAN OR REPLACE FRONT SPEED SENSOR BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 7 BC–165 INSPECT FRONT SPEED SENSOR (a) (b) (c) (d) Front Speed Sensor: 1 2 Turn the ignition switch off. Install the front speed sensor. Disconnect the front speed sensor connector. Measure the resistance according to the value(s) in the table below. Standard resistance: RH Tester Connection Condition Specified Condition 1 (FR+) - 2 (FR-) Always 1.4 to 1.8 kΩ at 20°C (68 °F) 1 (FR+) - Body ground Always 10 kΩ or higher 2 (FR-) - Body ground Always 10 kΩ or higher Tester Connection Condition Specified Condition 1 (FL+) - 2 (FL-) Always 1.4 to 1.8 kΩ at 20°C (68 °F) 1 (FL+) - Body ground Always 10 kΩ or higher 2 (FL-) - Body ground Always 10 kΩ or higher LH C136017E01 NOTICE: Check the speed sensor signal after replacement (See page BC-123). NG OK REPLACE FRONT SPEED SENSOR BC BC–166 8 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - FRONT SPEED SENSOR) (a) Disconnect the skid control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: RH Skid Control ECU Harness Side Connector Front View: A26 FR+ FL- Tester Connection Condition Specified Condition A26-3 (FR+) - A35-1 (FR+) Always Below 1 Ω A26-3 (FR+) - Body ground Always 10 kΩ or higher A26-17 (FR-) - A35-2 (FR-) Always Below 1 Ω A26-17 (FR-) - Body ground Always 10 kΩ or higher Tester Connection Condition Specified Condition A26-18 (FL+) - A14-1 (FL+) Always Below 1 Ω A26-18 (FL+) - Body ground Always 10 kΩ or higher A26-4 (FL-) - A14-2 (FL-) Always Below 1 Ω A26-4 (FL-) - Body ground Always 10 kΩ or higher LH FR- BC FL+ Front Speed Sensor Harness Side Connector Front View: A35 A14 NG FR- FR+ FL- FL+ C136018E01 OK REPAIR OR REPLACE HARNESS OR CONNECTOR BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 9 CHECK SPEED SENSOR AND SPEED SENSOR ROTOR SERRATIONS (a) Reconnect the front speed sensor connector. (b) Connect the oscilloscope to the front speed sensor terminal of the skid control ECU. (c) Check that a waveform is output when the tires are rotated. OK: The same waveform is output from all the 4 wheels and there is no noise or interference in the waveform. HINT: • As the vehicle speed (wheel revolution speed) increases, a cycle of the waveform narrows and the output voltage becomes greater. • When noise is identified in the waveform on the oscilloscope, the erratic signals are generated due to speed sensor rotor's scratches, looseness or foreign matter attached to it. Skid Control ECU Harness Side Connector Front View: A26 BC–167 FR+ FR- FL- FL+ Normal Signal Waveform: NG REPLACE BRAKE ACTUATOR ASSEMBLY GND 1 V/Division, 2 ms/Division C136019E04 OK 10 RECONFIRM DTC (a) (b) (c) (d) Reconnect the skid control ECU connector. Clear the DTC (See page BC-141). Start the engine. Drive the vehicle at the speed of 20 mph (32 km/h) or more for at least 60 seconds. (e) Check if the same DTC is recorded (See page BC-141). Result Condition Proceed to DTCs (C0200/31 and/or C0205/32) are output A DTCs (C0200/31 and/or C0205/32) are not output B HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step (See page BC-134). B USE SIMULATION METHOD TO CHECK BC BC–168 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) A REPLACE BRAKE ACTUATOR ASSEMBLY 11 REPAIR OR REPLACE HARNESS OR CONNECTOR (SKID CONTROL ECU - FRONT SPEED SENSOR) (a) Turn the ignition switch off. (b) Repair or replace the harness or connector. (c) Check for any momentary interruption between the skid control ECU and front speed sensor (See page BC-118). (d) Check that there is no momentary interruption. NEXT BC 12 RECONFIRM DTC (a) Clear the DTC (See page BC-141). (b) Start the engine. (c) Drive the vehicle at the speed of 20 mph (32 km/h) or more for at least 60 seconds. (d) Check if the same DTC is recorded (See page BC-141). Result Condition Proceed to DTCs (C0200/31 and/or C0205/32) are not output A DTCs (C0200/31 and/or C0205/32) are output B HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step (See page BC-134). B A END Go to step 2 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–169 DTC C0210/33 Rear Speed Sensor RH Circuit DTC C0215/34 Rear Speed Sensor LH Circuit DTC C1273/73 Low Output Signal of Rear Speed Sensor RH (Test Mode DTC) DTC C1274/74 Low Output Signal of Rear Speed Sensor LH (Test Mode DTC) DESCRIPTION The speed sensors detect wheel speed and transmit the signals to the ECU. These signals are used for control of the ABS control system. Each of the front and rear rotors have 48 serrations. When the rotors rotate, the magnetic field generated by the permanent magnet in the speed sensor induces an AC voltage. Since the frequency of this AC voltage changes in direct proportion to the speed of the rotor, the frequency is used by the ECU to detect the speed of each wheel. DTCs C1273/73 and C1274/74 can be deleted when the speed sensor sends a wheel speed signal or the Test Mode ends. DTCs C1273/73 and C1274/74 are output only in the Test Mode. Speed Sensor Rotor Coil N S Magnet To ECU Low speed High speed +V -V F000010E04 DTC No. DTC Detection Condition C0210/33 C0215/34 When any of the following is detected: 1. At a vehicle speed of 6 mph (10 km/h) or more, an open or short in the sensor signal circuit continues for 1 second or more. 2. Momentary interruption of the sensor signal from the abnormal wheel occurs 7 times or more. 3. An open in the speed sensor signal circuit continues for 0.5 seconds or more. HINT: • DTC C0210/33 is for the rear speed sensor RH. • DTC C0215/34 is for the rear speed sensor LH. Trouble Area • • • • • Rear speed sensor RH/LH Speed sensor circuit Speed sensor rotor Sensor installation Brake actuator assembly (Skid control ECU) BC BC–170 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) WIRING DIAGRAM Brake Actuator Assembly - Skid Control ECU Rear Speed Sensor RH 2 5 1 19 RR+ RR- Rear Speed Sensor LH BC 2 20 1 6 RL+ RL- C132772E06 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). 1 CHECK HARNESS AND CONNECTOR (MOMENTARY INTERRUPTION) (a) Using the intelligent tester, check for any momentary interruption in the wire harness and connector corresponding to a DTC (See page BC-118). ABS / VSC: Item (Display) Measurement Item / Range (Display) Normal Condition RR SPD OPN RR speed sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal RL SPD OPN RL speed sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal Result Condition Proceed to There are no momentary interruptions A There are momentary interruptions B There is a constant open circuit C HINT: Perform the above inspection before removing the sensor and connector. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) B Go to step 11 C Go to step 5 BC–171 A 2 READ VALUE OF INTELLIGENT TESTER (REAR SPEED SENSOR) (a) (b) (c) (d) Turn the ignition switch off. Connect the intelligent tester to the DLC3. Start the engine. Select the Data List mode on the intelligent tester. ABS / VSC: Item (Display) Measurement Item / Range (Display) Normal Condition RR WHEEL SPD RR wheel speed sensor reading / min.: 0 mph (0 km/ h), max.: 202 mph (326 km/h) Actual wheel speed RL WHEEL SPD RL wheel speed sensor reading / min.: 0 mph (0 km/ h), max.: 202 mph (326 km/h) Actual wheel speed (e) Check that there is no difference between the speed value output from the speed sensor displayed on the intelligent tester and the speed value displayed on the speedometer when driving the vehicle. OK: The speed value output from the speed sensor displayed on the intelligent tester is the same as the actual vehicle speed. NG Go to step 5 OK 3 PERFORM TEST MODE (SIGNAL CHECK) (a) Perform sensor check in the Test Mode procedure (See page BC-123). OK: All Test Mode DTCs are erased. NG Go to step 5 OK 4 RECONFIRM DTC (a) (b) (c) (d) Turn the ignition switch off. Clear the DTC (See page BC-141). Start the engine. Drive the vehicle at the speed of 20 mph (32 km/h) or more for at least 60 seconds. (e) Check if the same DTC is recorded (See page BC-141). BC BC–172 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) Result Condition Proceed to DTCs (C0210/33 and/or C0215/34) are not output A DTCs (C0210/33 and/or C0215/34) are output B HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step (See page BC-134). B Go to step 6 A USE SIMULATION METHOD TO CHECK BC 5 CHECK REAR SPEED SENSOR INSTALLATION (a) Turn the ignition switch off. (b) Check the speed sensor installation. OK: There is no clearance between the sensor and rear axle carrier. Rear Speed Sensor: NG No Clearance OK INSTALL REAR SPEED SENSOR CORRECTLY NG F010178E22 OK 6 INSPECT REAR SPEED SENSOR (a) Turn the ignition switch off. (b) Disconnect the rear speed sensor connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: RH Rear Speed Sensor: Tester Connection 1 Condition Specified Condition 2 (RR+) - 1 (RR-) Always 0.9 to 2.1 kΩ 2 (RR+) - Body ground Always 10 kΩ or higher 1 (RR-) - Body ground Always 10 kΩ or higher Tester Connection Condition Specified Condition LH 2 C113377E02 2 (RL+) - 1 (RL-) Always 0.9 to 2.1 kΩ 2 (RL+) - Body ground Always 10 kΩ or higher 1 (RL-) - Body ground Always 10 kΩ or higher BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–173 NOTICE: Check the speed sensor signal after replacement (See page BC-123). NG REPLACE REAR SPEED SENSOR OK 7 CHECK HARNESS AND CONNECTOR (SKID CONTROL SENSOR WIRE) Skid Control Sensor Wire: f1 :RH Vehicle Side Connector "B" (a) Disconnect the skid control sensor wire. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: RH g1 :LH Sensor Side Connector "A" Tester Connection Condition Specified Condition f1 ("A"-1) - f1 ("B"-2) Always Below 1 Ω f1 ("A"-1) - f1 ("B"-1) Always 10 kΩ or higher f1 ("A"-1) - Body ground Always 10 kΩ or higher f1 ("A"-2) - f1 ("B"-1) Always Below 1 Ω f1 ("A"-2) - f1 ("B"-2) Always 10 kΩ or higher f1 ("A"-2) - Body ground Always 10 kΩ or higher LH C136026E01 Tester Connection Condition Specified Condition g1 ("A"-1) - g1 ("B"-2) Always Below 1 Ω g1 ("A"-1) - g1 ("B"-1) Always 10 kΩ or higher g1 ("A"-1) - Body ground Always 10 kΩ or higher g1 ("A"-2) - g1 ("B"-1) Always Below 1 Ω g1 ("A"-2) - g1 ("B"-2) Always 10 kΩ or higher g1 ("A"-2) - Body ground Always 10 kΩ or higher NOTICE: Check the speed sensor signal after replacement (See page BC-123). NG OK REPLACE SKID CONTROL SENSOR WIRE BC BC–174 8 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - REAR SPEED SENSOR) (a) Disconnect the skid control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: RH Skid Control ECU Harness Side Connector Front View: RR+ A26 RL- RR- BC Tester Connection Condition A26-5 (RR+) - f1-1 (RR+) Always Below 1 Ω A26-5 (RR+) - Body ground Always 10 kΩ or higher A26-19 (RR-) - f1-2 (RR-) Always Below 1 Ω A26-19 (RR-) - Body ground Always 10 kΩ or higher Tester Connection Condition Specified Condition A26-20 (RL+) - g1-1 (RL+) Always Below 1 Ω A26-20 (RL+) - Body ground Always 10 kΩ or higher A26-6 (RL-) - g1-2 (RL-) Always Below 1 Ω A26-6 (RL-) - Body ground Always 10 kΩ or higher LH RL+ Rear Speed Sensor Harness Side Connector Front View: g1 f1 NG RR- RR+ RL- RL+ C136020E01 OK Specified Condition REPAIR OR REPLACE HARNESS OR CONNECTOR BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 9 CHECK SPEED SENSOR AND SPEED SENSOR ROTOR SERRATIONS (a) Reconnect the skid control sensor wire. (b) Reconnect the rear speed sensor connector. (c) Connect the oscilloscope to the rear speed sensor terminal of the skid control ECU. (d) Check that a waveform is output when the tires are rotated. OK: The same waveform is output from all the 4 wheels and there is no noise or interference in the waveform. HINT: • As the vehicle speed (wheel revolution speed) increases, a cycle of the waveform narrows and the output voltage becomes greater. • When noise is identified in the waveform on the oscilloscope, the erratic signals are generated due to speed sensor rotor's scratches, looseness or foreign matter attached to it. Skid Control ECU Harness Side Connector Front View: A26 BC–175 RR+ RL- RR- RL+ Normal Signal Waveform: NG REPLACE BRAKE ACTUATOR ASSEMBLY GND 1 V/Division, 2 ms/Division C136019E02 OK 10 RECONFIRM DTC (a) (b) (c) (d) Reconnect the skid control ECU connector. Clear the DTC (See page BC-141). Start the engine. Drive the vehicle at the speed of 20 mph (32 km/h) or more for at least 60 seconds. (e) Check if the same DTC is recorded (See page BC-141). Result Condition Proceed to DTCs (C0210/33 and/or C0215/34) are output A DTCs (C0210/33 and/or C0215/34) are not output B HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step (See page BC-134). B USE SIMULATION METHOD TO CHECK BC BC–176 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) A REPLACE BRAKE ACTUATOR ASSEMBLY 11 REPAIR OR REPLACE HARNESS OR CONNECTOR (SKID CONTROL ECU - REAR SPEED SENSOR) (a) Turn the ignition switch off. (b) Repair or replace the harness or connector. (c) Check for any momentary interruption between the skid control ECU and rear speed sensor (See page BC-118). (d) Check that there is no momentary interruption. NEXT BC 12 RECONFIRM DTC (a) Clear the DTC (See page BC-141). (b) Start the engine. (c) Drive the vehicle at the speed of 20 mph (32 km/h) or more for at least 60 seconds. (d) Check if the same DTC is recorded (See page BC-141). Result Condition Proceed to DTCs (C0210/33 and/or C0215/34) are not output A DTCs (C0210/33 and/or C0215/34) are output B HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step (See page BC-134). B A END Go to step 2 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DTC C0226/21 SFR Solenoid Circuit DTC C0236/22 SFL Solenoid Circuit DTC C0246/23 SRR Solenoid Circuit DTC C0256/24 SRL Solenoid Circuit DTC C1225/25 SM Solenoid Circuit BC–177 DESCRIPTION These solenoids turn on when signals are received from the skid control ECU and they control the pressure acting on the wheel cylinders to control the braking force. DTC No. DTC Detection Condition C0226/21 C0236/22 C0246/23 C0256/24 Trouble Area Open or short in the solenoid circuit continues for 0.05 seconds or more. • • Brake actuator assembly Solenoid circuit C1225/25 When any of the following is detected: • While outputting switching solenoid (SM1 or SM2) ON, overcurrent continues for 0.05 seconds or more. • While outputting switching solenoid (SM1 or SM2) OFF, an open circuit continues for 0.05 seconds or more. • While outputting switching solenoid (SM1 or SM2) ON, an open circuit continues for 0.1 second or more. • While outputting switching solenoid (SM1 or SM2) OFF, current continues to be applied for 0.1 second or more. • Short to GND in the switching solenoid (SM1 or SM2) continues for 0.1 second or more. • Switching solenoids SM1 and SM2 are shorted for 0.1 second or more. • • Brake actuator assembly SM1 or SM2 circuit BC BC–178 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) WIRING DIAGRAM Brake Actuator Assembly Skid Control ECU ALT ABS NO. 2 Solenoid Relay 31 +BS SFRH SFLH BC SRRH SRLH SFRR SFLR 32 GND1 SRRR SRLR FL MAIN 1 Battery GND2 SM1 SM2 C136021E01 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 1 BC–179 RECONFIRM DTC HINT: These codes are detected when a problem is determined in the brake actuator assembly. The solenoid circuits are in the brake actuator assembly. Therefore, solenoid circuit inspection and solenoid unit inspection cannot be performed. Be sure to check if any DTC code is output before replacing the brake actuator assembly. (a) Clear the DTC (See page BC-141). (b) Start the engine. (c) Drive the vehicle at the speed of 4 mph (6 km/h) or more. (d) Check if the same DTC is recorded (See page BC-141). Result Condition Proceed to DTCs (C0226/21, C0236/22, C0246/23, C0256/24 and/or C1225/25) are not output A DTCs (C0226/21, C0236/22, C0246/23, C0256/24 and/or C1225/25) are output B HINT: • If a speed signal of 4 mph (6 km/h) or more is input to the skid control ECU, with the ignition switch on (IG) and the stop light switch off, the ECU performs self diagnosis of the motor and solenoid circuits. • If the normal system code is output (the trouble code is not output), slightly jiggle the connectors, wire harness, and fuses of the brake actuator assembly. Make sure that no DTCs are output. • If any DTCs are output while jiggling a connector or wire harness of the brake actuator assembly (skid control ECU), inspect and repair the connector or wire harness. B A USE SIMULATION METHOD TO CHECK REPLACE BRAKE ACTUATOR ASSEMBLY BC BC–180 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DTC C0273/13 Open in ABS Motor Relay Circuit DTC C0274/14 Short to B+ in ABS Motor Relay Circuit DTC C1361/91 Short Circuit in ABS Motor Fail Safe Relay Circuit DESCRIPTION If a DTC of the motor line is stored, the VSC NO. 1 (fail safe) relay cuts off the power supply to the VSC NO. 2 relay and performs fail safe. While any of the ABS, TRAC, VSC, or BA is operating, the skid control ECU (housed in the actuator assembly) turns the VSC NO. 2 relay on and activates the pump motor in the brake actuator. This code may be stored if the motor relay (BM) voltage becomes lower than the DTC detecting condition due to insufficient output from the battery or alternator. DTC No. DTC Detection Condition C0273/13 When any of the following (1 or 2) is detected: 1. All of the following conditions continue for 0.12 seconds or more. • The IG1 terminal voltage is between 9.5 and 17.2 V. • During initial check and ABS, BA, TRAC, or VSC are operating. • Relay contact is open when the relay is ON. 2. All of the following conditions continue for 0.12 seconds. • The IG1 terminal voltage is 9.5 V or less. • Relay contact remains open when the relay is ON. • • • • ABS NO. 1 fuse VSC NO. 2 relay VSC NO. 2 relay circuit Brake actuator assembly C0274/14 When the motor relay is OFF, the VSC NO. 2 relay remains closed for 4 seconds or more. • • • • ABS NO. 1 fuse VSC NO. 2 relay VSC NO. 2 relay circuit Brake actuator assembly C1361/91 Immediately after the ignition switch is turned on (IG), the relay contact is closed for 4 seconds when the VSC NO. 1 (fail safe) relay is OFF. • • • • ABS NO. 1 fuse VSC NO. 1 (fail safe) relay VSC NO. 1 (fail safe) relay circuit Brake actuator assembly BC Trouble Area BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–181 WIRING DIAGRAM Brake Actuator Assembly R+ VSC NO. 1 (Fail Safe) 45 MRF 1 2 5 3 14 BC VSC NO. 2 MR ABS NO. 1 1 2 3 5 ALT 15 BM 2 Pump Motor FL MAIN Battery Skid Control ECU GND2 1 C136022E01 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). BC–182 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) INSPECT ABS NO. 1 FUSE (a) Remove the fusible link from the engine room R/B. Engine Room R/B: Fusible Link ABS NO. 1 (50 A) Fuse BC C136500E06 (b) Check if the fusible link is melted. OK: The fusible link is melted. (c) Install the fusible link to the engine room R/B with the nut. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) Fusible Link: NG ABS NO. 1 E130412E02 OK REPLACE FUSIBLE LINK (ABS NO. 1 FUSE) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 2 BC–183 INSPECT VSC NO. 2 RELAY (a) Remove the VSC NO. 2 relay. (b) Measure the resistance according to the value(s) in the table below. Standard resistance VSC NO. 2 Relay: F050240E07 Tester Connection Condition Specified Condition 3-5 Always 10 kΩ or higher 3-5 Apply B+ between terminals 1 and 2 Below 1 Ω NG REPLACE VSC NO. 2 RELAY OK 3 INSPECT VSC NO. 1 (FAIL SAFE) RELAY BC (a) Remove the VSC NO. 1 (fail safe) relay. (b) Measure the resistance according to the value(s) in the table below. Standard resistance VSC NO. 1 (Fail Safe) Relay: F050241E11 Tester Connection Condition Specified Condition 3-5 Always 10 kΩ or higher 3-5 Apply B+ between terminals 1 and 2 Below 1 Ω NG REPLACE VSC NO. 1 (FAIL SAFE) RELAY OK 4 INSPECT ENGINE ROOM RELAY BLOCK (POWER SOURCE TERMINAL) Engine Room R/B: VSC NO. 1 (Fail Safe) Relay (a) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition VSC NO. 1 (fail safe) relay terminal 5 Body ground Always 10 to 14 V NG C135809E01 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (POWER SOURCE CIRCUIT) BC–184 5 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) INSPECT ENGINE ROOM RELAY BLOCK Engine Room R/B: VSC NO. 1 (Fail Safe) Relay (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition VSC NO. 1 (fail safe) relay terminal 3 VSC NO. 2 relay terminal 5 Always Below 1 Ω VSC NO. 1 (fail safe) relay terminal 3 Body ground Always 10 kΩ or higher VSC NO. 2 Relay NG BC REPAIR OR REPLACE ENGINE ROOM RELAY BLOCK C135809E02 OK 6 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - ENGINE ROOM RELAY BLOCK) (a) Disconnect the skid control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: A26 BM Engine Room R/B: MRF R+ MR VSC NO. 1 (Fail Safe) Relay Tester Connection Condition Specified Condition A26-2 (BM) - VSC NO. 2 relay terminal 3 Always Below 1 Ω A26-2 (BM) - Body ground Always 10 kΩ or higher A26-14 (MRF) - VSC NO. 1 (fail safe) relay terminal 2 Always Below 1 Ω A26-14 (MRF) - Body ground Always 10 kΩ or higher A26-15 (MR) - VSC NO. 2 relay terminal 2 Always Below 1 Ω A26-15 (MR) - Body ground Always 10 kΩ or higher A26-45 (R+) - VSC NO. 1 (fail safe) relay terminal 1 Always Below 1 Ω A26-45 (R+) - Body ground Always 10 kΩ or higher NG VSC NO. 2 Relay C136023E03 REPAIR OR REPLACE HARNESS OR CONNECTOR BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–185 OK 7 RECONFIRM DTC (a) (b) (c) (d) Clear the DTC (See page BC-141). Start the engine. Drive the vehicle at the speed of 4 mph (6 km/h) or more. Check if the same DTC is recorded (See page BC-141). HINT: Reinstall the relays, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTCs (C0273/13, C0274/14 and/or C1361/91) are not output A DTCs (C0273/13, C0274/14 and/or C1361/91) are output B HINT: • If a speed signal of 4 mph (6 km/h) or more is input to the skid control ECU, with the ignition switch on (IG) and the stop light switch off, the ECU performs self diagnosis of the motor and solenoid circuits. • If the normal system code is output (the trouble code is not output), slightly jiggle the connectors, wire harness, and fuses of the brake actuator assembly. Make sure that no DTCs are output. • If any DTCs are output while jiggling a connector or wire harness of the brake actuator assembly (skid control ECU), inspect and repair the connector or wire harness. B A USE SIMULATION METHOD TO CHECK REPLACE BRAKE ACTUATOR ASSEMBLY BC BC–186 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DTC C0278/11 Open in ABS Solenoid Relay Circuit DTC C0279/12 Short to B+ in ABS Solenoid Relay Circuit DESCRIPTION The ABS solenoid relay supplies power to the ABS solenoid and TRAC solenoid. The solenoid relay is turned on 1.5 seconds after the ignition switch is turned on (IG), and is turned off if an open or short in the solenoid is detected by self diagnosis performed when the vehicle starts running. The ABS solenoid relay is housed in the skid control ECU in the actuator assembly. HINT: If a speed signal of 4 mph (6 km/h) or more is input to the skid control ECU, with the ignition switch on (IG) and the stop light switch off, the ECU performs self diagnosis of the motor and solenoid circuits. DTC No. BC DTC Detection Condition Trouble Area C0278/11 When any of the following (1 or 2) is detected: 1. Both of the following conditions continue for 0.2 seconds or more. • The IG1 terminal voltage is between 9.5 and 17.2 V. • The solenoid relay contact is open when the relay is ON. 2. Both of the following conditions continue for 0.2 seconds or more. • IG1 terminal voltage becomes lower than 9.5 V or less when the relay is turned on. • The relay contact remains open. • • • • C0279/12 Immediately after the ignition switch is turned on (IG), the solenoid relay contact is closed for 0.2 seconds when the relay is turned off. Brake actuator assembly ABS NO. 2 fuse ABS solenoid relay ABS solenoid relay circuit Brake actuator assembly BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–187 WIRING DIAGRAM Brake Actuator Assembly Skid Control ECU ALT ABS NO. 2 Solenoid Relay 31 +BS SFRH SFLH BC SRRH SRLH SFRR SFLR 32 GND1 SRRR SRLR FL MAIN 1 Battery GND2 SM1 SM2 C136021E01 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). BC–188 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) INSPECT ABS NO. 2 FUSE (a) Remove the fusible link from the engine room R/B. Engine Room R/B: Fusible Link ABS NO. 2 (30 A) Fuse BC C136500E07 (b) Check if the fusible link is melted. OK: The fusible link is melted. (c) Install the fusible link to the engine room R/B with the nut. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) Fusible Link: NG ABS NO. 2 E130412E03 OK REPLACE FUSIBLE LINK (ABS NO. 2 FUSE) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 2 BC–189 INSPECT SKID CONTROL ECU (+BS TERMINAL) (a) Disconnect the skid control ECU connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control ECU Harness Side Connector Front View: A26 Tester Connection Condition Specified Condition A26-31 (+BS) - Body ground Always 10 to 14 V NG +BS F049362E96 REPAIR OR REPLACE HARNESS OR CONNECTOR (+BS CIRCUIT) OK 3 INSPECT SKID CONTROL ECU (GND TERMINAL) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: A26 Tester Connection Condition Specified Condition A26-32 (GND1) - Body ground Always Below 1 Ω A26-1 (GND2) - Body ground Always Below 1 Ω NG GND2 GND1 F049362E97 REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) OK 4 RECONFIRM DTC (a) (b) (c) (d) (e) Reconnect the skid control ECU connector. Clear the DTC (See page BC-141). Start the engine. Drive the vehicle at the speed of 4 mph (6 km/h) or more. Check if the same DTC is recorded (See page BC-141). Result Condition Proceed to DTCs (C0278/11 and/or C0279/12) are not output A DTCs (C0278/11 and/or C0279/12) are output B HINT: • If a speed signal of 4 mph (6 km/h) or more is input to the skid control ECU, with the ignition switch on (IG) and the stop light switch off, the ECU performs self diagnosis of the motor and solenoid circuits. • If the normal system code is output (the trouble code is not output), slightly jiggle the connectors, wire harnesses, and fuses of the brake actuator assembly. Make sure that no DTCs are output. BC BC–190 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) • If any DTCs are output while jiggling a connector or wire harness of the brake actuator assembly (skid control ECU), inspect and repair the connector or wire harness. B A USE SIMULATION METHOD TO CHECK BC REPLACE BRAKE ACTUATOR ASSEMBLY BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DTC BC–191 C1201/51 Engine Control System Malfunction DESCRIPTION If a malfunction in the engine control system is detected, the operations of VSC and TRAC are prohibited by the fail safe function. When the signals from the engine are input normally, the fail safe is cancelled and the DTC is not stored. DTC No. C1201/51 DTC Detection Condition Trouble Area Engine control system malfunction signal continues for 5 seconds. Engine control system INSPECTION PROCEDURE 1 CHECK ENGINE CONTROL SYSTEM (a) Check if the engine control system DTC is output (See page ES-45 for 2GR-FE, or ES-38 for 2AZ-FE). Result Condition Proceed to DTC is not output A DTC is output B B A REPLACE ECM INSPECT ENGINE CONTROL SYSTEM BC BC–192 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DTC C1203/53 ECM Communication Circuit Malfunction DESCRIPTION The circuit is used to send TRAC and VSC control information from the skid control ECU to the ECM, and engine control information from the ECM to the skid control ECU. DTC No. DTC Detection Condition C1203/53 Engine, drive source and destination variations that are sent from the ECM do not match the ones of the skid control ECU. Trouble Area ECM INSPECTION PROCEDURE 1 CHECK PART NUMBER (ECM AND BRAKE ACTUATOR ASSEMBLY) (a) Check that the proper ECM and brake actuator assembly (skid control ECU) are installed. OK: Proper ECUs are installed. BC NG OK REPLACE ECM REPLACE ECUS WITH PROPER ONES BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–193 DTC C1210/36 Zero Point Calibration of Yaw Rate Sensor Undone DTC C1336/39 Zero Point Calibration of Acceleration Sensor Undone DESCRIPTION The skid control ECU receives signals from the yaw rate and acceleration sensor via the CAN communication system. The yaw rate sensor has the built in acceleration sensor and detects the vehicle's condition using 2 circuits (GL1, GL2). If there is trouble in the bus lines between the yaw rate and acceleration sensor and the CAN communication system, the DTCs U0123/62 (yaw rate sensor communication trouble) and U0124/95 (acceleration sensor communication trouble) are output. The DTCs are also output when the calibration has not been completed. DTC No. DTC Detection Condition C1210/36 Zero point calibration of yaw rate sensor undone. C1336/39 When either of the following is detected: 1. The vehicle runs in the normal mode with zero point calibration undone. 2. After the zero point has been obtained, the zero point voltage of the sensor is not between 2.38 and 2.62 V. Trouble Area • • • Brake actuator assembly (Skid control ECU) Yaw rate and acceleration sensor Zero point calibration undone (Perform zero point calibration and check DTC. If DTC is not output again, the sensor is normal) • • • Brake actuator assembly (Skid control ECU) Yaw rate and acceleration sensor Zero point calibration undone (Perform zero point calibration and check DTC. If DTC is not output again, the sensor is normal) INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). HINT: When U0123/62, U0124/95 or U0126/63 is output along with C1210/36 or C1336/39, inspect and repair trouble areas indicated by U0123/62, U0124/95 or U0126/63 first. 1 PERFORM ZERO POINT CALIBRATION OF YAW RATE AND ACCELERATION SENSOR (a) Perform zero point calibration of the yaw rate and acceleration sensor (See page BC-119). NEXT 2 RECONFIRM DTC (a) Clear the DTC (See page BC-141). (b) Check if the same DTCs are recorded (See page BC141). Result Condition Proceed to DTCs (C1210/36 and/or C1336/39) are output A DTCs (C1210/36 and/or C1336/39) are not output B BC BC–194 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) HINT: • The DTCs are recorded because zero point calibration has not been completed. • End the procedure as the same DTCs are not recorded after completion of zero point calibration. B END A 3 CHECK YAW RATE AND ACCELERATION SENSOR INSTALLATION (a) Turn the ignition switch off. (b) Check that the yaw rate and acceleration sensor has been installed properly (See page BC-448). OK: The sensor should be tightened to the specified torque. The sensor should not be tilted. BC NG OK REPLACE BRAKE ACTUATOR ASSEMBLY INSTALL YAW RATE AND ACCELERATION SENSOR CORRECTLY BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DTC BC–195 C1231/31 Steering Angle Sensor Circuit Malfunction DESCRIPTION The steering angle sensor signal is sent to the skid control ECU via the CAN communication system. When there is a malfunction in the CAN communication system, it will be detected by the steering angle sensor zero point malfunction diagnostic function. DTC No. DTC Detection Condition Trouble Area When ECU IG1 terminal voltage is 9.5 V or more, the steering angle sensor malfunction signal is received. C1231/31 • • • • Steering angle sensor Steering angle sensor circuit Steering angle sensor power supply Brake actuator assembly (Skid control ECU) WIRING DIAGRAM Brake Actuator Assembly CANL CANH BAT BC - Skid Control ECU Steering Angle Sensor 9 25 10 11 CANL CANH ECU-B NO. 1 3 2 1 From Battery IG1 IG ESS ECU-IG NO. 2 1 3 5 2 1 2 (*1): without Smart Key System From Ignition Switch (*1), Main Body ECU (*2) (*2): with Smart Key System C136024E04 INSPECTION PROCEDURE HINT: • When U0073/94, U0123/62, U0124/95 or U0126/63 is output together with C1231/31, inspect and repair the trouble areas indicated by U0073/94, U0123/62, U0124/95 or U0126/63 first. BC–196 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) • When the speed sensor or the yaw rate sensor has trouble, DTCs for the steering angle sensor may be output even when the steering angle sensor is normal. When DTCs for the speed sensor or yaw rate sensor are output together with other DTCs for the steering angle sensor, inspect and repair the speed sensor and yaw rate sensor first, and then inspect and repair the steering angle sensor. 1 CHECK DTC (a) Clear the DTC (See page BC-141). (b) Turn the ignition switch off. (c) Turn the ignition switch on (IG) again and check that no CAN communication system DTC is output. (d) Drive the vehicle and turn the steering wheel to the right and left at the speed of 22 mph (35 km/h) and check that no speed sensor and yaw rate sensor DTCs are output. Result BC Condition Proceed to No CAN communication system DTC and the speed sensor or yaw rate sensor DTC are output A CAN communication system DTC is output B Speed sensor or yaw rate sensor DTC is output C HINT: • If there is a malfunction in the speed sensor or the yaw rate sensor, an abnormal value may be output although the steering angle sensor is normal. • If the speed sensor and the yaw rate sensor DTCs are output simultaneously, repair the sensors and inspect the steering angle sensor. B INSPECT CAN COMMUNICATION SYSTEM C REPAIR CIRCUIT INDICATED BY OUTPUT DTC (See page BC-151) A 2 INSPECT STEERING ANGLE SENSOR (POWER SOURCE TERMINAL) (a) (b) (c) (d) Steering Angle Sensor Wire Harness View: E17-1 (IG) Turn the ignition switch off. Remove the steering wheel and the column cover lower. Disconnect the steering angle sensor connector. Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition E17-1 (IG) - Body ground Ignition switch on (IG) 10 to 14 V E17-3 (BAT) - Body ground Always 10 to 14 V NG E17-3 (BAT) G030156E15 REPAIR OR REPLACE HARNESS OR CONNECTOR (POWER SOURCE CIRCUIT) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–197 OK 3 INSPECT STEERING ANGLE SENSOR (GROUND TERMINAL) (a) Turn the ignition switch off. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Steering Angle Sensor Wire Harness View: Tester Connection Condition Specified Condition E17-2 (ESS) - Body ground Always Below 1 Ω HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step (See page BC-134). NG E17-2 (ESS) G030156E16 OK REPLACE STEERING ANGLE SENSOR REPAIR OR REPLACE HARNESS OR CONNECTOR (GROUND CIRCUIT) BC BC–198 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DTC C1232/32 Stuck in Acceleration Sensor DTC C0371/71 Yaw Rate Sensor (Test Mode DTC) DTC C1234/34 Yaw Rate Sensor Malfunction DTC C1243/43 Acceleration Sensor Stuck Malfunction DTC C1244/44 Open or Short in Acceleration Sensor Circuit DTC C1245/45 Acceleration Sensor Output Malfunction DTC C1279/79 Acceleration Sensor Output Voltage Malfunction (Test Mode DTC) DTC C1381/97 Yaw Rate and / or Acceleration Sensor Power Supply Voltage Malfunction BC DESCRIPTION The skid control ECU receives signals from the yaw rate and acceleration sensor via the CAN communication system. The yaw rate sensor has a built in acceleration sensor and detects the vehicle's condition using 2 circuits (GL1, GL2). If there is trouble in the bus lines between the yaw rate and acceleration sensor and the CAN communication system, the DTC U0123/62 (malfunction in CAN communication with the yaw rate sensor) and U0124/95 (malfunction in CAN communication with the acceleration sensor) are output. These DTCs are also output when calibration has not been completed. DTCs C0371/71 and C1279/79 can be deleted when the yaw rate and acceleration sensor sends a yaw rate and/or acceleration signal or the Test Mode ends. DTCs C0371/71 and C1279/79 are output only in the Test Mode. DTC No. DTC Detection Condition C1232/32 At a vehicle speed of 6 mph (10 km/h) or more, either GL1 or GL2 (input signal) does not change for 30 seconds or more. • • Yaw rate and acceleration sensor Yaw rate and acceleration sensor circuit Trouble Area C1234/34 Sensor malfunction signal is received from the yaw rate sensor. • • Yaw rate and acceleration sensor Yaw rate and acceleration sensor circuit C1243/43 While the vehicle speed changes from 19 mph (30 km/h) to 0 mph (0 km/h), the condition that the values of GL1 and GL2 do not change occurs 16 times or more. • • Yaw rate and acceleration sensor Yaw rate and acceleration sensor circuit C1244/44 When either of the following is detected: 1. A data malfunction signal is received from the acceleration sensor. 2. After the difference between GL1 and GL2 becomes 0.6 G or more with the vehicle stationary, the difference remains 0.4 G or more for 60 seconds or more. • • Yaw rate and acceleration sensor Yaw rate and acceleration sensor circuit C1245/45 At a vehicle speed of 19 mph (30 km/h) or more, the difference between the forward and backward G calculated from the acceleration sensor value and that calculated from the vehicle speed sensor exceeds 0.35 G for 60 seconds or more. • • Yaw rate and acceleration sensor Yaw rate and acceleration sensor circuit C1381/97 At a vehicle speed of more than 2 mph (3 km/h), the acceleration sensor power source malfunction signal is received for 10 seconds or more. • • Yaw rate and acceleration sensor Yaw rate and acceleration sensor power source circuit BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–199 WIRING DIAGRAM Brake Actuator Assembly Yaw Rate and Acceleration Sensor CANL CANH IG GND - Skid Control ECU 2 25 3 11 5 3 5 1 1 2 (*1): without Smart Key System CANH BC From Battery IG1 ECU-IG NO. 2 CANL From Ignition Switch (*1), Main Body ECU (*2) (*2): with Smart Key System C136028E04 INSPECTION PROCEDURE NOTICE: When replacing the yaw rate and acceleration sensor, perform zero point calibration (See page BC-119). HINT: When U0123/62, U0124/95 or U0126/63 is output together with C1232/32, C1234/34, C1243/43, C1244/ 44, C1245/45, or C1381/97, inspect and repair the trouble areas indicated by U0123/62, U0124/95 or U0126/63 first. 1 CHECK DTC (a) Clear the DTC (See page BC-141). (b) Turn the ignition switch off. (c) At a speed of 19 mph (30 km/h) or more, drive the vehicle, turn the steering wheel, and decelerate the vehicle (depress the brake pedal). BC–200 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) (d) Turn the ignition switch on (IG) again and check that no CAN communication system DTC is output. (e) Check if DTCs for zero point calibration of the yaw rate sensor undone (C1210/36) or for zero point calibration of the acceleration sensor undone (C1336/39) are output. Result Condition Proceed to DTCs (C1210/36, C1336/39 and/or CAN communication system DTC) are not output A CAN communication system DTC is output B DTCs (C1210/36 and/or C1336/39) are output C B INSPECT CAN COMMUNICATION SYSTEM C REPAIR CIRCUIT INDICATED BY OUTPUT DTC (See page BC-151) A BC 2 CHECK YAW RATE AND ACCELERATION SENSOR INSTALLATION (a) Turn the ignition switch off. (b) Check that the yaw rate and acceleration sensor has been installed properly (See page BC-448). OK: The sensor is tightened to the specified torque. The sensor is not tilted. NG INSTALL YAW RATE AND ACCELERATION SENSOR CORRECTLY OK 3 INSPECT YAW RATE AND ACCELERATION SENSOR (IG TERMINAL) Yaw Rate and Acceleration Sensor Harness Side Connector Front View: E34 IG (a) Disconnect the yaw rate and acceleration sensor connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition E34-5 (IG) - Body ground Ignition switch on (IG) 10 to 14 V G026359E61 NG OK REPAIR OR REPLACE HARNESS OR CONNECTOR (IG CIRCUIT) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 4 BC–201 INSPECT YAW RATE AND ACCELERATION SENSOR (GND TERMINAL) Yaw Rate and Acceleration Sensor Harness Side Connector Front View: E34 GND G026359E62 (a) Turn the ignition switch off. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition E34-1 (GND) - Body ground Always Below 1 Ω NOTICE: Check the yaw rate and acceleration sensor signal after replacement (See page BC-123). HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step (See page BC-134). NG REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) OK REPLACE YAW RATE AND ACCELERATION SENSOR BC BC–202 BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DTC C1235/35 Foreign Object is Attached on Tip of Front Speed Sensor RH DTC C1236/36 Foreign Object is Attached on Tip of Front Speed Sensor LH DTC C1238/38 Foreign Object is Attached on Tip of Rear Speed Sensor RH DTC C1239/39 Foreign Object is Attached on Tip of Rear Speed Sensor LH DTC C1275/75 Abnormal Change in Output Signal of Front Speed Sensor RH (Test Mode DTC) DTC C1276/76 Abnormal Change in Output Signal of Front Speed Sensor LH (Test Mode DTC) DTC C1277/77 Abnormal Change in Output Signal of Rear Speed Sensor RH (Test Mode DTC) DTC C1278/78 Abnormal Change in Output Signal of Rear Speed Sensor LH (Test Mode DTC) DESCRIPTION The speed sensors detect wheel speed and transmit the signals to the ECU. These signals are used for control of the ABS control system. Each of the front and rear rotors have 48 serrations. When the rotors rotate, the magnetic field generated by the permanent magnet in the speed sensor induces an AC voltage. Since the frequency of this AC voltage changes in direct proportion to the speed of the rotor, the frequency is used by the ECU to detect the speed of each wheel. DTCs C1275/75 to C1278/78 can be deleted when the speed sensor sends a vehicle speed signal or the Test Mode ends. DTCs from C1275/75 to C1278/78 are output only in the Test Mode. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–203 Speed Sensor Rotor Coil N S Magnet To ECU Low speed High speed +V -V F000010E04 DTC No. C1235/35 C1236/36 C1238/38 C1239/39 DTC Detection Condition At a vehicle speed of 12 mph (20 km/h) or more, noise occurs in the sensor signal from the abnormal wheel for 5 seconds or more. HINT: • DTC C1235/35 is for the front speed sensor RH. • DTC C1236/36 is for the front speed sensor LH. • DTC C1238/38 is for the rear speed sensor RH. • DTC C1239/39 is for the rear speed sensor LH. Trouble Area • • • • Speed sensor Speed sensor rotor Sensor installation Brake actuator assembly (Skid control ECU) BC BC–204 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) WIRING DIAGRAM Front Speed Sensor Circuit: Brake Actuator Assembly - Skid Control ECU Front Speed Sensor RH 2 1 3 17 BC FR+ FR- Front Speed Sensor LH 2 1 18 4 FL+ FL- C132772E07 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) Rear Speed Sensor Circuit: BC–205 Brake Actuator Assembly - Skid Control ECU Rear Speed Sensor RH 2 1 5 19 RR+ RR- Rear Speed Sensor LH 2 1 20 6 BC RL+ RL- C132772E08 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). HINT: When C0200/31, C0205/32, C0210/33, or C0215/34 is output together with C1235/35, C1236/36, C1238/ 38, or C1239/39, inspect and repair the trouble areas indicated by C0200/31, C0205/32, C0210/33, or C0215/34 first. BC–206 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) CHECK SPEED SENSOR AND SPEED SENSOR ROTOR SERRATIONS Skid Control ECU Harness Side Connector Front View: A26 FR+ FL- RR+ RL- FR- FL+ RR- RL+ Normal Signal Waveform: BC GND (a) Disconnect the skid control ECU connector. (b) Connect the oscilloscope to each speed sensor terminal of the skid control ECU. (c) Check that a waveform is output when the tires are rotated (by the sensor circuit). OK: The same waveform is output from all the 4 wheels and there is no noise or interference in the waveform. (d) Check that the waveform does not change while jiggling a connector or a wire harness. OK: The waveform does not change. HINT: • As the vehicle speed (wheel revolution speed) increases, a cycle of the waveform narrows and the output voltage becomes greater. • When noise is identified in the waveform on the oscilloscope, the erratic signals are generated due to speed sensor rotor's scratches, looseness or foreign matter attached to it. NG Go to step 3 1 V/Division, 2 ms/Division C136019E05 OK 2 RECONFIRM DTC (a) (b) (c) (d) Reconnect the skid control ECU connector. Clear the DTC (See page BC-141). Start the engine. Drive the vehicle at the speed of 12 mph (20 km/h) or more for at least 60 seconds. (e) Check if the same DTC is recorded (See page BC-141). Result Condition Proceed to DTCs (C1235/35, C1236/36, C1238/38 and/or C1239/39) are not output A DTCs (C1235/35, C1236/36, C1238/38 and/or C1239/39) are output B B A USE SIMULATION METHOD TO CHECK REPLACE BRAKE ACTUATOR ASSEMBLY BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 3 INSPECT EACH SPEED SENSOR (a) Disconnect each speed sensor connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: RH Front Speed Sensor: 1 2 Rear Speed Sensor: Tester Connection Condition Specified Condition 1 (FR+) - 2 (FR-) Always 1.4 to 1.8 kΩ at 20°C (68 °F) 1 (FR+) - Body ground Always 10 kΩ or higher 2 (FR-) - Body ground Always 10 kΩ or higher 2 (RR+) - 1 (RR-) Always 0.9 to 2.1 kΩ 2 (RR+) - Body ground Always 10 kΩ or higher 1 (RR-) - Body ground Always 10 kΩ or higher Tester Connection Condition Specified Condition 1 (FL+) - 2 (FL-) Always 1.4 to 1.8 kΩ at 20°C (68 °F) 1 (FL+) - Body ground Always 10 kΩ or higher 2 (FL-) - Body ground Always 10 kΩ or higher LH 1 2 2 (RL+) - 1 (RL-) Always 0.9 to 2.1 kΩ 2 (RL+) - Body ground Always 10 kΩ or higher 1 (RL-) - Body ground Always 10 kΩ or higher C136027E01 Result Result Proceed to OK (for rear) A OK (for front) B NG C B C A BC–207 Go to step 5 REPLACE EACH SPEED SENSOR BC BC–208 4 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) CHECK HARNESS AND CONNECTOR (SKID CONTROL SENSOR WIRE) Skid Control Sensor Wire: f1 :RH Vehicle Side Connector "B" (a) Disconnect the skid control sensor wire. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: RH g1 :LH Sensor Side Connector "A" Tester Connection Condition Specified Condition f1 ("A"-1) - f1 ("B"-2) Always Below 1 Ω f1 ("A"-1) - f1 ("B"-1) Always 10 kΩ or higher f1 ("A"-1) - Body ground Always 10 kΩ or higher f1 ("A"-2) - f1 ("B"-1) Always Below 1 Ω f1 ("A"-2) - f1 ("B"-2) Always 10 kΩ or higher f1 ("A"-2) - Body ground Always 10 kΩ or higher Tester Connection Condition Specified Condition g1 ("A"-1) - g1 ("B"-2) Always Below 1 Ω LH BC C136026E01 g1 ("A"-1) - g1 ("B"-1) Always 10 kΩ or higher g1 ("A"-1) - Body ground Always 10 kΩ or higher g1 ("A"-2) - g1 ("B"-1) Always Below 1 Ω g1 ("A"-2) - g1 ("B"-2) Always 10 kΩ or higher g1 ("A"-2) - Body ground Always 10 kΩ or higher NOTICE: Check the speed sensor signal after replacement (See page BC-123). NG OK REPLACE SKID CONTROL SENSOR WIRE BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 5 BC–209 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - EACH SPEED SENSOR) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: RH Skid Control ECU Harness Side Connector Front View: FR+ FL- RR+ RL- A26 RL+ FRFL+ RRFront Speed Sensor Harness Side Connector Front View: Tester Connection Condition Specified Condition A26-3 (FR+) - A35-1 (FR+) Always Below 1 Ω A26-3 (FR+) - Body ground Always 10 kΩ or higher A26-17 (FR-) - A35-2 (FR-) Always Below 1 Ω A26-17 (FR-) - Body ground Always 10 kΩ or higher A26-5 (RR+) - f1-1 (RR+) Always Below 1 Ω A26-5 (RR+) - Body ground Always 10 kΩ or higher A26-19 (RR-) - f1-2 (RR-) Always Below 1 Ω A26-19 (RR-) - Body ground Always 10 kΩ or higher Tester Connection Condition Specified Condition BC LH A35 A14 FLFRFR+ FL+ Rear Speed Sensor Harness Side Connector Front View: A26-18 (FL+) - A14-1 (FL+) Always Below 1 Ω A26-18 (FL+) - Body ground Always 10 kΩ or higher A26-4 (FL-) - A14-2 (FL-) Always Below 1 Ω A26-4 (FL-) - Body ground Always 10 kΩ or higher A26-20 (RL+) - g1-1 (RL+) Always Below 1 Ω A26-20 (RL+) - Body ground Always 10 kΩ or higher A26-6 (RL-) - g1-2 (RL-) Always Below 1 Ω A26-6 (RL-) - Body ground Always 10 kΩ or higher g1 f1 NG RR- RR+ RL- REPAIR OR REPLACE HARNESS OR CONNECTOR RL+ C136025E01 OK 6 RECONFIRM DTC (a) Reconnect the skid control sensor wire. (b) Reconnect the skid control ECU connector and the speed sensor connector. (c) Clear the DTC (See page BC-141). (d) Start the engine. (e) Drive the vehicle at the speed of 12 mph (20 km/h) or more for at least 60 seconds. (f) Check if the same DTC is recorded (See page BC-141). Result Condition Proceed to DTCs (C1235/35, C1236/36, C1238/38 and/or C1239/39) are output (for front) A DTCs (C1235/35, C1236/36, C1238/38 and/or C1239/39) are output (for rear) B BC–210 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) Condition Proceed to DTCs (C1235/35, C1236/36, C1238/38 and/or C1239/39) are not output B C C Go to step 8 USE SIMULATION METHOD TO CHECK A 7 CHECK FRONT SPEED SENSOR TIP (a) Turn the ignition switch off. (b) Remove the front speed sensor (See page BC-438). (c) Check the speed sensor tip. OK: No scratches or foreign matter on the sensor tip. NOTICE: Check the speed sensor signal after cleaning or replacement (See page BC-123). BC NG CLEAN OR REPLACE FRONT SPEED SENSOR OK 8 CHECK EACH SPEED SENSOR ROTOR (a) Turn the ignition switch off. (b) Remove each speed sensor rotor. (c) Check the speed sensor rotor. OK: No scratches, missing teeth, or foreign matter on the rotors. NOTICE: Check the speed sensor signal after cleaning or replacement (See page BC-123). NG CLEAN OR REPLACE EACH SPEED SENSOR ROTOR OK 9 RECONFIRM DTC (a) Install the front speed sensor and the speed sensor rotor. (b) Clear the DTC (See page BC-141). (c) Start the engine. (d) Drive the vehicle at the speed of 12 mph (20 km/h) or more for at least 60 seconds. (e) Check if the same DTC is recorded (See page BC-141). BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–211 Result Condition Proceed to DTCs (C1235/35, C1236/36, C1238/38 and/or C1239/39) are output A DTCs (C1235/35, C1236/36, C1238/38 and/or C1239/39) are not output B B USE SIMULATION METHOD TO CHECK A REPLACE BRAKE ACTUATOR ASSEMBLY BC BC–212 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DTC C1241/41 Low Battery Positive Voltage DESCRIPTION If a malfunction is detected in the power supply circuit, the skid control ECU (housed in the actuator assembly) stores this DTC and the fail safe function prohibits ABS operation. This DTC is stored when the IG1 terminal voltage deviates from the DTC detection condition due to a malfunction in the power supply or charging circuit such as the battery or alternator circuit, etc. The DTC is cancelled when the IG1 terminal voltage returns to normal. DTC No. DTC Detection Condition C1241/41 When any of the following is detected: 1. At a vehicle speed of 2 mph (3 km/h) or more, the IG1 terminal voltage is 9.5 V or less for 10 seconds or more. 2. When the solenoid relay remains ON and the IG1 terminal voltage is 9.5 V or less, the relay contact is open for 0.2 seconds or more. 3. While the VSC NO. 1 (fail safe) relay is ON after VSC NO. 2 relay ON, the IG1 terminal voltage is 9.5 V or less and the actuator pump drive motor is OFF for 0.1 second or more. BC Trouble Area • • • • • ECU-IG NO. 2 fuse Battery Charging system Power source circuit Internal power supply circuit of the skid control ECU WIRING DIAGRAM Brake Actuator Assembly - Skid Control ECU IG1 Ignition Switch (*1) AM1 (*1) 4 AM1 ALT ECU-IG NO. 2 5 3 2 1 46 IG1 IG1 1 Main Body ECU (*2) (*2) 3 FL MAIN IG1D 6 32 AM2 1 AM1 2 1 Battery GND1 GND2 (*1): without Smart Key System (*2): with Smart Key System C136029E03 BC–213 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). 1 INSPECT ECU-IG NO. 2 FUSE (a) Remove the ECU-IG NO. 2 fuse from the main body ECU. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Main Body ECU: Tester Connection Condition Specified Condition ECU-IG NO. 2 (7.5 A) fuse Always Below 1 Ω NG REPLACE ECU-IG NO. 2 FUSE BC ECU-IG NO. 2 Fuse C135806E01 OK 2 CHECK BATTERY (a) Install the ECU-IG NO. 2 fuse. (b) Check the battery voltage. Standard voltage: 10 to 14 V NG CHECK AND REPLACE CHARGING SYSTEM OR BATTERY OK 3 INSPECT SKID CONTROL ECU (IG1 TERMINAL) (a) Disconnect the skid control ECU connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control ECU Harness Side Connector Front View: A26 IG1 Tester Connection Condition Specified Condition A26-46 (IG1) - Body ground Ignition switch on (IG) 10 to 14 V F049362E98 NG REPAIR OR REPLACE HARNESS OR CONNECTOR (IG1 CIRCUIT) BC–214 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) OK 4 INSPECT SKID CONTROL ECU (GND TERMINAL) (a) Turn the ignition switch off. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: A26 GND2 GND1 F049362E97 Tester Connection Condition Specified Condition A26-32 (GND1) - Body ground Always Below 1 Ω A26-1 (GND2) - Body ground Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) OK BC 5 RECONFIRM DTC (a) (b) (c) (d) Reconnect the skid control ECU connector. Clear the DTC (See page BC-141). Turn the ignition switch on (IG). Check if the same DTC is recorded (See page BC-141). Result Condition Proceed to DTC (C1241/41) is not output A DTC (C1241/41) is output B HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step (See page BC-134). B A USE SIMULATION METHOD TO CHECK REPLACE BRAKE ACTUATOR ASSEMBLY BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–215 DTC C1246/46 Master Cylinder Pressure Sensor Malfunction DTC C1281/81 Master Cylinder Pressure Sensor Output Malfunction (Test Mode DTC) DESCRIPTION Master cylinder pressure sensor is connected to the skid control ECU in the brake actuator assembly. DTC C1281/81 can be deleted when the master cylinder pressure sensor sends a master cylinder pressure signal or the Test Mode ends. DTC C1281/81 is output only in the Test Mode. Brake Actuator Assembly Skid Control ECU From Battery IG1 BC VCM Master Cylinder Pressure Sensor From Stop Light Switch STP PMC To Body Ground GND E2 VCM: Power Supply for Master Cylinder Pressure Sensor PMC: Master Cylinder Pressure Sensor Input E2: Master Cylinder Pressure Sensor Ground C106656E05 BC–216 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DTC No. DTC Detection Condition Trouble Area C1246/46 When any of the following is detected: • At a vehicle speed of 4.3 mph (7 km/h) or more, when the PMC terminal voltage is over 0.86 V, it does not change by 0.005 V or more for 30 seconds. • Noise occurs in the PMC terminal 7 times or more within 5 seconds. • When the stop light switch is OFF, the PMC terminal voltage is more than 0.86 V or less than 0.3 V for 5 seconds or more. • With the IG1 terminal voltage between 9.5 and 17.2 V, the VCM terminal voltage is not between 4.4 and 5.6 V for 1.2 seconds or more. • When the VCM terminal voltage between 4.4 and 5.6 V, the PCM terminal voltage is not between 0.14 and 4.85 V for 1.2 seconds or more. • • • • Master cylinder pressure sensor Master cylinder pressure sensor circuit Stop light switch circuit Brake actuator assembly INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). BC 1 CHECK STOP LIGHT OPERATION (a) Check that the stop light comes on when the brake pedal is depressed, and goes off when the brake pedal is released. OK Condition Illumination Condition Brake pedal depressed ON Brake pedal released OFF NG INSPECT STOP LIGHT CIRCUIT OK 2 READ VALUE OF INTELLIGENT TESTER (MASTER CYLINDER PRESSURE SENSOR) (a) Connect the intelligent tester to the DLC3. (b) Start the engine. (c) Select the Data List mode on the intelligent tester. ABS / VSC: Item (Display) Measurement Item / Range (Display) MAS CYL PRESS 1 Master cylinder pressure sensor 1 reading / min.: 0 V, max.: 5 V Normal Condition When brake pedal is released: 0.3 to 0.5 V (d) Check that the brake fluid pressure value of the master cylinder pressure sensor observed on the intelligent tester changes when the brake pedal is depressed. OK: When the pedal is depressed, voltage displayed on the intelligent tester increases. NG OK REPLACE BRAKE ACTUATOR ASSEMBLY BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 3 BC–217 READ VALUE OF INTELLIGENT TESTER (STOP LIGHT SWITCH) (a) Select the Data List mode on the intelligent tester. ABS / VSC: Item (Display) STOP LAMP SW Measurement Item / Range (Display) Stop light switch / ON or OFF Normal Condition ON: Brake pedal depressed OFF: Brake pedal released (b) Check that the stop light condition observed on the intelligent tester changes when the brake pedal is depressed. OK: When the brake pedal is depressed, the intelligent tester displays "ON". NG REPLACE BRAKE ACTUATOR ASSEMBLY OK 4 BC RECONFIRM DTC (a) (b) (c) (d) Turn the ignition switch off. Clear the DTC (See page BC-141). Start the engine. At a speed of 18 mph (30 km/h) or more, drive the vehicle and perform braking test (decelerate the vehicle by depressing the brake pedal). (e) Check if the same DTC is recorded (See page BC-141). Result Condition Proceed to DTC (C1246/46) is not output A DTC (C1246/46) is output B B A USE SIMULATION METHOD TO CHECK REPLACE BRAKE ACTUATOR ASSEMBLY BC–218 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DTC C1249/49 Open in Stop Light Switch Circuit DESCRIPTION The skid control ECU (housed in the actuator assembly) inputs the stop light switch signal and the condition of brake operation. The skid control ECU has an open detection circuit, which outputs this DTC when detecting an open in the stop light input line while the stop light switch is OFF. BC DTC No. DTC Detection Condition C1249/49 When IG1 terminal voltage is 9.5 to 17.2 V, an open circuit of the stop light switch continues for 0.3 seconds or more. Trouble Area • • • • STOP fuse Stop light switch Stop light switch circuit Brake actuator assembly (Skid control ECU) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–219 WIRING DIAGRAM Brake Actuator Assembly - Skid Control ECU ECU-IG NO. 2 From IG1 Relay 46 IG1 Stop Light Switch STOP 2 From Battery 1 27 STP Open Detection Circuit BC Rear Combination Light LH 1 Stop 3 Rear Combination Light RH 1 3 Stop Center Stop Light 1 2 32 GND1 1 GND2 C136030E01 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). BC–220 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) INSPECT STOP FUSE (a) Remove the STOP fuse from the main body ECU. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Main Body ECU: Tester Connection Condition Specified Condition STOP (10 A) fuse Always Below 1 Ω NG REPLACE STOP FUSE STOP Fuse BC C135806E02 OK 2 CHECK STOP LIGHT OPERATION (a) Install the STOP fuse. (b) Check that the stop light comes on when the brake pedal is depressed, and goes off when the brake pedal is released. OK Condition Illumination Condition Brake pedal depressed ON Brake pedal released OFF NG Go to step 7 OK 3 INSPECT SKID CONTROL ECU (STP TERMINAL) (a) Disconnect the skid control ECU connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control ECU Harness Side Connector Front View: A26 Tester Connection Condition Specified Condition A26-27 (STP) - Body ground Stop light switch ON (Brake pedal depressed) 8 to 14 V A26-27 (STP) - Body ground Stop light switch OFF (Brake pedal released) Below 1.5 V STP F049362E99 NG REPAIR OR REPLACE HARNESS OR CONNECTOR (STP CIRCUIT) BC–221 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) OK 4 INSPECT SKID CONTROL ECU (IG1 TERMINAL) (a) Turn the ignition switch on (IG). (b) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control ECU Harness Side Connector Front View: Tester Connection Condition Specified Condition A26-46 (IG1) - Body ground Ignition switch on (IG) 10 to 14 V A26 IG1 NG F049362E98 REPAIR OR REPLACE HARNESS OR CONNECTOR (IG1 CIRCUIT) OK 5 BC INSPECT SKID CONTROL ECU (GND TERMINAL) (a) Turn the ignition switch off. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: Tester Connection A26 GND2 GND1 F049362E97 Condition Specified Condition A26-32 (GND1) - Body ground Always Below 1 Ω A26-1 (GND2) - Body ground Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) OK 6 RECONFIRM DTC (a) (b) (c) (d) Reconnect the skid control ECU connector. Clear the DTC (See page BC-141). Start the engine. Depress the brake pedal several times to test the stop light circuit. (e) Check if the same DTC is recorded (See page BC-141). Result Condition Proceed to DTC (C1249/49) is not output A DTC (C1249/49) is output B HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step (See page BC-134). B REPLACE BRAKE ACTUATOR ASSEMBLY BC–222 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) A USE SIMULATION METHOD TO CHECK 7 INSPECT STOP LIGHT SWITCH (POWER SOURCE TERMINAL) (a) Disconnect the stop light switch connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Stop Light Switch Harness Side Connector Front View: Tester Connection Condition Specified Condition A19-2 - Body ground Always 10 to 14 V A19 NG BC REPAIR OR REPLACE HARNESS OR CONNECTOR (POWER SOURCE CIRCUIT) I042363E16 OK 8 INSPECT STOP LIGHT SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard resistance Stop Light Switch: Tester Connection 2 1 NG Free Pushed in C124796E03 OK Condition Specified Condition 1-2 Switch pin free Below 1 Ω 1-2 Switch pin pushed in 10 kΩ or higher REPLACE STOP LIGHT SWITCH BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 9 BC–223 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - STOP LIGHT SWITCH) (a) Disconnect the skid control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: A26 Stop Light Switch Harness Side Connector Front View: STP Tester Connection Condition Specified Condition A26-27 (STP) - A19-1 Always Below 1 Ω A26-27 (STP) - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR BC A19 F049379E08 OK 10 RECONFIRM DTC (a) Reconnect the skid control ECU connector and the stop light switch connector. (b) Clear the DTC (See page BC-141). (c) Start the engine. (d) Depress the brake pedal several times to test the stop light circuit. (e) Check if the same DTC is recorded (See page BC-141). Result Condition Proceed to DTC (C1249/49) is not output A DTC (C1249/49) is output B HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step (See page BC-134). B REPLACE BRAKE ACTUATOR ASSEMBLY A INSPECT LIGHTING SYSTEM (STOP LIGHT CIRCUIT) BC–224 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DTC C1251/51 Open in Pump Motor Circuit DESCRIPTION DTC No. DTC Detection Condition • • C1251/51 Trouble Area Actuator pump motor does not operate properly. Open in actuator pump motor circuit continues for at least 2 seconds. • • Brake actuator assembly (GND circuit) Brake actuator assembly (Motor circuit) WIRING DIAGRAM Brake Actuator Assembly BC R+ VSC NO. 1 (Fail Safe) 45 MRF 1 2 5 3 14 VSC NO. 2 MR ABS NO. 1 ALT 1 2 3 5 15 BM 2 Pump Motor FL MAIN Battery Skid Control ECU GND2 1 C136022E01 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–225 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (ABS MOTOR RELAY) (a) Connect the intelligent tester to the DLC3. (b) Start the engine. (c) Select the Active Test mode on the intelligent tester. ABS / VSC: Item (Display) MOTOR RELAY Vehicle Condition / Test Details Diagnostic Note Operating sound of relay (clicking sound) and motor can be heard Turns ABS motor relay ON / OFF (d) Check the operating sound of the ABS motor relay and motor when operating it with the intelligent tester. OK: The operating sound of the ABS motor relay and motor can be heard. OK Go to step 3 NG 2 INSPECT SKID CONTROL ECU (GND2 TERMINAL) (a) Turn the ignition switch off. (b) Disconnect the skid control ECU connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: A26 GND2 C141143E01 Tester Connection Condition Specified Condition A26-1 (GND2) - Body ground Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR (GND2 CIRCUIT) OK 3 RECONFIRM DTC (a) (b) (c) (d) Reconnect the skid control ECU connector. Clear the DTC (See page BC-141). Start the engine. Drive the vehicle at the speed of 4.3 mph (7 km/h) or more. (e) Check if the same DTC is recorded (See page BC-141). Result Condition Proceed to DTC (C1251/51) is not output A DTC (C1251/51) is output B BC BC–226 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) HINT: • If a speed signal of 4 mph (6 km/h) or more is input to the skid control ECU, with the ignition switch on (IG) and the stop light switch off, the ECU performs self diagnosis of the motor and solenoid circuits. • If a normal system code is output (the trouble code is not output), slightly jiggle the connectors, wire harness, and fuses of the brake actuator assembly. Make sure that no DTCs are output. • If any DTCs are output while jiggling a connector or wire harness of the brake actuator assembly (skid control ECU), inspect and repair the connector or wire harness. B A BC USE SIMULATION METHOD TO CHECK REPLACE BRAKE ACTUATOR ASSEMBLY BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DTC BC–227 C1290/66 Steering Angle Sensor Zero Point Malfunction DESCRIPTION The skid control ECU acquires steering angle sensor zero point every time the ignition switch is turned on (IG) and the vehicle is driven at 22 mph (35 km/h) or more for approximately 5 seconds. The ECU also stores the previous zero point. If front wheel alignment or steering wheel position is adjusted without disconnecting the negative battery terminal, or if yaw rate and acceleration sensor zero point is not acquired after the adjustments have been completed, the skid control ECU detects the difference between the previous zero point and newly acquired zero point and outputs this DTC to indicate a poor adjustment. Warning of the steering angle sensor zero point malfunction will be cancelled by turning the ignition switch off. DTC No. DTC Detection Condition Trouble Area • C1290/66 The steering angle sensor zero point calibration position vastly differs from the recorded value • • Yaw rate and acceleration sensor zero point calibration incomplete Poor adjustment of the centered position of the steering wheel Poor adjustment of front wheel alignment INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). 1 PERFORM ZERO POINT CALIBRATION OF YAW RATE AND ACCELERATION SENSOR (a) Perform zero point calibration of the yaw rate and acceleration sensor (See page BC-119). HINT: • When the stored zero point of the yaw rate and acceleration sensor is erased, steering angle sensor zero point will also be erased. • If the zero point and output value of the yaw rate and acceleration sensor and the output value of the speed sensors are not normal, steering angle sensor zero point cannot be acquired normally even if the vehicle is driven straight ahead at 22 mph (35 km/h) or more. NEXT 2 CHECK STEERING ANGLE SENSOR ZERO POINT CALIBRATION (a) Drive the vehicle straight ahead at 22 mph (35 km/h) or more for at least 5 seconds. (b) Check that the centered position of the steering wheel is correctly set while driving straight ahead. HINT: If front wheel alignment and steering position are adjusted as a result of abnormal centered position of the steering wheel, acquire yaw rate and acceleration sensor zero point again after the adjustments are completed. BC BC–228 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) OK: The centered position of the steering wheel is correctly set. NG ADJUST FRONT WHEEL ALIGNMENT OR STEERING POSITION OK 3 RECONFIRM DTC (a) (b) (c) (d) Turn the ignition switch off. Clear the DTC (See page BC-141). Start the engine. Drive the vehicle and turn the steering wheel to the right and left at the speed of 22 mph (35 km/h) or more. (e) Check if the same DTC is recorded (See page BC-141). BC Result Condition Proceed to DTC (C1290/66) is not output A DTC (C1290/66) is output B B A END REPLACE BRAKE ACTUATOR ASSEMBLY BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–229 DTC U0073/94 Control Module Communication Bus OFF DTC U0100/65 Lost Communication with ECM / PCM DTC U0123/62 Lost Communication with Yaw Rate Sensor Module DTC U0124/95 Lost Communication with Lateral Acceleration Sensor Module DTC U0126/63 Lost Communication with Steering Angle Sensor Module DESCRIPTION The skid control ECU receives the signals from the ECM, steering angle sensor, and yaw rate and acceleration sensor via the CAN communication system. DTC No. DTC Detection Condition Trouble Area U0073/94 When any of the following is detected: 1. With the IG1 terminal voltage 10 V or more, after the output of data from the skid control ECU is completed, the sending continues for 5 seconds or more. 2. With the IG1 terminal voltage 10 V or more, the condition that bus OFF state occurs once or more within 100 ms occurs 10 times in succession. (Sent signals cannot be received.) 3. With the IG1 terminal voltage 10 V or more, a delay in receiving data from the yaw rate and acceleration sensor and steering angle sensor continues for 1 second or more. 4. With the IG1 terminal voltage 10 V or more, the condition that a delay in receiving data from the yaw rate and acceleration sensor and steering angle sensor occurs more than once within 5 seconds occurs 10 times in succession within 60 seconds. CAN communication system U0100/65 When either of the following is detected: 1. With the IG1 terminal voltage 10 V or more and the vehicle speed 9 mph (15 km/h) or more, data cannot be sent to the ECM for 2 seconds or more. 2. The IG1 terminal voltage 10 V or more and the vehicle speed 9 mph (15 km/h) or more for 2 seconds or more. CAN communication system (Skid control ECU to ECM) U0123/62 When either of the following is detected: 1. With the IG1 terminal voltage 10 V or more, data from the yaw rate sensor cannot be received for 1 second or more. 2. With the IG1 terminal voltage 10 V or more, the following occurs 10 times in succession within 60 seconds. • The condition that data from the yaw rate sensor cannot be received occurs once or more within 5 seconds. CAN communication system (Skid control ECU to yaw rate and acceleration sensor) U0124/95 When either of the following is detected: 1. With the IG1 terminal voltage 10 V or more, data from the acceleration sensor cannot be received for 1 second or more. 2. With the IG1 terminal voltage 10 V or more, the following occurs 10 times in succession within 60 seconds. • The condition that data from the acceleration sensor cannot be received occurs once or more within 5 seconds. CAN communication system (Skid control ECU to yaw rate and acceleration sensor) BC BC–230 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DTC No. DTC Detection Condition U0126/63 When either of the following is detected: 1. With the IG1 terminal voltage 10 V or more, data from the steering angle sensor cannot be received for 1 second or more. 2. With the IG1 terminal voltage 10 V or more, the following occurs 10 times in succession within 60 seconds. • The condition that data from the steering angle sensor cannot be received occurs once or more within 5 seconds. Trouble Area CAN communication system (Skid control ECU to steering angle sensor) WIRING DIAGRAM Brake Actuator Assembly BC ECM CANH CANL 41 1 2 11 49 7 8 25 Yaw Rate and Acceleration Sensor CANL 1 CANH CANL 10 4 CANH - Skid Control ECU J/C J/C Steering Angle Sensor 2 3 1 1 10 2 2 2 9 CANH CANL C136031E01 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–231 INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (MOMENTARY INTERRUPTION) (a) Using the intelligent tester, check for any momentary interruption in the wire harness and connector corresponding to a DTC (See page BC-118). ABS / VSC: Item (Display) Measurement Item / Range (Display) Normal Condition EFI communication open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal STEERING OPN Steering sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal YAW RATE OPN Yaw rate sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal EFI COM OPN Result Condition Proceed to There is a constant open circuit A There are no momentary interruptions B There are momentary interruptions C HINT: Perform the above inspection before removing the sensor and connector. B Go to step 3 C Go to step 4 A 2 CHECK IF EACH SENSOR AND ECM CONNECTOR IS SECURELY CONNECTED (a) Turn the ignition switch off. (b) Check if each sensor or ECM connector is securely connected. OK: The connector should be securely connected. NG CONNECT CONNECTOR TO EACH SENSOR OR ECM CORRECTLY OK 3 RECONFIRM DTC (a) Turn the ignition switch off. (b) Record the output DTCs (for ABS, VSC, and CAN communication) (See page BC-141). BC BC–232 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) HINT: If the CAN communication system DTC and the relevant sensor DTCs are output simultaneously, troubleshoot the relevant sensor DTCs (for ABS and VSC) after the CAN communication system returns to normal. Result Condition Proceed to DTC (CAN communication system DTC) is output A DTC (ABS and/or VSC DTC) is output B DTC is not output C B REPAIR CIRCUIT INDICATED BY OUTPUT DTC (See page BC-151) C USE SIMULATION METHOD TO CHECK A BC INSPECT CAN COMMUNICATION SYSTEM 4 REPAIR OR REPLACE HARNESS OR CONNECTOR (a) Turn the ignition switch off. (b) Repair or replace the harness or connector. (c) Check for any momentary interruption between the skid control ECU and each sensor or ECM (See page BC118). (d) Check that there is no momentary interruption. NEXT 5 RECONFIRM DTC (a) (b) (c) (d) Turn the ignition switch off. Clear the DTC (See page BC-141). Start the engine. Drive the vehicle and turn the steering wheel to the right and left at a speed of 9 mph (15 km/h) or more. (e) Check that no CAN communication system DTC is output. (f) If ABS and VSC DTCs are output, record them. Result Condition Proceed to DTC output for the CAN communication system A No DTC is output (ABS and/or VSC DTC is output) B No DTC is output (No ABS and/or VSC DTC is output) C HINT: The CAN communication system must be normal when repairing each sensor DTC (for ABS and VSC). BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–233 B REPAIR CIRCUIT INDICATED BY OUTPUT DTC (See page BC-151) C END A INSPECT CAN COMMUNICATION SYSTEM BC BC–234 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) ABS Warning Light Remains ON DESCRIPTION The skid control ECU is connected to the combination meter via CAN communication. If any of the following is detected, the ABS warning light remains on. • The skid control ECU connectors are disconnected from the skid control ECU. • There is a malfunction in the skid control ECU internal circuit. • There is an open in the harness between the combination meter and the skid control ECU. HINT: In some cases, the intelligent tester cannot be used when the skid control ECU is abnormal. BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–235 WIRING DIAGRAM Brake Actuator Assembly - Skid Control ECU Combination Meter CANL CANL 18 25 CANH 17 11 CANH MPX+B IG1 BC ECU-IG NO. 2 From Battery 5 3 2 1 46 IG1 ES 24 From Ignition Switch (*3), Main Body ECU (*4) IG+ ABS From IG2 Relay (*1), Ignition Switch (*2) Power Supply Circuit 32 GND1 GAUGE NO. 2 IG+ 13 (*1): 2GR-FE (*2): 2AZ-FE 1 GND2 (*3): without Smart Key System (*4): with Smart Key System C109474E03 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). BC–236 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) CHECK CAN COMMUNICATION SYSTEM (a) Check if the CAN communication system DTC is output (See page CA-25). Result Condition Proceed to DTC is not output A DTC is output B B INSPECT CAN COMMUNICATION SYSTEM A 2 CHECK IF SKID CONTROL ECU CONNECTOR IS SECURELY CONNECTED (a) Check if the skid control ECU connector is securely connected. OK: The connector should be securely connected. BC NG CONNECT CONNECTOR TO ECU CORRECTLY OK 3 CHECK BATTERY (a) Check the battery voltage. Standard voltage: 11 to 14 V NG CHECK AND REPLACE CHARGING SYSTEM OR BATTERY OK 4 INSPECT SKID CONTROL ECU (IG1 TERMINAL) (a) Disconnect the skid control ECU connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control ECU Harness Side Connector Front View: A26 Tester Connection Condition Specified Condition A26-46 (IG1) - Body ground Ignition switch on (IG) 10 to 14 V IG1 F049362E98 NG REPAIR OR REPLACE HARNESS OR CONNECTOR (IG1 CIRCUIT) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–237 OK 5 INSPECT SKID CONTROL ECU (GND TERMINAL) (a) Turn the ignition switch off. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: Tester Connection GND1 F049362E97 Specified Condition A26-32 (GND1) - Body ground Always Below 1 Ω A26-1 (GND2) - Body ground Always Below 1 Ω A26 GND2 Condition NG REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) OK BC 6 INSPECT COMBINATION METER ASSEMBLY (a) Reconnect the skid control ECU connector. (b) Perform Active Test of the combination meter (meter CPU) using the intelligent tester (See page ME-32). OK: The ABS warning light turns on or off in accordance with the intelligent tester. HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step before replacing the part (See page BC-134). NG OK REPLACE BRAKE ACTUATOR ASSEMBLY REPLACE COMBINATION METER ASSEMBLY BC–238 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) ABS Warning Light does not Come ON DESCRIPTION The skid control ECU is connected to the combination meter via CAN communication. BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–239 WIRING DIAGRAM Brake Actuator Assembly - Skid Control ECU Combination Meter CANL CANL 18 25 CANH 17 11 CANH MPX+B IG1 BC ECU-IG NO. 2 From Battery 5 3 2 1 46 IG1 ES 24 From Ignition Switch (*3), Main Body ECU (*4) IG+ ABS From IG2 Relay (*1), Ignition Switch (*2) Power Supply Circuit 32 GND1 GAUGE NO. 2 IG+ 13 (*1): 2GR-FE (*2): 2AZ-FE 1 GND2 (*3): without Smart Key System (*4): with Smart Key System C109474E03 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). BC–240 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) CHECK CAN COMMUNICATION SYSTEM (a) Check if the CAN communication system DTC is output (See page CA-25). Result Condition Proceed to DTC is not output A DTC is output B B INSPECT CAN COMMUNICATION SYSTEM A 2 CHECK ABS WARNING LIGHT (a) Disconnect the skid control ECU connector. (b) Turn the ignition switch on (IG). (c) Check that the ABS warning light comes on. OK: The ABS warning light comes on. HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step before replacing the part (See page BC-134). BC OK REPLACE BRAKE ACTUATOR ASSEMBLY NG 3 INSPECT COMBINATION METER ASSEMBLY (a) Turn the ignition switch off. (b) Reconnect the skid control ECU connector. (c) Perform Active Test of the combination meter (meter CPU) using the intelligent tester (See page ME-32). OK: The ABS warning light turns on or off in accordance with the intelligent tester. HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step (See page BC-134). NG OK REPLACE BRAKE ACTUATOR ASSEMBLY REPLACE COMBINATION METER ASSEMBLY BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–241 VSC Warning Light Remains ON DESCRIPTION The skid control ECU communicates with the combination meter via CAN communication. If the ECU stores a DTC, the DTC will be displayed on the multi information display in the combination meter (models with multi information display). On models without a multi information display, the VSC warning light will come on when the skid control ECU stores a DTC. BC BC–242 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) WIRING DIAGRAM Brake Actuator Assembly - Skid Control ECU Combination Meter CANL CANL 18 25 CANH 17 11 CANH MPX+B BC ES 24 From IG2 Relay (*1), Ignition Switch (*2) (*4) Power Supply Circuit GAUGE NO. 2 IG+ 13 (*1): 2GR-FE VSC (*3) IG+ (*2): 2AZ-FE (*3): Models without Multi Information Display (*4): Models with Multi Information Display C109475E02 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 1 BC–243 CHECK CAN COMMUNICATION SYSTEM (a) Check if the CAN communication system DTC is output (See page CA-25). Result Condition Proceed to DTC is not output A DTC is output B B INSPECT CAN COMMUNICATION SYSTEM A 2 CHECK IF SKID CONTROL ECU CONNECTOR IS SECURELY CONNECTED (a) Check if the skid control ECU connector is securely connected. OK: The connector should be securely connected. NG CONNECT CONNECTOR TO ECU CORRECTLY OK 3 CHECK BATTERY (a) Check the battery voltage. Standard voltage: 11 to 14 V NG CHECK AND REPLACE CHARGING SYSTEM OR BATTERY OK 4 INSPECT COMBINATION METER ASSEMBLY (a) Perform Active Test of the combination meter (meter CPU) using the intelligent tester (See page ME-32). OK: The VSC warning light (models without multi information display) or multi information display (models with multi information display) turns on or off in accordance with the intelligent tester. HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step before replacing the part (See page BC-134). BC BC–244 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) NG OK REPLACE BRAKE ACTUATOR ASSEMBLY BC REPLACE COMBINATION METER ASSEMBLY BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–245 VSC Warning Light does not Come ON DESCRIPTION The skid control ECU communicates with the combination meter via CAN communication. If the ECU stores a DTC, the DTC will be displayed on the multi information display in the combination meter (models with multi information display). On models without a multi information display, the VSC warning light will come on when the skid control ECU stores a DTC. BC BC–246 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) WIRING DIAGRAM Brake Actuator Assembly - Skid Control ECU Combination Meter CANL CANL 18 25 CANH 17 11 CANH MPX+B BC ES 24 From IG2 Relay (*1), Ignition Switch (*2) (*4) Power Supply Circuit GAUGE NO. 2 IG+ 13 (*1): 2GR-FE VSC (*3) IG+ (*2): 2AZ-FE (*3): Models without Multi Information Display (*4): Models with Multi Information Display C109475E02 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 1 BC–247 CHECK CAN COMMUNICATION SYSTEM (a) Check if the CAN communication system DTC is output (See page CA-25). Result Condition Proceed to DTC is not output A DTC is output B B INSPECT CAN COMMUNICATION SYSTEM A 2 CHECK VSC WARNING LIGHT (a) Connect the intelligent tester to the DLC3. (b) Start the engine. (c) Select "VSC WARN LAMP" in the Active Test and operate the VSC warning light (models without multi information display) or multi information display (models with multi information display) using the intelligent tester. ABS / VSC: Item (Display) VSC WARN LAMP Vehicle Condition / Test Details Turn VSC warning light (*1) or multi information display (*2) ON / OFF Diagnostic Note Observe combination meter (*1): Models without multi information display (*2): Models with multi information display (d) Check that "ON" and "OFF" of the VSC warning light (models without multi information display) or multi information display (models with multi information display) are indicated on the combination meter when using the intelligent tester. OK: The VSC warning light (models without multi information display) or multi information display (models with multi information display) turns on or off in accordance with the intelligent tester. HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step before replacing the part (See page BC-134). OK REPLACE BRAKE ACTUATOR ASSEMBLY NG 3 INSPECT COMBINATION METER ASSEMBLY (a) Turn the ignition switch off. BC BC–248 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) (b) Perform Active Test of the combination meter (meter CPU) using the intelligent tester (See page ME-32). OK: The VSC warning light (models without multi information display) or multi information display (models with multi information display) turns on or off in accordance with the intelligent tester. HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step (See page BC-134). NG OK BC REPLACE BRAKE ACTUATOR ASSEMBLY REPLACE COMBINATION METER ASSEMBLY BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–249 Brake Warning Light Remains ON DESCRIPTION The skid control ECU is connected to the combination meter via CAN communication. If any of the following is detected, the BRAKE warning light remains on: • The skid control ECU connector is disconnected from the skid control ECU. • The brake fluid level is insufficient. • The parking brake is applied. • EBD operation is not possible. BC BC–250 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) WIRING DIAGRAM Brake Actuator Assembly Combination Meter - Skid Control ECU CANL CANL 18 25 CANH 17 11 CANH MPX+B Parking Brake Switch 5 6 CANH 1 BC 14 (*5) 2 (*6) 19 CANL PKB Main Body ECU From IG2 Relay (*1), Ignition Switch (*2) Power Supply Circuit From Ignition Switch (*3), Main Body ECU (*4) IG+ GAUGE NO. 2 13 From Battery ES IG1 24 ECU-IG NO. 2 IG+ BRAKE 5 3 2 1 46 IG1 B/LE 6 (*1): 2GR-FE 1 Brake Fluid Level Warning Switch (*2): 2AZ-FE (*3): without Smart Key System (*4): with Smart Key System (*5): A/T (*6): M/T 32 1 GND1 GND2 2 C135799E03 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). BC–251 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 1 CHECK CAN COMMUNICATION SYSTEM (a) Check if the CAN communication system DTC is output (See page CA-25). Result Condition Proceed to DTC is not output A DTC is output B B INSPECT CAN COMMUNICATION SYSTEM A 2 CHECK IF SKID CONTROL ECU CONNECTOR IS SECURELY CONNECTED (a) Check if the skid control ECU connector is securely connected. OK: The connector should be securely connected. NG CONNECT CONNECTOR TO ECU CORRECTLY OK 3 CHECK BATTERY (a) Check the battery voltage. Standard voltage: 11 to 14 V NG CHECK AND REPLACE CHARGING SYSTEM OR BATTERY OK 4 INSPECT SKID CONTROL ECU (IG1 TERMINAL) (a) Disconnect the skid control ECU connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control ECU Harness Side Connector Front View: A26 IG1 Tester Connection Condition Specified Condition A26-46 (IG1) - Body ground Ignition switch on (IG) 10 to 14 V F049362E98 NG REPAIR OR REPLACE HARNESS OR CONNECTOR (IG1 CIRCUIT) BC BC–252 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) OK 5 INSPECT SKID CONTROL ECU (GND TERMINAL) (a) Turn the ignition switch off. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: A26 GND2 GND1 F049362E97 Tester Connection Condition Specified Condition A26-32 (GND1) - Body ground Always Below 1 Ω A26-1 (GND2) - Body ground Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) OK BC 6 INSPECT PARKING BRAKE SWITCH (a) Disconnect the parking brake switch connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Parking Brake Switch A/T: Free Pushed in Tester Connection Condition Specified Condition 1 - Body ground Parking brake switch ON (Switch pin free) Below 1 Ω 1 - Body ground Parking brake switch OFF (Switch pin pushed in) 10 kΩ or higher NG M/T: Free Pushed in C109430E02 OK REPLACE PARKING BRAKE SWITCH BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 7 BC–253 CHECK HARNESS AND CONNECTOR (MAIN BODY ECU - PARKING BRAKE SWITCH) (a) Disconnect the main body ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: A/T Main Body ECU Harness Side Connector Front View A/T: IC Tester Connection Condition Specified Condition IC-14 (PKB) - A18-1 Always Below 1 Ω IC-14 (PKB) - Body ground Always 10 kΩ or higher Tester Connection Condition Specified Condition IM-2 (PKB) - E33-1 Always Below 1 Ω IM-2 (PKB) - Body ground Always 10 kΩ or higher M/T M/T: NG IM Parking Brake Switch Harness Side Connector Front View: A18 : A/T E33 : M/T C136418E01 OK REPAIR OR REPLACE HARNESS OR CONNECTOR BC BC–254 8 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) INSPECT BRAKE FLUID LEVEL WARNING SWITCH (a) Remove the reservoir tank cap and strainer. (b) Disconnect the brake fluid level warning switch connector. (c) Measure the resistance according to the value(s) in the table below. HINT: A float is located inside the reservoir. Its position can be changed by increasing or decreasing the level of brake fluid. Standard resistance Brake Fluid Level Warning Switch: Tester Connection BC C140953E01 Specified Condition 1-2 Float up (Switch OFF) 1.9 to 2.1 kΩ 1-2 Float down (Switch ON) Below 1 Ω HINT: If there is no problem after finishing the above check, adjust the brake fluid level to the MAX level. NG OK Condition REPLACE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY (BRAKE FLUID LEVEL WARNING SWITCH) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 9 BC–255 CHECK HARNESS AND CONNECTOR (COMBINATION METER - BRAKE FLUID LEVEL WARNING SWITCH) (a) Disconnect the combination meter connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Combination Meter Wire Harness View: Tester Connection Condition Specified Condition F2-6 (B/LE) - A16-1 Always Below 1 Ω F2-6 (B/LE) - Body ground Always 10 kΩ or higher A16-2 - Body ground Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR BC F2-6 (B/LE) Brake Fluid Level Warning Switch Harness Side Connector Front View: A16 C136033E01 OK 10 INSPECT COMBINATION METER ASSEMBLY (a) Perform Active Test of the combination meter (meter CPU) using the intelligent tester (See page ME-32). OK: The BRAKE warning light turns on or off in accordance with the intelligent tester. HINT: • Reinstall the connectors and restore the vehicle to its prior condition before checking the combination meter. • If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step before replacing the part (See page BC-134). NG REPLACE COMBINATION METER ASSEMBLY BC–256 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) OK REPLACE BRAKE ACTUATOR ASSEMBLY BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–257 Brake Warning Light does not Come ON DESCRIPTION The skid control ECU is connected to the combination meter via CAN communication. BC BC–258 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) WIRING DIAGRAM Brake Actuator Assembly Combination Meter - Skid Control ECU CANL CANL 18 25 CANH 17 11 CANH MPX+B Parking Brake Switch 5 6 CANH 1 BC 14 (*5) 2 (*6) 19 CANL PKB Main Body ECU From IG2 Relay (*1), Ignition Switch (*2) Power Supply Circuit From Ignition Switch (*3), Main Body ECU (*4) IG+ GAUGE NO. 2 13 From Battery ES IG1 24 ECU-IG NO. 2 IG+ BRAKE 5 3 2 1 46 IG1 B/LE 6 (*1): 2GR-FE 1 Brake Fluid Level Warning Switch (*2): 2AZ-FE (*3): without Smart Key System (*4): with Smart Key System (*5): A/T (*6): M/T 32 1 GND1 GND2 2 C135799E03 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 1 BC–259 CHECK CAN COMMUNICATION SYSTEM (a) Check if the CAN communication system DTC is output (See page CA-25). Result Condition Proceed to DTC is not output A DTC is output B B INSPECT CAN COMMUNICATION SYSTEM A 2 CHECK BRAKE WARNING LIGHT (a) Disconnect the skid control ECU connector. (b) Turn the ignition switch on (IG). (c) Check that the BRAKE warning light comes on. OK: The BRAKE warning light comes on. HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step before replacing the part (See page BC-134). OK REPLACE BRAKE ACTUATOR ASSEMBLY NG 3 INSPECT COMBINATION METER ASSEMBLY (a) Turn the ignition switch off. (b) Reconnect the skid control ECU connector. (c) Perform Active Test of the combination meter (meter CPU) using the intelligent tester (See page ME-32). OK: The BRAKE warning light turns on or off in accordance with the intelligent tester. HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step (See page BC-134). NG OK REPLACE BRAKE ACTUATOR ASSEMBLY REPLACE COMBINATION METER ASSEMBLY BC BC–260 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) Slip Indicator Light Remains ON DESCRIPTION The skid control ECU is connected to the combination meter via CAN communication. The SLIP indicator light blinks during VSC and/or TRAC operation. When the system fails, the SLIP indicator light comes on to warn the driver (See page BC-138). BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–261 WIRING DIAGRAM Brake Actuator Assembly Combination Meter - Skid Control ECU CANL 18 25 CANH 17 11 CANL CANH MPX+B BC ES 24 IG+ SLIP Power Supply Circuit From IG2 Relay (*1), Ignition Switch (*2) GAUGE NO. 2 IG+ 13 (*1): 2GR-FE (*2): 2AZ-FE C109476E03 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). BC–262 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) CHECK CAN COMMUNICATION SYSTEM (a) Check if the CAN communication system DTC is output (See page CA-25). Result Condition Proceed to DTC is not output A DTC is output B B INSPECT CAN COMMUNICATION SYSTEM A 2 CHECK IF SKID CONTROL ECU CONNECTOR IS SECURELY CONNECTED (a) Check if the skid control ECU connector is securely connected. OK: The connector should be securely connected. BC NG CONNECT CONNECTOR TO ECU CORRECTLY OK 3 CHECK BATTERY (a) Check the battery voltage. Standard voltage: 11 to 14 V NG CHECK AND REPLACE CHARGING SYSTEM OR BATTERY OK 4 INSPECT COMBINATION METER ASSEMBLY (a) Perform Active Test of the combination meter (meter CPU) using the intelligent tester (See page ME-32). OK: The SLIP indicator light turns on or off in accordance with the intelligent tester. HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step before replacing the part (See page BC-134). NG REPLACE COMBINATION METER ASSEMBLY BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–263 OK REPLACE BRAKE ACTUATOR ASSEMBLY BC BC–264 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) Slip Indicator Light does not Come ON DESCRIPTION The skid control ECU is connected to the combination meter via CAN communication. The SLIP indicator light blinks during VSC and/or TRAC operation. When the system fails, the SLIP indicator light comes on to warn the driver (See page BC-138). BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–265 WIRING DIAGRAM Brake Actuator Assembly Combination Meter - Skid Control ECU CANL 18 25 CANH 17 11 CANL CANH MPX+B BC ES 24 IG+ SLIP Power Supply Circuit From IG2 Relay (*1), Ignition Switch (*2) GAUGE NO. 2 IG+ 13 (*1): 2GR-FE (*2): 2AZ-FE C109476E03 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). BC–266 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) CHECK CAN COMMUNICATION SYSTEM (a) Check if the CAN communication system DTC is output (See page CA-25). Result Condition Proceed to DTC is not output A DTC is output B B INSPECT CAN COMMUNICATION SYSTEM A 2 CHECK SLIP INDICATOR LIGHT (a) Connect the intelligent tester to the DLC3. (b) Start the engine. (c) Select "SLIP INDI LAMP" in the Active Test and operate the SLIP indicator light using the intelligent tester. BC ABS / VSC: Item (Display) SLIP INDI LAMP Vehicle Condition / Test Details Turn SLIP indicator light ON / OFF Diagnostic Note Observe combination meter (d) Check that "ON" and "OFF" of the SLIP indicator light are indicated on the combination meter when using the intelligent tester. OK: The SLIP indicator light turns on or off in accordance with the intelligent tester. HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step before replacing the part (See page BC-134). OK REPLACE BRAKE ACTUATOR ASSEMBLY NG 3 INSPECT COMBINATION METER ASSEMBLY (a) Turn the ignition switch off. (b) Perform Active Test of the combination meter (meter CPU) using the intelligent tester (See page ME-32). OK: The SLIP indicator light turns on or off in accordance with the intelligent tester. HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step (See page BC-134). BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) NG BC–267 REPLACE COMBINATION METER ASSEMBLY OK REPLACE BRAKE ACTUATOR ASSEMBLY BC BC–268 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) Skid Control Buzzer Circuit DESCRIPTION The skid control buzzer sounds while the accumulator pressure is abnormally low or when an abnormality causing low fluid pressure occurs, and then the VSC is activated. WIRING DIAGRAM Brake Actuator Assembly Skid Control Buzzer IG1 - Skid Control ECU ECU-IG NO. 2 BC 5 3 2 1 2 30 1 BZ From Ignition Switch (*1), Main Body ECU (*2) From Battery (*1): without Smart Key System (*2): with Smart Key System C136034E03 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SKID CONTROL BUZZER) (a) Connect the intelligent tester to the DLC3. (b) Start the engine. (c) Select the Active Test mode on the intelligent tester. ABS / VSC: Item (Display) BUZZER Vehicle Condition / Test Details Turns skid control buzzer ON / OFF Diagnostic Note Buzzer can be heard (d) Check that the buzzer sounds/stops when turning the skid control buzzer on/off by using the intelligent tester. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–269 Result Condition Proceed to Buzzer does not sound or sounds constantly A Buzzer sounds/stops B HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step (See page BC-134). B END A 2 INSPECT SKID CONTROL BUZZER (POWER SOURCE TERMINAL) (a) (b) (c) (d) Skid Control Buzzer Harness Side Connector Front View: E13 C107604E17 Turn the ignition switch off. Disconnect the skid control buzzer connector. Turn the ignition switch on (IG). Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition E13-2 - Body ground Ignition switch on (IG) 10 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR (POWER SOURCE CIRCUIT) OK 3 INSPECT SKID CONTROL BUZZER (a) Apply battery negative voltage to terminal 1, and battery positive voltage to terminal 2 of the skid control buzzer, and then check that the buzzer sounds. OK: The skid control buzzer sounds. Skid Control Buzzer: NG (+) (-) 1 2 C125130E01 OK REPLACE SKID CONTROL BUZZER BC BC–270 4 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - SKID CONTROL BUZZER) (a) Turn the ignition switch off. (b) Disconnect the skid control ECU connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: A26 Condition Specified Condition A26-30 (BZ) - E13-1 Always Below 1 Ω A26-30 (BZ) - Body ground Always 10 kΩ or higher HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step before replacing the part (See page BC-134). BZ Skid Control Buzzer Harness Side Connector Front View: BC Tester Connection NG E13 I045407E11 OK REPLACE BRAKE ACTUATOR ASSEMBLY REPAIR OR REPLACE HARNESS OR CONNECTOR BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–271 TC and CG Terminal Circuit DESCRIPTION Connecting terminals TC and CG of the DLC3 causes the ECU to display the DTC by blinking the ABS warning light. WIRING DIAGRAM Brake Actuator Assembly ECM DLC3 - Skid Control ECU CANH TC 27 13 11 CANH TC CANL CG 41 49 BC CANL 25 4 C109399E05 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). 1 CHECK CAN COMMUNICATION SYSTEM (a) Check if the CAN communication system DTC is output (See page CA-25). Result Condition Proceed to DTC is not output A DTC is output B B A INSPECT CAN COMMUNICATION SYSTEM BC–272 2 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) INSPECT DLC3 DLC3: (a) Turn the ignition switch on (IG). (b) Measure the voltage according to the value(s) in the table below. Standard voltage CG E10 TC Tester Connection Condition Specified Condition E10-13 (TC) - E10-4 (CG) Ignition switch on (IG) 10 to 14 V OK Go to step 5 G022986E20 NG BC 3 CHECK HARNESS AND CONNECTOR (TC of DLC3 - ECM) (a) Turn the ignition switch off. (b) Disconnect the ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: 2GR-FE DLC3: E10 TC Tester Connection Condition E10-13 (TC) - A55-27 (TC) Always Below 1 Ω E10-13 (TC) - Body ground Always 10 kΩ or higher 2AZ-FE ECM Wire Harness View: Tester Connection Condition Specified Condition E10-13 (TC) - A24-27 (TC) Always Below 1 Ω E10-13 (TC) - Body ground Always 10 kΩ or higher NG A55-27 (TC) (*1) A24-27 (TC) (*2) (*1): 2GR-FE (*2): 2AZ-FE C136035E02 OK Specified Condition REPAIR OR REPLACE HARNESS OR CONNECTOR BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 4 DLC3: BC–273 CHECK HARNESS AND CONNECTOR (CG of DLC3 - BODY GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance CG E10 Tester Connection Condition Specified Condition E10-4 (CG) - Body ground Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR G022986E21 OK 5 DLC3: CHECK ECM (TC of DLC3 INPUT) (a) (b) (c) (d) (e) CG Turn the ignition switch off. Reconnect the ECM connector. Using SST, connect terminals TC and CG of the DLC3. Turn the ignition switch on (IG). Check that the check engine warning light is blinking. E10 TC G022986E20 Result Condition Proceed to Check engine warning light is blinking A Check engine warning light is not blinking B HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step before replacing the part (See page BC-134). B A REPLACE BRAKE ACTUATOR ASSEMBLY REPAIR OR REPLACE WIRE HARNESS OR ECM (TC of ECM CIRCUIT) BC BC–274 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) TS and CG Terminal Circuit DESCRIPTION In the Test Mode (signal check), a malfunction of the speed sensor that cannot be detected when the vehicle is stopped can be detected while driving. Transition to the sensor check mode can be performed by connecting terminals TS and CG of the DLC3 and turning the ignition switch from off to on (IG). WIRING DIAGRAM Brake Actuator Assembly DLC3 BC TS CG - Skid Control ECU 12 24 TS 4 C109400E06 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 1 BC–275 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - TS of DLC3) (a) Disconnect the skid control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: A26 Tester Connection Condition Specified Condition A26-24 (TS) - E10-12 (TS) Always Below 1 Ω NG TS REPAIR OR REPLACE HARNESS OR CONNECTOR DLC3: BC E10 TS C128347E08 OK 2 DLC3: CHECK HARNESS AND CONNECTOR (CG of DLC3 - BODY GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance CG E10 Condition Specified Condition Always Below 1 Ω NG G022987E21 OK Tester Connection E10-4 (CG) - Body ground REPAIR OR REPLACE HARNESS OR CONNECTOR BC–276 3 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) CHECK HARNESS AND CONNECTOR (TS of DLC3 - BODY GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance DLC3: Condition Specified Condition Always 10 kΩ or higher HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step before replacing the part (See page BC-134). E10 TS Tester Connection E10-12 (TS) - Body ground G022987E22 NG BC OK REPLACE BRAKE ACTUATOR ASSEMBLY REPAIR OR REPLACE HARNESS OR CONNECTOR BC–272 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) PRECAUTION 1. Expression BC EXPRESSIONS OF IGNITION SWITCH The type of ignition switch used on this model differs according to the specifications of the vehicle. The expressions listed in the table below are used in this section. Switch Type Ignition Switch (Position) Engine Switch (Condition) Ignition switch off LOCK off Ignition switch on (IG) ON on (IG) Ignition switch on (ACC) ACC on (ACC) Engine start START start 2. 3. TROUBLESHOOTING PRECAUTION (a) When there is a malfunction in the contact point of the terminals or installation problems with parts, the removal and installation of the suspected problem parts may return the system to the normal condition either completely or temporarily. (b) In order to determine the malfunctioning area, be sure to check the conditions at the time the malfunction occurred, such as by DTC output and freeze frame data output, and record it before disconnecting each connector or removing and installing parts. (c) Since the vehicle stability control system may be influenced by a malfunction in the other systems, be sure to check for DTCs in the other systems. (d) Be sure to remove and install the brake actuator assembly and each sensor with the ignition switch off unless specified in the inspection procedure. (e) If the brake actuator or a sensor has been removed and installed, it is necessary to check the system for problems after the parts have been reassembled. Check for DTCs using the intelligent tester, also check that system functions and signals received by the ECU are normal using test mode. CAN COMMUNICATION SYSTEM PRECAUTION (a) The CAN communication system is used for data communication between the skid control ECU, the steering angle sensor, and the yaw rate and acceleration sensor. If there is trouble in the CAN communication line, a DTC of the communication line is output. (b) If a DTC of the CAN communication line is output, repair the malfunction in the communication line and troubleshoot the vehicle stability control system under the condition that data communication is normal. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 4. 5. BC–273 (c) In order to enable CAN communication, a specific type of wiring is used for the CAN communication lines. The wiring used for each communication line is a twisted pair of wires that have an equal length. A bypass wire should not be used, because the data being transmitted will be corrupted. DTC PRECAUTION (a) Warnings for some DTCs cannot be cleared by only repairing the malfunctioning parts. If the warning is displayed after repair work, the DTC should be cleared after turning the ignition switch off. NOTICE: If a DTC for a malfunctioning part reappears after it was cleared, then it has been stored again. CHASSIS DYNAMOMETER PRECAUTION (a) Enter Test Mode to disable TRAC and VSC control when using a chassis dynamometer. HINT: The vehicle may move unexpectedly out of the dynamometer because of TRAC and VSC operations. NOTICE: • Make sure that the VSC warning (multi information display and master caution indicator light) light is blinking (TEST Mode is achieved). • Secure the vehicle with the lock chain for safety. BC BC–274 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) PARTS LOCATION BRAKE ACTUATOR ASSEMBLY BRAKE MASTER CYLINDER ASSEMBLY - SKID CONTROL ECU FRONT SPEED SENSOR ROTOR FRONT SPEED SENSOR - BRAKE FLUID LEVEL WARNING SWITCH REAR SPEED SENSOR SKID CONTROL SENSOR ECM (2GR-FE) (REAR SPEED SENSOR ROTOR) BC ECM (2AZ-FE) ENGINE ROOM R/B SKID CONTROL SENSOR - FUSIBLE LINK (ABS NO. 1 ) (REAR SPEED SENSOR) - FUSIBLE LINK (ABS NO. 2) REAR SPEED SENSOR ROTOR FRONT SPEED SENSOR ROTOR FRONT SPEED SENSOR C131985E02 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) STOP LIGHT SWITCH BC–275 COMBINATION METER ASSEMBLY SKID CONTROL BUZZER - ABS WARNING LIGHT PARKING BRAKE SWITCH - SLIP INDICATOR LIGHT - MASTER CAUTION INDICATOR - VSC WARNING LIGHT - BRAKE WARNING LIGHT - MULTI-INFORMATION DISPLAY (Automatic Transaxle) BC DLC3 INSTRUMENT PANEL J/B - ECU-IG NO. 2 FUSE YAW RATE AND ACCELERATION SENSOR PARKING BRAKE SWITCH STEERING ANGLE SENSOR (Manual Transaxle) C131986E01 BC–276 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) SYSTEM DIAGRAM Brake Actuator Assembly Motor Relay Pump Motor Solenoid Relay Solenoid (Control) Stop Light Switch BC Speed Sensor (for Each Wheel) Skid Control (VSC Warning) Buzzer Skid Control ECU Solenoid (Linear) Master Cylinder Pressure Sensor C131981E02 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) Brake Actuator Assembly BC–277 Combination Meter Assembly Skid Control ECU Speedometer ABS Warning Light Brake Warning Light Steering Angle Sensor SLIP Indicator Light BC VSC Warning (MultiInformation Display) Yaw Rate and Acceleration Sensor VSC Warning Light (without Multi-Information Display) Body ECU Shift Position Switch Parking Brake Switch ECM CAN Communication System Accelerator Pedal Position Sensor Engine Revolution Sensor C132007E02 BC–278 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) Transmitting ECU (transmitter) Receiving ECU ECM Skid control ECU Skid control ECU Yaw rate and acceleration sensor Skid control ECU Steering angle sensor Skid control ECU ECM Signals • • • • • • CAN communication system Steering angle sensor request signal CAN communication system • • Wheel speed signal VSC data signal CAN communication system • • • Wheel speed signal ABS warning light ON signal BRAKE warning light ON signal VSC warning light ON signal (*1) Multi information display ON signal (*2) SLIP indicator light ON signal Master caution indicator light ON signal CAN communication system Combination meter • BC • • Main body ECU Skid control ECU CAN communication system Yaw rate and acceleration request signal • Skid control ECU Shift position signal Throttle position signal Engine revolution signal Intake air temperature signal Engine torque request signal Accelerator pedal position signal Communication method Parking brake switch signal CAN communication system (*1): without multi-information display (Combination meter) (*2): with multi-information display (Combination meter) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–279 SYSTEM DESCRIPTION 1. SYSTEM DESCRIPTION HINT: • The skid control ECU is located within the brake actuator assembly. • The yaw rate sensor and acceleration sensor are combined in a single unit. This unit communicates with the skid control ECU through the CAN communication system. (a) ABS operation (1) Based on the signals received from the 4 wheel speed sensors, the skid control ECU calculates the deceleration and speed of each wheel, while monitoring for wheel lock. If wheel lock is occurring, the ECU controls the solenoid valves in the brake actuator in order to adjust the hydraulic pressure applied to the brakes at each wheel. BC BC–280 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 2. FUNCTION DESCRIPTION (a) ABS (Anti-lock Brake System) The ABS helps prevent the wheels from locking when the brakes are applied firmly or when braking on a slippery surface. Brake Actuator Assembly Pump Motor Each Speed Sensor Each Wheel Cylinder Skid Control ECU Solenoid Valves BC Combination Meter ABS Warning Light CAN Communication System Hydraulic Pressure C132008E02 (1) Operation description The skid control ECU detects wheel lock condition by receiving vehicle speed signals from each speed sensor, and sends control signals to the pump motor and solenoid valves. The pump motor and solenoid valves avoid wheel lock by controlling the hydraulic pressure of each wheel cylinder. The ABS warning light comes on when the ABS system is malfunctioning. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–281 (b) EBD (Electronic Brake force Distribution) The EBD control utilizes ABS, which ensures proper brake force distribution between the front and rear wheels in accordance with driving conditions. In addition, when braking while cornering, it also controls the brake forces of the right and left wheels, helping to maintain vehicle behavior. Brake Actuator Assembly Each Speed Sensor Skid Control ECU Solenoid Valves Each Wheel Cylinder BC Combination Meter BRAKE Warning Light CAN Communication System Hydraulic Pressure C132009E02 (1) Operation description The skid control ECU receives a speed signal from each speed sensor, and uses these signals to detect locking of the wheels. The ECU uses this information in order to determine appropriate control of the solenoid valves. The solenoid valves control the hydraulic pressure applied to the brake cylinder at each wheel. In this way, the solenoid valves are used to control the brake power split between the front and rear, and left and right wheels. The BRAKE warning light comes on if there is a malfunction in the EBD system. BC–282 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) (c) BA (Brake Assist) The primary purpose of the brake assist system is to provide auxiliary brake force to assist a driver who cannot generate a large enough brake force during emergency braking. This system helps to maximize the brake performance of the vehicle. Brake Actuator Assembly Each Speed Sensor Pump Motor Skid Control ECU Each Wheel Cylinder Solenoid Valves BC Master Cylinder Pressure Sensor Combination Meter ECM ABS Warning Light CAN Communication System Hydraulic Pressure C132010E01 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–283 (1) Operation description The skid control ECU receives the speed signal from each speed sensor and the hydraulic pressure signal from the master cylinder pressure sensor to determine whether brake assist is necessary. If brake assist is considered to be necessary, the skid control ECU sends control signals to the pump motor and solenoid valve. The pump and solenoid valve then control the pressure applied to each wheel cylinder. The ABS warning light comes on to indicate a malfunction in the BA (brake assist) system. BC BC–284 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) (d) TRAC (Traction Control) The TRAC system helps prevent the drive wheel from slipping if the driver depresses the accelerator pedal excessively when starting off or accelerating on a slippery surface. Brake Actuator Assembly Each Speed Sensor Pump Motor Skid Control ECU Each Wheel Cylinder Solenoid Valves BC Yaw Rate and Acceleration Sensor Combination Meter Steering Angle Sensor VSC Warning (Multi-Information Display) SLIP Indicator Light ECM Master Caution Indicator Light CAN Communication System Hydraulic Pressure C132011E01 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–285 (1) Operation description The skid control ECU detects wheelspin condition by receiving signals from each speed sensor and the ECM via CAN communication. The skid control ECU controls engine torque with the ECM via CAN communication and brake hydraulic pressure through the pump and solenoid valve. The SLIP indicator light blinks when the system is operating. If a malfunction occurs in the TRAC system, both master caution and SLIP indicator lights will come on and the DTC will be displayed on the multi-information display. BC BC–286 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) (e) VSC (Vehicle Stability Control) The VSC system helps prevent the vehicle from slipping sideways as a result of a strong front or rear wheel skid during cornering. Brake Actuator Assembly Each Speed Sensor Pump Motor Each Wheel Cylinder Skid Control ECU Solenoid Valves Skid Control Buzzer BC Yaw Rate and Acceleration Sensor Combination Meter Steering Angle Sensor ECM VSC Warning (Multi-Information Display) SLIP Indicator Light Master Caution Indicator Light CAN Communication System Hydraulic Pressure C132012E02 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 3. 4. BC–287 (1) Operation description The skid control ECU determines the vehicle operating conditions based on signals received from the wheel speed sensors, yaw rate and acceleration sensor, and steering angle sensor. The skid control ECU sends signals via CAN communication to the ECM in order to control engine torque. The skid control ECU controls brake hydraulic pressure using the pump and solenoid valves. The SLIP indicator light will blink, and the skid control system buzzer will sound when the system is operating. If a malfunction occurs in the VSC system, both the master caution indicator light and the SLIP indicator light will come on. In addition to this, the DTC will appear on the multi-information display. Vehicles without a multi-information display will illuminate the VSC warning light and SLIP indicator light if a malfunction occurs. ABS with EBD, BA, TRAC and VSC OPERATION (a) The skid control ECU calculates vehicle stability tendency based on the signals from the speed sensor, yaw rate and acceleration sensor, and steering angle sensor. In addition, it evaluates the results of the calculations to determine whether any control actions (control of the engine output torque by electronic throttle control and of the wheel brake pressure by the brake actuator assembly) should be implemented. (b) The SLIP indicator blinks and the skid control buzzer sounds to inform the driver that the VSC system is operating. The SLIP indicator also blinks when traction control is operating, and the operation being performed is displayed. FAIL SAFE (a) When a failure occurs in the ABS with BA, TRAC and VSC systems, the ABS and VSC warning (with multi-information display) lights, and SLIP indicator light come on and ABS with BA, TRAC and VSC operations are prohibited. In addition, when there is a failure that disables the EBD operation, the BRAKE warning light also comes on and the EBD operation is prohibited. (b) If control is prohibited due to a malfunction during operation, control will be disabled gradually. This is to avoid sudden vehicle instability. BC BC–288 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 5. 6. INITIAL CHECK (a) When the vehicle speed first becomes approximately 4 mph (6 km/h) or more after the ignition switch is turned on (IG), each solenoid valve and motor of the brake actuator assembly is sequentially activated to perform an electrical check. During the initial check, the operating sound of solenoid valve and motor can be heard from the engine compartment, but this is not a malfunction. FUNCTION OF COMPONENTS Components Function • Brake actuator assembly • • Skid control ECU (housed in brake actuator assembly) BC • Changes the fluid path based on the signals from the skid control ECU during the operation of the ABS with EBD & Brake Assist & TRAC & VSC system, in order to control the fluid pressure that is applied to the wheel cylinders. Houses the skid control ECU. Judges the vehicle driving condition based on the signals from each sensor, and controls the brake actuator assembly. Sends and receives the control signals to or from the ECM, yaw rate and acceleration sensor, and steering angle sensor via CAN communication. Master cylinder pressure sensor • • Speed sensor Detects speed of each wheel and inputs the data into the skid control ECU. Stop light switch Illuminates the brake light when the brake pedal is depressed. (Sends a brake on signal to the skid control ECU) Motor relay • • Supplies power to the pump motor. Housed in the skid control ECU. Solenoid relay • • Supplies power to each solenoid. Housed in the skid control ECU. • • Controls the engine output based on the signals received from the skid control ECU. Sends the accelerator pedal position signal and the engine speed signal to the skid control ECU. • • Comes on to inform the driver that a malfunction in the ABS, EBD or BA (Brake Assist) has occurred. Blinks to output DTC. BRAKE warning light • • Comes on to inform the driver that the parking brake is ON when the system is normal. Comes on to inform the driver that a malfunction in the EBD has occurred. VSC warning light Comes on to inform the driver that a malfunction in the VSC system has occurred. SLIP indicator light Blinks to inform the driver that TRC and VSC are operating. Brake fluid level warning switch Detects the brake fluid level. ECM ABS warning light Skid control buzzer Intermittently sounds to inform the driver that the VSC is operating. • Yaw rate and acceleration sensor • • • • Steering angle sensor Detects the fluid pressure in the master cylinder. Housed in the brake actuator assembly. • Acceleration sensor measures the capacity of the condenser that changes the distance between the electrodes depending on G force, which occurs when the vehicle is accelerated, and converts the measured value into electrical signals. Yaw rate sensor detects the vehicle's angular velocity (yaw rate) in the vertical direction based on the amount and direction of the piezoelectric ceramics deflection. Sends signals to the skid control ECU via CAN communication. Installed in the steering column. Detects the steering amount and direction and sends the signals to the skid control ECU via CAN communication. Has the magnetic resistance element, which detects the rotation of the magnet housed in the detection gear in order to detect the changes in magnetic resistance and the steering amount and direction. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–289 HOW TO PROCEED WITH TROUBLESHOOTING 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS (a) Interview the customer to confirm the trouble. NEXT 3 CHECK CAN COMMUNICATION SYSTEM (a) Check for DTCs (See page BC-302). HINT: The skid control ECU is connected to the CAN communication system. Therefore, before starting troubleshooting, make sure to check that there is no trouble in the CAN communication system. Result Result Proceed to DTC is not output A DTC is output B B CHECK CAN COMMUNICATION CIRCUIT A 4 CHECK DTC AND FREEZE FRAME DATA (a) Check for DTCs and Freeze Frame Data (See page BC302 for DTC Check / Clear, BC-305 for Freeze Frame Data). (1) Record the DTCs and Freeze Frame Data. (b) Clear the DTCs. (c) Recheck for DTCs. (1) Reproduce the malfunction and check if the DTCs are output again. Result Result Proceed to DTC is output A DTC is not output (Problem symptom does not occur) B DTC is not output (Problem symptom occurs) C B GO TO STEP 9 BC BC–290 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) C GO TO STEP 10 A 5 DIAGNOSTIC TROUBLE CODE CHART (a) Go to "DIAGNOSTIC TROUBLE CODE CHART" (See page BC-311). NEXT 6 CIRCUIT INSPECTION NEXT BC 7 REPAIR OR REPLACE NEXT 8 CONFIRMATION TEST NEXT END 9 SYMPTOM SIMULATION NEXT 10 PROBLEM SYMPTOMS TABLE (a) Go to "PROBLEM SYMPTOMS TABLE" (See page BC295). NEXT 11 NEXT CIRCUIT INSPECTION BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 12 BC–291 REPAIR OR REPLACE NEXT 13 CONFIRMATION TEST NEXT END TEST MODE PROCEDURE ABS Warning Light: USA: CANADA: Master Caution Indicator Light: BRAKE Warning Light: USA: CANADA: SLIP Indicator Light: VSC Warning Light (without multi-information display) C137469E01 1. WARNING LIGHT AND INDICATOR LIGHT INITIAL CHECK (a) Release the parking brake. NOTICE: Before releasing the parking brake, move the shift lever to the P position for safety (Automatic Transaxle model) or set the chocks to hold the vehicle for safety (Manual Transaxle model). HINT: When the parking brake is applied or the level of the brake fluid is low, the BRAKE warning light comes on. (b) When the ignition switch is turned on (IG), check that the ABS, VSC (without multi-information display), BRAKE warning lights, and master caution, SLIP indicator lights come on for approximately 3 seconds. HINT: If the ECU stores any DTCs, the ABS, BRAKE, VSC warning (without multi-information display and master caution indicator light) lights, and SLIP indicator light come on. If the indicator remains on or does not come on, proceed to troubleshooting for the light circuits listed below. Trouble Area See procedure ABS warning light (Remains on) BC-380 ABS warning light (Does not come on) BC-385 BRAKE warning light (Remains on) BC-395 BRAKE warning light (Does not come on) BC-404 VSC warning light (Remains on) BC-388 VSC warning light (Does not come on) BC-392 SLIP indicator light (Remains on) BC-408 SLIP indicator light (Does not come on) BC-412 BC BC–292 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 2. (a) Procedure to enter Test Mode. (1) Turn the ignition switch off. (2) Connect the intelligent tester to the DLC3. (3) Check that the steering wheel is centered and move the shift lever to the P position (Automatic Transaxle) or apply the parking brake (Manual Transaxle). (4) Turn the ignition switch on (IG). Intelligent Tester BC DLC3 SENSOR SIGNAL CHECK BY TEST MODE (SIGNAL CHECK) (INTELLIGENT TESTER) HINT: If the ignition switch is turned from on (IG) to on (ACC) or off during Test Mode (signal check), DTCs recorded during the signal check function will be erased. CAN VIM C131977E05 (5) Set the intelligent tester to Test Mode (select "SIGNAL CHECK"). HINT: Refer to the intelligent tester operator's manual for further details. C106533 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) (6) Check that the ABS warning light comes on for several seconds and then blinks in Test Mode. HINT: If the ABS warning light does not blink, inspect the ABS warning light circuit. TEST MODE: Blinking Pattern: 0.13 sec. BC–293 0.13 sec. Trouble Area ON ABS warning light (Does not come on) OFF Display: USA: Canada: C132874E01 3. See procedure BC-404 (b) Check the sensor signal. (1) Drive the vehicle straight ahead. Accelerate the vehicle to a speed of 28 mph (45 km/h) or more for several seconds and check that the ABS warning light goes off when the brake pedal is depressed. HINT: • The sensor check may not be completed if wheelspin occurs, or if the steering wheel is turned during this check. • The ABS warning light goes off when the sensor signal check has been completed and the brake pedal is depressed. • The ABS warning light comes on immediately after a malfunction has been detected during the speed sensor signal check. (c) Stop the vehicle. NOTICE: • The speed sensor check may not be completed if the speed sensor check is started while turning the steering wheel or spinning the wheels. • If the signal check has not been completed, the ABS warning light will blink while driving and the ABS system will not operate. (d) Read the DTC(s) by following the tester screen. NOTICE: • If only the DTCs are displayed, repair the malfunction area and clear the DTCs. • If the DTCs or Test Mode codes (DTC of signal check function) are displayed, repair the malfunction area, clear the DTCs and perform the Test Mode inspection. HINT: See the list of DTCs (See procedure "A"). SENSOR SIGNAL CHECK BY TEST MODE (SIGNAL CHECK) (SST CHECK WIRE) HINT: If the ignition switch is turned from on (IG) to on (ACC) or off during Test Mode (signal check), DTCs recorded during the signal check will be erased. (a) Procedure to enter Test Mode. (1) Turn the ignition switch off. BC BC–294 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) (2) Check that the steering wheel is centered and move the shift lever to the P position (Automatic Transaxle) or apply the parking brake (Manual Transaxle). DLC3: (3) Using SST, connect terminals TS and CG of the DLC3. SST 09843-18040 (4) Turn the ignition switch on (IG). CG TS G022987E07 (5) Check that the ABS warning light comes on for several seconds and then blinks in Test Mode. HINT: If the ABS warning light does not blink, inspect the TS and CG terminal circuit, and ABS warning light circuit. TEST MODE: BC Blinking Pattern: 0.13 sec. 0.13 sec. ON Trouble Area OFF Display: USA: Canada: C132874E01 See procedure TS and CG terminal circuit BC-421 ABS warning light circuit (Does not come on) BC-385 (b) Check the sensor signal. (1) Drive the vehicle straight ahead. Accelerate the vehicle to a speed of 28 mph (45 km/h) or more for several seconds and check that the ABS warning light goes off when the brake pedal is depressed. HINT: • The sensor check may not be completed if wheelspin occurs, or if the steering wheel is turned during this check. • The ABS warning light goes off when the sensor signal check has been completed and the brake pedal is depressed. • The ABS warning light comes on immediately after a malfunction has been detected during the speed sensor signal check. (c) Stop the vehicle. NOTICE: • The speed sensor check may not be completed if the speed sensor check is started while turning the steering wheel or spinning the wheels. • If the signal check has not been completed, the ABS warning light will blink while driving and the ABS system will not operate. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DLC3: (d) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 (e) Count the number of blinks of the ABS warning light. CG TS BC–295 TC G022988E01 Blinking Pattern of Normal System Code: 0.25 sec. 0.25 sec. ON BC OFF Blinking Pattern of Trouble Code (Example Codes 71 and 72): 0.5 sec. 0.5 sec. 1.5 sec. 2.5 sec. 4 sec. Repeat ON OFF Code 71 Code 72 C132876E01 (f) NOTICE: • If only the DTCs are displayed, repair the malfunction area and clear the DTCs. • If the DTCs or Test Mode codes (DTC of signal check function) are displayed, repair the malfunction area, clear the DTCs and perform the Test Mode inspection. HINT: • If more than 1 malfunction is detected at the same time, the lowest numbered code will be displayed first. • See the list of DTCs (See procedure "A"). After performing the check, disconnect the SST from terminals TS and CG, and TC and CG of the DLC3, and turn the ignition switch off. BC–296 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 4. (g) Turn the engine switch on (IG) to cancel the Test Mode. HINT: • If the ignition switch is not turned on (IG) after the SST is removed from the DLC3, the previous Test Mode will continue. • If the ignition switch is turned on (IG) with terminals TS and CG shorted, the previous Test Mode will continue. DTC OF TEST MODE (SIGNAL CHECK) FUNCTION (Procedure "A") DTC of Test Mode (Signal Check): Code No. Diagnosis Trouble Area C1271/71 Low output signal of front speed sensor RH • • • C1272/72 Low output signal of front speed sensor LH • • • Front speed sensor LH Sensor installation Speed sensor rotor C1273/73 Low output signal of rear speed sensor RH • • • Rear speed sensor RH Sensor installation Speed sensor rotor C1274/74 Low output signal of rear speed sensor LH • • • Rear speed sensor LH Sensor installation Speed sensor rotor C1275/75 Abnormal change in output signal of front speed sensor RH • • • Front speed sensor RH Sensor installation Sensor rotor C1276/76 Abnormal change in output signal of front speed sensor LH • • • Front speed sensor LH Sensor installation Sensor rotor C1277/77 Abnormal change in output signal of rear speed sensor RH • • • Rear speed sensor RH Sensor installation Sensor rotor C1278/78 Abnormal change in output signal of rear speed sensor LH • • • Rear speed sensor LH Sensor installation Sensor rotor BC 5. Front speed sensor RH Sensor installation Speed sensor rotor HINT: The codes in this table are output only in Test Mode (signal check). ENGINE VARIANT LEARNING • Engine variant learning is automatically performed immediately after the Test Mode is entered. • The ABS, VSC, BRAKE, and SLIP indicators come on for 3 seconds after learning. BC–297 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) PROBLEM SYMPTOMS TABLE If there are no DTCs output but the problem still occurs, check the circuits for each problem symptom in the order given in the table below, and proceed to the relevant troubleshooting page. NOTICE: Before replacing the brake actuator assembly, sensor, or other related parts, turn the ignition switch off. Vehicle stability control system: Symptom ABS, BA and/or EBD does not operate ABS, BA and/or EBD does not operate efficiently VSC and/or TRACTION does not operate ABS sensor DTC check cannot be done Suspected area See page 1. Check for the DTC again and make sure that the normal system code is output. BC-302 2. IG power source circuit BC-361 3. Front speed sensor circuit BC-316 4. Rear speed sensor circuit BC-324 5. Check the brake actuator assembly with the intelligent tester (Check brake actuator assembly operation using the active test function). If abnormal, check the hydraulic circuit for leakage. BC-431 6. If the symptoms still occur even after the above circuits in suspected areas have been inspected and proved to be normal, replace the brake actuator assembly (skid control ECU). BC-432 1. Check for the DTC again and make sure that the normal system code is output. BC-302 2. Front speed sensor circuit BC-316 3. Rear speed sensor circuit BC-324 4. Stop light switch circuit BC-368 5. Check the brake actuator assembly with the intelligent tester (Check brake actuator assembly operation using the active test function). If abnormal, check the hydraulic circuit for leakage. BC-431 6. If the symptoms still occur even after the above circuits in suspected areas have been inspected and proved to be normal, replace the brake actuator assembly (skid control ECU). BC-432 1. Check for the DTC again and make sure that the normal system code is output. BC-302 2. IG power source circuit BC-361 3. Check the hydraulic circuit for leakage. - 4. Front speed sensor circuit BC-316 5. Rear speed sensor circuit BC-324 6. Yaw rate and deceleration sensor circuit BC-343 7. Steering angle sensor circuit BC-350 8. If the symptoms still occur even after the above circuits in suspected areas have been inspected and proved to be normal, replace the brake actuator assembly (skid control ECU). BC-432 1. Check for the DTC again and make sure that the normal system code is output. BC-302 2. TC and CG terminal circuit BC-418 3. If the symptoms still occur even after the above circuits in suspected areas have been inspected and proved to be normal, replace the brake actuator assembly (skid control ECU). BC-432 BC BC–298 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) Symptom See page BC-302 2. TC and CG terminal circuit BC-418 3. If the symptoms still occur even after the above circuits in suspected areas have been inspected and proved to be normal, replace the brake actuator assembly (skid control ECU). BC-432 1. TS and CG terminal circuit BC-421 2. Brake actuator assembly (skid control ECU) BC-432 ABS warning light abnormal (Remains on) ABS warning light circuit BC-380 ABS warning light abnormal (Does not come on) ABS warning light circuit BC-385 VSC sensor DTC check cannot be done Sensor signal check cannot be done BC Suspected area 1. Check for the DTC again and make sure that the normal system code is output. VSC warning light abnormal (Remains on) VSC warning light circuit BC-388 VSC warning light abnormal (Does not come on) VSC warning light circuit BC-392 Brake warning light abnormal (Remains on) Brake warning light circuit BC-395 Brake warning light abnormal (Does not come on) Brake warning light circuit BC-404 SLIP indicator light abnormal (Remains on) SLIP indicator light circuit BC-408 SLIP indicator light abnormal (Does not come on) SLIP indicator light circuit BC-412 Skid control buzzer abnormal Skid control buzzer circuit BC-415 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–299 TERMINALS OF ECU 1. TERMINALS OF ECU Skid Control ECU: A60 C113404E05 Symbols (Terminal No.) Terminal Description GND2 (1) Skid control ECU ground +BM (2) Power supply for motor +BS (3) Power supply for solenoid GND1 (4) Skid control ECU ground FL+ (5) Front left wheel speed sensor input FL- (6) Front left wheel speed sensor ground RL+ (7) Rear left wheel speed sensor input RR- (8) Rear right wheel speed sensor ground FR- (9) Front right wheel speed sensor ground FR+ (10) Front right wheel speed sensor input D/G (11) Diagnosis tester communication line CANL (14) CAN communication line L BZ (23) Buzzer output RL- (27) Rear left wheel speed sensor ground IG1 (28) ECU power supply RR+ (29) Rear right wheel speed sensor input STP1 (30) Stop light switch input SP1 (33) Speed signal output CANH (35) CAN communication line H TS (39) Sensor check switch input BC BC–300 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 2. TERMINAL INSPECTION (a) Disconnect the connector and measure the voltage and resistance according to the value(s) in the table below. Skid Control ECU (Harness Side Connector Front View): A60 BC C137467E01 HINT: Voltage cannot be measured with the connector connected to the skid control ECU, as the connector is watertight. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition GND2 (A60-1) - Body ground W-B - Body ground Actuator pump motor ground Always Below 1 Ω +BM (A60-2) - Body ground B - Body ground Power supply for motor Always 10 to 14 V +BS (A60-3) - Body ground L - Body ground Power supply for solenoid Always 10 to 14 V GND1 (A60-4) - Body ground W-B - Body ground Skid control ECU ground Always Below 1 Ω BZ (A60-23) - Body ground R - Body ground Buzzer warning light output Ignition switch on (IG), Buzzer does not sound 6 to 10 V IG1 (A60-28) - Body ground P - Body ground IG1 power supply Ignition switch on (IG) 10 to 14 V STP1 (A60-30) - Body ground P - Body ground Stop light switch input Stop light switch ON →OFF (Brake pedal depressed → released) 5 to 14 V → Below 3 V BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–301 DIAGNOSIS SYSTEM 1. CG (b) The vehicle's ECU uses the ISO 15765-4 for communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. HINT: Connect the cable of the intelligent tester to the DLC3, turn the ignition switch on (IG) and attempt to use the intelligent tester. If the screen displays a communication error message, a problem exists on either the vehicle side or the tester side. If the communication is normal when the tester is connected to another vehicle, inspect the DLC3 on the original vehicle. If the communication is still impossible when the tester is connected to another vehicle, the problem is probably in the tester itself. Consult the Service Department listed in the tester's instruction manual. SG CANH 1 2 3 4 5 6 7 8 9 10 11 1213141516 CANL BAT Symbols (Terminal No.) CG (4) - Body ground DIAGNOSIS SYSTEM (a) Inspect the battery voltage. Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge the battery before proceeding. A082779E65 Terminal Description Chassis ground Condition Specified Condition Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 9 to 14 V CANH (6) - CANL (14) HIGH-level CAN bus line Ignition switch OFF* 54 to 69 Ω CANH (6) - Battery positive HIGH-level CAN bus line Ignition switch OFF* 6 kΩ or higher CANH (6) - CG (4) HIGH-level CAN bus line Ignition switch OFF* 200 Ω or higher CANL (14) - Battery positive LOW-level CAN bus line Ignition switch OFF* 6 kΩ or higher CANL (14) - CG (4) LOW-level CAN bus line Ignition switch OFF* 200 Ω or higher 2. NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. DESCRIPTION NOTICE: When releasing the parking brake, set chocks to hold the vehicle for safety. BC BC–302 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) ABS Warning Light: USA: CANADA: Master Caution Indicator Light: (a) If the skid control ECU detects a malfunction, the ABS, VSC (without multi-information display), and BRAKE warning lights, and master caution and SLIP indicator lights will come on and the multiinformation display shows a warning message in order to warn the driver. The table below indicates which lights will come on when there is a malfunction in a particular function. BRAKE Warning Light: USA: CANADA: SLIP Indicator Light: BC VSC Warning Light (without multi-information display) C137469E01 Item/Trouble Area ABS EBD BA TRAC VSC ABS Warning Light { { { - - BRAKE Warning Light - { - - - VSC Warning Light (without multi-information display) { { { { { SLIP Indicator Light { { { { { {: Light ON -: Light OFF • The DTCs are simultaneously stored in the memory. The DTCs can be read by connecting the SST between terminals TC and CG of the DLC3 and observing the blinking pattern of the ABS warning light by connecting the intelligent tester (See page BC-302). • This system has a signal check function (TEST MODE) (See page BC-290). The DTC can be read by connecting the intelligent tester and observing the blinking pattern of the ABS warning. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 3. ABS Warning Light: USA: CANADA: Master Caution Indicator Light: BRAKE Warning Light: USA: CANADA: SLIP Indicator Light: VSC Warning Light (without multi-information display) WARNING LIGHT AND INDICATOR LIGHT INITIAL CHECK (a) Release the parking brake. NOTICE: Before releasing the parking brake, move the shift lever to the P position for safety (Automatic Transaxle model) or set the chocks to hold the vehicle for safety (Manual Transaxle model). HINT: When the parking brake is applied or the level of the brake fluid is low, the BRAKE warning light comes on. (b) When the ignition switch is turned on (IG), check that the ABS, VSC (without multi-information display), and BRAKE warning lights, and master caution and SLIP indicator lights come on for approximately 3 seconds. HINT: If the ECU stores any DTCs, the ABS, BRAKE, and VSC warning (multi-information display and master caution indicator light) lights, and SLIP indicator light come on. If the indicator remains on or does not come on, proceed to troubleshooting for the light circuits listed below. Trouble Area C137469E01 BC–303 See procedure ABS warning light (Remains on) BC-380 ABS warning light (Does not come on) BC-385 BRAKE warning light (Remains on) BC-395 BRAKE warning light (Does not come on) BC-404 VSC warning light (Remains on) BC-388 VSC warning light (Does not come on) BC-392 SLIP indicator light (Remains on) BC-408 SLIP indicator light (Does not come on) BC-412 4. SYMPTOM SIMULATION HINT: The most difficult case in troubleshooting is when no symptoms occur. In such cases, a thorough customer problem analysis must be carried out. Then the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be reproduced. No matter how experienced or skilled a technician may be, if he proceeds to troubleshoot without confirming the problem symptoms, he will likely overlook something important and make a wrong guess at some points in the repair operation. This leads to a standstill in troubleshooting. BC BC–304 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) (a) Vibration method: When vibration seems to be the major cause. HINT: Perform the simulation method only during the primary check period (for approximately 6 seconds after the ignition switch is turned on (IG)). (1) Slightly vibrate the part of the sensor considered to be the problem cause with your fingers and check whether the malfunction occurs. (2) Slightly shake the connector vertically and horizontally. HINT: Shaking the relays too strongly may result in open relays. (3) Slightly shake the wire harness vertically and horizontally. The connector joint and fulcrum of the vibration are the major areas to be checked thoroughly. Vibrate Slightly Shake Slightly BC Vibrate Slightly DLC3: D025083E14 DTC CHECK / CLEAR CG TC 1. G022986E01 DTC CHECK/CLEAR (WHEN USING SST CHECK WIRE:) (a) DTC check (1) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 (2) Turn the ignition switch on (IG). BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–305 (3) Observe the blinking pattern of the ABS and VSC (without multi-information display) warning lights or read the multi information display (with multi-information display) in order to identify the DTC. with Multi-Information Display Normal System Code of ABS and VSC: Trouble Code of ABS and VSC (Example Codes 11 and 21): 0.5 sec. 0.25 sec. 2 sec. 0.25 sec. ON ON OFF OFF with Multi-Information Display Normal System Code of VSC: 4 sec. 1.5 sec. 2.5 sec. Code 11 0.5 sec. 4 sec. Repeat BC Code 21 Trouble Code of VSC (Example Code 43): C137468E03 HINT: If no code appears, inspect the TC and CG terminal circuit, the ABS warning light circuit, and the VSC warning light circuit. Trouble Area See procedure ABS warning light (Remains on) BC-380 ABS warning light (Does not come on) BC-385 VSC warning light (Remains on) BC-388 VSC warning light (Does not come on) BC-392 TC and CG Terminal Circuit BC-418 • As an example, the blinking patterns for a normal system code and trouble codes 11 and 21 are shown in the illustration. (4) Codes are explained in the code table (See page BC-311). (5) After completing the check, disconnect terminals TC and CG of the DLC3, and turn off the display. If 2 or more DTCs are detected at the same time, the DTCs will be displayed in ascending order. BC–306 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DLC3: (b) DTC clear (1) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 (2) Turn the ignition switch on (IG). CG TC G022986E01 (3) Clear the DTCs stored in the ECU by depressing the brake pedal 8 times or more within 5 seconds. (4) Check that the warning light indicates a normal system code. (5) Remove the SST. HINT: Clearing the DTCs cannot be performed by disconnecting the battery terminal or the ECU-IG fuse. BC BR03890 2. Intelligent Tester DLC3 CAN VIM C131977E05 3. DTC CHECK/CLEAR (WHEN USING INTELLIGENT TESTER:) (a) DTC check (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch on (IG). (3) Read the DTCs by following the prompts on the tester screen. (b) DTC clear (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch on (IG). (3) Operate the intelligent tester to clear the codes. HINT: Refer to the intelligent tester operator's manual for further details. END OF DTC CHECK/CLEAR (a) Turn the ignition switch on (IG). (b) Check that the ABS warning light goes off within approximately 3 seconds. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–307 FREEZE FRAME DATA 1. Item (Display) FREEZE FRAME DATA (a) Whenever an ABS DTC is detected, the skid control ECU stores the current vehicle (sensor) state as Freeze Frame Data. The skid control ECU stores the number of times (maximum: 31) the ignition switch has been turned from off to on (IG) since the last time the ABS was activated. HINT: • However, if the vehicle is stopped or at a low speed (4.3 mph (7 km/h) or less), or if a DTC is detected, the skid control ECU will stop counting the number. • Freeze Frame Data at the time the ABS operates: The skid control ECU stores and updates data whenever the ABS system operates. When the ECU stores data at the time a DTC is detected, the data stored during ABS operation is erased. • Freeze Frame Data at the time a DTC is detected: When the skid control ECU stores data at the time a DTC is detected, no updates will be performed until the data is cleared. (b) Connect the intelligent tester to the DLC3. (c) Turn the ignition switch on (IG). (d) Select the "DTC INFO" on the tester display. (e) On the DTC data display screen, select the DTC data display with "*". Measurement Item Reference Value VEHICLE SPD Vehicle speed reading Min.: 0 mph (0 km/h), Max.: 202 mph (326.4 km/ h) STOP LAMP SW Stop light switch signal Stop light switch ON: ON, OFF: OFF #IG ON Number of operations of engine switch on (IG) after storing freeze frame data 0 to 31 MAS CYL PRESS 1 Master cylinder pressure sensor reading Brake pedal released: 0.3 to 0.5 V M/C PRESS GRADE Master cylinder pressure sensor change Min.: -30 MPa/s, Max.: 225 MPa/s YAW RATE Yaw rate sensor reading Min.: -128 deg/s, Max.: 127 deg/s STEERING SEN Steering angle sensor reading Left turn: Increase Right turn: Decrease SPD GRADE Vehicle speed grade Min.: -25.11 m/s2, Max.: 24.91 m/s2 BUZZER Skid control buzzer signal Skid control buzzer ON: ON, OFF: OFF PARKING BRAKE SW Parking brake switch signal Parking brake switch ON: ON, OFF: OFF ENGINE TORQUE Real engine torque Min.: -1024 Nm, Max.: 1023 Nm FR WHEEL SPD FR wheel speed Min.: 0 mph (0 km/h), Max.: 202 mph (326.4 km/ h) FL WHEEL SPD FL wheel speed Min.: 0 mph (0 km/h), Max.: 202 mph (326.4 km/ h) RR WHEEL SPD RR wheel speed Min.: 0 mph (0 km/h), Max.: 202 mph (326.4 km/ h) RL WHEEL SPD RL wheel speed Min.: 0 mph (0 km/h), Max.: 202 mph (326.4 km/ h) BC BC–308 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) Item (Display) Measurement Item Reference Value Lateral G Min.: -25.11 m/s2, Max.: 24.91 m/s2 Gear position information FAIL 1st 2nd 3rd 4th 5th 6th P, N R NOT R Shift lever position information FAIL 1st 2nd 3rd 4th 5th 6th/B D/M P, N R OPERATED SYSTEM Operated system status ABS activated: ABS VSC activated: VSC TRAC activated: TRAC BA activated: BA PB activated: PB Fail safe mode activated: FAIL No system activated: NON System prohibited: SYS FREEZE TIME Elapsed time after freeze trigger Min.: 0 ms, Max.: 500 ms TROUBLE CODE Freeze frame DTC Displays to output DTC INSPECTION MODE Inspection mode OTHER: Normal, INSPECT: Service LATERAL G GEAR POSITION * LEVER POSITION * BC *: Automatic Transaxle BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–309 FAIL-SAFE CHART 1. Malfunction FAIL SAFE OPERATION (a) If there is a problem with sensor signals or actuator systems, the skid control ECU prohibits power supply to the brake actuator assembly and informs the ECM of the VSC system failure. (b) The brake actuator assembly turns off each solenoid and the ECM shuts off the VSC control (traction control signal) from the skid control ECU accordingly, which turns out to be as if the vehicle stability control system was not installed. (c) ABS, VSC, and TRAC control will be prohibited, but EBD control continues as much as possible. If EBD control is impossible, the brake warning light comes on to warn the driver (See page BC-298). Symptom ABS system Prohibits the ABS, BA, TRAC, and VSC control BA system Prohibits the ABS, BA, TRAC, and VSC control EBD system Prohibits the ABS, EBD, BA, TRAC, and VSC control TRAC system Prohibits the TRAC and VSC control VSC system Prohibits the TRAC and VSC control HINT: • A malfunction in either the ABS or BA system results in an identical operation, with ABS, BA, TRAC, and VSC system control prohibited. • If control is prohibited due to a malfunction during operation, control will be disabled gradually to prevent the vehicle from becoming unstable suddenly. BC BC–310 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DATA LIST / ACTIVE TEST 1. Measurement Item / Range (Display) Item (Display) BC DATA LIST HINT: With the intelligent tester connected to the DLC3 and the ignition switch on (IG), the ABS, TRAC and VSC Data List can be displayed. Follow the prompts on the tester screen to access the Data List. Normal Condition Diagnostic Note MTR RELAY ABS motor relay / ON or OFF ON: Motor relay ON OFF: Motor relay OFF - SOL RELAY Solenoid relay / ON or OFF ON: Solenoid relay ON OFF: Solenoid relay OFF - IDLE SW Main idle switch / ON or OFF ON: Accelerator pedal released OFF: Accelerator pedal depressed - STOP LAMP SW Stop light switch / ON or OFF ON: Brake pedal depressed OFF: Brake pedal released - PARKING BRAKE SW Parking brake switch / ON or OFF ON: Parking brake applied OFF: Parking brake released - ENG REVOLUTIONS Engine revolutions / min.: 0 r/min, max.: 65,535 r/min - - GEAR POSITION * Gear position information / P/N, R, 1st-6th, FAIL, NOT R - - LEVER POSITION * Shift lever position information / P/N, R, D/M, 1st-6th/B, FAIL - - SHIFT INFO Shift information / ON or OFF ON: During gear change - FR WHEEL SPD FR wheel speed sensor reading / min.: 0 mph (0 km/h), max.: 202 mph (326 km/h) Actual wheel speed Similar speed as indicated on speedometer FL WHEEL SPD FL wheel speed sensor reading / min.: 0 mph (0 km/h), max.: 202 mph (326 km/h) Actual wheel speed Similar speed as indicated on speedometer RR WHEEL SPD RR wheel speed sensor reading / min.: 0 mph (0 km/h), max.: 202 mph (326 km/h) Actual wheel speed Similar speed as indicated on speedometer RL WHEEL SPD RL wheel speed sensor reading / min.: 0 mph (0 km/h), max.: 202 mph (326 km/h) Actual wheel speed Similar speed as indicated on speedometer Approximately 0+-0.13 G while stationary Reading changes when vehicle is bounced Acceleration sensor 1 reading / DECELERAT SEN min.: -18.52 m/s2, max.: 18.39 m/ s2 SFRR ABS solenoid (SFRR) / ON or OFF ON: Operates - SFRH ABS solenoid (SFRH) / ON or OFF ON: Operates - SFLR ABS solenoid (SFLR) / ON or OFF ON: Operates - SFLH ABS solenoid (SFLH) / ON or OFF ON: Operates - SRRR ABS solenoid (SRRR) / ON or OFF ON: Operates - SRRH ABS solenoid (SRRH) / ON or OFF ON: Operates - SRLR ABS solenoid (SRLR) / ON or OFF ON: Operates - SRLH ABS solenoid (SRLH) / ON or OFF ON: Operates - BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) Item (Display) Measurement Item / Range (Display) Normal Condition BC–311 Diagnostic Note SRM2 Master cut solenoid (SRM2) / ON or OFF ON: Operates - SRM1 Master cut solenoid (SRM1) / ON or OFF ON: Operated - SRC2 Master cut solenoid (SMC2) / ON or OFF ON: Operates - SRC1 Master cut solenoid (SRC1) / ON or OFF ON: Operates - VEHICLE SPD Maximum wheel speed sensor reading / min.: 0 mph (0 km/h), max.: 202 mph (326 km/h) Actual vehicle speed Speed indicated on speedometer YAW RATE SENS 1 Yaw rate sensor 1 / min.: -128 deg/s, max.: 127 deg/s Min.: -128 deg/s Max.: 127 deg/s - ZERO YAW RATE Memorized zero value / min.: 128 deg/s, max.: 127 deg/s Min.: -128 deg/s Max.: 127 deg/s - STEERING SEN Steering angle sensor / min.: 3,276.8 deg, max.: 3,276.7 deg Left turn: Increase Right turn: Decrease - MAS CYL PRESS 1 Master cylinder pressure sensor 1 reading / min.: 0 V, max.: 5 V When brake pedal is released: 0.3 to 0.5 V Reading increases when brake pedal is depressed ENGINE TORQUE Real engine torque / min.: -1024 N*m, max.: 1023 N*m - - FR SPD OPN FR speed sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - FL SPD OPN FL speed sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - RR SPD OPN RR speed sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - RL SPD OPN RL speed sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - YAW RATE OPN Yaw rate sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - DECELERAT OPN Acceleration sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - STEERING OPN Steering angle sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - EFI COM OPN EFI communication open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - #DTC Number of DTC / min.: 0, max.: 255 - - ABS WARN LAMP ABS warning light / ON or OFF ON: Warning light ON OFF: Warning light OFF - BRAKE WARN LAMP BRAKE warning light / ON or OFF ON: Warning light ON OFF: Warning light OFF - SLIP INDI LAMP SLIP indicator light / ON or OFF ON: Indicator light ON OFF: Indicator light OFF - BUZZER Skid control buzzer / ON or OFF ON: Buzzer ON OFF: Buzzer OFF - VSC WARN LAMP VSC warning (multi-information display and master caution indicator light) light / ON or OFF ON: Indicator ON OFF: Indicator OFF - FR wheel acceleration / min.: - Min.: -200.84 m/s2 FR WHEEL ACCEL FL WHEEL ACCEL RR WHEEL ACCEL 200.84 m/s2, max.: 199.27 m/s2 Min.: -200.84 m/s2 FL wheel acceleration / min.: 2 Max.: 199.27 m/s2 2 200.84 m/s , max.: 199.27 m/s Max.: 199.27 m/s2 RR wheel acceleration / min.: - Min.: -200.84 m/s2 2 2 200.84 m/s , max.: 199.27 m/s Max.: 199.27 m/s2 - - - BC BC–312 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) Item (Display) RL WHEEL ACCEL ZERO DECELERAT ZERO STEERING LATERAL G Normal Condition Min.: -200.84 m/s2 RL wheel acceleration / min.: 2 2 200.84 m/s , max.: 199.27 m/s Max.: 199.27 m/s2 Memorized zero value / min.: - Min.: -25.11 m/s2 25.11 m/s 2, max.: 24.91 m/s2 Max.: 24.91 m/s2 Memorized zero value / min.: 3,276.8 deg, max.: 3,276.7 deg Min.: -3,276.8 deg Max.: 3,276.7 deg Lateral G / min.: -25.11 m/s2, Min.: -25.11 m/s2 Diagnostic Note - - 2 Max.: 24.91 m/s2 Forward and rearward G / min.: - Min.: -25.11 m/s2 25.11 m/s2, max.: 24.91 m/s2 Max.: 24.91 m/s2 YAW RATE VALUE Yaw rate value / min.: -128 deg/s, max.: 127 deg/s Min.: -128 deg/s Max.: 127 deg/s - STEERING ANGLE Steering angle value / min.: 3,276.8 deg, max.: 3,276.7 deg Min.: -3,276.8 deg Max.: 3,276.7 deg - TRAC STATUS TRAC control status / ON or OFF ON: During the control - TRAC ENG STATUS TRAC engine control status / ON or OFF ON: During the control - TRAC BRK STATUS TRAC brake control status / ON or OFF ON: During the control - FR VSC STATUS FR wheel VSC control status / ON or OFF ON: During the control - FL VSC STATUS FL wheel VSC control status / ON or OFF ON: During the control - RR VSC STATUS RR wheel VSC control status / ON or OFF ON: During the control - RL VSC STATUS RL wheel VSC control status / ON or OFF ON: During the control - FR ABS STATUS FR wheel ABS control status / ON or OFF ON: During the control - FL ABS STATUS FL wheel ABS control status / ON or OFF ON: During the control - RR ABS STATUS RR wheel ABS control status / ON or OFF ON: During the control - RL ABS STATUS RL wheel ABS control status / ON or OFF ON: During the control - FR EBD STATUS FR wheel EBD control status / ON or OFF ON: During the control - FL EBD STATUS FL wheel EBD control status / ON or OFF ON: During the control - RR EBD STATUS RR wheel EBD control status / ON or OFF ON: During the control - RL EBD STATUS RL wheel EBD control status / ON or OFF ON: During the control - BA STATUS BA control status / ON or OFF ON: During the control - INSPECTION MODE Inspection mode / OTHER or INSPECT - - #IG ON2 Number of ignition switch on (IG) after entering the inspection mode / min.: 0, max.: 255 - - TROUBLE CODE Freeze frame DTC / min.: 0, max.: 65,535 - - FORWARD&REA G BC Measurement Item / Range (Display) max.: 24.91 m/s *: Automatic Transaxle - BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 2. Item (Display) BC–313 ACTIVE TEST HINT: Performing the Active Test using the intelligent tester allows the relay, actuator, and other items to operate without removing any parts. Performing the Active Test as the first step in troubleshooting is one of the methods to save labor time. It is possible to display the Data List during the Active Test. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) From the display on the tester, select the Active Test. HINT: The ignition switch must be turned on (IG) to proceed to the Active Test using the intelligent tester. Vehicle Condition / Test Details Diagnostic Note SFRR Turns ABS solenoid (SFRR) ON / OFF Operating sound of solenoid (clicking sound) can be heard SFRH Turns ABS solenoid (SFRH) ON / OFF Operating sound of solenoid (clicking sound) can be heard SFLR Turns ABS solenoid (SFLR) ON / OFF Operating sound of solenoid (clicking sound) can be heard SFLH Turns ABS solenoid (SFLH) ON / OFF Operating sound of solenoid (clicking sound) can be heard SRRR Turns ABS solenoid (SRRR) ON / OFF Operating sound of solenoid (clicking sound) can be heard SRRH Turns ABS solenoid (SRRH) ON / OFF Operating sound of solenoid (clicking sound) can be heard SRLR Turns ABS solenoid (SRLR) ON / OFF Operating sound of solenoid (clicking sound) can be heard SRLH Turns ABS solenoid (SRLH) ON / OFF Operating sound of solenoid (clicking sound) can be heard SRM2 Turns master cut solenoid (SRM2) ON / OFF Operating sound of solenoid (clicking sound) can be heard SRM1 Turns master cut solenoid (SRM1) ON / OFF Operating sound of solenoid (clicking sound) can be heard SRC2 Turns master cut solenoid (SRC2) ON / OFF Operating sound of solenoid (clicking sound) can be heard SRC1 Turns master cut solenoid (SRC1) ON / OFF Operating sound of solenoid (clicking sound) can be heard MOTOR RELAY Turns ABS motor relay ON / OFF Operating sound of relay (clicking sound) and motor can be heard ABS WARN LAMP Turns ABS warning light ON / OFF Observe combination meter VSC WARN LAMP Turns VSC warning (master caution indicator) light ON / OFF Observe combination meter SLIP INDI LAMP Turns SLIP indicator light ON / OFF Observe combination meter BRAKE WARN LAMP Turns BRAKE warning light ON / OFF Observe combination meter BUZZER Turns skid control buzzer ON / OFF Buzzer can be heard BC BC–314 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DIAGNOSTIC TROUBLE CODE CHART • If a trouble code is displayed during the DTC check, check the circuit indicated by the DTC. For details of each code, refer to the page for the respective "DTC No." in the DTC chart. • Inspect the fuse and relay before investigating the trouble areas as shown in the table below. DTC chart of ABS: DTC No. Detection Item Trouble Area See page C0200/31 Right Front Wheel Speed Sensor Signal Malfunction 1. Front speed sensor RH 2. Front speed sensor circuit RH 3. Front speed sensor rotor RH 4. Sensor installation 5. Brake actuator assembly (skid control ECU) BC-316 C0205/32 Left Front Wheel Speed Sensor Signal Malfunction 1. Front speed sensor LH 2. Front speed sensor circuit LH 3. Front speed sensor rotor LH 4. Sensor installation 5. Brake actuator assembly (skid control ECU) BC-316 C0210/33 Right Rear Wheel Speed Sensor Signal Malfunction 1. Rear speed sensor RH 2. Rear speed sensor circuit RH 3. Rear speed sensor rotor RH 4. Sensor installation 5. Brake actuator assembly (skid control ECU) BC-324 C0215/34 Left Rear Wheel Speed Sensor Signal Malfunction 1. Rear speed sensor LH 2. Rear speed sensor circuit LH 3. Rear speed sensor rotor LH 4. Sensor installation 5. Brake actuator assembly (skid control ECU) BC-324 C0226/21 SFR Solenoid Circuit 1. Each solenoid circuit 2. Brake actuator assembly BC-333 C0236/22 SFL Solenoid Circuit 1. Each solenoid circuit 2. Brake actuator assembly BC-333 C0246/23 SRR Solenoid Circuit 1. Each solenoid circuit 2. Brake actuator assembly BC-333 C0256/24 SRL Solenoid Circuit 1. Each solenoid circuit 2. Brake actuator assembly BC-333 C0273/13 Open or Short Circuit in ABS Motor Relay Circuit 1. ABS No. 1 fuse (Fusible link) 2. Brake actuator assembly (skid control ECU) 3. Motor relay circuit BC-335 C0278/11 Open or Short Circuit in ABS Solenoid Relay Circuit 1. ABS No. 2 fuse (Fusible link) 2. Brake actuator assembly (skid control ECU) 3. Solenoid relay circuit BC-339 C1225/25 SMC Solenoid Circuit 1. Brake actuator assembly (skid control ECU) 2. SMC1 solenoid circuit BC-348 C1226/26 SMC Solenoid Circuit 1. Brake actuator assembly (skid control ECU) 2. SMC2 circuit BC-348 C1227/27 SRC Solenoid Circuit 1. Brake actuator assembly (skid control ECU) 2. SRC1 circuit BC-348 C1228/28 SRC Solenoid Circuit 1. Brake actuator assembly (skid control ECU) 2. SRC2 circuit BC-348 BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) Trouble Area See page C1237/37 DTC No. Tires of Different Size Detection Item 1. Brake actuator assembly (skid control ECU) 2. Speed sensor 3. Speed sensor rotor (front) 4. Rear axle hub and bearing assembly 5. Speed sensor circuit 6. Tire and wheel circuit 7. Tire deformation BC-354 C1241/41 Low Battery Positive Voltage or Abnormally High Battery Positive Voltage 1. Battery 2. ECU-IG No. 2 fuse 3. Charging system 4. Power source circuit 5. Brake actuator assembly (internal power source circuit) BC-361 C1246/46 Master Cylinder Pressure Sensor Malfunction 1. Master cylinder pressure sensor 2. Master cylinder pressure sensor circuit 3. Stop light switch circuit 4. Brake actuator assembly (skid control ECU) BC-365 C1249/49 Open in Stop Light Switch Circuit 1. Stop light switch 2. Stop light switch circuit 3. Brake actuator assembly (skid control ECU) BC-368 C1271/71 Low Output Signal of Front Speed Sensor RH (Test Mode DTC) 1. Front speed sensor RH 2. Sensor installation 3. Speed sensor rotor BC-316 C1272/72 Low Output Signal of Front Speed Sensor LH (Test Mode DTC) 1. Front speed sensor LH 2. Sensor installation 3. Speed sensor rotor BC-316 C1273/73 Low Output Signal of Rear Speed Sensor RH (Test Mode DTC) 1. Rear speed sensor RH 2. Sensor installation 3. Speed sensor rotor BC-324 C1274/74 Low Output Signal of Rear Speed Sensor LH (Test Mode DTC) 1. Rear speed sensor LH 2. Sensor installation 3. Speed sensor rotor BC-324 C1275/75 Abnormal Change in Output Signal of Front Speed Sensor RH (Test Mode DTC) 1. Front speed sensosr RH 2. Sensor installation 3. Sensor rotor BC-316 C1276/76 Abnormal Change in Output Signal of Front Speed Sensor LH (Test Mode DTC) 1. Front speed sensosr LH 2. Sensor installation 3. Sensor rotor BC-316 C1277/77 Abnormal Change in Output Signal of Rear Speed Sensor RH (Test Mode DTC) 1. Rear speed sensosr RH 2. Sensor installation 3. Sensor rotor BC-324 C1278/78 Abnormal Change in Output Signal of Rear Speed Sensor LH (Test Mode DTC) 1. Rear speed sensosr LH 2. Sensor installation 3. Sensor rotor BC-324 C1288/88 ECU Version Miss Match ECM BC-374 C1300/62 Skid Control ECU Malfunction Brake actuator assembly (skid control ECU) BC-375 C1330/35 Right Front Speed Sensor Circuit 1. Front speed sensor RH 2. Front speed sensor circuit RH 3. Sensor installation BC-316 C1331/36 Left Front Speed Sensor Circuit 1. Front speed sensor LH 2. Front speed sensor circuit LH 3. Sensor installation BC-316 C1332/38 Right Rear Speed Sensor Circuit 1. Rear speed sensor RH 2. Rear speed sensor circuit RH 3. Sensor installation BC-324 BC–315 BC BC–316 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DTC No. Detection Item Trouble Area See page C1333/39 Left Rear Speed Sensor Circuit 1. Rear speed sensor LH 2. Rear speed sensor circuit LH 3. Sensor installation BC-324 U0073/94 Control Module Communication Bus OFF CAN communication system BC-377 (*1, *2): Even after the trouble areas are repaired, the ABS warning light will not go off unless the following operations are performed: • (*1): (a)Drive the vehicle at 12 mph (20 km/h) for 30 seconds or more and check that the ABS warning light goes off. (b)Clear the DTC. • (*2): (a)Keep the vehicle stationary for 5 seconds or more and depress the brake pedal lightly 2 or 3 times. (b)Drive the vehicle at the vehicle speed of 31 mph (50 km/h) and keep depressing the brake pedal strongly for approximately 3 seconds. (c) Repeat the above operation 3 times or more and check that the ABS warning light goes off. (d)Clear the DTC. HINT: In some cases, the intelligent tester cannot be used when the ABS warning light remains on. BC DTC chart of VSC: DTC No. 43 Detection Item Trouble Area See page ABS Control System Malfunction ABS control system BC-315 C0365/28 Malfunction in Deceleration Sensor 1. Yaw rate and acceleration sensor 2. Yaw rate and acceleration sensor circuit 3. Sensor installation 4. Brake actuator assembly (skid control ECU) BC-343 C1201/51 Engine Control System Malfunction Engine control system BC-347 C1231/31 Steering Angle Sensor Circuit Malfunction 1. Steering angle sensor 2. Steering angle sensor circuit 3. Steering angle sensor power supply BC-350 C1234/34 Yaw Rate Sensor Malfunction 1. Yaw rate and acceleration sensor 2. Yaw rate and acceleration sensor circuit BC-343 U0100/65 Lost Communication with ECM / PCM CAN communication system (skid control ECU to ECM) BC-377 U0123/62 Lost Communication with Yaw Rate Sensor Module CAN communication system (skid control ECU to yaw rate and acceleration sensor) BC-377 U0126/63 Lost Communication with Steering Angle Sensor Module CAN communication system (skid control ECU to steering angle sensor) BC-377 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DTC 43 BC–317 ABS Control System Malfunction DESCRIPTION This DTC is output when the VSC system detects a malfunction in the ABS control system. DTC No. 43 DTC Detection Condition Malfunction in the ABS control system Trouble Area ABS control system INSPECTION PROCEDURE 1 CHECK ABS CONTROL SYSTEM (a) Clear the DTC (See page BC-302). (b) Turn the ignition switch on (IG). (c) Check if the same DTC is recorded (See page BC-302). Result Condition Proceed to DTC (ABS control system DTC) is not output A DTC (ABS control system DTC) is output B B REPAIR CIRCUITS INDICATED BY OUTPUT DTCS (BRAKE CONTROL SYSTEM) (See page BC-311) A 2 CONFIRM DTC (a) Clear the DTC (See page BC-302). (b) Turn the ignition switch on (IG). (c) Check if the same DTC is recorded (See page BC-302). Result Condition Proceed to DTC (43) is not output A DTC (43) is output B B A END REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC BC–318 BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DTC C0200/31 Right Front Wheel Speed Sensor Signal Malfunction DTC C0205/32 Left Front Wheel Speed Sensor Signal Malfunction DTC C1271/71 Low Output Signal of Front Speed Sensor RH (Test Mode DTC) DTC C1272/72 Low Output Signal of Front Speed Sensor LH (Test Mode DTC) DTC C1275/75 Abnormal Change in Output Signal of Front Speed Sensor RH (Test Mode DTC) DTC C1276/76 Abnormal Change in Output Signal of Front Speed Sensor LH (Test Mode DTC) DTC C1330/35 Right Front Speed Sensor Circuit DTC C1331/36 Left Front Speed Sensor Circuit DESCRIPTION The speed sensors detects wheel speed and transmit the signals to the skid control ECU. These signals are used for control of the ABS control system. Each of the front and rear rotors has 48 serrations. When the rotors rotate, the magnetic field generated by the permanent magnet in the speed sensor induces AC voltage. Since the frequency of this AC voltage changes in direct proportion to the speed of the rotor, the frequency is used by the ECU to detect the speed of each wheel. DTCs C1271/71 to C1276/76 can be deleted when the speed sensor sends a wheel speed signal or the test mode ends. DTCs C1271/71 to C1276/76 are output only in the test mode. Speed Sensor Rotor Coil N S Magnet To ECU Low speed High speed +V -V F000010E16 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–319 DTC No. DTC Detecting Condition Trouble Area C0200/31 C0205/32 When either of the following is detected: • Vehicle speed is more than 25 mph (40 km/h), and pulses are not input for 0.03 sec. • When the vehicle speed has reached 8 mph (12 km/h) after the initial start or restart, a wheel speed of 0 mph (0 km/h) is detected. • • • • • Front speed sensor RH and/or LH Front speed sensor circuit RH and/or LH Front speed sensor rotor RH and/or LH Sensor installation Brake actuator assembly (skid control ECU) C1330/35 C1331/36 Abnormality in the resistance value of each speed sensor is detected. • • • Front speed sensor RH and/or LH Front speed sensor circuit RH and/or LH Sensor installation C1271/71 C1272/72 Detected only during test mode. • • • Front speed sensor Sensor installation Sensor rotor C1275/75 C1276/76 Detected only during test mode. • • • Front speed sensor Sensor installation Sensor rotor HINT: DTC No. C0200/31 and C1330/35 are for the front speed sensor RH. DTC No. C0205/32 and C1331/36 are for the front speed sensor LH. BC WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU with Actuator) A14 Front Speed Sensor LH 1 2 1 A35 Front Speed Sensor RH 2 5 A60 FL+ 6 A60 FL- 10 A60 FR+ 9 A60 FR- C122979E02 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). BC–320 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) READ VALUE OF INTELLIGENT TESTER (FRONT SPEED SENSOR) (a) Connect the intelligent tester to the DLC3. (b) Start the engine. (c) Select "DATA LIST" and read the value displayed on the intelligent tester (See page BC-307). DATA LIST: ABS/TRAC/VSC Measurement Item / Range (Display) Item Normal Condition FR WHEEL SPD Wheel speed sensor (FR) reading / min.: 0 MPH (0 km/h), max.: 202 MPH (326 km/h) Actual wheel speed FL WHEEL SPD Wheel speed sensor (FL) reading / min.: 0 MPH (0 km/h), max.: 202 MPH (326 km/h) Actual wheel speed (d) Check that there is no difference between the speed value output from the speed sensor displayed on the intelligent tester and the speed value displayed on the speedometer when driving the vehicle. OK: The speed value output from the speed sensor displayed on the intelligent tester is the same as the actual vehicle speed. BC NG Go to step 5 OK 2 PERFORM TEST MODE INSPECTION (SIGNAL CHECK) (a) Check if test mode (signal check) DTCs are detected (See page BC-290). Result Condition Proceed to Test mode (signal check) DTC is not output A Test mode (signal check) DTC is output B B A Go to step 5 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 3 BC–321 INSPECT SPEED SENSOR SIGNAL WAVEFORM A14 :LH FL+ FL- A35 :RH FR+ FR- Normal Signal Waveform: GND (a) Lift up the vehicle. (b) Perform the inspection using an oscilloscope. (1) Disconnect the front speed sensor connector. (2) Connect the oscilloscope to terminals 1 and 2 of the front speed sensor. (3) Check that a waveform is output when the tires are rotated. OK: The same waveform is output from front wheels and there is no noise or interference in the waveform. HINT: • As vehicle speed (wheel rotation speed) increases, the width of the waveform narrows and the output voltage becomes greater. • When noise is identified in the waveform on the oscilloscope, the erratic signals are generated due to rotor scratches, looseness or foreign matter attached to the speed sensor. (4) Connect the connector. NG 1 V/Division, 2 ms./Division Go to step 11 C136488E02 OK 4 RECONFIRM DTC (a) Clear the DTCs (See page BC-302). (b) Drive the vehicle at a speed of approximately 25 mph (40 km/h) or more for 60 seconds or more. (c) Check if the same DTCs are recorded (See page BC302). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTCs (C0200/31, C0205/32, C1330/35 and C1331/36) are output A DTCs (C0200/31, C0205/32, C1330/35 and C1331/36) are output (When troubleshooting in accordance with the PROBLEM SYMPTOMS TABLE) B DTCs (C0200/31, C0205/32, C1330/35 and C1331/36) are not output (When troubleshooting in accordance with the DTC CHART) C BC BC–322 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page BC-295) C END A 5 INSPECT FRONT SPEED SENSOR INSTALLATION (a) Check the front speed sensor installation. OK: The installation bolt is tightened properly. There is no clearance between the sensor and front steering knuckle. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) NOTICE: Check the speed sensor signal after replacement (See page BC-290). 8.0 N*m (82 kgf*cm, 71 in.*lbf) BC OK No clearance NG BR03795E21 NG INSTALL FRONT SPEED SENSOR CORRECTLY (See page BC-440) OK 6 INSPECT FRONT SPEED SENSOR 2 (a) Make sure that there is no looseness at the locking part and the connecting part of the connectors. (b) Disconnect the front speed sensor connectors. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: LH 1 C093876E01 Tester Connection Specified Condition A14-1 (FL+) - A14-2 (FL-) 0.92 to 1.22 kΩ at 20°C A14-1 (FL+) - Body ground 10 kΩ or higher A14-2 (FL-) - Body ground 10 kΩ or higher RH Tester Connection Specified Condition A35-1 (FR+) - A35-2 (FR-) 0.92 to 1.22 kΩ at 20°C A35-1 (FR+) - Body ground 10 kΩ or higher A35-2 (FR-) - Body ground 10 kΩ or higher NOTICE: Check the speed sensor signal after replacement (See page BC-290). NG REPLACE FRONT SPEED SENSOR (See page BC-438) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–323 OK 7 CHECK HARNESS AND CONNECTOR (FRONT SPEED SENSOR TO SKID CONTROL ECU) (a) Disconnect the skid control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: LH Skid Control ECU (Harness Side Connector Front View): FL+ FL- A60 Tester Connection Specified Condition A60-5 (FL+) - A14-1 (FL+) Below 1 Ω A60-6 (FL-) - A14-2 (FL-) Below 1 Ω A60-5 (FL+) - Body ground 10 kΩ or higher A60-6 (FL-) - Body ground 10 kΩ or higher Tester Connection Specified Condition A60-10 (FR+) - A35-1 (FR+) Below 1 Ω A60-9 (FR-) - A35-2 (FR-) Below 1 Ω RH FR- FR+ Front Speed Sensor (Harness Side Connecotor Front View): A14 A35 A60-10 (FR+) - Body ground 10 kΩ or higher A60-9 (FR-) - Body ground 10 kΩ or higher (c) Connect the connectors. NG FL- FL+ FR- FR+ C139143E01 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (FRONT SPEED SENSOR TO SKID CONTROL ECU) BC BC–324 8 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) INSPECT SPEED SENSOR SIGNAL WAVEFORM A14 :LH FL+ FL- (a) Lift up the vehicle. (b) Perform the inspection using an oscilloscope. (1) Disconnect the front speed sensor connector. (2) Connect the oscilloscope to terminals 1 and 2 of the front speed sensor. (3) Check that a waveform is output when the tires are rotated. OK: The same waveform is output from all the 4 wheels and there is no noise or interference in the waveform. HINT: • As vehicle speed (wheel rotation speed) increases, the width of the waveform narrows and the output voltage becomes greater. • When noise is identified in the waveform on the oscilloscope, the erratic signals are generated due to rotor scratches, looseness or foreign matter attached to the speed sensor. (4) Connect the connector. A35 :RH FR+ FR- Normal Signal Waveform: BC GND 1 V/Division, 2 ms./Division C136488E02 NG Go to step 11 OK 9 READ VALUE OF INTELLIGENT TESTER (FRONT SPEED SENSOR) (a) Connect the intelligent tester to the DLC3. (b) Start the engine. (c) Select "DATA LIST" and read the value displayed on the intelligent tester (See page BC-307). DATA LIST: ABS/TRAC/VSC Item Measurement Item / Range (Display) Normal Condition FR WHEEL SPD Wheel speed sensor (FR) reading / min.: 0 MPH (0 km/h), max.: 202 MPH (326 km/h) Actual wheel speed FL WHEEL SPD Wheel speed sensor (FL) reading / min.: 0 MPH (0 km/h), max.: 202 MPH (326 km/h) Actual wheel speed (d) Check that there is no difference between the speed value output from the speed sensor displayed on the intelligent tester and the speed value displayed on the speedometer when driving the vehicle. OK: The speed value output from the speed sensor displayed on the intelligent tester is the same as the actual vehicle speed. HINT: If troubleshooting has been carried out according to the "PROBLEM SYMPTOMS TABLE", refer back to the table and proceed to the next step before replacing the part (See page BC-295). BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) NG BC–325 REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) OK 10 RECONFIRM DTC (a) Clear the DTCs (See page BC-302). (b) Drive the vehicle at a speed of approximately 25 mph (40 km/h) or more for 60 seconds or more. (c) Check if the same DTCs are recorded (See page BC302). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTCs (C0200/31, C0205/32, C1330/35 and C1331/36) are output A DTCs (C0200/31, C0205/32, C1330/35 and C1331/36) are output (When troubleshooting in accordance with the PROBLEM SYMPTOMS TABLE) B DTCs (C0200/31, C0205/32, C1330/35 and C1331/36) are not output (When troubleshooting in accordance with the DTC CHART) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page BC-295) C END A 11 INSPECT SPEED SENSOR TIP Speed Sensor Rotor R000948E03 (a) Remove the front speed sensor. (b) Check the sensor tip. OK: No scratches or foreign matter on the sensor tip. NOTICE: Check the speed sensor signal after cleaning or replacement (See page BC-290). (c) Install the speed sensor. NG OK CLEAN OR REPLACE SPEED SENSOR ROTOR CLEAN OR REPLACE SPEED SENSOR BC BC–326 BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DTC C0210/33 Right Rear Wheel Speed Sensor Signal Malfunction DTC C0215/34 Left Rear Wheel Speed Sensor Signal Malfunction DTC C1273/73 Low Output Signal of Rear Speed Sensor RH (Test Mode DTC) DTC C1274/74 Low Output Signal of Rear Speed Sensor LH (Test Mode DTC) DTC C1277/77 Abnormal Change in Output Signal of Rear Speed Sensor RH (Test Mode DTC) DTC C1278/78 Abnormal Change in Output Signal of Rear Speed Sensor LH (Test Mode DTC) DTC C1332/38 Right Rear Speed Sensor Circuit DTC C1333/39 Left Rear Speed Sensor Circuit DESCRIPTION Refer to DTCs C0200/31, C0205/32, C1330/35, and C1331/36 (See page BC-316). DTCs from C1273/73 to C1278/78 can be deleted when the speed sensor sends a vehicle speed signal or the test mode ends. DTCs from C1273/73 to C1278/78 are output only in the test mode. DTC No. DTC Detecting Condition C0210/33 C0215/34 When either of the following is detected: • Vehicle speed is more than 25 mph (40 km/h) and pulses are not input for 0.03 sec. • When the vehicle speed has reached 8 mph (12 km/h), after the initial start or restart, a wheel speed of 0 mph (0 km/h) is detected. Trouble Area • • • • • Rear speed sensor RH and/or LH Rear speed sensor circuit RH and/or LH Rear speed sensor rotor RH and/or LH Sensor installation Brake actuator assembly (skid control ECU) C1332/38 C1333/39 Abnormality in the resistance value of each speed sensor is detected. • • • Rear speed sensor RH and/or LH Rear speed sensor circuit RH and/or LH Sensor installation C1273/73 C1274/74 Detected only during test mode. • • • Rear speed sensor Sensor installation Sensor rotor C1277/77 C1278/78 Detected only during test mode. • • • Rear speed sensor Sensor installation Sensor rotor HINT: DTC No. C0210/33 and C1332/38 are for the rear speed sensor RH. DTC No. C0215/34 and C1333/39 are for the rear speed sensor LH. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–327 WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU with Actuator) 1 7 A60 RL+ g1 Rear Speed Sensor LH 27 A60 RL- 2 BC 29 A60 RR+ 1 f1 Rear Speed Sensor RH 8 A60 RR- 2 C122948E03 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). 1 READ VALUE OF INTELLIGENT TESTER (REAR SPEED SENSOR) (a) Connect the intelligent tester to the DLC3. (b) Start the engine. (c) Select "DATA LIST" and read the value displayed on the intelligent tester (See page BC-307). DATA LIST: ABS/TRAC/VSC Item Measurement Item / Range (Display) Normal Condition RR WHEEL SPD Wheel speed sensor (RR) reading / min.: 0 MPH (0 km/h), max.: 202 MPH (326 km/h) Actual wheel speed RL WHEEL SPD Wheel speed sensor (RL) reading / min.: 0 MPH (0 km/h), max.: 202 MPH (326 km/h) Actual wheel speed (d) Check that there is no difference between the speed value output from the speed sensor displayed on the intelligent tester and the speed value displayed on the speedometer when driving the vehicle. BC–328 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) OK: The speed value output from the speed sensor displayed on the intelligent tester is the same as the actual vehicle speed. NG Go to step 5 OK 2 PERFORM TEST MODE INSPECTION (SIGNAL CHECK) (a) Check if test mode (signal check) DTCs are detected (See page BC-290). Result Condition Proceed to Test mode (signal check) DTC is not output A Test mode (signal check) DTC is output B BC B Go to step 5 A 3 INSPECT SPEED SENSOR SIGNAL WAVEFORM Skid Control ECU (Harness Side Connector Front View): A60 RL+ RR- RL- RR+ Normal Signal Waveform: GND (a) Lift up the vehicle. (b) Perform the inspection using an oscilloscope. (1) Disconnect the skid control ECU connector. (2) Connect the oscilloscope to the rear speed sensor terminals of the skid control ECU. (3) Check that a waveform is output when the tires are rotated. OK: The same waveform is output from all the 4 wheels and there is no noise or interference in the waveform. HINT: • As vehicle speed (wheel rotation speed) increases, the width of the waveform narrows and the output voltage becomes greater. • When noise is identified in the waveform on the oscilloscope, the erratic signals are generated due to rotor scratches, looseness or foreign matter attached to the speed sensor. (4) Connect the connector. NG 1 V/Division, 2 ms./Division C139144E01 REPAIR OR REPLACE SPEED SENSOR AND SENSOR ROTOR BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–329 OK 4 RECONFIRM DTC (a) Clear the DTCs (See page BC-302). (b) Drive the vehicle at a speed of approximately 25 mph (40 km/h) or more for 60 seconds or more. (c) Check if the same DTCs are recorded (See page BC302). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTCs (C0210/33, C0215/34, C1332/38 and C1333/39) are output A DTCs (C0210/33, C0215/34, C1332/38 and C1333/39) are output (When troubleshooting in accordance with the PROBLEM SYMPTOMS TABLE) B DTCs (C0210/33, C0215/34, C1332/38 and C1333/39) are not output (When troubleshooting in accordance with the DTC CHART) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page BC-295) C END A 5 INSPECT SPEED SENSOR INSTALLATION (a) Check the rear speed sensor installation. OK: There is no clearance between the sensor and rear axle carrier. NOTICE: Check the speed sensor signal after replacement (See page BC-290). No Clearance OK NG NG F010178E07 OK INSTALL REAR SPEED SENSOR CORRECTLY BC BC–330 6 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) INSPECT REAR SPEED SENSOR (a) Disconnect the rear speed sensor connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: LH Rear Speed Sensor: Tester Connection 2 g1-1 (RR+) - g1-2 (RR-) Below 2.2 kΩ g1-1 (RR+) - Body ground 10 kΩ or higher g1-2 (RR-) - Body ground 10 kΩ or higher Tester Connection Specified Condition RH 1 BC Specified Condition C113377E01 f1-1 (RL+) - f1-2 (RL-) Below 2.2 kΩ f1-1 (RL+) - Body ground 10 kΩ or higher f1-2 (RL-) - Body ground 10 kΩ or higher NOTICE: Check the speed sensor signal after replacement (See page BC-290). NG OK REPLACE REAR SPEED SENSOR (See page BC-443) BC–331 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 7 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU TO SKID CONTROL SENSOR WIRE) (a) Check the harness and connector. (1) Disconnect the skid control ECU connector and the rear speed sensor connector. (2) Disconnect the skid control sensor wire. (3) Measure the resistance according to the value(s) in the table below. Standard resistance: LH Skid Control ECU (Harness Side Connector Front View): A60 RL+ RL- RR- RR+ RL- f1 :RH RL+ RR- Specified Condition A60-7 (RL+) - g1-1 (RL+) Below 1 Ω A60-27 (RL-) - g1-2 (RL-) Below 1 Ω A60-7 (RL+) - Body ground 10 kΩ or higher A60-27 (RL-) - Body ground 10 kΩ or higher BC RH Rear Speed Sensor (Harness Side Connector Front View): g1 :LH Tester Connection RR+ NG Tester Connection Specified Condition A60-29 (RR+) - f1-1 (RR+) Below 1 Ω A60-8 (RR-) - f1-2 (RR-) Below 1 Ω A60-29 (RR+) - Body ground 10 kΩ or higher A60-8 (RR-) - Body ground 10 kΩ or higher REPAIR OR REPLACE HARNESS OR CONNECTOR (SKID CONTROL ECU TO SKID CONTROL SENSOR WIRE) C139145E02 OK 8 CHECK HARNESS AND CONNECTOR (SKID CONTROL SENSOR WIRE TO REAR SPEED SENSOR) Skid Control Sensor Wire: Vehicle Side Connector (a) Check harness and connector (skid control sensor wire). (1) Measure the resistance according to the value(s) in the table below. Standard resistance: LH Tester Connection g1 LH f1 RH A Specified Condition g1-1 - A-1 Below 1 Ω g1-1 - A-2 10 kΩ or higher g1-1 - Body ground 10 kΩ or higher g1-2 - A-2 Below 1 Ω g1-2 - A-1 10 kΩ or higher g1-2 - Body ground 10 kΩ or higher Tester Connection Specified Condition f1-1 - A-1 Below 1 Ω RH Sensor Side Connector C113396E05 BC–332 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) Tester Connection Specified Condition f1-1 - A-2 10 kΩ or higher f1-1 - Body ground 10 kΩ or higher f1-2 - A-2 Below 1 Ω f1-2 - A-1 10 kΩ or higher f1-2 - Body ground 10 kΩ or higher (2) Connect the connector. NG REPAIR OR REPLACE SKID CONTROL SENSOR WIRE OK 9 BC INSPECT SPEED SENSOR SIGNAL WAVEFORM Skid Control ECU (Harness Side Connector Front View): A60 RL+ RR- RL- RR+ Normal Signal Waveform: GND (a) Lift up the vehicle. (b) Perform the inspection using an oscilloscope. (1) Disconnect the skid control ECU connector. (2) Connect the oscilloscope to the rear speed sensor terminals of the skid control ECU. (3) Check that a waveform is output when the tires are rotated. OK: The same waveforms is output from rear wheels and there is no noise or interference in the waveform. HINT: • As vehicle speed (wheel rotation speed) increases, the width of the waveform narrows and the output voltage becomes greater. • When noise is identified in the waveform on the oscilloscope, the erratic signals are generated due to rotor scratches, looseness or foreign matter attached to the speed sensor. (4) Connect the connector. NG CLEAN OR REPLACE SPEED SENSOR AND SENSOR ROTOR 1 V/Division, 2 ms./Division C139144E01 OK 10 READ VALUE OF INTELLIGENT TESTER (REAR SPEED SENSOR) (a) Connect the intelligent tester to the DLC3. (b) Start the engine. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–333 (c) Select "DATA LIST" and read the value displayed on the intelligent tester (See page BC-307). DATA LIST: ABS/TRAC/VSC Measurement Item / Range (Display) Item Normal Condition RR WHEEL SPD Wheel speed sensor (RR) reading / min.: 0 MPH (0 km/h), max.: 202 MPH (326 km/h) Actual wheel speed RL WHEEL SPD Wheel speed sensor (RL) reading / min.: 0 MPH (0 km/h), max.: 202 MPH (326 km/h) Actual wheel speed (d) Check that there is no difference between the speed value output from the speed sensor displayed on the intelligent tester and the speed value displayed on the speedometer when driving the vehicle. OK: The speed value output from the speed sensor displayed on the intelligent tester is the same as the actual vehicle speed. HINT: • It is suspected that the DTCs were output due to a bad connection of the connector terminal. • If troubleshooting has been carried out according to the "PROBLEM SYMPTOMS TABLE", refer back to the table and proceed to the next step (See page BC295). NG REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) OK 11 RECONFIRM DTC (a) Clear the DTCs (See page BC-302). (b) Drive the vehicle at a speed of approximately 25 mph (40 km/h) or more for 60 seconds or more. (c) Check if the same DTCs are recorded (See page BC302). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTCs (C0210/33, C0215/34, C1332/38 and C1333/39) are output A DTCs (C0210/33, C0215/34, C1332/38 and C1333/39) are output (When troubleshooting in accordance with the PROBLEM SYMPTOMS TABLE) B DTCs (C0210/33, C0215/34, C1332/38 and C1333/39) are not output (When troubleshooting in accordance with the DTC CHART) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page BC-295) C END BC BC–334 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) A 12 INSPECT SPEED SENSOR ROTOR (a) Turn the ignition switch off. (b) Remove the rear axle. (c) Check the rotor. OK: No scratches, cracks, oil, or foreign matter on the rotors. NOTICE: Check the speed sensor signal after cleaning or replacement (See page BC-290). (d) Install the rear axle. NG BC CLEAN OR REPLACE SPEED SENSOR ROTOR OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DTC C0226/21 SFR Solenoid Circuit DTC C0236/22 SFL Solenoid Circuit DTC C0246/23 SRR Solenoid Circuit DTC C0256/24 SRL Solenoid Circuit BC–335 DESCRIPTION These solenoids turn on when signals are received from the skid control ECU and they control the pressure acting on the wheel cylinders to control the braking force. DTC No. DTC Detection Condition Trouble Area C0226/21 C0236/22 C0246/23 C0256/24 Solenoid valve signal does not match the check result. • • Each solenoid circuit Brake actuator assembly BC WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) ALT FL MAIN ABS No. 2 3 A60 +BS 4 A60 GND1 1 A60 GND2 Battery C131988E04 BC–336 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) INSPECTION PROCEDURE 1 RECONFIRM DTC HINT: These codes are detected when a problem is identified in the brake actuator assembly. The solenoid circuits are located in the brake actuator assembly. Therefore, solenoid circuit inspection and solenoid unit inspection cannot be performed. Be sure to check if the DTC is output before replacing the brake actuator assembly. (a) Clear the DTC (See page BC-302). (b) Start the engine. (c) Drive the vehicle at a speed of 12 mph (20 km/h) or more for 30 seconds or more. (d) Check if the same DTC is recorded (See page BC-302). BC Result Condition Proceed to DTC is not output A DTC is output B HINT: • If the normal system code is output (the trouble code is not output), slightly jiggle the connectors, wire harness, and fuses of the brake actuator assembly (skid control ECU). Make sure that no DTCs are output. • If any DTCs are output while jiggling a connector or wire harness of the brake actuator (skid control ECU), inspect and repair the connector or wire harness. • It is suspected that the DTCs were output due to a bad connection of the connector terminal. B A END REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DTC BC–337 Open or Short Circuit in ABS Motor Relay Circuit C0273/13 DESCRIPTION The ABS motor relay supplies power to the ABS pump motor. While the ABS is activated, the ECU switches the motor relay on and operates the ABS pump motor. If the voltage supplied to the motor relay (+BM) is below the DTCs detection threshold due to low voltage from the battery or alternator, the DTC may be stored. DTC No. DTC Detection Condition C0273/13 When any of the following is detected: • When the motor relay is actuated, voltage is not supplied to the pump motor within 0.1 seconds. • For 30 to 125 ms after the motor relay is turned from ON to OFF, the remaining high voltage is out of range. The motor relay is turned from ON to OFF 3 times. If the voltage is still out of range in the 3rd operation, this failure is detected. • When the motor relay is changed from ON to OFF, the remaining high voltage is more than 2 V for 1 second. Trouble Area • • • ABS No. 1 fuse (Fusible link) Brake actuator assembly (skid control ECU) Motor relay circuit BC WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) ALT ABS No. 1 2 A60 +BM 4 FL MAIN A60 GND1 1 A60 GND2 Battery C131988E05 INSPECTION PROCEDURE HINT: • When C1241/41 is output together with C0273/13, inspect and repair the trouble areas indicated by C1241/41 (See page BC-361). BC–338 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) • Check the condition of each related circuit connector before troubleshooting (See page IN-40). 1 INSPECT FUSIBLE LINK (ABS NO. 1 FUSE) Engine Room R/B Fusible Link (a) Remove the fusible link from the engine room R/B. (b) Check if the fusible link is malted. OK: The fusible link is not melted. (c) Install the fusible link to the engine room R/B with the nut. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) NG REPLACE FUSIBLE LINK ABS No. 1 BC C136500E04 OK 2 INSPECT SKID CONTROL ECU (+BM TERMINAL VOLTAGE) (a) Disconnect the skid control ECU connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control ECU (Harness Side Connector Front View): A60 Tester Connection Condition Specified Condition A60-2 (+BM) - Body ground Always 10 to 14 V NG +BM C136493E01 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (+BM CIRCUIT) BC–339 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 3 INSPECT SKID CONTROL ECU (GND TERMINAL CONTINUITY) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU (Harness Side Connector Front View): A60 Tester Connection Specified Condition A60-4 (GND1) - Body ground Below 1 Ω A60-1 (GND2) - Body ground Below 1 Ω (b) Connect the connector. NG GND2 REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) GND1 BC C136493E02 OK 4 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (ABS MOTOR RELAY) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Select "ACTIVE TEST" on the intelligent tester (See page BC-307). ACTIVE TEST: ABS/TRAC/VSC Item ABS MTR RELAY Measurement Item/Range (Display) Turns ABS motor relay ON/OFF Normal Condition Operating sound of motor is heard. (d) Check the operating sound of the ABS motor relay when operating it with the intelligent tester. OK: The operating sound of the ABS motor relay is heard. NG REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) OK 5 RECONFIRM DTC HINT: This code is detected when a problem is identified in the brake actuator assembly. The ABS motor relay is located in the brake actuator assembly. Therefore, ABS motor relay inspection and motor relay unit inspection cannot be performed. Be sure to check if the DTC is output before replacing the brake actuator assembly. (a) Clear the DTC (See page BC-302). BC–340 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) (b) Start the engine. (c) Drive the vehicle at a speed of 12 mph (20 km/h) or more for 30 seconds or more. (d) Check if the same DTC is recorded (See page BC-302). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTC is not output A DTC is output B HINT: • If the normal system code is output (the trouble code is not output), slightly jiggle the connectors, wire harness, and fuses of the brake actuator assembly (skid control ECU). Make sure that no DTCs are output. • If any DTCs are output while jiggling a connector or wire harness of the brake actuator assembly (skid control ECU), inspect and repair the connector or wire harness. • It is suspected that the DTCs were output due to a bad connection of the connector terminal. BC B REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) A CHECK FOR INTERMITTENT PROBLEMS (SYMPTOM SIMULATION) (See page BC-298) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DTC C0278/11 BC–341 Open or Short Circuit in ABS Solenoid Relay Circuit DESCRIPTION The ABS solenoid relay supplies power to the ABS solenoid. The solenoid relay is turned on 1.5 seconds after the ignition switch is turned on (IG), and is turned off if an open or short in the solenoid is detected by self diagnosis performed when the vehicle starts running. The ABS solenoid relay is housed in the skid control ECU in the brake actuator assembly. HINT: If a speed signal of 4 mph (6 km/h) or more is input to the skid control ECU, with the ignition switch on (IG) and the stop light switch off, the skid control ECU performs self diagnosis of the motor and solenoid circuits. DTC No. C0278/11 DTC Detection Condition Trouble Area When any of the following is detected: • When the relay is ON, the voltage is less than IG terminal voltage x 0.8 V for 0.5 seconds. • When the relay is OFF, the voltage is out of range (IG terminal voltage x 0.1 to IG terminal voltage x 0.8). • • • ABS No. 2 fuse (Fusible link) Brake actuator assembly (skid control ECU) Solenoid relay circuit WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) ALT FL MAIN ABS No. 2 3 A60 +BS 4 A60 GND1 1 A60 GND2 Battery C131988E04 BC BC–342 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) INSPECTION PROCEDURE HINT: • When C1241/41 is output together with C0278/11, inspect and repair the trouble areas indicated by C1241/41 (See page BC-361). • Check the condition of each related circuit connector before troubleshooting (See page IN-40). 1 INSPECT FUSIBLE LINK (ABS NO. 2 FUSE) (a) Remove the fusible link from the engine room R/B. (b) Check if the fusible link is melted. OK: The fusible link is not melted. (c) Install the fusible link to the engine room R/B with the nut. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) Engine Room R/B NG REPLACE FUSIBLE LINK BC ABS No. 2 C136500E05 OK 2 INSPECT SKID CONTROL ECU (+BS TERMINAL VOLTAGE) (a) Disconnect the skid control ECU connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control ECU (Harness Side Connector Front View): A60 Tester Connection Condition Specified Condition A60-3 (+BS) - Body ground Always 10 to 14 V NG +BS C136493E03 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (+BS CIRCUIT) BC–343 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 3 INSPECT SKID CONTROL ECU (GND TERMINAL CONTINUITY) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU (Harness Side Connector Front View): A60 Tester Connection Specified Condition A60-4 (GND1) - Body ground Below 1 Ω A60-1 (GND2) - Body ground Below 1 Ω (b) Connect the connector. NG GND2 REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) GND1 BC C136493E02 OK 4 RECONFIRM DTC HINT: This code is detected when a problem is identified in the brake actuator assembly. The solenoid circuit is located in the brake actuator assembly. Therefore, solenoid circuit inspection and solenoid unit inspection cannot be performed. Be sure to check if the DTC code is output before replacing the brake actuator assembly. (a) Clear the DTC (See page BC-302). (b) Start the engine. (c) Drive the vehicle at a speed of 12 mph (20 km/h) or more for 30 seconds or more. (d) Check if the same DTC is recorded (See page BC-302). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTC is not output A DTC is output B HINT: • If the normal system code is output (the trouble code is not output), slightly jiggle the connectors, wire harnesses, and fuses of the brake actuator assembly. Make sure that no DTCs are output. • If any DTCs are output while jiggling a connector or wire harness of the brake actuator (skid control ECU), inspect and repair the connector or wire harness. • It is suspected that the DTCs were output due to a bad connection of the connector terminal. BC–344 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) B REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) A CHECK FOR INTERMITTENT PROBLEMS (SYMPTOM SIMULATION) (See page BC-298) BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DTC C0365/28 Malfunction in Deceleration Sensor DTC C1234/34 Yaw Rate Sensor Malfunction BC–345 DESCRIPTION The deceleration sensor is combined with the yaw rate and acceleration sensor. The brake actuator receives signals from the yaw rate and acceleration sensor via the CAN communication system. If there is trouble in the CAN communication system, DTCs U0073/94 and U0123/62 are output. DTC No. C0365/28 DTC Detection Condition When any of the following is detected: • Lateral acceleration difference between sensor signal and reference value is large. • Offset value of sensor signal is higher than the standard value. • C1234/34 Trouble Area • • • • Yaw rate and acceleration sensor Yaw rate and acceleration sensor circuit Sensor installation Brake actuator assembly (skid control ECU) • • Yaw rate and acceleration sensor Yaw rate and acceleration sensor circuit Sensor signal is out of range (2.25 m/s2). Sensor malfunction signal is received from the yaw rate sensor. BC BC–346 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) E65 Yaw Rate and Acceleration Sensor CANH ECU IG No. 2 1 IG 35 A60 2 CANH 14 CANL GND A60 3 CANL 4 IG1 BC 5 3 2 1 E23 Ignition SW (*2) AM1 (*2) 4 AM1 IG1 1 (*1) Main Body ECU ALT (*1) 6 E7 AM1 IG1D 1 AM2 E6 3 E7 AM2 FL MAIN Battery *1: with Smart Key System *2: without Smart Key System C136507E01 INSPECTION PROCEDURE HINT: • Check the condition of each related circuit connector before troubleshooting (See page IN-40). BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–347 • When U0073/94, U0100/65, U0123/62 and/or U0126/63 is output together with C0365/28, inspect and repair the trouble areas indicated by U0073/94, U0100/65, U0123/62 and/or U0126/63 first. 1 CHECK DTC (a) Clear the DTCs (See page BC-302). (b) Start the engine. (c) At a speed of 18 mph (30 km/h) or more, drive the vehicle, turn the steering wheel, and decelerate (depress the brake pedal) the vehicle. (d) Turn the ignition switch on (IG) again and check that no CAN communication system DTC is output (See page BC-302). Result Condition Proceed to CAN communication system DTC is not output A CAN communication system DTC is output B B INSPECT CAN COMMUNICATION SYSTEM (See page CA-8) A 2 INSPECT YAW RATE AND ACCELERATION SENSOR INSTALLATION (a) Check that the yaw rate and acceleration sensor has been installed properly (See page BC-448). OK: The sensor should be tightened to the specified torque. The sensor should not be titled. NG INSTALL YAW RATE AND ACCELERATION SENSOR CORRECTLY OK 3 INSPECT YAW RATE AND ACCELERATION SENSOR (IG TERMINAL) (a) Disconnect the yaw rate and acceleration sensor connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Yaw Rate and Acceleration Sensor (Harness Side Connector Front View): E65 IG Tester Connection Condition Specified Condition E65-1 (IG) - Body ground Ignition switch on (IG) 10 to 14 V F048983E13 NG REPAIR OR REPLACE HARNESS OR CONNECTOR (IG CIRCUIT) BC BC–348 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) OK 4 INSPECT YAW RATE AND ACCELERATION SENSOR (GND TERMINAL) (a) Turn the ignition switch off. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Yaw Rate and Acceleration Sensor (Harness Side Connector Front View): E65 GND Tester Connection Condition Specified Condition E65-4 (GND) - Body ground Always Below 1 Ω NG F048983E12 REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) OK BC 5 RECONFIRM DTC (a) Clear the DTCs (See page BC-302). (b) Start the engine. (c) At a speed of 18 mph (30 km/h) or more, drive the vehicle, turn the steering wheel, and decelerate (depress the brake pedal) the vehicle. (d) Turn the ignition switch on (IG) again and check that no CAN communication system DTC is output (See page BC-302). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTC is output A DTC is output (When troubleshooting in accordance with the PROBLEM SYMPTOMS TABLE) B DTC is not output (When troubleshooting in accordance with the DTC CHART) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page BC-295) C CHECK FOR INTERMITTENT PROBLEMS (SYMPTOM SIMULATION) (See page BC-298) A REPLACE YAW RATE AND ACCELERATION SENSOR (See page BC-447) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DTC BC–349 C1201/51 Engine Control System Malfunction DESCRIPTION If a malfunction in the engine control system is detected, the operations of VSC and TRAC are prohibited by the fail safe function (See page BC-306). When the signals from the engine are input normally, the fail safe is cancelled and the DTC is not stored. DTC No. C1201/51 DTC Detecting Condition Trouble Area A trouble signal in the engine control system is input. Engine control system INSPECTION PROCEDURE 1 CHECK DTC (ENGINE CONTROL SYSTEM) (a) Clear the DTC (engine control system) (See page ES-38 for 2AZ-FE, ES-45 for 2GR-FE). (b) Perform a road test. (c) Check for the DTC (engine control system). Result Display (DTC Output) Proceed to DTC (engine control system) is not output A DTC (engine control system) is output B B A REPLACE ECM REPAIR CIRCUITS INDICATED BY OUTPUT DTCS (ENGINE CONTROL SYSTEM) BC BC–350 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DTC C1225/25 SMC Solenoid Circuit DTC C1226/26 SMC Solenoid Circuit DTC C1227/27 SRC Solenoid Circuit DTC C1228/28 SRC Solenoid Circuit DESCRIPTION These solenoids turn on when signals are received from the skid control ECU and they control the pressure acting on the wheel cylinders to control the braking force. DTC No. BC DTC Detecting Condition Trouble Area C1225/25 Solenoid valve signal does not match the check result • • Brake actuator assembly (skid control ECU) SMC1 circuit C1226/26 Solenoid valve signal does not match the check result • • Brake actuator assembly (skid control ECU) SMC2 circuit C1227/27 Solenoid valve signal does not match the check result • • Brake actuator assembly (skid control ECU) SRC1 circuit C1228/28 Solenoid valve signal does not match the check result • • Brake actuator assembly (skid control ECU) SRC2 circuit WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) ALT FL MAIN ABS No. 2 3 A60 +BS 4 A60 GND1 1 A60 GND2 Battery C131988E04 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–351 INSPECTION PROCEDURE 1 RECONFIRM DTC HINT: These codes are detected when a problem is identified in the brake actuator assembly. The solenoid circuits are located in the brake actuator assembly. Therefore, solenoid circuit inspection and solenoid unit inspection cannot be performed. Be sure to check if the DTC is output before replacing the brake actuator assembly. (a) Clear the DTC (See page BC-302). (b) Start the engine. (c) Drive the vehicle at a speed of 12 mph (20 km/h) or more for 30 seconds or more. (d) Check if the same DTC is recorded (See page BC-302). Result Condition Proceed to DTC is not output A DTC is output B HINT: • If the normal system code is output (the trouble code is not output), slightly jiggle the connectors, wire harness, and fuses of the brake actuator assembly (skid control ECU). Make sure that no DTCs are output. • If any DTCs are output while jiggling a connector or wire harness of the brake actuator (skid control ECU), inspect and repair the connector or wire harness. • It is suspected that the DTCs were output due to a bad connection of the connector terminal. B A END REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC BC–352 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DTC C1231/31 Steering Angle Sensor Circuit Malfunction DESCRIPTION The steering angle sensor signal is sent to the skid control ECU via the CAN communication system. When there is a malfunction in the CAN communication system, it will be detected by the steering angle sensor zero point malfunction diagnostic function. BC DTC No. DTC Detection Condition C1231/31 When any of the following is detected: • With ECU terminal IG1 voltage 9.8 V or more, the condition that the ECU does not receive data from the steering angle sensor continues. • Internal sensor failure • The offset value is out of range. • Sensor signal changes too rapidly. • Steering angle value difference between measured and reference is out of range. • Steering angle sensor signal is out of range. Trouble Area • • • Steering angle sensor Steering angle sensor circuit Steering angle sensor power supply BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–353 WIRING DIAGRAM E17 Steering Angle Sensor Brake Actuator Assembly (Skid Control ECU) 35 SHORT 1 ECU IB No. 1 3 2 ECU IG No. 2 1 BATT A60 CANH CANH 10 14 A60 CANL CANL 9 IG ESS 2 IG1 BC 5 3 2 1 E23 Ignition SW (*2) AM1 (*2) 4 AM1 ALT (*1) Main Body ECU 6 E7 (*1) IG1 1 AM2 1 E6 AM1 IG1D 3 E7 AM2 FL MAIN Battery *1: with Smart Key System *2: without Smart Key System C136508E01 BC–354 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) INSPECTION PROCEDURE HINT: • When U0073/94, U0100/63, U0123/62 and/or U0126/63 is output together with C1231/31, inspect and repair the trouble areas indicated by U0073/94, U0100/65, U0123/62 and/or U0126/63 first. • When the speed sensor or the yaw rate and acceleration sensor has trouble, DTCs for the steering angle sensor may be output even when the steering angle sensor is normal. When DTCs for the speed sensor or yaw rate and acceleration sensor are output together with other DTCs for the steering angle sensor, inspect and repair the speed sensor and yaw rate and acceleration sensor first, and then inspect and repair the steering angle sensor. • Check the condition of each related circuit connector before troubleshooting (See page IN-40). 1 CHECK DTC (a) Clear the DTC (See page BC-302). (b) Turn the ignition switch off. (c) Turn the ignition switch on (IG) again and check that no CAN communication system DTC is output. (d) Drive the vehicle and turn the steering wheel to the right and left at the speed of 22 mph (35 km/h) and check that no speed sensor and yaw rate and acceleration sensor DTCs are output (See page BC-302). BC Result Condition Proceed to No CAN communication system DTC and the speed sensor or yaw rate and acceleration sensor DTC are output A CAN communication system DTC is output B Speed sensor or yaw rate and acceleration sensor DTC is output C HINT: • If there is a malfunction in the speed sensor or the yaw rate and acceleration sensor, an abnormal value may be output although the steering angle sensor is normal. • If the speed sensor and the yaw rate and acceleration sensor DTCs are output simultaneously, repair the sensors and inspect the steering angle sensor. A B INSPECT CAN COMMUNICATION SYSTEM (See page CA-8) C REPAIR CIRCUITS INDICATED BY OUTPUT DTCS (See page BC-311) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 2 BC–355 INSPECT STEERING ANGLE SENSOR (POWER SOURCE TERMINAL) (a) Remove the column cover lower. (b) Disconnect the steering angle sensor connector. (c) Measure the voltage according to the value(s) in the table below. Standard voltage Steering Angle Sensor Wire Harness View: E17 IG Tester Connection Condition Specified Condition E17-1 (IG) - Body ground Ignition switch on (IG) 10 to 14 V E17-3 (BAT) - Body ground Always 10 to 14 V NG BATT REPAIR OR REPLACE HARNESS OR CONNECTOR (POWER SOURCE CIRCUIT) BC G030156E17 OK 3 INSPECT STEERING ANGLE SENSOR (GROUND TERMINAL) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Steering Angle Sensor Wire Harness View: E17 Tester Connection Condition Specified Condition E17-2 (ESS) - Body ground Always Below 1 Ω (b) Connect the connector. (c) Install the column cover lower. NG REPAIR OR REPLACE HARNESS OR CONNECTOR (GROUND CIRCUIT) ESS G030156E18 OK REPLACE STEERING ANGLE SENSOR (See page BC-450) BC–356 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DTC C1237/37 Tires of Different Size DESCRIPTION The skid control ECU measures the speed of each wheel by receiving signals from the speed sensor. These signals are used for recognizing that all 4 wheels are operating properly. Therefore, all wheel signals must be equal. DTC No. C1237/37 DTC Detecting Condition When any of the following is detected: • Wheel speed difference between the wheels. • Wheel sensor signal failure. • ABS control continues for 60 sec. or more. Trouble Area • • • • • • • Brake actuator assembly (skid control ECU) Speed sensor rotor (Front) Rear axle hub and bearing assembly Speed sensor Speed sensor circuit Tire and wheel size Tire deformation WIRING DIAGRAM BC Brake Actuator Assembly (Skid Control ECU with Actuator) A14 Front Speed Sensor LH 1 2 1 A35 Front Speed Sensor RH 2 5 A60 FL+ 6 A60 FL- 10 A60 FR+ 9 A60 FR- C122979E02 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–357 Brake Actuator Assembly (Skid Control ECU with Actuator) 1 g1 Rear Speed Sensor LH 2 1 f1 Rear Speed Sensor RH 2 7 A60 RL+ 27 A60 RL- 29 A60 RR+ BC 8 A60 RR- C122948E04 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). 1 CHECK TIRES (a) Check the size and condition of all 4 wheels (See page TW-3). HINT: The DTC is output when tire deformation or a difference in tire size is detected. OK: The diameter of all 4 tires and air pressure are the same. NG OK REPLACE TIRES SO THAT ALL 4 TIRES ARE THE SAME SIZE BC–358 2 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) INSPECT SPEED SENSOR AND SENSOR ROTOR SERRATIONS Skid Control ECU (Harness Side Connector Front View): A60 FL- RL+ FL+ RL- RRFR- (a) Lift up the vehicle. (b) Disconnect the skid control ECU connector. (c) Connect the oscilloscope to each speed sensor terminal of the skid control ECU connector. Terminals Connector FR+ Circuit A60-5 (FL+) - A60-6 (FL-) Front left speed sensor A60-10 (FR+) - A60-9 (FR-) Front right speed sensor A60-7 (RL+) - A60-27 (RL-) Rear left speed sensor A60-29 (RR+) - A60-8 (RR-) Rear right speed sensor RR+ BC C136493E04 Normal Signal Waveform: GND 1 V/Division, 2 ms./Division C140980E03 (d) Check that a waveform is output when the tires are rotated (by the sensor circuit). OK: A waveform as shown in the figure is output. HINT: • Each sensor circuit outputs the same waveform without noise. • As vehicle speed (wheel rotation speed) increases, the width of the waveform narrows and the fluctuation in the output voltage becomes greater. • When noise is identified in the waveform on the oscilloscope, the erratic signals are generated due to rotor scratches, looseness or foreign matter attached to the speed sensor. (e) Make sure that the waveform does not change while jiggling a connector or a wire harness. OK: The waveform does not change. HINT: If the waveform changes while jiggling a connector or a wire harness, there may be a malfunction in the connector or the wire harness. (f) Connect the connector. NG Go to step 4 OK 3 RECONFIRM DTC (a) Clear the DTC (See page BC-302). (b) Start the engine. (c) Drive the vehicle at a speed of 20 mph (32 km/h) or more for 60 seconds or more. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–359 (d) Check if the same DTC is recorded (See page BC-302). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTC is not output A DTC is output B B REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) A CHECK FOR INTERMITTENT PROBLEMS (SYMPTOM SIMULATION) (See page BC-298) 4 BC CHECK SPEED SENSOR ROTOR (a) Check the speed sensor rotor. Front Speed Sensor Rotor (Front drive outboard joint shaft assembly): (See page DS-23) Rear Speed Sensor Rotor (Rear axle hub and bearing assembly): (See page AH-14) OK: No scratches or foreign matter on the rotors. NOTICE: Check the speed sensor signal after the cleaning/ replacement (See page BC-290). NG CLEAN OR REPLACE SPEED SENSOR ROTOR OK 5 CHECK SPEED SENSOR TIP (a) Remove each speed sensor (See page BC-438 for front, BC-443 for rear). (b) Check the speed sensor tip. OK: No scratches or foreign matter on the sensor tip. NOTICE: Check the speed sensor signal after the cleaning/ replacement (See page BC-290). (c) Install the speed sensor. NG OK CLEAN OR REPLACE SPEED SENSOR BC–360 6 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) INSPECT SPEED SENSOR (a) Disconnect each speed sensor connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: FRONT Front Speed Sensor: 1 BC 2 Rear Speed Sensor: Tester Connection Condition Specified Condition A14-1 (FL+) - A14-2 (FL) Always 0.92 to 1.22 kΩ at 20°C A14-1 (FL+) - Body ground Always 10 kΩ or higher A14-2 (FL-) - Body ground Always 10 kΩ or higher A35-1 (FR+) - A35-2 (FR-) Always 0.92 to 1.22 kΩ at 20°C A35-1 (FR+) - Body ground Always 10 kΩ or higher A35-2 (FR-) - Body ground Always 10 kΩ or higher REAR 2 1 Tester Connection Condition Specified Condition g1-1 (RL+) - g1-2 (RL-) Always Below 2.2 kΩ g1-1 (RL+) - Body ground Always 10 kΩ or higher g1-2 (RL-) - Body ground Always 10 kΩ or higher f1-1 (RR+) - f1-2 (RR-) Always Below 2.2 kΩ f1-1 (RR+) - Body ground Always 10 kΩ or higher f1-2 (RR-) - Body ground Always 10 kΩ or higher C136027E02 NOTICE: Check the speed sensor signal after replacement (See page BC-290). NG OK REPLACE EACH SPEED SENSOR BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 7 BC–361 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU TO EACH SPEED SENSOR) Skid Control ECU (Harness Side Connector Front View): A60 RRFL- RL+ FRFR+ FL+ RL- RR+ Front Speed Sensor Harness Side Connector Front View: A14 A35 FL- FL+ FR- FR+ (a) Disconnect the skid control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: FRONT Tester Connection Condition Specified Condition A60-5 (FL+) - A14-1 (FL+) Always Below 1 Ω A60-5 (FL+) - Body ground Always 10 kΩ or higher A60-6 (FL-) - A14-2 (FL-) Always Below 1 Ω A60-6 (FL-) - Body ground Always 10 kΩ or higher A60-10 (FR+) - A35-1 (FR+) Always Below 1 Ω A60-10 (FR+) - Body ground Always 10 kΩ or higher A60-9 (FR-) - A35-2 (FR) Always Below 1 Ω A60-9 (FR-) - Body ground Always 10 kΩ or higher Tester Connection Condition Specified Condition A60-7 (RL+) - g1-1 (RL+) Always Below 1 Ω A60-7 (RL+) - Body ground Always 10 kΩ or higher A60-27 (RL-) - g1-2 (RL) Always Below 1 Ω A60-27 (RL-) - Body ground Always 10 kΩ or higher A60-29 (RR+) - f1-1 (RR+) Always Below 1 Ω A60-29 (RR+) - Body ground Always 10 kΩ or higher A60-8 (RR-) - f1-2 (RR-) Always Below 1 Ω A60-8 (RR-) - Body ground Always 10 kΩ or higher REAR Rear Speed Sensor Harness Side Connector Front View: g1 f1 RL- RL+ RR- RR+ C139146E02 (c) Connect the connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR (SKID CONTROL ECU TO EACH SPEED SENSOR) OK 8 RECONFIRM DTC (a) Clear the DTC (See page BC-302). (b) Start the engine. BC BC–362 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) (c) Drive the vehicle at a speed of 20 mph (32 km/h) or more for at least 60 seconds. (d) Check if the same DTC is recorded (See page BC-302). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTC (C1237/37) is not output A DTC (C1237/37) is output B B REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) A BC CHECK FOR INTERMITTENT PROBLEMS (SYMPTOM SIMULATION) (See page BC-298) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DTC C1241/41 BC–363 Low Battery Positive Voltage or Abnormally High Battery Positive Voltage DESCRIPTION If a malfunction is detected in the power supply circuit of the brake actuator assembly (skid control ECU), the skid control ECU (housed in the actuator assembly) stores this DTC and the fail-safe function prohibits ABS operation. This DTC is output when the IG1 terminal voltage deviates from the normal condition due to a malfunction in the power supply or charging circuit such as the battery or alternator circuit. This DTC is cancelled when the IG1 terminal voltage returns to normal (only when the voltage returns to normal from a voltage lower than the specified value). DTC No. C1241/41 DTC Detection Condition When either of the following is detected: • Battery voltage is 16.8 V or more. • Battery voltage is 9.2 V or less. Trouble Area • • • • • Battery ECU-IG No. 2 fuse Charging system Power source circuit Brake actuator assembly (internal power source circuit) BC BC–364 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) IG1 ECU IG No. 2 5 3 2 1 28 A60 IG1 4 A60 GND1 1 A60 GND2 E23 Ignition SW BC (*2) AM1 (*2) 4 AM1 IG1 1 Main Body ECU ALT (*1) 6 E7 (*1) AM2 AM1 IG1D 1 E6 3 AM2 FL MAIN Battery E7 *1: with Smart Key System *2: without Smart Key System C136502E02 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–365 INSPECTION PROCEDURE 1 INSPECT FUSE (ECU-IG NO. 2 FUSE) (a) Remove the ECU-IG No. 2 fuse from the instrument panel J/B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Instrument Panel J/B: ECU-IG No. 2 Fuse Tester Connection Specified Condition ECU-IG No. 2 fuse Below 1 Ω (Continuity) (c) Install the fuse. C136048E01 NG REPLACE FUSE OK 2 BC INSPECT BATTERY (a) Check the battery voltage. Standard voltage: 11 to 14 V NG INSPECT CHARGING SYSTEM OK 3 INSPECT SKID CONTROL ECU (IG1 TERMINAL VOLTAGE) (a) Disconnect the skid control ECU connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control ECU (Harness Side Connector Front View): A60 Tester Connection Condition Specified Condition A60-28 (IG1) - Body ground Ignition switch on (IG) 10 to 14 V NG IG1 C136493E05 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (IG1 CIRCUIT) BC–366 4 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) INSPECT SKID CONTROL ECU (GND TERMINAL CONTINUITY) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU (Harness Side Connector Front View): A60 Tester Connection Specified Condition A60-4 (GND1) - Body ground Below 1 Ω A60-1 (GND2) - Body ground Below 1 Ω (b) Connect the connector. NG GND2 REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) GND1 BC C136493E02 OK 5 RECONFIRM DTC (a) Clear the DTC (See page BC-302). (b) Start the engine. (c) Check if the same DTC is recorded (See page BC-302). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTC is not output A DTC is output (When troubleshooting in accordance with the PROBLEM SYMPTOMS TABLE) B DTC is output (When troubleshooting in accordance with the DTC CHART) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page BC-295) C REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) A CHECK FOR INTERMITTENT PROBLEMS (SYMPTOM SIMULATION) (See page BC-298) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DTC BC–367 C1246/46 Master Cylinder Pressure Sensor Malfunction DESCRIPTION The master cylinder pressure sensor is connected to the skid control ECU in the brake actuator assembly. Brake Actuator Assembly Skid Control ECU From Battery IG1 VCM Master Cylinder Pressure Sensor From Stop Light Switch STP PMC To Body ground GND E2 BC VCM: Power Supply for Master Cylinder Pressure Sensor PMC: Master Cylinder Pressure Sensor Input E2: Master Cylinder Pressure Sensor Ground C106656E03 DTC No. C1246/46 DTC Detection Condition When any of the following is detected: • The voltage of the sensor signal is out of range (less than 0.3 V, more than 4.86 V). • The sensor supply voltage is out of range (above 5.3 V, below 4.7 V). • The sensor signal offset value is out of range. • The sum of signal 1 and signal 2 is out of range (above 5.5 V, below 4.5 V). Trouble Area • • • • Master cylinder pressure sensor Master cylinder pressure sensor circuit Stop light switch circuit Brake actuator assembly (skid control ECU) INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). BC–368 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) CHECK STOP LIGHT OPERATION (a) Check that the stop light comes on when the brake pedal is depressed, and goes off when the brake pedal is released. OK Condition Illumination Condition Brake pedal depressed ON Brake pedal released OFF NG INSPECT STOP LIGHT CIRCUIT OK 2 READ VALUE OF INTELLIGENT TESTER (MASTER CYLINDER PRESSURE SENSOR) BC (a) Connect the intelligent tester to the DLC3. (b) Start the engine. (c) Select the "DATA LIST" mode on the intelligent tester (See page BC-307). DATA LIST: ABS/TRAC/VSC Item (Display) Measurement Item / Range (Display) MAS CYL PRESS 1 Master cylinder pressure sensor 1 reading / min.: 0 V, max.: 5 V Normal Condition When brake pedal is released: 0.3 to 0.5 V (d) Check that the hydraulic pressure value of the master cylinder pressure sensor observed on the intelligent tester changes when the brake pedal is depressed. OK: When the pedal is depressed, voltage displayed on the intelligent tester increases. NG REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) OK 3 READ VALUE OF INTELLIGENT TESTER (STOP LIGHT SWITCH) (a) Select the "DATA LIST" mode on the intelligent tester (See page BC-307). DATA LIST: ABS/TRAC/VSC Item (Display) STOP LAMP SW Measurement Item / Range (Display) Stop light switch / ON or OFF Normal Condition ON: Brake pedal depressed OFF: Brake pedal released (b) Check that the stop light condition observed on the intelligent tester changes when the brake pedal is depressed. OK: When the brake pedal is depressed, the intelligent tester displays "ON". BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) NG BC–369 REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) OK 4 RECONFIRM DTC (a) Clear the DTC (See page BC-302). (b) Start the engine. (c) At a speed of 18 mph (30 km/h) or more, drive the vehicle and perform braking test (decelerate the vehicle by depressing the brake pedal). (d) Check if the same DTC is recorded (See page BC-302). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTC (C1246/46) is not output A DTC (C1246/46) is output B B REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) A CHECK FOR INTERMITTENT PROBLEMS (SYMPTOM SIMULATION) (See page BC-298) BC BC–370 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DTC C1249/49 Open in Stop Light Switch Circuit DESCRIPTION This circuit recognizes brake operation by sending a stop light signal to the skid control ECU. The skid control ECU has an open detection circuit, which outputs this DTC when detecting an open in the stop light signal input line (STP terminal) or the ground line of the stop light circuit with the stop light switch off (brake pedal not depressed). BC DTC No. DTC Detection Condition C1249/49 When either of the following is detected: • After the ignition switch is turned on (IG), the STP terminal voltage of the ECU is 40% to 67% of its supplied voltage for 0.5 seconds. • When STP signal is OFF (release the brake pedal), the pressure sensor value exceeds 725 bar for 1 second. Trouble Area • • • Stop light switch Stop light switch circuit Brake actuator assembly (skid control ECU) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–371 WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) A19 Stop Light Switch STOP 1 2 30 A60 STP1 N16 Center Stop Light 2 1 BC S12 Rear Combination Light (RH) Tail 3 Stop 2 Multiplex Communication System (CAN) Tail ALT 3 Stop FL MAIN 2 S11 Rear Combination Light (LH) Battery 4 A60 GND1 1 A60 GND2 N15 Noise Filter (Dome and Stop) C131998E02 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). BC–372 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) CHECK STOP LIGHT SWITCH OPERATION (STOP LIGHT SWITCH CIRCUIT) (a) Check that the stop lights come on when the brake pedal is depressed and go off when the brake pedal is released. OK Pedal Condition Illumination Condition Brake pedal depressed ON Brake pedal released OFF NG Go to step 5 OK 2 INSPECT SKID CONTROL ECU (STP TERMINAL) BC (a) Disconnect the skid control ECU connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control ECU (Harness Side Connector Front View): A60 Tester Connection Switch Condition Specified Condition A60-30 (STP1) - Body ground Brake pedal depressed 8 to 14 V A60-30 (STP1) - Body ground Brake pedal released Below 4.0 V NG STP1 C136493E06 OK Go to step 7 BC–373 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 3 INSPECT SKID CONTROL ECU (GND TERMINAL CONTINUITY) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU (Harness Side Connector Front View): A60 Tester Connection Specified Condition A60-4 (GND1) - Body ground Below 1 Ω A60-1 (GND2) - Body ground Below 1 Ω (b) Connect the connector. NG GND2 REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) GND1 BC C136493E02 OK 4 RECONFIRM DTC (a) Clear the DTC (See page BC-302). (b) Start the engine. (c) Depress the brake pedal several times to test the stop light circuit. (d) Check if the same DTC is recorded (See page BC-302). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTC is not output A DTC is output B HINT: It is suspected that the DTCs were output due to a bad connection of the connector terminal. B REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) A CHECK FOR INTERMITTENT PROBLEMS (SYMPTOM SIMULATION) (See page BC-298) BC–374 5 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) CHECK HARNESS AND CONNECTOR (STOP LIGHT SWITCH POWER SOURCE TERMINAL VOLTAGE) (a) Disconnect the stop light switch connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Stop Light Switch (Harness Side Connector Front View): Tester Connection Condition Specified Condition A19-2 - Body ground Always 10 to 14 V A19 NG REPAIR OR REPLACE HARNESS OR CONNECTOR (STOP LIGHT SWITCH POWER SOURCE CIRCUIT) I042363E18 OK BC 6 INSPECT STOP LIGHT SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance Stop Light Switch Assembly: Free Switch Condition Specified Condition 1-2 Switch pin free Below 1 Ω 1-2 Switch pin pushed in 10 kΩ or higher (b) Connect the connector. Pushed In F047752E04 OK Tester Connection NG REPLACE STOP LIGHT SWITCH ASSEMBLY BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 7 BC–375 CHECK HARNESS AND CONNECTOR (STOP LIGHT SWITCH TO SKID CONTROL ECU) (a) Disconnect the stop light switch connector and skid control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU (Harness Side Connector Front View): A60 Tester Connection Specified Condition A60-30 (STP1) - A19-1 (STP1) Below 1 Ω (c) Connect the connectors. NG STP1 REPAIR OR REPLACE HARNESS OR CONNECTOR (STOP LIGHT SWITCH TO SKID CONTROL ECU) Stop Lignt Switch (Harness Side Connector Front View): BC A19 STP C139147E01 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (STOP LIGHT CIRCUIT) BC–376 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DTC C1288/88 ECU Version Miss Match DESCRIPTION DTC No. C1288/88 DTC Detection Condition ECM does not match Trouble Area ECM INSPECTION PROCEDURE 1 CHECK CAN COMMUNICATION SYSTEM (a) Check if a CAN communication system DTC is output (See page BC-302). Result Condition BC Proceed to CAN communication system DTC is not output A CAN communication system DTC is output B B INSPECT CAN COMMUNICATION SYSTEM (See page CA-8) A 2 PERFORM ENGINE VARIANT LEARNING (a) Perform engine variant learning (See page BC-290). NEXT 3 CONFIRM RECONFIRM DTC (a) Clear the DTC (See page BC-302). (b) Start the engine. (c) Check if the same DTC is recorded (See page BC-302). Result Condition Proceed to DTC is not output A DTC is output B B A END REPLACE ECM BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DTC BC–377 C1300/62 Skid Control ECU Malfunction DESCRIPTION The skid control ECU is housed in the brake actuator assembly. The skid control ECU judges the vehicle driving condition based on the signals from each sensor, and controls the brake actuator assembly. DTC No. DTC Detection Condition C1300/62 Trouble Area Internal failure of the skid control ECU control unit Brake actuator assembly (skid control ECU) INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). 1 CHECK DTC (a) Check the DTC (See page BC-302). BC Result Condition Proceed to DTC C1300/62 is output (only C1300/62) A Other DTCs are output B B REPAIR CIRCUITS INDICATED BY OUTPUT DTCS (See page BC-302) A 2 INSPECT SKID CONTROL ECU (IG1 TERMINAL VOLTAGE) (a) Disconnect the skid control ECU connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control ECU (Harness Side Connector Front View): A60 Tester Connection Condition Specified Condition A60-28 (IG1) - Body ground Ignition switch on (IG) 10 to 14 V NG IG1 C136493E05 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (IG1 CIRCUIT) BC–378 3 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) INSPECT SKID CONTROL ECU (GND TERMINAL CONTINUITY) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU (Harness Side Connector Front View): A60 Tester Connection Specified Condition A60-4 (GND1) - Body ground Below 1 Ω A60-1 (GND2) - Body ground Below 1 Ω (b) Connect the connector. NG GND2 BC REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) GND1 C136493E02 OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–379 DTC U0073/94 Control Module Communication Bus OFF DTC U0100/65 Lost Communication with ECM / PCM DTC U0123/62 Lost Communication with Yaw Rate Sensor Module DTC U0126/63 Lost Communication with Steering Angle Sensor Module DESCRIPTION The skid control ECU receives the signals from the ECM, steering angle sensor, and yaw rate and acceleration sensor via the CAN communication system. DTC No. DTC Detection Condition Trouble Area U0073/94 When either of the following is detected: 1. Bus OFF state continues for 300 msec. 2. The ECU detects that it cannot send a signal. CAN communication system U0100/65 When either of the following is detected: 1. At a vehicle speed of 4 mph (6 km/h) or more, the skid control ECU receives data that is out of range from the engine. 2. At a vehicle speed of 4 mph (6 km/h) or more, the skid control ECU receives abnormal data from the engine (5 cycles). CAN communication system (Skid control ECU to ECM) U0123/62 When any r of the following is detected: 1. The skid control ECU receives an abnormal signal from the yaw rate sensor (5 cycles). 2. The skid control ECU receives a signal that has a shorter message than normal. 3. The skid control ECU cannot receive a signal from the yaw rate sensor. CAN communication system (Skid control ECU to yaw rate and acceleration sensor) U0126/63 When any of the following is detected: 1. The skid control ECU receives an abnormal signal from the steering angle sensor (5 cycles). 2. The skid control ECU receives a signal that has a shorter message than normal. 3. The skid control ECU cannot receive a signal from the steering angle sensor. CAN communication system (Skid control ECU to steering angle sensor) BC BC–380 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) WIRING DIAGRAM A60 Brake Actuator Assembly (Skid Control ECU) E38 A/C Amplifier CANH CANL 11 35 12 14 E61 Option Connector (Bus Buffer) BC CAN+ CAN- CANL 1 (*1) 41 2 (*1) 49 CANL CANH CANL A24 ECM 13 (*2) 41 22 (*2) 49 CANH CANL E17 Steering Sensor E65 Yaw Rate Sensor CANH CANL A55 ECM E30 Airbag Sensor Assembly Center CANH CANH 2 10 3 9 CANH CANL *1: 2GR-FE *2: 2AZ-FE C136509E01 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) E10 DLC3 F1 Combination Meter CANH 6 CANL BC–381 14 17 18 CANH CANL E8 Main Body ECU 5 6 CANH BC CANL C132000E01 INSPECTION PROCEDURE Proceed to CAN communication system troubleshooting (See page CA-8). HINT: When a DTC indicating a CAN communication system malfunction is output, repair the CAN communication system before repairing each corresponding sensor. BC–382 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) ABS Warning Light Remains ON DESCRIPTION The skid control ECU is connected to the combination meter assembly via CAN communication. If any of the following is detected, the ABS warning light remains on. • The skid control ECU connectors are disconnected from the skid control ECU. • There is a malfunction in the skid control ECU internal circuit. • There is an open in the wire harness between the combination meter assembly and the skid control ECU. HINT: In some cases, the intelligent tester cannot be used when the skid control ECU is abnormal. BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–383 WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) F1 Combination Meter CANH 17 ABS MICRO COMPUTER DRIVER IC IG+ CANL 18 35 A60 CANH 14 A60 CANL IG1 ECU IG No. 2 5 3 2 1 BC 28 A60 IG1 4 A60 GND1 1 A60 GND2 E23 Ignition SW (*2) AM1 (*2) IG1 1 4 AM1 Main Body ECU ALT (*1) 6 E7 AM2 1 E6 (*1) AM1 IG1D AM2 FL MAIN Battery 3 E7 *1: with Smart Key System *2: without Smart Key System C136510E02 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). BC–384 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) CHECK CAN COMMUNICATION SYSTEM (a) Check if a CAN communication system DTC is output (See page BC-302). Result Condition Proceed to CAN communication system DTC is not output A CAN communication system DTC is output B B INSPECT CAN COMMUNICATION SYSTEM (See page CA-8) A 2 CHECK IF SKID CONTROL ECU CONNECTOR IS SECURELY CONNECTED BC (a) Check if the skid control ECU connector is securely connected. OK: The connector is securely connected. NG CONNECT CONNECTOR TO ECU CORRECTLY OK 3 CHECK BATTERY (a) Check the battery voltage. Standard voltage: 11 to 14 V NG OK CHECK AND REPLACE CHARGING SYSTEM OR BATTERY BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 4 BC–385 INSPECT SKID CONTROL ECU (IG1 TERMINAL) (a) Disconnect the skid control ECU connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control ECU (Harness Side Connector Front View): A60 Tester Connection Condition Specified Condition A60-28 (IG1) - Body ground Ignition switch on (IG) 10 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR (IG1 CIRCUIT) IG1 BC C136493E05 OK 5 INSPECT SKID CONTROL ECU (GND TERMINAL) (a) Turn the ignition switch off. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU (Harness Side Connector Front View): A60 Tester Connection Condition Specified Condition A60-4 (GND1) - Body ground Always Below 1 Ω A60-1 (GND2) - Body ground Always Below 1 Ω (c) Connect the connector. NG GND2 GND1 REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) C136493E02 OK 6 INSPECT COMBINATION METER ASSEMBLY (a) Connect the intelligent tester to the DLC3. (b) Perform "ACTIVE TEST" of the combination meter assembly using the intelligent tester (See page ME-32). (c) Check the ABS warning light operation. OK: The ABS warning light turns on or off in accordance with the intelligent tester. BC–386 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) NG REPLACE COMBINATION METER ASSEMBLY (See page ME-63) OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–387 ABS Warning Light does not Come ON DESCRIPTION The skid control ECU is connected to the combination meter assembly via CAN communication. BC BC–388 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) F1 Combination Meter CANH 17 ABS MICRO COMPUTER DRIVER IC IG+ CANL 18 35 A60 CANH 14 A60 CANL 28 A60 IG1 4 A60 GND1 1 A60 GND2 IG1 BC ECU IG No. 2 5 3 2 1 E23 Ignition SW (*2) AM1 (*2) IG1 1 4 AM1 Main Body ECU ALT (*1) 6 E7 AM2 1 E6 (*1) AM1 IG1D AM2 FL MAIN Battery 3 E7 *1: with Smart Key System *2: without Smart Key System C136510E02 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 1 BC–389 CHECK CAN COMMUNICATION SYSTEM (a) Check if a CAN communication system DTC is output (See page BC-302). Result Condition Proceed to CAN communication system DTC is not output A CAN communication system DTC is output B B INSPECT CAN COMMUNICATION SYSTEM (See page CA-8) A 2 CHECK ABS WARNING LIGHT (a) Disconnect the skid control ECU connector. (b) Turn the ignition switch on (IG). (c) Check that the ABS warning light comes on. OK: The ABS warning light comes on. (d) Connect the connector. OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) NG 3 INSPECT COMBINATION METER ASSEMBLY (a) Connect the intelligent tester to the DLC3. (b) Perform "ACTIVE TEST" of the combination meter assembly using the intelligent tester (See page ME-32). (c) Check ABS warning light operation. OK: The ABS warning light turns on or off in accordance with the intelligent tester. NG REPLACE COMBINATION METER ASSEMBLY (See page ME-63) OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC BC–390 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) VSC Warning Light Remains ON DESCRIPTION The skid control ECU communicates with the combination meter assembly via CAN communication. If the ECU stores a DTC, the master caution indicator light will illuminate, and the DTC will be displayed on the multi-information display in the combination meter (models with multi-information display). On models without a multi-information display, the VSC warning light will come on when the skid control ECU stores a DTC. BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–391 WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) F1 Combination Meter (*3) VSC IG+ CANH 17 MICRO COMPUTER Multi-display (*4) CANL 18 35 A60 CANH 14 A60 CANL IG1 ECU IG No. 2 5 3 2 1 BC 28 A60 IG1 E23 Ignition SW (*2) AM1 (*2) 4 AM1 IG1 1 Main Body ECU ALT (*1) 6 E7 1 E6 AM2 AM1 IG1D 3 E7 AM2 4 A60 GND1 FL MAIN *1: with Smart Key System Battery (*1) *2: without Smart Key System 1 A60 GND2 *3: without Multi-Information Display *4: with Multi-Information Display C136510E03 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). BC–392 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) CHECK CAN COMMUNICATION SYSTEM (a) Check if a CAN communication system DTC is output (See page BC-302). Result Condition Proceed to CAN communication system DTC is not output A CAN communication system DTC is output B B INSPECT CAN COMMUNICATION SYSTEM (See page CA-8) A 2 CHECK IF SKID CONTROL ECU CONNECTOR IS SECURELY CONNECTED BC (a) Check if the skid control ECU connector is securely connected. OK: The connector is securely connected. NG CONNECT CONNECTOR TO ECU CORRECTLY OK 3 CHECK BATTERY (a) Check the battery voltage. Standard voltage: 11 to 14 V NG CHECK AND REPLACE CHARGING SYSTEM OR BATTERY OK 4 INSPECT COMBINATION METER ASSEMBLY (a) Connect the intelligent tester to the DLC3. (b) Perform "ACTIVE TEST" of the combination meter assembly using the intelligent tester (See page ME-32). (c) Check VSC warning (multi-information display)/VSC warning light (without multi-information display) operation. OK: The VSC warning (multi-information display) or VSC warning light turns on or off in accordance with the intelligent tester. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) NG BC–393 REPLACE COMBINATION METER ASSEMBLY (See page ME-63) OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC BC–394 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) VSC Warning Light does not Come ON DESCRIPTION The skid control ECU communicates with the combination meter assembly via CAN communication. If the ECU stores a DTC, the master caution indicator light will illuminate, and the DTC will be displayed on the multi-information display in the combination meter (models with multi-information display). On models without a multi-information display, the VSC warning light will come on when the skid control ECU stores a DTC. BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–395 WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) F1 Combination Meter (*3) VSC IG+ CANH 17 MICRO COMPUTER Multi-display (*4) CANL 18 35 A60 CANH 14 A60 CANL IG1 ECU IG No. 2 5 3 2 1 BC 28 A60 IG1 E23 Ignition SW (*2) AM1 (*2) 4 AM1 IG1 1 Main Body ECU ALT (*1) 6 E7 1 E6 AM2 AM1 IG1D 3 E7 AM2 4 A60 GND1 FL MAIN *1: with Smart Key System Battery (*1) *2: without Smart Key System 1 A60 GND2 *3: without Multi-Information Display *4: with Multi-Information Display C136510E03 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). BC–396 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) CHECK CAN COMMUNICATION SYSTEM (a) Check if a CAN communication system DTC is output (See page BC-302). Result Condition Proceed to CAN communication system DTC is not output A CAN communication system DTC is output B B INSPECT CAN COMMUNICATION SYSTEM (See page CA-8) A 2 BC INSPECT COMBINATION METER ASSEMBLY (a) Connect the intelligent tester to the DLC3. (b) Perform "ACTIVE TEST" of the combination meter assembly using the intelligent tester (See page ME-32). (c) Check that "ON" and "OFF" of the VSC warning (multiinformation display) or VSC warning light are indicated on the combination meter assembly when using the intelligent tester. OK: The VSC warning (multi-information display) turns on or off in accordance with the intelligent tester. NG REPLACE COMBINATION METER ASSEMBLY (See page ME-63) OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–397 Brake Warning Light Remains ON DESCRIPTION The skid control ECU is connected to the combination meter assembly via CAN communication. If any of the following is detected, the BRAKE warning light remains on: • The skid control ECU connector is disconnected from the skid control ECU. • The brake fluid level is insufficient. • The parking brake is applied. • EBD operation is not possible. BC BC–398 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) Main Body ECU CANH 5 E8 CANL 6 E8 Combination Meter 17 CANH BC MICRO COMPUTER CANL F1 35 A60 CANH 18 14 F1 A60 CANL BRAKE DRIVER IC IG+ 6 F2 B/LE A16 Brake Fluid Level Warning SW 1 2 E33 (*1) A18 (*2) Parking Brake SW PKB 2 14 IM (*1) IC (*2) 1 4 A60 GND1 1 A60 GND2 *1: M/T *2: A/T C136504E02 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–399 IG1 ECU IG No. 2 5 3 2 1 28 A60 IG1 E23 Ignition SW (*2) AM1 (*2) IG1 1 4 AM1 BC Main Body ECU ALT E7 (*1) (*1) 6 AM1 1 AM2 E6 3 IG1D E7 AM2 FL MAIN Battery *1: with Smart Key System *2: without Smart Key System C136505E02 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). 1 CHECK CAN COMMUNICATION SYSTEM (a) Check if a CAN communication system DTC is output (See page BC-302). Result Condition Proceed to CAN communication system DTC is not output A CAN communication system DTC is output B BC–400 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) B INSPECT CAN COMMUNICATION SYSTEM (See page CA-8) A 2 CHECK IF SKID CONTROL ECU CONNECTOR IS SECURELY CONNECTED (a) Check if the skid control ECU connector is securely connected. OK: The connector is securely connected. NG CONNECT CONNECTOR TO ECU CORRECTLY OK BC 3 CHECK BATTERY (a) Check the battery voltage. Standard voltage: 11 to 14 V NG CHECK AND REPLACE CHARGING SYSTEM OR BATTERY OK 4 INSPECT SKID CONTROL ECU (IG1 TERMINAL) (a) Disconnect the skid control ECU connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control ECU (Harness Side Connector Front View): A60 Tester Connection Condition Specified Condition A60-28 (IG1) - Body ground Ignition switch on (IG) 10 to 14 V NG IG1 C136493E05 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (IG1 CIRCUIT) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 5 BC–401 INSPECT SKID CONTROL ECU (GND TERMINAL) (a) Turn the ignition switch off. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU (Harness Side Connector Front View): A60 Tester Connection Condition Specified Condition A60-4 (GND1) - Body ground Always Below 1 Ω A60-1 (GND2) - Body ground Always Below 1 Ω (c) Connect the connector. NG GND2 GND1 REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) BC C136493E02 OK 6 INSPECT PARKING BRAKE SWITCH (a) Disconnect the parking brake switch connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Parking Brake Switch: Automatic Transaxle: Free Pushed in Manual Transaxle: Condition Specified Condition 1 - Body ground Parking brake switch ON (Switch pin free) Below 1 Ω 1 - Body ground Parking brake switch OFF (Switch pin pushed in) 10 kΩ or higher NG Free Pushed in C109430E03 OK Tester Connection REPLACE PARKING BRAKE SWITCH BC–402 7 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) CHECK HARNESS AND CONNECTOR (MAIN BODY ECU TO PARKING BRAKE SWITCH) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: Automatic Transaxle Main Body ECU Wire Harness View: IC : Automatic Transaxle Tester Connection Condition Specified Condition IC-14 (PKB) - A18-1 Always Below 1 Ω IC-14 (PKB) - Body ground Always 10 kΩ or higher Tester Connection Condition Specified Condition IM-2 (PKB) - E33-1 Always Below 1 Ω IM-2 (PKB) - Body ground Always 10 kΩ or higher Manual Transaxle IM : Manual Transaxle BC (b) Connect the connector. NG Parking Brake Switch Harness Side Connector Front View: A18 : Automatic Transaxle E33 : Manual Transaxle C136418E03 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (MAIN BODY ECU TO PARKING BRAKE SWITCH) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 8 INSPECT BRAKE FLUID LEVEL WARNING SWITCH Brake Fluid Level Warning Switch (a) Remove the reservoir tank cap and strainer. (b) Disconnect the brake fluid level warning switch connector. (c) Measure the resistance according to the value(s) in the table below. HINT: A float is located inside the reservoir. Its position can be changed by increasing or decreasing the level of brake fluid. Standard resistance A16 MAX Level Tester Connection MIN Level C139740E01 Condition Specified Condition 1-2 Float up (Switch OFF) 1.9 to 2.1 kΩ 1-2 Float down (Switch ON) Below 1 Ω HINT: If there is no problem after finishing the above check, adjust the brake fluid level to the MAX level. NG OK BC–403 REPLACE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY (BRAKE FLUID LEVEL WARNING SWITCH) BC BC–404 9 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) CHECK HARNESS AND CONNECTOR (COMBINATION METER TO BRAKE FLUID LEVEL WARNING SWITCH) (a) Disconnect the combination meter connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Combination Meter Wire Harness View: Tester Connection Condition Specified Condition F2-6 (B/LE) - A16-1 Always Below 1 Ω F2-6 (B/LE) - Body ground Always 10 kΩ or higher A16-2 - Body ground Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR (COMBINATION METER TO BRAKE FLUID LEVEL WARNING SWITCH) BC F2-6 (B/LE) Brake Fluid Level Warning Switch Harness Side Connector Front View: A16 C136033E01 OK 10 INSPECT COMBINATION METER ASSEMBLY (a) Connect the intelligent tester to the DLC3. (b) Select the "ACTIVE TEST" on the tester (See page BC307). ACTIVE TEST: ABS/TRAC/VSC Item BRAKE WRN LIGHT Vehicle Condition/Test Details Turns brake warning light on / off Diagnostic Note Observe combination meter (c) Check BRAKE warning light operation. OK: The BRAKE warning light turns on or off in accordance with the intelligent tester. NG REPLACE COMBINATION METER ASSEMBLY (See page ME-63) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–405 OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC BC–406 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) Brake Warning Light does not Come ON DESCRIPTION The skid control ECU is connected to the combination meter assembly via CAN communication. BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–407 WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) Main Body ECU CANH 5 E8 CANL 6 E8 Combination Meter 17 CANH MICRO COMPUTER CANL F1 35 A60 CANH 18 14 F1 A60 CANL BC BRAKE DRIVER IC IG+ 6 F2 B/LE A16 Brake Fluid Level Warning SW 1 2 E33 (*1) A18 (*2) Parking Brake SW PKB 2 14 IM (*1) IC (*2) 1 4 A60 GND1 1 A60 GND2 *1: M/T *2: A/T C136504E02 BC–408 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) IG1 ECU IG No. 2 5 3 2 1 28 A60 IG1 E23 Ignition SW (*2) AM1 (*2) IG1 1 4 AM1 BC Main Body ECU ALT E7 (*1) (*1) 6 AM1 1 AM2 E6 3 IG1D E7 AM2 FL MAIN Battery *1: with Smart Key System *2: without Smart Key System C136505E02 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). 1 CHECK CAN COMMUNICATION SYSTEM (a) Check if a CAN communication system DTC is output (See page BC-302). Result Condition Proceed to CAN communication system DTC is not output A CAN communication system DTC is output B BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) B BC–409 INSPECT CAN COMMUNICATION SYSTEM (See page CA-8) A 2 CHECK BRAKE WARNING LIGHT (a) Disconnect the skid control ECU connector. (b) Turn the ignition switch on (IG). (c) Check that the BRAKE warning light comes on. OK: The BRAKE warning light comes on. (d) Connect the connector. OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) NG 3 BC INSPECT COMBINATION METER ASSEMBLY (a) Connect the intelligent tester to the DLC3. (b) Perform "ACTIVE TEST" of the combination meter assembly using the intelligent tester (See page ME-32). (c) Check BRAKE warning light operation. OK: The BRAKE warning light turns on or off in accordance with the intelligent tester. NG REPLACE COMBINATION METER ASSEMBLY (See page ME-63) OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC–410 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) Slip Indicator Light Remains ON DESCRIPTION The skid control ECU is connected to the combination meter assembly via CAN communication. The SLIP indicator light blinks during VSC and/or TRAC operation. When the system fails, the SLIP indicator light comes on to warn the driver (See page BC-278). BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–411 WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) F1 Combination Meter CANH 17 SLIP IG+ DRIVER IC MICRO COMPUTER CANL 18 35 A60 CANH 14 A60 CANL IG1 ECU IG No. 2 5 3 2 1 BC 28 A60 IG1 E23 Ignition SW (*2) AM1 (*2) 4 AM1 IG1 1 Main Body ECU ALT (*1) 6 E7 AM1 IG1D 1 AM2 E6 3 E7 AM2 4 A60 GND1 FL MAIN *1: with Smart Key System Battery (*1) *2: without Smart Key System 1 A60 GND2 C136510E05 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). BC–412 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) CHECK CAN COMMUNICATION SYSTEM (a) Check if a CAN communication system DTC is output (See page BC-302). Result Condition Proceed to CAN communication system DTC is not output A CAN communication system DTC is output B B INSPECT CAN COMMUNICATION SYSTEM (See page CA-8) A 2 CHECK IF SKID CONTROL ECU CONNECTOR IS SECURELY CONNECTED BC (a) Check if the skid control ECU connector is securely connected. OK: The connector is securely connected. NG CONNECT CONNECTOR TO ECU CORRECTLY OK 3 CHECK BATTERY (a) Check the battery voltage. Standard voltage: 11 to 14 V NG CHECK AND REPLACE CHARGING SYSTEM OR BATTERY OK 4 INSPECT COMBINATION METER ASSEMBLY (a) Connect the intelligent tester to the DLC3. (b) Perform "ACTIVE TEST" of the combination meter assembly using the intelligent tester (See page ME-32). (c) Check SLIP indicator light operation. OK: The SLIP indicator light turns on or off in accordance with the intelligent tester. NG REPLACE COMBINATION METER ASSEMBLY (See page ME-63) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–413 OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC BC–414 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) Slip Indicator Light does not Come ON DESCRIPTION The skid control ECU is connected to the combination meter assembly via CAN communication. The SLIP indicator light blinks during VSC and/or TRAC operation. When the system fails, the SLIP indicator light comes on to warn the driver (See page BC-278). BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–415 WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) F1 Combination Meter CANH 17 SLIP IG+ DRIVER IC MICRO COMPUTER CANL 18 35 A60 CANH 14 A60 CANL IG1 ECU IG No. 2 5 3 2 1 BC 28 A60 IG1 E23 Ignition SW (*2) AM1 (*2) 4 AM1 IG1 1 Main Body ECU ALT (*1) 6 E7 AM1 IG1D 1 AM2 E6 3 E7 AM2 4 A60 GND1 FL MAIN *1: with Smart Key System Battery (*1) *2: without Smart Key System 1 A60 GND2 C136510E05 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). BC–416 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) CHECK CAN COMMUNICATION SYSTEM (a) Check if a CAN communication system DTC is output (See page BC-302). Result Condition Proceed to CAN communication system DTC is not output A CAN communication system DTC is output B B INSPECT CAN COMMUNICATION SYSTEM (See page CA-8) A 2 BC INSPECT COMBINATION METER ASSEMBLY (a) Connect the intelligent tester to the DLC3. (b) Perform "ACTIVE TEST" of the combination meter assembly using the intelligent tester (See page ME-32). (c) Check the SLIP indicator light operation. OK: The SLIP indicator light turns on or off in accordance with the intelligent tester. NG REPLACE COMBINATION METER ASSEMBLY (See page ME-63) OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–417 Skid Control Buzzer Circuit DESCRIPTION The skid control buzzer sounds and the SLIP indicator light blinks during VSC operation. WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) E13 VSC Warning Buzzer IG1 ECU IG No. 2 5 2 3 Buzzer 1 23 A60 BZ 28 BC A60 IG1 2 1 E23 Ignition SW (*2) AM1 (*2) 4 AM1 IG1 1 Main Body ECU ALT (*1) 6 E7 (*1) AM2 1 E6 AM1 IG1D AM2 4 A60 GND1 FL MAIN *1: with Smart Key System Battery 3 E7 *2: without Smart Key System 1 A60 GND2 C136511E01 BC–418 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SKID CONTROL BUZZER) (a) Connect the intelligent tester to the DLC3. (b) Select the "ACTIVE TEST" on the intelligent tester (See page BC-307). ACTIVE TEST: ABS/TRAC/VSC Item (Display) BUZZER Vehicle Condition / Test Details Turns skid control buzzer ON / OFF Diagnostic Note Buzzer can be heard (c) Check that the buzzer sounds/stops when turning the skid control buzzer on/off by using the intelligent tester. Result Condition BC Proceed to Buzzer does not sound or sounds constantly A Buzzer sounds/stops B B CHECK FOR INTERMITTENT PROBLEMS (SYMPTOM SIMULATION) (See page BC-298) A 2 INSPECT SKID CONTROL BUZZER (POWER SOURCE TERMINAL) (a) Disconnect the skid control buzzer connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control Buzzer (Harness Side Connector Front View): E13 C107604E18 OK Tester Connection Condition Specified Condition E13-2 - Body ground Ignition switch on (IG) 10 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR (POWER SOURCE CIRCUIT) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 3 BC–419 INSPECT SKID CONTROL BUZZER (a) Apply battery negative voltage to terminal 1, and battery positive voltage to terminal 2 of the skid control buzzer, and then check that the buzzer sounds. OK: The skid control buzzer sounds. Skid Control Buzzer: NG (+) REPLACE SKID CONTROL BUZZER (See page BC-453) (-) 1 2 BC C125130E01 OK 4 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU TO SKID CONTROL BUZZER) (a) Disconnect the skid control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU (Harness Side Connector Front View): A60 BZ Tester Connection Condition Specified Condition A60-23 (BZ) - E13-1 Always Below 1 Ω A60-23 (BZ) - Body ground Always 10 kΩ or higher (c) Connect the connectors. NG Skid Control Buzzer (Harness Side Connector Front View): REPAIR OR REPLACE HARNESS OR CONNECTOR (SKID CONTROL ECU TO SKID CONTROL BUZZER) E13 C139149E01 OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC–420 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) TC and CG Terminal Circuit DESCRIPTION DTC output mode is set by connecting terminals TC and CG of the DLC3. DTCs are indicated by the blinking pattern of the ABS warning light. WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) ECM BC 41 CANH A55 *1 41 A24 *2 26 A60 CANH 49 CANL A55 *1 49 A24 *2 15 A60 CANL E10 DLC3 27 TC A55 *1 27 A24 *2 13 *1: 2GR FE *2: 2AZ-FE 4 TC CG C136514E01 HINT: When warning lights continue to blink, a ground short in the wiring of terminal TC of the DLC3 or an internal ground short in one or more ECUs is suspected. INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). 1 CHECK CAN COMMUNICATION SYSTEM (a) Check if a CAN communication DTC is output (See page BC-302). Result Result Proceed to CAN communication system DTC is output A CAN communication system DTC is not output B BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) B BC–421 Go to step 2 A GO TO CAN COMMUNICATION SYSTEM (See page CA-8) 2 CHECK HARNESS AND CONNECTOR (ECM TO DLC3) (a) Disconnect the ECM connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: 2GR-FE DLC3: E10 Tester Connection Specified Condition E10-13 (TC) - A55-27 (TC) Below 1 Ω E10-13 (TC) - Body ground 10 kΩ or higher 2AZ-FE TC Tester Connection ECM Wire Harness View: Specified Condition E10-13 (TC) - A24-27 (TC) Below 1 Ω E10-13 (TC) - Body ground 10 kΩ or higher (c) Connect the connector. NG A55-27 (TC) (*1) A24-27 (TC) (*2) (*1): 2GR-FE (*2): 2AZ-FE C136035E02 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (TC TERMINAL CIRCUIT) BC BC–422 3 DLC3: BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) CHECK HARNESS AND CONNECTOR (DLC3 TO CG CIRCUIT) (a) Measure the resistance according to the value(s) in the table below. Standard resistance CG Tester Connection Specified Condition E10-4 (CG) - Body ground Below 1 Ω E10 NG REPAIR OR REPLACE HARNESS OR CONNECTOR (CG TERMINAL CIRCUIT) G022986E27 OK BC 4 CHECK HARNESS AND CONNECTOR (TC TERMINAL CIRCUIT) (a) Measure the resistance according to the value(s) in the table below. Standard resistance DLC3: Tester Connection Specified Condition E10-13 (TC) - Body ground 10 kΩ or higher E10 NG TC REPAIR OR REPLACE HARNESS OR CONNECTOR (TC TERMINAL CIRCUIT) G022986E28 OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–423 TS and CG Terminal Circuit DESCRIPTION In the Test Mode (signal check), a malfunction of the speed sensor that cannot be detected when the vehicle is stopped can be detected while driving. Transition to the sensor check mode can be performed by connecting terminals TS and CG of the DLC3 and turning the ignition switch from off to on (IG). WIRING DIAGRAM Brake Actuator Assembly E10 DLC3 - Skid Control ECU 24 TS CG 12 BC A60 TS 4 C136515E01 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). BC–424 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU TO DLC3) (a) Disconnect the skid control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU (Harness Side Connector Front View): A60 TS Tester Connection Condition Specified Condition A60-24 (TS) - E10-12 (TS) Always Below 1 Ω (c) Connect the connector. NG DLC3: E10 REPAIR OR REPLACE HARNESS OR CONNECTOR (SKID CONTROL ECU TO DLC3) BC TS C139177E01 OK 2 DLC3: CHECK HARNESS AND CONNECTOR (DLC3 TO BODY GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance CG Tester Connection Condition Specified Condition E10-4 (CG) - Body ground Always Below 1 Ω E10 NG G022987E25 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (DLC3 TO BODY GROUND) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 3 BC–425 CHECK HARNESS AND CONNECTOR (TS TERMINAL CIRCUIT) (a) Measure the resistance according to the value(s) in the table below. Standard resistance DLC3: Tester Connection Condition Specified Condition E10-12 (TS) - Body ground Always 10 kΩ or higher E10 NG TS REPAIR OR REPLACE HARNESS OR CONNECTOR (TS TERMINAL CIRCUIT) G022987E26 OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC BC–424 BRAKE CONTROL – BRAKE ACTUATOR (for ADVICS Made) BRAKE ACTUATOR (for ADVICS Made) BRAKE CONTROL COMPONENTS 15 (155, 11) *14 (143, 10) 15 (155, 11) *14 (143, 10) RADIATOR RESERVE TANK ASSEMBLY BC 5.4 (55, 48 in.*lbf) BRAKE ACTUATOR 19 (195, 14) 5.4 (55, 48 in.*lbf) BRAKE ACTUATOR BRACKET ASSEMBLY 19 (195, 14) N*m (kgf*cm, ft.*lbf) : Specified torque * For use with SST C133321E01 BRAKE CONTROL – BRAKE ACTUATOR (for ADVICS Made) BC–425 ON-VEHICLE INSPECTION DLC3 1. CONNECT INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Start the engine and run it at idle . (c) Select the Active Test mode on the intelligent tester. HINT: Refer to the intelligent tester operator's manual for further details. 2. INSPECT ACTUATOR MOTOR OPERATION NOTICE: Do not keep a motor relay on continuously for more than 5 seconds. When operating it continuously, set an interval of more than 20 seconds. (a) With the motor relay on, check the actuator motor operation sounds. (b) Turn the motor relay off. (c) Depress the brake pedal and hold it for approximately 15 seconds. Check that the brake pedal cannot be depressed farther. (d) With the motor relay on, check that the pedal does not pulsate. (e) Turn the motor relay off and release the brake pedal. Intelligent Tester C131977E08 3. INSPECT RIGHT FRONT WHEEL OPERATION NOTICE: Do not turn on a solenoid in a manner different than described below. (a) Depress the brake pedal and hold it. (b) Turn the SFRH and SFRR solenoids on simultaneously, and check that the pedal cannot be depressed. (c) Turn the SFRH and SFRR solenoids off simultaneously, and check that the pedal can be depressed. NOTICE: Do not keep the motor relay on continuously for more than 5 seconds. When operating them continuously, set an interval of more than 20 seconds. (d) Turn the motor relay on and check that the pedal returns. NOTICE: Do not keep the motor relay on continuously for more than 5 seconds. When operating it continuously, set an interval of more than 20 seconds. (e) Turn the motor relay off and release the brake pedal. BC BC–426 BRAKE CONTROL – BRAKE ACTUATOR (for ADVICS Made) 4. BC INSPECT OTHER WHEEL OPERATION (a) Using the same procedure, check the solenoids of the other wheels. HINT: • Left front wheel: SFLH, SFLR • Right rear wheel: SRRH, SRRR • Left rear wheel: SRLH, SRLR BRAKE CONTROL – BRAKE ACTUATOR (for ADVICS Made) BC–427 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE RADIATOR RESERVE TANK ASSEMBLY (a) Separate the radiator reserve tank hose. (b) Remove the radiator reserve tank assembly. 3. DRAIN BRAKE FLUID NOTICE: If brake fluid leaks onto any painted surface, immediately clean it off completely. 4. REMOVE BRAKE ACTUATOR (a) Release the lock lever and disconnect the actuator connector. Connector BC C133326E01 (b) Using SST, disconnect the 6 brake lines from the actuator assembly with bracket. SST 09023-00101 SST C133324E01 (c) Use tags or make a memo to identify the places to reconnect. HINT: • *1: To Front Wheel Cylinder RH • *2: To Front Wheel Cylinder LH • *3: To Rear Wheel Cylinder RH • *4: To Rear Wheel Cylinder LH • *5: From 1st Master Cylinder • *6: From 2nd Master Cylinder *6 *2 *3 *4 *5 *1 C133323E01 BC–428 BRAKE CONTROL – BRAKE ACTUATOR (for ADVICS Made) (d) Remove the 3 bolts and brake actuator assembly with bracket from the body. NOTICE: Do not damage the brake tubes and wire harness. C133325E01 DISASSEMBLY 1. REMOVE BRAKE ACTUATOR BRACKET ASSEMBLY (a) Remove the 2 nuts and the brake actuator assembly from the actuator bracket assembly. BC C133322 REASSEMBLY 1. C133322 INSTALL BRAKE ACTUATOR BRACKET ASSEMBLY (a) Install the actuator assembly to the brake actuator bracket assembly with the 2 nuts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) NOTICE: Do not remove the hole plug before installing a new brake actuator because the brake actuator assembly is filled with brake fluid. INSTALLATION 1. C133325E01 INSTALL BRAKE ACTUATOR (a) Install the brake actuator assembly with bracket to the body with the 3 bolts. Torque: 19 N*m (195 kgf*cm, 14 ft.*lbf) NOTICE: Do not damage the brake tubes and wire harness. BRAKE CONTROL – BRAKE ACTUATOR (for ADVICS Made) (b) Temporarily tighten each brake tube to the correct positions of the brake actuator assembly with bracket as shown in the illustration. HINT: • *1: To Front Wheel Cylinder RH • *2: To Front Wheel Cylinder LH • *3: To Rear Wheel Cylinder RH • *4: To Rear Wheel Cylinder LH • *5: From 1st Master Cylinder • *6: From 2nd Master Cylinder *6 *2 *3 *4 BC–429 *5 *1 C133323E01 (c) Using SST, fully tighten each brake tube. SST 09023-00101 Torque: without SST 15 N*m (155 kgf*cm, 11 ft.*lbf) with SST 14 N*m (143 kgf*cm, 10 ft.*lbf) NOTICE: • Use a torque wrench with a fulcrum length of 300 mm (11.81 in.). • This torque value is effective when SST is parallel to a torque wrench. SST C133324E01 (d) Connect the actuator connector. NOTICE: Make sure that the connector is locked securely. 2. INSTALL RADIATOR RESERVE TANK ASSEMBLY (a) Install the radiator reserve tank assembly. (b) Connect the radiator reservoir tank hose. 3. FILL RESERVOIR WITH BRAKE FLUID (See page BR6) 4. BLEED BRAKE LINE (See page BR-7) 5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 6. BLEED BRAKE ACTUATOR (See page BR-8) 7. INSPECT BRAKE FLUID LEVEL (See page BR-10) 8. INSPECT FOR BRAKE FLUID LEAKAGE 9. PERFORM YAW RATE SENSOR ZERO POINT CALIBRATION HINT: (See page BC-119) Connector C133335E01 10. INSPECT ACTUATOR WITH INTELLIGENT TESTER HINT: (See page BC-425) BC BC–430 BRAKE CONTROL – BRAKE ACTUATOR (for BOSCH Made) BRAKE ACTUATOR (for BOSCH Made) BRAKE CONTROL COMPONENTS with VSC: 15 (155, 11) *14 (143, 10) 15 (155, 11) *14 (143, 10) 15 (155, 11) *14 (143, 10) BC 8.0 (82, 71 in.*lbf) 19 (194, 14) *17 (173, 13) 15 (155, 11) *14 (143, 10) 19 (195, 14) BRAKE ACTUATOR 8.0 (82, 71 in.*lbf) BRAKE ACTUATOR 19 (195, 14) RADIATOR RESERVE TANK ASSEMBLY BRAKE ACTUATOR BRACKET ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque *For use with SST C133318E01 BRAKE CONTROL – BRAKE ACTUATOR (for BOSCH Made) BC–431 ON-VEHICLE INSPECTION DLC3 1. CONNECT INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Start the engine and run it at idle. (c) Select the Active Test mode on the intelligent tester. HINT: Refer to the intelligent tester operator's manual for further details. 2. INSPECT ACTUATOR MOTOR OPERATION NOTICE: Do not keep a motor relay on continuously for more than 5 seconds. When operating it continuously, set an interval of more than 20 seconds. (a) With the motor relay on, check the actuator motor operation sounds. (b) Turn the motor relay off. (c) Depress the brake pedal and hold it for approximately 15 seconds. Check that the brake pedal cannot be depressed farther. (d) With the motor relay on, check that the pedal does not pulsate. (e) Turn the motor relay off and release the brake pedal. Intelligent Tester C131977E07 3. INSPECT RIGHT FRONT WHEEL OPERATION NOTICE: Do not turn on a solenoid in a manner different than described below. (a) Depress the brake pedal and hold it. (b) Turn the SFRH and SFRR solenoids on simultaneously, and check that the pedal cannot be depressed. (c) Turn the SFRH and SFRR solenoids off simultaneously, and check that the pedal can be depressed. NOTICE: Do not keep the motor relay on continuously for more than 5 seconds. When operating them continuously, set an interval of more than 20 seconds. (d) Turn the motor relay on and check that the pedal returns. NOTICE: Do not keep the motor relay on continuously for more than 5 seconds. When operating it continuously, set an interval of more than 20 seconds. (e) Turn the motor relay off and release the brake pedal. BC BC–432 BRAKE CONTROL – BRAKE ACTUATOR (for BOSCH Made) 4. BC INSPECT OTHER WHEEL OPERATION (a) Using the same procedure, check the solenoids of the other wheels. HINT: • Left front wheel: SFLH, SFLR • Right rear wheel: SRRH, SRRR • Left rear wheel: SRLH, SRLR BRAKE CONTROL – BRAKE ACTUATOR (for BOSCH Made) BC–433 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE RADIATOR RESERVE TANK ASSEMBLY (a) Separate the radiator reserve tank hose. (b) Remove the radiator reserve tank assembly. 3. DRAIN BRAKE FLUID NOTICE: If brake fluid leaks onto any painted surface, immediately clean it off completely. 4. REMOVE BRAKE ACTUATOR (a) Release the lock lever and disconnect the actuator connector. BC C132775E01 (b) Using SST, disconnect the 6 brake lines from the actuator assembly with bracket. SST 09023-00101 SST C132776E01 (c) Use tags or make a memo to identify the places to reconnect. HINT: • *1: To Front Wheel Cylinder RH • *2: To Front Wheel Cylinder LH • *3: To Rear Wheel Cylinder RH • *4: To Rear Wheel Cylinder LH • *5: From 2nd Master Cylinder • *6: From 1st Master Cylinder *2 *5 *3 *6 *4 *1 C132777E01 BC–434 BRAKE CONTROL – BRAKE ACTUATOR (for BOSCH Made) (d) Remove the 3 bolts and actuator assembly from the body with bracket. NOTICE: Do not damage the brake tubes and wire harness. C132778 DISASSEMBLY 1. BC REMOVE BRAKE ACTUATOR BRACKET ASSEMBLY (a) Remove the 2 nuts and the brake actuator assembly from the actuator bracket assembly. C132779E01 REASSEMBLY 1. C132779E01 INSTALL BRAKE ACTUATOR BRACKET ASSEMBLY (a) Install the actuator assembly to the actuator bracket assembly with the 2 nuts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) NOTICE: Do not remove the hole plug before installing a new brake actuator because the brake actuator assembly is filled with brake fluid. INSTALLATION 1. C132778 INSTALL BRAKE ACTUATOR (w/o VSC) (a) Install the actuator assembly with bracket to the body with the 3 bolts. Torque: 19 N*m (195 kgf*cm, 14 ft.*lbf) NOTICE: Do not damage the brake tubes and wire harness. BRAKE CONTROL – BRAKE ACTUATOR (for BOSCH Made) BC–435 (b) Temporarily tighten each brake tube to the correct positions of the actuator assembly with bracket as shown in the illustration. HINT: • *1: To Front Wheel Cylinder RH • *2: To Front Wheel Cylinder LH • *3: To Rear Wheel Cylinder RH • *4: To Rear Wheel Cylinder LH • *5: From 2nd Master Cylinder • *6: From 1st Master Cylinder *2 *5 *3 *6 *4 *1 C132777E01 (c) Using SST, fully tighten each brake tube. SST 09023-00101 Torque: without SST 15 N*m (155 kgf*cm, 11 ft.*lbf) with SST 14 N*m (143 kgf*cm, 10 ft.*lbf) NOTICE: • Use a torque wrench with a fulcrum length of 300 mm (11.81 in.). • This torque value is effective when SST is parallel to a torque wrench. SST C132776E01 (d) Connect the actuator connector. NOTICE: Make sure that the connector is locked securely. C133319 2. C132778 INSTALL BRAKE ACTUATOR (w/ VSC) (a) Install the actuator assembly with bracket to the body with the 3 bolts. Torque: 19 N*m (195 kgf*cm, 14 ft.*lbf) NOTICE: Do not damage the brake tubes. BC BC–436 BRAKE CONTROL – BRAKE ACTUATOR (for BOSCH Made) (b) Temporarily tighten each brake tube to the correct positions of the actuator assembly with bracket as shown in the illustration. HINT: • *1: To Front Wheel Cylinder RH • *2: To Front Wheel Cylinder LH • *3: To Rear Wheel Cylinder RH • *4: To Rear Wheel Cylinder LH • *5: From 2nd Master Cylinder • *6: From 1st Master Cylinder *2 *5 *3 *6 *4 *1 C132777E01 (c) Using SST, fully tighten each brake tube. SST 09023-00101, 09023-38200 Torque: bolt A M10 without SST 15 N*m (155 kgf*cm, 11 ft.*lbf) bolt A M10 with SST 14 N*m (143 kgf*cm, 10 ft.*lbf) bolt B M12 without SST 19 N*m (194 kgf*cm, 14 ft.*lbf) bolt B M12 with SST 17 N*m (173 kgf*cm, 13 ft.*lbf) NOTICE: • Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). • This torque value is effective when SST is parallel to a torque wrench. BC A B A A B A SST C132776E04 (d) Connect the actuator connector. NOTICE: Make sure that the connector is locked securely. C133319 3. INSTALL RADIATOR RESERVE TANK ASSEMBLY (a) Install the radiator reserve tank assembly. (b) Connect the radiator reservoir tank hose. 4. FILL RESERVOIR WITH BRAKE FLUID (See page BR6) 5. BLEED BRAKE LINE (See page BR-7) 6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 7. BLEED BRAKE ACTUATOR ASSEMBLY (w/ VSC) (See page BR-8) 8. INSPECT BRAKE FLUID LEVEL (See page BR-10) 9. INSPECT FOR BRAKE FLUID LEAKAGE 10. INSPECT ACTUATOR WITH INTELLIGENT TESTER HINT: (See page BC-431) BRAKE CONTROL – BRAKE ACTUATOR (for BOSCH Made) BC–437 11. PERFORM YAW RATE SENSOR ZERO POINT CALIBRATION (w/ VSC) HINT: (See page BC-278) 12. INSPECT SENSOR SIGNAL HINT: • without VSC (see page BC-11) • with VSC (see page BC-290) 13. INSPECT DTC AND CLEAR HINT: • without VSC (See page BC-21) • with VSC (See page BC-302) BC BC–437 BRAKE CONTROL – FRONT SPEED SENSOR FRONT SPEED SENSOR BRAKE CONTROL COMPONENTS FRONT SPEED SENSOR 5.0 (51, 44 in.*lbf) BC 19 (194, 14) 8.0 (82, 71 in.*lbf) FRONT FENDER LINER FRONT WHEEL OPENING EXTENSION PAD N*m (kgf*cm, ft.*lbf) : Specified torque C132784E01 BC–438 BRAKE CONTROL – FRONT SPEED SENSOR REMOVAL 1. REMOVE FRONT WHEEL 2. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH (See page ED-6) 3. REMOVE FRONT FENDER LINER (See page ED-6) 4. REMOVE FRONT SPEED SENSOR (a) Disconnect the front speed sensor connector and clamp. Clamp C132783E01 (b) Remove the 2 bolts from the body and the shock absorber assembly. (c) Disengage the 2 claws from the steering knuckle and body. BC C132781E01 (d) Remove the bolt and the front speed sensor. NOTICE: • Prevent foreign matter from attaching to the sensor tip. • Clean the installation hole and the surface for the speed sensor every time the speed sensor is removed. C132782 BRAKE CONTROL – FRONT SPEED SENSOR BC–439 INSPECTION 1. 2 INSPECT FRONT SPEED SENSOR (for BOSCH Made) (a) Inspect the front speed sensor. If any of the following occurs, replace the front speed sensor with a new one: • The surface of the front speed sensor is cracked, dented, or chipped off. • The connector or wire harness is scratched, cracked, or damaged. • The front speed sensor has been dropped. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: LH 1 Tester Connection Specified Condition 1 (FL+) - 2 (FL-) 0.92 to 1.22 kΩ at 20 °C (68°F) 1 (FL+) - Body ground 10 kΩ or higher 2 (FL-) - Body ground 10 kΩ or higher C093876E01 RH Tester Connection Specified Condition 1 (FR+) - 2 (FR-) 0.92 to 1.22 kΩ at 20 °C(68°F) 1 (FR+) - Body ground 10 kΩ or higher 2 (FR-) - Body ground 10 kΩ or higher If the value is not as specified, replace the front speed sensor. 2. INSPECT FRONT SPEED SENSOR (for ADVICS Made) (a) Inspect the front speed sensor. If any of the following occurs, replace the front speed sensor with a new one: • The surface of the front speed sensor is cracked, dented, or chipped off. • The connector or wire harness is scratched, cracked, or damaged. • The front speed sensor has been dropped. BC BC–440 BRAKE CONTROL – FRONT SPEED SENSOR (b) Measure the resistance according to the value(s) in the table below. Standard resistance: RH Front Speed Sensor: 1 2 Tester Connection Condition Specified Condition 1 (FR+) - 2 (FR-) Always 1.4 to 1.8 kΩ at 20°C (68 °F) 1 (FR+) - Body ground Always 10 kΩ or higher 2 (FR-) - Body ground Always 10 kΩ or higher LH Tester Connection C136017E01 Condition Specified Condition 1 (FL+) - 2 (FL-) Always 1.4 to 1.8 kΩ at 20°C (68 °F) 1 (FL+) - Body ground Always 10 kΩ or higher 2 (FL-) - Body ground Always 10 kΩ or higher If the value is not as specified, replace the front speed sensor. BC INSTALLATION 1. INSTALL FRONT SPEED SENSOR (a) Install the front speed sensor with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) NOTICE: Prevent foreign matter from attaching to the sensor tip. C132782 (b) Install the front speed sensor with the 2 bolts and engage the 2 claws. Torque: Bolt A 5.0 N*m (51 kgf*cm, 44 in.*lbf) Bolt B 19 N*m (194 kgf*cm, 14 ft.*lbf) NOTICE: Do not twist the wire harness for the front speed sensor when installing the speed sensor. A B C132781E03 BRAKE CONTROL – FRONT SPEED SENSOR BC–441 (c) Connect the front speed sensor connector and clamp. Clamp C132783E01 2. INSTALL FRONT FENDER LINER (See page ED-10) 3. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH (See page ED-10) 4. INSTALL FRONT WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 5. CHECK SPEED SENSOR SIGNAL HINT: • for BOSCH without VSC (See page BC-11) • for BOSCH with VSC (See page BC-290) • for ADVICS (See page BC-123) BC BC–442 BRAKE CONTROL – SKID CONTROL SENSOR SKID CONTROL SENSOR BRAKE CONTROL COMPONENTS 62 (632, 46) REAR DISC BRAKE CALIPER ASSEMBLY BC 80 (816, 59) REAR AXLE HUB AND BEARING ASSEMBLY WITH SKID CONTROL SENSOR 80 (816, 59) REAR DISC REAR AXLE HUB AND BEARING ASSEMBLY WITH SKID CONTROL SENSOR: REAR AXLE HUB AND BEARING ASSEMBLY SKID CONTROL SENSOR N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C132788E02 BRAKE CONTROL – SKID CONTROL SENSOR BC–443 REMOVAL C132787 SST Bolt Bolt SST SST C111530E01 1. REMOVE REAR WHEEL 2. DISCONNECT SKID CONTROL SENSOR WIRE (a) Disconnect the connector from the skid control sensor. NOTICE: Be careful not to damage the speed sensor. 3. REMOVE REAR DISC BRAKE CALIPER ASSEMBLY (See page AH-18) 4. REMOVE REAR DISC (See page BR-62) 5. REMOVE REAR AXLE HUB AND BEARING ASSEMBLY WITH SKID CONTROL SENSOR (See page AH-15) 6. REMOVE SKID CONTROL SENSOR (a) Mount the rear axle hub in a vise using aluminum plates. NOTICE: Replace the hub and bearing assembly if it is dropped or receives a strong shock. (b) Using a pin punch and hammer, drive out the 2 pins and remove the 2 attachments from SST. SST 09520-00031 (09521-00010, 09520-00040), 09521-00020 (c) Using SST and 2 bolts (Diameter: 12 mm, pitch: 1.5 mm), remove the skid control sensor from the hub and bearing assembly. SST 09520-00031 (09521-00010, 09520-00040), 09521-00020, 09950-00020 NOTICE: • Keep the sensor away from magnets. • Pull the skid control sensor off straight, taking care not to make contact with the skid control sensor rotor. • If the speed sensor rotor is damaged or deformed, replace the hub and bearing assembly. • Do not scratch the contact surface between the axle hub and the skid control sensor. • Do not attach foreign matter to the speed sensor rotor and tip. BC BC–444 BRAKE CONTROL – SKID CONTROL SENSOR INSPECTION 1. INSPECT SKID CONTROL SENSOR (for BOSCH Made) (a) Inspect the skid control sensor. If any of the following occurs, replace the skid control sensor with a new one: • The surface of the skid control sensor is cracked, dented, or chipped off. • The connector is scratched, cracked, or damaged. • The skid control sensor has been dropped. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: LH Rear Speed Sensor: Tester Connection BC Specified Condition 1 (RR+) - 2 (RR-) Below 2.2 kΩ 1 (RR+) - Body ground 10 kΩ or higher 2 (RR-) - Body ground 10 kΩ or higher Tester Connection Specified Condition RH 2 1 1 (RL+) - 2 (RL-) Below 2.2 kΩ 1 (RL+) - Body ground 10 kΩ or higher 2 (RL-) - Body ground 10 kΩ or higher C113377E01 If the value is not as specified, replace the skid control sensor. 2. INSPECT SKID CONTROL SENSOR (for ADVICS Made) (a) Inspect the skid control sensor. If any of the following occurs, replace the skid control sensor with a new one: • The surface of the skid control sensor is cracked, dented, or chipped off. • The connector is scratched, cracked, or damaged. • The skid control sensor has been dropped. BC–445 BRAKE CONTROL – SKID CONTROL SENSOR (b) Measure the resistance according to the value(s) in the table below. Standard resistance: RH Rear Speed Sensor: Tester Connection Condition Specified Condition 2 (RR+) - 1 (RR-) Always 0.9 to 2.1 kΩ 2 (RR+) - Body ground Always 10 kΩ or higher 1 (RR-) - Body ground Always 10 kΩ or higher Condition Specified Condition LH 2 Tester Connection 1 2 (RL+) - 1 (RL-) Always 0.9 to 2.1 kΩ 2 (RL+) - Body ground Always 10 kΩ or higher 1 (RL-) - Body ground Always 10 kΩ or higher C113377E01 If the value is not as specified, replace the skid control sensor. RH: INSTALLATION LH: 1. CONNECTOR C132785E01 INSTALL SKID CONTROL SENSOR (a) Clean the contact surface between the axle hub and a new skid control sensor. NOTICE: Prevent foreign matter from attaching to the sensor rotor. (b) Place the skid control sensor on the axle hub so that the connector is positioned as shown in the illustration. (c) Using SST, a press, 2 V-blocks, and 2 steel plates, install the skid control sensor to the axle hub. SST 09309-36010, 09213-58013 NOTICE: • Keep the sensor away from magnets. • Do not use a hammer on the skid control sensor. • Check that there is no foreign matter such as iron chips on the detecting portion of the skid control sensor. • Slowly press the skid control sensor straight. SST SST C132786E01 2. INSTALL REAR AXLE HUB AND BEARING ASSEMBLY WITH SKID CONTROL SENSOR (See page AH-16) 3. INSPECT REAR AXLE HUB BEARING LOOSENESS (See page AH-15) 4. INSPECT REAR AXLE HUB RUNOUT (See page AH15) 5. INSTALL REAR DISC (See page BR-63) 6. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY (See page AH-20) BC BC–446 BRAKE CONTROL – SKID CONTROL SENSOR C132787 BC 7. CONNECT SKID CONTROL SENSOR WIRE (a) Connect the connector to the skid control sensor. 8. INSTALL REAR WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 9. INSPECT AND ADJUST REAR WHEEL ALIGNMENT HINT: (See page SP-13) 10. CHECK SPEED SENSOR SIGNAL HINT: • for BOSCH without VSC (See page BC-11) • for BOSCH with VSC (See page BC-290) • for ADVICS (See page BC-123) BC–446 BRAKE CONTROL – YAW RATE AND ACCELERATION SENSOR (w/ VSC) YAW RATE AND ACCELERATION SENSOR (w/ VSC) BRAKE CONTROL COMPONENTS NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH NO. 2 INSTRUMENT for Manual Transaxle: CLUSTER FINISH PANEL GARNISH SHIFT LEVER KNOB SUB-ASSEMBLY UPPER CONSOLE PANEL FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY BC UPPER REAR CONSOLE PANEL SUB-ASSEMBLY SHIFT LEVER KNOB SUB-ASSEMBLY Bosch Type: UPPER REAR CONSOLE PANEL SUB-ASSEMBLY YAW RATE AND ACCELERATION SENSOR 13 (133, 10) BRACKET 5.0 (51, 44 in.*lbf) YAW RATE AND ACCELERATION SENSOR N*m (kgf*cm, ft.*lbf) : Specified torque C133327E01 BRAKE CONTROL – YAW RATE AND ACCELERATION SENSOR (w/ VSC) BC–447 REMOVAL 1. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-24) 2. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) (See page IP-24) 3. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-24) 4. REMOVE NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-25) 5. REMOVE FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-25) 6. REMOVE UPPER CONSOLE PANEL (for Manual Transaxle) (See page IP-25) 7. REMOVE UPPER REAR CONSOLE PANEL SUBASSEMBLY (for Manual Transaxle) (See page IP-26) 8. REMOVE UPPER REAR CONSOLE PANEL SUBASSEMBLY (for Automatic Transaxle) (See page IP26) 9. REMOVE YAW RATE AND ACCELERATION SENSOR (a) Disconnect the yaw rate sensor connector. (b) Remove the 2 bolts and yaw rate sensor. NOTICE: Do not remove the sensor from the bracket. C133329 10. REMOVE YAW RATE AND ACCELERATION SENSOR (for BOSCH Made) (a) Remove the 2 nuts and yaw rate sensor from the bracket. C133328 BC BC–448 BRAKE CONTROL – YAW RATE AND ACCELERATION SENSOR (w/ VSC) INSPECTION 1. INSPECT YAW RATE AND ACCELERATION SENSOR (a) Inspect the yaw rate sensor. If any of the following occurs, replace the yaw rate sensor with a new one: • The surface of the yaw rate sensor is cracked, dented, or chipped off. • The connector is scratched, cracked, or damaged. • The yaw rate sensor has been dropped. INSTALLATION BC 1. INSTALL YAW RATE AND ACCELERATION SENSOR (for BOSCH Made) (a) Install the yaw rate and acceleration sensor to the bracket with the 2 nuts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 2. INSTALL YAW RATE AND ACCELERATION SENSOR (a) Install the yaw rate sensor and acceleration with the 2 bolts. NOTICE: • Do not damage the yaw rate and acceleration sensor. • Make sure that the yaw rate and acceleration sensor is installed securely. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) (b) Connect the yaw rate and acceleration sensor connector. 3. INSTALL UPPER REAR CONSOLE PANEL SUBASSEMBLY (for Automatic Transaxle) (See page IP53) 4. INSTALL UPPER REAR CONSOLE PANEL SUBASSEMBLY (for Manual Transaxle) (See page IP-53) 5. INSTALL UPPER CONSOLE PANEL (for Manual Transaxle) (See page IP-54) 6. INSTALL FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (See page IP-53) 7. INSTALL NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-54) 8. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-55) 9. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) (See page IP-55) C133328 C133329 10. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-55) BRAKE CONTROL – YAW RATE AND ACCELERATION SENSOR (w/ VSC) BC–449 11. PERFORM YAW RATE SENSOR ZERO POINT CALIBRATION HINT: • for BOSCH (See page BC-278) • for ADVICS (See page BC-119) 12. INSPECT SENSOR SIGNAL HINT: • for BOSCH (See page BC-290) • for ADVICS (See page BC-123) BC BRAKE CONTROL – STEERING ANGLE SENSOR (w/ VSC) BC–449 STEERING ANGLE SENSOR (w/ VSC) BRAKE CONTROL COMPONENTS 3 Spoke Type: 50 (510, 37) STEERING PAD 8.8 (90, 78 in.*lbf) BC STEERING WHEEL ASSEMBLY STEERING COLUMN COVER STEERING WHEEL ASSEMBLY STEERING PAD 50 (510, 37) SPIRAL CABLE 8.8 (90, 78 in.*lbf) NO. 3 LOWER STEERING WHEEL COVER NO. 2 LOWER STEERING WHEEL COVER with VSC: SPIRAL CABLE SPIRAL CABLE SUB-ASSEMBLY WITH STEERING ANGLE SENSOR STEERING ANGLE SENSOR N*m (kgf*cm, ft.*lbf) : Specified torque C133868E04 BC–450 BRAKE CONTROL – STEERING ANGLE SENSOR (w/ VSC) REMOVAL BC 1. PRECAUTION CAUTION: Be sure to read "PRECAUTION" thoroughly before servicing (See page RS-1). 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment. 3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD NOTICE: When reconnecting the cable to the negative battery terminal after installing the steering sensor, check that the front tires and steering wheel are kept aligned straight ahead before and after connecting the cable to the negative battery terminal. 4. REMOVE NO. 2 STEERING WHEEL COVER LOWER (See page RS-349) 5. REMOVE NO. 3 STEERING WHEEL COVER LOWER (See page RS-349) 6. REMOVE STEERING PAD (See page RS-350) 7. REMOVE STEERING WHEEL ASSEMBLY (See page SR-38) 8. REMOVE STEERING COLUMN COVER (See page SR-39) 9. REMOVE SPIRAL CABLE SUB-ASSEMBLY WITH STEERING ANGLE SENSOR (See page RS-364) 10. REMOVE STEERING ANGLE SENSOR (a) Disengage the claws and remove the steering angle sensor from the spiral cable. C104804E04 BRAKE CONTROL – STEERING ANGLE SENSOR (w/ VSC) BC–451 INSPECTION 1. INSPECT STEERING ANGLE SENSOR (a) Inspect the steering angle sensor. If any of the following occurs, replace the steering angle sensor with a new one: • The surface of the steering angle sensor is cracked, dented, or chipped off. • The connector is scratched, cracked, or damaged. • The steering angle sensor has been dropped. INSTALLATION C104804E04 1. INSTALL STEERING ANGLE SENSOR (a) Align the locating pins, engage the claws, and install the steering angle sensor to the spiral cable subassembly. 2. INSTALL SPIRAL CABLE SUB-ASSEMBLY WITH STEERING ANGLE SENSOR (See page RS-366) 3. INSTALL STEERING COLUMN COVER (See page SR50) 4. ADJUST SPIRAL CABLE (See page RS-367) 5. INSTALL STEERING WHEEL ASSEMBLY (See page SR-51) 6. INSPECT STEERING WHEEL CENTER POINT (See page SR-47) 7. INSTALL STEERING PAD (See page RS-350) 8. INSTALL NO. 2 STEERING WHEEL COVER LOWER (See page RS-352) 9. INSTALL NO. 3 STEERING WHEEL COVER LOWER (See page RS-351) 10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 11. INSPECT STEERING PAD (See page RS-347) 12. INSPECT SRS WARNING LIGHT HINT: (See page RS-32) BC BC–452 BRAKE CONTROL – SKID CONTROL BUZZER (w/ VSC) SKID CONTROL BUZZER (w/ VSC) BRAKE CONTROL COMPONENTS for TMMK Made: with Smart Key System: LOWER INSTRUMENT PANEL FINISH PANEL BC LOWER INSTRUMENT PANEL FINISH PANEL NO. 1 INSTRUMENT PANEL SUB-ASSEMBLY SKID CONTROL BUZZER or

COWL SIDE TRIM SUB-ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL LH FRONT DOOR SCUFF PLATE C133330E01 BC–453 BRAKE CONTROL – SKID CONTROL BUZZER (w/ VSC) for TMC Made: with Smart Key System: LOWER INSTRUMENT PANEL FINISH PANEL LOWER INSTRUMENT PANEL FINISH PANEL NO. 1 INSTRUMENT PANEL SUB-ASSEMBLY BC SKID CONTROL BUZZER or COWL SIDE TRIM SUB-ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL LH FRONT DOOR SCUFF PLATE C133330E03 BC–454 BRAKE CONTROL – SKID CONTROL BUZZER (w/ VSC) REMOVAL BC 1. PRECAUTION (See page IP-20) 2. REMOVE FRONT DOOR SCUFF PLATE (See page IR24) 3. REMOVE COWL SIDE TRIM SUB-ASSEMBLY (See page IR-25) 4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (See page IP-20) 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (See page IP-21) 6. REMOVE NO. 1 INSTRUMENT PANEL SUBASSEMBLY (See page IP-22) 7. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (w/o Smart Key System) (See page IP-22) 8. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (w/ Smart Key System) (See page IP-22) 9. REMOVE SKID CONTROL BUZZER (a) Disconnect the skid control buzzer connector. (b) Remove the clip and skid control buzzer assembly. C133331E01 INSPECTION 1. (+) (-) Skid Control Buzzer 1 2 F002192E03 INSPECT SKID CONTROL BUZZER (a) Apply battery negative voltage to terminal 1, and battery positive voltage to terminal 2 of the skid control buzzer, and then check that the buzzer sounds. OK: The skid control buzzer sounds. If the skid control buzzer does not sound, replace the skid control buzzer. BRAKE CONTROL – SKID CONTROL BUZZER (w/ VSC) BC–455 INSTALLATION 1. INSTALL SKID CONTROL BUZZER (a) Attach the claw and install the skid control buzzer. (b) Connect the skid control buzzer assembly connector. 2. INSTALL NO. 1 INSTRUMENT PANEL SUBASSEMBLY (See page IP-57) 3. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/ Smart Key System) (See page IP-57) 4. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/o Smart Key System) (See page IP-57) 5. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (See page IP-58) 6. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (See page IP-59) 7. INSTALL COWL SIDE TRIM SUB-ASSEMBLY (See page IR-54) 8. INSTALL FRONT DOOR SCUFF PLATE (See page IR54) C133331E01 BC BC–456 BRAKE CONTROL – ABS MOTOR RELAY (w/ VSC) ABS MOTOR RELAY (w/ VSC) ON-VEHICLE INSPECTION 1. INSPECT VSC NO. 1 (FAIL SAFE) RELAY (a) Remove the VSC NO. 1 (fail safe) relay. (b) Measure the resistance according to the value(s) in the table below. Standard resistance VSC NO. 1 (Fail Safe) Relay: Tester Connection Specified Condition 3-5 Always 10 kΩ or higher 3-5 Apply B+ between terminals 1 and 2 Below 1 Ω If the value is not as specified, replace the VSC NO. 1 (fail safe) relay. F050241E11 2. BC Condition INSPECT VSC NO. 2 RELAY (a) Remove the VSC NO. 2 relay. (b) Measure the resistance according to the value(s) in the table below. Standard resistance VSC NO. 2 Relay: Tester Connection F050240E07 Condition Specified Condition 3-5 Always 10 kΩ or higher 3-5 Apply B+ between terminals 1 and 2 Below 1 Ω If the value is not as specified, replace the VSC NO. 2 relay. DL–1 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM POWER DOOR LOCK CONTROL SYSTEM PRECAUTION 1. Switch Type Ignition switch off Expression Ignition switch on (IG) Ignition switch on (ACC) Engine start EXPRESSIONS OF IGNITION SWITCH (a) The type of ignition switch used on this model differs according to the specifications of the vehicle. The expressions listed in the table below are used in this section. Ignition Switch (position) Engine Switch (condition) LOCK Off ON On (IG) ACC On (ACC) START Start DL DL–2 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM PARTS LOCATION FRONT DOOR LOCK REAR DOOR LOCK FRONT DOOR COURTESY SWITCH LUGGAGE DOOR LOCK DL REAR DOOR COURTESY SWITCH B112603E01 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM DL–3 UNLOCK WARNING SWITCH (*1) DOOR CONTROL SWITCH (MUTIPLEX NETWORK MASTER SWITCH) DOOR CONTROL SWITCH DLC3 INSTRUMENT PANEL J/B - MAIN BODY ECU DL SHIFT LOCK CONTROL ECU (*2) *1: W/O SMART KEY SYSTEM *2: W/ SMART KEY SYSTEM B112602E01 DL–4 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM SYSTEM DIAGRAM Door Lock Control System: Main Body ECU (Instrument Panel J/B) Multiplex Network Master Switch Assembly - Manual Door Lock Switch (Driver Side) Front Passenger Side Door Control Switch Assembly Front Door Lock Assembly LH Front Door Lock Assembly RH - Door Key Lock and Unlock Switch - Door Key Lock and Unlock Switch - Door Lock Motor - Door Lock Motor - Door Unlock Detection Switch - Door Unlock Detection Switch Rear Door Lock Assembly LH Rear Door Lock Assembly RH - Door Lock Motor - Door Lock Motor - Door Unlock Detection Switch - Door Unlock Detection Switch Front Door Courtesy Switch Assembly LH Front Door Courtesy Switch Assembly RH Rear Door Courtesy Switch Assembly LH Rear Door Courtesy Switch Assembly RH Unlock Warning Switch (*1) Luggage Compartment Door Lock Assembly DL - Luggage Compartment Door Courtesy Switch Shift Lock Control ECU (*2) - Door Lock Motor ECM *1: w/o Smart Key System : CAN Communication Line (MS bus) *2: w/ Smart Key System B112604E01 Transmitting ECU (Transmitter) ECM Receiving ECU (Receiver) Main Body ECU Signals Park / Neutral Position Switch Signal Communication method CAN (MS bus) DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM DL–5 SYSTEM DESCRIPTION 1. 2. POWER DOOR LOCK CONTROL SYSTEM DESCRIPTION (a) The power door lock system locks/unlocks all the doors. The master switch and the door control switch on the passenger door send "lock/unlock" request signals to the main body ECU. Then, the main body ECU sends these request signals to the lock motors in each door to lock/unlock all the doors at once in response to the inputs. Operating the driver's door lock using a mechanical key sends request signals to lock/unlock the doors to the main body ECU via the master switch. "2-step unlock function" is optional for unlocking procedures of the key-linked lock for the driver side door. FUNCTION OF MAIN COMPONENT Components Function Multiplex network master switch assembly (Manual door lock switch) Door control switch on master switch assembly locks/unlocks all doors. Door control switch Door control switch on passenger side door locks/unlocks all doors. Door courtesy switch Placed on each door. Detects door status (open or closed) and outputs data to main body ECU. Turns on when door is open and turns off when door is closed. • • Driver side door lock • Front passenger side door lock, luggage compartment door lock, rear LH and RH door locks 3. Function • • Built-in motor locks/unlocks door. Built-in door control switch (key-linked) detects door key operation's door status (locked or unlocked) and outputs data to main body ECU. Built-in position switch detects door status (locked or unlocked) and outputs data to main body ECU. This switch turns off when door is locked and turns on when door is unlocked. Built-in motor locks/unlocks door. Built-in position switch detects door status (locked or unlocked) and outputs data to main body ECU. This switch turns off when door is locked and turns on when door is unlocked. SYSTEM FUNCTION HINT: The following functions' default settings are ON. Some of these functions can be customized (See page DL-10). (a) This system is controlled by the main body ECU. The main body ECU outputs signals to each door lock motor. The door lock control system of the CAMRY has the following functions: Outline Manual lock and unlock function This function can lock or unlock all doors by the door lock control switch operation. Key-linked lock and unlock function This function, which is linked with the key cylinder, can lock or unlock all the doors when a lock or unlock operation is effected. Manual unlock prohibition function Performing the door lock operation with an electrical key (*1) or a mechanical key (transmitter) will prohibit the unlock operation by the door lock control switch. Key lock-in prevention function (Electrical key) If a each door lock (*1) or driver's door lock (*2) operation is performed when the electrical key (*1) or mechanical key is in the cabin (*1) or ignition key cylinder (*2), all the doors will be unlocked. DL DL–6 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM Function Outline Shift-linked automatic door lock function (A/T) When the conditions listed below are met consecutively, this function causes all the doors to be automatically locked. • The ignition switch is on (IG). • All doors are closed. • The shift lever is moved out of the P position. • Any of the doors are unlocked. Shift-linked automatic door unlock function (A/T) When the ignition switch is on (IG), if moving the shift lever to the P position from any other position, all the doors will be automatically unlocked. One-motion open When the door is locked, this function enables the door to be unlocked by pulling the inside handle of the driver's or front passenger's door. 2-step unlock function This function is provided to unlock the driver's door by turning the key cylinder once and to unlock the remaining doors by turning it the second time. *1: w/ Smart Key System *2: w/o Smart Key System DL DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM DL–7 HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use the following procedures to troubleshoot the power door lock control system. • The intelligent tester should be used in step 5 and 7. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS CHECK HINT: • In troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time the malfunction occurred. • Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases. • The following 5 items are important points in the problem analysis: What Vehicle model, system name When Date, time, occurrence frequency Where Road conditions Under what conditions? Running conditions, driving conditions, weather conditions How did it happen? Problem symptoms NEXT 3 INSPECT BATTERY VOLTAGE Standard Voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding to the next step. NEXT 4 PROBLEM SYMPTOMS TABLE Result Result Proceed to Fault is not listed in problem symptoms table A Fault is listed in problem symptoms table B DL DL–8 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM B After repair, go to step 7 A 5 OVERALL ANALYSIS AND TROUBLESHOOTING (a) Terminals of ECU (See page DL-13) (b) DATA LIST/ACTIVE TEST (See page DL-17) NEXT 6 REPAIR OR REPLACE NEXT 7 NEXT END DL CONFIRMATION TEST DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM DL–9 OPERATION CHECK 1. CHECK ELECTRICAL DOOR LOCK OPERATION NOTICE: The initial condition that the customizing function using the intelligent tester is not chosen is shown. (a) Check the basic function. (1) Check that all doors lock when the door control switch (for manual operation) is turned to LOCK and all doors unlock when turned to UNLOCK. (2) Check that all doors lock when the driver side door lock key cylinder is turned to LOCK using the mechanical key. (b) Check the electrical key lock-in prevention function (w/ Smart Key System). NOTICE: In order to prevent the electrical key from being actually locked-in, the following inspection should be performed with the driver side door window open. (1) Place the electrical key in the cabin. (2) With the driver side door open, check that all doors unlock immediately after the door lock knob for the driver side door is turned to LOCK. (3) With the driver side door open, check that all doors unlock immediately after the door control switch (for manual operation) is turned to LOCK. (4) With the driver side door open, turn the driver side door lock knob to LOCK, and then close the driver side door. Then check that all doors unlock. (c) Check the key lock-in prevention function (w/o Smart Key System). NOTICE: In order to prevent the key from being actually locked-in, the inspection should be performed with the driver side door window open. (1) Have the key inserted into the ignition key cylinder. (2) With the driver side door open, check that all doors unlock immediately after the door lock knob for the driver side door is turned to LOCK. (3) With the driver side door open, check that all doors unlock immediately after the door control switch (for manual operation) is turned to LOCK. (4) With the driver side door open, turn the driver side door lock knob to LOCK, and then close the driver side door. Then check that all doors unlock. (d) Check the security function. *1: w/ Smart Key System (1) Close all doors with the driver side door window open so that the door control switch can be operated from outside the vehicle. DL DL–10 DL DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM (2) Pull out the electrical key (*1) or mechanical key (transmitter), open the driver side door and then close and lock the door using the electrical key (*1) or mechanical key (transmitter). Under this condition, check that all doors do not unlock when the door control switch (for manual operation) is turned to UNLOCK from outside the vehicle. (3) Pull out the electrical key (*1) or the mechanical key, and close and lock the driver side door by mechanical key operation. Under this condition, check that all doors do not unlock when the door control switch (for manual operation) is turned to UNLOCK from outside the vehicle. (4) Pull out the electrical key (*1) or mechanical key (transmitter), close the driver side door, and lock the door by wireless door lock operation. Under this condition, check that all doors do not unlock when the door control switch (for manual operation) is turned to UNLOCK from outside the vehicle. HINT: Check that the security function is canceled under the following conditions: • The ignition switch is turned on (IG). • The driver side door is unlocked using the mechanical key (transmitter) or the electrical key. • The door control switch (for manual operation) is turned to UNLOCK after the door control knob is turned to UNLOCK manually. (e) Check the illumination function. (1) Set the room light switch to the DOOR position. (2) With all doors locked, check that driver's door unlock when the driver side door lock cylinder is turned to UNLOCK using the key. At the same time, the room light comes on. (3) Check that the room light goes off in approximately 15 seconds if the doors have not been opened. (f) Check the AUTO lock function (w/ Smart Key System). (1) Lock all doors. (2) Unlock driver's door using the electrical key. (3) Allow 30 seconds to elapse while all doors remain closed and the electrical key switch and the entry unlock switch remain untouched. Then, check that all doors will lock automatically. DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM DL–11 (g) Check the automatic locking function interlocked with the shift lever. *1: w/o Smart Key System and w/o Theft Deterrent System *2: Except *1 (1) When any door (*1), driver's door or passenger's door (*2) is unlocked with all doors closed and the engine started, check that all doors automatically lock when the shift lever is moved into any position from the P position (A/T). (2) When any door is unlocked after all doors automatically lock, check that all doors attempt to automatically lock once again (retry function). The retry function is canceled when any of the following conditions is fulfilled: • All doors are locked. • Any door is opened. • The shift lever is moved into the P position. • The doors are locked or unlocked by the user. • The ignition switch is turned off. • The engine is stopped. DL DL–12 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM CUSTOMIZE PARAMETERS 1. CUSTOMIZING FUNCTION WITH INTELLIGENT TESTER HINT: The following items can be customized. NOTICE: • Before attempting to customize vehicle settings, confirm whether it is possible to make the change that the customer has requested. • Be sure to record the current settings before customizing. • When troubleshooting, make sure that the item in question has not been disabled using the customizing function. DOOR LOCK: Display (Item) Default Contents Setting UNLOCK/PARK (Unlock w/ engine switch on (IG), shift P, speed 0 km/h (0 mph)) A/T: ON M/T: OFF (Cannot be changed) Function that unlocks doors when the shift lever is moved to the P position from any other position while the ignition switch is on (IG) ON/OFF A/T: OFF M/T: ON Function that unlocks all other doors when opening driver side door within 10 seconds after turning the ignition switch off from on (IG) ON/OFF ALL UNLK/OPN-CL (All unlock w/ D door open-close) • UNLK/KEY TWICE (Unlock w/ 2 times D key operation) Function that unlocks only the driver side door when the driver side door key cylinder is turned to unlock once and unlocks all the doors when it is turned to unlock twice In the OFF setting, turning it once unlocks all doors ON/OFF A/T: ON M/T: OFF (Cannot be changed) Function that locks doors when the shift lever is moved from the P position to any other position ON/OFF OFF Function that locks doors when vehicle reaches a vehicle speed 20 km/h (13 mph) ON/OFF ON • AUTO LOCK/SHIFT (Auto lock/shift not P) AUTO LOCK WIRELESS D LOCK: Display (Item) DL AUTO LOCK DELAY Default 60s Contents Function that selects AUTO LOCK time (30 sec. or 60 sec.) Setting 30s/60s DL–13 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM PROBLEM SYMPTOMS TABLE POWER DOOR LOCK CONTROL SYSTEM: Symptom Suspected area See page All doors cannot be locked/unlocked simultaneously by neither door control switch nor door key cylinder Power source circuit (Main body ECU) Replace main body ECU (Instrument panel J/B) - All doors cannot be locked/unlocked simultaneously by driver side door control switch Door control switch circuit (Driver side) DL-60 Replace main body ECU (Instrument panel J/B) - All doors cannot be locked/unlocked simultaneously by front passenger side door control switch Door control switch circuit (Front passenger side door) DL-60 All doors cannot be locked/unlocked simultaneously by door key cylinder Driver side door lock does not operate Passenger side door lock does not operate Rear LH side door lock does not operate Rear RH side door lock does not operate Luggage compartment door lock does not operate Key lock-in prevention function does not work properly (manual operation and key-linked lock are active) w/ Smart Key System Key lock-in prevention function does not work properly (manual operation and key-linked lock are active) w/o Smart Key System Shift-linked automatic door lock does not operate (A/T) One or more doors cannot be locked/unlocked simultaneously (Wireless key operation) One or more doors cannot be locked/unlocked simultaneously (Theft deterrent operation) DL-13 Replace main body ECU (Instrument panel J/B) - Driver side door key lock and unlock switch circuit DL-56 Multiplex network master switch assembly DL-13 Replace main body ECU (Instrument panel J/B) - Driver side door lock motor circuit DL-32 Replace main body ECU (Instrument panel J/B) - Front passenger side door lock motor circuit DL-35 Replace main body ECU (Instrument panel J/B) - Rear door lock motor LH circuit DL-38 Replace main body ECU (Instrument panel J/B) - Rear door lock motor RH circuit DL-41 Replace main body ECU (Instrument panel J/B) - Luggage compartment door lock circuit DL-47 Replace main body ECU (Instrument panel J/B) - Door courtesy switch circuit (Driver side) LI-52 Smart key system DL-147 Replace main body ECU (Instrument panel J/B) - Door courtesy switch circuit (Driver side) LI-52 Unlock warning switch circuit DL-205 Replace main body ECU (Instrument panel J/B) - CAN communication system CA-8 Replace main body ECU (Instrument panel J/B) - Wireless door lock system (w/ smart key system) DL-74 Wireless door lock system (w/o smart key system) DL-104 Driver side door unlock detection switch circuit DL-19 Front passenger door unlock detection switch circuit DL-22 Rear door unlock detection switch LH circuit DL-25 Rear door unlock detection switch RH circuit DL-28 Replace main body ECU (Instrument panel J/B) - Theft deterrent system (w/ smart key system) TD-15 Theft deterrent system (w/o smart key system) TD-53 Driver side door unlock detection switch circuit DL-19 Front passenger door unlock detection switch circuit DL-22 Rear door unlock detection switch LH circuit DL-25 Rear door unlock detection switch RH circuit DL-28 Replace main body ECU (Instrument panel J/B) - DL DL–14 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM TERMINALS OF ECU 1. CHECK MAIN BODY ECU (INSTRUMENT PANEL JUNCTION BLOCK) Front Side: IM IJ IL IF IE IC ID IK IN IR IB IP IA E7 IO E6 E8 II IH E9 Back Side: DL IG B112605E01 DL–15 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM (a) Disconnect the E6, E7, IO, IK, IM, ID, IA, IF, IJ, and E9 J/B and ECU connectors. (b) Measure the voltage and resistance according to the value(s) in the table below. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition DCTY (E7-24) - Body ground L - Body ground Driver door courtesy switch Driver door CLOSED → OPEN 10 kΩ or higher → Below 1 Ω RCTY (E6-5 (*1), 7 (*2)) - Body ground GR - Body ground Rear right door courtesy switch input Rear right door CLOSED → OPEN 10 kΩ or higher → Below 1 Ω PCTY (E6-21) - Body ground Y - Body ground Passenger door courtesy switch input Passenger door CLOSED → OPEN 10 kΩ or higher → Below 1 Ω LCTY (IO-7) - Body ground LG - Body ground Rear left door courtesy switch input Rear left door CLOSED → OPEN 10 kΩ or higher → Below 1 Ω GND2 (IM-9) - Body ground W-B - Body ground Ground Always Below 1 Ω 10 to 14 V → Below 1 V IG (IA-1) - Body ground B - Body ground Engine power supply Ignition switch on (IG) → off GND1 (IF-10) - Body ground W-B - Body ground Ground Always Below 1 Ω ACC (IA-1) - Body ground B - Body ground ACC power supply Always 10 to 14 V L1 (IJ-3) - Body ground L - Body ground Passenger door control switch LOCK input Passenger door control switch OFF → LOCK 10 kΩ or higher → Below 1 Ω UL1 (IJ-4) - Body ground G - Body ground Passenger door control switch UNLOCK input Passenger door control switch OFF → UNLOCK 10 kΩ or higher → Below 1 Ω L1 (IK-15) - Body ground V - Body ground Driver door control switch LOCK input Driver door control switch OFF → LOCK 10 kΩ or higher → Below 1 Ω UL1 (IK-12) - Body ground G - Body ground Driver door control switch UNLOCK input Driver door control switch OFF → UNLOCK 10 kΩ or higher → Below 1 Ω KSW (*1) (E9-5) - Body ground L - Body ground Unlock warning switch signal input No key is in ignition key cylinder → Key is in ignition key cylinder 10 kΩ or higher → Below 1 Ω LGCY (E6-25) - Body ground W - Body ground Luggage compartment door courtesy switch input Luggage compartment door CLOSED → OPEN 10 kΩ or higher → Below 1 Ω TSW (E6-2) - Body ground R - Body ground Luggage compartment door key-linked door unlock input Using mechanical key, operate luggage compartment door lock cylinder to LOCK → OPEN → UNLOCK 10 kΩ or higher → Below 1 Ω → 10 kΩ or higher → BECU (*1) (ID-10) - Body ground O - Body ground +B (BECU) power supply Always 10 to 14 V *1: w/o Smart Key System *2: w/ Smart Key System If the result is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the J/B and ECU connectors. (d) Measure the voltage according to the value(s) in the table below. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition LSWL (*2), LSR (*1) (IP-5) - Body ground GR - Body ground Rear left door lock position switch input Rear left door UNLOCK → LOCK Below 1 V → 10 to 14 V (or pulse generation) LSWL (*1) (IL-5) - Body ground GR - Body ground Rear right door lock position switch input Rear right door UNLOCK → LOCK Below 1 V → 10 to 14 V (or pulse generation) LSWD (E7-9) - Body ground L - Body ground Driver door lock position switch input Driver door UNLOCK → LOCK Below 1 V → 10 to 14 V (or pulse generation) DL DL–16 Symbols (Terminal No.) UL3 (E7-8) - Body ground L2 (IK-16) - Body ground UL2 (IK-7) - Body ground L2 (IJ-5) - Body ground ACT+ (IJ-1) - Body ground ACT+ (IP-11) - Body ground ACT+ (IF-5) - Body ground ACT- (IP-6) - Body ground ACT- (IF-18) - Body ground DL TR+ (E7-1) - Body ground ACTD (E7-5) - Body ground ACT+ (IK-2) - Body ground DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM Wiring Color Terminal Description Condition Specified Condition GR - Body ground Driver door key-linked door unlock input Using mechanical key, operate driver door lock cylinder to LOCK → UNLOCK BR - Body ground Driver door key-linked door lock input Using mechanical key, operate driver door lock cylinder to UNLOCK → LOCK Below 1 V → 10 to 14 V (or pulse generation) GR - Body ground Front passenger door keylinked door unlock input Using mechanical key, operate passenger door lock cylinder to LOCK → UNLOCK Below 1 V → 10 to 14 V (or pulse generation) W - Body ground Front passenger door keylinked door lock input Using mechanical key, operate passenger door lock cylinder to UNLOCK → LOCK Below 1 V → 10 to 14 V (or pulse generation) Door lock motor LOCK drive output (Front passenger door) Door control switch (Master switch or passenger side switch) or driver side door key cylinder OFF → LOCK → OFF Below 1 V → 10 to 14 V → Below 1 V Door lock motor LOCK drive output (Rear door LH) Door control switch (Master switch or passenger side switch) or driver side door key cylinder OFF → LOCK → OFF Below 1 V → 10 to 14 V → Below 1 V Door lock motor LOCK drive output (Rear door RH) Door control switch (Master switch or passenger side switch) or driver side door key cylinder OFF → LOCK → OFF Below 1 V → 10 to 14 V → Below 1 V Door lock motor UNLOCK drive output (Rear door LH) Door control switch (Master switch or passenger side switch) or driver side door key cylinder OFF → UNLOCK → OFF Below 1 V → 10 to 14 V → Below 1 V B - Body ground Door lock motor UNLOCK drive output (Rear door RH) Door control switch (Master switch or passenger side switch) or driver side door key cylinder OFF → UNLOCK → OFF Below 1 V → 10 to 14 V → Below 1 V B - Body ground Door lock motor UNLOCK drive output (Luggage compartment door) Luggage compartment open switch (Transmitter) or luggage compartment door key cylinder OFF → UNLOCK → OFF Below 1 V → 10 to 14 V → Below 1 V Door lock motor UNLOCK drive output (Driver door) Door control switch (Master switch or passenger side switch) or driver side door key cylinder OFF → UNLOCK → OFF Below 1 V → 10 to 14 V → Below 1 V Door lock motor LOCK drive output (Driver door) Door control switch (Master switch or passenger side switch) or driver side door key cylinder OFF → LOCK → OFF Below 1 V → 10 to 14 V → Below 1 V L - Body ground W - Body ground L - Body ground G - Body ground GR - Body ground W - Body ground Below 1 V → 10 to 14 V (or pulse generation) DL–17 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition Below 1 V → 10 to 14 V → Below 1 V ACT- (IJ-2) - Body ground LG - Body ground Door lock motor UNLOCK drive output (Front passenger) Door control switch (Master switch or passenger side switch) or driver side door key cylinder OFF → UNLOCK → OFF LSWR (*2) (E6-5) - Body ground V - Body ground Rear right door lock position switch input Rear right door UNLOCK → LOCK Below 1 V → 10 to 14 V (or pulse generation) LSWP (E6-27) - Body ground LG - Body ground Passenger door lock position switch input Passenger door UNLOCK → LOCK Below 1 V → 10 to 14 V (or pulse generation) *1: w/o Smart Key System *2: w/ Smart Key System If the result is not as specified, the main body ECU (instrument panel J/B) may have a malfunction. DL DL–18 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM DIAGNOSIS SYSTEM 1. DESCRIPTION (a) Power door lock control system data and Diagnostic Trouble Codes (DTCs) can be read through the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the intelligent tester to check for malfunctions and perform repairs. 2. CHECK DLC3 HINT: The vehicle uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. CG SG CANH SIL CANL BAT H100769E16 Symbols (Terminal No.) Terminal Description Condition Specified Condition CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω SIL (7) - SG (5) Bus "+" line During transmission Pulse generation BAT (16) - Body ground Battery positive Always 10 to 14 V CANH (6) - CANL (14) CAN bus line Ignition Switch OFF* 54 to 69 Ω CANH (6) - CG (4) HIGH-level CAN bus line Ignition Switch OFF* 200 Ω or more CANL (14) - CG (4) LOW-level CAN bus line Ignition Switch OFF* 200 Ω or more CANH (6) - BAT (16) HIGH-level CAN bus line Ignition Switch OFF* 6 kΩ or more CANL (14) - BAT (16) LOW-level CAN bus line Ignition Switch OFF* 6 kΩ or more DL DLC3 3. Intelligent Tester C131977E01 NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of the intelligent tester to the DLC3, turn the ignition switch on (IG) and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. • If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. INSPECT BATTERY VOLTAGE Standard Voltage: 11 to 14 V DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM DL–19 If the voltage is below 11 V, recharge or replace the battery before proceeding. DL DL–20 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM DATA LIST / ACTIVE TEST 1. READ DATA LIST HINT: Using the intelligent tester's DATA LIST allows switch, sensor, actuator, and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to save time. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST. (d) Read the DATA LIST according to the display on the tester. MAIN BODY: Item DL Measurement Item/Display (Range) Normal Condition Diagnostic Note D DOR CTY SW Driver side door courtesy light switch signal/ON or OFF ON: Driver side door is CLOSED OFF: Driver side door is OPEN - P DOR CTY SW Passenger side door courtesy light switch signal/ON or OFF ON: Passenger side door is CLOSED OFF: Passenger side door is OPEN - RR DOR CTY SW Rear right door courtesy light switch signal/ON or OFF ON: Rear right door is CLOSED OFF: Rear right door is OPEN - RL DOR CTY SW Rear left door courtesy light switch signal/ON or OFF ON: Rear left door is CLOSED OFF: Rear left door is OPEN - D LOCK POS SW Driver side door lock position switch signal/ON or OFF ON: Driver side door is unlocked ON: Driver side door is locked - P LOCK POS SW Front passenger side door lock position switch signal/ON or OFF ON: Front passenger side door is unlocked ON: Front passenger side door is locked - RR LOCK POS SW (*1) Rear right door lock position switch signal/ON or OFF ON: Rear right door is unlocked OFF: Rear right door is locked - RL LOCK POS SW (*1) Rear left door lock position switch signal/ON or OFF ON: Rear left door is unlocked OFF: Rear left door is locked - LUGG COURTSY SW Luggage compartment door courtesy light switch signal/ON or OFF ON: Luggage compartment door is OPEN OFF: Luggage compartment door is CLOSED - D/L SW-LOCK Door control switch lock signal/ ON or OFF ON: Door control switch is pushed to lock position OFF: Door control switch is not pushed to lock position - D/L SW-UNLOCK Door control switch unlock signal/ ON or OFF ON: Door control switch is pushed to unlock position OFF: Door control switch is not pushed to unlock position - DOR KEY SW-LOCK Driver door lock/unlock switch lock signal (key-linked lock switch)/ON or OFF ON: Driver side door key cylinder is turned to lock position OFF: Driver side door key cylinder is turned to unlock position - DOR KEY SW-ULCK Driver door lock/unlock switch unlock signal (key-linked unlock switch)/ON or OFF ON: Driver side door key cylinder is turned to unlock position OFF: Driver side door key cylinder is turned to lock position - DL–21 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM Item Measurement Item/Display (Range) Normal Condition D DOR KEY SW-UL Driver door lock/unlock switch unlock signal (2 times key-linked unlock switch)/ON or OFF ON: Driver side door key cylinder is turned to unlock position OFF: Driver side door key cylinder is turned to lock position - TRUNK KEY UNLK Luggage compartment door key cylinder switch/ON or OFF ON: Ignition key is inserted and turned to lock position OFF: Ignition key is inserted and turned to unlock position - 2. Diagnostic Note *1: w/ Smart Key System, w/o Smart Key System with Theft Deterrent System PERFORM ACTIVE TEST HINT: Performing the intelligent tester's ACTIVE TEST allows relays, VSVs, actuators, and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST. (d) Perform the ACTIVE TEST according to the display on the tester. MAIN BODY: Item Test Details Diagnostic Note DOOR LOCK Operate door lock motor LOCK/UNLOCK - D DOOR UNLOCK Operate driver door lock motor LOCK - TRUNK/BDOR OPEN Operate luggage compartment door lock motor LOCK - DL DL–22 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM Driver Side Door UNLOCK Detection Switch Circuit DESCRIPTION The driver's door unlock detection switch is built into the driver's door lock assembly. The switch turns on when the driver's door is locked and turns off when the door is unlocked. The main body ECU is connected to the driver's door lock assembly via terminal LSWD and driver's door lock/unlock state signals are input to the main body ECU. The main body ECU applies voltage to the door unlock detection switch via terminal LSWD. When the door unlock detection switch is on (there is continuity between the switch terminals), a lock state signal is input to the main body ECU. When the switch is off (there is no continuity between the switch terminals), an unlock state signal is input. WIRING DIAGRAM E7 Main Body ECU I7 Front Door Lock Assembly LH 7 E LSSR 8 9 LSWD B109777E18 INSPECTION PROCEDURE DL 1 READ VALUE OF DATA LIST (DOOR UNLOCK DETECTION SWITCH) (a) Check the DATA LIST to ensure proper function of the door unlock detection switch. MAIN BODY: Item Measurement Item / Display (Range) Normal Condition Diagnostic Note D LOCK POS SW Driver side door unlock detection switch signal /ON or OFF ON: Driver side door is unlocked OFF: Driver side door is locked - OK: The display is as specified in the normal condition column. NG Go to step 2 DL–23 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE 2 INSPECT FRONT DOOR LOCK ASSEMBLY (DOOR UNLOCK DETECTION SWITCH) (a) Remove the front door lock assembly LH. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Measurement Condition Door Lock Condition Specified Condition 7-8 Battery positive (+) → Terminal 4 Battery negative (-) → Terminal 1 Lock 10 kΩ or higher 7-8 Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 4 Unlock Below 1 Ω Unlock Lock NG REPLACE FRONT DOOR LOCK ASSEMBLY B065427E20 OK DL DL–24 3 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM CHECK WIRE HARNESS (FRONT DOOR LOCK ASSEMBLY - MAIN BODY ECU) Wire Harness Side: I7 Front Door Lock Assembly LH E LSSR (a) Disconnect the front door lock assembly LH connector. (b) Disconnect the main body ECU connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection (Symbols) Condition Specified Condition I7-8 (LSSR) - E7-9 (LSWD) Always Below 1 Ω I7-8 (LSSR) - Body ground Always 10 kΩ or higher I7-7 (E) - Body ground Always Below 1 Ω NG E7 Main Body ECU LSWD B112606E01 OK REPLACE MAIN BODY ECU DL REPAIR OR REPLACE HARNESS OR CONNECTOR DL–25 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM Front Passenger Side Door UNLOCK Detection Switch Circuit DESCRIPTION The front passenger door unlock detection switch is built into the front passenger door lock assembly. The switch turns on when the front passenger door is locked and turns off when the door is unlocked. The main body ECU is connected to the front passenger door lock assembly via terminal LSWP and front passenger door lock/unlock state signals are input to the ECU. The main body ECU applies voltage to the door unlock detection switch via terminal LSWP. When the door unlock detection switch is on (there is continuity between the switch terminals), a lock state signal is input to the ECU. When the switch is off (there is no continuity between the switch terminals), an unlock state signal is input. WIRING DIAGRAM Main Body ECU H8 Front Door Lock Assembly RH 8 E LSSR 7 27 E6 LSWP B109773E34 INSPECTION PROCEDURE 1 READ VALUE OF DATA LIST (DOOR UNLOCK DETECTION SWITCH) (a) Check the DATA LIST to ensure proper function of the door unlock detection switch. MAIN BODY: Item Measurement Item / Display (Range) Normal Condition Diagnostic Note P LOCK POS SW Passenger side door lock position switch signal /ON or OFF ON: Passenger side door lock is in UNLOCK position OFF: Passenger side door lock is in LOCK position - OK: The display is as specified in the normal condition column. DL DL–26 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM NG Go to step 2 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE 2 INSPECT FRONT DOOR LOCK ASSEMBLY (DOOR UNLOCK DETECTION SWITCH) (a) Remove the front door lock assembly RH. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Measurement Condition Door Lock Condition Specified Condition 7-8 Battery positive (+) → Terminal 4 Battery negative (-) → Terminal 1 LOCK 10 kΩ or higher 7-8 Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 4 UNLOCK Below 1 Ω Unlock Lock NG B065429E21 OK DL REPLACE FRONT DOOR LOCK ASSEMBLY DL–27 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM 3 CHECK WIRE HARNESS (FRONT DOOR LOCK ASSEMBLY - MAIN BODY ECU) (a) Disconnect the front door lock assembly RH connector. (b) Disconnect the ECU connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side: H8 Front Door Lock Assembly RH LSSR E Tester Connection (Symbols) Condition Specified Condition H8-7 (LSSR) - E6-27 (LSWP) Always Below 1 Ω H8-7 (LSSR) - Body ground Always 10 kΩ or higher H8-8 (E) - Body ground Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR E6 Main Body ECU LSWP B111708E12 OK REPLACE MAIN BODY ECU DL DL–28 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM Rear Door UNLOCK Detection Switch LH Circuit DESCRIPTION The rear left door unlock detection switch is built into the rear left door lock assembly. The switch turns on when the rear left door is locked and turns off when the door is unlocked. The main body ECU is connected to the rear left door lock assembly via terminal LSWL (w/ Smart key system) or LSR (w/o Smart key system) and rear left door lock/unlock state signals are input to the ECU. The main body ECU applies voltage to the door unlock detection switch via terminal LSWL (w/ Smart key system) or LSR (w/o Smart key system). When the door unlock detection switch is on (there is continuity between the switch terminals), a lock state signal is input to the ECU. When the switch is off (there is no continuity between the switch terminals), an unlock state signal is input. WIRING DIAGRAM Main Body ECU K5 Rear Door Lock Assembly LH 9 E LSSR 6 Instrument Panel J/B 5 IP 20 LSWL (*1) LSR (*2) *1: w/ Smart Key System *2: w/o Smart Key System B109775E08 INSPECTION PROCEDURE DL HINT: Start the inspection from step 1 when w/ smart key system or w/o smart key system and w/ theft deterrent system, and start from step 2 when w/o smart key system and w/o theft deterrent system. 1 READ VALUE OF DATA LIST (UNLOCK DETECTION SWITCH) (a) Check the DATA LIST to ensure proper function of the door unlock detection switch. MAIN BODY: Item Measurement Item / Display (Range) RL LOCK POS SW Rear left door lock position switch signal / ON or OFF Normal Condition ON: Rear left door lock is in UNLOCK position OFF: Rear left door lock is in LOCK position Diagnostic Note - DL–29 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM OK: The display is as specified in the normal condition column. NG Go to step 2 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE 2 INSPECT REAR DOOR LOCK ASSEMBLY (UNLOCK DETECTION SWITCH) (a) Remove the rear door lock assembly LH. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Lock Tester Connection Measurement Condition Door Lock Condition Specified Condition 6-9 Battery positive (+) → Terminal 4 Battery negative (-) → Terminal 1 Lock 10 kΩ or higher 6-9 Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 4 Unlock Below 1 Ω Unlock NG REPLACE REAR DOOR LOCK ASSEMBLY E123890E02 OK 3 CHECK WIRE HARNESS (REAR DOOR LOCK ASSEMBLY - MAIN BODY ECU) (a) Disconnect the rear door lock assembly LH connector. DL DL–30 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM Wire Harness Side: K5 Rear Door Lock Assembly LH LSSR E IP Instrument Panel J/B B112607E01 (b) Disconnect the ECU (instrument panel J/B) connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection (Symbols) Condition Specified Condition K5-6 (LSSR) - IP-5 Always Below 1 Ω K5-6 (LSSR) - Body ground Always 10 kΩ or higher K5-9 (E) - Body ground Always Below 1 Ω NG DL REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE MAIN BODY ECU (INSTRUMENT PANEL J/B) DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM DL–31 Rear Door UNLOCK Detection Switch RH Circuit DESCRIPTION The rear right door unlock detection switch is built into the rear right door lock assembly. The switch turns on when the rear right door is locked and turns off when the door is unlocked. The main body ECU is connected to the rear right door lock assembly via terminal LSWR (w/ smart key system), LSWL (w/o smart key system), and rear right door lock/unlock state signals are input to the ECU. The main body ECU applies voltage to the door unlock detection switch via terminal LSWR (w/ smart key system), LSWL (w/o smart key system). When the door unlock detection switch is on (there is continuity between the switch terminals), a lock state signal is input to the ECU. When the switch is off (there is no continuity between the switch terminals), an unlock state signal is input. WIRING DIAGRAM w/ SMART KEY SYSTEM: Main Body ECU J5 Rear Door Lock Assembly RH 9 E LSSR 6 5 E6 LSWR B109773E36 DL DL–32 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM w/o SMART KEY SYSTEM: Main Body ECU J5 Rear Door Lock Assembly RH 9 E Instrument Panel J/B 5 IL LSSR 6 20 LSWL B109775E09 INSPECTION PROCEDURE HINT: Start the inspection from step 1 when w/ smart key system or w/o smart key system and w/ theft deterrent system, and start from step 2 when w/o smart key system and w/o theft deterrent system. 1 READ VALUE OF DATA LIST (UNLOCK DETECTION SWITCH) (a) Check the DATA LIST to ensure proper function of the door unlock detection switch. MAIN BODY: Item RR LOCK POS SW Measurement Item / Display (Range) Normal Condition ON: Rear right door lock is in UNLOCK position OFF: Rear right door lock is in LOCK position Rear right door lock position switch signal / ON or OFF Diagnostic Note - OK: The display is as specified in the normal condition column. DL NG Go to step 2 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM 2 DL–33 INSPECT REAR DOOR LOCK ASSEMBLY (UNLOCK DETECTION SWITCH) (a) Remove the rear door lock assembly RH. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Unlock Tester Connection Measurement Condition Door Lock Condition Specified Condition 6-9 Battery positive (+) → Terminal 4 Battery negative (-) → Terminal 1 Lock 10 kΩ or higher 6-9 Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 4 Unlock Below 1 Ω Lock NG REPLACE REAR DOOR LOCK ASSEMBLY E123891E02 OK 3 CHECK WIRE HARNESS (REAR DOOR LOCK - MAIN BODY ECU (INSTRUMENT PANEL J/ B)) (a) Disconnect the rear door lock assembly RH connector. DL DL–34 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM Wire Harness Side: J5 Rear Door Lock Assembly RH LSSR IL (*1) Instrument Panel J/B E E6 (*2) Main Body ECU *1: w/o Smart Key System LSWR *2: w/ Smart Key System B112608E01 (b) Disconnect the ECU (instrument panel J/B) connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance DL Tester Connection (Symbols) Condition Specified Condition J5-6 (LSSR) - IL-5 (*1) Always Below 1 Ω J5-6 (LSSR) - E6-5 (LSWR) (*2) Always Below 1 Ω J5-6 (LSSR) - Body ground Always 10 kΩ or higher J5-9 (E) - Body ground Always Below 1 Ω *1: w/o SMART KEY SYSTEM *2: w/ SMART KEY SYSTEM NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE MAIN BODY ECU (INSTRUMENT PANEL J/B) DL–35 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM Driver Side Door Lock Motor Circuit DESCRIPTION The driver's door lock motor is built into the driver's door lock assembly. The main body ECU controls the driver's door lock motor to lock/unlock the driver's door. This ECU applies current from terminal ACT+ to terminal ACTD to operate the motor to lock the door. It reverses the direction of the current flow to operate the motor to unlock the door. WIRING DIAGRAM I7 Front Door Lock Assembly LH L 4 UL 1 Main Body ECU Instrument Panel J/B 2 IK 1 ACT+ 5 E7 ACTD B109770E04 DL DL–36 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM INSPECTION PROCEDURE 1 INSPECT FRONT DOOR LOCK ASSEMBLY (DOOR LOCK MOTOR) (a) Remove the front door lock assembly LH. (b) Apply battery voltage and check operation of the door lock motor. OK Measurement Condition Specified Condition Battery positive (+) → Terminal 4 Battery negative (-) → Terminal 1 Lock Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 4 Unlock NG REPLACE FRONT DOOR LOCK ASSEMBLY Unlock Lock B065427E20 OK 2 CHECK WIRE HARNESS (FRONT DOOR LOCK - MAIN BODY ECU (INSTRUMENT PANEL J/B)) (a) Disconnect the front door lock assembly LH connector. DL DL–37 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM Wire Harness Side: I7 Front Door Lock Assembly LH UL L IK Instrument Panel J/B E7 Main Body ECU ACTD B112609E01 (b) Disconnect the ECU (instrument panel J/B) connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection (Symbols) Condition Specified Condition I7-4 (L) - IK-2 Always Below 1 Ω I7-1 (UL) - E7-5 (ACTD) Always Below 1 Ω IK-2 - Body ground Always 10 kΩ or higher E7-5 (ACTD) - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE DL DL–38 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM Front Passenger Side Door Lock Motor Circuit DESCRIPTION The front passenger door lock motor is built into the front passenger door lock assembly. The main body ECU controls the front passenger door lock motor to lock/unlock the front passenger door. This ECU applies current from terminal ACT+ to terminal ACT- to operate the motor to lock the door. It reverses the direction of the current flow to operate the motor to unlock the door. WIRING DIAGRAM H8 Front Door Lock Assembly RH Main Body ECU Instrument Panel J/B 4 3 IJ 1 UL 1 2 IJ 3 L ACT+ ACT- B109771E16 DL DL–39 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM INSPECTION PROCEDURE 1 INSPECT FRONT DOOR LOCK ASSEMBLY (DOOR LOCK MOTOR) (a) Remove the front door lock assembly RH. (b) Apply battery voltage and check operation of the door lock motor. OK Measurement Condition Specified Condition Battery positive (+) → Terminal 4 Battery negative (-) → Terminal 1 Lock Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 4 Unlock NG REPLACE FRONT DOOR LOCK ASSEMBLY Unlock Lock B065429E21 OK 2 CHECK WIRE HARNESS (FRONT DOOR LOCK - MAIN BODY ECU (INSTRUMENT PANEL J/B)) (a) Disconnect the front door lock assembly RH connector. DL DL–40 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM Wire Harness Side: IJ Instrument Panel J/B H8 Front Door Lock Assembly RH UL L B112610E01 (b) Disconnect the ECU (instrument panel J/B) connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection (Symbols) Condition H8-4 (L) - IJ-1 Always Below 1 Ω H8-1 (UL) - IJ-2 Always Below 1 Ω IJ-1 - Body ground Always 10 kΩ or higher IJ-2 - Body ground Always 10 kΩ or higher NG DL Specified Condition REPAIR OR REPLACE HARNESS OR CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE DL–41 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM Rear Door Lock Motor LH Circuit DESCRIPTION The rear left door lock motor is built into the rear left door lock assembly. The main body ECU controls the rear left door lock motor to lock/unlock the rear left door. This ECU applies current from terminal ACT+ to terminal ACT- to operate the motor to lock the door. It reverses the direction of the current flow to operate the motor to unlock the door. WIRING DIAGRAM K5 Rear Door Lock Assembly LH Main Body ECU Instrument Panel J/B 4 11 IP 1 UL 1 6 IP 3 L ACT+ ACT- B109771E17 DL DL–42 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM INSPECTION PROCEDURE 1 INSPECT REAR DOOR LOCK ASSEMBLY (a) Remove the rear door lock assembly LH. (b) Apply battery voltage and check operation of the door lock motor. OK Measurement Condition Specified Condition Battery positive (+) → Terminal 4 Battery negative (-) → Terminal 1 Lock Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 4 Unlock NG Lock L REPLACE REAR DOOR LOCK ASSEMBLY Unlock UL E123890E03 OK 2 CHECK WIRE HARNESS (REAR DOOR LOCK - MAIN BODY ECU (INSTRUMENT PANEL J/ B)) (a) Disconnect the rear door lock assembly LH connector. DL DL–43 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM Wire Harness Side: K5 Raer Door Lock Assembly LH UL L IP Instrument Panel J/B B112611E01 (b) Disconnect the ECU (instrument panel J/B) connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection (Symbols) Condition Specified Condition K5-4 (L) - IP-11 Always Below 1 Ω K5-1 (UL) - IP-6 Always Below 1 Ω IP-11 - Body ground Always 10 kΩ or higher IP-6 - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE DL DL–44 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM Rear Door Lock Motor RH Circuit DESCRIPTION The rear right door lock motor is built into the rear right door lock assembly. The main body ECU controls the rear right door lock motor to lock/unlock the rear right door. This ECU applies current from terminal ACT+ to terminal ACT- to operate the motor to lock the door. It reverses the direction of the current flow to operate the motor to unlock the door. WIRING DIAGRAM J5 Rear Door Lock Assembly RH Main Body ECU Instrument Panel J/B 4 5 IF 1 UL 1 18 IF 3 L ACT+ ACT- B109771E18 DL DL–45 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM INSPECTION PROCEDURE 1 INSPECT REAR DOOR LOCK ASSEMBLY (a) Remove the rear door lock assembly RH. (b) Apply battery voltage and check operation of the door lock motor. OK Unlock L Lock Measurement Condition Specified Condition Battery positive (+) → Terminal 4 Battery negative (-) → Terminal 1 Lock Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 4 Unlock NG REPLACE REAR DOOR LOCK ASSEMBLY UL E123891E03 OK 2 CHECK WIRE HARNESS (REAR DOOR LOCK - MAIN BODY ECU (INSTRUMENT PANEL J/ B)) (a) Disconnect the rear door lock assembly RH connector. DL DL–46 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM Wire Harness Side: Instrument Panel J/B J5 Rear Door Lock Aseembly RH UL IF L B112612E01 (b) Disconnect the ECU (instrument panel J/B) connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection (Symbols) Specified Condition J5-4 (L) - IF-5 Always Below 1 Ω J5-1 (UL) - IF-18 Always Below 1 Ω IF-5 - Body ground Always 10 kΩ or higher IF-18 - Body ground Always 10 kΩ or higher NG DL Condition REPAIR OR REPLACE HARNESS OR CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM DL–47 Luggage Compartment Door Courtesy Switch Circuit DESCRIPTION The door courtesy switch turns on when the door is open and turns off when the door is closed. The main body ECU detects the condition of the door courtesy switch. WIRING DIAGRAM E6 Main Body ECU S5 Luggage Compartment Door Lock Assembly (Courtesy Switch) 2 3 25 LGCY B109777E19 INSPECTION PROCEDURE 1 READ VALUE OF DATA LIST (DOOR COURTESY SWITCH) (a) Check the DATA LIST for proper functioning of the door courtesy switch. MAIN BODY: Item LUGG COURTSY SW Measurement Item / Display (Range) Luggage compartment door courtesy light switch signal / ON or OFF Normal Condition ON: Luggage compartment door is OPEN OFF: Luggage compartment door is CLOSED Diagnostic Note - OK: "ON" (door is open) and "OFF" (door is closed) appear on the screen. NG Go to step 2 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE DL DL–48 2 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM INSPECT LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY (DOOR COURTESY SWITCH) (a) Remove the luggage compartment door lock. (b) Measure the resistance between the specified terminals of the switch. Standard resistance Tester Connection Condition 2-3 UNLOCK Below 1 Ω 2-3 LOCK 10 kΩ or higher UNLOCK NG LOCK B137937E01 OK DL Specified Condition REPLACE LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY DL–49 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM 3 CHECK WIRE HARNESS (LUGGAGE COMPARTMENT DOOR LOCK - MAIN BODY ECU) (a) Disconnect the ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side: E6 Main Body ECU Tester Connection (Symbols) Condition Specified Condition S5-3 - E6-25 (LGCY) Always Below 1 Ω S5-3 - Body ground Always 10 kΩ or higher S5-2 - Body ground Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR LGCY S5 Luggage Compartment Door Lock Assembly (Door Courtesy Switch) B137940E01 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE DL DL–50 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM Luggage Compartment Door Lock Circuit DESCRIPTION The luggage compartment door lock motor is built into the luggage compartment door lock assembly. The main body ECU receives a luggage compartment door unlock signal from the luggage compartment door lock cylinder or electrical key switch (w/ smart key system) and operates the door lock motor. WIRING DIAGRAM S5 Luggage Compartment Door Lock Assembly Main Body ECU 1 E7 TR+ 1 Door Lock Motor 2 DL B137939E01 INSPECTION PROCEDURE 1 PERFORM ACTIVE TEST (LUGGAGE COMPARTMENT DOOR) (a) Select the ACTIVE TEST, use the intelligent tester to generate a control command, and then check that the door lock operates. MAIN BODY: Item TRUNK/BDOR OPEN Test Details Operate luggage compartment door lock motor LOCK/UNLOCK Diagnostic Note - DL–51 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM OK: Door lock is locked/unlocked. NG Go to step 2 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE 2 INSPECT LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY (DOOR LOCK MOTOR) (a) Remove the luggage compartment door lock assembly. (b) Apply battery voltage and check operation of the door lock motor. Standard voltage UNLOCK Measurement Condition Specified Condition Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 2 Unlock NG REPLACE LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY LOCK B137937E01 OK DL DL–52 3 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM CHECK WIRE HARNESS (LUGGAGE COMPARTMENT DOOR LOCK - MAIN BODY ECU) (a) Disconnect the ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side: E7 Main Body ECU Tester Connection (Symbols) Condition Specified Condition E7-1 (TR+) - S5-1 Always Below 1 Ω S5-1 - Body ground Always 10 kΩ or higher S5-2 - Body ground Always Below 1 Ω TR+ NG REPAIR OR REPLACE HARNESS OR CONNECTOR S5 Luggage Compartment Door Lock Assembly B137938E01 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE DL DL–53 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM Luggage Compartment Door Key Cylinder Switch Circuit DESCRIPTION When the luggage compartment door lock cylinder is turned to unlock the door by key, there is continuity between terminal TSW of the main body ECU and body ground. WIRING DIAGRAM E6 Main Body ECU S8 (*1) S6 (*2) Luggage Compartment Door Lock Cylinder 3 (*1) E 1 (*2) LSSR 1 (*1) 2 (*2) 2 TSW *1: w/ Smart Key System *2: w/o Smart Key System B109777E25 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the intelligent tester main switch on. (c) Select the item below in the "DATA LIST" and read the display on the intelligent tester. MAIN BODY: Item TRUNK KEY UNLK Measurement Item/Display (Range) Luggage compartment door key cylinder switch/ON or OFF Normal Condition ON: Ignition key inserted and turned to lock position OFF: Ignition key inserted and turned to unlock position Diagnostic Note - OK: When the ignition switch is operated, the display changes as shown above. NG Go to step 2 DL DL–54 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE 2 INSPECT MAIN BODY ECU (TSW TERMINAL) (a) Turn the ignition switch off. (b) Disconnect the ECU connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side: TSW E6 Main Body ECU Tester Connection (Symbols) Condition Specified Condition E6-2 (TSW) - Body ground Luggage compartment door lock cylinder LOCK 10 kΩ or higher E6-2 (TSW) - Body ground Luggage compartment door lock cylinder OPEN Below 1 Ω E6-2 (TSW) - Body ground Luggage compartment door lock cylinder UNLOCK 10 kΩ or higher NG Go to step 3 B137943E02 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE DL DL–55 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM 3 INSPECT LUGGAGE COMPARTMENT DOOR LOCK CYLINDER (a) Disconnect the luggage compartment door lock cylinder connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance UNLOCK OPEN Tester Connection (Symbols) Condition Specified Condition *1 S8-1 - S8-3 Luggage compartment door lock cylinder LOCK 10 kΩ or higher *1 S8-1 - S8-3 Luggage compartment door lock cylinder OPEN Below 1 Ω *1 S8-1 - S8-3 Luggage compartment door lock cylinder UNLOCK 10 kΩ or higher *2 S6-2 - S6-1 Luggage compartment door lock cylinder LOCK 10 kΩ or higher *2 S6-2 - S6-1 Luggage compartment door lock cylinder OPEN Below 1 Ω *2 S6-2 - S6-1 Luggage compartment door lock cylinder UNLOCK 10 kΩ or higher LOCK S6 (*2) *1: w/ SMART KEY SYSTEM *2: w/o SMART KEY SYSTEM NG REPLACE LUGGAGE COMPARTMENT DOOR LOCK CYLINDER S8 (*1) B137942E01 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (MAIN BODY ECU, BODY GROUND - DOOR LOCK CYLINDER) DL DL–56 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM Door Key Lock / Unlock Switch Circuit DESCRIPTION The door lock and unlock switch is built into the door lock assembly. This switch is ON when the door key is in the unlock position and OFF when the door key is in the lock position. It is used as one of the operating conditions for the key confinement prevention function. WIRING DIAGRAM Main Body ECU H8 Front Door Lock Assembly RH L 6 8 E UL 5 Instrument Panel J/B 5 IJ 7 IK 10 24 L2 UL2 B109774E05 DL DL–57 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM INSPECTION PROCEDURE 1 INSPECT FRONT DOOR LOCK ASSEMBLY RH (DOOR KEY LOCK AND UNLOCK SWITCH) (a) Remove the front door lock assembly RH. (b) Measure the resistance according to the value(s) in the table below. Standard resistance LOCK Tester Connection Condition Specified Condition 5-8 ON (Door lock set to UNLOCK) Below 1 Ω 5-8 6-8 OFF (Free) 10 kΩ or higher 6-8 ON (Door lock set to LOCK) Below 1 Ω UNLOCK NG REPLACE FRONT DOOR LOCK ASSEMBLY LH B112613E01 OK 2 CHECK WIRE HARNESS (FRONT DOOR LOCK RH - MAIN BODY ECU (INSTRUMENT PANEL J/B)) (a) Disconnect the IJ J/B connector. DL DL–58 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM Wire Harness Side: IK Instrument Panel J/B IJ Instrument Panel J/B H8 Front Door Lock Assembly RH UL L E B138063E01 (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection (Symbols) Condition H8-6 (L) - IJ-5 Always Below 1 Ω H8-5 (UL) - IK-7 Always Below 1 Ω H8-8 (E) - Body ground Always Below 1 Ω H8-6 (L) - Body ground Always 10 kΩ or higher H8-5 (UL) - Body ground Always 10 kΩ or higher NG DL Specified Condition REPAIR OR REPLACE HARNESS OR CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE DL–59 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM Driver Side Door Key Lock and Unlock Switch Circuit DESCRIPTION The driver's door key lock and unlock switch is built into the driver's door lock assembly. When the driver's door key cylinder is turned to lock all the doors by key, there is continuity between terminals L and E of the key lock and unlock switch. When the cylinder is turned to unlock the door(s), there is continuity between terminals UL and E. Terminals L2 and UL3 of the main body ECU are connected to the door lock assembly, and door lock/ unlock request signals (by key) are input to the main body ECU. The main body ECU constantly applies voltage to terminal L of the driver's door lock assembly via terminal L2. When the driver's door key cylinder is turned to lock all the doors by key, current flows from terminal L2 to terminal L. The main body ECU also applies constant voltage to terminal UL of the door lock assembly via terminal UL3. When the door key cylinder is turned in the direction to unlock the door(s) by key, current flows from terminal UL3 to terminal UL. WIRING DIAGRAM E7 Maing Body ECU I7 Front Door Lock Assembly LH L 7 9 Instrument Panel J/B 16 IK 10 L2 E UL 10 10 UL3 DL B137941E01 DL–60 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM INSPECTION PROCEDURE 1 READ VALUE OF DATA LIST (a) Check the DATA LIST to ensure proper function of the door unlock detection switch. MAIN BODY: Item Measurement Item / Display (Range) Normal Condition Diagnostic Note DOR KEY SW-LOCK Driver door lock/unlock switch lock signal (key-linked lock switch) /ON or OFF ON: Driver side door key cylinder is turned to LOCK OFF: Driver side door key cylinder is not turned to LOCK - DOR KEY SW-ULCK Driver door lock/unlock switch unlock signal (key-linked unlock switch) /ON or OFF ON: Driver side door key cylinder is turned to UNLOCK OFF: Driver side door key cylinder is not turned to UNLOCK - OK: The display is as specified in the normal condition column. NG Go to step 2 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE 2 INSPECT FRONT DOOR LOCK ASSEMBLY (DOOR KEY LOCK AND UNLOCK SWITCH) Lock (a) Remove the front door lock assembly LH. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition 7-9 ON (Door lock set to LOCK) Below 1 Ω 7-9 7 - 10 OFF (Free) 10 kΩ or higher 7 - 10 ON (Door lock set to UNLOCK) Below 1 Ω Unlock DL NG B065428E11 OK REPLACE FRONT DOOR LOCK ASSEMBLY DL–61 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM 3 CHECK WIRE HARNESS (FRONT DOOR LOCK ASSEMBLY - MAIN BODY ECU) (a) Disconnect the front door lock assembly LH connector. Wire Harness Side: I7 Front Door Lock Assembly LH E IK Instrument Panel J/B L UL E7 Main Body ECU UL3 B112609E02 (b) Disconnect the main body ECU connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection (Symbols) Condition Specified Condition I7-9 (L) - IK-16 Always Below 1 Ω I7-10 (UL) - E7-10 (UL3) Always Below 1 Ω I7-7 (E) - Body ground Always Below 1 Ω I7-9 (L) - Body ground Always 10 kΩ or higher I7-10 (UL) - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR DL DL–62 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM OK REPLACE MAIN BODY ECU DL DL–63 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM Door Control Switch Circuit DESCRIPTION When the lock side of the door control switch is pressed, continuity is established between terminal 2 (driver side) or 4 (passenger side) and terminal 1 (driver side) or 3 (passenger side) of the switch. When the unlock side of the switch is pressed, continuity is established between terminal 9 (driver side) or 2 (passenger side) and terminal 1 (driver side) or 3 (passenger side). Terminals L1 and UL1 of the main body ECU are connected to the door control switch and door lock/ unlock request signals (by door control switch operation) are input to the ECU. The main body ECU constantly applies voltage to terminal 2 (driver side) or 4 (passenger side) of the door control switch via terminal L1. When the door control switch is operated to lock all doors, current flows from terminal L1 to terminal 2 (driver side) or 4 (passenger side). The main body ECU determines that this is door lock request signal input. The main body ECU also applies constant voltage to terminal 9 (driver side) or 2 (passenger side) of the door control switch via terminal UL1. When the door control switch is operated to unlock the doors, current flows from terminal UL1 to terminal 9 (driver side) or 2 (passenger side). The main body ECU determines that this is door unlock request signal input. WIRING DIAGRAM DRIVER SIDE: M1 Power Window Master Switch (Door Control Switch) LOCK 2 1 9 UNLOCK Main Body ECU Instrument Panel J/B 15 IK 12 IK 9 12 L1 UL1 B109774E06 DL DL–64 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM PASSENGER SIDE: Main Body ECU H5 Door Control Switch LOCK Instrument Panel J/B 3 IJ 4 IJ 4 3 2 UNLOCK 9 12 L1 UL1 B109774E08 INSPECTION PROCEDURE 1 INSPECT DOOR CONTROL SWITCH ASSEMBLY (a) Inspect driver side. (1) Remove the master switch. (2) Measure the resistance of the door control switch. Standard resistance Lock Unlock Tester Connection DL E123893E04 Switch Condition Specified Condition 2-1 Lock Below 1 Ω 2-1 OFF (Free) 10 kΩ or higher 9-1 Unlock Below 1 Ω 9-1 OFF (Free) 10 kΩ or higher DL–65 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM (b) Inspect passenger side. (1) Remove the door control switch assembly. (2) Measure the resistance according to the value(s) in the table below. Standard resistance Lock Unlock Tester Connection Switch Condition Specified Condition 4-3 Lock Below 1 Ω 4-3 2-3 OFF (Free) 10 kΩ or higher 2-3 Unlock Below 1 Ω NG REPLACE DOOR CONTROL SWITCH OR MASTER SWITCH L E UL E123894E01 OK 2 CHECK WIRE HARNESS (DOOR CONTROL SWITCH - MAIN BODY ECU (INSTRUMENT PANEL J/B)) (a) Disconnect the door control switch connector. DL DL–66 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM Wire Harness Side: Instrument Panel J/B H5 (*2) Door Control Switch IJ IK M1 (*1) Power Window Master Switch (Door Control Switch) *1: Driver Side *2: Passenger Side B137936E01 (b) Disconnect the ECU (instrument panel J/B) connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance DL Tester Connection Condition Specified Condition *1 M1-2 - IK-15 Always Below 1 Ω *1 M1-9 - IK-12 Always Below 1 Ω *1 M1-1 - Body ground Always Below 1 Ω *1 IK-15 - Body ground Always 10 kΩ or higher *1 IK-12 - Body ground Always 10 kΩ or higher *2 H5-4 - IJ-3 Always Below 1 Ω *2 H5-2 - IJ-4 Always Below 1 Ω *2 H5-3 - Body ground Always Below 1 Ω *2 IJ-3 - Body ground Always 10 kΩ or higher *2 IJ-4 - Body ground Always 10 kΩ or higher *1: Driver Side *2: Passenger Side NG REPAIR OR REPLACE HARNESS OR CONNECTOR DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM DL–67 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE DL DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) DL–65 WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) BODY ELECTRICAL DOOR LOCK PARTS LOCATION PERSONAL LIGHT ASSEMBLY SECURITY HORN ASSEMBLY LOW PITCHED HORN HAZARD WARNING LIGHT ENGINE ROOM R/B AND J/B - S-HORN RELAY - HORN RELAY - H-LP(RL) RELAY - H-LP(LL) RELAY HEADLIGHT WIRELESS DOOR LOCK BUZZER HIGH PITCHED HORN HAZARD WARNING LIGHT HEADLIGHT ENGINE SWITCH TURN SIGNAL FLASHER ASSEMBLY CERTIFICATION ECU DL MAIN BODY ECU (INSTRUMENT PANEL J/B) DLC3 - TAIL RELAY B128400E01 DL–66 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) REAR DOOR LOCK RH REAR DOOR COURTESY SWITCH RH FRONT DOOR LOCK RH FRONT DOOR COURTESY SWITCH RH DOOR CONTROL RECEIVER FRONT DOOR LOCK LH FRONT DOOR COURTESY SWITCH LH HAZARD WARNING LIGHT HAZARD WARNING LIGHT DL REAR DOOR LOCK LH TAILLIGHT TAILLIGHT REAR DOOR COURTESY SWITCH LH LUGGAGE COMPARTMENT DOOR LOCK B128397E01 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) DL–67 LOCK SWITCH UNLOCK SWITCH LUGGAGE OPEN SWITCH PANIC SWITCH DOOR CONTROL TRANSMITTER B128402E01 DL DL–68 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) SYSTEM DIAGRAM Certification ECU Main Body ECU Front Door Lock Assembly (LH, RH) Rear Door Lock Assembly (LH, RH) Luggage Compartment Door Lock Assembly Door Control Receiver Turn Signal Flasher Wireless Door Lock Buzzer Security Horn Hazard Warning Light DLC3 Personal Light Assembly Engine Switch Head Relay Front Door Courtesy Switch (LH, RH) DL Tail Relay Rear Door Courtesy Switch (LH, RH) Horn Relay CAN B128408E01 Transmitting ECU (Transmitter) Certification ECU Receiving ECU (Receiver) Main body ECU Signal Wireless door lock signal Line CAN DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) DL–69 SYSTEM DESCRIPTION 1. 2. Component Door control transmitter Door control receiver • • • Front door courtesy light switch Rear door courtesy light switch Luggage compartment door courtesy light switch WIRELESS DOOR LOCK CONTROL SYSTEM The wireless door lock control system functions to lock and unlock all the doors from a distance. The system is controlled by a hand-held transmitter which sends radio waves to the door control receiver. The certification ECU performs an ID code identification process and engages the door lock control. FUNCTION OF MAIN COMPONENTS Function • • Has LOCK, UNLOCK, LUGGAGE OPEN, and PANIC switches. Transmits weak radio waves (recognition codes and function codes) to the door control receiver. Receives weak radio waves from the door control transmitter and sends them to the certification ECU. Turns on when a door is opened and turns off when it is closed. Outputs door status codes (open or closed) to the main body ECU. Door lock position switch Transmits the door lock positions of each door to the main body ECU. Wireless door lock buzzer Emits beep (answer back) when doors are locked or unlocked, or luggage compartment door is opened by wireless operation. Certification ECU Sends wireless door lock control signals in response to the code data from the door control receiver and signals from each ECU. 3. Function SYSTEM FUNCTION The door control transmitter has the LOCK, UNLOCK, LUGGAGE OPEN, and PANIC switches. Operating these switches activates each function. The wireless door lock control system has the following functions: HINT: The default settings of the following functions are ON. Part of these functions can be customized (See page DL-73). Operation All door lock Pressing the LOCK switch locks all doors. All door unlock (2-step unlock) Pressing the UNLOCK switch twice within 3 seconds unlocks all the doors after the driver's door is unlocked. Automatic lock If none of the doors is opened within 60 seconds after they are unlocked by the wireless door lock control, all the doors will lock again automatically. Luggage compartment door open Pressing the LUGGAGE OPEN switch of the transmitter opens the luggage compartment door. • Answer back • • Panic alarm When the doors are locked by wireless operation, the hazard warning lights flash once and the wireless door lock buzzer sounds once. When the doors are unlocked by wireless operation, the hazard warning lights flash twice and the wireless door lock buzzer sounds twice. When the luggage compartment door is opened by wireless operation, the wireless door lock buzzer sounds. Pressing the PANIC switch of the transmitter for longer than about 0.8 seconds causes the following alarms to activate: • Sounds the horn and security horn. • Flashes the hazard lights, headlights, and taillights. • Illuminates the front interior light (when the switch is in the DOOR position). While the panic alarm is operating, pressing any switch of the transmitter cancels the alarm operation. DL DL–70 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) Function DL Operation Door ajar warning The buzzer sounds when LOCK is pressed when any of the doors are ajar. When all the doors are closed or when UNLOCK is pressed, the buzzer will stop after it sounds for 10 seconds continuously. Illuminated Entry When all the doors are locked, pressing the UNLOCK switch causes the interior light to come on simultaneously with the unlock operation. DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) DL–71 HOW TO PROCEED WITH TROUBLESHOOTING HINT: The wireless door lock control system troubleshooting procedures are based on the premise that the power door lock control system is operating normally. Check the power door lock control system first before troubleshooting the wireless door lock control system. Use this procedure to troubleshoot the wireless door lock control system. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS (a) Interview the customer to confirm the trouble (See page IN-45). NEXT 3 INSPECT COMMUNICATION FUNCTION OF CAN COMMUNICATION SYSTEM (a) Use the intelligent tester to check for normal function of the multiplex communication system. (1) (ECU unconnected, communication line malfunctioning) If no code is output, proceed to A. (2) (ECU unconnected, communication line malfunctioning) If any code is output, proceed to B. B Go To CAN COMMUNICATION SECTION A 4 DTC CHECK (a) Check for a DTC and note any codes that are output. (b) Delete the DTC. (c) Recheck for DTCs. Try to prompt the DTC by simulating the original symptom that the DTC suggests. (1) If the DTC does not reoccur, proceed to A. (2) If the DTC reoccurs, proceed to B. B A Go To DTC chart DL DL–72 5 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) SYMPTOM SIMULATION NEXT 6 PROBLEM SYMPTOMS TABLE (a) If the fault is not listed in the problem symptoms table, proceed to A. (b) If the fault is listed in the problem symptoms table, proceed to B. B Go to step 7 A 7 PERFORM TROUBLESHOOTING ACCORDING TO MALFUNCTION SYMPTOM (a) Terminals of ECU (See page DL-106) (b) DATA LIST/ACTIVE TEST (See page DL-81) NEXT 8 ADJUST, REPAIR OR REPLACE NEXT 9 NEXT END DL CONFIRMATION TEST DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) DL–73 OPERATION CHECK 1. 2. FUNCTIONS AND OPERATING CONDITIONS (a) The wireless door LOCK/UNLOCK function: This wireless door lock control function operates only when the following 4 conditions are met: (1) There is no wireless transmitter in the cabin. (2) All the doors are closed. (3) The power door lock system is functioning normally. (4) The function is not disabled by customization. HINT: The UNLOCK function operates even when any of the doors are open. (b) The wireless transmitter operational range differs depending on the situation. (1) The operational range differs depending on the user, the way the transmitter is held, and the location. (2) In certain areas, the operational range will be reduced due to the vehicle body shape and the influence of the surrounding environment. (3) Since the transmitter uses weak radio waves, the operational range may be reduced or the transmitter may not function if interference or stronger radio waves occur in the area where the transmitter is used. (4) When the battery is low, the operational range is reduced and/or the transmitter may not function. HINT: If the transmitter has been left in a place that is exposed to direct sunlight, such as on the instrument panel, the battery may be weakened or other problems may occur. CHECK WIRELESS DOOR LOCK CONTROL FUNCTIONS HINT: • The switches built into the door control transmitter send radio waves to the door lock control receiver. • The operational range must be taken into account during checks. (a) Establish conditions that allow the wireless control function to be operated successfully. (b) Check these basic functions. (1) Check that all the doors lock when the LOCK switch is pressed. (2) Check that the driver's door unlocks when the UNLOCK switch is pressed once, and all doors unlock when pressed twice within 3 seconds. (c) Check the automatic lock function. (1) Check that if the driver's door or all doors are unlocked with the UNLOCK switch and none of the doors are opened or locked within approximately 60 seconds, the doors automatically re-lock. DL DL–74 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) (d) (e) (f) (g) DL (h) (i) (2) Check that if the driver's door or all doors are unlocked with the UNLOCK switch and a door is opened or locked within approximately 60 seconds, the automatic lock function does not operate. Check the interior light ON function. HINT: Turn the interior light switch to the DOOR position before the check. (1) Check that the interior light comes on simultaneously with the unlocking operation when the UNLOCK switch has been pressed. (2) Check that the interior light goes off in approximately 15 seconds if none of the doors is opened after the unlocking operation. Check the answer back function. (1) When the doors are locked by wireless operation, the hazard warning lights flash once and the wireless door lock buzzer sounds once. (2) When the doors are unlocked by wireless operation, the hazard warning lights flash twice and the wireless door lock buzzer sounds twice. (3) When the luggage compartment door is opened by wireless operation, the wireless door lock buzzer sounds. Check the switch operation fail-safe function. (1) Check that the doors cannot be locked by operating a switch while the wireless transmitter is in the cabin. (2) Check that the doors cannot be locked or unlocked by operating a switch on the unregistered transmitter, and that the doors are locked and unlocked by operating a switch on the registered transmitter. Check the chattering prevention function. (1) Check that the corresponding operation occurs only once, and does not repeat itself while the switch is kept pressed. Check that the corresponding operation is carried out when the switch is operated repeatedly at 1-second intervals. Check the luggage compartment door opener function. (1) Check that the luggage compartment door opens when the LUGGAGE OPEN switch is held down for 0.6 seconds or more. Check the door ajar warning function. (1) Check that the wireless door lock buzzer sounds for approximately 10 seconds when the LOCK switch is pressed with any of the doors ajar or open. DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) DL–75 CUSTOMIZE PARAMETERS HINT: The following items can be customized. NOTICE: • When the customer requests a change in a function, first make sure that customization of the function(s) is possible. • Be sure to record the current settings before customizing. • When troubleshooting a function, first make sure that the function is not set to OFF. WIRELESS DOOR LOCK CONTROL SYSTEM Display (item) Default WIRELESS OPER (Wireless door lock control function) ON Function Function that turns wireless door lock function ON/OFF • Setting ON/OFF When the doors are locked by wireless operation, the hazard warning lights flash once. When the doors are unlocked by wireless operation, the hazard warning lights flash twice. ON/OFF ON The buzzer sounds when LOCK is pressed when any of the doors are ajar. ON/OFF 60 s This function regulates the interval between unlocking and automatic relocking of doors. 30 s/60 s UNLOCK /2OPER (Wireless unlock operated twice) ON This function unlocks the driver's door when the UNLOCK switch is pressed once, and unlocks all doors when pressed twice within 3 seconds. If set to OFF, pressing UNLOCK once unlocks all doors. ON/OFF ALARM FUNCTION (Panic function) ON This function operates the theft deterrent system when PANIC is pressed and held for 0.8 seconds. ON/OFF WIRLS BUZZ RESP (Wireless buzzer answer-back) ON Wireless door lock buzzer response/ON or OFF ON/OFF 0.6 s PR ON This function changes operation method of transmitter to open luggage compartment door. 1 TIME: Push 1 time 2 TIMES: Push 2 times 0.6 s PR: Push 0.6 seconds OFF: Does not operate 1 TIME/2 TIMES/0.6 s PR/ OFF HAZARD ANS BACK (Hazard answer-back for wireless door lock control) ON OPEN DOOR WARN (Door ajar warning) AUTO LOCK DELAY (Auto lock time) TRUNK LID OPER (Wireless trunk opener function setting) • DL DL–76 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) PROBLEM SYMPTOMS TABLE If a normal system code is displayed during the DTC check, but the problem still occurs, check the circuits for each problem symptom in the order given in the table below and proceed to the relevant troubleshooting page. HINT: • The following is the troubleshooting procedure for the wireless door lock control of a vehicle without the smart key system. • For the troubleshooting procedure for the wireless door lock control of a vehicle with the smart key system, refer to the wireless door lock control system (without Smart Key System). • Inspect the fuse and relay before investigating the suspected areas shown in the table below. • Inspect each malfunction circuit in numerical order for its corresponding symptom. WIRELESS DOOR LOCK CONTROL SYSTEM: Symptom The wireless door lock control system does not operate. The automatic lock function does not operate normally. The illuminated entry function only does not operate. DL The answer back function does not operate (Wireless door lock buzzer). The answer back function does not operate (Hazard warning light). Suspected area See page 1. Perform the operation check DL-71 2. Check if the CAN communication DTC is output CA-31 3. Door control transmitter DL-210 4. Door courtesy light switch circuit LI-52 5. Luggage compartment door courtesy light switch DL-44 6. Power source circuit DL-89 7. Replace door control receiver - 8. Replace certification ECU - 9. If the symptom still occurs after the above areas have been inspected and proved to be normal, replace the main body ECU (Instrument panel J/B) - 1. Perform the operation check DL-71 2. Door courtesy light switch circuit LI-52 3. If the symptom still occurs after the above areas have been inspected and proved to be normal, replace the main body ECU (Instrument panel J/B) - 1. Perform the operation check DL-71 2. Lighting system LI-12 3. If the symptom still occurs after the above areas have been inspected and proved to be normal, replace the main body ECU (Instrument panel J/B) - 1. Perform the operation check DL-71 2. Wireless door lock buzzer circuit DL-86 3. Replace certification ECU - 4. If the symptom still occurs after the above areas have been inspected and proved to be normal, replace the main body ECU (Instrument panel J/B) - 1. Perform the operation check DL-71 2. Wire harness - 3. Turn signal flasher LI-138 4. If the symptom still occurs after the above areas have been inspected and proved to be normal, replace the main body ECU (Instrument panel J/B) - DL–77 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) Symptom The door ajar warning function only does not operate. The panic alarm function only does not operate. The panic alarm function does not operate (Vehicle horn). The panic alarm function does not operate (Security horn). The panic alarm function does not operate (Hazard warning light). The panic alarm function does not operate (Headlight or taillight). Suspected area See page 1. Perform the operation check DL-71 2. Door courtesy switch circuit LI-52 3. If the symptom still occurs after the above areas have been inspected and proved to be normal, replace the main body ECU (Instrument panel J/B) - 1. Perform the operation check DL-71 2. Door control transmitter DL-210 3. If the symptom still occurs after the above areas have been inspected and proved to be normal, replace the main body ECU (Instrument panel J/B) - 1. Perform the operation check DL-71 2. Horn circuit TD-25 3. If the symptom still occurs after the above areas have been inspected and proved to be normal, replace the main body ECU (Instrument panel J/B) - 1. Perform the operation check DL-71 2. Security horn circuit TD-27 3. Replace certification ECU - 4. If the symptom still occurs after the above areas have been inspected and proved to be normal, replace the main body ECU (Instrument panel J/B) - 1. Perform the operation check DL-71 2. Wire harness - 3. Turn signal flasher LI-138 4. If the symptom still occurs after the above areas have been inspected and proved to be normal, replace the main body ECU (Instrument panel J/B) - 1. Perform the operation check DL-71 2. Lighting system LI-12 3. If the symptom still occurs after the above areas have been inspected and proved to be normal, replace the main body ECU (Instrument panel J/B) - DL DL–78 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) TERMINALS OF ECU 1. CHECK MAIN BODY ECU (INSTRUMENT PANEL J/B) (a) Disconnect the main body ECU (instrument panel J/ B) connectors. IM IF ID IO IA E7 DL E8 E6 E9 IG Main Body ECU B139428E01 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) DL–79 (b) Measure the resistance and voltage between each terminal of the wire harness side connectors and body ground. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition GR - Body ground Rear courtesy light switch RH input Rear door RH CLOSED (OFF) → OPEN (ON) 10 kΩ or higher → Below 1Ω PCTY (E6-21) - Body ground Y - Body ground Passenger side courtesy light switch input Passenger side door CLOSED (OFF) → OPEN (ON) 10 kΩ or higher → Below 1Ω LGCY (E6-25) - Body ground W - Body ground Luggage compartment door courtesy light switch input Luggage compartment door CLOSED (OFF) → OPEN (ON) 10 kΩ or higher → Below 1Ω DCTY (E7-24) - Body ground L - Body ground Driver side door courtesy light switch input Driver side door CLOSED (OFF) → OPEN (ON) 10 kΩ or higher → Below 1Ω ACC (IA-1) - Body ground B - Body ground Ignition power supply (ACC signal) Engine switch on (ACC) → off 10 to 14 V → Below 1 V IG (IA-1) - Body ground B - Body ground Ignition power supply (IG signal) Engine switch on (IG) → off 10 to 14 V → Below 1 V BATB (IA-1) - Body ground B - Body ground +B (power battery system) power supply Always 10 to 14 V ALTB (ID-16) - Body ground W - Body ground +B (power system alternator system) power supply Always 10 to 14 V GND1 (IF-10) - Body ground W-B - Body ground Ground Always Below 1 Ω GND2 (IM-9) - Body ground W-B - Body ground Ground Always Below 1 Ω LCTY (IO-7) - Body ground LG - Body ground Rear courtesy light switch LH input Rear door LH CLOSED (OFF) → OPEN (ON) 10 kΩ or higher → Below 1Ω RCTY (E6-7) - Body ground If the result is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the main body (instrument panel J/B) connectors. (d) Measure the voltage between each terminal of the wire harness side connectors and body ground. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition Below 1 V → 10 to 14 V*1 Below 1 V → 10 to 14 V*2 TR+ (E7-1) - Body ground B - Body ground Luggage compartment door opener motor input Luggage compartment door CLOSED (LOCKED) → OPEN (UNLOCKED) HAZ (E8-4) - Body ground W - Body ground Turn signal flasher relay signal Any transmitter switch is pressed → not pressed HINT: • *1: When operating the motor. • *2: When operating the answer back function. DL DL–80 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) 2. CHECK CERTIFICATION ECU ASSEMBLY (a) Disconnect the E58 ECU connector. E58 E125964E04 (b) Measure the voltage and resistance of the wire harness side connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition +B (E58-1) - E (E58-17) W - W-B Battery power supply Always 10 to 14 V E (E58-17) - Body ground W-B - Body ground Ground Always Below 1 Ω IG (E58-18) - E (E58-17) LG - W-B IG power supply Engine switch on (IG) 10 to 14 V IG (E58-18) - E (E58-17) LG - W-B IG power supply Engine switch off Below 1 V If the result is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the E58 ECU connector. (d) Measure the voltage of the connector. DL Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition BZR (E58-21) - Body ground O - Body ground Wireless door lock buzzer Wireless door lock buzzer OFF → ON 0 V → Pulse generation RC0 (E58-29) - E (E58-17) G - W-B Door control receiver power supply Engine switch off, all doors closed and transmitter switch not pressed Below 1 V RC0 (E58-29) - E (E58-17) G - W-B Door control receiver power supply Engine switch off, all doors closed and transmitter switch pressed 4.6 to 5.4 V RDA (E58-38) - E (E5817) Y - W-B Door control receiver output signal Engine switch off, all doors closed and transmitter switch not pressed 10 to 14 V RDA (E58-38) - E (E5817) Y - W-B Door control receiver output signal Engine switch off, all doors closed and transmitter switch pressed Pulse generation If the result is not as specified, the ECU may have a malfunction. DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) DL–81 DIAGNOSIS SYSTEM 1. DESCRIPTION The main body ECU stores trouble codes when trouble occurs on the vehicle. The diagnostic system allows for reading of the trouble codes from the DLC3. Use the intelligent tester to check and solve the problem. 2. CHECK DLC3 (a) The main body ECU uses ISO 15765-4 for communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. CG SG CANH SIL CANL BAT H100769E16 Symbols (Terminal No.) Terminal Description Condition Specified condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 10 to 14 V CANH (6) - CANL (14) CAN bus line Engine switch off* 54 to 67 Ω CANH (6) - CG (4) HIGH-level CAN bus line Engine switch off* 200 Ω or higher CANL (14) - CG (4) LOW-level CAN bus line Engine switch off* 200 Ω or higher CANH (6) - BAT (16) HIGH-level CAN bus line Engine switch off* 6 kΩ or higher CANL (14) - BAT (16) LOW-level CAN bus line Engine switch off* 6 kΩ or higher NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the engine switch, any other switches or the doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. DL DL–82 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) (b) Connect the cable of the intelligent tester (with CAN VIM) to the DLC3, turn the engine switch on (IG) and attempt to use the intelligent tester. If the screen displays a communication error message, a problem exists in the vehicle or in the tester. • If communication is normal when the tool is connected to another vehicle, inspect the DLC3 on the original vehicle. • If communication is still impossible when the tool is connected to another vehicle, the problem is probably in the tool itself. Consult the Service Department listed in the tool's instruction manual. DLC3 Intelligent Tester C131977E01 DTC CHECK / CLEAR 1. DLC3 Intelligent Tester C131977E01 DL CHECK DTC (a) Connect the intelligent tester to the DLC3. (b) Turn the engine switch on (IG). (c) Enter the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTC by following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. 2. CLEAR DTC (a) Connect the intelligent tester to the DLC3. (b) Turn the engine switch on (IG). (c) Enter the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CLEAR CODES. (d) Erase the DTC by following the directions on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) DL–83 DATA LIST / ACTIVE TEST 1. DATA LIST HINT: Using the intelligent tester DATA LIST allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to shorten labor time. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the engine switch on (IG). (c) Enter the following menus: DIAGNOSIS / OBD/ MOBD / BODY or SMART / DATA LIST. (d) Read the DATA LIST according to the display on the tester. MAIN BODY (Main body ECU): Item Measurement Item/Display (Range) Normal Condition Diagnostic Note WIRELESS OPER Wireless door lock control function / ON or OFF ON: Operating OFF: Not operating - HAZARD ANS BACK Hazard answer-back of wireless / ON or OFF ON: Operating OFF: Not operating - OPEN DOOR WARN Open door warning / ON or OFF ON: Operating OFF: Not operating - AUTO LOCK DELAY Automatic lock time / 60 s or 30 s 60 s: 60 seconds 30 s: 30 seconds - UNLOCK /2OPER 2 times operation of wireless unlock / ON or OFF ON: All doors unlock when UNLOCK is pressed twice OFF: All doors unlock when UNLOCK is pressed once - WIRLS BUZZ RESP Wireless door lock buzzer response / ON or OFF ON: Operating OFF: Not operating - Luggage compartment door open function type / 1 TIME/2 TIME/ 0.6 s PR/ OFF 1 TIME: Luggage compartment door opens when LUGGAGE OPEN switch is pressed once 2 TIME: Luggage compartment door opens when LUGGAGE OPEN switch is pressed twice 0.6 s PR: Luggage compartment door opens when LUGGAGE OPEN switch is pressed and held down for 0.6 seconds. OFF: Not operating - Normal Condition Diagnostic Note TRUNK LID OPER SMART (Certification ECU): Item ALARM FUNCTION Measurement Item/Display (Range) ON: Operating OFF: Not operating Panic function / ON or OFF 2. - ACTIVE TEST HINT: Performing the intelligent tester ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to shorten the labor time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the engine switch on (IG). (c) Enter the following menus: DIAGNOSIS / OBD/ MOBD / BODY or SMART / ACTIVE TEST. DL DL–84 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) (d) Perform the ACTIVE TEST according to the display on the tester. MAIN BODY (Main body ECU): Item Tester Detail Diagnostic Note HAZARD Turns the turn signal flasher relay ON / OFF Observe headlight and rear combination light for correct operation VEHICLE HORN Vehicle horn ON / OFF - TRUNK/BDOR OPEN Turns luggage compartment door opener motor ON / OFF Observe luggage compartment door SMART (Certification ECU): Item WIRELESS BUZZER DL Tester Detail Wireless door lock buzzer ON / OFF Diagnostic Note - DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) DL–85 DIAGNOSTIC TROUBLE CODE CHART HINT: If a trouble code is indicated during the DTC check, check the circuit listed for that code in the table below. Then proceed to the appropriate page. WIRELESS DOOR LOCK CONTROL SYSTEM: DTC No. Detection Item B1242 Wireless Door Lock Tuner Circuit Malfunction Trouble Area 1. Door control receiver 2. Wire harness 3. Certification ECU See page DL-83 DL DL–86 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) DTC B1242 Wireless Door Lock Tuner Circuit Malfunction DESCRIPTION • The electrical key antenna is used to receive electric waves relating to the entry functions of the smart access system with push-button start. The certification ECU decodes the requested smart access system with push-button start operation by identifying a key code based on electric waves received via the electrical key antenna and the door control receiver. • The door control receiver receives a signal from the wireless door control transmitter and sends signals to the main body ECU through the certification ECU. • The certification ECU then sends a command, according to the requested operation, to each ECU. (e.g. If door lock operation is requested, the ECU sends a door lock command to the main body ECU.) DTC No. DTC Detection Condition Trouble Area B1242 The certification ECU detects that there is a short in the circuit between terminals RSSI, or between terminals DATA and RDA. • • • Door Control Receiver Wire harness Certification ECU WIRING DIAGRAM O18 Door Control Receiver O19 Electrical Key Antenna ASEL RSSI ANT DL 1 7 ANT DATA +5 E58 Certification ECU 4 37 5 39 3 38 2 29 17 ASEL RSSI RDA RC0 E B131913E01 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) DL–87 INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (CERTIFICATION ECU - DOOR CONTROL RECEIVER) (a) Disconnect the E58 certification ECU connector and O18 door control receiver connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Connector Wire Harness Side: Certification ECU E58 RDA RSSI Door Control Receiver O18 Symbol (Tester Connection) Condition Specified Condition RSSI (E58-39) - RSSI (O18-5) Always Below 1 Ω RDA (E58-38) - DATA (O18-3) Always Below 1 Ω RSSI (E58-39) - RDA (E58-38) Always 10 kΩ or higher RSSI (E58-39) - Body ground Always 10 kΩ or higher RDA (E58-38) - Body ground Always 10 kΩ or higher NG DATA RSSI REPAIR OR REPLACE HARNESS OR CONNECTOR B139429E02 OK 2 INSPECT CERTIFICATION ECU (a) Reconnect the E58 ECU connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Connector Wire Harness Side: Certification ECU Symbol (Tester Connection) E58 RSSI (E58-39) - E (E5817) E RSSI RDA B139430E04 RDA (E58-38) - E (E5817) NG Condition Specified Condition Engine switch OFF, all doors closed, the electrical key is not in the actuation area Below 1 V Engine switch OFF, all doors closed, the electrical key is in the actuation area 4.6 to 5.4 V Engine switch OFF, all doors closed and transmitter switch not pressed Below 1 V Engine switch OFF, all doors closed and transmitter switch pressed 4.6 to 5.4 V DL REPLACE CERTIFICATION ECU DL–88 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) OK 3 REPLACE DOOR CONTROL RECEIVER (a) Replace the door control receiver with a normal one. (b) Perform the registration procedure. OK: The system returns to normal operation. NG OK END DL REPLACE CERTIFICATION ECU DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) DL–89 Wireless Door Lock Buzzer Circuit DESCRIPTION The certification ECU activates the wireless door lock buzzer when detecting a lock/unlock signal from the door control transmitter. WIRING DIAGRAM E58 Certification ECU A48 Wireless Door Lock Buzzer 21 2 1 BZR B139432E01 DL DL–90 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (CERTIFICATION ECU - WIRELESS DOOR LOCK BUZZER - BODY GROUND) (a) Disconnect the E58 certification ECU connector and A48 wireless door lock buzzer connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Connector Wire Harness View: Certification ECU E58 Symbol (Tester Connection) Condition BZR (E58-21) - A48-1 Always Below 1 Ω BZR (E58-21) - Body ground Always 10 kΩ or higher A48-2 - Body ground Always Below 1 Ω NG BZR Specified Condition REPAIR OR REPLACE HARNESS OR CONNECTOR Wire Harness Side Connector Front View: Wireless Door Lock Buzzer A48 B139431E01 OK 2 INSPECT WIRELESS DOOR LOCK BUZZER (a) Measure the resistance according to the value(s) in the table below. HINT: The buzzer activation circuit is built into the ECU, not into the buzzer itself. When battery voltage is applied directly to the buzzer, the buzzer will not sound. Standard resistance Wireless Door Lock Buzzer: DL A48 2 1 Tester Connection Condition Specified Condition A48-1 - A48-2 Always Approx. 1 kΩ NG B144393E01 REPLACE WIRELESS DOOR LOCK BUZZER DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) DL–91 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE DL DL–92 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) Power Source Circuit DESCRIPTION The certification ECU provides power for the door control receiver operation. WIRING DIAGRAM O18 Door Control Receiver +5 E58 Certification ECU 2 29 RC0 1 From Battery GND 17 6 +B E B139463E01 INSPECTION PROCEDURE 1 INSPECT CERTIFICATION ECU (+B TERMINAL) (a) Measure the voltage according to value(s) in the table below. Standard voltage Connector Wire Harness View: Certification ECU Symbol (Tester Connection) E58 DL +B (E58-1) - E (E58-17) NG E +B B139430E02 OK Condition Always Specified Condition 10 to 14 V REPAIR OR REPLACE HARNESS OR CONNECTOR DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) 2 DL–93 INSPECT CERTIFICATION ECU (RC0 TERMINAL) (a) Measure the voltage according to value(s) in the table below. Standard voltage Connector Wire Harness View: Certification ECU Symbol (Tester Connection) E58 RC0 (E58-29) - E (E5817) E RC0 OK Condition Specified Condition Engine switch off, all doors closed and transmitter switch not pressed Below 1 V Engine switch off, all doors closed and transmitter switch pressed 4.6 to 5.4 V Go to step 4 B139430E03 NG 3 CHECK HARNESS AND CONNECTOR (CERTIFICATION ECU - BATTERY - BODY GROUND) (a) Disconnect the E58 certification ECU connector. (b) Measure the voltage and resistance according to value(s) in the table below. Standard resistance Connector Wire Harness Side: Certification ECU Symbol (Tester Connection) E58 RC0 (E58-29) - Body ground NG Condition Specified Condition Always Below 1 V Always 10 kΩ or higher REPAIR OR REPLACE HARNESS OR CONNECTOR RC0 E125974E10 OK REPLACE CERTIFICATION ECU DL DL–94 4 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) CHECK HARNESS AND CONNECTOR (CERTIFICATION ECU - DOOR CONTROL RECEIVER) (a) Disconnect the O18 door control receiver connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Connector Wire Harness View: Certification ECU Symbol (Tester Connection) Condition Specified Condition RC0 (E58-29) - +5 (O182) Always Below 1 Ω NG E58 REPAIR OR REPLACE HARNESS OR CONNECTOR RC0 Door Control Receiver O18 +5 B139429E01 OK 5 CHECK HARNESS AND CONNECTOR (BODY GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Connector Wire Harness View: Door Control Receiver Symbol (Tester Connection) Condition Specified Condition GND (O18-6) - Body ground Always Below 1 Ω NG O18 DL REPAIR OR REPLACE HARNESS OR CONNECTOR GND B139462E01 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE DL–92 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) BODY ELECTRICAL DOOR LOCK PARTS LOCATION PERSONAL LIGHT ASSEMBLY SECURITY HORN ASSEMBLY LOW PITCHED HORN ENGINE ROOM R/B AND J/B HEADLIGHT - S-HORN RELAY - HORN RELAY - H-LP(RL) RELAY - H-LP(LL) RELAY HAZARD WARNING LIGHT WIRELESS DOOR LOCK BUZZER HAZARD WARNING LIGHT HIGH PITCHED HORN UNLOCK WARNING SWITCH HEADLIGHT TURN SIGNAL FLASHER ASSEMBLY DL MAIN BODY ECU (INSTRUMENT PANEL J/B) - TAIL RELAY DLC3 IGNITION SWITCH B128396E01 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) DL–93 REAR DOOR LOCK RH REAR DOOR COURTESY SWITCH RH FRONT DOOR LOCK RH FRONT DOOR COURTESY SWITCH RH DOOR CONTROL RECEIVER FRONT DOOR LOCK LH FRONT DOOR COURTESY SWITCH LH HAZARD WARNING LIGHT HAZARD WARNING LIGHT REAR DOOR LOCK LH DL TAILLIGHT TAILLIGHT REAR DOOR COURTESY SWITCH LH LUGGAGE COMPARTMENT DOOR LOCK B128397E01 DL–94 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) LOCK SWITCH PANIC SWITCH LED UNLOCK SWITCH LUGGAGE OPEN SWITCH DOOR CONTROL TRANSMITTER B128398E01 DL DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) DL–95 SYSTEM DIAGRAM Main Body ECU Front Door Lock Assembly (LH, RH) Rear Door Lock Assembly (LH, RH) Luggage Compartment Door Lock Assembly Door Control Receiver Front Door Courtesy Switch (LH, RH) Rear Door Courtesy Switch (LH, RH) Wireless Door Lock Buzzer Turn Signal Flasher Hazard Warning Light Personal Light Assembly Ignition Switch Head Relay Unlock Warning Switch Tail Relay DLC3 DL Horn Relay Security Horn CAN B128407E01 DL–96 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) SYSTEM DESCRIPTION 1. 2. Component Door control transmitter Function • • • Door control receiver • • • Front door courtesy light switch Rear door courtesy light switch Luggage compartment door courtesy light switch Has LOCK, UNLOCK, LUGGAGE OPEN, and PANIC switches. Transmits weak radio waves (recognition codes and function codes) to the door control receiver. Illuminates the indicator light (LED) during transmission. Receives weak radio waves (recognition codes and function codes) and outputs them as code data to the main body ECU. Turns on when a door is opened and turns off when it is closed. Outputs door status codes (open or closed) to the main body ECU. Unlock warning switch Detects if the key is inserted in the ignition key cylinder or not. Door lock position switch Transmits the door lock positions of each door to the main body ECU. Wireless door lock buzzer Emits beep (answer back) when doors are locked or unlocked, or luggage compartment door is opened by wireless operation. Main body ECU Sends wireless door lock control signals in response to the code data from the door control receiver and signals from each switch. 3. Function DL WIRELESS DOOR LOCK CONTROL SYSTEM The wireless door lock control system functions to lock and unlock all the doors from a distance. The system is controlled by a hand-held transmitter which sends radio waves to the door control receiver. The main body ECU performs an ID code identification process and engages the door lock control. FUNCTION OF MAIN COMPONENTS SYSTEM FUNCTION The door control transmitter has the LOCK, UNLOCK, LUGGAGE OPEN, and PANIC switches. Operating these switches activates each function. The wireless door lock control system has the following functions: HINT: The default settings of the following functions are ON. Part of these functions can be customized (See page DL-103). Operation All door lock Pressing the LOCK switch locks all doors. All door unlock (2-step unlock) Pressing the UNLOCK switch twice within 3 seconds unlocks all the doors after the driver's door is unlocked. Automatic lock If none of the doors is opened within 60 seconds after they are unlocked by the wireless door lock control, all the doors will lock again automatically. Panic alarm Pressing the PANIC switch of the transmitter for longer than about 0.8 seconds causes the following alarms to activate: • Sounds the horn and security horn. • Flashes the hazard lights, headlights, and taillights. • Illuminates the front interior light (when the switch is in the DOOR position). While the panic alarm is operating, pressing any switch of the transmitter cancels the alarm operation. Luggage compartment door opener Pressing the LUGGAGE OPEN switch of the transmitter opens the luggage compartment door. • Answer back • • When the doors are locked by wireless operation, the wireless door lock buzzer sounds once and the hazard warning lights flash once. When the doors are unlocked by wireless operation, the wireless door lock buzzer sounds twice and the hazard warning lights flash twice. When the luggage compartment door is opened by wireless operation, the wireless door lock buzzer sounds once. DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) Function DL–97 Operation Door ajar warning The buzzer sounds when LOCK is pressed when any of the doors are ajar. When all the doors are closed or when UNLOCK is pressed, the buzzer will stop after it sounds for 10 seconds continuously. Illuminated entry When all the doors are locked, pressing UNLOCK causes the interior lights to come on simultaneously with the unlock operation. Self-diagnostic mode The following are ways to enter the self-diagnostic mode: • If the door control receiver receives normal radio waves from the door control transmitter when the system is in diagnostic mode, it sounds the wireless door lock buzzer and flashes the interior light in a normal pattern that corresponds to the function of each switch. • Read DTCs with the intelligent tester. Transmitter recognition code registration Enables the registration (writing and storing) of 6 types of transmitter recognition codes in the EEPROM that is contained in the door control receiver. 4. Mode Add mode TRANSMITTER RECOGNITION CODE REGISTRATION FUNCTION The table below shows the 6 ID registration function modes by which up to 6 different codes can be registered. The codes are electronically registered (written and stored) in the EEPROM that is contained in the door control receiver. Function Adds a newly received code while preserving any previously registered codes. This mode is used when adding a new transmitter. If the number of registered codes exceeds 6, the oldest registered code is erased first. Rewrite mode Erases all previously registered codes and registers only newly input codes. Confirmation mode Confirms how many codes are currently registered. When adding a new code, this mode is used to check how many codes already exist. Prohibition mode Deletes all the registered codes and disables the wireless door lock function. This mode is used when the transmitter is lost. 5. CONDITIONS THAT WIRELESS FUNCTIONS DO NOT OPERATE (a) Lock operation is not available when: • Any of the doors is open. • The key is inserted in the ignition key cylinder. (b) Unlock operation is not available when: • The key is inserted in the ignition key cylinder. (c) Luggage compartment door opener is not available when: • The key is inserted in the ignition key cylinder. DL DL–98 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) HOW TO PROCEED WITH TROUBLESHOOTING HINT: The wireless door lock control system troubleshooting procedures are based on the premise that the power door lock control system is operating normally. Check the power door lock control system first before troubleshooting the wireless door lock control system. Use this procedure to troubleshoot the wireless door lock control system. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS (a) Interview the customer to confirm the trouble (See page IN-45). NEXT 3 INSPECT COMMUNICATION FUNCTION OF CAN COMMUNICATION SYSTEM (a) Use the intelligent tester to check for normal function of the multiplex communication system. (1) (ECU unconnected, communication line malfunctioning) If no code is output, proceed to A. (2) (ECU unconnected, communication line malfunctioning) If any code is output, proceed to B. B Go To CAN COMMUNICATION SECTION A 4 DL DTC CHECK (a) Check for a DTC and note any codes that are output. (b) Delete the DTC. (c) Recheck for DTCs. Try to prompt the DTC by simulating the original symptom that the DTC suggests. (1) If the DTC does not reoccur, proceed to A. (2) If the DTC reoccurs, proceed to B. B A Go To DTC chart DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) 5 DL–99 SYMPTOM SIMULATION NEXT 6 PROBLEM SYMPTOMS TABLE (a) If the fault is not listed in the problem symptoms table, proceed to A. (b) If the fault is listed in the problem symptoms table, proceed to B. B Go to step 7 A 7 PERFORM TROUBLESHOOTING ACCORDING TO MALFUNCTION SYMPTOM (a) Terminals of ECU (See page DL-106) (b) DATA LIST/ACTIVE TEST (See page DL-111) NEXT 8 ADJUST, REPAIR OR REPLACE NEXT 9 CONFIRMATION TEST NEXT END DL DL–100 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) OPERATION CHECK 1. 2. DL FUNCTIONS AND OPERATING CONDITIONS (a) The wireless door LOCK/UNLOCK function: This wireless door lock control function operates only when the following 4 conditions are met: (1) There is no key in the ignition key cylinder. (2) All the doors are closed. (3) The power door lock system is functioning normally. (4) The function is not disabled by customization. HINT: The UNLOCK function operates even when any of the doors are open. (b) The wireless transmitter operational range differs depending on the situation. (1) The operational range differs depending on the user, the way the transmitter is held and the location. (2) In certain areas, the operational range will be reduced due to the vehicle body shape and the influence of the surrounding environment. (3) Since the transmitter uses weak radio waves, the operational range may be reduced or the transmitter may not function if interference or stronger radio waves occur in the area where the transmitter is used. (4) When the battery is low, the operational range is reduced and/or the transmitter may not function. HINT: If the transmitter has been left in a place that is exposed to direct sunlight, such as on the instrument panel, the battery may be weakened or other problems may occur. CHECK WIRELESS DOOR LOCK CONTROL FUNCTIONS HINT: • The switches built into the door control transmitter send radio waves to the door lock control receiver. • The operational range must be taken into account during checks. (a) Establish conditions that allow the wireless control function to be operated successfully. (b) Check the following basic functions. (1) Check that the transmitter's LED lights up 3 times when each switch is pressed 3 times and that the LED blinks when each switch is pressed and held down. HINT: If the LED does not illuminate when the switch has been pressed 3 times or more, the battery may be depleted. (2) Check that all the doors lock when the LOCK switch is pressed. DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) (c) (d) (e) (f) (g) (h) DL–101 (3) Check that the driver's door unlocks when the UNLOCK switch is pressed once, and all the doors unlock when pressed twice within 3 seconds. Check the automatic lock function. (1) Check that if the driver's door or all doors are unlocked with the UNLOCK switch and none of the doors are opened or locked within approximately 60 seconds, the doors automatically re-lock. (2) Check that if the driver's door or all doors are unlocked with the UNLOCK switch and a door is opened or locked within approximately 60 seconds, the automatic lock function does not operate. Check the interior light ON function. HINT: Turn the interior light switch to the DOOR position before the check. (1) Check that the interior light comes on simultaneously with the unlocking operation when the UNLOCK switch is pressed. (2) Check that the interior light goes off in approximately 15 seconds if none of the doors is opened after the unlocking operation. Check the answer back function. (1) When the doors are locked by wireless operation, the wireless door lock buzzer sounds once and the hazard warning lights flash once. (2) When the doors are unlocked by wireless operation, the wireless door lock buzzer sounds twice and the hazard warning lights flash twice. (3) When the luggage compartment door is opened by wireless operation, the wireless door lock buzzer sounds once. Check the switch operation fail-safe function. (1) Check that the doors cannot be locked by operating a switch while the key is in the ignition key cylinder. HINT: This check cannot be made when the system is in recognition code registration mode. Check the chattering prevention function. (1) Check that the corresponding operation occurs only once, and does not repeat itself while the switch is kept pressed. Check that the corresponding operation is carried out when the switch is operated repeatedly at 1-second intervals. Check the luggage compartment door opener function. (1) Check that the luggage compartment door opens when the LUGGAGE OPEN switch is held down for 0.6 seconds or more. DL DL–102 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) (i) (j) DL Check the door ajar warning function. (1) Check that the buzzer sounds when the LOCK switch is pressed when any of the doors are ajar. When all the doors are closed or when the UNLOCK switch is pressed, the buzzer will stop after it sounds for 10 seconds continuously. Check the panic alarm function. (1) Check that the following alarms operate when the PANIC switch is pressed longer than about 0.8 seconds: • The vehicle horns and the security horn sound. • The hazard warning lights, headlights and taillights flash. • The front interior light illuminates (when the switch is in the DOOR position). (2) Check that during the panic alarm is operating, pressing any switch of transmitter cancels the alarm operation. DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) DL–103 REGISTRATION HINT: • Register the recognition code when replacing the door control transmitter or the door control receiver. • Add mode is used to register new recognition codes while still retaining codes already registered. This mode is used when a new transmitter is added. If the number of registered codes exceeds 6, the previously registered codes will be erased in order, starting from the first registered code. • Rewrite mode is used to erase all the previously registered recognition codes in order to register all-new recognition codes. This mode is used when the transmitter or the door control receiver is replaced with a new one. • Confirmation mode is used to confirm how many recognition codes have already been registered before another recognition code is registered. • Prohibition mode is used to erase all the registered codes and disable the wireless door lock function. This mode is used when the transmitter is lost. • All the following registration procedures must be performed in order. 1. REGISTRATION OF RECOGNITION CODE (USING INTELLIGENT TESTER) (a) Turn the ignition switch ON. (b) Select the add or rewrite mode according to the intelligent tester display. (c) The number of registered codes is indicated. (d) Registration of the door control transmitter. (1) If the add mode or rewrite mode has been selected, press the LOCK and UNLOCK switches on the transmitter simultaneously. (2) Within 3 seconds of releasing the LOCK and UNLOCK switches, press either of the switches on the door control transmitter. NOTICE: • Do not press the LOCK and UNLOCK switches simultaneously for more than 1.5 seconds. • Do the operation within 1 meter of the driver's seat to register the transmitter. • Do not push other transmitter switches during the transmitter registration process. (3) The main body ECU automatically performs the power door LOCK-UNLOCK operation once and sounds the wireless door lock buzzer twice, in order to indicate whether registration has been completed correctly or not. DL DL–104 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) (4) If registration is continued, the next recognition code must be registered in the door control transmitter within 30 seconds. HINT: Up to 6 recognition codes can be registered. (e) Completing the registration mode. (1) The registration mode will cease when any of the following occurs: • 30 seconds or more have elapsed after a code is registered. • The intelligent tester is used to complete. • The intelligent tester is disconnected. • The ignition switch is turned off. (f) Perform the following after registration is completed. (1) Perform the wireless door lock control operation check (See page DL-99). HINT: If the wireless door lock control does not operate, perform the registration procedure again. DL DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) DL–105 CUSTOMIZE PARAMETERS HINT: The following items can be customized. NOTICE: • When the customer requests a change in a function, first make sure that customization of the function(s) is possible. • Be sure to record the current settings before customizing. • When troubleshooting a function, first make sure that the function is not set to OFF. WIRELESS DOOR LOCK CONTROL SYSTEM: Display (item) Default WIRELESS OPER (Wireless door lock control function) ON Function Function that turns wireless door lock function ON/OFF • Setting ON/OFF When the doors are locked by wireless operation, the hazard warning lights flash once. When the doors are unlocked by wireless operation, the hazard warning lights flash twice. ON/OFF ON The buzzer sounds when LOCK is pressed when any of the doors are ajar. ON/OFF 60 s This function regulates the interval between unlocking and automatic relocking of doors. 30 s/60 s UNLOCK /2OPER (Wireless unlock operated twice) ON This function unlocks the driver's door when the UNLOCK switch is pressed once, and unlocks all doors when pressed twice within 3 seconds. If set to OFF, pressing UNLOCK once unlocks all doors. ON/OFF ALARM FUNCTION (Panic function) ON This function operates the theft deterrent system when PANIC is pressed and held for 0.8 seconds. ON/OFF WIRLS BUZZ RESP (Wireless buzzer answer-back) ON Wireless door lock buzzer response/ON or OFF ON/OFF 0.6 s ON This function changes operation method of transmitter to open luggage compartment door. 1 TIME: Push 1 time 2 TIMES: Push 2 times 0.6 s PR: Push 0.6 seconds OFF: Does not operate 1 TIME/2 TIMES/0.6 s PR/ OFF HAZARD ANS BACK (Hazard answer-back for wireless door lock control) ON OPEN DOOR WARN (Door ajar warning) AUTO LOCK DELAY (Auto lock time) TRUNK LID OPER (Wireless trunk opener function setting) • DL DL–106 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) PROBLEM SYMPTOMS TABLE If a normal system code is displayed during the DTC check, but the problem still occurs, check the circuits for each problem symptom in the order given in the table below and proceed to the relevant troubleshooting page. HINT: • The following is the troubleshooting procedure for the wireless door lock control of a vehicle without the smart key system. • For the troubleshooting procedure for the wireless door lock control of a vehicle with the smart key system, refer to the wireless door lock control system (with Smart Key System). • Inspect the fuse and relay before investigating the suspected areas shown in the table below. • Inspect each malfunction circuit in numerical order for its corresponding symptom. WIRELESS DOOR LOCK CONTROL SYSTEM Symptom The wireless door lock control system does not operate. The automatic lock function does not operate normally. The illuminated entry function only does not operate. DL The answer back function does not operate (Wireless door lock buzzer). The answer back function does not operate (Hazard warning light). Suspected area See page 1. Perform the operation check DL-99 2. Door control transmitter DL-216 3. Enter the self-diagnostic mode DL-109 4. If the recognition code does not match the key code, check that the key code can be registered in the rewrite or add mode of the recognition code registration - 5. Unlock warning switch circuit DL-205 6. Door courtesy switch circuit LI-52 7. Luggage compartment door courtesy switch circuit DL-44 8. If the symptoms still occur after the above areas have been inspected and proved to be normal, replace the main body ECU (Instrument Panel J/B) - 1. Perform the operation check DL-99 2. Unlock warning switch circuit DL-205 3. Door courtesy switch circuit LI-52 4. If the symptoms still occur after the above areas have been inspected and proved to be normal, replace the main body ECU (Instrument Panel J/B) - 1. Perform the operation check DL-99 2. Lighting system LI-12 3. If the symptoms still occur after the above area has been inspected and proved to be normal, replace the main body ECU (Instrument Panel J/B) - 1. Perform the operation check DL-99 2. Wireless door lock buzzer circuit DL-116 3. If the symptoms still occur after the above area has been inspected and proved to be normal, replace the main body ECU (Instrument Panel J/B) - 1. Perform the operation check DL-99 2. Wire harness - 3. Turn signal flasher LI-138 4. If the symptoms still occur after the above areas have been inspected and proved to be normal, replace the main body ECU (Instrument Panel J/B) - DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) Symptom The wireless trunk opener function only does not operate. The door ajar warning function only does not operate. The panic alarm function only does not operate. The panic alarm function does not operate (Vehicle horn). The panic alarm function does not operate (Security horn). The panic alarm function does not operate (Hazard warning light). The panic alarm function does not operate (Headlight, taillight or interior light). Suspected area DL–107 See page 1. Perform the operation check DL-99 2. Unlock warning switch circuit DL-205 3. Luggage compartment door courtesy switch circuit DL-44 4. If the symptoms still occur after the above areas have been inspected and proved to be normal, replace the main body ECU (Instrument Panel J/B) - 1. Perform the operation check DL-99 2. Door courtesy circuit LI-52 3. If the symptom still occurs after the above areas have been inspected and proved to be normal, replace the main body ECU (Instrument Panel J/B) - 1. Perform the operation check DL-99 2. Door control transmitter DL-216 3. If the symptoms still occur after the above areas have been inspected and proved to be normal, replace the main body ECU (Instrument Panel J/B) - 1. Perform the operation check DL-99 2. Horn circuit TD-62 3. If the symptom still occurs after the above areas have been inspected and proved to be normal, replace the main body ECU (Instrument Panel J/B) - 1. Perform the operation check DL-99 2. Security horn circuit TD-64 3. If the symptom still occurs after the above areas have been inspected and proved to be normal, replace the main body ECU (Instrument Panel J/B) - 1. Perform the operation check DL-99 2. Wire harness - 3. Turn signal flasher LI-138 4. If the symptom still occurs after the above areas have been inspected and proved to be normal, replace the main body ECU (Instrument Panel J/B) - 1. Perform the operation check DL-99 2. Lighting system LI-12 3. If the symptom still occurs after the above areas have been inspected and proved to be normal, replace the main body ECU (Instrument Panel J/B) - DL DL–108 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) TERMINALS OF ECU 1. CHECK MAIN BODY ECU (INSTRUMENT PANEL J/B) (a) Disconnect the main body ECU (instrument panel J/ B) connectors. IM IF ID IO IA E7 DL E8 E6 E9 IG Main Body ECU B139428E01 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) DL–109 (b) Measure the resistance and voltage between each terminal of the wire harness side connectors and body ground. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition GR - Body ground Rear courtesy light switch RH input Rear door RH CLOSED (OFF) → OPEN (ON) 10 kΩ or higher → Below 1Ω PCTY (E6-21) - Body ground Y - Body ground Passenger side courtesy light switch input Passenger side door CLOSED (OFF) → OPEN (ON) 10 kΩ or higher → Below 1Ω LGCY (E6-25) - Body ground W - Body ground Luggage compartment door courtesy light switch input Luggage compartment door CLOSED (OFF) → OPEN (ON) 10 kΩ or higher → Below 1Ω DCTY (E7-24) - Body ground L - Body ground Driver side door courtesy light switch input Driver side door CLOSED (OFF) → OPEN (ON) 10 kΩ or higher → Below 1Ω KSW (E9-5) - Body ground L - Body ground Unlock warning switch input No key in ignition key cylinder (OFF) → Key inserted (ON) 10 kΩ or higher → Below 1Ω ACC (IA-1) - Body ground B - Body ground Ignition power supply (ACC signal) Ignition switch ACC → OFF 10 to 14 V → Below 1 V IG (IA-1) - Body ground B - Body ground Ignition power supply (IG signal) Ignition switch ON → OFF 10 to 14 V → Below 1 V ALTB (ID-16) - Body ground W - Body ground +B (power system alternator system) power supply Always 10 to 14 V GND1 (IF-10) - Body ground W-B - Body ground Ground Always Below 1 Ω BECU (ID-10) - Body ground O - Body ground +B power supply Always 10 to 14 V GND2 (IM-9) - Body ground W-B - Body ground Ground Always Below 1 Ω LCTY (IO-7) - Body ground LG - Body ground Rear courtesy light switch LH input Rear door LH CLOSED (OFF) → OPEN (ON) 10 kΩ or higher → Below 1Ω RCTY (E6-5) - Body ground If the result is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the main body ECU (instrument panel J/ B) connectors. (d) Measure the voltage between each terminal of the wire harness side connectors and body ground. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition TR+ (E7-1) - Body ground B - Body ground Luggage compartment door opener motor input Luggage compartment door CLOSED (LOCKED) → OPEN (UNLOCKED) Below 1 V → 10 to 14 V*1 HAZ (E8-4) - Body ground W - Body ground Turn signal flasher relay signal Any transmitter switch is pressed → not pressed Below 1 V → 10 to 14 V*2 Wireless door lock buzzer Wireless door lock buzzer OFF → ON 0 V → Pulse generation BZR (E9-7) - Body ground O - Body ground HINT: • *1: When operating the motor. • *2: When operating the answer back function. DL DL–110 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) DIAGNOSIS SYSTEM 1. DESCRIPTION The main body ECU stores trouble codes when trouble occurs on the vehicle. The diagnostic system allows for reading of the trouble codes from the DLC3. Use the intelligent tester to check and solve the problem. 2. CHECK DLC3 (a) The main body ECU uses ISO 15765-4 for communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. CG SG CANH SIL CANL BAT H100769E16 Symbols (Terminal No.) Terminal Description Condition Specified condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 10 to 14 V CANH (6) - CANL (14) CAN bus line Ignition switch OFF* 54 to 67 Ω CANH (6) - CG (4) HIGH-level CAN bus line Ignition switch OFF* 200 Ω or higher CANL (14) - CG (4) LOW-level CAN bus line Ignition switch OFF* 200 Ω or higher CANH (6) - BAT (16) HIGH-level CAN bus line Ignition switch OFF* 6 kΩ or higher CANL (14) - BAT (16) LOW-level CAN bus line Ignition switch OFF* 6 kΩ or higher NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. DL DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) DL–111 (b) Connect the cable of the intelligent tester (with CAN VIM) to the DLC3, turn the ignition switch ON and attempt to use the intelligent tester. If the screen displays a communication error message, a problem exists in the vehicle or in the tester. • If communication is normal when the tool is connected to another vehicle, inspect the DLC3 on the original vehicle. • If communication is still impossible when the tool is connected to another vehicle, the problem is probably in the tool itself. Consult the Service Department listed in the tool's instruction manual. DLC3 Intelligent Tester C131977E01 DTC CHECK / CLEAR 1. DLC3 Intelligent Tester C131977E01 2. DTC CHECK/CLEAR (USING INTELLIGENT TESTER) (a) DTC check (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch ON. (3) Read DTCs on the tester screen. (b) DTC clear (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch ON. (3) Clear the DTCs following the prompts on the tester screen. HINT: The intelligent tester has a SNAPSHOT function which records the monitored data. Refer to the intelligent tester operator's manual for further details. SELF-DIAGNOSTIC MODE (OPERATING IGNITION KEY CYLINDER) (a) Switch to self-diagnostic mode. (1) Establish the vehicle's initial conditions (See page DL-99). (2) Insert the key into the ignition key cylinder and remove it. (3) Within 5 seconds after the key is removed, insert it into the ignition key cylinder and then turn the ignition switch ON then OFF 1 time (End in OFF). (4) Within 30 seconds of turning the ignition switch OFF, perform the following 9 times: Turn the ignition switch ON then OFF (End in OFF). HINT: • Turning the ignition switch ON after the procedure above has been completed will end the self-diagnostic mode. • Do not lock or unlock doors while performing the self-diagnostic mode. DL DL–112 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) NOTICE: If the system fails to enter the self-diagnostic mode, the system will return to normal mode. (b) Check that the system has switched to selfdiagnostic mode by checking the sound of the wireless door lock buzzer. (c) Check the diagnostic outputs when the door control transmitter switch is held down. The diagnostic outputs can be checked by the sound of the wireless door lock buzzer. Timing Chart Buzzer Output: ON OFF T3 T2 T1: 0.25 seconds T2: 0.5 seconds T3: 0.13 seconds B144376E01 Buzzer Output: Unmatching Recognition Code: Normal Wave ON (LOCK/UNLOCK or LUGGAGE OPEN Switch): OFF Wave is being received ON OFF No Diagnosis Output: T1 T2 OFF DL T1: 0.13 seconds T2: 0.5 seconds B113635E02 3. SELF-DIAGNOSTIC MODE (USING INTELLIGENT TESTER) (a) Switch to self-diagnostic mode. (1) Connect the intelligent tester to the DLC3. DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) DL–113 (2) Turn the ignition switch ON and turn the intelligent tester main switch on. HINT: Refer to the intelligent tester operator's manual for further details. DL DL–114 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) DATA LIST / ACTIVE TEST 1. DATA LIST HINT: Using the intelligent tester DATA LIST allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to shorten labor time. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the ignition switch ON. (c) Enter the following menus: DIAGNOSIS / OBD/ MOBD / BODY / DATA LIST. (d) Read the DATA LIST according to the display on the tester. BODY (Main body ECU RH): Item Measurement Item/Display (Range) Normal Condition Diagnostic Note WIRELESS OPER Wireless door lock control function / ON or OFF ON: Operating OFF: Not operating - HAZARD ANS BACK Hazard answer-back of wireless / ON or OFF ON: Operating OFF: Not operating - OPEN DOOR WARN Open door warning / ON or OFF ON: Operating OFF: Not operating - AUTO LOCK DELAY Automatic lock time / 60 s or 30 s 60 s: 60 seconds 30 s: 30 seconds - 2 times operation of wireless unlock / ON or OFF ON: All doors unlock when UNLOCK is pressed twice OFF: All doors unlock when UNLOCK is pressed once - Panic function / ON or OFF ON: Operating OFF: Not operating - Wireless door lock buzzer response / ON or OFF ON: Operating OFF: Not operating - Luggage compartment door open function type / 1 TIME/2 TIME/ 0.6 s PR/ OFF 1 TIME: Luggage compartment door opens when LUGGAGE OPEN switch is pressed once 2 TIME: Luggage compartment door opens when LUGGAGE OPEN switch is pressed twice 0.6 s PR: Luggage compartment door opens when LUGGAGE OPEN switch is pressed and held down for 0.6 seconds. OFF: Not operating - UNLOCK /2OPER ALARM FUNCTION WIRLS BUZZ RESP TRUNK LID OPER 2. DL ACTIVE TEST HINT: Performing the intelligent tester ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to shorten the labor time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the ignition switch ON. (c) Enter the following menus: DIAGNOSIS / OBD/ MOBD / BODY / ACTIVE TEST. (d) Perform the ACTIVE TEST according to the display on the tester. BODY (Main body ECU RH): Item Tester Detail Diagnostic Note BUZZ RESP SOUND Wireless door lock buzzer ON / OFF - DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) DL–115 Item Tester Detail Diagnostic Note HAZARD Turns the turn signal flasher relay ON / OFF Observe headlight and rear combination light for correct operation VEHICLE HORN Vehicle horn ON / OFF - TRUNK/BDOR OPEN Turns luggage compartment door opener motor ON / OFF Observe luggage compartment door DL DL–116 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) DIAGNOSTIC TROUBLE CODE CHART HINT: If a trouble code is displayed during the DTC check, inspect the trouble areas listed for that code. For details of the code, refer to "See Page" in the DTC chart. • The following is the troubleshooting procedure for the wireless door lock control of a vehicle without the smart key system. For the troubleshooting procedure for the wireless door lock control of a vehicle with the entry and start system, refer to the wireless door lock control system (with Smart Key System). • Inspect the fuse and relay before investigating the trouble areas shown in the table below. WIRELESS DOOR LOCK CONTROL SYSTEM: DL DTC No. Detection Item B1242 Wireless Door Lock Tuner Circuit Malfunction Trouble Area 1. Wire harness 2. Door control receiver 3. Main body ECU See page DL-113 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) DTC B1242 DL–117 Wireless Door Lock Tuner Circuit Malfunction DESCRIPTION The door control receiver receives signals from the transmitter and sends these signals to the main body ECU. DTC No. B1242 DTC Detection Condition Trouble Area In diagnostic mode, an applicable RDA signal cannot be received within 1 second after an PRG signal has been output from the main body ECU. • • • Wire harness Door control receiver Main body ECU (Instrument panel J/B) WIRING DIAGRAM Instrument Panel J/B E6 Main Body ECU O17 Door Control Receiver 1 From Battery 5 GND RDA +B PRG 2 12 3 10 RDA PRG B128409E01 DL DL–118 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (MAIN BODY ECU - DOOR CONTROL RECEIVER) (a) Disconnect the E6 main body ECU connector and the O17 door control receiver connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Connector Wire Harness Side: Main Body ECU E6 PRG Symbol (Tester Connection) Condition Specified Condition RDA (E6-12) - RDA (O17-2) Always Below 1 Ω RDA (E6-12) - Body ground Always 10 kΩ or higher PRG (E6-10) - PRG (O17-3) Always Below 1 Ω PRG (E6-10) - Body ground Always 10 kΩ or higher RDA NG REPAIR OR REPLACE HARNESS OR CONNECTOR Door Control Receiver O17 PRG RDA B139427E01 OK 2 CHECK HARNESS AND CONNECTOR (BATTERY, BODY GROUND) (a) Measure the voltage and resistance according to the value(s) in the table below. Standard Connector Wire Harness View: DL Door Control Receiver Symbol (Tester Connection) Condition Specified Condition GND (O17-1) - Body ground Always Below 1 Ω +B (O17-5) - Body ground Always 10 - 14 V NG O17 +B GND B113637E02 REPAIR OR REPLACE HARNESS OR CONNECTOR DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) DL–119 OK 3 REPLACE DOOR CONTROL RECEIVER (a) Reconnect the E6 main body ECU connector. (b) Replace the door control receiver with a normal one. (c) Perform the registration procedures (See page DL-101). HINT: If a normally functioning door control receiver is available, connect it and check if the wireless door lock function is normal or DTCs are output. If the alternative receiver functions normally, replace the original door control receiver. NEXT 4 CONFIRM DTC (a) Clear the DTCs (See page DL-109). (b) Check if the same DTC is detected. HINT: Reinstall the sensors, connectors, etc. and restore the previous vehicle conditions before rechecking for DTCs. Result Result Proceed To DTC is output A DTC is not output (When troubleshooting in accordance with the DTC CHART) B DTC is not output (When troubleshooting in accordance with the PROBLEM SYMPTOMS TABLE) C B END C PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE A REPLACE MAIN BODY ECU (INSTRUMENT PANEL JUNCTION BLOCK) DL DL–120 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) Wireless Door Lock Buzzer Circuit DESCRIPTION The main body ECU RH activates the wireless door lock buzzer when detecting a lock/unlock signal from the door control transmitter. WIRING DIAGRAM E9 Instrument Panel J/B Main Body ECU A48 Wireless Door Lock Buzzer 2 1 7 BZR B128410E01 DL DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) DL–121 INSPECTION PROCEDURE 1 INSPECT WIRELESS DOOR LOCK BUZZER (a) Disconnect the A48 wireless door lock buzzer connector. (b) Measure the resistance according to the value(s) in the table below. HINT: The buzzer activation circuit is built into the ECU, not into the buzzer itself. When battery voltage is applied directly to the buzzer, the buzzer will not sound. Standard resistance Wireless Door Lock Buzzer: A48 2 1 Tester Connection Condition Specified Condition A48-1 - A48-2 Always Approx. 1 kΩ NG REPLACE WIRELESS DOOR LOCK BUZZER B144393E01 OK 2 CHECK HARNESS AND CONNECTOR (MAIN BODY ECU - WIRELESS DOOR LOCK BUZZER - BODY GROUND) (a) Disconnect the E9 main body ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Connector Wire Harness View: Main Body ECU BZR E9 Wire Harness Side Connector Front View: Symbol (Tester Connection) Condition Specified Condition BZR (E9-7) - A48-1 Always Below 1 Ω BZR (E9-7) - Body ground Always 10 kΩ or higher A48-1 - Body ground Always 10 kΩ or higher A48-2 - Body ground Always Below 1 Ω NG Wireless Door Lock Buzzer REPAIR OR REPLACE HARNESS OR CONNECTOR DL A48 B113633E03 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE DL–118 DOOR LOCK – SMART KEY SYSTEM SMART KEY SYSTEM PRECAUTION 1. 2. DL PRECAUTIONS WHEN USING INTELLIGENT TESTER (a) When troubleshooting the smart key system using the intelligent tester with the engine switch off, connect the intelligent tester to the vehicle and repeat turning any of the courtesy light switches on and off until communication between the tester and the vehicle begins (the interval between ON and OFF should be less than 1.5 seconds). (b) After DTCs are all cleared, check if the trouble occurs again 6 seconds after the engine switch is turned on (IG). PRECAUTIONS FOR EACH FUNCTION (a) Precautions for the electrical key: The electrical key is a precision instrument. Be sure to observe the following: (1) Do not drop or strike the electrical key. (2) Do not keep the electrical key in a high temperature area for a long time. (3) Do not use an ultrasonic washing machine to clean the electrical key. (4) Keep the electrical key away from magnets or magnetized items during use. (5) Do not attach any stickers to the electrical key. (6) If an electrical key is lost, delete all registered electrical key ID codes and then reregister the remaining electrical keys. (b) Precautions for the entry unlock function: (1) As the sensor is built into the backside of the outside door handle, the user must touch the backside of the handle when performing the unlock function. (2) If touched with gloved hands, the response of the door may be delayed. (3) During the entry unlock operation, if the door handle is pulled before the door unlocks, the unlock function cannot be completed. Confirm that the door has been unlocked before pulling the door handle to open the door. DOOR LOCK – SMART KEY SYSTEM DL–119 (4) Make sure that the doors are unlocked when touching the touch sensor on the outside door handle while the electrical key is being carried. If the doors cannot be unlocked, the certification ECU orders the main body ECU to perform the door unlock operation 4 times at intervals of 0.75 seconds. At this time, the door may not be unlocked because the handle is being pulled due to some mechanical reasons. Be sure to return the door handle to its original position. If the door cannot be opened by pulling the handle, perform the entry unlock operation again. (5) If the electrical key is too close to the oscillator on the outside of the vehicle, the door may not be unlocked because the electrical key cannot react to the strong wave output from the transmitter. (6) If the electrical key is within the vehicle exterior detection area, the door can be unlocked even when a person other than the person carrying the electrical key holds the door handle. However, the doors other than the door that the codes match will not be unlocked. (If the electrical key is within the driver side door's detection area outside the vehicle, the doors will be unlocked when the person carrying the electrical key holds the driver side door handle. However, if any door handle other than that of the driver side door is held, the doors will not be unlocked). (7) If a door is not opened after the door unlock operation, the doors automatically lock after approximately 30 seconds. (8) If a large amount of water is applied to the door handle due to a car wash or heavy rain, the electrical key being within the vehicle exterior detection area may cause the doors to be unlocked. However, the doors will be locked again after approximately 30 seconds if a door is not opened. (9) If the electrical key of the smart key system is used while it is being carried with the electrical key of another smart key system, the time before the entry unlock operation will become longer than usual. This is not a malfunction. (c) Precautions for the entry lock function: (1) When performing the entry lock operation, firmly press the lock switch on the outside door handle. If pressed too quickly or lightly, the entry lock may not operate. DL DL–120 DL DOOR LOCK – SMART KEY SYSTEM (2) It is possible that signals output from the indoor electrical key antenna may leak through the window. Also, if the electrical key is too close to a door oscillator, the oscillator output signals are too strong and the electrical key cannot respond. As a result, when the electrical key is near the vehicle interior (window, door handle), the entry lock function may not operate. Also, the electrical key reminder warning buzzer may sound and the entry unlock operation may stop functioning. In this situation, move the electrical key away from the vehicle interior (window, door handle), perform the entry lock operation and perform the entry unlock operation. (3) Do not touch the lock switch while opening or closing the door. If the lock switch is pressed when opening or closing the door while the electrical key is being carried, the door ajar warning buzzer sounds (beeps outside the vehicle for 10 seconds). (4) If the electrical key is on the instrument panel, rear package tray, floor, or in the glove box, the electrical key reminder function may not operate and the electrical key may be locked in the vehicle. Always carry the electrical key. (5) If the electrical key is outside the vehicle but is very close to a window or door handle (the ECU determines that the electrical key is inside the vehicle) and the transmitter or mechanical key is used to lock the doors (entry lock is not used), entry unlock will not operate. To unlock the doors, perform a wireless door unlock operation. The entry lock function operates in this way to prevent the user from unintentionally unlocking the doors from outside the vehicle. For example, when a user operates the wireless door lock operation from inside the vehicle, radio waves from a door oscillator may leak into the vehicle interior and the doors may unlock. (6) To allow the user enough time to check if the doors are locked after performing a door lock operation (entry lock function or wireless door lock operation), the entry unlock function will not be permitted for 3 seconds after the door lock operation. (d) Precautions for the entry ignition function: (1) To start the engine, first depress the brake pedal firmly until the engine switch indicator illuminates green. (2) When operating the engine switch, firmly press the switch. If the switch is pressed too quickly, power source control and engine starting may not operate. DOOR LOCK – SMART KEY SYSTEM DL–121 (3) While driving the vehicle, continuously pressing the engine switch for 3 seconds or more will turn off the engine. Do not touch the engine switch while driving, except in an emergency. (4) Do not touch the engine switch with oily hands. (5) If the vehicle has been in a high temperature location for an extended period of time, be careful when touching the engine switch. It may be very hot and lead to burns. (6) Take care to avoid spilling beverages on the engine switch. Keep all liquids away from the engine switch. (7) Do not use the engine switch if it seems to be sticking or feels abnormal. (8) The vehicle continually records the power source mode (off, on (ACC), on (IG), start). When the battery cable is disconnected and reconnected, the power source mode will return to the mode that was selected before disconnecting the battery cable. Always turn the power off before disconnecting the battery cable. When the vehicle battery is fully depleted, power will be cut. As a result, the power source mode before the power was cut cannot be recognized, so be extremely careful. (9) Do not connect any electronic products to the ACC, IG1 or IG2 coil side wiring, as the vehicle power supply may be unable to be turned on, or other problems may occur. (10) After the battery cable has been disconnected and reconnected, the engine will not start on the first attempt. The engine will start normally on the second attempt. (11) When starting the engine immediately after reconnecting the battery cable, connect the cable and wait at least 10 seconds before attempting to start the engine. The engine may not start when attempting an engine start immediately after disconnecting and reconnecting the battery cable. (12) If the electrical key is held over the engine switch to start the engine because the electrical key battery is depleted, the following warnings will sound: • Driver's door open → closed: – An exit warning if the shift lever is in a position other than P and the power source is in a mode other than off. – An exit warning if the shift lever is in the P position and the power source is in a mode other than off. • Doors other than the driver door open → closed: DL DL–122 DL DOOR LOCK – SMART KEY SYSTEM Warning to inform that the electrical key has been taken out of the vehicle. These warnings will sound because whether the electrical key is in the cabin or not cannot be determined. They do not indicate system malfunctions. (e) Precautions for luggage compartment door entry function: Even if the electrical key is within the electrical key oscillator (outside luggage compartment) detection area, the luggage compartment door cannot be opened if the electrical key is in the following areas: • Near the center of the bumper • Too close to the ground or in a high place (f) Precautions for the function to prevent electrical key confinement in the luggage compartment: (1) Do not place the electrical key in the luggage compartment. If the luggage compartment is closed with the electrical key in it when all the doors are locked, the alarm to indicate electrical key confinement will operate (beeping sound for 2 seconds outside of the vehicle). However, the alarm may not operate for some reason relating to the electrical key location (near the spare tire or the side of the luggage compartment), the electrical key condition (covered with metal or near metal), or ambient radio waves. (2) If the luggage compartment is closed with the electrical key in it when any of the doors is unlocked or open, the electrical key confinement prevention function will not operate. In this case, use the luggage compartment opener in the cabin to open the luggage compartment and take out the electrical key. (3) The alarm may erroneously operate in the following conditions. If you can confirm that you are carrying the electrical key or that the electrical key is in the cabin, there is no problem. The entry luggage compartment open function may not operate if the alarm erroneously operates. In this case, use the luggage compartment opener in the cabin or perform a wireless operation to open the luggage compartment. - The electrical key is brought into the cabin after the luggage compartment is opened, and then the luggage compartment is closed. - The luggage compartment is closed by the person who is carrying the electrical key. DOOR LOCK – SMART KEY SYSTEM DL–123 (4) If the alarm operates when the luggage compartment is closed with all the doors locked, the electrical key is in the cabin or luggage compartment. Check the cabin and luggage compartment to find the electrical key. (5) If the luggage compartment is closed with the electrical key in it when all the doors are locked, the alarm will sound and the luggage compartment can be opened. This may increase the risk of the vehicle being stolen. (6) Do not open or close the luggage compartment after all the doors are locked if you want to keep the spare electrical keys in the cabin. As a result, the alarm may sound and the luggage compartment can be opened. This may increase the risk of the vehicle being stolen. (g) Precautions for the battery built into the electrical key and the vehicle battery: (1) The electrical key is constantly checking for signals from the vehicle, which requires power from the electrical key's built-in battery. The life of the battery is approximately 1 to 2 years depending on the usage conditions. Be sure to replace the battery when its power is low. When replacing the battery, do not touch the inner circuit board or other inner parts. (2) The electrical key is constantly checking for signals from the vehicle using battery power to determine whether the electrical key is being used or not. Even if the user is carrying 2 electrical keys and only 1 electrical key is used, both electrical keys will consume battery power. (3) The electrical key receives radio waves at approximately 314 MHz. If the electrical key continuously receives strong, identical frequency waves, this may drain the electrical key's battery. Store the electrical key at least 1 m (3.3 ft) from TVs, personal computers, or other electrical products. (4) When a door is being locked, the vehicle battery is used to transmit radio waves. The battery may be dead if the vehicle remains stopped for a long time. If the vehicle is not used for a long time, remove the battery from the vehicle or cancel the smart key system. (5) When a door is being locked with the electrical key in the detection area of a door oscillator, the battery is used for regular communication between the electrical key and vehicle. If the vehicle is not used, keep the electrical key away from the vehicle (more than 2 m (6.6 ft)). DL DL–124 DOOR LOCK – SMART KEY SYSTEM (6) After disconnecting and reconnecting the battery cable, the entry unlock function may not operate. If this occurs, perform a wireless door unlock and lock operation. (h) Precautions for the entry unlock mode switching function: (1) Perform the entry unlock mode switching function within a 1 m (3.3 ft) area around the vehicle. (2) The entry unlock mode switching function cannot be performed within 5 seconds of the previous mode change. Wait 5 seconds or more before performing a mode change. DL DL–125 DOOR LOCK – SMART KEY SYSTEM PARTS LOCATION ECM (2GR-FE) ENGINE ROOM J/B AND R/B - AM2 FUSE WIRELESS BUZZER ELECTRICAL KEY OSCILLATOR (FRONT) ELECTRICAL KEY OSCILLATOR (REAR) - ECU-B NO. 1 FUSE - DOOR NO. 1 FUSE DOOR CONTROL RECEIVER LUGGAGE COMPARTMENT OPENER SWITCH DL ENTRY LOCK AND UNLOCK SWITCH TOUCH SENSOR ELECTRICAL KEY OSCILLATOR (INSIDE LUGGAGE COMPARTMENT) ELECTRICAL KEY OSCILLATOR (OUTSIDE LUGGAGE COMPARTMENT) B137948E01 DL–126 DOOR LOCK – SMART KEY SYSTEM FRONT DOOR COURTESY SWITCH FRONT DOOR LOCK RH REAR DOOR LOCK RH FRONT DOOR LOCK LH FRONT DOOR COURTESY SWITCH REAR DOOR LOCK LH LUGGAGE DOOR LOCK REAR DOOR COURTESY SWITCH DL B137949E01 DOOR LOCK – SMART KEY SYSTEM DL–127 COMBINTAION METER ID CODE BOX CERTIFICATION ECU TURN SIGNAL FLASHER DLC3 MAIN BODY ECU (INSTRUMENT PANEL J/B) STEERING LOCK ECU - DOOR NO. 2 FUSE DL - ECU-ACC FUSE - ECU IG NO. 1 FUSE B137950E01 DL–128 DOOR LOCK – SMART KEY SYSTEM SYSTEM DIAGRAM IG Relay Output ACC Relay Output ECM Steering Lock Actuator Assembly Front Electrical Key Oscillator LH ID Code Box Main Body ECU - Steering Lock ECU To CAN Communication System Front Electrical Key Oscillator RH Certification ECU Stop Light Switch Front Door Outside Handle Assembly LH - Touch Sensor Front Door Outside Handle Assembly RH Engine Switch - Touch Sensor - Antenna - Antenna - Lock Switch - Lock Switch DL : CAN Electrical Key Oscillator (Console) : LIN Electrical Key B137952E01 DL–129 DOOR LOCK – SMART KEY SYSTEM Electrical Key Oscillator (Rear Seat) Electrical Key Door Control Receiver Electrical Key Oscillator (Inside Luggage Compartment) Electrical Key Antenna DL Luggage Compartment Opener Switch Electrical Key Oscillator (Outside Luggage Compartment) B137953E01 DL–130 DOOR LOCK – SMART KEY SYSTEM Transmitting ECU (Transmitter) Receiving ECU Signals Communication method Engine switch position signal Courtesy light switch signal Door lock output signal Luggage compartment door output signal Main body ECU Certification ECU Wireless door lock buzzer request signal CAN Door lock position switch signal D/P door key operated switch signal Luggage compartment door key operated switch signal Main body ECU Combination meter Certification ECU Main body ECU Certification ECU Driver seat ECU Wireless door lock buzzer request signal Illumination light request signal Light answer back signal Memory call replay request signal CAN CAN CAN Meter buzzer single-shot request signal Meter buzzer intermittence request signal Meter buzzer continuation request signal Door open display signal Certification ECU Combination meter Key loss warning signal CAN Low key battery warning signal Shift position warning signal Steering lock abnormal warning Steering lock unlock warning Certification ECU/Main body ECU Vehicle speed signal CAN Certification ECU • • • • • • • • • • • • • • • Matching request random number signal EEP ROM access malfunction Model code matching signal Model code mismatching signal ECM code receiving status Engine start permission request signal Engine start permission response signal S code matching result signal S code registration status signal S code registration mode signal L code matching result signal ECM communication signal Registered key number response signal Diagnosis mode switching signal Registered key number signal LIN Certification ECU ID code box • • • • 3 bit code request signal ID code matching result signal Registered key number signal Vehicle type handle signal LIN Certification ECU • • ID code box Steering lock ECU • • • • L code registration mode signal Diagnosis mode request signal DTC clear request signal L code registration status signal LIN Certification ECU ID code box • • • • • • • • Steering lock request signal Steering unlock signal Steering lock confirmation signal Steering unlock confirmation signal Diagnosis response signal Steering unlock drive relay signal Steering lock drive relay signal Steering lock motor operation signal LIN Combination meter ID code box DL Steering lock ECU • • DL–131 DOOR LOCK – SMART KEY SYSTEM Transmitting ECU (Transmitter) Receiving ECU Signals • • • • • Shift position P signal Power ON operation status signal Engine starting status signal ACC relay operating status signal IG relay operating status signal Communication method LIN Main body ECU Certification ECU Main body ECU Steering lock ECU Steering lock relay power supply status signal LIN • • • • • LIN Steering lock ECU Certification ECU Main body ECU Steering lock catching malfunction signal Push button start malfunction signal Engine operation signal DL DL–132 DOOR LOCK – SMART KEY SYSTEM SYSTEM DESCRIPTION CAUTION: If using a pacemaker, be sure to read the manual of the pacemaker before using the electrical key because the radio waves of the electrical key may affect the pacemaker. 1. SMART KEY SYSTEM DESCRIPTION (a) In addition to conventional mechanical key and wireless door lock control functions, the smart key system enables door locking/unlocking, steering lock releasing, engine starting, and luggage compartment door opening without operating the electrical key. The only requirement is that the electrical key is in the user's possession. • This system is controlled by the certification ECU. When the certification ECU detects the presence of an electrical key in one of the detection areas, it identifies and checks the ID code, and outputs operation signals to the related ECU in accordance with their functions. • The detection areas are formed by 6 oscillators (2 door oscillators, 2 luggage compartment oscillators, and 2 cabin oscillators). DL DL–133 DOOR LOCK – SMART KEY SYSTEM 2. DETECTION AREA Front Approx. 0.7 to 1.0 m (2.3 to 3.3 ft) Action Area Electrical Key Door Electrical Key Oscillator Electrical Key Oscillator (Console) Electrical Key Oscillator Approx. 80% of the Luggage Room Electrical Key Oscillator (Inside Luggage Compartment) Electrical Key Oscillator (Outside Luggage Compartment) Approx. 0.7 to 1.0 m (2.3 to 3.3 ft) Rear DL B137951E01 (a) Precautions for the entire system: • Be sure to carry the electrical key during inspection of the smart key system. • As weak radio waves are used to detect the electrical key, the electrical key detection area may decrease, or the electrical key may not be detected correctly in the following situations: (a)The electrical key battery is depleted. DL–134 DOOR LOCK – SMART KEY SYSTEM 3. (b)Any facilities that generate strong radio waves, such as a TV tower, power plant, broadcast station, or gas station, are located near the inspection site. (c) A wireless device, such as a cellular phone, is carried with the electrical key. (d)The electrical key is in contact with or covered with metal. (e)Another wireless door lock control function is operated near the vehicle. (f) The electrical key is located near a device that generates high voltage or noise. • The electrical key may be difficult to operate for a reason relating to the vehicle body shape. • The electrical key may not be detected correctly if it is around the vehicle's windows, the door handle, or the center of the bumper even when it is in the detection area outside the vehicle. • The electrical key may not be detected correctly if it is on the instrument panel, auxiliary box of the driver's side instrument panel, rear package tray, floor, or in the glove box even when it is in the detection area inside the vehicle. • The engine cannot be started even when the electrical key is in the detection area inside the luggage compartment. • The electrical key may not operate if the electrical key is not held properly. • The smart key system does not operate in the following conditions: (a)The smart key system is canceled. (b)The electrical key battery is completely depleted (the indicator does not blink when pushing any of the buttons on the electrical key). FUNCTION OF MAIN COMPONENTS Component DL Function Electrical Key Consists of mechanical key, transmitter for wireless door lock control, and transceiver for smart key system Certification ECU Controls smart key system in accordance with signals from each oscillator, various switches, ECUs, and electrical key • Judges and certifies ID code from entry door control receiver • Transmits engine immobiliser unset signal to ID code box • Transmits steering unlock signals to steering lock ECU Main Body ECU (Instrument Panel J/B) Controls push button start function in accordance with signals from various switches, ECUs, and combination meter • Transmits electrical key verification request signal to certification ECU in accordance with engine switch signal, and turns relays ON and OFF • Receives request signal from certification ECU and actuates door lock motor to unlock or lock door • Transmits each door condition signal to certification ECU ID Code ECU Receives steering unlock or engine immobiliser unset signals from certification ECU, certifies them, and transmits unset signals to steering lock ECU or ECM Outside Door Handle (driver and passenger doors) (antenna) Transmits request signals Outside Door Handle (driver and passenger doors) (touch sensor) Detects that person touches inside of outside handle DL–135 DOOR LOCK – SMART KEY SYSTEM Component Function Outside Door Handle (driver and passenger doors) (lock switch) Transmits door lock request signals to certification ECU Door Electrical Key Oscillator (driver and passenger doors) Receives request signal from certification ECU, and forms detection area around front door Indoor Electrical Key Oscillator (console and rear seat) Receives request signal from certification ECU, and forms detection area in vehicle interior Luggage Compartment Electrical Key Oscillator (inner) Receives request signal from certification ECU, and forms detection area in luggage compartment Luggage Compartment Electrical Key Oscillator (outer) Receives request signal from certification ECU, and forms detection area around luggage compartment door • Door Control Receiver • Receives ID code from electrical key in detection area and transmits it to certification ECU Receives ID code from electrical key in luggage compartment and transmits it to certification ECU Electrical Key Antenna Receives ID code from electrical key and transmits it to entry door control receiver Luggage Compartment Opener Switch Transmits luggage compartment door open request signal to certification ECU Stop Light Switch Outputs state of brake pedal to main body ECU Wireless Door Lock Buzzer • Combination Meter – Multi-information Display – Buzzer When certification ECU detects human errors such as those below, it warns driver by sounding wireless door lock buzzer, displaying information and sounding a buzzer in combination meter in accordance with request signal from ECU Example: • Electrical key is taken out of vehicle • Driver leaves vehicle while engine is still running • Driver leaves vehicle while shift lever is in any position other than P 4. CONSTRUCTION AND OPERATION (a) Electrical Key The electrical key consists of a mechanical key, a transmitter for the wireless door lock control, and a transceiver for the smart key system. • The transceiver for the smart key system receives signals from the oscillators and sends the ID code to the tuner. • The transmitter for the wireless door lock control has a LOCK switch, UNLOCK switch, LUGGAGE COMPARTMENT switch, and PANIC switch. • This mechanical key works for the driver door, luggage compartment door, and glove box, but cannot start the engine. DL DL–136 DOOR LOCK – SMART KEY SYSTEM A total of 7 electrical keys can be registered. LUGGAGE COMPARTMENT Switch LOCK Switch UNLOCK Switch PANIC Switch Mechanical Key Mechanical Key Electrical Key B137961E01 DL (b) Oscillator (front door oscillator, front and rear indoor oscillator, luggage compartment inner oscillator, luggage compartment outer oscillator) Each oscillator transmits the request signal received from the certification ECU, and forms an electrical key detection area to detect the presence of an electrical key. The detection area formed by front door oscillator and luggage compartment outer oscillator is approximately 0.7 to 1.0 m (2.3 to 3.3 ft) from the outside handle of front door or the center of the rear bumper. • The detection area of front door oscillator is formed by transmitting a request signal every 0.25 seconds while the engine switch is off and each door is locked. In this way, it detects the proximity of an electrical key. During entry lock, the detection area is formed with the lock switch on. • The detection area of the luggage compartment outer oscillator is formed when the power luggage door open switch is on. • The detection area of the indoor oscillator (front and rear) is formed when the driver door is opened or closed, entry luggage compartment open, electrical key lock-in prevention during start ignition, when a warning is activated, or when the lock switch is on. • The detection area of the luggage compartment inner oscillator is formed when the luggage compartment door is closed, entry luggage compartment open, electrical key lock-in prevention, the luggage compartment open switch or lock switch is pressed. DL–137 DOOR LOCK – SMART KEY SYSTEM 5. ENTRY FUNCTION OPERATION (a) The smart key system has the following functions: Function Outline Mechanical Key Operation is same as conventional mechanical key. Wireless Door Lock Control This function remotely locks and unlocks all doors or luggage compartment. Operation is same as wireless door lock control system. However, receiver in certification ECU uses entry door control receiver to control locking and unlocking. Entry Illumination When person carrying electrical key enters detection area, door will enter unlock standby mode and front map light will illuminate. Entry Unlock When electrical key is located in detection area of door oscillator, door will unlock by touching inside of outside door handle. Entry Unlock Mode Switching (See page DL-145) Changes doors that can be unlocked with entry unlock function between 2 modes. • Driver door mode • All door mode Entry Lock When electrical key is located in detection area of door oscillator and engine switch is off, door can be locked by pressing lock switch on outside door handle. Entry Luggage Compartment Open When electrical key is in detection area of luggage compartment outer oscillator, luggage compartment opens by pressing luggage compartment open switch. Memory Call This function operates driving position memory system in accordance with electrical key ID code. • • Electrical Key Lock-in Prevention Prevents confinement of electrical key if door is locked using outside door handle while electrical key is still inside vehicle. If all doors are locked and luggage compartment door is closed while electrical key is still in luggage compartment, warning buzzer sounds. If luggage compartment open switch is operated, luggage compartment door can be opened. Warning When any of situations below occur, smart key system causes certification ECU to sound buzzer in combination meter and wireless door lock buzzer, and display information in order to alert driver. • Exit warning if shift lever position is not P and power source mode is not off. • Exit warning if shift lever position is P and power source mode is not off. • Warning if occupant leaves with electrical key. • Warning if engine switch is operated while electrical key is outside actuation area. • Warning if entry lock is operated while electrical key is inside vehicle. • Warning if electrical key battery is weak. Battery Saving If electrical key is constantly located within actuation area of door oscillator, system maintains periodic communication with electrical key. Therefore, if vehicle remains parked in that state for a long time, electrical key battery and vehicle battery could be drained. Key Cancel (See page DL-145) Following electrical key functions can be cancelled by performing certain operations: • Entry Unlock/Lock • Memory Call • Entry Luggage Compartment Open • Electrical key Lock-in Prevention • Warning Electrical Key Code Registration The total number of electrical keys that can be registered is seven. Enables the registration (writing and storing) of transmitter recognition codes in the EEPROM that is contained in the certification ECU. 6. WIRELESS DOOR LOCK AND UNLOCK AND LUGGAGE COMPARTMENT OPEN FUNCTION Push the LOCK/UNLOCK/PANIC/LUGGAGE COMPARTMENT switch on the electrical key to operate each function. For details, (See page DL-69). DL DL–138 DOOR LOCK – SMART KEY SYSTEM 7. DL ENTRY UNLOCK FUNCTION (a) The detection area is formed by communication between a door oscillator and door control receiver when the door is locked in order to detect access of the person carrying the electrical key. (b) When the person carrying the electrical key enters the detection area around the vehicle, the matching of the ID codes for a door oscillator and electrical key will automatically be performed. After the matching is completed, the door will enter unlock standby mode. (c) In unlock standby mode, the antenna built into the outside handle starts sensing. If the outside handle is held (the back side of the handle is touched), the door unlock operation will be performed. At this time, the hazard warning light blinks twice and the wireless door lock buzzer sounds twice. (d) If any of the doors are not opened after a door unlock operation, all doors will automatically lock after 60 seconds. 8. ENTRY LOCK FUNCTION (a) After leaving the vehicle carrying the electrical key, push the lock switch on the outside handle when all the doors are closed. (b) The certification ECU determines whether the electrical key is located inside or outside of the cabin based on the information from a door oscillator and room oscillator. Then matching of the ID codes is performed. (c) When the matching result shows that the ID codes of the electrical key and indoor antenna do not match and the ID codes of the electrical key and door oscillator match, the door lock function will operate. At this time, the hazard warning lights blink once and the wireless door lock buzzer sounds once. (d) If the electrical key is located inside of the cabin, the door lock function will not operate and the alarm buzzer (beep sound) will sound for 2 seconds. 9. ENTRY LUGGAGE COMPARTMENT OPEN FUNCTION Stand in front of the luggage compartment with the electrical key and push the power luggage compartment opener switch to start the matching of the ID codes for the electrical key oscillator (outside luggage compartment). If the ID codes match, luggage compartment door open operation will be performed. 10. PREVENTION OF ELECTRICAL KEY CONFINEMENT FUNCTION (a) If you attempt to lock the door through keyless operation (move the lock knob to the lock position and then close the door) with the electrical key in the cabin, the system determines that the electrical key is located in the cabin and unlocks the door. DL–139 DOOR LOCK – SMART KEY SYSTEM (b) If the luggage compartment is closed with the electrical key in it, the alarm will sound and the luggage compartment can be opened only when all the doors are locked in order to prevent electrical key confinement in the vehicle. 11. ENTRY ILLUMINATION FUNCTION When a person carrying the electrical key enters the detection area, the door will enter unlock standby mode and the front map light will illuminate. HINT: The entry illumination function operates when the electrical key enters the vehicle exterior detection area from out of the detection area. If the electrical key remains in the detection area for 3 seconds or more, the illumination function does not operate. 12. MEMORY CALL FUNCTION When the engine switch is off and the driver side door is closed, opening the door will operate the memory call function (the door will move to a previously recorded driving position). Using the electrical key, memory call, electrical key registration and electrical key cancellation can be performed. 13. WARNING FUNCTION (a) General When any of the situations below occur, the smart key system causes the certification ECU to sound the buzzer in the combination meter and the wireless door lock buzzer, and illuminate the combination meter's multi-information display in order to alert the driver. Warning Function Operation Condition Situation Exit warning if shift lever position is not P and power source mode is not off. A Exit warning if shift lever position is P and power source mode is not off. B Warning if occupant leaves with electrical key. C Warning if engine switch is operated while electrical key is outside detection area. D Warning if entry lock is operated while electrical key is inside cabin. E Warning if electrical key battery is weak. F (b) Situation A There are 2 patterns for situation A. Pattern 1: In situation A, the door is opened and the user tries to leave the vehicle. Pattern 2: Then the user holds the electrical key and tries to move away from the vehicle. In these situations, the following control is performed: • Pattern 1 Possible Effects without Warning Warning Condition Sudden vehicle start, vehicle theft, vehicle roll-away Certification ECU gives warning when all following conditions are satisfied: • Shift lever position is not P • Engine switch is not off • Driver side door is opened • Vehicle speed is 5 km/h (3.1 mph) DL DL–140 DOOR LOCK – SMART KEY SYSTEM Possible Effects without Warning Sudden vehicle start, vehicle theft, vehicle roll-away Combination Meter • Buzzer Warning: Continuous sound Warning is stopped when one of following conditions is met: • Engine switch is off • Shift lever position is P • Driver side door is opened • Vehicle speed is above 5 km/h (3.1 mph) Combination Meter • Multi-information Display Warning: Continuous sound Warning is stopped when one of following conditions is met: • Engine switch is off • Shift lever position is P • Driver side door is opened • Vehicle speed is above 5 km/h (3.1 mph) Wireless Door Lock Buzzer - • Pattern 2 Possible Effects without Warning DL Sudden vehicle start, vehicle theft, vehicle roll-away Warning Condition Certification ECU gives warning when all following conditions are satisfied: • Shift lever position is not P • Engine switch is not off • Driver side door is opened and closed • Vehicle speed is 0 km/h (0 mph) • Electrical key is not in cabin or luggage compartment Combination Meter • Buzzer Warning: Continuous sound Warning is stopped when one of following conditions is met: • Engine switch is off • Shift lever position is P • Electrical key is in cabin or luggage compartment • Vehicle speed is above 0 km/h (0 mph) Combination Meter • Multi-information Display Warning: Information below is displayed alternately on combination meter: • "Shift to P Range" • "Key is not Detected" "Shift to P Range" warning is stopped when one of following conditions is met: • Engine switch is off • Vehicle speed is above 0 km/h (0 mph) • Shift lever position is P "Key is not Detected" warning is stopped when either of following conditions is met: • Engine switch is off • Electrical key is in cabin Wireless Door Lock Buzzer Warning: Continuous sound Warning is stopped when one of following conditions is met: • Engine switch is off • Shift lever position is P • Electrical key is in cabin or luggage compartment • Vehicle speed is above 0 km/h (0 mph) DL–141 DOOR LOCK – SMART KEY SYSTEM (c) Situation B There are 2 patterns for situation B. Pattern 1: In situation B, the door is opened and the user tries to leave the vehicle. Then the user holds the electrical key and tries to move away from the vehicle. Pattern 2: Then the user tries to use the entry lock and presses the lock switch. In these situations, the following control is performed: • Pattern 1 Possible Effects without Warning Vehicle theft, engine cannot be restarted Warning Condition Certification ECU gives warning when all following conditions are satisfied: • Shift lever position is P • Engine switch is not off • Driver side door is opened and closed • Electrical key is not in cabin or luggage compartment Combination Meter • Buzzer Warning: Sounds once Combination Meter • Multi-information Display Warning: Information below is displayed on combination meter: • "Key is not Detected" Warning is stopped when either of following conditions is met: • Engine switch is off • Electrical key is in cabin or luggage compartment Wireless Door Lock Buzzer Warning: Sounds 3 times Warning is stopped when either of following conditions is met: • Engine switch is off • Electrical key is in cabin or luggage compartment • Pattern 2 Possible Effects without Warning Vehicle theft Warning Condition Certification ECU gives warning when all following conditions are satisfied: • Shift lever position is P • Engine switch is not off • All doors are closed • Lock switch is "ON" • Electrical key is not in cabin or luggage compartment Combination Meter • Buzzer - Combination Meter • Multi-information Display - Wireless Door Lock Buzzer Warning: Sounds for 2 seconds (d) Situation C In this situation, the following control is performed: Possible Effects without Warning Engine cannot be restarted Warning Condition Certification ECU gives warning when all following conditions are satisfied: • Engine switch is not off • Door other than driver side door is opened and closed • Vehicle speed is 0 km/h (0 mph) • Electrical key is not in cabin or luggage compartment Combination Meter • Buzzer Warning: Sounds once DL DL–142 DOOR LOCK – SMART KEY SYSTEM Possible Effects without Warning Engine cannot be restarted Combination Meter • Multi-information Display Warning: Information below is displayed on combination meter: • "Key is not Detected" Warning is stopped when one of following conditions is met: • Engine switch is off • Vehicle speed is above 0 km/h (0 mph) • Electrical key is in cabin or luggage compartment Wireless Door Lock Buzzer Warning: Sounds 3 times Warning is stopped when one of following conditions is met: • Engine switch is off • Vehicle speed is above 0 km/h (0 mph) • Electrical key is in cabin or luggage compartment (e) Situation D In this situation, the following control is performed: Possible Effects without Warning Confuses the user Warning Condition Certification ECU gives warning when both following conditions are satisfied: • Engine switch is not off • Electrical key is not in cabin Combination Meter • Buzzer Warning: Sounds once Combination Meter • Multi-information Display Warning: Information below is displayed on combination meter for 8 seconds (disappears after 8 seconds): • "Key is not Detected" Wireless Door Lock Buzzer - (f) Situation E In this situation, the following control is performed: Possible Effects without Warning Vehicle theft Warning Condition Certification ECU gives warning when all following conditions are satisfied: • Engine switch is off • All doors are closed • Lock switch is "ON" • Electrical key is in cabin or luggage compartment Combination Meter • Buzzer - Combination Meter • Multi-information Display - Wireless Door Lock Buzzer Warning: Sounds for 2 seconds (g) Situation F In this situation, the following control is performed: DL Possible Effects without Warning Smart key system does not function Warning Condition Certification ECU gives warning when all following conditions are satisfied: • Engine switch is turned off after being left on (IG) for over 20 minutes • Electrical key battery voltage is low • Electrical key is in cabin Combination Meter • Buzzer Warning: Sounds once Combination Meter • Multi-information Display Information below is displayed on combination meter: • "Low Key Battery" Wireless Door Lock Buzzer - DL–143 DOOR LOCK – SMART KEY SYSTEM 14. BATTERY SAVING (a) Vehicle Battery Saving Function In the smart key system, signals are emitted outside of the vehicle at a prescribed interval (0.25 seconds) when the doors are locked. Therefore, the vehicle battery could be drained if the vehicle remains parked for a long time. For this reason, the controls listed below are carried out: Condition Control Both conditions below are met for 5 days: • Electrical key is not in detection area • Touch sensor or lock switch operation is not performed Signal transmission interval is extended from 0.25 to 0.75 seconds Both conditions below are met for 14 days: • Electrical key is not in detection area • Touch sensor or lock switch operation is not performed Automatically deactivates the smart key system Reinstatement Conditions • A wireless door lock control signal (lock, unlock) is input and the ID code matches. • A user carries the electrical key and pushes a lock switch on an outside door handle. • A door is locked or unlocked by the mechanical key. (b) Electrical Key Battery and Vehicle Battery Saving Function In the smart key system, if the electrical key is constantly located within the vehicle exterior detection area of the doors, the system maintains periodic communication with the electrical key. Therefore, if the vehicle remains parked in that state for a long time, the electrical key battery and the vehicle battery could be drained. For this reason, if this state continues longer than 10 minutes, the smart key system automatically becomes deactivated. Reinstatement Conditions • A wireless door lock control signal (lock, unlock) is input and the ID code matches. • A user carries the electrical key and pushes a lock switch on an outside door handle. • A door is locked or unlocked by the mechanical key. DL DL–144 DOOR LOCK – SMART KEY SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use the following procedures to troubleshoot the smart key system. • The intelligent tester can be used in steps 4, 5 and 7. • When troubleshooting the smart key system using the intelligent tester with the engine switch off, connect the intelligent tester to the vehicle and repeat turning any of the courtesy light switches on and off until communication between the tester and the vehicle begins (the interval between ON and OFF should be less than 1.5 sec.). 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS CHECK HINT: • In troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time the malfunction occurred. • Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases. • The following 5 items are important points in the problem analysis What Vehicle model, system name When Date, time, occurrence frequency Where Road conditions Under what conditions? Running conditions, driving conditions, weather conditions How did it happen? Problem symptoms DL NEXT 3 INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding to the next step. NEXT DL–145 DOOR LOCK – SMART KEY SYSTEM 4 INSPECT COMMUNICATION FUNCTION OF CAN COMMUNICATION SYSTEM (a) Use the intelligent tester to check if the CAN Communication System is functioning normally (See page CA-8). Result Result Proceed to CAN DTC is not output A CAN DTC is output B B GO TO CAN COMMUNICATION SYSTEM A 5 CHECK FOR DTC (a) Check for DTCs and note any codes that are output (See page DL-156). (b) Delete the DTCs. (c) Recheck for DTCs. Result Result Proceed to DTC does not reoccur A DTC reoccurs B B GO TO DIAGNOSTIC TROUBLE CODE CHART A 6 PROBLEM SYMPTOMS TABLE NEXT 7 OVERALL ANALYSIS AND TROUBLESHOOTING (a) On-vehicle inspection (See page DL-160) (b) DATA LIST/ACTIVE TEST (See page DL-156) (c) Terminals of ECU (See page DL-150) NEXT 8 NEXT REPAIR OR REPLACEMENT DL DL–146 9 NEXT END DL DOOR LOCK – SMART KEY SYSTEM CONFIRMATION TEST DOOR LOCK – SMART KEY SYSTEM DL–147 CUSTOMIZE PARAMETERS 1. CUSTOMIZING FUNCTION WITH INTELLIGENT TESTER HINT: The items in the table below can be customized. NOTICE: • When the customer requests a change in a function, first make sure that the function can be customized. • Be sure to make a note of the current setting before customizing. • When troubleshooting a function, first make sure that the function is set to the default setting. HINT: The following functions' default settings are ON. Part of these functions can be customized. SMART: Display (Item) Default Contents Setting 2.5s Function that sets waiting time to permit opening door after door is locked with entry lock function. 0.5s / 1.5s / 2.5s / 5.0s SMART UNLOCK D_DOOR Function that switches the entry unlock detection area. ALL / D_DOOR SMART IGNITION (SMART ignition available area) ALL Function to choose the available area for electrical key to start E/G and cancel the steering lock. FRONT / ALL SMART TRUNK (Luggage compartment opening operation) ON Function to open a luggage compartment when the driver has the electrical key and presses the luggage open button. ON / OFF PARK WAIT TIME (Wait time to permit opening door after locking) WIRELESS DOOR LOCK: Display (Item) ALARM FUNCTION (Panic function) Default Contents Function to operate the theft deterrent system by keeping pressing the lock button of the transmitter for 2.5 seconds. If there is a panic button, press the panic button instead of the lock button. ON Setting ON / OFF WARNING: Display (Item) KEY LOW-BATT WRN Default Contents Function to set a warning function for the time when a key battery becomes weak. ON 2. Setting ON / OFF Entry Unlock Mode Switching Function (a) To change the vehicle to entry unlock mode switching function, make sure the vehicle power is off and simultaneously press and hold the electrical key's LOCK switch and another electrical key switch for 4.5 seconds. When the switches are pressed and held for 4.5seconds, the entry door unlock mode changes in the following order: driver door mode, all door mode. NOTICE: After pressing and holding the switches for 4.5 seconds, wait 5 seconds before performing the same procedure again. DL DL–148 DOOR LOCK – SMART KEY SYSTEM • Driver door unlock mode: When the driver door's touch sensor is touched, only the driver door unlocks. When another touch sensor is touched, all doors unlock. • All door unlock mode: When the touch sensor is touched, all doors unlock. (b) The certification ECU receives this signal from the entry door control receiver and changes the smart key system to the entry unlock mode. (c) The certification ECU sounds the buzzers of the wireless door lock buzzer and combination meter to inform the user that the mode has been switched. Combination Meter Wireless Door Lock Buzzer Multi-information Display Mode Driver Door (Default) Passenger, rear LH and RH door “open” indication ON OFF Sounds 3 times All Doors (Customized) Displayed for 5 sec. All door “open” indication ON OFF Sounds 2 times Displayed for 5 sec. Buzzer Sounds once Sounds once Multi-information dispaly DL B137954E01 DOOR LOCK – SMART KEY SYSTEM 3. DL–149 HINT: The function only changes the entry unlock mode of the smart key system. It does not switch the unlocking of the wireless door lock control. Electrical Key Cancel The electrical key cancel operation disables the following functions: • Entry Ignition • Entry Unlock/Lock • Entry Luggage Compartment Open • Electrical Key Lock-in Prevention • Warning • Memory Call (a) The operation procedures are as follows: Precondition: Engine switch off, driver side door closed and unlocked. (1) Unlock the driver side door once with the UNLOCK switch of the electrical key. (2) Open the driver door within 5 seconds. (3) Unlock the driver side door twice with the UNLOCK switch of the electrical key within 5 seconds. (4) Repeat open → close twice for the driver door within 30 seconds, and open again. (Driver door: Open → Close → Open → Close → Open) (5) Unlock the driver side door twice with the UNLOCK switch of the electrical key within 5 seconds. (6) Repeat open → close once for the driver door within 30 seconds, and open again. (Driver door: Open → Close → Open) (7) Close the driver door within 5 seconds. When electrical key cancel is activated, the wireless door lock buzzer sounds twice. To return to the original condition, perform the procedures again. When the original condition is returned, the wireless door lock buzzer sounds once. DL DL–150 DOOR LOCK – SMART KEY SYSTEM PROBLEM SYMPTOMS TABLE HINT: • Use the table below to help determine the cause of the problem symptoms. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. • Inspect the fuses and relays related to this system before inspecting the suspected areas below. SMART KEY SYSTEM: Symptom Entry lock/unlock does not operate. Luggage compartment does not open (when the electrical key is outside the vehicle). DL All entry function does not operate. Suspected area See page 1. Check for DTCs in the smart key system (Starting function). ST-26 2. Refer to PROBLEM SYMPTOMS TABLE of the power door lock control system ("All doors cannot be locked/unlocked simultaneously by neither door control switch nor door key cylinder"). DL-11 3. Courtesy light switch circuit LI-52 4. Lock position switch circuit - - Driver door DL-19 - Front passenger door DL-22 - Rear passenger door LH DL-25 - Rear passenger door RH DL-28 5. Entry lock switch cirucit DL-173 6. Touch sensor circuit DL-177 7. Antenna circuit DL-180 8. Refer to "ID code matching inside the cabin cannot be performed". - 9. Door oscillator circuit DL-168 10. Replace the main body ECU. - 11. Replace the certification ECU. - 1. Check for DTCs in the smart key system (Starting function). ST-26 2. Check if any function is cancelled due to customization. DL-145 3. Refer to PROBLEM SYMPTOM TABLE of the power door lock control system ("Luggage compartment door opener does not operate"). DL-11 4. Operate the luggage compartment opener switch on the electrical key to check the wireless function. DL-71 5. Refer to PROBLEM SYMPTOMS TABLE of the wireless door lock control system of the wireless door lock control system ("The wireless door lock control system does not operate"). DL-74 6. Check operation of the cabin oscillator in active test. DL-156 7. Luggage oscillator circuit DL-182 8. Luggage compartment opener switch circuit DL-188 9. Replace the main body ECU. - 10. Replace the certification ECU. - 1. Registration of the key. EI-8 2. Certification ECU power source circuit DL-190 3. Replace certification ECU. - DL–151 DOOR LOCK – SMART KEY SYSTEM Symptom Function to prevent electrical key confinement in the luggage compartment does not operate. (The luggage compartment does not open.) Function to prevent electrical key confinement in the luggage compartment does not operate. (The alarm does not sound.) The outside alarm of the answer back and entry systems does not sound. The inside alarm of the entry system does not sound. ID code matching inside the cabin cannot be performed. ID code matching outside the cabin cannot be performed. Suspected area See page 1. Check for DTCs in the smart key system (Starting function). ST-26 2. Power door lock control system DL-11 3. Courtesy light switch circuit LI-52 4. Lock position switch circuit - - Driver door DL-19 - Front passenger door DL-22 - Rear passenger door LH DL-38 - Rear passenger door RH DL-28 5. Check if any function is not cancelled due to customization. DL-145 6. Operate the LOCK/UNLOCK SW on the key to check the wireless function. DL-71 7. Refer to PROBLEM SYMPTOMS TABLE of the wireless door lock control system ("The wireless door lock control system does not operate"). DL-74 8. Check operation of the cabin oscillator in active test. DL-156 9. Luggage oscillator circuit DL-182 10. Replace the main body ECU. - 11. Replace the certification ECU. - 1. Check if the function to prevent electrical key confinement in the luggage compartment operates. DL-160 2. Check if answer back is performed when the wireless door lock is operated. DL-74 3. Replace the certification ECU. - 1. Check if the function to prevent electrical key confinement in the luggage compartment operates. DL-160 2. Check that "WIRLS BUZZ RESP" and "HAZARD ANS BACK" in the DATA LIST of the main body ECU are YES. (If it is NO, go to power door lock system.) DL-81 3. Wireless door lock tuner circuit (DTC B1242) DL-164 4. Replace the certification ECU. - 1. Operate the LOCK/UNLOCK SW on the electrical key to check the wireless function. DL-71 2. Refer to PROBLEM SYMPTOMS TABLE of the wireless door lock control system ("Wireless door lock function"). DL-74 3. Check if the electrical key reminder buzzer sounds. DL-160 4. Replace the certification ECU. - 1. Check if any function is cancelled due to customization. DL-145 2. Operate the LOCK/UNLOCK SW on the key to check the wireless function. DL-71 3. Refer to PROBLEM SYMPTOMS TABLE of the wireless door lock control system ("The wireless door lock control system does not operate"). DL-74 4. Check the cabin oscillator operation in the active test. DL-156 5. Room oscillator circuit DL-185 6. Luggage oscillator circuit DL-182 7. Replace the certification ECU. - 1. Check if any function is cancelled due to customization. DL-145 2. Operate the LOCK/UNLOCK SW on the electrical key to check the wireless function. DL-71 3. Refer to PROBLEM SYMPTOMS TABLE of the wireless door lock control system ("The wireless door lock control system does not operate"). DL-74 4. Check operation of each door oscillator in active test. DL-156 5. Door oscillator circuit DL-168 DL DL–152 DOOR LOCK – SMART KEY SYSTEM Symptom Key reminder buzzer does not sound. DL Suspected area See page 1. Perform ACTIVE TEST for the combination meter. ME-32 2. Check "COURTESY SW" in the DATA LIST of the power door lock control system. DL-17 3. Check the key reminder buzzer when the engine switch is on (ACC) and the driver's door is opened. - 4. Check if the steering wheel is locked when all power supplies are OFF and the driver's door is opened. - 5. Refer to PROBLEM SYMPTOMS TABLE of the steering lock system ("Steering wheel cannot be locked"). SR-10 6. Check that the "LCK BAR STUCK" item in the DATA LIST of the certification ECU displays OK. SR-14 7. Replace the steering lock ECU. - 8. Replace the certification ECU. - DL–153 DOOR LOCK – SMART KEY SYSTEM TERMINALS OF ECU 1. CHECK CERTIFICATION ECU E58 E59 E125964E03 (a) Disconnect the E58 ECU connector. (b) Measure the voltage and resistance according to the value(s) in the table below. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition +B (E58-1) - Body ground W - Body ground +B power supply Always 10 to 14 V IG (E58-18) - Body ground LG - Body ground Ignition power supply Engine switch off Below 1 V IG (E58-18) - Body ground LG - Body ground E (E58-17) - Body ground W-B - Body ground Ignition power supply Engine switch on (IG) 10 to 14 V Ground Always Below 1 Ω ACC (E58-19) - Body ground L - Body ground ACC power supply Engine switch off Below 1 V ACC (E58-19) - Body ground L - Body ground ACC power supply Engine switch on (ACC) 10 to 14 V TSW1 (E58-3) - Body ground GR - Body ground Entry lock switch signal Front lock switch LH not pushed 10 kΩ or higher TSW1 (E58-3) - Body ground GR - Body ground Entry lock switch signal Front lock switch LH pushed Below 1 Ω TSW2 (E58-4) - Body ground L - Body ground Entry lock switch signal Front lock switch RH not pushed 10 kΩ or higher TSW2 (E58-4) - Body ground L - Body ground Entry lock switch signal Front lock switch RH pushed Below 1 Ω LIN (E58-10) - Body ground O - Body ground LIN line Always 10 kΩ or higher CANH (E58-27) - Body ground L - Body ground CAN line Always 10 kΩ or higher CANL (E58-28) - Body ground W - Body ground CAN line Always 10 kΩ or higher AGND (E58-40) - Body ground G - Body ground Ground Always Below 1 Ω TSW5 (E58-7) - Body ground G - Body ground Luggage compartment opener switch signal Opener switch OFF 10 kΩ or higher TSW5 (E58-7) - Body ground G - Body ground Luggage compartment opener switch signal Opener switch ON Below 1 Ω If the result is not as specified, the wire harness side may have a malfunction. (c) Reconnect the E58 ECU connector. (d) Measure the voltage according to the value(s) in the table below. Symbols (Terminal No.) Wiring Color Terminal Description Condition CLG1 (E58-33) - CG1B (E58-34) LG - L Door electrical key oscillator (front LH) sensor signal All doors closed, all doors locked and engine switch off Alternating between 5 V and below 1 V CLG1 (E58-33) - CG1B (E58-34) LG - L Door electrical key oscillator (front LH) sensor signal Door unlocked or door open Below 1 V Touch sensor detection signal Outside door handle touched Below 1 V SEN1 (E58-22) - E (E58-17) B - W-B Specified Condition DL DL–154 Symbols (Terminal No.) DL DOOR LOCK – SMART KEY SYSTEM Wiring Color Terminal Description Condition Specified Condition SEN1 (E58-22) - E (E58-17) B - W-B Touch sensor detection signal Outside door handle not touched (Have the electrical key outside the cabin) SEL1 (E58-5) - E (E58-17) V - W-B Touch sensor activation control signal Move the key more than 5 m (16.4 ft) away from the front door LH 10 to 14 V SEL1 (E58-5) - E (E58-17) V - W-B Touch sensor activation control signal Bring it to the outside handle Below 1 V CLG2 (E58-35) - CG2B (E58-36) GR - BR Door electrical key oscillator (front RH) sensor signal All doors closed, all doors locked and engine switch off Alternating between 5 V and below 1 V CLG2 (E58-35) - CG2B (E58-36) GR - BR Door electrical key oscillator (front RH) sensor signal Door unlocked or door open Below 1 V SEN2 (E58-23) - E (E58-17) O - W-B Touch sensor detection signal Outside door handle touched Below 1 V SEN2 (E58-23) - E (E58-17) O - W-B Touch sensor detection signal Outside door handle not touched (Have the electrical key outside the cabin) 10 to 14 V SEL2 (E58-6) - E (E58-17) P - W-B Touch sensor activation control signal Move the key more than 5 m (16.4 ft) away from the front door RH 10 to 14 V SEL2 (E58-6) - E (E58-17) P - W-B Touch sensor activation control signal Bring it to the outside handle Below 1 V CLG5 (E58-11) - CG5B (E58-12) R-W Indoor electrical key oscillator (front) sensor signal Within 30 seconds driver side door opened and closed, engine switch off Alternating between 5 V and below 1 V CLG5 (E58-11) - CG5B (E58-12) R-W Indoor electrical key oscillator (front) sensor signal Engine switch on (IG) Below 1 V CLG6 (E58-13) - CG6B (E58-14) Y-B Indoor electrical key oscillator (rear) sensor signal Within 30 seconds after driver side door opened and closed, engine switch off Alternating between 5 V and below 1 V CLG6 (E58-13) - CG6B (E58-14) Y-B Indoor electrical key oscillator (rear) sensor signal Engine switch on (IG) Below 1 V CLG7 (E58-15) - CG7B (E58-16) R-W Luggage electrical key oscillator (inner) sensor signal Luggage compartment door opening switch ON Alternating between 5 V and below 1 V CLG7 (E58-15) - CG7B (E58-16) R-W Luggage electrical key oscillator (inner) sensor signal Luggage compartment door opening switch OFF Below 1 V CLG8 (E58-31) - CG8B (E58-32) V-P Luggage electrical key oscillator (outer) sensor signal Luggage compartment door opening switch ON Alternating between 5 V and below 1 V CLG8 (E58-31) - CG8B (E58-32) V-P Luggage electrical key oscillator (outer) sensor signal Luggage compartment door opening switch OFF Below 1 V 10 to 14 V RC0 (E58-29) - E (E58-17) G - W-B Entry door control receiver power source Engine switch off, all doors closed and electrical key switch on 4.5 to 5.5 V RC0 (E58-29) - E (E58-17) G - W-B Entry door control receiver power source Engine switch off, all doors closed and electrical key switch off Below 1 V RSSI (E58-39) - E (E58-17) R - W-B Entry door control receiver electric wave existence signal Engine switch off, all doors closed, the electrical key is not in the action area 10 to 14 V DL–155 DOOR LOCK – SMART KEY SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition RSSI (E58-39) - E (E58-17) R - W-B Entry door control receiver electric wave existence signal Engine switch off, all doors closed, the electrical key is in the action area Specified Condition Below 1 V RDA (E58-38) - E (E58-17) Y - W-B Entry door control receiver data input signal Engine switch off, all doors closed and electrical key switch off 10 to 14 V (Pulse generation) RDA (E58-38) - E (E58-17) Y - W-B Entry door control receiver data input signal Engine switch off, all doors closed and electrical key switch on Pulse generation RDA (E58-38) - Body ground Y - Body ground Tuner input signal Engine switch off, all doors closed, the electrical key is not in the action area 10 to 14 V (Pulse generation) RDA (E58-38) - Body ground Y - Body ground Tuner input signal The electrical key is in the action area. Pulse generation ASEL (E58-37) - Body ground V - Body ground Cabin / luggage receiver select signal Engine switch off, luggage compartment door closed and the electrical key is in the luggage action area 4.6 to 6.0 V ASEL (E58-37) - Body ground V - Body ground Cabin / luggage receiver select signal Engine switch off, luggage compartment door open Below 1 V VC5 (E58-30) - Body ground R - Body ground Transponder key amplifier power supply Electrical key is not in the cabin. Below 1 V VC5 (E58-30) - Body ground R - Body ground Transponder key amplifier power supply Have the electrical key outside the cabin and open the driver's door. 4.5 to 5.5 V TXCT (E58-8) - Body ground GR - Body ground Transponder key amplifier output signal Electrical key is not in the cabin. Below 1 V TXCT (E58-8) - Body ground GR - Body ground Transponder key amplifier output signal Have the electrical key outside the cabin and open the driver's door. Pulse generation (see waveform 1) CODE (E58-9) - Body ground W - Body ground Transponder key amplifier communication signal Electrical key is not in the cabin. Below 1 V Pulse generation (see waveform 2) CODE (E58-9) - Body ground W - Body ground Transponder key amplifier communication signal Have the electrical key outside the cabin and open the driver's door. Hold the electrical key close to the engine switch with the brake pedal depressed. BZR (E58-21) - Body ground O - Body ground Wireless door lock buzzer signal Wireless door lock buzzer OFF Below 1 V BZR (E58-21) - Body ground O - Body ground Wireless door lock buzzer signal Wireless door lock buzzer ON Pulse generation If the result is not as specified, the ECU may have a malfunction. (e) Inspect using an oscilloscope. Waveform 1 (Reference): Terminal GND B112486E01 TXCT - Body ground Tool Setting 2 V/DIV, 10 ms./DIV Condition Have the electrical key outside the cabin and open the driver's door. DL DL–156 DOOR LOCK – SMART KEY SYSTEM (f) GND B112487E01 DL Inspect using an oscilloscope. Waveform 2 (Reference): Terminal CODE - Body ground Tool Setting 2 V/DIV, 20 ms./DIV Condition Have the electrical key outside the cabin and open the driver's door. Hold the electrical key close to the engine switch with the brake pedal depressed. DL–157 DOOR LOCK – SMART KEY SYSTEM 2. MAIN BODY ECU (INSTRUMENT PANEL JUNCTION BLOCK) (a) Measure the voltage and resistance according to the value(s) in the table below. Front Side: IK IM IL IF IC IJ IE ID IN IR IB Back Side: IP IA E7 E6 IO E8 E9 DL IG II IH B112605E02 DL–158 Symbols (Terminal No.) DOOR LOCK – SMART KEY SYSTEM Wiring Color Terminal Description Condition Specified Condition CANN (E8-15) - Body ground W - Body ground CAN Line Always 10 kΩ or higher CANP (E8-16) - Body ground L - Body ground CAN Line Always 10 kΩ or higher STP (IL-7) - Body ground L - Body ground Stop light switch signal Brake pedal depressed 10 to 14 V STP (IL-7) - Body ground L - Body ground Stop light switch signal Brake pedal depressed Below 1 V If the result is not as specified, the junction block may have a malfunction. DL DL–159 DOOR LOCK – SMART KEY SYSTEM DIAGNOSIS SYSTEM 1. DESCRIPTION (a) Smart key system data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the intelligent tester to check for malfunctions and perform repairs. 2. CHECK DLC3 The ECU uses ISO 15765-4 for communication. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. CG SG CANH SIL BAT CANL H100769E16 Symbols (Terminal No.) Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 11 to 14 V CANH (6) - CANL (14) CAN bus line Engine switch OFF* 54 to 69 Ω CANH (6) - Battery positive (+) HIGH-level CAN bus line Engine switch OFF* 6 kΩ or higher CANH (6) - CG (4) HIGH-level CAN bus line Engine switch OFF* 200 Ω or higher CANL (14) - Battery positive (+) LOW-level CAN bus line Engine switch OFF* 6 kΩ or higher CANL (14) - CG (4) LOW-level CAN bus line Engine switch OFF* 200 Ω or higher DLC3 *: Before measuring the resistance, leave the vehicle for at least 1 minute and do not operate the engine switch, any switches or doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of the intelligent tester (with CAN VIM) to the DLC3, turn the engine switch on (IG) and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. • If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. Intelligent Tester C131977E01 DL DL–160 DOOR LOCK – SMART KEY SYSTEM DTC CHECK / CLEAR 1. DLC3 Intelligent Tester C131977E01 DL CHECK DTC (a) Connect the intelligent tester to the DLC3. (b) Turn the engine switch on (IG). (c) Enter the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTC by following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. 2. CLEAR DTC (a) Connect the intelligent tester to the DLC3. (b) Turn the engine switch on (IG). (c) Enter the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CLEAR CODES. (d) Erase the DTC by following the directions on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. DL–161 DOOR LOCK – SMART KEY SYSTEM DATA LIST / ACTIVE TEST 1. READ DATA LIST HINT: Using the intelligent tester's DATA LIST allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the DATA LIST relay in troubleshooting is one way to save time. (a) Connect the intelligent tester to the DLC3. (b) Turn the engine switch on (IG). When the intelligent tester cannot be turned on due to a malfunction or other problem, refer to "precautions when using the intelligent tester" (See page DL-118). (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST. (d) Read the DATA LIST according to the display on the tester. SMART ACCESS (Certification ECU): Item Measurement Item / Range (Display) Normal Condition Diagnostic Note D TOUCH SENSOR Driver side door touch sensor / ON or OFF ON: Sensor is touched OFF: Sensor is not touched - P TOUCH SENSOR Front passenger side door touch sensor / ON or OFF ON: Sensor is touched OFF: Sensor is not touched - D TRIGGER SW Driver side door lock switch / ON or OFF ON: Switch is touched OFF: Switch is not touched - P TRIGGER SW Front passenger side door lock switch / ON or OFF ON: Switch is touched OFF: Switch is not touched - TR/B-DOOR UNLK Luggage compartment door unlock switch / ON or OFF ON: Switch is pushed OFF: Switch is not pushed - IG SW Engine switch / ON or OFF ON: Engine switch is on (IG) OFF: Engine switch is off - ACC SW Engine switch / ON or OFF ON: Engine switch is on (ACC) OFF: Engine switch is off - P/S 10-MIN Power save counter - 10 minutes / Min: 0; Max: 255 Power save counter after door LOCK/UNLOCK-10 minutes - P/S 5-DAY Power save counter - 5 days / Min: 0; Max: 255 Power save counter after door LOCK/UNLOCK-5 days - P/S 14-DAY Power save counter - 14 days / Min: 0; Max: 255 Power save counter after door LOCK/UNLOCK-14 days - UNMATCH V-ID Unmatched vehicle-ID / YES or NO YES: Key ID matches vehicle NO: Key ID does not match vehicle - NO RESPONSE No response / YES or NO YES: Response from key NO: No response from key - UNMATCH FORMAT Unmatched response code and format / YES or NO YES: Key ID code matches NO: Key ID code does not match - LOW BATTERY Key low battery / YES or NO YES: Key battery voltage drops NO: Key battery voltage is normal - WRONG CODE ID code difference / YES or NO YES: Key ID code matches NO: Key ID code does not match - WRONG C CODE Challenge code difference (Response) / YES or NO YES: Key ID code matches NO: Key ID code does not match - WRONG ID CODE ID code difference / YES or NO YES: Key ID code matches NO: Key ID code does not match - DL DL–162 DOOR LOCK – SMART KEY SYSTEM Item Measurement Item / Range (Display) Normal Condition Diagnostic Note WRONG ROL CODE Rolling code difference / YES or NO YES: Key rolling code matches NO: Key rolling code does not match - DOOR UNLOCK MOD Door unlock mode / ALL, D_DOOR Mode status is displayed - FUNCTION CANCEL Entry door lock function cancel / ON or OFF Mode status is displayed - MASTER KEY Master key / MATCH or NO MATCH MATCH: Key code is sent NO MATCH: Unmatched key code - SUB KEY Sub key / MATCH or NO MATCH MATCH: Key code is sent NO MATCH: Unmatched key code - BCC Transponder chip data / OK or NG OK: Correct data sensing NG: Incorrect data sensing - STATUS Transponder chip data / OK or NG OK: Data OK NG: Data error - ENCRYPT CODE Transponder chip data / OK or NG OK: Data OK NG: Data error - SERIAL NUMBER Transponder chip data / OK or NG OK: Data OK NG: Data error - FRAME Transponder chip data / OK or NG OK: Data OK NG: Data error - RESPONSE Transponder chip data / OK or NG OK: With no response NG: Those with a response - #CODE Diagnostic trouble code / Min.: 0, Max.: 255 - - IGNITION AREA Ignition available area / FRONT or ALL Customization status is displayed - PARK WAIT TIME Parking wait time / 0.5s, 1.5s, 2.5s, 5s Customization status is displayed - TRUNK OPEN MODE Luggage compartment door open mode with vehicle locked / ON or OFF Customization status is displayed - KEY LO-BATT WRN Key low battery warning / ON or OFF Customization status is displayed - MAIN BODY: DL Measurement Item / Range (Display) Normal Condition Diagnostic Note LUGG COURTESY SW Luggage compartment door courtesy light switch signal / ON or OFF ON: Luggage compartment door open OFF: Luggage compartment door closed - D DOR CTY SW Driver side door courtesy light switch signal / ON or OFF ON: Driver side door open OFF: Driver side door closed - P DOR CTY SW Front passenger side door courtesy light switch signal / ON or OFF ON: Front passenger side door open OFF: Front passenger side door closed - RL DOR CTY SW Rear door courtesy light switch LH signal / ON or OFF ON: Rear door open OFF: Rear door closed - RR DOR CTY SW Rear door courtesy light switch RH signal / ON or OFF ON: Rear door open OFF: Rear door closed - TRUNK KEY UNLOCK Luggage compartment door lock/ unlock switch / ON or OFF ON: Luggage compartment door lock switch is pushed OFF: Luggage compartment door lock switch is not pushed - Item DL–163 DOOR LOCK – SMART KEY SYSTEM Measurement Item / Range (Display) Item IG SW Normal Condition Diagnostic Note ON: Engine switch is on (IG) OFF: Engine switch is off Engine switch / ON or OFF - METER (Combination Meter): Measurement Item / Range (Display) Item Normal Condition Diagnostic Note KEY REMND VOLUM Key reminder buzzer volume condition / LARGE, MEDIUM, SMALL LARGE: Volume is large MEDIUM: Volume is medium SMALL: Volume is small - KEY REMND SOUND Key reminder buzzer sound condition / FAST, NORMAL, SLOW FAST: Buzz pattern is fast NORMAL: Buzz pattern is normal SLOW: Buzz pattern is slow - 2. PERFORM ACTIVE TEST HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Connect the intelligent tester to the DLC3. (b) Turn the engine switch on (IG). (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST. (d) Perform the ACTIVE TEST according to the display on the tester. SMART ACCESS (Certification ECU): Item OVERHEAD TUNER Test Details Entry door control receiver ON / OFF Diagnostic Note - IN LUG TUNER Luggage receiver ON / OFF - D TRANSMITTER Driver side electrical key oscillator ON / OFF - P TRANSMITTER Front passenger side electrical key oscillator ON / OFF - FR TRANSMITTER Indoor electrical key oscillator (console) ON / OFF - RR TRANSMITTER Indoor electrical key oscillator (rear seat) ON / OFF - IN_BDR TRNSMTTR Luggage compartment door inner oscillator ON / OFF - BDOOR TRNSMTTR Luggage compartment door outer oscillator ON / OFF - D SELECT SIG Driver side select ON / OFF - P SELECT SIG Front passenger side select ON / OFF - WIRELESS BUZZER Wireless buzzer ON / OFF - MAIN BODY: Item TRNK/BDOR OPEN Test Details Diagnostic Note Luggage compartment open switch signal ON / OFF - DL DL–164 DOOR LOCK – SMART KEY SYSTEM DIAGNOSTIC TROUBLE CODE CHART HINT: If a trouble code is indicated during the DTC check, check the circuit listed for that code in the table below. Then proceed to the appropriate page. Power door lock control system: DL DTC No. Detection Item B1242 Wireless Door Lock Tuner Circuit Malfunction Trouble Area 1. Electrical key antenna 2. Door control receiver 3. Wire harness 4. Certification ECU See page DL-164 DOOR LOCK – SMART KEY SYSTEM DL–165 ON-VEHICLE INSPECTION 1. 0.7 to 1.0 m (2.3 to 3.3 ft) Electrical Key B137955E01 Detection Area (Inner Side) Lock Switch Glove E107177E03 SMART KEY SYSTEM OPERATION INSPECTION HINT: Refer to PROBLEM SYMPTOMS TABLE if the results of the following checks are not normal (See page DL-147). (a) Check the entry unlock function. (1) Use the wireless lock operation to lock the doors. With the electrical key in your possession, touch a door's outside handle (touch sensor) and check that the door unlocks. (b) Check the entry unlock operation's detection area. (1) Step 1: Hold the electrical key at the same height as the door's outside handle (approximately 0.8 m (2.6 ft)). Pay attention to the direction of the electrical key in the illustration. (2) Step 2: When the electrical key is brought within 0.7 to 1.0 m (2.3 to 3.3 ft) of the vehicle, check that the system enters unlock standby mode. HINT: Unlock standby mode is signified by the electrical key's red LED illuminating. (3) Step 3: After the system enters unlock standby mode, touch the outside handle's sensor within 3 seconds. Check that the door unlocks. NOTICE: The electrical key cannot communicate with the system within a 0.2 m (0.6 ft) radius of each outside handle. (4) Step 4: Repeat steps 2 and 3 for the remaining doors. (5) Step 5: Inspect the door electrical key oscillator's response sensitivity. Wear protective gloves, set the system to unlock standby mode, and check that touching the inner side of the outside handle (the highlighted area in the illustration) with your finger causes the door to unlock. NOTICE: When touching the highlighted area, tapping too quickly or having extended contact may not trigger the sensor. In such a case, the door will not unlock. (6) Step 6: Repeat step 5 for the remaining doors. DL DL–166 DOOR LOCK – SMART KEY SYSTEM Approx. 0.3 m (0.9 ft) Key B137956E01 Center of Vehicle 0.7 to 1.0 m (2.3 to 3.3 ft) B137957E01 DL (c) Check the entry lock function. (1) Step 1: Close all of the vehicle's doors. With the electrical key in your possession outside the vehicle, check that pressing the lock switch locks the doors. (2) Step 2: Inspect the entry lock operation's detection area and the indoor electrical key antenna for wave leaks. Hold the electrical key at a height of 1 m (3.3 ft) (0.1 m (0.3 ft) above the lower edge of the window frame). Pay attention to the direction and position of the electrical key in the illustration. When the electrical key is approximately 0.3 m (0.9 ft) from the vehicle and the lock switch is pressed, check that the all doors lock and the warning buzzer (for when the electrical key is forgotten) does not sound. If the warning buzzer sounds, the indoor electrical key antenna may have a wave leak. HINT: Do not press the lock switch with the same hand that is holding the electrical key because the electrical key cannot communicate with the system within a 0.2 m (0.6 ft) radius of the outside handle. The doors will not lock. (3) Step 3: Repeat steps 1 and 2 for the remaining doors. (d) Check the entry luggage compartment door open function. (1) Close the luggage compartment door. With the electrical key in your possession, check that pressing the power luggage door open switch opens the luggage compartment door. (2) Inspect the entry luggage compartment door open operation's detection area. Hold the electrical key at the same height as the power luggage door open switch (approximately 0.8 m (2.6 ft)) and align the key with the center of the rear of the vehicle. Pay attention to the direction of the electrical key shown in the illustration. When the electrical key is brought within 0.7 to 1.0 m (2.3 to 3.3 ft) of the vehicle, check that pressing the power luggage door open switch opens the luggage compartment door. (e) Check the entry ignition function. (1) When the engine is off: With the electrical key in your possession and the brake pedal depressed, check that pressing the engine switch releases the steering wheel lock and starts the engine. HINT: The engine can be started only when the engine switch indicator illuminates in green. DOOR LOCK – SMART KEY SYSTEM (2) When the engine is running: With the electrical key in your possession, check that pressing the engine switch stops the engine. HINT: The shift position must be P to stop the engine. (3) Inspect the entry ignition operation's detection area. Pay attention to the direction of the electrical key in the illustration. When the electrical key is in either of the 2 inspection points in the illustration, check that the engine can start. NOTICE: The engine cannot be started when the electrical key is on the instrument panel, rear package tray, or in the glove box. Inspection Point B137958E01 Center of Vehicle Inspection Point DL–167 (f) Check the electrical key lock-in prevention function. (1) Place the electrical key in the luggage compartment with all doors locked. Check that: 1) closing the luggage compartment door triggers the electrical key's wireless buzzer (which lasts approximately 2 seconds), and 2) pressing the power luggage door open switch opens the luggage compartment door. Luggage Compartment B137959E01 Luggage End 0.1 m (0.3 ft) or more B137960E01 (2) Inspect the electrical key lock-in prevention's detection area. Pay attention to the direction of the electrical key shown in the illustration. When the electrical key is in either of the 2 inspection points in the illustration, check that: 1) closing the luggage compartment door sounds the electrical key's wireless buzzer, and 2) pressing the power luggage door open switch opens the luggage compartment door. NOTICE: If the electrical key is inside a metal storage item, such as a metal briefcase or metal box, the electrical key will not be detected by the system. DL DL–168 DOOR LOCK – SMART KEY SYSTEM (3) Inspect the electrical key lock-in prevention's detection area and the entry door control receiver for wave leaks. Hold the electrical key at the same height as the lower edge of the luggage compartment door and align the key with the center of the rear of the vehicle. Pay attention to the direction and position of the electrical key shown in the illustration. When the electrical key is over 0.1 m (0.3 ft) from the vehicle's rear bumper, check that the electrical key's wireless buzzer does not sound. If the warning buzzer sounds, the entry door control receiver may have a wave leak. (g) Check the electrical key cancel function. (1) While the engine switch is on (IG), check that the power luggage door open switch, entry ignition, electrical key lock-in prevention and warning are the only switch in the smart key system that can be operated. (2) While the electrical key cancel function (smart key system cancel function) is ON, check that all functions in the smart key system cannot be operated. (h) Check the answer-back function (hazard warning light flashing and buzzer sounding). Entry Operation Hazard Warning Light Entry Door Lock Flashes once Sounds once Entry Door Unlock Flashes twice Sounds twice Entry Luggage Compartment Door Open Does not flash Does not sound (i) (j) DL Buzzer Check that the electrical key reminder warning buzzer sounds. (1) Carry the electrical key in the vehicle and close the driver side door. Then turn the engine switch off or on (ACC). The steering lock is unlocked. (2) Open the driver side door and check that the buzzer sounds intermittently. Check that the electrical key reminder warning buzzer stops. (1) When the buzzer is sounding, check that the buzzer stops sounding if either of the following is performed: • Close the driver side door (front door courtesy light switch is off). • Turn the engine switch on (IG, ACC) and lock the steering lock. DL–169 DOOR LOCK – SMART KEY SYSTEM DTC B1242 Wireless Door Lock Tuner Circuit Malfunction DESCRIPTION • The electrical key antenna and the door control receiver are used as antennas for the entry and wireless door lock functions of the smart key system. • The certification ECU decodes the requested smart key system operation by identifying a key code based on electric waves received via the electrical key antenna and the door control receiver. The ECU then sends a command, according to the requested operation, to each ECU. (e.g. If door lock operation is requested, the ECU sends a door lock command to the main body ECU.) DTC No. DTC Detection Condition Trouble Area • • • • If the certification ECU detects that terminal RDA or RSSI is short-circuited, this DTC is stored. B1242 Electrical key antenna Door control receiver Wire harness Certification ECU WIRING DIAGRAM O18 Door Control Receiver O19 Electrical Key Antenna ASEL RSSI ANT 1 7 E58 Certification ECU 4 37 5 39 3 38 2 29 ASEL RSSI ANT DATA +5 RDA DL RC0 B112458E05 DL–170 DOOR LOCK – SMART KEY SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (CERTIFICATION ECU - DOOR CONTROL RECEIVER) (a) Disconnect the E58 ECU connector. (b) Disconnect the O18 receiver connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Certification ECU: E58 RSSI RDA RC0 ASEL Tester Connection (Symbols) Condition Specified Condition E58-37 (ASEL) - O18-4 (ASEL) Always Below 1 Ω E58-39 (RSSI) - O18-5 (RSSI) Always Below 1 Ω E58-38 (RDA) - O18-3 (DATA) Always Below 1 Ω E58-29 (RC0) - O18-2 (+5) Always Below 1 Ω E58-37 (ASEL) - Body ground Always 10 kΩ or higher E58-39 (RSSI) - Body ground Always 10 kΩ or higher E58-38 (RDA) - Body ground Always 10 kΩ or higher E58-29 (RC0) - Body ground Always 10 kΩ or higher NG Door Control Receiver: O18 DATA +5 ASEL RSSI OK DL B137962E01 REPAIR OR REPLACE HARNESS OR CONNECTOR DL–171 DOOR LOCK – SMART KEY SYSTEM 2 CHECK HARNESS AND CONNECTOR (DOOR CONTROL RECEIVER - ELECTRICAL KEY ANTENNA) (a) Disconnect the O19 antenna connector. (b) Measure the resistance according to the value(s) in the table below. HINT: Perform the measurement with the O18 receiver connector disconnected. Standard resistance Door Control Receiver: O18 Tester Connection (Symbols) Condition O18-7 (ANT) - O19-1 (ANT) Always Below 1 Ω O18-7 (ANT) - Body ground Always 10 kΩ or higher NG ANT Specified Condition REPAIR OR REPLACE HARNESS OR CONNECTOR Electrical Key Antenna: O19 ANT B112462E03 OK 3 CHECK AND REPLACE DOOR CONTROL RECEIVER (RECONFIRM DTC) (a) Replace the receiver. (b) Clear the DTCs and repeat the procedure to recheck for DTCs (See page DL-156). OK: DTC is not output. OK NG END (RECEIVER IS DEFECTIVE) DL DL–172 4 DOOR LOCK – SMART KEY SYSTEM CHECK AND REPLACE ELECTRICAL KEY ANTENNA (RECONFIRM DTC) (a) Replace the antenna. (b) Clear the DTCs and repeat the procedure to recheck for DTCs (See page DL-156). OK: DTC is not output. OK END (ANTENNA IS DEFECTIVE) NG 5 INSPECT CERTIFICATION ECU (a) (b) (c) (d) Certification ECU: E58 RSSI RDA Reconnect the E58 ECU connector. Reconnect the O19 antenna connector. Reconnect the O18 receiver connector. Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection (Symbols) E58-37 (ASEL) - Body ground RC0 ASEL B137963E01 E58-39 (RSSI) - Body ground E58-38 (RDA) -Body ground DL E58-29 (RC0) - Body ground NG Condition Specified Condition Engine switch OFF, luggage compartment door OPEN Below 1 V Engine switch OFF, luggage compartment door CLOSED 4.5 to 5.5 V Engine switch OFF, all doors closed, the electrical key is not in the action area 10 to 14 V Engine switch OFF, all doors closed, the electrical key in the action area Below 1 V Engine switch OFF, all doors closed and electrical key switch OFF 10 to 14 V (Pulse generation) Engine switch OFF, all doors closed and electrical key switch ON Pulse generation Engine switch OFF, all doors closed and electrical key switch OFF Below 1 V Engine switch OFF, all doors closed and electrical key switch ON 4.5 to 5.5 V REPLACE CERTIFICATION ECU OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE DOOR LOCK – SMART KEY SYSTEM DL–173 Door Oscillator Circuit DESCRIPTION Door oscillators are built into each door. Each of them forms its own action area around its door and detects the presence of the electrical key. DL DL–174 DOOR LOCK – SMART KEY SYSTEM WIRING DIAGRAM E58 Certification ECU X2 Electrical Key Oscillator (Front Door LH) CLG 1 33 5 34 CLG1 +B CLGB 7 10 CG1B GND W2 Electrical Key Oscillator (Front Door RH) CLG 1 +B CLGB 7 10 35 5 36 CLG2 CG2B GND Engine Room R/B DOME 1 2 1 1 DL From Battery B112459E04 DL–175 DOOR LOCK – SMART KEY SYSTEM INSPECTION PROCEDURE 1 INSPECT ELECTRICAL KEY OSCILLATOR (a) Disconnect the oscillator connectors. (b) Measure the voltage according to the value(s) in the table below. Standard voltage: Front LH side Door Oscillator: X2 W2 Tester Connection (Symbols) Condition Specified Condition X2-1 (+B) - X2-7 (GND) Always 10 to 14 V Tester Connection (Symbols) Condition Specified Condition W2-1 (+B) - W2-7 (GND) Always 10 to 14 V Front RH side +B GND B112463E04 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK DL DL–176 2 DOOR LOCK – SMART KEY SYSTEM CHECK HARNESS AND CONNECTOR (ELECTRICAL KEY OSCILLATOR CERTIFICATION ECU) (a) Disconnect the E58 ECU connector. Standard resistance Certification ECU: E58 CG2B CLG2 CG1B CLG1 Tester Connection (Symbols) Condition Specified Condition E58-33 (CLG1) - X2-10 (CLG) Always Below 1 Ω E58-34 (CG1B) - X2-5 (CLGB) Always Below 1 Ω E58-35 (CLG2) - W2-10 (CLG) Always Below 1 Ω E58-36 (CG2B) - W2-5 (CLGB) Always Below 1 Ω E58-33 (CLG1) - Body ground Always 10 kΩ or higher E58-34 (CG1B) - Body ground Always 10 kΩ or higher E58-35 (CLG2) - Body ground Always 10 kΩ or higher E58-36 (CG2B) - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR Door Oscillator: X2 W2 CLGB CLG B137964E01 OK DL 3 CHECK AND REPLACE ELECTRICAL KEY OSCILLATOR (CHECK OPERATION OF OSCILLATOR) (a) Replace the door oscillator. (b) Check that the entry LOCK/UNLOCK function operates normally. OK: Entry LOCK/UNLOCK function operates normally. OK NG END (ELECTRICAL KEY OSCILLATOR IS DEFECTIVE) DL–177 DOOR LOCK – SMART KEY SYSTEM 4 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (CERTIFICATION ECU OUTPUT SIGNAL) (a) (b) (c) (d) Reconnect the ECU and the oscillator connectors. Connect the intelligent tester to the DLC3. Turn the engine switch on (IG). Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST. (e) Following the display on the tester, select the "ACTIVE TEST". SMART ACCESS (Certification ECU): Certification ECU: E58 CG2B CLG2 CG1B CLG1 (f) Item Vehicle Condition/Test Details D TRANSMITTER Door Oscillator ON/OFF P TRANSMITTER Door Oscillator ON/OFF Measure the frequency according to the value(s) in the table below. Standard B137963E02 Tester Connection (Symbols) Condition Specified Condition E58-33 (CLG1) - E58-34 (CG1B) During ACTIVE TEST Frequency is generated (higher than 0 Hz) E58-35 (CLG2) - E58-36 (CG2B) During ACTIVE TEST Frequency is generated (higher than 0 Hz) NG REPLACE CERTIFICATION ECU OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE DL DL–178 DOOR LOCK – SMART KEY SYSTEM Entry Lock Switch Circuit DESCRIPTION The entry lock switches (trigger switch) are built into the outside handles of the LH/RH door. The certification ECU detects the conditions of the each lock switch. WIRING DIAGRAM X2 Electrical Key Oscillator (Front Door LH) X1 Entry Lock Switch (Front Door LH) TRG+ TRG- 9 W2 Electrical Key Oscillator (Front Door RH) E58 Certification ECU 1 3 3 TSW1 TRG- W1 Entry Lock Switch (Front Door RH) TRG+ 3 4 TSW2 DL TRG- 9 1 TRG- B112471E04 DL–179 DOOR LOCK – SMART KEY SYSTEM INSPECTION PROCEDURE 1 INSPECT ENTRY LOCK SWITCH (a) Remove the outside handle. (b) Disconnect the connectors. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Lock Switch: Tester Connection (Symbols) X1 W1 X1-1 (TRG-) - X1-3 (TRG+) W1-1 (TRG-) - W1-3 (TRG+) NG Condition Specified Condition Lock switch not pushed 10 kΩ or higher Lock switch pushed Below 1 Ω Lock switch not pushed 10 kΩ or higher Lock switch pushed Below 1 Ω REPLACE OUTSIDE HANDLE ASSEMBLY ON OFF B112465E07 OK DL DL–180 2 DOOR LOCK – SMART KEY SYSTEM CHECK HARNESS AND CONNECTOR (CERTIFICATION ECU - ENTRY LOCK SWITCH) (a) Disconnect the E58 ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Certification ECU: E58 Lock Switch Wire Harness: X1 W1 TRG+ B137967E01 DL Condition Specified Condition E58-3 (TSW1) - X1-3 (TRG+) Always Below 1 Ω E58-4 (TSW2) - W1-3 (TRG+) Always Below 1 Ω E58-3 (TSW1) - Body ground Always 10 kΩ or higher E58-4 (TSW2) - Body ground Always 10 kΩ or higher NG TSW1 TSW2 OK Tester Connection (Symbols) REPAIR OR REPLACE HARNESS OR CONNECTOR DL–181 DOOR LOCK – SMART KEY SYSTEM 3 CHECK HARNESS AND CONNECTOR (ELECTRICAL KEY OSCILLATOR - ENTRY LOCK SWITCH) (a) Disconnect the door oscillator connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Lock Switch Wire Harness: X1 W1 Tester Connection (Symbols) Condition Specified Condition X2-9 (TRG-) - X1-1 (TRG-) Always Below 1 Ω W2-9 (TRG-) - W1-1 (TRG-) Always Below 1 Ω X2-9 (TRG-) - Body ground Always 10 kΩ or higher W2-9 (TRG-) - Body ground Always 10 kΩ or higher TRG- NG Door Oscillator: REPAIR OR REPLACE HARNESS OR CONNECTOR X2 W2 TRGB112467E08 OK 4 CHECK AND REPLACE ELECTRICAL KEY OSCILLATOR (a) Replace the electrical key oscillator. (b) Check that the entry LOCK/UNLOCK function operates normally. OK: Entry LOCK/UNLOCK function operates normally. NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE OK END (ELECTRICAL KEY OSCILLATOR IS DEFECTIVE) DL DL–182 DOOR LOCK – SMART KEY SYSTEM Touch Sensor Circuit DESCRIPTION This circuit receives a signal indicating whether a touch sensor signal is detected. WIRING DIAGRAM E58 Certification ECU X2 Touch Sensor (Front Door Outside Handle LH) SEL SENS 5 4 22 6 SEL1 SEN1 W2 Touch Sensor (Front Door Outside Handle RH) SEL SENS 6 4 23 6 SEL2 SEN2 DL B112470E04 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Turn the engine switch on (IG). DL–183 DOOR LOCK – SMART KEY SYSTEM (c) Following the display on the tester, select "DATA LIST". SMART ACCESS (Certification ECU): Item Measurement Item/Range (Display) Normal Condition Diagnostic Note D TOUCH SENSOR Status of touch sensor front LH/ ON or OFF ON: Touch sensor is touched OFF: Touch sensor is not touched - P TOUCH SENSOR Status of touch sensor front RH/ ON or OFF ON: Touch sensor is touched OFF: Touch sensor is not touched - OK: "ON" (screen is touched) or "OFF" (screen is not touched) appears on the tester screen. OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG 2 CHECK HARNESS AND CONNECTOR (CERTIFICATION ECU - ELECTRICAL KEY OSCILLATOR) (a) Disconnect the E58 ECU connector. (b) Disconnect the oscillator connectors. Standard resistance Certification ECU: E58 SEL2 SEN2 SEL1 SEN1 Tester Connection (Symbols) Condition Specified Condition E58-5 (SEL1) - X2-4 (SEL) Always Below 1 Ω E58-22 (SEN1) - X2-6 (SENS) Always Below 1 Ω E58-6 (SEL2) - W2-4 (SEL) Always Below 1 Ω E58-23 (SEN2) - W2-6 (SENS) Always Below 1 Ω E58-5 (SEL1) - Body ground Always 10 kΩ or higher E58-22 (SEN1) - Body ground Always 10 kΩ or higher E58-6 (SEL2) - Body ground Always 10 kΩ or higher E58-23 (SEN2) - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR Door Oscillator: DL X2 W2 SEL SENS B137964E02 DL–184 DOOR LOCK – SMART KEY SYSTEM OK 3 CHECK AND REPLACE ELECTRICAL KEY OSCILLATOR (CHECK OPERATION OF OSCILLATOR) (a) Replace the door oscillator. (b) Check that the entry UNLOCK function operates normally. OK: Entry UNLOCK function operates normally. NG END (ELECTRICAL KEY OSCILLATOR IS DEFECTIVE) OK 4 INSPECT CERTIFICATION ECU (a) (b) (c) (d) Certification ECU: SEL2 SEL1 E58 SEN2 SEN1 Reconnect the ECU and the oscillator connectors. Connect the intelligent tester to the DLC3. Turn the engine switch on (IG). Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection (Symbols) Condition Specified Condition E58-5 (SEL1) - Body ground Move the key more than 5 m (16.4 ft) away from the front door LH 10 to 14 V E58-5 (SEL1) - Body ground Bring it to the outside handle Below 1 V E58-6 (SEL2) - Body ground Move the key more than 5 m (16.4 ft) away from the front door RH 10 to 14 V E58-6 (SEL2) - Body ground Bring it to the outside handle Below 1 V E58-22 (SEN1) - Body ground Front door LH outside handle is not held (Bring the electrical key to the outside handle) 10 to 14 V E58-22 (SEN1) - Body ground Front door LH outside handle is held Below 1 V E58-23 (SEN2) - Body ground Front door RH outside handle is not held (Bring the electrical key to the outside handle) 10 to 14 V E58-23 (SEN2) - Body ground Front door RH outside handle is held Below 1 V B137963E03 DL NG REPLACE CERTIFICATION ECU OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE DL–185 DOOR LOCK – SMART KEY SYSTEM Antenna Circuit DESCRIPTION Terminals ANT1 and ANT2 of the antenna (door outside handle) detect if the electrical key is within the action area around the door outside handle. WIRING DIAGRAM X1 (*1) W1 (*2) Touch Sensor and Antenna (Outside Handle) ANT2 SGT ANT1 X2 (*1) W2 (*2) Door Oscillator 2 8 6 2 5 3 ANT2 SGT ANT1 *1: Driver Side *2: Passenger Side B112492E04 DL DL–186 DOOR LOCK – SMART KEY SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (ELECTRICAL KEY OSCILLATOR - ANTENNA) (a) Remove the outside handle. (b) Disconnect the antenna and door oscillator connectors. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Antenna Wire Harness: X1 Tester Connection (Symbols) W1 ANT2 ANT1 SGT2 Door Oscillator: X2 W2 Condition Specified Condition X1-2 (ANT2) - X2-8 (ANT2) (*1) Always Below 1 Ω X1-6 (SGT) - X2-2 (SGT) (*1) Always Below 1 Ω X1-5 (ANT1) - X2-3 (ANT1) (*1) Always Below 1 Ω X1-2 (ANT2) - Body ground (*1) Always 10 kΩ or higher X1-6 (SGT) - Body ground (*1) Always 10 kΩ or higher X1-5 (ANT1) - Body ground (*1) Always 10 kΩ or higher W1-2 (ANT2) - W2-8 (ANT2) (*2) Always Below 1 Ω W1-6 (SGT) - W2-2 (SGT) (*2) Always Below 1 Ω W1-5 (ANT1) - W2-3 (ANT1) (*2) Always Below 1 Ω W1-2 (ANT2) - Body ground (*2) Always 10 kΩ or higher W1-6 (SGT) - Body ground (*2) Always 10 kΩ or higher W1-5 (ANT1) - Body ground (*2) Always 10 kΩ or higher *1: Driver side *2: Passenger side SGT ANT1 NG REPAIR OR REPLACE HARNESS OR CONNECTOR ANT2 B112467E07 OK 2 CHECK AND REPLACE DOOR OUTSIDE HANDLE (a) Replace the door outside handle. (b) Check that the entry LOCK/UNLOCK function operates normally. OK: Entry LOCK/UNLOCK function operates normally. DL NG OK END (DOOR OUTSIDE HANDLE IS DEFECTIVE) PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE DL–187 DOOR LOCK – SMART KEY SYSTEM Luggage Oscillator Circuit DESCRIPTION The certification ECU activates the inner and outer luggage compartment oscillators. The power is supplied from the certification ECU to both the inner and outer luggage compartment oscillators. The inner and outer luggage compartment oscillator circuits have the same wiring. If the entry luggage compartment function has a problem, check both the inner and outer luggage compartment oscillator circuits. WIRING DIAGRAM E58 Certification ECU N25 Electrical Key Oscillator (Inside Luggage Room) CLGB 16 3 CLG6 15 1 CG7B CLG7 S14 Electrical Key Oscillator (Outside Luggage Room) CLGB 32 2 CG8B DL CLG5 31 1 CLG8 B147262E01 DL–188 DOOR LOCK – SMART KEY SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (CERTIFICATION ECU - ELECTRICAL KEY OSCILLATOR) (a) Disconnect the E58 ECU connector. (b) Disconnect the oscillator connectors. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Certification ECU: E58 CG7B CLG7 CLG8 CG8B Electrical Key Oscillator (Inside Luggage Compartment): N25 CLGB CLG6 (Outside Luggage Compartment): DL S14 CLGB B137965E01 OK Condition Specified Condition E58-16 (CG7B) - N25-3 (CLGB) Always Below 1 Ω E58-15 (CLG7) - N25-1 (CLG6) Always Below 1 Ω E58-32 (CG8B) - S14-2 (CLGB) Always Below 1 Ω E58-31 (CLG8) - S14-1 (CLG5) Always Below 1 Ω E58-16 (CG7B) - Body ground Always 10 kΩ or higher E58-15 (CLG7) - Body ground Always 10 kΩ or higher E58-32 (CG8B) - Body ground Always 10 kΩ or higher E58-31 (CLG8) - Body ground Always 10 kΩ or higher NG Electrical Key Oscillator CLG5 Tester Connection (Symbols) REPAIR OR REPLACE HARNESS OR CONNECTOR DL–189 DOOR LOCK – SMART KEY SYSTEM 2 CHECK AND REPLACE ELECTRICAL KEY OSCILLATOR (a) Replace the electrical key oscillator. (b) Check that the luggage compartment door entry LOCK/ UNLOCK function operates normally. OK: Luggage compartment door entry LOCK/UNLOCK function operates normally. OK END (ELECTRICAL KEY OSCILLATOR IS DEFECTIVE) NG 3 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (a) (b) (c) (d) Certification ECU: Reconnect the oscillator and the ECU connectors. Connect the intelligent tester to the DLC3. Turn the engine switch on (IG). Following the display on the tester, select the "ACTIVE TEST". SMART ACCESS (Certification ECU): Item E58 CG7B CLG7 CG8B Vehicle Condition/Test Details IN-BDR TRNSMTTR Electrical key oscillator (Luggage compartment inner) ON/OFF BDOOR TRNSMTTR Electrical key oscillator (Luggage compartment outer) ON/OFF (e) Measure the frequency according to the value(s) in the table below. Standard CLG8 B137963E04 Tester Connection (Symbols) Condition Specified Condition E58-16 (CG7B) - E58-15 (CLG7) During ACTIVE TEST Frequency is generated (higher than 0 Hz) E58-32 (CG8B) - E58-31 (CLG8) During ACTIVE TEST Frequency is generated (higher than 0 Hz) NG REPLACE CERTIFICATION ECU OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE DL DL–190 DOOR LOCK – SMART KEY SYSTEM Room Oscillator Circuit DESCRIPTION The certification ECU activates the front and rear cabin oscillators. The power is supplied from the certification ECU to both the front and rear cabin oscillators. The front and rear cabin oscillator circuits have the same wiring. If the smart key system does not operate properly inside the vehicle, check both the front and rear cabin oscillator circuits. WIRING DIAGRAM E58 Certification ECU E56 Electrical Key Oscillator (Console) CLGB 12 3 CLG3 11 1 CG5B CLG5 N11 Electrical Key Oscillator (Rear Seat) CLGB 14 3 DL CLG4 13 1 CG6B CLG6 B112473E07 DL–191 DOOR LOCK – SMART KEY SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (CERTIFICATION ECU - ELECTRICAL KEY OSCILLATOR) (a) Disconnect the E58 ECU connector. (b) Disconnect the oscillator connectors. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Certification ECU: E58 CG6B CLG6 CLG5 CG5B Electrical Key Oscillator (Console): Tester Connection (Symbols) Condition Specified Condition E58-12 (CG5B) - E56-3 (CLGB) Always Below 1 Ω E58-11 (CLG5) - E56-1 (CLG3) Always Below 1 Ω E58-14 (CG6B) - N11-3 (CLGB) Always Below 1 Ω E58-13 (CLG6) - N11-1 (CLG4) Always Below 1 Ω E58-12 (CG5B) - Body ground Always 10 kΩ or higher E58-11 (CLG5) - Body ground Always 10 kΩ or higher E58-14 (CG6B) - Body ground Always 10 kΩ or higher E58-13 (CLG6) - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR E56 CLGB CLG3 Electrical Key Oscillator (Rear Seat): N11 DL CLGB CLG4 B137966E01 OK DL–192 2 DOOR LOCK – SMART KEY SYSTEM CHECK AND REPLACE ELECTRICAL KEY OSCILLATOR (a) Replace the electrical key oscillator. (b) Check that the entry LOCK/UNLOCK function operates normally. OK: Entry LOCK/UNLOCK function operates normally. OK END (ELECTRICAL KEY OSCILLATOR IS DEFECTIVE) NG 3 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (CERTIFICATION ECU OUTPUT SIGNAL) (a) (b) (c) (d) Certification ECU: Reconnect the oscillator and the ECU connectors. Connect the intelligent tester to the DLC3. Turn the engine switch on (IG). Following the display on the tester, select the "ACTIVE TEST". SMART ACCESS (Certification ECU): Item E58 CG6B CLG6 CG5B Vehicle Condition/Test Details Fr TRANSMITTER Electrical key oscillator (console) ON/OFF Rr TRANSMITTER Electrical key oscillator (rear seat) ON/OFF (e) Measure the frequency according to the value(s) in the table below. Standard CLG5 B137963E05 Tester Connection (Symbols) Condition Specified Condition E58-12 (CG5B) - E58-11 (CLG5) During ACTIVE TEST Frequency is generated (higher than 0 Hz) E58-14 (CG6B) - E58-13 (CLG6) During ACTIVE TEST Frequency is generated (higher than 0 Hz) NG REPLACE CERTIFICATION ECU OK DL PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE DL–193 DOOR LOCK – SMART KEY SYSTEM Luggage Compartment Door Open Switch Circuit DESCRIPTION If the certification ECU detects that the luggage compartment open switch is pressed when the driver is carrying the electrical key or when the electrical key is locked in the luggage compartment door, the certification ECU sends a luggage compartment door open motor drive request signal to the main body ECU. WIRING DIAGRAM E58 Certification ECU CAN S9 Luggage Compartment Open Switch 7 2 1 Main Body ECU CAN TSW5 DL B112474E03 DL–194 DOOR LOCK – SMART KEY SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (CERTIFICATION ECU - LUGGAGE COMPARTMENT OPEN SWITCH) (a) Disconnect the E58 ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Certification ECU: E58 Tester Connection (Symbols) E58-7 (TSW5) - Body ground OK TSW5 Condition Specified Condition Luggage compartment open switch not pushed 10 kΩ or higher Luggage compartment open switch pushed Below 1 Ω PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE B137968E01 NG 2 INSPECT LUGGAGE COMPARTMENT OPEN SWITCH (a) Disconnect the switch connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection S9-1 - S9-2 NG Pushed Free DL B137969E01 OK REPLACE CERTIFICATION ECU Condition Specified Condition Luggage compartment open switch not pushed (OFF) 10 kΩ or higher Luggage compartment open switch pushed (ON) Below 1 Ω REPLACE LUGGAGE COMPARTMENT OPEN SWITCH DOOR LOCK – SMART KEY SYSTEM DL–195 Certification ECU Power Source Circuit DESCRIPTION This is the power source circuit of the certification ECU. The certification ECU controls the following: • Electrical key verification confirmation • Cabin and door oscillator control • Entry door LOCK/UNLOCK request to the main body ECU • Steering LOCK/UNLOCK request • Immobilizer SET/UNSET request to the ID code box DL DL–196 DOOR LOCK – SMART KEY SYSTEM WIRING DIAGRAM E58 Certification ECU Instrument Panel J/B IGN 13 IM 18 2 IF 19 IG From IG1 Relay ECU-ACC ACC From ACC Relay Engine Room J/B and R/B EFI No. 1 2 1A 1 +B From Battery DL 17 E B112475E04 DL–197 DOOR LOCK – SMART KEY SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (POWER SOURCE CIRCUIT) (a) Disconnect the E58 certification ECU connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Certification ECU: Tester Connection (Symbols) E58-1 (+B) - Body ground E58 E58-18 (IG) - Body ground E58-19 (ACC) - Body ground E ACC IG +B Specified Condition Condition Always 10 to 14 V Engine switch OFF Below 1 V Engine switch ON (IG) 10 to 14 V Engine switch OFF Below 1 V Engine switch ON (ACC) 10 to 14 V (c) Measure the resistance according to the value(s) in the table below. Standard resistance B137963E07 Tester Connection (Symbols) Condition Specified Condition E58-17 (E) - Body ground Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE DL DOOR LOCK – KEY REMINDER WARNING SYSTEM DL–193 KEY REMINDER WARNING SYSTEM PRECAUTION 1. PRECAUTION FOR KEY REMINDER WARNING SYSTEM (a) For the inspection procedure of the key reminder warning system for models equipped with the entry and start system, refer to SMART KEY SYSTEM (See page DL-142). DL DL–194 DOOR LOCK – KEY REMINDER WARNING SYSTEM PARTS LOCATION COMBINATION METER ASSEMBLY FRONT DOOR COURTESY SWITCH - DRIVER’S SIDE DL MAIN BODY ECU DLC3 UNLOCK WARNING SWITCH B139170E01 DL–195 DOOR LOCK – KEY REMINDER WARNING SYSTEM SYSTEM DIAGRAM Front Door Courtesy Light Switch Assembly (Driver’s Side Door) Main Body ECU Unlock Warning Switch Assembly Combination Meter Assembly (Key Reminder Warning Buzzer) : CAN Communication Line (CAN) B112715E05 BODY ECU: Transmitting ECU Receiving ECU Signals Communication method Main Body ECU Combination Meter Assembly Driver's side door courtesy light switch signal CAN Main Body ECU Combination Meter Assembly Unlock warning switch signal CAN DL DL–196 DOOR LOCK – KEY REMINDER WARNING SYSTEM SYSTEM DESCRIPTION 1. DL KEY REMINDER WARNING SYSTEM DESCRIPTION (a) When the driver's side door is opened with the ignition key in the ACC or LOCK position, this system causes a buzzer to sound in order to warn the driver that the ignition key has not been removed. DOOR LOCK – KEY REMINDER WARNING SYSTEM DL–197 HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use the following procedures to troubleshoot the key reminder warning system. • The intelligent tester should be used in steps 3 and 5. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 INSPECT BATTERY VOLTAGE (a) Measure the battery voltage. Standard voltage: 10 to 14 V If the voltage is below 10 V, recharge or replace the battery before proceeding to the next step. NEXT 3 INSPECT COMMUNICATION FUNCTION OF CAN COMMUNICATION SYSTEM (CAN) (a) Use the intelligent tester to check if the CAN communication system (CAN) is functioning normally. (1) (ECU connected, communication line malfunctioning) If no code is output, proceed to A. (2) (ECU connected, communication line malfunctioning) If any code is output, proceed to B. B GO TO CAN COMMUNICATION SYSTEM A 4 PROBLEM SYMPTOMS TABLE (a) If the fault is not listed in the problem symptoms table, proceed to A. (b) If the fault is listed in the problem symptoms table, proceed to B. B Go to step 6 A 5 OVERALL ANALYSIS AND TROUBLESHOOTING (a) Inspection with the intelligent tester (DATA LIST) (b) TERMINALS OF ECU (See page DL-198) DL DL–198 DOOR LOCK – KEY REMINDER WARNING SYSTEM NEXT 6 REPAIR OR REPLACE NEXT 7 NEXT END DL CONFIRMATION TEST DOOR LOCK – KEY REMINDER WARNING SYSTEM DL–199 OPERATION CHECK 1. CHECK FUNCTION (a) Check that the key reminder warning buzzer sounds. (1) With the driver's side door closed, insert the key into the ignition key cylinder and then turn the key to the LOCK or ACC position. (2) Check that the buzzer sounds intermittently if the driver's side door is opened. (b) Check that the key reminder warning buzzer stops. (1) Check that the buzzer stops sounding if any of the following operations is performed while the buzzer is sounding: • Close the driver's side door (front door courtesy light switch is off). • Turn the ignition switch to the ON position. • Pull out the key from the ignition key cylinder. DL DL–200 DOOR LOCK – KEY REMINDER WARNING SYSTEM CUSTOMIZE PARAMETERS 1. PARAMETERS (USING INTELLIGENT TESTER) HINT: The following items can be customized. NOTICE: • Be sure to record current values before customizing. • When performing troubleshooting, be aware that the functions may be set to OFF by customizing. (Example: In case of the symptom in which "The wireless operation does not function", check that the wireless operation is not set to OFF by customizing, then perform the troubleshooting.) METER: Display (Item) DL Default Contents Setting KEY REMND VOLUM LARGE Function to change volume of the key reminder warning buzzer. LARGE/MEDIUM/SMALL KEY REMND SOUND NORMAL Function to change cycle of the key reminder warning buzzer. FAST/NORMAL/SLOW DL–201 DOOR LOCK – KEY REMINDER WARNING SYSTEM PROBLEM SYMPTOMS TABLE KEY REMINDER WARNING SYSTEM: Symptom Key reminder buzzer does not sound. Suspected area See page 1. Unlock warning switch circuit DL-205 2. Door courtesy switch circuit DL-202 3. Combination meter assembly (Key reminder buzzer) ME-15 4. Main body ECU (Instrument panel J/B) - DL DL–202 DOOR LOCK – KEY REMINDER WARNING SYSTEM TERMINALS OF ECU 1. CHECK MAIN BODY ECU (INSTRUMENT PANEL J/B) (a) Disconnect the IF and IM, ID*1 or IA*2 junction block connectors. *1: for TMC Made *2: for TMMK Made (b) Disconnect the E7 and E9 main body ECU connectors. Vehicle Rear Side IF IM IA*2 ID*1 Vehicle Front Side E7 E9 DL *1: for TMC Made *2: for TMMK Made B128346E01 DL–203 DOOR LOCK – KEY REMINDER WARNING SYSTEM (c) Measure the resistance and voltage according to the value(s) in the table below. Symbols (Terminal No.) GND1 (IF-10) - Body ground GND2 (IM-9) - Body ground Wiring Color W-B - Body ground BECU*1 (ID-10) - Body ground O*1 - Body ground BATB*2 (IA-1) - Body ground B*2 - Body ground DCTY (E7-24) - Body ground L - Body ground KSW (E9-5) - Body ground L - Body ground Terminal Description Condition Specified Condition Ground Always Below 1 Ω Power source Always 10 to 14 V Switch pushed (Door closed) Below 1 Ω Driver door courtesy light switch signal Key unlock warning switch signal Switch free (Door opened) 10 kΩ or higher No key is in ignition key cylinder 10 kΩ or higher Key is in ignition key cylinder Below 1 Ω *1: for TMC Made *2: for TMMK Made HINT: If the result is not as specified, there may be a malfunction on the wire harness side. DIAGNOSIS SYSTEM CG SG CANH SIL CANL 1. CHECK DLC3 (a) The vehicle's ECU uses ISO 15765-4 for communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. BAT H100769E16 Symbols (Terminal No.) Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω Below 1 Ω SG (5) - Body ground Signal ground Always BAT (16) - Body ground Battery positive Always CANH (6) - CANL (14) CANH (6) - CG (4) CANL (14) - CG (4) CAN bus line HIGH-level CAN bus line LOW-level CAN bus line 10 to 14 V Ignition switch OFF * 54 to 69 Ω Ignition switch OFF * 200 Ω or higher Ignition switch OFF * 200 Ω or higher * 6 kΩ or higher 6 kΩ or higher CANH (6) - BAT (16) HIGH-level CAN bus line Ignition switch OFF CANL (14) - BAT (16) LOW-level CAN bus line Ignition switch OFF* NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. DL DL–204 DLC3 DOOR LOCK – KEY REMINDER WARNING SYSTEM (b) Connect the cable of the intelligent tester (with CAN VIM) to the DLC3, turn the ignition switch to the ON position and attempt to use the intelligent tester. If the screen displays a communication error message, a problem exists in the vehicle side or tester side. HINT: • If communication is normal when the tool is connected to another vehicle, inspect the DLC3 on the original vehicle. • If communication is still impossible when the tool is connected to another vehicle, the problem is probably in the tool itself. Consult the Service Department listed in the tool's instruction manual. Intelligent Tester C131977E01 DL DL–205 DOOR LOCK – KEY REMINDER WARNING SYSTEM DATA LIST / ACTIVE TEST 1. READ DATA LIST HINT: Using the intelligent tester to read the DATA LIST allows the values or states of switches, sensors, actuators and other items to be read without removing any parts. This non intrusive inspection can be very useful as intermittent conditions or signals may be discovered before parts or wiring is disturbed. Reading the DATA LIST information early in troubleshooting is one way to save diagnostic time. (a) Connect the intelligent tester to the Controller Area Network Vehicle Interface Module (CAN VIM). Then connect the CAN VIM to the DLC3. (b) Turn the ignition switch to the ON position. (c) Read the DATA LIST. DLC3 Intelligent Tester C131977E01 MAIN BODY: Item KEY UNLK WRN SW D DOR CTY SW Measurement Item / Display (Range) Normal Condition Diagnostic Note Unlock warning switch signal /ON or OFF ON: Key is in ignition key cylinder OFF: No key is in ignition key cylinder - Driver's side door courtesy switch signal /ON or OFF ON: Driver's side door is open OFF: Driver's side door is closed - DL DL–206 DOOR LOCK – KEY REMINDER WARNING SYSTEM Door Courtesy Switch Circuit DESCRIPTION The main body ECU detects the condition of the front door courtesy light switch assembly (driver's side). WIRING DIAGRAM Main Body ECU N6 Door Courtesy Light Switch Assembly (Driver’s Side) 1 No. 3 J/B L 13 EN2 12 3O L 10 3F L 24 E7 DCTY B128328E02 INSPECTION PROCEDURE 1 DL READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the ignition switch to the ON position and turn the intelligent tester main switch on. (c) Select D DOR CTY SW in the DATA LIST and read the value displayed on the tester. BODY: Item Measurement Item/Display (Range) Normal Condition Diagnostic Note D DOR CTY SW Driver's side door courtesy switch signal/ON or OFF ON: Driver's side door is open OFF: Driver's side door is closed - OK: ON (Driver's door is open) appears on the screen. OK NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE DL–207 DOOR LOCK – KEY REMINDER WARNING SYSTEM 2 INSPECT FRONT DOOR COURTESY LIGHT SWITCH ASSEMBLY Front Door Courtesy Light Switch Side Connector Front View: Free (a) Remove the driver's side front door courtesy light switch (See page LI-128). (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Pushed 1 - Switch body NG Switch Body Condition Specified Condition Courtesy switch pushed (Door closed) 10 kΩ or higher Courtesy switch free (Door open) Below 1 Ω REPLACE FRONT DOOR COURTESY LIGHT SWITCH ASSEMBLY B111600E02 OK 3 CHECK HARNESS AND CONNECTOR (FRONT DOOR COURTESY LIGHT SWITCH - MAIN BODY ECU) Wire Harness Side Connector Front View: N6 Front Door Courtesy Light Switch Assembly (a) Disconnect the E7 ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection N6-1 - E7-24 (DCTY) N6-1 - Body ground NG Condition Always Specified Condition Below 1 Ω 10 kΩ or higher REPAIR OR REPLACE HARNESS OR CONNECTOR E7 Main Body ECU DL DCTY B139169E03 DL–208 DOOR LOCK – KEY REMINDER WARNING SYSTEM OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE DL DL–209 DOOR LOCK – KEY REMINDER WARNING SYSTEM Unlock Warning Switch Circuit DESCRIPTION The unlock warning switch detects if the key is in the ignition key cylinder. The unlock warning switch turns on when the key is inserted into the ignition key cylinder and turns off when the key is removed from the cylinder. The main body ECU is connected to the unlock warning switch via terminal KSW and key detection status signals are input to the main body ECU. The main body ECU applies voltage to the unlock warning switch via terminal KSW. When the unlock warning switch is on (there is continuity between the switch terminals), a signal indicating that the key is in the ignition key cylinder is input to the main body ECU. When the switch is off (there is no continuity between the switch terminals), a signal indicating that the key is not in the cylinder is input. WIRING DIAGRAM Main Body ECU E22 Unlock Warning Switch Assembly 2 1 W-B No. 3 J/B L 7 5 3A 3J 2 3 3A 3C 5 L E49 J/C W-B 9 2 W-B 12 E9 8 FE3 KSW W-B W-B E2 F1 B128326E02 INSPECTION PROCEDURE 1 DL READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the ignition switch to the ON position and turn the intelligent tester main switch on. (c) Select KEY UNLK WRN SW in the DATA LIST and read the value displayed on the tester. BODY: Item KEY UNLK WRN SW Measurement Item / Display (Range) Unlock warning switch signal /ON or OFF Normal Condition Diagnostic Note ON: Key is in ignition key cylinder OFF: No key is in ignition key cylinder - DL–210 DOOR LOCK – KEY REMINDER WARNING SYSTEM OK: ON (Key is in ignition key cylinder) appears on the screen. OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG 2 INSPECT UNLOCK WARNING SWITCH ASSEMBLY (a) Remove the unlock warning switch assembly (See page DL-225). (b) Measure the resistance according to the value(s) in the table below. Standard resistance Unlock Warning Switch Assembly: Free Push Tester Connection Condition Specified Condition 1-2 Switch free (Key removed) 10 kΩ or higher 1-2 Switch pushed (Key set) Below 1 Ω NG B118535E02 OK DL REPLACE UNLOCK WARNING SWITCH ASSEMBLY DL–211 DOOR LOCK – KEY REMINDER WARNING SYSTEM 3 CHECK HARNESS AND CONNECTOR (UNLOCK WARNING SWITCH - MAIN BODY ECU) Wire Harness Side Connector Front View: E22 Unlock Warning Switch Assembly (a) Disconnect the E22 switch and E9 ECU connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection E22-1 - E9-5 (KSW) E22-1 - Body ground NG Condition Always Specified Condition Below 1 Ω 10 kΩ or higher REPAIR OR REPLACE HARNESS OR CONNECTOR E9 Main Body ECU KSW B139168E01 OK 4 CHECK HARNESS AND CONNECTOR (UNLOCK WARNING SWITCH - BODY GROUND) Wire Harness Side Connector Front View: E22 Unlock Warning Switch Assembly (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition E22-2 - Body ground Always Below 1 Ω NG B139172E01 REPAIR OR REPLACE HARNESS OR CONNECTOR DL DL–212 DOOR LOCK – KEY REMINDER WARNING SYSTEM OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE DL DOOR LOCK – DOOR CONTROL TRANSMITTER (w/ Smart Key System) DL–209 DOOR CONTROL TRANSMITTER (w/ Smart Key System) BODY ELECTRICAL DOOR LOCK COMPONENTS TRANSMITTER HOUSING COVER TRANSMITTER BATTERY TRANSMITTER HOUSING CASE DL MECHANICAL KEY B107890E03 DL–210 DOOR LOCK – DOOR CONTROL TRANSMITTER (w/ Smart Key System) REMOVAL 1. REMOVE TRANSMITTER BATTERY (a) Remove the mechanical key. B140894 (b) Insert a screwdriver into the gap, and turn the screwdriver to detach the cover. HINT: Tape the screwdriver tip before use. B145443 DL B140897 (c) Insert a screwdriver into the gap and gently remove the battery (lithium battery). NOTICE: • Do not push the terminals with your finger. • Do not forcibly pry up the battery (lithium battery) because doing so will deform the terminals. • Do not touch the battery with wet hands. Water may result in corrosion. • Do not touch or move any components inside the transmitter because handling the components may interfere with proper operation of the transmitter. DOOR LOCK – DOOR CONTROL TRANSMITTER (w/ Smart Key System) DL–211 INSPECTION 1. B128411 INSPECT DOOR CONTROL TRANSMITTER (a) Inspect operation of the transmitter. (1) Remove the battery (lithium battery) from the transmitter (See page DL-210). (2) Install a new or normal battery (lithium battery). HINT: If a new or normal battery is not available, first connect 2 new 1.5 V batteries in series. Then connect leads to the batteries and apply 3 V to the transmitter, as shown in the illustration. (3) From outside the vehicle, approximately 1 m (3.28 ft.) away from the driver side outside door handle, test the transmitter by pointing its key plate at the vehicle and pressing a transmitter switch. OK: The door lock can be operated via the transmitter. The LED comes on more than once. • The operational area differs depending on the user, the way the transmitter is held, and the location. • The transmitter's faint electric waves may be affected if the area has strong electric waves or noise. The transmitter's operation area may be shortened or the transmitter may not function. (b) Inspect the battery capacity. HINT: • When checking the amount of energy left in the battery (lithium battery), the battery must be checked while it is installed in the transmitter (a resistance of 1.2 kΩ is applied to the battery). When the battery energy is checked by itself (removed from the vehicle), the voltage reading will be more than 2.5 V until the energy is depleted. • If the transmitter is malfunctioning, the voltage reading of the energy left in the battery will be inaccurate. (1) Remove the battery (lithium battery) from the transmitter (See page DL-210). (2) Connect a wire to the negative (-) terminal of the transmitter and install the battery. B139426 DL DL–212 DOOR LOCK – DOOR CONTROL TRANSMITTER (w/ Smart Key System) (3) Connect the tester positive (+) lead to the positive (+) battery (lithium battery), and the tester negative (-) lead to the wire connected in the previous step. (4) Press one of the transmitter switches on the transmitter for approximately 1 second. (5) Press the transmitter switch on the transmitter again to check the voltage. Voltage: 2.2 V or higher HINT: • If the temperature of the battery is low, the inspection cannot be performed correctly. If the result of the test is less than 2.2 V, perform the test again after leaving the battery in a place at a temperature of 18°C (64°F) for 30 minutes or more. • Read the voltage immediately after the switch is pressed. When 0.8 seconds have passed after the switch is pressed, the automatic power-off function starts and the resistance applied to the battery will cease. The voltage of the battery will be 2.5 V or more. • Press the switch at least 3 times before reading the voltage. If the battery has just been returned to 18°C (64°F), the voltage may be unusually high for the first or second voltage reading. B139435 INSTALLATION 1. INSTALL TRANSMITTER BATTERY (a) Install a new battery (lithium battery) with the positive (+) side up as shown in the illustration. B140899 (b) Press down gently on the battery to set it in place. NOTICE: • Be sure that the positive and negative sides of the transmitter battery are positioned correctly. • Be careful not to bend the terminals of the transmitter battery during installation. • Keep the interior of the transmitter case free of dust, water, and oil. DL B140900 DOOR LOCK – DOOR CONTROL TRANSMITTER (w/ Smart Key System) DL–213 (c) Install the cover by pressing down on it as shown in the illustration. B140901 (d) Install the mechanical key. HINT: After the installation, press one of the transmitter switches and check that the LED illuminates. B140902 DL DL–214 DOOR LOCK – DOOR CONTROL TRANSMITTER (w/o Smart Key System) DOOR CONTROL TRANSMITTER (w/o Smart Key System) BODY ELECTRICAL DOOR LOCK COMPONENTS TRANSMITTER HOUSING COVER TRANSMITTER BATTERY COVER DOOR CONTROL TRANSMITTER MODULE TRANSMITTER BATTERY (LITHIUM BATTERY: CR2016) TRANSMITTER BATTERY CASE DL TRANSMITTER HOUSING CASE B140903E01 DOOR LOCK – DOOR CONTROL TRANSMITTER (w/o Smart Key System) DL–215 REMOVAL 1. REMOVE TRANSMITTER BATTERY (a) Remove the transmitter battery. (1) Using a screwdriver with its tip wrapped in protective tape, pry open the transmitter housing cover. NOTICE: Do not use excessive force when prying open the housing cover. B145452 (b) Remove the door control transmitter module from the transmitter housing case. B102129 (c) Using a coin, or other flat object, pry open the transmitter cover. DL B102130 (d) Remove the transmitter battery (lithium battery). NOTICE: • Do not push the terminals with your finger. • Do not forcibly pry up the battery (lithium battery) because doing so will deform the terminals. • Do not touch the battery with wet hands. Water may result in corrosion. B102131 DL–216 DOOR LOCK – DOOR CONTROL TRANSMITTER (w/o Smart Key System) • Do not touch or move any components inside the transmitter because handling the components may interfere with proper operation of the transmitter. DL DOOR LOCK – DOOR CONTROL TRANSMITTER (w/o Smart Key System) DL–217 INSPECTION 1. B144374 INSPECT DOOR CONTROL TRANSMITTER (a) Inspect operation of the transmitter. (1) Remove the battery (lithium battery) from the transmitter (See page DL-215). (2) Install a new or normal battery (lithium battery). (3) If a new or normal battery is not available, connect 2 new 1.5 V batteries in a series. Connect the positive (+) battery electrode to the battery receptacle side terminal, and the negative (-) battery electrode to the bottom terminal, and apply a voltage of 3 V to the transmitter. (4) In a location that is approximately 1 m (3.28 ft) away from the driver side outside door handle, point the key plate of the transmitter at the vehicle and check operation of the transmitter by pressing the transmission switches on the transmitter body. Standard: The door lock/unlock can be operated via remote control. The LED lights up when each switch is pressed. HINT: • The minimum operational distance differs depending on the way the transmitter is held and the location. • Since the transmitter uses faint electric waves, the operational distance might be shortened if noise or a strong electric wave occurs in the area where the frequency is used. (5) Install the battery (lithium battery). (b) Inspect the battery capacity. HINT: • The capacity of the battery can be determined only when the battery is installed in the transmitter. For a lithium battery used in the transmitter, a voltage of more than 2.5 V is shown on the tester until the energy is completely consumed without the battery installed in the transmitter. Therefore, it is necessary to measure the voltage with the battery installed in the transmitter (a resistance of 1.2 kΩ is applied to the battery) to check the amount of energy left in the battery. • If the transmitter is faulty, the amount of energy left in the battery might not be checked correctly. (1) Remove the battery (lithium battery) from the transmitter (See page DL-215). (2) Connect the lead to the negative (-) terminal of the transmitter and install the battery. DL DL–218 DOOR LOCK – DOOR CONTROL TRANSMITTER (w/o Smart Key System) (3) Connect the positive (+) tester probe to the positive (+) side of the battery (lithium battery), and the negative (-) tester probe to the lead respectively. (4) Press one of the transmission switches on the transmitter for approximately 1 second. (5) Press the same or another transmission switch again and check the voltage. Voltage: 2.2 V or higher HINT: • If the temperature of the battery is low, the inspection cannot be done correctly. If the outcome of the test is less than 2.2 V, conduct the test again after leaving the battery in a place with a temperature of 18°C (64°F) for more than 30 minutes. • The automatic power-off function causes the battery voltage to be 2.5 V or more (with no resistance applied to the battery) when 0.8 seconds have passed after the switch is pressed. Therefore, make sure to read the voltage immediately after the switch is pressed. (6) Remove the lead. (7) Set the battery (lithium battery) in the transmitter. B144375 INSTALLATION 1. B102132 DL INSTALL TRANSMITTER BATTERY (a) Install the transmitter battery. (1) Install a battery (lithium battery: CR2016) with the positive (+) side up, as shown in the illustration. NOTICE: • Be sure that the positive and negative sides of the transmitter battery are positioned correctly. • Be careful not to bend the terminals of the transmitter battery during installation. • Keep the interior of the transmitter case free of dust, water, and oil. (b) Install the door control transmitter module into the transmitter housing case. B102133 DOOR LOCK – DOOR CONTROL TRANSMITTER (w/o Smart Key System) (c) DL–219 Install the transmitter housing cover securely onto the transmitter housing case. HINT: After the installation, press one of the transmitter switches and check that the LED illuminates. B102134 DL DOOR LOCK – DOOR CONTROL SWITCH DL–219 DOOR CONTROL SWITCH BODY ELECTRICAL DOOR LOCK COMPONENTS FRONT DOOR INSIDE HANDLE BEZEL PLUG POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY ASSIST GRIP COVER DL FRONT DOOR TRIM BOARD SUB-ASSEMBLY COURTESY LIGHT ASSEMBLY FRONT DOOR LOWER FRAME BRACKET GARNISH B136664E02 DL–220 DOOR LOCK – DOOR CONTROL SWITCH REMOVAL 1. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH (See page ED-14) 2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG (See page ED-14) 3. REMOVE ASSIST GRIP COVER (See page ED-15) 4. REMOVE COURTESY LIGHT ASSEMBLY (See page ED-15) 5. REMOVE FRONT DOOR TRIM BOARD SUBASSEMBLY (See page ED-15) 6. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (a) Disconnect the connector. (b) Remove the 3 screws and the power window regulator master switch assembly. B136405 INSPECTION Lock 1. Unlock INSPECT DOOR CONTROL SWITCH (for Driver Side) (a) Measure the resistance of the door control switch. Standard resistance Tester Connection DL E123893E05 Switch Condition Specified Condition 2-1 Lock Below 1 Ω 2-1 OFF (Free) 10 kΩ or higher 9-1 Unlock Below 1 Ω 9-1 OFF (Free) 10 kΩ or higher DL–221 DOOR LOCK – DOOR CONTROL SWITCH 2. INSPECT DOOR CONTROL SWITCH (for Front Passenger Side) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Switch Condition Specified Condition 4-3 Lock Below 1 Ω 4-3 2-3 OFF (Free) 10 kΩ or higher 2-3 Unlock Below 1 Ω E123894 INSTALLATION B136405 1. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (a) Install the power window regulator master switch assembly with the 3 screws. (b) Connect the connector. 2. REMOVE FRONT DOOR TRIM BOARD SUBASSEMBLY (See page ED-33) 3. REMOVE COURTESY LIGHT ASSEMBLY (See page ED-34) 4. REMOVE ASSIST GRIP COVER (See page ED-34) 5. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG (See page ED-34) 6. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH (See page ED-34) DL DL–222 DOOR LOCK – UNLOCK WARNING SWITCH UNLOCK WARNING SWITCH BODY ELECTRICAL DOOR LOCK COMPONENTS DRIVER SIDE KNEE AIRBAG ASSEMBLY 10 (102, 7.0) LOWER INSTRUMENT PANEL FINISH PANEL LH COWL SIDE TRIM SUB-ASSEMBLY LH DL FRONT DOOR SCUFF PLATE LH N*m (kgf*cm, ft.*lbf) : Specified torque C133871E04 DL–223 DOOR LOCK – UNLOCK WARNING SWITCH Without Cruise Control System: STEERING WHEEL ASSEMBLY STEERING PAD LOWER NO. 2 STEERING WHEEL COVER LOWER NO. 2 STEERING WHEEL COVER 50 (510, 37) 8.8 (90, 78 in.*lbf) LOWER NO. 3 STEERING WHEEL COVER TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY STEERING COLUMN COVER NO. 1 AIR DUCT DL N*m (kgf*cm, ft.*lbf) : Specified torque C115592E06 DL–224 DOOR LOCK – UNLOCK WARNING SWITCH TRANSPONDER KEY AMPLIFIER IGNITION SWITCH LOCK CYLINDER ASSEMBLY STEERING LOCK SUB-ASSEMBLY UNLOCK WARNING SWITCH ASSEMBLY TAPERED-HEAD BOLT STEERING COLUMN ASSEMBLY TMC Made: 21 (214, 16) TMMK Made: 25 (255, 18) TMC Made: 21 (214, 16) TMMK Made: 25 (255, 18) DL 35 (360, 26) Non-reusable part N*m (kgf*cm, ft.*lbf) : Specified torque B139059E01 DOOR LOCK – UNLOCK WARNING SWITCH DL–225 REMOVAL 1. PRECAUTION (See page RS-1) 2. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (See page RS-1) 4. REMOVE FRONT WHEEL LH 5. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-24) 6. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-25) 7. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (See page IP-20) 8. REMOVE DRIVER SIDE KNEE AIRBAG ASSEMBLY (See page RS-370) 9. REMOVE LOWER NO. 2 STEERING WHEEL COVER 10. REMOVE LOWER NO. 3 STEERING WHEEL COVER 11. REMOVE STEERING PAD (See page RS-350) 12. REMOVE STEERING WHEEL ASSEMBLY (See page SR-38) 13. REMOVE STEERING COLUMN COVER (See page SR-39) 14. REMOVE TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY (See page SR-39) 15. REMOVE NO. 1 AIR DUCT (See page SR-39) 16. REMOVE STEERING COLUMN ASSEMBLY (See page SR-39) 17. REMOVE TRANSPONDER KEY AMPLIFIER (See page SR-42) 18. REMOVE STEERING COLUMN UPPER WITH SWITCH BRACKET ASSEMBLY (See page SR-43) 19. REMOVE IGNITION SWITCH LOCK CYLINDER ASSEMBLY (See page SR-43) 20. REMOVE UNLOCK WARNING SWITCH ASSEMBLY (a) Remove the unlock warning switch assembly by pushing up the center part and releasing the 2 claws. C104851E03 DL DL–226 DOOR LOCK – UNLOCK WARNING SWITCH INSPECTION Unlock Warning Switch Assembly: 1. Free Push INSPECT UNLOCK WARNING SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition 1-2 Switch free (Key removed) 10 kΩ or higher 1-2 Switch pushed (Key set) Below 1 Ω If the result as specified, replace the unlock warning switch assembly. B118535E02 INSTALLATION C104837E02 1. INSTALL UNLOCK WARNING SWITCH ASSEMBLY (a) Engage the 2 claws to install the unlock warning switch assembly to the steering lock sub-assembly. 2. INSTALL IGNITION SWITCH LOCK CYLINDER ASSEMBLY (See page SR-46) 3. INSPECT STEERING LOCK OPERATION 4. INSTALL STEERING COLUMN UPPER WITH SWITCH BRACKET ASSEMBLY (See page SR-46) 5. INSTALL TRANSPONDER KEY AMPLIFIER (See page SR-46) 6. INSTALL STEERING COLUMN ASSEMBLY (See page SR-47) 7. INSTALL NO. 1 AIR DUCT (See page SR-50) 8. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 9. INSTALL TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY (See page SR-50) 10. INSTALL STEERING COLUMN COVER (See page SR50) DL 11. ADJUST SPIRAL CABLE SUB-ASSEMBLY (See page RS-367) 12. INSTALL STEERING WHEEL ASSEMBLY (See page SR-51) 13. INSPECT STEERING WHEEL CENTER POINT 14. INSPECT STEERING PAD (See page RS-352) 15. INSTALL STEERING PAD (See page RS-350) 16. INSTALL LOWER NO. 2 STEERING WHEEL COVER 17. INSTALL LOWER NO. 3 STEERING WHEEL COVER 18. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY (See page RS-370) DOOR LOCK – UNLOCK WARNING SWITCH DL–227 19. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (See page IP-55) 20. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-54) 21. INSTALL FRONT DOOR SCUFF PLATE LH (See page IR-54) 22. INSTALL FRONT WHEEL LH (See page SR-51) 23. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 24. INSPECT SRS WARNING LIGHT (See page RS-32) DL DL–228 DOOR LOCK – FRONT DOOR LOCK FRONT DOOR LOCK BODY ELECTRICAL DOOR LOCK COMPONENTS FRONT DOOR LOCK OPEN ROD FRONT DOOR GLASS SUB-ASSEMBLY FRONT DOOR OUTSIDE HANDLE COVER FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY 5.0 (51, 44 in.*lbf) SEAL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY FRONT DOOR LOCK ASSEMBLY FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY BUTYL TAPE FRONT DOOR SERVICE HOLE COVER FRONT DOOR TRIM BOARD SUB-ASSEMBLY FRONT DOOR INSIDE HANDLE BEZEL PLUG DL ASSIST GRIP COVER COURTESY LIGHT ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part FRONT DOOR LOWER FRAME BRACKET GARNISH Apply MP grease B136665E01 DOOR LOCK – FRONT DOOR LOCK DL–229 REMOVAL 1. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH (See page ED-14) 2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG (See page ED-14) 3. REMOVE ASSIST GRIP COVER (See page ED-15) 4. REMOVE COURTESY LIGHT ASSEMBLY (See page ED-15) 5. REMOVE FRONT DOOR TRIM BOARD SUBASSEMBLY (See page ED-15) 6. REMOVE FRONT DOOR SERVICE HOLE COVER (See page ED-17) 7. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY (See page ED-17) 8. REMOVE FRONT DOOR REAR LOWER FRAME SUBASSEMBLY (See page ED-19) 9. REMOVE FRONT DOOR OUTSIDE HANDLE COVER (See page ED-19) 10. REMOVE FRONT DOOR LOCK ASSEMBLY (a) Disconnect the connector. (b) Using a "torx" socket wrench (T30), remove the 3 screws. (c) Slide the front door lock assembly downward and pull out the front door lock open rod from the outside handle frame. Remove the front door lock assembly and cables as a unit. (d) Remove the front door lock open rod from the front door lock assembly. (e) Remove the door lock wiring harness seal from the front door lock assembly. B136428 (f) B140064 Remove the front door lock remote control cable assembly. DL DL–230 DOOR LOCK – FRONT DOOR LOCK (g) Using a screwdriver, disengage the 3 claws. HINT: Tape the screwdriver tip before use. B136431 (h) Remove the front door inside locking cable assembly. B140065 DL DL–231 DOOR LOCK – FRONT DOOR LOCK INSPECTION 1. INSPECT FRONT DOOR LOCK LH ASSEMBLY (a) Remove the front door lock assembly LH. (b) Check operation of the door lock motor. (1) Apply battery voltage and check operation of the door lock motor. OK Measurement Condition Specified Condition Battery positive (+) → Terminal 4 Battery negative (-) → Terminal 1 Lock Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 4 Unlock Unlock Lock B065427E20 Lock Unlock (c) Check operation of the door key lock and unlock switch. (1) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition 7-9 ON (Door lock set to LOCK) Below 1 Ω 7-9 7 - 10 OFF (Free) 10 kΩ or higher 7 - 10 ON (Door lock set to UNLOCK) Below 1 Ω DL B065428E02 DL–232 DOOR LOCK – FRONT DOOR LOCK (d) Check operation of the door unlock detection switch. (1) Measure the resistance according to the value(s) in the table below. Standard resistance Unlock Lock 2. Tester Connection Measurement Condition Door Lock Condition Specified Condition 7-8 Battery positive (+) → Terminal 4 Battery negative (-) → Terminal 1 Lock 10 kΩ or higher 7-8 Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 4 Unlock Below 1 Ω INSPECT FRONT DOOR LOCK RH ASSEMBLY (a) Remove the front door lock assembly RH. B065427E20 (b) Check operation of the door lock motor. (1) Apply battery voltage and check operation of the door lock motor. OK Unlock Lock DL B065429E21 Measurement Condition Specified Condition Battery positive (+) → Terminal 4 Battery negative (-) → Terminal 1 Lock Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 4 Unlock DL–233 DOOR LOCK – FRONT DOOR LOCK (c) Check operation of the door key lock and unlock switch. (1) Measure the resistance according to the value(s) in the table below. Standard resistance LOCK UNLOCK Tester Connection Condition Specified Condition 5-8 ON (Door lock set to UNLOCK) Below 1 Ω 5-8 6-8 OFF (Free) 10 kΩ or higher 6-8 ON (Door lock set to LOCK) Below 1 Ω B112613E01 (d) Check operation of the door unlock detection switch. (1) Measure the resistance according to the value(s) in the table below. Standard resistance Unlock Lock Tester Connection Measurement Condition Door Lock Condition (Specified Condition) 7-8 Battery positive (+) → Terminal 4 Battery negative (-) → Terminal 1 LOCK 10 kΩ or higher 7-8 Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 4 UNLOCK Below 1 Ω DL B065429E21 DL–234 DOOR LOCK – FRONT DOOR LOCK INSTALLATION 1. INSTALL FRONT DOOR LOCK ASSEMBLY NOTICE: • When reusing the removed front door lock assembly, replace the door lock wiring harness seal on the door lock with a new one. • Do not allow grease or dust to adhere to the surface of the door lock where the seal attaches. • Reusing the door lock wiring harness seal or using a damaged door lock wiring harness seal may allow water intrusion to the connection, and result in a malfunction in the front door lock assembly. (a) Install the front door inside locking cable assembly. B140065 (b) Engage the 3 claws. B136431 (c) Install the front door lock remote control cable assembly. (d) Apply MP grease to the sliding parts on the front door lock assembly. (e) Install a new door lock wiring harness seal to the front door lock assembly. DL B140064 DOOR LOCK – FRONT DOOR LOCK DL–235 (f) Insert the front door lock open rod to the front door lock assembly, and set the assembly to the front door outside handle frame. (g) Make sure that the front door lock open rod is securely connected to the front door lock assembly. (h) Using a "torx" socket wrench (T30), install the front door lock assembly with the 3 screws. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) (i) Connect the connector. B136428 2. INSTALL FRONT DOOR OUTSIDE HANDLE COVER (See page ED-29) 3. INSTALL FRONT DOOR REAR LOWER FRAME SUBASSEMBLY (See page ED-30) 4. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY (See page ED-31) 5. INSTALL FRONT DOOR SERVICE HOLE COVER (See page ED-32) 6. INSTALL FRONT DOOR TRIM BOARD SUBASSEMBLY (See page ED-33) 7. INSTALL COURTESY LIGHT ASSEMBLY (See page ED-34) 8. INSTALL ASSIST GRIP COVER (See page ED-34) 9. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG (See page ED-34) 10. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH (See page ED-34) DL DL–238 DOOR LOCK – REAR DOOR LOCK INSPECTION 1. INSPECT REAR DOOR LOCK LH ASSEMBLY (a) Remove the rear door lock assembly LH. (b) Check operation of the door lock motor. (1) Apply battery voltage and check operation of the door lock motor. OK Lock Measurement Condition Specified Condition Battery positive (+) → Terminal 4 Battery negative (-) → Terminal 1 Lock Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 4 Unlock Unlock UL L E123890E03 (c) Check operation of the unlock detection switch. (1) Measure the resistance according to the value(s) in the table below. Standard resistance Lock Unlock 2. DL E123890E02 Tester Connection Measurement Condition Door Lock Condition (Specified Condition) 6-9 Battery positive (+) → Terminal 4 Battery negative (-) → Terminal 1 Lock 10 kΩ or higher 6-9 Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 4 Unlock Below 1 Ω INSPECT REAR DOOR LOCK RH ASSEMBLY (a) Remove the rear door lock assembly RH. DL–239 DOOR LOCK – REAR DOOR LOCK (b) Check operation of the door lock motor. (1) Apply battery voltage and check operation of the door lock motor. OK Unlock Measurement Condition Specified Condition Battery positive (+) → Terminal 4 Battery negative (-) → Terminal 1 Lock Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 4 Unlock Lock UL L E123891E03 (c) Check operation of the unlock detection switch. (1) Measure the resistance according to the value(s) in the table below. Standard resistance Unlock Lock Tester Connection Measurement Condition Door Lock Condition (Specified Condition) 6-9 Battery positive (+) → Terminal 4 Battery negative (-) → Terminal 1 Lock 10 kΩ or higher 6-9 Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 4 Unlock Below 1 Ω DL E123891E02 DL–235 DOOR LOCK – REAR DOOR LOCK REAR DOOR LOCK BODY ELECTRICAL DOOR LOCK COMPONENTS REAR DOOR LOCK ASSEMBLY 5.0 (51, 44 in.*lbf) REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY DOOR LOCK WIRING HARNESS SEAL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY REAR DOOR SERVICE HOLE COVER BUTYL TAPE REAR DOOR INSIDE HANDLE BEZEL PLUG DL REAR DOOR TRIM BOARD SUB-ASSEMBLY DOOR ASSIST GRIP COVER N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Apply MP grease B136666E01 DL–236 DOOR LOCK – REAR DOOR LOCK REMOVAL 1. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG (See page ED-38) 2. REMOVE DOOR ASSIST GRIP COVER (See page ED38) 3. REMOVE REAR DOOR TRIM BOARD SUBASSEMBLY (See page ED-39) 4. REMOVE REAR DOOR SERVICE HOLE COVER (See page ED-41) 5. REMOVE REAR DOOR LOCK ASSEMBLY (a) Using a "torx" socket wrench (T30), remove the 3 screws. (b) Move the rear door lock assembly downward and pull the release plate out of the rear door outside handle frame. (c) Remove the door lock wiring harness seal from the rear door lock assembly. B136473 (d) Using a screwdriver, disengage the claw. HINT: Tape the screwdriver tip before use. B136475 (e) Remove the rear door inside locking cable assembly. DL B140066 DOOR LOCK – REAR DOOR LOCK (f) DL–237 Using a screwdriver, disengage the 3 claws. HINT: Tape the screwdriver tip before use. B136477 (g) Remove the rear door inside locking cable assembly. B140067 DL DL–240 DOOR LOCK – REAR DOOR LOCK INSTALLATION 1. INSTALL REAR DOOR LOCK ASSEMBLY NOTICE: • When reusing the removed rear door lock assembly, replace the door lock wiring harness seal on the door lock with a new one. • Do not allow grease or dust to adhere to the surface of the door lock where the seal attaches. • Reusing the door lock wiring harness seal or using a damaged door lock wiring harness seal may allow water intrusion to the connection, and result in a malfunction in the rear door lock assembly. (a) Install the rear door inside locking cable assembly. B140067 (b) Engage the 3 claws. B136477 (c) Install the rear door lock remote control cable assembly. DL B140066 DOOR LOCK – REAR DOOR LOCK DL–241 (d) Engage the claw. (e) Apply MP grease to the sliding parts on the rear door lock assembly. (f) Install a new door lock wiring harness seal to the rear door lock assembly. B136475 (g) Insert the rear door lock assembly to the rear door outside handle release plate, and set the assembly to the rear door panel. (h) Make sure that the rear door outside handle frame release plate is securely connected to the rear door lock assembly. (i) Using a "torx" socket wrench (T30), install the rear door lock assembly with the 3 screws. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) (j) Connect the connector. 2. INSTALL REAR DOOR SERVICE HOLE COVER (See page ED-53) 3. INSTALL REAR DOOR TRIM BOARD SUBASSEMBLY (See page ED-55) 4. INSTALL DOOR ASSIST GRIP COVER (See page ED56) 5. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG (See page ED-56) B136474 DL DOOR LOCK – ENTRY LOCK AND UNLOCK SWITCH DL–241 ENTRY LOCK AND UNLOCK SWITCH BODY ELECTRICAL DOOR LOCK COMPONENTS FRONT DOOR GLASS SUB-ASSEMBLY FRONT DOOR OUTSIDE HANDLE COVER FRONT DOOR OUTSIDE HANDLE SUB-ASSEMBLY FRONT DOOR SERVICE HOLE COVER BUTYL TAPE FRONT DOOR INSIDE HANDLE BEZEL PLUG FRONT DOOR TRIM BOARD SUB-ASSEMBLY DL FRONT DOOR LOWER FRAME BRACKET GARNISH ASSIST GRIP COVER COURTESY LIGHT ASSEMBLY Non-reusable part B136667E01 DL–242 DOOR LOCK – ENTRY LOCK AND UNLOCK SWITCH REMOVAL 1. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH (See page ED-14) 2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG (See page ED-14) 3. REMOVE ASSIST GRIP COVER (See page ED-15) 4. REMOVE COURTESY LIGHT ASSEMBLY (See page ED-15) 5. REMOVE FRONT DOOR TRIM BOARD SUBASSEMBLY (See page ED-15) 6. REMOVE FRONT DOOR SERVICE HOLE COVER (See page ED-17) 7. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY (See page ED-17) 8. REMOVE FRONT DOOR OUTSIDE HANDLE COVER (See page ED-19) 9. REMOVE FRONT DOOR OUTSIDE HANDLE SUBASSEMBLY (a) Disconnect the connector. B136857 (b) Remove the front door outside handle assembly as shown in the illustration. DL B136422 DL–243 DOOR LOCK – ENTRY LOCK AND UNLOCK SWITCH INSPECTION Lock Switch: 1. INSPECT ENTRY LOCK AND UNLOCK SWITCH (a) Remove the outside handle. (b) Disconnect the connectors. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition 1-3 Lock switch not pushed (OFF) 10 kΩ or higher Lock switch pushed (ON) Below 1 Ω ON OFF B112465E08 INSTALLATION 1. INSTALL FRONT DOOR OUTSIDE HANDLE SUBASSEMBLY (a) Insert the front end of the front door outside handle assembly into the front door outside handle frame. B136423 (b) Insert the rear end of the front door outside handle assembly into the front door outside handle frame. Slide the front door outside handle assembly to the front of the vehicle to install it. (c) Connect the connector. 2. INSTALL FRONT DOOR OUTSIDE HANDLE COVER (See page ED-29) 3. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY (See page ED-31) 4. INSTALL FRONT DOOR SERVICE HOLE COVER (See page ED-32) 5. INSTALL FRONT DOOR TRIM BOARD SUBASSEMBLY (See page ED-33) 6. INSTALL COURTESY LIGHT ASSEMBLY (See page ED-34) 7. INSTALL ASSIST GRIP COVER (See page ED-34) 8. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG (See page ED-34) B136857 DL DL–244 DOOR LOCK – ENTRY LOCK AND UNLOCK SWITCH 9. DL INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH (See page ED-34) DOOR LOCK – LUGGAGE COMPARTMENT DOOR OPENER OUTER SWITCH DL–245 LUGGAGE COMPARTMENT DOOR OPENER OUTER SWITCH BODY ELECTRICAL DOOR LOCK COMPONENTS LUGGAGE COMPARTMENT DOOR COVER DL LUGGAGE DOOR OPENING SWITCH ASSEMBLY B137926E01 DL–246 DOOR LOCK – LUGGAGE COMPARTMENT DOOR OPENER OUTER SWITCH REMOVAL 1. REMOVE LUGGAGE COMPARTMENT DOOR COVER (See page ET-61) 2. REMOVE LUGGAGE DOOR OPENING SWITCH ASSEMBLY (a) Disconnect the connector. (b) Remove the 2 screws and the luggage door opening switch assembly. INSPECTION 1. INSPECT LUGGAGE KEY ELECTRICAL SWITCH (a) Disconnect the switch connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection 1-2 Pushed Free B137969E01 DL Condition Specified condition Luggage compartment open switch not pushed (OFF) 10 kΩ or higher Luggage compartment open switch pushed (ON) Below 1 Ω DOOR LOCK – LUGGAGE COMPARTMENT DOOR OPENER OUTER SWITCH DL–247 INSTALLATION 1. INSTALL LUGGAGE DOOR OPENING SWITCH ASSEMBLY (a) Install the luggage door opening switch assembly with the 2 screws. (b) Connect the connector. 2. INSTALL LUGGAGE COMPARTMENT DOOR COVER (See page ET-64) DL IG–1 2AZ-FE IGNITION – IGNITION SYSTEM IGNITION SYSTEM 2AZ-FE IGNITION ENGINE PARTS LOCATION ECM IGNITION COIL ASSEMBLY INSTRUMENT PANEL J/B -INJ FUSE SPARK PLUG IG A137459E01 IG–2 2AZ-FE IGNITION – IGNITION SYSTEM SYSTEM DIAGRAM C11 Ignition Coil (No. 1) 1 4 +B GND IGT1 IGF 3 ECM 85 C24 IGT1 2 C13 Ignition Coil (No. 2) 1 4 INJ +B GND IGT2 IGF 3 84 C24 IGT2 2 C12 Ignition Coil (No. 3) 1 4 From Ignition Switch +B GND IGT3 IGF 3 93 C24 IGT3 2 C14 Ignition Coil (No. 4) 1 C16 Noise Filter (Ignition RH) 1 4 +B GND IGT4 IGF 3 2 82 C24 IGT4 81 C24 IGF1 IG A137001 2AZ-FE IGNITION – IGNITION SYSTEM IG–3 ON-VEHICLE INSPECTION 1. 16 mm Spark Plug Wrench CHECK IGNITION COIL ASSEMBLY AND PERFORM SPARK TEST NOTICE: In this section, the terms "cold" and "hot" refer to the temperature of the coils. "Cold" means approximately -10 to 50°C (14 to 122°F). "Hot" means approximately 50 to 100°C (122 to 212°F). (a) Check for DTCs. NOTICE: If any DTC is present, perform troubleshooting in accordance with the procedure for that DTC. (b) Check that sparks occur. (1) Remove the No. 1 engine cover. (2) Disconnect the 4 ignition coil connectors and remove the 4 bolts and ignition coils. (3) Using a 16 mm (0.63 in.) spark plug wrench, remove the 4 spark plugs. A124849E01 (4) Disconnect the 4 fuel injector connectors. (5) Install the spark plug to each ignition coil, and connect the ignition coil connectors. A097448E01 A124396 (6) Ground the spark plug. (7) Check if a spark occurs at each spark plug while the engine is being cranked. NOTICE: • Be sure to ground the spark plugs when checking. • Replace the ignition coil if it receives an impact. • Do not crank the engine for more than 2 seconds. IG IG–4 2AZ-FE IGNITION – IGNITION SYSTEM (c) Perform the spark test according to the flowchart below. (1) Check that the ignition coil connector is securely connected. Result Result Proceed to NG Connect securely OK Go to next step (2) Perform the spark test on each ignition coil. 1. Replace the ignition coil with a normal one. 2. Perform the spark test again. Result Result Proceed to OK Replace ignition coil NG Go to next step (3) Check the power supply to the ignition coil. 1. Turn the ignition switch to the ON position. 2. Measure the voltage between the terminals of the wire harness side connector. Standard voltage Tester Connection Specified Condition 1 (+B) - 4 (GND) 9 to 14 V Result Result Proceed to NG Check wire harness and connector OK Go to next step (4) Measure the resistance of the camshaft position sensor. Standard resistance A124397 Temperature Specified Condition Cold 835 to 1,400 Ω Hot 1,060 to 1,645 Ω Result Result IG Proceed to NG Replace camshaft position sensor OK Go to next step (5) Measure the resistance of the crankshaft position sensor. Standard resistance Temperature Specified Condition Cold 985 to 1,600 Ω Hot 1,265 to 1,890 Ω Result Result Proceed to NG Replace crankshaft position sensor OK Go to next step IG–5 2AZ-FE IGNITION – IGNITION SYSTEM (6) Check the IGT signal from the ECM. Result Result Proceed to NG Check ECM (see page ES-188) OK Repair wiring between ignition coil and ECM (7) Using a 16 mm (0.63 in.) plug wrench, install the spark plug. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) (8) Install the 4 ignition coils with the 4 bolts and connect the 4 ignition coil connectors. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) (9) Connect the 4 fuel injector connectors. (10) Install the No. 1 engine cover. 2. Ground I039522E10 A126881 CHECK SPARK PLUG (a) Check the electrode. (1) Using a megohmmeter, measure the insulation resistance. Standard insulation resistance: 10 MΩ or more HINT: • If a megohmmeter is not available, perform the following simple inspection instead. • If the result is 10 MΩ or less, clean the plug and measure the resistance again. (b) Alternative inspection method: (1) Quickly accelerate the engine to 4,000 rpm 5 times. (2) Remove the spark plug. (3) Visually check the spark plug. If the electrode is dry, the spark plug is functioning properly. If the electrode is damp, proceed to the next step. (c) Check the spark plug for any damage to its threads and insulator. If there is damage, replace the spark plug. Recommended spark plug Manufacturer Spark plug type DENSO SK20R11 NGK IFR6A11 (d) Check the spark plug electrode gap. Maximum electrode gap for used spark plug: 1.3 mm (0.051 in.) If the gap is greater than the maximum, replace the spark plug. Electrode gap for new spark plug: 1.0 to 1.1 mm (0.039 to 0.043 in.) 1.0 to 1.1 mm A126880E01 IG IG–6 2AZ-FE IGNITION – IGNITION SYSTEM B062019E01 IG (e) Clean the spark plugs. If the electrode has traces of wet carbon, clean the electrode with a spark plug cleaner and then dry it. Standard air pressure: 588 kPa (6 kgf*cm2, 85 psi) Standard duration: 20 seconds or less HINT: Only use the spark plug cleaner when the electrode is free of oil. If the electrode has traces of oil, use gasoline to clean off the oil before using the spark plug cleaner. IG–7 2AZ-FE IGNITION – IGNITION COIL IGNITION COIL 2AZ-FE IGNITION ENGINE COMPONENTS 9.0 (92, 80 in.*lbf) x2 IGNITION COIL CONNECTOR NO. 1 ENGINE COVER 9.0 (92, 80 in.*lbf) IGNITION COIL ASSEMBLY IG N*m (kgf*cm, ft.*lbf) : Specified torque A124364E04 IG–8 2AZ-FE IGNITION – IGNITION COIL REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE NO. 1 ENGINE COVER (See page EM-94) 3. REMOVE IGNITION COIL ASSEMBLY (a) Disconnect the 4 ignition coil connectors. (b) Remove the 4 bolts and 4 ignition coils. A124400 INSTALLATION A124400 IG 1. INSTALL IGNITION COIL ASSEMBLY (a) Install the 4 ignition coils with the 4 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) (b) Connect the 4 ignition coil connectors. 2. INSTALL NO. 1 ENGINE COVER (See page EM-121) 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page EM-120) 2AZ-FE EMISSION CONTROL – EMISSION CONTROL SYSTEM EC–1 EMISSION CONTROL SYSTEM 2AZ-FE EMISSION CONTROL ENGINE PARTS LOCATION VENTILATION VALVE VACUUM SWITCHING VALVE EC CANISTER HEATED OXYGEN SENSOR AIR FUEL RATIO SENSOR FUEL TANK CAP A135646E03 EC–2 2AZ-FE EMISSION CONTROL – EMISSION CONTROL SYSTEM SYSTEM DIAGRAM For PZEV : ECM Air Cleaner Intake Manifold Soak Timer Air Filter Canister EVAP VSV Service Port Fuel Cap Pump Module Roll-over Valve EC Cut-off Valve Fuel Tank A128935E01 EC–3 2AZ-FE EMISSION CONTROL – EMISSION CONTROL SYSTEM Except PZEV : ECM Air Cleaner Intake Manifold Soak Timer Air Filter Canister EVAP VSV Service Port Fuel Cap Pump Module Roll-over Valve Cut-off Valve EC Fuel Tank A128936E01 EC–4 2AZ-FE EMISSION CONTROL – EMISSION CONTROL SYSTEM N17 Canister Pump Module ECM MGND 6 34 A24 MTRB 1 Leak Detection Pump 70 C24 VCPP VCC Canister Pressure Sensor 4 71 C24 PPMP VOUT 3 94 C24 EPPM SGND 2 Vent Valve VLVB 42 A24 VPMP VGND 9 8 C6 VSV (Purge) EC 1 2 C22 Heated Oxgen Sensor 2 +B E2 4 EFI No. 3 C15 Air Fuel Ratio Sensor 1 HT1B OX1B 3 49 C24 PRG 87 C24 EX1B 64 C24 OX1B 47 C24 HT1B EFI EFI-MAIN 2 From Battery 1 +B HA1A A1AA1A+ 4 3 113 C24 A1A112 C24 A1A+ 109 C24 HA1A 44 A24 MREL A135723E01 EC–5 2AZ-FE EMISSION CONTROL – EMISSION CONTROL SYSTEM ON-VEHICLE INSPECTION 1. VISUALLY INSPECT HOSE, CONNECTIONS AND GASKETS (a) Check that there are no cracks, leaks or damage. HINT: • Detachment or other problems with the engine oil dipstick, filler cap, PCV hose and other components may cause the engine to run improperly. • Disconnection, looseness or cracks in the parts of the air induction system between the throttle body and cylinder head will allow air suction and cause an engine failure or engine malfunctions. If the result is not as specified, replace the parts as necessary. 2. INSPECT FUEL CUT RPM (a) Start and warm up the engine. (b) Open the throttle valve and keep the engine speed at 3,000 rpm. (c) Use a sound scope to check for injector operating sounds. (d) Check that when the accelerator pedal is released, injector operating sounds stop momentarily (at 2,500 rpm) and then resume (at 1400 rpm). Standard B000412 Item Specified condition Fuel cut off rpm 2,500 rpm Fuel return rpm 1,400 rpm If the result is not specified, check the injectors, wiring and ECM. A128092 3. INSPECT LINE AND CONNECTORS (a) Visually check for loose connections, sharp bends or damage. 4. CHECK AIR TIGHTNESS IN FUEL TANK AND FILLER PIPE (a) Disconnect the vent line hose from the fuel tank. (b) Connect the pressure gauge to the fuel tank. (c) Apply pressure to the fuel tank to create an internal pressure of 4 kPa (41 gf/cm2, 0.58 psi). (d) Check that the internal pressure of the fuel tank is maintained for 1 minute. (e) Check the connected portions of each hose and pipe. (f) Check the installed parts on the fuel tank. If any malfunctions, damage or other problems are found, replace the fuel tank and filler pipe. (g) Reconnect the vent line hose to the fuel tank. EC EC–6 2AZ-FE EMISSION CONTROL – EMISSION CONTROL SYSTEM 5. REMOVE FUEL TANK ASSEMBLY (a) Disconnect the vent line hose from the fuel tank. (b) Connect the pressure gauge to the fuel tank. (c) Fill the fuel tank with fuel. (d) Apply pressure of 4 kPa (41 gf/cm2, 0.58 psi) to the vent port of the fuel tank. HINT: Check the amount of fuel in the fuel tank. When the fuel tank is full, the float valve of the fill check valve is closed and no air can pass through. (e) Remove the fuel tank cap, and check that the pressure drops. If the pressure does not drop, replace the fuel tank assembly. (f) Reconnect the vent line hose to the fuel tank. 6. REMOVE AIR INLET LINE (a) Disconnect the air inlet line hose from the charcoal canister. (b) Check that air can flow freely into the air inlet line. If air cannot flow freely into the air inlet line, repair or replace it. (c) Reconnect the air inlet line hose to the charcoal canister. Fuel Tank Cap A126204E01 EC Air Inlet Hose Air A128093E02 2AZ-FE EMISSION CONTROL – CANISTER EC–7 CANISTER 2AZ-FE EMISSION CONTROL ENGINE COMPONENTS for PZEV: EC CHARCOAL CANISTER ASSEMBLY 39 (398, 29) N*m (kgf*cm, ft.*lbf) : Specified torque A135649E03 EC–8 2AZ-FE EMISSION CONTROL – CANISTER except PZEV: EC CHARCOAL CANISTER ASSEMBLY 39 (398, 29) N*m (kgf*cm, ft.*lbf) : Specified torque A135648E06 2AZ-FE EMISSION CONTROL – CANISTER EC–9 REMOVAL 1. REMOVE FUEL TANK ASSEMBLY HINT: (See page FU-34) 2. REMOVE CHARCOAL CANISTER ASSEMBLY (a) Disconnect the fuel tank vent hose from the charcoal canister. (1) Push the connector deep inside. (2) Pinch portion A. (3) Pull out the connector. Pinch A A Pinch A Push A A132954E01 (b) Disconnect the charcoal canister filter sub-assembly from the charcoal canister. (1) Push the connector deep inside. (2) Pinch portion A. (3) Pull out the connector. (c) Disconnect the vapor pressure sensor connector. (d) Disconnect the wire harness clamp. (e) Disconnect the purge line hose from the charcoal canister. A Pinch A Pinch Push A128095E01 (f) Remove the 2 bolts, clip and charcoal canister. A128096 INSPECTION 1. A112883E01 INSPECT CHARCOAL CANISTER ASSEMBLY (a) Visually check the charcoal canister for cracks or damage. If cracks or damage are found, replace the charcoal canister assembly. EC EC–10 2AZ-FE EMISSION CONTROL – CANISTER (b) Check charcoal canister operation. (1) With the purge port closed, blow 1.10 kPa (11.2 gf/cm2, 0.16 psi) of air into the vent port, and check that air flows from the air inlet port. If the result is not as specified, replace the charcoal canister assembly. Air Vent Port Air Inlet Port Purge Port A111044E02 Purge Port Air Inlet Port Air (2) With the vent port closed, blow 1.10 kPa (11.2 gf/cm2, 0.16 psi) of air into the air inlet port, and check that air flows from the purge port. If the result is not as specified, replace the charcoal canister assembly. Vent Port A111043E02 EC Purge Port Air Inlet Port (c) Check for air leakage. (1) With the purge port and air inlet port closed, apply 19.6 kPa (0.2 kgf/cm2, 2.81 psi) of pressurized air into the vent port, then confirm that pressure is retained for 1 minute. If the result is not as specified, replace the charcoal canister assembly. Pressure Gauge Vent Port SST A111042E02 (d) Check the leak detection pump. (1) Remove the detection pump from the charcoal canister. (2) Check that air flows from port A to B. If the result is not as specified, replace the charcoal canister assembly. A Air B A112886E01 2AZ-FE EMISSION CONTROL – CANISTER Valve 7 EC–11 (3) Connect the positive (+) lead of the battery to terminal 7 and the negative (-) lead to terminal 6. (4) Check that the valve is closed. If the result is not as specified, replace the charcoal canister assembly. (5) Install the detection pump. Closed 6 A111047E01 INSTALLATION 1. INSTALL CHARCOAL CANISTER ASSEMBLY (a) Install the 2 bolts, clip and charcoal canister. Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf) (b) Connect the purge line hose to the charcoal canister. (c) Connect the wire harness clamp. (d) Connect the vapor pressure sensor connector. (e) Connect the charcoal canister filter sub-assembly to the charcoal canister. (f) Connect the fuel tank vent hose to the charcoal canister. 2. INSTALL FUEL TANK ASSEMBLY HINT: (See page FU-39) 3. CHECK FOR EXHAUST GAS LEAKS A128096 EC EC–12 2AZ-FE EMISSION CONTROL – VACUUM SWITCHING VALVE VACUUM SWITCHING VALVE 2AZ-FE EMISSION CONTROL ENGINE COMPONENTS VACUUM SWITCHING VALVE CONNECTOR VACUUM SWITCHING VALVE PURGE LINE HOSE PURGE LINE HOSE EC A135652E03 EC–13 2AZ-FE EMISSION CONTROL – VACUUM SWITCHING VALVE REMOVAL 1. REMOVE VACUUM SWITCHING VALVE (a) Disconnect the vacuum switching valve connector. (b) Disconnect the wire harness clamp. (c) Disconnect the 2 purge line hoses from the purge VSV. (d) Remove the vacuum switching valve. A135666 INSPECTION 1. 23 to 26 Ω 1 INSPECT VACUUM SWITCHING VALVE (a) Measure the resistance of the purge VSV. Standard resistance Tester Connection Specified Condition 1-2 23 to 26 Ω at 20°C (68°F) 1 - Body ground 2 - Body ground 10 MΩ or higher If the result is not as specified, replace the purge VSV. 2 10 MΩ or higher EC A124791E01 (b) Check the operation of the purge VSV. (1) Check that air does not flow from port E to port F. F E Air A124792E01 (2) Apply battery voltage across the terminals. (3) Check that air flows from port E to port F. If the result is not as specified, replace the purge VSV. F E Air A124793E01 EC–14 2AZ-FE EMISSION CONTROL – VACUUM SWITCHING VALVE INSTALLATION 1. REMOVE VACUUM SWITCHING VALVE (a) Install the vacuum switching valve onto the air cleaner hose. (b) Connect the 2 purge line hoses to the vacuum switching valve. (c) Connect the vacuum switching valve connector. A135666 EC 2AZ-FE EMISSION CONTROL – VENTILATION VALVE EC–15 VENTILATION VALVE 2AZ-FE EMISSION CONTROL ENGINE COMPONENTS 7.0 (71, 62 in.*lbf) NO. 1 ENGINE COVER SUB-ASSEMBLY VENTILATION VALVE SUB-ASSEMBLY VENTILATION HOSE EC N*m (kgf*cm, ft.*lbf) : Specified torque Precoated part A135650E03 EC–16 2AZ-FE EMISSION CONTROL – VENTILATION VALVE REMOVAL 1. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY 2. REMOVE VENTILATION VALVE SUB-ASSEMBLY (a) Disconnect the ventilation hose from the ventilation valve sub-assmbly. A097786E01 (b) Using a 22 mm deep socket wrench, remove the ventilation valve sub-assembly. 22 mm Deep Socket Wrench EC A098067E01 INSPECTION Cylinder Head Side 1. Clean Hose A059511E02 INSPECT VENTILATION VALVE SUB-ASSEMBLY (a) Install a clean hose to the ventilation valve. (b) Inspect the ventilation valve operation. (1) Blow air into the cylinder head side, and check that air passes through easily. NOTICE: Do not suck air through the valve. Petroleum substances inside the valve are hazardous to your health. (2) Blow air into the intake manifold side, and check that air passes through with difficulty. If the result is not as specified, replace the ventilation valve. (c) Remove the clean hose from the ventilation valve. Intake Manifold Side Clean Hose A059512E11 2AZ-FE EMISSION CONTROL – VENTILATION VALVE EC–17 INSTALLATION Adhesive 1. INSTALL VENTILATION VALVE SUB-ASSEMBLY (a) Apply adhesive to 2 or 3 threads of the ventilation valve. Adhesive: Toyota genuine adhesive 1324, three bond 1324 or equivalent A092670E03 (b) Using a 22 mm deep socket wrench, install the ventilation valve. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) (c) Connect the ventilation hose. 22 mm Deep Socket Wrench 2. INSTALL ENGINE COVER SUB-ASSEMBLY 3. CHECK FOR ENGINE OIL LEAKS A098067E01 EC EC–18 2AZ-FE EMISSION CONTROL – AIR FUEL RATIO SENSOR AIR FUEL RATIO SENSOR 2AZ-FE EMISSION CONTROL ENGINE COMPONENTS except PZEV : EC x4 12 (122, 9) 44 (449, 33) NO. 1 EXHAUST MANIFOLD HEAT INSULATOR AIR FUEL RATIO SENSOR N*m (kgf*cm, ft.*lbf) : Specified torque A135654E03 2AZ-FE EMISSION CONTROL – AIR FUEL RATIO SENSOR EC–19 for PZEV : 44 (449, 33) AIR FUEL RATIO SENSOR EC N*m (kgf*cm, ft.*lbf) : Specified torque A132950E02 EC–20 2AZ-FE EMISSION CONTROL – AIR FUEL RATIO SENSOR REMOVAL 1. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (except PZEV) (a) Remove the 4 bolts and No. 1 exhaust manifold heat insulator. 2. REMOVE AIR FUEL RATIO SENSOR (except PZEV) (a) Disconnect the air fuel ratio sensor connector and clamp. A135682 A135681E01 (b) Using SST, remove the air fuel ratio sensor from the exhaust manifold converter sub-assembly No. 2. SST 09224-00010 NOTICE: Do not damage the air fuel ratio sensor. EC SST A135683E01 3. REMOVE AIR FUEL RATIO SENSOR (for PZEV) (a) Disconnect the air fuel ratio sensor connector. A135685E01 (b) Using SST, remove the air fuel ratio sensor. SST 09224-00010 NOTICE: Do not damage the air fuel ratio sensor. SST A135686E01 EC–21 2AZ-FE EMISSION CONTROL – AIR FUEL RATIO SENSOR INSPECTION +B 1. HT AF- INSPECT AIR FUEL RATIO SENSOR (a) Using an ohmmeter, measure the resistance between terminals 1 (HT) and 2 (+B). Standard resistance Condition Specified Condition 20°C (68°F) 1.8 to 3.4 Ω AF+ If the result is not as specified, replace the sensor. A075325E01 INSTALLATION 1. SST INSTALL AIR FUEL RATIO SENSOR (for PZEV) (a) Temporarily tighten the air fuel ratio sensor. NOTICE: Do not damage the air fuel ratio sensor. (b) Using SST, fully tighten the air fuel ratio sensor. SST 09224-00010 Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf) A135687E01 (c) Connect the air fuel ratio sensor connector and clamp. 2. INSTALL AIR FUEL RATIO SENSOR (except PZEV) (a) Temporarily tighten the air fuel ratio sensor. NOTICE: Do not damage the air fuel ratio sensor. A135685E01 (b) Using SST, fully tighten the air fuel ratio sensor. SST 09224-00010 Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf) SST A135684E01 (c) Connect the air fuel ratio sensor connector and clamp. A135681E01 EC EC–22 2AZ-FE EMISSION CONTROL – AIR FUEL RATIO SENSOR 3. A135682 EC INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (except PZEV) (a) Install the exhaust manifold heat insulator with the 4 bolts. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 2AZ-FE EMISSION CONTROL – HEATED OXYGEN SENSOR EC–23 HEATED OXYGEN SENSOR 2AZ-FE EMISSION CONTROL ENGINE COMPONENTS EC HEATED OXYGEN SENSOR 44 (449, 33) N*m (kgf*cm, ft.*lbf) : Specified torque A135656E02 EC–24 2AZ-FE EMISSION CONTROL – HEATED OXYGEN SENSOR REMOVAL 1. REMOVE HEATED OXYGEN SENSOR (a) Disconnect the heated oxygen sensor connector. A135678E01 (b) Using SST, remove the heated oxygen sensor from the exhaust pipe assembly front No. 3. SST 09224-00010 NOTICE: Do not damage the heated oxygen sensor. SST A135679E01 INSPECTION EC +B HT 1. A104021E01 INSPECT HEATED OXYGEN SENSOR (a) Measure the resistance between terminals 1 (HT) and 2 (+B). Standard resistance Condition Specified Condition 20°C (68°F) 11 to 16 Ω If the resistance is not as specified, replace the sensor. 2AZ-FE EMISSION CONTROL – HEATED OXYGEN SENSOR EC–25 INSTALLATION 1. INSTALL HEATED OXYGEN SENSOR (a) Temporarily tighten the heated oxygen sensor. NOTICE: Do not damage the heated oxygen sensor. (b) Using SST, fully tighten the heated oxygen sensor. SST 09224-00010 Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf) SST A135680E01 (c) Connect the heated oxygen sensor connector. EC A135678E01 2AZ-FE ENGINE MECHANICAL – ENGINE EM–1 ENGINE INSPECTION 1. INSPECT ENGINE COOLANT (a) Inspect the engine coolant (See page CO-1). 2. INSPECT ENGINE OIL (a) Inspect the engine oil (See page LU-1). 3. INSPECT BATTERY (a) Inspect the battery (See page CH-4). 4. INSPECT SPARK PLUGS (a) Inspect the spark plugs (See page IG-5). 5. INSPECT AIR CLEANER FILTER ELEMENT SUBASSEMBLY (a) Remove the air cleaner filter element sub-assembly. (b) Visually check that there is no dirt, blockage, and/or damage to the air cleaner filter element. HINT: • If there is any dirt or a blockage in the air cleaner filter element, clean it with compressed air. • If any dirt or a blockage remains even after cleaning the air cleaner filter element with compressed air, replace it. 6. Intelligent Tester CAN VIM DLC3 C110200E02 DLC3 CG 1 2 3 4 5 6 7 8 9 10 111213 14 1516 TC A082779E69 INSPECT IGNITION TIMING (a) Warm up the engine. (b) When using the intelligent tester: Check the ignition timing. (1) Connect the intelligent tester to the DLC3. (2) Enter DATA LIST MODE on the intelligent tester. Ignition timing: 8 to 12° BTDC at idle HINT: Refer to the intelligent tester operator's manual for help when selecting the DATA LIST. (c) When not using the intelligent tester: Check the ignition timing. (1) Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3. SST 09843-18040 NOTICE: • Confirm the terminal numbers before connecting them. Connection with a wrong terminal can damage the engine. • Turn off all electrical systems before connecting the terminals. • Perform this inspection after the cooling fan motor is turned off. EM EM–2 2AZ-FE ENGINE MECHANICAL – ENGINE (2) Remove the No. 1 engine cover. (3) Pull out the wire harness as shown in the illustration. Connect the clip of the timing light to the wire harness. NOTICE: • Use a timing light which can detect the first signal. • After checking, be sure to tape the wire harness. (4) Check the ignition timing at idle. Ignition timing: 8 to 12° BTDC at idle NOTICE: When checking the ignition timing, the transmission should be in neutral. HINT: After engine rpm is kept at 1,000 to 1,300 rpm for 5 seconds, check that it returns to idle speed. (5) Disconnect terminals 13 (TC) and 4 (CG) of the DLC3. (6) Check the ignition timing at idle. Ignition timing: 5 to 15° BTDC at idle (7) Confirm that the ignition timing moves to the advanced angle side when the engine rpm is increased. (8) Remove the timing light. A052004 EM 7. Intelligent Tester DLC3 CAN VIM C110200E02 INSPECT ENGINE IDLE SPEED (a) Warm up the engine. (b) When using the intelligent tester: Check the idle speed. (1) Connect the intelligent tester to the DLC3. HINT: Refer to the intelligent tester operator's manual for further details. (2) Enter DATA LIST MODE on the intelligent tester. Idle speed Item Specified Condition M/T 650 to 750 rpm A/T 610 to 710 rpm NOTICE: • When checking the idle speed, the transmission should be in neutral. • Check the idle speed with the cooling fan off. • Switch off all accessories and air conditioning before connecting the intelligent tester. EM–3 2AZ-FE ENGINE MECHANICAL – ENGINE (c) When not using the intelligent tester: Check the idle speed. (1) Using SST, connect the tachometer tester probe to terminal 9 (TAC) of the DLC3. SST 09843-18030 (2) Check the idle speed. Idle speed DLC3 1 2 3 4 5 6 7 8 9 10 1112131415 16 TAC A082779E70 8. Item Specified Condition M/T 650 to 750 rpm A/T 610 to 710 rpm INSPECT COMPRESSION (a) Warm up and stop the engine. (b) Disconnect the injector connectors. (c) Remove the ignition coils. (d) Remove the spark plugs. (e) Check the cylinder compression pressure. (1) Insert a compression gauge into the spark plug hole. (2) Fully open the throttle. (3) While cranking the engine, measure the compression pressure. Compression pressure: 1.360 MPa (13.9 kgf/ cm2, 198 psi) Minimum pressure: 0.98 MPa (10 kgf/ cm2, 142 psi) Difference between each cylinder: 100 kPa (1.0 kgf/ cm2, 14 psi) NOTICE: • Always use a fully charged battery to obtain an engine speed of 250 rpm or more. • Check the other cylinders' compression pressure in the same way. • This measurement must be done as quickly as possible. (4) If the cylinder compression is low, pour a small amount of engine oil into the cylinder through the spark plug hole and inspect again. HINT: • If adding oil increases the compression, the piston rings and/or cylinder bore may be worn or damaged. • If pressure stays low, a valve may be stuck or seated improperly, or there may be leakage in the gasket. A001037 9. INSPECT CO/HC (a) Start the engine. (b) Run the engine at 2,500 rpm for approximately 180 seconds. (c) Insert the CO/HC meter testing probe at least 40 cm (1.3 ft) into the tailpipe during idling. EM EM–4 2AZ-FE ENGINE MECHANICAL – ENGINE (d) Immediately check CO/HC concentration at idle and/or 2,500 rpm. HINT: • Complete the measuring within 3 minutes. • Check regulations and restrictions in your area when performing 2 mode CO/HC concentration testing (engine check at both idle speed and at 2,500 rpm). (e) If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below. (1) Check A/F sensor and heated oxygen sensor operation (See page EC-21). (2) See the table below for possible causes, and then inspect and repair. CO EM Normal Low High HC High High High Problems Causes Rough idle 1. Faulty ignitions: – Incorrect timing – Fouled, shorted or improperly gapped plugs 2. Incorrect valve clearance 3. Leaky intake and exhaust valves 4. Leaky cylinders Rough idle (fluctuating HC reading) 1. Vacuum leaks: – PCV hoses – Intake manifold – Throttle body – Brake booster line 2. Lean mixture causing misfire Rough idle (black smoke from exhaust) 1. Restricted air filter 2. Plugged PCV valve 3. Faulty SFI system: – Faulty pressure regulator – Defective ECT – Defective MAF meter – Faulty ECM – Faulty injectors – Faulty throttle position sensor 2AZ-FE ENGINE MECHANICAL – DRIVE BELT EM–5 DRIVE BELT 2AZ-FE ENGINE MECHANICAL ENGINE COMPONENTS V-RIBBED BELT FRONT FENDER APRON SEAL RH EM ENGINE UNDER COVER RH A134946E01 EM–6 2AZ-FE ENGINE MECHANICAL – DRIVE BELT REMOVAL 19 mm Socket Wrench 1. REMOVE FRONT WHEEL RH 2. REMOVE ENGINE UNDER COVER RH 3. REMOVE FRONT FENDER APRON SEAL RH 4. REMOVE V-RIBBED BELT (a) Using SST and 19 mm socket wrench, loosen the Vribbed belt tensioner arm clockwise, then remove the V-ribbed belt. SST 09216-42010 NOTICE: • Be sure to connect SST and the tools so that they are in line during use. • When retracting the tensioner, turn it clockwise slowly for 3 seconds or more. Do not apply force rapidly. • After the tensioner is fully retracted, do not apply force any more than necessary. SST A114351E03 EM INSPECTION REPLACE CORRECT 1. INSPECT V-RIBBED BELT (a) Visually check the V-ribbed belt for excessive wear, frayed cords, etc. If any defect has been found, replace the V-ribbed belt. HINT: • Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it should be replaced. • A "new belt" is a belt which has been used for less than 5 minutes with the engine running. • A "used belt" is a belt which has been used for 5 minutes or more with the engine running. INCORRECT A131418E01 19 mm Socket Wrench SST A114351E03 INSTALLATION 1. INSTALL V-RIBBED BELT (a) Using SST and 19 mm socket wrench, loosen the Vribbed belt tensioner arm clockwise, then install the V-ribbed belt. SST 09216-42010 NOTICE: • Be sure to connect SST and the tools so that they are in line during use. • When retracting the tensioner, turn it clockwise slowly for 3 seconds or more. Do not apply force rapidly. 2AZ-FE ENGINE MECHANICAL – DRIVE BELT EM–7 • After the tensioner is fully retracted, do not apply force any more than necessary. (b) After installing the V-ribbed belt, check that it fits properly in the ribbed grooves. Check to confirm that the belt has not slipped out of the grooves on the bottom of the crank pulley by hand. 2. INSTALL FRONT FENDER APRON SEAL RH 3. INSTALL ENGINE UNDER COVER RH 4. INSTALL FRONT WHEEL RH Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) EM EM–8 2AZ-FE ENGINE MECHANICAL – VALVE CLEARANCE VALVE CLEARANCE ADJUSTMENT EM Timing Mark 1. REMOVE FRONT WHEEL RH 2. REMOVE ENGINE UNDER COVER LH 3. REMOVE ENGINE UNDER COVER RH 4. REMOVE FRONT FENDER APRON SUB-ASSEMBLY RH 5. REMOVE NO. 1 ENGINE COVER (See page EM-94) 6. REMOVE IGNITION COIL ASSEMBLY (See page EM106) 7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (See page EM-21) 8. SET NO. 1 CYLINDER TO TDC/COMPRESSION (a) Turn the crankshaft pulley until its groove and the timing mark "0" of the timing chain cover are aligned. (b) Check that each timing mark of the camshaft timing gear and sprocket is aligned with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration. If not, turn the crankshaft by 1 revolution (360°) to align the timing marks as above. 9. CHECK VALVE CLEARANCE (a) Check only the valves indicated. (1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Standard valve clearance (cold) Timing Mark Groove A098345E09 No. 1 Cylinder TDC/Compression IN Item EX A098170E04 Standard Condition Intake 0.19 to 0.29 mm (0.0075 to 0.0114 in.) Exhaust 0.38 to 0.48 mm (0.0150 to 0.0189 in.) (2) Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve clearance lifters. (b) Turn the crankshaft 1 revolution (360°) and set the No. 4 cylinder to the TDC/compression. 2AZ-FE ENGINE MECHANICAL – VALVE CLEARANCE EM–9 (c) Check only the valves indicated. (1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Standard valve clearance (cold) No. 4 Cylinder TDC/Compression IN EX Item Standard Condition Intake 0.19 to 0.29 mm (0.0075 to 0.0114 in.) Exhaust 0.38 to 0.48 mm (0.0150 to 0.0189 in.) (2) Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifters. A098171E04 10. ADJUST VALVE CLEARANCE (a) Remove the No. 2 camshaft (see page EM-38). (b) Remove the camshaft (see page EM-38). (c) Remove the valve lifters. (d) Using a micrometer, measure the thickness of the removed valve lifters. (e) Calculate the thickness of a new lifter so that the valve clearance comes within the specified values. New lifter thickness A001082E01 Item Specification Intake A = B + (C - 0.24 mm (0.0095 in.)) Exhaust A = B + (C - 0.43 mm (0.0169 in.)) A New lifter thickness B Used lifter thickness C Measured valve clearance CALCULATION EXAMPLE (Intake): 1. Measured intake valve clearance = 0.40 mm (0.0158 in.) (Measured - Specification = Excess clearance) (a)0.40 mm (0.0158 in.) - 0.24 mm (0.0095 in.) = 0.16 mm (0.0063 in.) 2. Measured used lifter measurement = 5.250 mm (0.2067 in.) 3. New lifter thickness = 5.410 mm (0.2130 in.) (Excess clearance + Used lifter thickness = Ideal new lifter) (a)0.16 mm (0.0063 in.) + 5.250 mm (0.2067 in.) = 5.410 mm (0.2130 in.) 4. Closest new lifter = 5.420 mm (0.2134 in.) – Select No. 42 lifter EM EM–10 2AZ-FE ENGINE MECHANICAL – VALVE CLEARANCE (f) 42 A126901E01 EM Select a new lifter with a thickness as close as possible to the calculated values. HINT: • Lifters are available in 35 sizes in increments of 0.020 mm (0.0008 in.), from 5.060 to 5.740 mm (0.1992 to 0.2260 in.). • The identification number inside the valve lifters shows the value to 2 decimal places. (The illustration shows 5.420 mm (0.2134 in.) EM–11 2AZ-FE ENGINE MECHANICAL – VALVE CLEARANCE Measured clearance mm (in.) Installed lifter thickness mm (in.) ) 5.060 (0.1992) 5.080 (0.2000) 5.100 (0.2008) 5.120 (0.2016) 5.140 (0.2024) 5.160 (0.2031) 5.180 (0.2039) 5.200 (0.2047) 5.210 (0.2051) 5.220 (0.2055) 5.230 (0.2059) 5.240 (0.2063) 5.250 (0.2067) 5.260 (0.2071) 5.270 (0.2075) 5.280 (0.2079) 5.290 (0.2083) 5.300 (0.2087) 5.310 (0.2091) 5.320 (0.2094) 5.330 (0.2098) 5.340 (0.2102) 5.350 (0.2106) 5.360 (0.2110) 5.370 (0.2114) 5.380 (0.2118) 5.390 (0.2122) 5.400 (0.2126) 5.410 (0.2130) 5.420 (0.2134) 5.430 (0.2138) 5.440 (0.2142) 5.450 (0.2146) 5.460 (0.2150) 5.470 (0.2154) 5.480 (0.2157) 5.490 (0.2161) 5.500 (0.2165) 5.510 (0.2169) 5.520 (0.2173) 5.530 (0.2177) 5.540 (0.2181) 5.550 (0.2185) 5.560 (0.2189) 5.570 (0.2193) 5.580 (0.2197) 5.590 (0.2201) 5.600 (0.2205) 5.620 (0.2213) 5.640 (0.2220) 5.660 (0.2228) 5.680 (0.2236) 5.700 (0.2244) 5.720 (0.2252) 5.740 (0.2260) 0.000 - 0.030 (0.0000 - 0.0012) 0.031 - 0.050 (0.0012 - 0.0020) 0.051 - 0.070 (0.0020 - 0.0028) 0.071 - 0.090 (0.0028 - 0.0035) 0.091 - 0.110 (0.0036 - 0.0043) 0.111 - 0.130 (0.0044 - 0.0051) 0.131 - 0.150 (0.0052 - 0.0059) 0.151 - 0.170 (0.0059 - 0.0067) 0.171 - 0.189 (0.0067 - 0.0074) 0.190 - 0.290 (0.0075 - 0.0114) 0.291 - 0.310 (0.0115 - 0.0122) 0.311 - 0.330 (0.0122 - 0.0130) 0.331 - 0.350 (0.0130 - 0.0138) 0.351 - 0.370 (0.0138 - 0.0146) 0.371 - 0.390 (0.0146 - 0.0154) 0.391 - 0.410 (0.0154 - 0.0161) 0.411 - 0.430 (0.0162 - 0.0169) 0.431 - 0.450 (0.0170 - 0.0177) 0.451 - 0.470 (0.0178 - 0.0185) 0.471 - 0.490 (0.0185 - 0.0193) 0.491 - 0.510 (0.0193 - 0.0201) 0.511 - 0.530 (0.0201 - 0.0209) 0.531 - 0.550 (0.0209 - 0.0217) 0.551 - 0.570 (0.0217 - 0.0224) 0.571 - 0.590 (0.0225 - 0.0232) 0.591 - 0.610 (0.0233 - 0.0240) 0.611 - 0.630 (0.0241 - 0.0248) 0.631 - 0.650 (0.0248 - 0.0256) 0.651 - 0.670 (0.0256 - 0.0264) 0.671 - 0.690 (0.0264 - 0.0272) 0.691 - 0.710 (0.0272 - 0.0280) 0.711 - 0.730 (0.0280 - 0.0287) 0.731 - 0.750 (0.0288 - 0.0295) 0.751 - 0.770 (0.0296 - 0.0303) 0.771 - 0.790 (0.0304 - 0.0311) 0.791 - 0.810 (0.0311 - 0.0319) 0.811 - 0.830 (0.0319 - 0.0327) 0.831 - 0.850 (0.0327 - 0.0335) 0.851 - 0.870 (0.0335 - 0.0343) 0.871 - 0.890 (0.0343 - 0.0350) 0.891 - 0.910 (0.0351 - 0.0358) 0.911 - 0.930 (0.0359 - 0.0366) (g) Valve lifter selection chart (intake). 06 06 08 06 08 10 06 08 10 12 06 08 10 12 14 06 08 10 12 14 16 06 08 10 12 14 16 18 06 08 10 12 14 16 18 20 06 08 10 12 14 16 18 20 06 08 10 12 14 16 18 20 08 10 12 14 16 18 20 22 06 08 10 12 14 16 18 20 22 06 10 12 14 16 18 20 22 24 08 10 12 14 16 18 20 22 24 08 12 14 16 18 20 22 24 26 10 12 14 16 18 20 22 24 26 10 14 16 18 20 22 24 26 28 12 14 16 18 20 22 24 26 28 12 16 18 20 22 24 26 28 30 14 16 18 20 22 24 26 28 30 14 18 20 22 24 26 28 30 32 16 18 20 22 24 26 28 30 32 16 20 22 24 26 28 30 32 34 18 20 22 24 26 28 30 32 34 18 22 24 26 28 30 32 34 36 20 22 24 26 28 30 32 34 36 20 24 26 28 30 32 34 36 38 22 24 26 28 30 32 34 36 38 22 26 28 30 32 34 36 38 40 24 26 28 30 32 34 36 38 40 24 28 30 32 34 36 38 40 42 26 28 30 32 34 36 38 40 42 26 30 32 34 36 38 40 42 44 28 30 32 34 36 38 40 42 44 28 32 34 36 38 40 42 44 46 30 32 34 36 38 40 42 44 46 30 34 36 38 40 42 44 46 48 32 34 36 38 40 42 44 46 48 32 36 38 40 42 44 46 48 50 34 36 38 40 42 44 46 48 50 34 38 40 42 44 46 48 50 52 36 38 40 42 44 46 48 50 52 36 40 42 44 46 48 50 52 54 38 40 42 44 46 48 50 52 54 38 42 44 46 48 50 52 54 56 40 42 44 46 48 50 52 54 56 40 44 46 48 50 52 54 56 58 42 46 48 50 52 54 56 58 60 44 48 50 52 54 56 58 60 62 46 50 52 54 56 58 60 62 64 48 52 54 56 58 60 62 64 66 50 54 56 58 60 62 64 66 68 52 56 58 60 62 64 66 68 70 54 58 60 62 64 66 68 70 72 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 50 52 54 56 58 60 62 64 66 68 70 72 74 74 50 52 54 56 58 60 62 64 66 68 70 72 74 74 52 54 56 58 60 62 64 66 68 70 72 74 74 52 54 56 58 60 62 64 66 68 70 72 74 74 54 56 58 60 62 64 66 68 70 72 74 74 54 56 58 60 62 64 66 68 70 72 74 74 56 58 60 62 64 66 68 70 72 74 74 56 58 60 62 64 66 68 70 72 74 74 58 60 62 64 66 68 70 72 74 74 58 60 62 64 66 68 70 72 74 74 60 62 64 66 68 70 72 74 74 60 62 64 66 68 70 72 74 74 62 64 66 68 70 72 74 74 62 64 66 68 70 72 74 74 64 66 68 70 72 74 74 64 66 68 70 72 74 74 66 68 70 72 74 74 66 68 70 72 74 74 68 70 72 74 74 70 72 74 74 74 72 74 74 74 74 74 74 74 74 74 EM A126931E02 New lifter thickness Lifter No. Thickness mm (in.) Lifter No. Thickness mm (in.) Lifter No. Thickness mm (in.) 06 5.060 (0.1992) 30 5.300 (0.2087) 54 5.540 (0.2181) EM–12 EM 2AZ-FE ENGINE MECHANICAL – VALVE CLEARANCE Lifter No. Thickness mm (in.) Lifter No. Thickness mm (in.) Lifter No. Thickness mm (in.) 08 5.080 (0.2000) 32 5.320 (0.2094) 56 5.560 (0.2189) 10 5.100 (0.2008) 34 5.340 (0.2102) 58 5.580 (0.2197) 12 5.120 (0.2016) 36 5.360 (0.2110) 60 5.600 (0.2205) 14 5.140 (0.2024) 38 5.380 (0.2118) 62 5.620 (0.2213) 16 5.160 (0.2031) 40 5.400 (0.2126) 64 5.640 (0.2220) 18 5.180 (0.2039) 42 5.420 (0.2134) 66 5.660 (0.2228) 20 5.200 (0.2047) 44 5.440 (0.2142) 68 5.680 (0.2236) 22 5.220 (0.2055) 46 5.460 (0.2150) 70 5.700 (0.2244) 24 5.240 (0.2063) 48 5.480 (0.2157) 72 5.720 (0.2252) 26 5.260 (0.2071) 50 5.500 (0.2165) 74 5.740 (0.2260) 28 5.280 (0.2079) 52 5.520 (0.2173) - - Standard intake valve clearance (cold): 0.19 to 0.29 mm (0.0075 to 0.0114 in.) EXAMPLE: The 5.250 mm (0.2067 in.) lifter is installed, and the measured clearance is 0.400 mm (0.0157 in.). Replace the 5.250 mm (0.2067 in.) lifter with a new No. 42 lifter. EM–13 2AZ-FE ENGINE MECHANICAL – VALVE CLEARANCE Measured clearance clearance Measured mm (in.) mm (in.) Installed lifter thickness Installed lifter thickness mm (in.)mm (in.) 0.000 - 0.030 (0.0000 - 0.0012) 0.031 - 0.050 (0.0012 - 0.0020) 0.051 - 0.070 (0.0020 - 0.0028) 0.071 - 0.090 (0.0028 - 0.0035) 0.091 - 0.110 (0.0036 - 0.0043) 0.111 - 0.130 (0.0044 - 0.0051) 0.131 - 0.150 (0.0052 - 0.0059) 0.151 - 0.170 (0.0059 - 0.0067) 0.171 - 0.190 (0.0067 - 0.0075) 0.191 - 0.210 (0.0075 - 0.0083) 0.211 - 0.230 (0.0083 - 0.0091) 0.231 - 0.250 (0.0091 - 0.0098) 0.251 - 0.270 (0.0099 - 0.0106) 0.271 - 0.290 (0.0107 - 0.0114) 0.291 - 0.299 (0.0115 - 0.0118) 0.300 - 0.400 (0.0118 - 0.0157) 0.401 - 0.420 (0.0158 - 0.0165) 0.421 - 0.440 (0.0166 - 0.0173) 0.441 - 0.460 (0.0174 - 0.0181) 0.461 - 0.480 (0.0181 - 0.0189) 0.481 - 0.500 (0.0189 - 0.0197) 0.501 - 0.520 (0.0197 - 0.0205) 0.521 - 0.540 (0.0205 - 0.0213) 0.541 - 0.560 (0.0213 - 0.0220) 0.561 - 0.580 (0.0221 - 0.0228) 0.581 - 0.600 (0.0229 - 0.0236) 0.601 - 0.620 (0.0237 - 0.0244) 0.621 - 0.640 (0.0244 - 0.0252) 0.641 - 0.660 (0.0252 - 0.0260) 0.661 - 0.680 (0.0260 - 0.0268) 0.681 - 0.700 (0.0268 - 0.0276) 0.701 - 0.720 (0.0276 - 0.0283) 0.721 - 0.740 (0.0284 - 0.0291) 0.741 - 0.760 (0.0292 - 0.0299) 0.761 - 0.780 (0.0300 - 0.0307) 0.781 - 0.800 (0.0307 - 0.0315) 0.801 - 0.820 (0.0315 - 0.0323) 0.821 - 0.840 (0.0323 - 0.0331) 0.841 - 0.860 (0.0331 - 0.0339) 0.861 - 0.880 (0.0339 - 0.0346) 0.881 - 0.900 (0.0347 - 0.0354) 0.901 - 0.920 (0.0355 - 0.0362) 0.921 - 0.940 (0.0363 - 0.0370) 0.941 - 0.960 (0.0370 - 0.0378) 0.961 - 0.980 (0.0378 - 0.0386) 0.981 - 1.000 (0.0386 - 0.0394) 1.001 - 1.020 (0.0394 - 0.0402) 1.021 - 1.040 (0.0402 - 0.0409) 1.041 - 1.060 (0.0410 - 0.0417) 1.061 - 1.080 (0.0418 - 0.0425) (h) Valve lifter selection chart (exhaust). 5.060 (0.1992) 5.080 (0.2000) 5.100 (0.2008) 5.120 (0.2016) 5.140 (0.2024) 5.160 (0.2031) 5.180 (0.2039) 5.200 (0.2047) 5.210 (0.2051) 5.220 (0.2055) 5.230 (0.2059) 5.240 (0.2063) 5.250 (0.2067) 5.260 (0.2071) 5.270 (0.2075) 5.280 (0.2079) 5.290 (0.2083) 5.300 (0.2087) 5.310 (0.2091) 5.320 (0.2094) 5.330 (0.2098) 5.340 (0.2102) 5.350 (0.2106) 5.360 (0.2110) 5.370 (0.2114) 5.380 (0.2118) 5.390 (0.2122) 5.400 (0.2126) 5.410 (0.2130) 5.420 (0.2134) 5.430 (0.2138) 5.440 (0.2142) 5.450 (0.2146) 5.460 (0.2150) 5.470 (0.2154) 5.480 (0.2157) 5.490 (0.2161) 5.500 (0.2165) 5.510 (0.2169) 5.520 (0.2173) 5.530 (0.2177) 5.540 (0.2181) 5.550 (0.2185) 5.560 (0.2189) 5.570 (0.2193) 5.580 (0.2197) 5.590 (0.2201) 5.600 (0.2205) 5.620 (0.2213) 5.640 (0.2220) 5.660 (0.2228) 5.680 (0.2236) 5.700 (0.2244) 5.720 (0.2252) 5.740 (0.2260) 06 06 08 06 08 10 06 08 10 12 06 08 10 12 14 06 08 10 12 14 16 06 08 10 12 14 16 18 06 08 10 12 14 16 18 20 06 08 10 12 14 16 18 20 06 08 10 12 14 16 18 20 22 06 08 10 12 14 16 18 20 22 06 08 10 12 14 16 18 20 22 24 06 08 10 12 14 16 18 20 22 24 06 08 10 12 14 16 18 20 22 24 26 06 08 10 12 14 16 18 20 22 24 26 06 08 10 12 14 16 18 20 22 24 26 28 06 08 10 12 14 16 18 20 22 24 26 28 06 08 10 12 14 16 18 20 22 24 26 28 30 06 08 10 12 14 16 18 20 22 24 26 28 30 06 08 10 12 14 16 18 20 22 24 26 28 30 32 06 08 10 12 14 16 18 20 22 24 26 28 30 32 06 08 10 12 14 16 18 20 22 24 26 28 30 32 34 06 08 10 12 14 16 18 20 22 24 26 28 30 32 34 08 10 12 14 16 18 20 22 24 26 28 30 32 34 36 08 10 12 14 16 18 20 22 24 26 28 30 32 34 36 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74 52 54 56 58 60 62 64 66 68 70 72 74 74 74 52 54 56 58 60 62 64 66 68 70 72 74 74 74 54 56 58 60 62 64 66 68 70 72 74 74 74 54 56 58 60 62 64 66 68 70 72 74 74 74 56 58 60 62 64 66 68 70 72 74 74 74 56 58 60 62 64 66 68 70 72 74 74 74 58 60 62 64 66 68 70 72 74 74 74 58 60 62 64 66 68 70 72 74 74 74 60 62 64 66 68 70 72 74 74 74 60 62 64 66 68 70 72 74 74 74 62 64 66 68 70 72 74 74 74 62 64 66 68 70 72 74 74 74 64 66 68 70 72 74 74 74 64 66 68 70 72 74 74 74 66 68 70 72 74 74 74 68 70 72 74 74 74 70 72 74 74 74 72 74 74 74 74 74 74 74 74 74 ) A114356E01 New lifter thickness Lifter No. Thickness mm (in.) Lifter No. Thickness mm (in.) Lifter No. Thickness mm (in.) 06 5.060 (0.1992) 30 5.300 (0.2087) 54 5.540 (0.2181) EM EM–14 2AZ-FE ENGINE MECHANICAL – VALVE CLEARANCE Lifter No. Thickness mm (in.) Lifter No. Thickness mm (in.) Lifter No. Thickness mm (in.) 08 5.080 (0.2000) 32 5.320 (0.2094) 56 5.560 (0.2189) 10 5.100 (0.2008) 34 5.340 (0.2102) 58 5.580 (0.2197) 12 5.120 (0.2016) 36 5.360 (0.2110) 60 5.600 (0.2205) 14 5.140 (0.2024) 38 5.380 (0.2118) 62 5.620 (0.2213) 16 5.160 (0.2031) 40 5.400 (0.2126) 64 5.640 (0.2220) 18 5.180 (0.2039) 42 5.420 (0.2134) 66 5.660 (0.2228) 20 5.200 (0.2047) 44 5.440 (0.2142) 68 5.680 (0.2236) 22 5.220 (0.2055) 46 5.460 (0.2150) 70 5.700 (0.2244) 24 5.240 (0.2063) 48 5.480 (0.2157) 72 5.720 (0.2252) 26 5.260 (0.2071) 50 5.500 (0.2165) 74 5.740 (0.2260) 28 5.280 (0.2079) 52 5.520 (0.2173) - - EM (i) Standard exhaust valve clearance (cold): 0.38 to 0.48 mm (0.0150 to 0.0189 in.) EXAMPLE: The 5.340 mm (0.2102 in.) lifter is installed, and the measured clearance is 0.430 mm (0.0169 in.). Replace the 5.340 mm (0.2102 in.) lifter with a new No. 42 lifter. Install the selected valve lifter. 11. INSTALL CAMSHAFT (a) Apply a light coat of engine oil to the journal portion of the camshaft. Paint Mark (b) Install the timing chain onto the camshaft timing gear with the paint mark aligned with the timing mark on the camshaft timing gear as shown in the illustration. Timing Mark A098176E04 (c) Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps into the cylinder head. (d) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts. A098177E03 2AZ-FE ENGINE MECHANICAL – VALVE CLEARANCE No. 1 3 7 1 5 9 8 4 2 6 10 A098177E06 EM–15 (e) Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration. Torque: No. 1 bearing cap 30 N*m (301 kgf*cm, 22 ft.*lbf) No. 3 bearing cap 9.0 N*m (92 kgf*cm, 80 in.*lbf) 12. INSTALL NO. 2 CAMSHAFT (a) Apply a light coat of engine oil to the journal portion of the No. 2 camshaft. (b) Put the No. 2 camshaft on the cylinder head with the paint mark of the chain aligned with the timing mark on the camshaft timing sprocket. Paint Mark EM Timing Mark A098178E03 (c) While holding the No. 2 camshaft by hand, temporarily tighten the camshaft timing sprocket set bolt. A086659 (d) Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps onto the cylinder head. (e) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts. A098174E05 3 1 5 (f) 9 7 8 4 2 6 10 No. 2 A098174E07 Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration. Torque: No. 2 bearing cap 30 N*m (301 kgf*cm, 22 ft.*lbf) No. 3 bearing cap 9.0 N*m (92 kgf*cm, 80 in.*lbf) EM–16 2AZ-FE ENGINE MECHANICAL – VALVE CLEARANCE (g) While holding the camshaft with a wrench, tighten the camshaft timing sprocket set bolt. Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) NOTICE: Be careful not to damage the valve lifter. Tighten Hold A098173E04 7 Links Paint Mark Paint Mark EM (h) Check that the paint marks on the chain are aligned with the timing marks on the camshaft timing gear and camshaft timing sprocket. Also, check that the crankshaft pulley groove is aligned with the timing mark "0" of the timing chain cover. 13. INSTALL NO. 1 CHAIN TENSIONER (See page EM-32) 14. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (See page EM-33) Timing Mark Timing Mark 15. INSTALL IGNITION COIL ASSEMBLY (See page EM33) Groove 16. CHECK FOR ENGINE OIL LEAKS 17. INSTALL NO. 1 ENGINE COVER (See page EM-121) A098180E04 18. INSTALL FRONT FENDER APRON RH 19. INSTALL ENGINE UNDER COVER LH 20. INSTALL ENGINE UNDER COVER RH 21. INSTALL FRONT WHEEL RH 2AZ-FE ENGINE MECHANICAL – TIMING CHAIN EM–17 TIMING CHAIN 2AZ-FE ENGINE MECHANICAL ENGINE COMPONENTS ENGINE MOVING CONTROL ROD SUB-ASSEMBLY NO. 2 ENGINE MOUNTING BRACKET RH 64 (653, 47) 9.0 (92, 80 in.*lbf) 52 (531, 38) EM 64 (653, 47) NO. 1 ENGINE COVER SUB-ASSEMBLY NO. 2 ENGINE MOUNTING STAY RH V-RIBBED BELT 9.8 (100, 87 in.*lbf) 52 (531, 38) 21 (214, 15) GENERATOR ASSEMBLY FRONT FENDER APRON SEAL RH N*m (kgf*cm, ft.*lbf) : Specified torque A134948E01 EM–18 2AZ-FE ENGINE MECHANICAL – TIMING CHAIN 43 (439, 32) VANE PUMP ASSEMBLY EM FRONT EXHAUST PIPE ASSEMBLY EXHAUST PIPE GASKET 56 (571, 41) EXHAUST PIPE GASKET REAR EXHAUST PIPE NO. 1 62 (633, 46) SUPPORT BRACKET FRONT EXHAUST PIPE NO. 1 SUPPORT BRACKET 33 (337, 24) 33 (337, 24) ENGINE UNDER COVER RH ENGINE UNDER COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A134947E01 EM–19 2AZ-FE ENGINE MECHANICAL – TIMING CHAIN 9.0 (92, 80 in.*lbf) IGNITION COIL ASSEMBLY 14 (143, 10) 14 (143, 10) 11 (110, 8) x2 x6 11 (110, 8) EM CYLINDER HEAD COVER SUB-ASSEMBLY CYLINDER HEAD COVER GASKET CRANK POSITION SENSOR 9.0 (92, 80 in.*lbf) TMMK: 170 (1,733, 125) TMC: 180 (1,835, 133) OIL PAN SUB-ASSEMBLY CRANKSHAFT PULLEY 25 (255, 18) OIL PAN DRAIN PLUG GASKET x2 x12 9.0 (92, 80 in.*lbf) 9.0 (92, 80 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A134922E01 EM–20 2AZ-FE ENGINE MECHANICAL – TIMING CHAIN NO. 1 CHAIN VIBRATION DAMPER CHAIN SUB-ASSEMBLY CRANKSHAFT TIMING SPROCKET CHAIN TENSIONER SLIPPER NO. 2 CHAIN SUB-ASSEMBLY OIL PUMP DRIVE SPROCKET EM 19 (194, 14) SPRING CHAIN TENSIONER NO. 1 CRANKSHAFT POSITION SENSOR PLATE 12 (122, 9.0) 30 (301, 22) 9.0 (92, 80 in.*lbf) OIL PUMP DRIVEN SPROCKET NO. 1 CHAIN TENSIONER ASSEMBLY TIMING CHAIN GUIDE 9.0 (92, 80 in.*lbf) V-RIBBED BELT TENSIONER ASSEMBLY 11 (112, 8) GASKET 55 (561, 41) x4 22 (220, 16) STUD BOLT 9.0 (92, 80 in.*lbf) 60 (607, 44) TIMING CHAIN CASE OIL SEAL x8 25 (255, 18) N*m (kgf*cm, ft.*lbf) : Specified torque TIMING CHAIN COVER SUB-ASSEMBLY Non-reusable part A134923E01 2AZ-FE ENGINE MECHANICAL – TIMING CHAIN EM–21 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (See page EM-94) 3. REMOVE FRONT WHEEL RH 4. REMOVE ENGINE UNDER COVER LH 5. REMOVE ENGINE UNDER COVER RH 6. REMOVE FRONT FENDER APRON SEAL RH 7. DRAIN ENGINE OIL (See page LU-4) 8. REMOVE FRONT EXHAUST PIPE ASSEMBLY HINT: See page EX-2. 9. REMOVE NO. 2 ENGINE MOUNTING STAY RH (See page EM-95) 10. REMOVE ENGINE MOVING CONTROL ROD SUBASSEMBLY (See page EM-95) 11. REMOVE NO. 2 ENGINE MOUNTING BRACKET RH (See page EM-96) 12. REMOVE V-RIBBED BELT (See page EM-6) 13. REMOVE GENERATOR ASSEMBLY (See page CH-11) 14. REMOVE VANE PUMP ASSEMBLY (See page EM101) 15. REMOVE IGNITION COIL ASSEMBLY (See page EM106) 16. DISCONNECT VENTILATION HOSE 17. DISCONNECT NO. 2 VENTILATION HOSE 18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (a) Remove the 2 bolts and disconnect the 2 engine wires. A112210E01 EM EM–22 2AZ-FE ENGINE MECHANICAL – TIMING CHAIN (b) Remove the 8 bolts, 2 nuts, and the cylinder head cover. 19. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page EM-8) 20. REMOVE CRANKSHAFT PULLEY (See page EM-75) 21. REMOVE CRANK POSITION SENSOR (See page ES411) A127550E02 22. REMOVE OIL PAN SUB-ASSEMBLY (a) Remove the 12 bolts and 2 nuts. EM A114333 (b) Insert the blade of SST between the crankcase and oil pan. Cut through the sealer and remove the oil pan. SST 09032-00100 NOTICE: Be careful not to damage the contact surfaces of the crankcase, chain cover and oil pan. SST SST A000019E05 23. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY (a) Remove the 2 nuts, tensioner and gasket. NOTICE: Do not turn the crankshaft without the chain tensioner. A098348E01 24. INSTALL ENGINE HANGERS (a) Install the No. 1 engine hanger and No. 2 engine hanger with the bolts as shown in the illustration. Parts No.: No. 1 Engine Hanger No. 1 Engine hanger 12281-28010 No. 2 Engine hanger 12282-28010 Bolt 91512-61020 No. 2 Engine Hanger A052507E05 Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) (b) Attach the sling device to the engine hangers and chain block. 2AZ-FE ENGINE MECHANICAL – TIMING CHAIN EM–23 25. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (a) Lift the engine upward using the chain block. NOTICE: Do not lift the engine more than necessary. (b) Remove the bolt, nut and V-ribbed belt tensioner. A112212 26. REMOVE ENGINE MOUNTING INSULATOR (a) Attach the engine chain hoist to the engine hangers. CAUTION: Do not attempt to hang the engine by hooking the chain to any other part. (b) Remove the bolt and disconnect the engine mounting insulator FR. A059880 (c) M/T: Remove the bolt and disconnect the engine lateral control rod. M/T A060825E02 (d) Remove the 2 bolts and disconnect the steering gear return tube clamps from the frame. A138332 EM EM–24 2AZ-FE ENGINE MECHANICAL – TIMING CHAIN (e) Remove the 4 nuts from the engine mounting insulator RH. (f) Raise the engine and remove the engine mounting insulator RH. A059900 27. REMOVE ENGINE MOUNTING BRACKET RH (a) Remove the 3 bolts and engine mounting bracket. 28. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY (See page LU-11) 29. REMOVE TIMING CHAIN CASE OIL SEAL (See page LU-12) EM A052481 30. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE (a) Remove the crankshaft position sensor plate. A132571 31. REMOVE CHAIN TENSIONER SLIPPER (a) Remove the bolt and chain tensioner slipper. A125372 32. REMOVE NO. 1 CHAIN VIBRATION DAMPER (a) Remove the 2 bolts and chain vibration damper. A125371 2AZ-FE ENGINE MECHANICAL – TIMING CHAIN EM–25 33. REMOVE TIMING CHAIN GUIDE (a) Remove the bolt and timing chain guide. A125373 34. REMOVE CHAIN SUB-ASSEMBLY (a) Remove the chain sub-assembly. EM A128185 35. REMOVE CRANKSHAFT TIMING SPROCKET (a) Remove the crankshaft timing sprocket. A125374 36. REMOVE NO. 2 CHAIN SUB-ASSEMBLY (a) Turn the crankshaft by 90° counterclockwise to align the adjusting hole of the oil pump drive shaft sprocket with the groove of the oil pump. 90° Groove A098351E01 EM–26 2AZ-FE ENGINE MECHANICAL – TIMING CHAIN (b) Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft sprocket to lock the gear in position, and then remove the nut. Groove A098352E01 (c) Remove the bolt, chain tensioner plate and spring. Bolt EM Spring Chain Tensioner Plate B011415E03 (d) Remove the chain tensioner, oil pump driven sprocket and chain. A063847 2AZ-FE ENGINE MECHANICAL – TIMING CHAIN EM–27 INSPECTION 1. INSPECT CHAIN SUB-ASSEMBLY (See page EM-138) 2. INSPECT NO. 2 CHAIN SUB-ASSEMBLY (See page EM-138) 3. INSPECT OIL PUMP DRIVE SPROCKET (See page EM-138) 4. INSPECT OIL PUMP DRIVE SHAFT SPROCKET (See page EM-139) 5. INSPECT CHAIN TENSIONER SLIPPER (See page EM-140) 6. INSPECT NO. 1 CHAIN VIBRATION DAMPER (See page EM-140) 7. INSPECT CHAIN TENSIONER PLATE (See page EM140) 8. INSPECT NO. 1 CHAIN TENSIONER (See page EM140) INSTALLATION 1. INSTALL NO. 2 CHAIN SUB-ASSEMBLY (a) Set the crankshaft key into the left horizontal position. (b) Turn the drive shaft so that the cutout faces upward. B011424 (c) Align the yellow mark links with the timing marks of each gear as shown in the illustration. (d) Install the sprockets onto the crankshaft and oil pump shaft with the chain wrapped on the gears. (e) Temporarily tighten the oil pump drive shaft sprocket with the nut. Mark Link Timing Mark Oil Pump Drive Shaft Sprocket Mark Link Oil Pump Drive Sprocket Timing Mark A094198E06 EM EM–28 2AZ-FE ENGINE MECHANICAL – TIMING CHAIN (f) Insert the damper spring into the adjusting hole, and then install the chain tensioner plate with the bolt. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) Bolt Spring Chain Tensioner Plate A090851E03 EM (g) Align the adjusting hole of the oil pump drive shaft sprocket with the groove of the oil pump. (h) Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft gear to lock the gear in position, and then tighten the nut. Torque: 30 N*m (301 kgf*cm, 22 ft.*lbf) Groove A052512E02 (i) Rotate the crankshaft clockwise by 90°, and align the crankshaft key to the top. A036525 2. A125374 INSTALL CRANKSHAFT TIMING SPROCKET (a) Install the crankshaft timing sprocket. 2AZ-FE ENGINE MECHANICAL – TIMING CHAIN EM–29 3. INSTALL NO. 1 CHAIN VIBRATION DAMPER (a) Install the chain vibration damper with the 2 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 4. INSTALL CHAIN SUB-ASSEMBLY (a) Set the No. 1 cylinder to TDC/compression. (1) Turn the camshafts with a wrench (using the hexagonal lobe) to align the timing marks of the camshaft timing gear with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration. A132570 Timing Marks Timing Marks A053018E05 (2) Using the crankshaft pulley bolt, turn the crankshaft to position with the key on the crankshaft upward. A052505 Timing Mark Mark Link A094576E01 (b) Install the chain onto the crankshaft timing sprocket with the gold or pink mark link aligned with the timing mark on the crankshaft. EM EM–30 2AZ-FE ENGINE MECHANICAL – TIMING CHAIN (c) Using SST and a hammer, tap in the crankshaft timing sprocket. SST 09309-37010 SST A098369E01 (d) Align the gold or yellow link with each timing mark located on the camshaft timing gear and sprocket, then install the chain. Mark Link EM Timing Mark Timing Mark A098370E01 5. INSTALL CHAIN TENSIONER SLIPPER (a) Install the chain tensioner slipper with the bolt. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) 6. INSTALL TIMING CHAIN GUIDE (a) Install the timing chain guide with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 7. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE (a) Install the sensor plate with the "F" mark facing forward. 8. INSTALL TIMING CHAIN CASE OIL SEAL (See page LU-15) 9. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY (See page LU-15) Hold A124787E01 A125373 A124770 2AZ-FE ENGINE MECHANICAL – TIMING CHAIN EM–31 10. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (a) Install the V-ribbed belt tensioner with the bolt and nut. Torque: 60 N*m (607 kgf*cm, 44 ft.*lbf) NOTICE: Do not lift the engine more than necessary. A112212 11. INSTALL ENGINE MOUNTING BRACKET RH (a) Install the engine mounting bracket with the 3 bolts. Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) EM A052481 12. INSTALL ENGINE MOUNTING INSULATOR (a) Raise the engine and install the engine mounting insulator RH. (b) Install the engine mounting insulator RH with the 4 nuts. Torque: Nut A 95 N*m (969 kgf*cm, 70 ft.*lbf) Nut B 87 N*m (888 kgf*cm, 64 ft.*lbf) A B B B A059900E02 (c) Install the steering gear return tube clamps to the frame with the 2 bolts. Torque: 8.0 N*m (80 kgf*cm, 69 in.*lbf) A138332 (d) Install the engine mounting insulator FR with the bolt. Torque: 87 N*m (888 kgf*cm, 64 ft.*lbf) A059880 EM–32 2AZ-FE ENGINE MECHANICAL – TIMING CHAIN (e) M/T: Install the engine lateral control rod with the bolt. Torque: 89 N*m (910 kgf*cm, 66 ft.*lbf) M/T A060825E01 EM Seal Packing 6.0 mm (0.236 in.) 13. INSTALL OIL PAN SUB-ASSEMBLY (a) Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and oil pan. (b) Apply a continuous bead of seal packing (Diameter 3.0 to 4.0 mm (0.118 to 0.157 in.)) as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Block, Three Bond 1207B or Equivalent NOTICE: • Remove any oil from the contact surfaces. • Install the oil pan within 3 minutes after applying seal packing. • Do not start the engine for at least 2 hours after installing. (c) Install the oil pan to the cylinder block. Seal Diameter: 3.0 to 4.0 mm A114332E01 10 9 8 1, 15 7 11 12 13 (d) Uniformly tighten the 12 bolts and 2 nuts in the sequence shown in the illustration. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 14. INSTALL CRANK POSITION SENSOR (See page ES411) 15. INSTALL CRANKSHAFT PULLEY (See page EM-76) 6 5 4 3 2 14 A114333E01 16. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (a) Release the ratchet pawl, then fully push in the plunger and hook the hook to the pin so that the plunger is in the position shown in the illustration. Raise Push Pin Hook A098376E03 2AZ-FE ENGINE MECHANICAL – TIMING CHAIN EM–33 (b) Install a new gasket and the chain tensioner with the 2 nuts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) NOTICE: If the hook releases the plunger while the chain tensioner is being installed, set the hook again. Engine Front A098377E03 (c) Turn the crankshaft counterclockwise, then disconnect the plunger knock pin from the hook. Disconnect Hook Turn Pin A112204E02 (d) Turn the crankshaft clockwise, then check that the plunger is extended. 17. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (a) Remove any old packing material from the contact surface. Plunger Push Turn A112205E02 EM EM–34 2AZ-FE ENGINE MECHANICAL – TIMING CHAIN A094205E01 A A A A B B EM A Nut A (b) Apply seal packing to the 2 locations shown in the illustration. Seal packing: Toyota Genuine Seal Packing Block, Three Bond 1207B or Equivalent NOTICE: • Remove any oil from the contact surface. • Install the cylinder head cover within 3 minutes of applying seal packing. • Do not add engine oil for at least 2 hours after installing the cylinder head cover. (c) Install the cylinder head cover with the 8 bolts and 2 nuts. Torque: Bolt A 11 N*m (112 kgf*cm, 8 ft.*lbf) Bolt B 14 N*m (143 kgf*cm, 10 ft.*lbf) Nut 11 N*m (112 kgf*cm, 8 ft.*lbf) Nut A127550E01 (d) Install the 2 engine wires with the 2 bolts. Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) 18. INSTALL NO. 2 VENTILATION HOSE 19. INSTALL VENTILATION HOSE 20. INSTALL IGNITION COIL ASSEMBLY (a) Install the 4 ignition coils with the 4 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 21. INSTALL VANE PUMP ASSEMBLY (See page EM-113) 22. INSTALL GENERATOR ASSEMBLY (See page CH-19) 23. INSTALL V-RIBBED BELT (See page EM-6) A112210 24. INSTALL NO. 2 ENGINE MOUNTING BRACKET RH (See page EM-118) 25. INSTALL ENGINE MOVING CONTROL ROD SUBASSEMBLY (See page EM-119) 26. INSTALL NO. 2 ENGINE MOUNTING STAY RH (See page EM-119) 27. INSTALL FRONT EXHAUST PIPE ASSEMBLY HINT: See page EX-3. 28. ADD ENGINE OIL 29. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page EM-120) 30. CHECK FOR ENGINE OIL LEAKS 31. CHECK FOR EXHAUST GAS LEAKS 32. CHECK IGNITION TIMING (See page EM-1) 2AZ-FE ENGINE MECHANICAL – TIMING CHAIN EM–35 33. INSTALL FRONT FENDER APRON SEAL RH 34. INSTALL ENGINE UNDER COVER LH 35. INSTALL ENGINE UNDER COVER RH 36. INSTALL FRONT WHEEL RH 37. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (See page EM-121) EM 2AZ-FE ENGINE MECHANICAL – CAMSHAFT EM–35 CAMSHAFT 2AZ-FE ENGINE MECHANICAL ENGINE COMPONENTS V-RIBBED BELT 9.0 (92, 80 in.*lbf) NO. 1 ENGINE COVER SUB-ASSEMBLY EM FRONT FENDER APRON SEAL RH ENGINE UNDER COVER RH ENGINE UNDER COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque A134949E01 EM–36 2AZ-FE ENGINE MECHANICAL – CAMSHAFT 9.0 (92, 80 in.*lbf) IGNITION COIL ASSEMBLY 11 (112, 8) 14 (143, 10) 11 (112, 8) EM VENTILATION HOSE CYLINDER HEAD COVER SUB-ASSEMBLY GASKET N*m (kgf*cm, ft.*lbf) : Specified torque A134919E01 EM–37 2AZ-FE ENGINE MECHANICAL – CAMSHAFT 9.0 (92, 80 in.*lbf) NO. 3 CAMSHAFT BEARING CAP 30 (301, 22) x16 x4 NO. 3 CAMSHAFT BEARING CAP NO. 1 CAMSHAFT BEARING CAP CAMSHAFT NO. 2 CAMSHAFT BEARING CAP EM NO. 2 CAMSHAFT 54 (551, 40) CAMSHAFT TIMING GEAR ASSEMBLY NO. 2 CAMSHAFT TIMING SPROCKET 54 (551, 40) 9.0 (92, 80 in.*lbf) NO. 1 CHAIN TENSIONER ASSEMBLY GASKET N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A134921E01 EM–38 2AZ-FE ENGINE MECHANICAL – CAMSHAFT REMOVAL EM 1. REMOVE FRONT WHEEL RH 2. REMOVE ENGINE UNDER COVER LH 3. REMOVE ENGINE UNDER COVER RH 4. REMOVE FRONT FENDER APRON SEAL RH 5. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (See page EM-94) 6. REMOVE IGNITION COIL ASSEMBLY (See page EM106) 7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (See page EM-21) 8. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page EM-8) 9. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY (See page EM-22) 10. REMOVE NO. 2 CAMSHAFT (a) While holding the camshaft with a wrench, loosen the camshaft timing set bolt. Loosen Hold A098173E03 9 5 7 (b) Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. (c) Remove the 5 bearing caps. 3 1 2 6 10 8 4 A098174E11 (d) While holding the No. 2 camshaft by hand, remove the camshaft timing sprocket set bolt. (e) Remove the camshaft timing sprocket from the No. 2 camshaft with the timing chain wrapped on the sprocket. (f) Remove the camshaft timing sprocket from the timing chain. A086659 2AZ-FE ENGINE MECHANICAL – CAMSHAFT 5 1 9 7 3 2 6 10 8 4 EM–39 11. REMOVE CAMSHAFT (a) Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. (b) Remove the 5 bearing caps. (c) Remove the camshaft and camshaft timing gear while holding the timing chain by hand. A098175E04 (d) Tie the timing chain with a string as shown in the illustration. NOTICE: Be careful not to drop anything inside the timing chain cover. EM A052474 Advance Side Port 12. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY (a) Clamp the camshaft in a vise, and make sure that the camshaft timing gear does not rotate. (b) Cover all the oil ports except the advance side port shown in the illustration with vinyl tape. A090848E03 A031032 (c) Apply air pressure of 100 kPa (1.0 kgf/cm2, 14 psi) to the oil path, then turn the camshaft timing gear in the advance direction (counterclockwise) by hand. CAUTION: Cover the paths with a shop rag or piece of cloth to avoid oil splashes. HINT: Depending on the air pressure, the camshaft timing gear will turn to the advance angle side without applying force by hand. Also, if the pressure is difficult to apply because of air leakage from the port, the lock may be difficult to release. EM–40 2AZ-FE ENGINE MECHANICAL – CAMSHAFT (d) Remove the flange bolt of the camshaft timing gear. NOTICE: • Be sure not to remove the other 4 bolts. • If planning to reuse the gear, be sure to release the straight pin lock before installing the gear. A032639 INSPECTION Retard Side Path 1. Advance Side Path EM Close Open Open Close Vinyl Tape Rubber INSPECT CAMSHAFT TIMING GEAR ASSEMBLY (a) Check the lock of the camshaft timing gear. (1) Clamp the camshaft in a vise, and confirm that the camshaft timing gear is locked. NOTICE: Be careful not to damage the camshaft. (b) Release the lock pin. (1) Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration. HINT: The 2 advance side paths are provided in the groove of the camshaft. Plug one of the paths with a rubber piece. (2) Break through the tape of the advance side path and the retard side path on the opposite side to the hole of the advance side path, as shown in the illustration. A062190E02 Retard Side Path Advance Side Path A062191E03 (3) Apply approximately 200 kPa (2.0 kgf/cm2, 28 psi) of air pressure to the two broken paths. CAUTION: Cover the paths with a piece of cloth when applying pressure to keep oil from splashing. (4) Check that the camshaft timing gear revolves in the advance direction when reducing the air pressure of the retard side path. OK: Gear rotates in the advance direction. HINT: This operation releases the lock pin for the most retarded position. EM–41 2AZ-FE ENGINE MECHANICAL – CAMSHAFT (5) When the camshaft timing gear reaches the most advanced position, remove the air gun from the retard side path and advance side path, in that order. NOTICE: Do not remove the air gun from the advance side path first. The gear may abruptly shift in the retard direction and break the lock pin. (c) Check for smooth rotation. (1) Rotate the camshaft timing gear within its movable range several times, but do not turn it to the most retarded position. Check that the gear rotates smoothly. OK: Gear rotates smoothly. NOTICE: Do not use an air gun to check for smooth operation. (d) Check the lock in the most retarded position. (1) Confirm that the camshaft timing gear is locked at the most retarded position. 2. INSPECT CAMSHAFT (a) Inspect the camshaft for runout. (1) Place the camshaft on V-blocks. (2) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.03 mm (0.0012 in.) If the circle runout is greater than the maximum, replace the camshaft. EM01628E01 (b) Inspect the cam lobes. (1) Using a micrometer, measure the cam lobe height. Standard cam lobe height: 47.306 to 47.406 mm (1.8624 to 1.8664 in.) Minimum cam lobe height: 47.196 mm (1.8581 in.) If the cam lobe height is less than the minimum, replace the camshaft. A036687E01 (c) Inspect the camshaft journals. (1) Using a micrometer, measure the journal diameter. Standard journal diameter A036688E01 Journal Position Specified Condition No. 1 35.971 to 35.985 mm (1.4162 to 1.4167 in.) Other 22.959 to 22.975 mm (0.9039 to 0.9045 in.) EM EM–42 2AZ-FE ENGINE MECHANICAL – CAMSHAFT If the journal diameter is not as specified, check the oil clearance. 3. INSPECT NO. 2 CAMSHAFT (a) Inspect the camshaft for runout. (1) Place the camshaft on V-blocks. (2) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.03 mm (0.0012 in.) If the circle runout is greater than the maximum, replace the No. 2 camshaft. EM01628E01 (b) Inspect the cam lobes. (1) Using a micrometer, measure the cam lobe height. Standard cam lobe height: 45.983 to 46.083 mm (1.8104 to 1.8143 in.) Minimum cam lobe height: 45.873 mm (1.8060 in.) If the cam lobe height is less than the minimum, replace the No. 2 camshaft. EM A036687E01 (c) Inspect the camshaft journals. (1) Using a micrometer, measure the journal diameter. Standard journal diameter Journal Position Specified Condition No. 1 35.971 to 35.985 mm (1.4162 to 1.4167 in.) Other 22.959 to 22.975 mm (0.9039 to 0.9045 in.) A036688E01 INSTALLATION Straight Pin Key Groove If the journal diameter is not as specified, check the oil clearance. 1. A098365E02 INSTALL CAMSHAFT TIMING GEAR ASSEMBLY (a) Put the camshaft timing gear and camshaft together with the straight pin and key groove misaligned, as shown in the illustration. (b) Turn the camshaft timing gear as shown in the illustration while pushing it gently against the camshaft. Push further at the position where the pin fits into the groove. NOTICE: Be sure not to turn the camshaft timing gear to the retard angle side (the right angle). (c) Check that there is no clearance between the gear and camshaft. (d) Tighten the flange bolt with the camshaft timing gear fixed in place. Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) 2AZ-FE ENGINE MECHANICAL – CAMSHAFT EM–43 (e) Check that the camshaft timing gear can move to the retard angle side (the right direction) and is locked in the most retarded position. 2. INSTALL CAMSHAFT (a) Apply a light coat of engine oil to the journal portion of the camshaft. (b) Install the timing chain onto the camshaft timing gear with the paint mark aligned with the timing mark in the camshaft timing gear as shown in the illustration. Paint Mark Timing Mark A098176E03 EM (c) Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps into the cylinder head. (d) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts. A098177E03 (e) Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration. Torque: No. 1 Bearing cap 30 N*m (301 kgf*cm, 22 ft.*lbf) No. 3 Bearing cap 9.0 N*m (92 kgf*cm, 80 in.*lbf) No. 1 7 3 1 5 9 4 2 6 10 8 3. A098177E06 Paint Mark Timing Mark A098178E03 INSTALL NO. 2 CAMSHAFT (a) Apply a light coat of engine oil to the journal portion of the No. 2 camshaft. (b) Put the No. 2 camshaft on the cylinder head with the paint mark of the chain aligned with the timing mark on the camshaft timing sprocket. EM–44 2AZ-FE ENGINE MECHANICAL – CAMSHAFT (c) While holding the No. 2 camshaft by hand, temporarily tighten the camshaft timing sprocket set bolt. A086659 (d) Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps onto the cylinder head. (e) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts. EM A098174E05 1 3 5 (f) 9 7 8 4 2 6 10 Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration. Torque: No. 2 Bearing cap 30 N*m (301 kgf*cm, 22 ft.*lbf) No. 3 Bearing cap 9.0 N*m (92 kgf*cm, 80 in.*lbf) No. 2 A098174E07 (g) While holding the camshaft with a wrench, tighten the camshaft timing sprocket set bolt. Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) Tighten Hold A098173E04 2AZ-FE ENGINE MECHANICAL – CAMSHAFT Paint Mark Timing Marks 7 Links EM–45 (h) Check that the paint marks on the chain are aligned with the timing marks on the camshaft timing gear and camshaft timing sprocket. Also, check that the crankshaft pulley groove is aligned with the timing mark "0" of the timing chain cover. Paint Mark Timing Mark Groove A052460E05 4. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (See page EM-32) 5. CHECK VALVE CLEARANCE (See page EM-8) 6. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (See page EM-33) 7. INSTALL IGNITION COIL ASSEMBLY (See page EM33) 8. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (See page EM-121) 9. INSTALL FRONT FENDER APRON SEAL RH 10. INSTALL ENGINE UNDER COVER LH 11. INSTALL ENGINE UNDER COVER RH 12. INSTALL FRONT WHEEL RH 13. CHECK FOR ENGINE OIL LEAKS EM EM–46 2AZ-FE ENGINE MECHANICAL – CYLINDER HEAD CYLINDER HEAD 2AZ-FE ENGINE MECHANICAL ENGINE COMPONENTS FRONT WIPER ARM AND BLADE ASSEMBLY RH 20 (204, 15) FRONT FENDER TO COWL SIDE SEAL RH EM FRONT WIPER ARM AND BLADE ASSEMBLY LH COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 7.5 (77, 66 in.*lbf) 85 (867, 63) FRONT FENDER TO COWL SIDE SEAL LH 5.0 (51, 44 in.*lbf) WINDSHIELD WIPER LINK ASSEMBLY COWL TOP PANEL OUTER SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque A136912E01 2AZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–47 ENGINE MOVING CONTROL ROD SUB-ASSEMBLY NO. 2 ENGINE MOUNTING BRACKET RH 64 (653, 47) 9.0 (92, 80 in.*lbf) 52 (531, 38) 64 (653, 47) NO. 1 ENGINE COVER SUB-ASSEMBLY NO. 2 ENGINE MOUNTING STAY RH EM V-RIBBED BELT 9.8 (100, 87 in.*lbf) 52 (531, 38) 21 (214, 15) GENERATOR ASSEMBLY FRONT FENDER APRON SEAL RH N*m (kgf*cm, ft.*lbf) : Specified torque A134948E01 EM–48 2AZ-FE ENGINE MECHANICAL – CYLINDER HEAD AIR CLEANER CAP SUB-ASSEMBLY AIR CLEANER CASE SUB-ASSEMBLY 5.0 (51, 44 in.*lbf) 5.0 (51, 44 in.*lbf) EM 9.0 (92, 80 in.*lbf) 3.5 (36, 31 in.*lbf) AIR CLEANER INLET ASSEMBLY BATTERY BATTERY TRAY N*m (kgf*cm, ft.*lbf) : Specified torque A134950E01 EM–49 2AZ-FE ENGINE MECHANICAL – CYLINDER HEAD 43 (439, 32) VANE PUMP ASSEMBLY EM FRONT EXHAUST PIPE ASSEMBLY EXHAUST PIPE GASKET 56 (571, 41) EXHAUST PIPE GASKET REAR EXHAUST PIPE NO. 1 62 (633, 46) SUPPORT BRACKET FRONT EXHAUST PIPE NO. 1 SUPPORT BRACKET 33 (337, 24) 33 (337, 24) ENGINE UNDER COVER RH ENGINE UNDER COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A134947E01 EM–50 2AZ-FE ENGINE MECHANICAL – CYLINDER HEAD 20 (204, 15) INTAKE MANIFOLD FUEL DELIVERY PIPE WITH INJECTOR SPACER 30 (306, 22) INSURATOR INTAKE AIR CONTROL VALVE (For PZEV) VENTILATION HOSE GASKET EM NO. 1 MANIFOLD CONVERTER INSULATOR NO. 1 INTAKE MANIFOLD INSULATOR VENTILATION HOSE NO. 2 EXHAUST MANIFOLD CONVERTER SUBASSEMBLY For PZEV: 12 (122, 9) GASKET 37 (378, 27) x5 44 (449, 32) 44 (449, 32) 44 (449, 32) MANIFOLD STAY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part NO. 2 MANIFOLD STAY A136908E02 EM–51 2AZ-FE ENGINE MECHANICAL – CYLINDER HEAD x16 x4 9.0 (92, 80 in.*lbf) 30 (301, 22) NO. 3 BEARING CAP NO. 1 BEARING CAP CAMSHAFT BEARING NO. 1 CAMSHAFT TIMING SPROCKET NO. 2 BEARING CAP CAMSHAFT CAMSHAFT TIMING GEAR ASSEMBLY EM NO. 2 CAMSHAFT 54 (551, 39) 1st: 70 (714, 52) 2nd: Turn 90 ° NO. 2 CAMSHAFT BEARING x10 CYLINDER HEAD BOLT 9.0 (92, 80 in.*lbf) OIL CONTROL VALVE O-RING CYLINDER HEAD SUB-ASSEMBLY CYLINDER HEAD GASKET N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A134951E01 EM–52 2AZ-FE ENGINE MECHANICAL – CYLINDER HEAD VALVE LIFTER VALVE LIFTER VALVE SPRING RETAINER LOCK VALVE SPRING RETAINER LOCK VALVE SPRING RETAINER VALVE SPRING RETAINER INNER COMPRESSION SPRING INNER COMPRESSION SPRING VALVE STEM OIL SEAL VALVE STEM OIL SEAL EM VALVE SPRING SEAT VALVE SPRING SEAT EXHAUST VALVE GUIDE BUSH INTAKE VALVE GUIDE BUSH 86 (879, 64) NO. 1 STRAIGHT SCREW PLUG 9.5 (97, 84 in.*lbf) STUD BOLT GASKET 5.0 (51, 44 in.*lbf) 5.0 (51, 44 in.*lbf) STUD BOLT STUD BOLT RING PIN 86 (879, 64) NO. 1 STRAIGHT SCREW PLUG 9.5 (97, 84 in.*lbf) STUD BOLT GASKET 5.0 (51, 44 in.*lbf) STUD BOLT EXHAUST VALVE N*m (kgf*cm, ft.*lbf) : Specified torque INTAKE VALVE Non-reusable part A136083E01 2AZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–53 REMOVAL 1. DISCHARGE FUEL SYSTEM PRESSURE HINT: See page FU-1. 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 3. REMOVE ENGINE UNDER COVER LH 4. REMOVE ENGINE UNDER COVER RH 5. REMOVE FRONT FENDER APRON SEAL RH 6. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (See page EM-94) 7. DRAIN ENGINE COOLANT (See page CO-5) 8. DRAIN ENGINE OIL (See page LU-4) 9. REMOVE WINDSHIELD WIPER LINK ASSEMBLY HINT: See page WW-9. 10. REMOVE COWL TOP PANEL OUTER SUBASSEMBLY (See page ES-424) 11. REMOVE AIR CLEANER INLET ASSEMBLY (See page EM-94) 12. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-416) 13. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (See page EM-95) 14. REMOVE BATTERY (See page EM-95) 15. REMOVE THROTTLE BODY ASSEMBLY (See page ES-417) 16. DISCONNECT FUEL TUBE SUB-ASSEMBLY (See page FU-12) 17. REMOVE FUEL DELIVERY PIPE WITH INJECTOR (See page FU-13) 18. REMOVE INTAKE MANIFOLD (See page ES-424) 19. REMOVE INTAKE AIR CONTROL VALVE (For PZEV) (See page IT-7) 20. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR (See page EM-103) 21. REMOVE FRONT EXHAUST PIPE ASSEMBLY HINT: See page EX-2. 22. REMOVE NO. 2 ENGINE MOUNTING STAY RH (See page EM-95) 23. REMOVE ENGINE MOVING CONTROL ROD SUBASSEMBLY (See page EM-95) EM EM–54 2AZ-FE ENGINE MECHANICAL – CYLINDER HEAD 24. REMOVE NO. 2 ENGINE MOUNTING BRACKET RH (See page EM-96) 25. REMOVE V-RIBBED BELT (See page EM-6) 26. REMOVE GENERATOR ASSEMBLY (See page CH-11) 27. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY 28. REMOVE OIL LEVEL GAUGE GUIDE (See page EM104) 29. REMOVE MANIFOLD STAY (See page EM-104) 30. REMOVE NO. 2 MANIFOLD STAY (See page EM-104) 31. REMOVE EXHAUST MANIFOLD CONVERTER SUBASSEMBLY (See page EM-104) 32. REMOVE CHAIN SUB-ASSEMBLY HINT: See page EM-21. EM 5 9 7 33. REMOVE NO. 2 CAMSHAFT (a) Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. (b) Remove the 5 bearing caps and No. 2 camshaft. 3 1 2 6 10 8 4 A098174E11 5 1 9 7 3 2 34. REMOVE CAMSHAFT (a) Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. (b) Remove the 5 bearing caps and camshaft. 35. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (See page ES-405) 6 10 8 4 A098175E04 36. DISCONNECT RADIATOR HOSE INLET (See page EM-96) 37. DISCONNECT ENGINE WIRE (a) Disconnect the radio setting condenser connector. (b) Disconnect the engine oil pressure switch connector. (c) Disconnect the engine coolant temperature sensor connector. (d) Disconnect the camshaft position sensor connector. (e) Remove the bolt and ground cable. A098748E01 2AZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–55 38. REMOVE NO. 2 CAMSHAFT BEARING (a) Remove the No. 2 camshaft bearing. A128879 1 2 5 8 9 10 7 6 39. REMOVE CYLINDER HEAD SUB-ASSEMBLY (a) Using several steps, uniformly loosen and remove the 10 cylinder head bolts and 10 plate washers with a 10 mm bi-hexagon wrench in the sequence shown in the illustration. NOTICE: Head warpage or cracking could result from removing the bolts in the wrong order. 3 4 F050595E01 (b) Using a screwdriver with its tip wrapped with tape, pry between the cylinder head and cylinder block, and remove the cylinder head. NOTICE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block. A126930 40. REMOVE CYLINDER HEAD GASKET (a) Remove the cylinder head gasket. A126929 DISASSEMBLY 1. A062842E01 REMOVE VALVE LIFTER (a) Remove the valve lifters. HINT: Arrange the valve lifters in the correct order. EM EM–56 2AZ-FE ENGINE MECHANICAL – CYLINDER HEAD 2. REMOVE INTAKE VALVE (a) Using SST and wooden blocks, compress and remove the valve retainer locks. SST 09202-70020 (09202-00010) (b) Remove the retainer, valve spring and valve. HINT: Arrange the removed parts in the correct order. 3. REMOVE EXHAUST VALVE (a) Using SST and wooden blocks, compress and remove the valve retainer locks. SST 09202-70020 (09202-00010) (b) Remove the retainer, valve spring and valve. HINT: Arrange the removed parts in the correct order. 4. REMOVE VALVE STEM OIL SEAL (a) Using needle-nose pliers, remove the oil seals. 5. REMOVE VALVE SPRING SEAT (a) Using compressed air and a magnetic finger, remove the valve spring seats by blowing air onto them. 6. REMOVE NO. 1 STRAIGHT SCREW PLUG (a) Using a 14 mm straight hexagon wrench, remove the 2 screw plugs and 2 gaskets. NOTICE: If water leaks from the straight screw plug or the plug corrodes, replace it. 7. REMOVE STUD BOLT 8. REMOVE RING PIN SST Wooden Block A128225E01 SST EM Wooden Block A128226E01 A013356E04 A062845E01 A062841 2AZ-FE ENGINE MECHANICAL – CYLINDER HEAD 9. EM–57 REMOVE INTAKE VALVE GUIDE BUSH (a) Heat the cylinder head to 80 to 100°C (176 to 212°F). (b) Place the cylinder head on wooden blocks. (c) Using SST and a hammer, tap out the guide bush. SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) SST 10. REMOVE EXHAUST VALVE GUIDE BUSH (a) Heat the cylinder head to 80 to 100°C (176 to 212°F). (b) Place the cylinder head on wooden blocks. A036632E01 (c) Using SST and a hammer, tap out the guide bush. SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) SST A036633E03 INSPECTION 1. INSPECT CYLINDER HEAD FOR FLATNESS (a) Using a precision straight edge and a feeler gauge, measure the surface contacting the cylinder block and the manifolds for warpage. Maximum warpage Item Cylinder Block Side: Specified Condition Cylinder block side 0.05 mm (0.0020 in.) Intake manifold side 0.08 mm (0.0031 in.) Exhaust manifold side 0.08 mm (0.0031 in.) If the warpage is greater than the maximum, replace the cylinder head. Intake Manifold Side: Exhaust Manifold Side: A052445E01 EM EM–58 2AZ-FE ENGINE MECHANICAL – CYLINDER HEAD 2. INSPECT CYLINDER HEAD FOR CRACKS (a) Using a dye penetrant, check the intake ports, exhaust ports and cylinder surface for cracks. If cracked, replace the cylinder head. 3. INSPECT VALVE SEATS (a) Apply a light coat of prussian blue to the valve face. (b) Lightly press the valve face against the valve seat. (c) Check the valve face and valve seat according to the following procedure: (1) If prussian blue appears 360° around the valve face, the valve face is concentric. If not, replace the valve. (2) If prussian blue appears 360° around the valve seat, the guide and valve face are concentric. If not, resurface the valve seat. (3) Check that the valve seat contact is in the middle of the valve face with the width between 1.0 to 1.4 mm (Intake side (0.039 to 0.055 in.)). (4) Check that the valve seat contact is in the middle of the valve face with the width between 1.2 to 1.6 mm (Exhaust side (0.047 to 0.063 in.)). 4. REPAIR VALVE SEATS NOTICE: • Repair the seat while checking the seating position. • Keep the lip free from foreign matter. A013365 EM Width A052446E01 (a) Using a 45° cutter, resurface the valve seat so that the valve seat width is more than the specification. A128228 2AZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–59 (b) Using 30° and 75° cutters, correct the valve seat so that the valve contacts the entire circumference of the seat. The contact should be in the center of the valve seat, and the valve seat width should be maintained within the specified range around the entire circumference of the seat. Valve Seat Width 75° 45° 30° Width A128227E01 Item Specified Condition Intake Side 1.0 to 1.4 mm (0.039 to 0.055 in.) Exhaust Side 1.2 to 1.6 mm (0.047 to 0.063 in.) (c) Handrub the valve and valve seat with an abrasive compound. (d) Check the valve seating position. 5. INSPECT CAMSHAFT THRUST CLEARANCE (a) Install the camshafts (See page EM-70). (b) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance Item Specified Condition Intake 0.040 to 0.095 mm (0.0016 to 0.0037 in.) Exhaust 0.080 to 0.135 mm (0.0032 to 0.0053 in.) Maximum thrust clearance Item A036626 Specified Condition Intake 0.110 mm (0.0043 in.) Exhaust 0.150 mm (0.0059 in.) If the thrust clearance is greater than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft. 6. INSPECT CAMSHAFT OIL CLEARANCE (a) Clean the bearing caps and camshaft journals. (b) Place the camshafts on the cylinder head. (c) Lay a strip of Plastigage across each of the camshaft journals. (d) Install the bearing caps (See page EM-70). NOTICE: Do not turn the camshaft. (e) Remove the bearing caps (See page EM-53). Plastigage A036627E03 EM EM–60 2AZ-FE ENGINE MECHANICAL – CYLINDER HEAD (f) Plastigage A036628E01 Measure the Plastigage at its widest point. Standard oil clearance Item Specified Condition Camshaft No. 1 journal bearing mark 1 0.007 to 0.038 mm (0.0003 to 0.0015 in.) Camshaft No. 1 journal bearing mark 2 0.008 to 0.038 mm (0.0003 to 0.0015 in.) Camshaft No. 1 journal bearing mark 3 0.008 to 0.038 mm (0.0003 to 0.0015 in.) Camshaft other journals 0.025 to 0.062 mm (0.0010 to 0.0024 in.) No. 2 camshaft No. 1 journal 0.015 to 0.054 mm (0.0006 to 0.0021 in.) No. 2 camshaft other journals 0.025 to 0.062 mm (0.0010 to 0.0024 in.) Maximum oil clearance Item Specified Condition Intake 0.070 mm (0.0028 in.) Exhaust 0.100 mm (0.0039 in.) EM NOTICE: Completely remove the Plastigage after the inspection. • If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the cylinder head. • If the oil clearance on the camshaft No. 1 journal is greater than the maximum, choose a new bearing and install it. (1) Check the number mark shown in the illustration. Cylinder head journal bore diameter Number Mark Mark 1 Mark 2 Mark 3 40.000 to 40.008 mm (1.5748 to 1.5752 in.) 40.009 to 40.017 mm (1.5752 to 1.5755 in.) 40.018 to 40.025 mm (1.5755 to 1.5758 in.) Standard bearing center wall thickness Number Mark A013530E04 Mark 1 Mark 2 Mark 3 2.000 to 2.004 mm (0.0787 to 0.0789 in.) 2.005 to 2.008 mm (0.0789 to 0.0791 in.) 2.009 to 2.012 mm (0.0791 to 0.0792 in.) Camshaft journal diameter Mark 1 Mark 2 Mark 3 35.971 to 35.985 mm (1.4162 to 1.4167 in.) 35.971 to 35.985 mm (1.4162 to 1.4167 in.) 35.971 to 35.985 mm (1.4162 to 1.4167 in.) 2AZ-FE ENGINE MECHANICAL – CYLINDER HEAD 7. EM–61 INSPECT INNER COMPRESSION SPRING (a) Using vernier calipers, measure the free length of the valve spring. Free length: 47.43 mm (1.867 in.) If the free length is not as specified, replace the valve spring. EM00801 (b) Using steel squares, measure the deviation of the valve spring. Maximum deviation: 1.6 mm (0.063 in.) If the deviation is greater than the maximum, replace the valve spring. EM00988E01 8. INSPECT INTAKE VALVE (a) Using a gasket scraper, scrape off any carbon on the valve head. A126904 (b) Using vernier calipers, measure the overall length of the valve. Standard overall length: 101.71 mm (4.0043 in.) Minimum overall length: 101.21 mm (3.9846 in.) If the overall length is less than the minimum, replace the valve. Overall Length A121380E01 (c) Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: 5.470 to 5.485 mm (0.2154 to 0.2159 in.) If the valve stem is not as specified, check the oil clearance. A121378 EM EM–62 2AZ-FE ENGINE MECHANICAL – CYLINDER HEAD (d) Using vernier calipers, measure the valve head margin thickness. Standard margin thickness: 1.05 to 1.45 mm (0.0413 to 0.0571 in.) Minimum margin thickness: 0.50 mm (0.0197 in.) If the margin thickness is less than the minimum, replace the valve. Margin Thickness A014597E01 9. INSPECT EXHAUST VALVE (a) Using a gasket scraper, scrape off any carbon on the valve head. EM A126904 (b) Using vernier calipers, measure the overall length of the valve. Standard overall length: 101.15 mm (3.9823 in.) Minimum overall length: 100.70 mm (3.9646 in.) If the overall length is less than the minimum, replace the valve. Overall Length A121383E01 (c) Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: 5.465 to 5.480 mm (0.2152 to 0.2157 in.) If the valve stem is not as specified, check the oil clearance. A121381 (d) Using vernier calipers, measure the valve head margin thickness. Standard margin thickness: 1.20 to 1.60 mm (0.0472 to 0.0630 in.) Minimum margin thickness: 0.50 mm (0.0197 in.) If the margin thickness is less than the minimum, replace the valve. Margin Thickness A121382E01 2AZ-FE ENGINE MECHANICAL – CYLINDER HEAD A128229 A136163 EM–63 10. INSPECT INTAKE VALVE GUIDE BUSH (a) Using a caliper gauge, measure the inside diameter of the guide bush. Bushing inside diameter: 5.510 to 5.530 mm (0.2169 to 0.2177 in.) (b) Subtract the valve stem diameter measurement from the guide bush inside diameter measurement. Standard oil clearance: 0.025 to 0.060 mm (0.0010 to 0.0024 in.) Maximum oil clearance: 0.080 mm (0.0031 in.) If the clearance is greater than the maximum, replace the valve and guide bush. 11. INSPECT EXHAUST VALVE GUIDE BUSH (a) Using a caliper gauge, measure the inside diameter of the guide bush. Bushing inside diameter: 5.510 to 5.530 mm (0.2169 to 0.2177 in.) (b) Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement. Standard oil clearance: 0.030 to 0.065 mm (0.0012 to 0.0026 in.) Maximum oil clearance: 0.100 mm (0.0039 in.) If the clearance is greater than the maximum, replace the valve and guide bush. 12. INSPECT VALVE LIFTER (a) Using a micrometer, measure the lifter diameter. Lifter diameter: 30.966 to 30.976 mm (1.2191 to 1.2195 in.) P016860E01 A129853 (b) Using a caliper gauge, measure the lifter bore diameter of the cylinder head. Standard lifter bore diameter: 31.009 to 31.025 mm (1.2208 to 1.2215 in.) (c) Subtract the lifter diameter measurement from the lifter bore diameter measurement. Standard oil clearance: 0.033 to 0.059 mm (0.0013 to 0.0023 in.) Maximum oil clearance: 0.070 mm (0.0028 in.) If the oil clearance is greater than the maximum, replace the lifter. If necessary, replace the cylinder head. EM EM–64 2AZ-FE ENGINE MECHANICAL – CYLINDER HEAD 13. INSPECT CYLINDER HEAD SET BOLT (a) Using vernier calipers, measure the length of the head bolts from the seat to the end. Standard bolt length: 141.3 to 142.7 mm (5.563 to 5.618 in.) Maximum bolt length: 144.2 mm (5.677 in.) If the bolt length is greater than the maximum, replace the cylinder head set bolt. Length A094201E01 REASSEMBLY 1. EM INSTALL INTAKE VALVE GUIDE BUSH (a) Using a caliper gauge, measure the bush bore diameter of the cylinder head. Cylinder bore diameter: 10.285 to 10.306 mm (0.4049 to 0.4057 in.) Select a new guide bush (STD or O/S 0.05) Bush size A131495 Bush bore diameter Use STD 10.285 to 10.306 mm (0.4049 to 0.4057 in.) Use O/S 0.05 10.335 to 10.356 mm (0.4069 to 0.4077 in.) If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 in.) to install a O/S 0.05 valve guide bush. If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head. (b) Heat the cylinder head to 80 to 100°C (176 to 212°F). (c) Place the cylinder head on wooden blocks. Protrusion Height SST (d) Using SST and a hammer, tap in a new guide bush to the specified protrusion height. SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) Protrusion height: 9.6 to 10.0 mm (0.3779 to 0.3937 in.) A036634E03 (e) Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard specified clearance between the guide bush and valve stem. Standard oil clearance: 0.025 to 0.060 mm (0.0010 to 0.0024 in.) A136150 2AZ-FE ENGINE MECHANICAL – CYLINDER HEAD 2. EM–65 INSTALL EXHAUST VALVE GUIDE BUSH (a) Using a caliper gauge, measure the bush bore diameter of the cylinder head. Diameter: 10.285 to 10.306 mm (0.4049 to 0.4057 in.) Select a new guide bush (STD or O/S 0.05) Bush size Bush bore diameter Use STD 10.285 to 10.306 mm (0.4049 to 0.4057 in.) Use O/S 0.05 10.335 to 10.356 mm (0.4069 to 0.4077 in.) A124782 If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 in.) to install a O/S 0.05 valve guide bush. If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head. (b) Heat the cylinder head to 80 to 100°C (176 to 212°F). (c) Place the cylinder head on wooden blocks. (d) Using SST and a hammer, tap in a new guide bush to the specified protrusion height. SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) Protrusion height: 9.6 to 10.0 mm (0.3779 to 0.3937 in.) Protrusion Height SST A036635E03 (e) Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard specified clearance between the guide bush and valve stem. Standard oil clearance: 0.030 to 0.065 mm (0.0012 to 0.0026 in.) A124783 EM EM–66 2AZ-FE ENGINE MECHANICAL – CYLINDER HEAD Upper Side: 11 mm (0.43 in.) 8 mm (0.31 in.) 3 mm (0.12 in.) A128230E01 EM 3. INSTALL RING W/HEAD PIN (a) Using a plastic-faced hammer, tap in a new ring pin to the specified protrusion height. Protrusion height: 3 mm (0.12 in.) 4. INSTALL STUD BOLT NOTICE: If the stud bolt is deformed or the threads are damaged, replace it. EM–67 2AZ-FE ENGINE MECHANICAL – CYLINDER HEAD (a) Using E5 and E7 "torx" sockets, install the stud bolts. Upper Side: Front Side: A A B B Intake Side: EM Exhaust Side: C D 12 mm (0.47 in.) 24 mm (0.94 in.) 46.5 mm (1.83 in.) 49.5 mm (1.95 in.) 18 mm (0.71 in.) 12 mm (0.47 in.) 33 mm (1.30 in.) A (M6) 9 mm (0.35 in.) B (M6) 12 mm (0.47 in.) C (M8) 37.5 mm (1.48 in.) D (M8) 13 mm (0.51 in.) 13 mm (0.51 in.) A128231E01 Torque: Bolt A 5.0 N*m (51 kgf*cm, 44 in.*lbf) Bolt B 5.0 N*m (51 kgf*cm, 44 in.*lbf) Bolt C 9.5 N*m (97 kgf*cm, 84 in.*lbf) Bolt D 9.5 N*m (97 kgf*cm, 84 in.*lbf) EM–68 2AZ-FE ENGINE MECHANICAL – CYLINDER HEAD 5. INSTALL NO. 1 STRAIGHT SCREW PLUG (a) Using a 14 mm straight hexagon wrench, install 2 new gaskets and the 2 straight screw plugs. 6. INSTALL VALVE SPRING SEAT (a) Install the valve spring seats to the cylinder head. 7. INSTALL VALVE STEM OIL SEAL (a) Apply a light coat of engine oil to a new oil seal. NOTICE: Pay close attention when installing the intake and exhaust oil seals. For example, installing the intake oil seal into the exhaust side or installing the exhaust oil seal to the intake side can cause installation problems later. HINT: The intake valve oil seal is gray and the exhaust valve oil seal is black. A062841 EM A062872 Intake Side Exhaust Side Gray Black A052449E01 (b) Using SST, push in the oil seal. SST 09201-41020 NOTICE: Failure to use SST will cause the seal to be damaged or improperly seated. SST CORRECT INCORRECT A129854E01 2AZ-FE ENGINE MECHANICAL – CYLINDER HEAD 8. 30 mm (1.18 in.) or more EM–69 INSTALL INTAKE VALVE (a) Apply a sufficient coat of engine oil to the tip area of the intake valve shown in the illustration. (b) Install the valve, compression spring and spring retainer to the cylinder head. NOTICE: Install the same parts in the same combination to the original locations. A094935E04 (c) Using SST and wooden blocks, compress the spring and install the 2 retainer locks. SST 09202-70020 (09202-00010) SST EM Wooden Block A128225E01 (d) Using a 5 mm pin punch and plastic hammer, lightly tap the valve stem tip to ensure a proper fit. NOTICE: Be careful not to damage the valve stem tip. 5 mm Pin Punch A036640E01 9. 30 mm (1.18 in.) or more INSTALL EXHAUST VALVE (a) Apply a sufficient coat of engine oil to the tip area of the exhaust valve shown in the illustration. (b) Install the valve, compression spring and spring retainer to the cylinder head. NOTICE: Install the same parts in the same combination to the original locations. A094936E03 (c) Using SST and wooden blocks, compress the spring and install the 2 retainer locks. SST 09202-70020 (09202-00010) SST Wooden Block A128226E01 EM–70 2AZ-FE ENGINE MECHANICAL – CYLINDER HEAD (d) Using a 5 mm pin punch and plastic hammer, lightly tap the valve stem tip to ensure a proper fit. NOTICE: Be careful not to damage the valve stem tip. 5 mm Pin Punch A036641E01 10. INSTALL VALVE LIFTER (a) Assemble the valve lifter and the tip of the valve stem with a light coat of engine oil applied. NOTICE: Install the valve lifters in their original places. EM A062842E01 INSTALLATION Lot No. A126929E01 8 6 1 3 9 10 4 2 5 7 F050595E03 1. INSTALL CYLINDER HEAD GASKET (a) Place a new gasket on the cylinder block surface with the Lot No. stamp facing upward. NOTICE: • Remove any oil from the contact surface. • Make sure that the gasket is installed in the correct direction. 2. INSTALL CYLINDER HEAD SUB-ASSEMBLY HINT: The cylinder head bolts are tightened in 2 progressive steps. (a) Apply a light coat of engine oil to the bolt threads and the area beneath the bolt heads that come in contact with the washers. (b) Install the bolts and plate washers to the cylinder head. NOTICE: Do not drop the washers into the cylinder head. (c) Using several steps, uniformly install and tighten the 10 cylinder head set bolts and plate washers with a 10 mm bi-hexagon wrench in the order shown in the illustration. Torque: 70 N*m (714 kgf*cm, 52 ft.*lbf) 2AZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–71 (d) Mark the front side of the cylinder head bolt with paint. (e) Retighten the cylinder head bolts 90° in the sequence shown in the illustration. (f) Check that the paint mark is now at a 90° angle to the front. 90° Engine Front Paint Mark A098364E01 3. CONNECT ENGINE WIRE (a) Connect the ground cable with the bolt. Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) (b) Connect the camshaft position sensor connector. (c) Connect the engine coolant temperature sensor connector. (d) Connect the engine oil pressure switch connector. (e) Connect the radio setting condenser connector. 4. CONNECT RADIATOR HOSE INLET (See page EM118) 5. INSTALL NO. 2 CAMSHAFT BEARING (a) Install the No. 2 camshaft bearing. 6. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (See page ES-406) 7. INSTALL CAMSHAFTS (a) Apply a light coat of engine oil to the journal portion of the camshaft. A098748E01 A128879 (b) Place the 2 camshafts on the cylinder head with the No. 1 cam lobes facing the directions shown in the illustration. No. 1 Cam Lobe F050592E01 (c) Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps onto the cylinder head. (d) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts. F050591E01 EM EM–72 No. 1 2AZ-FE ENGINE MECHANICAL – CYLINDER HEAD 5 6 1 2 9 10 17 (e) Using several steps, uniformly tighten the 20 bearing cap bolts in the sequence shown in the illustration. Torque: No. 1 and No. 2 bearing cap 30 N*m (301 kgf*cm, 22 ft.*lbf) No. 3 bearing cap 9.0 N*m (92 kgf*cm, 80 in.*lbf) 18 13 14 15 16 No. 2 8 7 4 8. INSTALL CHAIN SUB-ASSEMBLY HINT: See page EM-27. 9. INSTALL EXHAUST MANIFOLD CONVERTER SUBASSEMBLY (See page EM-109) 3 12 11 20 19 F050596E05 10. INSTALL NO. 2 MANIFOLD STAY (See page EM-110) 11. INSTALL MANIFOLD STAY (See page EM-111) EM 12. INSTALL OIL LEVEL GAUGE GUIDE (See page EM111) 13. INSTALL OIL LEVEL GAUGE SUB-ASSEMBLY 14. INSTALL GENERATOR ASSEMBLY (See page CH-19) 15. INSTALL V-RIBBED BELT (See page EM-6) 16. INSTALL NO. 2 ENGINE MOUNTING BRACKET RH (See page EM-118) 17. INSTALL ENGINE MOVING CONTROL ROD SUBASSEMBLY (See page EM-119) 18. INSTALL NO. 2 ENGINE MOUNTING STAY RH (See page EM-119) 19. INSTALL FRONT EXHAUST PIPE ASSEMBLY HINT: See page EX-3. 20. INSTALL NO. 1 INTAKE MANIFOLD INSULATOR (See page EM-111) 21. INSTALL INTAKE AIR CONTROL VALVE (For PZEV) (See page IT-7) 22. INSTALL INTAKE MANIFOLD (See page ES-425) 23. INSTALL FUEL DELIVERY PIPE WITH INJECTOR (See page FU-15) 24. CONNECT FUEL TUBE SUB-ASSEMBLY (See page FU-16) 25. INSTALL THROTTLE BODY ASSEMBLY (See page ES-418) 26. INSTALL BATTERY (See page EM-119) 27. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (See page EM-120) 28. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See page ES-419) 2AZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–73 29. INSTALL AIR CLEANER INLET ASSEMBLY (See page EM-120) 30. INSTALL COWL TOP PANEL OUTER SUBASSEMBLY (See page ES-426) 31. INSTALL WINDSHIELD WIPER LINK ASSEMBLY HINT: See page WW-13. 32. CONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (See page EM-120) 33. ADD ENGINE OIL 34. CHECK FOR FUEL LEAKS (See page FU-9) 35. ADD COOLANT (See page CO-5) 36. CHECK FOR ENGINE COOLANT LEAKS (See page CO-1) 37. CHECK FOR ENGINE OIL LEAKS 38. CHECK FOR EXHAUST GAS LEAKS 39. INSPECT IGNITION TIMING (See page EM-1) 40. INSPECT IDLE SPEED (See page EM-2) 41. INSPECT COMPRESSION (See page EM-3) 42. INSPECT CO/HC (See page EM-3) 43. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (See page EM-121) 44. INSTALL FRONT FENDER APRON SEAL RH 45. INSTALL ENGINE UNDER COVER LH 46. INSTALL ENGINE UNDER COVER RH 47. INSTALL FRONT WHEEL RH (See page EM-120) EM EM–74 2AZ-FE ENGINE MECHANICAL – ENGINE FRONT OIL SEAL ENGINE FRONT OIL SEAL 2AZ-FE ENGINE MECHANICAL ENGINE COMPONENTS TMMK: 170 (1,733, 125) TMC: 180 (1,835, 133) V-RIBBED BELT CRANKSHAFT PULLEY TIMING CHAIN CASE OIL SEAL EM FRONT FENDER APRON SEAL RH ENGINE UNDER COVER RH ENGINE UNDER COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A134924E03 2AZ-FE ENGINE MECHANICAL – ENGINE FRONT OIL SEAL EM–75 REMOVAL 1. REMOVE FRONT WHEEL RH 2. REMOVE FRONT FENDER APRON SEAL RH 3. REMOVE ENGINE UNDER COVER LH 4. REMOVE ENGINE UNDER COVER RH 5. REMOVE V-RIBBED BELT (See page EM-6) 6. REMOVE CRANKSHAFT PULLEY (a) TMMK made: (1) Using SST, fix the pulley in place and loosen the pulley bolt. SST 09960-10010 (09962-01000, 0996301000) SST EM A062057E02 Hooking Point (2) Using SST, remove the pulley bolt and pulley. SST 09950-40011 (09951-04010, 0995204010, 09953-04030, 09955-04041, 09957-04010, 09954-04010, 9111151014) SST A062058E03 (b) TMC made: (1) Using SST, fix the pulley in place and loosen the pulley bolt. SST 09213-54015 (91651-60855), 0933000021 SST SST A013697E02 (2) Using SST, remove the pulley bolt and pulley. SST 09950-50013 (09951-05010, 0995205010, 09953-05020, 09954-05021), 09950-40011 (09957-04010) HINT: If necessary, remove the pulley and pulley bolt using SST. SST A124860E01 EM–76 2AZ-FE ENGINE MECHANICAL – ENGINE FRONT OIL SEAL 7. Cut Position A112529E02 EM REMOVE TIMING CHAIN CASE OIL SEAL (a) Using a knife, cut off the oil seal lip. (b) Using a screwdriver with the tip taped, pry out the oil seal. NOTICE: After the removal, check the crankshaft for damage. If it is damaged, smooth the surface with 400-grit sandpaper. 2AZ-FE ENGINE MECHANICAL – ENGINE FRONT OIL SEAL EM–77 INSTALLATION 1. INSTALL TIMING CHAIN CASE OIL SEAL (a) Apply MP grease to a new oil seal lip. NOTICE: Keep the lip free from foreign matter. (b) Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-22010 NOTICE: Wipe off extra grease from the crankshaft. 2. INSTALL CRANKSHAFT PULLEY (a) TMMK made: (1) Align the pulley set key with the key groove of the pulley. A032663 (2) Using SST, fix the pulley in place and tighten the bolt. SST 09960-10010 (09962-01000, 0996301000) Torque: 170 N*m (1,733 kgf*cm, 125 ft.*lbf) (b) TMC made: (1) Align the pulley set key with the key groove of the pulley. SST A062057E02 (2) Using SST, fix the pulley in place and tighten the bolt. SST 09213-54015 (91651-60855), 0933000021 Torque: 180 N*m (1,835 kgf*cm, 133 ft.*lbf) SST SST 3. INSTALL V-RIBBED BELT (See page EM-6) 4. INSTALL ENGINE UNDER COVER LH 5. INSTALL ENGINE UNDER COVER RH 6. INSTALL FRONT FENDER APRON SEAL RH 7. INSTALL FRONT WHEEL RH 8. CHECK FOR ENGINE OIL LEAKS A013697E03 EM 2AZ-FE ENGINE MECHANICAL – ENGINE REAR OIL SEAL EM–77 ENGINE REAR OIL SEAL 2AZ-FE ENGINE MECHANICAL ENGINE COMPONENTS M/T: ENGINE REAR OIL SEAL x8 EM 130 (1,330, 96) x6 19 (195, 14) FLYWHEEL SUB-ASSEMBLY CLUTCH DISC ASSEMBLY CLUTCH COVER ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A136909E01 EM–78 2AZ-FE ENGINE MECHANICAL – ENGINE REAR OIL SEAL A/T: EM ENGINE REAR OIL SEAL FRONT SPACER REAR SPACER 41 (418, 30) x6 x8 98 (1,000, 72) DRIVE PLATE & RING GEAR SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A136910E01 2AZ-FE ENGINE MECHANICAL – ENGINE REAR OIL SEAL EM–79 REMOVAL 1. SEPARATE AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle) HINT: See page AX-162. 2. SEPARATE MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle) HINT: See page MX-24. 3. REMOVE DRIVE PLATE & RING GEAR SUBASSEMBLY (for Automatic Transaxle) (a) TMMK made: (1) Using SST, hold the crankshaft. SST 09960-10010 (09962-01000, 0996301000) SST A062061E01 (b) TMC made: (1) Using SST, hold the crankshaft. SST 09213-54015 (91651-60855), 0933000021 SST A126932E01 (c) Remove the 8 bolts, rear spacer, drive plate and front spacer. 4. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle) (See page CL-32) 5. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle) (See page CL-32) 6. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle) (a) TMMK made: (1) Using SST, hold the crankshaft. SST 09960-10010 (09962-01000, 0996301000) A091018 SST A062061E01 EM EM–80 2AZ-FE ENGINE MECHANICAL – ENGINE REAR OIL SEAL (b) TMC made: (1) Using SST, hold the crankshaft. SST 09213-54015 (91651-60855), 0933000021 SST A126932E01 (c) Remove the 8 bolts and flywheel. EM A091020E01 7. Cut position A128873E01 REMOVE ENGINE REAR OIL SEAL (a) Using a knife, cut through the oil seal lip. (b) Using a screwdriver with its tip taped, pry out the oil seal. NOTICE: After the removal, check the crankshaft for damage. If it is damaged, smooth the surface with 400-grit sandpaper. 2AZ-FE ENGINE MECHANICAL – ENGINE REAR OIL SEAL EM–81 INSTALLATION 1. INSTALL ENGINE REAR OIL SEAL (a) Apply MP grease to a new oil seal lip. NOTICE: Keep the lip free from foreign matter. (b) Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-15030, 09950-70010 (09951-07100) NOTICE: Wipe off extra grease from the crankshaft. SST EM A128874E01 2. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle) (a) TMMK made: (1) Using SST, hold the crankshaft. SST 09960-10010 (09962-01000, 0996301000) SST A062061E01 (b) TMC made: (1) Using SST, hold the crankshaft. SST 09213-54015 (91651-60855), 0933000021 (c) Clean the bolt and the bolt hole. (d) Apply adhesive to 2 or 3 threads of the bolt end. Adhesive: Part No. 08833-00070, THREE BOND or equivalent SST A126932E01 (e) Install the flywheel with the 8 bolts. Uniformly tighten the 8 bolts in the sequence shown in the illustration. Torque: 130 N*m (1,330 kgf*cm, 96 ft.*lbf) A060816 3. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle) (See page CL-34) 4. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle) (See page CL-34) EM–82 2AZ-FE ENGINE MECHANICAL – ENGINE REAR OIL SEAL 5. INSTALL DRIVE PLATE & RING GEAR SUBASSEMBLY (for Automatic Transaxle) (a) TMMK made: (1) Using SST, hold the crankshaft. SST 09960-10010 (09962-01000, 0996301000) SST A062061E01 (b) TMC made: (1) Using SST, hold the crankshaft. SST 09213-54015 (91651-60855), 0933000021 (c) Clean the bolt and the bolt hole. (d) Apply adhesive to 2 or 3 threads of the bolt end. Adhesive: Part No. 08833-00070, THREE BOND or equivalent EM SST A126932E01 (e) Install the front spacer, drive plate and rear spacer with the 8 bolts. Uniformly tighten the 8 bolts in the sequence shown in the illustration. Torque: 98 N*m (1,000 kgf*cm, 72 ft.*lbf) 1 6 3 8 7 4 2 6. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle) HINT: See page MX-27. 7. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle) HINT: See page AX-168. 5 A112224E01 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–83 ENGINE ASSEMBLY 2AZ-FE ENGINE MECHANICAL ENGINE COMPONENTS FRONT WIPER ARM AND BLADE ASSEMBLY RH 20 (204, 15) FRONT FENDER TO COWL SIDE SEAL RH FRONT WIPER ARM AND BLADE ASSEMBLY LH COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY EM 7.5 (77, 66 in.*lbf) 85 (867, 63) FRONT FENDER TO COWL SIDE SEAL LH 5.0 (51, 44 in.*lbf) WINDSHIELD WIPER LINK ASSEMBLY COWL TOP PANEL OUTER SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque A136912E01 EM–84 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY ENGINE MOVING CONTROL ROD SUB-ASSEMBLY NO. 2 ENGINE MOUNTING BRACKET RH 64 (653, 47) 9.0 (92, 80 in.*lbf) 52 (531, 38) 64 (653, 47) NO. 1 ENGINE COVER SUB-ASSEMBLY EM NO. 2 ENGINE MOUNTING STAY RH V-RIBBED BELT 9.8 (100, 87 in.*lbf) 52 (531, 38) 21 (214, 15) GENERATOR ASSEMBLY FRONT FENDER APRON SEAL RH N*m (kgf*cm, ft.*lbf) : Specified torque A134948E01 EM–85 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY AIR CLEANER CAP SUB-ASSEMBLY AIR CLEANER CASE SUB-ASSEMBLY 5.0 (51, 44 in.*lbf) 5.0 (51, 44 in.*lbf) 9.0 (92, 80 in.*lbf) EM 3.5 (36, 31 in.*lbf) AIR CLEANER INLET ASSEMBLY BATTERY BATTERY TRAY ENGINE UNDER COVER RH R/B COVER ENGINE UNDER COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque A134915E01 EM–86 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY M/T: CLUTCH ACCUMULATOR ASSEMBLY CLIP 12 (120, 9) 12 (120, 9) EM CLUTCH RELEASE CYLINDER ASSEMBLY TRANSMISSION CONTROL CABLE ASSEMBLY NO. 1 OIL RESERVOIR TO PUMP HOSE NO. 1 VACUUM HOSE CONNECTOR RADIATOR HOSE OUTLET HEATER INLET WATER HOSE RETURN TUBE SUB-ASSEMBLY 25 (250, 18) COMPRESSOR AND MAGNETIC CLUTCH TRANSMISSION CONTROL CABLE ASSEMBLY (for A/T) 13 (133, 10) CLIP RADIATOR HOSE INLET OIL COOLER OUTLET HOSE N*m (kgf*cm, ft.*lbf) : Specified torque HEATER OUTLET WATER HOSE OIL COOLER INLET HOSE Non-reusable part A134916E01 EM–87 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY TIE ROD ASSEMBLY LH STEERING SLIDING YOKE 35 (357, 26) EM 74 (755, 55) 49 (500, 36) COTTER PIN 8.0 (82, 71 in.*lbf) FRONT SPEED SENSOR LH DRIVE SHAFT ASSEMBLY LH 294 (3,000, 217) FRONT AXLE HUB NUT LH 75 (755, 55) FRONT SUSPENSION LOWER NO. 1 ARM LH NO. 1 EXHAUST PIPE SUPPORT BRACKET EXHAUST PIPE GASKET 19 (194, 13) 56 (571, 41) EXHAUST PIPE GASKET 62 (633, 46) FRONT EXHAUST PIPE NO. 1 SUPPORT BRACKET 33 (337, 24) 33 (337, 24) REAR EXHAUST PIPE NO. 1 SUPPORT BRACKET FRONT EXHAUST PIPE ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A134917E01 EM–88 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY A/T: 43 (439, 32) 54 (551, 40) x3 95 (969, 70) VANE PUMP ASSEMBLY ENGINE MOUNTING BRACKET RH EM 95 (969, 70) 87 (888, 64) FRONT FRAME ASSEMBLY FRAME SIDE RAIL PLATE SUB-ASSEMBLY RH 32 (326, 24) 85 (867, 63) FRAME SUSPENSION MEMBER BRACE REAR RH FRAME SIDE RAIL PLATE SUB-ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque FRAME SUSPENSION MEMBER BRACE REAR LH 32 (326, 24) 85 (867, 63) A138330E01 EM–89 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY M/T: VANE PUMP ASSEMBLY 43 (439, 32) NO. 2 ENGINE MOUNTING BRACKET REAR 54 (551, 40) 64 (653, 47) 89 (910, 66) 95 (969, 70) ENGINE MOUNTING BRACKET RH EM 87 (888, 64) 143 (1,459, 105) FRONT FRAME ASSEMBLY FRAME SIDE RAIL PLATE SUBASSEMBLY RH 32 (326, 24) FRAME SUSPENSION MEMBER BRACE REAR RH 85 (867, 63) FRAME SIDE RAIL PLATE SUB-ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque FRAME SUSPENSION MEMBER BRACE REAR LH 32 (326, 24) 85 (867, 63) A138333E01 EM–90 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY A/T: FRONT DRIVE SHAFT ASSEMBLY RH HOLE SNAP RING 64 (653, 47) EM DRIVE SHAFT BEARING BRACKET FLYWHEEL HOUSING UNDER COVER 44 (450, 32) ENGINE WIRE FRONT SPACER 98 (1,000, 72) 41 (418, 30) 64 (650, 47) DRIVE PLATE & RING GEAR SUB-ASSEMBLY AUTOMATIC TRANSAXLE ASSEMBLY REAR SPACER 46 (470, 34) SNAP RING STARTER ASSEMBLY FRONT DRIVE SHAFT ASSEMBLY LH 39 (398, 29) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A139203E01 EM–91 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY FRONT DRIVE SHAFT ASSEMBLY RH M/T: HOLE SNAP RING 64 (653, 47) EM DRIVE SHAFT BEARING BRACKET FLYWHEEL SUB-ASSEMBLY 44 (450, 32) ENGINE WIRE 130 (1,330, 96) 19 (195, 14) 64 (650, 47) CLUTCH DISC ASSEMBLY 46 (470, 34) CLUTCH COVER ASSEMBLY 64 (650, 47) 46 (470, 34) MANUAL TRANSAXLE ASSEMBLY FRONT DRIVE SHAFT ASSEMBLY LH STARTER ASSEMBLY SNAP RING 39 (398, 29) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A137255E01 EM–92 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 20 (204, 15) INTAKE MANIFOLD FUEL DELIVERY PIPE WITH INJECTOR SPACER 30 (306, 22) INSURATOR INTAKE AIR CONTROL VALVE (For PZEV) VENTILATION HOSE GASKET EM NO. 1 MANIFOLD CONVERTER INSULATOR NO. 1 INTAKE MANIFOLD INSULATOR VENTILATION HOSE NO. 2 EXHAUST MANIFOLD CONVERTER SUBASSEMBLY For PZEV: 12 (122, 9) GASKET 37 (378, 27) x5 44 (449, 32) 44 (449, 32) 44 (449, 32) MANIFOLD STAY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part NO. 2 MANIFOLD STAY A136908E02 EM–93 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY IGNITION COIL ASSEMBLY 9.0 (92, 80 in.*lbf) 15 (153, 11) ENGINE OIL PRESSURE SWITCH ASSEMBLY KNOCK SENSOR GASKET 20 (208, 15) 20 (204, 15) ENGINE COOLANT TEMPERATURE SENSOR V-RIBBED BELT TENSIONER ASSEMBLY 10 (102, 7) RADIO SETTING CONDENSER OIL LEVEL GAUGE SUB-ASSEMBLY 9.0 (92, 80 in.*lbf) 60 (607, 44) 9.0 (92, 80 in.*lbf) NO. 1 WATER BY-PASS PIPE 9.0 (92, 80 in.*lbf) GASKET NO. 1 WATER HOUSING GASKET WATER INLET 9.0 (92, 80 in.*lbf) OIL LEVEL GAUGE GUIDE GASKET THERMOSTAT 9.0 (92, 80 in.*lbf) OIL COOLER PIPE (WITH OIL COOLER) N*m (kgf*cm, ft.*lbf) : Specified torque OIL LEVEL GAUGE GUIDE O-RING Non-reusable part A136911E02 EM EM–94 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY REMOVAL EM 1. DISCHARGE FUEL SYSTEM PRESSURE HINT: See page FU-1. 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 4. REMOVE FRONT WHEELS 5. REMOVE ENGINE UNDER COVER LH 6. REMOVE ENGINE UNDER COVER RH 7. REMOVE FRONT FENDER APRON SEAL RH 8. DRAIN ENGINE OIL (See page LU-4) 9. DRAIN ENGINE COOLANT (See page CO-5) 10. DRAIN AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle) (See page AX-162) 11. DRAIN MANUAL TRANSAXLE OIL (for Manual Transaxle) (See page MX-5) 12. DRAIN BRAKE FLUID (for Manual Transaxle) (See page BR-28) 13. REMOVE WINDSHIELD WIPER LINK ASSEMBLY HINT: See page WW-9. 14. REMOVE COWL TOP PANEL OUTER SUBASSEMBLY (See page ES-424) 15. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (a) Remove the 2 nuts and cover. 16. REMOVE V-RIBBED BELT (See page EM-6) A134904 17. REMOVE AIR CLEANER INLET ASSEMBLY (a) Remove the 2 bolts, clamp and air cleaner inlet. 18. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-416) A134903 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–95 19. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (a) Disconnect the hose clamp. (b) Remove the 3 bolts and air cleaner case. A134905 20. REMOVE BATTERY (a) Loosen the bolt and nut, and remove the battery clamp. (b) Remove the battery and battery tray. A134906 21. REMOVE NO. 2 ENGINE MOUNTING STAY RH (a) Remove the 2 bolts and No. 2 mounting stay RH. A134912 22. REMOVE ENGINE MOVING CONTROL ROD SUBASSEMBLY (a) Remove the bolt and disconnect the ground cable. A134909 EM EM–96 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY (b) Remove the 3 bolts and the engine moving control rod with bracket. A134910 23. REMOVE NO. 2 ENGINE MOUNTING BRACKET RH (a) Remove the 3 bolts and No. 2 mounting bracket RH. EM A134911 24. DISCONNECT NO. 1 VACUUM HOSE CONNECTOR (a) Remove the clamp and disconnect the vacuum hose connector. A134908 25. DISCONNECT RADIATOR HOSE INLET (a) Remove the clamp and disconnect the radiator hose inlet. A134907 26. DISCONNECT RADIATOR HOSE OUTLET (a) Remove the clamp and disconnect the radiator hose outlet. 27. DISCONNECT OIL COOLER INLET HOSE (for Automatic Transaxle) (See page CO-22) 28. DISCONNECT OIL COOLER OUTLET HOSE (for Automatic Transaxle) (See page CO-23) A127545 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–97 29. DISCONNECT HEATER INLET WATER HOSE (a) Disconnect the heater inlet water hose. A124832 30. DISCONNECT HEATER OUTLET WATER HOSE (a) Disconnect the heater outlet water hose. 31. REMOVE ECM HINT: See page ES-432. EM A124831 32. DISCONNECT ENGINE WIRE (a) Disconnect the engine wire from the engine room relay block. (1) Remove the nut and separate the wire harness. (2) Using a screwdriver, unlock the engine room R/ B. Pull the engine room R/B upward. (3) Disconnect the engine wire connectors. A132975 (b) Remove the clamp from the bracket. A134913 EM–98 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY (c) Remove the 2 bolts and clamp from the body. A134914 33. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle) (a) Remove the clip and nut, and separate the control lever. (b) Separate the clamp and separate the cable from the transaxle. EM A132974 34. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle) (a) Remove the 2 clips and 2 washers and disconnect the 2 cables from the transaxle. (b) Remove the 2 clips and disconnect the 2 cables from the control cable bracket. C132952 35. DISCONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE (a) Disconnect the No. 1 oil reservoir to pump hose. A060072 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–99 36. DISCONNECT RETURN TUBE SUB-ASSEMBLY (a) Disconnect the return tube sub-assembly. 37. REMOVE CLUTCH ACCUMULATOR ASSEMBLY (for Manual Transaxle) HINT: See page CL-27. A060073 38. REMOVE CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle) HINT: See page CL-24. 39. DISCONNECT FUEL TUBE SUB-ASSEMBLY (a) Remove the No. 1 fuel pipe clamp. EM A129626 A A B012941E15 (b) Disconnect the connector from the tube while pinching part A with your fingers as shown in the illustration. NOTICE: • Check for contamination in the pipe and around the connector. Clean if necessary and then disconnect the connector. • Disconnect the connector by hand. • Do not bend, fold or rotate the nylon tube. • If the pipe and connector are stuck together, push and pull the connector until it becomes free. • Put the pipe and connector ends in vinyl bags to prevent damage and contamination. 40. REMOVE GENERATOR ASSEMBLY (See page CH-11) 41. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (a) Disconnect the connector. (b) Remove the 4 bolts and separate the compressor. HINT: Hang up the hoses instead of detaching them. 42. REMOVE FRONT EXHAUST PIPE ASSEMBLY HINT: See page EX-2. A134944 43. REMOVE FRONT AXLE HUB NUT LH (See page DS7) 44. REMOVE FRONT AXLE HUB NUT RH HINT: Use the same procedures described for the LH side. EM–100 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 45. REMOVE FRONT STABILIZER LINK ASSEMBLY LH (See page DS-7) 46. REMOVE FRONT STABILIZER LINK ASSEMBLY RH HINT: Use the same procedures described for the LH side. 47. REMOVE FRONT SPEED SENSOR LH (See page DS7) 48. REMOVE FRONT SPEED SENSOR RH HINT: Use the same procedures described for the LH side. 49. DISCONNECT TIE ROD ASSEMBLY LH (See page DS-8) 50. DISCONNECT TIE ROD ASSEMBLY RH HINT: Use the same procedures described for the LH side. EM 51. DISCONNECT FRONT SUSPENSION LOWER NO. 1 ARM LH (See page DS-8) 52. DISCONNECT FRONT SUSPENSION LOWER NO. 1 ARM RH HINT: Use the same procedures described for the LH side. 53. SEPARATE FRONT AXLE ASSEMBLY LH (See page DS-8) 54. SEPARATE FRONT AXLE ASSEMBLY RH HINT: Use the same procedures described for the LH side. 55. REMOVE DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transaxle) (See page AX-164) 56. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET (a) Remove the 2 bolts and exhaust pipe support bracket. 57. SEPARATE STEERING SLIDING YOKE (See page PS40) 58. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (a) Set the engine lifter. (b) Remove the 4 bolts, 2 nuts and frame side rail plate RH and LH. A059877 EM–101 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY (c) Remove the 4 bolts, 2 nuts and front suspension member brace rear RH and LH. (d) Carefully remove the engine assembly from the vehicle. A059878 No . 1 Engine Hanger (e) Install the 2 engine hangers as shown in the illustration. Parts No.: No. 2 Engine Hanger A090847E03 (f) Parts Parts No. No. 1 Engine hanger 12281-28010 No. 2 Engine hanger 12282-28010 Bolt 91512-61020 Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) Using a chain block and an engine sling device, hang the engine assembly. 59. REMOVE VANE PUMP ASSEMBLY (a) Disconnect the oil pressure switch connector. (b) Loosen the 2 bolts and remove the vane pump from the engine. A059879 60. REMOVE FRONT FRAME ASSEMBLY (a) A/T: Remove the nut from the engine mounting insulator LH. A/T A052490E01 (b) M/T: Remove the bolt from the engine mounting insulator LH. M/T A059881E01 EM EM–102 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY (c) Remove the nut from the engine mounting insulator RH. A052482 (d) Remove the bolt from the engine mounting insulator FR. EM A059880 (e) M/T: Remove the bolt from the engine lateral control rod. (f) Raise the engine assembly and separate the front frame. M/T 61. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (See page DS-9) 62. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (See page DS-9) A060825E04 63. REMOVE ENGINE WIRE 64. REMOVE STARTER ASSEMBLY (for Manual Transaxle) (See page ST-5) 65. REMOVE STARTER ASSEMBLY (for Automatic Transaxle) (See page ST-5) 66. SEPARATE AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle) HINT: See page AX-162. 67. SEPARATE MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle) HINT: See page MX-24. 68. REMOVE DRIVE PLATE & RING GEAR SUBASSEMBLY (for Automatic Transaxle) (See page EM79) 69. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle) (See page CL-32) 70. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle) (See page CL-32) 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–103 71. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle) (See page EM-79) 72. INSTALL ENGINE STAND (a) Fix the engine onto a engine stand with the bolts. 73. REMOVE FUEL DELIVERY PIPE WITH INJECTOR (See page FU-13) 74. REMOVE INTAKE MANIFOLD (a) Remove the 5 bolts, 2 nuts, and intake manifold. EM A128862 (b) Remove the gasket from the intake manifold. 75. REMOVE INTAKE AIR CONTROL VALVE (for PZEV) (See page IT-7) 76. REMOVE NO. 2 VENTILATION HOSE A134342 77. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR (a) Remove the intake manifold insulator from the cylinder block. A134343 78. REMOVE DRIVE SHAFT BEARING BRACKET (a) Remove the 3 bolts and drive shaft bearing bracket. 79. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY A134945 EM–104 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 80. REMOVE OIL LEVEL GAUGE GUIDE (a) Remove the bolt and oil level gauge guide. (b) Remove the O-ring from the oil level gauge guide. A112218 81. REMOVE MANIFOLD STAY (a) Remove the bolt, nut and stay. EM A112193 82. REMOVE NO. 2 MANIFOLD STAY (a) Remove the bolt, nut and stay. A112192 83. REMOVE EXHAUST MANIFOLD CONVERTER SUBASSEMBLY (a) For PZEV: (1) Disconnect the air-fuel ratio sensor connector. A098744E01 (2) Remove the 5 nuts, manifold converter and gasket. A136913 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–105 (b) Except for PZEV: (1) Remove the 4 bolts and No. 1 insulator. A112189 (2) Disconnect the air-fuel ratio sensor connector. EM A098744E01 (3) Remove the 5 nuts, manifold converter and gasket. 84. REMOVE WATER INLET (See page CO-13) 85. REMOVE THERMOSTAT (See page CO-13) A112190 86. REMOVE NO. 1 WATER BY-PASS PIPE (a) Remove the bolt, 2 nuts and No. 1 water by-pass pipe with the gasket. A112226 87. REMOVE OIL COOLER PIPE (w/ Oil Cooler) (a) Remove the bolt, 2 nuts and oil cooler pipe with the gasket. A126879 EM–106 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 88. REMOVE ENGINE MOUNTING BRACKET RH (a) Remove the 3 bolts and engine mounting bracket RH. A052481 89. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (a) Remove the bolt, nut and belt tensioner. 90. REMOVE IGNITION COIL ASSEMBLY (a) Remove the 4 bolts and 4 ignition coils. 91. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (See page ES-405) EM A112212 92. REMOVE KNOCK SENSOR (a) Disconnect the sensor connector. (b) Remove the nut and sensor. 93. REMOVE RADIO SETTING CONDENSER (a) Remove the bolt and radio setting condenser. A112227 94. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY (a) Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly. A128875 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–107 95. REMOVE ENGINE COOLANT TEMPERATURE SENSOR (a) Using SST, remove the sensor and gasket. SST 09817-33190 Gasket SST A114367E01 INSPECTION 1. INSPECT INTAKE MANIFOLD (a) Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.20 mm (0.0079 in.) If the warpage is greater than maximum, replace the manifold. 2. INSPECT EXHAUST MANIFOLD CONVERTER SUBASSEMBLY (a) Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.70 mm (0.0276 in.) If the warpage is greater than the maximum, replace the manifold. A085564 A124780 INSTALLATION 1. Gasket SST A114367E01 INSTALL ENGINE COOLANT TEMPERATURE SENSOR (a) Using SST, install a new gasket and the ECT sensor. SST 09817-33190 Torque: 20 N*m (208 kgf*cm, 15 ft.*lbf) EM EM–108 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 2. Adhesive INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY (a) Clean the threads of the oil pressure switch. Apply adhesive to 2 or 3 threads of the oil. Adhesive: Part No. 08833-00080 THREE BOND 1344 or equivalent P012478E01 (b) Using a 24 mm deep socket wrench, install the oil pressure switch. Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) EM A128875 3. INSTALL RADIO SETTING CONDENSER (a) Install the condenser with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 4. INSTALL KNOCK SENSOR (a) Install the sensor with the nut as shown in the illustration. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 5. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (See page ES-406) 6. INSTALL IGNITION COIL ASSEMBLY (a) Install the 4 ignition coils with the 4 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 7. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (a) Install the V-ribbed belt tensioner with the bolt and nut. Torque: 60 N*m (607 kgf*cm, 44 ft.*lbf) A112227 Upper 10° Engine Front 10° A078436E01 A112212 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–109 8. INSTALL ENGINE MOUNTING BRACKET RH (a) Remove the engine mounting bracket RH with the 3 bolts. Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) 9. INSTALL OIL COOLER PIPE (w/ Oil Cooler) (a) Install a new gasket and the pipe with the bolt and 2 nuts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) A052481 EM A126879 10. INSTALL NO. 1 WATER BY-PASS PIPE (a) Install a new gasket and the pipe with the bolt and 2 nuts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 11. INSTALL THERMOSTAT (See page CO-13) 12. INSTALL WATER INLET (See page CO-14) A112226 2 4 3 1 5 A112190E01 13. INSTALL EXHAUST MANIFOLD CONVERTER SUBASSEMBLY (a) Except for PZEV: (1) Install a new gasket onto the cylinder head. (2) Temporarily tighten the exhaust manifold converter with the 5 nuts. (3) Tighten the 5 nuts in the sequence shown in the illustration. Torque: 37 N*m (378 kgf*cm, 27 ft.*lbf) EM–110 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY (4) Connect the air-fuel ratio sensor connector. A098744E01 (5) Install the exhaust manifold heat insulator with the 4 bolts. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) (b) For PZEV: (1) Install a new gasket onto the cylinder head. (2) Temporarily tighten the exhaust manifold converter with the 5 nuts. EM A112189 4 (3) Tighten the 5 nuts in the sequence shown in the illustration. Torque: 37 N*m (378 kgf*cm, 27 ft.*lbf) 3 2 1 5 A136913E01 (4) Connect the air-fuel ratio sensor connector. A098744E01 14. INSTALL NO. 2 MANIFOLD STAY (a) Install the stay with the bolt and nut. Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf) A112192 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–111 15. INSTALL MANIFOLD STAY (a) Install the stay with the bolt and nut. Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf) A112193 16. INSTALL OIL LEVEL GAUGE GUIDE (a) Apply a light coat of engine oil to a new O-ring and install it to the guide. (b) Install the oil level gauge guide with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 17. INSTALL OIL LEVEL GAUGE SUB-ASSEMBLY A112218 18. INSTALL DRIVE SHAFT BEARING BRACKET (a) Install the bracket with the 3 bolts. Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) A134945 19. INSTALL NO. 1 INTAKE MANIFOLD INSULATOR (a) Install the intake manifold insulator onto the cylinder block. 20. INSTALL NO. 2 VENTILATION HOSE 21. INSTALL INTAKE AIR CONTROL VALVE (for PZEV) (See page IT-7) A134343 22. INSTALL INTAKE MANIFOLD (a) Install a new gasket into the intake manifold. New Gasket A090130E02 EM EM–112 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY (b) Install the intake manifold with the 5 bolts and 2 nuts. Torque: 30 N*m (305 kgf*cm, 22 ft.*lbf) 23. INSTALL FUEL DELIVERY PIPE WITH INJECTOR (See page FU-15) 24. REMOVE ENGINE STAND 25. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle) (See page EM-80) A128862 26. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle) (See page CL-34) 27. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle) (See page CL-34) 28. INSTALL DRIVE PLATE & RING GEAR SUBASSEMBLY (for Automatic Transaxle) (See page EM81) EM 29. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle) HINT: See page MX-27. 30. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle) HINT: See page AX-168. 31. INSTALL STARTER ASSEMBLY (for Manual Transaxle) (See page ST-13) 32. INSTALL STARTER ASSEMBLY (for Automatic Transaxle) (See page ST-13) 33. INSTALL ENGINE WIRE 34. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (See page DS-20) 35. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (See page DS-21) 36. INSTALL FRONT FRAME ASSEMBLY (a) A/T: Install the engine mounting insulator LH with the nut. Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) A/T A052490E01 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–113 (b) M/T: Install the engine mounting insulator LH with the bolt. Torque: 143 N*m (1,459 kgf*cm, 105 ft.*lbf) M/T A059881E01 (c) Install the engine mounting insulator RH with the nut. Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) EM A052482 (d) Install the engine mounting insulator FR with the bolt. Torque: 87 N*m (888 kgf*cm, 64 ft.*lbf) A059880 (e) M/T: Install the engine lateral control rod with the bolt. Torque: 89 N*m (910 kgf*cm, 66 ft.*lbf) M/T A060825E01 37. INSTALL VANE PUMP ASSEMBLY (a) Install the vane pump to the engine with the 2 bolts. Torque: 43 N*m (439 kgf*cm, 32 ft.*lbf) (b) Connect the oil pressure switch connector. A059879 EM–114 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY B Nut Nut B A A A059877E02 Nut C Nut C EM D 38. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (a) Set the engine assembly with transaxle on the engine lifter. (b) Install the engine assembly to the vehicle. (c) Install the frame side plate LH and RH with the 4 bolts and 2 nuts. Torque: Bolt A 85 N*m (867 kgf*cm, 63 ft.*lbf) Bolt B and nut 32 N*m (326 kgf*cm, 24 ft.*lbf) (d) Install the front suspension member brace rear RH and LH with the 4 bolts and 2 nuts. Torque: Bolt C 85 N*m (867 kgf*cm, 63 ft.*lbf) Bolt D and nut 32 N*m (326 kgf*cm, 24 ft.*lbf) 39. INSTALL STEERING SLIDING YOKE (See page PS65) D A059878E02 40. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET (a) Install the exhaust pipe support bracket with the 2 bolts. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) 41. INSTALL DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transaxle) (See page AX-172) 42. INSTALL FRONT AXLE ASSEMBLY LH (See page DS21) 43. INSTALL FRONT AXLE ASSEMBLY RH HINT: Use the same procedures described for the LH side. 44. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM LH (See page DS-21) 45. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM RH HINT: Use the same procedures described for the LH side. 46. INSTALL TIE ROD ASSEMBLY LH (See page DS-21) 47. INSTALL TIE ROD ASSEMBLY RH HINT: Use the same procedures described for the LH side. 48. INSTALL FRONT SPEED SENSOR LH (See page DS21) 49. INSTALL FRONT SPEED SENSOR RH Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 50. INSTALL FRONT STABILIZER LINK ASSEMBLY LH (See page DS-22) 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–115 51. INSTALL FRONT STABILIZER LINK ASSEMBLY RH HINT: Use the same procedures described for the LH side. 52. INSTALL FRONT AXLE HUB NUT LH (See page DS22) 53. INSTALL FRONT AXLE HUB NUT RH HINT: Use the same procedures described for the LH side. 54. INSTALL FRONT EXHAUST PIPE ASSEMBLY HINT: See page EX-3. 55. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (a) Install the cooler compressor with the 4 bolts. Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) NOTICE: Tighten the bolts in the order shown in the illustration to install the cooler compressor. 2 1 4 1 56. INSTALL GENERATOR ASSEMBLY (See page CH-19) 3 1 1 A134944E01 57. CONNECT FUEL TUBE SUB-ASSEMBLY (a) Push in the fuel tube connector to the fuel pipe until the connector makes a "click" sound. NOTICE: • Check for damage or contamination on the connected part of the pipe. • Check if the pipe and the connector are securely connected by trying to pull them apart. B012944 (b) Install the No. 1 fuel pipe clamp. 58. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle) HINT: See page CL-25. A129626 59. REMOVE CLUTCH ACCUMULATOR ASSEMBLY (for Manual Transaxle) HINT: See page CL-29. EM EM–116 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 60. CONNECT RETURN TUBE SUB-ASSEMBLY (a) Connect the return tube sub-assembly. A060073 61. CONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE (a) Connect the No. 1 oil reservoir to pump hose. EM A060072 62. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle) (a) Connect the ends of the 2 cables and install the 2 washers and 2 clips. (b) Install 2 new clips to the control cable bracket. C132952 63. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle) (a) Install a new clip and nut, and connect the control lever. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) (b) Connect the clamp with the cable to the transaxle. A132974 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–117 64. CONNECT ENGINE WIRE (a) Install the 2 bolts and clamp to the body. Torque: Bolt A 8.4 N*m (85 kgf*cm, 74 in.*lbf) Bolt B 12 N*m (123 kgf*cm, 9 ft.*lbf) A B A134914E01 (b) Connect the clamp to the bracket. EM A134913 (c) Connect the wire to the engine room junction block. Then, install it with the nut and 3 connectors. Torque: 8.4 N*m (85 kgf*cm, 74 in.*lbf) 65. INSTALL ECM HINT: See page ES-433. A132975 66. CONNECT HEATER INLET WATER HOSE (a) Connect the heater inlet water hose. A124832 EM–118 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 67. CONNECT HEATER OUTLET WATER HOSE (a) Connect the heater outlet water hose. 68. CONNECT OIL COOLER INLET HOSE (See page CO30) 69. CONNECT OIL COOLER OUTLET HOSE (See page CO-30) A124831 70. CONNECT RADIATOR HOSE INLET (a) Install the clamp and connect the radiator hose inlet. EM A134907 71. CONNECT RADIATOR HOSE OUTLET (a) Install the clamp and connect the radiator hose outlet. A127545 72. CONNECT NO. 1 VACUUM HOSE CONNECTOR (a) Install the clamp and connect the vacuum hose connector. A134908 73. INSTALL NO. 2 ENGINE MOUNTING BRACKET RH (a) Install the 3 bolts and No. 2 mounting bracket RH. Torque: 52 N*m (531 kgf*cm, 38 ft.*lbf) A134911 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–119 74. INSTALL ENGINE MOVING CONTROL ROD SUBASSEMBLY (a) Install the engine moving control rod with the 3 bolts. Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) A134910 (b) Install the ground cable with the bolt. Torque: 8.4 N*m (85 kgf*cm, 74 in.*lbf) EM A134909 75. INSTALL NO. 2 ENGINE MOUNTING STAY RH (a) Install the No. 2 mounting stay RH with the 2 bolts. Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) 76. INSTALL BATTERY (a) Install the battery and battery tray. A134912 (b) Install the battery clamp with the bolt and nut. Torque: Bolt 9.0 N*m (92 kgf*cm, 80 in.*lbf) Nut 3.5 N*m (36 kgf*cm, 31 in.*lbf) A134906 EM–120 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 77. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (a) Install the air cleaner case with the 3 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) (b) Connect the hose clamp. 78. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See page ES-419) A134905 EM 79. INSTALL AIR CLEANER INLET ASSEMBLY (a) Install the air cleaner inlet with the 2 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 80. INSTALL V-RIBBED BELT (See page EM-6) 81. INSTALL COWL TOP PANEL OUTER SUBASSEMBLY (See page ES-426) A134903 82. INSTALL WINDSHIELD WIPER LINK ASSEMBLY HINT: See page WW-13. 83. INSTALL FRONT WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 84. ADD ENGINE OIL 85. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf) 86. BLEED CLUTCH LINE (for Manual Transaxle) (See page CL-25) 87. ADD ENGINE COOLANT (See page CO-5) 88. ADD MANUAL TRANSAXLE OIL (for Manual Transaxle) (See page MX-6) 89. ADD AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle) (See page AX-175) 90. ADD POWER STEERING FLUID 91. BLEED POWER STEERING FLUID (See page PS-7) 92. CHECK FOR FUEL LEAKS (See page FU-9) 93. CHECK FOR ENGINE OIL LEAKS 94. CHECK FOR ENGINE COOLANT LEAKS (See page CO-1) 95. CHECK FOR EXHAUST GAS LEAKS 96. CHECK SHIFT LEVER POSITION (See page AX-179) 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–121 97. ADJUST FRONT WHEEL ALIGNMENT HINT: See page SP-4. 98. CHECK IGNITION TIMING (See page EM-1) 99. CHECK ENGINE IDLE SPEED (See page EM-2) 100. INSPECT CO/HC (See page EM-3) 101. INSTALL FRONT FENDER APRON SEAL RH 102. INSTALL ENGINE UNDER COVER LH 103. INSTALL ENGINE UNDER COVER RH 104. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (a) Install the engine cover with the 2 nuts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 105. CHECK ABS SPEED SENSOR SIGNAL (a) ABS: See page BC-11. (b) VSC (for BOSCH): See page BC-123. (c) VSC (for ADVICS): See page BC-290. A134904 EM EM–122 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT ENGINE UNIT 2AZ-FE ENGINE MECHANICAL ENGINE COMPONENTS 14 (143, 10) OIL FILLER CAP SUB-ASSEMBLY 19 (194, 14) SPARK PLUG OIL FILLER CAP GASKET 11 (112, 8) 11 (112, 8) 19 (194, 14) VENTILATION VALVE SUB-ASSEMBLY x4 x6 CYLINDER HEAD COVER GASKET CYLINDER HEAD COVER SUB-ASSEMBLY EM V-RIBBED BELT TENSIONER ASSEMBLY CAMSHAFT POSITION SENSOR 22 (220, 16) STUD BOLT 60 (607, 44) WATER PUMP ASSEMBLY 9.0 (92, 80 in.*lbf) CRANKSHAFT POSITION SENSOR 9.0 (92, 80 in.*lbf) WIRE HARNESS CLAMP BRACKET x3 9.0 (92, 80 in.*lbf) 26 (265, 19) 9.0 (92, 80 in.*lbf) 9.0 (92, 80 in.*lbf) x4 30 (306, 22) with OIL COOLER: OIL FILTER UNION WATER PUMP PULLEY 25 (255, 18) UNION BOLT 180 (1,835, 133) CRANKSHAFT PULLEY 13 (133, 10) OIL FILTER SUB-ASSEMBLY 25 (255, 18) 9.0 (92, 80 in.*lbf) 79 (806, 58) N*m (kgf*cm, ft.*lbf) : Specified torque Precoated part OIL COOLER ASSEMBLY PLATE WASHER OIL PAN DRAIN PLUG Non-reusable part O-RING x12 9.0 (92, 80 in.*lbf) OIL FILTER UNION OIL PAN SUB-ASSEMBLY OIL PAN DRAIN PLUG GASKET A135392E01 EM–123 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT CHAIN TENSIONER SLIPPER CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 9.0 (92, 80 in.*lbf) NO. 1 CHAIN VIBRATION DAMPER O-RING 19 (194, 14) 9.0 (92, 80 in.*lbf) CRANKSHAFT TIMING SPROCKET CHAIN SUBASSEMBLY KEY EM OIL PUMP DRIVE GEAR NO. 2 CHAIN SUB-ASSEMBLY GASKET NO. 1 CRANKSHAFT POSITION SENSOR PLATE OIL PUMP ASSEMBLY 9.0 (92, 80 in.*lbf) TIMING CHAIN GUIDE 19 (193, 14) 30 (301, 22) OIL PUMP DRIVE SHAFT GEAR CHAIN DAMPER SPRING CHAIN TENSIONER PLATE 12 (122, 9) 11 (112, 8) 9.0 (92, 80 in.*lbf) NO. 1 CHAIN TENSIONER ASSEMBLY 55 (561, 41) GASKET 55 (561, 41) x4 9.0 (92, 80 in.*lbf) TIMING CHAIN CASE OIL SEAL TIMING CHAIN COVER SUB-ASSEMBLY 25 (255, 18) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Apply MP grease x8 Precoated part A135393E01 EM–124 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT NO. 3 CAMSHAFT BEARING CAP 9.0 (92, 80 in.*lbf) 30 (301, 22) NO. 1 CAMSHAFT BEARING CAP NO. 3 CAMSHAFT BEARING CAP NO. 2 CAMSHAFT BEARING CAP NO. 1 CAMSHAFT BEARING CAMSHAFT NO. 2 CAMSHAFT EM CAMSHAFT TIMING SPROCKET 54 (551, 40) 54 (551, 40) 1st: 70 (714, 52) CAMSHAFT TIMING GEAR ASSEMBLY 2nd: Turn 90° x10 x10 PLATE WASHER NO. 2 CAMSHAFT BEARING CYLINDER HEAD SUB-ASSEMBLY CYLINDER HEAD GASKET CYLINDER BLOCK WATER JACKET SPACER N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A135394E01 EM–125 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT ENGINE REAR OIL SEAL GASKET 30 (306, 22) SCREW PLUG without OIL COOLER: OIL CONTROL VALVE FILTER 26 (265, 19) O-RING NO. 1 TAPER SCREW PLUG STIFFENING CRANKCASE ASSEMBLY 24 (245, 18) without OIL COOLER: x5 13 (130, 9) 24 (245, 18) x6 CYLINDER BLOCK WATER DRAIN COCK PLUG NO. 1 BALANCESHAFT BEARING 25 (255, 18) CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY NO. 2 BALANCESHAFT SUB-ASSEMBLY NO. 1 BALANCESHAFT SUB-ASSEMBLY NO. 1 BALANCESHAFT BEARING NO. 1 BALANCESHAFT BEARING BALANCESHAFT HOUSING x8 1st: 22 (220, 16) 2nd: Turn 90° N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Apply MP grease Precoated part A135395E01 EM EM–126 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT NO. 1 COMPRESSION RING PISTON RING SET NO. 2 COMPRESSION RING OIL RING EXPANDER OIL RING PISTON PIN HOLE SNAP RING PISTON PISTON PIN PISTON PIN HOLE SNAP RING CONNECTING ROD SUB-ASSEMBLY CONNECTING ROD BEARING EM 5.0 (51, 44 in.*lbf) RING PIN STUD BOLT 9.5 (97, 84 in.*lbf) STUD BOLT STRAIGHT PIN RING PIN x2 STRAIGHT PIN STRAIGHT PIN x2 5.0 (51, 44 in.*lbf) STUD BOLT STRAIGHT PIN RING PIN x2 x10 CRANKSHAFT BEARING 7.0 (71, 62 in.*lbf) 5.0 (51, 44 in.*lbf) UPPER CRANKSHAFT THRUST WASHER x4 STUD BOLT NO. 1 OIL NOZZLE SUB-ASSEMBLY CRANKSHAFT NO. 2 CRANKSHAFT BEARING CONNECTING ROD BEARING CRANKSHAFT BEARING CAP CONNECTING ROD CAP 1st: 25 (250, 18) 1st: 20 (204, 15) 2nd: Turn 90° 2nd: 40 (408, 30) 3rd: Turn 90° N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A135396E01 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–127 DISASSEMBLY 1. REMOVE OIL FILLER CAP SUB-ASSEMBLY (a) Remove the oil filler cap. 2. REMOVE OIL FILLER CAP GASKET (a) Remove the oil filler cap gasket. A128158 EM A128159 3. REMOVE VENTILATION VALVE SUB-ASSEMBLY (a) Remove the ventilation valve. 4. REMOVE SPARK PLUG (a) Remove the spark plugs. 5. REMOVE OIL FILTER SUB-ASSEMBLY (a) Using SST, remove the oil filter. SST 09228-06501 HINT: Place a container for oil to be drained before removing the oil filter. A128160 A128161 SST A036541E01 EM–128 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT 6. REMOVE OIL FILTER UNION (w/o Oil Cooler) (a) Using a 12 mm hexagon wrench, remove the union. 7. REMOVE OIL COOLER ASSEMBLY (w/ Oil Cooler) (a) Remove the oil filter union, plate washer, nut, oil cooler and O-ring. (b) Remove the union bolt. 8. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (See page EM-21) 9. REMOVE CYLINDER HEAD COVER GASKET (a) Remove the cylinder head cover gasket. A128162 EM A135533 10. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (See page EM-23) A128166 11. REMOVE CRANKSHAFT POSITION SENSOR (a) Remove the wire harness clamp. (b) Separate the wire harness from the wire harness clamp bracket. A094516E01 (c) Remove the 2 bolts and sensor. A063828 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–129 12. REMOVE CAMSHAFT POSITION SENSOR (a) Remove the bolt and sensor. 13. REMOVE CRANKSHAFT PULLEY (See page EM-75) 14. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (See page ES-405) 15. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY (See page EM-22) A128164 16. REMOVE WATER PUMP PULLEY (See page CO-9) 17. REMOVE WATER PUMP ASSEMBLY (See page CO-9) 18. REMOVE OIL PAN DRAIN PLUG (a) Remove the oil pan drain plug and gasket. 19. REMOVE OIL PAN SUB-ASSEMBLY (See page EM22) 20. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY (See page LU-11) A128176 21. REMOVE TIMING CHAIN CASE OIL SEAL (a) Using a screwdriver and a hammer, remove the oil seal. 22. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE (See page EM-24) 23. REMOVE TIMING CHAIN GUIDE (See page EM-25) 24. REMOVE CHAIN TENSIONER SLIPPER (See page EM-24) A128180 25. REMOVE NO. 1 CHAIN VIBRATION DAMPER (See page EM-24) 26. REMOVE CHAIN SUB-ASSEMBLY (See page EM-25) 27. REMOVE CRANKSHAFT TIMING SPROCKET (See page EM-25) 28. REMOVE NO. 2 CHAIN SUB-ASSEMBLY (See page EM-25) 29. REMOVE KEYS (a) Remove the 2 pulley set keys from the crankshaft. A131498 EM EM–130 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT 5 9 7 30. REMOVE NO. 2 CAMSHAFT (a) Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. (b) Remove the 5 bearing caps. 3 1 2 6 10 8 4 A098174E11 5 1 EM 9 7 3 2 6 10 8 4 31. REMOVE CAMSHAFT (a) Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. (b) Remove the 5 bearing caps. A098175E04 32. REMOVE NO. 1 CAMSHAFT BEARING Remove the No. 1 camshaft bearing. A128191 33. REMOVE NO. 2 CAMSHAFT BEARING (a) Remove the No. 2 camshaft bearing. A032664 34. REMOVE CAMSHAFT TIMING SPROCKET (a) Clamp the camshaft in a vise. (b) Remove the flange bolt of the camshaft timing sprocket. 35. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY (See page EM-39) 36. REMOVE CYLINDER HEAD SUB-ASSEMBLY (See page EM-55) A032167 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–131 37. REMOVE CYLINDER HEAD GASKET (See page EM55) 38. REMOVE CYLINDER BLOCK WATER JACKET SPACER (a) Using needle-nose pliers, remove the cylinder block water jacket spacer. NOTICE: Be sure to remove the water jacket spacer if turning the cylinder block upside down. A128208 39. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY (w/o Oil Cooler) (a) Remove the water drain cock from the stiffening crankcase. (b) Remove the water drain cock plug from the water drain cocks. A128209 40. REMOVE OIL CONTROL VALVE FILTER (a) Using an 8 mm socket hexagon wrench, remove the plug and filter. A128210 41. REMOVE NO. 1 TAPER SCREW PLUG (w/o Oil Cooler) (a) Remove the taper screw plug. A128211 EM EM–132 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT 42. REMOVE OIL PUMP ASSEMBLY (a) Remove the 3 bolts, oil pump and gasket. A128253 EM 4 1 8 5 6 7 2 3 43. REMOVE NO. 1 AND NO. 2 BALANCESHAFT SUBASSEMBLY (a) Uniformly loosen and remove the 8 bolts in the sequence shown in the illustration. A128197E01 (b) Remove the No. 1 and No. 2 balanceshafts. No. 1 Balanceshaft No. 2 Balanceshaft A128203E02 44. REMOVE NO. 1 BALANCESHAFT BEARING (a) Remove the balanceshaft bearings. Stiffening Crankcase: Balanceshaft Housing: A128204E02 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT Cut Position EM–133 45. REMOVE ENGINE REAR OIL SEAL (a) Using a knife, cut off the oil seal lip. (b) Using a screwdriver with its tip taped, pry out the oil seal. NOTICE: After removing the oil seal, check the crankshaft for damage. If it is damaged, smooth the surface with 400-grit sandpaper. A128201E01 9 5 11 8 1 4 46. REMOVE STIFFENING CRANKCASE ASSEMBLY (a) Uniformly loosen and remove the 11 bolts in the sequence shown in the illustration. EM 3 2 6 10 7 A128202E02 (b) Using a screwdriver, remove the crankcase by prying between the crankcase and cylinder block. NOTICE: Be careful not to damage the contact surfaces of the crankcase and cylinder block. Protective Tape Protective Tape A128205E01 (c) Remove the O-ring from the cylinder block. A128206 EM–134 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT 47. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD (a) Using a ridge reamer, remove all the carbon from the top of the cylinder. A013469 (b) Check that the matchmarks on the connecting rod and cap are aligned to ensure the correct reassembly. HINT: The matchmarks on the connecting rods and caps are provided for ensuring the correct reassembly. Matchmark EM A063893E01 A013397 (c) Using a 12 mm socket wrench, uniformly loosen the 2 bolts. (d) Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left. HINT: Keep the lower bearing inserted in the connecting rod cap. (e) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. HINT: • Keep the bearing, connecting rod and cap together. • Arrange the piston and connecting rod assemblies in the correct order. 48. REMOVE CONNECTING ROD BEARING (a) Remove the connecting rod bearings. HINT: Arrange the removed parts in the correct order. 49. REMOVE PISTON RING SET (a) Using a piston ring expander, remove the 2 compression rings. (b) Remove the oil ring rail and oil ring expander by hand. HINT: Arrange the removed parts in the correct order. Piston Ring Expander A128232E01 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–135 50. REMOVE PISTON PIN HOLE SNAP RING (a) Using a screwdriver, pry out the 2 snap rings. A128233 51. REMOVE PISTON (a) Gradually heat the piston to approximately 80 to 90°C (176 to 194°F). EM A109729 (b) Using a plastic hammer and brass bar, lightly tap out the piston pin and remove the connecting rod. HINT: • The piston and pin are a matched set. • Arrange the pistons, pins, rings, connecting rods and bearings in the correct order. A106279 4 8 3 7 10 9 6 2 5 1 52. REMOVE CRANKSHAFT (a) Uniformly loosen and remove the 10 main bearing cap bolts in the sequence shown in the illustration. A128235E01 (b) Use 2 removed main bearing cap bolts to remove the 5 main bearing caps and 5 lower bearings. NOTICE: Insert the bolts into one of the caps. Ease the cap out by gently pulling up and applying force toward the front and back side of the cylinder block, as shown in the illustration. Take care not to damage the contact surfaces of the cap and cylinder block. A087781 EM–136 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT HINT: • Keep the lower bearing and main bearing cap together. • Arrange the main bearing caps in the correct order. (c) Lift out the crankshaft. 53. REMOVE UPPER CRANKSHAFT THRUST WASHER (a) Remove the upper thrust washers from the cylinder block. A013501 EM 54. REMOVE CRANKSHAFT BEARING (a) Remove the 5 upper main bearings from the cylinder block. HINT: Arrange the bearings in the correct order. A063901 55. REMOVE NO. 2 CRANKSHAFT BEARING (a) Remove the 5 lower main bearings from the 5 main bearing caps. HINT: Arrange the bearings in the correct order. 56. REMOVE STUD BOLT A063902 57. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY (a) Using a 5 mm hexagon wrench, remove the bolts and oil nozzles. 58. CLEAN CYLINDER BLOCK NOTICE: If the cylinder is washed at high temperatures, the cylinder liner will stick out beyond the cylinder block. Always wash the cylinder block at a temperature of 45°C (113°F) or less. A128251E01 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–137 INSPECTION 1. INSPECT BALANCESHAFT THRUST CLEARANCE (a) Install the balanceshafts (See page EM-149). (b) Using a dial indicator, measure the thrust clearance while moving the balanceshaft back and forth. Standard thrust clearance: 0.05 to 0.09 mm (0.0020 to 0.0035 in.) Maximum thrust clearance: 0.09 mm (0.0035 in.) If the thrust clearance is greater than the maximum, replace the balanceshaft housing and bearings. If necessary, replace the balanceshaft. A128196 2. INSPECT BALANCESHAFT OIL CLEARANCE (a) Clean each bearing and journal. (b) Check each bearing and journal for pitting and scratches. If a bearing or journal is damaged, replace the bearings. If necessary, replace the balanceshaft. (c) Place the No. 1 and No. 2 balanceshafts onto the crankcase. (d) Lay a strip of Plastigage across each journal. (e) Install the balanceshaft housing (See page EM149). NOTICE: Do not turn the balanceshafts. (f) Remove the balanceshafts (See page EM-127). Plastigage A128198E01 Plastigage A128199E01 (g) Measure the Plastigage at its widest point. Standard oil clearance: 0.004 to 0.049 mm (0.0002 to 0.0019 in.) Maximum oil clearance: 0.049 mm (0.0019 in.) NOTICE: Remove the Plastigage completely after the measurement. If the oil clearance is greater than the maximum, replace the bearing. If necessary, replace the balanceshaft. (h) If replacing a bearing, select a new one with the same number. Standard balanceshaft housing journal bore diameter Item Specified Condition Mark 1 26.000 to 26.006 mm (1.0236 to 1.0239 in.) Mark 2 26.007 to 26.012 mm (1.0239 to 1.0241 in.) Mark 3 26.013 to 26.018 mm (1.0241 to 1.0243 in.) EM EM–138 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT Standard bearing center wall thickness Item Specified Condition Mark 1 1.486 to 1.489 mm (0.05850 to 0.05862 in.) Mark 2 1.490 to 1.492 mm (0.05866 to 0.05874 in.) Mark 3 1.493 to 1.495 mm (0.0588 to 0.0589 in.) Standard balanceshaft journal diameter Item Journal diameter Mark 1 22.985 to 23.000 mm (0.9049 to 0.9055 in.) Mark 2 22.985 to 23.000 mm (0.9049 to 0.9055 in.) Mark 3 22.985 to 23.000 mm (0.9049 to 0.9055 in.) (i) EM Length Inspect the balanceshaft housing bolts. (1) Using vernier calipers, measure the length of the bolts from the seat to the end. Standard bolt length: 58.3 to 59.7 mm (2.295 to 2.350 in.) Maximum bolt length: 60.3 mm (2.374 in.) If the bolt length is greater than the maximum, replace the balanceshaft housing bolt. A131575E01 3. INSPECT CHAIN SUB-ASSEMBLY (a) Pull the chain with a force of 140 N (14.3 kgf, 31.5 lbf) as shown in the illustration. (b) Using vernier calipers, measure the length of 15 links. Maximum chain elongation: 114.5 mm (4.508 in.) NOTICE: Perform the measurement at 3 random places. Use the average of the measurements. If the elongation is greater than the maximum, replace the chain. 4. INSPECT NO. 2 CHAIN SUB-ASSEMBLY (a) Pull the chain with a force of 140 N (14.3 kgf, 31.5 lbf) as shown in the illustration. (b) Using vernier calipers, measure the length of 15 links. Maximum chain elongation: 102.2 mm (4.024 in.) NOTICE: Perform the measurement at 3 random places. Use the average of the measurements. If the elongation is greater than the maximum, replace the No. 2 chain. Measuring Area 123456 15 A135727E01 Measuring Area 123456 15 A135727E01 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT 5. INSPECT OIL PUMP DRIVE GEAR (a) Wrap the chain around the sprocket. (b) Using vernier calipers, measure the sprocket diameter with the chain wrapped around. Minimum gear diameter (with chain): 48.2 mm (1.898 in.) NOTICE: The vernier calipers must be in contact with the chain rollers when measuring. If the diameter is less than the minimum, replace the chain and sprocket. 6. INSPECT OIL PUMP DRIVE SHAFT GEAR (a) Wrap the chain around the sprocket. (b) Using vernier calipers, measure the sprocket diameter with the chain wrapped around. Minimum gear diameter (with chain): 48.2 mm (1.898 in.) NOTICE: The vernier calipers must be in contact with the chain rollers when measuring. If the diameter is less than the minimum, replace the chain and sprocket. A053035E01 A053036E01 7. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY (a) Wrap the chain around the sprocket. (b) Using vernier calipers, measure the sprocket diameter with the chain wrapped around. Minimum gear diameter (with chain): 97.3 mm (3.831 in.) NOTICE: The vernier calipers must be in contact with the chain rollers when measuring. If the diameter is less than the minimum, replace the chain and sprocket. 8. INSPECT CAMSHAFT TIMING SPROCKET (a) Wrap the chain around the sprocket. (b) Using vernier calipers, measure the sprocket diameter with the chain wrapped around. Minimum gear diameter (with chain): 97.3 mm (3.831 in.) NOTICE: The vernier calipers must be in contact with the chain rollers when measuring. If the diameter is less than the minimum, replace the chain and sprocket. A063864 A053025 EM–139 EM EM–140 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT 9. A053035E01 INSPECT CRANKSHAFT TIMING GEAR (a) Wrap the chain around the timing sprocket. (b) Using vernier calipers, measure the timing gear diameter with the chain wrapped around. Minimum gear diameter (with chain): 51.6 mm (2.031 in.) NOTICE: The vernier calipers must be in contact with the chain rollers when measuring. If the gear diameter is less than the minimum, replace the chain sub-assembly and crankshaft timing sprocket. 10. INSPECT CHAIN TENSIONER SLIPPER (a) Using vernier calipers, measure the tensioner slipper wear. Maximum wear: 1.0 mm (0.039 in.) If the wear is greater than the maximum, replace the chain tensioner slipper. EM A033838E01 11. INSPECT NO. 1 CHAIN VIBRATION DAMPER (a) Using vernier calipers, measure the vibration damper wear. Maximum wear: 1.0 mm (0.039 in.) If the wear is greater than the maximum, replace the No. 1 chain vibration damper. A036686E01 12. INSPECT CHAIN TENSIONER PLATE (a) Using vernier calipers, measure the vibration damper wear. Maximum wear: 0.5 mm (0.020 in.) If the wear is greater than the maximum, replace the chain tensioner plate. A126893 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–141 13. INSPECT NO. 1 CHAIN TENSIONER (a) Check that the plunger moves smoothly when the ratchet pawl is raised with your finger. (b) Release the ratchet pawl, then check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger. Raise 14. INSPECT CONNECTING ROD THRUST CLEARANCE (a) Install the connecting rod cap (See page EM-149). Lock Move A098357E01 (b) Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.160 to 0.362 mm (0.0063 to 0.0143 in.) Maximum thrust clearance: 0.362 mm (0.0143 in.) If the thrust clearance is greater than the maximum, replace the connecting rod assemblies as necessary. If necessary, replace the crankshaft. A036642 15. INSPECT CONNECTING ROD OIL CLEARANCE (a) Clean the crank pin and bearing. (b) Check the crank pin and bearing for pitting and scratches. (c) Lay a strip of Plastigage on the crank pin. Plastigage A013400E01 (d) Check that the front mark of the connecting rod cap is facing forward. (e) Install the connecting rod cap (See page EM-149). NOTICE: Do not turn the crankshaft. (f) Remove the 2 bolts and connecting rod cap (See page EM-127). Front Mark A036691E01 EM EM–142 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT (g) Measure the Plastigage at its widest point. Standard oil clearance: 0.032 to 0.063 mm (0.0013 to 0.0025 in.) Maximum oil clearance: 0.063 mm (0.0025 in.) NOTICE: Completely remove the Plastigage after the measurement. If the oil clearance is greater than the maximum, replace the connecting rod bearings. If necessary, inspect the crankshaft. HINT: If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap. Each bearing's standard thickness is indicated by a 1, 2, or 3 mark on its surface. Standard connecting rod large end bore diameter Plastigage 1, 2 or 3 Mark EM A129453E03 Mark Specified Condition Mark 1 51.000 to 51.007 mm (2.0079 to 2.0082 in.) Mark 2 51.008 to 51.013 mm (2.0082 to 2.0084 in.) Mark 3 51.014 to 51.020 mm (2.0084 to 2.0087 in.) Standard connecting rod bearing thickness Mark Specified Condition Mark 1 1.485 to 1.488 mm (0.0585 to 0.0586 in.) Mark 2 1.489 to 1.491 mm (0.0586 to 0.0587 in.) Mark 3 1.492 to 1.494 mm (0.0587 to 0.0588 in.) Standard crankshaft pin diameter Mark Specified Condition Mark 1 47.990 to 48.000 (1.8894 to 1.8898 in.) Mark 2 47.990 to 48.000 (1.8894 to 1.8898 in.) Mark 3 47.990 to 48.000 (1.8894 to 1.8898 in.) 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–143 16. INSPECT CYLINDER BLOCK FOR WARPAGE (a) Using a precision straightedge and feeler gauge, measure the warpage of the surface that is in contact with the cylinder head gasket. Maximum warpage: 0.05 mm (0.0020 in.) If the warpage is greater than the maximum, replace the cylinder block. EM A112240 17. INSPECT CYLINDER BORE (a) Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions. Standard diameter: 88.500 to 88.513 mm (3.4843 to 3.4847 in.) Maximum diameter: 88.633 mm (3.4894 in.) If the average diameter of the 4 positions is greater than the maximum, replace the cylinder block. Thrust Direction Front Axial Direction A B 10 mm (0.39 in.) A112241E02 18. INSPECT PISTON (a) Using a gasket scraper, remove the carbon from the piston top. A126913 EM–144 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT (b) Using a groove cleaning tool or a broken ring, clean the piston ring grooves. A126914 (c) Using a brush and solvent, thoroughly clean the piston. NOTICE: Do not use a wire brush. EM A126915 (d) Using a micrometer, measure the piston diameter at right angles to the piston pin hole, and at the piston 44.3 mm (1.7441 in.) from the piston head. Standard piston diameter: 88.469 to 88.479 mm (3.4830 to 3.4834 in.) If the diameter is not as specified, replace the piston. TMC Made: 19. INSPECT PISTON OIL CLEARANCE (a) Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.021 to 0.044 mm (0.0008 to 0.0017 in.) Maximum oil clearance: 0.10 mm (0.0039 in.) If the oil clearance is greater than the maximum, replace all the pistons. If necessary, replace the cylinder block. 44.3 mm (1.7441 in.) TMMK Made: 44.3 mm (1.7441 in.) A136099E01 20. INSPECT RING GROOVE CLEARANCE (a) Using a feeler gauge, measure the clearance between a new piston ring and wall of the ring groove. Standard ring groove clearance A126911 Item Specified Condition No. 1 Ring 0.020 to 0.070 mm (0.0008 to 0.0028 in.) No. 2 Ring 0.020 to 0.060 mm (0.0008 to 0.0024 in.) Oil Ring 0.020 to 0.070 mm (0.0008 to 0.0028 in.) 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–145 If the groove clearance is not as specified, replace the piston. 21. INSPECT PISTON RING END GAP (a) Using a piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block. 110 mm Piston Ring A098149E01 (b) Using a feeler gauge, measure the end gap. Standard end gap Item Specified Condition No. 1 Ring 0.24 to 0.31 mm (0.0094 to 0.0122 in.) No. 2 Ring 0.33 to 0.43 mm (0.0130 to 0.0169 in.) Oil Ring 0.10 to 0.30 mm (0.0040 to 0.0119 in.) Maximum end gap Item Specified Condition No. 1 Ring 0.89 mm (0.0350 in.) EM02552E01 No. 2 Ring 1.37 mm (0.0539 in.) Oil Ring 0.73 mm (0.0287 in.) If the end gap is greater than the maximum, replace the piston ring. If the end gap is greater than the maximum, even with a new piston ring, replace the cylinder block. 22. INSPECT PISTON PIN OIL CLEARANCE (a) Using a caliper gauge, measure the piston pin bore diameter. Standard piston pin bore diameter: 22.001 to 22.010 mm (0.8662 to 0.8665 in.) Item Specified Condition A 22.001 to 22.004 mm (0.8662 to 0.8663 in.) B 22.005 to 22.007 mm (0.8663 to 0.8664 in.) C 22.008 to 22.010 mm (0.8665 to 0.8665 in.) A112243 If the diameter is not as specified, replace the piston. EM EM–146 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT (b) Using a micrometer, measure the piston pin diameter. Standard piston pin diameter: 21.997 to 22.006 mm (0.8660 to 0.8664 in.) 5 mm (0.20 in.) Item Specified Condition A 21.997 to 22.000 mm (0.8660 to 0.8661 in.) B 22.001 to 22.003 mm (0.8662 to 0.8663 in.) C 22.004 to 22.006 mm (0.8663 to 0.8664 in.) If the diameter is not as specified, replace the piston pin. 30 mm (1.18 in.) 5 mm (0.20 in.) A120741E02 EM (c) Using a caliper gauge, measure the connecting rod small end bore diameter. Standard connecting rod small end bore diameter: 22.005 to 22.014 mm (0.8663 to 0.8667 in.) Item Specified Condition A 22.005 to 22.008 mm (0.8663 to 0.8665 in.) B 22.009 to 22.011 mm (0.8665 to 0.8666 in.) C 22.012 to 22.014 mm (0.8666 to 0.8667 in.) A001185E01 If the diameter is not as specified, replace the connecting rod. TMMK Made: TMC Made: Front Mark Piston Pin Bore Diameter Mark Connecting Rod Small End Bore Diameter Mark Front Mark A136100E01 (d) Subtract the piston pin diameter measurement from the piston pin bore diameter measurement. Standard oil clearance: 0.001 to 0.007 mm (0.00004 to 0.0003 in.) Maximum oil clearance: 0.010 mm (0.0004 in.) If the oil clearance is greater than the maximum, replace the connecting rod. If necessary, replace the piston and piston pin as a set. (e) Subtract the piston pin diameter measurement from the connecting rod small end bore diameter measurement. Standard oil clearance: 0.005 to 0.011 mm (0.0002 to 0.0004 in.) Maximum oil clearance: 0.011 mm (0.0004 in.) If the oil clearance is greater than the maximum, replace the connecting rod. If necessary, replace the connecting rod and piston pin as a set. 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–147 23. INSPECT CONNECTING ROD BOLT (a) Using vernier calipers, measure the tension portion diameter of the bolt. Standard diameter: 7.2 to 7.3 mm (0.283 to 0.287 in.) Minimum diameter: 7.0 mm (0.276 in.) If the diameter is less than the minimum, replace the connecting rod bolt. A036651 24. INSPECT CONNECTING ROD SUB-ASSEMBLY (a) Using a connecting rod aligner and feeler gauge, check the connecting rod alignment. (1) Check for misalignment. Maximum misalignment: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If the misalignment is greater than the maximum, replace the connecting rod. Z000064E03 (2) Check for twist. Maximum twist: 0.15 mm (0.0059 in.) per 100 mm (3.94 in.) If the twist is greater than the maximum, replace the connecting rod. Z000065E02 25. INSPECT CRANKSHAFT (a) Using a dial indicator and V-blocks, measure the circle runout as shown in the illustration. Maximum circle runout: 0.03 mm (0.0012 in.) If the taper and distortion are greater than the maximum, replace the crankshaft. A013491E01 EM EM–148 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT No. 1 No. 2 No. 3 No. 4 No. 5 EM A098151E01 ZF06928E02 (b) Using a micrometer, measure the diameter of each main journal. Standard diameter: 54.988 to 55.000 mm (2.1649 to 2.1654 in.) If the diameter is not as specified, check the crankshaft oil clearance. (c) Check each main journal for taper and distortion as shown in the illustration. Maximum taper and distortion: 0.003 mm (0.0001 in.) If the taper and distortion are greater than the maximum, replace the crankshaft. Standard diameter (Reference) Mark Specified Condition 0 54.999 to 55.000 mm (2.1653 to 2.1654 in.) 1 54.997 to 54.998 mm (2.1652 to 2.1653 in.) 2 54.995 to 54.996 mm (2.1652 to 2.1652 in.) 3 54.993 to 54.994 mm (2.1651 to 2.1651 in.) 4 54.991 to 54.992 mm (2.1650 to 2.1650 in.) 5 54.988 to 54.990 mm (2.1649 to 2.1650 in.) (d) Using a micrometer, measure the diameter of each crank pin. Standard diameter: 47.990 to 48.000 mm (1.8894 to 1.8898 in.) If the diameter is not as specified, check the connecting rod oil clearance. (e) Inspect each crank pin for taper and distortion as shown in the illustration. Maximum taper and distortion: 0.003 mm (0.0001 in.) If the taper and distortion are greater than the maximum, replace the crankshaft. 26. INSPECT CRANKSHAFT THRUST CLEARANCE (a) Install the main bearing cap (See page EM-149). A128234 (b) Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.04 to 0.24 mm (0.0016 to 0.0095 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.) If the thrust clearance is greater than the maximum, replace the thrust washers as a set. HINT: The thrust washer thickness is 1.93 to 1.98 mm (0.0760 to 0.0780 in.). 27. INSPECT CRANKSHAFT OIL CLEARANCE (a) Check the crank journal and bearing for pitting and scratches. (b) Install the crankshaft bearing (See page EM-149). (c) Place the crankshaft on the cylinder block. EM–149 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT Plastigage A087782E03 Plastigage No. 1 No. 2 No. 3 No. 4 No. 5 (d) Lay a strip of Plastigage across each journal. (e) Examine the front marks and numbers and install the bearing caps on the cylinder block. HINT: A number is marked on each main bearing cap to indicate the installation position. (f) Install the main bearing cap (See page EM-149). NOTICE: Do not turn the crankshaft. (g) Remove the main bearing caps (See page EM-127). (h) Measure the Plastigage at its widest point. Standard oil clearance: 0.017 to 0.040 mm (0.0007 to 0.0016 in.) Maximum oil clearance: 0.060 mm (0.0024 in.) NOTICE: Remove the Plastigage completely after the measurement. If the oil clearance is greater than the maximum, replace the crankshaft bearing. If necessary, replace the crankshaft. HINT: • If replacing a bearing, select a new one with the same number. If the number of the bearing cannot be determined, calculate the correct bearing number by adding together the numbers imprinted on the cylinder block and crankshaft. Then select a new bearing with the calculated number. There are 4 sizes of standard bearings, marked "1", "2", "3" and "4" accordingly. • EXAMPLE: Cylinder block "3" + Crankshaft "5" = Total number 8 (Use bearing "3") Cylinder block + Crankshaft 0 to 2 3 to 5 6 to 8 9 to 11 Bearing to be used "1" "2" "3" "4" Standard cylinder block journal bore diameter No. 2 No. 4 No. 1 No. 3 No. 5 Number Mark A129506E03 Mark Specified Condition 0 59.000 to 59.002 mm (2.3228 to 2.3229 in.) 1 59.003 to 59.004 mm (2.3230 to 2.3230 in.) 2 59.005 to 59.006 mm (2.3230 to 2.3231 in.) 3 59.007 to 59.009 mm (2.3231 to 2.3232 in.) 4 59.010 to 59.011 mm (2.3232 to 2.3233 in.) 5 59.012 to 59.013 mm (2.3233 to 2.3234 in.) 6 59.014 to 59.016 mm (2.3234 to 2.3235 in.) Standard crankshaft journal diameter Mark Specified Condition 0 54.999 to 55.000 mm (2.1653 to 2.1654 in.) 1 54.997 to 54.998 mm (2.1652 to 2.1653 in.) 2 54.995 to 54.996 mm (2.1652 to 2.1652 in.) 3 54.993 to 54.994 mm (2.1651 to 2.1651 in.) 4 54.991 to 54.992 mm (2.1650 to 2.1650 in.) EM EM–150 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT Mark Specified Condition 5 54.988 to 54.990 mm (2.1649 to 2.1650 in.) Standard bearing center wall thickness Mark Specified Condition 1 1.993 to 1.996 mm (0.0785 to 0.0786 in.) 2 1.997 to 1.999 mm (0.0786 to 0.0787 in.) 3 2.000 to 2.002 mm (0.0787 to 0.0788 in.) 4 2.003 to 2.005 mm (0.0789 to 0.0789 in.) 28. INSPECT CRANKSHAFT BEARING CAP SET BOLT (a) Using vernier calipers, measure the tension portion diameter of the bolts. Standard diameter: 7.3 to 7.5 mm (0.287 to 0.295 in.) Minimum diameter: 7.2 mm (0.284 in.) If the diameter is less than the minimum, replace the bolt. EM A064458 EM–151 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT REASSEMBLY 1. INSTALL RING PIN (a) Using a plastic hammer, tap into the ring pin. Upper Side: Lower Side: B A A 14.0 (0.551) 13.0 (0.512) EM B Protrusion Height A 12.0 (0.472) B 12.0 (0.472) mm (in.) A112251E02 Standard protrusion Item Protrusion Pin A 6 mm (0.236 in.) Pin B 5 mm (0.197 in.) EM–152 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT 2. INSTALL STUD BOLT (a) Install the stud bolts as shown in the illustration. Front Side: RH Side: C B A D LH Side: EM B 16.0 (0.630) 15.0 (0.591) 84.0 (3.307) 12.0 (0.472) 52.5 (2.067) 12.0 (0.472) 20.0 (0.787) 33.3 (1.311) 9.0 (0.354) A B 10.0 (0.394) 27.5 (1.083) C 9.0 (0.354) D mm (in.) A112253E02 Torque: Stud Bolt A 5.0 N*m (51 kgf*cm, 44 in.*lbf) Stud Bolt B 22 N*m (220 kgf*cm, 16 ft.*lbf) Stud Bolt C 9.5 N*m (97 kgf*cm, 84 in.*lbf) Stud Bolt D 5.0 N*m (51 kgf*cm, 44 in.*lbf) EM–153 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT 3. INSTALL STRAIGHT PIN (a) Using a plastic hammer, tap into the straight pin. Front Side: Lower Side: B A A B Rear Side: RH Side: EM C C C A D B 18.0 (0.709) 8.0 (0.315) 15.0 (0.591) 8.0 (0.315) 22.0 (0.866) 10.0 (0.394) D 14.0 (0.551) 7.0 (0.276) Protrusion Height mm (in.) A112252E02 Standard protrusion Item 4. A128251E01 Protrusion Pin A 8 mm (0.315 in.) Pin B 7.5 mm (0.295 in.) Pin C 12 mm (0.472 in.) Pin D 5 mm (0.197 in.) INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY (a) Using a 5 mm hexagon wrench, install the oil nozzles with the bolts. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) EM–154 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT 5. INSTALL PISTON (a) Using a screwdriver, install a new snap ring at one end of the piston pin hole. HINT: Make sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston. (b) Gradually heat the piston to approximately 80 to 90°C (176 to 194°F). A128244 (c) Align the front marks of the piston and connecting rod, and push in the piston with your thumb. (d) Using a screwdriver, install a new snap ring on the other end of the piston pin hole. HINT: Make sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston. TMC Made: EM Front Mark TMMK Made: Front Mark Front Mark A136101E01 (e) Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin. A107551 6. Oil Ring Oil Ring (Expander) Oil Ring (Expander) Oil Ring A131712E01 INSTALL PISTON RING SET (a) Install the oil ring expander and oil ring rail by hand. NOTICE: • Install the expander and oil ring so that their ring ends are at opposite sides. • Securely install the expander to the inner groove of the oil ring. 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT (b) Using a piston ring expander, install the 2 compression rings so that the paint marks are positioned as shown in the illustration. NOTICE: Install the compression ring No. 2 with the code mark (2N and 2A) facing upward. Piston Ring Expander Upward No. 1 EM–155 Paint Mark (TMC Made) Paint Mark EM No. 2 TMC Made: (2N) TMMK Made: (2A) A128246E01 TMC Made: No. 1 and Oil Ring Rail (c) Position the piston rings so that the ring ends are as shown in the illustration. No. 2 and Oil Ring Expander Front Mark TMMK Made: No. 1 and Oil Ring Rail No. 2 and Oil Ring Expander Front Mark A136102E01 7. A053015 INSTALL CRANKSHAFT BEARING (a) Install the upper bearing with an oil groove on the cylinder block. NOTICE: Do not apply engine oil to the bearings and the contact surfaces. EM–156 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT 8. INSTALL NO. 2 CRANKSHAFT BEARING (a) Install the lower bearing on the bearing cap. NOTICE: Clean the backside of the bearing and the bearing surface of the connecting rod. The surface should be free of dust and oils. 9. INSTALL UPPER CRANKSHAFT THRUST WASHER (a) Install the 2 thrust washers under the No. 3 journal of the cylinder block with the oil grooves facing outward. (b) Apply engine oil to the crankshaft thrust washer. Claw A063909E01 Oil Groove EM 10. INSTALL CRANKSHAFT (a) Apply engine oil to the upper bearing and install the crankshaft on the cylinder block. (b) Apply engine oil to the lower bearing. A013501E01 (c) Examine the front marks and install the bearing caps on the cylinder block. (d) Apply a light coat of engine oil to the threads and under the bearing cap bolts. (e) Install the crankshaft bearing cap bolts. NOTICE: The main bearing cap bolts are tightened in 2 progressive steps. Front Mark and Number A128241E01 (f) 7 3 8 4 1 2 5 9 6 10 Step 1 (1) Install and uniformly tighten the 10 main bearing cap bolts in the sequence shown in the illustration. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) A128235E02 7 3 8 4 1 2 5 9 6 10 A128235E02 (2) Retighten the 10 main bearing cap bolts in the sequence shown in the illustration. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT 90° Paint Mark Engine Front A050671E10 A128248E01 No. 1 and Oil Ring Rail No. 1 and Oil Ring Rail 12. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD NOTICE: The connecting rod cap bolts are tightened in 2 progressive steps. (a) Apply engine oil to the cylinder walls, the pistons, and the surfaces of connecting rod bearings. (b) Check the position of the piston ring ends. No. 2 and Oil Ring Expander Front Mark TMMK Made: (g) Step 2 (1) Mark the front of the bearing cap bolts with paint. (2) Retighten the bearing cap bolts by 90°in the numerical order shown in the illustration. (h) Check that the paint mark is now at a 90°angle to the front. (i) Check that the crankshaft turns smoothly. (j) Check the crankshaft thrust clearance (See page EM-147). 11. INSTALL CONNECTING ROD BEARING (a) Align the bearing claw with the groove of the connecting rod or connecting cap. NOTICE: Do not apply engine oil to the bearings and the contact surfaces. Claw TMC Made: EM–157 No. 2 and Oil Ring Expander Front Mark A136102E01 EM EM–158 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT (c) Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward. NOTICE: Match the numbered connecting rod cap with the connecting rod. TMC Made: EM TMMK Made: Front Front Front Mark Front Mark A136103E01 (d) Check that the protrusion of the connecting rod cap is facing in the correct direction. (e) Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts. (f) Install the connecting cap bolts. NOTICE: The connecting cap bolts should be tightened in 2 progressive steps. Front Mark A052515E01 (g) Step 1 (1) Install and alternately tighten the bolts of the connecting rod cap in several steps. Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) A013397 90° Paint Mark Engine Front A101478E03 (h) Step 2 (1) Mark the front of the connecting rod cap bolts with paint. (2) Retighten the cap bolts by 90°as shown in the illustration. (i) Check that the crankshaft turns smoothly. (j) Check the connecting rod thrust clearance (See page EM-140). 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–159 13. INSTALL NO. 1 BALANCESHAFT BEARING (a) Install the bearings in the crankcase and balanceshaft housing. NOTICE: Do not apply engine oil to the bearings and the contact surfaces. (b) Apply a light coat of engine oil to the bearings. Stiffening Crankcase: Balanceshaft Housing: EM A128204E02 No. 2 Driven Gear No. 1 Driven Gear Rotating Direction Align 14. INSTALL NO. 1 AND NO. 2 BALANCESHAFT SUBASSEMBLY (a) Rotate the driven gear No. 1 of balanceshaft No. 1 in the rotating direction until it hits the stopper. NOTICE: Confirm that the matchmarks on driven gears No. 1 and No. 2 are matched. A128213E01 No. 1 Balanceshaft No. 2 Balanceshaft (b) Align the timing marks of the No. 1 and No. 2 balanceshafts as shown in the illustration. Timing Mark A128214E02 No. 1 Balanceshaft Timing Mark No. 2 Balanceshaft A131707E02 (c) Place the No. 1 and No. 2 balanceshafts on the crankcase. (d) Apply a light coat of engine oil under the heads of the balanceshaft housing bolts. (e) Install the balanceshaft housing bolts. NOTICE: The balance shaft housing bolts are tightened in 2 progressive steps. EM–160 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT (f) 8 5 1 4 3 2 6 7 Step 1 (1) Install and uniformly tighten the 8 bolts in the sequence shown in the illustration. Torque: 22 N*m (220 kgf*cm, 16 ft.*lbf) A128197E04 (g) Step 2 (1) Mark the front side of each balanceshaft housing bolt head with paint. (2) Retighten the bolts by 90°as shown in the illustration. (3) Check that the paint marks are now at a 90°angle to the front. 90° EM Engine Front Paint Mark A037134E02 15. INSTALL STIFFENING CRANKCASE ASSEMBLY (a) Place a new O-ring on the cylinder block, as shown in the illustration. (b) Temporarily tighten the pulley set bolt. A128206 (c) Turn the crankshaft to set the crank pins of the No. 1 and No. 4 cylinders to the bottom. HINT: Make sure that the timing mark on the balanceshaft drive gear is positioned as shown in the illustration. Front View: No. 1 and No. 4 Crank Pin Approx 16° Drive Gear Timing Mark A128255E01 EM–161 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT 2.5 to 3.0 mm (0.098 to 0.118 in.) A C B D A B (d) Apply seal packing in a continuous bead (diameter: 2.5 to 3.0 mm (0.098 to 0.118 in.)) to the places shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three bond 1207B or Equivalent NOTICE: • Remove any oil from the contact surface. • Install the crankcase within 3 minutes after applying seal packing. • Do not start the engine for at least 2 hours after installing the crankcase stiffener. C,D EM 7.5 mm (0.295 in.) 7.5 mm (0.295 in.) 4.0 mm (0.158 in.) A128254E01 (e) Install the stiffening crankcase so that the reference holes on the balanceshafts are positioned as shown in the illustration. Timing Mark Reference Hole A131254E01 A A (f) B B B A A B A B B A128202E04 Temporarily install the crankcase with the 11 bolts. Bolt length Item Length Bolt A 122 mm (4.803 in.) Bolt B 45 mm (1.772 in.) EM–162 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT 3 7 1 4 11 8 (g) Uniformly tighten the 11 bolts in the sequence shown in the illustration. Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) (h) Wipe off the excess seal packing with a clean piece of cloth. 9 10 6 2 5 A128202E05 (i) Timing Mark (j) EM Approx. 5° Turn the crankshaft again to set the key groove to the bottom. Make sure that the timing marks are aligned as shown in the illustration. HINT: An '{' is stamped as a timing mark. Remove the pulley set bolt. Approx. 5° Reference Hole Key Groove A128215E01 16. INSTALL OIL PUMP ASSEMBLY (a) Install a new gasket and oil pump with the 3 bolts. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) A128253 SST A128212E01 17. INSTALL ENGINE REAR OIL SEAL (a) Using SST and a hammer, evenly tap the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-15030, 09950-70010 (09951-07100) NOTICE: Keep the lip free from foreign materials. (b) Apply MP grease to a new oil seal lip. NOTICE: Wipe off extra grease on the crankshaft. 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–163 18. INSTALL NO. 1 TAPER SCREW PLUG (w/o Oil Cooler) (a) Apply adhesive to 2 or 3 threads of the plug, and install the plug. Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent A128211 Oil Filter Control Valve Gasket 19. INSTALL OIL CONTROL VALVE FILTER (a) Check that no foreign matter is on the mesh part of the filter. (b) Using an 8 mm socket hexagon wrench, install a new gasket and the oil control valve filter with the screw plug. Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) NOTICE: Do not touch the mesh when installing the oil control valve filter. Plug A128210E01 20. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY (w/o Oil Cooler) (a) Apply adhesive around the drain cock. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent A135987 45° 45° A098363E01 (b) Install the water drain cock within the range shown in the illustration. Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) NOTICE: Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks to the specified torque. (c) Install the water drain cock plugs to the water drain cocks. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) EM EM–164 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT 21. INSTALL CYLINDER BLOCK WATER JACKET SPACER (a) Install the water jacket spacer as shown in the illustration. HINT: Be sure to face the slope to the front of the engine. Slope 22. INSTALL CYLINDER HEAD GASKET (See page EM70) A128252E01 23. INSTALL CYLINDER HEAD SUB-ASSEMBLY (See page EM-70) 24. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Apply a light coat of engine oil to a new O-ring, then install it onto the camshaft timing oil control valve. EM O-Ring A090053E02 (b) Install the camshaft timing oil control valve with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 25. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY (See page EM-42) A128171 26. INSTALL CAMSHAFT TIMING SPROCKET (a) Clamp the camshaft in a vise. (b) Tighten the flange bolt with the camshaft timing sprocket fixed. Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) A032167 27. INSTALL NO. 1 CAMSHAFT BEARING (a) Install the No. 1 camshaft bearing. 28. INSTALL NO. 2 CAMSHAFT BEARING (See page EM71) 29. INSTALL CAMSHAFT (a) Apply a light coat of engine oil to the journal portion of the camshaft. A128191 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–165 (b) Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps into the cylinder head. (c) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts. A098177E03 No. 1 3 7 1 5 9 8 4 2 6 10 A098177E06 (d) Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration. Torque: No. 1 Bearing cap 30 N*m (301 kgf*cm, 22 ft.*lbf) No. 3 Bearing cap 9.0 N*m (92 kgf*cm, 80 in.*lbf) 30. INSTALL NO. 2 CAMSHAFT (a) Apply a light coat of engine oil to the journal portion of the No. 2 camshaft. (b) Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps onto the cylinder head. (c) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts. A098174E05 3 1 5 9 7 8 4 2 6 10 (d) Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration. Torque: No. 1 Bearing cap 30 N*m (301 kgf*cm, 22 ft.*lbf) No. 3 Bearing cap 9.0 N*m (92 kgf*cm, 80 in.*lbf) No. 2 A098174E07 31. INSTALL KEYS (a) Install the 2 keys. 32. INSTALL NO. 2 CHAIN SUB-ASSEMBLY (See page EM-27) 33. INSTALL CRANKSHAFT TIMING SPROCKET (See page EM-28) 34. INSTALL NO. 1 CHAIN VIBRATION DAMPER (See page EM-28) A131498 35. INSTALL CHAIN SUB-ASSEMBLY (See page EM-28) EM EM–166 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT 36. INSTALL CHAIN TENSIONER SLIPPER (See page EM-29) 37. INSTALL TIMING CHAIN GUIDE (See page EM-30) 38. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE (See page EM-30) 39. INSTALL TIMING CHAIN CASE OIL SEAL (a) Using SST, tap in a new oil seal until its surface is flush with the timing chain cover edge. SST 09223-22010 (b) Apply a light coat of MP grease to the lip of the oil seal. NOTICE: Keep the gap between the timing chain cover edge and the oil seal free of foreign matter. SST A128223E01 EM 40. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY (See page LU-15) 41. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (See page EM-30) 42. INSTALL OIL PAN SUB-ASSEMBLY (See page EM-31) 43. INSTALL OIL PAN DRAIN PLUG (a) Install a new gasket and oil pan drain plug with a new gasket. Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 44. INSTALL WATER PUMP ASSEMBLY (See page CO10) 45. INSTALL WATER PUMP PULLEY (See page CO-11) A128176 46. INSTALL CRANKSHAFT POSITION SENSOR (a) Apply a light coat of engine oil to the O-ring of the sensor. O-Ring A095436E01 (b) Confirm that the wire harness of the sensor is placed as shown in the illustration. Wire Harness Clamp Rib A052071E05 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–167 (c) Install the sensor with the 2 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) A063828 (d) Install the clamp of the crankshaft position sensor onto the water pump. 47. INSTALL CRANKSHAFT PULLEY (See page EM-76) 48. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (See page EM-32) 49. INSPECT VALVE CLEARANCE (See page EM-8) 50. ADJUST VALVE CLEARANCE (See page EM-9) A094516E01 51. INSTALL CAMSHAFT POSITION SENSOR (a) Apply a light coat of engine oil to the O-ring of the sensor. O-Ring A095434E01 (b) Install the sensor with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) A128164 52. INSTALL CYLINDER HEAD COVER GASKET (a) Install the gasket to the cylinder head cover. NOTICE: Remove any oil from the contact surface. 53. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (See page EM-33) A128166 EM EM–168 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT 54. INSTALL OIL FILTER UNION (w/o Oil Cooler) (a) Using a 12 mm hexagon wrench, install the oil filter union. Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 55. INSTALL OIL COOLER ASSEMBLY (w/ Oil Cooler) (a) Clean the oil cooler contact surface on the cooler mounting. A128162 (b) Install a new O-ring to the oil cooler. (c) Apply a light coat of engine oil to the threads and under the head of the union bolt. New O-Ring EM A124389E01 A135533 (d) Install the oil cooler with the plate washer, oil filter union and nut. Torque: Oil Filter Union 79 N*m (806 kgf*cm, 58 ft.*lbf) Nut 9.0 N*m (92 kgf*cm, 80 in.*lbf) (e) Apply adhesive to the threads of the oil filter union. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent (f) Install the union bolt. Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 56. INSTALL OIL FILTER SUB-ASSEMBLY (a) Check and clean the oil filter installation surface. (b) Apply clean engine oil to the gasket of a new oil filter. (c) Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat. A129331 (d) When using a torque wrench: (1) Using SST, tighten the oil filter. SST 09228-06501 Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) SST A129850E01 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–169 (e) When not using a torque wrench: (1) Using SST, tighten it an additional 3/4 turn. SST 09228-06501 3/4 Turn SST A129851E01 57. INSTALL SPARK PLUG (a) Install the spark plugs. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) EM A128161 58. INSTALL VENTILATION VALVE SUB-ASSEMBLY (a) Apply adhesive to the threads of the ventilation valve. Adhesive A092670E03 (b) Install the ventilation valve. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent A128160 59. INSTALL OIL FILLER CAP GASKET (a) Install a new gasket to the cap. A128159 EM–170 2AZ-FE ENGINE MECHANICAL – ENGINE UNIT 60. INSTALL OIL FILLER CAP SUB-ASSEMBLY (a) Install the oil filler cap. A128158 EM SLIDING ROOF – SLIDING ROOF SYSTEM RF–1 SLIDING ROOF SYSTEM SLIDING ROOF BODY PARTS LOCATION ROOF CONSOLE BOX ASSEMBLY (SLIDING ROOF SWITCH ASSEMBLY) SLIDING ROOF DRIVE GEAR SUB-ASSEMBLY (SLIDING ROOF CONTROL ECU) RF MAIN BODY ECU INSTRUMENT PANEL J/B - S/R FUSE - ECU-IG NO. 1 FUSE B131105E02 RF–2 SLIDING ROOF – SLIDING ROOF SYSTEM SYSTEM DIAGRAM Overhead Junction Block (Sliding Roof Control Switch) Serial Line RF Sliding Roof Drive Gear LIN Bus Line Main Body ECU (Sliding Roof Control ECU) B130036E02 Communication table Sender Receiver Signal Line Main Body ECU Sliding Roof Control ECU Key-off operation signal LIN RF–3 SLIDING ROOF – SLIDING ROOF SYSTEM SYSTEM DESCRIPTION 1. 2. Component GENERAL This system has the following functions: manual slide open and close; auto slide open and close; manual tilt up and down; auto tilt up and down; jam protection; and key off operation. FUNCTION OF MAIN COMPONENT Outline Sliding Roof Drive Gear Sub-assembly (Sliding roof ECU) Sliding roof ECU controls sliding roof motor to rotate forward and backward, which tilts or slides sliding roof glass. Overhead Junction Block Output of operation signals from built-in sliding roof switch to sliding roof ECU is handled by overhead junction block. 3. Function SYSTEM OPERATION The sliding roof has the following features: Outline Manual slide open and close This function causes sliding roof to open (or close) when OPEN/ CLOSE switch is pressed for a maximum of 0.3 seconds. Sliding roof stops as soon as the switch is released. Auto slide open and close This function causes sliding roof to fully open (or close) when OPEN/ CLOSE switch is pressed for a minimum of 0.3 seconds. Manual tilt up and down This function causes sliding roof to tilt up (or tilt down) when UP/ DOWN switch is pressed for a maximum of 0.3 seconds. Auto tilt up and down This function enables sliding roof to tilt up (or down) when UP/DOWN switch is pressed for a minimum of 0.3 seconds. Jam protection The jam protection function automatically stops sliding roof, or stops sliding roof and makes it open halfway (or fully tilted up) if a foreign object gets jammed in sliding roof during auto close operation (or auto tilt down operation). Key off operation Key off operation function makes it possible to operate sliding roof for approximately 43 seconds after ignition switch is turned off, if front doors are not opened. RF RF–4 SLIDING ROOF – SLIDING ROOF SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use the following procedures to troubleshoot the sliding roof system. • *: Use the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding to the next step. RF NEXT 3 INSPECT COMMUNICATION FUNCTION OF CAN COMMUNICATION SYSTEM* (a) Using the intelligent tester, check if the CAN communication system is functioning normally. Result Result Proceed to DTC is not output A DTC is output B B Go to CAN COMMUNICATION SYSTEM A 4 PROBLEM SYMPTOMS TABLE Result Result Proceed to Fault is not listed in problem symptoms table A Fault is listed in problem symptoms table B B Go to step 6 A 5 OVERALL ANALYSIS AND TROUBLESHOOTING* 1. Data List / Active Test (See page RF-9) 2. Terminals of ECU (See page RF-5) 3. On-vehicle Inspection (See page RF-11) SLIDING ROOF – SLIDING ROOF SYSTEM RF–5 NEXT 6 ADJUST, REPAIR OR REPLACE NEXT 7 CONFIRMATION TEST NEXT END RF RF–6 SLIDING ROOF – SLIDING ROOF SYSTEM INITIALIZATION 1. RF INITIALIZE SLIDING ROOF DRIVE GEAR SUBASSEMBLY NOTICE: When replacing the sliding roof drive gear, the sliding roof drive gear requires initialization. If a reset is not executed, the following functions do not operate: auto operation and key off operation. (a) Turn the ignition switch on (IG). (b) Make sure that the sliding roof is fully closed. (c) Push and hold the CLOSE switch or the UP switch until the following movement finishes: Tilt up → approximately 1 second → tilt down → slide open → slide closed. (d) Check that the sliding roof stops at the fully closed position. (e) Finish the initialization. (f) Check that the AUTO operation works normally. NOTICE: If the following conditions occur during initialization procedure, initialization will fail. • Ignition switch is turned off. • Sliding roof control switch is released while sliding roof is operating. • Vehicle speed is 5 km/h (3 mph) or more. • Communication is cut off. • Another switch is turned on during initialization. • The vehicle experiences a strong vibration during initialization, such as the slamming of a door. HINT: • If the sliding roof cannot be fully closed or its position has become misaligned, perform initialization again. • If the roof glass stops moving or starts moving in the opposite direction while the CLOSE or UP switch is held down, continue to hold the switch for another 10 seconds or more to return the sliding roof control ECU to an uninitialized condition. Then perform the initialization procedure again. • If the AUTO operation function and jam protection function do not operate after the drive gear has been reset, replace the sliding roof drive gear (sliding roof ECU). RF–7 SLIDING ROOF – SLIDING ROOF SYSTEM PROBLEM SYMPTOMS TABLE HINT: Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected Area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. Inspect the fuses and relays related to this system before inspecting the suspected areas below. Sliding Roof System Symptom Suspected area See page Sliding function and tilt function do not operate Sliding roof ECU power source circuit RF-28 Either sliding function or tilt function does not operate Sliding roof control switch circuit RF-25 RF RF–8 SLIDING ROOF – SLIDING ROOF SYSTEM TERMINALS OF ECU 1. CHECK SLIDING ROOF DRIVE GEAR SUBASSEMBLY (SLIDING ROOF CONTROL ECU) (TMC MADE) Q13 B050671E36 RF (a) Disconnect the Q13 ECU connector. (b) Measure the resistance and voltage according to the value(s) in the table below. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition B (Q13-1) - E (Q13-2) B - W-B +B power supply Always 10 to 14 V IG (Q13-5) - E (Q13-2) Y - W-B Ignition switch power supply Ignition switch off Below 1 V IG (Q13-5) - E (Q13-2) Y - W-B Ignition switch power supply Ignition switch on (IG) 10 to 14 V OPN (Q13-7) - E (Q13-2) BR - W-B Sliding roof motor open OPEN switch OFF 10 kΩ or higher OPN (Q13-7) - E (Q13-2) BR - W-B Sliding roof motor open OPEN switch ON Below 1 Ω CLS (Q13-9) - E (Q13-2) L - W-B Sliding roof motor closed CLOSE switch OFF 10 kΩ or higher CLS (Q13-9) - E (Q13-2) L - W-B Sliding roof motor closed CLOSE switch ON Below 1 Ω UP (Q13-10) - E (Q13-2) W - W-B Sliding roof motor up UP switch OFF 10 kΩ or higher UP (Q13-10) - E (Q13-2) W - W-B Sliding roof motor up UP switch ON Below 1 Ω DWN (Q13-8) - E (Q13-2) G - W-B Sliding roof motor down DOWN switch OFF 10 kΩ or higher DWN (Q13-8) - E (Q13-2) G - W-B Sliding roof motor down DOWN switch ON Below 1 Ω E (Q13-2) - Body ground W-B - Body ground Ground Always Below 1 Ω If the result is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the Q13 ECU connector. (d) Measure the voltage according to the value(s) in the table below. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition OPN (Q13-7) - E (Q13-2) BR - W-B Sliding roof motor open Ignition switch on (IG), sliding roof closed, OPEN switch OFF OPN (Q13-7) - E (Q13-2) BR - W-B Sliding roof motor open Ignition switch on (IG), sliding roof closed, OPEN switch ON 10 to 14 V CLS (Q13-9) - E (Q13-2) L - W-B Sliding roof motor closed Ignition switch on (IG), sliding roof open, CLOSE switch OFF Below 1 V CLS (Q13-9) - E (Q13-2) L - W-B Sliding roof motor closed Ignition switch on (IG), sliding roof open, CLOSE switch ON 10 to 14 V UP (Q13-10) - E (Q13-2) W - W-B Sliding roof motor up Ignition switch on (IG), sliding roof tilted downward, UP switch OFF Below 1 V Below 1 V RF–9 SLIDING ROOF – SLIDING ROOF SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition UP (Q13-10) - E (Q13-2) W - W-B Sliding roof motor up Ignition switch on (IG), sliding roof tilted downward, UP switch ON DWN (Q13-8) - E (Q13-2) G - W-B Sliding roof motor down Ignition switch on (IG), sliding roof tilted upward, DOWN switch OFF Below 1 V DWN (Q13-8) - E (Q13-2) G - W-B Sliding roof motor down Ignition switch on (IG), sliding roof tilted upward, DOWN switch ON 10 to 14 V 2. 10 to 14 V If the result is not as specified, the ECU may have a malfunction. CHECK SLIDING ROOF DRIVE GEAR SUBASSEMBLY (SLIDING ROOF CONTROL ECU) (TMMK MADE) R1 RF B050671E35 (a) Disconnect the R1 ECU connector. (b) Measure the resistance and voltage according to the value(s) in the table below. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition B (R1-1) - E (R1-2) B - W-B +B power supply Always 10 to 14 V IG (R1-5) - E (R1-2) Y - W-B Ignition switch power supply Ignition switch off Below 1 V IG (R1-5) - E (R1-2) Y - W-B Ignition switch power supply Ignition switch on (IG) 10 to 14 V OPN (R1-10) - E (R1-2) BR - W-B Sliding roof motor open OPEN switch OFF 10 kΩ or higher OPN (R1-10) - E (R1-2) BR - W-B Sliding roof motor open OPEN switch ON Below 1 Ω CLS (R1-8) - E (R1-2) L - W-B Sliding roof motor closed CLOSE switch OFF 10 kΩ or higher CLS (R1-8) - E (R1-2) L - W-B Sliding roof motor closed CLOSE switch ON Below 1 Ω UP (R1-9) - E (R1-2) W - W-B Sliding roof motor up UP switch OFF 10 kΩ or higher UP (R1-9) - E (R1-2) W - W-B Sliding roof motor up UP switch ON Below 1 Ω DWN (R1-7) - E (R1-2) G - W-B Sliding roof motor down DOWN switch OFF 10 kΩ or higher DWN (R1-7) - E (R1-2) G - W-B Sliding roof motor down DOWN switch ON Below 1 Ω E (R1-2) - Body ground W-B - Body ground Ground Always Below 1 Ω If the result is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the R1 ECU connector. (d) Measure the voltage according to the value(s) in the table below. Symbols (Terminal No.) OPN (R1-10) - E (R1-2) Wiring Color BR - W-B Terminal Description Sliding roof motor open Condition Ignition switch on (IG), sliding roof closed, OPEN switch OFF Specified Condition Below 1 V RF–10 Symbols (Terminal No.) RF SLIDING ROOF – SLIDING ROOF SYSTEM Wiring Color Terminal Description Condition Specified Condition OPN (R1-10) - E (R1-2) BR - W-B Sliding roof motor open Ignition switch on (IG), sliding roof closed, OPEN switch ON CLS (R1-8) - E (R1-2) L - W-B Sliding roof motor closed Ignition switch on (IG), sliding roof open, CLOSE switch OFF Below 1 V CLS (R1-8) - E (R1-2) L - W-B Sliding roof motor closed Ignition switch on (IG), sliding roof open, CLOSE switch ON 10 to 14 V UP (R1-9) - E (R1-2) W - W-B Sliding roof motor up Ignition switch on (IG), sliding roof tilted downward, UP switch OFF Below 1 V UP (R1-9) - E (R1-2) W - W-B Sliding roof motor up Ignition switch on (IG), sliding roof tilted downward, UP switch ON 10 to 14 V DWN (R1-7) - E (R1-2) G - W-B Sliding roof motor down Ignition switch on (IG), sliding roof tilted upward, DOWN switch OFF Below 1 V DWN (R1-7) - E (R1-2) G - W-B Sliding roof motor down Ignition switch on (IG), sliding roof tilted upward, DOWN switch ON 10 to 14 V 10 to 14 V If the result is not as specified, the ECU may have a malfunction. RF–11 SLIDING ROOF – SLIDING ROOF SYSTEM DIAGNOSIS SYSTEM 1. DESCRIPTION (a) Sliding roof system data and Diagnostic Trouble Codes (DTCs) can be read through the vehicle's Data Link Connector 3 (DLC3). When the system seems to be malfunctioning, use the intelligent tester to check for malfunctions and perform repairs. 2. CHECK DLC3 HINT: The ECU uses ISO 15765-4 for communication. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. CG SG CANH SIL CANL BAT H100769E94 Symbols (Terminals No.) Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 11 to 14 V CANH (6) - CANL (14) CAN bus line Ignition switch off* 54 to 69 Ω CANH (6) - CG (4) CAN bus line Ignition switch off* 200 Ω or higher CANL (14) - CG (4) CAN bus line Ignition switch off* 200 Ω or higher CANH (6) - BAT (16) CAN bus line Ignition switch off* 6 kΩ or higher CANL (14) - BAT (16) CAN bus line Ignition switch off* 6 kΩ or higer NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of the intelligent tester to the DLC3, turn the ignition switch on (IG) and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. • If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. RF RF–12 SLIDING ROOF – SLIDING ROOF SYSTEM 3. DLC3 Intelligent Tester C131977E11 RF INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding to the next step. RF–13 SLIDING ROOF – SLIDING ROOF SYSTEM DATA LIST / ACTIVE TEST 1. READ DATA LIST HINT: Using the intelligent tester's Data List allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the Data List early in troubleshooting is one way to save time. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Read the Data List according to the display on the tester. SLIDE ROOF: Item Measurement Item/Display (Range) Normal Condition Diagnostic Note OPEN SW Slide switch open signal/ON or OFF ON: OPEN switch is pressed. OFF: OPEN switch is not pressed. - CLOSE SW Slide switch close signal/ON or OFF ON: CLOSE switch is pressed. OFF: CLOSE switch is not pressed. - UP SW Tilt switch up signal/ON or OFF ON: UP switch is pressed. OFF: UP switch is not pressed. - DOWN SW Tilt switch down signal/ON or OFF ON: DOWN switch is pressed. OFF: DOWN switch is not pressed. - HALL IC1 STATUS Sliding roof operation signal/ NORMAL or LOCK NORMAL: Sliding roof motor is operating. LOCK: Sliding roof motor is not operating. - HALL IC1 PULSE Sliding roof operation signal/LO or HI LO: Sliding roof motor is not operating. HI: Sliding roof motor is operating. - HALL IC2 STATUS Sliding roof operation signal/ NORMAL or LOCK NORMAL: Sliding roof motor is operating. LOCK: Sliding roof motor is not operating. - HALL IC2 PULSE Sliding roof operation signal/LO or HI LO: Sliding roof motor is not operating. HI: Sliding roof motor is operating. - D-DOOR WARN SW Driver's door courtesy light switch signal/ON or OFF ON: Driver's door is open. OFF: Driver's door is closed. - IG (MPX) Ignition switch signal (MPX signal)/ON or OFF ON: Ignition switch on (IG) OFF: Ignition switch off - IG (DIRCT SIG) Ignition switch signal/ON or OFF ON: Ignition switch on (IG) OFF: Ignition switch off - KEY OFF PERMS Key-OFF sliding roof operation permit signal (Current)/ON or OFF ON: Driver's side door is not closed within 45 sec. after ignition switch is turned off. OFF: Any status except "ON" status - CURRENT DOWN SW Down switch failure signal (Current)/Fail or Not Fail Fail: Sliding roof tilt down signal failure (Current) Not Fail: Sliding roof tilt down signal not fail (Current) - CURRENT UP SW Up switch failure signal (Current)/ Fail or Not Fail Fail: Sliding roof tilt up signal failure (Current) Not Fail: Sliding roof tilt up signal not fail (Current) - RF RF–14 SLIDING ROOF – SLIDING ROOF SYSTEM Item Measurement Item/Display (Range) Normal Condition Diagnostic Note CURRENT CLS SW Close switch failure signal (Current)/Fail or Not Fail Fail: Sliding roof close signal failure (Current) Not Fail: Sliding roof close signal not fail (Current) - CURRENT OPN SW Open switch failure signal (Current)/Fail or Not Fail Fail: Sliding roof open signal failure (Current) Not Fail: Sliding roof open signal not fail (Current) - PAST DOWN SW Down switch failure signal (Past)/ Fail or Not Fail Fail: Sliding roof tilt down signal failure (Past) Not Fail: Sliding roof tilt down signal not fail (Past) - PAST UP SW Up switch failure signal (Past)/ Fail or Not Fail Fail: Sliding roof tilt up signal failure (Past) Not Fail: Sliding roof tilt up signal not fail (Past) - PAST CLS SW Close switch failure signal (Past)/ Fail or Not Fail Fail: Sliding roof close signal failure (Past) Not Fail: Sliding roof close signal not fail (Past) - PAST OPN SW Open switch failure signal (Past)/ Fail or Not Fail Fail: Sliding roof open signal failure (Past) Not Fail: Sliding roof open signal not fail (Past) - #CODE Number of trouble code Number of trouble code - RF 2. PERFORM ACTIVE TEST HINT: Performing the intelligent tester's Active Test allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the Active Test early in troubleshooting is one way to save time. The Data List can be displayed during the Active Test. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Perform the Active Test according to the display on the tester. SLIDE ROOF: Item Test Details Diagnostic Note SLIDE ROOF Operate sliding roof SLIDE CLOSE/TILT UP CLOS/UP: Sliding roof SLIDE CLOSE or TILT UP operation occurs. OFF: Sliding roof is not operating - SLIDE ROOF Operate sliding roof SLIDE OPEN/TILT DOWN OPEN/DWN: Sliding roof SLIDE OPEN or TILT DOWN operation occurs OFF: Sliding roof is not operating - SLIDING ROOF – SLIDING ROOF SYSTEM RF–15 DIAGNOSTIC TROUBLE CODE CHART If any trouble code is displayed during DTC check, check the circuit corresponding to the code in the table below. Proceed to the page given for the circuit. Sliding Roof System DTC No. Detection Item Trouble Area See page B2341 Sensor (Motor) Failure 1. Sliding roof drive gear sub-assembly (Sliding roof control ECU) 2. Roof console box assembly (Sliding roof control switch) 3. Wire harness RF-14 B2342 Switch Failure 1. Sliding roof drive gear sub-assembly (Sliding roof control ECU) 2. Roof console box assembly (Sliding roof control switch) 3. Wire harness RF-18 B2343 Position Initialization Incomplete 1. Sliding roof drive gear sub-assembly (Sliding roof control ECU) 2. Roof console box assembly (Sliding roof control switch) 3. Wire harness RF-22 B2344 Position Failure 1. Sliding roof drive gear sub-assembly (Sliding roof control ECU) 2. Roof console box assembly (Sliding roof control switch) 3. Wire harness RF-14 RF RF–16 SLIDING ROOF – SLIDING ROOF SYSTEM ON-VEHICLE INSPECTION 1. CHECK AUTO OPERATION (a) Turn the ignition switch on (IG). (b) When the roof glass is fully closed, press the OPEN switch for 0.3 seconds or more. Check that the roof glass automatically slides until it is fully opened. (c) When the roof glass is fully open, press the CLOSE switch for 0.3 seconds or more. Check that the roof glass automatically slides until it is fully closed. (d) When the roof glass is fully closed, press the UP switch for 0.3 seconds or more. Check that the roof glass automatically tilts until it is fully tilted upward. (e) When the roof glass is fully open, press the DOWN switch for 0.3 seconds or more. Check that the roof glass automatically tilts until it is fully tilted downward. (f) When the auto operation is operating, check that pressing any personal light switch stops the roof glass operation. HINT: When pressing the switch for 0.3 seconds or less, the roof glass moves but auto operation does not operate. 2. CHECK SLIDING ROOF OPERATION AFTER IGNITION SWITCH IS TURNED OFF (a) Turn the ignition switch from on (IG) to off, and check that the sliding roof operates. Then open and close the driver's side door once, and check that the sliding roof does not operate. (b) Turn the ignition switch from on (IG) to off and wait for approximately 43 seconds. Check that the sliding roof does not operate. (c) Operate the auto (SLIDE OPEN/CLOSE or TILT UP/ DOWN) operation. While the roof glass is in motion, turn the ignition switch from on (IG) to off. Check that the auto operation continues until the roof glass opens or closes fully. 3. CHECK JAM PROTECTION FUNCTION CAUTION: • Do not use a part of your body, for example, your hand, to check the jam protection. • Do not allow anything to become caught in the sliding roof by accident in this procedure. • Perform the inspection from the inside of the vehicle. NOTICE: • Do not use hard objects such as a hammer, to avoid damage to the roof. • If the jam protection does not operate, reset the sliding roof drive gear (motor). RF SLIDING ROOF – SLIDING ROOF SYSTEM RF–17 (a) When the sliding roof auto operation is operating and an object is caught between the vehicle body and glass, check that the roof glass opens 218 mm (8.58 in.) from the point of contact with the object, or opens fully if there is not an opening distance of 218 mm (8.58 in.). B068295 (b) When the TILT UP/DOWN function is operating, and an object is caught between the vehicle body and the roof glass, check that the sliding roof tilts up fully. RF B068296 RF–18 SLIDING ROOF – SLIDING ROOF SYSTEM DTC B2341 Sensor (Motor) Failure DTC B2344 Position Failure DESCRIPTION When the sliding roof drive gear sub-assembly (sliding roof control ECU) detects malfunctions in the motor, and the sliding roof operation is stopped, DTC B2341 is output. When the sliding roof drive gear sub-assembly (sliding roof control ECU) detects malfunctions in the gear, and the sliding roof operation is stopped, DTC B2344 is output. DTC No. DTC Detection Condition Trouble Area • B2341 Sensor (motor) Failure • • • RF B2344 Position Failure • • Sliding roof drive gear sub-assembly (sliding roof control ECU) Roof console box assembly (sliding roof control switch) Wire harness Sliding roof drive gear sub-assembly (sliding roof control ECU) Roof console box assembly (sliding roof control switch) Wire harness WIRING DIAGRAM Sliding Roof Control ECU and Motor Q6 Overhead J/B UP DOWN CLS OPN GND 5 4 1 2 3 10 Q13 9 R1 (*1) (*2) 8 Q13 7 R1 (*1) (*2) 9 Q13 8 R1 (*1) (*2) 7 Q13 10 R1 (*1) (*2) (*1) (*2) 2 Q13 *1: TMC Made 2 R1 UP DWN CLS OPN E M *2: TMMK Made B146416E01 SLIDING ROOF – SLIDING ROOF SYSTEM RF–19 INSPECTION PROCEDURE 1 CHECK SLIDING ROOF FUNCTION (a) Check the auto operation with the OPEN, DOWN, CLOSE and UP switches (See page RF-11). OK: Auto operation operates normally with OPEN, DOWN, CLOSE and UP switches. NG Go to step 3 OK 2 DELETE DTC (a) Delete the DTCs (See page RF-8). RF NEXT END 3 INITIALIZE SLIDING ROOF DRIVE GEAR SUB-ASSEMBLY (SLIDING ROOF CONTROL ECU) (a) Check that the sliding roof drive gear sub-assembly can be initialized (See page RF-4). OK: Sliding roof drive gear sub-assembly can be initialized. NG Go to step 6 OK 4 CHECK SLIDING ROOF FUNCTION (a) Check the auto operation with the OPEN, DOWN, CLOSE and UP switches (See page RF-11). OK: Auto operation operates normally with OPEN, DOWN, CLOSE and UP switches. NG REPLACE SLIDING ROOF DRIVE GEAR SUB-ASSEMBLY (SLIDING ROOF CONTROL ECU) OK 5 DELETE DTC (a) Delete the DTCs (See page RF-8). RF–20 SLIDING ROOF – SLIDING ROOF SYSTEM NEXT END 6 CHECK WIRE HARNESS (SLIDING ROOF CONTROL ECU - ROOF CONSOLE BOX ASSEMBLY) Sliding Roof Control ECU Connector: (*1) (*2) Q13 R1 (a) Disconnect the Q13 (*1) or R1 (*2) and Q6 connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition (*1) Always Below 1 Ω Q13-7 (OPN) - Q6-2 (OPN) Always Below 1 Ω Always Below 1 Ω Always Below 1 Ω Always Below 1 Ω (*2) Always Below 1 Ω R1-7 (DWN) - Q6-4 (DOWN) Always Below 1 Ω Always Below 1 Ω (*2) Always Below 1 Ω R1-10 (OPN) - Q6-2 (OPN) Always Below 1 Ω Q6-1 (CLS) - Body ground Always 10 kΩ or higher Q6-2 (OPN) - Body ground Always 10 kΩ or higher Q6-3 (GND) - Body ground Always Below 1 Ω Q6-4 (DOWN) - Body ground Always 10 kΩ or higher Q6-5 (UP) - Body ground Always 10 kΩ or higher Q13-2 (E) - Q6-3 (GND) RF (*1) (*1) - E (*2) - E OPN DWN CLS DWN CLS UP UP OPN Q13-8 (DWN) - Q6-4 (DOWN) (*1) Roof Console Box Assembly Connector: Q13-9 (CLS) - Q6-1 (CLS) (*1) Q6 Q13-10 (UP) - Q6-5 (UP) (*1) R1-2 (E) - Q6-3 (GND) CLS OPN GND DOWN UP B131169E02 (*2) R1-8 (CLS) - Q6-1 (CLS) (*2) R1-9 (UP) - Q6-5 (UP) (*2) HINT: • *1: TMC made • *2: TMMK made NG REPAIR OR REPLACE HARNESS OR CONNECTOR RF–21 SLIDING ROOF – SLIDING ROOF SYSTEM OK 7 INSPECT ROOF CONSOLE BOX ASSEMBLY (SLIDING ROOF CONTROL SWITCH) (a) Remove the roof console box assembly. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Roof Console Box Assembly Connector: Sliding Roof Control Switch Tester Connection Switch Position Specified Condition Q6-1 (CLS) - Q6-3 (GND) CLOSE Below 100 Ω Q6-2 (OPN) - Q6-3 (GND) OPEN Below 100 Ω Q6-4 (DOWN) - Q6-3 (GND) DOWN Below 100 Ω Q6-5 (UP) - Q6-3 (GND) UP Below 100 Ω Q6-1 (CLS) - Q6-3 (GND) OPEN 1 kΩ or higher Q6-2 (OPN) - Q6-3 (GND) CLOSE 1 kΩ or higher Q6-4 (DOWN) - Q6-3 (GND) UP 1 kΩ or higher Q6-5 (UP) - Q6-3 (GND) DOWN 1 kΩ or higher NG Q6 REPLACE ROOF CONSOLE BOX ASSEMBLY (SLIDING ROOF CONTROL SWITCH) B131165E02 OK REPLACE SLIDING ROOF DRIVE GEAR SUB-ASSEMBLY (SLIDING ROOF CONTROL ECU) RF RF–22 SLIDING ROOF – SLIDING ROOF SYSTEM DTC B2342 Switch Failure DESCRIPTION This DTC is output when the sliding roof drive gear sub-assembly (sliding roof control ECU) detects that the OPEN, CLOSE, UP or DOWN switch in the roof console box assembly (sliding roof control switch) is stuck for 30 seconds or more. DTC No. DTC Detection Condition Trouble Area Sliding roof drive gear sub-assembly (sliding roof control ECU) detects OPEN, CLOSE, UP or DOWN switch in overhead junction block is stuck for 30 seconds or more B2342 • • • Sliding roof drive gear sub-assembly (sliding roof control ECU) Roof console box assembly (sliding roof control switch) Wire harness WIRING DIAGRAM Refer to DTC B2341 (See page RF-14). RF INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (SLIDE OPEN AND TILT UP SWITCH) (a) Use the DATA LIST to check if the sliding roof switch is functioning properly. Sliding roof ECU Item Measurement Item/Range (Display) Normal Condition Diagnostic Note OPEN SW Slide switch open signal/ON or OFF ON: OPEN switch is pressed. OFF: OPEN switch is not pressed. - CLOSE SW Slide switch close signal/ON or OFF ON: CLOSE switch is pressed. OFF: CLOSE switch is not pressed. - UP SW Tilt switch up signal/ON or OFF ON: UP switch is pressed. OFF: UP switch is not pressed. - DOWN SW Tilt switch down signal/ON or OFF ON: DOWN switch is pressed. OFF: DOWN switch is not pressed. - OK: The intelligent tester displays as shown in the table according to the operation of each switch. NG Go to step 4 OK 2 CHECK SLIDING ROOF FUNCTION (a) Check the auto operation with the OPEN, CLOSE, UP and DOWN switches (See page RF-11). OK: Auto operation operates normally with OPEN, CLOSE, UP and DOWN switches. NG Go to step 7 RF–23 SLIDING ROOF – SLIDING ROOF SYSTEM OK 3 DELETE DTC (a) Delete the DTCs (See page RF-8). NEXT END 4 INSPECT ROOF CONSOLE BOX ASSEMBLY (SLIDING ROOF CONTROL SWITCH) (a) Remove the roof console box assembly. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Roof Console Box Assembly Connector: Sliding Roof Control Switch Tester Connection Switch Position Specified Condition Q6-1 (CLS) - Q6-3 (GND) CLOSE Below 100 Ω Q6-2 (OPN) - Q6-3 (GND) OPEN Below 100 Ω Q6-4 (DOWN) - Q6-3 (GND) DOWN Below 100 Ω Q6-5 (UP) - Q6-3 (GND) UP Below 100 Ω Q6-1 (CLS) - Q6-3 (GND) OPEN 1 kΩ or higher Q6-2 (OPN) - Q6-3 (GND) CLOSE 1 kΩ or higher Q6-4 (DOWN) - Q6-3 (GND) UP 1 kΩ or higher Q6-5 (UP) - Q6-3 (GND) DOWN 1 kΩ or higher OK Q6 Go to step 10 B131165E02 NG 5 REPLACE ROOF CONSOLE BOX ASSEMBLY (SLIDING ROOF CONTROL SWITCH) (a) Temporarily replace the roof console box assembly (sliding roof control switch) with a new one or normally functioning one (See page LI-105). NEXT RF RF–24 6 SLIDING ROOF – SLIDING ROOF SYSTEM DELETE DTC (a) Delete the DTCs (See page RF-8). NEXT END 7 INITIALIZE SLIDING ROOF DRIVE GEAR SUB-ASSEMBLY (SLIDING ROOF CONTROL ECU) (a) Check that the sliding roof drive gear sub-assembly can be initialized (See page RF-4). OK: Sliding roof drive gear sub-assembly can be initialized. RF NG Go to step 10 OK 8 CHECK SLIDING ROOF FUNCTION (a) Check the auto operation with the OPEN, CLOSE, UP and DOWN switches (See page RF-11). OK: Auto operation operates normally with OPEN, CLOSE, UP and DOWN switches. NG REPLACE SLIDING ROOF DRIVE GEAR SUB-ASSEMBLY (SLIDING ROOF CONTROL ECU) OK 9 DELETE DTC (a) Delete the DTCs (See page RF-8). NEXT END RF–25 SLIDING ROOF – SLIDING ROOF SYSTEM 10 CHECK WIRE HARNESS (SLIDING ROOF CONTROL ECU - ROOF CONSOLE BOX ASSEMBLY) Sliding Roof Control ECU Connector: (*1) (*2) Q13 R1 (a) Disconnect the Q13 (*1) or R1 (*2) and Q6 connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition (*1) Always Below 1 Ω Q13-7 (OPN) - Q6-2 (OPN) Always Below 1 Ω Always Below 1 Ω Always Below 1 Ω Always Below 1 Ω (*2) Always Below 1 Ω R1-7 (DWN) - Q6-4 (DOWN) Always Below 1 Ω Always Below 1 Ω (*2) Always Below 1 Ω R1-10 (OPN) - Q6-2 (OPN) Always Below 1 Ω Q6-1 (CLS) - Body ground Always 10 kΩ or higher Q6-2 (OPN) - Body ground Always 10 kΩ or higher Q6-3 (GND) - Body ground Always Below 1 Ω Q6-4 (DOWN) - Body ground Always 10 kΩ or higher Q6-5 (UP) - Body ground Always 10 kΩ or higher Q13-2 (E) - Q6-3 (GND) (*1) (*1) - E (*2) - E OPN DWN CLS DWN CLS UP UP OPN Q13-8 (DWN) - Q6-4 (DOWN) (*1) Roof Console Box Assembly Connector: Q13-9 (CLS) - Q6-1 (CLS) (*1) Q6 Q13-10 (UP) - Q6-5 (UP) (*1) R1-2 (E) - Q6-3 (GND) CLS OPN GND DOWN UP B131169E02 (*2) R1-8 (CLS) - Q6-1 (CLS) (*2) R1-9 (UP) - Q6-5 (UP) (*2) HINT: • *1: TMC made • *2: TMMK made NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE SLIDING ROOF DRIVE GEAR SUB-ASSEMBLY (SLIDING ROOF CONTROL ECU) RF RF–26 SLIDING ROOF – SLIDING ROOF SYSTEM DTC B2343 Position Initialization Incomplete DESCRIPTION This DTC is output when the sliding roof drive gear sub-assembly (sliding roof control ECU) has not been initialized. DTC No. DTC Detection Condition Trouble Area • B2343 Sliding roof drive gear sub-assembly (sliding roof control ECU) has not been initialized • • Sliding roof drive gear sub-assembly (sliding roof control ECU) Roof console box assembly (sliding roof control switch) Wire harness WIRING DIAGRAM Refer to DTC B2341 (See page RF-14). INSPECTION PROCEDURE RF 1 INITIALIZE SLIDING ROOF DRIVE GEAR SUB-ASSEMBLY (SLIDING ROOF CONTROL ECU) (a) Check that the sliding roof drive gear sub-assembly can be initialized (See page RF-4). OK: Sliding roof drive gear sub-assembly can be initialized. NG Go to step 3 OK 2 CHECK SLIDING ROOF FUNCTION (a) Check the auto operation with the OPEN, CLOSE, UP and DOWN switches (See page RF-11). OK: Auto operation operates normally with OPEN, CLOSE, UP and DOWN switches. NG OK END REPLACE SLIDING ROOF DRIVE GEAR SUB-ASSEMBLY (SLIDING ROOF CONTROL ECU) RF–27 SLIDING ROOF – SLIDING ROOF SYSTEM 3 CHECK WIRE HARNESS (SLIDING ROOF DRIVE GEAR - OVERHEAD JUNCTION BLOCK) Sliding Roof Control ECU Connector: (*1) (*2) Q13 R1 (a) Disconnect the Q13 (*1) or R1 (*2) and Q6 connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition (*1) Always Below 1 Ω Q13-7 (OPN) - Q6-2 (OPN) Always Below 1 Ω Always Below 1 Ω Always Below 1 Ω Always Below 1 Ω (*2) Always Below 1 Ω R1-7 (DWN) - Q6-4 (DOWN) Always Below 1 Ω Always Below 1 Ω (*2) Always Below 1 Ω R1-10 (OPN) - Q6-2 (OPN) Always Below 1 Ω Q6-1 (CLS) - Body ground Always 10 kΩ or higher Q6-2 (OPN) - Body ground Always 10 kΩ or higher Q6-3 (GND) - Body ground Always Below 1 Ω Q6-4 (DOWN) - Body ground Always 10 kΩ or higher Q6-5 (UP) - Body ground Always 10 kΩ or higher Q13-2 (E) - Q6-3 (GND) (*1) (*1) - E (*2) - E OPN DWN CLS DWN CLS UP UP OPN Q13-8 (DWN) - Q6-4 (DOWN) (*1) Roof Console Box Assembly Connector: Q13-9 (CLS) - Q6-1 (CLS) (*1) Q6 Q13-10 (UP) - Q6-5 (UP) (*1) R1-2 (E) - Q6-3 (GND) CLS OPN GND DOWN UP B131169E02 (*2) R1-8 (CLS) - Q6-1 (CLS) (*2) R1-9 (UP) - Q6-5 (UP) (*2) HINT: • *1: TMC made • *2: TMMK made NG OK REPAIR OR REPLACE HARNESS OR CONNECTOR RF RF–28 4 SLIDING ROOF – SLIDING ROOF SYSTEM INSPECT ROOF CONSOLE BOX ASSEMBLY (SLIDING ROOF CONTROL SWITCH) (a) Remove the roof console box assembly. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Roof Console Box Assembly Connector: RF Sliding Roof Control Switch Tester Connection Switch Position Specified Condition Q6-1 (CLS) - Q6-3 (GND) CLOSE Below 100 Ω Q6-2 (OPN) - Q6-3 (GND) OPEN Below 100 Ω Q6-4 (DOWN) - Q6-3 (GND) DOWN Below 100 Ω Q6-5 (UP) - Q6-3 (GND) UP Below 100 Ω Q6-1 (CLS) - Q6-3 (GND) OPEN 1 kΩ or higher Q6-2 (OPN) - Q6-3 (GND) CLOSE 1 kΩ or higher Q6-4 (DOWN) - Q6-3 (GND) UP 1 kΩ or higher Q6-5 (UP) - Q6-3 (GND) DOWN 1 kΩ or higher NG Q6 REPLACE ROOF CONSOLE BOX ASSEMBLY (SLIDING ROOF CONTROL SWITCH) B131165E02 OK REPLACE SLIDING ROOF DRIVE GEAR SUB-ASSEMBLY (SLIDING ROOF CONTROL ECU) RF–29 SLIDING ROOF – SLIDING ROOF SYSTEM Sliding Roof Control Switch Circuit DESCRIPTION The sliding roof drive gear sub-assembly (sliding roof control ECU) receives slide switch and tilt switch signals and drives its built-in motor. WIRING DIAGRAM Refer to DTC B2341 (See page RF-14). INSPECTION PROCEDURE 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SLIDING ROOF OPERATION) (a) Select the ACTIVE TEST, use the intelligent tester to generate a control command, and then check that the sliding roof slides open/close and tilts up/down. RF Sliding roof ECU Item Test Details Diagnostic Note SLIDING ROOF Operate sliding roof SLIDE CLOSE/TILT UP CLOS/UP: Sliding roof SLIDE CLOSE or TILT UP operation occurs OFF: Sliding roof is not operating - SLIDING ROOF Operate sliding roof SLIDE OPEN/TILT DOWN OPEN/DOWN: Sliding roof SLIDE OPEN or TILT DOWN operation occurs OFF: Sliding roof is not operating - OK: Sliding roof operates normally. NG REPLACE SLIDING ROOF DRIVE GEAR SUB-ASSEMBLY (SLIDING ROOF CONTROL ECU) OK 2 READ VALUE OF INTELLIGENT TESTER (SLIDING ROOF SWITCH) (a) Use the DATA LIST to check if the sliding roof switch is functioning properly. Sliding roof ECU Item Measurement Item/Range (Display) Normal Condition Diagnostic Note OPEN SW Slide switch open signal/ON or OFF ON: OPEN switch is pressed. OFF: OPEN switch is not pressed. - CLOSE SW Slide switch close signal/ON or OFF ON: CLOSE switch is pressed. OFF: CLOSE switch is not pressed. - UP SW Tilt switch up signal/ON or OFF ON: UP switch is pressed. OFF: UP switch is not pressed. - DOWN SW Tilt switch down signal/ON or OFF ON: DOWN switch is pressed. OFF: DOWN switch is not pressed. - OK: RF–30 SLIDING ROOF – SLIDING ROOF SYSTEM The intelligent tester displays as shown in the table according to the operation of each switch. OK REPLACE SLIDING ROOF DRIVE GEAR SUB-ASSEMBLY (SLIDING ROOF CONTROL ECU) NG 3 CHECK WIRE HARNESS (SLIDING ROOF CONTROL ECU - ROOF CONSOLE BOX ASSEMBLY) Sliding Roof Control ECU Connector: (*1) (*2) Q13 R1 (a) Disconnect the Q13 (*1) or R1 (*2) and Q6 connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition (*1) Always Below 1 Ω Q13-7 (OPN) - Q6-2 (OPN) Always Below 1 Ω Always Below 1 Ω Always Below 1 Ω Always Below 1 Ω (*2) Always Below 1 Ω R1-7 (DWN) - Q6-4 (DOWN) Always Below 1 Ω Always Below 1 Ω (*2) Always Below 1 Ω R1-10 (OPN) - Q6-2 (OPN) Always Below 1 Ω Q6-1 (CLS) - Body ground Always 10 kΩ or higher Q6-2 (OPN) - Body ground Always 10 kΩ or higher Q6-3 (GND) - Body ground Always Below 1 Ω Q6-4 (DOWN) - Body ground Always 10 kΩ or higher Q6-5 (UP) - Body ground Always 10 kΩ or higher Q13-2 (E) - Q6-3 (GND) RF (*1) (*1) - E (*2) - E OPN DWN CLS DWN CLS UP UP OPN Q13-8 (DWN) - Q6-4 (DOWN) Roof Console Box Assembly Connector: (*1) Q13-9 (CLS) - Q6-1 (CLS) (*1) Q6 Q13-10 (UP) - Q6-5 (UP) (*1) R1-2 (E) - Q6-3 (GND) CLS OPN GND DOWN UP B131169E02 (*2) R1-8 (CLS) - Q6-1 (CLS) (*2) R1-9 (UP) - Q6-5 (UP) (*2) HINT: • *1: TMC made • *2: TMMK made SLIDING ROOF – SLIDING ROOF SYSTEM NG RF–31 REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ROOF CONSOLE BOX ASSEMBLY (SLIDING ROOF CONTROL SWITCH) RF RF–32 SLIDING ROOF – SLIDING ROOF SYSTEM Sliding Roof ECU Power Source Circuit DESCRIPTION The sliding roof drive gear sub-assembly (sliding roof control ECU) receives signals from the sliding roof switch and activates the sliding roof. However, malfunctions in the fuse, wire harness or sliding roof drive gear sub-assembly (sliding roof control ECU) may cause the sliding roof system to stop operating. WIRING DIAGRAM Sliding Roof Control ECU and Motor E8 Main Body ECU RF LIN2 10 4 Q13 4 R1 (*1) (*2) 10 Q13 9 R1 (*1) (*2) MPX1 Q6 Overhead J/B UP DOWN CLS OPN GND 5 4 1 2 8 Q13 7 R1 (*1) (*2) 9 Q13 8 R1 (*1) (*2) 7 Q13 10 R1 (*1) (*2) (*1) (*2) 2 Q13 3 ECU IG No. 1 From Ignition Switch S / ROOF From Battery *1: TMC Made 2 R1 5 Q13 5 R1 (*1) (*2) (*1) (*2) 1 Q13 UP DWN CLS OPN E IG 1 R1 B M *2: TMMK Made B146417E01 RF–33 SLIDING ROOF – SLIDING ROOF SYSTEM INSPECTION PROCEDURE 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SLIDING ROOF OPERATION) (a) Select the ACTIVE TEST, use the intelligent tester to generate a control command, and then check that the sliding roof slides open/close and tilts up/down. Sliding roof ECU Item Test Details Diagnostic Note SLIDING ROOF Operate sliding roof SLIDE CLOSE/TILT UP CLOS/UP: Sliding roof SLIDE CLOSE or TILT UP operation occurs OFF: Sliding roof is not operating - SLIDING ROOF Operate sliding roof SLIDE OPEN/TILT DOWN OPEN/DOWN: Sliding roof SLIDE OPEN or TILT DOWN operation occurs OFF: Sliding roof is not operating - OK: Sliding roof operates normally. NG Go to step 2 OK REPLACE SLIDING ROOF DRIVE GEAR SUB-ASSEMBLY (SLIDING ROOF CONTROL ECU) 2 INSPECT FUSE (S/ROOF, ECU-IG NO. 1) (a) Remove the S/ROOF and ECU-IG No. 1 fuses from the instrument panel J/B. (b) Measure the resistance of the fuses. Standard resistance: Below 1 Ω NG OK REPLACE FUSE RF RF–34 3 SLIDING ROOF – SLIDING ROOF SYSTEM CHECK WIRE HARNESS (SLIDING ROOF CONTROL ECU - BATTERY AND BODY GROUND) Sliding Roof Control ECU Connector: (*1) (*2) Q13 R1 (a) Disconnect the Q13 (*1) or R1 (*2) connectors. (b) Measure the voltage and resistance according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition B (Q13-1) - Body ground Always 10 to 14 V Ignition switch on (IG) 10 to 14 V Ignition switch off Below 1 V Always 10 to 14 V Ignition switch on (IG) 10 to 14 V Ignition switch off Below 1 V (*1) IG (Q13-5) - Body ground 3 4 1 2 5 6 7 8 (*1) 9 10 IG (Q13-5) - Body ground (*1) IG RF B E B (R1-1) - Body ground B130117E05 (*2) IG (R1-5) - Body ground (*2) IG (R1-5) - Body ground (*2) HINT: • *1: TMC made • *2: TMMK made Standard resistance Tester Connection Specified Condition E (Q13-2) - Body ground Below 1 Ω (*1) E (R1-2) - Body ground (*2) Below 1 Ω HINT: • *1: TMC made • *2: TMMK made NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE SLIDING ROOF DRIVE GEAR SUB-ASSEMBLY (SLIDING ROOF CONTROL ECU) RF–31 SLIDING ROOF – SLIDING ROOF HOUSING SLIDING ROOF HOUSING SLIDING ROOF BODY COMPONENTS for Manual Seat: FRONT SEAT HEADREST ASSEMBLY SEAT TRACK COVER RH RF 37 (377, 27) INNER SEAT TRACK BRACKET COVER RH 37 (377, 27) FRONT SEAT ASSEMBLY RH FRONT SEAT HEADREST ASSEMBLY INNER SEAT TRACK BRACKET COVER LH SEAT TRACK COVER LH 37 (377, 27) 37 (377, 27) FRONT SEAT ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque B132048E01 RF–32 SLIDING ROOF – SLIDING ROOF HOUSING for Power Seat: FRONT SEAT HEADREST ASSEMBLY SEAT TRACK COVER RH INNER SEAT TRACK BRACKET COVER LH 37 (377, 27) RF 37 (377, 27) FRONT SEAT ASSEMBLY RH FRONT SEAT HEADREST ASSEMBLY INNER SEAT TRACK BRACKET COVER RH 37 (377, 27) SEAT TRACK COVER LH 37 (377, 27) FRONT SEAT ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque B132047E01 RF–33 SLIDING ROOF – SLIDING ROOF HOUSING for Fixed Seat Type: REAR SEAT HEADREST ASSEMBLY REAR CENTER SEAT HEADREST ASSEMBLY RF REAR SEAT BACK ASSEMBLY 18 (184, 13) 18 (184, 13) REAR SEAT CUSHION ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B136589E02 RF–34 SLIDING ROOF – SLIDING ROOF HOUSING for Fold Down Seat Type: REAR SEAT HEADREST ASSEMBLY REAR CENTER SEAT HEADREST ASSEMBLY 18 (184, 13) RF 18 (184, 13) 18 (184, 13) REAR SIDE SEAT BACK ASSEMBLY RH SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH 18 (184, 13) REAR SEAT CUSHION ASSEMBLY REAR SIDE SEAT BACK ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque B136564E02 SLIDING ROOF – SLIDING ROOF HOUSING RF–35 for Reclining Seat Type: REAR SEAT HEADREST ASSEMBLY REAR CENTER SEAT HEADREST ASSEMBLY 18 (184, 13) SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH REAR SEAT BACK COVER CENTER SEAT BACK ASSEMBLY 18 (184, 13) RF 18 (184, 13) 18 (184, 13) REAR SEAT BACK COVER RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY RH 18 (184, 13) SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH 18 (184, 13) REAR SEAT CUSHION ASSEMBLY RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque B139577E01 RF–36 SLIDING ROOF – SLIDING ROOF HOUSING NO. 1 DOOR SCUFF PLATE CLAMP RF REAR DOOR INNER GLASS WEATHERSTRIP LH REAR DOOR INSIDE HANDLE BEZEL PLUG LH DOOR ASSIST GRIP COVER LH REAR DOOR TRIM BOARD SUB-ASSEMBLY LH B139576E01 RF–37 SLIDING ROOF – SLIDING ROOF HOUSING FRONT DOOR OPENING TRIM WEATHERSTRIP RH FRONT PILLAR GARNISH RH FRONT PILLAR GARNISH CLIP UPPER CENTER PILLAR GARNISH RH RF ROOF SIDE INNER GARNISH RH REAR DOOR OPENING TRIM WEATHERSTRIP RH REAR DOOR SCUFF PLATE RH FRONT SEAT OUTER BELT ASSEMBLY RH COWL SIDE TRIM CLIP FRONT DOOR SCUFF PLATE RH 42 (428, 31) LAP BELT OUTER ANCHOR COVER LOWER CENTER PILLAR GARNISH RH COWL SIDE TRIM SUB-ASSEMBLY RH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part B132050E01 RF–38 SLIDING ROOF – SLIDING ROOF HOUSING UPPER CENTER PILLAR GARNISH LH FRONT PILLAR GARNISH LH FRONT PILLAR GARNISH CLIP REAR DOOR OPENING TRIM WEATHERSTRIP LH FRONT DOOR OPENING TRIM WEATHERSTRIP LH RF ROOF SIDE INNER GARNISH LH 42 (428, 31) LAP BELT OUTER ANCHOR COVER REAR DOOR SCUFF PLATE LH LOWER CENTER PILLAR GARNISH LH COWL SIDE TRIM CLIP FRONT SEAT OUTER BELT ASSEMBLY LH FRONT DOOR SCUFF PLATE LH COWL SIDE TRIM SUB-ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part B132049E01 SLIDING ROOF – SLIDING ROOF HOUSING FRONT ASSIST GRIP SUB-ASSEMBLY RF–39 REAR ASSIST GRIP SUB-ASSEMBLY ASSIST GRIP COVER ASSIST GRIP COVER ROOF HEADLINING ASSEMBLY RF with Rear Sunshade: SUNSHADE TRIM HOLDER SPOT LIGHT ASSEMBLY VISOR BRACKET COVER REAR ASSIST GRIP SUB-ASSEMBLY VISOR ASSEMBLY RH ASSIST GRIP COVER ROOF CONSOLE BOX ASSEMBLY FRONT ASSIST GRIP SUB-ASSEMBLY ASSIST GRIP COVER VISOR HOLDER VISOR ASSEMBLY LH VISOR HOLDER VISOR BRACKET COVER SUN ROOF OPENING TRIM MOULDING B132052E02 RF–40 SLIDING ROOF – SLIDING ROOF HOUSING SPACER CURTAIN SHIELD AIRBAG ASSEMBLY RH 11 (112, 8) CLIP 11 (112, 8) 11 (112, 8) SPACER CLIP 11 (112, 8) RF CLIP 11 (112, 8) SPACER CURTAIN SHIELD AIRBAG ASSEMBLY LH CLIP N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part B132107E01 RF–41 SLIDING ROOF – SLIDING ROOF HOUSING SLIDING ROOF SIDE GARNISH RH SLIDING ROOF GLASS SUB-ASSEMBLY RF 4.0 (41, 35 in.*lbf) SLIDING ROOF WEATHERSTRIP 4.0 (41, 35 in.*lbf) SLIDING ROOF SIDE GARNISH LH SLIDING ROOF GLASS SUB-ASSEMBLY SLIDING ROOF DRAIN HOSE SLIDING ROOF HOUSING SUB-ASSEMBLY 5.5 (56, 49 in.*lbf) SLIDING ROOF DRAIN HOSE SLIDING ROOF DRAIN HOSE 5.5 (56, 49 in.*lbf) FRONT SIDE RAIL SPACER RH 5.5 (56, 49 in.*lbf) 5.5 (56, 49 in.*lbf) FRONT SIDE RAIL SPACER LH 5.5 (56, 49 in.*lbf) SLIDING ROOF DRAIN HOSE N*m (kgf*cm, ft.*lbf) : Specified torque B132105E01 RF–42 SLIDING ROOF – SLIDING ROOF HOUSING SLIDING ROOF DRIP CHANNEL SLIDING ROOF DRIVE CABLE SUB-ASSEMBLY 2.0 (20, 18 in.*lbf) RF SLIDING ROOF SIDE STOPPER SLIDING ROOF PIECE SUB-ASSEMBLY RH 2.0 (20, 18 in.*lbf) SLIDING ROOF SIDE STOPPER SLIDING ROOF DRIVE GEAR SUB-ASSEMBLY SLIDING ROOF PIECE SUB-ASSEMBLY LH 5.4 (55, 48 in.*lbf) SLIDING ROOF DRIVE GEAR BRACKET SUNSHADE TRIM SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B132106E01 SLIDING ROOF – SLIDING ROOF HOUSING RF–43 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (for Manual Seat) CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment (See page RS-1). 2. REMOVE FRONT SEAT HEADREST ASSEMBLY (for Manual Seat) 3. REMOVE SEAT TRACK COVER LH (for Manual Seat) (See page SE-16) 4. REMOVE INNER SEAT TRACK BRACKET COVER LH (for Manual Seat) (See page SE-16) 5. REMOVE FRONT SEAT ASSEMBLY LH (for Manual Seat) (See page SE-16) 6. REMOVE FRONT SEAT HEADREST ASSEMBLY (for Power Seat) 7. REMOVE SEAT TRACK COVER LH (for Power Seat) (See page SE-30) 8. REMOVE INNER SEAT TRACK BRACKET COVER RH (for Power Seat) (See page SE-30) 9. REMOVE FRONT SEAT ASSEMBLY LH (for Power Seat) (See page SE-30) 10. REMOVE FRONT SEAT HEADREST ASSEMBLY (for Manual Seat) 11. REMOVE SEAT TRACK COVER RH (for Manual Seat) HINT: Use the same procedures for the RH side and the LH side. 12. REMOVE INNER SEAT TRACK BRACKET COVER RH (for Manual Seat) HINT: Use the same procedures for the RH side and the LH side. 13. REMOVE FRONT SEAT ASSEMBLY RH (for Manual Seat) HINT: Use the same procedures for the RH side and the LH side. 14. REMOVE FRONT SEAT HEADREST ASSEMBLY (for Power Seat) 15. REMOVE SEAT TRACK COVER RH (for Power Seat) HINT: Use the same procedures for the RH side and the LH side. RF RF–44 SLIDING ROOF – SLIDING ROOF HOUSING 16. REMOVE INNER SEAT TRACK BRACKET COVER LH (for Power Seat) HINT: Use the same procedures for the RH side and the LH side. 17. REMOVE FRONT SEAT ASSEMBLY RH (for Power Seat) HINT: Use the same procedures for the RH side and the LH side. 18. REMOVE REAR SEAT CUSHION ASSEMBLY (See page SE-77) 19. REMOVE REAR SEAT HEADREST ASSEMBLY 20. REMOVE REAR CENTER SEAT HEADREST ASSEMBLY RF 21. REMOVE REAR SEAT BACK ASSEMBLY (for Fixed Seat Type) (See page SE-77) 22. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-47) 23. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) (See page SE-47) 24. REMOVE REAR SIDE SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-48) 25. REMOVE REAR SIDE SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) (See page SE-48) 26. REMOVE REAR SEAT BACK COVER (for Reclining Seat Type) (See page SE-63) 27. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Reclining Seat Type) (See page SE-63) 28. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Reclining Seat Type) (See page SE-64) 29. REMOVE CENTER SEAT BACK ASSEMBLY (for Reclining Seat Type) (See page SE-64) 30. REMOVE REAR DOOR SCUFF PLATE LH (See page IR-24) 31. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH 32. REMOVE REAR DOOR SCUFF PLATE RH (See page IR-24) 33. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH SLIDING ROOF – SLIDING ROOF HOUSING RF–45 34. REMOVE RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY LH (for Reclining Seat Type) (See page SE-68) 35. REMOVE RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY RH (for Reclining Seat Type) 36. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG LH (See page ED-38) 37. REMOVE DOOR ASSIST GRIP COVER LH (See page ED-38) 38. REMOVE REAR DOOR TRIM BOARD SUBASSEMBLY LH (See page ED-39) 39. REMOVE REAR DOOR INNER GLASS WEATHERSTRIP LH (See page ED-40) 40. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-24) 41. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-25) 42. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH 43. REMOVE LAP BELT OUTER ANCHOR COVER (See page IR-25) 44. DISCONNECT FRONT SEAT OUTER BELT ASSEMBLY LH (See page IR-25) 45. REMOVE LOWER CENTER PILLAR GARNISH LH (See page IR-26) 46. REMOVE UPPER CENTER PILLAR GARNISH LH (See page IR-26) 47. REMOVE FRONT DOOR SCUFF PLATE RH (See page IR-26) 48. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH (See page IR-26) 49. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH 50. REMOVE LAP BELT OUTER ANCHOR COVER (See page IR-26) 51. DISCONNECT FRONT SEAT OUTER BELT ASSEMBLY RH (See page IR-26) 52. REMOVE LOWER CENTER PILLAR GARNISH RH (See page IR-26) 53. REMOVE UPPER CENTER PILLAR GARNISH RH (See page IR-26) 54. REMOVE ROOF SIDE INNER GARNISH LH (See page IR-26) 55. REMOVE ROOF SIDE INNER GARNISH RH (See page IR-26) RF RF–46 SLIDING ROOF – SLIDING ROOF HOUSING 56. REMOVE FRONT PILLAR GARNISH LH (See page IR27) 57. REMOVE FRONT PILLAR GARNISH RH (See page IR27) 58. REMOVE ROOF CONSOLE BOX ASSEMBLY (See page IR-28) 59. REMOVE VISOR ASSEMBLY LH (See page IR-28) 60. REMOVE VISOR ASSEMBLY RH (See page IR-29) 61. REMOVE VISOR HOLDER (See page IR-29) 62. REMOVE FRONT ASSIST GRIP SUB-ASSEMBLY (See page IR-29) 63. REMOVE REAR ASSIST GRIP SUB-ASSEMBLY (See page IR-29) 64. REMOVE SPOT LIGHT ASSEMBLY (See page IR-30) RF 65. REMOVE SUN ROOF OPENING TRIM MOULDING (See page IR-31) 66. REMOVE SUNSHADE TRIM HOLDER (w/ Rear Sunshade) (See page IR-31) 67. REMOVE ROOF HEADLINING ASSEMBLY (See page IR-32) 68. REMOVE FRONT SIDE RAIL SPACER LH (a) Disengage the 2 claws and remove the front side rail spacer LH. 69. REMOVE FRONT SIDE RAIL SPACER RH HINT: Use the same procedures for the RH side and the LH side. 70. REMOVE CURTAIN SHIELD AIRBAG ASSEMBLY LH 71. REMOVE CURTAIN SHIELD AIRBAG ASSEMBLY RH HINT: Use the same procedures for the RH side and the LH side. 72. REMOVE SLIDING ROOF SIDE GARNISH LH (a) Disengage the 5 claws and remove the sliding roof side garnish LH. 73. REMOVE SLIDING ROOF SIDE GARNISH RH HINT: Use the same procedures for the RH side and the LH side. B132108 SLIDING ROOF – SLIDING ROOF HOUSING RF–47 74. REMOVE SLIDING ROOF GLASS SUB-ASSEMBLY (a) Using a T25 "TORX" driver, remove the 4 screws and sliding roof glass sub-assembly. RF B132109 75. REMOVE SLIDING ROOF HOUSING SUB-ASSEMBLY (a) Disconnect the 4 sliding roof drain hoses. (b) Remove the 8 bolts, 8 nuts, and sliding roof housing sub-assembly. B132110 76. REMOVE SLIDING ROOF WEATHERSTRIP (a) Remove the sliding roof weatherstrip from the sliding roof housing sub-assembly. RF–48 SLIDING ROOF – SLIDING ROOF HOUSING DISASSEMBLY 1. REMOVE SLIDING ROOF DRIVE GEAR SUBASSEMBLY (a) Disengage the claw and remove the sliding roof drive gear bracket. B132119 (b) Remove the 2 bolts and sliding roof drive gear subassembly. RF B125922 2. REMOVE SUNSHADE TRIM SUB-ASSEMBLY (a) Remove the screw and sliding roof piece subassembly LH. HINT: Use the same procedures for the RH side and the LH side. B132122 (b) Slide and remove the sunshade trim sub-assembly. 3. B132123 REMOVE SLIDING ROOF DRIVE CABLE SUBASSEMBLY NOTICE: Do not disassemble the sliding roof drive cable subassembly except when replacing it. SLIDING ROOF – SLIDING ROOF HOUSING RF–49 (a) Remove the 2 screws and sliding roof side stoppers. B125928 (b) Using a screwdriver, disengage the 2 claws. Then slide the sliding roof drip channel rearward to remove it. HINT: Tape the screwdriver tip before use. (c) Using a screwdriver, slide the sliding roof drive cable sub-assembly in the direction indicated by the arrow in the illustration to remove it. Protective Tape Protective Tape B125930E02 Sliding Roof Drive Cable Sub-assembly Window Deflector Hold the window deflector down until the sliding roof drive cable sub-assembly bocomes disengaged from the window deflector B139634E01 RF RF–50 SLIDING ROOF – SLIDING ROOF HOUSING HINT: Hold the window deflector down, as shown in the illustration, until the sliding roof drive cable subassembly becomes disengaged from the window deflector. RF RF–51 SLIDING ROOF – SLIDING ROOF HOUSING REASSEMBLY 1. INSTALL SLIDING ROOF DRIVE CABLE SUBASSEMBLY (a) Using a screwdriver, slide the sliding roof drive cable sub-assembly in the direction indicated by the arrow in the illustration to install it. Sliding Roof Drive Cable Sub-assembly RF Window Deflector Hold the window deflector down until the sliding roof drive cable sub-assembly runs on the window deflector B139633E01 NOTICE: Make sure that the spring indicated by the arrow in the illustration is securely installed. HINT: Hold the window deflector down, as shown in the illustration, until the sliding roof drive cable subassembly runs on the window deflector. RF–52 SLIDING ROOF – SLIDING ROOF HOUSING (b) Engage the 2 claws and install the sliding roof drip channel. B131978 (c) Install the 2 sliding roof side stoppers with the 2 screws. Torque: 2.0 N*m (20 kgf*cm, 18 in.*lbf) RF B125928 2. ADJUST FULLY CLOSED POSITION (a) Using a screwdriver, slide the sliding roof drive cable sub-assembly in either direction as indicated by the arrows in the illustration and align the matchmarks. HINT: Tape the screwdriver tip before use. 3. INSTALL SUNSHADE TRIM SUB-ASSEMBLY (a) Insert the sunshade trim into the sliding roof housing sub-assembly. Matchmarks B122196E01 B139574 SLIDING ROOF – SLIDING ROOF HOUSING RF–53 (b) Install the sliding roof piece sub-assemblies LH and RH with the 2 screws. Torque: 2.0 N*m (20 kgf*cm, 18 in.*lbf) B132122 4. INSTALL SLIDING ROOF DRIVE GEAR SUBASSEMBLY (a) Install the sliding roof drive gear sub-assembly with the 2 bolts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) B125922 (b) Engage the claw and install the sliding roof drive gear bracket. B132119 RF RF–60 SLIDING ROOF – SLIDING ROOF SWITCH ASSEMBLY SLIDING ROOF SWITCH ASSEMBLY Roof Console Box Assembly Connector: ON-VEHICLE INSPECTION 1. Sliding Roof Control Switch RF Q6 B131165E02 INSPECT ROOF CONSOLE BOX ASSEMBLY (a) Remove the roof console box assembly. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Switch Position Specified Condition Q6-1 (CLS) - Q6-3 (GND) CLOSE Below 100 Ω Q6-2 (OPN) - Q6-3 (GND) OPEN Below 100 Ω Q6-4 (DOWN) - Q6-3 (GND) DOWN Below 100 Ω Q6-5 (UP) - Q6-3 (GND) UP Below 100 Ω Q6-1 (CLS) - Q6-3 (GND) OPEN 1 kΩ or higher Q6-2 (OPN) - Q6-3 (GND) CLOSE 1 kΩ or higher Q6-4 (DOWN) - Q6-3 (GND) UP 1 kΩ or higher Q6-5 (UP) - Q6-3 (GND) DOWN 1 kΩ or higher If the result is not as specified, replace the roof console box assembly. RF–54 SLIDING ROOF – SLIDING ROOF HOUSING INSTALLATION 1. INSTALL SLIDING ROOF WEATHERSTRIP (a) Install the sliding roof weatherstrip as follows: (1) Position the joint of the weatherstrip at the rear center. (2) Align the marks on the weatherstrip with the middle marks at the corners of the sliding roof panel and install the weatherstrip. (3) Install the lip of the weatherstrip firmly. Normal: Joint Pinched RF Exposed Gap (raised, wavy, etc.) Abnormal: Rear Middle B139674E01 2. INSTALL SLIDING ROOF HOUSING SUB-ASSEMBLY (a) Install the sliding roof housing sub-assembly with the 8 bolts and 8 nuts. B132110 Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) SLIDING ROOF – SLIDING ROOF HOUSING RF–55 (b) Connect the 4 sliding roof drain hoses. NOTICE: The clip must face toward the outside of the vehicle and also be above the lower surface of the sliding roof housing when installing the drain hoses. 3. Clip Outer Side INSTALL SLIDING ROOF GLASS SUB-ASSEMBLY (a) Using a T25 "TORX" driver, temporarily install the sliding roof glass sub-assembly with the 4 screws. RF Front Side B122242E01 B132109 RF–56 SLIDING ROOF – SLIDING ROOF HOUSING C A C A B B D (b) Perform a level check. (1) Check the difference in level for "a" between the roof panel and the upper surface of the weatherstrip when the sliding roof glass is fully closed. Standard D a Area Measurement A-A 0 + 1.0 mm (0 + 0.039 in.) 0 - 2.0 mm (0 - 0.079 in.) B-B 0 + 2.0 mm (0 + 0.079 in.) 0 - 1.0 mm (0 - 0.039 in.) C-C 0 + 1.5 mm (0 + 0.059 in.) 0 - 1.5 mm (0 - 0.059 in.) D-D 0 + 1.5 mm (0 + 0.059 in.) 0 - 1.0 mm (0 - 0.039 in.) B132111E01 HINT: "+" represents the condition that the glass is above the panel level. "-" represents the condition that the glass is below the panel level. RF (c) Perform a gap check. (1) Check the gap between the roof panel and roof glass. NOTICE: The gap must be even all around. (d) After adjusting the sliding roof glass, using a T25 "TORX" driver, install the sliding roof glass subassembly with the 4 screws. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) Even 4. CHECK FOR WATER LEAKS (a) After adjusting the sliding roof glass sub-assembly, check for water leaks. (b) If there are any leaks, readjust the sliding roof glass sub-assembly. 5. INSTALL SLIDING ROOF SIDE GARNISH LH (a) Engage the 6 claws and install the sliding roof side garnish LH. 6. INSTALL SLIDING ROOF SIDE GARNISH RH HINT: Use the same procedures for the RH side and the LH side. 7. INSTALL CURTAIN SHIELD AIRBAG ASSEMBLY LH (See page RS-421) 8. INSTALL CURTAIN SHIELD AIRBAG ASSEMBLY RH HINT: Use the same procedures for the RH side and the LH side. 9. INSTALL FRONT SIDE RAIL SPACER LH (a) Engage the 2 claws and install the front side rail spacer LH. B132112E01 B132108 SLIDING ROOF – SLIDING ROOF HOUSING RF–57 10. INSTALL FRONT SIDE RAIL SPACER RH HINT: Use the same procedures for the RH side and the LH side. 11. INSTALL ROOF HEADLINING ASSEMBLY (See page IR-46) 12. INSTALL SUNSHADE TRIM HOLDER (w/ Rear Sunshade) (See page IR-47) 13. INSTALL SUN ROOF OPENING TRIM MOULDING (See page IR-47) 14. INSTALL SPOT LIGHT ASSEMBLY (See page IR-48) 15. INSTALL FRONT ASSIST GRIP SUB-ASSEMBLY (See page IR-49) 16. INSTALL REAR ASSIST GRIP SUB-ASSEMBLY (See page IR-49) 17. INSTALL VISOR HOLDER (See page IR-49) 18. INSTALL VISOR ASSEMBLY LH (See page IR-50) 19. INSTALL VISOR ASSEMBLY RH (See page IR-50) 20. INSTALL ROOF CONSOLE BOX ASSEMBLY (See page IR-50) 21. INSTALL FRONT PILLAR GARNISH LH (See page IR51) 22. INSTALL FRONT PILLAR GARNISH RH (See page IR52) 23. INSTALL ROOF SIDE INNER GARNISH LH (See page IR-52) 24. INSTALL ROOF SIDE INNER GARNISH RH (See page IR-52) 25. INSTALL UPPER CENTER PILLAR GARNISH LH (See page IR-53) 26. INSTALL LOWER CENTER PILLAR GARNISH LH (See page IR-53) 27. CONNECT FRONT SEAT OUTER BELT ASSEMBLY LH (See page IR-53) 28. INSTALL LAP BELT OUTER ANCHOR COVER (See page IR-53) 29. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH (See page IR-54) 30. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-54) 31. INSTALL FRONT DOOR SCUFF PLATE LH (See page IR-54) 32. INSTALL UPPER CENTER PILLAR GARNISH RH (See page IR-54) RF RF–58 SLIDING ROOF – SLIDING ROOF HOUSING 33. INSTALL LOWER CENTER PILLAR GARNISH RH (See page IR-54) 34. CONNECT FRONT SEAT OUTER BELT ASSEMBLY RH (See page IR-54) 35. INSTALL LAP BELT OUTER ANCHOR COVER (See page IR-54) 36. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH (See page IR-55) 37. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH (See page IR-55) 38. INSTALL FRONT DOOR SCUFF PLATE RH (See page IR-55) 39. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP LH (See page ED-54) RF 40. INSTALL REAR DOOR TRIM BOARD SUBASSEMBLY LH (See page ED-55) 41. INSTALL DOOR ASSIST GRIP COVER LH (See page ED-56) 42. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG LH (See page ED-56) 43. INSTALL RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY LH (for Reclining Seat Type) (See page SE-69) 44. INSTALL RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY RH (for Reclining Seat Type) HINT: Use the same procedures for the RH side and the LH side. 45. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (See page IR-55) 46. INSTALL REAR DOOR SCUFF PLATE LH (See page IR-56) 47. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH (See page IR-56) 48. INSTALL REAR DOOR SCUFF PLATE RH (See page IR-56) 49. INSTALL CENTER SEAT BACK ASSEMBLY (for Reclining Seat Type) (See page SE-71) 50. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Reclining Seat Type) (See page SE-72) 51. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Reclining Seat Type) (See page SE-71) 52. INSTALL REAR SEAT BACK COVER (for Reclining Seat Type) SLIDING ROOF – SLIDING ROOF HOUSING RF–59 53. INSTALL REAR SIDE SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-57) 54. INSTALL REAR SIDE SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) HINT: Use the same procedures for the RH side and the LH side. 55. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-57) 56. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) (See page SE-57) 57. INSTALL REAR SEAT BACK ASSEMBLY (for Fixed Seat Type) (See page SE-84) 58. INSTALL REAR CENTER SEAT HEADREST ASSEMBLY 59. INSTALL REAR SEAT HEADREST ASSEMBLY 60. INSTALL REAR SEAT CUSHION ASSEMBLY (See page SE-84) 61. INSTALL FRONT SEAT ASSEMBLY LH (for Power Seat) (See page SE-41) 62. INSTALL INNER SEAT TRACK BRACKET COVER RH (for Power Seat) (See page SE-42) 63. INSTALL SEAT TRACK COVER LH (for Power Seat) (See page SE-42) 64. INSTALL FRONT SEAT HEADREST ASSEMBLY (for Power Seat) 65. INSTALL FRONT SEAT ASSEMBLY LH (for Manual Seat) (See page SE-24) 66. INSTALL INNER SEAT TRACK BRACKET COVER LH (for Manual Seat) (See page SE-25) 67. INSTALL SEAT TRACK COVER LH (for Manual Seat) (See page SE-25) 68. INSTALL FRONT SEAT HEADREST ASSEMBLY (for Manual Seat) 69. INSTALL FRONT SEAT ASSEMBLY RH (for Power Seat) HINT: Use the same procedures for the RH side and the LH side. 70. INSTALL INNER SEAT TRACK BRACKET COVER LH (for Power Seat) HINT: Use the same procedures for the RH side and the LH side. RF RF–60 SLIDING ROOF – SLIDING ROOF HOUSING 71. INSTALL SEAT TRACK COVER RH (for Power Seat) HINT: Use the same procedures for the RH side and the LH side. 72. INSTALL FRONT SEAT HEADREST ASSEMBLY (for Power Seat) 73. INSTALL FRONT SEAT ASSEMBLY RH (for Manual Seat) HINT: Use the same procedures for the RH side and the LH side. 74. INSTALL INNER SEAT TRACK BRACKET COVER RH (for Manual Seat) HINT: Use the same procedures for the RH side and the LH side. RF 75. INSTALL SEAT TRACK COVER RH (for Manual Seat) HINT: Use the same procedures for the RH side and the LH side. 76. INSTALL FRONT SEAT HEADREST ASSEMBLY (for Manual Seat) 77. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 78. PERFORM ZERO POINT CALIBRATION AND SENSITIVITY CHECK (for Front Passenger Seat) (See page RS-242) 79. INSPECT SRS WARNING LIGHT (See page RS-32) 80. RESET SLIDING ROOF DRIVE GEAR SUBASSEMBLY (See page RF-4) 81. CHECK SLIDING ROOF SYSTEM (See page RF-11) 82. INSPECT FRONT SEAT ASSEMBLY (for Power Seat) (See page SE-42) 83. INSPECT FRONT SEAT ADJUSTER ASSEMBLY (for Manual Seat) CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CA–1 CAN COMMUNICATION SYSTEM PRECAUTION 1. 2. 3. F045104 STEERING SYSTEM HANDLING PRECAUTIONS (a) Care must be taken when replacing parts. Incorrect replacement could affect the performance of the steering system and result in hazardous driving. SRS AIRBAG SYSTEM HANDLING PRECAUTIONS (a) This vehicle is equipped with an SRS (Supplemental Restraint System) which includes parts such as the driver airbag and front passenger airbag. Failure to carry out service operations in the correct sequence could cause unexpected SRS deployment during servicing and may lead to a serious accident. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the precautionary notice for the Supplemental Restraint System (See page RS-1). BUS WIRE REPAIR (a) After repairing a bus wire with solder, wrap the repaired part with vinyl tape. NOTICE: • The CANL bus wire and CANH bus wire must be installed together at all times. • When installing, make sure that they are twisted. • CAN bus wires are likely to be influenced by noise if the bus wires are not twisted. • The difference in length between the CANL bus wire and CANH bus wire should be within 100 mm (3.937 in.). • Leave approximately 80 mm (3.150 in.) loose in the twisted wires around the connector. (b) Do not use bypass wiring between the connectors. NOTICE: The protective effect of the twisted wire harness will be lost if you use bypass wiring. Bypass Wire F045105E01 CA CA–2 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 4. CONNECTOR HANDLING (a) When checking resistance with a tester, insert the tester probes from the backside (harness side) of the connector. Tester Probe F045106E01 Service Wire 5. CA (b) Use a service wire to check the connector if it is impossible to check continuity from the rear of the connector. EXPRESSIONS OF IGNITION SWITCH The type of ignition switch used on this model differs according to the specifications of the vehicle. The expressions listed in the table below are used in this section. F045107E13 Expression Switch Type Ignition Switch (Position) Engine Switch (Condition) Ignition switch off LOCK Off Ignition switch on (IG) ON On (IG) Ignition switch on (ACC) ACC ON (ACC) Engine start START Start CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CA–3 PARTS LOCATION ECM (2GR-FE) SKID CONTROL ECU WITH ACTUATOR CA ECM (2AZ-FE) C136705E03 CA–4 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM STEERING ANGLE SENSOR CERTIFICATION ECU* NO. 2 CAN J/C (A40) NO. 2 CAN J/C (E41) A/C AMPLIFIER CA NO. 1 CAN J/C COMBINATION METER DLC3 ACCESSORY GATEWAY MAIN BODY ECU CENTER AIRBAG SENSOR ASSEMBLY YAW RATE SENSOR *: With Smart Key System C133236E01 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CA–5 SYSTEM DIAGRAM : CAN Main Bus Wire (CANH) : CAN Main Bus Wire (CANL) *1: with Smart Key System *2: with VSC : CAN Branch Wire (CANH) : CAN Branch Wire (CANL) : CAN MS Bus Wire (CANH) : CAN MS Bus Wire (CANL) Combination Meter 120 Ω Certification ECU*1 120 Ω No. 1 CAN J/C 120 Ω Main Body ECU DLC3 CA Yaw Rate Sensor*2 Steering Angle Sensor*2 Center Airbag Sensor Assembly No. 2 CAN J/C (Rear of the Vehicle) A/C Amplifier Accessory Gateway Skid Control ECU with Actuator No. 2 CAN J/C (Front of the Vehicle) 120 Ω ECM C136704E04 CA–6 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM HINT: • The skid control ECU detects and stores steering angle sensor and yaw rate sensor DTCs and allows DTC communication by receiving information from the steering angle sensor and yaw rate sensor. CA CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CA–7 SYSTEM DESCRIPTION 1. 2. BRIEF DESCRIPTION (a) Two different CAN busses are used. The CAN busses are classified into two types based on typical communication speed. The HS-CAN bus is a high-speed communication bus that is used for powertrain, chassis, and some body electrical communication. The HS-CAN bus is referred to as the "CAN bus" and it operates at speeds of approximately 500 kbps. Terminating resistors for the HS-CAN bus are located in the ECM and combination meter. The MS-CAN bus is a medium-speed communication bus that is used for body electrical communication. The MS-CAN bus is referred to as the "MS bus" and it operates at speeds of approximately 250 kbps. Terminating resistors for the MS-CAN bus are located in the main body ECU and the certification ECU. The resistance of the MSCAN bus cannot be measured from the DLC3 connector. Communication between these two networks is handled via the main body ECU, which acts as a gateway ECU. (b) By pairing the CANH and CANL bus wires, the CAN performs communication based on differential voltage. (c) Many ECUs (sensors) installed on the vehicle operate by sharing information and communicating with each other. (d) The CAN has two resistors of 120 Ω which are necessary to enable communication on the main bus wire. DEFINITION OF TERMS (a) Main bus wire (1) The main bus wire is a wire harness between the two terminus circuits on the bus (communication line). (b) Branch wire (1) The branch wire is a wire harness which diverges from the main bus wire to an ECU or sensor. CA CA–8 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 3. CA 4. 5. (c) Terminating resistors (1) Two resistors of 120 Ω resistance are installed in parallel across the ends of the CAN main bus wires. They are called terminating resistors. These resistors allow the changes of the voltage differential between the CAN bus wires to be accurately judged. To allow proper function of CAN communication, it is necessary to have both terminating resistors installed. Since the two resistors are installed in parallel, a measurement of resistance between the two CAN bus wires should produce a reading of approximately 60 Ω. ECUS OR SENSORS WHICH COMMUNICATE THROUGH CAN COMMUNICATION SYSTEM (a) Skid control ECU with actuator (b) Air conditioning amplifier (c) Main body ECU (d) Combination meter ECU (e) Yaw rate sensor (f) Steering angle sensor (g) Center airbag sensor (h) ECM (i) Certification ECU (with smart key system) (j) TCM (k) Accessory gateway DIAGNOSTIC CODE FOR CAN COMMUNICATION SYSTEM (a) DTCs for the CAN communication system are as follows: U0101, U0073, U0100, U0123, U0124, U0126, U0129, B1207, B1499, and B2326. TROUBLESHOOTING REMARKS (a) DTCs for the CAN communication system can be checked using the intelligent tester via the CAN VIM. The DLC3 is connected to the CAN communication system, but no DTCs exist regarding problems in the DLC3 or the DLC3 branch wires. If there is trouble in the DLC3 or the DLC3 branch wires, ECUs on the CAN network cannot output codes to the intelligent tester via the CAN VIM. (b) Trouble in the CAN buses (communication lines) can be checked by measuring the resistance between terminals of the DLC3. However, an open circuit in a branch wire other than the DLC3 branch wires cannot be checked from the DLC3. NOTICE: Do not insert the tester probes directly into the DLC3. Be sure to use a service wires. CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 6. CA–9 HOW TO DISTINGUISH THE CAN J/C CONNECTOR (a) In the CAN communication system, the shape of all connectors connected to the CAN J/C No. 1 is the same. The connectors connected to the CAN J/C No. 1 can be connecting side of the junction connector. HINT: See "TERMINALS OF ECU" (See page CA-10) for bus wire color or the type of connecting surface. CA CA–10 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING NOTICE: • DTCs for the CAN communication system are as follows: U0101, U0073, U0100, U0123, U0124, U0126, B1207, B1499, and B2326. • Refer to troubleshooting of each system if DTCs regarding the CAN communication system are not output. 1 CHECK AND CLEAR DTCS NEXT 2 CHECK FOR INSTALLED SYSTEMS (ECUS & SENSORS) THAT ADOPT CAN COMMUNICATION) CA (a) Check which of the following is adopted: SFI system, automatic transaxle system, brake control system, supplemental restraint system, smart key system, air conditioning system and meter / gauge system (See page CA-25). NEXT 3 CHECK CAN BUS LINE (a) Check the CAN bus wires (See page CA-65). NEXT 4 CHECK INTELLIGENT TESTER (a) Select "Communication Bus Check" (See page CA-25). Result Symptom Proceed See procedure All the ECUs and sensors connected to the CAN communication system are displayed on the screen. A Go to step 5 An ECU or sensor not connected to the CAN communication system is displayed on the screen. B CA-10 More than one of the ECUs and sensors not connected to the CAN communication system are displayed on the screen. (If the displayed ECUs and sensors are only those relating to the "Engine" and "ECT", proceed to B.) C CA-119 NOTICE: • The systems (ECUs, sensors) that adopt CAN communication vary depending on the vehicle and option settings. Check which systems (ECUs, sensors) are installed on the vehicle (See page CA-25). CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CA–11 • Non-installed ECUs or sensors are not displayed. Do not mistake ECUs that are not installed as being in communication stop mode. • If 2 or more ECUs or sensors are not displayed on the intelligent tester, perform troubleshooting for communication stop mode for each undisplayed ECU or sensor. (Open in one side of the CAN branch wires.) B GO TO "COMMUNICATION STOP MODE TABLE" C GO TO "OPEN IN ONE SIDE OF CAN BRANCH LINE" A 5 DTC COMBINATION TABLE (a) Confirm trouble according to the combination of output DTCs regarding the CAN communication system (See page CA-25). HINT: Previous CAN communication system DTCs may be the cause if CAN communication system DTCs are output and all ECUs and sensors connected to the CAN communication system are displayed on the intelligent tester "Communication Bus Check" screen. NEXT 6 CIRCUIT INSPECTION NEXT 7 IDENTIFICATION OF PROBLEM NEXT 8 REPAIR OR REPLACE NEXT 9 NEXT END CONFIRMATION TEST CA CA–12 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM PROBLEM SYMPTOMS TABLE RESULT LIST OF HOW TO PROCEED WITH TROUBLESHOOTING: Symptom Suspected area See page The result of "HOW TO PROCEED WITH TROUBLESHOOTING" is "Open in CAN Main Bus Line" Open in CAN Main Bus Wire CA-69 The result of "HOW TO PROCEED WITH TROUBLESHOOTING" is "Short in CAN Bus Line" Short in CAN Bus Wires CA-74 The result of "HOW TO PROCEED WITH TROUBLESHOOTING" is "Short to +B in CAN Bus Line" Short to B+ in CAN Bus Wire CA-89 The result of "HOW TO PROCEED WITH TROUBLESHOOTING" is "Short to GND in CAN Bus Line" Short to GND in CAN Bus Wire CA-104 The result of "HOW TO PROCEED WITH TROUBLESHOOTING" is "Open in One Side of CAN Sub Bus Line" Open in One Side of CAN Branch Wire CA-119 COMMUNICATION STOP MODE TABLE: Symptom CA Suspected area See page "ABS/VSC/TRAC" is not displayed on the intelligent tester (with VSC) Skid Control ECU Communication Stop Mode CA-42 "A/C " is not displayed on the intelligent tester Air Conditioning Amplifier Communication Stop Mode CA-46 "Body/Gateway" is not displayed on the intelligent tester Main Body ECU Communication Stop Mode CA-57 "Steering Angle Sensor" is not displayed on the intelligent tester Steering Angle Sensor Communication Stop Mode CA-49 "Yaw Rate/Deceleration Sensor" is not displayed on the intelligent tester Yaw Rate Sensor Communication Stop Mode CA-51 "Engine" are not displayed on the intelligent tester ECM Communication Stop Mode CA-54 "Meter " is not displayed on the intelligent tester Combination Meter Communication Stop Mode CA-61 "SRS Airbag" is not displayed on the intelligent tester Center Airbag Sensor Communication Stop Mode CA-63 CA–13 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM TERMINALS OF ECU NOTICE: This section describes the standard CAN values for all CAN related components. 1. JUNCTION CONNECTOR (NO. 1 CAN J/C, NO. 2 CAN J/C) (a) No. 1 CAN J/C No. 1 CAN J/C “B” side (without Earth Terminal): No. 1 CAN J/C “A” side (with Earth Terminal): Earth Terminal CA B W B W B W B W B W E46 E42 E62 E45 B W B W E63 E43 E44 Earth Terminal C137761E02 No. 1 CAN J/C connectors ("A" side, with earth terminal) Connector Color Wire Color (CAN-H) Wire Color (CAN-L) CAN Main Bus Wire (E42) White B W Airbag Sensor Assembly Center (E45) Black B W Connector Color Wire Color (CAN-H) Wire Color (CAN-L) Blue B W No. 1 CAN J/C connectors ("B" side, with earth terminal) Yaw Rate Sensor* (E46) DLC3 (E62) Gray B W Steering Angle Sensor* (E63) Brown B W Combination Meter (E43) White B W Main Body ECU (E44) Black B W *: with VSC CA–14 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM (b) No. 2 CAN J/C (FRONT OF THE VEHICLE) No. 2 CAN J/C (Front of the Vehicle) Wire Harness View: Front of the Vehicle CANH (for Skid Control ECU) CANH (for ECM) A40 CANL (for Skid Control ECU) CANL (for ECM) CA C137762E02 Terminals Wiring Color Connects to A40-1 (CANH) B ECM (CANH) A40-7 (CANL) W ECM (CANL) A40-2 (CANH) B Skid Control ECU (CANH) A40-8 (CANL) W Skid Control ECU (CANL) (c) No. 2 CAN J/C (REAR OF THE VEHICLE) No. 2 CAN J/C (Rear of the Vehicle) Wire Harness View: Front of the Vehicle E41 CANH (for No. 1 CAN J/C) CANH (for Accessory Gateway) CANL (for No. 1 CAN J/C) CANH (for A/C Amplifier) CANL (for A/C Amplifier) CANL (for Accessory Gateway) C137763E02 Terminals Wiring Color Connects to E41-1 (CANH) B Accessory Gateway (CANH) CA–15 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM Terminals Wiring Color Connects to E41-7 (CANL) W Accessory Gateway (CANL) E41-2 (CANH) B A/C Amplifier (CANH) E41-8 (CANL) W A/C Amplifier (CANL) E41-4 (CANH) B No. 1 CAN J/C (CANH) E41-10 (CANL) W No. 1 CAN J/C (CANL) CA CA–16 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM (d) Yaw Rate Sensor*2 DLC 3 Steering Angle Sensor*2 The connection diagram of the components which are connected to the CAN J/C Combination Meter Main Body ECU Certification ECU*1 “B” Side (without Earth Terminal) CANH CANL CANH CANL CANH CANL CANH CANL CANH CANL No. 1 CAN J/C CANH CANL CANH CANL “A” Side (with Earth Terminal) CA Center Airbag Sensor Assembly *1: with smart key system Accessory Gateway A/C Amplifier *2: with VSC Rear of the Vehicle (E41) CANH CANL CANH CANL CANH CANL No. 2 CAN J/C CANH CANL CANH CANL Front of the Vehicle (A40) Skid Control ECU with Actuator ECM C136707E02 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM DLC3: CG 2. E10 CANH CANL BAT CA–17 DLC3 (a) Measure the resistance according to the value(s) in the table below. C125062E02 Standard resistance Terminals Wiring Color Terminal Description Condition Specified Condition E10-6 (CANH) - E10-14 (CANL) B-W HIGH-level CAN bus wire LOW-level CAN bus wire Ignition Switch off 54 to 69 Ω E10-6 (CANH) - E10-4 (CG) B - W-B HIGH-level CAN bus wire Ground Ignition Switch off 200 Ω or higher E10-14 (CANL) - E10-4 (CG) W - W-B LOW-level CAN bus wire Ground Ignition Switch off 200 Ω or higher E10-6 (CANH) - E10-16 (BAT) B-L HIGH-level CAN bus wire Battery positive Ignition Switch off 1 MΩ or higher E10-14 (CANL) - E10-16 (BAT) W-L LOW-level CAN bus wire Battery positive Ignition Switch off 1 MΩ or higher 3. (b) Measure the resistance according to the value(s) in the table below. Skid Control ECU (Harness Side Connector Front View): A25 CANL +BS GND1 SKID CONTROL ECU (w/o VSC) (a) Disconnect the A25 connector from the skid control ECU. CANH C131970E11 Standard resistance Terminals Wiring Color Terminal Description Condition Specified Condition A25-26 (CANH) - A25-15 (CANL) B-W HIGH-level CAN bus wire LOW-level CAN bus wire Ignition Switch off 54 to 69 Ω A25-26 (CANH) - A25-4 (GND1) B - W-B HIGH-level CAN bus wire Ground Ignition Switch off 200 Ω or higher A25-15 (CANL) - A25-4 (GND1) W - W-B LOW-level CAN bus wire Ground Ignition Switch off 200 Ω or higher A25-26 (CANH) - A25-3 (+BS) B-L HIGH-level CAN bus wire Battery positive Ignition Switch off 6 kΩ or higher A25-15 (CANL) - A25-3 (+BS) W-L LOW-level CAN bus wire Battery positive Ignition Switch off 6 kΩ or higher CA CA–18 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 4. Skid Control ECU Connector Front View: CANH +BS A26 CANL GND1 SKID CONTROL ECU WITH ACTUATOR (w/ VSC) (a) TMC made (1) Disconnect A26 connector from the skid control ECU. (2) Measure the resistance according to the value(s) in the table below. E069126E52 Standard resistance Terminals CA Wiring Color Terminal Description Condition Specified Condition A26-11 (CANH) - A26-25 (CANL) B-W HIGH-level CAN bus wire LOW-level CAN bus wire Ignition Switch off 54 to 69 Ω A26-11 (CANH) - A26-32 (GND1) B - W-B HIGH-level CAN bus wire Ground Ignition Switch off 200 Ω or higher A26-25 (CANL) - A26-32 (GND1) W - W-B LOW-level CAN bus wire Ground Ignition Switch off 200 Ω or higher A26-11 (CANH) - A26-31 (+BS) B-L HIGH-level CAN bus wire Battery positive Ignition Switch off 6 kΩ or higher A26-25 (CANL)- A26-31 (+BS) W-L LOW-level CAN bus wire Battery positive Ignition Switch off 6 kΩ or higher (b) TMMK made (1) Disconnect the A60 connector from the skid control ECU. (2) Measure the resistance according to the value(s) in the table below. Skid Control ECU (Harness Side Connector Front View): +BS A60 GND1 CANL CANH C136493E10 Standard resistance Terminals Wiring Color Terminal Description Condition Specified Condition A60-35 (CANH) - A60-14 (CANL) B-W HIGH-level CAN bus wire LOW-level CAN bus wire Ignition Switch off 54 to 69 Ω A60-35 (CANH) - A60-4 (GND1) B - W-B HIGH-level CAN bus wire Ground Ignition Switch off 200 Ω or higher A60-14 (CANL) - A60-4 (GND1) W - W-B LOW-level CAN bus wire Ground Ignition Switch off 200 Ω or higher A60-35 (CANH) - A60-3 (+BS) B-L HIGH-level CAN bus wire Battery positive Ignition Switch off 6 kΩ or higher A60-14 (CANL)- A60-3 (+BS) W-L LOW-level CAN bus wire Battery positive Ignition Switch off 6 kΩ or higher CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 5. Steering Angle Sensor Wire Harness View: E17 BAT CANH CA–19 STEERING ANGLE SENSOR (W/ VSC) (a) Disconnect the E17 connector from the steering angle sensor. (b) Measure the resistance according to the value(s) in the table below. ESS CANL G026357E15 Standard resistance Terminals Wiring Color Terminal Description Condition Specified Condition E17-10 (CANH) - E17-9 (CANL) B-W HIGH-level CAN bus wire LOW-level CAN bus wire Ignition Switch off 54 to 69 Ω E17-10 (CANH) - E17-2 (ESS) B - W-B HIGH-level CAN bus wire Ground Ignition Switch off 200 Ω or higher E17-9 (CANL) - E17-2 (ESS) W - W-B LOW-level CAN bus wire Ground Ignition Switch off 200 Ω or higher E17-10 (CANH) - E17-3 (BAT) B-W HIGH-level CAN bus wire Battery positive Ignition Switch off 6 kΩ or higher E17-9 (CANL) - E17-3 (BAT) W-W LOW-level CAN bus wire Battery positive Ignition Switch off 6 kΩ or higher 6. Yaw Rate Sensor Connector Front View: E34 CANL YAW RATE SENSOR (W/ VSC) (a) TMC made (1) Disconnect the E34 connector from the yaw rate sensor. (2) Measure the resistance according to the value(s) in the table below. GND DLC3: CANH E10 BAT G026641E19 Standard resistance Terminals Wiring Color Terminal Description Condition Specified Condition E34-3 (CANH) - E34-2 (CANL) B-W HIGH-level CAN bus wire LOW-level CAN bus wire Ignition Switch off 54 to 69 Ω E34-3 (CANH) - E34-1 (GND) B - W-B HIGH-level CAN bus wire Ground Ignition Switch off 200 Ω or higher E34-2 (CANL) - E34-1 (GND) W - W-B LOW-level CAN bus wire Ground Ignition Switch off 200 Ω or higher E34-3 (CANH) - E10-16 (BAT) B-O HIGH-level CAN bus wire Battery positive Ignition Switch off 6 kΩ or higher CA CA–20 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM Terminals E34-2 (CANL) - E10-16 (BAT) Wiring Color Terminal Description Condition Specified Condition W-O LOW-level CAN bus wire Battery positive Ignition Switch off 6 kΩ or higher (b) TMMK made (1) Disconnect the E34 connector from the yaw rate sensor. (2) Measure the resistance according to the value(s) in the table below. CANL E65 CANH GND E10 CA BAT C136716E01 Standard resistance Terminals Wiring Color Terminal Description Condition Specified Condition E65-3 (CANH) - E65-2 (CANL) B-W HIGH-level CAN bus wire LOW-level CAN bus wire Ignition Switch off 54 to 69 Ω E65-3 (CANH) - E65-1 (GND) B - W-B HIGH-level CAN bus wire Ground Ignition Switch off 200 Ω or higher E65-2 (CANL) - E65-1 (GND) W - W-B LOW-level CAN bus wire Ground Ignition Switch off 200 Ω or higher E65-3 (CANH) - E10-16 (BAT) B-O HIGH-level CAN bus wire Battery positive Ignition Switch off 6 kΩ or higher E65-2 (CANL) - E10-16 (BAT) W-O LOW-level CAN bus wire Battery positive Ignition Switch off 6 kΩ or higher 7. CENTER AIRBAG SENSOR ASSEMBLY (a) Disconnect the E30 connector from the center airbag sensor assembly. CA–21 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM (b) Measure the resistance according to the value(s) in the table below. Center Airbag Sensor Wire Harness View : CANH CANL E30 E1 E10 BAT CA C125063E03 Standard resistance Terminals Wiring Color Terminal Description Condition Specified Condition E30-13 (CANH) - E30-22 (CANL) B-W HIGH-level CAN bus wire LOW-level CAN bus wire Ignition Switch off 54 to 69 Ω E30-13 (CANH) - E30-25 (E1) B - W-B HIGH-level CAN bus wire Ground Ignition Switch off 200 Ω or higher E30-22 (CANL) - E30-25 (E1) W - W-B LOW-level CAN bus wire Ground Ignition Switch off 200 Ω or higher E30-13 (CANH) - E10-16 (BAT) B-L HIGH-level CAN bus wire Battery positive Ignition Switch off 6 kΩ or higher E30-22 (CANL) - E10-16 (BAT) W-L LOW-level CAN bus wire Battery positive Ignition Switch off 6 kΩ or higher 8. ECM (a) 2AZ-FE ECM: CANH                                          A24                                                                                                                                                  CANL A107881E28 (1) Disconnect the A24 connector from the ECM. CA–22 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM (2) Measure the resistance according to the value(s) in the table below. Standard resistance Terminals Condition Specified Condition A24-41 (CANH) - A29-49 (CANL) Ignition Switch off 108 to 132 Ω (3) Measure the resistance according to the value(s) in the table below. ECM Wire Harness View: A24 CANH BATT C24 E1 CANL C136709E05 Standard resistance Terminals CA Wiring Color Terminal Description Condition Specified Condition A24-41 (CANH) - A24-49 (CANL) B-W HIGH-level CAN bus wire LOW-level CAN bus wire Ignition Switch off 108 to 132 Ω A24-41 (CANH) - C24-104 (E1) B - W-B HIGH-level CAN bus wire Ground Ignition Switch off 200 Ω or higher A24-49 (CANL) - C24-104 (E1) B - W-B LOW-level CAN bus wire Ground Ignition Switch off 200 Ω or higher A24-41 (CANH) - A24-20 (BATT) B-Y HIGH-level CAN bus wire Battery positive Ignition Switch off 6 kΩ or higher A24-49 (CANL) - A24-20 (BATT) W-Y LOW-level CAN bus wire Battery positive Ignition Switch off 6 kΩ or higher (b) 2GR-FE ECM: CANH                                          A55                                                                                                                                                  CANL A107881E23 (1) Disconnect the A55 connector from the ECM. (2) Measure the resistance according to the value(s) in the table below. Standard resistance Terminals Condition Specified Condition A55-41 (CANH) - A55-49 (CANL) Ignition Switch off 108 to 132 Ω CA–23 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM (3) Measure the resistance according to the value(s) in the table below. ECM Wire Harness View: A55 CANH BATT C55 E1 CANL C136709E06 Standard resistance Terminals Wiring Color Terminal Description Condition Specified Condition A55-41 (CANH) - A55-49 (CANL) B-W HIGH-level CAN bus wire LOW-level CAN bus wire Ignition Switch off 108 to 132 Ω A55-41 (CANH) - C55-81 (EC) B - W-B HIGH-level CAN bus wire Ground Ignition Switch off 200 Ω or higher A55-49 (CANL) - C55-81 (EC) B - W-B LOW-level CAN bus wire Ground Ignition Switch off 200 Ω or higher A55-41 (CANH) - A55-20 (BATT) B-Y HIGH-level CAN bus wire Battery positive Ignition Switch off 6 kΩ or higher A55-49 (CANL) - A55-20 (BATT) W-Y LOW-level CAN bus wire Battery positive Ignition Switch off 6 kΩ or higher Air Conditioning Amplifier (Wire Harness Side): E38 9. AIR CONDITIONING AMPLIFIER (a) Check the harness side connector (E38) of the air conditioning amplifier. (1) Disconnect the connector (E38) from the air conditioning amplifier. (2) Measure the resistance according to the value(s) in the table below. B GND CANL CANH E124470E20 Standard resistance Terminals Wiring Color Terminal Description Condition Specified Condition E38-11 (CANH) - E38-12 (CANL) B-W HIGH-level CAN bus wire LOW-level CAN bus wire Ignition Switch off 54 to 69 Ω E38-11 (CANH) - E38-14 (GND) B - W-B HIGH-level CAN bus wire Ground Ignition Switch off 200 Ω or higher E38-12 (CANL) - E38-14 (GND) W - W-B LOW-level CAN bus wire Ground Ignition Switch off 200 Ω or higher E38-11 (CANH) - E38-21 (B) B - GR HIGH-level CAN bus wire Battery positive Ignition Switch off 6 kΩ or higher E38-12 (CANL) - E38-21 (B) W - GR LOW-level CAN bus wire Battery positive Ignition Switch off 6 kΩ or higher 10. COMBINATION METER ECU (a) Disconnect the F1 connector from the combination meter. CA CA–24 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM Combination Meter (Component Side): (b) Measure the resistance according to the value(s) in the table below. F1 CANL CANH C133254E01 Standard resistance CA Terminals Condition Specified Condition F1-17 (CANH) - F1-18 (CANL) Ignition Switch off 108 to 132 Ω Combination Meter (Wire Harness Side): (c) Measure the resistance according to the value(s) in the table below. F1 B2 CANL CANH C133255E01 Standard resistance Terminals Wiring Color Terminal Description Condition Specified Condition F1-17 (CANH) - F1-18 (CANL) B-W HIGH-level CAN bus wire LOW-level CAN bus wire Ignition Switch off 108 to 132 Ω F1-17 (CANH) - F1-12 (E2) B - W-B HIGH-level CAN bus wire Ground Ignition Switch off 200 Ω or higher F1-18 (CANL) - F1-12 (E2) B - W-B LOW-level CAN bus wire Ground Ignition Switch off 200 Ω or higher F1-17 (CANH) - F1-2 (B2) B-R HIGH-level CAN bus wire Battery positive Ignition Switch off 6 kΩ or higher F1-18 (CANL) - F1-2 (B2) B-R LOW-level CAN bus wire Battery positive Ignition Switch off 6 kΩ or higher 11. CERTIFICATION ECU (W/ SMART KEY SYSTEM) (a) Disconnect the E58 connector from the certification ECU. CAN COMMUNICATION – CAN COMMUNICATION SYSTEM Certification ECU (Wire Harness Side): CA–25 (b) Measure the resistance according to the value(s) in the table below. E58 +B E CANL CANH C136713E01 Standard resistance Terminals Wiring Color Terminal Description Condition Specified Condition E58-27 (CANH) - E58-28 (CANL) B-W HIGH-level CAN bus wire LOW-level CAN bus wire Ignition Switch off 108 to 132 Ω E58-27 (CANH) - E58-17 (E) B - W-B HIGH-level CAN bus wire Ground Ignition Switch off 200 Ω or higher E58-28 (CANL) - E58-17 (E) B - W-B LOW-level CAN bus wire Ground Ignition Switch off 200 Ω or higher E58-27 (CANH) - E58-1 (+B) B-W HIGH-level CAN bus wire Battery positive Ignition Switch off 6 kΩ or higher E58-28 (CANL) - E58-1 (+B) W-W LOW-level CAN bus wire Battery positive Ignition Switch off 6 kΩ or higher 12. MAIN BODY ECU (INSTRUMENT PANEL J/B) (a) Disconnect the E8 connector from the main body ECU. CA CA–26 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM (b) Measure the resistance according to the value(s) in the table below. Main Body ECU: CANN E8 CANP CANH CANL CA C136714E01 Standard resistance Terminals Wiring Color Terminal Description Condition Specified Condition E8-5 (CANH) - E8-6 (CANL) B-W HIGH-level CAN bus wire LOW-level CAN bus wire Ignition Switch off 54 to 69 Ω E8-16 (CANP) - E8-15 (CANN) W-L HIGH-level CAN bus wire LOW-level CAN bus wire Ignition Switch off 108 to 132 Ω 13. ACCESSORY GATEWAY (a) Measure the resistance according to the value(s) in the table below. Accessory Gateway: CANL CANH C136715E02 Standard resistance Terminals Terminal Description Condition Specified Condition E61-6 (CANH) - E61-14 (CANL) HIGH-level CAN bus wire - LOW-level CAN bus wire Ignition Switch off 54 to 69 Ω CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CA–27 DIAGNOSIS SYSTEM 1. BUS CHECK (a) Select "BUS CHECK" from the "OBD/MOBD MENU" screen. HINT: The ECUs and sensors that are properly connected to the CAN communication system can be displayed using the intelligent tester via the CAN VIM. C113760 (b) Press "ENTER" on the intelligent tester. CA C113761 2. (c) The screen displays the ECUs and sensors that are properly connected to the CAN communication system. HINT: Properly connected ECUs or sensors that are not displayed on the screen indicate that a communication stop is occuring in the system, sensor, or ECU which is not displayed. CHECK FOR INSTALLED SYSTEMS (ECUS AND SENSORS) THAT USE CAN COMMUNICATION (a) Systems (ECUs, sensors) that use CAN communication vary depending on the vehicle's optional equipment. Check which systems (ECUs, sensors) are installed on the vehicle. C113762 ECU/Sensor name ABS/VSC/TRC Check method Installed on all vehicles STEERING SENSOR With VSC system YAW / DECELERAT With VSC system ENGINE Installed on all vehicles CA–28 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM ECU/Sensor name Check method ECT With automatic transaxle SRS AIRBAG Installed on all vehicles A/C Installed on all vehicles METER Installed on all vehicles MAIN BODY Installed on all vehicles ACCESSORY G/W With dealer option SMART ACCESS/KEY With smart key system 3. CA DTC No. U0101* DTC TABLE BY ECU HINT: • For the CAN communication system, CAN communication system DTCs stored in certain ECUs can be displayed using the intelligent tester. • If CAN communication system DTCs are output, trouble cannot be determined only by the DTCs. Perform troubleshooting according to "HOW TO PROCEED WITH TROUBLESHOOTING" (See page CA-8). (a) ECM (2AZ-FE) Detection Item High speed CAN Communication Bus HINT: • DTC communication is via the CAN communication system. • *: The ECM is malfunctioning if only U0101 is output. Replace the ECM. (b) ECM (2GR-FE) DTC No. U0101* Detection Item High speed CAN Communication Bus HINT: • DTC communication is via the CAN communication system. • *: The ECM is malfunctioning if only U0101 is output. Refer to SFI system (See page ES-389). (c) ECT (2AZ-FE) DTC No. U0100* Detection Item High speed CAN Communication Bus HINT: • DTC communication is via the CAN communication system. • *: The ECM is malfunctioning if only U0100 is output. Replace the ECM. (d) ECT (2GR-FE) DTC No. U0100* Detection Item High speed CAN Communication Bus HINT: • DTC communication is via the CAN communication system. CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CA–29 • *: The ECM is malfunctioning if only U0100 is output. Refer to Automatic Transaxle system (See page AX-151). (e) SKID CONTROL ECU (with VSC) DTC No. Detection Item U0073 Control Module Communication Bus Off U0100 Lost Communication With ECM/PCM "A" U0123 Lost Communication With Yaw Rate Sensor Module U0124* Lost Communication With Lateral Acceleration Sensor Module U0126 Lost Communication With Steering Angle Sensor Module (f) HINT: • DTC communication is via the CAN communication system. • *: TMC made only SKID CONTROL ECU (without VSC) DTC No. U0073 Detection Item Control Module Communication Bus Off HINT: DTC communication is via the CAN communication system. (g) COMBINATION METER ECU DTC No. Detection Item U0100 Lost Communication With ECM/PCM "A" U0129 Lost Communication with Brake System Control Mode HINT: DTC communication is via the CAN communication system. (h) AIR CONDITIONER AMPLIFIER DTC No. B1499 Detection Item Multiplex Communication Circuit (i) DTC No. HINT: DTC communication is via the CAN communication system. MAIN BODY ECU (with smart key system) Detection Item B1207* Certification ECU Communication Malfunction B2326* CAN MS Bus Line Communication Malfunction (j) HINT: • DTC communication is via the CAN communication system. • *: The main body ECU is malfunctioning if B1207 and/or B2326 are output alone. Refer to DTC chart (See page AX-46). MAIN BODY ECU (without smart key system) HINT: Although the center airbag sensor is connected to the CAN communication system, CAN communication DTCs are not output. CA CA–30 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 4. (k) CENTER AIRBAG SENSOR HINT: Although the center airbag sensor is connected to the CAN communication system, CAN communication DTCs are not output. (l) CERTIFICATION ECU HINT: Although the Main Body ECU is connected to the CAN communication system, CAN communication DTCs are not output. DTC COMBINATION TABLE (a) with VSC SYSTEM DTC Output from Trouble Mode U0073 U0100 CA ECM Communication Stop Mode Skid Control ECU Communication Stop Mode Steering Angle Sensor Communication Stop Mode Yaw Rate Sensor Communication Stop Mode X X X X X X Output DTC Skid Control ECU Combination Meter ECU Air Conditioner Amplifier ECU During driving During driving U0123 X { X { U0124* X { X { U0126 X { { X U0100 { X X X U0129 X { X X B1499 X X X X X X X X No DTC *: TMC made only. HINT: • {: Set • X: Not set or may be set according to the malfunctioning part when one side of the CAN bus wire opens • : Set under the condition shown in the table above DTC Output from Skid Control ECU Combination Meter ECU Air Conditioner Amplifier ECU No DTC Trouble Mode Output DTC Air Conditioner Amplifier ECU Communication Stop Mode Center Airbag Sensor Communication Stop Mode Main Body ECU Communication Stop Mode Combination Meter ECU Communication Stop Mode U0073 X X X X U0100 X X X X U0123 X X X X U0124* X X X X U0126 X X X X U0100 X X X X U0129 X X X X B1499 X X { { X X *: TMC made only. HINT: • {: Set CA–31 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM • X: Not set or may be set according to the malfunctioning part when one side of the CAN bus wire opens • : Set under the condition shown in the table above (b) without VSC SYSTEM DTC Output from Trouble Mode ECM Communicatio n Stop Mode Skid Control ECU Communicatio n Stop Mode Combination Meter ECU Communicatio n Stop Mode Air Conditioner Amplifier ECU Communicatio n Stop Mode Center Airbag Sensor Communicatio n Stop Mode Main Body ECU Communicatio n Stop Mode U0073 X X X X X X Output DTC Skid Control ECU Combination Meter ECU Air Conditioner Amplifier ECU No DTC U0100 { X X X X X U0129 X { X X X X B1499 X X X X X X { { X X HINT: • {: Set • X: Not set or may be set according to the malfunctioning part when one side of the CAN bus wire becomes open. (c) Perform troubleshooting depending on the combination of DTCs output. HINT: • ECM Communication Stop Mode (See Page CA54) • Skid Control ECU Communication Stop Mode (See page CA-42) • Steering Angle Sensor Communication Stop Mode (See page CA-49) • Yaw Rate Sensor Communication Stop Mode (See page CA-51) • Combination Meter ECU Communication Stop Mode (See page CA-61) • Center Airbag Sensor Communication Stop Mode (See page CA-63) • Air Conditioner Amplifier ECU Communication Stop Mode (See page CA-46) • Main Body ECU Communication Stop Mode (See page CA-57) CA CA–32 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM FAIL-SAFE CHART 1. Function CA VSC control (Controls driving force while VSC in operation) TRC control (Controls driving force and engine power when wheel slip detected during acceleration) ECM { { Skid Control ECU (Without VSC) - - FAIL-SAFE FUNCTION (a) When communication fails in any of the CAN bus wire (communication lines) due to a short circuit or other causes, a fail-safe functions, will operate. The fail-safe function that is specified for each system operates to prevent those systems from malfunctioning. (b) The following chart shows the relationships between components and system functions and effects of communication failure on these functions. (For further details, see the pages for each system.) Skid Control ECU (With VSC) z z Steering Sensor { - Yaw Rate Sensor Condition when communication impossible DTC detection (Driver detectable) { Control inoperative (gradually stops controlling during VSC control) Detectable (Light comes on) - Control inoperative (gradually stops controlling during TRC control) Detectable (Light comes on) Detectable (Light comes on) ABS control (Controls driving force while ABS in operation) { z z - { *1 Control is inoperative (gradually stops controlling during ABS control) Security function - - - - - Theft deterrent system cannot be set Detectable (Indicator light does not comes on) Air conditioning control { - - - - Air conditioning function stops None (Air conditioning inoperative) Detectable (Abnormal display) Meter Display (Displays operation condition and DTCs) { { { *2 - - Light does not come on, illuminates abnormally, or blinks abnormally Buzzer control { { { *2 - - Buzzer function stops Detectable (Buzzer does not sound) Illumination control { - - - - Light illumination rheostat inoperative None (Rheostat inoperative) - - - - - Unlock permitted None (Wireless door lock operation) Smart entry / Power door lock control*3 HINT: • z: Control master • {: System related • *1: TMC made CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CA–33 • *2: TMMK made • *3: with smart key system Function VSC control (Controls driving force while VSC in operation) TRC control (Controls driving force and engine power when wheel slip detected during acceleration) ABS control (Controls driving force while ABS in operation) Center Airbag Sensor Assembly - - - Air Conditioning Amplifier - - - Combination Meter ECU - - - Main Body ECU - - - Certification ECU*3 Condition when communication on impossible DTC detection (Driver detectable) - Control inoperative (gradually stops controlling during VSC control) Detectable (Light comes on) - Control inoperative (gradually stops controlling during TRC control) Detectable (Light comes on) - Control is inoperative (gradually stops controlling during ABS control) Detectable (Light comes on) Detectable (Indicator light does not comes on) Security function - - - { z Theft deterrent system cannot beset Air conditioning control - z { { - Air conditioning function stops None (Air conditioning inoperative) Detectable (Abnormal display) Meter Display (Displays operation condition and DTCs) { - z { { Light does not come on, illuminates abnormally, or blinks abnormally Buzzer control { - z - - Buzzer function stops Detectable (Buzzer does not sound) Illumination control - - { z - Light illumination rheostat inoperative None (Rheostat inoperative) - - { { z Unlock permitted None (Wireless door lock operation) Smart entry / Power door lock control*3 HINT: • z: Control master • {: System related • *3: with smart key system CA CA–34 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM DIAGNOSTIC TROUBLE CODE CHART CAN COMMUNICATION SYSTEM DTC No. CA Detection Item Trouble Area See page B1207 Certification ECU Communication Malfunction 1. CAN MS bus wire or connector 2.Certification ECU power source circuit 3. Certification ECU 4. Main Body ECU CA-32 B2326 CAN MS Bus Line Communication Malfunction 1. CAN MS bus wire or connector 2.Certification ECU power source circuit 3. Certification ECU 4. Main Body ECU CA-32 CA–35 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM DTC B1207 Certification ECU Communication Malfunction DTC B2326 CAN MS Bus Line Communication Malfunction DESCRIPTION The Main Body ECU and Certification ECU perform 2-way communication with each other via the Controller Area Network (CAN). If the Certification ECU cannot communicate with the Main Body ECU, the Main Body ECU will conclude that there is a malfunction in the CAN system, and set a DTC. DTC No. B1207 B2326 DTC Detection Condition No communication from certification ECU continues Trouble Area • • • • CAN MS bus wire or connector Certification ECU power source circuit Certification ECU Main body ECU WIRING DIAGRAM E58 Certification ECU CA E8 Main Body ECU EFI No. 1 +B CANH E L CANP W CANL 120 Ω : CAN MS Bus Line (CANP) CANN 120 Ω Trouble Area : CAN MS Bus Line (CANN) C133252E01 INSPECTION PROCEDURE NOTICE: • Turn the ignition switch off before measuring the resistance of the CAN main wire and CAN branch wires. • After the ignition switch is turned off, check that the key reminder warning system and light reminder warning system are not operating. • Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. If doors need to be opened in order to check connectors, open the doors and leave them open. CA–36 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM HINT: Operating the ignition switch, any other switches or any triggers related ECU and sensor communication on the CAN, which would cause resistance reading variations. 1 CHECK CAN MS BUS WIRE (a) Turn the ignition switch off. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Certification ECU Connector: E58 CANL CANH CA B139430E05 Tester Connection Condition Specified Condition Proceed to E58-27 (CANH) E58-28 (CANL) Ignition switch off 54 to 69 Ω A E58-27 (CANH) E58-28 (CANL) Ignition switch off 69 Ω or more B E58-27 (CANH) E58-28 (CANL) Ignition switch off 54 Ω or less C B Go to step 9 C Go to step 11 A 2 CHECK SHORT TO +B IN CAN MS BUS WIRE (a) Turn the ignition switch off. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Certification ECU Connector: E58 CANL CANH Condition Specified Condition E58-27 (CANH) - E58-1 (+B) Ignition switch off 6 kΩ or higher E58-2 (CANL) - E58-1 (+B) Ignition switch off 6 kΩ or higher NG +B B139430E06 OK Tester Connection Go to step 5 CA–37 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 3 CHECK SHORT TO GND IN CAN MS BUS WIRE (a) Turn the ignition switch off. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Certification ECU Connector: E58 Tester Connection Condition Specified Condition E58-27 (CANH) - E58-17 (E) Ignition switch off 200 Ω or higher E58-28 (CANL) - E58-17 (E) Ignition switch off 200 Ω or higher NG CANL E Go to step 7 CANH B139430E07 CA OK 4 CHECK CERTIFICATION ECU (POWER SOURCE CIRCUIT) (a) Turn the ignition switch off. (b) Disconnect the E58 certification ECU connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Certification ECU Connector +B E58 Tester Connection Condition Specified Condition E58-17 (E) - Body ground Always Below 1 Ω (d) Measure the voltage according to the value(s) in the table below. Standard voltage E ACC IG C136713E06 Tester Connection Condition Specified Condition E58-1 (B) - Body ground Always 10 to 14 V E58-18 (IG) - Body ground Ignition switch on (IG) 10 to 14 V E58-19 (ACC) - Body ground Ignition switch on (ACC) 10 to 14 V OK REPLACE CERTIFICATION ECU NG REPAIR OR REPLACE HARNESS OR CONNECTOR (FUSES - ECU, ECU - BODY GROUND) CA–38 5 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CHECK SHORT TO +B IN CAN MS BUS WIRE (CERTIFICATION ECU) (a) Turn the ignition switch off. (b) Disconnect the E58 certification ECU connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Certification ECU Connector (Wire Harness Side): E58 +B Tester Connection Condition Specified Condition E58-27 (CANH) - E58-1 (+B) Ignition switch off 6 kΩ or higher E58-28 (CANL) - E58-1 (+B) Ignition switch off 6 kΩ or higher OK CANL REPLACE CERTIFICATION ECU CANH C136713E02 CA NG 6 CHECK SHORT TO +B IN CAN MS BUS WIRE (CERTIFICATION ECU - MAIN BODY ECU) (a) Turn the ignition switch off. (b) Disconnect the E8 main body ECU connector. Main Body ECU: E8 C140857E01 CA–39 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM (c) Measure the resistance according to the value(s) in the table below. HINT: The resistance must be measured after the E58 certification ECU connector is disconnected. Standard resistance Certification ECU Connector (Wire Harness Side): E58 +B CANL CANH Tester Connection Condition Specified Condition E58-27 (CANH) - E58-1 (+B) Ignition switch off 6 kΩ or higher E58-28 (CANL) - E58-1 (+B) Ignition switch off 6 kΩ or higher OK REPLACE MAIN BODY ECU C136713E02 NG REPAIR OR REPLACE CAN MS BUS MAIN WIRE OR CONNECTOR 7 CHECK SHORT TO GND IN CAN MS BUS WIRE (CERTIFICATION ECU) (a) Turn the ignition switch off. (b) Disconnect the E58 certification ECU connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Certification ECU Connector (Wire Harness Side): E58 E CANL Tester Connection Condition Specified Condition E58-27 (CANH) - E58-17 (E) Ignition switch off 6 kΩ or higher E58-28 (CANL) - E58-17 (E) Ignition switch off 6 kΩ or higher OK CANH C136713E03 NG CA REPLACE CERTIFICATION ECU CA–40 8 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CHECK SHORT TO GND IN CAN MS BUS WIRE (a) Turn the ignition switch off. (b) Disconnect the E8 main body ECU connector. Main Body ECU: E8 CA C140857E01 (c) Measure the resistance according to the value(s) in the table below. HINT: The resistance must be measured after the E58 certification ECU connector is disconnected. Standard resistance Certification ECU Connector (Wire Harness Side): E58 E CANL CANH Tester Connection Condition Specified Condition E58-27 (CANH) - E58-17 (E) Ignition switch off 6 kΩ or higher E58-28 (CANL) - E58-17 (E) Ignition switch off 6 kΩ or higher OK REPLACE MAIN BODY ECU C136713E03 NG REPAIR OR REPLACE CAN MS BUS MAIN WIRE OR CONNECTOR CA–41 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 9 CHECK CAN MS BUS MAIN WIRE OR CONNECTOR (CERTIFICATION ECU) (a) Turn the ignition switch off. (b) Disconnect the E58 certification ECU connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Certification ECU Connector (Wire Harness Side): E58 Tester Connection Condition Specified Condition E58-27 (CANH) - E58-28 (CANL) Ignition switch off 108 to 132 Ω or higher OK REPLACE CERTIFICATION ECU E CANL CANH C136713E03 NG CA CA–42 10 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CHECK CAN MS BUS MAIN WIRE OR CONNECTOR (CERTIFICATION ECU - MAIN BODY ECU) (a) Turn the ignition switch off. (b) Disconnect the E8 main body ECU connector. (c) Measure the resistance according to the value(s) in the table below. HINT: The resistance must be measured after the E58 certification ECU connector is disconnected. Standard resistance Certification ECU Connector (Wire Harness Side): E58 CANL CANH Main Body ECU Connector (Wire Harness Side): Tester Connection Condition Specified Condition E58-27 (CANH) - E8-16 (CANP) Always Below 1 Ω E58-28 (CANL) - E8-15 (CANN) Always Below 1 Ω OK REPLACE MAIN BODY ECU CA E8 CANN CANP C133244E01 NG REPAIR OR REPLACE CAN MS BUS MAIN WIRE OR CONNECTOR CA–43 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 11 CHECK SHORT IN CAN MS BUS WIRES (CERTIFICATION ECU) (a) Turn the ignition switch off. (b) Disconnect the E58 certification ECU connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Certification ECU Connector (Wire Harness Side): E58 Tester Connection Condition Specified Condition E58-27 (CANH) - E58-28 (CANL) Ignition switch off 108 to 132 Ω or higher OK REPLACE CERTIFICATION ECU E CANL CANH C136713E03 CA NG 12 CHECK SHORT IN CAN MS BUS WIRES (a) Turn the ignition switch off. (b) Disconnect the E8 main body ECU connector. Main Body ECU: E8 C140857E01 CA–44 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM (c) Measure the resistance according to the value(s) in the table below. HINT: The resistance must be measured after the E58 certification ECU connector is disconnected. Standard resistance Certification ECU Connector (Wire Harness Side): E58 E CANL Tester Connection Condition Specified Condition E58-27 (CANH) - E58-28 (CANL) Ignition switch off 1 MΩ or higher OK REPLACE MAIN BODY ECU CANH C136713E03 NG CA REPAIR OR REPLACE CAN MS BUS MAIN WIRE OR CONNECTOR CA–45 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM Skid Control ECU Communication Stop Mode DESCRIPTION Detection Item Symptom • Skid Control ECU Communication Stop Mode • Trouble Area "ABS/VSC/TRC" is not displayed on the "Communication Bus Check" screen of the intelligent tester Applies to "Skid Control ECU Communication Stop Mode" in the "DTC COMBINATION TABLE" • • • Power source circuit of skid control ECU Skid control ECU branch wire or connector Brake actuator assembly (Skid control ECU) WIRING DIAGRAM without VSC: DLC3 Combination Meter ECU 120 Ω ECM No. 2 CAN J/C No. 1 CAN J/C 26 CANH 15 CANL ECU-IG No. 2 18 IG1 GND2 GND1 CA 120 Ω 1 4 A25 Skid Control ECU Trouble Area : CAN Main Bus Wire (CANH) : CAN Branch Wire (CANH) : CAN Main Bus Wire (CANL) : CAN Branch Wire (CANL) C126207E07 CA–46 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM with VSC: DLC3 Combination Meter ECU 120 Ω ECM No. 1 CAN J/C No. 2 CAN J/C 25*1 11*1 14*2 35*2 CANH CANL ECU-IG No. 2 CA 46*1 28*2 IG1 GND2 GND1 A26*1 Skid Control ECU A60*2 120 Ω 1 32*1 4*2 *1: TMC made *2: TMMK made Trouble Area : CAN Main Bus Line (CANH) : CAN Branch Line (CANH) : CAN Main Bus Line (CANL) : CAN Branch Line (CANL) C126207E08 INSPECTION PROCEDURE NOTICE: • Turn the ignition switch off before measuring the resistance of the CAN main wire and CAN branch wires. • After the ignition switch is turned off, check that the key reminder warning system and light reminder warning system are not operating. • Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. If doors need to be opened in order to check connectors, open the doors and leave them open. HINT: Operating the ignition switch, any other switches or any triggers related ECU and sensor communication on the CAN, which would cause resistance reading variations. 1 CHECK OPEN IN CAN BUS WIRE (SKID CONTROL ECU BRANCH WIRE) (a) Turn the ignition switch off. (b) Disconnect the skid control ECU connector. CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CA–47 (c) Measure the resistance according to the value(s) in the table below. Standard resistance: without VSC Skid Control ECU Connector (Front View): A25 without VSC: Tester Connection Condition Specified Value A25-26 (CANH) - A25-15 (CANL) Ignition switch off 54 to 69 Ω with VSC (TMC made) CANL CANH Tester Connection Condition Specified Value A26-11 (CANH) - A26-25 (CANL) Ignition switch off 54 to 69 Ω with VSC (TMMK made) with VSC (TMC Made): A26 Tester Connection Condition Specified Value A60-35 (CANH) - A60-14 (CANL) Ignition switch off 54 to 69 Ω NG CANH CANL with VSC (TMMK Made): A60 CANL CANH C133241E01 OK REPAIR OR REPLACE SKID CONTROL ECU BRANCH WIRE OR CONNECTOR (CAN-H, CAN-L) CA CA–48 2 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CHECK WIRE HARNESS (IG1, GND1, GND2) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: without VSC Skid Control ECU Connector (Front View): A25 without VSC: Tester Connection Condition Specified Value A25-4 (GND1) - Body ground Always Below 1 Ω A25-1 (GND2) - Body ground Always Below 1 Ω Tester Connection Condition Specified Value A26-32 (GND1) - Body ground Always Below 1 Ω A26-1 (GND2) - Body ground Always Below 1 Ω with VSC (TMC made) GND2 GND1 IG1 with VSC (TMC Made): A26 CA with VSC (TMMK made) GND2 GND1 IG1 with VSC (TMMK Made): A60 GND2 GND1 Tester Connection Condition Specified Value A60-4 (GND1) - Body ground Always Below 1 Ω A60-1 (GND2) - Body ground Always Below 1 Ω (b) Measure the voltage according to the value(s) in the table below. Standard voltage: without VSC IG1 Tester Connection Condition Specified Value A25-18 (IG1) - Body ground Ignition switch on (IG) 10 to 14 V with VSC (TMC made) C133241E02 Tester Connection Condition Specified Value A26-46 (IG1) - Body ground Ignition switch on (IG) 10 to 14 V with VSC (TMMK made) Tester Connection Condition Specified Value A60-28 (IG1) - Body ground Ignition switch on (IG) 10 to 14 V NG OK REPLACE BRAKE ACTUATOR ASSEMBLY REPAIR OR REPLACE HARNESS OR CONNECTOR CA–49 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM Air Conditioning Amplifier Communication Stop Mode DESCRIPTION Detection Item Symptom • Air Conditioning Amplifier Communication Stop Mode • Trouble Area "Air Conditioner" not displayed on "Communication Bus Check" screen of intelligent tester Applies to "Air Conditioning Amplifier Communication Stop Mode" in "DTC combination table" • • • Power source circuit of the air conditioning amplifier Air conditioning amplifier branch wire or connector Air conditioning amplifier WIRING DIAGRAM DLC3 ECM Combination Meter 120 Ω No. 1 CAN J/C No. 2 CAN J/C 11 12 CANH CANL A/C A/C No. 2 GND 21 B 1 CA 120 Ω 14 IG+ E38 A/C Amplifier Trouble Area : CAN Main Bus Wire (CANH) : CAN Branch Wire (CANH) : CAN Main Bus Wire (CANL) : CAN Branch Wire (CANL) C133239E01 INSPECTION PROCEDURE NOTICE: • Turn the ignition switch off before measuring the resistance of the CAN main wire and CAN branch wires. • After the ignition switch is turned off, check that the key reminder warning system and light reminder warning system are not operating. CA–50 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM • Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. If doors need to be opened in order to check connectors, open the doors and leave them open. HINT: Operating the ignition switch, any other switches or any triggers related ECU and sensor communication on the CAN, which would cause resistance reading variations. 1 CHECK CAN BUS LINE FOR DISCONNECTION (AIR CONDITIONING AMPLIFIER BRANCH WIRE) Air Conditioning Amplifier (Wire Harness Side): E38 CA (a) Turn the ignition switch off. (b) Disconnect the air conditioning amplifier connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition E38-11 (CANH) - E38-12 (CANL) Ignition Switch off 54 to 69 Ω NG CANH CANL REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO AIR CONDITIONING AMPLIFIER (CAN-H, CAN-L) E124470E21 OK 2 CHECK HARNESS AND CONNECTOR (IG+, B, GND) Air Conditioning Amplifier (Wire Harness Side): E38 (a) Disconnect the air conditioning amplifier connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition E38-14 (GND) - Body Ground Always Below 1 Ω (c) Measure the voltage according to the value(s) in the table below. Standard voltage GND B IG+ E124470E22 Tester Connection Condition Specified Condition E38-1 (IG+) - Body Ground Ignition Switch on (IG) 10 to 14 V E38-21 (B)- Body Ground Always 10 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CA–51 OK REPLACE AIR CONDITIONING AMPLIFIER CA CA–52 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM Steering Angle Sensor Communication Stop Mode DESCRIPTION Detection Item Symptom • Steering Angle Sensor Communication Stop Mode Trouble Area "Steering Angle Sensor" is not displayed on the "Communication Bus Check" screen of the intelligent tester Applies to "Steering Angle Sensor Communication Stop Mode" in the "DTC COMBINATION TABLE" • • • • Power source circuit of the steering angle sensor Steering angle sensor branch wire or connector Steering angle sensor WIRING DIAGRAM DLC3 Combination Meter ECM CA 120 Ω No. 1 CAN J/C No. 2 CAN J/C 10 CANH ECU-IG LH 1 120 Ω 9 CANL IG ESS 2 E17 Steering Angle Sensor Trouble Area : CAN Main Bus Wire (CANH) : CAN Branch Wire (CANH) : CAN Main Bus Wire (CANL) : CAN Branch Wire (CANL) C126215E03 INSPECTION PROCEDURE NOTICE: • Turn the ignition switch off before measuring the resistance of the CAN main wire and CAN branch wires. • After the ignition switch is turned off, check that the key reminder warning system and light reminder warning system are not operating. CA–53 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM • Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. If doors need to be opened in order to check connectors, open the doors and leave them open. HINT: Operating the ignition switch, any other switches or any triggers related ECU and sensor communication on the CAN, which would cause resistance reading variations. 1 CHECK OPEN IN CAN BUS WIRE (STEERING ANGLE SENSOR BRANCH LINE) (a) Turn the ignition switch off. (b) Disconnect the steering angle sensor connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Steering Angle Sensor Connector (Wire Harness View): Tester Connection Condition Specified Value E17-10 (CANH) - E17-9 (CANL) Ignition switch off 54 to 69 Ω NG CANH CANL REPAIR OR REPLACE STEERING ANGLE SENSOR BRANCH WIRE OR CONNECTOR (CANH, CANL) E17 G030155E40 OK 2 CHECK WIRE HARNESS (IG, ESS) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Steering Angle Sensor Connector (Wire Harness View): ESS Tester Connection Condition Specified Value E17-2 (ESS) - Body ground Always Below 1 Ω (b) Measure the voltage according to the value(s) in the table below. Standard voltage E17 IG G030155E41 OK REPLACE STEERING ANGLE SENSOR Tester Connection Condition Specified Value E17-1 (IG) - Body ground Ignition switch on (IG) 10 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR CA CA–54 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM Yaw Rate Sensor Communication Stop Mode DESCRIPTION Detection Item Symptom • Yaw Rate Sensor Communication Stop Mode Trouble Area "Yaw Rate/Decelerate Sensor" is not displayed on the "Communication Bus Check" screen of the intelligent tester Applies to "Yaw Rate Sensor Communication Stop Mode" in the "DTC COMBINATION TABLE" • • • • Power source circuit of the yaw rate sensor Yaw rate sensor branch wire or connector Yaw rate sensor WIRING DIAGRAM DLC3 Combination Meter ECM CA 120 Ω No. 1 CAN J/C No. 2 CAN J/C 3 CANH ECU-IG LH 5 120 Ω 2 CANL IG GND 1 E34 Yaw Rate Sensor Trouble Area : CAN Main Bus Wire (CANH) : CAN Branch Wire (CANH) : CAN Main Bus Wire (CANL) : CAN Branch Wire (CANL) C126215E04 INSPECTION PROCEDURE NOTICE: • Turn the ignition switch off before measuring the resistance of the CAN main wire and CAN branch wires. • After the ignition switch is turned off, check that the key reminder warning system and light reminder warning system are not operating. CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CA–55 • Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. If doors need to be opened in order to check connectors, open the doors and leave them open. HINT: Operating the ignition switch, any other switches or any triggers related ECU and sensor communication on the CAN, which would cause resistance reading variations. 1 CHECK OPEN IN CAN BUS WIRE (YAW RATE SENSOR BRANCH LINE) Yaw Rate Sensor Connector (Front View): TMC Made: E34 CANL CANH TMMK Made: (a) Turn the ignition switch off. (b) Disconnect the yaw rate sensor connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: TMC made Tester Connection Condition Specified Value E34-3 (CANH) - E34-2 (CANL) Ignition switch off 54 to 69 Ω Tester Connection Condition Specified Value E65-3 (CANL) - E65-2 (CANH) Ignition switch off 54 to 69 Ω TMMK made E65 NG CANH CANL C133237E01 OK REPAIR OR REPLACE YAW RATE SENSOR BRANCH WIRE OR CONNECTOR (CANH, CANL) CA CA–56 2 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CHECK WIRE HARNESS (IG, GND) Yaw Rate Sensor Connector (Front View): TMC Made: E34 (a) Measure the resistance according to the value(s) in the table below. Standard resistance: TMC made Tester Connection Condition Specified Value E34-1 (GND) - Body ground Always Below 1 Ω Tester Connection Condition Specified Value E65-4 (GND) - Body ground Always Below 1 Ω TMMK made GND IG TMMK Made: (b) Measure the voltage according to the value(s) in the table below. Standard voltage: TMC made E65 CA IG1 GND C133237E02 Tester Connection Condition Specified Value E34-5 (IG) - Body ground Ignition switch on (IG) 10 to 14 V Tester Connection Condition Specified Value E65-1 (IG1) - Body ground Ignition switch on (IG) 10 to 14 V TMMK made NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE YAW RATE AND ACCELERATION SENSOR CA–57 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM ECM Communication Stop Mode DESCRIPTION Detection Item Symptom • ECM Communication Stop Mode • Trouble Area "Engine" and "ECT" are not displayed on the "Communication Bus Check" screen of the intelligent tester Applies to "ECM Communication Stop Mode" in the "DTC COMBINATION TABLE" • • • Power source circuit of the ECM ECM main bus wire or connector ECM WIRING DIAGRAM 2AZ-FE: : CAN Main Bus Wire (CANH) : CAN Main Bus Wire (CANL) CA : CAN Branch Wire (CANH) : CAN Branch Wire (CANL) Trouble Area DLC3 Combination Meter ECM To EFI MAIN Relay 1 +B2 A24 2 +B A24 120 Ω No. 1 CAN J/C No. 2 CAN J/C 120 Ω 104 E1 A24 C126217E08 CA–58 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 2GR-FE: : CAN Main Bus Wire (CANH) : CAN Main Bus Wire (CANL) : CAN Branch Wire (CANH) : CAN Branch Wire (CANL) Trouble Area DLC3 Combination Meter ECM To EFI MAIN Relay 1 +B2 A55 CA 2 +B A55 120 Ω No. 1 CAN J/C No. 2 CAN J/C 120 Ω 81 E1 C55 C126217E09 INSPECTION PROCEDURE NOTICE: • Turn the ignition switch off before measuring the resistance of the CAN main wire and CAN branch wires. • After the ignition switch is turned off, check that the key reminder warning system and light reminder warning system are not operating. • Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. If doors need to be opened in order to check connectors, open the doors and leave them open. HINT: Operating the ignition switch, any other switches or any triggers related ECU and sensor communication on the CAN, which would cause resistance reading variations. CA–59 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 1 CHECK CAN BUS LINE FOR DISCONNECTION (ECU MAIN BUS LINE) ECM Connector (Front View): A24 *1 A55 *2 CANH *1: 2AZ-FE *2: 2GR-FE (a) Reconnect the CAN main bus line connector (A40) to the No. 2 CAN J/C (front side of the vehicle). (b) Disconnect the ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: 2AZ-FE Tester Connection CANL G100098E13 A24-38 (CANH) - A24-46 (CANL) Condition Specified Value Ignition switch off 108 to 132 Ω Condition Specified Value Ignition switch off 108 to 132 Ω 2GR-FE Tester Connection A55-38 (CANH) - A55-46 (CANL) NG REPAIR OR REPLACE CAN MAIN WIRE OR CONNECTOR OK 2 CHECK ECM POWER SOURCE CIRCUIT (a) Check the ECM power source circuit (2AZ-FE: See page ES-380 or 2GR-FE: See page ES-432) NG OK REPLACE ECM REPAIR OR REPLACE ECM POWER SOURCE CIRCUIT CA CA–60 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM Main Body ECU Communication Stop Mode DESCRIPTION Detection Item Symptom • Main Body ECU Communication Stop Mode • Trouble Area "Integrated J/B" not displayed on "Communication Bus Check" screen of the intelligent tester Applies to "Main Body ECU Communication Stop Mode" in "DTC combination table" • • • Power source circuit of the main body ECU Main body ECU branch wire or connector Main body ECU WIRING DIAGRAM without Smart Key System: DLC3 Combination Meter ECM CA 120 Ω No. 1 CAN J/C No. 2 CAN J/C 120 Ω E8 E8 6 CANH CANL 5 ECU-IG 11 1F IG ECU-B 1 1F BECU* GND1 Main Body ECU 1F *: TMC Mode Trouble Area : CAN Main Bus Line (CANH) : CAN Branch Line (CANH) : CAN Main Bus Line (CANL) : CAN Branch Line (CANL) C133247E01 CA–61 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM with Smart Key System: DLC3 Combination Meter ECM 120 Ω No. 1 CAN J/C AM2 No. 2 CAN J/C 120 Ω E8 6 5 E8 CANH CANL 6 E7 AM1 1 E6 AM2 4 GND3 F8 CA Main Body ECU Trouble Area : CAN Main Bus Line (CANH) : CAN Branch Line (CANH) : CAN Main Bus Line (CANL) : CAN Branch Line (CANL) C133291E01 INSPECTION PROCEDURE NOTICE: • Turn the ignition switch off before measuring the resistance of the CAN main wire and CAN branch wires. • After the ignition switch is turned off, check that the key reminder warning system and light reminder warning system are not operating. • Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. If doors need to be opened in order to check connectors, open the doors and leave them open. HINT: Operating the ignition switch, any other switches or any triggers related ECU and sensor communication on the CAN, which would cause resistance reading variations. CA–62 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 1 CHECK CAN BUS LINE FOR DISCONNECTION (MAIN BODY ECU BRANCH WIRE) Main Body ECU Connector (Front View): E8 (a) Turn the ignition switch off. (b) Disconnect the main body ECU connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition E8-5 (CANH) - E8-6 (CANL) Ignition switch off 54 to 69 Ω CANH CANL NG REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO MAIN BODY ECU (CAN-H, CAN-L) CA B137983E02 OK 2 CHECK HARNESS AND CONNECTOR (BECU, IG, GND1) (a) without Smart Key System (1) Disconnect the 1F J/B connector. (2) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side: Tester Connection Condition Specified Condition 1F-10 (GND1) - Body ground Always Below 1 Ω (3) Measure the voltage according to the value(s) in the table below. Standard voltage 1F GND1 IG BECU C133238E01 Tester Connection Condition Specified Condition 1F-1 (BECU)* - Body ground Always 10 to 14 V 1F-11 (IG) - Body ground Ignition switch on (IG) 10 to 14 V *: TMC Made only (4) Reconnect the J/B connector. CA–63 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM Main Body ECU Connector (Front View): E8 (b) with Smart Key System (1) Disconnect the E8 main body ECU connector. (2) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition E8-4 (GND3) - Body ground Always Below 1 Ω GND3 CA B137983E03 (3) Disconnect the E6 and E7 main body ECU connectors. (4) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness Side: E7 Main Body ECU AM1 Tester Connection Condition Specified Condition E7-6 (AM1) - Body ground Always 10 to 14 V E6-1 (AM2) - Body ground Always 10 to 14 V *: TMC Made only (5) Reconnect the main body ECU connectors. NG E6 AM2 B138000E01 OK REPLACE MAIN BODY ECU REPAIR OR REPLACE HARNESS OR CONNECTOR CA–64 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM Combination Meter ECU Communication Stop Mode DESCRIPTION Detection Item Symptom • Combination Meter ECU Communication Stop Mode • Trouble Area "Combination Meter" not displayed on "Communication Bus Check" screen of intelligent tester Applies to "Combination Meter ECU Communication Stop Mode" in "DTC combination table" • • • Power source circuit of the combination meter Combination meter main bus wire or connector Combination meter WIRING DIAGRAM : CAN Main Bus Wire (CANH) : CAN Main Bus Wire (CANL) CA : CAN Branch Wire (CANH) : CAN Branch Wire (CANL) Trouble Area DLC3 F1 Combination Meter GAUGE No. 2 MPX-B DOME 13 1 2 24 ECM IG+ B B2 ES 120 Ω No. 1 CAN J/C No. 2 CAN J/C 120 Ω C126214E03 INSPECTION PROCEDURE NOTICE: • Turn the ignition switch off before measuring the resistance of the CAN main wire and CAN branch wires. • After the ignition switch is turned off, check that the key reminder warning system and light reminder warning system are not operating. CA–65 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM • Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. If doors need to be opened in order to check connectors, open the doors and leave them open. HINT: Operating the ignition switch, any other switches or any triggers related ECU and sensor communication on the CAN, which would cause resistance reading variations. 1 CHECK CAN BUS LINE FOR DISCONNECTION (COMBINATION METER MAIN BUS WIRE) (a) Turn the ignition switch off. (b) Disconnect the combination meter connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Combination Meter Connector (Wire Harness Side View): F1 Tester Connection Condition Specified Condition F1-17 (CANH) - F1-18 (CANL) Ignition switch off 108 to 132 Ω NG CANL REPAIR OR REPLACE CAN BUS MAIN WIRE OR CONNECTOR (COMBINATION METER MAIN BUS LINE) CANH C133243E01 OK 2 CHECK HARNESS AND CONNECTOR (ES, IG+, B2) (a) Disconnect the combination meter connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Combination Meter Connector (Wire Harness Side View): F1 Condition Specified Condition F1-24 (ES) - Body ground Always Below 1 Ω (c) Measure the voltage according to the value(s) in the table below. Standard voltage B2 ES Tester Connection IG+ Tester Connection Condition Specified Condition F1-13 (IG+) - Body ground Ignition switch on (IG) 10 to 14 V F1-2 (B2) - Body ground Always 10 to 14 V C133243E02 NG OK REPLACE COMBINATION METER ECU REPAIR OR REPLACE HARNESS OR CONNECTOR CA CA–66 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM Center Airbag Sensor Communication Stop Mode DESCRIPTION Detection Item Symptom • Center Airbag Sensor Communication Stop Mode • Trouble Area "SRS Airbag" is not displayed on the "Communication Bus Check" screen of the intelligent tester Applies to "Center Airbag Sensor Communication Stop Mode" in the "DTC COMBINATION TABLE" • • • Power source circuit of the center airbag sensor Center airbag sensor branch wire or connector Center airbag sensor WIRING DIAGRAM DLC3 Combination Meter ECM CA 120 Ω No. 1 CAN J/C No. 2 CAN J/C 13 E30 CANH IGN E30 22 CANL 21 E30 IG2 120 Ω 25 E1 E30 26 E2 E30 Center Airbag Sensor Trouble Area : CAN Main Bus Wire (CANH) : CAN Branch Wire (CANH) : CAN Main Bus Wire (CANL) : CAN Branch Wire (CANL) C126212E03 INSPECTION PROCEDURE NOTICE: • Turn the ignition switch off before measuring the resistance of the CAN main wire and CAN branch wires. • After the ignition switch is turned off, check that the key reminder warning system and light reminder warning system are not operating. CA–67 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM • Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. If doors need to be opened in order to check connectors, open the doors and leave them open. HINT: Operating the ignition switch, any other switches or any triggers related ECU and sensor communication on the CAN, which would cause resistance reading variations. 1 CHECK OPEN IN CAN BUS WIRE (CENTER AIRBAG SENSOR BRANCH LINE) Center Airbag Sensor Wire Harness View: E30 CANH CANL C104732E06 (a) Turn the ignition switch off. (b) Disconnect the center airbag sensor connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Value E30-13 (CANH) - E30-22 (CANL) Ignition switch off 54 to 69 Ω NG REPAIR OR REPLACE CENTER AIRBAG SENSOR BRANCH WIRE OR CONNECTOR OK 2 CHECK WIRE HARNESS (IG2, E1, E2) Center Airbag Sensor Wire Harness View: E30 IG2 E2 E1 C104732E07 (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Value E30-25 (E1) - Body ground Always Below 1 Ω E30-26 (E2) - Body ground Always Below 1 Ω (b) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Value E30-21 (IG2) - Body ground Ignition switch on (IG) 10 to 14 V NG OK REPLACE CENTER AIRBAG SENSOR REPAIR OR REPLACE HARNESS OR CONNECTOR CA CA–68 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CAN Bus Line DESCRIPTION When any DTC of the CAN communication system is output, first measure the resistance between the terminals of the DLC3 to confirm the trouble area. CA CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CA–69 WIRING DIAGRAM : CAN Main Bus Wire (CANH) : CAN Main Bus Wire (CANL) *1: with Smart Key System *2: with VSC : CAN Branch Wire (CANH) : CAN Branch Wire (CANL) : CAN MS Bus Wire (CANH) : CAN MS Bus Wire (CANL) Combination Meter 120 Ω Certification ECU*1 120 Ω No. 1 CAN J/C 120 Ω Main Body ECU DLC3 CA Yaw Rate Sensor*2 Steering Angle Sensor*2 Center Airbag Sensor Assembly No. 2 CAN J/C (Rear of the Vehicle) A/C Amplifier Accessory Gateway Skid Control ECU with Actuator No. 2 CAN J/C (Front of the Vehicle) 120 Ω ECM C136704E04 CA–70 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM INSPECTION PROCEDURE NOTICE: • Turn the ignition switch off before measuring the resistance of the CAN main wire and CAN branch wires. • After the ignition switch is turned off, check that the key reminder warning system and light reminder warning system are not operating. • Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. If doors need to be opened in order to check connectors, open the doors and leave them open. HINT: Operating the ignition switch, any other switches or any triggers related ECU and sensor communication on the CAN, which would cause resistance reading variations. 1 CHECK CAN BUS WIRE (MAIN BUS WIRE FOR DISCONNECTION, BUS WIRES FOR SHORT CIRCUIT) DLC3: E10 (a) Measure the resistance according to the value(s) in the table below. Standard resistance CANH CA Tester Connection Condition Specified Value Result E10-6 (CANH) E10-14 (CANL) Ignition switch off 54 to 69 Ω OK Result CANL C126400E08 Result Proceed to OK A 69 Ω or higher B Below 54 Ω C B OPEN IN CAN BUS MAIN WIRE (See page CA-69) C SHORT IN CAN BUS WIRES (See page CA74) A 2 CHECK CAN BUS WIRE (SHORT TO B+ IN CAN BUS WIRE) DLC3: E10 (a) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester Connection Condition Specified Value E10-6 (CANH) - E10-16 (BAT) Ignition switch off 6 kΩ or higher E10-14 (CANL) E10-16 (BAT) Ignition switch off 6 kΩ or higher BAT CANL OK NG C126400E09 SHORT TO B+ IN CAN BUS WIRE (See page CA-89) CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 3 CA–71 CHECK CAN BUS WIRE (SHORT TO GND IN CAN BUS WIRE) DLC3: E10 CG CANH (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Value E10-4 (CG) - E10-6 (CANH) Ignition switch off 200 Ω or higher E10-4 (CG) - E10-14 (CANL) Ignition switch off 200 Ω or higher NG CANL C126400E10 SHORT TO GND IN CAN BUS WIRE (See page CA-104) OK GO TO "HOW TO PROCEED WITH TROUBLESHOOTING" (See page CA-8) CA CA–72 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM Open in CAN Main Bus Line DESCRIPTION There may be an open circuit in the CAN main bus wire and/or the DLC3 branch wire when the resistance between terminals 6 (CANH) and 14 (CANL) of the DLC3 is 69 Ω or more. Symptom Trouble Area Resistance between terminals 6 (CANH) and 14 (CANL) of the DLC3 is 69 Ω or more. • • • • • • CAN main bus wire or connector No. 1 CAN J/C No. 2 CAN J/C DLC3 branch wire or connector Combination meter ECM WIRING DIAGRAM : CAN Main Bus Wire (CANH) : CAN Main Bus Wire (CANL) CA : CAN Branch Wire (CANH) E10 DLC3 : CAN Branch Wire (CANL) CANL CANH 14 Combination Meter CANH 17 F1 18 120 Ω F1 CANL B W 1 6 W B 2 1 E62 A24*1 A55*2 ECM E62 E43 2 E43 Trouble Area No. 1 CAN J/C 1 1 B 4 E42 E41 A40 2 10 W E42 E41 A40 7 No. 2 CAN J/C B 41 CANH W 49 120 Ω CANL *1: 2AZ-FE *2: 2GR-FE C123381E05 CA–73 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM INSPECTION PROCEDURE NOTICE: • Turn the ignition switch off before measuring the resistance of the CAN main wire and CAN branch wires. • After the ignition switch is turned off, check that the key reminder warning system and light reminder warning system are not operating. • Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. If doors need to be opened in order to check connectors, open the doors and leave them open. HINT: Operating the ignition switch, any other switches or any triggers related ECU and sensor communication on the CAN, which would cause resistance reading variations. 1 CHECK DLC3 DLC3: E10 (a) Turn the ignition switch off. (b) Measure the resistance according to the value(s) in the table below. Standard resistance CANH CANL C126231E11 Tester Connection Condition Specified Value Result E10-6 (CANH) E101-14 (CANL) Ignition switch off 108 to 132 Ω A E10-6 (CANH) E10-14 (CANL) Ignition switch off 132 Ω or higher B NOTICE: When the measured value is 132 Ω or more and a CAN communication system diagnostic trouble code is output, there may be a fault besides disconnection of the DLC3 branch wire. For that reason, troubleshooting should be performed again from "HOW TO PROCEED WITH TROUBLESHOOTING" (See page CA-8 ) after repairing the trouble area. B A REPAIR OR REPLACE DLC3 BRANCH WIRE OR CONNECTOR (CANH, CANL) CA CA–74 2 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CHECK FOR OPEN IN CAN BUS MAIN WIRE (COMBINATION METER MAIN BUS LINE) (a) Disconnect the CAN main bus wire white connector (E43) from the No. 1 CAN J/C "B" side (without earth terminal). NOTICE: • Before disconnecting the connector, make a note of where it is connected. • Reconnect the connector to its original position. (b) Measure the resistance according to the value(s) in the table below. Standard resistance No. 1 CAN “B” J/C Side (without Earth Terminal) Wire Harness Side E43 CANH CANL Tester Connection Condition Specified Value E43-1 (CANH) - E43-2 (CANL) Ignition switch off 108 to 132 Ω NG Go to step 7 C133231E01 CA OK 3 CHECK FOR OPEN IN CAN BUS MAIN WIRE (NO. 1 CAN J/C) No. 1 CAN J/C “A” Side (with Earth Terminal) : CANH E42 CANL (a) Reconnect the CAN main bus wire connector (E43) to the No. 1 CAN J/C "B" side (without earth terminal). (b) Disconnect the CAN main bus wire white connector (E42) from the No. 1 CAN J/C "A" side (with earth terminal). NOTICE: • Before disconnecting the connector, make a note of where it is connected. • Reconnect the connector to its original position. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Value E41-1 (CANH) - E41-2 (CANL) Ignition switch off 108 to 132 Ω C133228E02 OK NG REPLACE NO. 1 CAN J/C CA–75 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 4 CHECK FOR OPEN IN CAN BUS MAIN WIRE (NO. 1 CAN J/C - NO. 2 CAN J/C) No. 2 CAN J/C Connector (Rear of the Vehicle) Wire Harness Side View: Front (a) Reconnect the CAN main bus wire connector (E42) to the No. 1 CAN J/C "A" side (with earth terminal). (b) Disconnect the CAN main bus wire connector (E41) from the No. 2 CAN J/C (rear of the vehicle). (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Value E42-4 (CANH) - E42-10 (CANL) Ignition switch off 108 to 132 Ω NG E41 REPAIR OR REPLACE CAN BUS MAIN WIRE OR CONNECTOR (NO. 1 CAN J/C - NO. 2 CAN J/C) CANH CA CANL C133246E01 OK 5 CHECK FOR OPEN IN CAN BUS MAIN WIRE (NO. 2 CAN J/C) No. 2 CAN J/C Connector (Front of the Vehicle) Wire Harness Side View: (a) Reconnect the CAN main bus wire connector (E41) to the No. 2 CAN J/C (rear of the vehicle). (b) Disconnect the CAN main bus wire connector (A40) from the No. 2 CAN J/C (front of the vehicle). (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Value A40-1 (CANH) - A40-7 (CANL) Ignition switch off 108 to 132 Ω OK Front A40 CANH CANL C133245E04 NG REPLACE NO. 2 CAN J/C CA–76 6 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CHECK FOR OPEN IN CAN BUS MAIN WIRE (ECM CAN MAIN BUS WIRE) ECM Connector (Front View): A24 *1 A55 *2 CANH *1: 2AZ-FE *2: 2GR-FE (a) Reconnect the CAN main bus wire connector (A40) to the No. 2 CAN J/C (front of the vehicle). (b) Disconnect the ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: 2AZ-FE Tester Connection CANL G100098E13 A24-38 (CANH) - A24-46 (CANL) Condition Specified Value Ignition switch off 108 to 132 Ω Condition Specified Value Ignition switch off 108 to 132 Ω 2GR-FE Tester Connection A55-38 (CANH) - A55-46 (CANL) CA OK REPLACE ECM NG REPAIR OR REPLACE CAN BUS MAIN WIRE OR CONNECTOR (NO. 2 CAN J/C - ECM) 7 CHECK FOR OPEN IN CAN BUS MAIN WIRE (COMBINATION METER - NO. 1 CAN J/C) (a) Reconnect the CAN main bus wire connector (E43) to the No. 1 CAN J/C "B" side (without earth terminal). (b) Disconnect the combination meter connector (F1). (c) Measure the resistance according to the value(s) in the table below. Standard resistance Combination Meter Connector (Wire Harness Side View): F1 Tester Connection Condition Specified Value F1-17 (CANH) - F1-18 (CANL) Ignition switch off 108 to 132 Ω OK CANL REPLACE COMBINATION METER CANH C133243E01 NG REPAIR OR REPLACE CAN BUS MAIN WIRE OR CONNECTOR (NO. 1 CAN J/C - COMBINATION METER) CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CA–77 Short in CAN Bus Lines DESCRIPTION The CAN bus wires are considered to be shorted when the resistance between terminals 6 (CANH) and 14 (CANL) of the DLC3 is below 54 Ω. Symptom Resistance between terminals 6 (CANH) and 14 (CANL) of the DLC3 is below 54 Ω. Trouble Area • • • • • • • • • • • Short in CAN bus wires Brake actuator assembly (Skid control ECU) Steering angle sensor Yaw rate sensor ECM Combination meter Main body ECU A/C amplifier Center airbag sensor No. 1 CAN J/C No. 2 CAN J/C CA CA–78 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM WIRING DIAGRAM F1 Combination Meter : CAN Main Bus Wire (CANH) : CAN Main Bus Wire (CANL) : CAN Branch Wire (CANH) : CAN Branch Wire (CANL) (x) CANH 17 (x) B CANL 18 W 1 E43 E10 DLC3 E43 2 1 E62 2 E62 No. 1 CAN J/C B (x) W 6 14 CANH CANL E34 Yaw Rate Sensor (*1) CA 1 E46 2 E46 E8 Main Body ECU (x) CANH 5 B CANL 6 W (x) B 3 CANH W 2 CANL (x) 1 E44 (x) 2 E44 E17 Steering Angle Sensor (*1) CANH 10 B (x) CANL 9 W 1 E63 (x) 2 E63 E30 Center Airbag Sensor 1 E45 2 E45 (x) (*1) : with VSC 1 E42 B E42 2 W B 13 CANH (x) W 22 CANL (x) : Suspected Area (Short in CAN Bus Wires) C133250E01 CA–79 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM : CAN Main Bus Line (CANH) : CAN Main Bus Line (CANL) : CAN Branch Line (CANH) : CAN Branch Line (CANL) (x) B A25 Skid Control ECU*1 W E41 10 4 E41 2 A40 8 A40 No. 2 CAN J/C B 26 CANH (x) W 15 CANL (x) A26 Skid Control ECU*2 CANH 11 (x) CANL 12 2 A40 8 A40 1 B E41 (x) 7 W E41 2 P A40 8 W A40 *2 : with VSC (TMC mode) *3 : with VSC (TMMK mode) 1 A40 (x) W 17 18 (x) A 24*4 A 55*5 ECM *4 : 2AZ-FE (x) B 35 CANH (x) W 14 CANL (x) A40 7 B CANH W 25 CANL A60 Skid Control ECU*3 2 B E41 (x) 8 W E41 *1 : without VSC (x) (x) E38 A/C Amplifier 1 E61 2 E61 B 11 CANH CANL : Suspected Area (Short in CAN bus lines) *5 : 2GR-FE C133251E01 INSPECTION PROCEDURE NOTICE: • Turn the ignition switch off before measuring the resistance of the CAN main wire and CAN branch wires. CA CA–80 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM • After the ignition switch is turned off, check that the key reminder warning system and light reminder warning system are not operating. • Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. If doors need to be opened in order to check connectors, open the doors and leave them open. HINT: Operating the ignition switch, any other switches or any triggers related ECU and sensor communication on the CAN, which would cause resistance reading variations. 1 CHECK FOR SHORT IN CAN BUS WIRES (DLC3 BRANCH WIRE) No. 1 CAN J/C “B” Side (without Earth Terminal) Wire Harness Side: CANH E62 (a) Turn the ignition switch off. (b) Disconnect the DLC3 branch wire gray connector (E62) from the No. 1 CAN J/C "B" side (without earth terminal). NOTICE: • Before disconnecting the connector, make a note of where it is connected. • Reconnect the connector to its original position. CA CANL C133233E01 DLC3: E10 (c) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester Connection E10-6 (CANH) - E10-14 (CANL) CANL OK Condition Specified Value Ignition switch off 1 MΩ or higher (d) Reconnect the DLC3 branch wire connector (E62) to the No. 1 CAN J/C "B" side (without earth terminal). C126231E11 NG REPAIR OR REPLACE DLC3 BRANCH WIRE OR CONNECTOR CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 2 CA–81 CHECK FOR SHORT IN CAN BUS WIRES (NO. 1 CAN J/C SIDE) No. 1 CAN J/C “A” Side (with Earth Terminal): (a) Disconnect the CAN main bus wire white connector (E42) from the No. 1 CAN J/C "A" side (with earth terminal). E42 C133228E01 DLC3: E10 (b) Connect the probes of an ohmmeter to terminals 6 (CANH) and 14 (CANL) of the DLC3. (c) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester Connection E10-6 (CANH) - E10-14 (CANL) CANL C126231E11 OK Condition Specified Value Ignition switch off 108 to 132 Ω Go to step 7 NG 3 CHECK FOR SHORT IN CAN BUS WIRES (NO. 1 CAN J/C BRANCH WIRE) DLC3: E10 CANH CANL C126231E11 (a) Reconnect the CAN main bus wire connector (E42) to the No. 1 CAN J/C "A" side (with earth terminal). (b) Connect the probes of an ohmmeter to terminals 6 (CANH) and 14 (CANL) of the DLC3. (c) While observing the resistance value shown on the tester, disconnect connectors E44, E45, E46 and E63 from the No. 1 CAN J/C one by one until the resistance becomes normal (between 54 and 69 Ω). HINT: Disconnect the branch wire connectors other than those of the DLC3. CA CA–82 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM Yaw Rate Sensor*2 DLC 3 Steering Angle Sensor*2 Combination Meter Main Body ECU Certification ECU*1 “B” Side (without Earth Terminal) CANH CANL CANH CANL CANH CANL CANH CANL CANH CANL No. 1 CAN J/C CANH CANL CANH CANL “A” Side (with Earth Terminal) CA Center Airbag Sensor Assembly *1: with smart key system Accessory Gateway A/C Amplifier *2: with VSC Rear of the Vehicle (E41) CANH CANL CANH CANL CANH CANL No. 2 CAN J/C CANH CANL CANH CANL Front of the Vehicle (A40) Skid Control ECU with Actuator ECM C136707E02 CA–83 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM No. 1 CAN J/C “B” side (without Earth Terminal): No. 1 CAN J/C “A” side (with Earth Terminal): Earth Terminal B W B W B W B W B W E46 E42 E62 E45 B W B W E63 CA E43 E44 Earth Terminal C137761E02 CAN J/C connectors ("A" side, with earth terminal) Connector Color Wire Color (CAN-H) Wire Color (CAN-L) Black B W Connector Color Wire Color (CAN-H) Wire Color (CAN-L) Blue B W Steering Angle Sensor* (E63) Brown B W Main Body ECU (E44) Black B W Airbag Sensor Assembly Center (E45) CAN J/C connectors ("B" side, with earth terminal) Yaw Rate Sensor* (E46) *: with VSC NOTICE: Do not reconnect the disconnected connectors until this inspection is complete because there may be a short in 2 or more branch wires. Result Symptom Proceed to The resistance is still below 54 Ω when all the specified connectors are disconnected. (There are no shorts in the branch wires.) A The resistance becomes normal (between 54 and 69 Ω) when a connector is disconnected. (There is a short in one or more of the branch wires.) B (d) When there is a short in one or more of the branch wires: (1) Reconnect all of the connectors to the No. 1 CAN J/ C, except for the one that was disconnected last (the short-circuited bus wire). Check that the resistance shown on the tester is normal (between 54 and 69 Ω) to confirm that there is a short in one branch wire only. CA–84 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM HINT: • The connectors connected to the No. 1 CAN J/C can be distinguished according to the color of the communication bus wires and the shape of the connectors. • Reconnecting the connectors to non-specified positions on the No. 1 CAN J/C does not affect system operation. However, it is preferred to reconnect the connectors to their specified positions to avoid negative effects on the wiring such as tension on the wiring harnesses, and to make future maintenance easier. B Go to step 15 A 4 CA CHECK FOR SHORT IN CAN BUS WIRES (COMBINATION METER MAIN BUS WIRE) (a) Disconnect the combination meter main bus wire white connector (E43) from the No. 1 CAN J/C "B" side (without earth terminal). NOTICE: • Before disconnecting the connector, make a note of where it is connected. • Reconnect the connector to its original position. No. 1 CAN “B” J/C Side (without Earth Terminal) Wire Harness Side E43 CANH CANL C133231E01 DLC3: E10 (b) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester Connection E10-6 (CANH) - E10-14 (CANL) NG CANL Condition Specified Value Ignition switch off 108 to 132 Ω REPLACE NO. 1 CAN J/C C126231E11 OK 5 RECONNECT CONNECTOR (a) Reconnect the combination meter main bus wire connector (E43) to the No. 1 CAN J/C "B" side (without earth terminal). CA–85 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM NEXT 6 CHECK FOR SHORT IN CAN BUS WIRES (COMBINATION METER) DLC3: E10 (a) Disconnect the combination meter connector (F1). (b) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester Connection E10-6 (CANH) - E10-14 (CANL) CANL C126231E11 Condition Specified Value Ignition switch off 108 to 132 Ω HINT: If the resistance changes to 108 to 132 Ω when the connector is disconnected, there may be a short in the Combination meter. NG REPAIR OR REPLACE CAN BUS MAIN WIRE (COMBINATION METER MAIN BUS WIRE) CA OK REPLACE COMBINATION METER 7 CHECK FOR SHORT IN CAN BUS WIRES (NO. 2 CAN - NO. 1 CAN J/C) No. 2 CAN J/C Connector (Rear of the Vehicle) Wire Harness Side View: Front E41 C133246E06 (a) Reconnect the No. 1 CAN J/C connector (E42). (b) Disconnect the No. 2 CAN J/C connector (E41). CA–86 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM DLC3: E10 (c) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester Connection E10-6 (CANH) - E10-14 (CANL) NG CANL C126400E08 Condition Specified Value Ignition switch off 108 to 132 Ω REPAIR OR REPLACE CAN BUS MAIN WIRE OR CONNECTOR (NO. 1 CAN J/C - NO. 2 CAN J/C) OK 8 CHECK FOR SHORT IN CAN BUS WIRES (NO. 1 CAN J/C - NO. 2 CAN J/C) No. 2 CAN J/C Connector (Front of the Vehicle) Wire Harness Side View: CA (a) Reconnect the No. 2 CAN J/C connector (E41) (rear of the vehicle). (b) Disconnect the No. 2 CAN J/C connector (A40) (front of the vehicle). Front A40 C133245E02 DLC3: E10 (c) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester Connection E10-6 (CANH) - E10-14 (CANL) OK CANL NG C126400E08 Condition Specified Value Ignition switch off 108 to 132 Ω Go to step 12 CA–87 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 9 CHECK FOR SHORT IN CAN BUS WIRES (A/C AMPLIFIER BRANCH WIRE) No. 2 CAN J/C Connector (Rear of the Vehicle) Wire Harness Side View: Front (a) Reconnect the No. 2 CAN J/C connector (A40) (front of the vehicle). (b) Disconnect the No. 2 CAN J/C connector (E41) (rear of the vehicle). (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Value E41-1 (CANH) - E41-7 (CANL) Ignition switch off 1 MΩ or higher NG E41 Go to step 11 CANH CA CANL C133246E05 OK 10 CHECK FOR SHORT IN CAN BUS WIRES (ACCESSORY GATEWAY BRANCH WIRE) No. 2 CAN J/C Connector (Rear of the Vehicle) Wire Harness Side View: (a) Disconnect the No. 2 CAN J/C connector (E41) (rear of the vehicle). (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Value E41-2 (CANH) - E41-8 (CANL) Ignition switch off 1 MΩ or higher Front NG E41 CANH CANL C133246E03 REPAIR OR REPLACE ACCESSORY GATEWAY BRANCH WIRE OR CONNECTOR CA–88 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM OK REPLACE NO. 2 CAN J/C 11 CHECK FOR SHORT IN CAN BUS WIRES (A/C AMPLIFIER - NO. 2 CAN J/C) No. 2 CAN J/C Connector (Rear of the Vehicle) Wire Harness Side View: Front CANH CANL C133246E05 OK REPLACE A/C AMPLIFIER Tester Connection Condition Specified Value E41-1 (CANH) - E41-7 (CANL) Ignition switch off 1 MΩ or higher NG CA E41 (a) Disconnect the A/C amplifier connector (E38). (b) Measure the resistance according to the value(s) in the table below. Standard resistance REPAIR OR REPLACE A/C AMPLIFIER BRANCH WIRE OR CONNECTOR CA–89 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 12 CHECK FOR SHORT IN CAN BUS WIRES (ECM MAIN BUS WIRE) No. 2 CAN J/C Connector (Front of the Vehicle) Wire Harness Side View: (a) Disconnect the No. 2 CAN J/C connector (A40). (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Value A40-1 (CANH) - A40-7 (CANL) Ignition switch off 108 to 132 Ω NG Go to step 14 Front A40 CANH CA CANL C133245E04 OK 13 CHECK FOR SHORT IN CAN BUS WIRES (SKID CONTROL ECU - NO. 2 CAN J/C) No. 2 CAN J/C Connector (Front of the Vehicle) Wire Harness Side View: (a) Disconnect the skid control ECU connector (A25, A26 or A60). (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Value A40-2 (CANH) - A40-8 (CANL) Ignition switch off 1 MΩ or higher HINT: Measure the resistance with the No. 2 CAN J/C connector (A40) disconnected. Front A40 OK CANH CANL C133245E05 REPLACE BRAKE ACTUATOR ASSEMBLY CA–90 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM NG REPAIR OR REPLACE SKID CONTROL ECU BRANCH WIRE OR CONNECTOR 14 CHECK FOR SHORT IN CAN BUS WIRES (ECM MAIN BUS WIRE) No. 2 CAN J/C Connector (Front of the Vehicle) Wire Harness Side View: (a) Disconnect the ECM connector (A24 or A55). (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Value A40-1 (CANH) - A40-7 (CANL) Ignition switch off 1 MΩ or higher HINT: Measure the resistance with the No. 2 CAN J/C connector (A40) disconnected. NG CA Front A40 REPAIR OR REPLACE CAN BUS MAIN WIRE OR CONNECTOR (ECM - NO. 2 CAN J/C) CANH CANL C133245E04 OK REPLACE ECM 15 RECONNECT CONNECTOR (a) Reconnect the connector for the short-circuited branch wire to the No. 1 CAN J/C (the connector that caused the bus wire resistance to become normal (between 54 and 69 Ω) when it was disconnected). NEXT CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 16 CA–91 CHECK FOR SHORT IN CAN BUS WIRES DLC3: E10 (a) Disconnect the connector that includes terminals CANH and CANL from the ECU (or sensor) to which the shortcircuited branch wire is connected. (See page CA-10) (b) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester Connection CANL E10-6 (CANH) - E10-14 (CANL) Condition Specified Value Ignition switch off 54 to 69 Ω C126231E11 HINT: If the resistance becomes normal (between 54 and 69 Ω) when the connector is disconnected from the ECU (or sensor), there may be a short in the ECU (or sensor). NG OK REPLACE CORRESPONDING ECU OR SENSOR REPAIR OR REPLACE CORRESPONDING ECU OR SENSOR BRANCH WIRE OR CONNECTOR CA CA–92 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM Short to B+ in CAN Bus Line DESCRIPTION A short to B+ is suspected in the CAN bus wire when the resistance between terminals 6 (CANH) and 16 (BAT), or terminals 14 (CANL) and 16 (BAT) of the DLC3 is below 6 kΩ. Symptom The resistance between terminals 6 (CANH) and 16 (BAT), or terminals 14 (CANL) and 16 (BAT) of the DLC3 is below 6 kΩ. CA Trouble Area • • • • • • • • • • Short to B+ in CAN bus wire Brake actuator assembly (Skid control ECU) Steering angle sensor Yaw rate sensor ECM Combination meter Main body ECU A/C amplifier Center airbag sensor No. 1 CAN J/C CA–93 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM WIRING DIAGRAM F1 Combination Meter : CAN Main Bus Line (CANH) : CAN Main Bus Line (CANL) : CAN Branch Line (CANH) : CAN Branch Line (CANL) CANH 17 B 1 E43 No. 1 CAN J/C CANL 18 To Battery W E10 DLC3 E43 2 1 E62 2 E62 B 6 CANH W 14 CANL BAT 16 E34 Yaw Rate Sensor (*1) 1 E46 2 E46 E8 Main Body ECU CANH 5 B CANL 6 W 1 E44 2 E44 CANL 9 W 1 E46 2 E46 1 E63 2 E63 (*2) : with VSC (TMMK Made) 1 E42 B W 2 CANL B 2 CANH W 3 CANL E65 Center Airbag Sensor 1 E45 2 E45 (*1) : with VSC (TMC Made) CANH E65 Yaw Rate Sensor (*2) E17 Steering Angle Sensor (*1) (*2) CANH 10 B B 3 E42 2 W B 13 CANH W 22 CANL : Suspected Area (Short in CAN bus lines) C133292E01 CA CA–94 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM : CAN Main Bus Line (CANH) : CAN Main Bus Line (CANL) : CAN Branch Line (CANH) : CAN Branch Line (CANL) B No. 2 CAN J/C CA A25 Skid Control ECU*1 W 4 E41 E41 10 2 A40 8 A40 B 26 CANH W 15 CANL A26 Skid Control ECU*2 E38 A/C Amplifier CANH 11 CANL 12 1 E61 2 E61 2 A40 8 A40 1 B E41 7 W E41 11 CANH W 25 CANL A26 Skid Control ECU*3 2 A40 8 A40 2 E41 W 8 E41 B *1 : without VSC 1 A40 *2 : with VSC (TMC Made) B W 17 CANH 18 CANL *3 : with VSC (TMMK Made) B B 35 CANH W 14 CANL A40 7 *4 : 2AZ-FE : Suspected Area (Short in CAN bus lines) *5 : 2GR-FE A 24*4 A 55*5 ECM C133249E01 INSPECTION PROCEDURE NOTICE: • Turn the ignition switch off before measuring the resistance of the CAN main wire and CAN branch wires. CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CA–95 • After the ignition switch is turned off, check that the key reminder warning system and light reminder warning system are not operating. • Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. If doors need to be opened in order to check connectors, open the doors and leave them open. HINT: Operating the ignition switch, any other switches or any triggers related ECU and sensor communication on the CAN, which would cause resistance reading variations. 1 CHECK FOR SHORT TO B+ IN CAN BUS WIRE (DLC3 BRANCH WIRE) No. 1 CAN J/C “B” Side (without Earth Terminal) Wire Harness Side: CANH E62 (a) Turn the ignition switch off. (b) Disconnect the DLC3 branch wire gray connector (E62) from the No. 1 CAN J/C "B" side (without earth terminal). NOTICE: • Before disconnecting the connector, make a note of where it is connected. • Reconnect the connector to its original position. CA CANL C133233E01 DLC3: E10 (c) Measure the resistance according to the value(s) in the table below. Standard resistance CANH BAT CANL C126231E12 Tester Connection Condition Specified Value E10-6 (CANH) - E10-16 (BAT) Ignition switch off 6 kΩ or higher E10-14 (CANL) - E10-16 (BAT) Ignition switch off 6 kΩ or higher (d) Reconnect the DLC3 branch wire connector (E62) to the No. 1 CAN J/C "B" side (without earth terminal). NG OK REPAIR OR REPLACE DLC3 BRANCH WIRE OR CONNECTOR CA–96 2 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 1 CAN J/C SIDE) No. 1 CAN J/C “A” Side (with Earth Terminal): (a) Disconnect the CAN main bus wire white connector (E42) from the No. 1 CAN J/C "A" side (with earth terminal). E42 C133228E01 CA DLC3: E10 (b) Measure the resistance between terminals 6 (CANH) and 16 (BAT), and between terminals 14 (CANL) and 16 (BAT) of the DLC3 each time a connector is disconnected. Standard resistance CANH BAT CANL Tester Connection Condition Specified Value E10-6 (CANH) - E10-16 (BAT) Ignition switch off 6 kΩ or higher E10-14 (CANL) - E10-16 (BAT) Ignition switch off 6 kΩ or higher C126231E12 OK Go to step 6 NG 3 DLC3: CHECK FOR SHORT TO B+ IN CAN BUS WIRE E10 CANH BAT CANL C126231E12 (a) Disconnect connectors from the No. 1 CAN J/C one at a time. HINT: Disconnect the ECU and sensor connectors other than the DLC3 branch wires and CAN main bus wires between the No. 1 CAN J/C. (b) Measure the resistance between terminals 6 (CANH) and 16 (BAT), and between terminals 14 (CANL) and 16 (BAT) of the DLC3 each time a connector is disconnected. CA–97 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM Yaw Rate Sensor*2 DLC 3 Steering Angle Sensor*2 Combination Meter Main Body ECU Certification ECU*1 “B” Side (without Earth Terminal) CANH CANL CANH CANL CANH CANL CANH CANL CANH CANL No. 1 CAN J/C CANH CANL CANH CANL “A” Side (with Earth Terminal) CA Center Airbag Sensor Assembly *1: with smart key system Accessory Gateway A/C Amplifier *2: with VSC Rear of the Vehicle (E41) CANH CANL CANH CANL CANH CANL No. 2 CAN J/C CANH CANL CANH CANL Front of the Vehicle (A40) Skid Control ECU with Actuator ECM C136707E02 CA–98 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM No. 1 CAN J/C “B” side (without Earth Terminal): No. 1 CAN J/C “A” side (with Earth Terminal): Earth Terminal B W B W B W B W B W CA E46 E42 E62 E45 B W B W E63 E43 E44 Earth Terminal C137761E02 No. 1 CAN J/C connectors ("A" side, with earth terminal) Connector Color Wire Color (CAN-H) Wire Color (CAN-L) Black B W Connector Color Wire Color (CAN-H) Wire Color (CAN-L) Blue B W Steering Angle Sensor* (E63) Brown B W Combination Meter (E43) White B W Main Body ECU (E44) Black B W Airbag Sensor Assembly Center (E45) No. 1 CAN J/C connectors ("A" side, with earth terminal) Yaw Rate Sensor* (E46) *: with VSC NOTICE: Do not reconnect the disconnected connectors until this inspection is complete because there may be a short to B+ in 2 or more CAN bus wires. Result Symptom Proceed to The resistance between terminals 6 (CANH) and 16 (BAT), or the resistance between 14 (CANL) and 16 (BAT) is still below 6 kΩ when all the specified connectors are disconnected from the No. 1 CAN J/C. (There is a short to B+ in the CAN main bus wires between the No. 1 CAN J/C and No. 2 CAN J/C.) OK The resistance between terminals 6 (CANH) and 16 (BAT), or the resistance between 14 (CANL) and 16 (BAT) becomes normal (6 kΩ or more) when a connector is disconnected from the No. 1 CAN J/C. (There is a short to B+ in one of the areas that relate to one or more of the disconnected bus wires.) NG (c) When there is a short to B+ in one or more of the bus wires that connect to an ECU (or sensor): CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CA–99 (1) Reconnect all of the connectors to the No. 1 CAN J/ C, except for the one that was disconnected last (the bus wire that is shorted to B+). Check that the resistance shown on the tester is normal (6 kΩ or more) to confirm that there is a short to B+ in one bus wire only. HINT: • The connectors connected to the No. 1 CAN J/C can be distinguished according to the color of the communication bus wires and the shape of the connectors. • Reconnecting the connectors to non-specified positions on the No. 1 CAN J/C does not affect system operation. However, it is preferred to reconnect the connectors to their specified positions to avoid negative effects on the wiring such as tension on the wiring harnesses, and to make future maintenance easier. OK REPLACE NO. 1 CAN J/C CA NG 4 RECONNECT CONNECTOR (a) Reconnect the connector of the bus wire that is shorted to B+ to the No. 1 CAN J/C (the connector that caused the bus wire resistance to change to 6 kΩ or more when it was disconnected). NEXT 5 DLC3: CHECK FOR SHORT TO B+ IN CAN BUS WIRE E10 (a) Disconnect the connector that includes terminals CANH and CANL from the ECU (or sensor) to which the bus wire shorted to B+ is connected. (See page CA-10) (b) Measure the resistance according to the value(s) in the table below. Standard resistance CANH BAT CANL C126231E12 Tester Connection Condition Specified Value E10-6 (CANH) - E10-16 (BAT) Ignition switch off 6 kΩ or higher E10-14 (CANL) - E10-16 (BAT) Ignition switch off 6 kΩ or higher HINT: If the resistance changes to 6 kΩ or higher when the connector is disconnected from the ECU (or sensor), there may be a short in the ECU (or sensor). NG REPAIR OR REPLACE CORRESPONDING ECU OR SENSOR BUS LINE OR CONNECTOR CA–100 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM OK REPLACE CORRESPONDING ECU OR SENSOR 6 CHECK FOR SHORT TO B+ IN CAN BUS WIRE No. 2 CAN J/C Connector (Front of the Vehicle) Wire Harness Side View: CA (a) Reconnect the CAN main bus wire connector (E42) to the No. 1 CAN J/C "A" side (with earth terminal). (b) Disconnect the No. 2 CAN J/C connector (A40) (front of the vehicle). Front A40 C133245E02 DLC3: E10 (c) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester Connection Condition Specified Value E10-6 (CANH) - E10-16 (BAT) Ignition switch off 6 kΩ or higher E10-14 (CANL) - E10-16 (BAT) Ignition switch off 6 kΩ or higher BAT CANL NG OK C126231E12 Go to step 11 CA–101 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 7 CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 1 CAN J/C - NO. 2 CAN J/C) No. 2 CAN J/C Connector (Rear of the Vehicle) Wire Harness Side View: (a) Disconnect the No. 2 CAN J/C connector (E41) (rear of the vehicle). Front E41 CA C133246E06 DLC3: E10 (b) Measure the resistance according to the value(s) in the table below. Standard resistance CANH BAT CANL C126231E12 Tester Connection Condition Specified Value E10-6 (CANH) - E10-16 (BAT) Ignition switch off 6 kΩ or higher E10-14 (CANL) - E10-16 (BAT) Ignition switch off 6 kΩ or higher HINT: Measure the resistance with the No. 2 CAN J/C connector (A40) disconnected. NG REPAIR OR REPLACE CAN BUS MAIN WIRE (NO. 1 CAN J/C - NO. 2 CAN J/C) OK 8 RECONNECT CONNECTOR (a) Reconnect the No. 2 CAN J/C connector (A40) (front of the vehicle). NEXT CA–102 9 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CHECK FOR SHORT TO B+ IN CAN BUS WIRE (A/C AMPLIFIER BRANCH WIRE) No. 2 CAN J/C Connector (Rear of the Vehicle) Wire Harness Side View: (a) Disconnect the No. 2 CAN J/C connector (E41) (rear of the vehicle). Front E41 CANH CA CANL C133246E05 DLC3: (b) Measure the resistance according to the value(s) in the table below. Standard resistance E10 BAT C126231E14 NG Tester Connection Condition Specified Value E41-1 (CANH) - E10-16 (BAT) Ignition switch off 6 kΩ or higher E41-7 (CANL) - E10-16 (BAT) Ignition switch off 6 kΩ or higher OK REPAIR OR REPLACE ACCESSORY GATEWAY BRANCH WIRE OR CONNECTOR CA–103 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 10 CHECK FOR SHORT TO B+ IN CAN BUS WIRE (A/C AMPLIFIER) No. 2 CAN J/C Connector (Rear of the Vehicle) Wire Harness Side View: (a) Disconnect the A/C amplifier connector (E38). Front E41 CANH CA CANL C133246E05 DLC3: (b) Measure the resistance according to the value(s) in the table below. Standard resistance E10 BAT C126231E14 Tester Connection Condition Specified Value E41-1 (CANH) - E10-16 (BAT) Ignition switch off 6 kΩ or higher E41-7 (CANL) - E10-16 (BAT) Ignition switch off 6 kΩ or higher HINT: Measure the resistance with the No. 2 CAN J/C connector (E41) disconnected. NG OK REPLACE A/C AMPLIFIER REPAIR OR REPLACE A/C AMPLIFIER BRANCH WIRE OR CONNECTOR CA–104 11 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CHECK FOR SHORT TO B+ IN CAN BUS WIRE (ECM MAIN BUS WIRE) No. 2 CAN J/C Connector (Front of the Vehicle) Wire Harness Side View: (a) Disconnect the No. 2 CAN J/C connector (E40) (front of the vehicle). Front CANH A40 CA CANL C133245E04 DLC3: (b) Measure the resistance according to the value(s) in the table below. Standard resistance E10 BAT C126231E14 NG Tester Connection Condition Specified Value A40-1 (CANH) - E10-16 (BAT) Ignition switch off 6 kΩ or higher A40-7 (CANL) - E10-16 (BAT) Ignition switch off 6 kΩ or higher OK Go to step 13 CA–105 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 12 CHECK FOR SHORT TO B+ IN CAN BUS WIRE (ECM) (a) Disconnect the ECM connector (A24 or A55). No. 2 CAN J/C Connector (Front of the Vehicle) Wire Harness Side View: Front CANH A40 CA CANL C133245E04 DLC3: (b) Measure the resistance according to the value(s) in the table below. Standard resistance E10 Tester Connection BAT C126231E14 REPLACE ECM Specified Value A40-1 (CANH) - E10-16 (BAT) Ignition switch off 6 kΩ or higher A40-7 (CANL) - E10-16 (BAT) Ignition switch off 6 kΩ or higher HINT: Measure the resistance with the No. 2 CAN J/C connector (A40) disconnected. NG OK Condition REPAIR OR REPLACE CAN BUS MAIN WIRE OR CONNECTOR (ECM - NO. 2 CAN J/C) CA–106 13 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CHECK FOR SHORT TO B+ IN CAN BUS WIRE (SKID CONTROL ECU) No. 2 CAN J/C Connector (Front of the Vehicle) Wire Harness Side View: (a) Disconnect the skid control ECU connector (A25, A26 or A60). Front CANH A40 CA CANL C133245E05 DLC3: (b) Measure the resistance according to the value(s) in the table below. Standard resistance E10 BAT Tester Connection Condition Specified Value A40-2 (CANH) - E10-16 (BAT) Ignition switch off 6 kΩ or higher A40-8 (CANL) - E10-16 (BAT) Ignition switch off 6 kΩ or higher OK REPLACE BRAKE ACTUATOR ASSEMBLY C126231E14 NG REPAIR OR REPLACE SKID CONTROL ECU BRANCH WIRE OR CONNECTOR CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CA–107 Short to GND in CAN Bus Line DESCRIPTION A short to GND is suspected in the CAN bus wire when the resistance between terminals 4 (CG) and 6 (CANH), or terminals 4 (CG) and 14 (CANL) of the DLC3 is below 200 Ω. Symptoms The resistance between terminals 6 (CANH) and 4 (CG), or terminals 14 (CANL) and 4 (CG) of the DLC3 is below 200 Ω. Trouble Area • • • • • • • • • • Short to GND in CAN bus wire ECM Brake actuator assembly (Skid control ECU) Steering angle sensor Yaw rate sensor Main Body ECU A/C amplifier Combination meter Center airbag sensor No. 1 CAN J/C CA CA–108 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM WIRING DIAGRAM F1 Combination Meter : CAN Main Bus Line (CANH) : CAN Main Bus Line (CANL) : CAN Branch Line (CANH) : CAN Branch Line (CANL) CANH 17 B No. 1 CAN J/C 1 E43 CANL 18 W E43 2 1 E62 2 E62 E10 DLC3 B 6 W CANH 14 CG CANL 4 E34 Yaw Rate Sensor (*1) CA 1 E46 2 E46 E8 Main Body ECU CANH 5 B CANL 6 W 1 E44 2 E44 CANL 9 W 1 E46 2 E46 1 E63 2 E63 (*2) : with VSC (TMMK Made) W 2 CANL B 2 CANH W 3 CANL E65 Center Airbag Sensor 1 E45 2 E45 (*1) : with VSC (TMC Made) CANH E65 Yaw Rate Sensor (*2) E17 Steering Angle Sensor (*1) (*2) CANH 10 B B 3 1 E42 B E42 2 W B 13 CANH W 22 CANL : Suspected Area (Short in CAN bus lines) C142701E01 CA–109 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM : CAN Main Bus Line (CANH) : CAN Main Bus Line (CANL) : CAN Branch Line (CANH) : CAN Branch Line (CANL) B No. 2 CAN J/C A25 Skid Control ECU*1 W 4 E41 E41 10 2 A40 8 A40 B 26 CANH W 15 CANL A26 Skid Control ECU*2 E38 A/C Amplifier CANH 11 CANL 12 1 E61 2 E61 2 A40 8 A40 1 B E41 7 W E41 11 CANH W 25 CANL A26 Skid Control ECU*3 2 A40 8 A40 2 E41 W 8 E41 B *1 : without VSC 1 A40 *2 : with VSC (TMC Made) B W 17 CANH 18 CANL *3 : with VSC (TMMK Made) B B 35 CANH W 14 CANL A40 7 *4 : 2AZ-FE : Suspected Area (Short in CAN bus lines) *5 : 2GR-FE A 24*4 A 55*5 ECM C133249E01 INSPECTION PROCEDURE NOTICE: • Turn the ignition switch off before measuring the resistance of the CAN main wire and CAN branch wires. CA CA–110 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM • After the ignition switch is turned off, check that the key reminder warning system and light reminder warning system are not operating. • Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. If doors need to be opened in order to check connectors, open the doors and leave them open. HINT: Operating the ignition switch, any other switches or any triggers related ECU and sensor communication on the CAN, which would cause resistance reading variations. 1 CHECK FOR SHORT TO GND IN CAN BUS WIRE (DLC3 BRANCH WIRE) No. 1 CAN J/C “B” Side (without Earth Terminal) Wire Harness Side: CANH E62 (a) Turn the ignition switch off. (b) Disconnect the DLC3 branch wire gray connector (E62) from the No. 1 CAN J/C "B" side (without earth terminal). NOTICE: • Before disconnecting the connector, make a note of where it is connected. • Reconnect the connector to its original position. CA CANL C133233E01 E10 DLC3: (c) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester Connection CG CANL Condition Specified Value E10-6 (CANH) - E10-4 (CG) Ignition switch off 200 Ω or higher E10-14 (CANL) - E10-4 (CG) Ignition switch off 200 Ω or higher (d) Reconnect the DLC3 branch wire connector (E62) to the No. 1 CAN J/C "B" side (without earth terminal). C126231E13 NG OK REPAIR OR REPLACE DLC3 BRANCH WIRE OR CONNECTOR CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 2 CA–111 CHECK FOR SHORT TO GND IN CAN BUS WIRE (NO. 1 CAN J/C SIDE) No. 1 CAN J/C “A” Side (with Earth Terminal): (a) Disconnect the CAN main bus wire white connector (E42) from the No. 1 CAN J/C "A" side (with earth terminal). E42 C133228E01 E10 DLC3: (b) Measure the resistance between terminals 6 (CANH) and 4 (CG), and between terminals 14 (CANL) and 4 (CG) of the DLC3 each time a connector is disconnected. Standard resistance CANH Tester Connection CG CANL Condition Specified Value E10-6 (CANH) - E10-4 (CG) Ignition switch off 200 Ω or higher E10-14 (CANL) - E10-4 (CG) Ignition switch off 200 Ω or higher C126231E13 OK Go to step 6 NG 3 CHECK FOR SHORT TO GND IN CAN BUS WIRE E10 DLC3: CG CANH CANL C126231E13 (a) Disconnect connectors from the No. 1 CAN J/C one at a time. HINT: Disconnect the ECU and sensor connectors other than the DLC3 branch wires and CAN main bus lines between the No. 1 CAN J/C. (b) Measure the resistance between terminals 6 (CANH) and 4 (CG), and between terminals 14 (CANL) and 4 (CG) of the DLC3 each time a connector is disconnected. CA CA–112 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM Yaw Rate Sensor*2 DLC 3 Steering Angle Sensor*2 Combination Meter Main Body ECU Certification ECU*1 “B” Side (without Earth Terminal) CANH CANL CANH CANL CANH CANL CANH CANL CANH CANL No. 1 CAN J/C CANH CANL CANH CANL “A” Side (with Earth Terminal) CA Center Airbag Sensor Assembly *1: with smart key system Accessory Gateway A/C Amplifier *2: with VSC Rear of the Vehicle (E41) CANH CANL CANH CANL CANH CANL No. 2 CAN J/C CANH CANL CANH CANL Front of the Vehicle (A40) Skid Control ECU with Actuator ECM C136707E02 CA–113 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM No. 1 CAN J/C “B” side (without Earth Terminal): No. 1 CAN J/C “A” side (with Earth Terminal): Earth Terminal B W B W B W B W B W E46 E42 E62 E45 B W B W E63 CA E43 E44 Earth Terminal C137761E02 No. 1 CAN J/C connectors ("A" side, with earth terminal) Airbag Sensor Assembly Center (E45) No. 1 CAN J/C connectors ("A" side, with earth terminal) Yaw Rate Sensor* (E46) Connector Color Wire Color (CAN-H) Wire Color (CAN-L) Black B W Connector Color Wire Color (CAN-H) Wire Color (CAN-L) Blue B W Steering Angle Sensor* (E63) Brown B W Combination Meter (E43) White B W Main Body ECU (E44) Black B W *: with VSC NOTICE: Do not reconnect the disconnected connectors until this inspection is complete because there may be a short to GND in 2 or more CAN bus wires. Result Symptom Proceed to The resistance between terminals 6 (CANH) and 4 (CG), or the resistance between 14 (CANL) and 4 (CG) is still below 200 Ω when all the specified connectors are disconnected from the No. 1 CAN J/C. (There is a short to GND in the CAN main bus wires between the No. 1 CAN J/ C and No. 2 CAN J/C.) A The resistance between terminals 6 (CANH) and 4 (CG), or the resistance between 14 (CANL) and 4 (CG) becomes normal (200 Ω or more) when a connector is disconnected from the CAN J/C. (There is a short to GND in one of the areas that relate to the disconnected bus wires.) B (c) When there is a short to GND in one or more of the bus wires that connect to an ECU (or sensor): CA–114 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM (1) Reconnect all of the connectors to the No. 1 CAN J/ C, except for the one that was disconnected last (the bus wire that is shorted to GND). Check that the resistance shown on the tester is normal (200 Ω or more) to confirm that there is a short to GND in one branch wire only. HINT: • The connectors connected to the No. 1 CAN J/C can be distinguished according to the color of the communication bus wires and the shape of the connectors. • Reconnecting the connectors to non-specified positions on the No. 1 CAN J/C does not affect system operation. However, it is preferred to reconnect the connectors to their specified positions to avoid negative effects on the wiring such as tension on the wiring harnesses, and to make future maintenance easier. A CA REPLACE NO. 1 CAN J/C B 4 RECONNECT CONNECTOR (a) Reconnect the connector of the bus wire that is shorted to GND to the No. 1 CAN J/C (the connector that caused the bus wire resistance to change to 200 Ω or more when it was disconnected). NEXT 5 CHECK FOR SHORT TO GND IN CAN BUS WIRE E10 DLC3: (a) Disconnect the connector that includes terminals CANH and CANL from the ECU (or sensor) to which the bus wire shorted to GND is connected (See page CA-10). (b) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester Connection CG CANL Condition Specified Value E10-6 (CANH) - E10-4 (CG) Ignition switch off 200 Ω or higher E10-14 (CANL) - E10-4 (CG) Ignition switch off 200 Ω or higher C126231E13 HINT: If the resistance changes to 200 Ω or higher when the connector is disconnected from the ECU (or sensor), there may be a short in the ECU (or sensor). NG REPAIR OR REPLACE CORRESPONDING ECU OR SENSOR BUS LINE OR CONNECTOR CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CA–115 OK REPLACE CORRESPONDING ECU OR SENSOR 6 CHECK FOR SHORT TO GND IN CAN BUS WIRE No. 2 CAN J/C Connector (Front of the Vehicle) Wire Harness Side View: (a) Reconnect the CAN main bus line connector (E42) to the No. 1 CAN J/C "A" side (with earth terminal). (b) Disconnect the No. 2 CAN J/C connector (A40) (front of the vehicle). CA Front A40 C133245E02 E10 DLC3: (c) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester Connection CG NG CANL Condition Specified Value E10-6 (CANH) - E10-4 (CG) Ignition switch off 200 Ω or higher E10-14 (CANL) - E10-4 (CG) Ignition switch off 200 Ω or higher OK C126231E13 Go to step 11 CA–116 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 7 CHECK FOR SHORT TO GND IN CAN BUS WIRE (NO. 1 CAN J/C - NO. 2 CAN J/C) No. 2 CAN J/C Connector (Rear of the Vehicle) Wire Harness Side View: (a) Disconnect the No. 2 CAN J/C connector (E41) (rear of the vehicle). Front E41 CANH CA CANL C133246E01 (b) Measure the resistance according to the value(s) in the table below. Standard resistance E10 DLC3: Tester Connection CG Condition Specified Value E41-4 (CANH) - E10-4 (CG) Ignition switch off 200 Ω or higher E41-10 (CANL) - E10-4 (CG) Ignition switch off 200 Ω or higher NG C126231E15 REPAIR OR REPLACE CAN BUS MAIN WIRE OR CONNECTOR (NO. 1 CAN J/C - NO. 2 CAN J/C) OK 8 RECONNECT CONNECTOR (a) Reconnect the No. 2 CAN J/C connector (A40) (front of the vehicle). NEXT CA–117 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 9 CHECK FOR SHORT TO GND IN CAN BUS WIRE (A/C AMPLIFIER BRANCH WIRE) No. 2 CAN J/C Connector (Rear of the Vehicle) Wire Harness Side View: (a) Disconnect the No. 2 CAN J/C connector (E41) (rear of the vehicle). Front E41 CANH CA CANL C133246E05 (b) Measure the resistance according to the value(s) in the table below. Standard resistance E10 DLC3: Tester Connection CG NG Specified Value E41-1 (CANH) - E10-4 (CG) Ignition switch off 200 Ω or higher E41-7 (CANL) - E10-4 (CG) Ignition switch off 200 Ω or higher OK C126231E15 Condition REPAIR OR REPLACE ACCESSORY GATEWAY BRANCH WIRE OR CONNECTOR CA–118 10 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CHECK FOR SHORT TO GND IN CAN BUS WIRE (A/C AMPLIFIER) No. 2 CAN J/C Connector (Rear of the Vehicle) Wire Harness Side View: (a) Disconnect the A/C amplifier connector (E38). Front E41 CANH CA CANL C133246E05 (b) Measure the resistance according to the value(s) in the table below. Standard resistance E10 DLC3: Tester Connection CG OK REPLACE A/C AMPLIFIER Condition Specified Value E41-1 (CANH) - E10-4 (CG) Ignition switch off 200 Ω or higher E41-7 (CANL) - E10-4 (CG) Ignition switch off 200 Ω or higher NG C126231E15 REPAIR OR REPLACE A/C AMPLIFIER BRANCH WIRE OR CONNECTOR CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 11 CA–119 CHECK FOR SHORT TO GND IN CAN BUS WIRE (ECM MAIN BUS WIRE) No. 2 CAN J/C Connector (Front of the Vehicle) Wire Harness Side View: (a) Disconnect the No. 2 CAN J/C connector (A40) (front of the vehicle). Front CANH A40 CA CANL C133245E04 (b) Measure the resistance according to the value(s) in the table below. Standard resistance E10 DLC3: Tester Connection CG NG Specified Value A40-1 (CANH) - E10-4 (CG) Ignition switch off 200 Ω or higher A40-7 (CANL) - E10-4 (CG) Ignition switch off 200 Ω or higher OK C126231E15 Condition Go to step 13 CA–120 12 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CHECK FOR SHORT TO GND IN CAN BUS WIRE (ECM) (a) Disconnect the ECM connector (A24 or A55). No. 2 CAN J/C Connector (Front of the Vehicle) Wire Harness Side View: Front CANH A40 CA CANL C133245E04 (b) Measure the resistance according to the value(s) in the table below. Standard resistance E10 DLC3: Tester Connection CG OK REPLACE ECM Specified Value A40-1 (CANH) - E10-4 (CG) Ignition switch off 200 Ω or higher A40-7 (CANL) - E10-4 (CG) Ignition switch off 200 Ω or higher NG C126231E15 Condition REPAIR OR REPLACE CAN BUS MAIN WIRE OR CONNECTOR (ECM - NO. 2 CAN J/C) CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 13 CA–121 CHECK FOR SHORT TO GND IN CAN BUS WIRE (SKID CONTROL ECU) No. 2 CAN J/C Connector (Front of the Vehicle) Wire Harness Side View: (a) Disconnect the skid control ECU connector (A25, A26 or A60). Front CANH A40 CA CANL C133245E05 (b) Measure the resistance according to the value(s) in the table below. Standard resistance E10 DLC3: Tester Connection CG Condition Specified Value A40-2 (CANH) - E10-4 (CG) Ignition switch off 200 Ω or higher A40-8 (CANL) - E10-4 (CG) Ignition switch off 200 Ω or higher OK REPLACE BRAKE ACTUATOR ASSEMBLY C126231E15 NG REPAIR OR REPLACE SKID CONTROL ECU BRANCH WIRE OR CONNECTOR CA–122 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM Open in One Side of CAN Branch Line DESCRIPTION If 2 or more ECUs and/or sensors do not appear on the intelligent tester "Communication Bus Check" screen, one side of the CAN branch line may be open. (One side of the CAN-H [branch line] / CAN-L [branch line] of the ECU and/or sensor is open.) Symptom 2 or more ECUs and/or sensors do not appear on the intelligent tester "Communication Bus Check" screen. CA Trouble Area • • • • • • • • • One side of the CAN branch line is open Steering angle sensor Skid control ECU ECM Yaw rate sensor Main body ECU A/C amplifier Center airbag sensor Combination meter CA–123 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM WIRING DIAGRAM F1 Combination Meter : CAN Main Bus Wire (CANH) : CAN Main Bus Wire (CANL) : CAN Branch Wire (CANH) : CAN Branch Wire (CANL) CANH 17 B W 1 E43 No. 1 CAN J/C CANL 18 E10 DLC3 E43 2 1 E62 2 E62 B W 6 14 CANH CANL E34 Yaw Rate Sensor (*1) 1 E46 2 E46 E8 Main Body ECU CANH 5 B CANL 6 W B 3 CANH W 2 CANL 1 E44 2 E44 E17 Steering Angle Sensor (*1) CANH 10 B CANL 9 W 1 E63 2 E63 E65 Center Airbag Sensor 1 E45 2 E45 (*1) : with VSC 1 E42 B E42 2 W B 13 CANH W 22 CANL : Suspected Area (Short in CAN Bus Wires) C133248E01 CA CA–124 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM : CAN Main Bus Line (CANH) : CAN Main Bus Line (CANL) : CAN Branch Line (CANH) : CAN Branch Line (CANL) B No. 2 CAN J/C CA A25 Skid Control ECU*1 W 4 E41 E41 10 2 A40 8 A40 B 26 CANH W 15 CANL A26 Skid Control ECU*2 E38 A/C Amplifier CANH 11 CANL 12 1 E61 2 E61 2 A40 8 A40 1 B E41 7 W E41 11 CANH W 25 CANL A26 Skid Control ECU*3 2 A40 8 A40 2 E41 W 8 E41 B *1 : without VSC 1 A40 *2 : with VSC (TMC Made) B W 17 CANH 18 CANL *3 : with VSC (TMMK Made) B B 35 CANH W 14 CANL A40 7 *4 : 2AZ-FE : Suspected Area (Short in CAN bus lines) *5 : 2GR-FE A 24*4 A 55*5 ECM C133249E01 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CA–125 INSPECTION PROCEDURE HINT: Perform the following inspection for the ECUs (sensors) which are not displayed on the intelligent tester. If the malfunction cannot be identified, then perform the following inspections for the ECUs (sensors) connected to CAN communication. 1 CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (a) Confirm the systems (ECUs and sensors), which use CAN communication, equipped on the vehicle. (See page CA-25) (b) Using the intelligent tester, select and perform "Communication Bus Check". (See page CA-25) [*1] (c) Disconnect the connectors from the ECUs or sensors that are not displayed on the screen. [*2] (d) Check that only the ECUs and sensors from which the connectors were disconnected in the previous step are not displayed on the "Communication Bus Check" screen. [*3] HINT: If any ECUs or sensors, other than those from which the connectors were disconnected in the previous step, are not displayed on the "Communication Bus Check" screen, reconnect the disconnected connectors and repeat the procedures [*1], [*2], and [*3]. (e) Perform the communication stop mode check for the ECUs and sensors which correspond to the disconnected connectors. (See page CA-10) NEXT GO TO CORRESPONDING COMMUNICATION STOP MODE CA PB–1 PARKING BRAKE – PARKING BRAKE SYSTEM PARKING BRAKE SYSTEM PROBLEM SYMPTOMS TABLE Use the table below to help determine the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. Symptom Brake drag Suspected area See page 1. Parking brake lever travel (Out of adjustment) PB-1 2. Parking brake pedal travel (Out of adjustment) PB-1 3. Parking brake wire (Sticking) [No. 1 cable] PB-48 4. Parking brake wire (Sticking) [No. 2/No. 3 cable] PB-48 5. Parking brake shoe clearance (Out of adjustment) PB-1 6. Parking brake shoe lining (Cracked or distorted) PB-60 7. Tension or return spring (Damaged) PB-58 PB PB–2 PARKING BRAKE – PARKING BRAKE SYSTEM ADJUSTMENT 1. REMOVE REAR WHEEL 2. ADJUST PARKING BRAKE SHOE CLEARANCE (a) Temporarily install the hub nuts. (b) Remove the shoe adjusting hole plug. (c) Turn the shoe adjuster and expand the shoe until the disc locks. (d) Turn and contract the shoe adjuster until the disc can rotate smoothly. Standard: Return 8 notches (e) Check that there is no brake drag against the shoe. (f) Install the shoe adjusting hole plug. (g) Remove the hub nuts. Expand Contract C131914E01 3. INSTALL REAR WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 4. INSPECT PARKING BRAKE PEDAL TRAVEL (for Automatic Transaxle) (a) Fully depress the parking brake pedal and release it to engage the parking brake. (b) Depress the pedal to the floor again, and release it to disengage the parking brake. PB (c) Slowly depress the parking brake pedal to the floor, and count the number of clicks. Parking brake pedal travel: 7 to 10 notches at 300 N (31 kgf, 67 lbf) 5. C107204 ADJUST PARKING BRAKE PEDAL TRAVEL (for Automatic Transaxle) (a) Depress the parking brake pedal. Hold the No. 1 wire adjusting nut using a wrench and loosen the lock nut. (b) Release the parking brake pedal. (c) Turn the No. 1 wire adjusting nut until the parking brake pedal travel meets the above specification. (d) Hold the No. 1 wire adjusting nut using a wrench or an equivalent tool and tighten the lock nut. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) (e) Count the number of clicks after depressing and releasing the parking brake pedal 3 or 4 times. (f) Check whether the parking brake drags. (g) When operating the parking brake pedal, check that the parking brake indicator light comes on. No. 1 Wire Adjusting Nut Lock Nut C133443E01 6. INSPECT PARKING BRAKE LEVER TRAVEL (for Manual Transaxle) (a) Pull the parking brake lever firmly. (b) Release the parking brake lock, and return the parking brake lever to its off position. PARKING BRAKE – PARKING BRAKE SYSTEM PB–3 (c) Slowly pull the parking brake lever all the way up, and count the number of clicks. Parking brake lever travel: 7 to 9 notches at 200 N (20 kgf, 45 lbf) 7. C131910 Wire Adjusting No. 1 Nut Lock Nut C131913E01 ADJUST PARKING BRAKE LEVER TRAVEL (for Manual Transaxle) (a) Pull up the parking brake lever. Hold the No. 1 wire adjusting nut using a wrench and loosen the lock nut. (b) Release the parking brake lever. (c) Turn the No. 1 wire adjusting nut until the parking brake lever travel meets the above specification. (d) Hold the No. 1 wire adjusting nut using a wrench or an equivalent tool and tighten the lock nut. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) (e) Count the number of clicks after depressing and releasing the parking brake lever 3 or 4 times. (f) Check whether the parking brake drags. (g) When operating the parking brake lever, check that the parking brake indicator light comes on. PB PB–3 PARKING BRAKE – PARKING BRAKE LEVER PARKING BRAKE LEVER PARKING BRAKE BRAKE COMPONENTS for Manual Seat: FRONT SEAT HEADREST ASSEMBLY SEAT TRACK COVER RH 37 (377, 27) INNER SEAT TRACK BRACKET COVER RH PB 37 (377, 27) FRONT SEAT ASSEMBLY RH FRONT SEAT HEADREST ASSEMBLY INNER SEAT TRACK BRACKET COVER LH SEAT TRACK COVER LH 37 (377, 27) 37 (377, 27) FRONT SEAT ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque B132048E01 PB–4 PARKING BRAKE – PARKING BRAKE LEVER for Power Seat: FRONT SEAT HEADREST ASSEMBLY SEAT TRACK COVER RH INNER SEAT TRACK BRACKET COVER LH 37 (377, 27) 37 (377, 27) PB FRONT SEAT ASSEMBLY RH FRONT SEAT HEADREST ASSEMBLY INNER SEAT TRACK BRACKET COVER RH 37 (377, 27) SEAT TRACK COVER LH 37 (377, 27) FRONT SEAT ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque B132047E01 PB–5 PARKING BRAKE – PARKING BRAKE LEVER for TMC made: DRIVER SIDE KNEE AIRBAG ASSEMBLY INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY 10 (102, 7) PB or LOWER INSTRUMENT PANEL FINISH PANEL LH LOWER INSTRUMENT PANEL SUB-ASSEMBLY UPPER CONSOLE PANEL SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C133459E01 PB–6 PARKING BRAKE – PARKING BRAKE LEVER for TMMK made: DRIVER SIDE KNEE AIRBAG ASSEMBLY INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY 10 (102, 7) PB or

or

LOWER INSTRUMENT PANEL FINISH PANEL LH LOWER INSTRUMENT PANEL SUB-ASSEMBLY UPPER CONSOLE PANEL SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C133459E02 PARKING BRAKE – PARKING BRAKE LEVER PB–7 NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH SHIFT LEVER KNOB SUB-ASSEMBLY UPPER CONSOLE PANEL PB UPPER CONSOLE REAR PANEL SUB-ASSEMBLY FLOOR CARPET BRACKET RH FLOOR CARPET BRACKET LH C133456E01 PB–8 PARKING BRAKE – PARKING BRAKE LEVER for TMC made: CONSOLE BOX POCKET CONSOLE BOX CARPET for Manual Air Conditioning System: NO. 1 CONSOLE BOX INSERT FRONT PB NO. 2 CONSOLE BOX INSERT FRONT CONSOLE BOX ASSEMBLY for Automatic Air Conditioning System: CONSOLE BOX ASSEMBLY C141955E01 PB–9 PARKING BRAKE – PARKING BRAKE LEVER for TMMK made: CONSOLE BOX POCKET CONSOLE BOX CARPET for Manual Air Conditioning System: NO. 1 CONSOLE BOX INSERT FRONT or or PB NO. 2 CONSOLE BOX INSERT FRONT CONSOLE BOX ASSEMBLY for Automatic Air Conditioning System: or or CONSOLE BOX ASSEMBLY C141955E02 PB–10 PARKING BRAKE – PARKING BRAKE LEVER FRONT DOOR OPENING TRIM WEATHERSTRIP RH REAR DOOR OPENING TRIM WEATHERSTRIP RH REAR DOOR SCUFF PLATE RH LOWER CENTER PILLAR GARNISH RH FRONT DOOR SCUFF PLATE RH COWL SIDE TRIM SUB-ASSEMBLY RH LUGGAGE DOOR LOCK OPEN LEVER SUB-ASSEMBLY PB FRONT FLOOR CARPET ASSEMBLY CROSS MEMBER FLOOR NO. 4 REINFORCEMENT SUB-ASSEMBLY REAR DOOR OPENING TRIM WEATHERSTRIP LH LOWER CENTER PILLAR GARNISH LH FRONT DOOR OPENING TRIM WEATHERSTRIP LH COWL SIDE TRIM SUB-ASSEMBLY LH REAR DOOR SCUFF PLATE LH FRONT DOOR SCUFF PLATE LH C132673E01 PARKING BRAKE – PARKING BRAKE LEVER PB–11 5.0 (51, 44 in.*lbf) 21 (214, 15)* 22 (224, 16)** NO. 1 WIRE ADJUSTING NUT PARKING BRAKE LEVER SUB-ASSEMBLY 1.0 (10, 9.0 in.*lbf) PARKING BRAKE SWITCH ASSEMBLY NO. 2 PARKING BRAKE CABLE ASSEMBLY NO. 3 PARKING BRAKE CABLE ASSEMBLY PB 21 (214, 15)* 22 (224, 16)** NO. 1 PARKING BRAKE CABLE ASSEMBLY PARKING BRAKE EQUALIZER N*m (kgf*cm, ft.*lbf) : Specified torque * For TMC made ** For TMMK made C132672E01 PB–12 PARKING BRAKE – PARKING BRAKE LEVER REMOVAL 1. PRECAUTION (See page IP-1) 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (for Manual Seat) CAUTION: Wait for 90 seconds after disconnecting the cable to prevent the airbag working. (See page RS-1) 3. REMOVE FRONT SEAT ASSEMBLY LH (for Manual Seat) HINT: Refer to the procedures up to "REMOVE FRONT SEAT ASSEMBLY (for Manual Seat)". (See page SE-16) 4. REMOVE FRONT SEAT ASSEMBLY RH (for Manual Seat) HINT: Use the same procedures for the RH side and the LH side. 5. REMOVE FRONT SEAT ASSEMBLY LH (for Power Seat) HINT: Refer to the procedures up to "REMOVE FRONT SEAT ASSEMBLY (for Power Seat)". (See page SE-30) 6. REMOVE FRONT SEAT ASSEMBLY RH (for Power Seat) HINT: Use the same procedures for the RH side and the LH side. 7. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-25) 8. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH (See page IR-26) 9. REMOVE INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY (See page IP-23) PB 10. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (See page IP-20) 11. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (See page IP-21) 12. REMOVE DRIVER SIDE KNEE AIRBAG ASSEMBLY (See page RS-370) 13. REMOVE LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMC Made) (See page IP-23) 14. REMOVE LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMMK Made) (See page IP-24) 15. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (See page IP-24) PARKING BRAKE – PARKING BRAKE LEVER PB–13 16. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-24) 17. REMOVE NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-25) 18. REMOVE UPPER CONSOLE PANEL (See page IP-25) 19. REMOVE UPPER CONSOLE REAR PANEL SUBASSEMBLY (See page IP-26) 20. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMC Made) (See page IP-27) 21. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMMK Made) (See page IP-27) 22. REMOVE CONSOLE BOX POCKET (See page IP-28) 23. REMOVE CONSOLE BOX CARPET (See page IP-28) 24. REMOVE CONSOLE BOX ASSEMBLY (for TMC Made) (See page IP-28) 25. REMOVE CONSOLE BOX ASSEMBLY (for TMMK Made) (See page IP-29) 26. REMOVE NO. 2 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-29) 27. REMOVE NO. 2 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-30) 28. REMOVE NO. 1 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-30) 29. REMOVE NO. 1 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-30) 30. REMOVE FLOOR CARPET BRACKET LH (See page AC-155) 31. REMOVE FLOOR CARPET BRACKET RH (See page AC-155) 32. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-24) 33. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH 34. REMOVE REAR DOOR SCUFF PLATE LH (See page IR-24) 35. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH 36. REMOVE LOWER CENTER PILLAR GARNISH LH (See page IR-25) 37. REMOVE FRONT DOOR SCUFF PLATE RH (See page IR-26) 38. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH PB PB–14 PARKING BRAKE – PARKING BRAKE LEVER 39. REMOVE REAR DOOR SCUFF PLATE RH (See page IR-24) 40. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH 41. REMOVE LOWER CENTER PILLAR GARNISH RH (See page IR-26) 42. REMOVE LUGGAGE DOOR LOCK OPEN LEVER SUB-ASSEMBLY (a) Remove the screw. (b) Disengage the claw and remove the luggage door open lever sub-assembly. 43. REMOVE FRONT FLOOR CARPET ASSEMBLY (a) Disengage the 6 clamps and the 2 claws. C132659 PB Clamp Clamp C132661E01 (b) Turn back the front floor carpet assembly until the bolts of the cross member floor No. 4 reinforcement sub-assembly can be seen. 44. REMOVE CROSS MEMBER FLOOR NO. 4 REINFORCEMENT SUB-ASSEMBLY (a) Remove the 8 bolts and the cross member floor No. 4 reinforcement sub-assembly. C132658 PARKING BRAKE – PARKING BRAKE LEVER PB–15 45. SEPARATE NO. 3 PARKING BRAKE CABLE ASSEMBLY (a) Separate the No. 3 parking brake cable assembly from the parking brake equalizer. C138184 46. SEPARATE NO. 2 PARKING BRAKE CABLE ASSEMBLY Separate the No. 2 parking brake cable assembly from the parking brake equalizer. C138185 47. REMOVE PARKING BRAKE EQUALIZER (a) Slide the rubber boot as shown in the illustration. C138196 (b) Remove the parking brake equalizer from the No. 1 parking brake cable assembly. C132657 48. REMOVE PARKING BRAKE LEVER SUB-ASSEMBLY (a) Disconnect the parking brake switch connector. (b) Remove the 2 bolts, the clip, and the parking brake lever. C131911 PB PB–16 PARKING BRAKE – PARKING BRAKE LEVER DISASSEMBLY 1. REMOVE NO. 1 PARKING BRAKE CABLE ASSEMBLY (a) Using a screwdriver, pull up the parking brake lever claw. C131912 (b) Remove the lock nut, the No. 1 wire adjusting nut, and the No. 1 parking brake cable assembly from the parking brake lever sub-assembly. Lock Nut No. 1 Wire Adjusting Nut C132670E01 PB 2. REMOVE PARKING BRAKE SWITCH ASSEMBLY (a) Remove the screw and the parking brake switch assembly. C132654 REASSEMBLY 1. INSTALL PARKING BRAKE SWITCH ASSEMBLY (a) Install the parking brake switch assembly with the screw. Torque: 1.0 N*m (10 kgf*cm, 9.0 in.*lbf) 2. INSTALL NO. 1 PARKING BRAKE CABLE ASSEMBLY (a) Pass the No. 1 parking brake cable assembly through the parking brake lever sub-assembly. C132654 Lock Nut No. 1 Wire Adjusting Nut C132670E01 (b) Temporarily tighten the lock nut and the No. 1 wire adjusting nut. NOTICE: Fully tighten the lock nut when adjusting the parking brake lever travel. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) PARKING BRAKE – PARKING BRAKE LEVER PB–17 (c) Bend the parking brake lever claw. C132671 INSTALLATION 1. INSTALL PARKING BRAKE LEVER SUB-ASSEMBLY (a) Install the parking brake lever sub-assembly with the 2 bolts and the clip. Torque: for TMC made 21 N*m (214 kgf*cm, 15 ft.*lbf) for TMMK made 22 N*m (224 kgf*cm, 16 ft.*lbf) (b) Connect the parking brake switch connector. 2. INSTALL PARKING BRAKE EQUALIZER (a) Install the parking brake equalizer to the No. 1 parking brake cable assembly. C131911 C132657 (b) Slide the rubber boot back as shown in the illustration. C132656 3. C138185 INSTALL NO. 2 PARKING BRAKE CABLE ASSEMBLY (a) Connect the No. 2 parking brake cable assembly to the parking brake equalizer. PB PB–18 PARKING BRAKE – PARKING BRAKE LEVER 4. INSTALL NO. 3 PARKING BRAKE CABLE ASSEMBLY (a) Connect the No. 3 parking brake cable assembly to the parking brake equalizer. 5. INSTALL CROSS MEMBER FLOOR NO. 4 REINFORCEMENT SUB-ASSEMBLY (a) Install the cross member floor No. 4 reinforcement sub-assembly with the 8 bolts. 6. INSTALL FRONT FLOOR CARPET ASSEMBLY (a) Engage the 6 clamps and the 2 claws and install the front floor carpet assembly. C138184 C132658 PB Clamp Clamp C132661E01 C132659 7. INSTALL LUGGAGE DOOR LOCK OPEN LEVER SUB-ASSEMBLY (a) Engage the claw and install the luggage door open lever sub-assembly with the screw. 8. INSTALL LOWER CENTER PILLAR GARNISH LH (See page IR-53) 9. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (See page IR-55) 10. INSTALL REAR DOOR SCUFF PLATE LH (See page IR-56) PARKING BRAKE – PARKING BRAKE LEVER PB–19 11. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH (See page IR-54) 12. INSTALL FRONT DOOR SCUFF PLATE LH (See page IR-54) 13. INSTALL LOWER CENTER PILLAR GARNISH RH (See page IR-54) 14. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH (See page IR-56) 15. INSTALL REAR DOOR SCUFF PLATE RH (See page IR-56) 16. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH (See page IR-55) 17. INSTALL FRONT DOOR SCUFF PLATE RH (See page IR-55) 18. INSTALL FLOOR CARPET BRACKET LH 19. INSTALL FLOOR CARPET BRACKET RH 20. INSTALL NO. 2 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-50) 21. INSTALL NO. 2 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-50) 22. INSTALL NO. 1 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-49) 23. INSTALL NO. 1 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-50) 24. INSTALL CONSOLE BOX ASSEMBLY (for TMC Made) (See page IP-51) 25. INSTALL CONSOLE BOX ASSEMBLY (for TMMK Made) (See page IP-51) 26. INSTALL CONSOLE BOX CARPET (See page IP-51) 27. INSTALL CONSOLE BOX POCKET (See page IP-51) 28. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMC Made) (See page IP-52) 29. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMMK Made) (See page IP-52) 30. INSTALL UPPER CONSOLE REAR PANEL SUBASSEMBLY (See page IP-53) 31. INSTALL UPPER CONSOLE PANEL (See page IP-54) 32. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-55) 33. INSTALL NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-54) 34. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (See page IP-55) PB PB–20 PARKING BRAKE – PARKING BRAKE LEVER 35. INSTALL LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMC Made) (See page IP-55) 36. INSTALL LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMMK Made) (See page IP-56) 37. INSTALL INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY (See page IP-56) 38. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY (See page RS-370) 39. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (See page IP-58) 40. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (See page IP-59) 41. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-54) 42. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH (See page IR-55) PB 43. INSTALL FRONT SEAT ASSEMBLY LH (for Manual Seat) HINT: Refer to the procedures up to "INSTALL FRONT SEAT ASSEMBLY (for Manual Seat)". (See page SE-24) 44. INSTALL FRONT SEAT ASSEMBLY RH (for Manual Seat) HINT: Use the same procedures for the RH side and the LH side. 45. INSTALL FRONT SEAT ASSEMBLY LH (for Power Seat) HINT: Refer to the procedures up to "INSTALL FRONT SEAT ASSEMBLY (for Power Seat)". (See page SE-41) 46. INSTALL FRONT SEAT ASSEMBLY RH (for Power Seat) HINT: Use the same procedures for the RH side and the LH side. 47. INSPECT PARKING BRAKE LEVER TRAVEL (See page PB-2) 48. ADJUST PARKING BRAKE LEVER TRAVEL (See page PB-2) 49. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (for Manual Seat) 50. PERFORM ZERO POINT CALIBRATION AND SENSITIVITY CHECK (See page RS-242) 51. INSPECT SRS WARNING LIGHT 52. INSPECT SLIDE ADJUSTER LOCK (for Manual Seat) PARKING BRAKE – PARKING BRAKE LEVER PB–21 53. INSPECT FRONT SEAT ASSEMBLY (for Power Seat) (See page SE-42) PB PB–21 PARKING BRAKE – PARKING BRAKE PEDAL PARKING BRAKE PEDAL PARKING BRAKE BRAKE COMPONENTS for TMC made: DRIVER SIDE KNEE AIRBAG ASSEMBLY 10 (102, 7) LOWER INSTRUMENT PANEL FINISH PANEL LH INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY or LOWER INSTRUMENT PANEL SUB-ASSEMBLY COWL SIDE TRIM SUB-ASSEMBLY RH COWL SIDE TRIM SUB-ASSEMBLY LH FRONT DOOR SCUFF PLATE LH FRONT DOOR SCUFF PLATE RH UPPER CONSOLE PANEL SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C133466E01 PB PB–22 PARKING BRAKE – PARKING BRAKE PEDAL for TMMK made: DRIVER SIDE KNEE AIRBAG ASSEMBLY 10 (102, 7) PB LOWER INSTRUMENT PANEL FINISH PANEL LH or

INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY or

LOWER INSTRUMENT PANEL SUB-ASSEMBLY COWL SIDE TRIM SUB-ASSEMBLY RH COWL SIDE TRIM SUB-ASSEMBLY LH FRONT DOOR SCUFF PLATE LH FRONT DOOR SCUFF PLATE RH UPPER CONSOLE PANEL SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C133466E02 PB–23 PARKING BRAKE – PARKING BRAKE PEDAL for TMC made: CONSOLE BOX POCKET NO. 1 CONSOLE BOX INSERT FRONT CONSOLE BOX CARPET for Manual Air Conditioning System: NO. 2 CONSOLE BOX INSERT FRONT PB 18 (184, 13) CONSOLE BOX ASSEMBLY for Automatic Air Conditioning System: CENTER AIRBAG SENSOR ASSEMBLY with VSC: 13 (133, 10) YAW RATE AND ACCELERATION SENSOR CONSOLE BOX ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C141956E01 PB–24 PARKING BRAKE – PARKING BRAKE PEDAL for TMMK made: CONSOLE BOX POCKET NO. 1 CONSOLE BOX INSERT FRONT CONSOLE BOX CARPET for Manual Air Conditioning System: or or NO. 2 CONSOLE BOX INSERT FRONT PB 18 (184, 13) CONSOLE BOX ASSEMBLY CENTER AIRBAG SENSOR ASSEMBLY for Automatic Air Conditioning System: or or with VSC: 13 (133, 10) YAW RATE AND ACCELERATION SENSOR CONSOLE BOX ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C141957E01 PARKING BRAKE – PARKING BRAKE PEDAL PB–25 NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH SHIFT LEVER KNOB SUB-ASSEMBLY NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY PB UPPER CONSOLE REAR PANEL SUB-ASSEMBLY FLOOR CARPET BRACKET RH for Automatic Air Conditioning System: 12 (122, 9) FLOOR CARPET BRACKET LH FLOOR SHIFT LEVER ASSEMBLY NO. 1 CONSOLE BOX DUCT 12 (122, 9) N*m (kgf*cm, ft.*lbf) : Specified torque C133457E02 PB–26 PARKING BRAKE – PARKING BRAKE PEDAL 39 (398, 29) 1.0 (10, 9.0 in.*lbf) PARKING BRAKE SWITCH ASSEMBLY PARKING PEDAL PAD PARKING BRAKE PEDAL ASSEMBLY 39 (398, 29) PB CLIP 5.4 (55, 48 in.*lbf) NO. 1 WIRE ADJUSTING NUT NO. 1 PARKING BRAKE CABLE CLAMP 15 (153, 11) 5.4 (55, 48 in.*lbf) NO. 4 PARKING BRAKE CABLE ASSEMBLY NO. 1 PARKING BRAKE CABLE ASSEMBLY 5.4 (55, 48 in.*lbf) CLIP PARKING BRAKE EQUALIZER TMMK made: NO. 2 PARKING BRAKE CABLE ASSEMBLY NO. 1 PARKING BRAKE CABLE ASSEMBLY NO. 4 PARKING BRAKE CABLE ASSEMBLY NO. 3 PARKING BRAKE CABLE ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque 5.4 (55, 48 in.*lbf) Non-reusable part C133442E02 PARKING BRAKE – PARKING BRAKE PEDAL PB–27 REMOVAL 1. PRECAUTION (See page IP-1) 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait for 90 seconds after disconnecting the cable to prevent the airbag working. (See page RS-1) 3. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-24) 4. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-25) 5. REMOVE FRONT DOOR SCUFF PLATE RH (See page IR-26) 6. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH (See page IR-26) 7. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (See page IP-58) 8. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (See page IP-21) 9. REMOVE DRIVER SIDE KNEE AIRBAG ASSEMBLY (See page RS-370) 10. REMOVE INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY (See page IP-23) 11. REMOVE LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMC Made) (See page IP-23) 12. REMOVE LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMMK Made) (See page IP-24) 13. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (See page IP-24) 14. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-24) 15. REMOVE NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-25) 16. REMOVE FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (See page IP-25) 17. REMOVE UPPER CONSOLE REAR PANEL SUBASSEMBLY (See page IP-26) 18. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMC Made) (See page IP-27) 19. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMMK Made) (See page IP-27) 20. REMOVE CONSOLE BOX POCKET (See page IP-28) 21. REMOVE CONSOLE BOX CARPET (See page IP-28) PB PB–28 PARKING BRAKE – PARKING BRAKE PEDAL 22. REMOVE CONSOLE BOX ASSEMBLY (for TMC Made) (See page IP-28) 23. REMOVE CONSOLE BOX ASSEMBLY (for TMMK Made) (See page IP-29) 24. REMOVE NO. 2 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-29) 25. REMOVE NO. 2 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-30) 26. REMOVE NO. 1 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-30) 27. REMOVE NO. 1 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-30) 28. REMOVE NO. 1 CONSOLE BOX DUCT (for Automatic Air Conditioning System) (See page AC-154) 29. REMOVE FLOOR CARPET BRACKET LH (See page AC-155) 30. REMOVE FLOOR CARPET BRACKET RH (See page AC-155) PB 31. REMOVE YAW RATE AND ACCELERATION SENSOR (w/ VSC) (See page BC-447) 32. REMOVE FLOOR SHIFT LEVER ASSEMBLY (a) Remove the 4 bolts and the floor shift lever assembly. 33. REMOVE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-442) C132691 34. DISCONNECT NO. 4 PARKING BRAKE CABLE ASSEMBLY (a) Using a wrench, hold the lock nut and loosen the turnbuckle. (b) Disconnect the No. 4 parking brake cable assembly from the No. 1 parking brake cable assembly. Hold Turn C132693E01 PARKING BRAKE – PARKING BRAKE PEDAL PB–29 35. REMOVE PARKING BRAKE PEDAL ASSEMBLY (a) Using needle-nose pliers, remove the clip from the No. 1 parking brake cable assembly. (b) Remove the bolt, nut, and the No. 1 parking brake cable clamp. C132692 PB C132694 (c) Separate the No. 1 parking brake cable assembly from the body. (d) Disconnect the parking brake switch connector. (e) Remove the bolt, 2 nuts, and the parking brake pedal assembly with the No. 1 parking brake cable assembly from the body. C132695 PB–30 PARKING BRAKE – PARKING BRAKE PEDAL DISASSEMBLY 1. REMOVE NO. 1 PARKING BRAKE CABLE ASSEMBLY (a) Using a screwdriver, pull up the parking brake pedal claw. C132698 (b) Remove the lock nut and the No. 1 wire adjusting nut. C132697 PB (c) Using needle nose pliers, remove the clip and the No. 1 parking brake cable from the parking brake pedal assembly. C132696 2. REMOVE PARKING BRAKE SWITCH ASSEMBLY (a) Remove the screw and the parking brake switch assembly. 3. REMOVE PARKING PEDAL PAD (a) Remove the parking pedal pad. C132700 C132702 PARKING BRAKE – PARKING BRAKE PEDAL PB–31 REASSEMBLY 1. INSTALL PARKING PEDAL PAD (a) Install the parking pedal pad to the parking brake pedal assembly. 2. INSTALL PARKING BRAKE SWITCH ASSEMBLY (a) Install the parking brake switch assembly with the screw. Torque: 1.0 N*m (10 kgf*cm, 9.0 in.*lbf) 3. INSTALL NO. 1 PARKING BRAKE CABLE ASSEMBLY (a) Pass the No. 1 parking brake cable assembly through the pedal guide. C132702 C132700 (b) Using a brass bar and a hammer, install the clip to the No. 1 parking brake cable assembly. C133439 (c) Temporarily tighten the the lock nut and No. 1 wire adjusting nut. NOTICE: Fully tighten the lock nut and the No. 1 wire adjusting nut when adjusting the parking brake pedal travel. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) C132697 (d) Bend the parking brake pedal claw. C132699 PB PB–32 PARKING BRAKE – PARKING BRAKE PEDAL INSTALLATION 1. INSTALL PARKING BRAKE PEDAL ASSEMBLY (a) Install the parking brake pedal assembly with the bolt and 2 nuts. Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf) (b) Connect the parking brake switch connector. (c) Install the No. 1 parking brake cable assembly to the body with the bolt, the nut, and a new No. 1 parking brake cable clamp. C132695 PB C133453 Torque: Bolt 15 N*m (153 kgf*cm, 11 ft.*lbf) Nut 5.4 N*m (55 kgf*cm, 48 in.*lbf) (d) Using a brass bar and a hammer, install the clip to the No. 1 parking brake cable assembly. 2. C133438 CONNECT NO. 4 PARKING BRAKE CABLE ASSEMBLY (a) Connect the No. 4 parking brake cable assembly to the No. 1 parking brake cable assembly. PARKING BRAKE – PARKING BRAKE PEDAL PB–33 (b) Using a wrench, hold the lock nut and tighten the turnbuckle. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) Hold 3. INSTALL CENTER AIRBAG SENSOR ASSEMBLY (See page RS-442) 4. INSTALL FLOOR SHIFT LEVER ASSEMBLY (a) Install the floor shift lever assembly with the 4 bolts. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 5. INSTALL YAW RATE AND ACCELERATION SENSOR (w/ VSC) (See page BC-448) 6. INSTALL FLOOR CARPET BRACKET LH 7. INSTALL FLOOR CARPET BRACKET RH 8. INSTALL NO. 1 CONSOLE BOX DUCT (for Automatic Air Conditioning System) (See page AC-177) 9. INSTALL NO. 2 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-50) Turn C132693E01 C132691 10. INSTALL NO. 2 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-50) 11. INSTALL NO. 1 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-49) 12. INSTALL NO. 1 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-50) 13. INSTALL CONSOLE BOX ASSEMBLY (for TMC Made) (See page IP-51) 14. INSTALL CONSOLE BOX ASSEMBLY (for TMMK Made) (See page IP-51) 15. INSTALL CONSOLE BOX CARPET (See page IP-51) 16. INSTALL CONSOLE BOX POCKET (See page IP-51) 17. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMC Made) (See page IP-52) 18. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMMK Made) (See page IP-52) 19. INSTALL UPPER CONSOLE REAR PANEL SUBASSEMBLY (See page IP-53) 20. INSTALL FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (See page IP-53) 21. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-55) 22. INSTALL NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-54) PB PB–34 PARKING BRAKE – PARKING BRAKE PEDAL 23. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (See page IP-55) 24. INSTALL LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMC Made) (See page IP-55) 25. INSTALL LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMMK Made) (See page IP-56) 26. INSTALL INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY (See page IP-56) 27. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY (See page RS-370) 28. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (See page IP-58) 29. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (See page IP-59) 30. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-54) PB 31. INSTALL FRONT DOOR SCUFF PLATE LH (See page IR-54) 32. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH (See page IR-55) 33. INSTALL FRONT DOOR SCUFF PLATE RH (See page IR-55) 34. INSPECT PARKING BRAKE PEDAL TRAVEL (See page PB-1) 35. ADJUST PARKING BRAKE PEDAL TRAVEL (See page PB-1) 36. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 37. INSPECT SENSOR SIGNAL (See page BC-448) PB–35 PARKING BRAKE – PARKING BRAKE CABLE PARKING BRAKE CABLE PARKING BRAKE BRAKE COMPONENTS for Manual Seat: FRONT SEAT HEADREST ASSEMBLY SEAT TRACK COVER RH 37 (377, 27) INNER SEAT TRACK BRACKET COVER RH PB 37 (377, 27) FRONT SEAT ASSEMBLY RH FRONT SEAT HEADREST ASSEMBLY INNER SEAT TRACK BRACKET COVER LH SEAT TRACK COVER LH 37 (377, 27) 37 (377, 27) FRONT SEAT ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque B132048E01 PB–36 PARKING BRAKE – PARKING BRAKE CABLE for Power Seat: FRONT SEAT HEADREST ASSEMBLY SEAT TRACK COVER RH INNER SEAT TRACK BRACKET COVER LH 37 (377, 27) 37 (377, 27) PB FRONT SEAT ASSEMBLY RH FRONT SEAT HEADREST ASSEMBLY INNER SEAT TRACK BRACKET COVER RH 37 (377, 27) SEAT TRACK COVER LH 37 (377, 27) FRONT SEAT ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque B132047E01 PB–37 PARKING BRAKE – PARKING BRAKE CABLE for TMC made: DRIVER SIDE KNEE AIRBAG ASSEMBLY INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY 10 (102, 7) PB or LOWER INSTRUMENT PANEL FINISH PANEL LH LOWER INSTRUMENT PANEL SUB-ASSEMBLY UPPER CONSOLE PANEL SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C133459E01 PB–38 PARKING BRAKE – PARKING BRAKE CABLE for TMMK made: DRIVER SIDE KNEE AIRBAG ASSEMBLY INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY 10 (102, 7) PB or

or

LOWER INSTRUMENT PANEL FINISH PANEL LH LOWER INSTRUMENT PANEL SUB-ASSEMBLY UPPER CONSOLE PANEL SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C133459E02 PB–39 PARKING BRAKE – PARKING BRAKE CABLE for TMC made: NO. 1 CONSOLE BOX INSERT FRONT CONSOLE BOX POCKET NO. 2 CONSOLE BOX INSERT FRONT CONSOLE BOX CARPET for Manual Air Conditioning System: PB for Automatic Transaxle: 18 (184, 13) CONSOLE BOX ASSEMBLY for Automatic Air Conditioning System: CENTER AIRBAG SENSOR ASSEMBLY for Automatic Transaxle with VSC: 13 (133, 10) YAW RATE AND ACCELERATION SENSOR CONSOLE BOX ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C141956E02 PB–40 PARKING BRAKE – PARKING BRAKE CABLE for TMMK made: CONSOLE BOX POCKET NO. 1 CONSOLE BOX INSERT FRONT NO. 2 CONSOLE BOX INSERT FRONT CONSOLE BOX CARPET for Manual Air Conditioning System: or or PB for Automatic Transaxle: 18 (184, 13) CONSOLE BOX ASSEMBLY CENTER AIRBAG SENSOR ASSEMBLY for Automatic Transaxle with VSC: for Automatic Air Conditioning System: or or 13 (133, 10) YAW RATE AND ACCELERATION SENSOR CONSOLE BOX ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C141957E02 PARKING BRAKE – PARKING BRAKE CABLE PB–41 for Manual Transaxle: NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH SHIFT LEVER KNOB SUB-ASSEMBLY UPPER CONSOLE PANEL PB UPPER CONSOLE REAR PANEL SUB-ASSEMBLY FLOOR CARPET BRACKET RH FLOOR CARPET BRACKET LH C133456E02 PB–42 PARKING BRAKE – PARKING BRAKE CABLE for Automatic Transaxle: NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH SHIFT LEVER KNOB SUB-ASSEMBLY NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY PB UPPER CONSOLE REAR PANEL SUB-ASSEMBLY FLOOR CARPET BRACKET RH for Automatic Air Conditioning System: 12 (122, 9) FLOOR CARPET BRACKET LH FLOOR SHIFT LEVER ASSEMBLY NO. 1 CONSOLE BOX DUCT 12 (122, 9) N*m (kgf*cm, ft.*lbf) : Specified torque C133457E03 PB–43 PARKING BRAKE – PARKING BRAKE CABLE FRONT DOOR OPENING TRIM WEATHERSTRIP RH REAR DOOR OPENING TRIM WEATHERSTRIP RH REAR DOOR SCUFF PLATE RH LOWER CENTER PILLAR GARNISH RH FRONT DOOR SCUFF PLATE RH COWL SIDE TRIM SUB-ASSEMBLY RH LUGGAGE DOOR LOCK OPEN LEVER SUB-ASSEMBLY PB FRONT FLOOR CARPET ASSEMBLY CROSS MEMBER FLOOR NO. 4 REINFORCEMENT SUB-ASSEMBLY REAR DOOR OPENING TRIM WEATHERSTRIP LH LOWER CENTER PILLAR GARNISH LH FRONT DOOR OPENING TRIM WEATHERSTRIP LH COWL SIDE TRIM SUB-ASSEMBLY LH REAR DOOR SCUFF PLATE LH FRONT DOOR SCUFF PLATE LH C132673E01 PB–44 PARKING BRAKE – PARKING BRAKE CABLE for Manual Transaxle: NO. 1 WIRE ADJUSTING NUT 5.0 (51, 44 in.*lbf) 21 (214, 15)* 22 (224, 16)** PARKING BRAKE LEVER SUB-ASSEMBLY NO. 2 PARKING BRAKE CABLE ASSEMBLY PB NO. 3 PARKING BRAKE CABLE ASSEMBLY 21 (214, 15)* 22 (224, 16)** NO. 1 PARKING BRAKE CABLE ASSEMBLY PARKING BRAKE EQUALIZER N*m (kgf*cm, ft.*lbf) : Specified torque * For TMC made ** For TMMK made C138181E01 PB–45 PARKING BRAKE – PARKING BRAKE CABLE for Automatic Transaxle: 39 (398, 29) PARKING BRAKE PEDAL ASSEMBLY 39 (398, 29) 5.4 (55, 48 in.*lbf) NO. 1 WIRE ADJUSTING NUT PB CLIP NO. 1 PARKING BRAKE CABLE ASSEMBLY 15 (153, 11) NO. 1 PARKING BRAKE CABLE CLAMP 5.4 (55, 48 in.*lbf) NO. 4 PARKING BRAKE CABLE ASSEMBLY 5.4 (55, 48 in.*lbf) CLIP PARKING BRAKE EQUALIZER TMMK made: 5.4 (55, 48 in.*lbf) NO. 2 PARKING BRAKE CABLE ASSEMBLY NO. 3 PARKING BRAKE CABLE ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque NO. 1 PARKING BRAKE CABLE ASSEMBLY NO. 4 PARKING BRAKE CABLE ASSEMBLY Non-reusable part C138178E01 PB–46 PARKING BRAKE – PARKING BRAKE CABLE PARKING BRAKE SHOE HOLD DOWN SPRING NO. 2 PIN 62 (632, 46) REAR DISC BRAKE CALIPER ASSEMBLY REAR DISC PARKING BRAKE SHOE HOLD DOWN SPRING NO. 1 PIN PARKING BRAKE SHOE RETURN TENSION NO. 1 SPRING PARKING BRAKE SHOE STRUT PB NO. 2 PARKING BRAKE SHOE ASSEMBLY PARKING BRAKE SHOE STRUT COMPRESSION SPRING NO. 1 PARKING BRAKE SHOE ASSEMBLY SHOE ADJUSTING HOLE PLUG PARKING BRAKE SHOE HOLD DOWN SPRING NO. 2 CUP PARKING BRAKE SHOE HOLD DOWN SPRING PARKING BRAKE SHOE HOLD DOWN SPRING NO. 1 CUP PARKING BRAKE SHOE HOLD DOWN SPRING NO. 2 CUP PARKING BRAKE SHOE HOLD DOWN SPRING N*m (kgf*cm, ft.*lbf) : Specified torque PARKING BRAKE SHOE HOLD DOWN SPRING NO. 1 CUP PARKING BRAKE SHOE RETURN TENSION NO. 2 SPRING PARKING BRAKE SHOE ADJUSTING SCREW SET Apply high temperature grease C138182E01 PB–47 PARKING BRAKE – PARKING BRAKE CABLE for 2AZ-FE: GASKET TAILPIPE ASSEMBLY 43 (438, 32) EXHAUST PIPE SUPPORT NO. 4 43 (438, 32) 56 (571, 41) CENTER EXHAUST PIPE ASSEMBLY PB EXHAUST PIPE SUPPORT NO. 4 56 (571, 41) GASKET for 2GR-FE: EXHAUST PIPE SUPPORT NO. 4 EXHAUST TAIL PIPE ASSEMBLY EXHAUST CENTER PIPE ASSEMBLY GASKET 43 (438, 32) 43 (438, 32) GASKET 56 (571, 41) 43 (438, 32) GASKET 56 (571, 41) EXHAUST TAIL EXHAUST PIPE SUPPORT NO. 4 PIPE ASSEMBLY 43 (438, 32) N*m (kgf*cm, ft.*lbf) : Specified torque EXHAUST PIPE SUPPORT NO. 4 Non-reusable part C138183E01 PB–48 PARKING BRAKE – PARKING BRAKE CABLE PARKING BRAKE EQUALIZER NO. 3 PARKING BRAKE CABLE ASSEMBLY 8.0 (82, 71 in.*lbf) 8.5 (87, 75 in.*lbf) 6.0 (61, 53 in.*lbf) PARKING BRAKE CABLE CLAMP for 2AZ-FE: PB NO. 2 FRONT FLOOR HEAT LOWER INSULATOR 4.9 (50, 43 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque C131895E01 PARKING BRAKE – PARKING BRAKE CABLE PB–49 REMOVAL HINT: • Use the same procedures for the No. 2 parking brake cable assembly and No. 3 parking brake cable assembly. • The procedures listed below are for the No. 3 parking brake cable assembly. 1. PRECAUTION (See page IP-20) 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (for Manual Seat) CAUTION: Wait for 90 seconds after disconnecting the cable to prevent the airbag working. (See page RS-1) 3. REMOVE FRONT SEAT ASSEMBLY LH (for Manual Seat) HINT: Refer to the procedures up to "REMOVE FRONT SEAT ASSEMBLY (for Manual Seat)". (See page SE-16) 4. REMOVE FRONT SEAT ASSEMBLY RH (for Manual Seat) HINT: Use the same procedures for the RH side and the LH side. 5. REMOVE FRONT SEAT ASSEMBLY LH (for Power Seat) HINT: Refer to the procedures up to "REMOVE FRONT SEAT ASSEMBLY (for Power Seat)". (See page SE-30) 6. REMOVE FRONT SEAT ASSEMBLY RH (for Power Seat) HINT: Use the same procedures for the RH side and the LH side. 7. REMOVE PARKING BRAKE LEVER SUB-ASSEMBLY (for Manual Transaxle) HINT: Refer to the procedures up to "REMOVE PARKING BRAKE LEVER". (See page PB-11) 8. REMOVE NO. 1 PARKING BRAKE CABLE ASSEMBLY (for Manual Transaxle) (See page PB-15) 9. REMOVE PARKING BRAKE PEDAL ASSEMBLY (for Automatic Transaxle) HINT: Refer to the procedures up to "REMOVE PARKING BRAKE PEDAL". (See page PB-27) 10. REMOVE NO. 1 PARKING BRAKE CABLE ASSEMBLY (for Automatic Transaxle) (See page PB30) PB PB–50 PARKING BRAKE – PARKING BRAKE CABLE 11. REMOVE LUGGAGE DOOR LOCK OPEN LEVER SUB-ASSEMBLY (for Automatic Transaxle) (See page PB-13) 12. REMOVE FRONT FLOOR CARPET ASSEMBLY (for Automatic Transaxle) (See page PB-14) 13. REMOVE CROSS MEMBER FLOOR NO. 4 REINFORCEMENT SUB-ASSEMBLY (for Automatic Transaxle) (See page PB-14) 14. SEPARATE NO. 3 PARKING BRAKE CABLE ASSEMBLY (for Automatic Transaxle) (a) Separate the No. 3 parking brake cable assembly from the parking brake equalizer. C133446 15. SEPARATE NO. 2 PARKING BRAKE CABLE ASSEMBLY (for Automatic Transaxle) (a) Separate the No. 2 parking brake cable assembly from the parking brake equalizer. PB C133455 16. REMOVE NO. 4 PARKING BRAKE CABLE ASSEMBLY (for Automatic Transaxle) (a) Slide the rubber boot as shown in the illustration. C132655 (b) Remove the No. 4 parking brake cable assembly from the parking brake equalizer as shown in the illustration. 17. REMOVE CENTER EXHAUST PIPE ASSEMBLY (for 2AZ-FE) (See page EX-2) 18. REMOVE EXHAUST TAIL PIPE ASSEMBLY (for 2GRFE) (See page EX-2) C132657 19. REMOVE EXHAUST CENTER PIPE ASSEMBLY (for 2GR-FE) (See page EX-2) PARKING BRAKE – PARKING BRAKE CABLE PB–51 20. REMOVE NO. 2 FRONT FLOOR HEAT LOWER INSULATOR (for 2AZ-FE) (a) Remove the 3 nuts and the No. 2 front floor heat lower insulator. 21. REMOVE REAR WHEEL 22. SEPARATE REAR DISC BRAKE CALIPER ASSEMBLY (See page PB-58) 23. REMOVE REAR DISC (See page PB-58) C132669 24. REMOVE PARKING BRAKE SHOE RETURN TENSION NO. 1 SPRING (See page PB-58) 25. REMOVE PARKING BRAKE SHOE STRUT (See page PB-58) 26. REMOVE NO. 1 PARKING BRAKE SHOE ASSEMBLY (See page PB-58) 27. REMOVE PARKING BRAKE SHOE ADJUSTING SCREW SET (See page PB-59) 28. REMOVE NO. 2 PARKING BRAKE SHOE ASSEMBLY (See page PB-59) 29. REMOVE NO. 3 PARKING BRAKE CABLE ASSEMBLY (a) Remove the 2 bolts and separate the No. 3 parking brake cable assembly from the backing plate. C132666 (b) Using needle-nose pliers, remove the clip from the No. 3 parking brake cable assembly. for Manual Transaxle: for Automatic Transaxle: C138186E01 PB PB–52 PARKING BRAKE – PARKING BRAKE CABLE (c) Remove the 3 bolts (A), the bolt (B), and the nut (C), and disengage each claw. Nut (C) Bolt (A) Bolt (B) PB Bolt (A) C132668E03 (d) Remove the No. 3 parking brake cable assembly from the body. (e) Remove the parking brake cable clamp. Axle Carrier Side C132667E01 PB–53 PARKING BRAKE – PARKING BRAKE CABLE INSTALLATION 1. Axle Carrier Side C132667E01 INSTALL NO. 3 PARKING BRAKE CABLE ASSEMBLY (a) Install the parking brake cable clamp to the No. 3 parking brake cable assembly. (b) Install the No. 3 parking brake cable assembly with the 3 bolts (A), the bolt (B) and the nut (C), and engage each claw. Torque: Bolt (A) 8.5 N*m (87 kgf*cm, 75 in.*lbf) Bolt (B) and Nut (C) 6.0 N*m (61 kgf*cm, 53 in.*lbf) Nut (C) PB Bolt (A) Bolt (B) Bolt (A) C132668E03 PB–54 PARKING BRAKE – PARKING BRAKE CABLE (c) Install the No. 3 parking brake cable assembly to the backing plate with the 2 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) C132666 (d) Using a brass bar and a hammer, install the clip to the No. 3 parking brake cable assembly. for Manual Transaxle: PB 2. INSTALL NO. 2 PARKING BRAKE SHOE ASSEMBLY (See page PB-61) 3. INSTALL PARKING BRAKE SHOE ADJUSTING SCREW SET (See page PB-62) 4. INSTALL NO. 1 PARKING BRAKE SHOE ASSEMBLY (See page PB-62) 5. INSTALL PARKING BRAKE SHOE STRUT (See page PB-62) 6. INSTALL PARKING BRAKE SHOE RETURN TENSION NO. 1 SPRING (See page PB-62) 7. CHECK PARKING BRAKE INSTALLATION (See page PB-63) 8. INSTALL REAR DISC (See page PB-63) 9. ADJUST PARKING BRAKE SHOE CLEARANCE (See page PB-63) for Automatic Transaxle: C138187E01 10. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY (See page PB-63) 11. INSTALL REAR WHEEL 12. INSTALL NO. 2 FRONT FLOOR HEAT LOWER INSULATOR (for 2AZ-FE) (a) Install the No. 2 front floor heat lower insulator with the 3 nuts. Torque: 4.9 N*m (50 kgf*cm, 43 in.*lbf) 13. INSTALL CENTER EXHAUST PIPE ASSEMBLY (for 2AZ-FE) (See page EX-4) C132669 14. INSTALL EXHAUST CENTER PIPE ASSEMBLY (for 2GR-FE) (See page EX-4) 15. INSTALL EXHAUST TAIL PIPE ASSEMBLY (for 2GRFE) (See page EX-5) PARKING BRAKE – PARKING BRAKE CABLE PB–55 16. INSTALL NO. 4 PARKING BRAKE CABLE ASSEMBLY (for Automatic Transaxle) (a) Install the No. 4 parking brake cable assembly to the parking brake equalizer. C132657 (b) Slide the rubber boot back as shown in the illustration. Rubber Boot C132656E01 17. CONNECT NO. 2 PARKING BRAKE CABLE ASSEMBLY (for Automatic Transaxle) (a) Connect the No. 2 parking brake cable assembly to the parking brake equalizer. C133455 18. CONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY (for Automatic Transaxle) (a) Connect the No. 3 parking brake cable assembly to the parking brake equalizer. 19. INSTALL CROSS MEMBER FLOOR NO. 4 REINFORCEMENT SUB-ASSEMBLY (for Automatic Transaxle) (See page PB-18) C133446 20. INSTALL FRONT FLOOR CARPET ASSEMBLY (for Automatic Transaxle) (See page PB-18) 21. INSTALL LUGGAGE DOOR LOCK OPEN LEVER SUB-ASSEMBLY (for Automatic Transaxle) (See page PB-18) 22. INSTALL NO. 1 PARKING BRAKE CABLE ASSEMBLY (for Manual Transaxle) (See page PB-16) 23. INSTALL PARKING BRAKE LEVER SUB-ASSEMBLY (for Manual Transaxle) HINT: Refer to the procedures up to "INSTALL PARKING BRAKE LEVER". (See page PB-17) PB PB–56 PARKING BRAKE – PARKING BRAKE CABLE 24. INSTALL NO. 1 PARKING BRAKE CABLE ASSEMBLY (for Automatic Transaxle) (See page PB-31) 25. INSTALL PARKING BRAKE PEDAL ASSEMBLY (for Automatic Transaxle) HINT: Refer to the procedures up to "INSTALL PARKING BRAKE PEDAL". (See page PB-32) 26. INSTALL FRONT SEAT ASSEMBLY LH (for Manual Seat) HINT: Refer to the procedures up to "INSTALL FRONT SEAT ASSEMBLY (for Manual Seat)". (See page SE-24) 27. INSTALL FRONT SEAT ASSEMBLY RH (for Manual Seat) HINT: Use the same procedures for the RH side and the LH side. PB 28. INSTALL FRONT SEAT ASSEMBLY LH (for Power Seat) HINT: Refer to the procedures up to "INSTALL FRONT SEAT ASSEMBLY (for Power Seat)". (See page SE-41) 29. INSTALL FRONT SEAT ASSEMBLY RH (for Power Seat) HINT: Use the same procedures for the RH side and the LH side. 30. INSPECT PARKING BRAKE LEVER TRAVEL (for Manual Transaxle) (See page PB-2) 31. INSPECT PARKING BRAKE PEDAL TRAVEL (for Automatic Transaxle) (See page PB-1) 32. ADJUST PARKING BRAKE LEVER TRAVEL (for Manual Transaxle) (See page PB-2) 33. ADJUST PARKING BRAKE PEDAL TRAVEL (for Automatic Transaxle) (See page PB-1) 34. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (for Manual Seat) 35. PERFORM ZERO POINT CALIBRATION AND SENSITIVITY CHECK HINT: (See page RS-242) 36. INSPECT SRS WARNING LIGHT 37. INSPECT SLIDE ADJUSTER LOCK (for Manual Seat) 38. INSPECT FRONT SEAT ASSEMBLY (for Power Seat) (See page SE-42) 39. CHECK FOR EXHAUST GAS LEAKS (See page EX-5) PB–57 PARKING BRAKE – PARKING BRAKE ASSEMBLY PARKING BRAKE ASSEMBLY PARKING BRAKE BRAKE COMPONENTS PARKING BRAKE SHOE HOLD DOWN SPRING NO. 2 PIN REAR DISC BRAKE CALIPER ASSEMBLY 62 (632, 46) PARKING BRAKE SHOE HOLD DOWN SPRING NO. 1 PIN REAR DISC PARKING BRAKE SHOE GUIDE PLATE PARKING BRAKE SHOE RETURN TENSION NO. 1 SPRING 18 (184, 13) PB PARKING BRAKE SHOE GUIDE PLATE SET BOLT PARKING BRAKE SHOE STRUT C-WASHER NO. 2 PARKING BRAKE SHOE ASSEMBLY PARKING BRAKE SHOE HOLD DOWN SPRING NO. 2 CUP PARKING BRAKE SHOE STRUT COMPRESSION SPRING NO. 1 PARKING BRAKE SHOE ASSEMBLY SHOE ADJUSTING HOLE PLUG SHIM PARKING BRAKE SHOE HOLD DOWN SPRING PARKING BRAKE SHOE LEVER PARKING BRAKE SHOE HOLD DOWN SPRING NO. 1 CUP PARKING BRAKE SHOE HOLD DOWN SPRING NO. 2 CUP PARKING BRAKE SHOE ADJUSTING SCREW SET PARKING BRAKE SHOE RETURN TENSION NO. 2 SPRING PARKING BRAKE SHOE HOLD DOWN SPRING N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part High temperature grease C131896E01 PB–58 PARKING BRAKE – PARKING BRAKE ASSEMBLY DISASSEMBLY HINT: • Use the same procedures for the RH side and the LH side. • The procedures listed below are for the LH side. 1. REMOVE REAR WHEEL 2. SEPARATE REAR DISC BRAKE CALIPER ASSEMBLY (a) Remove the 2 bolts and separate the rear disc brake caliper assembly. HINT: Do not disconnect the flexible hose from the disc brake caliper assembly. 3. REMOVE REAR DISC (a) Release the parking brake and place the matchmarks on the rear disc and the axle hub. (b) Remove the rear disc. HINT: If the disc cannot be removed easily, turn the shoe adjuster until the wheel turns freely. 4. REMOVE PARKING BRAKE SHOE RETURN TENSION NO. 1 SPRING (a) Using needle-nose pliers, remove the 2 parking brake shoe return tension No. 1 springs. 5. REMOVE PARKING BRAKE SHOE STRUT (a) Remove the parking brake shoe strut and the parking brake shoe strut compression spring. 6. REMOVE NO. 1 PARKING BRAKE SHOE ASSEMBLY (a) Release the claw of the parking brake shoe hold down spring No. 1 cup. (b) Remove the No. 1 parking brake shoe assembly as shown in the illustration. (c) Remove the parking brake shoe hold down spring No. 1 cup, the parking brake shoe hold down spring, the parking brake shoe hold down spring No. 2 cup, and the parking brake shoe hold down spring No. 1 pin. C132653 Matchmarks PB C132813E02 C132651 C133469 PARKING BRAKE – PARKING BRAKE ASSEMBLY PB–59 7. REMOVE PARKING BRAKE SHOE ADJUSTING SCREW SET (a) Remove the parking brake shoe adjusting screw set. (b) Remove the parking brake shoe return tension No. 2 spring. 8. REMOVE NO. 2 PARKING BRAKE SHOE ASSEMBLY (a) Release the claw of the the parking brake shoe hold down spring No. 1 cup. (b) Remove the No. 2 parking brake shoe assembly as shown in the illustration. (c) Remove the parking brake shoe hold down spring No. 1 cup, the parking brake shoe hold down spring, the parking brake shoe hold down spring No. 2 cup, and the parking brake shoe hold down spring No. 2 pin. Adjusting Screw Set Return Tension No. 2 Spring C133473E01 C133471 (d) Using needle-nose pliers, disconnect the No. 3 parking brake cable assembly from the parking brake shoe lever. NOTICE: Be careful not to damage the No. 3 parking brake cable assembly. C108700 9. REMOVE PARKING BRAKE SHOE LEVER (a) Using a screwdriver, remove the C-washer, shim and the parking brake shoe lever. C132646 10. REMOVE PARKING BRAKE SHOE GUIDE PLATE (a) Remove the parking brake shoe guide plate set bolt and the parking brake shoe guide plate. C141958 PB PB–60 PARKING BRAKE – PARKING BRAKE ASSEMBLY INSPECTION 1. INSPECT BRAKE DISC INSIDE DIAMETER (a) Using a brake drum gauge or an equivalent tool, measure the inside diameter of the disc. Standard inside diameter: 170 mm (6.69 in.) Maximum inside diameter: 171 mm (6.73 in.) If the inside diameter is more than the maximum, replace the disc. 2. INSPECT PARKING BRAKE SHOE LINING THICKNESS (a) Using a ruler, measure the thickness of the shoe lining. Standard thickness: 2.0 mm (0.079 in.) Minimum thickness: 1.0 mm (0.039 in.) If the lining thickness is less than the minimum, or if there is severe or uneven wear, replace the brake shoe. NOTICE: Always replace both the right and left parking brake shoes together. 3. INSPECT BRAKE DISC AND PARKING BRAKE SHOE LINING FOR PROPER CONTACT (a) Apply chalk to the inside surface of the disc, then grind down the brake shoe lining to fit the disc. If the contact between the disc and the brake shoe lining is improper, repair it using a brake shoe grinder or replace the brake shoe. C132647 R000311 PB BR00828 PB–61 PARKING BRAKE – PARKING BRAKE ASSEMBLY REASSEMBLY 1. APPLY HIGH TEMPERATURE GREASE (a) Apply high temperature grease to the backing plate which makes contact with the shoe. 2. INSTALL PARKING BRAKE SHOE GUIDE PLATE (a) Apply adhesive to the threads of the parking brake shoe guide plate set bolt. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent (b) Install the parking brake shoe guide plate with the parking brake shoe guide plate set bolt. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) C141958 3. INSTALL PARKING BRAKE SHOE LEVER (a) Install the parking brake shoe lever and shim to the No. 2 parking brake shoe assembly with a new Cwasher. C132646 (b) Using a feeler gauge, measure the clearance between the No. 2 parking brake shoe assembly and parking brake shoe lever. Standard clearance: Less than 0.35 mm (0.014 in.) If the clearance is not as specified, replace the shim with one of the correct size. C132648 4. C108700 Shim Thickness Shim Thickness 0.3 mm (0.012 in.) 0.9 mm (0.035 in.) 0.6 mm (0.024 in.) - INSTALL NO. 2 PARKING BRAKE SHOE ASSEMBLY (a) Using needle-nose pliers, connect the No. 3 parking brake cable assembly to the parking brake shoe lever. PB PB–62 PARKING BRAKE – PARKING BRAKE ASSEMBLY (b) Install the No. 2 parking brake shoe assembly with the parking brake shoe hold down spring No. 2 pin, the parking brake shoe hold down spring No. 2 cup, the parking brake shoe hold down spring and the parking brake shoe hold down spring No. 1 cup. (c) Engage the claw of the parking brake shoe hold down spring No. 1 cup to the No. 2 parking brake shoe assembly. C133472 5. INSTALL PARKING BRAKE SHOE ADJUSTING SCREW SET (a) Apply high temperature grease to the parking brake adjusting screw as shown in the illustration. C132649 PB (b) Install the parking brake shoe return tension No. 2 spring to the No. 1 parking brake shoe assembly and the No. 2 parking brake shoe assembly. (c) Install the parking brake shoe adjusting screw set to the No. 1 parking brake shoe assembly and the No. 2 parking brake shoe assembly. Return Tension No. 2 Spring Adjusting Screw Set C133474E01 C133470 6. INSTALL NO. 1 PARKING BRAKE SHOE ASSEMBLY (a) Install the No. 1 parking brake shoe assembly with the parking brake shoe hold down spring No. 1 pin, parking brake shoe hold down spring No. 2 cup, parking brake shoe hold down spring and parking brake shoe hold down spring No. 1 cup. 7. INSTALL PARKING BRAKE SHOE STRUT (a) Attach the parking brake shoe strut and the parking brake shoe strut compression spring to the No. 1 parking brake shoe assembly and No. 2 parking brake shoe assembly. PB–63 PARKING BRAKE – PARKING BRAKE ASSEMBLY 8. INSTALL PARKING BRAKE SHOE RETURN TENSION NO. 1 SPRING (a) Using needle-nose pliers, install the 2 parking brake shoe return tension No. 1 springs. HINT: First install the front side spring and then the rear side spring. 9. CHECK PARKING BRAKE INSTALLATION (a) Check that each part is installed properly. C132651 LH: RH: PB Front Front C132644E01 NOTICE: There should be no oil or grease on the friction surface of the shoe lining and disc. 10. INSTALL REAR DISC (a) Align the matchmarks and install the rear disc. 11. ADJUST PARKING BRAKE SHOE CLEARANCE (a) Temporarily install the hub nuts. (b) Remove the shoe adjusting hole plug. (c) Turn the adjuster and expand the shoes until the disc locks. (d) Contract the shoe adjuster until the disc rotates smoothly. Standard: Return 8 notches (e) Check that the shoe has no brake drag. (f) Install the shoe adjusting hole plug. Contract C108703E01 PB–64 PARKING BRAKE – PARKING BRAKE ASSEMBLY 12. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY (a) Install the rear disc brake caliper assembly with the 2 bolts. Torque: 62 N*m (632 kgf*cm, 46 ft.*lbf) 13. INSTALL REAR WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 14. INSPECT PARKING BRAKE PEDAL TRAVEL (for Automatic Transaxle) (See page PB-1) C132653 15. INSPECT PARKING BRAKE LEVER TRAVEL (for Manual Transaxle) (See page PB-2) 16. ADJUST PARKING BRAKE PEDAL TRAVEL (for Automatic Transaxle) (See page PB-1) 17. ADJUST PARKING BRAKE LEVER TRAVEL (for Manual Transaxle) (See page PB-2) PB AIR CONDITIONING – AIR CONDITIONING SYSTEM AC–1 AIR CONDITIONING SYSTEM PRECAUTION 1. Charging Cylinder 2. DO NOT HANDLE REFRIGERANT IN AN ENCLOSED AREA OR NEAR AN OPEN FLAME ALWAYS WEAR EYE PROTECTION AC02810E02 3. AC02811 4. 5. Wrong LO HI 6. Okay LO HI 7. N011084E03 8. 9. BE CAREFUL NOT TO GET LIQUID REFRIGERANT IN YOUR EYES OR ON YOUR SKIN If liquid refrigerant gets in your eyes or on your skin: (a) Wash the area with lots of cold water. CAUTION: Do not rub your eyes or skin. (b) Apply clean petroleum jelly to the skin. (c) Go immediately to a hospital or see a physician for professional treatment. NEVER HEAT CONTAINER OR EXPOSE THE CONTAINER TO OPEN FLAME BE CAREFUL NOT TO DROP CONTAINER OR APPLY PHYSICAL SHOCKS TO IT DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH REFRIGERANT IN REFRIGERANT SYSTEM If there is not enough refrigerant in the A/C system, oil lubrication will be insufficient and the compressor may be damaged. Necessary care should be taken to avoid this. DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE WHILE COMPRESSOR IS OPERATING (a) Open and close only the low pressure valve. If the high pressure valve is opened, refrigerant flows in the reverse direction causing the charging cylinder to rupture. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH REFRIGERANT If refrigerant is overcharged, it causes problems such as insufficient cooling, poor fuel economy, engine overheating, etc. DO NOT OPERATE ENGINE AND COMPRESSOR WITH NO REFRIGERANT CAUTION: Doing so may damage the inside of the compressor because the compressor parts always move regardless of whether the A/C system is turned on or off. AC AC–2 AIR CONDITIONING – AIR CONDITIONING SYSTEM 10. SUPPLEMENTAL RESTRAINT SYSTEM (SRS) (a) This vehicle is equipped with an SRS (Supplemental Restraint System) such as the driver, front passenger, side, and curtain shield air bags. Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the precautionary notices (See page RS-1). 11. GENERAL PRECAUTION (a) While using the battery during inspection, do not bring the positive and negative tester probes too close to each other as a short circuit may occur. 12. EXPRESSIONS OF IGNITION SWITCH (a) The type of ignition switch used on this model differs according to the specifications of the vehicle. The expressions listed in the table below are used in this section. Switch Type Ignition switch off Expression Ignition switch on (IG) Ignition switch on (ACC) Engine start AC Ignition Switch (Position) Engine Switch (Condition) LOCK Off ON On (IG) ACC On (ACC) START Start AIR CONDITIONING – AIR CONDITIONING SYSTEM AC–3 PARTS LOCATION ECM (for 2GR-FSE) ECM (for 2AZ-FE) AIR CONDITIONING PRESSURE SENSOR AC ENGINE ROOM RELAY BLOCK AND JUNCTION BLOCK CONDENSER - HTR FUSE AMBIENT TEMPERATURE SENSOR - MG CLT RELAY COMPRESSOR AND MAGNETIC CLUTCH (for 2GR-FSE) COMPRESSOR AND PULLEY (for 2AZ-FE) E124494E01 AC–4 AIR CONDITIONING – AIR CONDITIONING SYSTEM MANUAL A/C: A/C AMPLIFIER AC DLC3 INSTRUMENT PANEL JUNCTION BLOCK A/C CONTROL ASSEMBLY - A/C NO. 2 FUSE - A/C FUSE E124498E01 AC–5 AIR CONDITIONING – AIR CONDITIONING SYSTEM AUTO A/C: SOLAR SENSOR STEERING PAD SWITCH ION GENERATOR (PLASMACLUSTERTM) A/C AMPLIFIER A/C CONTROL ASSEMBLY AC DLC3 INSTRUMENT PANEL JUNCTION BLOCK ROOM TEMPERATURE SENSOR - MAIN BODY ECU - A/C NO. 2 FUSE - A/C FUSE E124496E01 AC–6 AIR CONDITIONING – AIR CONDITIONING SYSTEM AIR INLET CONTROL SERVO MOTOR AIR OUTLET CONTROL SERVO MOTOR EXPANSION VALVE EVAPORATOR AC AIR CONDITIONING HARNESS BLOWER MOTOR AIR MIX CONTROL SERVO MOTOR AIR MIX CONTROL SERVO MOTOR (for DRIVER SIDE) EVAPORATOR TEMPERATURE SENSOR HEATER RADIATOR UNIT SUB-ASSEMBLY (for FRONT PASSENGER SIDE) E124499E01 AC–7 AIR CONDITIONING – AIR CONDITIONING SYSTEM SYSTEM DIAGRAM Auto A/C, Manual A/C: A/C Control Assembly Main Body ECU DLC3 Combination Meter ECM A/C Amplifier CAN (V-BUS) AC LIN E124510E01 Transmitter Receiver Line Signal Magnetic Clutch Request Signal Heater Idle Up Request Signal A/C Idle Up Request Signal Outside Temperature Data A/C Amplifier ECM CAN External Variable Control Solenoid Current Signal Prior A/C Control Request Signal Refrigerant Gas Pressure Sensor Signal A/C Amplifier Combination Meter CAN Outside Temperature Data A/C Amplifier DLC3 CAN Diagnostic Tool Response A/C Amplifier A/C Control Assembly LIN A/C Operating State Signal Auto Dimmer Signal Main Body ECU A/C Amplifier CAN Destination Package Destination Symbol Steering Wheel Combination Meter A/C Amplifier CAN Vehicle Speed Signal AC–8 AIR CONDITIONING – AIR CONDITIONING SYSTEM Transmitter Receiver Line Signal Engine Coolant Temperature Signal ECM A/C Amplifier Engine rpm Data CAN A/C Control Cut-off Signal A/C-E/G Cooperation Control A/C Control Assembly A/C Amplifier LIN A/C Operation Signal Manual A/C: Air Mix Control Servo Motor A/C Solenoid A/C Magnetic Clutch (for 2GR-FSE) Air Inlet Control Servo Motor Air Outlet Control Servo Motor AC A/C Pressure Sensor A/C Amplifier Blower Motor A/C Ambient Temperature Sensor Rear Defogger Relay A/C Evaporator Temperature Sensor A/C Control Assembly A/C Lock Sensor (for 2GR-FSE) LIN E124512E01 AC–9 AIR CONDITIONING – AIR CONDITIONING SYSTEM Auto A/C: A/C Solar Sensor (for Driver Side) Air Mix Control Servo Motor (for Driver Side) A/C Solar Sensor (for Front Passenger Side) Air Mix Control Servo Motor (for Front Passenger Side) A/C Solenoid Air Inlet Control Servo Motor Air Outlet Control Servo Motor A/C Magnetic Clutch (for 2GR-FSE) A/C Lock Sensor (for 2GR-FSE) A/C Amplifier Plasmacluster TM (Ion Generator) A/C Room Temperature Sensor AC Blower Motor A/C Ambient Temperature Sensor A/C Evaporator Temperature Sensor Rear Defogger Relay A/C Control Assembly Steering Pad Switch Assembly A/C Pressure Sensor LIN E124511E01 AC–10 AIR CONDITIONING – AIR CONDITIONING SYSTEM SYSTEM DESCRIPTION 1. Control GENERAL The air conditioning system has the following controls: Manual A/C Automatic A/C Neural Network Control This control is capable of effecting complex control by artificially simulating the information processing method of the nervous system of living organisms in order to establish a complex input / output relationship that is similar to a human brain. - { Manual Control The A/C amplifier controls the damper positions (air inlet control damper, air mix control damper and mode control damper) and blower speed in accordance with the positions of the switches (temperature control switch, blower switch, mode select switch and air inlet control switch). { - Based on the temperature set at the temperature control switch, the neural network control calculates the outlet air temperature based on the input signals from various sensors. - { The temperature setting for the driver and front passenger are controlled independently in order to provide a separate vehicle interior temperatures for the right and left side of the cabin. Thus, air conditioning that accommodates the occupants' preferences has been realized. - { Controls the blower motor in accordance with the airflow volume that has been calculated by the neural network control based on the input signals from various sensors. - { Automatically switches the air outlets in accordance with the outlet mode that has been calculated by the neural network control based on the input signals from various sensors. - { In accordance with the engine coolant temperature, outside air temperature, amount of sunlight, required blower, outlet temperature, and vehicle speed conditions, this control automatically switches the blower outlet to the FOOT / DEF mode to prevent the windows from becoming fogged when the outside air temperature is low. - { Automatically controls the air inlet control damper to achieve the calculated required outlet air temperature. - { Drives the servo motor (for air inlet) according to the operation of the air inlet control switch and moves the dampers to the FRESH or RECIRC position. - { Through the calculation of the target evaporator temperature based on various sensor signals, the A/C amplifier optimally controls the discharge capacity by regulating the opening extent of the A/C compressor solenoid valve. { { The A/C amplifier compares the A/C pulley speed signals, which are transmitted by the lock sensor located on the A/C compressor, with the engine speed signals, which are transmitted by the ECM (crankshaft position sensor). When the A/C amplifier determines that the A/C pulley is locked, it turns off the magnetic clutch. (for 2GR-FE) { { MAX A/C Control When the temperature control switch is in the MAX A/C position, the A/C amplifier turns the compressor on and activates the servomotor (air inlet) to set the air inlet control damper to the RECIRC position, improving the cooling efficiency. { - Rear Window Defogger Control Switches the rear defogger and outside rear view mirror heaters on for 15 minutes when the rear defogger button is pressed. Switches them off if the button is pressed while they are operating. { { Outside Temperature Indication Control Calculates the outside temperature using signals transmitted by the outside temperature sensor. Calculated values are corrected by the A/ C amplifier and then indicated on the multi-information display. { { Self-Diagnosis A DTC (Diagnostic Trouble Code) is stored in the memory when the A/ C amplifier detects a problem with the air conditioning system. { { Outlet Air Temp. Control Blower Control Air Outlet Control AC Air Inlet Control Compressor Control Outline AIR CONDITIONING – AIR CONDITIONING SYSTEM 2. AC–11 NEURAL NETWORK CONTROL • In previous automatic air conditioning systems, the A/ C amplifier determined the required outlet air temperature and blower air volume in accordance with the calculation formula that has been obtained based on information received from the sensors. However, because the senses of a person are rather complex, a given temperature is sensed differently, depending on the environment in which the person is situated. For example, a given amount of solar radiation can feel comfortably warm in a cold climate, or extremely uncomfortable in a hot climate. Therefore, as a technique for effecting a higher level of control, a neural network has been adopted in the automatic air conditioning system. With this technique, the data that has been collected under varying environmental conditions is stored in the A/C amplifier. The A/C amplifier can then effect control to provide enhanced air conditioning comfort. • The neural network control consists of neurons in the input layer, intermediate layer, and output layer. The input layer neurons process the input data of the outside temperature, the amount of sunlight, and the room temperature based on the outputs of the switches and sensors, and output them to the intermediate layer neurons. Based on this data, the intermediate layer neurons adjust the strength of the links among the neurons. The sum of these is then calculated by the output layer neurons in the form of the required outlet temperature, solar correction, target airflow volume, and outlet mode control volume. Accordingly, the A/C amplifier controls the servo motors and blower motor in accordance with the control volumes that have been calculated by the neural network control. AC AC–12 AIR CONDITIONING – AIR CONDITIONING SYSTEM Intermediate Layer Input Layer Outer Layer Target Output Temp. Ambient Temp. Amount of Sunlight Room Temp. Control Neural Network Outlet Processing Input Processing Terget Outlet Temp. Temp. Control Correction AC Air Mix Control Damper Amount of Sunlight Correction Temp. Setting Sensor Input Target Airflow Volume Various Types of Airflow Volume Correction Blower Motor Outlet Mode Various Types of Mode Correction Mode Control Damper Inlet Mode Various Types of Correction Air Inlet Control Damper Switch Input Compressor Compressor : Neural Network Operation Range E116942E01 AC–13 AIR CONDITIONING – AIR CONDITIONING SYSTEM 3. MODE POSITION AND DAMPER OPERATION (a) Mode Position and Damper Operation (for Manual A/C) Center Defroster Side Defroster Side Defroster FG Fresh Air Recirc. Air B H I A E D S Q R C Blower Motor Evaporator J O K Heater Core M L P N Side Register Side Register Front Center Front Foot Well Front Foot Well Register Register Duct Rear Foot Well Register Duct Register Duct AC Y E133954E01 Functions of Main Dampers: Control Damper Air Inlet Control Damper Air Mix Control Damper Operation Position Damper Position FRESH A Brings in fresh air. RECIRC B Recirculates internal air. MAX COLD to MAX HOT Temperature Setting C-D-E Operation Varies the mixture ratio of the fresh air and the recirculation air in order to regulate the temperature continuously from HOT to COLD. AC–14 AIR CONDITIONING – AIR CONDITIONING SYSTEM Control Damper Operation Position Damper Position F, J, L, P, S G, J, L, P, Q Defrosts the windshield through the center defroster, side defroster, side register, and rear register, while air is also blown out from the front and rear foot well register ducts. H, J, L, P, Q Air blows out of the foot well register duct and side register. In addition, air blows out slightly from the center defroster and side defroster. I, K, N, O, R Air blows out of the front center register, side register and front and rear foot well register ducts. I, K, M, O, S Air blows out of the front center register and side register. FOOT / DEF FOOT Air Outlet Control Damper Operation Defrosts the windshield through the center defroster, side defroster, side register, and rear register. DEF BI-LEVEL FACE (b) Mode Position and Damper Operation (for Automatic A/C) Center Defroster Side Defroster Side Defroster AC FG Fresh Air Blower Motor To Passenger Side H I Recric. Air B To Driver Side A S Q R E D C E D C E‘ C‘ D‘ T V U Evaporator K J Heater Core Side Register W Front Foot Well Register Dust X Y M L N O P Side Register Front Center Register Raer Center Register Front Foot Well Register Dust Rear Foot Well Register Dust Y C118756E03 Functions of Main Dampers: Control Damper Air Inlet Control Damper Operation Position Damper Position Operation FRESH A Brings in fresh air. RECIRC B Recirculates internal air. AC–15 AIR CONDITIONING – AIR CONDITIONING SYSTEM Control Damper Operation Position Damper Position MAX COLD to MAX HOT Temperature Setting Air Mix Control Damper Operation C-D-E (C' - D' - E') T-U-V Varies the mixture ratio of the fresh air and the recirculation air in order to regulate the temperature continuously from HOT to COLD. F, J, L, P, S, Y Defrosts the windshield through the center defroster, side defroster, and side register. G, J, L, P, Q, X Defrosts the windshield through the center defroster, side defroster, side register, and rear center register, while air is also blown out from the front and rear foot well register ducts. H, J, L, P, Q, X Air blows out of the foot well register dust, and side register. In addition, air blows out slightly from the center defroster and side defroster. I, K, N, O, R, X Air blows out of the front and rear center registers, side register and front and rear foot well register ducts. I, K, M, O, S, W Air blows out of the front and rear center registers, and side register. DEF FOOT / DEF FOOT Air Outlet Control Damper BI-LEVEL FACE 4. AIR OUTLETS AND AIRFLOW VOLUME (a) Air Outlets and Airflow Volume AC F F G B G A A B D D D D C E Y E E133944E02 AC–16 INDICATION (MODE) AIR CONDITIONING – AIR CONDITIONING SYSTEM SELECTION (Auto / Manual) FACE FOOT DEF CTR SIDE RR FR RR CTR SIDE A B C*6 D E F G FACE {/{ B/L-U*1 {/{ B/L-L*2 {/- FOOT-F*3 {/{ FOOT-R*4 {/- FOOT-D*5 {/- F/D {/{ AC DEF {/{ 5. The size of the circle { indicates the proportion of airflow volume. *1: Greater airflow volume at the upper area *2: Greater airflow volume at the lower area *3: Greater airflow volume at the front *4: Greater airflow volume at the rear *5: Greater airflow volume at the defroster *6: Only for models with automatic air conditioning. PLASMACLUSTER ION GENERATOR CONTROL (a) General: (1) A Plasmacluster ion generator is provided inside the air duct of the side register on the driver seat side to improve the air quality and comfort in the cabin. (2) This generator is controlled by the A/C amplifier and operates in conjunction with the blower motor. NOTICE: • The Plasmacluster ion generator uses a high voltage, which is hazardous. Therefore, if the Plasmacluster ion generator requires repairs, be sure to have them done at a TOYOTA dealer. AIR CONDITIONING – AIR CONDITIONING SYSTEM 6. AC–17 • Do not apply any type of spray (such as a cleaning solvent or hair spray) or stick any foreign matter into the Plasmacluster ion outlet, as this could cause improper operation or a malfunction. • After use, dust may accumulate around the side register on the driver seat side. If this occurs, press the OFF switch on the heater control panel to stop the blower motor before cleaning the area. • It is normal for the Plasmacluster ion generator to emit a slight sound during operation. This sound is created when electrons collide with the electrode while Plasmacluster ions are being generated. HINT: PlasmaclusterTM, plasmacluster, and plasmacluster ions are a trademark of the SHARP Corporation. (b) Operation: (1) The Plasmacluster ion generator produces positive and negative ions from the water molecules (H2O) and oxygen molecules (O2) in the air, and emits them into the air. These ions reduce airborne germs. BLOWER MOTOR The blower motor has a built-in blower controller, and is controlled with duty control from the A/C amplifier. AC AC–18 AIR CONDITIONING – AIR CONDITIONING SYSTEM 7. BUS CONNECTOR (a) A BUS connector is used in the wire harness connection that connects the servo motor from the A/C amplifier. Top View: Bus Connector To Air Mix Servo Motor (For Driver) To A/C Amplifier Bus Connector To Air Inlet Servo Motor Side View: Bus Connector AC Evaporator Temp. Sensor To Air Outlet Servo Motor Bus Connector To Air Mix Servo Motor (For Front Passenger) E116948E01 AC–19 AIR CONDITIONING – AIR CONDITIONING SYSTEM (b) The BUS connector has a built-in communication/ driver IC which communicates with each servo motor connector, actuates the servo motor, and has a position detection function. This enables bus communication for the servo motor wire harness, for a more lightweight construction and a reduced number of wires. with BUS Connector: BUS Connector Communication/Driver IC A/C Amplifier Communication IC Servo Motor CPU without BUS Connector: A/C Amplifier Drive IC AC Servo Motor CPU Drive IC E116949E01 AC–20 AIR CONDITIONING – AIR CONDITIONING SYSTEM 8. SERVO MOTOR (a) The pulse pattern type servo motor consists of a printed circuit board and servo motor. The printed circuit board has three contact points, and transmits to the A/C amplifier two ON-OFF signals for the difference of the pulse phase. The BUS connector detects the damper position and movement direction with this signal. Contact Points Conductive Portion Printed-circuit Board Contact Points A GND A B GND B A Hi Lo B AC Hi Lo Conductive Portion 1 Rotation Printed-circuit Board E116950E01 9. A/C COMPRESSOR (a) General (1) The A/C compressor is a continuously variable capacity type in which its capacity can be varied in accordance with the cooling load of the air conditioning. (2) This compressor consists of the A/C pulley, shaft, lug plate, swash plate, piston, shoe, crank chamber, cylinder, and solenoid valve. (3) The A/C pulley with built-in magnetic clutch and the lock sensor that detects whether the magnetic clutch is locked are installed on models with the 2GR-FE. (4) The DL (Damper Limiter) type A/C pulley is installed on models with the 2AZ-FE. (5) A solenoid valve that adjusts the suction pressure so that the compressor capacity can be controlled as desired is provided. AIR CONDITIONING – AIR CONDITIONING SYSTEM AC–21 (6) The internal valve is provided on models with 2AZ-FE to improve the A/C compressor durability under the high speed and large thermal load conditions. The internal valve is integrated into the solenoid valve. (b) Solenoid Valve Operation (1) The crank chamber is connected to the discharge passage. A solenoid valve is provided between the discharge passage (LO pressure) and the discharge passage (HI pressure). (2) The solenoid valve operates under duty cycle control in accordance with the signals from A/C amplifier. (3) When the solenoid valve closes (solenoid coil is energized), a difference in pressure is created and the pressure in the crank chamber decreases. Then, the pressure that is applied to the right side of the piston becomes greater than the pressure that is applied to the left side of the piston. This compresses the spring and tilts the swash plate. As a result, the piston stroke increases and the discharge capacity increases. (4) When the solenoid valve opens (solenoid coil is not energized), the difference in pressure disappears. Then, the pressure that is applied to the left side of the piston becomes the same as the pressure that is applied to the right side of the piston. Thus, the spring elongates and eliminates the tilt of the swash plate. As a result, there is no piston stroke and the discharge capacity is reduced. (c) Internal Valve Operation (for 2AZ-FE) (1) The internal valve operates when the A/C compressor speed has increased rapidly, the A/ C compressor speed is high, or when thermal load has suddenly changed. As a result, the A/C compressor capacity is reduced, increasing the durability of the A/C compressor. (d) DL type A/C Pulley (for 2AZ-FE) (1) This pulley contains a damper to absorb the torque fluctuations of the engine and a limiter mechanism to protect the drive belt in case the compressor locks. In the event that the compressor locks, the limiter mechanism causes the spoke portion of the pulley to break, thus separating the pulley from the compressor. 10. LOCK SENSOR (for 2GR-FE) The lock sensor sends A/C pulley speed signals to the A/ C amplifier. The A/C amplifier determines whether the magnetic clutch is locked or not by using those signals and engine speed signals. AC AC–22 AIR CONDITIONING – AIR CONDITIONING SYSTEM 11. ROOM TEMPERATURE SENSOR (for AUTO A/C) The room temperature sensor detects the cabin temperature based on changes in the resistance of its built-in thermistor and sends a signal to the A/C amplifier. 12. AMBIENT TEMPERATURE SENSOR The ambient temperature sensor detects the outside temperature based on changes in the resistance of its built-in thermistor and sends a signal to the A/C amplifier. 13. SOLAR SENSOR (for AUTO A/C) (a) The solar sensor consists of a photo diode, two amplifier circuits for the solar sensor, and frequency converter circuit for the light control sensor. (b) A solar sensor detects (in the form of changes in the current that flows through the built-in photo diode) the changes in the amount of sunlight from the LH and RH sides (2 directions) and outputs these sunlight strength signals to the A/C amplifier. Internal circuit of the solar sensor LH Side RH Side Photo Diode AC Frequency Convert Circuit Amplifier Circuit (LH) Amplifier Circuit (RH) Sensor Portion To Main Body ECU To A/C Amplifier E116951E01 14. EVAPORATOR TEMPERATURE SENSOR The evaporator temperature sensor detects the temperature of the cool air immediately past the evaporator in the form of resistance changes, and outputs it to the A/C amplifier. AIR CONDITIONING – AIR CONDITIONING SYSTEM AC–23 15. A/C PRESSURE SENSOR The A/C pressure sensor detects the refrigerant pressure and outputs it to the A/C amplifier in the form of voltage changes. AC AC–24 AIR CONDITIONING – AIR CONDITIONING SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use the following procedures to troubleshoot the air conditioning system. • *: Use the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 INSPECT BATTERY VOLTAGE (a) Inspect the battery voltage. Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT 3 CHECK COMMUNICATION FUNCTION OF CAN COMMUNICATION SYSTEM* (a) Use the intelligent tester to check if the CAN Communication System is functioning normally. Result AC B Result Proceed to CAN DTC is not output A CAN DTC is output B Go to CAN COMMUNICATION SYSTEM A 4 CHECK FOR DTC* (a) Check for DTCs and note any codes that are output. HINT: Refer to the DTC CHECK / CLEAR (See page AC-32). (b) Delete the DTCs. (c) Recheck for DTCs. Based on the DTCs output above, try to force output of the A/C system DTC by simulating the operation indicated by the DTC. Result Result B Proceed to DTC is not output A DTC is output B Go to step 7 AC–25 AIR CONDITIONING – AIR CONDITIONING SYSTEM A 5 PROBLEM SYMPTOMS TABLE (a) Refer to the problem symptoms table (See page AC-25). Result Result Proceed to Fault is not listed in problem symptoms table A Fault is listed in problem symptoms table B B Go to step 8 A 6 OVERALL ANALYSIS AND TROUBLESHOOTING* (a) (b) (c) (d) (e) Actuator Check (See page AC-43 for AUTO A/C) DATA LIST / ACTIVE TEST (See page AC-38) Terminals of ECU (See page AC-29) On-vehicle Inspection Inspection NEXT 7 NEXT END ADJUST, REPAIR OR REPLACE AC AC–26 AIR CONDITIONING – AIR CONDITIONING SYSTEM CUSTOMIZE PARAMETERS HINT: The following items can be customized. NOTICE: • When the customer requests a change in a function, first make sure that the function can be customized. • Be sure to make a note of the current settings before customizing. • When troubleshooting a function, first make sure that the function is set to the default setting. AIR CONDITIONER (AUTO A/C) DISPLAY (ITEM) DEFAULT CONTENTS SETTING NORMAL To shift the temperature against the displayed temperature +2 C / +1 C / NORMAL / -1 C / -2 C AIR INLET MODE (Air Inlet Mode) AUTO In case of turning the A/C ON when you desire to make the compartment cool down quickly, this is the function to change the mode automatically to RECIRCULATION mode MANUAL / AUTO COMPRESSOR MODE (Compressor Mode) AUTO Function to turn the A/C ON automatically by pressing the AUTO button when the blower is ON and the A/C is OFF MANUAL / AUTO COMPRS / DEF OPER (Compressor / Air Inlet DEF Operation) LINK Function to turn the A/C ON automatically linked with the FRONT DEF button when the A/C is OFF NORMAL / LINK EVAP CTRL (Evaporator Control) AUTO Function to set the evaporator control to the AUTOMATIC position (AUTO) to save power, or to the coldest position (MANUAL) to dehumidify the air and to prevent the windows from fogging up MANUAL / AUTO FOOT / DEF MODE (Foot / DEF auto mode) ON Function to turn the airflow from FOOT / DEF ON automatically when AUTO MODE is ON OFF / ON AUTO BLOW UP (Foot / DEF automatic blower up function) ON Function to change the blower level automatically when the defroster is ON OFF / ON AMBIENT TMP SFT (Ambient Temperature Shift) NORMAL SET TEMP SHIFT (Set Temperature Shift) AC Function to shift the ambient temperature against the displayed ambient temperature +3 C / +2 C / +1 C / NORMAL / -1 C / -2 C / -3 C AC–27 AIR CONDITIONING – AIR CONDITIONING SYSTEM PROBLEM SYMPTOMS TABLE MANUAL A/C: Symptom All functions of the A/C system do not operate Air Flow Control: No blower operation Air Flow Control: No blower control Air Flow Control: Insufficient air flow Temperature Control: No cool air comes out Temperature Control: No warm air comes out Temperature Control: Output air is warmer or cooler than the set temperature or response is slow. Suspected area See page 1. IG power source circuit AC-113 2. Back-up power source circuit AC-116 3. Heater control panel power source circuit AC-98 4. LIN communication circuit AC-118 5. A/C control assembly AC-255 6. A/C amplifier AC-258 1. Blower motor circuit AC-91 2. Heater control panel power source circuit AC-98 3. LIN communication circuit AC-118 4. A/C control assembly AC-255 5. A/C amplifier AC-258 1. Blower motor circuit AC-91 2. Heater control panel power source circuit AC-98 3. LIN communication circuit AC-118 4. A/C control assembly AC-255 5. A/C amplifier AC-258 1. Blower motor circuit AC-91 2. A/C amplifier AC-258 1. Refrigerant volume AC-120 2. Refrigerant pressure AC-120 3. Pressure switch circuit AC-65 4. Air conditioning compressor magnetic clutch circuit (for 2GR-FSE) AC-100 5. Compressor lock sensor circuit (for 2GR-FSE) AC-61 6. Compressor solenoid circuit AC-84 7. Air mix control servo motor circuit AC-74 8. Evaporator temperature sensor circuit AC-53 9. Ambient temperature sensor circuit AC-49 10. Heater control panel power source circuit AC-98 11. LIN communication circuit AC-118 12. Expansion valve AC-159 13. A/C control assembly AC-255 14. A/C amplifier AC-258 15. ECM (for 2AZ-FE) ES-432 16. ECM (for 2GR-FSE) ES-518 1. Air mix control servo motor circuit AC-74 2. Evaporator temperature sensor circuit AC-53 3. Ambient temperature sensor circuit AC-49 4. A/C amplifier AC-258 1. Refrigerant volume AC-120 2. Refrigerant pressure AC-120 3. Ambient temperature sensor circuit AC-49 4. Air mix control servo motor circuit AC-74 5. Radiator unit sub-assembly AC-159 6. Expansion valve AC-159 7. A/C amplifier AC-258 AC AC–28 AIR CONDITIONING – AIR CONDITIONING SYSTEM Symptom Temperature control: No temperature control (only Max. cool or Max. warm) No air inlet control No air flow mode control Engine idle up does not occur, or is continuous Diagnostic trouble codes are not recorded. Set mode is cleared when ignition switch is turned OFF. Suspected area See page 1. Air mix control servo motor circuit AC-74 2. Ambient temperature sensor circuit AC-49 3. Evaporator temperature sensor circuit AC-53 4. A/C control assembly AC-255 5. A/C amplifier AC-258 1. Air inlet control servo motor circuit AC-77 2. A/C amplifier AC-258 1. Air outlet control servo motor circuit AC-79 2. A/C amplifier AC-258 1. Air conditioning compressor magnetic clutch circuit (for 2GR-FSE) AC-100 2. Compressor lock sensor circuit (for 2GR-FSE) AC-61 3. Compressor solenoid circuit AC-84 4. Heater control panel power source circuit AC-98 5. LIN communication circuit AC-118 6. A/C control assembly AC-255 7. A/C amplifier AC-258 8. ECM (for 2AZ-FE) ES-432 9. ECM (for 2GR-FSE) ES-518 1. Back-up power source circuit AC-116 2. A/C amplifier AC-258 AUTO A/C: Symptom AC All functions of the A/C system do not operate Air Flow Control: No blower operation Air Flow Control: No blower control Air Flow Control: Insufficient air flow Suspected area See page 1. IG power source circuit AC-113 2. Back-up power source circuit AC-116 3. Heater control panel power source circuit AC-98 4. LIN communication circuit AC-118 5. Steering pad switch circuit AC-108 6. A/C control assembly AC-255 7. A/C amplifier AC-258 1. Blower motor circuit AC-91 2. Heater control panel power source circuit AC-98 3. LIN communication circuit AC-118 4. A/C control assembly AC-255 5. A/C amplifier AC-258 1. Blower motor circuit AC-91 2. Heater control panel power source circuit AC-98 3. LIN communication circuit AC-118 4. A/C control assembly AC-255 5. A/C amplifier AC-258 1. Blower motor circuit AC-91 2. A/C amplifier AC-258 AC–29 AIR CONDITIONING – AIR CONDITIONING SYSTEM Symptom Temperature Control: No cool air comes out Temperature Control: No warm air comes out Temperature Control: Output air is warmer or cooler than the set temperature or response is slow. Temperature control: No temperature control (only Max. cool or Max. warm) No air inlet control No air flow mode control Suspected area See page 1. Refrigerant volume AC-120 2. Refrigerant pressure AC-120 3. Pressure switch circuit AC-65 4. Air conditioning compressor magnetic clutch circuit (for 2GR-FSE) AC-100 5. Compressor lock sensor circuit (for 2GR-FSE) AC-61 6. Compressor solenoid circuit AC-84 7. Air mix control servo motor circuit (Driver side) AC-82 8. Air mix control servo motor circuit (Passenger side) AC-74 9. Evaporator temperature sensor circuit AC-53 10. Room temperature sensor circuit AC-45 11. Ambient temperature sensor circuit AC-49 12. Heater control panel power source circuit AC-98 13. LIN communication circuit AC-118 14. Expansion valve AC-159 15. A/C control assembly AC-255 16. A/C amplifier AC-258 17. ECM (for 2AZ-FE) ES-432 18. ECM (for 2GR-FSE) ES-518 1. Air mix control servo motor circuit (Driver side) AC-82 2. Air mix control servo motor circuit (Passenger side) AC-74 3. Evaporator temperature sensor circuit AC-53 4. Room temperature sensor circuit AC-45 5. Ambient temperature sensor circuit AC-49 6. A/C amplifier AC-258 1. Refrigerant volume AC-120 2. Refrigerant pressure AC-120 3. Solar sensor circuit (Driver side) AC-69 4. Solar sensor circuit (Passenger side) AC-56 5. Room temperature sensor circuit AC-45 6. Ambient temperature sensor circuit AC-49 7. Air mix control servo motor circuit (Driver side) AC-82 8. Air mix control servo motor circuit (Passenger side) AC-74 9. Radiator unit sub-assembly AC-159 10. Expansion valve AC-159 11. A/C amplifier AC-258 1. Air mix control servo motor circuit (Driver side) AC-82 2. Air mix control servo motor circuit (Passenger side) AC-74 3. Room temperature sensor circuit AC-45 4. Ambient temperature sensor circuit AC-49 5. Evaporator temperature sensor circuit AC-53 6. Solar sensor circuit (Driver side) AC-69 7. Solar sensor circuit (Passenger side) AC-56 8. A/C control assembly AC-255 9. A/C amplifier AC-258 1. Air inlet control servo motor circuit AC-77 2. A/C amplifier AC-258 1. Air outlet control servo motor circuit AC-79 2. A/C amplifier AC-258 AC AC–30 AIR CONDITIONING – AIR CONDITIONING SYSTEM Symptom Engine idle up does not occur, or is continuous Blinking of A/C indicator Unable to control A/C with the steering pad switch Plasmacluster indicator does not come on (Plasmacluster does not operate) Diagnostic trouble codes are not recorded. Set mode is cleared when ignition switch is turned OFF. AC Suspected area See page 1. Air conditioning compressor magnetic clutch circuit (for 2GR-FSE) AC-100 2. Compressor lock sensor circuit (for 2GR-FSE) AC-61 3. Compressor solenoid circuit AC-84 4. Heater control panel power source circuit AC-98 5. LIN communication circuit AC-118 6. A/C control assembly AC-255 7. A/C amplifier AC-258 8. ECM (for 2AZ-FE) ES-432 9. ECM (for 2GR-FSE) ES-518 1. Compressor solenoid circuit AC-84 2. A/C amplifier AC-258 1. Steering pad switch circuit AC-108 2. Heater control panel power source circuit AC-98 3. LIN communication circuit AC-118 4. A/C control assembly AC-255 5. A/C amplifier AC-258 1. Blower motor circuit AC-91 2. Plasmacluster circuit AC-105 3. A/C amplifier AC-258 1. Back-up power source circuit AC-116 2. A/C amplifier AC-258 AC–31 AIR CONDITIONING – AIR CONDITIONING SYSTEM TERMINALS OF ECU 1. A/C AMPLIFIER e1 E38 E124486E01 HINT: Check from the rear of the connector while it is connected to the A/C amplifier. Terminal No. (Symbols) Wiring Color Condition Specified Condition Ignition switch on (IG) 10 to 14 V Terminal Description E38-1 (IG+) - E38-14 (GND) V - W-B Power source (IG) E38-1 (IG+) - E38-14 (GND) V - W-B Power source (IG) Ignition switch off Below 1 V Pulse generation (See waveform 1) E38-2 (SOL+) - E38-14 (GND) W - W-B A/C compressor operation signal Engine is running A/C switch: ON Blower switch: LO E38-5 (TAM) - E38-14 (GND) P - W-B A/C ambient temperature sensor signal Ignition switch on (IG) at 25°C (77°F) 1.35 to 1.75 V E38-5 (TAM) - E38-14 (GND) P - W-B A/C ambient temperature sensor signal Ignition switch on (IG) at 40°C (104°F) 0.9 to 1.2 V E38-8 (LOCK)*1 - E38-14 (GND) G - W-B A/C compressor lock sensor signal Engine is running Blower switch: LO A/C switch: ON E38-9 (PRE) - E38-13 (SG-2) E38-9 (PRE) - E38-13 (SG-2) V-L V-L A/C pressure sensor signal A/C pressure sensor signal Start engine, Operate A/C system, Refrigerant pressure: Abnormal pressure (more than V-L A/C pressure sensor signal 4.74 V or higher 3,140 kPa (32.0 kgf/cm2, 455 psi)) Start engine, Operate A/C system, Refrigerant pressure: Abnormal pressure (less than 196 kPa (2.0 E38-9 (PRE) - E38-13 (SG-2) Pulse generation (See waveform 2) kgf/cm2, Below 0.76 V 28 psi)) Start engine, Operate A/C system, Refrigerant pressure: Abnormal pressure (more than 3,140 kPa (32.0 kgf/cm2, 455 psi) and less than 196 kPa (2.0 kgf/ 0.76 to 4.74 V cm2, 28 psi)) E38-10 (S5-3) - E38-13 (SG-2) BR - L Power supply for A/C pressure sensor Ignition switch on (IG) A/C switch: ON 4.5 to 5.5 V E38-10 (S5-3) - E38-13 (SG-2) BR - L Power supply for A/C pressure sensor Ignition switch on (IG) A/C switch: OFF Below 1 V E38-11 (CANH) - E38-12 (CANL) B-W CAN communication system CAN communication circuit Ground for A/C pressure sensor, A/C ambient temperature sensor, A/C lock sensor Always Below 1 V Ground for main power supply Always Below 1 V E38-13 (SG-2) - Body ground L - Body ground E38-14 (GND) - Body ground W-B - Body ground Pulse generation AC AC–32 AC AIR CONDITIONING – AIR CONDITIONING SYSTEM Condition Specified Condition A/C compressor magnetic clutch operation signal Ignition switch on (IG) Blower switch: LO A/C switch: OFF 10 to 14 V LG - W-B A/C compressor magnetic clutch operation signal Ignition switch on (IG) Blower switch: LO A/C switch: ON Below 1 V GR - W-B Power source (Back-up) Always Blower motor speed control signal Ignition switch on (IG) Blower switch: ON Terminal No. (Symbols) Wiring Color Terminal Description E38-20 (MGC)*1 - E38-14 (GND) LG - W-B E38-20 (MGC)*1 - E38-14 (GND) E38-21 (B) - E38-14 (GND) 10 to 14 V Pulse generation (See waveform 3) E38-23 (BLW) - E38-14 (GND) R - W-B E38-29 (TR)*2 - E38-34 (SG-1) P - LG A/C room temperature sensor signal Ignition switch on (IG) Cabin temperature at 25°C (77°F) 1.8 to 2.2 V E38-29 (TR)*2 - E38-34 (SG-1) P - LG A/C room temperature sensor signal Ignition switch on (IG) Cabin temperature at 40°C (104°F) 1.2 to 1.6 V E38-32 (TSP)*2 - E38-14 (GND) Y - W-B A/C solar sensor signal (for Front passenger side) Ignition switch on (IG) Solar sensor is subjected to electric light. 0.8 to 4.3 V E38-32 (TSP)*2 - E38-14 (GND) Y - W-B A/C solar sensor signal (for Front passenger side) Ignition switch on (IG) Solar sensor is covered with a cloth. Below 0.8 V E38-33 (TSD)*2 - E38-14 (GND) O - W-B A/C solar sensor signal (for Driver side) Ignition switch on (IG) Solar sensor is subjected to electric light. 0.8 to 4.3 V E38-33 (TSD)*2 - E38-14 (GND) O - W-B A/C solar sensor signal (for Driver side) Ignition switch on (IG) Solar sensor is covered with a cloth. Below 0.8 V E38-34 (SG-1)*2 - Body ground LG - Body ground Ground for A/C room temperature sensor Always E38-37 (LIN1) - E38-14 (GND) GR - W-B LIN communication signal Ignition switch on (IG) Pulse generation Below 1 V 10 to 14 V E38-38 (RDFG) - E38-14 (GND) G - W-B DEF relay signal Ignition switch on (IG) REAR DEF switch: ON E38-38 (RDFG) - E38-14 (GND) G - W-B DEF relay signal Ignition switch on (IG) REAR DEF switch: OFF E38-39 (PCD1)*2 - E38-14 (GND) R - W-B PlasmaclusterTM operation signal E38-39 (PCD1)*2 - E38-14 (GND) R - W-B e1-2 (BUS G) - Body ground - PlasmaclusterTM operation signal Ground for BUS IC Ignition switch on (IG) Blower switch: OFF Below 1 V 10 to 14 V (plasmaclusterTM not operating) Ignition switch on (IG) Blower switch: ON Below 1 V (plasmaclusterTM operating) Always Below 1 V e1-3 (BUS) - e1-2 (BUS G) - BUS IC control signal Ignition switch off → on (IG) e1-4 (B BUS) - e1-2 (BUS G) - Power supply for BUS IC Ignition switch off Below 1 V e1-4 (B BUS) - e1-2 (BUS G) - Power supply for BUS IC Ignition switch on (IG) 10 to 14 V e1-5 (SGA) - Body ground - Ground for evaporator temperature sensor Always Below 1 V e1-6 (TEA) - e1-5 (SGA) - A/C evaporator temperature sensor signal Ignition switch on (IG) Evaporator temperature at 0°C (32°F) 1.7 to 2.1 V e1-6 (TEA) - e1-5 (SGA) - A/C evaporator temperature sensor signal Ignition switch on (IG) Evaporator temperature at 15°C (59°F) 0.7 to 1.3 V *1: For 2GR-FSE *2: For AUTO A/C Pulse generation AC–33 AIR CONDITIONING – AIR CONDITIONING SYSTEM (a) Waveform 1: Item GND Contents Terminal No. (Symbols) E38-2 (SOL+) - E38-14 (GND) Tool Setting 5 V/DIV., 500 µs/DIV. Vehicle Condition Engine is running A/C switch: ON E106664E02 (b) Waveform 2: Item GND Contents Terminal No. (Symbols) E38-8 (LOCK) - E38-14 (GND) Tool Setting 200 mV/DIV., 10 ms./DIV. Vehicle Condition Engine is running Blower switch: LO A/C switch: ON E116941E01 (c) Waveform 3: Item Terminal No. (Symbols) GND Contents E38-23 (BLW) - E38-14 (GND) Tool Setting 1 V/DIV., 500 µs/DIV. Vehicle Condition Ignition switch on (IG) Blower switch: ON 2. AC A/C CONTROL ASSEMBLY E103396E01 F16 E124487E01 HINT: Check from the rear of the connector while it is connected to the A/C control assembly. Terminal No. (Symbols) Wiring Color Terminal Description Condition Specified Condition Ground for A/C control assembly Always L - W-B LIN communication circuit Ignition switch on (IG) F16-5 (IG+) - F16-3 (GND) V - W-B Power source (IG) Ignition switch off Below 1 V F16-5 (IG+) - F16-3 (GND) V - W-B Power source (IG) Ignition switch on (IG) 10 to 14 V F16-3 (GND) - Body ground W-B - Body ground F16-4 (TX+) - F16-3 (GND) Below 1 V Pulse generation AC–34 AIR CONDITIONING – AIR CONDITIONING SYSTEM DIAGNOSIS SYSTEM 1. CG SG CANH SIL CANL CHECK DLC3 (a) The vehicle's ECU uses the ISO 15765-4 for communication. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. BAT H100769E16 Symbol (Terminal No.) Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always CANH (6) - CANL (14) CANH (6) - BAT (16) CANH (6) - CG (4) CANL (14) - BAT (16) CANL (14) - CG (4) AC CAN bus line HIGH-level CAN bus line HIGH-level CAN bus line LOW-level CAN bus line LOW-level CAN bus line 10 to 14 V Ignition switch off * 54 to 69 Ω Ignition switch off * 6 kΩ or higher Ignition switch off * 200 Ω or higher Ignition switch off * 6 kΩ or higher Ignition switch off* 200 Ω or higher NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches, or the doors. HINT: Connect the cable of the intelligent tester to the DLC3, turn the ignition switch on (IG) and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. • If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. AIR CONDITIONING – AIR CONDITIONING SYSTEM AC–35 DTC CHECK / CLEAR HINT: *: For AUTO A/C 1. DTC CHECK (SENSOR CHECK)* (a) Start the engine and warm it up. (b) Perform the indicator check (See page AC-34). HINT: After the indicator check is completed, the system enters the DTC check mode automatically. A/C Control Assembly: DTC E124467E01 (c) Read the code displayed on the panel. (Trouble codes are output on the temperature display.) NOTICE: • In the sensor check mode, which is automatically transferred from the indicator check mode, troubleshooting may be partially performed. Be sure to perform the actuator check, and then the sensor check again. • If the check is performed in a dark place, DTC 21 or 24 may be displayed even though the system is normal. HINT: Refer to the DTC chart (Diagnostic Trouble Code chart) for details of the codes (See page AC-41). • When there are no problems, DTC 00 is output. • As an example, the illustration shows that display code 21 is output. (d) If the steps are difficult to read because they change automatically, push the "MODE" switch to display the steps one at a time so that they can be read easily. The items are displayed step by step each time the "MODE" switch is pushed. • Push the "OFF" switch to finish panel diagnosis. • Push the "R/F" switch to enter the actuator check mode. A/C Control Assembly: E124466E03 AC AC–36 AIR CONDITIONING – AIR CONDITIONING SYSTEM 2. CLEARING DTC* (a) During the sensor check, press the "FRONT DEF" switch and "REAR DEF" switch at the same time. 3. DTC CHECK USING INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Turn the tester ON. (d) Enter the following menu items: DIAGNOSIS / OBD/ MOBD / DTC INFO / CURRENT CODES. HINT: Refer to the intelligent tester operator's manual for further details. (e) Check the details of the DTCs. (f) Clear the DTCs. HINT: After repairing the malfunctions, clear the DTC. (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch on (IG). (3) Enter the following menu items: DIAGNOSIS / OBD/MOBD / DTC INFO / CLEAR CODES. HINT: Refer to the intelligent tester operator's manual for further details. (4) Press the YES button. A/C Control Assembly: E124466E04 AC DLC3 Intelligent Tester C131977E01 AIR CONDITIONING – AIR CONDITIONING SYSTEM AC–37 CHECK MODE PROCEDURE HINT: *: For AUTO A/C AC AC–38 AIR CONDITIONING – AIR CONDITIONING SYSTEM 1. Turn the ignition switch on (IG) while pressing AUTO and Recirculation / Fresh switches. Hold both switches until the indicator check screen appears. LIST OF OPERATION METHODS* (a) By operating each of the A/C control switches as shown in the diagram below, it is possible to enter the diagnostic check mode. AUTO and Recirculation/Fresh switches are not pressed at the same time. Indicator Check (continuous operation) OFF DTC Check (sensor check) (continuous operation) Actuator Check (continuous operation) R/F OFF AUTO AC MODE MODE OFF DTC Check (sensor check) (step operation) R/F AUTO R/F Actuator Check (step operation) OFF AUTO MODE MODE Cancel the check mode and start A/C control. : Indicates switch operation R/F: Recirculation/Fresh switch MODE: Air outlet mode switch E106866E19 AIR CONDITIONING – AIR CONDITIONING SYSTEM 2. AC–39 INDICATOR CHECK* (a) Turn the ignition switch off. (b) Turn the ignition switch on (IG) while pressing the A/ C control "AUTO" switch and "R/F" switch simultaneously. Hold both switches until the indicator check screen appears. A/C Control Assembly: E124466E05 A/C Control Assembly: 3. Indicator Blinking Pattern: 1 sec. 1 sec. ON OFF E124468E01 (c) The indicator check is automatically performed when panel diagnosis is activated. Check that the indicators light up and go off at 1 second intervals 4 times in succession. HINT: • The sensor check automatically starts when the indicator check is completed. • Press the "OFF" switch to cancel the check mode. • If a navigation system is installed, the indicator will blink and the buzzer will sound. DTC CHECK (SENSOR CHECK)* (a) Start the engine and warm it up. (b) Perform the indicator check. HINT: After the indicator check is completed, the system enters the DTC check mode automatically. AC AC–40 AIR CONDITIONING – AIR CONDITIONING SYSTEM (c) Read the code displayed on the panel. NOTICE: • In the sensor check mode, which is automatically transferred from the indicator check mode, troubleshooting may be partially performed. Be sure to perform the actuator check, and then the sensor check again. • If the check is performed in a dark place, DTC 21 or 24 may be displayed even though the system is normal. HINT: Refer to the DTC chart (Diagnostic Trouble Code chart) for details of the codes (See page AC-41). • When there are no problems, DTC 00 is output. • As an example, the illustration shows that display code 21 is output. A/C Control Assembly: DTC E124467E01 A/C Control Assembly: 4. AC (d) If the steps are difficult to read because they change automatically, push the "MODE" switch to display the steps one at a time so that they can be read easily. The items are displayed step by step each time the "MODE" switch is pushed. • Push the "OFF" switch to finish panel diagnosis. • Push the "R/F" switch to enter the actuator check mode. ACTUATOR CHECK* (a) Start the engine and warm it up. (b) Perform the indicator check. E124466E03 (c) Push the "R/F" switch to perform the actuator check. HINT: Be sure to perform the actuator check after starting the engine. A/C Control Assembly: E124466E02 AC–41 AIR CONDITIONING – AIR CONDITIONING SYSTEM (d) As the actuator check is repeated from steps 1 to 10 at 1 second intervals, check the temperature and air flow visually and by hand. HINT: • The display blinks at 1 second intervals in the step operation. • Push the "OFF" switch to finish panel diagnosis. • Push the "AUTO" switch to enter the sensor check mode. A/C Control Assembly: Display Code E124466E06 Conditions Step No. Display Code Blower Level Air Mix Damper Airflow Vent Air Inlet Damper Compressor 1 0 0 0% open FACE FRESH OFF 2 1 1 0% open FACE FRESH OFF ON 3 2 17 0% open FACE RECIRCULATION / FRESH 4 3 17 0% open FACE RECIRCULATION ON 5 4 17 50% open B/L RECIRCULATION ON 6 5 17 50% open B/L RECIRCULATION ON 7 6 17 50% open FOOT FRESH ON 8 7 17 100% open FOOT-0 FRESH ON 9 8 17 100% open F/D FRESH ON 10 9 31 100% open DEF FRESH ON (e) If the steps are difficult to read because they change automatically, push the "MODE" switch to display the steps one at a time so that they can be read easily. The items are displayed step by step each time the "MODE" switch is pushed. HINT: • Push the "OFF" switch to finish panel diagnosis. • Push the "R/F" switch to enter the sensor check mode. A/C Control Assembly: E124466E03 AC AC–42 AIR CONDITIONING – AIR CONDITIONING SYSTEM DATA LIST / ACTIVE TEST 1. DATA LIST HINT: Using the intelligent tester's DATA LIST allows switch, sensor, actuator, and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to save time. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Turn the tester on. (d) Enter the following menus: DIAGNOSIS / OBD/ MOBD / AIR CONDITIONER / DATA LIST. (e) Check the value(s) by referring to the table below. AIR CONDITIONER (for MANUAL A/C) AC Item Measurement Item / Display (Range) Normal Condition Diagnostic Note AMBI TEMP SENS (Ambient temperature sensor) Ambient temperature sensor / Min.: -23.3°C (-9.94°F), Max.: 65.95°C (150.71°F) Actual ambient temperature is displayed - AMBI TEMP (Adjusted ambient temperature) Adjusted ambient temperature / Min.: -30.8°C (-23.44°F), Max.: 50.8°C (123.44°F) - - EVAP FIN TEMP (Evaporator fin thermistor) Evaporator fin thermistor / Min.: 29.7°C (-21.46°F), Max.: 59.55°C (139.19°F) Actual evaporator temperature is displayed - COOLANT TEMP (Engine coolant temperature) Engine coolant temperature / Min.: 1.3°C (34.34°F), Max.: 90.55°C (194.99°F) Actual engine coolant temperature is displayed while engine is warmed up - Actual refrigerant pressure is displayed - REG PRESS SENS (Regulator pressure sensor) Regulator pressure sensor / Min.: -0.5 kgf/cm2G, Max.: 37.75 kgf/ 2 cm G REG CTRL CURRNT (Regulator control current) Compressor variable output current / Min.: 0 A, Max.: 0.996 A - - AIR MIX PULSE-D (Air mix servomotor target pulse (D side)) Driver side air mix servo motor target pulse / Min.: 0, Max.: 255 MAX. COLD: 105 (pulse) MAX. HOT: 7 (pulse) - AIR OUT PULSE-D (Air out pulse-D) Driver side air outlet servo motor target pulse / Min.: 0, Max.: 255 FACE: 8 (pulse) B/L: 30 to 38 (pulse) FOOT: 50 to 74 (pulse) FOOT/DEF: 80 (pulse) DEF: 97 (pulse) - A/I DAMP PLS (Air inlet damper target pulse) Air inlet damper target pulse / Min.: 0, Max.: 255 RECIRCULATION: 7 (pulse) FRESH: 28 (pulse) - #CODES (Number of trouble codes) Number of trouble codes / Min.: 0, Max.: 255 Number of DTCs will be displayed - AIR CONDITIONER (for AUTO A/C) Item Measurement Item / Display (Range) Normal Condition Diagnostic Note ROOM TEMP (Room temperature sensor) Room temperature sensor / Min.: -6.5°C (20.3°F), Max.: 57.25°C (135.05°F) Actual cabin temperature is displayed - AMBI TEMP SENS (Ambient temperature sensor) Ambient temperature sensor / Min.: -23.3°C (-9.94°F), Max.: 65.95°C (150.71°F) Actual ambient temperature is displayed - AMBI TEMP (Adjusted ambient temperature) Adjusted ambient temperature / Min.: -30.8°C (-23.44°F), Max.: 50.8°C (123.44°F) - - AC–43 AIR CONDITIONING – AIR CONDITIONING SYSTEM Item Measurement Item / Display (Range) Normal Condition Diagnostic Note EVAP FIN TEMP (Evaporator fin thermistor) Evaporator fin thermistor / Min.: 29.7°C (-21.46°F), Max.: 59.55°C (139.19°F) Actual evaporator temperature is displayed - SOLAR SENS-D (Solar sensor (D side)) Driver side solar sensor / Min.: 0, Max.: 255 Driver side solar sensor value increases as brightness increases - SOLAR SENS-P (Solar sensor (P side)) Passenger side solar sensor / Min.: 0, Max.: 255 Passenger side solar sensor value increases as brightness increases - COOLANT TEMP (Engine coolant temperature) Engine coolant temperature / Min.: 1.3°C (34.34°F), Max.: 90.55°C (194.99°F) Actual engine coolant temperature is displayed while engine is warmed up - SET TEMP-D (Set temperature (D - side)) Driver side set temperature / Min.: 0°C (32°F), Max.: 30°C (54°F) Driver side set temperature is displayed - SET TEMP-P (Set temperature (P - side)) Passenger side set temperature / Min.: 0°C (32°F), Max.: 30°C (54°F) Passenger side set temperature is displayed - ESTIMATE TEMP-D (Estimate temperature (D side) Driver side estimate temperature / Min.: -358.4°C (-613.12°F), Max.: 358.4°C (677.12°F) Damper is at "MAX. COOL": 358.4°C (-613.12°F) Damper is at "MAX. HOT": 358.4°C (677.12°F) - ESTIMATE TEMP-P (Estimate temperature (P side) Passenger side estimate temperature / Min.: -358.4, Max.: 358.4 Damper is at "MAX. COOL": 358.4°C (-613.12°F) Damper is at "MAX. HOT": 358.4°C (677.12°F) - HAND FREE TEL (Hand free telephone) Hands free telephone / OFF or ON - - BLOWER LEVEL (Blower motor speed level) Blower motor speed level / Min.: 0 level, Max.: 31 level Increases in the range between 0 and 31 as the blower motor speed increases - Actual refrigerant pressure is displayed - REG PRESS SENS (Regulator pressure sensor) Regulator pressure sensor / Min.: -0.5 kgf/cm2G, Max.: 37.75 kgf/ cm2G REG CTRL CURRNT (Regulator control current) Compressor variable output current / Min.: 0 A, Max.: 0.996 A - - AIR MIX PULSE-D (Air mix servomotor target pulse (D side)) Driver side air mix servo motor target pulse / Min.: 0, Max.: 255 MAX. COLD: 5 (pulse) MAX. HOT: 103 (pulse) - AIR MIX PULSE-P (Air mix servomotor target pulse (P side)) Passenger side air mix servo motor target pulse / Min.: 0, Max.: 255 MAX. COLD: 105 (pulse) MAX. HOT: 7 (pulse) - AIR OUT PULSE-D (Air out pulse-D) Driver side air outlet servo motor target pulse / Min.: 0, Max.: 255 FACE: 8 (pulse) B/L: 30 to 38 (pulse) FOOT: 50 to 74 (pulse) FOOT/DEF: 80 (pulse) DEF: 97 (pulse) - A/I DAMP PLS (Air inlet damper target pulse) Air inlet damper target pulse / Min.: 0, Max.: 255 RECIRCULATION: 7 (pulse) FRESH: 28 (pulse) - #CODES (Number of trouble codes) Number of trouble codes / Min.: 0, Max.: 255 Number of DTCs will be displayed - Item Measurement Item / (Range) Display Normal Condition Diagnostic Note A/C SIGNAL (A/C signal) A/C signal / ON or OFF ON: A/C ON OFF: A/C OFF - A/C MAG CLUTCH (A/C magnetic clutch relay) A/C magnetic clutch relay / ON or OFF ON: A/C magnetic clutch ON OFF: A/C magnetic clutch OFF - ENGINE AC AC–44 AIR CONDITIONING – AIR CONDITIONING SYSTEM 2. ACTIVE TEST HINT: Performing the intelligent tester's ACTIVE TEST allows relays, VSVs, actuators and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed in the ACTIVE TEST. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Turn the tester on. (d) Enter the following menus: DIAGNOSIS / OBD/ MOBD / AIR CONDITIONER / ACTIVE TEST. (e) Perform the ACTIVE TEST by referring to the table below. AIR CONDITIONER (for MANUAL A/C) Item Test Details / Display (Range) Diagnostic Note DEFOGER RLY-R (Defogger relay (Rear)) Defogger relay (Rear) / OFF, ON - AIR MIX PULSE-D (Air mix servomotor pulse (D side)) Driver side air mix servo motor pulse / Min.: 0, Max.: 255 - AIR OUT PULSE-D (Air outlet servomotor pulse (D side) Driver side air outlet servo motor pulse / Min.: 0, Max.: 255 - A/I DAMP PLS (Air inlet damper target pulse) Air inlet damper target pulse / Min.: 0, Max.: 255 - AIR CONDITIONER (for AUTO A/C) Item Test Details / Display (Range) Diagnostic Note BLOWER MOTOR (Blower motor) Blower motor / Min.: Level 0, Max.: Level 31 - DEFOGER RLY-R (Defogger relay (Rear)) Defogger relay (Rear) / OFF, ON - AIR MIX PULSE-D (Air mix servomotor pulse (D side)) Driver side air mix servo motor pulse / Min.: 0, Max.: 255 - AIR MIX PULSE-P (Air mix servomotor pulse (P side)) Passenger side air mix servo motor pulse / Min.: 0, Max.: 255 - AIR OUT PULSE-D (Air outlet servomotor pulse (D side) Driver side air outlet servo motor pulse / Min.: 0, Max.: 255 - A/I DAMP PLS (Air inlet damper target pulse) Air inlet damper target pulse / Min.: 0, Max.: 255 - Item Test Details / Display (Range) Diagnostic Note A/C MAG CLUTCH (Magnetic clutch relay) Magnetic clutch relay / ON or OFF - AC ENGINE AC–45 AIR CONDITIONING – AIR CONDITIONING SYSTEM DIAGNOSTIC TROUBLE CODE CHART AIR CONDITIONING SYSTEM Memory *4 See page Room Temperature Sensor Circuit 1. Room temperature sensor 2. Harness or connector between room temperature sensor and A/ C amplifier 3. A/C amplifier Memorized (8.5 min. or more) AC-45 B1412/12 Ambient Temperature Sensor Circuit 1. Ambient temperature sensor 2. Harness or connector between ambient temperature sensor and A/ C amplifier 3. A/C amplifier Memorized (8.5 min. or more) AC-49 B1413/13 Evaporator Temperature Sensor Circuit 1. Air conditioning harness (evaporator temperature sensor) 2. A/C amplifier Memorized (8.5 min. or more) AC-53 Solar Sensor Circuit (Passenger Side) 1. Solar sensor 2. Harness or connector between solar sensor and A/C amplifier 3. Harness or connector between solar sensor and main body ECU 4. A/C amplifier 5. Main body ECU Memorized (8.5 min. or more) (only when circuit is shorted) AC-56 Compressor Lock Sensor Circuit 1. A/C compressor (A/C lock sensor) 2. Compressor drive belt 3. Harness or connector between compressor and magnetic clutch (A/C lock sensor) 4. A/C amplifier 5. CAN communication system - AC-61 Pressure Switch Circuit 1. Pressure sensor 2. Harness or connector between pressure sensor and A/C amplifier 3. Refrigerant pipe line 4. A/C amplifier - AC-65 B1424/24 *3, *5 Solar Sensor Circuit (Driver Side) 1. Solar sensor 2. Harness or connector between solar sensor and A/C amplifier 3. Harness or connector between solar sensor and main body ECU 4. A/C amplifier 5. Main body ECU Memorized (8.5 min. or more) (only when circuit is shorted) AC-69 B1441/41 Air Mix Damper Control Servo Motor Circuit (Passenger Side) 1. A/C amplifier 2. Air conditioning harness 3. Air mix control servo motor Memorized (30 sec.) AC-74 B1442/42 Air Inlet Damper Control Servo Motor Circuit 1. A/C amplifier 2. Air conditioning harness 3. Air inlet control servo motor Memorized (30 sec.) AC-77 DTC No. B1411/11 *1, *5 B1421/21 *3, *5 B1422/22 B1423/23 Detection Item Trouble Area AC AC–46 AC AIR CONDITIONING – AIR CONDITIONING SYSTEM Memory *4 See page 1. A/C amplifier 2. Air conditioning harness 3. Air outlet control servo motor Memorized (30 sec.) AC-79 Air Mix Damper Control Servo Motor Circuit (Driver Side) 1. A/C amplifier 2. Air conditioning harness 3. Air mix control servo motor Memorized (30 sec.) AC-82 B1451/51 Compressor Solenoid Circuit 1. A/C compressor 2. Harness or connector between A/C amplifier and solenoid of externally changeable compressor 3. A/C amplifier - AC-84 B1497/97 BUS IC Communication Malfunction 1. Air conditioning harness 2. A/C amplifier Memorized (10 sec. or more) AC-87 B1499/99 Multiplex Communication Circuit CAN communication system Memorized AC-90 DTC No. Detection Item Trouble Area B1443/43 Air Outlet Damper Control Servo Motor Circuit B1446/46 *5 *1: If the room temperature is approx. -18.6°C (-1.48°F) or lower, DTC B1411/11 may be output even though the system is normal. *2: If the ambient temperature is approx. -52.9°C (-63.22°F) or lower, DTC B1412/12 may be output even though the system is normal. *3: If the check is performed in a dark place, DTC B1421/21 or B1424/24 (solar sensor circuit abnormal) may be output even though the system is normal. *4: The A/C amplifier memorizes the DTC of the respective malfunction if it has occurred for the period of time indicated in the brackets. *5: For AUTO A/C AC–47 AIR CONDITIONING – AIR CONDITIONING SYSTEM ACTUATOR CHECK HINT: *: For AUTO A/C 1. ACTUATOR CHECK* (a) Start the engine and warm it up. (b) Perform the indicator check (See page AC-34). (c) Push the "R/F" switch to perform the actuator check. HINT: Be sure to perform the actuator check after starting the engine. A/C Control Assembly: E124466E02 (d) As the actuator check is repeated from steps 1 to 10 at 1 second intervals, check the temperature and air flow visually and by hand. HINT: • The display blinks at 1 second intervals in the step operation. • Push the "OFF" switch to finish panel diagnosis. • Push the "AUTO" switch to enter the sensor check mode. A/C Control Assembly: Display Code E124466E06 Conditions Step No. Display Code Blower Level Air Mix Damper Airflow Vent Air Inlet Damper Compressor 1 0 0 0% open FACE FRESH OFF 2 1 1 0% open FACE FRESH OFF ON 3 2 17 0% open FACE RECIRCULATION / FRESH 4 3 17 0% open FACE RECIRCULATION ON 5 4 17 50% open B/L RECIRCULATION ON 6 5 17 50% open B/L RECIRCULATION ON 7 6 17 50% open FOOT FRESH ON 8 7 17 100% open FOOT-0 FRESH ON 9 8 17 100% open F/D FRESH ON 10 9 31 100% open DEF FRESH ON AC AC–48 AIR CONDITIONING – AIR CONDITIONING SYSTEM (e) If the steps are difficult to read because they change automatically, push the "MODE" switch to display the steps one at a time so that they can be read easily. The items are displayed step by step each time the "MODE" switch is pushed. HINT: • Push the "OFF" switch to finish panel diagnosis. • Push the "R/F" switch to enter the sensor check mode. A/C Control Assembly: E124466E03 AC AC–49 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1411/11 Room Temperature Sensor Circuit DESCRIPTION This sensor detects the cabin temperature that is used as the basis for temperature control and sends a signal to the A/C amplifier. DTC No. B1411/11 DTC Detection Condition Room temperature sensor circuit (Open or short) Trouble Area • • • A/C room temperature sensor Harness or connector between A/C room temperature sensor and A/C amplifier A/C amplifier WIRING DIAGRAM A/C Amplifier 29 E38 E27 A/C Room Temperature Sensor TR 1 AC 2 34 E38 SG-1 I008282E06 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the intelligent tester main switch on. AC–50 AIR CONDITIONING – AIR CONDITIONING SYSTEM (c) Select the item below in the DATA LIST, and read the display on the intelligent tester. DATA LIST / AIR CONDITIONER: Item Measurement Item / Display (Range) Normal Condition Diagnostic Note ROOM TEMP (Room temperature sensor) Room temperature sensor / min.: -6.5°C (20.3°F), max.: 57.25°C (135.05°F) Actual cabin temperature is displayed - OK: The display is as specified in the normal condition column. Result Result Proceed to NG A OK (When troubleshooting according to the PROBLEM SYMPTOMS TABLE) B OK (When troubleshooting according to the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 2 AC INSPECT AIR CONDITIONING AMPLIFIER (a) Remove the A/C amplifier with the connectors still connected. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Air Conditioning Amplifier Connector Wire Harness View: E38 SG-1 Tester Connection Condition Specified Condition E38-29 (TR) - E38-34 (SG-1) Ignition switch on (IG) at 25°C (77°F) 1.35 to 1.75 V E38-29 (TR) - E38-34 (SG-1) Ignition switch on (IG) at 40°C (104°F) 0.9 to 1.2 V TR HINT: As the temperature increases, the voltage decreases. Result E124471E02 Result Proceed to NG A OK (When troubleshooting according to the PROBLEM SYMPTOMS TABLE) B OK (When troubleshooting according to the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER AC–51 AIR CONDITIONING – AIR CONDITIONING SYSTEM A 3 INSPECT A/C ROOM TEMPERATURE SENSOR (a) Remove the A/C room temperature sensor. (b) Measure the resistance according to the value(s) in the table below. Standard resistance A/C Room Temperature Sensor Connector Front View: E27 Resistance (kΩ) Tester Connection Condition Specified Condition E27-1 - E27-2 10°C (50°F) 3.00 to 3.73 kΩ E27-1 - E27-2 15°C (59°F) 2.45 to 2.88 kΩ E27-1 - E27-2 20°C (68°F) 1.95 to 2.30 kΩ E27-1 - E27-2 25°C (77°F) 1.60 to 1.80 kΩ E27-1 - E27-2 30°C (86°F) 1.28 to 1.47 kΩ E27-1 - E27-2 35°C (95°F) 1.00 to 1.22 kΩ E27-1 - E27-2 40°C (104°F) 0.80 to 1.00 kΩ 4.0 E27-1 - E27-2 45°C (113°F) 0.65 to 0.85 kΩ 3.5 E27-1 - E27-2 50°C (122°F) 0.50 to 0.70 kΩ E27-1 - E27-2 55°C (131°F) 0.44 to 0.60 kΩ E27-1 - E27-2 60°C (140°F) 0.36 to 0.50 kΩ 3.0 2.5 2.0 1.5 1.0 0.5 0.0 (°C) 10 (°F) 50 20 68 30 86 40 104 50 122 60 140 Temperature NOTICE: • Hold the sensor only by its connector. Touching the sensor may change the resistance value. • When measuring, the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (see the graph). E110805E04 NG OK REPLACE A/C ROOM TEMPERATURE SENSOR AC AC–52 4 AIR CONDITIONING – AIR CONDITIONING SYSTEM CHECK HARNESS AND CONNECTOR (A/C ROOM TEMPERATURE SENSOR - AIR CONDITIONING AMPLIFIER) (a) Disconnect the connector from the A/C amplifier. A/C Amplifier Connector Wire Harness View: E38 SG-1 TR E124470E29 (b) Disconnect the connector from the A/C room temperature sensor. (c) Measure the resistance according to the value(s) in the table below. Standard resistance A/C Room Temperature Sensor Connector Front View: AC E27 Tester Connection Condition Specified Condition E38-29 (TR) - E27-1 Always Below 1 Ω E38-34 (SG-1) - E27-2 Always Below 1 Ω E38-29 (TR) - Body ground Always 10 kΩ or higher E38-34 (SG-1) - Body ground Always 10 kΩ or higher NG E124472E02 OK REPLACE AIR CONDITIONING AMPLIFIER REPAIR OR REPLACE HARNESS OR CONNECTOR AC–53 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1412/12 Ambient Temperature Sensor Circuit DESCRIPTION The ambient temperature sensor is installed in front of the condenser to detect the ambient temperature which is used to control the air conditioner "AUTO" mode. This sensor is connected to the A/C amplifier and detects fluctuations in the ambient temperature. This data is used for controlling the cabin temperature. The sensor sends a signal to the A/C amplifier. The resistance of the ambient temperature sensor changes in accordance with the ambient temperature. As the temperature decreases, the resistance increases. As the temperature increases, the resistance decreases. The A/C amplifier applies voltage (5 V) to the ambient temperature sensor and reads voltage changes as the resistance of the ambient temperature sensor changes. DTC No. B1412/12 DTC Detection Condition Open or short in ambient temperature sensor circuit Trouble Area • • • Ambient temperature sensor Harness or connector between ambient temperature sensor and A/C amplifier A/C amplifier WIRING DIAGRAM A/C Amplifier AC 5 E38 TAM 2 A2 Ambient Temperature Sensor 1 13 E38 SG-2 I008282E07 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. AC–54 AIR CONDITIONING – AIR CONDITIONING SYSTEM (b) Turn the ignition switch on (IG) and turn the intelligent tester main switch on. (c) Select the item below in the DATA LIST, and read the display on the intelligent tester. DATA LIST / AIR CONDITIONER: Item Measurement Item / Display (Range) Normal Condition Diagnostic Note AMBI TEMP SENS (Ambient temperature sensor) Ambient temperature sensor / Min: -23.3°C (-9.94°F), Max: 65.95°C (150.71°F) Actual ambient temperature is displayed Open in circuit: -23.3°C (-9.94°F) Short in circuit: 65.95°C (150.71°F) OK: The display is as specified in the normal condition column. Result Result Proceed to NG A OK (When troubleshooting according to the PROBLEM SYMPTOMS TABLE) B OK (When troubleshooting according to the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A AC 2 INSPECT AIR CONDITIONING AMPLIFIER (a) Remove the A/C amplifier connectors still connected. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Air Conditioning Amplifier Connector Wire Harness View: E38 SG-2 Tester Connection Condition Specified Condition E38-5 (TAM) - E38-13 (SG-2) Ignition switch on (IG) at 25°C (77°F) 1.35 to 1.75 V E38-5 (TAM) - E38-13 (SG-2) Ignition switch on (IG) at 40°C (104°F) 0.9 to 1.2 V HINT: As the temperature increases, the voltage decreases. Result TAM Result E124471E15 Proceed to NG A OK (When troubleshooting according to the PROBLEM SYMPTOMS TABLE) B OK (When troubleshooting according to the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AC–55 AIR CONDITIONING – AIR CONDITIONING SYSTEM C REPLACE AIR CONDITIONING AMPLIFIER A 3 INSPECT AMBIENT TEMPERATURE SENSOR Ambient Temperature Sensor Connector Front View: Tester Connection Sensor Area A2 (a) Remove the ambient temperature sensor. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Resistance (kΩ) Condition Specified Condition A2-1 - A2-2 10°C (50°F) 3.00 to 3.73 kΩ A2-1 - A2-2 15°C (59°F) 2.45 to 2.88 kΩ A2-1 - A2-2 20°C (68°F) 1.95 to 2.30 kΩ A2-1 - A2-2 25°C (77°F) 1.60 to 1.80 kΩ A2-1 - A2-2 30°C (86°F) 1.28 to 1.47 kΩ A2-1 - A2-2 35°C (95°F) 1.00 to 1.22 kΩ A2-1 - A2-2 40°C (104°F) 0.80 to 1.00 kΩ A2-1 - A2-2 45°C (113°F) 0.65 to 0.85 kΩ A2-1 - A2-2 50°C (122°F) 0.50 to 0.70 kΩ A2-1 - A2-2 55°C (131°F) 0.44 to 0.60 kΩ A2-1 - A2-2 60°C (140°F) 0.36 to 0.50 kΩ 4.0 NOTICE: • Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor. • When measuring, the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (see the graph). 3.5 3.0 2.5 2.0 1.5 1.0 0.5 0.0 10 50 20 68 30 86 40 104 50 60 (°C) 122 140 (°F) Temperature E118395E04 OK NG REPLACE AMBIENT TEMPERATURE SENSOR AC AC–56 4 AIR CONDITIONING – AIR CONDITIONING SYSTEM CHECK HARNESS AND CONNECTOR (AMBIENT TEMPERATURE SENSOR - A/C AMPLIFIER) (a) Disconnect the ambient temperature sensor connector. Ambient Temperature Sensor Connector Front View: A2 E124473E02 (b) Disconnect the A/C amplifier connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Air Conditioning Amplifier Connector Wire Harness View: E38 AC SG-2 Tester Connection Condition Specified Condition A2-2 - E38-5 (TAM) Always Below 1 Ω A2-1 - E38-13 (SG-2) Always Below 1 Ω E38-5 (TAM) - Body ground Always 10 kΩ or higher E38-13 (SG-2) - Body ground Always 10 kΩ or higher NG TAM E124470E03 OK REPLACE AIR CONDITIONING AMPLIFIER REPAIR OR REPLACE HARNESS OR CONNECTOR AC–57 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1413/13 Evaporator Temperature Sensor Circuit DESCRIPTION The evaporator temperature sensor (A/C thermistor) is installed on the evaporator in the air conditioning unit. It detects the temperature of the cooled air that has passed through the evaporator and its signal is used to control the air conditioning. It sends a signal to the A/C amplifier. The resistance of the evaporator temperature sensor (A/C thermistor) changes in accordance with the temperature of the cooled air that has passed through the evaporator. As the temperature decreases, the resistance increases. As the temperature increases, the resistance decreases. The A/C amplifier applies voltage (5 V) to the evaporator temperature sensor (A/C thermistor) and reads voltage changes as the resistance of the evaporator temperature sensor (A/C thermistor) changes. This sensor is used to prevent the evaporator from freezing. DTC No. DTC Detection Condition B1413/13 Open or short in evaporator temperature sensor circuit Trouble Area • • Air conditioning harness (evaporator temperature sensor) A/C amplifier WIRING DIAGRAM Air Conditioning Harness A/C Amplifier AC 6 e1 TEA Evaporator Temperature Sensor (A/C Thermistor) 5 e1 SGA E118397E03 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the intelligent tester main switch on. AC–58 AIR CONDITIONING – AIR CONDITIONING SYSTEM (c) Select the item below in the DATA LIST, and read the display on the intelligent tester. DATA LIST / AIR CONDITIONER: Item Measurement Item / Display (Range) Normal Condition Diagnostic Note EVAP FIN TEMP (Evaporator fin thermistor) Evaporator fin thermistor / Min.: 29.7°C (-21.46°F), Max.: 59.55°C (139.19°F) Actual evaporator temperature is displayed Open in circuit: -29.7°C (21.46°F) Short in circuit: 59.55°C (139.19°F) OK: The display is as specified in the normal condition column. Result Result NG A OK (When troubleshooting according to the PROBLEM SYMPTOMS TABLE) B OK (When troubleshooting according to the DTC) C A AC Proceed to B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER AIR CONDITIONING – AIR CONDITIONING SYSTEM 2 AC–59 INSPECT AIR CONDITIONING HARNESS Air Conditioning Harness: (A/C Evaporator Temperature Sensor) Sensor Area (a) Remove the air conditioning harness (evaporator temperature sensor). (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition e1 Resistance (kΩ) 10.0 9.0 8.0 7.0 6.0 5.0 4.0 3.0 2.0 1.0 0.0 -10 14 e1-5 - e1-6 -10°C (14°F) 7.30 to 9.10 kΩ e1-5 - e1-6 -5°C (23°F) 5.65 to 6.95 kΩ e1-5 - e1-6 0°C (32°F) 4.40 to 5.35 kΩ e1-5 - e1-6 5°C (41°F) 3.40 to 4.15 kΩ e1-5 - e1-6 10°C (50°F) 2.70 to 3.25 kΩ e1-5 - e1-6 15°C (59°F) 2.14 to 2.58 kΩ e1-5 - e1-6 20°C (68°F) 1.71 to 2.05 kΩ e1-5 - e1-6 25°C (77°F) 1.38 to 1.64 kΩ e1-5 - e1-6 30°C (86°F) 1.11 to 1.32 kΩ NOTICE: • Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor. • When measuring, the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (see the graph). 0 32 10 50 20 68 30 (°C) 86 (°F) NG Temperature E124474E01 OK REPLACE AIR CONDITIONING AMPLIFIER REPLACE AIR CONDITIONING HARNESS AC AC–60 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1421/21 Solar Sensor Circuit (Passenger Side) DESCRIPTION Resistance of Photodiode High Low Weak Strong Strength of Solar Radiation E107008E01 The solar sensor, which is installed on the upper side of the instrument panel, detects sunlight and controls the air conditioning in AUTO mode. The output voltage from the solar sensor varies according to the amount of sunlight. When the sunlight increases, the output voltage increases. As the sunlight decreases, the output voltage decreases. The A/C amplifier detects voltage output from the solar sensor. DTC No. DTC Detection Condition Trouble Area • • AC B1421/21 Open or short in passenger side solar sensor circuit • • • Solar sensor Harness or connector between solar sensor and A/ C amplifier Harness or connector between solar sensor and main body ECU A/C amplifier Main body ECU AC–61 AIR CONDITIONING – AIR CONDITIONING SYSTEM WIRING DIAGRAM E11 Automatic Light Control Sensor (Built-in Solar Sensor) CLTB CLTE Main Body ECU 6 20 E6 CLTB 3 18 E6 CLTE A/C Amplifier TSR 32 E38 TSP 2 C E109253E11 INSPECTION PROCEDURE HINT: • If DTC B1244 is output at the same time, troubleshoot DTC B1244 first (See page LI-23). • If the check is performed in a dark place, DTC B1421/21 or B1424/24 (solar sensor circuit abnormal) may be output even though the system is normal. 1 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the intelligent tester main switch on. (c) Expose the sensing portion of the solar sensor to light. HINT: Use an incandescent light for inspection. (d) Select the item below in the DATA LIST, and read the display on the intelligent tester. DATA LIST / AIR CONDITIONER: Item Measure Item / Display (Range) Normal Condition Diagnostic Note SOLAR SENS-P (Solar sensor (P side)) Passenger side solar sensor / Min.: 0, Max.: 255 Passenger side solar sensor value increases as brightness increases - OK: The display is as specified in the normal condition column. Result Result Proceed to NG A OK (When troubleshooting according to the PROBLEM SYMPTOMS TABLE) B OK (When troubleshooting according to the DTC) C AC AC–62 AIR CONDITIONING – AIR CONDITIONING SYSTEM B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 2 CHECK HARNESS AND CONNECTOR (SOLAR SENSOR) (a) Disconnect the solar sensor connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage A/C Solar Sensor Connector Wire Harness View: E11 CLTE Tester Connection Condition Specified Condition E11-6 (CLTB) - E11-3 (CLTE) Ignition switch off Below 1 V E11-6 (CLTB) - E11-3 (CLTE) Ignition switch on (IG) 10 to 14 V OK Go to step 4 CLTB E124476E02 AC NG 3 CHECK HARNESS AND CONNECTOR (MAIN BODY ECU - SOLAR SENSOR) (a) Disconnect the main body ECU connector. Main Body ECU Connector Front View: E6 CLTE CLTB E124475E02 AC–63 AIR CONDITIONING – AIR CONDITIONING SYSTEM (b) Measure the resistance according to the value(s) in the table below. Standard resistance A/C Solar Sensor Connector Wire Harness View: E11 CLTE Tester Connection Condition Specified Condition E6-20 (CLTB) - E11-6 (CLTB) Always Below 1 Ω E6-18 (CLTE) - E11-3 (CLTE) Always Below 1 Ω E6-20 (CLTB) - Body ground Always 10 kΩ or higher E6-18 (CLTE) - Body ground Always 10 kΩ or higher CLTB NG REPAIR OR REPLACE HARNESS OR CONNECTOR E124476E02 OK REPLACE MAIN BODY ECU 4 CHECK SOLAR SENSOR Solar Sensor Connector Front View: E11 TSR CLTE CLTB E109215E12 (a) Remove the solar sensor with its connector still connected. (b) Connect the positive (+) lead from the battery to terminal 6 (CLTB), and the negative (-) lead to terminal 3 (CLTE) of the solar sensor. (c) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition E11-2 (TSR) - E11-3 (CLTE) Sensor is subjected to electric light 0.8 to 4.3 V E11-2 (TSR) - E11-3 (CLTE) Sensor is covered with a cloth Below 0.8 V NOTICE: • The connection procedure for using a digital tester such as a TOYOTA electrical tester is shown above. When using an analog tester, connect the negative (-) lead to terminal 6, and the positive (+) lead to terminal 3 of the solar sensor. • While using the battery during inspection, do not bring the positive and negative tester probes too close to each other as a short circuit may occur. HINT: • Use an incandescent light for inspection. Bring it within about 30 cm (11.8 in.) of the solar sensor. • As the inspection light is moved away from the sensor, the voltage increases. NG REPLACE SOLAR SENSOR AC AC–64 AIR CONDITIONING – AIR CONDITIONING SYSTEM OK 5 CHECK HARNESS AND CONNECTOR (SOLAR SENSOR - A/C AMPLIFIER) (a) Disconnect the solar sensor connector. A/C Solar Sensor Connector Wire Harness View: E11 TSR E124476E03 (b) Disconnect the A/C amplifier connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Air Conditioning Amplifier Connector Wire Harness View: E38 AC Tester Connection (Symbols) Condition Specified Condition E38-32 (TSP) - E11-2 (TSR) Always Below 1 Ω E38-32 (TSP) - Body ground Always 10 kΩ or higher NG TSP E124470E04 OK REPLACE AIR CONDITIONING AMPLIFIER REPAIR OR REPLACE HARNESS OR CONNECTOR AC–65 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1422/22 Compressor Lock Sensor Circuit SYSTEM DESCRIPTION The ECM sends a signal to the A/C amplifier via CAN communication. The A/C amplifier reads the difference between compressor speed and engine speed. When the difference becomes too large, the A/C amplifier determines that the compressor locks, and turns the magnetic clutch off. DTC No. B1422/22 DTC Detection Condition Trouble Area • • • Open or short in compressor lock sensor circuit • • A/C compressor (A/C lock sensor) Compressor drive belt Harness or connector between compressor and magnetic clutch (A/C lock sensor) A/C amplifier CAN communication system WIRING DIAGRAM A/C Amplifier ECM 41 CANH CANL A55 11 CAN Communication System E38 49 12 A55 E38 2 1 8 C53 C53 E38 CANH AC CANL LOCK A/C Compressor (A/C Lock Sensor) 13 E38 SG-2 E124488E03 INSPECTION PROCEDURE 1 CHECK CAN COMMUNICATION SYSTEM (a) Use the intelligent tester to check if the CAN Communication System is functioning normally. AC–66 AIR CONDITIONING – AIR CONDITIONING SYSTEM Result Result Proceed to CAN DTC is not output A CAN DTC is output B B GO TO CAN COMMUNICATION SYSTEM A 2 INSPECT AIR CONDITIONING AMPLIFIER (a) Remove the A/C amplifier with the connectors still connected. Air Conditioning Amplifier Connector Wire Harness View: E38 LOCK SG-2 AC E124471E03 (b) Measure the waveform of the connector. 200 mV/DIV. Item GND Contents Tool setting 200 mV/DIV., 10 ms./DIV. Vehicle condition Engine is running A/C switch: ON Blower switch: LO Standard 10 ms./DIV. E116941E03 Tester Connection (Symbols) Condition Specified Condition E38-8 (LOCK) - E38-13 (SG-2) Engine is running A/C switch: ON Blower switch: LO Pulse generation Result Result Proceed to NG A OK (When troubleshooting according to the PROBLEM SYMPTOMS TABLE) B OK (When troubleshooting according to the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER AC–67 AIR CONDITIONING – AIR CONDITIONING SYSTEM A 3 INSPECT COMPRESSOR AND MAGNETIC CLUTCH (A/C LOCK SENSOR) (a) Disconnect the connector from the A/C compressor. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition C53-1 (SSR+) - C53-2 (SSR-) Always (at 20°C (68°F)) 165 to 205 Ω NG E005280 REPLACE COMPRESSOR AND MAGNETIC CLUTCH (A/C LOCK SENSOR) OK 4 CHECK HARNESS AND CONNECTOR (A/C AMPLIFIER - A/C LOCK SENSOR) (a) Disconnect the connector from the A/C amplifier. Air Conditioning Amplifier Connector Wire Harness View: E38 AC SG-2 LOCK E124470E05 (b) Measure the resistance according to the value(s) in the table below. Standard resistance Compressor and Magnetic Clutch Connector Front View: C53 SSR+    Tester Connection (Symbols) Condition Specified Condition E38-8 (LOCK) - C53-1 (SSR+) Always Below 1 Ω E38-13 (SG-2) - C53-2 (SSR-) Always Below 1 Ω E38-8 (LOCK) - Body ground Always 10 kΩ or higher E38-13 (SG-2) - Body ground Always 10 kΩ or higher NG SSRE124442E04 REPAIR OR REPLACE HARNESS OR CONNECTOR AC–68 AIR CONDITIONING – AIR CONDITIONING SYSTEM OK REPLACE AIR CONDITIONING AMPLIFIER AC AC–69 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1423/23 Pressure Sensor Circuit DESCRIPTION This DTC is output when refrigerant pressure is extremely low (0.19 MPa (2.0 kgf/cm2, 28 psi) or less) or extremely high (3.14 MPa (32.0 kgf/cm2, 455 psi) or more). The pressure sensor, which is installed on the pipe of the high pressure side to detect refrigerant pressure, outputs a refrigerant pressure signal to the A/ C amplifier. The A/C amplifier converts this signal to pressure according to the sensor characteristics to control the compressor. HINT: Be sure to check the refrigerant volume first when this DTC is output because this DTC can also be output if there is no refrigerant in the system. DTC No. DTC Detection Condition Trouble Area • • B1423/23 Open or short in pressure switch circuit • • Pressure sensor Harness or connector between pressure sensor and A/C amplifier Refrigerant pipe line A/C amplifier WIRING DIAGRAM A27 A/C Pressure Sensor PR - + A/C Amplifier 2 9 E38 PRE 1 13 E38 SG-2 3 10 E38 S5-3 AC E116878E04 AC–70 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 CHECK REFRIGERANT PRESSURE (a) Install the manifold gauge set (See page AC-120). (b) Read the manifold gauge pressure when the following conditions are established. (1) Prepare the vehicle according to the chart below. E050573 Item Condition Vehicle Doors Fully open Temperature Setting MAX COLD Blower Speed HI A/C switch ON R/F Switch RECIRCULATION (30 to 35°C (86 to 95°F)) Standard pressure: Low pressure side: 0.15 to 0.25 MPa (1.5 to 2.5 kgf/cm2, 21.3 to 35.6 psi) High pressure side: 1.37 to 1.57 MPa (14 to 16 kgf/cm2, 199 to 228 psi) NG AC CHARGE REFRIGERANT OK 2 CHECK HARNESS AND CONNECTOR (PRESSURE SENSOR - A/C AMPLIFIER) (a) Disconnect the pressure sensor connector. A/C Pressure Sensor Connector Front View: A27 - 1 2 PR 3 + E124477E02 AC–71 AIR CONDITIONING – AIR CONDITIONING SYSTEM (b) Disconnect the A/C amplifier connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Air Conditioning Amplifier Connector Wire Harness View: E38 SG-2 S5-3 PRE Tester Connection Condition Specified Condition A27-2 (PR) - E38-9 (PRE) Always Below 1 Ω A27-3 (+) - E38-10 (S5-3) Always Below 1 Ω A27-1 (-) - E38-13 (SG-2) Always Below 1 Ω E38-9 (PRE) - Body ground Always 10 kΩ or higher E38-10 (S5-3) - Body ground Always 10 kΩ or higher E38-13 (SG-2) - Body ground Always 10 kΩ or higher E124470E08 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 INSPECT PRESSURE SENSOR (a) Install the manifold gauge set (See page AC-120). (b) Connect the three 1.5 V dry cell batterie's positive (+) lead to terminal 3, and the negative (-) lead to terminal 1. Then connect the voltmeter's positive (+) lead to terminal 2, and the negative (-) lead to terminal 1. Measure the voltage. OK: The voltage changes according to refrigerant pressure, as shown in the graph. Result A/C Pressure Sensor Connector Front View: B4 2 (PR) 3 (+) 1 (-) Result (V) Voltage (57) (463) MPa (psi) Refrigerant Pressure E107326E05 Proceed to NG A OK (When troubleshooting according to the DTC) B OK (When troubleshooting according to the PROBLEM SYMPTOMS TABLE) C B REPLACE AIR CONDITIONING AMPLIFIER C PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AC AC–72 AIR CONDITIONING – AIR CONDITIONING SYSTEM A REPLACE PRESSURE SENSOR AC AC–73 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1424/24 Solar Sensor Circuit (Driver Side) DESCRIPTION Resistance of Photodiode High Low Weak Strong Strength of Solar Radiation E107008E01 The solar sensor, which is installed on the upper side of the instrument panel, detects sunlight and controls the air conditioning in AUTO mode. The output voltage from the solar sensor varies according to the amount of sunlight. When the sunlight increases, the output voltage increases. As the sunlight decreases, the output voltage decreases. The A/C amplifier detects output voltage from the solar sensor. DTC No. DTC Detection Condition Trouble Area • • B1424/24 Open or short in driver side solar sensor circuit • • • Solar sensor Harness or connector between solar sensor and A/ C amplifier Harness or connector between solar sensor and main body ECU A/C amplifier Main body ECU AC AC–74 AIR CONDITIONING – AIR CONDITIONING SYSTEM WIRING DIAGRAM E11 Automatic Light Control Sensor (Built-in Solar Sensor) CLTB CLTE Main Body ECU 6 20 E6 CLTB 3 18 E6 CLTE A/C Amplifier TSL 33 E38 TSD 1 C E109253E12 INSPECTION PROCEDURE AC HINT: • If DTC B1244 is output at the same time, troubleshoot DTC B1244 first (See page LI-23). • If the check is performed in a dark place, DTC B1421/21 or B1424/24 (solar sensor circuit abnormal) may be output even though the system is normal. 1 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the intelligent tester main switch on. (c) Expose the sensing portion of the solar sensor to light. HINT: Use an incandescent light for inspection. (d) Select the item below in the DATA LIST, and read the display on the intelligent tester. DATA LIST / AIR CONDITIONER: Item Measure Item / Display (Range) Normal Condition Diagnostic Note SOLAR SENS-D (Solar sensor (D side)) Driver side solar sensor / Min.: 0, Max.: 255 Driver side solar sensor value increases as brightness increases - OK: The display is as specified in the normal condition column. Result Result NG Proceed to A OK (When troubleshooting according to the PROBLEM SYMPTOMS TABLE) B OK (When troubleshooting according to the DTC) C AC–75 AIR CONDITIONING – AIR CONDITIONING SYSTEM B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 2 CHECK HARNESS AND CONNECTOR (SOLAR SENSOR) (a) Disconnect the solar sensor connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage A/C Solar Sensor Connector Wire Harness View: E11 CLTE Tester Connection Condition Specified Condition E11-6 (CLTB) - E11-3 (CLTE) Ignition switch on (IG) 10 to 14 V E11-6 (CLTB) - E11-3 (CLTE) Ignition switch off Below 1 V OK Go to step 4 CLTB E124476E02 AC NG 3 CHECK HARNESS AND CONNECTOR (SOLAR SENSOR - MAIN BODY ECU) (a) Disconnect the main body ECU connector. Main Body ECU Connector Front View: E6 CLTE CLTB E124475E02 AC–76 AIR CONDITIONING – AIR CONDITIONING SYSTEM (b) Measure the resistance according to the value(s) in the table below. Standard resistance A/C Solar Sensor Connector Wire Harness View: E11 CLTE Tester Connection Condition Specified Condition E6-20 (CLTB) - E11-6 (CLTB) Always Below 1 Ω E6-18 (CLTE) - E11-3 (CLTE) Always Below 1 Ω E6-20 (CLTB) - Body ground Always 10 kΩ or higher E6-18 (CLTE) - Body ground Always 10 kΩ or higher CLTB NG REPAIR OR REPLACE HARNESS OR CONNECTOR E124476E02 OK REPLACE MAIN BODY ECU 4 AC CHECK SOLAR SENSOR Solar Sensor Connector Front View: E11 TSL CLTE CLTB E109215E15 (a) Remove the solar sensor with its connector still connected. (b) Connect the positive (+) lead from the battery to terminal 6 (CLTB), and the negative (-) lead to terminal 3 (CLTE) of the solar sensor. (c) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition E11-1 (TSL) - E11-3 (CLTE) Sensor is subjected to electric light 0.8 to 4.3 V E11-1 (TSL) - E11-3 (CLTE) Sensor is covered with a cloth Below 0.8 V NOTICE: • The connection procedure for using a digital tester such as a TOYOTA electrical tester is shown above. When using an analog tester, connect the negative (-) lead to terminal 6, and the positive (+) lead to terminal 3 of the solar sensor. • While using the battery during inspection, do not bring the positive and negative tester probes too close to each other as a short circuit may occur. HINT: • Use an incandescent light for inspection. Bring it within about 30 cm (11.8 in.) of the solar sensor. • As the inspection light is moved away from the sensor, the voltage increases. NG REPLACE SOLAR SENSOR AC–77 AIR CONDITIONING – AIR CONDITIONING SYSTEM OK 5 CHECK HARNESS AND CONNECTOR (SOLAR SENSOR - A/C AMPLIFIER) (a) Disconnect the solar sensor connector. A/C Solar Sensor Connector Wire Harness View: E11 TSL E124476E04 (b) Disconnect the A/C amplifier connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Air Conditioning Amplifier Connector Wire Harness View: E38 Tester Connection Condition Specified Condition E38-33 (TSD) - E11-1 (TSL) Always Below 1 Ω E38-33 (TSD) - Body ground Always 10 kΩ or higher NG TSD E124470E09 OK REPLACE AIR CONDITIONING AMPLIFIER REPAIR OR REPLACE HARNESS OR CONNECTOR AC AC–78 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1441/41 Air Mix Damper Control Servo Motor Circuit (Passenger Side) DESCRIPTION The air mix damper servo sends pulse signals to inform the air conditioning amplifier of the damper position. The air conditioning amplifier activates the motor (normal, reverse) based on the signals to move the air mix damper (passenger seat) to any position, which adjusts the amount of air passing the heater core after passing the evaporator to control the blowing temperature. HINT: Confirm that no mechanical problem is present because this diagnostic code can be output when either a damper link or damper is mechanically locked. DTC No. DTC Detection Condition B1441/41 Air mix damper position sensor value does not change even if air conditioning amplifier operates air mix control servo motor Trouble Area • • • Air mix control servo motor Air conditioning harness A/C amplifier WIRING DIAGRAM Air Mix Control Servo Motor Air Conditioning Harness A/C Amplifier AC 4 e1 BBUS 3 e1 BUS 2 e1 BUSG E116879E09 AC–79 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the intelligent tester main switch on. (c) Operate the front passenger side temperature adjustment switch. (d) Select the item below in the DATA LIST, and read the display on the intelligent tester. DATA LIST / AIR CONDITIONER: Item Measurement Item / Display (Range) Normal Condition Diagnostic Note AIR MIX PULSE-P (Air mix servomotor target pulse (P side)) Passenger side air mix servo motor target pulse / Min.: 0, Max.: 255 MAX. COLD: 105 (pulse) MAX. HOT: 7 (pulse) - OK: The display is as specified in the normal condition column. Result Result Proceed to NG A OK (When troubleshooting according to the PROBLEM SYMPTOMS TABLE) B OK (When troubleshooting according to the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 2 REPLACE AIR MIX CONTROL SERVO MOTOR (a) Replace the air mix control servo motor. HINT: Since the servo motor cannot be inspected while it is removed from the vehicle, replace the servo motor with a normal one and check that the condition returns to normal. (b) Check for DTCs. Result Result Proceed to DTC B1441/41 is output A DTC B1441/41 is not output B B END AC AC–80 AIR CONDITIONING – AIR CONDITIONING SYSTEM A REPLACE AIR CONDITIONING HARNESS AC AC–81 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1442/42 Air Inlet Damper Control Servo Motor Circuit DESCRIPTION The damper servo (air inlet control) sends pulse signals to inform the air conditioning amplifier of the damper position. The air conditioning amplifier activates the motor (normal, reverse) based on the signals to move the air inlet damper to any position, which controls the intake air settings (FRESH, FRESH/ RECIRCULATION, and RECIRCULATION). HINT: Confirm that no mechanical problem is present because this diagnostic code can be output when either a damper link or damper is mechanically locked. DTC No. DTC Detection Condition B1442/42 Air inlet damper position sensor value does not change even if air conditioning amplifier operates air inlet control servo motor Trouble Area • • • Air inlet control servo motor Air conditioning harness A/C amplifier WIRING DIAGRAM Air Inlet Control Servo Motor Air Conditioning Harness A/C Amplifier AC 4 e1 BBUS 3 e1 BUS 2 e1 BUSG E116879E10 AC–82 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the intelligent tester main switch on. (c) Operate the R/F (Recirculation/Fresh) switch. (d) Select the item below in the DATA LIST, and read the display on the intelligent tester. DATA LIST / AIR CONDITIONER: Item Measurement Item / Display (Range) Normal Condition Diagnostic Note A/I DAMP PLS (Air inlet damper target pulse) Air inlet damper target pulse / Min.: 0, Max.: 255 RECIRCULATION: 7 (pulse) FRESH: 28 (pulse) - OK: The display is as specified in the normal condition column. Result Result Proceed to NG A OK (When troubleshooting according to the PROBLEM SYMPTOMS TABLE) B OK (When troubleshooting according to the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER AC A 2 REPLACE AIR INLET CONTROL SERVO MOTOR (a) Replace the air inlet control servo motor. HINT: Since the servo motor cannot be inspected while it is removed from the vehicle, replace the servo motor with a normal one and check that the condition returns to normal. (b) Check for DTCs. Result Result Proceed to DTC B1442/42 is output A DTC B1442/42 is not output B B A REPLACE AIR CONDITIONING HARNESS END AC–83 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1443/43 Air Outlet Damper Control Servo Motor Circuit DESCRIPTION The mode damper servo sends pulse signals to inform the air conditioning amplifier of the damper position. The air conditioning amplifier activates the motor (normal, reverse) based on the signals to move the air outlet damper to any position, which controls the air outlet switching. HINT: Confirm that no mechanical problem is present because this diagnostic code can be output when either a damper link or damper is mechanically locked. DTC No. B1443/43 DTC Detection Condition Air outlet damper position sensor value does not change even if air conditioning amplifier operates air outlet control servo motor Trouble Area • • • Air outlet control servo motor Air conditioning harness A/C amplifier WIRING DIAGRAM Air Outlet Control Servo Motor Air Conditioning Harness A/C Amplifier AC 4 e1 BBUS 3 e1 BUS 2 e1 BUSG E116879E11 AC–84 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the intelligent tester main switch on. (c) Operate the MODE switch. (d) Select the item below in the DATA LIST, and read the display on the intelligent tester. DATA LIST / AIR CONDITIONER: Item Measurement Item / Display (Range) Normal Condition Diagnostic Note AIR OUT PULSE-D (Air outlet servomotor target pulse (D side)) Driver side air outlet servo motor target pulse / Min.: 0, Max.: 255 FACE: 8 (pulse) B/L: 30 to 38 (pulse) FOOT: 50 to 74 (pulse) FOOT/DEF: 80 (pulse) DEF: 97 (pulse) - OK: The display is as specified in the normal condition column. Result Result Proceed to NG A OK (When troubleshooting according to the PROBLEM SYMPTOMS TABLE) B OK (When troubleshooting according to the DTC) C AC B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 2 REPLACE AIR OUTLET CONTROL SERVO MOTOR (a) Replace the air outlet control servo motor. HINT: Since the servo motor cannot be inspected while it is removed from the vehicle, replace the servo motor with a normal one and check that the condition returns to normal. (b) Check for DTCs. Result Result Proceed to DTC B1443/43 is output A DTC B1443/43 is not output B B END AIR CONDITIONING – AIR CONDITIONING SYSTEM AC–85 A REPLACE AIR CONDITIONING HARNESS AC AC–86 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1446/46 Air Mix Damper Control Servo Motor Circuit (Driver Side) DESCRIPTION The air mix damper servo sends pulse signals to inform the air conditioning amplifier of the damper position. The air conditioning amplifier activates the motor (normal, reverse) based on the signals to move the air mix damper (driver seat) to any position. As a result, the amount of air passing through the heater core after passing through the evaporator is adjusted, and the temperature of the air blowing toward the driver seat side is controlled. HINT: Confirm that no mechanical problem is present because this diagnostic code can be output when either a damper link or damper is mechanically locked. DTC No. DTC Detection Condition B1446/46 Air mix damper position sensor value does not change even if air conditioning amplifier operates air mix control servo motor Trouble Area • • • Air mix control servo motor Air conditioning harness Air amplifier WIRING DIAGRAM Air Mix Control Servo Motor Air Conditioning Harness A/C Amplifier AC 4 e1 BBUS 3 e1 BUS 2 e1 BUSG E116879E09 AC–87 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the intelligent tester main switch on. (c) Operate the driver side temperature adjustment switch. (d) Select the item below in the DATA LIST, and read the display on the intelligent tester. DATA LIST / AIR CONDITIONER: Item Measurement Item / Display (Range) Normal Condition Diagnostic Note AIR MIX PULSE-D (Air mix servomotor target pulse (D side)) Driver side air mix servo motor target pulse / Min.: 0, Max.: 255 MAX COLD: 5 (pulse) MAX HOT: 103 (pulse) - OK: The display is as specified in the normal condition column. Result Result Proceed to NG A OK (When troubleshooting according to the PROBLEM SYMPTOMS TABLE) B OK (When troubleshooting according to the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 2 REPLACE AIR MIX CONTROL SERVO MOTOR (a) Replace the air mix control servo motor. HINT: Since the servo motor cannot be inspected while it is removed from the vehicle, replace the servo motor with a normal one and check that the condition returns to normal. (b) Check for DTCs. Result Result Proceed to DTC B1446/46 is output A DTC B1446/46 is not output B B A REPLACE AIR CONDITIONING HARNESS END AC AC–88 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1451/51 Compressor Solenoid Circuit DESCRIPTION In this circuit, the compressor receives a refrigerant compression demand signal from the air conditioning amplifier. Based on this signal, the compressor changes the amount of compressor output. DTC No. B1451/51 DTC Detection Condition Open or short in solenoid of the externally changeable compressor circuit Trouble Area • • • A/C compressor Harness or connector between A/C amplifier and solenoid of externally changeable compressor A/C amplifier WIRING DIAGRAM A/C Amplifier C21 A/C Compressor AC 1 SOL- SOL+ 2 2 E38 SOL+ E116880E04 AC–89 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 INSPECT A/C COMPRESSOR (a) Disconnect the A/C compressor connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance A/C Compressor Connector Front View: Condition Specified Condition 20°C (68°F) 10 to 11 Ω NG C21 SOL+ Tester Connection C21-2 (SOL+) - C21-1 (SOL-) REPLACE A/C COMPRESSOR SOL- E116970E02 OK 2 CHECK HARNESS AND CONNECTOR (A/C COMPRESSOR - BODY GROUND) (a) Disconnect the A/C compressor connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance A/C Compressor Connector Front View: Tester Connection Condition Specified Condition C21-1 (SOL-) - Body ground Always Below 1 Ω NG C21 SOLE116971E02 OK REPAIR OR REPLACE HARNESS OR CONNECTOR AC AC–90 3 AIR CONDITIONING – AIR CONDITIONING SYSTEM CHECK HARNESS AND CONNECTOR (A/C COMPRESSOR - A/C AMPLIFIER) (a) Disconnect the A/C compressor connector. A/C Compressor Connector Front View: C21 SOL+ E116971E03 (b) Disconnect the A/C amplifier connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Air Conditioning Amplifier Connector Wire Harness View: E38 AC Tester Connection Condition Specified Condition E38-2 (SOL+) - C21-2 (SOL+) Always Below 1 Ω E38-2 (SOL+) - Body ground Always 10 kΩ or higher Result Result SOL+ E124470E10 Proceed to NG A OK (When troubleshooting according to the PROBLEM SYMPTOMS TABLE) B OK (When troubleshooting according to the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A REPAIR OR REPLACE HARNESS OR CONNECTOR AC–91 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1497/97 BUS IC Communication Malfunction DESCRIPTION The air conditioning harness connects the air conditioning amplifier and each servo motor. The air conditioning amplifier supplies power and sends operation instructions to each servo motor through the air conditioning harness. Each servo motor sends the damper position information to the air conditioning amplifier. DTC No. B1497/97 DTC Detection Condition Communication line error or open Trouble Area • • Air conditioning harness A/C amplifier WIRING DIAGRAM Servo Motor Air Conditioning Harness A/C Amplifier 4 e1 B BUS 3 e1 BUS AC 2 e1 14 E38 BUS G GND E130105E01 INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (a) Remove the A/C amplifier. AC–92 AIR CONDITIONING – AIR CONDITIONING SYSTEM (b) Disconnect the connector from the A/C amplifier. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Air Conditioning Amplifier Connector Wire Harness View: E38 Tester Connection Condition Specified Condition E38-14 (GND) - Body ground Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR GND E124470E11 OK 2 INSPECT AIR CONDITIONING AMPLIFIER (a) Reconnect the connector to the A/C amplifier. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Air Conditioning Amplifier Connector Wire Harness View: E38 e1 AC Tester Connection Condition Specified Condition e1-2 (BUS G) - E38-14 (GND) Always Below 1 Ω NG GND BUS G E124471E04 OK REPLACE AIR CONDITIONING AMPLIFIER AC–93 AIR CONDITIONING – AIR CONDITIONING SYSTEM 3 INSPECT AIR CONDITIONING AMPLIFIER (a) Disconnect the connector (e1) from the A/C amplifier . (b) Measure the voltage according to the value(s) in the table below. Standard voltage Air Conditioning Amplifier Connector Wire Harness View: e1 B BUS Tester Connection Condition Specified Condition e1-4 (B BUS) - Body ground Ignition switch off Below 1 V e1-4 (B BUS) - Body ground Ignition switch on (IG) 10 to 14 V NG REPLACE AIR CONDITIONING AMPLIFIER E124471E10 OK 4 REPLACE AIR CONDITIONING HARNESS (a) Replace the air conditioning harness. HINT: Since the air conditioning harness cannot be inspected while it is removed from the vehicle, replace the air conditioning harness with a normal one and check that the condition returns to normal. (b) Check for DTCs. Result Result Proceed to DTC B1497/97 is output. A DTC B1497/97 is not output. B B A REPLACE AIR CONDITIONING AMPLIFIER END AC AC–94 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1499/99 Multiplex Communication Circuit DESCRIPTION DTC No. B1499/99 DTC Detecting Condition Open in CAN communication circuit Trouble Area CAN communication system INSPECTION PROCEDURE 1 GO TO CAN COMMUNICATION SYSTEM (a) Refer to the CAN communication system (See page CA8). NEXT END AC AIR CONDITIONING – AIR CONDITIONING SYSTEM AC–95 Blower Motor Circuit DESCRIPTION Blower Level HI M2 M1 LO 0 67 80.5 23.5 33 30 43 100 70 SI Duty (%) Duty Ratio = ON OFF A A+B 㨄 100 (%) A B AC 1 Cycle E107334E04 The blower motor is operated by signals from the A/C amplifier. The blower motor speed is controlled using various duty ratios. Duty Ratio: The duty ratio is the ratio of the blower motor ON time (A) to the total of the blower motor ON and OFF time (A + B). The blower motor controller controls the blower motor speed. AC–96 AIR CONDITIONING – AIR CONDITIONING SYSTEM WIRING DIAGRAM A/C Amplifier E39 Blower Motor 23 SI 3 +B GND HTR E38 BLW 2 1 ALT FL MAIN AC Battery E116881E05 INSPECTION PROCEDURE HINT: • AUTO A/C: Start inspection from step 1. • MANUAL A/C: Start inspection from step 2. 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the intelligent tester main switch on. (c) Select the item below in the ACTIVE TEST and then check that the blower motor operates. ACTIVE TEST / AIR CONDITIONER: Item Test Details / Display (Range) Diagnostic Note BLOWER MOTOR (Blower motor) Blower motor / Min.: Level 01, Max.: Level 31 - AC–97 AIR CONDITIONING – AIR CONDITIONING SYSTEM Result Result Proceed to OK A NG (blower motor does not operate) B NG (blower motor operates but does not change speed) C B Go to step 2 C Go to step 6 A PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE 2 INSPECT FUSIBLE LINK (HTR) (a) Remove the fusible link from the engine room R/B. Engine Room R/B: Fusible Link: AC HTR Fuse C136500E03 AC–98 AIR CONDITIONING – AIR CONDITIONING SYSTEM (b) Check if the fusible link is melted. OK: The point indicated by "A" is not melted. (c) Install the fusible link to the engine room R/B with the nut. Fusible Link: NG REPLACE FUSIBLE LINK (HTR) “A” (HTR Fuse) E130412E01 OK 3 AC CHECK HARNESS AND CONNECTOR (BLOWER MOTOR - BODY GROUND) (a) Disconnect the blower motor connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Blower Motor Connector Front View: E39 GND Tester Connection Condition Specified Condition E39-1 (GND) - Body ground Always Below 1 Ω NG I041124E15 REPAIR OR REPLACE HARNESS OR CONNECTOR OK 4 CHECK HARNESS AND CONNECTOR (BLOWER MOTOR - BATTERY) (a) Disconnect the blower motor connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Blower Motor Connector Front View: E39 Tester Connection Condition Specified Condition E39-3 (+B) - Body ground Always 10 to 14 V +B NG I041124E16 REPAIR OR REPLACE HARNESS OR CONNECTOR AC–99 AIR CONDITIONING – AIR CONDITIONING SYSTEM OK 5 CHECK HARNESS AND CONNECTOR (A/C AMPLIFIER - BLOWER MOTOR) (a) Disconnect the A/C amplifier connector. Air Conditioning Amplifier Connector Wire Harness View: E38 BLW E124470E12 (b) Measure the resistance according to the value(s) in the table below. Standard resistance Blower Motor Connector Front View: E39 SI Tester Connection (Symbols) Condition Specified Condition E39-2 (SI) - E38-23 (BLW) Always Below 1 Ω E39-2 (SI) - Body ground Always 10 kΩ or higher I041124E17 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 6 INSPECT BLOWER MOTOR (a) Reconnect the connector to the blower motor. AC AC–100 AIR CONDITIONING – AIR CONDITIONING SYSTEM (b) Measure the voltage on the A/C amplifier connector side according to the value(s) in the table below. Standard voltage Air Conditioning Amplifier Connector Wire Harness View: E38 Tester Connection Condition Specified Condition E38-23 (BLW) - Body ground Ignition switch on (IG) 4.5 to 5.5 V NG REPLACE BLOWER MOTOR BLW E124470E12 OK 7 INSPECT AIR CONDITIONING AMPLIFIER (a) Remove the A/C amplifier. (b) Reconnect the connector to the A/C amplifier. Air Conditioning Amplifier Connector Wire Harness View: AC E38 BLW E124471E06 GND (c) Turn the ignition switch on (IG) . (d) Turn the blower switch ON. (e) Measure the waveform between terminal E38-23 (BLW) of the A/C amplifier and body ground. OK: Waveform is as shown in the illustration. HINT: Waveform varies with the blower level. Item E103396E01 Contents Tool setting 1 V/DIV., 500 µs/DIV. Vehicle condition Ignition switch on (IG) Blower switch: ON NG REPLACE AIR CONDITIONING AMPLIFIER AIR CONDITIONING – AIR CONDITIONING SYSTEM AC–101 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AC AC–102 AIR CONDITIONING – AIR CONDITIONING SYSTEM Heater Control Panel Power Source Circuit DESCRIPTION Battery voltage is supplied to the heater control panel (A/C control assembly) through the A/C No. 2 fuse. WIRING DIAGRAM A/C Control Assembly A/C NO. 2 From IG1 Relay 5 F16 IG+ 3 AC F16 GND E130413E01 AC–103 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (IG+ - BODY GROUND) (a) Disconnect the connector from the heater control panel. (b) Measure the voltage according to the value(s) in the table below. Standard voltage A/C Control Assembly Connector Wire Harness View: Tester Connection (Symbols) Condition Specified Condition F16-5 (IG+) - Body ground Ignition switch on (IG) 10 to 14 V F16-5 (IG+) - Body ground Ignition switch off Below 1 V Result F16 Result Proceed to OK IG+ E124480E02 A NG (without Smart key system) B NG (with Smart key system) C B GO TO STARTING SYSTEM C GO TO PUSH BUTTON START SYSTEM A 2 AC CHECK HARNESS AND CONNECTOR (GND - BODY GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance A/C Control Assembly Connector Wire Harness View: Tester Connection (Symbols) Condition Specified Condition F16-3 (GND) - Body ground Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR F16 GND E124480E03 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AC–104 AIR CONDITIONING – AIR CONDITIONING SYSTEM Air Conditioning Compressor Magnetic Clutch Circuit DESCRIPTION When the A/C amplifier is turned on, a magnetic clutch ON signal is sent from the MGC terminal of the A/ C amplifier. Then, the MG CLT relay turns on to operate the magnetic clutch. WIRING DIAGRAM A/C Amplifier Engine Room R/B and J/B MG CLT 1 5 3 1 2 1 20 1 1 E38 MGC A/C No. 2 From IG1 Relay AC 3 C53 MG+ A/C Compressor (Magnetic Clutch) 1 A E124490E01 INSPECTION PROCEDURE 1 CHECK CAN COMMUNICATION SYSTEM (a) Use the intelligent tester to check if the CAN Communication System is functioning normally. Result Result Proceed to CAN DTC is not output A CAN DTC is output B AC–105 AIR CONDITIONING – AIR CONDITIONING SYSTEM B GO TO CAN COMMUNICATION SYSTEM A 2 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the intelligent tester main switch on. (c) Turn the A/C switch on and off. (d) Select the item below in the DATA LIST, and read the display on the intelligent tester. DATA LIST / ENGINE: Item Measure Item Normal Condition Diagnostic Note A/C SIGNAL (A/C Signal) A/C signal / ON or OFF ON: A/C ON OFF: A/C OFF - OK: The display is as specified in the normal condition column. NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE OK 3 AC INSPECT FUSE (A/C NO. 2) (a) Remove the A/C No. 2 fuse from the instrument panel J/ B. (b) Measure the resistance of the fuse. Standard resistance Instrument Panel J/B: Tester Item Condition Specified Condition A/C No. 2 fuse Always Below 1 Ω (c) Reconnect the A/C No. 2 fuse to the instrument panel J/ B. NG A/C No. 2 E124481E02 OK REPLACE FUSE (A/C NO. 2) AC–106 4 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECT RELAY (MG CLT) 1 3 5 2 1 2 5 (a) Remove the MG CLT relay from the engine room R/B and J/B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 3 B060778E04 (c) Install the MG CLT relay to the engine room R/B and J/B. NG REPLACE RELAY (MG CLT) OK 5 CHECK HARNESS AND CONNECTOR (A/C AMPLIFIER - BATTERY) (a) Disconnect the connector from the A/C amplifier. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Air Conditioning Amplifier Connector Wire Harness View: E38 AC Tester Connection (Symbols) Condition Specified Condition E38-20 (MGC) - Body ground Ignition switch off Below 1 V E38-20 (MGC) - Body ground Ignition switch on (IG) 10 to 14 V NG MGC E124470E13 OK REPAIR OR REPLACE HARNESS OR CONNECTOR AC–107 AIR CONDITIONING – AIR CONDITIONING SYSTEM 6 INSPECT AIR CONDITIONING AMPLIFIER (a) Reconnect the connector to the A/C amplifier. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Air Conditioning Amplifier Connector Wire Harness View: E38 MGC Tester Connection (Symbols) Condition Specified Condition E38-20 (MGC) - Body ground Ignition switch on (IG) A/C switch: OFF 10 to 14 V E38-20 (MGC) - Body ground Ignition switch on (IG) A/C switch: ON Below 1 V NG REPLACE AIR CONDITIONING AMPLIFIER E124471E11 OK 7 INSPECT A/C COMPRESSOR A/C Compressor Connector Front View: (a) Disconnect the connector from the A/C compressor. AC C53 MG+ E005280E15 (b) Disconnect the connector from the magnetic clutch. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Magnetic Clutch Connector Front View: A Tester Connection (Symbols) Condition Specified Condition C53-3 (MG+) - A-1 Always Below 1 Ω C53-3 (MG+) - Body ground Always 10 kΩ or higher E124482E01 NG OK REPLACE A/C COMPRESSOR AC–108 8 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECT MAGNETIC CLUTCH (a) Measure the resistance according to the value(s) in the table below. Standard resistance Magnetic Clutch Connector Front View: A E113611E01 Tester Connection Condition Specified Condition A-1 - Body ground Always 3.4 to 3.8 Ω (b) When connector terminal A1 is connected to the positive (+) battery terminal, check that the following occurs: 1) the magnetic clutch's operating sound can be heard, and 2) the magnetic clutch's hub and rotor lock. NG REPLACE MAGNETIC CLUTCH OK 9 CHECK HARNESS AND CONNECTOR (ENGINE ROOM R/B AND J/B - BATTERY) (a) Remove the MG CLT relay from the engine room R/B and J/B. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Engine Room R/B and J/B: AC Tester Connection Specified Condition Relay block MG CLT relay terminal 5 - Body ground 10 to 14 V Relay block MG CLT relay terminal 1 - Body ground 10 to 14 V MG CLT Relay NG E124483E01 OK REPAIR OR REPLACE HARNESS OR CONNECTOR REPAIR OR REPLACE HARNESS OR CONNECTOR (ENGINE ROOM R/B AND J/B A/C COMPRESSOR) AC–109 AIR CONDITIONING – AIR CONDITIONING SYSTEM Plasmacluster Circuit DESCRIPTION The plasmaclusterTM operates in conjunction with blower switch operation. The plasmaclusterTM operation indicator (CLEAN) illuminates on the A/C control assembly when the plasmaclusterTM is operating. WIRING DIAGRAM A/C No. 2 A/C Amplifier From IG1 Relay 2 IG 39 4 E38 PCL 5 PCD1 GND E12 Ion Generator (Plasmacluster TM ) AC E124491E02 INSPECTION PROCEDURE 1 INSPECT AIR CONDITIONING AMPLIFIER (a) Remove the A/C amplifier with the connectors still connected. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Air Conditioning Amplifier Connector Wire Harness View: E38 PCD1 Tester Connection (Symbols) Condition Specified Condition E38-39 (PCD1) - Body ground Ignition switch on (IG) Blower switch: OFF 10 to 14 V E38-39 (PCD1) - Body ground Ignition switch on (IG) Blower switch: ON Below 1 V NG E124471E07 Go to step 2 AC–110 AIR CONDITIONING – AIR CONDITIONING SYSTEM OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE 2 CHECK HARNESS AND CONNECTOR (ION GENERATOR - BODY GROUND) Ion Generator Connector Front View: E12 (a) Disconnect the connector from the ion generator. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection (Symbols) Condition Specified Condition E12-5 (GND) - Body ground Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR GND E116928E03 OK AC 3 CHECK HARNESS AND CONNECTOR (ION GENERATOR - BATTERY) Ion Generator Connector Front View: E12 (a) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection (Symbols) Condition Specified Condition E12-2 (IG) - Body ground Ignition switch off Below 1 V E12-2 (IG) - Body ground Ignition switch on (IG) 10 to 14 V NG IG E116928E04 OK REPAIR OR REPLACE HARNESS OR CONNECTOR AC–111 AIR CONDITIONING – AIR CONDITIONING SYSTEM 4 CHECK HARNESS AND CONNECTOR (ION GENERATOR - A/C AMPLIFIER) (a) Disconnect the connector from the A/C amplifier. Air Conditioning Amplifier Connector Wire Harness View: E38 PCD1 E124470E14 Ion Generator Connector Front View: E12 (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection (Symbols) Condition Specified Condition E12-4 (PCL) - E38-39 (PCD1) Always Below 1 Ω E12-4 (PCL) - Body ground Always 10 kΩ or higher NG PCL E116928E05 OK REPLACE ION GENERATOR REPAIR OR REPLACE HARNESS OR CONNECTOR AC AC–112 AIR CONDITIONING – AIR CONDITIONING SYSTEM Steering Pad Switch Circuit DESCRIPTION AUTO, OFF, TEMP UP (+), and TEMP DOWN (-) switches are located on the steering pad switch. The resistance of the steering pad switch changes in accordance with switch operation. The A/C control assembly outputs voltage to the steering pad switch and reads voltage changes due to the resistance changes that result from switch operation. HINT: If there is an open in the circuit, the A/C system cannot be operated by the steering pad switch assembly. If there is a short in the circuit, the resulting condition is the same as if the switch were continuously depressed. Therefore, the A/C control assembly cannot be operated by the steering pad switch assembly, and the A/C control assembly will not be able to function correctly. WIRING DIAGRAM Spiral Cable Sub-assembly 2 3 a1 AC 9 8 E18 F16 10 9 E18 F16 EAC a1 AC1 A/C Control Assembly SG ADI1 Steering Pad Switch Assembly (Steering Pad Switch RH) AUTO OFF TEMP+ TEMP- E124492E02 AC–113 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 INSPECT A/C CONTROL ASSEMBLY (a) Remove the A/C control assembly with the connectors still connected. (b) Measure the resistance according to the value(s) in the table below. Standard resistance A/C Control Assembly Connector Wire Harness View: F16 ADI1 SG Tester Connection (Symbols) Condition Specified Condition F16-9 (ADI1) - F16-8 (SG) AUTO switch: ON Below 2.5 Ω F16-9 (ADI1) - F16-8 (SG) OFF switch: ON Approx. 329 Ω F16-9 (ADI1) - F16-8 (SG) TEMP+ switch: ON Approx. 1,000 Ω F16-9 (ADI1) - F16-8 (SG) TEMP- switch: ON Approx. 3,110 Ω E124479E02 NG Go to step 2 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AC 2 INSPECT STEERING PAD SWITCH ASSEMBLY (a) Remove the steering pad switch assembly. (b) Disconnect the connector from the steering pad switch assembly. AC–114 AIR CONDITIONING – AIR CONDITIONING SYSTEM Steering Pad Switch Assembly Connector Front View: a1 EAC AC1 (RH) AUDIO OFF (HOLD) E124484E01 (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection (Symbols) Condition a1-3 (AC1) - a1-2 (EAC) AUTO switch: ON Below 2.5 Ω a1-3 (AC1) - a1-2 (EAC) OFF switch: ON Approx. 329 Ω a1-3 (AC1) - a1-2 (EAC) TEMP+ switch: ON Approx. 1,000 Ω a1-3 (AC1) - a1-2 (EAC) TEMP- switch: ON Approx. 3,110 Ω AC NG OK Specified Condition REPLACE STEERING PAD SWITCH ASSEMBLY AIR CONDITIONING – AIR CONDITIONING SYSTEM 3 AC–115 INSPECT SPIRAL CABLE SUB-ASSEMBLY Steering Pad Switch Assembly Side: a1 AC1 EAC (a) Disconnect the connector from the spiral cable subassembly. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection (Symbols) Condition Specified Condition Center E18-10 (AC1) - a1-3 (AC1) 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right Center E18-9 (EAC) - a1-2 (EAC) 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right Vehicle Side: HINT: The spiral cable makes a maximum of approximately 5 rotations. NG EAC E18 REPLACE SPIRAL CABLE SUB-ASSEMBLY AC1 AC I039337E26 OK 4 CHECK HARNESS AND CONNECTOR (A/C CONTROL ASSEMBLY - SPIRAL CABLE SUB-ASSEMBLY) (a) Disconnect the connector from the A/C control assembly. A/C Control Assembly Connector Wire Harness View: F16 ADI1 SG E124480E04 AC–116 AIR CONDITIONING – AIR CONDITIONING SYSTEM Spiral Cable Sub-assembly Connector Front View: E18 EAC AC1 I046136E06 (b) Disconnect the connector from the spiral cable subassembly. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition F16-9 (ADI1) - E18-10 (AC1) Always Below 1 Ω F16-8 (SG) - E18-9 (EAC) Always Below 1 Ω F16-9 (ADI1) - E18-10 (AC1) Always 10 kΩ or higher F16-8 (SG) - E18-9 (EAC) Always 10 kΩ or higher NG OK REPLACE A/C CONTROL ASSEMBLY AC REPAIR OR REPLACE HARNESS OR CONNECTOR AC–117 AIR CONDITIONING – AIR CONDITIONING SYSTEM IG Power Source Circuit DESCRIPTION The main power source is supplied to the A/C amplifier when the ignition switch is turned on (IG). The power source is used for operating the A/C amplifier and servo motor, etc. WIRING DIAGRAM A/C Amplifier IG1 Relay A/C No. 2 From Battery 1 E38 IG+ From Ignition Switch 14 E38 GND AC From Main Body ECU E124493E01 INSPECTION PROCEDURE HINT: Start the engine before inspection. Check the IG1 relay or battery if the engine does not start. AC–118 1 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECT FUSE (A/C NO. 2) (a) Remove the A/C No. 2 fuse from the instrument panel J/ B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Instrument Panel J/B: Tester Item Condition Specified Condition A/C No. 2 fuse Always Below 1 Ω NG REPLACE FUSE (A/C NO. 2) A/C No. 2 E124481E02 OK 2 AC INSPECT AIR CONDITIONING AMPLIFIER (IG+ - GND) (a) Remove the A/C amplifier with its connectors still connected. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Air Conditioning Amplifier Connector Wire Harness View: E38 GND Tester Connection Condition Specified Condition E38-1 (IG+) - E38-14 (GND) Ignition switch on (IG) 10 to 14 V NG IG+ Go to step 3 E124471E09 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AC–119 AIR CONDITIONING – AIR CONDITIONING SYSTEM 3 CHECK WIRE HARNESS (AIR CONDITIONING AMPLIFIER - BATTERY) (a) Disconnect the A/C amplifier connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Air Conditioning Amplifier Connector Wire Harness View: E38 Tester Connection Condition Specified Condition E38-1 (IG+) - Body ground Ignition switch off Below 1 V Ignition switch on (IG) 10 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR IG+ E124470E15 OK 4 CHECK WIRE HARNESS (AIR CONDITIONING AMPLIFIER - BODY GROUND) (a) Disconnect the A/C amplifier connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Air Conditioning Amplifier Connector Wire Harness View: E38 Tester Connection Condition Specified Condition E38-14 (GND) - Body ground Always Below 1 Ω NG GND E124470E11 OK REPLACE AIR CONDITIONING AMPLIFIER REPAIR OR REPLACE HARNESS OR CONNECTOR AC AC–120 AIR CONDITIONING – AIR CONDITIONING SYSTEM Back-up Power Source Circuit DESCRIPTION The back-up power source circuit for the A/C amplifier is shown below. Power is supplied even when turning the ignition switch off and is used for diagnostic trouble code memory, etc. WIRING DIAGRAM A/C Amplifier A/C 21 E38 B From Battery E116884E03 INSPECTION PROCEDURE AC 1 INSPECT FUSE (A/C) (a) Remove the A/C fuse from the instrument panel J/B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Instrument Panel J/B: NG A/C E124481E03 OK Tester Item Condition Specified Condition A/C fuse Always Below 1 Ω REPLACE FUSE (A/C) AC–121 AIR CONDITIONING – AIR CONDITIONING SYSTEM 2 INSPECT AIR CONDITIONING AMPLIFIER (AIR CONDITIONING AMPLIFIER - BODY GROUND) (a) Disconnect the A/C amplifier connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Air Conditioning Amplifier Connector Wire Harness View: E38 Tester Connection Condition Specified Condition E38-21 (B) - Body ground Always 10 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR B E124470E16 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AC AC–122 AIR CONDITIONING – AIR CONDITIONING SYSTEM LIN Communication Circuit DESCRIPTION The operation signal of a switch etc. is exchanged between terminal TX+ of the A/C control assembly and terminal LIN1 of the A/C amplifier. WIRING DIAGRAM F16 A/C Control Assembly TX+ A/C Amplifier 37 E38 4 LIN1 AC E116883E02 INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (A/C CONTROL ASSEMBLY - AIR CONDITIONING AMPLIFIER) (a) Disconnect the connector from the A/C control assembly. A/C Control Assembly Connector Wire Harness View: F16 TX+ E124480E05 AC–123 AIR CONDITIONING – AIR CONDITIONING SYSTEM (b) Disconnect the connector from the A/C amplifier. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Air Conditioning Amplifier Connector Wire Harness View: E38 Tester connection (Symbols) Condition Specified condition E38-37 (LIN1) - F16-4 (TX+) Always Below 1 Ω E38-37 (LIN1) - Body ground Always 10 kΩ or higher NG LIN1 REPAIR OR REPLACE HARNESS OR CONNECTOR E124470E17 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AC AC–120 AIR CONDITIONING – REFRIGERANT REFRIGERANT ON-VEHICLE INSPECTION 1. INSPECT REFRIGERANT VOLUME HINT: Vehicles manufactured by TMC are equipped with a sight glass. A simple inspection of refrigerant volume can be performed using this sight glass. The inspection procedure is as follows. (a) Check the sight glass on the air conditioning tube & accessory assembly. (1) Prepare the vehicle according to the chart below. Item Condition Vehicle door Fully open Temperature setting MAX COLD Blower speed HI A/C ON Sight Glass (2) Compare the sight glass to the following chart. E129988E01 AC Item Symptom Amount of refrigerant Corrective Actions 1 Bubbles exist Insufficient* 1. Check for gas leakage and repair if necessary 2. Recharge with proper amount of refrigerant 2 No bubbles exist (DTC 76 is output) Empty, insufficient, or excessive Refer to 3 and 4 3 No temperature difference between compressor inlet and outlet Empty or nearly empty 1. Check for gas leakage and repair if necessary 2. Evacuate the AC system and recharge with the proper amount of refrigerant 4 Considerable temperature difference between compressor inlet and outlet Proper or excessive Refer to 5 and 6 5 Immediately after air conditioning is turned off, refrigerant remains clear Excessive 1. Recover refrigerant 2. Evacuate the AC system and recharge with the proper amount of refrigerant 6 Immediately after air conditioning is turned off, refrigerant foams and then becomes clear Proper - *: Bubbles in the sight glass with the vehicle's interior temperature above 35°C (95°F) can be considered normal if cooling is sufficient. 2. INSPECT REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET HINT: This is a method where a manifold gauge set is used to help locate the problem. AC–121 AIR CONDITIONING – REFRIGERANT (a) Read the manifold gauge pressure when the following conditions are established. Test conditions: • Temperature at the air inlet with the switch set at RECIRC is 30 to 35°C (86 to 95°F) • Engine is running at 1,500 rpm • Blower speed control switch is at "HI" • Temperature control dial is at "COOL" • A/C switch is ON • Doors are fully open • Ignition switch is in a position that enables the AC compressor to run. (1) Normally functioning refrigeration system Gauge reading Pressure side Refrigerant volume Low 0.15 to 0.25 MPa (1.5 to 2.5 kgf/cm2, 21.3 to 35.5 psi) High 1.37 to 1.57 MPa (14 to 16 kgf/cm2, 199.1 to 227.5 psi) (2) Moisture is present in refrigeration system. E050573 Condition: Periodically cools and then fails to cool AC I022117E21 Symptom Probable Cause During operation, pressure on low pressure side cycles between normal and vacuum Moisture in AC system will freeze at the expansion valve orifice, causing the refrigeration cycle to temporarily stop After the system stops, and warms up again, the ice will melt and normal operation will be temporarily restored Diagnosis • • Cooler dryer (integrated into condenser tank) in oversaturated state Moisture in refrigeration system freezes at expansion valve orifice and blocks circulation of refrigerant Corrective Actions 1. Replace cooler dryer 2. Remove moisture in system by repeatedly evacuating air 3. Supply a proper amount of new refrigerant (3) Insufficient cooling Condition: Cooling system does not function effectively. I022118E13 AC–122 AIR CONDITIONING – REFRIGERANT Symptom • • • Pressure is low on both low and high pressure sides Bubbles are seen through sight glass continuously Insufficient cooling performance Probable Cause Gas leakage from the refrigeration system Diagnosis • • Insufficient refrigerant Refrigerant leaking Corrective Actions 1. Check for gas leakage and repair if necessary 2. Supply a proper amount of new refrigerant 3. If the gauge indicates a pressure of close to 0, then it will be necessary to evacuate the system after repairing the leak (4) Poor circulation of refrigerant Condition: Cooling system does not function effectively. I022119E14 Symptom • • Pressure is low on both low and high pressure sides Frost exists on pipe from condenser to unit Probable Cause Refrigerant flow is obstructed by dirt inside the pipes of the condenser core Diagnosis Receiver is clogged Corrective Actions Replace condenser (5) Refrigerant does not circulate. AC Condition : Cooling system does not function. (Sometimes it may function.) I022120E14 Symptom • • Vacuum is indicated on low pressure side and very low pressure is indicated on high pressure side Frost or condensation is seen on piping on both sides of receiver/drier or expansion valve Probable Cause • • Refrigerant flow is obstructed by moisture or dirt in refrigeration system Refrigerant flow is disrupted by gas leaking internally through the expansion valve Diagnosis Corrective Actions 1. 2. 3. 4. Refrigerant does not circulate Check the expansion valve Replace expansion valve Replace condenser Evacuate air and supply a proper amount of new refrigerant 5. For internal gas leak at expansion valve, replace expansion valve AC–123 AIR CONDITIONING – REFRIGERANT (6) Refrigerant is overcharged or cooling effectiveness of condenser is insufficient. Condition: Cooling system does not function. I022121E14 Symptom • • Pressure is too high on both low and high pressure sides No air bubbles are seen through sight glass even when engine rpm lowers Probable Cause • • Unable to develop sufficient performance due to excessive use of refrigeration system Cooling effectiveness of condenser is insufficient Diagnosis • • Excessive refrigerant in cycle → excessive refrigerant was added during recharging Condenser cooling effectiveness is insufficient → condenser fins are clogged at cooling fan Corrective Actions 1. Clean condenser 2. Check the operation of the condenser cooling fan 3. If 1 and 2 are normal state, check the amount of refrigerant and supply proper amount of refrigerant (7) Air is present in refrigeration system. Condition: Cooling system does not function. NOTE: These gauge indications occur when the refrigeration system opens and the refrigerant is charged without vacuum purging. AC I022122E06 Symptom • • • Pressure is too high on both low and high pressure sides The low pressure piping is too hot to touch Bubbles can be seen through sight glass Probable Cause Diagnosis • Air in system • Air present in refrigeration system Insufficient vacuum purging Corrective Actions 1. Check compressor oil to see if it is dirty or insufficient 2. Evacuate the system and recharge it with new or purified refrigerant (8) Expansion valve malfunction Condition: Insufficient cooling I022123E05 AC–124 AIR CONDITIONING – REFRIGERANT Symptom • • Pressure is too high on both low and high pressure sides Frost or a large amount of condensation on piping on low pressure side Probable Cause Diagnosis • Expansion valve may be sticking • Excessive refrigerant in low pressure piping Expansion valve opened too wide Corrective Actions Check expansion valve (9) Insufficient compressor compression Condition: Insufficient cooling I022124E05 Symptom • • Pressure is too high both on low and high pressure sides Pressure is too low on high pressure side Probable Cause Diagnosis • • Internal leak in compressor Low compression Leak from a damaged valve, or parts may be broken Corrective Actions Replace compressor Gauge readings (Reference) Pressure on low pressure side AC MPa (kgf/cm2, psi) 0.5 (5.0, 71.1) Blower HI Zone 0.4 (4.0, 56.9) 1.06 (10.9, 150) 0.3 (3.0, 42.7) 0.27 (2.8, 40.5) Blower LO Zone 1.2 (12.3, 175) 0.2 (2.0, 28.4) 0.22 (2.25, 32) 0.2 (2.1, 29.9) 1.25 (12.8, 178) 0.14 (1.5, 21.3) 0.5 (5.0, 71.1) Pressure on high pressure side 1.32 (13.5, 192) 1.0 (10.0, 14.2) 1.5 (15.0, 213) 2.0 (20.0, 284) MPa (kgf/cm2, psi) I030081E07 AIR CONDITIONING – REFRIGERANT AC–125 REPLACEMENT 1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM (a) Start up the engine. (b) Turn the A/C switch on. (c) Operate the cooler compressor at an engine speed of approximately 1,000 rpm for 5 to 6 minutes to circulate the refrigerant. This causes most of the compressor oil from the various components of the A/C system to collect in the A/C compressor. (d) Stop the engine. (e) Recover the refrigerant from the A/C system using a refrigerant recovery unit. 2. CHARGE WITH REFRIGERANT (a) Perform vacuum purging using a vacuum pump. (b) Charge with refrigerant HFC-134a (R134a). Mean value in proper range Amount to be charged Charge 100 g (3.53 oz.) +-50 g (+-1.80 oz.) Overcharged AC Point where bubbles disappear High Pressure Refrigerant Amount Sub-cool System I037365E09 Standard: 450 to 550 g (15.9 to 19.4 oz.) SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080) NOTICE: • Do not turn the A/C on before charging with refrigerant. Doing so will cause the cooler compressor to work without refrigerant, resulting in overheating of the cooler compressor. AC–126 AIR CONDITIONING – REFRIGERANT • Approximately 100 g (3.53 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by quantity, not with the sight glass. HINT: Ensure that sufficient refrigerant is available to recharge the system when using a refrigerant recovery unit. Refrigerant recovery units are not always able to recover 100 % of the refrigerant from an A/C system. AC Check for Leakage Gas Leak Detector I042222E02 3. WARM UP ENGINE (a) Keep the A/C switch on for at least 2 minutes to warm up the compressor. NOTICE: Be sure to warm up the compressor when turning the A/C on after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor. 4. CHECK FOR LEAKAGE OF REFRIGERANT (a) After recharging with refrigerant gas, check for leakage of refrigerant gas using a halogen leak detector. (b) Carry out the test under the following conditions: • IG OFF • Secure good ventilation (the gas leak detector may react to volatile gases which are not refrigerant, such as evaporated gasoline and exhaust gas). • Repeat the test 2 or 3 times. • Make sure that there is some refrigerant remaining in the refrigeration system. When the compressor is off: approx. 392 to 588 kPa (4 to 6 kgf/cm2, 57 to 85 psi) (c) Using a gas leak detector, check for leakage from the refrigerant lines. AIR CONDITIONING – REFRIGERANT Drain Hose Gas Leak Detector N014519E01 AC–127 (d) Bring the gas leak detector close to the drain hose with the detector's power off, and then turn the detector on. HINT: • After the blower motor has stopped, let the cooling unit stand for more than 15 minutes. • Bring the gas leak detector sensor under the drain hose. • When bringing the gas leak detector close to the drain hose, make sure that the gas leak detector does not react to volatile gases. If it is not possible to avoid interference from volatile gases, the vehicle should be lifted up to allow testing. (e) If a gas leak is not detected from the drain hose, remove the blower motor control from the cooling unit. Insert the gas leak detector sensor into the unit and perform the test. (f) Disconnect the pressure switch connector and leave it for approximately 20 minutes. Bring the gas leak detector close to the pressure switch and perform the test. AC AC–128 AIR CONDITIONING – REFRIGERANT LINE REFRIGERANT LINE HEATER AIR CONDITIONING & AIR CONDITIONING SYSTEM COMPONENTS for TMC Made 2AZ-FE: COOLER REFRIGERANT DISCHARGE PIPE AIR CONDITIONER TUBE AND ACCESSORY 9.8 (100, 87 in.*lbf) 9.8 (100, 87 in.*lbf) AC SUCTION PIPE SUB-ASSEMBLY 9.8 (100, 87 in.*lbf) 9.8 (100, 87 in.*lbf) 9.8 (100, 87 in.*lbf) NO. 1 COOLER REFRIGERANT DISCHARGE HOSE NO. 1 COOLER REFRIGERANT SUCTION HOSE N*m (kgf*cm, ft.*lbf) : Specified torque E128497E01 AIR CONDITIONING – REFRIGERANT LINE AC–129 for TMC Made 2GR-FE: COOLER REFRIGERANT DISCHARGE PIPE AIR CONDITIONER TUBE AND ACCESSORY 9.8 (100, 87 in.*lbf) SUCTION PIPE SUB-ASSEMBLY 9.8 (100, 87 in.*lbf) 9.8 (100, 87 in.*lbf) 9.8 (100, 87 in.*lbf) AC 9.8 (100, 87 in.*lbf) NO. 1 COOLER REFRIGERANT NO. 1 COOLER REFRIGERANT SUCTION HOSE DISCHARGE HOSE N*m (kgf*cm, ft.*lbf) : Specified torque E128496E01 AC–130 AIR CONDITIONING – REFRIGERANT LINE for TMMK Made 2AZ-FE: COOLER REFRIGERANT DISCHARGE PIPE AIR CONDITIONER TUBE AND ACCESSORY 9.8 (100, 87 in.*lbf) SUCTION PIPE SUB-ASSEMBLY 9.8 (100, 87 in.*lbf) 9.8 (100, 87 in.*lbf) AC 9.8 (100, 87 in.*lbf) NO. 1 COOLER REFRIGERANT DISCHARGE HOSE NO. 1 COOLER REFRIGERANT SUCTION HOSE N*m (kgf*cm, ft.*lbf) : Specified torque E129999E01 AIR CONDITIONING – REFRIGERANT LINE AC–131 for TMMK Made 2GR-FE: COOLER REFRIGERANT DISCHARGE PIPE AIR CONDITIONER TUBE AND ACCESSORY 9.8 (100, 87 in.*lbf) SUCTION PIPE SUB-ASSEMBLY 9.8 (100, 87 in.*lbf) 9.8 (100, 87 in.*lbf) AC 9.8 (100, 87 in.*lbf) NO. 1 COOLER REFRIGERANT NO. 1 COOLER REFRIGERANT SUCTION HOSE DISCHARGE HOSE N*m (kgf*cm, ft.*lbf) : Specified torque E130000E01 AC–132 AIR CONDITIONING – AIR CONDITIONING UNIT AIR CONDITIONING UNIT HEATER AIR CONDITIONING & AIR CONDITIONING SYSTEM COMPONENTS 20 (204, 15) FRONT WIPER ARM AND BLADE ASSEMBLY RH FRONT WIPER ARM AND BLADE ASSEMBLY LH 20 (204, 15) FRONT FENDER TO COWL SIDE SEAL RH COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 85 (867, 63) FRONT FENDER TO COWL SIDE SEAL LH 5.0 (51, 44 in.*lbf) 7.5 (77, 66 in.*lbf) 85 (867, 63) 5.0 (51, 44 in.*lbf) WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY AC COWL TOP OUTER FRONT PANEL SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque E134150E02 AC–133 AIR CONDITIONING – AIR CONDITIONING UNIT for TMC Made: TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY 2.0 (20, 18 in.*lbf) STEERING COLUMN COVER AC 50 (510, 37) STEERING WHEEL ASSEMBLY LOWER NO. 2 STEERING WHEEL COVER LOWER NO. 3 STEERING WHEEL COVER 8.8 (90, 78 in.*lbf) STEERING PAD N*m (kgf*cm, ft.*lbf) : Specified torque B137279E01 AC–134 AIR CONDITIONING – AIR CONDITIONING UNIT for TMMK Made: TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY 2.0 (20, 18 in.*lbf) STEERING COLUMN COVER for 4 Spoke: 50 (510, 37) STEERING WHEEL ASSEMBLY LOWER NO. 2 STEERING WHEEL COVER AC LOWER NO. 3 STEERING WHEEL COVER STEERING PAD 8.8 (90, 78 in.*lbf) for 3 Spoke: STEERING WHEEL ASSEMBLY 50 (510, 37) LOWER NO. 2 STEERING WHEEL COVER LOWER NO. 3 STEERING WHEEL COVER STEERING PAD 8.8 (90, 78 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque B137280E01 AC–135 AIR CONDITIONING – AIR CONDITIONING UNIT for TMC Made: COMBINATION METER ASSEMBLY INSTRUMENT CLUSTER FINISH PANEL without Smart Key System: LOWER INSTRUMENT PANEL FINISH PANEL with Smart Key System: AC NO. 1 INSTRUMENT PANEL SUB-ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL COWL SIDE TRIM SUB-ASSEMBLY LH COWL SIDE TRIM CLIP LOWER INSTRUMENT PANEL FINISH PANEL LH FRONT DOOR SCUFF PLATE LH B137281E01 AC–136 AIR CONDITIONING – AIR CONDITIONING UNIT for TMMK Made: COMBINATION METER ASSEMBLY without Smart Key System: INSTRUMENT CLUSTER FINISH PANEL LOWER INSTRUMENT PANEL FINISH PANEL with Smart Key System: AC NO. 1 INSTRUMENT PANEL SUB-ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL COWL SIDE TRIM SUB-ASSEMBLY LH COWL SIDE TRIM CLIP or

LOWER INSTRUMENT PANEL FINISH PANEL LH FRONT DOOR SCUFF PLATE LH B137281E03 AIR CONDITIONING – AIR CONDITIONING UNIT AC–137 for TMC Made: LOWER INSTRUMENT PANEL SUB-ASSEMBLY or COWL SIDE TRIM SUB-ASSEMBLY RH AC COWL SIDE TRIM CLIP FRONT DOOR SCUFF PLATE RH INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY B137282E01 AC–138 AIR CONDITIONING – AIR CONDITIONING UNIT for TMMK Made: LOWER INSTRUMENT PANEL SUB-ASSEMBLY or

COWL SIDE TRIM SUB-ASSEMBLY RH AC COWL SIDE TRIM CLIP FRONT DOOR SCUFF PLATE RH INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY B137282E03 AIR CONDITIONING – AIR CONDITIONING UNIT AC–139 NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH for Automatic Transaxle: SHIFT LEVER KNOB SUB-ASSEMBLY FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY UPPER CONSOLE REAR PANEL SUB-ASSEMBLY AC for Manual Transaxle: SHIFT LEVER KNOB SUB-ASSEMBLY UPPER CONSOLE PANEL UPPER CONSOLE REAR PANEL SUB-ASSEMBLY B137283E01 AC–140 AIR CONDITIONING – AIR CONDITIONING UNIT for TMC Made: INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY without Navigation System: with Navigation System: AC RADIO RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY NAVIGATION RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY UPPER CONSOLE PANEL SUB-ASSEMBLY B137284E01 AIR CONDITIONING – AIR CONDITIONING UNIT AC–141 for TMMK Made: INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY without Navigation System: with Navigation System: AC RADIO RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY NAVIGATION RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY UPPER CONSOLE PANEL SUB-ASSEMBLY B137284E03 AC–142 AIR CONDITIONING – AIR CONDITIONING UNIT for TMC Made: FRONT PILLAR GARNISH CLIP FRONT PILLAR GARNISH CLIP FRONT PILLAR GARNISH RH FRONT PILLAR GARNISH LH INSTRUMENT PANEL NO. 3 REGISTER ASSEMBLY INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY NO. 1 CONSOLE BOX INSERT FRONT AC NO. 2 CONSOLE BOX INSERT FRONT CONSOLE BOX CARPET CONSOLE BOX ASSEMBLY CONSOLE BOX POCKET Non-reusable part B137285E01 AC–143 AIR CONDITIONING – AIR CONDITIONING UNIT for TMMK Made: FRONT PILLAR GARNISH CLIP FRONT PILLAR GARNISH CLIP FRONT PILLAR GARNISH RH FRONT PILLAR GARNISH LH INSTRUMENT PANEL NO. 3 REGISTER ASSEMBLY INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY NO. 1 CONSOLE BOX INSERT FRONT or or AC NO. 2 CONSOLE BOX INSERT FRONT CONSOLE BOX CARPET CONSOLE BOX ASSEMBLY CONSOLE BOX POCKET Non-reusable part B137285E03 AC–144 AIR CONDITIONING – AIR CONDITIONING UNIT for TMC Made: INSTRUMENT PANEL NO. 1 SPEAKER PANEL SUB-ASSEMBLY INSTRUMENT PANEL NO. 2 SPEAKER PANEL SUB-ASSEMBLY NO. 1 DEFROSTER NOZZLE GARNISH for RH Side: for LH Side: FRONT NO. 2 SPEAKER ASSEMBLY FRONT NO. 2 SPEAKER ASSEMBLY AC or or or or 20 (204, 15) INSTRUMENT PANEL SAFETY PAD ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B137286E01 AC–145 AIR CONDITIONING – AIR CONDITIONING UNIT for TMMK Made: INSTRUMENT PANEL NO. 1 SPEAKER PANEL SUB-ASSEMBLY INSTRUMENT PANEL NO. 2 SPEAKER PANEL SUB-ASSEMBLY NO. 1 DEFROSTER NOZZLE GARNISH for RH Side: for LH Side: FRONT NO. 2 SPEAKER ASSEMBLY FRONT NO. 2 SPEAKER ASSEMBLY AC , or , or 20 (204, 15) INSTRUMENT PANEL SAFETY PAD ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B137286E03 AC–146 AIR CONDITIONING – AIR CONDITIONING UNIT NO. 6 HEATER TO REGISTER DUCT ASSEMBLY 20 (204, 15) 6.0 (61, 53 in.*lbf) 17 (175, 13) 17 (175, 13) CAP CAP 17 (175, 13) 6.0 (61, 53 in.*lbf) INSTRUMENT PANEL REINFORCEMENT ASSEMBLY 25 (255, 18) STEERING COLUMN ASSEMBLY AC FLOOR CARPET BRACKET RH 25 (255, 18) for Automatic Air Conditioning System FLOOR CARPET BRACKET LH NO. 1 CONSOLE BOX DUCT REAR NO. 2 AIR DUCT REAR NO. 1 AIR DUCT N*m (kgf*cm, ft.*lbf) : Specified torque E128500E01 AC–147 AIR CONDITIONING – AIR CONDITIONING UNIT for TMC Made: SUCTION PIPE SUB-ASSEMBLY 9.8 (100, 87 in.*lbf) NO. 2 AIR DUCT SUB-ASSEMBLY O-RING AIR CONDITIONER TUBE AND ACCESSORY HEATER OUTLET WATER HOSE HEATER INLET WATER HOSE 9.8 (100, 87 in.*lbf) 9.8 (100, 87 in.*lbf) NO. 1 AIR DUCT 9.8 (100, 87 in.*lbf) AC AIR CONDITIONING AMPLIFIER ASSEMBLY BLOWER ASSEMBLY AIR CONDITIONING UNIT ASSEMBLY Compressor oil ND-OIL 8 or equivalent Non-reusable part N*m (kgf*cm, ft.*lbf) : Specified torque E128501E01 AC–148 AIR CONDITIONING – AIR CONDITIONING UNIT for TMMK Made: SUCTION PIPE SUB-ASSEMBLY 9.8 (100, 87 in.*lbf) NO. 2 AIR DUCT SUB-ASSEMBLY O-RING AIR CONDITIONER TUBE AND ACCESSORY HEATER OUTLET WATER HOSE HEATER INLET WATER HOSE 9.8 (100, 87 in.*lbf) 9.8 (100, 87 in.*lbf) NO. 1 AIR DUCT 9.8 (100, 87 in.*lbf) AC COOLER EXPANSION VALVE 3.5 (35, 30 in.*lbf) O-RING AIR CONDITIONING AMPLIFIER ASSEMBLY BLOWER ASSEMBLY AIR CONDITIONING UNIT ASSEMBLY Compressor oil ND-OIL 8 or equivalent Non-reusable part N*m (kgf*cm, ft.*lbf) : Specified torque E129993E01 AC–149 AIR CONDITIONING – AIR CONDITIONING UNIT for TMC Made: COOLER EXPANSION VALVE O-RING 3.5 (35, 30 in.*lbf) NO. 1 COOLER THERMISTOR NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY AC AIR MIX CONTROL SERVO MOTOR AIR OUTLET CONTROL SERVO MOTOR DRAIN COOLER HOSE HEATER CLAMP CLAMP HEATER RADIATOR UNIT SUB-ASSEMBLY Compressor oil ND-OIL 8 or equivalent Non-reusable part AIR CONDITIONER HARNESS N*m (kgf*cm, ft.*lbf) : Specified torque E128502E01 AC–150 AIR CONDITIONING – AIR CONDITIONING UNIT for TMMK Made: NO. 1 COOLER THERMISTOR NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY AC AIR MIX CONTROL SERVO MOTOR AIR OUTLET CONTROL SERVO MOTOR DRAIN COOLER HOSE HEATER CLAMP CLAMP HEATER RADIATOR UNIT SUB-ASSEMBLY AIR CONDITIONER HARNESS E129998E01 AIR CONDITIONING – AIR CONDITIONING UNIT AC–151 REMOVAL 1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM (See page AC-125) 2. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 3. DISCONNECT BATTERY NEGATIVE TERMINAL NOTICE: Wait for 90 seconds after disconnecting the terminal to prevent the airbag from deploying. (See page RS1) 4. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH (See page WW-9) 5. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH (See page WW-9) 6. REMOVE FRONT FENDER TO COWL SIDE SEAL LH (See page WW-9) 7. REMOVE FRONT FENDER TO COWL SIDE SEAL RH (See page WW-9) 8. REMOVE COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See page WW-10) 9. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (See page WW-10) 10. REMOVE COWL TOP OUTER FRONT PANEL SUBASSEMBLY (See page BR-29) 11. DISCONNECT SUCTION PIPE SUB-ASSEMBLY (a) Remove the bolt, and slide the hook connector. (b) Disconnect the suction pipe sub-assembly. (c) Remove the O-ring from the suction hose subassembly. NOTICE: Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter. E128510 12. DISCONNECT AIR CONDITIONER TUBE AND ACCESSORY (a) Disconnect the air conditioner tube and accessory. (b) Remove the O-ring from the air conditioner tube and accessory. NOTICE: Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter. AC AC–152 AIR CONDITIONING – AIR CONDITIONING UNIT 13. DISCONNECT HEATER OUTLET WATER HOSE (a) Using pliers, grip the claws of the clip and slide the clip to disconnect the heater outlet water hose. NOTICE: • Do not apply excessive force to the heater outlet water hose. • Prepare a drain pan or cloth in case the coolant leaks. 14. DISCONNECT HEATER INLET WATER HOSE HINT: Disconnection procedure for the heater inlet water hose is the same as that for the heater outlet water hose. 15. REMOVE LOWER NO. 3 STEERING WHEEL COVER (See page RS-349) E128511 16. REMOVE LOWER NO. 2 STEERING WHEEL COVER (See page RS-349) 17. REMOVE STEERING PAD (See page RS-350) 18. REMOVE STEERING WHEEL ASSEMBLY (See page SR-38) 19. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-24) 20. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-25) AC 21. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (See page IP-20) 22. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (See page IP-21) 23. REMOVE STEERING COLUMN COVER (for TMC Made) (See page IP-21) 24. REMOVE STEERING COLUMN COVER (for TMMK Made) (See page IP-21) 25. REMOVE TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY (See page SR-39) 26. REMOVE NO. 1 INSTRUMENT PANEL SUBASSEMBLY (See page IP-22) 27. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (w/o Smart Key System) (See page IP-22) 28. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (w/ Smart Key System) (See page IP-22) 29. REMOVE INSTRUMENT CLUSTER FINISH PANEL (See page IP-22) 30. REMOVE COMBINATION METER ASSEMBLY (for TMC Made) (See page IP-23) 31. REMOVE COMBINATION METER ASSEMBLY (for TMMK Made) (See page IP-23) AIR CONDITIONING – AIR CONDITIONING UNIT AC–153 32. REMOVE FRONT DOOR SCUFF PLATE RH (See page IR-26) 33. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH (See page IR-26) 34. REMOVE INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY (See page IP-23) 35. REMOVE LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMC Made) (See page IP-23) 36. REMOVE LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMMK Made) (See page IP-24) 37. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-24) 38. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) (See page IP-24) 39. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-24) 40. REMOVE NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-25) 41. REMOVE FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-25) 42. REMOVE UPPER CONSOLE PANEL (for Manual Transaxle) (See page IP-25) 43. REMOVE UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Automatic Transaxle) (See page IP26) 44. REMOVE UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Manual Transaxle) (See page IP-26) 45. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMC Made) (See page IP-27) 46. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMMK Made) (See page IP-27) 47. REMOVE INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY (See page IP-27) 48. REMOVE RADIO RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY (w/o Navigation System) (See page AV-146) 49. REMOVE NAVIGATION RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY (See page NS-195) 50. REMOVE CONSOLE BOX POCKET (See page IP-28) 51. REMOVE CONSOLE BOX CARPET (See page IP-28) 52. REMOVE CONSOLE BOX ASSEMBLY (for TMC Made) (See page IP-28) 53. REMOVE CONSOLE BOX ASSEMBLY (for TMMK Made) (See page IP-29) AC AC–154 AIR CONDITIONING – AIR CONDITIONING UNIT 54. REMOVE NO. 2 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-29) 55. REMOVE NO. 2 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-30) 56. REMOVE NO. 1 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-30) 57. REMOVE NO. 1 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-30) 58. REMOVE FRONT PILLAR GARNISH LH (See page IR27) 59. REMOVE INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY (See page IP-31) 60. REMOVE INSTRUMENT PANEL NO. 1 SPEAKER PANEL SUB-ASSEMBLY (See page IP-31) 61. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (for LH Side) (See page AV-156) 62. REMOVE FRONT PILLAR GARNISH RH (See page IR27) 63. REMOVE INSTRUMENT PANEL NO. 3 REGISTER ASSEMBLY (See page IP-31) 64. REMOVE INSTRUMENT PANEL NO. 2 SPEAKER PANEL SUB-ASSEMBLY (See page IP-32) AC 65. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (for RH Side) (See page IP-32) 66. REMOVE NO. 1 DEFROSTER NOZZLE GARNISH (See page IP-32) 67. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY (for TMC Made) (See page IP-32) 68. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY (for TMMK Made) (See page IP-34) 69. REMOVE NO. 1 CONSOLE BOX DUCT (for Automatic Air Conditioning System) (a) Remove the clip and No. 1 console box duct . C129716 AIR CONDITIONING – AIR CONDITIONING UNIT AC–155 70. REMOVE FLOOR CARPET BRACKET LH (a) Release the clamp. (b) Turn back the floor carpet. Clamp E129146E01 (c) Remove the 3 clips. (d) Remove the floor carpet bracket LH. E128512 71. REMOVE FLOOR CARPET BRACKET RH (a) Release the clamp. (b) Turn back the floor carpet. AC Clamp E129147E01 (c) Remove the 3 clips. (d) Remove the floor carpet bracket RH. E128513 72. REMOVE REAR NO. 2 AIR DUCT (a) Release the 2 claws and remove the rear No. 2 air duct. C129721 AC–156 AIR CONDITIONING – AIR CONDITIONING UNIT 73. REMOVE REAR NO. 1 AIR DUCT (a) Release the 2 claws and remove the rear No. 1 air duct. 74. REMOVE NO. 1 AIR DUCT (See page SR-39) 75. SEPARATE STEERING COLUMN ASSEMBLY (for TMC Made) (See page SR-39) 76. REMOVE STEERING POST ASSEMBLY (for TMMK Made) (See page SR-41) C129722 77. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY (a) Disconnect the 2 connectors. (b) Remove the 2 bolts and air conditioning amplifier assembly. E128518E01 78. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY (a) Remove the 28 clamps, disconnect the 11 connectors, and then disconnect the wire harness. (b) Remove the 6 nuts, 7 bolts, and junction block. AC E128519 AIR CONDITIONING – AIR CONDITIONING UNIT AC–157 (c) Remove the 2 caps and 2 bolts from the engine compartment side. AC E128520 (d) Remove the 2 bolts and nut. AC–158 AIR CONDITIONING – AIR CONDITIONING UNIT (e) Using a "Torx" socket wrench (T40), remove the 5 "Torx" bolts. “Torx” bolt Collar AC E128521E01 (f) HINT: The "Torx" bolts on the passenger side can be removed with the collars for adjustment. Using a hexagon wrench 12 mm, remove the 2 collars and instrument panel reinforcement assembly with the air conditioner unit assembly. AIR CONDITIONING – AIR CONDITIONING UNIT AC–159 (g) Remove the 3 bolts, 2 screws, and instrument panel reinforcement assembly. E128522 DISASSEMBLY 1. 2. E128523 REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY (for TMC Made) (a) Release the 2 claws and remove the No. 2 air duct sub-assembly as shown in the illustration. REMOVE BLOWER ASSEMBLY (for TMC Made) (a) Disconnect the connector. AC AC–160 AIR CONDITIONING – AIR CONDITIONING UNIT (b) Remove the 2 screws and blower assembly. E128524 3. REMOVE NO. 6 HEATER TO REGISTER DUCT ASSEMBLY (for TMC Made) (a) Release the 4 claws and remove the No. 6 heater to register duct assembly. 4. REMOVE DRAIN COOLER HOSE (for TMC Made) (a) Remove the drain cooler hose from the air conditioning radiator assembly. 5. REMOVE AIR OUTLET CONTROL SERVO MOTOR (for TMC Made) (a) Disconnect the 2 connectors and remove the air conditioner harness. (b) Remove the 3 screws and then remove the air outlet control servo motor. AC E128525 E128535 E128526 AIR CONDITIONING – AIR CONDITIONING UNIT AC–161 6. REMOVE AIR MIX CONTROL SERVO MOTOR (for Automatic Air Conditioning System) (a) Remove the 2 screws and air mix control servo motor. 7. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY (for TMC Made) (a) Remove the screw and clamp. (b) Release the 4 claws and remove the clamp. C129729 C129730 (c) Remove the heater radiator unit sub-assembly from the air conditioning radiator assembly. NOTICE: Prepare a drain pan or cloth in case the cooling water leaks. AC E128528 8. REMOVE COOLER EXPANSION VALVE (for TMC Made) (a) Using a 4 mm hexagon wrench, remove the 2 hexagon bolts and cooler expansion valve. 9. REMOVE NO. 1 COOLER EVAPORATOR SUBASSEMBLY (for TMC Made) (a) Remove the 6 screws, release the 4 claws, and remove the plate cover. C129879 E128529 AC–162 AIR CONDITIONING – AIR CONDITIONING UNIT (b) Remove the clamp and No. 1 cooler thermistor. : Clamp C129878E02 (c) Remove the No. 1 cooler evaporator sub-assembly. C129880 (d) Remove the 2 O-rings from the No. 1 cooler evaporator sub-assembly. AC C129881 10. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY (for TMMK Made) (a) Release the 2 claws and remove the No. 2 air duct sub-assembly as shown in the illustration. E128523 AIR CONDITIONING – AIR CONDITIONING UNIT AC–163 11. REMOVE COOLER EXPANSION VALVE (for TMMK Made) (a) Using a 4 mm hexagon wrench, remove the 2 hexagon bolts and cooler expansion valve. C129879 12. REMOVE BLOWER ASSEMBLY (for TMMK Made) (a) Remove the connector and clamp, and disconnect the wire harness. E129996 (b) Remove the 6 screws and then the blower assembly with the cooler evaporator sub-assembly. E129997 13. REMOVE NO. 6 HEATER TO REGISTER DUCT ASSEMBLY (for TMMK Made) (a) Release the 4 claws and remove the No. 6 heater to register duct assembly. E128525 AC AC–164 AIR CONDITIONING – AIR CONDITIONING UNIT 14. REMOVE DRAIN COOLER HOSE (for TMMK Made) (a) Remove the drain cooler hose from the air conditioning radiator assembly. E128535 15. REMOVE AIR OUTLET CONTROL SERVO MOTOR (for TMMK Made) (a) Disconnect the 2 connectors and remove the air conditioner harness. C129727 (b) Remove the 3 screws and then the air outlet control servo motor. AC C129728 16. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY (for TMMK Made) (a) Remove the screw and clamp. (b) Release the 4 claws and remove the clamp. C129730 (c) Remove the heater radiator unit sub-assembly from the air conditioning radiator assembly. NOTICE: Prepare a drain pan or cloth in case the cooling water leaks. E128528 AIR CONDITIONING – AIR CONDITIONING UNIT AC–165 17. REMOVE NO. 1 COOLER EVAPORATOR SUBASSEMBLY (for TMMK Made) (a) Remove the clamp and No. 1 cooler thermistor. : Clamp C129878E02 (b) Remove the No. 1 cooler evaporator sub-assembly. C129880 (c) Remove the 2 O-rings from the No. 1 cooler evaporator sub-assembly. AC C129881 REASSEMBLY Sensor 34.3 mm (1.35 in.) 1. 50 mm (1.96 in.) C129887E02 INSTALL NO. 1 COOLER THERMISTOR (for TMC Made) (a) If using a new evaporator: (1) Install the No. 1 cooler thermistor to the evaporator as shown in the illustration. AC–166 AIR CONDITIONING – AIR CONDITIONING UNIT 0 to 1 mm Grommet (0 to 0.039 in.) (b) If reusing the evaporator: (1) Install the No. 1 cooler thermistor to the evaporator as shown in the illustration. Sensor Tube Case 50 mm (1.96 in.) C129888E01 2. INSTALL NO. 1 COOLER EVAPORATOR SUBASSEMBLY (for TMC Made) (a) Sufficiently apply compressor oil to 2 new O-rings and the fitting surfaces. Install the 2 O-rings to the No. 1 cooler evaporator sub-assembly. Compressor oil: ND-OIL 8 or equivalent C129881 AC (b) Install the No. 1 cooler evaporator sub-assembly. C129880 (c) Engage the 4 claws and install the plate cover with the 6 screws. E128529 AIR CONDITIONING – AIR CONDITIONING UNIT AC–167 3. INSTALL COOLER EXPANSION VALVE (for TMC Made) (a) Using a 4 mm hexagon wrench, install the cooler expansion valve with the 2 hexagon bolts. Torque: 3.5 N*m (35 kgf*cm, 30 in.*lbf) 4. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY (for TMC Made) (a) Install the heater radiator unit sub-assembly to the air conditioner radiator assembly. C129879 E128528 (b) Install the clamp with the screw. (c) Engage the 4 claws and install the heater clamp. AC C129730 5. INSTALL AIR MIX CONTROL SERVO MOTOR (for Automatic Air Conditioning System) (a) Install the air mix control servo motor with the 2 screws. 6. INSTALL AIR OUTLET CONTROL SERVO MOTOR (for TMC Made) (a) Install the air outlet control servo motor with the 3 screws. (b) Connect the 2 connectors and install the air conditioner harness. C129729 E128526 AC–168 AIR CONDITIONING – AIR CONDITIONING UNIT 7. INSTALL DRAIN COOLER HOSE (for TMC Made) (a) Install the drain cooler hose to the air conditioner radiator assembly. 8. INSTALL NO. 6 HEATER TO REGISTER DUCT ASSEMBLY (for TMC Made) (a) Engage the 4 claws to install the No. 6 heater to register duct assembly. 9. INSTALL BLOWER ASSEMBLY (for TMC Made) (a) Install the blower assembly with the 2 screws. (b) Connect the connector. E128535 E128525 AC E128524 AIR CONDITIONING – AIR CONDITIONING UNIT AC–169 10. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY (for TMC Made) (a) Engage the 2 claws to install the No. 2 air duct subassembly. E129155 11. INSTALL NO. 1 COOLER THERMISTOR (for TMMK Made) (a) If using a new evaporator: (1) Install the No. 1 cooler thermistor to the evaporator as shown in the illustration. Sensor AC 34.3 mm (1.35 in.) 50 mm (1.96 in.) C129887E02 0 to 1 mm Grommet (0 to 0.039 in.) Sensor Tube Case 50 mm (1.96 in.) C129888E01 (b) If reusing the evaporator: (1) Install the No. 1 cooler thermistor to the evaporator as shown in the illustration. AC–170 AIR CONDITIONING – AIR CONDITIONING UNIT 12. INSTALL NO. 1 COOLER EVAPORATOR SUBASSEMBLY (for TMMK Made) (a) Sufficiently apply compressor oil to 2 new O-rings and the fitting surfaces. Install the 2 O-rings to the No. 1 cooler evaporator sub-assembly. Compressor oil: ND-OIL 8 or equivalent C129881 (b) Install the No. 1 cooler evaporator sub-assembly. C129880 13. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY (for TMMK Made) (a) Install the heater radiator unit sub-assembly to the air conditioner radiator assembly. AC E128528 (b) Install the clamp with the screw. (c) Engage the 4 claws and install the heater clamp. C129730 14. INSTALL AIR OUTLET CONTROL SERVO MOTOR (for TMMK Made) (a) Install the air outlet control servo motor with the 3 screws. C129728 AIR CONDITIONING – AIR CONDITIONING UNIT AC–171 (b) Connect the 2 connectors and install the air conditioner harness. C129727 15. INSTALL DRAIN COOLER HOSE (for TMMK Made) (a) Install the drain cooler hose to the air conditioner radiator assembly. E128535 16. INSTALL NO. 6 HEATER TO REGISTER DUCT ASSEMBLY (for TMMK Made) (a) Engage the 4 claws to install the No. 6 heater to register duct assembly. AC E128525 17. INSTALL BLOWER ASSEMBLY (for TMMK Made) (a) Install the blower assembly with the 6 screws. E129997 AC–172 AIR CONDITIONING – AIR CONDITIONING UNIT (b) Connect the connector. E129996 18. INSTALL COOLER EXPANSION VALVE (for TMMK Made) (a) Using a 4 mm hexagon wrench, install the cooler expansion valve with the 2 hexagon bolts. Torque: 3.5 N*m (35 kgf*cm, 30 in.*lbf) C129879 AC 19. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY (for TMMK Made) (a) Engage the 2 claws to install the No. 2 air duct subassembly. E129155 AC–173 AIR CONDITIONING – AIR CONDITIONING UNIT INSTALLATION 1. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY (a) Install the conditioner unit assembly to the instrument panel reinforcement assembly with the 2 screws and 3 bolts. (2) (3) (1) (5) (4) E128522E01 Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) NOTICE: Tighten the bolts and screws in the order shown in the illustration to install the air conditioner unit assembly. AC AC–174 AIR CONDITIONING – AIR CONDITIONING UNIT (b) Driver seat: (1) Using a "Torx" socket wrench (T40), install the instrument panel reinforcement assembly with the 3 "Torx" bolts. Collar “Torx” bolt AC E129156E03 Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf) (c) Passenger seat: (1) Using a 12 mm hexagon wrench, adjust the position of the 2 collars. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) (2) Using a "Torx" socket wrench (T40), install the instrument panel reinforcement assembly with the 2 "Torx" bolts. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) AIR CONDITIONING – AIR CONDITIONING UNIT AC–175 (d) Install the instrument panel reinforcement assembly with the 2 bolts and nut. AC E128520 Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) (NUT) (e) Install the 2 bolts and 2 caps. (f) Connect the connectors and clamps. AC–176 AIR CONDITIONING – AIR CONDITIONING UNIT (g) Install the 6 nuts and 7 bolts. AC E128519 C129722 2. INSTALL STEERING COLUMN ASSEMBLY (for TMC Made) (See page SR-47) 3. INSTALL STEERING POST ASSEMBLY (for TMMK Made) (See page SR-49) 4. INSTALL NO. 1 AIR DUCT (See page SR-50) 5. INSTALL REAR NO. 1 AIR DUCT (a) Engage the 2 claws to install the rear No. 1 air duct. AIR CONDITIONING – AIR CONDITIONING UNIT AC–177 6. INSTALL REAR NO. 2 AIR DUCT (a) Engage the 2 claws to install the rear No. 2 air duct. 7. INSTALL FLOOR CARPET BRACKET RH 8. INSTALL FLOOR CARPET BRACKET LH 9. INSTALL NO. 1 CONSOLE BOX DUCT (for Automatic Air Conditioning System) (a) Install the No. 1 console box duct with the clip. C129721 10. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY (for TMC Made) (See page IP-44) 11. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY (for TMMK Made) (See page IP-45) C129716 12. INSTALL NO. 1 DEFROSTER NOZZLE GARNISH (See page IP-48) 13. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (for LH Side) (See page AV-156) 14. INSTALL INSTRUMENT PANEL NO. 1 SPEAKER PANEL SUB-ASSEMBLY (See page IP-48) 15. INSTALL INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY (See page IP-48) 16. INSTALL FRONT PILLAR GARNISH LH (See page IR51) 17. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (for RH Side) (See page IP-48) 18. INSTALL INSTRUMENT PANEL NO. 2 SPEAKER PANEL SUB-ASSEMBLY (See page IP-49) 19. INSTALL INSTRUMENT PANEL NO. 3 REGISTER ASSEMBLY (See page IP-49) 20. INSTALL FRONT PILLAR GARNISH RH (See page IR52) 21. INSTALL NO. 1 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-49) 22. INSTALL NO. 1 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-50) 23. INSTALL NO. 2 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-50) 24. INSTALL NO. 2 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-50) 25. INSTALL CONSOLE BOX ASSEMBLY (for TMC Made) (See page IP-51) AC AC–178 AIR CONDITIONING – AIR CONDITIONING UNIT 26. INSTALL CONSOLE BOX ASSEMBLY (for TMMK Made) (See page IP-51) 27. INSTALL CONSOLE BOX CARPET (See page IP-51) 28. INSTALL CONSOLE BOX POCKET (See page IP-51) 29. INSTALL RADIO RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY (w/o Navigation System) (See page AV-147) 30. INSTALL NAVIGATION RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY (w/ Navigation System) (See page NS-196) 31. INSTALL INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY (See page IP-52) 32. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMC Made) (See page IP-52) 33. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMMK Made) (See page IP-52) 34. INSTALL UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Automatic Transaxle) (See page IP53) 35. INSTALL UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Manual Transaxle) (See page IP-53) AC 36. INSTALL FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-53) 37. INSTALL UPPER CONSOLE PANEL (for Manual Transaxle) (See page IP-54) 38. INSTALL NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-54) 39. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-55) 40. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-55) 41. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) (See page IP-55) 42. INSTALL LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMC Made) (See page IP-55) 43. INSTALL LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMMK Made) (See page IP-56) 44. INSTALL INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY (See page IP-56) 45. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH (See page IR-55) 46. INSTALL FRONT DOOR SCUFF PLATE RH (See page IR-55) AIR CONDITIONING – AIR CONDITIONING UNIT AC–179 47. INSTALL COMBINATION METER ASSEMBLY (for TMC Made) (See page IP-56) 48. INSTALL COMBINATION METER ASSEMBLY (for TMMK Made) (See page IP-56) 49. INSTALL INSTRUMENT CLUSTER FINISH PANEL (See page IP-57) 50. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/o Smart Key System) (See page IP-57) 51. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/ Smart Key System) (See page IP-57) 52. INSTALL NO. 1 INSTRUMENT PANEL SUBASSEMBLY (See page IP-57) 53. INSTALL TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY (See page SR-50) 54. ADJUST SPIRAL CABLE SUB-ASSEMBLY (See page RS-367) 55. INSTALL STEERING COLUMN COVER (for TMC Made) (See page IP-58) 56. INSTALL STEERING COLUMN COVER (for TMMK Made) (See page IP-58) 57. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (See page IP-58) 58. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (See page IP-59) 59. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-54) 60. INSTALL FRONT DOOR SCUFF PLATE LH (See page IR-54) 61. INSTALL STEERING WHEEL ASSEMBLY (See page SR-51) 62. INSTALL STEERING PAD (See page RS-350) 63. INSTALL LOWER NO. 3 STEERING WHEEL COVER (See page RS-351) 64. INSTALL LOWER NO. 2 STEERING WHEEL COVER (See page RS-352) AC AC–180 AIR CONDITIONING – AIR CONDITIONING UNIT 65. INSTALL HEATER INLET WATER HOSE (a) Install the water hose and attach the clip. 66. INSTALL HEATER OUTLET WATER HOSE (a) Use the same procedures described for the heater inlet water hose. E128511 67. INSTALL AIR CONDITIONER TUBE AND ACCESSORY (a) Remove the attached vinyl tape from the tube. (b) Sufficiently apply compressor oil to a new O-ring and fitting surface of the air conditioning tube assembly. Compressor oil: ND-OIL 8 or equivalent (c) Install the O-ring on the air conditioner tube and accessory. (d) Install the air conditioner tube and accessory. 68. INSTALL SUCTION HOSE SUB-ASSEMBLY (a) Remove the attached vinyl tape from the hose. (b) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction hose subassembly. Compressor oil: ND-OIL 8 or equivalent (c) Install the O-ring on the suction hose sub-assembly. (d) Move the hook connector in the direction indicated by the arrow in the illustration. (e) Insert the pipe joint into the fitting hole securely and tighten the bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) AC 69. INSTALL COWL TOP OUTER FRONT PANEL SUBASSEMBLY (See page BR-36) 70. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (See page WW-14) 71. INSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See page WW-15) 72. INSTALL FRONT FENDER TO COWL SIDE SEAL LH (See page WW-15) E129157 73. INSTALL FRONT FENDER TO COWL SIDE SEAL RH (See page WW-15) 74. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH (See page WW-15) 75. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH (See page WW-16) 76. CONNECT NEGATIVE BATTERY TERMINAL 77. INSPECT STEERING PAD (See page RS-352) 78. INSPECT SRS WARNING LIGHT (See page RS-32) AIR CONDITIONING – AIR CONDITIONING UNIT AC–181 79. ADD ENGINE COOLANT (for 2AZ-FE) (See page CO5) 80. ADD ENGINE COOLANT (for 2GR-FE) (See page CO6) 81. CHECK FOR ENGINE COOLANT LEAKS 82. CHARGE WITH REFRIGERANT (See page AC-125) 83. WARM UP ENGINE (See page AC-126) 84. CHECK FOR REFRIGERANT LEAKS (See page AC126) AC AC–182 AIR CONDITIONING – BLOWER UNIT BLOWER UNIT HEATER AIR CONDITIONING & AIR CONDITIONING SYSTEM COMPONENTS FRONT WIPER ARM AND BLADE ASSEMBLY RH 20 (204, 15) 20 (204, 15) FRONT WIPER ARM AND BLADE ASSEMBLY LH FRONT FENDER TO COWL SIDE SEAL RH COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY AC 7.5 (77, 66 in.*lbf) WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY FRONT FENDER TO COWL SIDE SEAL LH N*m (kgf*cm, ft.*lbf) : Specified torque E133392E01 AC–183 AIR CONDITIONING – BLOWER UNIT for TMC Made: TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY 2.0 (20, 18 in.*lbf) STEERING COLUMN COVER AC 50 (510, 37) STEERING WHEEL ASSEMBLY LOWER NO. 2 STEERING WHEEL COVER LOWER NO. 3 STEERING WHEEL COVER 8.8 (90, 78 in.*lbf) STEERING PAD N*m (kgf*cm, ft.*lbf) : Specified torque B137279E01 AC–184 AIR CONDITIONING – BLOWER UNIT for TMMK Made: TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY 2.0 (20, 18 in.*lbf) STEERING COLUMN COVER for 4 Spoke: 50 (510, 37) STEERING WHEEL ASSEMBLY LOWER NO. 2 STEERING WHEEL COVER AC LOWER NO. 3 STEERING WHEEL COVER STEERING PAD 8.8 (90, 78 in.*lbf) for 3 Spoke: STEERING WHEEL ASSEMBLY 50 (510, 37) LOWER NO. 2 STEERING WHEEL COVER LOWER NO. 3 STEERING WHEEL COVER STEERING PAD 8.8 (90, 78 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque B137280E01 AC–185 AIR CONDITIONING – BLOWER UNIT for TMC Made: COMBINATION METER ASSEMBLY INSTRUMENT CLUSTER FINISH PANEL without Smart Key System: LOWER INSTRUMENT PANEL FINISH PANEL with Smart Key System: AC NO. 1 INSTRUMENT PANEL SUB-ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL COWL SIDE TRIM SUB-ASSEMBLY LH COWL SIDE TRIM CLIP LOWER INSTRUMENT PANEL FINISH PANEL LH FRONT DOOR SCUFF PLATE LH B137281E01 AC–186 AIR CONDITIONING – BLOWER UNIT for TMMK Made: COMBINATION METER ASSEMBLY without Smart Key System: INSTRUMENT CLUSTER FINISH PANEL LOWER INSTRUMENT PANEL FINISH PANEL with Smart Key System: AC NO. 1 INSTRUMENT PANEL SUB-ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL COWL SIDE TRIM SUB-ASSEMBLY LH COWL SIDE TRIM CLIP or

LOWER INSTRUMENT PANEL FINISH PANEL LH FRONT DOOR SCUFF PLATE LH B137281E03 AIR CONDITIONING – BLOWER UNIT AC–187 for TMC Made: LOWER INSTRUMENT PANEL SUB-ASSEMBLY or COWL SIDE TRIM SUB-ASSEMBLY RH AC COWL SIDE TRIM CLIP FRONT DOOR SCUFF PLATE RH INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY B137282E01 AC–188 AIR CONDITIONING – BLOWER UNIT for TMMK Made: LOWER INSTRUMENT PANEL SUB-ASSEMBLY or

COWL SIDE TRIM SUB-ASSEMBLY RH AC COWL SIDE TRIM CLIP FRONT DOOR SCUFF PLATE RH INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY B137282E03 AIR CONDITIONING – BLOWER UNIT AC–189 NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH for Automatic Transaxle: SHIFT LEVER KNOB SUB-ASSEMBLY FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY UPPER CONSOLE REAR PANEL SUB-ASSEMBLY AC for Manual Transaxle: SHIFT LEVER KNOB SUB-ASSEMBLY UPPER CONSOLE PANEL UPPER CONSOLE REAR PANEL SUB-ASSEMBLY B137283E01 AC–190 AIR CONDITIONING – BLOWER UNIT for TMC Made: INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY without Navigation System: with Navigation System: AC RADIO RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY NAVIGATION RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY UPPER CONSOLE PANEL SUB-ASSEMBLY B137284E01 AC–191 AIR CONDITIONING – BLOWER UNIT for TMC Made: FRONT PILLAR GARNISH CLIP FRONT PILLAR GARNISH CLIP FRONT PILLAR GARNISH RH FRONT PILLAR GARNISH LH INSTRUMENT PANEL NO. 3 REGISTER ASSEMBLY INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY NO. 1 CONSOLE BOX INSERT FRONT AC NO. 2 CONSOLE BOX INSERT FRONT CONSOLE BOX CARPET CONSOLE BOX ASSEMBLY CONSOLE BOX POCKET Non-reusable part B137285E01 AC–192 AIR CONDITIONING – BLOWER UNIT for TMMK Made: FRONT PILLAR GARNISH CLIP FRONT PILLAR GARNISH CLIP FRONT PILLAR GARNISH RH FRONT PILLAR GARNISH LH INSTRUMENT PANEL NO. 3 REGISTER ASSEMBLY INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY NO. 1 CONSOLE BOX INSERT FRONT AC or or NO. 2 CONSOLE BOX INSERT FRONT CONSOLE BOX CARPET CONSOLE BOX ASSEMBLY CONSOLE BOX POCKET Non-reusable part B137285E03 AC–193 AIR CONDITIONING – BLOWER UNIT for TMC Made: INSTRUMENT PANEL NO. 1 SPEAKER PANEL SUB-ASSEMBLY INSTRUMENT PANEL NO. 2 SPEAKER PANEL SUB-ASSEMBLY NO. 1 DEFROSTER NOZZLE GARNISH for RH Side: for LH Side: FRONT NO. 2 SPEAKER ASSEMBLY FRONT NO. 2 SPEAKER ASSEMBLY AC or or or or 20 (204, 15) INSTRUMENT PANEL SAFETY PAD ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B137286E01 AC–194 AIR CONDITIONING – BLOWER UNIT for TMMK Made: INSTRUMENT PANEL NO. 1 SPEAKER PANEL SUB-ASSEMBLY INSTRUMENT PANEL NO. 2 SPEAKER PANEL SUB-ASSEMBLY NO. 1 DEFROSTER NOZZLE GARNISH for RH Side: for LH Side: FRONT NO. 2 SPEAKER ASSEMBLY FRONT NO. 2 SPEAKER ASSEMBLY AC , or , or 20 (204, 15) INSTRUMENT PANEL SAFETY PAD ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B137286E03 AC–195 AIR CONDITIONING – BLOWER UNIT NO. 6 HEATER TO REGISTER DUCT ASSEMBLY 20 (204, 15) 6.0 (61, 53 in.*lbf) 17 (175, 13) 17 (175, 13) CAP CAP 17 (175, 13) 6.0 (61, 53 in.*lbf) INSTRUMENT PANEL REINFORCEMENT ASSEMBLY 25 (255, 18) STEERING COLUMN ASSEMBLY AC FLOOR CARPET BRACKET RH 25 (255, 18) for Automatic Air Conditioning System FLOOR CARPET BRACKET LH NO. 1 CONSOLE BOX DUCT REAR NO. 2 AIR DUCT REAR NO. 1 AIR DUCT N*m (kgf*cm, ft.*lbf) : Specified torque E128500E01 AC–196 AIR CONDITIONING – BLOWER UNIT for TMC Made: SUCTION PIPE SUB-ASSEMBLY 9.8 (100, 87 in.*lbf) NO. 2 AIR DUCT SUB-ASSEMBLY O-RING AIR CONDITIONER TUBE AND ACCESSORY HEATER OUTLET WATER HOSE HEATER INLET WATER HOSE 9.8 (100, 87 in.*lbf) 9.8 (100, 87 in.*lbf) NO. 1 AIR DUCT 9.8 (100, 87 in.*lbf) AC AIR CONDITIONING AMPLIFIER ASSEMBLY BLOWER ASSEMBLY AIR CONDITIONING UNIT ASSEMBLY Compressor oil ND-OIL 8 or equivalent Non-reusable part N*m (kgf*cm, ft.*lbf) : Specified torque E128501E01 AC–197 AIR CONDITIONING – BLOWER UNIT for TMMK Made: SUCTION PIPE SUB-ASSEMBLY 9.8 (100, 87 in.*lbf) NO. 2 AIR DUCT SUB-ASSEMBLY O-RING AIR CONDITIONER TUBE AND ACCESSORY HEATER OUTLET WATER HOSE HEATER INLET WATER HOSE 9.8 (100, 87 in.*lbf) 9.8 (100, 87 in.*lbf) NO. 1 AIR DUCT 9.8 (100, 87 in.*lbf) AC COOLER EXPANSION VALVE 3.5 (35, 30 in.*lbf) O-RING AIR CONDITIONING AMPLIFIER ASSEMBLY BLOWER ASSEMBLY AIR CONDITIONING UNIT ASSEMBLY Compressor oil ND-OIL 8 or equivalent Non-reusable part N*m (kgf*cm, ft.*lbf) : Specified torque E129993E01 AC–198 AIR CONDITIONING – BLOWER UNIT for TMC Made: AIR DUCT SUB-ASSEMBLY AC AIR INLET SERVO MOTOR CLEAN AIR FILTER BLOWER WITH FAN MOTOR SUB-ASSEMBLY AIR FILTER COVER PLATE E128503E01 AC–199 AIR CONDITIONING – BLOWER UNIT AIR DUCT SUB-ASSEMBLY AIR INLET SERVO MOTOR CLEAN AIR FILTER AC AIR FILTER COVER PLATE BLOWER WITH FAN MOTOR SUB-ASSEMBLY E129995E01 AC–200 AIR CONDITIONING – BLOWER UNIT REMOVAL AC 1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM (See page AC-125) 2. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 3. DISCONNECT BATTERY NEGATIVE TERMINAL CAUTION: Wait for 90 seconds after disconnecting the terminal to prevent the airbag from deploying. (See page RS1) 4. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH (See page WW-9) 5. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH (See page WW-9) 6. REMOVE FRONT FENDER TO COWL SIDE SEAL LH (See page WW-9) 7. REMOVE FRONT FENDER TO COWL SIDE SEAL RH (See page WW-9) 8. REMOVE COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See page WW-10) 9. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (See page WW-10) 10. REMOVE COWL TOP OUTER FRONT PANEL SUBASSEMBLY (See page BR-29) 11. DISCONNECT SUCTION PIPE SUB-ASSEMBLY (See page AC-151) 12. DISCONNECT AIR CONDITIONER TUBE AND ACCESSORY (See page AC-151) 13. DISCONNECT HEATER OUTLET WATER HOSE (See page AC-152) 14. DISCONNECT HEATER INLET WATER HOSE (See page AC-152) 15. REMOVE LOWER NO. 3 STEERING WHEEL COVER (See page RS-349) 16. REMOVE LOWER NO. 2 STEERING WHEEL COVER (See page RS-349) 17. REMOVE STEERING PAD (See page RS-350) 18. REMOVE STEERING WHEEL ASSEMBLY (See page SR-38) 19. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-24) 20. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-25) 21. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (See page IP-20) AIR CONDITIONING – BLOWER UNIT AC–201 22. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (See page IP-21) 23. REMOVE STEERING COLUMN COVER (for TMC Made) (See page IP-21) 24. REMOVE STEERING COLUMN COVER (for TMMK Made) (See page IP-21) 25. REMOVE TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY (See page SR-39) 26. REMOVE NO. 1 INSTRUMENT PANEL SUBASSEMBLY (See page IP-22) 27. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (w/o Smart Key System) (See page IP-22) 28. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (w/ Smart Key System) (See page IP-22) 29. REMOVE INSTRUMENT CLUSTER FINISH PANEL (See page IP-22) 30. REMOVE COMBINATION METER ASSEMBLY (for TMC Made) (See page IP-23) 31. REMOVE COMBINATION METER ASSEMBLY (for TMMK Made) (See page IP-23) 32. REMOVE FRONT DOOR SCUFF PLATE RH (See page IR-26) 33. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH (See page IR-26) 34. REMOVE INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY (See page IP-23) 35. REMOVE LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMC Made) (See page IP-23) 36. REMOVE LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMMK Made) (See page IP-24) 37. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-24) 38. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) (See page IP-24) 39. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-24) 40. REMOVE NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-25) 41. REMOVE FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-25) 42. REMOVE UPPER CONSOLE PANEL (for Manual Transaxle) (See page IP-25) AC AC–202 AIR CONDITIONING – BLOWER UNIT 43. REMOVE UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Automatic Transaxle) (See page IP26) 44. REMOVE UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Manual Transaxle) (See page IP-26) 45. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMC Made) (See page IP-27) 46. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMMK Made) (See page IP-27) 47. REMOVE INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY (See page IP-27) 48. REMOVE RADIO RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY (w/o Navigation System) (See page AV-146) 49. REMOVE NAVIGATION RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY (See page NS-195) 50. REMOVE CONSOLE BOX POCKET (See page IP-28) 51. REMOVE CONSOLE BOX CARPET (See page IP-28) 52. REMOVE CONSOLE BOX ASSEMBLY (for TMC Made) (See page IP-28) 53. REMOVE CONSOLE BOX ASSEMBLY (for TMMK Made) (See page IP-29) AC 54. REMOVE NO. 2 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-29) 55. REMOVE NO. 2 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-30) 56. REMOVE NO. 1 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-30) 57. REMOVE NO. 1 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-30) 58. REMOVE FRONT PILLAR GARNISH LH (See page IR27) 59. REMOVE INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY (See page IP-31) 60. REMOVE INSTRUMENT PANEL NO. 1 SPEAKER PANEL SUB-ASSEMBLY (See page IP-31) 61. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (for LH Side) (See page AV-156) 62. REMOVE FRONT PILLAR GARNISH RH (See page IR27) 63. REMOVE INSTRUMENT PANEL NO. 3 REGISTER ASSEMBLY (See page IP-31) 64. REMOVE INSTRUMENT PANEL NO. 2 SPEAKER PANEL SUB-ASSEMBLY (See page IP-32) AIR CONDITIONING – BLOWER UNIT AC–203 65. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (for RH Side) 66. REMOVE NO. 1 DEFROSTER NOZZLE GARNISH (See page IP-32) 67. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY (for TMC Made) (See page IP-32) 68. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY (for TMMK Made) (See page IP-34) 69. REMOVE NO. 1 CONSOLE BOX DUCT (for Automatic Air Conditioning System) (See page AC-154) 70. REMOVE FLOOR CARPET BRACKET LH (See page AC-155) 71. REMOVE FLOOR CARPET BRACKET RH (See page AC-155) 72. REMOVE REAR NO. 2 AIR DUCT (See page AC-155) 73. REMOVE REAR NO. 1 AIR DUCT (See page AC-156) 74. REMOVE NO. 1 AIR DUCT (See page SR-39) 75. SEPARATE STEERING COLUMN ASSEMBLY (for TMC Made) (See page SR-39) 76. REMOVE STEERING POST ASSEMBLY (for TMMK Made) (See page SR-41) 77. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY (See page AC-259) 78. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY (See page AC-156) 79. REMOVE BLOWER ASSEMBLY (for TMC Made) (a) Disconnect the connector. (b) Remove the 2 screws and blower assembly. 80. REMOVE COOLER EXPANSION VALVE (for TMMK Made) (See page AC-163) E128524 AC AC–204 AIR CONDITIONING – BLOWER UNIT 81. REMOVE BLOWER ASSEMBLY (for TMMK Made) (a) Remove the connector and clamp, and disconnect the wire harness. E129996 (b) Remove the 6 screws and then the blower assembly with the cooler evaporator sub-assembly. E129997 AC DISASSEMBLY 1. E128536 REMOVE AIR DUCT SUB-ASSEMBLY (for TMC Made) (a) Release the 4 claws and remove the air duct subassembly. AIR CONDITIONING – BLOWER UNIT AC–205 2. REMOVE AIR FILTER COVER PLATE (for TMC Made) (a) Release the 2 claws and remove the air filter cover plate. 3. REMOVE CLEAN AIR FILTER (for TMC Made) (a) Remove the clean air filter as shown in the illustration. 4. REMOVE AIR INLET SERVO MOTOR (for TMC Made) (a) Remove the 3 screws and air inlet servo motor. 5. REMOVE BLOWER WITH FAN MOTOR SUBASSEMBLY (for TMC Made) (a) Remove the 3 screws and blower with fan motor sub-assembly. E128537 E128538 E128539 E128540 AC AC–206 AIR CONDITIONING – BLOWER UNIT 6. REMOVE AIR DUCT SUB-ASSEMBLY (for TMMK Made) (a) Disengage the 4 claws and then remove the air duct sub-assembly. 7. REMOVE AIR FILTER COVER PLATE (for TMMK Made) (a) Release the 2 claws and remove the air filter cover plate. 8. REMOVE CLEAN AIR FILTER (for TMMK Made) (a) Remove the clean air filter as shown in the illustration. 9. REMOVE AIR INLET SERVO MOTOR (for TMMK Made) (a) Remove the 3 screws and air inlet servo motor. E129994 AC E133137 E133138 C129884 AIR CONDITIONING – BLOWER UNIT AC–207 10. REMOVE BLOWER WITH FAN MOTOR SUBASSEMBLY (for TMMK Made) (a) Remove the 3 screws and blower with fan motor sub-assembly. C129886 REASSEMBLY 1. INSTALL BLOWER WITH FAN MOTOR SUBASSEMBLY (for TMC Made) (a) Install the blower with fan motor sub-assembly with the 3 screws. 2. INSTALL AIR INLET SERVO MOTOR (for TMC Made) (a) Install the air inlet servo motor with the 3 screws. E128540 AC E128539 3. E129158 INSTALL CLEAN AIR FILTER (for TMC Made) (a) Install the clean air filter as shown in the illustration. AC–208 AIR CONDITIONING – BLOWER UNIT 4. INSTALL AIR FILTER COVER PLATE (for TMC Made) (a) Engage the 2 claws to install the air filter cover plate. 5. INSTALL AIR DUCT SUB-ASSEMBLY (for TMC Made) (a) Engage the 4 claws to install the air duct subassembly. 6. INSTALL BLOWER WITH FAN MOTOR SUBASSEMBLY (for TMMK Made) (a) Install the blower with fan motor sub-assembly with the 3 screws. 7. INSTALL AIR INLET SERVO MOTOR (for TMMK Made) (a) Install the air inlet servo motor with the 3 screws. E128537 AC E128536 C129886 C129884 AIR CONDITIONING – BLOWER UNIT AC–209 8. INSTALL CLEAN AIR FILTER (for TMMK Made) (a) Install the clean air filter as shown in the illustration. 9. INSTALL AIR FILTER COVER PLATE (for TMMK Made) (a) Engage the 2 claws to install the air filter cover plate. E133138 E133137 10. INSTALL AIR DUCT SUB-ASSEMBLY (for TMMK Made) (a) Engage the 4 claws to install the air duct subassembly. E129994 AC AC–210 AIR CONDITIONING – BLOWER UNIT INSTALLATION 1. INSTALL BLOWER ASSEMBLY (for TMC Made) (a) Install the blower assembly with the 2 screws. (b) Connect the connector. 2. INSTALL COOLER EXPANSION VALVE (for TMMK Made) (See page AC-172) 3. INSTALL BLOWER ASSEMBLY (for TMMK Made) (a) Install the blower assembly with the 6 screws. E128524 E129997 AC (b) Connect the connector. 4. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY (See page AC-173) 5. INSTALL STEERING COLUMN ASSEMBLY (for TMC Made) (See page SR-47) 6. INSTALL STEERING POST ASSEMBLY (for TMMK Made) (See page SR-49) 7. INSTALL NO. 1 AIR DUCT (See page SR-50) 8. INSTALL REAR NO. 1 AIR DUCT (See page AC-176) 9. INSTALL REAR NO. 2 AIR DUCT (See page AC-177) 10. INSTALL FLOOR CARPET BRACKET RH E129996 11. INSTALL FLOOR CARPET BRACKET LH 12. INSTALL NO. 1 CONSOLE BOX DUCT (for Automatic Air Conditioning System) (See page AC-177) 13. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY (for TMC Made) (See page IP-44) 14. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY (for TMMK Made) (See page IP-45) 15. INSTALL NO. 1 DEFROSTER NOZZLE GARNISH (See page IP-48) AIR CONDITIONING – BLOWER UNIT AC–211 16. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (for LH Side) (See page AV-156) 17. INSTALL INSTRUMENT PANEL NO. 1 SPEAKER PANEL SUB-ASSEMBLY (See page IP-48) 18. INSTALL INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY (See page IP-48) 19. INSTALL FRONT PILLAR GARNISH LH (See page IR51) 20. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (for RH Side) (See page IP-48) 21. INSTALL INSTRUMENT PANEL NO. 2 SPEAKER PANEL SUB-ASSEMBLY (See page IP-49) 22. INSTALL INSTRUMENT PANEL NO. 3 REGISTER ASSEMBLY (See page IP-49) 23. INSTALL FRONT PILLAR GARNISH RH (See page IR52) 24. INSTALL NO. 1 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-49) 25. INSTALL NO. 1 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-50) 26. INSTALL NO. 2 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-50) 27. INSTALL NO. 2 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-50) 28. INSTALL CONSOLE BOX ASSEMBLY (for TMC Made) (See page IP-51) 29. INSTALL CONSOLE BOX ASSEMBLY (for TMMK Made) (See page IP-51) 30. INSTALL CONSOLE BOX CARPET (See page IP-51) 31. INSTALL CONSOLE BOX POCKET (See page IP-51) 32. INSTALL RADIO RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY (w/o Navigation System) (See page AV-147) 33. INSTALL NAVIGATION RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY (w/ Navigation System) (See page NS-196) 34. INSTALL INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY (See page IP-52) 35. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMC Made) (See page IP-52) 36. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMMK Made) (See page IP-52) 37. INSTALL UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Automatic Transaxle) (See page IP53) AC AC–212 AIR CONDITIONING – BLOWER UNIT 38. INSTALL UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Manual Transaxle) (See page IP-53) 39. INSTALL FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-53) 40. INSTALL UPPER CONSOLE PANEL (for Manual Transaxle) (See page IP-54) 41. INSTALL NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-54) 42. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-55) 43. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-55) 44. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) (See page IP-55) 45. INSTALL LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMC Made) (See page IP-55) 46. INSTALL LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMMK Made) (See page IP-56) 47. INSTALL INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY (See page IP-56) AC 48. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH (See page IR-55) 49. INSTALL FRONT DOOR SCUFF PLATE RH (See page IR-55) 50. INSTALL COMBINATION METER ASSEMBLY (for TMC Made) (See page IP-56) 51. INSTALL COMBINATION METER ASSEMBLY (for TMMK Made) (See page IP-56) 52. INSTALL INSTRUMENT CLUSTER FINISH PANEL (See page IP-57) 53. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/o Smart Key System) (See page IP-57) 54. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/ Smart Key System) (See page IP-57) 55. INSTALL NO. 1 INSTRUMENT PANEL SUBASSEMBLY (See page IP-57) 56. INSTALL TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY (See page SR-50) 57. ADJUST SPIRAL CABLE SUB-ASSEMBLY (See page RS-367) 58. INSTALL STEERING COLUMN COVER (for TMC Made) (See page IP-58) 59. INSTALL STEERING COLUMN COVER (for TMMK Made) (See page IP-58) AIR CONDITIONING – BLOWER UNIT AC–213 60. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (See page IP-58) 61. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (See page IP-59) 62. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-54) 63. INSTALL FRONT DOOR SCUFF PLATE LH (See page IR-54) 64. INSTALL STEERING WHEEL ASSEMBLY (See page SR-51) 65. INSTALL STEERING PAD (See page RS-352) 66. INSTALL LOWER NO. 3 STEERING WHEEL COVER (See page RS-351) 67. INSTALL LOWER NO. 2 STEERING WHEEL COVER (See page RS-352) 68. INSTALL HEATER INLET WATER HOSE (See page AC-180) 69. INSTALL HEATER OUTLET WATER HOSE (See page AC-180) 70. INSTALL AIR CONDITIONER TUBE AND ACCESSORY (See page AC-180) 71. INSTALL SUCTION HOSE SUB-ASSEMBLY (See page AC-180) 72. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (See page WW-14) 73. INSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See page WW-15) 74. INSTALL FRONT FENDER TO COWL SIDE SEAL LH (See page WW-15) 75. INSTALL FRONT FENDER TO COWL SIDE SEAL RH (See page WW-15) 76. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH (See page WW-15) 77. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH (See page WW-16) 78. CONNECT NEGATIVE BATTERY TERMINAL 79. INSPECT STEERING PAD (See page RS-352) 80. INSPECT SRS WARNING LIGHT (See page AC-180) 81. ADD ENGINE COOLANT (for 2AZ-FE) (See page CO5) 82. ADD ENGINE COOLANT (for 2GR-FE) (See page CO6) 83. CHECK FOR ENGINE COOLANT LEAKS AC AC–214 AIR CONDITIONING – BLOWER UNIT 84. CHARGE WITH REFRIGERANT (See page AC-125) 85. WARM UP ENGINE (See page AC-126) 86. CHECK FOR REFRIGERANT LEAKS (See page AC126) AC AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH (for 2GR-FE) AC–215 COMPRESSOR AND MAGNETIC CLUTCH (for 2GR-FE) HEATER AIR CONDITIONING & AIR CONDITIONING SYSTEM COMPONENTS V-BANK COVER SUB-ASSEMBLY 5.0 (51, 44 in.*lbf) x2 AIR CLEANER INLET ASSEMBLY 5.0 (51, 44 in.*lbf) NO. 1 AIR CLEANER INLET AIR CLEANER CAP SUB-ASSEMBLY AIR CLEANER FILTER ELEMENT COOL AIR INTAKE DUCT SEAL AC N*m (kgf*cm, ft.*lbf) : Specified torque A134975E01 AC–216 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH (for 2GR-FE) 7.0 (71, 62 in.*lbf) x4 RADIATOR SUPPORT UPPER HOOD LOCK ASSEMBLY x2 7.5 (77, 66 in.*lbf) HORN CONNECTOR 7.0 (71, 62 in.*lbf) RADIATOR GRILLE PROTECTOR 7.5 (77, 66 in.*lbf) AC x2 x2 FRONT BUMPER ENERGY ABSORBER x2 ENGINE UNDER COVER LH FRONT BUMPER ASSEMBLY x9 ENGINE UNDER COVER RH FRONT WHEEL OPENING EXTENSION PAD RH FRONT WHEEL OPENING EXTENSION PAD LH N*m (kgf*cm, ft.*lbf) : Specified torque A133359E06 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH (for 2GR-FE) AC–217 V-RIBBED BELT FRONT FENDER APRON SEAL RH 9.8 (100, 87 in.*lbf) 8.4 (86, 74 in.*lbf) WIRE HARNESS CLAMP STAY 43 (438, 32) RADIATOR INLET HOSE RADIATOR OUTLET HOSE 20 (204, 15) 43 (438, 32) 20 (204, 15) GENERATOR BRACKET GENERATOR ASSEMBLY FAN MOTOR CONNECTOR RADIATOR ASSEMBLY FAN SHROUD x4 3.0 (31, 27 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque A133878E02 AC AC–218 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH (for 2GR-FE) NO. 1 COOLER REFRIGERANT DISCHARGE HOSE 9.8 (100, 87 in.*lbf) O-RING PIPING CLAMP O-RING 9.8 (100, 87 in.*lbf) NO. 1 COOLER REFRIGERANT SUCTION HOSE 25 (255, 18) COMPRESSOR AND MAGNETIC CLUTCH AC MAGNETIC CLUTCH ASSEMBLY SNAP RING MAGNETIC CLUTCH WASHER AIR COMPRESSOR ASSEMBLY SNAP RING 18 (184, 13) Compressor oil ND-OIL 8 or equivalent Non-reusable part N*m (kgf*cm, ft.*lbf) : Specified torque E128508E01 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH (for 2GR-FE) AC–219 REMOVAL 1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM (See page AC-125) 2. DISCONNECT BATTERY NEGATIVE TERMINAL CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment (See page RS-1) 3. REMOVE FRONT WHEEL RH 4. REMOVE FRONT FENDER APRON SEAL RH 5. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH 6. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH 7. REMOVE ENGINE UNDER COVER RH 8. REMOVE ENGINE UNDER COVER LH 9. DRAIN ENGINE COOLANT (See page CO-5) 10. REMOVE COOL AIR INTAKE DUCT SEAL (See page EM-23) 11. REMOVE V-BANK COVER SUB-ASSEMBLY (See page EM-23) 12. REMOVE AIR CLEANER INLET ASSEMBLY (See page EM-24) 13. REMOVE AIR CLEANER CAP SUB-ASSEMBLY 14. REMOVE NO. 1 AIR CLEANER INLET (See page EM24) 15. REMOVE FRONT BUMPER COVER (w/o Fog Light) (See page ET-5) 16. REMOVE FRONT BUMPER COVER (w/ Fog Light) (See page ET-6) 17. REMOVE FRONT BUMPER ENERGY ABSORBER (See page ET-9) 18. SEPARATE RADIATOR RESERVE TANK HOSE (See page CO-24) 19. SEPARATE RADIATOR INLET HOSE (See page CO24) 20. SEPARATE RADIATOR OUTLET HOSE (See page CO-24) 21. REMOVE NO. 1 OIL COOLER INLET HOSE (for Automatic Transaxle) (See page CO-25) 22. REMOVE NO. 1 OIL COOLER OUTLET HOSE (for Automatic Transaxle) (See page CO-25) 23. REMOVE RADIATOR SUPPORT UPPER (See page CO-25) AC AC–220 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH (for 2GR-FE) 24. REMOVE FAN SHROUD (See page CO-26) 25. REMOVE RADIATOR ASSEMBLY (See page CO-26) 26. REMOVE V-RIBBED BELT (See page EM-6) 27. REMOVE GENERATOR ASSEMBLY (See page CH-14) 28. REMOVE PIPING CLAMP (a) Remove the piping clamp from the No. 1 cooler refrigerant discharge hose and No. 1 cooler refrigerant suction hose. E129142 E129143 29. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE (a) Remove the bolt and disconnect the No. 1 cooler refrigerant discharge hose from the compressor. (b) Remove the O-ring from the discharge hose subassembly. NOTICE: Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter. E129144 30. DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE (a) Remove the bolt and disconnect the No. 1 cooler refrigerant suction hose from the compressor. (b) Remove the O-ring from the cooler refrigerant suction hose. NOTICE: Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter. AC 31. REMOVE COMPRESSOR AND MAGNETIC CLUTCH (a) Disconnect the magnetic clutch connector. (b) Remove the 4 bolts. (c) Remove the compressor and magnetic clutch. E129145 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH (for 2GR-FE) AC–221 DISASSEMBLY 1. E075074 REMOVE MAGNETIC CLUTCH ASSEMBLY (a) Place the compressor and magnetic clutch in a vise. (b) Using locking pliers, hold the magnetic clutch hub. (c) Remove the bolt, magnetic clutch hub, and magnetic clutch washers. HINT: There is no set number of magnetic clutch washers because they are used for adjustment. (d) Using a snap ring expander, remove the snap ring and then remove the magnetic clutch rotor. NOTICE: Take care not to damage the seal cover of the bearing when removing the snap ring. (e) Disconnect the connector. (f) Remove the screw. E037091 (g) Using a snap ring expander, remove the snap ring and magnetic clutch stator. AC I030400 INSPECTION 1. E005280 INSPECT COMPRESSOR AND MAGNETIC CLUTCH (A/C LOCK SENSOR) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition 1-2 Always (at 20°C (68°F)) 165 to 205 Ω If the resistance is not as specified, replace the compressor and magnetic clutch. AC–222 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH (for 2GR-FE) 2. Compressor and Magnetic Clutch Connector Front View: INSPECT COMPRESSOR AND MAGNETIC CLUTCH (A/C COMPRESSOR SOLENOID) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition 2-1 20°C (68°F) 10 to 11 Ω If the resistance is not as specified, replace the compressor and magnetic clutch. E116970E04 A/C Compressor Connector Front View: 3. INSPECT COMPRESSOR AND MAGNETIC CLUTCH (a) Disconnect the connector from the compressor and magnetic clutch. A E005280E18 AC (b) Disconnect the connector from the magnetic clutch. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Magnetic Clutch Connector Front View: B 4. E113611E02 Condition Specified Condition A-3 - B-1 Always Below 1 Ω A-3 - Body ground Always 10 kΩ or higher If the resistance is not as specified, replace the compressor and magnetic clutch. E124482E03 Magnetic Clutch Connector Front View: Tester Connection INSPECT MAGNETIC CLUTCH (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition 1 - Body ground Always 3.4 to 3.8 Ω If the resistance is not as specified, replace the magnetic clutch. (b) When connector terminal 1 is connected to the positive (+) battery terminal, check that the following occurs: 1) the magnetic clutch's operating sound can be heard, and 2) the magnetic clutch's hub and rotor lock. OK: 1): AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH (for 2GR-FE) AC–223 The magnetic clutch's operating sound can be heard. 2): The magnetic clutch's hub and rotor lock. If the result is not as specified, replace the magnetic clutch. REASSEMBLY 1. INSTALL MAGNETIC CLUTCH ASSEMBLY (a) Install the magnetic clutch stator while aligning the protrusion on the stator with the notch on the air compressor assembly as shown in the illustration. E075075 (b) Using a snap ring expander, install a new snap ring with the chamfered side facing up. NOTICE: Take care not to damage the seal cover of the bearing when installing the snap ring. (c) Connect the connector. Inside I032461E03 Inside I031582E07 (d) Using a snap ring expander, install the magnetic clutch rotor and a new snap ring with the chamfered side facing up. NOTICE: • Do not expand the snap ring by more than 35.5 mm (1.39 in.) when installing it. • Do not damage the seal cover of the bearing when installing the snap ring. (e) Install the magnetic clutch washer and magnetic clutch hub. NOTICE: Do not change the combination of the magnetic clutch washers used before disassembly. (f) E075076 Using vise pliers, hold the magnetic clutch hub and install the bolt. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) NOTICE: Make sure that there is no foreign matter or oil on the compressor shaft, bolt, and clutch hub. AC AC–224 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH (for 2GR-FE) 2. INSPECT MAGNETIC CLUTCH CLEARANCE (a) Set the dial indicator to the magnetic clutch hub. (b) Connect the battery positive lead to terminal 1 of the magnetic clutch connector, and the negative lead to the ground wire. Turn the magnetic clutch on and off and measure the clearance. Standard clearance: 0.26 to 0.60 mm (0.010 to 0.024 in.) If the measured value is not within the standard range, remove the magnetic clutch hub and adjust it with magnetic clutch washers. NOTICE: Adjustment should be performed with 3 or less magnetic clutch washers. (c) Remove the compressor and magnetic clutch from the vise. 3. ADJUST COMPRESSOR OIL LEVEL (a) When replacing the compressor and magnetic clutch with a new one, gradually discharge the inert gas (helium) from the service valve, and drain the following amount of oil from the new compressor and magnetic clutch before installation. Standard: (Oil capacity inside the new compressor and magnetic clutch: 130 + 15 cc (4.6 + 0.51 fl.oz.) ) - (Remaining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be removed from the new compressor when replacing) NOTICE: • When checking the compressor oil level, observe the precautions on the cooler removal/installation. • If a new compressor and magnetic clutch is installed without removing some oil, due to the oil remaining in the pipes of the vehicle, the oil amount will be too large. This prevents heat exchange in the refrigerant cycle and causes refrigerant failure. • If the volume of oil remaining in the removed compressor and magnetic clutch is too small, check for oil leakage. • Be sure to use ND-OIL 8 or equivalent for compressor oil. E075077 AC AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH (for 2GR-FE) AC–225 INSTALLATION 1. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (a) Install the compressor and magnetic clutch with the 4 bolts. Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) NOTICE: Tighten the bolts in the order shown in the illustration to install the compressor and magnetic clutch. 2. INSTALL NO. 1 COOLER REFRIGERANT SUCTION HOSE (a) Remove the attached vinyl tape from the hose. (b) Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor and magnetic clutch. Compressor oil: ND-OIL 8 or equivalent (c) Install the O-ring onto the No. 1 cooler refrigerant suction hose. (d) Install the No. 1 cooler refrigerant suction hose onto the compressor and magnetic clutch with the bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 3. INSTALL NO. 1 COOLER REFRIGERANT DISCHARGE HOSE (a) Remove the attached vinyl tape from the hose. (b) Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor and magnetic clutch. Compressor oil: ND-OIL 8 or equivalent (c) Install the O-ring onto the No. 1 cooler refrigerant discharge hose sub-assembly. (d) Install the No. 1 cooler refrigerant discharge hose onto the compressor and magnetic clutch with the bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) (1) (4) (3) (2) E129987E01 E129144 E129143 E129142 4. INSTALL PIPING CLAMP (a) Install the piping clamp to the No. 1 cooler refrigerant suction hose and No. 1 cooler refrigerant discharge hose. 5. INSTALL GENERATOR ASSEMBLY (See page CH-22) 6. INSTALL V-RIBBED BELT (See page EM-7) 7. INSTALL RADIATOR ASSEMBLY (See page CO-31) 8. INSTALL FAN SHROUD (See page CO-32) 9. INSTALL RADIATOR SUPPORT UPPER (See page CO-32) 10. INSTALL NO. 1 OIL COOLER OUTLET TUBE (for Automatic Transaxle) (See page CO-33) AC AC–226 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH (for 2GR-FE) 11. INSTALL NO. 1 OIL COOLER INLET TUBE (for Automatic Transaxle) (See page CO-33) 12. CONNECT RADIATOR OUTLET HOSE (See page CO33) 13. CONNECT RADIATOR INLET HOSE (See page CO33) 14. CONNECT RADIATOR RESERVE TANK HOSE (See page CO-34) 15. INSTALL FRONT BUMPER ENERGY ABSORBER (See page ET-10) 16. INSTALL FRONT BUMPER ASSEMBLY (w/o Fog Light) (See page ET-13) 17. INSTALL FRONT BUMPER ASSEMBLY (w/ Fog Light) (See page ET-14) 18. INSTALL NO. 1 AIR CLEANER INLET (See page EM49) 19. INSTALL AIR CLEANER CAP SUB-ASSEMBLY 20. INSTALL AIR CLEANER INLET ASSEMBLY (See page EM-50) 21. CONNECT BATTERY NEGATIVE TERMINAL 22. ADD ENGINE COOLANT (See page CO-6) AC 23. CHECK FOR ENGINE COOLANT LEAKS (See page CO-1) 24. CHARGE WITH REFRIGERANT (See page AC-125) 25. WARM UP ENGINE (See page AC-126) 26. CHECK FOR REFRIGERANT LEAKS (See page AC126) 27. INSTALL V-BANK COVER SUB-ASSEMBLY (See page EM-52) 28. INSTALL COOL AIR INTAKE DUCT SEAL (See page EM-52) 29. INSTALL ENGINE UNDER COVER RH 30. INSTALL ENGINE UNDER COVER LH 31. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH 32. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH 33. INSTALL FRONT FENDER APRON SEAL RH 34. INSTALL FRONT WHEEL RH 35. VEHICLE PREPARATION FOR FOG LIGHT AIMING (w/ Fog Light) (See page LI-79) 36. PREPARATION FOR FOG LIGHT AIMING (w/ Fog Light) (See page LI-80) AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH (for 2GR-FE) AC–227 37. INSPECT FOG LIGHT AIMING (w/ Fog Light) (See page LI-81) 38. ADJUST FOG LIGHT AIMING (w/ Fog Light) (See page LI-82) AC AC–228 AIR CONDITIONING – COMPRESSOR AND PULLEY (for 2AZ-FE) COMPRESSOR AND PULLEY (for 2AZ-FE) HEATER AIR CONDITIONING & AIR CONDITIONING SYSTEM COMPONENTS V-RIBBED BELT 8.4 (86, 74 in.*lbf) 9.8 (100, 87 in.*lbf) 52 (530, 38) AC 21 (215, 16) GENERATOR ASSEMBLY FRONT FENDER APRON SEAL RH ENGINE UNDER COVER RH N*m (kgf*cm, ft.*lbf) : Specified torque A133568E01 AIR CONDITIONING – COMPRESSOR AND PULLEY (for 2AZ-FE) AC–229 NO. 1 COOLER REFRIGERANT DISCHARGE HOSE 9.8 (100, 87 in.*lbf) O-RING 9.8 (100, 87 in.*lbf) PIPING CLAMP COMPRESSOR AND PULLEY AC O-RING NO. 1 COOLER REFRIGERANT SUCTION HOSE 25 (255, 18) ENGINE WIRE HARNESS BRACKET Compressor oil ND-OIL 8 or equivalent Non-reusable part N*m (kgf*cm, ft.*lbf) E129149E01 AC–230 AIR CONDITIONING – COMPRESSOR AND PULLEY (for 2AZ-FE) ON-VEHICLE INSPECTION Example: 1. INSPECT COMPRESSOR FOR METALLIC SOUND (a) Check if there is abnormal metallic sound from the compressor when the A/C switch is on and the compressor operates. If abnormal metallic sound is heard, replace the compressor and pulley. 2. INSPECT REFRIGERANT PRESSURE HINT: (See page AC-120) 3. INSPECT FOR LEAKAGE OF REFRIGERANT (a) Using a gas leak detector, check for leakage of refrigerant. If there is any leakage, replace the compressor and pulley. 4. INSPECT COMPRESSOR AND PULLEY (a) Check operation of compressor and pulley. (1) Start the engine. (2) Inspect the compressor pulley. Pulley AC Pulley E130370E02 Standard: The compressor shaft rotates along with the pulley. If the result is not as specified, replace the compressor and pulley. AIR CONDITIONING – COMPRESSOR AND PULLEY (for 2AZ-FE) AC–231 REMOVAL 1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM (See page AC-125) 2. DISCONNECT REFRIGERANT FROM REFRIGERATION SYSTEM CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment (See page RS-1) 3. DRAIN ENGINE COOLANT (See page CO-5) 4. REMOVE FRONT WHEEL RH 5. REMOVE ENGINE UNDER COVER RH 6. REMOVE FRONT FENDER APRON SEAL RH 7. REMOVE V-RIBBED BELT (See page EM-6) 8. REMOVE GENERATOR ASSEMBLY (See page CH-11) 9. DISCONNECT RADIATOR HOSE OUTLET (a) Using pliers, grip the claws of the clip and slide the clip to disconnect the radiator hose outlet. AC E129150 10. REMOVE PIPING CLAMP (a) Remove the piping clamp from the No. 1 cooler refrigerant discharge hose and No. 1 cooler refrigerant suction hose. E129151 E129152 11. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE (a) Remove the bolt and disconnect the No. 1 cooler refrigerant discharge hose from the compressor and pulley. (b) Remove the O-ring from the No. 1 cooler refrigerant discharge hose. NOTICE: Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter. AC–232 AIR CONDITIONING – COMPRESSOR AND PULLEY (for 2AZ-FE) E129153 12. DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE (a) Remove the bolt and disconnect the No. 1 cooler refrigerant suction hose from the compressor and pulley. (b) Remove the O-ring from the No. 1 cooler refrigerant suction hose. NOTICE: Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter. 13. REMOVE COMPRESSOR AND PULLEY (a) Disconnect the connector. (b) Remove the 4 bolts, engine wire harness bracket, and the compressor and pulley. E129154 AC INSPECTION Compressor and Pulley Connector Front View: 1. INSPECT COMPRESSOR AND PULLEY (A/C COMPRESSOR SOLENOID) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition 2-1 20°C (68°F) 10 to 11 Ω If the resistance is not as specified, replace the compressor and pulley. E116970E03 INSTALLATION Drain bolt and washer 1. E117281E01 ADJUST COMPRESSOR OIL LEVEL (a) When replacing the cooler compressor assembly with a new one, gradually discharge the inert gas (helium) from the service valve, and drain the following amount of oil from the vents indicated by the arrows in the illustration before installation. HINT: The drain bolt and washer can be reused. AIR CONDITIONING – COMPRESSOR AND PULLEY (for 2AZ-FE) AC–233 Standard: AC (Oil capacity inside the new compressor and magnetic clutch: 160 + 15 cc (5.4 + 0.51 fl.oz.)) - (Remaining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be removed from the new compressor when replacing) NOTICE: • If a new compressor and magnetic clutch is installed without removing some oil, due to the oil remaining in the pipes of the vehicle, the oil amount will be too large. This prevents heat exchange in the refrigerant cycle and causes refrigeration system failure. • If the volume of oil remaining in the removed compressor and magnetic clutch is too small, check for oil leakage. • Be sure to use ND-OIL 8 or equivalent for compressor oil. 2. (1) (4) (3) INSTALL COMPRESSOR AND PULLEY (a) Install the compressor and pulley and the engine wire harness bracket with the 4 bolts. Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) NOTICE: Tighten the bolts in the order shown in the illustration to install the compressor and pulley. (2) AC E129985E01 3. INSTALL NO. 1 COOLER REFRIGERANT SUCTION HOSE (a) Remove the attached vinyl tape from the hose. (b) Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor and magnetic clutch. Compressor oil: ND-OIL 8 or equivalent (c) Install the O-ring onto the No. 1 cooler refrigerant suction hose. (d) Install the No. 1 cooler refrigerant suction hose onto the compressor and magnetic clutch with the bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 4. INSTALL NO. 1 COOLER REFRIGERANT DISCHARGE HOSE (a) Remove the attached vinyl tape from the hose. (b) Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor and magnetic clutch. Compressor oil: ND-OIL 8 or equivalent (c) Install the O-ring onto the No. 1 cooler refrigerant discharge hose. E129153 E129152 AC–234 AIR CONDITIONING – COMPRESSOR AND PULLEY (for 2AZ-FE) (d) Install the discharge hose sub-assembly onto the compressor and magnetic clutch with the bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 5. INSTALL PIPING CLAMP (a) Install the piping clamp to the No. 1 cooler refrigerant suction hose and No. 1 cooler refrigerant discharge hose. 6. INSTALL GENERATOR ASSEMBLY (See page CH-19) 7. INSTALL V-RIBBED BELT (See page EM-6) 8. INSTALL FRONT FENDER APRON SEAL RH 9. INSTALL RADIATOR HOSE OUTLET (a) Install the radiator hose outlet and attach the clip. E129151 10. CONNECT BATTERY NEGATIVE TERMINAL 11. ADD ENGINE COOLANT (See page CO-5) E129150 AC 12. CHECK FOR ENGINE COOLANT LEAKS NOTICE: Do not turn the A/C on before charging with refrigerant. Doing so will cause the cooler compressor to work without refrigerant, resulting in overheating of the cooler compressor. 13. INSTALL ENGINE UNDER COVER RH 14. INSTALL FRONT WHEEL RH 15. CHARGE WITH REFRIGERANT (See page AC-125) 16. WARM UP ENGINE (See page AC-126) 17. CHECK FOR REFRIGERANT LEAKS (See page AC126) AIR CONDITIONING – CONDENSER AC–235 CONDENSER HEATER AIR CONDITIONING & AIR CONDITIONING SYSTEM COMPONENTS 2AD-FE: AIR CLEANER CAP SUB-ASSEMBLY 5.0 (51, 44 in.*lbf) AIR CLEANER FILTER ELEMENT x2 AIR CLEANER INLET ASSEMBLY AC N*m (kgf*cm, ft.*lbf) : Specified torque E133914E01 AC–236 AIR CONDITIONING – CONDENSER 2GR-FE: V-BANK COVER SUB-ASSEMBLY 5.0 (51, 44 in.*lbf) x2 AIR CLEANER INLET SUB-ASSEMBLY 5.0 (51, 44 in.*lbf) AIR CLEANER CAP SUB-ASSEMBLY NO. 1 AIR CLEANER INLET COOL AIR INTAKE DUCT SEAL AC N*m (kgf*cm, ft.*lbf) : Specified torque E133915E01 AC–237 AIR CONDITIONING – CONDENSER 7.0 (71, 62 in.*lbf) RADIATOR SUPPORT UPPER HOOD LOCK ASSEMBLY 7.5 (77, 66 in.*lbf) 7.0 (71, 62 in.*lbf) HORN CONNECTOR 7.5 (77, 66 in.*lbf) 7.5 (77, 66 in.*lbf) HOOD LOCK SUPPORT SUB-ASSEMBLY AC RADIATOR GRILIE PROTECTOR FRONT BUMPER ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque E129982E01 AC–238 AIR CONDITIONING – CONDENSER 5.0 (51, 44 in.*lbf) 5.0 (51, 44 in.*lbf) COOLER REFRIGERANT DISCHARGE PIPE O-RING 9.8 (100, 87 in.*lbf) 9.8 (100, 87 in.*lbf) 5.0 (51, 44 in.*lbf) O-RING 5.0 (51, 44 in.*lbf) AIR CONDITIONER TUBE AND ACCESSORY COOLER CONDENSER ASSEMBLY AC COOLER DRYER 2.9 (30, 26 in.*lbf) Compressor oil ND-OIL 8 or equivalent N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part E128507E01 AIR CONDITIONING – CONDENSER AC–239 REMOVAL 1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 2. REMOVE V-BANK COVER SUB-ASSEMBLY (for 2GRFE) (See page EM-23) 3. REMOVE COOL AIR INTAKE DUCT SEAL (for 2GRFE) (See page EM-23) 4. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (for 2AZ-FE) (See page ES-416) 5. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (for 2GR-FE) (See page ES-503) 6. REMOVE AIR CLEANER INLET ASSEMBLY (for 2AZFE) (See page EM-94) 7. REMOVE AIR CLEANER INLET SUB-ASSEMBLY (for 2GR-FE) (See page EM-24) 8. REMOVE NO. 1 AIR CLEANER INLET (for 2GR-FE) (See page EM-24) 9. REMOVE FRONT BUMPER ASSEMBLY (w/o Fog Light) (See page ET-5) 10. REMOVE FRONT BUMPER ASSEMBLY (w/ Fog Light) (See page ET-6) 11. REMOVE RADIATOR SUPPORT UPPER 12. REMOVE HOOD LOCK SUPPORT SUB-ASSEMBLY (a) Remove the bolt and hood lock support subassembly. E129983 13. DISCONNECT AIR CONDITIONER TUBE AND ACCESSORY (a) Remove the bolt and disconnect the air conditioning tube assembly from the condenser. (b) Remove the O-ring from the air conditioning tube assembly. NOTICE: Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter. E128544 AC AC–240 AIR CONDITIONING – CONDENSER 14. DISCONNECT COOLER REFRIGERANT DISCHARGE PIPE (a) Remove the bolt and disconnect the cooler refrigerant discharge pipe from the condenser. (b) Remove the O-ring from the cooler refrigerant discharge pipe. NOTICE: Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter. E128545 15. REMOVE COOLER CONDENSER ASSEMBLY (a) Remove the 4 bolts and condenser. AC E129141 16. REMOVE COOLER DRYER (a) Using a 14 mm straight hexagon wrench, remove the cap from the modulator. E101931 (b) Using pliers, remove the cooler dryer. E050386 AIR CONDITIONING – CONDENSER AC–241 INSTALLATION 1. INSTALL COOLER DRYER (a) Using pliers, install the cooler dryer to the modulator. E050386 (b) Apply sufficient compressor oil to an O-ring and cap fitting surface. Compressor oil: ND-OIL 8 or equivalent I032475 (c) Using a straight hexagon wrench 14 mm, install the cap to the cooler condenser core. Torque: 2.9 N*m (30 kgf*cm, 26 in.*lbf) AC E101931 2. E129141 INSTALL COOLER CONDENSER ASSEMBLY (a) Install the cooler condenser assembly with the 4 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) HINT: If the condenser is replaced with a new one, add compressor oil to the new condenser. Capacity: 40 cc (1.4 fl. oz.) Compressor oil: ND-8 or equivalent AC–242 AIR CONDITIONING – CONDENSER 3. INSTALL COOLER REFRIGERANT DISCHARGE PIPE (a) Remove the attached vinyl tape from the pipe and the connecting part of the cooler condenser assembly. (b) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the pipe joint. Compressor oil: ND-OIL 8 or equivalent (c) Install the O-ring on the cooler refrigerant discharge pipe. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 4. INSTALL AIR CONDITIONER TUBE AND ACCESSORY (a) Remove the attached vinyl tape from the tube and the connecting part of the cooler condenser assembly. (b) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the tube joint. Compressor oil: ND-OIL 8 or equivalent (c) Install the O-ring on the air conditioning tube assembly. (d) Install the air conditioning tube assembly on the cooler condenser assembly with the bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 5. INSTALL HOOD LOCK SUPPORT SUB-ASSEMBLY (a) Install the hood lock support sub-assembly with the bolt. Torque: 7.5 N*m (77 kgf*cm, 66 in.*lbf) 6. INSTALL RADIATOR SUPPORT UPPER 7. INSTALL FRONT BUMPER ASSEMBLY (w/o Fog Light) (See page ET-13) 8. INSTALL FRONT BUMPER ASSEMBLY (w/ Fog Light) (See page ET-14) 9. INSTALL NO. 1 AIR CLEANER INLET (for 2GR-FE) (See page EM-49) E128545 AC E128544 E129983 10. INSTALL AIR CLEANER INLET ASSEMBLY (for 2AZFE) (See page EM-120) 11. INSTALL AIR CLEANER INLET SUB-ASSEMBLY (for 2GR-FE) (See page EM-50) 12. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 2AZ-FE) (See page ES-419) AIR CONDITIONING – CONDENSER AC–243 13. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 2GR-FE) (See page ES-506) 14. INSTALL COOL AIR INTAKE DUCT SEAL (for 2GRFE) (See page EM-52) 15. INSTALL V-BANK COVER SUB-ASSEMBLY (for 2GRFE) (See page EM-52) 16. ADD ENGINE COOLANT (for 2AZ-FE) (See page CO5) 17. ADD ENGINE COOLANT (for 2GR-FE) (See page CO6) 18. CHECK FOR ENGINE COOLANT LEAKS 19. CHARGE WITH REFRIGERANT (See page AC-125) 20. WARM UP ENGINE (See page AC-126) 21. CHECK FOR REFRIGERANT LEAKS (See page AC126) AC AC–244 AIR CONDITIONING – ROOM TEMPERATURE SENSOR ROOM TEMPERATURE SENSOR HEATER AIR CONDITIONING & AIR CONDITIONING SYSTEM COMPONENTS ROOM TEMPERATURE SENSOR COWL SIDE TRIM SUB-ASSEMBLY LH COWL SIDE TRIM CLIP LOWER INSTRUMENT PANEL FINISH PANEL LH AC FRONT DOOR SCUFF PLATE LH E129991E01 AC–245 AIR CONDITIONING – ROOM TEMPERATURE SENSOR REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-24) 2. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-25) 3. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (See page IP-20) 4. REMOVE ROOM TEMPERATURE SENSOR (a) Disconnect the connector and air hose. (b) Release the claw and remove the sensor. E129986 INSPECTION A/C Room Temperature Sensor Connector Front View: 1. Resistance (kΩ) 4.0 3.5 INSPECT ROOM TEMPERATURE SENSOR (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition 1-2 10°C (50°F) 3.00 to 3.73 kΩ 1-2 15°C (59°F) 2.45 to 2.88 kΩ 1-2 20°C (68°F) 1.95 to 2.30 kΩ 1-2 15°C (77°F) 1.60 to 1.80 kΩ 1-2 30°C (86°F) 1.28 to 1.47 kΩ 1-2 35°C (95°F) 1.00 to 1.22 kΩ 1-2 40°C (104°F) 0.80 to 1.00 kΩ 1-2 45°C (113°F) 0.65 to 0.85 kΩ 3.0 1-2 50°C (122°F) 0.50 to 0.70 kΩ 2.5 1-2 55°C (131°F) 0.44 to 0.60 kΩ 2.0 1-2 60°C (140°F) 0.36 to 0.50 kΩ 1.5 1.0 0.5 0.0 (°C) 10 (°F) 50 20 68 30 86 40 104 50 122 60 140 Temperature E110805E05 NOTICE: • Hold the sensor only by its connector. Touching the sensor may change the resistance value. • When measuring, the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (see the graph). AC AC–246 AIR CONDITIONING – ROOM TEMPERATURE SENSOR If the resistance is not as specified, replace the room temperature sensor. INSTALLATION E129986 AC 1. INSTALL ROOM TEMPERATURE SENSOR (a) Engage the claw to install the sensor. (b) Connect the connector and attach the air hose. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (See page IP-58) 3. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-54) 4. INSTALL FRONT DOOR SCUFF PLATE LH (See page IR-54) AIR CONDITIONING – AMBIENT TEMPERATURE SENSOR AC–247 AMBIENT TEMPERATURE SENSOR HEATER AIR CONDITIONING & AIR CONDITIONING SYSTEM COMPONENTS for 2GR-FE: COOL AIR INTAKE DUCT SEAL AMBIENT TEMPERATURE SENSOR AC RADIATOR GRILLE PROTECTOR RADIATOR GRILLE PROTECTOR FRONT BUMPER ASSEMBLY E128509E01 AC–248 AIR CONDITIONING – AMBIENT TEMPERATURE SENSOR REMOVAL E128543 AC 1. REMOVE COOL AIR INTAKE DUCT SEAL (for 2GRFE) (See page ET-4) 2. REMOVE FRONT BUMPER ASSEMBLY (w/o Fog Light) (See page ET-5) 3. REMOVE FRONT BUMPER ASSEMBLY (w/ Fog Light) (See page ET-6) 4. REMOVE AMBIENT TEMPERATURE SENSOR (a) Disconnect the connector and detach the clamp. (b) Remove the ambient temperature sensor. AC–249 AIR CONDITIONING – AMBIENT TEMPERATURE SENSOR Ambient Temperature Sensor Connector Front View: INSPECTION 1. Sensor Area Resistance (kΩ) 4.0 3.5 2.5 2.0 1.5 1.0 0.5 10 50 20 68 30 86 40 104 Tester Connection Condition Specified Condition 1-2 10°C (50°F) 3.00 to 3.73 kΩ 1-2 15°C (59°F) 2.45 to 2.88 kΩ 1-2 20°C (68°F) 1.95 to 2.30 kΩ 1-2 25°C (77°F) 1.60 to 1.80 kΩ 1-2 30°C (86°F) 1.28 to 1.47 kΩ 1-2 35°C (95°F) 1.00 to 1.22 kΩ 1-2 40°C (104°F) 0.80 to 1.00 kΩ 1-2 45°C (113°F) 0.65 to 0.85 kΩ 1-2 50°C (122°F) 0.50 to 0.70 kΩ 1-2 55°C (131°F) 0.44 to 0.60 kΩ 1-2 60°C (140°F) 0.36 to 0.50 kΩ NOTICE: • Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor. • When measuring, the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (see the graph). If the resistance is not as specified, replace the ambient temperature sensor. 3.0 0.0 INSPECT AMBIENT TEMPERATURE SENSOR (a) Measure the resistance according to the value(s) in the table below. Standard resistance 50 60 (°C) 122 140 (°F) Temperature E118395E07 INSTALLATION E128543 1. INSTALL AMBIENT TEMPERATURE SENSOR (a) Install the ambient temperature sensor with the clamp. (b) Connect the connector. 2. INSTALL FRONT BUMPER ASSEMBLY (w/o Fog Light) (See page ET-13) 3. INSTALL FRONT BUMPER ASSEMBLY (w/ Fog Light) (See page ET-14) 4. INSTALL COOL AIR INTAKE DUCT SEAL 5. VEHICLE PREPARATION FOR FOG LIGHT AIMING (w/ Fog Light) (See page LI-79) 6. PREPARATION FOR FOG LIGHT AIMING (w/ Fog Light) (See page LI-80) 7. INSPECT FOG LIGHT AIMING (w/ Fog Light) (See page LI-81) 8. ADJUST FOG LIGHT AIMING (w/ Fog Light) (See page LI-82) AC AC–250 AIR CONDITIONING – EVAPORATOR TEMPERATURE SENSOR Air Conditioning Harness: (A/C Evaporator Temperature Sensor) EVAPORATOR TEMPERATURE SENSOR ON-VEHICLE INSPECTION Sensor Area 1. Resistance (kΩ) AC 10.0 9.0 8.0 7.0 6.0 5.0 4.0 3.0 2.0 1.0 0.0 -10 14 0 32 10 50 20 68 30 (°C) 86 (°F) Temperature E124474E02 INSPECT EVAPORATOR TEMPERATURE SENSOR (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition 5-6 -10°C (14°F) 7.30 to 9.10 kΩ 5-6 -5°C (23°F) 5.65 to 6.95 kΩ 5-6 0°C (32°F) 4.40 to 5.35 kΩ 5-6 5°C (41°F) 3.40 to 4.15 kΩ 5-6 10°C (50°F) 2.70 to 3.25 kΩ 5-6 15°C (59°F) 2.14 to 2.58 kΩ 5-6 20°C (68°F) 1.71 to 2.05 kΩ 5-6 25°C (77°F) 1.38 to 1.64 kΩ 5-6 30°C (86°F) 1.11 to 1.32 kΩ NOTICE: • Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor. • When measuring, the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (see the graph). If the resistance is not as specified, replace the evaporator temperature sensor. AIR CONDITIONING – AIR CONDITIONING PRESSURE SENSOR AC–251 AIR CONDITIONING PRESSURE SENSOR ON-VEHICLE INSPECTION 1. (b) Connect the three 1.5 V dry cell batterie's positive (+) lead to terminal 3 and the negative (-) lead to terminal 1. Then connect the voltmeter's positive (+) lead to terminal 2 and the negative (-) lead to terminal 1. Measure the voltage. OK: The voltage changes according to refrigerant pressure, as shown in the graph. If the voltage is not as specified, replace the pressure sensor. A/C Pressure Sensor Connector Front View: B4 2 3 INSPECT PRESSURE SENSOR (a) Install the manifold gauge set (See page AC-120). 1 (V) Voltage AC (57) (463) MPa (psi) Refrigerant Pressure E107326E08 AC–252 AIR CONDITIONING – AIR CONDITIONING CONTROL ASSEMBLY AIR CONDITIONING CONTROL ASSEMBLY HEATER AIR CONDITIONING & AIR CONDITIONING SYSTEM COMPONENTS Automatic Air Conditioning System: INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY UPPER CONSOLE PANEL SUB-ASSEMBLY AC NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH SHIFT LEVER KNOB SUB-ASSEMBLY FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY UPPER CONSOLE REAR PANEL SUB-ASSEMBLY E129159E01 AIR CONDITIONING – AIR CONDITIONING CONTROL ASSEMBLY AC–253 Manual Air Conditioning System: INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH for Manual Transaxle: SHIFT LEVER KNOB SUB-ASSEMBLY AC UPPER CONSOLE PANEL SUB-ASSEMBLY for Automatic Transaxle: FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY UPPER CONSOLE PANEL UPPER CONSOLE REAR PANEL SUB-ASSEMBLY SHIFT LEVER KNOB SUB-ASSEMBLY UPPER CONSOLE REAR PANEL SUB-ASSEMBLY E129160E01 AC–254 AIR CONDITIONING – AIR CONDITIONING CONTROL ASSEMBLY for Automatic Air Conditioning System: NAVIGATION RECEIVER WITH HEATER CONTROL PANEL RADIO NO. 1 BRACKET RADIO NO. 2 BRACKET AIR CONDITIONING CONTROL ASSEMBLY for Manual Air Conditioning System: AC RADIO RECEIVER WITH HEATER CONTROL ASSEMBLY RADIO NO. 1 BRACKET RADIO NO. 2 BRACKET AIR CONDITIONING CONTROL ASSEMBLY E128505E01 AIR CONDITIONING – AIR CONDITIONING CONTROL ASSEMBLY AC–255 REMOVAL 1. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-24) 2. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) (See page IP-24) 3. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-24) 4. REMOVE NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-25) 5. REMOVE FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-25) 6. REMOVE UPPER CONSOLE PANEL (for Manual Transaxle) (See page IP-25) 7. REMOVE UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Automatic Transaxle) (See page IP26) 8. REMOVE UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Manual Transaxle) (See page IP-26) 9. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (See page IP-27) 10. REMOVE INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY (See page IP-27) 11. REMOVE RADIO RECEIVER WITH HEATER CONTROL ASSEMBLY (for Manual Air Conditioning System) (See page AV-146) 12. REMOVE NAVIGATION RECEIVER WITH HEATER CONTROL PANEL (for Automatic Air Conditioning System) (See page NS-195) 13. REMOVE RADIO NO. 1 BRACKET (for Manual Air Conditioning System) (See page AV-146) 14. REMOVE RADIO NO. 1 BRACKET (for Automatic Air Conditioning System) (See page NS-195) 15. REMOVE RADIO NO. 2 BRACKET (for Manual Air Conditioning System) (See page AV-146) 16. REMOVE RADIO NO. 2 BRACKET (for Automatic Air Conditioning System) (See page NS-195) AC AC–256 AIR CONDITIONING – AIR CONDITIONING CONTROL ASSEMBLY 17. REMOVE AIR CONDITIONING CONTROL ASSEMBLY (for Manual Air Conditioning System) (a) Remove the air conditioning control assembly as shown in the illustration. E128541 18. REMOVE AIR CONDITIONING CONTROL ASSEMBLY (for Automatic Air Conditioning System) (a) Remove the air conditioning control assembly as shown in the illustration. E129984 INSTALLATION 1. INSTALL AIR CONDITIONING CONTROL ASSEMBLY (for Manual Air Conditioning System) (a) Install the air conditioning control assembly as shown in the illustration. 2. INSTALL AIR CONDITIONING CONTROL ASSEMBLY (for Automatic Air Conditioning System) (a) Install the air conditioning control assembly as shown in the illustration. 3. INSTALL RADIO NO. 2 BRACKET (for Manual Air Conditioning System) (See page AV-147) 4. INSTALL RADIO NO. 2 BRACKET (for Automatic Air Conditioning System) (See page NS-196) 5. INSTALL RADIO NO. 1 BRACKET (for Manual Air Conditioning System) (See page AV-147) 6. INSTALL RADIO NO. 1 BRACKET (for Automatic Air Conditioning System) (See page NS-196) 7. INSTALL RADIO RECEIVER WITH HEATER CONTROL ASSEMBLY (for Manual Air Conditioning System) (See page AV-147) 8. INSTALL NAVIGATION RECEIVER WITH HEATER CONTROL PANEL (for Automatic Air Conditioning System) (See page NS-196) AC E129989 E129990 AIR CONDITIONING – AIR CONDITIONING CONTROL ASSEMBLY 9. AC–257 INSTALL INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY (See page IP-52) 10. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (See page IP-52) 11. INSTALL UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Automatic Transaxle) (See page IP53) 12. INSTALL UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Manual Transaxle) (See page IP-53) 13. INSTALL FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-53) 14. INSTALL UPPER CONSOLE PANEL (for Manual Transaxle) (See page IP-54) 15. INSTALL NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-54) 16. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-55) 17. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-55) 18. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) (See page IP-55) AC AC–258 AIR CONDITIONING – AIR CONDITIONING AMPLIFIER AIR CONDITIONING AMPLIFIER HEATER AIR CONDITIONING & AIR CONDITIONING SYSTEM COMPONENTS COWL SIDE TRIM SUB-ASSEMBLY RH COWL SIDE TRIM CLIP FRONT DOOR SCUFF PLATE RH AC AIR CONDITIONING AMPLIFIER ASSEMBLY INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY LOWER INSTRUMENT PANEL SUB-ASSEMBLY E129148E02 AIR CONDITIONING – AIR CONDITIONING AMPLIFIER AC–259 REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE RH (See page IR-26) 2. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH (See page IR-26) 3. REMOVE INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY (See page IP-23) 4. REMOVE LOWER INSTRUMENT PANEL SUBASSEMBLY (See page IP-23) 5. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY (a) Disconnect the connectors. (b) Remove the 2 bolts and air conditioning amplifier assembly. E128518E01 INSTALLATION 1. E128518E01 INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY (a) Install the air conditioning amplifier assembly with the 2 bolts. (b) Connect the connectors. 2. INSTALL LOWER INSTRUMENT PANEL SUBASSEMBLY (See page IP-55) 3. INSTALL INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY (See page IP-56) 4. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH (See page IR-55) 5. INSTALL FRONT DOOR SCUFF PLATE RH (See page IR-55) AC AC–274 AIR CONDITIONING – PLASMACLUSTER REMOVAL 1. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 2. DISCONNECT BATTERY NEGATIVE TERMINAL NOTICE: Wait for 90 seconds after disconnecting the terminal to prevent the airbag from deploying. (See page RS1) 3. REMOVE LOWER NO. 3 STEERING WHEEL COVER (See page RS-349) 4. REMOVE LOWER NO. 2 STEERING WHEEL COVER (See page RS-349) 5. REMOVE STEERING PAD (See page RS-350) 6. REMOVE STEERING WHEEL ASSEMBLY (See page SR-38) 7. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-24) 8. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-25) 9. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (See page IP-20) 10. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (See page IP-21) AC 11. REMOVE STEERING COLUMN COVER (for TMC Made) (See page IP-21) 12. REMOVE STEERING COLUMN COVER (for TMMK Made) (See page IP-21) 13. REMOVE TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY (See page SR-39) 14. REMOVE NO. 1 INSTRUMENT PANEL SUBASSEMBLY (See page IP-22) 15. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (w/o Smart Key System) (See page IP-22) 16. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (w/ Smart Key System) (See page IP-22) 17. REMOVE INSTRUMENT CLUSTER FINISH PANEL (See page IP-22) 18. REMOVE COMBINATION METER ASSEMBLY (for TMC Made) (See page IP-23) 19. REMOVE COMBINATION METER ASSEMBLY (for TMMK Made) (See page IP-23) 20. REMOVE FRONT DOOR SCUFF PLATE RH (See page IR-26) 21. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH AIR CONDITIONING – PLASMACLUSTER AC–275 22. REMOVE INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY (See page IP-23) 23. REMOVE LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMC Made) (See page IP-23) 24. REMOVE LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMMK Made) (See page IP-24) 25. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-24) 26. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) (See page IP-24) 27. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-24) 28. REMOVE NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-25) 29. REMOVE FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-25) 30. REMOVE UPPER CONSOLE PANEL (for Manual Transaxle) (See page IP-25) 31. REMOVE UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Automatic Transaxle) (See page IP26) 32. REMOVE UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Manual Transaxle) (See page IP-26) 33. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMC Made) (See page IP-27) 34. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMMK Made) (See page IP-27) 35. REMOVE INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY (See page IP-27) 36. REMOVE RADIO RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY (w/o Navigation System) (See page AV-146) 37. REMOVE NAVIGATION RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY (See page NS-195) 38. REMOVE CONSOLE BOX POCKET (See page IP-28) 39. REMOVE CONSOLE BOX CARPET (See page IP-28) 40. REMOVE CONSOLE BOX ASSEMBLY (for TMC Made) (See page IP-28) 41. REMOVE CONSOLE BOX ASSEMBLY (for TMMK Made) (See page IP-29) 42. REMOVE NO. 2 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-29) 43. REMOVE NO. 2 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-30) AC AC–276 AIR CONDITIONING – PLASMACLUSTER 44. REMOVE NO. 1 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-30) 45. REMOVE NO. 1 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-30) 46. REMOVE FRONT PILLAR GARNISH LH (See page IR27) 47. REMOVE INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY (See page IP-31) 48. REMOVE INSTRUMENT PANEL NO. 1 SPEAKER PANEL SUB-ASSEMBLY (See page IP-31) 49. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (for LH Side) (See page AV-156) 50. REMOVE FRONT PILLAR GARNISH RH (See page IR27) 51. REMOVE INSTRUMENT PANEL NO. 3 REGISTER ASSEMBLY (See page IP-31) 52. REMOVE INSTRUMENT PANEL NO. 2 SPEAKER PANEL SUB-ASSEMBLY (See page IP-32) 53. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (for RH Side) (See page IP-32) 54. REMOVE NO. 1 DEFROSTER NOZZLE GARNISH (See page IP-32) AC 55. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY (for TMC Made) (See page IP-32) 56. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY (for TMMK Made) (See page IP-34) 57. REMOVE SIDE NO. 1 DEFROSTER NOZZLE DUCT (See page IP-37) 58. REMOVE NO. 1 HEATER TO REGISTER DUCT (See page IP-38) 59. REMOVE PLASMACLUSTER (a) Remove the 2 screws and "Plasmacluster". E128542 AIR CONDITIONING – PLASMACLUSTER AC–277 INSTALLATION 1. INSTALL PLASMACLUSTER (a) Install the "Plasmacluster" with the 2 screws. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 2. INSTALL NO. 1 HEATER TO REGISTER DUCT (See page IP-42) 3. INSTALL SIDE NO. 1 DEFROSTER NOZZLE DUCT (See page IP-43) 4. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY (for TMC Made) (See page IP-44) 5. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY (for TMMK Made) (See page IP-45) 6. INSTALL NO. 1 DEFROSTER NOZZLE GARNISH (See page IP-48) 7. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (for LH Side) (See page AV-156) 8. INSTALL INSTRUMENT PANEL NO. 1 SPEAKER PANEL SUB-ASSEMBLY (See page IP-48) 9. INSTALL INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY (See page IP-48) E128542 10. INSTALL FRONT PILLAR GARNISH LH (See page IR51) 11. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (for RH Side) (See page IP-48) 12. INSTALL INSTRUMENT PANEL NO. 2 SPEAKER PANEL SUB-ASSEMBLY (See page IP-49) 13. INSTALL INSTRUMENT PANEL NO. 3 REGISTER ASSEMBLY (See page IP-49) 14. INSTALL FRONT PILLAR GARNISH RH (See page IR52) 15. INSTALL NO. 1 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-49) 16. INSTALL NO. 1 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-50) 17. INSTALL NO. 2 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-50) 18. INSTALL NO. 2 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-50) 19. INSTALL CONSOLE BOX ASSEMBLY (for TMC Made) (See page IP-51) 20. INSTALL CONSOLE BOX ASSEMBLY (for TMMK Made) (See page IP-51) 21. INSTALL CONSOLE BOX CARPET (See page IP-51) 22. INSTALL CONSOLE BOX POCKET (See page IP-51) AC AC–278 AIR CONDITIONING – PLASMACLUSTER 23. INSTALL RADIO RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY (w/o Navigation System) (See page AV-147) 24. INSTALL NAVIGATION RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY (w/ Navigation System) (See page NS-196) 25. INSTALL INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY (See page IP-52) 26. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMC Made) (See page IP-52) 27. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMMK Made) (See page IP-52) 28. INSTALL UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Automatic Transaxle) (See page IP53) 29. INSTALL UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Manual Transaxle) (See page IP-53) 30. INSTALL FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-53) 31. INSTALL UPPER CONSOLE PANEL (for Manual Transaxle) (See page IP-54) AC 32. INSTALL NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-54) 33. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-55) 34. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-55) 35. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) (See page IP-55) 36. INSTALL LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMC Made) (See page IP-55) 37. INSTALL LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMMK Made) (See page IP-56) 38. INSTALL INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY (See page IP-56) 39. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH (See page IR-55) 40. INSTALL FRONT DOOR SCUFF PLATE RH (See page IR-55) 41. INSTALL COMBINATION METER ASSEMBLY (for TMC Made) (See page IP-56) 42. INSTALL COMBINATION METER ASSEMBLY (for TMMK Made) (See page IP-56) AIR CONDITIONING – PLASMACLUSTER AC–279 43. INSTALL INSTRUMENT CLUSTER FINISH PANEL (See page IP-57) 44. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/o Smart Key System) (See page IP-57) 45. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/ Smart Key System) (See page IP-57) 46. INSTALL NO. 1 INSTRUMENT PANEL SUBASSEMBLY (See page IP-57) 47. INSTALL TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY (See page SR-50) 48. ADJUST SPIRAL CABLE SUB-ASSEMBLY (See page RS-367) 49. INSTALL STEERING COLUMN COVER (for TMC Made) (See page IP-58) 50. INSTALL STEERING COLUMN COVER (for TMMK Made) (See page IP-58) 51. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (See page IP-58) 52. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (See page IP-59) 53. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-54) 54. INSTALL FRONT DOOR SCUFF PLATE LH (See page IR-54) 55. INSTALL STEERING WHEEL ASSEMBLY (See page SR-51) 56. INSTALL STEERING PAD (See page RS-350) 57. INSTALL LOWER NO. 3 STEERING WHEEL COVER (See page RS-351) 58. INSTALL LOWER NO. 2 STEERING WHEEL COVER (See page RS-352) 59. CONNECT NEGATIVE BATTERY TERMINAL 60. INSPECT STEERING PAD (See page RS-352) 61. INSPECT SRS WARNING LIGHT (See page IP-59) AC AC–260 AIR CONDITIONING – PLASMACLUSTER PLASMACLUSTER HEATER AIR CONDITIONING & AIR CONDITIONING SYSTEM COMPONENTS for TMC Made: TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY 2.0 (20, 18 in.*lbf) AC STEERING COLUMN COVER 50 (510, 37) STEERING WHEEL ASSEMBLY LOWER NO. 2 STEERING WHEEL COVER LOWER NO. 3 STEERING WHEEL COVER 8.8 (90, 78 in.*lbf) STEERING PAD N*m (kgf*cm, ft.*lbf) : Specified torque B137279E01 AC–261 AIR CONDITIONING – PLASMACLUSTER for TMMK Made: TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY 2.0 (20, 18 in.*lbf) STEERING COLUMN COVER for 4 Spoke: 50 (510, 37) STEERING WHEEL ASSEMBLY LOWER NO. 2 STEERING WHEEL COVER AC LOWER NO. 3 STEERING WHEEL COVER STEERING PAD 8.8 (90, 78 in.*lbf) for 3 Spoke: STEERING WHEEL ASSEMBLY 50 (510, 37) LOWER NO. 2 STEERING WHEEL COVER LOWER NO. 3 STEERING WHEEL COVER STEERING PAD 8.8 (90, 78 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque B137280E01 AC–262 AIR CONDITIONING – PLASMACLUSTER for TMC Made: COMBINATION METER ASSEMBLY INSTRUMENT CLUSTER FINISH PANEL without Smart Key System: LOWER INSTRUMENT PANEL FINISH PANEL with Smart Key System: AC NO. 1 INSTRUMENT PANEL SUB-ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL COWL SIDE TRIM SUB-ASSEMBLY LH COWL SIDE TRIM CLIP LOWER INSTRUMENT PANEL FINISH PANEL LH FRONT DOOR SCUFF PLATE LH B137281E01 AC–263 AIR CONDITIONING – PLASMACLUSTER for TMMK Made: COMBINATION METER ASSEMBLY without Smart Key System: INSTRUMENT CLUSTER FINISH PANEL LOWER INSTRUMENT PANEL FINISH PANEL with Smart Key System: AC NO. 1 INSTRUMENT PANEL SUB-ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL COWL SIDE TRIM SUB-ASSEMBLY LH COWL SIDE TRIM CLIP or

LOWER INSTRUMENT PANEL FINISH PANEL LH FRONT DOOR SCUFF PLATE LH B137281E03 AC–264 AIR CONDITIONING – PLASMACLUSTER for TMC Made: LOWER INSTRUMENT PANEL SUB-ASSEMBLY or COWL SIDE TRIM SUB-ASSEMBLY RH AC COWL SIDE TRIM CLIP FRONT DOOR SCUFF PLATE RH INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY B137282E01 AIR CONDITIONING – PLASMACLUSTER AC–265 for TMMK Made: LOWER INSTRUMENT PANEL SUB-ASSEMBLY or

COWL SIDE TRIM SUB-ASSEMBLY RH AC COWL SIDE TRIM CLIP FRONT DOOR SCUFF PLATE RH INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY B137282E03 AC–266 AIR CONDITIONING – PLASMACLUSTER NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH for Automatic Transaxle: SHIFT LEVER KNOB SUB-ASSEMBLY FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY AC UPPER CONSOLE REAR PANEL SUB-ASSEMBLY for Manual Transaxle: SHIFT LEVER KNOB SUB-ASSEMBLY UPPER CONSOLE PANEL UPPER CONSOLE REAR PANEL SUB-ASSEMBLY B137283E01 AIR CONDITIONING – PLASMACLUSTER AC–267 for TMC Made: INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY without Navigation System: with Navigation System: AC RADIO RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY NAVIGATION RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY UPPER CONSOLE PANEL SUB-ASSEMBLY B137284E01 AC–268 AIR CONDITIONING – PLASMACLUSTER for TMMK Made: INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY without Navigation System: with Navigation System: AC RADIO RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY NAVIGATION RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY UPPER CONSOLE PANEL SUB-ASSEMBLY B137284E03 AC–269 AIR CONDITIONING – PLASMACLUSTER for TMC Made: FRONT PILLAR GARNISH CLIP FRONT PILLAR GARNISH CLIP FRONT PILLAR GARNISH RH FRONT PILLAR GARNISH LH INSTRUMENT PANEL NO. 3 REGISTER ASSEMBLY INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY NO. 1 CONSOLE BOX INSERT FRONT AC NO. 2 CONSOLE BOX INSERT FRONT CONSOLE BOX CARPET CONSOLE BOX ASSEMBLY CONSOLE BOX POCKET Non-reusable part B137285E01 AC–270 AIR CONDITIONING – PLASMACLUSTER for TMMK Made: FRONT PILLAR GARNISH CLIP FRONT PILLAR GARNISH CLIP FRONT PILLAR GARNISH RH FRONT PILLAR GARNISH LH INSTRUMENT PANEL NO. 3 REGISTER ASSEMBLY INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY NO. 1 CONSOLE BOX INSERT FRONT AC or or NO. 2 CONSOLE BOX INSERT FRONT CONSOLE BOX CARPET CONSOLE BOX ASSEMBLY CONSOLE BOX POCKET Non-reusable part B137285E03 AC–271 AIR CONDITIONING – PLASMACLUSTER for TMC Made: INSTRUMENT PANEL NO. 1 SPEAKER PANEL SUB-ASSEMBLY INSTRUMENT PANEL NO. 2 SPEAKER PANEL SUB-ASSEMBLY NO. 1 DEFROSTER NOZZLE GARNISH for RH Side: for LH Side: FRONT NO. 2 SPEAKER ASSEMBLY FRONT NO. 2 SPEAKER ASSEMBLY AC or or or or 20 (204, 15) INSTRUMENT PANEL SAFETY PAD ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B137286E01 AC–272 AIR CONDITIONING – PLASMACLUSTER for TMMK Made: INSTRUMENT PANEL NO. 1 SPEAKER PANEL SUB-ASSEMBLY INSTRUMENT PANEL NO. 2 SPEAKER PANEL SUB-ASSEMBLY NO. 1 DEFROSTER NOZZLE GARNISH for RH Side: for LH Side: FRONT NO. 2 SPEAKER ASSEMBLY FRONT NO. 2 SPEAKER ASSEMBLY AC , or , or 20 (204, 15) INSTRUMENT PANEL SAFETY PAD ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B137286E03 AIR CONDITIONING – PLASMACLUSTER AC–273 5.4 (55, 48 in.*lbf) PLASMACLUSTER SIDE NO. 1 DEFROSTER NOZZLE DUCT AC NO. 1 HEATER TO REGISTER DUCT N*m (kgf*cm, ft.*lbf) : Specified torque E129992E01 FU–1 2GR-FE FUEL – FUEL SYSTEM FUEL SYSTEM PRECAUTION 1. Switch Type Ignition Switch off Expression Ignition Switch on (IG) Ignition Switch on (ACC) Engine Start 2. 3. A129607 EXPRESSIONS OF IGNITION SWITCH (a) The type of the ignition switch used on this model differs according to the specifications of the vehicle. The expressions listed in the table below are used in this section. Ignition Switch (position) Engine Switch (condition) LOCK Off ON On (IG) ACC On (ACC) START Start PRECAUTION (a) Before inspecting and repairing the fuel system, disconnect the negative (-) battery terminal. (b) Do not smoke or work near fire when handling the fuel system. (c) Keep gasoline away from rubber or leather parts. DISCHARGE FUEL SYSTEM PRESSURE CAUTION: • Perform the following procedures to prevent fuel from spilling out before removing any fuel system parts. • Pressure will still remain in the fuel line even after performing the following procedures. When disconnecting the fuel line, cover it with a shop rag or a piece of cloth to prevent fuel from spraying or coming out. (a) Disconnect the fuel pump connector. (1) Remove the rear seat cushion assembly. (2) Remove the rear floor service hole cover. (3) Disconnect the fuel pump connector. (4) Start the engine. (5) After the engine stops, turn the ignition switch off. HINT: DTC P0171/25 (fuel problem) and/or P0191/49 (fuel pressure sensor signal error) may be detected. (6) Crank the engine again. Check that the engine does not start. (7) Remove the fuel tank cap to discharge pressure from the fuel tank. (8) Disconnect the negative (-) battery terminal cable. (9) Reconnect the fuel pump connector. (10)Install the rear floor service hole cover. (11)Install the rear seat. FU FU–2 2GR-FE FUEL – FUEL SYSTEM 4. FUEL SYSTEM (a) When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe the following procedures: (1) Discharge the fuel system pressure. (step 3) (2) Disconnect the fuel pump tube (See page FU27). (3) Drain the fuel that remains inside the fuel pump tube. (4) To protect the disconnected fuel pump tube from damage and contamination, cover it with a plastic bag. (5) Put a container under the connection part. Plastic Bag B000679E07 (b) Observe the following precautions when removing and installing the fuel injectors: (1) Never reuse an O-ring. (2) When placing a new O-ring on the injector, do not damage the O-ring. (3) Coat a new O-ring with spindle oil or gasoline before installing it. NOTICE: Do not use engine oil, gear oil or brake fluid. CORRECT FU INCORRECT O-Ring Delivery Pipe A140742E01 Delivery Pipe O-ring Injector Intake Manifold Insulator A129458E01 (c) Install the injector to the delivery pipe and lower intake manifold as shown in the illustration. NOTICE: Before installing the injector, be sure to apply grease or gasoline to the place where the delivery pipe or cylinder head contacts the Oring of the injector. 2GR-FE FUEL – FUEL SYSTEM FU–3 (d) Observe the following precautions when disconnecting the fuel tube connectors (Quick type A): (1) Remove the No. 1 fuel pipe clamp. (2) Check that there is no dirt or other foreign objects on the pipe and around the connector before disconnecting them. Clean them if necessary. No. 1 Fuel Pipe Clamp A060083E16 (3) Disconnect the connector from the pipe by hand. (4) When the connector and the pipe are stuck, push in and pull on the connector to release it. Pull the connector out of the pipe carefully. (5) Check that there is no dirt or other foreign objects on the sealing surface of the disconnected pipe. Clean it away if necessary. Quick Type A A088336E10 (6) Do not damage the disconnected pipe and connector, and prevent entry of foreign objects by covering them with a plastic bag. Quick Type A Plastic Bag B009222E04 (e) Observe the following precautions when connecting the fuel tube connectors (Quick Type A): (1) Check if there is any damage or foreign objects on the connecting parts of the pipes. (2) Line up the two parts of the pipes to be connected, and push them together until the connector makes a "click" sound. If the pipe is difficult to push into the connector, apply a small amount of clean engine oil to the tip of the pipe and reinsert it. (3) After connecting the pipes, check that the pipe and connector are securely connected by pulling on them. (4) Check for fuel leaks. Quick Type A Push Pull A121423E01 FU FU–4 2GR-FE FUEL – FUEL SYSTEM (f) Quick Type B A129459E01 Observe the following precautions when disconnecting the fuel tube connector (Quick type B): (1) Before disconnecting the connector, clean off any dirt that may be present. (2) Pinch the tabs of the fuel tube retainer to disengage the 2 claws. Push the retainer down as shown in the illustration. HINT: Be sure to disconnect the connector by hand. (3) If the connector and pipe are stuck, hold the fuel pipe by hand, and push and pull on the connector. Pull the two pipes apart to separate the connector. (4) If there is any dirt or any other foreign objects on the sealing surfaces of the disconnected pipes, clean them if necessary. Quick Type B A091246E06 FU (5) Do not damage the disconnected pipe and connector, and prevent entry of foreign objects by covering them with a plastic bag. Quick Type B Plastic Bag A093309E03 Quick Type B A132390E01 (g) Observe the following precautions when connecting the fuel tube connector (Quick Type B): (1) Line up the two parts of the pipes to be connected, and fully push the fuel tube connector and pipe together until they are fully seated. Next, push the retainer into the connector until its claws lock. If the pipe is difficult to push in to the connector, apply a small amount of clean engine oil to the tip of the pipe and reinsert it. (2) After connecting the pipes, check that the pipe and connector are securely connected by pulling on them. (3) Check for fuel leaks. (h) Observe the following precautions when handling a nylon tube: CAUTION: • Do not twist the connection part of the nylon tube and the quick connector when connecting them. • Do not bend or twist the nylon tube. 2GR-FE FUEL – FUEL SYSTEM 5. FU–5 • Do not remove the EPDM protector on the outside of the nylon tube. • Do not close the piping by bending the nylon tube. CHECK FOR FUEL LEAKS (a) Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs (See page FU-8). FU FU–6 2GR-FE FUEL – FUEL SYSTEM PARTS LOCATION ECM FU FUEL PUMP ENGINE ROOM RELAY BLOCK FUEL INJECTOR A136014E01 FU–7 2GR-FE FUEL – FUEL SYSTEM SYSTEM DIAGRAM ECM C7 Fuel Injector (No. 1) IG2 IG2 From Battery 5 3 2 1 2 1 45 C55 #10 85 C55 #20 44 C55 #30 84 C55 #40 43 C55 #50 83 C55 #60 44 A55 MREL 7 A55 FC C9 Fuel Injector (No. 2) 2 1 C8 Fuel Injector (No. 3) 2 E23 Ignition Switch 1 C10 Fuel Injector (No. 4) ST/AM2 *2 From Battery 5 AM2 IG2 6 2 1 C36 Fuel Injector (No. 5) E6 Main Body ECU 2 1 FU C37 Fuel Injector (No. 6) IG2D *1 11 2 1 EFI MAIN From Battery EFI C/OPN N10 Fuel Suction Pump and Gauge Assembly 4 From Ignition Switch IGN 5 Pump *1: with Smart Key System *2: without Smart Key System A140778E01 FU–8 2GR-FE FUEL – FUEL SYSTEM ON-VEHICLE INSPECTION 1. CHECK FOR FUEL PUMP OPERATION AND FUEL LEAKS (a) Check fuel pump operation. (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch on (IG) and push the intelligent tester main switch on. NOTICE: Do not start the engine. (3) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / FUEL PUMP / SPD. (4) Check for pressure in the fuel inlet tube from the fuel line. Check that sound of fuel flowing in the fuel tank can be heard. If no sound can be heard, check the integration relay, fuel pump, ECM and wiring connector. (b) Check for fuel leaks. (1) Check that there are no fuel leaks anywhere on the system after performing maintenance. If there is a fuel leak, repair or replace parts as necessary. (c) Turn the ignition switch off. (d) Disconnect the intelligent tester from the DLC3. 2. CHECK FUEL PRESSURE (a) Discharge the fuel system pressure (See page FU1). (b) Using a voltmeter, measure the battery voltage. Standard voltage: 11 to 14 V (c) Disconnect the negative (-) battery terminal. (d) Disconnect the fuel hose from the fuel main tube (See page FU-1). FU 2GR-FE FUEL – FUEL SYSTEM SST (Clip) SST (T-joint) SST (Clip) SST (Gauge) SST (Hose) SST (Hose) SST (Clip) SST (Tube Connector) Fuel Tube A129461E01 FU–9 (e) Install SST (pressure gauge) using SST and a fuel tube connector as shown in the illustration. SST 09268-31011 (09268-41500, 90467-13001, 95336-08070), 09268-45014 (09268-41200, 09268-41220, 09268-41250) (f) Wipe up any gasoline. (g) Connect the negative (-) battery terminal. (h) Connect the intelligent tester to the DLC3. (i) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / FUEL PUMP / SPD. (j) Measure the fuel pressure. Fuel pressure: 304 to 343 kPa (3.1 to 3.5 kgf*cm2, 44.1 to 49.7 psi) • If the fuel pressure is greater than the standard value, replace the fuel pressure regulator. • If the fuel pressure is less than the standard value, check the fuel hoses and connections, fuel pump, fuel filter and fuel pressure regulator. (k) Disconnect the intelligent tester from the DLC3. (l) Start the engine. (m) Measure the fuel pressure at idle. Fuel pressure: 304 to 343 kPa (3.1 to 3.5 kgf*cm2, 44.1 to 49.7 psi) (n) Stop the engine. (o) Check that the fuel pressure remains as specified for 5 minutes after the engine stops. Fuel pressure: 147 kPa (1.5 kgf*cm2, 21 psi) or more If the fuel pressure is not as specified, check the fuel pump, pressure regulator and/or fuel injectors. (p) After checking the fuel pressure, carefully disconnect the negative (-) battery cable, and remove the SST and fuel tube connector to prevent gasoline from splashing. (q) Reconnect the fuel tube to the main fuel tube (fuel tube connector). (r) Install the No. 1 fuel pipe clamp to the fuel tube connector. (s) Check for fuel leaks (step 1). FU FU–10 2GR-FE FUEL – FUEL INJECTOR FUEL INJECTOR 2GR-FE FUEL ENGINE COMPONENTS FRONT WIPER ARM AND BLADE ASSEMBLY LH 20 (204, 15) FRONT WIPER ARM AND BLADE ASSEMBLY RH 20 (204, 15) FRONT FENDER TO COWL SIDE SEAL RH COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY CLIP x2 AIR CLEANER CAP SUB-ASSEMBLY 7.0 (71, 62 in.*lbf) x4 80 (816, 59) FRONT FENDER TO COWL SIDE SEAL LH FU WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 5.0 (51, 44 in.*lbf) COWL TOP PANEL OUTER SUB-ASSEMBLY AIR CLEANER FILTER ELEMENT V-BANK COVER SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque A137328E01 FU–11 2GR-FE FUEL – FUEL INJECTOR UNION TO CHECK VALVE HOSE INTAKE AIR SURGE TANK ASSEMBLY CONNECTOR * 21 (214, 15) 5.4 (55, 48 in.*lbf) NO. 1 VENTILATION HOSE 16 (163, 12) HOSE CLAMP x4 * 18 (184, 13) VACUUM HOSE 16 (163, 12) * 21 (214, 15) AIR FLOW METER CONNECTOR VAPOR FEED HOSE NO. 2 WATER BY-PASS HOSE NO. 3 WATER BY-PASS HOSE AIR SURGE TANK TO INTAKE MANIFOLD GASKET N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part * DO NOT apply oil A114551E03 FU FU–12 2GR-FE FUEL – FUEL INJECTOR WIRE HARNESS 21 (214, 15) 21 (214, 15) FUEL TUBE SUB-ASSEMBLY 21 (214, 15) 21 (214, 15) FU NO. 2 FUEL PIPE CLAMP O-RING WIRE HARNESS FUEL INJECTOR ASSEMBLY FUEL DELIVERY PIPE SUB-ASSEMBLY INJECTOR VIBRATION INSULATOR N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A114552E03 2GR-FE FUEL – FUEL INJECTOR FU–13 REMOVAL 1. DISCHARGE FUEL SYSTEM PRESSURE HINT: See page FU-1. 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 3. DRAIN ENGINE COOLANT (See page CO-5) 4. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH (See page WW-9) 5. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH (See page WW-9) 6. REMOVE FRONT FENDER TO COWL SIDE SEAL LH (See page WW-9) 7. REMOVE FRONT FENDER TO COWL SIDE SEAL RH (See page WW-9) 8. REMOVE COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See page WW-10) 9. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (See page WW-10) 10. REMOVE COWL TOP PANEL OUTER SUBASSEMBLY (See page ES-481) 11. REMOVE V-BANK COVER SUB-ASSEMBLY (See page EM-23) 12. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-503) (b) (c) (a) (a) (c) 13. REMOVE INTAKE AIR SURGE TANK ASSEMBLY (a) Disconnect the 2 water by-pass hoses from the throttle with motor body assembly. (b) Disconnect the vapor feed hose. (c) Disconnect the throttle with motor body assembly connector and clamp. A129464E01 (d) Disconnect the No. 1 ventilation hose. (e) Disconnect the union to check valve hose. (d) (e) (e) A129465E05 FU FU–14 2GR-FE FUEL – FUEL INJECTOR (f) Remove the bolt and vacuum hose clamp. A129466 (g) Disconnect the connector. A129467 FU (i) (i) (h) (h) (h) (i) (h) Using a 5 mm socket hexagon wrench, remove the 4 bolts. (i) Remove the 2 nuts, 2 bolts and intake air surge tank. (j) Remove the gasket from the intake air surge tank. (h) (i) A129468E01 Pinch Pull Pinch Fuel Pipe Clamp Tube Connector Nylon Tube O-Ring Pipe A129469E02 14. DISCONNECT FUEL TUBE SUB-ASSEMBLY (a) Remove the No. 2 fuel pipe clamp. (b) Pinch the tube connector and then pull out the fuel pipe. NOTICE: • Check that there is no dirt or other foreign objects around the connector before this operation and clean the connector as necessary. • It is necessary to prevent mud or dirt from entering the quick connector. If mud enters the connector, the O-rings may not seal properly. • Remove the quick connector by hand. • Do not bend or twist the nylon tube. Protect the connector by covering it with a plastic bag. • If the pipe and the connector are stuck, try wiggling or pushing and pulling the connector to release it and pull the connector off of the pipe carefully. 2GR-FE FUEL – FUEL INJECTOR FU–15 15. REMOVE FUEL INJECTOR ASSEMBLY (a) Disconnect the 6 fuel injector connectors. A137341 (b) Remove the 5 bolts and fuel delivery pipe together with the 6 fuel injectors. NOTICE: Be careful not to drop the fuel injectors when removing the fuel delivery pipe. A129471 (c) Remove the 6 insulators from the intake manifold. A129472 (d) Pull out the fuel injectors from the fuel delivery pipe. A129473 (e) Remove the 6 O-rings from the injectors. O-Ring A129475E02 FU FU–16 2GR-FE FUEL – FUEL INJECTOR INSPECTION 1. Fuel Tube SST (Tube Connector) Clip FU SST (Hose) (1) Install the fuel tube connector to SST (hose), then connect the tube connector to the fuel pipe (vehicle side). SST 09268-31011 (09268-41500, 9046713001, 95336-08070) (2) Install the O-ring to the fuel injector. A088228E05 O-Ring SST SST (Adaptor) SST (Clamp) Vinyl Tube A129474E01 Connect INSPECT FUEL INJECTOR ASSEMBLY (a) Inspect injector resistance. (1) Using an ohmmeter, measure the resistance between the terminals. Resistance: 11.6 to 12.4 Ω at 20°C (68°F) If the resistance is not as specified, replace the injector. (b) Inspect the injection volume. CAUTION: This test involves high-pressure fuel and electricity. Take every precaution regarding safe handling of both the fuel and the electricity. Perform this test in a safe area, and avoid any sparks or flames. Do not smoke. SST (Wire) A075915E04 (3) Connect SST (adaptor and hose) to the injector, and hold the injector and union with SST (clamp). SST 09268-31011 (90467-13001, 9533608070), 09268-41140, 09268-41400 (4) Put the injector into the graduated cylinder. CAUTION: Install a suitable vinyl tube onto the injector to contain gasoline spray. (5) Operate the fuel pump (See page FU-8). (6) Connect SST (wire) to the injector and the battery for 15 seconds, and measure the injection volume with the graduated cylinder. Test each injector 2 or 3 times. SST 09842-30080 Volume: 84 to 100 cm3 (5.1 to 6.0 cu in.) in 15 seconds Difference between each injector: 16 cm3 (0.98 cu in.) or less If the injection volume is not as specified, replace the injector. 2GR-FE FUEL – FUEL INJECTOR FU–17 (c) Check for leakage. (1) In the condition above, disconnect the tester probes of SST (wire) from the battery and check for fuel leakage from the injector. Fuel drop: 1 drop or less in 16 minutes A132391 INSTALLATION 1. INSTALL FUEL INJECTOR ASSEMBLY (a) Apply a light coat of spindle oil or gasoline to new Orings, and install them to each injector. New O-Ring A129475E01 Turn Push A129476E01 (b) Apply a light coat of spindle oil or gasoline where the fuel delivery pipe contacts the O-ring. (c) Push the fuel injector while turning it to install the injector in the fuel delivery pipe. (d) Position the fuel injector connector outward. NOTICE: • Be careful not to twist the O-ring. • After installing the fuel injector, check that it turns smoothly. If not, reinstall it with a new O-ring. (e) Install 6 new insulators to the intake manifold. A129472 (f) A129471 Place the fuel delivery pipe and the 6 fuel injectors together to the intake manifold. NOTICE: Be careful not to drop the fuel injectors when installing the fuel delivery pipe. (g) Temporarily install the 5 bolts which are used to hold the fuel delivery pipe to the intake manifold. NOTICE: After installing the fuel injector, check that it turns smoothly. If not, reinstall it with a new Oring. FU FU–18 2GR-FE FUEL – FUEL INJECTOR (h) Tighten the 5 bolts which are used to hold the fuel delivery pipe to the intake manifold. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) (i) Connect the 6 fuel injector connectors. A137341 FU 2. CONNECT FUEL TUBE SUB-ASSEMBLY (a) Push in the tube connector to the pipe until the tube connector makes a "click" sound. NOTICE: • Before connecting the tube, make sure that it is not damaged. Make sure that there is no dirt present on the connecting surfaces. • After connecting, check if the fuel tube connector and the pipe are securely connected by pulling on them. (b) Install the No. 2 fuel pipe clamp. 3. INSTALL INTAKE AIR SURGE TANK ASSEMBLY NOTICE: DO NOT apply oil to the bolts as listed below Fuel Pipe Clamp A129477E01 Tightening Parts (c) (c) (b) (b) (b) (b) (c) (c) A129468E03 Torque N*m (kgf*cm, ft.*lbf) QTY Surge Tank and Intake Manifold 18 (184, 13) 4 No. 1 Surge Tank Stay and Surge Tank 21 (214, 15) 1 Throttle Body Bracket and Surge Tank 21 (214, 15) 1 (a) Install a new gasket to the intake air surge tank. (b) Using a 5 mm hexagon socket wrench, install the 4 bolts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) (c) Install the intake air surge tank with the 2 nuts and 2 bolts. Torque: Nut 16 N*m (163 kgf*cm, 12 ft.*lbf) Bolt 21 N*m (214 kgf*cm, 15 ft.*lbf) 2GR-FE FUEL – FUEL INJECTOR FU–19 (d) Connect the connector. A129467 (e) Install the vacuum hose clamp with the bolt. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) A129466 (f) Connect the union to check valve hose. (g) Connect the No. 1 ventilation hose. (g) (f) (f) A129465E06 (h) Install the clamp and connect the throttle with motor body assembly connector. (i) Connect the vapor feed hose. (j) Connect the 2 water by-pass hoses to the throttle with motor body assembly. (i) (h) (j) (j) (h) A129464E02 4. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See page ES-506) 5. ADD ENGINE COOLANT (See page CO-6) 6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 7. CHECK FOR ENGINE COOLANT LEAKS (See page CO-1) 8. CHECK FOR FUEL LEAKS (See page FU-8) 9. INSTALL COWL TOP PANEL OUTER SUBASSEMBLY (See page ES-485) 10. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (See page WW-14) FU FU–20 2GR-FE FUEL – FUEL INJECTOR 11. INSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See page WW-15) 12. INSTALL FRONT FENDER TO COWL SIDE SEAL RH (See page WW-15) 13. INSTALL FRONT FENDER TO COWL SIDE SEAL LH (See page WW-15) 14. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH (See page WW-15) 15. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH (See page WW-16) 16. INSTALL V-BANK COVER SUB-ASSEMBLY (See page EM-52) FU FU–21 2GR-FE FUEL – FUEL PRESSURE PULSATION DAMPER FUEL PRESSURE PULSATION DAMPER 2GR-FE FUEL ENGINE COMPONENTS FRONT WIPER ARM AND BLADE ASSEMBLY LH 20 (204, 15) FRONT WIPER ARM AND BLADE ASSEMBLY RH 20 (204, 15) FRONT FENDER TO COWL SIDE SEAL RH COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY CLIP x2 AIR CLEANER CAP SUB-ASSEMBLY 7.0 (71, 62 in.*lbf) x4 80 (816, 59) FRONT FENDER TO COWL SIDE SEAL LH FU WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 5.0 (51, 44 in.*lbf) COWL TOP PANEL OUTER SUB-ASSEMBLY AIR CLEANER FILTER ELEMENT V-BANK COVER SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque A137328E01 FU–22 2GR-FE FUEL – FUEL PRESSURE PULSATION DAMPER UNION TO CHECK VALVE HOSE INTAKE AIR SURGE TANK ASSEMBLY CONNECTOR * 21 (214, 15) 5.4 (55, 48 in.*lbf) NO. 1 VENTILATION HOSE 16 (163, 12) HOSE CLAMP * 18 (184, 13) x4 * 21 (214, 15) VACUUM HOSE AIR FLOW METER CONNECTOR FU 16 (163, 12) VAPOR FEED HOSE NO. 2 WATER BY-PASS HOSE NO. 3 WATER BY-PASS HOSE AIR SURGE TANK TO INTAKE MANIFOLD GASKET CLIP FUEL PRESSURE PULSATION DAMPER ASSEMBLY O-RING N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part * DO NOT apply oil A114553E02 2GR-FE FUEL – FUEL PRESSURE PULSATION DAMPER FU–23 REMOVAL 1. DISCHARGE FUEL SYSTEM PRESSURE HINT: See page FU-1 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 3. DRAIN ENGINE COOLANT (See page CO-5) 4. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH (See page WW-9) 5. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH (See page WW-9) 6. REMOVE FRONT FENDER TO COWL SIDE SEAL LH (See page WW-9) 7. REMOVE FRONT FENDER TO COWL SIDE SEAL RH (See page WW-9) 8. REMOVE COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See page WW-10) 9. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (See page WW-10) 10. REMOVE COWL TOP PANEL OUTER SUBASSEMBLY (See page ES-481) 11. REMOVE V-BANK COVER SUB-ASSEMBLY (See page EM-23) 12. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-503) 13. REMOVE INTAKE AIR SURGE TANK ASSEMBLY (See page FU-13) Clip Pulsation Damper O-Ring 14. REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY (a) Remove the clip. (b) Pull out the fuel pressure pulsation damper from the fuel delivery pipe. (c) Remove the O-ring from the fuel pressure pulsation damper. A129609E01 Clip Pulsation Damper INSTALLATION 1. O-Ring A129609E01 INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY (a) Apply a light coat of spindle oil or gasoline to a new O-ring and install it to the fuel pressure pulsation damper. (b) Install the fuel pressure pulsation damper to the fuel delivery pipe. (c) Install the clip. FU FU–24 2GR-FE FUEL – FUEL PRESSURE PULSATION DAMPER 2. INSTALL INTAKE AIR SURGE TANK ASSEMBLY (See page FU-18) 3. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See page ES-506) 4. ADD ENGINE COOLANT (See page CO-6) 5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 6. CHECK FOR ENGINE COOLANT LEAKS (See page CO-1) 7. CHECK FOR FUEL LEAKS (See page FU-8) 8. INSTALL COWL TOP PANEL OUTER SUBASSEMBLY (See page ES-485) 9. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (See page WW-14) 10. INSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See page WW-15) FU 11. INSTALL FRONT FENDER TO COWL SIDE SEAL RH (See page WW-15) 12. REMOVE FRONT FENDER TO COWL SIDE SEAL LH (See page WW-15) 13. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH (See page WW-15) 14. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH (See page WW-16) 15. INSTALL V-BANK COVER SUB-ASSEMBLY (See page EM-52) 2GR-FE FUEL – FUEL PUMP FU–25 FUEL PUMP 2GR-FE FUEL ENGINE COMPONENTS REAR SEAT CUSHION ASSEMBLY FU REAR FLOOR SERVICE HOLE COVER FUEL PUMP TUBE SUB-ASSEMBLY TUBE JOINT CLIP 5.9 (60, 52 in.*lbf) x8 FUEL TANK VENT TUBE SET PLATE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE GASKET N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A131719E01 FU–26 2GR-FE FUEL – FUEL PUMP FUEL SUCTION PLATE SUB-ASSEMBLY FUEL PUMP HARNESS FU FUEL SENDER GAUGE ASSEMBLY O-RING FUEL PRESSURE REGULATOR ASSEMBLY FUEL FILTER FUEL PUMP FUEL PUMP CUSHION RUBBER NO. 2 FUEL SUCTION SUPPORT Non-reusable part A136243E01 2GR-FE FUEL – FUEL PUMP FU–27 REMOVAL 1. DISCHARGE FUEL SYSTEM PRESSURE HINT: See page FU-1. 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 3. REMOVE REAR SEAT CUSHION ASSEMBLY (for Fixed Seat Type) (See page SE-77) 4. REMOVE REAR SEAT CUSHION ASSEMBLY (for Fold Down Seat Type) (See page SE-47) 5. REMOVE REAR SEAT CUSHION ASSEMBLY (for Reclining Seat Type) (See page SE-62) 6. REMOVE REAR FLOOR SERVICE HOLE COVER (a) Remove the rear floor service hole cover. (b) Disconnect the fuel pump connector. FU A129478 Tube Joint Clip Fuel Tube Joint Fuel Tube O-Ring Tube Joint Clip A136246E01 7. SEPARATE FUEL PUMP TUBE SUB-ASSEMBLY (a) Remove the tube joint clip, and pull out the fuel pump tube. NOTICE: • Check that there is no dirt around the fuel tube joint before this work and clean any dirt away. • It is necessary to prevent mud or dirt from entering the fuel tube joint. If mud enters the joint, the O-rings may not seal the fuel tube connector and fuel suction plate properly. • Do not use any tools in this work. • Do not bend or twist the nylon tube. • After disconnecting, cover the fuel tube joint with a plastic bag. • If the fuel tube joint and fuel suction plate are stuck, pinch the fuel tank tube between fingers, and turn it carefully to release. Disconnect the fuel tank tube. FU–28 2GR-FE FUEL – FUEL PUMP 8. REMOVE FUEL TANK VENT TUBE SET PLATE (a) Remove the 8 bolts and set plate. 9. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE (a) Pull out the fuel suction tube from the fuel tank. NOTICE: • Do not damage the fuel pump filter. • Be careful that the arm of the sender gauge does not bend. (b) Remove the gasket from the fuel suction tube. A129480 A129481 FU DISASSEMBLY Tape 1. REMOVE NO. 2 FUEL SUCTION SUPPORT (a) Using a screwdriver with its tip wrapped with tape, disengage the 5 snap claws from the claw holes, and remove the No. 2 fuel suction support. NOTICE: Do not damage the fuel suction support. 2. REMOVE FUEL PUMP CUSHION RUBBER (a) Remove the fuel pump cushion rubber from the fuel pump. 3. REMOVE FUEL SENDER GAUGE ASSEMBLY (a) Disconnect the fuel sender gauge connector (*1). (b) Unlock the fuel sender gauge, and slide it to remove (*2). A077832E05 A079492E01 (*1) Slide (*2) A129482E02 2GR-FE FUEL – FUEL PUMP FU–29 4. REMOVE FUEL SUCTION PLATE SUB-ASSEMBLY (a) Disconnect the fuel pump connector (*1). (b) Using a screwdriver with its tip wrapped with tape, disengage the 4 snap claws from the claw holes, and pull out the fuel suction plate. NOTICE: Do not damage the fuel suction support. 5. REMOVE FUEL PUMP HARNESS (a) Disconnect the connector (*1). (b) Using a screwdriver, pry out the fuel pump harness (*2). 6. REMOVE FUEL PUMP (a) Pull out the fuel pump from the fuel filter. 7. REMOVE FUEL PRESSURE REGULATOR ASSEMBLY (a) Pull out the fuel pressure regulator from the fuel filter. Tape (*1) A129483E02 (*2) (*1) (*2) A079495E05 A079496E01 A133536E01 (b) Remove the O-ring from the fuel pressure regulator. O-Ring A133534E02 FU FU–30 Component Side: 2GR-FE FUEL – FUEL PUMP INSPECTION Fuel Pump 1. A095616E06 FU INSPECT FUEL PUMP (a) Inspect fuel pump resistance. (1) Using an ohmmeter, measure the resistance between the terminals. Resistance: 0.2 to 3.0 Ω at 20°C (68°F) If the result is not as specified, replace the fuel pump assembly. (b) Inspect fuel pump operation. (1) Apply battery voltage to both the terminals. Check that the pump operates. NOTICE: • These tests must be done quickly (within 10 seconds) to prevent damage to the pump. • Keep the fuel pump as far away from the battery as possible. • Always switch the voltage on and off on the battery side, not on the fuel pump side. If the pump does not operate, replace the fuel pump assembly. REASSEMBLY O-Ring 1. INSTALL FUEL PRESSURE REGULATOR ASSEMBLY (a) Apply a light coat of spindle oil or gasoline to a new O-ring, and install it to the fuel pressure regulator. A133534E01 (b) Push in the fuel pressure regulator to the fuel filter. A065037 2GR-FE FUEL – FUEL PUMP FU–31 2. INSTALL FUEL PUMP (a) Apply a light coat of gasoline or grease to the O-ring of the fuel pump. (b) Push in the fuel pump to the fuel filter. 3. INSTALL FUEL PUMP HARNESS (a) Connect the connector (*1). (b) Install the fuel pump harness (*2). 4. INSTALL FUEL SUCTION PLATE SUB-ASSEMBLY (a) Connect the fuel pump connector (*1). (b) Install the fuel suction plate. 5. INSTALL FUEL SENDER GAUGE ASSEMBLY (a) Slide the fuel sender gauge to engage with the claw (*1). (b) Connect the fuel sender gauge connector (*2). 6. INSTALL FUEL PUMP CUSHION RUBBER (a) Install the fuel pump cushion rubber to the fuel pump. A079496E01 (*2) (*1) (*2) A079495E05 (*1) A129485E02 (*2) Slide (*1) A136741E01 A079492E01 FU FU–32 2GR-FE FUEL – FUEL PUMP 7. INSTALL NO. 2 FUEL SUCTION SUPPORT (a) Install the No. 2 fuel suction support. A129487 INSTALLATION 1. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE (a) Install a new gasket to the fuel suction tube. (b) Install the fuel suction tube. NOTICE: • Do not damage the fuel pump filter. • Be careful that the arm of the sender gauge does not bend. 2. INSTALL FUEL TANK VENT TUBE SET PLATE (a) Align the mark of the set plate with the fuel suction tube. (b) Install the set plate with the 8 bolts. Torque: 5.9 N*m (60 kgf*cm, 52 in.*lbf) A129481 FU Mark A129480E01 2GR-FE FUEL – FUEL PUMP FU–33 3. CONNECT FUEL PUMP TUBE SUB-ASSEMBLY (a) Install the fuel pump tube with the tube joint clip. NOTICE: • Check that there are no scratches or foreign objects on the connecting part. • Check that the fuel tube joint is inserted securely. • Check that the tube joint clip is on the collar of the fuel tube joint. • After installing the tube joint clip, check that the fuel tube joint is pulled off. 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 5. CHECK FOR FUEL LEAKS (See page FU-8) Tube Joint Clip Fuel Tube Joint Fuel Tube O-Ring Tube Joint Clip Tube Joint Clip FU Collars Collars CORRECT INCORRECT A136247E01 A129478 6. INSTALL REAR FLOOR SERVICE HOLE COVER (a) Connect the fuel pump connector. (b) Install the rear floor service hole cover with new butyl tape. 7. INSTALL REAR SEAT CUSHION ASSEMBLY (for Fixed Seat Type) (See page SE-84) 8. INSTALL REAR SEAT CUSHION ASSEMBLY (for Fold Down Seat Type) (See page SE-58) 9. INSTALL REAR SEAT CUSHION ASSEMBLY (for Reclining Seat Type) (See page SE-73) FU–34 2GR-FE FUEL – FUEL TANK FUEL TANK 2GR-FE FUEL ENGINE COMPONENTS REAR SEAT CUSHION ASSEMBLY FU REAR FLOOR SERVICE HOLE COVER FUEL PUMP TUBE SUB-ASSEMBLY TUBE JOINT CLIP 5.9 (60, 52 in.*lbf) x8 FUEL TANK VENT TUBE SET PLATE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE GASKET N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A131719E01 FU–35 2GR-FE FUEL – FUEL TANK NO. 1 FUEL TUBE FUEL TANK ASSEMBLY HOSE CLAMP FUEL TANK TO FILLER PIPE HOSE For SE Grade: FUEL TANK PROTECTOR LOWER CENTER FUEL TANK PROTECTOR LOWER CENTER FU x4 5.4 (55, 48 in.*lbf) FUEL TANK BAND 39 (400, 29) 39 (400, 29) PIN FUEL TANK BAND 6.0 (61, 53 in.*lbf) GASKET PIN NO. 2 PARKING BRAKE CABLE ASSEMBLY 43 (438, 32) 6.0 (61, 53 in.*lbf) 43 (438, 32) 43 (438, 32) 8.5 (87, 75 in.*lbf) 8.5 (87, 75 in.*lbf) NO. 3 PARKING BRAKE CABLE ASSEMBLY GASKET 43 (438, 32) 56 (571, 41) GASKET CENTER EXHAUST PIPE ASSEMBLY 56 (571, 41) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A136744E01 FU–36 2GR-FE FUEL – FUEL TANK FUEL PUMP TUBE SUB-ASSEMBLY FUEL TANK ASSEMBLY NO. 2 FUEL TANK CUSHION X7 FUEL TANK VENT HOSE FU CLIP NUT X4 5.4 (55, 48 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque FUEL MAIN TUBE SUPPORT Non-reusable part A109012E08 2GR-FE FUEL – FUEL TANK FU–37 REMOVAL 1. DISCHARGE FUEL SYSTEM PRESSURE HINT: See page FU-1. 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 3. REMOVE REAR SEAT CUSHION ASSEMBLY (for Fixed Seat Type) (See page SE-77) 4. REMOVE REAR SEAT CUSHION ASSEMBLY (for Fold Down Seat Type) (See page SE-47) 5. REMOVE REAR SEAT CUSHION ASSEMBLY (for Reclining Seat Type) (See page SE-62) 6. REMOVE REAR FLOOR SERVICE HOLE COVER (See page FU-27) 7. SEPARATE FUEL PUMP TUBE SUB-ASSEMBLY (See page FU-27) 8. REMOVE FUEL TANK VENT TUBE SET PLATE (See page FU-28) 9. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE (See page FU-28) 10. DRAIN FUEL 11. REMOVE CENTER EXHAUST PIPE ASSEMBLY (See page EX-2) 12. DISCONNECT NO. 2 PARKING BRAKE CABLE ASSEMBLY (a) Remove the set bolt and set nut of the No. 2 parking brake cable assembly. A135222 13. DISCONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY (a) Remove the set bolt and set nut of the No. 3 parking brake cable assembly. A135223 FU FU–38 2GR-FE FUEL – FUEL TANK 14. REMOVE REAR STABILIZER BAR NO. 1 BRACKET (a) Remove the 4 bolts and 2 rear stabilizer bar No. 1 brackets. A136008E01 15. REMOVE FUEL TANK PROTECTOR LOWER CENTER (a) Remove the 4 bolts and fuel tank protector (Except SE Grade). A135224 FU (b) Remove the 4 bolts and 2 clips (for SE Grade). (c) Remove the fuel tank protector (for SE Grade). Clip A135225E01 Pinch Retainer Pull Pull Pinch Fuel Tube Connector Retainer Pipe O-Ring A121573E02 16. REMOVE FUEL TANK ASSEMBLY (a) Disconnect the fuel pump tube. (1) Pinch the tab of the retainer to disengage the lock claws and pull it down as shown in the illustration. (2) Pull out the fuel tank main tube. NOTICE: • Check that there is no dirt or other foreign objects around the connector before this operation and clean the connector if necessary. • It is necessary to prevent mud or dirt from entering the quick connector. If mud enters the connector, the O-rings may not seal properly. • Remove the quick connector by hand. • Do not bend or twist the nylon tube. Protect the connector by covering it with a plastic bag. 2GR-FE FUEL – FUEL TANK FU–39 • If the pipe and connector are stuck, try wiggling or pushing and pulling the connector to release it and pull the connector off of the pipe carefully. Pinch Pull Pinch Tube Connector Nylon Tube O-Ring Pipe (b) Disconnect the No. 1 fuel tube. (1) Pinch the tube connector and then pull out the No. 1 fuel tube. NOTICE: • Check that there is no dirt or other foreign objects around the connector before this operation and clean the connector as necessary. • It is necessary to prevent mud or dirt from entering the quick connector. If mud enters the connector, the O-rings may not seal properly. • Remove the quick connector by hand. • Do not bend or twist the nylon tube. Protect the connector by covering it with a plastic bag. • If the pipe and connector are stuck, try wiggling or pushing and pulling the connector to release it and pull the connector off of the pipe carefully. A121576E01 (c) Place a engine lifter under the fuel tank assembly. A136009 FU FU–40 2GR-FE FUEL – FUEL TANK (*1) (d) Remove the 2 set bolts of the fuel tank bands. (*1) (e) Remove the hose clamp and disconnect the fuel tank to filter pipe hose. (*2) (f) Slightly lower the transmission jack. (g) Disconnect the fuel tank vent hose from the charcoal canister. (*3) (1) Push the connector deep into the charcoal canister to release the locking pin. (2) Pinch portion A. (3) Pull out the connector. (h) Remove the fuel tank. (*1) Pinch (*3) Push Pinch A (*2) A A091352E05 FU (i) Remove the 2 pins and 2 fuel tank bands as shown in the illustration. (j) Remove the 4 clip nuts (Except SE Grade). A079478 A136004 (k) Remove the 4 clip nuts (for SE Grade). A136005 2GR-FE FUEL – FUEL TANK Push A FU–41 17. REMOVE FUEL TANK VENT HOSE (a) Push the connector deep into the charcoal canister to release the locking pin. (b) Pinch portion A. (c) Pull out the connector. A Pinch Pinch A079479E03 18. REMOVE FUEL PUMP TUBE SUB-ASSEMBLY (a) Remove the fuel pump tube from the fuel main tube support. A079480 19. REMOVE FUEL MAIN TUBE SUPPORT (a) Remove the bolt and tube support. A079481 20. REMOVE NO. 2 FUEL TANK CUSHION (a) Remove the 7 No. 2 fuel tank cushions. A079484 INSTALLATION 1. A079484 INSTALL NO. 2 FUEL TANK CUSHION (a) Install 7 new No. 2 fuel tank cushions to the fuel tank. FU FU–42 2GR-FE FUEL – FUEL TANK 2. INSTALL FUEL MAIN TUBE SUPPORT (a) Install the fuel main tube support with the bolt. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 3. INSTALL FUEL PUMP TUBE SUB-ASSEMBLY (a) Install the fuel pump tube to the fuel main tube support. 4. INSTALL FUEL TANK VENT HOSE (a) Install the fuel tank vent hose. 5. INSTALL FUEL TANK ASSEMBLY (a) Install the 4 clip nuts (Except SE Grade). A079481 A079480 FU A129490 A136004 (b) Install the 4 clip nuts (for SE Grade). A136005 2GR-FE FUEL – FUEL TANK FU–43 (c) Install the 2 fuel tank bands with the 2 pins. (d) Set the fuel tank assembly onto the transmission jack. A129491 (e) Raise the transmission jack so that the fuel tank vent hose can be connected. (*1) NOTICE: Slowly raise the jack to prevent the fuel tank assembly from dropping. (f) Connect the fuel tank inlet pipe with the fuel filter pipe clamp. (*2) (g) Tighten the 2 set bolts of the fuel tank bands. (*3) Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) (*3) (*1) FU (*3) (*2) A129492E02 Fuel Tube Connector Pipe A091572E03 (h) Connect the No. 1 fuel tube. (1) Push the fuel tube connector into the pipe until the fuel tube connector makes a "click" sound. NOTICE: • Before connecting the tube, make sure that it is not damaged. Make sure that there is no dirt present on the connecting surfaces. • After connecting, check if the fuel tube connector and the pipe are securely connected by pulling on them. (i) Retainer A081598E03 Connect the fuel pump tube. (1) Push the fuel tube connector into the pipe and push up the retainer so that the claws engage. NOTICE: • Before connecting the tube, make sure that it is not damaged. Make sure that there is no dirt present on the connecting surfaces. FU–44 2GR-FE FUEL – FUEL TANK • After connecting, check if the fuel tube connector and the pipe are securely connected by pulling on them. 6. INSTALL FUEL TANK PROTECTOR LOWER CENTER (a) Install the 4 bolts and fuel tank protector (Except SE Grade). Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) A135224 (b) Install the fuel tank protector with the 4 bolts and 2 clips (for SE Grade). Torque: Bolt 5.4 N*m (55 kgf*cm, 48 in.*lbf) Clip FU A135225E01 7. INSTALL REAR STABILIZER BAR NO. 1 BRACKET (a) Install the 2 rear stabilizer bar No. 1 brackets with the 4 bolts. Torque: 31 N*m (316 kgf*cm, 23 ft.*lbf) 8. INSTALL NO. 3 PARKING BRAKE CABLE ASSEMBLY (a) Install the No. 3 parking brake cable assembly with the bolt and nut. Torque: Bolt 6.0 N*m (61 kgf*cm, 53 in.*lbf) Nut 8.5 N*m (87 kgf*cm, 75 in.*lbf) A136008E01 A135223 2GR-FE FUEL – FUEL TANK 9. FU–45 INSTALL NO. 2 PARKING BRAKE CABLE ASSEMBLY (a) Install the No. 2 parking brake cable assembly with the bolt and nut. Torque: Bolt 6.0 N*m (61 kgf*cm, 53 in.*lbf) Nut 8.5 N*m (87 kgf*cm, 75 in.*lbf) 10. INSTALL CENTER EXHAUST PIPE ASSEMBLY (See page EX-4) A135222 11. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE (See page FU-32) 12. INSTALL FUEL TANK VENT TUBE SET PLATE (See page FU-32) 13. CONNECT FUEL PUMP TUBE SUB-ASSEMBLY (See page FU-33) 14. ADD FUEL 15. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 16. CHECK FOR FUEL LEAKS (See page FU-8) 17. CHECK FOR EXHAUST GAS LEAKS 18. INSTALL REAR FLOOR SERVICE HOLE COVER (See page FU-33) 19. INSTALL REAR SEAT CUSHION ASSEMBLY (for Fixed Seat Type) (See page SE-84) 20. INSTALL REAR SEAT CUSHION ASSEMBLY (for Fold Down Seat Type) (See page SE-58) 21. INSTALL REAR SEAT CUSHION ASSEMBLY (for Reclining Seat Type) (See page SE-73) FU CC–1 CRUISE CONTROL – CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM PRECAUTION 1. Switch Type Expression EXPRESSIONS OF IGNITION SWITCH (a) The type of ignition switch used on this model differs according to the specifications of the vehicle. Ignition Switch (position) Engine Switch (condition) Ignition switch off LOCK Off Ignition switch on (IG) ON On (IG) Ignition switch on (ACC) ACC On (ACC) Engine start START Start 2. HANDLING PRECAUTION FOR CRUISE CONTROL SYSTEM (a) Turn the cruise control main switch off when not using the cruise control system. (b) Be careful as the vehicle speed increases when driving downhill with the cruise control system on. (c) The + (ACCEL)/RES (RESUME) operation changes according to the cruise control system status. When the cruise control system is operating, the + (ACCEL) function operates. When the cruise control system is not operating, the RES (RESUME) function operates. (d) If the CRUISE main indicator light blinks while the cruise control system is operating, turn the cruise control main switch off to reset the cruise control system. After the reset, if the cruise control main switch cannot be turned on, or the cruise control system is canceled immediately after turning the cruise control main switch on, the system may have a malfunction. (e) Do not use the cruise control system where the road conditions are as follows: • Heavy traffic • Steep decline • Roads with sharp turns • Icy or snowy roads • Slippery roads CC CC–2 CRUISE CONTROL – CRUISE CONTROL SYSTEM PARTS LOCATION SKID CONTROL ECU WITH ACTUATOR REAR VEHICLE SPEED SENSOR RH FRONT VEHICLE SPEED SENSOR RH ECM (*1) THROTTLE BODY ASSEMBLY CC REAR VEHICLE SPEED SENSOR LH - THROTTLE POSITION SENSOR ECM (*2) - THROTTLE CONTROL MOTOR PARK / NEUTRAL POSITION SWITCH (*3) FRONT VEHICLE SPEED SENSOR LH ENGINE ROOM R/B AND J/B -ALT FUSE -ST/AM2 FUSE TRANSMISSION CONTROL ECU (*1) -FL MAIN FUSE *1: 2GR-FE *2: 2AZ-FE *3: U660E E129946E01 CC–3 CRUISE CONTROL – CRUISE CONTROL SYSTEM CLUTCH SWITCH (*1) STOP LIGHT SWITCH COMBINATION METER - CRUISE MAIN INDICATOR LIGHT ACCELERATOR PEDAL POSITION SENSOR DLC3 INSTRUMENT PANEL J/B CC CRUISE CONTROL MAIN SWITCH SPIRAL CABLE -STOP FUSE -IGN FUSE *1: M/T E129947E01 CC–4 CRUISE CONTROL – CRUISE CONTROL SYSTEM SYSTEM DIAGRAM Stop Light Switch Park / Neutral Position Switch (A/T) Transmission Control ECU (2GR-FE) CRUISE Main Indicator Light Accelerator Pedal Position Sensor Throttle Position Sensor and Motor ECM Cruise Main Switch Combination Meter Clutch Switch (M/T) CC Skid Control ECU DLC3 Vehicle Speed Sensor : CAN E129950E01 Communication Table: Sender ECM Receiver Combination Meter ECU Signal CRUISE main indicator operation signal Line CAN CRUISE CONTROL – CRUISE CONTROL SYSTEM CC–5 SYSTEM DESCRIPTION 1. 2. CRUISE CONTROL SYSTEM This system is controlled by the ECM, and is activated by the throttle position sensor and motor. The ECM controls the following functions: ON-OFF, - (COAST)/SET, + (ACCEL)/RES (RESUME), CANCEL, vehicle speed operation, motor output control, and overdrive control. • The ECM compares the driving vehicle speed from the speed sensor with the stored vehicle speed set through the cruise control main switch. The ECM instructs the throttle valve motor of the throttle body assembly to close the valve when the driving speed is greater than the stored speed, and instructs it to open the valve when the driving speed is less than the stored speed. • The ECM receives signals such as ON-OFF, (COAST)/SET, + (ACCEL)/RES (RESUME), and CANCEL from the cruise control main switch and executes the command. • The ECM illuminates the combination meter's CRUISE main indicator light when it receives a cruise control main switch ON signal. • The ECM cancels the cruise control system when the brake pedal is depressed and the ECM receives a stop light switch signal. • The ECM cancels the cruise control system when the shift lever is moved from the D to the N position or the transmission is shifted to the 3rd, 2nd, or 1st gear with the shift lever in the S position, and the ECM receives a park/neutral position switch signal. • The ECM cancels the cruise control system when the clutch pedal is depressed and the ECM receives a clutch switch signal. LIMIT CONTROL (a) Low speed limit The lowest possible limit of the speed setting range is set at approximately 40 km/h (25 mph). The cruise control system cannot be set when the driving vehicle speed is below the low speed limit. Cruise control operation will be automatically canceled but the stored vehicle speed will be retained when the vehicle speed drops below the low speed limit 40 km/h (25 mph) while the cruise control is in operation. (b) High speed limit The highest possible limit of the speed setting range is set at approximately 200 km/h (125 mph). The cruise control system cannot be set when the driving vehicle speed is over the high speed limit. Also, + (ACCEL)/RES (RESUME) cannot be used to increase speed beyond the high speed limit. CC CC–6 CRUISE CONTROL – CRUISE CONTROL SYSTEM 3. CC OPERATION OF CRUISE CONTROL The cruise control main switch operates 7 functions: SET, - (COAST), TAP-DOWN, RES (RESUME), + (ACCEL), TAP-UP, and CANCEL. The SET, TAP-DOWN, and - (COAST) functions, and the RES (RESUME), TAPUP, and + (ACCEL) functions are operated with the same switch. The cruise control main switch is an automatic return type switch which turns on only while operating it in the direction of each arrow and turns off after releasing it. (a) SET CONTROL The vehicle speed is stored and constant speed control is maintained when pushing the cruise control main switch to - (COAST)/SET while driving with the main switch on (the CRUISE main indicator light is on), and the vehicle speed is within the set speed range (between the low and high speed limits). (b) - (COAST) CONTROL When the cruise control main switch is set to (COAST)/SET and held in that position while the cruise control system is operating, the ECM sends a "throttle valve opening angle 0°" demand signal to the cruise control system. Then the vehicle speed, when the cruise control main switch is released, is stored and maintained. HINT: An actual throttle valve opening angle of 0° is not possible due to the idle speed control, etc. (c) TAP-DOWN CONTROL When tapping down the cruise control main switch to - (COAST)/SET (for approximately 0.6 seconds) while the cruise control system is in operation, the stored vehicle speed decreases each time by approximately 1.6 km/h (1.0 mph). When the cruise control main switch is released from - (COAST)/SET and the difference between the driving and stored vehicle speed is more than 5 km/h (3 mph), the driving vehicle speed is stored and constant speed control is maintained. (d) ACCELERATION CONTROL The throttle valve motor of the throttle body assembly is instructed by the ECM to open the throttle valve when + (ACCEL)/RES (RESUME) on the cruise control main switch is pressed and held while the cruise control system is in operation. When the cruise control main switch is released from + (ACCEL)/RES (RESUME), the vehicle speed is stored and the vehicle is controlled at a constant speed. CRUISE CONTROL – CRUISE CONTROL SYSTEM 4. CC–7 (e) TAP-UP CONTROL When tapping up the cruise control main switch to + (ACCEL)/RES (RESUME) (for approximately 0.6 seconds) while the cruise control system is in operation, the stored vehicle speed increases each time by approximately 1.6 km/h (1.0 mph). However, when the difference between the driving and the stored vehicle speed is more than 5 km/h (approximately 3.1 mph), the stored vehicle speed will not be changed. (f) RESUME CONTROL If cruise control operation was canceled with the stop light switch or the CANCEL switch, and if driving speed is within the limit range, pushing the cruise control main switch to + (ACCEL)/RES (RESUME) restores vehicle speed memorized at the time of cancellation, and maintains constant speed control. (g) MANUAL CANCEL CONTROL Performing any of the following cancels the cruise control system while in operation (the stored vehicle speed in the ECM is maintained). • Depressing the brake pedal • Depressing the clutch pedal • The shift lever is moved from the D to the N position or the transmission is shifted to the 3rd, 2nd, or 1st gear with the shift lever in the S position. • Pulling the cruise control main switch to CANCEL • Turning the cruise control main switch off (the stored vehicle speed in the ECM is not maintained). AUTO CANCEL (FAIL-SAFE) This system has an automatic cancellation function (failsafe) (See page CC-16). CC CC–8 CRUISE CONTROL – CRUISE CONTROL SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use the following procedures to troubleshoot the cruise control system. • *: Use the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 PROBLEM SYMPTOM CONFIRMATION NEXT 3 CHECK CAN COMMUNICATION SYSTEM* Refer to PRECAUTION (See page CA-1). (a) Check for output DTCs. Result Result Proceed to CAN DTC is not output A CAN DTC is output B HINT: The ECM of this system is connected to the CAN communication system. Therefore, before starting troubleshooting, make sure to check that there is no trouble in the CAN communication system. B CC PROCEED TO "CAN COMMUNICATION SYSTEM" A 4 DTC CHECK AND CLEAR* Refer to DTC CHECK / CLEAR (See page CC-16). NEXT 5 DTC CHECK (OTHER THAN CAN SYSTEM DTC)* Result Result Proceed to DTC is not output A DTC is output B CC–9 CRUISE CONTROL – CRUISE CONTROL SYSTEM A GO TO STEP 7 B 6 DTC CHART Refer to DIAGNOSTIC TROUBLE CODE CHART (See page CC-18). NEXT GO TO STEP 10 7 PROBLEM SYMPTOM CONFIRMATION Result A Result Proceed to Symptom occurs A Symptom does not occur B GO TO STEP 9 B 8 SYMPTOM SIMULATION Refer to ELECTRONIC CIRCUIT INSPECTION PROCEDURE (See page IN-40). NEXT CC Go to step 7 9 PROBLEM SYMPTOMS TABLE Refer to the PROBLEM SYMPTOMS TABLE (See page CC11). NEXT 10 CIRCUIT INSPECTION NEXT 11 TERMINALS OF ECM Refer to TERMINALS OF ECM (See page CC-13). CC–10 CRUISE CONTROL – CRUISE CONTROL SYSTEM NEXT 12 IDENTIFICATION OF PROBLEM NEXT 13 REPAIR OR REPLACE NEXT 14 CONFIRMATION TEST NEXT END ROAD TEST 1. E107085 CC E107086 PROBLEM SYMPTOM CONFIRMATION (a) Inspect the SET function. (1) Turn the cruise control main switch on. (2) Drive at the required speed (40 km/h (25 mph) or higher). (3) Push the cruise control main switch to (COAST)/SET. (4) After releasing the switch, check that the vehicle cruises at the set speed. (b) Inspect the ACCELERATION function. (1) Turn the cruise control main switch on. (2) Drive at the required speed (40 km/h (25 mph) or higher). (3) Push the cruise control main switch to (COAST)/SET. (4) Check that vehicle speed increases while the cruise control main switch is pushed to + (ACCEL)/RES (RESUME), and that the vehicle cruises at the newly set speed when the switch is released. (5) Push the cruise control main switch to + (ACCEL)/RES (RESUME) and then release it immediately. Check that vehicle speed increases by approximately 1.6 km/h (1.0 mph) (tap-up control). CRUISE CONTROL – CRUISE CONTROL SYSTEM E107085 E107087 E107086 CC–11 (c) Inspect the - (COAST) function. (1) Turn the cruise control main switch on. (2) Drive at the required speed between 40 km/h (25 mph) and 200 km/h (125 mph). (3) Push the cruise control main switch to (COAST)/SET. (4) Check that vehicle speed decreases while the cruise control main switch is pushed to (COAST)/SET, and the vehicle cruises at the newly set speed when the switch is released. (5) Push the cruise control main switch to (COAST)/SET, and then release it immediately. Check that vehicle speed decreases by approximately 1.6 km/h (1.0 mph) (tap-down control). (d) Inspect the CANCEL function. (1) Turn the cruise control main switch on. (2) Drive at the required speed between 40 km/h (25 mph) and 200 km/h (125 mph). (3) Push the cruise control main switch to (COAST)/SET. (4) When performing any one of the following, check that the cruise control system is canceled and that the normal driving mode is reset. • Depressing the brake pedal • Depressing the clutch pedal • The shift lever is moved from the D to the N position or the transmission is shifted to the 3rd, 2nd, or 1st gear with the shift lever in the S position • Turning the cruise control main switch off • Pulling the cruise control main switch to CANCEL (e) Inspect the RES (RESUME) function. (1) Turn the cruise control main switch on. (2) Drive at the required speed between 40 km/h (25 mph) and 200 km/h (125 mph). (3) Push the cruise control main switch to (COAST)/SET. (4) Cancel the cruise control system by performing any of the above operations (other than turning the main switch off). (5) After pushing the cruise control main switch to + (ACCEL)/RES (RESUME) at a driving speed of more than 40 km/h (25 mph), check that the vehicle resumes the speed set prior to the cancellation. CC CC–12 CRUISE CONTROL – CRUISE CONTROL SYSTEM PROBLEM SYMPTOMS TABLE HINT: Be sure to perform the SYMPTOM SIMULATION procedure before replacing the ECM. If these symptoms do not persist, the cause of the problem may be poor intermittent electrical contact (open or short) of a wire harness or connector. Cruise control system: Symptom Vehicle speed cannot be set. (The CRUISE main indicator light comes on.) Pushing the ON-OFF button does not turn the cruise control system on. (Vehicle speed cannot be set.) CC The cruise control is canceled while it is operating. Pulling back on the control main switch does not cancel the cruise control. (The CRUISE main indicator light remains on.) Pulling back on the control main switch does not cancel the cruise control. (The CRUISE main indicator light goes off.) Suspected area See page 1. Cruise control switch circuit CC-28 2. Combination meter ME-15 3. Vehicle speed sensor circuit CC-19 4. Stop light switch CC-20 5. Transmission range sensor circuit (U250E) AX-39 5. Park / Neutral position sensor circuit (U660E) AX-158 6. Clutch switch circuit CC-25 7. If the symptoms still occur after the above ares have been inspected and have proven to be normal, replace the ECM. (2AZ-FE) ES-432 7. If the symptoms still occur after the above ares have been inspected and have proven to be normal, replace the ECM. (2GR-FE) ES-518 1. Stop light switch circuit CC-20 2. Clutch switch circuit (M/T) CC-25 3. Vehicle speed sensor circuit CC-19 4. Cruise control switch circuit CC-28 5. Transmission range sensor circuit (U250E) AX-39 5. Park / Neutral position sensor circuit (U660E) AX-158 6. If the symptoms still occur after the above areas have been inspected and have proven to be normal, replace the ECM. (2AZ- FE) ES-432 6. If the symptoms still occur after the above areas have been inspected and have proven to be normal, replace the ECM. (2GR-FE) ES-518 1. Stop light switch circuit CC-20 2. Clutch switch circuit (M/T) CC-25 3. Transmission range sensor circuit (U250E) AX-39 3. Park / Neutral position sensor circuit (U660E) AX-158 4. Cruise control switch circuit CC-28 5. Vehicle speed sensor circuit CC-19 6. Combination meter ME-15 7. If the symptoms still occur after the above areas have been inspected and have proven to be normal, replace the ECM. (2AZ-FE) ES-432 7. If the symptoms still occur after the above areas have been inspected and have proven to be normal, replace the ECM. (2GR-FE) ES-518 1. Cruise control switch circuit CC-28 2. If the symptoms still occur after the above area has been inspected and has proven to be normal, replace the ECM. (2AZ-FE) ES-432 2. If the symptoms still occur after the above area has been inspected and has proven to be normal, replace the ECM. (2GR-FE) ES-518 Replace ECM (2AZ-FE) ES-432 Replace ECM (2GR-FE) ES-518 CC–13 CRUISE CONTROL – CRUISE CONTROL SYSTEM Symptom The cruise control is not canceled when vehicle speed drops below the low speed limit. (The CRUISE main indicator light remains on.) The cruise control is not canceled when vehicle speed drops below the low speed limit. (The CRUISE main indicator light goes off.) Depressing the brake pedal does not cancel the cruise control. (The CRUISE main indicator light remains on.) Depressing the brake pedal does not cancel the cruise control. (The CRUISE main indicator light goes off.) Depressing the clutch pedal does not cancel the cruise control. (The CRUISE main indicator light remains on.) Depressing the clutch pedal does not cancel the cruise control. (The CRUISE main indicator light goes off.) Moving the shift liver does not cancel the cruise control. Hunting (Speed is not constant.) The CRUISE main indicator light remains blinking. Suspected area See page 1. Vehicle speed sensor circuit CC-19 2. If the symptoms still occur after the above area has been inspected and has proven to be normal, replace the ECM. (2AZ-FE) ES-432 2. If the symptoms still occur after the above area has been inspected and has proven to be normal, replace the ECM. (2GR-FE) ES-518 Replace ECM (2AZ-FE) CC-13 Replace ECM (2GR-FE) ES-518 1. Stop light switch circuit CC-20 2. If the symptoms still occur after the above area has been inspected and has proven to be normal, replace the ECM. (2AZ-FE) ES-432 2. If the symptoms still occur after the above area has been inspected and has proven to be normal, replace the ECM. (2GR-FE) ES-518 Replace ECM (2AZ-FE) ES-432 Replace ECM (2GR-FE) ES-518 1. Clutch switch circuit CC-25 2. If the symptoms still occur after the above area has been inspected and has proven to be normal, replace the ECM. (2AZ-FE) ES-432 2. If the symptoms still occur after the above area has been inspected and has proven to be normal, replace the ECM. (2GR-FE) ES-518 Replace ECM (2AZ-FE) ES-432 Replace ECM (2GR-FE) ES-518 1. Transmission range sensor circuit (U250E) AX-39 1. Park / Neutral position sensor circuit (U660E) AX-158 2. If the symptoms still occur after the above area has been inspected and has proven to be normal, replace the ECM. (2AZ-FE) ES-432 2. If the symptoms still occur after the above area has been inspected and has proven to be normal, replace the ECM. (2GR-FE) ES-518 1. Vehicle speed sensor circuit CC-19 2. Combination meter ME-15 3. If the symptoms still occur after the above ares have been inspected and have proven to be normal, replace the ECM. (2AZ-FE) ES-432 3. If the symptoms still occur after the above ares have been inspected and have proven to be normal replace the ECM. (2GR-FE) ES-518 1. TC and CG terminal circuit CC-35 2. If the symptoms still occur after the above area has been inspected and has proven to be normal, replace the ECM. CC-13 CC CC–14 CRUISE CONTROL – CRUISE CONTROL SYSTEM TERMINALS OF ECM 1.                         CHECK ECM C24 *2 A24 *2 C55 *1 A55 *1                                                                                                                                                                   *1: 2GR-FE *2: 2AZ-FE A107881E45 Symbols (Terminal No.) A55-27 (TC) - C55-81 Wiring Color (E1)*1 A24-27 (TC) - C24-104 (E1)*2 A55-27 (TC) - C55-81 (E1)*1 A24-27 (TC) - C24-104 (E1)*2 A55-36 (STP) - C55-81 (E1)*1 A24-36 (STP) - C24-104 (E1)*2 A55-36 (STP) - C55-81 (E1)*1 A24-36 (STP) - C24-104 (E1)*2 A55-40 (CCS) - C55-81 (E1)*1 A24-40 (CCS) - C24-104 (E1)*2 A55-40 (CCS) - C55-81 (E1)*1 A24-40 (CCS) - C24-104 (E1)*2 A55-40 (CCS) - C55-81 (E1)*1 A24-40 (CCS) - C24-104 (E1)*2 CC A55-40 (CCS) - C55-81 (E1)*1 A24-40 (CCS) - C24-104 (E1) *2 A55-40 (CCS) - C55-81 (E1)*1 A24-40 (CCS) - C24-104 (E1)*2 A55-35 (ST1-) - C55-81 (E1)*1 A24-35 (ST1-) - C24-104 (E1)*2 A55-35 (ST1-) - C55-81 (E1)*1 A24-35 (ST1-) - C24-104 (E1)*2 C24-56 (D) - C55-81 (E1)*1 C24-56 (D) - C24-104 (E1)*2 C24-56 (D) - C55-81 (E1)*1 C24-56 (D) - C24-104 (E1)*2 Terminal Description Condition Specified Condition P - W-B Ground Ignition switch on (IG) 10 to 14 V P - W-B Ground Connect terminals TC and CG of DLC3 Below 1 V W - W-B Stop light signal Ignition switch on (IG), Depress brake pedal 10 to 14 V W - W-B Stop light signal Ignition switch on (IG), Release brake pedal Below 1 V W - W-B Cruise control main switch circuit Ignition switch on (IG) 10 to 14 V W - W-B Cruise control main switch circuit CANCEL switch ON 6.6 to 10.1 V W - W-B Cruise control main switch circuit SET/COAST switch ON 4.5 to 7.1 V W - W-B Cruise control main switch circuit RES/ACC switch ON 2.3 to 4.0 V W - W-B Cruise control main switch circuit MAIN switch ON Below 1 V GR - W-B Stop light signal Ignition switch on (IG), Depress brake pedal Below 1 V GR - W-B Stop light signal Ignition switch on (IG), Release brake pedal 10 to 14 V C - W-B Clutch signal Ignition switch on (IG), Depress clutch pedal Below 1 V C - W-B Clutch signal Ignition switch on (IG), Release brake pedal 10 to 14 V HINT: *1: 2GR-FE *2: 2AZ-FE CC–15 CRUISE CONTROL – CRUISE CONTROL SYSTEM DIAGNOSIS SYSTEM 1. DESCRIPTION The ECU controls the cruise control system of the vehicle. The data and DTCs relating to the cruise control system can be read from the DLC3 of the vehicle. If either DTC or CRUISE OK is not displayed on the multiinformation display on the combination meter when checking for DTCs, there may be a problem with either the combination meter or the CAN communication and multiplex communication systems. Use the intelligent tester to check and solve the problem. 2. CHECK DLC3 (a) The ECU uses the ISO 15765-4 for communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. CG SG CANH SIL CANL BAT H100769E16 Terminal No. (Symbols) Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always CANH (6) - CANL (14) CANH (6) - CG (4) CANL (14) - CG (4) CANH (6) - BAT (16) CANL (14) - BAT (16) CAN bus line HIGH-level CAN bus line LOW-level CAN bus line HIGH-level CAN bus line LOW-level CAN bus line 10 to 14 V Ignition switch off * 54 to 69 Ω Ignition switch off * 200 Ω or higher Ignition switch off * 200 Ω or higher Ignition switch off * 6 kΩ or higher Ignition switch off * 6 kΩ or higher NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. (b) Connect the cable of the intelligent tester to the DLC3, turn the ignition switch on (IG), and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem with either the vehicle or the tester. • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. CC CC–16 CRUISE CONTROL – CRUISE CONTROL SYSTEM • If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. 3. CRUISE Main Indicator Light CHECK INDICATOR (a) Turn the ignition switch on (IG). E129948E01 (b) Check that the CRUISE main indicator light illuminates when the cruise control main switch is turned on, and that the indicator light turns off when the main switch is turned off. If the results are not as specified, inspect the CRUISE main indicator light circuit (See page CC-34). HINT: While driving with cruise control, the ECM activates AUTO CANCEL of the cruise control system when a malfunction occurs in one of the following: vehicle speed sensors, stop light switch, or other related parts. When AUTO CANCEL is activated, the CRUISE main indicator light outputs the blinking pattern shown to the left. At the same time, data of the malfunction is stored as a DTC. CRUISE Main Indicator Light 1.5 sec. 0.5 sec. ON OFF BE04034E23 DTC CHECK / CLEAR 1. CC DLC3 Intelligent Tester 2. C131977E04 DTC CHECK (a) Connect the intelligent tester to the DLC3. (1) Connect the intelligent tester to the Controller Area Network Vehicle Interface Module (CAN VIM). Then connect the CAN VIM to the Data Link Connector 3 (DLC3). (b) Turn the ignition switch on (IG). (c) Read the DTCs by following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. DTC CLEAR (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Operate the intelligent tester to erase the codes. HINT: Refer to the intelligent tester operator's manual for further details. CC–17 CRUISE CONTROL – CRUISE CONTROL SYSTEM FAIL-SAFE CHART HINT: If the following conditions are detected while the cruise control is in operation, the system clears the stored vehicle speed in the ECM and cancels the cruise control operation. Vehicle Condition Auto Cancel Condition • CRUISE main indicator light blinks There is open or short in stop light switch circuit There is problem with vehicle speed signal There is problem with throttle position sensor and motor Turn cruise control main switch on again There is problem with input circuit of stop light switch circuit There is problem with cancel circuit • • • Vehicle speed is lower than low speed limit (approx. 40 km/h (25 mph)) while running with cruise control on Push cruise control main switch to + (ACCEL)/RES (RESUME) • Vehicle speed is lower than stored speed by approx. 16 km/h (9.9 mph) or more Push cruise control main switch to - (COAST)/ SET • • • CRUISE main indicator light blinks • CRUISE main indicator light remains on (Cruise control is canceled) Re-operation Condition Turn cruise control main switch on again Turn ignition switch off then on again CC CC–18 CRUISE CONTROL – CRUISE CONTROL SYSTEM DATA LIST / ACTIVE TEST 1. READ DATA LIST HINT: Using the intelligent tester's DATA LIST allows switch, sensor, actuator, and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to save time. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Read the DATA LIST according to the display on the tester. ECM (Cruise control): CC Item Measurement Item / Display (Range) VEHICLE SPD Vehicle speed / min.: 0 km/h (0 mph), max.: 255 km/h (158 mph) Actual vehicle speed - MEMORY SPD Cruise control memorized speed / min.: 36 km/h (22.5 mph), max.: 200 km/h (125 mph) Actual stored vehicle speed - THROTTLE Throttle opening angle / min.: 0°, max.: 125° Actual demanded throttle angle - SHIFT D POS Shift D position / ON or OFF ON: Shift lever in D or 4 OFF: Shift lever is except D or 4 position - CRUISE CONTROL Cruise control system active condition / ON or OFF ON: Cruise control activated OFF: Cruise control deactivated - CCS INDICATOR M Cruise indicator signal (Main CPU) / ON or OFF ON: "CRUISE" on OFF: "CRUISE" off - MAIN SW (MAIN) Main switch signal (Main CPU) / ON or OFF ON: Cruise control main switch on OFF: Cruise control main switch off "1" MAIN SW (SUB) Main switch signal (Main CPU) / ON or OFF ON: Cruise control main switch on OFF: Cruise control main switch off - SHIFT D POS Clutch pedal / ON or OFF ON: Clutch pedal released OFF: Clutch pedal depressed - CANCEL SW CANCEL switch signal / ON or OFF ON: CANCEL switch on OFF: CANCEL switch off - SET/COAST SW SET / COAST switch signal / ON or OFF ON: - (COAST) / SET switch on OFF: - (COAST) / SET switch off - RES/ACC SW RES / ACC switch signal / ON or OFF ON: + (ACCEL) / RES (RESUME) switch on OFF: + (ACCEL) / RES (RESUME) switch off - STP LIGHT SW M (STP) Stop light switch signal (Main CPU) / ON or OFF ON: Brake pedal depressed OFF: Brake pedal released - STP LIGHT SW S2 (STP) Stop light switch signal (Sub CPU) / ON or OFF ON: Brake pedal depressed OFF: Brake pedal released - STP LIGHT SW S1 (ST1-) Stop light switch signal (Sub CPU) ON: Brake pedal depressed OFF: Brake pedal released - Normal Condition Diagnostic Note HINT: • "1" is OK but CRUISE main indicator light does not illuminate → CRUISE main indicator light, wire harness, or ECM failure CC–19 CRUISE CONTROL – CRUISE CONTROL SYSTEM 2. PERFORM ACTIVE TEST HINT: Performing the intelligent tester's ACTIVE TEST allows relays, VSVs, actuators, and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Perform the ACTIVE TEST according to the display on the tester. HINT: The ignition switch must be turned on (IG) to proceed to with the ACTIVE TEST using the intelligent tester. Combination meter: Item Vehicle Condition / Test Details Diagnostic Note CRUISE INDIC Turns CRUISE main indicator light ON / OFF - CC CC–20 CRUISE CONTROL – CRUISE CONTROL SYSTEM DIAGNOSTIC TROUBLE CODE CHART If a trouble code is displayed during the DTC check, check the trouble areas listed for that code in the table below and proceed to the appropriate page. Cruise control system: DTC No. CC Detection Item Trouble Area See page P0500 Vehicle Speed Sensor Malfunction 1. Vehicle speed sensor 2. Vehicle speed sensor signal circuit 3. ECM CC-19 P0503 Vehicle Speed Sensor "A" Intermittent / Erratic / High 1. Vehicle speed sensor 2. Vehicle speed sensor signal circuit 3. ECM CC-19 P0571 Brake Switch "A" Circuit 1. Stop light switch 2. Stop light switch circuit 3. ECM CC-20 P0607 Control Module Performance ECM CC-24 CC–21 CRUISE CONTROL – CRUISE CONTROL SYSTEM DTC P0500 Vehicle Speed Sensor Malfunction DTC P0503 Vehicle Speed Sensor "A" Intermittent / Erratic / High DESCRIPTION Refer to DTC P0500 (See page ES-229). DTC No. DTC Detection Condition Trouble Area P0500 The vehicle speed signal from the vehicle speed sensor is cut for 0.14 sec. or more while cruise control is in operation. • • • Vehicle speed sensor Vehicle speed sensor signal circuit ECM P0503 Momentary interruption and noise are detected when a rapid change of vehicle speed occurs while cruise control is in operation. • • • Vehicle speed sensor Vehicle speed sensor signal circuit ECM WIRING DIAGRAM Refer to DTC P0500 (See page ES-231). INSPECTION PROCEDURE Refer to DTC P0500 (See page ES-231). CC CC–22 CRUISE CONTROL – CRUISE CONTROL SYSTEM DTC P0571 Brake Switch "A" Circuit DESCRIPTION When the brake pedal is depressed, the stop light switch sends a signal to the ECM. When the ECM receives this signal, it cancels the cruise control. The fail-safe function operates to enable normal driving even if there is a malfunction in the stop light signal circuit. The cancellation condition occurs when voltage is applied to terminal STP. When the brake is applied, voltage is normally applied to terminal STP of the ECM through the STOP SW fuse and the stop light switch, and the ECM turns the cruise control off. DTC No. DTC Detection Condition P0571 When voltage of STP terminal and that of ST1- terminal of ECM are less than 1 V for 0.5 sec. or more Trouble Area • • • Stop light switch Stop light switch circuit ECM WIRING DIAGRAM Without Smart Key System: A19 Stop Light Switch STOP 2 ECM 1 Ignition Switch 5 AM2 IG2 6 IGN 3 4 ST2 36 36 A24 A55 *2 *1 35 A24 35 A55 *2 *1 STP ST1- ST/AM2 ALT CC *1: 2GR-FE FL MAIN Battery *2: 2AZ-FE E129952E01 CC–23 CRUISE CONTROL – CRUISE CONTROL SYSTEM With Smart Key System: A19 Stop Light Switch ECM STOP SW 2 1 IGN 3 4 36 36 A24 *2 A55 *1 35 35 A24 A55 *2 *1 STP IG ST1- IG2 MAIN RHJ/B-AM ALT Battery *1: 2GR-FE *2: 2AZ-FE E129951E01 INSPECTION PROCEDURE 1 READ VALUE ON INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG), and turn the intelligent tester main switch on. (c) Check the DATA LIST for proper functioning of the stop light switch. ECM (Cruise control): Item Measurement Item / Display (Range) STP LIGHT SW M (STP) Stop light switch signal (Main CPU) / ON or OFF ON: Brake pedal depressed OFF: Brake pedal released - STP LIGHT SW S2 (STP) Stop light switch signal (Sub CPU) / ON or OFF ON: Brake pedal depressed OFF: Brake pedal released - STP LIGHT SW S1 (ST1-) Stop light switch signal (Sub CPU) / ON or OFF ON: Brake pedal depressed OFF: Brake pedal released - Normal Condition Diagnostic Note OK: When the brake pedal is operated, the display changes as shown above. OK NG REPLACE ECM CC CC–24 2 CRUISE CONTROL – CRUISE CONTROL SYSTEM CHECK HARNESS AND CONNECTOR (STOP LIGHT SWITCH - BATTERY) (a) Disconnect the A19 connector from the stop light switch. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Stop Light Switch Wire Harness Side Connector Front View: A19 E114084E08 Tester Connection Condition Specified Condition A19-2 - Body ground Always 10 to 14 V A19-3 - Body ground Ignition switch on (IG) 10 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 INSPECT STOP LIGHT SWITCH (a) Remove the stop light switch. (See page CC-42) (b) Measure the resistance according to the value(s) in the table below. Standard resistance Stop Light Switch:  Not Pushed Pushed   Tester Connection Switch Condition Specified Condition 1-2 Switch pin not pushed Below 1 Ω  E128781E02 3-4 Switch pin not pushed 10 kΩ or higher 1-2 Switch pin pushed 10 kΩ or higher 3-4 Switch pin pushed Below 1 Ω (c) Install the stop light switch. NG OK CC REPLACE STOP LIGHT SWITCH CRUISE CONTROL – CRUISE CONTROL SYSTEM 4 CC–25 CHECK ECM (a) (b) (c) (d) (e) ECM Wire Harness View: A24 *2 A55 *1 Reconnect the stop light switch connector. Disconnect the A55 connector from the ECM. (2GR-FE) Disconnect the A24 connector from the ECM. (2AZ-FE) Turn the ignition switch on (IG). Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Brake Pedal Condition Specified Condition Depressed 10 to 14 V Released Below 1 V Depressed Below 1 V Released 10 to 14 V A55-36 (STP) - Body ground*1 A24-36 (STP) - Body ground*2 A55-36 (STP) - Body ground*1 A24-36 (STP) - Body ground*2 STP ST1- *1: 2GR-FE A55-35 (ST1-) - Body ground*1 A24-35 (ST1-) - Body ground *2: 2AZ-FE *2 A55-35 (ST1-) - Body E126835E03 ground*1 A24-35 (ST1-) - Body ground *2 HINT: *1: 2GR-FE *2: 2AZ-FE NG REPAIR OR REPLACE HARNESS OR CONNECTOR (STOP LIGHT SWITCH - ECM) OK REPLACE ECM CC CC–26 CRUISE CONTROL – CRUISE CONTROL SYSTEM DTC P0607 Control Module Performance DESCRIPTION This DTC indicates the internal abnormalities of the ECM. DTC No. DTC Detection Condition P0607 When both of the following conditions are met: • STP signals input to the ECM supervisory CPU and control ECU are different for 0.15 sec. or more • 0.4 sec. have passed after cruise cancel input signal (STP input) is input to the ECM Trouble Area ECM HINT: The ECM receives signals from each sensor to control all functions of the cruise control system. When a trouble code is detected, the fail-safe function remains on until the ignition switch is turned off. INSPECTION PROCEDURE 1 NEXT END CC REPLACE ECM CC–27 CRUISE CONTROL – CRUISE CONTROL SYSTEM Clutch Switch Circuit DESCRIPTION Clutch switch circuit inspection is necessary for M/T vehicles. When the clutch pedal is released, the ECM receives positive (+) battery voltage through the ECU IG fuse. While depressing the clutch pedal, the clutch switch sends a signal to terminal D of the ECM. The ECM cancels cruise control drive when terminal D receives the signal. WIRING DIAGRAM A21 Clutch Switch ECM 56 1 C24 D 2 ECU IG from Battery E113306E06 INSPECTION PROCEDURE 1 INSPECT ECM (a) Disconnect the C24 connector from the ECM. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage ECM Wire Harness View: C24 Tester Connection Condition Specified Condition C24-56 (D) - Body ground Clutch pedal depressed Below 1 V Clutch pedal released 10 to 14 V OK D E129949E01 PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE CC CC–28 CRUISE CONTROL – CRUISE CONTROL SYSTEM NG 2 INSPECT CLUTCH SWITCH (a) (b) (c) (d) Turn the ignition switch off. Disconnect the A21 connector from the clutch switch. Remove the clutch switch. (See page CC-42) Measure the resistance according to the value(s) in the table below. Standard resistance Clutch Switch: Tester Connection 1-2 Pushed in Free NG A21 E133093E01 OK CC Condition Specified Condition Switch pin free (Clutch pedal depressed) 10 kΩ or higher Switch pin pushed in (Clutch pedal released) Below 1Ω REPLACE CLUTCH SWITCH CC–29 CRUISE CONTROL – CRUISE CONTROL SYSTEM 3 CHECK HARNESS AND CONNECTOR (a) Measure the resistance according to the value(s) in the table below. Standard resistance ECM Wire Harness View: C24 Tester Connection Condition Specified Condition C24-56 (D) - A21-2 Always Below 1 Ω C24-56 (D) - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR (ECM - CLUTCH SWITCH) D Clutch Switch (Wire Harness Side) Connector Front View: CC D E129955E01 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (BATTERY - CLUTCH SWITCH) CC–30 CRUISE CONTROL – CRUISE CONTROL SYSTEM Cruise Control Switch Circuit DESCRIPTION The cruise control main switch operates 7 functions: SET, - (COAST), TAP-DOWN, RES (RESUME), + (ACCEL), TAP-UP, and CANCEL. The SET, TAP-DOWN, and - (COAST) functions, and the RES (RESUME), TAP-UP, and + (ACCEL) functions are operated with the same switch. The cruise control main switch is an automatic return type switch which turns on only while operating it in the direction of each arrow and turns off after releasing it. The internal contact point of the cruise control main switch is turned on with the switch operation. Then the ECM reads the voltage value that has been changed by the switch operation to control SET, - (COAST), RES (RESUME), + (ACCEL), and CANCEL. WIRING DIAGRAM ECM 3 b1 4 b1 CCS ECC 1 40 E18 A24 2 40 A55 CCS *2 *1 104 81 C24 C55 *2 *1 E18 Cruise Control Main Switch CCS CC CANCEL - (SET) + (RES) A ON-OFF ECC *1: 2GR-FE 1 3 A E1 *1: 2AZ-FE E133779E01 CC–31 CRUISE CONTROL – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 READ VALUE ON INTELLIGENT TESTER + (ACCEL)/RES (RESUME) CANCEL ON/OFF (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the intelligent tester main switch on. (c) Check the DATA LIST for proper functioning of the cruise control main switch. - (COAST)/SET E107091E05 ECM (Cruise control): Item Measurement Item/Display (Range) MAIN SW (MAIN) Main switch signal (Main CPU)/ ON or OFF CANCEL SW CANCEL switch signal/ON or OFF SET / COAST SW Normal Condition Diagnostic Note ON: Cruise control main switch on OFF: Cruise control main switch off - ON: CANCEL switch on OFF: CANCEL switch off - SET / COAST switch signal/ON or OFF ON: - (COAST)/SET switch on OFF: - (COAST)/SET switch off - RES / ACC SW RES / ACC switch signal/ON or OFF ON: + (ACCEL)/RES (RESUME) switch on OFF: + (ACCEL)/RES (RESUME) switch off - MAIN SW (SUB) Main switch signal (Sub CPU) / ON or OFF ON: Cruise control main switch ON OFF: Cruise control main switch OFF - OK: When the cruise control main switch is operated, the display changes as shown above. Result Result Proceed to OK A NG (All items are defective) B NG (1 to 4 items are defective) C A PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE CRUISE CONTROL MAIN SWITCH B 2 INSPECT CRUISE CONTROL MAIN SWITCH (a) Remove the cruise control main switch (See page CC38). CC CC–32 CRUISE CONTROL – CRUISE CONTROL SYSTEM (b) Measure the resistance according to the value(s) in the table below. Cruise Control Main Switch: + (ACCEL)/RES (RESUME) ON/OFF CANCEL - (COAST)/SET A E106137E06 Standard resistance Tester Connection Switch Condition Specified Condition A-1 (CCS) - A-3 (ECC) Neutral 10 kΩ or higher A-1 (CCS) - A-3 (ECC) + (ACCEL)/RES (RESUME) 216 to 264 Ω A-1 (CCS) - A-3 (ECC) - (COAST)/SET 567 to 693 Ω A-1 (CCS) - A-3 (ECC) CANCEL 1,386 to 1,694 Ω A-1 (CCS) - A-3 (ECC) Main Switch off 10 kΩ or higher A-1 (CCS) - A-3 (ECC) Main Switch on Below 1 Ω NG CC OK REPLACE CRUISE CONTROL MAIN SWITCH CC–33 CRUISE CONTROL – CRUISE CONTROL SYSTEM 3 CHECK HARNESS AND CONNECTOR (CRUISE CONTROL MAIN SWITCH - SPIRAL CABLE) (a) Disconnect the b1 connector from the spiral cable. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Spiral Cable Side: b1 NG Tester connection Specified condition A-1 - b1-3 Below 1 Ω A-3 - b1-4 Below 1 Ω REPAIR OR REPLACE HARNESS OR CONNECTOR Cruise Control Main Switch Side: A E103330E03 OK CC CC–34 4 CRUISE CONTROL – CRUISE CONTROL SYSTEM CHECK SPIRAL CABLE NOTICE: The spiral cable is an important part of the SRS airbag system. Incorrect removal or installation of the spiral cable may prevent the airbag from deploying. Be sure to read the page shown in the brackets. HINT: • Removal (See page RS-363) • Installation (See page RS-366) (a) Remove the spiral cable. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Cruise Control Main Switch Side: b1 ECC CCS Tester Connection Spiral Cable Position Specified Condition Center b1-3 - E18-1 (CCS) 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right Center Vehicle Side: b1-4 - E18-2 (ECC) 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right E18 HINT: The spiral cable makes a maximum of approximately 5 rotations. CCS NG ECC E106780E15 OK CC REPLACE SPIRAL CABLE CC–35 CRUISE CONTROL – CRUISE CONTROL SYSTEM 5 CHECK WIRE HARNESS (SPIRAL CABLE - ECM AND BODY GROUND) Vehicle Side Connector Front View: (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection E18 E18-1 - A55-40 (CCS) Condition Specified Condition Always Below 1 Ω Always 10 kΩ or higher Always Below 1 Ω *1 E18-1 - A24-40 (CCS)*2 A55-40 (CCS) - Body ground*1 A24-40 (CCS) - Body CCS ground*2 ECC ECM Wire Harness View: E18-2 (ECC) - Body ground HINT: *1: 2GR-FE *2: 2AZ-FE A24 *2 A55 *1 NG *1: 2GR-FE REPAIR OR REPLACE HARNESS OR CONNECTOR CCS *2: 2AZ-FE E126837E02 OK REPLACE ECM CC CC–36 CRUISE CONTROL – CRUISE CONTROL SYSTEM Cruise Main Indicator Light Circuit DESCRIPTION • The ECM detects a cruise control switch signal and sends it to the combination meter through CAN. Then the CRUISE main indicator light comes on. • The CRUISE main indicator light circuit uses CAN for communication. If there is a malfunction in this circuit, check for DTCs in the CAN communication system before troubleshooting this circuit. INSPECTION PROCEDURE 1 PERFORM ACTIVE TEST USING INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Check the CRUISE main indicator light by performing the ACTIVE TEST. Combination meter: Item Test Details Diagnostic Note CRUISE INDIC Turns CRUISE main indicator light ON / OFF - OK: Indicator light comes on / goes off. NG REPLACE COMBINATION METER ASSEMBLY OK 2 CC READ VALUE ON INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the intelligent tester main switch on. (c) Check the DATA LIST for proper functioning of the CRUISE main indicator light. ECM (Cruise control): Item Measurement Item / Display (Range) CCS INDICATOR M Cruise indicator signal (Main CPU) / ON or OFF Normal Condition ON: "CRUISE" on OFF: "CRUISE" off Diagnostic Note - OK: When the cruise control main switch is operated, the display changes as shown above. NG REPLACE ECM OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE CC–37 CRUISE CONTROL – CRUISE CONTROL SYSTEM TC and CG Terminal Circuit DESCRIPTION Connecting terminals TC and CG of the DLC3 causes the system to enter self-diagnostic mode. If a malfunction is present, DTCs will be output. HINT: When a particular warning light remains blinking, a ground short in the wiring of terminal TC of the DLC3 or an internal ground short in the relevant ECU is suspected. WIRING DIAGRAM E10 DLC3 ECM TC 13 27 27 A24 A55 *2 *1 TC To Other Systems CG 4 *1: 2GR-FE *2: 2AZ-FE E129954E01 CC CC–38 CRUISE CONTROL – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 CHECK WIRE HARNESS (TERMINAL TC of DLC3 - ECM) (a) Disconnect the A55 connector from the ECM. (2GR-FE) (b) Disconnect the A24 connector from the ECM. (2AZ-FE) (c) Measure the resistance according to the value(s) in the table below. Standard resistance DLC3: E10 Tester Connection Condition Specified Condition Always Below 1 Ω A55-27 (TC) - E10-13 (TC)*1 A24-27 (TC) - E10-13                 *2 (TC) TC ECM Wire Harness View: NG A24 *2 REPAIR OR REPLACE HARNESS OR CONNECTOR (DLC3 - ECM) A55 *1 TC *1: 2GR-FE CC *2: 2AZ-FE E126838E04 OK 2 CHECK WIRE HARNESS (TERMINAL CG of DLC3 - BODY GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance DLC3: CG 1 E10 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Tester connection Condition Specified condition E10-4 (CG) - Body ground Always Below 1 Ω NG C126742E20 REPAIR OR REPLACE HARNESS OR CONNECTOR (DLC3 - BODY GROUND) CC–39 CRUISE CONTROL – CRUISE CONTROL SYSTEM OK 3 CHECK WIRE HARNESS (TERMINAL TC of DLC3 - BODY GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance DLC3: E10 1 2 3 4 5 6 7 8 Tester Connection Condition Specified Condition E10-13 (TC) - Body ground Always 10 kΩ or higher 9 10 11 12 13 14 15 16 NG TC REPAIR OR REPLACE HARNESS OR CONNECTOR OR EACH ECU C126742E31 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE CC CC–38 CRUISE CONTROL – CRUISE CONTROL MAIN SWITCH CRUISE CONTROL MAIN SWITCH CRUISE CONTROL SYSTEM COMPONENTS CRUISE CONTROL MAIN SWITCH 8.8 (90, 78 in.*lbf) 2.4 (24, 21 in.*lbf) STEERING PAD LOWER NO. 3 STEERING WHEEL COVER LOWER NO. 2 STEERING WHEEL COVER N*m (kgf*cm, ft.*lbf) : Specified torque CC E128301E01 CRUISE CONTROL – CRUISE CONTROL MAIN SWITCH CC–39 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation (See page RS-1). 2. REMOVE LOWER NO. 3 STEERING WHEEL COVER (See page RS-349) 3. REMOVE LOWER NO. 2 STEERING WHEEL COVER (See page RS-349) 4. REMOVE STEERING PAD (See page RS-350) 5. REMOVE CRUISE CONTROL MAIN SWITCH (a) Disconnect the connector. (b) Remove the 2 screws and the cruise control main switch. E128297 CC CC–40 CRUISE CONTROL – CRUISE CONTROL MAIN SWITCH INSPECTION 1. INSPECT CRUISE CONTROL MAIN SWITCH (a) Remove the cruise control main switch + (ACCEL)/ RES (RESUME) MODE ON-OFF CANCEL - (COAST)/SET A E107856E03 (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection CC Switch Condition Specified Condition A-1(ECC) - A-2(R/N), A-1(ECC) - A-3(CCS) Neutral 10 kΩ or higher A-1(ECC) - A-3(CCS) + (ACCEL)/RES (RESUME) 216 to 264Ω A-1(ECC) - A-3(CCS) - (COAST)/SET 567 to 693Ω A-1(ECC) - A-3(CCS) CANCEL 1,386 to 1,694Ω A-1(ECC) - A-3(CCS) Main Switch off 10kΩ or higher A-1(ECC) - A-3(CCS) Main Switch on Below 1Ω A-1(ECC) - A-2(R/N) Main Switch on and Mode Switch on Below 1Ω If the result is not as specified, replace the cruise control main switch INSTALLATION E128297 1. INSTALL CRUISE CONTROL MAIN SWITCH (a) Install the cruise control main switch with the 2 screws. Torque: 2.4 N*m (24 kgf*cm, 21 in.*lbf) (b) Connect the connector. 2. INSTALL STEERING PAD (See page RS-350) 3. INSTALL LOWER NO. 2 STEERING WHEEL COVER (See page RS-352) 4. INSTALL LOWER NO. 3 STEERING WHEEL COVER (See page RS-351) CRUISE CONTROL – CRUISE CONTROL MAIN SWITCH 5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 6. INSPECT SRS WARNING LIGHT (See page RS-32) CC–41 CC CC–41 CRUISE CONTROL – CLUTCH SWITCH CLUTCH SWITCH CRUISE CONTROL SYSTEM COMPONENTS CLUTCH SWITCH ASSEMBLY MAIN BODY ECU (COWL SIDE JUNCTION BLOCK LH) 15.7 (160, 12) 8.0 (82, 71 in.*lbf) COWL SIDE TRIM SUB-ASSEMBLY LH CC COWL SIDE TRIM CLIP INSTRUMENT PANEL FINISH LOWER PANEL LH FRONT DOOR SCUFF PLATE LH N*m (kgf*cm, ft.*lbf) : Specified torque E128304E01 CC–42 CRUISE CONTROL – CLUTCH SWITCH REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-24) 2. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-25) 3. REMOVE INSTRUMENT PANEL FINISH LOWER PANEL LH (for TMC Made) (See page IP-20) 4. REMOVE INSTRUMENT PANEL FINISH LOWER PANEL LH (for TMMK Made) (See page IP-21) 5. REMOVE MAIN BODY ECU (COWL SIDE JUNCTION BLOCK LH) (a) Disconnect all connectors. (b) Remove the 2 nuts and the main body ECU (cowl side junction block LH). 6. REMOVE CLUTCH SWITCH ASSEMBLY (a) Disconnect the connector. E128298 (b) Loosen the nut and remove the clutch switch assembly. CC E128299 INSPECTION Clutch Switch: 1. Pushed in Free INSPECT CLUTCH SWITCH (a) Remove the clutch switch. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition 1-2 Switch pin free (Clutch pedal depressed) 10 kΩ or higher Switch pin pushed in (Clutch pedal released) Below 1Ω E113308E01 CRUISE CONTROL – CLUTCH SWITCH CC–43 If the result is not as specified, replace the clutch switch. CC CC–44 CRUISE CONTROL – CLUTCH SWITCH INSTALLATION 1. INSTALL CLUTCH SWITCH ASSEMBLY (a) Completely loosen the lock nut of the clutch switch assembly. (b) Adjust the clutch switch until the threaded portion makes gentle contact with the cushion. Tighten the lock nut and verify the contact of the switch threaded portion with the cushion. Torque: 15.7 N*m (160 kgf*cm, 12 ft.*lbf) (c) Connect the connector. Lock Nut Cushion E128300E01 E128298 CC 2. INSTALL MAIN BODY ECU (COWL SIDE JUNCTION BLOCK LH) (a) Install the main body ECU (cowl side junction block LH) with the 2 nuts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (b) Connect all connectors. 3. INSTALL INSTRUMENT PANEL FINISH LOWER PANEL LH (for TMC Made) (See page IP-58) 4. INSTALL INSTRUMENT PANEL FINISH LOWER PANEL LH (for TMMK Made) (See page IP-59) 5. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-54) 6. INSTALL FRONT DOOR SCUFF PLATE LH (See page IR-54) MIRROR – POWER MIRROR CONTROL SYSTEM MI–1 POWER MIRROR CONTROL SYSTEM MIRROR BODY PARTS LOCATION ENGINE ROOM R/B, J/B - RR DEF RELAY MI - RR DEF FUSE OUTER REAR VIEW MIRROR OUTER MIRROR SWITCH OUTER REAR VIEW MIRROR MAIN BODY ECU (INSTRUMENT PANEL J/B) - A/C NO. 2 FUSE - ECU-ACC FUSE - ECU-IG FUSE B137068E01 MI–2 MIRROR – POWER MIRROR CONTROL SYSTEM SYSTEM DIAGRAM E3 Outer Mirror Switch Assembly MI I3 Outer Rear View Mirror (LH) MH MV M+ from ECU-ACC fuse 8 1 5 5 4 2 6 B MLH MLV M+ H2 Outer Rear View Mirror (RH) MH MV M+ 1 2 5 3 2 7 MRH MRV E B140703E01 MI–3 MIRROR – POWER MIRROR CONTROL SYSTEM Mirror Heater Operation: Engine Room R/B, J/B E38 F16 A/C Amplifier Assembly Heater Control Panel Assembly MI RR DEF Relay from A/C No. 2 fuse 1 from RR DEF fuse 1 1 2 5 3 1 38 RDFG 37 LIN1 9 TX+ 1 4 Instrument Panel J/B MIR HTR fuse 1 1K 2 1B 1 1J H2 Outer Rear View Mirror Assembly RH 3 4 I3 Outer Rear View Mirror Assembly LH 3 4 : LIN B137069E01 MI–4 MIRROR – POWER MIRROR CONTROL SYSTEM PROBLEM SYMPTOMS TABLE Power Mirror Control System Symptom Suspected area 1. ECU-ACC fuse Power mirrors cannot be adjusted manually MI Mirror heater does not operate See page - 2. Outer mirror switch MI-22 3. Outer rear view mirror LH/RH MI-12 4. Wire harness - 1. MIR HTR, A/C No. 2, RR DEF fuses - 2. Heater control panel assembly - 3. A/C amplifier assembly - 4. RR DEF relay 5. Outer rear view mirror LH/RH 6. Wire harness MI-12 - MI–5 MIRROR – INNER REAR VIEW MIRROR INNER REAR VIEW MIRROR MIRROR BODY PARTS LOCATION MI INNER REAR VIEW MIRROR (AUTOMATIC GLARE-RESISTANT EC MIRROR) MAIN BODY ECU (INSTRUMENT PANEL J/B) - ECU-ACC FUSE B137081E01 MI–6 MIRROR – INNER REAR VIEW MIRROR COMPONENTS without EC Mirror: TMC made: TMMK made: MI 1.8 (18, 16 in.*lbf) INNER REAR VIEW MIRROR ASSEMBLY INNER REAR VIEW MIRROR ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B136831E01 MIRROR – INNER REAR VIEW MIRROR MI–7 with EC Mirror: INNER REAR VIEW MIRROR STAY HOLDER COVER INNER REAR VIEW MIRROR ASSEMBLY MI N*m (kgf*cm, ft.*lbf) : Specified torque 1.8 (18, 16 in.*lbf) B136832E01 MI–8 MIRROR – INNER REAR VIEW MIRROR SYSTEM DIAGRAM Inner Rear View Mirror Assembly (Auto Glare-resistant EC Mirror) MI from ECU-IG No. 1 Fuse 4 1 C IG E B111209E20 MIRROR – INNER REAR VIEW MIRROR MI–9 CALIBRATION 1. 2. 3. 4. SELECT COMPASS DISPLAY MODE (a) The COMP switch allows you to select the Display or Non-display mode of the compass. SET ZONE (a) Deviation between the "magnetic north" and "actual north" differs depending on the location. Therefore, adjustment of the magnetism is required. Since the magnetic condition differs depending on the area where the vehicle is used, it is necessary for each user to set the zone (Refer to Compass Zone Map). The zone setting can be changed using the COMP switch of the inner mirror. PERFORM CALIBRATION (a) Because each vehicle has its own magnetic field, calibration should be performed for each vehicle. This compass function is used when storing the record of the vehicle's magnetic field. WHEN COMPASS IS MAGNETIZED (a) A compass could be magnetized during shipping by vessels or freight cars. Therefore, make sure to perform calibration and ensure that calibration is performed properly before delivery. If it cannot be done (cannot be completed in spite of driving around several times), it may be caused by magnetization. Demagnetize the vehicle using a demagnetizer and perform calibration again. MI MI–10 MIRROR – INNER REAR VIEW MIRROR 5. COMP Switch SET COMPASS On Duration Normal Ignition switch on (IG) Pressed MI Compass Non-display Mode Pressed for 3 sec. Zone Setting Mode (Step 6) Pressed for 6 sec. COMP Switch ON Zone area +1 Calibration (Step 7) Leaving it untouched for a while Normal Mode B111243E06 6. 7. ZONE SETTING MODE (a) Pressing the COMP switch for 3 seconds in the normal mode will activate the zone setting mode. A number (1 to 15) is displayed on the compass display. NOTICE: In the initial state, "8" is displayed. (b) The displayed number increases by 1 every time the COMP switch is pressed. Referring to the map, check the number for the area where the vehicle will be used and set the zone number. (c) Leave it untouched for several seconds after setting and check that the compass display shows an azimuthal direction (N, NE, E, SE, S, SW, W or NW) or "C". CALIBRATION SETTING MODE (a) Pressing the COMP switch for 6 seconds in the normal mode will activate the calibration setting mode. MIRROR – INNER REAR VIEW MIRROR MI–11 (b) Drive the vehicle at a slow speed of 8 km/h (5 mph) or less in the circular direction. (c) Driving around the circle 1 to 3 times will display the azimuthal direction on the display, completing the calibration. NOTICE: After the calibration is completed, it is not necessary to perform the above procedures unless the magnetic field strength is drastically changed. If this happens, the azimuthal display will be changed to "C". Zone Setting Map: B057087E01 MI MI–12 MIRROR – INNER REAR VIEW MIRROR PROBLEM SYMPTOMS TABLE AUTOMATIC GLARE-RESISTANT EC MIRROR Symptom Suspected area 1. ECU-IG No. 1 fuse Auto glare-resistant EC mirror does not operate 2. Inner rear view mirror 3. Wire harness See page MI-12 - REMOVAL MI 1. REMOVE INNER REAR VIEW MIRROR ASSEMBLY (for TMC Made without EC Mirror) (a) Disengage the 2 claws and the cover. B136836 (b) Pull the lever in the direction indicated by the arrow shown in the illustration and slide the inner rear view mirror assembly upward to remove it. B136837 2. B136890 REMOVE INNER REAR VIEW MIRROR ASSEMBLY (for TMMK Made without EC Mirror) (a) Using a "torx" socket wrench (T20), remove the screw. (b) Slide the inner rear view mirror assembly in the direction indicated by the arrow shown in the illustration to remove it. MIRROR – INNER REAR VIEW MIRROR 3. MI–13 REMOVE INNER REAR VIEW MIRROR STAY HOLDER COVER (w/ EC Mirror) (a) Disengage the 2 claws and slide the inner rear view mirror stay holder cover as shown in the illustration. MI B136833 (b) Disengage the 6 claws and remove the inner rear view mirror stay holder cover. B136834 4. B136835 REMOVE INNER REAR VIEW MIRROR ASSEMBLY (w/ EC Mirror) (a) Disconnect the connector. (b) Using a "torx" socket wrench (T20), remove the screw and the inner rear view mirror. MI–14 MIRROR – INNER REAR VIEW MIRROR INSPECTION 1. 4 1 MI Black Colored Tape INSPECT INNER REAR VIEW MIRROR ASSEMBLY (a) Inspect operation of the electrochromic inner mirror. (1) Connect the positive (+) lead from the battery to terminal 4 and the negative (-) lead to terminal 1. (2) Attach black colored tape to the forward sensor to prevent it from sensing. (3) Light up the mirror with an electric light, and check that the mirror surface changes from bright to dark. Standard: Mirror surface changes from bright to dark. If the result is not as specified, replace the mirror assembly. Forward Sensor B137080E01 INSTALLATION 1. B136887 INSTALL INNER REAR VIEW MIRROR ASSEMBLY (for TMC Made without EC Mirror) (a) Slide the inner rear view mirror assembly in the direction indicated by the arrow shown in the illustration to install it. MIRROR – INNER REAR VIEW MIRROR MI–15 (b) Engage the 2 claws and install the cover. MI B136836 2. INSTALL INNER REAR VIEW MIRROR ASSEMBLY (for TMMK Made without EC Mirror) (a) Slide the inner rear view mirror assembly in the direction indicated by the arrow shown in the illustration to install it. (b) Using a "torx" socket wrench (T20), install the screw. Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf) 3. INSTALL INNER REAR VIEW MIRROR ASSEMBLY (w/ EC Mirror) (a) Using a "torx" socket wrench (T20), install the inner rear view mirror with the screw. Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf) (b) Connect the connector. 4. INSTALL INNER REAR VIEW MIRROR STAY HOLDER COVER (w/ EC Mirror) (a) Engage the 6 claws and install the inner rear view mirror stay holder cover. B140444 B136835 B136834 (b) Engage the 2 claws and install the inner rear view mirror stay holder cover as shown in the illustration. B136841 MI–15 MIRROR – OUTER REAR VIEW MIRROR OUTER REAR VIEW MIRROR MIRROR BODY COMPONENTS MI OUTER REAR VIEW MIRROR ASSEMBLY 5.5 (56, 49 in.*lbf) FRONT DOOR LOWER FRAME BRACKET GARNISH N*m (kgf*cm, ft.*lbf) : Specified torque B136888E01 MI–16 MIRROR – OUTER REAR VIEW MIRROR REMOVAL 1. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH (See page ED-14) 2. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY (a) Disconnect the connector. (b) Remove the 3 nuts. (c) Disengage the claw and remove the outer rear view mirror assembly. MI B136838 INSPECTION (A) (C) 1. (D) (B) INSPECT OUTER REAR VIEW MIRROR ASSEMBLY RH (a) Inspect outer mirror motor operation. (1) Apply battery voltage and check operation of the mirror face, as shown in the table and illustration. Standard Measurement Condition M+ MH H- H+ MV B137078E01 Specified Condition Battery positive (+) → Terminal 5 (MV) Battery negative (-) → Terminal 2 (M+) Turns upward (A) Battery positive (+) → Terminal 2 (M+) Battery negative (-) → Terminal 5 (MV) Turns downward (B) Battery positive (+) → Terminal 1 (MH) Battery negative (-) → Terminal 2 (M+) Turns left (C) Battery positive (+) → Terminal 2 (M+) Battery negative (-) → Terminal 1 (MH) Turns right (D) (b) Inspect outer mirror heater operation. (1) Apply battery voltage and check operation of the mirror face, as shown in the table below. Standard Measurement Condition Specified Condition Battery positive (+) → Terminal 3 (H+) Battery negative (-) → Terminal 4 (H-) Mirror surface temperature becomes higher MI–17 MIRROR – OUTER REAR VIEW MIRROR 2. (A) (C) (D) (B) INSPECT OUTER REAR VIEW MIRROR ASSEMBLY LH (a) Inspect outer mirror motor operation. (1) Remove the outer rear view mirror assembly. (2) Apply battery voltage and check operation of the mirror face, as shown in the table and illustration. Standard Measurement Condition M+ H- MH H+ MV B137079E01 Specified Condition Battery positive (+) → Terminal 5 (MV) Battery negative (-) → Terminal 2 (M+) Turns upward (A) Battery positive (+) → Terminal 2 (M+) Battery negative (-) → Terminal 5 (MV) Turns downward (B) Battery positive (+) → Terminal 1 (MH) Battery negative (-) → Terminal 2 (M+) Turns left (C) Battery positive (+) → Terminal 2 (M+) Battery negative (-) → Terminal 1 (MH) Turns right (D) (b) Inspect outer mirror heater operation. (1) Apply battery voltage and check operation of the mirror face, as shown in the table below. Standard Measurement Condition Specified Condition Battery positive (+) → Terminal 3 (H+) Battery negative (-) → Terminal 4 (H-) Mirror surface temperature becomes higher INSTALLATION B136838 1. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY (a) Engage the claw to install the outer rear view mirror assembly. (b) Install the outer rear view mirror assembly with the 3 nuts. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) (c) Connect the connector. 2. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH (See page ED-34) MI MI–18 MIRROR – OUTER REAR VIEW MIRROR GLASS OUTER REAR VIEW MIRROR GLASS MIRROR BODY COMPONENTS TMC made: MI OUTER REAR VIEW MIRROR GLASS TMMK made: OUTER REAR VIEW MIRROR GLASS B146018E01 REPLACEMENT 1. Moulding Remover REMOVE OUTER REAR VIEW MIRROR GLASS (for TMC Made) (a) Push the upper part of the mirror surface and tilt it. (b) Using a moulding remover, disengage the 2 claws at the lower part of the outer rear view mirror, and remove the outer rear view mirror glass. Protective Tape B136868E01 (c) with Mirror Heater: (1) Disconnect the connector and remove the outer rear view mirror glass. B136869 MIRROR – OUTER REAR VIEW MIRROR GLASS 2. Moulding Remover MI–19 REMOVE OUTER REAR VIEW MIRROR GLASS (for TMMK Made) (a) Push the lower part of the mirror surface and tilt it. (b) Using a moulding remover, disengage the 2 claws at the upper part of the outer rear view mirror, and remove the outer rear view mirror glass. Protective Tape MI B146019E01 (c) with Mirror Heater: (1) Disconnect the connector and remove the outer rear view mirror glass. B146020 3. INSTALL OUTER REAR VIEW MIRROR GLASS (for TMC Made) (a) with Mirror Heater: (1) Connect the connector. B136869 (b) Engage the 2 claws on the upper part of the outer rear view mirror glass to the outer rear view mirror. (c) Engage the 2 claws on the lower part of the outer rear view mirror glass to the outer rear view mirror as shown in the illustration. B136870 4. B146020 INSTALL OUTER REAR VIEW MIRROR GLASS (for TMMK Made) (a) with Mirror Heater: (1) Connect the connector. MI–20 MIRROR – OUTER REAR VIEW MIRROR GLASS (b) Engage the 2 claws on the lower part of the outer rear view mirror glass to the outer rear view mirror. (c) Engage the 2 claws on the upper part of the outer rear view mirror glass to the outer rear view mirror as shown in the illustration. MI B146021 MIRROR – OUTER MIRROR SWITCH MI–21 OUTER MIRROR SWITCH MIRROR BODY COMPONENTS MI NO. 1 INSTRUMENT PANEL SUB-ASSEMBLY OUTER MIRROR SWITCH ASSEMBLY B136891E01 MI–22 MIRROR – OUTER MIRROR SWITCH REMOVAL 1. REMOVE NO. 1 INSTRUMENT PANEL SUBASSEMBLY (See page IP-22) 2. REMOVE OUTER MIRROR SWITCH ASSEMBLY (a) Disengage the 2 claws and remove the outer mirror switch assembly. MI B136840 INSPECTION 1. INSPECT OUTER MIRROR SWITCH ASSEMBLY (a) Inspect the outer mirror switch. (1) Measure the resistance according to the value(s) in the table below when the switch is operated. Standard resistance: Select "L" on the left/right adjustment switch Tester Connection 4-8 Switch Position Specified Condition UP 6-7 4-7 DOWN 6-8 Below 1 Ω 5-8 LEFT 6-7 5-7 RIGHT 6-8 Select "R" on the left/right adjustment switch B127553E01 Tester Connection 3-8 6-7 3-7 6-8 2-8 6-7 2-7 6-8 Switch Position Specified Condition UP DOWN Below 1 Ω LEFT RIGHT MIRROR – OUTER MIRROR SWITCH MI–23 INSTALLATION 1. INSTALL OUTER MIRROR SWITCH ASSEMBLY (a) Engage the 2 claws and install the outer mirror switch assembly. 2. INSTALL NO. 1 INSTRUMENT PANEL SUBASSEMBLY (See page IP-57) MI B136840 FOREWORD This wiring diagram manual has been prepared to provide information on the electrical system of the 2007 CAMRY. Applicable models: GSV40 Series ACV40 Series Refer to the following manuals for additional service specifications and repair procedures for these models: Manual Name D 2007 CAMRY Repair Manual D 2007 CAMRY New Car Features Pub. No. RM0250U NM0250U All information in this manual is based on the latest product information at the time of publication. However, specifications and procedures are subject to change without notice. NOTICE Always follow the directions given in the above repair manuals when handling supplemental restraint system components (such as removal, installation, inspection, etc.) in order to prevent accidents and supplemental restraint system malfunction. E2006 All rights reserved. This book may not be reproduced or copied, in whole or in part, without the written permission of Toyota Motor Corporation. First Printing : Jan. 13, 2006 01–060113–00 2007 CAMRY ELECTRICAL WIRING DIAGRAM Section Code Page INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . A . . . . 2 HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . B . . . . 3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . C . . . . 12 ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . D . . . . 17 GLOSSARY OF TERMS AND SYMBOLS . . . . . E . . . . 18 RELAY LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . F . . . . 20 ELECTRICAL WIRING ROUTING . . . . . . . . . . . G . . . . 48 SYSTEM CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . H . . . . 70 GROUND POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . I . . . . 396 POWER SOURCE (Current Flow Chart) . . . . . J . . . . 404 CONNECTOR LIST . . . . . . . . . . . . . . . . . . . . . . . . K . . . . 414 PART NUMBER OF CONNECTORS . . . . . . . . . L . . . . 436 OVERALL ELECTRICAL WIRING DIAGRAM . M . . . . 440 1 CAMRY (EM0250U) A INTRODUCTION This manual consists of the following 13 sections: No. Section Description INDEX Index of the contents of this manual. INTRODUCTION Brief explanation of each section. B HOW TO USE THIS MANUAL Instructions on how to use this manual. C TROUBLE– SHOOTING Describes the basic inspection procedures for electrical circuits. D ABBREVIATIONS Defines the abbreviations used in this manual. E GLOSSARY OF TERMS AND SYMBOLS Defines the symbols and functions of major parts. F RELAY LOCATIONS Shows position of the Electronic Control Unit, Relays, Relay Block, etc. This section is closely related to the system circuit. G ELECTRICAL WIRING ROUTING Describes position of Parts Connectors, Splice points, Ground points, etc. This section is closely related to the system circuit. INDEX Index of the system circuits. SYSTEM CIRCUITS Electrical circuits of each system are shown from the power supply through ground points. Wiring connections and their positions are shown and classified by code according to the connection method. (Refer to the section, ”How to use this manual”). The ”System Outline” and ”Service Hints” useful for troubleshooting are also contained in this section. I GROUND POINT Shows ground positions of all parts described in this manual. J POWER SOURCE (Current Flow Chart) Describes power distribution from the power supply to various electrical loads. K CONNECTOR LIST Describes the form of the connectors for the parts appeared in this book. This section is closely related to the system circuit. L PART NUMBER OF CONNECTORS Indicates the part number of the connectors used in this manual. M OVERALL ELECTRICAL WIRING DIAGRAM Provides circuit diagrams showing the circuit connections. A H 2 CAMRY (EM0250U) HOW TO USE THIS MANUAL B This manual provides information on the electrical circuits installed on vehicles by dividing them into a circuit for each system. The actual wiring of each system circuit is shown from the point where the power source is received from the battery as far as each ground point. (All circuit diagrams are shown with the switches in the OFF position.) When troubleshooting any problem, first understand the operation of the circuit where the problem was detected (see System Circuit section), the power source supplying power to that circuit (see Power Source section), and the ground points (see Ground Point section). See the System Outline to understand the circuit operation. When the circuit operation is understood, begin troubleshooting of the problem circuit to isolate the cause. Use Relay Location and Electrical Wiring Routing sections to find each part, junction block and wiring harness connectors, wiring harness and wiring harness connectors and ground points of each system circuit. Internal wiring for each junction block is also provided for better understanding of connection within a junction block. Wiring related to each system is indicated in each system circuit by arrows (from__, to__). When overall connections are required, see the Overall Electrical Wiring Diagram at the end of this manual. 3 CAMRY (EM0250U) B HOW TO USE THIS MANUAL * The system shown here is an EXAMPLE ONLY. It is different to the actual circuit shown in the SYSTEM CIRCUITS SECTION. [A] Stop Light (BAT) [M] (IG) 15A STOP 7.5A GAUGE 2 [B] 3 IB 4 IB L (S/D) W–R R–L 1 7 3C 2 [G] [C] H6 Stop Lamp SW 15 3C 14 CH1 8 11 W–B [I] (Shielded) 2 H17 Center Stop Lamp [J] 1 W–B W–B W–B 6 W–B W–B 1 HJ1 H1 50 Rear Lights 4 G–B H9 Rear Combination Lamp (LH) G–R Stop Stop [N] 3 3 H4 Light Failure Sensor 1 G–R J7 Rear Combination Lamp (RH) 1 HJ1 [F] G–R [H] 13 Y–G L G–W (S/D) G–W 2 G–R [E] [K] H2 [L] 4 CAMRY (EM0250U) H7 Combination Meter 4 15 CH1 7 4 R–L L (S/D) R G–W Skid Control ECU with Actuator [D] (W/G) 1 B [A] : System Title [H] : Indicates the wiring color. Wire colors are indicated by an alphabetical code. [B] : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: Indicates Relay Block No.1 [C] : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. B = Black W = White BR = Brown L = Blue V SB = Sky Blue = Violet R = Red G = Green LG = Light Green P Y GR = Gray = Pink = Yellow O = Orange The first letter indicates the basic wire color and the second letter indicates the color of the stripe. [D] : Indicates related system. [E] : Indicates the code for the (male and female) connectors which are used to join two wire harnesses. The connector code consists of two alphabetical and one numerical characters. Example: L–Y L (Blue) [I] Female Male ( Y (Yellow) : Indicates a shielded cable. ) The first character of the connector code indicates the alphabetical code allocated to the wire harness which has the female connector, and the second shows that of the wire harness which has the male connector. The third character indicates a serial number used to distinguish between the wire harness combinations in cases when more than one of the same combination of wire harnesses exist (e.g. CH1 and CH2). [J] : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in other from upper left to lower right Symbol ( ) indicates the male terminal connector. Numbers outside connector codes indicate the pin numbers of both male and female connectors. [F] : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. [G] : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. Female Numbered in other from upper right to lower left Male [K] : Indicates the ground point. The code consists of the two characters: A letter and number. The first character of the code indicates the alphabetical code allocated to the wire harness. The second character indicates a serial number used to distinguish between the ground points in cases when more than one ground point exist on the same wire harness. [L] : Page No. [M] : Indicates the ignition key position(s) when the power is supplied to the fuse(s). Example: 3C indicates that it is inside Junction Block No.3 [N] : Indicates a wiring Splice Point. Example: 5 CAMRY (EM0250U) B HOW TO USE THIS MANUAL [O] System Outline Current is applied at all times through the STOP fuse to TERMINAL 2 of the stop lamp SW. When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL 8 of the light failure sensor, and also flows through the rear lights warning light to TERMINAL 4 of the light failure sensor. Stop Light Disconnection Warning When the ignition SW is turned on and the brake pedal is pressed (Stop lamp SW on), if the stop light circuit is open, the current flowing from TERMINAL 7 of the light failure sensor to TERMINALS 1, 2 changes, so the light failure sensor detects the disconnection and the warning circuit of the light failure sensor is activated. As a result, the current flows from TERMINAL 4 of the light failure sensor to TERMINAL 11 to GROUND and turns the rear lights warning light on. By pressing the brake pedal, the current flowing to TERMINAL 8 of the light failure sensor keeps the warning circuit on and holds the warning light on until the ignition SW is turned off. [P] : Parts Location Code See Page Code See Page Code See Page H4 36 H7 36 H17 38 H6 36 H9 38 J7 38 [Q] : Relay Blocks Code 1 [R] See Page 18 Relay Blocks (Relay Block Location) R/B No.1 (Instrument Panel Brace LH) : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) 3C 22 Instrument Panel Wire and J/B No.3 (Instrument Panel Brace LH) IB 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) [S] : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) CH1 42 Engine Room Main Wire and Instrument Panel Wire (Left Kick Panel) HJ1 50 Instrument Panel Wire and Floor Wire (Right Kick Panel) [T] : Ground Points Code See Page Ground Points Location H1 50 Under the Left Center Pillar H2 50 Back Panel Center 6 CAMRY (EM0250U) B [O] : Explains the system outline. [P] : Indicates reference pages showing the parts locations in the system circuit on the vehicle. Example : Code ”H4” (Light Failure Sensor) is on page 36 of the manual. * The first character of the code indicates the alphabetical code allocated to the wire harness, and the second character indicates the serial number of the parts connected to the wire harness. Example : H 4 Á Á Serial number for the connected parts Code for the wire harness [Q] : Indicates the reference page showing the position on the vehicle of Relay Block Connectors in the system circuit. Example : Connector ”1” is described on page 18 of this manual and is installed on the left side of the instrument panel. [R] : Indicates the reference page showing the position on the vehicle of J/B and Wire Harness in the system circuit. Example : Connector ”3C” connects the Instrument Panel Wire and J/B No.3. It is described on page 22 of this manual, and is installed on the instrument panel left side. [S] : Indicates the reference page describing the wiring harness and wiring harness connector (the female wiring harness is shown first, followed by the male wiring harness). Example : Connector ”CH1” connects the Engine Room Main Wire (female) and Instrument Panel Wire (male). It is described on page 42 of this manual, and is installed on the left side kick panel. [T] : Indicates the reference page showing the position of the ground points on the vehicle. Example : Ground point ”H2” is described on page 50 of this manual and is installed on the back panel center. 7 CAMRY (EM0250U) B HOW TO USE THIS MANUAL The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points ( A1 , A2 and D4 shown below) can also be checked this way. I GROUND POINT 12 HB4 9 DB1 BR BR W–B L5 Power Window Master SW W–B A22 Cooling Fan Motor No.3 (E) (E) 5 BR 4 3 BR 2 11 BR 8 3 LA1 W–B 7 1 W–B A25 Junction Connector A20 Headlamp Leveling (LH E) Motor (LH) (Shielded) 4 BR BR BR (Shielded) (SG) (Shielded) H23 DLC3 D43 Junction Connector 6 10 BR (L) D63 Throttle Position SW (E1) D60 Injection Pump Assembly (E1) (E01) D2 Engine ECU (E02) W–B 3 W–B A5 Pressure SW W–B A11 Windshield Wiper Motor (E) I9 Headlamp Leveling SW (E) A6 Clearance Lamp (Front RH) (E) A21 Clearance Lamp (Front LH) (E) W–B W–B W–B 5 CA1 W–B W–B W–B W–B (E) 12 IH2 W–B 7 HA1 W–B W–B W–B (E) C2 Fog Lamp (Front LH) (E) C4 Fog Lamp (Front RH) (E) A10 Brake Fluid Level Warning SW (E) A1 Turn Signal Lamp (Front RH) (E) K5 Power Window Master SW W–B A23 Turn Signal Lamp (Front LH) (5L–E) W–B W–B 3 KA1 W–B W–B (–S) D4 W–B A8 Headlamp Leveling (RH E) Motor (RH) W–B W–B W–B 20 W – B (Shielded) 19 W – B (Shielded) 18 W – B (Shielded) 17 W – B (Shielded) A1 (GND) 21 AB1 W–B W–B 12 AB1 W–B 16 W–B W–B (GND) W–B 6 AB1 W–B B19 Skid Control ECU with Actuator B36 Junction Connector (GND1) W–B W–B (GND2) W–B A24 Option Connector (Vacuum) W–B W–B A2 * The system shown here is an EXAMPLE ONLY. It is different to the actual circuit shown in the SYSTEM CIRCUITS SECTION. 8 CAMRY (EM0250U) B The ”Current Flow Chart” section, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. J POWER SOURCE (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fues, etc.) and other parts 10A ECU–B 2 2 Short Pin 7.5A DOME 15A EFI Battery 2 30A AM2 6 Fusible Link Block 10A HAZARD 2 20A RADIO NO.1 S2 Starter 10A HORN 6 100A ALT 5 60A ABS Engine Room R/B (See Page 20) 20A 10A Fuse System Page STOP ABS ABS and Traction Control Cruise Control Electronically Controlled Transmission Multiplex Communication System 194 187 180 166 210 DOME Cigarette Lighter Combination Meter Headlight Interior Light Key Reminder and Seat Belt Warning Light Auto Turn Off System Theft Deterrent and Door Lock Control 214 230 112 122 Power Source B 1 BA1 W 1.25B FL MAIN Battery 50A MAIN B 2 1 7.5A DOME 2 2 W 7 AH1 W W 1 1 2 R 1 7.5A AM1 2 1 2 2 W–R 6 AH1 W–R W B 15A HAZ–RADIO 2 W 8 4 AM2 2 AM1 1 ST2 IG2 ST1 IG1 ACC H8 Ignition SW 2 20A DEFOG B–Y ∗ 1 1 2 1 W–R The system shown here is an EXAMPLE ONLY. It is different to the actual circuit shown in the SYSTEM CIRCUITS SECTION. 9 CAMRY (EM0250U) B HOW TO USE THIS MANUAL K CONNECTOR LIST [A] A1 A2 A3 Black Gray 1 2 3 4 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 [D] [B] B1 B2 Black 1 3 [C] Gray 2 4 5 6 1 2 3 4 5 6 7 8 9 10111213 K CONNECTOR LIST BA1 1 2 3 4 5 6 7 8 9 10 11 12 13 Black BD2 [E] 1 2 3 4 5 6 7 8 9 10 11 5 4 3 2 1 13 12 11 10 9 8 7 6 Gray [F] 4 3 2 1 11 10 9 8 7 6 5 [A] : Indicates connector to be connected to a part. (The numeral indicates the pin No.) [B] : Junction Connector Indicates a connector which is connected to a short terminal. Junction Connector Junction connector in this manual include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. Short Terminal [C] : Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. [D] : Connector Color Connectors not indicated are milky white in color. [E] : Indicates the connector shapes which are used to join wire harnesses. On Left : Female connector shapes On Right : Male connector shapes Numbers indicate pin numbers. [F] : Indicates connector colors. (Connectors with not indicated colors are white) 10 CAMRY (EM0250U) B L PART NUMBER OF CONNECTORS Part Name Code Part Number Code Part Name Part Number A1 Turn Signal Lamp (Front RH) 90980–11019 B22 Door Courtesy SW (Front LH) 90980–12470 A2 Inlet Air Temp. Sensor 90980–11163 B23 Front Seat Outer Belt (LH) 90980–12253 A3 Air Flow Meter 90980–12292 B24 Blower SW (Rear Heater) 90980–10463 A4 A/C Pressure Sensor 90980–10845 B25 Front Seat Outer Belt (RH) 90980–12253 A5 Pressure SW 90980–10943 B26 Door Courtesy SW (Front RH) 90980–12470 A6 Clearance Lamp (Front RH) 90980–11156 B27 Cooling Fan ECU No.1 Headlamp [B](RH) 90980–11314 [C] B28 Cooling Fan ECU No.2 Headlamp Leveling Motor (RH) 90980–11016 B29 Water Temp. Sensor (Radiator) 90980–10735 A7 [A] A8 90980–10841 A9 Brake Vacuum Warning SW 90980–11252 B30 Fuel Filter Warning SW 90980–11003 A10 Brake Fluid Level Warning SW 90980–11207 B32 Door Control Relay (LH) 90980–10789 A11 Windshield Washer Motor 90980–11599 B33 Step Lamp (LH) 90980–10121 A12 Airbag Sensor (Front RH) 90980–11856 B34 Junction Connector A13 Airbag Squib B35 Junction Connector 90980–11398 90980–12490 [A] : Part Code [B] : Part Name [C] : Part Number Toyota Part Number are indicated. Not all of the above part numbers of the connector are established for the supply. 11 CAMRY (EM0250U) C TROUBLESHOOTING To Ignition SW IG Terminal (a) Establish conditions in which voltage is present at the check point. Example: [A] – Ignition SW on [B] – Ignition SW and SW 1 on [C] – Ignition SW, SW 1 and Relay on (SW 2 off) Fuse [A] SW 1 VOLTAGE CHECK Voltmeter [B] (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Relay [C] Solenoid SW 2 CONTINUITY AND RESISTANCE CHECK (a) Disconnect the battery terminal or wire so there is no voltage between the check points. Ohmmeter (b) Contact the two leads of an ohmmeter to each of the check points. SW If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Ohmmeter Diode Digital Type Analog Type (c) Use a volt/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting of the electrical circuit. 12 CAMRY (EM0250U) C FINDING A SHORT CIRCUIT To Ignition SW IG Terminal (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Test Light Fuse Case Example: [A] – Ignition SW on [B] – Ignition SW and SW 1 on [C] – Ignition SW, SW 1 and Relay on (Connect the Relay) and SW 2 off (or Disconnect SW 2) Short [A] SW 1 (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. Short [B] Disconnect (e) Find the exact location of the short by lightly shaking the problem wire along the body. Disconnect Light Relay CAUTION: (a) Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) (b) When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Short [C] Disconnect SW 2 Solenoid DISCONNECTION OF MALE AND FEMALE CONNECTORS To pull apart the connectors, pull on the connector itself, not the wire harness. HINT : Check to see what kind of connector you are disconnecting before pulling apart. Pull Up Pull Up Press Down Press Down 13 CAMRY (EM0250U) C TROUBLESHOOTING HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Reference: 1. PREPARE THE SPECIAL TOOL 10 3 1 Example: (Case 1) 1 HINT : To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. DISCONNECT CONNECTOR 0.2 (mm) Up Tool 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTICE: Do not remove the terminal retainer from connector body. Terminal Retainer [A] Terminal Retainer For Non–Waterproof Type Connector HINT : The needle insertion position varies according to the connector’s shape (number of terminals etc.), so check the position before inserting it. ”Case 1” [Retainer at Full Lock Position] Raise the terminal retainer up to the temporary lock position. Stopper Terminal Retainer [Retainer at Temporary Lock Position] Example: (Case 2) Secondary Locking Device ”Case 2” Open the secondary locking device. 14 CAMRY (EM0250U) C Tool Tab Tab Example: (Case 1) [B] Terminal Retainer Tool [Male] Access Hole ( Mark) Tool For Waterproof Type Connector HINT : Terminal retainer color is different according to connector body. Example: Terminal Retainer Black or White Black or White Gray or White : Connector Body : Gray : Dark Gray : Black [Female] ”Case 1” Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (YMark) and pull the terminal retainer up to the temporary lock position. Retainer at Full Lock Position HINT : The needle insertion position varies according to the connector’s shape (Number of terminals etc.), so check the position before inserting it. Retainer at Temporary Lock Position [Male] Example: (Case 2) [Female] ”Case 2” Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Tool Tool [Male] Press Down Press Down [Female] 15 CAMRY (EM0250U) C TROUBLESHOOTING Push the terminal retainer down to the temporary lock position. Retainer at Full Lock Position Retainer at Temporary Lock Position [Male] [Female] (c) Release the locking lug from terminal and pull the terminal out from rear. Locking Lug Tool 4. INSTALL TERMINAL TO CONNECTOR (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR 16 CAMRY (EM0250U) ABBREVIATIONS D ABBREVIATIONS The following abbreviations are used in this manual. A/C = Air Conditioning A/T = Automatic Transaxle ABS = Anti–Lock Brake System ACIS = Acoustic Control Induction System ACM = Active Control Engine Mount CAN = Controller Area Network EC = Electrochromic ECU = Electronic Control Unit ESA = Electronic Spark Advance ETCS–i = Electronic Throttle Control System–intelligent FL = Fusible Link IC = Integrated Circuit J/B = Junction Block LCD = Liquid Crystal Display LH = Left–Hand M/T = Manual Transaxle R/B = Relay Block RH = Right–Hand SFI = Sequential Multiport Fuel Injection SRS = Supplemental Restraint System SW = Switch TEMP. = Temperature TRAC = Traction Control VSC = Vehicle Stability Control VSV = Vacuum Switching Valve VVT = Variable Valve Timing VVT–i = Variable Valve Timing–intelligent w/ = With w/o = Without ∗ The titles given inside the components are the names of the terminals (terminal codes) and are not treated as being abbreviations. 17 CAMRY (EM0250U) E GLOSSARY OF TERMS AND SYMBOLS GROUND The point at which wiring attaches to the Body, thereby providing a return path for an electrical circuit; without a ground, current cannot flow. BATTERY Stores chemical energy and converts it into electrical energy. Provides DC current for the auto’s various electrical circuits. CAPACITOR (Condenser) A small holding unit for temporary storage of electrical voltage. CIGARETTE LIGHTER An electric resistance heating element. HEADLIGHTS Current flow causes a headlight 1. SINGLE FILAMENT filament to heat up and emit light. A headlight may have either a single (1) filament or a double (2) filament 2. DOUBLE FILAMENT CIRCUIT BREAKER Basically a reusable fuse, a circuit breaker will heat and open if too much current flows through it. Some units automatically reset when cool, others must be manually reset. HORN An electric device which sounds a loud audible signal. DIODE A semiconductor which allows current flow in only one direction. IGNITION COIL Converts low–voltage DC current into high–voltage ignition current for firing the spark plugs. DIODE, ZENER LIGHT Current flow through a filament causes the filament to heat up and emit light. A diode which allows current flow in one direction but blocks reverse flow only up to a specific voltage. Above that potential, it passes the excess voltage. This acts as a simple voltage regulator. PHOTODIODE The photodiode is a semiconductor which controls the current flow according to the amount of light. LED (LIGHT EMITTING DIODE) Upon current flow, these diodes emit light without producing the heat of a comparable light. DISTRIBUTOR, IIA Channels high–voltage current from the ignition coil to the individual spark plugs. METER, ANALOG Current flow activates a magnetic coil which causes a needle to move, thereby providing a relative display against a background calibration. FUSE METER, DIGITAL Current flow activates one or many LED’s, LCD’s, or fluorescent displays, which provide a relative or digital display. A thin metal strip which burns through when too much current flows through it, thereby stopping current flow and protecting a circuit from damage. FUEL FUSIBLE LINK (for Medium Current Fuse) (for High Current Fuse or Fusible Link) A heavy–gauge wire placed in high amperage circuits which burns through on overloads, thereby protecting the circuit. The numbers indicate the crosssection surface area of the wires. M 18 CAMRY (EM0250U) MOTOR A power unit which converts electrical energy into mechanical energy, especially rotary motion. E RELAY Basically, an electrically operated 1. NORMALLYswitch which may be normally CLOSED closed (1) or open (2). Current flow through a small coil creates a magnetic field which either opens or closes an attached switch. 2. NORMALLY OPEN RELAY, DOUBLE THROW A relay which passes current through one set of contacts or the other. SPEAKER An electromechanical device which creates sound waves from current flow. SWITCH, MANUAL Opens and closes circuits, thereby 1. NORMALLY stopping (1) or OPEN allowing (2) current flow. 2. NORMALLY CLOSED RESISTOR An electrical component with a fixed resistance, placed in a circuit to reduce voltage to a specific value. SWITCH, DOUBLE THROW A switch which continuously passes current through one set of contacts or the other. RESISTOR, TAPPED A resistor which supplies two or more different non adjustable resistance values. SWITCH, IGNITION A key operated switch with several positions which allows various circuits, particularly the primary ignition circuit, to become operational. RESISTOR, VARIABLE or RHEOSTAT A controllable resistor with a variable rate of resistance. Also called a potentiometer or rheostat. (Reed Switch Type) SENSOR (Thermistor) A resistor which varies its resistance with temperature. SWITCH, WIPER PARK Automatically returns wipers to the stop position when the wiper switch is turned off. SENSOR, SPEED Uses magnetic impulses to open and close a switch to create a signal for activation of other components. TRANSISTOR A solidstate device typically used as an electronic relay; stops or passes current depending on the voltage applied at ”base”. SHORT PIN Used to provide an unbroken connection within a junction block. SOLENOID An electromagnetic coil which forms a magnetic field when current flows, to move a plunger, etc. WIRES Wires are always drawn as (1) NOT straight lines on wiring CONNECTED diagrams. Crossed wires (1) without a black dot at the junction are not joined; crossed wires (2) with a black dot or octagonal ( ) (2) SPLICED mark at the junction are spliced (joined) connections. 19 CAMRY (EM0250U) F RELAY LOCATIONS [Engine Compartment] Engine Control Module(2AZ-FE) Engine Control Module(2GR-FE) Engine Room R/B Engine Room J/B Skid Control ECU with Actuator Cooling Fan ECU Transmission Control ECU [Instrument Panel] ID Code Box (*1) Transponder Key ECU (*2) Junction Connector (CAN) J/B No.4 A/C Amplifier J/B No.3 Certification ECU Turn Signal Flasher Tire Pressure Warning ECU Airbag Sensor Assembly Center Stereo Component Amplifier Main Body ECU Instrument Panel J/B * 1:w/ Smart System * 2:w/o Smart System Steering Lock ECU Transponder Key Amplifier 20 CAMRY (EM0250U) Shift Lock Control ECU F [Body] Sliding Roof Control ECU and Motor Overhead J/B Door Control Receiver Tire Pressure Warning Antenna and Receiver [Seat] Occupant Classification ECU 21 CAMRY (EM0250U) F RELAY LOCATIONS 1 : Engine Room R/B : Engine Room J/B 1 Engine Compartment Left (See Page 20) * 1:120A ALT (for High Current) * 2:30A ST/AM2 (for High Current) * 3:50A HTR (for High Current) * 4:50A ABS No.1 (for High Current) * 5:50A FAN MAIN (for High Current) * 6:30A ABS No.2 (for High Current) * 7:50A RR DEF (for High Current) * 8:40A CDS FAN (for High Current) * 9:40A RDI FAN (for High Current) 1G (from Engine Room Main Wire) Wire Color : W *9 *2 *8 1 EFI MAIN 30A 2 1F 1 H-LP (LH) 15A H-LP (RH) 15A H-LP (LL) 15A H-LP (RL) 15A HORN 10A *7 1 *6 *5 DOOR NO.1 25A Unit D AMP 25A 2 (from Engine Room Main Wire) Wire Color : B Unit B 2 *4 *1 1 EFI NO.1 10A MPX-B 10A A/F 20A S-HORN 7.5A EFI NO.2 1 15A 2 EFI NO.3 1 10A 2 Unit A 1C 1 4 1 (from Engine Wire) Wire Color : B STR LOCK 1 20A 2 IG2 1 20A 2 HAZ 1 15A 2 RADIO NO.1 ETCS 1 10A 2 2 15A 1 ECU-B NO.1 2 10A 1 DOME 2 10A 1 SHORT 2 1 ALT-S 1 7.5A 2 AM2 1 7.5A 2 3 RR DEF Relay *3 2 5 1 IG2 Relay VSC No.1 Relay 5 3 2 3 5 ST CUT Relay 1 3 5 2 1 2 ST Relay 2 3 5 MGC Relay 1 3 5 2 1 Unit C 3 5 1 2 Unit E 22 CAMRY (EM0250U) VSC NO.2 Relay F Unit E 2AZ-FE 2GR-FE 1 FAN NO.1 Relay 5 3 5 3 2 1 FAN NO.3 Relay 2 2 3 1 FAN NO.2 Relay 4 2 5 5 FAN MAIN Relay 3 1 23 CAMRY (EM0250U) F RELAY LOCATIONS 1 : Engine Room R/B : Engine Room J/B Engine Compartment Left (See Page 20) Unit D View A View B View C 24 CAMRY (EM0250U) F View A Black 5 4 3 2 1 (from Engine Room Main Wire) 6 5 4 3 2 1 (from Engine Room Main Wire) 1A 1B 6 5 4 3 2 1 5 4 3 2 1 View B Black 13121110 9 8 7 6 5 4 3 2 1 (from Engine Room Main Wire) 1D 5 4 3 2 1 1312 1110 9 8 7 6 13 12 11 10 9 8 7 6 5 4 3 2 1 (from Engine Room Main Wire) 1E 5 4 3 2 1 1312 1110 9 8 7 6 View C 25 CAMRY (EM0250U) F RELAY LOCATIONS [Engine Room R/B and Engine Room J/B Inner Circuit] Unit C 1 1 2 15A EFI NO.2 2 1 1 1 10A EFI NO.3 1 1 1 2 15A RADIO NO.1 2 1 SHORT 1 1G 1 2 10A ECU-B NO.1 2 1 10A DOME 1 2 7.5A AM2 2 1 1 1 1 1 1 7.5A ALT-S 1 1 1 1 2 10A ETCS 2 1 15A HAZ 2 1 20A IG2 2 1 20A STR LOCK 2 1 1 1 1 1 1 30A EFI MAIN 1 1 2 25A AMP 1 2 25A DOOR NO.1 (Cont. Next Page) 26 CAMRY (EM0250U) 1 1 F (Cont'd) Unit A 30A ST/AM2 1 1 1 1 120A ALT 1 1 1 1C 1 1 1F 1 Unit B 1 50A HTR 1 50A ABS No.1 1 50A FAN MAIN 1 30A ABS No.2 1 50A RR DEF 1 1 1 40A CDS FAN 1 40A RDI FAN 1 (Cont. Next Page) 27 CAMRY (EM0250U) F RELAY LOCATIONS [Engine Room R/B and Engine Room J/B Inner Circuit] (Cont'd) Unit D 20A A/F A/F Relay 4 1A 7.5A S-HORN S-HORN Relay 5 1A 11 1D 10A MPX-B 3 1A 10A EFI NO.1 2 1A 15A H-LP (RL) H-LP (RL) Relay 5 1B 15A H-LP (LL) H-LP (LL) Relay 4 1B 15A H-LP (RH) DRL Relay 3 1B 2 1B 15A H-LP (LH) (Cont. Next Page) 28 CAMRY (EM0250U) F (Cont'd) 10A HORN HORN Relay 6 1B 10 1D 9 1D Light Control Circuit 10 1E 8 1D 11 1E EFI Relay 12 1E 9 1E C/OPN Relay 6 1E 13 1E 7 1E 8 1E 12 1D 29 CAMRY (EM0250U) F RELAY LOCATIONS : Instrument Panel J/B Cowl Side Left (See Page 20) IM 20 19 18 17 16 15 141312 11 10 9 8 7 6 5 4 3 2 1 IJ (from Instrument Panel Wire) 1 2 345 6 7 8 9 101112 IK 1615 14 1312 11 10 9 8 7 6 5 4 3 2 1 (from Instrument Panel Wire) (from Instrument Panel Wire) 9 10 111213141516 1 2 3 45678 Yellow 11121314 15 16 17 18 19 20 1 2 3 4 5 6 7 8 9 10 6 543 2 1 121110 9 8 7 IE IL 12 11 10 9 8 7 6 5 4 3 2 1 (from Instrument Panel Wire) 7 8 9 10 11 12 1 2 3 4 5 6 (from Instrument Panel Wire) 654321 87 10 9 11121314 15 16 17 18 19 20 1 2 3 4 5 6 7 8 9 10 IF IC 14 13 12 11 10 9 8 7 6 5 4 3 2 1 (from Engine Room Main Wire) 8 9 10 11 121314 1 2 3 4 5 67 (from Engine Room Main Wire) 2 1 6 5432 1 121110 9 8 7 IR IO IB 1 2 1 12 11 10 9 8 7 13 6 5 4 3 2 1 (from Floor Wire) (from Engine Room Main Wire) IA 1 2345 6 7 8 9 1011 12 (from Instrument Panel Wire) 7 8 9 10 11 12 13 123 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 1 20 19 18 17 16 15 14 131211 10 9 8 7 6 5 4 3 2 1 (from Instrument Panel Wire) 9 101112 13 14 15 16 123 4 5 6 7 8 ID 16 15 14 13 12 1110 9 8 7 6 5 4 3 2 1 123456 78 910 2 1 5 3 2 4 1 5 3 3 1 2 2 5 (from Engine Room Main Wire) FOG Relay IP 3 1 5 3 1 2 5 12 11 10 9 8 7 6 5 4 3 2 1 (from Floor Wire) IG1 Relay PWR Relay ACC Relay TAIL Relay 30 CAMRY (EM0250U) F 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Main Body ECU IG 121110 9 8 7 6 5 4 3 2 1 IH (from Instrument Panel Wire) 7 8 910 1112 1 2 3456 6 7 8 9 10 1 2 345 9 10 111213 14 15 16 12345 6 7 8 2 2 1 1 (from Instrument Panel Wire) 10 9 8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 30A POWER (for High Current) 30A P/SEAT (for High Current) II (from Instrument Panel Wire) 31 CAMRY (EM0250U) 32 CAMRY (EM0250U) PWR OUTLET 20A RADIO NO.2 7.5A MIR HTR 10A AM1 7.5A A/C 7.5A PWR 25A DOOR NO.2 25A S/ROOF 30A TAIL 15A PANEL 7.5A STOP 10A FR FOG 15A OBD 7.5A RR DOOR RH 25A RR DOOR LH 25A : Instrument Panel J/B INJ 15A IGN 10A GAUGE NO.2 7.5A ECU-ACC 7.5A ECU IG NO.1 10A ECU IG NO.2 7.5A A/C NO.2 10A WASH 10A S-HTR 20A GAUGE NO.1 10A WIP 25A F RELAY LOCATIONS Cowl Side Left (See Page 20) F [Instrument Panel J/B Inner Circuit] 4 IC 5 IC 1 IE 6 ID 2 IE 14 ID 10 IF 11 IH 1 IR 3 IL 15A TAIL 8 IP 4 3 5 1 IA 6 IF 7. 5A PANEL 2 IO 2 1 3 IR 4 IK TAIL Relay 4 IH 5 IK 1 IC 6 IK 5 ID 11 IM 4 ID 5 3 1 2 6 IG 15A FR FOG 4 IL 8 II FOG Relay 10 IM 11 IO 6 IE 12 IF 10 IH 10 IO 5 IE 7.5A RADIO NO.2 10 IG 3 5 3 IM 12 IO 20A PWR OUTLET 1 2 3 II ACC Relay 2 IB 8 IK 5 IH 10A MIR HTR 3 IE 3 IG 12 IJ 1 IK 10 IE 1 IH 2 IF 7.5A ECU-ACC 13 IO 3 IF 16 IM 11 IL 1 2 4 IO 30A P/SEAT 7 ID 12 IM 8 ID 9 IJ 8 IG 14 IK 6 II 4 IR 12 IP (Cont. Next Page) 33 CAMRY (EM0250U) F RELAY LOCATIONS [Instrument Panel J/B Inner Circuit] (Cont'd) 2 IP 6 IC 14 IF 11 IF 16 IH 3 IO 9 IO 4 IE 10 IR 10A ECU IG NO.1 10A GAUGE NO.1 4 IF 2 IC 2 II 25A WIP 12 IH 11 IC 6 IM 12 IC 8 IF 10A WASH 12 ID 9 IF 16 IF 1 IG 10A A/C NO.2 19 IM 11 IR 20 IM 11 IJ 20A S-HTR 13 IK 3 5 2 IR 19 IF 6 IO 7.5A ECU IG NO.2 2 9 II 1 7 IJ 13 ID IG1 Relay 1 7 IF 2 30A POWER 10 IK 1 IP 10 IL 7 IP 10 IP 5 3 6 IR 1 7 IR 3 IC 2 25A RR DOOR LH 1 IL 25A RR DOOR RH PWR Relay 9 IC 8 IM 7.5A A/C 11 IK 2 IG 18 IM 1 II 4 II 9 IL 7.5A AM1 9 IK 25A DOOR NO.2 12 IR 17 IF 30A S/ROOF 6 IJ 12 IL 4 IM 7.5A OBD 4 IP 17 IM 8 IC 10A STOP 25A PWR (Cont. Next Page) 34 CAMRY (EM0250U) 5 IM F (Cont'd) 13 IF 7 IC 7 IK 14 IC 9 IP 4 IG 13 IC 3 IH 15 IF 2 IM 7 IL 7 IM 12 IG 7.5A GAUGE NO.2 3 IP 1 ID 7 II 9 IE 10A IGN 9 IG 10 IC 2 IH 15 ID 13 IM 5 IG 14 IM 10 II 8 IO 1 IM 11 IG 15A INJ 5 IR 7 IH 18 IF 8 IH 2 IJ 5 IF 6 IP 1 IJ 4 IJ 2 IK 12 IK 11 IP 12 7 IE 9 IR 8 IE 14 3 18 UL1 PWS LIN1 ACT- 21 13 23 24 19 5 7 HU STP UL2 PKB TRLY ILE GND1 8 Main Body ECU 15 IH 9 IM 13 IH 3 IJ L1 9 15 IK 5 IJ HORN L2 26 4 3 ID HRLY 20 LSR (*2) LSWL (*1) 25 16 ID 6 LCTY 10 ID 1 IF 2 GND2 17 11 ID 5 II 15 ALTB 5 IL 5 IP 22 16 6 IL 7 IO 1 IG BATB ACT+ ACC (*1) DRL BECU (*2) 10 11 16 IK 9 ID *1:w/ Smart Key System *2:w/o Smart Key System 35 CAMRY (EM0250U) F RELAY LOCATIONS : J/B No.3 Behind the Combination Meter (See Page 20) 3P Gray 3Q 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 3R 12 11 10 9 8 7 6 5 4 3 2 1 (from Instrument Panel No.2 Wire) (from Instrument Panel No.2 Wire) 1 2 3 4 5 6 7 8 9 10 11 12 (from Instrument Panel No.2 Wire) 3S 12 11 10 9 8 7 6 5 4 3 2 1 (from Instrument Panel No.2 Wire) 1 2 3 4 5 6 7 8 9 10 11 12 3U 12 11 10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10 11 12 3B Gray 12 11 10 9 8 7 6 5 4 3 2 1 (from Instrument Panel Wire) Gray (from Instrument Panel No.2 Wire) 3A 12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10 11 12 (from Instrument Panel Wire) 1 2 3 4 5 6 7 8 9 10 11 12 3D 3F 3C 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 12 11 10 9 8 7 6 5 4 3 2 1 3E 12 11 10 9 8 7 6 5 4 3 2 1 (from Instrument Panel Wire) 12 11 10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10 11 12 (from Instrument Panel Wire) 1 2 3 4 5 6 7 8 9 10 11 12 3G 12 11 10 9 8 7 6 5 4 3 2 1 (from Instrument Panel Wire) 3H 12 11 10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10 11 12 (from Instrument Panel Wire) Gray 1 2 3 4 5 6 7 8 9 10 11 12 3J 12 11 10 9 8 7 6 5 4 3 2 1 (from Instrument Panel Wire) Gray (from Instrument Panel Wire) 1 2 3 4 5 6 7 8 9 10 11 12 (from Instrument Panel Wire) Gray Gray 12 11 10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10 11 12 (from Instrument Panel No.2 Wire) Gray 3T 1 2 3 4 5 6 7 8 9 10 11 12 3I 12 11 10 9 8 7 6 5 4 3 2 1 3K (from Instrument Panel Wire) 1 2 3 4 5 6 7 8 9 10 11 12 12 11 10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10 11 12 (from Instrument Panel Wire) 3M 1 2 3 4 5 6 7 8 9 10 11 12 12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10 11 12 (from Instrument Panel Wire) (from Instrument Panel Wire) 1 2 3 4 5 6 7 8 9 10 11 12 Gray 3L 3O 12 11 10 9 8 7 6 5 4 3 2 1 (from Instrument Panel Wire) 3N 12 11 10 9 8 7 6 5 4 3 2 1 (from Instrument Panel Wire) 36 CAMRY (EM0250U) Memo 37 CAMRY (EM0250U) F RELAY LOCATIONS [J/B No.3 Inner Circuit] 2 3P 10 3P 10 3N 3 3J 3 3P 2 3J 10 3T 1 3Q 9 3T 1 3R 10 3U 12 3B 9 3U 11 3G 10 3B 12 3H 9 3J 12 3I 10 3M 12 3L 10 3O 2 3Q 4 3P 10 3K 11 3C 10 3L 5 3P 12 3N 8 3G 3 3Q 8 3H 11 3J 6 3P 4 3Q 7 3O 4 3R 7 3P 11 3S 7 3F 11 3T 7 3G 12 3U 8 3P 11 3U 6 3E 9 3B 9 3P 9 3C 3 3B 5 3Q 11 3P 11 3A 3 3D 10 3D 5 3C 11 3H 5 3K 10 3H 4 3K 6 3Q 5 3L 6 3A 5 3I 7 3J 5 3O 7 3M (Cont. Next Page) 38 CAMRY (EM0250U) F (Cont'd) 7 3Q 6 3R 8 3Q 8 3E 8 3R 7 3R 2 3S 5 3S 2 3T 5 3T 5 3U 4 3T 4 3U 3 3T 3 3U 4 3A 2 3U 4 3B 1 3U 4 3C 9 3Q 4 3L 9 3R 3 3L 2 3G 11 3R 1 3H 5 3D 10 3Q 6 3K 10 3R 6 3B 11 3Q 12 3R 3 3O 2 3O 12 3Q 12 3S 1 3D 9 3A 2 3R 10 3S 12 3C 10 3C 11 3I 9 3E 11 3K 9 3H 11 3L 9 3L 3 3R 11 3N 9 3F 9 3S 9 3M 8 3S 5 3R 7 3S 9 3D 6 3S 9 3K 8 3K 8 3M 8 3L (Cont. Next Page) 39 CAMRY (EM0250U) F RELAY LOCATIONS [J/B No.3 Inner Circuit] (Cont'd) 4 3S 12 3A 3 3M 11 3F 3 3S 10 3F 3 3A 12 3O 1 3S 11 3O 2 3C 5 3A 1 3L 6 3C 1 3M 5 3G 12 3T 5 3N 10 3A 4 3I 8 3T 2 3A 8 3A 2 3B 7 3T 3 3F 6 3T 3 3G 7 3U 6 3H 6 3U 3 3H 6 3L 3 3I 1 3T 2 3K 1 3A 1 3K 8 3U 2 3M 7 3D 1 3N 7 3A 1 3O 7 3B 3 3C 5 3J 11 3B 5 3B 12 3E 5 3H 8 3B 6 3O 8 3C 1 3B 7 3K 1 3C 7 3L 1 3J 8 3N (Cont. Next Page) 40 CAMRY (EM0250U) F (Cont'd) 7 3C 12 3F 7 3I 12 3J 6 3N 12 3K 12 3D 8 3F 6 3M 9 3O 11 3D 8 3O 11 3M 4 3F 8 3D 4 3J 6 3D 2 3F 7 3E 3 3N 6 3F 1 3F 6 3J 2 3L 4 3D 12 3G 4 3O 9 3N 2 3D 10 3G 2 3N 10 3I 11 3E 9 3G 10 3J 4 3G 10 3E 9 3I 12 3M 6 3G 5 3E 6 3I 5 3F 1 3G 4 3E 2 3I 4 3H 1 3I 3 3E 7 3H 3 3K 8 3J 2 3E 2 3H 4 3M 5 3M 1 3E 8 3I 4 3N 7 3N 41 CAMRY (EM0250U) F RELAY LOCATIONS : J/B No.4 Instrument Panel Brace Center (See Page 20) 4A Gray 4B 1 2 3 4 5 6 7 8 9 101112 (from Instrument Panel Wire) Gray 4D 1 2 3 4 5 6 7 8 9 101112 (from Instrument Panel Wire) Gray 4F 12 1110 12 1110 12 1110 12 1110 12 1110 12 1110 12 1110 9 9 9 9 9 9 9 8 8 8 8 8 8 8 7 7 7 7 7 7 7 6 6 6 6 6 6 6 5 5 5 5 5 5 5 4 4 4 4 4 4 4 3 3 3 3 3 3 3 2 2 2 2 2 2 2 1 1 1 1 1 1 1 1 2 3 4 5 6 7 8 9 101112 4C (from Instrument Panel Wire) 4E (from Instrument Panel Wire) 4G (from Instrument Panel Wire) 1 2 3 4 5 6 7 8 9 101112 1 2 3 4 5 6 7 8 9 101112 1 2 3 4 5 6 7 8 9 101112 1 2 3 4 5 6 7 8 9 101112 (from Instrument Panel Wire) Gray (from Instrument Panel Wire) 4H 1 2 3 4 5 6 7 8 9 101112 (from Instrument Panel Wire) Gray Gray 1 2 3 4 5 6 7 8 9 101112 4J 4L 12 1110 12 1110 12 1110 12 1110 12 1110 12 1110 9 9 9 9 9 9 8 8 8 8 8 8 7 7 7 7 7 7 6 6 6 6 6 6 5 5 5 5 5 5 4 4 4 4 4 4 3 3 3 3 3 3 2 2 2 2 2 2 1 1 1 1 1 1 4I 4K 1 2 3 4 5 6 7 8 9 101112 4M (from Instrument Panel Wire) 1 2 3 4 5 6 7 8 9 101112 (from Instrument Panel Wire) (from Instrument Panel Wire) 42 CAMRY (EM0250U) F [J/B No.4 Inner Circuit] 12 4D 8 4B 11 4H 9 4B 12 4H 10 4B 12 4K 8 4C 12 4L 8 4D 1 4A 10 4H 1 4D 11 4J 1 4E 12 4J 2 4E 4 4I 1 4G 5 4I 1 4I 6 4K 4 4A 3 4B 5 4D 4 4B 6 4F 5 4B 6 4I 4 4D 11 4B 4 4H 11 4I 3 4J 12 4I 4 4J 11 4M 5 4J 12 4B 3 4A 9 4D 3 4I 10 4D 7 4A 11 4D 7 4L 10 4J 12 4E 10 4K 12 4G 11 4K 12 4M 2 4D 4 4E 1 4F 5 4E 2 4F 5 4H 11 4A 4 4L 12 4C 5 4L (Cont. Next Page) 43 CAMRY (EM0250U) F RELAY LOCATIONS [J/B No.4 Inner Circuit] (Cont'd) 3 4G 9 4A 5 4K 10 4C 2 4A 9 4L 1 4B 8 4H 2 4B 7 4I 3 4D 8 4I 3 4F 9 4H 4 4F 9 4I 1 4H 10 4I 2 4H 2 4G 3 4H 2 4K 2 4I 3 4K 1 4J 4 4K 2 4J 8 4A 1 4K 7 4F 1 4L 8 4F 5 4C 1 4M 4 4M 10 4E 9 4F 10 4M 9 4G 6 4H 9 4E 5 4M 8 4K 7 4H 9 4C 6 4M 7 4K 6 4C 10 4A 8 4L 10 4G 3 4L 5 4A 3 4M 5 4G 1 4C 10 4L 2 4C 11 4L 3 4C (Cont. Next Page) 44 CAMRY (EM0250U) F (Cont'd) 9 4J 4 4C 9 4M 5 4F 6 4J 6 4E 6 4L 6 4G 8 4J 11 4F 8 4M 9 4K 7 4J 12 4A 7 4M 12 4F 8 4E 2 4L 8 4G 2 4M 7 4E 6 4A 7 4G 6 4B 11 4E 7 4B 11 4G 7 4C 3 4E 6 4D 4 4G 7 4D 11 4C 10 4F 45 CAMRY (EM0250U) F RELAY LOCATIONS Junction Connector (CAN) Instrument Panel Brace Center (See Page 20) E42 E45 Black 2 2 1 1 1 1 2 2 2 2 2 2 2 1 1 1 1 1 E46 Blue E62 Gray E63 Brown E43 1 1 1 1 1 2 2 2 2 2 E44 Black 46 CAMRY (EM0250U) F [Junction Connector (CAN) Inner Circuit] E42(A), E43(B), E44(C), E45(D), E46(E), E62(G), E63(H) 1 A 1 B 1 C 1 D 1 E 1 G 1 H 2 A 2 B 2 C 2 D 2 E 2 G 2 H 47 CAMRY (EM0250U) G ELECTRICAL WIRING ROUTING Position of Parts in Engine Compartment [2GR–FE] A16 A14 A8 A35 A26 (*2) A29 A37 * 1:w/o VSC * 2:w/ VSC TMC Made A34 A28 A25 A27 A23 A4 A2 A5 A3 A13 A1 (*1) A 1 A 2 A 3 A 4 A 5 A 8 A 13 A 14 A 16 Fog Lamp (Front LH) Ambient Temp. Sensor Horn (High) Horn (Low) Engine Hood Courtesy SW Headlamp (LH High) Airbag Sensor (Front LH) Speed Sensor (Front LH) Brake Fluid Level Warning SW A 23 A 25 A 26 A 27 A 28 A 29 A 34 A 35 A 37 Security Horn Skid Control ECU with Actuator Skid Control ECU with Actuator A/C Pressure Sensor Airbag Sensor (Front RH) Headlamp (RH High) Fog Lamp (Front RH) Speed Sensor (Front RH) Windshield Washer Motor 48 CAMRY (EM0250U) G Position of Parts in Engine Compartment [2GR–FE] (*5) (*4) A55 A60 A59 B1 (*3) A47 A51 A46 A50 A45 A49 A48 A43 * 3:w/ VSC TMMK Made * 4:TMC Made * 5:TMMK Made A52 A 43 A 45 A 46 A 47 A 48 A 49 A 50 A 51 A 52 A 53 A 54 A 55 A 59 A 60 Junction Connector Headlamp (LH Low) Turn Signal and Parking Lamp (Front LH) Side Marker Lamp (Front LH) Wireless Door Lock Buzzer Headlamp (RH Low) Turn Signal and Parking Lamp (Front RH) Side Marker Lamp (Front RH) Washer Level Warning SW VSV (Air Intake Control) Cooling Fan ECU Engine Control Module Windshield Wiper Motor Skid Control ECU with Actuator A54 A53 B 1 Windshield Wiper Motor 49 CAMRY (EM0250U) G ELECTRICAL WIRING ROUTING Position of Parts in Engine Compartment [2GR–FE] C17 C11 C12 C16 C15 C5 C2 C10 C4 C7 C1 C8 C6 C9 C3 C13 C14 C23 C 1 C 2 C 3 C 4 C 5 C 6 C 7 C 8 C 9 C10 C 11 Park/Neutral Position SW Mass Air Flow Meter Starter Engine Coolant Temp. Sensor Throttle Body Assembly VSV (Purge) Fuel Injector (No.1) Fuel Injector (No.3) Fuel Injector (No.2) Fuel Injector (No.4) Ignition Coil (No.1) C12 C13 C14 C15 C16 C17 C18 C19 C21 C23 C21 C18 C19 Ignition Coil (No.3) Ignition Coil (No.2) Ignition Coil (No.4) Air Fuel Ratio Sensor (Bank 1 Sensor 1) Noise Filter (Ignition RH) Power Steering Oil Pressure SW Generator Generator A/C Compressor Engine Oil Pressure SW 50 CAMRY (EM0250U) G Position of Parts in Engine Compartment [2GR–FE] C55 C40 C36 C38 C57 C42 V2 C43 V1 C41 C37 C48 C49 C47 C35 C46 C39 C45 C56 C53 C34 C35 C36 C37 C38 C39 C40 C41 C42 C43 C44 C45 C46 C47 C48 C49 C50 C51 C52 C53 C55 C56 C57 VSV (ACM) Air Fuel Ratio Sensor (Bank 2 Sensor 1) Fuel Injector (No.5) Fuel Injector (No.6) Ignition Coil (No.5) Ignition Coil (No.6) VVT Sensor (Bank 1 Exhaust Side) VVT Sensor (Bank 1 Intake Side) Camshaft Timing Oil Control Valve (RH Exhaust Side) Camshaft Timing Oil Control Valve (RH Intake Side) VVT Sensor (Bank 2 Exhaust Side) VVT Sensor (Bank 2 Intake Side) Camshaft Timing Oil Control Valve (LH Exhaust Side) Camshaft Timing Oil Control Valve (LH Intake Side) VSV (ACIS) Noise Filter (Ignition LH) Crankshaft Position Sensor Heated Oxygen Sensor (Bank 2 Sensor 2) Heated Oxygen Sensor (Bank 1 Sensor 2) A/C Compressor Engine Control Module Transmission Control ECU Junction Connector C50 C52 C51 C44 C34 D1 D 1 Starter V 1 Knock Control Sensor (Bank 2) V 2 Knock Control Sensor (Bank 1) 51 CAMRY (EM0250U) G ELECTRICAL WIRING ROUTING Position of Parts in Engine Compartment [2AZ–FE] A16 A24 A14 A8 A35 A26 (*2) A29 A37 * 1:w/o VSC * 2:w/ VSC TMC Made A34 A28 A25 A27 A23 A4 A2 A6 A5 A3 A7 A13 A1 (*1) A 1 A 2 A 3 A 4 A 5 A 6 A 7 A 8 A 13 A 14 A 16 Fog Lamp (Front LH) Ambient Temp. Sensor Horn (High) Horn (Low) Engine Hood Courtesy SW A/C Condenser Fan Motor Radiator Fan Motor Headlamp (LH High) Airbag Sensor (Front LH) Speed Sensor (Front LH) Brake Fluid Level Warning SW A 23 A 24 A 25 A 26 A 27 A 28 A 29 A 34 A 35 A 37 Security Horn Engine Control Module Skid Control ECU with Actuator Skid Control ECU with Actuator A/C Pressure Sensor Airbag Sensor (Front RH) Headlamp (RH High) Fog Lamp (Front RH) Speed Sensor (Front RH) Windshield Washer Motor 52 CAMRY (EM0250U) G Position of Parts in Engine Compartment [2AZ–FE] B1 A60 (*4) (*5) A59 (*3) A47 A51 A46 A50 A45 A49 A48 A52 * 3:w/ VSC TMMK Made * 4:TMC Made * 5:TMMK Made A 45 A 46 A 47 A 48 A 49 A 50 A 51 A 52 A 59 A 60 Headlamp (LH Low) Turn Signal and Parking Lamp (Front LH) Side Marker Lamp (Front LH) Wireless Door Lock Buzzer Headlamp (RH Low) Turn Signal and Parking Lamp (Front RH) Side Marker Lamp (Front RH) Washer Level Warning SW Windshield Wiper Motor Skid Control ECU with Actuator B 1 Windshield Wiper Motor 53 CAMRY (EM0250U) G ELECTRICAL WIRING ROUTING Position of Parts in Engine Compartment [2AZ–FE] C9 C13 C8 C12 C10 C14 C5 C6 C2 C15 C16 C7 C4 C11 C3 C17 C1 C19 C18 C 1 C 2 C 3 C 4 C 5 C 6 C 7 C 8 C 9 C10 Park/Neutral Position SW Mass Air Flow Meter Starter Engine Coolant Temp. Sensor Throttle Body Assembly VSV (Purge) Fuel Injector (No.1) Fuel Injector (No.3) Fuel Injector (No.2) Fuel Injector (No.4) C 11 C12 C13 C14 C15 C16 C17 C18 C19 Ignition Coil (No.1) Ignition Coil (No.3) Ignition Coil (No.2) Ignition Coil (No.4) Air Fuel Ratio Sensor (Bank 1 Sensor 1) Noise Filter (Ignition RH) Power Steering Oil Pressure SW Generator Generator 54 CAMRY (EM0250U) G Position of Parts in Engine Compartment [2AZ–FE] C20 C32 C21 C22 C30 C33 C31 C23 D1 C24 C28 C27 C29 C26 C25 C20 C21 C22 C23 C24 C25 C26 C27 C28 C29 C30 C31 C32 C33 Crankshaft Position Sensor A/C Compressor Heated Oxygen Sensor (Bank 1 Sensor 2) Engine Oil Pressure SW Engine Control Module Electronically Controlled Transmission Solenoid Transmission Revolution Sensor (Turbine) Transmission Revolution Sensor (Counter Gear) Back–Up Lamp SW Starter Knock Control Sensor (Bank 1) Camshaft Position Sensor Camshaft Timing Oil Control Valve Intake Air Control Valve D 1 Starter 55 CAMRY (EM0250U) G ELECTRICAL WIRING ROUTING Position of Parts in Instrument Panel (*1) E7 E6 E1 E15 E14 E12 E11 E24 E23 E25 E27 E10 E5 E8 E9 E13 E3 * 1:w/o Smart Key System E2 E21 E17 E16 E18 E20 E19 E22 E30 E29 E32 E33 E31 (*1) E 1 E 2 E 3 E 5 E 6 E 7 E 8 E 9 E 10 E 11 E 12 E 13 E 14 E 15 E 16 Diode (Door Courtesy Rear LH) Diode (Door Courtesy Rear RH) Outer Mirror SW Diode (Door Courtesy Front LH) Main Body ECU Main Body ECU Main Body ECU Main Body ECU Data Link Connector 3 Automatic Light Control Sensor Ion Generator VSC Warning Buzzer Turn Signal Flasher Transponder Key ECU Airbag Squib (Steering Wheel Pad) E 17 E 18 E 19 E 20 E 21 E 22 E 23 E 24 E 25 E 27 E 29 E 30 E 31 E 32 E 33 Steering Sensor Spiral Cable Windshield Wiper SW Assembly Windshield Wiper SW Assembly Headlamp Dimmer SW Assembly Unlock Warning SW Ignition SW Key Interlock Solenoid Transponder Key Amplifier A/C Room Temp. Sensor Power Outlet Socket (Front) Airbag Sensor Assembly Center Transmission Control SW Shift Lock Control ECU Parking Brake SW 56 CAMRY (EM0250U) G Position of Parts in Instrument Panel (*2) E40 E50 E46 E62 E63 E43 E44 E45 E38 E58 E37 E41 E61 E59 E60 E39 * 2:w/ Smart Key System * 3:TMC Made * 4:TMMK Made E51 E42 E52 E54 E48 E49 E55 E56 E57 E53 E35 (*2) E 34 E 35 E 37 E 38 E 39 E 40 E 41 E 42 E 43 E 44 E 45 E 46 E 48 E 49 E 50 Yaw Rate Sensor Power Outlet Socket (Rear) Diode (Door Courtesy Front RH) A/C Amplifier Blower Motor Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector ID Code Box E 51 E 52 E 53 E 54 E 55 E 56 E 57 E 58 E 59 E 60 E 61 E 62 E 63 E 65 E65 E34 (*4) (*3) Steering Lock ECU Power SW Tire Pressure Warning SW (Reset) Airbag Squib (Knee Airbag) Seat Heater SW Electrical Key Oscillator (Console) Shift Lock Control ECU Certification ECU Certification ECU Tire Pressure Warning ECU Option Connector (Bus Buffer) Junction Connector Junction Connector Yaw Rate Sensor 57 CAMRY (EM0250U) G ELECTRICAL WIRING ROUTING Position of Parts in Instrument Panel (*5) (*6) F21 F22 F2 F1 F6 F3 F8 F4 (*8) (*7) F26 F9 F11 F14 (*5) (*6) F24 F23 F13 F5 F25 F12 F15 F16 * 5:8 Speaker * 6:6 Speaker * 7:8 Speaker w/ Navigation System * 8:8 Speaker w/o Navigation System F7 F 1 F 2 F 3 F 4 F 5 F 6 F 7 F 8 F 9 F 10 F 11 F 12 F 13 Combination Meter Combination Meter Clock Hazard Warning Signal SW Glove Box Lamp Radio Receiver Assembly Radio Receiver Assembly Radio Receiver Assembly Navigation Receiver Assembly Navigation Receiver Assembly Radio Receiver Assembly Navigation Receiver Assembly Navigation Receiver Assembly F10 F17 F 14 F 15 F 16 F 17 F 18 F 19 F 20 F 21 F 22 F 23 F 24 F 25 F 26 F20 F18 F19 Navigation Receiver Assembly Antenna Amplifier A/C Control Assembly Stereo Jack Adapter Stereo Component Amplifier Stereo Component Amplifier Stereo Component Amplifier Tweeter (Front LH) Tweeter (Front LH) Tweeter (Front RH) Tweeter (Front RH) Junction Connector Radio Receiver Assembly 58 CAMRY (EM0250U) G Position of Parts in Instrument Panel a1 b1 c1 c2 A42 A17 N1 O1 A58 A22 A21 A18 A19 A 17 A 18 A 19 A 21 A 22 A 40 A 41 A 42 A 56 A 57 A 58 Accelerator Position Sensor Parking Brake SW Stop Lamp SW Cruise Control Clutch SW Clutch Start SW Junction Connector Junction Connector Junction Connector Short Connector Short Connector Junction Connector N 1 Airbag Sensor Assembly Center A41 A57 e1 A56 A40 O 1 Airbag Sensor Assembly Center a 1 Spiral Cable Steering Pad SW b 1 Cruise Control SW Spiral Cable c 1 Airbag Squib (Front Passenger’s Airbag Assembly) c 2 Airbag Squib (Front Passenger’s Airbag Assembly) e 1 A/C Amplifier A/C Blower Assembly 59 CAMRY (EM0250U) G ELECTRICAL WIRING ROUTING Position of Parts in Body N18 N29 O16 N19 O6 O7 O8 O18 O17 P1 N21 O12 N34 O21 N6 O10 N7 O19 O13 N8 N 6 N 7 N 8 N10 N 11 N12 N13 N15 N16 N17 N18 N19 N21 N23 N24 N25 N26 N28 N29 N34 N13 N15 N12 N16 N11 Door Courtesy SW (Driver’s Side) Side Airbag Sensor (Front LH) Pretensioner (LH) Fuel Suction Pump and Gage Assembly Electrical Key Oscillator (Rear Seat) Side Airbag Sensor (Rear LH) Door Courtesy SW (Rear LH) Noise Filter (Dome and Stop) Center Stop Lamp Canister Pump Module Noise Filter (Rear Window Defogger) Rear Window Defogger Curtain Shield Airbag Squib (LH) Diode (Luggage Compartment Lamp) Luggage Compartment Lamp Electrical Key Oscillator (Inside Luggage Room) Luggage Compartment Lamp Junction Connector Junction Connector Tire Pressure Warning Antenna and Receiver N10 N28 N23 O14 N17 O 6 O 7 O 8 O 9 O10 O12 O13 O14 O15 O16 O17 O18 O19 O21 N25 O15 N26 N24 O9 Door Courtesy SW (Front Passenger’s Side) Side Airbag Sensor (Front RH) Pretensioner (RH) Side Airbag Sensor (Rear RH) Door Courtesy SW (Rear RH) Speaker (Rear LH) Speaker (Rear RH) Speaker (Rear LH) Speaker (Rear RH) Curtain Shield Airbag Squib (RH) Door Control Receiver Door Control Receiver Electrical Key Antenna Junction Connector P 1 Rear Window Defogger 60 CAMRY (EM0250U) G Position of Parts in Body Q7 Q6 Q13 Q3 Q9 (*2) (*1) Q12 Q5 H2 Q8 Q2 H4 H5 H6 Q11 Q10 W1 H8 H7 J1 J3 Q1 J5 H1 S10 W2 S11 I3 S9 I1 g1 I5 S4 I4 S13 M1 S12 X1 S2 X2 S1 * 1:TMC Made * 2:TMMK Made * 3:w/ Smart Key System * 4:w/o Smart Key System I6 I7 H 1 Speaker (Front Door RH) H 2 Outer Rear View Mirror (RH) H 4 Power Window Regulator Motor (Front Passenger’s Side) H 5 Door Lock Control SW H 6 Power Window SW (Front Passenger’s Side) H 7 Courtesy Lamp (Front Door RH) H 8 Door Lock Assembly (Front Passenger’s Side) I I I I I I 1 3 4 5 6 7 Speaker (Front Door LH) Outer Rear View Mirror (LH) Power Window Regulator Motor (Front LH) Power Window Regulator Motor (Front LH) Courtesy Lamp (Front Door LH) Door Lock Assembly (Driver’s Side) J 1 Power Window SW (Rear RH) J 3 Power Window Regulator Motor (Rear RH) J 5 Door Lock Assembly (Rear RH) K 1 Power Window SW (Rear LH) K 3 Power Window Regulator Motor (Rear LH) K 5 Door Lock Assembly (Rear LH) M 1 Power Window Master SW Q Q Q Q Q Q 1 2 3 5 6 7 Vanity Lamp SW (LH) Vanity Lamp SW (RH) Inner Rear View Mirror Microphone (Navigation) Overhead J/B Vanity Lamp (LH) K1 K3 K5 f1 S15 S16 S3 S14 S5 S6 S8 (*4) (*3) Q 8 Q 9 Q10 Q11 Q12 Q13 Vanity Lamp (RH) Room Lamp (Center) Map Lamp (RH) Map Lamp (LH) Microphone (Navigation) Sliding Roof Control ECU and Motor S 1 S 2 S 3 S 4 S 5 S 6 S 8 S 9 S 10 S 11 S 12 S 13 S 14 S 15 S 16 License Plate Lamp (RH) Rear Combination Lamp (RH) Rear Combination Lamp (LH) License Plate Lamp (LH) Door Lock Assembly (Luggage) Luggage Compartment Door Lock Cylinder Luggage Compartment Door Lock Cylinder Luggage Electrical Key SW Turn Signal Lamp (Rear LH) Rear Combination Lamp (LH) Rear Combination Lamp (RH) Turn Signal Lamp (Rear RH) Electrical Key Oscillator (Outside Luggage Room) Junction Connector Junction Connector W 1 Door Outside Handle (Front RH) W 2 Electrical Key Oscillator (Front Door RH) X 1 Door Outside Handle (Front LH) X 2 Electrical Key Oscillator (Front Door LH) f 1 Speed Sensor (Rear LH) g 1 Speed Sensor (Rear RH) 61 CAMRY (EM0250U) G ELECTRICAL WIRING ROUTING Position of Parts in Seat [w/ Power Seat] U11 N27 N3 U3 U6 U4 U5 T7 T1 T11 T6 O20 T18 T8 T14 T15 T10 T16 T17 T3 Y1 U1 U2 Z1 U7 U8 U U U U U N 3 Front Seat Inner Belt (Driver’s Side) N27 Junction Connector O20 Junction Connector T 1 Power Seat Motor (Front Passenger’s Seat Slide Control) T 3 Power Seat Motor (Front Passenger’s Seat Reclining Control) T 6 Seat Heater (RH) T 7 Front Seat Inner Belt (Front Passenger’s Side) T 8 Power Seat SW (Front Passenger’s Seat) T 10 Occupant Classification ECU T 11 Occupant Classification ECU T 14 Occupant Classification Sensor (Front LH) T 15 Occupant Classification Sensor (Rear LH) T 16 Occupant Classification Sensor (Front RH) T 17 Occupant Classification Sensor (Rear RH) T 18 Junction Connector 1 2 3 4 5 U 6 U 7 U 8 U 11 Power Seat Motor (Driver’s Seat Slide Control) Power Seat Motor (Driver’s Seat Front Vertical Control) Power Seat Motor (Driver’s Seat Reclining Control) Power Seat Motor (Driver’s Seat Lifter Control) Power Seat Motor (Driver’s Seat Lumbar Support Control) Seat Heater (LH) Power Seat SW (Driver’s Seat) Power Seat SW (Driver’s Seat Lumbar Support Control) Junction Connector Y 1 Side Airbag Squib (RH) Z 1 Side Airbag Squib (LH) 62 CAMRY (EM0250U) G Position of Parts in Seat [w/o Power Seat] Z1 N3 d2 d3 O3 O4 d1 d4 d5 Y1 N 3 Front Seat Inner Belt (Driver’s Side) Z 1 Side Airbag Squib (LH) O 3 Front Seat Inner Belt (Front Passenger’s Side) O 4 Occupant Classification ECU d d d d d Y 1 Side Airbag Squib (RH) 1 2 3 4 5 Occupant Classification ECU Occupant Classification Sensor (Front LH) Occupant Classification Sensor (Rear LH) Occupant Classification Sensor (Front RH) Occupant Classification Sensor (Rear RH) 63 CAMRY (EM0250U) G ELECTRICAL WIRING ROUTING : Location of Connector Joining Wire Harness and Wire Harness : Location of Ground Points [2GR–FE] Engine Room Main Wire C4 Sensor Wire C7 CV1 Engine Room No.2 Wire AB1 C5 CA3 CA1 CA2 Engine Wire Engine No.2 Wire A4 A1 A5 A2 64 CAMRY (EM0250U) G : Location of Connector Joining Wire Harness and Wire Harness : Location of Ground Points [2AZ–FE] Engine Room Main Wire Engine Wire Engine Room No.2 Wire AB1 CA3 CA1 CA2 Engine No.2 Wire A4 A5 A1 A2 C6 C4 65 CAMRY (EM0250U) G ELECTRICAL WIRING ROUTING : Location of Connector Joining Wire Harness and Wire Harness Roof Wire AE7 AE2 FE3 FE2 AE3 AE4 AE5 AE6 EQ1 OF1 Front Door RH Wire Engine Room Main Wire Front Door LH Wire HE2 HE1 IE2 EO1 IE1 EO2 EN1 Floor No.2 Wire EN2 Floor Wire NA1 EA1 Instrument Panel Instrument Panel Instrument Panel Wire No.2 Wire Wire Assembly : Location of Ground Points E1 F1 E3 A3 E2 F2 66 CAMRY (EM0250U) A6 F3 Ec1 OA1 G : Location of Connector Joining Wire Harness and Wire Harness : Location of Ground Points Roof Wire Front Door RH Wire IM1 IM2 Electrical Key Wire Harness RH HW1 JO1 Rear Door No.1 Wire Floor No.3 Wire (*1) (*2) P1 Electrical Key Wire Harness LH O1 IX1 gN1 KN1 Skid Control Sensor Wire * 1:w/ Jam Protection * 2:w/o Jam Protection Floor No.2 Wire SN1 Front Door Rear Door Floor Wire LH Wire No.2 Wire fO1 Skid Control Sensor Wire N1 S1 Luggage Room Wire 67 CAMRY (EM0250U) G ELECTRICAL WIRING ROUTING : Location of Connector Joining Wire Harness and Wire Harness [w/ Power Seat] Front Seat Airbag Assembly LH NZ2 Floor Wire Floor No.2 Wire Front Seat LH Wire OY2 Front Seat RH Wire 68 CAMRY (EM0250U) OT1 Front Seat Airbag Assembly RH G : Location of Connector Joining Wire Harness and Wire Harness [w/o Power Seat] Front Seat Airbag Assembly LH NZ2 Floor Wire Floor No.2 Wire OY2 Front Seat Airbag Assembly RH Front Seat RH Wire 69 CAMRY (EM0250U) H SYSTEM CIRCUITS 2007 CAMRY ELECTRICAL WIRING DIAGRAM SYSTEM CIRCUITS ABS (w/ VSC TMC Made) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ABS (w/ VSC TMMK Made) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ABS (w/o VSC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Audio System (6 Speaker) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Audio System (8 Speaker w/ Navigation System) . . . . . . . . . . . . . . . . . . . . . . Audio System (8 Speaker w/o Navigation System) . . . . . . . . . . . . . . . . . . . . . Automatic Glare–Resistant EC Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic Light Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back–Up Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Combination Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling Fan (2GR–FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cruise Control (2AZ–FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cruise Control (2GR–FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Data Link Connector 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Door Lock Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronically Controlled Transmission and A/T Indicator (2AZ–FE) . . . . . Electronically Controlled Transmission and A/T Indicator (2GR–FE) . . . . Engine Control (2AZ–FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Control (2GR–FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Immobiliser System (w/o Smart Key System) . . . . . . . . . . . . . . . . . . Fog Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Garage Door Opener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition (2AZ–FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition (2GR–FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Illumination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interior Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Key Reminder (w/o Smart Key System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Auto Turn Off System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Luggage Compartment Door Opener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mirror Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multiplex Communication System (CAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Navigation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Seat (Driver’s Seat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Seat (Front Passenger’s Seat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator Fan and Condenser Fan (2AZ–FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Window Defogger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Control Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat Belt Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 CAMRY (EM0250U) Page 242 252 262 386 360 346 354 338 160 188 100 202 364 374 292 282 140 214 312 300 126 108 138 150 336 144 204 106 102 172 164 190 160 214 342 156 346 200 322 326 72 206 380 342 340 190 328 H Shift Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sliding Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Smart Key System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ∗ Engine Immobiliser ∗ Push Button Start System ∗ Steering Lock ∗ Wireless Door Lock Control SRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting (w/o Smart Key System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stop Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Taillight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Theft Deterrent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tire Pressure Warning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRAC (TMC Made) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRAC (TMMK Made) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turn Signal and Hazard Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VSC (TMC Made) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VSC (TMMK Made) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiper and Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wireless Door Lock Control (w/o Smart Key System) . . . . . . . . . . . . . . . . . . Page 320 330 78 273 96 186 172 230 270 242 252 182 242 252 196 224 71 CAMRY (EM0250U) Power Source 50A ABS No. 1 B 1 1F 1 30A ABS No. 2 L B B Y Y 50A RR DEF 1 1 50A HTR 1 50A FAN MAIN W (∗1) G 40A RDI FAN 1 1 W (∗2) 20A STR LOCK 1 1C B 1 1 B 25A AMP 40A CDS FAN 120A ALT 2 1 A (∗1) 1 C (∗2) 1 G 1 2 (∗2) 1 BR B 15A HAZ 10A DOME SHORT 1 2 1 2 C19(A), (C) Generator 1 LG 1 2 1 O 1 L 1 2 R 2 1 LG 7. 5A ALT–S 15A RADIO NO. 1 1 1 10A ETCS 10A ECU–B NO. 1 1 2 1 2 1 W 1 1G W 30A EFI MAIN 1 2 1 Y FL MAIN 3. 0W 15A H–LP (LH) DRL Relay 15A H–LP (RH) Battery 10A MPX–B 10A EFI NO. 1 72 CAMRY (EM0250U) Y B B 1 W–B 4 Y 1 V 1 5 3 1 2 1 1 2 IB W 10A MIR HTR G RR DEF Relay ∗ ∗ ∗ ∗ 1 2 3 4 : 2GR–FE : 2AZ–FE : w/ Smart Key System : w/o Smart Key System G (∗3) 30A ST/AM2 B 1 (∗4) 25A DOOR NO. 1 1 2 1 W 7. 5A AM2 1 2 Y 1 (∗3) 20A IG2 1 2 Y 1 (∗1) 15A EFI NO. 2 12 1E Y 6 1E B 1 1 2 1 R 10A EFI NO. 3 1 EFI Relay HORN Relay 20A A/F 7. 5A S–HORN A/F Relay H–LP (LL) Relay S–HORN Relay H–LP (RL) Relay 2 1 GR 10A HORN 15A H–LP (LL) 15A H–LP (RL) 73 CAMRY (EM0250U) Power Source B B O (∗4) O B W(∗4) IG1 1 P(∗4) P(∗4) ST1 5 AM2 IG2 6 (∗4) Y Y (∗2) (∗2) Y ST2 (∗1 ∗4) B (∗4) W(∗4) 4 AM1 (∗4) 1 AE7 ACC 2 E23 Ignition SW B (∗4) 12 4G L (∗3) 22 ACCD B 6 B AM1 3 IG1D B 7 EA1 Y (∗3) O Y (∗1 ∗3) 16 EA1 L (∗3) LG (∗1 ∗3) 12 4E 12 4M 10 4E 10 4M L (∗3) LG (∗1 ∗3) 1 A AM2 17 SSW1 B 11 A IG2D 16 SSW2 B W W (∗3) (∗3) P P (∗3) (∗3) L (∗3) V (∗3) 6 4G 6 4E 7 4G 7 4E L (∗3) V (∗3) (∗1) E6(A), E7(B) Main Body ECU 10 EA1 B (∗1 ∗4) O (∗1 ∗3) Y (∗1) 1 1 1 Y (∗1 ∗4) 2 5 3 IG2 Relay 74 CAMRY (EM0250U) 1 1 BR (∗1) BR (∗1) 18 EA1 BR (∗1) 1 IA B B 25A DOOR NO. 2 15A FR FOG 7. 5A RADIO NO. 2 7. 5A OBD 7. 5A ECU–ACC O ACC Relay (∗4) W(∗4) 3 II W (∗4) P(∗4) 5 3 20A PWR OUTLET 2 1 10A GAUGE NO. 1 10A ECU IG NO. 1 4 II O (∗4) W (∗2) 25A WIP (∗3) Y 7. 5A AM1 IG1 Relay 9 II P (∗4) 5 3 10A WASH 2 1 10A A/C NO. 2 20A S–HTR W 2 1 (∗3) P 30A P/SEAT 7. 5A ECU IG NO. 2 (∗3) P 4 (∗3) 5 3 15A TAIL 1 2 7. 5A PANEL L (∗3) TAIL Relay V (∗3) 2 7 SS2 SS1 E49 Junction Connector 10 W–B 10 IF 30A POWER 5 3 2 1 SS2 GND SS1 2 1 25A RR DOOR LH PWR Relay 2 25A RR DOOR RH W–B Free Y (∗2) BR BR (∗1) (∗1) 4 4E 7 II (∗3) 4 W–B 5 (∗3) COM W–B GND 25A PWR E52 Power SW Full Traveling 7. 5A GAUGE NO. 2 30A S/ROOF 10A IGN 7. 5A A/C 15A INJ 10A STOP 5 4E (∗3) ∗ ∗ ∗ ∗ E1 W–B 3 IM (∗3) 10 IG W–B W–B 5 4H 1 2 3 4 : 2GR–FE : 2AZ–FE : w/ Smart Key System : w/o Smart Key System E2 75 CAMRY (EM0250U) Power Source : Parts Location Code C19 E6 See Page Code E7 See Page A 50 (2GR–FE) B 56 C 54 (2AZ–FE) E23 56 A 56 E49 57 Code E52 See Page 57 : Relay Blocks Code 1 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code See Page 1C 22 1E 25 1F 1G Junction Block and Wire Harness (Connector Location) Engine Wire and Engine Room J/B (Engine Compartment Left) Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 22 4E 4G 4H 42 Instrument Panel Wire and J/B No.4 (Instrument Panel Brace Center) 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) 4M IA IB IF IG II IM 30 31 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) 30 : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) AE7 66 Engine Room Main Wire and Instrument Panel Wire (Right Side of the Instrument Panel J/B) EA1 66 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) : Ground Points Code See Page Ground Points Location E1 66 Instrument Panel Left E2 66 Instrument Panel Brace LH 76 CAMRY (EM0250U) Memo 77 CAMRY (EM0250U) Smart Key System W 25A DOOR NO. 1 7. 5A AM2 E6(A), E7(B), E8(C), E9(D) Main Body ECU 25A DOOR NO. 2 2 2 1 1 (BAT) BATB ALTB 2 6 AM2 AM1 6 B 1 1 A L 30A ST/AM2 (BAT) L (BAT) (BAT) 12 4G 12 4M W W Y G 16 ID 7 EA1 L L 12 4E G G G G 1 4 CA2 1 8 CA2 Y 1 1 Y 2 C1(A) Park/Neutral Position SW 3 L–B W ST Relay 5 GR W–B 1 B L P N 9 A W W 1 CA1 4 A 1 A 10 11 7 CA2 V C3(A), D1(C) Starter M Battery STA NSW C56 Transmission Control ECU 1 C L B LG FL MAIN 3. 0W Y B W A1 W–B W–B V A3 78 CAMRY (EM0250U) W W E6(A), E7(B), E8(C), E9(D) Main Body ECU LG 20A IG2 9 4G STSW 4 D STP TACH 8 C 23 (BAT) 7 IL 10A STOP 10 4M 4 4M 7 4K 9 4L 10 4E 5 4C 9 4C 10 4C L 8 4K G V (BAT) ACCR 3 A B IG2D 11 A GR STR 8 B P STR2 6 D 2 9 4E 9 4F 8 IC GR B 8 AE5 6 AE5 B R B B P 15 AE5 9 AE2 LG G V 1 O Y Y G A19 Stop Lamp SW G 16 EA1 W 2 13 AE6 13 EA1 1 4 AE5 1 2 1 5 1 1 3 A W STP NE+ STA 62 B 48 A 110 B (Shielded) 63 B NE– 111 B R TACH V NSW 36 A 15 A L–B STAR STSW 2 II C50 Crankshaft Position Sensor 7 BR L–B R 18 CA2 14 A ACCR BR 10A IGN 18 EA1 13 A R 9 IG A55(A), C55(B) Engine Control Module L R 1 BR 1 12 3F BR 1 Y 1 G 2 B 3 1 A41(A), A42(B) Junction Connector 8 B 12 3J R 3 IG2 Relay B R L–B Y ST CUT Relay L 5 1 1 BR BR V 6 L A43 Junction Connector 5 A2 C5 79 CAMRY (EM0250U) Smart Key System W W E6(A), E7(B), E8(C), E9(D) Main Body ECU CANL 6 C CANH 5 C V P L R L B 17 A 9 B 9 C 20 A 7 B 7 C 6 A 27 B 17 C 5 A 29 B 19 C B 2 B 1 B 14 FE3 13 FE3 E42(A), E43(B), E44(C) Junction Connector B 1 A 1 C B 2 A W 6 AE6 2 C B 10 B SP1 12 A (∗1) 33 B (∗2) 23 C (∗3) W 4 B RR– W 8 A RR+ B W 2 A RL– W 7 A 25 A 14 B 15 C W 1 A RL+ CANL 11 A 35 B 26 C B CANH FR– BR FR+ 19 A (∗1) 8 B (∗2) 8 C (∗3) W FL– A40(A), E41(B) Junction Connector FL+ W LG 3 A 10 B 10 C B 11 A Y IMI 10 A G IMO CANH 4 A 6 B 6 C W 41 A CANL 18 A 5 B 5 C B B 49 A A55(A), C55(B) Engine Control Module W A25(C), A26(A), A60(B) Skid Control ECU with Actuator W Speed Sensors B ∗ 1 : w/ VSC TMC Made ∗ 2 : w/ VSC TMMK Made ∗ 3 : w/o VSC W W Y G 80 CAMRY (EM0250U) W W E6(A), E7(B), E8(C), E9(D) Main Body ECU SPD 9 C (BAT) (BAT) (IG) 7. 5A GAUGE NO. 2 10A MPX–B V 10A DOME 7 IF 1 3Q 13 ID LG R SB 12 3L 2 EA1 R IG2 V V 12 B 12 3Q GR 9 3Q 3 3P +S 1 R 1 3D 3 1A V 2 3G GR 10 3M V 12 IG GR 2 13 A 1 A 2 A IG+ B B2 +B(DOME) Master Warning Power Supply Circuit Buzzer MULTI LCD F1(A), F2(B) Combination Meter MICRO COMPUTER DRIVE IC IG2 CAN I/F CANH 17 A SI CANL 18 A 14 B E2 ES 24 A 12 A BR 5 3Q 3 3D 2 3U 8 3R 10 3D W–B W–B BR B 17 A 18 B BR W 4 CA3 W–B 15 EA1 GR W–B 7 3Q A41(A), A42(B) Junction Connector W 11 3P W W B GR W W–B Y Y G G W–B 3 F1 C57 Junction Connector C7 81 CAMRY (EM0250U) Smart Key System W W E6(A), E7(B), E8(C), E9(D) Main Body ECU BR (IG) 10A IGN 10 4G SLP LIN1 18 B 14 (BAT) (BAT) P SLR+ 19 B 9 IR 20A STR LOCK 5 4G 10A EFI NO. 1 2 2 1A IG2 GND 6 1 8 A 11 EA1 SGND LIN B 3 B A41(A), A42(B) Junction Connector SLP1 E51 Steering Lock ECU O 7 LG 5 P 2 W–B W–B B O 4 IGE M W P 3 1 B 5 4A P 10 4A BR B 14 IM 21 AE2 8 4F 7 4F O 1 3J O 8 4A O W 1 4M 3 1 3C W E50 ID Code Box EFII 6 5 1 L G 5 4F 11 4C 4 4C L G E49 Junction Connector W–B 1 10 4F 3 4F W–B 3 4D +B 2 4D 1 4F 2 4F W EFIO 8 W GND W–B 2 4A W LIN1 W 7 AE5 2 13 AE5 W–B O W–B Y G Y E1 W–B W–B G E2 82 CAMRY (EM0250U) W W E6(A), E7(B), E8(C), E9(D) Main Body ECU INDW 25 B LG O SWIL 15 B P INDS 14 B V SSW2 16 B L SSW1 17 B W–B GND3 1 C G 6 4G 7 4G 11 4G 4 4G GR 8 4G W R G 13 O P 2 SS1 SS2 LG V 7 12 INDW R 8 4E W 11 4E 3 4E GR 7 4E L 6 4E 11 INDS 8 9 10 14 SWIL AGND TXCT CODE VC5 SS1 SS2 GND Free Full Traveling W–B 4 W–B COM 5 W–B GND 4 4E 5 4E E52 Power SW 5 4L W–B 5 4H 10 IG 3 IM W O O W–B W–B W–B W E1 83 CAMRY (EM0250U) Smart Key System W W E6(A), E7(B), E8(C), E9(D) Main Body ECU L CANP 16 C W CANN 15 C G E56 Electrical Key Oscillator (Console) GR W R CLG3 CLGB 2 B E49 Junction Connector W 1 G Y R 14 EO1 13 EO1 12 EO1 Y R 4 2 A2 3 5 DATA RSSI ANT GND 7 6 1 ANT 6 W–B W–B 3 A43 Junction Connector 2 +5 E2 A3 84 CAMRY (EM0250U) O18 Door Control Receiver A48 Wireless Door Lock Buzzer O R F3 Clock 1 2 1 RSSI 39 A 11 EO1 ASEL O RDA 38 A 9 4K 5 AE2 A5 Engine Hood Courtesy SW 19 RC0 29 A G O 2 AE2 37 A O 8 CG5B V W–B 3 4D W–B R 11 4F R Y 4 4F LP Security Indicator GND1 W–B 21 A 11 3E 10 3J ASEL BZR 17 A 5 3D 11 3R W E HSW 24 B 12 A CLG5 V IND 2 A Y LIN 10 A O +B 1 A 11 A CANH O1 O21 Junction Connector L 27 A CANL W–B W 28 A AGND W G 40 A TXCT O19 Electrical Key Antenna GR 8 A CODE W W 9 A VC5 3 R R 30 A W E58(A), E59(B) Certification ECU 1 W W N11 Electrical Key Oscillator (Rear Seat) N25 Electrical Key Oscillator (Inside Luggage Room) CLG5 CLGB CLGB CLG6 12 SN1 13 SN1 CLGB P 15 EN1 P V 16 EN1 V 13 EN1 W 14 EN1 R 11 EN1 B 12 EN1 Y W 3 R 1 B 3 Y 1 P CLG4 2 V 1 13 A 14 A 15 A 16 A 31 A 32 A CLG6 CG6B CLG7 CG7B TSW1 SEL1 3 A S14 Electrical Key Oscillator (Outside Luggage Room) E6(A), E7(B), E8(C), E9(D) Main Body ECU 5 A E58(A), E59(B) Certification ECU CLG8 SEN1 22 A CLG1 33 A CG8B CG1B 34 A R V B LG L R GR W–B 13 IE1 14 IE1 17 IE1 16 IE1 12 IE1 LG L R W–B 4 IX1 3 IX1 2 IX1 1 IX1 8 IX1 P Y BR 6 IX1 B V GR G O R 15 IE1 5 1 L W R 3 6 5 2 1 9 8 3 2 4 6 10 TRG+ SGT ANT1 ANT2 TRG– TRG– ANT2 ANT1 SGT SEL SENS B V 7 IX1 X1 Door Outside Handle (Front LH) CLG CLGB +B 7 GND X2 Electrical Key Oscillator (Front Door LH) 85 CAMRY (EM0250U) Smart Key System W W E6(A), E7(B), E8(C), E9(D) Main Body ECU IG ACC 15 22 (IG) (IG) (ACC) 10A ECU IG NO. 1 7. 5A ECU–ACC 12 3C 10A IGN 13 IM LG L 11 3L 2 IF P G L G 12 4F P 6 4F LG 12 4A L E58(A), E59(B) Certification ECU 5 4D 19 A 18 A 20 B 7 A ACC IG TSW2 SEL2 4 A 6 A SEN2 23 A CLG2 35 A SH– TSW5 CG2B 36 A R R R W–B W–B L P O GR BR R W–B 15 HE1 13 HE1 14 HE1 17 HE1 16 HE1 12 HE1 O GR BR R W–B 4 HW1 3 HW1 2 HW1 1 HW1 8 HW1 P Y BR P 6 HW1 O L R 5 1 G L 7 HW1 R 3 6 5 2 1 9 8 3 2 4 6 10 TRG+ SGT ANT1 ANT2 TRG– TRG– ANT2 ANT1 SGT SEL SENS B V W W1 Door Outside Handle (Front RH) W2 Electrical Key Oscillator (Front Door RH) 86 CAMRY (EM0250U) CLG CLGB +B 7 GND W W E6(A), E7(B), E8(C), E9(D) Main Body ECU TKUL 2 C TSW 2 A R (BAT) 10A DOME O 2 3F 2 3 3N 1 P LG R P G G 19 EN2 17 EN1 8 EN2 12 AE6 Y 5 SN1 R O 14 SN1 4 SN1 1 12 3H R R O 2 R W–B W–B 2 R 1 S8 Luggage Compartment Door Lock Cylinder 12 3L S9 Luggage Electrical Key SW G R 7 IF G 13 ID Y 3 W–B 17 HE2 17 IE2 R 2 4E W–B 2 E2 1 S15 Junction Connector 9 13 E49 Junction Connector W–B 5 W–B W–B W–B W–B 1 4E R W–B W–B 1 4A S1 87 CAMRY (EM0250U) Smart Key System W W E6(A), E7(B), E8(C), E9(D) Main Body ECU LSWP 11 ID ACT+ 1 B 27 A LG LSWD 9 B L ACTD 5 B GR HORN 25 L W 24 IE2 9 IE2 L R 8 4 B 6 1B 10 1D B 1 1G W 5 1A L Y 11 1D LG 10A HORN 7. 5A S–HORN HORN Relay S–HORN Relay 2 IK Y GR 1 A4 Horn (Low) 1 A3 Horn (High) 7 1 17 IE2 25 IE2 W–B GR I7 Door Lock Assembly (Driver' s Side) W A23 Security Horn W–B 1 M W–B W 88 CAMRY (EM0250U) W W E6(A), E7(B), E8(C), E9(D) Main Body ECU ACT– LSWR 3 5 A V LSWL 20 1 IJ 6 IP 11 IP 5 IP 2 IJ 18 IF 5 IF L B LG GR W L G 4 3O LG 4 3D GR 5 3O 8 EO1 GR B L GR L GR B L GR 4 6 4 6 7 4 M 9 LG W–B W–B 17 HE2 25 HE2 4 KN1 4 JO1 W–B W–B 9 LG 1 W–B 1 M W–B 1 M J5 Door Lock Assembly (Rear RH) W 3 JO1 K5 Door Lock Assembly (Rear LH) G 1 JO1 H8 Door Lock Assembly (Front Passenger' s Side) 10 JO1 L 3 KN1 LG 1 KN1 LG 10 KN1 B 16 EO1 9 HE2 7 HE1 8 4 EO1 L 5 3I W–B W–B W–B W W 2 8 N29 Junction Connector N1 O21 Junction Connector O1 89 CAMRY (EM0250U) Smart Key System W W E6(A), E7(B), E8(C), E9(D) Main Body ECU 7 3C 12 3O 6 EO2 13 EN2 W 5 EO2 5 7 IO 9 IM 10 IF 6 10 1 IR (∗6) 6 3C 4 W–B L 9 3E L 10 3F GND1 GND2 W–B GR 6 3N GR 5 3N Y 9 3M LCTY 17 W–B 24 B Y DCTY 7 A W RCTY 21 A LG PCTY HAZ 4 C 8 HAZ L 2 11 W–B E49 Junction Connector (∗7) 13 W–B W–B 5 W–B 1 A (∗4) 1 B (∗5) W–B 1 A (∗4) 1 B (∗5) N13(A), (B) Door Courtesy SW (Rear LH) 1 N6(A), (B) Door Courtesy SW (Driver' s Side) 1 O10 Door Courtesy SW (Rear RH) O6 Door Courtesy SW (Front Passenger' s Side) Y GR E14 Turn Signal Flasher W–B (∗6) W–B W–B (∗7) W W E2 90 CAMRY (EM0250U) W (BAT) E6(A), E7(B), E8(C), E9(D) Main Body ECU LGCY 10A DOME ILE 1 B W B TR+ 25 A 21 2 1 5 IR 5 EN1 W 16 EQ1 14 6 IR S5 Door Lock Assembly (Luggage) R (∗6) (∗7) W R (∗6) W M 7 EQ1 15 EQ1 (∗7) W(∗7) 3 (∗7) 2 W 8 (∗6) V V OFF ON DOOR E CTY 6 W–B Q6 Overhead J/B Map Lamp (∗6) 1 (∗6) W B 3 (∗7) W 16 SN1 B Q9 Room Lamp (Center) 1 7 W 3 SN1 (∗7) R (∗6) 13 N28 Junction Connector BR B W LG 17 EN2 10 IL W–B (∗7) W–B (∗6) 18 EQ1 W–B 9 11 EQ1 W–B 1 S15 Junction Connector W–B 2 (∗7) W LG 13 ID (∗6) W–B (∗7) W ∗ ∗ ∗ ∗ 4 5 6 7 : TMC Made : TMMK Made : w/ Sliding Roof : w/o Sliding Roof S1 91 CAMRY (EM0250U) Smart Key System System Outline ∗ Steering lock Receiving signals from the power SW and the key, the certification ECU sends instruction for locking and unlocking the steering lock to the steering lock ECU (Built in the steering lock) in order to activate the motor. The steering lock ECU detects position of the lock bar and stops the motor at the specified position. : Parts Location Code See Page Code See Page A3 48 (2GR–FE) E8 C 56 A4 48 (2GR–FE) E9 D 56 E14 56 Code See Page N11 N13 60 A 60 B 60 A5 48 (2GR–FE) A19 59 E41 B 57 N25 60 A23 48 (2GR–FE) E42 A 57 N28 60 A25 C 48 (2GR–FE) E43 B 57 N29 60 A26 A 48 (2GR–FE) E44 C 57 O6 60 A40 A 59 E49 57 O10 60 A41 A 59 E50 57 O18 60 B A42 59 E51 57 O19 60 A43 49 (2GR–FE) E52 57 O21 60 A48 49 (2GR–FE) E56 57 Q6 61 A55 A 49 (2GR–FE) E58 A 57 Q9 61 A60 B 49 (2GR–FE) E59 B 57 S5 61 C1 A 50 (2GR–FE) F1 A 58 S8 61 C3 A 50 (2GR–FE) F2 B 58 S9 61 C50 51 (2GR–FE) F3 58 S14 61 51 (2GR–FE) H8 61 S15 61 C56 51 (2GR–FE) I7 61 W1 61 C57 51 (2GR–FE) J5 61 W2 61 K5 61 X1 61 A 60 X2 61 B 60 C55 B D1 C 51 (2GR–FE) E6 A 56 E7 B 56 N6 : Relay Blocks Code 1 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) 92 CAMRY (EM0250U) : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) 1A 1B 25 1D 1G Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 22 3C 3D 3E 3F 3G 3H 3I 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) 36 Instrument Panel No.2 Wire and J/B No.3 (Behind the Combination Meter) 42 Instrument Panel Wire and J/B No.4 (Instrument Panel Brace Center) 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) 3J 3L 3M 3N 3O 3P 3Q 3R 3U 4A 4C 4D 4E 4F 4G 4H 4K 4L 4M IC ID IF IG II 30 31 IJ IK IL Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) 30 IM IO IP IR 30 Floor Wire and Instrument Panel J/B (Cowl Side Left) 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) 93 CAMRY (EM0250U) Smart Key System : Connector Joining Wire Harness and Wire Harness Code AE2 See Page Joining Wire Harness and Wire Harness (Connector Location) 66 Engine Room Main Wire and Instrument Panel Wire (Right Side of the Instrument Panel J/B) 66 Engine Room Main Wire and Instrument Panel Wire (Instrument Panel Right) 64 (2GR–FE) Engine Wire and Engine Room Main Wire (Inside of the Engine Room R/B and Engine Room J/B) 66 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) 66 Instrument Panel Wire and Floor Wire (Left Kick Panel) 66 Instrument Panel Wire and Floor No.2 Wire (Right Kick Panel) EQ1 66 Instrument Panel Wire and Roof Wire (Lower Part of Front Pillar LH) FE3 66 Instrument Panel No.2 Wire and Instrument Panel Wire (Instrument Panel Center) 66 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) 67 Front Door RH Wire and Electrical Key Wire Harness RH (Inside of the Front Door RH) 66 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) AE5 AE6 CA1 CA2 CA3 EA1 EN1 EN2 EO1 EO2 HE1 HE2 HW1 IE1 IE2 IX1 67 Front Door LH Wire and Electrical Key Wire Harness LH (Inside of the Front Door LH) JO1 67 Rear Door No.1 Wire and Floor No.2 Wire (Right Center Pillar) KN1 67 Rear Door No.2 Wire and Floor Wire (Left Center Pillar) SN1 67 Luggage Room Wire and Floor Wire (Luggage Room Left) : Ground Points Code A1 A2 See Page Ground Points Location 64 (2GR–FE) Front Left Fender A3 66 Left Cowl Side Panel C5 64 (2GR–FE) Right Side of the Cylinder Block C7 64 (2GR–FE) Left Side of the Cylinder Block E1 66 Instrument Panel Left E2 66 Instrument Panel Brace LH F1 66 Instrument Panel Left N1 67 Left Rear Quarter Panel O1 67 Right Rear Quarter Panel S1 67 Lower Back Panel Center 94 CAMRY (EM0250U) Memo 95 CAMRY (EM0250U) Starting without Smart Key System ACC 4 AM1 IG1 GR O ST1 3 5 AM2 4 IG2 II 1 AE7 2 AE7 B L L E23 Ignition SW B 7. 5A AM1 ST2 7 1 1 5 1 3 2 4 CA2 1 R(M/T) ST Relay 120A ALT 30A ST/AM2 1 W(A/T) 1 1F G B 1 IA 1 W–B W GR 1 1G B 1 CA1 B 1 C 1 A (A/T) 1 B (M/T) M Battery C3(A), C29(B), D1(C) Starter FL MAIN 3. 0W R(M/T) A1 96 CAMRY (EM0250U) W–B W–B W(A/T) A3 5 3F GR 5 3E GR ∗ 1 : 2AZ–FE A/T B (2AZ–FE) A41(A), A42(B) Junction Connector 11 B 10 B P A22 Clutch Start SW P (∗1) 8 CA2 Y 4 A (2GR–FE) 4 B (2AZ–FE) 62 B (2GR–FE) 52 D (2AZ–FE) NSW B 11 NSW P N STA W 9 A (2GR–FE) 5 B (2AZ–FE) (A/T) STA 48 A (2GR–FE) 48 C (2AZ–FE) C1(A), (B) Park/Neutral Position SW L C56 Transmission Control ECU Y (A/T) SB (∗1) L (2GR–FE) V A24(C), A55(A), C24(D), C55(B) Engine Control Module R (M/T) L–B (2GR–FE) 10 Y R 18 CA2 9 CA3 (A/T) G (M/T) 2 A (∗1) 1 A 2 (2GR–FE) 1 (2GR–FE) R (M/T) 6 EA1 LG 7 CA2 R(M/T) R(M/T) R(M/T) W(A/T) W(A/T) W(A/T) Y(2GR–FE) 97 CAMRY (EM0250U) Starting without Smart Key System : Parts Location Code See Page A22 59 Code See Page C1 B C3 A Code 54 (2AZ–FE) A24 C 52 (2AZ–FE) A41 A 59 50 (2GR–FE) A42 B 59 C24 D 55 (2AZ–FE) A55 A 49 (2GR–FE) C29 B 55 (2AZ–FE) C1 A 50 (2GR–FE) C55 B 51 (2GR–FE) 54 (2AZ–FE) See Page C56 D1 51 (2GR–FE) C E23 51 (2GR–FE) 55 (2AZ–FE) 56 : Relay Blocks Code 1 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1F See Page Junction Block and Wire Harness (Connector Location) 22 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) IA 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) II 31 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) 1G 3E 3F : Connector Joining Wire Harness and Wire Harness Code AE7 CA1 CA2 See Page 66 Joining Wire Harness and Wire Harness (Connector Location) Engine Room Main Wire and Instrument Panel Wire (Right Side of the Instrument Panel J/B) 64 (2GR–FE) 65 (2AZ–FE) 64 (2GR–FE) Engine Wire and Engine Room Main Wire (Inside of the Engine Room R/B and Engine Room J/B) 65 (2AZ–FE) CA3 65 (2AZ–FE) EA1 66 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) : Ground Points Code A1 A3 See Page 64 (2GR–FE) 65 (2AZ–FE) 66 Ground Points Location Front Left Fender Left Cowl Side Panel 98 CAMRY (EM0250U) Memo 99 CAMRY (EM0250U) Charging (IG) (IG) 10A GAUGE NO. 1 (BAT) 7. 5A GAUGE NO. 2 7. 5A ALT–S 2 12 IG 1 W R GR 16 IH 2 3G GR 9 3Q B 14 EA1 13 A IG+ IG2 ALT 10 CA2 3 B L 2 B M IG 11 FE3 5 CA2 W B G–R 1 A (2GR–FE) 1 C (2AZ–FE) CHG– 23 A Y 1 1G R L (2AZ–FE) B 120A ALT 50 B Charge 1 1C F1(A) Combination Meter O C24(B) Engine Control Module IC Regulator FL MAIN 3. 0W 1 B 4 B Y L G–R S Battery 100 CAMRY (EM0250U) LG C18(B), C19(A), (C) Generator 3 EA1 2 CA2 : Parts Location Code C18 See Page 50 (2GR–FE) B 54 (2AZ–FE) Code C19 See Page Code See Page A 50 (2GR–FE) C24 B 55 (2AZ–FE) C 54 (2AZ–FE) F1 A 58 : Relay Blocks Code 1 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) 1C 22 Engine Wire and Engine Room J/B (Engine Compartment Left) 1G 22 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 3G 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) 3Q 36 Instrument Panel No.2 Wire and J/B No.3 (Behind the Combination Meter) 31 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) IG IH : Connector Joining Wire Harness and Wire Harness Code CA2 See Page 64 (2GR–FE) 65 (2AZ–FE) Joining Wire Harness and Wire Harness (Connector Location) Engine Wire and Engine Room Main Wire (Inside of the Engine Room R/B and Engine Room J/B) EA1 66 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) FE3 66 Instrument Panel No.2 Wire and Instrument Panel Wire (Instrument Panel Center) 101 CAMRY (EM0250U) Ignition for 2GR–FE (BAT) (BAT) (BAT) 7. 5A AM2 30A ST/AM2 20A IG2 2 2 1 B B (∗2) 7 CA3 Y (∗1) Y B B 1 1 BR 1 AE7 BR L BR B (∗2) L BR IG2 6 Y (∗2) ST2 B E23 Ignition SW 1 2 BR L BR 3 1 BR (∗1) LG IGF 3 5 2 L IGT1 IG2 Relay 10 4M (∗1) 4 GND L 1 1 12 4M L (∗2) B 10 4E 1 +B W LG 1 C49 Noise Filter (Ignition LH) 12 4E (∗1) L (∗1) O(∗1) 16 EA1 C16 Noise Filter (Ignition RH) 1 7 EA1 1 B 11 A BR (∗2) IG2D BR AM2 (∗1) 1 A 40 B E6(A) Main Body ECU IGT1 106 B IGF1 C55(B) Engine Control Module 6 A43 Junction Connector A2 C11 Ignition Coil (No. 1) BR 10 EA1 B 5 AM2 A2 102 CAMRY (EM0250U) ∗ 1 : w/ Smart Key System ∗ 2 : w/o Smart Key System B B–W 2 CA3 BR L B BR W–B W–B W–B L L W–L BR BR W–L IGT2 38 B IGT3 37 B IGT4 36 B IGT5 IGT6 IGF 3 2 C39 Ignition Coil (No. 6) 4 GND W–L 2 W–B B IGF 3 +B L–B IGT5 C38 Ignition Coil (No. 5) 1 W–L 2 W–B BR IGF 3 4 GND P IGT4 +B 35 B IGT6 C55(B) Engine Control Module W–B 39 B 1 R 2 4 GND C14 Ignition Coil (No. 4) BR IGF 3 +B LG L IGT3 C12 Ignition Coil (No. 3) 2 1 R IGF 3 4 GND G IGT2 +B W L 1 C13 Ignition Coil (No. 2) 4 GND G–R +B B B–W 1 W W B B C7 103 CAMRY (EM0250U) Ignition for 2GR–FE : Parts Location Code See Page Code See Page A43 49 (2GR–FE) C14 50 (2GR–FE) Code See Page C49 51 (2GR–FE) C11 50 (2GR–FE) C16 50 (2GR–FE) C55 B 51 (2GR–FE) C12 50 (2GR–FE) C38 51 (2GR–FE) E6 A 56 C13 50 (2GR–FE) C39 51 (2GR–FE) E23 56 : Relay Blocks Code 1 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 4E 4M See Page 42 Junction Block and Wire Harness (Connector Location) Instrument Panel Wire and J/B No.4 (Instrument Panel Brace Center) : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) AE7 66 Engine Room Main Wire and Instrument Panel Wire (Right Side of the Instrument Panel J/B) CA3 64 (2GR–FE) Engine Wire and Engine Room Main Wire (Inside of the Engine Room R/B and Engine Room J/B) EA1 66 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) : Ground Points Code See Page Ground Points Location A2 64 (2GR–FE) Front Left Fender C7 64 (2GR–FE) Left Side of the Cylinder Block 104 CAMRY (EM0250U) Memo 105 CAMRY (EM0250U) Ignition for 2AZ–FE (IG) 15A INJ B 7 IH B 10 EA1 BR 7 CA3 BR BR BR BR W–B 2 IGT4 IGF 3 2 C14 Ignition Coil (No. 4) BR IGF 3 W–B W–B IGT3 4 GND W–L 2 +B LG IGF 3 1 C12 Ignition Coil (No. 3) IGT2 4 GND W–L W–L W–L +B G 2 1 W–L IGF 3 4 GND G–R IGT1 +B C13 Ignition Coil (No. 2) 1 BR W–B W–B W–B BR 4 GND W +B C11 Ignition Coil (No. 1) 1 W–B BR 1 C16 Noise Filter (Ignition RH) BR W–B W–L BR W–L 85 B IGT1 81 B IGF1 84 B IGT2 83 B IGT3 82 B IGT4 W–B C24(B) Engine Control Module C4 106 CAMRY (EM0250U) : Parts Location Code See Page Code See Page C11 54 (2AZ–FE) C13 54 (2AZ–FE) C12 54 (2AZ–FE) C14 54 (2AZ–FE) Code See Page C16 C24 54 (2AZ–FE) B 55 (2AZ–FE) : Junction Block and Wire Harness Connector Code IH See Page 31 Junction Block and Wire Harness (Connector Location) Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) : Connector Joining Wire Harness and Wire Harness Code See Page CA3 65 (2AZ–FE) Joining Wire Harness and Wire Harness (Connector Location) Engine Wire and Engine Room Main Wire (Inside of the Engine Room R/B and Engine Room J/B) EA1 66 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) : Ground Points Code C4 See Page 65 (2AZ–FE) Ground Points Location Cylinder Block 107 CAMRY (EM0250U) Engine Control for 2GR–FE (BAT) 30A EFI MAIN 2 W 12 1E 1 1G LG 12 1D 1 A 6 B A58(A), E40(B) Junction Connector Y 1 A/F Relay Y C/OPN Relay EFI Relay 1 1 1 CA2 10A EFI NO. 3 B 15A EFI NO. 2 2 2 8 1E GR Y W 1 13 1E 9 NA1 GR 4 1A 4 Pump 11 1E N10 Fuel Suction Pump and Gage Assembly 9 1E BR BR B 6 1E 10 1E O 20A A/F M 5 1 1 GR GR R R W W–B Y GR GR FL MAIN 3. 0W R O R BR BR B Battery A3 A1 108 CAMRY (EM0250U) W–B W–B W–B N1 30A ST/AM2 20A IG2 10A IGN (BAT) (BAT) ∗ 1 : w/ Smart Key System ∗ 2 : w/o Smart Key System E23 Ignition SW 2 1 1 4 ACC II 4 AM1 (∗2) (∗2) Y B O Y 2 1 Y 9 IG 7. 5A AM2 IG1 ST1 3 GR (∗2) 1 AE7 12 3F B (∗2) 5 AM2 IG2 6 ST2 5 3F 5 3E (∗1) (BAT) (BAT) 7. 5A AM1 (IG) GR 7 EA1 (∗2) Y 6 EA1 (∗2) L P (∗2) (∗1) 12 3K 12 3J 10 EA1 B O (∗1) Y (∗2) 8 CA2 (∗1) Y Y Y (∗2) G (∗1) 1 1 L–B 1 Y 5 IG2 Relay 4 A 2 1 P N 9 A BR (∗1) BR (∗2) 2 CA1 B W B 1 L C1(A) Park/Neutral Position SW 3 ST Relay W LG W O(∗1) Y(∗1) Y Y W GR GR GR GR R R O O R R B B A43 Junction Connector (∗2) BR 6 A2 A2 109 CAMRY (EM0250U) Engine Control for 2GR–FE E6(A), E7(B), E8(C), E9(D) Main Body ECU CANL 6 C CANH 5 C TACH 8 C (∗1) P G GR STSW 4 D (∗1) 8 B (∗1) V ACCR 3 A STR STR2 6 D (∗1) LG L IG2D 11 A (∗1) (∗1) L AM2 1 A (∗1) AM1 6 B ∗ 1 : w/ Smart Key System B 12 4G 12 4M 10 4M 8 4K 9 4G 4 4M 7 4K (∗1) B GR P G 9 4C W (∗1) 5 4C (∗1) LG (∗1) 13 AE6 15 AE5 13 EA1 1 B (∗1) (∗1) G (∗1) 8 AE5 Y (∗1) G R (∗1) (∗1) L 9 4F (∗1) 9 4E V 10 4E (∗1) 12 4E 4 AE5 1 1 L R 1 (∗1) 1 Y ST CUT Relay 3 (∗1) R (∗1) O 2 (∗1) L–B 5 (∗1) 16 EA1 18 CA2 R(∗1) R(∗1) B(∗1) LG 7 CA2 R(∗1) V Y(∗1) V Y Y W W GR GR GR GR R R O O R R B B L L–B (∗1) O(∗1) 5 A43 Junction Connector A2 110 CAMRY (EM0250U) B(∗1) B W W–B GR R B R (∗1) (BAT) B W–L W R 10A EFI NO. 1 W–L 2 C34 VSV (ACM) 8 A 9 A 2 1 A41(A) Junction Connector W–L 1 2 1A W B 2 C48 VSV (ACIS) O 1 C6 VSV (Purge) 3 CA2 B W–L 12 NA1 GR GR 16 NA1 W–B W–B W–L L–B B–W 20 A 63 B STA FC 62 B 48 A 7 A (∗1) R B R (∗1) B 13 A BATT Y ACM ACIS A55(A), C55(B) Engine Control Module STAR ACCR NSW V STSW 14 A GR 42 B 107 B PRG L–B 2 B 108 B (∗1) 1 B G–R 10 A A41(A), A42(B) Junction Connector W–B Y 10 CA3 R(∗1) B(∗1) R(∗1) L–B V Y W W GR B GR R R O O R R B B W–L W–B R C4 111 CAMRY (EM0250U) Engine Control for 2GR–FE B(∗1) B(∗1) B B W W W–B GR N17 Canister Pump Module R Leak Detection Pump Canister Pressure Sensor Vent Valve G 3 NA1 4 NA1 R 76 B 77 B 75 B 83 B PPMP B W W W 2 2 A 1 MPMP +B2 MREL 2 A 1 A 44 A V 2 B 2 2 W 1 C37 Fuel Injector (No. 6) C36 Fuel Injector (No. 5) C10 Fuel Injector (No. 4) 2 W W 1 +B ACIV 4 A V W 2 W W 2 1 W 2 1 C8 Fuel Injector (No. 3) C9 Fuel Injector (No. 2) C7 Fuel Injector (No. 1) 1 34 A VCPP O 43 B G 13 CA2 R # 40 84 B Y R B 14 CA2 R W # 30 44 B W–L # 20 85 B 12 CA2 VPMP EPPM A55(A), C55(B) Engine Control Module # 50 # 60 L # 10 45 B W–B Y 14 NA1 Y 13 NA1 42 A ETHA 6 BR THA MGND 1 B 74 B VG MTRB 5 NA1 B G–R 71 B E2G VCC 4 L P 72 B E2 VOUT 3 BR L–B 73 B 2 BR 2 SGND 8 G THA 1 VGND 9 W VG 5 VLVB GR E2G 4 LG +B A56(A), A57(B) Short Connector C2 Mass Air Flow Meter W B A53 VSV (Air Intake Control) R 3 M 1 R O R B B W–L W–L R R 112 CAMRY (EM0250U) B(∗1) B(∗1) B B W W (BAT) (IG) (BAT) ∗ 1 : w/ Smart Key System 10A IGN 10A STOP 10A ETCS 2 8 IC 9 IG 1 ID NE– 111 B HT1B EX1B 48 B 65 B BR E2 (Shielded) W–B 4 1 3 1 4 HT2B OX1B HT1B Y B (Shielded) 3 OX2B LG 1 C50 Crankshaft Position Sensor 2 +B E2 +B C51 Heated Oxygen Sensor (Bank 2 Sensor 2) 2 C52 Heated Oxygen Sensor (Bank 1 Sensor 2) R W–L (Shielded) (Shielded) 2 BR Y OX1B 88 B R G (Shielded) IGSW A55(A), C55(B) Engine Control Module OX2B EX2B HT2B 87 B 64 B 47 B W NE+ 28 A ST1– STP 110 B Y 35 A 36 A +BM 12 3K Y A19 Stop Lamp SW W 3 A 6 B 4 GR 1 L 3 A A41(A), A42(B) Junction Connector LG 8 B 2 A 12 3F A58(A), E40(B) Junction Connector 3 L 2 B Y B 1 B B W–L R C5 113 CAMRY (EM0250U) Engine Control for 2GR–FE B(∗1) B(∗1) B B W W C5 Throttle Body Assembly VC E2 M+ M– 2 1 W–L P G R 3 B 4 Y C4 Engine Coolant Temp. Sensor 1 VTA2 5 (Shielded) VTA 6 98 B 96 B 99 B 97 B 19 B 18 B P 79 B 78 B G–R B 2 3 CV1 +B C15 Air Fuel Ratio Sensor (Bank 1 Sensor 1) C35 Air Fuel Ratio Sensor (Bank 2 Sensor 1) 1 B W 2 2 B B (Shielded) B (Shielded) C5 114 CAMRY (EM0250U) 1 2 (Shielded) W 4 CV1 2 CV1 V1 Knock Control Sensor (Bank 2) +B 2 1 CV1 G 1 HA2A B 4 A2A– EKN2 117 B R 3 A2A+ 118 B V2 Knock Control Sensor (Bank 1) 1 HA1A KNK2 EKNK G 4 A1A– GE01 94 B W 3 A1A+ KNK1 95 B 41 B M– R 109 B M+ B 119 B BR 120 B B–W HA1A 86 B (Shielded) L (Shielded) A1A– 116 B G A1A+ 93 B VCTA VTA1 VTA2 ETA A55(A), C55(B) Engine Control Module A2A+ A2A– HA2A Y ETHW P THW B(∗1) B(∗1) B B W W ∗ 1 : w/ Smart Key System ME01 E02 B LG Y E03 E05 E1 81 B W–B 46 B W–B 21 B W 20 B VCE2 W 104 B 112 B EV2– B–W VPA2 89 B EV2+ B–W 3 VPA E01 22 B 66 B VCE1 B 6 EPA E04 23 B 114 B EV1– B 5 91 B EV1+ B 4 VCPA 68 B B 2 EPA2 VC2 3 W–B 1 VCP2 EX– 2 W–B 56 A G 55 A Y 59 A B 57 A EX+ 1 W EPA 60 A R VCPA 58 A O EPA2 113 B VV2– VCV2 A55(A), C55(B) Engine Control Module VPA VPA2 VC2 3 L 90 B VV2+ EX– 2 G–R 67 B VCV1 EX+ 1 W 115 B VC 3 C44 VVT Sensor (Bank 2 Exhaust Side) R 2 C40 VVT Sensor (Bank 1 Exhaust Side) L VCP2 VV1– VVL– 1 B 92 B VV1+ VVL+ W 69 B VC 3 Y 2 LG VVR– 1 L VVR+ C45 VVT Sensor (Bank 2 Intake Side) R C41 VVT Sensor (Bank 1 Intake Side) 4 6 5 C4 C57 Junction Connector A17 Accelerator Position Sensor C7 115 CAMRY (EM0250U) 2 2 IGF IGT3 2 IGF L W–L BR W–L IGT4 IGF 36 B 35 B 70 B L–B B R 17 B 14 B 15 B 58 B OC1+ OC1– OC2+ A55(A), C55(B) Engine Control Module IGT3 IGT4 57 B 52 B 51 B 3 OC2– IGT5 IGT5 3 IGF 116 CAMRY (EM0250U) G BR 16 B Y B C46 Camshaft Timing Oil Control Valve (LH Exhaust Side) C43 Camshaft Timing Oil Control Valve (RH Intake Side) 2 2 2 7 AE5 IMI IGT6 IGF 11 A 10 A IGT6 3 (∗1) G (∗1) L C47 Camshaft Timing Oil Control Valve (LH Intake Side) 5 13 10 4F 5 4F 11 4C 4 4C EFIO 2 13 AE5 IMO PSW 1 (∗2) EFII 6 G G (∗1) EFIO (∗2) L L (∗1) E50 ID Code Box C17 Power Steering Oil Pressure SW 37 B P W 2 L–B P Y C42 Camshaft Timing Oil Control Valve (RH Exhaust Side) ∗ 1 : w/ Smart Key System ∗ 2 : w/o Smart Key System C39 Ignition Coil (No. 6) 3 1 C38 Ignition Coil (No. 5) 3 W–L IGT2 W–L 38 B LG IGT2 1 C14 Ignition Coil (No. 4) 3 OE2– LG W–L 2 C12 Ignition Coil (No. 3) 39 B G IGT1 1 R IGF OE2+ G OE1– C13 Ignition Coil (No. 2) 40 B G–R LG 2 R IGT1 G–R IGF1 L 106 B W L 1 C11 Ignition Coil (No. 1) W OE1+ L BR Engine Control for 2GR–FE B(∗1) B(∗1) B B W W E15 Transponder Key ECU 12 EFII B(∗1) B B W W B W B W V 14 B (∗1) C56 Transmission Control ECU CANL TAC 9 4L TC 14 AE5 13 6 A 6 AE5 B Y B P G V 12 AE5 2 B 1 B 15 A 27 A 43 A 8 A CAN+ CAN– TC TACH RFC SPD W B B (∗2) 5 A W 5 3B P B A41(A) Junction Connector 5 3H B (∗1) V 9 4A Cooling Fan ECU 10 4C B 7 B CAN– 6 (∗1) CAN+ (∗2) P 9 E10 Data Link Connector 3 6 CANH 49 A 41 A CANL CANH A55(A), C55(B) Engine Control Module W BR 24 A R 5 AE5 R 117 CAMRY (EM0250U) Engine Control for 2GR–FE B W B W V V ∗ 3 : w/ VSC TMC Made ∗ 4 : w/ VSC TMMK Made ∗ 5 : w/o VSC L R L B 3 A 10 B 10 C 17 A 9 B 9 C 20 A 7 B 7 C 6 A 27 B 17 C 5 A 29 B 19 C FR– RL+ RL– RR+ RR– W B W B 2 G 1 G 2 C 1 C 6 AE6 2 A 1 A 2 B 1 B W B SP1 12 A (∗3) 33 B (∗4) 23 C (∗5) BR B 10 B 14 FE3 13 FE3 B 4 B W 8 A W 2 A W W 7 A CANL 25 A 14 B 15 C B B 1 A FR+ W CANH 11 A 35 B 26 C FL– A40(A), E41(B) Junction Connector FL+ 19 A (∗3) 8 B (∗4) 8 C (∗5) E42(A), E43(B), E44(C), E62(G) Junction Connector P 4 A 6 B 6 C W V 18 A 5 B 5 C B A25(C), A26(A), A60(B) Skid Control ECU with Actuator B W W LG Speed Sensors B W W R R 118 CAMRY (EM0250U) (IG) (BAT) (BAT) 7. 5A GAUGE NO. 2 10A DOME 10A MPX–B 2 V 1 3 1A 1 3D LG R V 2 3G R GR 10 3B 12 3L 7 IF 1 3Q 13 ID V V SB GR 12 IG 2 EA1 V R 12 B +S IG2 12 3Q GR 9 3Q 13 A 1 A 2 A IG+ B V 3 3P B2 Power Supply Circuit +B(DOME) MULTI LCD Master Warning Temp. Tachometer Malfunction Indicator Lamp Speedometer IG2 Buzzer MICRO COMPUTER DRIVE IC IG2 ES E2 24 A 11 3P 7 3Q 5 3Q GR 17 A 3 3B 3 3D 2 3U 10 3D W BR BR W–B W 15 EA1 R 3 F1 C57 Junction Connector 4 CA3 W–B B W GR 18 B A41(A), A42(B) Junction Connector 12 A BR W 14 B W–B 18 A 9 3P SI CANL 17 A B CANH R CHK 4 B W F1(A), F2(B) Combination Meter CAN I/F C7 119 CAMRY (EM0250U) Engine Control for 2GR–FE System Outline The engine control system utilizes a microcomputer and maintains overall control of the engine, transaxle etc. An outline of the engine control is given here. 1. Input Signals (1) Engine coolant temp. signal circuit The engine coolant temp. sensor detects the engine coolant temp. and has a built–in thermistor with a resistance which varies according to the engine coolant temp. The engine coolant temp. is input into TERMINAL THW of the engine control module as a control signal. (2) Intake air temp. signal circuit The intake air temp. sensor is installed in the mass air flow meter and detects the intake air temp., which is input as a control signal to TERMINAL THA of the engine control module. (3) Oxygen sensor signal circuit The oxygen density in the exhaust emission is detected and is input as a control signal from the heated oxygen sensors to TERMINALS OX1B and OX2B of the engine control module. (4) RPM signal circuit Camshaft position is detected by the VVT sensor (Bank 1 exhaust side, bank 1 intake side, bank 2 exhaust side and back 2 intake side), and their signals are input to TERMINALS EV1+, EV2+, VV1+ and VV2+ of the engine control module as control signals. Also, the engine RPM is detected by the crankshaft position sensor installed in the cylinder block and the signal is input into TERMINAL NE+ of the engine control module as a control signal. (5) Throttle position sensor signal circuit The throttle position sensor detects the throttle valve opening angle as a control signal, which is input into TERMINALS VTA1 and VTA2 of the engine control module. (6) Vehicle speed circuit The vehicle speed sensor detects the vehicle speed, and the signal is input into TERMINAL SPD of the engine control module via the combination meter, from TERMINAL SP1 of the skid control ECU with actuator. (7) Battery signal circuit Voltage is constantly applied to TERMINAL BATT of the engine control module. When the power SW is pushed on (Power SW type), or when the ignition SW is turned on (Ignition SW type), the voltage for engine control module start–up power supply is applied to TERMINAL +B and +B2 of engine control module via EFI relay. (8) Intake air volume signal circuit The intake air volume is detected by the mass air flow meter, and is input as a control signal to TERMINAL VG of the engine control module. (9) Stop lamp SW signal circuit The stop lamp SW is used to detect whether the vehicle is braking or not, and the signal is input into TERMINAL STP of the engine control module as a control signal. (10) Starter signal circuit To confirm whether the engine is cranking, the voltage applied to the starter motor when the engine is cranking is detected, and is input into TERMINAL STA of the engine control module as a control signal. (11) Engine knock signal circuit Engine knocking is detected by the knock control sensors, and is input into TERMINALS KNK1 and KNK2 of the engine control module as a control signal. (12) Air fuel ratio signal circuit The air fuel ratio is detected and input as a control signal into TERMINALS A1A+, A2A+ of the engine control module. 120 CAMRY (EM0250U) 2. Control System ∗ SFI system The SFI system monitors the engine condition through the signals input from each sensors to the engine control module. The control signal is sent to the engine control module TERMINALS #10, #20, #30, #40, #50 and #60 to operate the injector (Fuel injection). The SFI system controls the fuel injection by the engine control module in response to the driving conditions. ∗ ESA system The ESA system monitors the engine condition through the signals input from each sensors to the engine control module. The best ignition timing is decided according to this data and the data memorized in the engine control module. The control signal is output to TERMINALS IGT1, IGT2, IGT3, IGT4, IGT5 and IGT6, and these signals control the igniter to provide the best ignition timing. ∗ Heated oxygen sensor heater control system The heated oxygen sensor heater control system turns the heater on when the intake air volume is low (Temp. of exhaust emission is low), and warms up the heated oxygen sensors to improve their detection performance. The engine control module evaluates the signals from each sensors, and outputs current to TERMINALS HT1B or HT2B to control the heater. ∗ Air fuel ratio sensor heater control system The air fuel ratio sensor heater control system turns the heater on when the intake air volume is low (Temp. of exhaust emission is low), and warms up the air fuel ratio sensor to improve detection performance of the sensor. The engine control module evaluates the signals from each sensor, current is output to TERMINALS HA1A and HA2A, controlling the heater. ∗ ACIS The ACIS includes a valve in the bulkhead separating the surge tank into two parts. This valve is opened and closed in accordance with the driving conditions to control the intake manifold length in two stages, for increased engine output in all ranges from low to high speeds. ∗ ETCS–i The ETCS–i controls the engine output at its optimal level in accordance with the opening of the accelerator pedal, under all driving conditions. ∗ Dual VVT–i Dual VVT–i controls the intake and exhaust valve timing to the most appropriate levels in accordance with the engine conditions. 3. Diagnosis System When there is a malfunction in the engine control module signal system, the malfunctioning system is recorded in the memory. The malfunctioning system can be found by reading the code displayed on the malfunction indicator lamp. 4. Fail–Safe System When a malfunction has occurred in any system, there is a possibility of causing engine trouble due to continued control based on that system. In that case, the fail–safe system either controls the system using the data (Standard values) recorded in the engine control module memory, or else stops the engine. 121 CAMRY (EM0250U) Engine Control for 2GR–FE : Parts Location Code See Page A17 A19 Code See Page 59 C12 50 (2GR–FE) Code See Page C56 51 (2GR–FE) 59 C13 50 (2GR–FE) A25 C 48 (2GR–FE) C14 50 (2GR–FE) E6 C57 A 51 (2GR–FE) 56 A26 A 48 (2GR–FE) C15 50 (2GR–FE) E7 B 56 A40 A 59 C17 50 (2GR–FE) E8 C 56 A41 A 59 C34 51 (2GR–FE) E9 D 56 A42 B 59 C35 51 (2GR–FE) E10 56 A43 49 (2GR–FE) C36 51 (2GR–FE) E15 56 A53 49 (2GR–FE) C37 51 (2GR–FE) E23 56 A55 A 49 (2GR–FE) C38 51 (2GR–FE) E40 B 57 A56 A 59 C39 51 (2GR–FE) E41 B 57 A57 B 59 C40 51 (2GR–FE) E42 A 57 A58 A 59 C41 51 (2GR–FE) E43 B 57 A60 B 49 (2GR–FE) C42 51 (2GR–FE) E44 C 57 A C1 50 (2GR–FE) C43 51 (2GR–FE) C2 50 (2GR–FE) C44 51 (2GR–FE) E62 G 57 C4 50 (2GR–FE) C45 51 (2GR–FE) F1 A 58 C5 50 (2GR–FE) C46 51 (2GR–FE) F2 B 58 C6 50 (2GR–FE) C47 51 (2GR–FE) N10 60 C7 50 (2GR–FE) C48 51 (2GR–FE) N17 60 C8 50 (2GR–FE) C50 51 (2GR–FE) V1 51 (2GR–FE) V2 51 (2GR–FE) C9 50 (2GR–FE) C51 51 (2GR–FE) C10 50 (2GR–FE) C52 51 (2GR–FE) C11 50 (2GR–FE) C55 B 51 (2GR–FE) : Relay Blocks Code 1 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) 122 CAMRY (EM0250U) E50 57 : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) 1A 1D 25 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 1E 1G 22 3B 3D 3E 3F 3G 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) 36 Instrument Panel No.2 Wire and J/B No.3 (Behind the Combination Meter) 42 Instrument Panel Wire and J/B No.4 (Instrument Panel Brace Center) 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) 3H 3J 3K 3L 3P 3Q 3U 4A 4C 4E 4F 4G 4K 4L 4M IC ID IF IG II 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) 31 : Connector Joining Wire Harness and Wire Harness Code AE5 See Page Joining Wire Harness and Wire Harness (Connector Location) 66 Engine Room Main Wire and Instrument Panel Wire (Instrument Panel Right) 66 Engine Room Main Wire and Instrument Panel Wire (Right Side of the Instrument Panel J/B) 64 (2GR–FE) Engine Wire and Engine Room Main Wire (Inside of the Engine Room R/B and Engine Room J/B) CV1 64 (2GR–FE) Engine Wire and Sensor Wire (Left Side of the Cylinder Block) EA1 66 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) FE3 66 Instrument Panel No.2 Wire and Instrument Panel Wire (Instrument Panel Center) NA1 66 Floor Wire and Engine Room Main Wire (Left Kick Panel) AE6 AE7 CA1 CA2 CA3 123 CAMRY (EM0250U) Engine Control for 2GR–FE : Ground Points Code A1 See Page Ground Points Location 64 (2GR–FE) Front Left Fender A3 66 Left Cowl Side Panel C4 64 (2GR–FE) Cylinder Head C5 64 (2GR–FE) Right Side of the Cylinder Block C7 64 (2GR–FE) Left Side of the Cylinder Block F1 66 Instrument Panel Left N1 67 Left Rear Quarter Panel A2 124 CAMRY (EM0250U) Memo 125 CAMRY (EM0250U) Engine Control for 2AZ–FE (BAT) (IG) (IG) 30A EFI MAIN 10A IGN 15A INJ 2 1 8 IH 9 IG Y LG BR 12 1D Y 12 1E 12 3F BR 1 EA1 12 3K 10 1E 13 1E 1 W 1 16 B 10A EFI NO. 3 2 W–B 15A EFI NO. 2 2 GR LG M 5 W–B 1 1 1 A 4 Pump 17 A N10 Fuel Suction Pump and Gage Assembly 1 A41(A), A42(B) Junction Connector 9 NA1 1 CA2 8 1E O BR BR L B GR 9 1E Y 6 1E 11 1E 7 1E A58(A), E40(B) Junction Connector Y 6 B W 2 CA1 C/OPN Relay EFI Relay GR GR R R Y O GR GR R BR R W–B A1 W W–B W–B W–B W A3 N1 126 CAMRY (EM0250U) Leak Detection Pump Vent Valve MPMP W GR 12 NA1 O 14 CA2 13 CA2 R 12 CA2 L GR 34 A 5 NA1 G 10 CA3 3 NA1 W 14 NA1 Y 13 NA1 B 4 NA1 BR 16 NA1 Y 9 B VLVB 8 BR VGND 4 G VCC 3 G VOUT 2 W–B SGND 1 W–B MTRB 6 W–B 1 B A41(A), A42(B) Junction Connector O 10 A MGND 94 B 71 B 70 B EPPM PPMP N17 Canister Pump Module Canister Pressure Sensor M 42 A VCPP VPMP A24(A), C24(B) Engine Control Module R +B2 1 A R +B 2 A O MREL 44 A Y FC 7 A Y O GR GR 3 CA2 V R R W W V W W–B W C6 127 CAMRY (EM0250U) Engine Control for 2AZ–FE (BAT) (BAT) 10A EFI NO. 1 10A ETCS 2 2 1A 1 W A17 Accelerator Position Sensor 8 A 9 A VCP2 VPA2 EPA2 VCPA VPA EPA 1 3 2 4 6 5 C18(B) Generator A41(A) Junction Connector M LG Y L R O B G Y L 3 B 3 A 20 A 58 A 56 A 60 A 57 A 55 A 59 A 50 B +BM BATT VCP2 VPA2 EPA2 VCPA VPA EPA ALT A24(A), C24(B) Engine Control Module 2 THA ETHA 65 B 88 B 5 4 1 2 VG E2G THA 2 1 1 1 1 1 W W V C6 VSV (Purge) W C7 Fuel Injector (No. 1) W C9 Fuel Injector (No. 2) E2G 116 B Y 2 C8 Fuel Injector (No. 3) VG 118 B P 2 C10 Fuel Injector (No. 4) PRG 49 B W R Y L 2 # 10 108 B SB # 20 107 B O # 30 106 B B # 40 105 B E2 +B C2 Mass Air Flow Meter V 3 W V W W V V W B–R B–R W 128 CAMRY (EM0250U) C5 Throttle Body Assembly W–L B M– 1 42 B 41 B G–R 96 B M+ 2 R P 97 B 3 G B B Y 2 E2 4 C4 Engine Coolant Temp. Sensor 1 W VTA2 (Shielded) 1 C32 Camshaft Timing Oil Control Valve 2 VC 5 P VTA 6 100 B 123 B OC1– OC1+ THW 115 B ETHW 67 B VTA1 114 B 91 B VTA2 VCTA ETA M+ 63 B M– GE01 A24(A), C24(B) Engine Control Module HT1B OX1B 47 B 64 B EX1B A1A+ 87 B 112 B A1A– 113 B HA1A NE+ G2+ NE– 122 B 109 B 121 B 99 B G2– 98 B G HA1A 1 2 BR Y (Shielded) R G 1 1 C31 Camshaft Position Sensor +B 2 (Shielded) C20 Crankshaft Position Sensor 4 A1A– C15 Air Fuel Ratio Sensor (Bank 1 Sensor 1) (Shielded) P (Shielded) L 3 A1A+ G 2 B–R +B 1 (Shielded) W E2 LG HT1B 4 C22 Heated Oxygen Sensor (Bank 1 Sensor 2) 3 OX1B (Shielded) BR W (Shielded) LG (Shielded) 2 B–R W 129 CAMRY (EM0250U) Engine Control for 2AZ–FE IGF 3 2 W–L W BR G–R G LG W–L 21 A 22 A 85 B 81 B 84 B 83 B 82 B FANH FANL C14 Ignition Coil (No. 4) W–L IGT4 W–L 2 LG IGF 3 C12 Ignition Coil (No. 3) IGT3 G 2 C13 Ignition Coil (No. 2) W–L IGF 3 W–L W W–L IGT2 G–R 2 C11 Ignition Coil (No. 1) IGF 3 W FAN NO. 1 Relay FAN NO. 2 Relay IGT1 R FAN NO. 3 Relay ∗ 1 : California IGT1 IGF1 IGT2 IGT3 IGT4 A24(A), C24(B) Engine Control Module EIA 126 B IAC+ 33 A L (Shielded) IAC– 52 A PSW 53 A BR IACA 93 B W VCIA 103 B (∗1) EKNK 111 B (∗1) KNK1 110 B L (∗1) (∗1) B–W B (Shielded) (∗1) (Shielded) 9 CA2 19 CA2 3 CA3 5 IAC+ G B 1 4 EIA 2 CA3 IAC– M W–B C30 Knock Control Sensor (Bank 1) C33 Intake Air Control Valve 1 CA3 B–W 1 2 IACA C17 Power Steering Oil Pressure SW L 2 1 VCIA (∗1) W R G (Shielded) 3 (∗1) (Shielded) B–W 130 CAMRY (EM0250U) Y 2 IMO 48 A 52 B STA (A/T) 18 CA2 (A/T) G 10 A IMI 7 CA2 SB Y 9 CA3 11 A (A/T) LG 13 AE5 V G 7 AE5 W R G (M/T) GR 12 L 13 (M/T) EFII 5 B R 5 3E EFIO N R E15 Transponder Key ECU P W 5 3F B (M/T) C1(B) Park/Neutral Position SW 1 6 EA1 E23 Ignition SW ST Relay 4 B L A22 Clutch Start SW GR ST1 3 (A/T) 11 B IG1 R 4 AM1 (M/T) O (A/T) 10 B ACC II 8 CA2 A41(A), A42(B) Junction Connector Y 2 A B 4 1 A (A/T) R 7. 5A AM1 (A/T) (BAT) NSW A24(A), C24(B) Engine Control Module W W–B EC 32 A EOM 9 A 18 A 16 A W–B W–B B B–W 16 B A41(A), A42(B) Junction Connector B 104 B W–B 45 B W E1 E01 46 B W–B E04 E03 86 B B ME01 43 B B–W E02 44 B B–W W–B B C4 C6 A3 131 CAMRY (EM0250U) Engine Control for 2AZ–FE B (BAT) (IG) W B W 10A IGN V 6 CANH 14 CANL 8 IC 9 IG 1 ID TAC P Y 12 3K B 5 3H 5 3B 12 AE5 14 AE5 B 4 ST1– IGSW W B 28 A L 35 A P GR 36 A B W 6 AE5 STP V Y W P 1 6 B TC 13 12 3F Y 2 A A58(A), E40(B) Junction Connector B 3 Y B 2 A19 Stop Lamp SW B 9 E10 Data Link Connector 3 10A STOP 15 A 27 A 8 A 49 A 41 A TACH TC SPD CANL CANH A24(A), C24(B) Engine Control Module W BR 24 A R 5 AE5 R 132 CAMRY (EM0250U) B W V V ∗ 2 : w/ VSC TMC Made ∗ 3 : w/ VSC TMMK Made ∗ 4 : w/o VSC L R L B 18 A 5 B 5 C 4 A 6 B 6 C 3 A 10 B 10 C 17 A 9 B 9 C 20 A 7 B 7 C 6 A 27 B 17 C 5 A 29 B 19 C FR+ RL+ RL– RR+ RR– 1 G 2 B 1 B B B 14 FE3 13 FE3 B 1 A W 10 B 2 A W 4 B A40(A), E41(B) Junction Connector 8 A 6 AE6 E42(A), E43(B), E62(G) Junction Connector BR 2 G W 2 A W B W 7 A B B 1 A B SP1 12 A (∗2) 33 B (∗3) 23 C (∗4) 25 A 14 B 15 C W CANL FR– W CANH 11 A 35 B 26 C FL– 19 A (∗2) 8 B (∗3) 8 C (∗4) W FL+ W P A25(C), A26(A), A60(B) Skid Control ECU with Actuator B V W LG Speed Sensors B W W R R 133 CAMRY (EM0250U) Engine Control for 2AZ–FE (IG) 7. 5A GAUGE NO. 2 V (BAT) (BAT) 10A MPX–B 10A DOME 2 1 3 1A 1 3D LG R V 2 3G R GR 10 3B 12 3L 7 IF 1 3Q 13 ID V V SB GR 12 IG 2 EA1 3 3P V R 13 A 1 A 2 A IG+ B V 12 B +S IG2 12 3Q GR 9 3Q B2 Power Supply Circuit MULTI LCD Master Warning Temp. Malfunction Indicator Lamp Tachometer +B(DOME) Speedometer IG2 Buzzer MICRO COMPUTER DRIVE IC F1(A), F2(B) Combination Meter IG2 CAN I/F SI E2 ES BR 9 3P 11 3P 7 3Q 5 3Q 3 3B 3 3D 2 3U 10 3D BR W–B 24 A W–B 12 A W 14 B W 18 A W CANL 17 A B CANH R CHK 4 B 15 EA1 GR B W W 4 CA3 W–B R F1 134 CAMRY (EM0250U) C6 System Outline The engine control system utilizes a microcomputer and maintains overall control of the engine, transaxle etc. An outline of the engine control is given here. 1. Input Signals (1) Engine coolant temp. signal circuit The engine coolant temp. sensor detects the engine coolant temp. and has a built–in thermistor with a resistance, which varies according to the engine coolant temp.. The engine coolant temp. which is input into TERMINAL THW of the engine control module as a control signal. (2) Intake air temp. signal circuit The intake air temp. sensor is installed in the mass air flow meter and detects the intake air temp. which is input as a control signal to TERMINAL THA of the engine control module. (3) Oxygen density signal circuit The oxygen density in the exhaust emission is detected by the heated oxygen sensor and input as a control signal to TERMINAL OX1B of the engine control module. (4) RPM signal circuit Camshaft position and crankshaft position are detected by the camshaft position sensor and crankshaft position sensor. Camshaft position is input as a control signal to TERMINAL G2+ of the engine control module, and engine RPM is input into TERMINAL NE+. (5) Throttle position signal circuit The throttle position sensor detects the throttle valve opening angle as a control signal, which is input into TERMINALS VTA1 and VTA2 of the engine control module. (6) Vehicle speed circuit The vehicle speed sensor, detects the vehicle speed and input to speed sensor of the skid control ECU with actuator, from skid control ECU with actuator to TERMINAL SPD of the engine control module, Via combination meter. (7) Battery signal circuit Voltage is constantly applied to TERMINAL BATT of the engine control module. With the ignition SW turned on, the voltage for engine control module start–up power supply is applied to TERMINALS +B and +B2 of the engine control module via the EFI relay. (8) Stop lamp SW signal circuit The stop lamp SW is used to detect whether the vehicle is braking or not and the signal is input into TERMINAL STP of the engine control module as a control signal. (9) Starter signal circuit To confirm whether the engine is cranking, the voltage is applied to the starter motor during cranking is detected and the signal is input into TERMINAL STA of the engine control module as a control signal. (10) Engine knock signal circuit Engine knocking is detected by knock sensor and the signal is input into TERMINAL KNK1 as a control signal. (11) Air fuel ratio signal system The air fuel ratio is detected and input as a control signal into TERMINAL A1A+ of the engine control module. 135 CAMRY (EM0250U) Engine Control for 2AZ–FE 2. Control System ∗ SFI system The SFI system monitors the engine condition through the signals input from each sensor to the engine control module. And the control signal is output to TERMINALS #10, #20, #30, #40 of the engine control module to operate the fuel injector (Inject the fuel). The SFI system controls the fuel injection operation by the engine control module in response to the driving conditions. ∗ ESA system The ESA system monitors the engine condition through the signals input to the engine control module from each sensor. The best ignition timing is decided according to this data and the memorized data in the engine control module and the control signal is output to TERMINALS IGT1, IGT2, IGT3, IGT4. This signal controls the igniter to provide the best ignition timing for the driving conditions. ∗ Heated oxygen sensor heater control system The heated oxygen sensor heater control system turns the heater on when the intake air volume is low (Temp. of exhaust emissions is low), and warms up the heated oxygen sensor to improve detection performance of the sensor. The engine control module evaluates the signals from each sensor, and outputs current to TERMINAL HT1B to control the heater. 3. Diagnosis System With the diagnosis system, when there is a malfunction in the engine control module signal system, the malfunctioning system is recorded in the memory. The malfunctioning system can be found by reading the code displayed by the malfunction indicator lamp. 4. Fail–Safe System When a malfunction has occurred in any system, if there is a possibility of engine trouble being caused by continued control based on the signals from that system, the fail–safe system either controls the system by using data (Standard values) recorded in the engine control module memory or else stops the engine. : Parts Location Code See Page Code See Page Code See Page A17 59 C7 54 (2AZ–FE) C32 55 (2AZ–FE) A19 59 C8 54 (2AZ–FE) C33 55 (2AZ–FE) A22 59 C9 54 (2AZ–FE) E10 56 C10 54 (2AZ–FE) E15 56 A24 A 52 (2AZ–FE) A25 C 52 (2AZ–FE) C11 54 (2AZ–FE) A26 A 52 (2AZ–FE) C12 54 (2AZ–FE) E40 B 57 A40 A 59 C13 54 (2AZ–FE) E41 B 57 A41 A 59 C14 54 (2AZ–FE) E42 A 57 A42 B 59 C15 54 (2AZ–FE) E43 B 57 A58 A 59 C17 54 (2AZ–FE) E62 G 57 A60 B 53 (2AZ–FE) 54 (2AZ–FE) F1 A 58 C1 B 54 (2AZ–FE) 55 (2AZ–FE) F2 B 58 C18 B C20 C2 54 (2AZ–FE) C4 54 (2AZ–FE) C22 C5 54 (2AZ–FE) C30 55 (2AZ–FE) C6 54 (2AZ–FE) C31 55 (2AZ–FE) C24 B 1 See Page 22 56 55 (2AZ–FE) N10 60 55 (2AZ–FE) N17 60 : Relay Blocks Code E23 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) 136 CAMRY (EM0250U) : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) 1A 1D 25 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) 36 Instrument Panel No.2 Wire and J/B No.3 (Behind the Combination Meter) 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) 1E 3B 3D 3E 3F 3G 3H 3K 3L 3P 3Q 3U IC ID IF 30 IG IH Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) 31 II : Connector Joining Wire Harness and Wire Harness Code AE5 See Page Joining Wire Harness and Wire Harness (Connector Location) 66 Engine Room Main Wire and Instrument Panel Wire (Instrument Panel Right) 65 (2AZ–FE) Engine Wire and Engine Room Main Wire (Inside of the Engine Room R/B and Engine Room J/B) EA1 66 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) FE3 66 Instrument Panel No.2 Wire and Instrument Panel Wire (Instrument Panel Center) NA1 66 Floor Wire and Engine Room Main Wire (Left Kick Panel) AE6 CA1 CA2 CA3 : Ground Points Code See Page Ground Points Location A1 65 (2AZ–FE) Front Left Fender A3 66 Left Cowl Side Panel 65 (2AZ–FE) Cylinder Block F1 66 Instrument Panel Left N1 67 Left Rear Quarter Panel C4 C6 137 CAMRY (EM0250U) Engine Immobiliser System without Smart Key System (BAT) (IG) 10A EFI NO. 1 2 1A 1 2 3 4 : 2GR–FE : 2AZ–FE : TMC Made : TMMK Made 13 IM W 8 A A41(A), A42(B) Junction Connector E10 Data Link Connector 3 ∗ ∗ ∗ ∗ 10A IGN SIL 7 LG LG GR 3 B E25 Transponder Key Amplifier 12 IM 21 AE2 Transponder Key Coil GR W 3 IF 7 3L 1 3J ANT1 ANT2 VC5 W 1 D 2 +B IG 14 15 4 CODE TXCT VC5 V GR 9 AGND 7 BR 1 3B 5 O 8 3B TXCT 4 R CODE 1 5 AGND CTY 13 3 16 8 7 L B W–B P EFII EFIO KSW GND Y IND 12 G E15 Transponder Key ECU 12 3A 13 AE5 7 AE5 2 3B 7 3B 6 3B 11 3R A24(C), A55(A) Engine Control Module GND W–B L 2 3U 19 E2 138 CAMRY (EM0250U) F1 N6(A), (B) Door Courtesy SW (Driver' s Side) IMI 8 3R W–B IMO W–B 11 A (∗1) 11 C (∗2) W–B 10 A 10 C 2 LP F3 Clock 9 2 13 EN2 8 E49 Junction Connector E22 Unlock Warning SW 1 L 3 3C Y 2 3A Security Indicator L Y G 7 3A W–B 12 3O 1 A (∗3) 1 B (∗4) : Parts Location Code See Page Code See Page Code A24 C 52 (2AZ–FE) E10 56 E49 A41 A 59 E15 56 F3 A42 B 59 E22 56 A55 A 49 (2GR–FE) E25 56 N6 See Page 57 58 A 60 B 60 : Junction Block and Wire Harness Connector Code 1A See Page Junction Block and Wire Harness (Connector Location) 25 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) 36 Instrument Panel No.2 Wire and J/B No.3 (Behind the Combination Meter) 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) 3A 3B 3C 3J 3L 3O 3R 3U IF IM : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) AE2 68 Engine Room Main Wire and Instrument Panel Wire (Right Side of the Instrument Panel J/B) AE5 66 Engine Room Main Wire and Instrument Panel Wire (Instrument Panel Right) EN2 66 Instrument Panel Wire and Floor Wire (Left Kick Panel) : Ground Points Code See Page Ground Points Location E2 66 Instrument Panel Brace LH F1 66 Instrument Panel Left 139 CAMRY (EM0250U) Data Link Connector 3 (BAT) B B 7. 5A OBD 6 AE5 B (∗3) 4 IM (∗4) Junction Connector L B 10 4C W 9 BAT B B 16 (∗3) 9 4A 6 14 CANH TAC CANL 4 3E 1 IH 10 IE 7 AE6 W 4 AE6 C7 (∗7) GR (∗7) L GR O 13 A (∗7) TS D/G 16 A SIL (∗2) W–B C57 Junction Connector 3 24 A 39 B (∗8) 25 C (∗9) 4 CA3 (∗1) W–B 3 IF (∗2) A41(A), A42(B) Junction Connector 42 A WFSE W–B 12 IM (∗7) BR BR GR 17 A 4 CA3 E2 4 3H (∗1) 18 B (∗1) 2 E49 Junction Connector 8 AE6 9 GR 15 EA1 GR GR 10 3D SIL 7 O 3 3C TS 12 O 11 3H WFSE 15 Y 3 3H TC (∗7) BR 13 W–B SG 5 W–B CG 4 P E10 Data Link Connector 3 A25(C), A26(A), A60(B) Skid Control ECU with Actuator E30(A) Airbag Sensor Assembly Center P C6 140 CAMRY (EM0250U) ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ 1 2 3 4 5 6 7 8 9 : 2GR–FE : 2AZ–FE : w/ Smart Key System : w/o Smart Key System : w/ Power Seat : w/o Power Seat : w/ VSC TMC Made : w/ VSC TMMK Made : w/o VSC E15 Transponder Key ECU E60 Tire Pressure Warning ECU D SIL 9 3 O4(C), T10(A) Occupant Classification ECU 15 A (∗1) 15 C (∗2) TACH DIA 2 A (∗5) 2 C (∗6) TC 27 A (∗1) 27 C (∗2) GR (∗5) P 10 TC A24(C), A55(A) Engine Control Module B B O GR (∗6) P P GR GR (∗4) 12 AE5 2 OT1 8 3C 6 3O 5 3B 8 3C 5 3H GR P O 8 3B (∗5) 7 3L 4 EO2 GR P 141 CAMRY (EM0250U) Data Link Connector 3 : Parts Location Code See Page A24 C A25 C A26 A A41 A Code See Page 52 (2AZ–FE) A42 B 59 48 (2GR–FE) A55 A 49 (2GR–FE) 52 (2AZ–FE) A60 48 (2GR–FE) B Code See Page E15 E30 56 A 49 (2GR–FE) E49 53 (2AZ–FE) E60 56 57 57 52 (2AZ–FE) C57 51 (2GR–FE) O4 C 63 (*2) 59 E10 56 T10 A 62 (*1) : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) 3B 3C 3D 3E 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) 42 Instrument Panel Wire and J/B No.4 (Instrument Panel Brace Center) 3H 3L 3O 4A 4C IE IF 30 IH 31 IM 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) : Connector Joining Wire Harness and Wire Harness Code AE5 AE6 CA3 See Page 66 Joining Wire Harness and Wire Harness (Connector Location) Engine Room Main Wire and Instrument Panel Wire (Instrument Panel Right) 64 (2GR–FE) 65 (2AZ–FE) Engine Wire and Engine Room Main Wire (Inside of the Engine Room R/B and Engine Room J/B) EA1 66 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) EO2 66 Instrument Panel Wire and Floor No.2 Wire (Right Kick Panel) OT1 68 (*1) Floor No.2 Wire and Front Seat RH Wire (Under the Front Passenger’s Seat) : Ground Points Code See Page Ground Points Location C6 65 (2AZ–FE) Cylinder Block C7 64 (2GR–FE) Left Side of the Cylinder Block E2 66 Instrument Panel Brace LH * 1 : w/ Power Seat * 2 : w/o Power Seat 142 CAMRY (EM0250U) Memo 143 CAMRY (EM0250U) A1 A3 W–B W–B 4 1B 2 1 A6 144 CAMRY (EM0250U) 2 1 W–B Battery A5 A49 Headlamp (RH Low) B 11 1E A45 Headlamp (LH Low) BR BR 9 1D 8 1D V 5 1B P 15A H–LP (LH) 15A H–LP (RH) 15A H–LP (RL) 15A H–LP (LL) Light Control Circuit W–B FL MAIN 3. 0W W–B 2 W–B BR 1 A8 Headlamp (LH High) 2 1B W–B 2 Y 3 1B W–B 1 A29 Headlamp (RH High) G 1 1G W–B W–B W–B W H–LP (RL) Relay H–LP (LL) Relay DRL Relay Headlight V P E6(A), E7(B), E8(C) Main Body ECU (ACC) 7. 5A ECU–ACC IG 15 DRL HRLY GND2 11 8 4 9 ID 3 ID 9 IM W–B ACC 22 P 10A ECU IG NO. 1 V (IG) V P W–B 145 CAMRY (EM0250U) Headlight E6(A), E7(B), E8(C) Main Body ECU HF HU 13 B HEAD 17 A 13 P 5 IG R 9 3N P LG 12 3G 17 11 E21 Headlamp Dimmer SW Assembly 20 Dimmer SW HF Low High Flash HL HU ED Light Control SW T H EL A DRL–OFF(USA) OFF (Except USA) AUTO Tail Head W–B 12 3 3G W–B 3 3C 9 W–B W–B 6 W–B 2 E2 146 CAMRY (EM0250U) E49 Junction Connector E6(A), E7(B), E8(C) Main Body ECU B (BAT) CANH 5 C W CANL 6 C (BAT) (IG) 7. 5A GAUGE NO. 2 10A DOME 10A MPX–B 2 1 3 1A 12 IG BR 13 ID 12 3L 1 3D 2 3G 2 EA1 R 5 3Q SB LG GR V V 2 A 13 A 1 A IG+ BR B2 V 12 3Q 9 3Q GR 1 3Q R 7 IF 10 3D F1(A) Combination Meter B +B(DOME) Head (USA) 15 EA1 E2 13 FE3 14 FE3 C7 W 2 B 1 C 2 C W E43(B), E44(C) Junction Connector B W–B 3 1 B 2 3U C57 Junction Connector W–B (2GR–FE) W–B (2AZ–FE) CANL 18 A 4 CA3 7 3Q C6 CANH 17 A W 12 A B A41(A), A42(B) Junction Connector ES 24 A B 4 CA3 CAN I/F W–B GR 17 A (2GR–FE) GR (2AZ–FE) 18 B DRIVE IC BR BR (2GR–FE) MICRO COMPUTER Beam Power Supply Circuit F1 147 CAMRY (EM0250U) Headlight E6(A), E7(B), E8(C) Main Body ECU (BAT) (BAT) 25A DOOR NO. 1 25A DOOR NO. 2 PKB 19 GND1 5 BECU (∗2) ALTB BATB (∗1) 26 6 2 (BAT) 2 10A ECU–B NO. 1 2 16 ID W 1 ∗ 1 : w/ Smart Key System ∗ 2 : w/o Smart Key System 10 2 W–B 4 FE3 W–B W–B 12 E49 Junction Connector F1 E2 148 CAMRY (EM0250U) 1 O 10 ID W 10 IF O (Pedal Type) L A18 Parking Brake SW Y E33 Parking Brake SW 1 14 IC (Lever Type) 2 IM W–B 1 : Parts Location Code See Page Code 48 (2GR–FE) A8 A45 52 (2AZ–FE) A18 59 A49 48 (2GR–FE) A29 See Page 52 (2AZ–FE) Code 49 (2GR–FE) C57 E8 See Page C 53 (2AZ–FE) E21 49 (2GR–FE) E33 56 56 56 53 (2AZ–FE) E43 B 57 51 (2GR–FE) E44 C 57 A41 A 59 E6 A 56 A42 B 59 E7 B 56 E49 F1 57 A 58 : Relay Blocks Code 1 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) 1A 1B 1D 25 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 1E 1G 22 3C 3D 3G 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) 36 Instrument Panel No.2 Wire and J/B No.3 (Behind the Combination Meter) 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) 3L 3N 3Q 3U IC ID IF 30 IG 31 IM 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) : Connector Joining Wire Harness and Wire Harness Code CA3 See Page 64 (2GR–FE) 65 (2AZ–FE) Joining Wire Harness and Wire Harness (Connector Location) Engine Wire and Engine Room Main Wire (Inside of the Engine Room R/B and Engine Room J/B) EA1 66 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) FE3 66 Instrument Panel No.2 Wire and Instrument Panel Wire (Instrument Panel Center) : Ground Points Code A1 A3 A5 See Page 64 (2GR–FE) 65 (2AZ–FE) 66 64 (2GR–FE) 65 (2AZ–FE) Ground Points Location Front Left Fender Left Cowl Side Panel Front Right Fender A6 66 Right Cowl Side Panel C6 65 (2AZ–FE) Cylinder Block C7 64 (2GR–FE) Left Side of the Cylinder Block E2 66 Instrument Panel Brace LH F1 66 Instrument Panel Left 149 CAMRY (EM0250U) Fog Light (BAT) (BAT) 25A DOOR NO. 1 10A ECU–B NO. 1 25A DOOR NO. 2 (ACC) 10A ECU IG NO. 1 E6(A), E7(B), E8(C) Main Body ECU 7. 5A ECU–ACC 2 ACC 1 22 15 BATB (∗1) BECU (∗2) ALTB 2 26 6 10 ID 16 ID O O W 1 IG W 2 (IG) (BAT) E21 Headlamp Dimmer SW Assembly Dimmer SW HF HL HU ED Low High Flash W 16 W 150 CAMRY (EM0250U) ∗ 1 : w/ Smart Key System ∗ 2 : w/o Smart Key System E6(A), E7(B), E8(C) Main Body ECU FFOG V 12 3G 6 4H V P 9 IM 5 4M P E21 Headlamp Dimmer SW Assembly H A 4 EL DRL–OFF(USA) OFF (Except USA) LFG Fog SW Light Control SW 4 9 3N 20 T GND2 28 A W–B HEAD 17 A AUTO Tail BFG OFF On Head 3 W W–B 12 W 3 3G E49 Junction Connector W–B 3 3C 9 6 W–B W–B 2 E2 151 CAMRY (EM0250U) Fog Light E6(A), E7(B), E8(C) Main Body ECU (BAT) (BAT) (IG) 7. 5A GAUGE NO. 2 10A DOME 10A MPX–B 2 3 1A 12 IG 12 3L 1 3D 2 3G R V 13 ID SB LG GR 1 2 EA1 7 IF 2 A V R BR 12 3Q 9 3Q GR 1 3Q 1 A 13 A IG+ B2 B 5 3Q Power Supply Circuit +B(DOME) Front Fog BR 10 3D MICRO COMPUTER 15 EA1 DRIVE IC GR 4 CA3 (2GR–FE) E2 18 A W B 4 CA3 C57 Junction Connector W–B W–B (2GR–FE) W–B (2AZ–FE) 3 C7 F1(A) Combination Meter 7 3Q 2 3U C6 CANL 17 A W CANH 12 A B 17 A 24 A BR A41(A), A42(B) Junction Connector GR (2AZ–FE) ES 18 B W–B BR (2GR–FE) CAN I/F F1 152 CAMRY (EM0250U) (BAT) (BAT) E6(A), E7(B), E8(C) Main Body ECU 120A ALT CANL CANH GND1 FFGO 5 C 4 B 5 TRLY 1 1F 7 B 6 C 15A FR FOG B 5 1 3 2 TAIL Relay W R 1 IA 1 B B 14 FE3 13 FE3 10 IF 3 IL W 2 B 15A TAIL W–B 1 C E43(B), E44(C) Junction Connector 2 C W 4 B 1 5 2 3 5 ID 1 IC R 2 2 10 A1 Fog Lamp (Front LH) W–B E49 Junction Connector W 1 A34 Fog Lamp (Front RH) II R 8 Y FOG Relay W 4 IL W–B 1 (2GR–FE ∗2) 1 F1 E2 A2 W–B BR (2GR–FE ∗2) W–B (2AZ–FE) A43 Junction Connector W–B 4 FE3 W–B ∗ 1 : w/ Smart Key System ∗ 2 : w/o Smart Key System 2 (2GR–FE ∗1) W–B 12 W–B B A2 A5 153 CAMRY (EM0250U) Fog Light : Parts Location Code See Page Code 48 (2GR–FE) A1 52 (2AZ–FE) A34 See Page A43 C57 E43 51 (2GR–FE) E44 48 (2GR–FE) E6 A 56 52 (2AZ–FE) E7 B 56 E8 C 56 A41 A 59 A42 B 59 E21 Code 49 (2GR–FE) See Page B 57 C 57 E49 F1 57 A 58 56 : Relay Blocks Code 1 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code See Page 1A 25 1F 22 Junction Block and Wire Harness (Connector Location) Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 3C 3D 3G 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) 36 Instrument Panel No.2 Wire and J/B No.3 (Behind the Combination Meter) 42 Instrument Panel Wire and J/B No.4 (Instrument Panel Brace Center) 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) 3L 3N 3Q 3U 4H 4M IA IC ID IF IG II IL IM 30 31 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) 30 : Connector Joining Wire Harness and Wire Harness Code CA3 See Page 64 (2GR–FE) 65 (2AZ–FE) Joining Wire Harness and Wire Harness (Connector Location) Engine Wire and Engine Room Main Wire (Inside of the Engine Room R/B and Engine Room J/B) EA1 66 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) FE3 66 Instrument Panel No.2 Wire and Instrument Panel Wire (Instrument Panel Center) : Ground Points Code A2 A5 See Page 64 (2GR–FE) 65 (2AZ–FE) 64 (2GR–FE) 65 (2AZ–FE) Ground Points Location Front Left Fender Front Right Fender C6 65 (2AZ–FE) Cylinder Block C7 64 (2GR–FE) Left Side of the Cylinder Block E2 66 Instrument Panel Brace LH F1 66 Instrument Panel Left 154 CAMRY (EM0250U) Memo 155 CAMRY (EM0250U) Multiplex Communication System – CAN E61 Option Connector (Bus Buffer) CANH CANL 12 A CAN+ CAN– 1 2 B B W 11 A B W E38(A) A/C Amplifier 11 A 35 B CANH 25 A (∗2) 14 B (∗3) CANL 41 A CAN+ 2 B B A26(A), A60(B) Skid Control ECU with Actuator CANL CAN– 1 B (2GR–FE) A25 Skid Control ECU with Actuator 6 7 CAN+ CAN– 156 CAMRY (EM0250U) 41 A CANH W (2AZ–FE) B C56 Transmission Control ECU (2AZ–FE) W 49 A CANH 10 B A40(A), E41(B) Junction Connector (2GR–FE) B (2GR–FE) 7 A W 1 A (w/ VSC) 8 A B 2 A 4 B 49 A CANL A24(A) Engine Control Module CANL 8 B A55(A), C55(B) Engine Control Module CANH 2 B Y 15 7 B (2GR–FE) 26 1 B (w/ VSC) W (w/o VSC) B (w/o VSC) W E34(A), E65(B) Yaw Rate Sensor CANL CANL CANH B 6 W 14 B CANH 3 A (∗2) 2 B (∗3) W 2 A 3 B E10 Data Link Connector 3 2 A 1 A 2 E 1 E 2 G 1 G 2 D 1 D 2 H 1 H 2 B 1 B B ∗ 1 : w/ Smart Key System ∗ 2 : TMC Made ∗ 3 : TMMK Made 10 18 A 17 A 5 C 6 C CANH CANH CANH CANN F1(A) Combination Meter 15 C W E17 Steering Sensor E42(A), E43(B), E44(C), E45(D), E46(E), E62(G), E63(H) Junction Connector CANP 16 C (∗1) E30(A) Airbag Sensor Assembly Center CANL 28 A CANL L CANL E8(C) Main Body ECU W 9 CANL (∗1) B B W B CANH W 13 A CANL 13 FE3 2 C B B 22 A 14 FE3 1 C W W W 27 A CANH E58(A) Certification ECU 157 CAMRY (EM0250U) Multiplex Communication System – CAN System Outline CAN has two lines as a pair which make communication with operating voltage. CAN has excellent data speed and error detecting capacity. It consists of vehicle control systems such as engine control module, yaw rate sensor, skid control ECU with actuator, steering sensor, data link connector 3, A/C amplifier, transmission control ECU, airbag sensor assembly center, combination meter, certification ECU and main body ECU. : Parts Location Code A24 See Page A 48 (2GR–FE) A25 A26 A A40 A55 Code 52 (2AZ–FE) See Page C56 E8 C Code See Page 51 (2GR–FE) E44 C 57 56 E45 D 57 52 (2AZ–FE) E10 56 E46 E 57 48 (2GR–FE) E17 56 E58 A 57 52 (2AZ–FE) E30 A 56 A 59 E34 A 57 E62 G 57 A 49 (2GR–FE) E38 A 57 E63 H 57 49 (2GR–FE) E41 B 57 E65 B 57 53 (2AZ–FE) E42 A 57 F1 A 58 51 (2GR–FE) E43 B 57 A60 B C55 B E61 57 : Connector Joining Wire Harness and Wire Harness Code FE3 See Page 66 Joining Wire Harness and Wire Harness (Connector Location) Instrument Panel No.2 Wire and Instrument Panel Wire (Instrument Panel Center) 158 CAMRY (EM0250U) Memo 159 CAMRY (EM0250U) Automatic Light Control and Light Auto Turn Off System (BAT) (BAT) (BAT) 25A DOOR NO. 1 10A ECU–B NO. 1 (ACC) 25A DOOR NO. 2 (IG) 10A ECU IG NO. 1 7. 5A ECU–ACC E6(A), E7(B) Main Body ECU 2 2 1 IG O W 1 15 ACC 22 BATB (∗1) ALTB 2 6 W 16 ID W H–LP (LL) Relay 1 1G H–LP (RL) Relay 120A ALT O 9 1D 1 1F P B FL MAIN 3. 0W Battery B P 160 CAMRY (EM0250U) ∗ ∗ ∗ ∗ 1 2 3 4 : w/ Smart Key System : w/o Smart Key System : TMC Made : TMMK Made E6(A), E7(B) Main Body ECU 8 3 PCTY RCTY 7 A (∗1) 5 A (∗2) 21 A 17 7 IO 5 3N 6 3N 10 3F 6 3C 7 3C 12 3O 3 ID LCTY DCTY 24 B L 2 HRLY 5 GR 10 ID GND1 Y 7 TAIL Relay TRLY 26 4 L 6 EO2 13 EN2 L 1 A (∗3) 1 B (∗4) N13(A), (B) Door Courtesy SW (Rear LH) 1 N6(A), (B) Door Courtesy SW (Driver' s Side) O10 Door Courtesy SW (Rear RH) O6 Door Courtesy SW (Front Passenger' s Side) E49 Junction Connector W–B 10 12 1 LG GR 5 EO2 Y O GR 10 IF Y 1 IA W–B 5 B 1 P O BECU (∗2) 1 A (∗3) 1 B (∗4) W–B 2 4 FE3 B F1 W–B W–B P E2 161 CAMRY (EM0250U) Automatic Light Control and Light Auto Turn Off System ∗ 5 : Automatic A/C ∗ 6 : Manual A/C E6(A), E7(B) Main Body ECU TAIL B 9 IM HEAD 17 A P 23 B 4 A 21 B G GND2 9 3N W–B G CLTS 19 A BR CLTE 18 A B CLTB 20 A P 12 3G 18 20 6 A 3 B CLTB 3 A 6 B CLTE 5 A (∗5) 4 B (∗6) CLTS Light Control SW T 19 H A EL DRL–OFF(USA) OFF (Except USA) AUTO Tail Head E21 Headlamp Dimmer SW Assembly 12 W–B E11(A), (B) Automatic Light Control Sensor 3 3G 9 W–B 6 W–B 2 E2 162 CAMRY (EM0250U) E49 Junction Connector W–B 3 3C System Outline Automatic Light Control Operation The automatic light control system works when the light control SW is turned to AUTO. The automatic light control sensor detects the brightness around the vehicle. By this function, the system automatically turns the tail lamp and headlamp on if the brightness is below the regular level and turns the tail lamp and headlamp off when the surroundings become brighter than the regular level. Light Auto Turn Off Operation ∗ When the other lamps than headlamps are lit under ’TAIL’ or ’AUTO’ condition of the light control SW, the tail lamps and front fog lamps are turned OFF if the power SW is changed from ’IG ON’ to ’IG OFF’ (Power SW type) or the ignition SW is turned from ON to OFF (Ignition SW type), and the driver side door is opened from closed condition. ∗ When the headlamps are lit under ’HEAD’ or ’AUTO’ condition of the light control SW, if the power SW is changed from ’IG ON’ to ’IG OFF’ (Power SW type) or the ignition SW is turned from ON to OFF (Ignition SW type), and the light OFF delay time (30 seconds) has passed since all the doors are closed from open condition or under all the door locked condition, operating the wireless door lock function turns OFF the headlamps, tail lamps and front fog lamps. : Parts Location Code See Page Code See Page E6 A 56 E21 56 E7 B 56 E49 57 A 56 B 56 E11 N6 Code N13 See Page A 60 B 60 A 60 O6 60 B 60 O10 60 : Relay Blocks Code 1 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1D 1F 1G See Page Junction Block and Wire Harness (Connector Location) 25 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 22 3C 3F 3G 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) 30 Floor Wire and Instrument Panel J/B (Cowl Side Left) 3N 3O IA ID IF IM IO : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) EN2 66 Instrument Panel Wire and Floor Wire (Left Kick Panel) EO2 66 Instrument Panel Wire and Floor No.2 Wire (Right Kick Panel) FE3 66 Instrument Panel No.2 Wire and Instrument Panel Wire (Instrument Panel Center) : Ground Points Code See Page Ground Points Location E2 66 Instrument Panel Brace LH F1 66 Instrument Panel Left 163 CAMRY (EM0250U) Interior Light (BAT) 25A DOOR NO. 1 2 (BAT) (BAT) 10A ECU–B NO. 1 (IG) 25A DOOR NO. 2 (ACC) 10A ECU IG NO. 1 E6(A), E7(B) Main Body ECU 7. 5A ECU–ACC 2 ACC 1 22 15 BATB (∗1) BECU (∗2) 2 26 O W 1 IG 10 ID O W ∗ ∗ ∗ ∗ ∗ 1 2 3 4 5 : w/ Smart Key System : w/o Smart Key System : TMC Made : TMMK Made : w/ Sliding Roof 164 CAMRY (EM0250U) 2 1 N6(A), (B) Door Courtesy SW (Driver' s Side) 1 A (∗3) 1 B (∗4) CAMRY (EM0250U) 13 EN2 2 1 1 Y Y L 6 3C E37 Diode (Door Courtesy Front RH) Y 11 3F O6 Door Courtesy SW (Front Passenger' s Side) 6 EO2 12 3O L 7 3I E5 Diode (Door Courtesy Front LH) L LG L Y 24 B DCTY O 1 GR 7 3C (∗5) LG RCTY 7 A (∗1) 5 A (∗2) O 1 A (∗3) 1 B (∗4) GR 1 B 2 GR W E2 Diode (Door Courtesy Rear RH) GR 6 IL E1 Diode (Door Courtesy Rear LH) 7 IO (∗5) 16 ID O10 Door Courtesy SW (Rear RH) L 17 (∗5) LCTY 6 (∗5) N13(A), (B) Door Courtesy SW (Rear LH) ALTB W E6(A), E7(B) Main Body ECU 21 A PCTY 6 3N 10 3F 5 3N 4 3I 5 EO2 2 1 O O B(∗5) L(∗5) 165 Interior Light E6(A), E7(B) Main Body ECU LGCY ILE GND2 25 A 21 W 4 (BAT) 5 IR 9 IM 10 II BR(∗2) 17 EN2 W W (∗5) BR 1 2 2 W 1 W Q1 Vanity Lamp SW (LH) 2 +B E B E W (∗5) (∗5) W 3 W ∗ 2 : w/o Smart Key System ∗ 5 : w/ Sliding Roof ∗ 6 : w/o Sliding Roof 2 W S5 Door Lock Assembly (Luggage) 1 2 1 1 2 (∗5) (∗5) W Q2 Vanity Lamp SW (RH) V (∗5) W (∗6) LG W–B W W 1 16 EQ1 3 SN1 N23 Diode (Luggage Compartment Lamp) 2 Q8 Vanity Lamp (RH) 14 6 E49 Junction Connector 13 N28 Junction Connector 2 15 (∗5) Q7 Vanity Lamp (LH) W W–B 10A DOME W–B W–B B 18 EQ1 V(∗5) B O O O B(∗5) B(∗5) L(∗5) L(∗5) LG W–B 9 W(∗6) W–B 1 S15 Junction Connector O S1 W–B E2 166 CAMRY (EM0250U) E6(A), E7(B) Main Body ECU R(∗5) BR(∗2) BR(∗2) W W W W W (∗5) W (∗6) W (∗6) R (∗5) (∗5) W (∗5) 1 2 2 3 L E 3 8 B Q11 Map Lamp (LH) E Q10 Map Lamp (RH) E 8 W–B CTY 6 OFF ON Map Lamp 2 B DOOR Map Lamp Q6 Overhead J/B B Q9 Room Lamp (Center) 7 B V(∗5) Q6 Overhead J/B 7 E L 4 4 5 W L (∗5) W 19 EQ1 (∗5) (∗5) B W (∗5) W (∗6) W W(∗6) W (∗6) 17 EQ1 (∗5) W–B 11 EQ1 W (∗5) (∗5) W (∗5) W (∗5) V(∗5) B B O O O O B(∗5) L(∗5) W–B(∗5) W(∗6) LG LG W–B W–B 167 CAMRY (EM0250U) Interior Light E6(A), E7(B) Main Body ECU R(∗5) ∗ 1 : w/ Smart Key System ∗ 2 : w/o Smart Key System ∗ 5 : w/ Sliding Roof BR(∗2) 2 1 H7 Courtesy Lamp (Front Door RH) ILL+ I6 Courtesy Lamp (Front Door LH) ILL– Ignition Key Cylinder Light E25 Transponder Key Amplifier 6 2 1 B N24(A), N26(B) Luggage Compartment Lamp O 3 HE2 O O 3 IE2 O BR (∗2) W 2 A (∗1) 2 B (∗2) 1 A (∗1) 1 B (∗2) R N28 Junction Connector R R R R 20 18 11 3G 12 3I O 10 IP LG R B 13 ID 12 3L 7 IF R 17 N15 Noise Filter (Dome and Stop) R R 12 3B 10 IL 2 HE2 R 6 IR 2 IE2 (∗2) R 7 EQ1 (∗5) 15 EQ1 W W (∗5) 2 1 R O W–B(∗5) W–B(∗5) LG W–B W–B 168 CAMRY (EM0250U) E6(A), E7(B) Main Body ECU SWIL 25 B 1 IR 10 IF 8 4G W–B (∗5) O 5 W–B GND1 O 8 4E 11 SWIL 4 W–B COM 5 W–B GND 4 4E 5 4E E52 Power SW W–B 5 4H 10 IG 10 E49 Junction Connector 3 IM 12 W–B W–B(∗5) 2 W–B 11 W–B W–B W–B 4 FE3 W–B E2 F1 E1 169 CAMRY (EM0250U) Interior Light System Outline 1. Dome Light and Ignition Key Illumination Function When any door is opened, the dome light (If SW is set to ’DOOR’) and ignition key cylinder light are lit in fade–in manner. Then when all the doors are closed (Any door is unlocked), the illumination is kept ON with the timer for approximately for 15 seconds and then is turned OFF in fade–out manner when the timer is completed. 2. Battery Saver Function If the illumination is kept on for 20 minutes with a door open, it is turned OFF automatically. : Parts Location Code See Page E1 56 E2 56 E5 56 Code N6 N13 See Page Code See Page A 60 Q1 61 B 60 Q2 61 A 60 Q6 61 B 60 Q7 61 E6 A 56 E7 B 56 N15 60 Q8 61 E25 56 N23 60 Q9 61 E37 57 N24 A 60 Q10 61 E49 57 N26 B 60 Q11 61 E52 57 N28 60 S5 61 H7 61 O6 60 S15 61 I6 61 O10 60 : Relay Blocks Code 1 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) 3B 3C 3F 3G 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) 42 Instrument Panel Wire and J/B No.4 (Instrument Panel Brace Center) ID 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) IF 30 3I 3L 3N 3O 4E 4G 4H IG II IL IM IO IP IR 31 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) 30 30 Floor Wire and Instrument Panel J/B (Cowl Side Left) 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) 170 CAMRY (EM0250U) : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) EN2 66 Instrument Panel Wire and Floor Wire (Left Kick Panel) EO2 66 Instrument Panel Wire and Floor No.2 Wire (Right Kick Panel) EQ1 66 Instrument Panel Wire and Roof Wire (Lower Part of Front Pillar LH) FE3 66 Instrument Panel No.2 Wire and Instrument Panel Wire (Instrument Panel Center) HE2 66 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) IE2 66 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) SN1 67 Luggage Room Wire and Floor Wire (Luggage Room Left) : Ground Points Code See Page Ground Points Location E1 66 Instrument Panel Left E2 66 Instrument Panel Brace LH F1 66 Instrument Panel Left S1 67 Lower Back Panel Center 171 CAMRY (EM0250U) Taillight and Illumination (BAT) (BAT) (IG) 7. 5A GAUGE NO. 2 10A DOME (BAT) 25A DOOR NO. 1 10A MPX–B 2 2 W SB GR LG 2 1 3 1A 12 IG 1 10A ECU–B NO. 1 1 O (BAT) 13 ID 2 EA1 R V 7 IF 10 3D 12 3L O 1 3D 2 3G W 12 3Q V 9 3Q GR 1 3Q R BR 5 3Q 2 A 13 A 1 A B2 IG+ F1(A) Combination Meter B Rheostat Tail Cancel SW BR 15 EA1 CANL 18 A W GR (2GR–FE) CANH 17 A 4 CA3 W–B W–B (2AZ–FE) 4 CA3 ES 24 A W (2GR–FE) GR (2AZ–FE) 17 A B A41(A), A42(B) Junction Connector 18 B DRIVE IC CAN I/F BR BR (2GR–FE) MICRO COMPUTER B 3 C57 Junction Connector C6 Tail (Except USA) +B(DOME) Power Supply Circuit C7 172 CAMRY (EM0250U) (ACC) E6(A), E7(B), E8(C) Main Body ECU 7. 5A ECU–ACC IG 15 BATB (∗1) 2 BECU (∗2) ALTB 26 6 10 ID 16 ID CANL 6 C CANH 5 C B ACC 22 W 10A ECU IG NO. 1 25A DOOR NO. 2 W (IG) O (BAT) 2 C 1 C 2 B 1 B O F1(A) Combination Meter +B(DOME) IG2 +B(DOME) IG2 E43(B), E44(C) Junction Connector W +B(DOME) IG2 11 A BR 7 3Q W B 13 FE3 W B LCD Illumination 14 FE3 ILL– 12 A W–B E2 Pointer Illumination Illumination +B (DOME) ∗ 1 : w/ Smart Key System ∗ 2 : w/o Smart Key System W–B 2 3U W B BR F1 173 CAMRY (EM0250U) Taillight and Illumination E6(A), E7(B), E8(C) Main Body ECU ACAN TAIL 16 A GND2 23 B 4 GND1 5 TRLY 7 B 2 3O W–B O 9 IM O 12 3R 18 4 ILL+ H A EL DRL–OFF(USA) OFF (Except USA) E21 Headlamp Dimmer SW Assembly AUTO Tail Head 10 IF W–B Light Control SW 19 F3 Clock T GND1 3 3G W–B W–B 2 3U 3 3C 6 10 W–B 9 2 W–B W–B 12 E49 Junction Connector W–B 8 3R W–B W–B 12 W–B W–B 4 FE3 BR BR F1 F1 174 CAMRY (EM0250U) E2 A1 1 2 1 2 2 1 A5 CAMRY (EM0250U) 6 ID Parking W 14 ID BR 5 IC W–B 15A TAIL A50 Turn Signal and Parking Lamp (Front RH) 2 GR 3 BR 1 A51 Side Marker Lamp (Front RH) L TAIL Relay 4 5 A47 Side Marker Lamp (Front LH) Parking P B G 6 IF BR BR 1 IA W–B W–B A46 Turn Signal and Parking Lamp (Front LH) (BAT) 120A ALT G 1 1F BR 8 IP 7. 5A PANEL 4 IC 1 2 BR BR A6 175 W–B W–B 1 W–B 6 9 1 W–B BR S1 176 CAMRY (EM0250U) 2 3 3 W–B 2 2 1 1 BR BR BR BR BR G 1 S2 Rear Combination Lamp (RH) Tail S3 Rear Combination Lamp (LH) Tail 3 W–B 19 S1 License Plate Lamp (RH) 22 BR BR 18 W–B BR 21 S4 License Plate Lamp (LH) 3 S12 Rear Combination Lamp (RH) L 16 S16 Junction Connector Side Marker Tail Stop S11 Rear Combination Lamp (LH) Stop 2 L Stop Lamp SW BR BR 17 W–B 1 W–B Tail Side Marker Taillight and Illumination G BR 9 SN1 20 W–B 7 1 S15 Junction Connector BR ∗ ∗ ∗ ∗ G 3 4 5 6 : 8 Speaker w/ Navigation System : 8 Speaker w/o Navigation System : Automatic A/C : 6 Speaker 4 3L 4 3B 4 3C 7 3R 5 3S 5 3T P G G G G LG R (∗5) 1 3A 9 3A 1 3T 12 3S 8 4D 1 8 BR ILL– 8 7 R 11 ILL+ ILL– 8 SG BR 7 W–B ILL– 12 E (∗3) 12 D (∗4) 5 B (∗6) SWG (∗5) P ILL+ 6 F (∗3) 6 C (∗4) 6 C (∗6) BR BR 5 4B 2 E 2 D 10 A F16 A/C Control Assembly A/T Shift Lever Illumination 2 F6(A), F7(B), F8(C), F26(D) Radio Receiver Assembly F9(E), F10(F) Navigation Receiver Assembly ILL+ F4 Hazard Warning Signal SW 4 E55 Seat Heater SW E31 Transmission Control SW G 9 4B 4 3R 11 3T 11 3S BR 4 4D 9 3B 9 3C BR 4 3Q BR 177 CAMRY (EM0250U) Taillight and Illumination 4 3A 4 3T LG BR ∗ 5 : Automatic A/C ∗ 7 : Manual A/C P R E18(A), a1(B) Spiral Cable P R (∗5) (∗5) 9 A 4 A EAC 8 B 5 B R IL+2 B (∗5) 2 B GR 12 A EAU F5 Glove Box Lamp Seek MODE Volume TEL Steering SW LH TEMP AUTO/OFF DISP Voice Steering SW RH 2 1 W–B (∗7) a1(B) Steering Pad SW 2 3T W–B 2 3U F1 178 CAMRY (EM0250U) : Parts Location Code See Page A41 A 59 A42 B 59 49 (2GR–FE) A46 A47 A50 C57 See Page A Code 56 F9 E21 56 F10 E31 56 See Page E 58 F 58 F16 F26 58 53 (2AZ–FE) E43 B 57 49 (2GR–FE) E44 C 57 S1 D 58 61 53 (2AZ–FE) E49 57 S2 61 49 (2GR–FE) E55 57 S3 61 53 (2AZ–FE) A51 Code E18 58 S4 61 49 (2GR–FE) F1 F3 A 58 S11 61 53 (2AZ–FE) F4 58 S12 61 51 (2GR–FE) F5 58 S15 61 S16 E6 A 56 F6 A 58 E7 B 56 F7 B 58 E8 C 56 F8 C 58 a1 61 B 59 : Relay Blocks Code 1 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code See Page 1A 25 1F 22 Junction Block and Wire Harness (Connector Location) Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 3A 3B 3C 3D 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) 36 Instrument Panel No.2 Wire and J/B No.3 (Behind the Combination Meter) 42 Instrument Panel Wire and J/B No.4 (Instrument Panel Brace Center) 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) 3G 3L 3O 3Q 3R 3S 3T 3U 4B 4D IA IC ID IF 30 IG 31 IM 30 IP 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) Floor Wire and Instrument Panel J/B (Cowl Side Left) : Connector Joining Wire Harness and Wire Harness Code CA3 See Page 64 (2GR–FE) 65 (2AZ–FE) Joining Wire Harness and Wire Harness (Connector Location) Engine Wire and Engine Room Main Wire (Inside of the Engine Room R/B and Engine Room J/B) EA1 66 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) FE3 66 Instrument Panel No.2 Wire and Instrument Panel Wire (Instrument Panel Center) SN1 67 Luggage Room Wire and Floor Wire (Luggage Room Left) 179 CAMRY (EM0250U) Taillight and Illumination : Ground Points Code A1 A5 See Page 64 (2GR–FE) 65 (2AZ–FE) 64 (2GR–FE) 65 (2AZ–FE) Ground Points Location Front Left Fender Front Right Fender A6 66 Right Cowl Side Panel C6 65 (2AZ–FE) Cylinder Block C7 64 (2GR–FE) Left Side of the Cylinder Block E2 66 Instrument Panel Brace LH F1 66 Instrument Panel Left S1 67 Lower Back Panel Center 180 CAMRY (EM0250U) Memo 181 CAMRY (EM0250U) 3 2 9 S1 182 CAMRY (EM0250U) BR 4 EN1 11 SN1 7 ID 3 IC G 6 2 A1 Turn 9 IL G B G B 3 3 A50 Turn Signal and Parking Lamp (Front RH) Turn 4 W–B 2 A46 Turn Signal and Parking Lamp (Front LH) G 2 BR 2 1 S13 Turn Signal Lamp (Rear RH) 10 SN1 G 12 IP S15 Junction Connector 1 G IG W–B Y 1 S10 Turn Signal Lamp (Rear LH) Y 15A HAZ W–B W–B W–B 1 Y R (BAT) Y R Turn Signal and Hazard Warning Light (IG) 10A GAUGE NO. 1 E14 Turn Signal Flasher 14 IF 2 3L 9 EA1 1 3F 3 LL 2 LR II 1 II 2 A6 ∗ 1 : 2GR–FE ∗ 2 : 2AZ–FE E14 Turn Signal Flasher W–B E 7 W HAZ 8 ER EL 6 5 O L 9 3F 13 15 4 7 3F 8 3G TR Turn SW G LG 5 3P L 5 7 3P 1 B E B 3 3F 3 3G 18 B GR A41(A), A42(B) Junction Connector 5 3Q BR(∗1) 4 CA3 2 3U 3 3C W–B 7 3Q (∗1) 9 (∗1) W–B GR(∗2) (∗2) W–B 3 C6 C7 C57 Junction Connector 4 CA3 2 E49 Junction Connector W–B W–B BR 17 A 15 EA1 8 3R GR (∗1) 10 3D W–B W–B W–B 19 W–B E2 12 A BR 12 F3 Clock W–B ES 24 A TL GND1 F1(A), F2(B) Combination Meter Turn LH Turn RH B LH RH 20 2 B EL E21 Headlamp Dimmer SW Assembly W G 8 IG F4 Hazard Warning Signal SW 2 IG B 3 3R F1 E2 183 CAMRY (EM0250U) Turn Signal and Hazard Warning Light : Parts Location Code See Page Code See Page A41 A 59 C57 51 (2GR–FE) A42 B 59 E14 49 (2GR–FE) E21 53 (2AZ–FE) E49 A46 A50 Code See Page F3 58 56 F4 58 56 S10 61 57 S13 61 S15 61 49 (2GR–FE) F1 A 58 53 (2AZ–FE) F2 B 58 : Relay Blocks Code 1 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) 3C 3D 3F 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) 36 Instrument Panel No.2 Wire and J/B No.3 (Behind the Combination Meter) 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) 3G 3L 3P 3Q 3R 3U IC ID IF IG II 30 31 IL 30 IP 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) Floor Wire and Instrument Panel J/B (Cowl Side Left) : Connector Joining Wire Harness and Wire Harness Code CA3 See Page 64 (2GR–FE) 65 (2AZ–FE) Joining Wire Harness and Wire Harness (Connector Location) Engine Wire and Engine Room Main Wire (Inside of the Engine Room R/B and Engine Room J/B) EA1 66 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) EN1 66 Instrument Panel Wire and Floor Wire (Left Kick Panel) SN1 67 Luggage Room Wire and Floor Wire (Luggage Room Left) : Ground Points Code A1 See Page 64 (2GR–FE) 65 (2AZ–FE) Ground Points Location Front Left Fender A6 66 Right Cowl Side Panel C6 65 (2AZ–FE) Cylinder Block C7 64 (2GR–FE) Left Side of the Cylinder Block E2 66 Instrument Panel Brace LH F1 66 Instrument Panel Left S1 67 Lower Back Panel Center 184 CAMRY (EM0250U) Memo 185 CAMRY (EM0250U) 1 N29 Junction Connector 5 W–B N1 186 CAMRY (EM0250U) S15 Junction Connector 1 SN1 W–B Stop BR BR L L 9 Tail L 8 S11 Rear Combination Lamp (LH) Tail Stop S12 Rear Combination Lamp (RH) 8 N28 Junction Connector 10 1 1 W–B 2 N16 Center Stop Lamp L 7 W–B 2 L 3 IP W–B W–B L 2 N15 Noise Filter (Dome and Stop) L B L A19 Stop Lamp SW W W B Stop Light (BAT) 10A STOP 8 IC 1 9 AE2 7 IL 8 SN1 S16 Junction Connector 9 10 TAIL Fuse 3 2 2 3 6 7 9 S1 : Parts Location Code See Page Code See Page Code See Page A19 59 N28 60 S12 61 N15 60 N29 60 S15 61 N16 60 S11 61 S16 61 : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) IC 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) IL 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) IP 30 Floor Wire and Instrument Panel J/B (Cowl Side Left) : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) AE2 66 Engine Room Main Wire and Instrument Panel Wire (Right Side of the Instrument Panel J/B) SN1 67 Luggage Room Wire and Floor Wire (Luggage Room Left) : Ground Points Code See Page Ground Points Location N1 67 Left Rear Quarter Panel S1 67 Lower Back Panel Center 187 CAMRY (EM0250U) W–B S15 Junction Connector L W–B R R 10 CA2 GR 14 EA1 2 A (2GR–FE) 1 B (2AZ–FE) 2 188 CAMRY (EM0250U) S16 Junction Connector L (A/T) L R (A/T) (M/T) O R (∗1) 6 AE3 R R E48 Junction Connector (∗1) 2 20 CA2 17 SN1 2 4 3 1 W–B 1 9 S1 Back–Up P (A/T) R 3 S2 Rear Combination Lamp (RH) R B (M/T) (∗1) R ∗ 1 : w/ Mirror Heater ∗ 2 : w/o Mirror Heater Back–Up RB S3 Rear Combination Lamp (LH) C1(A), (B) Park/Neutral Position SW 1 A 2 B W–B (M/T) C28 Back–Up Lamp SW Back–Up Light (IG) 10A GAUGE NO. 1 16 IH (∗2) R 9 EN1 1 R RL 3 R 4 3 : Parts Location Code C1 See Page Code See Page Code See Page A 50 (2GR–FE) E48 57 S15 61 B 54 (2AZ–FE) S2 61 S16 61 55 (2AZ–FE) S3 61 C28 : Junction Block and Wire Harness Connector Code IH See Page 31 Junction Block and Wire Harness (Connector Location) Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) : Connector Joining Wire Harness and Wire Harness Code AE3 CA2 See Page 66 Joining Wire Harness and Wire Harness (Connector Location) Engine Room Main Wire and Instrument Panel Wire (Instrument Panel Right) 64 (2GR–FE) 65 (2AZ–FE) Engine Wire and Engine Room Main Wire (Inside of the Engine Room R/B and Engine Room J/B) EA1 66 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) EN1 66 Instrument Panel Wire and Floor Wire (Left Kick Panel) SN1 67 Luggage Room Wire and Floor Wire (Luggage Room Left) : Ground Points Code S1 See Page 67 Ground Points Location Lower Back Panel Center 189 CAMRY (EM0250U) Key Reminder without Smart Key System and Seat Belt Warning (BAT) (BAT) (IG) 7. 5A GAUGE NO. 2 10A MPX–B 10A DOME 2 3 1A Front Passenger Seat Belt Warning Light IG PBEW LG 13 ID 2 EA1 GR GR G 10 V 3 12 3L 1 3D 2 3G 9 3R 10 3R 1 3Q 12 3Q 9 3Q 1 A 2 A G 13 A B BR B2 10 3Q GR V R R 7 IF F3 Clock 12 IG SB 1 9 A IG+ P/SB Power Supply Circuit 5 3Q MICRO COMPUTER 10 3D 4 CA3 W–B W–B GR CANH CANL 18 A W 17 A 13 FE3 14 FE3 7 3Q 2 3U (∗1) 4 CA3 (∗2) E2 12 A (∗1) 17 A ES 24 A B A41(A), A42(B) Junction Connector 18 B CAN I/F BR BR (∗1) GR (∗2) 15 EA1 W–B F1(A), F2(B) Combination Meter BR Buzzer C57 Junction Connector C6 C7 W–B W 3 B F1 190 CAMRY (EM0250U) ∗ ∗ ∗ ∗ ∗ 1 2 3 4 5 : 2GR–FE : 2AZ–FE : w/ VSC TMC Made : w/ VSC TMMK Made : w/o VSC IG2 IG2 P L R L B 4 A 6 B 6 C 3 A 10 B 10 C 17 A 9 B 9 C 20 A 7 B 7 C 6 A 27 B 17 C 5 A 29 B 19 C FL+ FL– SI FR– RL+ RL– RR+ 19 A (∗3) 8 B (∗4) 8 C (∗5) RR– SP1 12 A (∗3) 33 B (∗4) 23 C (∗5) W 14 B F1(A), F2(B) Combination Meter DRIVE IC FR+ W V 18 A 5 B 5 C BR Driver' s Seat Belt MICRO COMPUTER A25(C), A26(A), A60(B) Skid Control ECU with Actuator IG2 LG Speedometer Speed Sensors 6 AE6 W 11 3P W 3 3D W W B B 191 CAMRY (EM0250U) Key Reminder without Smart Key System and Seat Belt Warning ∗ 6 : w/o Smart Key System ∗ 7 : w/ Power Seat ∗ 8 : w/o Power Seat ∗ 9 : TMC Made ∗10 : TMMK Made KSW B DCTY 5 D 24 B 1 13 EN2 2 L LBE– N3 Front Seat Inner Belt (Driver' s Side) (∗6) B W–B 1 B 1 C 4 FE3 E43(B), E44(C), E45(D) Junction Connector (∗6) 2 B 2 C W–B 1 D (∗6) 2 D W 12 W–B W E49 Junction Connector (∗6) W–B B W B W 9 2 B E2 F1 192 CAMRY (EM0250U) Y 4 A (∗7) 4 C (∗8) FSR– O4(C), T10(A), T11(B), d1(D) Occupant Classification ECU 3 3C Buckle SW (∗8) B L FSR+ 2 3A LBE+ (∗7) W (∗8) 8 A 8 C L L (∗6) CANH 13 A 12 3O W–B R 3 W G 1 CANL 22 A 7 3A (∗6) DBE– 12 B 10 3F B DBE+ 11 B FSP+ 5 3J E22 Unlock Warning SW 12 C FSP– E30(A), N1(B), O1(C) Airbag Sensor Assembly Center 13 C 4 OT1 L L (∗6) B W 1 OT1 (∗7) CANH 5 C (∗7) W W (∗8) W (∗7) B (∗8) B (∗7) CANL 6 C (∗7) E7(B), E8(C), E9(D) Main Body ECU 1 A (∗9) 1 B (∗10) N6(A), (B) Door Courtesy SW (Driver' s Side) (IG) (BAT) 10A ECU–B NO. 1 10A IGN 2 W 1 A 1 C IG +B P(∗7) 7 A 7 C SIG1 11 B 11 D 7 B 7 D SVC1 SGD1 3 A (∗7) 3 B (∗8) 2 A 2 B R W (∗7) BR 5 OT1 (∗7) 6 OT1 SVC1 1 A 1 B SIG1 SVC2 1 A 1 B SIG2 SGD2 3 A (∗7) 3 B (∗8) 2 A 2 B O 1 IF T16(A), d4(B) Occupant Classification Sensor (Front RH) L 9 3L T14(A), d2(B) Occupant Classification Sensor (Front LH) W 10 ID G O 10 3C SB(∗8) W LG LG (∗8) W 3 EO2 (∗7) 2 EO2 BR B 1 (∗7) BR (∗8) 2 IH 1 B 1 D 12 B 12 D 8 B 8 D 2 B (∗7) 2 D (∗8) SGD1 SVC2 SIG2 SGD2 O4(C), T10(A), T11(B), d1(D) Occupant Classification ECU W V B(∗7) 1 A 1 B 2 A 2 B 3 A (∗7) 3 B (∗8) 1 A 1 B 2 A 2 B SVC3 SIG3 SGD3 SVC4 SGD4 4 B (∗7) 4 D (∗8) SIG4 10 B 10 D SIG4 BR SVC4 6 B 6 D R(∗8) SGD3 3 B 3 D Y B (∗7) 1 A (∗7) 1 B (∗8) SIG3 9 B 9 D 3 A (∗7) 3 B (∗8) SGD4 T17(A), d5(B) Occupant Classification Sensor (Rear RH) Buckle SW (∗7) O3(B), T7(A) Front Seat Inner Belt (Front Passenger' s Side) O21 Junction Connector W–B 10 EO2 O1 2 A 2 B SVC3 5 B 5 D T15(A), d3(B) Occupant Classification Sensor (Rear LH) (∗7) W–B (∗8) W–B 5 A 3 P(∗8) O20(A), T18(B) Junction Connector (∗7) W–B 3 B BGND 5 A 5 C GR BSW 9 A 9 C GR GND 3 A 3 C E3 193 CAMRY (EM0250U) Key Reminder without Smart Key System and Seat Belt Warning System Outline Key Reminder Operation With the ignition key inserted in the key cylinder (Unlock warning SW on), the ignition SW still off and driver’s door open (Door courtesy SW on), when a signal is input to the combination meter, the combination meter operates key reminder buzzer sounds. Seat Belt Warning Operation When the driver has not fastened the seat belt while the power SW is pushed to IG ON position (Power SW type), or while the ignition SW is ON (Ignition SW type), the driver seat belt warning light blinks, and a warning buzzer comes on. Also, in the front passenger seat, a sensor recognizes passenger, and when the passenger has not fastened the seat belt, the front passenger seat belt warning light blinks. : Parts Location Code A25 See Page C Code 48 (2GR–FE) E44 52 (2AZ–FE) E45 48 (2GR–FE) See Page Code See Page C 57 D 57 T7 A 62 (*1) 57 T10 A 62 (*1) E49 O21 60 A26 A 52 (2AZ–FE) F1 A 58 T11 B 62 (*1) A41 A 59 F2 B 58 T14 A 62 (*1) A42 B 59 58 T15 A 62 (*1) 59 T16 A 62 (*1) 62 (*1) T17 A 62 (*1) 63 (*2) T18 B 62 (*1) A 60 d1 D 63 (*2) B 60 d2 B 63 (*2) A60 F3 49 (2GR–FE) B N1 B 53 (2AZ–FE) C57 N3 51 (2GR–FE) E7 B 56 E8 C 56 D 56 O1 C 59 d3 B 63 (*2) 56 O3 B 63 (*2) d4 B 63 (*2) d5 B 63 (*2) E9 E22 N6 E30 A 56 O4 C 63 (*2) E43 B 57 O20 A 62 (*1) : Relay Blocks Code 1 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1A See Page Junction Block and Wire Harness (Connector Location) 25 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) 36 Instrument Panel No.2 Wire and J/B No.3 (Behind the Combination Meter) ID 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) IF 30 3A 3C 3D 3F 3G 3J 3L 3O 3P 3Q 3R 3U IG IH 31 * 1 : w/ Power Seat Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) * 2 : w/o Power Seat 194 CAMRY (EM0250U) : Connector Joining Wire Harness and Wire Harness Code AE6 CA3 See Page 66 Joining Wire Harness and Wire Harness (Connector Location) Engine Room Main Wire and Instrument Panel Wire (Instrument Panel Right) 64 (2GR–FE) 65 (2AZ–FE) Engine Wire and Engine Room Main Wire (Inside of the Engine Room R/B and Engine Room J/B) EA1 66 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) EN2 66 Instrument Panel Wire and Floor Wire (Left Kick Panel) EO2 66 Instrument Panel Wire and Floor No.2 Wire (Right Kick Panel) FE3 66 Instrument Panel No.2 Wire and Instrument Panel Wire (Instrument Panel Center) OT1 68 (*1) Floor No.2 Wire and Front Seat RH Wire (Under the Front Passenger’s Seat) : Ground Points Code See Page Ground Points Location C6 65 (2AZ–FE) Cylinder Block C7 64 (2GR–FE) Left Side of the Cylinder Block E2 66 Instrument Panel Brace LH E3 66 Instrument Panel Right F1 66 Instrument Panel Left O1 67 Right Rear Quarter Panel * 1 : w/ Power Seat * 2 : w/o Power Seat 195 CAMRY (EM0250U) Wiper and Washer WF 3 A GR EW 2 A W–B +1 +S 1 B W +2 E19(A), E20(B) Windshield Wiper SW Assembly Wiper Relay +1 3 B +2 4 B +B 2 B P HI LO INT OFF +B +S INT1 INT2 B1 MIST Front Wiper SW On W EW Off Front Washer SW 196 CAMRY (EM0250U) G L (IG) (IG) 25A WIP 10A WASH ∗ 1 : TMC Made ∗ 2 : TMMK Made 2 IC 12 IC R II L 2 5 A B M 1 A37 Windshield Washer Motor (∗2) LG A58(A), E40(B) Junction Connector LG 2 (∗1) 2 B GR W–B W W P P G 25 AE2 17 AE2 +2 +1 B (∗1) B B (∗2) (∗2) LG LG (∗1) LG (∗1) (∗2) BR 5 A 5 B (∗1) BR 3 A 3 B 1 AB1 (∗1) BR (∗1) (∗2) P P(∗1) P 2 AB1 1 A (∗1) 1 B (∗2) 2 A 2 B B +S M E 4 A (∗1) 4 B (∗2) W–B (∗1) 4 AB1 W–B A59(B), B1(A) Windshield Wiper Motor W–B (∗1) W–B W–B 9 EO1 W–B G 5 AB1 W–B 8 B 3 AB1 (∗1) 11 A A58(A), E40(B) Junction Connector P(∗2) L (∗2) A3 A2 E2 O1 197 CAMRY (EM0250U) Wiper and Washer : Parts Location Code See Page 48 (2GR–FE) A37 52 (2AZ–FE) A58 A 59 A59 B 49 (2GR–FE) Code See Page A59 B B1 A E19 A Code See Page 53 (2AZ–FE) E20 B 56 49 (2GR–FE) E40 B 57 53 (2AZ–FE) 56 : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) IC 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) II 31 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) : Connector Joining Wire Harness and Wire Harness Code AB1 AE2 See Page 64 (2GR–FE) 65 (2AZ–FE) 66 Joining Wire Harness and Wire Harness (Connector Location) Engine Room Main Wire and Engine Room No.2 Wire (Near the Windshield Wiper Motor) Engine Room Main Wire and Instrument Panel Wire (Right Side of the Instrument Panel J/B) : Ground Points Code A2 See Page 64 (2GR–FE) 65 (2AZ–FE) Ground Points Location Front Left Fender A3 66 Left Cowl Side Panel E2 66 Instrument Panel Brace LH O1 67 Right Rear Quarter Panel 198 CAMRY (EM0250U) Memo 199 CAMRY (EM0250U) W–B 2 W–B B E E35 Power Outlet Socket (Rear) 1 B E 4 8 E29 Power Outlet Socket (Front) R R R R 12 IO E49 Junction Connector 2 W–B Power Outlet (ACC) 20A PWR OUTLET 16 IM 11 EN2 1 2 E2 200 CAMRY (EM0250U) : Parts Location Code See Page E29 56 Code E35 See Page 57 Code E49 See Page 57 : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) IM 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) IO 30 Floor Wire and Instrument Panel J/B (Cowl Side Left) : Connector Joining Wire Harness and Wire Harness Code EN2 See Page 66 Joining Wire Harness and Wire Harness (Connector Location) Instrument Panel Wire and Floor Wire (Left Kick Panel) : Ground Points Code E2 See Page 66 Ground Points Location Instrument Panel Brace LH 201 CAMRY (EM0250U) Clock (BAT) (ACC) 7. 5A ECU– ACC 10A DOME 2 2 IF LG 1 L 13 ID 12 3L 11 3L 1 3R 2 3R R L R 7 IF 1 2 GND1 A/B RSET 19 5 6 V ACC W–B B F3 Clock LG P 1 2 A/B E 20 5 RSET E 8 3R F4 Hazard Warning Signal SW W–B 2 3U F1 202 CAMRY (EM0250U) : Parts Location Code See Page F3 Code 58 F4 See Page Code See Page 58 : Relay Blocks Code 1 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 3L See Page Junction Block and Wire Harness (Connector Location) 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) 36 Instrument Panel No.2 Wire and J/B No.3 (Behind the Combination Meter) ID 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) IF 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) 3R 3U : Ground Points Code F1 See Page 66 Ground Points Location Instrument Panel Left 203 CAMRY (EM0250U) W Horn 1 1G HORN Relay 10 1D 6 1B B B 10A HORN 11 ID GR 5 II A4 Horn (Low) W W 1 8 A HO FL MAIN 3. 0W E18(A), a1(B) Spiral Cable Horn SW L 1 B Battery a1(B) Steering Pad SW 204 CAMRY (EM0250U) 1 A3 Horn (High) : Parts Location Code See Page 48 (2GR–FE) A3 52 (2AZ–FE) Code A4 See Page Code See Page 48 (2GR–FE) E18 A 56 52 (2AZ–FE) a1 B 59 : Junction Block and Wire Harness Connector Code 1B 1D See Page 25 Junction Block and Wire Harness (Connector Location) Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 1G 22 ID 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) II 31 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) 205 CAMRY (EM0250U) Power Window 25A DOOR NO. 2 (BAT) 10A ECU IG NO. 1 10A ECU–B NO. 1 25A DOOR NO. 1 (IG) 7. 5A ECU–ACC (ACC) (BAT) (BAT) 2 2 E7(B), E8(C) Main Body ECU 1 O 2 206 CAMRY (EM0250U) IG 15 ACC 22 BECU (∗2) ALTB 26 6 10 ID 16 ID W BATB (∗1) O W 1 ∗ ∗ ∗ ∗ 1 2 3 4 : w/ Smart Key System : w/o Smart Key System : TMC Made : TMMK Made E7(B), E8(C) Main Body ECU DCTY 4 L GND2 24 B 9 IM W–B 10 3F L 12 3O E49 Junction Connector W–B 1 A (∗3) 1 B (∗4) 12 2 10 13 W–B W–B W–B W–B 6 4 FE3 F1 W–B W–B W–B N6(A), (B) Door Courtesy SW (Driver' s Side) L 13 EN2 W–B E2 207 CAMRY (EM0250U) Power Window E7(B), E8(C) Main Body ECU LIN2 10 C M1(A), (B) Power Window Master SW P (∗5) (BAT) 25A PWR E48 Junction Connector 4 E LED 1 A 1 B (∗6) 3 A A D 4 A 5 A 4 B U 8 A (∗5) 3 B (∗6) 17 IM G (∗6) BR (∗6) O (∗5) R (∗5) B (∗5) LG W–B (∗5) W 6 3D (∗5) P (∗5) 13 6 3F AUTO UP1 M LIN (∗5) P (∗5) E 1 (∗5) 9 9 IM2 (∗6) BR 1 10 DWN1 10 IM2 (∗6) O (∗5) R (∗5) 7 W–B B W 17 IE2 5 IM1 2 2 W–B 4 IM1 I4 Power Window Regulator Motor (Front LH) G 4 LED I5 Power Window Regulator Motor (Front LH) W (∗5) 3 IE1 (∗5) P 23 IE2 B LG 5 15 IM1 (∗5) 6 IM1 (∗5) W–B (∗5) P 18 IM1 (∗5) 13 IM2 (∗6) M W–B W–B W–B 208 CAMRY (EM0250U) ∗ 5 : w/ Jam Protection ∗ 6 : w/o Jam Protection E7(B), E8(C) Main Body ECU U D 10 A 10 B 18 A 18 B 17 IM1 12 IM2 LG 1 IM1 (∗5) 1 IM2 (∗6) Y LG 8 IE1 4 IE1 7 IE1 2 IE1 GR B 8 IM1 (∗5) 4 IM2 (∗6) L 9 IM1 5 IM2 2 EN1 7 EN1 2 EO1 7 EO1 B Y LG 6 KN1 16 KN1 6 JO1 16 JO1 Y Y R 2 SD 1 H4 Power Window Regulator Motor (Front Passenger' s Side) 1 M 2 D B 4 1 3 R Up U R 3 V Up B 1 J3 Power Window Regulator Motor (Rear RH) M D 4 R GR 2 U R 3 V B 1 K3 Power Window Regulator Motor (Rear LH) D 4 Y Up U Down 5 SU J1 Power Window SW (Rear RH) 2 SD Down 5 SU K1 Power Window SW (Rear LH) 2 SD Down 5 SU G H6 Power Window SW (Front Passenger' s Side) LG L 1 HE1 LG R 6 HE1 W W GR LG 1 IE1 Y R 6 IE1 B W 1 IE2 L W 2 IM1 (∗5) 2 IM2 (∗6) 11 IM1 7 IM2 10 IM1 (∗5) 6 IM2 (∗6) B 6 A (∗5) 6 B (∗6) GR D 13 A 13 B Y U 12 A 12 B B D 15 A 15 B L U 16 A 16 B R M1(A), (B) Power Window Master SW 1 M 2 GR R R GR W–B W–B 209 CAMRY (EM0250U) Power Window (BAT) 120A ALT E7(B), E8(C) Main Body ECU B 1 1F PWS 18 1 3 2 5 PWR Relay 5 GND1 1 25A RR DOOR LH 25A RR DOOR RH 30A POWER 7 IP 10 IF W–B GR 1 IL V 7 IJ G 10 IK GR 2 7 JO1 R 7 KN1 R 1 HE2 GR G 3 EO1 GR R R GR W–B 210 CAMRY (EM0250U) 1 IA System Outline 1. Manual Down or Up Operation When the power window master SW is pushed one step, the motor rotates to open the window. When the power window master SW is pulled up one step, the motor rotates in the opposite direction, to close the window. All the other windows can be opened/closed as well, by the operation of the power window master SW or respective power window SW. 2. Auto Down or Up Operation When the power window master SW is pushed two steps, the motor rotates to open the window automatically. When the power window master SW is pulled up two steps, the motor rotates to close the window automatically. (w/ jam protection) 3. Jam Protection Function When any foreign object gets caught during power window UP operation, the motor rotates in the opposite direction to open the window. : Parts Location Code See Page Code See Page E7 B 56 I4 61 E8 C 56 I5 61 E48 57 J1 61 E49 57 J3 61 H4 61 K1 61 H6 61 K3 61 Code M1 N6 See Page A 61 B 61 A 60 B 60 : Relay Blocks Code 1 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1F See Page Junction Block and Wire Harness (Connector Location) 22 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) 30 Floor Wire and Instrument Panel J/B (Cowl Side Left) 3D 3F 3O IA ID IF IJ IK IL IM IP 211 CAMRY (EM0250U) Power Window : Connector Joining Wire Harness and Wire Harness Code EN1 See Page Joining Wire Harness and Wire Harness (Connector Location) 66 Instrument Panel Wire and Floor Wire (Left Kick Panel) EO1 66 Instrument Panel Wire and Floor No.2 Wire (Right Kick Panel) FE3 66 Instrument Panel No.2 Wire and Instrument Panel Wire (Instrument Panel Center) 66 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) 66 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) 67 Front Door LH Wire and Front Door LH No.2 Wire (Inside of the Front Door LH) JO1 67 Rear Door No.1 Wire and Floor No.2 Wire (Right Center Pillar) KN1 67 Rear Door No.2 Wire and Floor Wire (Left Center Pillar) EN2 HE1 HE2 IE1 IE2 IM1 IM2 : Ground Points Code See Page Ground Points Location E2 66 Instrument Panel Brace LH F1 66 Instrument Panel Left 212 CAMRY (EM0250U) Memo 213 CAMRY (EM0250U) Door Lock Control and Luggage Compartment Door Opener (BAT) (BAT) 25A DOOR NO. 1 10A ECU–B NO. 1 25A DOOR NO. 2 (ACC) 10A ECU IG NO. 1 7. 5A ECU–ACC E6(A), E7(B), E8(C), E9(D) Main Body ECU 1 1 ACC 15 BATB (∗1) BECU (∗2) ALTB 2 26 6 10 ID 16 ID O W 22 IG W 2 O 2 (IG) (BAT) 214 CAMRY (EM0250U) ∗ ∗ ∗ ∗ 1 2 3 4 : w/ Smart Key System : w/o Smart Key System : TMC Made : TMMK Made E6(A), E7(B), E8(C), E9(D) Main Body ECU DCTY 24 B PCTY 21 A B 5 EN1 W 17 EN2 Y L 1 B W 7 IO GR TR+ LGCY 25 A LG 13 B RCTY 7 A (∗1) 5 A (∗2) N28 Junction Connector LCTY 17 W B 3 1 1 M 2 1 S15 Junction Connector 1 A (∗3) 1 B (∗4) O6 Door Courtesy SW (Front Passenger' s Side) L N6(A), (B) Door Courtesy SW (Driver' s Side) 9 W–B 1 16 SN1 W–B Y 5 EO2 Y 13 EN2 GR 6 EO2 O10 Door Courtesy SW (Rear RH) N13(A), (B) Door Courtesy SW (Rear LH) 1 A (∗3) 1 B (∗4) 3 SN1 6 3C L 12 3O 5 3N GR 7 3C 10 3F S5 Door Lock Assembly (Luggage) 6 3N W 14 S1 215 CAMRY (EM0250U) Door Lock Control and Luggage Compartment Door Opener E6(A), E7(B), E8(C), E9(D) Main Body ECU V GND2 2 A 9 IM 2 3F 5 3J Unlock 1 W–B 1 18 IM1 (∗5) 13 IM2 (∗6) (∗2) W–B 2 5 4E 9 W–B 3 A (∗1) 1 B (∗2) 2 M1 Power Window Master SW Lock 1 A (∗1) 2 B (∗2) W–B E52 Power SW (∗1) E22 Unlock Warning SW R 4 4E W–B 4 (∗1) COM 5 W–B GND S6(B), S8(A) Luggage Compartment Door Lock Cylinder E58(A) Certification ECU G 4 SN1 SS1 SS2 GND V L CANH (∗2) CANL Full Traveling G W–B 27 A 28 A Free 14 IM1 (∗5) 8 IM2 (∗6) 13 IM1 3 IM2 R V (∗1) 2 SS1 SS2 7 IE2 V R (∗1) 8 EN2 7 15 IE2 G 7 3A 7 4E 12 IK V L (∗1) W 15 IK 3 3N 6 4E L L1 9 7 4G (∗1) 6 4G KSW 5 D 4 R 16 C L 15 C (∗1) L (∗1) TSW CANP CANN SSW2 16 B (∗2) SSW1 17 B 2 3A W–B W–B W–B (∗1) W–B (∗2) 3 3C 5 4H 17 IE2 W–B 10 IG 3 IM 1 S15 Junction Connector 6 9 13 2 E1 S1 216 CAMRY (EM0250U) W–B W–B (∗1) W–B 9 E2 E49 Junction Connector ∗ ∗ ∗ ∗ 1 2 5 6 : w/ Smart Key System : w/o Smart Key System : w/ Jam Protection : w/o Jam Protection E6(A), E7(B), E8(C), E9(D) Main Body ECU GR UL2 1 24 16 IK 2 IK 7 IK 5 IJ 1 IJ L 7 HE2 ACT+ W G 15 HE2 L2 10 GR 10 B L UL3 9 B 4 IJ L 3 IJ LSWD 5 B GR ACTD UL1 12 LG GR W L 8 IE2 16 IE2 9 IE2 7 HE1 8 HE2 16 HE2 9 HE2 LG GR W L 9 3I R 5 3I BR W BR GR 9 3G GR L 5 3O 8 10 9 4 7 5 6 4 M 8 W–B 25 IE2 GR 17 HE2 1 LG 1 25 HE2 LG W–B I7 Door Lock Assembly (Driver' s Side) W–B 7 W–B W W–B H8 Door Lock Assembly (Front Passenger' s Side) M Key Lock Key Unlock Key Unlock W–B 3 24 IE2 Key Lock Lock H5 Door Lock Control SW 2 Unlock 4 LG L L G LG LG W–B W–B 5 10 W–B W–B E49 Junction Connector 217 CAMRY (EM0250U) Door Lock Control and Luggage Compartment Door Opener ∗ ∗ ∗ ∗ 1 2 7 8 : w/ Smart Key System : w/o Smart Key System : 2GR–FE : 2AZ–FE E6(A), E7(B), E8(C), E9(D) Main Body ECU 2 IJ 18 IF 5 IF G W GR LG B L LG 5 IP 5 10 IF 4 3O 5 IL GR 11 IP 5 A (∗2) 6 IP GND1 LSWR LSWP 27 A 3 V ACT– 20 (∗1) LSR (∗2) LSWL (∗1) LG GR B L GR 1 KN1 3 KN1 10 JO1 1 JO1 3 JO1 10 3D GR B L GR 4 6 4 6 W–B 9 4 KN1 4 JO1 BR 1 9 15 EA1 (∗7) M W–B 1 J5 Door Lock Assembly (Rear RH) M BR GR 10 KN1 K5 Door Lock Assembly (Rear LH) W 5 3Q L 16 EO1 G 4 EO1 B 8 EO1 BR BR (∗1) W–B 4 3D A41(A), A42(B) Junction Connector (∗8) 17 A W–B W–B GR 18 B 2 W–B (∗7) BR (∗7) 4 CA3 8 N29 Junction Connector N1 4 CA3 (∗8) W–B W–B GR LG 3 O21 Junction Connector O1 218 CAMRY (EM0250U) C57 Junction Connector C6 C7 E6(A), E7(B), E8(C), E9(D) Main Body ECU (BAT) (BAT) (IG) B(∗8) 7. 5A GAUGE NO. 2 10A DOME W(∗8) 10A MPX–B V 2 3 1A 12 IG 13 ID 12 3L SB GR LG 1 1 3D 2 3G R 2 EA1 V 1 A 13 A IG+ B Power Supply Circuit R(∗8) MULTI LCD R MICRO COMPUTER 2 B C1(B) Park/Neutral Position SW B2 (∗8) 2 A V 12 3Q 9 3Q GR 1 3Q R 7 IF DRIVE IC 17 A CANL 18 A GR B (∗8) W 49 A 41 A CANL CANH 73 B P F1(A) Combination Meter A24(A), C24(B) Engine Control Module W 12 A CANH B 24 A W–B E2 BR ES 6 B (∗8) CAN I/F (∗8) Master Warning P +B(DOME) BR 2 3U W W–B 7 3Q B F1 219 CAMRY (EM0250U) Door Lock Control and Luggage Compartment Door Opener ∗ 7 : 2GR–FE ∗ 8 : 2AZ–FE E6(A), E7(B), E8(C), E9(D) Main Body ECU CANL 6 C N3 Front Seat Inner Belt (Driver' s Side) CANH 5 C W(∗8) Buckle SW B(∗8) (IG) 10A GAUGE NO. 1 LBE+ R 11 B 12 B 10 CA2 1 C 4 B 10 B 2 A 1 A 2 B 1 B B B B 2 C 14 FE3 13 FE3 B W W (∗8) W 1 D W 41 A 2 D W CANL 7 A W 49 A 1 A W P (∗7) B (∗8) B 24 B CANH 13 A B B (∗7) W (∗7) B–W 3 A (∗7) P C1(A) Park/Neutral Position SW 1 A A40(A), E41(B) Junction Connector R (∗7) R(∗8) (∗7) CANL 22 A CANH A55(A), C55(B) Engine Control Module W B 220 CAMRY (EM0250U) E42(A), E43(B), E44(C), E45(D) Junction Connector DBE– O DBE+ B 14 EA1 E30(A), N1(B) Airbag Sensor Assembly Center W R 16 IH LBE– 3 G 1 System Outline 1. Manual Unlock Operation When the door lock control SW of the driver’s or passenger’s side door is pushed to UNLOCK, the door lock will unlock. 2. Manual Lock Operation When the door lock control SW of the driver’s or passenger’s side door is pushed to LOCK, the door lock will lock. 3. Door Key Unlock Operation ∗ Unlock operation from driver’s side door When the driver’s side door is unlocked once using the ignition key, only the driver’s side door is unlocked. If this operation is repeated within 3 seconds, all the other doors are unlocked. : Parts Location Code See Page Code See Page Code See Page A24 A 52 (2AZ–FE) E41 B 57 A40 A 59 E42 A 57 A41 A 59 E43 B 57 A42 B 59 E44 C 57 A55 A 49 (2GR–FE) E45 D 57 A 50 (2GR–FE) E49 57 B 54 (2AZ–FE) E52 57 N28 60 C24 B 55 (2AZ–FE) E58 A 57 N29 60 C55 B 51 (2GR–FE) F1 A 58 O6 60 C1 C57 62 (*1) N3 N6 N13 63 (*2) A 60 B 60 A 60 B 60 51 (2GR–FE) H5 61 O10 60 E6 A 56 H8 61 O21 60 E7 B 56 I7 61 S5 E8 C 56 J5 61 S6 B 61 E9 D 56 K5 61 S8 A 61 56 M1 61 E22 E30 A 56 N1 B S15 61 61 59 : Relay Blocks Code 1 See Page 22 * 1 : w/ Power Seat Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) * 2 : w/o Power Seat 221 CAMRY (EM0250U) Door Lock Control and Luggage Compartment Door Opener : Junction Block and Wire Harness Connector Code 1A See Page Junction Block and Wire Harness (Connector Location) 25 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) 36 Instrument Panel No.2 Wire and J/B No.3 (Behind the Combination Meter) 42 Instrument Panel Wire and J/B No.4 (Instrument Panel Brace Center) ID 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) IF 30 3A 3C 3D 3F 3G 3I 3J 3L 3N 3O 3Q 3U 4E 4G 4H IG IH 31 IJ IK IL Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) 30 IM IO IP 30 Floor Wire and Instrument Panel J/B (Cowl Side Left) : Connector Joining Wire Harness and Wire Harness Code CA2 CA3 EA1 EN1 EN2 EO1 EO2 FE3 HE1 HE2 IE2 IM1 IM2 See Page Joining Wire Harness and Wire Harness (Connector Location) 64 (2GR–FE) 65 (2AZ–FE) 64 (2GR–FE) Engine Wire and Engine Room Main Wire (Inside of the Engine Room R/B and Engine Room J/B) 65 (2AZ–FE) 66 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) 66 Instrument Panel Wire and Floor Wire (Left Kick Panel) 66 Instrument Panel Wire and Floor No.2 Wire (Right Kick Panel) 66 Instrument Panel No.2 Wire and Instrument Panel Wire (Instrument Panel Center) 66 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) 66 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) 67 Front Door LH Wire and Front Door LH No.2 Wire (Inside of the Front Door LH) JO1 67 Rear Door No.1 Wire and Floor No.2 Wire (Right Center Pillar) KN1 67 Rear Door No.2 Wire and Floor Wire (Left Center Pillar) SN1 67 Luggage Room Wire and Floor Wire (Luggage Room Left) 222 CAMRY (EM0250U) : Ground Points Code See Page Ground Points Location C6 65 (2AZ–FE) Cylinder Block C7 64 (2GR–FE) Left Side of the Cylinder Block E1 66 Instrument Panel Left E2 66 Instrument Panel Brace LH F1 66 Instrument Panel Left N1 67 Left Rear Quarter Panel O1 67 Right Rear Quarter Panel S1 67 Lower Back Panel Center 223 CAMRY (EM0250U) Wireless Door Lock Control without Smart Key System E6(A), E7(B), E8(C), E9(D) Main Body ECU (IG) (BAT) 10 ID 10A ECU IG NO. 1 12 A 4 3N 2 3N 1 IF 7 D 4 9 IM W–B 10A ECU–B NO. 1 GND2 BZR RDA 10 A O (ACC) 7. 5A ECU–ACC PRG BECU 26 L IG 15 R ACC 22 5 AE2 W O 2 1 3E 2 3D P O O 1 13 EO1 14 EO1 1 A48 Wireless Door Lock Buzzer (2AZ–FE) B B GND (2GR–FE) +B 5 O17 Door Control Receiver 2 RDA W–B 3 PRG W 9 3L 2 O P Buzzer 1 W 9 3E A42(B) Junction Connector 15 EO1 17 B (2AZ–FE) W–B W–B (2GR–FE) 16 B 5 O1 224 CAMRY (EM0250U) O21 Junction Connector W–B A3 E6(A), E7(B), E8(C), E9(D) Main Body ECU LSWD ACT+ 5 B 27 A 9 B 1 GR LG L ACTD KSW LSWP LSR 20 L 5 D 5 IP 2 IJ LG 11 IP GR G L 5 3J 6 IP W 1 IJ W 2 IK LG 5 3O 4 6 7 4 GR M W–B W–B 17 HE2 25 HE2 4 KN1 W–B 5 LG 2 W–B W–B 6 9 LG 12 9 1 W–B 13 E49 Junction Connector W–B W–B W–B 3 3C 1 M W–B 8 K5 Door Lock Assembly (Rear LH) GR I7 Door Lock Assembly (Driver' s Side) 3 KN1 GR W–B W 2 3A 1 KN1 L W 25 IE2 G W–B 17 IE2 10 KN1 B 2 9 HE2 7 HE1 H8 Door Lock Assembly (Front Passenger' s Side) 1 L 7 W–B E22 Unlock Warning SW M 1 L 4 LG R 8 5 3I LG 9 IE2 L 24 IE2 L 7 3A W–B F1 4 FE3 2 W–B W–B W–B N29 Junction Connector N1 E2 225 CAMRY (EM0250U) Wireless Door Lock Control without Smart Key System E6(A), E7(B), E8(C), E9(D) Main Body ECU 17 RCTY 5 A DCTY PCTY 24 B 21 A TR+ LGCY 25 A 1 B B LCTY 3 W ACT– 17 EN2 5 EN1 N28 Junction Connector 13 B W GR Y L L 5 IL GR 5 IF LG 18 IF B 7 IO 16 SN1 B 3 1 1 2 1 4 JO1 W–B 9 W–B 8 O21 Junction Connector O1 S1 226 CAMRY (EM0250U) S15 Junction Connector 1 A (∗3) 1 B (∗4) M W–B Y 1 S5 Door Lock Assembly (Luggage) L 5 EO2 Y GR 13 EN2 GR W–B 9 1 A (∗3) 1 B (∗4) 6 3C O6 Door Courtesy SW (Front Passenger' s Side) M 12 3O 6 EO2 O10 Door Courtesy SW (Rear RH) 6 J5 Door Lock Assembly (Rear RH) 4 N13(A), (B) Door Courtesy SW (Rear LH) GR 3 JO1 GR L 1 JO1 L 10 JO1 B B 7 3C 1 3 SN1 16 EO1 L 4 EO1 N6(A), (B) Door Courtesy SW (Driver' s Side) 8 EO1 5 3N 10 3F W 6 3N W 14 (BAT) ∗ ∗ ∗ ∗ 1 2 3 4 : w/ Sliding Roof : w/o Sliding Roof : TMC Made : TMMK Made 10A DOME 2 E6(A), E7(B), E8(C), E9(D) Main Body ECU HAZ W 4 C GND1 LG 1 ILE 5 21 10 IF 1 IR 5 IR 10 II BR BR (∗1) W–B W–B 9 3M W BR W 16 EQ1 (∗2) R (∗1) 9 3F 1 10 11 W–B (∗2) Ignition Key Cylinder Light E25 Transponder Key Amplifier (∗1) R R R 7 EQ1 10 IL 12 3B 13 ID 7 IF 12 3L R W (∗2) E49 Junction Connector W–B 2 18 EQ1 ILL+ 6 IR LG (∗1) W–B W–B W 15 EQ1 ILL– 2 (∗1) W(∗2) W 3 (∗2) 2 (∗2) OFF ON Q9 Room Lamp (Center) 8 W(∗2) V (∗1) 6 11 EQ1 E CTY (∗1) E14 Turn Signal Flasher Map Lamp 6 W–B Q6 Overhead J/B V B (∗1) W HAZ (∗2) 7 DOOR 8 E2 227 CAMRY (EM0250U) Wireless Door Lock Control without Smart Key System System Outline Door lock control (Lock and unlock) and panic control (Theft alarm and flash) is performed by remote control, without the ignition key inserted in the door key cylinder, using low–power electrical waves emitted by a transmitter. 1. Wireless Door Lock or Unlock Normal Operation With the ignition key not inserted into the ignition key cylinder (Unlock warning SW off) and all the doors completely closed, when the lock or unlock button (Transmitter) is pushed, the door control receiver receives the electrical waves from the transmitter, and sends a signal to the main body ECU, causing it to operate. As a result, the main body ECU judges whether the door is locked or unlocked based on the signal from the door lock motor and door unlock detection SW, and sends a signal to switch the condition from lock to unlock or vice versa, causing the door lock motor to operate. 2. Visual Confirmation of Lock or Unlock If all doors indicate that they are locked after the lock command, turn signal light will flash once. If any door indicates that it is open after the unlock command, turn signal light will flash twice. 3. Buzzer Sound Function If all doors indicate that they are locked after the lock command, the keyless buzzer goes on once. If any door indicates that it is open after the unlock command, the keyless buzzer goes on twice. 4. Illuminated Entry Function When the main body ECU detects the unlock state after the unlock operation has been made, it turns on the lights, such as the ignition key cylinder light and interior light for approx. 15 sec. If all the doors are locked during this operation, lighting is cancelled and the lights immediately fade out. 5. Wireless Door Unlock Operation Pushing the unlock button (Transmitter) once, driver’s door is unlocked. Furthermore, pushing the button again within 3 seconds, the other doors are unlocked. 6. Automatic Lock Operation With the ignition key not inserted into the ignition key cylinder (Unlock warning SW off) and all the doors completely closed, after pushing the button (Transmitter) to unlock all the doors, if a door is not opened within 30 seconds, all the doors will be automatically relocked. 7. Wireless Control Stop Function If a door is open (Door courtesy SW on), a signal is input from the door courtesy SW to the main body ECU stopping wireless door lock or unlock. If the ignition key is in the ignition key cylinder (Unlock warning SW on), the unlock warning SW inputs a signal to the main body ECU stopping wireless door lock or unlock. 8. Repeat Function If the door lock or unlock condition does not change after wireless door lock or unlock operation, 2 seconds later, the main body ECU sends current again to the door lock motor. 9. Remote Panic Operation Panic will function when doors are locked or unlocked, open or closed. When the panic button (Transmitter) is pushed once, theft alarm and horn sounds and turn signal light, headlights and taillight flash. Then, the panic or the unlock button (Transmitter) is pushed once more, sounding and flashing will stop. Panic will not function when ignition key is in ignition key cylinder. : Parts Location Code A42 See Page B A48 Code See Page Code See Page 59 E49 57 N29 60 49 (2GR–FE) H8 61 O6 60 53 (2AZ–FE) I7 61 O10 60 E6 A 56 J5 61 O17 60 E7 B 56 K5 61 O21 60 E8 C 56 A 60 Q6 61 E9 D 56 B 60 Q9 61 A 60 S5 61 B 60 S15 61 E14 56 E22 56 E25 56 N6 N13 N28 60 228 CAMRY (EM0250U) : Relay Blocks Code 1 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) 3A 3B 3C 3D 3E 3F 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) ID 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) IF 30 II 31 3I 3J 3L 3M 3N 3O IJ IK IL Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) 30 IM IO IP IR 30 Floor Wire and Instrument Panel J/B (Cowl Side Left) 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) : Connector Joining Wire Harness and Wire Harness Code AE2 See Page Joining Wire Harness and Wire Harness (Connector Location) 66 Engine Room Main Wire and Instrument Panel Wire (Right Side of the Instrument Panel J/B) 66 Instrument Panel Wire and Floor Wire (Left Kick Panel) 66 Instrument Panel Wire and Floor No.2 Wire (Right Kick Panel) EQ1 66 Instrument Panel Wire and Roof Wire (Lower Part of Front Pillar LH) FE3 66 Instrument Panel No.2 Wire and Instrument Panel Wire (Instrument Panel Center) 66 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) EN1 EN2 EO1 EO2 HE1 HE2 IE2 66 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) JO1 67 Rear Door No.1 Wire and Floor No.2 Wire (Right Center Pillar) KN1 67 Rear Door No.2 Wire and Floor Wire (Left Center Pillar) SN1 67 Luggage Room Wire and Floor Wire (Luggage Room Left) : Ground Points Code See Page Ground Points Location A3 66 Left Cowl Side Panel E2 66 Instrument Panel Brace LH F1 66 Instrument Panel Left N1 67 Left Rear Quarter Panel O1 67 Right Rear Quarter Panel S1 67 Lower Back Panel Center 229 CAMRY (EM0250U) Theft Deterrent E6(A), E7(B), E8(C), E9(D) Main Body ECU TRLY B 1 IA 3 2 4 P 9 1D B L 6 1B 10 1D B Y 1 TAIL Relay H–LP (LL) Relay HORN Relay 5 1A 5 10A HORN 7. 5A S–HORN 11 1D W 120A ALT 1 1G H–LP (RL) Relay 1 1F S–HORN Relay B 7 P B GR 1 A23 Security Horn 1 A4 Horn (Low) 1 A3 Horn (High) FL MAIN 3. 0W Y Battery 230 CAMRY (EM0250U) ∗ 1 : w/ Smart Key System ∗ 2 : w/o Smart Key System E6(A), E7(B), E8(C), E9(D) Main Body ECU HRLY HORN 8 25 3 ID 11 ID SH CANN 6 D 15 C ACC CANP 16 C IG 22 15 (ACC) (IG) 10A ECU IG NO. 1 L (∗1) W (∗1) P (∗2) B P 7. 5A ECU–ACC P (∗1) 12 AE6 28 A 20 B CANL CANH Y SH– E58(A), E59(B) Certification ECU 27 A IND RSSI 2 A Y R (∗1) 39 A (∗1) RDA 38 A Y G V (∗1) R (∗1) RC0 29 A (∗1) ASEL 37 A (∗1) HSW 24 B 11 3E 11 EO1 14 EO1 13 EO1 12 EO1 R (∗1) Y (∗1) G (∗1) V 10 3J (∗1) P 4 2 ASEL +5 3 5 DATA RSSI (∗1) O19 Electrical Key Antenna 1 A2 Y (∗1) 6 O21 Junction Connector 3 W–B W 6 A43 Junction Connector W GND ANT 1 (∗1) Y A5 Engine Hood Courtesy SW 2 ANT 7 (∗1) R (∗1) 2 AE2 O18 Door Control Receiver R (∗1) B O1 231 CAMRY (EM0250U) Theft Deterrent E6(A), E7(B), E8(C), E9(D) Main Body ECU GND2 4 R HCTY 16 B 9 IM BECU (∗2) HAZ 4 C PRG 10 A 26 RDA 12 A 4 3F W 2 L (∗2) R (∗2) 9 3L 4 3N 2 3N 9 3E 1 3E 2 3D O 9 3M 1 IF (∗2) W 10 ID 10A ECU–B NO. 1 W–B (∗2) (BAT) O (∗2) P W R (∗2) W 9 3F (∗2) 4 3J (∗2) 1 15 EO1 13 EO1 14 EO1 O (∗2) P (∗2) W 5 +B 3 2 PRG RDA 2 A5 Engine Hood Courtesy SW GND 6 1 2 3 4 5 : w/ Smart Key System : w/o Smart Key System : w/ Jam Protection : w/o Jam Protection : w/o Sliding Roof E49 Junction Connector W–B W ∗ ∗ ∗ ∗ ∗ (∗2) W–B 1 1 (∗2) O17 Door Control Receiver E14 Turn Signal Flasher (∗2) R HAZ (∗2) 8 2 AE2 2 Y Y W–B (∗2) (∗1) W–B (∗1) 5 O21 Junction Connector A2 E2 O1 232 CAMRY (EM0250U) E6(A), E7(B), E8(C), E9(D) Main Body ECU KSW UL1 9 12 11 3R L G L G 7 IE2 15 HE2 7 HE2 14 IM1 (∗3) 8 IM2 (∗4) 13 IM1 3 IM2 (∗2) 4 IJ 15 IE2 V 7 3A Y Y R (∗1) 5 3D 3 3N 5 3J 3 IJ G 6 3K 2 3F 12 IK V 15 IK G L Y (∗2) R L1 5 D L IND 4 D (∗2) TSW 2 A 4 2 2 W–B 2 3A 2 3U 3 3C W–B W–B W–B Unlock H5 Door Lock Control SW Lock G W–B W–B W–B 13 17 HE2 E49 Junction Connector W–B W–B (∗2) 17 IE2 S15 Junction Connector 5 9 10 11 (∗5) W–B W–B 2 W–B 12 9 W–B 1 W–B W–B R 3 A (∗1) 1 B (∗2) 3 W–B (∗2) W–B 8 3R 1 18 IM1 (∗3) 13 IM2 (∗4) 1 A (∗1) 2 B (∗2) W–B S6(B), S8(A) Luggage Compartment Door Lock Cylinder F3 Clock GND1 19 Unlock 1 Security Indicator 4 SN1 9 W–B E22 Unlock Warning SW LP 2 M1 Power Window Master SW Lock R 8 V 8 EN2 W–B W–B Y W–B (∗1) (∗5) W–B W–B S1 4 FE3 W–B F1 E2 233 CAMRY (EM0250U) Theft Deterrent E6(A), E7(B), E8(C), E9(D) Main Body ECU ACT+ 24 16 IK 2 IK 7 IK 5 IJ 1 IJ L UL2 1 W L2 10 GR GR UL3 10 B L LSWD 9 B GR ACTD 5 B LG LG GR W L 9 IE2 7 HE1 8 HE2 16 HE2 9 HE2 BR R LG GR W L 8 10 9 4 7 5 6 4 LG W–B 1 25 IE2 25 HE2 LG 8 W Key Unlock 1 M GR W–B 7 M Key Lock W 16 IE2 I7 Door Lock Assembly (Driver' s Side) BR 8 IE2 Key Lock 24 IE2 Key Unlock GR 9 3I GR 5 3I L 9 3G L 5 3O H8 Door Lock Assembly (Front Passenger' s Side) LG LG W–B W–B W–B W–B (∗5) (∗5) W–B W–B 234 CAMRY (EM0250U) E6(A), E7(B), E8(C), E9(D) Main Body ECU ACT– 20 LSWP 11 IP 5 IP 2 IJ 18 IF 5 IF V LG 6 IP LSWR 5 A 27 A 3 (∗1) LSR (∗2) LSWL (∗1) 5 IL GR (∗2) L B LG GR W G 4 3O LG 4 3D GR (∗1) B L GR 3 KN1 10 JO1 1 JO1 3 JO1 GR B L GR 4 6 4 6 M M 9 9 W–B 1 W–B 1 J5 Door Lock Assembly (Rear RH) GR 1 KN1 K5 Door Lock Assembly (Rear LH) W 10 KN1 L 16 EO1 G 4 EO1 B 8 EO1 4 KN1 4 JO1 W–B ∗ 1 : w/ Smart Key System ∗ 2 : w/o Smart Key System ∗ 5 : w/o Sliding Roof W–B LG W–B W–B (∗5) (∗5) W–B W–B 2 8 N29 Junction Connector O21 Junction Connector O1 N1 235 CAMRY (EM0250U) Theft Deterrent E6(A), E7(B), E8(C), E9(D) Main Body ECU PCTY 21 A TR+ LGCY 25 A 1 B B DCTY 24 B W RCTY 7 A (∗1) 5 A (∗2) LCTY 17 17 EN2 5 EN1 N28 Junction Connector 13 B W Y L LG GR 7 IO W B 3 1 M 1 2 1 S15 Junction Connector O6 Door Courtesy SW (Front Passenger' s Side) 1 A (∗7) 1 B (∗8) S5 Door Lock Assembly (Luggage) Y L N6(A), (B) Door Courtesy SW (Driver' s Side) O10 Door Courtesy SW (Rear RH) 16 SN1 Y L 5 EO2 GR 13 EN2 1 3 SN1 6 3C 6 EO2 LG N13(A), (B) Door Courtesy SW (Rear LH) 1 A (∗7) 1 B (∗8) 12 3O GR 7 3C 5 3N 10 3F W–B 6 3N W 14 ∗ ∗ ∗ ∗ ∗ ∗ 1 2 5 6 7 8 : w/ Smart Key System : w/o Smart Key System : w/o Sliding Roof : w/ Sliding Roof : TMC Made : TMMK Made W–B 9 W–B W–B (∗5) W–B W–B W–B (∗5) S1 236 CAMRY (EM0250U) E6(A), E7(B), E8(C), E9(D) Main Body ECU ILE 21 (BAT) II BR BR 10A DOME 10 (∗2) 5 IR 2 16 EQ1 (∗6) W–B BR (∗2) (∗6) W (∗5) R R ILL– Ignition Key Cylinder Light E25 Transponder Key Amplifier (∗6) 7 EQ1 ILL+ 2 R 3 W OFF ON DOOR 2 15 EQ1 8 (∗6) V E 6 (∗2) CTY 6 W(∗5) Map Lamp W(∗5) Q6 Overhead J/B B (∗5) 1 7 Q9 Room Lamp (Center) W (∗5) R (∗6) V (∗6) W (∗5) LG 1 6 IR 10 IL 12 3B 13 ID 7 IF 12 3L LG (∗6) W–B 11 EQ1 R (∗2) W–B (∗6) W–B (∗5) 18 EQ1 W (∗5) W–B W–B 237 CAMRY (EM0250U) Theft Deterrent (BAT) (BAT) E6(A), E7(B), E8(C), E9(D) Main Body ECU 25A DOOR NO. 1 25A DOOR NO. 2 2 GND1 ALTB 5 1 2 10 IF 16 ID W–B W (∗6) 1 IR W–B W 6 BATB (∗1) ∗ 1 : w/ Smart Key System ∗ 6 : w/ Sliding Roof W–B (∗6) W–B 238 CAMRY (EM0250U) : Parts Location Code See Page Code 48 (2GR–FE) A3 52 (2AZ–FE) A4 A5 A23 A43 See Page E25 E49 Code See Page 56 N28 60 57 N29 60 48 (2GR–FE) E58 A 57 O6 60 52 (2AZ–FE) E59 B 57 O10 60 48 (2GR–FE) F3 58 O17 60 52 (2AZ–FE) H5 61 O18 60 48 (2GR–FE) H8 61 O19 60 52 (2AZ–FE) I7 61 O21 60 49 (2GR–FE) J5 61 Q6 61 61 E6 A 56 K5 61 Q9 E7 B 56 M1 61 S5 E8 C 56 E9 D 56 E14 56 E22 56 N6 N13 61 A 60 S6 B 61 B 60 S8 A 61 A 60 B 60 S15 61 : Relay Blocks Code 1 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) 239 CAMRY (EM0250U) Theft Deterrent : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) 1A 1B 25 1D 1F 1G Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 22 3A 3B 3C 3D 3E 3F 3G 3I 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) 36 Instrument Panel No.2 Wire and J/B No.3 (Behind the Combination Meter) 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) 3J 3K 3L 3M 3N 3O 3R 3U IA ID IF 30 II 31 IJ IK IL Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) 30 IM IO IP IR 30 Floor Wire and Instrument Panel J/B (Cowl Side Left) 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) AE2 66 Engine Room Main Wire and Instrument Panel Wire (Right Side of the Instrument Panel J/B) AE6 66 Engine Room Main Wire and Instrument Panel Wire (Instrument Panel Right) 66 Instrument Panel Wire and Floor Wire (Left Kick Panel) 66 Instrument Panel Wire and Floor No.2 Wire (Right Kick Panel) EQ1 66 Instrument Panel Wire and Roof Wire (Lower Part of Front Pillar LH) FE3 66 Instrument Panel No.2 Wire and Instrument Panel Wire (Instrument Panel Center) 66 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) 66 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) 67 Front Door LH Wire and Front Door LH No.2 Wire (Inside of the Front Door LH) EN1 EN2 EO1 EO2 HE1 HE2 IE2 IM1 IM2 JO1 67 Rear Door No.1 Wire and Floor No.2 Wire (Right Center Pillar) KN1 67 Rear Door No.2 Wire and Floor Wire (Left Center Pillar) SN1 67 Luggage Room Wire and Floor Wire (Luggage Room Left) 240 CAMRY (EM0250U) : Ground Points Code A2 See Page 64 (2GR–FE) 65 (2AZ–FE) Ground Points Location Front Left Fender E2 66 Instrument Panel Brace LH F1 66 Instrument Panel Left N1 67 Left Rear Quarter Panel O1 67 Right Rear Quarter Panel S1 67 Lower Back Panel Center 241 CAMRY (EM0250U) ABS, TRAC and VSC (TMC Made) (BAT) (BAT) 50A ABS No. 1 (IG) 30A ABS No. 2 1 7. 5A ECU IG NO. 2 1 19 IF Y O O B 5 3L 1 1 1 5 3C 7 4D 1 6 4A L 1 1 1 15 R L 2 14 AE6 P B LG 3 A 1 B 2 Buzzer P 3 4 B 1 O 2 E13 VSC Warning Buzzer 2 1 A58(A), E40(B) Junction Connector 3 5 Y 1 VSC NO. 2 Relay 5 W VSC No. 1 Relay 4 3K 14 MRF +BM 45 MR 31 R+ 46 +BS 30 IG1 BZ 1 2 W L W L L 1 NA1 10 NA1 1 gN1 2 gN1 A35 Speed Sensor (Front RH) A14 Speed Sensor (Front LH) 2 W–B A6 A4 242 CAMRY (EM0250U) 1 g1 Speed Sensor (Rear LH) 2 RL– 6 BR 1 RL+ 20 B FR– R 17 R 3 W FR+ 4 W–B W–B FL– 18 L FL+ 1 P GND2 V GND1 32 LG A26 Skid Control ECU with Actuator (BAT) B W B W 10A STOP 6 14 B W GR 12 IM 4 3E 1 IH W O 4 3H Y A19 Stop Lamp SW 7 4 B 10 B 2 A 8 A W SIL 12 B TS 15 B WFSE 2 A40(A), E41(B) Junction Connector CANL B CANH E10 Data Link Connector 3 8 IC 1 W L 7 IL Y O GR 9 AE2 8 AE6 4 AE6 7 AE6 L P L O GR 13 IC 27 42 24 13 STP1 WFSE TS D/G 2 fO1 2 CANH 25 11 B W W 1 fO1 B B B 10 OA1 W 1 OA1 CANL 12 W SP1 RR– 19 f1 Speed Sensor (Rear RH) RR+ 5 BR A26 Skid Control ECU with Actuator 1 BR 243 CAMRY (EM0250U) ABS, TRAC and VSC (TMC Made) B B W W B B W W W(∗2) 1 A A40(A), E41(B) Junction Connector B(∗2) 7 A ∗ 1 : 2GR–FE ∗ 2 : 2AZ–FE W(∗2) W (∗1) A55(A), C55(B) Engine Control Module 49 A 41 A CANL NE+ VTA1 VCTA 96 B VTA2 99 B ETA 19 B M– 18 B GE01 41 B 1 6 5 VC 4 VTA2 3 E2 R (∗1) G (∗1) (∗1) 2 1 M+ M– (∗1) VTA (Shielded) P (∗1) (∗1) W–L B (∗1) Y (∗1) (∗1) 2 BR M+ 97 B G–R 98 B C50 Crankshaft Position Sensor G (∗1) (∗1) (Shielded) NE– 111 B 110 B (∗1) CANH R B (∗1) B(∗2) C5 Throttle Body Assembly BR BR C5 244 CAMRY (EM0250U) B B W W B B W W W(∗2) W(∗2) B(∗2) B(∗2) (IG) (IG) R (∗1) 7. 5A ECU IG NO. 2 10A GAUGE NO. 1 1 A 7 A O (∗1) G (∗1) (∗1) L–B P (∗1) (∗1) B–W 14 EA1 24 B 25 B 27 B 26 B P R N D SFTU 16 A SFTD 51 A A55(A), C55(B) Engine Control Module 10 CA2 S 25 A BR O DL 8 A (∗1) NL 2 A 5 3L 5 3C O RL 19 IF (∗1) PL 3 A R 16 IH (∗1) R (∗1) 7 4D Y (∗1) L (∗1) R (∗1) 7 4C (∗1) 10 AE5 20 AE5 O 10 3D 11 AE5 (∗1) C1(A) Park/Neutral Position SW RB Y (∗1) L (∗1) (∗1) G (∗1) 1 SFTU 7 SFTD S E O (∗1) W–B 12 4C (∗1) W–B 4 CA3 IG 3 5 (∗1) GR (∗1) 11 4A E31 Transmission Control SW 17 A 2 BR 18 B 10 3H A41(A), A42(B) Junction Connector BR (∗1) 15 EA1 BR 3 C57 Junction Connector BR C7 245 CAMRY (EM0250U) ABS, TRAC and VSC (TMC Made) B B W W B B W W W(∗2) R(∗2) (IG) B(∗2) LL 6 B 1 B 9 B 7 B 3 B 8 B 14 EA1 V (∗2) G (∗2) 73 B 53 B 54 B 56 B 26 A 55 B P R N D 3 2 CANL NE+ NE– VTA1 121 B 115 B VCTA 67 B VTA2 114 B A24(A), C24(B) Engine Control Module ETA M+ 91 B 42 B M– 41 B GE01 63 B R (∗2) (∗2) G (∗2) (∗2) (Shielded) P (∗2) W–L (∗2) B Y L (∗2) 6 VTA 5 VC 4 VTA2 3 E2 2 1 M+ M– (∗2) 2 CA3 W–B 2 C20 Crankshaft Position Sensor 1 (∗2) R (∗2) G (∗2) (Shielded) G–R 122 B B SB (∗2) P (∗2) B (∗2) CANH 16 CA2 (∗2) (∗2) W 49 A 11 CA2 (∗2) G 41 A GR 17 CA2 (∗2) B (∗2) GR (∗2) O (∗2) (∗2) V (∗2) R (∗2) G (∗2) 10 CA2 22 AE6 W 2L SB DL (∗2) NL R RL (∗2) 21 AE6 PL L 16 IH (∗2) R (∗2) R RB (∗2) C1(B) Park/Neutral Position SW 2 B (∗2) R (∗2) L(∗2) 10A GAUGE NO. 1 1 CA3 C5 Throttle Body Assembly (∗2) BR B–W BR C4 246 CAMRY (EM0250U) 25 A 74 B 4 L ATL 2 AT4 1 NSSD NSSL Y (∗2) R (∗2) L (∗2) O (∗2) Y (∗2) W B 2 A 1 A 2 G 1 G 2 B 1 B 2 E 1 E W B 13 FE3 B 14 FE3 W E42(A), E43(B), E44(C), E46(E), E62(G), E63(H) Junction Connector O (∗2) E31 Transmission Control SW 5 B 6 W 15 CA2 BR CAMRY (EM0250U) B W BR (∗2) 16 AE5 A24(A), C24(B) Engine Control Module G (∗2) B W B W R(∗2) L(∗2) 19 AE6 B W ∗ 2 : 2AZ–FE B W BR 247 ABS, TRAC and VSC (TMC Made) E8(C) Main Body ECU CANL 6 C (BAT) CANH 10A ECU–B NO. 1 PKB 5 C (IG) 7. 5A ECU IG NO. 2 19 2 19 IF O O (Pedal Type) L 5 3L 1 IF 5 3C 6 4B O O 7 4B 3 1 5 CANH CANL ESS 10 9 2 W–B IG W BAT E34 Yaw Rate Sensor 9 3H O W 7 4D W 9 3L B A18 Parking Brake SW E33 Parking Brake SW 10 ID 1 E17 Steering Sensor 1 H E42(A), E43(B), E44(C), E46(E), E62(G), E63(H) Junction Connector B Y IG CANH 3 CANL GND 2 1 W–B W 2 H 1 C 1 B W 2 C 1 14 IC (Lever Type) 2 IM B W 1 4B W–B 2 4B 1 2 B E49 Junction Connector W–B 3 4D B W BR BR W–B W E2 248 CAMRY (EM0250U) (IG) (BAT) (BAT) 7. 5A GAUGE NO. 2 10A DOME 10A MPX–B V 2 12 IG ∗ 1 : 2GR–FE ∗ 2 : 2AZ–FE 3 1A SB LG GR 1 13 ID 2 3G 12 3L 1 3D R 2 EA1 13 A 1 A B2 F1(A), F2(B) Combination Meter B +B(DOME) IG2 Speedometer ABS VSC IG+ Power Supply Circuit IG2 Brake(Except USA) BRAKE(USA) V 2 A Master Warning GR 12 3Q Slip 9 3Q 1 3Q R 7 IF V DRIVE IC MICRO COMPUTER DRIVE IC IG2 IG2 Buzzer MULTI LCD CAN I/F E2 ES 5 3Q 3 3D 2 3U 10 3D W–B BR 17 A B 15 EA1 BR(∗1) 4 CA3 GR(∗2) W–B 18 B GR BR 7 3Q (∗1) W–B 11 3P GR (∗1) (∗1) W 24 A W 12 A A41(A), A42(B) Junction Connector SI 14 B W CANL 18 A B CANH 17 A 6 AE6 4 CA3 W F1 (∗2) W–B 3 C6 C57 Junction Connector BR C7 249 CAMRY (EM0250U) ABS, TRAC and VSC (TMC Made) System Outline 1. ABS Operation If the brake pedal is depressed suddenly, the ABS controls the hydraulic pressure of the wheel cylinders for all the four wheels to automatically avoid wheel locking and ensure the directional and steering stability of the vehicle. If the brake pedal is depressed suddenly, the skid control ECU controls the solenoids in the actuators using the signals from the sensors to move the brake fluid to the reservoir in order to release the braking pressure applied to the wheel cylinder. If the skid control ECU detects that the fluid pressure in the wheel cylinder is insufficient, the ECU controls the solenoids in the actuators to increase the braking pressure. 2. Traction Control Operation The traction control system controls the engine torque, the hydraulic pressure of the driving wheel cylinders, slipping of the wheels which may occur at start or acceleration of the vehicle, to ensure an optimal driving power and vehicle stability corresponding to the road conditions. 3. VSC Operation Unexpected road conditions, vehicle speed, emergency situation, and any other external factors may cause large under– or over–steering of the vehicle. If this occurs, the VSC system automatically controls the engine power and wheel brakes to reduce the under– or over–steering. To reduce large over–steering : If the VSC system determines that the over–steering is large, it activates the brakes for the outer turning wheels depending on the degree of the over–steering to produce the moment toward the outside of the vehicle and reduce the over–steering. To reduce large under–steering : If the VSC system determines that the under–steering is large, it controls the engine power and activates the rear wheel brakes to reduce the under–steering. 4. Fail Safe Function If an error occurs in the skid control ECU, sensor signals, and/or actuators, the skid control ECU inhibits the brake actuator control and inputs the error signal to the engine control module. According to the error signal, the brake actuator turns off the solenoid and the engine control module rejects any electronically controlled throttle open request from the VSC system. As a result, the vehicle functions regardless of the ABS, TRAC, and VSC systems. : Parts Location Code See Page 48 (2GR–FE) A14 59 A19 59 A 52 (2AZ–FE) C5 C20 C24 48 (2GR–FE) A26 52 (2AZ–FE) 52 (2AZ–FE) B C50 C55 48 (2GR–FE) A35 See Page B 52 (2AZ–FE) A18 A24 Code C1 B C57 E8 C Code See Page 54 (2AZ–FE) E40 B 57 50 (2GR–FE) E41 B 57 54 (2AZ–FE) E42 A 57 55 (2AZ–FE) E43 B 57 55 (2AZ–FE) E44 C 57 51 (2GR–FE) E46 E 57 51 (2GR–FE) E49 57 51 (2GR–FE) E62 G 57 56 E63 H 57 A40 A 59 E10 56 F1 A 58 A41 A 59 E13 56 F2 B 58 A42 B 59 E17 56 f1 61 A55 A 49 (2GR–FE) E31 56 g1 61 A58 A 59 E33 56 C1 A 50 (2GR–FE) E34 57 : Relay Blocks Code 1 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) 250 CAMRY (EM0250U) : Junction Block and Wire Harness Connector Code 1A See Page Junction Block and Wire Harness (Connector Location) 25 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) 36 Instrument Panel No.2 Wire and J/B No.3 (Behind the Combination Meter) 42 Instrument Panel Wire and J/B No.4 (Instrument Panel Brace Center) 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) 3C 3D 3E 3G 3H 3K 3L 3P 3Q 3U 4A 4B 4C 4D IC ID IF IG IH IL IM 30 31 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) 30 : Connector Joining Wire Harness and Wire Harness Code AE2 AE5 AE6 CA2 CA3 See Page Joining Wire Harness and Wire Harness (Connector Location) 66 Engine Room Main Wire and Instrument Panel Wire (Right Side of the Instrument Panel J/B) 66 Engine Room Main Wire and Instrument Panel Wire (Instrument Panel Right) 64 (2GR–FE) 65 (2AZ–FE) 64 (2GR–FE) Engine Wire and Engine Room Main Wire (Inside of the Engine Room R/B and Engine Room J/B) 65 (2AZ–FE) EA1 66 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) FE3 66 Instrument Panel No.2 Wire and Instrument Panel Wire (Instrument Panel Center) NA1 66 Floor Wire and Engine Room Main Wire (Left Kick Panel) OA1 66 Floor No.2 Wire and Engine Room Main Wire (Right Kick Panel) fO1 67 Skid Control Sensor Wire and Floor No.2 Wire (Quarter Wheel House Panel LH) gN1 67 Skid Control Sensor Wire and Floor Wire (Quarter Wheel House Panel RH) : Ground Points Code A4 See Page 64 (2GR–FE) 65 (2AZ–FE) Ground Points Location Near the Skid Control ECU with Actuator A6 66 Right Cowl Side Panel C4 65 (2AZ–FE) Cylinder Block C5 64 (2GR–FE) Right Side of the Cylinder Block C6 65 (2AZ–FE) Cylinder Block C7 64 (2GR–FE) Left Side of the Cylinder Block E2 66 Instrument Panel Brace LH F1 66 Instrument Panel Left 251 CAMRY (EM0250U) ABS, TRAC and VSC (TMMK Made) (BAT) (BAT) 50A ABS No. 1 (IG) 30A ABS No. 2 1 7. 5A ECU IG NO. 2 1 19 IF O L B O 5 3L 5 3C 7 4D 6 4A O 4 3K Buzzer B 1 14 AE6 B L R P 3 A E13 VSC Warning Buzzer 4 B A58(A), E40(B) Junction Connector P 2 2 3 +BM +BS 28 23 IG1 BZ RL+ 9 7 L 2 W B W B BR 1 10 NA1 1 gN1 2 gN1 B 2 1 NA1 R 1 RL– 27 W FR+ A35 Speed Sensor (Front RH) A14 Speed Sensor (Front LH) 2 W–B A6 A4 252 CAMRY (EM0250U) 1 g1 Speed Sensor (Rear LH) FR– 10 L FL– 6 R FL+ 5 W–B W–B 1 P GND2 4 V GND1 LG A60 Skid Control ECU with Actuator (BAT) B W B W 10A STOP 6 14 B W B W 4 B 10 B 2 A 8 A W A19 Stop Lamp SW O 12 B TS 2 A40(A), E41(B) Junction Connector CANL B CANH E10 Data Link Connector 3 8 IC 4 3H 1 W L 4 3E 7 IL O 9 AE2 L 13 IC P O 4 AE6 30 39 STP1 TS 2 fO1 2 CANH 14 35 B W W 1 fO1 B B B 10 OA1 W 1 OA1 CANL 33 W SP1 RR– 8 f1 Speed Sensor (Rear RH) RR+ 29 BR A60 Skid Control ECU with Actuator 1 BR 253 CAMRY (EM0250U) ABS, TRAC and VSC (TMMK Made) B B W W B B W W W(∗2) 1 A A40(A), E41(B) Junction Connector B(∗2) 7 A ∗ 1 : 2GR–FE ∗ 2 : 2AZ–FE W(∗2) W CANH NE+ CANL NE– VTA1 111 B 98 B VCTA 96 B VTA2 99 B ETA 19 B M– 18 B GE01 41 B 1 6 5 VC 4 VTA2 3 E2 R (∗1) G (∗1) (∗1) 2 1 M+ M– (∗1) VTA (Shielded) P (∗1) (∗1) W–L B (∗1) Y (∗1) C50 Crankshaft Position Sensor R (∗1) G (∗1) (∗1) 2 BR M+ 97 B G–R 110 B (Shielded) A55(A), C55(B) Engine Control Module 49 A (∗1) 41 A (∗1) B (∗1) B(∗2) C5 Throttle Body Assembly BR BR C5 254 CAMRY (EM0250U) B B W W B B W W W(∗2) W(∗2) B(∗2) B(∗2) (IG) (IG) R (∗1) 10A GAUGE NO. 1 1 A 7. 5A ECU IG NO. 2 7 A O (∗1) G (∗1) (∗1) L–B P (∗1) (∗1) B–W 14 EA1 24 B 25 B 27 B 26 B P R N D SFTU 16 A SFTD 51 A A55(A), C55(B) Engine Control Module 10 CA2 S 25 A BR O DL 8 A (∗1) NL 2 A 5 3L 5 3C O RL 19 IF (∗1) PL 3 A R 16 IH (∗1) R (∗1) 7 4D Y (∗1) L (∗1) R (∗1) 7 4C (∗1) 10 AE5 20 AE5 O 10 3D 11 AE5 (∗1) C1(A) Park/Neutral Position SW RB Y (∗1) L (∗1) (∗1) G (∗1) 1 SFTU 7 SFTD S E O (∗1) W–B 12 4C (∗1) W–B 4 CA3 IG 3 5 (∗1) GR (∗1) 11 4A E31 Transmission Control SW 17 A 2 BR 18 B 10 3H A41(A), A42(B) Junction Connector BR (∗1) 15 EA1 BR 3 C57 Junction Connector BR C7 255 CAMRY (EM0250U) ABS, TRAC and VSC (TMMK Made) B B W W B B W W W(∗2) R(∗2) (IG) B(∗2) LL 6 B 1 B 9 B 7 B 3 B 8 B 14 EA1 V (∗2) G (∗2) 73 B 53 B 54 B 56 B 26 A 55 B P R N D 3 2 CANL NE+ NE– VTA1 121 B 115 B VCTA 67 B VTA2 114 B A24(A), C24(B) Engine Control Module ETA M+ 91 B 42 B M– 41 B GE01 63 B R (∗2) (∗2) G (∗2) (∗2) (Shielded) P (∗2) W–L (∗2) B Y L (∗2) 6 VTA 5 VC 4 VTA2 3 E2 2 1 M+ M– (∗2) 2 CA3 W–B 2 C20 Crankshaft Position Sensor 1 (∗2) R (∗2) G (∗2) (Shielded) G–R 122 B B SB (∗2) P (∗2) B (∗2) CANH 16 CA2 (∗2) (∗2) W 49 A 11 CA2 (∗2) G 41 A GR 17 CA2 (∗2) B (∗2) GR (∗2) O (∗2) (∗2) V (∗2) R (∗2) G (∗2) 10 CA2 22 AE6 W 2L SB DL (∗2) NL R RL (∗2) 21 AE6 PL L 16 IH (∗2) R (∗2) R RB (∗2) C1(B) Park/Neutral Position SW 2 B (∗2) R (∗2) L(∗2) 10A GAUGE NO. 1 1 CA3 C5 Throttle Body Assembly (∗2) BR B–W BR C4 256 CAMRY (EM0250U) 25 A 74 B 4 L ATL 2 AT4 1 NSSD NSSL Y (∗2) R (∗2) L (∗2) O (∗2) Y (∗2) W B 2 A 1 A 2 G 1 G 2 B 1 B 2 E 1 E W B 13 FE3 B 14 FE3 W E42(A), E43(B), E44(C), E46(E), E62(G), E63(H) Junction Connector O (∗2) E31 Transmission Control SW 5 B 6 W 15 CA2 BR CAMRY (EM0250U) B W BR (∗2) 16 AE5 A24(A), C24(B) Engine Control Module G (∗2) B W B W R(∗2) L(∗2) 19 AE6 B W ∗ 2 : 2AZ–FE B W BR 257 ABS, TRAC and VSC (TMMK Made) E8(C) Main Body ECU CANL 6 C (BAT) CANH 10A ECU–B NO. 1 PKB 5 C (IG) 7. 5A ECU IG NO. 2 19 2 19 IF O O (Pedal Type) L 5 3L 1 IF 5 3C 6 4B O O 7 4B 3 1 1 CANH CANL ESS 10 9 2 W–B IG W BAT E65 Yaw Rate Sensor 9 3H O W 7 4D W 9 3L B A18 Parking Brake SW E33 Parking Brake SW 10 ID 1 E17 Steering Sensor 1 H E42(A), E43(B), E44(C), E46(E), E62(G), E63(H) Junction Connector B Y IG CANH 2 CANL GND 3 4 W–B W 2 H 1 C 1 B W 2 C 1 14 IC (Lever Type) 2 IM B W 1 4B W–B 2 4B 1 2 B E49 Junction Connector W–B 3 4D B W BR BR W–B W E2 258 CAMRY (EM0250U) (IG) (BAT) (BAT) 7. 5A GAUGE NO. 2 10A DOME 10A MPX–B V 2 12 IG ∗ 1 : 2GR–FE ∗ 2 : 2AZ–FE 3 1A SB LG GR 1 13 ID 2 3G 12 3L 1 3D R 2 EA1 13 A 1 A B2 F1(A), F2(B) Combination Meter B +B(DOME) IG2 Speedometer ABS VSC IG+ Power Supply Circuit IG2 Brake(Except USA) BRAKE(USA) V 2 A Master Warning GR 12 3Q Slip 9 3Q 1 3Q R 7 IF V DRIVE IC MICRO COMPUTER DRIVE IC IG2 IG2 Buzzer MULTI LCD CAN I/F E2 ES 5 3Q 3 3D 2 3U 10 3D W–B BR 17 A B 15 EA1 BR(∗1) 4 CA3 GR(∗2) W–B 18 B GR BR 7 3Q (∗1) W–B 11 3P GR (∗1) (∗1) W 24 A W 12 A A41(A), A42(B) Junction Connector SI 14 B W CANL 18 A B CANH 17 A 6 AE6 4 CA3 W F1 (∗2) W–B 3 C6 C57 Junction Connector BR C7 259 CAMRY (EM0250U) ABS, TRAC and VSC (TMMK Made) System Outline 1. ABS Operation If the brake pedal is depressed suddenly, the ABS controls the hydraulic pressure of the wheel cylinders for all the four wheels to automatically avoid wheel locking and ensure the directional and steering stability of the vehicle. If the brake pedal is depressed suddenly, the skid control ECU controls the solenoids in the actuators using the signals from the sensors to move the brake fluid to the reservoir in order to release the braking pressure applied to the wheel cylinder. If the skid control ECU detects that the fluid pressure in the wheel cylinder is insufficient, the ECU controls the solenoids in the actuators to increase the braking pressure. 2. Traction Control Operation The traction control system controls the engine torque, the hydraulic pressure of the driving wheel cylinders, slipping of the wheels which may occur at start or acceleration of the vehicle, to ensure an optimal driving power and vehicle stability corresponding to the road conditions. 3. VSC Operation Unexpected road conditions, vehicle speed, emergency situation, and any other external factors may cause large under– or over–steering of the vehicle. If this occurs, the VSC system automatically controls the engine power and wheel brakes to reduce the under– or over–steering. To reduce large over–steering : If the VSC system determines that the over–steering is large, it activates the brakes for the outer turning wheels depending on the degree of the over–steering to produce the moment toward the outside of the vehicle and reduce the over–steering. To reduce large under–steering : If the VSC system determines that the under–steering is large, it controls the engine power and activates the rear wheel brakes to reduce the under–steering. 4. Fail Safe Function If an error occurs in the skid control ECU, sensor signals, and/or actuators, the skid control ECU inhibits the brake actuator control and inputs the error signal to the engine control module. According to the error signal, the brake actuator turns off the solenoid and the engine control module rejects any electronically controlled throttle open request from the VSC system. As a result, the vehicle functions regardless of the ABS, TRAC, and VSC systems. : Parts Location Code See Page 48 (2GR–FE) A14 59 A19 59 A 52 (2AZ–FE) C5 C20 C24 48 (2GR–FE) A35 52 (2AZ–FE) See Page B 52 (2AZ–FE) A18 A24 Code C1 B C50 C55 Code E41 B 57 50 (2GR–FE) E42 A 57 54 (2AZ–FE) E43 B 57 55 (2AZ–FE) E44 C 57 55 (2AZ–FE) E46 E 57 51 (2GR–FE) B E49 51 (2GR–FE) E62 51 (2GR–FE) E63 57 G 57 H 57 A40 A 59 A41 A 59 A42 B 59 E10 56 F1 A 58 A55 A 49 (2GR–FE) E13 56 F2 B 58 A58 A 59 E17 56 f1 61 49 (2GR–FE) E31 56 g1 61 53 (2AZ–FE) E33 56 A60 C1 A 50 (2GR–FE) C57 See Page 54 (2AZ–FE) E8 C E40 B 56 57 : Relay Blocks Code 1 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) 260 CAMRY (EM0250U) E65 57 : Junction Block and Wire Harness Connector Code 1A See Page Junction Block and Wire Harness (Connector Location) 25 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) 36 Instrument Panel No.2 Wire and J/B No.3 (Behind the Combination Meter) 42 Instrument Panel Wire and J/B No.4 (Instrument Panel Brace Center) 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) 3C 3D 3E 3G 3H 3K 3L 3P 3Q 3U 4A 4B 4C 4D IC ID IF IG IH IL IM 30 31 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) 30 : Connector Joining Wire Harness and Wire Harness Code AE2 AE5 AE6 CA2 CA3 See Page Joining Wire Harness and Wire Harness (Connector Location) 66 Engine Room Main Wire and Instrument Panel Wire (Right Side of the Instrument Panel J/B) 66 Engine Room Main Wire and Instrument Panel Wire (Instrument Panel Right) 64 (2GR–FE) 65 (2AZ–FE) 64 (2GR–FE) Engine Wire and Engine Room Main Wire (Inside of the Engine Room R/B and Engine Room J/B) 65 (2AZ–FE) EA1 66 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) FE3 66 Instrument Panel No.2 Wire and Instrument Panel Wire (Instrument Panel Center) NA1 66 Floor Wire and Engine Room Main Wire (Left Kick Panel) OA1 66 Floor No.2 Wire and Engine Room Main Wire (Right Kick Panel) fO1 67 Skid Control Sensor Wire and Floor No.2 Wire (Quarter Wheel House Panel LH) gN1 67 Skid Control Sensor Wire and Floor Wire (Quarter Wheel House Panel RH) : Ground Points Code A4 See Page 64 (2GR–FE) 65 (2AZ–FE) Ground Points Location Near the Skid Control ECU with Actuator A6 66 Right Cowl Side Panel C4 65 (2AZ–FE) Cylinder Block C5 64 (2GR–FE) Right Side of the Cylinder Block C6 65 (2AZ–FE) Cylinder Block C7 64 (2GR–FE) Left Side of the Cylinder Block E2 66 Instrument Panel Brace LH F1 66 Instrument Panel Left 261 CAMRY (EM0250U) ABS without VSC 50A ABS No. 1 (IG) (BAT) 30A ABS No. 2 W 7. 5A ECU IG NO. 2 10A STOP 19 IF 8 IC 6 14 CANH CANL B TS 5 3L 2 12 4 3H 1 L 4 B W 4 3E 7 IL O 9 AE2 3 A P A58(A), E40(B) Junction Connector L O A19 Stop Lamp SW O 4 3K B E10 Data Link Connector 3 1 O 1 B W (BAT) B (BAT) L 13 IC +BS 18 IG1 O 3 P 2 +BM 4 AE6 20 25 STP TS L A6 A4 262 CAMRY (EM0250U) W 1 fO1 2 fO1 B 2 1 g1 Speed Sensor (Rear LH) 2 gN1 1 gN1 B B 10 OA1 W 1 OA1 BR 10 NA1 R B(∗4) W–B 1 NA1 W 2 RR– 8 2 1 f1 Speed Sensor (Rear RH) P 1 W (∗3) L 2 19 W V 1 RR+ RL– 17 B 7 L RL+ 9 FR+ R FR– 10 (∗3) FL– 6 L FL+ 5 A35 Speed Sensor (Front RH) A14 Speed Sensor (Front LH) W–B W–B 1 B(∗4) GND2 4 W GND1 LG A25 Skid Control ECU with Actuator B B W W B 7 A 10A GAUGE NO. 1 1 A PL RB NL P W B W(∗2) N B(∗2) 3 A 8 A 16 IH R 1 A (IG) (∗1) 8 A B(∗2) C1(A) Park/Neutral Position SW 2 A W(∗2) : 2GR–FE : 2AZ–FE : TMC Made : TMMK Made R 10 B 1 2 3 4 (∗1) W 4 B ∗ ∗ ∗ ∗ A40(A), E41(B) Junction Connector B W O (∗1) (∗1) L–B (∗1) B–W W (∗1) B (∗1) 14 EA1 B W 10 CA2 26 15 CANH CANL 41 A 49 A CANH (∗1) 24 B 27 B P N CANL NE+ 110 B NE– VTA1 111 B 98 B VCTA 96 B VTA2 99 B ETA M+ 19 B 97 B M– 18 B G–R R (∗1) G (∗1) (∗1) (Shielded) P (∗1) (∗1) W–L B (∗1) Y (∗1) C50 Crankshaft Position Sensor R 2 (∗1) G (∗1) (∗1) (Shielded) 23 1 6 BR VTA 5 VC 4 VTA2 3 E2 2 1 M+ M– (∗1) BR GE01 41 B (∗1) SP1 A25 Skid Control ECU with Actuator R A55(A), C55(B) Engine Control Module C5 Throttle Body Assembly BR C5 263 CAMRY (EM0250U) ABS without VSC B B W W B B W W W(∗2) (IG) R (∗2) B(∗2) 10A GAUGE NO. 1 2 B NL 6 B 9 B R O O CANL NE+ NE– SB 54 B P N VTA1 121 B 115 B A24(A), C24(B) Engine Control Module VCTA 67 B VTA2 114 B ETA M+ 91 B 42 B M– 41 B GE01 63 B L R (∗2) G (∗2) (∗2) (Shielded) P (∗2) (∗2) W–L B (∗2) (∗2) 6 VTA 5 VC 4 VTA2 3 E2 2 1 M+ M– (∗2) 2 CA3 W–B 2 C20 Crankshaft Position Sensor 1 (∗2) Y R (∗2) G (∗2) (Shielded) G–R 122 B 73 B (∗2) 49 A CANH (∗2) (∗2) GR W (∗2) B (∗2) 41 A 14 EA1 (∗2) 10 CA2 (∗2) 16 IH (∗2) N R P (∗2) RB C1(B) Park/Neutral Position SW PL 1 CA3 C5 Throttle Body Assembly (∗2) BR B–W BR C4 264 CAMRY (EM0250U) E8(C) Main Body ECU B W 6 C CANH PKB 5 C 19 W W B 2 B 1 B 14 FE3 13 FE3 L (Lever Type) A18 Parking Brake SW B 1 C E33 Parking Brake SW W 2 C 1 14 IC 1 E42(A), E43(B), E44(C), E62(G) Junction Connector B 1 G B 2 G B 1 A W 2 A W W Y 2 IM (Pedal Type) CANL B ∗ 2 : 2AZ–FE B W BR BR 265 CAMRY (EM0250U) ABS without VSC (IG) (BAT) (BAT) 7. 5A GAUGE NO. 2 10A DOME 10A MPX–B V 2 12 IG ∗ 1 : 2GR–FE ∗ 2 : 2AZ–FE 3 1A SB LG GR 1 13 ID 2 3G 12 3L 1 3D R 2 EA1 9 3Q V 12 3Q GR 1 3Q R 7 IF 2 A 13 A 1 A B2 V F1(A), F2(B) Combination Meter B IG+ IG2 Power Supply Circuit Brake(Except USA) BRAKE(USA) Speedometer ABS IG2 DRIVE IC DRIVE IC MICRO COMPUTER IG2 IG2 CAN I/F E2 ES 7 3Q 5 3Q 3 3D 2 3U 10 3D 17 A 18 B W BR BR(∗1) 15 EA1 B GR BR 11 3P GR (∗1) (∗1) W–B 24 A W 12 A A41(A), A42(B) Junction Connector SI 14 B W CANL 18 A B CANH 17 A 4 CA3 GR(∗2) 6 AE6 (∗1) W–B W–B 4 CA3 W 3 F1 266 CAMRY (EM0250U) C6 C7 C57 Junction Connector (∗2) W–B BR System Outline ∗ ABS system This system controls the respective brake fluid pressures acting on the disc brake cylinders of the right front wheel, left front wheel and rear wheels when the brakes are applied in a panic stop so that the wheels do not lock. This results in improved directional stability and steerability during panic braking. ∗ Front and rear braking force distribution system Using the hydraulic controlling device, this system distributes the braking force to the front and rear wheel in appropriately according to the running condition of the vehicle. 1. Input Signals (1) Speed sensor signal The speed of the wheels is detected and input to TERMINALS 5, 7, 10 and 19 of the skid control ECU with actuator. (2) Stop light SW signal A signal is input to TERMINAL 20 of the skid control ECU with actuator when the brake pedal is depressed. 2. System Operation During sudden braking the skid control ECU with actuator has signals input from each sensor, which controls the current to the solenoid inside the actuator and lets the hydraulic pressure acting on each wheel cylinder escape to the reservoir. The pump inside the actuator is also operating at this time and it returns the brake fluid from the reservoir to the master cylinder, thus preventing locking of the vehicle wheels. If the skid control ECU with actuator judges that the hydraulic pressure acting on the wheel cylinder is insufficient, the current on the solenoid is controlled and the hydraulic pressure is increased. Holding of the hydraulic pressure is also controlled by the skid control ECU with actuator, by the same method as above. Pressure reduction, holding and increase are repeated to maintain vehicle stability and to improve steerability during sudden braking. : Parts Location Code See Page A14 52 (2AZ–FE) A58 A 59 A 50 (2GR–FE) E40 B 57 B 54 (2AZ–FE) E41 B 57 50 (2GR–FE) E42 A 57 54 (2AZ–FE) E43 B 57 55 (2AZ–FE) E44 C 57 55 (2AZ–FE) E62 G 57 51 (2GR–FE) F1 A 58 51 (2GR–FE) F2 B 58 59 C1 52 (2AZ–FE) C5 48 (2GR–FE) 52 (2AZ–FE) 48 (2GR–FE) A35 See Page 49 (2GR–FE) A19 A25 Code A 59 A See Page A55 A18 A24 Code 48 (2GR–FE) C20 C24 52 (2AZ–FE) A40 A 59 A41 A 59 A42 B 59 B C50 C55 B C57 E8 C E10 56 E33 56 51 (2GR–FE) f1 61 56 g1 61 : Relay Blocks Code 1 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) 267 CAMRY (EM0250U) ABS without VSC : Junction Block and Wire Harness Connector Code 1A See Page Junction Block and Wire Harness (Connector Location) 25 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) 36 Instrument Panel No.2 Wire and J/B No.3 (Behind the Combination Meter) 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) 3D 3E 3G 3H 3K 3L 3P 3Q 3U IC ID IF IG IH IL IM 30 31 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) 30 : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) AE2 66 Engine Room Main Wire and Instrument Panel Wire (Right Side of the Instrument Panel J/B) AE6 66 Engine Room Main Wire and Instrument Panel Wire (Instrument Panel Right) CA2 CA3 64 (2GR–FE) 65 (2AZ–FE) 64 (2GR–FE) Engine Wire and Engine Room Main Wire (Inside of the Engine Room R/B and Engine Room J/B) 65 (2AZ–FE) EA1 66 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) FE3 66 Instrument Panel No.2 Wire and Instrument Panel Wire (Instrument Panel Center) NA1 66 Floor Wire and Engine Room Main Wire (Left Kick Panel) OA1 66 Floor No.2 Wire and Engine Room Main Wire (Right Kick Panel) fO1 67 Skid Control Sensor Wire and Floor No.2 Wire (Quarter Wheel House Panel LH) gN1 67 Skid Control Sensor Wire and Floor Wire (Quarter Wheel House Panel RH) : Ground Points Code A4 See Page 64 (2GR–FE) 65 (2AZ–FE) Ground Points Location Near the Skid Control ECU with Actuator A6 66 Right Cowl Side Panel C4 65 (2AZ–FE) Cylinder Block C5 64 (2GR–FE) Right Side of the Cylinder Block C6 65 (2AZ–FE) Cylinder Block C7 64 (2GR–FE) Left Side of the Cylinder Block F1 66 Instrument Panel Left 268 CAMRY (EM0250U) Memo 269 CAMRY (EM0250U) Tire Pressure Warning System (IG) 10A ECU IG NO. 1 B 11 IF V 10 3L V B 12 3N E60 Tire Pressure Warning ECU 7 2 IG CLSW IND GR L 1 3O 6 3O 8 3C 3 3O 1 3N 3 3C 5 3H 7 3L 11 3Q L 5 GR LG G BR 1 10 P 6 EN2 SIL 3 P 5 EN2 TC 9 W–B LG 4 EN2 GND W–B G 1 BR 6 W–B RF5V E53 Tire Pressure Warning SW (Reset) RDA 12 O GND2 11 SPD 1 5 GND RDA +5V N34 Tire Pressure Warning Antenna and Receiver 3 IF 9 E49 Junction Connector 4 W–B 2 12 IM P GR W–B 2 13 7 TC E10 Data Link Connector 3 E2 270 CAMRY (EM0250U) SIL L (BAT) (BAT) ∗ ∗ ∗ ∗ ∗ 10A MPX–B 10A DOME 7. 5A GAUGE NO. 2 (IG) 2 1 : 2GR–FE : 2AZ–FE : w/ VSC TMC Made : w/ VSC TMMK Made : w/o VSC 3 1A Speed Sensors SB 12 IG LG V 1 2 3 4 5 13 ID 9 3Q L R L B 17 A 9 B 9 C 20 A 7 B 7 C 6 A 27 B 17 C 5 A 29 B 19 C W P 3 A 10 B 10 C FL+ FL– FR+ FR– RL+ RR+ RR– SP1 12 A (∗3) 33 B (∗4) 23 C (∗5) 1 A IG+ RL– 19 A (∗3) 8 B (∗4) 8 C (∗5) B IG2 Tire Pressure Power Supply Circuit BR B2 IG2 4 A 6 B 6 C Speedometer +S 12 3Q 13 A 2 A 12 B V A25(C), A26(A), A60(B) Skid Control ECU with Actuator 1 3Q 1 3D V V 3 3P 2 3G GR 12 3L R 10 3O 18 A 5 B 5 C V R V 7 IF LG GR 2 EA1 MICRO COMPUTER 6 AE6 ES SI 24 A 7 3Q 5 3Q 14 B W W BR L E2 12 A W–B TIRE 7 A F1(A), F2(B) Combination Meter IG2 11 3P GR 15 EA1 W GR BR(∗1) 4 CA3 GR(∗2) W–B 18 B 3 3D (∗1) BR 17 A L (∗1) 10 3D A41(A), A42(B) Junction Connector 2 3U W–B (∗1) F1 (∗2) W–B 3 C6 C57 Junction Connector 4 CA3 C7 271 CAMRY (EM0250U) Tire Pressure Warning System : Parts Location Code A25 See Page 48 (2GR–FE) C Code A60 52 (2AZ–FE) See Page B Code 49 (2GR–FE) See Page E60 57 53 (2AZ–FE) F1 A 58 48 (2GR–FE) C57 51 (2GR–FE) F2 B 58 52 (2AZ–FE) E10 56 A26 A A41 A 59 E49 57 A42 B 59 E53 57 N34 60 : Relay Blocks Code 1 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1A See Page Junction Block and Wire Harness (Connector Location) 25 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) 36 Instrument Panel No.2 Wire and J/B No.3 (Behind the Combination Meter) ID 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) IF 30 IG 31 IM 30 3C 3D 3G 3H 3L 3N 3O 3P 3Q 3U Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) : Connector Joining Wire Harness and Wire Harness Code AE6 CA3 See Page 66 Joining Wire Harness and Wire Harness (Connector Location) Engine Room Main Wire and Instrument Panel Wire (Instrument Panel Right) 64 (2GR–FE) 65 (2AZ–FE) Engine Wire and Engine Room Main Wire (Inside of the Engine Room R/B and Engine Room J/B) EA1 66 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) EN2 66 Instrument Panel Wire and Floor Wire (Left Kick Panel) : Ground Points Code See Page Ground Points Location C6 65 (2AZ–FE) Cylinder Block C7 64 (2GR–FE) Left Side of the Cylinder Block E2 66 Instrument Panel Brace LH F1 66 Instrument Panel Left 272 CAMRY (EM0250U) SRS NOTICE: When inspecting or repairing the SRS, perform service in accordance with the following precautionary instructions and the procedure, and precautions in the Repair Manual applicable for the model year. D Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most important source of information when troubleshooting. When troubleshooting the SRS, always inspect the DTCs before disconnecting the battery. D Work must be started more than 90 seconds after the ignition SW is turned to the ”LOCK” position (Ignition SW type) or the power SW is pushed to the ”OFF” position (Power SW type) and the negative (–) terminal cable is disconnected from the battery. (The SRS is equipped with a back–up power source so that if work is started within 90 seconds from disconnecting the negative (–) terminal cable of the battery, the SRS may deploy.) D When the negative (–) terminal cable is disconnected from the battery, the memory of the clock and audio system will be cleared. So before starting work, make a record of the contents in the audio memory system. When work is finished, reset the audio systems as they were before and adjust the clock. Some vehicles have power tilt steering, power telescopic steering, power seat and power outside rear view mirror which are all equipped with memory function. However, it is not possible to make a record of these memory contents. So when the work is finished, it will be necessary to explain it to your customer, and ask the customer to adjust the features and reset the memory. To avoid erasing the memory in each system, never use a back–up power supply from outside the vehicle. D Before repair, remove the airbag sensor if shocks are likely to be applied to the sensor during repair. D Do not expose the following parts directly to hot air or flame; D Even in cases of a minor collision where the SRS does not deploy, the following parts should be inspected; D Never use SRS parts from another vehicle. When replacing parts, replace with new parts. D For the purpose of reuse, never disassemble and repair the following parts. D If the following parts have been dropped, or have cracks, dents and other defects in their case, bracket, and connector, replace with new one. D Use a volt/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting electrical circuits of the system. D Information labels are attached to the periphery of the SRS components. Follow the instructions of the notice. D After work on the SRS is completed, check the SRS warning light. D If the vehicle is equipped with a mobile communication system, refer to the precaution in the IN section of the Repair Manual. ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ Steering wheel pad Front passenger airbag assembly Side airbag assembly Curtain shield airbag assembly Knee airbag assembly Seat belt pretensioner Center airbag sensor assembly Front airbag sensor assembly Side airbag sensor assembly Rear airbag sensor assembly 273 CAMRY (EM0250U) SRS (BAT) (BAT) (IG) 7. 5A GAUGE NO. 2 10A DOME 10A MPX–B V 2 12 IG 3 1A ∗ 1 : 2GR–FE ∗ 2 : 2AZ–FE SB LG GR 1 13 ID 12 3L 2 3G 1 3D R 2 EA1 9 3Q 12 3Q V GR 1 3Q R 7 IF 13 A 2 A V B2 1 A B IG+ IG2 SRS Power Supply Circuit MICRO COMPUTER F1(A) Combination Meter DRIVE IC CAN I/F E2 BR 15 EA1 B BR(∗1) 4 CA3 GR(∗2) W–B 10 3D W–B 18 B 2 3U W (∗1) 17 A (∗1) 5 3Q (∗2) W–B 3 C6 C57 Junction Connector 4 CA3 F1 CANL 18 A GR (∗1) GR BR 7 3Q CANH 17 A A41(A), A42(B) Junction Connector 24 A W–B ES 12 A C7 274 CAMRY (EM0250U) E10 Data Link Connector 3 CANL CANH SIL 6 7 GR 14 E54 Airbag Squib (Knee Airbag) W Y Y–B 16 A 9 A 10 A DK– W 8 3C DK+ E30(A), N1(B), O1(C) Airbag Sensor Assembly Center CANH CANL 13 A 22 A B GR 13 FE3 B 14 FE3 GR 7 3L B 1 D B W 2 D W 1 B DK– 2 10 IE SIL W 2 B 1 G E43(B), E45(D), E62(G) Junction Connector 3 IF 2 G DK+ 1 B W 12 IM W B GR 275 CAMRY (EM0250U) SRS ∗ 3 : w/ Power Seat ∗ 4 : w/o Power Seat Z1 Side Airbag Squib (LH) L+ R+ L– 1 2 1 2 1 2 Y–B Y Y–B O8 Pretensioner (RH) Y N8 Pretensioner (LH) Y1 Side Airbag Squib (RH) N21 Curtain Shield Airbag Squib (LH) ICL+ R– 1 2 ICR– 1 2 Y–B Y Y–B Y Y–B Y Y Y–B Y Y–B 2 OY2 Y 1 OY2 2 Y–B 2 NZ2 ICR+ ICL– 1 1 NZ2 O16 Curtain Shield Airbag Squib (RH) 2 B 1 B 4 C 5 C 9 B 10 B 7 C 6 C 7 B 6 B 9 C 10 C PD+ PD– PP+ PP– SFD+ SFD– SFP+ SFP– ICD+ ICD– ICP+ ICP– –SL +SR –SR W B 3 AE4 4 AE4 2 AE4 1 AE4 1 B 2 B 1 A 2 A B R 4 Ec1 W G 27 A Y–G 29 A Y–R 28 A 3 Ec1 2 1 2 1 +SL –SL +SR –SR 3 D2+ D2– P+ E16 Airbag Squib (Steering Wheel Pad) +SL 30 A R 2 Ec1 P2– 2 A G Y 1 Ec1 P2+ 1 A Y–G 4 Spiral Cable 3 A Y–R D– D2– Y–P 2 D+ P– 4 A Y–B Y 1 P+ 7 A Y–GR D2+ 8 A Y–R D– 6 A Y–B D+ 5 A Y–G E30(A), N1(B), O1(C) Airbag Sensor Assembly Center P– P2+ P2– c1(A), c2(B) Airbag Squib (Front Passenger' s Airbag Assembly) GR A13 Airbag Sensor (Front LH) A28 Airbag Sensor (Front RH) GR 276 CAMRY (EM0250U) (IG) 10A IGN 2 IH B 9 IE 5 3R 8 3E 9 3D B 6 3R BBD+ 17 A 23 A P–AB 21 A IG2 PAON FSP+ FSR+ E30(A), N1(B), O1(C) Airbag Sensor Assembly Center 3 IM 10 IF DBE– 12 B 1 BCR– 1 2 Y (∗3) (∗4) FSR– DSP– 13 B B 2 4 LBE– LSP+ LSP– 2 1 BCR+ BCR– 10 W–B 2 E49 Junction Connector W–B G BCR+ 3 LBE+ DSP+ 14 B W 1 IE DBE+ 11 B R 5 IE 4 A (∗3) 4 C (∗4) O4(C), T10(A), T11(B), d1(D) Occupant Classification ECU G W–B R 3 BBR– E1 25 A W–B G 4 BBR+ E2 26 A W–B O9 Side Airbag Sensor (Rear RH) BBP– 11 C R O7 Side Airbag Sensor (Front RH) BBP+ 8 C B L 8 A 8 C 12 C FSP– (∗3) W (∗4) W B 13 C (∗3) W BBD– B 15 B R R 8 B (∗4) 4 IE 4 OT1 B 6 IE (∗4) 3 12 IH B BBL– 4 10 IH (∗3) BBL+ 1 OT1 B 2 BCL– R 1 BCL+ G N7 Side Airbag Sensor (Front LH) B 1 R BCL– 2 PAON 13 G BCL+ P–AB 14 (∗3) AIRBAG ON/OFF Indicator R N12 Side Airbag Sensor (Rear LH) F3 Clock Buckle SW Seat Position Airbag Sensor N3 Front Seat Inner Belt (Driver' s Side) GR GR W–B E3 E1 E2 277 CAMRY (EM0250U) SRS (BAT) ∗ 3 : w/ Power Seat ∗ 4 : w/o Power Seat 10A ECU–B NO. 1 B 2 W 1 W O LG (∗4) LG (∗3) BR 3 EO2 (∗3) BR (∗4) 2 EO2 10 3C 10 ID 9 3L 1 IF T14(A), d2(B) Occupant Classification Sensor (Front LH) T16(A), d4(B) Occupant Classification Sensor (Front RH) W SVC1 SIG1 SGD2 3 A (∗3) 3 B (∗4) O 7 B 7 D SIG2 2 A 2 B L +B 11 B 11 D SVC2 1 A 1 B W IG SGD1 3 A (∗3) 3 B (∗4) G 1 A 1 C P(∗3) 7 A 7 C R W (∗3) BR 5 OT1 (∗3) 6 OT1 SIG1 2 A 2 B SB(∗4) SVC1 1 A 1 B 1 B 1 D 12 B 12 D 8 B 8 D 2 B (∗3) 2 D (∗4) SGD1 SVC2 SIG2 SGD2 O4(C), T10(A), T11(B), d1(D) Occupant Classification ECU 1 A (∗3) 1 B (∗4) SGD3 SVC4 1 A 1 B 2 A 2 B 3 A (∗3) 3 B (∗4) 1 A 1 B 2 A 2 B SVC3 SIG3 SGD3 SVC4 SGD4 4 B (∗3) 4 D (∗4) SIG4 10 B 10 D B(∗3) 6 B 6 D V 3 B 3 D SIG4 (∗4) (∗3) T15(A), d3(B) Occupant Classification Sensor (Rear LH) 10 EO2 GR 4 EO2 W–B W–B (∗3) W–B Buckle SW 3 O1 O3(B), T7(A) Front Seat Inner Belt (Front Passenger' s Side) O21 Junction Connector GR E3 278 CAMRY (EM0250U) T17(A), d5(B) Occupant Classification Sensor (Rear RH) BR SIG3 9 B 9 D R(∗4) SVC3 5 B 5 D W GR B 2 A 2 B (∗3) P(∗4) (∗3) 5 A O20(A), T18(B) Junction Connector W–B GR 3 B O 5 A 5 C (∗3) 2 OT1 (∗3) O(∗4) BGND BSW 9 A 9 C Y GND 3 A 3 C GR DIA 2 A 2 C 3 A (∗3) 3 B (∗4) SGD4 System Outline ∗ The system reaches an ignition judgment to deploy the following device based on the signals received from the front airbag sensor and deceleration sensor. – Driver Airbag – Front Passenger Airbag – Knee Airbag – Seat Belt Pretensioner ∗ The system reaches an ignition judgment to deploy the following device based on the signals received from the side airbag sensors. – Side Airbags – Curtain Shield Airbags ∗ The dual–stage SRS airbag system has been used for the driver and front passenger airbags. This system controls the optimal airbag inflation by judging the extent of impact, seat position (driver seat) and whether or not the seat belt is fastened(driver seat) and infomation from the Front Passenger Occupant Classification System. ∗ The front passenger occupant classification system judges whether the front passenger seat is occupied by an adult or child (with child seat) or is unoccupied, according to the load applied to the front passenger seat and whether the seat belt is buckled. Based on the results, it restricts the deployment of the front passenger airbag, front passenger side airbag, and front passenger seat belt pretensioner. In addition, the system informs the driver of the result of the judgment through the use of the AIRBAG ON/OFF indicator lights. : Parts Location Code See Page Code 48 (2GR–FE) A13 N3 52 (2AZ–FE) A28 See Page Code See Page 62 (*1) T14 A 62 (*1) 63 (*2) T15 A 62 (*1) 48 (2GR–FE) N7 60 T16 A 62 (*1) 52 (2AZ–FE) N8 60 T17 A 62 (*1) T18 B 62 (*1) A41 A 59 N12 60 A42 B 59 N21 60 C57 51 (2GR–FE) O1 C 59 E10 56 O3 B 63 (*2) E16 56 O4 C 63 (*2) 62 (*1) Y1 63 (*2) 62 (*1) Z1 63 (*2) E30 A 56 O7 60 c1 A 59 E43 B 57 O8 60 c2 B 59 E45 D 57 O9 60 d1 D 63 (*2) 60 d2 B 63 (*2) 62 (*1) d3 B 63 (*2) 60 d4 B 63 (*2) d5 B 63 (*2) E49 57 E54 57 O16 O20 A E62 G 57 F1 A 58 T7 A 62 (*1) 58 T10 A 62 (*1) 59 T11 B 62 (*1) F3 N1 B O21 : Relay Blocks Code 1 See Page 22 * 1 : w/ Power Seat Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) * 2 : w/o Power Seat 279 CAMRY (EM0250U) SRS : Junction Block and Wire Harness Connector Code 1A See Page Junction Block and Wire Harness (Connector Location) 25 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) 36 Instrument Panel No.2 Wire and J/B No.3 (Behind the Combination Meter) 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) 3C 3D 3E 3G 3L 3Q 3R 3U ID IE IF IG IH IM 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) 31 30 : Connector Joining Wire Harness and Wire Harness Code AE4 CA3 See Page 66 Joining Wire Harness and Wire Harness (Connector Location) Engine Room Main Wire and Instrument Panel Wire (Instrument Panel Right) 64 (2GR–FE) 65 (2AZ–FE) Engine Wire and Engine Room Main Wire (Inside of the Engine Room R/B and Engine Room J/B) EA1 66 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) EO2 66 Instrument Panel Wire and Floor No.2 Wire (Right Kick Panel) Ec1 66 Instrument Panel Wire and Instrument Panel Wire Assembly (Behind The Glove Box) FE3 66 Instrument Panel No.2 Wire and Instrument Panel Wire (Instrument Panel Center) NZ2 OT1 OY2 68 (*1) Floor Wire and Front Seat Airbag Assembly LH (Under the Driver’s Seat) 69 (*2) 68 (*1) Floor No.2 Wire and Front Seat RH Wire (Under the Front Passenger’s Seat) 68 (*1) Floor No.2 Wire and Front Seat Airbag Assembly RH (Under the Front Passenger’s Seat) 69 (*2) : Ground Points Code See Page Ground Points Location C6 65 (2AZ–FE) Cylinder Block C7 64 (2GR–FE) Left Side of the Cylinder Block E1 66 Instrument Panel Left E2 66 Instrument Panel Brace LH E3 66 Instrument Panel Right F1 66 Instrument Panel Left O1 67 Right Rear Quarter Panel * 1 : w/ Power Seat * 2 : w/o Power Seat 280 CAMRY (EM0250U) Memo 281 CAMRY (EM0250U) Cruise Control for 2GR–FE L (BAT) 30A EFI MAIN 2 C5 Throttle Body Assembly M– 5 4 3 2 1 B W–L P G R VTA 7 1E M+ 6 Y L Y 1 VC VTA2 E2 1 (Shielded) C4 Engine Coolant Temp. Sensor 12 1E EFI Relay B P 96 B VCTA O BR VTA1 BR 41 B 79 B 78 B 9 1E 98 B B G–R 6 1E 10 1E 11 1E 2 99 B VTA2 97 B ETA 19 B 18 B M+ M– GE01 THW ETHW A55(A), C55(B) Engine Control Module EPA VPA VPA2 59 A 55 A 56 A R VCPA 57 A O EPA2 60 A L VCP2 58 A R +B2 1 A R +B 2 A O MREL 44 A 1 B Y G 1 1 2 4 5 6 3 VCP2 EPA2 VCPA EPA VPA VPA2 15A EFI NO. 2 2 R R 1 A3 W–B W–B BR BR A17 Accelerator Position Sensor A1 282 CAMRY (EM0250U) L L BR (BAT) (BAT) 10A EFI NO. 1 2 10A STOP BR 2 1A 10A IGN 8 IC B 3 A 1 4 12 3F 12 3K L 4 A 6 B Y 8 B 2 A A58(A), E40(B) Junction Connector B L 3 A19 Stop Lamp SW 9 A 2 A41(A), A42(B) Junction Connector 8 A Y A41(A), A42(B) Junction Connector W LG 4 B 1 ID 9 IG Y 1 (IG) (BAT) Y 10A ETCS LG W GR 3 A Y LG 20 A 36 A 35 A +BM BATT 28 A ST1– STP IGSW A55(A), C55(B) Engine Control Module E04 23 B E01 22 B E03 104 B ME01 20 B E02 21 B E05 46 B E1 CCS 81 B 40 A BR W W–B W B–W B B W–B W BR 17 AE5 ECC CCS 18 B 3 C R 4 C 17 A A41(A), A42(B) Junction Connector BR GR 1 A 2 A B E18(A), b1(C) Spiral Cable BR 15 EA1 GR ON–OFF C4 C7 –SET 3 CANCEL C57 Junction Connector 5 4 CA3 W–B W–B 6 b1(C) Cruise Control SW W 4 C57 Junction Connector B–W B B W–B W +RES C7 283 CAMRY (EM0250U) Cruise Control for 2GR–FE L L BR BR LG LG V P W P B B W 5 3H 5 3B P B–W P L–B 12 AE5 27 A 8 A 49 A TC SPD 41 A CANL G L–B P V B–W P G 24 B 25 B 27 B 26 B P R N D CANH A55(A), C55(B) Engine Control Module 1 B Y Y CAN– 2 B B CAN+ S 25 A L SFTD 51 A R SFTU 16 A BR 10 AE5 20 AE5 11 AE5 G L Y 7. 5A ECU IG NO. 2 11 3A 2 1 7 SFTD 19 IF S BR SFTU 11 4A 5 3 O 12 4C IG W–B E Y O 10 3H E31 Transmission Control SW 10 3D (IG) BR BR B 5 3L 5 3C 7 4C 7 4D O 284 CAMRY (EM0250U) L L BR BR LG LG V V P P W W B B R (IG) 1 A 3 3P 10A GAUGE NO. 1 RB V C1(A) Park/Neutral Position SW 10 3B PL RL NL DL 3 A 2 A 8 A 7 A V 16 IH P R G 14 AE5 V P L–B P B–W 5 A 6 A G O G G 7 A A41(A) Junction Connector 14 EA1 L–B R W 10 CA2 19 CA2 15 BR R 16 R 3 SPD1 D SL2+ SL2– SL3+ SL3– SL4+ SL4– SLU+ SLU– B L B G B W B 1 SL1– O 2 SL1+ B E01 R 9 B E1 BR 8 BR 6 B–W CAN+ 7 B–W CAN– Y C56 Transmission Control ECU Y B C57 Junction Connector C7 285 CAMRY (EM0250U) Cruise Control for 2GR–FE L BR LG V V P P W W B B (IG) 10A IGN Y 9 IG Y W–L W 1 18 12 STP BATT 6 CA2 L–B L 11 CA2 4 AE5 Y BR 9 CA3 12 3J Y LG 9 CA2 B 12 3F 13 +B IG2 BR NCB NCO CAMRY (EM0250U) NTO NCB NCO NTB NTO HALL SENSOR 286 NTB R O E2 W THO1 B TPS3 Y TPS2 Y TPS1 GR B SL W SLT– L SLT+ GR C56 Transmission Control ECU HALL SENSOR V V P W B P L R L B 4 A 6 B 6 C 3 A 10 B 10 C 17 A 9 B 9 C 20 A 7 B 7 C 6 A 27 B 17 C 5 A 29 B 19 C FL– FR+ FR– RL+ RL– RR+ TC 19 A (∗1) 8 B (∗2) 8 C (∗3) CANL RR– 14 SP1 12 A (∗1) 33 B (∗2) 23 C (∗3) 2 G 1 G 2 B 1 B W B 14 FE3 13 FE3 W B 10 B 1 A B 4 B 2 A W 8 A 6 AE6 W W 2 A A40(A), E41(B) Junction Connector 7 A W W 1 A B B B BR 25 A 14 B 15 C B CANL 6 W CANH 11 A 35 B 26 C CANH E42(A), E43(B), E62(G) Junction Connector FL+ 13 E10 Data Link Connector 3 V 18 A 5 B 5 C W LG A25(C), A26(A), A60(B) Skid Control ECU with Actuator P Speed Sensors B ∗ 1 : w/ VSC TMC Made ∗ 2 : w/ VSC TMMK Made ∗ 3 : w/o VSC W W 287 CAMRY (EM0250U) Cruise Control for 2GR–FE (IG) (BAT) (BAT) 7. 5A GAUGE NO. 2 10A DOME 10A MPX–B 3 1A 12 IG 1 LG R 1 3D R V 2 3G 12 3L 7 IF 1 3Q 13 ID V GR SB GR V 2 EA1 12 3Q IG2 R +S V 12 B GR V 9 3Q 13 A 1 A 2 A IG+ B B2 Power Supply Circuit Cruise Speedometer IG2 MICRO COMPUTER DRIVE IC CAN I/F ES E2 24 A 11 3P 7 3Q 5 3Q GR 17 A 10 3D 18 B BR BR 2 3U W–B W 3 3D B GR BR 12 A W–B 14 B W 18 A A41(A), A42(B) Junction Connector SI CANL 17 A W CANH B F1(A), F2(B) Combination Meter IG2 W 3 F1 288 CAMRY (EM0250U) C7 C57 Junction Connector 4 CA3 W–B 15 EA1 W System Outline The cruise control system is a constant vehicle speed controller which controls the opening angle of the engine throttle valve by the SW, and allows driving at a constant speed without depressing the accelerator pedal. Set Operation When the ON–OFF SW is turned on, the systems starts preparations for cruise control and turns on the indicator light in the combination meter. Set Speed Control When the – SET SW is operated with the ON–OFF SW turned on during driving, the speed is controlled at a constant speed. Coast Control When the – SET SW is kept turned on during cruise control driving, the engine control module controls the throttle valve to decelerate the vehicle speed. Every time the – SET SW is turned on instantaneously, the vehicle speed is decelerated by approx. 1.6 km/h. Accel Control When the + RES SW is kept turned on during cruise control driving, the engine control module controls the throttle valve to accelerate the vehicle speed. Every time the + RES SW is turned on instantaneously, the vehicle speed is accelerated by approx. 1.6 km/h. Resume Control If the vehicle speed is within the low speed limit (Approx. 40 km/h, 25 mph) when canceling the cruise control, operation of the + RES SW accelerates the vehicle speed and resumes the level before canceling the cruise control. Manual Cancel Mechanism If any one of the following signals is input during cruise control driving, the cruise control is canceled. ∗ The stop light SW is on ∗ The CANCEL SW is turned on ∗ The ON–OFF SW is turned off ∗ When switching from ON to OFF of ”D” position circuit in neutral start switch. When the transmission is shifted from ”D” to ”N”. When the transmission is shifted from 5, 4 to 3, 2, 1 in S mode. Auto Cancel Function If any of the following conditions are detected, the cruise control is canceled: ∗ Failure in the stop light SW wiring ∗ Abnormality in the vehicle speed signal ∗ Malfunction in the electronically controlled throttle parts ∗ When the vehicle speed gets slower than the low speed limit. ∗ When the vehicle speed falls to 16 km/h less than the set speed. Overdrive Function The overdrive may be canceled if the vehicle travels on a upward slope during cruise control driving. When the throttle opening information indicates the hill climbing is finished after the overdrive is canceled, the vehicle returns to overdrive mode again as the overdrive return timer is completed. : Parts Location Code See Page A17 A19 Code 59 A60 59 C1 See Page Code See Page B 49 (2GR–FE) A 50 (2GR–FE) E40 B 57 50 (2GR–FE) E41 B 57 50 (2GR–FE) E42 A 57 51 (2GR–FE) E43 B 57 C4 E31 56 A25 C 48 (2GR–FE) A26 A 48 (2GR–FE) A40 A 59 A41 A 59 C56 51 (2GR–FE) E62 G 57 A42 B 59 C57 51 (2GR–FE) F1 A 58 A55 A 49 (2GR–FE) E10 56 F2 B 58 A58 A 59 56 b1 C 59 C5 C55 E18 B A : Relay Blocks Code 1 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) 289 CAMRY (EM0250U) Cruise Control for 2GR–FE : Junction Block and Wire Harness Connector Code 1A 1E See Page Junction Block and Wire Harness (Connector Location) 25 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) 36 Instrument Panel No.2 Wire and J/B No.3 (Behind the Combination Meter) 42 Instrument Panel Wire and J/B No.4 (Instrument Panel Brace Center) 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) 3A 3B 3C 3D 3F 3G 3H 3J 3K 3L 3P 3Q 3U 4A 4C 4D IC ID IF IG IH 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) 31 : Connector Joining Wire Harness and Wire Harness Code AE5 See Page Joining Wire Harness and Wire Harness (Connector Location) 66 Engine Room Main Wire and Instrument Panel Wire (Instrument Panel Right) 64 (2GR–FE) Engine Wire and Engine Room Main Wire (Inside of the Engine Room R/B and Engine Room J/B) EA1 66 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) FE3 66 Instrument Panel No.2 Wire and Instrument Panel Wire (Instrument Panel Center) AE6 CA2 CA3 : Ground Points Code See Page Ground Points Location A1 64 (2GR–FE) Front Left Fender A3 66 Left Cowl Side Panel C4 64 (2GR–FE) Cylinder Head C7 64 (2GR–FE) Left Side of the Cylinder Block F1 66 Instrument Panel Left 290 CAMRY (EM0250U) Memo 291 CAMRY (EM0250U) Cruise Control for 2AZ–FE (BAT) (BAT) (BAT) 30A EFI MAIN 10A EFI NO. 1 10A ETCS 2 2 1 1 2 1A W Y A17 Accelerator Position Sensor 12 1E 8 A 9 A VCP2 VPA2 EPA2 VCPA VPA EPA 1 3 2 4 6 5 L R O B G Y 3 A 20 A 58 A 56 A 60 A 57 A 55 A 59 A 9 1E O BR 10 1E BR B 6 1E 11 1E Y EFI Relay LG A41(A) Junction Connector BATT +BM VCP2 VPA2 EPA2 VCPA VPA EC 32 A EOM 9 A W +B2 1 A W–B W–B 2 +B 2 A R 16 B 15A EFI NO. 2 MREL 44 A R 1 O 17 A 1 A41(A), A42(B) Junction Connector A24(A), C24(B) Engine Control Module 18 A 16 A W–B W–B W–B W–B BR 16 B A1 A3 A3 292 CAMRY (EM0250U) A41(A), A42(B) Junction Connector R R 1 EPA (IG) (IG) 7. 5A ECU IG NO. 2 10A IGN 8 IC P 19 IF 5 3L 19 B 12 A 35 A W (M/T) 8 CA3 G BR GR W STP A58(A), E40(B) Junction Connector O 4 (M/T) 4 3K (M/T) 12 3K 4 B 36 A 1 2 4 A 1 A41(A), A42(B) Junction Connector O (M/T) 12 3F Y 6 B (M/T) Y 2 A 1 ID Y A58(A), E40(B) Junction Connector B 3 Y B 2 A19 Stop Lamp SW B 9 IG A21 Cruise Control Clutch SW 10A STOP (M/T) (BAT) O G (M/T) (M/T) 28 A ST1– IGSW A24(A), C24(B) Engine Control Module E1 W W–B CCS 104 B 40 A W 45 B B E01 46 B W–B E04 E03 86 B B ME01 43 B B–W E02 44 B 15 EA1 4 C 3 C ON–OFF GR +RES W–B B b1(C) Cruise Control SW W–B B B–W CCS 4 CA3 W–B C4 1 A ECC B BR 10 3D 2 A R 11 3A E18(A), b1(C) Spiral Cable BR GR BR 17 AE5 –SET CANCEL C6 293 CAMRY (EM0250U) Cruise Control for 2AZ–FE (IG) 10A GAUGE NO. 1 R L R 16 IH O C1(B) Park/Neutral Position SW R 2 B Y L 21 AE6 22 AE6 LL 6 B 1 B 9 B 7 B 3 B 8 B G R V 10 CA2 14 EA1 11 CA2 16 CA2 16 AE5 15 CA2 O GR 17 CA2 G V G G (A/T) B G BR B P 19 AE6 Y 2L O DL W NL SB RL GR PL SB R R RB (M/T) 73 B 53 B 54 B 56 B 26 A 55 B 25 A 74 B P R N D 3 2 4 L A24(A), C24(B) Engine Control Module ETHO 4 11 3 2 8 10 5 12 6 13 1 7 SL3+ SL3– S4 SLT+ SLT– DSL SL2+ SL2– SL1+ SL1– THO E2 BR W B O O G 9 SR LG BR 95 B SB LG THO1 72 B Y SL1– 77 B GR R SL1+ 57 B L SL2– 59 B Y BR SL2+ 58 B G DSL 79 B L L SLT– 75 B W SLT+ 76 B R Y S4 78 B GR SL3– 61 B V G SL3+ 60 B O SR 80 B C25 Electronically Controlled Transmission Solenoid 294 CAMRY (EM0250U) V B W B W 6 14 CANH L CANL O TC Y E10 Data Link Connector 3 R P 13 5 3B 8 A 27 A SPD TC B 12 AE5 B W 14 AE5 P P W V NSSL L 5 NSSD E31 Transmission Control SW R 1 49 A 41 A CANL CANH A24(A), C24(B) Engine Control Module VTA1 VCTA 67 B VTA2 114 B ETA M+ 91 B M– 42 B 41 B GE01 63 B 3 VTA2 E2 R 4 VC G 5 VTA (Shielded) 6 P G–R 115 B W–L AT4 B 2 ATL Y 6 L Y O 5 3H 2 1 M+ M– C5 Throttle Body Assembly 295 CAMRY (EM0250U) Cruise Control for 2AZ–FE V V B W ∗ 1 : w/ VSC TMC Made ∗ 2 : w/ VSC TMMK Made ∗ 3 : w/o VSC L R L B 18 A 5 B 5 C 4 A 6 B 6 C 3 A 10 B 10 C 17 A 9 B 9 C 20 A 7 B 7 C 6 A 27 B 17 C 5 A 29 B 19 C FR+ RL+ RL– RR+ RR– 1 G 2 B 1 B B B 14 FE3 13 FE3 B 1 A W 10 B 2 A W 4 B A40(A), E41(B) Junction Connector 8 A 6 AE6 E42(A), E43(B), E62(G) Junction Connector BR 2 G W 2 A W B W 7 A B B 1 A B SP1 12 A (∗1) 33 B (∗2) 23 C (∗3) 25 A 14 B 15 C W CANL FR– W CANH 11 A 35 B 26 C FL– 19 A (∗1) 8 B (∗2) 8 C (∗3) W FL+ W P A25(C), A26(A), A60(B) Skid Control ECU with Actuator B V W LG Speed Sensors B W W 296 CAMRY (EM0250U) V (IG) (BAT) (BAT) 7. 5A GAUGE NO. 2 10A MPX–B 10A DOME 2 3 1A 1 1 3D LG R V 2 3G R GR 10 3B 12 3L 7 IF 1 3Q 13 ID V V SB GR 12 IG 2 EA1 3 3P IG2 R +S V 12 B 12 3Q GR V 9 3Q 13 A 1 A 2 A IG+ B B2 Power Supply Circuit Cruise Speedometer IG2 DRIVE IC MICRO COMPUTER IG2 SI E2 ES 11 3P 7 3Q 5 3Q 3 3D 2 3U 10 3D BR BR 24 A W–B 12 A W–B 14 B W 18 A W CANL 17 A B CANH W F1(A), F2(B) Combination Meter CAN I/F 15 EA1 GR B W W W–B 4 CA3 F1 C6 297 CAMRY (EM0250U) Cruise Control for 2AZ–FE System Outline The cruise control system is a constant vehicle speed controller which controls the opening angle of the engine throttle valve by the SW, and allows driving at a constant speed without depressing the accelerator pedal. Set Operation When the ON–OFF SW is turned on, the systems starts preparations for cruise control and turns on the indicator light in the combination meter. Set Speed Control When the – SET SW is operated with the ON–OFF SW turned on during driving, the speed is controlled at a constant speed. Coast Control When the – SET SW is kept turned on during cruise control driving, the engine control module controls the throttle valve to decelerate the vehicle speed. Every time the – SET SW is turned on instantaneously, the vehicle speed is decelerated by approx. 1.6 km/h. Accel Control When the + RES SW is kept turned on during cruise control driving, the engine control module controls the throttle valve to accelerate the vehicle speed. Every time the + RES SW is turned on instantaneously, the vehicle speed is accelerated by approx. 1.6 km/h. Resume Control If the vehicle speed is within the low speed limit (Approx. 40 km/h, 25 mph) when canceling the cruise control, operation of the + RES SW accelerates the vehicle speed and resumes the level before canceling the cruise control. Manual Cancel Mechanism If any one of the following signals is input during cruise control driving, the cruise control is canceled. ∗ The stop light SW is on ∗ The CANCEL SW is turned on ∗ The ON–OFF SW is turned off ∗ Gear is shifted D position to other positions than D. (A/T) ∗ The clutch pedal is depressed. (M/T) Auto Cancel Function If any of the following conditions are detected, the cruise control is canceled: ∗ Failure in the stop light SW wiring ∗ Abnormality in the vehicle speed signal ∗ Malfunction in the electronically controlled throttle parts ∗ When the vehicle speed gets slower than the low speed limit. ∗ When the vehicle speed falls to 16 km/h less than the set speed. Overdrive Function The overdrive may be canceled if the vehicle travels on a upward slope during cruise control driving. When the throttle opening information indicates the hill climbing is finished after the overdrive is canceled, the vehicle returns to overdrive mode again as the overdrive return timer is completed. : Parts Location Code See Page Code See Page Code See Page A17 59 A58 A 59 E40 B 57 A19 59 A60 B 53 (2AZ–FE) E41 B 57 A21 59 C1 B 54 (2AZ–FE) E42 A 57 54 (2AZ–FE) E43 B 57 55 (2AZ–FE) E62 G 57 A24 A 52 (2AZ–FE) C5 A25 C 52 (2AZ–FE) A26 A 52 (2AZ–FE) C25 55 (2AZ–FE) F1 A 58 A40 A 59 E10 56 F2 B 58 A41 A 59 56 b1 C 59 A42 B 59 C24 E18 B A E31 56 : Relay Blocks Code 1 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) 298 CAMRY (EM0250U) : Junction Block and Wire Harness Connector Code 1A 1E See Page Junction Block and Wire Harness (Connector Location) 25 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) 36 Instrument Panel No.2 Wire and J/B No.3 (Behind the Combination Meter) 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) 3A 3B 3D 3F 3G 3H 3K 3L 3P 3Q 3U IC ID IF IG IH 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) 31 : Connector Joining Wire Harness and Wire Harness Code AE5 See Page Joining Wire Harness and Wire Harness (Connector Location) 66 Engine Room Main Wire and Instrument Panel Wire (Instrument Panel Right) 65 (2AZ–FE) Engine Wire and Engine Room Main Wire (Inside of the Engine Room R/B and Engine Room J/B) EA1 66 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) FE3 66 Instrument Panel No.2 Wire and Instrument Panel Wire (Instrument Panel Center) AE6 CA2 CA3 : Ground Points Code See Page Ground Points Location A1 65 (2AZ–FE) Front Left Fender A3 66 Left Cowl Side Panel 65 (2AZ–FE) Cylinder Block 66 Instrument Panel Left C4 C6 F1 299 CAMRY (EM0250U) ECT and A/T Indicator for 2GR–FE (BAT) (BAT) (BAT) ∗ 1 : w/ Smart Key System ∗ 2 : w/o Smart Key System 7. 5A AM1 30A EFI MAIN 7. 5A AM2 2 2 ACC II 4 AM1 IG1 Y O 1 (∗2) Y ST1 3 GR (∗2) 5 3F 5 3E (∗1) 4 1 GR (∗2) 7 EA1 AM2 IG2 6 EA1 L ST2 12 1E P E23 Ignition SW (∗2) (∗1) G (∗1) Y 8 CA2 L Y EFI Relay 4 A 9 1E C1(A) Park/Neutral Position SW L O BR B L BR 6 1E 10 1E 11 1E 7 1E B P N 9 A W 1 1 1 10A EFI NO. 3 15A EFI NO. 2 1 1 ST Relay W Y W–B W–B GR LG GR R R L–B BR 2 2 R R O A3 W–B W–B BR L A1 300 CAMRY (EM0250U) E6(A), E7(B), E9(D) Main Body ECU L (IG) Y L 8 B 8 4K G (∗1) V L 12 4M 10A IGN STR 9 IG 9 4G Y 12 4G STR2 6 D (∗1) L 1 A (∗1) 6 B AM2 (∗1) AM1 12 3F 12 4E 9 4E 9 4F Y G (∗1) V (∗1) 12 3J L 13 AE6 (∗1) 4 AE5 G (∗1) G (∗1) Y (∗1) 13 EA1 1 1 2 3 1 ST CUT Relay 5 L R 1 (∗1) 1 (∗1) R (∗1) L 18 CA2 R(∗1) R(∗1) L–B L–B Y 7 CA2 LG V V GR GR R R R R O O L L 5 A43 Junction Connector A2 301 CAMRY (EM0250U) ECT and A/T Indicator for 2GR–FE L L Y Y L L ∗ 1 : w/ Smart Key System R R C5 Throttle Body Assembly C2 Mass Air Flow Meter W–L 3 VTA +B VC VTA2 5 6 4 E2 3 M+ M– 2 1 B W–L P G R 96 B 99 B 97 B 19 B 18 B (Shielded) Y 98 B E2 2 73 B 72 B 71 B 74 B G–R G–R THA 1 P VG 5 L–B E2G 4 LG GR 3 CA2 E2G VG THA ETHA VCTA VTA1 VTA2 A55(A), C55(B) Engine Control Module MREL 44 A O +B2 1 A R +B 2 A R STA 48 A V R (∗1) NSW 62 B L–B STAR 63 B R(∗1) L–B V GR R R O 302 CAMRY (EM0250U) ETA M+ M– 41 B GE01 L L Y Y L L BR (BAT) (BAT) 10A ETCS 10A EFI NO. 1 2 2 1A A41(A), A42(B) Junction Connector BR 1 W 4 B LG C4 Engine Coolant Temp. Sensor 1 8 A 9 A P 79 B 78 B Y B 2 3 A THW +BM 20 A ETHW BATT A55(A), C55(B) Engine Control Module B–W W W–B W W–B VPA2 E1 81 B B–W 3 VPA E05 46 B B 6 EPA E02 21 B B 5 ME01 20 B B G 4 VCPA E03 104 B B Y 2 EPA2 E01 22 B W–B B 1 VCP2 E04 23 B W–B VPA2 56 A W VPA 55 A W EPA 59 A R VCPA 57 A O EPA2 60 A L VCP2 58 A 4 6 5 C4 C57 Junction Connector A17 Accelerator Position Sensor C7 303 CAMRY (EM0250U) ECT and A/T Indicator for 2GR–FE L L Y Y L L BR BR LG (IG) (BAT) 10A STOP 10A IGN 8 IC 1 ID A19 Stop Lamp SW 1 Y 12 3K Y 6 B 12 3F 4 W GR L Y 3 A 4 A A41(A), A42(B) Junction Connector 8 B 2 A A58(A), E40(B) Junction Connector 3 L 2 B Y B 9 IG 36 A 35 A LG STP 28 A IGSW ST1– A55(A), C55(B) Engine Control Module Y S 25 A L SFTD 51 A R SFTU 16 A BR (IG) 10 AE5 20 AE5 11 AE5 G L Y 10 3D 7. 5A ECU IG NO. 2 7 SFTD 19 IF S GR 11 4A C57 Junction Connector W–B 3 5 3L 5 3C O O 12 4C 4 CA3 IG 3 W–B E 5 O 1 SFTU E31 Transmission Control SW 17 A 2 BR 18 B 10 3H A41(A), A42(B) Junction Connector BR 15 EA1 7 4C C7 304 CAMRY (EM0250U) 7 4D O L L Y Y L L BR BR LG LG V P W P B B W 5 3H 5 3B P B–W P L–B 12 AE5 27 A TC 49 A CANL 41 A CANH G L–B 24 B 25 B 27 B 26 B P R N D A55(A), C55(B) Engine Control Module CAN+ CAN– 2 B 1 B Y SPD B 8 A P V B–W P G Y B 305 CAMRY (EM0250U) ECT and A/T Indicator for 2GR–FE L L Y Y L L BR BR LG LG V V P P W W B B R (IG) 1 A 3 3P 10A GAUGE NO. 1 RB V C1(A) Park/Neutral Position SW 10 3B PL RL NL DL 3 A 2 A 8 A 7 A V 16 IH P R G 14 AE5 V P L–B P B–W 5 A 6 A G O G G 7 A A41(A) Junction Connector 14 EA1 L–B R W 10 CA2 19 CA2 BR R 15 16 R 3 SPD1 D SL1+ SL1– SL2+ SL2– SL3+ SL3– SL4+ SL4– SLU+ SLU– R B O B L B G B W B E01 9 BR B E1 8 BR 6 B–W CAN+ 7 B–W CAN– Y C56 Transmission Control ECU 2 1 Y B C57 Junction Connector C7 306 CAMRY (EM0250U) L Y L BR LG V V P P W W B B (IG) 10A IGN Y 9 IG Y LG BR L 9 CA2 9 CA3 11 CA2 B W–L W Y L 12 3F 1 18 10 11 12 STP BATT 4 AE5 6 CA2 Y L–B Y 12 3J +B STA 13 NSW IG2 BR NCB NCO NTB NTO R O E2 W THO1 B TPS3 Y TPS2 Y TPS1 GR B SL W SLT– L SLT+ GR C56 Transmission Control ECU NCB NCO NTB NTO HALL SENSOR HALL SENSOR 307 CAMRY (EM0250U) ECT and A/T Indicator for 2GR–FE V V P W B P L R L B 4 A 6 B 6 C 3 A 10 B 10 C 17 A 9 B 9 C 20 A 7 B 7 C 6 A 27 B 17 C 5 A 29 B 19 C FL– FR+ FR– RL+ RL– RR+ TC 19 A (∗3) 8 B (∗4) 8 C (∗5) CANL RR– 14 BR 2 G 1 G 2 B 1 B W B 14 FE3 13 FE3 B 1 A B 10 B 2 A W 4 B 6 AE6 W 8 A A40(A), E41(B) Junction Connector W 2 A W B W 7 A B B 1 A B SP1 12 A (∗3) 33 B (∗4) 23 C (∗5) 25 A 14 B 15 C W CANL 6 W CANH 11 A 35 B 26 C CANH E42(A), E43(B), E62(G) Junction Connector FL+ 13 E10 Data Link Connector 3 V 18 A 5 B 5 C W LG A25(C), A26(A), A60(B) Skid Control ECU with Actuator P Speed Sensors B W ∗ 3 : w/ VSC TMC Made ∗ 4 : w/ VSC TMMK Made ∗ 5 : w/o VSC W 308 CAMRY (EM0250U) (IG) (BAT) (BAT) 7. 5A GAUGE NO. 2 10A DOME 10A MPX–B 2 1 3 1A 12 IG LG R 1 3D R V 2 3G 12 3L 7 IF 1 3Q 13 ID V GR SB GR V 2 EA1 IG2 R +S V 12 B 12 3Q GR V 9 3Q 13 A 1 A 2 A IG+ B B2 Power Supply Circuit MICRO COMPUTER S D N R LCD A/T Range P Speedometer IG2 DRIVE IC F1(A), F2(B) Combination Meter IG2 CAN I/F ES E2 24 A 11 3P 7 3Q 5 3Q GR 17 A 2 3U 10 3D 18 B BR BR W–B W 3 3D B GR BR 12 A W–B W 14 B W 18 A A41(A), A42(B) Junction Connector SI CANL 17 A B CANH W 3 F1 C57 Junction Connector 4 CA3 W–B 15 EA1 W C7 309 CAMRY (EM0250U) ECT and A/T Indicator for 2GR–FE System Outline 1. Line Pressure Optimal Control Through the use of the solenoid valve SLT, the line pressure is optimally controlled in accordance with the engine torque information, as well as with the internal operating conditions of the torque converter and the transaxle. Accordingly, the line pressure can be controlled minutely in accordance with the engine output, traveling condition, and the ATF temperature, thus realizing smooth shift characteristics and optimizing the workload in the oil pump. 2. Clutch Pressure Optimal Control The engine control module monitors the signals from various types of sensor such as the input turbine speed sensor, allowing shift solenoid valves SL1, SL2 and SL3 to minutely control the clutch pressure in accordance with engine output and driving conditions. As a result, smooth shift characteristics have been realized. 3. Shifting Control in Uphill/Downhill Traveling This control minimizes the shifting of gears when the driver operates the accelerator pedal while driving on a winding road with ups and downs, in order to ensure a smooth drive. 4. Flex Lock–Up Clutch Control The flex lock–up clutch control operates during acceleration, in the 4th and 5th gear in the D range, and during deceleration, in the 4th and 5th gear in the D range and in the 4th gear in the 4 range. 5. Multi Mode Automatic Transmission Multi mode automatic transmission have [S]–position is beside of [D]–position. If moving the selector lever ”S” side, you can select shift range just link manual shifting. : Parts Location Code See Page A17 59 A19 Code C1 See Page A Code 50 (2GR–FE) See Page E23 56 59 C2 50 (2GR–FE) A25 C 48 (2GR–FE) C4 50 (2GR–FE) E40 B 57 A26 A 48 (2GR–FE) C5 50 (2GR–FE) E41 B 57 A40 A 59 51 (2GR–FE) E42 A 57 A41 A 59 51 (2GR–FE) E43 B 57 B 59 51 (2GR–FE) A42 A43 C55 B C56 C57 E62 G 57 E6 A 56 F1 A 58 F2 B 58 A 49 (2GR–FE) E7 B 56 A58 A 59 E9 D 56 A60 B 49 (2GR–FE) E10 56 : Relay Blocks 1 See Page 22 56 49 (2GR–FE) A55 Code E31 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) 310 CAMRY (EM0250U) : Junction Block and Wire Harness Connector Code 1A 1E See Page Junction Block and Wire Harness (Connector Location) 25 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) 36 Instrument Panel No.2 Wire and J/B No.3 (Behind the Combination Meter) 42 Instrument Panel Wire and J/B No.4 (Instrument Panel Brace Center) 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) 3B 3C 3D 3E 3F 3G 3H 3J 3K 3L 3P 3Q 3U 4A 4C 4D 4E 4F 4G 4K 4M IC ID IF 30 IG IH Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) 31 II : Connector Joining Wire Harness and Wire Harness Code AE5 See Page Joining Wire Harness and Wire Harness (Connector Location) 66 Engine Room Main Wire and Instrument Panel Wire (Instrument Panel Right) 64 (2GR–FE) Engine Wire and Engine Room Main Wire (Inside of the Engine Room R/B and Engine Room J/B) EA1 66 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) FE3 66 Instrument Panel No.2 Wire and Instrument Panel Wire (Instrument Panel Center) AE6 CA2 CA3 : Ground Points Code A1 A2 See Page Ground Points Location 64 (2GR–FE) Front Left Fender A3 66 Left Cowl Side Panel C4 64 (2GR–FE) Cylinder Head C7 64 (2GR–FE) Left Side of the Cylinder Block F1 66 Instrument Panel Left 311 CAMRY (EM0250U) ECT and A/T Indicator for 2AZ–FE (BAT) (BAT) (BAT) 10A EFI NO. 1 10A ETCS 30A EFI MAIN 2 2 1 2 1A W Y 1 12 1E 8 A 9 A C4 Engine Coolant Temp. Sensor 1 A41(A) Junction Connector Y B P 3 A 20 A 97 B 96 B 9 1E O BR 10 1E BR B 6 1E 11 1E LG EFI Relay +BM BATT W–B 16 B 2 1 ETHW +B2 1 A R 15A EFI NO. 2 +B 2 A R 10A EFI NO. 3 MREL 44 A O 17 A A41(A), A42(B) Junction Connector 1 2 THW A24(A), C24(B) Engine Control Module 1 1 2 R R GR 1 W–B W–B W–B GR A1 A3 312 CAMRY (EM0250U) 3 CA2 V (BAT) (IG) 10A STOP 10A IGN 8 IC 9 IG 1 ID EPA 1 3 2 4 6 5 B B 2 A L R O B G Y 1 W GR 58 A 56 A 60 A 57 A 55 A 59 A 36 A 35 A VCP2 VPA2 EPA2 VCPA VPA 12 3K 4 STP EPA 6 B Y VPA 12 3F Y VCPA A58(A), E40(B) Junction Connector EPA2 3 Y VPA2 2 A19 Stop Lamp SW VCP2 B Y A17 Accelerator Position Sensor 28 A ST1– IGSW A24(A), C24(B) Engine Control Module Y 2 THA E1 104 B E2 +B 3 EC 32 A EOM 9 A W–B 45 B W–B E01 46 B 18 A 16 A 16 B A41(A), A42(B) Junction Connector P 1 E2G E04 E03 86 B W W 4 VG ME01 43 B W–B SB 5 E02 44 B W ETHA 88 B B THA 65 B B E2G 116 B B–W VG 118 B C2 Mass Air Flow Meter W–B W–B B B–W V W–B B C4 C6 A3 313 CAMRY (EM0250U) ECT and A/T Indicator for 2AZ–FE (IG) 10A GAUGE NO. 1 R L R 16 IH O C1(B) Park/Neutral Position SW R 2 B Y L 21 AE6 22 AE6 LL 6 B 1 B 9 B 7 B 3 B 8 B G R V 10 CA2 14 EA1 11 CA2 16 CA2 16 AE5 15 CA2 O GR 17 CA2 G V G B G BR B P 19 AE6 Y 2L O DL W NL SB RL GR PL SB R R RB 73 B 53 B 54 B 56 B 26 A 55 B 25 A 74 B P R N D 3 2 4 L A24(A), C24(B) Engine Control Module ETHO 4 11 3 2 8 10 5 12 6 13 1 7 SL3+ SL3– S4 SLT+ SLT– DSL SL2+ SL2– SL1+ SL1– THO E2 BR W B O O G 9 SR LG BR 95 B SB LG THO1 72 B Y SL1– 77 B GR R SL1+ 57 B L SL2– 59 B Y BR SL2+ 58 B G DSL 79 B L L SLT– 75 B W SLT+ 76 B R Y S4 78 B GR SL3– 61 B V G SL3+ 60 B O SR 80 B C25 Electronically Controlled Transmission Solenoid 314 CAMRY (EM0250U) V B W B W 6 14 CANH L CANL E10 Data Link Connector 3 R O TC Y P 13 R 5 3B W 12 AE5 8 A 27 A SPD TC B 14 AE5 B W P NSSL P 5 NSSD V 1 AT4 L 2 ATL E31 Transmission Control SW 6 L Y O 5 3H 49 A 41 A CANL CANH A24(A), C24(B) Engine Control Module NT+ NT– 124 B NC+ 101 B NC– 102 B VTA1 115 B VCTA 67 B ETA VTA2 114 B M+ 91 B M– 42 B 41 B GE01 63 B R 3 G 4 (Shielded) 5 P 6 W–L B LG W P Y 1 2 C27 Transmission Revolution Sensor (Counter Gear) 2 C26 Transmission Revolution Sensor (Turbine) G G–R 125 B 2 1 M+ M– 1 VTA VC VTA2 E2 C5 Throttle Body Assembly 315 CAMRY (EM0250U) ECT and A/T Indicator for 2AZ–FE V V B W ∗ 1 : w/ VSC TMC Made ∗ 2 : w/ VSC TMMK Made ∗ 3 : w/o VSC L R L B 18 A 5 B 5 C 4 A 6 B 6 C 3 A 10 B 10 C 17 A 9 B 9 C 20 A 7 B 7 C 6 A 27 B 17 C 5 A 29 B 19 C FR+ RL+ RL– RR+ RR– 1 G 2 B 1 B B B 14 FE3 13 FE3 B 1 A W 10 B 2 A W 4 B A40(A), E41(B) Junction Connector 8 A 6 AE6 E42(A), E43(B), E62(G) Junction Connector BR 2 G W 2 A W B W 7 A B B 1 A B SP1 12 A (∗1) 33 B (∗2) 23 C (∗3) 25 A 14 B 15 C W CANL FR– W CANH 11 A 35 B 26 C FL– 19 A (∗1) 8 B (∗2) 8 C (∗3) W FL+ W P A25(C), A26(A), A60(B) Skid Control ECU with Actuator B V W LG Speed Sensors B W W 316 CAMRY (EM0250U) V (IG) (BAT) 7. 5A GAUGE NO. 2 (BAT) 10A MPX–B 10A DOME 2 12 IG 1 1 3D LG R V 2 3G R GR 10 3B 12 3L 7 IF 1 3Q 13 ID V V SB GR 3 1A 2 EA1 3 3P V R IG2 GR V 12 B +S 12 3Q 9 3Q 13 A 1 A 2 A IG+ B B2 Power Supply Circuit MICRO COMPUTER 4, 3, 2, L D N R P Speedometer IG2 DRIVE IC F1(A), F2(B) Combination Meter IG2 CAN I/F SI E2 ES BR 11 3P 7 3Q 5 3Q 3 3D 2 3U 10 3D BR W–B 24 A W–B 12 A W 14 B W 18 A W CANL 17 A B CANH 15 EA1 GR B W W W–B 4 CA3 F1 C6 317 CAMRY (EM0250U) ECT and A/T Indicator for 2AZ–FE System Outline 1. Line Pressure Optimal Control Through the use of the solenoid valve SLT, the line pressure is optimally controlled in accordance with the engine torque information, as well as with the internal operating conditions of the torque converter and the transaxle. Accordingly, the line pressure can be controlled minutely in accordance with the engine output, traveling condition, and the ATF temperature, thus realizing smooth shift characteristics and optimizing the workload in the oil pump. 2. Clutch Pressure Optimal Control The engine control module monitors the signals from various types of sensor such as the input turbine speed sensor, allowing shift solenoid valves SL1, SL2 and SL3 to minutely control the clutch pressure in accordance with engine output and driving conditions. As a result, smooth shift characteristics have been realized. 3. Shifting Control in Uphill/Downhill Traveling This control minimizes the shifting of gears when the driver operates the accelerator pedal while driving on a winding road with ups and downs, in order to ensure a smooth drive. 4. Flex Lock–Up Clutch Control The flex lock–up clutch control operates during acceleration, in the 4th and 5th gear in the D range, and during deceleration, in the 4th and 5th gear in the D range and in the 4th gear in the 4 range. : Parts Location Code See Page A17 A19 Code 59 A60 59 C1 See Page B 53 (2AZ–FE) B 54 (2AZ–FE) Code See Page E10 56 E31 56 A24 A 52 (2AZ–FE) C2 54 (2AZ–FE) E40 B 57 A25 C 52 (2AZ–FE) C4 54 (2AZ–FE) E41 B 57 A26 A 52 (2AZ–FE) C5 54 (2AZ–FE) E42 A 57 A40 A 59 55 (2AZ–FE) E43 B 57 A41 A 59 C25 55 (2AZ–FE) E62 G 57 A42 B 59 C26 55 (2AZ–FE) F1 A 58 A58 A 59 C27 55 (2AZ–FE) F2 B 58 C24 B : Relay Blocks Code 1 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1A 1E See Page Junction Block and Wire Harness (Connector Location) 25 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) 36 Instrument Panel No.2 Wire and J/B No.3 (Behind the Combination Meter) 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) 3B 3D 3F 3G 3H 3K 3L 3P 3Q 3U IC ID IF IG IH 30 31 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) 318 CAMRY (EM0250U) : Connector Joining Wire Harness and Wire Harness Code AE5 See Page Joining Wire Harness and Wire Harness (Connector Location) 66 Engine Room Main Wire and Instrument Panel Wire (Instrument Panel Right) 65 (2AZ–FE) Engine Wire and Engine Room Main Wire (Inside of the Engine Room R/B and Engine Room J/B) EA1 66 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) FE3 66 Instrument Panel No.2 Wire and Instrument Panel Wire (Instrument Panel Center) AE6 CA2 CA3 : Ground Points Code See Page Ground Points Location A1 65 (2AZ–FE) Front Left Fender A3 66 Left Cowl Side Panel 65 (2AZ–FE) Cylinder Block 66 Instrument Panel Left C4 C6 F1 319 CAMRY (EM0250U) Shift Lock (ACC) 7. 5A ECU IG NO. 2 10A STOP 7. 5A ECU–ACC 2 IF 16 IH 8 IC B P CANL 6 C R (∗1) W (∗1) L G 2 (∗1) L CANH 5 C 2 D (∗2) O 10A GAUGE NO. 1 E8(C), E9(D) Main Body ECU B 19 IF (IG) (BAT) (∗1) (IG) 1 C 2 C 1 1 A 10 CA2 W R W (∗1) B 9 AE2 (∗1) L 2 A (∗2) O 8 3L O 15 IF (∗1) 11 3K (∗1) 5 3K E42(A), E44(C) Junction Connector 7 IL W 11 3L A19 Stop Lamp SW 14 EA1 5 3L 8 3K 4 B 10 B 1 A 7 A G P2 STP E32(B), E57(A) Shift Lock Control ECU 1 A C1(A) Park/Neutral Position SW ACC IG 11 A (∗1) 6 A 4 B (∗2) P 6 B A40(A), E41(B) Junction Connector 12 A 8 B (∗1) W L 3 A KLS+ E2 SLS+ SLS– (∗1) B–W W (∗1) Shift Lock Solenoid B Y 5 B (∗2) (∗2) 3 A (∗1) 1 B P (∗1) E 41 A 2 2 3K (∗2) W–B CANH 1 3K ∗ 1 : w/ Smart Key System ∗ 2 : w/o Smart Key System W–B 3 3C 9 E49 Junction Connector W–B 2 E2 320 CAMRY (EM0250U) 49 A CANL 24 B P A55(A), C55(B) Engine Control Module W–B E24 Key Interlock Solenoid 1 System Outline Shift Lock Mechanism If the brake pedal is depressed with the power SW is pushed to IG ON position (Power SW type), or the ignition SW is turned to ON (Ignition SW type), the shift lock control ECU is activated, allowing the driver to change the shift lever to a position other than the P position. : Parts Location Code See Page Code See Page Code See Page A 59 C55 B 51 (2GR–FE) E41 B 57 B 59 E8 C 56 E42 A 57 A40 A 59 E9 D 56 E44 C 57 A55 A 49 (2GR–FE) C1 A 50 (2GR–FE) A19 E24 E32 56 B 56 E49 E57 57 A 57 : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) 3C 3K 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) IC 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) IF 30 IH 31 IL 30 3L Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) AE2 66 Engine Room Main Wire and Instrument Panel Wire (Right Side of the Instrument Panel J/B) CA2 64 (2GR–FE) Engine Wire and Engine Room Main Wire (Inside of the Engine Room R/B and Engine Room J/B) EA1 66 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) : Ground Points Code E2 See Page 66 Ground Points Location Instrument Panel Brace LH 321 CAMRY (EM0250U) Power Seat for Driver’s Seat (BAT) 30A P/SEAT 2 LG 4 IO 6 A N27(A), U11(B) Junction Connector 9 B 8 B LG LG LG 3 3 B R1 1 2 1 M 2 W–B W–B W–B U5 Power Seat Motor (Driver' s Seat Lumbar Support Control) Y W–B 2 B R W–B H 4 W E 5 U8 Power Seat SW (Driver' s Seat Lumbar Support Control) Rear Front B 4 B N27(A), U11(B) Junction Connector W–B 5 A W–B 10 EN2 E2 322 CAMRY (EM0250U) 2 M 1 10 3 2 M 1 Reclining 2 RCLR 1 M 2 CAMRY (EM0250U) LUP 7 V FDWN RCLF W 5 U4 Power Seat Motor (Driver' s Seat Lifter Control) 6 Front Vertical BR FUP P SLDR B Slide U3 Power Seat Motor (Driver' s Seat Reclining Control) L Down Up Rear Front Down Up Rear Front 1 U2 Power Seat Motor (Driver' s Seat Front Vertical Control) 9 G 4 Y SLDF U1 Power Seat Motor (Driver' s Seat Slide Control) W–B E W–B LG LG U7 Power Seat SW (Driver' s Seat) B Lifter 8 LDWN 1 M 2 323 Power Seat for Driver’s Seat : Parts Location Code N27 See Page A Code See Page 62 (*1) U3 62 (*1) U1 62 (*1) U4 62 (*1) U2 62 (*1) U5 62 (*1) : Junction Block and Wire Harness Connector Code IO See Page 30 Junction Block and Wire Harness (Connector Location) Floor Wire and Instrument Panel J/B (Cowl Side Left) : Connector Joining Wire Harness and Wire Harness Code EN2 See Page 66 Joining Wire Harness and Wire Harness (Connector Location) Instrument Panel Wire and Floor Wire (Left Kick Panel) : Ground Points Code E2 See Page 66 * 1 : w/ Power Seat Ground Points Location Instrument Panel Brace LH * 2 : w/o Power Seat 324 CAMRY (EM0250U) Code See Page U7 62 (*1) U8 U11 62 (*1) B 62 (*1) Memo 325 CAMRY (EM0250U) Power Seat for Front Passenger’s Seat (BAT) 30A P/SEAT 2 G 11 IL G 1 EO2 6 A O20(A), T18(B) Junction Connector G 8 B T8 Power Seat SW (Front Passenger' s Seat) 1 T1 Power Seat Motor (Front Passenger' s Seat Slide Control) 1 M 2 Rear Front Reclining RCLR E W–B 4 2 BR 3 P L SLDR RCLF 6 T3 Power Seat Motor (Front Passenger' s Seat Reclining Control) Slide 9 Y SLDF Rear Front B 1 M 4 B O20(A), T18(B) Junction Connector 2 W–B 5 A W–B 10 EO2 E3 326 CAMRY (EM0250U) : Parts Location Code O20 See Page A T1 Code See Page 62 (*1) T3 62 (*1) 62 (*1) T8 62 (*1) Code T18 See Page B 62 (*1) : Junction Block and Wire Harness Connector Code IL See Page 30 Junction Block and Wire Harness (Connector Location) Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) : Connector Joining Wire Harness and Wire Harness Code EO2 See Page 66 Joining Wire Harness and Wire Harness (Connector Location) Instrument Panel Wire and Floor No.2 Wire (Right Kick Panel) : Ground Points Code E3 See Page 66 * 1 : w/ Power Seat Ground Points Location Instrument Panel Right * 2 : w/o Power Seat 327 CAMRY (EM0250U) W–B 10 EO2 E3 W–B 5 A 1 B O20(A), T18(B) Junction Connector 2 W–B 5 A 2 10 EN2 1 B E2 328 CAMRY (EM0250U) Seat Cushion Seat Back P P L P E 20 EO2 20 EN2 8 A 6 B 1 1 2 N27(A), U11(B) Junction Connector W–B L 4 W–B 7 N27(A), U11(B) Junction Connector U6 Seat Heater (LH) 6 B O20(A), T18(B) Junction Connector 8 A E49 Junction Connector L RH W–B W–B Seat Cushion Seat Back 3 W–B W–B T6 Seat Heater (RH) LH E55 Seat Heater SW LH Side Seat SW RH Side Seat SW B Seat Heater (IG) 20A S–HTR 19 IM 5 IG 6 : Parts Location Code See Page E49 57 E55 N27 Code O20 57 A See Page A T6 62 (*1) T18 62 (*1) B Code 62 (*1) See Page U6 U11 62 (*1) B 62 (*1) 62 (*1) : Junction Block and Wire Harness Connector Code IM See Page 30 Junction Block and Wire Harness (Connector Location) Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) EN2 66 Instrument Panel Wire and Floor Wire (Left Kick Panel) EO2 66 Instrument Panel Wire and Floor No.2 Wire (Right Kick Panel) : Ground Points Code See Page Ground Points Location E2 66 Instrument Panel Brace LH E3 66 Instrument Panel Right * 1 : w/ Power Seat * 2 : w/o Power Seat 329 CAMRY (EM0250U) Sliding Roof (BAT) (BAT) (IG) 7. 5A GAUGE NO. 2 10A DOME 10A MPX–B 2 3 1A 12 IG SB GR LG 1 13 ID 2 EA1 24 A 5 3Q GR V 2 3G 1 3D 1 3Q 9 3Q 12 3Q 2 A ES V GR R 12 3L R BR BR 7 IF 1 A 13 A B2 B IG+ 10 3D +B(DOME) BR Master Warning Power Supply Circuit MICRO COMPUTER 15 EA1 DRIVE IC GR W CANL 18 A B A41(A), A42(B) Junction Connector CANH 17 A F1(A) Combination Meter 7 3Q C57 Junction Connector C7 2 3U W W–B 3 C6 E2 12 A 4 CA3 W–B W–B (2AZ–FE) 4 CA3 (2GR–FE) 17 A (2GR–FE) GR (2AZ–FE) 18 B CAN I/F MULTI LCD W–B BR (2GR–FE) Buzzer B F1 330 CAMRY (EM0250U) 25A DOOR NO. 2 (BAT) 10A ECU IG NO. 1 10A ECU–B NO. 1 25A DOOR NO. 1 (IG) 7. 5A ECU–ACC (ACC) (BAT) (BAT) 2 2 E7(B), E8(C) Main Body ECU 1 O 2 IG 15 ACC 22 BECU (∗2) ALTB 26 6 10 ID 16 ID W BATB (∗1) O W 1 ∗ 1 : w/ Smart Key System ∗ 2 : w/o Smart Key System W W B B 331 CAMRY (EM0250U) Sliding Roof P P ∗ 3 : TMC Made ∗ 4 : TMMK Made E7(B), E8(C) Main Body ECU 10 C LIN2 GND2 GND1 5 9 IM 10 IF 1 IR L 4 W–B DCTY 24 B W–B CANH 5 C W–B CANL 6 C 10 3F L 12 3O 2 B 1 B L N6(A), (B) Door Courtesy SW (Driver' s Side) 1 C E43(B), E44(C) Junction Connector 2 C 1 A (∗3) 1 B (∗4) W–B B 6 10 12 2 W–B B 13 FE3 W–B W 14 FE3 W W–B W–B W B W 13 EN2 4 FE3 W–B B F1 E2 332 CAMRY (EM0250U) E49 Junction Connector (IG) (BAT) P 10A ECU IG NO. 1 30A S/ROOF 4 E48 Junction Connector 10 IR 12 IR P B Y 8 EQ1 10 EQ1 6 EQ1 P B Y 5 4 1 MPX1 5 B IG Q13 Sliding Roof Control ECU and Motor UP OPN 9 7 BR 4 1 2 CLS OPN DOWN E 2 W–B CLS 8 L W Q6 Overhead J/B 5 DWN G UP 10 M Sliding Roof Control SW GND W–B 3 W–B 11 EQ1 W–B W–B 333 CAMRY (EM0250U) Sliding Roof : Parts Location Code See Page Code See Page A41 A 59 E43 B 57 A42 B 59 E44 C 57 C57 Code N6 See Page A 60 B 60 51 (2GR–FE) E48 57 Q6 61 E49 57 Q13 61 E7 B 56 E8 C 56 F1 A 58 : Relay Blocks Code 1 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1A See Page Junction Block and Wire Harness (Connector Location) 25 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) 36 Instrument Panel No.2 Wire and J/B No.3 (Behind the Combination Meter) ID 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) IF 30 IG 31 3D 3F 3G 3L 3O 3Q 3U IM IR Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) 30 : Connector Joining Wire Harness and Wire Harness Code CA3 See Page 64 (2GR–FE) 65 (2AZ–FE) Joining Wire Harness and Wire Harness (Connector Location) Engine Wire and Engine Room Main Wire (Inside of the Engine Room R/B and Engine Room J/B) EA1 66 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) EN2 66 Instrument Panel Wire and Floor Wire (Left Kick Panel) EQ1 66 Instrument Panel Wire and Roof Wire (Lower Part of Front Pillar LH) FE3 66 Instrument Panel No.2 Wire and Instrument Panel Wire (Instrument Panel Center) : Ground Points Code See Page Ground Points Location C6 65 (2AZ–FE) Cylinder Block C7 64 (2GR–FE) Left Side of the Cylinder Block E2 66 Instrument Panel Brace LH F1 66 Instrument Panel Left 334 CAMRY (EM0250U) Memo 335 CAMRY (EM0250U) Garage Door Opener (BAT) 10A DOME 2 LG 1 13 ID R 10 IL R 7 EQ1 7 B Garage Door Opener E Q6 Overhead J/B W–B 8 W–B 11 EQ1 1 IR W–B 10 IF 10 12 4 FE3 W–B W–B 2 W–B E49 Junction Connector E2 F1 336 CAMRY (EM0250U) : Parts Location Code See Page E49 57 Code Q6 See Page Code See Page 61 : Relay Blocks Code 1 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code ID See Page Junction Block and Wire Harness (Connector Location) 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) IF IL IR : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) EQ1 66 Instrument Panel Wire and Roof Wire (Lower Part of Front Pillar LH) FE3 66 Instrument Panel No.2 Wire and Instrument Panel Wire (Instrument Panel Center) : Ground Points Code See Page Ground Points Location E2 66 Instrument Panel Brace LH F1 66 Instrument Panel Left 337 CAMRY (EM0250U) Automatic Glare–Resistant EC Mirror (IG) 10A ECU IG NO. 1 Y 10 IR Y 6 EQ1 4 E Q3 Inner Rear View Mirror IG W–B 1 W–B 11 EQ1 1 IR 4 FE3 10 W–B 12 E49 Junction Connector W–B 10 IF F1 W–B W–B 2 E2 338 CAMRY (EM0250U) : Parts Location Code See Page E49 57 Code Q3 See Page Code See Page 61 : Junction Block and Wire Harness Connector Code IF IR See Page 30 Junction Block and Wire Harness (Connector Location) Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) EQ1 66 Instrument Panel Wire and Roof Wire (Lower Part of Front Pillar LH) FE3 66 Instrument Panel No.2 Wire and Instrument Panel Wire (Instrument Panel Center) : Ground Points Code See Page Ground Points Location E2 66 Instrument Panel Brace LH F1 66 Instrument Panel Left 339 CAMRY (EM0250U) Remote Control Mirror (ACC) 7. 5A ECU–ACC L 2 IF 11 3L L 11 3I E3 Outer Mirror SW 8 Down Left Right MRH MLV Select SW E 6 7 W–B M+ 2 3I 3 3I 1 3I 3 3C W–B 3 B 4 BR MRV 2 W 5 V MLH 1 3G V B 20 HE2 21 HE2 V B BR 22 HE2 BR B 21 IE2 B W 22 IE2 W 20 IE2 LG LG B 1 5 2 5 1 2 MH MV M+ MV MH M+ M M M Operation SW Up Right Right/ Down Right Left Left/ Up Left B 9 M W–B 2 I3 Outer Rear View Mirror (LH) H2 Outer Rear View Mirror (RH) 340 CAMRY (EM0250U) E2 E49 Junction Connector : Parts Location Code See Page Code See Page E3 56 H2 61 E49 57 I3 61 Code See Page : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) 3C 3G 3I 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) 3L IF : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) HE2 66 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) IE2 66 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) : Ground Points Code E2 See Page 66 Ground Points Location Instrument Panel Brace LH 341 CAMRY (EM0250U) Rear Window Defogger and Mirror Heater (BAT) (IG) 10A A/C NO. 2 12 ID 16 IF 1 W–B GR V 3 3M 2 1 (2GR–FE) 2 3U 4 RR DEF Relay 1 W–B 3 1 1 W 14 B V V 1 3S 5 G 4 3S 22 A V 2 3S 1 (2AZ–FE) 4 L TX+ 3 W–B GND 1 3L A41(A), A42(B) Junction Connector Rear Window Defogger SW 1 (2GR–FE) IG+ V 5 F16 A/C Control Assembly Y V 50A RR DEF 5 EA1 37 A 38 A E38(A) A/C Amplifier RDFG G LIN1 12 3D G W W–B G 6 3M F1 342 CAMRY (EM0250U) P1 W–B 1 B W–B Y Y 10 HE2 Y Y 1 A 3 3 2 E2 1 IK 4 17 IE2 17 HE2 5 H2 Outer Rear View Mirror (RH) Mirror Heater I3 Outer Rear View Mirror (LH) Mirror Heater 13 IO A1 W–B W–B 1 N18 Noise Filter (Rear Window Defogger) W 10 IE2 N19(A), P1(B) Rear Window Defogger 2 B 2 IB W–B W–B W–B W–B 10A MIR HTR 12 IJ W 4 13 E49 Junction Connector W–B A3 343 CAMRY (EM0250U) Rear Window Defogger and Mirror Heater : Parts Location Code See Page Code See Page Code See Page A41 A 59 F16 58 N19 A 60 A42 B 59 H2 61 P1 B 60 E38 A 57 I3 61 57 N18 60 E49 : Relay Blocks Code 1 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) 3D 3L 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) 36 Instrument Panel No.2 Wire and J/B No.3 (Behind the Combination Meter) 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) 30 Floor Wire and Instrument Panel J/B (Cowl Side Left) 3M 3S 3U IB ID IF IJ IK IO : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) EA1 66 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) HE2 66 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) IE2 66 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) : Ground Points Code A1 See Page 64 (2GR–FE) 65 (2AZ–FE) Ground Points Location Front Left Fender E2 66 Instrument Panel Brace LH F1 66 Instrument Panel Left P1 67 Right Rear Quarter Panel 344 CAMRY (EM0250U) Memo 345 CAMRY (EM0250U) Navigation System and Audio System with 8 Speaker (BAT) (ACC) (BAT) 7. 5A RADIO NO. 2 25A AMP 2 15A RADIO NO. 1 2 1 ATX– 15 D ATX+ SLD1 5 D 13 E (Shielded) ACC 11 D R GR 6 3U 6 3T 7 B 8 B IVO– 12 E IVO+ 11 E ACC TX– R 12 B G L–Y GR 9 FE3 GR 5 FE3 GR B 1 D G 17 EA1 GR 6 3L L–Y 8 EA1 L–Y L F9(D), F10(E), F12(G), F13(H), F14(I) Navigation Receiver Assembly GR 12 IF BR 1 22 B 23 B TX+ INT– INT+ F18(A), F19(B), F20(C) Stereo Component Amplifier WFL+ LG 7 FE3 5 IE1 9 IE1 5 HE1 9 HE1 LG LG 2 FE3 L 6 FE3 L 1 FE3 P L WFR+ 9 C P WFR– 3 C V 2 C P GR 1 WFL– 1 C V GR 2 FL+ 8 A V GR 7 FL– 7 A P +B2 5 A V +B 1 A F25 Junction Connector 2 1 F21 Tweeter (Front LH) 2 1 I1 Speaker (Front Door LH) 346 CAMRY (EM0250U) 2 1 H1 Speaker (Front Door RH) F9(D), F10(E), F12(G), F13(H), F14(I) Navigation Receiver Assembly MUTE 7 D SLD 10 D R+ R– L+ L– 8 D 18 D 9 D 19 D ANT TSW– 13 D SGND 12 G 18 G W B G R O (Shielded) O P 1 B F15 Antenna Amplifier 1 B 6 B MUTE SLD 5 B 4 B 3 B 2 B R+ R– L+ L– F18(A), F19(B), F20(C) Stereo Component Amplifier R B RR+ 10 A 1 OF1 10 OF1 8 OF1 17 OF1 R Y RR– 4 A W G–W 11 OF1 SR+ 5 C W BR 2 OF1 G–W B 18 OF1 BR Y 9 OF1 SR– 12 C L SL+ 4 C L SL– 10 C Y RL+ 3 A Y RL– 9 A 3 1 4 2 4 2 3 1 – + WF1– WF1+ WF2– WF2+ – + O14 Speaker (Rear LH) O15 Speaker (Rear RH) 347 CAMRY (EM0250U) Navigation System and Audio System with 8 Speaker F9(D), F10(E), F12(G), F13(H), F14(I) Navigation Receiver Assembly REV VAR+ 2 I 7 3D R ADPG 6 I G R 3 3P 10A GAUGE NO. 1 (Shielded) V 8 3U V (IG) 9 3U VA– 5 I BR 3 I G VAL+ 5 H R SPD 3 H V R E48 Junction Connector 8 BR 16 IH 10 3U 1 2 ALO ARO 3 ASGN 4 AUXO 2 R F17 Stereo Jack Adapter 11 B 14 EA1 SPD F18(A), F19(B), F20(C) Stereo Component Amplifier 7 C GND 6 C O E FR+ 2 A GR FR– 6 A 6 AE3 10 CA2 P L LG R BR BR L 20 CA2 2 A 1 B RL 1 A (2GR–FE) 2 B (2AZ–FE) RB R 2 C1(A), (B) Park/Neutral Position SW 1 V F23 Tweeter (Front RH) F3 348 CAMRY (EM0250U) ∗ 1 : TMC Made ∗ 2 : TMMK Made F9(D), F10(E), F12(G), F13(H), F14(I) Navigation Receiver Assembly Y 8 3T 7 FE2 R 12 EQ1 3 EQ1 2 EQ1 ACC G R 1 A 1 B (Shielded) On Hook LG Seek– Voice Steering SW RH MODE Steering SW LH B E18(A), a1(B) Spiral Cable 9 B Seek+ Volume+ 10 FE2 1 EQ1 G 8 B 9 FE2 AU2 EAU W 10 B 8 FE2 G 5 A (Shielded) 4 A LG Y 6 A AU1 20 D 8 3A P 1 3A O 10 3A GND MIC– 9 G BR P 1 3T LG O 12 3T MIC+ 19 G W–B MACC 17 G R SW2 8 E G SWG 6 E (Shielded) SW1 7 E 3 A 3 B 5 A (∗1) 5 B (∗2) MI1+ MIC– Off Hook Volume– Q5(A), Q12(B) Microphone (Navigation) a1(B) Steering Pad SW BR V W–B V F2 349 CAMRY (EM0250U) Navigation System and Audio System with 8 Speaker (BAT) (BAT) ∗ ∗ ∗ ∗ ∗ 10A MPX–B 10A DOME 7. 5A GAUGE NO. 2 (IG) 3 4 5 6 7 : w/ VSC TMC Made : w/ VSC TMMK Made : w/o VSC : 2GR–FE : 2AZ–FE 2 1 12 IG 3 1A LG SB Speed Sensors 13 ID P L R L B 4 A 6 B 6 C 3 A 10 B 10 C 17 A 9 B 9 C 20 A 7 B 7 C 6 A 27 B 17 C 5 A 29 B 19 C W V 18 A 5 B 5 C R A25(C), A26(A), A60(B) Skid Control ECU with Actuator V 7 IF LG GR 2 EA1 12 3L 9 3Q GR 1 3D 12 3Q V 1 3Q R 2 3G 13 A 2 A FL– FR+ FR– RL+ RL– RR+ RR– SP1 12 A (∗3) 33 B (∗4) 23 C (∗5) 1 A IG+ B2 FL+ 19 A (∗3) 8 B (∗4) 8 C (∗5) B Power Supply Circuit BR Speedometer IG2 MICRO COMPUTER 6 AE6 ES SI 24 A 7 3Q 5 3Q 14 B W BR V E2 12 A W–B +S 12 B 11 3P GR 15 EA1 V W GR BR(∗6) 4 CA3 GR(∗7) W–B 18 B 3 3D (∗6) BR 17 A (∗6) 10 3D A41(A), A42(B) Junction Connector 2 3U W–B (∗6) F1 (∗7) W–B 3 C6 C57 Junction Connector 4 CA3 C7 350 CAMRY (EM0250U) W F1(A), F2(B) Combination Meter IG2 : Parts Location Code A25 See Page Code 48 (2GR–FE) C See Page E48 57 Code F20 See Page C 58 52 (2AZ–FE) F1 A 58 F21 58 48 (2GR–FE) F2 B 58 F23 58 52 (2AZ–FE) F9 D 58 F25 58 A26 A A41 A 59 F10 E 58 H1 61 A42 B 59 F12 G 58 I1 61 49 (2GR–FE) F13 H 58 O14 60 53 (2AZ–FE) F14 I 58 A60 C1 B 60 50 (2GR–FE) F15 58 Q5 A 61 B 54 (2AZ–FE) F17 58 Q12 B 61 a1 B 59 C57 E18 O15 A A 51 (2GR–FE) F18 A 58 56 F19 B 58 : Relay Blocks Code 1 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1A See Page Junction Block and Wire Harness (Connector Location) 25 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) 36 Instrument Panel No.2 Wire and J/B No.3 (Behind the Combination Meter) ID 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) IF 30 3A 3D 3G 3L 3P 3Q 3T 3U IG IH Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) 31 : Connector Joining Wire Harness and Wire Harness Code AE3 AE6 CA2 CA3 See Page 66 Joining Wire Harness and Wire Harness (Connector Location) Engine Room Main Wire and Instrument Panel Wire (Instrument Panel Right) 64 (2GR–FE) 65 (2AZ–FE) 64 (2GR–FE) Engine Wire and Engine Room Main Wire (Inside of the Engine Room R/B and Engine Room J/B) 65 (2AZ–FE) EA1 66 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) EQ1 66 Instrument Panel Wire and Roof Wire (Lower Part of Front Pillar LH) 66 Instrument Panel No.2 Wire and Instrument Panel Wire (Instrument Panel Center) HE1 66 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) IE1 66 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) OF1 66 Floor No.2 Wire and Instrument Panel No.2 Wire (Instrument Panel Right) FE2 FE3 351 CAMRY (EM0250U) Navigation System and Audio System with 8 Speaker : Ground Points Code See Page Ground Points Location C6 65 (2AZ–FE) Cylinder Block C7 64 (2GR–FE) Left Side of the Cylinder Block F1 66 Instrument Panel Left F2 66 Instrument Panel Brace RH F3 66 Under the Front Passenger’s Seat 352 CAMRY (EM0250U) Memo 353 CAMRY (EM0250U) Audio System with 8 Speaker without Navigation (BAT) (ACC) (BAT) 7. 5A RADIO NO. 2 25A AMP 15A RADIO NO. 1 2 2 8 EA1 6 3L 17 EA1 F8(C), F11(F), F26(D) Radio Receiver Assembly +B B 5 F 1 D ACC 11 D ACC ATX– 16 F ATX+ 15 D 5 D MUTE 7 D 11 5 F25 Junction Connector 9 O 10 R 13 G L–Y GR GR GR GR 12 7 B 8 B 1 B GR 9 FE3 L–Y 6 3T L 6 3U L–Y 5 FE3 GR GR L–Y L 1 GR 12 IF BR 1 12 B ACC TX– TX+ MUTE F18(A), F19(B), F20(C) Stereo Component Amplifier WFL+ 1 F21 Tweeter (Front LH) SL+ G–W 18 OF1 2 OF1 11 OF1 2 1 I1 Speaker (Front Door LH) 354 CAMRY (EM0250U) G–W BR 9 OF1 BR B 9 IE1 B 4 C 5 IE1 F25 Junction Connector 2 SL– 10 C Y 6 FE3 RL+ 3 A Y P 1 FE3 RL– 9 A P V 2 C P GR 1 WFL– 1 C V GR 2 FL+ 8 A V GR 7 FL– 7 A P +B2 5 A V +B 1 A 3 1 4 2 – + WF1– WF1+ O14 Speaker (Rear LH) G B W IVO+ IVO– 11 C 12 C ANT SLD ALI 13 D 13 C ARI 17 C 15 C ASGN 16 C AUXI 19 C G BR (Shielded) O (Shielded) BR 19 D G L– 9 D R L+ 18 D G R– 8 D R SLD R R+ 10 D (Shielded) F8(C), F11(F), F26(D) Radio Receiver Assembly 1 1 2 ALO ARO 3 4 ASGN AUXO B F15 Antenna Amplifier 6 B SLD 5 B 4 B 3 B 2 B R+ R– L+ L– 23 B INT+ F17 Stereo Jack Adapter 22 B INT– F18(A), F19(B), F20(C) Stereo Component Amplifier E FR+ GND SPD 6 C 11 B 2 FE3 7 FE3 10 3U L LG BR V 7 C LG 2 A BR FR– 6 A LG WFR+ 9 C L WFR– 3 C L R RR+ 10 A W RR– 4 A L SR+ 5 C Y SR– 12 C 17 OF1 5 HE1 R L 4 2 3 1 WF2– WF2+ – + 9 HE1 V 8 OF1 LG 10 OF1 W Y 1 OF1 L 3 3P 2 1 2 1 V O15 Speaker (Rear RH) H1 Speaker (Front Door RH) F23 Tweeter (Front RH) F3 355 CAMRY (EM0250U) Audio System with 8 Speaker without Navigation F8(C), F11(F), F26(D) Radio Receiver Assembly 7 FE2 9 B 12 EQ1 2 EQ1 ACC G R 1 A 1 B (Shielded) On Hook LG Seek– Voice Steering SW RH MODE Steering SW LH B 3 EQ1 AU2 Seek+ Volume+ 10 FE2 1 EQ1 G 8 B E18(A), a1(B) Spiral Cable R EAU W 10 B 9 FE2 G 5 A (Shielded) 4 A LG Y 6 A AU1 8 FE2 GND 20 D 8 3A P 1 3A O 10 3A GND 14 F BR Y 8 3T MIC– 1 F BR P 1 3T LG O 12 3T MIC+ 2 F W–B MCVD 7 F R SW2 8 C G SWG 6 C (Shielded) SW1 7 C 3 A 3 B 5 A (∗1) 5 B (∗2) MI1+ MIC– Off Hook Volume– Q5(A), Q12(B) Microphone (Navigation) a1(B) Steering Pad SW F2 356 CAMRY (EM0250U) BR BR V W–B V (BAT) (BAT) ∗ ∗ ∗ ∗ ∗ ∗ ∗ 10A MPX–B 10A DOME 7. 5A GAUGE NO. 2 (IG) 2 1 12 IG 3 1A 1 2 3 4 5 6 7 : TMC Made : TMMK Made : w/ VSC TMC Made : w/ VSC TMMK Made : w/o VSC : 2GR–FE : 2AZ–FE LG SB Speed Sensors 13 ID P L R L B 4 A 6 B 6 C 3 A 10 B 10 C 17 A 9 B 9 C 20 A 7 B 7 C 6 A 27 B 17 C 5 A 29 B 19 C W V A25(C), A26(A), A60(B) Skid Control ECU with Actuator R 9 3Q GR 1 3D 12 3Q V 1 3Q R 2 3G B2 FL– FR+ FR– RL+ RL– RR+ RR– SP1 12 A (∗3) 33 B (∗4) 23 C (∗5) 1 A 13 A 2 A FL+ 19 A (∗3) 8 B (∗4) 8 C (∗5) B Speedometer IG+ Power Supply Circuit BR 12 3L IG2 18 A 5 B 5 C V 7 IF LG GR 2 EA1 MICRO COMPUTER 6 AE6 ES SI 24 A 7 3Q 5 3Q 14 B W W BR V E2 12 A W–B +S 12 B F1(A), F2(B) Combination Meter IG2 11 3P GR 15 EA1 V W GR BR(∗6) 4 CA3 GR(∗7) W–B 18 B 3 3D (∗6) BR 17 A (∗6) 10 3D A41(A), A42(B) Junction Connector 2 3U W–B (∗6) F1 (∗7) W–B 3 C6 C57 Junction Connector 4 CA3 C7 357 CAMRY (EM0250U) Audio System with 8 Speaker without Navigation : Parts Location Code A25 See Page C Code 48 (2GR–FE) F1 52 (2AZ–FE) 48 (2GR–FE) 52 (2AZ–FE) See Page Code See Page A 58 F23 58 F2 B 58 F8 C 58 F11 F 58 H1 61 F25 F26 58 D 58 A26 A A41 A 59 F15 58 I1 61 A42 B 59 F17 58 O14 60 A 58 O15 60 A60 B C57 E18 A 49 (2GR–FE) F18 53 (2AZ–FE) F19 B 58 Q5 A 61 51 (2GR–FE) F20 C 58 Q12 B 61 58 a1 B 59 56 F21 : Relay Blocks Code 1 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1A See Page Junction Block and Wire Harness (Connector Location) 25 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) 36 Instrument Panel No.2 Wire and J/B No.3 (Behind the Combination Meter) ID 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) IF 30 IG 31 3A 3D 3G 3L 3P 3Q 3T 3U Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) : Connector Joining Wire Harness and Wire Harness Code AE6 CA3 See Page 66 Joining Wire Harness and Wire Harness (Connector Location) Engine Room Main Wire and Instrument Panel Wire (Instrument Panel Right) 64 (2GR–FE) 65 (2AZ–FE) Engine Wire and Engine Room Main Wire (Inside of the Engine Room R/B and Engine Room J/B) EA1 66 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) EQ1 66 Instrument Panel Wire and Roof Wire (Lower Part of Front Pillar LH) 66 Instrument Panel No.2 Wire and Instrument Panel Wire (Instrument Panel Center) HE1 66 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) IE1 66 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) OF1 66 Floor No.2 Wire and Instrument Panel No.2 Wire (Instrument Panel Right) FE2 FE3 : Ground Points Code See Page Ground Points Location C6 65 (2AZ–FE) Cylinder Block C7 64 (2GR–FE) Left Side of the Cylinder Block F1 66 Instrument Panel Left F2 66 Instrument Panel Brace RH F3 66 Under the Front Passenger’s Seat 358 CAMRY (EM0250U) Memo 359 CAMRY (EM0250U) Audio System with 6 Speaker (BAT) (ACC) 15A RADIO NO. 1 7. 5A RADIO NO. 2 2 17 EA1 6 3L L–Y GR 12 IF L 1 6 3T GR L–Y 9 FE3 4 A 3 A B ACC F6(A), F7(B), F8(C) Radio Receiver Assembly RL+ 2 B RR– RR+ 3 B 1 B 2 1 L W B Y R TWR+ – + LG 7 FE3 LG 2 FE3 5 HE1 9 HE1 L LG 17 OF1 L 8 OF1 1 L 18 OF1 R 9 OF1 2 O12 Speaker (Rear LH) 1 2 1 O13 Speaker (Rear RH) BR I1 Speaker (Front Door LH) 2 3 P 9 IE1 V 5 IE1 4 W 6 FE3 P 1 FE3 V 1 P + 3 V – FR+ 1 A TWR– B TWL+ Y 2 TWL– F22 Tweeter (Front LH) 4 FR– 5 A F2 360 CAMRY (EM0250U) 2 1 H1 Speaker (Front Door RH) F24 Tweeter (Front RH) RL– 6 B LG FL+ 2 A P V FL– 6 A BR GND 7 A F17 Stereo Jack Adapter AUXO ARO ALO 2 1 ASGN F15 Antenna Amplifier 3 BR 4 R 15 C 17 C BR O O G (Shielded) B 1 19 C AUXI ARI ALI 16 C 8 A ASGN ANT F6(A), F7(B), F8(C) Radio Receiver Assembly SW1 SWG SPD SW2 3 C 12 3T 1 3T 8 3T V Y 8 C P 6 C O 7 C 9 3T 10 3A 1 3A 8 3A P Y 6 A 4 A 5 A 9 B Seek+ MODE Seek– On Hook Voice Steering SW RH B AU2 Steering SW LH 8 B W 10 B EAU E18(A), a1(B) Spiral Cable G AU1 V O 3 3P V Volume+ Off Hook Volume– a1(B) Steering Pad SW 361 CAMRY (EM0250U) Audio System with 6 Speaker (BAT) ∗ ∗ ∗ ∗ ∗ (BAT) 10A MPX–B 10A DOME 7. 5A GAUGE NO. 2 (IG) 1 2 3 4 5 : 2GR–FE : 2AZ–FE : w/ VSC TMC Made : w/ VSC TMMK Made : w/o VSC 2 1 12 IG 3 1A LG SB Speed Sensors 13 ID P L R L B 4 A 6 B 6 C 3 A 10 B 10 C 17 A 9 B 9 C 20 A 7 B 7 C 6 A 27 B 17 C 5 A 29 B 19 C W V 18 A 5 B 5 C R A25(C), A26(A), A60(B) Skid Control ECU with Actuator V 7 IF LG GR 2 EA1 9 3Q GR 1 3D 12 3Q V 1 3Q R 2 3G 13 A 2 A FL– FR+ FR– RL+ RL– RR+ RR– SP1 12 A (∗3) 33 B (∗4) 23 C (∗5) 1 A IG+ B Speedometer B2 FL+ IG2 Power Supply Circuit BR 12 3L 19 A (∗3) 8 B (∗4) 8 C (∗5) MICRO COMPUTER 6 AE6 ES SI 24 A 7 3Q 5 3Q 14 B W BR V E2 12 A W–B +S 12 B 11 3P GR 15 EA1 V W GR BR(∗1) 4 CA3 GR(∗2) W–B 18 B 3 3D (∗1) BR 17 A (∗1) 10 3D A41(A), A42(B) Junction Connector 2 3U W–B (∗1) F1 (∗2) W–B 3 C6 C57 Junction Connector 4 CA3 C7 362 CAMRY (EM0250U) W F1(A), F2(B) Combination Meter IG2 : Parts Location Code A25 See Page Code 48 (2GR–FE) C See Page C57 Code See Page 51 (2GR–FE) F17 58 52 (2AZ–FE) E18 A 56 F22 58 48 (2GR–FE) F1 A 58 F24 58 52 (2AZ–FE) F2 B 58 H1 61 A26 A A41 A 59 F6 A 58 I1 61 A42 B 59 F7 B 58 O12 60 49 (2GR–FE) F8 C 58 O13 60 A60 B 53 (2AZ–FE) F15 58 a1 B 59 : Relay Blocks Code 1 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1A See Page Junction Block and Wire Harness (Connector Location) 25 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) 36 Instrument Panel No.2 Wire and J/B No.3 (Behind the Combination Meter) ID 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) IF 30 IG 31 3A 3D 3G 3L 3P 3Q 3T 3U Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) : Connector Joining Wire Harness and Wire Harness Code AE6 CA3 See Page 66 Joining Wire Harness and Wire Harness (Connector Location) Engine Room Main Wire and Instrument Panel Wire (Instrument Panel Right) 64 (2GR–FE) 65 (2AZ–FE) Engine Wire and Engine Room Main Wire (Inside of the Engine Room R/B and Engine Room J/B) EA1 66 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) FE3 66 Instrument Panel No.2 Wire and Instrument Panel Wire (Instrument Panel Center) HE1 66 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) IE1 66 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) OF1 66 Floor No.2 Wire and Instrument Panel No.2 Wire (Instrument Panel Right) : Ground Points Code See Page Ground Points Location C6 65 (2AZ–FE) Cylinder Block C7 64 (2GR–FE) Left Side of the Cylinder Block F1 66 Instrument Panel Left F2 66 Instrument Panel Brace RH 363 CAMRY (EM0250U) 2 CA3 C4 2 NE+ 1 2 SPD 111 B NE– 49 A CANL 79 B THW 1 1 1 CA3 C5 364 CAMRY (EM0250U) CANH 78 B ETHW 2 1 A 7 A (∗2) W (∗1) B (∗1) (∗1) Y BR (∗2) BR 20A IG2 (∗2) (IG) W (∗1) W (∗2) B (∗1) A55(A), C55(B) Engine Control Module B 41 A A40(A), E41(B) Junction Connector 110 B 8 A P # 10 (∗1) 45 B (∗1) 1 C4 Engine Coolant Temp. Sensor ETHW B W (∗1) 96 B (∗1) C7 Fuel Injector (No. 1) V 2 CA1 C50 Crankshaft Position Sensor B 2 (∗1) 3 R B 1 (∗1) 5 (∗1) B (∗2) 2 CA1 G THW CANH A24(A), C24(B) Engine Control Module W (∗2) C7 Fuel Injector (No. 1) W (∗2) 1 EA1 (∗1) 97 B 41 A (Shielded) NE– CANL P 49 A (∗2) L (∗2) B (∗2) 8 IH (∗1) B 121 B (∗2) SPD BR L (∗2) 8 A C4 Engine Coolant Temp. Sensor (∗2) # 10 W–B 108 B (∗2) B–W 2 R NE+ (∗2) 122 B C20 Crankshaft Position Sensor 1 (∗2) G (Shielded) Combination Meter L(∗2) V(∗1) 15A INJ (BAT) 2 1 1 1 IG2 Relay 1 2 2 L(∗2) L(∗2) V(∗1) V(∗1) E6(A), E7(B), E8(C) Main Body ECU CANL 6 C PKB CANH 5 C 19 L R L B Y P 20 A 7 B 7 C 6 A 27 B 17 C 5 A 29 B 19 C FR+ RL+ RL– RR+ RR– 1 C 2 A 1 A 2 B 1 B W W B B 6 AE6 14 FE3 13 FE3 B 10 B A40(A), E41(B) Junction Connector 4 B W 8 A 1 E42(A), E43(B), E44(C) Junction Connector B BR 2 C W B 2 A 1 SP1 12 A (∗3) 33 B (∗4) 23 C (∗5) 25 A 14 B 15 C W CANL FR– W CANH 11 A 35 B 26 C FL– 19 A (∗3) 8 B (∗4) 8 C (∗5) W FL+ E33 Parking Brake SW V 17 A 9 B 9 C W LG 3 A 10 B 10 C B A25(C), A26(A), A60(B) Skid Control ECU with Actuator 4 A 6 B 6 C (Lever Type) Speed Sensors 18 A 5 B 5 C 14 IC B W 2 IM L : 2GR–FE : 2AZ–FE : w/ VSC TMC Made : w/ VSC TMMK Made : w/o VSC (Pedal Type) 1 2 3 4 5 A18 Parking Brake SW ∗ ∗ ∗ ∗ ∗ B W W 365 CAMRY (EM0250U) Combination Meter L(∗2) L(∗2) V(∗1) V(∗1) V(∗6) E6(A), E7(B), E8(C) Main Body ECU 9 C SPD RCTY 7 A (∗6) 5 A (∗11) LCTY DCTY 24 B PCTY 21 A HCTY LGCY 25 A 16 B CANN 15 C CANP 16 C L (∗6) W 17 EN2 (∗6) R 7 IO (∗11) W 17 W R HSW 24 B R 5 3N (∗11) W 10 3F CANH 4 3J 14 6 3N 27 A CANL (∗6) N28 Junction Connector 28 A 13 E58(A), E59(B) Certification ECU Y L LG GR 4 3F 2 AE2 3 SN1 11 3E R 10 3J (∗6) 5 EO2 R 13 EN2 (∗11) 6 EO2 W Y 6 3C L 12 3O GR 7 3C (∗6) R 2 2 A5 Engine Hood Courtesy SW 3 W (∗6) W (∗11) 1 S15 Junction Connector 1 A5 Engine Hood Courtesy SW 1 2 W–B 1 S5 Door Lock Assembly (Luggage) Y L 1 A (∗7) 1 B (∗8) O6 Door Courtesy SW (Front Passenger' s Side) 1 N6(A), (B) Door Courtesy SW (Driver' s Side) 1 A (∗7) 1 B (∗8) O10 Door Courtesy SW (Rear RH) N13(A), (B) Door Courtesy SW (Rear LH) GR 2 AE2 9 W W W W S1 366 CAMRY (EM0250U) W (∗11) W–B W B A2 (∗6) B 3 A2 A43 Junction Connector L(∗2) V(∗1) SPD 2 SPD 3 C F8(C) Radio Receiver Assembly SPD 3 H V (∗10) V 10 3U V 10 3M V 10 3B (∗9) V (∗6) V L 5 A 11 B (∗1) V 6 A A41(A) Junction Connector 7 A (∗1) G SPD1 (∗1) C56 Transmission Control ECU 14 AE5 E60 Tire Pressure Warning ECU SPD 3 F13(H) Navigation Receiver Assembly 19 CA2 F19(B) Stereo Component Amplifier L (∗1) L BR (∗1) (∗2) V(∗6) 9 3U 10 3O 9 3T V 3 3P F1(A), F2(B) Combination Meter 12 B +S Temp. Fuel Tachometer Speedometer IG2 MICRO COMPUTER IG2 CAN I/F CANL SI 14 B W 18 A W CANH 17 A B ∗ 1 : 2GR–FE ∗ 2 : 2AZ–FE ∗ 6 : w/ Smart Key System ∗ 7 : TMC Made ∗ 8 : TMMK Made ∗ 9 : 8 Speaker ∗10 : 6 Speaker ∗11 : w/o Smart Key System 11 3P 3 3D W B W W 367 CAMRY (EM0250U) Combination Meter R (BAT) (IG) (BAT) 7. 5A GAUGE NO. 2 10A DOME 10A MPX–B E18(A), a1(B) Spiral Cable V 3 1A 12 IG R 2 1 V SB 1 3Q 9 3Q 12 3Q R 2 A 13 A 1 A IG+ B2 GR V V R GR 6 3Q 7 IF a1(B) Steering Pad SW 1 3D 2 B Steering SW RH 2 3G 6 3A V 12 3L 7 B Y 2 EA1 13 ID 9 A EAC DISP LG GR 3 A +DP 22 A DISP B LCD (ODO/Trip) (Outside Temp. ) MULTI LCD Power Supply Circuit MICRO COMPUTER Buzzer +B(DOME) IG2+ ES P/SB 9 A F1(A), F2(B) Combination Meter 17 A 7 3O 10 3N 10 3D 18 B (∗1) GR(∗2) 3 (∗2) 4 CA3 W–B Gage Clock P W–B BR(∗1) 15 EA1 3 N10 Fuel Suction Pump and Gage Assembly 4 CA3 (∗1) 15 EN2 C6 2 368 CAMRY (EM0250U) C7 C57 Junction Connector 14 EN2 (∗1) BR P 5 3Q P 2 3P GR 6 3P GR BR GR P 24 A GR 16 B GR FE 15 B A41(A), A42(B) Junction Connector FR Rheostat Tail Cancel SW ODO/Trip SW LCD A/T Range R R ∗ 1 : 2GR–FE ∗ 2 : 2AZ–FE Charge Brake(Except USA) BRAKE(USA) SRS MAINT REQD Low Fuel S, 4, 3, 2, L D N R P Washer Level IG2 DRIVE IC WLVL B/LE 5 A 6 B CHG– 23 A 8 3P L LG LG F1(A), F2(B) Combination Meter 11 3J E A52 Washer Level Warning SW 2 3 AE6 W–B LG 2 B 3 AE2 LG S 6 3E Generator 1 1 LG 3 3Q A16 Brake Fluid Level Warning SW LG LG LG A5 A3 369 CAMRY (EM0250U) 1 C23 Engine Oil Pressure SW LG 4 EA1 O 4 B 7 A R L O 8 A S Tire Pressure Warning ECU Engine Control Module Y CHK DRIVE IC TIRE F1(A), F2(B) Combination Meter 10 FE3 6 CA3 370 CAMRY (EM0250U) Beam Tail (Except USA) Head (USA) DOOR IG2 Front Fog Master Warning Cruise Slip ABS VSC Driver' s Seat Belt Tire Pressure Malfunction Indicator Lamp Oil Pressure Combination Meter R R +B(DOME) Turn Signal Flasher R R Illuminations 9 3A 8 11 A B SG ILL– GND +B(DOME) IG2 +B(DOME) IG2 +B(DOME) IG2 3 LCD Illumination Pointer Illumination Illumination Turn RH E2 12 A F1(A), F2(B) Combination Meter W–B W–B 2 3S 7 3Q 2 3U W–B W–B Turn LH W–B +B (DOME) F16 A/C Control Assembly 1 B B R BR G L 2 B 12 3S F1 371 CAMRY (EM0250U) Combination Meter : Parts Location Code See Page A5 52 (2AZ–FE) 48 (2GR–FE) C A26 A A40 C23 52 (2AZ–FE) C24 52 (2AZ–FE) 48 (2GR–FE) B C50 C55 E58 50 (2GR–FE) E59 58 F2 B 58 55 (2AZ–FE) F8 C 58 55 (2AZ–FE) F13 H 58 51 (2GR–FE) 59 C57 51 (2GR–FE) A41 A 59 E6 A 56 A42 B 59 E7 B 56 49 (2GR–FE) E8 C 56 49 (2GR–FE) E18 A 56 53 (2AZ–FE) A60 B C4 E33 F16 F19 N6 1 N13 O6 60 57 O10 60 49 (2GR–FE) E42 A 57 S5 61 53 (2AZ–FE) E43 B 57 S15 50 (2GR–FE) E44 C 57 a1 See Page Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) See Page Junction Block and Wire Harness (Connector Location) 25 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) 36 Instrument Panel No.2 Wire and J/B No.3 (Behind the Combination Meter) 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) 3E 3J 3L 3M 3N 3O 3P 3Q 3T 3U ID IF IG IH 30 31 IM 30 IO 30 60 56 3D IC 60 B B 3B 3S 60 A E41 3C 3G 60 60 3A 3F 60 B N28 : Junction Block and Wire Harness Connector 1A 58 A 49 (2GR–FE) 22 Code 58 B N10 : Relay Blocks Code 57 50 (2GR–FE) A A 57 A 51 (2GR–FE) A55 B F1 C56 A52 57 E60 51 (2GR–FE) B See Page A 55 (2AZ–FE) 52 (2AZ–FE) A43 Code 54 (2AZ–FE) 54 (2AZ–FE) C20 59 A A25 C7 48 (2GR–FE) A18 See Page C4 52 (2AZ–FE) A16 A24 Code 48 (2GR–FE) Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) Floor Wire and Instrument Panel J/B (Cowl Side Left) 372 CAMRY (EM0250U) 61 B 59 : Connector Joining Wire Harness and Wire Harness Code AE2 AE5 AE6 CA1 CA2 CA3 See Page Joining Wire Harness and Wire Harness (Connector Location) 66 Engine Room Main Wire and Instrument Panel Wire (Right Side of the Instrument Panel J/B) 66 Engine Room Main Wire and Instrument Panel Wire (Instrument Panel Right) 64 (2GR–FE) 65 (2AZ–FE) 64 (2GR–FE) Engine Wire and Engine Room Main Wire (Inside of the Engine Room R/B and Engine Room J/B) 64 (2GR–FE) 65 (2AZ–FE) EA1 66 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) EN2 66 Instrument Panel Wire and Floor Wire (Left Kick Panel) EO2 66 Instrument Panel Wire and Floor No.2 Wire (Right Kick Panel) FE3 66 Instrument Panel No.2 Wire and Instrument Panel Wire (Instrument Panel Center) SN1 67 Luggage Room Wire and Floor Wire (Luggage Room Left) : Ground Points Code A2 A3 A5 See Page 64 (2GR–FE) 65 (2AZ–FE) 66 64 (2GR–FE) 65 (2AZ–FE) Ground Points Location Front Left Fender Left Cowl Side Panel Front Right Fender C4 65 (2AZ–FE) Cylinder Block C5 64 (2GR–FE) Right Side of the Cylinder Block C6 65 (2AZ–FE) Cylinder Block C7 64 (2GR–FE) Left Side of the Cylinder Block F1 66 Instrument Panel Left S1 67 Lower Back Panel Center 373 CAMRY (EM0250U) Cooling Fan for 2GR–FE (BAT) (IG) V W 10A ECU IG NO. 1 50A FAN MAIN 6 IC W LG W LG 1 B 1 3 1 C4 Engine Coolant Temp. Sensor 1 1 FAN MAIN Relay V W B 1 79 B 78 B 8 A 49 A 41 A W–B B 1 P 2 B 5 2 ETHW THW NE+ RFC 110 B 43 A M A55(A), C55(B) Engine Control Module B Sub Fan Motor 3 A56(A), A57(B) Short Connector 2 W–B G BR 1 A A1 C5 374 CAMRY (EM0250U) 1 C50 Crankshaft Position Sensor W–B G W–B 1 R E1 2 1 B +B1 G S1 M– (S) (Shielded) M+ (S) G M– (M) A54 Cooling Fan ECU M+ (M) CANL NE– 111 B M Main Fan Motor SPD CANH V V W W B B (IG) ∗ 1 : Automatic A/C 10A A/C NO. 2 16 IF V F16 A/C Control Assembly 1 3L R 3 3S 12 3S L 4 W–B TX+ 3 (∗1) GND 8 B SG 9 (∗1) ADI1 V IG+ 5 2 3S 4 3S 3 3A 9 3A 2 3U 3 3M GR 1 3S W–B A27 A/C Pressure Sensor PR 2 R 2 B + 3 V 3 B GR EAC A58(A), E40(B) Junction Connector 9 A AC1 L E18(A), a1(B) Spiral Cable R (∗1) B (∗1) 10 A P 20 AE6 18 AE6 7 A 37 A TEMP– BR V 2 3E 11 3D 8 3M 4 3M 11 3M V TEMP+ 9 3K BR OFF L AUTO L 10 B Steering SW RH 13 A 10 A 9 A SG–2 LIN1 S5–3 PRE E38(A) A/C Amplifier a1(B) Steering Pad SW W–B V – 1 F1 375 CAMRY (EM0250U) Cooling Fan for 2GR–FE V W Speed Sensors B R L B 20 A 7 B 7 C 6 A 27 B 17 C 5 A 29 B 19 C CANH CANL B W 7 A 2 A 8 A 1 B 7 B 4 B 10 B B W FR+ FR– RL+ RL– RR+ 6 A 5 A RR– SP1 12 A (∗2) 33 B (∗3) 23 C (∗4) ∗ 2 : w/ VSC TMC Made ∗ 3 : w/ VSC TMMK Made ∗ 4 : w/o VSC CANH W B 1 B B W 2 B 14 FE3 13 FE3 B 1 A W 2 A W 11 A 6 AE6 W B BR W 1 A W 25 A 14 B 15 C B 11 A 35 B 26 C FL– E42(A), E43(B) Junction Connector FL+ 19 A (∗2) 8 B (∗3) 8 C (∗4) A41(A) Junction Connector L 17 A 9 B 9 C L P 3 A 10 B 10 C V V 4 A 6 B 6 C W LG 18 A 5 B 5 C B A40(A), E41(B) Junction Connector A25(C), A26(A), A60(B) Skid Control ECU with Actuator L 12 A CANL E38(A) A/C Amplifier B W W 376 CAMRY (EM0250U) (IG) (BAT) 7. 5A GAUGE NO. 2 (BAT) 10A MPX–B 10A DOME L 2 3 1A 1 L LG SB GR 12 IG 1 3D R V 2 3G R GR 10 3B 12 3L 7 IF 1 3Q 13 ID V V 14 AE5 2 EA1 R +S V V 12 B 12 3Q GR 9 3Q 3 3P 13 A 1 A 2 A IG+ B IG2 B2 Speedometer Power Supply Circuit MICRO COMPUTER IG2 CAN I/F E2 ES 11 3P 7 3Q 5 3Q GR 17 A 10 3D 18 B BR BR W–B 2 3U W 3 3D B W W–B 15 EA1 4 CA3 W 3 F1 C57 Junction Connector BR 24 A W–B 12 A A41(A), A42(B) Junction Connector GR SI 14 B W 18 A W CANL 17 A B CANH F1(A), F2(B) Combination Meter C7 377 CAMRY (EM0250U) Cooling Fan for 2GR–FE System Outline System Operation When the power SW is pushed to IG ON position (Power SW type), or when the ignition SW is turned to ON (Ignition SW type), the current from the ECU IG NO.1 fuse is sent to the coil side and the FAN MAIN relay is turned to ON. Then the current flows to TERMINAL 3 of the cooling fan ECU. At the same time, the conditions of the A/C SW, A/C pressure sensor, engine coolant temp. sensor and engine rotation are sent to the TERMINAL 2 as signals from engine control module. As a result of that, the cooling fan ECU continuously controls the rotation of the fan motor and keeps a balance between the cooling efficiency and silentness with the optimal fan rotation. : Parts Location Code See Page Code See Page Code See Page A25 C 48 (2GR–FE) A57 B 59 E40 B 57 A26 A 48 (2GR–FE) A58 A 59 E41 B 57 48 (2GR–FE) A60 B 49 (2GR–FE) E42 A 57 A27 A40 A 59 C4 50 (2GR–FE) E43 B 57 A41 A 59 C50 51 (2GR–FE) F1 A 58 A42 B 59 51 (2GR–FE) F2 B 58 A54 49 (2GR–FE) C55 B C57 51 (2GR–FE) A55 A 49 (2GR–FE) E18 A 56 A56 A 59 E38 A 57 F16 a1 58 B 59 : Relay Blocks Code 1 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1A See Page Junction Block and Wire Harness (Connector Location) 25 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) 36 Instrument Panel No.2 Wire and J/B No.3 (Behind the Combination Meter) 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) 3A 3B 3D 3E 3G 3K 3L 3M 3P 3Q 3S 3U IC ID IF 30 IG 31 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) : Connector Joining Wire Harness and Wire Harness Code AE5 See Page Joining Wire Harness and Wire Harness (Connector Location) 66 Engine Room Main Wire and Instrument Panel Wire (Instrument Panel Right) CA3 64 (2GR–FE) Engine Wire and Engine Room Main Wire (Inside of the Engine Room R/B and Engine Room J/B) EA1 66 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) FE3 66 Instrument Panel No.2 Wire and Instrument Panel Wire (Instrument Panel Center) AE6 378 CAMRY (EM0250U) : Ground Points Code See Page Ground Points Location A1 64 (2GR–FE) Front Left Fender C5 64 (2GR–FE) Right Side of the Cylinder Block C7 64 (2GR–FE) Left Side of the Cylinder Block F1 66 Instrument Panel Left 379 CAMRY (EM0250U) Radiator Fan and Condenser Fan for 2AZ–FE (BAT) (IG) (BAT) W 10A ECU IG NO. 1 40A RDI FAN 40A CDS FAN 6 IC G W B 1 LG 1 L LG 1 C4 Engine Coolant Temp. Sensor W LG LG G W–B 1 1 1 1 1 1 2 L 2 1 1 97 B 96 B 8 A 49 A 41 A 1 THW ETHW SPD CANL CANH R B W W W B 1 W 1 3 L 3 P 1 1 B 2 2 1 4 L 5 5 L NE+ 122 B NE– 121 B R L W–B 1 G 2 W M A7 Radiator Fan Motor M 2 (Shielded) 1 A6 A/C Condenser Fan Motor L W FANH 22 A R FANL 21 A A24(A), C24(B) Engine Control Module 5 FAN NO. 2 Relay 1 FAN NO. 3 Relay 1 FAN NO. 1 Relay 3 W–B 2 2 CA3 W–B 1 C20 Crankshaft Position Sensor W–B B–W 1 CA3 A1 C4 380 CAMRY (EM0250U) L L W W B B (IG) ∗ 1 : Automatic Air Conditioning 10A A/C NO. 2 16 IF V F16 A/C Control Assembly 1 3L R 3 3S 12 3S L 4 W–B TX+ 3 (∗1) GND 8 B SG 9 (∗1) ADI1 V IG+ 5 2 3S 4 3S 3 3A 9 3A 2 3U 3 3M GR 1 3S W–B A27 A/C Pressure Sensor PR 2 R 2 B + 3 V 3 B GR EAC A58(A), E40(B) Junction Connector 9 A AC1 L E18(A), a1(B) Spiral Cable R (∗1) B (∗1) 10 A P 20 AE6 18 AE6 7 A 37 A TEMP– BR V 2 3E 11 3D 8 3M 4 3M 11 3M V TEMP+ 9 3K BR OFF L AUTO L 10 B Steering SW RH 13 A 10 A 9 A SG–2 LIN1 S5–3 PRE E38(A) A/C Amplifier a1(B) Steering Pad SW W–B V – 1 F1 381 CAMRY (EM0250U) Radiator Fan and Condenser Fan for 2AZ–FE L L W LG V P L R L B 3 A 10 B 10 C 17 A 9 B 9 C 20 A 7 B 7 C 6 A 27 B 17 C 5 A 29 B 19 C CANH CANL B W 1 A 7 A 2 A 8 A 1 B 7 B 4 B 10 B B W FR+ FR– RL+ RL– RR+ RR– SP1 12 A (∗2) 33 B (∗3) 23 C (∗4) ∗ 2 : w/ VSC TMC Made ∗ 3 : w/ VSC TMMK Made ∗ 4 : w/o VSC CANH W B 1 B B W 2 B 14 FE3 13 FE3 B 1 A W 2 A W 11 A 6 AE6 W B BR W 25 A 14 B 15 C W 11 A 35 B 26 C FL– 19 A (∗2) 8 B (∗3) 8 C (∗4) E42(A), E43(B) Junction Connector FL+ B A25(C), A26(A), A60(B) Skid Control ECU with Actuator 4 A 6 B 6 C B A40(A), E41(B) Junction Connector 18 A 5 B 5 C W Speed Sensors B 12 A CANL E38(A) A/C Amplifier B W W 382 CAMRY (EM0250U) (IG) L (BAT) (BAT) 7. 5A GAUGE NO. 2 10A DOME 10A MPX–B 2 3 1A 1 LG SB L GR 12 IG 1 3D R V 2 3G R GR 10 3B 12 3L 7 IF 1 3Q 13 ID V V 14 AE5 2 EA1 R +S V V 12 B 12 3Q GR 9 3Q 3 3P 13 A 1 A 2 A IG+ B IG2 B2 Speedometer Power Supply Circuit MICRO COMPUTER IG2 CAN I/F SI ES E2 BR 11 3P 7 3Q 5 3Q 3 3D 2 3U 10 3D 15 EA1 BR W–B 24 A W–B 12 A W 14 B GR W 18 A W CANL 17 A B CANH F1(A), F2(B) Combination Meter B 4 CA3 GR W W–B W F1 C6 383 CAMRY (EM0250U) Radiator Fan and Condenser Fan for 2AZ–FE : Parts Location Code See Page A6 52 (2AZ–FE) A7 Code A60 See Page B Code See Page 53 (2AZ–FE) E42 A 57 52 (2AZ–FE) C4 54 (2AZ–FE) E43 B 57 A24 A 52 (2AZ–FE) C20 55 (2AZ–FE) F1 A 58 A25 C 52 (2AZ–FE) C24 B 55 (2AZ–FE) F2 B 58 A26 A 52 (2AZ–FE) E18 A 56 52 (2AZ–FE) E38 A 57 A27 A40 A 59 E40 B 57 A58 A 59 E41 B 57 F16 a1 58 B 59 : Relay Blocks Code 1 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1A See Page Junction Block and Wire Harness (Connector Location) 25 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) 36 Instrument Panel No.2 Wire and J/B No.3 (Behind the Combination Meter) 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) 3A 3B 3D 3E 3G 3K 3L 3M 3P 3Q 3S 3U IC ID IF 30 IG 31 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) : Connector Joining Wire Harness and Wire Harness Code AE5 See Page Joining Wire Harness and Wire Harness (Connector Location) 66 Engine Room Main Wire and Instrument Panel Wire (Instrument Panel Right) CA3 65 (2AZ–FE) Engine Wire and Engine Room Main Wire (Inside of the Engine Room R/B and Engine Room J/B) EA1 66 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) FE3 66 Instrument Panel No.2 Wire and Instrument Panel Wire (Instrument Panel Center) AE6 : Ground Points Code A1 C4 C6 F1 See Page Ground Points Location 65 (2AZ–FE) Front Left Fender 65 (2AZ–FE) Cylinder Block 66 Instrument Panel Left 384 CAMRY (EM0250U) Memo 385 CAMRY (EM0250U) Air Conditioning (BAT) (IG) 10A A/C NO. 2 50A HTR V 1 12 ID A27 A/C Pressure Sensor 16 IF + 10 B P A58(A), E40(B) Junction Connector 5 A TAM 11 3D 8 3M 4 3M 11 3M G 1 7 4L 12 3M 7 4A 10 3E (∗1) 8 3J W G G MGC Relay 3 SOL+ (∗1) 7 3H R W–B 1 2 PRE 2 A (∗1) 2 5 9 A S5–3 1 W V (∗1) G (∗1) 8 A 1 10 A E38(A), e1(B) A/C Amplifier SI 1 13 A SG–2 LOCK 1 R V 2 3E V 7 3M +B GND V 9 3K BR 12 B 18 AE6 L E39 Blower Motor 20 AE6 7 A 7 3J A41(A), A42(B) Junction Connector V (∗1) W 3 2 BR 8 A L 9 A L P G (∗1) 13 AE2 (∗1) 22 A PR 3 1 V 1 AE3 A2 Ambient Temp. Sensor G V – 1 O V (∗1) G 2 12 EA1 BR 12 CA3 W W 11 CA3 B 1 A SOL– W–B W–B SOL+ BR 2 A SSR+ Flow Control Valve P (∗1) 1 B SSR– Lock Sensor Magnetic Clutch C21(A), C53(B) A/C Compressor L 2 B MG+ W–B 8 CA3 (∗1) G 3 B 3 CA3 G R (∗1) 1 CA3 (∗1) L (∗1) (∗1) (∗1) B 10 AE2 B(∗1) R E3 A1 386 CAMRY (EM0250U) A3 ∗ 1 : 2GR–FE ∗ 2 : Automatic A/C W–B(∗2) E12 Ion Generator (∗2) V W–B V (BAT) 7. 5A A/C 5 GND PCL 8 IM R 10 4L 2 3H 1 3M 2 3C 12 4D 11 4L 5 3M V GR 12 4L R V 1 3S (∗2) V 1 3L V V (∗2) (∗2) 4 GR IG 2 (∗2) 1 A 39 A PCD1 IG+ 21 A B E38(A), e1(B) A/C Amplifier GND 3 3C 9 18 AE5 BUS BUS G 3 B 2 B Connector Housing Color (Black) Connector Housing Color (Red) M M Damper Servo Motor (Air Inlet) Damper Servo Motor (Air Vent Mode) 2 W–B B 4 B W–B 6 4C LG 2 3M (∗1) 8 4L (∗1) B BUS 14 A E49 Junction Connector R (∗1) LG BLW 23 A W–B MGC 20 A e1(B) A/C Blower Assembly B(∗1) R E2 387 CAMRY (EM0250U) Air Conditioning W–B(∗2) W–B(∗2) V V 1 A 2 4L 3 4L TSP O 3 4M 32 A SG–1 O (∗2) Y 34 A TR 2 4M Y LG 29 A (∗2) P (∗2) 1 (∗2) TSR 2 A (∗2) 2 (∗2) E27 A/C Room Temp. Sensor A/C Solar Sensor E11(A) Automatic Light Control Sensor TSL 33 A TSD E38(A), e1(B) A/C Amplifier TEA SGA 5 B Connector Housing Color (Blue) M Damper Servo Motor (Air Mix Driver Side) Connector Housing Color (Green) M Damper Servo Motor (Air Mix Front Passenger Side) (∗2) (Air Mix) (∗3) e1(B) A/C Blower Assembly 388 CAMRY (EM0250U) A/C Evaporator Temp. Sensor (∗2) (∗2) (∗2) 6 B ∗ 2 : Automatic A/C ∗ 3 : Manual A/C W–B(∗2) V V F16 A/C Control Assembly 5 GND 8 3 3 3M 3 3A 9 3A 2 3U 3 4D W–B W–B (∗2) W–B (∗2) R (∗2) 1 4L E18(A), a1(B) Spiral Cable R (∗2) B 2 3S B 12 3S (∗2) L 3 3S 9 A AC1 EAC 3 B 2 B P AUTO OFF TEMP+ TEMP– a1(B) Steering Pad SW E49 Junction Connector 1 (∗2) 2 W–B 11 A GR CANH B W 12 A 10 A Steering SW RH LIN1 E38(A), e1(B) A/C Amplifier W–B GR 4 3S 37 A CANL (∗2) SG 9 W–B ADI1 (∗2) TX+ 4 W–B IG+ B W F1 E2 389 CAMRY (EM0250U) Air Conditioning L (∗4) W (∗4) B (∗4) C4 Engine Coolant Temp. Sensor 1 B CANH R G VPA2 56 A (∗4) Y VPA 55 A (∗4) EPA 59 A (∗4) B L (∗4) L (∗4) R C20 Crankshaft Position Sensor VCPA 57 A 1 2 4 5 6 3 VCP2 EPA2 VCPA EPA VPA VPA2 2 CA3 W–B 2 EPA2 60 A (∗4) VCP2 58 A (∗4) G 1 A24(A), C24(B) Engine Control Module 41 A CANL NE– (∗4) W (∗4) L SPD 121 B (∗4) (∗4) (Shielded) 49 A O ETHW NE+ 122 B 8 A (∗4) THW (∗4) P 96 B (∗4) 97 B (∗4) B (∗4) 2 A17 Accelerator Position Sensor (∗4) B–W 1 CA3 B B W W C4 390 CAMRY (EM0250U) L(∗4) L (∗4) V(∗1) W (∗4) B (∗4) ∗ 1 : 2GR–FE ∗ 4 : 2AZ–FE C4 Engine Coolant Temp. Sensor 1 B VCPA VPA 55 A EPA 59 A 4 6 5 VCPA VPA EPA A17 Accelerator Position Sensor 1 A 7 A 1 B 7 B W 2 EPA2 A40(A), E41(B) Junction Connector Y (∗1) G (∗1) B (∗1) O (∗1) R (∗1) (∗1) (∗1) L 1 3 VPA2 B BR (∗1) 2 1 VCP2 C50 Crankshaft Position Sensor R G (∗1) (∗1) (Shielded) B 57 A W EPA2 60 A (∗4) VPA2 56 A W VCP2 CANH (∗1) CANL 58 A (∗1) W (∗1) V SPD A55(A), C55(B) Engine Control Module 41 A B NE– 111 B 110 B 49 A (∗4) NE+ 8 A ETHW THW (∗1) P 78 B (∗1) 79 B (∗1) B (∗1) 2 B W C5 391 CAMRY (EM0250U) Air Conditioning L(∗4) L(∗4) V(∗1) : 2GR–FE : 2AZ–FE : w/ VSC TMC Made : w/ VSC TMMK Made : w/o VSC L V P L R L B 4 A 6 B 6 C 3 A 10 B 10 C 17 A 9 B 9 C 20 A 7 B 7 C 6 A 27 B 17 C 5 A 29 B 19 C FR+ CANL 25 A 14 B 15 C FR– RL+ RL– RR+ SP1 12 A (∗5) 33 B (∗6) 23 C (∗7) B 14 FE3 13 FE3 B 1 B W W 2 B W B 1 A B 10 B 2 A W 4 B 6 AE6 W 8 A A40(A), E41(B) Junction Connector 2 A L RR– BR 11 A 35 B 26 C W CANH FL– 19 A (∗5) 8 B (∗6) 8 C (∗7) E42(A), E43(B) Junction Connector FL+ W LG 18 A 5 B 5 C B A25(C), A26(A), A60(B) Skid Control ECU with Actuator Speed Sensors 5 A A41(A) Junction Connector 6 A (∗1) (∗1) V 1 4 5 6 7 (∗1) ∗ ∗ ∗ ∗ ∗ B W W 392 CAMRY (EM0250U) L(∗4) (BAT) 7. 5A GAUGE NO. 2 L L 10A MPX–B V 2 (∗1) L (∗4) 10A DOME (∗1) (BAT) (IG) 3 1A 12 IG SB LG GR 1 14 AE5 12 3L 2 3G 1 3D 2 EA1 V R 13 ID 7 IF 1 3Q 9 3Q V 12 3Q V R GR 10 3B V 3 3P 13 A 2 A 12 B +S B2 IG2 1 A IG+ B Speedometer Power Supply Circuit MICRO COMPUTER IG2 CAN I/F E2 12 A 24 A W–B BR ES 14 B W SI 18 A W CANL 17 A B CANH F1(A), F2(B) Combination Meter GR (∗1) 10 3D W–B BR 18 B 4 CA3 B W W–B BR(∗1) 15 EA1 GR(∗4) W 3 F1 (∗4) W–B 4 CA3 C6 C57 Junction Connector 2 3U GR 3 3D W 17 A (∗1) 5 3Q (∗1) 7 3Q A41(A), A42(B) Junction Connector 11 3P C7 393 CAMRY (EM0250U) Air Conditioning : Parts Location Code See Page 48 (2GR–FE) A2 52 (2AZ–FE) A17 A24 48 (2GR–FE) A 52 (2AZ–FE) C20 C21 A C24 B 48 (2GR–FE) A27 53 (2AZ–FE) C50 57 B 57 50 (2GR–FE) E42 A 57 55 (2AZ–FE) E43 B 57 55 (2AZ–FE) A42 B 59 A55 A 49 (2GR–FE) A58 A 59 E11 A E12 E18 A 58 F2 B 58 F16 a1 B 59 56 e1 B 59 56 : Relay Blocks Code 1 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1A See Page Junction Block and Wire Harness (Connector Location) 25 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) 36 Instrument Panel No.2 Wire and J/B No.3 (Behind the Combination Meter) 42 Instrument Panel Wire and J/B No.4 (Instrument Panel Brace Center) ID 30 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Left) IF 30 IG 31 IM 30 3A 3B 3C 3D 3E 3G 3H 3J 3K 3L 3M 3P 3Q 3S 3U 4A 4C 4D 58 51 (2GR–FE) 56 A 57 F1 51 (2GR–FE) C57 E49 51 (2GR–FE) B 59 57 E41 C55 A 57 55 (2AZ–FE) 51 (2GR–FE) A41 A E39 B B 59 E38 56 E40 C53 A See Page E27 54 (2AZ–FE) 52 (2AZ–FE) A40 Code 49 (2GR–FE) 50 (2GR–FE) C4 48 (2GR–FE) 52 (2AZ–FE) See Page B 52 (2AZ–FE) C A26 A60 59 A A25 Code 4L 4M Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) 394 CAMRY (EM0250U) : Connector Joining Wire Harness and Wire Harness Code AE2 See Page Joining Wire Harness and Wire Harness (Connector Location) 66 Engine Room Main Wire and Instrument Panel Wire (Right Side of the Instrument Panel J/B) 66 Engine Room Main Wire and Instrument Panel Wire (Instrument Panel Right) AE3 AE5 AE6 CA3 64 (2GR–FE) 65 (2AZ–FE) Engine Wire and Engine Room Main Wire (Inside of the Engine Room R/B and Engine Room J/B) EA1 66 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) FE3 66 Instrument Panel No.2 Wire and Instrument Panel Wire (Instrument Panel Center) : Ground Points Code A1 See Page 64 (2GR–FE) 65 (2AZ–FE) Ground Points Location Front Left Fender A3 66 Left Cowl Side Panel C4 65 (2AZ–FE) Cylinder Block C5 64 (2GR–FE) Right Side of the Cylinder Block C6 65 (2AZ–FE) Cylinder Block C7 64 (2GR–FE) Left Side of the Cylinder Block E2 66 Instrument Panel Brace LH E3 66 Instrument Panel Right F1 66 Instrument Panel Left 395 CAMRY (EM0250U) I GROUND POINT (GND) C13 Ignition Coil (No. 2) (GND) C14 Ignition Coil (No. 4) (GND) C39 Ignition Coil (No. 6) (GND) B–W 4 W–B B (2GR–FE) 2 W (2GR–FE) B–W (E) (E1) (2GR–FE) 1 BR W–B 3 (2GR–FE) W–B 1 C56 Transmission Control ECU (E01) (2GR–FE) 4 CA3 W–B (2GR–FE) W–B FAN NO. 2 Relay (E02) (2GR–FE) (2GR–FE) C55 Engine Control Module (E05) (2GR–FE) C57 Junction Connector C38 Ignition Coil (No. 5) W 6 W (2GR–FE) B (GND) (E1) (2GR–FE) (2GR–FE) C12 Ignition Coil (No. 3) W–B 5 B (2GR–FE) W (GND) (2GR–FE) C11 Ignition Coil (No. 1) GR (2GR–FE) BR (2GR–FE) (2AZ–FE) A8 Headlamp (LH High) (E) A45 Headlamp (LH Low) (E) BR W–B (2AZ–FE) W–B BR (E) 10 1E (L) 11 1E (SGND) EFI Relay A/F Relay Light Control Circuit BR W–B (2GR–FE) BR A7 Radiator Fan Motor (2GR–FE) (2GR–FE) FAN MAIN Relay W–B 1 W–B (–S) W–B C7 W–B (E1) A47 Side Marker Lamp (Front LH) (E) W–B W–B A54 Cooling Fan ECU (2GR–FE) W–B W–B W–B A46 Turn Signal and Parking Lamp (Front LH) (E) 1 (E) 1 (–S) W–B BR BR BR A1 12 CA3 W W–B(2AZ–FE) W–B(2AZ–FE) (E02) W–B B (2AZ–FE) W–B(2AZ–FE) (2AZ–FE) (ME01) B–W B–W (2AZ–FE) (2AZ–FE) 1 CA3 C4 396 CAMRY (EM0250U) W–B (2AZ–FE) 2 CA3 ST Relay (SOL–) C21 A/C Compressor W–B(2AZ–FE) C24 Engine Control Module RR DEF Relay L (2AZ–FE) (GND) C14 Ignition Coil (No. 4) (GND) C13 Ignition Coil (No. 2) (GND) C12 Ignition Coil (No. 3) (GND) C11 Ignition Coil (No. 1) (Shielded) I (2AZ–FE) W–B W–B (2AZ–FE) (2AZ–FE) (2AZ–FE) (2AZ–FE) 4 CA3 15 EA1 GR (2AZ–FE) BR W 16 NA1 W–B W–B BR B BR (2AZ–FE) C6 (MGND) N17 Leak Detection Pump Assembly (2AZ–FE) (2GR–FE) (E03) (2AZ–FE) 10 CA3 (2GR–FE) (E04) W–B W–B (E1) W–B (2AZ–FE) (E01) W–B(2AZ–FE) C24 Engine Control Module 11 3H BR 5 3Q BR 10 3H 11 3A BR 11 4A 12 4C 10 3D W–B (2GR–FE) (SG) E10 Data Link Connector 3 (ES) F1 Combination Meter (ECC) E18 Spiral Cable (E) E31 Transmission Control SW GR (2GR–FE) BR (2AZ–FE) (2AZ–FE) A24 Engine Control Module W–B (EC) (2AZ–FE) W (EOM) (2AZ–FE) 17 A 18 B 18 A 16 B 16 A 17 B ∗ 1 : 2GR–FE w/ Smart Key System ∗ 2 : 2GR–FE w/o Smart Key System B (2GR–FE) W–B(2AZ–FE) BR A41(A), A42(B) Junction Connector A48 Wireless Door Lock Buzzer B (E) (2AZ–FE) W–B W–B 4 AB1 W–B W–B W–B W–B BR (2GR–FE) (2GR–FE) BR W–B (E) A48 Wireless Door Lock Buzzer (E) A16 Brake Fluid Level Warning SW (E) B1 Windshield Wiper Motor (E) A59 Windshield Wiper Motor BR ST CUT Relay A5 Engine Hood Courtesy SW (–S) 1 (–ST) 1 (E) BR (∗2) BR A3 A43 Junction Connector 6 (∗1) L 5 (∗1) W(∗1) 3 W(2AZ–FE, ∗2) A1 Fog Lamp (Front LH) (E) W–B(∗1) BR W–B(∗2) (∗2) IG2 Relay BR (∗2) 1 W–B BR (2AZ–FE) A2 397 CAMRY (EM0250U) I GROUND POINT C55 Engine Control Module (E01) W–B (2GR–FE) (E) A51 Side Marker Lamp (Front RH) (E) A50 (E) Turn Signal and Parking Lamp (Front RH) A29 Headlamp (RH High) (E) W–B (2GR–FE) 10 CA3 W–B (2GR–FE) W–B B (2GR–FE) B (E03) A49 Headlamp (RH Low) 16 NA1 W–B (MGND) (2GR–FE) (2GR–FE) N17 Canister Pump Module W (2GR–FE) (2GR–FE) W–B C4 B W–B A26 Skid Control ECU with Actuator (GND1) W–B (w/o VSC) W–B W–B (GND2) A25 Skid Control ECU with Actuator (GND2) A26 Skid Control ECU with Actuator W–B W–B (w/ VSC) A4 4 B W–B 3 B W–B 1 B W–B (∗3) (∗3) (∗3) 5 4L W–B 4 4E W–B 5 4H 5 4E W–B 10 IG 5 IE W–B W–B (∗3) W–B : 2GR–FE w/ Smart Key System : w/ Power Seat : w/ Sliding Roof : w/o Sliding Roof : w/ Jam Protection : w/o Jam Protection (∗1) (∗1) (∗1) W–B W–B (∗1) E3 (E) T8 Power Seat SW (Front Passenger' s Seat) (GND) T10 Occupant Classification ECU (E) T6 Seat Heater (RH) (GND3) E8 Main Body ECU (GND) E1 398 CAMRY (EM0250U) E52 Power SW (COM) (E2) E30 Airbag Sensor Assembly Center (GND) E51 Steering Lock ECU 3 IM W–B (∗3) W–B W–B 10 EO2 (GND) A34 Fog Lamp (Front RH) A5 O20(A), T18(B) Junction Connector E39 Blower Motor (E) (w/o VSC) 5 A 1 3 4 5 6 7 A52 Washer Level Warning SW W–B W–B A6 ∗ ∗ ∗ ∗ ∗ ∗ (E) BR W–B (GND1) (E04) BR (w/ VSC) A25 Skid Control ECU with Actuator (ME01) C55 Engine Control Module I E35 Power Outlet Socket (Rear) (E) E29 Power Outlet Socket (Front) (E) E55 Seat Heater SW (E) E65 Yaw Rate Sensor (GND) E34 Yaw Rate Sensor (GND) W–B 6 4 W–B (A/T) W–B W–B W–B 10 8 9 IM (GND2) 10 IF (GND1) Main Body ECU Main Body ECU 7 PWR Relay W–B (w/ VSC TMMK Made) IG1 Relay W–B W–B (w/ VSC TMC Made) W–B 1 IR ACC Relay 1 IE TAIL Relay 1 4B (GND) E51 Steering Lock ECU E58 Certification ECU E50 ID Code Box H2 Outer Rear View Mirror (RH) (SGND) (E) (GND) (–) H8 (E) Door Lock Assembly (Front Passenger' s Side) H5 Door Lock Control SW (E) (w/ VSC) W–B 1 4L W–B 2 4A (∗1) W–B 3 W–B 1 4D 9 (∗1) (∗4) (∗1) W–B W–B W–B (∗4) W–B W–B 17 HE2 W–B 5 W–B(∗4) W–B I5 Power Window Regulator Motor (Front LH) (E) Q6 Overhead J/B (E) W W–B W 8 IX1 11 12 18 EQ1 W–B W–B W W (∗5) (∗5) W (E) Q9 Room Lamp (Center) (E) Q10 Map Lamp (RH) (E) Q11 Map Lamp (LH) (E) Q1 Vanity Lamp SW (LH) 17 IE2 W–B 13 W W–B W–B 4 FE3 (∗6) 18 IM1 (∗6) 13 IM2 (∗7) W–B W–B W–B W–B 2 (E) Q2 Vanity Lamp SW (RH) (∗5) (∗5) M1 (E) Power Window Master SW (GND) (∗5) E49 Junction Connector BR (∗1) (∗1) W–B X2 (GND) Electrical Key Oscillator (Front Door LH) (E) Q3 Inner Rear View Mirror BR (∗1) I7 Door Lock Assembly (Driver' s Side) (E) (∗5) W W2 (GND) Electrical Key (Front Oscillator Door RH) (–) Q13 Sliding Roof Control ECU and Motor W 8 HW1 I3 Outer Rear View Mirror (LH) (E) 11 EQ1 3 4F W–B E30 Airbag Sensor Assembly Center W–B W–B 4 4F W–B (E1) W–B W–B E12 Ion Generator 2 4B W–B (∗1) (ESS) W–B E17 Steering Sensor W–B W–B W–B 399 CAMRY (EM0250U) I GROUND POINT E22 Unlock Warning SW (UN–) E15 (GND) Transponder Key ECU E10 Data Link Connector 3 E3 Outer Mirror SW (CG) (E) E24 Key Interlock Solenoid (KLS–) E38 A/C Amplifier (GND) 2 3A 1 3O W–B 2 3B 1 3N W–B W–B 3 3H 3 3F W–B W–B 3 3I 3 3G W–B W–B 1 3K 2 3K W–B (∗10) W–B (∗10) (∗10) W–B (∗10) 2 3M W–B W–B (∗1) (GND) E60 Tire Pressure Warning ECU (E) E53 Tire Pressure Warning SW (Reset) (E) E14 Turn Signal Flasher (EL) E21 Headlamp Dimmer SW Assembly (E) E32 Shift Lock Control ECU (E) E57 Shift Lock Control ECU (E) U6 Seat Heater (LH) (E) U8 Power Seat SW (Driver' s Seat Lumbar Support Control) W–B 3 3C N27(A), U11(B) Junction Connector W–B F16 (GND) A/C Control Assembly F5 Glove Box Lamp (E) W–B 8 3R W–B 2 3S W–B (∗3) 5 A W–B 2 B W–B 3 B W–B 4 B W–B 6 W–B (∗3) (∗3) (R1) (∗3) (∗3) (E) U7 Power Seat SW (Driver' s Seat) (GND) O18 Door Control Receiver (GND) O17 Door Control Receiver (E) J5 Door Lock Assembly (Rear RH) (GND) O4 Occupant Classification ECU (EW) E19 Windshield Wiper SW Assembly 10 EN2 (∗1) 2 3T 5 O21 Junction Connector (GND1) W–B (∗3) F3 Clock (E2) 7 3Q W–B F1 Combination Meter W–B 1 B W–B 2 3U W–B (∗10) 8 W–B 3 4 JO1 W–B (Manual Seat) W–B W–B O1 W–B 9 EO1 F1 W–B W–B W–B W–B E2 400 CAMRY (EM0250U) I W–B (E) S3 (E) Rear Combination Lamp (LH) W–B W–B S15 Junction Connector W–B W–B W–B (E) (∗10) W–B S1 (E) License Plate Lamp (RH) W–B (ACT–) W–B 1 3 W–B 7 W–B 6 W–B 2 W–B (E) S8 Luggage Compartment Door Lock Cylinder (E) S9 Luggage Electrical Key SW (E) S10 Turn Signal Lamp (Rear LH) (E) S11 Rear Combination Lamp (LH) (E) S12 Rear Combination Lamp (RH) (E) S13 Turn Signal Lamp (Rear RH) (E) N16 Center Stop Lamp (E) K5 Door Lock Assembly (Rear LH) (E) N10 Fuel Suction Pump and Gage Assembly (E) P1 Rear Window Defogger 9 1 SN1 W–B W–B W–B S5 Door Lock Assembly (Luggage) (∗1) (∗1) S2 (E) Rear Combination Lamp (RH) S6 Luggage Compartment Door Lock Cylinder W–B W–B S4 License Plate Lamp (LH) N29 Junction Connector S1 W–B 5 2 W–B 4 KN1 W–B W–B W–B W–B N1 W–B P1 (Shielded) ∗ 1 : 2GR–FE w/ Smart Key System ∗ 3 : w/ Power Seat ∗ 8 : 6 Speaker ∗ 9 : 8 Speaker ∗10 : w/o Smart Key System ∗11 : 8 Speaker w/ Navigation System ∗12 : 8 Speaker w/o Navigation System (Shielded) (Shielded) B (2GR–FE) BR (2GR–FE) (Shielded) BR (∗8) BR C5 (∗12) BR BR W–B (∗9) BR (E) BR (∗11) (∗9) F3 F6 Radio Receiver Assembly (GND) F11 Radio Receiver Assembly (GND) F26 Radio Receiver Assembly (GND) F9 Navigation Receiver Assembly (∗12) (∗12) W–B (GND) (∗11) F20 Stereo Component Amplifier (GND) F2 401 CAMRY (EM0250U) I GROUND POINT : Parts Location Code A41 A42 See Page A 59 B 59 Code See Page E49 N27 A43 49 (2GR–FE) C57 51 (2GR–FE) A N29 O20 Code 57 A 62 (*1) 1 See Page 22 S15 1E B 62 (*1) 62 (*1) U11 B 62 (*1) Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) See Page Junction Block and Wire Harness (Connector Location) 25 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 36 Instrument Panel Wire and J/B No.3 (Behind the Combination Meter) 36 Instrument Panel No.2 Wire and J/B No.3 (Behind the Combination Meter) 42 Instrument Panel Wire and J/B No.4 (Instrument Panel Brace Center) 3A 3B 3C 3D 3F 3G 3H 3I 3K 3M 3N 3O 3Q 3R 3S 3T 3U 4A 4B 4C 4D 4E 4F 4H 4L IE IF IG IM IR 30 31 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Left) 30 * 1 : w/ Power Seat 61 T18 : Junction Block and Wire Harness Connector Code 60 60 : Relay Blocks Code See Page O21 * 2 : w/o Power Seat 402 CAMRY (EM0250U) I : Connector Joining Wire Harness and Wire Harness Code AB1 CA3 See Page 64 (2GR–FE) 65 (2AZ–FE) 64 (2GR–FE) 65 (2AZ–FE) Joining Wire Harness and Wire Harness (Connector Location) Engine Room Main Wire and Engine Room No.2 Wire (Near the Windshield Wiper Motor) Engine Wire and Engine Room Main Wire (Inside of the Engine Room R/B and Engine Room J/B) EA1 66 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) EN2 66 Instrument Panel Wire and Floor Wire (Left Kick Panel) 66 Instrument Panel Wire and Floor No.2 Wire (Right Kick Panel) EQ1 66 Instrument Panel Wire and Roof Wire (Lower Part of Front Pillar LH) FE3 66 Instrument Panel No.2 Wire and Instrument Panel Wire (Instrument Panel Center) HE2 66 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) HW1 67 Front Door RH Wire and Electrical Key Wire Harness RH (Inside of the Front Door RH) IE2 66 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) 67 Front Door LH Wire and Front Door LH No.2 Wire (Inside of the Front Door LH) EO1 EO2 IM1 IM2 IX1 67 Front Door LH Wire and Electrical Key Wire Harness LH (Inside of the Front Door LH) JO1 67 Rear Door No.1 Wire and Floor No.2 Wire (Right Center Pillar) KN1 67 Rear Door No.2 Wire and Floor Wire (Left Center Pillar) NA1 66 Floor Wire and Engine Room Main Wire (Left Kick Panel) QR1 67 Roof Wire and Roof No.2 Wire (Near the Overhead J/B) SN1 67 Luggage Room Wire and Floor Wire (Luggage Room Left) : Ground Points Code A1 A2 A3 A4 A5 A6 See Page Ground Points Location 64 (2GR–FE) 65 (2AZ–FE) 64 (2GR–FE) Front Left Fender 65 (2AZ–FE) 66 64 (2GR–FE) 65 (2AZ–FE) 64 (2GR–FE) 65 (2AZ–FE) Left Cowl Side Panel Near the Skid Control ECU with Actuator Front Right Fender 66 Right Cowl Side Panel 64 (2GR–FE) Cylinder Head 65 (2AZ–FE) Cylinder Block C5 64 (2GR–FE) Right Side of the Cylinder Block C6 65 (2AZ–FE) Cylinder Block C7 64 (2GR–FE) Left Side of the Cylinder Block E1 66 Instrument Panel Left E2 66 Instrument Panel Brace LH E3 66 Instrument Panel Right F1 66 Instrument Panel Left F2 66 Instrument Panel Brace RH F3 66 Under the Front Passenger’s Seat N1 67 Left Rear Quarter Panel 67 Right Rear Quarter Panel 67 Lower Back Panel Center C4 O1 P1 S1 403 CAMRY (EM0250U) J POWER SOURCE (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other Parts. (*1) 30A ST/AM2 1 20A IG2 1 7.5A ALT-S (*2) Ignition SW (AM2) E23 (*1) IG2 Relay (Point Side) 1 ACC Relay (Point Side) 2 50A RR DEF 1 TAIL Relay (Point Side) 2 IG1 Relay (Point Side) 2 PWR Relay (Point Side) 2 7.5A AM2 10A EFI NO.1 10A ETCS 10A MPX-B 1 15A HAZ 20A STR LOCK 25A AMP 25A DOOR NO.1 Battery FL MAIN 3.0W 120A ALT 1 DRL Relay 1 15A H-LP (LH) 1 15A H-LP (RH) HORN Relay (Point Side) 1 10A HORN 1 30A EFI MAIN 1 EFI Relay (Point Side) 1 H-LP (RL) Relay (Point Side) 1 15A H-LP (RL) 1 H-LP (LL) Relay (Point Side) 1 15A H-LP (LL) 1 A/F Relay (Point Side) 1 20A A/F 1 SHORT 1 S-HORN Relay (Point Side) 1 7.5A S-HORN 1 404 CAMRY (EM0250U) (*2) (*1) J (*2) 1 : Engine Room R/B and Engine Room J/B (See Page 22) 2 : Instrument Panel J/B (See Page 30) 7.5A GAUGE NO.2 (*1) 2 10A IGN 7.5A ECU-ACC 15A INJ 7.5A RADIO NO.2 2 20A PWR OUTLET RR DEF Relay (Point Side) 1 10A MIR HTR 2 30A ABS No.2 40A CDS FAN 40A RDI FAN 7.5A A/C 1 50A ABS No.1 7.5A AM1 50A FAN MAIN 7.5A OBD 50A HTR 10A STOP 2 15A FR FOG 25A DOOR NO.2 7.5A PANEL 25A WIP 2 15A TAIL 25A PWR 20A S-HTR 30A P/SEAT 10A ECU IG NO.1 30A S/ROOF 10A GAUGE NO.1 2 10A WASH 25A RR DOOR LH 10A A/C NO.2 2 25A RR DOOR RH 7.5A ECU IG NO.2 30A POWER * 1:2GR-FE * 2:2AZ-FE 10A EFI NO.3 1 15A EFI NO.2 Example Starter S1 Parts Code or Location 10A DOME 10A ECU-B NO.1 1 7.5A DRL 4 Location 15A RADIO NO.1 Electrical Source 405 CAMRY (EM0250U) J POWER SOURCE (Current Flow Chart) Engine Room R/B and Engine Room J/B (See Page 22) Fuse 7.5A System Page ALT–S Charging 100 7.5A AM2 Electronically Controlled Transmission and A/T Indicator (2GR–FE) Engine Control (2GR–FE) Ignition (2GR–FE) Smart Key System 300 108 102 78 7.5A S–HORN Smart Key System Theft Deterrent 78 230 DOME ABS (w/ VSC), TRAC and VSC (TMC Made) ABS (w/ VSC), TRAC and VSC (TMMK Made) ABS (w/o VSC) Air Conditioning Audio System (6 Speaker) Audio System (8 Speaker w/o Navigation System) Clock Combination Meter Cooling Fan (2GR–FE) Cruise Control (2AZ–FE) Cruise Control (2GR–FE) Door Lock Control and Luggage Compartment Door Opener Electronically Controlled Transmission and A/T Indicator (2AZ–FE) Electronically Controlled Transmission and A/T Indicator (2GR–FE) Engine Control (2AZ–FE) Engine Control (2GR–FE) Fog Light Garage Door Opener Headlight Interior Light Key Reminder (w/o Smart Key System) and Seat Belt Warning Navigation System and Audio System (8 Speaker) Radiator Fan and Condenser Fan (2AZ–FE) Sliding Roof Smart Key System SRS Taillight and Illumination Theft Deterrent Tire Pressure Warning System Wireless Door Lock Control (w/o Smart Key System) 242 252 262 386 360 354 202 364 374 292 282 214 312 300 126 108 150 336 144 164 190 346 380 330 78 273 172 230 270 224 ECU–B NO.1 ABS (w/ VSC), TRAC and VSC (TMC Made) ABS (w/ VSC), TRAC and VSC (TMMK Made) Automatic Light Control and Light Auto Turn Off System Door Lock Control and Luggage Compartment Door Opener Fog Light 242 252 160 214 150 10A 10A ∗ These are the page numbers of the first page on which the related system is shown. 406 CAMRY (EM0250U) J Fuse 10A 10A 10A 10A 10A 10A System Page ECU–B NO.1 Headlight Interior Light Key Reminder (w/o Smart Key System) and Seat Belt Warning Power Window Sliding Roof SRS Taillight and Illumination Theft Deterrent Wireless Door Lock Control (w/o Smart Key System) 144 164 190 206 330 273 172 230 224 EFI NO.1 Cruise Control (2AZ–FE) Cruise Control (2GR–FE) Electronically Controlled Transmission and A/T Indicator (2AZ–FE) Electronically Controlled Transmission and A/T Indicator (2GR–FE) Engine Control (2AZ–FE) Engine Control (2GR–FE) Engine Immobiliser System (w/o Smart Key System) Smart Key System 292 282 312 300 126 108 138 78 EFI NO.3 Electronically Controlled Transmission and A/T Indicator (2AZ–FE) Electronically Controlled Transmission and A/T Indicator (2GR–FE) Engine Control (2AZ–FE) Engine Control (2GR–FE) 312 300 126 108 ETCS Cruise Control (2AZ–FE) Cruise Control (2GR–FE) Electronically Controlled Transmission and A/T Indicator (2AZ–FE) Electronically Controlled Transmission and A/T Indicator (2GR–FE) Engine Control (2AZ–FE) Engine Control (2GR–FE) 292 282 312 300 126 108 HORN Horn Smart Key System Theft Deterrent 204 78 230 MPX–B ABS (w/ VSC), TRAC and VSC (TMC Made) ABS (w/ VSC), TRAC and VSC (TMMK Made) ABS (w/o VSC) Air Conditioning Audio System (6 Speaker) Audio System (8 Speaker w/o Navigation System) Combination Meter Cooling Fan (2GR–FE) Cruise Control (2AZ–FE) Cruise Control (2GR–FE) Door Lock Control and Luggage Compartment Door Opener Electronically Controlled Transmission and A/T Indicator (2AZ–FE) Electronically Controlled Transmission and A/T Indicator (2GR–FE) Engine Control (2AZ–FE) 242 252 262 386 360 354 364 374 292 282 214 312 300 126 ∗ These are the page numbers of the first page on which the related system is shown. 407 CAMRY (EM0250U) J POWER SOURCE (Current Flow Chart) Fuse System Page MPX–B Engine Control (2GR–FE) Fog Light Headlight Key Reminder (w/o Smart Key System) and Seat Belt Warning Navigation System and Audio System (8 Speaker) Radiator Fan and Condenser Fan (2AZ–FE) Sliding Roof Smart Key System SRS Taillight and Illumination Tire Pressure Warning System 108 150 144 190 346 380 330 78 273 172 270 15A EFI NO.2 Cruise Control (2AZ–FE) Cruise Control (2GR–FE) Electronically Controlled Transmission and A/T Indicator (2AZ–FE) Electronically Controlled Transmission and A/T Indicator (2GR–FE) Engine Control (2AZ–FE) Engine Control (2GR–FE) 292 282 312 300 126 108 15A HAZ Turn Signal and Hazard Warning Light 182 15A H–LP (LH) Headlight 144 15A H–LP (LL) Headlight 144 15A H–LP (RH) Headlight 144 15A H–LP (RL) Headlight 144 15A RADIO NO.1 Audio System (6 Speaker) Audio System (8 Speaker w/o Navigation System) Navigation System and Audio System (8 Speaker) 360 354 346 20A A/F Engine Control (2GR–FE) 108 20A IG2 Combination Meter Engine Control (2GR–FE) Ignition (2GR–FE) Smart Key System 364 108 102 78 20A STR LOCK Smart Key System 78 25A AMP Audio System (8 Speaker w/o Navigation System) Navigation System and Audio System (8 Speaker) 354 346 DOOR NO.1 Automatic Light Control and Light Auto Turn Off System Door Lock Control and Luggage Compartment Door Opener Fog Light Headlight Interior Light Power Window Sliding Roof Smart Key System Taillight and Illumination Theft Deterrent 160 214 150 144 164 206 330 78 172 230 10A 25A ∗ These are the page numbers of the first page on which the related system is shown. 408 CAMRY (EM0250U) J Fuse System Page ABS No.2 ABS (w/ VSC), TRAC and VSC (TMC Made) ABS (w/ VSC), TRAC and VSC (TMMK Made) ABS (w/o VSC) 242 252 262 30A EFI MAIN Cruise Control (2AZ–FE) Cruise Control (2GR–FE) Electronically Controlled Transmission and A/T Indicator (2AZ–FE) Electronically Controlled Transmission and A/T Indicator (2GR–FE) Engine Control (2AZ–FE) Engine Control (2GR–FE) 292 282 312 300 126 108 30A S/ROOF Sliding Roof 330 30A ST/AM2 Engine Control (2GR–FE) Ignition (2GR–FE) Smart Key System Starting (w/o Smart Key System) 108 102 78 96 40A CDS FAN Radiator Fan and Condenser Fan (2AZ–FE) 380 40A RDI FAN Radiator Fan and Condenser Fan (2AZ–FE) 380 50A ABS No.1 ABS (w/ VSC), TRAC and VSC (TMC Made) ABS (w/ VSC), TRAC and VSC (TMMK Made) ABS (w/o VSC) 242 252 262 50A FAN MAIN Cooling Fan (2GR–FE) 374 50A HTR Air Conditioning 386 50A RR DEF Rear Window Defogger and Mirror Heater 342 ALT Automatic Light Control and Light Auto Turn Off System Charging Fog Light Power Window Starting (w/o Smart Key System) Taillight and Illumination Theft Deterrent 160 100 150 206 96 172 230 30A 120A Instrument Panel J/B (See Page 30) Fuse 7.5A System Page A/C Air Conditioning 386 AM1 Electronically Controlled Transmission and A/T Indicator (2GR–FE) Engine Control (2AZ–FE) Engine Control (2GR–FE) Starting (w/o Smart Key System) 300 126 108 96 ABS (w/ VSC), TRAC and VSC (TMC Made) ABS (w/ VSC), TRAC and VSC (TMMK Made) ABS (w/o VSC) 7.5A ECU IG NO.2 Cruise Control (2AZ–FE) Cruise Control (2GR–FE) Electronically Controlled Transmission and A/T Indicator (2GR–FE) Shift Lock ∗ These are the page numbers of the first page on which the related system is shown. 242 252 262 292 282 300 320 7.5A 409 CAMRY (EM0250U) J POWER SOURCE (Current Flow Chart) Fuse System Page ECU–ACC Automatic Light Control and Light Auto Turn Off System Clock Door Lock Control and Luggage Compartment Door Opener Fog Light Headlight Interior Light Power Window Remote Control Mirror Shift Lock Sliding Roof Smart Key System Taillight and Illumination Theft Deterrent Wireless Door Lock Control (w/o Smart Key System) 160 202 214 150 144 164 206 340 320 330 78 172 230 224 7.5A GAUGE NO.2 ABS (w/ VSC), TRAC and VSC (TMC Made) ABS (w/ VSC), TRAC and VSC (TMMK Made) ABS (w/o VSC) Air Conditioning Audio System (6 Speaker) Audio System (8 Speaker w/o Navigation System) Charging Combination Meter Cooling Fan (2GR–FE) Cruise Control (2AZ–FE) Cruise Control (2GR–FE) Door Lock Control and Luggage Compartment Door Opener Electronically Controlled Transmission and A/T Indicator (2AZ–FE) Electronically Controlled Transmission and A/T Indicator (2GR–FE) Engine Control (2AZ–FE) Engine Control (2GR–FE) Fog Light Headlight Key Reminder (w/o Smart Key System) and Seat Belt Warning Navigation System and Audio System (8 Speaker) Radiator Fan and Condenser Fan (2AZ–FE) Sliding Roof Smart Key System SRS Taillight and Illumination Tire Pressure Warning System 242 252 262 386 360 354 100 364 374 292 282 214 312 300 126 108 150 144 190 346 380 330 78 273 172 270 7.5A OBD Data Link Connector 3 140 7.5A PANEL Taillight and Illumination 172 7.5A ∗ These are the page numbers of the first page on which the related system is shown. 410 CAMRY (EM0250U) J Fuse 7.5A 10A 10A 10A 10A System Page RADIO NO.2 Audio System (6 Speaker) Audio System (8 Speaker w/o Navigation System) Navigation System and Audio System (8 Speaker) 360 354 346 A/C NO.2 Air Conditioning Cooling Fan (2GR–FE) Radiator Fan and Condenser Fan (2AZ–FE) Rear Window Defogger and Mirror Heater 386 374 380 342 ECU IG NO.1 Automatic Glare–Resistant EC Mirror Automatic Light Control and Light Auto Turn Off System Cooling Fan (2GR–FE) Door Lock Control and Luggage Compartment Door Opener Fog Light Headlight Interior Light Power Window Radiator Fan and Condenser Fan (2AZ–FE) Sliding Roof Smart Key System Taillight and Illumination Theft Deterrent Tire Pressure Warning System Wireless Door Lock Control (w/o Smart Key System) 338 160 374 214 150 144 164 206 380 330 78 172 230 270 224 GAUGE NO.1 ABS (w/ VSC), TRAC and VSC (TMC Made) ABS (w/ VSC), TRAC and VSC (TMMK Made) ABS (w/o VSC) Back–Up Light Charging Cruise Control (2AZ–FE) Cruise Control (2GR–FE) Door Lock Control and Luggage Compartment Door Opener Electronically Controlled Transmission and A/T Indicator (2AZ–FE) Electronically Controlled Transmission and A/T Indicator (2GR–FE) Navigation System and Audio System (8 Speaker) Shift Lock Turn Signal and Hazard Warning Light 242 252 262 188 100 292 282 214 312 300 346 320 182 IGN Cruise Control (2AZ–FE) Cruise Control (2GR–FE) Electronically Controlled Transmission and A/T Indicator (2AZ–FE) Electronically Controlled Transmission and A/T Indicator (2GR–FE) Engine Control (2AZ–FE) Engine Control (2GR–FE) Engine Immobiliser System (w/o Smart Key System) Key Reminder (w/o Smart Key System) and Seat Belt Warning 292 282 312 300 126 108 138 190 ∗ These are the page numbers of the first page on which the related system is shown. 411 CAMRY (EM0250U) J POWER SOURCE (Current Flow Chart) Fuse System Page 10A IGN Smart Key System SRS 78 273 10A MIR HTR Rear Window Defogger and Mirror Heater 342 10A STOP ABS (w/ VSC), TRAC and VSC (TMC Made) ABS (w/ VSC), TRAC and VSC (TMMK Made) ABS (w/o VSC) Cruise Control (2AZ–FE) Cruise Control (2GR–FE) Electronically Controlled Transmission and A/T Indicator (2AZ–FE) Electronically Controlled Transmission and A/T Indicator (2GR–FE) Engine Control (2AZ–FE) Engine Control (2GR–FE) Shift Lock Smart Key System Stop Light 242 252 262 292 282 312 300 126 108 320 78 186 10A WASH Wiper and Washer 196 15A FR FOG Fog Light 150 15A INJ Combination Meter Engine Control (2AZ–FE) Ignition (2AZ–FE) 364 126 106 15A TAIL Fog Light Taillight and Illumination 150 172 20A PWR OUTLET Power Outlet 200 20A S–HTR Seat Heater 328 25A DOOR NO.2 Automatic Light Control and Light Auto Turn Off System Door Lock Control and Luggage Compartment Door Opener Fog Light Headlight Interior Light Power Window Sliding Roof Smart Key System Taillight and Illumination Theft Deterrent 160 214 150 144 164 206 330 78 172 230 25A PWR Power Window 206 25A RR DOOR LH Power Window 206 25A RR DOOR RH Power Window 206 25A WIP Wiper and Washer 196 30A POWER Power Window 206 30A P/SEAT Power Seat (Driver’s Seat) Power Seat (Front Passenger’s Seat) 322 326 ∗ These are the page numbers of the first page on which the related system is shown. 412 CAMRY (EM0250U) Memo 413 CAMRY (EM0250U) K CONNECTOR LIST A1 A2 A3 A4 A5 Black Black Black Black Black 1 1 2 1 2 2 1 A6 A7 A8 A13 A14 Gray Black Black Yellow Black 1 1 1 2 1 A16 A17 Gray Black 1 1 A18 A19 A21 Blue 1 A23 A24 Black Black 2 4 1 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 A25 Black 2 3 4 1 A22 Black 1 3 1 2 2 2 1 2 3 4 5 6 2 2 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 414 CAMRY (EM0250U) 1 2 1 2 K 1 2 31 32 A26 A27 A28 Black Black Yellow 1 1 2 3 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 2 33 34 35 36 37 38 39 40 41 42 43 44 45 46 A29 A34 A35 A37 Black Black Gray Black 1 2 2 1 1 1 2 2 A40 A41 Blue 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 7 8 9 10 11 12 12 13 14 15 16 17 18 19 20 21 22 A42 A43 Gray 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 12 13 14 15 16 17 18 19 20 21 22 1 A45 A46 A47 A48 A49 Black Gray Black Black Black 1 2 3 1 2 2 1 2 1 2 415 CAMRY (EM0250U) K CONNECTOR LIST A50 A51 Gray Black 1 2 3 1 2 A52 1 2 A53 A54 Black Black 1 2 1 A55 A56 2 3 A57 Black 1 2 3 3 2 1 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 5 6 6 5 4 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 A58 A59 Black Black 1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 11 12 A60 B1 Black Black 1 2 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 4 5 C1 C2 C3 C4 C5 Gray Black Black Black Black 1 2 1 5 6 2 7 3 4 1 2 3 4 5 1 8 9 416 CAMRY (EM0250U) 1 2 3 4 5 6 K C6 C7 C8 C9 C10 Black Gray Gray Gray Gray 1 2 1 2 1 2 1 2 1 2 C11 C12 C13 C14 C15 Black Black Black Black Dark Gray 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 C16 C17 C18 C19 C19 Gray Black Black (2AZ–FE) (2GR–FE) 1 1 1 2 C20 C21 Black Black 1 2 1 1 2 3 4 C22 1 2 3 4 1 C23 Gray 2 1 2 3 4 1 C24 Black 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 41 42 43 44 45 46 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99100101102103 110111112113114115116117118119120121122123124125126 104105106107108109 C25 C26 C27 C28 C29 Gray Black Black Gray Black 1 2 3 4 5 6 7 8 9 10 11 12 13 1 1 2 1 2 1 2 417 CAMRY (EM0250U) K CONNECTOR LIST C30 C31 C32 C33 C34 Gray Black Black Black Black 1 2 1 2 1 2 1 2 3 1 2 4 5 C35 C36 C37 C38 C39 Dark Gray Gray Gray Black Black 1 2 1 2 1 2 3 4 1 2 3 4 1 2 3 4 C40 C41 C42 C43 C44 Black Black Black Black Black 1 2 1 2 1 2 3 1 2 3 1 2 3 C45 C46 C47 C48 C49 Black Black Black Gray Gray 1 2 1 2 1 2 1 2 3 1 1 2 C50 C51 C52 C53 Black Black Dark Gray Gray 2 1 2 3 4 1 2 3 4 1 2 3 C55 Black 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 41 42 43 44 45 46 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99100101102103 110111112113114115116117118119120121122123124125126 104105106107108109 418 CAMRY (EM0250U) K C56 C57 Black Gray D1 1 8 1 2 3 4 5 6 7 10 11 12 13 14 15 16 17 19 20 21 22 23 24 25 26 9 18 1 2 3 4 5 6 E1 E2 Black Black E3 Black E5 1 2 1 2 1 2 1 2 3 4 5 6 7 8 9 10 E6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 E7 1 2 3 E8 4 5 6 1 2 3 E9 4 1 2 7 8 9 10 11 12 13 14 15 16 17 5 6 7 8 9 10 3 4 5 6 18 19 20 21 11 12 13 14 15 16 7 8 9 10 22 23 24 25 26 E10 E11 E11 Black (Automatic A/C) Blue (Manual A/C) Black 1 3 5 16 15 14 13 12 11 10 9 25 26 27 28 2 4 6 1 3 5 2 4 6 E12 E13 Black 1 2 3 4 5 1 2 8 7 6 5 4 3 2 1 E14 E15 Black E16 E17 Yellow Black 1 2 3 4 1 2 3 4 5 6 7 8 9 10 12 3 456 78 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 419 CAMRY (EM0250U) K CONNECTOR LIST E18 E19 E20 E21 E22 Black 1 1 2 3 4 5 6 7 8 9 101112 2 3 1 7 5 2 3 1 2 4 1 2 3 4 5 6 7 8 9 10 4 E23 56 6789 10 11 12 13 14 15 16 17 18 19 20 E24 E25 E27 Black Black Black 1 2 1 2 3 4 5 6 7 8 12 1 E30 E29 2 3 4 5 6 E31 1 2 7 E32 E33 E34 Yellow Black 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 1 2 3 4 5 6 7 8 1 2 3 4 5 1 2 3 4 5 6 7 8 21 22 23 24 25 26 27 28 29 30 E35 E37 E38 E39 Black 1 2 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 E40 E41 E42 Blue 1 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 7 8 9 10 11 12 420 CAMRY (EM0250U) 2 3 K E43 E44 E45 E46 Black Black Blue 1 1 1 1 2 2 2 2 E48 E49 Black 1 2 3 4 5 6 7 8 9 10111213 1 2 3 4 5 6 7 8 9 10111213 E50 1 1 2 3 4 5 6 7 8 E51 E52 E53 Black Black Black 2 3 4 5 6 1 2 7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 E54 E55 Yellow Black 1 2 1 E56 E57 1 2 3 1 2 3 4 5 6 7 8 9 101112 2 3 4 5 6 E58 1 2 3 4 5 6 7 8 9 E59 10 11 12 13 14 15 16 17 1 2 3 4 5 6 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 E60 E61 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 E62 E63 E65 Gray Brown Black 1 1 2 2 1 1 2 3 4 5 6 7 8 9 101112 1 2 2 4 3 421 CAMRY (EM0250U) K CONNECTOR LIST F1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 F5 F3 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 9 10111213141516 11 12 13 14 15 16 17 18 19 20 F6 1 2 1 F2 2 F7 3 4 5 6 7 8 9 10 F4 1 2 3 4 5 6 7 8 F8 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 F9 1 F10 2 3 4 5 6 7 8 9 10 1 2 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 6 7 8 9 4 5 6 7 8 9 10 11 12 13 14 15 16 11 12 13 14 15 16 17 18 19 20 F12 1 2 3 4 5 F11 F13 F14 Gray Blue F15 1 2 3 4 5 1 2 3 1 4 5 6 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 F16 F17 F18 Gray Gray Blue 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 1 2 F19 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 F20 1 2 3 4 5 6 7 8 9 101112 F21 F22 F23 1 2 3 4 1 2 F24 1 2 3 4 1 2 422 CAMRY (EM0250U) K F25 F26 1 H1 10 1 11 12 13 14 15 16 17 18 19 20 2 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10111213 H2 H4 H5 H6 H7 Black 1 3 5 1 2 4 6 1 1 2 3 4 2 3 4 5 6 H8 2 1 2 3 4 5 I1 I3 I4 I5 I6 Black 1 2 3 1 3 5 1 4 2 5 6 7 8 9 10 1 2 4 6 1 2 3 4 5 6 1 2 2 3 4 5 6 7 8 9 10 I7 1 2 J1 3 J3 1 2 3 4 5 4 1 J5 K1 2 1 3 4 5 6 5 6 7 8 9 10 2 3 1 2 3 4 5 4 5 6 7 8 9 10 K3 K5 M1 N1 Yellow 1 2 3 4 5 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 6 7 8 9 10 11 12 13 14 15 423 CAMRY (EM0250U) K CONNECTOR LIST N3 N6 N6 (TMC Made) (TMMK Made) Black 1 1 1 2 3 4 N7 N8 Yellow Yellow 1 1 2 3 4 N10 2 1 2 4 N11 N12 N13 1 N13 N15 N16 2 1 1 2 5 Black (TMC Made) Black (TMMK Made) Yellow 3 1 1 2 1 2 3 N17 N18 N19 N21 N23 N24 Black Black Black Black Black Gray 1 1 2 3 4 5 6 7 8 9 10 N25 1 1 2 1 2 2 N26 N27 Gray 1 2 1 2 3 1 2 6 7 3 4 5 8 9 1011121314151617 N28 N29 Blue 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 1 2 3 4 5 6 7 8 9 10 11 424 CAMRY (EM0250U) 1 2 K N34 O1 O3 O4 Yellow O6 Black 1 2 3 4 5 1 2 3 4 5 1 6 7 8 9 10 1 1 2 3 4 5 6 7 8 9 101112 2 11 12 13 14 15 O7 O8 O9 O10 Yellow Yellow Yellow Black 1 1 2 3 4 O14 O15 2 1 1 2 O16 O17 O12 O13 2 1 2 1 O18 O19 Black 1 2 3 4 Gray 1 1 2 3 1 2 1 2 3 4 4 5 6 1 2 3 4 5 O20 7 O21 P1 Black 1 1 2 6 7 3 4 5 8 9 1 2 3 4 5 6 7 8 9 10 11 1011121314151617 Q1 Q2 Q3 1 2 3 4 5 2 1 2 1 425 CAMRY (EM0250U) K CONNECTOR LIST Q5 Q6 Q7 Q8 Gray Gray 1 2 1 2 1 2 3 4 5 6 7 8 1 2 3 4 5 Q9 Q10 Q11 Q12 Gray Brown Gray Black 1 2 3 5 4 3 2 1 5 4 3 2 1 1 2 3 4 5 Q13 S1 S2 S3 S4 S5 Black 1 2 3 4 1 2 1 5 6 7 8 9 10 S6 1 2 3 4 S8 2 1 S13 Black Gray 2 1 4 3 6 5 S16 S11 Gray Black 1 2 3 2 1 S14 1 2 S10 1 2 2 1 S12 1 2 3 1 2 3 S9 4 3 2 1 2 3 4 S15 1 2 3 4 5 6 7 8 9 101112 T1 T3 Black Black 1 2 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 426 CAMRY (EM0250U) T6 1 2 K T7 T8 T10 T11 Black Black Gray 1 2 1 3 4 5 6 7 8 9 10 2 1 2 3 4 5 6 7 8 9 101112 1 2 3 4 5 6 7 8 9 101112 T14 T15 T16 T17 Black Gray Gray Black 1 2 3 1 2 3 1 2 3 T18 1 2 6 7 3 4 5 8 9 1 2 3 U1 U2 U3 Black Black Black 1 2 1 2 1 2 1011121314151617 U4 U5 U6 U7 Black 1 2 1 2 1 2 U11 1 2 6 7 U8 Black 3 4 5 8 9 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 V1 V2 Gray Black 1 2 1 2 W1 1 2 3 4 5 6 1011121314151617 427 CAMRY (EM0250U) K CONNECTOR LIST W2 X1 X2 Black Y1 Z1 1 2 1 2 Black 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 a1 b1 1 2 3 4 5 c1 c2 d1 Black Orange Gray 1 2 1 2 1 2 3 4 5 6 7 8 9 101112 1 2 6 7 8 9 10 3 4 d2 d3 d4 d5 Black Black Black Black 1 2 3 1 2 3 1 2 3 e1 1 2 3 1 2 3 4 5 6 7 8 f1 g1 Gray Gray 1 2 1 2 428 CAMRY (EM0250U) Memo 429 CAMRY (EM0250U) K CONNECTOR LIST AB1 AE2 Gray 1 2 3 3 2 1 4 5 5 4 1 2 3 4 5 6 7 8 9 17 10 11 12 13 14 15 16 25 18 19 20 21 22 23 24 AE3 AE4 Gray 9 8 7 6 5 4 3 2 25 16 15 14 13 12 11 10 17 24 23 22 21 20 19 18 Yellow 2 1 1 2 3 4 5 6 2 1 65 43 4 3 1 2 3 4 AE5 1 11 10 10 2 3 4 5 6 7 8 9 20 1 9 8 7 6 5 4 3 2 20 12 13 14 15 16 17 18 19 11 19 18 17 16 15 14 13 12 AE6 AE7 Gray 1 1 2 3 4 5 6 7 8 9 17 10 11 12 13 14 15 16 25 18 19 20 21 22 23 24 9 8 7 6 5 4 3 2 1 2 1 25 16 15 14 13 12 11 10 17 24 23 22 21 20 19 18 430 CAMRY (EM0250U) 2 1 K CA1 CA2 Black 1 2 2 1 1 2 3 4 5 6 7 8 9 10 11 1213141516171819 20 10 9 8 7 6 5 4 3 2 1 20 1918171615141312 11 CA3 CV1 1 2 3 4 5 6 7 8 9 10 11 12 2 1 2 3 4 1 Gray 2 1 4 3 7 6 5 4 3 12 11 10 9 8 EA1 1 2 8 9 9 10 11 3 4 5 6 7 17 18 12 13 14 15 16 8 2 1 18 17 7 6 5 4 3 11 10 16 15 14 13 12 EN1 1 2 6 7 3 4 5 8 9 1011121314151617 5 4 9 8 3 2 1 7 6 1716151413121110 431 CAMRY (EM0250U) K CONNECTOR LIST EN2 1 11 10 10 2 3 4 5 6 7 8 9 Blue 20 20 12 13 14 15 16 17 18 19 1 9 8 7 6 5 4 3 2 11 19 18 17 16 15 14 13 12 EO1 1 2 6 7 3 4 5 8 9 5 4 9 8 EO2 11 2 3 4 5 6 7 8 9 2 1 7 6 1716151413121110 1011121314151617 1 3 Blue 10 10 20 20 12 13 14 15 16 17 18 19 1 9 8 7 6 5 4 3 2 11 19 18 17 16 15 14 13 12 EQ1 Ec1 Yellow 4 1 11 2 3 4 5 6 7 8 9 12 13 14 15 16 17 18 19 10 10 20 20 1 9 8 7 6 5 4 3 2 11 19 18 17 16 15 14 13 12 432 CAMRY (EM0250U) 1 2 3 4 3 2 1 K FE2 1 11 10 10 2 3 4 5 6 7 8 9 Blue 20 20 12 13 14 15 16 17 18 19 6 7 3 4 5 8 9 HE1 Gray 5 2 9 4 3 8 2 7 1 1 2 6 7 3 4 5 8 9 6 1716151413121110 1011121314151617 11 19 18 17 16 15 14 13 12 FE3 1 1 9 8 7 6 5 4 3 2 2 3 4 5 6 7 8 IE1 1 6 2 7 3 4 8 9 9 8 8 7 6 5 4 3 2 3 1 7 6 Gray 4 3 2 1 8 7 6 5 1 2 3 4 5 6 7 8 1 2 25 16 15 14 13 12 11 10 17 24 23 22 21 20 19 18 IE2 Gray 5 4 9 8 3 2 1 7 6 5 1 2 3 4 5 6 7 8 9 17 10 11 12 13 14 15 16 25 18 19 20 21 22 23 24 9 1011121314151617 4 HW1 9 17 10 11 12 13 14 15 16 25 18 19 20 21 22 23 24 5 1716151413121110 1011121314151617 HE2 1 Gray 9 8 7 6 5 4 3 2 1 25 16 15 14 13 12 11 10 17 24 23 22 21 20 19 18 1716151413121110 433 CAMRY (EM0250U) K CONNECTOR LIST IM1 1 2 8 9 9 10 11 3 4 5 6 7 17 18 12 13 14 15 16 IM2 1 2 3 4 5 6 7 8 9 10 11 12 13 8 2 1 18 17 7 6 5 4 3 11 10 16 15 14 13 12 IX1 Blue 1 2 3 4 5 6 7 8 5 4 3 2 1 13 12 11 10 9 8 7 6 JO1 1 2 3 4 5 6 7 7 6 5 10 4 3 2 1 17 16 15141312 11 20 1918 10 7 6 8 9 9 8 11 12131415 16 1819 20 17 KN1 1 2 3 4 5 6 7 8 9 10 11 12131415 16 1819 20 5 4 3 2 1 16 15141312 11 20 1918 10 9 8 17 17 434 CAMRY (EM0250U) Gray 4 3 2 1 8 7 6 5 K NA1 NZ2 Black Yellow 2 1 1 2 8 9 9 10 11 3 4 5 6 7 17 18 12 13 14 15 16 2 8 9 8 8 2 1 18 17 7 6 5 4 3 11 10 16 15 14 13 12 OF1 2 1 2 1 Black 9 10 11 3 4 5 6 7 17 18 12 13 14 15 16 1 2 18 17 7 6 5 4 3 11 10 16 15 14 13 12 OA1 1 8 9 10 11 3 4 5 6 7 17 18 12 13 14 15 16 OT1 Black 9 8 2 3 2 1 6 5 4 1 2 3 4 5 6 1 Gray 18 17 7 6 5 4 3 11 10 16 15 14 13 12 OY2 SN1 Yellow 2 1 1 2 1 2 8 9 10 11 3 4 5 6 7 17 18 12 13 14 15 16 fO1 8 2 1 18 17 7 6 5 4 3 11 10 16 15 14 13 12 gN1 Gray 1 2 9 2 1 Gray 1 2 2 1 435 CAMRY (EM0250U) L PART NUMBER OF CONNECTORS Code Part Number Code A1 Fog Lamp (Front LH) Part Name 82824–60460 B1 Windshield Wiper Motor 90980–11599 A2 Ambient Temp. Sensor 90980–11070 C1 Park/Neutral Position SW 90980–12362 A3 Horn (High) C2 Mass Air Flow Meter 90980–12292 A4 Horn (Low) C3 Starter 90980–11400 A5 Engine Hood Courtesy SW C4 Engine Coolant Temp. Sensor 90980–10735 A6 A/C Condenser Fan Motor C5 Throttle Body Assembly 90980–11858 A7 Radiator Fan Motor C6 VSV (Purge) 90980–11156 90980–10619 90980–11002 90980–10928 Part Name Part Number A8 Headlamp (LH High) 90980–11659 C7 Fuel Injector (No.1) A13 Airbag Sensor (Front LH) 90980–12490 C8 Fuel Injector (No.3) A14 Speed Sensor (Front LH) 90980–11002 C9 Fuel Injector (No.2) A16 Brake Fluid Level Warning SW 90980–11207 C10 Fuel Injector (No.4) A17 Accelerator Position Sensor 90980–12303 C11 Ignition Coil (No.1) A18 Parking Brake SW 90980–10871 C12 Ignition Coil (No.3) A19 Stop Lamp SW 90980–11118 C13 Ignition Coil (No.2) A21 Cruise Control Clutch SW 90980–10906 C14 Ignition Coil (No.4) A22 Clutch Start SW 90980–10825 C15 Air Fuel Ratio Sensor (Bank 1 Sensor 1) 90980–11178 A23 Security Horn 90980–10619 C16 Noise Filter (Ignition RH) 90980–10843 A24 Engine Control Module 90980–12461 C17 Power Steering Oil Pressure SW 90980–11428 A25 Skid Control ECU with Actuator 90980–WB001 C18 Generator 90980–11964 A26 Skid Control ECU with Actuator 90980–12297 Generator (2AZ–FE) 90980–09213 C19 90980–11875 90980–11885 A27 A/C Pressure Sensor 90980–10845 Generator (2GR–FE) 90980–09983 A28 Airbag Sensor (Front RH) 90980–12490 C20 Crankshaft Position Sensor 90980–10947 A29 Headlamp (RH High) 90980–11659 C21 A/C Compressor 90980–11156 Heated Oxygen Sensor (Bank 1 Sensor 2) 90980–11028 A34 Fog Lamp (Front RH) 82824–60460 C22 A35 Speed Sensor (Front RH) 90980–11002 C23 Engine Oil Pressure SW 90980–11363 A37 Windshield Washer Motor 90980–11019 C24 Engine Control Module 90980–12398 A40 Junction Connector 90980–11661 C25 90980–12326 A41 Junction Connector Electronically Controlled Transmission Solenoid A42 Junction Connector 90980–12372 C26 Transmission Revolution Sensor (Turbine) A43 Junction Connector 90980–11194 C27 Transmission Revolution Sensor (Counter Gear) 90980–11156 A45 Headlamp (LH Low) 82824–60460 C28 Back–Up Lamp SW 90980–11250 A46 Turn Signal and Parking Lamp (Front LH) 90980–11020 C29 Starter 90980–11400 A47 Side Marker Lamp (Front LH) 90980–11162 C30 Knock Control Sensor (Bank 1) 90980–11875 A48 Wireless Door Lock Buzzer 90980–11142 C31 Camshaft Position Sensor 90980–10947 A49 Headlamp (RH Low) 82824–60460 C32 Camshaft Timing Oil Control Valve 90980–11162 A50 Turn Signal and Parking Lamp (Front RH) 90980–11020 C33 Intake Air Control Valve 90980–11599 A51 Side Marker Lamp (Front RH) 90980–11162 C34 VSV (ACM) 90980–11156 A52 Washer Level Warning SW 90980–11068 C35 Air Fuel Ratio Sensor (Bank 2 Sensor 1) 90980–11178 A53 VSV (Air Intake Control) 90980–11156 C36 Fuel Injector (No.5) A54 Cooling Fan ECU 90980–12058 C37 Fuel Injector (No.6) A55 Engine Control Module 90980–12462 C38 Ignition Coil (No.5) A56 Short Connector 90980–12204 C39 Ignition Coil (No.6) A57 Short Connector 90980–12012 C40 VVT Sensor (Bank 1 Exhaust Side) A58 Junction Connector 90980–11661 C41 VVT Sensor (Bank 1 Intake Side) A59 Windshield Wiper Motor 90980–11599 A60 Skid Control ECU with Actuator 90980–WA008 Note: Not all of the above part numbers of the connector are established for the supply. 436 CAMRY (EM0250U) 90980–11875 90980–11885 90980–12353 L Code C42 C43 C44 Part Name Part Number Camshaft Timing Oil Control Valve (RH Exhaust Side) Camshaft Timing Oil Control Valve (RH Intake Side) 90980–11162 VVT Sensor (Bank 2 Exhaust Side) C45 VVT Sensor (Bank 2 Intake Side) C46 Camshaft Timing Oil Control Valve (LH Exhaust Side) C47 Camshaft Timing Oil Control Valve (LH Intake Side) 90980–12353 90980–11162 C48 VSV (ACIS) C49 Noise Filter (Ignition LH) 90980–10843 C50 Crankshaft Position Sensor 90980–12611 C51 Heated Oxygen Sensor (Bank 2 Sensor 2) 90980–11028 C52 Heated Oxygen Sensor (Bank 1 Sensor 2) 90980–10869 C53 A/C Compressor 90980–11016 C55 Engine Control Module 90980–12396 C56 Transmission Control ECU 90980–12649 C57 Junction Connector 90980–11194 D1 Starter 90980–09463 E1 Diode (Door Courtesy Rear LH) E2 Diode (Door Courtesy Rear RH) E3 Outer Mirror SW 90980–11657 E5 Diode (Door Courtesy Front LH) 90980–10962 E6 Main Body ECU 90980–12330 E7 Main Body ECU 90980–12561 E8 Main Body ECU 90980–12329 E9 Main Body ECU 90980–12328 E10 Data Link Connector 3 90980–11665 E11 Automatic Light Control Sensor 90980–12056 E12 Ion Generator 90980–11909 E13 VSC Warning Buzzer 90980–10906 E14 Turn Signal Flasher 90980–10799 E15 Transponder Key ECU 90980–12423 E16 Airbag Squib (Steering Wheel Pad) 90980–12160 E17 Steering Sensor 90980–12162 E18 Spiral Cable 90980–12552 E19 Windshield Wiper SW Assembly 90980–12358 E20 Windshield Wiper SW Assembly 90980–12359 E21 Headlamp Dimmer SW Assembly 90980–12460 E22 Unlock Warning SW 90980–12063 E23 Ignition SW 90980–11615 E24 Key Interlock Solenoid 90980–12063 E25 Transponder Key Amplifier 90980–12092 E27 A/C Room Temp. Sensor 90980–11918 E29 Power Outlet Socket (Front) 90980–12498 E30 Airbag Sensor Assembly Center 90980–12391 90980–10962 Code Part Name Part Number E31 Transmission Control SW E32 Shift Lock Control ECU E33 Parking Brake SW 90980–10871 E34 Yaw Rate Sensor 90980–11904 E35 Power Outlet Socket (Rear) 90980–12498 E37 Diode (Door Courtesy Front RH) 90980–10962 E38 A/C Amplifier 90980–12557 E39 Blower Motor 90980–11667 E40 Junction Connector E41 Junction Connector E42 Junction Connector E43 Junction Connector E44 Junction Connector E45 Junction Connector E46 Junction Connector E48 Junction Connector E49 Junction Connector E50 ID Code Box 90980–12558 E51 Steering Lock ECU 90980–12092 E52 Power SW 90980–12370 E53 Tire Pressure Warning SW (Reset) 90980–10906 E54 Airbag Squib (Knee Airbag) 90980–12253 E55 Seat Heater SW 90980–10797 E56 Electrical Key Oscillator (Console) 90980–12296 E57 Shift Lock Control ECU 90980–12552 E58 Certification ECU 90980–12567 E59 Certification ECU 90980–12566 E60 Tire Pressure Warning ECU 90980–12552 E61 Option Connector (Bus Buffer) 90980–10860 E62 Junction Connector E63 Junction Connector E65 Yaw Rate Sensor 90080–98249 F1 Combination Meter 90980–12554 F2 Combination Meter 90980–12553 F3 Clock 90980–12460 F4 Hazard Warning Signal SW 90980–12113 F5 Glove Box Lamp 90980–11098 F6 Radio Receiver Assembly 90980–10997 F7 Radio Receiver Assembly 90980–10996 F8 Radio Receiver Assembly 90980–12460 F9 Navigation Receiver Assembly 90980–12038 F10 Navigation Receiver Assembly 90980–12460 F11 Radio Receiver Assembly 90980–12423 F12 Navigation Receiver Assembly 90980–12404 F13 Navigation Receiver Assembly 90980–11909 90980–12551 90980–11661 90980–12355 90980–11542 90980–12355 437 CAMRY (EM0250U) L PART NUMBER OF CONNECTORS Code Part Number Code F14 Navigation Receiver Assembly Part Name 90980–12209 N12 F15 Antenna Amplifier 90980–10871 F16 A/C Control Assembly 90980–12559 F17 Stereo Jack Adapter 82824–21030 F18 Stereo Component Amplifier 90980–10801 F19 Stereo Component Amplifier 90980–12554 F20 Stereo Component Amplifier 90980–10803 F21 Tweeter (Front LH) 90980–10860 F22 Tweeter (Front LH) 90980–12304 F23 Tweeter (Front RH) 90980–10860 F24 Tweeter (Front RH) 90980–12304 F25 Junction Connector 90980–11542 F26 Radio Receiver Assembly 90980–12038 H1 Speaker (Front Door RH) 90980–10935 H2 Outer Rear View Mirror (RH) 90980–12056 H4 Power Window Regulator Motor (Front Passenger’s Side) 90980–10797 H5 Door Lock Control SW 90980–11950 H6 Power Window SW (Front Passenger’s Side) 90980–10789 H7 Courtesy Lamp (Front Door RH) 90980–11148 H8 Door Lock Assembly (Front Passenger’s Side) 90980–12226 I1 Speaker (Front Door LH) 90980–10935 I3 Outer Rear View Mirror (LH) 90980–12056 I4 Power Window Regulator Motor (Front LH) 90980–10797 I5 Power Window Regulator Motor (Front LH) 90980–12328 I6 Courtesy Lamp (Front Door LH) 90980–11148 I7 Door Lock Assembly (Driver’s Side) 90980–12226 J1 Power Window SW (Rear RH) 90980–10789 J3 Power Window Regulator Motor (Rear RH) 90980–10797 J5 Door Lock Assembly (Rear RH) 90980–12226 K1 Power Window SW (Rear LH) 90980–10789 K3 Power Window Regulator Motor (Rear LH) 90980–10797 K5 Door Lock Assembly (Rear LH) 90980–12226 M1 Power Window Master SW 90980–12122 N1 Airbag Sensor Assembly Center 90980–12449 N3 Front Seat Inner Belt (Driver’s Side) 90980–10942 Door Courtesy SW (Driver’s Side) (TMC Made) 90980–10871 Door Courtesy SW (Driver’s Side) (TMMK Made) 82824–33280 N7 Side Airbag Sensor (Front LH) 90980–12225 N6 Part Name Part Number Side Airbag Sensor (Rear LH) 90980–11856 Door Courtesy SW (Rear LH) (TMC Made) 82824–33280 N13 Door Courtesy SW (Rear LH) (TMMK Made) 90980–10871 N15 Noise Filter (Dome and Stop) 90980–10916 N16 Center Stop Lamp 90980–11159 N17 Canister Pump Module 90980–12380 N18 Noise Filter (Rear Window Defogger) 90980–10916 N19 Rear Window Defogger 90980–10913 N21 Curtain Shield Airbag Squib (LH) 90980–12575 N23 Diode (Luggage Compartment Lamp) 90980–10962 N24 Luggage Compartment Lamp 90980–11148 N25 Electrical Key Oscillator (Inside Luggage Room) 90980–12296 N26 Luggage Compartment Lamp 90980–11148 N27 Junction Connector 90980–12374 N28 Junction Connector 90980–11915 N29 Junction Connector 90980–11539 N34 Tire Pressure Warning Antenna and Receiver 90980–12366 O1 Airbag Sensor Assembly Center 90980–12450 O3 Front Seat Inner Belt (Front Passenger’s Side) 90980–11156 O4 Occupant Classification ECU 90980–12356 O6 Door Courtesy SW (Front Passenger’s Side) 90980–10871 O7 Side Airbag Sensor (Front RH) 90980–12225 O8 Pretensioner (RH) 90980–12253 O9 Side Airbag Sensor (Rear RH) 90980–11856 O10 Door Courtesy SW (Rear RH) 82824–33280 O12 Speaker (Rear LH) O13 Speaker (Rear RH) O14 Speaker (Rear LH) O15 Speaker (Rear RH) O16 Curtain Shield Airbag Squib (RH) 90980–12575 O17 Door Control Receiver 90980–12366 O18 Door Control Receiver 90980–50011 O19 Electrical Key Antenna 90980–12043 O20 Junction Connector 90980–12374 O21 Junction Connector 90980–11539 P1 Rear Window Defogger 90980–10914 Q1 Vanity Lamp SW (LH) Q2 Vanity Lamp SW (RH) N8 Pretensioner (LH) 90980–12253 Q3 Inner Rear View Mirror N10 Fuel Suction Pump and Gage Assembly 90980–11077 Q5 Microphone (Navigation) N11 Electrical Key Oscillator (Rear Seat) 90980–12296 Q6 Overhead J/B Note: Not all of the above part numbers of the connector are established for the supply. 438 CAMRY (EM0250U) 90980–11299 90980–10795 90980–12322 90980–12366 90980–11989 L Code Part Name Part Number Q7 Vanity Lamp (LH) Q8 Vanity Lamp (RH) Q9 Room Lamp (Center) Q10 Map Lamp (RH) Q11 Map Lamp (LH) Q12 Microphone (Navigation) 90980–12366 Q13 Sliding Roof Control ECU and Motor 90980–10997 S1 License Plate Lamp (RH) S2 Rear Combination Lamp (RH) S3 Rear Combination Lamp (LH) S4 License Plate Lamp (LH) 90980–11148 S5 Door Lock Assembly (Luggage) 90980–10908 S6 Luggage Compartment Door Lock Cylinder S8 Luggage Compartment Door Lock Cylinder S9 Luggage Electrical Key SW S10 Turn Signal Lamp (Rear LH) S11 Rear Combination Lamp (LH) U2 Power Seat Motor (Driver’s Seat Front Vertical Control) U3 Power Seat Motor (Driver’s Seat Reclining Control) U4 Power Seat Motor (Driver’s Seat Lifter Control) 90980–11148 U5 Power Seat Motor (Driver’s Seat Lumbar Support Control) 90980–10795 U6 Seat Heater (LH) 90980–10906 U7 Power Seat SW (Driver’s Seat) 90980–10997 U8 Power Seat SW (Driver’s Seat Lumbar Support Control) 90980–10789 90980–11060 U11 Junction Connector 90980–12374 90980–12212 V1 Knock Control Sensor (Bank 2) 90980–11967 V2 Knock Control Sensor (Bank 1) 90980–10906 W1 Door Outside Handle (Front RH) 90980–12382 W2 Electrical Key Oscillator (Front Door RH) 90980–12380 X1 Door Outside Handle (Front LH) 90980–12382 X2 Electrical Key Oscillator (Front Door LH) 90980–12380 Y1 Side Airbag Squib (RH) Z1 Side Airbag Squib (LH) – 90980–10908 Rear Combination Lamp (RH) Turn Signal Lamp (Rear RH) 90980–10906 S14 Electrical Key Oscillator (Outside Luggage Room) 90980–12381 S15 Junction Connector 90980–10803 S16 Junction Connector 90980–11915 Power Seat Motor (Front Passenger’s Seat Slide Control) 90980–10825 T3 T6 Seat Heater (RH) 90980–10906 T7 Front Seat Inner Belt (Front Passenger’s Side) 90980–11156 T8 Power Seat SW (Front Passenger’s Seat) 90980–10997 T10 Occupant Classification ECU 90980–12356 T11 Occupant Classification ECU 90980–12357 T15 Occupant Classification Sensor (Rear LH) 90980–10825 90980–11875 90980–12452 Spiral Cable a1 Steering Pad SW 90980–12361 Cruise Control SW Power Seat Motor (Front Passenger’s Seat Reclining Control) Occupant Classification Sensor (Front LH) Part Number U1 S13 T14 Part Name Power Seat Motor (Driver’s Seat Slide Control) S12 T1 Code 90980–12353 b1 Occupant Classification Sensor (Front RH) T17 Occupant Classification Sensor (Rear RH) 90980–12353 T18 Junction Connector 90980–12374 90980–12360 c1 Airbag Squib (Front Passenger’s Airbag Assembly) 90980–12219 c2 Airbag Squib (Front Passenger’s Airbag Assembly) 90980–12224 d1 Occupant Classification ECU 90980–12357 d2 Occupant Classification Sensor (Front LH) d3 Occupant Classification Sensor (Rear LH) d4 Occupant Classification Sensor (Front RH) d5 Occupant Classification Sensor (Rear RH) 90980–12354 T16 Spiral Cable 90980–12353 A/C Amplifier e1 A/C Blower Assembly f1 Speed Sensor (Rear LH) g1 Speed Sensor (Rear RH) 90980–12264 90980–10860 439 CAMRY (EM0250U) [A] S ta rtin g E n g in e C o n tro l 1 B- R B- R B- R ACC IG1 [M] 2 B- W IG2 7 B- R ST2 2 B- L 7. 5A IGN W- R 8 AM2 A11 Heated Oxygen Sensor (BAT) 1 ST1 1 15A EFI [L] 2 2 2 2 (2L- T) 1 2 GR R- Y B- W [B] A6 Ignition SW 3 B 4 AM1 B- W W 4 3 2 R- Y R- Y R- Y B C B Y- R B- R B- W Y- R 1 21 BA3 Y- R Y- R Y- R D Battery M [K] A1 A1 Y- R B1 Data Link Connector 1 B- R 8 +B FP 2 W- R 17 BA3 1 W- R W- R A3 BR 1 E1 3 BR 1 R- G 1 OX1 R- G B- R 2 B12 Injection No. 4 B- R 2 B10 Injection No. 3 B- R 2 B11 Injection No. 2 B- R 1 4 W- R W- R W- R W- B W- B 1 B- R W- R 2 B- R W- R A37 Fuel Pump B38(A), B39(B) Starter B- R W- R R- G M B9 Injection No. 1 16 AD1 1 B 15 3C [D] 5 AD2 1 A B [F] R- G 2 6 W- B B- W (2L- T) 1 7 3C R- G B- W 1 [G] R- G B- W 6 AB3 3 W- R 2 A19 Circuit Opening Relay Y- R W- B B- W (22R- E) [J] 12 BA1 1 (Shielded) 2 B- W W- B B- W 2 B (2L- T) 2 A (2L- T) 2 1 [I] Emission ECU < 9- 8> B- L A40(A), A41(B) Starter Relay 1 4 EFI MAIN Relay 7 BA3 1 B 2 30A AM2 40A AM1 100A ALT 2 1 A [C] (22R- E) W- R W 2 [H] (2L- T) W (2L- T) 1 3 A B- R [E] B B CAMRY (EM0250U) B- L B1 E F M OVERALL ELECTRICAL WIRING DIAGRAM 440 * The system shown here is an EXAMPLE ONLY. It is different to the actual circuit shown in the wiring diagram section. HOW TO READ THIS SECTION [A] : System Title [B] : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black W = White BR = Brown L = Blue V SB = Sky Blue = Violet R = Red G = Green LG = Light Green P Y GR = Gray = Pink = Yellow [F] : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. Example: 3C indicates that it is inside Junction Block No.3 O = Orange The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Example: L–Y [G] : Indicates related system. CAMRY (EM0250U) L (Blue) [H] : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows ( ). Outside numerals are pin numbers. Y (Yellow) [C] : The position of the parts is the same as shown in the wiring diagram and wire routing. [D] : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in other from upper left to lower right Numbered in other from upper right to lower left Female [I] Male ( ) : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. [J] : Indicates a shielded cable. Female Male The numbering system for the overall wiring diagram is the same as above [E] : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: Indicates Relay Block No.1 [K] : Indicates a ground point. [L] : The same code occurring on the next page indicates that the wire harness is continuous. [M] : Indicates the ignition key position(s) when the power is supplied to the fuse(s). M 441 SYSTEMS LOCATION CAMRY (EM0250U) ABS (w/ VSC TMC Made) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–1 ABS (w/ VSC TMMK Made) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–1 ABS (w/o VSC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14–1 Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27–1 Audio System (6 Speaker) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24–1 Audio System (8 Speaker w/ Navigation System) . . . . . . . . . . . . . . . 22–1 Audio System (8 Speaker w/o Navigation System) . . . . . . . . . . . . . . 23–1 Automatic Glare–Resistant EC Mirror . . . . . . . . . . . . . . . . . . . . . . . . . 17–4 Back–Up Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1 Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3 Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17–1 Combination Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–1 Cooling Fan (2GR–FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–1 Cruise Control (2AZ–FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–13 Cruise Control (2GR–FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–18 Data Link Connector 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1 Electronically Controlled Transmission and A/T Indicator (2AZ–FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–14 Electronically Controlled Transmission and A/T Indicator (2GR–FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–19 Engine Control (2AZ–FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1 Engine Control (2GR–FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 Engine Immobiliser System (w/o Smart Key System) . . . . . . . . . . . . . 9–3 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21–2 Ignition (2AZ–FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 Ignition (2GR–FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 Mirror Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18–3 Multiplex Communication System (CAN) . . . . . . . . . . . . . . . . . . . . . . . 2–1 ∗ Automatic Light Control ∗ Door Lock Control ∗ Fog Light ∗ Garage Door Opener ∗ Headlight ∗ Illumination ∗ Interior Light SYSTEMS LOCATION ∗ Key Reminder ∗ Light Auto Turn Off System ∗ Luggage Compartment Door Opener ∗ Power Window ∗ Seat Belt Warning ∗ Taillight ∗ Theft Deterrent ∗ Wireless Door Lock Control (w/o Smart Key System) Navigation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22–1 Power Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21–1 Power Seat (Driver’s Seat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–1 Power Seat (Front Passenger’s Seat) . . . . . . . . . . . . . . . . . . . . . . . . . 20–3 Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 Radiator Fan and Condenser Fan (2AZ–FE) . . . . . . . . . . . . . . . . . . . 26–3 Rear Window Defogger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18–3 Remote Control Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18–1 Seat Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19–3 Shift Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21–4 Sliding Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17–2 Smart Key System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 ∗ Engine Immobiliser ∗ Push Button Start System ∗ Steering Lock ∗ Wireless Door Lock Control SRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–1 Starting (w/o Smart Key System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 Stop Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–3 Tire Pressure Warning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16–1 TRAC (TMC Made) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–1 TRAC (TMMK Made) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–1 Turn Signal and Hazard Warning Light . . . . . . . . . . . . . . . . . . . . . . . . 11–1 VSC (TMC Made) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–1 VSC (TMMK Made) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–1 Wiper and Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19–1 M OVERALL ELECTRICAL WIRING DIAGRAM 442 SYSTEM INDEX ∗ ∗ ∗ ∗ P o w e r S o u rc e 1 1 2 3 4 : 2GR–FE : 2AZ–FE : w/ Smart Key System : w/o Smart Key System 4 3 2 50A ABS No. 1 B 1 1F 1 B 50A RR DEF 4 1 1 Y Y V 50A HTR 1 50A FAN MAIN W (∗1) 5 1 3 1 1 G 2 A W–B 1 30A ABS No. 2 L B 2 IB W 1 10A MIR HTR G 1 RR DEF Relay 40A RDI FAN 1 1 W (∗2) 20A STR LOCK 1 2 1 B 25A AMP 40A CDS FAN 120A ALT 1 A (∗1) 1 C (∗2) 1 G 1 G 2 (∗2) 1 BR (∗3) 30A ST/AM2 B 1 2 1 2 C19(A), (C) Generator 1 LG 1 2 1 R 1 1 2 1 O 1 2 1 2 LG 1 2 2 7. 5A ALT–S 1 L 1 2 1 (∗3) 1 W 2 Y 1 (∗1) 15A EFI NO. 2 30A EFI MAIN 2 1 Y Y FL MAIN 3. 0W HORN Relay 12 1E 6 1E DRL Relay A/F Relay H–LP (LL) Relay S–HORN Relay H–LP (RL) Relay 15A H–LP (LL) Battery 10A MPX–B 7. 5A S–HORN 1 1 2 1 R 10A EFI NO. 3 15A H–LP (LH) 20A A/F B 10A HORN EFI Relay 15A H–LP (RH) C 20A IG2 1 10A EFI NO. 1 Y 1 W 1 1G 1 B 25A DOOR NO. 1 1 15A RADIO NO. 1 (∗4) 7. 5A AM2 10A ETCS 10A ECU–B NO. 1 B 1 15A HAZ 10A DOME SHORT W CAMRY (EM0250U) 1 1C B 15A H–LP (RL) 1 2 1 GR D M OVERALL ELECTRICAL WIRING DIAGRAM 444 (Cont. next page) 1 CAMRY 1 CAMRY (Cont' d) ∗ ∗ ∗ ∗ P o w e r S o u rc e 5 A B 1 IA B O ACC 2 W(∗4) IG1 1 P(∗4) 4 AM1 (∗4) B 5 AM2 (∗4) (∗4) C 9 II AM1 W W Y (∗3) O (∗1 ∗3) 16 EA1 L (∗3) LG (∗1 ∗3) 12 4E 12 4M 10 4E 10 4M L (∗3) LG (∗1 ∗3) 1 5 3 25A WIP 2 1 10A WASH 30A P/SEAT P 2 1 AM2 11 A IG2D 16 SSW2 B L (∗3) V (∗3) 6 4G 6 4E 7 4G 7 4E L 7. 5A ECU IG NO. 2 (∗3) V 4 (∗3) 5 2 E6(A), E7(B) Main Body ECU SS2 SS1 1 (∗1) E49 Junction Connector 10 GND COM 4 4E W–B 5 3 IG2 Relay 1 1 BR 25A PWR 5 4H (∗1) 18 EA1 25A RR DOOR LH 25A RR DOOR RH BR (∗1) 1 BR BR (∗1) (∗1) 7 II 7. 5A GAUGE NO. 2 30A S/ROOF 10A IGN 7. 5A A/C 15A INJ 10A STOP 3 IM W–B 10 IG E1 W–B 1 2 2 2 1 5 4E (∗3) (∗1) 1 3 (∗3) Y 1 30A POWER 5 PWR Relay (∗2) W–B O 10 IF 2 Y (∗1 ∗3) 7. 5A PANEL W–B (∗3) W–B Y (∗1 ∗4) 2 4 (∗3) 10 EA1 B W–B 5 E52 Power SW Full Traveling (∗1 ∗4) 15A TAIL TAIL Relay Free Y 3 7 SS2 GND SS1 D 20A S–HTR (∗3) 17 SSW1 B 1 A 2 20A PWR OUTLET 10A A/C NO. 2 (∗3) 3 IG1D B 7 EA1 (∗4) P (∗3) 3 10A ECU IG NO. 1 (∗3) B (∗4) 5 (∗3) Y CAMRY (EM0250U) B L 7. 5A ECU–ACC IG1 Relay P 22 ACCD B 7. 5A OBD 7. 5A AM1 E23 Ignition SW 6 B 7. 5A RADIO NO. 2 4 II O ST2 12 4G 15A FR FOG 10A GAUGE NO. 1 (∗2) IG2 6 (∗4) 3 II W ST1 (∗1 ∗4) (∗4) 1 AE7 25A DOOR NO. 2 ACC Relay Y B : 2GR–FE : 2AZ–FE : w/ Smart Key System : w/o Smart Key System 8 7 6 1 2 3 4 E2 M 445 ∗ 1 : TMC Made ∗ 2 : TMMK Made M u ltip le x C o m m u n ic a tio n S y s te m (C A N ) 1 E61 Option Connector (Bus Buffer) CAN– 1 2 CANL CANH 3 A (∗1) 2 B (∗2) CANL 14 CANH 6 B 2 A 3 B W B W B CAN+ B CANL 12 A E10 Data Link Connector 3 W CANH 11 A E34(A), E65(B) Yaw Rate Sensor 2 A 1 A 2 E 1 E 2 G 1 G 2 D 1 D 2 H 1 H 2 B 1 B B W E38(A) A/C Amplifier 4 3 2 CANH CANL CAN+ A26(A), A60(B) Skid Control ECU with Actuator B A25 Skid Control ECU with Actuator CAN– 1 B (2GR–FE) 2 B CANH CANL CANH E30(A) Airbag Sensor Assembly Center 10 CANH E17 Steering Sensor W B 18 A 17 A CANL E42(A), E43(B), E44(C), E45(D), E46(E), E62(G), E63(H) Junction Connector W 9 CANL 2 C B 13 A CANL B 22 A 13 FE3 W 49 A B W (2AZ–FE) B (2AZ–FE) 41 A B CANL W 49 A CANH W CANL 25 A (∗1) 14 B (∗2) Y CANH 11 A 35 B 14 FE3 1 C CANH F1(A) Combination Meter (2GR–FE) 15 A24(A) Engine Control Module 41 A 26 10 B A40(A), E41(B) Junction Connector A55(A), C55(B) Engine Control Module 7 A W 1 A 4 B (2GR–FE) 8 A B 2 A (2GR–FE) 8 B W 2 B (w/ VSC) 7 B B 1 B (w/ VSC) W (w/o VSC) B CAMRY (EM0250U) (w/o VSC) W 6 7 CAN+ CAN– C56 Transmission Control ECU W B A B M OVERALL ELECTRICAL WIRING DIAGRAM 446 (Cont. next page) 2 CAMRY 2 CAMRY (Cont' d) (Cont. next page) ∗ 3 : w/ Smart Key System ∗ 4 : w/o Smart Key System M u ltip le x C o m m u n ic a tio n S y s te m (C A N ) 5 8 7 6 B A B E6(A), E7(B), E8(C), E9(D) Main Body ECU 1 1F CANN 28 A 1 1G 5 1A 11 1D 3 1B 2 1B 4 1B 11 1E CANP L 16 C (∗3) W 15 C (∗3) CANH 5 C B P CANL 6 C W 3 ID P 9 ID SH 6 D (∗4) 8 V H–LP (RL) Relay HRLY 15A H–LP (RL) Light Control Circuit 15A H–LP (LL) 15A H–LP (LH) 7. 5A S–HORN 120A ALT CAMRY (EM0250U) 15A H–LP (RH) DRL Relay H–LP (LL) Relay S–HORN Relay DRL 11 5 1B 9 1D 8 1D CANL 27 A CANH V P 12 AE6 1 A49 Headlamp (RH Low) Y W–B 2 W–B 1 A45 Headlamp (LH Low) 2 (∗4) BR B BR 2 A8 Headlamp (LH High) 1 W–B 2 A29 Headlamp (RH High) 1 W–B FL MAIN 3. 0W A23 Security Horn 1 Y G Y (∗4) (∗4) L W E58(A) Certification ECU BR Battery W–B B A1 A3 A6 W–B W–B W–B W–B B W W–B A W–B A5 M 447 (Cont. next page) ∗ 3 : w/ Smart Key System ∗ 4 : w/o Smart Key System M u ltip le x C o m m u n ic a tio n S y s te m (C A N ) 9 12 11 10 B A B A E6(A), E7(B), E8(C), E9(D) Main Body ECU ACAN 16 A 12 3R Flash ED 19 H 4 EL A DRL–OFF(USA) OFF(Except USA) LFG AUTO 5 3Q 10 3D BFG OFF BR Low High HU 10A ECU IG NO. 1 7. 5A ECU–ACC O V 20 Fog SW HL Light Control SW Dimmer SW (∗4) R HF (IG) BR 18 Clock < 17–1> E21 Headlamp Dimmer SW Assembly T 2 AE2 IG 15 W 2 3O 6 4H P R (∗4) 11 ACC 22 Turn Signal Flasher < 11–4> O 5 4M 4 3J 17 HAZ 4 C (ACC) HORN Relay < 21–2> 12 3G 25 On Tail Head 15 EA1 BR (2GR–FE) 3 W 1 12 W–B 16 W A5 Engine Hood Courtesy SW 2 A41(A), A42(B) Junction Connector 18 B GR 9 E49 Junction Connector 2 12 W–B W–B W–B W–B 4 FE3 F1 (2AZ–FE) C6 W–B 4 CA3 E2 BR 4 CA3 6 (2GR–FE) W–B A2 17 A (2GR–FE) GR W–B W 3 3C (2AZ–FE) 3 3G (∗4) CAMRY (EM0250U) Shift Lock Control ECU < 21–4> 4 3F HORN 28 A G B LG R W–B (∗4) 9 3N FFOG SPD 9 C V P 2 D V A 21 B (∗3) HEAD 17 A P 5 IG 9 IM R TAIL 23 B Combination Meter < 25–2> HU 13 G HF 13 B 4 (∗3) GND2 HCTY 16 B 3 C57 Junction Connector C7 B M OVERALL ELECTRICAL WIRING DIAGRAM 448 2 CAMRY (Cont' d) 2 CAMRY (Cont' d) (Cont. next page) M u ltip le x C o m m u n ic a tio n S y s te m (C A N ) 13 16 15 14 B A B A E6(A), E7(B), E8(C), E9(D) Main Body ECU GR (BAT) (IG) G 7. 5A GAUGE NO. 2 10A DOME B (BAT) C 10A MPX–B V 2 12 3L 1 3D 9 3Q 12 3Q 10 3R 2 EA1 P 1 A F1(A) Combination Meter 9 A B P/SB +B(DOME) IG2 +B(DOME) IG2 LCD Illumination Illumination Pointer Illumination +B (DOME) Beam Tail (Except USA) Head (USA) MICRO COMPUTER +B(DOME) IG2 +B(DOME) DOOR IG2 MULTI LCD Power Supply Circuit Front Fog IG+ Master Warning 13 A B2 10 3Q Driver' s Seat Belt 2 A V V GR 1 3Q R 7 IF G 2 3G SB 9 3R R 13 ID 3 1A GR CAMRY (EM0250U) LG 12 IG GR 1 Buzzer DRIVE IC Rheostat Tail Cancel SW CAN I/F CANL BR 18 A B BR E2 ILL– 12 A 11 A BR CANH 17 A W–B ES 24 A 7 3Q D W–B F1 M 449 Multiplex Communication System (CAN)< 2–3> < 2–4> BR 2 3U (Cont. next page) ∗ ∗ ∗ ∗ M u ltip le x C o m m u n ic a tio n S y s te m (C A N ) 17 : w/ Smart Key System : w/o Smart Key System : w/ Jam Protection : w/o Jam Protection 20 19 18 3 4 5 6 B A B A E6(A), E7(B), E8(C), E9(D) Main Body ECU 12 4 IJ 15 IE2 7 IE2 15 HE2 7 HE2 1 3E 2 3D 3 3N 5 3J O V 14 IM1 (∗5) 8 IM2 (∗6) 4 2 V G B L 2 (∗4) R 13 IM1 3 IM2 G 7 3B L 7 3A 8 EN2 (∗4) O (∗4) P 6 3K (∗4) Buzzer 14 EO1 A48 Wireless Door Lock Buzzer 1 13 EO1 G R O (∗4) P (∗4) (∗4) W (∗4) O (∗4) 2 1 CAMRY (EM0250U) G 3 IJ L 12 IK G 15 IK V 2 3F L 2 3N 5 AE2 Y UL1 9 (∗4) 4 3N L1 5 D R O 1 IF 10A ECU–B NO. 1 KSW 2 A 7 D (∗4) 10 ID L R (BAT) G C TSW BZR RDA 12 A (∗4) B PRG 10 A 26 (∗4) BECU (∗4) IND 4 D GR 2 9 W–B (∗4) W–B W (∗4) GND1 3 W–B W–B 1 Unlock H5 Door Lock Control SW Lock Unlock M1 Power Window Master SW Lock Transponder Key ECU < 9–3> 2 W–B 3 A (∗3) 1 B (∗4) 1 1 18 IM1 (∗5) 13 IM2 (∗6) (∗4) 1 A (∗3) 2 B (∗4) E22 Unlock Warning SW S6(B), S8(A) Luggage Compartment Door Lock Cylinder R B GND (2AZ–FE) B +B 5 O17 Door Control Receiver 2 RDA 9 3E W Y (∗3) 3 PRG W–B F3 Clock Front Passenger Seat Belt Warning Light 9 3L (∗4) Security Indicator 5 3D Certification ECU < 3–12> LP P 8 IG (∗4) 3 6 3B Transponder Key ECU< 9–4> PBEW Y 10 GR G 11 3R (2GR–FE ∗4) 4 SN1 W–B 2 3A (∗4) W–B W–B 17 HE2 W–B 13 9 E49 Junction Connector 12 2 O21 Junction Connector W–B S1 F1 4 FE3 W–B W–B 5 A3 10 11 W–B W–B C W–B W–B E BR BR O1 5 9 W–B D W–B W–B 17 IE2 (∗4) W–B S15 Junction Connector A42(B) Junction Connector 3 3C 1 W–B W–B 2 3U (2AZ–FE) 16 B W–B 8 3R (2GR–FE ∗4) 17 B W–B W–B 15 EO1 W–B 19 E2 B D F M OVERALL ELECTRICAL WIRING DIAGRAM 450 2 CAMRY (Cont' d) 2 CAMRY (Cont' d) (Cont. next page) ∗ ∗ ∗ ∗ ∗ M u ltip le x C o m m u n ic a tio n S y s te m (C A N ) 21 1 2 3 4 7 : TMC Made : TMMK Made : w/ Smart Key System : w/o Smart Key System : w/ Sliding Roof 24 23 22 B A B A E6(A), E7(B), E8(C), E9(D) Main Body ECU LSR (∗4) LSWL (∗3) UL2 ACT+ 1 24 16 IK 2 IK 7 IK ACT– LSWP 27 A 3 20 5 IJ 1 IJ 6 IP 11 IP 5 IP 2 IJ 18 IF 5 IF LCTY 17 V LSWR 5 A (∗3) L2 10 LG GR UL3 10 B L LSWD 9 B GR ACTD 5 B 7 IO 6 IL 5 IL LG (∗7) E1 Diode (Door Courtesy Rear LH) CAMRY (EM0250U) LG LG GR (∗4) L B LG GR W G L W GR 4 3O 4 3D 2 5 3O 9 3G GR 1 JO1 3 JO1 B L GR B L GR L GR 10 JO1 8 10 9 4 7 5 6 4 4 6 4 6 1 9 M 1 9 25 HE2 W–B 4 KN1 4 JO1 W–B W–B 25 IE2 W–B LG W–B M 1 LG 8 W Key Unlock 1 GR Key Unlock W–B 7 M N13(A), (B) Door Courtesy SW (Rear LH) L 3 KN1 1 A (∗1) 1 B (∗2) J5 Door Lock Assembly (Rear RH) B 1 KN1 K5 Door Lock Assembly (Rear LH) 10 KN1 M 1 (∗7) GR 9 HE2 L W G 16 HE2 H8 Door Lock Assembly (Front Passenger' s Side) 8 HE2 W L W 7 HE1 Key Lock 9 IE2 I7 Door Lock Assembly (Driver' s Side) 16 IE2 24 IE2 Key Lock 8 IE2 GR GR 16 EO1 LG LG 4 EO1 R W BR 8 EO1 BR GR 9 3I GR 5 3I L L (∗3) L(∗7) W–B W–B B D E F B W–B W–B D W–B BR C W–B W–B BR C E F 2 8 N29 Junction Connector N1 O21 Junction Connector O1 M 451 (Cont. next page) ∗ ∗ ∗ ∗ M u ltip le x C o m m u n ic a tio n S y s te m (C A N ) 25 1 2 3 4 ∗ 7 : w/ Sliding Roof ∗ 8 : w/o Sliding Roof ∗ 9 : Automatic A/C ∗10 : Manual A/C : TMC Made : TMMK Made : w/ Smart Key System : w/o Smart Key System 28 27 26 B A B A E6(A), E7(B), E8(C), E9(D) Main Body ECU TR+ LGCY 25 A 17 EN2 5 EN1 ILE 1 B 21 (BAT) B 1 1 M V W (∗7) E 2 B E 1 W (∗7) 2 W L(∗7) W–B W–B D W–B BR D 18 EQ1 W–B S15 Junction Connector W W–B 1 B O O B(∗7) L(∗7) V(∗7) W–B E F G H I J K W–B F W–B E +B 1 B C 2 1 9 B 1 W 2 S5 Door Lock Assembly (Luggage) N23 Diode (Luggage Compartment Lamp) 2 O 1 E37 Diode (Door Courtesy Front RH) Y 1 O6 Door Courtesy SW (Front Passenger' s Side) 2 O B 1 1 A (∗1) 1 B (∗2) E5 Diode (Door Courtesy Front LH) L N6(A), (B) Door Courtesy SW (Driver' s Side) 2 (∗7) 1 E2 Diode (Door Courtesy Rear RH) O10 Door Courtesy SW (Rear RH) GR 3 Q2 Vanity Lamp SW (RH) 5 EO2 (∗8) W GR (∗7) GR 13 EN2 6 EO2 Q7 Vanity Lamp (LH) 1 16 EQ1 W 16 SN1 2 (∗7) LG 3 SN1 B 4 3I W L 6 3C Y 11 3F Y 12 3O L 7 3I 2 W 5 3N 10 3F E11(A), (B) Automatic Light Control Sensor 7 3C 1 14 W 12 3A B C (∗7) (∗7) 13 15 CLTS BR(∗4) W (∗7) BR 5 A (∗9) 4 B (∗10) N28 Junction Connector CLTE II 2 (∗4) CAMRY (EM0250U) Y 3 A 6 B 10 W W 6 A 3 B CLTB 6 3N BR B Y L GR Transponder Key ECU< 9–4> 5 IR 10A DOME (∗7) CLTS 19 A Q1 Vanity Lamp SW (LH) CLTE 18 A Q8 Vanity Lamp (RH) CLTB 20 A B PCTY 21 A W DCTY 24 B G RCTY 7 A (∗3) 5 A (∗4) S1 W(∗8) LG BR L M N O M OVERALL ELECTRICAL WIRING DIAGRAM 452 2 CAMRY (Cont' d) 2 CAMRY (Cont' d) (Cont. next page) ∗ ∗ ∗ ∗ M u ltip le x C o m m u n ic a tio n S y s te m (C A N ) 29 : w/ Smart Key System : w/o Smart Key System : w/ Sliding Roof : w/o Sliding Roof 32 31 30 3 4 7 8 B A B A E6(A), E7(B), E8(C), E9(D) Main Body ECU W W W W (∗8) W (∗8) W (∗7) BR(∗4) W (∗7) R C (∗7) B O 3 IE2 3 HE2 B O CAMRY (EM0250U) W O R H7 Courtesy Lamp (Front Door RH) O I6 Courtesy Lamp (Front Door LH) R R 2 IE2 2 HE2 12 3I N28 Junction Connector 11 3G 20 18 W (∗7) F G H I J K B O O B(∗7) L(∗7) V(∗7) W–B W–B L M N W(∗8) LG BR 12 3L 7 IF 1 R R LG E 10 IP R 17 N15 Noise Filter (Dome and Stop) 12 3B R R 10 IL R W 6 IR R 7 EQ1 (∗7) L (∗7) W (∗7) B (∗8) 1 19 EQ1 13 ID O 1 1 A (∗3) 1 B (∗4) 2 R W (∗8) W W W (∗8) (∗7) W–B W ILL+ 2 2 A (∗3) 2 B (∗4) 2 (∗4) 17 EQ1 15 EQ1 D (∗4) BR (∗7) ILL– Ignition Key Cylinder Light 5 R 4 W E25 Transponder Key Amplifier L W (∗7) (∗7) 11 EQ1 4 6 E (∗7) E 3 W 8 L W 3 B Q11 Map Lamp (LH) 2 Q10 Map Lamp (RH) E 2 B OFF ON Q9 Room Lamp (Center) Map Lamp Q6 Overhead J/B Garage Door Opener Map Lamp 8 (∗7) V 6 E W–B Q6 Overhead J/B CTY 2 (∗7) 1 B (∗7) 7 B DOOR 7 N24(A), N26(B) Luggage Compartment Lamp (∗7) W–B W–B(∗7) W–B BR B C D E M 453 (Cont. next page) ∗ 5 : w/ Jam Protection ∗ 6 : w/o Jam Protection ∗ 7 : w/ Sliding Roof M u ltip le x C o m m u n ic a tio n S y s te m (C A N ) 33 36 35 34 B A B A E6(A), E7(B), E8(C), E9(D) Main Body ECU LIN2 10 C M1(A), (B) Power Window Master SW U D U D U D 16 A 16 B 15 A 15 B 12 A 12 B 13 A 13 B 10 A 10 B 18 A 18 B 17 IM1 12 IM2 Y LG GR 1 IE2 LG B 2 IE1 Y L 7 IE1 B R 4 IE1 L W G (∗6) 8 IE1 2 EN1 7 EN1 2 EO1 7 EO1 L B Y LG 6 JO1 16 JO1 M 1 M 2 Up GR U D B 4 1 3 R 3 R B 1 V Up D 4 J3 Power Window Regulator Motor (Rear RH) 2 U R 3 R B 1 V D 4 Down 2 SD J1 Power Window SW (Rear RH) 5 SU Down 2 SD U 1 Y Y 5 SU K1 Power Window SW (Rear LH) 2 SD Down 5 SU K3 Power Window Regulator Motor (Rear LH) M LG R 16 KN1 R W (∗6) 6 KN1 GR (∗5) P (∗5) (∗5) E 1 1 IM1 (∗5) 1 IM2 (∗6) 8 IM1 (∗5) 4 IM2 (∗6) 1 HE1 G LIN 9 W–B B 9 IM1 5 IM2 6 HE1 Y M 1 IE1 W UP1 6 IE1 Up 1 10 DWN1 2 IM1 (∗5) 2 IM2 (∗6) 10 IM1 (∗5) 6 IM2 (∗6) 9 IM2 H6 Power Window SW (Front Passenger' s Side) 7 AUTO (∗6) BR BR (∗5) O O (∗5) R B (∗5) (∗5) R (∗5) 10 IM2 2 W E W–B W–B(∗7) W–B BR 5 IM1 11 IM1 7 IM2 H4 Power Window Regulator Motor (Front Passenger' s Side) I5 Power Window Regulator Motor (Front LH) W (∗5) P (∗5) 3 IE1 2 C B 4 LED B 4 IM1 (∗6) I4 Power Window Regulator (Front Motor LH) G 5 D 15 IM1 (∗5) LG (∗5) W W–B LG (∗5) 6 IM1 (∗5) P W–B Sliding Roof Control ECU and Motor < 17–3> (∗5) P (∗5) P W CAMRY (EM0250U) 18 IM1 (∗5) 13 IM2 (∗6) 6 3F 23 IE2 LG 17 IM 13 6 3D B 6 A (∗5) 6 B (∗6) GR U 8 A 3 B Y D 5 A 4 B B A 4 A LED 3 A LG 4 5 E 1 A 1 B (∗6) L E48 Junction Connector 25A PWR R P (BAT) 1 M 2 W–B(∗7) W–B BR GR R R GR B C D E F G H M OVERALL ELECTRICAL WIRING DIAGRAM 454 2 CAMRY (Cont' d) 2 CAMRY (Cont' d) (Cont. next page) ∗ 3 : w/ Smart Key System ∗ 4 : w/o Smart Key System ∗ 7 : w/ Sliding Roof M u ltip le x C o m m u n ic a tio n S y s te m (C A N ) 37 40 39 38 B A (BAT) G E6(A), E7(B), E8(C), E9(D) Main Body ECU A G B 15A FR FOG BATB (∗3) ALTB 6 14 IC 16 ID 5 25A DOOR NO. 2 25A DOOR NO. 1 L W (Pedal Type) Y CAMRY (EM0250U) (Lever Type) R GND1 5 TRLY 1 IA 7 6 IF (BAT) (BAT) 2 IM PWS 18 2 1 1 3 2 4 3 2 5 TAIL Relay 19 PWR Relay PKB FFGO 4 B 2 1 A18 Parking Brake SW E33 Parking Brake SW 1 1 1 25A RR DOOR RH 30A POWER 25A RR DOOR LH 15A TAIL 7. 5A PANEL 2 10 IF 3 IL 5 IC 2 3 1 A47 Side Marker Lamp (Front LH) G GR FOG Relay 5 Parking 1 3 EO1 A46 Turn Signal and Parking Lamp (Front LH) V G 4 IL GR 14 ID L 1 IR P 7 IP W 1 IL W–B 7 IJ (∗7) 10 IK W–B B 2 1 2 2 D E F G H 1 W–B W–B W–B W–B A1 Fog Lamp (Front LH) W–B R (2GR–FE ∗3) W–B(∗7) W–B BR GR R R GR BR 1 A2 A43 Junction Connector C R GR B 1 BR 2 BR 1 IC A34 Fog Lamp (Front RH) 5 ID (2GR–FE ∗4) II R 8 R 7 KN1 Y 7 JO1 (2AZ–FE) 1 HE2 C BR (2GR–FE ∗4) A2 A5 A1 M 455 A5 W–B BR W–B 1 A6 Stop 1 6 9 BR S1 1 W–B 2 3 3 W–B 2 W–B 4 IC 1 1 B 2 1 S2 Rear Combination Lamp (RH) Tail S3 Rear Combination Lamp (LH) Tail 19 BR BR BR BR 42 S1 License Plate Lamp (RH) 22 BR BR 18 S4 License Plate Lamp (LH) 3 Side Marker BR 21 BR Stop Light System < 10–4> 16 S16 Junction Connector S12 Rear Combination Lamp (RH) 3 Tail Stop 2 S11 Rear Combination Lamp (LH) 17 BR BR BR 41 W–B 1 W–B W–B 1 Tail Side Marker W 8 IP W–B Parking A50 Turn Signal and Parking Lamp (Front RH) GR 6 ID W–B C 2 (Cont. next page) M u ltip le x C o m m u n ic a tio n S y s te m (C A N ) G 43 44 G BR A 9 SN1 20 W–B 2 7 1 S15 Junction Connector B M OVERALL ELECTRICAL WIRING DIAGRAM BR A W–B CAMRY (EM0250U) A51 Side Marker Lamp (Front RH) 456 2 CAMRY (Cont' d) 2 CAMRY (Cont' d) M u ltip le x C o m m u n ic a tio n S y s te m (C A N ) 45 ∗ 9 : Automatic A/C ∗10 : Manual A/C ∗11 : 8 Speaker ∗12 : 6 Speaker ∗13 : w/ Navigation System ∗14 : w/o Navigation System G A 48 47 46 G 7 3R 5 3S 5 3T 4 3A 4 3T BR 4 3C G 4 3B LG 4 3L 9 4B 1 3T 12 3S P ILL+ ILL– SG 5 B R IL+2 8 B B 8 GR R 11 12 A EAU 2 4 4D F5 Glove Box Lamp Seek MODE Volume TEL Steering SW LH TEMP AUTO/OFF DISP 7 Voice ILL– 12 E (∗11 ∗13) 12 D (∗11 ∗14) 5 B (∗12) SWG 4 A 2 B F16 A/C Control Assembly ILL+ (∗9) 6 F (∗11 ∗13) 6 C (∗11 ∗14) 6 C (∗12) Steering SW RH BR BR 5 4B 9 A EAC BR 8 2 E 2 D 10 A W–B 1 7 F6(A), F7(B), F8(C), F26(D) Radio Receiver Assembly F9(E), F10(F) Navigation Receiver Assembly ILL– 8 2 F4 Hazard Warning Signal SW G A/T Shift Lever Illumination E55 Seat Heater SW ILL+ BR E31 Transmission Control SW 4 E18(A), a1(B) Spiral Cable P 9 3A R 1 3A (∗9) CAMRY (EM0250U) 8 4D (∗9) G G G LG P R (∗9) 1 BR W–B (∗10) 9 3B 9 3C 4 3R 11 3T 11 3S a1(B) Steering Pad SW 2 3T BR 4 3Q B BR W–B 2 3U F1 M 457 S m a rt K e y S y s te m 1 4 3 2 E6(A), E7(B), E8(C), E9(D) Main Body ECU AM1 BATB 2 AM2 6 B 2 STR2 6 D 1 A STR IG2D 8 B 11 A GR 10 4M 4 4M 7 4K 10 4E 5 4C 9 4C G 8 4K 9 4G TACH GND1 GND2 5 4 10 IF 9 IM W–B 12 4M 8 C P 12 4G 20A IG2 STSW 4 D LG Y G V 1 L L (BAT) ACCR 3 A 2 W–B 25A DOOR NO. 2 B 7. 5A AM2 30A ST/AM2 1 W (BAT) (BAT) (BAT) 9 4F G V CAMRY (EM0250U) 15 AE5 8 AE5 LG L GR 1 P 9 4E 12 4E 16 EA1 B G G O Y G G Y G 1 R 13 AE6 Engine Control Module < 7–19> 7 EA1 4 CA2 13 EA1 1 1 4 AE5 1 1 1 1 5 2 5 1 Y ST Relay Y 5 W ST CUT Relay Y GR 4 A 1 1 3 1 12 3F 2 1 1 L Y P N BR L BR B R 1 W–B 1 3 R 2 C1(A) Park/Neutral Position SW 3 IG2 Relay 12 3J Engine Control Module < 7–17> 8 CA2 9 IG 9 A 18 CA2 A1 A3 W–B L–B BR 2 6 L A43 Junction Connector 5 A2 W–B W–B W–B Battery Engine Control Module< 7–17> M BR V 6 10 E2 E49 Junction Connector C3(A), D1(C) Starter II Engine Control Module< 7–17> 1 C 7 7 CA2 Transmission Control ECU < 7–23> B 1 A L FL MAIN 3. 0W Y LG B R W BR W W 10A IGN 18 EA1 1 CA1 A M OVERALL ELECTRICAL WIRING DIAGRAM 458 (Cont. next page) 3 CAMRY 3 CAMRY (Cont' d) (Cont. next page) S m a rt K e y S y s te m A 5 W 8 7 6 W A E6(A), E7(B), E8(C), E9(D) Main Body ECU BR (IG) 10A IGN 10 4G SLP CANH 18 B CANN CANL 5 C 6 C 15 C CANP 16 C LIN1 14 (BAT) (BAT) (IG) (BAT) P SLR+ 19 B 9 IR 20A STR LOCK 5 4G 7. 5A GAUGE NO. 2 10A MPX–B 10A DOME 2 R 12 3L 7 IF 1 3Q 13 ID 1 LG R 12 3Q SB 9 3Q V V 1 3D GR O 2 EA1 5 B 1 4M R LIN 13 A 1 A 2 A IG+ B B2 7 8 4A +B(DOME) Power Supply Circuit 7 4F O 8 4F Master Warning 2 V SGND GR 1 B GND P IG2 6 2 3G 3 1A 11 EA1 P SLP1 M E51 Steering Lock ECU O IGE 1 W–B P 4 W–B Buzzer O O MULTI LCD MICRO COMPUTER E50 ID Code Box DRIVE IC 3 EFIO EFII 8 6 5 1 W 3 4D 10 4F 5 4F W–B CANH 17 A 24 A CANL 18 A 10 3D Multiplex Communication System (CAN)< 2–3> < 2–4> W–B BR 15 EA1 BR 18 B GR 2 3U 17 A 4 CA3 W–B 5 3Q A41(A), A42(B) Junction Connector 7 3Q 13 AE5 G 7 AE5 BR 4 4C W–B 11 4C G GR L E49 Junction Connector ES E2 12 A Y 2 CAN I/F 3 4F W–B 1 +B F1(A) Combination Meter GND G 2 4A L LIN1 W–B CAMRY (EM0250U) BR 5 4A 3 B B 10 4A 12 IG GR Multiplex Communication System (CAN)< 2–8> 2 14 IM O E1 E2 3 Engine Control Module < 7–17> W–B W–B W–B W F1 B C C57 Junction Connector C7 M 459 (Cont. next page) S m a rt K e y S y s te m A 9 W 12 11 10 W E6(A), E7(B), E8(C), E9(D) Main Body ECU GND3 1 C SSW1 17 B INDW SSW2 16 B INDS 14 B 15 B SWIL 25 B O 10A EFI NO. 1 11 4G 8 4G 3 4E 11 4E 8 4E Multiplex Communication System (CAN)< 2–8> LG 4 4G W–B P (BAT) 2 12 INDW R W GR O LG 13 SS1 SS2 8 9 10 14 SWIL AGND TXCT CODE VC5 11 INDS SS1 SS2 GND Power Source System< 1–6> < 1–7> GR G Free W 8 A 7 R W 3 B 30 A 9 A 8 A 40 A Full Traveling IND 2 A 2 4D 2 4F 5 4L W–B W W 5 4H HSW 17 A 24 B 4 4F 11 3E 3 4D 10 3J 2 AE2 Security Indicator < 2–17> W–B 1 4F E CANH R 10 A 27 A CANL R LIN 1 A 28 A W–B 5 4E +B AGND W–B 4 4E E52 Power SW TXCT Y 4 CODE O COM 5 W–B GND W–B W 1 3C VC5 W 1 3J E58(A), E59(B) Certification ECU CAMRY (EM0250U) 21 AE2 A41(A), A42(B) Junction Connector P LG G W 2 1A 1 3 IM E49 Junction Connector R 10 IG 2 A5 Engine Hood Courtesy SW 2 1 W E1 W–B C O W W–B B E2 3 A2 A43 Junction Connector A M OVERALL ELECTRICAL WIRING DIAGRAM 460 3 CAMRY (Cont' d) 3 CAMRY (Cont' d) (Cont. next page) S m a rt K e y S y s te m A 13 W 16 15 14 W A E6(A), E7(B), E8(C), E9(D) Main Body ECU IG ACC 15 22 (ACC) (IG) N11 Electrical Key Oscillator (Rear Seat) N25 Electrical Key Oscillator (Inside Luggage Room) 10A ECU IG NO. 1 7. 5A ECU–ACC 10A IGN V E56 Electrical Key Oscillator (Console) (IG) 14 A 15 A 16 A 31 A 32 A 14 EO1 13 EO1 12 EO1 TSW1 SEL1 3 A 5 A SEN1 22 A CLG1 33 A IG CG1B 34 A 13 IE1 14 IE1 17 IE1 16 IE1 12 IE1 GR 11 EO1 18 A R RSSI 39 A 19 A ACC CG8B L RDA 38 A CLG8 LG RC0 29 A R 11 4F O19 Electrical Key Antenna O 37 A CG7B 12 4F B ASEL BZR 21 A CLG7 6 4F V CG6B E58(A), E59(B) Certification ECU 12 4A LG 13 A S14 Electrical Key Oscillator (Outside Luggage Room) 5 4D L P 15 EN1 P V 16 EN1 V W 13 EN1 W R 14 EN1 R B 11 EN1 CLG6 2 IF L 12 EN1 Y CG5B 13 SN1 3 1 G CLG5 3 1 13 IM CLGB B 12 A CLG6 V 11 A CLGB Y W 3 R CAMRY (EM0250U) 1 CLG4 Y CLGB CLG5 LG 12 SN1 CLG3 11 3L 1 CLGB L P V 12 3C 2 ANT 1 R W–B W–B 3 IX1 2 IX1 1 IX1 8 IX1 17 IE2 Y BR GR 4 IX1 5 1 R 3 6 5 2 1 9 8 3 2 4 6 10 TRG+ SGT ANT1 ANT2 TRG– TRG– ANT2 ANT1 SGT SEL SENS B 1 V GND 6 O18 Door Control Receiver CLG CLGB +B 7 GND W–B L W 7 IX1 W–B 13 E49 Junction Connector X1 Door Outside Handle (Front LH) 6 W–B B 2 A3 O1 O21 Junction Connector X2 Electrical Key Oscillator (Front Door LH) 2 W–B A48 Wireless Door Lock Buzzer 6 IX1 L RSSI +5 P DATA G LG 5 B 3 V 2 O 5 AE2 O ASEL R ANT Y 4 G V 7 R 15 IE1 O W 9 4K R B E2 M 461 S m a rt K e y S y s te m A 17 W 20 19 18 (BAT) E6(A), E7(B), E8(C), E9(D) Main Body ECU HORN 23 ILE 25 21 LSWL ACT+ ACT– LCTY 20 1 3 17 LGCY 25 A DCTY PCTY 21 A 24 B RCTY 7 A 10A DOME LSWD 9 B LSWP HAZ 4 C 27 A LSWR ACTD 5 B 5 A TR+ TKUL 1 B 2 C 2 W STP 7 IO 1 Stop Lamp SW < 10–3> O LG 1 1G Multiplex Communication System (CAN) < 2–11> < 2–21> < 2–22> < 2–23> < 2–27> 13 ID Multiplex Communication System (CAN) < 2–12> < 2–21> < 2–23> < 2–24> < 2–25> < 2–26> < 2–27> S–HORN Relay 7 IF O GR BR R 14 HE1 17 HE1 16 HE1 12 HE1 P O GR BR R W–B L 6 HW1 4 HW1 3 HW1 2 HW1 1 HW1 8 HW1 W–B G L 7 HW1 2 1 9 8 3 2 4 6 10 ANT1 ANT2 TRG– TRG– ANT2 ANT1 SGT SEL SENS 5 1 CLGB +B 7 2 1 9 GND W–B CLG Y R 5 SGT P V O 6 B 3 TRG+ BR 5 W E49 Junction Connector 17 HE2 R B W2 Electrical Key Oscillator (Front Door RH) W–B W1 Door Outside Handle (Front RH) R E2 3 S1 S15 Junction Connector 1 R 5 1A L 12 3H 11 1D Y Y W–B 2 2 W–B P 13 HE1 W–B L 1 15 HE1 P O CG2B 36 A 12 3L A23 Security Horn 1 4A 2 4E 1 4E R CLG2 35 A 7. 5A S–HORN R SEN2 23 A 5 SN1 S8 Luggage Compartment Door Lock Cylinder 6 A 14 SN1 O SEL2 TSW2 4 A TSW5 W–B SH– G 7 A 12 AE6 G G 20 B 19 EN2 S9 Luggage Electrical Key SW P G R CAMRY (EM0250U) E58(A), E59(B) Certification ECU 17 EN1 M OVERALL ELECTRICAL WIRING DIAGRAM 462 3 CAMRY (Cont' d) 4 CAMRY S ta rtin g (w /o S m a rt K e y S y s te m ) 1 C h a rg in g 4 3 2 (IG) 10A GAUGE NO. 1 ACC 4 AM1 (IG) (BAT) 7. 5A GAUGE NO. 2 7. 5A ALT–S IG1 5 3F GR 5 3E 2 GR ∗ 1 : 2AZ–FE A/T 12 IG 16 IH O ST1 3 1 6 EA1 4 IG2 GR 5 AM2 II ST2 7 GR Charge F1(A) Combination Meter L 5 CA2 Y G–R IC Regulator 3 EA1 C18(B), C19(A), (C) Generator W 11 FE3 2 CA2 L 4 B Y Y (2GR–FE) LG S 1 B A1 A3 M 463 Transmission Control ECU< 7–23> V 7 CA2 W–B Battery O Engine Control Module < 8–9> 9 A (2GR–FE) 5 B (2AZ–FE) Engine Control Module < 7–17> < 8–11> M Transmission Control ECU< 7–23> N IG R(M/T) W(A/T) W–B 1 C 1 A (A/T) 1 B (M/T) C3(A), C29(B), D1(C) Starter B B 2 B M (A/T) R(M/T) 3 B B P B C1(A), (B) Park/Neutral Position SW Engine Control Module < 7–17> < 8–10> GR W–B L 1 CA1 FL MAIN 3. 0W W R P 1 A (2GR–FE) 1 C (2AZ–FE) 4 A (2GR–FE) 4 B (2AZ–FE) LG 1 1 1G CHG– 23 A R Y Y SB (∗1) (M/T) R R (M/T) W(A/T) L (2GR–FE) IG+ IG2 10 CA2 L–B (2GR–FE) (A/T) 1 (2GR–FE) B P (∗1) R (∗1) 8 CA2 18 CA2 L 9 CA3 13 A (2AZ–FE) 2 9 3Q 14 EA1 G–R 3 4 CA2 2 A B 1 10 B (A/T) 5 (M/T) G 1 A41(A), A42(B) Junction Connector ST Relay 30A ST/AM2 1 (2AZ–FE) R G 1 1 1F 120A ALT (M/T) 1 A A22 Clutch Start SW L 2 L B 11 B B 1 1 IA B 1 1C 2 AE7 1 AE7 W CAMRY (EM0250U) B 7. 5A AM1 2 3G E23 Ignition SW ∗ 1 : w/ Smart Key System ∗ 2 : w/o Smart Key System Ig n itio n (2 G R – F E ) 1 (BAT) (BAT) 30A ST/AM2 7. 5A AM2 4 3 2 (BAT) M OVERALL ELECTRICAL WIRING DIAGRAM 464 5 CAMRY 20A IG2 2 2 1 5 AM2 IG2 6 B B ST2 B Y Y B (∗2) (∗2) B 1 AE7 (∗1) Y 1 (∗2) 1 E23 Ignition SW 10 EA1 7 CA3 B (∗2) 16 EA1 BR L BR LG (∗1) L (∗1) L B BR 1 1 BR 5 W–B W–L W–L IGT4 IGF IGT5 IGF IGT6 IGF 3 2 3 2 3 2 W–L C39 Ignition Coil (No. 6) 4 GND L–B +B W–B B 1 C38 Ignition Coil (No. 5) W–B BR 4 GND BR L BR W BR 2 +B W–L L IGF 3 1 P G–R IGT3 4 GND C14 Ignition Coil (No. 4) 2 +B R IGF 3 1 LG IGT2 2 4 GND R IGF 3 +B W L 1 IGT1 (∗2) BR BR (∗1) E6(A) Main Body ECU 4 GND L IG2D +B W–B W–B G 1 B 4 GND C13 Ignition Coil (No. 2) +B B–W 1 C11 Ignition Coil (No. 1) 1 B LG 11 A 1 W AM2 (∗1) L 1 A B BR 1 1 BR 3 C49 Noise Filter (Ignition LH) 2 L 10 4M C16 Noise Filter (Ignition RH) 12 4M B C12 Ignition Coil (No. 3) 1 10 4E IG2 Relay 12 4E (∗1) Engine Control Module < 7–17> < 7–18> W–B CAMRY (EM0250U) 7 EA1 O(∗1) BR B–W 2 CA3 6 A43 Junction Connector A2 A2 C7 6 CAMRY Ig n itio n (2 A Z – F E ) 1 4 3 2 (IG) 15A INJ B 7 IH B 10 EA1 BR BR BR BR BR W–B W–B 1 +B IGT2 IGF IGT3 IGF IGT4 IGF 3 2 3 2 3 2 LG W–L C12 Ignition Coil (No. 3) 4 GND C14 Ignition Coil (No. 4) BR 4 GND W–B W–B BR +B W–L W–L 1 G 2 4 GND W–L IGF 3 G–R IGT1 +B C13 Ignition Coil (No. 2) 1 W–B BR 4 GND W–L +B C11 Ignition Coil (No. 1) 1 W–B BR W–B W 1 C16 Noise Filter (Ignition RH) W–B BR CAMRY (EM0250U) 7 CA3 W–L BR W–L W–B Engine Control Module < 8–10> C4 M 465 ∗ 1 : w/ Smart Key System ∗ 2 : w/o Smart Key System E n g in e C o n tro l (2 G R – F E ) 4 3 2 (BAT) (IG) 30A EFI MAIN 10A IGN 2 7. 5A AM2 30A ST/AM2 20A IG2 W 9 IG 2 1 1 1 5 AM2 B B 2 2 Y 3 12 4E 10 4M 12 4M B LG GR 1 L 1 9 NA1 4 11 A 1 A AM2 (∗1) BR BR (∗2) IG2D 2 CA1 M E6(A) Main Body ECU Y 1 GR W–B W GR GR R W R 10 4E 2 5 1 L LG IG2 Relay 7 EA1 (∗1) 16 EA1 1 W 1 CA2 10A EFI NO. 3 15A EFI NO. 2 8 1E Pump 1 N10 Fuel Suction Pump and Gage Assembly 1 1 13 1E GR 4 1A 1 (∗1) 1 Y W 11 1E BR O BR B L 9 1E (∗2) (∗1) C/OPN Relay 5 6 1E 10 1E Y O (∗1) CAMRY (EM0250U) (∗2) 10 EA1 12 3K 20A A/F Y (∗2) E23 Ignition SW 12 3F 6 B EFI Relay IG2 6 ST2 Y B (∗2) (∗1) B 1 A A/F Relay 1 AE7 Y Y 12 1D A58(A), E40(B) Junction Connector 1 1G (∗2) LG Y 12 1E GR R FL MAIN 3. 0W R O BR BR B Battery W–B A1 N1 BR A43 Junction Connector (∗2) W–B 6 W–B A3 A (BAT) 2 1 7 1E L (BAT) (BAT) (∗1) 1 A2 A2 B C D E F G H I M OVERALL ELECTRICAL WIRING DIAGRAM 466 (Cont. next page) 7 CAMRY 7 CAMRY (Cont' d) (Cont. next page) E n g in e C o n tro l (2 G R – F E ) A 5 L 8 7 6 L BR (BAT) 10A EFI NO. 1 R R W–L Leak Detection Pump Canister Pressure Sensor M 3 NA1 4 NA1 14 CA2 13 CA2 W 12 CA2 PRG ACIS ACM E2G VG THA 76 B 77 B 75 B VPMP EPPM 7 A Y Y FC 20 A # 10 # 20 45 B G H I # 30 85 B # 40 44 B # 50 84 B 43 B W # 60 83 B W 1 2 2 W C37 Fuel Injector (No. 6) BR W–L W 2 1 W 1 C36 Fuel Injector (No. 5) C10 Fuel Injector (No. 4) 2 W W 1 L Y 2 W W 1 W 1 C8 Fuel Injector (No. 3) C7 Fuel Injector (No. 1) F MPMP 2 B 2 E 34 A VCPP A55(A), C55(B) Engine Control Module Y W PPMP B GR R 42 A ETHA L 107 B R 1 B 108 B G 10 A BATT D W–B G 14 NA1 G Y 74 B 13 NA1 Y G–R 71 B 6 B P 72 B MGND 1 5 NA1 B L–B 73 B MTRB BR LG 42 B E2 VCC 4 BR 2 VOUT 3 W 1 2 GR 5 L–B C34 VSV (ACM) C48 VSV (ACIS) O 4 B–W GR GR W–B A41(A), A42(B) Junction Connector THA 2 SGND 8 C9 Fuel Injector (No. 2) Y VG 1 VGND 9 B 9 A E2G 2 VLVB 10 CA3 A41(A), A42(B) Junction Connector 8 A W 4 B C6 VSV (Purge) W–L 12 NA1 +B 1 2 C2 Mass Air Flow Meter 3 G–R W–B 3 CA2 W–B CAMRY (EM0250U) BR 1 16 NA1 W–L B B W R Vent Valve W–L C B N17 Canister Pump Module W–L 2 1A B A W GR GR B R R R R O O B B W–B W–L R C D E F G H I C4 M 467 E n g in e C o n tro l (2 G R – F E ) A B 9 L 12 11 10 L BR BR (BAT) A B (IG) 10A IGN 10A ETCS C5 Throttle Body Assembly 2 9 IG VC VTA2 E2 4 G R M– 1 P M+ 2 W–L 3 B 5 98 B 96 B 99 B 97 B 19 B 18 B 2 12 3K P 79 B 78 B G–R B 4 GR 3 A 35 A 28 A ST1– +BM (Shielded) C4 Engine Coolant Temp. Sensor Y 6 B 6 Y Y VTA 1 12 3F Y 1 1 ID Y CAMRY (EM0250U) A19 Stop Lamp SW LG 2 A A58(A), E40(B) Junction Connector 3 Stop Light System < 10–2> 2 B 1 IGSW THW ETHW VTA1 VTA2 VCTA ETA M+ M– 41 B GE01 A55(A), C55(B) Engine Control Module H I Y 4 HT1B EX1B 48 B 65 B W W–B 3 OX1B 88 B A1A+ 93 B A1A– 116 B HA1A A2A+ 86 B 120 B E2 +B A2A– 119 B HA2A 109 B 2 B–W Y 4 1 3 4 1 A1A– HA1A A2A+ A2A– HA2A +B C52 Heated Oxygen Sensor (Bank 1 Sensor 2) BR (Shielded) 3 A1A+ 2 +B C15 Air Fuel Ratio Sensor (Bank 1 Sensor 1) 2 C35 Air Fuel Ratio Sensor (Bank 2 Sensor 1) B C51 Heated Oxygen Sensor (Bank 2 Sensor 2) G 4 P 1 HT1B L 3 OX1B (Shielded) BR 1 HT2B W W–L (Shielded) (Shielded) LG E2 R A53 VSV (Air Intake Control) OX2B O B B B (Shielded) W–L C R B F G R R 47 B 2 (Shielded) E HT2B 64 B +B 1 BR D 1 C50 Crankshaft Position Sensor (Shielded) 2 V C B EX2B 87 B R G (Shielded) 111 B 2 B 2 OX2B NE– 110 B B NE+ MREL 44 A O A56(A), A57(B) Short Connector V 2 A +B2 1 A R +B 2 A R ACIV 4 A C5 C5 M OVERALL ELECTRICAL WIRING DIAGRAM 468 (Cont. next page) 7 CAMRY (Cont' d) (Cont. next page) 7 CAMRY (Cont' d) E n g in e C o n tro l (2 G R – F E ) 16 15 14 L BR VVR+ VVR– 1 2 VC 3 VVL+ VVL– 1 2 C40 VVT Sensor (Bank 1 Exhaust Side) VC 3 CAMRY (EM0250U) VCV1 EX+ EX– VC2 EX+ EX– VC2 1 2 3 1 2 3 VV2– VCV2 1 1 EV2+ EV2– 2 VCE2 Y W B BR R 112 B W–L 89 B VCE1 2 2 LG 114 B EV1– 1 L 91 B 1 LG L 66 B R 68 B EV1+ G–R 113 B B 90 B VV2+ Y 67 B R B 115 B VV1– W LG Y L 92 B VV1+ B C44 VVT Sensor (Bank 2 Exhaust Side) 2 69 B A C47 Camshaft Timing Oil Control Valve (LH Intake Side) C45 VVT Sensor (Bank 2 Intake Side) C43 Camshaft Timing Oil Control Valve (RH Intake Side) C41 VVT Sensor (Bank 1 Intake Side) C46 Camshaft Timing Oil Control Valve (LH Exhaust Side) B 13 L BR C42 Camshaft Timing Oil Control Valve (RH Exhaust Side) A 16 B 17 B 14 B 15 B 58 B 57 B 52 B 51 B OE1+ OE1– OE2+ OE2– OC1+ OC1– OC2+ OC2– A55(A), C55(B) Engine Control Module W W–B W–B VPA2 W 3 VPA B–W 6 EPA E1 B–W 5 E05 46 B B 4 VCPA E02 21 B B 2 EPA2 104 B ME01 20 B B G 1 VCP2 E03 B Y W–B E01 22 B W–B E04 23 B W VPA2 56 A W VPA 55 A R R V2 Knock Control Sensor (Bank 1) EPA 59 A B W 2 VCPA 57 A O B 3 CV1 EPA2 60 A 81 B 4 6 5 G G 4 CV1 W 1 CV1 B 2 CV1 1 VCP2 58 A L EKN2 117 B R 118 B (Shielded) KNK2 EKNK 94 B 1 V1 Knock Control Sensor (Bank 2) KNK1 95 B A17 Accelerator Position Sensor 2 (Shielded) C C57 Junction Connector C4 C7 M 469 E n g in e C o n tro l (2 G R – F E ) 20 19 18 L BR BR ∗ 1 : w/ Smart Key System ∗ 2 : w/o Smart Key System Data Link Connector 3 < 9–1> B 10 4C B B–W Combination Meter < 25–1> P Ignition Coils < 5–2> < 5–3> < 5–4> B ACCR IGF1 L–B G IGT6 8 A 24 B TACH SPD 25 B 27 B 26 B P R N D Y 15 A RFC B 43 A TC G 27 A L–B 35 B IGT5 P 36 B IGT4 B–W 37 B IGT3 V L–B 38 B IGT2 B P 39 B IGT1 Y G LG 40 B 6 AE5 P G 106 B STP G–R BR 36 A W 13 A STSW W (∗1) 14 A NSW B R 62 B STA (∗1) L–B 48 A 2 B 1 B CAN+ C D E F G H CAN– A55(A), C55(B) Engine Control Module SFTU CCS 16 A 40 A Y BR 10 AE5 20 AE5 11 AE5 5 AE5 Y W 24 A L S 25 A L BR SFTD 51 A R CANL 49 A G CANH 41 A BR Y IMI 11 A G IMO 10 A W PSW 70 B 17 AE5 10 3D 11 3A 3 C 18 B B R 4 C 2 1 SFTU BR A41(A), A42(B) Junction Connector CCS BR E18(A), b1(C) Spiral Cable 10 3H ECC R 1 A 7 SFTD S 17 A E 3 O +RES IG 5 W–B GR ON–OFF E31 Transmission Control SW GR 2 A 15 EA1 R 4 CA3 3 CANCEL C7 C57 Junction Connector –SET W–B 12 4C b1(C) Cruise Control SW Multiplex Communication System (CAN) < 2–2> C17 Power Steering Oil Pressure SW BR 1 ID Code Box(∗1)< 3–6> Transponder Key ECU(∗2)< 9–3> STAR V 63 B B R (∗1) CAMRY (EM0250U) (∗2) P B 12 AE5 B 9 4A (∗1) Cooling Fan ECU < 26–1> 9 4L A (∗2) Data Link Connector 3 < 9–1> B (∗1) B (∗1) Data Link Connector 3 < 9–2> Stop Lamp SW < 10–3> Main Body ECU < 3–4> Park/Neutral Position SW < 3–3> < 4–2> ST Relay < 3–2> < 4–2> ST CUT Relay < 3–3> Main Body ECU < 3–4> B 17 L A E le c tro n ic a lly C o n tro lle d T ra n s m is s io n a n d A /T In d ic a to r (2 G R – F E ) C ru is e C o n tro l (2 G R – F E ) O 11 4A BR I J M OVERALL ELECTRICAL WIRING DIAGRAM 470 (Cont. next page) 7 CAMRY (Cont' d) 7 CAMRY (Cont' d) (Cont. next page) E le c tro n ic a lly C o n tro lle d T ra n s m is s io n a n d A /T In d ic a to r (2 G R – F E ) A B 21 L 24 23 22 (IG) BR R (IG) 10A GAUGE NO. 1 RB L–B G BR L 10 CA2 9 CA3 11 CA2 12 3J G O L–B 12 3F 4 AE5 9 CA2 19 CA2 BR P LG R P 6 CA2 G 16 R B 15 L 6 CAN+ Y 7 CAN– R W Y R B W–L Y G O H 14 EA1 Y 1 18 10 11 12 BATT D +B STA NSW 13 3 STP IG2 SPD1 C56 Transmission Control ECU SLT+ SLT– O B L B G B W B GR B SL TPS1 TPS2 TPS3 THO1 E2 NCB NCO NTB NTO R SLU– W SLU+ B SL4– Y SL4+ Y SL3– BR SL3+ O SL2– GR SL2+ W SL1– L SL1+ B BR 5 3C E01 9 B–W E1 8 R 5 3L NCB NCO NTB NTO O CAMRY (EM0250U) F G B–W W E B–W B D Park/Neutral Position SW < 3–3> < 4–3> 16 IH L–B 7 A Y DL 8 A Y NL 2 A Combination Meter < 25–1> RL Stop Lamp SW < 10–3> PL 3 A P C1(A) Park/Neutral Position SW 9 IG O 19 IF C 10A IGN (IG) 1 A 7. 5A ECU IG NO. 2 HALL SENSOR HALL SENSOR 7 4D O 7 4C R BR J R O B–W I 2 1 A C57 Junction Connector C7 M 471 E le c tro n ic a lly C o n tro lle d T ra n s m is s io n a n d A /T In d ic a to r (2 G R – F E ) 25 28 27 26 (IG) (BAT) (BAT) 7. 5A GAUGE NO. 2 10A DOME 10A MPX–B 12 3L 7 IF 1 3Q 13 ID 1 LG R 12 3Q R 9 3Q SB 1 3D 3 1A V V 2 3G GR GR 2 12 IG GR V R 2 EA1 13 A 1 A 2 A IG+ B B2 CAMRY (EM0250U) Power Supply Circuit DRIVE IC MULTI LCD MICRO COMPUTER +B(DOME) Master Warning LCD A/T Range Cruise Speedometer Temp. Tachometer S D N R IG2 P Malfunction Indicator Lamp IG2 DRIVE IC F1(A), F2(B) Combination Meter Buzzer CAN I/F ES CANH 17 A W–B BR 9 3P 7 3Q 5 3Q 3 3B 2 3U 10 3D CANL 18 A GR Multiplex Communication System (CAN)< 2–3> < 2–4> 17 A R BR 15 EA1 BR 4 CA3 W–B A W–B 18 B GR R 24 A 3 F1 C7 C57 Junction Connector E2 12 A A41(A), A42(B) Junction Connector CHK 4 B M OVERALL ELECTRICAL WIRING DIAGRAM 472 7 CAMRY (Cont' d) CAMRY (EM0250U) Memo 473 E n g in e C o n tro l (2 A Z – F E ) 4 3 2 (BAT) (IG) (IG) 30A EFI MAIN 10A IGN 15A INJ Leak Detection Pump 2 Canister Pressure Sensor M 8 IH 9 IG Vent Valve 1 Y LG 16 B Pump 10A EFI NO. 3 15A EFI NO. 2 Y W GR W O B MPMP 14 CA2 13 CA2 R 12 CA2 L Y BR 34 A 12 NA1 G O W A41(A), A42(B) Junction Connector 10 A 5 NA1 B G G 10 CA3 3 NA1 BR W–B W–B 2 CA1 W–B 14 NA1 94 B 71 B 70 B EPPM PPMP VCPP 42 A VPMP A24(A), C24(B) Engine Control Module 1 B M W–B 1 W–B 5 2 1 9 4 N10 Fuel Suction Pump and Gage Assembly 17 A A41(A), A42(B) Junction Connector 1 2 VLVB 8 GR 1 1 VGND 4 GR LG 9 NA1 1 CA2 A58(A), E40(B) Junction Connector Y 1 A VCC 3 O BR BR B L 8 1E Y 13 1E 9 1E GR 10 1E W R R W A1 V V A3 N1 W–B W W–B W–B 3 CA2 W–B BR GR W–B GR O GR R Y R CAMRY (EM0250U) 6 1E 11 1E 7 1E VOUT 2 13 NA1 12 3K 6 B SGND 1 4 NA1 1 EA1 C/OPN Relay MTRB 6 16 NA1 12 3F EFI Relay MGND BR Y BR 12 1D 12 1E N17 Canister Pump Module 1 C6 A B C D E F G M OVERALL ELECTRICAL WIRING DIAGRAM 474 (Cont. next page) 8 CAMRY 8 CAMRY (Cont' d) (Cont. next page) E n g in e C o n tro l (2 A Z – F E ) 5 8 7 6 (BAT) (BAT) 10A EFI NO. 1 10A ETCS A17 Accelerator Position Sensor 2 C5 Throttle Body Assembly 8 A 9 A 1 C4 Engine Coolant Temp. Sensor W 2 C32 Camshaft Timing Oil Control Valve 2 1A 1 1 VCP2 VPA2 EPA2 VCPA VPA EPA VTA 1 3 2 4 6 5 6 VC VTA2 5 E2 4 3 M+ M– 2 1 Y 55 A 59 A 42 B 41 B G–R R G 57 A G B 60 A P O 56 A (Shielded) R 58 A W–L L 96 B B P 97 B Y B B Y CAMRY (EM0250U) LG A41(A) Junction Connector W 2 3 A 20 A 100 B BATT +BM 123 B OC1+ OC1– THW ETHW VCP2 VPA2 EPA2 VCPA VPA 115 B EPA 67 B VTA1 114 B VCTA 91 B VTA2 ETA M+ M– 63 B GE01 A24(A), C24(B) Engine Control Module FC 7 A MREL 44 A +B 2 A # 40 +B2 1 A # 30 105 B # 20 106 B 107 B # 10 PRG 108 B VG 49 B 118 B E2G 116 B THA 65 B ETHA 88 B HT1B OX1B 47 B 64 B EX1B A1A+ 87 B 112 B A1A– 113 B HA1A 109 B D E F G W G P L +B HA1A 2 2 1 G +B 1 W V W HT1B 4 A1A– B–R C2 Mass Air Flow Meter 3 A1A+ LG V W W R V E2 +B R W 4 OX1B O 3 C 3 E2 B C15 Air Fuel Ratio Sensor (Bank 1 Sensor 1) 1 (Shielded) 2 THA (Shielded) C22 Heated Oxygen Sensor (Bank 1 Sensor 2) Y 1 E2G (Shielded) P 4 VG LG W 5 BR 1 SB O 2 C6 VSV (Purge) 2 A W 1 B R 1 2 C7 Fuel Injector (No. 1) 2 C9 Fuel Injector (No. 2) Y C8 Fuel Injector (No. 3) L C10 Fuel Injector (No. 4) R R 1 W B Y 2 W A O Y (Shielded) W V V B–R W M 475 (Cont. next page) E n g in e C o n tro l (2 A Z – F E ) ∗ 1 : California SB 48 A 15 A 8 A 36 A 27 A 11 A 10 A NSW IGF1 Multiplex Communication System (CAN)< 2–2> G BR 52 B Y LG 81 B IGT4 P G 82 B IGT3 W G–R 83 B IGT2 L W 84 B IGT1 B L 85 B ALT 12 AE5 V W 50 B FANH (A/T) R 22 A FANL STA TACH SPD STP TC IMI 41 A 49 A CANH IMO CANL A24(A), C24(B) Engine Control Module E02 ME01 E03 43 B 86 B 44 B E04 46 B E01 45 B E1 104 B W–B L PSW 53 A W–B (Shielded) A IAC– 52 A W IAC+ 33 A B EIA 126 B B IACA 93 B B VCIA 103 B B–W EKNK 111 B B–W KNK1 110 B BR G2– 98 B W G2+ 99 B (∗1) NE– 121 B (∗1) NE+ 122 B (Shielded) (∗1) L (∗1) B–W B 19 CA2 3 CA3 5 IAC+ B G (∗1) 4 EIA 1 IAC– W–B M C33 Intake Air Control Valve 1 CA3 W–B 1 2 IACA 2 CA3 B–W 2 1 VCIA C17 Power Steering Oil Pressure SW 2 C30 Knock Control Sensor (Bank 1) 1 C31 Camshaft Position Sensor C20 Crankshaft Position Sensor L 3 (∗1) W R G (Shielded) BR Y (Shielded) 2 9 CA2 R G 1 (∗1) B (Shielded) CAMRY (EM0250U) 6 AE5 21 A Transponder Key ECU < 9–3> P Stop Lamp SW < 10–3> Combination Meter < 25–1> Data Link Connector 3 < 9–2> Data Link Connector 3 < 9–1> B Ignition Coils < 6–2> < 6–3> ST Relay < 4–2> Park/Neutral Position SW (A/T)< 4–2> Generator < 4–3> 12 11 10 FAN NO. 1 Relay < 26–3> FAN NO. 2 Relay < 26–3> FAN NO. 3 Relay < 26–4> 9 B–W W–B B C4 C6 W–B A M OVERALL ELECTRICAL WIRING DIAGRAM 476 8 CAMRY (Cont' d) (Cont. next page) 8 CAMRY (Cont' d) C ru is e C o n tro l (2 A Z – F E ) E le c tro n ic a lly C o n tro lle d T ra n s m is s io n a n d A /T In d ic a to r (2 A Z – F E ) 13 (IG) 7. 5A ECU IG NO. 2 (M/T) R NL DL 2L LL 1 B 9 B 7 B 3 B 8 B R V GR P 17 CA2 GR B B C V G P G (A/T) (M/T) G GR 8 CA3 4 B LG RL G A58(A), E40(B) Junction Connector 4 3K W PL 6 B SB W BR 4 A 12 3K G RB 5 3L 2 6 B Y 2 B (M/T) O Y 2 A C1(B) Park/Neutral Position SW 2 (M/T) A58(A), E40(B) Junction Connector 12 3F 4 GR 1 2 A 1 1 12 A Y CAMRY (EM0250U) A19 Stop Lamp SW Stop Light System < 10–2> 1 C27 Transmission Revolution Sensor (Counter Gear) C26 Transmission Revolution Sensor (Turbine) Y B 3 1 ID R A21 Cruise Control Clutch SW 19 B 19 IF 2 P (M/T) A41(A), A42(B) Junction Connector 10A IGN 9 IG 16 15 14 (IG) O (M/T) 35 A 28 A ST1– 125 B IGSW 124 B NT+ 101 B NT– 102 B NC+ 73 B 53 B 54 B 56 B 26 A 55 B P R N D 3 2 NC– A24(A), C24(B) Engine Control Module CCS 40 A EC SR EOM 80 B 9 A SL3+ 60 B SL3– 61 B S4 78 B SLT+ 76 B SLT– 75 B DSL 79 B SL2+ 58 B SL2– 59 B SL1+ 57 B SL1– 77 B THO1 72 B ETHO 95 B 15 EA1 GR BR Y LG L R G BR W L GR Y O G 11 3 2 8 10 5 12 6 13 1 7 SL3– S4 SLT+ SLT– DSL SL2+ SL2– SL1+ SL1– THO E2 R L Y G GR SB LG BR W B O O 16 B W–B +RES b1(C) Cruise Control SW W–B 4 SL3+ ON–OFF 4 CA3 A 9 SR V 3 C A41(A), A42(B) Junction Connector CCS R 4 C W BR 10 3D 16 A 1 A ECC B E18(A), b1(C) Spiral Cable 2 A BR 11 3A 18 A GR BR 17 AE5 W–B W 32 A C25 Electronically Controlled Transmission Solenoid –SET CANCEL A3 M 477 E le c tro n ic a lly C o n tro lle d T ra n s m is s io n a n d A /T In d ic a to r (2 A Z – F E ) 17 7. 5A GAUGE NO. 2 R 7 IF 1 3Q 13 ID 1 LG R SB 12 3Q V 9 3Q 12 3L 2 EA1 V R Power Supply Circuit A24(A), C24(B) Engine Control Module MICRO COMPUTER DRIVE IC Buzzer W 24 A BR CAN I/F CHK ES W–B BR 24 A 9 3P 7 3Q 5 3Q R 5 AE5 E2 12 A R 4 B CANH 17 A CANL 18 A Multiplex Communication System (CAN)< 2–3> < 2–4> 10 3D 15 EA1 BR 2 3U GR R 3 3B W–B 4 CA3 F1 C6 Cruise Speedometer Temp. Tachometer 4, 3, 2, L DRIVE IC MULTI LCD +B(DOME) Master Warning IG2 W–B L F1(A), F2(B) Combination Meter B2 D 74 B 4 2 A B N 25 A 1 A IG+ IG2 Malfunction Indicator Lamp BR B G CAMRY (EM0250U) GR 13 A R NSSL GR 5 NSSD P 1 AT4 E31 Transmission Control SW 2 ATL R 15 CA2 L Y 16 AE5 O O 16 CA2 Y W 11 CA2 6 O 1 3D 3 1A 19 AE6 SB 14 EA1 V L 22 AE6 2 3G GR R 21 AE6 R R 12 IG GR 2 10 CA2 C 10A DOME 10A MPX–B R 16 IH B (BAT) (BAT) (IG) 10A GAUGE NO. 1 A 20 19 18 (IG) M OVERALL ELECTRICAL WIRING DIAGRAM 478 8 CAMRY (Cont' d) E2 3 C7 C6 EFIO +B 2 IG 6 3O KSW 3 7 AE5 14 9 VC5 16 GND 3 3C BR R TXCT 5 15 4 CODE TXCT V 4 (∗1) CODE (∗1) VC5 (∗1) 1 Y 13 W ANT1 (∗1) 1 P 1 3B O SIL (∗1) 1 3J (∗1) EFII (∗1) LG (∗1) LG (∗1) A41(A), A42(B) Junction Connector W (∗1) 3 Door Courtesy SW (Driver' s Side)< 2–25> 13 AE5 W 3 B (∗1) 12 (∗1) 2 1A W–B D B 8 A (∗1) 10A EFI NO. 1 Security Indicator < 2–17> 15 EA1 L : w/o Smart Key System : 2GR–FE : 2AZ–FE : TMC Made w/ VSC (∗1) 5 3H (∗1) Tire Pressure Warning ECU< 16–2> (BAT) W–B 5 3B 9 Unlock Warning SW < 2–19> 8 3C Y 10 IE 8 3C (∗1) 1 IH 8 3B (∗1) GR GR G 7 (∗1) TS P 12 CANL Tire Pressure Warning ECU< 16–2> E10 Data Link Connector 3 G 4 3E P WFSE 14 (∗1) 10 3D P 15 1 2 3 4 GR CANH GR ∗ ∗ ∗ ∗ (∗1) 7. 5A OBD Engine Control Module < 7–18> < 8–12> 3 3C GR 2 Engine Control Module < 7–17> < 8–12> 4 CA3 Multiplex Communication System (CAN)< 2–3> < 2–4> Engine Control Module < 7–19> < 8–11> 1 Occupant Classification ECU < 15–6> 7 3L W TAC GR TC 6 Airbag Sensor Assembly Center < 15–5> 3 IF GR 9 O B 4 IM (∗4) 12 IM O 13 Y BAT (∗4) 16 Skid Control ECU with Actuator < 12–3> < 13–3> < 14–2> 4 3H P (BAT) E49 Junction Connector GR (∗3) BR 11 3H BR L D a ta L in k C o n n e c to r 3 (∗1) 4 CA3 W–B 17 A (∗3) 18 B A41(A), A42(B) Junction Connector BR (∗2) SG 5 W–B GR (∗2) W–B 3 3H W–B CG 4 C57 Junction Connector (∗2) 2 W–B 9 E49 Junction Connector CAMRY (EM0250U) W–B 9 CAMRY E n g in e Im m o b ilis e r S y s te m (w /o S m a rt K e y S y s te m ) (IG) 4 10A IGN 13 IM E25 Transponder Key Amplifier Transponder Key Coil 21 AE2 ANT2 AGND 7 AGND 5 E15 Transponder Key ECU IND CTY 8 7 2 3B 2 E2 M 479 9 S1 1 1 W–B 3 2 2 1 W–B N1 S16 Junction Connector 8 9 3 2 1 SN1 2 5 N29 Junction Connector 3 1 6 7 9 W–B S1 S11 Rear Combination Lamp (LH) L 9 Stop 8 3K Tail 8 Tail 10 L 7 L 8 3L Stop 3 IP S12 Rear Combination Lamp (RH) 15 IF N28 Junction Connector L 3 L W L P (2AZ–FE) 13 IC S15 Junction Connector 1 Skid Control ECU with Actuator < 12–3> < 13–3> < 14–2> 3 W–B W–B W–B 3 4 3 A W 2 7 IL N16 Center Stop Lamp 1 Engine Control Module < 8–11> 9 AE2 L R L 1 L 2 (2GR–FE) R N15 Noise Filter (Dome and Stop) 8 B A41(A), A42(B) Junction Connector (∗2) W–B 4 4 A W B R 2 W 2 A (2GR–FE) 1 B (2AZ–FE) (∗1) R (∗1) 10A GAUGE NO. 1 Engine Control Module< 7–17> RL E48 Junction Connector (IG) Transmission Control ECU< 7–23> 17 SN1 A19 Stop Lamp SW 20 CA2 LG R R 1 Back–Up R 9 EN1 S2 Rear Combination Lamp (RH) (A/T) R (A/T) R RB 2 Shift Lock Control ECU < 21–4> W–B 14 EA1 W–B L (∗1) R 3 S16 Junction Connector 10 CA2 6 AE3 GR Navigation Receiver Assembly < 22–6> R 8 W–B L P R (M/T) 1 A 2 B (A/T) O ∗ 1 : w/ Mirror Heater ∗ 2 : w/o Mirror Heater Back–Up S3 Rear Combination Lamp (LH) 2 C1(A), (B) Park/Neutral Position SW R 16 IH S15 Junction Connector B (M/T) B a c k – U p L ig h t S to p L ig h t (BAT) 4 10A STOP 8 IC W Main Body ECU < 3–17> 8 SN1 Multiplex Communication System (CAN)< 2–42> 10 M OVERALL ELECTRICAL WIRING DIAGRAM (M/T) C28 Back–Up Lamp SW CAMRY (EM0250U) L 480 10 CAMRY 11 CAMRY ∗ 1 : 2GR–FE ∗ 2 : 2AZ–FE T u rn S ig n a l a n d H a z a rd W a rn in g L ig h t 1 4 3 2 (IG) (BAT) E14 Turn Signal Flasher 10A GAUGE NO. 1 15A HAZ 2 14 IF Y R 1 2 3L 9 EA1 1 3F LR E W II ER 7 8 G B 1 EL 6 5 9 3F W 8 3G 5 7 3P 5 3P L G LG G G 2 B 1 B E 4 CA3 L W–B 2 3U 3 3C W–B GR(∗2) 9 4 CA3 C6 C7 2 E49 Junction Connector W–B 3 (∗2) 15 EA1 W–B W–B BR W–B W–B BR(∗1) 10 3D A6 3 3G (∗1) S15 Junction Connector 18 B A1 3 3F W–B 7 3Q GR A41(A), A42(B) Junction Connector 17 A (∗1) W–B BR BR BR W–B W–B S1 8 3R GR 12 A 5 3Q 9 W–B 19 (∗1) 3 12 F3 Clock E2 24 A 2 TL GND1 W–B ES LH W–B Turn LH Turn RH B C57 Junction Connector 2 F1(A), F2(B) Combination Meter 2 3 Turn Turn 3 A50 Turn Signal and Parking Lamp (Front RH) 2 A46 Turn Signal and Parking Lamp (Front LH) G 1 S13 Turn Signal Lamp (Rear RH) 2 B 15 EL RH 20 11 SN1 1 TR W–B 10 SN1 13 Turn SW 7 3F Main Body ECU < 2–12> 4 EN1 F4 Hazard Warning Signal SW 4 G 9 3M B 3 3R 2 IG G 8 IG G Y 3 IC W O II 7 ID 9 IL 12 IP Y CAMRY (EM0250U) 6 HAZ 2 E21 Headlamp Dimmer SW Assembly LL 3 W–B B 4 S10 Turn Signal Lamp (Rear LH) Y R IG 1 F1 E2 M 481 A B S (w / V S C ), T R A C a n d V S C (T M C M a d e ) 1 (BAT) 50A ABS No. 1 4 3 2 (BAT) (IG) 30A ABS No. 2 7. 5A ECU IG NO. 2 19 IF O O 1 Combination Meter System< 25–2> Y 1 1 1 7 4D 1 6 4A O O GR 4 AE6 7 AE6 +S IG2 GR P 42 24 13 27 R L 15 P B LG 2 8 AE6 12 B 14 AE6 3 A O 1 Y 1 L 1 1 B L 2 F1(A), F2(B) Combination Meter Buzzer P 3 4 B 1 E13 VSC Warning Buzzer 2 A58(A), E40(B) Junction Connector 2 1 14 MRF +BM 45 MR 31 R+ 46 +BS 30 IG1 BZ WFSE TS D/G STP1 A26 Skid Control ECU with Actuator GND1 FL+ GND2 32 1 18 FL– FR+ 4 3 FR– 17 RL+ 20 MICRO COMPUTER RL– RR+ 6 5 RR– 19 CANL CANH 25 11 SP1 12 BR W–B 11 3P 7 3Q 3 3D 2 3U W–B 1 E2 12 A W 1 2 SI 14 B W A35 Speed Sensor (Front RH) A14 Speed Sensor (Front LH) 2 Multiplex Communication System (CAN)< 2–1> W W B 2 fO1 B L 1 fO1 1 gN1 f1 Speed Sensor (Rear RH) R B L 2 gN1 W W BR L 10 OA1 B 2 1 OA1 g1 Speed Sensor (Rear LH) 1 10 NA1 R 2 1 NA1 W P V 1 W W–B LG IG2 L 3 5 Y W VSC NO. 2 Relay 1 W–B CAMRY (EM0250U) VSC No. 1 Relay 4 3K 5 Stop Lamp SW < 10–3> 1 5 3C Data Link Connector 3 < 9–1> < 9–2> B 5 3L 6 AE6 W–B A6 A4 F1 M OVERALL ELECTRICAL WIRING DIAGRAM 482 (Cont. next page) 12 CAMRY 12 CAMRY (Cont' d) A B S (w / V S C ), T R A C a n d V S C (T M C M a d e ) 5 (IG) 8 7 6 (BAT) (BAT) (BAT) 7. 5A GAUGE NO. 2 10A DOME 10A ECU–B NO. 1 10A MPX–B V 2 (IG) 7. 5A ECU IG NO. 2 ∗ 1 : 2GR–FE ∗ 2 : 2AZ–FE 2 12 IG 3 1A 19 IF 1 1 3Q 9 3Q 12 3Q GR V 2 A 13 A 1 A 5 3L 1 IF 5 3C F1(A), F2(B) Combination Meter 7 4D 7 4B 6 4B O O 3 1 5 BAT E34 Yaw Rate Sensor DRIVE IC 9 3H W IG2 E17 Steering Sensor Slip DRIVE IC MICRO COMPUTER IG ESS CANL CANH 2 9 10 IG GND CANL 1 2 CANH 3 W–B CANL 18 A GR(∗2) Multiplex Communication System (CAN)< 2–3> < 2–4> 4 CA3 (∗1) BR(∗1) W–B GR 1 4B W–B (∗1) 18 B 10 3D A41(A), A42(B) Junction Connector 17 A 5 3Q 2 4B 3 4D W–B BR GR (∗1) Multiplex Communication System (CAN)< 2–3> CANH 17 A Multiplex Communication System (CAN)< 2–3> ES 24 A W–B MULTI LCD CAN I/F BR +B(DOME) ABS Power Supply Circuit VSC Speedometer IG2 15 EA1 9 3L B IG+ Buzzer O 10 ID Brake(Except USA) BRAKE(USA) B2 2 EA1 V Master Warning CAMRY (EM0250U) R 7 IF O 1 3D O 2 3G W 12 3L R 13 ID SB LG GR 1 1 C6 C7 E49 Junction Connector 2 W–B (∗2) W–B 3 C57 Junction Connector 4 CA3 E2 M 483 A B S (w / V S C ), T R A C a n d V S C (T M M K M a d e ) 1 (BAT) 50A ABS No. 1 4 3 2 (BAT) (IG) 30A ABS No. 2 7. 5A ECU IG NO. 2 19 IF Combination Meter System< 25–2> O 1 7 4D Data Link Connector 3 < 9–2> 6 4A O 4 3K P 28 +BS Buzzer O B IG2 4 AE6 14 AE6 P L 3 12 B 39 30 R B 2 +BM F1(A), F2(B) Combination Meter 1 3 A 23 IG1 BZ TS STP1 A60 Skid Control ECU with Actuator GND1 GND2 4 1 FL+ FL– 5 6 FR+ 10 MICRO COMPUTER FR– RL+ 9 7 RL– RR+ 27 29 RR– CANL CANH 8 14 35 SP1 33 BR W–B 11 3P 7 3Q 3 3D 2 3U W–B 1 E2 12 A W 1 2 SI 14 B W A35 Speed Sensor (Front RH) A14 Speed Sensor (Front LH) 2 Multiplex Communication System (CAN)< 2–1> W W B B L 2 fO1 f1 Speed Sensor (Rear RH) R B B 1 fO1 W W 2 gN1 1 gN1 g1 Speed Sensor (Rear LH) B 10 OA1 BR 2 1 OA1 B 1 10 NA1 R 2 1 NA1 W L P V 1 W W–B LG IG2 W–B CAMRY (EM0250U) 4 B A58(A), E40(B) Junction Connector P E13 VSC Warning Buzzer 2 Stop Lamp SW < 10–3> 5 3C O 5 3L L B O 1 6 AE6 W–B A6 A4 F1 M OVERALL ELECTRICAL WIRING DIAGRAM 484 (Cont. next page) 13 CAMRY 13 CAMRY (Cont' d) A B S (w / V S C ), T R A C a n d V S C (T M M K M a d e ) 5 8 7 6 (BAT) (BAT) (BAT) (IG) 7. 5A GAUGE NO. 2 10A DOME 10A ECU–B NO. 1 10A MPX–B V 2 (IG) 7. 5A ECU IG NO. 2 ∗ 1 : 2GR–FE ∗ 2 : 2AZ–FE 2 12 IG 3 1A 19 IF 1 1 3Q 9 3Q 12 3Q GR V 2 A 13 A 1 A IG+ 5 3L 1 IF 5 3C F1(A), F2(B) Combination Meter 7 4D 7 4B 6 4B O O 3 1 1 BAT E65 Yaw Rate Sensor DRIVE IC 9 3H W IG2 E17 Steering Sensor Slip DRIVE IC MICRO COMPUTER IG ESS CANL CANH 2 9 10 IG GND CANL 4 3 CANH 2 W–B CANL 18 A GR(∗2) Multiplex Communication System (CAN)< 2–3> < 2–4> 4 CA3 (∗1) BR(∗1) W–B GR 1 4B W–B (∗1) 18 B 10 3D A41(A), A42(B) Junction Connector 17 A 5 3Q 2 4B 3 4D W–B BR GR (∗1) Multiplex Communication System (CAN)< 2–3> CANH 17 A Multiplex Communication System (CAN)< 2–3> ES 24 A W–B MULTI LCD CAN I/F BR +B(DOME) ABS VSC Speedometer Power Supply Circuit 15 EA1 9 3L B IG2 Buzzer O 10 ID Brake(Except USA) BRAKE(USA) B2 2 EA1 V Master Warning CAMRY (EM0250U) R 7 IF O 1 3D O 2 3G W 12 3L R 13 ID SB LG GR 1 1 C6 C7 E49 Junction Connector 2 W–B (∗2) W–B 3 C57 Junction Connector 4 CA3 E2 M 485 ∗ ∗ ∗ ∗ A B S (w /o V S C ) 1 (BAT) (IG) 30A ABS No. 2 7. 5A ECU IG NO. 2 (BAT) (IG) 7. 5A GAUGE NO. 2 10A DOME 10A MPX–B V 2 12 IG 19 IF 1 O GR SB LG Combination Meter System< 25–2> 12 3L 2 3G 1 3D 1 3Q 9 3Q 12 3Q 26 15 CANH CANL STP TS B(∗2) 19 8 1 NA1 10 NA1 1 OA1 10 OA1 23 IG2 E2 CAN I/F 12 A 24 A W W–B BR ES 14 B 11 3P 7 3Q 5 3Q CANH 17 A CANL 18 A GR (∗3) 17 A Multiplex Communication System (CAN)< 2–3> < 2–4> 2 3U W–B 18 B 3 3D W W B B 1 2 f1 Speed Sensor (Rear RH) A35 Speed Sensor (Front RH) A14 Speed Sensor (Front LH) 2 W 2 fO1 g1 Speed Sensor (Rear LH) BR 1 fO1 B R 2 gN1 W L (∗1) (∗1) L W–B SI 1 gN1 Speedometer 2 17 DRIVE IC SP1 RR– BR 1 RR+ W L 2 RL– B P 7 W 9 V 1 10 RL+ L 6 DRIVE IC MICRO COMPUTER FR– R 5 FR+ Brake(Except USA) BRAKE(USA) Power Supply Circuit 1 10 3D BR 15 EA1 BR(∗3) 4 CA3 GR(∗4) 6 AE6 4 CA3 A6 W–B A4 F1 (∗4) 3 W–B C6 C7 C57 Junction Connector 20 FL– B(∗2) 1 IG2 GR 25 FL+ LG 4 V R IG2 (∗3) 18 IG1 W GND2 B IG2 A25 Skid Control ECU with Actuator GND1 F1(A), F2(B) Combination Meter 1 A IG+ B2 ABS P +BS O 3 13 A 2 A 12 B V 4 AE6 P 2 GR R 2 EA1 7 IF W–B A58(A), E40(B) Junction Connector 4 B 13 ID 3 A W–B CAMRY (EM0250U) Stop Lamp SW< 10–3> O L B 4 3K Multiplex Communication System (CAN)< 2–1> Data Link Connector 3 < 9–2> 5 3L +BM 3 1A 1 O 1 (∗3) 50A ABS No. 1 : TMC Made : TMMK Made : 2GR–FE : 2AZ–FE 4 3 2 (BAT) A41(A), A42(B) Junction Connector (BAT) 1 2 3 4 M OVERALL ELECTRICAL WIRING DIAGRAM 486 14 CAMRY CAMRY (EM0250U) Memo 487 SRS 1 (BAT) 4 3 2 (IG) (BAT) 7. 5A GAUGE NO. 2 10A DOME ∗ 1 : 2GR–FE ∗ 2 : 2AZ–FE 10A MPX–B V 2 12 IG 3 1A 1 Y1 Side Airbag Squib (RH) 2 EA1 O8 Pretensioner (RH) 1 2 1 2 B DK+ DK– 1 2 L+ R+ L– 1 2 ICL+ 2 Y–B Y–B Y Y–B Y Y–B Y Y–B Y Y Y–B Y Y–B SRS 2 B 1 B 4 C 5 C 9 B 10 B 7 C 6 C 7 B 6 B 9 C 10 C SFD– SFP+ SFP– ICD+ G R W B 4 AE4 2 AE4 1 AE4 4 CA3 GR(∗2) Spiral Cable E16 Airbag Squib (Steering Wheel Pad) (∗2) 3 C7 C57 Junction Connector 4 CA3 W–B D– 2 B 1 A P– P2+ 2 A B W R Y–G Y–R Y–P D2+ D2– 2 1 2 1 +SL –SL +SR –SR P2– c1(A), c2(B) Airbag Squib (Front Passenger' s Airbag Assembly) A13 Airbag Sensor (Front LH) A28 Airbag Sensor (Front RH) 3 BBL– BCL+ BCL– 1 2 2 1 BCL+ BCL– BBP– 11 C R Y–G 3 AE4 4 BBL+ BBP+ 8 C 4 3 BBR+ BBR– BCR+ BCR– 1 2 G Y–R 4 Ec1 BBD– 15 B G Y 3 Ec1 BBD+ 8 B R 27 A G 29 A R 3 28 A O7 Side Airbag Sensor (Front RH) 4 30 A Y–GR GR BR(∗1) C6 ICP– ICP+ O9 Side Airbag Sensor (Rear RH) 2 –SR 2 A P+ (∗1) 15 EA1 ICD– G 1 +SR 1 A 2 Ec1 P2– –SL P– 3 A 1 Ec1 P2+ +SL P+ 4 A Y–B D2– 7 A 1 B W–B 10 3D W–B SFD+ PP– (∗1) A41(A), A42(B) Junction Connector 17 A 5 3Q 18 B F1 D2+ 8 A Y–G F1(A) Combination Meter D– 6 A GR (∗1) BR PP+ 18 A Multiplex Communication System (CAN)< 2–3> < 2–4> 2 3U PD– Y–R BR CANL D+ 5 A D+ 7 3Q PD+ DRIVE IC CANH 17 A DK– Y W–B ES 24 A 2 OY2 10 A Y–B E2 2 E30(A), N1(B), O1(C) Airbag Sensor Assembly Center CAN I/F 12 A ICR– 1 9 A DK+ MICRO COMPUTER 1 OY2 ICR+ 2 Y IG2 2 NZ2 O16 Curtain Shield Airbag Squib (RH) ICL– 1 1 NZ2 Power Supply Circuit N21 Curtain Shield Airbag Squib (LH) R– 1 G CAMRY (EM0250U) 1 A IG+ B2 N8 Pretensioner (LH) V GR 13 A 2 A E54 Airbag Squib (Knee Airbag) V R 12 3Q N7 Side Airbag Sensor (Front LH) 9 3Q N12 Side Airbag Sensor (Rear LH) 1 3Q R 7 IF Y–B 1 3D Y 2 3G Y–B 12 3L R 13 ID Y SB LG GR Z1 Side Airbag Squib (LH) 2 1 BCR+ BCR– M OVERALL ELECTRICAL WIRING DIAGRAM 488 (Cont. next page) 15 CAMRY 15 CAMRY (Cont' d) ∗ 3 : w/ Power Seat ∗ 4 : w/o Power Seat SRS 5 8 7 6 (BAT) (IG) 10A ECU–B NO. 1 10A IGN F3 Clock 2 IH W O 10 3C 10 ID LG (∗4) LG (∗3) BR W(∗3) (∗3) B(∗4) BR 9 3D 3 EO2 B(∗3) (∗4) 8 3E 2 EO2 B B 5 3R 9 IE (∗3) R 6 3R T14(A), d2(B) Occupant Classification Sensor (Front LH) T16(A), d4(B) Occupant Classification Sensor (Front RH) W(∗4) 7 B 7 D SIG2 SGD2 3 A (∗3) 3 B (∗4) 2 A 2 B O P(∗3) 11 B 11 D SVC2 1 A 1 B L R 1 A (∗3) 1 C (∗4) W SGD1 3 A (∗3) 3 B (∗4) W SIG1 2 A 2 B G SVC1 1 A 1 B (∗3) BR (∗3) W 5 OT1 1 B 1 D 12 B 12 D 8 B 8 D 2 B (∗3) 2 D (∗4) IG2 PAON FSP– 8 A 8 C FSP+ 4 A 4 C FSR+ 7 A 7 C IG FSR– +B SVC1 E30(A), N1(B), O1(C) Airbag Sensor Assembly Center DSP+ 14 B DSP– E1 E2 BGND 5 A (∗3) 5 C (∗4) SGD2 SVC3 5 B 5 D SIG3 9 B 9 D SGD3 3 B 3 D SVC4 6 B 6 D SIG4 SGD4 4 B (∗3) 4 D (∗4) 10 B 10 D 2 A 2 B 3 A (∗3) 3 B (∗4) 1 A 1 B 2 A 2 B SVC3 SIG3 T15(A), d3(B) Occupant Classification Sensor (Rear LH) SGD3 SVC4 SIG4 BR B(∗3) 1 A 1 B R(∗4) V P(∗4) (∗3) W–B (∗4) 1 A (∗3) 1 B (∗4) 3 A (∗3) 3 B (∗4) SGD4 T17(A), d5(B) Occupant Classification Sensor (Rear RH) 10 EO2 N3 Front Seat Inner Belt (Driver' s Side) 3 O1 (∗3) O21 Junction Connector Buckle SW W–B Seat Position Airbag Sensor 2 A 2 B GR 4 EO2 Buckle SW W–B 5 A E49 Junction Connector SIG2 W 3 B O E3 (∗3) 2 OT1 LSP– Data Link Connector 3 < 9–2> W–B O20(A), T18(B) Junction Connector 4 LSP+ W–B W–B W–B 2 9 A 9 C (∗3) W–B 2 LBE– 10 IF 10 SVC2 B GR 3 LBE+ BSW 3 A 3 C 2 A 2 C (∗3) 1 3 IM GND DIA 13 B O(∗4) 1 IE DBE– 12 B W 5 IE DBE+ 11 B R E1 25 A SGD1 O4(C), T10(A), T11(B), d1(D) Occupant Classification ECU G E2 26 A SIG1 Y 23 A P–AB GR 17 A GR SIL B 16 A (∗3) CANL B 22 A CANH W–B 13 A R W Y 12 C 6 OT1 (∗3) 13 C L 21 A 4 OT1 (∗3) 4 IE W(∗3) 6 IE B(∗3) 12 IH B B 10 IH 1 OT1 SB(∗4) 1 IF 9 3L R Data Link Connector 3 < 9–2> PAON 13 W–B CAMRY (EM0250U) Multiplex Communication System (CAN)< 2–3> P–AB 2 W 1 AIRBAG ON/OFF Indicator 14 B O3(B), T7(A) Front Seat Inner Belt (Front Passenger' s Side) E3 M 489 T ire P re s s u re W a rn in g S y s te m 1 4 3 2 (BAT) (IG) 10A ECU IG NO. 1 (BAT) (IG) 7. 5A GAUGE NO. 2 10A DOME ∗ 1 : 2GR–FE ∗ 2 : 2AZ–FE 10A MPX–B 2 1 LG 10 3L 13 ID 12 IG 3 1A GR SB B 11 IF 2 EA1 12 3L 2 3G 1 3D 1 3Q 9 3Q 12 3Q B R V 7 IF 12 3N GND TC 9 3 SIL 10 SPD IND 2 5 13 A 2 A L V GR P TIRE 9 E2 ES 12 A 24 A 7 3Q 5 3Q 2 3U 10 3D GR (∗1) L E49 Junction Connector 7 A N34 Tire Pressure Warning Antenna and Receiver 17 A 2 W–B 18 B BR 15 EA1 (∗1) W–B 11 3Q L 3 3C W–B W–B 1 3N BR(∗1) 4 CA3 GR(∗2) (∗1) +5V BR RDA Power Supply Circuit W–B GND 2 B IG2 W–B 5 3 3O 1 A IG+ Tire Pressure 1 Combination Meter < 25–2> LG 4 1 3O Data Link Connector 3 < 9–3> G 1 Data Link Connector 3 < 9–3> 6 EN2 W–B LG 5 EN2 E53 Tire Pressure Warning SW (Reset) G 4 EN2 O BR B2 4 CA3 W–B 3 E2 F1 C6 C7 C57 Junction Connector 1 F1(A) Combination Meter CLSW GR 6 W–B RF5V A41(A), A42(B) Junction Connector RDA 12 (∗2) GND2 11 V R GR IG BR CAMRY (EM0250U) E60 Tire Pressure Warning ECU 7 M OVERALL ELECTRICAL WIRING DIAGRAM 490 16 CAMRY 17 CAMRY C lo c k 7. 5A ECU– ACC (IG) (BAT) 7. 5A GAUGE NO. 2 10A DOME 3 1A 12 IR P Y V 12 IG 2 IF 10A ECU IG NO. 1 B 1 (IG) 30A S/ROOF 10A MPX–B 2 2 (BAT) SB 10A DOME 4 3 2 (BAT) Main Body ECU < 2–33> 1 (ACC) (BAT) A u to m a tic G la re – R e s is ta n t E C M irro r S lid in g R o o f 10 EQ1 8 EQ1 6 EQ1 10 IR GR LG LG 1 13 ID 12 3L 2 3G 1 3D 1 3Q 9 3Q 12 3Q 13 ID L Y R 2 EA1 Y V Y P B V GR R R 1 A IG+ B2 4 B 11 3L IG +B(DOME) 1 2 3R ACC 6 E2 E 12 A 20 L BR W–B F1(A) Combination Meter 5 LG P ES 24 A GR E RSET (∗1) E 7 3Q 5 3Q 10 3D 18 B W–B 2 3U F4 Hazard Warning Signal SW A41(A), A42(B) Junction Connector 17 A W–B 4 DOWN 1 2 3 CLS OPN GND Sliding Roof Control SW 11 EQ1 W–B A/B 5 GR 2 UP (∗1) 1 W–B 2 W–B RSET Main Body ECU < 2–11> 7 W–B A/B 5 2 3U OPN 9 W–B BR ILL+ 4 V GND1 8 3R CLS 8 Buzzer 19 O UP F3 Clock W–B B DWN 10 DRIVE IC MICRO COMPUTER E 1 M G 2 IG W L 1 MULTI LCD 5 MPX1 Q13 Sliding Roof Control ECU and Motor Q6 Overhead J/B R Power Supply Circuit 4 B Master Warning 1 3R W–B CAMRY (EM0250U) 13 A 2 A 12 3L Y 7 IF Q3 Inner Rear View Mirror 7 IF 1 IR 4 CA3 F1 C6 C7 W–B 10 W–B 12 2 W–B C57 Junction Connector (∗2) 3 W–B F1 4 FE3 4 CA3 E49 Junction Connector GR(∗2) F1 W–B ∗ 1 : 2GR–FE ∗ 2 : 2AZ–FE W–B W–B BR 15 EA1 (∗1) 10 IF BR(∗1) E2 M 491 R e m o te C o n tro l M irro r M OVERALL ELECTRICAL WIRING DIAGRAM 492 18 CAMRY R e a r W in d o w D e fo g g e r a n d M irro r H e a te r 1 4 3 2 (IG) (ACC) (BAT) 10A A/C NO. 2 7. 5A ECU–ACC 50A RR DEF 12 ID 1 Y L 2 IF V W G Y 2 10 IE2 10 HE2 1 A 3 1 V 5 EA1 1 2 MH M+ 9 M E2 H2 Outer Rear View Mirror (RH) Y Mirror Heater W–B 5 W–B 2 W–B H2 Outer Rear View Mirror (RH) 17 HE2 13 E49 Junction Connector 2 I3 Outer Rear View Mirror (LH) 17 IE2 P1 E2 E49 Junction Connector W–B A1 W–B 5 MV 4 W–B 2 M+ 4 W–B 5 MV W–B 1 MH M A/C Amplifier < 27–6> B V BR B W 1 B I3 Outer Rear View Mirror (LH) B 21 HE2 Mirror Heater V 20 HE2 W–B BR 22 HE2 3 W–B B 21 IE2 G W 22 IE2 W–B LG 20 IE2 N19(A), P1(B) Rear Window Defogger 3 3C 6 3M M 12 IJ 12 3D 1 3I M 1 IK Y 3 3I 13 IO Y 2 3I 10A MIR HTR 2 IB N18 Noise Filter (Rear Window Defogger) 7 1 W E 6 1 B M+ 1 3G B 3 (2GR–FE) Operation SW Right/ Down Select SW MRV 3 2 W–B 1 G V W 4 W–B MLV B MRH 2 4 1 Right BR Left Left/ Up Down Up Right Left 5 LG CAMRY (EM0250U) MLH Right 5 RR DEF Relay 14 B B Left (2AZ–FE) V L 22 A 8 1 A41(A), A42(B) Junction Connector 11 3I E3 Outer Mirror SW 1 (2GR–FE) 11 3L A3 19 CAMRY W ip e r a n d W a s h e r (IG) (IG) 5 A B 2 12 IC 19 IM R B 1 M 5 A37 Windshield Washer Motor IG RH Side Seat SW LG(∗1) A58(A), E40(B) Junction Connector LG(∗2) GR HI LO INT OFF 2 B 20A S–HTR W–B +S 1 B W +1 3 B +2 4 B +B 2 B G E55 Seat Heater SW INT1 EW 2 A +S RH +1 +S T6 Seat Heater (RH) B P P W–B 2 M W–B 5 A A2 A3 E2 O1 E3 2 W–B 1 B O20(A), T18(B) Junction Connector W–B W–B 5 A W–B 10 EO2 W–B A59(B), B1(A) Windshield Wiper Motor 1 B 9 EO1 W–B W–B E 4 A (∗1) 4 B (∗2) W–B 2 (∗1) W–B 10 EN2 W–B (∗1) W–B W–B 4 AB1 N27(A), U11(B) Junction Connector P O20(A), T18(B) Junction Connector W–B 7 Seat Back +2 Seat Cushion 1 A (∗1) 1 B (∗2) 1 N27(A), U11(B) Junction Connector U6 Seat Heater (LH) B(∗1) 2 A 2 B 1 E49 Junction Connector LG(∗1) 5 A 5 B 6 B L L BR(∗1) 3 A 3 B 8 A 6 B Seat Cushion 1 AB1 Seat Back 2 AB1 B(∗2) W 5 AB1 LG(∗2) B(∗1) 8 A P(∗1) W 17 AE2 P(∗2) P(∗1) On 3 AB1 EW Off 11 A 20 EN2 25 AE2 LG(∗1) Front Washer SW BR(∗2) 8 B BR(∗1) L LH 6 20 EO2 P P E 4 L 3 A58(A), E40(B) Junction Connector +1 +2 +B CAMRY (EM0250U) INT2 B1 MIST Front Wiper SW 2 IC II L 2 WF 3 A (IG) 10A WASH 25A WIP Wiper Relay 4 3 2 LH Side Seat SW 1 E19(A), E20(B) Windshield Wiper SW Assembly ∗ 1 : TMC Made ∗ 2 : TMMK Made S e a t H e a te r E2 M 493 W–B(∗2) 10 EO2 10 EN2 W–B 2 B E2 3 B 4 B N27(A), U11(B) Junction Connector M 2 M 1 1 2 M 1 B Reclining 2 RCLR 1 M 2 LUP 7 Lifter 8 LDWN 1 M 2 SLDF 9 Slide 6 SLDR RCLF 1 M 2 Rear 6 A Front LG Rear G U7 Power Seat SW (Driver' s Seat) Front G 3 3 Reclining 2 M W–B 3 Down 8 B BR FDWN RCLF Up N27(A), U11(B) Junction Connector T3 Power Seat Motor (Front Passenger' s Seat Reclining Control) 5 Rear 6 A P Front Vertical Front G Y 10 V FUP W SLDR BR 6 P Slide Down LG LG 2 T1 Power Seat Motor (Front Passenger' s Seat Slide Control) L 9 U4 Power Seat Motor (Driver' s Seat Lifter Control) SLDF 4 U3 Power Seat Motor (Driver' s Seat Reclining Control) 1 E B 2 Up 1 U2 Power Seat Motor (Driver' s Seat Front Vertical Control) R1 1 Rear Front 3 G R Y H U1 Power Seat Motor (Driver' s Seat Slide Control) 4 L E W–B Rear 9 B W–B LG 4 IO W Front U8 Power Seat SW (Driver' s Seat Lumbar Support Control) 1 W–B 2 U5 Power Seat Motor (Driver' s Seat Lumbar Support Control) Y 5 W–B W–B W–B P o w e r S e a t (D riv e r' s S e a t) P o w e r S e a t (F ro n t P a s s e n g e r' s S e a t) (BAT) 4 30A P/SEAT 2 11 IL G 1 EO2 O20(A), T18(B) Junction Connector 8 B T8 Power Seat SW (Front Passenger' s Seat) B B RCLR 4 E 2 5 A 5 A E3 M OVERALL ELECTRICAL WIRING DIAGRAM W–B CAMRY (EM0250U) W–B 494 20 CAMRY 1 4 B O20(A), T18(B) Junction Connector 21 CAMRY P o w e r O u tle t H o rn 1 S h ift L o c k 4 3 2 (IG) (ACC) (ACC) 7. 5A ECU IG NO. 2 20A PWR OUTLET 7. 5A ECU–ACC L (∗2) O R 2 IF W 16 IM R 19 IF 12 IO 5 3L 11 3L 5 3K 11 3K 11 A ACC E32(B), E57(A) Shift Lock Control ECU 6 1B E KLS+ 3 A (∗1) 1 B 5 B (∗2) Y 2 B Stop Lamp SW < 10–3> W SLS– E24 Key Interlock Solenoid W–B W–B (∗2) 2 W 8 E49 Junction Connector 4 E2 SLS+ STP 1 II W 5 P P2 6 A (∗1) 4 B (∗2) Shift Lock Solenoid W–B 11 ID G L 6 B (∗2) E 12 A 8 B IG 10 1D B E 2 B Main Body ECU < 2–11> B E29 Power Outlet Socket (Front) 1 E35 Power Outlet Socket (Rear) 1 (∗2) R R 10A HORN W–B CAMRY (EM0250U) HORN Relay O 11 EN2 (∗1) Main Body ECU < 2–11> 1 1G 2 8 A HO FL MAIN 3. 0W 1 3K GR 1 B A4 Horn (Low) 1 A3 Horn (High) ∗ 1 : w/ Smart Key System ∗ 2 : w/o Smart Key System 3 3C W–B L 1 Horn SW W–B 2 3K E18(A), a1(B) Spiral Cable 9 Battery E49 Junction Connector E2 W–B 2 a1(B) Steering Pad SW E2 M 495 N a v ig a tio n S y s te m a n d A u d io S y s te m (8 S p e a k e r) 1 (BAT) (BAT) 7. 5A RADIO NO. 2 25A AMP 4 3 2 (ACC) F9(D), F10(E), F12(G), F13(H), F14(I) Navigation Receiver Assembly R– L+ L– 5 D 13 E 12 E 11 E 7 D 10 D 8 D 18 D 9 D 19 D R O G B W ATX– ATX+ SLD1 IVO– IVO+ MUTE SLD SPD 3 H V R+ 15 D G GR 17 EA1 L–Y L 6 3L 11 D 6 3T 6 B 5 B 4 B 3 B 2 B R+ R– L+ L– Combination Meter < 25–2> V L–Y GR GR GR 12 B 7 B ACC TX– 8 B 22 B TX+ 23 B INT– 1 B INT+ MUTE SLD 11 B SPD F18(A), F19(B), F20(C) Stereo Component Amplifier WFL+ RL– RL+ F21 Tweeter (Front LH) SR– SR+ RR– RR+ WFR– WFR+ 10 A 3 C 9 C BR G–W Y L W 9 OF1 18 OF1 2 OF1 11 OF1 1 OF1 10 OF1 8 OF1 BR G–W Y L W R L 2 1 I1 Speaker (Front Door LH) 1 – O14 Speaker (Rear LH) 4 + 2 WF1– 4 WF1+ 2 WF2– O15 Speaker (Rear RH) 3 WF2+ LG B 9 HE1 9 IE1 B 5 HE1 Y 17 OF1 5 IE1 Y 7 FE3 P 2 FE3 P LG 4 A LG 5 C L 12 C 6 FE3 3 1 SL+ 4 C 1 FE3 F25 Junction Connector 2 SL– 10 C L 3 A R 9 A P 2 C V 1 WFL– 1 C V GR 2 FL+ 8 A V GR 7 FL– 7 A P +B2 5 A V +B 1 A GR CAMRY (EM0250U) 9 FE3 R 6 3U 5 FE3 (Shielded) GR L–Y 8 EA1 ACC 1 D (Shielded) B 1 GR 12 IF BR 1 R 2 G 2 15A RADIO NO. 1 1 – + 2 1 H1 Speaker (Front Door RH) M OVERALL ELECTRICAL WIRING DIAGRAM 496 (Cont. next page) 22 CAMRY 22 CAMRY (Cont' d) N a v ig a tio n S y s te m a n d A u d io S y s te m (8 S p e a k e r) 5 8 7 6 ∗ 1 : TMC Made ∗ 2 : TMMK Made F9(D), F10(E), F12(G), F13(H), F14(I) Navigation Receiver Assembly 1 3A 8 3A (Shielded) LG Y P 6 A 2 A E 7 C 4 6 A AUXO 4 A AU1 10 B 9 B 12 EQ1 MODE Seek– On Hook 6 C Voice LG Seek+ GND (Shielded) F17 Stereo Jack Adapter 1 A 1 B ACC 2 EQ1 1 EQ1 3 A 3 B 5 A (∗1) 5 B (∗2) MI1+ MIC– Off Hook BR BR Volume+ 3 EQ1 10 FE2 AU2 EAU 8 B E18(A), a1(B) Spiral Cable 5 A 9 FE2 G 3 ASGN Steering SW RH FR+ ARO Steering SW LH F18(A), F19(B), F20(C) Stereo Component Amplifier FR– 2 ALO B F15 Antenna Amplifier 1 W B 8 FE2 R O BR R 7 FE2 BR 10 3A 1 Park/Neutral Position SW < 10–1> CAMRY (EM0250U) 7 3D GND 20 D BR 8 3T MIC– 9 G W–B 1 3T 19 G R 12 3T G G R (Shielded) O 8 3U MIC+ 17 G W–B MACC SW2 8 E R SWG 6 E LG R SW1 7 E G ADPG 6 I BR P VA– 5 I (Shielded) VAR+ 2 I G VAL+ 3 I G REV 5 H Y SGND 18 G P TSW– 12 G O ANT 13 D Q5(A), Q12(B) Microphone (Navigation) L LG Volume– a1(B) Steering Pad SW 2 1 F23 Tweeter (Front RH) F3 F2 M 497 A u d io S y s te m (8 S p e a k e r w /o N a v ig a tio n S y s te m ) 1 (BAT) (BAT) 7. 5A RADIO NO. 2 25A AMP 4 3 2 (ACC) F8(C), F11(F), F26(D) Radio Receiver Assembly SLD IVO– ANT IVO+ 13 C 12 C 11 C 13 D O 19 D R 9 D G SLD (Shielded) MUTE GR L–Y L–Y GR GR ATX+ Combination Meter < 25–2> 9 18 D W F25 Junction Connector 8 D B 5 L– 10 D G 11 L+ 7 D R 10 R– 5 D (Shielded) 13 9 FE3 1 V B F15 Antenna Amplifier 12 B 7 B ACC 8 B TX– 1 B TX+ 6 B MUTE SLD 5 B 4 B 3 B 2 B R+ R– L+ L– 11 B 22 B SPD 23 B INT– INT+ F18(A), F19(B), F20(C) Stereo Component Amplifier WFL+ RL– RL+ F21 Tweeter (Front LH) SR– SR+ RR– RR+ WFR– WFR+ 10 A 3 C 9 C BR G–W Y L W 9 OF1 18 OF1 2 OF1 11 OF1 1 OF1 10 OF1 8 OF1 BR G–W Y L W R L 2 1 I1 Speaker (Front Door LH) 1 – O14 Speaker (Rear LH) 4 + 2 WF1– 4 WF1+ 2 WF2– O15 Speaker (Rear RH) 3 WF2+ LG B 9 HE1 9 IE1 B 5 HE1 Y 17 OF1 5 IE1 Y 7 FE3 P 2 FE3 P LG 4 A LG 5 C L 12 C 6 FE3 3 1 SL+ 4 C 1 FE3 F25 Junction Connector 2 SL– 10 C L 3 A R 9 A P 2 C V 1 WFL– 1 C V GR 2 FL+ 8 A V GR 7 FL– 7 A P +B2 5 A V +B 1 A GR CAMRY (EM0250U) 12 R+ 15 D O ATX– 6 3T 5 FE3 GR ACC 16 F R GR 6 3U ACC 11 D GR 17 EA1 B 1 D GR 6 3L +B 5 F L–Y 8 EA1 L–Y L 1 GR 12 IF BR 1 G 2 L 2 15A RADIO NO. 1 1 – + 2 1 H1 Speaker (Front Door RH) M OVERALL ELECTRICAL WIRING DIAGRAM 498 (Cont. next page) 23 CAMRY 23 CAMRY (Cont' d) A u d io S y s te m (8 S p e a k e r w /o N a v ig a tio n S y s te m ) 5 8 7 6 ∗ 1 : TMC Made ∗ 2 : TMMK Made F8(C), F11(F), F26(D) Radio Receiver Assembly AU2 9 B 12 EQ1 MODE Seek– On Hook 6 C Voice (Shielded) Seek+ GND 1 A 1 B ACC 1 EQ1 3 A 3 B 5 A (∗1) 5 B (∗2) MI1+ MIC– Off Hook BR BR Volume+ BR 7 C 2 EQ1 BR E 3 EQ1 10 FE2 R FR+ B W F18(A), F19(B), F20(C) Stereo Component Amplifier 2 A 8 B E18(A), a1(B) Spiral Cable 5 A EAU LG 10 B F17 Stereo Jack Adapter 6 A (Shielded) LG 4 A AU1 Steering SW RH 6 A FR– Y 4 AUXO 9 FE2 G 3 ASGN Steering SW LH ARO P 2 ALO O BR CAMRY (EM0250U) 1 8 FE2 BR (Shielded) LG G R (Shielded) 7 FE2 BR 8 3A GND 20 D W–B 1 3A GND 14 F W–B 10 3A MIC– 1 F R 8 3T 2 F R 1 3T MIC+ 7 F G 12 3T MCVD 8 C BR 6 C G SW2 Y SWG 7 C G SW1 AUXI 19 C P ASGN 16 C O ARI 15 C G ALI 17 C Q5(A), Q12(B) Microphone (Navigation) L LG Volume– a1(B) Steering Pad SW 2 1 F23 Tweeter (Front RH) F3 F2 F2 M 499 A u d io S y s te m (6 S p e a k e r) 1 4 3 2 (BAT) (ACC) 15A RADIO NO. 1 7. 5A RADIO NO. 2 F17 Stereo Jack Adapter 2 L AUXO 4 ALO 2 1 ASGN F15 Antenna Amplifier 3 BR 6 3L 8 A 3 C BR 3 A B V 4 A O 17 C GR L–Y 15 C 1 19 C ACC AUXI ARI 16 C ALI ASGN ANT SPD F6(A), F7(B), F8(C) Radio Receiver Assembly 8 OF1 17 OF1 P Y 8 3T 10 3A 1 3A 8 3A P 6 A 6 FE3 2 FE3 4 A AU2 L LG 5 HE1 9 HE1 B W 8 B 9 B Seek+ MODE 1 I1 Speaker (Front Door LH) Seek– On Hook Volume+ Off Hook LG L P V 2 2 1 O12 Speaker (Rear LH) 2 1 O13 Speaker (Rear RH) 2 1 H1 Speaker (Front Door RH) Volume– F2 a1(B) Steering Pad SW Voice Steering SW RH R W B P Y V 9 IE1 E18(A), a1(B) Spiral Cable 5 A EAU 7 FE3 10 B 5 IE1 Y O 1 3T O 12 3T AU1 1 FE3 SW2 8 C G 18 OF1 SWG 6 C Steering SW LH 9 OF1 + 1 LG – F24 Tweeter (Front RH) TWR+ 3 SW1 7 C R TWR– L P + 1 V – W 2 B 4 Y 2 3 1 B FR+ 1 A TWL+ 3 B FR– LG RR+ 5 A TWL– 2 B RR– L RL+ 6 B F22 Tweeter (Front LH) 4 RL– P FL+ 2 A V FL– 6 A BR GND 7 A BR CAMRY (EM0250U) R 6 3T 9 FE3 B O G (Shielded) L–Y 17 EA1 ARO Combination Meter < 25–2> 12 IF GR 1 M OVERALL ELECTRICAL WIRING DIAGRAM 500 24 CAMRY CAMRY (EM0250U) Memo 501 F1 2 3 +B(DOME) IG2+ 16 B FE 14 EN2 15 EN2 24 A 6 3P 2 3P 5 3Q 7 3O 10 3N 10 3D BR 13 A IG+ ES 15 EA1 1 A Buzzer B LCD A/T Range 17 A 18 B BR(∗1) 4 CA3 GR(∗2) 4 CA3 3 C6 C7 Multiplex Communication System (CAN)< 2–3> < 2–4> B2 Temp. 1 3D 2 EA1 6 3Q 3 1A 6 3A V 9 A P/SB GR 17 A CANH 18 A (∗1) 3 A EAC 9 A 7 B 2 B V 22 A DISP MULTI LCD LCD (ODO/Trip) (Outside Temp. ) +B(DOME) IG2 Rheostat Tail Cancel SW ODO/Trip SW Power Supply Circuit MICRO COMPUTER CAN I/F CANL E18(A), a1(B) Spiral Cable V Radio Receiver Assembly< 24–4> Tire Pressure Warning ECU< 16–2> Main Body ECU< 2–11> Stereo Component Amplifier < 22–4> < 23–4> Navigation Receiver Assembly< 22–4> +DP 1 2 3 4 5 Air Conditioning System < 27–7> GR Y L (∗1) 10A MPX–B DISP Steering SW RH V Engine Control Module< 7–19> Transmission Control ECU < 7–24> Engine Control Module< 8–11> 3 a1(B) Steering Pad SW V 1 C57 Junction Connector 2 A 12 3Q Fuel IG2 9 3Q GR 9 3T SB L (∗1) 12 IG (∗1) FR GR (∗5) V V (∗3) V V V (∗1) 2 Tachometer 12 B 7. 5A GAUGE NO. 2 (∗1) 15 B 1 3Q Speedometer 7 IF 2 3G W–B SI (IG) A41(A), A42(B) Junction Connector 14 B 12 3L V 3 3P 10A DOME (∗2) 13 ID GR R R LG V (∗4) V G (∗1) 14 AE5 Multiplex Communication System (CAN) < 2–14> F1(A), F2(B) Combination Meter BR E2 P IG2 P +B(DOME) IG2 P +S 9 3U 10 3M 10 3O GR ILL– 10 3U GR 11 A 10 3B (BAT) W–B 2 3U 2 Gage 7 3Q L GR +B(DOME) IG2 (∗2) N10 Fuel Suction Pump and Gage Assembly V L C o m b in a tio n M e te r ∗ ∗ ∗ ∗ ∗ (Cont. next page) : 2GR–FE : 2AZ–FE : w/ Smart Key System : 8 Speaker : 6 Speaker (BAT) 4 M OVERALL ELECTRICAL WIRING DIAGRAM 12 A (∗2) 1 ABS (w/ VSC), TRAC and VSC System< 12–4> < 13–4> ABS (w/o VSC) System< 14–3> +B (DOME) 5 A LCD Illumination B 6 A A41(A) Junction Connector Multiplex Communication System (CAN) < 2–15> Turn Signal and Hazard Warning Light System < 11–3> 7 A Pointer Illumination 1 B Illumination B W–B Turn RH 2 B W–B CAMRY (EM0250U) Turn LH 502 25 CAMRY 3 AE2 1 S 1 LG A5 6 3E 3 AE6 O 8 A S 8 3P 10 FE3 4 EA1 1 23 A CHG– 2 6 CA3 4 B Tire Pressure Warning System < 16–3> O B/LE Engine Control System < 7–25> < 8–18> LG 6 B Charging System < 4–4> Y LG WLVL LG 3 3Q A16 Brake Fluid Level Warning SW LG 5 A LG E W–B 2 CHK DRIVE IC 7 Beam Tail (Except USA) Head (USA) DOOR Front Fog IG2 Master Warning Cruise Slip 6 ABS IG2 VSC Driver' s Seat Belt Tire Pressure Malfunction Indicator Lamp Charge Oil Pressure Brake(Except USA) BRAKE(USA) SRS MAINT REQD Low Fuel S, 4, 3, 2, L D N R P Washer Level 5 C23 Engine Oil Pressure SW B 11 3J A52 Washer Level Warning SW LG CAMRY (EM0250U) LG 25 CAMRY (Cont' d) C o m b in a tio n M e te r 8 F1(A), F2(B) Combination Meter +B(DOME) DRIVE IC 7 A TIRE LG A3 M 503 C o o lin g F a n (2 G R – F E ) (BAT) (IG) 10A ECU IG NO. 1 1 40A CDS FAN 6 IC 1 W 1 LG LG 1 LG W W LG W (BAT) 10A ECU IG NO. 1 40A RDI FAN 6 IC LG 1 (IG) LG 50A FAN MAIN 4 3 2 (BAT) G 1 R a d ia to r F a n a n d C o n d e n s e r F a n (2 A Z – F E ) G CAMRY (EM0250U) W–B 3 1 1 1 1 1 1 1 FAN MAIN Relay 1 2 4 2 5 1 3 3 2 W–B 5 B 5 FAN NO. 3 Relay 1 1 1 FAN NO. 2 Relay 2 FAN NO. 1 Relay 3 5 1 1 1 1 1 1 1 1 A56(A), A57(B) Short Connector Engine Control Module< 7–19> W–B W–B G W–B A1 B 1 M 2 A6 A/C Condenser Fan Motor 1 A A1 R Engine Control Module< 8–9> Engine Control Module< 8–9> M A7 Radiator Fan Motor 2 W–B 1 W–B E1 2 1 B W B +B1 G S1 M– (S) W–B M+ (S) A54 Cooling Fan ECU M– (M) L L Sub Fan Motor 3 M+ (M) B M Main Fan Motor L M W L W M OVERALL ELECTRICAL WIRING DIAGRAM 504 26 CAMRY CAMRY (EM0250U) Memo 505 ∗ 1 : 2GR–FE ∗ 2 : Automatic A/C A ir C o n d itio n in g 1 4 3 2 (BAT) V W–B A27 A/C Pressure Sensor E12 Ion Generator A2 Ambient Temp. Sensor 2 16 IF 20 AE6 18 AE6 TAM GR R 11 4L 5 3M V GR 1 A S5–3 PRE 39 A 21 A PCD1 IG+ B 12 3M 8 4L 2 3M 7 4A 10 3E 6 4C 3 3C BR W BUS G 2 B Connector Housing Color (Black) B Damper Servo Motor (Air Inlet) SOL– W–B SOL+ (∗1) 1 A A1 A3 M 2 W–B 2 A 18 AE5 BR W 12 CA3 W–B SSR+ 11 CA3 Flow Control Valve SSR– 9 B (∗1) P L G (∗1) 1 B Lock Sensor Magnetic Clutch 8 CA3 2 B MG+ C21(A), C53(B) A/C Compressor (∗1) G 3 B 3 CA3 (∗1) (∗1) R 1 CA3 BUS 3 B E49 Junction Connector 10 AE2 L (∗1) B BUS 4 B W–B LG 12 EA1 (∗1) 1 R LG 7 4L G G G (∗1) 8 3J GND 14 A W 3 BLW 23 A W 2 MGC Relay 5 MGC 20 A (∗1) 7 3H 1 (∗1) 1 SOL+ 2 A W–B 8 A (∗1) (∗2) 12 4D R 2 3C 9 A (∗1) SI B (∗2) 1 3M 10 A (∗1) G 2 3H 13 A SG–2 2 R 10 4L E38(A), e1(B) A/C Amplifier 1 W–B 12 4L (∗2) 11 3M V 4 3M V V 8 3M 1 3S (∗2) 5 A LOCK E3 8 IM 1 3L V BR 11 3D V L 2 3E BR P 10 B 9 3K +B 1 PCL 4 V L 7 A 7 3M 3 GND IG 2 L V (∗1) V (∗1) W 2 L A58(A), E40(B) Junction Connector G (∗1) O 8 A P 9 A 7 3J 12 B W–B CAMRY (EM0250U) 22 A 3 7. 5A A/C 5 GND PR 1 A41(A), A42(B) Junction Connector 1 AE3 E39 Blower Motor 1 13 AE2 G V (∗1) G V + R 12 ID – V 1 (BAT) (∗2) 10A A/C NO. 2 50A HTR 1 W–B(∗2) (IG) E2 e1(B) A/C Blower Assembly A B M OVERALL ELECTRICAL WIRING DIAGRAM 506 (Cont. next page) 27 CAMRY 27 CAMRY (Cont' d) ∗ 2 : Automatic A/C ∗ 3 : Manual A/C A ir C o n d itio n in g A 8 7 6 V V B 5 W–B(∗2) TSL 33 A TSP 38 A TSD RDFG 11 A CANH CANL 3 3A 9 3A 2 3U 3 4D W–B LIN1 R 10 A 9 A AC1 E38(A), e1(B) A/C Amplifier EAC 3 B TEA 2 B SGA 6 B (∗2) 3 3M 5 B (∗2) 1 4L 37 A 12 A W–B W–B 2 3S (∗2) 12 3S W–B R (∗2) (∗2) B G O (∗2) Y 32 A 3 3S E18(A), a1(B) Spiral Cable SG–1 (∗2) LG 34 A 4 3S GR TR (∗2) P (∗2) M M OFF Connector Housing Color (Green) Steering SW RH (∗2) Connector Housing Color (Blue) A/C Evaporator Temp. Sensor Connector Housing Color (Red) (∗2) AUTO (∗2) CAMRY (EM0250U) 29 A 3 B 3 4L GND 8 (∗2) 2 4L SG 9 P 3 4M ADI1 GR 2 4M 1 TX+ 4 L RR DEF Relay < 18–3> O (∗2) Y (∗2) 2 A Multiplex Communication System (CAN)< 2–1> TSR E11(A) Automatic Light Control Sensor IG+ A/C Solar Sensor E27 A/C Room Temp. Sensor 2 F16 A/C Control Assembly 5 1 A TEMP+ M TEMP– Damper Servo Motor (Air Mix Front Passenger Side) (∗2) (Air Mix) (∗3) (∗2) Damper Servo Motor (Air Mix Driver Side) W–B a1(B) Steering Pad SW Damper Servo Motor (Air Vent Mode) E49 Junction Connector e1(B) A/C Blower Assembly 1 F1 (∗2) W–B W–B 2 E2 M 507 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–1 SFI SYSTEM PRECAUTION NOTICE: • Perform the RESET MEMORY (AT) initialization operation after replacing the automatic transmission assembly, engine assembly or ECM (See page AX-25). • Perform REGISTRATION (VIN registration) when replacing the ECM (See page ES-20). ES ES–2 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DEFINITION OF TERMS Terms ES Definition Monitor Description Description of what ECM monitors and how to detect malfunctions (monitoring purpose and its details). Related DTCs A group of diagnostic trouble codes that are output by ECM based on the same malfunction detection logic. Typical Enabling Condition Preconditions that allow ECM to detect malfunctions. With all preconditions satisfied, ECM sets DTC when monitored value(s) exceeds malfunction threshold(s). Sequence of Operation Order of monitor priority, applied if multiple sensors and components are involved in single malfunction detection process. Each sensor and component monitored in turn and not monitored until previous detection operation is completed. Required Sensor/Components Sensors and components used by ECM to detect each malfunction. Frequency of Operation Number of times ECM checks for each malfunction during each driving cycle. "Once per driving cycle" means that ECM checks for malfunctions only once in single driving cycle. "Continuous" means that ECM checks for malfunctions whenever enabling conditions are met. Duration Minimum time for which ECM must detect continuous deviation in monitored value(s) in order to set DTC. Timing begins when Typical Enabling Conditions are met. Malfunction Thresholds Value, beyond which, ECM determines malfunctions exist and sets DTCs. MIL Operation Timing of MIL illumination after a malfunction is detected. "Immediate" means that ECM illuminates MIL as soon as a malfunction is detected. "2 driving cycle" means that ECM illuminates MIL if the same malfunction is detected twice during next sequential driving cycle. ES–3 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PARTS LOCATION ECM MASS AIR FLOW METER ENGINE ROOM R/B - EFI RELAY ES - A/F RELAY - C/OPN RELAY - ST RELAY PURGE VSV - ST CUT RELAY - IG2 RELAY CANISTER HEATED OXYGEN SENSOR (BANK 1 SENSOR 2) FUEL PUMP ACTIVE MOUNT CONTROL VSV HEATED OXYGEN SENSOR (BANK 2 SENSOR 2) A134870E01 ES–4 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM COMBINATION METER ES DLC3 INSTRUMENT PANEL J/B - IGN FUSE - STOP FUSE ACCELERATOR PEDAL STOP LIGHT SWITCH A139510E01 ES–5 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM VVT SENSOR FOR INTAKE CAMSHAFT (BANK 2) VVT SENSOR (BANK 1 INTAKE SIDE) CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (BANK 1 INTAKE SIDE) CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (BANK 2 INTAKE SIDE) IGNITION COIL WITH IGNITER ENGINE COOLANT TEMPERATURE SENSOR FUEL INJECTOR ES AIR FUEL RATIO SENSOR (BANK 2 SENSOR 1) VVT SENSOR FOR EXHAUST CAMSHAFT (BANK 2) CRANKSHAFT POSITION SENSOR VVT SENSOR FOR EXHAUST CAMSHAFT (BANK 1) AIR FUEL RATIO SENSOR (BANK 1 SENSOR 1) CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (BANK 2 EXHAUST SIDE) A114586E05 ES–6 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM THROTTLE BODY (THROTTLE POSITION SENSOR) ES ACIS ACTUATOR KNOCK SENSOR (BANK 1) KNOCK SENSOR (BANK 2) A114543E04 ES–7 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM SYSTEM DIAGRAM 1. Without Smart Key System: IG2 GAUGE No. 2 IG2 IGN ST/AM2 IG SW AM2 ECM IG2 NSW ST2 AM1 ES IGSW PNP SW IG1 Combination Meter ST1 STA W AM1 SPD ST MIL VVT OCV (Intake Side RH) OC1+ C/OPN ALT OC1VVT OCV (Intake Side LH) Fuel Pump FC OC2+ OC2ETCS VVT OCV (Exhaust Side RH) +BM EFI No. 1 BATT OE1+ OE1- EFI VVT OCV (Exhaust Side LH) EFI MAIN OE2+ FL MAIN MREL OE2E02 E05 Battery Starter A E1 A137635E02 ES–8 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ECM A APP Sensor EFI No. 3 VCP2 EFI No. 2 +B +B2 AICV EPA2 VCPA VPA EPA VSV for ACIS ES VPA2 PRG CAN+ VSV for EVAP System ACIS Transmission Control ECU CAN- VSV for ACIS ACM IMO IMI VSV for Active Control Mount System Stop Light SW THA MAF Meter E2G VG ETHA STOP STP ST1- HO2 Sensor (Bank 1 Sensor 2) Transponder Key ECU IGN HT1B EX1B Power Steering Oil Pressure SW OX1B PSW HO2 Sensor (Bank 2 Sensor 2) HT2B E04 EX2B E01 OX2B E03 ME01 B A137631E02 ES–9 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM B Canister Pump Module ECM VPMP KNK1 EPPM EKNK Knock Sensor (Bank 1) PPMP VCPP MPMP KNK2 ES EKN2 Knock Sensor (Bank 2) VVT Sensor (Bank 1 Intake Side) VV1+ VV1- #10 No. 1 Fuel Injector VCV1 #20 VVT Sensor (Bank 2 Intake Side) VV2+ No. 2 Fuel Injector VV2VCV2 #30 No. 3 Fuel Injector VVT Sensor (Bank 1 Exhaust Side) EV1+ EV1- #40 No. 4 Fuel Injector VCE1 #50 VVT Sensor (Bank 2 Exhaust Side) EV2+ No. 5 Fuel Injector EV2VCE2 #60 No. 6 Fuel Injector To Main Body ECU CANH CANL To IG2 Relay A137632E02 ES–10 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Crankshaft Position Sensor ECM VTA1 VCTA Throttle Body Assembly NE+ NE- VTA2 ETA M+ M- DLC3 TC GE01 ES Ignition Coil (No. 1) ECT Sensor THW IGT1 IGF1 ETHW Ignition Coil (No. 2) IGT2 A/F Sensor (Bank 1 Sensor 1) Ignition Coil (No. 3) HA1A A1A+ IGT3 Ignition Coil (No. 4) A1AIGT4 A/F Sensor (Bank 2 Sensor 1) HA2A A2A+ Ignition Coil (No. 5) IGT5 A2AA/F A/F Ignition Coil (No. 6) IGT6 To Battery To IG2 Relay To EFI Relay Noise Filter (RH Side) Noise Filter (LH Side) A137633E02 ES–11 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM GAUGE No. 1 Transmission Control SW ECM To IG1 Relay S Park / Neutral Position SW ECU IG No. 2 SFTD P To IG1 Relay SFTU R Spiral Cable Cruise Control SW N D ES Transmission Control ECU CCS A137634E02 ES–12 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2. With Smart Key System: Main Body ECU GAUGE No. 2 ECM To ECU-ACC Fuse ACC STSW STSW ACCR ACCR IG2 Combinatiion Meter To IG2 Fuse IG2D W ES SPD ST CUT MIL IGN STR VVT OCV (Intake Side RH) STAR OC1+ STR2 OC1- ETCS +BM ST VVT OCV (Intake Side LH) ST/AM2 PNP SW NSW OC2+ OC2- STA IGSW C/OPN To IGN Fuse VVT OCV (Exhaust Side RH) OE1+ FC Fuel Pump OE1VVT OCV (Exhaust Side LH) EFI No. 1 EFI MAIN FL MAIN BATT OE2+ OE2- EFI MREL E02 E05 E1 Battery Starter A A137630E02 ES–13 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ECM A APP Sensor EFI No. 3 VCP2 EFI No. 2 +B +B2 AICV VPA2 EPA2 VCPA VPA EPA VSV for ACIS PRG CAN+ VSV for EVAP System ACIS ES Transmission Control ECU CAN- VSV for ACIS ACM IMO IMI VSV for Active Control Mount System Stop Light SW THA MAF Meter E2G VG ETHA STOP STP ST1- HO2 Sensor (Bank 1 Sensor 2) Transponder Key ECU IGN HT1B EX1B Power Steering Oil Pressure SW OX1B PSW HO2 Sensor (Bank 2 Sensor 2) HT2B E04 EX2B E01 OX2B E03 ME01 B A137631E02 ES–14 B 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Canister Pump Module ECM VPMP KNK1 EPPM EKNK Knock Sensor (Bank 1) PPMP VCPP MPMP ES KNK2 EKN2 Knock Sensor (Bank 2) VVT Sensor (Bank 1 Intake Side) VV1+ VV1- #10 No. 1 Fuel Injector VCV1 #20 VVT Sensor (Bank 2 Intake Side) VV2+ No. 2 Fuel Injector VV2VCV2 #30 No. 3 Fuel Injector VVT Sensor (Bank 1 Exhaust Side) EV1+ EV1- #40 No. 4 Fuel Injector VCE1 #50 VVT Sensor (Bank 2 Exhaust Side) EV2+ No. 5 Fuel Injector EV2VCE2 #60 No. 6 Fuel Injector To Main Body ECU CANH CANL To IG2 Relay A137632E02 ES–15 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Crankshaft Position Sensor ECM VTA1 VCTA Throttle Body Assembly NE+ NE- VTA2 ETA M+ M- DLC3 TC GE01 Ignition Coil (No. 1) ECT Sensor THW ES IGT1 IGF1 ETHW Ignition Coil (No. 2) IGT2 A/F Sensor (Bank 1 Sensor 1) Ignition Coil (No. 3) HA1A A1A+ IGT3 Ignition Coil (No. 4) A1AIGT4 A/F Sensor (Bank 2 Sensor 1) HA2A A2A+ Ignition Coil (No. 5) IGT5 A2AA/F A/F Ignition Coil (No. 6) IGT6 To Battery To IG2 Relay To EFI Relay Noise Filter (RH Side) Noise Filter (LH Side) A137633E02 ES–16 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM GAUGE No. 1 Transmission Control SW ECM To IG1 Relay S Park / Neutral Position SW ECU IG No. 2 SFTD P To IG1 Relay SFTU R Spiral Cable Cruise Control SW N D ES Transmission Control ECU CCS A137634E02 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–17 HOW TO PROCEED WITH TROUBLESHOOTING HINT: *: Use the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS ES NEXT 3 CONNECT INTELLIGENT TESTER TO DLC3* HINT: If the display indicates a communication fault in the tester, inspect the DLC3. NEXT 4 CHECK DTC AND FREEZE FRAME DATA* HINT: Record or print DTCs and freeze frame data, if necessary. NEXT 5 CLEAR DTC AND FREEZE FRAME DATA* NEXT 6 CONDUCT VISUAL INSPECTION NEXT 7 SET CHECK MODE DIAGNOSIS* NEXT 8 CONFIRM PROBLEM SYMPTOMS HINT: If the engine does not start, perform steps 10 and 12 first. ES–18 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Result Result Proceed to Malfunction does not occur A Malfunction occurs B B GO TO STEP 10 A 9 SIMULATE SYMPTOMS NEXT ES 10 CHECK FOR DTCS* Result B Result Proceed to Trouble code A No code B GO TO STEP 12 A 11 REFER TO DTC CHART NEXT GO TO STEP 14 12 CONDUCT BASIC INSPECTION Result Result Proceed to Malfunctioning parts not confirmed A Malfunctioning parts confirmed B B GO TO STEP 17 A 13 REFER TO PROBLEM SYMPTOMS TABLE Result Result Proceed to Malfunctioning circuit confirmed A ES–19 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Result Proceed to Malfunctioning parts confirmed B B GO TO STEP 17 A 14 CHECK ECM POWER SOURCE CIRCUIT NEXT 15 CONDUCT CIRCUIT INSPECTION ES Result Result Proceed to Malfunction not confirmed A Malfunction confirmed B B A 16 CHECK FOR INTERMITTENT PROBLEMS NEXT GO TO STEP 18 17 CONDUCT PARTS INSPECTION NEXT 18 IDENTIFY PROBLEM NEXT 19 NEXT ADJUST AND/OR REPAIR GO TO STEP 18 ES–20 20 NEXT END ES 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CONDUCT CONFIRMATION TEST 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–21 CHECK FOR INTERMITTENT PROBLEMS HINT: Inspect the vehicle's ECM using check mode. Intermittent problems are easier to detect with an intelligent tester when the ECM is in check mode. In check mode, the ECM uses 1 trip detection logic, which is more sensitive to malfunctions than normal mode (default), which uses 2 trip detection logic. 1. Clear the DTCs. 2. Switch the ECM from normal mode to check mode using an intelligent tester (See page ES-49). 3. Perform a simulation test (See page IN-40). 4. Check and wiggle the harness(es), connector(s) and terminal(s) (See page IN-45). ES ES–22 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM BASIC INSPECTION When the malfunction is not confirmed by the DTC check, troubleshooting should be carried out in all circuits considered to be possible causes of the problem. In many cases, by carrying out the basic engine check shown in the following flowchart, the location of the problem can be found quickly and efficiently. Therefore, using this check is essential when troubleshooting the engine. 1 CHECK BATTERY VOLTAGE NOTICE: Carry out this check with the engine stopped and the engine switch off. Result ES NG Result Proceed to 11 V or more OK Below 11 V NG CHARGE OR REPLACE BATTERY OK 2 CHECK WHETHER ENGINE CRANKS NG PROCEED TO PROBLEM SYMPTOMS TABLE OK 3 CHECK WHETHER ENGINE STARTS NG GO TO STEP 6 OK 4 CHECK AIR FILTER (a) Visually check that the air filter is not excessively contaminated with dirt or oil. NG REPLACE AIR FILTER NG TROUBLESHOOT IDLING SPEED AND PROCEED TO NEXT STEP OK 5 CHECK IDLING SPEED 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–23 OK 6 CHECK FUEL PRESSURE NG TROUBLESHOOT FUEL PRESSURE AND PROCEED TO NEXT STEP NG TROUBLESHOOT SPARK AND PROCEED TO NEXT STEP OK 7 CHECK FOR SPARKS OK PROCEED TO PROBLEM SYMPTOMS TABLE ES ES–24 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM REGISTRATION NOTICE: The Vehicle Identification Number (VIN) must be input into the replacement ECM. HINT: The VIN is in the form of a 17-digit alphanumeric vehicle identification number. An intelligent tester is required to register the VIN. 1. INPUT INSTRUCTIONS (a) The general VIN input instructions using an intelligent tester are explained below: (b) The arrow buttons (UP, DOWN, RIGHT and LEFT) and numerical buttons (0 to 9) are used, in order to input the VIN. (c) Cursor Operation To move the cursor around the tester screen, press the RIGHT and LEFT buttons. (d) Alphabetical Character Input (1) Press the UP and DOWN buttons to select the desired alphabetical character. (e) Numeric Character Input (1) Press the numerical button corresponding to the number that you want to input. HINT: Numerical characters can be selected by using the UP and DOWN buttons. (f) Correction (1) When correcting the input character(s), put the cursor onto the character using the RIGHT or LEFT button. (2) Select or input the correct character using the UP and DOWN buttons, or the numerical buttons. (g) Finishing Input Operation (1) Make sure that the input VIN matches the vehicle VIN after input. (2) Press the ENTER button on the tester. 2. READ VIN (Vehicle Identification Number) (a) The flowchart of the VIN reading process is shown. This process allows the VIN stored in the ECM to be read, in order to confirm that the two VINs, provided with the vehicle and stored in the vehicle's ECM, are the same. (b) Read VIN using an intelligent tester. (c) Check the vehicle's VIN. (d) Connect the intelligent tester to the DLC3. (e) Turn the ignition switch on (IG). (f) Turn the tester on. ES ES–25 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (g) Enter the following menus: DIAGNOSIS / ENHANCED OBD ll / VIN. Menu Screen: Select VIN READ ES VIN Previously Stored DTC P0630 Set VIN Not Stored 17-digit VIN displayed [EXIT] [EXIT] [EXIT] To Menu Screen A103812E03 3. WRITE VIN (a) The flowchart of the VIN writing process is shown. This process allows the VIN to be input into the ECM. If the ECM is changed, or the VINs do not match, the VIN can be registered, or overwritten in the ECM by following this procedure. (b) Write VIN using the intelligent tester. (c) Check the vehicle's VIN. (d) Connect the intelligent tester to the DLC3. (e) Turn the ignition switch on (IG). (f) Turn the tester on. ES–26 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (g) Enter the following menus: DIAGNOSIS / ENHANCED OBD ll / VIN. Menu Screen: Select VIN WRITE ES VIN Previously Stored [NO] [YES] [YES] [YES] To Menu Screen 17-digit VIN displayed [NO] Continue to next illustration To Menu Screen A103813E01 ES–27 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM New Registration [ENTER] Input Instructions ES [ENTER] [ENTER] [ENTER] Input Error [EXIT] Continue to next illustration A103814E03 ES–28 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Writing Successful Writing Error Communication Error [ENTER] [EXIT] [EXIT] ES To Menu Screen To Menu Screen To Menu Screen A103815E03 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–29 CHECKING MONITOR STATUS The purpose of the monitor result (mode 06) is to allow access to the results for on-board diagnostic monitoring tests of specific components/systems that are not continuously monitored. Examples are catalyst, evaporative emission (EVAP) and thermostat. The monitor result allows the OBD II scan tool to display the monitor status, test value, minimum test limit and maximum test limit. These data are displayed after the vehicle has been driven to run the monitor. When the test value is not between the minimum test limit and maximum test limit, the ECM (PCM) interprets this as a malfunction. When the component is not malfunctioning, if the difference of the test value and test limit is very small, the component will malfunction in the near future. Perform the following instructions to view the monitor status. Although the Toyota diagnostic tester is used in the following instructions, it can be checked using a generic OBD II scan tool. Refer to your scan tool operator's manual for specific procedures. 1. PERFORM MONITOR DRIVE PATTERN The monitor results and test values can be checked with the OBD II scan tool or the intelligent tester. The engine control module (ECM) monitors the emissions-related components such as the thermostat, catalyst converter and evaporative emissions (EVAP), and determines whether they are functioning normally or not. When monitoring is finished, the ECM stores the monitor results and the test values. The monitor result indicates whether the component is functioning normally or not. The test value is the value that was used to determine the monitor result. If the test value is outside of the test limit (malfunction criterion), the ECM determines the component is malfunctioning. Some emissions-related components have multiple test values to determine monitor result. If one of these test values is outside of the test limit, the ECM determines the component is malfunctioning. (a) Connect the intelligent tester to the DLC3. (b) Start the engine and turn the tester on. (c) Clear the DTCs. (d) Run the vehicle in accordance with the applicable drive pattern described in READINESS MONITOR DRIVE PATTERN (See page ES-28). DO NOT turn the engine switch off. NOTICE: The test results will be lost if the engine switch is turned off. ES ES–30 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2. ACCESS MONITOR RESULT (a) Select the following menus on the intelligent tester: DIAGNOSIS, ENHANCED OBDII, MONITOR INFO and MONITOR RESULT. The monitor status appears after the component name. • INCMP: The component has not been monitored yet. • PASS: The component is functioning normally. • FAIL: The component is malfunctioning. (b) Confirm that the component is either PASS or FAIL. (c) Select the component and press ENTER. The accuracy test value appears if the monitor status is either PASS or FAIL. HINT: The monitor result might be PASS on rare occasions even if the Malfunction Indicator Lamp (MIL) is illuminated. This indicates that the system was malfunctioning in the previous driving cycle. This might be caused by an intermittent problem. 3. CHECK COMPONENT STATUS (a) Compare the test value with the minimum test limit (MIN LIMIT) and maximum test limit (MAX LIMIT). (b) If the test value is between the minimum test limit and maximum test limit, the component is functioning normally. If not, the component is malfunctioning. The test value is usually significantly higher or lower than the test limit. If the test value is on the borderline of the test limit, the component will malfunction in the near future. HINT: The monitor result might be PASS on rare occasions even if the Malfunction Indicator Lamp (MIL) is illuminated. This indicates that the system was malfunctioning in the previous driving cycle. This might be caused by an intermittent problem. 4. MONITOR RESULT INFORMATION If you use a generic scan tool, multiply the test value by the scaling value listed below. ES A/F Sensor Bank 1: Monitor ID Test ID Scaling Unit $01 $8E Multiply by 0.0003 No dimension $01 $91 Multiply by 0.004 mA Description A/F sensor deterioration level A/F sensor current HO2S Bank 1 Sensor 2: Monitor ID Test ID Scaling Unit $02 $07 Multiply by 0.001 V Minimum sensor voltage Description $02 $08 Multiply by 0.001 V Maximum sensor voltage $02 $8F Multiply by 0.003 g Maximum oxygen storage capacity A/F Sensor Bank 2: Monitor ID Test ID Scaling Unit $05 $8E Multiply by 0.0003 No dimension $05 $91 Multiply by 0.004 mA Description A/F sensor deterioration level A/F sensor current 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–31 HO2S Bank 2 Sensor 2: Monitor ID Test ID Scaling Unit Description $06 $07 Multiply by 0.001 V Minimum sensor voltage $06 $08 Multiply by 0.001 V Maximum sensor voltage $06 $8F Multiply by 0.003 g Maximum oxygen storage capacity Catalyst-Bank 1: Monitor ID Test ID Scaling Unit $21 $A9 Multiply by 0.003 No dimension Description Oxygen storage capacity of catalyst-bank 1 Catalyst-Bank 2: Monitor ID Test ID Scaling Unit $22 $A9 Multiply by 0.003 No dimension Description Monitor ID Test ID Scaling Unit $3D $C9 Multiply by 0.001 kPa Test value for small leak (P0456) $3D $CA Multiply by 0.001 kPa Test value for gross leak (P0455) Oxygen storage capacity of catalyst-bank 2 EVAP: Description $3D $CB Multiply by 0.001 kPa Test value for leak detection pump OFF stuck (P2401) $3D $CD Multiply by 0.001 kPa Test value for leak detection pump ON stuck (P2402) $3D $CE Multiply by 0.001 kPa Test value for vent valve OFF stuck (P2420) $3D $CF Multiply by 0.001 kPa Test value for vent valve ON stuck (P2419) $3D $D0 Multiply by 0.001 kPa Test value for reference orifice low flow (P043E) $3D $D1 Multiply by 0.001 kPa Test value for reference orifice high flow (P043F) $3D $D4 Multiply by 0.001 kPa Test value for purge VSV close stuck (P0441) $3D $D5 Multiply by 0.001 kPa Test value for purge VSV open stuck (P0441) $3D $D7 Multiply by 0.001 kPa Test value for purge flow insufficient (P0441) Monitor ID Test ID Scaling Unit $A1 $0B Multiply by 1 Time Exponential Weighted Moving Average (EWMA) misfire for all cylinders: Misfire counts for last ten driving cycles-Total $A1 $0C Multiply by 1 Time Misfire rate for all cylinders: Misfire counts for last/current driving cycles-Total $A2 $0B Multiply by 1 Time EWMA misfire for cylinder 1: Misfire counts for last ten driving cyclesTotal $A2 $0C Multiply by 1 Time Misfire rate for cylinder 1: Misfire counts for last/current driving cycleTotal $A3 $0B Multiply by 1 Time EWMA misfire for cylinder 2: Misfire counts for last ten driving cyclesTotal $A3 $0C Multiply by 1 Time Misfire rate for cylinder 2: Misfire counts for last/current driving cycleTotal $A4 $0B Multiply by 1 Time EWMA misfire for cylinder 3: Misfire counts for last ten driving cyclesTotal $A4 $0C Multiply by 1 Time Misfire rate for cylinder 3: Misfire counts for last/current driving cycleTotal $A5 $0B Multiply by 1 Time EWMA misfire for cylinder 4: Misfire counts for last ten driving cyclesTotal $A5 $0C Multiply by 1 Time Misfire rate for cylinder 4: Misfire counts for last/current driving cycleTotal $A6 $0B Multiply by 1 Time EWMA misfire for cylinder 5: Misfire counts for last ten driving cyclesTotal $A6 $0C Multiply by 1 Time Misfire rate for cylinder 5: Misfire counts for last/current driving cycleTotal $A7 $0B Multiply by 1 Time EWMA misfire for cylinder 6: Misfire counts for last ten driving cyclesTotal Misfire: Description ES ES–32 Monitor ID $A7 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Test ID $0C Scaling Multiply by 1 Unit Description Time Misfire rate for cylinder 6: Misfire counts for last/current driving cycleTotal Rear Oxygen Sensor Heater: ES Monitor ID Test ID Scaling Unit $42 $91 Multiply by 0.001 Ohm Oxygen sensor heater resistance bank 1 sensor 2 Description $46 $91 Multiply by 0.004 Ohm Oxygen sensor heater resistance bank 2 sensor 2 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–33 READINESS MONITOR DRIVE PATTERN 1. PURPOSE OF READINESS TESTS • The On-Board Diagnostic (OBD II) system is designed to monitor the performance of emissionrelated components, and indicate any detected abnormalities with DTCs (Diagnostic Trouble Codes). Since various components need to be monitored in different driving conditions, the OBD II system is designed to run separate monitoring programs called Readiness Monitors. • The intelligent tester's software must be version 9.0 or newer to view the Readiness Monitor status. To view the status, select the following menu items: DIAGNOSIS / ENHANCED OBD II / MONITOR INFO / MONITOR STATUS. • When the Readiness Monitor status reads COMPL (complete), the necessary conditions have been met for running the performance tests for that Readiness Monitor. • A generic OBD II scan tool can also be used to view the Readiness Monitor status. HINT: Many Inspection and Maintenance (I/M) programs require a vehicle's Readiness Monitor status to show COMPL before beginning emission tests. The Readiness Monitor will be reset to INCMPL (incomplete) if: • The ECM has lost battery power or broken a fuse. • DTCs have been cleared. • The conditions for running the Readiness Monitor have not been met. If the Readiness Monitor status shows INCMPL, follow the appropriate Readiness Monitor Drive Pattern to change the status to COMPL. CAUTION: Strictly observe posted speed limits, traffic laws, and road conditions when performing these drive patterns. NOTICE: These drive patterns represent the fastest method of satisfying all conditions necessary to achieve complete status for each specific Readiness Monitor. In the event of a drive pattern being interrupted (possibly due to factors such as traffic conditions), the drive pattern can be resumed. In most cases, the Readiness Monitor will still achieve complete status upon completion of the drive pattern. To ensure completion of the Readiness Monitors, avoid sudden changes in vehicle load and speed (driving up and down hills and/or sudden acceleration). ES ES–34 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2. CATALYST MONITOR (ACTIVE AIR-FUEL RATIO CONTROL TYPE) Vehicle Speed NOTICE: Between 40 mph and 70 mph (64 km/h and 113 km/h) This test will not be completed if the vehicle is driven under absolute constant speed condition such as with cruise control activated. Idling ES Ignition Switch off 10 minutes Warm up Time Note: Even when vehicle stops during driving pattern, the test can be resumed A079199E85 3. (a) Preconditions The monitor will not run unless: • The MIL is OFF. (b) Drive Pattern (1) Connect an intelligent tester. (2) Turn the ignition switch on (IG). (3) Turn the tester or scan tool ON. (4) Clear the DTCs. (5) Start the engine and warm it up. (6) Drive the vehicle at between 40 mph and 70 mph (64 km/h and 113 km/h) for at least 10 minutes. (c) Monitor Status (1) Check the Readiness Monitor status displayed on the tester. (2) If the status does not switch to COMPL (complete), extend the driving time. EVAP MONITOR (KEY-OFF TYPE) (a) Preconditions The monitor will not run unless: • The fuel tank is less than 90% full. • The altitude is less than 8,000 ft (2,450 m). • The vehicle is stationary. • The engine coolant temperature is between 4.4°C and 35°C (40°F to 95°F). • The intake air temperature is between 4.4°C and 35°C (40°F to 95°F). • Vehicle was driven in the city area (or on freeway) for 10 minutes or more. (b) Monitor Conditions (1) Turn the ignition switch off and wait for 6 hours. HINT: Do not start the engine until checking Readiness Monitor status. If the engine is started, the step described above must be repeated. ES–35 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 4. (c) Monitor Status (1) Connect an intelligent tester to the DLC3. (2) Turn the ignition switch on (IG). (3) Turn the tester or scan tool on. (4) Check the Readiness Monitor status displayed on the tester or scan tool. If the status does not switch to COMPL (complete), restart the engine, make sure that the preconditions have been met, and then perform the Monitor Conditions again. A/F SENSOR AND HO2S MONITORS Monitor Drive Pattern: ECT: 75°C (167°F) or more Accelerator Pedal Depressed At least 3 times Vehicle Speed 38 to 75 mph (60 to 120 km/h) Accelerator Pedal Released (Fuel-cut) 40 mph (64 km/h) or more 6 mph (10 km/h) Idling Time Warming up 10 minutes or more 10 seconds or more 4 seconds or more G039003E12 (a) Preconditions The monitor will not run unless: • 2 minutes or more have elapsed since the engine was started. • The Engine Coolant Temperature (ECT) is 75°C (167°F) or more. • Cumulative driving time at a vehicle speed of 30 mph (48 km/h) or more exceeds 6 minutes. • Air-fuel ratio feedback control is performed. • Fuel-cut control is performed for 8 seconds or more (for the Rear HO2 Sensor Monitor). (b) Drive Pattern for front A/F sensor and HO2 sensor (1) Connect an intelligent tester to the DLC3. (2) Turn the ignition switch on (IG). (3) Turn the tester on. (4) Clear the DTCs. (5) Start the engine, and warm it up until the ECT reaches 75°C (167°F) or higher. (6) Drive the vehicle at 38 mph (60 km/h) or more for at least 10 minutes. (7) Change the transmission to the 2nd gear. (8) Accelerate the vehicle to 40 mph (64 km/h) or more by depressing the accelerator pedal for at least 10 seconds (Procedure "A"). ES ES–36 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES 5. (9) Soon after performing procedure "A" above, release the accelerator pedal for at least 4 seconds without depressing the brake pedal, in order to execute fuel-cut control (Procedure "B"). (10)Allow the vehicle to decelerate until the vehicle speed declines to less than 6 mph (10 km/h) (Procedure "C"). (11)Repeat procedures from "A" through "C" above at least 3 times in one driving cycle. (c) Monitor Status (1) Check the Readiness Monitor status displayed on the tester. (2) If the status does not switch to COMPL (complete), make sure that the preconditions have been met and then perform the Drive Pattern again. AIR-FUEL RATIO (A/F) AND HEATED OXYGEN (HO2) SENSOR HEATER MONITORS (FRONT A/F AND REAR HO2 SENSOR TYPE) Vehicle Speed 25 mph (40 km/h) Idling Ignition Switch off 10 minutes or more 2 minutes or more A078886E24 (a) Preconditions The monitor will not run unless: • The MIL is OFF. (b) Drive Pattern (1) Connect an intelligent tester to the DLC3. (2) Turn the ignition switch on (IG). (3) Clear the DTCs. (4) Start the engine. (5) Allow the engine to idle for 10 minutes or more. (6) Drive the vehicle at 25 mph (40 km/h) or more for at least 2 minutes. 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–37 (c) Monitor Status (1) Check the Readiness Monitor status displayed on the tester or scan tool. If the status does not switch to COMPL (complete), make sure that the preconditions have been met, and repeat the Drive Pattern. ES ES–38 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PROBLEM SYMPTOMS TABLE HINT: When a malfunction is not confirmed by a DTC (Diagnostic Trouble Code) check and the cause of problem cannot be identified through a basic inspection, troubleshoot according to the priority order indicated in the table below. SFI SYSTEM Symptom Without Smart Key System: Engine does not crank (Does not start) ES With Smart Key System: Engine does not crank (Does not start) No initial combustion (Does not start) Engine cranks normally but difficult to start Difficult to start with cold engine Difficult to start with warm engine Suspected area See page 1. Immobilizer system (with smart key system) EI-7 2. Immobilizer system (without smart key system) EI-55 3. Starter signal circuit ES-304 4. Starter ST-143 5. STARTER relay ST-149 1. Immobilizer system (with smart key system) EI-7 2. Immobilizer system (without smart key system) EI-55 3. Cranking holding function circuit ES-455 4. Starter signal circuit ES-304 5. Starter ST-143 6. STARTER relay ST-149 7. ECM power source circuit ES-432 8. ECM ES-518 1. ECM power source circuit ES-432 2. Ignition system IG-3 3. Fuel pump control circuit ES-449 4. Injector FU-15 5. Crank angle sensor ES-497 6. ECM ES-518 1. Electronic Throttle Control System (ETCS) ES-320 2. Fuel pump control circuit ES-449 3. Ignition system IG-3 4. Spark plug IG-5 5. Compression EM-3 6. Injector FU-15 7. Crank angle sensor ES-497 1. Starter signal circuit ES-304 2. Electronic Throttle Control System (ETCS) ES-320 3. Fuel pump control circuit ES-449 4. Spark plug IG-5 5. Ignition system IG-3 6. Injector FU-15 7. Engine coolant temperature sensor ES-500 1. Starter signal circuit ES-304 2. Electronic Throttle Control System (ETCS) ES-320 3. Fuel pump control circuit ES-449 4. Spark plug IG-5 5. Ignition system IG-3 6. Injector FU-15 7. Engine coolant temperature sensor ES-500 ES–39 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Symptom Suspected area 1. Electronic Throttle Control System (ETCS) High engine idling speed (Poor idling) Low engine idling speed (Poor idling) Rough idling (Poor idling) Hunting (Poor idling) Hesitation/Poor acceleration (Poor driveability) Surging (Poor driveability) See page ES-320 2. ECM power source circuit ES-432 3. A/C signal circuit (Compressor circuit) - 4. Acoustic Control Induction System (ACIS) ES-462 5. PCV hose EC-5 6. ECM ES-518 1. Electronic Throttle Control System (ETCS) ES-320 2. ECM power source circuit ES-432 3. A/C signal circuit (Compressor circuit) - 4. Acoustic Control Induction System (ACIS) ES-462 5. PCV hose EC-5 6. Injector FU-15 7. ECM ES-518 1. Electronic Throttle Control System (ETCS) ES-320 2. Injector FU-15 3. Ignition system IG-3 4. Compression EM-3 5. Fuel pump control circuit ES-449 6. Spark plug IG-5 7. Acoustic Control Induction System (ACIS) ES-462 8. PCV hose EC-5 1. Electronic Throttle Control System (ETCS) ES-320 2. ECM power source circuit ES-432 3. Fuel pump control circuit ES-449 4. Spark plug IG-5 5. Ignition system IG-3 6. Injector FU-15 7. Acoustic Control Induction System (ACIS) ES-462 8. PCV hose EC-5 1. Injector FU-15 2. Fuel pump control circuit ES-449 3. Ignition system IG-3 4. Spark plug IG-5 5. Air Intake Control System (AICS) ES-462 6. A/T faulty AX-9 1. Fuel pump control circuit ES-449 2. Spark plug IG-5 3. Ignition system IG-3 4. Injector FU-15 1. Fuel pump control circuit ES-449 2. Electronic Throttle Control System (ETCS) ES-320 3. Crank angle sensor ES-497 4. Spark plug IG-5 5. Ignition system IG-3 6. Injector FU-15 1. A/C signal circuit - 2. ECM ES-518 Unable/difficult to refuel Refueling valve (canister) - Engine vibrates frequently when idling (Active Control engine Mount (ACM) system does not operate) Active control engine mount circuit ES-393 Engine stalls soon after starting Engine stalls during A/C operation ES ES–40 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TERMINALS OF ECM 1. SFI SYSTEM C55  ES                                A55                                                                                                                                                           A107881E29 HINT: The standard normal voltage between each pair of the ECM terminals is shown in the table below. The appropriate conditions for checking each pair of the terminals are also indicated. The check results should be compared with the standard normal voltage for that pair of terminals, listed in the "STD Voltages" column. The illustration above can be used as a reference to identify the ECM terminal locations. Symbols (Terminal No.) Wiring Colors +B (A55-2) - E1 (C55-81) R - W-B +B2 (A55-1) - E1 (C55-81) Terminal Descriptions Conditions STD Voltages Power source of ECM Ignition switch on (IG) 9 to 14 V R - W-B Power source of ECM Ignition switch on (IG) 9 to 14 V BATT (A55-20) - E1 (C55-81) Y - W-B Battery (for measuring the battery voltage and for the ECM memory) Always 9 to 14 V VPMP (A55-42) - E1 (C55-81) W - W-B Vent valve operation signal (built into pump module) Ignition switch on (IG) 9 to 14 V MPMP (A55-34) - E1 (C55-81) G - W-B Vacuum pump operation signal (built into pump module) Vacuum pump OFF 0 to 3 V MPMP (A55-34) - E1 (C55-81) G - W-B Vacuum pump operation signal (built into pump module) Vacuum pump ON 9 to 14 V +BM (A55-3) - E1 (C55-81) LG - W-B Power source of ETCS throttle motor Always 9 to 14 V MREL (A55-44) - E1 (C55-81) O - W-B EFI relay operation signal Ignition switch on (IG) 9 to 14 V IGSW (A55-28) - E1 (C55-81) Ignition switch signal Ignition switch on (IG) 9 to 14 V FC (A55-7) - E1 (C55-81) FC (A55-7) - E1 (C55-81) Y - W-B C/OPEN relay operation signal (fuel pump control) Ignition switch on (IG), Engine stopped 9 to 14 V FC (A55-7) - E1 (C55-81) FC (A55-7) - E1 (C55-81) C/OPEN relay operation signal (fuel pump control) Ignition switch on (IG), Engine idling 0 to 1.5 V W-Brake pedal depressed 7.5 to 14 V STP ( A55-36 ) - E1 (C55-81) - W-B Stop light switch signal STP (A55-36) - E1 (C55-81) - W-B Stop light switch signal W-Brake pedal released Below 1.5 V Stop light switch signal (opposite to STP terminal) Ignition switch on (IG), W-Brake pedal depressed Below 1.5 V ST1- (A55-35) - E1 (C55-81) GR - W-B 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Symbols (Terminal No.) ST1- (A55-35) - E1 (C55-81) Conditions ES–41 Wiring Colors Terminal Descriptions GR - W-B Stop light switch signal (opposite to STP terminal) Ignition switch on (IG), W-Brake pedal released STD Voltages 7.5 to 14 V ACCR*2 (A24-17) - E1 (C55-81) B - W-B ACC relay control signal Cranking Below 1.5 V VPA (A55-55) - E1 (C55-81) G - W-B Accelerator pedal position sensor signal (for engine control) Ignition switch on (IG), Accelerator pedal fully released 0.5 to 1.1 V VPA (A55-55) - E1 (C55-81) G - W-B Accelerator pedal position sensor signal (for engine control) Ignition switch on (IG), Accelerator pedal fully depressed 2.6 to 4.5 V VPA2 (A55-58) - EPA2 (A55-60) R-O Accelerator pedal position sensor signal (for sensor malfunction detection) Ignition switch on (IG), Accelerator pedal fully released 1.2 to 2.0 V VPA2 (A55-58) - EPA2 (A55-60) R-O Accelerator pedal position sensor signal (for sensor malfunction detection) Ignition switch on (IG), Accelerator pedal fully depressed 3.4 to 5.0 V EPA (A5-59) - VPA (A55-55) Y-G Accelerator pedal position sensor signal (for engine control) Ignition switch on (IG), Accelerator pedal fully released 0.5 to 1.1 V EPA (A5-59) - VPA (A55-55) Y-G Accelerator pedal position sensor signal (for engine control) Ignition switch on (IG), Accelerator pedal fully depressed 2.6 to 4.5 V EPA2 (A55-60) - VPA2 (A55-58) O-R Accelerator pedal position sensor signal (for sensor malfunction detection) Ignition switch on (IG), Accelerator pedal fully released 1.2 to 2.0 V EPA2 (A55-60) - VPA2 (A55-58) O-R Accelerator pedal position sensor signal (for sensor malfunction detection) Ignition switch on (IG), Accelerator pedal fully depressed 3.4 to 5.0 V PPMP (C55-77) - E1 (C55-81) L - W-B Pressure sensor signal (built into pump module) Ignition switch on (IG) 3 to 3.6 V TC (A55-27) - E1 (C55-81) P - W-B Terminal TC of DLC3 Ignition switch on (IG) 9 to 14 V VCPA (A55-57) - EPA (A55-59) R-Y Power source of accelerator pedal position sensor (for VPA) Ignition switch on (IG) 4.5 to 5.0 V VCP2 (A55-56) - EPA2 (A55-60) L-O Power source of accelerator pedal position sensor (for VPA2) Ignition switch on (IG) 4.5 to 5.0 V B - W-B Engine speed signal (for combination meter) Idling CCS (A55-40) - E1 (C55-81) W - W-B Cruise control main switch signal Ignition switch on (IG) CANCEL switch ON SET/COAST switch ON RES/ACC switch ON Main switch ON SPD (A55-24) - E1 (C55-81) BR - W-B Vehicle speed signal from combination meter Ignition switch on (IG), driving wheel rotated slowly W (A55-24) - E1 (C55-81) BR - W-B Malfunction Indicator Lamp (MIL) operation signal Ignition switch on (IG) W (A55-24) - E1 (C55-81) BR - W-B Malfunction Indicator Lamp (MIL) operation signal Idling B-W CAN communication circuit Ignition switch off 54 to 69 Ω Earth (ground) circuit of ECM Always Below 1 V TACH (A55-15) - E1 (C55-81) CANH (A55-41) - CANL (A55-49) E1 (C55-81) - Body ground W-B - - Pulse generation (see waveform 11) 10 to 16 V 6.6 to 10.1 V 4.5 to 7.1 V 2.3 to 4.0 V Below 1 V Pulse generation (see waveform 8) Below 3.0 V 9 to 14 V ES ES–42 Symbols (Terminal No.) ES 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Wiring Colors Terminal Descriptions Conditions #10 (C55-45) - E01 (C55-22) #20 (C55-85) - E01 (C55-22) #30 (C55-44) - E01 (C55-22) #40 (C55-84) - E01 (C55-22) #50 (C55-43) - E01 (C55-22) #60 (C55-83) - E01 (C55-20) B - W-B R - W-B Y - W-B L - W-B W-L - W-B BR - W-B Fuel injector operation signal Ignition switch on (IG) #10 (C55-45) - E01 (C55-22) #20 (C55-85) - E01 (C55-22) #30 (C55-44) - E01 (C55-22) #40 (C55-84) - E01 (C55-22) #50 (C55-43) - E01 (C55-22) #60 (C55-83) - E01 (C55-20) B - W-B R - W-B Y - W-B L - W-B W-L - W-B BR - W-B Fuel injector operation signal Idling STD Voltages 9 to 14 V Pulse generation (see waveform 3) PSW (C55-810) - E1 (C55-81) B - W-B P/S pressure switch signal Ignition switch on (IG) 9 to 14 V STA (A55-48) - E1 (C55-81) V - W-B Starter relay operation signal Cranking 9 to 14 V STSW*2 (A55-14) - E1 (C55-81) R - W-B Starter relay operation signal Cranking 9 to 14 V OC2- (C55-51) - OC2+ (C55-52) R - BR Camshaft timing Oil Control Valve (OCV) operation signal (Intake side) Ignition switch on (IG) Pulse generation (see waveform 1) OC2+ (C55-52) - OC2- (C55-51) BR - R Camshaft timing Oil Control Valve (OCV) operation signal (Intake side) Ignition switch on (IG) Pulse generation (see waveform 1) OC1- (C55-57) - OC1+ (C55-58) B-W Camshaft timing Oil Control Valve (OCV) operation signal (Intake side) Ignition switch on (IG) Pulse generation (see waveform 1) OC1+ (C55-58) - OC1- (C55-57) W-B Camshaft timing Oil Control Valve (OCV) operation signal (Intake side) Ignition switch on (IG) Pulse generation (see waveform 1) VV2+ (C55-67) - VV2- (C55-90) W-B Variable Valve Timing (VVT) sensor signal (Intake side) Idling Pulse generation (see waveform 5) VV1+ (C55-69) - VV1- (C55-92) L - LG Variable Valve Timing (VVT) sensor signal (Intake side) Idling Pulse generation (see waveform 5) NE- (C55-111) - NE+ (C55-110) R-G Crankshaft position sensor signal Idling Pulse generation (see waveform 5) NE+ (C55-110) - NE- (C55-111) G-R Crankshaft position sensor signal Idling Pulse generation (see waveform 5) EV2- (C55-89) - EV2+ (C55-66) L - G-R Variable Valve Timing (VVT) sensor signal (Exhaust side) Idling Pulse generation (see waveform 5) EV2+ (C55-66) - EV2- (C55-89) G-R - L Variable Valve Timing (VVT) sensor signal (Exhaust side) Idling Pulse generation (see waveform 5) EV1- (C55-91) - EV1+ (C55-68) B-Y Variable Valve Timing (VVT) sensor signal (Exhaust side) Idling Pulse generation (see waveform 5) EV1+ (C55-68) - EV1- (C55-91) Y-B Variable Valve Timing (VVT) sensor signal (Exhaust side) Idling Pulse generation (see waveform 5) OE1+ (C55-16) - OE1- (C55-17) L - LG Camshaft timing Oil Control Valve (OCV) operation signal (Exhaust side) Ignition switch on (IG) Pulse generation (see waveform 1) 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Symbols (Terminal No.) Wiring Colors Terminal Descriptions OE2+ (C55-14) - OE2- (C55-15) W-L - Y Camshaft timing Oil Control Valve (OCV) operation signal (Exhaust side) Ignition switch on (IG) Pulse generation (see waveform 1) VV2- (C55-90) - VV2+ (C55-67) B-W Variable Valve Timing (VVT) sensor signal (Intake side) Idling Pulse generation (see waveform 5) VV1- (C55-92) - VV1+ (C55-69) LG - L Variable Valve Timing (VVT) sensor signal (Intake side) Idling Pulse generation (see waveform 5) LG - L Camshaft timing Oil Control Valve (OCV) operation signal (Exhaust side) Ignition switch on (IG) Pulse generation (see waveform 1) Y - W-L Camshaft timing Oil Control Valve (OCV) operation signal (Exhaust side) Ignition switch on (IG) Pulse generation (see waveform 1) OE1- (B47-31) - OE1+ (B47-26) OE2- (C55-15) - OE2+ (C55-14) Conditions ES–43 STD Voltages HT1B (C55-48) - E1 (C55-81) HT2B (C55-47) - E1 (C55-81) LG - W-B Y - W-B Heated oxygen sensor heater operation signal Idling HT1B (C55-48) - E1 (C55-81) HT2B (C55-47) - E1 (C55-81) LG - W-B Y - W-B Heated oxygen sensor heater operation signal Ignition switch on (IG) 9 to 14 V ACM (C55-42) - E1 (C55-81) L-B - W-B VSV for active control mount system operation signal Ignition switch on (IG) 9 to 14 V M- (C55-18) - ME01 (C55-20) R-B Throttle drive motor operation signal (negative terminal) Idling with warm engine Pulse generation (see waveform 10) M+ (C55-19) - ME01 (C55-20) G-B Throttle drive motor operation signal (positive terminal) Idling with warm engine Pluse generation (see waveform 9) Below 3.0 V E02 (C55-21) - Body ground B-W - - Earth (ground) circuit of ECM Always Below 1 V E01 (C55-22) - Body ground W-B - - Earth (ground) circuit of ECM Always Below 1 V IGT1 (C55-40) - E1 (C55-81) IGT2 (C55-39) - E1 (C55-81) IGT3 (C55-38) - E1 (C55-81) IGT4 (C55-37) - E1 (C55-81) IGT5 (C55-36) - E1 (C55-81) IGT6 (C55-35) - E1 (C55-81) W - W-B GR - W-B G - W-B LG - W-B P - W-B G-R - W-B Ignition coil with igniter (ignition signal) Idling GE01(C55-41) - E1 (C55-81) G-R - W-B Shielded earth (ground) circuit of throttle drive motor Always OX1B (C55-88) - EX1B (C55-65) OX2B (C55-87) - EX2B (C55-64) W - BR B - W-B Heated oxygen sensor signal With engine speed at 2,500 rpm for 2 minutes after warming up Pulse generation (see waveform 2) VTA2 (C55-99) - ETA (C55-97) W-L - P Throttle position sensor signal (for sensor malfunction detection) Ignition switch on (IG), Accelerator pedal fully released 2.1 to 3.1 V VTA2 (C55-99) - ETA (C55-97) W-L - P Throttle position sensor signal (for sensor malfunction detection) Ignition switch on (IG), Accelerator pedal fully depressed 4.5 to 5.0 V VTA1 (C55-98) - ETA (C55-97) Y-P Throttle position sensor signal (for engine control) Ignition switch on (IG), Throttle valve fully closed 0.5 to 1.2 V VTA1 (C55-98) - ETA (C55-97) Y-P Throttle position sensor signal (for engine control) Ignition switch on (IG), Throttle valve fully open 3.2 to 4.8 V THW (C55-79) - ETHW (C55-78) B-P Engine coolant temperature sensor signal Idling, Engine coolant temperature 80°C (176°F) 0.2 to 1.0 V THA (C55-71) - ETHA (C55-74) P - G-R Intake air temperature sensor signal Idling, Intake air temperature 20°C (68°F) 0.5 to 3.4 V Pulse generation (see waveform 6) Below 1 V ES ES–44 Symbols (Terminal No.) 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Wiring Colors Terminal Descriptions Conditions STD Voltages IGF1 (C55-106) - E1 (C55-81) BR - W-B Ignition coil with igniter (ignition confirmation signal) IGF1 (C55-106) - E1 (C55-81) BR - W-B Ignition coil with igniter (ignition confirmation signal) Idling VSV for Air intake control system operation signal Ignition switch on (IG) 9 to 14 V Below 1 V Ignition switch on (IG) 4.5 to 5.0 V Pulse generation (see waveform 6) AICV (A55-4) - E1 (C55-81) V - W-B E2G (C55-73) - E1 (C55-81) LG - W-B Earth (ground) circuit of sensor for mass air flow meter Always VG (C55-72) - E2G (C55-73) L-B - LG Mass Air Flow (MAF) meter signal Idling, Shift lever position P or N, A/C switch OFF ACIS (C55-107) - E1 (C55-81) R - W-B VSV for ACIS (Acoustic Control Induction System) operation signal Ignition switch on (IG) 9 to 14 V PRG (C55-108) - E1 (C55-81) G-R - W-B Purge VSV for EVAP system operation signal Ignition switch on (IG) 9 to 14 V PRG (C55-108) - E1 (C55-81) G-R - W-B Purge VSV for EVAP system operation signal Idling Pulse generation (see waveform 7) Below 3.0 V ES 0.5 to 3.0 V HA2A (C55-109) - E05 (C55-46) B-W - W A/F sensor heater operation signal Idling HA2A (C55-109) - E05 (C55-46) B-W - W A/F sensor heater operation signal Ignition switch on (IG) HA1A (C55-86) - E04 (C55-23) G-W A/F sensor heater operation signal Idling HA1A (C55-86) - E04 (C55-23) G-W A/F sensor heater operation signal Ignition switch on (IG) 9 to 14 V ME01 (C55-20) - E1 (C55-81) B - W-R Earth (ground) circuit of ECM Always Below 1 V E03 (C55-104) - E1 (C55-81) B - W-B Earth (ground) circuit of ECM Always Below 1 V HT2B (C55-47) - E1 (C55-81) HT1B (C55-48) - E1 (C55-81) Y - W-B LG - W-B Heated oxygen sensor heater operation signal Idling HT2B (C55-47) - E1 (C55-81) HT1B (C55-48) - E1 (C55-81) Y - W-B LG - W-B Heated oxygen sensor heater operation signal Ignition switch on (IG) 9 to 14 V E05 (C55-46) - E1 (C55-81) W - W-B Earth (ground) circuit of ECM Always Below 1 V E04 (C55-23) - E1 (C55-81) W - W-B Earth (ground) circuit of ECM Always Below 1 V NSW (C55-62) - E1 (C55-81) R - W-B Park/Neutral position switch signal Ignition switch on (IG), Shift lever position P or N Below 3.0 V NSW (C55-62) - E1 (C55-81) R - W-B Park/Neutral position switch signal Ignition switch on (IG), Shift lever position other than P or N 9 to 14 V 9 to 14 V Below 3.0 V Below 3.0 V EKN2 (C55-117) - KNK2 (C55118) W-B Earth (ground) circuit of knock sensor With engine speed at 4,000 rpm after warming up Pulse generation (see waveform 4) KNK2 (C55-118) - EKN2 (C55117) B-W Knock sensor signal With engine speed at 4,000 rpm after warming up Pulse generation (see waveform 4) A1A+ (C55-93) - E1 (C55-81) P - W-B A/F sensor signal Ignition switch on (IG) 3.3 V*1 A1A+ (C55-93) - E1 (C55-81) P - W-B A/F sensor signal Ignition switch on (IG) 3.0 V*1 A2A+ (C55-120) - E1 (C55-81) L - W-B A/F sensor signal Ignition switch on (IG) 3.3 V*1 A2A+ (C55-120) - E1 (C55-81) L - W-B A/F sensor signal Ignition switch on (IG) 3.0 V*1 EKNK (C55-94) - KNK1 (C55-95) G-R Earth (ground) circuit of knock sensor With engine speed at 4,000 rpm after warming up Pulse generation (see waveform 4) KNK1 (C55-95) - EKNK (C55-94) R-G Knock sensor signal With engine speed at 4,000 rpm after warming up Pulse generation (see waveform 4) A/F sensor Ignition switch on (IG) A1A- (C55-116) - E1 (C55-81) P - W-B 3.3 V*1 ES–45 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Symbols (Terminal No.) Wiring Colors Terminal Descriptions Conditions STD Voltages A1A- (B46-30) - E1 (C55-81) P - W-B A/F sensor Ignition switch on (IG) 3.0 V*1 A2A- (C55-119) - E1 (C55-81) Y - W-B A/F sensor Ignition switch on (IG) 3.3 V*1 A2A- (C55-119) - E1 (C55-81) Y - W-B A/F sensor Ignition switch on (IG) 3.0 V*1 OX2B (C55-87) - EX2B (C55-64) OX1B (C55-88) - EX1B (C55-65) B - W-R W - BR Heated oxygen sensor signal With engine speed at 2,500 rpm for 2 minutes after warming up Pulse generation (see waveform 2) *1 : The ECM terminal voltage is constant regardless of the output voltage from the sensor. *2: With Smart Key system (a) WAVEFORM 1 (1) Camshaft timing Oil Control Valve (OCV) operation signal 5 V/DIV ECM Terminal Names Ground Tester Ranges Conditions 1 ms./DIV A093229E19 Between OC1+ and OC1- , OC2+ and OC2- , OE1+ and OE1- , or OE2+ and OE25 V/DIV, 1 ms./DIV Idling HINT: The wavelength becomes shorter as the engine rpm increases. (b) WAVEFORM 2 (1) Heated oxygen sensor signal 0.2 V/DIV ECM Terminal Names Tester Ranges Conditions Ground 200 ms./DIV A088863E21 Between OX1B and EX1B, or OX2B and EX2B 0.2 V/DIV, 200 ms./DIV Engine speed is maintained at 2,500 rpm for 2 minutes after sensor is warmed up HINT: In the DATA LIST, item O2S B1S2 shows the ECM input values from the heated oxygen sensor. (c) WAVEFORM 3 (1) Fuel injector operation signal 30 V/DIV ECM Terminal Names Tester Ranges Conditions Ground 20 ms./DIV Between #10 (to 60) and E01 30 V/DIV, 20 ms./DIV Idling HINT: The wavelength becomes shorter as the engine rpm increases. G035622E06 ES ES–46 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (d) WAVEFORM 4 (1) Knock sensor signal 1 V/DIV ECM Terminal Names Tester Ranges Ground 1 ms./DIV (e) WAVEFORM 5 (1) Variable Valve Timing (VVT) sensor signal (1) (2) Crankshaft position sensor signal (2) GND (2) NE ECM Terminal Names (1) VV1 or EV1 GND VV2 or EV2 GND 20 ms./DIV (Idling) Tester Ranges Conditions (f) (1) Tester Ranges Conditions (2) Ground 20 ms./DIV G035664E08 5 V/DIV, 20 ms./DIV Idling WAVEFORM 6 (1) Igniter IGT signal (from ECM to igniter) (1) (2) Igniter IGF signal (from igniter to ECM) (2) ECM Terminal Names Ground (1) Between VV1+ and VV1- , VV2+ and VV2-, EV1+ and EV1-, or EV2+ and EV2(2) Between NE+ and NE- HINT: The wavelength becomes shorter as the engine rpm increases. G035795E23 2 V/DIV Engine speed is maintained at 4,000 rpm after engine is warmed up HINT: • The wavelength becomes shorter as the engine rpm increases. • The waveforms and amplitudes displayed differ slightly depending on the vehicle. A085286E41 5 V/DIV ES Conditions Between KNK1 and EKNK, or KNK2 and EKN2 0.01 to 10 V/DIV, 0.01 to 10 ms./DIV (1) Between IGT (1 to 6) and E1 (2) Between IGF1 and E1 2 V/DIV, 20 ms./DIV Idling HINT: The wavelength becomes shorter as the engine rpm increases. (g) WAVEFORM 7 (1) Purge VSV for EVAP system operation signal 10 V/DIV ECM Terminal Names Between PRG and E1 Tester Ranges 10 V/DIV, 50 ms./DIV Conditions Ground 50 ms./DIV G042964E02 Idling HINT: If the waveform is not similar to that shown in the illustration, check the waveform again after idling for 10 minutes or more. 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–47 (h) WAVEFORM 8 (1) Vehicle speed signal 2 V/DIV ECM Terminal Names Tester Ranges Conditions Ground 20 ms./DIV (i) 5 V/DIV WAVEFORM 9 (1) Throttle drive motor operation signal (positive terminal) ECM Terminal Names Tester Ranges Conditions A093274E21 (j) Tester Ranges Conditions 1 ms./DIV A093275E21 5 V/DIV, 1 ms./DIV Idling with warm engine WAVEFORM 10 (1) Throttle drive motor operation signal (negative terminal) ECM Terminal Names Ground Between M+ and ME01 HINT: The duty ratio varies depending on the throttle actuator operation. 1 ms./DIV 5 V/DIV Driving at 12 mph (20 km/h) HINT: • The wavelength becomes shorter as the vehicle speed increases. • Depending on the vehicle, the output waveform voltage may rise to 12 V if influenced by optionally installed systems. A093224E20 Ground Between SPD and E1 2 V/DIV, 20 ms./DIV Between M- and ME01 5 V/DIV, 1 ms./DIV Idling with warm engine HINT: The duty ratio varies depending on the throttle actuator operation. (k) WAVEFORM 11 (1) Engine speed signal 5 V/DIV ECM Terminal Names Tester Ranges Conditions Ground 10 ms./DIV Between TACH and E1 5 V/DIV, 10 ms./DIV Idling HINT: The wavelength becomes shorter as the engine rpm increases. A093225E18 ES ES–48 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DIAGNOSIS SYSTEM 1. ES FI00534 Intelligent Tester DLC3 C110200E01 2. 3. DESCRIPTION When troubleshooting OBD II (On-Board Diagnostics) vehicles, the intelligent tester (complying with SAE J1987) must be connected to the DLC3 (Data Link Connector 3) of the vehicle. Various data in the vehicle's ECM (Engine Control Module) can be then read. OBD ll regulations require that the vehicle's on-board computer illuminates the MIL (Malfunction Indicator Lamp) on the instrument panel when the computer detects a malfunction in: (a)The emission control systems and components. (b)The power train control components (which affect vehicle emissions). (c) The computer itself. In addition, the applicable DTCs (Diagnostic Trouble Codes) prescribed by SAE J2012 are recorded on 3 consecutive trips, the MIL turns off automatically but the DTCs remain recorded in the ECM memory. To check for DTCs, connect the intelligent tester to the DLC3. The tester displays DTCs, freeze frame data, and a variety of the engine data. The DTCs and freeze frame data can be erased with the tester. In order to enhance OBD function on vehicles and develop the Off-Board diagnosis system, CAN communication is introduced in this system (CAN: Controller Area Network). It minimizes a gap between technician skills and vehicle technology. CAN is a network, which uses a pair of data transmission lines, spanning multiple computers and sensors. It allows a high speed communication between the systems and simplification of the wire harness connection. Since this system is equipped with the CAN communication, connecting the CAN VIM (VIM: Vehicle Interface Module) with the intelligent tester is necessary to display any information from the ECM. (Also the communication between the intelligent tester and the ECM uses CAN communication signal). When confirming the DTCs and any data of the ECM, connect the CAN VIM between the DLC3 and the intelligent tester. NORMAL MODE AND CHECK MODE The diagnosis system operates in normal mode during normal vehicle use. In normal mode, 2 trip detection logic is used to ensure accurate detection of malfunctions. Check mode is also available as an option for technicians. In check mode, 1 trip detection logic is used for simulating malfunction symptoms and increasing the system's ability to detect malfunctions, including intermittent problems (intelligent tester only). 2 TRIP DETECTION LOGIC When a malfunction is first detected, the malfunction is temporarily stored in the ECM memory (1st trip). If the same malfunction is detected during the next subsequent drive cycle, the MIL is illuminated (2nd trip). ES–49 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 4. FREEZE FRAME DATA The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 5. DLC3 (Data link Connector 3) The vehicle's ECM uses ISO 15765-4 for communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. DLC3 1 2 3 4 5 6 7 8 ES 9 10 11 12 13 14 15 16 A122830E11 Symbols Terminal No. Names Reference terminal Results Condition SIL 7 Bus "+" line 5 - Signal ground Pulse generation During transmission CG 4 Chassis ground Body ground 1 Ω or less Always SG 5 Signal ground Body ground 1 Ω or less Always BAT 16 Battery ground Body ground 9 to 14 V Always CANH 6 CAN "High" line CANL 54 to 69 Ω Engine switch off CANH 6 CAN "High" line Battery positive 1 MΩ or higher Engine switch off CANH 6 CAN "High" line CG 1 kΩ or higher Engine switch off CANL 14 CAN "Low" line Battery positive 1 MΩ or higher Engine switch off CANL 14 CAN "Low" line CG 1 kΩ or higher Engine switch off 6. 7. HINT: The DLC3 is the interface prepared for reading various data from the vehicle's ECM. After connecting the cable of an intelligent tester, turn the ignition switch on (IG) and turn the tester on. If a communication failure message is displayed on the tester screen (on the tester: UNABLE TO CONNECT TO VEHICLE), a problem exists in either the vehicle or tester. In order to identify the location of the problem, connect the tester to another vehicle. If communication is normal: Inspect the DLC3 on the original vehicle. If communication is still not possible: The problem is probably in the tester itself. Consult the Service Department listed in the instruction manual. BATTERY VOLTAGE Standard Voltage: 11 to 14 V If voltage is below 11 V, replace or recharge the battery before proceeding to the next step. MIL (Malfunction Indicator Lamp) (a) The MIL is illuminated when the engine switch is first turned on (the engine is not running). ES–50 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (b) The MIL should turn OFF when the engine is started. If the MIL remains illuminated, the diagnosis system has detected a malfunction or abnormality in the system. HINT: If the MIL is not illuminated when the engine switch is first turned on, check the MIL circuit (See page ES-471). ES 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–51 DTC CHECK / CLEAR NOTICE: When the diagnosis system is changed from the normal mode to check mode or vice versa, all DTCs and freeze frame data recorded in normal mode are erased. Before changing modes, always check and make a note of DTCs and freeze frame data. HINT: • DTCs which are stored in the ECM can be displayed on an intelligent tester. An intelligent tester can display the current and pending DTCs. • Some DTCs are not set if the ECM does not detect the same malfunction again during a second consecutive driving cycle. However, such malfunctions, detected on only one occasion, are stored as pending DTCs. 1. CHECK DTC (Using an intelligent tester) (a) Connect an intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Turn the tester on. (d) Enter the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Check the DTC(s) and freeze frame data, and then write them down. (f) Check the details of the DTC(s) (See page ES-63). 2. CLEAR DTC (Using an intelligent tester) (a) Connect an intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Turn the tester on. (d) Enter the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CLEAR CODES. (e) Press the YES button. 3. CLEAR DTC (Without using an intelligent tester) (a) Perform either one of the following operations: (1) Disconnect the negative battery cable for more than 1 minute. (2) Remove the EFI MAIN and ETCS fuses from the Engine Room relay block located inside the engine compartment for more than 1 minute. ES ES–52 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM FREEZE FRAME DATA 1. DTC was set. ES 0.5 seconds 0.5 seconds 0.5 seconds Freeze frame data which can be read 2. DESCRIPTION The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. HINT: If it is impossible to duplicate the problem even though a DTC is detected, confirm the freeze frame data. The ECM records engine conditions as freeze frame data every 0.5 seconds. Using the intelligent tester, five separate sets of freeze frame data, including the data values at the time when the DTC was set, can be checked. – 3 data set before the DTC was set. – 1 data set when the DTC was set. – 1 data set after the DTC was set. These data sets can be used to simulate the condition of the vehicle around the time of the occurrence of the malfunction. The data may assist in identifying of the cause of the malfunction, and in judging whether it was temporary or not. LIST OF FREEZE FRAME DATA A103809E02 LABEL (Intelligent Tester Display) Measurement Item/Range Diagnostic Note IGN ADVANCE Ignition advance - CALC LOAD Calculate load Calculated load by ECM VEHICLE LOAD Vehicle load - MAF Mass air flow volume If value is approximately 0.0 g/s: • Mass air flow meter power source circuit open or shorted • VG circuit open or shorted If value is 160.0 g/s or more: • E2G circuit open ENGINE SPD Engine speed - VEHICLE SPD Vehicle speed Speed indicated on speedometer COOLANT TEMP Engine coolant temperature If value is -40°C (-40°F), sensor circuit open If value is 140°C (284°F), sensor circuit shorted INTAKE AIR Intake air temperature If value is -40°C (-40°F), sensor circuit open If value is 140°C (284°F), sensor circuit shorted FUEL PRESS Fuel pressure - AIR-FUEL PATIO Air-fuel ratio - AMBIENT TEMP Ambient temperature - PURGE DENSITY Learning value of purge density - PURGE FLOW Purge flow - EVAP PURGE VSV EVAP purge VSV duty ratio - KNOCK CRRT VAL Correction learning value of knocking - ES–53 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM LABEL (Intelligent Tester Display) Measurement Item/Range Diagnostic Note KNOCK FB VAL Feedback value of knocking - ACCEL POS #1 Absolute Accelerator Pedal Position (APP) No. 1 - ACCEL POS #2 Absolute APP No. 2 - THROTTLE POS Throttle position Read value with ignition switch on (IG) (Do not start engine) THROTTLE POS Throttle sensor positioning Read value with ignition switch on (IG) (Do not start engine) THROTTLE POS #2 Throttle sensor positioning #2 - THROTTLE MOT Throttle motor - O2S B1 S2 Heated oxygen sensor output Performing INJ VOL or A/F CONTROL function of ACTIVE TEST enables technician to check output voltage of sensor O2S B2 S2 Heated oxygen sensor output Performing INJ VOL or A/F CONTROL function of ACTIVE TEST enables technician to check output voltage of sensor AFS B1 S1 A/F sensor output Performing INJ VOL or A/F CONTROL function of ACTIVE TEST enables technician to check output voltage of sensor AFS B2 S1 A/F sensor output Performing INJ VOL or A/F CONTROL function of ACTIVE TEST enables technician to check output voltage of sensor TOTAL FT #1 Total fuel trim - TOTAL FT #2 Total fuel trim - SHORT FT #1 Short-term fuel trim Short-term fuel compensation used to maintain air-fuel ratio at stoichiometric air-fuel ratio LONG FT #1 Long-term fuel trim Overall fuel compensation carried out in longterm to compensate for a continual deviation of short-term fuel trim from central valve SHORT FT #2 Short-term fuel trim Short-term fuel compensation used to maintain air-fuel ratio at stoichiometric air-fuel ratio LONG FT #2 Long-term fuel trim Overall fuel compensation carried out in longterm to compensate for a continual deviation of short-term fuel trim from central valve • • • FUEL SYS #1 Fuel system status (Bank 1) • • • • • FUEL SYS #2 Fuel system status (Bank 2) • • OL (Open Loop): Has not yet satisfied conditions to go closed loop CL (Closed Loop): Using heated oxygen sensor as feedback for fuel control OL DRIVE: Open loop due to driving conditions (fuel enrichment) OL FAULT: Open loop due to detected system fault CL FAULT: Closed loop but heated oxygen sensor, which used for fuel control malfunctioning OL (Open Loop): Has not yet satisfied conditions to go closed loop CL (Closed Loop): Using heated oxygen sensor as feedback for fuel control OL DRIVE: Open loop due to driving conditions (fuel enrichment) OL FAULT: Open loop due to detected system fault CL FAULT: Closed loop but heated oxygen sensor, which used for fuel control malfunctioning O2FT B1 S2 Fuel trim at heated oxygen sensor Same as SHORT FT #1 O2FT B2 S2 Fuel trim at heated oxygen sensor Same as SHORT FT #1 ES ES–54 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM LABEL (Intelligent Tester Display) ES Measurement Item/Range Diagnostic Note AF FT B1 S1 Fuel trim at A/F sensor - AF FT B2 S1 Fuel trim at A/F sensor - CAT TEMP B1 S1 Catalyst temperature - CAT TEMP B2 S1 Catalyst temperature - CAT TEMP B1 S2 Catalyst temperature - CAT TEMP B2 S2 Catalyst temperature - INI COOL TEMP Initial engine coolant temperature - INI INTAKE TEMP Initial intake air temperature - INJ VOL Injection volume - ING TIMMING D4 Injection timing (D4) - FUEL PUMP D4 Fuel pump duty (D4) - COMBUSTION D4 Combustion status (D4) - ACC RELAY ACC relay - STARTER RELAY Starter relay - STARTER SIG Starter signal - STARTER CONTROL Starter control - CTP SW Closed throttle position switch - A/C SIGNAL A/C signal - PNP SW (NSW) Neutral position switch signal - ELECT LOAD SIG Electrical load signal - STOP LIGHT SW Stop light switch - ENG OIL PRES SW Engine oil pressure switch signal Always ON while engine is running BATTERY VOLTAGE Battery voltage - ATM PRESSURE Atmospheric pressure - FUEL PMP SP CTL Fuel pump speed control status - VVT CTRL B2 VVT control status (bank 2) - EVAP (Purge) VSV EVAP Purge VSV - A/C MAG CLUTCH A/C magnetic clutch relay - FUEL PUMP/SPD Fuel pump/speed status - VVT CTRL B1 VVT control status (bank 1) - TC/TE1 TC and TE1 terminals of DLC3 - SCV DUTY RATIO SCV duty ratio - VVTL AIM ANGL#1 VVT aim angle (bank 1) - VVT CHNG ANGL#1 VVT change angle (bank 1) - VVT OCV D B1 VVT OCV operation duty (bank 1) - VVT EX HOLD B1 VVT exhaust hold duty ratio learning value (bank 1) - VVT EX CHG ANG1 VVT exhaust change angle (bank 1) - VVT EX OCV D B1 VVT exhaust OCV duty (bank 1) - VVTL AIM ANGL#2 VVT aim angle (bank 2) - VVT CHNG ANGL#2 VVT change angle (bank 2) - VVT OCV DUTY B2 VVT OCV operation duty (bank 2) - VVT EX HOLD B2 VVT exhaust hold duty ratio learning value (bank 2) - VVT EX CHG ANG2 VVT exhaust change angle (bank 2) - VVT EX OCV D B2 VVT exhaust OCV duty (bank 2) - FC IDL Idle fuel cut ON: when throttle valve fully closed and engine speed over 1,500 rpm FC TAU FC TAU Fuel cut being performed under very light load to prevent incomplete engine combustion ES–55 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM LABEL (Intelligent Tester Display) Measurement Item/Range Diagnostic Note IGNITION Ignition - CYL ALL All cylinder misfire rate Displayed only during idling MISFIRE RPM Misfire RPM - CYL ALL All cylinder misfire rate Displayed only during idling MISFIRE RPM Misfire RPM - MISFIRE LOAD Misfired load - MISFIRE MARGIN Misfire monitoring - ENG RUN TIME Accumulated engine running time - TIME DTC CLEAR Cumulative time after DTC cleared - DIST DTC CLEAR Accumulated distance after DTC cleared - WU CYC DTC CLEAR Warm-up cycle after DTC cleared - ES ES–56 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK MODE PROCEDURE HINT: Intelligent tester only: Compared to the normal mode, check mode is more sensitive to malfunctions. Therefore, check mode can detect the malfunctions that cannot be detected in normal mode. NOTICE: All the stored DTCs and freeze frame data are erased if: 1) the ECM is changed from normal mode to check mode or vice versa; or 2) the engine switch is turned from on (IG) to ACC or off while in check mode. Before changing modes, always check and note any DTCs and freeze frame data. 1. Intelligent Tester ES DLC3 C110200E06 0.13 seconds ON OFF 0.13 seconds A076900E04 CHECK MODE PROCEDURE (Using an intelligent tester) (a) Check and ensure the following conditions: (1) Battery positive voltage 11 V or more. (2) Throttle valve fully closed. (3) Transmission in the P or N position. (4) A/C switch OFF. (b) Turn the engine switch off. (c) Connect the intelligent tester to the DLC3. (d) Turn the ignition switch on (IG). (e) Turn the tester on. (f) Enter the following menus: DIAGNOSIS / ENHANCED OBD ll / CHECK MODE. (g) Switch the ECM from normal mode to check mode. (h) Make sure that the MIL flashes as shown in the illustration. (i) Start the engine. (j) Make sure that the MIL turns OFF. (k) Simulate the conditions of the malfunction described by the customer. (l) Check for DTCs and freeze frame data using the tester. ES–57 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM FAIL-SAFE CHART If any of the following DTCs are set, the ECM enters fail-safe mode to allow the vehicle to be driven temporarily. DTCs Components Fail-Safe Operations Fail-Safe Deactivation Conditions P0031, P0032, P0051 and P0052 Air-Fuel Ratio (A/F) Sensor Heater ECM turns off A/F sensor heater Ignition switch off P0037, P0038, P0057 and P0058 Heated Oxygen (HO2) Sensor Heater ECM turns off HO2 sensor heater Ignition switch off P0100, P0102 and P0103 Mass Air Flow (MAF) Meter ECM calculates ignition timing according to engine speed and throttle valve position Pass condition detected P0110, P0112 and P0113 Intake Air Temperature (IAT) Sensor ECM estimates IAT to be 20°C (68°F) Pass condition detected P0115, P0117 and P0118 Engine Coolant Temperature (ECT) Sensor ECM estimates ECT to be 80°C (176°F) Pass condition detected P0120, P0121, P0122, P0123, P0220, P0222, P0223, P0604, P0606, P0607, P0657, P2102, P2103, P2111, P2112, P2118, P2119 and P2135 Electronic Throttle Control System (ETCS) ECM cuts off throttle actuator current and throttle valve returned to 6.5° throttle position by return spring ECM then adjusts engine output by controlling fuel injection (intermittent fuel-cut) and ignition timing in accordance with accelerator pedal opening angle, to allow vehicle to continue at Pass condition detected and then ignition switch turned off minimal speed* P0327, P0328, P0332 and P0333 Knock Sensor ECM sets ignition timing to maximum retard Ignition switch off P0351 to P0356 Igniter ECM cuts fuel Pass condition detected Accelerator Pedal Position (APP) Sensor APP sensor has 2 sensor circuits: Main and Sub If either of circuits malfunctions, ECM controls engine using the other circuit If both of circuits malfunction, ECM regards accelerator pedal as being released. As a result, throttle valve is closed and engine idles Pass condition detected and then ignition switch turned off P2120, P2121, P2122, P2123, P2125, P2127, P2128 and P2138 NOTE: *: The vehicle can be driven slowly when the accelerator pedal is depressed slowly. If the accelerator pedal is depressed quickly, the vehicle may speed up and slow down erratically. ES ES–58 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DATA LIST / ACTIVE TEST 1. ES Intelligent Tester Display DATA LIST HINT: By reading the DATA LIST displayed on an intelligent tester, you can check values, including those of the switches, sensors, and actuators, without removing any parts. Reading the DATA LIST as the first step in troubleshooting is one method of shortening diagnostic time. NOTICE: In the table below, the values listed under Normal Condition are reference only. Do not depend solely on these values when determining whether or not a part is faulty. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester to the DLC3. (d) Turn the ignition switch on (IG). (e) Turn the tester on. (f) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST. (g) Check the values by referring to the table below. Measurement Item: Range (Display) Normal Condition*1 Diagnostic Note INJECTOR Injection period of No. 1 cylinder: Min.: 0 ms, Max.: 32.64 ms 1.2 to 2.4 ms: Idling - IGN ADVANCE Ignition timing advance for No. 1 cylinder: Min.: -64 deg, Max.: 63.5 deg BTDC 7 to 24 deg: Idling - CALC LOAD Load calculated by ECM: Min.: 0%, Max.: 100% VEHICLE LOAD Vehicle load: Min.: 0%, Max.: 25,700% • • 10 to 20%: Idling 10 to 20%: Running without load at 2,500 rpm Load value Load percentage in terms of maximum intake air flow amount Actual vehicle load MAF Air flow rate from MAF meter: Min.: 0 g/sec., Max.: 655.35 g/sec. 2 to 5 g/sec.: Idling 8 to 19 g/sec.: Running without load at 2,500 rpm ENGINE SPD Engine speed: Min.: 0 rpm, Max.: 16,383.75 rpm 600 to 700 rpm: Idling VEHICLE SPD Vehicle speed: Min.: 0 km/h, Max.: 255 km/h Actual vehicle speed COOLANT TEMP Engine coolant temperature: Min.: -40°C, Max.: 140°C 80 to 100°C (176 to 212°F): After warming up INTAKE AIR Intake air temperature: Min.: -40°C, Max.: 140°C Equivalent to ambient air temperature AIR-FUEL RATIO Ratio compared to stoichiometric level: Min.: 0, Max.: 1.999 0.8 to 1.2: Idling PURGE DENSITY Learning value of purge density: Min.: -50, Max.: 350 -40 to 0: Idling If value is approximately 0.0 g/ sec.: • Mass air flow meter power source circuit open • VG circuit open or shorted If value is 160.0 g/sec. or more: • E2G circuit open Speed indicated on speedometer • • • • If value is -40°C (-40°F): sensor circuit open If value is 140°C (284°F) or more: sensor circuit shorted If value is -40°C (-40°F): sensor circuit open If value is 140°C (284°F) or more: sensor circuit shorted - Service data ES–59 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Intelligent Tester Display Measurement Item: Range (Display) Normal Condition*1 Diagnostic Note EVAP PURGE FLOW Ratio of evaporative purge flow to intake air volume: Min.: 0%, Max.: 102.4% 0 to 8%: Idling EVAP PURGE VSV EVAP (PURGE) VSV control duty: Min.: 0%, Max.: 100% 0 to 100%: Idling Command signal from ECM VAPOR PRES PUMP Vapor pressure: Min.: 33.853 kPa, Max.: 125.596 kPa 0 kPa: Fuel tank cap removed EVAP system pressure monitored by canister pressure sensor VAPOR PRES CALC Vapor pressure (calculated): Min.: -5.632 kPa, Max.: 715.264 kPa 0 kPa: Fuel tank cap removed EVAP system pressure monitored by canister pressure sensor KNOCK CRRT VAL Correction learning value of knocking: Min: -64°CA, Max.: 1,984°CA 0 to 22°CA: Driving at 70 km/h (44 mph) Service data KNOCK FB VAL Feedback value of knocking: Min: -64°CA, Max.: 1,984°CA -22 to 0°CA: Driving at 70 km/h (44 mph) Service data CLUTCH Clutch current: Min.: 0 A, Max.: 2.49 A EVAP VAPOR PRES EVAP vapor pressure: Min.: 0 kPa, Max.: 327.675 kPa 0 kPa: Fuel tank cap removed EVAP system pressure monitored by canister pressure sensor ACCEL POS #1 Absolute Accelerator Pedal Position (APP) No. 1: Min.: 0%, Max.: 100% 10 to 22%: Accelerator pedal released 54 to 86%: Accelerator pedal fully depressed Read value with ignition switch ON (Do not start engine) ACCEL POS #2 Absolute APP No. 2: Min.: 0%, Max.: 100% 12 to 42%: Accelerator pedal released 66 to 98%: Accelerator pedal fully depressed Read value with ignition switch ON (Do not start engine) ACCEL POS #1 APP sensor No. 1 voltage: Min.: 0 V, Max.: 4.98 V - ETCS freeze frame data ACCEL POS #2 APP sensor No. 2 voltage: Min.: 0 V, Max.: 4.98 V - ETCS freeze frame data ACCEL POS #1 APP sensor No. 1 voltage: Min.: 0 V, Max.: 5 V 0.5 to 1.1 V: Accelerator pedal released 2.6 to 4.5 V: Accelerator pedal fully depressed Read value with ignition switch ON (Do not start engine) ACCEL POS #2 APP sensor No. 2 voltage: Min.: 0 V, Max.: 5 V 1.2 to 2.0 V: Accelerator pedal released 3.4 to 5.0 V: Accelerator pedal fully depressed Read value with ignition switch ON (Do not start engine) ACCEL IDL POS Whether or not accelerator pedal position sensor detecting idle: ON or OFF ON: Idling - THRTL LEARN VAL Throttle valve fully closed (learned value): Min.: 0 V, Max.: 5 V 0.4 to 0.8 V - ACCEL SSR #1 AD Accelerator fully closed value No. 1 (AD): Min.: 0 V, Max.: 4.98 V - ETCS service data ACCEL LRN VAL#1 Accelerator fully closed learning value No. 1: Min.: 0 deg, Max.: 124.512 deg - ETCS service data ACCEL LRN VAL#2 Accelerator fully closed learning value No. 2: Min.: 0 deg, Max.: 124.512 deg - ETCS service data FAIL #1 Whether or not fail safe function executed: ON or OFF - - ON: ETCS has failed ES - - ES–60 Intelligent Tester Display 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Measurement Item: Range (Display) Normal Condition*1 FAIL #2 Whether or not fail safe function executed: ON or OFF ON: ETCS has failed - ST1 Starter signal: ON or OFF ON: Cranking - SYS GUARD JUDGE System guard: ON or OFF - ETCS service data OPN MALFUNCTION Open side malfunction: ON or OFF - ETCS service data THROTTLE POS Absolute throttle position sensor: Min.: 0%, Max.: 100% THROTTL IDL POS Whether or not throttle position sensor detecting idle: ON or OFF ON: Idling - THRTL REQ POS Throttle requirement position: Min.: 0 V, Max.: 5 V 0.5 to 1.0 V: Idling - THROTTLE POS Throttle position: Min.: 0%, Max.: 100% 0 to 18%: Idling THROTTLE POS #2 Absolute throttle position sensor No. 2: Min.: 0%, Max.: 100% - Calculated value based on VTA2 THROTTLE POS #1 Throttle position sensor No. 1 output voltage: Min.: 0 V, Max.: 4.98 V - ETCS freeze frame data THROTTLE POS #2 Throttle position sensor No. 2 output voltage: Min.: 0 V, Max.: 4.98 V - ETCS freeze frame data THROTTLE POS #1 Throttle position sensor No. 1 output voltage: Min.: 0 V, Max.: 5 V THROTTLE POS #2 Throttle position sensor No. 2 output voltage: Min.: 0 V, Max.: 5 V THRTL COMND VAL Throttle position command value: Min.: 0 V, Max.: 4.9804 V 0.5 to 4.8 V Read value with ignition switch ON (Do not start engine) THROTTLE SSR #1 Throttle sensor opener position No. 1: Min.: 0 V, Max.: 4.9804 V 0.6 to 0.9 V ETCS service data THROTTLE SSR #2 Throttle sensor opener position No. 2: Min.: 0 V, Max.: 4.9804 V 2.2 to 2.6 V ETCS service data THRTL SSR #1 AD Throttle position sensor No. 1 output voltage (AD): Min.: 0 V, Max.: 4.9804 V 0.6 to 0.9 V ETCS service data THROTTLE MOT Whether or not throttle actuator control permitted: ON or OFF ON: Idling Read value with ignition switch ON (Do not start engine) THROTTLE MOT Throttle actuator current: Min.: 0 A, Max.: 80 A 0 to 3.0 A: Idling - THROTTLE MOT Throttle actuator: Min.: 0%, Max.: 100% 0.5 to 40%: Idling - THROTTLE MOT Throttle actuator current: Min.: 0 A, Max.: 19.92 A 0 to 3.0 A: Idling - • ES Diagnostic Note • • • • • 10 to 24%: Throttle fully closed 64 to 96%: Throttle fully open • • Calculated value based on VTA1 Read value with ignition switch ON (Do not start engine) Calculated value based on VTA1 0.5 to 1.2 V: Throttle fully closed 3.2 to 4.8 V: Throttle fully open - 2.0 to 2.9 V: Throttle fully closed 4.6 to 5.0 V: Throttle fully open Read value with ignition switch ON (Do not start engine) ES–61 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Intelligent Tester Display Measurement Item: Range (Display) Normal Condition*1 Diagnostic Note • THROTL OPN DUTY Throttle actuator opening duty ratio: Min.: 0%, Max.: 100% 0 to 40%: Idling • • When accelerator pedal is depressed, duty ratio increaseds Read value with ignition switch ON (Do not start engine) When accelerator pedal is increaseds quickly, duty ratio increaseds Read value with ignition switch ON (Do not start engine) Throttle actuator closed duty ratio: Min.: 0%, Max.: 100% 0 to 40%: Idling THRTL MOT (OPN) Throttle actuator duty ratio (open): Min.: 0%, Max.: 100% - ETCS service data THRTL MOT (CLS) Throttle actuator duty ratio (closed): Min.: 0%, Max.: 100% - ETCS service data O2S B1 S2 Heated oxygen sensor output voltage for bank 1 sensor 2: Min.: 0 V Max.: 1.275 V 0.1 to 0.9 V: Driving at 70 km/h (44 mph) Performing INJ VOL or A/F CONTROL function of ACTIVE TEST enables technician to check output voltage of sensor O2S B2 S2 Heated oxygen sensor output voltage for bank 2 sensor 2: Min.: 0 V Max.: 1.275 V 0.1 to 0.9 V: Driving at 70 km/h (44 mph) Performing INJ VOL or A/F CONTROL function of ACTIVE TEST enables technician to check output voltage of sensor THROTL CLS DUTY • • AF FT B1 S1 Short-term fuel trim associated with sensor 1: Min.: 0, Max.: 1.999 • • • AF FT B2 S1 Short-term fuel trim associated with sensor 1: Min.: 0, Max.: 1.999 • • Value less than 1 (0.000 to 0.999) =Lean Stoichiometric air-fuel ratio=1 Value greater than 1 (1.001 to 1.999) = Rich - Value less than 1 (0.000 to 0.999) =Lean Stoichiometric air-fuel ratio=1 Value greater than 1 (1.001 to 1.999) = Rich - 2.8 to 3.8 V: Idling Performing INJ VOL or A/F CONTROL function of ACTIVE TEST enables technician to check output voltage of sensor AFS B2 S1 A/F sensor output voltage for bank 2 sensor 1: Min.: 0 V Max.: 7.999 V 2.8 to 3.8 V: Idling Performing INJ VOL or A/F CONTROL function of ACTIVE TEST enables technician to check output voltage of sensor TOTAL FT #1 Total fuel trim of bank 1 Average value for fuel system of bank 1: Min.: -0.5, Max.: 0.496 -0.2 to 0.2: Idling - TOTAL FT #2 Total fuel trim of bank 2 Average value for fuel system of bank 2: Min.: -0.5, Max.: 0.496 -0.2 to 0.2: Idling - SHORT FT #1 Short-term fuel trim of bank 1: Min.: -100%, Max.: 99.2% -20 to 20% Short-term fuel compensation used to maintain air-fuel ratio at stoichiometric air-fuel ratio SHORT FT #2 Short-term fuel trim of bank 2: Min.: -100%, Max.: 99.2% -20 to 20% Short-term fuel compensation used to maintain air-fuel ratio at stoichiometric air-fuel ratio LONG FT #1 Long-term fuel trim of bank 1: Min.: -100%, Max.: 99.2% -20 to 20% Overall fuel compensation carried out in long-term to compensate for continual deviation of short-term fuel trim from central value AFS B1 S1 A/F sensor output voltage for bank 1 sensor 1: Min.: 0 V Max.: 7.999 V ES ES–62 Intelligent Tester Display LONG FT #2 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Measurement Item: Range (Display) Long-term fuel trim of bank 2: Min.: -100%, Max.: 99.2% Normal Condition*1 Diagnostic Note Overall fuel compensation carried out in long-term to compensate for continual deviation of short-term fuel trim from central value -20 to 20% • • FUEL SYS #1 Fuel system status (Bank 1): OL or CL or OL DRIVE or OL FAULT or CL FAULT CL: Idling after warming up • • • ES • • FUEL SYS #2 Fuel system status (Bank 2): OL or CL or OL DRIVE or OL FAULT or CL FAULT CL: Idling after warming up • • • OL (Open Loop): Has not yet satisfied conditions to go closed loop CL (Closed Loop): Using A/F sensor as feedback for fuel control OL DRIVE: Open loop due to driving conditions (fuel enrichment) OL FAULT: Open loop due to detected system fault CL FAULT: Closed loop but A/ F sensor, which used for fuel control malfunctioning OL (Open Loop): Has not yet satisfied conditions to go closed loop CL (Closed Loop): Using A/F sensor as feedback for fuel control OL DRIVE: Open loop due to driving conditions (fuel enrichment) OL FAULT: Open loop due to detected system fault CL FAULT: Closed loop but A/ F sensor, which used for fuel control, malfunctioning O2FT B1 S2 Short-term fuel trim associated with bank 1 sensor 2: Min.: -100%, Max.: 99.2% -20 to 20% Same as SHORT FT #1 O2FT B2 S2 Short-term fuel trim associated with bank 2 sensor 2: Min.: -100%, Max.: 99.2% -20 to 20% Same as SHORT FT #2 AF FT B1 S1 Short-term fuel trim associated with bank 1 sensor 1: Min.: 0, Max.: 1.999 • • • • AF FT B2 S1 Short-term fuel trim associated with bank 2 sensor 1: Min.: 0, Max.: 1.999 • • Value less than 1 (0.000 to 0.999) = Lean Stoichiometric air-fuel ratio =1 Value greater than 1 (1.001 to 1.999) = Rich - Value less than 1 (0.000 to 0.999) = Lean Stoichiometric air-fuel ratio =1 Value greater than 1 (1.001 to 1.999) = Rich - AFS B1 S1 A/F sensor current: Min.: -128 mA, Max.: 127.99 mA - - AFS B2 S1 A/F sensor current: Min.: -128 mA, Max.: 127.99 mA - - CAT TEMP B1S1 Estimated catalyst temperature (bank 1 sensor 1): Min.: -40°C, Max.: 6,513.5°C - - CAT TEMP B1S2 Estimated catalyst temperature (bank 1 sensor 2): Min.: -40°C, Max.: 6,513.5°C - - CAT TEMP B2S1 Estimated catalyst temperature (bank 2 sensor 1): Min.: -40°C, Max.: 6,513.5°C - - ES–63 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Intelligent Tester Display Measurement Item: Range (Display) Normal Condition*1 Diagnostic Note CAT TEMP B2S2 Estimated catalyst temperature (bank 2 sensor 2): Min.: -40°C, Max.: 6,513.5°C - - S O2S B1S2 Sub heated oxygen sensor impedance (bank 1 sensor 2): Min.: 0 Ω, Max.: 21,247.68 Ω - - S O2S B2S2 Sub heated oxygen sensor impedance (bank 2 sensor 2): Min.: 0 Ω, Max.: 21,247.68 Ω - - INI COOL TEMP Engine coolant temperature at engine start: Min.: -40°C, Max.: 120°C Close to ambient air temperature - INI INTAKE TEMP Intake air temperature at engine start: Min.: -40°C, Max.: 120°C Close to ambient air temperature - INJ VOL Injection volume (cylinder 1): Min.: 0 ml, Max.: 2.048 ml Max.: 0.5 ml STARTER SIG Starter signal: ON or OFF ON: Cranking - PS SW Power steering signal: ON or OFF ON: Power steering operation - PS SIGNAL Power steering signal (history): ON or OFF ON: When steering wheel is first turned after battery terminals connected CTP SW Closed throttle position switch: ON or OFF • • A/C SIGNAL A/C signal: ON or OFF ON: A/C ON - PNP SW [NSW] PNP switch status: ON or OFF ON: P or N position - ELECT LOAD SIG Electrical load signal: ON or OFF ON: Headlights or defogger turned ON - STOP LIGHT SW Stop light switch: ON or OFF ON: Brake pedal depressed - +BM Whether or not electric throttle control system power input: ON or OFF ON: Idling - +BM VOLTAGE +BM voltage: Min.: 0, Max.: 19.922 10 to 15 V: Idling BATTERY VOLTAGE Battery voltage: Min.: 0 V, Max.: 65.535 V 9 to 14 V: Idling ACTUATOR POWER Actuator power supply: ON or OFF ON: Idling ATM PRESSURE Atmospheric pressure: Min.: 0 kPa, Max.: 255 kPa Equivalent to atmospheric pressure (absolute pressure) BATTERY CURRENT Battery current: Min.: -100 A, Max.: 100 A - - BATTERY TEMP Battery temperature: Min.: -45 °C, Max.: 156.4 °C - - ALT OUTPUT DUTY Generator output duty ratio: Min.: 0%, Max.: 100% - ALT V NORMAL Request output voltage: Min.: 0 V, Max.: 20 V 9 to 14 V ALT V ACT TST Request output voltage: Min.: 0 V, Max.: 20 V - FUEL PMP SP CTL Fuel pump speed control status: ON or OFF Fuel volume injected over 10 injections ON: Throttle fully closed OFF: Throttle open Signal status usually ON until battery terminals disconnected - ETCS service data ETCS service data Idling: ON - During charge control Not during alternator forced activation During alternator forced activation Active Test support data ES ES–64 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Intelligent Tester Display ES Measurement Item: Range (Display) Normal Condition*1 Diagnostic Note ACIS VSV VSV for Acoustic Control Induction System Status: ON or OFF - ON: Open OFF: Closed EVAP (Purge) VSV Purge VSV status: ON or OFF - Active Test support data FUEL PUMP / SPD Fuel pump status: ON or OFF - Active Test support data VVT CTRL B1 VVT control (bank 1) status: ON or OFF - Active Test support data VVT CTRL B2 VVT control (bank 2) status: ON or OFF - Active Test support data VACUUM PUMP Key-off EVAP system leak detection pump status: ON or OFF - Active Test support data EVAP VENT VAL Key-off EVAP system vent valve status: ON or OFF - Active Test support data FAN MOTOR Electric fan motor: ON or OFF ON: Electric fan motor operating Active Test support data AICV VSV VSV for Air Intake Control System Status: ON or OFF - TC/TE1 TC and CG (TE1) terminal of DLC3: ON or OFF - VVTL AIM ANGL#1*2 VVT aim angle (bank 1 Intake side): Min.: 0%, Max.: 100% - VVT CHNG ANGL#1*2 VVT change angle (bank 1 Intake side): Min.: 0°FR, Max.: 60°FR 0 to 5°FR: Idling Displacement angle during intrusive operation VVT OCV DUTY B1*2 VVT OCV operation duty (bank 1 Intake side): Min.: 0%, Max.: 100% 0 to 100% Requested duty value for intrusive operation VVT exhaust hold duty ratio learning value (bank 1 Exhaust side): Min.: 0%, Max.: 100% 10 to 50%: Idling Requested duty value for intrusive operation VVT EX CHG ANG1*2 VVT change angle (bank 1 Exhaust side): Min.: 0° FR, Max.: 60° FR 0 to 5° FR: Idling Displacement angle during intrusive operation VVT EX OCV D B1*2 VVT OCV operation duty (bank 1 Exhaust side): Min.: 0%, Max.: 100% 0 to 100% Requested duty value for intrusive operation VVTL AIM ANGL #2*2 VVT aim angle (bank 2 Intake side): Min.: 0%, Max.: 100% VVT CHNG ANGL #2*2 VVT change angle (bank 2 Intake side): Min.: 0° FR, Max.: 60° FR 0 to 5° FR: Idling Displacement angle during intrusive operation VVT OCV DUTY B2*2 VVT OCV operation duty (bank 2 Intake side): Min.: 0%, Max.: 100% 0 to 100% Requested duty value for intrusive operation VVT exhaust hold duty ratio learning value (bank 2 Exhaust side): Min.: 0%, Max.: 100% 10 to 50%: Idling Requested duty value for intrusive operation VVT change angle (bank 2 Exhaust side): Min.: 0° FR, Max.: 60° FR 0 to 5° FR: Idling Displacement angle during intrusive operation VVT EX HOLD VVT EX HOLD B1*2 B2*2 VVT EX CHG ANG2*2 - - Active Test support data - - ES–65 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Intelligent Tester Display Measurement Item: Range (Display) Normal Condition*1 Diagnostic Note VVT EX OCV D B2*2 VVT exhaust operation duty (bank 2 Exhaust side): Min.: 0%, Max.: 100% 0 to 100% Requested duty value for intrusive operation FC IDL Fuel cut idle: ON or OFF ON: Fuel cut operation FC IDL = "ON" when throttle valve fully closed and engine speed over 2,800 rpm FC TAU Fuel cut TAU (Fuel cut with very light load): ON or OFF ON: Fuel cut operating Fuel cut being performed with very light load to prevent incomplete engine combustion IGNITION Ignition counter: Min.: 0, Max.: 800 0 to 800 CYL #1 Misfire ratio of cylinder 1: Min.: 0, Max.: 255 0 This item displayed only during idling CYL #2 Misfire ratio of cylinder 2: Min.: 0, Max.: 255 0 This item displayed only during idling CYL #3 Misfire ratio of cylinder 3: Min.: 0, Max.: 255 0 This item displayed only during idling CYL #4 Misfire ratio of cylinder 4: Min.: 0, Max.: 255 0 This item displayed only during idling CYL #5 Misfire ratio of cylinder 5: Min.: 0, Max.: 255 0 This item displayed only during idling CYL #6 Misfire ratio of cylinder 6: Min.: 0, Max.: 255 0 This item displayed only during idling CYL ALL All cylinders misfire rate: Min.: 0, Max.: 255 0 to 35 - MISFIRE RPM Engine RPM for first misfire range: Min.: 0 rpm, Max.: 6,375 rpm 0 rpm: Misfire 0 - MISFIRE LOAD Engine load for first misfire range: Min.: 0 g/rev, Max.: 3.98 g/rev MISFIRE MARGIN Misfire monitoring: Min.: -100%, Max.: 99.22% #CODES #Codes: Min.: 0, Max.: 255 CHECK MODE Check mode: ON or OFF SPD TEST Check mode result for vehicle speed sensor: COMPL or INCMPL - - MISFIRE TEST Check mode result for misfire monitor: COMPL or INCMPL - - OXS1 TEST Check mode result for HO2 sensor (bank 1): COMPL or INCMPL - - OXS2 TEST Check mode result for HO2 sensor (bank 2): COMPL or INCMPL - - A/F SSR TEST B1 Check mode result for air-fuel ratio sensor (bank 1): COMPL or INCMPL - - A/F SSR TEST B2 Check mode result for air-fuel ratio sensor (bank 2): COMPL or INCMPL - - MIL MIL status: ON or OFF ON: MIL ON - MIL ON RUN DIST MIL ON run distance: Min.: 0 km, Max.: 65,535 km Distance driven after DTC detected - - 0 g/rev: Misfire 0 -100 to 99.22% Misfire detecting margin ON: Check mode ON Number of detected DTCs (see page ES-49) ES ES–66 Intelligent Tester Display ES 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Measurement Item: Range (Display) Normal Condition*1 Diagnostic Note MIL ON RUN TIME Running time from MIL ON: Min.: 0 minutes, Max.: 65,535 minutes Running time after MIL ON - ENG RUN TIME Engine run time: Min.: 0 seconds, Max.: 65,535 seconds Time after engine start - TIME DTC CLEAR Time after DTC cleared: Min.: 0 minutes, Max.: 65,535 minutes Time after DTCs erased - DIST DTC CLEAR Distance after DTC cleared: Min.: 0 km, Max.: 65,535 km Distance driven after DTCs erased - WU CYC DTC CLEAR Warm-up cycle after DTC cleared: Min.: 0, Max.: 255 OBD CERT OBD requirement #CARB CODES Number of emission related DTCs - - COMP MON Comprehensive component monitor: NOT AVL or AVAIL - - FUEL MON Fuel system monitor: NOT AVL or AVAIL - - MISFIRE MON Misfire monitor: NOT AVL or AVAIL - - O2S (A/FS) HTR O2S (A/FS) heater monitor: NOT AVL or AVAIL - - O2S (A/FS) HTR O2S (A/FS) heater monitor: COMPL or INCMPL - - O2S (A/FS) MON O2S (A/FS) monitor: NOT AVL or AVAIL - - O2S (A/FS) MON O2S (A/FS) monitor: COMPL or INCMPL - - EVAP MON EVAP monitor: NOT AVL or AVAIL - - EVAP MON EVAP monitor: COMPL or INCMPL - - CAT MON Catalyst monitor: NOT AVL or AVAIL - - CAT MON Catalyst monitor: COMPL or INCMPL - - CCM ENA Comprehensive component monitor: UNABLE or ENABLE - - CCM CMPL Comprehensive component monitor: COMPL or INCMPL - - FUEL ENA Fuel system monitor: UNABLE or ENABLE - - FUEL CMPL Fuel system monitor: COMPL or INCMPL - - MISFIRE ENA Misfire monitor: UNABLE or ENABLE - - MISFIRE CMPL Misfire monitor: COMPL or INCMPL - - EGR ENA EGR monitor: UNABLE or ENABLE - - EGR CMPL EGR monitor: COMPL or INCMPL - - HTR ENA O2S (A/FS) heater monitor: UNABLE or ENABLE - - OBD2 Number of warm-up cycles after DTC cleared - ES–67 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Intelligent Tester Display Measurement Item: Range (Display) Normal Condition*1 Diagnostic Note HTR CMPL O2S (A/FS) heater monitor: COMPL or INCMPL - - O2S (A/FS) ENA O2S (A/FS) monitor: UNABLE or ENABLE - - O2S (A/FS) CMPL O2S (A/FS) monitor: COMPL or INCMPL - - ACRF ENA A/C monitor: UNABLE or ENABLE - - ACRF CMPL A/C monitor: COMPL or INCMPL - - AIR ENA 2nd Air monitor: UNABLE or ENABLE - - AIR CMPL 2nd Air monitor: COMPL or INCMPL - - EVAP ENA EVAP monitor: UNABLE or ENABLE - - EVAP CMPL EVAP monitor: COMPL or INCMPL - - HCAT ENA Heated catalyst monitor: UNABLE or ENABLE - - HCAT CMPL Heated catalyst monitor: COMPL or INCMPL - - CAT ENA Catalyst monitor: UNABLE or ENABLE - - CAT CMPL Catalyst monitor: COMPL or INCMPL - - MODEL CODE Model code information - Identifying model code: GSA3# ENGINE TYPE Engine type information - Identifying engine type: 2GRFE CYLINDER NUMBER Cylinder number: Min.: 0, Max.: 255 - Identifying cylinder number: 6 TRANSMISSION Transmission type information - Identifying transmission type: 5AT DESTINATION Destination information - Identifying destination: A (America) MODEL YEAR Model year: Min.: 1900, Max.: 2155 - Identifying model year: 200# SYSTEM Engine system information - Identifying engine system: GASLIN (gasoline engine) HINT: • *1: If no idling conditions are specified, the transmission gear selector lever should be in the N or P position, and the A/C switch and all accessory switches should be OFF. • *2: DATA LIST values are displayed only when performing the following ACTIVE TESTs: VVT B1, VVT B2, VVT EX B1 and VVT EX B2. For other ACTIVE TESTs, the DATA LIST value will be 0. ES ES–68 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2. ES Intelligent Tester Displays ACTIVE TEST HINT: Performing an ACTIVE TEST enables components including the relays, VSV (Vacuum Switching Valve) and actuators, to be operated without removing any parts. The ACTIVE TEST can be performed with an intelligent tester. Performing an ACTIVE TEST as the first step in troubleshooting is one method of shortening diagnostic time. DATA LIST can be displayed during ACTIVE TEST. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Turn the tester on. (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST. (e) Perform the ACTIVE TEST by referring to the table below. Test Details Control Ranges Diagnostic Note • • INJ VOL Change injection volume Between -12.5 and 24.8 % • • • All injectors tested at the same time Perform test at less than 3,000 rpm Injection volume can be changed in 1 % graduations within control range Perform test at less than 3,000 rpm A/F CONTROL enables to check and to graph A/F (Air Fuel Ratio) sensor and Heated Oxygen (HO2) sensor voltage outputs To conduct test, select following menu items: ACTIVE TEST / A/F CONTROL / USER DATA / AFS B1S1 and O2S B1S2, and press YES and ENTER followed by F4 Change injection volume Lower by 12.5 % or increase by 24.8 % FUEL PMP SP CTL Fuel pump speed control ON (low speed)/OFF (high speed) Test is possible when following conditions are met: • Ignition switch is on (IG) • Engine is stopped EVAP (PURGE) VSV Activate VSV for EVAP (Purge) ON/OFF - EVAP VSV (ALONE) Activate EVAP VSV control ON/OFF A/F CONTROL • • VVT CTRL B1 Turn on and off OCV (Oil Control Valve) VVT CTRL B2 Turn on and off OCV (Oil Control Valve) ON/OFF A/C MAG CLUTCH Control the A/C magnet clutch ON/OFF - FUEL PUMP / SPD Activate fuel pump (C/OPN Relay) ON/OFF - TC/TE1 Turn on and off TC and TE1 connection ON/OFF • • FC IDL PROHBT Prohibit idling fuel cut control ON/OFF - ON/OFF • • • Engine stalls or idles roughly when OCV turned ON Normal engine running or idling when OCV OFF Engine stalls or idles roughly when OCV turned ON Normal engine running or idling when OCV OFF ON: TC and TE1 connected OFF: TC and TE1 disconnected ES–69 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Intelligent Tester Displays COOLING FAN Test Details Control Electric Cooling Fan Control Ranges Diagnostic Note ON/OFF Test is possible when following conditions are met: • Ignition switch is on (IG) • Ignition is stopped ACC CUT Active ACC cut relay ON/OFF Test is possible when following conditions are met: • Ignition switch is on (IG) • Ignition is stopped STARTER Starter ON/OFF - ETCS OPEN SLOW Throttle actuator ON: Throttle valve opens slowly Test is possible when following conditions are met: • Ignition switch is on (IG) • Ignition is stopped • Accelerator pedal is fully depressed (APP: 58 degrees or more) ETCS CLOSE SLOW Throttle actuator ON: Throttle valve closes slowly Same as above ETCS OPEN FAST Throttle actuator ON: Throttle valve opens fast Same as above ETCS CLOSE FAST Throttle actuator ON: Throttle valve closes fast Same as above FUEL CUT #1 Cylinder #1 injector fuel cut ON/OFF Test is possible during vehicle stopping and engine idling. FUEL CUT #2 Cylinder #2 injector fuel cut ON/OFF Same as above FUEL CUT #3 Cylinder #3 injector fuel cut ON/OFF Same as above FUEL CUT #4 Cylinder #4 injector fuel cut ON/OFF Same as above FUEL CUT #5 Cylinder #5 injector fuel cut ON/OFF Same as above FUEL CUT #6 Cylinder #6 injector fuel cut ON/OFF Same as above COMPRESS CHECK Check the cylinder compression pressure ON/OFF Fuel injection and ignition stop in all cylinders. VVT B1 Control VVT (bank 1) -128 to 127 % This valve added to present OCV control duty 100 %: Maximum advance -100 %: Maximum retard Engine stalls or roughly idles when VVT actuator is operated by 100 %. Test is possible during idling. VVT B2 Control VVT (bank 2) Between -128 and 127% Same as above VVT EX B1 Control VVT (bank 1) -128 to 127 % This valve added to present OCV control duty 100 %: Maximum advance -100 %: Maximum retard - VVT EX B2 Control VVT (bank 2) Between -128 and 127 % Same as above TARGET FUEL PRS Control the target fuel pressure Between -12.5 and 24.8 % Test is possible during vehicle stopping and engine idling. INJ TIMING #1 Control injection timing #1 Between -16 CA and 16 CA Test is possible during vehicle stopping and engine idling. INJ TIMING #2 Control injection timing #2 Between -16 CA and 16 CA Same as above INJ TIMING #3 Control injection timing #3 Between -16 CA and 16 CA Same as above INJ TIMING #4 Control injection timing #4 Between -16 CA and 16 CA Same as above INJ TIMING #5 Control injection timing #5 Between -16 CA and 16 CA Same as above INJ TIMING #6 Control injection timing #6 Between -16 CA and 16 CA Same as above VACUUM PUMP Vacuum pump ON/OFF - VENT VALVE Vent valve ON/OFF - ES ES–70 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 3. ES Intelligent Tester Display SYSTEM CHECK HINT: Performing a SYSTEM CHECK enables the system, which consists of multiple actuators, to be operated without removing any parts. In addition, it can show whether or not any DTCs are set, and can detect potential malfunctions in the system. The SYSTEM CHECK can be performed with an intelligent tester. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Turn the tester on. (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK. (e) Perform the SYSTEM CHECK by referring to the table below. Test Detail Recommended Fuel Temperature Diagnostic Note • EVAP SYS CHECK (AUTO OPERATION) Perform 4 steps in order to operate EVAP key-off monitor automatically EVAP SYS CHECK (MANUAL OPERATION) Perform 4 steps in order to operate EVAP key-off monitor automatically 35°C (95°F) or less • • 35°C (95°F) or less • If no DTCs are in PENDING CODE after performing this test, system is functioning normally Refer to EVAP system Used to detect malfunctioning parts Refer to EVAP system 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–71 DIAGNOSTIC TROUBLE CODE CHART HINT: The parameters listed in the chart may not conform exactly to those read during the DTC check due to the type of instrument or other factors. If a trouble code is displayed during the DTC check in the check mode, check the circuit for the code listed in the table below. For details of each code, refer to the "See page" column in the DTC chart. SFI SYSTEM: DTC No. Detection Item Suspected Trouble Area MIL Memory Camshaft Position "A" Actuator Circuit (Bank 1) 1. Open or short in Oil Control Valve (OCV) for intake camshaft circuit 2. OCV for intake camshaft (bank 1) 3. ECM Comes on P0011 Camshaft Position "A" - Timing OverAdvanced or System Performance (Bank 1) 1. Valve timing 2. OCV for intake camshaft 3. OCV filter 4. Intake camshaft timing gear assembly 5. ECM Comes on DTC stored ES-84 P0012 Camshaft Position "A" - Timing OverRetarded (Bank 1) Same as DTC P0011 Comes on DTC stored ES-84 P0013 Camshaft Position "B" Actuator Circuit / Open (Bank 1) 1. Open or short in Oil Control Valve (OCV) for exhaust camshaft circuit 2. OCV for exhaust camshaft (bank 1) 3. ECM Comes on DTC stored ES-91 P0014 Camshaft Position "B" - Timing OverAdvanced or System Performance (Bank 1) 1. Valve timing 2. OCV for exhaust camshaft 3. OCV filter 4. Exhaust camshaft 5. ECM Comes on DTC stored ES-96 P0015 Camshaft Position "B" - Timing OverRetarded (Bank 1) Same as DTC P0014 Comes on DTC stored ES-96 P0016 Crankshaft Position Camshaft Position Correlation (Bank 1 Sensor A) 1. Mechanical system (Timing chain has jumped teeth or chain is stretched) 2. ECM Comes on DTC stored ES-104 P0017 Crankshaft Position Camshaft Position Correlation (Bank 1 Sensor B) Same as DTC P0016 Comes on DTC stored ES-104 P0018 Crankshaft Position Camshaft Position Correlation (Bank 2 Sensor A) Same as DTC P0016 Comes on DTC stored ES-104 P0019 Crankshaft Position Camshaft Position Correlation (Bank 2 Sensor B) Same as DTC P0016 Comes on DTC stored ES-104 P0010 DTC stored See page ES-79 ES ES–72 DTC No. ES 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Detection Item Suspected Trouble Area MIL Memory See page P0020 Camshaft Position "A" Actuator Circuit (Bank 2) 1. Open or short in Oil Control Valve (OCV) for intake camshaft circuit 2. OCV for intake camshaft (bank 2) 3. ECM Comes on DTC stored ES-79 P0021 Camshaft Position "A" - Timing OverAdvanced or System Performance (Bank 2) Same as DTC P0011 Comes on DTC stored ES-84 P0022 Camshaft Position "A" - Timing OverRetarded (Bank 2) Same as DTC P0011 Comes on DTC stored ES-84 P0023 Camshaft Position "B" Actuator Circuit / Open (Bank 2) 1. Open or short in Oil Control Valve (OCV) for exhaust camshaft circuit 2. OCV for exhaust camshaft (bank 2) 3. ECM Comes on DTC stored ES-91 P0024 Camshaft Position "B" - Timing OverAdvanced or System Performance (Bank 2) Same as DTC P0014 Comes on DTC stored ES-96 P0025 Camshaft Position "B" - Timing OverRetarded (Bank 2) Same as DTC P0014 Comes on DTC stored ES-96 P0031 Oxygen (A/F) Sensor Heater Control Circuit Low (Bank 1 Sensor 1) 1. Open in Air-Fuel Ratio (A/F) sensor heater circuit 2. A/F sensor heater (bank 1 sensor 1) 3. A/F sensor heater relay 4. ECM Comes on DTC stored ES-107 P0032 Oxygen (A/F) Sensor Heater Control Circuit High (Bank 1 Sensor 1) 1. Short in A/F sensor heater circuit 2. A/F sensor heater (bank 1 sensor 1) 3. A/F sensor heater relay 4. ECM Comes on DTC stored ES-107 P0037 Oxygen Sensor Heater Control Circuit Low (Bank 1 Sensor 2) 1. Open in Heated Oxygen (HO2) sensor heater circuit 2. HO2 sensor heater (bank 1 sensor 2) 3. Engine room junction block (EFI relay) 4. ECM Comes on DTC stored ES-115 P0038 Oxygen Sensor Heater Control Circuit High (Bank 1 Sensor 2) 1. Short in HO2 sensor heater circuit 2. HO2 sensor heater (bank 1 sensor 2) 3. Engine room junction block (EFI relay) 4. ECM Comes on DTC stored ES-115 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MIL Memory ES–73 DTC No. Detection Item Suspected Trouble Area See page P0051 Oxygen (A/F) Sensor Heater Control Circuit Low (Bank 2 Sensor 1) 1. Open in A/F sensor heater circuit 2. A/F sensor heater (bank 2 sensor 1) 3. A/F sensor heater relay 4. ECM Comes on DTC stored ES-107 P0052 Oxygen (A/F) Sensor Heater Control Circuit High (Bank 2 Sensor 1) 1. Short in A/F sensor heater circuit 2. A/F sensor heater (bank 2 sensor 1) 3. A/F sensor heater relay 4. ECM Comes on DTC stored ES-107 P0057 Oxygen Sensor Heater Control Circuit Low (Bank 2 Sensor 2) 1. Open in HO2 sensor heater circuit 2. HO2 sensor heater (bank 2 sensor 2) 3. Engine room junction block (EFI relay) 4. ECM Comes on DTC stored ES-115 P0058 Oxygen Sensor Heater Control Circuit High (Bank 2 Sensor 2) 1. Short in HO2 sensor heater circuit 2. HO2 sensor heater (bank 2 sensor 2) 3. Engine room junction block (EFI relay) 4. ECM Comes on DTC stored ES-115 P0100 Mass or Volume Air Flow Circuit 1. Open or short in Mass Air Flow (MAF) meter circuit 2. MAF meter 3. ECM Comes on DTC stored ES-125 P0101 Mass Air Flow Circuit Range / Performance Problem MAF meter Comes on DTC stored ES-133 P0102 Mass or Volume Air Flow Circuit Low Input 1. Open in MAF meter circuit 2. Short in MAF meter circuit 3. MAF meter 4. ECM Comes on DTC stored ES-125 P0103 Mass or Volume Air Flow Circuit High Input 1. Short in MAF meter circuit (+B circuit) 2. MAF meter 3. ECM Comes on DTC stored ES-125 P0110 Intake Air Temperature Circuit Malfunction 1. Open or short in Intake Air Temperature (IAT) sensor circuit 2. IAT sensor (built into Mass Air Flow [MAF] meter) 3. ECM Comes on DTC stored ES-136 P0111 Intake Air Temperature Sensor Gradient Too High MAF meter Comes on DTC stored ES-142 ES ES–74 DTC No. ES 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Detection Item Suspected Trouble Area MIL Memory See page P0112 Intake Air Temperature Circuit Low Input 1. Short in IAT sensor circuit 2. IAT sensor (built into MAF meter) 3. ECM Comes on DTC stored ES-136 P0113 Intake Air Temperature Circuit High Input 1. Open in IAT sensor circuit 2. IAT sensor (built into MAF meter) 3. ECM Comes on DTC stored ES-136 P0115 Engine Coolant Temperature Circuit Malfunction 1. Open or short in Engine Coolant Temperature (ECT) sensor circuit 2. ECT sensor 3. ECM Comes on DTC stored ES-145 P0116 Engine Coolant Temperature Circuit Range / Performance Problem 1. Thermostat 2. ECT sensor Comes on DTC stored ES-151 P0117 Engine Coolant Temperature Circuit Low Input 1. Short in ECT sensor circuit 2. ECT sensor 3. ECM Comes on DTC stored ES-145 P0118 Engine Coolant Temperature Circuit High Input 1. Open in ECT sensor circuit 2. ECT sensor 3. ECM Comes on DTC stored ES-145 P0120 Throttle / Pedal Position Sensor / Switch "A" Circuit Malfunction 1. Throttle Position (TP) sensor (built into throttle body) 2. ECM Comes on DTC stored ES-154 P0121 Throttle / Pedal Position Sensor / Switch "A" Circuit Range / Performance Problem TP sensor (built into throttle body) Comes on DTC stored ES-161 P0122 Throttle / Pedal Position Sensor / Switch "A" Circuit Low Input 1. TP sensor (built into throttle body) 2. Short in VTA1 circuit 3. Open in VC circuit 4. ECM Comes on DTC stored ES-154 P0123 Throttle / Pedal Position Sensor / Switch "A" Circuit High Input 1. TP sensor (built into throttle body) 2. Open in VTA1 circuit 3. Open in E2 circuit 4. Short between VC and VTA1 circuits 5. ECM Comes on DTC stored ES-154 P0125 Insufficient Coolant Temperature for Closed Loop Fuel Control 1. Cooling system 2. ECT sensor 3. Thermostat Comes on DTC stored ES-165 P0128 Coolant Thermostat (Coolant Temperature Below Thermostat Regulating Temperature) 1. Thermostat 2. Cooling system 3. ECT sensor 4. ECM Comes on DTC stored ES-168 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. MIL Memory ES–75 Detection Item Suspected Trouble Area See page P0136 Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 2) 1. Open or short in HO2 sensor (bank 1 sensor 2) circuit 2. HO2 sensor (bank 1 sensor 2) 3. HO2 sensor heater (bank 1 sensor 2) 4. A/F sensor (bank 1 sensor 1) 5. Engine room junction block (EFI relay) 6. Gas leakage from exhaust system Comes on DTC stored ES-171 P0137 Oxygen Sensor Circuit Low Voltage (Bank 1 Sensor 2) 1. Open in HO2 sensor (bank 1 sensor 2) circuit 2. HO2 sensor (bank 1 sensor 2) 3. HO2 sensor heater (bank 1 sensor 2) 4. Engine room junction block (EFI relay) 5. Gas leakage from exhaust system Comes on DTC stored ES-171 P0138 Oxygen Sensor Circuit High Voltage (Bank 1 Sensor 2) 1. Short in HO2 sensor (bank 1 sensor 2) circuit 2. HO2 sensor (bank 1 sensor 2) 3. ECM internal circuit malfunction Comes on DTC stored ES-171 P0141 Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 2) 1. HO2 sensor 2. ECM Comes on DTC stored ES-115 P0156 Oxygen Sensor Circuit Malfunction (Bank 2 Sensor 2) 1. Open or short in HO2 sensor (bank 2 sensor 2) circuit 2. HO2 sensor (bank 2 sensor 2) 3. HO2 sensor heater (bank 2 sensor 2) 4. A/F sensor (bank 2 sensor 1) 5. Engine room junction block (EFI relay) 6. Gas leakage from exhaust system Comes on DTC stored ES-171 P0157 Oxygen Sensor Circuit Low Voltage (Bank 2 Sensor 2) 1. Open in HO2 sensor (bank 2 sensor 2) circuit 2. HO2 sensor (bank 2 sensor 2) 3. HO2 sensor heater (bank 2 sensor 2) 4. Engine room junction block (EFI relay) 5. Gas leakage from exhaust system Comes on DTC stored ES-171 ES ES–76 DTC No. 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Detection Item Suspected Trouble Area MIL Memory See page P0158 Oxygen Sensor Circuit High Voltage (Bank 2 Sensor 2) 1. Short in HO2 sensor (bank 2 sensor 2) circuit 2. HO2 sensor (bank 2 sensor 2) 3. ECM internal circuit malfunction Comes on DTC stored ES-171 P0161 Oxygen Sensor Heater Circuit Malfunction (Bank 2 Sensor 2) 1. HO2 sensor 2. ECM Comes on DTC stored ES-115 P0171 System Too Lean (Bank 1) 1. Air induction system 2. Injector blockage 3. MAF meter 4. ECT sensor 5. Fuel pressure 6. Gas leakage from exhaust system 7. Open or short in A/ F sensor (bank 1 sensor 1) circuit 8. A/F sensor (bank 1 sensor 1) 9. A/F sensor heater (bank 1 sensor 1) 10. A/F sensor heater relay 11. A/F sensor heater and A/F sensor heater relay circuits 12. PCV hose connections 13. PCV valve and hose 14. ECM Comes on DTC stored ES-191 P0172 System Too Rich (Bank 1) 1. Injector leakage or blockage 2. MAF meter 3. ECT sensor 4. Ignition system 5. Fuel pressure 6. Gas leakage from exhaust system 7. Open or short in A/ F sensor (bank 1 sensor 1) circuit 8. A/F sensor (bank 1 sensor 1) 9. A/F sensor heater (bank 1 sensor 1) 10. A/F sensor heater relay 11. A/F sensor heater and A/F sensor heater relay circuits 12. ECM Comes on DTC stored ES-191 ES 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. P0174 Detection Item System Too Lean (Bank 2) Suspected Trouble Area MIL 1. Air induction system 2. Injector blockage 3. MAF meter 4. ECT sensor 5. Fuel pressure 6. Gas leakage from exhaust system 7. Open or short in A/ F sensor (bank 2 sensor 1) circuit 8. A/F sensor (bank 2 sensor 1) 9. A/F sensor heater (bank 2 sensor 1) 10. A/F sensor heater relay 11. A/F sensor heater and A/F sensor heater relay circuits 12. PCV hose connections 13. PCV valve and hose 14. ECM Comes on Memory DTC stored ES–77 See page ES-191 ES P0175 System Too Rich (Bank 2) 1. Injector leakage or blockage 2. MAF meter 3. ECT sensor 4. Ignition system 5. Fuel pressure 6. Gas leakage from exhaust system 7. Open or short in A/ F sensor (bank 2 sensor 1) circuit 8. A/F sensor (bank 2 sensor 1) 9. A/F sensor heater (bank 2 sensor 1) 10. A/F sensor heater relay 11. A/F sensor heater and A/F sensor heater relay circuits 12. ECM Comes on DTC stored ES-191 P0220 Throttle / Pedal Position Sensor / Switch "B" Circuit 1. TP sensor (built into throttle body) 2. ECM Comes on DTC stored ES-154 P0222 Throttle / Pedal Position Sensor / Switch "B" Circuit Low Input 1. TP sensor (built into throttle body) 2. Short in VTA2 circuit 3. Open in VC circuit 4. ECM Comes on DTC stored ES-154 P0223 Throttle / Pedal Position Sensor / Switch "B" Circuit High Input 1. TP sensor (built into throttle body) 2. Open in VTA2 circuit 3. Open in E2 circuit 4. Short between VC and VTA2 circuits 5. ECM Comes on DTC stored ES-154 ES–78 DTC No. 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Detection Item Suspected Trouble Area MIL Memory See page P0300 Random / Multiple Cylinder Misfire Detected 1. Open or short in engine wire harness 2. Connector connections 3. Vacuum hose connection 4. Ignition system 5. Injector 6. Fuel pressure 7. Mass Air Flow (MAF) meter 8. Engine Coolant Temperature (ECT) sensor 9. Compression pressure 10. Valve clearance 11. Valve timing 12. PCV valve and hose 13. PCV hose connections 14. Air induction system 15. ECM Comes on or flashes DTC stored ES-204 P0301 Cylinder 1 Misfire Detected Same as DTC P0300 Comes on or flashes DTC stored ES-204 P0302 Cylinder 2 Misfire Detected Same as DTC P0300 Comes on or flashes DTC stored ES-204 P0303 Cylinder 3 Misfire Detected Same as DTC P0300 Comes on or flashes DTC stored ES-204 P0304 Cylinder 4 Misfire Detected Same as DTC P0300 Comes on or flashes DTC stored ES-204 P0305 Cylinder 5 Misfire Detected Same as DTC P0300 Comes on or flashes DTC stored ES-204 P0306 Cylinder 6 Misfire Detected Same as DTC P0300 Comes on or flashes DTC stored ES-204 P0327 Knock Sensor 1 Circuit Low Input (Bank 1 or Single Sensor) 1. Short in knock sensor 1 circuit 2. Knock sensor 1 3. ECM Comes on DTC stored ES-216 P0328 Knock Sensor 1 Circuit High Input (Bank 1 or Single Sensor) 1. Open in knock sensor 1 circuit 2. Knock sensor 1 3. ECM Comes on DTC stored ES-216 P0332 Knock Sensor 2 Circuit Low Input (Bank 2) 1. Short in knock sensor 2 circuit 2. Knock sensor 2 3. ECM Comes on DTC stored ES-216 P0333 Knock Sensor 2 Circuit High Input (Bank 2) 1. Open in knock sensor 2 circuit 2. Knock sensor 2 3. ECM Comes on DTC stored ES-216 P0335 Crankshaft Position Sensor "A" Circuit 1. Open or short in Crankshaft Position Sensor (CKP) circuit 2. CKP sensor 3. Sensor plate (CKP sensor plate) 4. ECM Comes on DTC stored ES-222 P0339 Crankshaft Position Sensor "A" Circuit Intermittent Same as DTC P0335 Does not come on DTC stored ES-222 ES 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. MIL Memory ES–79 Detection Item Suspected Trouble Area See page P0340 Camshaft Position Sensor Circuit Malfunction 1. Open or short in VVT sensor for intake camshaft circuit 2. VVT sensor for intake camshaft 3. Camshaft timing gear for intake camshaft 4. Jumped tooth of timing chain for intake camshaft 5. ECM Comes on DTC stored ES-228 P0342 Camshaft Position Sensor "A" Circuit Low Input (Bank 1 or Single Sensor) Same as DTC P0340 Comes on DTC stored ES-228 P0343 Camshaft Position Sensor "A" Circuit High Input (Bank 1 or Single Sensor) Same as DTC P0340 Comes on DTC stored ES-228 P0345 Camshaft Position Sensor "A" Circuit (Bank 2) Same as DTC P0340 Comes on DTC stored ES-228 P0347 Camshaft Position Sensor "A" Circuit Low Input (Bank 2) Same as DTC P0340 Comes on DTC stored ES-228 P0348 Camshaft Position Sensor "A" Circuit High Input (Bank 2) Same as DTC P0340 Comes on DTC stored ES-228 P0351 Ignition Coil "A" Primary / Secondary Circuit 1. Ignition system 2. Open or short in IGF1 or IGT circuit (1 to 6) between ignition coil and ECM 3. No. 1 to No. 6 ignition coils 4. ECM Comes on DTC stored ES-234 P0352 Ignition Coil "B" Primary / Secondary Circuit Same as DTC P0351 Comes on DTC stored ES-234 P0353 Ignition Coil "C" Primary / Secondary Circuit Same as DTC P0351 Comes on DTC stored ES-234 P0354 Ignition Coil "D" Primary / Secondary Circuit Same as DTC P0351 Comes on DTC stored ES-234 P0355 Ignition Coil "E" Primary / Secondary Circuit Same as DTC P0351 Comes on DTC stored ES-234 P0356 Ignition Coil "F" Primary / Secondary Circuit Same as DTC P0351 Comes on DTC stored ES-234 P0365 Camshaft Position Sensor "B" Circuit (Bank 1) 1. Open or short in VVT sensor for exhaust camshaft circuit 2. VVT sensor for exhaust camshaft 3. Exhaust camshaft 4. Jumped tooth of timing chain 5. ECM Comes on DTC stored ES-243 ES ES–80 DTC No. 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Detection Item Suspected Trouble Area P0367 Camshaft Position Sensor "B" Circuit Low Input (Bank 1) 1. Open or short in VVT sensor for exhaust camshaft circuit 2. VVT sensor for exhaust camshaft 3. Exhaust camshaft 4. Jumped tooth of timing chain 5. ECM Comes on DTC stored ES-243 P0368 Camshaft Position Sensor "B" Circuit High Input (Bank 1) 1. Open or short in VVT sensor for exhaust camshaft circuit 2. VVT sensor for exhaust camshaft 3. Exhaust camshaft 4. Jumped tooth of timing chain 5. ECM Comes on DTC stored ES-243 P0390 Camshaft Position Sensor "B" Circuit (Bank 2) 1. Open or short in VVT sensor for exhaust camshaft circuit 2. VVT sensor for exhaust camshaft 3. Exhaust camshaft 4. Jumped tooth of timing chain 5. ECM Comes on DTC stored ES-243 P0392 Camshaft Position Sensor "B" Circuit Low Input (Bank 2) 1. Open or short in VVT sensor for exhaust camshaft circuit 2. VVT sensor for exhaust camshaft 3. Exhaust camshaft 4. Jumped tooth of timing chain 5. ECM Comes on DTC stored ES-243 P0393 Camshaft Position Sensor "B" Circuit High Input (Bank 2) 1. Open or short in VVT sensor for exhaust camshaft circuit 2. VVT sensor for exhaust camshaft 3. Exhaust camshaft 4. Jumped tooth of timing chain 5. ECM Comes on DTC stored ES-243 P0420 Catalyst System Efficiency Below Threshold (Bank 1) 1. Gas leakage from exhaust system 2. A/F sensor (bank 1 sensor 1) 3. HO2 sensor (bank 1 sensor 2) 4. Exhaust manifold (Three-Way Catalytic Converter [TWC]) Comes on DTC stored ES-249 ES MIL Memory See page 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. MIL Memory ES–81 Detection Item Suspected Trouble Area See page P0430 Catalyst System Efficiency Below Threshold (Bank 2) 1. Gas leakage from exhaust system 2. A/F sensor (bank 2 sensor 1) 3. HO2 sensor (bank 2 sensor 2) 4. Exhaust manifold (Three-Way Catalytic Converter [TWC]) Comes on DTC stored ES-249 P043E Evaporative Emission System Reference Orifice Clog Up 1. Pump module 2. Connector / wire harness (Pump module - ECM) 3. ECM Comes on DTC stored ES-255 P043F Evaporative Emission System Reference Orifice High Flow 1. Pump module 2. Connector / wire harness (Pump module - ECM) 3. ECM Comes on DTC stored ES-255 P0441 Evaporative Emission Control System Incorrect Purge Flow 1. EVAP VSV 2. Connector / wire harness (EVAP VSV ECM) 3. ECM 4. Pump module 5. Leakage from EVAP system 6. Leakage from EVAP line (EVAP VSV - Intake manifold) Comes on DTC stored ES-260 P0450 Evaporative Emission Control System Pressure Sensor / Switch 1. Pump module (including pressure sensor) 2. ECM Comes on DTC stored ES-267 P0451 Evaporative Emission Control System Pressure Sensor Range / Performance 1. Pump module (including pressure sensor) 2. Connector / wire harness (between pump module and ECM) 3. ECM Comes on DTC stored ES-267 P0452 Evaporative Emission Control System Pressure Sensor / Switch Low Input 1. Pump module (including pressure sensor) 2. Connector / wire harness (between pump module and ECM) 3. ECM Comes on DTC stored ES-267 P0453 Evaporative Emission Control System Pressure Sensor / Switch High Input 1. Pump module (include pressure sensor) 2. Connector / wire harness (between pump module and ECM) 3. ECM Comes on DTC stored ES-267 ES ES–82 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. Detection Item Suspected Trouble Area P0455 Evaporative Emission Control System Leak Detected (Gross Leak) 1. Fuel tank cap (loose) 2. Leakage from EVAP line (Canister Fuel tank) 3. Leakage from EVAP line (EVAP VSV - Canister) 4. Pump module 5. Leakage from fuel tank 6. Leakage from canister Comes on DTC stored ES-274 P0456 Evaporative Emission Control System Leak Detected (Very Small Leak) Same as DTC P0455 Comes on DTC stored ES-274 P0500 Vehicle Speed Sensor "A" 1. Vehicle speed sensor 2. Vehicle speed sensor signal circuit 3. Combination meter 4. ECM 5. Skid control ECU Comes on DTC stored ES-279 P0504 Brake Switch "A" / "B" Correlation 1. Short in stop light switch signal circuit 2. Stop light switch 3. ECM Does not come on DTC stored ES-284 P0505 Idle Control System Malfunction 1. ETCS (Electronic Throttle Control System) 2. Air induction system 3. PCV hose connection 4. ECM Comes on DTC stored ES-288 P050A Cold Start Idle Air Control System Performance 1. Throttle body assembly 2. MAF meter 3. Air induction system 4. PCV hose connections 5. VVT system 6. Air cleaner filter element 7. ECM Comes on DTC stored ES-291 P050B Cold Start Ignition Timing Performance Same as DTC P050A Comes on DTC stored ES-291 P0560 System Voltage 1. Open in back-up power source circuit 2. ECM Comes on DTC stored ES-297 P0604 Internal Control Module Random Access Memory (RAM) Error ECM Comes on DTC stored ES-302 P0606 ECM / PCM Processor ECM Comes on (except when there is a malfunction in the ECM internal circuit) DTC stored ES-302 ES MIL Memory See page 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. Detection Item Suspected Trouble Area MIL Memory ES–83 See page P0607 Control Module Performance ECM Comes on (except when there is a malfunction in the cruise control switch circuit) DTC stored ES-302 P0617 Starter Relay Circuit High 1. Park / Neutral Position (PNP) switch 2. Starter relay circuit 3. Cranking holding function circuit 4. Ignition switch 5. ECM Comes on DTC stored ES-304 P0630 VIN not Programmed or Mismatch - ECM / PCM ECM Comes on DTC stored ES-309 P0657 Actuator Supply Voltage Circuit / Open ECM Comes on DTC stored ES-302 P0705 Transmission Range Sensor Circuit Malfunction (PRNDL Input) 1. Short in park / neutral position switch circuit 2. Park / neutral position switch 3. ECM Comes on DTC stored ES-311 P0724 Brake Switch "B" Circuit High 1. Short in stop light switch signal circuit 2. Stop light switch 3. ECM Comes on DTC stored ES-284 P2102 Throttle Actuator Control Motor Circuit Low 1. Open in throttle actuator circuit 2. Throttle actuator 3. ECM Comes on DTC stored ES-320 P2103 Throttle Actuator Control Motor Circuit High 1. Short in throttle actuator circuit 2. Throttle actuator 3. Throttle valve 4. Throttle body assembly 5. ECM Comes on DTC stored ES-320 P2111 Throttle Actuator Control System Stuck Open 1. Throttle actuator 2. Throttle body 3. Throttle valve Comes on DTC stored ES-324 P2112 Throttle Actuator Control System Stuck Closed Same as DTC P2111 Comes on DTC stored ES-324 P2118 Throttle Actuator Control Motor Current Range / Performance 1. Open in ETCS power source circuit 2. ETCS fuse 3. ECM Comes on DTC stored ES-327 P2119 Throttle Actuator Control Throttle Body Range / Performance 1. ETCS 2. ECM Comes on DTC stored ES-331 P2120 Throttle / Pedal Position Sensor / Switch "D" Circuit 1. Accelerator Pedal Position (APP) sensor 2. ECM Comes on DTC stored ES-334 P2121 Throttle / Pedal Position Sensor / Switch "D" Circuit Range / Performance 1. Accelerator Pedal Position (APP) sensor 2. ECM Comes on DTC stored ES-341 ES ES–84 DTC No. 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Detection Item Suspected Trouble Area MIL Memory See page P2122 Throttle / Pedal Position Sensor / Switch "D" Circuit Low Input 1. Accelerator Pedal Position (APP) sensor 2. Open in VCP1 circuit 3. Open or ground short in VPA circuit 4. ECM Comes on DTC stored ES-334 P2123 Throttle / Pedal Position Sensor / Switch "D" Circuit High Input 1. Accelerator Pedal Position (APP) sensor 2. Open in EPA circuit 3. ECM Comes on DTC stored ES-334 P2125 Throttle / Pedal Position Sensor / Switch "E" Circuit 1. Accelerator Pedal Position (APP) sensor 2. ECM Comes on DTC stored ES-334 P2127 Throttle / Pedal Position Sensor / Switch "E" Circuit Low Input 1. Accelerator Pedal Position (APP) sensor 2. Open in VCP2 circuit 3. Open or ground short in VPA2 circuit 4. ECM Comes on DTC stored ES-334 P2128 Throttle / Pedal Position Sensor / Switch "E" Circuit High Input 1. Accelerator Pedal Position (APP) sensor 2. Open in EPA2 circuit 3. ECM Comes on DTC stored ES-334 P2135 Throttle / Pedal Position Sensor / Switch "A" / "B" Voltage Correlation 1. Short between VTA1 and VTA2 circuits 2. TP sensor (built into throttle body) 3. ECM Comes on DTC stored ES-154 P2138 Throttle / Pedal Position Sensor / Switch "D" / "E" Voltage Correlation 1. Short between VPA and VPA2 circuits 2. APP sensor 3. ECM Comes on DTC stored ES-334 P2195 Oxygen (A/F) Sensor Signal Stuck Lean (Bank 1 Sensor 1) 1. Open or short in A/ F sensor (bank 1 sensor 1) circuit 2. A/F sensor (bank 1 sensor 1) 3. A/F sensor heater (bank 1 sensor 1) 4. A/F sensor heater relay 5. A/F sensor heater and relay circuits 6. Air induction system 7. Fuel pressure 8. Injector 9. ECM Comes on DTC stored ES-345 P2196 Oxygen (A/F) Sensor Signal Stuck Rich (Bank 1 Sensor 1) Same as DTC P2195 Comes on DTC stored ES-345 ES 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MIL Memory ES–85 DTC No. Detection Item Suspected Trouble Area See page P2197 Oxygen (A/F) Sensor Signal Stuck Lean (Bank 2 Sensor 1) 1. Open or short in A/ F sensor (bank 2 sensor 1) circuit 2. A/F sensor (bank 2 sensor 1) 3. A/F sensor heater (bank 2 sensor 1) 4. A/F sensor heater relay 5. A/F sensor heater and relay circuits 6. Air induction system 7. Fuel pressure 8. Injector 9. ECM Comes on DTC stored ES-345 P2198 Oxygen (A/F) Sensor Signal Stuck Rich (Bank 2 Sensor 1) Same as DTC P2197 Comes on DTC stored ES-345 P2238 Oxygen (A/F) Sensor Pumping Current Circuit Low (Bank 1 Sensor 1) 1. Open or short in A/ F sensor (bank 1 sensor 1) circuit 2. A/F sensor (bank 1 sensor 1) 3. A/F sensor heater (bank 1 sensor 1) 4. A/F sensor heater relay 5. A/F sensor heater and relay circuits 6. ECM Comes on DTC stored ES-364 P2239 Oxygen (A/F) Sensor Pumping Current Circuit High (Bank 1 Sensor 1) Same as DTC P2238 Comes on DTC stored ES-364 P2241 Oxygen (A/F) Sensor Pumping Current Circuit Low (Bank 2 Sensor 1) 1. Open or short in A/ F sensor (bank 2 sensor 1) circuit 2. A/F sensor (bank 2 sensor 1) 3. A/F sensor heater (bank 2 sensor 1) 4. A/F sensor heater relay 5. A/F sensor heater and relay circuits 6. ECM Comes on DTC stored ES-364 P2242 Oxygen (A/F) Sensor Pumping Current Circuit High (Bank 2 Sensor 1) Same as DTC P2241 Comes on DTC stored ES-364 P2252 Oxygen (A/F) Sensor Reference Ground Circuit Low (Bank 1 Sensor 1) Same as DTC P2238 Comes on DTC stored ES-364 P2253 Oxygen (A/F) Sensor Reference Ground Circuit High (Bank 1 Sensor 1) Same as DTC P2238 Comes on DTC stored ES-364 P2255 Oxygen (A/F) Sensor Reference Ground Circuit Low (Bank 2 Sensor 1) Same as DTC P2241 Comes on DTC stored ES-364 ES ES–86 ES 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. Detection Item Suspected Trouble Area MIL Memory See page P2256 Oxygen (A/F) Sensor Reference Ground Circuit High (Bank 2 Sensor 1) Same as DTC P2241 Comes on DTC stored ES-364 P2401 Evaporative Emission System Leak Detection Pump Control Circuit Low 1. Pump module 2. Connector / wire harness (Pump module - ECM) 3. ECM Comes on DTC stored ES-255 P2402 Evaporative Emission System Leak Detection Pump Control Circuit High 1. Pump module 2. Connector / wire harness (Pump module - ECM) 3. ECM Comes on DTC stored ES-255 P2419 Evaporative Emission System Switching Valve Control Circuit Low 1. Pump module 2. Connector / wire harness (Pump module - ECM) 3. ECM Comes on DTC stored ES-255 P2420 Evaporative Emission System Switching Valve Control Circuit High 1. Pump module (0.02 inch orifice, vacuum pump, vent valve) EVAP system monitor 2. Connector / wire harness (Pump module ECM) 3. ECM Comes on DTC stored ES-373 P2610 ECM / PCM Internal Engine Off Timer Performance ECM Comes on DTC stored ES-377 P2A00 A/F Sensor Circuit Slow Response (Bank 1 Sensor 1) 1. Open or short in A/ F sensor (bank 1 sensor 1) circuit 2. A/F sensor (bank1 sensor 1) 3. ECM Comes on DTC stored ES-380 P2A03 A/F Sensor Circuit Slow Response (Bank 2 Sensor 1) 1. Open or short in A/ F sensor (bank 2 sensor 1) circuit 2. A/F sensor (bank 2 sensor 1) 3. ECM Comes on DTC stored ES-380 U0101 Lost Communication with TCM 1. Open or short in TCM and ECM circuit 2. TCM 3. ECM Comes on DTC stored ES-389 *1: This DTC is related to the A/F sensor, although the caption in the "Detection Item" column refers to the heated oxygen sensor. *2: This DTC indicates a malfunction related to the primary circuit. ES–87 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0010 Camshaft Position "A" Actuator Circuit (Bank 1) DTC P0020 Camshaft Position "A" Actuator Circuit (Bank 2) DESCRIPTION The Variable Valve Timing (VVT) system includes the ECM, Oil Control Valve (OCV) and VVT controller. The ECM sends a target duty-cycle control signal to the OCV. This control signal regulates the oil pressure supplied to the VVT controller. Camshaft timing control is performed according to engine operating conditions such as intake air volume, throttle valve position and engine coolant temperature. The ECM controls the OCV, based on the signals transmitted by several sensors. The VVT controller regulates the intake camshaft angle using oil pressure through the OCV. As a result, the relative positions of the camshaft and crankshaft are optimized, the engine torque and fuel economy improves, and the exhaust emissions decrease under overall driving conditions. The ECM detects the actual intake valve timing using signals from the camshaft and crankshaft position sensors, and performs feedback control. This is how the target intake valve timing is verified by the ECM. ECM Crankshaft Position Sensor Duty Control Target Valve Timing MAF Meter Throttle Position Sensor Feedback ECT Sensor Correction Camshaft Timing Oil Control Valve (OCV) Vehicle Speed Signal Actual Valve Timing Camshaft Position Sensor A103843E02 DTC No. DTC Detection Condition P0010 Open or short in OCV for intake camshaft (bank 1) circuit (1 trip detection logic) P0020 Open or short in OCV for intake camshaft (bank 2) circuit (1 trip detection logic) Trouble Area • • • • • • Open or short in OCV for intake camshaft (bank 1) circuit OCV for intake camshaft (bank 1) ECM Open or short in OCV for intake camshaft (bank 2) circuit OCV for intake camshaft (bank 2) ECM ES ES–88 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR DESCRIPTION After the ECM sends the "target" duty-cycle signal to the OCV, the ECM monitors the OCV current to establish an "actual" duty-cycle. The ECM detects a malfunction and sets a DTC when the actual dutycycle ratio varies from the target duty-cycle ratio. MONITOR STRATEGY ES Related DTCs P0010: VVT OCV (bank 1) open/short P0020: VVT OCV (bank 2) open/short Required sensors / components (Main) VVT OCV (Variable Valve Timing oil control valve) Required sensors / components (Sub) - Frequency of operation Continuous Duration 1 second MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS Monitor will run whenever these DTCs are not present None All of the following conditions are met: - Starter OFF Engine switch ON Time after turning ignition switch off to on (IG) 0.5 seconds or more TYPICAL MALFUNCTION THRESHOLDS One of the following conditions is met: Condition A, B or C A. All of the following conditions are met: - Battery voltage 11 to 13 V Target duty ratio Less than 70 % Output signal duty ratio 100 % B. All of the following conditions are met: - Battery voltage 13 V or more Target duty ratio Less than 80 % Output signal duty ratio 100 % C. All of the following conditions are met: - Current cut status Not cut Output signal duty ratio 3 % or less COMPONENT OPERATING RANGE VVT OCV duty ratio More than 3 %, and Less than 100 % ES–89 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM C43 OCV for Intake Camshaft (Bank 1) 1 58 OC1+ C55 2 57 OC1C55 ES C47 OCV for Intake Camshaft (Bank 2) 1 52 OC2+ C55 2 51 OC2C55 A133849E01 INSPECTION PROCEDURE HINT: • If DTC P0010 is displayed, check the intake camshaft circuit for the right bank VVT system. • Bank 1 refers to the bank that includes cylinder No. 1. • If DTC P0020 is displayed, check the intake camshaft circuit for the left bank VVT system. • Bank 2 refers to the bank that does not include cylinder No. 1. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). 1 PERFORM ACTIVE TEST BY CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (OCV) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Start the engine and turn the tester on. Warm up the engine. On the tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VVT CTRL B1 or VVT CTRL B2. (e) Check the engine speed while operating the Oil Control Valve (OCV) using the tester. ES–90 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK Tester Operation Specified Condition OCV OFF Normal engine speed OCV ON Engine idles roughly or stalls (soon after OCV switched from OFF to ON) OK CHECK FOR INTERMITTENT PROBLEMS (See page ES-33) NG 2 INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Disconnect the C43 or C47 OCV connector. (b) Measure the resistance between the terminals of the OCV. Standard resistance ES Tester Connection Condition Specified Condition 1-2 20°C (68°F) 6.9 to 7.9 Ω (c) Reconnect the OCV connector. A095415E03 OK REPLACE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (See page ES481) NG 3 CHECK HARNESS AND CONNECTOR (OCV - ECM) (a) Disconnect the C43 or C47 OCV connector. (b) Disconnect the C55 ECM connector. (c) Measure the resistance between the terminals. Standard resistance (Check for open) Wire Harness Side Front View: OCV Connector Tester Connection Specified Condition C43 OC1+ (C55-58) - C43-1 Below 1 Ω C47 OC1- (C55-57) - C43-2 Below 1 Ω OC2+ (C55-52) - C47-1 Below 1 Ω OC2- (C55-51) - C47-2 Below 1 Ω C55 OC1- OC2- Standard resistance (Check for short) ECM Connector OC1+ Tester Connection Specified Condition OC1+ (C55-58) or C43-1 - Body ground 10 kΩ or higher OC1- (C55-57) or C43-2 - Body ground 10 kΩ or higher OC2+ (C55-52) or C47-1 - Body ground 10 kΩ or higher OC2- (C55-51) or C47-2 - Body ground 10 kΩ or higher (d) Reconnect the OCV connector. (e) Reconnect the ECM connector. OC2+ A106380E13 NG REPAIR OR REPLACE HARNESS OR CONNECTOR 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–91 OK REPLACE ECM (See page ES-518) ES ES–92 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0011 Camshaft Position "A" - Timing Over-Advanced or System Performance (Bank 1) DTC P0012 Camshaft Position "A" - Timing Over-Retarded (Bank 1) DTC P0021 Camshaft Position "A" - Timing Over-Advanced or System Performance (Bank 2) DTC P0022 Camshaft Position "A" - Timing Over-Retarded (Bank 2) ES DESCRIPTION The Variable Valve Timing (VVT) system includes the ECM, Oil Control Valve (OCV) and VVT controller. The ECM sends a target duty-cycle control signal to the OCV. This control signal regulates the oil pressure supplied to the VVT controller. Camshaft timing control is performed according to engine operating conditions such as intake air volume, throttle valve position and engine coolant temperature. The ECM controls the OCV, based on the signals transmitted by several sensors. The VVT controller regulates the intake camshaft angle using oil pressure through the OCV. As a result, the relative positions of the camshaft and crankshaft are optimized, the engine torque and fuel economy improve, and the exhaust emissions decrease under overall driving conditions. The ECM detects the actual intake valve timing using signals from the camshaft and crankshaft position sensors, and performs feedback control. This is how the target intake valve timing is verified by the ECM. DTC No. DTC Detection Condition P0011 P0021 Advanced cam timing: With warm engine and engine speed of between 500 rpm and 4,000 rpm, all conditions (1), (2) and (3) are met (1 trip detection logic): 1. Difference between target and actual intake valve timing is more than 5°CA (Crankshaft Angle) for 4.5 seconds 2. Current intake valve timing is fixed (timing changes less than 5°CA in 5 seconds) 3. Variations in VVT controller timing is more than 19°CA of maximum delayed timing (advance) P0012 P0022 Retarded cam timing: With warm engine and engine speed of between 500 rpm and 4,000 rpm, all conditions (1), (2) and (3) are met (2 trip detection logic): 1. Difference between target and actual intake valve timing is more than 5°CA (Crankshaft Angle) for 4.5 seconds 2. Current intake valve timing is fixed (timing changes less than 5°CA in 5 seconds) 3. Variations in VVT controller timing is 19°CA or less of maximum delayed timing (retarded) Trouble Area • • • • • Valve timing Oil Control valve (OCV) for intake camshaft (bank 1) OCV filter (bank 1) Intake camshaft (bank 1) timing gear assembly ECM • • • • • Valve timing OCV for intake camshaft (bank 2) OCV filter (bank 2) Intake camshaft (bank 2) timing gear assembly ECM MONITOR DESCRIPTION 1. The ECM optimizes the intake valve timing using the VVT (Variable Valve Timing) system to control the intake camshaft. The VVT system includes the ECM, the Oil Control Valve (OCV) and the VVT controller. 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–93 2. The ECM sends a target duty-cycle control signal to the OCV. This control signal regulates the oil pressure supplied to the VVT controller. The VVT controller can advance or retard the intake camshaft. If the difference between the target and actual intake valve timing is large, and changes in the actual intake valve timing are small, the ECM interprets this as the VVT controller stuck malfunction and sets a DTC. Example: A DTC will be set when the following conditions 1), 2) and 3) are met: 1) The difference between the target and actual intake valve timings is more than 5° CA (Crankshaft Angle) and the condition continues for more than 4.5 seconds. 2) It takes 5 seconds or more to change the valve timing by 5° CA. 3) After above conditions 1) and 2) are met, the OCV is forcibly activated 63 times or more. 3. DTCs P0011 and P0021 (Advanced Cam Timing) are detected with 1 trip detection logic. 4. DTCs P0012 and P0022 (Retarded Cam Timing) are detected with 2 trip detection logic. These DTCs indicate that the VVT controller cannot operate properly due to OCV malfunctions or the presence of foreign objects in the OCV. 5. The monitor will not run unless the following conditions are met: (a)The engine is warm (the engine coolant temperature is 75°C (167°F) or more). (b)The vehicle has been driven at more than 40 mph (64 km/h) for 3 minutes. (c) The engine has idled for 3 minutes. MONITOR STRATEGY Related DTCs P0011: Advanced camshaft timing (bank 1) P0012: Retard camshaft timing (bank 1) P0021: Advanced camshaft timing (bank 2) P0022: Retard camshaft timing (bank 2) Required sensors / components (Main) VVT OCV and VVT Actuator Required sensors / components (Sub) Crankshaft position sensor, camshaft position sensor and Engine coolant temperature sensor Frequency of operation Once per drive cycle Duration Within 10 seconds MIL operation Advanced camshaft timing (bank 1): Immediately Advanced camshaft timing (bank 2): Immediately Retard camshaft timing (bank 1): 2 driving cycles Retard camshaft timing (bank 2): 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present P0100 - P0103 (MAF sensor) P0115 - P0118 (ECT sensor) P0125 (Insufficient ECT for closed loop) P0335 (CKP sensor) P0340, P0341 (CMP sensor) P0351 - P0358 (ignitor) Battery voltage 11 V or more Engine 500 to 4,000 rpm ECT 75 to 100°C (167 to 212°F) TYPICAL MALFUNCTION THRESHOLDS Advanced camshaft timing: Difference between actual valve timing and target valve timing More than 5°CA Valve timing No change in advanced valve timing Retard camshaft timing: Difference between actual valve timing and target valve timing More than 5°CA ES ES–94 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Valve timing No change in retarded valve timing WIRING DIAGRAM Refer to DTC P0010 (See page ES-81). INSPECTION PROCEDURE HINT: Advanced timing over (Valve timing is out of specified range) Retarded timing over (Valve timing is out of specified range) Bank 1 P0011 P0012 Bank 2 P0021 P0022 Abnormal bank ES • If DTC P0011 or P0012 is displayed, check the right bank VVT system for intake camshaft circuit (bank 1). • Bank 1 refers to the bank that includes cylinder No. 1. • If DTC P0021 or P0022 is displayed, check the intake camshaft circuit for the left bank VVT system (bank 2). • Bank 2 refers to the bank that does not include cylinder No. 1. • Read freeze frame data using an intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P0011, P0012, P0021 OR P0022) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the tester on. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs. Result Display (DTC Output) Proceed to P0011, P0012, P0021 or P0022 A P0011, P0012, P0021 or P0022 and other DTCs B HINT: If any DTCs other than P0011, P0012, P0021 or P0022 are output, troubleshoot those DTCs first. B GO TO DTC CHART (See page ES-63) A 2 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (OPERATE OCV) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Start the engine and turn the tester on. Warm up the engine. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VVT CTRL B1 or VVT CTRL B2. 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–95 (e) Check the engine speed while operating the Oil Control Valve (OCV) using the tester. OK Tester Operation Specified Condition OCV OFF Normal engine speed OCV ON Engine idles roughly or stalls (soon after OCV switched from OFF to ON) NG Go to step 4 OK 3 CHECK WHETHER DTC OUTPUT RECURS (DTC P0011, P0012, P0021 OR P0022) (a) (b) (c) (d) (e) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG) and turn the tester on. Clear the DTCs. Start the engine and warm it up. Switch the ECM from normal mode to check mode using the tester. (f) Drive the vehicle for more than 10 minutes. (g) Read the DTCs using the tester. OK: No DTC output. NG OK END Go to step 4 ES ES–96 4 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK VALVE TIMING (CHECK FOR LOOSE AND JUMPED TEETH ON TIMING CHAIN) Timing Mark ES Timing Mark (a) Remove the cylinder head covers RH and LH. (b) Turn the crankshaft pulley, and align its groove with the timing mark "0" of the timing chain cover. (c) Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing cap as shown in the illustration. If not, turn the crankshaft 1 revolution (360°), then align the marks as above. OK: Timing marks on camshaft timing gears are aligned as shown in the illustration. (d) Reinstall the cylinder head cover. NG ADJUST VALVE TIMING Timing Mark Timing Mark A135015E01 OK 5 INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (OCV) (a) Remove the OCV. (b) Measure the resistance between the terminals of the OCV. Standard resistance Valve Moves A097066E01 Tester Connection Condition Specified Condition 1-2 20°C (68°F) 6.9 to 7.9 Ω (c) Apply positive battery voltage to terminal 1 and negative battery voltage to terminal 2. Check the valve operation. OK: Valve moves quickly. (d) Reinstall the OCV. 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NG ES–97 REPLACE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (See page ES481) OK 6 INSPECT OIL CONTROL VALVE FILTER AND PIPE (a) Remove the oil pipe No. 1 or No. 2. (b) Remove the oil control valve filter. (c) Check that the filter and pipe are not clogged. OK: The filter and pipe are not clogged. RH Bank: NG CLEAN OIL CONTROL VALVE FILTER AND PIPE LH Bank: G042497E01 OK 7 REPLACE CAMSHAFT TIMING GEAR ASSEMBLY NEXT 8 CHECK WHETHER DTC OUTPUT RECURS (a) (b) (c) (d) (e) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG) and turn the tester on. Clear the DTCs. Start the engine and warm it up. Switch the ECM from normal mode to check mode using the tester. (f) Driver the vehicle for more than 10 minutes. (g) Read the output DTCs using the intelligent tester. OK: No DTC output. ES ES–98 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: DTC P0011, P0012, P0021 or P0022 is output when foreign objects in engine oil are caught in some parts of the system. These codes will stay output even if the system returns to normal after a short time. These foreign objects are then captured by the oil filter, thus eliminating the source of the problem. OK NG REPLACE ECM (See page ES-518) ES SYSTEM IS OK ES–99 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0013 Camshaft Position "B" Actuator Circuit / Open (Bank 1) DTC P0023 Camshaft Position "B" Actuator Circuit / Open (Bank 2) DESCRIPTION The Variable Valve Timing (VVT) system includes the ECM, OCV and VVT controller. The ECM sends a target duty-cycle control signal to the OCV. This control signal regulates the oil pressure supplied to the VVT controller. Camshaft timing control is performed according to engine operating conditions such as the intake air volume, throttle valve position and engine coolant temperature. The ECM controls the OCV, based on the signals transmitted by several sensors. The VVT controller regulates the exhaust camshaft angle using oil pressure through the OCV. As a result, the relative positions of the camshaft and crankshaft are optimized, the engine torque and fuel economy improve, and the exhaust emissions decrease under overall driving conditions. The ECM detects the actual exhaust valve timing using signals from the camshaft and crankshaft position sensors, and performs feedback control. This is how the target intake valve timing is verified by the ECM. ECM Crankshaft Position Sensor Duty Control Target Valve Timing MAF Meter Throttle Position Sensor Feedback ECT Sensor Correction Camshaft Timing Oil Control Valve (OCV) Vehicle Speed Signal Actual Valve Timing Camshaft Position Sensor A103843E02 DTC No. DTC Detection Condition P0013 Open or short in OCV for exhaust camshaft (bank 1) circuit (1 trip detection logic) P0023 Open or short in OCV for exhaust camshaft (bank 2) circuit (1 trip detection logic) Trouble Area • • • • • • Open or short in OCV for exhaust camshaft (bank 1) circuit OCV for exhaust camshaft (bank 1) ECM Open or short in OCV for exhaust camshaft (bank 2) circuit OCV for exhaust camshaft (bank 2) ECM ES ES–100 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR DESCRIPTION The ECM optimizes the valve timing using the VVT system to control the exhaust camshaft. The VVT system includes the ECM, the OCV and the VVT controller. The ECM sends a target duty-cycle control signal to the OCV. This control signal regulates the oil pressure supplied to the VVT controller. The VVT controller can advance or retard the exhaust camshaft. After the ECM sends the target duty-cycle signal to the OCV, the ECM monitors the OCV current to establish an actual duty-cycle. The ECM determines the existence of a malfunction and sets the DTC when the actual duty-cycle ratio varies from the target duty-cycle ratio. MONITOR STRATEGY ES Related DTCs P0013: VVT OCV (bank 1) open/short P0023: VVT OCV (bank 2) open/short Required sensors / components (Main) VVT OCV (Variable Valve Timing oil control valve) Required sensors / components (Sub) - Frequency of operation Continuous Duration 1 second MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present None All of the following conditions are met: - Starter OFF Engine switch ON Time after engine switch off to on 0.5 seconds or more TYPICAL MALFUNCTION THRESHOLDS One of the following conditions is met: Condition A, B or C A. All of the following conditions are met: - Battery voltage 11 to 13 V Target duty ratio Less than 70% Output signal duty ratio 100 % B. All of the following conditions are met: - Battery voltage 13 V or more Target duty ratio Less than 80% Output duty ratio 100 % C. All of the following conditions are met: - Current cut status Not cut Output signal duty ratio 3% or less COMPONENT OPERATING RANGE VVT duty ratio More than 3, and less than 100 % ES–101 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM C42 OCV for Exhaust Camshaft (Bank 1) 1 16 OE1+ C55 2 17 OE1C55 ES C46 OCV for Exhaust Camshaft (Bank 2) 1 14 OE2+ C55 2 15 OE2C55 A133849E02 INSPECTION PROCEDURE HINT: • If DTC P0013 is displayed, check the exhaust camshaft circuit for the bank 1 VVT system. • Bank 1 refers to the bank that includes cylinder No. 1. • If DTC P0023 is displayed, check the exhaust camshaft circuit for the bank 2 VVT system. • Bank 2 refers to the bank that does not include cylinder No. 1. • Read freeze frame data using an intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (OPERATE OCV) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Start the engine and turn the tester on. Warm up the engine. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VVT CTRL B1 or VVT CTRL B2. (e) Check the engine speed while operating the Oil Control Valve (OCV) using the tester. ES–102 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK Tester Operation Specified Condition OCV OFF Normal engine speed OCV ON Engine idles roughly or stalls (soon after OCV switched from OFF to ON) NG Go to step 2 OK CHECK FOR INTERMITTENT PROBLEMS ES 2 INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Disconnect the C42 or C46 OCV connector. (b) Measure the resistance between the terminals of the OCV. Standard resistance Valve Moves Tester Connection Condition Specified Condition 1-2 20°C (68°F) 6.9 to 7.9 Ω (c) Reconnect the OCV connector. A097066E01 NG Go to step 3 OK REPLACE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (See page ES-481) ES–103 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 3 CHECK HARNESS AND CONNECTOR (OCV - ECM) (a) Disconnect the C42 or C46 OCV connector. (b) Disconnect the C55 ECM connector. (c) Measure the resistance between the terminals. Standard resistance (Check for open) Wire Harness Side Front View: OCV Connector Tester Connection Specified Condition C42 OE1+ (C55-16) - C42-1 Below 1 Ω C46 OE1- (C55-17) - C42-2 Below 1 Ω OE2+ (C55-14) - C46-1 Below 1 Ω OE2- (C55-15) - C46-2 Below 1 Ω C55 Standard resistance (Check for short) ECM Connector Tester Connection OE2+ OE1- Specified Condition OE1+ (C55-16) or C42-1 - Body ground 10 kΩ or higher OE1- (C55-17) or C42-2 - Body ground 10 kΩ or higher OE2+ (C55-14) or C46-1 - Body ground 10 kΩ or higher OE2- (C55-15) or C46-2 - Body ground 10 kΩ or higher (d) Reconnect the ECM connector. (e) Reconnect the OCV connector. OE2- OE1+ A106380E14 OK REPLACE ECM (See page ES-481) NG REPAIR OR REPLACE HARNESS OR CONNECTOR ES ES–104 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0014 Camshaft Position "B" - Timing Over-Advanced or System Performance (Bank 1) DTC P0015 Camshaft Position "B" - Timing Over-Retarded (Bank 1) DTC P0024 Camshaft Position "B" - Timing Over-Advanced or System Performance (Bank 2) DTC P0025 Camshaft Position "B" - Timing Over-Retarded (Bank 2) ES DESCRIPTION HINT: If DTC P0014, P0015, P0024 or P0025 is present, check the VVT (Variable Valve Timing) system. The Variable Valve Timing (VVT) system includes the ECM, OCV and VVT controller. The ECM sends a target duty-cycle control signal to the OCV. This control signal regulates the oil pressure supplied to the VVT controller. Camshaft timing control is performed according to engine operating conditions such as the intake air volume, throttle valve position and engine coolant temperature. The ECM controls the OCV, based on the signals transmitted by several sensors. The VVT controller regulates the exhaust camshaft angle using oil pressure through the OCV. As a result, the relative positions of the camshaft and crankshaft are optimized, the engine torque and fuel economy improve, and the exhaust emissions decrease under overall driving conditions. The ECM detects the actual exhaust valve timing using signals from the camshaft and crankshaft position sensors, and performs feedback control. This is how the target intake valve timing is verified by the ECM. ES–105 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ECM Crankshaft Position Sensor Duty Control Target Valve Timing MAF Meter Throttle Position Sensor Feedback ECT Sensor Correction ES Camshaft Timing Oil Control Valve (OCV) Vehicle Speed Signal Actual Valve Timing Camshaft Position Sensor A103843E02 DTC No. DTC Detection Condition P0014 P0024 Advanced cam timing: With warm engine and engine speed of between 500 rpm and 4,000 rpm, all conditions (a), (b) and (c) are met (2 trip detection logic): (a) Difference between target and actual exhaust valve timing is more than 5°CA (Crankshaft Angle) for 4.5 seconds (b) Current exhaust valve timing is fixed (timing changes less than 5°CA in 5 seconds) (c) Variations in VVT controller timing are more than 19°CA of maximum delayed timing (advanced) P0015 P0025 Retarded cam timing: With warm engine and engine speed of between 500 rpm and 4,000 rpm, all conditions (a), (b) and (c) are met (1 trip detection logic): (a) Difference between target and actual exhaust valve timing is more than 5°CA (Crankshaft Angle) for 4.5 seconds (b) Current exhaust valve timing is fixed (timing changes less than 5°CA in 5 seconds) (c) Variations in VVT controller timing are more than 19°CA or less of maximum delayed timing (retarded) Trouble Area • • • • • Valve timing Oil control valve (OCV) for exhaust camshaft (bank 1) OCV filter (bank 1) Exhaust camshaft ECM • • • • • Valve timing OCV for exhaust camshaft (bank 2) OCV filter (bank 2) Exhaust camshaft ECM MONITOR DESCRIPTION 1. The ECM optimizes the exhaust valve timing using the VVT (Variable Valve Timing) system to control the exhaust camshaft. The VVT system includes the ECM, the Oil Control Valve (OCV) and the VVT controller. ES–106 ES 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2. The ECM sends a target duty-cycle control signal to the OCV. This control signal regulates the oil pressure supplied to the VVT controller. The VVT controller can advance or retard the exhaust camshaft. If the difference between the target and actual exhaust valve timings is large, and changes in actual exhaust valve timing are small, the ECM interprets this as the VVT controller stuck malfunction and sets a DTC. Example: A DTC is set when the following conditions A, B and C are met: (1)The difference between the target and actual exhaust valve timings is more than 5°CA (Crankshaft Angle) and the condition continues for more than 4.5 seconds (Procedure "A"). (2)It takes 5 seconds or more to change the valve timing by 5°CA (Procedure "B"). (3)After above procedures "A" and "B" are met, the OCV is forcibly activated 63 times or more (Procedure "C"). 3. DTCs P0014 and P0024 (Advanced Cam Timing) are detected with 1 trip detection logic. 4. DTCs P0015 and P0025 (Retarded Cam Timing) are detected with 2 trip detection logic. These DTCs indicate that the VVT controller cannot operate properly due to OCV malfunctions or the presence of foreign objects in the OCV. 5. The monitor will not run unless the following conditions are met: (a)The engine is warm (the engine coolant temperature is 75°C [167°F] or more). (b)The vehicle has been driven at more than 40 mph (64 km/h) for 3 minutes. (c) The engine has idled for 3 minutes. MONITOR STRATEGY Related DTCs P0014: Advanced camshaft timing (bank 1) P0015: Retarded camshaft timing (bank 1) P0024: Advanced camshaft timing (bank 2) P0025: Retarded camshaft timing (bank 2) Required sensors / components (Main) VVT OCV and VVT Actuator Required sensors / components (Related) Crankshaft position sensor, Camshaft position sensor and Engine coolant temperature sensor Frequency of operation Once per driving cycle Duration Within 10 seconds MIL operation Advanced camshaft timing (bank 1): Immediate Advanced camshaft timing (bank 2): Immediate Retarded camshaft timing (bank 1): 2 driving cycles Retarded camshaft timing (bank 2): 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present P0100 - P0103 (MAF sensor) P0115 - P0118 (ECT sensor) P0125 (insufficient ECT for closed loop) P0335 (CKP sensor) P0340, P0341 (CMP sensor) P0351 - P0358 (ignitor) Battery voltage 11 V or more Engine RPM 500 to 4,000 rpm Engine coolant temperature 75 to 100°C (167 to 212°F) TYPICAL MALFUNCTION THRESHOLDS Advanced camshaft timing: Valve timing No change Valve timing Advanced position ES–107 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Retarded camshaft timing: Valve timing No change Valve timing Retard position WIRING DIAGRAM Refer to DTC P0013 (See page ES-93). INSPECTION PROCEDURE HINT: • • • • • Abnormal bank Advanced timing over (Valve timing is out of specified range) Retarded timing over (Valve timing is out of specified range) Bank 1 P0014 P0015 Bank 2 P0024 P0025 If DTC P0014 or P0015 is displayed, check the exhaust camshaft circuit for the bank 1 VVT system. Bank 1 refers to the bank that includes cylinder No. 1. If DTC P0024 or P0025 is displayed, check for exhaust camshaft circuit for the bank 2 VVT system. Bank 2 refers to the bank that does not include cylinder No. 1. Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P0014, P0015, P0024 OR P0025) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the tester on. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs. Result Display (DTC output) Proceed to P0014, P0015, P0024 or P0025 A P0014, P0015, P0024 or P0025 and other DTCs B HINT: If any DTCs other than P0014, P0015, P0024 or P0025 are output, troubleshoot those DTCs first. B GO TO DTC CHART (See page ES-63) A 2 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (OPERATE OCV) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Start the engine and turn the tester on. Warm up the engine. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VVT CTRL B1. ES ES–108 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (e) Check the engine speed while operating the Oil Control Valve (OCV) using the tester. OK Tester Operation Specified Condition OCV OFF Normal engine speed OCV ON Engine idles roughly or stalls (soon after OCV switched from OFF to ON) NG Go to step 4 OK 3 CHECK WHETHER DTC OUTPUT RECURS (DTC P0014, P0015, P0024 OR P0025) (a) (b) (c) (d) (e) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG) and turn the tester on. Clear the DTCs (See page ES-45). Start the engine and warm it up. Switch the ECM from normal mode to check mode using the tester (See page ES-49). (f) Drive the vehicle for more than 10 minutes. (g) Read the DTCs using the tester. OK: No DTC output. ES NG OK END Go to step 4 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 4 ES–109 CHECK VALVE TIMING (CHECK FOR LOOSE AND JUMPED TEETH ON TIMING CHAIN) Timing Mark Timing Mark (a) Remove the cylinder head covers RH and LH. (b) Turn the crankshaft pulley, and align its groove with the timing mark "0" of the timing chain cover. (c) Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing cap as shown in the illustration. If not, turn the crankshaft 1 revolution (360°), then align the marks as above. OK: Timing marks on crankshaft timing gears are aligned as shown in the illustration. (d) Reinstall the cylinder head covers. NG ADJUST VALVE TIMING Timing Mark Timing Mark A135015E01 OK 5 INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (OCV FOR EXHAUST CAMSHAFT) (a) Remove the OCV. (b) Measure the resistance between the terminals of the OCV. Standard resistance Valve Moves A097066E01 Tester Connection Condition Specified Condition 1-2 20°C (68°F) 6.9 to 7.9 Ω (c) Apply positive battery voltage to terminal 1 and negative battery voltage to terminal 2. Check the valve operation. OK: Valve moves quickly. (d) Reinstall the OCV. ES ES–110 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NG REPLACE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (See page ES481) OK 6 INSPECT OIL CONTROL VALVE FILTER AND PIPE (a) Remove the oil pipe No. 1 or No. 2. (b) Remove the oil control valve filter. (c) Check that the filter and pipe are not clogged. OK: Filter is not clogged. RH Bank: ES NG CLEAN OIL CONTROL VALVE FILTER AND PIPE LH Bank: G042497E01 OK 7 REPLACE EXHAUST CAMSHAFT NEXT 8 CHECK WHETHER DTC OUTPUT RECURS (a) Clear the DTCs. (1) Operate the intelligent tester, or disconnect the EFI and ETCS fuses more than 60 seconds to erase the codes. (b) Start the engine and warm up the engine. (c) Switch the ECM from normal mode to check mode using the intelligent tester (See page ES-49). (d) Drive the vehicle for more than 10 minutes or more. (e) Read the output DTCs using the intelligent tester. OK: No DTC output. 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–111 HINT: DTC P0014, P0015, P0024 or P0025 is output when foreign objects in engine oil are caught in some parts of the system. These codes will stay output even if the system returns to normal after a short time. These foreign objects are then captured by the oil, thus eliminating the source of the problem. OK SYSTEM IS OK NG REPLACE ECM (See page ES-518) ES ES–112 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0016 Crankshaft Position - Camshaft Position Correlation (Bank 1 Sensor A) DTC P0017 Crankshaft Position - Camshaft Position Correlation (Bank 1 Sensor B) DTC P0018 Crankshaft Position - Camshaft Position Correlation (Bank 2 Sensor A) DTC P0019 Crankshaft Position - Camshaft Position Correlation (Bank 2 Sensor B) ES DESCRIPTION In the VVT system, the appropriate intake and exhaust valve open and close timings are controlled by the ECM. The ECM performs intake and exhaust valve control by performing the following: 1) controlling the camshaft and camshaft oil control valve, and operating the camshaft timing gear; and 2) changing the relative positions of the gaps between the camshaft and crankshaft. DTC No. DTC Detection Condition • P0016 Deviation in crankshaft position sensor signal and VVT sensor 1 (for intake camshaft (bank 1)) signal (2 trip detection logic) Deviation in crankshaft position sensor signal and VVT sensor 1 (for exhaust camshaft (bank 1)) signal (2 trip detection logic) • P0017 • P0018 Deviation in crankshaft position sensor signal and VVT sensor 2 (for intake camshaft (bank 2)) signal (2 trip detection logic) Deviation in crankshaft position sensor signal and VVT sensor 2 (for exhaust camshaft (bank 2)) signal (2 trip detection logic) • P0019 Trouble Area • • • • Mechanical system (Timing chain has jumped teeth or chain stretched) ECM Mechanical system (Timing chain has jumped teeth or chain stretched) ECM Mechanical system (Timing chain has jumped teeth or chain stretched) ECM Mechanical system (Timing chain has jumped teeth or chain stretched) ECM MONITOR DESCRIPTION To monitor the correlation of the intake camshaft position and crankshaft position, the ECM checks the VVT learning value while the engine is idling. The VVT learning value is calibrated based on the camshaft position and crankshaft position. The intake valve timing is set to the most retarded angle while the engine is idling. If the VVT learning value is out of the specified range in consecutive driving cycles, the ECM illuminates the MIL and sets the DTC P0016 (Bank 1) or P0018 (Bank 2). To monitor the correlation of the exhaust camshaft position and crankshaft position, the ECM checks the VVT learning value while the engine is idling. The VVT learning value is calibrated based on the camshaft position and crankshaft position. The exhaust valve timing is set to the most advanced angle while the engine is idling. If the VVT learning value is out of the specified range in consecutive driving cycles, the ECM illuminates the MIL and sets the DTC P0017 (Bank 1) or P0019 (Bank 2). MONITOR STRATEGY Related DTCs P0016: Camshaft timing misalignment at idle (intake camshaft bank 1) P0017: Camshaft timing misalignment at idle (exhaust camshaft bank 1) P0018: Camshaft timing misalignment at idle (intake camshaft bank 2) P0019: Camshaft timing misalignment at idle (exhaust camshaft bank 2) Required sensors/components (Main) VVT actuator 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Required sensors/components (Sub) Camshaft position sensor, Crankshaft position sensor Frequency of operation Once per drive cycle Duration Within 1 minute MIL operation 2 driving cycles Sequence of operation None ES–113 TYPICAL ENABLING CONDITIONS All: Monitor runs whenever following DTCs are not present P0011 (VVT system 1 - advance) P0012 (VVT system 1 - retard) P0021 (VVT system 2 - advance) P0115 - P0118 (ECT sensor) Intake side: Engine speed 500 to 1,000 rpm Exhaust side: VVT feedback mode Executing VVT Maximum advanced position Engine speed 500 to 1,000 rpm TYPICAL MALFUNCTION THRESHOLDS Intake side: One of the following conditions is met: Condition 1 or 2 1. VVT leaning value at maximum retarded valve timing Less than 18.5°CA 2. VVT leaning valve at maximum retarded valve timing More than 43.5°CA Exhaust side: One of the following conditions is met: Condition 1 or 2 1. VVT leaning value Less than 77°CA 2. VVT leaning value More than 102°CA WIRING DIAGRAM Refer to DTC P0335 (See page ES-224). INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). ES ES–114 1 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK VALVE TIMING (CHECK FOR LOOSE AND A JUMPED TOOTH OF TIMING CHAIN) Timing Mark ES Timing Mark (a) Remove the cylinder head covers RH and LH. (b) Turn the crankshaft pulley, and align its groove with the timing mark "0" of the timing chain cover. (c) Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing cap as shown in the illustration. If not, turn the crankshaft 1 revolution (360°), then align the marks as above. OK: Timing marks on camshaft timing gears are aligned as shown in the illustration. (d) Reinstall the cylinder head covers. NG Timing Mark Timing Mark A135015E01 OK REPLACE ECM (See page ES-518) ADJUST VALVE TIMING (REPAIR OR REPLACE TIMING CHAIN) 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–115 DTC P0031 Oxygen (A/F) Sensor Heater Control Circuit Low (Bank 1 Sensor 1) DTC P0032 Oxygen (A/F) Sensor Heater Control Circuit High (Bank 1 Sensor 1) DTC P0051 Oxygen (A/F) Sensor Heater Control Circuit Low (Bank 2 Sensor 1) DTC P0052 Oxygen (A/F) Sensor Heater Control Circuit High (Bank 2 Sensor 1) DESCRIPTION HINT: • Although the DTC titles include oxygen sensor, these DTCs relate to the Air-Fuel Ratio (A/F) sensor. • Sensor 1 refers to the sensor mounted in front of the Three-Way Catalytic Converter (TWC) and located near the engine assembly. The A/F sensor generates voltage* that corresponds to the actual air-fuel ratio. This sensor voltage is used to provide the ECM with feedback so that it can control the air-fuel ratio. The ECM determines the deviation from the stoichiometric air-fuel ratio level, and regulates the fuel injection time. If the A/F sensor malfunctions, the ECM is unable to control the air-fuel ratio accurately. The A/F sensor is the planar type and is integrated with the heater, which heats the solid electrolyte (zirconia element). This heater is controlled by the ECM. When the intake air volume is low (the exhaust gas temperature is low), a current flows into the heater to heat the sensor, in order to facilitate accurate oxygen concentration detection. In addition, the sensor and heater portions are narrower than the conventional type. The heat generated by the heater is conducted to the solid electrolyte through the alumina, therefore the sensor activation is accelerated. A three-way catalytic converter (TWC) is used in order to convert the carbon monoxide (CO), hydrocarbon (HC), and nitrogen oxide (NOx) into less harmful substances. To allow the TWC to function effectively, it is necessary to keep the air-fuel ratio of the engine near the stoichiometric air-fuel ratio. *: Value changes inside the ECM. Since the A/F sensor is the current output element, a current is converted to a voltage inside the ECM. Any measurements taken at the A/F sensor or ECM connectors will show a constant voltage. ES ES–116 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Ideal Air-Fuel Mixture Output Voltage Heater Solid electrolyte (Zirconia Element) Element Platinum electrode Cover ES Air Exhaust Gas A A Rich - Air Fuel Ratio - Lean A-A Section A107164E13 HINT: • When any of these DTCs are set, the ECM enters fail-safe mode. The ECM turns off the A/F sensor heater in fail-safe mode. Fail-safe mode continues until the engine switch is turned off. • The ECM provides a pulse width modulated control circuit to adjust the current through the heater. The A/F sensor heater circuit uses a relay on the B+ side of the circuit. Reference (System Diagram of Bank 1 Sensor 1): A/F Relay From Battery ECM A/F Sensor A/F +B Heater HA1A HA1A A1A+ A1A+ Sensor A1A- From EFI Relay Duty Control A1A- A133850E04 DTC No. DTC Detection Condition P0031 P0051 Air-Fuel Ratio (A/F) sensor heater (bank 1, 2, sensor 1) current is less than 0.8 A (1 trip detection logic) Trouble Area • • • • Open in A/F sensor heater (bank 1, 2, sensor 1) circuit A/F sensor heater (bank 1, 2, sensor 1) A/F HTR relay ECM ES–117 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. DTC Detection Condition Trouble Area • P0032 P0052 Air-Fuel Ratio (A/F) sensor heater (bank 1, 2, sensor 1) current is more than 10 A (1 trip detection logic) • • • Short in A/F sensor heater (bank 1, 2, sensor 1) circuit A/F sensor heater (sensor 1) A/F HTR relay ECM HINT: • Bank 1 refers to the bank that includes cylinder No. 1. • Bank 2 refers to the bank that does not include cylinder No. 1. • Sensor 1 refers to the sensor closest to the engine assembly. • Sensor 2 refers to the sensor farthest away from the engine assembly. MONITOR DESCRIPTION 1. The ECM uses information from the Air-Fuel Ratio (A/F) sensor to regulate the air-fuel ratio and keep it close to the stoichiometric level. This maximizes the ability of the Three-Way Catalytic Converter (TWC) to purify the exhaust gases. 2. The A/F sensor detects oxygen levels in the exhaust gas and transmits the information to the ECM. The inner surface of the sensor element is exposed to the outside air. The outer surface of the sensor element is exposed to the exhaust gas. The sensor element is made of platinum coated zirconia and includes an integrated heating element. 3. The zirconia element generates a small voltage when there is a large difference in the oxygen concentrations between the exhaust gas and outside air. The platinum coating amplifies this voltage generation. 4. The A/F sensor is more efficient when heated. When the exhaust gas temperature is low, the sensor cannot generate useful voltage signals without supplementary heating. The ECM regulates the supplementary heating using a duty-cycle approach to adjust the average current in the sensor heater element. If the heater current is outside the normal range, the signal transmitted by the A/F sensor will be inaccurate, as a result, the ECM will be unable to regulate air-fuel ratio properly. 5. When the current in the A/F sensor heater is outside the normal operating range, the ECM interprets this as a malfunction in the sensor heater and sets a DTC. Example: The ECM sets DTC P0032 or P0052 when the current in the A/F sensor heater is more than 10 A. Conversely, when the heater current is less than 0.8 A, DTC P0031 or P0051 is set. MONITOR STRATEGY Related DTCs P0031: A/F sensor heater (bank 1) open/short (Low electrical current) P0032: A/F sensor heater (bank 1) open/short (High electrical current) P0051: A/F sensor heater (bank 2) open/short (Low electrical current) P0052: A/F sensor heater (bank 2) open/short (High electrical current) Required sensors / components (Main) A/F sensor heater (bank 1 and 2) Required sensors / components (Sub) - Frequency of operation Continuous Duration 10 seconds MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS All: Monitor runs whenever following DTCs are not present P0300 - P0306 (misfire) P0031 and P0051: Battery voltage 10.5 V or more Heater output duty 50 % or more ES ES–118 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Time after engine start 10 seconds or more P0032 and P0052: Battery voltage Less than 20 V Engine Running Heater output duty More than 0 % TYPICAL MALFUNCTION THRESHOLDS P0031 and P0051: A/F sensor heater current Less than 0.8 A P0032 and P0052: Hybrid IC high current limiter port ES Fail COMPONENT OPERATING RANGE P0031 and P0051: A/F sensor heater current 1.8 to 3.4 A at 20°C (68°F) WIRING DIAGRAM Refer to DTC P2195 (See page ES-350) INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). ES–119 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 1 INSPECT AIR FUEL RATIO SENSOR (HEATER RESISTANCE) (a) Disconnect the C15 or C35 A/F sensor connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance (Bank 1 sensor 1) Component Side: Air Fuel Ratio Sensor +B HA1A C15 Bank 1 Tester Connection Condition Specified Condition HA1A (1) - +B (2) 20°C (68°F) 1.8 to 3.4 Ω HA1A (1) - A1A- (4) - 10 kΩ or higher Standard resistance (Bank 2 sensor 1) A1A- A1A+ Tester Connection Condition Specified Condition HA2A (1) - +B (2) 20°C (68°F) 1.8 to 3.4 Ω HA2A (1) - A2A- (4) - 10 kΩ or higher (c) Reconnect the A/F sensor connector. +B HA2A NG C35 Bank 2 REPLACE AIR FUEL RATIO SENSOR (See page EC-19) A2A+ A2A- A140627E01 OK 2 CHECK TERMINAL VOLTAGE (+B OF A/F SENSOR) (a) Disconnect the C15 or C35 A/F sensor Connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage between the terminals of the A/F sensor connector and body ground. Standard voltage Wire Harness Side Front View: A/F Sensor Connector C15 : Bank 1 +B C35 : Bank 2 Tester Connection Specified Condition +B (C15-2) - Body ground 9 to 14 V +B (C35-2) - Body ground 9 to 14 V A076787E15 OK Go to step 7 NG 3 INSPECT FUSE (A/F) (a) Remove the A/F sensor fuse from the No. 1 integration relay. (b) Measure the A/F sensor fuse resistance. Standard resistance: Below 1 Ω (c) Reinstall the A/F fuse. NG REPLACE A/F FUSE ES ES–120 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK 4 INSPECT ENGINE ROOM JUNCTION BLOCK (EFI RELAY, A/F RELAY) (a) Remove the engine room junction block from the engine room R/B. (b) Inspect the EFI relay. (1) Measure the EFI relay resistance. Standard resistance Engine Room Junction Block 1G 1A Tester Connection Specified Condition 1E-12 - 1E-6 10 kΩ or higher 1E-12 - 1E-6 Below 1 Ω (Apply battery voltage between terminals 1E-9 and 1E-10) ES (c) Inspect the A/F relay. (1) Measure the A/F relay resistance. Standard resistance 1E Tester Connection Specified Condition 1G-1 - 1A-4 10 kΩ or higher 1G-1 - 1A-4 Below 1 Ω (Apply battery voltage between terminals 1E-9 and 1E-10) NG REPLACE ENGINE ROOM JUNCTION BLOCK Engine Room Relay Block A140654E01 OK 5 INSPECT FUSE (EFI MAIN) EFI MAIN (a) Remove the EFI MAIN fuse from the engine room R/B. (b) Measure the EFI MAIN fuse resistance. Standard resistance: Below 1 Ω (c) Reinstall the EFI MAIN fuse. NG Engine Room Relay Block A135017E01 REPLACE EFI MAIN FUSE ES–121 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK 6 CHECK HARNESS AND CONNECTOR (A/F SENSOR - A/F RELAY) (a) Disconnect the C15 or C35 A/F sensor connector. (b) Remove the engine room junction block from the engine room R/B. (c) Measure the resistance between the terminals. Standard resistance (Check for open) Wire Harness Side: A/F Sensor Connector C15 : Bank 1 C35 : Bank 2 Tester Connection Specified Condition +B (C15-2) - 1A-4 (Engine room R/B) Below 1 Ω +B (C35-2) - 1A-4 (Engine room R/B) Below 1 Ω Standard resistance (Check for short) Engine Room Junction Block Tester Connection Specified Condition +B (C15-2) or 1A-4 (Engine room R/B) - Body ground 10 kΩ or higher +B (C35-2) or 1A-4 (Engine room R/B) - Body ground 10 kΩ or higher (d) Reinstall the engine room junction block. (e) Reconnect the A/F sensor connector. NG A1 REPAIR OR REPLACE HARNESS OR CONNECTOR Engine Room Relay Block A141109E01 OK CHECK ECM POWER SOURCE CIRCUIT (See page ES-432) ES ES–122 7 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (a) Disconnect the C15 or C35 A/F sensor connector. (b) Disconnect the C55 ECM connector. (c) Measure the resistance between the terminals. Standard resistance (Check for open) Wire Harness Side: A/F Sensor Connector C15 : Bank 1 Tester Connection Specified Condition HA1A (C55-86) - HA1A (C15-1) Below 1 Ω HA2A (C55-109) - HA2A (C35-1) Below 1 Ω C35 : Bank 2 ES Standard resistance (Check for short) C55 ECM Connector A1A+ Tester Connection Specified Condition HA1A (C55-86) or HA1A (C15-1) - Body ground 10 kΩ or higher HA2A (C55-109) or HA2A (C35-1) - Body ground 10 kΩ or higher (d) Reconnect the ECM connector. (e) Reconnect the A/F sensor connectors. NG A1A- A2A- A2A+ HA2A REPAIR OR REPLACE HARNESS OR CONNECTOR HA1A A127715E19 OK 8 CHECK WHETHER DTC OUTPUT RECURS (a) (b) (c) (d) (e) (f) (g) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the intelligent tester on. Clear the DTCs (See page ES-45). Start the engine. Allow the engine to idle for 1 minute or more. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (h) Read the DTCs. Result Display (DTC Output) Proceed to No output A P0031, P0032, P0051 and/or P0052 B B A CHECK FOR INTERMITTENT PROBLEMS REPLACE ECM (See page ES-518) 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–123 DTC P0037 Oxygen Sensor Heater Control Circuit Low (Bank 1 Sensor 2) DTC P0038 Oxygen Sensor Heater Control Circuit High (Bank 1 Sensor 2) DTC P0057 Oxygen Sensor Heater Control Circuit Low (Bank 2 Sensor 2) DTC P0058 Oxygen Sensor Heater Control Circuit High (Bank 2 Sensor 2) DTC P0141 Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 2) DTC P0161 Oxygen Sensor Heater Circuit Malfunction (Bank 2 Sensor 2) DESCRIPTION A three-way catalytic converter (TWC) is used in order to convert the carbon monoxide (CO), hydrocarbon (HC), and nitrogen oxide (NOx) into less harmful substances. To allow the TWC to function effectively, it is necessary to keep the air-fuel ratio of the engine near the stoichiometric air-fuel ratio. For the purpose of helping the ECM to deliver accurate air-fuel ratio control, a Heated Oxygen (HO2) sensor is used. The HO2 sensor is located behind the TWC, and detects the oxygen concentration in the exhaust gas. Since the sensor is integrated with the heater that heats the sensing portion, it is possible to detect the oxygen concentration even when the intake air volume is low (the exhaust gas temperature is low). When the air-fuel ratio becomes lean, the oxygen concentration in the exhaust gas becomes rich. The HO2 sensor informs the ECM that the post-TWC air-fuel ratio is lean (low voltage, i.e. less than 0.45 V). Conversely, when the air-fuel ratio is richer than the stoichiometric air-fuel level, the oxygen concentration in the exhaust gas becomes lean. The HO2 sensor informs the ECM that the post-TWC air-fuel ratio is rich (high voltage, i.e. more than 0.45 V). The HO2 sensor has the property of changing its output voltage drastically when the air-fuel ratio is close to the stoichiometric level. The ECM uses the supplementary information from the HO2 sensor to determine whether the air-fuel ratio after the TWC is rich or lean, and adjusts the fuel injection time accordingly. Thus, if the HO2 sensor is working improperly due to internal malfunctions, the ECM is unable to compensate for deviations in the primary air-fuel ratio control. ES ES–124 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Atmospheric Air Ideal Air-Fuel Mixture Housing Output Voltage Solid Electrolyte (Zirconia Element) Platinum Electrode Heater Cover Richer - Air-Fuel Ratio - Leaner Coating (Ceramic) Exhaust Gas ES A088111E14 HINT: • Sensor 2 refers to the sensor mounted behind the Three-Way Catalytic Converter (TWC) and located far from the engine assembly. • When any of these DTCs are set, the ECM enters fail-safe mode. The ECM turns off the Heated Oxygen (HO2) Sensor heater in fail-safe mode. Fail-safe mode continues until the engine switch is turned off. • The ECM provides a pulse width modulated control circuit to adjust the current through the heater. The HO2 sensor heater circuit uses a relay on the B+ side of the circuit. Reference (System Diagram of Bank 1 Sensor 2): HO2 Sensor EFI Relay From Battery EFI MAIN EFI No. 3 +B E2 ECM Heater Sensor HT1B HT1B OX1B OX1B Duty Control EX1B MREL Ground A103832E40 DTC No. DTC Detection Condition Trouble Area P0037 P0057 Heated Oxygen (HO2) sensor heater current is less than 0.3 A (1 trip detection logic) • • • • P0038 P0058 Heated Oxygen (HO2) sensor heater current is more than 2 A (1 trip detection logic) • • • • Open in HO2 sensor heater circuit HO2 sensor heater Engine room junction block (EFI relay) ECM Short in HO2 sensor heater circuit HO2 sensor heater Engine room junction block (EFI relay) ECM ES–125 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. DTC Detection Condition P0141 P0161 Cumulative heater resistance correction value exceeds the acceptable threshold. (2 trip detection logic) Trouble Area • • HO2 sensor heater ECM HINT: • Bank 1 refers to the bank that includes cylinder No. 1. • Bank 2 refers to the bank that does not include cylinder No. 1. • Sensor 1 refers to the sensor closest to the engine assembly. • Sensor 2 refers to the sensor farthest away from the engine assembly. MONITOR DESCRIPTION The sensing position of the Heated Oxygen (HO2) sensor has a zirconia element which is used to detect the oxygen concentration in the exhaust gas. If the zirconia element is at the appropriate temperature, and the difference between the oxygen concentrations surrounding the inside and outside surfaces of the sensor is large, the zirconia element generates voltage signals. In order to increase the oxygen concentration detecting capacity of the zirconia element, the ECM supplements the heat from the exhaust with heat from a heating element inside the sensor. Heated oxygen sensor heater range check (P0037,P0038, P0057 and P0058): The ECM monitors the current applied to the O2 sensor heater to check the heater for malfunctions. If the current is below the threshold value, the ECM will determine that there is an open circuit in the heater. If the current is above the threshold value, the ECM will determine that there is a short circuit in the heater. Example: The ECM sets DTC P0038 or P0058 when the current in the HO2 sensor heater is more than 2 A. Conversely, when the heater current is less than 0.3 A, DTC P0037 or P0057 is set. Heated oxygen sensor heater performance (P0141 and P0161): After the accumulated heater ON time exceeds 100 seconds, the ECM calculates the heater resistance using the battery voltage and the current applied to the heater. If the resistance is above the threshold value, the ECM will determine that there is a malfunction in the HO2S heater and set DTC P0141 and P0161. MONITOR STRATEGY Related DTCs P0037: Heated oxygen sensor heater (bank 1 sensor 2) open/short (Low electrical current) P0038: Heated oxygen sensor heater (bank 1 sensor 2) open/short (High electrical current) P0057: Heated oxygen sensor heater (bank 2 sensor 2) open/short (Low electrical current) P0058: Heated oxygen sensor heater (bank 2 sensor 2) open/short (High electrical current) P0141: Heated oxygen sensor heater performance (bank 1 sensor 2) P0161: Heated oxygen sensor heater performance (bank 2 sensor 2) Required sensors / components (Main) Heated oxygen sensor heater (bank 1 sensor 2) Heated oxygen sensor heater (bank 2 sensor 2) Required sensors / components (Sub) Vehicle speed sensor Frequency of operation Continuous Duration 1 second: P0037, P0038, P0057 and P0058 10 seconds: P0141 and P0161 MIL operation Immediate: P0037, P0038, P0057 and P0058 2 driving cycles: P0141 and P0161 Sequence of operation None TYPICAL ENABLING CONDITIONS All: Monitor runs whenever following DTCs are not present None ES ES–126 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM P0037 and P0057: Battery voltage 10.5 to 20 V P0038 and P0058 (Case 1): Battery voltage 10.5 V or more Engine Running Starter OFF P0038 and P0058 (Case 2): Battery voltage 10.5 to 20 V P0141 and P0161: ES One of the following conditions is met: Condition A or B A. All of the following conditions are met: Conditions 1, 2, 3, 4 and 5 1. Battery voltage 10.5 V or more 2. Fuel cut OFF 3. Time after fuel cut ON to OFF 30 seconds or more 4. Accumulated heater ON time 100 seconds or more 5. Learned heater OFF current operation Completed B. Duration that rear heated oxygen sensor impedance is less than 15 kΩ 2 seconds or more TYPICAL MALFUNCTION THRESHOLDS P0037 and P0057: Heater current Less than 0.3 A P0038 and P0058: One of the following conditions is met: Condition A or B A. Learned heater OFF current More than 2 A B. Heater current 2 A or more P0141 and P0161 (Heater performance monitor check): Accumulated heater resistance Varies with sensor element temperature (Example: More than 23 ohm) COMPONENT OPERATING RANGE Heated Oxygen (HO2) sensor heater current 0.4 to 1 A (when engine idles, HO2 sensor warmed up and battery voltage 11 to 14 V) MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-25). WIRING DIAGRAM Refer to DTC P0136 (See page ES-178). INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). ES–127 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 1 INSPECT HEATED OXYGEN SENSOR (HEATER RESISTANCE) (a) Disconnect the C52 heated oxygen sensor connector (Bank 1 Sensor 2) or C51 heated oxygen sensor connector (Bank 2 Sensor 2). (b) Measure the resistance according to the value(s) in the table below. Standard resistance (Bank 1 sensor 2) Component Side: Heated Oxygen Sensor +B HT1B Tester Connection Condition C52 HT1B (1) - +B (2) 20°C (68°F) 11 to 16 Ω Bank 1 HT1B (1) - E2 (4) Always 10 kΩ or higher E2 OX1B Standard resistance (Bank 2 sensor 2) HT2B +B Specified Condition Tester Connection Condition Specified Condition HT2B (1) - +B (2) 20°C (68°F) 11 to 16 Ω HT2B (1) - E2 (4) Always 10 kΩ or higher (c) Reconnect the HO2 sensor connector. C51 Bank 2 E2 NG OX2B REPLACE HEATED OXYGEN SENSOR (See page EC-20) A137614E06 OK 2 CHECK TERMINAL VOLTAGE (+B OF HO2 SENSOR) Wire Harness Side: Heated Oxygen Sensor Connector C52 +B Bank 1 (a) Disconnect the C52 heated oxygen sensor connector (Bank 1 Sensor 2) or C51 heated oxygen sensor connector (Bank 2 Sensor 2). (b) Turn the ignition switch on (IG). (c) Measure the voltage between the terminals. Standard voltage Tester Connection Specified Condition +B (C52-2) - Body ground 9 to 11 V +B (C51-2) - Body ground 9 to 11 V (d) Reconnect the HO2 sensor connector. OK +B C51 Bank 2 A137619E01 NG Go to step 7 ES ES–128 3 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT FUSE (EFI NO. 3) (a) Remove the EFI No. 3 fuse from the engine room R/B. (b) Measure the EFI No. 3 fuse resistance. Standard resistance: Below 1 Ω (c) Reinstall the EFI No. 3 fuse. EFI No. 3 NG REPLACE EFI NO. 3 FUSE Engine Room Relay Block ES A135018E01 OK 4 INSPECT ENGINE ROOM JUNCTION BLOCK (a) Remove the engine room junction block from the engine room R/B. (b) Inspect the EFI relay. (1) Measure the EFI relay resistance. Standard resistance Engine Room Junction Block Tester Connection Specified Condition 1E-12 - 1E-6 10 kΩ or higher 1E-12 - 1E-6 Below 1 Ω (Apply battery voltage between terminals 1E-9 and 1E-10) (c) Reinstall the engine room junction block. 1E NG Engine Room Relay Block A140654E02 OK REPLACE ENGINE ROOM JUNCTION BLOCK 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 5 INSPECT FUSE (EFI MAIN) EFI MAIN (a) Remove the EFI MAIN fuse from the engine room R/B. (b) Measure the EFI MAIN fuse. Standard resistance: Below 1 Ω (c) Reinstall the EFI MAIN fuse. NG Engine Room Relay Block REPLACE EFI MAIN FUSE ES A135017E01 OK ES–129 ES–130 6 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (HO2 SENSOR - EFI RELAY) Wire Harness Side: Heated Oxygen Sensor Connector C52 (a) Disconnect the C52 or C51 HO2 sensor connector. (b) Remove the engine room junction block from the engine room R/B. (c) Measure the resistance between the terminals. Standard resistance (Check for open) +B Bank 1 Tester Connection Specified Condition +B (C52-2) - 1E-6 (Engine room R/B) Below 1 Ω +B (C51-2) - 1E-6 (Engine room R/B) Below 1 Ω Standard resistance (Check for short) ES +B C51 Bank 2 Tester Connection Specified Condition +B (C52-2) or 1E-6 (Engine room R/B) - Body ground 10 kΩ or higher +B (C51-2) or 1E-6 (Engine room R/B) - Body ground 10 kΩ or higher (d) Reinstall the engine room junction block. (e) Reconnect the HO2 sensor connector. NG Engine Room Junction Block 1E Engine Room Rlay Block A140656E01 OK CHECK ECM POWER SOURCE CIRCUIT REPAIR OR REPLACE HARNESS OR CONNECTOR ES–131 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 7 CHECK HARNESS AND CONNECTOR (HO2 SENSOR - ECM) (a) Disconnect the C52 heated oxygen sensor connector (Bank 1 Sensor 2) or C51 heated oxygen sensor connector (Bank 2 Sensor 2). (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness Side: Heated Oxygen Sensor Connector HT1B +B C52 Bank 1 E2 OX1B HT2B C51 Bank 2 E2 C55 ECM Connector EX2B HT2B Specified Condition 9 to 14 V +B (C51-2) - Body ground 9 to 14 V (d) Turn the engine switch off. (e) Disconnect the C55 ECM connector. (f) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for open) +B OX2B Terminal Connection +B (C52-2) - Body ground Terminal Connection Specified Condition HT1B (C52-1) - HT1B (C55-48) Below 1 Ω OX1B (C52-3) - OX1B (C55-88) Below 1 Ω E2 (C52-4) - EX1B (C55-65) Below 1 Ω HT2B (C51-1) - HT2B (C55-47) Below 1 Ω OX2B (C51-3) - OX2B (C55-87) Below 1 Ω E2 (C51-4) - EX2B (C55-64) Below 1 Ω HT1B Standard resistance (Check for short) OX2B OX1B EX1B A137615E06 Terminal Connection Specified Condition HT1B (C52-1) or HT1B (C55-48) - Body ground 10 kΩ or higher OX1B (C52-3) - OX1B (C55-88) - Body ground 10 kΩ or higher E2 (C52-4) or EX1B (C55-65) - Body ground 10 kΩ or higher HT2B (C51-1) or HT2B (C55-47) - Body ground 10 kΩ or higher OX2B (C51-3) or OX2B (C55-87) - Body ground 10 kΩ or higher E2 (C51-4) or EX2B (C55-64) - Body ground 10 kΩ or higher (g) Reconnect the HO2 sensor connector. (h) Reconnect the ECM connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 8 CHECK WHETHER DTC OUTPUT RECURS (a) (b) (c) (d) (e) (f) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the intelligent tester on. Clear the DTCs (See page ES-45). Start the engine. Allow the engine to idle for 2 minutes. ES ES–132 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (g) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (h) Read the DTCs. Result Display (DTC Output) Proceed to No output A P0037, P0038, P0057 and/or P0058 B B REPLACE ECM (See page ES-518) A CHECK FOR INTERMITTENT PROBLEMS (See page ES-33) ES ES–133 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0100 Mass or Volume Air Flow Circuit DTC P0102 Mass or Volume Air Flow Circuit Low Input DTC P0103 Mass or Volume Air Flow Circuit High Input DESCRIPTION The Mass Air Flow (MAF) meter is a sensor that measures the amount of air flowing through the valve. The ECM uses this information to determine the fuel injection time and to prove appropriate air-fuel ratio. Inside the MAF meter, there is a heated platinum wire which is exposed to the flow of intake air. By applying a specific electrical current to the wire, the ECM heats it to a given temperature. The flow of incoming air cools both the wire and an internal thermistor, affecting their resistance. To maintain a constant current value, the ECM varies the voltage applied to these components in the MAF meter. The voltage level is proportional to the airflow through the sensor, and the ECM uses it to calculate the intake air volume. The circuit is constructed so that the platinum hot wire and the temperature sensor provide a bridge circuit, and the power transistor is controlled so that the potentials of A and B remain equal to maintain the predetermined temperature. HINT: When any of these DTCs are set, the ECM enters fail-safe mode. During fail-safe mode, the ignition timing is calculated by the ECM, according to the engine RPM and throttle valve position. Fail-safe mode continues until a pass condition is detected. +B Temperature Sensor (Thermistor) Power Transistor Platinum Hot Wire (Heater) A B Output Voltage Temperature Sensor (Thermistor) Platinum Hot Wire (Heater) A140749E04 DTC No. DTC Detection Condition Trouble Area P0100 Open or short in Mass Air Flow (MAF) meter circuit for 3 seconds • • • Open or short in MAF meter circuit MAF meter ECM P0102 Open in Mass Air Flow (MAF) meter circuit for 3 seconds • • • • Open in MAF meter circuit Short in MAF meter circuit MAF meter ECM P0103 Short in Mass Air Flow (MAF) meter circuit for 3 seconds • • • Short in MAF meter circuit (+B circuit) MAF meter ECM ES ES–134 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: When any of these DTCs are set, check the air-flow rate by entering the following menus on the intelligent tester: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / MAF. Mass Air Flow Rate (gm/s) Approximately 0.0 271.0 or more Malfunctions • • Open in Mass Air Flow (MAF) meter power source circuit Open or short in VG circuit Open in EVG circuit MONITOR DESCRIPTION ES If there is a defect in the MAF meter or an open or short circuit, the voltage level deviates from the normal operating range. The ECM interprets this deviation as a malfunction in the MAF meter and sets a DTC. Example: When the sensor output voltage remains less than 0.2 V, or more than 4.9 V, for more than 3 seconds, the ECM sets a DTC. If the malfunction is not repaired successfully, a DTC is set 3 seconds after the engine is next started. MONITOR STRATEGY Related DTCs P0100: Mass air flow meter range check (Fluctuating) P0102: Mass air flow meter range check (Low voltage) P0103: Mass air flow meter range check (High voltage) Required Sensors/Components (Main) MAF meter Required Sensors/Components (Sub) Crankshaft position sensor Frequency of Operation Continuous Duration 3 seconds MIL Operation Immediate: Engine RPM less than 4,000 rpm 2 driving cycles: Engine RPM 4,000 rpm or more Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present None TYPICAL MALFUNCTION THRESHOLDS P0100: Mass air flow meter voltage Less than 0.2 V, or more than 4.9 V P0102: Mass air flow meter voltage Less than 0.2 V P0103: Mass air flow meter voltage More than 4.9 V COMPONENT OPERATING RANGE Mass air flow meter voltage Between 0.4 V and 2.2 V ES–135 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM C2 MAF Meter EFI No. 3 +B VG 3 5 E2G 4 72 C55 VG 73 C55 E2G EFI Relay 44 A55 MREL ES EFI MAIN FL MAIN Battery A117876E02 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). 1 READ VALUE OF MASS AIR FLOW METER (MAF) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Start the engine. Turn the tester on. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / MAF. (e) Read the values displayed on the tester. ES–136 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Result Mass Air Flow Rate (gm/s) Proceed to 0.0 A 271.0 or more B Between 1.0 and 270.0 (*1) C *1: The value must be changed when the throttle valve is open or closed. B C Go to step 8 CHECK FOR INTERMITTENT PROBLEMS (See page ES-33) A ES 2 INSPECT MASS AIR FLOW METER (POWER SOURCE VOLTAGE) (a) Disconnect the C2 mass air flow (MAF) meter connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness Side Front View: +B (+) C2 MAF Meter Connector Tester Connection Specified Condition +B (C2-3) - Body ground 9 to 14 V (d) Reconnect the MAF meter connector. A127724E07 NG Go to step 5 OK 3 INSPECT MASS AIR FLOW METER (VG VOLTAGE) MAF Meter VG E2G +B 5 4 3 2 1 A127786E02 OK (a) Inspect the output voltage. (1) Apply battery voltage across terminals +B and E2G. (2) Connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E2G. (3) Measure the voltage between the terminals. Standard voltage Tester Connection Specified Condition 5 (VG) - 4 (E2G) 0.2 to 4.9 V NG REPLACE MASS AIR FLOW METER ES–137 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 4 CHECK HARNESS AND CONNECTOR (MASS AIR FLOW METER - ECM) (a) Disconnect the C2 MAF meter connector. (b) Disconnect the C55 ECM connector. (c) Measure the resistance between the terminals. Standard resistance (Check for open) Wire Harness Side: MAF Meter Connector C2 Specified Condition VG (C55-72) - VG (C2-5) Below 1 Ω E2G (C55-73) - E2G (C2-4) Below 1 Ω Standard resistance (Check for short) E2G C55 Tester Connection VG Tester Connection ECM Connector Specified Condition VG (C55-72) or VG (C2-5) - Body ground 10 kΩ or higher E2G (C55-73) or E2G (C2-4) - Body ground 10 kΩ or higher (d) Reconnect the MAF meter connector. (e) Reconnect the ECM connector. NG VG REPAIR OR REPLACE HARNESS OR CONNECTOR E2G A127959E13 OK REPLACE ECM 5 INSPECT FUSE (EFI NO. 3) (a) Remove the EFI No. 3 fuse from the engine room R/B. (b) Measure the EFI No. 3 fuse resistance. Standard resistance: Below 1 Ω (c) Reinstall the EFI No. 3 fuse. EFI No. 3 Engine Room Relay Block A135018E01 OK NG REPLACE EFI NO. 3 FUSE ES ES–138 6 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (MASS AIR FLOW METER - ENGINE ROOM JUNCTION BLOCK) (a) Disconnect the C2 MAF meter connector. (b) Remove the engine room junction block from the engine room R/B. (c) Measure the resistance between the terminals. Standard resistance (Check for open) Wire Harness Side: MAF Meter Connector C2 Tester Connection Specified Condition +B (C2-3) - 1E-6 (Engine room R/B) Below 1 Ω Standard resistance (Check for short) ES Tester Connection Specified Condition +B (C2-3) or 1E-6 (Engine room R/B) - Body ground 10 kΩ or higher (d) Reinstall the engine room junction block. (e) Reconnect the C2 MAF meter connector. NG Engine Room Junction Block 1E Engine Room Relay Block A140657E01 OK REPAIR OR REPLACE HARNESS OR CONNECTOR ES–139 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 7 INSPECT ENGINE ROOM JUNCTION BLOCK (EFI RELAY) (a) Remove the engine room junction block from the engine room R/B. (b) Inspect the EFI relay. (1) Measure the EFI relay resistance. Standard resistance Engine Room Junction Block Tester Connection Specified Condition 1E-12 - 1E-6 10 kΩ or higher 1E-12 - 1E-6 Bellow 1 Ω (Apply battery voltage between terminals 1E9 and 1E-10) (c) Reinstall the engine room junction block. 1E NG REPLACE ENGINE ROOM JUNCTION BLOCK Engine Room Relay Block A140654E02 OK CHECK ECM POWER SOURCE CIRCUIT (See page ES-432) 8 CHECK HARNESS AND CONNECTOR (SENSOR GROUND) (a) Disconnect the C2 MAF meter connector. (b) Measure the resistance between the terminals. Standard resistance Wire Harness Side Front View: E2G Tester Connection Specified Condition E2G (C2-4) - Body ground Below 1 Ω (c) Reconnect the MAF meter connector. C2 OK MAF Meter Connector A127724E08 NG REPLACE MASS AIR FLOW METER (See page ES-477) ES ES–140 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 9 CHECK HARNESS AND CONNECTOR (MASS AIR FLOW METER - ECM) (a) Disconnect the C2 MAF meter connector. (b) Disconnect the C55 ECM connector. (c) Measure the resistance between the terminals. Standard resistance (Check for open) Wire Harness Side: MAF Meter Connector C2 C55 Specified Condition VG (C55-72) - VG (C2-5) Below 1 Ω E2G (C55-73) - E2G (C2-4) Below 1 Ω Standard resistance (Check for short) E2G ES Tester Connection VG Tester Connection ECM Connector Specified Condition VG (C55-72) or VG (C2-5) - Body ground 10 kΩ or higher E2G (C55-73) or E2G (C2-4) - Body ground 10 kΩ or higher (d) Reconnect the MAF meter connector. (e) Reconnect the ECM connector. NG VG E2G A127959E13 OK REPLACE ECM (See page ES-518) REPAIR OR REPLACE HARNESS OR CONNECTOR ES–141 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0101 Mass Air Flow Circuit Range / Performance Problem DESCRIPTION The Mass Air Flow (MAF) meter is a sensor that measures the amount of air flowing through the valve. The ECM uses this information to determine the fuel injection time and to prove appropriate air-fuel ratio. Inside the MAF meter, there is a heated platinum wire which is exposed to the flow of intake air. By applying a specific electrical current to the wire, the ECM heats it to a given temperature. The flow of incoming air cools both the wire and an internal thermistor, affecting their resistance. To maintain a constant current value, the ECM varies the voltage applied to these components in the MAF meter. The voltage level is proportional to the airflow through the sensor, and the ECM uses it to calculate the intake air volume. The circuit is constructed so that the platinum hot wire and the temperature sensor provide a bridge circuit, and the power transistor is controlled so that the potentials of A and B remain equal to maintain the predetermined temperature. HINT: When any of these DTCs are set, the ECM enters fail-safe mode. During fail-safe mode, the ignition timing is calculated by the ECM, according to the engine RPM and throttle valve position. Fail-safe mode continues until a pass condition is detected. +B Temperature Sensor (Thermistor) Power Transistor Platinum Hot Wire (Heater) A B Output Voltage Temperature Sensor (Thermistor) Platinum Hot Wire (Heater) A140749E05 DTC No. DTC Detection Condition P0101 Test value calculated with engine load and fuel trim are out of specified threshold under the following conditions (2 trip detection logic): – Engine load is 30 % or more and constant – Engine coolant temperature is 70°C (158°F) or higher Trouble Area MAF meter ES ES–142 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR DESCRIPTION The MAF meter is a sensor that measures the amount of air flowing through the throttle valve. The ECM uses this information to determine the fuel injection time and to provide an appropriate air-fuel ratio. Inside the MAF meter, there is a heated platinum wire which is exposed to the flow of intake air. By applying a specific electrical current to the wire, the ECM heats it to a specific temperature. The flow of incoming air cools both the wire and an internal thermistor, affecting their resistance. To maintain a constant current value, the ECM varies the voltage applied to these components of the MAF meter. The voltage level is proportional to the airflow through the sensor, and the ECM uses it to calculate the intake air volume. If there is a defect in the sensor, or an open or short in the circuit, the voltage level deviates from the normal operating range. The ECM interprets this deviation as a malfunction in the MAF meter and sets the DTC. Example: If the voltage is more than 2.2 V, or less than 1.48 V while idling, the ECM determines that there is a malfunction in the MAF meter and sets the DTC. ES MONITOR STRATEGY Related DTCs P0101: Mass air flow meter rationality Required Sensors/Components (Main) Mass air flow meter Required Sensors/Components (Sub) Crankshaft position sensor, engine coolant temperature sensor and throttle position sensor Frequency of Operation Continuos Duration 10 seconds MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present P0115 - P0118 (ECT sensor) P0120 - P0223, P2135 (TP sensor) P0125 (Insufficient ECT for closed loop) P0335 (CKP sensor) P0340, P0341 (CMP sensor) TP (Throttle position) sensor voltage 0.24 V or more Engine Running Battery voltage 10.5 V or more ECT 70°C (158°F) or more IAT sensor circuit OK ECT sensor circuit OK CKP sensor circuit OK TP sensor circuit OK FTP sensor circuit OK EVAP leak detection pump OK EVAP vent valve OK TYPICAL MALFUNCTION THRESHOLDS Average engine load WIRING DIAGRAM Refer to DTC P0100 (See page ES-127). Less than 0.838 %, or more than 1.287 % 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–143 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P0101) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the tester on. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. Result Display (DTC Output) Proceed to P0101 and other DTCs A P0101 B (e) Read the DTCs. HINT: If any DTCs other than P0101 are output, troubleshoot those DTCs first. B A GO TO DTC CHART (See page ES-63) REPLACE MASS AIR FLOW METER (See page ES-477) ES ES–144 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0110 Intake Air Temperature Circuit Malfunction DTC P0112 Intake Air Temperature Circuit Low Input DTC P0113 Intake Air Temperature Circuit High Input DESCRIPTION Fig. 1 Resistance (kΩ) ES Acceptable Temperature (°C) (°F) A067628E20 The Intake Air Temperature (IAT) sensor, mounted on the Mass Air Flow (MAF) meter, monitors the IAT. The IAT sensor has a built-in thermistor with a resistance that varies according to the temperature of the intake air. When the IAT drops, the resistance of the thermistor increases. When the temperature rises, the resistance drops. These variations in resistance are transmitted to the ECM as voltage changes (See Fig. 1). The IAT sensor is powered by a 5 V supply from the THA terminal of the ECM, via resistor R. Resistor R and the IAT sensor are connected in series. When the resistance value of the IAT sensor changes, according to changes in the IAT, the voltage at terminal THA also varies. Based on this signal, the ECM increases the fuel injection volume when the engine is cold to improve driveability. HINT: When any of DTCs P0110, P0112 and P0113 are set, the ECM enters fail-safe mode. During fail-safe mode, the IAT is estimated to be 20°C (68°F) by the ECM. Fail-safe mode continues until a pass condition is detected. DTC No. Proceed to DTC Detection Condition Trouble Area • • • Open or short in IAT sensor circuit IAT sensor (built into MAF meter) ECM P0110 Step 1 Open or short in Intake Air Temperature (IAT) sensor circuit for 0.5 seconds (1 trip detection logic) P0112 Step 4 Short in Intake Air Temperature (IAT) sensor circuit for 0.5 seconds (1 trip detection logic) • • • Short in IAT sensor circuit IAT sensor (built into MAF meter) ECM P0113 Step 2 Open in Intake Air Temperature (IAT) sensor circuit for 0.5 seconds (1 trip detection logic) • • • Open in IAT sensor circuit IAT sensor (built into MAF meter) ECM 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–145 HINT: When any of these DTCs are set, check the IAT by entering the following menus on the intelligent tester: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / INTAKE AIR. Temperature Displayed Malfunction -40°C (-40°F) Open circuit 140°C (284°F) or higher Short circuit MONITOR DESCRIPTION The ECM monitors the sensor voltage and uses this value to calculate the Intake Air Temperature (IAT). When the sensor output voltage deviates from the normal operating range, the ECM interprets this as a malfunction in the IAT sensor and sets a DTC. Example: If the sensor output voltage is -40°C (-40°F) for 0.5 seconds or more, the ECM determines that there is an open in the IAT sensor circuit, and sets DTC P0113. Conversely, if the output voltage is more than 140°C (284°F) for 0.5 seconds or more, the ECM determines that there is a short in the sensor circuit, and sets DTC P0112. If the malfunction is not repaired successfully, a DTC is set 0.5 seconds after the engine is next started. MONITOR STRATEGY Related DTCs P0110: Intake air temperature sensor open/short (Fluctuating) P0112: Intake air temperature sensor short (Low electrical resistance) P0113: Intake air temperature sensor open (High electrical resistance) Required Sensors/Components (Main) Intake Air Temperature (IAT) sensor Required Sensors/Components (Sub) - Frequency of Operation Continuous Duration 0.5 seconds MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present None TYPICAL MALFUNCTION THRESHOLDS P0110: Intake air temperature sensor voltage Less than 0.18 V, or more than 4.91 V P0112: Intake air temperature sensor voltage Less than 0.18 V P0113: Intake air temperature sensor voltage More than 4.91 V COMPONENT OPERATING RANGE Intake air temperature sensor resistance 98.5 Ω to 156 kΩ [-40 to 140°C (-40 to 284°F)] ES ES–146 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM C2 IAT Sensor (Built into MAF Meter) ECM 5V 71 THA C55 THA 1 74 E2 2 C55 R ETHA ES A110108E15 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). 1 CHECK DTC OUTPUT (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the intelligent tester on. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read the DTCs. Result Display (DTC output) Proceed to P0110 A P0112 B P0113 C B Go to step 6 C Go to step 4 A 2 READ VALUE OF INTAKE AIR TEMPERATURE SENSOR (INTAKE AIR) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Turn the tester on. 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–147 (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / INTAKE AIR. (e) Read the value displayed on the tester. Standard: Same as actual Intake Air Temperature (IAT). Result Temperature Displayed Proceed to -40°C (-40°F) A 140°C (284°F) or higher B Same as actual IAT C HINT: • If there is an open circuit, the intelligent tester indicates 40°C (-40°F). • If there is a short circuit, the intelligent tester indicates 140°C (284°F) or higher. B C Go to step 5 CHECK FOR INTERMITTENT PROBLEMS (See page ES-33) A 3 CHECK MASS AIR FLOW METER (CHECK FOR OPEN IN SENSOR) (a) Confirm good connection of the Mass Air Flow (MAF) meter. (b) Disconnect the C2 MAF meter connector. (c) Connect terminals THA and E2 of the MAF meter wire harness side connector. (d) Connect the intelligent tester to the DLC3. (e) Turn the ignition switch on (IG). (f) Turn the tester on. (g) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / INTAKE AIR. (h) Read the value displayed on the tester. Standard: 140°C (284°F) or higher (i) Reconnect the MAF meter connector. ECM MAF Meter THA ETHA Wire Harness Side: MAF Meter Connector OK C2 THA E2 A127961E03 NG REPLACE MASS AIR FLOW METER (See page ES-477) ES ES–148 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 4 CHECK HARNESS AND CONNECTOR (MASS AIR FLOW METER - ECM) (a) Disconnect the C2 MAF meter connector. (b) Disconnect the C55 ECM connector. (c) Measure the resistance between the terminals. Standard resistance (Check for open) Wire Harness Side: MAF Meter Connector C2 THA Specified Condition THA (C55-71) - THA (C2-1) Below 1 Ω ETHA (C55-74) - E2 (C2-2) Below 1 Ω Standard resistance (Check for short) E2 Tester Connection ECM Connector ES Tester Connection C55 Specified Condition THA (C55-71) or THA (C2-1) - Body ground 10 kΩ or higher ETHA (C55-74) or E2 (C2-2) - Body ground 10 kΩ or higher (d) Reconnect the MAF meter connector. (e) Reconnect the ECM connector. NG THA REPAIR OR REPLACE HARNESS OR CONNECTOR ETHA A127959E14 OK REPLACE ECM (See page ES-518) 5 CHECK MASS AIR FLOW METER (CHECK FOR SHORT IN SENSOR) C2 MAF Meter (a) (b) (c) (d) (e) ECM THA ETHA A084869E58 Disconnect the C2 MAF meter connector. Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the tester on. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / INTAKE AIR. (f) Read the value displayed on the tester. Standard: -40°C (-40°F) or higher (g) Reconnect the MAF meter connector. OK NG REPLACE MASS AIR FLOW METER (See page ES-477) ES–149 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 6 CHECK HARNESS AND CONNECTOR (MASS AIR FLOW METER- ECM) (a) Disconnect the C2 MAF meter connector. (b) Disconnect the C55 ECM connector. (c) Measure the resistance between the terminals. Standard resistance Wire Harness Side: MAF Meter Connector C2 Tester Connection Specified Condition THA (C55-71) or THA (C2-1) - Body ground 10 kΩ or higher (d) Reconnect the MAF meter connector. (e) Reconnect the ECM connector. THA NG C55 ECM Connector THA A127959E15 OK REPLACE ECM (See page ES-518) REPAIR OR REPLACE HARNESS OR CONNECTOR ES ES–150 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0111 Intake Air Temperature Sensor Gradient Too High DESCRIPTION Fig. 1 Resistance (kΩ) Acceptable ES Temperature (°C) (°F) A067628E20 The Intake Air Temperature (IAT) sensor, mounted on the Mass Air Flow (MAF) meter, monitors the IAT. The IAT sensor has a built-in thermistor with a resistance that varies according to the temperature of the intake air. When the IAT drops, the resistance of the thermistor increases. When the temperature rises, the resistance drops. These variations in resistance are transmitted to the ECM as voltage changes (See Fig. 1). The IAT sensor is powered by a 5 V supply from the THA terminal of the ECM, via resistor R. Resistor R and the IAT sensor are connected in series. When the resistance value of the IAT sensor changes, according to changes in the IAT, the voltage at terminal THA also varies. Based on this signal, the ECM increases the fuel injection volume when the engine is cold to improve driveability. DTC No. DTC Detection Condition P0111 1. The intake air temperature rise is large, from the previous trip warm-up to the following trip. (2 trip detection logic) 2. When the change in the intake air temperature after engine start is less than the threshold value. Trouble Area Mass air flow meter assembly MONITOR DESCRIPTION The ECM performs OBD II monitoring based on the values from the intake air temperature sensor. If there is no change of the sensor value within the normal range, the ECM will not be able to perform OBD II monitoring or will misdiagnose that there is a malfunction in the sensor. The ECM detects the stuck intake air temperature sensor value by performing monitoring after the engine switch is turned off or the engine is started (short soak or long soak). MONITOR STRATEGY Related DTCs P0111: Intake air temperature sensor rationality (After engine stop) P0111: Intake air temperature sensor rationality (After cold engine start) 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Required Sensors/Components (Main) Intake Air Temperature (IAT) sensor Required Sensors/Components (Sub) - Frequency of Operation Once per driving cycle Duration 5 hours MIL Operation 2 driving cycles Sequence of Operation None ES–151 TYPICAL ENABLING CONDITIONS All: Monitor runs whenever following DTCs are not present None After engine stop: Time after engine start 10 seconds or more Battery voltage 10.5 V or more ECT sensor circuit OK ECT change since engine stopped Less than 180°C (356°F) ECT before engine stop 70°C (158°F) or more Time that MAF is low before engine stop 70 minutes Accumulated MAF amount before engine stop 3,800 g or more Key-off duration 30 minutes After cold engine start: Key-off duration 5 hours Time after engine start 10 seconds or more ECT sensor circuit OK ECT 70°C (158°F) or more Accumulated MAF amount 6,300 g or more One of the following conditions 1 or 2 is met: - 1. Duration while engine load is low 129 seconds or more 2. Duration while engine load is high 10 seconds or more TYPICAL MALFUNCTION THRESHOLDS After engine stop: IAT change Less than 1°C (2°F) After cold engine start: IAT change Less than 1°C (2°F) WIRING DIAGRAM Refer to DTC P0110 (See page ES-138). INSPECTION PROCEDURE 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P0111) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the tester on. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. ES ES–152 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (e) Read the DTCs. Result Display (DTC Output) Proceed to P0111 and other DTCs A P0111 B HINT: If any DTCs other than P0111 are output, troubleshoot those DTCs first. B A ES GO TO DTC CHART (See page ES-63) REPLACE MASS AIR FLOW METER (See page ES-477) ES–153 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0115 Engine Coolant Temperature Circuit Malfunction DTC P0117 Engine Coolant Temperature Circuit Low Input DTC P0118 Engine Coolant Temperature Circuit High Input DESCRIPTION A thermistor is built into the Engine Coolant Temperature (ECT) sensor, of which the resistance value varies according to the ECT. The structure of the sensor and its connection to the ECM are the same as those of the Intake Air Temperature (IAT) sensor. HINT: When any of DTCs P0115, P0117 and P0118 are set, the ECM enters fail-safe mode. During fail-safe mode, the ECT is estimated to be 80°C (176°F) by the ECM. Fail-safe mode continues until a pass condition is detected. DTC No. Proceed to DTC Detection Condition Trouble Area P0115 Step 1 Open or short in Engine Coolant Temperature (ECT) sensor circuit for 0.5 seconds (1 trip detection logic) • • • Open or short in ECT sensor circuit ECT sensor ECM P0117 Step 4 Short in Engine Coolant Temperature (ECT) sensor circuit for 0.5 seconds (1 trip detection logic) • • • Short in ECT sensor circuit ECT sensor ECM P0118 Step 2 Open in Engine Coolant Temperature (ECT) sensor circuit for 0.5 seconds (1 trip detection logic) • • • Open in ECT sensor circuit ECT sensor ECM HINT: When any of these DTCs are set, check the ECT by entering the following menus on the intelligent tester: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / COOLANT TEMP. Temperature Displayed Malfunction -40°C (-40°F) Open circuit 140°C (284°F) or higher Short circuit MONITOR DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to monitor the ECT. The ECT sensor has a thermistor with a resistance that varies according to the temperature of the engine coolant. When the coolant temperature drops, the resistance in the thermistor increases. When the temperature rises, the resistance drops. These variations in resistance are reflected in the output voltage from the sensor. The ECM monitors the sensor voltage and uses this value to calculate the ECT. When the sensor output voltage deviates from the normal operating range, the ECM interprets this as a fault in the ECT sensor and sets a DTC. Example: If the sensor output voltage is -40°C (-40°F) for 0.5 seconds or more, the ECM determines that there is an open in the ECT sensor circuit, and sets DTC P0118. Conversely, if the voltage output is more than 140°C (284°F) for 0.5 seconds or more, the ECM determines that there is a short in the sensor circuit, and sets DTC P0117. If the malfunction is not repaired successfully, a DTC is set 0.5 seconds after the engine is next started. ES ES–154 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR STRATEGY P0115: Engine coolant temperature sensor open/short (Fluctuating) P0117: Engine coolant temperature sensor short (Low electrical resistance) P0118: Engine coolant temperature sensor open (High electrical resistance) Related DTCs ES Required Sensors/Components (Main) Engine coolant temperature sensor Required Sensors/Components (Sub) - Frequency of Operation Continuous Duration 0.5 seconds MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present None TYPICAL MALFUNCTION THRESHOLDS P0115: Engine coolant temperature sensor voltage Less than 0.14 V, or more than 4.91 V P0117: Engine coolant temperature sensor voltage Less than 0.14 V P0118: Engine coolant temperature sensor voltage More than 4.91 V COMPONENT OPERATING RANGE Engine coolant temperature sensor resistance 79 Ω to 156 kΩ [-40 to 140°C (-40 to 284°F)] WIRING DIAGRAM C4 Engine Coolant Temperature Sensor ECM 5V 2 79 THW C55 1 78 ETHW C55 R A110108E16 ES–155 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). 1 CHECK DTC OUTPUT (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs. Result Display (DTC Output) Proceed to P0115 A P0117 B P0118 C B Go to step 6 C Go to step 4 A 2 READ VALUE OF ENGINE COOLANT TEMPERATURE SENSOR (COOLANT TEMP) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the tester on. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / COOLANT TEMP. (e) Read the value displayed on the tester. Standard: Between 80°C and 97°C (176°F and 207°F) with warm engine. Result Temperature Displayed Proceed to -40°C (-40°F) A 140°C (284°F) or higher B Between 80°C and 97°C (176°F and 207°F) C HINT: • If there is an open circuit, the intelligent tester indicates -40°C (-40°F). • If there is a short circuit, the intelligent tester indicates 140°C (284°F) or higher. B Go to step 5 ES ES–156 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM C CHECK FOR INTERMITTENT PROBLEMS A 3 CHECK ENGINE COOLANT TEMPERATURE SENSOR (CHECK FOR OPEN IN SENSOR) C4 ECT Sensor (a) Confirm good connection of the sensor. (b) Disconnect the C4 engine coolant temperature (ECT) sensor connector. (c) Connect terminals 1 and 2 of the ECT sensor connector on the wire harness side. (d) Connect the intelligent tester to the DLC3. (e) Turn the ignition switch on (IG). (f) Turn the tester on. (g) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / COOLANT TEMP. (h) Read the value displayed on the tester. Standard: 140°C (284°F) or higher. (i) Reconnect the ECT sensor connector. ECM THW ES ETHW Wire Harness Side: C4 ECT Sensor OK A107691E25 NG REPLACE ENGINE COOLANT TEMPERATURE SENSOR (See page ES-499) ES–157 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 4 CHECK HARNESS AND CONNECTOR (ENGINE COOLANT TEMPERATURE SENSOR ECM) (a) Disconnect the C4 ECT sensor connector. (b) Disconnect the C55 ECM connector. (c) Measure the resistance between the terminals. Standard resistance Wire Harness Side Front View: ECT Sensor Connector Tester Connection C4 Specified Condition THW (C55-79) - C4-2 Below 1 Ω ETHW (C55-78) - C4-1 Below 1 Ω (d) Reconnect the ECM connector. (e) Reconnect the ECT connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR C55 ECM Connector ETHW THW A135019E01 OK REPLACE ECM (See page ES-518) 5 CHECK ENGINE COOLANT TEMPERATURE SENSOR (CHECK FOR SHORT IN SENSOR) C4 ECT Sensor (a) (b) (c) (d) (e) ECM THW ETHW A084869E59 Disconnect the C4 ECT sensor connector. Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the tester on. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / COOLANT TEMP. (f) Read the value displayed on the tester. Standard: -40°C (-40°F) (g) Reconnect the ECT sensor connector. OK REPLACE ENGINE COOLANT TEMPERATURE SENSOR (See page ES-499) ES ES–158 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NG 6 CHECK HARNESS AND CONNECTOR (ENGINE COOLANT TEMPERATURE SENSOR ECM) (a) Disconnect the C4 ECT sensor connector. (b) Disconnect the C55 ECM connector. (c) Measure the resistance between the terminals. Standard resistance Wire Harness Side Front View: ECT Sensor Connector C4 Tester Connection Specified Condition THW (C55-79) or C4-2 - Body ground 10 kΩ or higher (d) Reconnect the ECT sensor connector. (e) Reconnect the ECM connector. ES NG ECM Connector C55 THW A135019E02 OK REPLACE ECM (See page ES-518) REPAIR OR REPLACE HARNESS OR CONNECTOR ES–159 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0116 Engine Coolant Temperature Circuit Range / Performance Problem DESCRIPTION A thermistor is built into the Engine Coolant Temperature (ECT) sensor, of which the resistance value varies according to the ECT. The structure of the sensor and its connection to the ECM are the same as those of the Intake Air Temperature (IAT) sensor. DTC No. DTC Detection Condition Trouble Area ECTs as listed below are nearly same (2 trip detection logic): – ECT when engine is started at lower than 60°C (140°F) of ECT – ECT when engine is warmed up P0116 ECTs as listed below are nearly same when engine is started at higher than 60°C (140°F) of ECT (2 trip detection logic) – ECT when engine is stopped after driving – ECT when engine is started at lower than 60°C (140°F) of ECT • • Thermostat ECT sensor MONITOR DESCRIPTION The ECT sensor is used to monitor the ECT. The ECT sensor has a built-in thermistor with a resistance that varies according to the temperature of the engine coolant. When the ECT drops, the resistance of the thermistor increases. When the temperature rises, the resistance drops. These variations in the resistance are reflected in the output voltage from the ECT sensor. The ECM monitors the sensor voltage and uses this value to calculate the ECT. If the sensor output voltage deviates from the normal operating range, the ECM interprets this deviation as a malfunction in the ECT sensor and sets the DTC. Examples: (1)Upon starting the engine, the ECT is between 35°C and 60°C (95°F and 140°F). If, after driving for 250 seconds, the ECT remains within 3°C (5.4°F) of the starting temperature, the DTC is set (2 trip detection logic). (2)Upon starting the engine, the ECT is over 60°C (140°F). If, after driving for 250 seconds, the ECM remains within 1°C (1.8°F) of the starting temperature, the DTC is set (6 trip detection logic). MONITOR STRATEGY Related DTCs P0116: Engine coolant temperature sensor rationality (ECT sensor cold start monitor) P0116: Engine coolant temperature sensor rationality (ECT sensor soak monitor) Required Sensors/Components (Main) Engine coolant temperature (ECT) sensor Required Sensors/Components (Sub) - Frequency of Operation Once per driving cycle Duration 10 MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS All: Monitor runs whenever following DTCs are not present P0100 - P0103 (MAF sensor) ES ES–160 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ECT sensor cold start monitor: Battery voltage 10.5 V or more Time after engine start 1 second or more ECT at engine start Less than 60°C (140°F) IAT sensor circuit OK Soak time 5 hours Accumulated MAF 1,056.06 g or more Engine Running Fuel cut OFF Difference between ECT at engine start and IAT Less than 40°C (104°F) ECT sensor soak monitor: Battery voltage ES 10.5 V or more Engine Running Soak time 5 hours or more ECT at engine start 60°C (140°F) or more Accumulated MAF 2,101.98 times or more TYPICAL MALFUNCTION THRESHOLDS ECT sensor cold start monitor: ECT sensor value change Less than 5°C (9°F) ECT sensor soak monitor: Difference between current ECT sensor value and previous ECT sensor value when engine stopped Less than 5°C (9°F) COMPONENT OPERATING RANGE Engine coolant temperature Varies with actual engine coolant temperature INSPECTION PROCEDURE HINT: • If any of DTCs P0115, P0117, P0118 or P0125 are set simultaneously with DTC P0116, the ECT sensor may have an open or a short circuit. Troubleshoot those DTCs first. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). 1 CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P0116) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the tester on. Enter the following menus: DIAGNOSIS / ENHANCED II / DTC INFO / CURRENT CODES. (e) Read the DTC. Result Display (DTC output) Proceed to P0116 A 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Display (DTC output) Proceed to P0116 and other DTCs B B ES–161 GO TO DTC CHART (See page ES-63) A 2 INSPECT THERMOSTAT (a) Remove the thermostat (See page CO-13). (b) Check the valve opening temperature of the thermostat. Standard: 80 to 84°C (176 to 183°F) HINT: In addition to the above check, confirm that the valve is completely closed when the temperature is below the standard. (c) Reinstall the thermostat (See page CO-14). NG REPLACE THERMOSTAT (See page CO-13) OK REPLACE ENGINE COOLANT TEMPERATURE SENSOR (See page ES-499) ES ES–162 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0120 Throttle / Pedal Position Sensor / Switch "A" Circuit Malfunction DTC P0122 Throttle / Pedal Position Sensor / Switch "A" Circuit Low Input DTC P0123 Throttle / Pedal Position Sensor / Switch "A" Circuit High Input DTC P0220 Throttle / Pedal Position Sensor / Switch "B" Circuit DTC P0222 Throttle / Pedal Position Sensor / Switch "B" Circuit Low Input DTC P0223 Throttle / Pedal Position Sensor / Switch "B" Circuit High Input DTC P2135 Throttle / Pedal Position Sensor / Switch "A" / "B" Voltage Correlation ES DESCRIPTION HINT: This ETC (Electrical Throttle Control System) does not use a throttle cable. The Throttle Position (TP) sensor is mounted on the throttle body, and detects the opening angle of the throttle valve. This sensor is a non-contact type, and uses Hall-effect elements, in order to yield accurate signals, even in extreme driving conditions, such as at high speeds as well as very low speeds. The TP sensor has two sensor circuits which each transmits a signal, VTA1 and VTA2. VTA1 is used to detect the throttle valve angle and VTA2 is used to detect malfunctions in VTA1. The sensor signal voltages vary between 0 V and 5 V in proportion to the throttle valve opening angle, and are transmitted to the VTA terminals of the ECM. As the valve closes, the sensor output voltage decreases and as the valve opens, the sensor output voltage increases. The ECM calculates the throttle valve opening angle according to these signals and controls the throttle actuator in response to driver inputs. These signals are also used in calculations such as air-fuel ratio correction, power increase correction and fuel-cut control. ES–163 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Fail Safe Angle Sensor Output Voltage (V) 5.0 VTA2 Throttle Position Sensor VTA1 2.55 2.25 Magnet 0.93 0.69 ECM ES 6° IC No. 1 VC E2 84° Throttle Valve Opening Angle (degrees) VTA1 VTA2 Usable Range 0° Note: The throttle valve opening angle detected by the sensor terminal VTA1 is expressed as percentages. Between 10 % and 24 %: Throttle valve fully closed IC No. 2 Between 64 % and 96 %: Throttle valve fully open Magnet Approximately 19 %: Fail-safe angle (6°) A019802E50 DTC No. DTC Detection Condition P0120 Output voltage of VTA1 quickly fluctuates beyond lower and upper malfunction thresholds for 2 seconds (1 trip detection logic) Trouble Area • • Throttle Position (TP) sensor (built into throttle body) ECM P0122 Output voltage of VTA1 is 0.2 V or less for 2 seconds (1 trip detection logic) • • • • TP sensor (built into throttle body) Short in VTA1 circuit Open in VC circuit ECM P0123 Output voltage of VTA1 is 4.535 V or more for 2 seconds (1 trip detection logic) • • • • • TP sensor (built into throttle body) Open in VTA1 circuit Open in E2 circuit Short between VC and VTA1 circuits ECM P0220 Output voltage of VTA2 quickly fluctuates beyond lower and upper malfunction thresholds for 2 seconds (1 trip detection logic) • • TP sensor (built into throttle body) ECM ES–164 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. ES DTC Detection Condition Trouble Area P0222 Output voltage of VTA2 is 1.75 V or less for 2 seconds (1 trip detection logic) • • • • TP sensor (built into throttle body) Short in VTA2 circuit Open in VC circuit ECM P0223 Output voltage of VTA2 is 4.8 V or more, and VTA1 is between 0.2 V and 2.02 V, for 2 seconds (1 trip detection logic) • • • • • TP sensor (built into throttle body) Open in VTA2 circuit Open in E2 circuit Short between VC and VTA2 circuits ECM P2135 Either condition (a) or (b) is met (1 trip detection logic): (a) Difference between output voltages of VTA1 and VTA2 is 0.02 V or less for 0.5 seconds or more (b) Output voltage of VTA1 is 0.2 V or less, and VTA2 is 1.75 V or less, for 0.4 seconds or more • • • Short between VTA1 and VTA2 circuits TP sensor (built into throttle body) ECM HINT: • When any of these DTCs are set, check the throttle valve opening angle by entering the following menus on an intelligent tester: DIAGNOSIS / ENHANCED OBD ll / DATA LIST / ETCS / THROTTLE POS AND THROTTLE POS #2. • THROTTLE POS denotes the VTA1 signal (expressed in percentages), and THROTTLE POS #2 denotes the VTA2 signal (expressed in voltages). Reference (Normal Condition): Tester Display Accelerator Pedal Fully Released Accelerator Pedal Fully Depressed THROTTLE POS 10 to 24 % 64 to 96 % THROTTLE POS #2 2.1 to 3.1 V 4.5 to 5.0 V MONITOR DESCRIPTION The ECM uses the Throttle Position (TP) sensor to monitor the throttle valve opening angle. There are several checks that the ECM performs to confirm the proper operation of the TP sensor. • A specific voltage difference is expected between the sensor terminals, VTA1 and VTA2, for each throttle valve opening angle. If the difference between VTA1 and VTA2 is incorrect, the ECM interprets this as a malfunction in the sensor, and sets a DTC. • VTA1 and VTA2 each have a specific voltage range. If VTA1 or VTA2 is outside the normal operating range, the ECM interprets this as a malfunction in the sensor, and sets a DTC. • VTA1 and VTA2 should never be close to the same voltage level. If VTA1 is within 0.02 V of VTA2, the ECM determines that there is a short circuit in the sensor, and sets a DTC. MONITOR STRATEGY Related DTCs P0120: Throttle position sensor 1 range check (Fluctuating) P0122: Throttle position sensor 1 range check (Low voltage) P0123: Throttle position sensor 1 range check (High voltage) P0220: Throttle position sensor 2 range check (Fluctuating) P0222: Throttle position sensor 2 range check (Low voltage) P0223: Throttle position sensor 2 range check (High voltage) P2135: Throttle position sensor range check (Correlation) Required Sensors/Components (Main) Throttle position sensor Required Sensors/Components (Sub) - Frequency of Operation Continuous ES–165 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Duration Throttle position sensor 1 range check (Fluctuating): 2 seconds (Accelerator pedal ON) Throttle position sensor 1 range check (Low voltage): 2 seconds (Accelerator pedal ON) Throttle position sensor 1 range check (High voltage): 2 seconds (Accelerator pedal ON) Throttle position sensor 2 range check (Fluctuating): 2 seconds (Accelerator pedal ON) Throttle position sensor 2 range check (Low voltage): 2 seconds (Accelerator pedal ON) Throttle position sensor 2 range check (High voltage): 2 seconds (Accelerator pedal ON) Throttle position sensor 1 range check (Fluctuating): 10 seconds (Accelerator pedal OFF) Throttle position sensor 1 range check (Low voltage): 10 seconds (Accelerator pedal OFF) Throttle position sensor 1 range check (High voltage): 10 seconds (Accelerator pedal OFF) Throttle position sensor 2 range check (Fluctuating): 10 seconds (Accelerator pedal OFF) Throttle position sensor 2 range check (Low voltage): 10 seconds (Accelerator pedal OFF) Throttle position sensor 2 range check (High voltage): 10 seconds (Accelerator pedal OFF) Throttle position sensor range check (Correlation): Within 0.5 seconds MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present None TYPICAL MALFUNCTION THRESHOLDS P0120: VTA1 voltage 0.2 V or less, or 4.535 V or more P0122: VTA1 voltage 0.2 V or less P0123: VTA1 voltage 4.535 V or more P0220: VTA2 voltage 1.75 V or less, or 4.8 V or more P0222: VTA2 voltage 1.75 V or less P0223: VTA2 voltage when VTA1 is 0.2 to 2.02 V 4.8 V or more P2135: Either of following conditions A or B is met: - Condition A Difference between VTA1 and VTA2 voltages 0.02 V or less Condition B - VTA1 voltage 0.2 V or less VTA2 voltage 1.75 V or less ES ES–166 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM COMPONENT OPERATING RANGE VTA1 voltage 0.69 to 4.05 V VTA2 voltage 2.25 to 4.8 V FAIL-SAFE When any of these DTCs, as well as other DTCs relating to ETCS (Electronic Throttle Control System) malfunctions, are set, the ECM enters fail-safe mode. During fail-safe mode, the ECM cuts the current to the throttle actuator off, and the throttle valve is returned to a 6° throttle angle by the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing, in accordance with the accelerator pedal opening angle, to allow the vehicle to continue at a minimal speed. If the accelerator pedal is depressed gently, the vehicle can be driven slowly. WIRING DIAGRAM ES C5 Throttle Position Sensor (Built into Throttle Body) VC VTA VTA2 E2 ECM 5 96 VCTA C55 6 98 C55 4 3 99 C55 5V VTA1 VTA2 97 C55 ETA A085458E17 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). 1 READ VALUE OF THROTTLE POSITION SENSOR (THROTTLE POS AND THROTTLE POS #2) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the intelligent tester on. ES–167 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ETCS / THROTTLE POS and THROTTLE POS #2. (d) Check the values displayed on the tester. Result TP#1 (VTA1) When AP Released TP#2 (VTA2) When AP Released TP#1 (VTA1) When AP Depressed TP#2 (VTA2) When AP Depressed Trouble Area Proceed to 0% Between 0 V and 0.2 V 0% Between 0 V and 0.2 V VC circuit open A 100 % Between 4.5 V and 5.0 V 100 % Between 4.5 V and 5.0 V E2 circuit open A 0 % or 100 % Between 2.1 V and 3.1 V (Fail-safe) 0 % or 100 % Between 2.1 V and 3.1 V (Fail-safe) VTA1 circuit open or ground short A Approx. 19 % (Fail-safe) Between 0 V and 0.2 V, or 4.5 V and 5.0 V Between 10 % and 24 % (Fail-safe) Between 0 V and 0.2 V, or 4.5 V and 5.0 V VTA2 circuit open or ground short A Between 10 % and 24 % Between 2.1 V and 3.1 V Between 64 % and 96 % (Not fail-safe) Between 4.5 V and 5.0 V (Not fail-safe) TP sensor circuit normal B HINT: • TP#1 denotes THROTTLE POS, and TP#2 denotes THROTTLE POS#2. • AP denotes Accelerator Pedal. • VTA1 is expressed as percentages, and VTA2 is expressed as voltages. B Go to step 5 A 2 CHECK HARNESS AND CONNECTOR (THROTTLE POSITION SENSOR - ECM) Wire Harness Side Front View: C5 Throttle Body Connector E2 1 2 3 4 5 6 VTA2 Tester Connection Specified Condition VTA VC (C5-5) - VCTA (C55-96) Below 1 Ω VC C55 (a) Disconnect the C5 throttle body connector. (b) Disconnect the C55 ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for open) ECM Connector VTA (C5-6) - VTA1 (C55-98) Below 1 Ω VTA2 (C5-4) - VTA2 (C55-99) Below 1 Ω E2 (C5-3) - ETA (C55-97) Below 1 Ω Standard resistance (Check for short) VTA1 VCTA VTA2 Tester Connection Specified Condition VC (C5-5) or VCTA (C55-96) - Body ground 10 kΩ or higher VTA (C5-6) or VTA1 (C55-98) - Body ground 10 kΩ or higher VTA2 (C5-4) or VTA2 (C55-99) - Body ground 10 kΩ or higher (d) Reconnect the throttle body connector. (e) Reconnect the ECM connector. ETA A107944E08 ES ES–168 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 INSPECT ECM (VC VOLTAGE) Wire Harness Side Front View: Throttle Body Connector C5 E2 VC (a) Disconnect the C5 throttle body connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage 1 2 3 4 5 6 ES Tester Connection Specified Condition VC (C5-5) - E2 (C5-3) 4.5 to 5.0 V (d) Reconnect the throttle body connector. A107895E07 NG REPLACE ECM (See page ES-518) OK 4 REPLACE THROTTLE BODY (a) Replace the throttle body assembly (See page ES-503). NEXT 5 CHECK WHETHER DTC OUTPUT RECURS (THROTTLE POSITION SENSOR DTCS) (a) (b) (c) (d) (e) (f) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG) and turn the tester on. Clear the DTCs (See page ES-45). Start the engine. Allow the engine to idle for 15 seconds or more. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (g) Read the DTCs. Result Display (DTC Output) Proceed to P0120, P0122, P0123, P0220, P0223, and/or P2135 A No output B B A REPLACE ECM (See page ES-518) SYSTEM IS OK 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0121 ES–169 Throttle / Pedal Position Sensor / Switch "A" Circuit Range / Performance Problem DESCRIPTION HINT: This ETC (Electrical Throttle Control System) does not use a throttle cable. The Throttle Position (TP) sensor is mounted on the throttle body, and detects the opening angle of the throttle valve. This sensor is a non-contact type, and uses Hall-effect elements, in order to yield accurate signals, even in extreme driving conditions, such as at high speeds as well as very low speeds. The TP sensor has two sensor circuits which each transmits a signal, VTA1 and VTA2. VTA1 is used to detect the throttle valve angle and VTA2 is used to detect malfunctions in VTA1. The sensor signal voltages vary between 0 V and 5 V in proportion to the throttle valve opening angle, and are transmitted to the VTA terminals of the ECM. As the valve closes, the sensor output voltage decreases and as the valve opens, the sensor output voltage increases. The ECM calculates the throttle valve opening angle according to these signals and controls the throttle actuator in response to driver inputs. These signals are also used in calculations such as air-fuel ratio correction, power increase correction and fuel-cut control. ES ES–170 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Fail Safe Angle Sensor Output Voltage (V) 5.0 VTA2 Throttle Position Sensor VTA1 2.55 2.25 Magnet ES 0.93 0.69 ECM 6° IC No. 1 VC 0° E2 84° Throttle Valve Opening Angle (degrees) VTA1 VTA2 Usable Range Note: The throttle valve opening angle detected by the sensor terminal VTA1 is expressed as percentages. Between 10 % and 24 %: Throttle valve fully closed IC No. 2 Between 64 % and 96 %: Throttle valve fully open Magnet Approximately 19 %: Fail-safe angle (6°) A019802E31 HINT: This DTC relates to the Throttle Position (TP) sensor. DTC No. DTC Detection Condition P0121 Difference between VTA1 and VTA2 voltages less than 0.8 V, or more than 1.6 V for 2 seconds (1 trip detection logic) Trouble Area TP sensor (built into throttle body) MONITOR DESCRIPTION The ECM uses the TP sensor to monitor the throttle valve opening angle. This sensor transmits two signals: VTA1 and VTA2. VTA1 is used to detect the throttle opening angle and VTA2 is used to detect malfunctions in VTA1. The ECM performs several checks to confirm the proper operation of the TP sensor and VTA1. 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–171 For each throttle opening angle, a specific voltage difference is expected between the outputs of VTA1 and VTA2. If the output voltage difference between the two signals deviates from the normal operating range, the ECM interprets this as a malfunction of the TP sensor. The ECM illuminates the MIL and sets the DTC. If the malfunction is not repaired successfully, the DTC is set 2 seconds after the engine is next started. MONITOR STRATEGY Related DTCs P0121: TP sensor rationality Required Sensors/Components (Main) TP sensor Required Sensors/Components (Sub) - Frequency of Operation Continuous Duration Within 2 seconds MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present P0120, P0122, P0123, P0220, P0222, P0223, P2135 (TP sensor) Either of following conditions A or B is met: - A. Engine switch ON B. Electric throttle motor power ON TP sensor malfunction (P0120, P0122, P0123, P0220, P0222, P0223, P2135) Not detected TYPICAL MALFUNCTION THRESHOLDS Difference in voltage between VAT1 and VTA2 TP sensor 1 - [TP sensor 2 x 0.8 (corrected by learning value)] Less than 0.8 V or more than 1.6 V FAIL-SAFE When this DTC, as well as other DTCs relating to ETCS (Electronic Throttle Control System) malfunctions, is set, the ECM enters fail-safe mode. During fail-safe mode, the ECM cuts the current to the throttle actuator off, and the throttle valve is returned to a 6° throttle angle by the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing, in accordance with the accelerator pedal opening angle, to allow the vehicle to continue at a minimal speed. If the accelerator pedal is depressed firmly and gently, the vehicle can be driven slowly. Fail-safe mode continues until a pass condition is detected, and the engine switch is then turned off. INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). 1 CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P0121) (a) Connect the intelligent tester to the DLC3. (b) Turn the engine switch on (IG). (c) Turn the tester on. ES ES–172 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (d) Enter the following menus: DIAGNOSIS / ENHANCED II / DTC INFO / CURRENT CODES. (e) Read the DTC. Result Display (DTC output) Proceed to P0121 A P0121 and other DTCs B B A REPLACE THROTTLE BODY (See page ES-503) ES GO TO DTC CHART (See page ES-63) ES–173 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0125 Insufficient Coolant Temperature for Closed Loop Fuel Control DESCRIPTION A thermistor is built into the Engine Coolant Temperature (ECT) sensor, and its resistance value varies according to the ECT. The structure of the sensor and its connection to the ECM are the same as those of the Intake Air Temperature (IAT) sensor. DTC No. P0125 DTC Detection Condition Engine coolant temperature (ECT) does not reach closed-loop enabling temperature for 20 minutes (this period varies with ECT when engine start) Trouble Area • • • Engine coolant temperature sensor Cooling system Thermostat ES MONITOR DESCRIPTION The resistance of the ECT varies in proportion to the actual ECT. The ECT supplies a constant voltage to the sensor and monitors the signal output voltage of the sensor. The signal voltage output varies according to the changing resistance of the sensor. After the engine is started, the ECT is monitored through this signal. If the ECT sensor indicates that the engine is not yet warm enough for closed-loop fuel control, despite a specified period of time having elapsed since the engine was started, the ECM interprets this as a malfunction in the sensor or cooling system and sets the DTC. Example: The ECT is 0°C (32°F) at engine start. After 5 minutes running time, the ECT sensor still indicates that the engine is not warm enough to begin closed-loop fuel (air-fuel ratio feedback) control. The ECM interprets this as a malfunction in the sensor or cooling system and sets the DTC. MONITOR STRATEGY Related DTCs P0125: Insufficient engine coolant temperature for closed-loop fuel control Required Sensors/Components (Main) Thermostat, cooling system Required Sensors/Components (Related) Engine coolant temperature sensor and mass air flow meter Frequency of Operation Once per driving cycle Duration 64 seconds: Closed-loop enabling temperature - 8.34°C (15°F) or more 111.2 seconds: Closed-loop enabling temperature - 19.45 to 8.34°C (35 to 15°F) 1,200 seconds: Less than closed-loop enabling temperature - 19.45°C (35°F) MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present P0100 - P0103 (MAF sensor) P0110 - P0113 (IAT sensor) P0115 - P0118 (ECT sensor) MAF sensor circuit fail Not detected IAT sensor circuit fail Not detected ECT sensor circuit fail Not detected Thermostat fail Not detected ES–174 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TYPICAL MALFUNCTION THRESHOLDS 64 seconds or more: Engine coolant temperature at engine start is - 8.34°C (15°F) or more 111.2 seconds or more: Engine coolant temperature at engine start is - 19.45 to 8.35°C (15 to 35°F) 1,200 seconds or more: Engine coolant temperature at engine start is less than - 19.4°C (35°F) Time until actual engine coolant temperature reaches closedloop fuel control enabling temperature WIRING DIAGRAM Refer to DTC P0115 (See page ES-146). INSPECTION PROCEDURE ES HINT: • If any of DTCs P0115, P0116, P0117 or P0118 are set simultaneously with DTC P0125, the Engine Coolant Temperature (ECT) sensor may have an open or a short circuit. Troubleshoot those DTCs first. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P0125) (a) (b) (c) (d) Connect an intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the tester on. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read the DTCs. Result Display (DTC Output) Proceed to P0125 A P0125 and other DTCs B HINT: If any DTCs other than P0125 are output, troubleshoot those DTCs first. B GO TO DTC CHART (See page ES-63) A 2 INSPECT THERMOSTAT (a) Remove the thermostat (See page CO-13). (b) Check the valve opening temperature of the thermostat. Standard: 80 to 84°C (176 to 183°F) HINT: In addition to the above check, confirm that the valve is completely closed when the temperature is below the standard. (c) Reinstall the thermostat (See page CO-14). 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NG ES–175 REPLACE THERMOSTAT (See page CO-13) OK 3 CHECK COOLING SYSTEM (a) Check for defects in the cooling system that might cause the system to be too cold, such as abnormal radiator fan operation or any modifications. NG REPAIR OR REPLACE COOLING SYSTEM OK REPLACE ENGINE COOLANT TEMPERATURE SENSOR (See page ES-499) ES ES–176 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC Coolant Thermostat (Coolant Temperature Below Thermostat Regulating Temperature) P0128 DESCRIPTION This DTC is set when the Engine Coolant Temperature (ECT) does not reach 75°C (167°F) despite sufficient engine warm-up time. ES DTC No. DTC Detection Condition Trouble Area P0128 Conditions (a), (b) and (c) are met for 5 seconds (2 rip detection logic): (a) Cold start (b) Engine warmed up (c) ECT less than 75°C (167°F) • • • • Thermostat Cooling system ECT sensor ECM MONITOR DESCRIPTION 5 seconds Estimated ECT Threshold (75°C (167°F)) Indicated Coolant Temperature Reading ECT Time DTC Set (after 2 Driving Cycles) A082385E20 The ECM estimates the ECT based on the starting temperature, engine loads, and engine speeds. The ECM then compares the estimated temperature with the actual ECT. When the estimated ECT reaches 75°C (167°F), the ECM checks the actual ECT. If the actual ECT is less than 75°C (167°F), the ECM interprets this as a malfunction in the thermostat or the engine cooling system and sets the DTC. MONITOR STRATEGY Related DTCs P0128: Coolant Thermostat Required Sensors/Components (Main) Thermostat Required Sensors/Components (Sub) Engine Coolant Temperature (ECT) sensor, Intake Air Temperature (IAT) sensor, Vehicle speed sensor Frequency of Operation Once per driving cycle 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Duration 900 seconds MIL Operation 2 driving cycles Sequence of Operation None ES–177 TYPICAL ENABLING CONDITIONS P0010, P0020 (VVT OCV Bank 1, 2) P0011 (VVT System 1 - Advance) P0012 (VVT System 1 - Retard) P0021 (VVT System 2 - Advance) P0022 (VVT System 2 - Retard) P0031, P0032, P0051, P0052 (A/F sensor heater - Sensor 1) P0100 - P0103 (MAF meter) P0110 - P0113 (IAT sensor) P0115 - P0118 (ECT sensor) P0125 (Insufficient ECT for Closed Loop) P0171, P0172 (Fuel system) P0300 - P0308 (Misfire) P0335 (CKP sensor) P0340, P0341 (CMP sensor) P0351 - P0356 (Ignitor) P0500 (VSS) P2196, P2198 (A/F sensor - rationality) P2A00, P2A03 (A/F sensor - slow response) Monitor will run whenever this DTC is not present Battery voltage 11 V or more Either of following conditions 1 or 2 is met: - 1. All of following conditions are met: - • ECT at engine start - IAT at engine start -15 to 7°C (-27 to 12.6°F) • ECT at engine start -10 to 56°C (14 to 133°F) • IAT at engine start -10 to 56°C (14 to 133°F) 2. All of following conditions are met: - • ECT at engine start - IAT at engine start More than 7°C (12.6°F) • ECT at engine start 56°C (132.8°F) or less • IAT at engine start -10°C (14°F) or more Accumulated time with 80 mph (128 km/h) or more of vehicle speed Less than 20 seconds TYPICAL MALFUNCTION THRESHOLDS Duration that both of the following conditions 1 and 2 are met: 5 seconds or more 1. Estimated ECT 75°C (167°F) or more 2. ECT sensor output Less than 75°C (167°F) INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). 1 CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P0128) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Turn the tester on. ES ES–178 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (d) Enter the following menus: DIAGNOSIS / ENHANCED II / DTC INFO / CURRENT CODES. (e) Read the DTC. Result Display (DTC Output) Proceed to P0128 A P0128 and other DTCs B HINT: If any DTC other than P0128 are output, troubleshoot those DTCs first. B GO TO DTC CHART (See page ES-63) A ES 2 CHECK COOLING SYSTEM (a) Check for defects in the cooling system that might cause the system to be too cold, such as abnormal radiator fan operation or any modifications. NG REPAIR OR REPLACE COOLING SYSTEM OK 3 INSPECT THERMOSTAT (a) Remove the thermostat (See page CO-13). (b) Check the valve opening temperature of the thermostat. Standard: 80 to 84°C (176 to 183°F) HINT: In addition to the above check, confirm that the valve is completely closed when the temperature is below the standard. (c) Reinstall the thermostat (See page CO-14). NG OK REPLACE ECM (See page ES-518) REPLACE THERMOSTAT (See page CO-13) 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–179 DTC P0136 Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 2) DTC P0137 Oxygen Sensor Circuit Low Voltage (Bank 1 Sensor 2) DTC P0138 Oxygen Sensor Circuit High Voltage (Bank 1 Sensor 2) DTC P0156 Oxygen Sensor Circuit Malfunction (Bank 2 Sensor 2) DTC P0157 Oxygen Sensor Circuit Low Voltage (Bank 2 Sensor 2) DTC P0158 Oxygen Sensor Circuit High Voltage (Bank 2 Sensor 2) DESCRIPTION A three-way catalytic converter (TWC) is used in order to convert the carbon monoxide (CO), hydrocarbon (HC), and nitrogen oxide (NOx) into less harmful substances. To allow the TWC to function effectively, it is necessary to keep the air-fuel ratio of the engine near the stoichiometric air-fuel ratio. For the purpose of helping the ECM to deliver accurate air-fuel ratio control, the Heated Oxygen (HO2) sensor is used. The HO2 sensor is located behind the TWC, and detects the oxygen concentration in the exhaust gas. Since the sensor is integrated with the heater that heats the sensing portion, it is possible to detect the oxygen concentration even when the intake air volume is low (the exhaust gas temperature is low). When the air-fuel ratio becomes lean, the oxygen concentration in the exhaust gas becomes rich. The HO2 sensor informs the ECM that the post-TWC air-fuel ratio is lean (low voltage, i.e. less than 0.45 V). Conversely, when the air-fuel ratio is richer than the stoichiometric air-fuel level, the oxygen concentration in the exhaust gas becomes lean. The HO2 sensor informs the ECM that the post-TWC air-fuel ratio is rich (high voltage, i.e. more than 0.45 V). The HO2 sensor has the property of changing its output voltage drastically when the air-fuel ratio is close to the stoichiometric level. The ECM uses the supplementary information from the HO2 sensor to determine whether the air-fuel ratio after the TWC is rich or lean, and adjusts the fuel injection time accordingly. Thus, if the HO2 sensor is working improperly due to internal malfunctions, the ECM is unable to compensate for deviations in the primary air-fuel ratio control. ES ES–180 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Atmospheric Air Housing Ideal Air Fuel Mixture Output Voltage Platinum Electrode Solid Electrolyte (Zirconia Element) Heater Coating (Ceramic) ES Cover Richer - Air Fuel Ratio - Leaner Exhaust Gas A115539E08 DTC No. DTC Detection Condition • P0136 P0156 • • P0137 P0157 • • P0138 P0158 • Abnormal voltage output: During active air-fuel ratio control, following conditions (a) and (b) are met for a certain period of time (2 trip detection logic) (a) Heated Oxygen (HO2) sensor voltage does not decrease to less than 0.2 V (b) HO2 sensor voltage does not increase to more than 0.6 V Low impedance: Sensor impedance is less than 5 Ω for more than 30 seconds when ECM presumes sensor to being warmed up and operating normally (2 trip detection logic) Trouble Area • • • • • • Open or short in HO2 sensor (bank 1, 2 sensor 2) circuit HO2 sensor (bank 1, 2 sensor 2) HO2 sensor heater (bank 1, 2 sensor 2) Air-Fuel Ratio (A/F) sensor (bank 1, 2 sensor 1) Engine room junction block (EFI relay) Gas leakage from exhaust system Low voltage (open): During active air-fuel ratio control, following conditions (a) and (b) are met for a certain period of time (2 trip detection logic) (a) HO2 sensor voltage output less than 0.21 V (b) Target air-fuel ratio rich High impedance: Sensor impedance is 15 kΩ or more for more than 90 seconds when ECM presumes sensor to being warmed up and operating normally (2 trip detection logic) • • • • • Open in HO2 sensor (bank 1, 2 sensor 2) circuit HO2 sensor (bank 1, 2 sensor 2) HO2 sensor heater (bank 1, 2 sensor 2) Engine room junction block (EFI relay) Gas leakage from exhaust system High voltage (short): During active air-fuel ratio control, following conditions (a) and (b) are met for a certain period of time (2 trip detection logic) (a) HO2 sensor voltage output 0.59 V or more (b) Target air-fuel ratio lean Extremely high voltage (short): HO2 sensor voltage output exceeds 1.2 V for more than 30 seconds (2 trip detection logic) • • • Short in HO2 sensor (bank 1, 2 sensor 2) circuit HO2 sensor (bank 1, 2 sensor 2) ECM internal circuit malfunction 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–181 MONITOR DESCRIPTION 1. 2. Active Air-Fuel Ratio Control The ECM usually performs air-fuel ratio feedback control so that the Air-Fuel Ratio (A/F) sensor output indicates a near stoichiometric air-fuel level. This vehicle includes active air-fuel ratio control in addition to regular air-fuel ratio control. The ECM performs active air-fuel ratio control to detect any deterioration in the Three-Way Catalytic Converter (TWC) and Heated Oxygen (HO2) sensor malfunctions (refer to the diagram below). Active air-fuel ratio control is performed for approximately 15 to 20 seconds while driving with a warm engine. During active air-fuel ratio control, the air-fuel ratio is forcibly regulated to become lean or rich by the ECM. If the ECM detects a malfunction, one of the following DTCs is set: DTC P0136 or P0156 (abnormal voltage output), P0137 or P0157 (open circuit) or P0138 or P0158 (short circuit). Abnormal Voltage Output of HO2 Sensor (DTCs P0136 and P0156) While the ECM is performing active air-fuel ratio control, the air-fuel ratio is forcibly regulated to become rich or lean. If the sensor is not functioning properly, the voltage output variation is small. For example, when the HO2 sensor voltage does not decrease to less than 0.21 V and does not increase to more than 0.59 V during active air-fuel ratio control, the ECM determines that the sensor voltage output is abnormal and sets DTCs P0136 and P0156. HO2 SENSOR CIRCUIT MALFUNCTION (P0136 and P0156: ABNORMAL VOLTAGE): 15 to 20 seconds Operation Active air-fuel ratio control Off Normal 0.59 V HO2 sensor voltage Abnormal 0.21 V A076837E10 3. Open or Short in Heated Oxygen (HO2) Sensor Circuit (DTCs P0137 and P0157 or P0138 and P0158) During active air-fuel ratio control, the ECM calculates the Oxygen Storage Capacity (OSC)* of the Three- Way Catalytic Converter (TWC) by forcibly regulating the air-fuel ratio to become rich or lean. If the HO2 sensor has an open or short circuit, or the voltage output of the sensor noticeably decreases, the OSC indicates an extraordinarily high value. Even if the ECM attempts to continue regulating the air-fuel ratio to become rich or lean, the HO2 sensor output does not change. While performing active air-fuel ratio control, when the target air-fuel ratio is rich and the HO2 sensor voltage output is 0.21 V or less (lean), the ECM interprets this as an abnormally low sensor output voltage and sets DTC P0137 or P0157. When the target air-fuel ratio is lean and the voltage output is 0.59 V or more (rich) during active air-fuel ratio control, the ECM determines that the sensor voltage output is abnormally high, and sets DTC P0138 or P0158. HINT: DTC P0138 or P0158 is also set if the HO2 sensor voltage output is more than 1.2 V for 30 seconds or more. ES ES–182 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM *: The TWC has the capability to store oxygen. The OSC and the emission purification capacity of the TWC are mutually related. The ECM determines whether the catalyst has deteriorated, based on the calculated OSC value (See page ES-249). HO2 SENSOR CIRCUIT LOW VOLTAGE (P0137 and P0157: OPEN): Active air-fuel ratio control Target air-fuel ratio Off Normal 15 to 20 seconds Operation Stoichiometric Air-Fuel Level Rich HO2 sensor voltage ES Abnormal Normal 0.21 V Abnormal HO2 SENSOR CIRCUIT HIGH VOLTAGE (P0138 and P0158: SHORT): Operation Active air-fuel ratio control Target air-fuel ratio Off Stoichiometric Air-Fuel Level HO2 sensor voltage Lean Abnormal 0.59 V A080024E11 Interrelation between temperature of element and impedance: DTC Detection Area 15,000 1,000 Ω 100 10 5 300 400 500 600 700 800 (572) (752) (932)(1,112)(1,292)(1,472) °C (°F) A076841E09 4. High or Low Impedance of Heated Oxygen (HO2) Sensor (DTCs P0136 and P0156 or P0137 and P0157) During normal air-fuel ratio feedback control, there are small variations in the exhaust gas oxygen concentration. In order to continuously monitor the slight variation of the HO2 sensor signal while the engine is running, the impedance* of the sensor is measured by the ECM. The ECM determines that there is a malfunction in the sensor when the measured impedance deviates from the standard range. *: The effective resistance in an alternating current electrical circuit. HINT: • The impedance cannot be measured using an ohmmeter. 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–183 • DTCs P0136 and P0156 indicate the deterioration of the HO2 sensor. The ECM sets the DTCs by calculating the impedance of the sensor when the typical enabling conditions are satisfied (1 driving cycle). • DTCs P0137 and P0157 indicate an open or short circuit in the HO2 sensor (1 driving cycle). The ECM sets the DTCs when the impedance of the sensor exceeds the threshold of 15 kΩ. MONITOR STRATEGY Related DTCs P0136: HO2S voltage (Bank 1) P0136: HO2S low impedance (Bank 1) P0137: HO2S high impedance (Bank 1) P0137: HO2S low voltage (Bank 1) P0138: HO2S high voltage (Bank 1) P0138: HO2S high voltage (Extremely high) (Bank 1) P0156: HO2S voltage (Bank 2) P0156: HO2S low impedance (Bank 2) P0157: HO2S high impedance (Bank 2) P0157: HO2S low voltage (Bank 2) P0158: HO2S high voltage (Bank 2) P0158: HO2S high voltage (Extremely high) (Bank 2) Required Sensors/Components (Main) HO2S Required Sensors/Components (Sub) Crankshaft position sensor, Engine coolant temperature sensor, Mass air flow meter, Throttle position sensor Frequency of Operation Once per driving cycle Duration 20 seconds: HO2S voltage (P0136, P0156), HO2S low voltage (P0137, P0157), HO2S high voltage (P0138, P0158) 30 seconds: HO2S low impedance (P0136, P0156) 90 seconds: HO2S high impedance (P0137, P0157) 10 seconds: HO2S high voltage (P0138, P0158) MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS All: Monitor runs whenever following DTCs are not present P0031, P0032, P0051, P0052 (A/F sensor heater - Sensor 1) P0037, P0038, P0057, P0058 (O2 Sensor Heater - Sensor 2) P0100 - P0103 (MAF meter) P0110 - P0113 (IAT sensor) P0115 - P0118 (ECT sensor) P0120 - P0223, P2135 (TP sensor) P0125 (Insufficient ECT for Closed Loop) P0171, P0172 (Fuel system) P0300 - P0308 (Misfire) P0335 (CKP sensor) P0340, P0341 (CMP sensor) P0442 - P0456 (EVAP system) P0500 (VSS) P2196, P2198 (A/F sensor - rationality) P2A00, P2A03 (A/F sensor - slow response) HO2S voltage (P0136, P0156), HO2S low voltage (P0137, P0157), HO2S high voltage (P0138, P0158): Active A/F control Performing Battery voltage 11 V or more ECT 75 °C (167°F) or more Idle OFF ES ES–184 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Engine rpm Less than 3,200 rpm A/F sensor status Activated Fuel system status Closed loop Fuel-cut OFF Engine load 10 to 70% Shift position 4th or more HO2S low impedance (P0136, P0156): Battery voltage 11 V or more Estimated rear HO2S temperature Less than 700°C (1,292°F) ECM monitor Completed P0606 Not set HO2S high impedance (P0137, P0157): ES Battery voltage 11 V or more Estimated rear HO2S temperature 450°C (842°F) or more P0606 Not preset HO2S high voltage (Extremely high) (P0138, P0158): Battery voltage 11 V or more Time after engine start 2 seconds or more TYPICAL MALFUNCTION THRESHOLDS HO2S voltage (P0136, P0156): Either of the following conditions 1 or 2 is met: - 1. All of the following conditions (a), (b) and (c) are met: - (a) Commanded air-fuel ratio 14.3 or less (b) Rear HO2S voltage 0.21 to 0.59 V (c) OSC (Oxygen capacity of catalyst) 2 g or more 2. All of the following conditions (d), (e) and (f) are met: - (d) Commanded air-fuel ratio 14.9 or more (e) Rear HO2S voltage 0.21 to 0.59 V (f) OSC (Oxygen capacity of catalyst) 2 g or more HO2S low impedance (P0136, P0156): Duration that following condition is met: 30 seconds or more Rear HO2S impedance Less than 5 Ω HO2S high impedance (P0137, P0157): Duration that following condition is met: 90 seconds or more Rear HO2S impedance 15 kΩ or more HO2S low voltage (P0137, P0157): All of the following conditions 1, 2 and 3 are met: - 1. Commanded air-fuel ratio 14.3 or less 2. Rear HO2S voltage Less than 0.21 V 3. OSC (Oxygen capacity of catalyst) 2 g or more HO2S high voltage (P0138, P0158): All of the following conditions 1, 2 and 3 are met: - 1. Commanded air-fuel ratio 14.9 or more 2. Rear HO2S voltage More than 0.59 V 3. OSC (Oxygen capacity of catalyst) 2 g or more 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–185 HO2S high voltage (Extremely high) (P0138, P0158): Duration that following condition is met: 10 seconds or more Rear HO2S voltage 1.2 V or more COMPONENT OPERATING RANGE Duration that following condition is met: 30 seconds or more Heated oxygen sensor voltage Varies between 0.1 and 0.9 V MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-25). ES ES–186 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM C52 Heated Oxygen Sensor (Bank 1 Sensor 2) +B HT1B 2 1 E2 *1 OX1B 4 3 48 HT1B C55 88 C55 OX1B 65 C55 EX1B ES C51 Heated Oxygen Sensor (Bank 2 Sensor 2) +B HT2B 2 1 E2 OX2B 4 3 *1 47 HT2B C55 87 C55 OX2B 64 C55 EX2B EFI No. 3 EFI Relay EFI MAIN 44 MREL A55 EL MAIN *1: Shielded Battery A133851E02 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–187 CONFIRMATION DRIVING PATTERN HINT: • This confirmation driving pattern is used in steps 5, 8 and 11 of the following diagnostic troubleshooting procedure when using an intelligent tester. • Performing this confirmation driving pattern will activate the Heated Oxygen (HO2) sensor monitor. (The catalyst monitor is performed simultaneously.) This is very useful for verifying the completion of a repair. NOTICE: This test will not be completed if the vehicle is driven under absolutely constant speed conditions such as with cruise control activated. Vehicle Speed (B) Between 40 mph and 70 mph (64 km/h and 113 km/h) ES (A) Idling Ignition Switch OFF Warm up 10 minutes Time (Note: Even if vehicle stops during driving pattern, test can be resumed) A079199E48 A098191E02 1. 2. 3. 4. 5. 6. 7. 8. Connect an intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the tester on. Clear the DTCs (where set) (See page ES-45). Select the following menu items: DIAGNOSIS / CARB OBD II / READINESS TESTS. Check that O2S EVAL is INCMPL (incomplete). Start the engine and warm it up (Procedure "A"). Drive the vehicle at between 40 mph and 70 mph (64 km/h and 113 km/h) for at least 10 minutes (Procedure "B"). 9. Note the state of the Readiness Tests items. Those items will change to COMPL (complete) as O2S EVAL monitor operates. 10.On the tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES and check if any DTCs (any pending DTCs) are set. HINT: If O2S EVAL does not change to COMPL, and any pending DTCs fail to set, extend the driving time. ES–188 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE ES HINT: Intelligent tester only: Malfunctioning areas can be identified by performing the A/F CONTROL function provided in the ACTIVE TEST. The A/F CONTROL function can help to determine whether the Air-Fuel Ratio (A/F) sensor, Heated Oxygen (HO2) sensor and other potential trouble areas are malfunctioning. The following instructions describe how to conduct the A/F CONTROL operation using an intelligent tester. 1. Connect the intelligent tester to the DLC3. 2. Start the engine and turn the tester on. 3. Warm up the engine at an engine speed of 2,500 rpm for approximately 90 seconds. 4. On the tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. 5. Perform the A/F CONTROL operation with the engine in an idling condition (press the RIGHT or LEFT button to change the fuel injection volume). 6. Monitor the voltage outputs of the A/F and HO2 sensors (AFS B1S1 and O2S B1S2 or AFS B2S1 and O2S B2S2) displayed on the tester. HINT: • The A/F CONTROL operation lowers the fuel injection volume by 12.5 % or increases the injection volume by 25 %. • Each sensor reacts in accordance with increases in the fuel injection volume. Tester Display (Sensor) Injection Volume Status Voltage AFS B1S1 or AFS B2S1 (A/F) +25 % Rich Less than 3.0 V AFS B1S1 or AFS B2S1 (A/F) -12.5 % Lean More than 3.35 V O2S B1S2 or O2S B2S2 (HO2) +25 % Rich More than 0.55 V O2S B1S2 or O2S B2S2 (HO2) -12.5 % Lean Less than 0.4 V NOTICE: The Air-Fuel Ratio (A/F) sensor has an output delay of a few seconds and the Heated Oxygen (HO2) sensor has a maximum output delay of approximately 20 seconds. Case 1 2 A/F Sensor (Sensor 1) Output Voltage HO2 Sensor (Sensor 2) Output Voltage Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage More than 3.35 V Less than 3.0 V Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage Almost no reaction Output Voltage More than 0.55 V Less than 0.4 V Main Suspected Trouble Area - • • • A/F sensor A/F sensor heater A/F sensor circuit ES–189 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Case 3 4 A/F Sensor (Sensor 1) Output Voltage HO2 Sensor (Sensor 2) Output Voltage Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage More than 3.35 V Less than 3.0 V Output Voltage Almost no reaction Injection volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage Almost no reaction Output Voltage Almost no reaction Main Suspected Trouble Area • • • HO2 sensor HO2 sensor heater HO2 sensor circuit • • Fuel pressure Gas leakage from exhaust system (Air-fuel ratio extremely lean or rich) • Following the A/F CONTROL procedure enables technicians to check and graph the voltage outputs of both the A/F and HO2 sensors. • To display the graph, enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL / USER DATA / AFS B1S1 and O2S B1S2 or AFS B2S1 and O2S B2S2, and press the YES button and then the ENTER button followed by the F4 button. HINT: • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). • If the OX1B wire from the ECM connector is short-circuited to the +B wire, DTC P0136 will be set. • If the OX2B wire from the ECM connector is short-circuited to the +B wire, DTC P0156 will be set. 1 READ DTC OUTPUT (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the tester on. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs. Result Display (DTC Output) Proceed to P0138 or P0158 A P0137 or P0157 B P0136 or P0156 C B Go to step 14 C Go to step 7 A 2 READ VALUE OF OXYGEN SENSOR (OUTPUT VOLTAGE) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the tester on. ES ES–190 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / O2S B1S2 or O2S B2S2. (d) Allow the engine to idle. (e) Read the Heated Oxygen (HO2) sensor output voltage while idling. Result HO2 Sensor Output Voltage Proceed to More than 1.2 V A Less than 1.0 V B B Go to step 5 A ES 3 CHECK HARNESS AND CONNECTOR (CHECK FOR SHORT) Wire Harness Side Front View: C55 HT2B ECM Connector HT1B (a) Turn the engine switch off and wait for 5 minutes. (b) Disconnect the C55 ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition HT1B (C55-48) - OX1B (C55-88) 10 kΩ or higher HT2B (C55-47) - OX2B (C55-87) 10 kΩ or higher (d) Reconnect the ECM connector. NG OX2B OX1B A107892E78 OK REPLACE ECM (See page ES-518) Go to step 4 ES–191 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 4 INSPECT HEATED OXYGEN SENSOR (CHECK FOR SHORT) (a) Disconnect the C52 oxygen sensor connector (Bank 1 Sensor 2) or C51 oxygen sensor connector (Bank 2 sensor 2). (b) Measure the resistance according to the value(s) in the table below. Standard resistance (Bank 1 sensor 2) Component Side: Heated Oxygen Sensor +B HT1B Tester Connection Specified Condition +B (2) - E2 (4) 10 kΩ or higher +B (2) - OX1B (3) 10 kΩ or higher C52 Bank 1 E2 +B OX1B Standard resistance (Bank 2 sensor 2) HT2B NG C51 Bank 2 E2 Tester Connection Specified Condition +B (2) - E2 (4) 10 kΩ or higher +B (2) - OX2B (3) 10 kΩ or higher REPLACE HEATED OXYGEN SENSOR (See page EC-20) OX2B A137614E04 OK REPAIR OR REPLACE HARNESS OR CONNECTOR 5 PERFORM CONFIRMATION DRIVING PATTERN NEXT 6 CHECK WHETHER DTC OUTPUT RECURS (DTC P0138 or P0158) (a) On the intelligent tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (b) Read the DTCs. Result Display (DTC Output) Proceed to P0138 or P0158 A No output B B CHECK FOR INTERMITTENT PROBLEMS A REPLACE HEATED OXYGEN SENSOR (See page EC-20) ES ES–192 7 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM READ VALUE OF OXYGEN SENSOR (OUTPUT VOLTAGE) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG) and turn the tester on. Start the engine. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / O2S B1S2 or O2S B1S2. (e) After warming up the engine, run the engine at an engine speed of 2,500 rpm for 3 minutes. (f) Read the output voltage of the HO2 sensor when the engine rpm is suddenly increased. HINT: Quickly accelerate the engine to 4,000 rpm 3 times using the accelerator pedal. Standard voltage: Fluctuates between 0.4 V or less and 0.5 V or more. ES NG Go to step 14 OK 8 PERFORM CONFIRMATION DRIVING PATTERN NEXT 9 CHECK WHETHER DTC OUTPUT RECURS (DTC P0136 or P0156) (a) On the intelligent tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (b) Read the DTCs. Result Display (DTC Output) Proceed to P0136 or P0156 A No output B B CHECK FOR INTERMITTENT PROBLEMS A 10 REPLACE HEATED OXYGEN SENSOR (a) Replace the hated oxygen sensor (See page EC-20). NEXT ES–193 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 11 PERFORM CONFIRMATION DRIVING PATTERN NEXT 12 CHECK WHETHER DTC OUTPUT RECURS (DTC P0136 or P0156) (a) On the intelligent tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (b) Read the DTCs. Result Display (DTC Output) Proceed to P0136 or P0156 A No output B B ES END A 13 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INJECTION VOLUME) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Start the engine and turn the tester on. Warm up the engine. Enter the following menus: DIAGNOSIS / ENHANCED OBD II /ACTIVE TEST / INJ VOL. (e) Change the fuel injection volume using the tester, while monitoring the output voltage of Air-Fuel Ratio (A/F) and HO2 sensor displayed on the tester. HINT: • Change the fuel injection volume within the range of -12 % and +12 %. The injection volume can be changed in 1 % graduations within the range. • The A/F sensor is displayed as AFS B1S1 or AFS B2S1, and the HO2 sensor is displayed as O2S B1S2 or O2S B2S2, on the intelligent tester. Result Tester Display (Sensor) Voltage Variation Proceed to AFS B1S1 (A/F) AFS B2S1 (A/F) Alternates between more and less than 3.3 V OK AFS B1S1 (A/F) AFS B2S1 (A/F) Remains more than 3.3 V NG AFS B1S1 (A/F) AFS B2S1 (A/F) Remains less than 3.3 V NG HINT: A normal HO2 sensor voltage (O2S B1S2 or O2S B2S2) reacts in accordance with increases and decreases in fuel injection volumes. When the A/F sensor voltage remains either less or more than 3.3 V despite the HO2 sensor indicating a normal reaction, the A/F sensor is malfunctioning. ES–194 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Injection Volume +12 % Malfunction -12 % A/F Sensor Output Normal 3.3 V HO2 Sensor Output ES Malfunction 1V 0V A087979E16 NG REPLACE AIR FUEL RATIO SENSOR (See page EC-19) OK CHECK AND REPAIR EXTREMELY RICH OR LEAN ACTUAL AIR FUEL RATIO (INJECTOR, FUEL PRESSURE, GAS LEAKAGE FROM EXHAUST SYSTEM) 14 CHECK FOR EXHAUST GAS LEAKS OK: No gas leakage. NG OK REPAIR OR REPLACE EXHAUST GAS LEAKAGE POINT ES–195 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 15 INSPECT HEATED OXYGEN SENSOR (HEATER RESISTANCE) (a) Disconnect the C52 oxygen sensor connector (Bank 1 Sensor 2) or C51 oxygen sensor connector (Bank 2 sensor 2). (b) Measure the resistance according to the value(s) in the table below. Standard resistance (Bank 1 sensor 2) Component Side: Heated Oxygen Sensor +B HT1B Tester Connection Condition C52 HT1B (1) - +B (2) 20°C (68°F) 11 to 16 Ω Bank 1 HT1B (1) - E2 (4) Always 10 kΩ or higher E2 +B OX1B Standard resistance (Bank 2 sensor 2) HT2B OX2B A137614E04 OK Tester Connection Condition Specified Condition HT2B (1) - +B (2) 20°C (68°F) 11 to 16 Ω HT2B (1) - E2 (4) Always 10 kΩ or higher NG C51 Bank 2 E2 Specified Condition REPLACE HEATED OXYGEN SENSOR (See page EC-20) ES ES–196 16 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT ENGINE ROOM JUNCTION BLOCK (EFI MAIN RELAY) (a) Remove the engine room junction block from the engine room R/B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Engine Room Junction Block NG Engine Room Relay Block A140654E02 OK Specified Condition 1E-12 - 1E-6 10 kΩ or higher 1E-12 - 1E-6 Below 1 Ω (when battery voltage applied to terminals 1E-9 and 1E-10) (c) Reinstall the engine room junction block. 1E ES Terminal Connection REPLACE ENGINE ROOM JUNCTION BLOCK ES–197 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 17 CHECK HARNESS AND CONNECTOR (HEATED OXYGEN SENSOR - ECM) (a) Disconnect the C52 oxygen sensor connector (Bank 1 Sensor 2) or C51 oxygen sensor connector (Bank 2 sensor 2). (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness Side: Heated Oxygen Sensor Connector HT1B +B C52 Bank 1 E2 OX1B HT2B C51 Bank 2 E2 C55 ECM Connector EX2B HT2B Specified Condition 9 to 14 V +B (C51-2) - Body ground 9 to 14 V (d) Turn the engine switch off. (e) Disconnect the C55 ECM connector. (f) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for open) +B OX2B Terminal Connection +B (C52-2) - Body ground HT1B Terminal Connection Specified Condition HT1B (C52-1) - HT1B (C55-48) Below 1 Ω OX1B (C52-3) - OX1B (C55-88) Below 1 Ω E2 (C52-4) - EX1B (C55-65) Below 1 Ω HT2B (C51-1) - HT2B (C55-47) Below 1 Ω OX2B (C51-3) - OX2B (C55-87) Below 1 Ω E2 (C51-4) - EX2B (C55-64) Below 1 Ω Standard resistance (Check for short) OX2B OX1B EX1B A137615E05 Terminal Connection Specified Condition HT1B (C52-1) or HT1B (C55-48) - Body ground 10 kΩ or higher OX1B (C52-3) or OX1B (C55-88) - Body ground 10 kΩ or higher E2 (C52-4) or EX1B (C55-65) - Body ground 10 kΩ or higher HT2B (C51-1) or HT2B (C55-47) - Body ground 10 kΩ or higher OX2B (C51-3) or OX2B (C55-87) - Body ground 10 kΩ or higher E2 (C51-4) or EX2B (C55-64) - Body ground 10 kΩ or higher (g) Reconnect the HO2 sensor connector. (h) Reconnect the ECM connector. ES ES–198 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Reference (System Diagram of Bank 1 Sensor 2): HO2 Sensor EFI Relay From Battery EFI MAIN EFI No. 3 +B E2 ECM Heater Sensor HT1B HT1B OX1B OX1B Duty Control EX1B ES MREL Ground A103832E39 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE HEATED OXYGEN SENSOR (See page EC-20) ES–199 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0171 System Too Lean (Bank 1) DTC P0172 System Too Rich (Bank 1) DTC P0174 System Too Lean (Bank 2) DTC P0175 System Too Rich (Bank 2) DESCRIPTION The fuel trim is related to the feedback compensation value, not to the basic injection time. The fuel trim consists of both the short-term and long-term fuel trims. The short-term fuel trim is fuel compensation that is used to constantly maintain the air-fuel ratio at stoichiometric levels. The signal from the Air-Fuel Ratio (A/F) sensor indicates whether the air-fuel ratio is rich or lean compared to the stoichiometric ratio. This triggers a reduction in the fuel injection volume if the air-fuel ratio is rich and an increase in the fuel injection volume if it is lean. Factors such as individual engine differences, wear over time and changes in operating environment cause short-term fuel trim to vary from the central value. The long-term fuel trim, which controls overall fuel compensation, compensates for long-term deviations in the fuel trim from the central value caused by the short-term fuel trim compensation. If both the short-term and long-term fuel trims are lean or rich beyond predetermined values, it is interpreted as a malfunction, and the ECM illuminates the MIL and sets a DTC. DTC No. P0171 P0174 DTC Detection Conditions With warm engine and stable air-fuel ratio feedback, fuel trim considerably in error to lean side (2 trip detection logic) Trouble Areas • • • • • • • • • • • • • • P0172 P0175 With warm engine and stable air-fuel ratio feedback, fuel trim considerably in error to rich side (2 trip detection logic) • • • • • • • • • • • • Air induction system Injector blockage Mass Air Flow (MAF) meter Engine Coolant Temperature (ECT) sensor Fuel pressure Gas leakage from exhaust system Open or short in A/F sensor (bank 1, 2 sensor 1) circuit A/F sensor (bank 1, 2 sensor 1) A/F sensor heater (bank 1, 2 sensor 1) A/F sensor heater relay A/F sensor heater and A/F sensor heater relay circuits PCV valve and hose PCV hose connections ECM Injector leakage or blockage MAF meter ECT sensor Ignition system Fuel pressure Gas leakage from exhaust system Open or short in A/F sensor (bank 1, 2 sensor 1) circuit A/F sensor (bank 1, 2 sensor 1) A/F sensor heater (bank 1, 2 sensor 1) A/F sensor heater relay A/F sensor heater and A/F sensor heater relay circuits ECM HINT: • When DTC P0171 or P0174 is set, the actual air-fuel ratio is on the lean side. When DTC P0172 or P0175 is set, the actual air-fuel ratio is on the rich side. • If the vehicle runs out of fuel, the air-fuel ratio is lean and DTC P0171 or P0174 may be set. The MIL is then illuminated. ES ES–200 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM • When the total of the short-term and long-term fuel trim values is within the malfunction threshold (and the engine coolant temperature is more than 75°C [167°F]), the system is functioning normally. MONITOR DESCRIPTION Under closed-loop fuel control, fuel injection volumes that deviate from those estimated by the ECM cause changes in the long-term fuel trim compensation value. The long-term fuel trim is adjusted when there are persistent deviations in the short-term fuel trim values. Deviations from the ECM's estimated fuel injection volumes also affect the average fuel trim learning value, which is a combination of the average short-term fuel trim (fuel feedback compensation value) and the average long-term fuel trim (learning value of the air-fuel ratio). If the average fuel trim learning value exceeds the malfunction thresholds, the ECM interprets this as a fault in the fuel system and sets a DTC. Example: The average fuel trim learning value is more than +35% or less than -35%, the ECM interprets this as a fuel system malfunction. ES Fuel Compensation Amount P0171 or P0174: 1.35 +35 (%) Lean Malfunction Threshold 1.0 P0172 or P0175: 0.65 -35 (%) Rich Malfunction Threshold A082386E30 MONITOR STRATEGY Related DTCs P0171: Fuel trim Lean (Bank 1) P0172: Fuel trim Rich (Bank 1) P0174: Fuel trim Lean (Bank 2) P0175: Fuel trim Rich (Bank 2) Required Sensors / Components (Main) Fuel system Required Sensors / Components (Related) A/F sensor, Mass air flow meter, Crankshaft position sensor Frequency of Operation Continuous Duration Less than 10 seconds MIL Operation 2 driving cycles Sequence of Operation None ES–201 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TYPICAL ENABLING CONDITIONS Fuel-trim: The monitor will run whenever these DTCs are not present P0010, P0020 (VVT VSV1, 2), P0011, P0012 (VVT System-Advance, Retard), P0021, P0022(VVT System2-Adavance, Retard), P0031, P0031, P0032, P0051, P0052 (A/F Sensor heater Sensor 1), P0100, P0101, P0102, P0103 (MAF Sensor), P0115, P0116, P0117, P0118 (ECT Sensor), P0120, P0121, P0122, P0123, P0220, P0222, P0223 , P2135 (TP Sensor), P0125 (Insufficient ECT for Closed Loop), P0335 (CKP Sensor), P0340, P0342, P0343, P0345 (VVT Sensor 1, 2), P0351, P0352, P0353, P0354, P0356 (Ignitor), P0500 (VSS), Fuel system status Closed-loop Battery voltage 11 V or more Either of following conditions is met Condition 1 or 2 1. Engine RPM Less than 1,100 rpm 2. Intake air amount per revolution 0.22 g/rev or more ES TYPICAL MALFUNCTION THRESHOLDS Fuel trim: EVAP purge-cut Executing Either of following conditions met Condition 1 or 2 1. Average between short-term fuel trim and long-term fuel trim 35% or more at 80°C (176°F) of ECT 2. Average between short-term fuel trim and long-term fuel trim -35% or less at 80°C (176°F) of ECT WIRING DIAGRAM Refer to DTC P2195 (See page ES-350). INSPECTION PROCEDURE HINT: For use of the intelligent tester only: Malfunctioning areas can be identified by performing the A/F CONTROL function provided in the ACTIVE TEST. The A/F CONTROL function can help to determine whether the Air-Fuel Ratio (A/F) sensor, Heated Oxygen (HO2) sensor and other potential trouble areas are malfunctioning. The following instructions describe how to conduct the A/F CONTROL operation using the intelligent tester. 1. Connect the intelligent tester to the DLC3. 2. Start the engine and turn the tester on. 3. Warm up the engine at an engine speed of 2,500 rpm for approximately 90 seconds. 4. Select the following menu items on the tester: DIAGNOSIS / ENHANCEDOBD II / ACTIVE TEST / A/F CONTROL. 5. Perform the A/F CONTROL operation with the engine in an idling condition (press the RIGHT or LEFT button to change the fuel injection volume). 6. Monitor the voltage outputs of the A/F and HO2 sensors (AFS B1S1 and O2S B1S2 or AFS B2S1 and O2S B2S2) displayed on the tester. HINT: • The A/F CONTROL operation lowers the fuel injection volume by 12.5% or increases the injection volume by 25%. • Each sensor reacts in accordance with increases and decreases in the fuel injection volume. Standard voltage Tester Display (Sensor) Injection Volumes Status Voltages AFS B1S1 or AFS B2S1 (A/F) +25% Rich Less than 3.0 AFS B1S1 or AFS B2S1 (A/F) -12.5% Lean More than 3.35 ES–202 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Tester Display (Sensor) Injection Volumes Status Voltages O2S B1S2 or O2S B2S2 (HO2) +25% Rich More than 0.55 O2S B1S2 or O2S B2S2 (HO2) -12.5% Lean Less than 0.4 NOTICE: The Air-Fuel Ratio (A/F) sensor has an output delay of a few seconds and the Heated Oxygen (HO2) sensor has a maximum output delay of approximately 20 seconds. Case A/F Sensor (Sensor 1) Output Voltage HO2 Sensor (Sensor 2) Output Voltage Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage More than 3.35 V Less than 3.0 V Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage Almost no reaction Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage More than 3.35 V Less than 3.0 V Output Voltage Almost no reaction Injection volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage Almost no reaction Output Voltage Almost no reaction - 1 ES Main Suspected Trouble Area 2 3 4 • • • A/F sensor A/F sensor heater A/F sensor circuit • • • HO2 sensor HO2 sensor heater HO2 sensor circuit • • • Injector Fuel pressure Gas leakage from exhaust system (Air-fuel ratio extremely lean or rich) – Following the A/F CONTROL procedure enables technicians to check and graph the voltage outputs of both the A/F and HO2 sensors. – To display the graph, select the following menu items on the tester: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL / USER DATA / AFS B1S1 and O2S B1S2 or AFS B2S1 and O2S B2S2. Press the YES button and then the ENTER button. Then press the F4 button. HINT: • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. • A low A/F sensor voltage could be caused by a rich air-fuel mixture. Check for conditions that would cause the engine to run rich. • A high A/F sensor voltage could be caused by a lean air-fuel mixture. Check for conditions that would cause the engine to run lean. ES–203 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P0171, P0172, P0174 OR P0175) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs. Result Display (DTC Output) Proceed to P0171, P0172, P0174 or P0175 A P0171, P0172, P0174 or P0175 and other DTCs B HINT: If any DTCs other than P0171, P0172, P0174 or P0175 are output, troubleshoot those DTCs first. B GO TO DTC CHART (See page ES-63) A 2 CHECK PCV HOSE CONNECTIONS OK: PCV hose is connected correctly and is not damaged. NG REPAIR OR REPLACE PCV HOSE OK 3 CHECK AIR INDUCTION SYSTEM (a) Check the air induction system for vacuum leakage. OK: No leakage from the air induction system. NG REPAIR OR REPLACE AIR INDUCTION SYSTEM OK 4 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (A/F CONTROL) (a) Connect the intelligent tester to the DLC3. (b) Start the engine and turn the tester on. (c) Warm up the engine at an engine speed of 2,500 rpm for approximately 90 seconds. (d) Select the following menu items on the tester: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. (e) Perform the A/F CONTROL operation with the engine in an idling condition (press the RIGHT or LEFT button to change the fuel injection volume). ES ES–204 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (f) Monitor the voltage outputs of the A/F and HO2 sensors (AFS B1S1 and O2S B1S2 or AFS B2S1 and O2S B2S2) displayed on the tester. HINT: • The A/F CONTROL operation lowers the fuel injection volume by 12.5% or increases the injection volume by 25%. • Each sensor reacts in accordance with increases and decreases in the fuel injection volume. Standard voltage ES Tester Display (Sensor) Injection Volumes Status Voltages AFS B1S1 or AFS B2S1 (A/F) +25% Rich Less than 3.0 AFS B1S1 or AFS B2S1 (A/F) -12.5% Lean More than 3.35 O2S B1S2 or O2S B2S2 (HO2) +25% Rich More than 0.55 O2S B1S2 or O2S B2S2 (HO2) -12.5% Lean Less than 0.4 Result Status AFS B1S1 or AFS B2S1 Status O2S B1S2 or O2S B2S2 A/F Condition and A/F Sensor Condition Misfires Lean/Rich Lean/Rich Normal • • • • Lean Lean Actual air-fuel ratio lean May occur • • • • • • Suspected Trouble Areas Proceed to - C PCV valve and hose PCV hose connections Injector blockage Gas leakage from exhaust system Air induction system Fuel pressure Mass Air Flow (MAF) meter Engine Coolant Temperature (ECT) sensor A Injector leakage or blockage Gas leakage from exhaust system Ignition system Fuel pressure MAF meter ECT sensor A Rich Rich Actual air-fuel ratio rich - Lean Lean/Rich A/F sensor malfunction - A/F sensor B Rich Lean/Rich A/F sensor malfunction - A/F sensor B • • • • Lean: During A/F CONTROL, the A/F sensor output voltage (AFS) is consistently more than 3.35 V, and the HO2 sensor output voltage (O2S) is consistently less than 0.4 V. Rich: During A/F CONTROL, the AFS is consistently less than 3.0 V, and the O2S is consistently more than 0.55 V. Lean/Rich: During A/F CONTROL of the ACTIVE TEST, the output voltage of the heated oxygen sensor alternates correctly. B Go to step 11 C Go to step 15 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–205 A 5 READ VALUE OF INTELLIGENT TESTER (COOLANT TEMP) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / COOLANT TEMP. (d) Read the COOLANT TEMP twice, when the engine is both cold and warmed up. Standard: With cold engine: Same as ambient air temperature. With warm engine: Between 75°C and 95°C (167°F and 203°F) NG REPLACE ENGINE COOLANT TEMPERATURE SENSOR (See page ES-499) OK 6 READ VALUE OF INTELLIGENT TESTER (MAF) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / MAF and COOLANT TEMP. (d) Allow the engine to idle until the COOLANT TEMP reaches 75°C (167°F) or more. (e) Read the MAF with the engine in an idling condition and at an engine speed of 2,500 rpm. Standard: MAF while engine is idling: Between 3.2 g/s and 4.7 g/s (shift position: N, A/ C: OFF). MAF at engine speed of 2,500 rpm: Between 13.1 g/s and 18.9 g/s (shift position: N, A/C: OFF). NG REPLACE MASS AIR FLOW METER (See page ES-477) OK 7 CHECK FUEL PRESSURE (a) Check the fuel pressure (See page FU-8). NG REPAIR OR REPLACE FUEL SYSTEM ES ES–206 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK 8 CHECK FOR EXHAUST GAS LEAKS OK: No gas leakage. NG REPAIR OR REPLACE EXHAUST SYSTEM OK 9 ES CHECK FOR SPARKS AND IGNITION (a) Check for sparks and ignition (See page IG-3). HINT: If the spark plugs or ignition system malfunctions, engine misfire may occur. The misfire count can be read using the intelligent tester. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / CYL #1 (to CYL #6). NG REPAIR OR REPLACE IGNITION SYSTEM OK 10 INSPECT FUEL INJECTOR ASSEMBLY (INJECTION AND VOLUME) (a) Inspect the fuel injector assembly (See page FU-15). HINT: If the injectors malfunction, engine misfire may occur. The misfire count can be read using the intelligent tester. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / CYL #1 (to CYL #6). NG OK REPLACE FUEL INJECTOR ASSEMBLY (See page FU-13) ES–207 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 11 INSPECT AIR FUEL RATIO SENSOR (HEATER RESISTANCE) (a) Disconnect the C15 or C35 A/F sensor connector. (b) Measure the resistance between the terminals of the A/F sensor connector. Standard resistance: Bank 1 C15 A/F Sensor Bank 1 +B A1A- HA1A Specified Conditions HA1A (1) - +B (2) 1.8 to 3.4 Ω at 20°C (68°F) HA1A (1) - A1A- (4) 10 kΩ or higher Bank 2 A1A+ C35 A/F Sensor Bank 2 +B Tester Connections HA2A Tester Connections Specified Conditions HA2A (1) - +B (2) 1.8 to 3.4 Ω at 20°C (68°F) HT2A (1) - A2A- (4) 10 kΩ or higher (c) Reconnect the A/F sensor connector. NG A2A- A2A+ A126269E03 OK REPLACE AIR FUEL RATIO SENSOR (See page EC-19) ES ES–208 12 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT ENGINE ROOM JUNCTION BLOCK (A/F SENSOR HEATER RELAY) (a) Remove the engine room junction block from the engine room R/B. (b) Measure the A/F relay resistance. Standard resistance Engine Room Junction Block Tester Connections Specified Conditions 1G-1 - 1A-4 10 kΩ or higher 1G-1 - 1A-4 Below 1 Ω (when battery voltage applied to terminals 1E-6 and 1E-10) 1G 1A (c) Reinstall the engine room junction block. 1E ES NG Engine Room Relay Block A140654E01 OK REPLACE ENGINE ROOM JUNCTION BLOCK ES–209 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 13 CHECK HARNESS AND CONNECTOR (A/F SENSOR - ECM) Wire Harness Side: Air Fuel Ratio Sensor Connector C15 Bank 1 C35 Bank 2 C55 ECM Connector A1A+ A1A- A2A- A2A+ HA1A HA2A A127715E14 (a) Disconnect the C15 or C35 A/F sensor connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage between the +B terminal of the A/F sensor connector and body ground. Standard voltage Tester Connections Specified Conditions +B (C15-2) - Body ground 9 to 14 V +B (C35-2) - Body ground 9 to 14 V (d) Turn the ignition switch off. (e) Disconnect the C55 ECM connector. (f) Measure the resistance. Standard resistance (Check for open) ES Tester Connections Specified Conditions HA1A (C15-1) - HA1A (C55-86) Below 1 Ω A1A+ (C15-3) - A1A+ (C55-93) Below 1 Ω A1A- (C15-4) - A1A- (C55-116) Below 1 Ω HA2A (C35-1) - HA2A (C55-109) Below 1 Ω A2A+ (C35-3) - A2A+ (C55-120) Below 1 Ω A2A- (C35-4) - A2A- (C55-119) Below 1 Ω Standard resistance (Check for short) Tester Connections Specified Conditions HA1A (C15-1) or HA1A (C55-86) - Body ground 10 kΩ or higher A1A+ (C15-3) or A1A+ (C55-93) - Body ground 10 kΩ or higher A1A- (C15-4) or A1A- (C55-116) - Body ground 10 kΩ or higher HA2A (C35-1) or HA2A (C55-109) - Body ground 10 kΩ or higher A2A+ (C35-3) or A2A+ (C55-120) - Body ground 10 kΩ or higher A2A- (C35-4) or A2A- (C55-119) - Body ground 10 kΩ or higher (g) Reconnect the ECM connector. (h) Reconnect the A/F sensor connector. ES–210 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Reference (System Diagram of Bank 1 Sensor 1): A/F Relay From Battery ECM A/F Sensor A/F +B Heater HA1A HA1A A1A+ A1A+ Sensor A1A- ES From EFI Relay Duty Control A1A- A133850E04 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 14 REPLACE AIR FUEL RATIO SENSOR (a) Replace the air fuel ratio sensor (See page EC-19). NEXT 15 PERFORM CONFIRMATION DRIVING PATTERN (a) Connect the intelligent tester to the DLC3 (Procedure A). (b) Turn the ignition switch on (IG) and turn the tester on (Procedure B). (c) Clear the DTCs (See page ES-45) (Procedure C). (d) Select the check mode using the tester (See page ES49) (Procedure D). (e) Start the engine and warm it up with all the accessories switched off (Procedure E). (f) Drive the vehicle at between 38 mph and 75 mph (60 km/h and 120 km/h) and at an engine speed of between 1,400 rpm and 3,200 rpm for 3 to 5 minutes (Procedure F). ES–211 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Engine Speed “F” Between 1,400 rpm and 3,200 rpm Between 38 mph and 75 mph (60 km/h and 120 km/h) “E” Idling 2 minutes Ignition Switch off 3 to 5 minutes Time “A”, “B”, “C”, “D” A079199E68 HINT: If the system is still malfunctioning, the MIL will be illuminated during procedure "F". NOTICE: If the conditions in this test are not strictly followed, no malfunction will be detected. NEXT 16 CHECK WHETHER DTC OUTPUT RECURS (DTC P0171, P0172, P0174 OR P0175) (a) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. (b) Read the DTCs. Result Display (DTC Output) Proceed to No output A P0171, P0172, P0174 or P0175 B B A END Go to step 5 ES ES–212 ES 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0300 Random / Multiple Cylinder Misfire Detected DTC P0301 Cylinder 1 Misfire Detected DTC P0302 Cylinder 2 Misfire Detected DTC P0303 Cylinder 3 Misfire Detected DTC P0304 Cylinder 4 Misfire Detected DTC P0305 Cylinder 5 Misfire Detected DTC P0306 Cylinder 6 Misfire Detected DESCRIPTION When the engine misfires, high concentrations of hydrocarbons (HC) enter the exhaust gas. Extremely high HC concentration levels can cause an increase in exhaust emission levels. High concentrations of HC can also cause increases in the Three-Way Catalytic Converter (TWC) temperature, which may cause damage to the TWC. To prevent this increase in emissions and to limit the possibility of thermal damage, the ECM monitors the misfire rate. When the temperature of the TWC reaches the point of thermal degradation, the ECM blinks the MIL. To monitor misfires, the ECM uses both the Camshaft Position (CMP) sensor and the Crankshaft Position (CKP) sensor. The CMP sensor is used to identify any misfiring cylinders and the CKP sensor is used to measure variations in the crankshaft rotation speed. Misfires are counted when the crankshaft rotation speed variations exceed predetermined thresholds. If the misfire exceeds the threshold levels and may cause emission deterioration, the ECM illuminates the MIL and sets a DTC. DTC No. P0300 DTC Detection Condition Simultaneous misfiring of several cylinder detected (2 trip detection logic) Trouble Area • • • • • • • • • • • • • • • Open or short in engine wire harness Connector connection Vacuum hose connections Ignition system Injector Fuel pressure Mass Air Flow (MAF) meter Engine Coolant Temperature (ECT) sensor Compression pressure Valve clearance Valve timing PCV valve and hose PCV hose connections Air induction system ECM ES–213 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. P0301 P0302 P0303 P0304 P0305 P0306 DTC Detection Condition Misfiring of specific cylinder detected (2 trip detection logic) Trouble Area • • • • • • • • • • • • • • • • Open or short in engine wire harness Connector connection Vacuum hose connections Ignition system Injector for direct injector Injector for port injector Fuel pressure Mass Air Flow (MAF) meter Engine Coolant Temperature (ECT) sensor Compression pressure Valve clearance Valve timing PCV valve and hose PCV hose connections Air induction system ECM If DTCs that indicate misfires are set for different cylinders, but DTC P0300 is not set, it indicates that misfires have been detected in different cylinders at different times. DTC P0300 is only set when several misfiring cylinders are detected at the same time. MONITOR DESCRIPTION Intake Camshaft Position Sensor Exhaust Camshaft Position Sensor ECM Crankshaft Position Sensor (36-2 teeth) A107734E02 The ECM illuminates the MIL and sets a DTC when either one of the following conditions, which could cause emission deterioration, is detected (2 trip detection logic): • Within the first 1,000 crankshaft revolutions of the engine starting, an excessive misfiring rate (approximately 20 to 50 misfires per 1, 000 crankshaft revolutions) occurs once. • After the first 1,000 crankshaft revolutions, an excessive misfiring rate (approximately 20 to 60 misfires per 1, 000 crankshaft revolutions) occurs 4 times in sequential crankshaft revolutions. The ECM flashes the MIL and sets a DTC when either one of the following conditions, which could cause the Three-Way Catalytic Converter (TWC) damage, is detected (2 trip detection logic): • In every 200 crankshaft revolutions at a high engine rpm, the threshold misfiring percentage is recorded once. • In every 200 crankshaft revolutions at a normal engine rpm, the threshold misfiring percentage is recorded 3 times. ES ES–214 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR STRATEGY ES Related DTCs P0300: Multiple cylinder misfire P0301: Cylinder 1 misfire P0302: Cylinder 2 misfire P0303: Cylinder 3 misfire P0304: Cylinder 4 misfire P0305: Cylinder 5 misfire P0306: Cylinder 6 misfire Required Sensors/Components (Main) Injector, Ignition coil, Spark plug Required Sensors/Components (Related) Crankshaft, Camshaft, Engine coolant temperature and intake air temperature sensors and Mass air flow meter Frequency of Operation Continuous Duration 1,000 to 4,000 crankshaft revolutions: Emission related misfire 200 to 600 crankshaft revolutions: Catalyst damaged misfire MIL Operation 2 driving cycles: Emission related misfire MIL flashes immediately: Catalyst damaged misfire Sequence of Operation None TYPICAL ENABLING CONDITIONS Misfire: Monitor runs whenever following DTCs are not present P0100 - P0103 (MAF meter) P0110 - P0113 (IAT sensor) P0115 - P0118 (ECT sensor) P0120 - P0223, P2135 (TP sensor) P0125 (Insufficient ECT for Closed Loop) P0327 - P0333 (Knock sensor) P0335 (CKP sensor) P0340, P0341 (CMP sensor) P0500 (VSS) Battery voltage 8 V or more VVT system Not operated by scan tool Engine RPM 450 to 6,500 rpm Either of following conditions (a) or (b) is met: - (a) ECT at engine start More than -7°C (19°F) (b) ECT More than 20°C (68°F) Fuel cut OFF Monitor period of emission-related-misfire: First 1,000 revolutions after engine start, or Check Mode Crankshaft 1,000 revolutions Except above Crankshaft 1,000 revolutions x 4 Monitor period of catalyst-damaged-misfire (MIL blinks): All of following conditions 1, 2 and 3 are met: Crankshaft 200 revolutions 1. Driving cycles 1st 2. Check mode OFF 3. Engine RPM Less than 2,500 rpm Except above Crankshaft 200 revolutions x 3 TYPICAL MALFUNCTION THRESHOLDS Monitor period of emission-related-misfire: Misfire rate 1 % or more Monitor period of catalyst-damage-misfire (MIL blinks): Number of misfire per 200 revolutions 94 or more (varies with intake air amount and RPM) Paired cylinders misfire (MIL blinks immeditately) Detected ES–215 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-25). WIRING DIAGRAM ECM C7 No. 1 Fuel Injector E6 Main Body ECU 1 11 C9 No. 2 Fuel Injector AM2 C8 No. 3 Fuel Injector IG2D C10 No. 4 Fuel Injector 45 C55 #10 85 C55 #20 ES 44 C55 #30 84 C55 #40 C36 No. 5 Fuel Injector 43 C55 #50 C37 No. 6 Fuel Injector 83 C55 #60 AM2 22 C55 E01 E23 Ignition SW ST/AM2 IG2 5 6 AM2 IG2 IG2 2 1 5 3 FL MAIN Battery A134880E01 ES–216 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CONFIRMATION DRIVING PATTERN 1. 2. 3. 4. 5. 6. Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the tester on. Record the DTC(s) and freeze frame data. Using the tester, switch the ECM from normal mode to check mode (See page ES-49). Read the misfire counts of each cylinder (CYL #10 to #60) with the engine in an idling condition. If any misfire count is displayed, skip the following confirmation driving pattern. 7. Drive the vehicle several times with the conditions, such as engine rpm and engine load, shown in MISFIRE RPM and MISFIRE LOAD in the DATA LIST. HINT: In order to store misfire DTCs, it is necessary to operate the vehicle for the period of time shown in the table below, using the MISFIRE RPM and MISFIRE LOAD in the DATA LIST. ES Engine RPM Duration Idling 3.5 minutes or more 1,000 3 minutes or more 2,000 1.5 minutes or more 3,000 1 minute or more 8. Check whether misfires have occurred by checking DTCs and freeze frame data. HINT: Do not turn the engine switch off until the stored DTC(s) and freeze frame data have been recorded. When the ECM returns to normal mode (default), the stored DTC(s), freeze frame data and other data will be erased. 9. Record the DTC(s), freeze frame data and misfire counts. 10.Turn the engine switch off and wait for at least 5 seconds. INSPECTION PROCEDURE HINT: • If any DTCs other than misfire DTCs are output, troubleshoot those DTCs first. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). • If the misfire does not recur when the vehicle is brought to the workshop, reproduce the conditions stored in the ECM as freeze frame data. • If the misfire still cannot be reproduced even though the conditions stored in the ECM as freeze frame data have been reproduced, one of the following factors is considered to be a possible cause of the problem: (a)There was insufficient fuel in the tank. (b)Improper fuel is used. (c) The spark plugs have been contaminated. (d)The problem requires further diagnosis. • After finishing repairs, check the misfire counts of the cylinders (CYL #1, #2, #3, #4, #5 and #6). • Be sure to confirm that no misfiring cylinder DTCs are set again by conducting the confirmation driving pattern after finishing repairs. • For 6 and 8 cylinder engines, the ECM intentionally does not set the specific misfiring cylinder DTCs at high engine RPM. If misfires occur only in high engine RPM areas, only DTC P0300 is set. In the event of DTC P0300 being present, perform the following operations: (a)Clear the DTC (See page ES-45). (b)Start the engine and conduct the confirmation driving pattern. (c) Read the misfiring rates of each cylinder or DTC(s) using the tester. ES–217 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (d)Repair the cylinder(s) that has a high misfiring rate or is indicated by the DTC. (e)After finishing repairs, conduct the confirmation driving pattern again, in order to verify that DTC P0300 is not set. • When one of SHORT FT #1, LONG FT #1, SHORT FT #2 or LONG FT #2 in the freeze frame data is outside the range of +-20 %, the air-fuel ratio may be RICH (-20 % or less) or LEAN (+20 % or more). • When the COOLANT TEMP in the freeze frame data is less than 75°C (167°F), the misfire have occurred only while warming up the engine. 1 CHECK ANY OTHER DTC OUTPUT (IN ADDITION TO MISFIRE DTCS) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the tester on. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read the DTCs. Result Display (DTC output) Proceed to P0300, P0301, P0302, P0303, P0304, P0305 and/or P0306 A P0300, P0301, P0302, P0303, P0304, P0305 and/or P0306 and other DTCs B HINT: If any DTCs other than P0300, P0301, P0302, P0303, P0304, P0305 and P0306 are output, troubleshoot those DTCs first. B GO TO DTC CHART (See page ES-63) A 2 READ VALUE OF INTELLIGENT TESTER (MISFIRE RPM AND MISFIRE LOAD) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the tester on. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / MISFIRE / MISFIRE RPM and MISFIRE LOAD. (d) Read and note the MISFIRE RPM and MISFIRE LOAD (engine load) values. HINT: The MISFIRE RPM and MISFIRE LOAD values indicate the vehicle conditions under which the misfire occurred. NEXT 3 CHECK PCV HOSE (HOSE CONNECTIONS) OK: PCV hose is connected correctly and is not damaged. NG OK REPAIR OR REPLACE PCV HOSE ES ES–218 4 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK MISFIRE COUNT (CYL #1, #2, #3, #4, #5 AND #6) (a) (b) (c) (d) (e) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the tester on. Clear DTCs. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / MISFIRE / CYL #1, #2, #3, #4, #5 and #6 (Step "A"). (f) Allow the engine to idle (Step "B"). (g) Read the value of CYL #1 to #6 displayed on the tester. If no misfire counts occur in any cylinders, perform the following operations (Step "C"): (1) Shift the gear selector lever to the D position. (2) Repeat steps "A" to "C" above. (3) Check the CYL #1 to #6. (4) If misfire counts are still no displayed, perform steps "D" and "E" and then check the misfire counts again. (h) Drive the vehicle with the MISFIRE RPM and MISFIRE LOAD noted in step 2 (Step "D"). (i) Read the CYL #1 to #6 or DTCs displayed on the tester (Step "E"). ES Result Misfire count Proceed to 1 or 2 cylinders have misfire counts A 3 cylinders or more have misfire counts B B Go to step 13 A 5 CHECK SPARK PLUG Electrode Gap (a) Remove the ignition coil and the spark plug of the misfiring cylinder. (b) Measure the spark plug electrode gap. Standard: Between 1.0 mm and 1.4 mm (0.039 in. and 0.055 in.) (c) Check the electrode for carbon deposits. Recommended spark plug: A107715E01 Manufacture Product DENSO FK20HBR11 NOTICE: If the electrode gap is larger than standard, replace the spark plug. Do not adjust the electrode gap. NG OK REPLACE SPARK PLUG 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 6 ES–219 CHECK FOR SPARKS AND IGNITION (a) Disconnect the injector connectors, in order to prevent the engine from starting. (b) Install the spark plug to the ignition coil. (c) Attach the spark plug assembly to the cylinder head cover. (d) Crank the engine for less than 2 seconds and check the sparks. OK: Sparks jump across the electrode gap. (e) Reconnect the injector connectors. NG Go to step 8 OK 7 CHECK CYLINDER COMPRESSION PRESSURE (MALFUNCTION CYLINDER) (a) Measure the cylinder compression pressure of the misfiring cylinder. OK Go to step 9 NG REPAIR OR REPLACE ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION 8 CHANGE SPARK PLUG WITH NORMAL ONE AND CHECK FOR SPARKS OF MISFIRING CYLINDER (a) Change the installed spark plug with a spark plug that functions normally. (b) Perform a spark test. CAUTION: Always disconnect each injector connector. NOTICE: Do not crank the engine for more than 2 seconds. (1) Install the spark plug to the ignition coil and connect the ignition coil connector. (2) Disconnect the injector connector. (3) Ground the spark plug. (4) Check if sparks occur while the engine is being cranked. OK: Sparks jump across the electrode gap. NG REPLACE IGNITION COIL ASSEMBLY (See page IG-9) ES ES–220 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK REPLACE SPARK PLUG 9 INSPECT ECM (#10, #20, #30, #40, #50 AND/OR #60 VOLTAGE)) Wire Harness Side Front View: ECM Connector #30 (+) #50 (+) E01 (-) C55 ES #10 (+) #60 (+) #20 (+) #40 (+) (a) Disconnect the C55 ECM connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage between the terminals. Standard voltage Tester Connection Specified Condition #10 (C55-45) - E01 (C55-22) 9 to 14 V #20 (C55-85) - E01 (C55-22) 9 to 14 V #30 (C55-44) - E01 (C55-22) 9 to 14 V #40 (C55-84) - E01 (C55-22) 9 to 14 V #50 (C55-43) - E01 (C55-22) 9 to 14 V #60 (C55-83) - E01 (C55-22) 9 to 14 V (d) Reconnect the ECM connector. OK Go to step 12 A107892E80 NG 10 CHECK HARNESS AND CONNECTOR (INJECTOR - ECM) (a) Disconnect the injector connector (misfire cylinder). (b) Disconnect the C55 ECM connector. (c) Measure the resistance between the terminals. Standard resistance Wire Harness Side Front View: Injector Connector C7 C8 C9 C10 C36 C37 ECM Connector C55 #50 #60 #40 #30 #10 #20 A106388E07 Tester Connection Specified Condition #10 (C55-45) - C7-1 Below 1 Ω #20 (C55-85) - C9-1 Below 1 Ω #30 (C55-44) - C8-1 Below 1 Ω #40 (C55-84) - C10-1 Below 1 Ω #50 (C55-43) - C36-1 Below 1 Ω #60 (C55-83) - C37-1 Below 1 Ω #10 (C55-45) or C7-1 - Body ground 10 kΩ or higher #20 (C55-85) or C9-1 - Body ground 10 kΩ or higher #30 (C55-44) or C8-1 - Body ground 10 kΩ or higher #40 (C55-84) or C10-1 - Body ground 10 kΩ or higher #50 (C55-43) or C36-1 - Body ground 10 kΩ or higher #60 (C55-83) or C37-1 - Body ground 10 kΩ or higher (d) Reconnect the injector connector. (e) Reconnect the ECM connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–221 OK 11 CHECK FUEL INJECTOR ASSEMBLY (MISFIRING CYLINDER) (a) Check the injector injection (whether fuel volume high or low, and whether injection pattern is poor). NG REPLACE FUEL INJECTOR ASSEMBLY (See page FU-13) OK 12 CHECK VALVE CLEARANCE (MISFIRING CYLINDER) ES NG ADJUST VALVE CLEARANCE OK 13 CHECK AIR INDUCTION SYSTEM (a) Check the air induction system for vacuum leakage. OK: No leakage from air induction system. NG OK REPAIR OR REPLACE AIR INDUCTION SYSTEM ES–222 14 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK VALVE TIMING Timing Mark ES Timing Mark (a) Remove the cylinder head covers. (b) Turn the crankshaft pulley, and align its groove with the timing mark "0" of the timing chain cover. (c) Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing cap as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks as above. OK: Timing marks on camshaft timing gears are aligned as shown in illustration. (d) Reinstall the cylinder head covers. NG ADJUST VALVE TIMING Timing Mark Timing Mark A135015E01 OK 15 CHECK FUEL PRESSURE (a) Check the fuel pressure (high or low pressure). Standard Item Standard Condition Fuel pressure 147 kPa (1.5 kgf/cm2, 21 psi) NG CHECK AND REPLACE FUEL SYSTEM OK 16 READ VALUE OF INTELLIGENT TESTER (COOLANT TEMP) (a) Connect the intelligent tester to the DLC3. 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–223 (b) Turn the ignition switch on (IG). (c) Turn the tester on. (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / COOLANT TEMP. (e) Read the COOLANT TEMP twice, when the engine is both cold and warmed up. Standard: With cold engine: Same as ambient air temperature. With warm engine: Between 75°C and 95°C (167°F and 203°F). NG REPLACE ENGINE COOLANT TEMPERATURE SENSOR (See page ES-499) ES OK 17 READ VALUE OF INTELLIGENT TESTER (MAF) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Turn the tester on. (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / MAF and COOLANT TEMP. (e) Allow the engine to idle until the COOLANT TEMP reaches 75°C (167°F) or more. (f) Read the MAF with the engine in an idling condition and at an engine speed of 2,500 rpm. Standard: MAF while engine is idling: Between 2.1 g/sec and 3.1 g/sec (shift position: N, A/C: OFF). MAF at an engine speed of 2,500 rpm: Between 7.8 g/sec and 11.4 g/sec (shift position: N, A/C: OFF). NG REPLACE MASS AIR FLOW METER (See page ES-477) OK 18 CHECK MISFIRE COUNT (CYL #1, #2, #3, #4, #5 AND #6) HINT: • If the result of step 4 is "1 or 2 cylinders", proceed to A. • If the result of step 4 os "more than 3 cylinders", proceed to B. B A CHECK FOR INTERMITTENT PROBLEMS Go to step 5 ES–224 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0327 Knock Sensor 1 Circuit Low Input (Bank 1 or Single Sensor) DTC P0328 Knock Sensor 1 Circuit High Input (Bank 1 or Single Sensor) DTC P0332 Knock Sensor 2 Circuit Low Input (Bank 2) DTC P0333 Knock Sensor 2 Circuit High Input (Bank 2) DESCRIPTION ES A flat type knock sensor (non-resonant type) has a structure that can detect vibrations over a wide band of frequencies: between approximately 6 kHz and 15 kHz. Knock sensors are fitted onto the engine block to detect engine knocking. The knock sensor contains a piezoelectric element which generates a voltage when it becomes deformed. The voltage is generated when the engine block vibrates due to knocking. Any occurrence of engine knocking can be suppressed by delaying the ignition timing. DTC No. DTC Detection Condition Trouble Area P0327 P0332 Output voltage of knock sensor 1 or 2 is 0.5 V or less (1 trip detection logic) • • • Short in knock sensor 1 or 2 circuit Knock sensor 1 or 2 ECM P0328 P0333 Output voltage of knock sensor 1 or 2 is 4.5 V or more (1 trip detection logic) • • • Open in knock sensor 1 or 2 circuit Knock sensor 1 or 2 ECM HINT: When any of DTCs P0327, P0328, P0332 and P0333 are set, the ECM enters fail-safe mode. During failsafe mode, the ignition timing is delayed to its maximum retardation. Fail-safe mode continues until the engine switch is turned off. Reference: Inspection using an oscilloscope KNK1 Signal Waveform 1 V/DIV. GND 1 ms./Division A140638E01 The correct waveform is as shown. Item Content Terminals KNK1 - EKNK or KNK2 -EKN2 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Item Content Equipment Settings 0.01 to 10 V/DIV. 0.01 to 10 ms./DIV. Conditions Keep engine speed at 4,000 rpm with warm engine ES–225 MONITOR DESCRIPTION The knock sensor, located on the cylinder block, detects spark knock. When spark knock occurs, the piezoelectric element of the sensor vibrates. When the ECM detects a voltage in this frequency range, it retards the ignition timing to suppress spark knock. The ECM also senses background engine noise with the knock sensor and uses this noise to check for faults in the sensor. If the knock sensor signal level is too low for more than 10 seconds, or if the knock sensor output voltage is outside the normal range, the ECM interprets this as a fault in the knock sensor and sets a DTC. ES MONITOR STRATEGY Related DTCs P0327: Knock sensor (Bank 1) open/short (Low voltage) P0328: Knock sensor (Bank 1) open/short (High voltage) P0332: Knock sensor (Bank 2) open/short (Low voltage) P0333: Knock sensor (Bank 2) open/short (High voltage) Required Sensors/Components (Main) Knock sensor (Bank 1 and 2) Required Sensors/Components (Related) - Frequency of Operation Continuous Duration 1 second MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present None Battery voltage 10.5 V or more Time after engine start 5 seconds or more Engine switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Knock Sensor Range Check (Low voltage) P0327 and P0332: Knock sensor voltage Less than 0.5 V Knock Sensor Range Check (High voltage) P0328 and P0333: Knock sensor voltage More than 4.5 V ES–226 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM V2 Knock Sensor (Bank 1) 1 2 Shielded 2 CV1 95 KNK1 C55 1 CV1 94 EKNK C55 4 CV1 118 KNK2 C55 3 CV1 117 EKN2 C55 ES V1 Knock Sensor (Bank 2) 1 2 A133852E01 INSPECTION PROCEDURE HINT: • DTCs P0327 and P0328 are for the bank 1 knock sensor circuit. • DTCs P0332 and P0333 are for the bank 2 knock sensor circuit. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). ES–227 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 1 READ OUTPUT DTC (CHECK KNOCK SENSOR CIRCUIT) Knock Sensor ECM CV1 1 2 1 2 Male Connector - Female Connector 2 95 C55 1 1 94 C55 4 4 118 C55 3 3 117 C55 2 Terminal 2 - Terminal 4 Terminal 1 - Terminal 3 Terminal 4 - Terminal 2 Terminal 3 - Terminal 1 (c) (d) (e) (f) CV1 Male (a) Disconnect the CV1 connector. (b) Using lead wires, connect the connectors as follows: Female G041090E02 Warm up the engine. Run the engine at 3,000 rpm for 10 seconds or more. Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG) and turn the intelligent tester on. (g) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (h) Read the DTCs. Result Display Proceed to DTCs same as when vehicle brought in P0327, P0328 → P0327, P0328 or P0332, P0333 → P0332, P0333 A DTCs different from when vehicle brought in P0327, P0328 → P0332, P0333 or P0332, P0333 → P0327, P0328 B (i) B A Reconnect the CV1 connector. Go to step 4 ES ES–228 2 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK WIRE HARNESS AND CONNECTOR (CONNECTOR - ECM) (a) Disconnect the CV1 connector. (b) Disconnect the C55 ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for open) Wire Harness Side: CV1 Female ES ECM Connector C55 EKNK EKN2 Tester Connection Specified Condition CV1 female connector 2 - KNK1 (C55-95) Below 1 Ω CV1 female connector 1 - EKNK (C55-94) Below 1 Ω CV1 female connector 4 - KNK2 (C55-118) Below 1 Ω CV1 female connector 3 - EKN2 (C55-117) Below 1 Ω Standard resistance (Check for short) KNK1 KNK2 A135193E01 Tester Connection Specified Condition CV1 female connector 2 or KNK1 (C55-95) - Body ground 10 kΩ or higher CV1 female connector 1 or EKNK (C55-94) - Body ground 10 kΩ or higher CV1 female connector 4 or KNK2 (C55-118) - Body ground 10 kΩ or higher CV1 female connector 3 or EKN2 (C55-117) - Body ground 10 kΩ or higher (d) Reconnect the CV1 connector. (e) Reconnect the ECM connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 INSPECT ECM (a) Disconnect the CV1 connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage CV1 Female A137955E01 Tester Connection Specified Condition CV1 female connector 2 - 1 4.5 to 5.5 V CV1 female connector 4 - 3 4.5 to 5.5 V (d) Reconnect the ECM connector. NG OK CHECK FOR INTERMITTENT PROBLEMS REPLACE ECM (See page ES-518) ES–229 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 4 INSPECT KNOCK SENSOR (a) Disconnect the CV1 connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side: CV1 Tester Connection Specified Condition Male CV1 male connector 1 - 2 120 to 280 kΩ CV1 male connector 3- 4 120 to 280 kΩ (c) Reconnect the CV1 connector. G042949E02 OK CHECK FOR INTERMITTENT PROBLEMS ES NG 5 CHECK HARNESS AND CONNECTOR (CONNECTOR - KNOCK SENSOR) HINT: • If DTC P0327 or P0328 has changed to P0332 or P0333, check the knock sensor circuit on the right bank side. • If DTC P0332 or P0333 has changed to P0327 or P0328, check the knock sensor circuit on the left bank side. (a) Disconnect the CV1 connector. (b) Disconnect the V2 and V1 knock sensor connectors. (c) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for open) Wire Harness Side: CV1 Male Tester Connection Specified Condition CV1 male connector 2 - V2-2 Below 1 Ω CV1 male connector 1 - V2-1 Below 1 Ω CV1 male connector 4 - V1-2 Below 1 Ω CV1 male connector 3 - V1-1 Below 1 Ω Standard resistance (Check for short) Knock Sensor Connector V2 Bank 1 V1 Bank 2 Tester Connection Specified Condition CV1 male connector 2 or V2-2 - Body ground 10 kΩ or higher CV1 male connector 1 or V2-1 - Body ground 10 kΩ or higher CV1 male connector 4 or V1-2 - Body ground 10 kΩ or higher CV1 male connector 3 or V1-1 - Body ground 10 kΩ or higher (d) Reconnect the CV1 connector. (e) Reconnect the knock sensor connectors. A135025E01 NG OK REPLACE KNOCK SENSOR (See page ES-510) REPAIR OR REPLACE HARNESS OR CONNECTOR ES–230 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0335 Crankshaft Position Sensor "A" Circuit DTC P0339 Crankshaft Position Sensor "A" Circuit Intermittent DESCRIPTION ES The crankshaft position (CKP) sensor system consists of a crankshaft position sensor plate and a magnetic coil. The sensor plate has 34 teeth and is installed on the crankshaft. The pickup coil is made of windings, an iron core and magnet. The sensor plate rotates and as each tooth passes through the pickup coil, a pulse signal is created. The pickup coil generates 34 signals for each engine revolution. Based on these signals, the ECM calculates the crankshaft position and engine RPM. Using these calculations, the fuel injection time and ignition time are controlled. DTC No. DTC Detection Condition P0335 • • • • Open or short in CKP sensor circuit CKP sensor CKP sensor plate ECM Under conditions (a), (b) and (c), no CKP sensor signal to ECM for 0.05 seconds or more (1 trip detection logic): (a) Engine speed 1,000 rpm or more (b) Starter signal OFF (c) 3 seconds or more have elapsed since starter signal switched from ON to OFF • • • • Open or short in CKP sensor circuit CKP sensor CKP sensor plate ECM • P0339 Trouble Area No CKP sensor signal to ECM while cranking (1 trip detection logic) No CKP sensor signal to ECM at engine speed of 600 rpm or more (1 trip detection logic) • Reference: Inspection using an oscilloscope. VV1, VV2 and NE Signal Waveforms 5 V/DIV. NE GND VV1 GND VV2 GND 20 ms./DIV. A107148E09 HINT: • The correct waveform is as shown. • VV1+ and VV2+ stand for the VVT sensor signal, and NE+ stands for the CKP sensor signal. Item Content Terminals VV1+ - VV1VV2+ - VV2NE+ - NE- Equipment Settings 5 V/DIV, 20 ms./DIV. Conditions Cranking or idling 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–231 MONITOR DESCRIPTION If there is no signal from the crankshaft position sensor despite the engine revolving, the ECM interprets this as a malfunction of the sensor. If the malfunction is not repaired successfully, these DTCs are set 10 seconds after the engine is next started. MONITOR STRATEGY Related DTCs P0335: CKP sensor signal check when starter ON P0335: CKP sensor signal check when starter OFF P0335: sensor pulse check Required Sensors/Components (Main) Crankshaft Position (CKP) sensor Required Sensors/Components (Sub) - Frequency of Operation Continuous Duration Within 5 seconds and 3 times MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS All: Monitor will run whenever these DTCs are not present - CKP sensor signal check when starter OFF: Engine rpm 600 rpm or more Time after starter ON to OFF 3 seconds or more CKP sensor pulse check: Battery voltage 7 V or higher Starter ON Number of VVT sensor signal pulse 6 times CMP sensor circuit fail Not detected Ignition switch ON TYPICAL MALFUNCTION THRESHOLDS CKP sensor signal check when starter OFF: Sensor signal No signal CKP sensor pulse check: Number of sensor pulse 132 or less, or 174 or more COMPONENT OPERATING RANGE CKP sensor • • CKP sensor output voltage fluctuates while crankshaft is revolving 34 CKP sensor signals per crankshaft revolution ES ES–232 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM 115 C55 VCV1 C41 VVT Sensor (for Intake Camshaft (bank 1)) VVR+ 3 ES VC VVR- 1 2 EX+ C50 Crankshaft Position Sensor 92 C55 VV1114 C55 VCE1 C40 VVT Sensor (for Exhaust Camshaft (bank 1)) 3 69 C55 VV1+ VC2 EX- 1 2 * 68 C55 EV1+ 91 C55 EV1- 110 C55 NE+ 1 111 C55 NE- 2 112 C55 VCE2 C44 VVT Sensor (for Exhaust Camshaft (bank 2)) EX+ 3 VC2 EX- 1 2 66 C55 EV2+ 89 C55 EV2113 C55 VCV2 C45 VVT Sensor (for Intake Camshaft (bank 2)) VVL+ 3 VC VVL- 1 2 67 C55 VV2+ 90 C55 VV2- *: Shielded A122758E03 ES–233 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE HINT: • If no problem is found by this diagnostic troubleshooting procedure, troubleshoot the engine mechanical system. • Check the engine speed. The engine speed can be checked by using the intelligent tester. To check, follow the procedure below: (a)Connect the intelligent tester to the DLC3. (b)Start the engine. (c) Turn the tester on. (d)Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / ENGINE SPD. The engine speed may be indicated as zero despite the engine revolving normally. This is caused by a lack of NE signals from the crankshaft position (CKP) sensor. Alternatively, the engine speed may be indicated as lower than the actual engine speed, if the CKP sensor output voltage is insufficient. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). 1 INSPECT CRANKSHAFT POSITION SENSOR (a) Disconnect the C50 crankshaft position (CKP) sensor connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance CKP Sensor C50 A078431E19 Tester Connection Condition Specified Condition 1-2 Cold 1,630 to 2,740 Ω 1-2 Hot 2,065 to 3,225 Ω HINT: Terms "cold" and "hot" refer to the temperature of the coils. "Cold" means approximately -10 to 50°C (14 to 122°F). "Hot" means approximately 50 to 100°C (122 to 212°F). (c) Reconnect the CKP sensor connector. NG OK REPLACE CRANKSHAFT POSITION SENSOR (See page ES-496) ES ES–234 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2 CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - ECM) (a) Disconnect the C50 CKP sensor connector. (b) Disconnect the C55 ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for open) Wire Harness Side: Crankshaft Position Sensor C50 Tester Connection Specified Condition C50-1 - NE+ (C55-110) Below 1 Ω C50-2 - NE- (C55-111) Below 1 Ω Standard resistance (Check for short) ES Specified Condition 10 kΩ or higher C50-2 or NE- (C55-111) - Body ground 10 kΩ or higher (d) Reconnect the ECM connector. (e) Reconnect the CKP sensor connector. ECM Connector C55 NG NE+ Tester Connection C50-1 or NE+ (C55-110) - Body ground REPAIR OR REPLACE HARNESS OR CONNECTOR NEA135026E01 OK 3 CHECK CRANK POSITION SENSOR (SENSOR INSTALLATION) (a) Check the CKP sensor installation condition. OK: Sensor is installed correctly. NG REPAIR OR REPLACE CRANK POSITION SENSOR Clearance OK NG BR03795E10 OK 4 CHECK CRANKSHAFT POSITION SENSOR PLATE (TEETH OF SENSOR PLATE) (a) Check the teeth of the sensor plate. 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–235 OK: Sensor plate does not have any cracks or deformation. NG REPLACE CRANKSHAFT POSITION SENSOR PLATE OK REPLACE ECM (See page ES-518) ES ES–236 ES 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0340 Camshaft Position Sensor Circuit Malfunction DTC P0342 Camshaft Position Sensor "A" Circuit Low Input (Bank 1 or Single Sensor) DTC P0343 Camshaft Position Sensor "A" Circuit High Input (Bank 1 or Single Sensor) DTC P0345 Camshaft Position Sensor "A" Circuit (Bank 2) DTC P0347 Camshaft Position Sensor "A" Circuit Low Input (Bank 2) DTC P0348 Camshaft Position Sensor "A" Circuit High Input (Bank 2) DESCRIPTION The intake camshaft's Variable Valve Timing (VVT) sensor (G signal) consists of a magnet and MRE (Magneto Resistance Element). The VVT camshaft drive gear has a sensor plate with 3 teeth on its outer circumference. When the gear rotates, changes occur in the air gaps between the sensor plate and MRE, which affects the magnetic field. As a result, the resistance of the MRE material fluctuates. The VVT sensor converts the gear rotation data to pulse signals, uses the pulse signals to determine the camshaft angle, and sends it to the ECM. The crankshaft angle sensor plate has 34 teeth. The pickup coil generates 34 signals for each engine revolution. Based on combination of the G signal and NE signal, the ECM detects the crankshaft angle. Then the ECM uses this data to control fuel injection time and injection timing. Also, based on the NE signal, the ECM detects the engine speed. DTC No. DTC Detection Condition • P0340 P0345 • Input voltage to ECM remains 0.3 V or less, or 4.7 V or higher for more than 5 seconds, when 2 or more seconds have elapsed after turning engine switch on (IG) (1 trip detection logic) No VVT sensor signal to ECM during cranking (1 trip detection logic) Trouble Area • • • • • • P0342 P0347 Output voltage of VVT sensor 0.3 V or less is for 5 seconds (1 trip detection logic) • • • • • P0343 P0348 Output voltage of VVT sensor 4.7 V or more is for 5 seconds (1 trip detection logic) • • • • Open or short in VVT sensor for intake camshaft circuit VVT sensor for intake camshaft Camshaft timing gear for intake camshaft Jumped tooth of timing chain for intake camshaft ECM Open or short in VVT sensor for intake camshaft circuit VVT sensor for intake camshaft Camshaft timing gear for intake camshaft Jumped tooth of timing chain for intake camshaft ECM Open or short in VVT sensor for intake camshaft circuit VVT sensor for intake camshaft Camshaft timing gear for intake camshaft Jumped tooth of timing chain for intake camshaft ECM 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–237 Reference: Inspection using an oscilloscope VV1, VV2 and NE Signal Waveforms 5 V/DIV. NE GND VV1 GND VV2 GND 20 ms./DIV. ES A107148E09 HINT: • The correct waveform is as shown. • VV1+ and VV2+ stand for the VVT sensor signal, and NE+ stands for the CKP sensor signal. Item Content Terminals NE+ - NEVV1+ - VV1VV2+ - VV2- Equipment Settings 5 V/DIV. 20 ms./DIV. Conditions Cranking or idling MONITOR DESCRIPTION If no signal is transmitted by the VVT sensor despite the engine revolving, or the rotations of the camshaft and the crankshaft are not synchronized, the ECM interprets this as a malfunction of the sensor. MONITOR STRATEGY Related DTCs P0340: VVT sensor (Bank 1) open/short P0340: VVT position/Crankshaft position misalignment (Bank 1) P0342: VVT position sensor (Bank 1) range check (low voltage) P0343: VVT position sensor (Bank 1) range check (high voltage) P0345: VVT sensor (Bank 2) open/short P0345: VVT position/Crankshaft position misalignment (Bank 2) P0347: VVT position sensor (Bank 2) range check (low voltage) P0348: VVT position sensor (Bank 2) range check (high voltage) Required Sensors/Components (Main) VVT position sensor (Bank 1 and 2) Required Sensors/Components (Sub) Crankshaft position sensor Frequency of Operation Continuous Duration 5 seconds MIL Operation 2 driving cycles: P0340 (cranking), P0345 (cranking) Immediate: Others Sequence of Operation None TYPICAL ENABLING CONDITIONS All: Monitor runs whenever following DTCs are not present None ES–238 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM P0340 (Engine running): Engine speed 600 rpm or more Starter OFF P0345 (Engine running): Engine speed 600 rpm or more Battery voltage 8 V or more Starter OFF Engine switch ON P0340 (Cranking): ES Starter ON Minimum battery voltage Less than 11 V CPU initial Not initial P0345 (Cranking): Starter ON Battery voltage while starter is ON at least once Less than 11 V P0340, P0342, P0343 (Chattering, Low voltage, High voltage): Starter OFF Engine switch ON Time after engine switch off to on 2 seconds or more P0345, P0347, P0348 (Chattering, Low voltage, High voltage): Starter OFF Engine switch ON Time after engine switch off to on 2 seconds or more Battery Voltage 8 V or more TYPICAL MALFUNCTION THRESHOLDS P0340 (Engine running): Camshaft position and crankshaft position phase Misaligned Camshaft position signal No signal P0340 (Cranking): Camshaft position signal No signal P0340 (Chattering): Camshaft position sensor voltage Less than 0.3 V, or more than 4.7 V P0342 (Low voltage): Camshaft position sensor voltage Less than 0.3 V P0343 (High voltage): Camshaft position sensor voltage More than 4.7 V P0345 (Engine running, cranking): VVT sensor signal No signal P0345 (Chattering): VVT sensor voltage Less than 0.3 V, or more than 4.7 V P0347 (Low voltage): VVT sensor voltage Less than 0.3 V ES–239 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM P0348 (High voltage): VVT sensor voltage More than 4.7 V COMPONENT OPERATING RANGE VVT sensor voltage 0.3 to 4.7 V WIRING DIAGRAM Refer to DTC P0335 (See page ES-224). INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). 1 CHECK HARNESS AND CONNECTOR (SENSOR POWER SOURCE) (a) Disconnect the C41 or C45 VVT sensor connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness Side: VVT Sensor C41 Bank 1 VC A107149E16 OK Specified Condition VC (C41-3) - Body ground 4.5 to 5.0 V VC (C45-3) - Body ground 4.5 to 5.0 V (c) Reconnect the VVT sensor connector. NG C45 Bank 2 Tester Connection REPAIR OR REPLACE HARNESS OR CONNECTOR ES ES–240 2 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (VVT SENSOR FOR INTAKE CAMSHAFT - ECM) (a) Disconnect the C41 or C45 VVT sensor connector. (b) Disconnect the C55 ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for open) Wire Harness Side: VVT Sensor C41 Tester Connection Bank 1 Specified Condition VVR+ (C41-1) - VV1+ (C55-69) Below 1 Ω VVR- (C41-2) - VV1- (C55-92) Below 1 Ω C45 VVL+ (C45-1) - VV2+ (C55-67) Below 1 Ω Bank 2 VVL- (C45-2) - VV2- (C55-90) Below 1 Ω ES Standard resistance (Check for short) ECM Connector VV2+ C55 Tester Connection Specified Condition VVR+ (C41-1) or VV1+ (C55-69) - Body ground 10 kΩ or higher VVR- (C41-2) or VV1- (C55-92) - Body ground 10 kΩ or higher VVL+ (C45-1) or VV2+ (C55-67) - Body ground 10 kΩ or higher VVL- (C45-2) or VV2- (C55-90) - Body ground 10 kΩ or higher (d) Reconnect the VVT sensor connector. (e) Reconnect the ECM connector. NG VV2- VV1+ VV1- REPAIR OR REPLACE HARNESS OR CONNECTOR A135027E01 OK 3 CHECK VVT SENSOR FOR INTAKE CAMSHAFT (SENSOR INSTALLATION) (a) Check the CKP sensor installation condition. OK: Sensor is installed correctly. NG REPAIR OR REPLACE VVT SENSOR Clearance OK NG BR03795E17 OK 4 CHECK CAMSHAFT TIMING GEAR ASSEMBLY (TEETH OF PLATE) (a) Check the teeth of the signal plate. 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–241 OK: Sensor plate teeth do not have any cracks or deformation. NG REPLACE CAMSHAFT TIMING GEAR ASSEMBLY OK 5 REPLACE VVT SENSOR NEXT 6 ES CHECK WHETHER DTC OUTPUT RECURS (a) (b) (c) (d) (e) (f) Connect the intelligent tester to the DLC3. Turn the ignition switch to on (IG). Turn the intelligent tester on. Clear the DTCs (See page ES-45). Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. Read the DTCs. Result Display (DTC Output) Proceed to No output A P0340, P0342, P0343, P0345, P0347 or P0348 B HINT: If the engine does not start, replace the ECM. B A END REPLACE ECM (See page ES-518) ES–242 ES 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0351 Ignition Coil "A" Primary / Secondary Circuit DTC P0352 Ignition Coil "B" Primary / Secondary Circuit DTC P0353 Ignition Coil "C" Primary / Secondary Circuit DTC P0354 Ignition Coil "D" Primary / Secondary Circuit DTC P0355 Ignition Coil "E" Primary / Secondary Circuit DTC P0356 Ignition Coil "F" Primary / Secondary Circuit DESCRIPTION HINT: • These DTCs indicate malfunctions relating to the primary circuit. • If DTC P0351 is set, check the No. 1 ignition coil circuit. • If DTC P0352 is set, check the No. 2 ignition coil circuit. • If DTC P0353 is set, check the No. 3 ignition coil circuit. • If DTC P0354 is set, check the No. 4 ignition coil circuit. • If DTC P0355 is set, check the No. 5 ignition coil circuit. • If DTC P0356 is set, check the No. 6 ignition coil circuit. A Direct Ignition System (DIS) is used on this vehicle. The DIS is a 1-cylinder ignition system in which each cylinder is ignited by one ignition coil and spark plug is connected to the end of each secondary wiring. A powerful voltage, generated in the secondary wiring, is applied directly to each spark plug. The sparks of the spark plugs pass from the center electrode to the ground electrodes. The ECM determines the ignition timing and transmits the ignition signals (IGT) to each cylinder. Using the IGT signal, the ECM turns the power transistor inside the igniter on and off. The power transistor, in turn, switches on and off the current to the primary coil. When the current to the primary coil is cut off, a powerful voltage is generated in the secondary coil. This voltage is applied to the spark plugs, causing them to spark inside the cylinders. As the ECM cuts the current to the primary coil off, the igniter sends back an ignition confirmation signal (IGF) to the ECM, for each cylinder ignition. ES–243 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ECM From Battery Igniter No. 1 Ignition Coil IGT1 No. 1 Cylinder IGF Crankshaft Position Sensor Ignition Coil Spark Plug ES IGT2 No. 2 Ignition Coil No. 2 Cylinder IGT3 Camshaft Position Sensor No. 3 Ignition Coil No. 3 Cylinder IGT4 No. 4 Ignition Coil No. 4 Cylinder Other Sensors (Engine Coolant Temperature Sensor, Mass Air Flow Meter, Throttle Position Sensor, etc.) IGT5 No. 5 Ignition Coil No. 5 Cylinder IGT6 No. 6 Ignition Coil No. 6 Cylinder To Tachometer TAC A133853E01 ES–244 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. P0351 P0352 P0353 P0354 P0355 P0356 DTC Detection Condition No IGF signal to ECM while engine is running (1 trip detection logic) Trouble Area • • • • Ignition system Open or short in IGF1 or IGT circuit (1 to 6) between ignition coil and ECM No. 1 to No. 6 ignition coils ECM Reference: Inspection using an oscilloscope. IGT and IGF Signal waveform 2 V/DIV. CH1 ES GND CH2 20 ms./Division GND A140641E02 While cranking or idling the engine, check the waveform between terminals IGT (1 to 6) and E1, and IGF1, IGF1 and E1 of the ECM connector. Item Content Terminals CH1: IGT1, IGT2, IGT3, IGT4, IGT5, IGT6 - E1 CH2: IGF1 - E1 Equipment Settings 2 V/DIV. 20 ms./DIV. Conditions Cranking or idling 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–245 MONITOR DESCRIPTION Ignition Coil IGT ECM Igniter IGF Ignition Coil ES Ignition Signal (IGT) Normal Ignition Confirmation Signal (IGF) Malfunction Circuit Open Time A082388E07 If the ECM does not receive any IGF signals despite transmitting the IGT signal, it interprets this as a fault in the igniter and sets a DTC. If the malfunction is not repaired successfully, a DTC is set 1 second after the engine is next started. MONITOR STRATEGY Related DTCs P0351: Igniter (cylinder 1) malfunction P0352: Igniter (cylinder 2) malfunction P0353: Igniter (cylinder 3) malfunction P0354: Igniter (cylinder 4) malfunction P0355: Igniter (cylinder 5) malfunction P0356: Igniter (cylinder 6) malfunction Required Sensors/Components (Main) Igniter (Cylinder 1 to 6) Required Sensors/Components (Sub) Crankshaft position sensor Frequency of Operation Continuous Duration 0.256 seconds and 4 sparks MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever the following DTCs are not present None Either of the following condition A or B is met: - A. Engine RPM 1,500 rpm or less B. Starter OFF Either of the following condition C or D is met: - ES–246 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM C. Both of the following conditions are met: - (a) Engine speed 500 rpm or less (b) Battery voltage 6 V or more D. All of the following conditions are met: - (a) Engine speed More than 500 rpm (b) Battery voltage 10 V or more (c) Number of sparks after CPU reset 5 sparks or more TYPICAL MALFUNCTION THRESHOLDS ES Ignition signal fail count More than 2 times Ignition signal fail count No ignition confirmation signal from ignitor COMPONENT OPERATING RANGE IGF signal Igniter transmits IGF signal when it receives IGT signal from ECM ES–247 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM 1 IGT1 +B 40 C55 3 IGT1 IGF GND 4 2 C11 No. 1 Ignition Coil 1 4 IGT3 +B GND IGF 38 C55 3 IGT3 ES 2 C12 No. 3 Ignition Coil A 1 IGT5 +B GND 36 C55 3 IGT5 IGF 4 2 C38 No. 5 Ignition Coil 1 +B IGT2 3 IGF GND 4 2 C13 No. 2 Ignition Coil 1 +B IGT4 3 39 C55 106 IGT2 C55 IGF1 37 C55 IGT4 IGF GND 2 4 C14 No. 4 Ignition Coil 1 +B GND IGT6 IGF 3 C16 C49 4 Noise Noise C39 No. 6 Ignition Coil Filter Filter 35 C55 IGT6 2 A133854E01 ES–248 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM IG2 Relay IG2 5 3 1 2 A E23 Ignition SW FL MAIN ST/AM2 5 AM2 *2 IG2 6 *2 *1 ES E6 Main Body ECU Battery IG2D *1: with Smart Key System *2: without Smart Key System 11 A133855E01 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). 1 INSPECT IGNITION COIL ASSEMBLY (POWER SOURCE) (a) Disconnect the C11, C13, C12, C14, C38 or C39 ignition coil connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness Side: Ignition Coil Connector Tester Connection Specified Condition C11 C13 C12 C11-1 - Body ground 9 to 14 V C14 C38 C39 C13-1 - Body ground 9 to 14 V C12-1 - Body ground 9 to 14 V C14-1 - Body ground 9 to 14 V C38-1 - Body ground 9 to 14 V C39-1 - Body ground 9 to 14 V A054393E66 (d) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition C11-4 - Body ground Below 1 Ω C13-4 - Body ground Below 1 Ω ES–249 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NG Tester Connection Specified Condition C12-4 - Body ground Below 1 Ω C14-4 - Body ground Below 1 Ω C38-4 - Body ground Below 1 Ω C39-4 - Body ground Below 1 Ω REPAIR OR REPLACE HARNESS OR CONNECTOR OK 2 CHECK HARNESS AND CONNECTOR (IGNITION COIL ASSEMBLY - ECM (IGT SIGNAL TERMINAL)) Wireࠗࠣ࠾࠶࡚ࠪࡦࠦࠗ࡞#55;ゞਔ஥ࠦࡀࠢ࠲ Harness Side Front View: Ignition Coil with Igniter Connector C11 C12 C13 C14 C38 C39 IGF ECM Connector IGT1 IGT2 IGT3 IGT4 ࠛࡦࠫࡦࠦࡦ࠻ࡠ࡯࡞ࠦࡦࡇࡘ࡯࠲ゞਔ஥ࠦࡀࠢ࠲ C55 IGT3 IGT2 IGT1 (a) Disconnect the C11, C13, C12, C14, C38 or C39 ignition coil connector. (b) Disconnect the ECM C55 connectors. (c) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for open) Tester Connection Specified Condition IGT1 (C11-3) - IGT1 (C55-40) Below 1 Ω IGT2 (C13-3) - IGT2 (C55-39) Below 1 Ω IGT3 (C12-3) - IGT3 (C55-38) Below 1 Ω IGT4 (C14-3) - IGT4 (C55-37) Below 1 Ω IGT5 (C38-3) - IGT5 (C55-36) Below 1 Ω IGT6 (C39-3) - IGT6 (C55-35) Below 1 Ω Standard resistance (Check for short) IGT6 IGT5 IGT4 IGF1 A105983E07 Tester Connection Specified Condition IGT1 (C11-3) or IGT1 (C55-40) - Body ground 10 kΩ or higher IGT2 (C13-3) or IGT2 (C55-39) - Body ground 10 kΩ or higher IGT3 (C12-3) or IGT3 (C55-38) - Body ground 10 kΩ or higher IGT4 (C14-3) or IGT4 (C55-37) - Body ground 10 kΩ or higher IGT5 (C38-3) or IGT5 (C55-36) - Body ground 10 kΩ or higher IGT6 (C39-3) or IGT6 (C55-35) - Body ground 10 kΩ or higher Standard resistance (Check for open) Tester Connection Specified Condition IGF (C11-2) - IGF1 (C55-106) Below 1 Ω IGF (C13-2) - IGF1 (C55-106) Below 1 Ω IGF (C12-2) - IGF1 (C55-106) Below 1 Ω IGF (C14-2) - IGF1 (C55-106) Below 1 Ω IGF (C38-2) - IGF1 (C55-106) Below 1 Ω IGF (C39-2) - IGF1 (C55-106) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition IGF (C11-2) or IGF1 (C55-106) - Body ground 10 kΩ or higher IGF (C13-2) or IGF1 (C55-106) - Body ground 10 kΩ or higher IGF (C12-2) or IGF1 (C55-106)- Body ground 10 kΩ or higher IGF (C14-2) or IGF1 (C55-106) - Body ground 10 kΩ or higher ES ES–250 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Tester Connection Specified Condition IGF (C38-2) or IGF1 (C55-106) - Body ground 10 kΩ or higher IGF (C39-2) or IGF1 (C55-106) - Body ground 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 PERFORM SIMULATION TEST (a) Clear the DTC(s) (See page ES-45). (b) Change the arrangement of the ignition coils (with igniters). NOTICE: Do not change the location of the connectors. (c) Reform a simulation test. ES Result Display (DTC Output) Proceed to Same DTCs (that have been erased) A Other DTCs B B A REPLACE ECM (See page ES-518) REPLACE IGNITION COIL ASSEMBLY ES–251 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0365 Camshaft Position Sensor "B" Circuit (Bank 1) DTC P0367 Camshaft Position Sensor "B" Circuit Low Input (Bank 1) DTC P0368 Camshaft Position Sensor "B" Circuit High Input (Bank 1) DTC P0390 Camshaft Position Sensor "B" Circuit (Bank 2) DTC P0392 Camshaft Position Sensor "B" Circuit Low Input (Bank 2) DTC P0393 Camshaft Position Sensor "B" Circuit High Input (Bank 2) DESCRIPTION The exhaust camshaft's Variable Valve Timing (VVT) sensor consists of a magnet and MRE (Magneto Resistance Element). The exhaust camshaft has a sensor plate with 3 teeth on its outer circumference. When the exhaust camshaft rotates, changes occur in the air gaps between the 3 teeth and MRE, which affects the magnet. As a result, the resistance of the MRE material fluctuates. The VVT sensor converts the exhaust camshaft rotation data to pulse signals, uses the pulse signals to determine the camshaft angle, and sends it to the ECM. DTC No. DTC Detection Condition • P0365 P0390 • Input voltage to ECM remains 0.3 V or less, or 4.7 V or higher for more than 5 seconds, when 2 or more seconds have elapsed after turning engine switch on (IG) (1 trip detection logic) No VVT sensor signal to ECM during cranking (1 trip detection logic) Trouble Area • • • • • • P0367 P0392 Output voltage of VVT sensor is 0.3 V or less for 5 seconds (1 trip detection logic) P0368 P0393 Output voltage of VVT sensor is 4.7 V or more for 5 seconds (1 trip detection logic) • • • • • • • • • Open or short in VVT sensor for exhaust camshaft circuit VVT sensor for exhaust camshaft Exhaust camshaft Jumped tooth of timing chain ECM Open or short in VVT sensor for exhaust camshaft circuit VVT sensor for exhaust camshaft Exhaust camshaft Jumped tooth of timing chain ECM Open or short in VVT sensor for exhaust camshaft circuit VVT sensor for exhaust camshaft Exhaust camshaft Jumped tooth of timing chain ECM ES ES–252 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Reference: Inspection using an oscilloscope EV1, EV2 and NE Signal Waveform 5 V/DIV. NE GND EV1 GND EV2 GND 20 ms./DIV. ES A140642E02 HINT: • The correct waveform is as shown. • EV1+ and EV2+ stand for the VVT sensor signal, and NE+ stands for the CKP sensor signal. Item Content Terminal NE+ - NEEV1+ - EV1EV2+ - EV2- Equipment Setting 5 V/DIV. 20 ms./DIV. Condition Cranking or idling MONITOR DESCRIPTION If no signal is transmitted by the VVT sensor despite the engine revolving, or the rotations of the camshaft and the crankshaft are not synchronized, the ECM interprets this as a malfunction of the sensor. MONITOR STRATEGY Related DTCs P0365: VVT sensor (Bank 1) open/short P0365: VVT position/Crankshaft position misalignment (Bank 1) P0367: VVT position sensor (Bank 1) range check (low voltage) P0368: VVT position sensor (Bank 1) range check (high voltage) P0390: VVT sensor (Bank 2) open/short P0390: VVT position/Crankshaft position misalignment (Bank 2) P0392: VVT position sensor (Bank 2) range check (low voltage) P0393: VVT position sensor (Bank 2) range check (high voltage) Required Sensors/Components (Main) VVT position sensor (Bank 1 and 2) Required Sensors/Components (Sub) Crankshaft position sensor Frequency of Operation Continuous Duration 5 seconds MIL Operation 2 driving cycles: P0365, P0390 (cranking) Immediate: Others Sequence of Operation None TYPICAL ENABLING CONDITIONS All: Monitor runs whenever following DTCs are not present None 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–253 Chattering, Low voltage, High voltage: Starter OFF Engine switch ON Time after engine switch off to on 2 seconds or more Battery voltage 8 V or more P0365, P0390 (Engine running): Engine speed 600 rpm or more Battery voltage 8 V or more Starter OFF Engine switch ON P0365, P0390 (Cranking): Starter ON Minimum battery voltage Less than 11 V TYPICAL MALFUNCTION THRESHOLDS P0365, P0390 (Chattering): Exhaust camshaft position sensor voltage Less than 0.3 V, or more than 4.7 V P0367, P0392 (Low voltage): Exhaust camshaft position sensor voltage Less than 0.3 V P0368, P0393 (High voltage): Exhaust camshaft position sensor voltage More than 4.7 V P0365, P0390 (Engine running, Cranking): Exhaust camshaft position signal No signal COMPONENT OPERATING RANGE VVT sensor voltage 0.3 to 4.7 V WIRING DIAGRAM Refer to DTC P0335 (See page ES-224). INSPECTION PROCEDURE Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). ES ES–254 1 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (SENSOR POWER SOURCE) (a) Disconnect the C40 or C44 VVT sensor connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness Side: C40 Bank 1 C44 Bank 2 Tester Connection Specified Condition VC2 (C40-3) - Body ground 4.5 to 5.0 V VC2 (C44-3) - Body ground 4.5 to 5.0 V (c) Reconnect the VVT sensor connector. NG ES VVT Sensor REPAIR OR REPLACE HARNESS OR CONNECTOR VC2 A107149E17 OK 2 CHECK HARNESS AND CONNECTOR (VVT SENSOR - ECM) (a) Disconnect the C40 or C44 VVT sensor connector. (b) Disconnect the C55 ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for open) Wire Harness Side: VVT Sensor C40 Tester Connection Bank 1 Specified Condition EX+ (C40-1) - EV1+ (C55-68) Below 1 Ω EX- (C40-2) - EV1- (C55-91) Below 1 Ω C44 EX+ (C44-1) - EV2+ (C55-66) Below 1 Ω Bank 2 EX- (C44-2) - EV2- (C55-89) Below 1 Ω Standard resistance (Check for short) ECM Connector EV2+ C55 Tester Connection Specified Condition EX+ (C40-1) or EV1+ (C55-68) - Body ground 10 kΩ or higher EX- (C40-2) or EV1- (C55-91) - Body ground 10 kΩ or higher EX+ (C44-1) or EV2+ (C55-66) - Body ground 10 kΩ or higher EX- (C44-2) or EV2- (C55-89) - Body ground 10 kΩ or higher (d) Reconnect the VVT sensor connector. (e) Reconnect the ECM connector. NG EV2- EV1+ EV1A135027E02 OK REPAIR OR REPLACE HARNESS OR CONNECTOR 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 3 ES–255 CHECK VVT SENSOR FOR EXHAUST CAMSHAFT (SENSOR INSTALLATION) (a) Check the VVT sensor installation condition. OK: Sensor is installed correctly. NG Normal Clearance REPAIR OR REPLACE VVT SENSOR ES Abnormal BR03795E18 OK 4 CHECK EXHAUST CAMSHAFT (a) Check the teeth of the camshaft. NG REPLACE EXHAUST CAMSHAFT OK 5 REPLACE VVT SENSOR NEXT 6 CHECK WHETHER DTC OUTPUT RECURS (a) (b) (c) (d) (e) (f) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the intelligent tester on. Clear the DTCs (See page ES-45). Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. Read the DTCs. Result Display (DTC Output) Proceed to No output A P0365, P0352, P0353, P0354, P0355 or P0356 B HINT: If the engine does not start, replace the ECM. B REPLACE ECM (See page ES-518) ES–256 A END ES 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–257 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0420 Catalyst System Efficiency Below Threshold (Bank 1) DTC P0430 Catalyst System Efficiency Below Threshold (Bank 2) MONITOR DESCRIPTION The ECM uses the sensors mounted in front of and behind the Three-Way Catalytic Converter (TWC) to monitor its efficiency. The first sensor, the Air-Fuel Ratio (A/F) sensor, sends pre-catalyst information to the ECM. The second sensor, the Heated Oxygen (HO2) sensor, sends post-catalyst information to the ECM. In order to detect any deterioration in the TWC, the ECM calculates the Oxygen Storage Capacity (OSC) of the TWC. This calculation is based on the voltage output of the HO2 sensor while performing active airfuel ratio control, rather than the conventional detecting method, which uses the locus ratio. The OSC value is an indication of the oxygen storage capacity of the TWC. When the vehicle is being driven with a warm engine, active air-fuel ratio control is performed for approximately 15 to 20 seconds. When it is performed, the ECM deliberately sets the air-fuel ratio to lean or rich levels. If a rich-lean cycle of the HO2 sensor is long, the OSC becomes greater. There is a direct correlation between the OSCs of the HO2 sensor and the TWC. The ECM uses the OSC value to determine the state of the TWC. If any deterioration has occurred, it illuminates the MIL and sets a DTC. DTC No. DTC Detection Condition Trouble Area P0420 OSC value is smaller than standard value under active air-fuel ratio control (2 trip detection logic) • • • • P0430 OSC value is smaller than standard value under active air-fuel ratio control (2 trip detection logic) • • • • Gas leakage from exhaust system A/F sensor (bank 1 sensor 1) HO2 sensor (bank 1 sensor 2) Exhaust manifold (TWC) Gas leakage from exhaust system A/F sensor (bank 2 sensor 1) HO2 sensor (bank 2 sensor 2) Exhaust manifold (TWC) HINT: • Bank 1 refers to the bank that includes cylinder No. 1. • Bank 2 refers to the bank that does not include cylinder No. 1. • Sensor 1 refers to the sensor closest to the engine assembly. • Sensor 2 refers to the sensor farthest away from the engine assembly. MONITOR STRATEGY Related DTCs P0420: Catalyst Deterioration P0420: Catalyst Deterioration Required Sensors/Components (Main) TWC Required Sensors/Components (Sub) A/F sensor, heated oxygen sensor, intake air temperature sensor, mass air flow meter, crankshaft position sensor and engine coolant temperature sensor Frequency of Operation Once per driving cycle Duration Approximately 30 seconds MIL Operation 2 driving cycles Sequence of Operation None ES ES–258 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present ES P0011, 14 (VVT System 1 - Advance) P0012, 15 (VVT System 1 - Retard) P0031, 32, 51, 52 (A/F Sensor heater - Sensor 1) P0037, 38, 58, 59 (O2 Sensor heater - Sensor 2) P0100 - P0103 (MAF meter) P0115 - P0118 (ECT sensor) P0120 - P0223, P2135 (TP sensor) P0125 (Insufficient ECT for Closed Loop) P0136, P0156(O2 Sensor - Sensor 2) P0171, P0172, P0174, P0175 (Fuel system) P0300 - P0304 (Misfire) P0335 (CKP sensor) P0340 (CMP sensor) P0351 - P0354 (Igniter) P0500 (VSS) P2196, P2198 (A/F Sensor - rationality) P2A00, P2A03 (A/F Sensor - slow response) Battery voltage 11 V or more IAT -10°C (14°F) or more ECT 70 kPa (525 mmHg) or more Atmospheric pressure - Idle OFF Engine RPM Less than 3,200 rpm A/F sensor Activated Fuel system status Closed loop Engine load 10 to 70 % All of the following conditions 1, 2 and 3 are met: - 1. MAF 5 to 25 g/sec. 2. Front catalyst temperature (estimated) 600 to 750°C (1,112 to 1,382°F) 3. Rear catalyst temperature (estimated) 100 to 900°C (212 to 1,652°F) EVAP system monitor The monitor has not run yet or the vacuum introduction has been completed. A/F sensor monitor Completed Rear HO2S monitor Completed Shift position 4th or higher TYPICAL MALFUNCTION THRESHOLDS OSC (Oxygen Storage Capacity) of Catalyst Less than 0.046 g MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-25). CONDITIONING FOR SENSOR TESTING Perform the operation with the engine speeds and time durations described below prior to checking the waveforms of the A/F and HO2 sensors. This is performed in order to heat the sensors sufficiently to obtain the appropriate inspection results. ES–259 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Engine Speed (C) 3,000 rpm (D) (D) 2,000 rpm Idling Engine Switch Off (B) (A) Time Warming up At least 3 minutes 2 seconds Check A093766E21 1. Connect the intelligent tester to the DLC3 (Procedure "A"). 2. Start the engine and warm it up with all the accessories switched OFF, until the engine coolant temperature stabilizes (Procedure "B"). 3. Run the engine at an engine speed of between 2,500 rpm and 3,000 rpm for at least 3 minutes (Procedure "C"). 4. While running the engine at 3,000 rpm for 2 seconds and 2,000 rpm for 2 seconds, check the waveforms of the A/F and HO2 sensors using the tester or scan tool (Procedure "D"). NOTICE: The Air-Fuel Ratio (A/F) sensor has an output delay of a few seconds and the Heated Oxygen (HO2) sensor has a maximum output delay of approximately 20 seconds. Case 1 2 3 4 A/F Sensor (Sensor 1) Output Voltage HO2 Sensor (Sensor 2) Output Voltage Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage More than 3.35 V Less than 3.0 V Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage Almost no reaction Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage More than 3.35 V Less than 3.0 V Output Voltage Almost no reaction Injection volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage Almost no reaction Output Voltage Almost no reaction Main Suspected Trouble Area - • • • A/F sensor A/F sensor heater A/F sensor circuit • • • HO2 sensor HO2 sensor heater HO2 sensor circuit • • Fuel pressure Gas leakage from exhaust system (Air-fuel ratio extremely lean or rich) ES ES–260 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM • Following the A/F CONTROL procedure enables technicians to check and graph the output voltages of both the A/F and HO2 sensors. • To display the graph, enter the following menus on the tester: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL / USER DATA / AFS B1 S1 and O2S B1 S2 or AFS B2 S1 and O2S B2 S2, and press the YES button and then the ENTER button followed by the F4 button. INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). ES 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P0420 AND/OR P0430) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the tester on. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs. Result Display (DTC output) Proceed to P0420 and/or P0430 A P0420 and/or P0430 and other DTCs B HINT: If any DTCs other than P0420 or P0430 are output, troubleshoot those DTCs first. B GO TO DTC CHART (See page ES-63) A 2 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (A/F CONTROL) (a) Connect the intelligent tester to the DLC3. (b) Start the engine and turn the tester on. (c) Warm up the engine at a engine speed of 2,500 rpm for approximately 90 seconds. (d) On the tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. (e) Perform the A/F CONTROL operation with the engine in an idling condition (press the RIGHT or LEFT button to change the fuel injection volume.) (f) Monitor the output voltages of the A/F and HO2 sensors (AFS B1 S1 and O2S B1 S2 or AFS B2 S1 and O2S B2 S2) displayed on the tester. HINT: • The A/F CONTROL operation lowers the fuel injection volume by 12.5 % or increases the injection volume by 25 %. ES–261 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM • Each sensor reacts in accordance with increases and decreases in the fuel injection volume. Tester Display (Sensor) Injection Volume Status Voltage AFS B1 S1 or AFS B2 S1 (A/F) +25 % Rich Less than 3.0 V AFS B1 S1 or AFS B2 S1 (A/F) -12.5 % Lean More than 3.35 V O2S B1 S2 or O2S B2 S2 (HO2) +25 % Rich More than 0.55 V O2S B1 S2 or O2S B2 S2 (HO2) -12.5 % Lean Less than 0.4 V Result Status AFS B1 S1 or AFS B2 S1 Status O2S B1 S2 or O2S B2 S2 A/F Condition and A/F and HO2 Sensor Conditions Misfire Lean/Rich Lean/Rich Normal - Lean Lean/Rich A/F sensor malfunction - Rich Lean/Rich A/F sensor malfunction Lean/Rich Lean Lean/Rich Main Suspected Trouble Areas • Proceed to Three-Way Catalytic Converter (TWC) Gas leakage from exhaust system A • A/F sensor B May occur • A/F sensor B HO2 sensor malfunction - • • HO2 sensor Gas leakage from exhaust system C Rich HO2 sensor malfunction - • • HO2 sensor Gas leakage from exhaust system C • Lean Lean Actual air-fuel ratio lean May occur Extremely rich or lean actual air-fuel ratio Gas leakage from exhaust system A Rich Rich Actual air-fuel ratio lean - Extremely rich or lean actual air-fuel ratio Gas leakage from exhaust system A • • • • Lean: During A/F CONTROL, the A/F sensor (AFS) output voltage is consistently more than 3.35 V, and the HO2 sensor output voltage (O2S) is consistently less than 0.4 V. Rich: During A/F CONTROL, the AFS is consistently less than 3.0 V, and the O2S is consistently more than 0.55 V. Lean/Rich: During A/F CONTROL of the ACTIVE TEST, the output voltage of the HO2 sensor alternates correctly. B CHECK AND REPLACE AIR FUEL RATIO SENSOR ES ES–262 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM C CHECK AND REPLACE HEATED OXYGEN SENSOR, AND CHECK AND REPAIR EXHAUST GAS LEAKAGE A 3 CHECK FOR EXHAUST GAS LEAKAGE OK: No gas leakage. NG ES OK REPLACE THREE-WAY CATALYTIC CONVERTER REPAIR OR REPLACE EXHAUST GAS LEAKAGE POINT ES–263 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P043E Evaporative Emission System Reference Orifice Clog Up DTC P043F Evaporative Emission System Reference Orifice High Flow DTC P2401 Evaporative Emission System Leak Detection Pump Control Circuit Low DTC P2402 Evaporative Emission System Leak Detection Pump Control Circuit High DTC Evaporative Emission System Switching Valve Control Circuit Low P2419 DTC SUMMARY DTCs Monitoring Items P043E 0.02 inch orifice clogged P043F 0.02 inch orifice high-flow P2401 Vacuum pump stuck OFF P2402 Vacuum pump stuck ON P2419 Vent valve stuck open (vent) Malfunction Detection Conditions P043E, P043F, P2401, P2402, P2419 are present when one of the following conditions is met during key-off EVAP monitor • Reference orifice clogged • Reference orifice high-flow • Leak detection pump OFF malfunction • Leak detection pump ON malfunction • Vent valve ON (close) malfunction Trouble Areas • • • Pump module Connector/wire harness (Pump module - ECM) ECM Detection Timings While ignition switch OFF Detection Logic 2 trip HINT: The 0.02 inch orifice is located inside the pump module. DESCRIPTION The circuit description can be found in the EVAP (Evaporative Emission) System (See page ES-400). INSPECTION PROCEDURE Refer to the EVAP System (See page ES-400). MONITOR DESCRIPTION 5 hours*1 after the ignition switch is turned off, the electric vacuum pump creates negative pressure (vacuum) in the EVAP (Evaporative Emission) system. The ECM monitors for leaks and actuator malfunctions based on the EVAP pressure. HINT: *1: If the engine coolant temperature is not below 35°C (95°F) 5 hours after the ignition switch is turned off, the monitor check starts 2 hours later. If it is still not below 35°C (95°F) 7 hours after the ignition switch is turned off, the monitor check starts 2.5 hours later. Sequence - Operations ECM activation Descriptions Activated by soak timer, 5 hours (7 or 9.5 hours) after ignition switch turned off. Duration - ES ES–264 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Sequence Operations Descriptions Duration A Atmospheric pressure measurement Vent valve turned OFF (vent) and EVAP system pressure measured by ECM in order to register atmospheric pressure. If pressure in EVAP system is not between 70 kPa and 110 kPa (525 mmHg and 825 mmHg), ECM cancels EVAP system monitor. B First 0.02 inch leak pressure measurement In order to determine 0.02 inch leak pressure standard, vacuum pump creates negative pressure (vacuum) through 0.02 inch orifice and then ECM checks if vacuum pump and vent valve operate normally. 60 seconds C EVAP system pressure measurement Vent valve turned ON (closed) to shut EVAP system. Negative pressure (vacuum) is created in EVAP system, and EVAP system pressure then measured. Write down measured value as it will be used in leak check. If EVAP pressure does not stabilize within 15 minutes, ECM cancels EVAP system monitor. 15 minutes*2 D Purge VSV monitor Purge VSV is opened and then EVAP system pressure is measured by ECM. Large increase indicates normal. 10 seconds E Second 0.02 inch leak pressure measurement After second 0.02 inch leak pressure measurement, leak check is performed by comparing first and second 0.02 inch leak pressure standards. If stabilized system pressure is higher than second 0.02 inch leak pressure standard, ECM determines that EVAP system leaking. 60 seconds F Final check Atmospheric pressure is measured and then monitoring result is recorded by ECM. ES 10 seconds - *2: If there is only a small amount of fuel in the fuel tank, stabilizing the EVAP pressure takes longer than usual. Operation A: Operation B, E: Atmospheric Pressure Measurement 0.02 Inch Leak Pressure Measurement Canister Fuel Tank Purge VSV: OFF Vent Valve: OFF (vent) OFF OFF (vent) 0.02 Inch Orifice Pressure Sensor Air Filter Vacuum Pump: OFF Operation C: EVAP System Pressure Measurement OFF ON Pump Module ON (closed) Operation D: Purge VSV Monitor ON Atmospheric Pressure ON Negative Pressure ON (closed) ON A096746E31 ES–265 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM EVAP pressure during EVAP key-off monitor ON ON: Open Purge VSV OFF: Closed ON Vent Valve ON: Closed ON: Vent ON Pump EVAP Pressure (mmHg) 760 752 OK Malfunction ES 724 A Sequence Time 10 seconds B C 60 seconds Within 15 minutes D E 60 10 seconds seconds A138478E01 The leak detection pump creates negative pressure through the reference orifice. When the system is normal, the EVAP pressure is in 724 to 752 mmHg* and saturated within a minute. If not, the ECM interprets this as a malfunction. The ECM will illuminate the MIL and set DTC if this malfunction is detected in consecutive drive cycle. * : Typical valve MONITOR STRATEGY Related DTCs P043E: 0.02 inch orifice clog (built-in pump module) P043F: 0.02 inch orifice high-flow (built-in pump module) P2401: Vacuum pump stuck OFF P2402: Vacuum pump stuck ON P2419: Vent valve stuck open (vent) Required Sensors / Components Pump module Frequency of Operation Once per driving cycle Duration Within 2 minutes MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present None EVAP key-off monitor is run when all of the following conditions are met - Atmospheric pressure 70 to 110 kPa (525 to 825 mmHg) Battery voltage 10.5 V or more Vehicle speed Below 2.5 mph (4 km/h) Ignition switch OFF Time after key-off 5 or 7 or 9.5 hours EVAP pressure sensor malfunction (P0450, P0451, P0452, P0453) Not detected EVAP canister purge valve Not operated by scan tool ES–266 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM EVAP canister vent valve Not operated by scan tool EVAP leak detection pump Not operated by scan tool Both of the following conditions 1 and 2 are met before key-off Conditions 1 and 2 1. Duration that vehicle driven 5 minutes or more 2. EVAP purge operation Performed ECT 4.4 to 35°C (40 to 95°F) IAT 4.4 to 35°C (40 to 95°F) Key-off monitor sequence 1 to 8 1. Atmospheric pressure measurement ES Next sequence is run if the following condition is met: - Atmospheric pressure measurement Less than 0.3 kPa (2.25 mmHg) in 1 second 2. First reference pressure measurement Next sequence is run if all of the following conditions are met: Conditions 1, 2 and 3 1. EVAP pressure just after reference pressure measurement -1 kPa (-7.5 mmHg) or less 2. Reference pressure -4.85 to -1.057 kPa (-36.384 to -7.929 mmHg) 3. Reference pressure Saturated within 1 minute 3. EVAP canister vent valve close stuck check Next sequence is run if the following condition is met: - EVAP pressure change after vent valve is ON 0.3 kPa (2.25 mmHg) or more 4. Vacuum introduction Next sequence is run if the following condition is met: - Vacuum introduction time Saturated within 15 minutes 5. EVAP canister purge valve close stuck check Next sequence is run if the following condition is met: - EVAP pressure change after purge valve is open 0.3 kPa (2.25 mmHg) or more 6. Second reference pressure measurement Next sequence is run if all of the following conditions are met: Conditions 1, 2, 3 and 4 1. EVAP pressure just after reference pressure -1 kPa (-7.5 mmHg) or less 2. Reference pressure -4.85 to -1.057 kPa (-36.384 to -7.929 mmHg) 3. Reference pressure Saturated 4. Difference between first reference pressure and second reference pressure Less than 0.7 kPa (5.25 mmHg) 7. Leak check Next sequence is run if the following condition is met - EVAP pressure when vacuum introduction was complete Lower than second reference pressure 8. Atmospheric pressure measurement EVAP monitor is complete if the following condition is met: - Atmospheric pressure difference between sequence 1 and 8 Within 0.3 kPa (2.25 mmHg) TYPICAL MALFUNCTION THRESHOLDS One of following conditions met - 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM EVAP pressure just after reference pressure measurement start ES–267 More than -1 kPa (-7.5 mmHg) Reference pressure Less than -4.85 kPa (-36.384 mmHg) Reference pressure -1.057 kPa (-7.929 mmHg) or more Reference pressure Not saturated Difference between first reference pressure and second reference pressure 0.7 kPa (5.25 mmHg) or more MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-25). ES ES–268 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0441 Evaporative Emission Control System Incorrect Purge Flow DTC SUMMARY DTC No. P0441 Monitoring Item DTC Detection Condition EVAP VSV (Vacuum Switching Valve) stuck open Vacuum pump creates negative pressure (vacuum) in EVAP system and EVAP system pressure measured. 0.02 inch leak pressure standard measured at start and at end of leak check. If stabilized pressure higher than [second 0.02 inch leak pressure standard x 0.2], ECM determines that EVAP VSV stuck open EVAP VSV stuck closed After EVAP leak check performed, EVAP VSV turned ON (open), and atmospheric air introduced into EVAP system. 0.02 inch leak pressure standard measured at start and at end of the check. If pressure does not return to near atmospheric pressure, ECM determines that purge valve stuck closed Purge flow While engine running, following conditions are successively met: • Negative pressure not created in EVAP system when EVAP VSV turned ON (open) • EVAP system pressure change less than 0.5 kPa (3.75 mmHg) when vent valve turned ON (closed) • Atmospheric pressure change before and after purge flow monitor less than 0.1 kPa (0.75 mmHg) ES P0441 P0441 Detection Timing Detection Logic EVAP VSV Connector/wire harness (EVAP VSV - ECM) ECM Pump module Leakage from EVAP system While engine switch off 2 trip EVAP VSV Connector/wire harness (EVAP VSV - ECM) ECM Pump module Leakage from EVAP system While engine switch off 2 trip EVAP VSV Connector/wire harness (EVAP VSV - ECM) Leakage from EVAP line (EVAP VSV - Intake manifold) ECM While engine running 2 trip Trouble Area • • • • • • • • • • • • • • DESCRIPTION The circuit description can be found in the EVAP (Evaporative Emission) System (See page ES-400). INSPECTION PROCEDURE Refer to the EVAP System (See page ES-400). MONITOR DESCRIPTION The two monitors, Key-off and Purge Flow, are used to detect malfunctions relating to DTC P0441. The key-off monitor is initiated by the ECM internal timer, known as the soak timer, 5 hours* after the engine switch is turned off. The purge flow monitor runs while the engine is running. ES–269 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 1. KEY-OFF MONITOR 5 hours* after the engine switch is turned off, the electric vacuum pump creates negative pressure (vacuum) in the EVAP (Evaporative Emission) system. The ECM monitors for leaks and actuator malfunctions based on the EVAP pressure. HINT: *: If the engine coolant temperature is not below 35°C (95°F) 5 hours after the engine switch is turned off, the monitor check starts 2 hours later. If it is still not below 35°C (95°F) 7 hours after the engine switch is turned off, the monitor check starts 2.5 hours later. Sequence Operation Description Duration ECM activation Activated by soak timer, 5 hours (7 or 9.5 hours) after engine switch turned off. - Atmospheric pressure measurement Vent valve turned OFF (vent) and EVAP system pressure measured by ECM in order to register atmospheric pressure. If pressure in EVAP system not between 70 kPa and 110 kPa (525 mmHg and 825 mmHg), ECM cancels EVAP system monitor. 10 seconds First 0.02 inch leak pressure measurement In order to determine 0.02 inch leak pressure standard, vacuum pump creates negative pressure (vacuum) through 0.02 inch orifice and then ECM checks if vacuum pump and vent valve operate normally. 60 seconds C EVAP system pressure measurement Vent valve turned ON (closed) to shut EVAP system. Negative pressure (vacuum) created in EVAP system, and EVAP system pressure then measured. Write down measured value as they will be used in leak check. If EVAP pressure does not stabilize within 15 minutes, ECM cancels EVAP system monitor. 15 seconds* D EVAP VSV monitor EVAP VSV opened and then EVAP system pressure measured by ECM. Large increase indicates normal. 10 seconds E Second 0.02 inch leak pressure measurement After second 0.02 inch leak pressure measurement, leak check performed by comparing first and second 0.02 inch leak pressure standards. If stabilized system pressure higher than second 0.02 inch leak pressure standard, ECM determines that EVAP system leaking. 60 seconds F Final check Atmospheric pressure measured and then monitoring result recorded by ECM. - - A B ES HINT: *: If only a small amount of fuel is in the fuel tank, it takes longer for the EVAP pressure to stabilize. ES–270 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Operation A: Atmospheric Pressure Measurement VSV (for EVAP): OFF Operation B, E: 0.02 Inch Leak Pressure Measurement Canister Fuel tank OFF Vent Valve: OFF (vent) 0.02 Inch Orifice Pump Module Air Filter Vacuum Pump: OFF ES OFF (vent) ON Operation C: EVAP System Pressure Measurement Operation D: VSV (for EVAP) Monitor ON (closed) OFF ON Atmospheric Pressure ON (closed) Negative Pressure ON ON A106055E14 ES–271 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (a) EVAP VSV stuck open In operation C, the vacuum pump creates negative pressure (vacuum) in the EVAP (Evaporative Emission) system. The EVAP system pressure is then measured by the ECM using the pressure sensor. If the stabilized system pressure is higher than [second 0.02 inch leak pressure standard x 0.2], the ECM interprets this as the EVAP VSV (Vacuum Switching Valve) being stuck open. The ECM illuminates the MIL and sets the DTC (2 trip detection logic). EVAP Pressure when VSV (for EVAP) Stuck Open: ON VSV (for EVAP) ON: Open OFF: Closed ON: Closed ON Vent Valve ON: Vent ES ON Vacuum Pump EVAP Pressure Malfunction Positive Negative First 0.02 Inch Leak Pressure Standard [Second 0.02 Inch Leak Pressure Standard] x 0.2 OK Sequence Time A B 10 seconds 60 seconds C Within 15 minutes D E 10 60 seconds seconds A108008E11 ES–272 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (b) EVAP VSV stuck closed In operation D, the pressure sensor measures the EVAP (Evaporative Emission) system pressure. The pressure measurement for EVAP VSV monitor is begun when the EVAP VSV is turned ON (open) after the EVAP leak check. When the measured pressure indicates an increase of 0.3 kPa (2.25 mmHg) or more, the EVAP VSV is functioning normally. If the pressure does not increase, the ECM interprets this as the EVAP VSV being stuck closed. The ECM illuminates the MIL and sets the DTC (2 trip detection logic). EVAP Pressure when VSV (for EVAP) Stuck Closed: ON VSV (for EVAP) ES ON: Open OFF: Closed ON: Closed ON Vent Valve ON: Vent ON Vacuum Pump EVAP Pressure OK Positive Negative Malfunction First 0.02 Inch Leak Pressure Standard Sequence Time A B 10 seconds 60 seconds C Within 15 minutes D E 10 60 seconds seconds A106059E09 2. EVAP Pressure During Purge Flow Monitor: Open VSV (for EVAP) ON (Closed) Vent Valve Malfunction 0.1 kPa EVAP Pressure OK OK 1st Monitor 0.5 kPa 2nd Monitor A071563E14 PURGE FLOW MONITOR The purge flow monitor consists of the two step monitors. The 1st monitor is conducted every time and the 2nd monitor is activated if necessary. • The 1st monitor While the engine is running and the EVAP VSV (vacuum Switching Valve) is ON (open), the ECM monitors the purge flow by measuring the EVAP pressure change. If negative pressure is not created, the ECM begins the 2nd monitor. • The 2nd monitor The vent valve is turned ON (closed) and the EVAP pressure is then measured. If the variation in the pressure is less than 0.5 kPa (3.75 mmHg), the ECM interprets this as the EVAP VSV being stuck closed, and illuminates the MIL and sets DTC P0441 (2 trip detection logic). Atmospheric pressure check: 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–273 In order to ensure reliable malfunction detection, the variation between the atmospheric pressure, before and after conduction of the purge flow monitor, is measured by the ECM. OBD II MONITOR SPECIFICATIONS 1. Key-off Monitor Monitor Strategy: Required Sensors/Components EVAP VSV and pump module Frequency of Operation Once per driving cycle Duration Within 15 minutes MIL Operation 2 driving cycles Sequence of Operation None Typical Enabling Conditions: EVAP key-off monitor runs when all of following conditions are met: - Atmospheric pressure 70 to 110 kPa (525 to 825 mmHg) Battery voltage 10.5 V or more Vehicle speed Below 2.5 mph (4 km/h) Engine switch OFF Time after key off 5, 7 or 9.5 hours EVAP pressure sensor malfunction (P0450, P0451, P0452 and/or P0453) Not detected EVAP VSV Not operated by scan tool Vent valve Not operated by scan tool Leak detection pump Not operated by scan tool Both of following conditions are met before key off: Conditions 1 and 2 1. Duration that vehicle is being driven 5 minutes or more 2. EVAP purge operation Performed ECT 4.4 to 35°C (40 to 95°F) IAT 4.4 to 35°C (40 to 95°F) (a) Key-off monitor sequence 1 to 8 1. Atmospheric pressure Next sequence is run if following condition is met: - Atmospheric pressure change Less than 0.3 kPa (2.25 mmHg) for 1 second 2. First reference pressure Next sequence is run if all of following conditions are met: Conditions 1, 2 and 3 1. EVAP pressure when 4 seconds. after reference pressure measurement -1 kPa (-7.5 mmHg) or less 2. Reference pressure -4.85 to -1.05 kPa (-36.38 to -7.87 mmHg) 3. Reference pressure Saturated within 1 minute 3. Vent valve stuck closed check Next sequence is run if following condition is met: - EVAP pressure change after vent valve is ON 0.3 kPa (2.25 mmHg) or more 4. Vacuum introduction and leak Next sequence is run if both of following condition is met: - Vacuum introduction time 15 minutes or less 5. EVAP VSV stuck closed check Next sequence is run if following condition is met: - ES ES–274 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM EVAP pressure change after purge VSV ON 0.3 kPa (2.25 mmHg) or more 6. Second reference pressure measurement Next sequence is run if all of following conditions are met: Conditions 1, 2, 3 and 4 1. EVAP pressure just after reference pressure measurement -1 kPa (-7.5 mmHg) or less 2. Reference pressure -4.85 to -1.05 kPa (-36.38 to -7.87 mmHg) 3. Reference pressure Saturated within 1 minute 4. Reference pressure difference between first and second Less than 0.7 kPa (5.25 mmHg) 7. Leak check Next sequence is run if following condition is met: - EVAP pressure when vacuum introduction was complete Less than second reference pressure 8. Atmospheric pressure ES Monitor is complete - Atmospheric pressure difference between sequence 1 and 8 0.3 kPa (2.25 mmHg) or less Typical Malfunction Thresholds: One of the following conditions is met: - (a) EVAP VSV stuck open - EVAP pressure when vacuum introduction is complete Higher than reference pressure x 0.2 (b) EVAP VSV stuck closed - EVAP pressure change after EVAP canister purge valve is open Less than 0.3 kPa (2.25 mmHg) 2. Purge Flow Monitor Monitor Strategy: Required Sensors/Components EVAP VSV and pump module Frequency of Operation Once per driving cycle Duration Within 10 minutes MIL Operation 2 driving cycles Sequence of Operation None Typical Enabling Conditions: Monitor runs whenever these DTCs are not present - Engine Running ECT 4.4°C (40°F) or more IAT 4.4°C (40°F) or more EVAP pressure sensor malfunction Not detected EVAP VSV Not operated by scan tool EVAP system check Not detected by scan tool Battery voltage 10 V or more Purge duty cycle 8 % or more Typical Malfunction Thresholds: Both of following conditions are met: Condition 1 or 2 1. EVAP pressure change when purge operation is started Less than 0.1 kPa (0.75 mmHg) 2. EVAP pressure change during purge operation when vent valve is closed Less than 0.5 kPa (3.75 mmHg) MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-25). ES–275 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0450 Evaporative Emission Control System Pressure Sensor / Switch DTC P0451 Evaporative Emission Control System Pressure Sensor Range / Performance DTC P0452 Evaporative Emission Control System Pressure Sensor / Switch Low Input DTC P0453 Evaporative Emission Control System Pressure Sensor / Switch High Input DTC SUMMARY DTC No. Monitoring Item Malfunction Detection Condition Trouble Area Detection Timing • P0450 Pressure sensor voltage abnormal fluctuation Sensor output voltage rapidly fluctuates beyond upper and lower malfunction thresholds for 0.5 seconds. • • Pump module ECM • • P0451 Pressure sensor noising Sensor output voltage fluctuates frequently in a certain time period. • • • P0451 Pressure sensor stuck Sensor output voltage does not vary in a certain time period. • • • Pump module Connector / wire harness (Pump module - ECM) ECM Pump module Connector / wire harness (Pump module - ECM) ECM • • • P0452 Pressure sensor voltage low Sensor output voltage less than 0.45 V for 0.5 seconds. • • • Pump module Connector / wire harness (Pump module - ECM) ECM • • P0453 Pressure sensor voltage high Sensor output voltage more than 4.9V for 0.5 seconds. • • • Pump module Connector / wire harness (Pump module - ECM) ECM • Detection logic EVAP monitoring (engine switch off) Engine switch on 1 trip EVAP monitoring (engine switch off) Engine switch running 2 trip EVAP monitoring (engine switch off) 2 trip EVAP monitoring (engine switch off) Engine switch on 1 trip EVAP monitoring (engine switch off) Engine switch on 1 trip HINT: The pressure sensor is built into the pump module. DESCRIPTION The circuit description can be found in the EVAP (Evaporative Emission) System (See page ES-400). ES ES–276 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR DESCRIPTION 1. DTC P0450: Pressure sensor voltage abnormal fluctuation If the pressure sensor output voltage rapidly fluctuates between less than 0.45 V and more than 4.9 V, the ECM interprets this as an open or short circuit malfunction in the pressure sensor or its circuit, and stops the EVAP (Evaporative Emission) system monitor. The ECM then illuminates the MIL and sets the DTC (1 trip detection logic). Pressure Sensor Specification: Output Voltage Malfunction Area 4.900 V 4.150 V ES Usable Range 1.425 V Malfunction Area 0.450 V 60 110 (450 ) (825) Pressure kPa (mmHg) HINT: Standard atmospheric Pressure is 101.3 kPa A140644E01 2. DTC P0451: Pressure sensor noising or stuck If the pressure sensor output voltage fluctuates rapidly for 10 seconds, the ECM stops the EVAP system monitor. The ECM interprets this as noise from the pressure sensor, and stops the EVAP system monitor. The ECM then illuminates the MIL and sets the DTC. Alternatively, if the sensor output voltage does not change for 10 seconds, the ECM interprets this as the sensor being stuck, and stops the monitor. The ECM then illuminates the MIL and sets the DTC. (Both the malfunctions are detected by 2 trip detection logic). 3. DTC P0452: Pressure sensor voltage low If the pressure sensor output voltage is below 0.45 V, the ECM interprets this as an open or short circuit malfunction in the pressure sensor or its circuit, and stops the EVAP system monitor. The ECM then illuminates the MIL and sets the DTC (1 trip detection logic). 4. DTC P0453: Pressure sensor voltage high If the pressure sensor voltage output is 4.9 V or more, the ECM interprets this as an open or short circuit malfunction in the pressure sensor or its circuit, and stops the EVAP system monitor. The ECM then illuminates the MIL and sets the DTC (1 trip detection logic). MONITOR STRATEGY Related DTCs P0450: Pressure sensor chattering P0451: Pressure sensor noise P0451: Pressure sensor stuck P0452: Pressure sensor low voltage P0453: Pressure sensor high voltage Required Sensors/Components Pump module Frequency of Operation Once per driving cycle: P0451 sensor stuck Continuous: P0451 sensor noising, P0450, P0452 and P0453 Duration 0.5 seconds: P0450, P0452, P0453 Within 15 seconds: P0451 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MIL Operation Immediate: P0450, P0452, P0453 2 driving cycles: P0451 Sequence of Operation None ES–277 TYPICAL ENABLING CONDITIONS P0450, P0452 and P0453 (Pressure sensor chattering, low voltage, high voltage): Monitor runs whenever following DTCs are not present: None Battery voltage 8 V or more Starter OFF Engine switch ON P0451 (Pressure sensor noise): Atmospheric pressure 70 kPa (525 mmHg) to 110 kPa (825 mmHg) Battery voltage 10.5 V or more Intake air temperature 4.4 to 35°C (40 to 95°F) EVAP pressure sensor malfunction (P0450, P0452, P0453) Not detected Either of following conditions is met: 1 or 2 1. Engine Running 2. Time after key off 5, 7 or 9.5 hours P0451 (Pressure sensor stuck): Atmospheric pressure Less than 70 kPa (525 mmHg), or 110 kPa (825 mmHg) or more Battery voltage 10.5 V or more Intake air temperature 4.4 to 35°C (40 to 95°F) EVAP pressure sensor malfunction (P0450, P0452, P0453) Not detected Time after key off 5, 7 or 9.5 hours TYPICAL MALFUNCTION THRESHOLDS P0450: Pressure sensor chattering EVAP Pressure Less than 42.11 kPa (315.82 mmHg), or more than 123.761 kPa (928.207 mmHg) P0451: Pressure sensor noise Frequency that EVAP pressure change is 0.3 kPa or more 10 times or more in 10 seconds P0451: Pressure sensor stuck EVAP pressure change during reference pressure Less than 0.65 kPa (4.87 mmHg) P0452: Pressure sensor low voltage EVAP Pressure Less than 42.11 kPa (315.82 mmHg) P0453: Pressure sensor high voltage EVAP Pressure More than 123.761 kPa (928.207 mmHg) ES ES–278 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM C6 VSV (Purge) 1 108 C55 PRG 2 N17 Pump Module 9 Canister Closed Valve 8 ES 6 1 42 A55 VPMP 34 A55 MPMP Vacuum Pump Canister 4 Pressure Sensor 3 2 EFI No. 3 EFI No. 2 75 C55 VCPP 77 C55 PPMP 76 C55 EPPM 2 A55 +B EFI Relay EFI MAIN FL MAIN 44 A55 MREL Battery A133856E01 ES–279 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE NOTICE: • When a vehicle is brought into a workshop, leave it as it is. Do not change the vehicle condition. For example, do not tighten the fuel tank cap. • Do not disassemble the pump module. • The intelligent tester is required to conduct the following diagnostic troubleshooting procedure. 1 CHECK HARNESS AND CONNECTOR (PUMP MODULE - ECM) (a) Disconnect the N17 canister connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage and resistance according to the value(s) in the table below. Standard voltage Tester Connection Specified Condition N17-4 - Body ground 4.5 to 5.0 V N17-3 - Body ground 4.5 to 5.0 V N17-2 - Body ground 100 Ω or less Result Test Result Wire Harness Side: VOUT Suspected Trouble Area Proceed to Voltage and resistance within standard ranges Open in pressure sensor circuit A Voltage and resistance outside standard ranges Open in wire harness/ connector (ECM pressure sensor) B (d) Reconnect the canister connector. VCC B SGND Go to step 3 N17 Canister Pump Module Connector A135029E01 A 2 REPLACE CHARCOAL CANISTER ASSEMBLY (a) Replace the canister assembly (See page EC-9). NOTICE: When replacing the canister, check the canister pump module interior and related pipes for water, fuel and other liquids. If liquids are present, check for disconnections and/or cracks in the following: 1) the pipe from the air inlet port to the canister pump module; 2) the canister filter; and 3) the fuel tank vent hose. ES ES–280 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES Air Inlet Port Fuel Tank Vent Hose Inspection Area* Vent Hose Vent Hose *: Check for disconnection and/or crack A132283E04 NEXT 3 Go to step 5 CHECK HARNESS AND CONNECTOR Wire Harness Side: VOUT VCC SGND (a) Disconnect the N17 canister pump module connector. (b) Disconnect the C55 ECM connector. (c) Measure the resistance between the terminals of the wire harness side connectors. Standard resistance (Check for open) N17 Canister Pump Module Connector Tester Connection Specified Condition N17-4 (VCC) - C55-75 (VCPP) Below 1 Ω N17-3 (VOUT) - C55-77 (PPMP) Below 1 Ω N17-2 (SGND) - C55-76 (EPPM) Below 1 Ω Standard resistance (Check for short) C55 ECM Connector Tester Connection Specified Condition N17-4 (VCC) or C55-75 (VCPP) - Body ground 10 kΩ or higher N17-3 (VOUT) or C55-77 (PPMP) - Body ground 10 kΩ or higher N17-2 (SGND) or C55-76 (EPPM) - Body ground 10 kΩ or higher (d) Reconnect the canister pump module connector. (e) Reconnect the ECM connector. VCPP EPPM PPMP A140651E03 NG REPAIR OR REPLACE HARNESS OR CONNECTOR 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–281 OK 4 REPLACE ECM (a) Replace the ECM (See page ES-518). NEXT 5 CHECK WHETHER DTC OUTPUT RECURS (AFTER REPAIR) (a) (b) (c) (d) (e) NEXT COMPLETED Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG) (do not start the engine). Turn the tester on. Wait for at least 60 seconds. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. HINT: If no pending DTCs are displayed on the tester, the repair has been successfully completed. ES ES–282 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0455 Evaporative Emission Control System Leak Detected (Gross Leak) DTC P0456 Evaporative Emission Control System Leak Detected (Very Small Leak) DTC SUMMARY DTC No. ES P0455 P0456 Malfunction Detection Condition Monitoring Item EVAP gross leak EVAP small leak Vacuum pump creates negative pressure (vacuum) in EVAP system and EVAP system pressure measured. 0.02 inch leak pressure standard measured at start and at end of leak check. If stabilized pressure higher than [second 0.02 inch leak pressure standard x 0.2], ECM determines that EVAP system has a large leak Vacuum pump creates negative pressure (vacuum) in EVAP system and EVAP system pressure measured. 0.02 inch leak pressure standard measured at start and at end of leak check. If stabilized pressure higher than second 0.02 inch leak pressure standard, ECM determines that EVAP system has a small leak Trouble Area • • • • • • Fuel tank cap (loose) Leakage from EVAP line (Canister - Fuel tank) Leakage from EVAP line (EVAP VSV - Canister) Pump module Leakage from fuel tank Leakage from canister Same above Detection logic Detection Timing While engine switch off 2 trip While engine switch off 2 trip DESCRIPTION The circuit description can be found in the EVAP (Evaporative Emission) System (See page ES-400). INSPECTION PROCEDURE Refer to the EVAP System (See page ES-400). MONITOR DESCRIPTION 5 hours* after the engine switch is turned off, the electric vacuum pump creates negative pressure (vacuum) in the EVAP (Evaporative Emission) system. The ECM monitors for leaks and actuator malfunctions based on the EVAP pressure. HINT: *: If the engine coolant temperature is not below 35°C (95°F) 5 hours after the engine switch is turned off, the monitor check starts 2 hours later. If it is still not below 35°C (95°F) 7 hours after the engine switch is turned off, the monitor check starts 2.5 hours later. Sequence - A Operation Description Duration ECM activation Activated by soak timer, 5 hours (7 or 9.5 hours) after engine switch turned off. - Atmospheric pressure measurement Vent valve turned OFF (vent) and EVAP system pressure measured by ECM in order to register atmospheric pressure. If pressure in EVAP system not between 70 kPa and 110 kPa (525 mmHg and 825 mmHg), ECM cancels EVAP system monitor. 10 seconds ES–283 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Sequence Operation Description Duration First 0.02 inch leak pressure measurement In order to determine 0.02 inch leak pressure standard, vacuum pump creates negative pressure (vacuum) through 0.02 inch orifice and then ECM checks if vacuum pump and vent valve operate normally. 60 seconds C EVAP system pressure measurement Vent valve turned ON (closed) to shut EVAP system. Negative pressure (vacuum) created in EVAP system, and EVAP system pressure then measured. Write down measured value as they will be used in leak check. If EVAP pressure does not stabilize within 15 minutes, ECM cancels EVAP system monitor. 15 minutes* D EVAP VSV monitor EVAP VSV opened and then EVAP system pressure measured by ECM. Large increase indicates normal. 10 seconds E Second 0.02 inch leak pressure measurement After second 0.02 inch leak pressure measurement, leak check performed by comparing first and second 0.02 inch leak pressure standards. If stabilized system pressure higher than second 0.02 inch leak pressure standard, ECM determines that EVAP system leaking. 60 seconds F Final check Atmospheric pressure measured and then monitoring result recorded by ECM. - B ES HINT: *: If only a small amount of fuel is in the fuel tank, it takes longer for the EVAP pressure to stabilize. Operation A: Atmospheric Pressure Measurement Purge VSV: OFF Operation B, E: 0.02 Inch Leak Pressure Measurement Canister Fuel tank OFF OFF (vent) Vent Valve: OFF (vent) 0.02 Inch Orifice Pump Module Air Filter Vacuum Pump: OFF ON Operation C: EVAP System Pressure Measurement Operation D: Purge VSV Monitor ON (closed) OFF ON Atmospheric Pressure ON (closed) Negative Pressure ON ON A106055E15 1. P0455: EVAP (Evaporative Emission ) gross leak In operation C, the vacuum pump creates negative pressure (vacuum) in the EVAP system and the EVAP system pressure is measured. If the stabilized system pressure is higher than [second 0.02 inch leak pressure standard x 0.2] (near atmospheric pressure), the ECM determines that the EVAP system has a large leak, illuminates the MIL and sets the DTC (2 trip detection logic). ES–284 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2. P0456: EVAP very small leak In operation C, the vacuum pump creates negative pressure (vacuum) in the EVAP system and the EVAP system pressure is measured. If the stabilized system pressure is higher than the second 0.02 inch leak pressure standard, the ECM determines that the EVAP system has a small leak, illuminates the MIL and sets the DTC (2 trip detection logic). EVAP Pressure when EVAP System Leaks: ON VSV (for EVAP) ES ON: Open OFF: Closed Vent Valve ON Vacuum Pump ON ON: Closed ON: Vent EVAP Pressure P0455 Positive Negative P0456 First 0.02 Inch Leak Pressure Standard Sequence Time OK A B C 10 seconds 60 seconds Within 15 minutes D E 60 seconds 10 seconds A129400E02 MONITOR STRATEGY Required Sensors/Components EVAP VSV and pump module Frequency of Operation Once per driving cycle Duration Within 15 minutes (varies with amount of fuel in tank) MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS EVAP key-off monitor runs when all of following conditions are met: - Atmospheric pressure 70 to 110 kPa (525 to 825 mmHg) Battery voltage 10.5 V or more Vehicle speed Below 2.5 mph (4 km/h) Engine switch OFF 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Time after key off 5, 7 or 9.5 hours EVAP pressure sensor malfunction (P0450, P0451, P0452 and P0453) Not detected EVAP VSV Not operated by scan tool Vent valve Not operated by scan tool Leak detection pump Not operated by scan tool Both of following conditions are met before key OFF: Conditions 1 and 2 1. Duration that vehicle is being driven 5 minutes or more 2. EVAP purge operation Performed ECT 4.4 to 35°C (40 to 95°F) IAT 4.4 to 35°C (40 to 95°F) ES–285 1. Key-off monitor sequence 1 to 8 1. Atmospheric pressure Next sequence is run if following condition is met: - Atmospheric pressure change Less than 0.3 kPa (2.25 mmHg) for 1 second 2. First reference pressure Next sequence is run if all of following conditions are met: Conditions 1, 2 and 3 1. EVAP pressure when 4 seconds after reference pressure measurement -1 kPa (-7.5 mmHg) or less 2. Reference pressure -4.85 to -1.05 kPa (-36.38 to -7.87 mmHg) 3. Reference pressure Saturated within 1 minute 3. Vent valve stuck closed check Next sequence is run if following condition is met: - EVAP pressure change after vent valve is ON 0.3 kPa (2.25 mmHg) or more 4. Vacuum introduction and leak Next sequence is run if both of following conditions are met: - Vacuum introduction time 15 minutes or less 5. EVAP VSV stuck closed check Next sequence is run if following condition is met: - EVAP pressure change after purge VSV ON 0.3 kPa (2.25 mmHg) or more 6. Second reference pressure measurement Next sequence is run if all of following conditions are met: Conditions 1, 2, 3 and 4 1. EVAP pressure just after reference pressure measurement -1 kPa (-7.5 mmHg) or less 2. Reference pressure -4.85 to -1.05 kPa (-36.38 to -7.87 mmHg) 3. Reference pressure Saturated within 1 minute 4. Reference pressure difference between first and second Less than 0.7 kPa (5.25 mmHg) 7. Leak check Next sequence is run if following condition is met: - EVAP pressure when vacuum introduction was complete Less than second reference pressure 8. Atmospheric pressure Monitor is complete - Atmospheric pressure difference between sequence 1 and 8 0.3 kPa (2.25 mmHg) or less TYPICAL MALFUNCTION THRESHOLDS "Saturated" indicates that the EVAP pressure change is less than 0.1 kPa (0.75 mmHg) in 30 seconds. P0455: EVAP gross leak EVAP pressure when vacuum introduction is complete Higher than reference pressure x 0.2 ES ES–286 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM P0456: EVAP small leak EVAP pressure when vacuum introduction is complete Between reference pressure and reference pressure x 0.2 MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-25). ES ES–287 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0500 Vehicle Speed Sensor "A" DESCRIPTION The speed sensor detects the wheel speed and sends the appropriate signals to the skid control ECU. The skid control ECU converts these wheel speed signals into a 4-pulse signal and outputs it to the ECM via the combination meter. The ECM determines the vehicle speed based on the frequency of these pulse signals. 4-Pulse From Speed Sensor 4-Pulse Skid Control ECU ES ECM Combination Meter A079413E16 DTC No. P0500 DTC Detection Condition Vehicle speed signal from vehicle speed sensor is cut for 0.14 sec. or more while cruise control is in operation Trouble Area • • • • • Vehicle speed sensor Vehicle speed sensor signal circuit Combination meter ECM Skid control ECU MONITOR DESCRIPTION The ECM assumes that the vehicle is being driven when the transmission counter gear indicates more than 300 rpm and over 30 seconds have passed since the park/neutral position switch was turned OFF. If there is no signal from the vehicle speed sensor with these conditions satisfied, the ECM concludes that the vehicle speed sensor is malfunctioning. The ECM will turn on the MIL and a DTC will be set. MONITOR STRATEGY Related DTCs P0500: Vehicle Speed Sensor Circuit Required sensors / components (Main) Vehicle speed sensor, Combination meter, ABS ECU Required sensors / components (Sub) Counter gear Speed (CS) sensor, ECT sensor Frequency of operation Continuous Duration 8 seconds MIL operation 2 driving cycles Sequence operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present P0100 - P0103 (MAF sensor) P0105 - P0108 (MAP sensor) P0115 - P0118 (ECT sensor) P0120 - P02238 (TP sensor) P0125 (VSS/ECT1 sensor, non-ECT) Engine coolant temperature 70°C (158°F) or more ES–288 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Engine speed 2,000 to 5,000 rpm Engine load 30.37 % or more Fuel cut high engine speed Not executing Battery voltage 8 V or more Engine switch ON ETC sensor circuit fail Not detected MAF sensor circuit fail Not detected Starter OFF TYPICAL MALFUNCTION THRESHOLDS Vehicle speed sensor signal ES No pulse input WIRING DIAGRAM F2 Combination Meter +S 12 ECM 8 SPD A55 A135032E01 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester or the OBD II scan tool. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). 1 CHECK SPEEDOMETER (a) Drive the vehicle and check whether the operation of the speedometer in the combination meter is normal. HINT: • The vehicle speed sensor is operating normally if the speedometer reading is normal. ES–289 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM • If the speedometer does not operate, check it by following the procedure described in speedometer malfunction. NG GO TO SPEEDOMETER CIRCUIT OK 2 READ VALUE OF INTELLIGENT TESTER (VEHICLE SPEED) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the tester on. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / VEHICLE SPD. (e) Drive the vehicle. (f) Read the value displayed on the tester. OK: Vehicle speeds displayed on tester and speedometer display are equal. NG CHECK INTERMITTENT PROBLEMS OK 3 CHECK COMBINATION METER ASSEMBLY (+S VOLTAGE) (a) Disconnect the F2 combination meter connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage between the terminal of the combination meter and body ground. Standard voltage Wire Harness Side: F2 +S Combination Meter Connector Specified Condition F2-12 (+S) - Body ground 4.5 to 5.5 V (d) Reconnect the combination meter connector. A132286E01 OK Tester Connection NG Go to step 5 ES ES–290 4 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK COMBINATION METER ASSEMBLY (SPD SIGNAL WAVEFORM) (a) Shift the transmission gear selector lever to the neutral position. (b) Jack up the vehicle. (c) Turn the ignition switch on (IG). (d) Measure the voltage between the terminal of the combination meter and body ground while the wheel is turned slowly. Standard voltage Wire Harness Side: Combination Meter Connector F2 +S ES Specified Condition Voltage generated intermittently HINT: The output voltage should fluctuate up and down, similarly to the diagram, when the wheel is turned slowly. 0 to 12 V NG 0V Tester Connection F2-12 (+S) - Body ground REPLACE COMBINATION METER ASSEMBLY (See page ME-63) Turn Wheel A132287E01 OK 5 CHECK HARNESS AND CONNECTOR (COMBINATION METER ASSEMBLY - ECM) (a) Disconnect the F2 combination meter connector. (b) Disconnect the A55 ECM connector. (c) Measure the resistance. Standard resistance (Check for open) Wire Harness Side: Combination Meter Connector Front View F2 +S Specified Condition +S (F2-12) - SPD (A55-8) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition +S (F2-12) or SPD (A55-8) - Body ground 10 kΩ or higher (d) Reconnect the combination meter connector. (e) Reconnect the ECM connector. ECM Connector NG A55 Front View Tester Connection SPD A132288E02 REPAIR OR REPLACE HARNESS OR CONNECTOR 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–291 OK REPLACE ECM (See page ES-518) ES ES–292 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0504 Brake Switch "A" / "B" Correlation DTC P0724 Brake Switch "B" Circuit High DESCRIPTION The stop light switch is a duplex system that transmits two signals: STP and ST1-. These two signals are used by the ECM to monitor whether or not the brake system is working properly. If the signals, which indicate the brake pedal is being depressed and released, are detected simultaneously, the ECM interprets this as a malfunction in the stop light switch and sets the DTC. HINT: The normal conditions are as shown in the table below. The signals can be read using an intelligent tester. Signal Brake Pedal Released In Transition Brake Pedal Depressed STP OFF ON ON ST1- ON ON OFF ES DTC No. DTC Detection Condition Trouble Area P0504 Conditions (a), (b) and (c) continue for 0.5 seconds or more (1 trip detection logic): (a) Ignition switch on (IG) (b) Brake pedal released (c) STP signal OFF when ST1- signal OFF • • • Short in stop light switch signal circuit Stop light switch ECM P0724 The stop light switch remains ON even when the vehicle is driven in a STOP (less than 2 mph (3 km/h)) and GO (19 mph (30 km/h) or more) fashion 5 times. (2 trip detection logic) • • • Short in stop light switch signal circuit Stop light switch ECM MONITOR DESCRIPTION This DTC indicates that the stop light switch remains on. When the stop light switch remains ON during "stop and go" driving, the ECM interprets this as a fault in the stop light switch and the MIL comes on and the ECM stores the DTC. The vehicle must stop (less than 2 mph (3 km/h)) and go (19 mph (30 km/h) or more) 5 times in two driving cycles in order to detect a malfunction. MONITOR STRATEGY Related DTCs P0724: Stop light switch/Rationality Required sensors/Components Stop light switch, Vehicle speed sensor Frequency of operation Continuous Duration GO and STOP 5 times MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present None Engine switch ON Starter OFF Battery voltage 8 V or more GO (Vehicle speed is 18.65 mph (30 km/h) or more) Once STOP (Vehicle speed is less than 1.86 mph (3 km/h)) Once ES–293 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TYPICAL MALFUNCTION THRESHOLDS Brake switch Remain ON during GO and STOP 5 times WIRING DIAGRAM E6 Main Body ECU ECM IG2D 11 IGN 5 1 ES A19 Stop Light SW IG2 Relay 3 3 *1 2 4 1 2 *2 35 A55 ST136 STP A55 IG2 STOP ALT *2 ST/AM2 FL MAIN Battery E23 Ignition SW *2 5 AM2 IG2 6 81 C55 E1 *1: with Smart Key System *2: without Smart Key System A133857E01 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). ES–294 1 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK STOP LIGHT (OPERATION OF STOP LIGHT) (a) Check whether the stop lights turn on and off normally when the brake pedal is depressed and released. OK: Stop lights turn ON when brake pedal is depressed. NG REPAIR OR REPLACE STOP LIGHT SWITCH CIRCUIT OK ES 2 READ VALUE OF INTELLIGENT TESTER (STP SIGNAL AND ST1 - VOLTAGE) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the tester on. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / STOP LIGHT SW. (d) Check the STP signal when the brake pedal is depressed and released. OK Brake Pedal Operation Depressed Released Specified Condition Depressed STP signal ON Released STP signal OFF FI07052E06 (e) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / ST1. (f) Check the ST1 signal when the brake pedal is depressed and released. OK Brake Pedal Operation Specified Condition Depressed ST1 signal OFF Released ST1 signal ON OK CHECK FOR INTERMITTENT PROBLEMS NG 3 INSPECT STOP LIGHT SWITCH ASSEMBLY Not Pushed Pushed 2 1 (a) Remove the stop light switch assembly. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Switch Position 4 3 A072924E25 Tester Connection Specified Condition Switch pin free 1-2 Below 1 Ω Switch pin free 3-4 10 kΩ or higher Switch pin pushed in 1-2 10 kΩ or higher Switch pin pushed in 3-4 Below 1 Ω (c) Reinstall the stop light switch assembly. ES–295 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NG REPLACE STOP LIGHT SWITCH ASSEMBLY (See page LI-125) OK 4 CHECK ECM (STP, ST1 - VOLTAGE) Brake Pedal Depressed (a) Disconnect the A55 ECM connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Brake Pedal Released Wire Harness Side Front View: Brake Pedal Operation Specified Condition STP (A55-36) - Body ground Depressed 9 to 14 V STP (A55-36) - Body ground Released 0 to 3 V ST1- (A55-35) - Body ground Depressed 0 to 3 V ST1- (A55-35) - Body ground Released 9 to 14 V NG A55 ECM Connector ST1- Tester Connection STP A112585E08 OK REPLACE ECM (See page ES-518) REPAIR OR REPLACE HARNESS OR CONNECTOR ES ES–296 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0505 Idle Control System Malfunction DESCRIPTION The idle speed is controlled by the Electronic Throttle Control System (ETCS). The ETCS is comprised of: 1) one valve type throttle body; 2) the throttle actuator, which operates the throttle valve; 3) the throttle position sensor, which detects the opening angle of the throttle valve; 4) the accelerator pedal position sensor, which detects the accelerator pedal position; 5) the ECM, which controls the ETCS. Based on the target idle speed, the ECM controls the throttle actuator to provide the proper throttle valve opening angle. DTC No. P0505 ES DTC Detection Condition Trouble Area Idle speed continues to vary greatly from target speed (2 trip detection logic) • • • • ETCS Air induction system PCV hose connection ECM MONITOR DESCRIPTION The ECM monitors the idling speed and idling air flow volume to conduct Idle Speed Control (ISC). The ECM determines that the ISC system is malfunctioning if the following conditions are met: • The learned idling air flow volume remains at the maximum or minimum 5 times or more during a driving cycle • While driving at 6 mph (10 km/h) or more, the actual engine idling speed varies from the target idling speed by between 100 rpm and 200 rpm, 5 times or more during a driving cycle. Example: If the actual idling speed varies from the target idling speed by more than 200 rpm* 5 times during a driving cycle, the ECM illuminates the MIL and sets the DTC. HINT: *: Threshold idling speed varies with engine load. Example Learned Idling Air Volume Idling Speed Maximum Large Target Speed 0 Actual Idling Speed Time Minimum Small Time A082389E26 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–297 MONITOR STRATEGY Related DTCs P0505: ISC function Required Sensors/Components (Main) ETCS Required Sensors/Components (Sub) Crankshaft position sensor, Engine coolant temperature sensor, and Vehicle speed sensor Frequency of Operation Continuous Duration 10 minutes MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS Functional check: Monitor will run whenever these DTCs are not present None Engine Running ES TYPICAL MALFUNCTION THRESHOLDS Functional check: Either of the following conditions 1 or 2 is met: - 1. Frequency that following conditions (a) and (b) are met: 5 time or more (a) Engine RPM - target engine RPM Below -100 rpm, or 200 rpm or more (b) Vehicle condition Stop after vehicle was driven by 6.25 mph (10 km/h) or more 2. Frequency that following conditions (a) and (b) are met: Once (a) Engine RPM - target engine RPM Below -100 rpm, or 200 rpm or more (b) ISC flow rate learning value 1.3 L/sec. or less. or 8.5 L/sec. or more INSPECTION PROCEDURE HINT: • The following conditions may also cause DTC P0505 to be set: (a)The floor carpet overlapping onto the accelerator pedal, causing the accelerator pedal to be slightly depressed and therefore the throttle valve position to be slightly open. (b)The accelerator pedal being not fully released. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P0505) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the tester on. Enter the following the menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read the DTCs. Result Display (DTC output) Proceed to P0505 A ES–298 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Display (DTC output) Proceed to P0505 and other DTCs B HINT: If any DTCs other than P0505 are output, troubleshoot those DTCs first. B GO TO DTC CHART (See page ES-63) A 2 CHECK PCV HOSE (HOSE CONNECTIONS) OK: PCV hose is connected correctly and is not damaged. ES NG REPAIR OR REPLACE PCV HOSE OK 3 CHECK AIR INDUCTION SYSTEM (a) Check the air induction system for vacuum leakage. OK: No leakage from air induction system. NG REPAIR OR REPLACE AIR INDUCTION SYSTEM OK 4 CHECK THROTTLE BODY (VISUALLY CHECK THROTTLE VALVE) (a) Check for contamination between the throttle valve and the housing. If necessary, clean the throttle body. And check that the throttle valve moves smoothly. OK: Throttle valve is not contamainated with foreign objects and moves smoothly. NG OK REPLACE ECM (See page ES-518) REPLACE THROTTLE BODY (See page ES503) ES–299 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P050A Cold Start Idle Air Control System Performance DTC P050B Cold Start Ignition Timing Performance DESCRIPTION The Electronic Throttle Control System (ETCS) controls the engine idling speed. The ETCS operates the throttle actuator to open and close the throttle valve, and adjusts the intake air amount to achieve the target idling speed. In addition, the ECM retards the ignition timing and the ETCS increases the intake air amount to quickly increase the catalyst temperature at cold start to reduce emissions. DTC No. P050A P050B DTC Detection Conditions Trouble Areas Accumulated intake air amount during 10 seconds of idling after cold start, less than threshold (2 trip detection logic) • • • • • • • Throttle body assembly Mass air flow meter Air induction system PCV hose connections VVT system Air cleaner filter element ECM Ignition timing retard value insufficient for 5 seconds or more during 10 seconds of P050A monitoring at cold start (2 trip detection logic) • • • • • • • Throttle body assembly Mass air flow meter Air induction system PCV hose connections VVT system Air cleaner filter element ECM ES MONITOR DESCRIPTION Ignition Timing Accumulated Intake Air Value (g) P050B Detected Advanced Pass Condition Detected 5 or more P050A Detected Threshold Threshold Pass Condition Detected 0 Retarded 10 3 Engine Start Time (Second) 3 Engine Start 10 (Second) Time A112588E02 ES–300 ES 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM The ECM monitors the intake air amount during idling and the ignition timing. When the Engine Coolant Temperature (ECT) is between -10°C and 50°C (14°F and 122°F), the ECM calculates the idling intake air amount for 10 seconds, beginning 3 seconds after the engine starts. When the accumulated value is below the threshold, the ECM interprets this as a malfunction in the Idle Speed Control (ISC) system at cold start. The ECM also monitors the ignition timing at cold start, and judges it to be incorrect when it is advanced to the same value for a warm engine for 5 seconds or more of the 10 second monitoring period. Example: P050A is detected when all conditions below are met (2 trip detection logic). 1. The ECT is between -10°C and 50°C (14°F and 122°F) when the engine starts. 2. The engine idles for 13 seconds after engine start. 3. The accumulated intake air amount is below the threshold. The ECM sets the DTC and illuminates the MIL 13 seconds after the engine is next started. NOTICE: When the negative battery terminal is disconnected during inspection or repairs, the ISC learning values are cleared. The ISC learning must be performed by warming up the engine and idling for 5 minutes with the ECT at 75°C (167°F) or more because DTCs cannot be detected with the ISC learning values cleared. MONITOR STRATEGY Related DTCs P050A: Idle speed control problem at cold P050B: Idle ignition timing problem at cold Required Sensors/Components (Main) Mass air flow meter Required Sensors/Components (Related) Engine Coolant Temperature (ECT) sensor, Throttle position sensor, Vehicle speed sensor Frequency of Operation Once per driving cycle Duration 10 seconds MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS P050A: Battery voltage 8 V or more Time after engine start 3 seconds or more Starter OFF ECT at engine start -10°C (14°F) or more ECT -10°C to 50°C (14°F to 122°F) Engine idling time 3 seconds or more Fuel-cut OFF Vehicle speed Less than 1.875 mph (3 km/h) Time after shift position changed 1 second or more Atmospheric pressure 76 kPa (570 mmHg) or more P050B: Battery voltage 8 V or more Time after engine start 3 seconds or more Starter OFF ECT at engine start -10°C (14°F) or more ECT -10°C to 50°C (14°F to 122°F) Engine idling time 3 seconds or more Fuel-cut OFF Vehicle speed Less than 1.875 mph (3 km/h) 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–301 TYPICAL MALFUNCTION THRESHOLDS P050A: Accumulated mass air flow Varies with ECT (Example: Less than 42.5 g) P050B: Accumulated time when ignition timing retard is cut off 5 seconds or more INSPECTION PROCEDURE HINT: Read freeze frame data using an intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P050A AND/OR P050B) (a) (b) (c) (d) Connect an intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the tester on. Select the following the menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read the DTCs. Result Display (DTC Output) Proceed to P050A and/or P050B A P050A and/or P050B and other DTCs B HINT: If any DTCs other than P050A and P050B are output, troubleshoot those DTCs first. B GO TO DTC CHART (See page ES-63) A 2 READ VALUE USING INTELLIGENT TESTER (FUEL TRIM) HINT: Calculate the total fuel trim values to check the characteristic deviation of the mass air flow meter. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Turn the tester on. (d) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / SHORT FT #1 and LONG FT #1. (e) Read the values displayed on the tester. (f) Add together the SHORT FT #1 and LONG FT #1 values to obtain the total FUEL TRIM. ES ES–302 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK: Total of SHORT FT #1 and LONG FT #1 values is between -20 % and 20 %. OK Go to step 12 NG 3 PERFORM ACTIVE TEST USING INTELLIGENT TESTER (OPERATE OCV) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Start the engine and turn the tester ON. Warm up the engine. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VVT CTRL B1. (e) Check the engine speed while operating the Oil Control Valve (OCV) using the tester. ES OK Tester Operations Specified Conditions OCV OFF Normal engine speed OCV ON Engine idles roughly or stalls (soon after OCV switched from OFF to ON) NG Go to step 8 OK 4 CHECK PCV HOSE CONNECTIONS OK: PCV hose is connected correctly and is not damaged. NG Go to step 9 OK 5 CHECK AIR INDUCTION SYSTEM (a) Check the air induction system for vacuum leakage. OK: No leakage from air induction system. NG Go to step 10 OK 6 CHECK AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY (a) Visually check that the air cleaner filter element is not excessively contaminated with dirt or oil. OK: Air cleaner filter element is not excessively contaminated with dirt or oil. 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NG ES–303 Go to step 11 OK 7 REPLACE MASS AIR FLOW METER NEXT 8 Go to step 15 CHECK AND REPAIR VVT SYSTEM NEXT Go to step 15 ES 9 REPAIR OR REPLACE PCV HOSE NEXT 10 REPAIR OR REPLACE AIR INDUCTION SYSTEM NEXT 11 Go to step 15 REPLACE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY NEXT 12 Go to step 15 Go to step 15 CHECK THROTTLE VALVE (a) Check for deposits around the throttle valve and throttle valve condition. OK: No deposits around throttle valve and throttle valve moves smoothly. NG Go to step 14 NEXT Go to step 15 OK 13 14 REPLACE ECM REPAIR OR REPLACE THROTTLE BODY ASSEMBLY NEXT Go to step 15 ES–304 15 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK WHETHER DTC OUTPUT RECURS (DTC P050A AND/OR P050B) NOTICE: In this operation, the engine must be cold (the same level as the engine coolant temperature recorded in the freeze frame data). (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Turn the tester on. (d) Clear the DTCs (See page ES-45). (e) Switch the ECM from normal mode to check mode using the tester (See page ES-49). (f) Start the engine to idle for a minute. OK: Stable fast idling. (g) Read the DTCs. OK: No DTC output. ES NEXT END ES–305 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0560 System Voltage DESCRIPTION The battery supplies electricity to the ECM even when the ignition switch is off. This power allows the ECM to store data such as DTC history, freeze frame data and fuel trim values. If the battery voltage falls below a minimum level, these memories are cleared and the ECM determines that there is a malfunction in the power supply circuit. When the engine is next started, the ECM illuminates the MIL and sets the DTC. DTC No. P0560 DTC Detection Condition Trouble Area Open in ECM back-up power source circuit (1 trip detection logic) • • Open in back-up power source circuit ECM HINT: If DTC P0560 is set, the ECM does not store other DTCs. MONITOR STRATEGY Related DTCs P0560: ECM system voltage Required Sensors/Components (Main) ECM Required Sensors/Components (Sub) - Frequency of Operation Continuous Duration 3 seconds MIL Operation Immediate (MIL illuminated after next engine start) Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present: None Stand-by RAM Initialized TYPICAL MALFUNCTION THRESHOLDS ECM power source Less than 3.5 V ES ES–306 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM EFI No. 1 ES FL MAIN 20 BATT A55 81 C55 E1 Battery A122745E02 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 1 ES–307 INSPECT FUSE (EFI NO. 1) Engine Room Relay Block (a) Remove the EFI No. 1 fuse from the engine room R/B. (b) Measure the EFI No. 1 fuse resistance. Standard resistance: Below 1 Ω (c) Reinstall the EFI No. 1 fuse. NG REPLACE EFI NO. 1 FUSE EFI No. 1 ES A135030E01 OK ES–308 2 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (a) Check the harness and connector between the EFI No. 1 fuse and ECM. (1) Remove the EFI No. 1 fuse from the engine room R/ B. (2) Disconnect the A55 ECM connector. (3) Measure the resistance between the terminals. Standard resistance (Check for open) EFI No. 1 Fuse Tester Connection Specified Condition Engine room R/B EFI No. 1 fuse terminal 2 - BATT (A55-20) Below 1 Ω Standard resistance (Check for short) ES Engine Room Relay Block Tester Connection Specified Condition Engine room R/B EFI No. 1 fuse terminal 2 or BATT (A55-20) - Body ground 10 kΩ or higher (4) Reinstall the ECM connector. (b) Check the harness and the connector between the EFI No. 1 fuse and battery. (1) Disconnect the negative battery terminal. (2) Disconnect the positive battery terminal. (3) Measure the resistance between the terminals. Standard resistance (Check for open) Tester Connection Specified Condition Battery positive terminal - Engine room R/B EFI No 1 fuse terminal 1 Below 1 Ω Standard resistance (Check for short) ECM Connector Tester Connection Specified Condition Battery positive terminal or Engine room R/B EFI No. 1 fuse terminal 1 - Body ground 10 kΩ or higher (4) Reconnect the positive battery terminal. (5) Disconnect the negative battery terminal. (6) Reinstall the EFI No. 1 fuse. A55 NG BATT REPAIR OR REPLACE HARNESS OR CONNECTOR A132292E02 OK 3 INSPECT BATTERY (a) Check that the battery is not depleted. OK: Battery is not depleted. NG OK REPLACE BATTERY 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 4 ES–309 CHECK BATTERY TERMINAL (a) Check that the battery terminals are not loose or corroded. OK: Battery terminals are not loose or corroded. NG REPAIR OR REPLACE BATTERY TERMINAL OK 5 CHECK WHETHER DTC OUTPUT RECURS (a) (b) (c) (d) (e) (f) (g) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the intelligent tester on. Clear the DTCs (See page ES-45). Turn the intelligent tester off. Start the engine and turn the intelligent tester on. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (h) Read the DTCs. Result Display (DTC Output) Proceed to P0560 A No output B B A REPLACE ECM (See page ES-518) CHECK FOR INTERMITTENT PROBLEMS ES ES–310 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0604 Internal Control Module Random Access Memory (RAM) Error DTC P0606 ECM / PCM Processor DTC P0607 Control Module Performance DTC P0657 Actuator Supply Voltage Circuit / Open DESCRIPTION ES The ECM continuously monitors its internal memory status, internal circuits, and output signals sent to the throttle actuator. This self-check ensures that the ECM is functioning properly. If any malfunction is detected, the ECM will set the appropriate DTC and illuminate the MIL. The ECM memory status is diagnosed by internal "mirroring" of the main CPU and the sub CPU to detect Random Access Memory (RAM) errors. The 2 CPUs also perform continuous mutual monitoring. The ECM illuminates the MIL and sets a DTC if: 1) outputs from the 2 CPUs are different and deviate from the standards, 2) the signals sent to the throttle actuator deviate from the standards, 3) a malfunction is found in the throttle actuator supply voltage, and 4) any other ECM malfunction is found. DTC No. P0604 P0606 P0607 P0657 DTC Detection Condition Trouble Area ECM internal error (1 trip detection logic) ECM MONITOR STRATEGY Related DTCs P0604: ECM RAM error P0606: ECM range check P0607: ECM CPU malfunction P0657: ETCS power supply Required Sensors/Components (Main) ECM Required Sensors/Components (Sub) - Frequency of Operation Continuous Duration Within 1 second MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present None TYPICAL MALFUNCTION THRESHOLDS ECM RAM errors (P0604): RAM mirror check Fail ECM CPU range check (P0606): Either of following conditions is met: - Difference between throttle valve position of main CPU and throttle valve position of sub CPU 0.3 V or more Difference between accelerator pedal position of main CPU and accelerator pedal position of sub CPU 0.3 V or more 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–311 ECM CPU malfunction (P0607): Either A or B is met - A. Following conditions are met: - CPU reset 1 time or more Learned TP - learned APP 0.4 V or more Throttle actuator OFF B. CPU reset 2 times or more ETCS power supply (P0657): ETCS (Electronic Throttle Control System) power supply when ignition switch turned on (IG) 7 V or more INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). 1 CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P0604/P0606/P0607/P0657) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the tester on. Enter the following menus: DIAGNOSIS / ENHANCED II / DTC INFO / CURRENT CODES. (e) Read the DTCs. Result Display (DTC output) Proceed to P0604, P0606, P0607, P0657 A No output DTC B B A REPLACE ECM (See page ES-518) END ES ES–312 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0617 Starter Relay Circuit High DESCRIPTION While the engine is being cranked, the positive battery voltage is applied to terminal STA of the ECM. If the ECM detects the Starter Control (STA) signal while the vehicle is being driven, it determines that there is a malfunction in the STA circuit. The ECM then illuminates the MIL and sets the DTC. This monitor runs when the vehicle is driven at 12.4 mph (20 km/h) for over 20 seconds. DTC No. P0617 ES DTC Detection Condition Trouble Area When conditions (a), (b) and (c) are met, positive (+B) battery voltage 10.5 V or more applied to ECM for 20 seconds (1 trip detection logic): (a) Vehicle speed more than 12.4 mph (20 km/h) (b) Engine speed more than 1,000 rpm (c) STA signal ON • • • • • Park/Neutral Position (PNP) switch Starter relay circuit Cranking holding function circuit (With smart key system) Ignition switch (Without smart key system) ECM MONITOR STRATEGY Related DTCs P0617: Starter signal Required Sensors/Components (Main) STARTER relay, PMP switch, Engine switch Required Sensors/Components (Sub) Vehicle speed sensor (VSS), Crankshaft Position (CKP) sensor Frequency of Operation Continuous Duration 20 seconds MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever these DTCs are not present: None Battery voltage 10.5 V or more Vehicle speed 12.43 mph (20 km/h) or more Engine speed 1,000 rpm or more TYPICAL MALFUNCTION THRESHOLDS Starter signal ON ES–313 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM With Smart Key System: Main Body ECU ECM 4 STSW E9 14 A55 STSW 3 ACCR E6 6 STR2 E9 13 A55 ACCR ST CUT 8 E7 STR 11 IG2D E6 IG2 5 3 2 1 ES 63 C55 STAR IGN 1 2 5 3 62 C55 NSW 4 C1 Park / Neutral Position SW B L P N 48 A55 STA 9 ST/AM2 IG2 Starter FL MAIN 1 D1 1 C3 ST 3 5 2 1 Battery A133858E02 ES–314 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Without Smart Key System: E23 Ignition Switch ECM AM1 ALT 4 AM1 ST1 3 5 AM2 ST2 7 62 C55 NSW ST/AM2 L B ES P N C1 Park / Neutral Position SW 48 A55 STA Starter FL MAIN 1 D1 1 C3 ST 3 5 2 1 Battery A133859E02 INSPECTION PROCEDURE HINT: • The following troubleshooting flowchart is based on the premise that the engine is cranked normally. If the engine does not crank, proceed to the problem symptoms table (See page ES-33). • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). 1 READ VALUE OF INTELLIGENT TESTER (STARTER SIGNAL) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the tester on. ES–315 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / STARTER SIG. (d) Check the value displayed on the tester when the ignition switch is turned on (IG) and the engine is started. OK Engine Switch Condition ON (IG) ENGINE START STARTER SIG OFF ON OK REPLACE ECM (See page ES-518) NG 2 INSPECT PARK / NEUTRAL POSITION SWITCH ASSEMBLY (a) Inspect the Park / Neutral Position (PNP) switch. (1) Disconnect the C1 switch connector. (2) Measure the resistance according to the value(s) in the table below. Standard resistance Component Side: Gear Selector Lever Position Tester Connection Specified Condition P 4-5 Below 1 Ω N 4-5 Below 1 Ω C1 (3) Reconnect the PNP switch connector. Result Park / Neutral Position Switch A107908E03 A Result Proceed to OK (without smart key system) A OK (with smart key system) B NG C B CHECK CRANKING HOLDING FUNCTION CIRCUIT (See page ES-455) C REPLACE PARK / NEUTRAL POSITION SWITCH (THEN CHECK CRANKING HOLDING FUNCTION CIRCUIT) (See page AX-174) ES ES–316 3 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT IGNITION SWITCH ASSEMBLY (a) Disconnect the E23 ignition switch connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Component Side: E23 Switch Condition Tester Connection Specified Condition LOCK 3-4, 5-7 10 kΩ or higher START 3-4, 5-7 Below 1 Ω (c) Reconnect the ignition switch connector. NG ES REPAIR OR REPLACE IGNITION SWITCH ASSEMBLY Ignition Switch A135034E01 OK 4 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the tester on. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / STARTER SIG. (d) Check the value displayed on the tester when the ignition switch is turned on (IG) and the ignition is started. OK Engine Switch Condition ON (IG) ENGINE START STARTER SIG OFF ON NG OK SYSTEM IS OK REPAIR OR REPLACE HARNESS OR CONNECTOR ES–317 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0630 VIN not Programmed or Mismatch - ECM / PCM DESCRIPTION DTC P0630 is set when the Vehicle Identification Number (VIN) is not stored in the Engine Control Module (ECM) or the input VIN is not accurate. Input the VIN with the intelligent tester. DTC No. DTC Detection Condition • • P0630 Trouble Area VIN not stored in ECM Input VIN in ECM not accurate ECM MONITOR STRATEGY Related DTCs P0630: VIN not programmed Required Sensors/Components (Main) ECM Required Sensors/Components (Sub) - Frequency of Operation Continuous Duration 0.325 seconds MIL Operation Immediate Sequence of Operation None ES TYPICAL ENABLING CONDITIONS Battery voltage 8 V or more Engine switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS VIN code Not programmed COMPONENT OPERATING RANGE VIN code Programmed INSPECTION PROCEDURE 1 READ DTC OUTPUT (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the tester on. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs. Result Display (DTC Output) Proceed to P0630 A P0630 and other DTCs B If any DTCs other than P0630 are output, troubleshoot those DTCs first. ES–318 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NOTICE: If P0630 is set, the VIN must be input to the ECM using the intelligent tester. However, all DTCs are cleared automatically by the tester when inputting the VIN. If DTCs other than P0630 are set, check them first. B A 2 ES NEXT END INPUT VIN WITH INTELLIGENT TESTER GO TO DTC CHART (See page ES-518) 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0705 ES–319 Transmission Range Sensor Circuit Malfunction (PRNDL Input) DESCRIPTION The park / neutral position switch detects the shift lever position and sends signals to the ECM. DTC No. DTC Detection Condition Trouble Area P0705 (A) Any 2 or more signals of the following are ON simultaneously (2-trip detection logic) • P input signal is ON. • N input signal is ON. • R input signal is ON. • D input signal is ON. (B) Any 2 or more signals of the following are ON simultaneously (2-trip detection logic) • NSW input signal is ON. • R input signal is ON. • D input signal is ON. (C) Any of following conditions is met for 2.0 sec. or more in the S position (2-trip detection logic). • NSW input signal is ON. • P input signal is ON. • N input signal is ON. • R input signal is ON. (D) All switches are OFF simultaneously for NSW, P, R, N and D. • • • Short in park / neutral position switch circuit Park / neutral position switch ECM MONITOR DESCRIPTION These DTCs indicate a problem with the park / neutral position switch and the wire harness in the park / neutral position switch circuit. The park / neutral position switch detects the shift lever position and sends a signal to the ECM. For security, the park / neutral position switch detects the shift lever position so that engine can be started only when the shift lever is in the P or N position. The park / neutral position switch sends a signal to the ECM according to the shift position (P, R, N or D). The ECM determines that there is a problem with the switch or related parts if it receives more than 1 position signal simultaneously. The ECM will turn on the MIL and store the DTC. MONITOR STRATEGY Related DTCs P0705: Park / neutral position switch/Verify switch input Required sensors/Components Park / neutral position switch Frequency of operation Continuous Duration 2 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever this DTC is not present. None Ignition switch ON Battery voltage 10.5 V or more Condition (C): One of the following conditions is met: Condition (a), (b), (c) or (d) (a) Park Neutral position switch ON (b) Park position switch ON ES ES–320 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (c) Neutral position switch ON (d) R range position switch ON TYPICAL MALFUNCTION THRESHOLDS 1. One of the following conditions is met: Condition (A), (B) and (C) Condition (A): Number of the following signal input at the same time 2 or more Park position switch ON Neutral position switch ON R range position switch ON D range position switch ON Condition (B): ES Number of the following signal input at the same time 2 or more Park neutral position switch ON R range switch ON D range switch ON Condition (C): ''M'' switch ON Condition (D): Park position switch OFF Neutral position switch OFF Park neutral position switch OFF R range switch OFF D range switch OFF COMPONENT OPERATING RANGE Park / neutral Position switch The park / neutral position switch sends only one signal to the ECM. ES–321 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM C1 Park/Neutral Position Switch DL 7 NL To GAUGE No. 1 Fuse RB 8 1 RL 2 PL 3 To ST Relay 9 L B 4 ECM 26 C55 D 27 C55 N 25 C55 R 24 C55 P ES 62 C55 NSW 48 A55 STA E31 Transmission Control Switch To ECU IG No. 2 Fuse 3 IG S 7 25 A55 S A140667E01 INSPECTION PROCEDURE HINT: According to the DATA LIST displayed by the intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. 1. READ DATA LIST (a) Turn the ignition switch off. (b) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (c) Turn the ignition switch on (IG). (d) Turn on the tester. (e) Select the item "DIAGNOSIS / ENHANCED OBD II / DATA LIST". ES–322 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (f) According to the display on the tester, read the "DATA LIST". Measurement Item / Range (Display) Item ES 1 Normal Condition Diagnostic Note When the shift lever position displayed on the intelligent tester differs from the actual position, adjustment of the PNP switch or the shift cable may be incorrect. PNP SW [NSW] PNP SW Status / ON or OFF Shift lever position is; P and N: ON Except P or N: OFF REVERSE PNP SW Status / ON or OFF Shift lever position is; R: ON Except R: OFF ↑ DRIVE PNP SW Status / ON or OFF Shift lever position is; D and S: ON Except D or S: OFF ↑ CHECK HARNESS AND CONNECTOR (BATTERY - PARK / NEUTRAL POSITION SWITCH) (a) Disconnect the park / neutral position switch connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness Side: Park / Neutral Position SW C1 1 5 6 2 7 3 4 8 9 NG Tester Connection Specified Condition 2 - Body ground 10 to 14 V REPAIR OR REPLACE HARNESS OR CONNECTOR C117645E10 OK 2 CHECK ECM (OUTPUT SIGNAL) (a) Turn the ignition switch on (IG). (b) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness Side: Park / Neutral Position SW C1 1 5 6 2 7 3 4 8 9 NG C117645E10 Tester Connection Specified Condition 4 - Body ground 10 to 14 V Go to step 9 ES–323 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK 3 CHECK HARNESS AND CONNECTOR (PARK/NEUTRAL POSITION SWITCH - BODY GROUND) (a) Disconnect the C1 park/neutral position switch connector. (b) Measure the resistance between the terminals. Standard resistance Wire Harness Side: Park / Neutral Position SW C1 1 5 6 2 7 3 4 8 9 Tester Connection Specified Condition L (C1-9) - Body ground Below 1 Ω (c) Reconnect the park/neutral position switch connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR C117645E10 OK 4 INSPECT PARK / NEUTRAL POSITION SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below when the shift lever is moved to each position. Standard resistance Component Side: Park / Neutral Position SW Shift Position P Except P R C1 Except R N Except N D, S, ''+'' and ''-'' Except D, S, ''+'' and ''-'' C110340E45 OK NG Tester Connection 1 - 3 and 4 - 9 1-2 1 - 8and 4 - 9 1-7 Specified Condition Below 1 Ω 10 kΩ or higher Below 1 Ω 10 kΩ or higher Below 1 Ω 10 kΩ or higher Below 1 Ω 10 kΩ or higher REPLACE PARK/NEUTRAL POSITION SWITCH ASSEMBLY ES ES–324 5 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (a) Connect the park / neutral position switch connector. (b) Disconnect the ECM connectors. (c) Turn the ignition switch on (IG), and measure the voltage according to the value(s) in the table below when the shift lever is moved to each position. Wire Harness Side: C55 ECM Connector ES P R D N A55 ECM Connector S C136857E05 Standard voltage Shift Position P Except P N Except N R Tester Connection C55-24 (P) - Body ground C55-27 (N) - Body ground C55-25 (R) - Body ground Except R D and S Except D and S S, ''+'' and ''-'' Except S, ''+'' and ''-'' Specified Condition 10 to 14 V Below 1 V 10 to 14 V Below 1 V 10 to 14 V* Below 1 V C55-26 (D) - Body ground A55-25 (S) - Body ground 10 to 14 V Below 1 V 10 to 14 V Below 1 V HINT: The voltage will drop slightly due to lighting up of the back up light. *: NG OK REPAIR OR REPLACE HARNESS OR CONNECTOR ES–325 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 6 CHECK HARNESS AND CONNECTOR (a) Disconnect the transmission control switch connector of the shift lock control unit assembly. (b) Turn the ignition switch on (IG). (c) Measure the voltage between the terminals. Standard voltage Wire Harness Side: Transmission Control Switch Tester Connection Specified Condition 3 - Body ground 10 to 14 V (d) Reconnect the transmission control switch connector. E31 NG REPAIR OR REPLACE HARNESS OR CONNECTOR C110345E20 OK 7 INSPECT TRANSMISSION CONTROL SWITCH (a) Measure the resistance according to the value(s) in the table below when the shift lever is moved to each position. Standard resistance Component Side: Shift Position Transmission Control Switch S, ''+'' and ''-'' Except S, ''+'' and ''-'' E31 NG C136860E03 OK Tester Connection 3-7 Specified Condition Below 1 Ω 10 kΩ or higher REPLACE TRANSMISSION CONTROL SWITCH ES ES–326 8 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (a) Connect the transmission control switch connector of the shift lock control unit assembly. (b) Turn the ignition switch on (IG), and measure the voltage according to the value(s) in the table below when the shift lever is moved to each position. Wire Harness Side: C55 ECM Connector ES P R D N A55 ECM Connector S C136857E05 Standard voltage Shift Position Tester Connection Specified Condition P C55-24 (P) - Body ground 10 to 14 V Except P ↑ Below 1 V N C55-27 (N) - Body ground 10 to 14 V Except N ↑ Below 1 V R C55-25 (R) - Body ground 10 to 14 V * Except R ↑ Below 1 V D and S C55-26 (D) - Body ground 10 to 14 V Except D and S ↑ Below 1 V S, "+" and "-" A55-25 (S) - Body ground 10 to 14 V Except S, "+" and "-" ↑ Below 1 V NG OK REPLACE ECM REPAIR OR REPLACE HARNESS OR CONNECTOR ES–327 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 9 CHECK HARNESS AND CONNECTOR (PARK / NEUTRAL POSITION SWITCH - ECM) (a) Disconnect the ECM connectors. (b) Turn the ignition switch off. (c) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for open) Wire Harness Side: Park / Neutral Position SW C1 1 2 5 6 7 3 4 C55 ECM Connector OK REPLACE ECM Specified Condition B (C1-4) - NSW (C55-62) Below 1 Ω Standard resistance (Check for short) 8 9 NSW Tester Connection NG C136861E06 Tester Connection Specified Condition B (C1-4) or NSW (C55-62) - Body ground 10 kΩ or higher REPAIR OR REPLACE HARNESS OR CONNECTOR ES ES–328 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2102 Throttle Actuator Control Motor Circuit Low DTC P2103 Throttle Actuator Control Motor Circuit High SYSTEM DESCRIPTION The throttle actuator is operated by the ECM and opens and closes the throttle valve using the gears. The opening angle of the throttle valve is detected by the Throttle Position (TP) sensor, which is mounted on the throttle body. The TP sensor provides feedback to the ECM. This feedback allows the ECM to appropriately control the throttle actuator and monitor the throttle opening angle as the ECM responds to driver inputs. HINT: This ETCS (Electronic Throttle Control System) does not use a throttle cable. DTC No. ES DTC Detection Condition Trouble Area P2102 Conditions (a) and (b) continue for 2.0 seconds (1 trip detection logic): (a) Throttle actuator duty ratio 80 % or more (b) Throttle actuator current 0.5 A or less • • • Open in throttle actuator circuit Throttle actuator ECM P2103 Either of the following conditions is met: • Hybrid IC diagnosis signal fails • Hybrid IC current limiter port fails • • • • • Short in throttle actuator circuit Throttle actuator Throttle valve Throttle body assembly ECM MONITOR DESCRIPTION The ECM monitors the electrical current through the electronic actuator, and detects malfunctions and open circuits in the throttle actuator based on this value. If the current is outside the standard range, the ECM determines that there is a malfunction in the throttle actuator. In addition, if the throttle valve does not function properly (for example, stuck on), the ECM determines that there is a malfunction. The ECM then illuminates the MIL and sets a DTC. Example: When the electrical current is more than 10 A, or less than 0.5 A and the throttle actuator duty ratio exceeds 80 %, the ECM interprets this as the current being outside the standard range, and illuminates the MIL and sets a DTC. If the malfunction is not repaired successfully, a DTC is set when the engine is quickly revved up to a high rpm several times after the engine has idled for 5 seconds after engine start. MONITOR STRATEGY Related DTCs P2102: Throttle actuator current (low current) P2103: Throttle actuator current (high current) Required Sensors/Components (Main) Throttle actuator (throttle body) Required Sensors/Components (Related) None Frequency of Operation Continuous Duration P2102 (Throttle actuator current (low current)): 2 seconds P2103 (Throttle actuator current (high current)): 25 times or 0.6 seconds MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS All: Monitor runs whenever following DTCs are not present None 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–329 P2102: Throttle motor ON Duty-cycle ratio to open throttle actuator 80 % or more Throttle actuator power supply 8 V or more Current motor current - Motor current at 0.016 sec. before Less than 0.2 A P2103: Throttle motor ON Either of the following conditions 1 or 2 is met: - 1. Throttle actuator power supply 8 V or more 2. Throttle actuator power ON Battery voltage 8 V or more Starter OFF ES TYPICAL MALFUNCTION THRESHOLDS P2102: Throttle actuator current Less than 0.5 A P2103: Either of following conditions is met: A or B A. Hybrid IC diagnosis signal Fail B. Hybrid IC current limiter port Fail FAIL-SAFE When either of these DTCs, as well as other DTCs relating to ETCS (Electronic Throttle Control System) malfunctions, is set, the ECM enters fail-safe mode. During fail-safe mode, the ECM cuts the current to the throttle actuator off, and the throttle valve is returned to a 6° throttle angle by the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing, in accordance with the accelerator pedal opening angle, to allow the vehicle to continue running at a minimal speed. If the accelerator pedal is depressed gently, the vehicle can be driven slowly. Fail-safe mode continues until a pass condition is detected, and the engine switch is then turned off. ES–330 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM C5 Throttle Actuator ECM Shielded 19 M+ C55 M+ 2 M- Throttle Actuator Control Circuit 18 MC55 1 ES 41 C55 GE01 A133860E01 INSPECTION PROCEDURE HINT: • Read freeze frame data using an intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). • The throttle actuator current (THROTTLE MOT) and the throttle actuator duty ratio (THROTTLE OPN / THROTTLE CLS) can be read using the intelligent tester. However, the ECM shuts off the throttle actuator current when the ETCS malfunctions. 1 INSPECT THROTTLE BODY (RESISTANCE OF THROTTLE CONTROL MOTOR) (a) Disconnect the C5 throttle body connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Component Side: Throttle Body C5 Tester Connection Condition Specified Condition M+ (C5-2) - M- (C5-1) 20°C (68°F) 0.3 to 100 Ω (c) Reconnect the throttle body connector. M+ MA059778E40 OK NG REPLACE THROTTLE BODY (See page ES503) ES–331 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2 CHECK HARNESS AND CONNECTOR (THROTTLE CONTROL MOTOR - ECM) Wire Harness Side Front View: C5 Throttle Body Connector (a) Disconnect the C5 throttle body connector. (b) Disconnect the C55 ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for open) M+ M- 1 2 3 4 5 6 Tester Connection Specified Condition M+ (C5-2) - M+ (C55-19) Below 1 Ω M- (C5-1) - M- (C55-18) Below 1 Ω Standard resistance (Check for short) C55 ECM Connector M- Tester Connection Specified Condition M+ (C5-2) or M+ (C55-19) - Body ground 10 kΩ or higher M- (C5-1) or M- (C55-18) - Body ground 10 kΩ or higher (d) Reconnect the throttle body connector. (e) Reconnect the ECM connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR M+ A115662E07 OK 3 INSPECT THROTTLE BODY (VISUALLY CHECK THROTTLE VALVE) (a) Check for foreign objects between the throttle valve and the housing. NG REMOVE FOREIGN OBJECT AND CLEAN THROTTLE BODY OK 4 INSPECT THROTTLE VALVE (a) Check if the throttle valve opens and closes smoothly. NG OK REPLACE ECM (See page ES-518) REPLACE THROTTLE BODY (See page ES503) ES ES–332 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2111 Throttle Actuator Control System - Stuck Open DTC P2112 Throttle Actuator Control System - Stuck Closed SYSTEM DESCRIPTION ES The throttle actuator is operated by the ECM, and opens and closes the throttle valve using the gears. The opening angle of the throttle valve is detected by the Throttle Position (TP) sensor, which is mounted on the throttle body. The TP sensor provides feedback to the ECM. This feedback allows the ECM to appropriately control the throttle actuator and monitor the throttle opening angle as the ECM responds to driver inputs. HINT: This ETCS (Electronic Throttle Control System) does not use a throttle cable. DTC No. DTC Detection Condition Trouble Area P2111 ECM signals throttle actuator to close, but stuck (1 trip detection logic) • • • P2112 ECM signals throttle actuator to open, but stuck (1 trip detection logic) • • • Throttle actuator Throttle body Throttle valve Throttle actuator Throttle body Throttle valve MONITOR DESCRIPTION The ECM determines that there is a malfunction in the ETCS when the throttle valve remains at a fixed angle despite a high drive current from the ECM. The ECM illuminates the MIL and sets a DTC. If the malfunction is not repaired successfully, a DTC is set when the accelerator pedal is fully depressed and released quickly (to fully open and close the throttle valve) after the engine is next started. MONITOR STRATEGY Related DTCs P2111: Throttle actuator stuck open P2112: Throttle actuator stuck closed Required Sensors/Components (Main) Throttle actuator Required Sensors/Components (Sub) - Frequency of Operation Continuous Duration 0.5 seconds MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS All: Monitor runs whenever following DTCs are not present None P2111 (Throttle actuator stuck open): System guard* ON Throttle actuator current 2 A or more Duty cycle to close throttle 80 % or more P2112 (Throttle actuator stuck closed): System guard* ON Throttle actuator current 2 A or more Duty cycle to open throttle 80 % or more 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM *System guard set when following conditions are met: - Throttle actuator ON Throttle actuator duty calculation Executing Throttle position sensor Fail determined Throttle actuator current-cut operation Not executing Throttle actuator power supply 4 V or more Throttle actuator Fail determined ES–333 TYPICAL MALFUNCTION THRESHOLDS P2111 (Throttle actuator stuck open): TP sensor voltage change No change P2112 (Throttle actuator stuck closed): TP sensor voltage change No change ES FAIL-SAFE When either of these DTCs, as well as other DTCs relating to ETCS (Electronic Throttle Control System) malfunctions, is set, the ECM enters fail-safe mode. During fail-safe mode, the ECM cuts the current to the throttle actuator off, and the throttle valve is returned to a 6° throttle angle by the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing, in accordance with the accelerator pedal opening angle, to allow the vehicle to continue running at a minimal speed. If the accelerator pedal is depressed firmly and gently, the vehicle can be driven slowly. Fail-safe mode continues until a pass condition is detected, and the ignition switch is then turned off. WIRING DIAGRAM Refer to DTC P2102 (See page ES-320). INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P2111 or P2112) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the tester on. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read the DTCs. Result Display (DTC Output) Proceed to P2111 or P2112 A P2111 or P2112 and other DTCs B HINT: If any DTCs other than P2111 or P2112 are output, troubleshoot those DTCs first. ES–334 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM B GO TO DTC CHART (See page ES-63) A 2 INSPECT THROTTLE BODY (VISUALLY CHECK THROTTLE VALVE) (a) Check for contamination between the throttle valve and the housing. If necessary, clean the throttle body. And check that the throttle valve moves smoothly. OK: Throttle valve is not contaminated with foreign objects and moves smoothly. NG ES REPLACE THROTTLE BODY ASSEMBLY (See page ES-503) OK 3 CHECK WHETHER DTC OUTPUT RECURS (DTC P2111 OR P2112) (a) (b) (c) (d) (e) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the tester on. Clear the DTCs (See page ES-45). Start the engine, and fully depress and release the accelerator pedal quickly (to fully open and close the throttle valve). (f) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (g) Read the DTCs. Result Display (DTC Output) Proceed to No DTC A P2111 or P2112 B B A CHECK FOR INTERMITTENT PROBLEMS REPLACE ECM (See page ES-518) ES–335 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2118 Throttle Actuator Control Motor Current Range / Performance DESCRIPTION The ETCS (Electronic Throttle Control System) has a dedicated power supply circuit. When the monitored voltage (+BM) is low (less than 4 V), the ECM determines that there is a malfunction in the ETCS and cuts off the current to the throttle actuator. When the voltage becomes unstable, the ETCS itself becomes unstable. For this reason, when the voltage is low, the current to the throttle actuator is cut. If repairs are made and the system returns to normal, turn the ignition switch off. The ECM then allows the current to flow to the throttle actuator so that it can be restarted. HINT: The ETCS does not use a throttle cable. ES ECM ETCS From Battery +BM Throttle Actuator Throttle Actuator Control Circuit +M -M ME01 A085832E02 DTC No. P2118 DTC Detection Condition Trouble Area • • • Open in ETCS power source (+BM) circuit (1 trip detection logic) Open in ETCS power source circuit ETCS fuse ECM MONITOR DESCRIPTION The ECM monitors the battery supply voltage applied to the throttle actuator. When the power supply voltage (+BM) drops below 4 V for 0.8 seconds or more, the ECM interprets this as an open in the power supply circuit (+BM). The ECM illuminates the MIL and sets the DTC. If the malfunction is not repaired successfully, the DTC is set 5 seconds after the engine is next started. MONITOR STRATEGY Related DTCs P2118: Throttle actuator power supply Required Sensors/Components (Main) Throttle actuator, throttle valve, ETCS fuse Required Sensors/Components (Sub) None Frequency of Operation Continuous Duration 0.8 seconds ES–336 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present None Battery voltage 8 V or more Throttle actuator power ON TYPICAL MALFUNCTION THRESHOLDS Throttle actuator power supply voltage (+BM) ES Less than 4 V COMPONENT OPERATING RANGE Throttle actuator power supply voltage 9 to 14 V FAIL-SAFE When this DTC, as well as other DTCs relating to ETCS (Electronic Throttle Control System) malfunctions, is set, the ECM enters fail-safe mode. During fail-safe mode, the ECM cuts the current to the throttle actuator off, and the throttle valve is returned to a 6° throttle angle by the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing, in accordance with the accelerator pedal opening angle, to allow the vehicle to continue running at a minimal speed. If the accelerator pedal is depressed firmly and gently, the vehicle can be driven slowly. Fail-safe mode continues until a pass condition is detected, and the ignition switch is then turned off. WIRING DIAGRAM ECM ETCS 3 A55 +BM FL MAIN Battery A122748E02 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–337 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). 1 CHECK FUSE (ETCS FUSE) Engine Room Relay Block (a) Remove the ETCS fuse from the engine room R/B. (b) Measure the resistance of the ETCS fuse. Standard resistance: Below 1 Ω (c) Reinstall the ETCS fuse. NG REPLACE ETCS FUSE ETCS A135037E01 OK 2 INSPECT ECM (+BM VOLTAGE) (a) Disconnect the A55 ECM connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness Side: A55 ECM Connector Tester Connection Specified Condition +BM (A55-3) - Body ground 9 to 14 V (c) Reconnect the ECM connector. OK +BM A115671E46 NG CHECK FOR INTERMITTENT PROBLEMS ES ES–338 3 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (ECM - ETCS FUSE, ETCS FUSE - BATTERY) (a) Check the harness and connector between the ETCS fuse and ECM. (1) Remove the ETCS fuse from the engine room R/B. (2) Disconnect the A55 ECM connector. (3) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for open) Engine Room Junction Block ETCS Tester Connection Specified Condition Engine room R/B ETCS fuse terminal 2 - +BM (A55-3) Below 1 Ω Standard resistance (Check for short) ES Tester Connection Specified Condition Engine room R/B ETCS fuse terminal 2 or +BM (A553) - Body ground 10 kΩ or higher (4) Reinstall the ETCS fuse. (5) Reconnect the ECM connector. (b) Check the harness and connector between the ETCS fuse and positive battery cable. (1) Remove the ETCS fuse from the engine room R/B. (2) Disconnect the negative battery terminal. (3) Disconnect the positive battery terminal. (4) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for open) Tester Connection Specified Condition Positive battery terminal - Engine room R/B ETCS fuse terminal 1 Below 1 Ω A55 ECM Connector Standard resistance (Check for short) Tester Connection Specified Condition Positive battery terminal or Engine room R/B ETCS fuse terminal 1 - Body ground 10 kΩ or higher (5) Reinstall the ETCS fuse. (6) Reconnect the positive battery terminal. (7) Reconnect the negative battery terminal. +BM A140650E01 OK REPLACE ECM (See page ES-518) NG REPAIR OR REPLACE HARNESS OR CONNECTOR ES–339 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC Throttle Actuator Control Throttle Body Range / Performance P2119 SYSTEM DESCRIPTION The Electronic Throttle Control System (ETCS) is composed of the throttle actuator, Throttle Position (TP) sensor, Accelerator Pedal Position (APP) sensor, and ECM. The ECM operates the throttle actuator to regulate the throttle valve in response to driver inputs. The TP sensor detects the opening angle of the throttle valve, and provides the ECM with feedback so that the throttle valve can be appropriately controlled by the ECM. DTC No. P2119 DTC Detection Condition Trouble Area Throttle valve opening angle continues to vary greatly from target opening angle (1 trip detection logic) • • ETCS ECM ES MONITOR DESCRIPTION The ECM determines the actual opening angle of the throttle valve from the TP sensor signal. The actual opening angle is compared to the target opening angle commanded by the ECM. If the difference between these two values is outside the standard range, the ECM interprets this as a malfunction in the ETCS. The ECM then illuminates the MIL and sets the DTC. If the malfunction is not repaired successfully, the DTC is set when the accelerator pedal is quickly released (to close the throttle valve) after the engine speed reaches 5,000 rpm by fully depressing the accelerator pedal (fully open the throttle valve). MONITOR STRATEGY Related DTCs P2119: ETCS malfunction Required Sensors/Components (Main) Throttle actuator Required Sensors/Components (Sub) - Frequency of Operation Continuous Duration 1 second MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present None System guard* ON *System guard set when following conditions are met: - Throttle actuator ON Throttle actuator duty calculation Executing TP sensor Fail determined Throttle actuator current-cut operation Not executing Throttle actuator power supply 4 V or more Throttle actuator Fail determined TYPICAL MALFUNCTION THRESHOLDS Either of following conditions A or B is met - A. Commanded closed TP - current closed TP 0.3 V or more for 1 second B. Commanded open TP - current open TP 0.3 V or more for 0.6 seconds ES–340 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM FAIL-SAFE When this DTC, as well as other DTCs relating to ETCS (Electronic Throttle Control System) malfunctions, is set, the ECM enters fail-safe mode. During fail-safe mode, the ECM cuts the current to the throttle actuator off, and the throttle valve is returned to a 6° throttle angle by the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing, in accordance with the accelerator pedal opening angle, to allow the vehicle to continue running at a minimal speed. If the accelerator pedal is depressed firmly and gently, the vehicle can be driven slowly. Fail-safe mode continues until a pass condition is detected, and the ignition switch is then turned off. WIRING DIAGRAM Refer to DTC P2102 (See page ES-322). INSPECTION PROCEDURE ES HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P2119) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the tester on. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read the DTCs. Result Display (DTC Output) Proceed to P2119 A P2119 and other DTCs B HINT: If any DTCs other than P2119 are output, troubleshoot those DTCs first. B GO TO DTC CHART (See page ES-63) A 2 CHECK WHETHER DTC OUTPUT RECURS (DTC P2119) (a) (b) (c) (d) (e) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the tester on. Clear the DTCs (See page ES-45). Allow the engine to idle for 15 seconds. CAUTION: Exercise extreme care and take precautions at procedure "A" and "B" below. Failure to do so may result in the vehicle unexpectedly rolling away. 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–341 (f) Securely apply the parking brake and move the gear selector lever to the D position (Procedure "A"). (g) While depressing the brake pedal securely, fully depress the accelerator pedal for 5 seconds (Procedure "B"). (h) On the tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (i) Read the DTCs. HINT: The output voltage of the throttle position sensor can be checked during procedure "B" using the intelligent tester. Variations in the output voltage indicate that the throttle actuator is in operation. To check the output voltage using the intelligent tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / THROTTLE POS #1. OK: No DTC output. NG OK END REPLACE THROTTLE BODY ASSEMBLY (See page ES-503) ES ES–342 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2120 Throttle / Pedal Position Sensor / Switch "D" Circuit DTC P2122 Throttle / Pedal Position Sensor / Switch "D" Circuit Low Input DTC P2123 Throttle / Pedal Position Sensor / Switch "D" Circuit High Input DTC P2125 Throttle / Pedal Position Sensor / Switch "E" Circuit DTC P2127 Throttle / Pedal Position Sensor / Switch "E" Circuit Low Input DTC P2128 Throttle / Pedal Position Sensor / Switch "E" Circuit High Input DTC P2138 Throttle / Pedal Position Sensor / Switch "D" / "E" Voltage Correlation ES DESCRIPTION This ETCS (Electronic Throttle Control System) does not use a throttle cable. The Accelerator Pedal Position (APP) sensor is mounted on the accelerator pedal bracket and has 2 sensor circuits: VPA (main) and VPA2 (sub). This sensor is a non-contact type, and uses Hall-effect elements, in order to yield accurate signals, even in extreme driving conditions, such as at high speeds as well as very low speeds. The voltage, which is applied to terminals VPA and VPA2 of the ECM, varies between 0 V and 5 V in proportion to the operating angle of the accelerator pedal (throttle valve). A signal from VPA indicates the actual accelerator pedal opening angle (throttle valve opening angle) and is used for engine control. A signal from VPA2 conveys the status of the VPA circuit and is used to check the APP sensor itself. The ECM monitors the actual accelerator pedal opening angle (throttle valve opening angle) through the signals from VPA and VPA2, and controls the throttle actuator according to these signals. ES–343 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Accelerator Pedal Position Sensor Output Voltage (V) *1 Accelerator Pedal Position Sensor *2 5 ECM Magnet VPA IC No. 1 3.4 to 5.0 2.6 to 4.5 EPA VCPA 1.6 VPA2 0.8 ES EPA2 25 0 VCP2 IC No. 2 Usable Range Accelerator Pedal Turning Angle (deg) Magnet *1: Accelerator Pedal Fully Released *2: Accelerator Pedal Fully Depressed A019803E27 DTC No. DTC Detection Condition Trouble Area P2120 VPA fluctuates rapidly beyond upper and lower malfunction thresholds for 0.5 seconds or more (1 trip detection logic) • • Accelerator Pedal Position (APP) sensor ECM P2122 VPA is 0.4 V or less for 0.5 seconds or more when accelerator pedal is fully released (1 trip detection logic) • • • • APP sensor Open in VCP1 circuit Open or ground short in VPA circuit ECM P2123 VPA is 4.8 V or more for 2.0 seconds or more (1 trip detection logic) • • • APP sensor Open in EPA circuit ECM P2125 VPA2 fluctuates rapidly beyond upper and lower malfunction thresholds for 0.5 seconds or more (1 trip detection logic) • • APP sensor ECM P2127 VPA2 is 1.2 V or less for 0.5 seconds or more when accelerator pedal is fully released (1 trip detection logic) • • • • APP sensor Open in VCP2 circuit Open or ground short in VPA2 circuit ECM P2128 Conditions (a) and (b) continue for 2.0 seconds or more (1 trip detection logic): (a) VPA2 is 4.8 V or more (b) VPA is between 0.4 V and 3.45 V • • • APP sensor Open in EPA2 circuit ECM ES–344 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. DTC Detection Condition P2138 Condition (a) or (b) continues for 2.0 seconds or more (1 trip detection logic): (a) Difference between VPA and VPA2 is 0.02 V or less (b) VPA is 0.4 V or less and VPA2 1.2 V or less Trouble Area • • • Short between VPA and VPA2 circuits APP sensor ECM HINT: When any of these DTCs are set, check the APP sensor voltage by entering the following menus on the intelligent tester: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / ACCEL POS #1 and ACCEL POS #2. ES Trouble Areas ACCEL POS #1 When AP Released ACCEL POS #2 When AP Released ACCEL POS #1 When AP Depressed ACCEL POS #2 When AP Depressed VCP circuit open 0 to 0.4 V 0 to 1.2 V 0 to 0.4 V 0 to 1.2 V Open or ground short in VPA circuit 0 to 0.4 V 1.2 to 2.0 V 0 to 0.4 V 3.4 to 5.0 V Open or ground short in VPA2 circuit 0.5 to 1.1 V 0 to 0.2 V 2.6 to 4.5 V 0 to 0.2 V EPA circuit open 4.5 to 5.0 V 4.5 to 5.0 V 4.5 to 5.0 V 4.5 to 5.0 V Normal condition 0.5 to 1.1 V 1.2 to 2.0 V 2.6 to 4.5 V 3.4 to 5.0 V HINT: • Accelerator pedal positions are expressed as voltages. • AP denotes Accelerator Pedal. MONITOR DESCRIPTION When either of the output voltages of VPA or VPA2 deviates from the standard range, or the difference between the output voltages of the 2 sensor circuits is less than the threshold, the ECM determines that there is a malfunction in the APP sensor. The ECM then illuminates the MIL and sets a DTC. Example: When the output voltage of VPA drops below 0.4 V for more than 0.5 seconds when the accelerator pedal is fully depressed, DTC P2122 is set. If the malfunction is not repaired successfully, a DTC is set 2 seconds after the engine is next started. MONITOR STRATEGY Related DTCs P2120: Accelerator Pedal Position (APP) sensor 1 range check (fluctuating) P2122: APP sensor 1 range check (low voltage) P2123: APP sensor 1 range check (high voltage) P2125: APP sensor 2 range check (fluctuating) P2127: APP sensor 2 range check (low voltage) P2128: APP sensor 2 range check (high voltage) P2138: APP sensor range check (correlation) Required Sensors/Components (Main) APP sensor Required Sensors/Components (Sub) - Frequency of Operation Continuous Duration Accelerator Pedal Position (APP) sensor 1 range check (fluctuating): 0.5 seconds APP sensor 1 range check (low voltage): 0.5 seconds APP sensor 1 range check (high voltage): 2 seconds APP sensor 2 range check (fluctuating): 0.5 seconds APP sensor 2 range check (low voltage): 0.5 seconds APP sensor 2 range check (high voltage): 2 seconds APP sensor range check (correlation): 2 seconds MIL Operation Immediate Sequence of Operation None 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–345 TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present None TYPICAL MALFUNCTION THRESHOLDS P2120: One of the following conditions is met: - VPA voltage when VPA2 is 0.04 V or more 0.4 V or less VPA voltage 4.8 V or more P2122: VPA voltage when VPA2 is 0.04 V or more 0.4 V or less P2123: VPA voltage ES 4.8 V or more P2125: One of the following conditions is met: - VPA2 voltage when VPA 0.04 V or more 1.2 V or less VPA2 voltage when VPA 0.4 to 3.45 V 4.8 V or more P2127: VPA2 voltage when VPA is 0.04 V or more 1.2 V or less P2128: VPA2 voltage when VPA is 0.4 to 3.45 V 4.8 V or more P2138: Either of following conditions A or B is met: - Condition A - Difference between VPA and VPA 2 voltages 0.02 V or less Condition B - VPA voltage 0.4 V or less VPA2 voltage 1.2 V or less COMPONENT OPERATING RANGE Parameter VPA voltage Standard Value 0.4 V to 4.8 V VPA2 voltage 0.5 V to 4.8 V Difference between VPA and VPA2 voltages More than 0.02 V FAIL-SAFE When any of DTCs P2120, P2121, P2122, P2123, P2125, P2127, P2128 and P2138 are set, the ECM enters fail-safe mode. If either of the 2 sensor circuits malfunctions, the ECM uses the remaining circuit to calculate the accelerator pedal position to allow the vehicle to continue driving. If both of the circuits malfunction, the ECM regards the accelerator pedal as being released. As a result, the throttle valve is closed and the engine idles. Fail-safe mode continues until a pass condition is detected, and the engine switch is then turned off. ES–346 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM A17 Accelerator Pedal Position Sensor VPA EPA VCPA VPA2 ES EPA2 VCP2 ECM 55 VPA A55 6 59 A55 5 EPA 57 VCPA A55 4 56 VPA2 A55 3 60 A55 EPA2 58 VCP2 A55 2 1 A105237E15 INSPECTION PROCEDURE HINT: • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). • These DTCs relate to the Accelerator Pedal Position (APP) sensor. 1 READ VALUE OF INTELLIGENT TESTER (ACCEL POS #1 AND ACCEL POS #2) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the tester on. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / ACCEL POS #1 and ACCEL POS #2. (d) Read the value displayed on the tester. Standard voltage Depressed Released Accelerator Pedal Operations FI07052E06 OK NG ACCEL POS #1 (AP#1) ACCEL POS #2 (AP#2) Released 0.5 to 1.1 V 1.2 to 2.0 V Depressed 2.6 to 4.5 V 3.4 to 5.0 V Go to step 5 ES–347 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2 CHECK HARNESS AND CONNECTOR (ACCELERATOR PEDAL POSITION SENSOR ECM) (a) Disconnect the A17 Accelerator Pedal Position (APP) sensor connector. (b) Disconnect the A55 ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for open) Wire Harness Side Front View: A17 APP Sensor Connector VPA2 VCPA EPA2 EPA VCP2 VPA 1 2 3 4 5 6 A55 VPA ECM Connector VCPA Tester Connection Specified Condition VPA (A17-6) - VPA (A55-55) Below 1 Ω EPA (A17-5) - EPA (A55-59) Below 1 Ω VCPA (A17-4) - VCPA (A55-57) Below 1 Ω VPA2 (A17-3) - VPA2 (A55-56) Below 1 Ω EPA2 (A17-2) - EPA2 (A55-60) Below 1 Ω VCP2 (A17-1) - VCP2 (A55-58) Below 1 Ω Standard resistance (Check for short) EPA Tester Connection VPA2 EPA2 VCP2 Specified Condition VPA (A17-6) or VPA (A55-55) - body ground 10 kΩ or higher EPA (A17-5) or EPA (A55-59) - body ground 10 kΩ or higher VCPA (A17-4) or VCPA (A55-57) - body ground 10 kΩ or higher VPA2 (A17-3) or VPA2 (A55-56) - body ground 10 kΩ or higher EPA2 (A17-2) or EPA2 (A55-60) - body ground 10 kΩ or higher VCP2 (A17-1) or VCP2 (A55-58) - body ground 10 kΩ or higher (d) Reconnect the APP sensor connector. (e) Reconnect the ECM connector. A115665E06 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 INSPECT ACCELERATOR POSITION SENSOR (VCPA AND VCP2 VOLTAGE) (a) Disconnect the A17 APP sensor connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness Side Front View: APP Sensor Connector A17 1 2 3 4 5 6 Tester Connection Specified Condition VCPA (A17-4) - EPA (A17-5) 4.5 to 5.0 V VCP2 (A17-1) - EPA2 (A17-2) 4.5 to 5.0 V (d) Reconnect the APP sensor connector. VCP2 EPA2 VCPA NG EPA A115666E08 REPLACE ECM (See page ES-518) ES ES–348 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK 4 REPLACE ACCELERATOR PEDAL ROD ASSEMBLY NEXT 5 CHECK WHETHER DTC OUTPUT RECURS (ACCELERATOR PEDAL POSITION SENSOR DTCS) (a) (b) (c) (d) (e) (f) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG) and turn the tester on. Clear the DTCs (See page ES-45). Start the engine. Allow the engine to idle for 15 seconds. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES (g) Read the DTCs. ES Result Display (DTC Output) Proceed to P2120, P2122, P2123, P2125, P2127, P2128, and/or P2138 A No output B B A REPLACE ECM (See page ES-518) SYSTEM IS OK ES–349 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC Throttle / Pedal Position Sensor / Switch "D" Circuit Range / Performance P2121 DESCRIPTION This ETCS (Electronic Throttle Control System) does not use a throttle cable. The Accelerator Pedal Position (APP) sensor is mounted on the accelerator pedal bracket and has 2 sensor circuits: VPA (main) and VPA2 (sub). This sensor is a non-contact type, and uses Hall-effect elements, in order to yield accurate signals, even in extreme driving conditions, such as at high speeds as well as very low speeds. The voltage, which is applied to terminals VPA and VPA2 of the ECM, varies between 0 V and 5 V in proportion to the operating angle of the accelerator pedal (throttle valve). A signal from VPA indicates the actual accelerator pedal opening angle (throttle valve opening angle) and is used for engine control. A signal from VPA2 conveys the status of the VPA circuit and is used to check the APP sensor itself. The ECM monitors the actual accelerator pedal opening angle (throttle valve opening angle) through the signals from VPA and VPA2, and controls the throttle actuator according to these signals. Accelerator Pedal Position Sensor Output Voltage (V) *1 Accelerator Pedal Position Sensor *2 5 ECM Magnet VPA IC No. 1 3.4 to 5.0 2.6 to 4.5 EPA VCPA 1.6 VPA2 0.8 EPA2 25 0 VCP2 IC No. 2 Usable Range Accelerator Pedal Turning Angle (deg) Magnet *1: Accelerator Pedal Fully Released *2: Accelerator Pedal Fully Depressed A019803E27 DTC No. DTC Detection Condition P2121 Difference between VPA and VPA2 is less than 0.4 V, or more than 1.2 V for 0.5 seconds (1 trip detection logic) Trouble Area • • Accelerator Pedal Position (APP) sensor ECM ES ES–350 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR DESCRIPTION The accelerator pedal position sensor is mounted on the accelerator pedal bracket. The accelerator pedal position sensor has 2 sensor elements and 2 signal outputs: VPA and VPA2. VPA is used to detect the actual accelerator pedal angle (used for engine control) and VPA2 is used to detect malfunctions in VPA. When the difference between the output voltages of VPA and VPA2 deviates from the standard, the ECM determines that the accelerator pedal position sensor is a malfunctioning. The ECM turns on the MIL and the DTC is set. MONITOR STRATEGY ES Related DTCs P2121: Accelerator pedal position (APP) sensor rationality Required Sensors/Components (Main) APP sensor Required Sensors/Components (Sub) - Frequency of Operation Continuous Duration 0.5 seconds MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present None TYPICAL MALFUNCTION THRESHOLDS Difference between VPA1 voltage (learned value) and VPA2 voltage (learned value) Less than 0.4 V, or more than 1.2 V FAIL-SAFE The accelerator pedal position sensor has two (main and sub) sensor circuits. If a malfunction occurs in either of the sensor circuits, the ECM detects the abnormal signal voltage difference between the two sensor circuits and switches to limp mode. In limp mode, the functioning circuit is used to calculate the accelerator pedal opening angle to allow the vehicle to continue driving. If both circuits malfunction, the ECM regards the opening angle of the accelerator pedal as being fully closed. In this case, the throttle valve remains closed as if the engine is idling. If a pass condition is detected and then the ignition switch is turned off, the fail-safe operation stops and the system returns to a normal condition. WIRING DIAGRAM Refer to DTC P2120 (See page ES-338). INSPECTION PROCEDURE HINT: • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). • This DTC relates to the Accelerator Pedal Position (APP) sensor. ES–351 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 1 READ VALUE OF INTELLIGENT TESTER (ACCEL POS #1 AND ACCEL POS #2) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the tester on. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / ACCEL POS #1 and ACCEL POS #2. (d) Read the values displayed on the tester. Standard voltage Depressed Released Accelerator Pedal Operations ACCEL POS #1 (AP#1) Released 0.5 to 1.1 V 1.2 to 2.0 V Depressed 2.6 to 4.5 V 3.4 to 4.7 V FI07052E06 OK ACCEL POS #2 (AP#2) Go to step 3 NG 2 CHECK HARNESS AND CONNECTOR (ACCELERATOR PEDAL POSITION SENSOR ECM) (a) Disconnect the A17 Accelerator Pedal Position (APP) sensor connector. (b) Disconnect the A55 ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for open) Wire Harness Side Front View: A17 APP Sensor Connector VPA2 VCPA EPA2 VCP2 EPA 1 2 3 4 5 6 A55 VPA VPA ECM Connector VCPA Tester Connection Specified Condition VPA (A17-6) - VPA (A55-55) Below 1 Ω EPA (A17-5) - EPA (A55-59) Below 1 Ω VCPA (A17-4) - VCPA (A55-57) Below 1 Ω VPA2 (A17-3) - VPA2 (A55-56) Below 1 Ω EPA2 (A17-2) - EPA2 (A55-60) Below 1 Ω VCP2 (A17-1) - VCP2 (A55-58) Below 1 Ω Standard resistance (Check for short) EPA Tester Connection VPA2 VCP2 EPA2 Specified Condition VPA (A17-6) or VPA (A55-55) - body ground 10 kΩ or higher EPA (A17-5) or EPA (A55-59) - body ground 10 kΩ or higher VCPA (A17-4) or VCPA (A55-57) - body ground 10 kΩ or higher VPA2 (A17-3) or VPA2 (A55-56) - body ground 10 kΩ or higher EPA2 (A17-2) or EPA2 (A55-60) - body ground 10 kΩ or higher VCP2 (A17-1) or VCP2 (A55-58) - body ground 10 kΩ or higher (d) Reconnect the APP sensor connector. (e) Reconnect the ECM connector. A115665E06 NG OK REPAIR OR REPLACE HARNESS OR CONNECTOR ES ES–352 3 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM REPLACE ACCELERATOR PEDAL ROD ASSEMBLY NEXT 4 CHECK WHETHER DTC OUTPUT RECURS (ACCELERATOR PEDAL POSITION SENSOR DTCS) (a) (b) (c) (d) (e) (f) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG) and turn the tester on. Clear the DTCs (See page ES-45). Start the engine. Allow the engine to idle for 15 seconds. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (g) Read the DTCs. ES Result Display (DTC Output) Proceed to P2121 A No output B B A REPLACE ECM (See page ES-518) END 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–353 DTC P2195 Oxygen (A/F) Sensor Signal Stuck Lean (Bank 1 Sensor 1) DTC P2196 Oxygen (A/F) Sensor Signal Stuck Rich (Bank 1 Sensor 1) DTC P2197 Oxygen (A/F) Sensor Signal Stuck Lean (Bank 2 Sensor 1) DTC P2198 Oxygen (A/F) Sensor Signal Stuck Rich (Bank 2 Sensor 1) DESCRIPTION HINT: • Although the DTC titles include oxygen sensor, these DTCs relate to the Air-Fuel Ratio (A/F) sensor. • Sensor 1 refers to the sensor mounted in front of the Three-Way Catalytic Converter (TWC) and located near the engine assembly. The A/F sensor generates voltage* that corresponds to the actual air-fuel ratio. This sensor voltage is used to provide the ECM with feedback so that it can control the air-fuel ratio. The ECM determines the deviation from the stoichiometric air-fuel ratio level, and regulates the fuel injection time. If the A/F sensor malfunctions, the ECM is unable to control the air-fuel ratio accurately. The A/F sensor is the planar type and is integrated with the heater, which heats the solid electrolyte (zirconia element). This heater is controlled by the ECM. When the intake air volume is low (the exhaust gas temperature is low), a current flows into the heater to heat the sensor, in order to facilitate accurate oxygen concentration detection. In addition, the sensor and heater portions are narrower than the conventional type. The heat generated by the heater is conducted to the solid electrolyte through the alumina, therefore the sensor activation is accelerated. A three-way catalytic converter (TWC) is used in order to convert the carbon monoxide (CO), hydrocarbon (HC), and nitrogen oxide (NOx) into less harmful substances. To allow the TWC to function effectively, it is necessary to keep the air-fuel ratio of the engine near the stoichiometric air-fuel ratio. *: Value changes inside the ECM. Since the A/F sensor is the current output element, a current is converted to a voltage inside the ECM. Any measurements taken at the A/F sensor or ECM connectors will show a constant voltage. ES ES–354 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Ideal Air-Fuel Mixture Output Voltage Heater Solid electrolyte (Zirconia Element) Element Platinum electrode Cover ES Air Exhaust Gas A A Rich - Air Fuel Ratio - Lean A-A Section A107164E14 DTC No. DTC Detection Condition P2195 P2197 Conditions (a) and (b) continue for 2 seconds or more (2 trip detection logic): (a) Air-Fuel Ratio (A/F) sensor voltage is more than 3.8 V (b) Heated Oxygen (HO2) sensor voltage is 0.15 V or more P2195 P2197 While fuel-cut operation is performed (during vehicle deceleration), air-fuel ratio (A/F) sensor current is 3.6 mA or more for 3 seconds (2 trip detection logic) Trouble Area • P2196 P2198 Conditions (a) and (b) continue for 2 seconds or more (2 trip detection logic): (a) A/F sensor voltage is less than 2.8 V (b) HO2 sensor voltage is less than 0.85 V P2196 P2198 While fuel-cut operation is performed (during vehicle deceleration), air-fuel ratio (A/F) sensor current is 1.4 mA for 3 seconds (2 trip detection logic) • • • • • • • Open or short in A/F sensor (bank 1, 2 sensor 1) circuit A/F sensor (bank 1, 2 sensor 1) A/F sensor (bank 1, 2 sensor 1) heater A/F sensor heater relay A/F sensor heater and relay circuits Air induction system Injector ECM • • A/F sensor ECM • • • • • • • • Open or short in A/F sensor (bank 1, 2 sensor 1) circuit A/F sensor (bank 1, 2 sensor 1) A/F sensor (bank 1, 2 sensor 1) heater A/F sensor heater relay A/F sensor heater and relay circuits Air induction system Injector ECM • • A/F sensor ECM HINT: • DTCs P2195 and P2196 indicate malfunctions related to the bank 1 A/F sensor circuit. • DTCs P2197 and P2198 indicate malfunctions related to the bank 2 A/F sensor circuit. • Bank 1 refers to the bank that includes cylinder No. 1. • Bank 2 refers to the bank that includes cylinder No. 2. • When any of these DTCs are set, check the A/F sensor output voltage by entering the following menus on the intelligent tester: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / AFS B1S1. • Short-term fuel trim values can also be read using an intelligent tester. • The ECM regulates the voltages at the A1A+, A2A+, A1A- and A2A- terminals of the ECM to a constant level. Therefore, the A/F sensor output voltage cannot be confirmed without using the intelligent tester. ES–355 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM • If a A/F sensor malfunction is detected, the ECM sets a DTC. MONITOR DESCRIPTION Sensor voltage detection monitor Under the air-fuel ratio feedback control, if the A/F sensor output voltage indicates rich or lean for a certain period of time, the ECM determines that there is a malfunction in the A/F sensor. The ECM illuminates the MIL and sets a DTC. Example: (1)If the A/F sensor voltage output is less than 2.8 V (very rich condition) for 10 seconds, despite the HO2 sensor output voltage being less than 0.6 V, the ECM sets DTC P2196. Alternatively, if the A/F sensor output voltage is more than 3.8 V (very lean condition) for 15 seconds, despite the HO2 sensor output voltage being 0.15 V or more, DTC P2195 is set. (2)Sensor current detection monitor (3)A rich air-fuel mixture causes a low A/F sensor current, and a lean air-fuel mixture causes a high A/ F sensor current. Therefore, the sensor output becomes low during acceleration, and it becomes high during deceleration with the throttle valve fully closed. The ECM monitors the A/F sensor current during fuel-cut and detects any abnormal current values. (4)If the A/F sensor output is 3.6 mA or more for more than 3 seconds of cumulative time, the ECM interprets this as a malfunction in the A/F sensor and sets DTC P2195 (high-side stuck). If the A/F sensor output is 1.0 mA or less for more than 3 seconds of cumulative time, the ECM sets DTC P2196 (low-side stuck). Air Fuel Ratio Sensor Current Monitor Cumulative Time "t" = t1 + t2 =3 seconds or more ON Fuel-Cut OFF Delay (3 seconds) Delay (3 seconds) Delay (3 seconds) Sensor Current (mA) High Side Threshold Low Side Threshold 3 seconds or more Normal Sensor Output t1 t2 Abnormal Sensor Output Time A107165E05 MONITOR STRATEGY Related DTCs P2195: A/F sensor (Bank 1) signal stuck lean P2196: A/F sensor (Bank 1) signal stuck rich P2197: A/F sensor (Bank 2) signal stuck lean P2198: A/F sensor (Bank 2) signal stuck rich ES ES–356 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Required Sensors/Components (Main) A/F sensor Required Sensors/Components (Related) HO2 sensor Frequency of Operation Continuous Duration 10 seconds MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS Sensor voltage detection monitor (Lean side malfunction P2195, P2197): ES The monitor will run whether these DTCs are not present P0031, P0032, P0051, P0052 (A/F sensor heater - Sensor 1) P0100 - P0103 (MAF meter) P0110 - P0113 (IAT sensor) P0115 - P0118 (ECT sensor) P0120 - P0223, P2135 (TP sensor) P0125 (Insufficient ECT for Closed Loop) P0136, P0156 (HO2 Sensor - Sensor 2) P0171, P0172 (Fuel system) P0300 - P0308 (Misfire) P0335 (CKP sensor) P0340, P0341 (CMP sensor) P0500 (VSS) Time while all of following conditions are met: 2 seconds or more Rear HO2 sensor voltage 0.15 V or more Time after engine start 30 seconds or more A/F sensor status Activated Fuel system status Closed-loop Engine Running Sensor voltage detection monitor (Rich side malfunction P2196, P2198): The monitor will run whether these DTCs are not present P0031, P0032, P0051, P0052 (A/F sensor heater - Sensor 1) P0100 - P0103 (MAF meter) P0110 - P0113 (IAT sensor) P0115 - P0118 (ECT sensor) P0120 - P0223, P2135 (TP sensor) P0125 (Insufficient ECT for Closed Loop) P0136, P0156 (HO2 Sensor - Sensor 2) P0171, P0172 (Fuel system) P0300 - P0308 (Misfire) P0335 (CKP sensor) P0340, P0341 (CMP sensor) P0500 (VSS) Time while all of following conditions are met: 2 seconds or more Rear HO2 sensor voltage Less than 0.6 V Time after engine start 30 seconds or more A/F sensor status Activated Fuel system status Closed-loop Engine Running 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–357 Sensor current detection monitor (High and low side malfunction P2195, P2196, P2197 and P2198): Monitor runs whenever following DTCs are not present P0031, P0032, P0051, P0052 (A/F sensor heater - Sensor 1) P0037, P0038, P0057, P0058 (HO2 sensor heater - Sensor 2) P0100 - P0103 (MAF meter) P0110 - P0113 (IAT sensor) P0115 - P0118 (ECT sensor) P0120 - P0223, P2135 (TP sensor) P0125 (Insufficient ECT for Closed Loop) P0136, P0156 (O2 Sensor - Sensor 2) P0171, P0172 (Fuel system) P0300 - P0308 (Misfire) P0335 (CKP sensor) P0340, P0341 (CMP sensor) P0500 (VSS) Battery voltage 11 V or more Atmospheric pressure 22.5 kPa (570 mmHg) or more A/F sensor status Activated Continuous time of fuel cut 3 to 10 seconds ECT 75°C (167°F) or more TYPICAL MALFUNCTION THRESHOLDS Sensor voltage detection monitor (Lean side malfunction P2195, P2197): A/F sensor voltage More than 3.8 V Sensor voltage detection monitor (Rich side malfunction P2196, P2198): A/F sensor voltage Less than 2.8 V Sensor current detection monitor (High side malfunction P2195, P2197): A/F sensor current 3.6 mA or more Sensor current detection monitor (Low side malfunction P2196, P2198): A/F sensor current Less than 1.4 mA MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-49). ES ES–358 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM C15 Air Fuel Ratio Sensor A/F A/F +B 86 HA1A C55 HA1A 1 2 A1A- * A1A+ 4 93 A1A+ C55 3 116 A1AC55 C35 Air Fuel Ratio Sensor ES EFI +B 109 HA2A C55 HA2A 1 2 A2A4 A2A+ 3 * 120 A2A+ C55 119 A2AC55 EFI MAIN 44 A55 MREL FL MAIN Battery *: Shielded A133861E01 CONFIRMATION DRIVING PATTERN This confirmation driving pattern is used in steps 2, 4, 7, 17 and 21 of the following diagnostic troubleshooting procedure when using an intelligent tester. ES–359 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Monitor Driving Pattern ECT: 75°C (167°F) or more Vehicle Speed Accelerator Pedal Depressed Between 38 and 75 mph (60 and 120 km/h) (B) Idling At least 3 times (D) 40 mph (64 km/h) or more (A) Accelerator Pedal Released (Fuel-cut) (E) (F) 6 mph (10 km/h) (C) Time 10 minutes or more Warming up ES 10 seconds 4 seconds or more or more Refer to figure below A107162E21 Driving Pattern Detail for (C) through (F) Cumulative Detection Period "t" = t1 + t2 + t3 = 3 seconds or more Reference Engine RPM Delay Detection Period t1 (D) (E) (F) 2,500 rpm 1,000 rpm Idling t2 (C) t3 Time Idling 4 seconds or more 4 seconds or more 4 seconds or more A107163E08 1. 2. 3. 4. 5. 6. Connect an intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the tester on. Clear the DTCs. Start the engine, and warm it up until the ECT reaches 75°C (167°F) or higher (Procedure "A"). On the intelligent tester, enter the following menus to check the fuel-cut status: DIAGNOSIS / ENHANCED OBD II / DATA LIST / USER DATA / FC IDLE. 7. Drive the vehicle at between 38 mph (60 km/h) and 75 mph (120 km/h) for at least 10 minutes (Procedure "B"). 8. Change the transmission to the 2nd gear (Procedure "C"). ES–360 ES 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 9. Drive the vehicle at a proper vehicle speed to perform fuel-cut operation (refer to the following HINT ) (Procedure "D"). HINT: Fuel-cut is performed when the following conditions are met: • Accelerator pedal is fully released. • Engine speed is 2,500 rpm or more (fuel injection resumes at 1,000 rpm). 10.Accelerate the vehicle to 40 rpm (64 km/h) or more by depressing the accelerator pedal for at least 10 seconds (Procedure "E"). 11.Soon after performing procedure E above, release the accelerator pedal for at least 4 seconds without depressing the brake pedal, in order to execute fuel-cut control (Procedure "F"). 12.Allow the vehicle to decelerate until the vehicle speed declines to less than 6 mph (10 km/h). 13.Repeat procedure from C through F above at least 3 times in one driving cycle. HINT: Completion of all A/F sensor monitors is required to change the value in TEST RESULT. CAUTION: Strictly observe posted speed limits, traffic laws, and road conditions when performing these drive patterns. INSPECTION PROCEDURE HINT: Malfunctioning areas can be identified by performing the A/F CONTROL function provided in the ACTIVE TEST. The A/F CONTROL function can help to determine whether the Air-fuel Ratio (A/F) sensor, Heated Oxygen (HO2) sensor and other potential trouble areas are malfunctioning. The following instructions describe how to conduct the A/F CONTROL operation using the intelligent tester. 1. Connect the intelligent tester to the DLC3. 2. Start the engine and turn the tester on. 3. Warm up the engine at an engine speed of 2,500 rpm for approximately 90 seconds. 4. On the intelligent tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. 5. Perform the A/F CONTROL operation with the engine in an idling condition (press the RIGHT or LEFT button to change the fuel injection volume). 6. Monitor the output voltages of the A/F and HO2 sensors (AFS B1 S1 and O2S B1 S2 or AFS B2 S1 and O2S B2 S2) displayed on the tester. HINT: • The A/F CONTROL operation lowers the fuel injection volume by 12.5 % or increases the injection volume by 25 %. • Each sensor reacts in accordance with increases in the fuel injection volume. Tester Display (Sensor) Injection Volume Status Voltage AFS B1S1 or AFS B2S1 (A/F) +25 % Rich Less than 3.0 V AFS B1S1 or AFS B2S1 (A/F) -12.5 % Lean More than 3.35 V O2S B1S2 or O2S B2S2 (HO2) +25 % Rich More than 0.55 V O2S B1S2 or O2S B2S2 (HO2) -12.5 % Lean Less than 0.4 V NOTICE: The Air-Fuel Ratio (A/F) sensor has an output delay of a few seconds and the HO2S (sensor 2) output has a maximum output delay of 20 seconds. ES–361 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Case 1 2 3 4 A/F Sensor (Sensor 1) Output Voltage HO2 Sensor (Sensor 2) Output Voltage Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage More than 3.35 V Less than 3.0 V Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage Almost no reaction Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage More than 3.35 V Less than 3.0 V Output Voltage Almost no reaction Injection volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage Almost no reaction Output Voltage Almost no reaction Main Suspected Trouble Areas - • • • A/F sensor A/F sensor heater A/F sensor circuit ES • • • HO2 sensor HO2 sensor heater HO2 sensor circuit • • Fuel pressure Gas leakage from exhaust system (Air-fuel ratio extremely lean or rich) • Following the A/F CONTROL procedure enables technicians to check and graph the voltage outputs of both the A/F and HO2 sensors. • To display the graph, enter the following menus on the tester: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL / USER DATA / AFS B1 S1 and O2S B 1S2 or AFS B2 S1 and O2S B2 S2 and press the YES button and then the ENTER button followed by the F4 button. HINT: • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). • A low A/F sensor voltage could be caused by a rich air-fuel mixture. Check for conditions that would cause the engine to run rich. • A high A/F sensor voltage could be caused by a lean air-fuel mixture. Check for conditions that would cause the engine to run lean. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO P2195, P2196, 2197 OR P2198) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the tester on. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read the DTCs. ES–362 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Result Display (DTC Output) Proceed to P2195, P2196, P2197, or P2198 A P2195, P2196, P2197, or P2198 and other DTCs B HINT: If any DTCs other than P2195, P2196, P2197 or P2198 are output, troubleshoot those DTCs first. B GO TO DTC CHART (See page ES-63) A 2 READ VALUE OF INTELLIGENT TESTER (TEST VALUE OF A/F SENSOR) ES (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG) and turn the tester on. Clear the DTCs. Allow the vehicle to drive in accordance with the driving pattern described in the CONFIRMATION DRIVING PATTERN. (e) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / MONITOR INFO / MONITOR STATUS. (f) Check the status of O2S MON is COMPL. If the status is still INCMPL, drive the vehicle according to the driving pattern again. HINT: • AVAIL indicates that the component has not been monitored yet. • COMPL indicates that the component is functioning normally. • INCMPL indicates that the component is malfunctioning. (g) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / MONITOR INFO / TEST RESULT / RANGE B1 S1, then press the ENTER button. (h) Check the test value of the A/F sensor output current during fuel-cut. Result Test Value Proceed to Within normal range (1.4 mA or more, and less than 3.6 mA) A Outside normal range (Less than 1.4 mA, or 3.6 mA or more) B B Go to step 20 A 3 READ VALUE OF INTELLIGENT TESTER (OUTPUT VOLTAGE OF A/F SENSOR) (a) Connect the intelligent tester to the DLC3. (b) Start the engine. (c) Turn the tester on. ES–363 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (d) Warm up the Air-Fuel Ratio (A/F) sensor at an engine speed of 2,500 rpm for 90 seconds. (e) On the tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / SNAPSHOT / MANUAL SNAPSHOT / USER DATA / AFS B1 S1 or AFS B2 S1 and ENGINE SPD. (f) Check the A/F sensor voltage three times, when the engine is in each of the following conditions: (1) While idling (check for at least 30 seconds) (2) At an engine speed of approximately 2,500 rpm (without any sudden changes in engine speed) (3) Raise the engine speed to 4,000 rpm and then quickly release the accelerator pedal so that the throttle valve is fully closed. Standard voltage ES Condition A/F Sensor Voltage Variation Reference (1) and (2) Changes at approximately 3.3 V Between 3.1 V and 3.5 V (3) Increases to 3.8 V or more This occurs during engine deceleration (when fuel-cut performed) HINT: • For more information, see the diagrams below. Malfunction Condition: Normal Condition: (3) Approximately 4,000 rpm (2) Approximately 2,500 rpm (3) Approximately 4,000 rpm (2) Approximately 2,500 rpm (1) Idling (1) Idling (1) Idling Engine RPM Engine RPM A/F Sensor Voltage A/F Sensor Voltage Fuel-cut Fuel-cut "Condition (1), (2)" Change at approximately 3.3 V (1) Idling "Condition (3)" 3.8 V or more When A/F sensor circuit is malfunctioning, voltage output does not change A107161E14 • If the output voltage of the A/F sensor remains at approximately 3.3 V (see Malfunction Condition diagram) under any conditions, including those above, the A/F sensor may have an open circuit. (this will also happen if the A/F sensor heater has an open circuit.) • If the output voltage of the A/F sensor remains at either approximately 3.8 V or more, or 2.8 V or less (see Malfunction Condition diagram) under any conditions, including those above, the A/F sensor may have a short circuit. ES–364 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM • The ECM stops fuel injection (fuel cut) during engine deceleration. This causes a lean condition and results in a momentary increase in the A/F sensor output voltage. • The ECM must establish a closed throttle valve position learning value to perform fuel cut. If the battery terminal has been reconnected, the vehicle must be driven over 10 mph (16 km/h) to allow the ECM terminal to be reconnected, the vehicle must be driven at over 10 mph (16 km/h) to allow the ECM to learn the closed throttle valve position. • When the vehicle is driven: The output voltage of the A/F sensor may be below 2.8 V during fuel enrichment. For the vehicle, this translates to a sudden increase in speed with the accelerator pedal fully depressed when trying to overtake another vehicle. The A/ F sensor is functioning normally. • The A/F sensor is a current output element; therefore, the current is converted into a voltage inside the ECM. Measuring the voltage at the connectors of the A/F sensor or ECM will show a constant voltage result. ES NG Go to step 10 OK 4 PERFORM CONFIRMATION DRIVING PATTERN NEXT 5 CHECK WHETHER DTC OUTPUT RECURS (DTC P2195, P2196, P2197 OR P2198) (a) Read the DTCs using the intelligent tester. (b) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. Result Display (DTC Output) Proceed to P2195, P2196, P2197, or P2198 A No output B B Go to step 9 A 6 REPLACE AIR FUEL RATIO SENSOR (a) Replace the air fuel ratio sensor (See page EC-19). NEXT 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 7 ES–365 PERFORM CONFIRMATION DRIVING PATTERN NEXT 8 CHECK WHETHER DTC OUTPUT RECURS (DTC P2195, P2196, P2197 OR P2198) (a) Read the DTCs using the intelligent tester. (b) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. Result Display (DTC Output) Proceed to No output A P2195, P2196, P2197, or P2198 B B REPLACE ECM (See page ES-518) A 9 CONFIRM IF VEHICLE HAS RUN OUT OF FUEL IN PAST (a) Has the vehicle run out of fuel in the past? NO YES DTC CAUSED BY RUNNING OUT OF FUEL CHECK FOR INTERMITTENT PROBLEMS ES ES–366 10 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT AIR FUEL RATIO SENSOR (HEATER RESISTANCE) (a) Disconnect the C15 or C35 A/F sensor connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance (Bank 1 sensor 1) Component Side: +B HA1A C15 Bank 1 Condition Specified Condition HA1A (1) - +B (2) 20°C (68°F) 1.8 Ω to 3.4 Ω HA1A (1) - A1A- (4) Always 10 kΩ or higher Standard resistance (Bank 2 sensor 1) A1AA1A+ A/F Sensor Front View ES Tester Connection +B HA2A Tester Connection Condition Specified Condition HA2A (1) - +B (2) 20°C (68°F) 1.8 Ω to 3.4 Ω HA2A (1) - A2A- (4) Always 10 kΩ or higher (c) Reconnect the A/F sensor connector. NG C35 Bank 2 REPLACE AIR FUEL RATIO SENSOR (See page EC-19) A2AA2A+ A/F Sensor Front View A126269E11 OK 11 INSPECT FUSE (A/F FUSE) (a) Remove the A/F fuse from the integration relay. (b) Measure the A/F fuse resistance. Standard resistance: Below 1 Ω (c) Reinstall the A/F fuse. NG OK REPLACE A/F FUSE 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 12 INSPECT ENGINE ROOM JUNCTION BLOCK (A/F RELAY) (a) Remove the engine room junction block from the engine room R/B. (b) Inspect the A/F relay. (1) Measure the A/F relay resistance. Standard resistance Engine Room Junction Block 1G 1A Tester Connection Specified Condition 1G-1 - 1A-4 10 kΩ or higher 1G-1 - 1A-4 Below 1 Ω (Apply battery voltage between terminals 1E9 and 1E-10) (c) Reinstall the engine room junction block. 1E NG Engine Room Relay Block A140654E01 OK ES–367 REPLACE ENGINE ROOM JUNCTION BLOCK ES ES–368 13 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (A/F SENSOR - ECM) (a) Disconnect the C15 and C35 A/F sensor connectors. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness Side: A/F Sensor Connector ES C15 : Bank 1 Tester Connection Specified Condition +B (C15-2) - Body ground 9 to 14 V C35 : Bank 2 +B (C35-2) - Body ground 9 to 14 V (d) Turn the ignition switch off. (e) Disconnect the C55 ECM connector. (f) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for open) C55 ECM Connector A1A+ A1A- A2A- A2A+ HA2A HA1A A127715E20 Tester Connection Specified Condition HA1A (C15-1) - HA1A (C55-86) Below 1 Ω A1A+ (C15-3) - A1A+ (C55-93) Below 1 Ω A1A- (C15-4) - A1A- (C55-116) Below 1 Ω HA2A (C35-1) - HA2A (C55-109) Below 1 Ω A2A+ (C35-3) - A2A+ (C55-120) Below 1 Ω A2A- (C35-4) - A2A- (C55-119) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition HA1A (C15-1) or HA1A (C55-86) - Body ground 10 kΩ or higher A1A+ (C15-3) or A1A+ (C55-93) - Body ground 10 kΩ or higher A1A- (C15-4) or A1A- (C55-116) - Body ground 10 kΩ or higher HA2A (C35-1) or HA2A (C55-109) - Body ground 10 kΩ or higher A2A+ (C35-3) or A2A+ (C55-120) - Body ground 10 kΩ or higher A2A- (C35-4) or A2A- (C55-119) - Body ground 10 kΩ or higher (g) Reconnect the ECM connector. (h) Reconnect the A/F sensor connector. ES–369 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Reference (System Diagram of Bank 1 Sensor 1): A/F Relay From Battery ECM A/F Sensor A/F +B Heater HA1A HA1A A1A+ A1A+ Sensor A1A- From EFI Relay Duty Control A1A- ES A133850E06 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 14 CHECK AIR INDUCTION SYSTEM (a) Check the air induction system for vacuum leakage. OK: No leakage from air induction system. NG REPAIR OR REPLACE AIR INDUCTION SYSTEM OK 15 CHECK FUEL PRESSURE (HIGH PRESSURE SIDE AND LOW PRESSURE SIDE) (a) Check the fuel pressure. NG REPAIR OR REPLACE FUEL SYSTEM OK 16 REPLACE AIR FUEL RATIO SENSOR (a) Replace the air fuel ratio sensor (See page EC-19). NEXT ES–370 17 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PERFORM CONFIRMATION DRIVING PATTERN NEXT 18 CHECK WHETHER DTC OUTPUT RECURS (DTC P2195, P2196, P2197 OR P2198) (a) Read the DTCs using the intelligent tester. (b) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. Result Display (DTC Output) ES Proceed to No output A P2195, P2196, P2197 or P2198 B B REPAIR OR REPLACE ECM A 19 CONFIRM IF VEHICLE HAS RUN OUT OF FUEL IN PAST (a) Has the vehicle run out of fuel in the past? NO CHECK FOR INTERMITTENT PROBLEMS YES DTC CAUSED BY RUNNING OUT OF FUEL 20 REPLACE AIR FUEL RATIO SENSOR (a) Replace the air fuel ratio sensor (See page EC-19). NEXT 21 PERFORM CONFIRMATION DRIVING PATTERN NEXT 22 CHECK WHETHER DTC OUTPUT RECURS (DTC P2195, P2196, P2197 OR P2198) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG) and turn the tester on. Read the DTCs using the intelligent tester. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–371 Result Display (DTC Output) Proceed to No output A P2195, P2196, P2197 or P2198 (A/F sensor pending DTCs) B B REPLACE ECM (See page ES-518) A END ES ES–372 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2238 Oxygen (A/F) Sensor Pumping Current Circuit Low (Bank 1 Sensor 1) DTC P2239 Oxygen (A/F) Sensor Pumping Current Circuit High (Bank 1 Sensor 1) DTC P2241 Oxygen (A/F) Sensor Pumping Current Circuit Low (Bank 2 Sensor 1) DTC P2242 Oxygen (A/F) Sensor Pumping Current Circuit High (Bank 2 Sensor 1) DTC P2252 Oxygen (A/F) Sensor Reference Ground Circuit Low (Bank 1 Sensor 1) DTC P2253 Oxygen (A/F) Sensor Reference Ground Circuit High (Bank 1 Sensor 1) DTC P2255 Oxygen (A/F) Sensor Reference Ground Circuit Low (Bank 2 Sensor 1) DTC P2256 Oxygen (A/F) Sensor Reference Ground Circuit High (Bank 2 Sensor 1) ES DESCRIPTION HINT: • Although the DTC titles include oxygen sensor, these DTCs relate to the Air-Fuel Ratio (A/F) sensor. • Sensor 1 refers to the sensor mounted in front of the Three-Way Catalytic Converter (TWC) and located near the engine assembly. The A/F sensor generates voltage* that corresponds to the actual air-fuel ratio. This sensor voltage is used to provide the ECM with feedback so that it can control the air-fuel ratio. The ECM determines the deviation from the stoichiometric air-fuel ratio level, and regulates the fuel injection time. If the A/F sensor malfunctions, the ECM is unable to control the air-fuel ratio accurately. The A/F sensor is the planar type and is integrated with the heater, which heats the solid electrolyte (zirconia element). This heater is controlled by the ECM. When the intake air volume is low (the exhaust gas temperature is low), a current flows into the heater to heat the sensor, in order to facilitate accurate oxygen concentration detection. In addition, the sensor and heater portions are narrower than the conventional type. The heat generated by the heater is conducted to the solid electrolyte through the alumina, therefore the sensor activation is accelerated. A three-way catalytic converter (TWC) is used in order to convert the carbon monoxide (CO), hydrocarbon (HC), and nitrogen oxide (NOx) into less harmful substances. To allow the TWC to function effectively, it is necessary to keep the air-fuel ratio of the engine near the stoichiometric air-fuel ratio. *: Value changes inside the ECM. Since the A/F sensor is the current output element, a current is converted to a voltage inside the ECM. Any measurements taken at the A/F sensor or ECM connectors will show a constant voltage. ES–373 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Ideal Air-Fuel Mixture Output Voltage Heater Solid electrolyte (Zirconia Element) Element Platinum electrode Cover Air Exhaust Gas A A Rich - Air Fuel Ratio - Lean A-A Section A107164E14 DTC No. P2238 P2241 DTC Detection Condition • Case 1: Condition (a) or (b) continues for 5.0 seconds or more (1 trip detection logic): (a) AF+ voltage is 0.5 V or less (b) (AF+) - (AF-) = 0.1 V or less • Case 2: A/F sensor admittance: Less than 0.022 1/Ω (2 trip detection logic) Trouble Area • • • • • • • P2239 P2242 AF+ voltage is more than 4.5 V for 5.0 seconds or more (2 trip detection logic) • • • • • • P2252 P2255 AF- voltage is 0.5 V or less for 5.0 seconds or more (2 trip detection logic) • • • • • • P2253 P2256 AF- voltage is more than 4.5 V for 5.0 seconds or more (2 trip detection logic) • • • • • Open or short in A/F sensor (bank 1, 2 sensor 1) circuit A/F sensor (bank 1, 2 sensor 1) A/F sensor heater A/F sensor heater relay A/F sensor heater and relay circuits ECM Open or short in A/F sensor (bank 1, 2 sensor 1) circuit A/F sensor (bank 1, 2 sensor 1) A/F sensor heater A/F sensor heater relay A/F sensor heater and relay circuits ECM Open or short in A/F sensor (bank 1, 2 sensor 1) circuit A/F sensor (bank 1, 2 sensor 1) A/F sensor heater A/F sensor heater relay A/F sensor heater and relay circuits ECM Open or short in A/F sensor (bank 1, 2 sensor 1) circuit A/F sensor (bank 1, 2 sensor 1) A/F sensor heater A/F sensor heater relay A/F sensor heater and relay circuits ECM HINT: • DTCs P2238, P2239, P2252 and P2253 indicate malfunctions related to the bank 1 A/F sensor circuit. • DTCs P2241, P2242, P2255 and P2256 indicate malfunctions related to the bank 2 A/F sensor circuit. • Bank 1 refers to the bank that includes cylinder No. 1. • Bank 2 refers to the bank that includes cylinder No. 2. ES ES–374 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR DESCRIPTION The Air-Fuel Ratio (A/F) sensor varies its output voltage in proportion to the air-fuel ratio. If the A/F sensor impedance (alternating current resistance) or output voltage deviates greatly from the standard range, the ECM determines that there is an open or short malfunction in the A/F sensor circuit. MONITOR STRATEGY Related DTCs P2238: A/F sensor (Bank 1) open circuit between AF+ and AFP2238: A/F sensor (Bank 1) short circuit between AF+ and AFP2238: A/F sensor (Bank 1) short circuit between AF+ and GND P2239: A/F sensor (Bank 1) short circuit between AF+ and +B P2241: A/F sensor (Bank 2) open circuit between AF+ and AFP2241: A/F sensor (Bank 2) short circuit between AF+ and AFP2241: A/F sensor (Bank 2) short circuit between AF+ and GND P2242: A/F sensor (Bank 2) short circuit between AF+ and +B P2252: A/F sensor (Bank 1) short circuit between AF- and GND P2253: A/F sensor (Bank 1) short circuit between AF- and +B P2255: A/F sensor (Bank 2) short circuit between AF- and GND P2256: A/F sensor (Bank 2) short circuit between AF- and +B Required Sensors/Components (Main) A/F sensor Required Sensors/Components (Sub) Engine Coolant Temperature (ECT) sensor, Crankshaft position sensor Frequency of Operation Once per driving cycle Duration 10 seconds MIL Operation 2 driving cycles Sequence of Operation None ES TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present P0031, P0032, P0051, P0052 (A/F sensor heater - Sensor 1) P0100 - P0103 (MAF meter) P0110 - P0113 (IAT sensor) P0115 - P0118 (ECT sensor) P0120 - P0223, P2135 (TP sensor) P0125 (Insufficient ECT for Closed Loop) P0171, P0172 (Fuel system) P0300 - P0308 (Misfire) P0335 (CKP sensor) P0500 (VSS) P2238 and P2241 (open circuit between AF+ and AF-): AF+ terminal voltage 0.5 to 4.5 V AF- terminal voltage 0.5 to 4.5 V Difference between AF+ and AF- terminal voltages 0.1 to 0.8 V ECT 5°C (41°F) or more (Varies with ECT at engine start) Engine condition Running Fuel-cut OFF Time after engine start 10 seconds or more A/F sensor heater duty-cycle ON Time after A/F sensor heating 5 seconds or more Battery voltage 11 V or more Ignition switch ON Others: Battery voltage 10.5 V or more Ignition switch ON ES–375 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TYPICAL MALFUNCTION THRESHOLDS P2238 and P2241 (Open circuit between AF+ and AF-): A/F sensor admittance Below 0.022 1/Ω P2238 and P2241 (Short circuit between AF+ and GND): AF+ terminal voltage 0.5 V or less P2238 and P2241 (Short circuit between AF+ and AF-): Difference between AF+ and AF- terminal voltages 0.1 v or less P2239 and P2242 (Short circuit between AF+ and +B): AF+ terminal voltage More than 4.5 V P2252 and P2255 (Short circuit between AF- and GND): AF- terminal voltage 0.5 V or less ES P2253 and P2256 (Short circuit between AF- and +B): AF- terminal voltage More than 4.5 V WIRING DIAGRAM Refer to DTC P2195 (See page ES-350). INSPECTION PROCEDURE HINT: Intelligent tester only: Malfunctioning areas can be identified by performing the A/F CONTROL function provided in the ACTIVE TEST. The A/F CONTROL function can help to determine whether the Air-Fuel Ratio (A/F) sensor, Heated Oxygen (HO2) sensor and other potential trouble areas are malfunctioning. The following instructions describe how to conduct the A/F CONTROL operation using the intelligent tester. 1. Connect the intelligent tester to the DLC3. 2. Start the engine and turn the tester on. 3. Warm up the engine at an engine speed of 2,500 rpm for approximately 90 seconds. 4. On the tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. 5. Perform the A/F CONTROL operation with the engine in an idling condition (press the RIGHT or LEFT button to change the fuel injection volume). 6. Monitor the output voltages of the A/F and HO2 sensors (AFS B1 S1 and O2S B1 S2 or AFS B2 S1 and O2S B2 S2) displayed on the tester. HINT: • The A/F CONTROL operation lowers the fuel injection volume by 12.5 % or increases the injection volume by 25 %. • Each sensor reacts in accordance with increases and decreases in the fuel injection volume. Tester Display (Sensor) Injection Volume Status Voltage AFS B1S1 or AFS B2S1 (A/F) +25 % Rich Less than 3.0 V AFS B1S1 or AFS B2S1 (A/F) -12.5 % Lean More than 3.35 V O2S B1S2 or O2S B2S2 (HO2) +25 % Rich More than 0.55 V O2S B1S2 or O2S B2S2 (HO2) -12.5 % Lean Less than 0.4 V ES–376 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NOTICE: The Air-Fuel Ratio (A/F) sensor has an output delay of a few seconds and the Heated Oxygen (HO2) sensor has a maximum output delay of approximately 20 seconds. Case 1 ES 2 3 4 A/F Sensor (Sensor 1) Output Voltage HO2 Sensor (Sensor 2) Output Voltage Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage More than 3.35 V Less than 3.0 V Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage Almost no reaction Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage More than 3.35 V Less than 3.0 V Output Voltage Almost no reaction Injection volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage Almost no reaction Output Voltage Almost no reaction Main Suspected Trouble Areas - • • • A/F sensor A/F sensor heater A/F sensor circuit • • • HO2 sensor HO2 sensor heater HO2 sensor circuit • • • Injector Fuel pressure Gas leakage from exhaust system (Air-fuel ratio extremely lean or rich) • Following the A/F CONTROL procedure enables technicians to check and graph the output voltages of both the A/F and HO2 sensors. • To display the graph, enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL / USER DATA / AFS B1 S1 and O2S B1 S2 or AFS B2 S1 and O2S B2 S2, and press the YES button and then the ENTER button followed by the F4 button. HINT: • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). ES–377 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 1 INSPECT AIR FUEL RATIO SENSOR (HEATER RESISTANCE) (a) Disconnect the C15 or C35 A/F sensor connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance (Bank 1 sensor 1) Component Side: +B HA1A C15 Bank 1 Tester Connection Condition Specified Condition HA1A (1) - +B (2) 20°C (68°F) 1.8 to 3.4 Ω HA1A (1) - A1A- (4) - 10 kΩ or higher Standard resistance (Bank 2 sensor 1) A1AA1A+ A/F Sensor Front View +B HA2A Tester Connection Condition Specified Condition HA2A (1) - +B (2) 20°C (68°F) 1.8 to 3.4 Ω HA2A (1) - A2A- (4) - 10 kΩ or higher (c) Reconnect the A/F sensor connector. NG C35 Bank 2 REPLACE AIR FUEL RATIO SENSOR (See page EC-19) A2AA2A+ A/F Sensor Front View A126269E12 OK 2 INSPECT A/F FUSE Engine Room Relay Block (a) Remove the A/F fuse from the engine room junction block. (b) Measure the A/F fuse resistance. Standard resistance: Below 1 Ω (c) Reinstall the A/F fuse. NG A/F A135031E01 OK REPLACE A/F FUSE ES ES–378 3 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT ENGINE ROOM JUNCTION BLOCK (A/F RELAY) (a) Remove the engine room junction block from the engine room R/B. (b) Inspect the A/F relay. (1) Measure the A/F relay resistance. Standard resistance Engine Room Junction Block 1G 1A Specified Condition 1G-1 - 1A-4 10 kΩ or higher 1G-1 - 1A-4 Below 1 Ω (Apply battery voltage between terminals 1E6 and 1E-10) (c) Reinstall the engine room junction block. 1E ES Tester Connection NG Engine Room Relay Block A140654E01 OK REPLACE ENGINE ROOM JUNCTION BLOCK ES–379 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 4 CHECK HARNESS AND CONNECTOR (A/F SENSOR - ECM) (a) Disconnect the C15 and C35 A/F sensor connectors. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness Side: A/F Sensor Connector C15 : Bank 1 Tester Connection Specified Condition +B (C15-2) - Body ground 9 to 14 V C35 : Bank 2 +B (C35-2) - Body ground 9 to 14 V (d) Turn the ignition switch off. (e) Disconnect the C55 ECM connector. (f) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for open) C55 ECM Connector A1A+ A1A- A2A- A2A+ HA2A HA1A A127715E20 Tester Connection Specified Condition HA1A (C15-1) - HA1A (C55-86) Below 1 Ω A1A+ (C15-3) - A1A+ (C55-93) Below 1 Ω A1A- (C15-4) - A1A- (C55-116) Below 1 Ω HA2A (C35-1) - HA2A (C55-109) Below 1 Ω A2A+ (C35-3) - A2A+ (C55-120) Below 1 Ω A2A- (C35-4) - A2A- (C55-119) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition HA1A (C15-1) or HA1A (C55-86) - Body ground 10 kΩ or higher A1A+ (C15-3) or A1A+ (C55-93) - Body ground 10 kΩ or higher A1A- (C15-4) or A1A- (C55-116) - Body ground 10 kΩ or higher HA2A (C35-1) or HA2A (C55-109) - Body ground 10 kΩ or higher A2A+ (C35-3) or A2A+ (C55-120) - Body ground 10 kΩ or higher A2A- (C35-4) or A2A- (C55-119) - Body ground 10 kΩ or higher (g) Reconnect the ECM connector. (h) Reconnect the A/F sensor connector. ES ES–380 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Reference (System Diagram of Bank 1 Sensor 1): A/F Relay From Battery ECM A/F Sensor A/F +B Heater HA1A HA1A A1A+ A1A+ Sensor A1A- ES From EFI Relay Duty Control A1A- A133850E02 NG OK REPLACE ECM (See page ES-518) REPAIR OR REPLACE HARNESS OR CONNECTOR ES–381 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2420 Evaporative Emission System Switching Valve Control Circuit High DTC SUMMARY DTC No. P2420 Monitoring Item DTC Detection Condition Vent valve stuck open (vent) The following condition is met during key-off EVAP monitor • EVAP pressure change when vent valve is closed (ON) less than 2.3 mmHg • • • Trouble Area Detection Timing Detection Logic Pump module (0.02 inch orifice, vacuum pump, vent valve) Connector / wire harness (Pump module - ECM) ECM Ignition switch off 2 trip DESCRIPTION The circuit description can be found in the EVAP (Evaporative Emission) System (See page ES-400). INSPECTION PROCEDURE Refer to the EVAP System (See page ES-400). MONITOR DESCRIPTION 5 hours*1 after the ignition switch is turned off, the electric vacuum pump creates negative pressure (vacuum) in the EVAP (Evaporative Emission) system. The ECM monitors for leaks and actuator malfunctions based on the EVAP pressure. HINT: *1: If the engine coolant temperature is not below 35°C (95°F) 5 hours after the ignition switch is turned off, the monitor check starts 2 hours later. If it is still not below 35°C (95°F) 7 hours after the ignition switch is turned off, the monitor check starts 2.5 hours later. Sequence *2: Operations Descriptions Duration - ECM activation Activated by soak timer, 5 hours (7 or 9.5 hours) after ignition switch turned off. - A Atmospheric pressure measurement Vent valve turned OFF (vent) and EVAP system pressure measured by ECM in order to register atmospheric pressure. If pressure in EVAP system is not between 70 kPa and 110 kPa (525 mmHg and 825 mmHg), ECM cancels EVAP system monitor. 10 seconds B First 0.02 inch leak pressure measurement In order to determine 0.02 inch leak pressure standard, vacuum pump creates negative pressure (vacuum) through 0.02 inch orifice and then ECM checks if vacuum pump and vent valve operate normally. 60 seconds C EVAP system pressure measurement Vent valve is turned ON (closed) to shut EVAP system. Negative pressure (vacuum) is created in EVAP system, and then EVAP system pressure is measured. Write down measured value as they will be used in leak check. If EVAP pressure does not stabilize within 15 minutes, ECM cancels EVAP system monitor. 15 minutes*2 D Purge VSV monitor Purge VSV is opened and then EVAP system pressure is measured by ECM. Large increase indicates normal. 10 seconds E Second 0.02 inch leak pressure measurement After second 0.02 inch leak pressure measurement, leak check is performed by comparing first and second 0.02 inch leak pressure standards. If stabilized system pressure is higher than second 0.02 inch leak pressure standard, ECM determines that there is a leak in EVAP system. 60 seconds F Final check Atmospheric pressure is measured and then monitoring result is recorded by ECM. - If only a small amount of fuel is in the fuel tank, it takes longer for the EVAP pressure to stabilize. ES ES–382 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Operation A: Operation B, E: Atmospheric Pressure Measurement 0.02 Inch Leak Pressure Measurement Canister Fuel Tank Purge VSV: OFF Vent Valve: OFF (vent) OFF OFF (vent) 0.02 Inch Orifice Pressure Sensor Air Filter Vacuum Pump: OFF Operation C: EVAP System Pressure Measurement ON Pump Module Operation D: Purge VSV Monitor ES ON (closed) OFF ON ON (closed) Atmospheric Pressure Negative Pressure ON ON A096746E32 The vent valve turns ON (closes) and the EVAP (Evaporative Emission) system pressure is then measured by the ECM, using the pressure sensor, to conduct an EVAP leak check. If the pressure does not increase when the vent valve is open, the ECM interprets this as the vent valve being stuck open. The ECM illuminates the MIL and sets the DTC. EVAP Pressure when Vent Valve Stuck OFF: ON Purge VSV ON: Closed ON Vent Valve ON: Open OFF: Closed OFF: Vent ON Vacuum Pump EVAP Pressure Positive Negative OK First 0.02 Inch Leak Pressure Standard Sequence Time A 10 seconds B 60 seconds Malfunction C With 15 minutes D E 10 60 seconds seconds F G036780E10 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–383 MONITOR STRATEGY Related DTC P2420: Vent valve stuck open (vent) Required Sensors/Components Purge VSV and pump module Frequency of Operation Once per driving cycle Duration Within 2 minutes MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present None Key-off monitor is run when all of the following conditions are met - Atmospheric pressure 70 to 110 kPa (525 to 825 mmHg) Battery voltage 10.5 V or more Vehicle speed 2.5 mph (4 km/h) or less Ignition switch OFF Time after key-off 5 or 7 or 9.5 hours EVAP pressure sensor malfunction (P0450, P0452, P0453) Not detected EVAP canister purge valve Not operated by scan tool EVAP canister vent valve Not operated by scan tool EVAP leak detection pump Not operated by scan tool Both of the following conditions 1 and 2 are set before key-off - 1. Duration that vehicle has been driven 5 minutes or more 2. EVAP purge operation Performed ECT 4.4 to 35°C (40 to 95°F) IAT 4.4 to 35°C (40 to 95°F) Key-off monitor sequence 1 to 8 1. Atmospheric pressure measurement Next sequence is run if the following condition is met - Atmospheric pressure change Less than 0.3 kPa (2.25 mmHg) in 1 second 2. First reference pressure measurement Next sequence is run if the following conditions are met Conditions 1, 2 and 3 1. EVAP pressure just after reference pressure measurement start -1 kPa (-7.5 mmHg) or less 2. Reference pressure -4.85 to -1.057 kPa (-36.384 to -7.929 mmHg) 3. Reference pressure Saturated 3. EVAP canister vent valve close stuck check Next sequence is run if the following condition is met - EVAP pressure change after vent valve is ON 0.3 kPa (2.25 mmHg) or more 4. Vacuum introduction Next sequence is run if the following condition is met - EVAP pressure Saturated within 15 minutes 5. EVAP canister purge valve close stuck check Next sequence is run if the following condition is met - EVAP pressure change after purge valve is open 0.3 kPa (2.25 mmHg) or more ES ES–384 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 6. Second reference pressure measurement Next sequence is run if the following conditions are met Conditions 1, 2, 3 and 4 1. EVAP pressure just after reference pressure -1 kPa (-7.5 mmHg) or less 2. Reference pressure -4.85 to -1.057 kPa (-36.384 to -7.929 mmHg) 3. Reference pressure Saturated 4. Difference between first reference pressure and second reference pressure Less than 0.7 kPa (5.25 mmHg) 7. Leak check Next sequence is run if the following condition is met - EVAP pressure when vacuum introduction is complete Lower than second reference pressure 8. Atmospheric pressure measurement ES EVAP monitor is complete if the following condition is met - Atmospheric pressure difference between sequence 1 and 8 Within 0.3 kPa (2.25 mmHg) TYPICAL MALFUNCTION THRESHOLDS EVAP pressure change after EVAP canister vent valve is ON Less than 0.3 kPa (2.25 mmHg) MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-25). ES–385 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2610 ECM / PCM Internal Engine Off Timer Performance DTC SUMMARY DTC No. Monitoring Item P2610 Soak timer (built into ECM) DTC Detection Condition ECM internal malfunction Trouble Area ECM Detection Timing Detection Logic Engine running 2 trip DESCRIPTION To ensure the accuracy of the EVAP (Evaporative Emission) monitor values, the soak timer, which is built into the ECM, measures 5 hours (+/- 15 minutes) from when the ignition switch is turned off, before the monitor is run. This allows the fuel to cool down, which stabilizes the Fuel Tank Pressure (FTP). When 5 hours have elapsed, the ECM turns on. Soak Timer Circuit (fig. 3): ECM IG2 IGN IGSW Soak Timer IC IG2 Ignition Switch ST/AM2 FL MAIN Main Body ECU IG2D EFI MAIN +B EFI Power Source IC EFI No. 2 MREL Main Relay Control IC Battery A136968E01 MONITOR DESCRIPTION 5 hours after the ignition switch is turned off, the soak timer activates the ECM to begin the EVAP system monitor. While the engine is running, the ECM monitors the synchronization of the soak timer and the CPU clock. If these two are not synchronized, the ECM interprets this as a malfunction, illuminates the MIL and sets the DTC (2 trip detection logic). MONITOR STRATEGY Required Sensors/Components ECM Frequency of Operation Once per driving cycle ES ES–386 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Duration 10 minutes MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS Case 1: Engine switch ON Engine Running Battery voltage 8 V or more Starter OFF Case 2: Internal engine OFF timer (elapsed time from engine stop) ES 10 to 300 minutes Battery voltage 8 V or more Engine switch ON Starter OFF Case 3: Internal engine OFF timer (elapsed time from engine stop) 310 minutes Battery voltage 8 V or more Engine switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Case 1: Soak timer measurement when ECM CPU clock counts 10 minutes Less than 7 minutes or more than 13 minutes Case 2: ECM had the started record by internal engine Yes Case 3: ECM had the started record by internal engine No INSPECTION PROCEDURE HINT: • DTC P2610 is set if an internal ECM problem is detected. In this case, diagnostic procedures are not required. ECM replacement is required. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). 1 REPLACE ECM (a) Replace the ECM (See page ES-518). NEXT 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2 ES–387 CHECK WHETHER DTC OUTPUT RECURS (a) (b) (c) (d) (e) (f) Connect the intelligent tester to the DLC3. Turn the engine switch on. Clear the DTCs (See page ES-45). Start the engine and wait for 10 minutes or more. On the tester, enter the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC / INFO / PENDING CODEs. If no pending DTC is displayed, the repair has been successfully completed. NEXT ES END ES–388 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2A00 A/F Sensor Circuit Slow Response (Bank 1 Sensor 1) DTC P2A03 A/F Sensor Circuit Slow Response (Bank 2 Sensor 1) DESCRIPTION ES HINT: • DTC P2A00 indicates malfunctions related to the bank 1 A/F sensor. • DTC P2A03 indicates malfunctions related to the bank 2 A/F sensor. • Bank 1 refers to the bank that includes cylinder No. 1. • Bank 2 refers to the bank that includes cylinder No. 2. • Sensor 1 refers to the sensor mounted in front of the Three-Way Catalytic Converter (TWC) and located near the engine assembly. • Although the DTC titles say oxygen sensor, these DTCs relate to the Air-Fuel Ratio (A/F) sensor. • Sensor 1 refers to the sensor mounted in front of the Three-Way Catalytic Converter (TWC) and located near the engine assembly. The A/F sensor generates voltage* that corresponds to the actual air-fuel ratio. This sensor voltage is used to provide the ECM with feedback so that it can control the air-fuel ratio. The ECM determines the deviation from the stoichiometric air-fuel ratio level, and regulates the fuel injection time. If the A/F sensor malfunctions, the ECM is unable to control the air-fuel ratio accurately. The A/F sensor is the planar type and is integrated with the heater, which heats the solid electrolyte (zirconia element). This heater is controlled by the ECM. When the intake air volume is low (the exhaust gas temperature is low), a current flows into the heater to heat the sensor, in order to facilitate accurate oxygen concentration detection. In addition, the sensor and heater portions are narrower than the conventional type. The heat generated by the heater is conducted to the solid electrolyte through the alumina, therefore the sensor activation is accelerated. A three-way catalytic converter (TWC) is used in order to convert the carbon monoxide (CO), hydrocarbon (HC), and nitrogen oxide (NOx) into less harmful substances. To allow the TWC to function effectively, it is necessary to keep the air-fuel ratio of the engine near the stoichiometric air-fuel ratio. *: Value changes inside the ECM. Since the A/F sensor is the current output element, a current is converted to a voltage inside the ECM. Any measurements taken at the A/F sensor or ECM connectors will show a constant voltage. ES–389 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Ideal Air-Fuel Mixture Output Voltage Heater Solid electrolyte (Zirconia Element) Element Platinum electrode Cover Air Exhaust Gas A A Rich - Air Fuel Ratio - Lean A-A Section A107164E13 DTC No. DTC Detection Conditions P2A00 P2A03 Calculated value for air-fuel ratio (A/F) sensor response rate deterioration level is less than threshold Trouble Area • • • Open or short in A/F sensor circuit A/F sensor ECM MONITOR DESCRIPTION After the engine is warmed up, the ECM performs air-fuel ratio feedback control to maintain the air-fuel ratio at the stoichiometric level. In addition, active A/F ratio control is performed for approximately 10 seconds after preconditions are met in order to measure the A/F sensor response rate. During active A/F ratio control, the ECM forcibly increases and decreases the injection volume by a certain amount, based on the stoichiometric air-fuel ratio learned during normal air-fuel ratio control, and measures the A/F sensor response rate. The ECM receives a signal from the A/F sensor while performing active A/F ratio control and uses it to calculate the A/F sensor response rate deterioration level. If the value for A/F sensor response rate deterioration level is less than the threshold, the ECM interprets this as a malfunction and sets the DTC. ES ES–390 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Approximately 10 seconds Air-fuel Ratio Sensor Output: OFF ON Active A/F Ratio Control Normal Malfunction A/F Sensor Output ES Increase Fuel Injection Volume Decrease G034991E09 CONFIRMATION DRIVING PATTERN HINT: Performing this confirmation pattern will activate the A/F sensor response monitor. Vehicle Speed Between 25 mph and 75 mph (40 km/h and 120 km/h) Idling (B) (A) Ignition Switch OFF Warming up 3 minutes Time A079199E49 Tester Display G034992E01 1. Connect an intelligent tester to the DLC3. 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–391 2. 3. 4. 5. Turn the ignition switch on (IG). Turn the tester on. Clear the DTCs (where set). Select the following menu items: DIAGNOSIS /ENHANCED OBD II / MONITOR INFO / MONITOR RESULT. 6. Check that RES RATE B1S1 is INCOMP. 7. Start the engine and warm it up (Procedure "A"). 8. Drive the vehicle at between 25 mph and 75 mph (40 km/h and 120 km/h) for 3 minutes. However, the vehicle should be driven at a constant speed (Procedure "B"). 9. Check the monitor result values on the intelligent tester by selecting the following menu items: DIAGNOSIS / ENHANCED OBD II / MONITOR INFO / TEST RESULT. 10.If the values indicated on the tester do not change, perform READINESS MONITOR DRIVE PATTERN for the A/F sensor and the heated oxygen sensor (See page ES-338). HINT: Completion of all A/F sensor monitors is required to change the value in TEST RESULT. 11.Note the value of the Monitor Result. 12.Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. 13.Check if any DTCs (any pending DTCs) are set. MONITOR STRATEGY Related DTCs P2A00: A/F sensor (Bank 1) slow response P2A03: A/F sensor (Bank 2) slow response Required Sensors/Components (Main) A/F sensor Required Sensors/Components (Related) Vehicle speed sensor, Crankshaft position sensor Frequency of Operation Once per driving cycle Duration 10 to 15 seconds MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present P0031, P0032, P0051, P0052 (A/F sensor heater - Sensor 1) P0100 - P0103 (MAF meter) P0110 - P0113 (IAT sensor) P0115 - P0118 (ECT sensor) P0120 - P0223, P2135 (TP sensor) P0125 (Insufficient ECT for Closed Loop) P0171, P0172, P0173, P0174 (Fuel system) P0300 - P0308 (Misfire) P0335 (CKP sensor) P0340, P0341 (CMP sensor) P0500 (VSS) P2196, P2198 (A/F sensor - rationality) Battery voltage 11 V or more ECT 75°C (167°F) or more Idle OFF Engine rpm Less than 4,000 rpm A/F sensor status Activated Fuel-cut OFF Engine load 10 to 70 % Shift position 2 or more Catalyst monitor Not yet MAF 2.5 to 15 g/sec. ES ES–392 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TYPICAL MALFUNCTION THRESHOLDS Response rate deterioration level Less than 0.18 V MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-25). WIRING DIAGRAM Refer to DTC P2195 (See page ES-350). INSPECTION PROCEDURE ES HINT: Intelligent tester only: Malfunctioning areas can be identified by performing the A/F CONTROL function provided in the ACTIVE TEST. The A/F CONTROL function can help to determine whether the Air-fuel Ratio (A/F) sensor, Heated Oxygen (HO2) sensor and other potential trouble areas are malfunctioning. The following instructions describe how to conduct the A/F CONTROL operation using the intelligent tester. 1. Connect the intelligent tester to the DLC3. 2. Start the engine and turn the tester on. 3. Warm up the engine at an engine speed of 2,500 rpm for approximately 90 seconds. 4. On the intelligent tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. 5. Perform the A/F CONTROL operation with the engine in an idling condition (press the RIGHT or LEFT button to change the fuel injection volume). 6. Monitor the output voltages of the A/F and HO2 sensors (AFS B1 S1 and O2S B1 S2 or AFS B2 S1 and O2S B2 S2) displayed on the tester. HINT: • The A/F CONTROL operation lowers the fuel injection volume by 12.5 % or increases the injection volume by 25 %. • Each sensor reacts in accordance with increases in the fuel injection volume. Tester Display (Sensor) Injection Volume Status Voltage AFS B1 S1 or AFS B2 S1 (A/F) +25 % Rich Less than 3.0 V AFS B1 S1 or AFS B2 S1 (A/F) -12.5 % Lean More than 3.35 V O2S B1 S2 or O2S B2 S2 (HO2) +25 % Rich More than 0.55 V O2S B1 S2 or O2S B2 S2 (HO2) -12.5 % Lean Less than 0.4 V NOTICE: The Air-Fuel Ratio (A/F) sensor has an output delay of a few seconds and the Heated Oxygen (HO2) sensor has a maximum output delay of approximately 20 seconds. Case 1 A/F Sensor (Sensor 1) Output Voltage HO2 Sensor (Sensor 2) Output Voltage Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage More than 3.35 V Less than 3.0 V Output Voltage More than 0.55 V Less than 0.4 V Main Suspected Trouble Area - ES–393 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Case 2 3 4 A/F Sensor (Sensor 1) Output Voltage HO2 Sensor (Sensor 2) Output Voltage Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage Almost no reaction Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage More than 3.35 V Less than 3.0 V Output Voltage Almost no reaction Injection volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage Almost no reaction Output Voltage Almost no reaction Main Suspected Trouble Area • • A/F sensor A/F sensor heater A/F sensor circuit • • • HO2 sensor HO2 sensor heater HO2 sensor circuit • • Fuel pressure Gas leakage from exhaust system (Air-fuel ratio extremely lean or rich) ES • Following the A/F CONTROL procedure enables technicians to check and graph the voltage outputs of both the A/F and HO2 sensors. • To display the graph, enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL / USER DATA / AFS B1 S1 and O2S B1 S2 or AFS B2 S1 and O2S B2 S2, and press the YES button and then the ENTER button followed by the F4 button. HINT: • DTC P2A00 or P2A03 may also be set, when the air-fuel ratio is stuck rich or lean. • A low A/F sensor voltage could be caused by a rich air-fuel mixture. Check for conditions that would cause the engine to run rich. • A high A/F sensor voltage could be caused by a lean air-fuel mixture. Check for conditions that would cause the engine to run lean. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P2A00 AND/OR P2A03) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the tester on. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read the DTCs. Result Display (DTC Output) Proceed to P2A00 and/or P2A03 A P2A00 and/or P2A03 and other DTCs B ES–394 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: If any DTCs other than P2A00 or P2A03 are output, troubleshoot those DTCs first. B GO TO DTC CHART (See page ES-63) A 2 INSPECT AIR FUEL RATIO SENSOR (HEATER RESISTANCE) (a) Disconnect the C15 or C35 A/F sensor connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance (Bank 1 sensor 1) Component Side: +B ES HA1A C15 Bank 1 Condition Specified Condition HA1A (1) - +B (2) 20°C (68°F) 1.8 to 3.4 Ω HA1A (1) - A1A- (4) - 10 kΩ or higher Standard resistance (Bank 2 sensor 1) A1AA1A+ A/F Sensor Front View +B HA2A Tester Connection Condition Specified Condition HA2A (1) - +B (2) 20°C (68°F) 1.8 to 3.4 Ω HA2A (1) - A2A- (4) - 10 kΩ or higher (c) Reconnect the A/F sensor connector. NG C35 Bank 2 A2AA2A+ A/F Sensor Front View A126269E12 OK Tester Connection REPLACE AIR FUEL RATIO SENSOR (See page EC-19) ES–395 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 3 CHECK HARNESS AND CONNECTOR (A/F SENSOR - ECM) Wire Harness Side: Air Fuel Ratio Sensor Connector (a) Disconnect the C15 and C35 A/F sensor connectors. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage C15 Bank 1 C35 Bank 2 C55 ECM Connector A1A+ A1A- A2A- A2A+ HA1A Tester Connection Specified Condition +B (C15-2) - Body ground 9 to 14 V +B (C35-2) - Body ground 9 to 14 V (d) Turn the ignition switch off. (e) Disconnect the C55 ECM connector. (f) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for open) HA2A A127715E14 Tester Connection Specified Condition HA1A (C15-1) - HA1A (C55-86) Below 1 Ω A1A+ (C15-3) - A1A+ (C55-93) Below 1 Ω A1A- (C15-4) - A1A- (C55-116) Below 1 Ω HA2A (C35-1) - HA2A (C55-109) Below 1 Ω A2A+ (C35-3) - A2A+ (C55-120) Below 1 Ω A2A- (C35-4) - A2A- (C55-119) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition HA1A (C15-1) or HA1A (C55-86) - Body ground 10 kΩ or higher A1A+ (C15-3) or A1A+ (C55-93) - Body ground 10 kΩ or higher A1A- (C15-4) or A1A- (C55-116) - Body ground 10 kΩ or higher HA1A (C35-1) or HA2A (C55-109) - Body ground 10 kΩ or higher A2A+ (C35-3) or A2A+ (C55-120) - Body ground 10 kΩ or higher A2A- (C35-4) or A2A- (C55-119) - Body ground 10 kΩ or higher (g) Reconnect the ECM connector. (h) Reconnect the A/F sensor connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 4 PERFORM CONFIRMATION DRIVING PATTERN NEXT 5 CHECK WHETHER DTC OUTPUT RECURS (DTC P2A00 AND/OR P2A03) (a) Read the DTCs using the intelligent tester. (b) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. ES ES–396 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Result Display (DTC Output) Proceed to P2A00 and/or P2A03 A No output B B REPLACE ECM (See page ES-518) A 6 REPLACE AIR FUEL RATIO SENSOR (a) Replace the air fuel ratio sensor (See page EC-19). ES NEXT 7 PERFORM CONFIRMATION DRIVING PATTERN NEXT 8 CHECK WHETHER DTC OUTPUT RECURS (DTC P2A00 AND/OR P2A03) (a) Read the DTCs using the intelligent tester. (b) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. Result Display (DTC Output) Proceed to No output A P2A00 and/or P2A03 B B A END REPLACE ECM (See page ES-518) ES–397 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC U0101 Lost Communication with TCM DESCRIPTION The Transmission Control Module (TCM) and ECM perform 2-way communications with each other via the Controller Area Network (CAN). The TCM sends signals to the ECM concerning required engine rpm, required engine torques, warning indicators in the combination meter, DTCs and other data. The ECM sends signals to the TCM concerning engine rpm, opening angles of the throttle valve, temperature of intake air, temperature of engine coolant, engine torques and other data. If the TCM cannot communicate with the ECM, the TCM will conclude that there is a malfunction in the CAN system, illuminate the MIL and set a DTC. DTC No. U0101 DTC Detection Condition No communication from TCM continues Trouble Area • • • Open or short in TCM and ECM circuit TCM ECM ES MONITOR STRATEGY Related DTCs U0101: Verify communication Required Sensors/Components (Main) ECM Required Sensors/Components (Sub) - Frequency of Operation Continuous Duration 1.25 seconds MIL Operation immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present None Battery Voltage 10.5 V or more (0.5 second or more) Engine switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Communication signal TCM Lost communication with TCM ECM 7 CAN- C56 1 C55 CAN- 6 CAN+ C56 2 C55 CAN+ A113695E02 ES–398 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE 1 CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC U0101) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the tester on. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read the DTCs. Result ES Display (DTC output) Proceed to U0101 A U0101 and other DTCs B B GO TO DTC CHART (See page ES-63) A 2 CHECK TCM TERMINAL VOLTAGE (+B AND E1 TERMINALS) (a) Disconnect the TCM connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage of the TCM connectors. Standard voltage Wire Harness Side: TCM Connector (Front View) C56 +B E1 C133210E08 Specified Condition 9 to 14 V (d) Turn the ignition switch off. (e) Measure the resistance of the TCM connector. Standard resistance NG OK Tester Connection C56-18 (+B) - C56-8 (E1) Tester Connection Specified Condition C56-8 (E1) - Body ground Below 1 Ω REPAIR OR REPLACE HARNESS OR CONNECTOR ES–399 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 3 CHECK HARNESS AND CONNECTOR (a) Disconnect the C56 TCM connector. (b) Disconnect the C55 ECM connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side: ECM Connector (Front View) CAN- CAN+ TCM Connector (Front View) CAN+ Tester Connection Specified Condition C56-6 (CAN+) - C55-2 (CAN+) Below 1 Ω C56-7 (CAN-) - C55-1 (CAN-) Below 1 Ω C56-6 (CAN+) or C55-2 (CAN+) - Body ground 1 MΩ or more C56-7 (CAN-) or C55-1 (CAN-) - Body ground 1 MΩ or more NG REPAIR OR REPLACE HARNESS OR CONNECTOR CANC133242E02 OK 4 REPLACE ECM (a) Replace the ECM (See page ES-518). NOTICE: Replace the ECM with a ECM from a normally functioning vehicle of the same model. NEXT 5 CHECK IF DTC RECURS (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Clear the DTC. Start the engine. Read the DTCs. Result Display (DTC Output) Proceed to U0101 A No DTC B B REPLACE ECM ES ES–400 A REPLACE TCM ES 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–401 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Active Control Engine Mount System DESCRIPTION LOCATION Hose B ES Hose A Vacuum Switching Valve Engine Mounting Insulator Engine Room R/B: EFI No. 3 Fuse A136282E01 The Active Control Engine Mount (ACM) system decreases engine vibration at a low engine speed using the ACM VSV. The VSV is controlled by a pulse signal transmitted to the VSV from the ECM. The frequency of this pulse signal is matched to the engine speed to decrease engine vibration. ES–402 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM EFI EFI No. 3 C34 ACM VSV 42 C55 ACM 24 A55 MREL EFI MAIN FL MAIN ES Battery A137040E01 INSPECTION PROCEDURE 1 CHECK VACUUM HOSES Intake Air Control Valve Actuator Vacuum Tank NG Air Cleaner ECM Engine B A VSV Engine Mounting Insulator A138733E01 OK (a) If the hose is damaged, replace the vacuum hose assembly. (b) Check the air and vacuum hoses for looseness, disconnection and blockage. REPAIR OR REPLACE VACUUM HOSES 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2 ES–403 CHECK VACUUM (a) Start the engine. (b) Disconnect the vacuum hose from the air cleaner cap. (c) Check that the disconnected port located on the vacuum tank applies suction to your finger. OK: Vacuum pressure exists. (d) Reconnect the vacuum hose. NG G041079 CHECK AND REPLACE VACUUM SOURCE AND HOSES ES OK 3 INSPECT DUTY VACUUM SWITCHING VALVE (OPERATION) (a) Remove the VSV for ACM. (b) Check operation of the VSV for ACM when positive battery voltage is applied to the terminals of the VSV for ACM connector. Positive battery voltage is not applied: The air from pipe G is flowing out through pipes E and H. Positive battery voltage is applied: The air from pipe F is flowing out through pipes E and H. (c) Reinstall the VSV for ACM. G E F H G E NG F H REPLACE DUTY VACUUM SWITCHING VALVE A052014E04 OK 4 INSPECT DUTY VACUUM SWITCHING VALVE (RESISTANCE) (a) Disconnect the C34 VSV for ACM connector. (b) Measure the resistance between terminals 1 and 2. Standard resistance: 19 to 21 Ω at 20°C (68°F) (c) Reconnect the VSV for ACM connector. Component Side: C34 2 NG 1 C058536E23 OK REPLACE DUTY VACUUM SWITCHING VALVE ES–404 5 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT ENGINE MOUNTING INSULATOR ASSEMBLY FRONT A051989 ES (a) Disconnect the vacuum hose from the front engine mount insulator. (b) Using a vacuum pump, apply vacuum of 80 kPa (600 mmHg, 25 in.Hg) and wait for 1 minute. (c) Check that there is no change in the needle movement of the vacuum pump gauge. (d) Check that there is no fluid leakage caused by a break in the diaphragm. OK: Vacuum pressure exists. (e) Reconnect the vacuum hose. NG REPLACE FRONT ENGINE MOUNTING INSULATOR ASSEMBLY OK 6 CHECK HARNESS AND CONNECTOR (VSV FOR ACM - ECM) (a) Check the wire harness between the VSV for ACM connector and the ECM connector. (1) Disconnect the C34 VSV for ACM connector. (2) Disconnect the C55 ECM connector. (3) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side: VSV for ACM Connector C34 1 2 Tester Connections Specified Conditions VSV for ACM (C34-2) - ACM (C55-42) Below 1 Ω Standard resistance (Check for open) Front View C55 ECM Connector Tester Connections Specified Conditions VSV for ACM (C34-2) or ACM (C55-42) - Body ground 10 kΩ or higher (4) Reconnect the ECM connector. (5) Reconnect the VSV connector. NG ACM A135959E01 OK REPAIR OR REPLACE HARNESS OR CONNECTOR ES–405 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 7 INSPECT DUTY VACUUM SWITCHING VALVE (VOLTAGE) (a) Disconnect the C34 VSV connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage between the terminals. Standard voltage Wire Harness Side: C34 1 2 VSV for ACM Connector NG Tester Connection Specified Condition C34-1 - Body ground 9 to 14 V Go to step 8 A135958E01 OK REPLACE ECM (See page ES-518) ES ES–406 8 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (VSV FOR ACM - ENGINE JUNCTION BLOCK (EFI RELAY)) (a) Check the wire harness between the VSV for ACM and the EFI relay. (1) Disconnect the C34 VSV connector. (2) Remove the engine room junction block. (3) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side: VSV for ACM Connector C34 1 2 Tester Connections Specified Condition VSV for ACM (C34-1) - 1E-6 (Engine room relay block) Below 1 Ω ES Standard resistance (Check for short) Tester Connections Specified Condition VSV for ACM (C34-1) or 1E-6 (Engine room relay block) - Body ground 10 kΩ or higher (4) Reconnect the VSV for ACM connector. (5) Reinstall the engine room junction block. Engine Room Junction Block NG 1E Engine Room Rleay Block A140658E01 OK REPAIR OR REPLACE HARNESS OR CONNECTOR 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 9 ES–407 INSPECT ENGINE ROOM JUNCTION BLOCK (EFI RELAY) (a) Remove the engine room junction block. (b) Measure the EFI relay resistance. Standard resistance Engine Room Junction Block Tester Connection Specified Condition 1E-12 - 1E-6 10 kΩ or higher 1E-12 - 1E-6 Bellow 1 Ω (Apply battery voltage between terminals 1E9 and 1E-10) (c) Reinstall the engine room junction block. NG 1E Engine Room Relay Block A140654E02 OK REPLACE ECM (See page ES-518) REPLACE ENGINE ROOM JUNCTION BLOCK ES ES–408 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM EVAP System RELATED DTCS DTCs ES Monitoring Items P043E Reference orifice clogged (built into canister pump module) P043F Reference orifice high-flow (built into canister pump module) P0441 • • • P0450 Canister pressure sensor (built into canister pump module) voltage abnormal fluctuation P0451 • • P0452 Canister pressure sensor (built into canister pump module) voltage low P0453 Canister pressure sensor (built into canister pump module) voltage high P0455 EVAP gross leak P0456 EVAP small leak Purge VSV (Vacuum Switching Valve) stuck closed Purge VSV stuck open Purge flow Canister pressure sensor (built into canister pump module) noise Canister pressure sensor (built into canister pump module) signal becomes fixed/flat P2401 Leak detection pump stuck OFF (built into canister pump module) P2402 Leak detection pump stuck ON (built into canister pump module) See page ES-255 ES-260 ES-267 ES-274 ES-255 P2419 Vent valve stuck closed (built into canister pump module) ES-255 P2420 Vent valve stuck open (vent) (built into canister pump module) ES-373 P2610 Soak timer (built into ECM) ES-377 If any EVAP system DTCs are set, the malfunctioning area can be determined using the table below. 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTCs Malfunctioning Areas ES–409 P2401 P043E P0441 P0450 P0451 P0452 P0453 P0455 P0456 P2419 P2420 P2402 P043F Reference orifice clogged Reference orifice high-flow Purge VSV stuck open Purge VSV stuck closed Canister pressure sensor fixed output Canister pressure sensor noise ES Canister pressure sensor low output Canister pressure sensor high output Gross leak Small leak Leak detection pump stuck OFF Leak detection pump stuck ON Vent valve stuck closed Vent valve stuck open (vent) A106731E11 NOTICE: If the reference pressure difference between the first and second checks is greater than the specification, all the DTCs relating to the reference pressure (P043E, P043F, P2401, P2402 and P2419) are stored. ES–410 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DESCRIPTION Location of EVAP (Evaporative Emission) System: EVAP Hose (To Throttle Body) Purge VSV (Vacuum Switching Valve) Fuel Tank ES Refueling Valve Air Inlet Port Pump Module Canister Air Filter To Purge VSV EVAP Hose (From Canister) Fuel Tank Cap Recirculation Pipe A134243E03 EVAP System Circuit: Throttle Valve Air Cleaner Intake Manifold ECM Soak Timer Canister Pump Module Purge VSV Air Filter Canister Fuel Cap Refueling Valve Restrictor (0.08 inch) Cut-off Valve Roll-Over Valve Fuel Tank A122570E03 NOTICE: In this vehicle's EVAP system, turning ON the vent valve does not seal off the EVAP system. To check for leaks in the EVAP system, disconnect the air inlet vent hose and apply pressure from the atmospheric side of the canister. While the engine is running, if a predetermined condition (closed-loop, etc.) is met, the purge VSV is opened by the ECM and fuel vapors stored in the canister are purged into the intake manifold. The ECM changes the duty cycle ratio of the purge VSV to control purge flow volume. The purge flow volume is also determined by the intake manifold pressure. Atmospheric pressure is allowed into the canister through the vent valve to ensure that the purge flow is maintained when negative pressure (vacuum) is applied to the canister. ES–411 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM The following two monitors run to confirm the appropriate EVAP system operation. 1. Key-off monitor This monitor checks for EVAP (Evaporative Emission) system leaks and canister pump module malfunctions. The monitor starts 5 hours* after the ignition switch is turned off. At least 5 hours are required for the fuel to cool down to stabilize the EVAP pressure, thus making the EVAP system monitor more accurate. The leak detection pump creates negative pressure (vacuum) in the EVAP system and the pressure is measured. Finally, the ECM monitors for leaks from the EVAP system, and malfunctions in both the canister pump module and purge VSV, based on the EVAP pressure. HINT: *: If the engine coolant temperature is not below 35°C (95°F) 5 hours after the ignition switch is turned off, the monitor check starts 2 hours later. If it is still not below 35°C (95°F) 7 hours after the ignition switch is turned off, the monitor check starts 2.5 hours later. 2. Purge flow monitor The purge flow monitor consists of the two monitors. The 1st monitor is conducted every time and the 2nd monitor is activated if necessary. • The 1st monitor While the engine is running and the purge VSV (Vacuum Switching Valve) is ON (open), the ECM monitors the purge flow by measuring the EVAP pressure change. If negative pressure is not created, the ECM begins the 2nd monitor. • The 2nd monitor The vent valve is turned OFF (open) and the EVAP pressure is measured. If the variation in the pressure is less than 0.5 kPa-g (3.75 mmHg-g), the ECM interprets this as the purge VSV being stuck closed, and illuminates the MIL and sets DTC P0441 (2 trip detection logic). Atmospheric pressure check: In order to ensure reliable malfunction detection, the variation between the atmospheric pressures, before and after conduction of the purge flow monitor, is measured by the ECM. EVAP Purge Flow: Reference Orifice (0.02 inch) Fuel Cap Refueling Valve Canister Pressure Sensor To Atmosphere Purge VSV (ON) Fuel Tank Canister To Intake Manifold ECM Air Filter Vent Valve (OFF) Leak Detection Pump (OFF) Soak Timer Canister Pump Module A122571E06 ES ES–412 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Components ES Operations Canister Contains activated charcoal to absorb EVAP (Evaporative Emissions) generated in fuel tank. Cut-off valve Located in fuel tank. Valve floats and closes when fuel tank 100 % full. Purge VSV (Vacuum Switching Valve) Opens or closes line between canister and intake manifold. ECM uses purge VSV to control EVAP purge flow. In order to discharge EVAP absorbed by canister to intake manifold, ECM opens purge VSV. EVAP discharge volume to intake manifold controlled by purge VSV duty cycle ratio (current-carrying time) (Open: ON; Closed: OFF). Refueling valve Controls EVAP pressure from fuel tank to canister. Valve consists of diaphragm, spring and restrictor (diameter: 0.08 inch). When fuel vapor and pressure inside fuel tank increase, valve opens. While EVAP purged, valve closes and restrictor prevents large amount of vacuum from affecting pressure in fuel tank. Valve opened while refueling. Roll-over valve Located in fuel tank. Valve closed by its own weight when vehicle overturns to prevent fuel from spilling out. Soak timer Built into ECM. To ensure accurate EVAP monitor, measures 5 hours (+-15 min) after ignition switch turned off. This allows fuel to cool down, stabilizing EVAP pressure. When approximately 5 hours elapsed, ECM in activated (refer to fig. 3). Canister pump module Consists of (a) to (d) below. Canister pump module cannot be disassembled. (a) Vent valve Vents and closes EVAP system. When ECM turns valve ON, EVAP system closed. When ECM turns valve off, EVAP system vented. Negative pressure (vacuum) created in EVAP system to check for EVAP leaks by closing purge VSV, turning on vent valve (closed) and operating leak detection pump (refer to fig. 1). (b) Canister pressure sensor Indicates pressure as voltages. ECM supplies regulated 5 V to canister pressure sensor, and uses feedback from sensor to monitor EVAP system pressure (refer to fig. 2). (c) Leak detection pump Creates negative pressure (vacuum) in EVAP system for leak check. (d) Reference orifice Has opening with 0.02 inch diameter. Vacuum produced through orifice by closing purge VSV, turning off vent valve and operating leak detection pump, to monitor reference pressure. Reference pressure indicates small leak of EVAP. : Airflow Canister Pump Module (fig. 1): Condition: Purge Flow Vent Valve: OFF (vent) Condition: Leak Check To Canister Filter (Atmosphere) Canister Reference Orifice (0.02 Inch) Canister Pressure Sensor From Refueling Valve Leak Detection Pump: OFF Vent Valve: ON (closed) Leak Detection Pump: ON A115902E02 ES–413 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Canister Pressure Sensor Specification (fig. 2): Malfunction Area Output Voltage 4.900 V 4.150 V Usable Range ES 1.425 V Malfunction Area 0.450 V 60 (450) 110 (825) Pressure kPa-a (mmHg-a) HINT: Standard atmospheric pressure is 101.3 kPa-a (760 mmHg-a) A115543E06 Soak Timer Circuit (fig. 3): ECM IG2 IGN IGSW Soak Timer IC IG2 Ignition Switch ST/AM2 FL MAIN Main Body ECU IG2D EFI MAIN EFI +B Power Source IC EFI No. 2 MREL Main Relay Control IC Battery A136968E01 ES–414 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM N17 Pump Module ECM Leak Detection Pump MGND 6 34 A55 MPMP MTRB M 8 ES VCC Canister Pressure Sensor 75 VCPP C55 4 77 PPNP C55 VOUT 3 76 EPPM C55 SGND 2 Vent Valve VLVB 42 A55 VPMP VGND 9 1 EFI No. 2 C6 Purge VSV EFI No. 3 1 FL MAIN EFI MAIN 2 108 C55 PRG EFI 44 MREL A55 Battery A136971E01 INSPECTION PROCEDURE NOTICE: The intelligent tester is required to conduct the following diagnostic troubleshooting procedure. HINT: • Using intelligent tester monitor results enables the EVAP (Evaporative Emission) system to be confirmed. 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–415 • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45). 1 CONFIRM DTC (a) (b) (c) (d) (e) (f) Turn the ignition switch off and wait for 10 seconds. Turn the ignition switch on (IG). Turn the ignition switch off and wait for 10 seconds. Connect an intelligent tester to the DLC3. Turn the ignition switch on (IG) and turn the tester ON. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (g) Confirm DTCs and freeze frame data. If any EVAP system DTCs are set, the malfunctioning area can be determined using the table below. NOTICE: If the reference pressure difference between the first and second checks is greater than the specification, all the DTCs relating to the reference pressure (P043E, P043F, P2401, P2402 and P2419) are stored. ES ES–416 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTCs Malfunctioning Areas P2401 P043E P0441 P0450 P0451 P0452 P0453 P0455 P0456 P2419 P2420 P2402 P043F Reference orifice clogged Reference orifice high-flow Purge VSV stuck open Purge VSV stuck closed ES Canister pressure sensor fixed output Canister pressure sensor noise Canister pressure sensor low output Canister pressure sensor high output Gross leak Small leak Leak detection pump stuck OFF Leak detection pump stuck ON Vent valve stuck closed Vent valve stuck open (vent) A106731E11 NEXT 2 PERFORM EVAP SYSTEM CHECK (AUTO OPERATION) NOTICE: • The EVAP SYSTEM CHECK (AUTO OPERATION) consists of 5 steps performed automatically by the intelligent tester. It takes a maximum of approximately 18 minutes. • Do not perform the EVAP SYSTEM CHECK when the fuel tank is more than 90% full because the cut-off valve may be closed, making the fuel tank leak check unavailable. • Do not run the engine during this operation. • When the temperature of the fuel is 35°C (95°F) or more, a large amount of vapor forms and any check results become inaccurate. When performing the EVAP SYSTEM CHECK, keep the temperature below 35°C (95°F). (a) Clear the DTCs (See page ES-45). ES–417 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (b) On the tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION. (c) After the EVAP SYSTEM CHECK is completed, check for pending DTCs by selecting the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. HINT: If no pending DTCs are displayed, perform the MONITOR CONFIRMATION (see "Diagnostic Help" menu). After this confirmation, check for pending DTCs. If no DTCs are displayed, the EVAP system is normal. NEXT 3 ES PERFORM EVAP SYSTEM CHECK (MANUAL OPERATION) EVAP SYSTEM CHECK ON: Open ON Purge VSV Vent Valve OFF: Closed ON: Closed ON OFF: Vent Leak Dtection Pump ON EVAP Pressure Gross Leak Positive Negative Small Leak First Reference Pressure [Second Reference Pressure] x 0.2 Normal Pressure Steps Time (Reference) 1/5 2/5 10 seconds 60 seconds 3/5 No Leak Within 15 minutes 4/5 5/5 60 10 seconds seconds A106735E14 NOTICE: • In the EVAP SYSTEM CHECK (MANUAL OPERATION), perform the series of 5 EVAP SYSTEM CHECK steps manually using the intelligent tester. • Do not perform the EVAP SYSTEM CHECK when the fuel tank is more than 90% full because the cut-off valve may be closed, making the fuel tank leak check unavailable. • Do not run the engine during this operation. ES–418 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM • When the temperature of the fuel is 35°C (95°F) or more, a large amount of vapor forms and any check results become inaccurate. When performing the EVAP SYSTEM CHECK, keep the temperature below 35°C (95°F). (a) Clear the DTCs (See page ES-45). (b) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / MANUAL OPERATION. NEXT 4 PERFORM EVAP SYSTEM CHECK (STEP 1/5) ES ON Purge VSV ON: Open OFF: Closed Vent Valve ON: Closed ON OFF: Vent Leak Detection Pump ON Canister Pressure Sensor Noise EVAP Pressure Positive Negative OK First Reference Pressure Steps Time 1/5 10 seconds (Reference) A106736E08 (a) Check the EVAP pressure in step 1/5. Result DTCs* P0451 Test Results Suspected Trouble Areas Proceed to Virtually no variation in EVAP pressure Not yet determined A EVAP pressure fluctuates by +-0.3 kPa-g (2.25 mmHg-g) or more Canister pressure sensor noise B *: These DTCs are already present in the ECM when the vehicle arrives and are confirmed in the "CONFIRM DTC" procedures above. B Go to step 29 ES–419 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM A 5 PERFORM EVAP SYSTEM CHECK (STEP 1/5 TO 2/5) ON Purge VSV ON: Open OFF: Closed ON: Closed Vent Valve ON Leak Detection Pump OFF: Vent ON ES EVAP Pressure Positive Negative Leak Detection Pump Stuck ON First Reference Pressure Steps Time (Reference) 1/5 2/5 10 seconds 60 seconds A106737E08 (a) Check the EVAP pressure in steps 1/5 and 2/5. Result DTCs* Test Results - Virtually no variation in EVAP pressure during step 1/5. Then decreases to reference pressure Not yet determined A Small difference between EVAP pressures during steps 1/5 and 2/5 Leak detection pump stuck ON B P2402 Suspected Trouble Areas Proceed to *: These DTCs are already present in the ECM when the vehicle arrives and are confirmed in the "CONFIRM DTC" procedures above. HINT: The first reference pressure is the value determined in step 2/5. B A Go to step 22 ES–420 6 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PERFORM EVAP SYSTEM CHECK (STEP 2/5) ON Purge VSV OFF: Closed OFF: Vent Leak Detection Pump EVAP Pressure Positive ON: Closed ON Vent Valve ES ON: Open ON Leak Detection Pump Stuck OFF Reference Orifice High-flow 4 seconds Negative Vent Valve Stuck Closed First Reference Pressure Standard OK Reference Orifice Clogged Steps Time (Reference) 3/5 2/5 Within 15 minutes 60 seconds A106738E05 HINT: Make a note of the pressures checked in steps "A" and "B" below. (a) Check the EVAP pressure 4 seconds after the leak detection pump is activated* (Step "A"). *: The leak detection pump begins to operate as step 1/5 finishes and step 2/5 starts. (b) Check the EVAP pressure again when it has stabilized. This pressure is the reference pressure (Step "B"). Result DTCs* Test Results - EVAP pressure in step (b) between -4.85 kPa-g and -1.057 kPa-g (-36.4 mmHg-g and -7.93 mmHg-g) Suspected Trouble Areas Not yet determined A P043F and P2401 EVAP pressure in step (b) -1.057 kPa-g (-7.93 mmHg-g) or more • • B P043E EVAP pressure in step (b) below -4.85 kPa-g (36.4 mmHg-g) Reference orifice clogged C P2419 EVAP pressure in step (a) more than -1.057 kPa-g (-7.93 mmHg-g) Vent valve stuck closed D Reference orifice high-flow Leak detection pump stuck OFF Proceed to *: These DTCs are already present in the ECM when the vehicle arrives and are confirmed in the "CONFIRM DTC" procedures above. ES–421 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM B Go to step 11 C Go to step 29 D Go to step 20 A 7 PERFORM EVAP SYSTEM CHECK (STEP 2/5 TO 3/5) ON Purge VSV Vent Valve ON Leak Detection Pump ON ON: Open OFF: Closed ON: Closed OFF: Vent EVAP Pressure Positive Negative Vent Valve Stuck Open (vent) First Reference Pressure Steps Time 2/5 3/5 Within 15 minutes (Reference) A106739E05 (a) Check the EVAP pressure increase in step 3/5. Result DTCs* Test Results Suspected Trouble Areas Proceed to EVAP pressure increases by 0.3 kPa-g (2.25 mmHg-g) or more within 10 seconds of proceeding from step 2/5 to step 3/5 Not yet determined A P2420 No variation in EVAP pressure despite proceeding from step 2/5 to step 3/5 Vent valve stuck open (vent) B P0451 No variation in EVAP pressure during steps 1/ 5 through 3/5 Canister pressure sensor malfunction fixed C - *: These DTCs are already present in the ECM when the vehicle arrives and are confirmed in the "CONFIRM DTC" procedures above. B Go to step 19 ES ES–422 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM C Go to step 29 A 8 PERFORM EVAP SYSTEM CHECK (STEP 3/5) ON Purge VSV ES Vent Valve Leak Detection Pump ON ON: Open OFF: Closed ON: Closed OFF: Vent ON EVAP Pressure Positive Negative First Reference Pressure Steps Time (Reference) 3/5 Within 15 minutes A106740E05 (a) Wait until the EVAP pressure change is less than 0.1 kPa-g (0.75 mmHg-g) for 30 seconds. (b) Measure the EVAP pressure and record it. HINT: A few minutes are required for the EVAP pressure to become saturated. When there is little fuel in the fuel tank, it takes up to 15 minutes. NEXT 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 9 ES–423 PERFORM EVAP SYSTEM CHECK (STEP 4/5) ON Purge VSV ON: Open OFF: Closed ON: Closed ON Vent Valve OFF: Vent Leak Detection Pump ON EVAP Pressure ES OK Positive Negative Purge VSV Stuck Closed First Reference Pressure Steps 4/5 Time 10 seconds (Reference) A106741E05 (a) Check the EVAP pressure in step 4/5. Result DTCs* Test Results Suspected Trouble Areas Proceed to - EVAP pressure increases by 0.3 kPa-g (2.25 mmHg-g) or more within 10 seconds of proceeding from step 3/5 to step 4/5 Not yet determined A P0441 EVAP pressure increases by 0.3 kPa-g (2.25 mmHg-g) or more within 10 seconds of proceeding from step 3/5 to step 4/5 Problems in EVAP hose between purge VSV and intake manifold B P0441 Variation in EVAP pressure less than 0.3 kPa-g (2.25 mmHg-g) for 10 seconds, after proceeding from step 3/5 to step 4/5 Purge VSV stuck closed C *: These DTCs are already present in the ECM when the vehicle arrives and are confirmed in the "CONFIRM DTC" procedures above. A B Go to step 15 C Go to step 12 ES–424 10 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PERFORM EVAP SYSTEM CHECK (STEP 5/5) ON Purge VSV Vent Valve OFF: Closed ON: Closed ON OFF: Vent Leak Detection Pump ES ON: Open ON EVAP Pressure Gross Leak Positive Negative Small Leak [Second Reference Pressure] x 0.2 No Leak [Second Reference Pressure] First Reference Pressure Steps 5/5 Time 60 seconds (Reference) A106735E15 (a) Check the EVAP pressure in step 5/5. (b) Compare the EVAP pressure in step 3/5 and the second reference pressure (step 5/5). Result DTCs* Test Results Suspected Trouble Areas Proceed to EVAP pressure (step 3/5) lower than second reference pressure (step 5/5) Not yet determined (no leakage from EVAP system) A P0441 and P0455 EVAP pressure (step 3/5) higher than [second reference pressure (step 5/5) x 0.2] • • B P0456 EVAP pressure (step 3/5) higher than second reference pressure (step 5/5) EVAP small leak - Purge VSV stuck open EVAP gross leak B *: These DTCs are already present in the ECM when the vehicle arrives and are confirmed in the "CONFIRM DTC" procedures above. A Go to step 35 B Go to step 12 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 11 ES–425 PERFORM EVAP SYSTEM CHECK (STEP 3/5) ON Purge VSV Vent Valve OFF: Closed ON: Closed ON Leak Detection Pump ON: Open OFF: Vent ON Leak Detection Pump Stuck OFF EVAP Pressure ES Positive Negative Reference Orifice High-flow First Reference Pressure Steps Time 2/5 3/5 Within 15 minutes (Reference) A106742E04 (a) Check the EVAP pressure in step 3/5. Result DTCs* Test Results P043F EVAP pressure less than [reference pressure] measured at 2/5 Suspected Trouble Areas Proceed to Reference orifice high-flow A P2401 EVAP pressure almost same as [reference pressure] measured at 2/5 Leak detection pump stuck OFF B *: These DTCs are already present in the ECM when the vehicle arrives and are confirmed in the "CONFIRM DTC" procedures above. HINT: The first reference pressure is the value determined in step 2/5. A Go to step 29 B Go to step 22 ES–426 12 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PERFORM ACTIVE TEST USING INTELLIGENT TESTER (PURGE VSV) Purge VSV Hose (to Canister) A136279E01 ES (a) On the intelligent tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / EVAP VSV (ALONE). (b) Disconnect the hose (connected to the canister) from the purge VSV. (c) Start the engine. (d) Using the tester, turn off the purge VSV (EVAP VSV: OFF). (e) Use your finger to confirm that the purge VSV has no suction. (f) Using the tester, turn on the purge VSV (EVAP VSV: ON). (g) Use your finger to confirm that the purge VSV has suction. Result Test Results Suspected Trouble Areas Proceed to No suction when purge VSV turned OFF, and suction applied when turned ON Purge VSV normal A Suction applied when purge VSV turned OFF Purge VSV stuck open B No suction when purge VSV turned ON • • C Purge VSV stuck closed Problems with EVAP hose between purge VSV and intake manifold (h) Reconnect the hose. B Go to step 14 C Go to step 15 A 13 CHECK FUEL CAP ASSEMBLY (a) Check that the fuel cap is correctly installed and confirm the fuel cap meets OEM specifications. (b) Tighten the fuel cap until a few click sounds are heard. HINT: If an EVAP tester is available, check the fuel cap using the tester. 1. Remove the fuel cap and install it onto a fuel cap adapter. 2. Connect an EVAP tester pump hose to the adapter, and pressurize the cap to 3.2 to 3.7 kPa (24 to 28 mmHg) using an EVAP tester pump. 3. Seal the adapter and wait for 2 minutes. 4. Check the pressure. If the pressure is 2 kPa (15 mmHg) or more, the fuel cap is normal. Result Test Results Fuel cap correctly installed Suspected Trouble Areas Proceed to - A 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Test Results Suspected Trouble Areas • • • Fuel cap loose Fuel cap improperly installed Defective fuel cap Fuel cap does not meet OEM specifications ES–427 Proceed to B Defective fuel cap - B No fuel cap - C (c) Reinstall the fuel cap. 14 A Go to step 28 B Go to step 26 C Go to step 27 ES INSPECT DUTY VACUUM SWITCHING VALVE (PURGE VSV) Hose (to Canister) (a) Turn the ignition switch off. (b) Disconnect the C6 purge VSV connector. (c) Disconnect the hose (connected to the canister) from the purge VSV. (d) Start the engine. (e) Use your finger to confirm that the purge VSV has no suction. Purge VSV A136280E01 Result Test Results Suspected Trouble Areas Proceed to No suction ECM A Suction applied Purge VSV B (f) Reconnect the purge VSV connector. (g) Reconnect the hose. 15 A Go to step 34 B Go to step 30 CHECK EVAP HOSE (PURGE VSV - INTAKE MANIFOLD) (a) Disconnect the hose (connected to the intake manifold) from the purge VSV. (b) Start the engine. (c) Use your finger to confirm that the hose has suction. Hose (to Intake Manifold) Purge VSV A136281E01 ES–428 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Result Test Results Suspected Trouble Areas Proceed to Suction applied EVAP hose between purge VSV and intake manifold normal A No suction • • B Intake manifold port EVAP hose between purge VSV and intake manifold (d) Reconnect the hose. B Go to step 25 A 16 INSPECT DUTY VACUUM SWITCHING VALVE (PURGE VSV) ES Purge VSV A (a) Remove the purge VSV. (b) Apply the battery voltage to the terminals of the purge VSV. (c) Using an air gun, confirm that air flows from port A to port B. B A112597E01 Result Test Results Suspected Trouble Areas Proceed to Air flows Purge VSV normal A No air flow Purge VSV B (d) Install the purge VSV. B Go to step 30 A 17 CHECK HARNESS AND CONNECTOR (POWER SOURCE OF PURGE VSV) (a) Disconnect the C6 purge VSV connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage between terminal 2 of the purge VSV connector and body ground. Wire Harness Side: Front View C6 Purge VSV Connector A052933E29 Result Test Results Suspected Trouble Areas Proceed to 9 to 14 V Normal A Other than result above Wire harness or connectors between purge VSV and ECM B 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–429 (d) Reconnect the purge VSV connector. B Go to step 31 A 18 CHECK HARNESS AND CONNECTOR (PURGE VSV - ECM) (a) Disconnect the C55 ECM connector and the C6 purge VSV connector. (b) Measure the resistance. Standard resistance Wire Harness Side: C55 ECM Connector Front View Tester Connections Specified Conditions C55-108 (PRG) - C6-2 (Purge VSV) Below 1 Ω C55-108 (PRG) - Body ground 10 kΩ or higher C6-2 (Purge VSV) - Body ground 10 kΩ or higher (c) Reconnect the purge VSV connector. (d) Reconnect the ECM connector. PRG Purge VSV Connector C6 Front View A112616E06 OK Go to step 34 NG Go to step 31 ES ES–430 19 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT CANISTER PUMP MODULE (POWER SOURCE FOR VENT VALVE) (a) (b) (c) (d) Turn the ignition switch off. Disconnect the N17 canister pump module connector. Turn the ignition switch on (IG). Measure the voltage between the VLVB terminal of the canister pump module connector and body ground. N17 ES Wire Harness Side: Canister Pump Module Connector 1 2 3 4 5 N17 6 7 8 9 10 VLVB A136176E02 Result Test Results Suspected Trouble Areas Proceed to 9 to 14 V 1. Wire harness between vent valve and ECM 2. Vent valve 3. ECM A Below 3 V Power source wire harness of vent valve B (e) Reconnect the canister pump module connector. B A Go to step 31 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 20 ES–431 INSPECT CANISTER PUMP MODULE (VENT VALVE OPERATION) Charcoal Canister Assembly: VGND (-) VLVB (+) (a) Turn the ignition switch off. (b) Disconnect the N17 canister pump module connector. (c) Apply battery voltage to the VLVB and VGND terminals of the canister pump module. (d) Touch the canister pump module to confirm the vent valve operation. A112598E01 Result Test Results Suspected Trouble Areas Proceed to Operating 1. Wire harness between vent valve and ECM 2. ECM A Not operating Vent valve B (e) Reconnect the canister connector. B Go to step 29 A 21 CHECK HARNESS AND CONNECTOR (ECM - CANISTER PUMP MODULE) (a) Disconnect the A55 ECM connector. (b) Disconnect the N17 canister pump module connector. (c) Measure the resistance between the VPMP terminal of the ECM connector and the VGND terminal of the canister pump module connector. Wire Harness Side: A55 ECM Connector VPMP Front View Canister Pump Module Connector N17 1 2 3 4 5 6 7 8 9 10 VGND Front View A112621E15 Result Test Results Suspected Trouble Areas Proceed to Below 1 Ω ECM A 10 kΩ or higher Wire harness between ECM and canister pump module B ES ES–432 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (d) Reconnect the ECM connector. (e) Reconnect the canister pump module connector. 22 A Go to step 34 B Go to step 31 PERFORM ACTIVE TEST USING INTELLIGENT TESTER (VACUUM PUMP (ALONE)) (a) (b) (c) (d) Turn the ignition switch off. Disconnect the N17 canister pump module connector. Turn the ignition switch on (IG). On the intelligent tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VACUUM PUMP. (e) Measure the voltage between MTRB terminal 1 of the canister pump module connector and body ground when the leak detection pump is turned ON and OFF using the tester. ES N17 Wire Harness Side: Canister Pump Module Connector N17 1 2 3 4 5 6 7 8 9 10 MTRB A136176E03 Result Test Results Suspected Trouble Areas Proceed to Below 3 V when OFF 9 to 14 V when ON 1. Wire harness between leak detection pump and body ground 2. Leak detection pump A Below 3 V when OFF and ON 1. Wire harness between leak detection pump and ECM 2. ECM B B A Go to step 24 ES–433 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 23 CHECK HARNESS AND CONNECTOR (CANISTER PUMP MODULE - BODY GROUND) (a) Turn the ignition switch off. (b) Disconnect the N17 canister pump module connector. (c) Measure the resistance between the MGND terminal of the canister pump module connector and body ground. N17 ES Wire Harness Side: Canister Pump Module Connector N17 1 2 3 4 5 6 7 8 9 10 MGND A136176E04 Result Test Results Suspected Trouble Areas Proceed to Below 1 Ω Leak detection pump A 10 kΩ or higher Wire harness between canister pump module and body ground B (d) Reconnect the canister pump module connector. A Go to step 29 B Go to step 31 ES–434 24 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (ECM - CANISTER PUMP MODULE) (a) (b) (c) (d) Wire Harness Side: ECM Connector Turn the ignition switch off. Disconnect the N17 canister pump module connector. Disconnect the C55 ECM connector. Measure the resistance between the MPMP terminal of the ECM connector and the MTRB terminal of the canister pump module connector. A55 MPMP ES Canister Pump Module Connector N17 1 2 3 4 5 6 7 8 9 10 MTRB A112621E16 Result Test Results Suspected Trouble Areas Proceed to Below 1 Ω ECM A 10 kΩ or higher Wire harness between ECM and canister pump module B (e) Reconnect the canister pump module connector. (f) Reconnect the ECM connector. 25 A Go to step 34 B Go to step 31 INSPECT INTAKE MANIFOLD (EVAP PURGE PORT) (a) (b) (c) (d) Stop the engine. Disconnect the EVAP hose from the intake manifold. Start the engine. Use your finger to confirm that the port of the intake manifold has suction. Result Test Results Suspected Trouble Areas Proceed to Suction applied EVAP hose between intake manifold and purge VSV A No suction Intake manifold B (e) Reconnect the EVAP hose. A Go to step 32 B Go to step 33 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 26 ES–435 CORRECTLY REINSTALL OR REPLACE FUEL CAP HINT: • When reinstalling the fuel cap, tighten it until a few click sounds are heard. • When replacing the fuel cap, use a fuel cap that meets OEM specifications, and install it until a few click sounds are heard. NEXT 27 Go to step 36 REPLACE FUEL CAP HINT: When installing the fuel cap, tighten it until a few click sounds are heard. NEXT 28 Go to step 36 LOCATE EVAP LEAK PART Cainster Pump Module EVAP Pressure Tester Tool Adapter A137044E01 (a) Disconnect the vent hose. (b) Connect the EVAP pressure tester tool to the canister pump module with the adapter. ES ES–436 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (c) Pressurize the EVAP system to 3.2 to 3.7 kPa (24 to 28 mmHg). (d) Apply soapy water to the piping and connecting parts of the EVAP system. (e) Look for areas where bubbles appear. This indicates the leak point. (f) Repair or replace the leak point. HINT: Disconnect the hose between the canister and the fuel tank from the canister. Block the canister side and conduct an inspection. In this way, the fuel tank can be excluded as an area suspected of causing fuel leaks. NEXT ES 29 Go to step 36 REPLACE CHARCOAL CANISTER ASSEMBLY (a) Replace the canister assembly (See page EC-9). Inspection Area* Air Inlet Port Fuel Tank Vent Hose Vent Hose Vent Hose *: Check for disconnection and/or crack A132283E02 NOTICE: When replacing the canister, check the canister pump module interior and related pipes for water, fuel and other liquids. If liquids are present, check for disconnections and/or cracks in the following: 1) the pipe from the air inlet port to the canister pump module; 2) the canister filter; and 3) the fuel tank vent hose. 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NEXT 30 ES–437 Go to step 36 REPLACE DUTY VACUUM SWITCHING VALVE (PURGE VSV) (a) Disconnect the connector and the hoses from the purge VSV. (b) Remove the purge VSV (See page EC-13). (c) Install a new purge VSV (See page EC-14). (d) Reconnect the connector and hoses. NEXT Go to step 36 ES A134246 31 REPAIR OR REPLACE HARNESS OR CONNECTOR NEXT 32 REPLACE EVAP HOSE (INTAKE MANIFOLD - PURGE VSV) NEXT 33 Go to step 36 Go to step 36 INSPECT INTAKE MANIFOLD (EVAP PURGE PORT) (a) Check that the EVAP purge port of the intake manifold is not clogged. If necessary, replace the intake manifold. NEXT 34 Go to step 36 REPLACE ECM (a) Replace the ECM (See page ES-518). NEXT 35 Go to step 36 REPAIR OR REPLACE PARTS AND COMPONENTS INDICATED BY OUTPUT DTCS (a) Repair the malfunctioning areas indicated by the DTCs that had been confirmed when the vehicle was brought in. NEXT Go to step 36 ES–438 36 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PERFORM EVAP SYSTEM CHECK (AUTO OPERATION) NOTICE: • The EVAP SYSTEM CHECK (AUTO OPERATION) consists of 5 steps performed automatically by the intelligent tester. It takes a maximum of approximately 18 minutes. • Do not perform the EVAP SYSTEM CHECK when the fuel tank is more than 90% full because the cut-off valve may be closed, making the fuel tank leak check unavailable. • Do not run the engine in this step. • When the temperature of the fuel is 35°C (95°F) or more, a large amount of vapor forms and any check results become inaccurate. When performing an EVAP SYSTEM CHECK, keep the temperature below 35°C (95°F). (a) Clear the DTCs (See page ES-45). (b) On the intelligent tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION. (c) After the SYSTEM CHECK is completed, check for pending DTCs by selecting the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. HINT: If no pending DTCs are found, the repair has been successfully completed. ES NEXT COMPLETED CONFIRMATION DRIVING PATTERN HINT: After a repair, check Monitor Status by performing the Key-Off Monitor Confirmation and Purge Flow Monitor Confirmation described below. 1. KEY-OFF MONITOR CONFIRMATION (a) Preconditions The monitor will not run unless: • The vehicle has been driven for 10 minutes or more (in a city area or on a freeway). • The fuel tank is less than 90 % full. • The altitude is less than 8,000 ft (2,400 m). • The Engine Coolant Temperature (ECT) is between 4.4°C and 35°C (40°F and 95°F). • The Intake Air Temperature (IAT) is between 4.4°C and 35°C (40°F and 95°F). • The vehicle remains stationary (the vehicle speed is 0 mph (0 km/h)). (b) Monitor Conditions 1. Allow the engine to idle for at least 5 minutes. 2. Turn the ignition switch off and wait for 6 hours (8 or 10.5 hours). HINT: Do not start the engine until checking MONITOR STATUS. If the engine is started, the steps described above must be repeated. 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2. ES–439 (c) Monitor Status 1. Connect the intelligent tester to the DLC3. 2. Turn the ignition switch on (IG) and turn the tester on. 3. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / MONITOR STATUS. 4. Check the Monitor Status displayed on the tester. HINT: If INCMP is displayed, the monitor is not complete. Make sure that the preconditions have been met, and perform the Monitor Conditions again. PURGE FLOW MONITOR CONFIRMATION (P0441) HINT: Perform this monitor confirmation after the Key-Off Monitor Confirmation shows COMPL (complete). (a) Preconditions The monitor will not run unless: • The vehicle has been driven for 10 minutes or more (in a city area or on a freeway) • The ECT is between 4.4°C and 35°C (40°F and 95°F) • The IAT is between 4.4°C and 35°C (40°F and 95°F) (b) Monitor Conditions 1. Release the pressure from the fuel tank by removing and reinstalling the fuel cap. 2. Warm the engine up until the ECT reaches more than 75°C (167°F). 3. Increase the engine speed to 3,000 rpm once. 4. Allow the engine to idle and turn A/C ON for 1 minute. (c) Monitor Status 1. Turn the ignition switch off (if ON or the engine is running). 2. Connect the intelligent tester to the DLC3. 3. Turn the ignition switch on (IG) and turn the tester on. 4. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / MONITOR STATUS. 5. Check the Monitor Status displayed on the tester. HINT: If INCMP is displayed, the monitor is not complete. Make sure that the preconditions have been met, and perform the Monitor Conditions again. MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-25). ES ES–440 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ECM Power Source Circuit DESCRIPTION When the ignition switch is turned on (IG), the battery voltage is applied to terminal IGSW of the ECM. The ECM MREL output signal causes a current to flow to the coil, closing the contacts of the EFI MAIN relay and supplying power to terminal +B of the ECM. If the ignition switch is turned off, the ECM holds the EFI MAIN relay ON for a maximum of 2 seconds to allow for the initial setting of the throttle valve. When the ignition switch is turned on (IG), voltage from the ECM's MREL terminal applies to the engine room junction block (EFI relay). This causes the contacts of the engine room junction block (EFI relay) to close, which supplies power to terminal +B or +B1 of the ECM. ES ES–441 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM E6 Main Body ECU AM2 1 11 ECM 44 A55 MREL AM2 1 A55 +B2 EFI IG2D EFI No. 3 EFI MAIN ES 2 A55 +B 28 A55 IGSW E23 Ignition SW IGN IG2 ST/AM2 IG2 5 AM2 IG2 6 1 5 2 3 81 C55 E1 FL MAIN Battery A134882E01 ES–442 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (ECM - BODY GROUND) (a) Disconnect the C55 ECM connector. (b) Measure the resistance between the terminals. Standard resistance Wire Harness Side: C55 ECM Connector Tester Connection Specified Condition E1 (C55-81) - Body ground Below 1 Ω (c) Reconnect the ECM connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR ES E1 A137016E01 OK 2 CHECK ENGINE ROOM JUNCTION BLOCK (EFI RELAY VOLTAGE) (a) Remove the engine room junction block from the engine room R/B. (b) Turn the ignition switch on (IG). (c) Measure the voltage between the terminals. Standard voltage Wire Harness Side: Engine Room Junction Block Tester Connection Specified Condition 1E-6 - Body ground 9 to 14 V OK 1E Engine Room Relay Block A138922E03 Go to step 5 ES–443 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NG 3 INSPECT EFI MAIN FUSE Engine Room Relay Block (a) Remove the EFI MAIN fuse from the engine room R/B. (b) Measure the EFI MAIN fuse resistance. Standard resistance: Below 1 Ω (c) Reinstall the EFI MAIN fuse. NG REPLACE EFI MAIN FUSE EFI MAIN ES A137020E01 OK 4 CHECK HARNESS AND CONNECTOR (ENGINE ROOM RELAY BLOCK - BATTERY) (a) Disconnect the negative battery terminal. (b) Disconnect the positive battery terminal. (c) Remove the engine room junction block from the engine room R/B. (d) Measure the resistance between the terminals. Standard resistance (Check for open) Component Side: Engine Room Relay Block 1G A140659E03 Tester Connection Specified Condition 1G-1 - Positive battery terminal Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition 1G-1 or Positive battery terminal - Body ground 10 kΩ or higher (e) Reinstall the engine room junction block. (f) Reconnect the positive battery terminal. (g) Reconnect the negative battery terminal. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page ES-33) ES–444 5 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT ENGINE ROOM JUNCTION BLOCK (EFI RELAY) (a) Remove the engine room junction block from the engine room R/B. (b) Measure the resistance between the terminals. Standard resistance Engine Room Junction Block Tester Connection Specified Condition 1E-6 - 1E-12 10 kΩ or higher 1E-6 - 1E-12 Below 1 Ω (Apply battery voltage between terminals 1E-9 and 1E-11) (c) Reinstall the engine room junction block. ES NG 1E Engine Room Relay Block A140654E02 OK REPLACE ENGINE ROOM JUNCTION BLOCK 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 6 ES–445 INSPECT EFI NO. 2 FUSE Engine Room R/B: (a) Remove the EFI No. 2 fuse from the engine room R/B. (b) Measure the EFI No. 2 fuse resistance. Standard resistance: Below 1 Ω (c) Reinstall the EFI No. 2 fuse. NG REPLACE EFI NO 2 FUSE EFI No. 2 ES A135067E01 OK ES–446 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 7 CHECK HARNESS AND CONNECTOR (ECM - ENGINE ROOM JUNCTION BLOCK) (a) Disconnect the A55 ECM connector. (b) Remove the engine room junction block from the engine room R/B. (c) Measure the resistance between the terminals. Standard resistance (Check for open) Wire Harness Side: Engine Room Junction Block Tester Connection Specified Condition 1E-6 - +B (A55-2) Below 1 Ω 1E-6 - +B2 (A55-1) Below 1 Ω Standard resistance (Check for short) ES 1E Engine Room Relay Block A55 ECM Connector +B A140660E01 OK Specified Condition 10 kΩ or higher 1E-6 or +B2 (A55-1) - Body ground 10 kΩ or higher (d) Reinstall the engine room junction block. (e) Reconnect the ECM connector. NG +B2 Tester Connection 1E-6 or +B (A55-2) - Body ground REPAIR OR REPLACE HARNESS OR CONNECTOR ES–447 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 8 INSPECT ECM (IGSW VOLTAGE) (a) Disconnect the A55 ECM connector. (b) Measure the voltage between the terminals. Standard voltage Wire Harness Side: A55 ECM Connector Tester Connection Specified Condition IGSW (A55-28) - Body ground 9 to 14 V (c) Reconnect the ECM connector. OK Go to step 12 ES IGSW A115671E30 NG 9 INSPECT IG2 RELAY (a) Remove the IG2 relay from the engine room R/B. (b) Measure the resistance between the terminals. Standard resistance Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (Apply battery voltage between terminals 1 and 2) (c) Reinstall the IG2 relay. B016200E02 OK NG REPLACE IG2 RELAY ES–448 10 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (IG2 RELAY - BODY GROUND) (a) Remove the IG2 relay from the engine room R/B. (b) Measure the resistance between the terminals. Standard resistance Wire Harness Side: Engine Room Relay Block ES Tester Connection Specified Condition IG2 relay terminal 2 - Body ground Below 1 Ω (c) Reinstall the IG2 relay. Result Result Proceed to OK (Without smart key system) A OK (With smart key system) B NG C IG2 Relay B GO TO SMART ACCESS SYSTEM WITH PUSH-BUTTON START C REPAIR OR REPLACE HARNESS OR CONNECTOR A137039E01 A 11 INSPECT IGNITION SWITCH ASSEMBLY (a) Disconnect the E23 ignition switch connector. (b) Measure the resistance between the terminals. Standard resistance Component Side: A056879E35 Tester Connection Ignition Switch Position Specified Condition All terminals LOCK 10 kΩ or higher 2-4 ACC 1 - 2 - 4, 5 - 6 ON 1 - 3 - 4, 5 - 6 - 7 START Below 1 Ω (c) Reconnect the ignition switch connector. NG REPLACE IGNITION SWITCH ASSEMBLY OK REPAIR OR REPLACE HARNESS OR CONNECTOR (ECM - BATTERY) ES–449 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 12 CHECK HARNESS AND CONNECTOR (ECM - BODY GROUND) (a) Disconnect the A55 ECM connector. (b) Measure the resistance between the terminals. Standard resistance Wire Harness Side: A55 ECM Connector Tester Connection Specified Condition MREL (A55-24) - Body ground Below 1 Ω (c) Reconnect the ECM connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR ES MREL A115671E31 OK REPLACE ECM (See page ES-518) ES–450 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM VC Output Circuit DESCRIPTION The ECM constantly uses 5 V from the battery voltages supplied to the +B (BATT) terminal to operate the microprocessor. The ECM also provides this power to the sensors through the VC output circuit. When the VC circuit is short-circuited, the microprocessor in the ECM and sensors that are supplied power through the VC circuit are inactivated because the power is not supplied from the VC circuit. Under this condition, the system does not start up and the MIL does not illuminate even if the system malfunctions. HINT: Under normal conditions, the MIL is illuminated for several seconds when the ignition switch is first turned on (IG). The MIL goes off when the engine is started. ES ECM From EFI MAIN Fuse From EFI Relay Throttle Position Sensor, Accelerator Pedal Position Sensor, etc. (Sensors which have IC) Engine Coolant Temperature Sensor, Intake Air Temperature Sensor, etc. BATT 5 V Constant Voltage Circuit +B Microprocessor VC R A116143E14 ES–451 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM C5 Throttle Position Sensor VC VTA VTA2 E2 5 96 VCTA C55 6 98 C55 VTA1 4 99 C55 VTA2 3 97 ETA C55 A17 Accelerator Pedal VCPA 4 Position Sensor 1 VCP2 57 VCPA A55 58 VCP2 A55 6 55 A55 VPA 3 56 A55 VPA2 5 59 EPA A55 2 60 EPA2 A55 N17 4 Canister Pressure VCC Sensor (bulit into Canister VOUT 3 Pump Module) 75 VCPP C55 2 76 EPPM C55 VPA VPA2 EPA EPA2 SGND ES 77 C55 PPMP A135050E02 ES–452 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ECM 115 C55 VCV1 C41 VVT Sensor (for Intake Camshaft (bank 1)) VVR+ 3 ES VC VVR- 1 2 EX+ VC2 EX- 1 2 68 C55 EV1+ 91 C55 EV1- 112 C55 VCE2 C44 VVT Sensor (for Exhaust Camshaft (bank 2)) EX+ 3 92 C55 VV1114 C55 VCE1 C40 VVT Sensor (for Exhaust Camshaft (bank 1)) 3 69 C55 VV1+ VC2 EX- 1 2 66 C55 EV2+ 89 C55 EV2113 C55 VCV2 C45 VVT Sensor (for Intake Camshaft (bank 2)) VVL+ 3 VC VVL- 1 2 67 C55 VV2+ 90 C55 VV2- A140661E01 INSPECTION PROCEDURE 1 CHECK MIL (a) Check that Malfunction Indicator Lamp (MIL) lights up when turning the ignition switch on (IG). OK: MIL lights up. 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK ES–453 GO TO MIL CIRCUIT (See page ES-471) NG 2 CHECK CONNECTION BETWEEN INTELLIGENT TESTER AND ECM (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and tester on. (c) Check the communication between the tester and ECM. Result Result Proceed to Communication is possible A Communication is not possible B A GO TO MIL CIRCUIT (See page ES-471) B 3 CHECK THROTTLE BODY ASSEMBLY (CHECK MIL ILLUMINATED) (a) Disconnect the throttle body connector. (b) Turn the ignition switch on (IG). (c) Check the MIL. Result Result Proceed to MIL illuminates A MIL does not illuminate B (d) Reconnect the throttle body connector. A REPLACE THROTTLE BODY ASSEMBLY (See page ES-503) B 4 CHECK ACCELERATOR PEDAL ASSEMBLY (CHECK MIL ILLUMINATED) (a) Disconnect the accelerator pedal position sensor connector. (b) Turn the ignition switch on (IG). (c) Check the MIL. Result Result Proceed to MIL illuminates A MIL does not illuminate B (d) Reconnect the accelerator pedal position sensor connector. A REPLACE ACCELERATOR PEDAL ASSEMBLY (See page ES-521) ES ES–454 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM B 5 CHECK VVT SENSOR FOR INTAKE CAMSHAFT BANK 1 (CHECK MIL ILLUMINATED) (a) Disconnect the VVT sensor for intake camshaft bank 1 connector. (b) Turn the ignition switch on (IG). (c) Check the MIL. Result Result Proceed to MIL illuminates A MIL does not illuminate B (d) Reconnect the VVT sensor for intake camshaft bank 1 connector. ES A REPLACE VVT SENSOR FOR INTAKE CAMSHAFT BANK 1 (See page ES-489) B 6 CHECK VVT SENSOR FOR EXHAUST CAMSHAFT BANK 1 (CHECK MIL ILLUMINATED) (a) Disconnect the VVT sensor for exhaust camshaft bank 1 connector. (b) Turn the ignition switch on (IG). (c) Check the MIL. Result Result Proceed to MIL illuminates A MIL does not illuminate B (d) Reconnect the VVT sensor for exhaust camshaft bank 1 connector. A REPLACE VVT SENSOR FOR EXHAUST CAMSHAFT BANK 1 (See page ES-489) B 7 CHECK VVT SENSOR FOR INTAKE CAMSHAFT BANK 2 (CHECK MIL ILLUMINATED) (a) Disconnect the VVT sensor for intake camshaft bank 2 connector. (b) Turn the ignition switch on (IG). (c) Check the MIL. Result Result Proceed to MIL illuminates A MIL does not illuminate B (d) Reconnect the VVT sensor for intake camshaft bank 2 connector. 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM A ES–455 REPLACE VVT SENSOR FOR INTAKE CAMSHAFT BANK 2 (See page ES-489) B 8 CHECK VVT SENSOR FOR EXHAUST CAMSHAFT BANK 2 (CHECK MIL ILLUMINATED) (a) Disconnect the VVT sensor for exhaust camshaft bank 2 connector. (b) Turn the ignition switch on (IG). (c) Check the MIL. Result Result Proceed to MIL illuminates A MIL does not illuminate B (d) Reconnect the VVT sensor for exhaust camshaft bank 2 connector. A REPLACE VVT SENSOR FOR EXHAUST CAMSHAFT BANK 2 (See page ES-489) B 9 CHECK CHARCOAL CANISTER ASSEMBLY (CHECK MIL ILLUMINATED) (a) Disconnect the canister pump module connector. (b) Turn the ignition switch on (IG). (c) Check the MIL. Result Result Proceed to MIL illuminates A MIL does not illuminate B (d) Reconnect the canister pump module connector. A B REPLACE CHARCOAL CANISTER ASSEMBLY (See page EC-9) ES ES–456 10 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR Wire Harness Side: C55 ECM Connector ES VCE2 VCE1 VCTA VCV2 VCV1 VCPP A55 ECM Connector (a) Disconnect the throttle body connector. (b) Disconnect the accelerator pedal position sensor connector. (c) Disconnect the VVT sensor for intake camshaft bank 1 connector. (d) Disconnect the VVT sensor for exhaust camshaft bank 1 connector. (e) Disconnect the VVT sensor for intake camshaft bank 2 connector. (f) Disconnect the VVT sensor for exhaust camshaft bank 2 connector. (g) Disconnect the canister pump module connector. (h) Disconnect the C55 and A55 ECM connectors. (i) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short) VCPA VCP2 Tester Connections Specified Conditions VCTA (C55-96) - Body ground 10 kΩ or higher VCV1 (C55-115) - Body ground 10 kΩ or higher VCV2 (C55-113) - Body ground 10 kΩ or higher VCE1 (C55-114) - Body ground 10 kΩ or higher VCE2 (C55-112) - Body ground 10 kΩ or higher VCPA (A55-57) - Body ground 10 kΩ or higher VCP2 (A55-58) - Body ground 10 kΩ or higher VCPP (C55-75) - Body ground 10 kΩ or higher A107934E23 (j) (k) (l) (m) (n) (o) (p) (q) (r) Reconnect the ECM connectors. Reconnect the canister pump module connector. Reconnect the fuel pressure sensor connector. Reconnect the VVT sensor for exhaust camshaft bank 2 connector. Reconnect the VVT sensor for intake camshaft bank 2 connector. Reconnect the VVT sensor for exhaust camshaft bank 1 connector. Reconnect the VVT sensor for intake camshaft bank 1 connector. Reconnect the accelerator pedal position sensor connector. Reconnect the throttle body connector. NG OK REPLACE ECM (See page ES-518) REPAIR OR REPLACE HARNESS OR CONNECTOR 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–457 Fuel Pump Control Circuit DESCRIPTION In the diagram below, when the engine is cranked, current flows from terminal ST1 (STR) of the ignition switch (power source control ECU) to the starter relay (Marking: ST) coil and also current flows to terminal STA of ECM (STA signal). When the STA signal and NE signal are input to the ECM, Tr is turned ON, current flows to coil of the circuit opening relay (Marking: C/OPN), the relay switches on, power is supplied to the fuel pump and the fuel pump operates. While the NE signal is generated (engine running), the ECM keeps Tr ON (circuit opening relay ON) and the fuel pump also keeps operating. ES ES–458 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM IG2 ECM C/OPN IGN FC Tr1 Fuel Pump M IG2 ES EFI EFI MAIN Main Body ECU AM2 *1 AM1 *2 *1 AM1 *1 ST1 *2 AM2 ALT *2 Ignition Switch ST2 *2 *2 *1 AM2 IG2D STR *2 *2 Park / Neutral position Switch ST/AM2 FL MAIN IG2 *1 ST NSW To Starter Battery MREL STA *1: with Smart Key System NE Signal NE+ *2: without Smart Key System A141108E01 ES–459 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM E6 Main Body ECU AM2 1 *1 11 *1 ECM AM2 C/OPN IG2D 7 A55 FC EFI EFI MAIN ES E23 Ignition SW *2 44 A55 MREL ST/AM2 5 AM2 IG2 *2 IG2 6 FL MAIN Battery IGN IG2 1 2 5 3 81 C55 E1 N10 Fuel Pump M *1: with Smart Key System *2: without Smart Key System A137394E02 INSPECTION PROCEDURE 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (OPERATE C/OPN RELAY) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and tester on. ES–460 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / FUEL PUMP / SPD. (d) Check whether the fuel pump operation sound occurs when performing the Active Test on the tester. OK: Fuel pump operating sound occurs. NG Go to step 2 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page ES-33) ES 2 CHECK ECM POWER SOURCE CIRCUIT NG REPAIR OR REPLACE ECM POWER SOURCE CIRCUIT OK 3 INSPECT ENGINE ROOM JUNCTION BLOCK (C/OPN RELAY) (a) Remove the integration relay from the engine room relay block. (b) Inspect the C/OPN relay. (1) Measure the C/OPN relay resistance. Standard resistance Engine Room Junction Block Tester Connections Specified Conditions 10 kΩ or higher 1E-7 - 1E-13 1D Below 1 Ω (Apply battery voltage between terminals 1D-12 and 1E-8) (c) Reinstall the integration relay. 1E NG Engine Room Relay Block A140654E03 REPLACE ENGINE ROOM JUNCTION BLOCK ES–461 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK 4 INSPECT ECM (FC VOLTAGE) (a) Disconnect the A55 and C55 ECM connectors. (b) Measure the voltage between the terminals of the A24 and C24 ECM connectors. Standard voltage Wire Harness Side: Tester Connection Specified Condition A55-7 (FC) - C55-81 (E1) 9 to 14 V (c) Reconnect the ECM connectors. E1 C55 ECM Connector NG REPAIR OR REPLACE HARNESS OR CONNECTOR (ECM - BATTERY) NG REPLACE FUEL PUMP (See page FU-27) FC A55 ECM Connector A106902E12 OK 5 OK INSPECT FUEL PUMP ES ES–462 6 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (C/OPN RELAY - FUEL PUMP - BODY GROUND) (a) Check the harness and the connectors between the engine room relay block and the fuel pump. (1) Disconnect the integration relay connector. (2) Disconnect the N10 fuel pump connector. (3) Measure the resistance. Standard resistance (Check for open) Wire Harness Side: Fuel Pump Connector N10 1 2 3 4 5 Tester Connections Specified Conditions 1E-13 - N10-4 (Fuel pump) Below 1 Ω Standard resistance (Check for short) ES Engine Room Junction Block Tester Connections Specified Conditions 1E-13 or N10-4 (Fuel pump) - Body ground 10 kΩ or higher (b) Check the harness and the connectors between the fuel pump and body ground. (1) Disconnect the N10 fuel pump connector. (2) Measure the resistance. Standard resistance (Check for open) 1E Tester Connection Specified Condition N10-5 (Fuel pump) - Body ground Below 1 Ω (c) Reconnect the integration relay connector. (d) Reconnect the fuel pump connector. NG Engine Room Relay Block A140662E01 OK REPLACE ECM (See page ES-518) REPAIR OR REPLACE HARNESS OR CONNECTOR 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–463 Cranking Holding Function Circuit DESCRIPTION The cranking holding control system provides current to the starter when the ECM detects the engine switch's start signal (STSW). When the ECM performs a firing judgment, the system cuts current to the starter. When an ECM receives the STSW signal, it turns on the ST CUT relay, which prevents flickering of the combination meter, clock, audio system, etc. Also, the ECM sends a signal to the ECM's STAR terminal. Then the STAR output signal travels through the park/neutral position (PNP) switch to the STARTER relay, causing the starter to activate. When the engine is cranking, the starter operation signal is sent to the ECM's STA terminal. Keeps cranking until the firing of the engine is judged ES ON Start Input Signal (STSW) OFF When no cranking holding control is effected ON Start Output Signal (STAR) ACC Cut Input Signal (ACCR) (for start control) OFF Prevents meters, clock, etc. from flickering ON OFF Firing judgment line Engine Speed Signal (NE) Engine Switch ST Position When the NE signal reaches a predetermined value, the ECM determines that the engine has started successfully Elapse of Time A103821E19 WIRING DIAGRAM Refer to DTC P0617 (See page ES-305). ES–464 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE 1 CHECK CRANKING (a) When starting the engine, check whether the starter motor starts. OK CHECK FOR INTERMITTENT PROBLEMS NG 2 READ VALUE OF INTELLIGENT TESTER (STA SIGNAL) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the intelligent tester on. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / STARTER SIG. Read the values. (e) Check the result when the ignition switch is turned on (IG) and when the engine is started. ES Standard Display (STARTER SIG) Ignition Switch Position OFF ON ON START OK Go to step 7 NG 3 INSPECT ECM (STSW VOLTAGE) (a) Disconnect the A55 ECM Connector. (b) Measure the voltage between the terminals of the ECM connector and body ground while cranking the engine. Standard voltage Wire Harness Side: A55 ECM Connector Tester Connection Specified Condition STSW (A55-14) - Body ground 9 to 14 V (c) Reconnect the ECM connector. OK STSW A115671E32 OK Go to step 11 ES–465 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 4 INSPECT ECM (STAR VOLTAGE) (a) Remove the ST CUT relay from the engine room R/B. (b) Measure the voltage between the terminals of the engine room R/B and body ground while cranking the engine. Standard voltage Wire Harness Side: Engine Room Rlay Block Tester Connection Specified Condition ST CUT relay (3) - Body ground 9 to 14 V (c) Reinstall the ST CUT relay. NG Go to step 8 ES ST CUT Relay A137045E01 OK 5 INSPECT ST CUT RELAY (a) Remove the ST CUT relay from the engine room R/B. (b) Measure the resistance between the terminals. Standard resistance Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage applied to terminals 1 and 2) (c) Reinstall the ST CUT relay. B016200E02 OK NG REPLACE ST CUT RELAY ES–466 6 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT PARK/NEUTRAL SWITCH ASSEMBLY (a) Inspect the Park / Neutral Position (PNP) switch. (1) Disconnect the C1 switch connector. (2) Measure the resistance according to the value(s) in the table below. Standard resistance Component Side: Gear Selector Lever Position Tester Connection Specified Condition P 4-5 Below 1 Ω N 4-5 Below 1 Ω C1 (3) Reconnect the PNP switch connector. Park / Neutral Position Switch ES NG REPLACE PARK/NEUTRAL POSITION SWITCH ASSEMBLY (See page AX-174) A107908E03 OK CHECK HARNESS AND CONNECTOR 7 INSPECT STARTER RELAY (a) Remove the ST relay from the engine room R/B. (b) Measure the resistance between the terminals. Standard resistance Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage applied to terminals 1 and 2) (c) Reinstall the ST relay. B016200E02 OK NG REPLACE STARTER RELAY ES–467 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 8 CHECK HARNESS AND CONNECTOR (PARK / NEUTRAL POSITION SWITCH - STARTER RELAY) (a) Disconnect the C1 park/neutral position switch connector. (b) Remove the ST relay from the engine room R/B. (c) Measure the resistance between the terminals. Standard resistance (Check for open) Wire Harness Side: Park / Neutral Position Switch Tester Connection Specified Condition C1-9 - ST relay terminal (5) Below 1 Ω Standard resistance (Check for open) C1 Tester Connection Specified Condition C1-9 or ST relay terminal (5) - Body ground 10 kΩ or higher (d) Reinstall the ST relay. NG Front View Engine Room Relay Block ST Relay A137047E03 OK REPAIR OR REPLACE HARNESS OR CONNECTOR ES ES–468 9 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT ENGINE ROOM RELAY BLOCK (STARTER RELAY VOLTAGE) (a) Remove the ST relay from the engine room R/B. (b) Measure the voltage between the terminals of the engine room R/B and body ground. Standard voltage Wire Harness Side: Engine Room Relay Block Tester Connection Specified Condition ST relay (5) - Body ground 9 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR NG REPAIR OR REPLACE STARTER ASSEMBLY ES ST Relay A137046E01 OK 10 INSPECT STARTER ASSEMBLY OK REPAIR OR REPLACE HARNESS OR CONNECTOR (STARTER RELAY - STARTER, STARTER BATTERY) ES–469 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 11 CHECK HARNESS AND CONNECTOR (MAIN BODY ECU - ECM) (a) Disconnect the E6 main body ECU connector. (b) Disconnect the A55 ECM connector. (c) Measure the resistance between the terminals. Standard resistance (Check for open) Wire Harness Side: Main Body ECU Tester Connection Specified Condition STSW (E9-4) - STSW (A55-14) Below 1 Ω Standard resistance (Check for short) E9 Tester Connection Specified Condition STSW (E9-4) or STSW (A55-14) - Body ground 10 kΩ or higher (d) Reconnect the main body ECU connector. (e) Reconnect the ECM connector. OK A55 ECM Connector STSW A137048E01 OK GO TO SMART KEY SYSTEM REPAIR OR REPLACE HARNESS OR CONNECTOR ES ES–470 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ACIS Control Circuit DESCRIPTION This circuit opens and closes the Intake Air Control Valve (IACV) in response to changes in the engine load in order to increase the intake efficiency (ACIS: Acoustic Control Induction System). When the engine speed is between 0 and 4,450 rpm and the throttle valve opening angle is 60° or more, the ECM supplies current to the VSV (ON status), to close the IACV. Under other conditions, the VSV is usually OFF and the IACV is open. Engine Speed Throttle Valve Opening Angle ECM ES ACIS Actuator VSV 6 4 2 Throttle Sensor IACV Closed (VSV: ON) IACV Engine Speed 5 3 1 Throttle Valve Opening Angle 60° Throttle Valve Opening Angle ECM ACIS Actuator VSV 6 4 0 rpm 2 Throttle Sensor 4,450 rpm Engine Speed IACV Open (VSV: OFF) IACV 5 3 1 G041080E04 ES–471 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM C48 VSV (ACIS) EFI EFI No. 3 ECM 107 C55 ACIS 44 A55 MREL EFI MAIN FL MAIN ES Battery A137320E01 INSPECTION PROCEDURE 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (OPERATE VSV FOR ACIS) (a) Connect the intelligent tester to the DLC3. (b) Start the engine and turn the intelligent tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / INTAKE CTL VSC48. Operate the VSV for AICS. OK: Operational noise can be heard. OK NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page ES-33) ES–472 2 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK INTAKE AIR CONTROL VALVE (OPERATION) (a) Disconnect the C48 air intake valve connector. (b) Apply battery voltage between the terminals of the air intake valve connector. (c) Check the air intake valve operation. OK: Operational noise can be heard. Component Side: C48 2 1 NG ACIS VSV E121181E02 ES OK REPLACE INTAKE AIR SURGE TANK ES–473 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 3 CHECK HARNESS AND CONNECTOR (VSV FOR ACIS - ECM, VSV FOR ACIS - EFI RELAY) (a) Check the wire harness and connectors between the VSV for ACIS and ECM. (1) Disconnect the C48 VSV for ACIS connector. (2) Disconnect the C55 ECM connector. (3) Measure the resistance between the terminals of the VSV for ACIS connector and ECM connector. Standard resistance (Check for open) Wire Harness Side: C48 ACIS VSV Tester Connections Specified Conditions VSV for ACIS (C48-1) - ACIS (C55-107) Below 1 Ω Standard resistance (Check for short) Engine Room Junction Block Tester Connections Specified Conditions VSV for ACIS (C48-1) or ACIS (C55-107) - Body ground 10 kΩ or higher (4) Reconnect the VSV for ACIS connector. (5) Reconnect the ECM connector. (b) Check the EFI No. 3 fuse. (1) Remove the EFI No. 3 fuse from the engine room R/ B. (2) Measure the EFI No. 3 fuse resistance. Standard resistance: Below 1 Ω (3) Reinstall the EFI No. 3 fuse (c) Check the wire harness between the VSV for ACIS connector and EFI MAIN relay. (1) Remove the engine room junction block from the engine room R/B. (2) Disconnect the C48 VSV connector. (3) Measure the resistance between the terminals. Standard resistance (Check for open) 1E Tester Connections Specified Conditions VSV for ACIS (C48-2) - 1E-6 Below 1 Ω (4) Reinstall the engine room junction block. (5) Reconnect the VSV connector. Engine Room Relay Block NG C55 ECM Connector ACIS A137082E01 REPAIR OR REPLACE HARNESS OR CONNECTOR ES ES–474 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK REPLACE ECM (See page ES-518) ES ES–475 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Air Intake Control Circuit DESCRIPTION The air cleaner is equipped with two inlets, one of which is opened or closed by the Air Intake Control Valve (AICV). This system reduces intake noise and increases engine power at low-to-high engine speeds range. When the engine is operating in the low-to-mid speed range, this control operates the AICV to close one of the air cleaner inlets. When the engine speed is more than 3,600 rpm and the opening angle of the throttle valve is more than 60°, the ECM activates the VSV and opens the AICV. Vacuum Tank VSV AICV Open (VSV: ON) Throttle Valve Opening Angle Air Intake Control Valve (AICV) ES 60° 3,600 rpm Engine Speed Air Cleaner Inlet A061332E03 WIRING DIAGRAM EFI EFI No. 3 ECM A53 AICV VSV 4 A55 EFI MAIN AICV 44 A55 MREL FL MAIN Battery A137320E02 ES–476 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (VSV FOR AICV) VSV is ON VSV is OFF Air Port F Port E Air Port F Port E (a) Turn the ignition switch on (IG) and turn the intelligent tester ON. (b) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / INTAKE CTL VSV1 and operate the VSV for AICV. (c) Check the operation of the VSV when the VSV is operated by the intelligent tester. Standard Tester Operation Specified Condition VSV is ON Air from port E flows out through port F VSV is OFF Air from port E flows out through the air filter A067588E07 ES OK Go to step 4 NG 2 CHECK VSV (FOR AICV) (a) Inspect the intake air control valve assembly (See page IT-5). NG OK REPLACE INTAKE AIR CONTROL VALVE ASSEMBLY ES–477 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 3 CHECK HARNESS AND CONNECTOR (VSV FOR AICV - ECM, VSV FOR AICV - EFI RELAY) (a) Check the wire harness between the VSV for AICV connector and the ECM connector. (1) Disconnect the A53 VSV for AICV connector. (2) Disconnect the A55 ECM connector. (3) Measure the resistance between the terminals of the wire harness side connectors and body ground. Standard resistance (Check for open) Wire Harness Side: AICV VSV A53 1 2 Tester Connection Specified Condition VSV for AICV (A53-2) - AICV (A55-4) Below 1 Ω Standard resistance (Check for short) Engine Room Junction Block Tester Connection Specified Condition VSV for AICV (A53-2) or AICV (A55-4) - Body ground 10 kΩ or higher (4) Reconnect the ECM connector. (b) Check the EFI No. 3 fuse. (1) Remove the EFI No. 3 fuse from the engine room R/ B. (2) Measure the resistance EFI No. 3 fuse. Standard resistance: Below 1 Ω (3) Reinstall the EFI No. 3 fuse. (c) Check the wire harness between the VSV for AICV and the EFI relay. (1) Remove the engine room junction block from the engine room R/B. (2) Measure the resistance between the terminals of the wire harness side connectors. Standard resistance (Check for open) 1E Tester Connection Specified Condition VSV for AICV (A53-1) - 1E-6 Below 1 Ω (3) Reconnect the VSV for AICV connector. (4) Reinstall the engine room junction block. NG Engine Room Relay Block A55 ECM Connector AICV A137083E01 REPAIR OR REPLACE HARNESS OR CONNECTOR ES ES–478 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK 4 INSPECT VACUUM TANK (a) Inspect the vacuum tank (See page IT-3). NG OK REPLACE ECM (See page ES-518) ES REPAIR OR REPLACE AIR CLEANER CAP ES–479 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MIL Circuit DESCRIPTION The MIL (Malfunction Indicator Lamp) is used to indicate vehicle malfunctions detected by the ECM. When the ignition switch is turned on (IG), power is supplied to the MIL circuit, and the ECM provides the circuit ground which illuminates the MIL. The MIL operation can be checked visually: When the ignition switch is first turned on (IG), the MIL should be illuminated and should then turn off. If the MIL remains illuminated or is not illuminated, conduct the following troubleshooting procedure using the intelligent tester. WIRING DIAGRAM ECM Combination Meter IG2 GAUGE No. 2 5 3 1 2 IG2 13 F1 IG+ CHK ST/AM2 *2 5 AM2 24 W A55 E6 Main Body ECU E23 Ignition SW *2 4 F2 ES *1 *2 IG2 6 11 AM2 *1 1 IG2D AM2 FL MAIN *1: with Smart Key System Battery *2: without Smart Key System A137345E01 INSPECTION PROCEDURE 1 CHECK THAT MIL IS ILLUMINATED (a) Perform troubleshooting in accordance with the table below: Result B Conditions Proceed to MIL remains ON A MIL does not illuminate B Go to step 5 ES–480 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM A 2 CHECK WHETHER MIL TURNS OFF (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Check if any DTCs have been stored. Note down any DTCs. (e) Clear the DTCs (See page ES-38). (f) Check if the MIL goes off. Standard: MIL goes off. ES OK REPAIR CIRCUITS INDICATED BY OUTPUT DTCS (See page ES-63) NG 3 CHECK HARNESS AND CONNECTOR (CHECK FOR SHORT IN WIRE HARNESS) (a) Disconnect the A55 ECM connector. (b) Turn the ignition switch on (IG). (c) Check that the MIL is not illuminated. OK: MIL is not illuminated. (d) Reconnect the ECM connector. A55 ECM Connector OK A115671E35 NG REPLACE ECM (See page ES-518) ES–481 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 4 CHECK HARNESS AND CONNECTOR (COMBINATION METER - ECM) (a) Disconnect the A55 ECM connector. (b) Disconnect the F2 combination meter connector. (c) Measure the resistance. Standard resistance (Check for short) Wire Harness Side: Combination Meter Connector Tester Connection Specified Condition A55-24 (W) or F2-4 (CHK) - Body ground 10 kΩ or higher (d) Reconnect the ECM connector. (e) Reconnect the combination meter connector. F2 OK REPAIR OR REPLACE COMBINATION METER ASSEMBLY A55 ECM Connector W A132305E02 NG REPAIR OR REPLACE HARNESS OR CONNECTOR 5 CHECK THAT MIL IS ILLUMINATED (a) Check if the MIL is illuminated when the ignition switch is turned on (IG). OK: MIL is illuminated. OK SYSTEM OK NG 6 CHECK THAT ENGINE STARTS (a) Turn the ignition switch on (IG). (b) Start the engine. Result Result Proceed to Engine starts A Engine does not start* B ES ES–482 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: *: The intelligent tester cannot communicate with the ECM. B GO TO VC OUTPUT CIRCUIT (See page ES442) A 7 INSPECT COMBINATION METER ASSEMBLY (MIL CIRCUIT) (a) Check the MIL circuit (See page ME-19). NG ES REPAIR OR REPLACE COMBINATION METER ASSEMBLY OK CHECK AND REPLACE HARNESS AND CONNECTOR (COMBINATION METER - ECM) 2GR-FE ENGINE CONTROL SYSTEM – MASS AIR FLOW METER ES–475 MASS AIR FLOW METER 2GR-FE ENGINE CONTROL SYSTEM ENGINE COMPONENTS MASS AIR FLOW METER CONNECTOR ES MASS AIR FLOW METER A135627E01 ES–476 2GR-FE ENGINE CONTROL SYSTEM – MASS AIR FLOW METER ON-VEHICLE INSPECTION 1. (a) Perform confirmation driving pattern. (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch on (IG). (3) Turn the tester on. (4) Clear the DTCs (See page ES-45). (5) Start the engine and warm it up with all accessory switches off (until the engine coolant temperature is 75 °C(167°F) or more). (6) Drive the vehicle at 31 mph (50 km/h) or more for 3 minutes or more (*1). (7) Allow the engine to idle (accelerator pedal fulley released) for 2 minutes or more (*2). (8) Perform steps (*1) and (*2) at least 3 times or more. Intelligent Tester ES DLC3 CHECK MASS AIR FLOW METER NOTICE: • Perform the MAF meter inspection by following the procedures below. • Only replace the MAF meter when both the LONG FT#1 value and MAF value in the DATA LIST (with the engine stopped) are not within the normal operating range. CAN VIM C131977E05 (Vehicle Speed) *1 *1 *1 31 mph (50 km/h) Idling Ignition switch OFF *2 *2 *2 Warming up *1: 3 minutes or more *2: 2 minutes or more A116436E18 (b) Read values using the intelligent tester (LONG FT#1). (1) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / LONG FT#1. 2GR-FE ENGINE CONTROL SYSTEM – MASS AIR FLOW METER ES–477 (2) Read the values displayed on the tester. Standard value: Within -15 to +15 % If the result is not within the specified range, perform the inspection below. (c) Read values using the intelligent tester (MAF). NOTICE: • Turn off the engine. • Perform the inspection with the vehicle indoors and on a level surface. • Perform the inspection of the MAF meter while it is installed to the air cleaner case (installed to the vehicle). • During the test, do not use the exhaust air duct to perform suction on the exhaust pipe. (1) Turn off the engine (do not run the engine). (2) Turn the ignition switch on (IG). (3) Turn the tester on. (4) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / PRIMARY / MAF. (5) Wait 30 seconds, and read the values on the intelligent tester. Standard condition: Less than 0.56 g/sec • If the result is not as specified, replace the MAF meter. • If the result is within the specified range, inspect the cause of the extremely rich or lean air fuel ratio (See page EC-19). REMOVAL 1. REMOVE MASS AIR FLOW METER (a) Disconnect the mass air flow meter connector. (b) Remove the 2 screws and mass air flow meter. A135694 INSTALLATION 1. A135694 INSTALL MASS AIR FLOW METER (a) Install the mass air flow meter with the 2 screws. (b) Connect the mass air flow meter connector. ES ES–478 2GR-FE ENGINE CONTROL SYSTEM – CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 2GR-FE ENGINE CONTROL SYSTEM ENGINE COMPONENTS AIR CLEANER CAP SUB-ASSEMBLY V-BANK COVER SUB-ASSEMBLY AIR CLEANER FILTER ELEMENT ES COOL AIR INTAKE DUCT SEAL 5.0 (51, 44 in.*lbf) 5.0 (51, 44 in.*lbf) AIR CLEANER INLET ASSEMBLY AIR CLEANER CASE SUB-ASSEMBLY 5.0 (51, 44 in.*lbf) NO. 1 AIR CLEANER INLET ENGINE UNDER COVER RH ENGINE UNDER COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque A135093E01 2GR-FE ENGINE CONTROL SYSTEM – CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY ES–479 20 (204, 15) WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH 20 (204, 15) FRONT FENDER TO COWL SIDE SEAL LH COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH 7.5 (77, 66 in.*lbf) 7.5 (77, 66 in.*lbf) FRONT FENDER TO COWL SIDE SEAL RH 5.0 (51, 44 in.*lbf) 85 (867, 63) x4 WINDSHIELD WIPER MOTOR AND LINK x4 COWL TOP PANEL OUTER SUB-ASSEMBLY VACUUM HOSE CLAMP SURGE TANK STAY NO. 1 * UNION TO CHECK VALVE HOSE 21 (214, 15) VENTILATION HOSE NO. 2 5.4 (55, 48 in.*lbf) 16 (163, 12) INTAKE AIR SURGE TANK * x2 * x4 THROTTLE BODY BRACKET 18 (184, 13) VACUUM HOSE 21 (214, 15) VAPOR FEED HOSE WATER BY-PASS HOSE AIR SURGE TANK TO INTAKE MANIFOLD GASKET N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part * DO NOT apply oil A135104E01 ES 2GR-FE ENGINE CONTROL SYSTEM – CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY ES–480 CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 10 (102, 7) 10 (102, 7) ES O-RING 10 (102, 7) 10 (102, 7) O-RING O-RING O-RING CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A135629E01 2GR-FE ENGINE CONTROL SYSTEM – CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY ON-VEHICLE INSPECTION Intelligent Tester 1. DLC3 ES–481 INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the ignition switch on (IG). (c) Start and warm up the engine. (d) Connect the intelligent tester and select VVT from the ACTIVE TEST menu. (e) Check the engine speed when the OCV is operated with the intelligent tester. OK Condition CAN VIM Specified Condition VVT system is OFF (OCV is OFF) Normal engine speed VVT system is ON (OCV is ON) Rough idle or engine stalled C131977E05 ES ES–482 2GR-FE ENGINE CONTROL SYSTEM – CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY REMOVAL 1. REMOVE ENGINE UNDER COVER LH 2. REMOVE ENGINE UNDER COVER RH 3. DRAIN ENGINE COOLANT (See page CO-5) 4. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH (See page WW-9) 5. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH (See page WW-9) 6. REMOVE FRONT FENDER TO COWL SIDE SEAL LH (See page WW-9) 7. REMOVE FRONT FENDER TO COWL SIDE SEAL RH (See page WW-9) 8. REMOVE COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See page WW-10) 9. REMOVE WINDSHIELD WIPER MOTOR AND LINK (See page WW-10) ES 10. REMOVE COWL TOP PANEL OUTER SUBASSEMBLY (a) Remove the 4 bolts, 4 nuts and cowl top panel outer sub-assembly. 11. REMOVE COOL AIR INTAKE DUCT SEAL (See page EM-23) 12. REMOVE V-BANK COVER SUB-ASSEMBLY (See page EM-23) A136272 13. REMOVE AIR CLEANER INLET ASSEMBLY (See page EM-24) 14. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-503) 15. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (See page EM-24) 16. REMOVE NO. 1 AIR CLEANER INLET (See page EM24) 17. REMOVE INTAKE AIR SURGE TANK (See page FU13) 18. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE (for Bank 1 Exhaust Side) (a) Disconnect the camshaft timing oil control valve connector. (b) Remove the bolt and camshaft timing oil control valve. (c) Remove the O-ring from the camshaft timing oil control valve. A135698 2GR-FE ENGINE CONTROL SYSTEM – CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY ES–483 19. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE (for Bank 1 Intake Side) (a) Disconnect the camshaft timing oil control valve connector. (b) Remove the bolt and camshaft timing oil control valve. (c) Remove the O-ring from the camshaft timing oil control valve. A135697 20. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE (for Bank 2 Exhaust Side) (a) Disconnect the camshaft timing oil control valve connector. (b) Remove the bolt and camshaft timing oil control valve. (c) Remove the O-ring from the camshaft timing oil control valve. A135696 21. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE (for Bank 2 Intake Side) (a) Disconnect the camshaft timing oil control valve connector. (b) Remove the bolt and camshaft timing oil control valve. (c) Remove the O-ring from the camshaft timing oil control valve. A135695 ES ES–484 2GR-FE ENGINE CONTROL SYSTEM – CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY INSPECTION 1. 1 INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Resistance inspection. (1) Using an ohmmeter, measure the resistance between the terminals. Standard resistance: 6.9 to 7.9 Ω at 20°C (68°F) If necessary, replace the camshaft timing oil control valve assembly. (b) Movement inspection. (1) Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2, and check the movement of the valve. NOTICE: Confirm that the valve moves freely and does not stick in any position. If necessary, replace the camshaft timing oil control valve assembly. HINT: Accumulation of foreign objects causes subtle pressure leaks. The subtle pressure leaks will cause the camshaft to advance, and this will cause a DTC to be set. 2 Valve ES B001689E02 INSTALLATION New O-Ring 1. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE (for Bank 2 Intake Side) (a) Apply a light coat of engine oil to a new O-ring and install it to the camshaft timing oil control valve. A093611E01 (b) Install the camshaft timing oil control valve with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTICE: Make sure that the O-ring is not cracked or jammed when installing the oil control valve. (c) Connect the camshaft timing oil control valve connector. A135695 2GR-FE ENGINE CONTROL SYSTEM – CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 2. New O-Ring ES–485 INSTALL CAMSHAFT TIMING OIL CONTROL VALVE (for Bank 2 Exhaust Side) (a) Apply a light coat of engine oil to a new O-ring and install it to the camshaft timing oil control valve. A093611E01 (b) Install the camshaft timing oil control valve with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTICE: Make sure that the O-ring is not cracked or jammed when installing the oil control valve. (c) Connect the camshaft timing oil control valve connector. A135696 3. New O-Ring INSTALL CAMSHAFT TIMING OIL CONTROL VALVE (for Bank 1 Intake Side) (a) Apply a light coat of engine oil to a new O-ring and install it to the camshaft timing oil control valve. A093611E01 (b) Install the camshaft timing oil control valve with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTICE: Make sure that the O-ring is not cracked or jammed when installing the oil control valve. (c) Connect the camshaft timing oil control valve connector. A135697 4. New O-Ring A093611E01 INSTALL CAMSHAFT TIMING OIL CONTROL VALVE (for Bank 1 Exhaust Side) (a) Apply a light coat of engine oil to a new O-ring and install it to the camshaft timing oil control valve. ES ES–486 2GR-FE ENGINE CONTROL SYSTEM – CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (b) Install the camshaft timing oil control valve with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTICE: Make sure that the O-ring is not cracked or jammed when installing the oil control valve. (c) Connect the camshaft timing oil control valve connector. 5. INSTALL INTAKE AIR SURGE TANK (See page FU18) 6. INSTALL NO. 1 AIR CLEANER INLET (See page EM49) 7. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (See page EM-50) 8. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See page ES-506) 9. INSTALL AIR CLEANER INLET ASSEMBLY (See page EM-50) A135698 ES 10. INSTALL V-BANK COVER SUB-ASSEMBLY (See page EM-52) 11. INSTALL COOL AIR INTAKE DUCT SEAL (See page EM-52) 12. INSTALL COWL TOP PANEL OUTER SUBASSEMBLY (a) Install the cowl top panel outer sub-assembly with the 4 bolts and 4 nuts. Torque: Bolt 5.0 N*m (51 kgf*cm, 44 in.*lbf) Nut 85 N*m (867 kgf*cm, 63 ft.*lbf) A136272 13. INSTALL WINDSHIELD WIPER MOTOR AND LINK (See page WW-14) 14. INSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See page WW-15) 15. INSTALL FRONT FENDER TO COWL SIDE SEAL RH (See page WW-15) 16. INSTALL FRONT FENDER TO COWL SIDE SEAL LH (See page WW-15) 17. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH (See page WW-15) 18. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH (See page WW-16) 19. ADD ENGINE COOLANT (See page CO-6) 20. CHECK FOR ENGINE COOLANT LEAKS (See page CO-1) 21. INSTALL ENGINE UNDER COVER RH 2GR-FE ENGINE CONTROL SYSTEM – CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY ES–487 22. INSTALL ENGINE UNDER COVER LH ES 2GR-FE ENGINE CONTROL SYSTEM – VVT SENSOR ES–487 VVT SENSOR 2GR-FE ENGINE CONTROL SYSTEM ENGINE COMPONENTS AIR CLEANER CAP SUB-ASSEMBLY V-BANK COVER SUB-ASSEMBLY AIR CLEANER FILTER ELEMENT ES COOL AIR INTAKE DUCT SEAL 5.0 (51, 44 in.*lbf) 5.0 (51, 44 in.*lbf) AIR CLEANER INLET ASSEMBLY AIR CLEANER CASE SUB-ASSEMBLY 5.0 (51, 44 in.*lbf) NO. 1 AIR CLEANER INLET ENGINE UNDER COVER RH ENGINE UNDER COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque A135093E01 ES–488 2GR-FE ENGINE CONTROL SYSTEM – VVT SENSOR 20 (204, 15) WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH 20 (204, 15) FRONT FENDER TO COWL SIDE SEAL LH COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH 7.5 (77, 66 in.*lbf) ES 7.5 (77, 66 in.*lbf) FRONT FENDER TO COWL SIDE SEAL RH 5.0 (51, 44 in.*lbf) 85 (867, 63) x4 WINDSHIELD WIPER MOTOR AND LINK x4 COWL TOP PANEL OUTER SUB-ASSEMBLY VACUUM HOSE CLAMP SURGE TANK STAY NO. 1 * UNION TO CHECK VALVE HOSE 21 (214, 15) VENTILATION HOSE NO. 2 5.4 (55, 48 in.*lbf) 16 (163, 12) INTAKE AIR SURGE TANK * x2 * x4 THROTTLE BODY BRACKET 18 (184, 13) VACUUM HOSE 21 (214, 15) VAPOR FEED HOSE WATER BY-PASS HOSE AIR SURGE TANK TO INTAKE MANIFOLD GASKET N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part * DO NOT apply oil A135104E01 ES–489 2GR-FE ENGINE CONTROL SYSTEM – VVT SENSOR VVT SENSOR VVT SENSOR 10 (102, 7) 10 (102, 7) VVT SENSOR 10 (102, 7) VVT SENSOR ES 10 (102, 7) N*m (kgf*cm, ft.*lbf) : Specified torque A132949E01 ES–490 2GR-FE ENGINE CONTROL SYSTEM – VVT SENSOR REMOVAL 1. REMOVE ENGINE UNDER COVER LH 2. REMOVE ENGINE UNDER COVER RH 3. DRAIN ENGINE COOLANT (See page CO-5) 4. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH (See page WW-9) 5. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH (See page WW-9) 6. REMOVE FRONT FENDER TO COWL SIDE SEAL LH (See page WW-9) 7. REMOVE FRONT FENDER TO COWL SIDE SEAL RH (See page WW-9) 8. REMOVE COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See page WW-10) 9. REMOVE WINDSHIELD WIPER MOTOR AND LINK (See page WW-10) ES 10. REMOVE COWL TOP PANEL OUTER SUBASSEMBLY (See page ES-481) 11. REMOVE COOL AIR INTAKE DUCT SEAL (See page EM-23) 12. REMOVE V-BANK COVER SUB-ASSEMBLY (See page EM-23) 13. REMOVE AIR CLEANER INLET ASSEMBLY (See page EM-24) 14. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-503) 15. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (See page EM-24) 16. REMOVE NO. 1 AIR CLEANER INLET (See page EM24) 17. REMOVE INTAKE AIR SURGE TANK ASSEMBLY (See page FU-13) 18. REMOVE VVT SENSOR (for Bank 1 Intake Side) (a) Disconnect the VVT sensor connector. (b) Remove the bolt and VVT sensor. A135701 2GR-FE ENGINE CONTROL SYSTEM – VVT SENSOR ES–491 19. REMOVE VVT SENSOR (for Bank 1 Exhaust Side) (a) Disconnect the VVT sensor connector. (b) Remove the bolt and VVT sensor. A135702 20. REMOVE VVT SENSOR (for Bank 2 Intake Side) (a) Disconnect the VVT sensor connector. (b) Remove the bolt and VVT sensor. ES A135700 21. REMOVE VVT SENSOR (for Bank 2 Exhaust Side) (a) Disconnect the VVT sensor connector. (b) Remove the bolt and VVT sensor. A135699 INSTALLATION 1. INSTALL VVT SENSOR (for Bank 2 Exhaust Side) (a) Install the VVT sensor with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) (b) Connect the VVT sensor connector. 2. INSTALL VVT SENSOR (for Bank 2 Intake Side) (a) Install the VVT sensor with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) (b) Connect the VVT sensor connector. A135699 A135700 ES–492 2GR-FE ENGINE CONTROL SYSTEM – VVT SENSOR 3. INSTALL VVT SENSOR (for Bank 1 Exhaust Side) (a) Install the VVT sensor with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) (b) Connect the VVT sensor connector. 4. INSTALL VVT SENSOR (for Bank 1 Intake Side) (a) Install the VVT sensor with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) (b) Connect the VVT sensor connector. 5. INSTALL INTAKE AIR SURGE TANK ASSEMBLY (See page FU-18) 6. INSTALL NO. 1 AIR CLEANER INLET (See page EM49) 7. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (See page EM-50) 8. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See page ES-506) 9. INSTALL AIR CLEANER INLET ASSEMBLY (See page EM-50) A135702 ES A135701 10. INSTALL V-BANK COVER SUB-ASSEMBLY (See page EM-52) 11. INSTALL COOL AIR INTAKE DUCT SEAL (See page EM-52) 12. INSTALL COWL TOP PANEL OUTER SUBASSEMBLY (See page ES-485) 13. INSTALL WINDSHIELD WIPER MOTOR AND LINK (See page WW-14) 14. INSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See page WW-15) 15. INSTALL FRONT FENDER TO COWL SIDE SEAL RH (See page WW-15) 16. INSTALL FRONT FENDER TO COWL SIDE SEAL LH (See page WW-15) 17. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH (See page WW-15) 18. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH (See page WW-16) 19. ADD ENGINE COOLANT (See page CO-6) 20. CHECK FOR ENGINE COOLANT LEAKS (See page CO-1) 21. INSTALL ENGINE UNDER COVER RH 2GR-FE ENGINE CONTROL SYSTEM – VVT SENSOR ES–493 22. INSTALL ENGINE UNDER COVER LH ES 2GR-FE ENGINE CONTROL SYSTEM – CRANKSHAFT POSITION SENSOR ES–493 CRANKSHAFT POSITION SENSOR 2GR-FE ENGINE CONTROL SYSTEM ENGINE COMPONENTS V-BANK COVER SUB-ASSEMBLY 5.0 (51, 44 in.*lbf) x2 ES AIR CLEANER INLET ASSEMBLY 5.0 (51, 44 in.*lbf) NO. 1 AIR CLEANER INLET AIR CLEANER CAP SUB-ASSEMBLY AIR CLEANER FILTER ELEMENT COOL AIR INTAKE DUCT SEAL N*m (kgf*cm, ft.*lbf) : Specified torque A134975E01 ES–494 2GR-FE ENGINE CONTROL SYSTEM – CRANKSHAFT POSITION SENSOR 7.0 (71, 62 in.*lbf) x4 RADIATOR SUPPORT UPPER HOOD LOCK ASSEMBLY x2 7.5 (77, 66 in.*lbf) HORN CONNECTOR ES 7.0 (71, 62 in.*lbf) RADIATOR GRILLE PROTECTOR 7.5 (77, 66 in.*lbf) x2 x2 FRONT BUMPER ENERGY ABSORBER x2 ENGINE UNDER COVER LH FRONT BUMPER ASSEMBLY x9 ENGINE UNDER COVER RH FRONT WHEEL OPENING EXTENSION PAD RH FRONT WHEEL OPENING EXTENSION PAD LH N*m (kgf*cm, ft.*lbf) : Specified torque A133359E05 2GR-FE ENGINE CONTROL SYSTEM – CRANKSHAFT POSITION SENSOR ES–495 V-RIBBED BELT FRONT FENDER APRON SEAL RH 9.8 (100, 87 in.*lbf) 8.4 (86, 74 in.*lbf) WIRE HARNESS CLAMP STAY 43 (438, 32) RADIATOR INLET HOSE ES RADIATOR OUTLET HOSE 20 (204, 15) 43 (438, 32) 20 (204, 15) GENERATOR BRACKET GENERATOR ASSEMBLY FAN MOTOR CONNECTOR RADIATOR ASSEMBLY FAN SHROUD x4 5.0 (51, 44 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque A133878E03 ES–496 2GR-FE ENGINE CONTROL SYSTEM – CRANKSHAFT POSITION SENSOR NO. 1 COOLER REFRIGERANT DISCHARGE HOSE 9.8 (100, 87 in.*lbf) O-RING COMPRESSOR AND MAGNETIC CLUTCH O-RING 9.8 (100, 87 in.*lbf) ES 25 (255, 18) NO. 1 COOLER REFRIGERANT SUCTION HOSE 10 (102, 7) CRANKSHAFT POSITION SENSOR N*m (kgf*cm, ft.*lbf) : Specified torque Compressor oil ND-OIL 8 or equivalent Non-reusable part A135633E01 2GR-FE ENGINE CONTROL SYSTEM – CRANKSHAFT POSITION SENSOR ES–497 REMOVAL 1. REMOVE GENERATOR ASSEMBLY HINT: (See page CH-13) 2. DISCONNECT COOLER COMPRESSOR ASSEMBLY HINT: (See page AC-219) 3. REMOVE CRANKSHAFT POSITION SENSOR (a) Disconnect the crankshaft position sensor connector. (b) Remove the bolt and crankshaft position sensor. ES A076417 INSPECTION 1. A094922 INSPECT CRANKSHAFT POSITION SENSOR (a) Using an ohmmeter, measure the resistance between the terminals. Resistance: 1,630 to 2,740 Ω at cold 2,065 to 3,225 Ω at hot NOTICE: The terms "cold" and "hot" refer to the temperature of the coils. "Cold" means approximately -10 to 50°C (14 to 122°F). "Hot" means approximately 50 to 100°C (122 to 212°F). If the resistance is not as specified, replace the sensor. ES–498 2GR-FE ENGINE CONTROL SYSTEM – CRANKSHAFT POSITION SENSOR INSTALLATION 1. INSTALL CRANKSHAFT POSITION SENSOR (a) Apply a light coat of engine oil to the O-ring of the crankshaft position sensor. (b) Install the crankshaft position sensor with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) (c) Connect the crankshaft position sensor connector. ES ) A106634E02 2. INSTALL COOLER COMPRESSOR ASSEMBLY HINT: (See page AC-225) 3. INSTALL GENERATOR ASSEMBLY HINT: (See page CH-22 ) ES–498 2GR-FE ENGINE CONTROL SYSTEM – ENGINE COOLANT TEMPERATURE SENSOR ENGINE COOLANT TEMPERATURE SENSOR 2GR-FE ENGINE CONTROL SYSTEM ENGINE COMPONENTS AIR CLEANER CAP SUB-ASSEMBLY V-BANK COVER SUB-ASSEMBLY AIR CLEANER FILTER ELEMENT ES COOL AIR INTAKE DUCT SEAL 5.0 (51, 44 in.*lbf) 5.0 (51, 44 in.*lbf) AIR CLEANER INLET ASSEMBLY AIR CLEANER CASE SUB-ASSEMBLY 5.0 (51, 44 in.*lbf) NO. 1 AIR CLEANER INLET ENGINE UNDER COVER RH ENGINE UNDER COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque A135093E01 2GR-FE ENGINE CONTROL SYSTEM – ENGINE COOLANT TEMPERATURE SENSOR ENGINE COOLANT TEMPERATURE SENSOR ES–499 20 (204, 15) ES N*m (kgf*cm, ft.*lbf) : Specified torque A135635E01 ES–500 2GR-FE ENGINE CONTROL SYSTEM – ENGINE COOLANT TEMPERATURE SENSOR REMOVAL 1. REMOVE ENGINE UNDER COVER LH 2. REMOVE ENGINE UNDER COVER RH 3. DRAIN ENGINE COOLANT (See page CO-5) 4. REMOVE V-BANK COVER SUB-ASSEMBLY (See page EM-23) 5. REMOVE AIR CLEANER INLET ASSEMBLY (See page EM-24) 6. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-503) 7. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (See page EM-24) 8. REMOVE NO. 1 AIR CLEANER INLET (See page EM24) 9. REMOVE ENGINE COOLANT TEMPERATURE SENSOR (a) Remove the engine coolant temperature sensor connector. (b) Remove the engine coolant temperature sensor. ES A135703E01 INSPECTION 1. kΩ INSPECT ENGINE COOLANT TEMPERATURE SENSOR (a) Measure the resistance between the terminals. Standard resistance Condition Specified Condition Approx. 20°C (68°F) 2.32 to 2.59 kΩ Approx. 80°C (176°F) 0.31 to 0.326 kΩ If the result is not as specified, replace the sensor. NOTICE: If checking the ECT sensor in the water, keep the terminals dry. After checking, dry the sensor. °C (°F) A092795E03 2GR-FE ENGINE CONTROL SYSTEM – ENGINE COOLANT TEMPERATURE SENSOR ES–501 INSTALLATION 1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR (a) Install a new gasket to the engine coolant temperature sensor. (b) Install the engine coolant temperature sensor. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) (c) Connect the engine coolant temperature sensor connector. A135703 2. INSTALL NO. 1 AIR CLEANER INLET (See page EM49) 3. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (See page EM-50) 4. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See page ES-506) 5. INSTALL AIR CLEANER INLET ASSEMBLY (See page EM-50) 6. INSTALL V-BANK COVER SUB-ASSEMBLY (See page EM-52) 7. ADD ENGINE COOLANT (See page CO-6) 8. CHECK FOR ENGINE COOLANT LEAKS (See page CO-1) 9. INSTALL ENGINE UNDER COVER RH 10. INSTALL ENGINE UNDER COVER LH ES ES–502 2GR-FE ENGINE CONTROL SYSTEM – THROTTLE BODY THROTTLE BODY 2GR-FE ENGINE CONTROL SYSTEM ENGINE COMPONENTS AIR CLEANER CAP SUB-ASSEMBLY COOL AIR INTAKE DUCT SEAL V-BANK COVER SUB-ASSEMBLY ES AIR CLEANER INLET ASSEMBLY 5.0 (51, 44 in.*lbf) AIR CLEANER SUB-ASSEMBLY GASKET 5.0 (51, 44 in.*lbf) x4 5.0 (51, 44 in.*lbf) THROTTLE BODY 10 (102, 7) AIR CLEANER CASE SUB-ASSEMBLY NO. 1 AIR CLEANER INLET ENGINE UNDER COVER RH ENGINE UNDER COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A135108E01 2GR-FE ENGINE CONTROL SYSTEM – THROTTLE BODY ES–503 ON-VEHICLE INSPECTION 1. A129612 (b) Inspect the throttle position sensor. (1) Connect the intelligent tester (with CAN VIM) to the DLC3. (2) Turn the ignition switch on (IG). (3) Check that the MIL is off. (4) Check that, under the CURRENT DATA, THROTTLE POS (throttle valve opening percentage) is within the standard range below. Standard throttle valve opening percentage: 60 % or more If operation is not as specified, check the throttle position sensor, wiring and ECM (See page ES-505). Intelligent Tester DLC3 INSPECTION THROTTLE BODY (a) Inspect the throttle control motor for operating sounds. (1) Turn the ignition switch on (IG). (2) When turning the accelerator pedal position sensor lever, check for running sounds of the motor. The motor should be running smoothly without friction sounds. If operation is not as specified, check the throttle control motor, wiring and ECM (See page ES-505). CAN VIM C131977E05 ES ES–504 2GR-FE ENGINE CONTROL SYSTEM – THROTTLE BODY REMOVAL 1. REMOVE ENGINE UNDER COVER LH 2. REMOVE ENGINE UNDER COVER RH 3. DRAIN ENGINE COOLANT (See page CO-5) 4. REMOVE COOL AIR INTAKE DUCT SEAL (See page EM-23) 5. REMOVE V-BANK COVER SUB-ASSEMBLY (See page EM-23) 6. REMOVE AIR CLEANER INLET ASSEMBLY (See page EM-24) 7. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (a) Disconnect the 3 vacuum hoses. ES A135704 (b) Disconnect the mass air flow meter connector (*1). (c) Disconnect the No. 2 ventilation hose (*2). (d) Disconnect the hose band (*3). (*1) (*3) (*2) A135705E01 (e) Disconnect the 3 bands, and remove the air cleaner cap sub-assembly. A135706 8. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (See page EM-24) 9. REMOVE NO. 1 AIR CLEANER INLET (See page EM24) 2GR-FE ENGINE CONTROL SYSTEM – THROTTLE BODY ES–505 10. REMOVE THROTTLE BODY (a) Disconnect the throttle body connector and clamp. A135707 (b) Disconnect the 2 water by-pass hoses from the throttle body. ES A135708 (c) Remove the 4 bolts and throttle body. (d) Remove the throttle body gasket from the intake air surge tank. A135709 INSPECTION 1. VTA VC VTA2 E2 M+ M- INSPECT THROTTLE BODY (a) Measure the resistance between the terminals. Standard resistance Tester Connection Condition Specified Condition 2 (M+) - 1 (M-) 20°C (68°F) 0.3 to 100 Ω 5 (VC) - 3 (E2) 20°C (68°F) 1.2 to 3.2 kΩ If the result is not as specified, replace the throttle body assembly. A075258E15 INSTALLATION 1. Recess A133820E01 INSTALL THROTTLE BODY (a) Install a new throttle body gasket to the intake air surge tank. ES–506 2GR-FE ENGINE CONTROL SYSTEM – THROTTLE BODY (b) Install the throttle body with the 4 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) A135709 (c) Connect the 2 water by-pass hoses. ES A135708 (d) Connect the throttle body connector and clamp. 2. INSTALL NO. 1 AIR CLEANER INLET (See page EM49) 3. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (See page EM-50) 4. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (a) Install the air cleaner cap sub-assembly, and connect the 3 bands. A135707 A135706 (*1) (*3) (*2) A135705E01 (b) Connect the mass air flow meter connector (*1). (c) Connect the No. 2 ventilation hose (*2). (d) Connect the hose band (*3). 2GR-FE ENGINE CONTROL SYSTEM – THROTTLE BODY ES–507 (e) Connect the 3 vacuum hoses. 5. INSTALL AIR CLEANER INLET ASSEMBLY (See page EM-50) 6. INSTALL COOL AIR INTAKE DUCT SEAL (See page EM-52) 7. ADD ENGINE COOLANT (See page CO-6) 8. CHECK FOR ENGINE COOLANT LEAKS (See page CO-1) 9. CHECK FUNCTION OF THROTTLE BODY (See page ES-503) A135704 10. INSTALL V-BANK COVER SUB-ASSEMBLY (See page EM-52) ES 2GR-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR ES–507 KNOCK SENSOR 2GR-FE ENGINE CONTROL SYSTEM ENGINE COMPONENTS AIR CLEANER CAP SUB-ASSEMBLY V-BANK COVER SUB-ASSEMBLY AIR CLEANER FILTER ELEMENT ES COOL AIR INTAKE DUCT SEAL 5.0 (51, 44 in.*lbf) 5.0 (51, 44 in.*lbf) AIR CLEANER INLET ASSEMBLY AIR CLEANER CASE SUB-ASSEMBLY 5.0 (51, 44 in.*lbf) NO. 1 AIR CLEANER INLET ENGINE UNDER COVER RH ENGINE UNDER COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque A135093E01 ES–508 2GR-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR 20 (204, 15) WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH 20 (204, 15) FRONT FENDER TO COWL SIDE SEAL LH COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH 7.5 (77, 66 in.*lbf) ES 7.5 (77, 66 in.*lbf) 5.0 (51, 44 in.*lbf) FRONT FENDER TO COWL SIDE SEAL RH 85 (867, 63) x4 x4 WINDSHIELD WIPER MOTOR AND LINK COWL TOP OUTER PANEL SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque A135105E01 ES–509 2GR-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR VACUUM HOSE CLAMP UNION TO CHECK VALVE HOSE THROTTLE BODY BRACKET * SURGE TANK STAY NO. 1 21 (214, 15) VENTILATION HOSE NO. 2 16 (163, 12) 5.4 (55, 48 in.*lbf) INTAKE AIR SURGE TANK * 18 (184, 13) * x4 VACUUM HOSE 21 (214, 15) ES 16 (163, 12) 23 (235, 17) VAPOR FEED HOSE 38 (387, 28) 21 (214, 15) WATER BY-PASS HOSE AIR SURGE TANK TO INTAKE MANIFOLD GASKET ENGINE MOUNTING STAY NO. 2 RH FUEL MAIN TUBE 21 (214, 15) INTAKE MANIFOLD INTAKE MANIFOLD TO HEAD GASKET NO. 1 21 (214, 15) 20 (204, 15) KNOCK CONTROL SENSOR KNOCK CONTROL SENSOR N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part * DO NOT apply oil A138532E01 ES–510 2GR-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR REMOVAL 1. DISCHARGE FUEL SYSTEM PRESSURE (See page FU-13) 2. REMOVE ENGINE UNDER COVER LH 3. REMOVE ENGINE UNDER COVER RH 4. DRAIN ENGINE COOLANT (See page CO-5) 5. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH (See page WW-9) 6. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH (See page WW-9) 7. REMOVE FRONT FENDER TO COWL SIDE SEAL LH (See page WW-9) 8. REMOVE FRONT FENDER TO COWL SIDE SEAL RH (See page WW-9) 9. REMOVE COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See page WW-10) ES 10. REMOVE WINDSHIELD WIPER MOTOR AND LINK (See page WW-10) 11. REMOVE COWL TOP PANEL OUTER SUBASSEMBLY (See page ES-481) 12. REMOVE COOL AIR INTAKE DUCT SEAL (See page ES-481) 13. REMOVE V-BANK COVER SUB-ASSEMBLY (See page EM-23) 14. REMOVE AIR CLEANER INLET ASSEMBLY (See page EM-24) 15. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-503) 16. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (See page EM-24) 17. REMOVE NO. 1 AIR CLEANER INLET (See page EM24) 18. REMOVE INTAKE AIR SURGE TANK (See page FU13) 19. SEPARATE FUEL TUBE SUB-ASSEMBLY (See page EM-28) 20. REMOVE INTAKE MANIFOLD (See page EM-32) 2GR-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR ES–511 21. REMOVE KNOCK CONTROL SENSOR (a) Disconnect the 2 knock control sensor connectors. (b) Remove the 2 bolts and 2 knock control sensors. A129615 INSPECTION 1. INSPECT KNOCK CONTROL SENSOR (a) Using an ohmmeter, measure the resistance between the terminals. Standard resistance: 120 to 280 kΩ at 20°C (68°F) If the result is not as specified, replace the sensor. A065174 INSTALLATION RH Bank : 1. INSTALL KNOCK CONTROL SENSOR (a) Install the 2 knock control sensors with the 2 bolts as shown in the illustration. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) (b) Connect the 2 knock control sensor connectors. 2. INSTALL INTAKE MANIFOLD (See page EM-41) 3. CONNECT FUEL TUBE SUB-ASSEMBLY (See page EM-46) 4. INSTALL INTAKE AIR SURGE TANK (See page FU18) 5. INSTALL NO. 1 AIR CLEANER INLET (See page EM49) 6. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (See page EM-50) 7. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See page ES-506) 8. INSTALL AIR CLEANER INLET ASSEMBLY (See page EM-50) 9. INSTALL V-BANK COVER SUB-ASSEMBLY (See page EM-52) 5q 10q LH Bank : Front 10q 5q A132951E01 10. INSTALL COOL AIR INTAKE DUCT SEAL (See page EM-52) 11. INSTALL COWL TOP PANEL OUTER SUBASSEMBLY (See page ES-485) 12. INSTALL WINDSHIELD WIPER MOTOR AND LINK (See page WW-14) ES ES–512 2GR-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR 13. INSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See page WW-15) 14. INSTALL FRONT FENDER TO COWL SIDE SEAL RH (See page WW-15) 15. INSTALL FRONT FENDER TO COWL SIDE SEAL LH (See page WW-15) 16. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH (See page WW-15) 17. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH (See page WW-16) 18. ADD ENGINE COOLANT (See page CO-6) ES 19. CHECK FOR ENGINE COOLANT LEAKS (See page CO-1) 20. CHECK FOR FUEL LEAKS (See page FU-8) 21. INSTALL ENGINE UNDER COVER RH 22. INSTALL ENGINE UNDER COVER LH 2GR-FE ENGINE CONTROL SYSTEM – IG2 RELAY ES–513 IG2 RELAY INSPECTION 1. B016200 INSPECT IG2 RELAY (a) Using an ohmmeter, measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (Battery voltage applied between terminals 1 and 2) If the result is not as specified, replace the relay. ES ES–514 2GR-FE ENGINE CONTROL SYSTEM – EFI RELAY EFI RELAY Engine Room R/B Unit D: INSPECTION 1. 1E INSPECT EFI RELAY (a) Using an ohmmeter, measure the resistance according to the value(s) in the table below. Standard resistance Tester connection 12 10 9 ES 7 A137364E01 Specified Condition 1E-9 - 1E-10 Below 1 Ω 1E-7 - 1E-12 10 kΩ or higher 1E-7 - 1E-12 Below 1 Ω (Battery voltage applied between terminals 1E-9 and 1E-10) 2GR-FE ENGINE CONTROL SYSTEM – CIRCUIT OPENING RELAY ES–515 CIRCUIT OPENING RELAY Engine Room R/B Unit D: INSPECTION 1. 1E INSPECT CIRCUIT OPENING RELAY (a) Using an ohmmeter, measure the resistance according to the value(s) in the table below. Standard resistance Tester connection 1E-8 - 1E-12 13 12 8 7 A137364E02 Specified Condition Below 1 Ω 1E-7 - 1E-13 10 kΩ or higher 1E-7 - 1E-13 Below 1 Ω (Battery voltage applied between terminals 1E-8 and 1E-12) ES ES–516 2GR-FE ENGINE CONTROL SYSTEM – AIR FUEL RATIO SENSOR RELAY AIR FUEL RATIO SENSOR RELAY Engine Room R/B Unit D: INSPECTION 1. 1A 1E INSPECT AIR FUEL RATIO SENSOR RELAY (a) Using an ohmmeter, measure the resistance according to the value(s) in the table below. Standard resistance Tester connection 1E-7 - 1E-10 4 ES 3 10 7 A137364E03 Specified Condition Below 1 Ω 1A-3 - 1A-4 10 kΩ or higher 1A-3 - 1A-4 Below 1 Ω (Battery voltage applied between terminals 1E-7 and 1E-10) ES–517 2GR-FE ENGINE CONTROL SYSTEM – ECM ECM 2GR-FE ENGINE CONTROL SYSTEM ENGINE COMPONENTS 20 (204, 15) WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH 20 (204, 15) WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH FRONT FENDER TO COWL SIDE SEAL LH ES FRONT FENDER TO COWL SIDE SEAL RH 7.5 (77, 66 in.*lbf) 7.5 (77, 66 in.*lbf) COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY WINDSHIELD WIPER MOTOR AND LINK 3.0 (31, 27 in.*lbf) 85 (867, 63) 8.0 (82, 71 in.*lbf) 5.0 (51, 44 in.*lbf) 5.0 (51, 44 in.*lbf) 85 (867, 63) ECM 5.0 (51, 44 in.*lbf) 85 (867, 63) 8.0 (82, 71 in.*lbf) 3.0 (31, 27 in.*lbf) COWL TOP PANEL OUTER SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque A135644E03 ES–518 2GR-FE ENGINE CONTROL SYSTEM – ECM REMOVAL ES 1. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH (See page WW-9) 2. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH (See page WW-9) 3. REMOVE FRONT FENDER TO COWL SIDE SEAL LH (See page WW-9) 4. REMOVE FRONT FENDER TO COWL SIDE SEAL RH (See page WW-9) 5. REMOVE COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See page WW-10) 6. REMOVE WINDSHIELD WIPER MOTOR AND LINK (See page WW-10) 7. REMOVE COWL TOP OUTER PANEL SUBASSEMBLY (See page ES-481) 8. REMOVE ECM (a) Remove the 3 nuts. A135711 Lock Push A128952E01 (b) Disconnect the 2 ECM connectors and remove the ECM. (1) Raise the 2 levers while pushing the locks on the 2 levers, and disconnect the 2 ECM connectors. NOTICE: After disconnecting the connector, make sure that dirt, water and other foreign matter do not contact the connecting part of the connector. (2) Remove the ECM. 2GR-FE ENGINE CONTROL SYSTEM – ECM ES–519 (c) Remove the 4 screws and 2 ECM brackets. A135713 INSTALLATION 1. A135713 INSTALL ECM (a) Install the ECM bracket with the 4 screws. Torque: 3.0 N*m (31 kgf*cm, 27 in.*lbf) (b) Connect the 2 ECM connectors. NOTICE: When connecting the connector, make sure that dirt, water and other foreign matter do not become stuck between the connector and other parts. (1) Connect the 2 ECM connectors and lower the 2 levers. NOTICE: Make sure that the 2 levers are securely lowered. A128949 (c) Install the ECM with the 3 nuts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) A135711 2. INSTALL COWL TOP PANEL OUTER SUBASSEMBLY (See page ES-485) 3. INSTALL WINDSHIELD WIPER MOTOR AND LINK (See page WW-14) 4. INSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See page WW-15) 5. INSTALL FRONT FENDER TO COWL SIDE SEAL RH (See page WW-15) 6. INSTALL FRONT FENDER TO COWL SIDE SEAL LH (See page WW-15) 7. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH (See page WW-15) 8. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH (See page WW-16) 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page EM-51) ES ES–520 2GR-FE ENGINE CONTROL SYSTEM – ACCELERATOR PEDAL ACCELERATOR PEDAL 2GR-FE ENGINE CONTROL SYSTEM ENGINE COMPONENTS ES 5.4 (55, 48 in.*lbf) ACCELERATOR PEDAL ROD N*m (kgf*cm, ft.*lbf) : Specified torque A135645E01 2GR-FE ENGINE CONTROL SYSTEM – ACCELERATOR PEDAL ES–521 ON-VEHICLE INSPECTION Intelligent Tester 1. DLC3 CAN VIM CHECK ACCELERATOR PEDAL ROD (a) Measure the voltage. (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch on (IG). (3) Turn the intelligent tester ON. (4) Select the menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / ACCEL POS #1, ACCEL POS #2. (5) Operate the accelerator pedal, and then check that the ACCEL POS #1 and ACCEL POS #2 values are within the specifications. Standard voltage (ACCEL POS #1) Accelerator Pedal Condition B127989E01 Specified Condition Released 0.5 to 1.1 V Depressed 2.5 to 4.5 V Standard voltage (ACCEL POS #2) Accelerator Pedal Condition Specified Condition Released 1.2 to 2.0 V Depressed 3.4 to 5.0 V If the result is not as specified, check the accelerator pedal rod, wire harness or ECM. REMOVAL 1. A135676 REMOVE ACCELERATOR PEDAL (a) Disconnect the accelerator pedal connector. (b) Remove the 2 bolts and the accelerator pedal assembly. ES ES–522 2GR-FE ENGINE CONTROL SYSTEM – ACCELERATOR PEDAL INSTALLATION 1. INSTALL ACCELERATOR PEDAL NOTICE: • Avoid physical shock to the accelerator pedal assembly. • Do not disassemble the accelerator pedal assembly. (a) Install the accelerator pedal assembly with the 2 bolts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) (b) Connect the accelerator pedal connector. ES A135676 SE–1 SEAT – FRONT POWER SEAT CONTROL SYSTEM FRONT POWER SEAT CONTROL SYSTEM PRECAUTION 1. Switch Type Ignition switch off Expression EXPRESSIONS OF IGNITION SWITCH (a) The type of ignition switch used on this model differs according to the specifications of the vehicle. The expressions listed in the table below are used in this section. Ignition Switch (position) Engine Switch (condition) LOCK Off Ignition switch on (IG) ON On (IG) Ignition switch on (ACC) ACC On (ACC) Engine start START Start SE SE–2 SEAT – FRONT POWER SEAT CONTROL SYSTEM PARTS LOCATION ENGINE ROOM J/B AND R/B - ALT FUSE SE MAIN BODY ECU (INSTRUMENT PANEL J/B) - P/SEAT FUSE B126234E01 SE–3 SEAT – FRONT POWER SEAT CONTROL SYSTEM (RECLINING MOTOR) LUMBAR SUPPORT ADJUSTER ASSEMBLY SE (LIFTER MOTOR) FRONT POWER SEAT LUMBAR SWITCH POWER SEAT SWITCH FRONT SEAT FRAME WITH ADJUSTER - RECLINING MOTOR (SLIDE MOTOR) - SLIDE MOTOR (FRONT VERTICAL MOTOR) - LIFTER MOTOR - FRONT VERTICAL MOTOR B126235E01 SE–4 SEAT – FRONT POWER SEAT CONTROL SYSTEM (RECLINING MOTOR) POWER SEAT SWITCH SE FRONT SEAT FRAME WITH ADJUSTER - RECLINING MOTOR (SLIDE MOTOR) - SLIDE MOTOR B126236E01 SE–5 SEAT – FRONT POWER SEAT CONTROL SYSTEM SYSTEM DIAGRAM Driver Side: U7 Power Seat Switch LH 1 B E 4 Front Rear Up Down Front Up Rear Down SE Slide Front Vertical Reclining Rear Vertical SLDF 9 SLDR FUP FDWN RCLF RCLR LUP LDWN 7 2 8 6 10 5 3 U1 U2 U3 U4 Slide Front Reclining Lifter Control Vertical Control Control 2 2 1 1 Motor Control Motor Motor Motor 1 1 2 2 P/SEAT ALT 2 5 R1 E Battery R 1 U8 Front Power Seat Lumbar Switch Front Rear FL MAIN 3 B U5 Lumbar Support Motor H 4 1 2 B127144E09 SE–6 SEAT – FRONT POWER SEAT CONTROL SYSTEM Front Passenger Side: T8 Power Seat Switch RH 1 B E 4 Front Rear SE Front Rear Slide Reclining SLDF 9 T1 Slide Control Motor SLFR 6 RCLF 3 RCLR 1 2 T9 Reclining 1 Control Motor 2 2 P/SEAT ALT FL MAIN Battery B126237E01 SEAT – FRONT POWER SEAT CONTROL SYSTEM SE–7 SYSTEM DESCRIPTION 1. 2. Components FRONT POWER SEAT CONTROL SYSTEM DESCRIPTION The driver seat and front passenger seat are equipped with slide, reclining, lifter, front vertical, and lumbar support adjustment functions. FUNCTION OF MAIN COMPONENTS The following functions are available: Function Power seat motor assembly (slide motor) Activated based on a signal from the power seat switch, a motor is activated and slides the seat forward and rearward. Power seat motor assembly (reclining motor) Activated based on a signal from the power seat switch, a motor is activated and tilts and reclines the seat. Power seat motor assembly (front vertical motor) Activated based on a signal from the power seat switch and raises and lowers the seat cushion front vertically. Power seat motor assembly (lifter motor) Activated based on a signal from the power seat switch and raises and lowers the seat vertically. Lumbar support adjuster motor Activated based on a signal from the front power seat lumbar switch and adjusts lumbar support. Front power seat lumbar switch Based on switches operated, the seat is adjusted accordingly. OPERATION CHECK Reclining Function 1. Lumbar Support Function Lifter Function Front Vertical Function Sliding Function B126238E01 CHECK POWER SEAT FUNCTION (a) Check the basic functions. (1) Operate the power seat switches and check that the following functions work: • Sliding • Reclining • Lumbar support (Driver side only) • Front vertical (Driver side only) • Lifter (Driver side only) SE SE–8 SEAT – FRONT POWER SEAT CONTROL SYSTEM PROBLEM SYMPTOMS TABLE HINT: • Inspect the fuses and relays before confirming the suspected areas in the table below. • Inspect each suspected area in numerical order for the corresponding symptom. Front Power Seat Control System (Driver Side): Symptom Suspected area 1. P/SEAT fuse Power seat does not operate (slide, front vertical, lifter, reclining). SE Only slide operation function does not operate. Only front vertical operation function does not operate. Only lifter operation function does not operate. Only reclining operation function does not operate. Only lumbar support operation function does not operate. See page - 2. Power seat switch LH SE-87 3. Wire harness or connector - 1. Power seat switch LH SE-87 2. Front seat frame with adjuster LH (slide motor) SE-90 3. Wire harness or connector - 1. Power seat switch LH SE-87 2. Front seat frame with adjuster LH (front vertical motor) SE-90 3. Wire harness or connector - 1. Power seat switch LH SE-87 2. Front seat frame with adjuster LH (lifter motor) SE-90 3. Wire harness or connector - 1. Power seat switch LH SE-87 2. Front seat frame with adjuster LH (reclining motor) SE-90 3. Wire harness or connector - 1. Front power seat lumbar switch LH SE-94 2. Lumbar support adjuster assembly LH SE-98 3. Wire harness or connector - Front Power Seat Control System (Front Passenger Side): Symptom Suspected area 1. P/SEAT fuse Power seat does not operate (slide and reclining). Only slide operation function does not operate. Only reclining operation function does not operate. See page - 2. Power seat switch RH SE-89 3. Wire harness or connector - 1. Power seat switch RH SE-89 2. Front seat frame with adjuster RH (slide motor) SE-91 3. Wire harness or connector - 1. Power seat switch RH SE-89 2. Front seat frame with adjuster RH (reclining motor) SE-91 3. Wire harness or connector - SE–9 SEAT – SEAT HEATER SYSTEM SEAT HEATER SYSTEM PRECAUTION 1. Switch Type Expression EXPRESSIONS OF IGNITION SWITCH (a) The type of ignition switch used on this model differs according to the specifications of the vehicle. The expressions listed in the table below are used in this section. Ignition Switch (position) Engine Switch (condition) Ignition switch off LOCK Off Ignition switch on (IG) ON On (IG) Ignition switch on (ACC) ACC On (ACC) Engine start START Start SE SE–10 SEAT – SEAT HEATER SYSTEM PARTS LOCATION SEAT HEATER SWITCH SE COMBINATION METER SEAT HEATER SWITCH MAIN BODY ECU (INSTRUMENT PANEL J/B) - S-HTR FUSE - PANEL FUSE FRONT SEAT CUSHION HEATER FRONT SEAT CUSHION HEATER (SEAT CUSHION HEATER RH) (SEAT CUSHION HEATER LH) FRONT SEATBACK HEATER FRONT SEATBACK HEATER (SEATBACK HEATER LH) (SEATBACK HEATER RH) B137070E01 SE–11 SEAT – SEAT HEATER SYSTEM SYSTEM DIAGRAM E55 Seat Heater Switch From S-HTR Fuse 5 IG SE T6 Seat Heater RH 2 Seat Cushion 1 3 RH RH Side Seat SW Seat Back 4 E U6 Seat Heater LH 2 Seat Cushion 1 6 LH LH Side Seat SW Seat Back B126243E01 SE–12 SEAT – SEAT HEATER SYSTEM SYSTEM DESCRIPTION 1. SE GENERAL DESCRIPTION (a) By operating the seat heater switch, which is located in the console box, the temperature can be controlled within the range of 30 to 40°C (86 to 104°F). (b) The seat heater switch indicator light provides seat heater on/off status. (c) The seat heaters of both seats are controlled by the seat heater controls, which are located under the respective seat. SE–13 SEAT – SEAT HEATER SYSTEM PROBLEM SYMPTOMS TABLE SEAT HEATER SYSTEM: Symptom Seat heater does not operate. (Front LH side) Seat heater does not operate. (Front RH side) Temperature of seat heater cannot be adjusted. Suspected area See page 1. S-HTR fuse - 2. Seat heater switch SE-101 3. Front seat cushion heater SE-106 4. Front seat back heater SE-111 5. Wire harness - 1. S-HTR fuse - 2. Seat heater switch SE-101 3. Front seat cushion heater SE-106 4. Front seat back heater SE-111 5. Wire harness - Seat heater switch SE-101 SE SE–13 SEAT – FRONT SEAT ASSEMBLY (for Manual Seat) FRONT SEAT ASSEMBLY (for Manual Seat) SEAT BODY COMPONENTS SE FRONT SEAT HEADREST ASSEMBLY 37 (377, 27) INNER SEAT TRACK BRACKET COVER FRONT SEAT ASSEMBLY SEAT TRACK COVER 37 (377, 27) 37 (377, 27) N*m (kgf*cm, ft.*lbf) : Specified torque B139116E01 SE–14 SEAT – FRONT SEAT ASSEMBLY (for Manual Seat) SEPARATE TYPE FRONT SEAT CUSHION COVER HOG RING SE SEPARATE TYPE FRONT SEAT CUSHION PAD FRONT SEAT CUSHION COVER WITH PAD LOWER SEAT TRACK SPACER 42 (428, 31) FRONT SEAT CUSHION SHIELD FRONT SEAT INNER BELT ASSEMBLY RECLINING ADJUSTER RELEASE HANDLE FRONT INNER SEAT CUSHION SHIELD for Front Passenger Seat: RECLINING ADJUSTER RELEASE HANDLE VERTICAL ADJUSTING HANDLE NO. 2 VERTICAL ADJUSTER COVER LH FRONT SEAT CUSHION SHIELD Non-reusable part N*m (kgf*cm, ft.*lbf) : Specified torque B139117E01 SE–15 SEAT – FRONT SEAT ASSEMBLY (for Manual Seat) FRONT SEAT HEADREST SUPPORT SE HOG RING FRONT SEAT BACK BOARD SUB-ASSEMBLY 5.5 (56, 49 in.*lbf) FRONT SEPARATE TYPE SEAT BACK COVER FRONT SEPARATE TYPE SEAT BACK PAD FRONT LOWER SEAT CUSHION SHIELD RH FRONT SEAT BACK COVER WITH PAD FRONT LOWER SEAT CUSHION SHIELD LH RECLINING ADJUSTER INSIDE COVER RH RECLINING ADJUSTER INSIDE COVER RH RECLINING ADJUSTER INSIDE COVER LH 8.0 (82, 71 in.*lbf) SEAT SLIDE POSITION SENSOR PROTECTOR SEAT POSITION SENSOR Non-reusable part RECLINING ADJUSTER INSIDE COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque B139118E01 SE–16 SEAT – FRONT SEAT ASSEMBLY (for Manual Seat) REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait for 90 seconds after disconnecting the cable to prevent the airbag from deploying (See page RS-1). 2. REMOVE FRONT SEAT HEADREST ASSEMBLY 3. REMOVE SEAT TRACK COVER (a) Move the front seat assembly fully forward by operating the slide handle. SE (b) Using a screwdriver, disengage the 4 claws and remove the seat track cover. HINT: Tape the screwdriver tip before use. B139099 B139100 4. REMOVE INNER SEAT TRACK BRACKET COVER (a) Using a screwdriver, disengage the 4 claws and remove the inner seat track bracket cover. HINT: Tape the screwdriver tip before use. 5. REMOVE FRONT SEAT ASSEMBLY (a) Move the front seat assembly to the rearmost position by operating the slide handle. SEAT – FRONT SEAT ASSEMBLY (for Manual Seat) SE–17 (b) Remove the 2 bolts on the front seat track bracket. (c) Move the front seat assembly fully forward by operating the slide handle. B139101 (d) Remove the 2 bolts on the rear seat track bracket. (e) Move the front seat assembly to the center position and adjust the seatback to the vertical position by operating the slide and reclining adjuster release handle. (f) Disconnect the connectors and clamp. (g) Remove the front seat assembly. B139102 SE SE–26 SEAT – FRONT SEAT ASSEMBLY (for Manual Seat) INSTALLATION 1. SE INSTALL FRONT SEAT ASSEMBLY (a) Place the front seat assembly in the vehicle and align the adjuster pin with the hole on the vehicle side. (b) Connect the connector and clamp. (c) Move the front seat assembly to the rearmost position by operating the slide handle. NOTICE: Check that the seat is locked. (d) Temporarily install the front seat track bracket with the 2 bolts. (e) Move the front seat assembly fully forward by operating the slide handle. NOTICE: Check that the seat is locked. B139101 (f) B139102 Temporarily install the rear seat track bracket with the 2 bolts. (g) Move the front seat assembly to the rearmost position by operating the slide handle. NOTICE: Check that the seat is locked. (h) Fully tighten the 2 bolts on the front seat track bracket in the order of the inner side bolt and then the outer side bolt. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) (i) Move the front seat assembly fully forward by operating the slide handle. NOTICE: Check that the seat is locked. (j) Fully tighten the 2 bolts on the rear seat track bracket in the order of the inner side bolt and then the outer side bolt. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) SEAT – FRONT SEAT ASSEMBLY (for Manual Seat) 2. Claw A SE–27 INSTALL INNER SEAT TRACK BRACKET COVER (a) Slide the inner seat track bracket cover along the seat rail toward the front of the vehicle. Engage claw A to the seat rail. (b) Push the seat track bracket cover inner to engage claw B. (2) (1) Claw B SE Claw B139100E01 3. INSTALL SEAT TRACK COVER (a) Slide the seat track cover along the seat rail toward the front of the vehicle. Engage claw A to the seat rail. (b) Push the seat track cover to engage claw B. 4. INSTALL FRONT SEAT HEADREST ASSEMBLY 5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 6. INSPECT SLIDE ADJUSTER LOCK 7. PERFORM ZERO POINT CALIBRATION AND SENSITIVITY CHECK (for Front Passenger Seat) (See page RS-242) 8. INSPECT SRS WARNING LIGHT Check the SRS warning light (See page RS-32). Claw A (1) (2) Claw B Claw B139099E01 SE–18 SEAT – FRONT SEAT ASSEMBLY (for Manual Seat) DISASSEMBLY NOTICE: Wear protective gloves. Sharp areas on the seat frame and adjuster may injure your hands. 1. REMOVE VERTICAL ADJUSTER COVER LH (for Driver Seat) (a) Using a screwdriver, disengage the 2 claws and remove the vertical adjuster cover LH. HINT: Tape the screwdriver tip before use. 2. REMOVE VERTICAL ADJUSTING HANDLE NO. 2 (for Driver Seat) (a) Remove the 2 screws and vertical adjusting handle. 3. REMOVE RECLINING ADJUSTER RELEASE HANDLE (a) Lift the reclining adjuster release handle. (b) Using a screwdriver, disengage the claw and remove the reclining adjuster release handle. HINT: Tape the screwdriver tip before use. 4. REMOVE FRONT SEAT CUSHION SHIELD (a) Disengage the 2 hooks. SE B139103 B139104 B139105 B139108 SEAT – FRONT SEAT ASSEMBLY (for Manual Seat) SE–19 (b) Remove the 3 screws. (c) Disengage the 2 claws and remove the front seat cushion shield. B139106 5. REMOVE LOWER SEAT TRACK SPACER (a) Remove the 2 screws and lower seat track spacer. 6. REMOVE FRONT SEAT INNER BELT ASSEMBLY (See page SB-15) 7. REMOVE FRONT INNER SEAT CUSHION SHIELD (a) Remove the screw. (b) Disengage the claw and clip, and then remove the front inner seat cushion shield. 8. REMOVE FRONT SEAT CUSHION COVER WITH PAD (a) Disengage the clamp. (b) Disengage the hooks and remove the front seat cushion cover with pad. B139122 B139107 Clamp B139123E01 SE SE–20 SEAT – FRONT SEAT ASSEMBLY (for Manual Seat) 9. REMOVE SEPARATE TYPE FRONT SEAT CUSHION COVER (a) Remove the 16 hog rings and separate type front seat cushion cover. SE Hog Ring B139121E01 10. REMOVE FRONT SEAT BACK BOARD SUBASSEMBLY (a) Remove the 2 screws. (b) Disconnect the 14 clamps and front separate type seat back cover. (c) Pull the seat back board in the direction indicated by the arrow in the illustration to detach the 2 claws. Then, remove the seat back board. Clamp B134682E01 11. REMOVE FRONT SEAT HEADREST SUPPORT (a) Detach the 2 claws and remove the headrest support. 12. REMOVE FRONT SEAT HEADREST SUPPORT B134683 13. REMOVE FRONT SEAT BACK COVER WITH PAD (a) Disengage the 3 hooks. B139109 SEAT – FRONT SEAT ASSEMBLY (for Manual Seat) SE–21 (b) Remove the 2 hog rings. Hog Ring B139110E01 (c) Remove the nut and separate the 2 brackets. (d) Remove the front seat back cover with pad. B139111 14. REMOVE FRONT SEPARATE TYPE SEAT BACK COVER (a) Remove the 10 hog rings and front separate type seat back cover. 15. REMOVE RECLINING ADJUSTER INSIDE COVER LH (a) Disconnect the clamp. Hog Ring B139112E01 (b) Remove the screw. (c) Disengage the claw and remove the reclining adjuster inside cover LH. 16. REMOVE RECLINING ADJUSTER INSIDE COVER RH HINT: Use the same procedures for the RH side and LH side. B139113 17. REMOVE RECLINING ADJUSTER INSIDE COVER LH (a) Remove the screw and reclining adjuster inside cover LH. 18. REMOVE RECLINING ADJUSTER INSIDE COVER RH HINT: Use the same procedures for the RH side and LH side. B139114 SE SE–22 SEAT – FRONT SEAT ASSEMBLY (for Manual Seat) 19. REMOVE FRONT LOWER SEAT CUSHION SHIELD LH (a) Using a screwdriver, disengage the claw and remove the front lower seat cushion shield LH. 20. REMOVE FRONT LOWER SEAT CUSHION SHIELD RH HINT: Use the same procedures for the RH side and LH side. B139115 SE 21. REMOVE SEAT POSITION SENSOR (for Driver Seat) (See page RS-461) SEAT – FRONT SEAT ASSEMBLY (for Manual Seat) SE–23 REASSEMBLY NOTICE: Wear protective gloves. Sharp areas on the seat frame and adjuster may injure your hands. 1. INSTALL SEAT POSITION SENSOR (for Driver Side) (See page RS-464) 2. INSTALL FRONT LOWER SEAT CUSHION SHIELD LH 3. INSTALL FRONT LOWER SEAT CUSHION SHIELD RH 4. INSTALL RECLINING ADJUSTER INSIDE COVER LH 5. INSTALL RECLINING ADJUSTER INSIDE COVER RH 6. INSTALL RECLINING ADJUSTER INSIDE COVER LH 7. INSTALL RECLINING ADJUSTER INSIDE COVER RH 8. INSTALL FRONT SEPARATE TYPE SEAT BACK COVER (a) Using hog ring pliers, install the front separate type seat back cover to the front separate type seat back pad with 10 new hog rings. NOTICE: • Be careful not to damage the cover. • When installing the hog rings, take care to minimize wrinkles as much as possible. 9. INSTALL FRONT SEAT BACK COVER WITH PAD (a) Fully cover the airbag with the 2 seat back cover brackets and tighten the nut. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) NOTICE: • For vehicles with side airbags, the seat back cover must be securely installed. Otherwise, the side airbags may not deploy properly. • Make sure that the strap is not twisted after installing the bracket. • Install the bracket securely. Hog Ring Pliers Hog Ring B140574E01 B139111 SE SE–24 SEAT – FRONT SEAT ASSEMBLY (for Manual Seat) (b) Using hog ring pliers, install the seat back cover (with pad) to the seat frame with 2 new hog rings, and attach the hooks. SE Hog Ring Pliers Hog Ring B140573E01 (c) Engage the 3 hooks. 10. INSTALL FRONT SEAT HEADREST SUPPORT 11. INSTALL FRONT SEAT HEADREST SUPPORT 12. INSTALL FRONT SEAT BACK BOARD SUBASSEMBLY B139109 13. INSTALL SEPARATE TYPE FRONT SEAT CUSHION COVER (a) Using hog ring pliers, install the separate type front seat cushion cover to the seat back pad with 16 new hog rings. NOTICE: • Be careful not to damage the cover. • When installing the hog rings, take care to minimize wrinkles as much as possible. 14. INSTALL FRONT SEAT CUSHION COVER WITH PAD 15. INSTALL FRONT INNER SEAT CUSHION SHIELD 16. INSTALL FRONT SEAT INNER BELT ASSEMBLY (See page SB-16) 17. INSTALL LOWER SEAT TRACK SPACER Hog Ring Pliers 18. INSTALL FRONT SEAT CUSHION SHIELD (for Driver Seat) 19. INSTALL RECLINING ADJUSTER RELEASE HANDLE Hog Ring B140572E01 SEAT – FRONT SEAT ASSEMBLY (for Manual Seat) SE–25 20. INSTALL VERTICAL ADJUSTING HANDLE NO. 2 (for Driver Seat) 21. INSTALL VERTICAL ADJUSTER COVER LH (for Driver Seat) SE SE–26 SEAT – FRONT SEAT ASSEMBLY (for Power Seat) FRONT SEAT ASSEMBLY (for Power Seat) SEAT BODY COMPONENTS SE FRONT SEAT HEADREST ASSEMBLY INNER SEAT TRACK BRACKET COVER FRONT SEAT ASSEMBLY SEAT TRACK COVER 37 (377, 27) 37 (377, 27) 37 (377, 27) N*m (kgf*cm, ft.*lbf) : Specified torque B134694E01 SE–27 SEAT – FRONT SEAT ASSEMBLY (for Power Seat) FRONT SEPARATE TYPE SEAT CUSHION COVER SE HOG RING FRONT SEPARATE TYPE SEAT CUSHION PAD FRONT INNER SEAT CUSHION SHIELD LOWER SEAT TRACK SPACER FRONT SEAT CUSHION SHIELD LOWER SEAT TRACK SPACER 42 (428, 31) FRONT SEAT INNER BELT ASSEMBLY FRONT POWER SEAT SWITCH FRONT LUMBAR POWER SEAT SWITCH FRONT INNER NO. 1 SEAT CUSHION SHIELD Non-reusable part SLIDE AND VERTICAL POWER SEAT SWITCH KNOB RECLINING POWER SEAT SWITCH KNOB N*m (kgf*cm, ft.*lbf) : Specified torque B134695E01 SE–28 SEAT – FRONT SEAT ASSEMBLY (for Power Seat) FRONT SEAT HEADREST SUPPORT SE 5.5 (56, 49 in.*lbf) FRONT SEAT BACK BOARD SUB-ASSEMBLY HOG RING FRONT SEPARATE TYPE SEAT BACK COVER for Sport Seat Type : Non-reusable part N*m (kgf*cm, ft.*lbf) : Specified torque B134696E01 SE–29 SEAT – FRONT SEAT ASSEMBLY (for Power Seat) SEAT RECLINING ADJUSTER INSIDE COVER RH LUMBAR SUPPORT ADJUSTER ASSEMBLY RECLINING ADJUSTER INSIDE COVER RH FRONT LOWER SEAT CUSHION SHIELD SE RECLINING ADJUSTER INSIDE COVER LH SEAT SLIDE POSITION SENSOR PROTECTOR SEAT RECLINING ADJUSTER INSIDE COVER LH 8.0 (82, 71 in.*lbf) SEAT POSITION SENSOR FRONT LOWER SEAT CUSHION SHIELD LH for Sport Seat Type: FRONT SEAT WIRE N*m (kgf*cm, ft.*lbf) : Specified torque B144024E01 SE–30 SEAT – FRONT SEAT ASSEMBLY (for Power Seat) REMOVAL 1. REMOVE FRONT SEAT HEADREST ASSEMBLY 2. REMOVE SEAT TRACK COVER (a) Operate the power seat switch knob and move the seat to the position farthest forward. (b) Using a screwdriver, detach the 4 claws and remove the seat track cover. HINT: Tape the screwdriver tip before use. SE B139099 B139100 3. REMOVE INNER SEAT TRACK BRACKET COVER (a) Using a screwdriver, detach the 4 claws and remove the inner seat track bracket cover. 4. REMOVE FRONT SEAT ASSEMBLY (a) Operate the power seat switch knob and move the seat to the rearmost position. SEAT – FRONT SEAT ASSEMBLY (for Power Seat) SE–31 (b) Remove the 2 bolts on the front seat track bracket. (c) Operate the power seat switch knob and move the seat to the position farthest forward. SE B140607 B139102 (d) Remove the 2 bolts on the rear seat track bracket. (e) Disconnect the cable from the negative (-) battery terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent the airbag and seat belt pretensioner from deploying (See page RS-1). (f) Disconnect the connectors under the seat. Then remove the front seat assembly. SE–32 SEAT – FRONT SEAT ASSEMBLY (for Power Seat) DISASSEMBLY CAUTION: Wear protective gloves. Sharp areas on the seat frame and adjuster may injure your hands. 1. REMOVE RECLINING POWER SEAT SWITCH KNOB (a) Using a screwdriver, detach the reclining power seat switch knob. HINT: Tape the screwdriver tip before use. 2. REMOVE SLIDE AND VERTICAL POWER SEAT SWITCH KNOB (a) Using a screwdriver, detach the slide and vertical power seat switch knob. HINT: Tape the screwdriver tip before use. 3. REMOVE FRONT SEAT CUSHION SHIELD ASSEMBLY (a) Disconnect the 2 hooks. SE B134671 B134672 B134678 (b) Remove the 5 screws. (c) Disengage the claw and separate the front seat cushion shield assembly. (d) Disconnect the connector from the front power seat lumbar switch. B134673 SEAT – FRONT SEAT ASSEMBLY (for Power Seat) SE–33 4. REMOVE FRONT INNER NO. 1 SEAT CUSHION SHIELD (a) Remove the screw. (b) Detach the 2 claws and remove the front inner No. 1 seat cushion shield. 5. REMOVE FRONT LUMBAR POWER SEAT SWITCH (a) Remove the 2 screws and front lumbar power seat switch. 6. REMOVE FRONT SEAT INNER BELT ASSEMBLY (See page SB-16) 7. REMOVE FRONT INNER SEAT CUSHION SHIELD (a) Remove the screw. (b) Using a clip remover, detach the clip. (c) Using a screwdriver, detach the claw and remove the front inner seat cushion shield. HINT: Tape the screwdriver tip before use. B134674 B134675 B134676 SE SE–34 SEAT – FRONT SEAT ASSEMBLY (for Power Seat) 8. REMOVE LOWER SEAT TRACK SPACER (a) Remove the 2 screws and lower seat track spacer. 9. REMOVE FRONT POWER SEAT SWITCH (a) Remove the 3 screws. (b) Disconnect the connector and remove the front power seat switch. RH SIDE: SE LH SIDE: B134698E01 B134677 10. REMOVE FRONT SEPARATE TYPE SEAT CUSHION ASSEMBLY (a) Disconnect the 2 clamps. (b) Remove the 4 hooks. Clamp B134679E01 SEAT – FRONT SEAT ASSEMBLY (for Power Seat) SE–35 (c) Using a screwdriver, detach the hooks and remove the front separate type seat cushion assembly. SE B134680 11. REMOVE FRONT SEPARATE TYPE SEAT CUSHION COVER (for Except Sports Seat Type) (a) Remove the 16 hog rings and front separate type seat cushion cover from the seat cushion pad. Hog Ring B134681E01 12. REMOVE FRONT SEPARATE TYPE SEAT CUSHION COVER (for Sports Seat Type) (a) Remove the 17 hog rings and front separate type seat cushion cover from the seat cushion pad. Hog Ring B144026E01 SE–36 SEAT – FRONT SEAT ASSEMBLY (for Power Seat) 13. REMOVE FRONT SEAT BACK BOARD SUBASSEMBLY (a) Remove the 2 screws. (b) Disconnect the 14 clamps and front separate type seat back cover. (c) Pull the seat back board in the direction indicated by the arrow in the illustration to detach the 2 claws. Then, remove the seat back board. SE Clamp B134682E01 14. REMOVE FRONT SEAT HEADREST SUPPORT (a) Detach the 2 claws and remove the headrest support. 15. REMOVE FRONT SEAT HEADREST SUPPORT B134683 16. REMOVE FRONT SEPARATE TYPE SEAT BACK ASSEMBLY (a) Remove the 2 hog rings and 3 hooks. Hog Ring B134684E01 (b) Remove the nut and 2 seat back cover brackets. B134685 SEAT – FRONT SEAT ASSEMBLY (for Power Seat) SE–37 17. REMOVE FRONT SEPARATE TYPE SEAT BACK COVER (for Except Sports Seat Type) (a) Remove the 10 hog rings and front separate type seat back cover from the seat back pad. : Hog Ring B134686E01 18. REMOVE FRONT SEPARATE TYPE SEAT BACK COVER (for Sports Seat Type) (a) Remove the 14 hog rings and front separate type seat back cover from the seat back pad. Hog Ring B144025E01 19. REMOVE LUMBAR SUPPORT ADJUSTER ASSEMBLY (a) Disconnect the connector. (b) Remove the 2 screws and lumbar support adjuster assembly. 20. REMOVE RECLINING ADJUSTER INSIDE COVER RH (a) Disconnect the harness. B134693 (b) Remove the 2 screws and reclining adjuster inside cover RH. 21. REMOVE RECLINING ADJUSTER INSIDE COVER LH (a) Disconnect the harness. B134687 (b) Remove the 2 screws and reclining adjuster inside cover LH. B134688 SE SE–38 SEAT – FRONT SEAT ASSEMBLY (for Power Seat) 22. REMOVE SEAT RECLINING ADJUSTER INSIDE COVER RH (a) Remove the screw. (b) Detach the claw and remove the seat reclining adjuster inside cover RH. B134689 23. REMOVE SEAT RECLINING ADJUSTER INSIDE COVER LH (a) Remove the screw. (b) Detach the claw and remove the seat reclining adjuster inside cover LH. SE B134690 24. REMOVE FRONT LOWER SEAT CUSHION SHIELD LH (a) Remove the screw and detach the hook of the front lower seat cushion shield LH. 25. REMOVE FRONT LOWER SEAT CUSHION SHIELD 26. REMOVE SEAT POSITION SENSOR (for Driver Side) (See page RS-462) 27. REMOVE FRONT SEAT WIRE B134692 SEAT – FRONT SEAT ASSEMBLY (for Power Seat) SE–39 REASSEMBLY CAUTION: Wear protective gloves. Sharp areas on the seat adjuster may injure your hands. 1. INSTALL FRONT SEAT WIRE 2. INSTALL SEAT POSITION SENSOR (for Driver Side) (See page RS-462) 3. INSTALL FRONT LOWER SEAT CUSHION SHIELD 4. INSTALL FRONT LOWER SEAT CUSHION SHIELD LH 5. INSTALL SEAT RECLINING ADJUSTER INSIDE COVER LH 6. INSTALL SEAT RECLINING ADJUSTER INSIDE COVER RH 7. INSTALL RECLINING ADJUSTER INSIDE COVER LH 8. INSTALL RECLINING ADJUSTER INSIDE COVER RH 9. INSTALL LUMBAR SUPPORT ADJUSTER ASSEMBLY 10. INSTALL FRONT SEPARATE TYPE SEAT BACK COVER (for Except Sports Seat Type) (a) Using hog ring pliers, install the front separate type seat back cover to the front seat back pad with 16 new hog rings. NOTICE: • Be careful not to damage the cover. • When installing the hog rings, take care to minimize wrinkles as much as possible. Hog Ring B136592E01 SE SE–40 SEAT – FRONT SEAT ASSEMBLY (for Power Seat) 11. INSTALL FRONT SEPARATE TYPE SEAT BACK COVER (for Sports Seat Type) (a) Using hog ring pliers, install the front separate type seat back cover to the front seat back pad with 14 new hog rings. NOTICE: • Be careful not to damage the cover. • When installing the hog rings, take care to minimize wrinkles as much as possible. SE Hog Ring B144038E01 B134685 12. INSTALL FRONT SEPARATE TYPE SEAT BACK ASSEMBLY (a) Fully cover the airbag with the 2 seat back cover brackets and tighten the nut. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) NOTICE: • For vehicles with side airbags, the seat back cover must be securely installed. Otherwise, the side airbags may not deploy properly. • Make sure that the strap is not twisted after installing the bracket. • Install the bracket securely. SEAT – FRONT SEAT ASSEMBLY (for Power Seat) SE–41 (b) Engage the 3 hooks. (c) Using hog ring pliers, install 2 new hog rings. NOTICE: • Be careful not to damage the cover. • When installing the hog rings, take care to minimize wrinkles as much as possible. 13. INSTALL FRONT SEAT HEADREST SUPPORT 14. INSTALL FRONT SEAT HEADREST SUPPORT 15. INSTALL FRONT SEAT BACK BOARD SUBASSEMBLY Hog Ring B136594E01 16. INSTALL FRONT SEPARATE TYPE SEAT CUSHION COVER (for Except Sports Seat Type) (a) Using hog ring pliers, install the front separate type seat cushion cover to the front separate type seat pad with 16 new hog rings. NOTICE: • Be careful not to damage the cover. • When installing the hog rings, take care to minimize wrinkles as much as possible. Hog Ring B136593E01 SE SE–42 SEAT – FRONT SEAT ASSEMBLY (for Power Seat) 17. INSTALL FRONT SEPARATE TYPE SEAT CUSHION COVER (for Sports Seat Type) (a) Using hog ring pliers, install the front separate type seat cushion cover to the front separate type seat pad with 17 new hog rings. NOTICE: • Be careful not to damage the cover. • When installing the hog rings, take care to minimize wrinkles as much as possible. 18. INSTALL FRONT SEPARATE TYPE SEAT CUSHION ASSEMBLY SE 19. INSTALL FRONT POWER SEAT SWITCH 20. INSTALL LOWER SEAT TRACK SPACER 21. INSTALL FRONT INNER SEAT CUSHION SHIELD 22. INSTALL FRONT LUMBAR POWER SEAT SWITCH 23. INSTALL FRONT SEAT INNER BELT ASSEMBLY (See page SB-17) Hog Ring B144037E01 24. INSTALL FRONT INNER NO. 1 SEAT CUSHION SHIELD 25. INSTALL FRONT SEAT CUSHION SHIELD ASSEMBLY 26. INSTALL SLIDE AND VERTICAL POWER SEAT SWITCH KNOB 27. INSTALL RECLINING POWER SEAT SWITCH KNOB SEAT – FRONT SEAT ASSEMBLY (for Power Seat) SE–43 INSTALLATION 1. INSTALL FRONT SEAT ASSEMBLY (a) Place the seat in the cabin. (b) Connect the connectors under the seat. (c) Connect the cable to the negative (-) battery terminal. (d) Move the front seat assembly fully forward by operating the slide and vertical power seat switch knob. NOTICE: Check that the seat is locked. (e) Temporarily install the front side of the front seat assembly with the 2 bolts. (f) Move the front seat assembly fully forward by operating the slide and vertical power seat switch knob. NOTICE: Check that the seat is locked. B140607 B139102 (g) Temporarily install the rear side of the front seat assembly with the 2 bolts. (h) Move the front seat assembly to the rearmost position by operating the slide and vertical power seat switch knob. NOTICE: Check that the seat is locked. (i) Fully tighten the 2 bolts on the front side of the front seat assembly in the order of the inner side bolt and then the outer side bolt. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) (j) Move the front seat assembly fully forward by operating the slide and vertical power seat switch knob. NOTICE: Check that the seat is locked. (k) Fully tighten the 2 bolts on the rear side of the front seat assembly in the order of the inner side bolt and then the outer side bolt. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) SE SE–44 SEAT – FRONT SEAT ASSEMBLY (for Power Seat) 2. INSTALL INNER SEAT TRACK BRACKET COVER (a) Slide the inner seat track bracket cover along the seat rail toward the front of the vehicle. Engage claw A to the seat rail. (b) Push the inner seat track bracket cover to engage claw B. 3. INSTALL SEAT TRACK COVER (a) Slide the seat track cover along the seat rail toward the front of the vehicle. Engage claw A to the seat rail. (b) Push the seat track cover to engage claw B. 4. INSTALL FRONT SEAT HEADREST ASSEMBLY 5. PERFORM ZERO POINT CALIBRATION AND SENSITIVITY CHECK (for Front Passenger Seat) (See page RS-242) 6. CHECK SRS WARNING LIGHT Check the SRS warning light. (See page RS-32) 7. INSPECT FRONT SEAT ASSEMBLY (a) Check the power seat operation. (b) Check the seat heater operation (with seat heater system). (1) Turn the ignition switch on (IG). (2) Turn the seat heater switch ON. (3) Wait 5 minutes or more and confirm that the seat surface becomes warm. Claw A (2) (1) Claw B SE Claw B139100E01 Claw A (1) (2) Claw B Claw B139099E01 SE–43 SEAT – REAR SEAT ASSEMBLY (for Fold Down Seat Type) REAR SEAT ASSEMBLY (for Fold Down Seat Type) SEAT BODY COMPONENTS REAR SEAT HEADREST ASSEMBLY SE REAR CENTER SEAT HEADREST ASSEMBLY 18 (184, 13) 18 (184, 13) 18 (184, 13) REAR SIDE SEAT BACK ASSEMBLY RH SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH 18 (184, 13) REAR SEAT CUSHION ASSEMBLY REAR SIDE SEAT BACK ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque B136564E01 SE–44 SEAT – REAR SEAT ASSEMBLY (for Fold Down Seat Type) REAR SEAT HEADREST SUPPORT REAR SEAT SHOULDER BELT GUIDE RH REAR SEAT BACK LOCK BEZEL UPPER SE REAR SIDE SEAT BACK ASSEMBLY RH REAR SEAT BELT HOOK REAR SEAT BACK FRAME SUB-ASSEMBLY RH REAR SEPARATE TYPE SEAT BACK COVER HOG RING BUSH REAR SEAT BACK HINGE COVER BUSH REAR CENTER SEAT ARMREST ASSEMBLY NO. 1 SEAT ARMREST CAP Non-reusable part B136565E01 SE–45 SEAT – REAR SEAT ASSEMBLY (for Fold Down Seat Type) REAR SEAT HEADREST SUPPORT REAR SEPARATE TYPE SEAT BACK PAD SE REAR SEAT SHOULDER BELT GUIDE LH REAR SEAT BACK LOCK BEZEL UPPER REAR SEAT BACK FRAME SUB-ASSEMBLY LH REAR SEPARATE TYPE SEAT BACK COVER REAR SEAT SHOULDER BELT GUIDE LH HOG RING REAR SIDE SEAT BACK ASSEMBLY LH Non-reusable part B136566E01 SE–46 SEAT – REAR SEAT ASSEMBLY (for Fold Down Seat Type) REAR BENCH TYPE SEAT CUSHION COVER SE HOG RING REAR BENCH TYPE CUSHION PAD Non-reusable part B136567E01 SEAT – REAR SEAT ASSEMBLY (for Fold Down Seat Type) SE–47 REMOVAL 1. A A:100 mm (3.94 in.) or less Hook REMOVE REAR SEAT CUSHION ASSEMBLY (a) Detach the 2 front hooks of the seat cushion from the vehicle body. NOTICE: Follow the instructions below carefully as the cushion frame can be deformed easily. (1) Choose a hook to detach first. Place your hands near the hook as shown in the illustration. Then lift the seat cushion to detach the hook. (2) Repeat the step above for the other hook. (b) Remove the seat cushion. 2. REMOVE REAR SEAT HEADREST ASSEMBLY (a) Remove the 2 rear seat headrest assemblies. 3. REMOVE REAR CENTER SEAT HEADREST ASSEMBLY (a) Remove the rear center seat headrest assembly. 4. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (a) Remove the 2 bolts and separate type rear seat back assembly RH. 5. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (a) Remove the 2 bolts and separate type rear seat back assembly LH. B134699E01 B134700 B136539 SE SE–48 SEAT – REAR SEAT ASSEMBLY (for Fold Down Seat Type) B136561 SE 6. REMOVE REAR SIDE SEAT BACK ASSEMBLY LH (a) Remove the bolt and rear side seat back assembly LH. 7. REMOVE REAR SIDE SEAT BACK ASSEMBLY RH HINT: Use the same procedures for the RH side and LH side. SEAT – REAR SEAT ASSEMBLY (for Fold Down Seat Type) SE–49 DISASSEMBLY 1. REMOVE REAR BENCH TYPE SEAT CUSHION COVER (a) Remove the 36 hog rings. SE Hog Ring B136540E01 (b) Remove the 16 hog rings and rear bench type seat cushion cover. Hog Ring B136541E01 2. B136542 REMOVE NO. 1 SEAT ARMREST CAP (a) Using a screwdriver, remove the No. 1 seat armrest cap. HINT: Tape the screwdriver tip before use. SE–50 SEAT – REAR SEAT ASSEMBLY (for Fold Down Seat Type) 3. REMOVE REAR SEAT BACK HINGE COVER (a) Remove the bolt and bush. B136543 (b) Remove the rear seat back hinge cover. SE B136544 4. (1) REMOVE REAR CENTER SEAT ARMREST ASSEMBLY (a) Remove the rear center seat armrest assembly as shown in the illustration. (2) B136545E01 (b) Remove the bush. B136546 5. B136563 REMOVE REAR SEAT BELT HOOK (a) Remove the rear seat belt hook. HINT: Use the same procedures for the RH side and LH side. SEAT – REAR SEAT ASSEMBLY (for Fold Down Seat Type) 6. SE–51 REMOVE REAR SEAT SHOULDER BELT GUIDE LH (a) Seat Back: (1) Remove the 2 screws and rear seat shoulder belt guide LH. B136554 (b) Side Seat Back: (1) Remove the 2 screws and rear seat shoulder belt guide LH. B136562 7. REMOVE REAR SEAT SHOULDER BELT GUIDE RH (a) Remove the 2 screws and rear seat shoulder belt guide RH. 8. REMOVE REAR SEAT BACK LOCK BEZEL UPPER (for RH Side) (a) Disengage the 4 claws and remove the rear seat back lock bezel upper. 9. REMOVE REAR SEAT HEADREST SUPPORT (for RH Side) (a) Disengage the 2 hooks and separate the rear separate type seat back cover. B139124 B136547 B136548 SE SE–52 SEAT – REAR SEAT ASSEMBLY (for Fold Down Seat Type) (b) Remove the 7 hog rings. Hog Ring B136549E01 (c) Disengage the 4 claws and remove the 2 rear seat headrest supports. SE 10. REMOVE REAR SEAT HEADREST SUPPORT (for RH Side) B136550E01 11. REMOVE REAR SEAT BACK LOCK BEZEL UPPER (for LH Side) (a) Disengage the 4 claws and remove the rear seat back lock bezel upper. B136555 12. REMOVE REAR SEAT HEADREST SUPPORT (for LH Side) (a) Disengage the 2 hooks and separate the rear separate type seat back cover. B136556 (b) Remove the 6 hog rings. Hog Ring B136557E01 SEAT – REAR SEAT ASSEMBLY (for Fold Down Seat Type) SE–53 (c) Disengage the 2 claws and remove the rear seat headrest support. 13. REMOVE REAR SEAT HEADREST SUPPORT (for LH Side) B136558E01 14. REMOVE REAR SEAT BACK FRAME SUBASSEMBLY RH (a) Remove the rear seat back frame sub-assembly RH. B136551 15. REMOVE REAR SEAT BACK FRAME SUBASSEMBLY LH (a) Remove the rear seat back frame sub-assembly LH. B136559 16. REMOVE REAR SEPARATE TYPE SEAT BACK COVER (for RH Side) (a) Remove the 7 hog rings. Hog Ring B136552E01 (b) Remove the 9 hog rings and rear separate type seat back cover. Hog Ring B136553E01 SE SE–54 SEAT – REAR SEAT ASSEMBLY (for Fold Down Seat Type) 17. REMOVE REAR SEPARATE TYPE SEAT BACK COVER (for LH Side) (a) Remove the 9 hog rings and rear separate type seat back cover. Hog Ring B136560E01 REASSEMBLY SE 1. INSTALL REAR SEPARATE TYPE SEAT BACK COVER (for LH Side) (a) Using hog ring pliers, install the rear separate type seat back cover with 9 new hog rings. NOTICE: • Be careful not to damage the cover. • When installing the hog rings, take care to minimize wrinkles as much as possible. 2. INSTALL REAR SEPARATE TYPE SEAT BACK COVER (for RH Side) (a) Using hog ring pliers, install the rear separate type seat back cover to the seat back pad with 9 new hog rings. NOTICE: • Be careful not to damage the cover. • When installing the hog rings, take care to minimize wrinkles as much as possible. Hog Ring Pliers Hog Ring B140575E01 Hog Ring Pliers Hog Ring B140576E01 SEAT – REAR SEAT ASSEMBLY (for Fold Down Seat Type) SE–55 (b) Using hog ring pliers, install the rear separate type seat back cover to the seat back pad with 7 new hog rings. NOTICE: • Be careful not to damage the cover. • When installing the hog rings, take care to minimize wrinkles as much as possible. 3. INSTALL REAR SEAT BACK FRAME SUBASSEMBLY RH 4. INSTALL REAR SEAT BACK FRAME SUBASSEMBLY LH Hog Ring Pliers Hog Ring B140577E01 5. INSTALL REAR SEAT HEADREST SUPPORT (for LH Side) (a) Engage the 2 claws to install the 2 front seat headrest supports. B136558E01 (b) Using hog ring pliers, install the rear separate type seat back cover to the seat back frame with 6 new hog rings. NOTICE: • Be careful not to damage the cover. • When installing the hog rings, take care to minimize wrinkles as much as possible. Hog Ring Pliers Hog Ring B140578E01 SE SE–56 SEAT – REAR SEAT ASSEMBLY (for Fold Down Seat Type) 6. INSTALL REAR SEAT HEADREST SUPPORT (for LH Side) (a) Engage the 2 claws to install the 2 front seat headrest supports. B136550 (b) Using hog ring pliers, install the rear separate type seat back cover to the seat back frame with 7 new hog rings. NOTICE: • Be careful not to damage the cover. • When installing the hog rings, take care to minimize wrinkles as much as possible. SE Hog Ring Pliers 7. INSTALL REAR SEAT BACK LOCK BEZEL UPPER 8. INSTALL REAR SEAT HEADREST SUPPORT (for RH Side) 9. INSTALL REAR SEAT HEADREST SUPPORT (for RH Side) 10. INSTALL REAR SEAT BACK LOCK BEZEL UPPER (for RH Side) 11. INSTALL REAR SEAT SHOULDER BELT GUIDE RH 12. INSTALL REAR SEAT SHOULDER BELT GUIDE LH 13. INSTALL REAR SEAT BELT HOOK Hog Ring B140579E01 14. INSTALL REAR CENTER SEAT ARMREST ASSEMBLY 15. INSTALL REAR SEAT BACK HINGE COVER 16. INSTALL NO. 1 SEAT ARMREST CAP SE–57 SEAT – REAR SEAT ASSEMBLY (for Fold Down Seat Type) 17. INSTALL REAR BENCH TYPE SEAT CUSHION COVER (a) Using hog ring pliers, install 16 new hog rings. Hog Ring Pliers SE Hog Ring B140580E01 NOTICE: • Be careful not to damage the cover. • When installing the hog rings, take care to minimize wrinkles as much as possible. (b) Using hog ring pliers, install the rear bench type seat cushion cover to the seat cushion pad with 36 new hog rings. Hog Ring Pliers Hog Ring B140581E01 NOTICE: • Be careful not to damage the cover. • When installing the hog rings, take care to minimize wrinkles as much as possible. SE–58 SEAT – REAR SEAT ASSEMBLY (for Fold Down Seat Type) INSTALLATION 1. INSTALL REAR SIDE SEAT BACK ASSEMBLY LH (a) Install the rear side seat back assembly with the bolt. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 2. INSTALL REAR SIDE SEAT BACK ASSEMBLY RH 3. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (a) Install the separate type rear seat back assembly with the 2 bolts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 4. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (a) Install the separate type rear seat back assembly with the 2 bolts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 5. INSTALL REAR CENTER SEAT HEADREST ASSEMBLY 6. INSTALL REAR SEAT HEADREST ASSEMBLY B136561 SE B136539 B134700 SEAT – REAR SEAT ASSEMBLY (for Fold Down Seat Type) 7. SE–59 INSTALL REAR SEAT CUSHION ASSEMBLY (a) Attach the front hooks of the bench type rear seat cushion assembly to the vehicle body. (b) Confirm that the seat cushion is firmly installed. NOTICE: When installing the bench type rear seat cushion assembly, make sure that the seat belt buckle is not under the bench type rear seat cushion assembly. SE Hook B140584E01 SEAT – REAR SEAT ASSEMBLY (for Reclining Seat Type) SE–59 REAR SEAT ASSEMBLY (for Reclining Seat Type) SEAT BODY COMPONENTS REAR SEAT HEADREST ASSEMBLY SE 18 (184, 13) REAR CENTER SEAT HEADREST ASSEMBLY CENTER SEAT BACK ASSEMBLY REAR SEAT BACK COVER 18 (184, 13) 18 (184, 13) 18 (184, 13) SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH REAR SEAT BACK COVER 18 (184, 13) SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH REAR SEAT CUSHION ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B139095E02 SE–60 SEAT – REAR SEAT ASSEMBLY (for Reclining Seat Type) REAR SEAT BACK FRAME SUB-ASSEMBLY REAR SEAT HEADREST SUPPORT REAR SEPARATE TYPE SEAT BACK PAD SE REAR SEAT SHOULDER BELT GUIDE LH REAR SEAT BELT HOOK REAR SEPARATE TYPE SEAT BACK COVER 18 (184, 13) 18 (184, 13) REAR SEAT RECLINING ADJUSTER ASSEMBLY 18 (184, 13) RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY REAR DOOR OPENING TRIM WEATHERSTRIP LH REAR DOOR SCUFF PLATE LH N*m (kgf*cm, ft.*lbf) : Specified torque B139096E01 SEAT – REAR SEAT ASSEMBLY (for Reclining Seat Type) SE–61 CENTER SEAT BACK ASSEMBLY SE REAR SEAT HEADREST SUPPORT HOG RING CENTER SEAT ARMREST PLATE INNER CENTER SEAT BACK COVER SUB-ASSEMBLY CENTER SEAT BACK FRAME SUB-ASSEMBLY BUSH CENTER SEAT ARMREST BRACKET SUB-ASSEMBLY REAR SEAT CENTER ARMREST BOX ASSEMBLY REAR CENTER SEAT ARMREST ASSEMBLY Non-reusable part B139097E02 SE–62 SEAT – REAR SEAT ASSEMBLY (for Reclining Seat Type) REAR BENCH TYPE SEAT CUSHION COVER SE HOG RING REAR BENCH TYPE CUSHION PAD Non-reusable part B136567E01 REMOVAL 1. REMOVE REAR SEAT CUSHION ASSEMBLY (a) Detach the 2 front hooks of the seat cushion from the vehicle body. NOTICE: Follow the instructions below carefully as the cushion frame can be deformed easily. (1) Choose a hook to detach first. Place your hands near the hook as shown in the illustration. Then lift the seat cushion to detach the hook. (2) Repeat the step above for the other hook. (b) Remove the seat cushion. 2. REMOVE REAR SEAT HEADREST ASSEMBLY A A:100 mm (3.94 in.) or less : Hook B139074E01 SEAT – REAR SEAT ASSEMBLY (for Reclining Seat Type) SE–63 3. REMOVE REAR CENTER SEAT HEADREST ASSEMBLY 4. REMOVE REAR SEAT BACK COVER (a) Using a screwdriver, detach the claws and remove the 2 rear seat back covers. NOTICE: • Tape the screwdriver tip before use. • Use the same procedures for the RH side and LH side. SE B139075 5. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (a) Separate the 2 rear seat belts. B139076E01 (b) Disengage the 3 clamps and then separate the cover. Clamp B139081E01 (c) Remove the 2 bolts and 2 nuts and separate type rear seat back assembly LH. B139077 SE–64 SEAT – REAR SEAT ASSEMBLY (for Reclining Seat Type) 6. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (a) Separate the rear seat belt. B139078E01 (b) Disengage the 3 clamps and then separate the cover. SE Clamp B139082E01 (c) Remove the 2 bolts and 2 nuts and separate type rear seat back assembly RH. B139079 7. B139080 REMOVE CENTER SEAT BACK ASSEMBLY (a) Remove the 2 bolts and center seat back assembly. SEAT – REAR SEAT ASSEMBLY (for Reclining Seat Type) SE–65 DISASSEMBLY 1. REMOVE REAR BENCH TYPE SEAT CUSHION COVER (a) Remove the 36 hog rings. SE Hog Ring B136540E01 (b) Remove the 16 hog rings and rear bench type seat cushion cover. Hog Ring B136541E01 2. B139085 REMOVE REAR SEAT SHOULDER BELT GUIDE LH (a) Remove the 4 screws and 2 rear seat shoulder belt guides LH. SE–66 SEAT – REAR SEAT ASSEMBLY (for Reclining Seat Type) 3. REMOVE REAR SEAT HEADREST SUPPORT (for LH Side) (a) Disengage the hook. Hook B139086E01 (b) Disengage the 2 claws and remove the rear seat headrest support. SE 4. REMOVE REAR SEAT HEADREST SUPPORT (for LH Side) 5. REMOVE REAR SEPARATE TYPE SEAT BACK COVER (a) Disengage the hooks and remove the rear seat back assembly. B139098 B139087 (b) Remove the rear seat belt hook. (c) Remove the rear separate type seat back cover. B139088 SEAT – REAR SEAT ASSEMBLY (for Reclining Seat Type) SE–67 6. REMOVE REAR CENTER SEAT ARMREST ASSEMBLY (a) Remove the 2 bolts and 2 bushes. (b) Remove the rear center seat armrest assembly. 7. REMOVE REAR SEAT HEADREST SUPPORT (a) Disengage the 2 claws and remove the rear seat headrest support. 8. REMOVE REAR SEAT HEADREST SUPPORT HINT: Use the same procedures for the RH side and LH side. 9. REMOVE CENTER SEAT BACK COVER SUBASSEMBLY (a) Remove the 2 hog rings. (b) Disengage the hooks and remove the center seat back cover sub-assembly. B139089 B139090E01 Hog Ring B139091E01 10. REMOVE CENTER SEAT ARMREST PLATE INNER (a) Disengage the 11 claws and then remove the center seat armrest plate inner. B139092 SE SE–68 SEAT – REAR SEAT ASSEMBLY (for Reclining Seat Type) 11. REMOVE REAR SEAT CENTER ARMREST BOX ASSEMBLY (a) Remove the 2 nuts. (b) Disengage the 2 claws and then remove the rear seat center armrest box assembly. 12. REMOVE REAR DOOR SCUFF PLATE LH (See page IR-24) B139093 13. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH 14. REMOVE RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY (a) Remove the bolt. (b) Disengage the 2 clips and the claw and then separate the reclining remote control lever subassembly. SE B139083 (c) Separate the rear seat reclining control cable and remove the reclining remote control lever subassembly. B139084 15. REMOVE REAR SEAT RECLINING ADJUSTER ASSEMBLY (a) Remove the 4 bolts and rear seat reclining adjuster assembly. B139094 SEAT – REAR SEAT ASSEMBLY (for Reclining Seat Type) SE–69 REASSEMBLY HINT: A bolt without a torque specification is shown in the standard bolt chart. (See page SS-2) 1. (1) (2) (4) (3) INSTALL REAR SEAT RECLINING ADJUSTER ASSEMBLY (a) Install the rear seat reclining adjuster assembly with the 4 bolts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) NOTICE: Tighten the bolts in the order shown in the illustration to install the rear seat reclining adjuster assembly. B139094E01 2. INSTALL RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY (a) Install the rear seat reclining control cable. B139084 (b) Engage the 2 clips and claw and then install the reclining remote control lever sub-assembly. (c) Install the bolt. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) B139083 (d) Adjust the control lever to set the rear reclining adjuster assembly to its upper most position. (e) Pull plate A toward the front of the vehicle to lock the plate. Plate A Upper most position B144036E01 3. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH 4. INSTALL REAR DOOR SCUFF PLATE LH (See page IR-56) 5. INSTALL REAR SEAT CENTER ARMREST BOX ASSEMBLY 6. INSTALL CENTER SEAT ARMREST PLATE INNER SE SE–70 SEAT – REAR SEAT ASSEMBLY (for Reclining Seat Type) 7. INSTALL CENTER SEAT BACK COVER SUBASSEMBLY (a) Install the center seat back cover sub-assembly with the hook. (b) Using hog ring pliers, install 2 new hog rings. 8. INSTALL REAR SEAT HEADREST SUPPORT 9. INSTALL REAR SEAT HEADREST SUPPORT 10. INSTALL REAR CENTER SEAT ARMREST ASSEMBLY SE 11. INSTALL REAR SEPARATE TYPE SEAT BACK COVER Hog Ring Pliers 12. INSTALL REAR SEAT HEADREST SUPPORT (for LH Side) 13. INSTALL REAR SEAT HEADREST SUPPORT (for LH Side) Hog Ring B140590E01 14. INSTALL REAR BENCH TYPE SEAT CUSHION COVER (a) Using hog ring pliers, install 16 new hog rings. Hog Ring Pliers Hog Ring B140580E01 NOTICE: • Be careful not to damage the cover. • When installing the hog rings, take care to minimize wrinkles as much as possible. SE–71 SEAT – REAR SEAT ASSEMBLY (for Reclining Seat Type) (b) Using hog ring pliers, install the rear bench type seat cushion cover to the seat cushion pad with 36 new hog rings. Hog Ring Pliers SE Hog Ring B140581E01 INSTALLATION 1. INSTALL CENTER SEAT BACK ASSEMBLY (a) Install the center seat back assembly with the 2 bolts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 2. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (a) Install the separate type rear seat back assembly RH with the 2 bolts and 2 nuts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) B140592 B139079 (b) Engage the 3 clamps and install the cover. Clamp B139082E01 SE–72 SEAT – REAR SEAT ASSEMBLY (for Reclining Seat Type) (c) Install the rear seat belt. B139078E01 3. SE INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (a) Install the separate type rear seat back assembly LH with the 2bolts and 2 nuts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) B139077 (b) Engage the 3 clamps and install the cover. Clamp B139081E01 (c) Install the 2 rear seat belts. B139076E01 4. INSTALL REAR SEAT BACK COVER 5. INSTALL REAR CENTER SEAT HEADREST ASSEMBLY 6. INSTALL REAR SEAT HEADREST ASSEMBLY SEAT – REAR SEAT ASSEMBLY (for Reclining Seat Type) 7. SE–73 INSTALL REAR SEAT CUSHION ASSEMBLY (a) Attach the front hooks of the bench type rear seat cushion assembly to the vehicle body. (b) Confirm that the seat cushion is firmly installed. NOTICE: When installing the bench type rear seat cushion assembly, make sure that the seat belt buckle is not under the bench type rear seat cushion assembly. SE : Hook B140591E01 SE–74 SEAT – REAR SEAT ASSEMBLY (for Fixed Type) REAR SEAT ASSEMBLY (for Fixed Type) SEAT BODY COMPONENTS REAR SEAT HEADREST ASSEMBLY SE REAR CENTER SEAT HEADREST ASSEMBLY REAR SEAT BACK ASSEMBLY 18 (184, 13) 18 (184, 13) REAR SEAT CUSHION ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B136589E01 SEAT – REAR SEAT ASSEMBLY (for Fixed Type) SE–75 SE ARMREST ASSEMBLY REAR SEAT CENTER ARMREST BOX ASSEMBLY INNER CENTER SEAT ARMREST PLATE CUP HOLDER CENTER SEAT ARMREST BRACKET SUB-ASSEMBLY BUSH BUSH B136590E02 SE–76 SEAT – REAR SEAT ASSEMBLY (for Fixed Type) REAR SEAT SHOULDER BELT GUIDE LH REAR SEAT SHOULDER BELT GUIDE RH REAR SEAT HEADREST SUPPORT SE REAR BENCH TYPE SEAT BACK PAD SUB-ASSEMBLY REAR BENCH TYPE SEAT BACK COVER HOG RING REAR BENCH TYPE SEAT CUSHION COVER REAR BENCH TYPE SEAT CUSHION PAD SUB-ASSEMBLY HOG RING Non-reusable part B136591E01 SEAT – REAR SEAT ASSEMBLY (for Fixed Type) SE–77 REMOVAL 1. A:100 mm (3.94 in.) or less Hook REMOVE REAR SEAT CUSHION ASSEMBLY (a) Detach the 2 front hooks of the seat cushion from the vehicle body. NOTICE: Follow the instructions below carefully as the cushion frame can be deformed easily. (1) Choose a hook to detach first. Place your hands near the hook as shown in the illustration. Then lift the seat cushion to detach the hook. (2) Repeat the step above for the other hook. (b) Remove the rear seat cushion assembly. 2. REMOVE REAR SEAT HEADREST ASSEMBLY 3. REMOVE REAR CENTER SEAT HEADREST ASSEMBLY 4. REMOVE REAR SEAT BACK ASSEMBLY (a) Remove the 3 rear seat belts from the 3 rear seat shoulder belt guides. B136575E01 B136576 (b) Remove the 4 bolts and rear seat back assembly. B136577 SE SE–78 SEAT – REAR SEAT ASSEMBLY (for Fixed Type) DISASSEMBLY 1. REMOVE REAR BENCH TYPE SEAT CUSHION COVER (a) Remove the 36 hog rings. SE Hog Ring B136578E01 (b) Remove the 14 hog rings and rear bench type seat cushion cover from the seat cushion frame (with pad). Hog Ring B136579E01 SEAT – REAR SEAT ASSEMBLY (for Fixed Type) 2. SE–79 REMOVE ARMREST ASSEMBLY (a) Remove the 2 nuts. (b) Disengage the 2 claws and remove the armrest assembly. SE B136580 3. REMOVE CENTER SEAT ARMREST BRACKET SUBASSEMBLY (a) Remove the 2 bolts and bushes. (b) Remove the center seat armrest bracket subassembly. 4. REMOVE CUP HOLDER (a) Remove the 2 mats. B136581 B136582 (b) Remove the 2 screws and cup holder. B136583 SE–80 SEAT – REAR SEAT ASSEMBLY (for Fixed Type) 5. REMOVE INNER CENTER SEAT ARMREST PLATE (a) Disengage the 11 claws and remove the inner center seat armrest plate. 6. REMOVE REAR SEAT HEADREST SUPPORT (a) Disengage the 6 claws and remove the 3 rear seat headrest supports. SE B136584 B136585 B136586 7. REMOVE REAR SEAT HEADREST SUPPORT 8. REMOVE REAR SEAT SHOULDER BELT GUIDE RH (a) Remove the 2 screws and rear seat shoulder belt guide RH. 9. REMOVE REAR SEAT SHOULDER BELT GUIDE LH HINT: Use the same procedures for the RH side and LH side. SEAT – REAR SEAT ASSEMBLY (for Fixed Type) SE–81 10. REMOVE REAR BENCH TYPE SEAT BACK COVER (a) Remove the 44 hog rings and strap guide. Rear Seat Belt Hook Rear Seat Belt Hook : Hog Ring B136587E02 (b) Remove the 2 rear seat belt hooks. (c) Remove the 20 hog rings and seat back cover from the seat back frame (with pad). Hog Ring B136588E01 SE SE–82 SEAT – REAR SEAT ASSEMBLY (for Fixed Type) REASSEMBLY HINT: A bolt without a torque specification is shown in the standard bolt chart. (See page SS-2) 1. INSTALL REAR BENCH TYPE SEAT BACK COVER NOTICE: • Be careful not to damage the cover. • When installing the hog rings, take care to minimize wrinkles as much as possible. (a) Using hog ring pliers, install 20 new hog rings. SE Hog Ring Pliers : Hog Ring B140586E01 SE–83 SEAT – REAR SEAT ASSEMBLY (for Fixed Type) (b) Using hog ring pliers, install the rear bench type seat back cover to the seat back frame (with pad) with 44 new hog rings. Rear Seat Belt Hook Rear Seat Belt Hook Hog Ring Pliers SE : Hog Ring B140585E01 2. INSTALL REAR SEAT SHOULDER BELT GUIDE LH 3. INSTALL REAR SEAT SHOULDER BELT GUIDE RH 4. INSTALL REAR SEAT HEADREST SUPPORT 5. INSTALL REAR SEAT HEADREST SUPPORT 6. INSTALL INNER CENTER SEAT ARMREST PLATE 7. INSTALL CUP HOLDER 8. INSTALL CENTER SEAT ARMREST BRACKET SUBASSEMBLY 9. INSTALL ARMREST ASSEMBLY 10. INSTALL REAR BENCH TYPE SEAT CUSHION COVER NOTICE: • Be careful not to damage the cover. • When installing the hog rings, take care to minimize wrinkles as much as possible. SE–84 SEAT – REAR SEAT ASSEMBLY (for Fixed Type) (a) Using hog ring pliers, install 14 new hog rings. Hog Ring Pliers SE Hog Ring B140587E01 (b) Using hog ring pliers, install the rear seat cushion cover to the rear seat cushion pad with 36 new hog rings. Hog Ring Pliers Hog Ring B140588E01 INSTALLATION 1. B136577 INSTALL REAR SEAT BACK ASSEMBLY (a) Place the seat back in the cabin. NOTICE: Be careful not to damage the vehicle body. (b) Install the rear seat back assembly with the 4 bolts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) SEAT – REAR SEAT ASSEMBLY (for Fixed Type) SE–85 (c) Pass the 3 seat belts through and close the cap of the 2 rear seat shoulder belt guides. (d) Install the floor anchor part with the bolt. 2. INSTALL REAR CENTER SEAT HEADREST ASSEMBLY 3. INSTALL REAR SEAT HEADREST ASSEMBLY 4. INSTALL REAR SEAT CUSHION ASSEMBLY (a) Attach the 2 front hooks of the seat cushion to the vehicle body. (b) Confirm that the seat cushion is firmly installed. NOTICE: When installing the seat cushion, make sure the seat belt buckle is not under the seat cushion. B136576 Hook B140589E01 SE SE–85 SEAT – POWER SEAT SWITCH POWER SEAT SWITCH SEAT BODY COMPONENTS SE FRONT SEAT HEADREST ASSEMBLY INNER SEAT TRACK BRACKET COVER FRONT SEAT ASSEMBLY SEAT TRACK COVER 37 (377, 27) 37 (377, 27) 37 (377, 27) N*m (kgf*cm, ft.*lbf) : Specified torque B134694E01 SE–86 SEAT – POWER SEAT SWITCH SE POWER SEAT SWITCH FRONT SEAT CUSHION SHIELD ASSEMBLY SLIDE AND VERTICAL POWER SEAT SWITCH KNOB RECLINING POWER SEAT SWITCH KNOB B136569E01 SE–87 SEAT – POWER SEAT SWITCH REMOVAL 1. REMOVE FRONT SEAT HEADREST ASSEMBLY 2. REMOVE SEAT TRACK COVER (See page SE-30) 3. REMOVE INNER SEAT TRACK BRACKET COVER (See page SE-30) 4. REMOVE FRONT SEAT ASSEMBLY (See page SE-30) 5. REMOVE RECLINING POWER SEAT SWITCH KNOB (See page SE-31) 6. REMOVE SLIDE AND VERTICAL POWER SEAT SWITCH KNOB (See page SE-31) 7. REMOVE FRONT SEAT CUSHION SHIELD ASSEMBLY (See page SE-32) 8. REMOVE POWER SEAT SWITCH (a) Remove the 3 screws. (b) Disconnect the connector and remove the power seat switch. B134677 INSPECTION Slide Switch 1. Reclining Switch Front Vertical Switch Lifter Switch U7 E FUP SLDF B RCLF RCLR LDWN LUP SLDR FDWN B105970E08 INSPECT FRONT POWER SEAT SWITCH LH (a) Measure the resistance between the specified terminals when each switch is operated. Standard resistance (Slide switch) Tester Connection Switch Condition Specified Condition U7-1 (B) - U7-9 (SLDF) FRONT Below 1 Ω U7-4 (E) - U7-6 (SLDR) FRONT Below 1 Ω U7-1 (B) - U7-6 (SLDR) FRONT 10 kΩ or higher U7-4 (E) - U7-9 (SLDF) FRONT 10 kΩ or higher U7-4 (E) - U7-6 (SLDR) OFF Below 1 Ω U7-4 (E) - U7-9 (SLDF) OFF Below 1 Ω U7-1 (B) - U7-6 (SLDR) OFF 10 kΩ or higher U7-1 (B) - U7-9 (SLDF) OFF 10 kΩ or higher U7-1 (B) - U7-6 (SLDR) REAR Below 1 Ω U7-4 (E) - U7-9 (SLDF) REAR Below 1 Ω U7-1 (B) - U7-9 (SLDF) REAR 10 kΩ or higher U7-4 (E) - U7-6 (SLDR) REAR 10 kΩ or higher Standard resistance (Front vertical switch) Tester Connection Switch Condition Specified Condition U7-1 (B) - U7-10 (FUP) UP Below 1 Ω U7-4 (E) - U7-5 (FDWN) UP Below 1 Ω U7-1 (B) - U7-5 (FDWN) UP 10 kΩ or higher U7-4 (E) - U7-10 (FUP) UP 10 kΩ or higher U7-4 (E) - U7-5 (FDWN) OFF Below 1 Ω SE SE–88 SEAT – POWER SEAT SWITCH Tester Connection Switch Condition Specified Condition U7-4 (E) - U7-10 (FUP) OFF Below 1 Ω U7-1 (B) - U7- 5 (FDWN) OFF 10 kΩ or higher U7-1 (B) - U7-10 (FUP) OFF 10 kΩ or higher U7-1 (B) - U7-5 (FDWN) DOWN Below 1 Ω U7-4 (E) - U7-10 (FUP) DOWN Below 1 Ω U7-1 (B) - U7-10 (FUP) DOWN 10 kΩ or higher U7-4 (E) - U7-5 (FDWN) DOWN 10 kΩ or higher Standard resistance (Lifter switch) SE Tester Connection Switch Condition Specified Condition U7-1 (B) - U7-7 (LUP) UP Below 1 Ω U7-4 (E) - U7-8 (LDWN) UP Below 1 Ω U7-1 (B) - U7-8 (LDWN) UP 10 kΩ or higher U7-4 (E) - U7-7 (LUP) UP 10 kΩ or higher U7-4 (E) - U7-7 (LUP) OFF Below 1 Ω U7-4 (E) - U7-8 (LDWN) OFF Below 1 Ω U7-1 (B) - U7-7 (LUP) OFF 10 kΩ or higher U7-1 (B) - U7-8 (LDWN) OFF 10 kΩ or higher U7-1 (B) - U7-8 (LDWN) DOWN Below 1 Ω U7-4 (E) - U7-7 (LUP) DOWN Below 1 Ω U7-1 (B) - U7-7 (LUP) DOWN 10 kΩ or higher U7-4 (E) - U7-8 (LDWN) DOWN 10 kΩ or higher Standard resistance (Reclining switch) Tester Connection Switch Condition Specified Condition U7-1 (B) - U7-3 (RCLF) FRONT Below 1 Ω U7-4 (E) - U7-2 (RCLR) FRONT Below 1 Ω U7-1 (B) - U7-2 (RCLR) FRONT 10 kΩ or higher U7-4 (E) -U7-3 (RCLF) FRONT 10 kΩ or higher U7-4 (E) - U7-2 (RCLR) OFF Below 1 Ω U7-4 (E) - U7-3 (RCLF) OFF Below 1 Ω U7-1 (B) - U7-3 (RCLF) OFF 10 kΩ or higher U7-1 (B) - U7-2 (RCLR) OFF 10 kΩ or higher U7-1 (B) - U7-2 (RCLR) REAR Below 1 Ω U7-4 (E) - U7-3 (RCLF) REAR Below 1 Ω U7-1 (B) - U7-3 (RCLF) REAR 10 kΩ or higher U7-4 (E) - U7-2 (RCLR) REAR 10 kΩ or higher If the result is not as specified, replace the switch. SE–89 SEAT – POWER SEAT SWITCH 2. Reclining Switch Slide Switch RCLF T8 E RCLR B INSPECT FRONT POWER SEAT SWITCH RH (a) Measure the resistance between the specified terminals when each switch is operated. Standard resistance (Slide switch) Tester Connection Switch Condition Specified Condition T8-1 (B) - T8-9 (SLDF) FRONT Below 1 Ω T8-4 (E) - T8-6 (SLDR) FRONT Below 1 Ω T8-1 (B) - T8-6 (SLDR) FRONT 10 kΩ or higher T8-4 (E) - T8-9 (SLDF) FRONT 10 kΩ or higher T8-4 (E) - T8-6 (SLDR) OFF Below 1 Ω T8-4 (E) - T8-9 (SLDF) OFF Below 1 Ω T8-1 (B) - T8-6 (SLDR) OFF 10 kΩ or higher T8-1 (B) - T8-9 (SLDF) OFF 10 kΩ or higher T8-1 (B) - T8-6 (SLDR) REAR Below 1 Ω T8-4 (E) - T8-9 (SLDF) REAR Below 1 Ω T8-1 (B) - T8-9 (SLDF) REAR 10 kΩ or higher T8-4 (E) - T8-6 (SLDR) REAR 10 kΩ or higher Standard resistance (Reclining switch) SLDF SLDR Tester Connection Switch Condition Specified Condition T8-1 (B) - T8-3 (RCLF) FRONT Below 1 Ω B105969E06 T8-4 (E) - T8-2 (RCLR) FRONT Below 1 Ω T8-1 (B) - T8-2 (RCLR) FRONT 10 kΩ or higher T8-4 (E) - T8-3 (RCLF) FRONT 10 kΩ or higher T8-4 (E) - T8-2 (RCLR) OFF Below 1 Ω T8-4 (E) - T8-3 (RCLF) OFF Below 1 Ω T8-1 (B) - T8- 3 (RCLF) OFF 10 kΩ or higher T8-1 (B) - T8-2 (RCLR) OFF 10 kΩ or higher T8-1 (B) - T8-2 (RCLR) REAR Below 1 Ω T8-4 (E) - T8-3 (RCLF) REAR Below 1 Ω T8-1 (B) - T8-3 (RCLF) REAR 10 kΩ or higher T8-4 (E) - T8-2 (RCLR) REAR 10 kΩ or higher If the result is not as specified, replace the switch. INSTALLATION 1. INSTALL POWER SEAT SWITCH (a) Install the power seat switch with the 3 screws. (b) Connect the connector. 2. INSTALL FRONT SEAT CUSHION SHIELD ASSEMBLY 3. INSTALL SLIDE AND VERTICAL POWER SEAT SWITCH KNOB 4. INSTALL RECLINING POWER SEAT SWITCH KNOB 5. INSTALL FRONT SEAT ASSEMBLY (See page SE-41) 6. INSTALL INNER SEAT TRACK BRACKET COVER (See page SE-42) 7. INSTALL SEAT TRACK COVER (See page SE-42) B134677 SE SE–90 SEAT – FRONT SEAT FRAME WITH ADJUSTER FRONT SEAT FRAME WITH ADJUSTER U1 INSPECTION 1. B081621E19 SE INSPECT FRONT SEAT FRAME WITH ADJUSTER LH (a) Check operation of the seat frame (slide motor). (1) Check if the seat frame moves smoothly when the battery is connected to the slide motor connector terminals. OK Measurement Condition Operational Direction Battery positive (+) → U1-1 Battery negative (-) → U1-2 Forward Battery positive (+) → U1-2 Battery negative (-) → U1-1 Backward If the result is not as specified, replace the seat frame with adjuster. (b) Check operation of the seat frame (front vertical motor). (1) Check if the seat frame moves smoothly when the battery is connected to the front vertical motor connector terminals. OK U2 B081621E20 Measurement Condition Operational Direction Battery positive (+) → U2-1 Battery negative (-) → U2-2 Upward Battery positive (+) → U2-2 Battery negative (-) → U2-1 Downward If the result is not as specified, replace the seat frame with adjuster. (c) Check operation of the seat frame (reclining motor). (1) Check if the seat frame moves smoothly when the battery is connected to the reclining motor connector terminals. OK U3 B081621E21 Measurement Condition Operational Direction Battery positive (+) → U3-2 Battery negative (-) → U3-1 Forward Battery positive (+) → U3-1 Battery negative (-) → U3-2 Backward If the result is not as specified, replace the seat frame with adjuster. SE–91 SEAT – FRONT SEAT FRAME WITH ADJUSTER (d) Check operation of the seat frame (lifter motor). (1) Check if the seat frame moves smoothly when the battery is connected to the lifter motor connector terminals. OK U4 B081621E22 Measurement Condition Operational Direction Battery positive (+) → U4-2 Battery negative (-) → U4-1 Upward Battery positive (+) → U4-1 Battery negative (-) → U4-2 Downward If the result is not as specified, replace the seat frame with adjuster. 2. T1 B081621E23 INSPECT FRONT SEAT FRAME WITH ADJUSTER RH (a) Check operation of the seat frame (slide motor). (1) Check if the seat frame moves smoothly when the battery is connected to the slide motor connector terminals. OK Measurement Condition Operational Direction Battery positive (+) → T1-2 Battery negative (-) → T1-1 Forward Battery positive (+) → T1-1 Battery negative (-) → T1-2 Backward If the result is not as specified, replace the seat frame with adjuster. (b) Check operation of the seat frame (reclining motor). (1) Check if the seat frame moves smoothly when the battery is connected to the reclining motor connector terminals. OK T3 B081621E24 Measurement Condition Operational Direction Battery positive (+) → T3-2 Battery negative (-) → T3-1 Forward Battery positive (+) → T3-1 Battery negative (-) → T3-2 Backward If the result is not as specified, replace the seat frame with adjuster. SE SE–92 SEAT – FRONT POWER SEAT LUMBAR SWITCH FRONT POWER SEAT LUMBAR SWITCH SEAT BODY COMPONENTS SE FRONT SEAT HEADREST ASSEMBLY INNER SEAT TRACK BRACKET COVER FRONT SEAT ASSEMBLY SEAT TRACK COVER 37 (377, 27) 37 (377, 27) 37 (377, 27) N*m (kgf*cm, ft.*lbf) : Specified torque B134694E01 SE–93 SEAT – FRONT POWER SEAT LUMBAR SWITCH SE FRONT POWER SEAT LUMBAR SWITCH FRONT SEAT CUSHION SHIELD ASSEMBLY SLIDE AND VERTICAL POWER SEAT SWITCH KNOB RECLINING POWER SEAT SWITCH KNOB B136570E01 SE–94 SEAT – FRONT POWER SEAT LUMBAR SWITCH REMOVAL SE 1. REMOVE FRONT SEAT HEADREST ASSEMBLY 2. REMOVE SEAT TRACK COVER (See page SE-30) 3. REMOVE INNER SEAT TRACK BRACKET COVER (See page SE-30) 4. REMOVE FRONT SEAT ASSEMBLY (See page SE-30) 5. REMOVE RECLINING POWER SEAT SWITCH KNOB (See page SE-31) 6. REMOVE SLIDE AND VERTICAL POWER SEAT SWITCH KNOB (See page SE-31) 7. REMOVE FRONT SEAT CUSHION SHIELD ASSEMBLY (See page SE-32) 8. REMOVE FRONT POWER SEAT LUMBAR SWITCH (a) Remove the 2 screws and front power seat lumbar switch. B134675 FRONT INSPECTION U8 H E 1. R1 B R INSPECT FRONT POWER SEAT LUMBAR SWITCH LH (a) Measure the resistance between the terminals when the switch is operated. Standard resistance Tester Connection REAR B105971E05 Switch Condition Specified Condition U8-1 (R) - U8-2 (R1) FRONT Below 1 Ω U8-3 (B) - U8-4 (H) FRONT Below 1 Ω U8-1 (R) - U8-2 (R1) OFF Below 1 Ω U8-4 (H) - U8-5 (E) OFF Below 1 Ω U8-1 (R) - U8-3 (B) REAR Below 1 Ω U8-4 (H) - U8-5 (E) REAR Below 1 Ω If the result is not as specified, replace the switch. INSTALLATION 1. INSTALL FRONT POWER SEAT LUMBAR SWITCH (a) Install the front power seat lumbar switch with the 2 screws. 2. INSTALL FRONT SEAT CUSHION SHIELD ASSEMBLY 3. INSTALL SLIDE AND VERTICAL POWER SEAT SWITCH KNOB 4. INSTALL RECLINING POWER SEAT SWITCH KNOB 5. INSTALL FRONT SEAT ASSEMBLY (See page SE-41) B134675 SEAT – FRONT POWER SEAT LUMBAR SWITCH SE–95 6. INSTALL INNER SEAT TRACK BRACKET COVER (See page SE-42) 7. INSTALL SEAT TRACK COVER (See page SE-42) 8. INSTALL FRONT SEAT HEADREST ASSEMBLY SE SE–96 SEAT – LUMBAR SUPPORT ADJUSTER ASSEMBLY LUMBAR SUPPORT ADJUSTER ASSEMBLY SEAT BODY COMPONENTS SE FRONT SEAT HEADREST ASSEMBLY INNER SEAT TRACK BRACKET COVER FRONT SEAT ASSEMBLY SEAT TRACK COVER 37 (377, 27) 37 (377, 27) 37 (377, 27) N*m (kgf*cm, ft.*lbf) : Specified torque B134694E01 SEAT – LUMBAR SUPPORT ADJUSTER ASSEMBLY SE–97 FRONT SEAT HEADREST SUPPORT SE 5.5 (56, 49 in.*lbf) HOG RING SEPARATE TYPE FRONT SEAT BACK ASSEMBLY FRONT SEAT BACK BOARD SUB-ASSEMBLY FRONT SEAT CUSHION SHIELD INNER 42 (428, 31) LUMBAR SUPPORT ADJUSTER ASSEMBLY FRONT SEAT INNER BELT ASSEMBLY FRONT SEAT CUSHION SHIELD ASSEMBLY SLIDE AND VERTICAL POWER SEAT SWITCH KNOB RECLINING POWER SEAT SWITCH KNOB N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part B136568E01 SE–98 SEAT – LUMBAR SUPPORT ADJUSTER ASSEMBLY REMOVAL SE 1. REMOVE FRONT SEAT HEADREST ASSEMBLY 2. REMOVE SEAT TRACK COVER (See page SE-30) 3. REMOVE INNER SEAT TRACK BRACKET COVER (See page SE-30) 4. REMOVE FRONT SEAT ASSEMBLY (See page SE-30) 5. REMOVE RECLINING POWER SEAT SWITCH KNOB (See page SE-31) 6. REMOVE SLIDE AND VERTICAL POWER SEAT SWITCH KNOB (See page SE-31) 7. REMOVE FRONT SEAT CUSHION SHIELD ASSEMBLY (See page SE-32) 8. REMOVE FRONT SEAT INNER BELT ASSEMBLY (See page SB-16) 9. REMOVE FRONT SEAT CUSHION SHIELD INNER (See page SE-33) 10. REMOVE FRONT SEAT BACK BOARD SUBASSEMBLY (See page SE-35) 11. REMOVE FRONT SEAT HEADREST SUPPORT (See page SE-35) 12. REMOVE FRONT SEAT HEADREST SUPPORT 13. REMOVE SEPARATE TYPE FRONT SEAT BACK ASSEMBLY (See page SE-35) 14. REMOVE LUMBAR SUPPORT ADJUSTER ASSEMBLY (a) Disconnect the connector. (b) Remove the 2 screws and lumbar support adjuster. B134693 INSPECTION Counterclockwise 1. Clockwise U5 Driving Axis B065478E06 INSPECT LUMBAR SUPPORT ADJUSTER ASSEMBLY LH (a) Check operation of the lumbar support adjuster. (1) Check if the lumber support adjuster moves smoothly when the battery is connected to the lumbar support adjuster motor connector terminals. OK Measurement Condition Operation Direction Battery positive (+) → U5-2 Battery negative (-) → U5-1 Clockwise Battery positive (+) → U5-1 Battery negative (-) → U5-2 Counterclockwise SEAT – LUMBAR SUPPORT ADJUSTER ASSEMBLY SE–99 If the result is not as specified, replace the lumbar support adjuster. INSTALLATION B134693 1. INSTALL LUMBAR SUPPORT ADJUSTER ASSEMBLY (a) Install the lumbar support adjuster assembly with the 2 screws. (b) Connect the connector. 2. INSTALL SEPARATE TYPE FRONT SEAT BACK ASSEMBLY 3. INSTALL FRONT SEAT HEADREST SUPPORT 4. INSTALL FRONT SEAT HEADREST SUPPORT 5. INSTALL FRONT SEAT BACK BOARD SUBASSEMBLY 6. INSTALL FRONT SEAT CUSHION SHIELD INNER 7. INSTALL FRONT SEAT INNER BELT ASSEMBLY (See page SB-17) 8. INSTALL FRONT SEAT CUSHION SHIELD ASSEMBLY 9. INSTALL SLIDE AND VERTICAL POWER SEAT SWITCH KNOB 10. INSTALL RECLINING POWER SEAT SWITCH KNOB 11. INSTALL FRONT SEAT ASSEMBLY 12. INSTALL INNER SEAT TRACK BRACKET COVER (See page SE-42) 13. INSTALL SEAT TRACK COVER (See page SE-42) 14. INSTALL FRONT SEAT HEADREST ASSEMBLY SE SE–100 SEAT – SEAT HEATER SWITCH SEAT HEATER SWITCH SEAT BODY COMPONENTS NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH SE NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH SHIFT LEVER KNOB SUB-ASSEMBLY FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY SEAT HEATER SWITCH B140582E02 SE–101 SEAT – SEAT HEATER SWITCH REMOVAL 1. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (See page IP-24) 2. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-24) 3. REMOVE NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-25) 4. REMOVE FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (See page IP-25) 5. REMOVE SEAT HEATER SWITCH (a) Disengage the 2 claws and remove the seat heater switch. B140583E01 INSPECTION 1. INSPECT SEAT HEATER SWITCH (a) Inspect the driver side seat heater switch operation. (1) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Switch Position Specified Condition E55-3 (LH) - E55-5 (IG) OFF 10 kΩ or higher E55-3 (LH) - E55-5 (IG) ON Below 1 Ω If the result is not as specified, replace the switch. (2) Turn the seat heater switch on and check if the seat heater switch indicator comes on. OK E55 LH IG E B126240E01 Measurement Condition Specified Condition Battery positive (+) → Terminal E55-5 (IG) Battery negative (-) → Terminal E55-4 (E) Comes on If the result is not as specified, replace the switch. SE SE–102 SEAT – SEAT HEATER SWITCH (b) Inspect the front passenger side seat heater switch operation. (1) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Switch Position Specified Condition E55-5 (IG) - E55-6 (RH) OFF 10 kΩ or higher E55-5 (IG) - E55-6 (RH) ON Below 1 Ω If the result is not as specified, replace the switch. (2) Turn the seat heater switch on and check if the seat heater switch indicator comes on. OK SE E55 RH Measurement Condition Specified Condition Battery positive (+) → Terminal E55-5 (IG) Battery negative (-) → Terminal E55-4 (E) Comes on If the result is not as specified, replace the switch. IG E B126242E01 (c) Check if the seat heater switch indicator comes on. OK Measurement Condition Specified Condition Battery positive (+) → Terminal E55-1 (ILL+) Battery negative (-) → Terminal E55-2 (ILL-) Comes on If the result is not as specified, replace the switch. E55 ILL- ILL+ B126241E01 INSTALLATION B140583E01 1. INSTALL SEAT HEATER SWITCH (a) Engage the 2 claws and install the seat heater switch. 2. INSTALL FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (See page IP-53) 3. INSTALL NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-54) SEAT – SEAT HEATER SWITCH SE–103 4. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-55) 5. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (See page IP-55) SE SE–103 SEAT – FRONT SEATBACK HEATER FRONT SEATBACK HEATER SEAT BODY COMPONENTS SE FRONT SEAT HEADREST ASSEMBLY INNER SEAT TRACK BRACKET COVER FRONT SEAT ASSEMBLY SEAT TRACK COVER 37 (377, 27) 37 (377, 27) 37 (377, 27) N*m (kgf*cm, ft.*lbf) : Specified torque B134694E01 SE–104 SEAT – FRONT SEATBACK HEATER FRONT SEAT HEADREST SUPPORT FRONT SEPARATE TYPE SEAT BACK PAD SE 5.5 (55, 49 in.*lbf) FRONT SEAT BACK BOARD SUB-ASSEMBLY HOG RING SEPARATE TYPE FRONT SEAT BACK ASSEMBLY FRONT INNER SEAT CUSHION SHIELD 42 (428, 31) FRONT SEAT CUSHION SHIELD ASSEMBLY FRONT SEAT INNER BELT ASSEMBLY SLIDE AND VERTICAL POWER SEAT SWITCH KNOB RECLINING POWER SEAT SWITCH KNOB N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part B139119E01 SEAT – FRONT SEATBACK HEATER SE–105 REMOVAL 1. REMOVE FRONT SEAT HEADREST ASSEMBLY 2. REMOVE SEAT TRACK COVER (See page SE-30) 3. REMOVE INNER SEAT TRACK BRACKET COVER (See page SE-30) 4. REMOVE FRONT SEAT ASSEMBLY (See page SE-30) 5. REMOVE RECLINING POWER SEAT SWITCH KNOB (See page SE-31) 6. REMOVE SLIDE AND VERTICAL POWER SEAT SWITCH KNOB (See page SE-31) 7. REMOVE FRONT SEAT CUSHION SHIELD ASSEMBLY (See page SE-32) 8. REMOVE FRONT SEAT INNER BELT ASSEMBLY (See page SB-16) 9. REMOVE FRONT INNER SEAT CUSHION SHIELD (See page SE-33) 10. REMOVE FRONT SEAT BACK BOARD SUBASSEMBLY (See page SE-35) 11. REMOVE FRONT SEAT HEADREST SUPPORT (See page SE-35) 12. REMOVE FRONT SEAT HEADREST SUPPORT 13. REMOVE SEPARATE TYPE FRONT SEAT BACK ASSEMBLY 14. REMOVE FRONT SEPARATE TYPE SEAT BACK COVER (for Except Sports Seat Type) (a) Remove the 10 hog rings and front separate type seat back cover from the seat back pad. : Hog Ring B134686E01 15. REMOVE FRONT SEPARATE TYPE SEAT BACK COVER (for Sports Seat Type) (a) Remove the 14 hog rings and front separate type seat back cover from the seat back pad. Hog Ring B144025E01 SE SE–106 SEAT – FRONT SEATBACK HEATER INSPECTION 1. INSPECT FRONT SEAT BACK HEATER (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition 1-2 Always Below 1 Ω B030883 SE INSTALLATION 1. INSTALL FRONT SEPARATE TYPE SEAT BACK COVER (for Except Sports Seat Type) (a) Using hog ring pliers, install the front separate type seat back cover to the front seat back pad with 10 new hog rings. NOTICE: • Be careful not to damage the cover. • When installing the hog rings, take care to minimize wrinkles as much as possible. 2. INSTALL FRONT SEPARATE TYPE SEAT BACK COVER (for Sports Seat Type) (a) Using hog ring pliers, install the front separate type seat back cover to the front seat back pad with 14 new hog rings. NOTICE: • Be careful not to damage the cover. • When installing the hog rings, take care to minimize wrinkles as much as possible. 3. INSTALL SEPARATE TYPE FRONT SEAT BACK ASSEMBLY 4. INSTALL FRONT SEAT HEADREST SUPPORT 5. INSTALL FRONT SEAT HEADREST SUPPORT 6. INSTALL FRONT SEAT BACK BOARD SUBASSEMBLY 7. INSTALL FRONT INNER SEAT CUSHION SHIELD 8. INSTALL FRONT SEAT INNER BELT ASSEMBLY (See page SB-17) Hog Ring B136592E01 Hog Ring B144038E01 SEAT – FRONT SEATBACK HEATER 9. SE–107 INSTALL FRONT SEAT CUSHION SHIELD ASSEMBLY 10. INSTALL SLIDE AND VERTICAL POWER SEAT SWITCH KNOB 11. INSTALL RECLINING POWER SEAT SWITCH KNOB 12. INSTALL FRONT SEAT ASSEMBLY (See page SE-41) 13. INSTALL INNER SEAT TRACK BRACKET COVER (See page SE-42) 14. INSTALL SEAT TRACK COVER (See page SE-42) 15. INSTALL FRONT SEAT HEADREST ASSEMBLY SE SE–108 SEAT – FRONT SEAT CUSHION HEATER FRONT SEAT CUSHION HEATER SEAT BODY COMPONENTS SE FRONT SEAT HEADREST ASSEMBLY INNER SEAT TRACK BRACKET COVER FRONT SEAT ASSEMBLY SEAT TRACK COVER 37 (377, 27) 37 (377, 27) 37 (377, 27) N*m (kgf*cm, ft.*lbf) : Specified torque B134694E01 SE–109 SEAT – FRONT SEAT CUSHION HEATER FRONT SEPARATE TYPE SEAT CUSHION ASSEMBLY SE HOG RING FRONT SEPARATE TYPE SEAT CUSHION PAD FRONT INNER SEAT CUSHION SHIELD FRONT SEAT CUSHION SHIELD ASSEMBLY 42 (428, 31) FRONT SEAT INNER BELT ASSEMBLY SLIDE AND VERTICAL POWER SEAT SWITCH KNOB N*m (kgf*cm, ft.*lbf) : Specified torque RECLINING POWER SEAT SWITCH KNOB Non-reusable part B139120E01 SE–110 SEAT – FRONT SEAT CUSHION HEATER REMOVAL SE 1. REMOVE FRONT SEAT HEADREST ASSEMBLY 2. REMOVE SEAT TRACK COVER (See page SE-30) 3. REMOVE INNER SEAT TRACK BRACKET COVER (See page SE-30) 4. REMOVE FRONT SEAT ASSEMBLY (See page SE-30) 5. REMOVE RECLINING POWER SEAT SWITCH KNOB (See page SE-31) 6. REMOVE SLIDE AND VERTICAL POWER SEAT SWITCH KNOB (See page SE-31) 7. REMOVE FRONT SEAT CUSHION SHIELD ASSEMBLY (See page SE-32) 8. REMOVE FRONT SEAT INNER BELT ASSEMBLY (See page SB-16) 9. REMOVE FRONT INNER SEAT CUSHION SHIELD (See page SE-33) 10. REMOVE FRONT SEPARATE TYPE SEAT CUSHION ASSEMBLY (See page SE-34) 11. REMOVE FRONT SEPARATE TYPE SEAT CUSHION COVER (for Except Sport Seat Type) (a) Remove the 16 hog rings and seat cushion cover from the seat cushion pad. Hog Ring B134681E01 SEAT – FRONT SEAT CUSHION HEATER SE–111 12. REMOVE FRONT SEPARATE TYPE SEAT CUSHION COVER (for Sport Seat Type) (a) Remove the 17 hog rings and seat cushion cover from the seat cushion pad. SE Hog Ring B144026E01 INSPECTION 1. INSPECT FRONT SEAT CUSHION HEATER (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition 1-2 Always Below 1 Ω B030883 INSTALLATION 1. Hog Ring B136593E01 INSTALL FRONT SEPARATE TYPE SEAT CUSHION COVER (for Except Sport Seat Type) (a) Using hog ring pliers, install 16 new hog rings. NOTICE: • Be careful not to damage the cover. • When installing the hog rings, take care to minimize wrinkles as much as possible. SE–112 SEAT – FRONT SEAT CUSHION HEATER SE Hog Ring B144037E01 2. INSTALL FRONT SEPARATE TYPE SEAT CUSHION COVER (for Sport Seat Type) (a) Using hog ring pliers, install 17 new hog rings. NOTICE: • Be careful not to damage the cover. • When installing the hog rings, take care to minimize wrinkles as much as possible. 3. INSTALL FRONT SEPARATE TYPE SEAT CUSHION ASSEMBLY 4. INSTALL FRONT INNER SEAT CUSHION SHIELD 5. INSTALL FRONT SEAT INNER BELT ASSEMBLY (See page SB-17) 6. INSTALL FRONT SEAT CUSHION SHIELD ASSEMBLY 7. INSTALL SLIDE AND VERTICAL POWER SEAT SWITCH KNOB 8. INSTALL RECLINING POWER SEAT SWITCH KNOB 9. INSTALL FRONT SEAT ASSEMBLY (See page SE-41) 10. INSTALL INNER SEAT TRACK BRACKET COVER (See page SE-42) 11. INSTALL SEAT TRACK COVER (See page SE-42) 12. INSTALL FRONT SEAT HEADREST ASSEMBLY AV–1 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AUDIO AND VISUAL SYSTEM BODY ELECTRICAL AUDIO / VISUAL PARTS LOCATION FRONT SIDE SPEAKER SPIRAL CABLE -FRONT NO. 2 SPEAKER LH RADIO RECEIVER COMBINATION METER MICROPHONE STEERING PAD SWITCH FRONT SIDE SPEAKER -FRONT NO. 2 SPEAKER RH ANTENNA ANTENNA AMPLIFIER FRONT SIDE SPEAKER -FRONT NO. 1 SPEAKER INSTRUMENT PANEL J/B REAR SIDE SPEAKER -TAIL RELAY -REAR SPEAKER -ACC RELAY -RADIO NO. 2 FUSE -PANEL FUSE STEREO COMPONENT AMPLIFIER (*1) AV STEREO JACK ADAPTER ENGINE ROOM R/B AND J/B -RADIO NO. 1 FUSE -AMP FUSE *1: for Premium Model E132132E02 AV–2 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM SYSTEM DIAGRAM Standard Model: Steering Pad Switch Combination Meter Spiral Cable Speed Signal Switch Signal Radio Receiver Antenna Antenna Amplifier Speakers Sound Signal Stereo Jack Adapter Sound Signal AV E129797E03 AV–3 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Premium Model: Steering Pad Switch Combination Meter Antenna Spiral Cable Speed Signal Switch Signal Stereo Component Amplifier Radio Receiver (Master Unit) Antenna Amplifier (Slave Unit) Sound Signal Speakers Microphone Assembly Stereo Jack Adapter Microphone Voice Signal Sound Signal AV : AVC-LAN E129796E02 AV–4 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM SYSTEM DESCRIPTION 1. DISC PLAYER OUTLINE (a) A CD player uses a laser pickup to read digital signals recorded on CDs. By converting the digital signals to analog, music and other content can be played. CAUTION: Do not look directly at the laser pickup because the CD player uses an invisible laser beam. Be sure to operate the player only as instructed. NOTICE: • Do not disassemble any part of the CD player. • Do not apply oil to the CD player. • Do not insert anything but a CD into the CD player. (b) Usable discs (1) The CD player can only play audio CDs, CD-Rs (CD-Recordable), and CD-RWs (CDReWritable) that have any of the following marks: E119759 AV (c) Precautions for use of discs NOTICE: • Copy-protected CDs cannot be played. • CD-Rs and CD-RWs may not be played depending on the recording conditions or characteristics of the discs, or due to damage, dirt, or deterioration caused by leaving the discs in the cabin for a long time. • Unfinalized CD-Rs and CD-RWs cannot be played. • Keep the discs away from dirt. Be careful not to damage the discs or leave your fingerprints on them. • Hold discs by the outer edge and center hole with the label side up. • Leaving the disc exposed halfway out of the slot for a long time after pressing the disc eject button may cause deformation of the disc, making the disc unusable. • If discs have adhesive tape, stickers, CDR labels, or any traces of such labels attached, the discs may not be ejected or player malfunctions may result. AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–5 • Keep the discs away from direct sunlight. (Exposure to direct sunlight may cause deformation of the disc, making the disc unusable.) • Do not use odd-shaped CDs because these may cause player malfunctions. • Do not use discs whose recording portion is transparent or translucent because they may not be inserted, ejected, or played normally. HINT: • When it is cold or it is raining, if the windows mist up, mist and also dew may form in the player. In such a case, the CD may skip or the CD may stop in the middle of play. Ventilate or dehumidify the cabin for a while before using the player. • The CD may skip if the player experiences strong vibrations when the vehicle is driven on rough road or similar uneven surface(s). (d) Cleaning NOTICE: Do not use a lens cleaner because it may cause a malfunction in the pickup portion of the player. I100151 2. (1) If dirt is on the disc surface, wipe it clean with a soft dry cloth such as an eyeglass cleaner for plastic lenses from the inside to the outside in a radial direction. NOTICE: • Pressing on the disc by hand or rubbing the disc with a hard cloth may scratch the disc surface. • Use of solvent such as a record spray, antistatic agent, alcohol, benzine, and thinner, or a chemical cloth may cause damage to the disc, making the disc unusable. MP3/WMA OUTLINE (a) Playable MP3 file standards Compatible standard MP3 (MPEG1 LAYER3, MPEG2 LSF LAYER 3) Compatible sampling frequency • • MPEG1 LAYER3: 32, 44.1, 48 (kHz) MPEG2 LSF LAYER3: 16, 22.05, 24 (kHz) • MPEG1 LAYER3: 64, 80, 96, 112, 128, 160, 192, 224, 256, 320 (kbps) MPEG2 LSF LAYER3: 64, 80, 96, 112, 128, 144, 160 (kbps) Compatible with VBR Compatible bit rate Compatible channel mode • • Stereo, joint stereo, dual channel, monaural (b) Playable WMA file standards Compatible standard WMA Ver. 7, 8, and 9 Compatible sampling frequency 32, 44.1, 48 (kHz) Compatible bit rate • • • Ver. 7, 8: CBR48, 64, 80, 96, 128, 160, 192 (kbps) Ver. 9: CBR48, 64, 80, 96, 128, 160, 192, 256, 320 (kbps) Compatible with playback of channel 2 only AV AV–6 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM (c) ID3 tag and WMA tag (1) Additional textual information called ID3 tag can be input to MP3 files. Information such as song titles and artist names can be stored. HINT: This player is compatible with the ID3 tags of ID3 Ver. 1.0 and 1.1, and ID3 Ver. 2.2 and 2.3. (Number of characters complies with ID3 Ver. 1.0 and 1.1.) (2) Additional textual information called WMA tag can be input to WMA files. Information such as song titles and artist names can be stored. (d) Usable media (1) Only CD-ROMs, CD-Rs (CD-Recordable), and CD-RWs (CD-ReWritable) can be used to play MP3/WMA files. NOTICE: • CD-Rs and CD-RWs are more easily affected by a hot and humid environment than discs used for normal audio CDs. For this reason, some CD-Rs and CD-RWs may not be played. • If there are fingerprints or scratches on the disc, the disc may not be played or the CD may skip. • Some CD-Rs and CD-RWs deteriorate if they are left in the cabin for a long time. • Keep CD-Rs and CD-RWs in a storage case that is impenetrable to light. (e) Usable media format (1) Usable media format Disc format CD-ROM Mode 1, CD-ROM XA Mode 2 Form1 File format ISO9660 Level 1 and Level 2 (Joliet, Romeo) HINT: • As for MP3/WMA files written in any format other than those above, the contents of the files may not be played normally or the file names or folder names may not be displayed correctly. • This player is compatible with multi-session discs and can play CD-Rs and CD-RWs on which MP3/WMA files are added. However, only the first session can be played. • Discs whose first session includes both music data and MP3 or WMA format data cannot be played. (2) Standard and restrictions AV Maximum directory levels 8 levels Maximum number of characters for a folder name/file name 32 characters Maximum number of folders 192 (Including empty folders, route folders, and folders that do not contain MP3/WMA files) Maximum number of files in a disc 255 (Including non-MP3/WMA files) AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–7 (f) 3. File names (1) Only files with an extension of ".mp3" or ".wma" can be recognized and played as MP3 or WMA files. (2) Save MP3 or WMA files with an extension of ".mp3" or ".wma". NOTICE: If saving non-MP3 or non-WMA files with an extension of ".mp3" or ".wma", those files are wrongly recognized as MP3 or WMA files and played. A loud noise may occur and damage to the speaker may result. AVC-LAN DESCRIPTION (a) What is AVC-LAN? Example: Radio Receiver (Resistor 60 to 80 Ω) AVC-LAN Stereo Component Amplifier I100319E09 AVC-LAN, an abbreviation for "Audio Visual Communication Local Area Network", is a united standard developed by the manufacturers in affiliation with Toyota Motor Corporation. This standard pertains to audio and visual signals as well as switch and communication signals. (b) Purpose: Recently, car audio systems have rapidly developed and the functions have vastly changed. The conventional car audio system is being integrated with multi-media interfaces similar to those in navigation systems. At the same time, customers are demanding higher quality from their audio systems. This is merely an overview of the standardization background. The specific purposes are as follows: (1) To solve sound problems, etc. caused by using components of different manufacturers through signal standardization. (2) To allow each manufacturer to concentrate on developing products they do best. From this, reasonably priced products can be produced. HINT: • If a short to +B or short to ground is detected in the AVC-LAN circuit, communication is interrupted and the audio system will stop functioning. AV AV–8 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 4. 5. 6. E100921 AV • If the audio system has a navigation system installed, the multi-display unit acts as the master unit. If the navigation system is not installed, the audio head unit acts as the master unit instead. If the radio and navigation assembly is installed, it is the master unit. • The radio receiver contains a resistor that is necessary to enable communication on the different AVC-LAN circuits. • The car audio system with an AVC-LAN circuit has a diagnostic function. • Each component has a specified number (3digit) called a physical address. Each function has a number (2-digit) called a logical address. COMMUNICATION SYSTEM OUTLINE (a) Components of the audio system communicate with each other via the AVC-LAN. (b) The master component of the AVC-LAN is a radio receiver with a 60 to 80 Ω resistor. This is essential for communication. (c) If a short circuit or open circuit occurs in the AVCLAN circuit, communication is interrupted and the audio system will stop functioning. DIAGNOSTIC FUNCTION OUTLINE (a) The audio system has a diagnostic function (the result is indicated on the master unit). (b) A 3-digit hexadecimal component code (physical address) is allocated to each component on the AVC-LAN. Using this code, the component in the diagnostic function can be displayed. "BLUETOOTH" OUTLINE (a) "Bluetooth" is a trademark owned by Bluetooth SIG. Inc. AV–9 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM (b) "Bluetooth" is a new wireless connection technology that uses the 2.4 GHz frequency band. This makes it possible to connect a cellular phone ("Bluetooth" compatible phone *1) to the radio receiver (the "Bluetooth" system is built in), and use the handsfree function of the cellular phone, even if it is in a pocket or bag. As a result, it is not necessary to use a connector attached directly to the cellular phone. *1 : Some versions of "Bluetooth" compatible cellular phones may not function. Example: Radio Receiver (Built-in “Bluetooth” receiver antenna) Cellular Phone (”Bluetooth” type) Cellular Tower E129829E02 HINT: The communication performance of "Bluetooth" may vary depending on obstructions or radio wave conditions between communication devices, electromagnetic radiation, communication device sensitivity, or antenna capacity. AV AV–10 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT 3 BASIC INSPECTION (a) Turn the ignition switch on (IG). (b) Check whether or not the radio receiver turns on. Result Result Proceed to Radio receiver turns on A Radio receiver does not turn on B B Go to step 6 A 4 CHECK FOR DTC (a) Check for DTCs and note any codes that are output. (b) Delete the DTCs. (c) Recheck for DTCs by simulating the operation indicated by the DTCs. HINT: • If the system cannot enter the diagnostic mode, inspect the AVC-LAN and all the components that connect to the AVC-LAN for short circuits and repair or replace the problem part. • Even if the malfunction symptom is not confirmed, check the DTCs. This is because the system stores past DTCs. • Check and clear past DTCs. Then check for DTCs. AV Result Result Proceed to DTC is output again A DTC is not output B AV–11 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM B Go to step 6 A 5 DIAGNOSTIC TROUBLE CODE CHART Find the output code in the diagnostic trouble code chart (See page AV-27). NEXT Go to step 8 6 PROBLEM SYMPTOMS TABLE Refer to the problem symptoms table (See page AV-13). Result Result Proceed to Fault is not listed in problem symptoms table A Fault is listed in problem symptoms table B B Go to step 8 A 7 OVERALL ANALYSIS AND TROUBLESHOOTING (a) Terminals of ECU (See page AV-15). NEXT 8 ADJUST, REPAIR OR REPLACE NEXT 9 NEXT END CONFIRMATION TEST AV AV–12 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM IDENTIFICATION OF NOISE SOURCE 1. Frequency 300 kHz 30 kHz Designation Radio Description (a) Radio frequency band (1) Radio broadcasts use the radio frequency bands shown in the table below. LF MF Modulation HF VHF FM Amplitude modulation MF: Medium Frequency 300 MHz 30 MHz AM Radio Wave LF: Low Frequency 30 MHz HF: High Frequency Frequency modulation VHF: Very High Frequency E108734E01 (b) Service area (1) The service areas of AM and FM broadcasts are vastly different. Sometimes an AM broadcast can be received very clearly but an FM stereo cannot. FM stereo has the smallest service area, and is prone to pick up static and other types of interference such as noise. (c) Radio reception problems HINT: In addition to static, other problems such as "phasing", "multipath", and "fade out" exist. These problems are not caused by electrical noise, but by the radio signal propagation method itself. FM (Stereo) FM (Monaural) AM E108735E01 Phasing Ionosphere AV I100011E02 (1) Phasing AM broadcasts are susceptible to electrical interference and another kind of interference called phasing. Occurring only at night, phasing is the interference created when a vehicle receives 2 radio wave signals from the same transmitter. One signal is reflected off the ionosphere and the other signal is received directly from the transmitter. AV–13 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM (2) Multipath Multipath is a type of interference created when a vehicle receives 2 radio wave signals from the same transmitter. One signal is reflected off buildings or mountains and the other signal is received directly from the transmitter. Multipath I100012E02 (3) Fade out Fade out is caused by objects (buildings, mountains, and other such large obstacles) that deflect away part of a signal, resulting in a weaker signal when the object is between the transmitter and vehicle. High frequency radio waves, such as FM broadcasts, are easily deflected by obstructions. Low frequency radio waves, such as AM broadcasts, are much more difficult to deflect. (d) Noise problem Technicians must have a clear understanding about each customer's noise complaint. Use the following table to diagnose noise problems. Fade Out I100013E02 Radio Frequency Noise Occurrence Condition Presumable Cause AM Noise occurs in a specified area Foreign noise AM Noise occurs when listening to an intermittent broadcast An identical program transmitted from multiple towers can cause noise where the signals overlap AM Noise occurs only at night Music beat from a distant broadcast FM Noise occurs while driving in a specified area Multipath or phasing noise resulting from a change in FM frequency HINT: If the noise does not match the examples above, refer to the descriptions about phasing and multipath. AV AV–14 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM PROBLEM SYMPTOMS TABLE HINT: • Before inspecting the suspected areas listed in the table below, check the fuse and relay. • Before inspecting the suspected areas listed in the table below, check for DTCs. • Methods used to verify the cause of the problem are listed in order of probability in the suspected area column. Audio Function: Symptom Pressing power switch does not turn on system. See page 1. Proceed to "Pressing Power Switch does not Turn on System" AV-68 2. Radio receiver power source circuit AV-140 3. AVC-LAN circuit AV-118 4. Radio receiver AV-145 1. Steering pad switch circuit AV-91 2. AVC-LAN circuit AV-118 3. Radio receiver AV-145 1. Radio receiver power source circuit AV-140 2. Proceed to "No Sound can be Heard from Speakers" AV-69 3. Stereo component amplifier power source circuit AV-142 4. Proceed to "Sound Signal Circuit between Radio Receiver and Stereo Component Amplifier" AV-111 5. Speaker circuit AV-103 6. Proceed to "Mute Signal Circuit between Radio Receiver and Stereo Component Amplifier" AV-115 7. Stereo component amplifier AV-150 8. Radio receiver AV-145 1. Radio receiver power source circuit AV-140 2. Proceed to "No Sound can be Heard from Speakers" AV-69 3. Speaker circuit AV-103 4. Radio receiver AV-145 1. Proceed to "Poor Sound Quality in All Modes (Low Volume)" AV-80 2. Speaker circuit. AV-103 3. Proceed to "Sound Signal Circuit between Radio Receiver and Stereo Component Amplifier" AV-111 4. Proceed to "Mute Signal Circuit between Radio Receiver and Stereo Component Amplifier" AV-115 5. Stereo component amplifier AV-150 6. Radio receiver AV-145 1. Proceed to "Poor Sound Quality in All Modes (Low Volume)" AV-80 2. Speaker circuit AV-103 3. Radio receiver AV-145 ASL does not function. (for premium model) Proceed to "Vehicle Speed Signal Circuit between Stereo Component Amplifier and Combination Meter" AV-120 ASL does not function. (for standard model) Proceed to "Vehicle Speed Signal Circuit between Radio Receiver and Combination Meter" AV-87 1. Radio receiver power source circuit AV-140 2. Proceed to "Sound Signal Circuit between Radio Receiver and Stereo Jack Adapter" AV-113 3. Stereo jack adapter AV-223 4. Radio receiver AV-145 Panel switch does not function. No sound can be heard from speakers. (Audio is mute.) (for premium model) No sound can be heard from speakers. (Audio is mute.) (for standard model) Sound quality is bad in all modes. (Volume is too low.) (for premium model) Sound quality is bad in all modes. (Volume is too low.) (for standard model) AV Suspected area External device sound cannot be heard or sound quality is bad. (Stereo jack is used.) AV–15 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Symptom Abnormal noise occurs. (for premium model) Abnormal noise occurs. (for standard model) Radio broadcast cannot be received or poor reception. CD cannot be inserted / played or CD is ejected right after insertion. CD cannot be ejected. Suspected area See page 1. Proceed to "Noise occurs" AV-66 2. Stereo component amplifier AV-150 3. Radio receiver AV-145 1. Proceed to "Noise occurs" AV-66 2. Radio receiver AV-145 Proceed to "Radio Broadcast cannot be Received or Poor Reception" AV-76 1. Radio receiver power source circuit AV-140 2. Proceed to "CD cannot be Inserted / Played or CD is Ejected Right After Insertion" AV-72 1. Radio receiver power source circuit AV-140 2. Proceed to "CD cannot be Ejected" AV-71 Sound quality is bad only when CD is played. (Volume is too low.) Proceed to "Sound Quality is Bad Only when CD is Played (Volume is Too Low)" AV-70 CD sound skips. Proceed to "CD Sound Skips" AV-74 1. Illumination circuit AV-96 2. Radio receiver AV-145 Radio receiver cannot be illuminated at night. Steering Pad Switch Function: Symptom Audio system cannot be operated with steering pad switch. Steering pad switch cannot be illuminated at night. Suspected area See page 1. Steering pad switch circuit AV-91 2. Radio receiver AV-145 1. Illumination circuit AV-96 2. Radio receiver AV-145 "Bluetooth" Function (*1): Symptom Cellular phone registration failure, phone directory transfer failure. Cellular phone cannot send / receive. The other caller's voice cannot be heard, is too quiet, or distorted. The other caller cannot hear your voice, or your voice is too quiet or distorted. Suspected area See page Proceed to "Cellular Phone Registration Failure, Phone Directory Transfer Failure" AV-81 1. Proceed to "Cellular Phone cannot Send / Receive" AV-83 2. Steering pad switch circuit AV-91 3. Radio receiver AV-145 1. Proceed to "The Other Caller's Voice cannot be Heard, is too Quiet, or Distorted" AV-85 2. Proceed to "Cellular Phone Voice Circuit between Radio Receiver and Stereo Component Amplifier" AV-124 3. Radio receiver AV-145 4. Stereo component amplifier AV-150 1. Proceed to "The Other Caller cannot Hear Your Voice, or Your Voice is too Quiet or Distorted" AV-86 2. Proceed to "Microphone Circuit between Microphone and Radio Receiver" AV-126 3. Microphone AV-232 4. Radio receiver AV-145 *1: for Premium Model AV AV–16 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM TERMINALS OF ECU 1. F26 RADIO RECEIVER (PREMIUM MODEL) F8 F11 E129787E03 Wiring Color Terminal Description Condition Specification B (F26-1) - GND (F26-20) Symbols (Terminal No.) L-Y - BR Battery Always 10 to 14 V ILL+ (F26-2) - GND (F26-20) G - BR Illumination signal Light control switch OFF → TAIL Below 1 V → 10 to 14 V ATX+ (F26-5) - GND (F26-20) R - BR AVC-LAN communication signal Turn ignition switch on (ACC) 2 to 3 V MUTE (F26-7) - GND (F26-20) O - BR MUTE signal Audio system is playing → Changing Above 3.5 V → Below 1 V R+ (F26-8) - GND (F26-20) R - BR Sound signal (Right) Audio system is playing A waveform synchronized with sounds is output L+ (F26-9) - GND (F26-20) B - BR Sound signal (Left) Audio system is playing A waveform synchronized with sounds is output SLD (F26-10) - Body ground Shielded - Body ground Shield ground Always Below 1 V ACC (F26-11) - GND (F26-20) GR - BR Accessory (ON) Turn ignition switch on (ACC) 10 to14 V ILL- (F26-12) - GND (F26-20) W-B - BR Illumination (rheostat) signal Light control switch OFF → TAIL Below 1 V → Pulse generation ANT (F26-13) - GND (F26-20) O - BR Power source of antenna Radio switch ON and AM or FM 10 to 14 V ATX- (F26-15) - GND (F26-20) G - BR AVC-LAN communication signal Turn ignition switch on (ACC) 2 to 3 V R- (F26-18) - GND (F26-20) G - BR Sound signal (Right) Audio system is playing A waveform synchronized with sounds is output L- (F26-19) - GND (F26-20) W - BR Sound signal (Left) Audio system is playing A waveform synchronized with sounds is output GND (F26-20) - Body ground BR - Body ground Ground Always Below 1 V P - BR Steering pad switch ground Always Below 1 V Steering pad switch signal Steering pad switch not operated → SEEK+ switch pushed → SEEK- switch pushed → VOL+ switch pushed → VOL- switch pushed 4 V or more → Approx. 0.5 V → Approx. 0.9 V → Approx. 2.0 V → Approx. 3.4 V 4 V or more → Approx. 0.5 V → Approx. 0.9 V → Approx. 2.0 V A waveform synchronized with sounds is output SWG (F8-6) - GND (F26-20) SW1 (F8-7) - GND (F26-20) O - BR AV SW2 (F8-8) - GND (F26-20) Y - BR Steering pad switch signal Steering pad switch not operated → MODE switch pushed → ON HOOK switch pushed → OFF HOOK switch pushed IVO+ (F8-11) - GND (F26-20) R - BR Voice signal "Bluetooth" handsfree voice signal is playing AV–17 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specification A waveform synchronized with sounds is output IVO- (F8-12) - GND (F26-20) G - BR Voice signal "Bluetooth" handsfree voice signal is playing SLD (F8-13) - Body ground Shielded - Body ground Shield ground Always Below 1 V ARI (F8-15) - GND (F26-20) G - BR Sound signal (Right) External device is playing (When stereo jack is used) A waveform synchronized with sounds is output ASGN (F8-16) - GND (F26-20) BR - BR Shield ground Always Below 1 V ALI (F8-17) - GND (F26-20) R - BR Sound signal (Left) External device is playing (When stereo jack is used) A waveform synchronized with sounds is output AUXI (F8-19) - GND (F26-20) G - BR External device connection detection signal External device is connected Below 1 V MIC- (F11-1) - GND (F26-20) R - BR Microphone voice signal Bluetooth handsfree function is ON A waveform synchronized with sounds is output MIC+ (F11-2) - GND (F26-20) G - BR Microphone voice signal Bluetooth handsfree function is ON A waveform synchronized with sounds is output +B (F11-5) - GND (F26-20) L - BR Battery Always 10 to 14 V MCVD (F11-7) - GND (F26-20) LG - BR Microphone AMP power supply Turn ignition switch off → on (IG) Below 1 V → 5 V GND (F11-14) - Body ground BR - Body ground Ground Always Below 1 V Accessory (ON) Turn ignition switch off → on (ACC) Below 1 V → 10 to 14 V ACC (F11-16) - GND (F26-20) GR - BR 2. F6 RADIO RECEIVER (STANDARD MODEL) F7 F8 E119761E04 Symbols (Terminal No.) Wiring Color Terminal Description Condition Specification FR+ (F6-1) - GND (F6-7) LG - BR Sound signal (Front Right) Audio system is playing A waveform synchronized with sounds is output FL+ (F6-2) - GND (F6-7) P - BR Sound signal (Front Left) Audio system is playing A waveform synchronized with sounds is output ACC (F6-3) - GND (F6-7) GR - BR Accessory (ON) Turn ignition switch off→ on (ACC) Below 1 V → 10 to 14 V B (F6-4) - GND (F6-7) L-Y - BR Battery Always 10 to 14 V FR- (F6-5) - GND (F6-7) L - BR Sound signal (Front Right) Audio system is playing A waveform synchronized with sounds is output FL- (F6-6) - GND (F6-7) V - BR Sound signal (Front Left) Audio system is playing A waveform synchronized with sounds is output GND (F6-7) - Body ground BR - Body ground Ground Always Below 1 V 10 to 14 V ANT (F6-8) - GND (F6-7) O - BR Power source of antenna Radio switch ON and AM or FM ILL+ (F6-10) - GND (F6-7) G - BR Illumination signal Light control switch OFF → TAIL or HEAD Below 1 V → 10 to 14 V RR+ (F7-1) - GND (F6-7) R - BR Sound signal (Rear Right) Audio system is playing A waveform synchronized with sounds is output RL+ (F7-2) - GND (F6-7) B - BR Sound signal (Rear Left) Audio system is playing A waveform synchronized with sounds is output AV AV–18 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specification RR- (F7-3) - GND (F6-7) W - BR Sound signal (Rear Right) Audio system is playing A waveform synchronized with sounds is output ILL- (F7-5) - GND (F6-7) W-B - BR Illumination (rheostat) signal Light control switch OFF → TAIL or HEAD Below 1 V → Pulse generation RL- (F7-6) - GND (F6-7) Y - BR Sound signal (Rear Left) Audio system is playing A waveform synchronized with sounds is output SPD (F8-3) - GND (F6-7) V - BR Speed signal from combination meter Turn ignition switch on (IG). Turn drive wheels slowly. Pulse generation SWG (F8-6) - GND (F6-7) P - BR Steering pad switch ground Always Below 1 V 4 V or more → Approx. 0.5 V → Approx. 0.9 V → Approx. 2.0 V → Approx. 3.4 V SW1 (F8-7) - GND (F6-7)) O - BR Steering pad switch signal Steering pad switch not operated → SEEK+ switch pushed → SEEK- switch pushed → VOL+ switch pushed → VOL- switch pushed SW2 (F8-8) - GND (F6-7) Y - BR Steering pad switch signal Steering pad switch not operated → MODE switch pushed 4 V or more → Below 2.5 V ARI (F8-15) - GND (F6-7) O - BR Sound signal (Right) External device is playing (When stereo jack is used) A waveform synchronized with sounds is output ASGN (F8-16) - GND (F6-7) BR - BR Shield ground Always Below 1 V ALI (F8-17) - GND (F6-7) R - BR Sound signal (Left) External device is playing (When stereo jack is used) A waveform synchronized with sounds is output AUXI (F8-19) - GND (F6-7) G - BR External device connection detection signal External device is connected Below 1 V 3. STEREO COMPONENT AMPLIFIER (PREMIUM MODEL) F18 F20 F19 E126133E02 Symbols (Terminal No.) AV Wiring Color Terminal Description Condition Specification MUTE (F19-1) - GND (F20-6) O - BR Mute signal from radio receiver Audio system is playing → Changing Above 3.5 V → Below 1 V L- (F19-2) - GND (F20-6) W - BR Sound signal (Left) Audio system is playing A waveform synchronized with sounds is output L+ (F19-3) - GND (F20-6) B - BR Sound signal (Left) Audio system is playing A waveform synchronized with sounds is output R- (F19-4) - GND (F20-6) G - BR Sound signal (Right) Audio system is playing A waveform synchronized with sounds is output R+ (F19-5) - GND (F20-6) R - BR Sound signal (Right) Audio system is playing A waveform synchronized with sounds is output SLD (F19-6) - Body ground Shielded - Body ground Shield ground Always Blow 1 V TX- (F19-7) - GND (F20-6) G - BR AVC-LAN communication signal Turn ignition switch on (ACC) 2 to 3 V AV–19 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specification TX+ (F19-8) - GND (F20-6) R - BR AVC-LAN communication signal Turn ignition switch on (ACC) 2 to 3 V SPD (F19-11) - GND (F20-6) V - BR Speed signal from combination meter Turn ignition switch on (IG). Turn drive wheels slowly. Pulse generation ACC (F19-12) - GND (F20-6) GR - BR Accessory (ON) Turn ignition switch off → on (ACC) Below 1 V → 10 to 14 V INT- (F19-22) - GND (F20-6) G - BR Voice signal Navigation or "Bluetooth " handsfree voice signal is provided A waveform synchronized with sounds is output INT+ (F19-23) - GND (F20-6) R - BR Voice signal Navigation or "Bluetooth " handsfree voice signal is provided A waveform synchronized with sounds is output +B (F18-1) - GND (F20-6) GR - BR Battery Always 10 to 14 V FR+ (F18-2) - GND (F20-6) LG - BR Sound signal (Front Right) Audio system is playing A waveform synchronized with sounds is output RL+ (F18-3) - GND (F20-6) B - BR Sound signal (Rear Left) Audio system is playing A waveform synchronized with sounds is output RR- (F18-4) - GND (F20-6) W - BR Sound signal (Rear Right) Audio system is playing A waveform synchronized with sounds is output +B2 (F18-5) - GND (F20-6) GR - BR Battery Always 10 to 14 V FR- (F18-6) - GND (F20-6) L - BR Sound signal (Front Right) Audio system is playing A waveform synchronized with sounds is output FL- (F18-7) - GND (F20-6) V - BR Sound signal (Front Left) Audio system is playing A waveform synchronized with sounds is output FL+ (F18-8) - GND (F20-6) P - BR Sound signal (Front Left) Audio system is playing A waveform synchronized with sounds is output RL- (F18-9) - GND (F20-6) Y - BR Sound signal (Rear Left) Audio system is playing A waveform synchronized with sounds is output RR+ (F18-10) - GND (F20-6) R - BR Sound signal (Rear Right) Audio system is playing A waveform synchronized with sounds is output WFL- (F20-1) - GND (F20-6) V - BR Sound signal (Front Left) Audio system is playing A waveform synchronized with sounds is output WFL+ (F20-2) - GND (F20-6) P - BR Sound signal (Front Left) Audio system is playing A waveform synchronized with sounds is output WFR- (F20-3) - GND (F20-6) L - BR Sound signal (Front Right) Audio system is playing A waveform synchronized with sounds is output SL+ (F20-4) - GND (F20-6) G-W - BR Sound signal (Rear Left) Audio system is playing A waveform synchronized with sounds is output SR+ (F20-5) - GND (F20-6) L - BR Sound signal (Rear Right) Audio system is playing A waveform synchronized with sounds is output GND (F20-6) - Body ground BR - Body ground Ground Always Below 1 V E (F20-7) - Body ground BR - Body ground Ground Always Below 1 V WFR+ (F20-9) - GND (F20-6) LG - BR Sound signal (Front Right) Audio system is playing A waveform synchronized with sounds is output SL- (F20-10) - GND (F20-6) BR - BR Sound signal (Rear Left) Audio system is playing A waveform synchronized with sounds is output SR- (F20-12) - GND (F20-6) Y - BR Sound signal (Rear Right) Audio system is playing A waveform synchronized with sounds is output AV AV–20 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC CHECK / CLEAR HINT: If the system cannot enter the diagnostic mode, inspect the AVC-LAN and all the components that connect to the AVCLAN for short circuits and repair or replace the problem part. (See page AV-118) 1. SEEK TRACK DISC 2. 1 6 E129786E01 STARTING DIAGNOSTIC MODE (a) Turn the ignition switch on (ACC). (b) Turn off the audio system. (c) While pressing the preset switches "1" and "6" at the same time, press the "DISC" switch 3 times. HINT: A beep is emitted 3 times and the diagnostic function is activated. The system enters the all element illumination mode and the switch check mode. ALL ELEMENT ILLUMINATION MODE AND SWITCH CHECK MODE HINT: Illumination status of all switches and operations of the panel switches can be checked. (a) Check that all elements are on. (b) When pressing each panel switch, check that a beep is emitted. NOTICE: Pressing the "SEEK TRACK UP" switch transfers the screen to the stereo jack adapter connection check screen. Check the operation of this switch by confirming the transfer of the screen. Example: E119764E02 3. When a stereo jack adapter is connected: When a stereo jack adapter is not connected: AV 4. E119765E02 5. STEREO JACK ADAPTER CONNECTION CHECK MODE (a) Press the "SEEK TRACK UP" switch. (b) Check if the stereo jack adapter is recognized. HINT: Vehicles that do not have a stereo jack adapter also have this function. NOTICE: This function is not to check connection information on an external device, but to check recognition information on a stereo jack adapter. SERVICE CHECK MODE (a) Press the "SEEK TRACK UP" switch. HINT: For details of the service check mode, refer to "6. CHECK DTC" and "7. DTC CLEAR/RECHECK". FINISHING DIAGNOSTIC MODE (a) Press the "DISC" switch for 2 seconds or more, or turn the ignition switch off. AV–21 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 6. CHECK DTC HINT: Illustrations may differ from the actual vehicle depending on the device settings and options. Therefore, some detailed areas may not be shown exactly the same as on the actual vehicle. (a) Reference: In the system check mode, the system check and the diagnostic memory check are performed, and the check results are displayed in ascending order of the component codes (physical address). Terms Meaning Component code (Physical address) Three-digit code (in hexadecimal) given to each device comprising AVC-LAN. Corresponding to its function, individual symbol is provided. Two-digit code (in hexadecimal) given to each function and device unit in each device comprising AVC-LAN. Logical address (b) Service check result display Display Previous term Meaning Action to be taken good Good (normal) No DTCs are detected in both "System Check Mode" and "Diagnostic Memory Mode". - nCon No connection ECHn Exchange CHEC Check OLd Old version nrES No response The system recognized the component when it was registered, but the component gives no response to the "Diagnostic Mode ON Request". Check the power source circuit and the communication circuit of the component indicated by the component code (physical address). One or more DTCs for "Exchange" are detected in either "System Check Mode" or "Diagnostic Memory Mode". Go to the detailed information mode to check the trouble area referring to the DTC list. When no DTCs are detected for "Exchange", one or more DTCs for "Check" are detected in either "System Check Mode" or "Diagnostic Memory Mode". Go to the detailed information mode to check the trouble area referring to the DTC list. Old DTC application is identified and DTC is detected in either "System Check Mode" or "Diagnostic Memory Mode". The device gives no response to any one of "System Check Mode ON Request", "System Check Result Request", and "Diagnostic Memory Request". Check the power source circuit and the communication circuit of the component indicated by the component code (physical address). (c) Device name and physical address Physical address No. Name 190 Radio receiver 440 Stereo component amplifier 19D "Bluetooth" handsfree module (d) Service check mode (1) Press the "SEEK TRACK" switch to see the check result of each component. (2) The component code (physical address) is displayed first, and then the check result follows. HINT: • If all check results are "good", the system judges that no DTC exists. AV AV–22 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM • If the preset switch "1" is pressed in the service check mode, service check is performed again. • This illustration is only an example and may differ in cases such as for each option part and output DTCs. Service Check Mode: (*1) (*2) (*3) (*1) (*2) (*4) (*1) (*2) (*3) (*1) (*2) PRESET SWITCH “2” Detailed Information Mode 1 (*4) (*1) (*2) PRESET SWITCH “3” (*3) (*1) (*2) PRESET SWITCH “2” Detailed Information Mode 2 (*4) (*1) (*2) PRESET SWITCH “3” Continues to display check result when more components are installed. (*1) (*1) (*2) (*5) (*2) PRESET SWITCH “5” (Press for 2 seconds or more) DTC Clear (*6) AV *1: SEEK TRACK DOWN *4: Result *2: SEEK TRACK UP *5: Up-to-date connection check number *3: P...Indicates physical address *6: Memory clear 190/440/1C6...Physical address E110920E07 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–23 (e) Detailed information mode 1 HINT: • "Detailed Information Mode 1" is displayed when there is no response to "System Check Result Request" and DTC is detected only in "Diagnostic Memory Request". • The component device code (physical address) is displayed first, and then the check result follows. • This illustration is only an example and may differ in cases such as for each option part and output DTCs. (1) Press the preset switch "2" to go to the "Detailed Information Mode 1". (2) Press the "SEEK TRACK" switch to display the physical address and DTC of the component. (3) Press the preset switch "3" to go to the "Service Check Mode". (4) Distinguish between the displays of the responses to "System Check Result Request" and "Diagnostic Memory Request". In order to distinguish the information detected in "System Check Mode" and "Diagnostic Memory Mode" in "ECHn", "CHEC", and "OLd" in "Detailed Information Mode 1", refer to the following: • "SyS" is displayed before the detailed codes detected as a result of "System Check Result Request" are displayed. • "COdE" is displayed before the detailed codes detected as a result of "Diagnostic Memory Request" are displayed. HINT: • The response to "System Check Result Request" is the current information given from each ECU as a result of the system check. • The response to "Diagnostic Memory Request" contains the information received from each ECU or stored in each ECU in the past. • The response to "Diagnostic Memory Request" is the output DTCs as a result of the diagnostic memory check or the DTCs received from each ECU. • "System Check Result Request (SyS)" is displayed first, and then the logical address and DTC appear in order. • "Diagnostic Memory Request (COdE)" is displayed first, and then the logical address, DTC, sub-code, connection check number, and the number of occurrence appear in order. AV AV–24 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Service Check Mode: (*1) PRESET SWITCH “3” Detailed Information Mode 1: (DTC is detected only in the response to “Diagnostic Memory Request”.) (*2) PRESET SWITCH “2” (*2) (*1) (*3) (*1) PRESET SWITCH “5” (*2) (*4) (*1) (*2) *1: SEEK TRACK DOWN (*5) (*1) (*2) (*1) (*2) (*7) (*1) *2: SEEK TRACK UP *3: P...Indicates physical address (*6) Detailed information of the first code is displayed. (Press for 2 seconds or more) (*2) 440...Physical address *4: “COdE” indicates the display start of the response to “Diagnostic Memory Request”. (*8) (*1) (*2) *5: 1...The first code (*9) (*1) (*2) 01...Logical address (*10) (*1) (*2) (*1) (*2) (*11) (*1) (*2) (*8) (*1) AV *7: Physical address appears as the sub-code. *9: The number of times of occurrence (*2) Continues to display detailed information when more DTCs are detected. (*1) DC...DTC *8: Connection check number (*2) (*9) (*1) *6: 1...The first code d...Indicates DTC (*10) Detailed information of the second code is displayed. L...Indicates logical address *10: 2...The second code *11: For DTCs without sub-codes, physical address is not displayed. (*2) E110919E06 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM (f) AV–25 Detailed information mode 2 HINT: • "Detailed Information Mode 2" is displayed when DTCs are detected in the responses to both "System Check Result Request" and "Diagnostic Memory Request". • The component device code (physical address) is displayed first, and then the check result follows. • This illustration is only an example and may differ in cases such as for each option part and output DTCs. (1) Press the preset switch "2" to go to the "Detailed Information Mode 2". (2) Press the "SEEK TRACK" switch to display the physical address and DTC of the component. (3) Press the preset switch "3" to go to the "Service Check Mode". (4) Distinguish between the displays of the responses to "System Check Result Request" and "Diagnostic Memory Request". In order to distinguish the information detected in "System Check Mode" and "Diagnostic Memory Mode" in "ECHn", "CHEC", and "OLd" in "Detailed Information Mode 2", refer to the following: • "SyS" is displayed before the detailed codes detected as a result of "System Check Result Request" are displayed. • "COdE" is displayed before the detailed codes detected as a result of "Diagnostic Memory Request" are displayed. HINT: • The response to "System Check Result Request" is the current information given from each ECU as a result of the system check. • The response to "Diagnostic Memory Request" contains the information received from each ECU or stored in each ECU in the past. • The response to "Diagnostic Memory Request" is the output DTCs as a result of the diagnostic memory check or the DTCs received from each ECU. • "System Check Result Request (SyS)" is displayed first, and then the logical address and DTC appear in order. • "Diagnostic Memory Request (COdE)" is displayed first, and then the logical address, DTC, sub-code, connection check number, and the number of occurrence appear in order. AV AV–26 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM System Check Mode: PRESET SWITCH “3” PRESET SWITCH “2” Detailed Information Mode 2: (DTCs are detected in the responses to both “System Check Result Request” and “Diagnostic Memory Request”.) (*1) (*2) (*3) (*1) (*2) PRESET SWITCH “5” (Press 2 seconds or more) (*4) (*1) (*2) L...Indicates logical address (*5) Detailed information of the first code is displayed. (*1) (*2) 62...Logical address *6: 1...The first code (*6) (*1) *5: 1...The first code (*2) d...Indicates DTC 47...DTC Continues to display (*12) (*1) (*2) *7: “COdE” indicates the display start of the response to “Diagnostic Memory Request”. (*7) (*1) (*2) (*8) Detailed information of the second code is displayed. (*1) (*2) (*1) (*2) (*9) (*1) (*2) (*10) (*1) (*2) (*11) *1: SEEK TRACK DOWN AV (*1) *8: 2...The second code *9: Physical address appears as the sub-code. *10: Connection check number *11: The number of times of occurrence *12: Continues to display detailed information when more DTCs are detected in the response to “System Check Result Request”. (*2) *2: SEEK TRACK UP *3: P...Indicates physical address Continues to display (*13) 190...Physical address *4: “SyS” indicates the display start of the response to “System Check Result Request”. (*1) (*2) *13: Continues to display detailed information when more DTCs are detected in the response to “Diagnostic Memory Request”. E110918E05 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 7. 5 E129786E02 AV–27 DTC CLEAR/RECHECK (a) Clearing All DTC Memory (when clearing all the memory of the DTCs previously detected). (1) When the preset switch "5" is pressed for 2 seconds or more during "Service Check Mode", the DTCs for all components are cleared. ("CLr" is displayed at this time.) HINT: • A beep sound is emitted once when the DTC memory is completely cleared. • When the DTC memory for all the components is cleared, only the component codes (physical address) are displayed. • After the DTC memory is cleared, the "Service Check Mode" is restored. (b) Clearing Individual DTC Memory (when clearing the memory of the DTC previously detected individually). (1) When the preset switch "5" is pressed for 2 seconds or more during "Detailed Information Mode 1" or "Detailed Information Mode 2", the DTCs for the target component are cleared. HINT: • A beep sound is emitted once when the DTC memory is completely cleared. • When the DTC memory is cleared, only the component code (physical address) is displayed for the target component. • After the DTC memory is cleared, the "Service Check Mode" is restored. • To check DTCs, press the preset switch "1" and perform the system check again. (c) Press the preset switch "1" to perform the service check again, and check that no DTCs are displayed for all the component codes (physical address). AV AV–28 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DIAGNOSTIC TROUBLE CODE CHART COMMUNICATION DIAGNOSIS: DTC No. 01-21 AV Detection Item ROM Error Trouble Area See page Radio receiver AV-31 01-22 RAM Error Radio receiver AV-31 01-D5 Absence of Registration Unit 1. Power source circuit of the component shown by the subcode 2. AVC-LAN circuit between the radio receiver and the component shown by the sub-code 3. Component shown by the subcode AV-32 01-D6 No Master 1. Radio receiver power source circuit 2. Power source circuit of the component which has stored this code 3. AVC-LAN circuit between the radio receiver and the component which has stored this code 4. Component which has stored this code 5. Radio receiver AV-34 01-D7 Connection Check Error 1. Radio receiver power source circuit 2. Power source circuit of the component which has stored this code 3. AVC-LAN circuit between the radio receiver and the component which has stored this code 4. Component which has stored this code 5. Radio receiver AV-34 01-D8 No Response for Connection Check 1. Power source circuit of the component shown by the subcode 2. AVC-LAN circuit between the radio receiver and the component shown by the sub-code 3. Component shown by the subcode AV-32 01-D9 Last Mode Error 1. Power source circuit of the component shown by the subcode 2. AVC-LAN circuit between the radio receiver and the component shown by the sub-code 3. Component shown by the subcode AV-32 01-DA No Response Against ON / OFF Command 1. Power source circuit of the component shown by the subcode 2. AVC-LAN circuit between the radio receiver and the component shown by the sub-code 3. Component shown by the subcode AV-32 AV–29 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC No. Trouble Area See page 01-DB Mode Status Error Detection Item 1. Power source circuit of the component shown by the subcode 2. AVC-LAN circuit between the radio receiver and the component shown by the sub-code 3. Component shown by the subcode AV-32 01-DC Transmission Error If the same sub-code is recorded in other components, check harness for power supply and communication system of all components shown by code AV-39 01-DD Master Reset 1. Radio receiver power source circuit 2. AVC-LAN circuit between the radio receiver and the component which has stored this code 3. Radio receiver 4. Component which has stored this code AV-42 01-DE Slave Reset 1. Power source circuit of the component shown by the subcode 2. AVC-LAN circuit between the radio receiver and the component shown by the sub-code 3. Component shown by the subcode AV-32 01-DF Master Error 1. Radio receiver power source circuit 2. AVC-LAN circuit between the radio receiver and the component which has stored this code 3. Radio receiver 4. Component which has stored this code AV-47 01-E0 Registration Complete Indication Error - AV-51 01-E1 Voice Processing Device ON Error 1. Radio receiver power source circuit 2. AVC-LAN circuit between the radio receiver and the component which has stored this code 3. Radio receiver 4. Component which has stored this code AV-42 01-E2 ON / OFF Indication Parameter Error Radio receiver AV-52 01-E3 Registration Demand Transmission - AV-51 01-E4 Multiple Frame Incomplete - AV-51 AV CD PLAYER DTC No. 62-10 Detection Item Trouble Area See page CD Player Mechanical Error Radio receiver AV-54 62-11 CD Insertion and Ejection Error Radio receiver AV-54 62-12 CD Reading Abnormal Radio receiver AV-54 62-41 Wrong Disc 1. CD 2. Radio receiver AV-55 62-42 Disc cannot be Read 1. CD 2. Radio receiver AV-55 AV–30 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC No. Detection Item Trouble Area See page 62-43 CD-ROM Abnormal 1. CD 2. Radio receiver AV-57 62-44 CD Abnormal Radio receiver AV-59 62-45 Eject Error Radio receiver AV-60 62-46 Scratched / Reversed Disc 1. CD 2. Radio receiver AV-61 62-47 High Temperature Radio receiver AV-63 62-48 Excess Current Radio receiver AV-59 62-50 Tray Insertion / Ejection Error Radio receiver AV-59 62-51 Elevator Error Radio receiver AV-60 62-52 Clamp Error Radio receiver AV-60 62-78 DSP Error - AV-64 62-7D Disc cannot be Played 1. CD 2. Radio receiver AV-65 62-7E No Playable Files 1. CD 2. Radio receiver AV-65 62-7F Copyright Protection Error 1. CD 2. Radio receiver AV-65 IN-DASH CD CHANGER DTC No. AV Detection Item Trouble Area See page 63-10 CD Changer Mechanical Error Radio receiver AV-54 63-11 CD Insertion and Ejection Error Radio receiver AV-54 63-12 CD Reading Abnormal Radio receiver AV-54 63-41 Wrong Disc 1. CD 2. Radio receiver AV-55 63-42 Disc cannot be Read 1. CD 2. Radio receiver AV-55 63-43 CD-ROM Abnormal 1. CD 2. Radio receiver AV-57 63-44 CD Abnormal Radio receiver AV-59 63-45 Eject Error Radio receiver AV-60 63-46 Scratched / Reversed Disc 1. CD 2. Radio receiver AV-61 63-47 High Temperature Radio receiver AV-63 63-48 Excess Current Radio receiver AV-59 63-50 Tray Insertion / Ejection Error Radio receiver AV-59 63-51 Elevator Error Radio receiver AV-60 63-52 Clamp Error Radio receiver AV-60 63-78 DSP Error - AV-64 63-7D Disc cannot be Played 1. CD 2. Radio receiver AV-65 63-7E No Playable Files 1. CD 2. Radio receiver AV-65 63-7F Copyright Protection Error 1. CD 2. Radio receiver AV-65 TELEPHONE: DTC No. 57-47 Detection Item Bluetooth Module Initialization Failed Trouble Area Radio receiver See page AV-53 AV–31 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 01-21 ROM Error DTC 01-22 RAM Error DESCRIPTION DTC No. DTC Detection Condition 01-21 A malfunction exists in ROM. 01-22 A malfunction exists in RAM. Trouble Area Radio receiver INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 REPLACE RADIO RECEIVER NEXT END AV AV–32 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 01-D5 Absence of Registration Unit DTC 01-D8 No Response for Connection Check DTC 01-D9 Last Mode Error DTC 01-DA No Response Against ON / OFF Command DTC 01-DB Mode Status Error DTC 01-DE Slave Reset DESCRIPTION AV DTC No. DTC Detection Condition 01-D5 *1, *3 A device that the sub-code shows is (was) disconnected from the system when turning the ignition switch on (ACC or IG). The communication condition with the device that the code shows cannot be obtained when the engine starts. 01-D8 *2, *3 The device indicated by the sub-code is (was) disconnected from the system after the engine starts. 01-D9 *1, *3 The device that had functioned before the engine stopped is (was) disconnected from the system when turning the ignition switch is on (ACC or IG). 01-DA *3 No response is identified when changing mode. Sound and image do not change by switch operation. 01-DB *1, *3 A dual alarm is detected. 01-DE *3, *4 A slave device has been disconnected after the engine starts Trouble Area • • • Power source circuit of the component shown by the sub-code AVC-LAN circuit between the radio receiver and the component shown by the sub-code Component shown by the sub-code HINT: • *1: Even if no fault is present, this trouble code may be stored depending on the battery condition or engine start voltage. • *2: If the power connector is disconnected after the engine starts, this code is stored after 180 seconds. • *3: If the device is reported as not existing during verification, check the power source circuit and AVCLAN circuit for the device. • *4: This code may be stored if the engine is started and the ignition switch is turned to the START position again. (Key type ignition switch only) NOTICE: • Before starting troubleshooting, be sure to clear DTCs to erase codes stored due to the reasons described in the HINT above. Then, check for DTCs and troubleshoot according to the output DTCs. • The radio receiver is the master unit. • Be sure to clear and recheck DTCs after the inspection is completed to confirm that no DTCs are output. INSPECTION PROCEDURE NOTICE: Be sure to read DESCRIPTION before performing the following procedures. AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 1 AV–33 CHECK "RADIO RECEIVER COMMUNICATION ERROR" IN FLOW CHART Refer to the radio receiver communication error (See page AV-129). NEXT END AV AV–34 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 01-D6 No Master DTC 01-D7 Connection Check Error DESCRIPTION DTC No. DTC Detection Condition 01-D6 *1 When either of the following conditions is met: • The device that stores (stored) the code has (had) been disconnected when the ignition switch is turned on (ACC or IG). • The master device has (had) been disconnected when this code is stored. 01-D7 *2 When either of the following conditions is met: • The device that stored the code has (had) been disconnected after the engine starts (started). • The master device has (had) been disconnected when this code is (was) stored. Trouble Area • • • • • Radio receiver power source circuit Power source circuit of the component which has stored this code AVC-LAN circuit between the radio receiver and the component which has stored this code Component which has stored this code Radio receiver HINT: • *1: Even if no fault is present, this trouble code may be stored depending on the battery condition or engine start voltage. • *2: When 210 seconds have elapsed after disconnecting the power supply connector of the master component with the ignition switch on (ACC or IG), this code is stored. NOTICE: • Before starting troubleshooting, be sure to clear DTCs to erase codes stored due to the reasons described in the HINT above. Then, check for DTCs and troubleshoot according to the output DTCs. • The radio receiver is the master unit. • Be sure to clear and recheck DTCs after the inspection is completed to confirm that no DTCs are output. INSPECTION PROCEDURE NOTICE: Be sure to read DESCRIPTION before performing the following procedures. 1 CHECK RADIO RECEIVER POWER SOURCE CIRCUIT Refer to the radio receiver power source circuit (See page AV-140). If the power source circuit is operating normally, proceed to the next step. NEXT AV 2 IDENTIFY THE COMPONENT WHICH HAS STORED THIS CODE (a) Enter the diagnostic mode. AV–35 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Example: Service Check Mode (*1) (*2) (*1) (*2) (*1) (*2) (*1) (*2) (*1) (*2) Detailed Information Mode Component which has stored this code (*3) (*4) Continues to display check result when more components are installed. (*1) (*1) (*2) (*1) (*2) (*1) (*2) (*1) (*2) (*2) (*2) (*1) *1: SEEK TRACK DOWN *2: SEEK TRACK UP DTC Continues to display detailed information of the first code. (*1) (*2) Continues to display detailed information when more DTCs are detected. *3: PRESET SWITCH “2” *4: PRESET SWITCH “3” (*1) (*2) E110915E04 (b) Press the preset switch "3" to change to "Detailed Information Mode". (c) Identify the component which has stored this code. Component Table: Component Physical address Stereo component amplifier 440 "Bluetooth" handsfree module 19D HINT: • "440 (stereo component amplifier)" is the component which has stored this code in the example shown in the illustration. • For details of the DTC display, refer to "DTC CHECK/ CLEAR" (See page AV-19). AV AV–36 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM NEXT 3 CHECK COMPONENT WHICH HAS STORED THIS CODE (a) Select the component which has stored this code. HINT: The "Bluetooth" handsfree module is built into the radio receiver. If there is a problem between the "Bluetooth" handsfree module and radio receiver, replace the radio receiver. Component Table: Component Proceed to "Bluetooth" handsfree module A Except "Bluetooth" handsfree module B A REPLACE RADIO RECEIVER B 4 CHECK POWER SOURCE CIRCUIT OF COMPONENT WHICH HAS STORED THIS CODE (a) Inspect the power source circuit of the component which has stored this code. If the power source circuit is operating normally, proceed to the next step. Component Table: Component Proceed to Stereo component amplifier Stereo component amplifier power source circuit (See page AV-142) NEXT 5 INSPECT RADIO RECEIVER Premium Model Wire Harness View: F26 ATX+ AV (a) Disconnect the radio receiver connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Condition Specified condition ATX+ (F26-5) - ATX(F26-15) Always 60 to 80 Ω NG ATX- E129798E04 REPLACE RADIO RECEIVER AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–37 OK 6 CHECK HARNESS AND CONNECTOR (RADIO RECEIVER - COMPONENT WHICH HAS STORED THIS CODE) HINT: For details of the connectors, refer to the "TERMINALS OF ECU" (See page AV-15). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the radio receiver and the component which has stored this code. (1) Disconnect all connectors between the radio receiver and the component which has stored this code. (2) Check for an open or short in the AVC-LAN circuit between the radio receiver and the component which has stored this code. OK: There is no open or short circuit. AVC-LAN WIRING DIAGRAM Premium Model: 5 ATX+ F26 8 F19 TX+ Stereo Component Amplifier (*2) Radio Receiver (*1) 15 ATX- F26 7 F19 TX- *1: Master Unit *2: Slave Unit E111831E15 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 7 REPLACE COMPONENT WHICH HAS STORED THIS CODE (a) Replace the component which has stored this code with a normal one and check if the same problem occurs again. AV AV–38 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM OK: Same problem does not occur. NG OK END AV REPLACE RADIO RECEIVER AV–39 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 01-DC Transmission Error DESCRIPTION DTC No. 01-DC *1 DTC Detection Condition Trouble Area Transmission to component shown by sub-code failed (Detecting this DTC does not always mean actual failure) If the same sub-code is recorded in other components, check harness for power supply and communication system of all components shown by code HINT: *1: This code may be stored if the engine is started, idled for 60 seconds and then the ignition switch is turned to the START position again. (Key type ignition switch only) NOTICE: • Before starting troubleshooting, be sure to clear DTCs to erase codes stored due to the reasons described in the HINT above. Then, check for DTCs and troubleshoot according to the output DTCs. • The radio receiver is the master unit. • Be sure to clear and recheck DTCs after the inspection is completed to confirm that no DTCs are output. INSPECTION PROCEDURE NOTICE: Be sure to read DESCRIPTION before performing the following procedures. 1 CHECK FOR DTC OF OTHER COMPONENTS (a) Check if the component shown by the sub-code is displayed in the check result of the other components. (1) Check if "01-DC" is output for the other components. (2) If "01-DC" is output for any other components, check if the same physical address is displayed. Result Result Proceed to "01-DC" is output and the same physical address is displayed A "01-DC" is not output or the same physical address is not displayed B HINT: For the list of the components shown by sub-codes, refer to the table in step 2. B Go to step 4 AV A 2 IDENTIFY THE COMPONENT WHICH HAS STORED THIS CODE (a) Enter the diagnostic mode. AV–40 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Example: Service Check Mode (*1) (*2) (*1) (*2) (*1) (*2) (*1) (*2) (*1) (*2) Detailed Information Mode Component which has stored this code (*3) (*4) Continues to display check result when more components are installed. (*1) (*1) (*2) (*1) (*2) (*1) (*2) (*1) (*2) (*2) (*2) (*1) *1: SEEK TRACK DOWN *2: SEEK TRACK UP DTC Continues to display detailed information of the first code. (*1) (*2) Continues to display detailed information when more DTCs are detected. *3: PRESET SWITCH “2” *4: PRESET SWITCH “3” (*1) (*2) E110915E04 (b) Press the preset switch "3" to change to "Detailed Information Mode". (c) Identify the component which has stored this code. Component Table: Component AV Physical address Stereo component amplifier 440 "Bluetooth" handsfree module 19D Radio receiver 190 HINT: • "440 (stereo component amplifier)" is the component which has stored this code in the example shown in the illustration. • For details of the DTC display, refer to "DTC CHECK/ CLEAR" (See page AV-19). AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–41 NEXT 3 CHECK COMPONENT WHICH HAS STORED THIS CODE (a) Select the component which has stored this code. Component Table: Component Proceed to Stereo component amplifier Stereo component amplifier communication error (See page AV-133) "Bluetooth" handsfree module "Bluetooth" handsfree module communication error (See page AV136) Radio receiver Radio receiver communication error (See page AV-129) NEXT END 4 CLEAR DTC (a) Clear the DTCs (See page AV-19). HINT: If "01-DC" is output for only one component, this may not indicate a malfunction. NEXT 5 RECHECK DTC (a) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. NG Go to step 3 OK END AV AV–42 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 01-DD Master Reset DTC 01-E1 Voice Processing Device ON Error DESCRIPTION DTC No. DTC Detection Condition Trouble Area 01-DD *1 The device that should be the master has been disconnected after engine start. • • 01-E1 *2 The AMP device records that the AMP output does not function even while the source device operates. • • Radio receiver power source circuit AVC-LAN circuit between the radio receiver and the component which has stored this code Radio receiver Component which has stored this code HINT: *1: This code may be stored if the engine is started and the ignition switch is turned to START position again. (Key type ignition switch only) *2: Even if no fault is present, this trouble code may be stored depending on the battery condition or engine start voltage. NOTICE: • Before starting troubleshooting, be sure to clear DTCs to erase codes stored due to the reasons described in the HINT above. Then, check for DTCs and troubleshoot according to the output DTCs. • The radio receiver is the master unit. • Be sure to clear and recheck DTCs after the inspection is completed to confirm that no DTCs are output. INSPECTION PROCEDURE NOTICE: Be sure to read DESCRIPTION before performing the following procedures. 1 CHECK RADIO RECEIVER POWER SOURCE CIRCUIT Refer to the radio receiver power source circuit (See page AV-140). If the power source circuit is operating normally, proceed to the next step. NEXT AV AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 2 AV–43 INSPECT RADIO RECEIVER Premium Model Wire Harness View: F26 ATX+ (a) Disconnect the radio receiver connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Condition Specified condition ATX+ (F26-5) - ATX(F26-15) Always 60 to 80 Ω NG REPLACE RADIO RECEIVER ATX- E129798E04 OK 3 IDENTIFY THE COMPONENT WHICH HAS STORED THIS CODE (a) Enter the diagnostic mode. AV AV–44 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Example: Service Check Mode (*1) (*2) (*1) (*2) (*1) (*2) (*1) (*2) (*1) (*2) Detailed Information Mode Component which has stored this code (*3) (*4) Continues to display check result when more components are installed. (*1) (*1) (*2) (*1) (*2) (*1) (*2) (*1) (*2) (*2) (*2) (*1) *1: SEEK TRACK DOWN *2: SEEK TRACK UP DTC Continues to display detailed information of the first code. (*1) (*2) Continues to display detailed information when more DTCs are detected. *3: PRESET SWITCH “2” *4: PRESET SWITCH “3” (*1) (*2) E110915E04 (b) Press the preset switch "3" to change to "Detailed Information Mode". (c) Identify the component which has stored this code. Component Table: Component AV Physical address Stereo component amplifier 440 "Bluetooth" handsfree module 19D HINT: • "440 (stereo component amplifier)" is the component which has stored this code in the example shown in the illustration. • For details of the DTC display, refer to "DTC CHECK/ CLEAR" (See page AV-19). AV–45 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM NEXT 4 CHECK COMPONENT WHICH HAS STORED THIS CODE (a) Select the component which has stored this code. HINT: The "Bluetooth" handsfree module is built into the radio receiver. If there is a problem between the "Bluetooth" handsfree module and radio receiver, replace the radio receiver. Component Table: Component Proceed to "Bluetooth" handsfree module A Except "Bluetooth" handsfree module B A REPLACE RADIO RECEIVER B 5 CHECK HARNESS AND CONNECTOR (RADIO RECEIVER - COMPONENT WHICH HAS STORED THIS CODE) HINT: For details of the connectors, refer to the "TERMINALS OF ECU" (See page AV-15). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the radio receiver and the component which has stored this code. (1) Disconnect all connectors between the radio receiver and the component which has stored this code. (2) Check for an open or short in the AVC-LAN circuit between the radio receiver and the component which has stored this code. OK: There is no open or short circuit. AV AV–46 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AVC-LAN WIRING DIAGRAM Premium Model: 5 ATX+ F26 8 F19 TX+ Stereo Component Amplifier (*2) Radio Receiver (*1) 15 ATX- F26 7 F19 TX- *1: Master Unit *2: Slave Unit E111831E15 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 6 REPLACE RADIO RECEIVER (a) Replace the radio receiver with a normal one and check if the same problem occurs again. OK: Same problem does not occur. NG OK END AV REPLACE COMPONENT WHICH HAS STORED THIS CODE AV–47 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 01-DF Master Error DESCRIPTION DTC No. DTC Detection Condition Trouble Area The device with a display fails and the master is switched to the audio device. Also when a communication error between the submaster (audio) and master occurs, this code is stored. 01-DF *1 • • • • Radio receiver power source circuit AVC-LAN circuit between the radio receiver and the component which has stored this code Radio receiver Component which has stored this code HINT: *1: When 210 seconds have elapsed after disconnecting the power supply connector of the master component with the ignition switch on (ACC or IG), this code is stored. NOTICE: • Before starting troubleshooting, be sure to clear DTCs to erase codes stored due to the reasons described in the HINT above. Then, check for DTCs and troubleshoot according to the output DTCs. • The radio receiver is the master unit. • Be sure to clear and recheck DTCs after the inspection is completed to confirm that no DTCs are output. INSPECTION PROCEDURE NOTICE: Be sure to read DESCRIPTION before performing the following procedures. 1 CHECK RADIO RECEIVER POWER SOURCE CIRCUIT Refer to the radio receiver power source circuit (See page AV-140). If the power source circuit is operating normally, proceed to the next step. NEXT 2 INSPECT RADIO RECEIVER Premium Model Wire Harness View: F26 ATX+ (a) Disconnect the radio receiver connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Condition Specified condition ATX+ (F26-5) - ATX(F26-15) Always 60 to 80 Ω NG ATX- E129798E04 REPLACE RADIO RECEIVER AV AV–48 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM OK 3 IDENTIFY THE COMPONENT WHICH HAS STORED THIS CODE (a) Enter the diagnostic mode. Example: Service Check Mode (*1) (*2) (*1) (*2) (*1) (*2) (*1) (*2) (*1) (*2) Detailed Information Mode Component which has stored this code (*3) (*4) Continues to display check result when more components are installed. (*1) (*1) (*2) (*1) (*2) (*1) (*2) (*1) (*2) (*2) (*2) (*1) *1: SEEK TRACK DOWN *2: SEEK TRACK UP DTC Continues to display detailed information of the first code. (*1) (*2) Continues to display detailed information when more DTCs are detected. *3: PRESET SWITCH “2” *4: PRESET SWITCH “3” (*1) (*2) E110915E04 AV (b) Press the preset switch "3" to change to "Detailed Information Mode". (c) Identify the component which has stored this code. Component Table: Component Physical address Stereo component amplifier 440 "Bluetooth" handsfree module 19D AV–49 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM HINT: • "440 (stereo component amplifier)" is the component which has stored this code in the example shown in the illustration. • For details of the DTC display, refer to "DTC CHECK/ CLEAR" (See page AV-19). NEXT 4 CHECK COMPONENT WHICH HAS STORED THIS CODE (a) Select the component which has stored this code. HINT: The "Bluetooth" handsfree module is built into the radio receiver. If there is a problem between the "Bluetooth" handsfree module and radio receiver, replace the radio receiver. Component Table: Component Proceed to "Bluetooth" handsfree module A Except "Bluetooth" handsfree module B A REPLACE RADIO RECEIVER B 5 CHECK HARNESS AND CONNECTOR (RADIO RECEIVER - COMPONENT WHICH HAS STORED THIS CODE) HINT: For details of the connectors, refer to the "TERMINALS OF ECU" (See page AV-15). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the radio receiver and the component which has stored this code. (1) Disconnect all connectors between the radio receiver and the component which has stored this code. (2) Check for an open or short in the AVC-LAN circuit between the radio receiver and the component which has stored this code. OK: There is no open or short circuit. AV AV–50 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AVC-LAN WIRING DIAGRAM Premium Model: 5 ATX+ F26 8 F19 TX+ Stereo Component Amplifier (*2) Radio Receiver (*1) 15 ATX- F26 7 F19 TX- *1: Master Unit *2: Slave Unit E111831E15 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 6 REPLACE RADIO RECEIVER (a) Replace the radio receiver with a normal one and check if the same problem occurs again. OK: Same problem does not occur. NG OK END AV REPLACE COMPONENT WHICH HAS STORED THIS CODE AV–51 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 01-E0 Registration Complete Indication Error DTC 01-E3 Registration Demand Transmission DTC 01-E4 Multiple Frame Incomplete DESCRIPTION DTC No. DTC Detection Condition Trouble Area 01-E0 "Registration complete" signal from the master device cannot be received. - 01-E3 The registration demand signal from the slave device is output. Or the registration demand signal is output by receiving connection confirmation signal from the submaster device. - 01-E4 The multiple frame transmission is incomplete. - HINT: Even if no fault is present, this trouble code may be stored depending on the battery condition or engine start voltage. INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. These DTCs do not indicate a malfunction. AV AV–52 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 01-E2 ON / OFF Indication Parameter Error DESCRIPTION DTC No. 01-E2 DTC Detection Condition The command for ON/OFF control from the master device has a problem. INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 NEXT END AV REPLACE RADIO RECEIVER Trouble Area Radio receiver AV–53 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 57-47 Bluetooth Module Initialization Failed DESCRIPTION DTC No. 57-47 DTC Detection Condition • • • "Bluetooth" module is not installed. Problem with "Bluetooth" module Problem in communication line to "Bluetooth" module Trouble Area Radio receiver INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 REPLACE RADIO RECEIVER NEXT END AV AV–54 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 62-10 CD Player Mechanical Error DTC 62-11 CD Insertion and Ejection Error DTC 62-12 CD Reading Abnormal DTC 63-10 CD Changer Mechanical Error DTC 63-11 CD Insertion and Ejection Error DTC 63-12 CD Reading Abnormal DESCRIPTION DTC No. DTC Detection Condition 62-10 A mechanical error in the CD player is detected while the CD is not being inserted or ejected. 62-11 CD insertion or ejection is failed. 62-12 CD read problem occurs. 63-10 A mechanical error in the CD changer is detected while the CD is not being inserted or ejected. 63-11 CD insertion or ejection is failed. 63-12 CD read problem occurs. INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 NEXT END AV REPLACE RADIO RECEIVER Trouble Area Radio receiver AV–55 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 62-41 Wrong Disc DTC 62-42 Disc cannot be Read DTC 63-41 Wrong Disc DTC 63-42 Disc cannot be Read DESCRIPTION DTC No. DTC Detection Condition 62-41 An unsuitable disc is inserted. 62-42 The disc cannot be read. 63-41 An unsuitable disc is inserted. 63-42 The disc cannot be read. Trouble Area • • CD Radio receiver INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK DISC (a) Check that the disc is not deformed or cracked. OK: No deformation or cracks on the disc. NG CHANGE DISC I100152 OK 2 DISC CLEANING (a) Disc cleaning (1) If dirt is on the disc surface, wipe it clean with a soft cloth from the inside to the outside in a radial direction. NOTICE: Do not use a conventional record cleaner or anti-static preservative. I100151 NEXT AV AV–56 3 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM CLEAR DTC (a) Clear the DTCs (See page AV-19). NEXT 4 RECHECK DTC (a) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. OK END NG 5 REPLACE DISC WITH ANOTHER AND RECHECK (a) Replace the disc with another and recheck. (1) Replace the disc with another normal one. (2) Clear the DTCs (See page AV-19). (3) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. NG OK END AV REPLACE RADIO RECEIVER AV–57 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 62-43 CD-ROM Abnormal DTC 63-43 CD-ROM Abnormal DESCRIPTION DTC No. DTC Detection Condition 62-43 CD-ROM operation is abnormal 63-43 CD-ROM operation is abnormal Trouble Area • • CD Radio receiver INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK IF A PROPER CD IS INSERTED (a) Make sure that the CD is an audio CD or a CD with an MP3 or WMA file, and that it is not deformed, flawed, stained, burred, or otherwise defective. OK: Normal CD HINT: • Translucent or uniquely-shaped CDs cannot be played. • CDs with adhesive paper labels should not be played. • Commercial audio CDs can be played. • CD-DA files on CD-ROMs, CD-Rs, and CD-RWs can be played. • MP3 and WMA files on CD-ROMs, CD-Rs, and CDRWs can be played. • For details on playable CDs, refer to the Owner's Manual. NG CHANGE DISC OK 2 REPLACE CD WITH ANOTHER AND RECHECK (a) Replace the CD with another and recheck. (1) Replace the CD with another normal one. (2) Clear the DTCs (See page AV-19). (3) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. NG REPLACE RADIO RECEIVER AV AV–58 OK END AV AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–59 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 62-44 CD Abnormal DTC 62-48 Excess Current DTC 62-50 Tray Insertion / Ejection Error DTC 63-44 CD Abnormal DTC 63-48 Excess Current DTC 63-50 Tray Insertion / Ejection Error DESCRIPTION DTC No. DTC Detection Condition 62-44 Operation error in the CD mechanism 62-48 Excess current is present in the CD player 62-50 Malfunction in insertion/ejection system 63-44 Operation error in the CD mechanism 63-48 Excess current is present in the CD changer 63-50 Malfunction in insertion/ejection system Trouble Area Radio receiver INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CLEAR DTC (a) Clear the DTCs (See page AV-19). NEXT 2 RECHECK DTC (a) Recheck for DTCs and check if the same trouble occurs again. HINT: If DTCs are detected frequently, replace the radio receiver. OK: Malfunction disappears. NG OK END REPLACE RADIO RECEIVER AV AV–60 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 62-45 Eject Error DTC 62-51 Elevator Error DTC 62-52 Clamp Error DTC 63-45 Eject Error DTC 63-51 Elevator Error DTC 63-52 Clamp Error DESCRIPTION DTC No. DTC Detection Condition Trouble Area 62-45 Disc cannot be ejected. 62-51 Mechanical error occurs during elevator operation. 62-52 Error occurs in CD player clamp. 63-45 Magazine cannot be ejected. 63-51 Mechanical error occurs during elevator operation. 63-52 Error occurs in CD changer clamp. Radio receiver INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK RADIO RECEIVER (a) Check if a disc can be changed, inserted or ejected normally. OK: Malfunction disappears. NG OK END AV REPLACE RADIO RECEIVER AV–61 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 62-46 Scratched / Reversed Disc DTC 63-46 Scratched / Reversed Disc DESCRIPTION DTC No. DTC Detection Condition Trouble Area 62-46 Scratches or dirt is found on CD surface or CD is set upside down. 63-46 Scratches or dirt is found on CD surface or CD is set upside down. • • CD Radio receiver INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK THAT CD IS INSERTED PROPERLY (a) Check whether or not the CD is inserted upside down. OK: CD is properly inserted. NG REINSERT DISC PROPERLY OK 2 CHECK DISC (a) Check that the disc is not deformed or cracked. OK: No deformation or cracks on the disc. NG CHANGE DISC I100152 OK AV AV–62 3 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DISC CLEANING (a) Disc cleaning (1) If dirt is on the disc surface, wipe it clean with a soft cloth from the inside to the outside in a radial direction. NOTICE: Do not use a conventional record cleaner or anti-static preservative. I100151 NEXT 4 CLEAR DTC (a) Clear the DTCs (See page AV-19). NEXT 5 RECHECK DTC (a) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. OK END NG 6 REINSERT DISC PROPERLY (a) Replace the disc with another and recheck. (1) Replace the disc with another normal one. (2) Clear the DTCs (See page AV-19). (3) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. AV NG OK END REPLACE RADIO RECEIVER AV–63 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 62-47 High Temperature DTC 63-47 High Temperature DESCRIPTION DTC No. DTC Detection Condition Trouble Area 62-47 Sensor detects that CD unit temperature is high. (Over 80°C) 63-47 Sensor detects that CD unit temperature is high. (Over 80°C) Radio receiver INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK RADIO RECEIVER (a) Park the vehicle in a cool place. (b) Check that the temperature of the radio receiver becomes sufficiently low, and start the engine. Check that the malfunction disappears. OK: Malfunction disappears. NG REPLACE RADIO RECEIVER OK END AV AV–64 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 62-78 DSP Error DTC 63-78 DSP Error DESCRIPTION DTC No. DTC Detection Condition Trouble Area 62-78 An error occurs during the decode process (MP3/ WMA). - 63-78 An error occurs during the decode process (MP3/ WMA). - INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. NOTICE: • These codes may be output even if there is no malfunction. • If these codes are output frequently, replace the radio receiver. 1 CLEAR DTC (a) Clear the DTCs (See page AV-19). NEXT 2 RECHECK DTC (a) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. NG OK END AV REPLACE RADIO RECEIVER AV–65 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 62-7D Disc cannot be Played DTC 62-7E No Playable Files DTC 62-7F Copyright Protection Error DTC 63-7D Disc cannot be Played DTC 63-7E No Playable Files DTC 63-7F Copyright Protection Error DESCRIPTION DTC No. DTC Detection Condition Trouble Area • • An incompatible MP3/WMA file is used. Although the file has an extension of ".mp3" or ".wma", the header information cannot be read. 62-7E • • A disc with no music data is used. Playable files are not on the disc (MP3/WMA). 62-7F A copy-protected file, which cannot be played, is used. 63-7D • • An incompatible MP3/WMA file is used Although the file has an extension of ".mp3" or ".wma", the header information cannot be read. 63-7E • • A disc with no music data is used. Playable files are not on the disc (MP3/WMA). 63-7F A copy-protected file, which cannot be played, is used. 62-7D • • CD Radio receiver INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHANGE DISC (a) Insert a disc with a playable file and check if the disc can be played correctly. HINT: For details on playable files and discs, refer to the Owner's Manual. OK: The disc can be played correctly. NG OK END REPLACE RADIO RECEIVER AV AV–66 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Noise Occurs INSPECTION PROCEDURE 1 NOISE CONDITION (a) Check from which direction the noise comes (front left or right, or rear left or right). (1) Check from which direction the noise comes. OK: The location of the noise source can be determined. NG Go to step 3 OK 2 CHECK SPEAKERS (a) Check the installation conditions of the speaker units that are located near the noise source and that there are no cracks, scratches, deformation, or other failures. Result Condition Proceed to A speaker is installed incorrectly A Foreign objects are in the speaker B A speaker cone paper is broken C No malfunction is found D A REINSTALL SPEAKER B REMOVE FOREIGN OBJECT C REPLACE SPEAKER D 3 CHECK NOISE CONDITIONS (a) Check the noise condition. HINT: The radio has a noise prevention function to reduce noise when listening to the radio. If a loud noise occurs, check whether the ground at the antenna mounting base and the noise prevention unit are installed and wired correctly. AV Conditions under which noise occurs Noise increases when the accelerator pedal is depressed, but stops when the engine is stopped. Noise occurs during A/C or heater operation. Noise occurs when the vehicle accelerates rapidly on an unpaved road or after the ignition switch is turned on (IG or ACC). Noise source Generator Blower motor Fuel pump AV–67 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Conditions under which noise occurs Noise source Noise occurs when the horn switch is pressed and released or when pressed and held. Horn Noise occurs synchronously with the blink of the turn signal. Flasher Noise occurs during window washer operation. Washer Noise occurs while the engine is running, and continues even after the engine is stopped. Noise occurs during wiper operation. Water temperature sensor Wiper Noise occurs when the brake pedal is depressed. Stop light switch Others Static electricity HINT: • In the chart's left column, find the situation that matches the customer's complaint. Then, in the right column, find the part that is causing the noise. Check the noise filter on or for the part. • To save time and avoid a misdiagnosis, first make sure that the noise is not coming from outside the vehicle. • Noise should be removed in descending order of loudness. • Setting the radio to a frequency where no signal is received may make recognition of the noise problem easier. OK: The noise source cannot be determined. NG REPAIR OR REPLACE NOISE SOURCE OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV AV–68 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Pressing Power Switch does not Turn on System INSPECTION PROCEDURE 1 CHECK VEHICLE CONDITION (a) Check that conditions in the cabin are not likely to cause condensation. HINT: This problem occurs when the cabin is humid and the temperature changes rapidly. This may produce condensation, resulting in a short circuit. OK: Condensation is not likely to be produced. NG DRY OUT CABIN AND RECHECK CONDITION OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–69 No Sound can be Heard from Speakers INSPECTION PROCEDURE 1 CHECK RADIO RECEIVER (a) Check radio receiver setting. (1) Check that the volume is not set to "0". (2) Check that "MUTE" is off. OK: The volume is not set to "0" and "MUTE" is off. OK END NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV AV–70 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Sound Quality is Bad Only when CD is Played (Volume is Too Low) INSPECTION PROCEDURE 1 REPLACE CD WITH ANOTHER AND RECHECK (a) Replace the CD with another one and recheck. (1) Check if the problem recurs using another CD. OK: Malfunction disappears. NG OK END AV REPLACE RADIO RECEIVER AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–71 CD cannot be Ejected INSPECTION PROCEDURE 1 PRESS "EJECT" AND CHECK OPERATION (a) Press the CD EJECT switch of the radio receiver for 2 seconds or more and check that the CD is ejected. OK: CD is ejected. NG REPLACE RADIO RECEIVER OK 2 REPLACE CD WITH ANOTHER AND RECHECK (a) Insert another CD and check if it is ejected. OK: CD is ejected. NG REPLACE RADIO RECEIVER OK END AV AV–72 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM CD cannot be Inserted / Played or CD is Ejected Right After Insertion INSPECTION PROCEDURE 1 CHECK IF A PROPER CD IS INSERTED (a) Make sure that the CD is an audio CD or a CD with an MP3 or WMA file, and that it is not deformed, flawed, stained, burred, or otherwise defective. OK: Normal CD. HINT: • Translucent or uniquely-shaped CDs cannot be played. • CDs with adhesive paper labels should not be played. • Commercial audio CDs can be played. • CD-DA files on CD-ROMs, CD-Rs, and CD-RWs can be played. • MP3 and WMA files on CD-ROMs, CD-Rs, and CDRWs can be played. • For details on playable CDs, refer to the Owner's Manual. NG CHANGE DISC OK 2 CHECK THAT CD IS INSERTED PROPERLY (a) Check whether or not the CD is inserted upside down. OK: CD is properly inserted. NG INSERT CD PROPERLY OK 3 CHECK CD (a) Clean the disc by wiping it with a soft cloth from the inside to the outside in a radial direction. OK: Malfunction disappears. NOTICE: Do not use a conventional record cleaner or antistatic preservative. AV NG I100151 Go to step 4 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–73 OK END 4 REPLACE CD WITH ANOTHER AND RECHECK (a) Replace the CD with a normal one and check that the malfunction disappears. OK: Malfunction disappears. NG REPLACE RADIO RECEIVER OK END AV AV–74 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM CD Sound Skips INSPECTION PROCEDURE 1 CHECK CD (a) Check the CD. OK: The CD is clean. HINT: If dirt is on the CD surface, wipe it clean with a soft cloth from the inside to the outside in a radial direction. NOTICE: Do not use a conventional record cleaner or antistatic preservative. I100151 NG CLEAN CD OK 2 CHECK CD (a) Check that the CD is not deformed or cracked. OK: No deformation or cracks on the CD. NG CHANGE DISC I100152 OK 3 CHECK OPERATION USING ANOTHER CD (a) Check using another CD. (1) Check if the problem recurs using another CD. OK: The problem does not occur. AV OK END NG 4 CHECK RADIO RECEIVER (a) Check the radio receiver installation condition. (1) Check that the radio receiver is properly installed. OK: Radio receiver is properly installed. AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM NG AV–75 REINSTALL RADIO RECEIVER PROPERLY OK REPLACE RADIO RECEIVER AV AV–76 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Radio Broadcast cannot be Received or Poor Reception INSPECTION PROCEDURE 1 CHECK RADIO RECEIVER (a) Check the radio's automatic station search function. (1) Check the radio's automatic station search function by activating it. OK: The radio's automatic station search function works properly. OK REPLACE RADIO RECEIVER NG 2 INSPECT RADIO RECEIVER Wire Harness View (Premium Model): F26 (a) Disconnect the radio receiver connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Tester connection Condition Specified condition ANT - Body ground Ignition SW on (IG) Radio SW ON 10 to 14 V NG ANT Wire Harness View (Standard Model): F6 AV ANT E129799E03 REPLACE RADIO RECEIVER AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–77 OK 3 CHECK OPTIONAL COMPONENTS (a) Check optional components (sun-shade film, telephone antenna, etc.). (1) Check if any optional components, such as sunshade film or telephone antenna that may decrease reception capacity, are installed. OK: Optional components are installed. NOTICE: Do not remove any optional components installed by the customer without his or her consent. OK REMOVE OPTIONAL COMPONENTS AND CHECK AGAIN (SEE NOTICE ABOVE) NG 4 CHECK RADIO RECEIVER E050367 (a) Preparation for check (1) Remove the antenna plug from the radio receiver. (b) Check for noise (1) Turn the ignition switch on (ACC) with the radio receiver connector connected. (2) Turn the radio on and put into AM mode. (3) Place a screwdriver, thin wire, or other metal object on the radio receiver's antenna jack and check that noise can be heard from the speaker. OK: Noise occurs. NG REPLACE RADIO RECEIVER OK AV AV–78 5 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM CHECK GLASS ANTENNA (a) Check for continuity of the antenna. HINT: Check for continuity at the center of each antenna wire as shown in the illustration. NOTICE: When cleaning the glass, wipe it in the direction of the wire with a soft dry cloth. Take care not to damage the wire. Do not use detergents or glass cleaners with abrasive ingredients. When measuring voltage, wrap a piece of tin foil around the tip of the negative probe and press the foil against the wire with your finger, as shown in the illustration. OK: There is continuity in the antenna. Tester Probe Tin Foil Antenna Wire NG REPAIR GLASS ANTENNA E111994E01 OK 6 CHECK ANTENNA CORD (a) Remove the antenna plug of the radio receiver and antenna. (b) Measure the resistance between the antenna and radio receiver to check for an open circuit in the antenna cord. Standard resistance: Below 1 Ω (c) Measure the resistance between the antenna cord and body ground to check for a short circuit in the antenna cord. Standard resistance: 10 kΩ or higher NG AV REPLACE ANTENNA CORD OK 7 REPLACE AMPLIFIER ANTENNA (a) Replace the amplifier antenna and check if radio broadcasts can be received normally. OK: Radio broadcasts can be received. OK NORMAL OPERATION AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–79 NG REPLACE RADIO RECEIVER AV AV–80 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Poor Sound Quality in All Modes (Low Volume) INSPECTION PROCEDURE 1 CHECK AUDIO SETTINGS (a) Set "BASS", "MID", and "TREB" to the initial values and check that sound is normal. OK: Malfunction disappears. OK END NG 2 COMPARE WITH ANOTHER VEHICLE OF SAME MODEL (a) Compare with another vehicle of the same model. (1) Compare with another vehicle of the same model which does not have trouble to see if there is any difference in the sound quality. OK: No difference is found. OK END NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV AV–81 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Cellular Phone Registration Failure, Phone Directory Transfer Failure INSPECTION PROCEDURE 1 CHECK CURRENT CONDITIONS (a) Proceed to the next step according to the table below. RESULT Conditions Proceed to Another "Bluetooth" compatible cellular phone is present. A Another "Bluetooth" compatible vehicle is present. B None of the above C B Go to step 3 C Go to step 4 A 2 CHECK USING ANOTHER CELLULAR PHONE (a) Check if the system functions using another "Bluetooth" compatible cellular phone. HINT: • Confirm that either the same or a different version of another "Bluetooth" compatible cellular phone complies with the system. • Depending on the version, some "Bluetooth" compatible cellular phones cannot be used. OK: The system functions. NG REPLACE RADIO RECEIVER OK USE A "BLUETOOTH" COMPATIBLE CELLULAR PHONE 3 CHECK USING ANOTHER "BLUETOOTH" COMPATIBLE VEHICLE (a) Register the cellular phone with another vehicle and check if the system functions normally. HINT: Depending on the version, some "Bluetooth" compatible cellular phones cannot be used. OK: The system functions. OK REPLACE RADIO RECEIVER AV AV–82 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM NG USE A "BLUETOOTH" COMPATIBLE CELLULAR PHONE 4 CHECK CELLULAR PHONE (a) Check if the cellular phone is "Bluetooth" compatible. HINT: Some versions of "Bluetooth" compatible cellular phones may not function. OK: The phone is Bluetooth compatible. NG USE A "BLUETOOTH" COMPATIBLE CELLULAR PHONE OK 5 CHECK CELLULAR PHONE (a) Check if a call can be made from the cellular phone. HINT: When the battery is low, registration or directory transfer cannot be done. OK: A call can be made from the cellular phone. NG OK REPLACE RADIO RECEIVER AV REPAIR OR REPLACE CELLULAR PHONE AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–83 Cellular Phone cannot Send / Receive INSPECTION PROCEDURE 1 CHECK "BLUETOOTH" SETTINGS (a) Check if the "Bluetooth" settings are correct. OK: "Bluetooth" settings are correct. NG SET SETTINGS CORRECTLY OK 2 CHECK CELLULAR PHONE (a) Check if the cellular phone is "Bluetooth" compatible. HINT: Some versions of "Bluetooth" compatible cellular phones may not function. OK: Phone is "Bluetooth" compatible. NG END (ONLY A "BLUETOOTH" COMPATIBLE CELLULAR PHONE CAN BE USED) OK 3 CHECK SETTINGS (a) Check if the cellular phone functions. HINT: The cellular phone is unable to call under any of the following conditions. • The cellular phone is locked. • The directory is being transferred. • The line is crossed. • Transmission is regulated. • The power is off. • The cellular phone is not connected to "Bluetooth" ("BT" is displayed while connected). OK: None of the above conditions exist. NG SET CORRECTLY OK 4 CHECK CELLULAR PHONE (a) Check if the cellular phone can make a call. AV AV–84 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM HINT: When the battery is low, calls cannot be made or received. OK: Cellular phone can make a call. NG REPAIR OR REPLACE CELLULAR PHONE OK 5 CHECK RECEPTION (a) Set the cellular phone so that it can receive calls. (b) Place the cellular phone close to the radio receiver. (c) Check if the cellular phone has reception according to the radio receiver. OK: Cellular phone has reception. NG REPLACE RADIO RECEIVER OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–85 The Other Caller's Voice cannot be Heard, is too Quiet, or Distorted INSPECTION PROCEDURE 1 CHECK CELLULAR PHONE (a) Check if the voice on the other side can be heard using a cellular phone. OK: Voice can be heard. NG REPAIR OR REPLACE CELLULAR PHONE OK 2 CHECK AUDIO AND VISUAL SYSTEM (a) Check that audio sound can be heard from the driver side speaker. OK: Audio sound can be heard. HINT: If audio sound cannot be heard, proceed to "No sound can be heard from speakers. (Audio is mute.)" in the PROBLEM SYMPTOMS TABLE (See page AV-13). NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE OK 3 CHECK SETTINGS (a) Check that the received voice level setting on the cellular phone is not too low. OK: The received voice level setting is not too low. NG SET VOLUME TO HIGH OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV AV–86 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM The Other Caller cannot Hear Your Voice, or Your Voice is too Quiet or Distorted INSPECTION PROCEDURE 1 CHECK CELLULAR PHONE (a) Check if the other side can hear your voice properly. OK: Your voice can be heard correctly. NG REPLACE CELLULAR PHONE OK 2 CHECK SETTINGS (a) Check if the mute is set to ON. OK: Mute is not set to ON. NG TURN MUTE OFF OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV AV–87 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Vehicle Speed Signal Circuit between Radio Receiver and Combination Meter DESCRIPTION This circuit is necessary for the ASL (Auto Sound Leveliser) built into the radio receiver. Speed signals are received from the combination meter and used for the ASL. The ASL function automatically adjusts the sound data in order to enable hearing the clear audio sound even when vehicle noise increases (as vehicle noise increases, the volume is turned up etc.). HINT: • A voltage of 12 V or 5 V is output from each ECU and then input to the combination meter. The signal is changed to a pulse signal at the transistor in the combination meter. Each ECU controls the respective system based on the pulse signal. • If a short occurs in an ECU, all systems in the diagram below will not operate normally. WIRING DIAGRAM Radio Receiver 3 F8 *1 From Main Body ECU *2 From Tire Pressure Warning ECU SPD From Transmission Control ECU From Engine Control Module +S 12 F2 Combination Meter From Speed Sensor AV *1: with Smart Key System *2: for 2GR-FE E129788E01 AV–88 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM INSPECTION PROCEDURE 1 CHECK OPERATION OF SPEEDOMETER (a) Drive the vehicle and check if the function of the speedometer on the combination meter is normal. OK: Actual vehicle speed and the speed indicated on the speedometer are the same. HINT: The vehicle speed sensor is functioning normally when the indication on the speedometer is normal. NG CHECK COMBINATION METER OK 2 INSPECT RADIO RECEIVER (a) Disconnect the radio receiver connector F8. (b) Measure the voltage. (1) Jack up either one of the drive wheels. (2) Move the shift lever to the neutral position. (3) Turn the ignition switch on (IG). Wire Harness View: F8 SPD E129800E01 (4) Measure the voltage between terminal SPD of the wire harness connector and body ground when the drive wheels are turned slowly. OK: Voltage pulses as shown in the illustration. OK 4.5 to 14 V AV Below 2 V 0 Turn the wheel E110855E03 NG REPLACE RADIO RECEIVER AV–89 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 3 CHECK HARNESS AND CONNECTOR (COMBINATION METER - RADIO RECEIVER) Radio Receiver Wire Harness View: (a) Disconnect the radio receiver connector F8 and combination meter connector F2. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Condition Specified condition SPD - +S Ignition switch off Below 1 Ω F8 NG REPAIR OR REPLACE HARNESS OR CONNECTOR SPD Combination Meter Wire Harness View: F2 +S E129801E01 OK AV AV–90 4 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM CHECK HARNESS AND CONNECTOR (RADIO RECEIVER - BODY GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness View: Tester connection Condition Specified condition SPD - Body ground Ignition switch off 10 kΩ or higher HINT: If the resistance between terminal SPD and body ground is less than 10 kΩ, there may be a short in a wire harness, connector, or an ECU that is connected to the SPD signal wire. F8 NG SPD E129800E01 OK REPLACE COMBINATION METER AV REPAIR OR REPLACE HARNESS OR CONNECTOR OR EACH ECU AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–91 Steering Pad Switch Circuit DESCRIPTION This circuit sends an operation signal from the steering pad switch to the radio receiver. If there is an open in the circuit, the audio system cannot be operated using the steering pad switch. If there is a short in the circuit, the same condition as that when the switch is continuously depressed occurs. Therefore, the radio receiver cannot be operated using the steering pad switch, and also the radio receiver itself cannot function. AV AV–92 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM WIRING DIAGRAM 3 Spoke Type: Steering Pad Switch LH Spiral Cable 10 a1 VOL- VOL+ SEEK- SEEK+ 8 a1 MODE 9 a1 AU1 EAU AU2 Radio Receiver 6 7 E18 F8 4 6 E18 F8 5 8 E18 F8 SW1 SWG SW2 Steering Pad Switch RH ON HOOK OFF HOOK 4 Spoke Type: Steering Pad Switch LH Spiral Cable 10 a1 SEEK+ 8 a1 MODE 9 a1 AU1 EAU AU2 Radio Receiver 6 7 E18 F8 4 6 E18 F8 5 8 E18 F8 SW1 SWG SW2 AV ON HOOK OFF HOOK SEEK- VOL+ VOL- E129802E02 AV–93 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM INSPECTION PROCEDURE NOTICE: The vehicle is equipped with an SRS (Supplemental Restraint System) which includes components such as airbags. Before servicing (including removal or installation of parts), be sure to read the precautionary notice for the Supplemental Restraint System (See page RS-1). 1 INSPECT RADIO RECEIVER Wire Harness View (Premium Model): (a) Disconnect the radio receiver connector F8. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection F8 SW2 SW1 SWG Condition Specified condition SW1 - SWG No switch is pushed Approx. 100 kΩ SW1 - SWG SEEK+ switch: push 0 to 2.5 Ω SW1 - SWG SEEK- switch: push Approx. 0.3 kΩ SW1 - SWG VOL+ switch: push Approx. 1 kΩ SW1 - SWG VOL- switch: push Approx. 3.1 kΩ SW2 - SWG No switch is pushed Approx. 100 kΩ SW2 - SWG MODE switch: push 0 to 2.5 Ω SW2 - SWG ON HOOK switch: push (*1) Approx. 0.3 kΩ SW2 - SWG OFF HOOK switch: push (*1) Approx. 1 kΩ *1: for Premium model Wire Harness View (Standard Model): NG Go to step 2 F8 SW2 SW1 SWG E129803E02 OK AV PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE 2 INSPECT STEERING PAD SWITCH ASSEMBLY (a) Disconnect the steering pad switch assembly connector. (b) Measure the resistance according to the values in the table below. AV–94 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 3 Spoke Type: a1 AUD IO OFF (HO LD) EAU AU2 AU1 4 Spoke Type: a1 AUDIO OFF (HOLD) EAU AU2 AU1 E129804E01 Standard resistance AV Tester connection Condition Specified condition AU1 - EAU No switch is pushed Approx. 100 kΩ AU1 - EAU SEEK+ switch: push 0 to 2.5 Ω AU1 - EAU SEEK- switch: push Approx. 0.3 kΩ AU1 - EAU VOL+ switch: push Approx. 1 kΩ AU1 - EAU VOL- switch: push Approx. 3.1 kΩ AU2 - EAU No switch is pushed Approx. 100 kΩ AU2 - EAU MODE switch: push 0 to 2.5 Ω AU2 - EAU ON HOOK switch: push (*1) Approx. 0.3 kΩ AU2 - EAU OFF HOOK switch: push (*1) Approx. 1 kΩ *1: for Premium model AV–95 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM NG REPLACE STEERING PAD SWITCH ASSEMBLY OK 3 INSPECT SPIRAL CABLE (a) Disconnect the steering pad switch and spiral cable connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Steering Pad Switch Side: AU2 EAU Tester connection Spiral cable position Specified condition Center AU1 EAU - EAU 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right Center AU1 - AU1 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right Center AU2 - AU2 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right Vehicle Side: AU2 EAU AU1 I039337E29 NOTICE: The spiral cable is an important part of the SRS airbag system. Incorrect removal or installation of the spiral cable may prevent the airbag from deploying. Be sure to read the page shown in the brackets. HINT: • Removal (See page RS-363) • Installation (See page RS-366) NG REPLACE SPIRAL CABLE OK REPAIR OR REPLACE HARNESS OR CONNECTOR (SPIRAL CABLE - RADIO RECEIVER) AV AV–96 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Illumination Circuit DESCRIPTION Power is supplied to the radio receiver and steering pad switch illumination when the light control switch is in the TAIL or HEAD position. WIRING DIAGRAM Steering Pad SW Radio Receiver Spiral Cable 5 IL+2 a1 8 EAU a1 12 10 E18 F6 F26 ILL+ (*1) (*2) 4 6 6 E18 F8 F8 (*1) (*2) 7 20 TAIL 4 From Battery 2 SWG F6 F26 GND (*1) (*2) PANEL 5 3 1 2 To Main Body ECU F1 Combination Meter 5 12 E2 ILL- 11 12 F7 F26 ILL- (*1) (*2) *1: Standard Model *2: Premium Model AV E129789E04 INSPECTION PROCEDURE NOTICE: The vehicle is equipped with an SRS (Supplemental Restraint System) which includes components such as airbags. Before servicing (including removal or installation of parts), be sure to read the precautionary notice for the supplemental restraint system (See page RS-1). AV–97 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 1 CHECK ILLUMINATION (a) Check if the illumination for the radio receiver, steering pad switch, glove box or others (hazard switch, transmission control switch, etc.) comes on when the light control switch is turned to the HEAD or TAIL position. Result Result Proceed to Illumination comes on for all components except steering pad switch. A Illumination comes on for all components except radio receiver. B No illumination comes on (radio receiver, hazard switch, glove box, etc.). C Illumination comes on only for glove box and steering pad switch. D B Go to step 6 C GO TO LIGHTING SYSTEM D GO TO COMBINATION METER SYSTEM A 2 CHECK HARNESS AND CONNECTOR (BATTERY - SPIRAL CABLE) Spiral Cable Connector Front View: (a) Disconnect the spiral cable connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Tester connection Condition Specified condition IL+2 - Body ground Light control SW TAIL or HEAD 10 to 14 V IL+2 NG E121218E05 REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 INSPECT STEERING PAD SWITCH ASSEMBLY (a) Disconnect the steering pad switch connector. (b) Connect the positive (+) lead to terminal IL+2 and the negative (-) lead to terminal EAU of the steering pad switch assembly connector. AV AV–98 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 3 Spoke Type: a1 AUD IO OFF (HO LD) 4 Spoke Type: a1 AUDIO OFF (HOLD) E129805E01 (c) Check if the illumination for the steering pad switch assembly comes on. OK: Illumination for the steering pad switch assembly comes on. AV NG OK REPLACE STEERING PAD SWITCH ASSEMBLY AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 4 AV–99 INSPECT SPIRAL CABLE (a) Disconnect the steering pad switch and spiral cable connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Steering Pad Switch Side: IL+2 EAU Tester connection Spiral cable position EAU - EAU 2.5 rotations to the left Specified condition Center Below 1 Ω 2.5 rotations to the right Center IL+2 - IL+2 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right Vehicle Side: IL+2 NOTICE: The spiral cable is an important part of the SRS airbag system. Incorrect removal or installation of the spiral cable may prevent the airbag from deploying. Be sure to read the page shown in the brackets. HINT: • Removal (See page RS-363) • Installation (See page RS-366) NG REPLACE SPIRAL CABLE EAU I039337E30 OK AV AV–100 5 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM CHECK HARNESS AND CONNECTOR (SPIRAL CABLE - RADIO RECEIVER) (a) Disconnect the connectors from the radio receiver and spiral cable. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Radio Receiver Wire Harness View (Premium Model): Tester connection Condition SWG - EAU Always Below 1 Ω SWG - Body ground Always 10 kΩ or higher NG F8 Specified condition REPAIR OR REPLACE HARNESS OR CONNECTOR SWG Radio Receiver Wire Harness View (Standard Model): F8 SWG Spiral Cable Connector Front View: AV EAU E129806E02 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV–101 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 6 CHECK HARNESS AND CONNECTOR (BATTERY - RADIO RECEIVER) Wire Harness View (Premium Model): (a) Disconnect the radio receiver connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Tester connection Condition Specified condition ILL+ - Body ground Light control switch TAIL or HEAD 10 to 14 V F26 NG REPAIR OR REPLACE HARNESS OR CONNECTOR ILL+ Wire Harness View (Standard Model): F6 ILL+ E129807E03 OK AV AV–102 7 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM CHECK HARNESS AND CONNECTOR (RADIO RECEIVER - COMBINATION METER) (a) Disconnect the radio receiver connector and combination meter connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Radio Receiver Wire Harness View (Premium Model): Tester connection Condition Specified condition ILL- - ILL- Always Below 1 Ω ILL- - Body ground Always 10 kΩ or higher F26 NG REPAIR OR REPLACE HARNESS OR CONNECTOR ILLRadio Receiver Wire Harness View (Standard Model): F7 ILL- Combination Meter Wire Harness View: F1 AV ILLE129808E02 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–103 Speaker Circuit DESCRIPTION • When the vehicle has a built-in type amplifier, a sound signal is sent from the radio receiver to the speakers via the "Standard Model" circuit. • When the vehicle has a separate type amplifier, a sound signal from the radio receiver is amplified by the stereo component amplifier and then transmitted to the speaker via the "Premium Model" circuit. If there is a short in this circuit, the stereo component amplifier detects it and stops output to the speakers. Thus sound cannot be heard from the speakers even if there is no malfunction in the stereo component amplifier or speakers. AV AV–104 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM WIRING DIAGRAM Standard Model: F22 Front No. 2 Speaker LH 1 I1 Front No. 1 Speaker LH + TWL+ 2 1 4 2 3 - TWL- Radio Receiver 2 F6 FL+ 6 F6 FL- F24 Front No. 2 Speaker RH 1 + H1 Front No. 1 Speaker RH TWR+ 2 1 1 F6 FR+ 5 2 3 - TWR- 4 F6 FR- 2 1 O12 Rear Speaker LH F7 RL+ 6 2 F7 RL- 1 1 O13 Rear Speaker RH RR+ 3 2 AV F7 F7 RR- E121225E04 AV–105 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Premium Model: F21 Front No. 2 Speaker LH Stereo Component Amplifier 1 2 F23 Front No. 2 Speaker RH 1 2 I1 Front No. 1 Speaker LH 1 2 H1 Front No. 1 Speaker RH 1 2 8 F18 FL+ 7 F18 FL- 2 F18 FR+ 6 F18 FR- 2 F20 WFL+ 1 F20 WFL- 9 F20 WFR+ 3 F20 WFR- E126150E06 AV AV–106 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Rear Speaker LH 2 WF1+ O14 4 WF1- O14 1 + O14 4 F20 SL+ 10 F20 SL- 3 F18 RL+ 3 9 O14 F18 RL- 2 WF2+ O15 5 F20 SR+ 12 F20 SR- - Rear Speaker RH 4 WF2- O15 1 + O15 3 - O15 10 F18 RR+ 4 F18 RR- E129782E01 AV AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–107 INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR Stereo Component Amplifier Wire Harness View (Premium Model): F20 F18 SL+ SR+ FR+ FRFLFL+ RL+ SRSLWFR+ WFR- WFL+ RRRR+ RL- WFL- Radio Receiver Wire Harness View (Standard Model): F6 F7 FL+ RR+ FR+ RRFLFR- RL+ RL- Front No. 1 Speaker Connector Front View: I1 H1 Front No. 2 Speaker Connector Front View: F22 (*1) F21 (*2) F24 (*1) F23 (*2) *1: Standard Model *2: Premium Model E129814E04 (a) Disconnect the connectors shown in the illustration from the stereo component amplifier or radio receiver and speakers. (b) Premium Model: Measure the resistance between each of the front No. 2 speakers and the stereo component amplifier to check for an open circuit in the wire harness. Standard resistance: Below 1 Ω (c) Standard Model: Measure the resistance between each of the front No. 2 speakers and the radio receiver to check for an open circuit in the wire harness. Standard resistance: Below 1 Ω (d) Premium Model: Measure the resistance between each of the front No. 1 speakers and the stereo component amplifier to check for an open circuit in the wire harness. Standard resistance: Below 1 Ω (e) Standard Model: Measure the resistance between each of the front No. 2 speakers and each of the front No. 1 speakers to check for an open circuit in the wire harness. Standard resistance: Below 1 Ω (f) Premium Model: Measure the resistance between each of the rear speakers and the stereo component amplifier to check for an open circuit in the wire harness. Standard resistance: Below 1 Ω (g) Standard Model: Measure the resistance between each of the rear speakers and the radio receiver to check for an open circuit in the wire harness. Standard resistance: Below 1 Ω AV AV–108 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Rear Speaker Connector Front View (Standard Model): (h) Measure the resistance between each speaker and body ground to check for a short circuit in the wire harness. Standard resistance: 10 kΩ or higher NG O12 REPAIR OR REPLACE HARNESS OR CONNECTOR O13 Rear Speaker Connector Front View (Premium Model): O14 O15 E129815E01 OK 2 INSPECT FRONT NO. 1 SPEAKER (a) Resistance check. (1) Measure the resistance between the terminals of the speaker. Standard resistance: Premium Model: 1.8 to 2.6 Ω Standard Model: Approximately 4 Ω NG REPLACE FRONT NO. 1 SPEAKER OK 3 AV INSPECT FRONT NO. 2 SPEAKER (a) Check that the malfunction disappears when another speaker in good condition is installed. OK: Malfunction disappears. HINT: • Connect all the connectors to the front No. 2 speaker. • When there is a possibility that either the right or left front speaker is detective, inspect by interchanging the right one with the left one. • Perform the above inspection on both LH and RH sides. OK REPLACE FRONT NO. 2 SPEAKER AV–109 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM NG 4 CONFIRM MODEL Result Result Proceed to Premium Model A Standard Model B B Go to step 6 A 5 INSPECT REAR SPEAKER Woofer (+) Woofer (-) Tweeter (+) Tweeter (-) (a) Woofer speaker: (1) Measure the resistance according to the value(s) in the table below. NOTICE: The speaker should not be removed for checking. Standard resistance Tester connection Condition Specified condition 2-4 Always 1.8 to 2.6 Ω E129809E01 (b) Tweeter speaker: (1) Check that the malfunction disappears when another rear speaker in good condition is installed. OK: Malfunction appears. HINT: • Connect all the connectors to the rear speaker. • When there is a possibility that either the right or left rear speaker is detective, inspect by interchanging the right one with the left one. NG REPLACE REAR SPEAKER OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV 6 INSPECT REAR SPEAKER (a) Resistance check. (1) Measure the resistance between the terminals of the speaker. Standard resistance: Approximately 4 Ω AV–110 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM NG REPLACE REAR SPEAKER OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV AV–111 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Sound Signal Circuit between Radio Receiver and Stereo Component Amplifier DESCRIPTION The radio receiver sends a sound signal to the stereo component amplifier through this circuit. The sound signal that has been sent is amplified by the stereo component amplifier, and then is sent to the speakers. If there is an open or short in the circuit, sound cannot be heard from the speakers even if there is no malfunction in the stereo component amplifier or speakers. WIRING DIAGRAM Radio Receiver Stereo Component Amplifier 6 SLD F19 L- 2 F19 3 L+ F19 4 R- F19 5 R+ F19 (Sielded) 10 F26 SLD 19 F26 L- 9 F26 L+ 18 F26 R- 8 F26 R+ E129783E05 AV AV–112 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (RADIO RECEIVER - STEREO COMPONENT AMPLIFIER) (a) Disconnect the connectors from the radio receiver and stereo component amplifier. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Radio Receiver Wire Harness View: F26 L+ SLD R+ L- R- Stereo Component Amplifier Wire Harness View: NG Tester connection Condition Specified condition L+ - L+ Always Below 1 Ω L- - L- Always Below 1 Ω R+ - R+ Always Below 1 Ω R- - R- Always Below 1 Ω SLD - SLD Always Below 1 Ω L+ - Body ground Always 10 kΩ or higher L- - Body ground Always 10 kΩ or higher R+ - Body ground Always 10 kΩ or higher R- - Body ground Always 10 kΩ or higher SLD - Body ground Always 10 kΩ or higher REPAIR OR REPLACE HARNESS OR CONNECTOR F19 SLD LR+ R- L+ E129816E05 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV AV–113 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Sound Signal Circuit between Radio Receiver and Stereo Jack Adapter DESCRIPTION The stereo jack adapter sends an external device sound signal to the radio receiver through this circuit. The sound signal that has been sent is amplified by the stereo component amplifier or radio receiver, and then is sent to the speakers. If there is an open or short in the circuit, sound cannot be heard from the speakers even if there is no malfunction in the stereo component amplifier, radio receiver, or speakers. WIRING DIAGRAM Radio Receiver Stereo Jack Adapter 19 4 F8 AUXO F17 2 AUXI 15 F8 ARI ARO F17 17 1 F8 ALO F17 3 ALI 16 F8 ASGN F17 ASGN (Shielded) E129784E03 AV AV–114 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (RADIO RECEIVER - STEREO JACK ADAPTER) (a) Disconnect the connectors from the stereo jack adapter and radio receiver. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Radio Receiver Wire Harness View (Premium Model): Tester connection ARI ALI ASGN Radio Receiver Wire Harness View (Standard Model): Specified condition AUXO - AUXI Always Below 1 Ω ASGN - ASGN Always Below 1 Ω ARO - ARI Always Below 1 Ω ALO - ALI Always Below 1 Ω AUXO - Body ground Always 10 kΩ or higher ASGN - Body ground Always 10 kΩ or higher ARO - Body ground Always 10 kΩ or higher ALO - Body ground Always 10 kΩ or higher F8 AUXI Condition NG REPAIR OR REPLACE HARNESS OR CONNECTOR F8 ARI AUXI ALI ASGN Stereo Jack Adapter Connector Front View: F17 AV ALO AUXO ARO ASGN E129810E01 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV–115 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Mute Signal Circuit between Radio Receiver and Stereo Component Amplifier DESCRIPTION This circuit sends a signal to the stereo component amplifier to mute noise. Because of that, the noise produced by changing the sound source ceases. If there is an open in the circuit, noise can be heard from the speakers when changing the sound source. If there is a short in the circuit, even though the stereo component amplifier is normal, no sound, or only an extremely small sound, can be produced. WIRING DIAGRAM Stereo Component Amplifier Radio Receiver 7 1 F26 MUTE MUTE F19 E110892E25 INSPECTION PROCEDURE 1 INSPECT STEREO COMPONENT AMPLIFIER (a) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness View: F19 MUTE E126155E02 NG Tester connection Condition Specified condition MUTE - Body ground Turn ignition switch on (ACC), Audio system is playing → Changing Above 3.5 V → Below 1 V OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV AV–116 2 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM CHECK HARNESS AND CONNECTOR (RADIO RECEIVER - STEREO COMPONENT AMPLIFIER) Radio Receiver Wire Harness View: F26 (a) Disconnect the radio receiver connector F26 and stereo component amplifier connector F19. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Condition Specified condition MUTE - MUTE Always Below 1 Ω MUTE - Body ground Always 10 kΩ or higher NG MUTE Stereo Component Amplifier Wire Harness View: F19 MUTE E129816E06 OK AV REPAIR OR REPLACE HARNESS OR CONNECTOR AV–117 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 3 INSPECT STEREO COMPONENT AMPLIFIER (OUTPUT SIGNAL) Premium Model Wire Harness View: F26 (a) Reconnect the stereo component amplifier connector F19. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Tester connection Condition Specified condition MUTE - Body ground Turn ignition switch on (ACC), Audio system is playing. Above 3.5 V NG REPLACE STEREO COMPONENT AMPLIFIER MUTE E131994E04 OK REPLACE RADIO RECEIVER AV AV–118 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AVC-LAN Circuit DESCRIPTION Each unit of the audio system connected to the AVC-LAN (communication bus) transfers the signal of each switch by communication. When a short to +B or short to ground occurs in this AVC-LAN, the audio system will not function normally as the communication is discontinued. INSPECTION PROCEDURE 1 INSPECT RADIO RECEIVER Premium Model Wire Harness View: F26 ATX+ (a) Disconnect the radio receiver connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Condition Specified condition ATX+ (F26-5) - ATX(F26-15) Always 60 to 80 Ω NG REPLACE RADIO RECEIVER ATX- E129798E04 OK 2 CHECK HARNESS AND CONNECTOR HINT: For details of the connectors, refer to the "TERMINALS OF ECU" (See page AV-15). (a) Referring to the AVC-LAN wiring diagram below, check all AVC-LAN circuits. (1) Disconnect all connectors in all AVC-LAN circuits. (2) Check for an open or short in all AVC-LAN circuits. OK: There is no open or short circuit. AV AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–119 AVC-LAN WIRING DIAGRAM Premium Model: 5 ATX+ F26 8 F19 TX+ Stereo Component Amplifier (*2) Radio Receiver (*1) 15 ATX- F26 7 F19 TX- *1: Master Unit *2: Slave Unit E111831E15 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV AV–120 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Vehicle Speed Signal Circuit between Stereo Component Amplifier and Combination Meter DESCRIPTION This circuit is necessary for the ASL (Auto Sound Leveliser) built into the stereo component amplifier. Speed signals are received from the combination meter and used for the ASL. The ASL function automatically adjusts the sound data in order to enable hearing the clear audio sound even when vehicle noise increases (as vehicle noise increases, the volume is turned up etc.). HINT: • A voltage of 12 V or 5 V is output from each ECU and then input to the combination meter. The signal is changed to a pulse signal at the transistor in the combination meter. Each ECU controls the respective system based on the pulse signal. • If a short occurs in an ECU, all systems in the diagram below will not operate normally. WIRING DIAGRAM Stereo Component Amplifier 11 F19 SPD *1 From Main Body ECU *2 From Tire Pressure Warning ECU From Transmission Control ECU From Engine Control Module +S 12 F2 Combination Meter From Speed Sensor AV *1: with Smart Key System *2: for 2GR-FE E129788E02 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–121 INSPECTION PROCEDURE 1 OPERATION OF SPEEDOMETER (a) Drive the vehicle and check if the function of the speedometer on the combination meter is normal. OK: Actual vehicle speed and the speed indicated on the speedometer are the same. HINT: The vehicle speed sensor is functioning normally when the indication on the speedometer is normal. NG CHECK COMBINATION METER OK 2 INSPECT STEREO COMPONENT AMPLIFIER (a) Disconnect the stereo component amplifier connector F19. (b) Measure the voltage. (1) Jack up either one of the drive wheels. (2) Move the shift lever to the neutral position. (3) Turn the ignition switch on (IG). Wire Harness View: F19 SPD E132126E01 (4) Measure the voltage between terminal SPD of the wire harness connector and body ground when the drive wheels are turned slowly. OK: Voltage pulses as shown in the illustration. NG 4.5 to 14 V Go to step 3 AV Below 2 V 0 Turn the wheel E110855E01 AV–122 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM OK REPLACE STEREO COMPONENT AMPLIFIER 3 CHECK HARNESS AND CONNECTOR (COMBINATION METER - STEREO COMPONENT AMPLIFIER) (a) Disconnect the stereo component amplifier connector F19 and combination meter connector F2. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Stereo Component Amplifier Wire Harness View: F19 Tester connection Condition Specified condition SPD - +S Ignition switch off Below 1 Ω NG SPD Combination Meter Wire Harness View: F2 +S E129817E01 OK AV REPAIR OR REPLACE HARNESS OR CONNECTOR AV–123 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 4 CHECK HARNESS AND CONNECTOR (STEREO COMPONENT AMPLIFIER - BODY GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Stereo Component Amplifier Wire Harness View: F19 Tester connection Condition Specified condition SPD - Body ground Ignition switch off 10 kΩ or higher HINT: If the resistance between terminal SPD and body ground is less than 10 kΩ, there may be a short in a wire harness, connector, or an ECU that is connected to the SPD signal wire. NG SPD REPAIR OR REPLACE HARNESS OR CONNECTOR OR CHECK EACH ECU E132126E09 OK REPLACE COMBINATION METER AV AV–124 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Cellular Phone Voice Circuit between Radio Receiver and Stereo Component Amplifier SYSTEM DESCRIPTION This circuit is used when the cellular phone voice in the "Bluetooth" handsfree system is on. WIRING DIAGRAM Radio Receiver Stereo Component Amplifier (Shielded) SLD 13 F8 IVO- 12 F8 22 F19 INT- IVO+ 11 F8 23 F19 INT+ E119672E05 AV AV–125 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (RADIO RECEIVER - STEREO COMPONENT AMPLIFIER) Radio Receiver Wire Harness View: F8 (a) Disconnect the radio receiver connector F8 and stereo component amplifier connector F19. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Condition Specified condition IVO+ - INT+ Always Below 1 Ω IVO- - INT- Always Below 1 Ω IVO+ - Body ground Always 10 kΩ or higher IVO- - Body ground Always 10 kΩ or higher NG IVO+ IVO- REPAIR OR REPLACE HARNESS OR CONNECTOR Stereo Component Amplifier Wire Harness View: F19 INT+ INT- E133935E01 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV AV–126 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Microphone Circuit between Microphone and Radio Receiver DESCRIPTION This circuit sends a microphone signal from the microphone to the radio receiver. It also supplies power from the radio receiver to the microphone. WIRING DIAGRAM Radio Receiver Microphone 1 2 Q5 (*1) Q12 (*2) MIC- 5 Q5 (*1) 3 Q12 (*2) MI1+ 3 Q5 (*1) 1 Q12 (*2) ACC 7 F11 MCVD 1 F11 MIC2 F11 MIC+ (Shielded) (Shielded) (Shielded) *1: TMC Made *2: TMMK Made E129791E05 AV AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–127 INSPECTION PROCEDURE 1 INSPECT RADIO RECEIVER (a) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness View: Tester connection Condition Specified condition MCVD - Body ground Ignition SW on (ACC) 4 to 6 V F11 NG REPLACE RADIO RECEIVER MCVD E129811E02 OK AV AV–128 2 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM CHECK HARNESS AND CONNECTOR (MICROPHONE - RADIO RECEIVER) (a) Disconnect the microphone connector and radio receiver connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Microphone Connector Front View (TMC Made): Q5 Tester connection ACC ACC ACC - MCVD Always Below 1 Ω MI1+ - MIC+ Always Below 1 Ω MIC- - MIC- Always Below 1 Ω Always 10 kΩ or higher MIC+ - Body ground Always 10 kΩ or higher MIC- - Body ground Always 10 kΩ or higher NG Microphone Connector Front View (TMMK Made): Specified condition ACC - Body ground MIC- MI1+ Condition REPAIR OR REPLACE HARNESS OR CONNECTOR Q12 MI1+ MIC- Radio Receiver Wire Harness View: MIC+ F11 MICMCVD AV E131895E02 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV–129 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Radio Receiver Communication Error INSPECTION PROCEDURE 1 IDENTIFY THE COMPONENT SHOWN BY SUB-CODE (a) Enter the diagnostic mode. Example: Service Check Mode *2 *1 *2 *1 *2 *1 *2 *1 *2 Detailed Information Mode *3 *4 Continues to display check result when more components are installed. *1 *2 *1 *2 *1 *2 *1 *2 *2 *1 *1 *2 *1 *1 *1: SEEK TRACK DOWN *2 DTC Component shown by the sub-code Continues to display detailed information of the first code. *2: SEEK TRACK UP *3: PRESET SWITCH “2” *4: PRESET SWITCH “3” *1 *2 Continues to display detailed information when more DTCs are detected. *1 *2 AV E110917E05 (b) Press the preset switch "3" to change to "Detailed Information Mode". (c) Identify the component shown by the sub-code. HINT: • "190 (radio receiver)" is the component shown by the subcode in the example shown in the illustration. AV–130 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM • For details of the DTC display, refer to "DTC CHECK/ CLEAR" (See page AV-19). NEXT 2 CHECK COMPONENT SHOWN BY SUB-CODE (a) Select the component shown by sub-code. HINT: The "Bluetooth" handsfree module is built into the radio receiver. If there is a problem between the "Bluetooth" handsfree module and radio receiver, replace the radio receiver. Component Table: Component Proceed to "Bluetooth" handsfree module (19D) A Except "Bluetooth" handsfree module B A REPLACE RADIO RECEIVER B 3 CHECK POWER SOURCE CIRCUIT OF COMPONENT SHOWN BY SUB-CODE (a) Inspect the power source circuit of the component shown by the sub-code. If the power source circuit is operating normally, proceed to the next step. Component Table: Component Proceed to Stereo component amplifier (440) Stereo component amplifier power source circuit (See page AV-142) NEXT 4 INSPECT RADIO RECEIVER Premium Model Wire Harness View: F26 ATX+ AV (a) Disconnect the radio receiver connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Condition Specified condition ATX+ (F26-5) - ATX(F26-15) Always 60 to 80 Ω NG ATX- E129798E04 REPLACE RADIO RECEIVER AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–131 OK 5 CHECK HARNESS AND CONNECTOR (RADIO RECEIVER - COMPONENT SHOWN BY SUB-CODE) HINT: • Start the check from the circuit that is near the component shown by the sub-code first. • For details of the connectors, refer to the "TERMINALS OF ECU" (See page AV-15). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the radio receiver and the component shown by the sub-code. (1) Disconnect all connectors between the radio receiver and the component shown by the subcode. (2) Check for an open or short in the AVC-LAN circuit between the radio receiver and the component shown by the sub-code. OK: There is no open or short circuit. AVC-LAN WIRING DIAGRAM Premium Model: 5 ATX+ F26 8 F19 TX+ Stereo Component Amplifier (*2) Radio Receiver (*1) 15 ATX- F26 7 F19 TX- *1: Master Unit *2: Slave Unit E111831E15 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 6 REPLACE COMPONENT SHOWN BY SUB-CODE (a) Replace the component shown by the sub-code with a normal one and check if the same problem occurs again. AV AV–132 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM OK: Same problem does not occur. NG OK END AV REPLACE RADIO RECEIVER AV–133 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Stereo Component Amplifier Communication Error INSPECTION PROCEDURE 1 IDENTIFY THE COMPONENT SHOWN BY SUB-CODE (a) Enter the diagnostic mode. Example: Service Check Mode *2 *1 *2 *1 *2 *1 *2 *1 *2 Detailed Information Mode *3 *4 Continues to display check result when more components are installed. *1 *2 *1 *2 *1 *2 *1 *2 *2 *1 *1 *2 *1 *1 *1: SEEK TRACK DOWN *2 DTC Component shown by the sub-code Continues to display detailed information of the first code. *2: SEEK TRACK UP *3: PRESET SWITCH “2” *4: PRESET SWITCH “3” *1 *2 Continues to display detailed information when more DTCs are detected. *1 *2 AV E110917E05 (b) Press the preset switch "3" to change to "Detailed Information Mode". (c) Identify the component shown by the sub-code. HINT: • "190 (radio receiver)" is the component shown by the subcode in the example shown in the illustration. AV–134 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM • For details of the DTC display, refer to "DTC CHECK/ CLEAR" (See page AV-19). NEXT 2 CHECK POWER SOURCE CIRCUIT OF COMPONENT SHOWN BY SUB-CODE (a) Inspect the power source circuit of the component shown by the sub-code. If the power source circuit is operating normally, proceed to the next step. HINT: The "Bluetooth" handsfree module is built into the radio receiver. Component Table: Component Proceed to "Bluetooth" handsfree module (19D) Radio receiver power source circuit (See page AV-140) Radio receiver (190) Radio receiver power source circuit (See page AV-140) NEXT 3 INSPECT RADIO RECEIVER Premium Model Wire Harness View: F26 ATX+ (a) Disconnect the radio receiver connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Condition Specified condition ATX+ (F26-5) - ATX(F26-15) Always 60 to 80 Ω NG REPLACE RADIO RECEIVER ATX- E129798E04 OK AV 4 CHECK HARNESS AND CONNECTOR (STEREO COMPONENT AMPLIFIER COMPONENT SHOWN BY SUB-CODE) HINT: • Start the check from the circuit that is near the component shown by the sub-code first. • For details of the connectors, refer to the "TERMINALS OF ECU" (See page AV-15). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the stereo component amplifier and the component shown by the sub-code. AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–135 (1) Disconnect all connectors between the stereo component amplifier and the component shown by the sub-code. (2) Check for an open or short in the AVC-LAN circuit between the stereo component amplifier and the component shown by the sub-code. OK: There is no open or short circuit. AVC-LAN WIRING DIAGRAM Premium Model: 5 ATX+ F26 8 F19 TX+ Stereo Component Amplifier (*2) Radio Receiver (*1) 15 ATX- F26 7 F19 TX- *1: Master Unit *2: Slave Unit E111831E15 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 5 REPLACE COMPONENT SHOWN BY SUB-CODE (a) Replace the component shown by the sub-code with a normal one and check if the same problem occurs again. OK: Same problem does not occur. NG OK END REPLACE STEREO COMPONENT AMPLIFIER AV AV–136 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Bluetooth Handsfree Module Communication Error INSPECTION PROCEDURE 1 IDENTIFY THE COMPONENT SHOWN BY SUB-CODE (a) Enter the diagnostic mode. Example: Service Check Mode *2 *1 *2 *1 *2 *1 *2 *1 *2 Detailed Information Mode *3 *4 Continues to display check result when more components are installed. *1 *2 *1 *2 *1 *2 *1 *2 *2 *1 *1 *2 *1 *1 *1: SEEK TRACK DOWN *2 DTC Component shown by the sub-code Continues to display detailed information of the first code. *2: SEEK TRACK UP *3: PRESET SWITCH “2” *4: PRESET SWITCH “3” AV *1 *2 Continues to display detailed information when more DTCs are detected. *1 *2 E110917E05 (b) Press the preset switch "3" to change to "Detailed Information Mode". (c) Identify the component shown by the sub-code. HINT: • "190 (radio receiver)" is the component shown by the subcode in the example shown in the illustration. AV–137 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM • For details of the DTC display, refer to "DTC CHECK/ CLEAR" (See page AV-19). NEXT 2 CHECK COMPONENT SHOWN BY SUB-CODE (a) Select the component shown by sub-code. HINT: The "Bluetooth" handsfree module is built into the radio receiver. If there is a problem between the "Bluetooth" handsfree module and radio receiver, replace the radio receiver. Component Table: Component Proceed to Radio Receiver (190) A Except Radio Receiver B A REPLACE RADIO RECEIVER B 3 CHECK POWER SOURCE CIRCUIT OF COMPONENT SHOWN BY SUB-CODE (a) Inspect the power source circuit of the component shown by the sub-code. If the power source circuit is operating normally, proceed to the next step. Component Table: Component Proceed to Stereo component amplifier (440) Stereo component amplifier power source circuit (See page AV-142) NEXT 4 INSPECT RADIO RECEIVER Premium Model Wire Harness View: F26 ATX+ (a) Disconnect the radio receiver connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Condition Specified condition ATX+ (F26-5) - ATX(F26-15) Always 60 to 80 Ω NG ATX- E129798E04 REPLACE RADIO RECEIVER AV AV–138 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM OK 5 CHECK HARNESS AND CONNECTOR ("BLUETOOTH" HANDSFREE MODULE COMPONENT SHOWN BY SUB-CODE) HINT: • Start the check from the circuit that is near the component shown by the sub-code first. • For details of the connectors, refer to the "TERMINALS OF ECU" (See page AV-15). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the "Bluetooth" handsfree module and the component shown by the sub-code. (1) Disconnect all connectors between the "Bluetooth" handsfree module and the component shown by the sub-code. (2) Check for an open or short in the AVC-LAN circuit between the "Bluetooth" handsfree module and the component shown by the sub-code. OK: There is no open or short circuit. AVC-LAN WIRING DIAGRAM Premium Model: 5 ATX+ F26 8 F19 TX+ Stereo Component Amplifier (*2) Radio Receiver (*1) 15 ATX- F26 7 F19 TX- *1: Master Unit *2: Slave Unit E111831E15 AV NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 6 REPLACE COMPONENT SHOWN BY SUB-CODE (a) Replace the component shown by the sub-code with a normal one and check if the same problem occurs again. AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–139 OK: Same problem does not occur. NG REPLACE RADIO RECEIVER (BUILT-IN "BLUETOOTH" HANDSFREE MODULE) OK END AV AV–140 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Radio Receiver Power Source Circuit DESCRIPTION This circuit provides power to the radio receiver. WIRING DIAGRAM Radio Receiver RADIO NO. 1 4 F6 From Battery 1 F26 B (*1) (*2) 5 F11 +B (*2) RADIO NO. 2 3 F6 From ACC Relay 11 F26 ACC (*1) (*2) 16 F11 ACC (*2) 7 F6 20 F26 GND (*1) (*2) *1: Standard Model *2: Premium Model AV 14 F11 GND (*2) E129790E05 AV–141 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM INSPECTION PROCEDURE 1 INSPECT RADIO RECEIVER Wire Harness View (Premium Model): +B ACC GND F26 F11 (a) Disconnect the radio receiver connector. (b) Measure the resistance according to the value in the table below. Standard resistance Tester connection Condition Specified condition GND - Body ground Always Below 1 Ω (c) Measure the voltage according to the values in the table below. Standard voltage Tester connection Condition Specified condition +B - GND (*1) Always 10 to 14 V B - GND Always 10 to 14 V ACC - GND Ignition SW on (ACC) 10 to 14 V B ACC GND *1: Premium model Wire Harness View (Standard Model): NG REPAIR OR REPLACE HARNESS OR CONNECTOR F6 B ACC GND E129813E05 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV AV–142 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Stereo Component Amplifier Power Source Circuit DESCRIPTION This circuit provides power to the stereo component amplifier. WIRING DIAGRAM Stereo Component Amplifier AMP 1 F18 +B From Battery 5 F18 +B2 RADIO NO. 2 12 From ACC Relay F19 ACC 7 F20 E 6 F20 GND AV E125108E06 AV–143 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM INSPECTION PROCEDURE 1 INSPECT STEREO COMPONENT AMPLIFIER (a) Disconnect the stereo component amplifier connectors. (b) Measure the resistance according to the values in the table below. Standard resistance Wire Harness View: F20 F18 F19 Tester connection Condition Specified condition GND - Body ground Always Below 1 Ω E - Body ground Always Below 1 Ω (c) Measure the voltage according to the values in the table below. Standard voltage +B E GND +B2 Tester connection Condition Specified condition +B - GND Always 10 to 14 V +B2 - GND Always 10 to 14 V ACC - GND Ignition SW on (ACC) 10 to 14 V ACC E126146E03 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV AV–144 AUDIO / VISUAL – RADIO RECEIVER RADIO RECEIVER BODY ELECTRICAL AUDIO / VISUAL COMPONENTS INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY RADIO RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH UPPER CONSOLE PANEL SUB-ASSEMBLY NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH for Automatic Transaxle: for Manual Transaxle: SHIFT LEVER KNOB SUB-ASSEMBLY FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY SHIFT LEVER KNOB SUB-ASSEMBLY UPPER CONSOLE PANEL AV UPPER CONSOLE REAR PANEL SUB-ASSEMBLY UPPER CONSOLE REAR PANEL SUB-ASSEMBLY E129174E01 AV–145 AUDIO / VISUAL – RADIO RECEIVER RADIO RECEIVER ASSEMBLY RADIO NO. 2 BRACKET RADIO NO. 1 BRACKET HEATER CONTROL PANEL E129973E01 AV AV–146 AUDIO / VISUAL – RADIO RECEIVER REMOVAL 1. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-24) 2. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) (See page IP-24) 3. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-24) 4. REMOVE NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-25) 5. REMOVE FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-25) 6. REMOVE UPPER CONSOLE PANEL (for Manual Transaxle) (See page IP-25) 7. REMOVE UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Automatic Transaxle) (See page IP26) 8. REMOVE UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Manual Transaxle) (See page IP-26) 9. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (See page IP-27) 10. REMOVE INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY (See page IP-27) 11. REMOVE RADIO RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY (a) Remove the 4 bolts. (b) Pull the radio receiver with heater control panel assembly toward the rear of the vehicle and disengage the 4 clips. (c) Disconnect each connector and remove the radio receiver with heater control panel assembly. E129175 AV AUDIO / VISUAL – RADIO RECEIVER AV–147 12. REMOVE RADIO NO. 1 BRACKET (a) Remove the 5 bolts and radio No. 1 bracket. E129176 13. REMOVE RADIO NO. 2 BRACKET (a) Remove the 5 bolts and radio No. 2 bracket. E129177 14. REMOVE RADIO RECEIVER ASSEMBLY (a) Remove the radio receiver assembly as shown in the illustration. E129178 INSTALLATION 1. INSTALL RADIO RECEIVER ASSEMBLY (a) Install the radio receiver assembly as shown in the illustration. 2. INSTALL RADIO NO. 2 BRACKET (a) Install the radio No. 2 bracket with the 5 bolts. E129179 E129177 AV AV–148 AUDIO / VISUAL – RADIO RECEIVER 3. INSTALL RADIO NO. 1 BRACKET (a) Install the radio No. 1 bracket with the 5 bolts. 4. INSTALL RADIO RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY (a) Connect each connector. (b) Engage the 4 clips. (c) Install the radio receiver with heater control panel assembly with the 4 bolts. 5. INSTALL INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY (See page IP-52) 6. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (See page IP-52) 7. INSTALL UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Automatic Transaxle) (See page IP53) 8. INSTALL UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Manual Transaxle) (See page IP-53) 9. INSTALL FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-53) E129176 E129175 10. INSTALL UPPER CONSOLE PANEL (for Manual Transaxle) (See page IP-54) 11. INSTALL NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-54) 12. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-55) 13. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-55) 14. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) (See page IP-55) AV AV–149 AUDIO / VISUAL – STEREO COMPONENT AMPLIFIER STEREO COMPONENT AMPLIFIER BODY ELECTRICAL AUDIO / VISUAL COMPONENTS FRONT SEAT ASSEMBLY RH 37 (377, 27) 37 (377, 27) SEAT TRACK COVER RH SEAT TRACK BRACKET COVER INNER RH AUDIO AMPLIFIER COVER AV STEREO COMPONENT AMPLIFIER ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque E129196E01 AV–150 AUDIO / VISUAL – STEREO COMPONENT AMPLIFIER REMOVAL AV E129197 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait for 90 seconds after disconnecting the cable to prevent the airbag working. 2. REMOVE SEAT TRACK COVER RH (for Manual Seat) HINT: Use the same procedures for the RH side and the LH side (see page SE-16). 3. REMOVE SEAT TRACK BRACKET COVER INNER RH (for Manual Seat) HINT: Use the same procedures for the RH side and the LH side (see page SE-16). 4. REMOVE FRONT SEAT ASSEMBLY RH (for Manual Seat) HINT: Use the same procedures for the RH side and the LH side (see page SE-16). 5. REMOVE SEAT TRACK COVER RH (for Power Seat) HINT: Use the same procedures for the RH side and the LH side (see page SE-30). 6. REMOVE SEAT TRACK BRACKET COVER INNER RH (for Power Seat) HINT: Use the same procedures for the RH side and the LH side (see page SE-30). 7. REMOVE FRONT SEAT ASSEMBLY RH (for Power Seat) HINT: Use the same procedures for the RH side and the LH side (see page SE-30). 8. REMOVE AUDIO AMPLIFIER COVER (a) Remove the 2 clips and audio amplifier cover. AUDIO / VISUAL – STEREO COMPONENT AMPLIFIER 9. AV–151 REMOVE STEREO COMPONENT AMPLIFIER ASSEMBLY (a) Disconnect each connector and remove the bolt. (b) Disengage the clip. E129198 (c) Remove the bolt and stereo component amplifier assembly as shown in the illustration. E129199 INSTALLATION 1. INSTALL STEREO COMPONENT AMPLIFIER ASSEMBLY (a) Install the stereo component amplifier assembly as shown in the illustration. E129200 (b) Install the bolt and connect each connector. (c) Engage the clip. (d) Install the bolt. AV E129198 AV–152 AUDIO / VISUAL – STEREO COMPONENT AMPLIFIER 2. INSTALL AUDIO AMPLIFIER COVER (a) Install the audio amplifier cover with the 2 clips. 3. INSTALL FRONT SEAT ASSEMBLY RH (for Manual Seat) HINT: Use the same procedures for the RH side and the LH side (see page SE-24). 4. INSTALL SEAT TRACK BRACKET COVER INNER RH (for Manual Seat) HINT: Use the same procedures for the RH side and the LH side (see page SE-25). 5. INSTALL SEAT TRACK COVER RH (for Manual Seat) HINT: Use the same procedures for the RH side and the LH side (see page SE-25). 6. INSTALL FRONT SEAT ASSEMBLY RH (for Power Seat) HINT: Use the same procedures for the RH side and the LH side (see page SE-41). 7. INSTALL SEAT TRACK BRACKET COVER INNER RH (for Power Seat) HINT: Use the same procedures for the RH side and the LH side (see page SE-42). 8. INSTALL SEAT TRACK COVER RH (for Power Seat) HINT: Use the same procedures for the RH side and the LH side (see page SE-42). 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL E129197 10. PERFORM ZERO POINT CALIBRATION AND SENSITIVITY CHECK (See page RS-242) AV AUDIO / VISUAL – FRONT SIDE SPEAKER AV–153 FRONT SIDE SPEAKER BODY ELECTRICAL AUDIO / VISUAL COMPONENTS FRONT DOOR LOWER FRAME BRACKET GARNISH FRONT DOOR INNER GLASS WEATHERSTRIP FRONT DOOR INSIDE HANDLE BEZEL PLUG FRONT NO. 1 SPEAKER ASSEMBLY FRONT DOOR TRIM BOARD SUB-ASSEMBLY AV ASSIST GRIP COVER COURTESY LIGHT ASSEMBLY E129163E01 AV–154 AUDIO / VISUAL – FRONT SIDE SPEAKER INSTRUMENT PANEL NO. 2 SPEAKER PANEL SUB-ASSEMBLY for Premium Audio System: FRONT PILLAR GARNISH FRONT NO. 2 SPEAKER ASSEMBLY FRONT NO. 2 SPEAKER ASSEMBLY E129165E01 AV AUDIO / VISUAL – FRONT SIDE SPEAKER AV–155 ON-VEHICLE INSPECTION 1. INSPECT FRONT NO. 1 SPEAKER HINT: Remove interior parts so that the front No. 1 speaker can be seen. (a) Check the speaker installation. OK: The speaker is securely installed. If the result is not as specified, reinstall the front No. 1 speaker. (b) Visually check the speaker. OK: The cone paper of the speaker is not torn. If the result is not as specified, replace the front No. 1 speaker. (c) Speaker resistance check (1) Disconnect the front No. 1 speaker connector. (2) Measure the resistance between the terminals of the speaker. Standard resistance: Premium Model: 1.8 to 2.6 Ω Standard Model: Approximately 4 Ω If the result is not as specified, replace the front No. 1 speaker. 2. INSPECT FRONT NO. 2 SPEAKER HINT: Remove interior parts so that the front No. 2 speaker can be seen. (a) Check the speaker installation. OK: The speaker is securely installed. If the result is not as specified, reinstall the front No. 2 speaker. (b) Visually check the speaker. OK: The cone paper of the speaker is not torn. If the result is not as specified, replace the front No. 2 speaker. AV AV–156 AUDIO / VISUAL – FRONT SIDE SPEAKER REMOVAL 1. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH (See page ED-14) 2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG (See page ED-14) 3. REMOVE ASSIST GRIP COVER (See page ED-15) 4. REMOVE COURTESY LIGHT ASSEMBLY (See page ED-15) 5. REMOVE FRONT DOOR TRIM BOARD SUBASSEMBLY (See page ED-15) 6. REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP (See page ED-16) 7. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY (a) Disconnect the connector. (b) Remove the 4 bolts and front No. 1 speaker assembly. NOTICE: Do not touch the cone part of the speaker. 8. REMOVE FRONT PILLAR GARNISH (See page IR-27) 9. REMOVE INSTRUMENT PANEL NO. 2 SPEAKER PANEL SUB-ASSEMBLY (a) Engage the 6 claws and 2 clips. (b) Remove the instrument panel No. 2 speaker panel sub-assembly. E129164 Guide E129166E01 10. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (a) Remove the 2 bolts and front No. 2 speaker assembly. (b) Disconnect the connector. AV E129167 AUDIO / VISUAL – FRONT SIDE SPEAKER AV–157 INSTALLATION 1. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (a) Connect the connector. (b) Install the front No. 2 speaker assembly with the 2 bolts. E129167 2. INSTALL INSTRUMENT PANEL NO. 2 SPEAKER PANEL SUB-ASSEMBLY (a) Engage the 6 claws and 2 clips and install the instrument panel No. 2 speaker panel subassembly. 3. INSTALL FRONT PILLAR GARNISH (See page IR-51) 4. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY (a) Install the front No. 1 speaker assembly with the 4 bolts. (b) Connect the connector. 5. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP (See page ED-32) 6. INSTALL FRONT DOOR TRIM BOARD SUBASSEMBLY (See page ED-33) 7. INSTALL COURTESY LIGHT ASSEMBLY (See page ED-34) 8. INSTALL ASSIST GRIP COVER (See page ED-34) 9. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG (See page ED-34) Guide E129974E01 E129164 10. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH (See page ED-34) AV AV–158 AUDIO / VISUAL – REAR SIDE SPEAKER REAR SIDE SPEAKER BODY ELECTRICAL AUDIO / VISUAL COMPONENTS for Fixed Seat Type: REAR SEAT HEADREST ASSEMBLY REAR CENTER SEAT HEADREST ASSEMBLY REAR SEAT BACK ASSEMBLY 18 (184, 13) 18 (184, 13) AV REAR SEAT CUSHION ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B136589E02 AV–159 AUDIO / VISUAL – REAR SIDE SPEAKER for Fold Down Seat Type: REAR SEAT HEADREST ASSEMBLY REAR CENTER SEAT HEADREST ASSEMBLY 18 (184, 13) 18 (184, 13) 18 (184, 13) REAR SIDE SEAT BACK ASSEMBLY RH SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH 18 (184, 13) REAR SEAT CUSHION ASSEMBLY REAR SIDE SEAT BACK ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque B136564E02 AV AV–160 AUDIO / VISUAL – REAR SIDE SPEAKER for Reclining Seat Type: REAR SEAT HEADREST ASSEMBLY 18 (184, 13) REAR CENTER SEAT HEADREST ASSEMBLY CENTER SEAT BACK ASSEMBLY REAR SEAT BACK COVER 18 (184, 13) 18 (184, 13) 18 (184, 13) SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH REAR SEAT BACK COVER 18 (184, 13) SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH AV REAR SEAT CUSHION ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B139095E03 AUDIO / VISUAL – REAR SIDE SPEAKER AV–161 ROOF SIDE INNER GARNISH RH REAR DOOR OPENING TRIM WEATHERSTRIP RH for Reclining Seat Type: 18 (184, 13) RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY RH REAR DOOR SCUFF PLATE RH ROOF SIDE INNER GARNISH LH for Reclining Seat Type: REAR DOOR OPENING TRIM WEATHERSTRIP LH 18 (184, 13) RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY LH REAR DOOR SCUFF PLATE LH AV N*m (kgf*cm, ft.*lbf) : Specified torque B132018E01 AV–162 AUDIO / VISUAL – REAR SIDE SPEAKER REAR SEAT SHOULDER BELT COVER REAR SEAT SHOULDER BELT HOLE COVER 42 (428, 31) PACKAGE TRAY TRIM PANEL ASSEMBLY Reclining Seat Type: REAR SEAT OUTER BELT ASSEMBLY 42 (428, 31) REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH REAR SEAT OUTER BELT ASSEMBLY PACKAGE TRAY TRIM PANEL ASSEMBLY REAR SPEAKER ASSEMBLY REAR SPEAKER ASSEMBLY for Premium Audio System: AV REAR SPEAKER ASSEMBLY REAR SPEAKER ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque E129168E01 AV–163 AUDIO / VISUAL – REAR SIDE SPEAKER ON-VEHICLE INSPECTION 1. (2) Measure the resistance between the terminals of the speaker. Standard resistance (Premium Model (Only Woofer Speaker)) Premium Model: Woofer (+) Woofer (-) Tweeter (+) Tweeter (-) E129809E02 INSPECT REAR SPEAKER HINT: Remove interior parts so that the rear speaker can be seen. (a) Check the speaker installation. OK: The speaker is securely installed. If the result is not as specified, reinstall the rear speaker. (b) Visually check the speaker. OK: The cone paper of the speaker is not torn. If the result is not as specified, replace the rear speaker. (c) Speaker resistance check (1) Disconnect the rear speaker connector. Tester connection Condition Specified condition 2-4 Always 1.8 to 2.6 Ω Standard resistance (Standard Model): Approximately 4 Ω If the result is not as specified, replace the rear speaker. AV AV–164 AUDIO / VISUAL – REAR SIDE SPEAKER REMOVAL 1. REMOVE REAR SEAT HEADREST ASSEMBLY 2. REMOVE REAR CENTER SEAT HEADREST ASSEMBLY 3. REMOVE REAR SEAT CUSHION ASSEMBLY (See page SE-62) 4. REMOVE REAR SEAT BACK ASSEMBLY (for Fixed Seat Type) (See page SE-77) 5. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) (See page SE-47) 6. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-47) 7. REMOVE REAR SIDE SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-48) 8. REMOVE REAR SIDE SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) (See page SE-48) 9. REMOVE REAR SEAT BACK COVER (for Reclining Seat Type) (See page SE-63) 10. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Reclining Seat Type) (See page SE-63) 11. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Reclining Seat Type) (See page SE-64) 12. REMOVE CENTER SEAT BACK ASSEMBLY (for Reclining Seat Type) (See page SE-64) 13. REMOVE REAR DOOR SCUFF PLATE LH (See page IR-24) 14. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Reclining Seat Type) 15. REMOVE REAR DOOR SCUFF PLATE RH (See page IR-24) 16. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH (for Reclining Seat Type) AV 17. REMOVE RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY LH (for Reclining Seat Type) (See page SE-68) 18. REMOVE RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY RH (for Reclining Seat Type) 19. DISCONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH (for TMC Made) (See page SB35) AUDIO / VISUAL – REAR SIDE SPEAKER AV–165 20. DISCONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH (for TMMK Made) (See page SB-35) 21. REMOVE ROOF SIDE INNER GARNISH LH (See page IR-26) 22. REMOVE ROOF SIDE INNER GARNISH RH (See page IR-26) 23. DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) (See page SB-50) 24. DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) (See page SB-50) 25. REMOVE REAR SEAT SHOULDER BELT COVER (See page SB-50) 26. REMOVE REAR SEAT SHOULDER BELT HOLE COVER (See page SB-51) 27. REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY (See page SB-37) 28. REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY (for Reclining Seat Type) (See page SB-37) 29. REMOVE REAR SPEAKER ASSEMBLY (for LH Side) (a) Turn up the partition pad. (b) Disconnect the connector. (c) Remove the 4 bolts and the rear speaker assembly. 30. REMOVE REAR SPEAKER ASSEMBLY (for RH Side) (a) Turn up the partition pad. E129170 (b) Disconnect the connector. (c) Remove the 4 bolts and the rear speaker assembly. AV E129169 AV–166 AUDIO / VISUAL – REAR SIDE SPEAKER INSTALLATION 1. INSTALL REAR SPEAKER ASSEMBLY (for RH Side) (a) Install the rear speaker assembly with the 4 bolts. (b) Connect the connector. (c) Install the partition pad. 2. INSTALL REAR SPEAKER ASSEMBLY (for LH Side) (a) Install the rear speaker assembly with the 4 bolts. (b) Connect the connector. (c) Install the partition pad. 3. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY (See page SB-38) 4. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY (for Reclining Seat Type) (See page SB-39) 5. INSTALL REAR SEAT SHOULDER BELT HOLE COVER (See page SB-51) 6. INSTALL REAR SEAT SHOULDER BELT COVER (See page SB-52) 7. CONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) (See page SB-52) 8. CONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) (See page SB-52) 9. INSTALL ROOF SIDE INNER GARNISH LH (See page IR-52) E129169 E129170 10. INSTALL ROOF SIDE INNER GARNISH RH (See page IR-52) 11. CONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH (for TMC Made) (See page SB-40) 12. CONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH (for TMMK Made) (See page SB-40) 13. INSTALL RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY LH (for Reclining Seat Type) (See page SE-69) AV 14. INSTALL RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY RH (for Reclining Seat Type) (See page SB-53) 15. CONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Reclining Seat Type) (See page IR-55) 16. INSTALL REAR DOOR SCUFF PLATE LH (See page IR-56) AUDIO / VISUAL – REAR SIDE SPEAKER AV–167 17. CONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH (for Reclining Seat Type) (See page IR-56) 18. INSTALL REAR DOOR SCUFF PLATE RH (See page IR-56) 19. INSTALL CENTER SEAT BACK ASSEMBLY (for Reclining Seat Type) (See page SE-71) 20. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Reclining Seat Type) (See page SE-72) 21. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Reclining Seat Type) (See page SE-71) 22. INSTALL REAR SEAT BACK COVER (for Reclining Seat Type) 23. INSTALL REAR SIDE SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-57) 24. INSTALL REAR SIDE SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) 25. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-57) 26. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) (See page SE-57) 27. INSTALL REAR SEAT BACK ASSEMBLY (for Fixed Seat Type) (See page SE-84) 28. INSTALL REAR SEAT CUSHION ASSEMBLY (See page SE-58) 29. INSTALL REAR CENTER SEAT HEADREST ASSEMBLY 30. INSTALL REAR SEAT HEADREST ASSEMBLY AV AUDIO / VISUAL – RADIO ANTENNA CORD AV–193 REMOVAL 1. PRECAUTION (See page IP-1) 2. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment (See page RS-1). 4. REMOVE LOWER NO. 3 STEERING WHEEL COVER (See page RS-349) 5. REMOVE LOWER NO. 2 STEERING WHEEL COVER (See page RS-349) 6. REMOVE STEERING PAD (See page RS-350) 7. REMOVE STEERING WHEEL ASSEMBLY (See page SR-38) 8. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-24) 9. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-25) 10. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (See page IP-20) 11. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (See page IP-21) 12. REMOVE STEERING COLUMN COVER (for TMC Made) (See page IP-21) 13. REMOVE STEERING COLUMN COVER (for TMMK Made) (See page IP-21) 14. REMOVE TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY (See page SR-39) 15. REMOVE NO. 1 INSTRUMENT PANEL SUBASSEMBLY (See page IP-22) 16. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (w/o Smart Key System) (See page IP-22) 17. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (w/ Smart Key System) (See page IP-22) 18. REMOVE INSTRUMENT CLUSTER FINISH PANEL (See page IP-22) 19. REMOVE COMBINATION METER ASSEMBLY (for TMC Made) (See page IP-23) 20. REMOVE COMBINATION METER ASSEMBLY (for TMMK Made) (See page IP-23) 21. REMOVE FRONT DOOR SCUFF PLATE RH (See page IR-26) AV AV–194 AUDIO / VISUAL – RADIO ANTENNA CORD 22. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH 23. REMOVE INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY (See page IP-23) 24. REMOVE LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMC Made) (See page IP-23) 25. REMOVE LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMMK Made) (See page IP-24) 26. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-24) 27. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) (See page IP-24) 28. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-24) 29. REMOVE NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-25) 30. REMOVE FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-25) 31. REMOVE UPPER CONSOLE PANEL (for Manual Transaxle) (See page IP-25) 32. REMOVE UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Automatic Transaxle) (See page IP26) 33. REMOVE UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Manual Transaxle) (See page IP-26) 34. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMC Made) (See page IP-27) 35. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMMK Made) (See page IP-27) 36. REMOVE INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY (See page IP-27) 37. REMOVE RADIO RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY (w/o Navigation System) (See page AV-146) 38. REMOVE NAVIGATION RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY (See page NS-195) AV 39. REMOVE CONSOLE BOX POCKET (See page IP-28) 40. REMOVE CONSOLE BOX CARPET (See page IP-28) 41. REMOVE CONSOLE BOX ASSEMBLY (for TMC Made) (See page IP-28) 42. REMOVE CONSOLE BOX ASSEMBLY (for TMMK Made) (See page IP-29) 43. REMOVE NO. 2 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-29) AUDIO / VISUAL – RADIO ANTENNA CORD AV–195 44. REMOVE NO. 2 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-30) 45. REMOVE NO. 1 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-30) 46. REMOVE NO. 1 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-30) 47. REMOVE FRONT PILLAR GARNISH LH (See page IR27) 48. REMOVE INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY (See page IP-31) 49. REMOVE INSTRUMENT PANEL NO. 1 SPEAKER PANEL SUB-ASSEMBLY (See page IP-31) 50. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (for LH Side) (See page AV-156) 51. REMOVE FRONT PILLAR GARNISH RH (See page IR27) 52. REMOVE INSTRUMENT PANEL NO. 3 REGISTER ASSEMBLY (See page IP-31) 53. REMOVE INSTRUMENT PANEL NO. 2 SPEAKER PANEL SUB-ASSEMBLY (See page IP-32) 54. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (for RH Side) HINT: Use the same procedures for the RH side and the LH side (See page AV-156). 55. REMOVE NO. 1 DEFROSTER NOZZLE GARNISH (See page IP-32) 56. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY (for TMC Made) (See page IP-32) 57. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY (for TMMK Made) (See page IP-34) 58. REMOVE SIDE NO. 1 DEFROSTER NOZZLE DUCT (for TMC Made) (See page IP-37) 59. REMOVE SIDE NO. 1 DEFROSTER NOZZLE DUCT (for TMMK Made) (See page IP-37) 60. REMOVE SIDE NO. 2 DEFROSTER NOZZLE DUCT (for TMC Made) (See page IP-38) 61. REMOVE SIDE NO. 2 DEFROSTER NOZZLE DUCT (for TMMK Made) (See page IP-38) 62. REMOVE DEFROSTER NOZZLE ASSEMBLY (for TMC Made) (See page IP-38) 63. REMOVE DEFROSTER NOZZLE ASSEMBLY (for TMMK Made) (See page IP-38) 64. REMOVE NO. 1 HEATER TO REGISTER DUCT (for TMC Made) (See page IP-38) AV AV–196 AUDIO / VISUAL – RADIO ANTENNA CORD 65. REMOVE NO. 1 HEATER TO REGISTER DUCT (for TMMK Made) (See page IP-39) 66. REMOVE NO. 3 HEATER TO REGISTER DUCT (for TMC Made) (See page IP-39) 67. REMOVE NO. 3 HEATER TO REGISTER DUCT (for TMMK Made) (See page IP-39) 68. REMOVE NO. 2 HEATER TO REGISTER DUCT (for TMC Made) (See page IP-39) 69. REMOVE NO. 2 HEATER TO REGISTER DUCT (for TMMK Made) (See page IP-39) 70. REMOVE NO. 2 ANTENNA CORD SUB-ASSEMBLY (a) Disengage the 6 clamps and clip and remove the No. 2 antenna cord sub-assembly. Clamp E129184E01 71. REMOVE FRONT SEAT HEADREST ASSEMBLY (for Manual Seat) 72. REMOVE SEAT TRACK COVER LH (for Manual Seat) (See page SE-16) 73. REMOVE INNER SEAT TRACK BRACKET COVER LH (for Manual Seat) (See page SE-16) 74. REMOVE FRONT SEAT ASSEMBLY LH (for Manual Seat) (See page SE-16) 75. REMOVE FRONT SEAT HEADREST ASSEMBLY (for Power Seat) AV 76. REMOVE SEAT TRACK COVER LH (for Power Seat) (See page SE-30) 77. REMOVE SEAT TRACK COVER RH (for Power Seat) (See page SE-30) 78. REMOVE FRONT SEAT ASSEMBLY LH (for Power Seat) (See page SE-30) 79. REMOVE FRONT SEAT HEADREST ASSEMBLY (for Manual Seat) AUDIO / VISUAL – RADIO ANTENNA CORD AV–197 80. REMOVE SEAT TRACK COVER RH (for Manual Seat) (See page IR-22) 81. REMOVE INNER SEAT TRACK BRACKET COVER RH (for Manual Seat) (See page IR-22) 82. REMOVE FRONT SEAT ASSEMBLY RH (for Manual Seat) (See page IR-22) 83. REMOVE FRONT SEAT HEADREST ASSEMBLY (for Power Seat) 84. REMOVE SEAT TRACK COVER RH (for Power Seat) (See page IR-22) 85. REMOVE SEAT TRACK COVER LH (for Power Seat) (See page IR-23) 86. REMOVE FRONT SEAT ASSEMBLY RH (for Power Seat) (See page IR-23) 87. REMOVE REAR SEAT CUSHION ASSEMBLY (See page SE-77) 88. REMOVE REAR SEAT HEADREST ASSEMBLY 89. REMOVE REAR CENTER SEAT HEADREST ASSEMBLY 90. REMOVE REAR SEAT BACK ASSEMBLY (for Fixed Seat Type) (See page SE-77) 91. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-47) 92. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) (See page SE-47) 93. REMOVE REAR SIDE SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-48) 94. REMOVE REAR SIDE SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) (See page SE-48) 95. REMOVE REAR SEAT BACK COVER (for Reclining Seat Type) (See page SE-63) 96. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Reclining Seat Type) (See page SE-63) 97. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Reclining Seat Type) (See page SE-64) 98. REMOVE CENTER SEAT BACK ASSEMBLY (for Reclining Seat Type) (See page SE-64) 99. REMOVE REAR DOOR SCUFF PLATE LH (See page IR-24) 100. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH AV AV–198 AUDIO / VISUAL – RADIO ANTENNA CORD 101. REMOVE REAR DOOR SCUFF PLATE RH (See page IR-24) 102. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH 103. REMOVE RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY LH (for Reclining Seat Type) (See page SE-68) 104. REMOVE RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY RH (for Reclining Seat Type) 105. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG LH (See page ED-38) 106. REMOVE DOOR ASSIST GRIP COVER LH (See page ED-38) 107. REMOVE REAR DOOR TRIM BOARD SUBASSEMBLY LH (See page ED-39) 108. REMOVE REAR DOOR INNER GLASS WEATHERSTRIP LH (See page ED-40) 109. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-24) 110. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-25) 111. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH 112. REMOVE LAP BELT OUTER ANCHOR COVER (See page IR-25) 113. DISCONNECT FRONT SEAT OUTER BELT ASSEMBLY LH (See page IR-25) 114. REMOVE LOWER CENTER PILLAR GARNISH LH (See page IR-25) 115. REMOVE UPPER CENTER PILLAR GARNISH LH (See page IR-26) 116. REMOVE FRONT DOOR SCUFF PLATE RH (See page IR-26) 117. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH (See page IR-26) AV 118. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH 119. REMOVE LAP BELT OUTER ANCHOR COVER (See page IR-26) 120. DISCONNECT FRONT SEAT OUTER BELT ASSEMBLY RH (See page IR-26) 121. REMOVE LOWER CENTER PILLAR GARNISH RH (See page IR-26) 122. REMOVE UPPER CENTER PILLAR GARNISH RH (See page IR-26) AUDIO / VISUAL – RADIO ANTENNA CORD AV–199 123. REMOVE ROOF SIDE INNER GARNISH LH (See page IR-26) 124. REMOVE ROOF SIDE INNER GARNISH RH (See page IR-26) 125. REMOVE FRONT PILLAR GARNISH LH (See page IR27) 126. REMOVE FRONT PILLAR GARNISH RH (See page IR27) 127. REMOVE ROOF CONSOLE BOX ASSEMBLY (See page IR-28) 128. REMOVE VISOR ASSEMBLY LH (See page IR-28) 129. REMOVE VISOR ASSEMBLY RH (See page IR-29) 130. REMOVE VISOR HOLDER (See page IR-29) 131. REMOVE FRONT ASSIST GRIP SUB-ASSEMBLY (See page IR-29) 132. REMOVE REAR ASSIST GRIP SUB-ASSEMBLY (See page IR-29) 133. REMOVE NO. 1 ROOM LIGHT ASSEMBLY (w/o Sliding Roof) (See page IR-30) 134. REMOVE SPOT LIGHT ASSEMBLY (w/ Sliding Roof) (See page IR-30) 135. REMOVE SUN ROOF OPENING TRIM MOULDING (w/ Sliding Roof) (See page IR-31) 136. REMOVE SUNSHADE TRIM HOLDER (w/ Rear Sunshade) (See page IR-31) 137. REMOVE ROOF HEADLINING ASSEMBLY (w/o Sliding Roof) (See page IR-31) 138. REMOVE ROOF HEADLINING ASSEMBLY (w/ Sliding Roof) (See page IR-32) 139. REMOVE ANTENNA CORD SUB-ASSEMBLY (a) Peel the strips of the tape used to secure the antenna cord only to the extent that allows removal of the antenna cord. HINT: Tape is not available as a supply part. Try to leave as much tape as possible on the roof headlining so that the tape can be reused. AV AV–200 AUDIO / VISUAL – RADIO ANTENNA CORD (b) Remove the antenna cord from the roof headlining. TMC Made: without Sliding Roof: Tape Tape Front Side Tape with Sliding Roof: Tape Tape Front Side AV Double-sided Tape E129975E01 AV–201 AUDIO / VISUAL – RADIO ANTENNA CORD TMMK Made: without Sliding Roof: Tape Tape Front Side Tape with Sliding Roof: Tape Tape Tape Tape Front Side AV Double-sided Tape E129191E02 AV–202 AUDIO / VISUAL – RADIO ANTENNA CORD INSTALLATION 1. AV INSTALL ANTENNA CORD SUB-ASSEMBLY HINT: The double-sided tape and tape are not available as supply parts. If these tapes still have enough adhesion to secure the roof headlining and antenna cord, reuse the tapes. If the roof headlining has been replaced with a new one, or if the tape and/or the double-sided tape is no longer sticky, apply new tape following the procedures below. AUDIO / VISUAL – RADIO ANTENNA CORD AV–203 (a) Apply new double-sided tape. without Sliding Roof: Front Side with Sliding Roof: Front Side Double-sided Tape 1 mm (0.039 in.) AV 15 mm (0.591 in.) Double-sided Tape E129190E01 (1) Remove the double-sided tape from the roof headlining assembly. AV–204 AUDIO / VISUAL – RADIO ANTENNA CORD (2) Peel off the appropriate amount of new doublesided tape. Be careful not to touch the adhesive surface. (3) Apply the double-sided tape to the roof headlining while aligning the tape with the markings on the roof headlining assembly. (4) Peel off the backing sheet from the doublesided tape. AV AUDIO / VISUAL – RADIO ANTENNA CORD AV–205 (b) Install the antenna cord to the roof headlining assembly from the front of the vehicle. TMC Made: Protrusion Marking Tape without Sliding Roof: Marking Tape Tape Front Side with Sliding Roof: Tape Tape Protrusion Marking Tape Marking Tape Tape Tape Front Side AV Double-sided Tape E129975E03 AV–206 AUDIO / VISUAL – RADIO ANTENNA CORD TMMK Made: Protrusion Marking Tape without Sliding Roof: Marking Tape Tape Tape Tape Front Side with Sliding Roof: Protrusion Marking Tape Marking Tape Tape Tape Tape Front Side AV Double-sided Tape E129191E03 HINT: Align the taped part of the antenna cable with the protrusion of the roof headlining, and apply tape to secure the cable to the headlining. AUDIO / VISUAL – RADIO ANTENNA CORD AV–207 (c) Put the strips of the tape back to the positions shown in the illustration in order to secure the antenna cord to the roof headlining assembly. HINT: • If the tape is no longer sticky, use other tape, such as packing tape, that has enough adhesion to secure the antenna cord to the roof headlining assembly. • For the right front corner of the roof headlining assembly, align the marking tape on the antenna cord with the protrusion of the roof headlining, and wrap tape around the antenna cord and roof headlining assembly once or twice to securely hold them. • For the right rear corner of the roof headlining assembly, align the marking tape on the antenna cord with the rear edge of the roof headlining, and secure the antenna cord to the roof headlining assembly with tape. 2. INSTALL ROOF HEADLINING ASSEMBLY (w/o Sliding Roof) (See page IR-45) 3. INSTALL ROOF HEADLINING ASSEMBLY (w/ Sliding Roof) (See page IR-46) 4. INSTALL SUNSHADE TRIM HOLDER (w/ Rear Sunshade) (See page IR-47) 5. INSTALL SUN ROOF OPENING TRIM MOULDING (w/ Sliding Roof) (See page IR-47) 6. INSTALL SPOT LIGHT ASSEMBLY (w/ Sliding Roof) (See page IR-48) 7. INSTALL NO. 1 ROOM LIGHT ASSEMBLY (w/o Sliding Roof) (See page IR-48) 8. INSTALL FRONT ASSIST GRIP SUB-ASSEMBLY (See page IR-49) 9. INSTALL REAR ASSIST GRIP SUB-ASSEMBLY (See page IR-49) 10. INSTALL VISOR HOLDER (See page IR-49) 11. INSTALL VISOR ASSEMBLY LH (See page IR-50) 12. INSTALL VISOR ASSEMBLY RH (See page IR-50) 13. INSTALL ROOF CONSOLE BOX ASSEMBLY (See page IR-50) 14. INSTALL FRONT PILLAR GARNISH LH (See page IR51) 15. INSTALL FRONT PILLAR GARNISH RH (See page IR52) 16. INSTALL ROOF SIDE INNER GARNISH LH (See page IR-52) AV AV–208 AUDIO / VISUAL – RADIO ANTENNA CORD 17. INSTALL ROOF SIDE INNER GARNISH RH (See page IR-52) 18. INSTALL UPPER CENTER PILLAR GARNISH LH (See page IR-53) 19. INSTALL LOWER CENTER PILLAR GARNISH LH (See page IR-53) 20. CONNECT FRONT SEAT OUTER BELT ASSEMBLY LH (See page IR-53) 21. INSTALL LAP BELT OUTER ANCHOR COVER (See page IR-53) 22. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH (See page IR-54) 23. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-54) 24. INSTALL FRONT DOOR SCUFF PLATE LH (See page IR-54) 25. INSTALL UPPER CENTER PILLAR GARNISH RH (See page IR-54) 26. INSTALL LOWER CENTER PILLAR GARNISH RH (See page IR-54) 27. CONNECT FRONT SEAT OUTER BELT ASSEMBLY RH (See page IR-54) 28. INSTALL LAP BELT OUTER ANCHOR COVER (See page IR-54) 29. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH (See page IR-55) 30. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH (See page IR-55) 31. INSTALL FRONT DOOR SCUFF PLATE RH (See page IR-55) 32. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP LH (See page ED-54) 33. INSTALL REAR DOOR TRIM BOARD SUBASSEMBLY LH (See page ED-55) 34. INSTALL DOOR ASSIST GRIP COVER LH (See page ED-56) AV 35. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG LH (See page ED-56) 36. INSTALL RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY LH (for Reclining Seat Type) (See page SE-69) 37. INSTALL RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY RH (for Reclining Seat Type) 38. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (See page IR-55) AUDIO / VISUAL – RADIO ANTENNA CORD AV–209 39. INSTALL REAR DOOR SCUFF PLATE LH (See page IR-56) 40. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH (See page IR-56) 41. INSTALL REAR DOOR SCUFF PLATE RH (See page IR-56) 42. INSTALL CENTER SEAT BACK ASSEMBLY (for Reclining Seat Type) (See page SE-71) 43. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Reclining Seat Type) (See page SE-72) 44. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Reclining Seat Type) (See page SE-71) 45. INSTALL REAR SEAT BACK COVER (for Reclining Seat Type) 46. INSTALL REAR SIDE SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-57) 47. INSTALL REAR SIDE SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) 48. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-57) 49. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) (See page SE-57) 50. INSTALL REAR SEAT BACK ASSEMBLY (for Fixed Seat Type) (See page SE-84) 51. INSTALL REAR CENTER SEAT HEADREST ASSEMBLY 52. INSTALL REAR SEAT HEADREST ASSEMBLY 53. INSTALL REAR SEAT CUSHION ASSEMBLY (See page SE-58) 54. INSTALL FRONT SEAT ASSEMBLY LH (for Power Seat) (See page SE-41) 55. INSTALL SEAT TRACK COVER RH (for Power Seat) (See page SE-42) 56. INSTALL SEAT TRACK COVER LH (for Power Seat) (See page SE-42) 57. INSTALL FRONT SEAT HEADREST ASSEMBLY (for Power Seat) 58. INSTALL FRONT SEAT ASSEMBLY LH (for Manual Seat) (See page SE-24) 59. INSTALL INNER SEAT TRACK BRACKET COVER LH (for Manual Seat) (See page SE-25) AV AV–210 AUDIO / VISUAL – RADIO ANTENNA CORD 60. INSTALL SEAT TRACK COVER LH (for Manual Seat) (See page SE-25) 61. INSTALL FRONT SEAT HEADREST ASSEMBLY (for Manual Seat) 62. INSTALL FRONT SEAT ASSEMBLY RH (for Power Seat) (See page IR-57) 63. INSTALL SEAT TRACK COVER LH (for Power Seat) (See page IR-57) 64. INSTALL SEAT TRACK COVER RH (for Power Seat) (See page IR-57) 65. INSTALL FRONT SEAT HEADREST ASSEMBLY (for Power Seat) 66. INSTALL FRONT SEAT ASSEMBLY RH (for Manual Seat) (See page IR-57) 67. INSTALL INNER SEAT TRACK BRACKET COVER RH (for Manual Seat) (See page IR-58) 68. INSTALL SEAT TRACK COVER RH (for Manual Seat) (See page IR-58) 69. INSTALL FRONT SEAT HEADREST ASSEMBLY (for Manual Seat) 70. INSTALL NO. 2 ANTENNA CORD SUB-ASSEMBLY (a) Engage the 6 clamps and clip and install the No. 2 antenna cord sub-assembly. Clamp E129184E01 AV 71. INSTALL NO. 2 HEATER TO REGISTER DUCT (for TMC Made) (See page IP-41) 72. INSTALL NO. 2 HEATER TO REGISTER DUCT (for TMMK Made) (See page IP-41) 73. INSTALL NO. 3 HEATER TO REGISTER DUCT (for TMC Made) (See page IP-41) 74. INSTALL NO. 3 HEATER TO REGISTER DUCT (for TMMK Made) (See page IP-41) AUDIO / VISUAL – RADIO ANTENNA CORD AV–211 75. INSTALL NO. 1 HEATER TO REGISTER DUCT (for TMC Made) (See page IP-42) 76. INSTALL NO. 1 HEATER TO REGISTER DUCT (for TMMK Made) (See page IP-42) 77. INSTALL DEFROSTER NOZZLE ASSEMBLY (for TMC Made) (See page IP-42) 78. INSTALL DEFROSTER NOZZLE ASSEMBLY (for TMMK Made) (See page IP-42) 79. INSTALL SIDE NO. 2 DEFROSTER NOZZLE DUCT (for TMC Made) (See page IP-42) 80. INSTALL SIDE NO. 2 DEFROSTER NOZZLE DUCT (for TMMK Made) (See page IP-43) 81. INSTALL SIDE NO. 1 DEFROSTER NOZZLE DUCT (for TMC Made) (See page IP-43) 82. INSTALL SIDE NO. 1 DEFROSTER NOZZLE DUCT (for TMMK Made) (See page IP-43) 83. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY (for TMC Made) (See page IP-44) 84. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY (for TMMK Made) (See page IP-45) 85. INSTALL NO. 1 DEFROSTER NOZZLE GARNISH (See page IP-48) 86. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (for LH Side) (See page AV-156) 87. INSTALL INSTRUMENT PANEL NO. 1 SPEAKER PANEL SUB-ASSEMBLY (See page IP-48) 88. INSTALL INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY (See page IP-48) 89. INSTALL FRONT PILLAR GARNISH LH (See page IR51) 90. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (for RH Side) HINT: Use the same procedures for the RH side and the LH side (See page AV-156). 91. INSTALL INSTRUMENT PANEL NO. 2 SPEAKER PANEL SUB-ASSEMBLY (See page IP-49) 92. INSTALL INSTRUMENT PANEL NO. 3 REGISTER ASSEMBLY (See page IP-49) 93. INSTALL FRONT PILLAR GARNISH RH (See page IR52) 94. INSTALL NO. 1 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-49) 95. INSTALL NO. 1 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-50) AV AV–212 AUDIO / VISUAL – RADIO ANTENNA CORD 96. INSTALL NO. 2 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-50) 97. INSTALL NO. 2 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-50) 98. INSTALL CONSOLE BOX ASSEMBLY (for TMC Made) (See page IP-51) 99. INSTALL CONSOLE BOX ASSEMBLY (for TMMK Made) (See page IP-51) 100. INSTALL CONSOLE BOX CARPET (See page IP-51) 101. INSTALL CONSOLE BOX POCKET (See page IP-51) 102. INSTALL RADIO RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY (w/o Navigation System) (See page AV-147) 103. INSTALL NAVIGATION RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY (w/ Navigation System) (See page NS-196) 104. INSTALL INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY (See page IP-52) 105. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMC Made) (See page IP-52) 106. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMMK Made) (See page IP-52) 107. INSTALL UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Automatic Transaxle) (See page IP53) 108. INSTALL UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Manual Transaxle) (See page IP-53) 109. INSTALL FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-53) 110. INSTALL UPPER CONSOLE PANEL (for Manual Transaxle) (See page IP-54) 111. INSTALL NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-54) 112. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-55) AV 113. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-55) 114. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) (See page IP-55) 115. INSTALL LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMC Made) (See page IP-55) 116. INSTALL LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMMK Made) (See page IP-56) AUDIO / VISUAL – RADIO ANTENNA CORD AV–213 117. INSTALL INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY (See page IP-56) 118. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH (See page IR-55) 119. INSTALL FRONT DOOR SCUFF PLATE RH (See page IR-55) 120. INSTALL COMBINATION METER ASSEMBLY (for TMC Made) (See page IP-56) 121. INSTALL COMBINATION METER ASSEMBLY (for TMMK Made) (See page IP-56) 122. INSTALL INSTRUMENT CLUSTER FINISH PANEL (See page IP-57) 123. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/o Smart Key System) (See page IP-57) 124. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/ Smart Key System) (See page IP-57) 125. INSTALL NO. 1 INSTRUMENT PANEL SUBASSEMBLY (See page IP-57) 126. INSTALL TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY 127. ADJUST SPIRAL CABLE SUB-ASSEMBLY (See page RS-367) 128. INSTALL STEERING COLUMN COVER (for TMC Made) (See page IP-58) 129. INSTALL STEERING COLUMN COVER (for TMMK Made) (See page IP-58) 130. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (See page IP-58) 131. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (See page IP-59) 132. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-54) 133. INSTALL FRONT DOOR SCUFF PLATE LH (See page IR-54) 134. INSTALL STEERING WHEEL ASSEMBLY (See page SR-51) 135. INSTALL STEERING PAD (See page RS-350) 136. INSTALL LOWER NO. 3 STEERING WHEEL COVER (See page RS-351) 137. INSTALL LOWER NO. 2 STEERING WHEEL COVER (See page RS-352) 138. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 139. INSPECT FRONT SEAT ASSEMBLY AV AV–214 AUDIO / VISUAL – RADIO ANTENNA CORD 140. INSPECT FRONT SEAT ADJUSTER ASSEMBLY 141. INSPECT STEERING PAD (See page RS-352) 142. PERFORM ZERO POINT CALIBRATION AND SENSITIVITY CHECK (for Front Passenger Seat) (See page RS-242) 143. INSPECT SRS WARNING LIGHT (See page RS-32) AV AV–168 AUDIO / VISUAL – RADIO ANTENNA CORD RADIO ANTENNA CORD BODY ELECTRICAL AUDIO / VISUAL COMPONENTS for TMC Made: TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY 2.0 (20, 18 in.*lbf) STEERING COLUMN COVER 50 (510, 37) STEERING WHEEL ASSEMBLY LOWER NO. 2 STEERING WHEEL COVER LOWER NO. 3 STEERING WHEEL COVER 8.8 (90, 78 in.*lbf) AV STEERING PAD N*m (kgf*cm, ft.*lbf) : Specified torque B137279E01 AV–169 AUDIO / VISUAL – RADIO ANTENNA CORD for TMMK Made: TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY 2.0 (20, 18 in.*lbf) STEERING COLUMN COVER for 4 Spoke: 50 (510, 37) STEERING WHEEL ASSEMBLY LOWER NO. 2 STEERING WHEEL COVER LOWER NO. 3 STEERING WHEEL COVER STEERING PAD 8.8 (90, 78 in.*lbf) for 3 Spoke: STEERING WHEEL ASSEMBLY 50 (510, 37) LOWER NO. 2 STEERING WHEEL COVER LOWER NO. 3 STEERING WHEEL COVER AV STEERING PAD 8.8 (90, 78 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque B137280E01 AV–170 AUDIO / VISUAL – RADIO ANTENNA CORD for TMC Made: COMBINATION METER ASSEMBLY INSTRUMENT CLUSTER FINISH PANEL without Smart Key System: LOWER INSTRUMENT PANEL FINISH PANEL with Smart Key System: NO. 1 INSTRUMENT PANEL SUB-ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL COWL SIDE TRIM SUB-ASSEMBLY LH COWL SIDE TRIM CLIP AV LOWER INSTRUMENT PANEL FINISH PANEL LH FRONT DOOR SCUFF PLATE LH B137281E01 AV–171 AUDIO / VISUAL – RADIO ANTENNA CORD for TMMK Made: COMBINATION METER ASSEMBLY INSTRUMENT CLUSTER FINISH PANEL without Smart Key System: LOWER INSTRUMENT PANEL FINISH PANEL with Smart Key System: NO. 1 INSTRUMENT PANEL SUB-ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL COWL SIDE TRIM SUB-ASSEMBLY LH COWL SIDE TRIM CLIP or

AV LOWER INSTRUMENT PANEL FINISH PANEL LH FRONT DOOR SCUFF PLATE LH B137281E03 AV–172 AUDIO / VISUAL – RADIO ANTENNA CORD for TMC Made: LOWER INSTRUMENT PANEL SUB-ASSEMBLY or COWL SIDE TRIM SUB-ASSEMBLY RH COWL SIDE TRIM CLIP FRONT DOOR SCUFF PLATE RH INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY B137282E01 AV AUDIO / VISUAL – RADIO ANTENNA CORD AV–173 for TMMK Made: LOWER INSTRUMENT PANEL SUB-ASSEMBLY or

COWL SIDE TRIM SUB-ASSEMBLY RH COWL SIDE TRIM CLIP FRONT DOOR SCUFF PLATE RH INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY B137282E03 AV AV–174 AUDIO / VISUAL – RADIO ANTENNA CORD NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH for Automatic Transaxle: SHIFT LEVER KNOB SUB-ASSEMBLY FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY UPPER CONSOLE REAR PANEL SUB-ASSEMBLY for Manual Transaxle: SHIFT LEVER KNOB SUB-ASSEMBLY UPPER CONSOLE PANEL AV UPPER CONSOLE REAR PANEL SUB-ASSEMBLY B137283E01 AUDIO / VISUAL – RADIO ANTENNA CORD AV–175 for TMC Made: INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY without Navigation System: RADIO RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY with Navigation System: NAVIGATION RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY UPPER CONSOLE PANEL SUB-ASSEMBLY AV B137284E01 AV–176 AUDIO / VISUAL – RADIO ANTENNA CORD for TMMK Made: INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY without Navigation System: RADIO RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY with Navigation System: NAVIGATION RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY AV UPPER CONSOLE PANEL SUB-ASSEMBLY B137284E03 AV–177 AUDIO / VISUAL – RADIO ANTENNA CORD for TMC Made: FRONT PILLAR GARNISH CLIP FRONT PILLAR GARNISH CLIP FRONT PILLAR GARNISH RH FRONT PILLAR GARNISH LH INSTRUMENT PANEL NO. 3 REGISTER ASSEMBLY INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY NO. 1 CONSOLE BOX INSERT FRONT NO. 2 CONSOLE BOX INSERT FRONT CONSOLE BOX CARPET AV CONSOLE BOX ASSEMBLY CONSOLE BOX POCKET Non-reusable part B137285E01 AV–178 AUDIO / VISUAL – RADIO ANTENNA CORD for TMMK Made: FRONT PILLAR GARNISH CLIP FRONT PILLAR GARNISH CLIP FRONT PILLAR GARNISH RH FRONT PILLAR GARNISH LH INSTRUMENT PANEL NO. 3 REGISTER ASSEMBLY INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY NO. 1 CONSOLE BOX INSERT FRONT or or NO. 2 CONSOLE BOX INSERT FRONT CONSOLE BOX CARPET AV CONSOLE BOX ASSEMBLY CONSOLE BOX POCKET Non-reusable part B137285E03 AV–179 AUDIO / VISUAL – RADIO ANTENNA CORD for TMC Made: INSTRUMENT PANEL NO. 1 SPEAKER PANEL SUB-ASSEMBLY INSTRUMENT PANEL NO. 2 SPEAKER PANEL SUB-ASSEMBLY NO. 1 DEFROSTER NOZZLE GARNISH for RH Side: for LH Side: FRONT NO. 2 SPEAKER ASSEMBLY FRONT NO. 2 SPEAKER ASSEMBLY or or or 20 (204, 15) or INSTRUMENT PANEL SAFETY PAD ASSEMBLY AV N*m (kgf*cm, ft.*lbf) : Specified torque B137286E01 AV–180 AUDIO / VISUAL – RADIO ANTENNA CORD for TMMK Made: INSTRUMENT PANEL NO. 1 SPEAKER PANEL SUB-ASSEMBLY INSTRUMENT PANEL NO. 2 SPEAKER PANEL SUB-ASSEMBLY NO. 1 DEFROSTER NOZZLE GARNISH for RH Side: for LH Side: FRONT NO. 2 SPEAKER ASSEMBLY FRONT NO. 2 SPEAKER ASSEMBLY , or AV , or 20 (204, 15) INSTRUMENT PANEL SAFETY PAD ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B137286E03 AUDIO / VISUAL – RADIO ANTENNA CORD AV–181 DEFROSTER NOZZLE ASSEMBLY SIDE NO. 2 DEFROSTER NOZZLE DUCT SIDE NO. 1 DEFROSTER NOZZLE DUCT NO. 2 HEATER TO REGISTER DUCT NO. 3 HEATER TO REGISTER DUCT NO. 1 HEATER TO REGISTER DUCT NO. 2 ANTENNA CORD SUB-ASSEMBLY E129187E01 AV AV–182 AUDIO / VISUAL – RADIO ANTENNA CORD for Manual Seat: FRONT SEAT HEADREST ASSEMBLY SEAT TRACK COVER RH 37 (377, 27) INNER SEAT TRACK BRACKET COVER RH 37 (377, 27) FRONT SEAT ASSEMBLY RH FRONT SEAT HEADREST ASSEMBLY INNER SEAT TRACK BRACKET COVER LH SEAT TRACK COVER LH 37 (377, 27) 37 (377, 27) AV FRONT SEAT ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque B132048E01 AV–183 AUDIO / VISUAL – RADIO ANTENNA CORD for Power Seat: FRONT SEAT HEADREST ASSEMBLY SEAT TRACK COVER RH INNER SEAT TRACK BRACKET COVER LH 37 (377, 27) 37 (377, 27) FRONT SEAT ASSEMBLY RH FRONT SEAT HEADREST ASSEMBLY INNER SEAT TRACK BRACKET COVER RH 37 (377, 27) SEAT TRACK COVER LH 37 (377, 27) AV FRONT SEAT ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque B132047E01 AV–184 AUDIO / VISUAL – RADIO ANTENNA CORD for Fixed Seat Type: REAR SEAT HEADREST ASSEMBLY REAR CENTER SEAT HEADREST ASSEMBLY REAR SEAT BACK ASSEMBLY 18 (184, 13) 18 (184, 13) REAR SEAT CUSHION ASSEMBLY AV N*m (kgf*cm, ft.*lbf) : Specified torque B136589E02 AV–185 AUDIO / VISUAL – RADIO ANTENNA CORD for Fold Down Seat Type: REAR SEAT HEADREST ASSEMBLY REAR CENTER SEAT HEADREST ASSEMBLY 18 (184, 13) 18 (184, 13) 18 (184, 13) REAR SIDE SEAT BACK ASSEMBLY RH SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH 18 (184, 13) REAR SEAT CUSHION ASSEMBLY REAR SIDE SEAT BACK ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque B136564E02 AV AV–186 AUDIO / VISUAL – RADIO ANTENNA CORD for Reclining Seat Type: REAR SEAT HEADREST ASSEMBLY REAR CENTER SEAT HEADREST ASSEMBLY 18 (184, 13) SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH REAR SEAT BACK COVER CENTER SEAT BACK ASSEMBLY 18 (184, 13) 18 (184, 13) 18 (184, 13) REAR SEAT BACK COVER RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY RH 18 (184, 13) SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH 18 (184, 13) REAR SEAT CUSHION ASSEMBLY RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY LH AV N*m (kgf*cm, ft.*lbf) : Specified torque B139577E01 AUDIO / VISUAL – RADIO ANTENNA CORD AV–187 NO. 1 DOOR SCUFF PLATE CLAMP REAR DOOR INNER GLASS WEATHERSTRIP LH REAR DOOR INSIDE HANDLE BEZEL PLUG LH DOOR ASSIST GRIP COVER LH REAR DOOR TRIM BOARD SUB-ASSEMBLY LH AV B139576E01 AV–188 AUDIO / VISUAL – RADIO ANTENNA CORD FRONT DOOR OPENING TRIM WEATHERSTRIP RH FRONT PILLAR GARNISH RH FRONT PILLAR GARNISH CLIP UPPER CENTER PILLAR GARNISH RH ROOF SIDE INNER GARNISH RH REAR DOOR OPENING TRIM WEATHERSTRIP RH REAR DOOR SCUFF PLATE RH FRONT SEAT OUTER BELT ASSEMBLY RH COWL SIDE TRIM CLIP FRONT DOOR SCUFF PLATE RH 42 (428, 31) LAP BELT OUTER ANCHOR COVER LOWER CENTER PILLAR GARNISH RH AV COWL SIDE TRIM SUB-ASSEMBLY RH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part B132050E01 AV–189 AUDIO / VISUAL – RADIO ANTENNA CORD UPPER CENTER PILLAR GARNISH LH FRONT PILLAR GARNISH LH FRONT PILLAR GARNISH CLIP REAR DOOR OPENING TRIM WEATHERSTRIP LH FRONT DOOR OPENING TRIM WEATHERSTRIP LH ROOF SIDE INNER GARNISH LH 42 (428, 31) LAP BELT OUTER ANCHOR COVER REAR DOOR SCUFF PLATE LH LOWER CENTER PILLAR GARNISH LH COWL SIDE TRIM CLIP FRONT SEAT OUTER BELT ASSEMBLY LH FRONT DOOR SCUFF PLATE LH AV COWL SIDE TRIM SUB-ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part B132049E01 AV–190 AUDIO / VISUAL – RADIO ANTENNA CORD without Sliding Roof: REAR ASSIST GRIP SUB-ASSEMBLY FRONT ASSIST GRIP SUB-ASSEMBLY ASSIST GRIP COVER ASSIST GRIP COVER ROOF HEADLINING ASSEMBLY REAR ASSIST GRIP SUB-ASSEMBLY NO. 1 ROOM LIGHT ASSEMBLY LENS COVER VISOR BRACKET COVER FRONT ASSIST GRIP SUB-ASSEMBLY ASSIST GRIP COVER VISOR ASSEMBLY RH VISOR HOLDER ASSIST GRIP COVER ROOF CONSOLE BOX ASSEMBLY AV VISOR ASSEMBLY LH VISOR HOLDER VISOR BRACKET COVER B132051E01 AUDIO / VISUAL – RADIO ANTENNA CORD with Sliding Roof: FRONT ASSIST GRIP SUB-ASSEMBLY AV–191 REAR ASSIST GRIP SUB-ASSEMBLY ASSIST GRIP COVER ASSIST GRIP COVER ROOF HEADLINING ASSEMBLY with Rear Sunshade: SUNSHADE TRIM HOLDER SPOT LIGHT ASSEMBLY VISOR BRACKET COVER REAR ASSIST GRIP SUB-ASSEMBLY VISOR ASSEMBLY RH ASSIST GRIP COVER ROOF CONSOLE BOX ASSEMBLY FRONT ASSIST GRIP SUB-ASSEMBLY ASSIST GRIP COVER VISOR HOLDER VISOR ASSEMBLY LH VISOR HOLDER VISOR BRACKET COVER AV SUN ROOF OPENING TRIM MOULDING B132052E01 AV–192 AUDIO / VISUAL – RADIO ANTENNA CORD without Sliding Roof: ANTENNA CORD SUB-ASSEMBLY with Sliding Roof: ANTENNA CORD SUB-ASSEMBLY AV E129189E01 AV–215 AUDIO / VISUAL – AMPLIFIER ANTENNA AMPLIFIER ANTENNA BODY ELECTRICAL AUDIO / VISUAL COMPONENTS for Fixed Seat Type: REAR SEAT HEADREST ASSEMBLY REAR CENTER SEAT HEADREST ASSEMBLY REAR SEAT BACK ASSEMBLY 18 (184, 13) 18 (184, 13) AV REAR SEAT CUSHION ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B136589E02 AV–216 AUDIO / VISUAL – AMPLIFIER ANTENNA for Fold Down Seat Type: REAR SEAT HEADREST ASSEMBLY REAR CENTER SEAT HEADREST ASSEMBLY 18 (184, 13) 18 (184, 13) 18 (184, 13) REAR SIDE SEAT BACK ASSEMBLY RH SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH 18 (184, 13) REAR SEAT CUSHION ASSEMBLY REAR SIDE SEAT BACK ASSEMBLY LH AV N*m (kgf*cm, ft.*lbf) : Specified torque B136564E02 AUDIO / VISUAL – AMPLIFIER ANTENNA AV–217 for Reclining Seat Type: REAR SEAT HEADREST ASSEMBLY 18 (184, 13) REAR CENTER SEAT HEADREST ASSEMBLY CENTER SEAT BACK ASSEMBLY REAR SEAT BACK COVER 18 (184, 13) 18 (184, 13) 18 (184, 13) SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH REAR SEAT BACK COVER 18 (184, 13) SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH REAR SEAT CUSHION ASSEMBLY AV N*m (kgf*cm, ft.*lbf) : Specified torque B139095E03 AV–218 AUDIO / VISUAL – AMPLIFIER ANTENNA ROOF SIDE INNER GARNISH RH REAR DOOR OPENING TRIM WEATHERSTRIP RH for Reclining Seat Type: 18 (184, 13) RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY RH REAR DOOR OPENING TRIM WEATHERSTRIP LH for Reclining Seat Type: REAR DOOR SCUFF PLATE RH 18 (184, 13) REAR DOOR SCUFF PLATE LH RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY LH AV N*m (kgf*cm, ft.*lbf) : Specified torque E131414E01 AUDIO / VISUAL – AMPLIFIER ANTENNA AV–219 for Premium Audio System: AMPLIFIER ANTENNA ASSEMBLY AMPLIFIER ANTENNA ASSEMBLY E129976E01 AV AV–220 AUDIO / VISUAL – AMPLIFIER ANTENNA REMOVAL 1. REMOVE REAR SEAT HEADREST ASSEMBLY 2. REMOVE REAR CENTER SEAT HEADREST ASSEMBLY 3. REMOVE REAR SEAT CUSHION ASSEMBLY (See page SE-62) 4. REMOVE REAR SEAT BACK ASSEMBLY (for Fixed Seat Type) (See page SE-77) 5. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) (See page SE-48) 6. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-47) 7. REMOVE REAR SIDE SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-48) 8. REMOVE REAR SIDE SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) (See page SE-48) 9. REMOVE REAR SEAT BACK COVER (for Reclining Seat Type) (See page SE-63) 10. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Reclining Seat Type) (See page SE-63) 11. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Reclining Seat Type) (See page SE-64) 12. REMOVE CENTER SEAT BACK ASSEMBLY (for Reclining Seat Type) (See page SE-64) 13. REMOVE REAR DOOR SCUFF PLATE LH (See page IR-24) 14. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Reclining Seat Type) 15. REMOVE REAR DOOR SCUFF PLATE RH (See page IR-24) 16. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH (for Reclining Seat Type) AV 17. REMOVE RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY LH (for Reclining Seat Type) (See page SE-68) 18. REMOVE RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY RH (for Reclining Seat Type) 19. REMOVE ROOF SIDE INNER GARNISH RH HINT: Use the same procedures for the RH side and the LH side (see page IR-26). AUDIO / VISUAL – AMPLIFIER ANTENNA AV–221 20. REMOVE AMPLIFIER ANTENNA ASSEMBLY (a) Disconnect each connector. (b) Standard audio system: (1) Remove the bolt and amplifier antenna assembly. E129183 (c) Premium audio system: (1) Remove the 2 bolts and amplifier antenna assembly. E129193 INSTALLATION 1. INSTALL AMPLIFIER ANTENNA ASSEMBLY (a) Standard audio system: (1) Install the amplifier antenna assembly with the bolt. E129183 (b) Premium audio system: (1) Install the amplifier antenna assembly with the 2 bolts. (c) Connect each connector. E129193 2. INSTALL ROOF SIDE INNER GARNISH RH HINT: Use the same procedures for the RH side and the LH side (see page IR-52). 3. INSTALL RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY LH (for Reclining Seat Type) (See page SE-69) 4. INSTALL RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY RH (for Reclining Seat Type) (See page SB-53) 5. CONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Reclining Seat Type) (See page IR-55) AV AV–222 AUDIO / VISUAL – AMPLIFIER ANTENNA 6. INSTALL REAR DOOR SCUFF PLATE LH (See page IR-56) 7. CONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH (for Reclining Seat Type) (See page IR-56) 8. INSTALL REAR DOOR SCUFF PLATE RH (See page IR-56) 9. INSTALL CENTER SEAT BACK ASSEMBLY (for Reclining Seat Type) (See page SE-71) 10. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Reclining Seat Type) (See page SE-72) 11. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Reclining Seat Type) (See page SE-71) 12. INSTALL REAR SEAT BACK COVER (for Reclining Seat Type) 13. INSTALL REAR SIDE SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-57) 14. INSTALL REAR SIDE SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) 15. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-57) 16. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) 17. INSTALL REAR SEAT BACK ASSEMBLY (for Fixed Seat Type) (See page SE-84) 18. INSTALL REAR CENTER SEAT HEADREST ASSEMBLY 19. INSTALL REAR SEAT HEADREST ASSEMBLY 20. INSTALL REAR SEAT CUSHION ASSEMBLY (See page SE-58) AV AV–223 AUDIO / VISUAL – AUDIO TERMINAL AUDIO TERMINAL BODY ELECTRICAL AUDIO / VISUAL COMPONENTS NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH UPPER CONSOLE PANEL SUB-ASSEMBLY AUDIO TERMINAL for Automatic Transaxle: for Manual Transaxle: SHIFT LEVER KNOB SUB-ASSEMBLY SHIFT LEVER KNOB SUB-ASSEMBLY FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY UPPER CONSOLE REAR PANEL SUB-ASSEMBLY UPPER CONSOLE PANEL UPPER CONSOLE REAR PANEL SUB-ASSEMBLY E129180E01 AV AV–224 AUDIO / VISUAL – AUDIO TERMINAL REMOVAL 1. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-24) 2. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) (See page IP-24) 3. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-24) 4. REMOVE NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-25) 5. REMOVE FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-25) 6. REMOVE UPPER CONSOLE PANEL (for Manual Transaxle) (See page IP-25) 7. REMOVE UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Automatic Transaxle) (See page IP26) 8. REMOVE UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Manual Transaxle) (See page IP-26) 9. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (See page IP-27) 10. REMOVE AUDIO TERMINAL (a) Disengage the 2 claws and remove the audio terminal. E129181 INSTALLATION 1. INSTALL AUDIO TERMINAL (a) Engage the 2 claws and install the audio terminal. 2. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (See page IP-52) 3. INSTALL UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Automatic Transaxle) (See page IP53) 4. INSTALL UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Manual Transaxle) (See page IP-53) 5. INSTALL FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-53) 6. INSTALL UPPER CONSOLE PANEL (for Manual Transaxle) (See page IP-54) AV E129181 AUDIO / VISUAL – AUDIO TERMINAL AV–225 7. INSTALL NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-54) 8. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-55) 9. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-55) 10. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) (See page IP-55) AV AV–225 AUDIO / VISUAL – STEERING PAD SWITCH STEERING PAD SWITCH BODY ELECTRICAL AUDIO / VISUAL COMPONENTS for 4 Spoke: STEERING PAD 2.4 (24, 21 in.*lbf) STEERING PAD SWITCH LH NO. 3 LOWER STEERING WHEEL COVER 8.8 (90, 78 in.*lbf) NO. 2 LOWER STEERING WHEEL COVER STEERING PAD 2.4 (24, 21 in.*lbf) AV STEERING PAD SWITCH ASSEMBLY NO. 3 LOWER STEERING WHEEL COVER 8.8 (90, 78 in.*lbf) NO. 2 LOWER STEERING WHEEL COVER N*m (kgf*cm, ft.*lbf) : Specified torque E129172E01 AV–226 AUDIO / VISUAL – STEERING PAD SWITCH for 3 Spoke: STEERING PAD 2.4 (24, 21 in.*lbf) STEERING PAD SWITCH LH NO. 3 LOWER STEERING WHEEL COVER NO. 2 LOWER STEERING WHEEL COVER 8.8 (90, 78 in.*lbf) STEERING PAD 2.4 (24, 21 in.*lbf) STEERING PAD SWITCH ASSEMBLY AV NO. 3 LOWER STEERING WHEEL COVER NO. 2 LOWER STEERING WHEEL COVER 8.8 (90, 78 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque E129201E01 AUDIO / VISUAL – STEERING PAD SWITCH AV–227 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait for 90 seconds after disconnecting the cable to prevent the airbag working. 2. REMOVE NO. 3 LOWER STEERING WHEEL COVER (See page RS-349) 3. REMOVE NO. 2 LOWER STEERING WHEEL COVER (See page RS-349) 4. REMOVE STEERING PAD (See page RS-350) 5. REMOVE STEERING PAD SWITCH LH (for 4 Spoke) (a) Disconnect the pad switch connector from the spiral cable. (b) Remove the screw. (c) Disengage the 2 pins and remove the steering pad switch LH. 6. REMOVE STEERING PAD SWITCH ASSEMBLY (for 4 Spoke) (a) Disconnect the pad switch connector from the spiral cable. (b) Remove the screw. (c) Disengage the 2 pins and remove the steering pad switch. Pin E129186E01 Pin E129186E01 (d) Remove the screw. (e) Disengage the 2 pins and remove the steering pad switch assembly. Pin E129977E01 AV AV–228 Pin AUDIO / VISUAL – STEERING PAD SWITCH 7. REMOVE STEERING PAD SWITCH LH (for 3 Spoke) (a) Disconnect the pad switch connector from the spiral cable and disengage the clamp. (b) Remove the screw. (c) Disengage the 2 pins and remove the steering pad switch LH. 8. REMOVE STEERING PAD SWITCH ASSEMBLY (for 3 Spoke) (a) Disconnect the pad switch connector from the spiral cable. (b) Disengage the clamp and remove the screw. (c) Disengage the 2 pins and remove the steering pad switch. Clamp E129202E01 Pin Clamp E129971E01 (d) Disengage the clamp and remove the screw. (e) Disengage the 2 pins and remove the steering pad switch assembly. Pin Clamp E129203E01 AV AV–229 AUDIO / VISUAL – STEERING PAD SWITCH INSPECTION 1. INSPECT STEERING PAD SWITCH (a) Disconnect the steering pad switch assembly connector. 3 Spoke Model: AUD IO OFF (HO LD) EAU AU2 AU1 EAU AU2 AU1 4 Spoke Model: AUDIO OFF (HOLD) E129804E02 (b) Measure the resistance according to the values in the table below. Standard resistance Tester connection Condition Specified condition AU1 - EAU No switch is pushed Approx. 100 kΩ AU1 - EAU SEEK+ switch: push 0 to 2.5 Ω AU1 - EAU SEEK- switch: push Approx. 0.3 kΩ AU1 - EAU VOL+ switch: push Approx. 1 kΩ AU1 - EAU VOL- switch: push Approx. 3.1 kΩ AU2 - EAU No switch is pushed Approx. 100 kΩ AV AV–230 AUDIO / VISUAL – STEERING PAD SWITCH Tester connection Condition Specified condition AU2 - EAU MODE switch: push 0 to 2.5 Ω AU2 - EAU VOICE switch: push (*1) Approx. 3.1 kΩ AU2 - EAU ON HOOK switch: push (*2) Approx. 0.3 kΩ AU2 - EAU OFF HOOK switch: push (*2) Approx. 1 kΩ *1: with Navigation System *2: with "Bluetooth" Module If the result is not as specified, replace the steering pad switch. INSTALLATION 1. INSTALL STEERING PAD SWITCH ASSEMBLY (for 4 Spoke) (a) Engage the 2 pins and install the steering pad switch assembly. (b) Install the screw. Torque: 2.4 N*m (24 kgf*cm, 21 in.*lbf) Pin E129977E01 (c) Engage the 2 pins and install the steering pad switch assembly. (d) Install the screw. Torque: 2.4 N*m (24 kgf*cm, 21 in.*lbf) (e) Connect the connector to the spiral cable. Pin E129186E01 2. INSTALL STEERING PAD SWITCH LH (for 4 Spoke) (a) Engage the 2 pins and install the steering pad switch LH. (b) Install the screw. Torque: 2.4 N*m (24 kgf*cm, 21 in.*lbf) (c) Connect the connector to the spiral cable. 3. INSTALL STEERING PAD SWITCH ASSEMBLY (for 3 Spoke) (a) Engage the 2 pins and install the steering pad switch assembly. (b) Install the screw and engage the clamp. Torque: 2.4 N*m (24 kgf*cm, 21 in.*lbf) Pin E129186E01 AV Pin Clamp E129203E01 AUDIO / VISUAL – STEERING PAD SWITCH AV–231 (c) Engage the 2 pins and install the steering pad switch assembly. (d) Install the screw and engage the clamp. Torque: 2.4 N*m (24 kgf*cm, 21 in.*lbf) (e) Connect the connector to the spiral cable. Pin Clamp E129971E01 Pin Clamp 4. INSTALL STEERING PAD SWITCH LH (for 3 Spoke) (a) Engage the 2 pins and install the steering pad switch LH. (b) Install the screw and engage the clamp. Torque: 2.4 N*m (24 kgf*cm, 21 in.*lbf) (c) Connect the connector to the spiral cable. 5. INSTALL STEERING PAD (See page RS-350) 6. INSTALL NO. 3 LOWER STEERING WHEEL COVER (See page RS-351) 7. INSTALL NO. 2 LOWER STEERING WHEEL COVER (See page RS-352) 8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 9. INSPECT SRS WARNING LIGHT (See page RS-32) E129202E01 AV AV–232 AUDIO / VISUAL – MICROPHONE MICROPHONE BODY ELECTRICAL AUDIO / VISUAL COMPONENTS TELEPHONE MICROPHONE ASSEMBLY ROOF CONSOLE BOX ASSEMBLY E129194E01 AV AUDIO / VISUAL – MICROPHONE AV–233 REMOVAL 1. REMOVE ROOF CONSOLE BOX ASSEMBLY (See page IR-28) 2. REMOVE TELEPHONE MICROPHONE ASSEMBLY (a) Disconnect the connector. (b) Disengage the 2 claws and remove the telephone microphone assembly. E129195 INSTALLATION 1. INSTALL TELEPHONE MICROPHONE ASSEMBLY (a) Engage the 2 claws and install the telephone microphone assembly. (b) Connect the connector. 2. INSTALL ROOF CONSOLE BOX ASSEMBLY (See page IR-50) E129195 AV AV–234 AUDIO / VISUAL – WINDOW GLASS ANTENNA WIRE WINDOW GLASS ANTENNA WIRE ON-VEHICLE INSPECTION Tester Probe 1. Tin Foil Antenna Wire E111994E01 INSPECT WINDOW GLASS ANTENNA WIRE (a) Check for continuity of the antenna. HINT: Check for continuity at the center of each antenna wire as shown in the illustration. NOTICE: • When cleaning the glass, wipe it in the direction of the wire with a soft, dry cloth. Take care not to damage the wire. Do not use detergents or glass cleaners with abrasive ingredients. • When measuring voltage, wrap a piece of tin foil around the tip of the negative probe and press the foil against the wire with your finger, as shown in the illustration. OK: There is continuity in the antenna. If the result is not as specified, repair the window glass antenna wire. REPAIR 1. Tester Probe Tin Foil Antenna Wire B066134E02 WINDOW GLASS ANTENNA WIRE NOTICE: • When cleaning the glass, wipe it in the direction of the wire with a soft, dry cloth. Take care not to damage the wire. Do not use detergents or glass cleaners with abrasive ingredients. • When measuring voltage, wrap a piece of tin foil around the tip of the negative probe and press the foil against the wire with your finger, as shown in the illustration. (a) Check the voltage at the center of each wire, as shown in the illustration. AV E032576 AUDIO / VISUAL – WINDOW GLASS ANTENNA WIRE 2. Repair Point Masking Tape AV–235 REPAIR WINDOW GLASS ANTENNA WIRE (a) Clean the broken wire tips with a grease, wax and silicone remover. (b) Place masking tape along both sides of the wire to be repaired. (c) Thoroughly mix the repair agent (Dupont paste No. 4817 or equivalent). Broken Wire B063722E02 (d) Using a fine tip brush, apply a small amount of the repair agent to the wire. (e) After a few minutes, remove the masking tape. Fine Tip Brush Repair Point B063723E01 AV ST–1 2GR-FE STARTING – STARTING SYSTEM STARTING SYSTEM 2GR-FE STARTING ENGINE PARTS LOCATION ECM STARTER TRANSMISSION CONTROL ECU ENGINE ROOM R/B -STARTER RELAY -IGNITION RELAY PARK/NEUTRAL POSITION SWITCH -STARTER CUT RELAY -IG2 FUSE -AM2 FUSE -ST/AM2 FUSE -ALT FUSE MAIN BODY ECU with SMART KEY SYSTEM: INSTRUMENT PANEL J/B -IGN FUSE -AM1 FUSE ST -ENGINE SWITCH without SMART KEY SYSTEM: -IGNITION SWITCH A135519E01 ST–2 2GR-FE STARTING – STARTING SYSTEM SYSTEM DIAGRAM without Smart Key System: Transmission Control ECU ECM 62 C55 NSW 11 NSW C56 4 C1 L B Park/Neutral P Position Switch N 9 10 STA C56 48 A55 STA E23 Ignition Switch ACC AM1 4 ST1 AM2 AM1 IG1 IG2 ST 3 5 1 2 5 3 ST2 7 ALT ST/AM2 Starter FL MAIN 1 D1 1 C3 M ST Battery A135061E01 ST–3 2GR-FE STARTING – STARTING SYSTEM with Smart Key System: Main Body ECU ECM 6 AM1 E7 AM2 From Battery 1 AM2 E6 62 C55 NSW 6 STR2 E9 ST CUT 8 STR E7 5 3 2 1 63 C55 STAR IGN From Battery 11 IG2D E6 From Battery IG2 IG2 5 3 1 2 ST ST/AM2 5 3 1 2 48 A55 STA 9 C1 B L Park/Neutral P Position Switch N 4 ST A135062E01 ST–4 2GR-FE STARTING – STARTING SYSTEM 17 SSW1 E7 16 SSW2 E7 2 SS2 SS2 7 SS1 GND E52 Engine Switch SS1 Free Full Traveling GND 5 Starter 1 D1 1 C3 Battery A135063E01 ST 2GR-FE STARTING – SMART KEY SYSTEM ST–5 SMART KEY SYSTEM PRECAUTION 1. EMERGENCY ENGINE START CONTROL (a) If there is a malfunction in the stop light switch or STOP fuse, their signals may not be correctly transmitted to the main body ECU. This may result in the engine not starting even if the engine switch is pressed while the brake pedal is depressed and the shift lever is in the P position. To activate the starter: (1) Turn the engine switch from off to on (ACC). (2) Press and hold the engine switch for 15 seconds. 2. PRECAUTIONS FOR PUSH-BUTTON START FUNCTION: (a) Before starting the engine, firmly depress the brake pedal until the indicator in the engine switch turns green. (b) The power source mode (off, on (ACC), on (IG)) is always retained in memory by the vehicle. If the battery is disconnected, the power source mode that was present before disconnection will be restored after the battery is reconnected. Be sure to turn the engine switch off before disconnecting the cable from the negative battery terminal. Be careful if the power source mode of a vehicle with a discharged battery is not known. (c) After the battery is reconnected, be sure to wait 10 seconds or more before attempting to start the engine. The engine may not start immediately after the battery is reconnected. (d) If the electrical key is held near the engine switch to start the engine when the electrical key battery is depleted, the following warnings will sound: (1) Driver's door open → closed • An exit warning will sound if the shift lever is in a position other than P and the power source is in a mode other than off. • An exit warning will sound if the shift lever is in the P position and the power source is in a mode other than off. (2) Doors other than the driver door open → closed • A warning will sound to indicate that the electrical key has been taken out of the vehicle. These warnings will sound because it is not possible for the vehicle to determine if the key is present in the vehicle (due to the depleted key battery). These warnings do not indicate system malfunctions. ST ST–6 2GR-FE STARTING – SMART KEY SYSTEM PARTS LOCATION PARK / NEUTRAL POSITION SWITCH ECM (2GR-FE) ENGINE ROOM J/B AND R/B WIRELESS BUZZER - AM2 FUSE - ST / AM2 FUSE - IG2 FUSE - ECU-B NO. 1 FUSE - IG2 RELAY - ST CUT RELAY - ST RELAY ELECTRICAL KEY OSCILLATOR (CONSOLE) ST ELECTRICAL KEY OSCILLATOR (REAR SEAT) DOOR CONTROL RECEIVER B137944E01 ST–7 2GR-FE STARTING – SMART KEY SYSTEM CERTIFICATION ECU COMBINATION METER ID CODE BOX TURN SIGNAL FLASHER ASSEMBLY STOP LIGHT SWITCH DLC3 MAIN BODY ECU (INSTRUMENT PANEL J/B) - IG1 RELAY - ACC RELAY SHIFT LOCK CONTROL ECU ENGINE SWITCH STEERING LOCK ECU - ECU-ACC FUSE - ECU IG NO. 1 FUSE - DOOR NO. 2 FUSE ST B137945E01 ST–8 2GR-FE STARTING – SMART KEY SYSTEM SYSTEM DIAGRAM Engine Switch MAIN BODY ECU AM2 AM1 AM2 From Battery SSW1 SSW2 CAN Line CAN Stop Light Switch STP Shift Lock Control ECU P Combination Meter SPD IG1 SLP Steering Lock ECU LIN1 IG1D IG2 ID Code Box IG2D Certification ECU ACC ACCD Key ST CUT STR2 LIN ST CAN A B B137946E01 ST–9 2GR-FE STARTING – SMART KEY SYSTEM A B STR STSW Park / Neutral Position Switch TACH GND1 GND2 ACCR Transmission Control ECU MAIN BODY ECU STA NSW ECM NSW ST STAR ACCR STA TACH STSW Starter Crankshaft Position Sensor NE+ NEBattery ST B137970E01 Communication table: Transmitting ECU (Transmitter) Receiving ECU (Receiver) Signal Communication method Combination meter Main body ECU Vehicle speed signal CAN/Local communication Steering lock ECU Main body ECU Steering lock/unlock signal LIN/Local communication ST–10 Transmitting ECU (Transmitter) 2GR-FE STARTING – SMART KEY SYSTEM Receiving ECU (Receiver) Signal Communication method Starter signal ECM Main body ECU Shift position signal CAN Engine revolution speed signal Engine switch position signal Main body ECU Certification ECU Courtesy light switch signal CAN Wireless door lock buzzer request signal Main body ECU Combination meter Entry start key signal CAN Main body ECU Combination meter Wireless door lock buzzer request signal CAN Certification ECU Main body ECU Illumination light request signal CAN Certification ECU Driver seat ECU Memory call replay request signal CAN Certification ECU Main body ECU Light answer back signal CAN Meter buzzer single-shot request signal Meter buzzer intermittence request signal Meter buzzer continuation request signal Certification ECU Combination meter Door open display signal CAN Key loss warning signal Low key battery warning signal Shift position warning signal Steering lock abnormal warning Steering lock unlock warning Combination meter ST Certification ECU/Main body ECU Vehicle speed signal CAN Shift lock control ECU Main body ECU Shift position signal CAN/Local communication Certification ECU Main body ECU Key ID matching request signal LIN Main body ECU Certification ECU ID required signal LIN ST–11 2GR-FE STARTING – SMART KEY SYSTEM SYSTEM DESCRIPTION 1. 2. PUSH-BUTTON START FUNCTION DESCRIPTION (a) The push-button start function uses a push-type engine switch, which the driver can operate by merely carrying the electrical key. This system consists primarily of the main body ECU, engine switch, ID code box, steering lock ECU, electrical key, ACC relay, IG1 relay, IG2 relay and certification ECU. The main body ECU controls the function. This function operates in cooperation with the smart key system. FUNCTION OF COMPONENT Component Function • • Engine Switch • Transponder Key Amplifier • Transmits engine switch signal to main body ECU. Informs driver of power source mode or system abnormality with illumination of indicator light. Receives ID code and transmits it to certification ECU when key battery is low. Electrical Key Receives signals from oscillators and returns ID code to entry door control receiver. Electrical Key Oscillator • Console and Rear Seat Receives request signals from certification ECU and forms detection area in vehicle interior. Steering Lock ECU Receives lock/unlock request signals from certification ECU and main body ECU. Entry Door Control Receiver Receives ID code from electrical key and transmits it to certification ECU. • Main body ECU • Changes power source mode in 4 stages (off, on (ACC), on (IG), start) in accordance with shift position and state of stop light switch. Controls push-button start function in accordance with signals received from switches and each ECU. Certification ECU Certifies ID code received from entry door control receiver and transmits certification results to ID code ECU and steering lock ECU. Stop Light Switch Outputs state of brake pedal to main body ECU. ID Code Box Receives steering unlock or engine immobiliser unset signals from certification ECU, certifies them, and transmits each unset signal to steering lock ECU or ECM. • ECM • 3. SYSTEM FUNCTION The electric controls of the push-button start function are described below: Control Outline • Engine switch control • Diagnosis Receives engine start request signal from main body ECU, turns ON ST relay, and starts engine. Receives signal from ID code ECU and performs engine ignition and injection. When driver operates engine switch with electrical key in driver's possession, certification ECU starts indoor electrical key oscillator, which transmits request signal to electrical key. Upon receiving this signal, the electrical key transmits ID code signal to main body ECU. ID code box verifies check results received from certification ECU via LIN and sends them to main body ECU. Based on these results, main body ECU authorizes operation of engine switch. When main body ECU detects malfunction, main body ECU diagnoses and memorizes failed section. ST ST–12 2GR-FE STARTING – SMART KEY SYSTEM 4. Indicator Light START STOP A109251E01 CONSTRUCTION AND OPERATION (a) Engine Switch The engine switch consists of a momentary type switch, 3 color (amber, green, greenish white) LEDs, and a transponder key amplifier. • The greenish white LED is for illumination. • The amber and green LEDs are for the indicator lights. The driver can check the present power source mode and whether the engine can start in accordance with the illumination state of the indicator light. • When the main body ECU detects an abnormality in the push-button start function, it makes the amber indicator light flash. If the engine stopped in this state, it may not be possible to restart it. (b) Indicator Light Condition Engine switch indicator light condition: Power Source Mode/Condition Indicator Light Condition Brake pedal released off OFF ON (Green) (When key and vehicle IDs match) on (ACC, IG) ON (Amber) ON (Green) Engine running OFF OFF Steering lock not unlocked Flashes (Green) for 15 sec. Flashes (Green) for 15 sec. System malfunction Flashes (Amber) for 15 sec. Flashes (Amber) for 15 sec. 5. ST Brake pedal depressed, shift lever in P or N Brake Pedal Depressed (c) Main body ECU The main body ECU consists of the IG1 and IG2 relay actuation circuits and CPU. HINT: Before removing the battery, make sure to turn the engine switch off. The main body ECU constantly stores the present power source mode in its memory. Therefore, if the main body ECU is interrupted by disconnecting the battery, the main body ECU restores the power source mode after the battery is reconnected. For this reason, if the battery is disconnected when the engine switch is not off, the power will be restored to the vehicle at the same time the power is restored to the main body ECU (by reconnecting the battery). PUSH-BUTTON START FUNCTION OPERATION (a) This system has different power source mode patterns depending on the brake pedal condition and shift lever position. Shift Lever P or N position P position Not depressed Except P position Power Source Mode Pattern When the engine switch is pushed once. • off → engine start • on (ACC) → engine start • on (IG) → engine start Each time the engine switch is pushed. • off → on (ACC) → on (IG) → off Each time the engine switch is pushed. • off → on (ACC) → on (IG) → on (ACC) ST–13 2GR-FE STARTING – SMART KEY SYSTEM Brake Pedal Shift Lever Power Source Mode Pattern - P position When the engine switch is pushed with power source mode on (IG) (engine running). • on (IG) → off - Except P position When the engine switch is pushed with power source mode on (IG) (engine running). • on (IG) → on (ACC) When the battery of the key is low, the push-button start function can be operated by holding the key against the engine switch. • After approximately 1 hour has passed with the engine switch on (ACC) and the shift position in P, the main body ECU will automatically cut the power supply (the power source mode changes to off). ST ST–14 2GR-FE STARTING – SMART KEY SYSTEM • The illustration below shows the transition of power source modes. Transition of power source mode: Shift Position P Engine Switch Position Engine switch pushed Engine switch pushed N Engine Not operated switch pushed for 1 hour Except P and N Engine switch pushed Brake pedal depressed Brake pedal depressed Engine switch pushed Engine switch pushed Brake pedal depressed off on (ACC) on (IG) Engine start Transition of power source mode (Always) ST Transition of power source mode (only when key code is certified) Transition of power source mode (only with vehicle stopped) B138065E01 2GR-FE STARTING – SMART KEY SYSTEM ST–15 HINT: While the vehicle is being driven normally, operation of the engine switch is disabled. However, if the engine must be stopped in an emergency while the vehicle is being driven, pressing the engine switch for 3 seconds or more stops the engine. Power source mode changes from start to on (ACC). 6. Required Distance: 10 mm (0.39 in.) Engine Switch Key B137947E01 WHEN KEY BATTERY IS LOW (a) To operate the push-button start function when the key battery is low, hold the key close to the engine switch with the brake pedal depressed. (b) The main body ECU transmits a key verification request signal from the stop light switch to the certification ECU. (c) The certification ECU does not receive an ID code response from the entry door control receiver, so it actuates the transponder key amplifier built into the engine switch. (d) The transponder key amplifier outputs an engine immobiliser radio wave to the key. (e) The key receives the radio wave, and returns a radio wave response to the transponder key amplifier. (f) The transponder key amplifier combines the key ID codes with the radio wave response, and transmits it to the certification ECU. (g) The certification ECU judges and verifies the ID code, and transmits a key verification OK signal to the main body ECU. The buzzer in the combination meter sounds at the same time. (h) After the buzzer sounds, if the engine switch is pressed within 5 seconds with the brake pedal not depressed, the power source mode changes to on (ACC) or on (IG), the same as in the normal condition. 7. DIAGNOSIS The main body ECU can detect malfunctions in the pushbutton start function when the power source mode is on (IG). When the ECU detects a malfunction, the amber indicator light of the engine switch flashes to warn the driver. At the same time, the ECU stores a 5-digit DTC (Diagnostic Trouble Code) in the memory. • The indicator light warning continues for 15 seconds even after the power source mode is changed to off. • The DTC can be read by connecting the intelligent tester to the DLC3. • The push-button start function cannot be operated if a malfunction occurs. ST ST–16 2GR-FE STARTING – SMART KEY SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use the following procedures to troubleshoot the pushbutton start function. • The intelligent tester should be used in steps 4, 5 and 8. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS CHECK HINT: • In troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time the malfunction occurred. • Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases. • The following 5 items are important points in the problem analysis: What Vehicle model, system name When Date, time, occurrence frequency Where Road conditions Under what conditions? Running conditions, driving conditions, weather conditions How did it happen? Problem symptoms NEXT 3 INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. ST NEXT 4 INSPECT COMMUNICATION FUNCTION OF CAN COMMUNICATION SYSTEM (a) Use the intelligent tester to check if the CAN Communication System is functioning normally (See page CA-8). ST–17 2GR-FE STARTING – SMART KEY SYSTEM Result Result Proceed to CAN DTC is not output A CAN DTC is output B B GO TO CAN COMMUNICATION SYSTEM A 5 CHECK FOR DTC (a) Check for DTCs and note any codes that are output (See page ST-26). (b) Delete DTCs. (c) Recheck for DTCs. Result Result Proceed to DTC does not reoccur A DTC reoccurs B B GO TO DIAGNOSTIC TROUBLE CODE CHART A 6 INSPECT BASIC OPERATION (a) Turn the engine switch on (START) and check that the engine starts normally. Make sure the brake pedal is depressed and the shift position is P at this time. (b) Check that the engine switch mode can be changed by pushing the engine switch. HINT: Without depressing the brake pedal, push the engine switch repeatedly. Engine switch mode should turn from off to on (ACC) to on (IG) and back to off. With the brake pedal depressed, push the engine switch repeatedly. Engine switch mode should turn to ENGINE START from any status. OK: Engine can start normally. NEXT 7 ST PROBLEM SYMPTOMS TABLE Result Result Proceed to Fault is not listed in the problem symptoms table A Fault is listed in the problem symptoms table B ST–18 2GR-FE STARTING – SMART KEY SYSTEM B Go to step 9 A 8 OVERALL ANALYSIS AND TROUBLESHOOTING (a) Terminals of ECU (See page ST-19) (b) DATA LIST/ACTIVE TEST (See page ST-26) NEXT 9 REPAIR OR REPLACE NEXT 10 NEXT END ST CONFIRMATION TEST ST–19 2GR-FE STARTING – SMART KEY SYSTEM PROBLEM SYMPTOMS TABLE HINT: • Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. • Inspect the fuses and relays related to the system before inspecting the suspected areas below. PUSH-BUTTON START FUNCTION: Symptom Power does not turn on (neither ACC nor IG is possible). Power is not turned on (only ACC is not turned on). Power is not turned on (only IG is not turned on). Engine does not start. Engine switch indicator light does not come on. Suspected area See page 1. AM2 Fuse ST-114 2. Engine Switch - 3. Wire Harness or Connector - 4. Main Body ECU (Instrument Panel J/B) - 5. Certification ECU - 6. ID Code Box - 7. Steering Lock ECU - 8. Smart Key System (Entry Function) - 1. AM2 Fuse ST-131 2. Wire Harness or Connector - 3. Main Body ECU (Instrument Panel J/B) - 1. AM2 Fuse ST-122 2. IG1 Relay - 3. IG2 Relay - 4. Wire Harness or Connector - 5. Main Body ECU (Instrument Panel J/B) - 1. Main Body ECU (Instrument Panel J/B) ST-95 2. Certification ECU - 3. Shift Lock Control ECU - 4. ID Code Box - 5. Stop SW Fuse - 6. Stop Light Switch - 7. Electrical Steering Lock Function - 8. Engine Control System - 9. Engine Immobiliser System - 10. Wire Harness or Connector - Engine Switch Indicator Light Circuit ST-110 ST ST–20 2GR-FE STARTING – SMART KEY SYSTEM TERMINALS OF ECU 1. CHECK MAIN BODY ECU (INSTRUMENT PANEL J/B) Front Side: IK IM IL IF IC IJ IE ID IN IR IB IA IP IO Back Side: E7 E6 IG II E8 E9 IH ST B112605E03 (a) Disconnect the IR, IA, IK, ID, IF, IM E6, E7 and E8 ECU connectors. ST–21 2GR-FE STARTING – SMART KEY SYSTEM (b) Measure the voltage and resistance of the wire harness side connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition AM1 (E7-6) - Body ground L - Body ground +B power supply Always 10 to 14 V AM2 (E6-1) - Body ground L - Body ground +B power supply Always 10 to 14 V SSW1 (E7-17) - Body ground L - Body ground Engine switch signal Engine switch pushed Below 1 Ω SSW1 (E7-17) - Body ground L - Body ground Engine switch signal Engine switch not pushed 10 kΩ or higher SSW2 (E7-16) - Body ground V - Body ground Engine switch signal Engine switch pushed Below 1 Ω SSW2 (E7-16) - Body ground V - Body ground Engine switch signal Engine switch not pushed 10 kΩ or higher GND3 (E8-1) - Body ground W-B - Body ground Ground Always Below 1 Ω LIN1 (IR-9) - Body ground O - Body ground LIN line Always 10 kΩ or higher BATB (IA-1) - Body ground B - Body ground +B Power supply Always 10 to 14 V GND1 (IF-10) - Body ground W-B - Body ground Ground Always Below 1 Ω GND2 (IM-9) - Body ground W-B - Body ground Ground Always Below 1 Ω CANN (E8-15) - Body ground W - Body ground CAN Line Always 10 kΩ or higher CANP (E8-16) - Body ground L - Body ground CAN Line Always 10 kΩ or higher CANH (E8-5) - Body ground R - Body ground CAN Line Always 10 kΩ or higher CANL (E8-6) - Body ground W - Body ground CAN Line Always 10 kΩ or higher ACC (IA-1) - Body ground B - Body ground ACC power supply Always 10 to 14 V IG (IA-1) - Body ground B - Body ground IG power supply Always 10 to 14 V If the result is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the ECU connectors. (d) Measure the voltage of the connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition ACCD (E7-22) - GND3 (E8-1) W - W-B ACC signal Engine switch on (ACC) Output voltage at terminal AM1 or AM2 is -2 V or more. ACCD (E7-22) - GND3 (E8-1) W - W-B ACC signal Engine switch off Below 1 V IG1D (E7-3) - GND3 (E8-1) P - W-B IG1 signal Engine switch on (IG) Output voltage at terminal AM1 or AM2 is -2 V or more. IG1D (E7-3) - GND3 (E8-1) P - W-B IG1 signal Engine switch on (ACC) Below 1 V IG2D (E6-11) - GND3 (E8-1) LG - W-B IG2 signal Engine switch on (IG) Output voltage at terminal AM1 or AM2 is -2 V or more. IG2D (E6-11) - GND3 (E8-1) LG - W-B IG2 signal Engine switch on (ACC) Below 1 V STP (IL-7) - GND3 (E8-1) L - W-B Stop light signal Brake pedal depressed Output voltage at terminal AM1 or AM2 is -2 V or more. STP (IL-7) - GND3 (E8-1) L - W-B Stop light signal Brake pedal released Below 1 V SLR+ (E7-19) - GND3 (E8-1) BR - W-B Steering lock motor signal Steering lock motor operating Below 1 V SLR+ (E7-19) - GND3 (E8-1) BR - W-B Steering lock motor signal Steering lock motor does not operate Output voltage at terminal AM1 or AM2 is -2 V or more. SLP (E7-18) - GND3 (E8-1) P - W-B Steering lock actuator position signal Steering lock is locked Pulse generation (See waveform 3) SLP (E7-18) - GND3 (E8-1) P - W-B Steering lock actuator position signal Steering lock is released Pulse generation (See waveform 3) SPD (E8-9) - GND3 (E8-1) V - W-B Vehicle speed signal Engine switch on (IG), rotate rear wheel slowly Pulse generation (See waveform 1) TACH (E8-8) - GND3 (E8-1) B - W-B Tachometer signal Engine running Pulse generation (See waveform 2) ST ST–22 Symbols (Terminal No.) 2GR-FE STARTING – SMART KEY SYSTEM Wiring Color Terminal Description Condition Specified Condition P (E9-2) - GND3 (E8-1) G - W-B Shift lock signal Shift lever P position Output voltage at terminal AM1 or AM2 is -2 V or more. P (E9-2) - GND3 (E8-1) G - W-B Shift lock signal Shift lever not P position Below 1 V 0.1 to 0.8 V *1 → Output voltage at terminal AM1 or AM2 is -2 V or more. ACCR (E6-3) - GND3 (E8-1) P - W-B Starter assist signal Brake pedal depressed, shift lever P position, engine switch is pushed once → on (IG) STSW (E9-4) - GND3 (E8-1) GR - W-B Starter activation request signal Brake pedal depressed, engine switch held on (ST) Output voltage at terminal AM1 or AM2 is -2 V or more. STR (E7-8) - GND3 (E8-1) G - W-B Park/neutral position switch Shift lever P or N position Below 1 V STR2 (E9-6) - GND3 (E8-1) V - W-B Starter signal Brake pedal depressed, shift lever P or N position, engine switch on (ST) Output voltage at terminal AM1 or AM2 is -3.5 V or more. *2 INDS (E7-15) - GND3 (E8-1) LG - W-B Vehicle condition signal Brake pedal depressed, shift lever P position. Output voltage at terminal AM1 or AM2 is -3 V or more. INDW (E7-14) - GND3 (E8-1) P - W-B Warning signal Brake pedal depressed, shift lever P position, engine switch on (ACC, IG) Output voltage at terminal AM1 or AM2 is -3 V or more. SWIL (E7-25) - GND3 (E8-1) O - W-B Illumination signal Light control switch TAIL or HEAD Output voltage at terminal AM1 or AM2 is -2 V or more. HINT: *1: Voltage is output only when the engine is cranking. *2: Voltage is output for 0.3 seconds when the engine is cranking to start. Disconnect the C55 connector from the ECM before measuring the voltage. If the result is not as specified, the ECU may have a malfunction. (e) Using an oscilloscope, check the signal waveform of the ECU. (1) Waveform 1 Waveform 1 (Reference): GND I042329E01 ST Terminal No. E8-9 (SPD) - Body ground Tool Setting 5 V/DIV., 10 ms./DIV. Vehicle Condition Driving at approx. 20 km/h (12 mph) HINT: As the vehicle speed increases, the wavelength shortens. ST–23 2GR-FE STARTING – SMART KEY SYSTEM (2) Waveform 2 Waveform 2 (Reference): Terminal No. E8-8 (TACH) - Body ground Tool Setting 5 V/DIV., 10 ms./DIV. Vehicle Condition Engine idling HINT: As the engine revolution speed increases, the wavelength shortens. GND I042330E01 (3) Waveform 3 Waveform 3 (Reference): Terminal No. Lock E7-18 (SLP) - Body ground Tool Setting 2 V/DIV., 100 ms./DIV. Vehicle Condition Steering lock/unlock 2. CHECK CERTIFICATION ECU GND Unlock A130277E01 E58 E59 E125964E05 (a) Disconnect the E58 ECU connector. (b) Measure the voltage and resistance of the wire harness side connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition +B (E58-1) - Body ground W - Body ground +B power supply Always 10 to 14 V IG (E58-18) - Body ground LG - Body ground Ignition power supply Engine switch on (IG) 10 to 14 V IG (E58-18) - Body ground LG - Body ground Ignition power supply Engine switch off Below 1 V LIN (E58-10) - Body ground O - Body ground LIN line Always 10 kΩ or higher E (E58-17) - Body ground W-B - Body ground Ground Always Below 1 Ω If the result is not as specified, there may be a malfunction on the wire harness side. ST ST–24 2GR-FE STARTING – SMART KEY SYSTEM 3. CHECK ECM A55 C55                                                                                                                                                                                           A107881E32 (a) Disconnect the C55 and A55 ECM connectors. (b) Measure the voltage and resistance of the wire harness side connectors. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition +B (A55-2) - Body ground R - Body ground Power source of ECM Engine switch on (IG) 10 to 14 V +B2 (A55-1) - Body ground R - Body ground Power source of ECM Engine switch on (IG) 10 to 14 V IGSW (A55-28) - Body ground Y - Body ground Ignition switch signal Engine switch on (IG) 10 to 14 V E01 (C55-22) - Body ground W-B - Body ground Ground Always Below 1 Ω E02 (C55-21) - Body ground W-B - Body ground Ground Always Below 1 Ω E03 (C55-104) - Body ground B - Body ground Ground Always Below 1 Ω E04 (C55-23) - Body ground W - Body ground Ground Always Below 1 Ω E05 (C55-46) - Body ground W - Body ground Ground Always Below 1 Ω E1 (C55-81) - Body ground W-B - Body ground Ground Always Below 1 Ω ME01 (C55-20) - Body ground B - Body ground Ground Always Below 1 Ω If the result is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the ECM connectors. (d) Measure the voltage of the connectors. ST Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition STA (A55-48) - E1 (C55-81) V - W-B Starter relay operation signal Cranking 10 to 14 V ACCR (A55-13) - E1 (C55-81) B - W-B ACC relay cut signal (output) Brake pedal depressed, shift lever P position, engine switch is pushed once → on (IG) 0.1 to 0.8 V *1 → Output voltage at terminal AM1 or AM2 is -2 V or more. TACH (A55-15) - E1 (C55-81) B - W-B Engine revolution signal (output) Idling Pulse generation (see waveform 1) STP (A55-36) - E1 (C55-81) W - W-B Stop light switch signal (input) Brake pedal depressed 7.5 to 14 V STP (A55-36) - E1 (C55-81) W - W-B Stop light switch signal (input) Brake pedal released Below 1.5 V STAR (C55-63) - E1 (C55-81) R - W-B PNP switch signal (input) Engine switch on (IG), shift position P or N 10 to 14 V HINT: *1: Voltage is output only when the engine is cranking. ST–25 2GR-FE STARTING – SMART KEY SYSTEM If the result is not as specified, the ECM may have a malfunction. (e) Using an oscilloscope, check the signal waveform of the ECM. Waveform 1 (Reference): Terminal No. A55-15 (TACH) - C55-81 (E1) Tool Setting 5 V/DIV., 10 ms./DIV. Vehicle Condition Engine idling GND I042330E01 4. HINT: As the vehicle speed increases, the wavelength shortens. CHECK STEERING LOCK ECU E51 7 6 5 4 3 2 1 B106649E13 (a) Disconnect the E51 ECU connector. (b) Measure the voltage and resistance of the wire harness side connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition B (E51-7) - Body ground P - Body ground +B power supply Always 10 to 14 V IG2 (E51-6) - Body ground B - Body ground Ignition power supply Engine switch on (IG) 10 to 14 V IG2 (E51-6) - Body ground B - Body ground Ignition power supply Engine switch off Below 1 V GND (E51-1) - Body ground W-B - Body ground Ground Always Below 1 Ω SGND (E51-2) - Body ground W-B - Body ground Ground Always Below 1 Ω If the result is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the E51 ECU connector. (d) Measure the voltage of the connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition SLP1 (E51-4) - GND (E51-1) P - W-B Steering lock actuator position signal Steering is locked 10 to 14 V SLP1 (E51-4) - GND (E51-1) P - W-B Steering lock actuator position signal Steering is released Below 1 V If the result is not as specified, the ECU may have a malfunction. ST ST–26 2GR-FE STARTING – SMART KEY SYSTEM DIAGNOSIS SYSTEM 1. DESCRIPTION (a) Push-button start function data and the Diagnostic Trouble Codes (DTCs) can be read through the Data Link Connector 3 (DLC3) of the vehicle. When the function seems to be malfunctioning, use the intelligent tester to check for malfunctions and perform repairs. 2. CHECK DLC3 HINT: The ECU uses ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. CG SG CANH SIL CANL BAT H100769E16 Symbols (Terminal No.) Terminal Description Condition Specified Condition CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω SIL (7) - SG (5) Bus "+" line During transmission Pulse generation BAT (16) - Body ground Battery positive Always 10 to 14 V CANH (6) - CANL (14) CANH (6) - CG (4) CANL (14) - CG (4) CANH (6) - BAT (16) CANL (14) - BAT (16) CAN bus line HIGH-level CAN bus line LOW-level CAN bus line HIGH-level CAN bus line LOW-level CAN bus line * 56 to 69 Ω * 200 Ω or more * 200 Ω or more * 6 kΩ or more * 6 kΩ or more Engine Switch OFF Engine Switch OFF Engine Switch OFF Engine Switch OFF Engine Switch OFF NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the engine switch, any other switches or the doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. ST 2GR-FE STARTING – SMART KEY SYSTEM CAN VIM DLC3 3. Intelligent Tester C131977E12 ST–27 HINT: Connect the cable of the intelligent tester to the DLC3, turn the engine switch on (IG) and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. • If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. DTC CHECK / CLEAR 1. CAN VIM DLC3 Intelligent Tester C131977E12 CHECK DTC (a) Connect the intelligent tester to the DLC3. (b) Turn the engine switch on (IG). (c) Enter the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTC by following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. 2. CLEAR DTC (a) Connect the intelligent tester to the DLC3. (b) Turn the engine switch on (IG). (c) Enter the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CLEAR CODES. (d) Erase the DTC by following the directions on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. ST ST–28 2GR-FE STARTING – SMART KEY SYSTEM DATA LIST / ACTIVE TEST 1. READ DATA LIST HINT: Using the intelligent tester to read the Data List allows the values or states of switches, sensors, actuators and other items to be read without removing any parts. This non-intrusive inspection can be very useful as intermittent conditions or signals may be discovered before parts or wiring is disturbed. Reading the DATA LIST information early in troubleshooting is one way to save diagnostic time. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. When using the intelligent tester with the engine switch off, turn on and off any of the door courtesy light switches repeatedly at 1.5 or less second intervals until communication between the tester and vehicle starts. (b) Turn the engine switch on (IG). (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST. (d) Read the DATA LIST. MAIN BODY: Item Normal Condition Diagnostic Note Engine switch on (ACC) / ON or OFF ON: Engine switch on (ACC) OFF: Engine switch off - IG SW Engine switch on (IG) / ON or OFF ON: Engine switch on (IG) OFF: Engine switch off - SHIFT P SIG Shift P position signal / ON or OFF ON: Shift position is P OFF: Shift position is not P - STR UNLOCK SW Steering lock condition / ON or OFF ON: Steering is unlocked OFF: Steering is locked - STOP LAMP SW Stop light switch / ON or OFF ON: Brake pedal depressed OFF: Brake pedal released - STSW1 Start switch 1 / ON or OFF ON: Engine switch is pushed OFF: Engine switch is not pushed - START SW2 Start switch 2 / ON or OFF ON: Engine switch is pushed OFF: Engine switch is not pushed - N SW / C SW Neutral start switch / ON or OFF ON: Shift position is P or N OFF: Shift position is neither P nor N - RATCH CIRCUIT Ratch circuit / ON or OFF ON: Engine switch on (IG) or engine running OFF: Engine switch off or on (ACC) - IG1 RELAY MON1 IG1 outer relay monitor / ON or OFF ON: Engine switch on (IG) OFF: Engine switch off - IG1 RELAY MON2 IG1 inner relay monitor / ON or OFF ON: Engine switch on (IG) OFF: Engine switch off - IG2 RELAY MON1 IG2 outer relay monitor / ON or OFF ON: Engine switch on (IG) OFF: Engine switch off - IG2 RELAY MON2 IG2 inner relay monitor / ON or OFF ON: Engine switch on (IG) OFF: Engine switch off - ST RELAY MON STARTER relay monitor / ON or OFF ON: Engine is cranking OFF: Engine is not cranking ACC SW ST Measurement Item / Display (Range) Engine is cranking with engine switch on (IG) and shift lever in P or N ST–29 2GR-FE STARTING – SMART KEY SYSTEM Measurement Item / Display (Range) Item Normal Condition Diagnostic Note ST REQUEST SIG Starter request signal monitor / ON or OFF ON: ST relay is ON OFF: ST relay is OFF ACC RELAY MON ACC relay monitor / ON or OFF ON: Engine switch on (ACC) OFF: Engine switch off - ACC CUT SIG ACC relay cut signal / ON or OFF ON: Engine is cranking OFF: Engine is not cranking - E/G COND Engine condition / STOP or RUN STOP: Engine is stopped RUN: Engine is running - Vehicle speed signal / STOP or RUN STOP: Vehicle is stopped RUN: Vehicle is running - PWR COND Power supply condition / ALL, ACC ON, IG1 IG2, ST ON ALL: All relays are OFF ACC ON: ACC relay is ON IG1: IG1 relay is ON IG2: IG2 relay is ON ST ON: ST request signal is ON - READY SIG Ready Signal / ON or OFF or Unknown VEHICLE SPD SIG COM ENTRY&STRT - Communication for certification ECU / OK or STOP 2. Engine switch pressed and held with shift lever in P or N OK: Communication STOP: No communication - PERFORM ACTIVE TEST HINT: Performing the intelligent tester's ACTIVE TEST allows the relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Connect the intelligent tester to the DLC3 (b) Turn the engine switch on (IG). (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST. (d) Perform the ACTIVE TEST according to the display on the tester. MAIN BODY: Item Test Details Diagnostic Note LIGHTING IND Indicator for lighting ON / OFF - IND CONDITION Engine switch indicator Green / Amber / No Sig - STR LOCK PWR Power supply for steering lock ECU ON / OFF - ST ST–30 2GR-FE STARTING – SMART KEY SYSTEM DIAGNOSTIC TROUBLE CODE CHART PUSH-BUTTON START FUNCTION: DTC No. Detection Item B2271 Ignition Hold Monitor Malfunction 1. AM2 fuse 2. Main body ECU (Instrument panel J/B) 3. Wire harness or connector ST-31 B2272 Ignition 1 Monitor Malfunction 1. IG1 relay 2. Main body ECU (Instrument panel J/B) 3. Wire harness or connector ST-34 B2273 Ignition 2 Monitor Malfunction 1. IG2 relay 2. Main body ECU (Instrument panel J/B) 3. Wire harness or connector ST-39 B2274 ACC Monitor Malfunction 1. ACC relay 2. Main body ECU (Instrument panel J/B) 3. Wire harness or connector ST-43 B2275 STSW Monitor Malfunction 1. ECM 2. Main body ECU (Instrument panel J/B) 3. Wire harness or connector ST-48 B2276 ACCR Signal Circuit Malfunction 1. Main body ECU (Instrument panel J/B) 2. ECM 3. Wire harness or connector ST-51 B2277 Detecting Vehicle Submersion Main body ECU (Instrument panel J/B) ST-54 B2278 Engine Switch Circuit Malfunction 1. Engine switch 2. Main body ECU (Instrument panel J/B) 3. Wire harness or connector ST-55 B2281 "P" Signal Malfunction 1. Main body ECU (Instrument panel J/B) 2. Shift lock control ECU 3. Wire harness or connector ST-60 B2282 Vehicle Speed Signal Malfunction 1. CAN communication system 2. Combination meter system 3. Main body ECU (Instrument panel J/B) 4. Wire harness or connector ST-63 B2283 Vehicle Speed Sensor Malfunction 1. B2282 detection area 2. Combination meter 3. Speed sensor 4. Skid control ECU 5. Main body ECU (Instrument panel J/B) 6. Wire harness or connector ST-69 B2284 Brake Signal Malfunction 1. Stop light switch 2. CAN communication system 3. ECM 4. Main body ECU (Instrument panel J/B) 5 Wire harness or connector ST-72 B2285 Steering Lock Position Signal Circuit Malfunction 1. Main body ECU (Instrument panel J/B) 2. Steering lock ECU 3. Wire harness or connector ST-77 B2286 Runnable Signal Malfunction 1. CAN communication system 2. ECM 3. Main body ECU (Instrument panel J/B) 4. Wire harness or connector ST-81 ST Trouble Area See page ST–31 2GR-FE STARTING – SMART KEY SYSTEM DTC No. Detection Item Trouble Area See page B2287 LIN Communication Master Malfunction 1. Main body ECU (Instrument panel J/B) 2. Certification ECU 3. Wire harness or connector ST-85 B2288 Steering Lock Signal Circuit Malfunction 1. Main body ECU (Instrument panel J/B) 2. Steering lock ECU 3. Wire harness or connector ST-88 B2289 Key Collation Waiting Time Over 1. Main body ECU (Instrument panel J/B) 2. Engine immobiliser system 3. Wire harness or connector 4. Certification ECU ST-91 ST ST–32 2GR-FE STARTING – SMART KEY SYSTEM ON-VEHICLE INSPECTION 1. Brake Pedal CHECK POWER SOURCE MODE CHANGE FUNCTION (a) Check the function of the engine switch. (1) Check that power source mode changes in accordance with the conditions of the shift position and brake pedal. Shift Lever Depressed Power Source Mode Pattern When the engine switch is pushed once. • off → engine start • on (ACC) → engine start • on (IG) → engine start P or N Position Each time the engine switch is pushed. • off → on (ACC) → on (IG) → off P position Not depressed Each time the engine switch is pushed. • off → on (ACC) → on (IG) → on (ACC) Except P Position - P Position When the engine switch is pushed with power source mode on (IG) (engine running). • on (IG) → off - Except P Position When the engine switch is pushed with power source mode on (IG) (engine running). • on (IG) → on (ACC) (b) Check if power source mode changes without pressing the engine switch. (1) With power source mode on (ACC) and the shift position in P, wait for at least 1 hour. Check that power source mode changes from on (ACC) to off automatically. 2. Indicator Light CHECK INDICATOR CONDITION (a) Check the indicator on the engine switch. (1) Check that the engine switch indicator turns on and changes color according to the table below. START STOP A109251E01 Power Source Mode/Condition ST Indicator Light Condition Brake pedal released Brake pedal depressed, shift lever in P or N off OFF ON (Green) (When key and vehicle IDs match) on (ACC, IG) ON (Amber) ON (Green) Engine running OFF OFF Steering lock not unlocked Flashes (Green) for 15 sec. Flashes (Green) for 15 sec. System malfunction Flashes (Amber) for 15 sec. Flashes (Amber) for 15 sec. ST–33 2GR-FE STARTING – SMART KEY SYSTEM DTC B2271 Ignition Hold Monitor Malfunction DESCRIPTION This DTC is output when a problem such as an open in the AM2 fuse, an open or short in the wire harness between the fuse and main body ECU, a short in the IG output circuit inside the main body ECU, a short between the main body ECU and relay, and a short in the relay is detected. HINT: When the main body ECU is replaced with a new one and the negative (-) battery terminal is connected, the power source mode becomes the IG-ON mode. When the battery is removed and reinstalled, the power source mode that was selected when the battery was removed is restored. After the main body ECU is replaced, perform the registration procedures for the engine immobiliser system (See page EI-8). DTC No. B2271 DTC Detection Condition Hold circuit, IG1 relay actuation circuit or IG2 relay actuation circuit inside main body ECU is open or shorted Trouble Area • • • AM2 fuse Main body ECU Wire harness or connector WIRING DIAGRAM Main Body ECU Engine Room J/B and R/B 1 1G FL MAIN AM2 1 6 E7 AM1 1 E6 AM2 Battery B137971E01 INSPECTION PROCEDURE 1 CHECK DTC OUTPUT ST (a) Delete the DTCs (See page ST-26). HINT: After all DTCs are cleared, check if the trouble occurs again 6 seconds after the engine switch is turned on (IG). (b) Check for DTCs again. ST–34 2GR-FE STARTING – SMART KEY SYSTEM OK: No DTC is output. NG Go to step 2 OK CHECK INTERMITTENT PROBLEMS 2 INSPECT FUSE (AM2) (a) Remove the AM2 fuse from the engine room J/B. (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω NG REPLACE FUSE OK 3 CHECK WIRE HARNESS (MAIN BODY ECU - BATTERY) (a) Disconnect the E6 and E7 ECU connectors. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness Side: E7 Main Body ECU Terminal No. (Symbol) Condition Specified Condition E7-6 (AM1) - Body ground Always 10 to 14 V E6-1 (AM2) - Body ground Always 10 to 14 V AM1 NG E6 ST AM2 B138000E01 REPAIR OR REPLACE HARNESS OR CONNECTOR 2GR-FE STARTING – SMART KEY SYSTEM ST–35 OK REPLACE MAIN BODY ECU ST ST–36 2GR-FE STARTING – SMART KEY SYSTEM DTC B2272 Ignition 1 Monitor Malfunction DESCRIPTION This DTC is output when there is a problem in the IG1D output circuit, which is from the inside of the main body ECU to the IG1 relay. HINT: When the main body ECU is replaced with a new one and the negative (-) battery terminal is connected, the power source mode becomes the IG-ON mode. When the battery is removed and reinstalled, the power source mode that was selected when the battery was removed is restored. After the main body ECU is replaced, perform the registration procedures for the engine immobiliser system (See page EI-8). DTC No. DTC Detection Condition Trouble Area • • • IG1 relay actuation circuit inside main body ECU or other related circuit is malfunctioning B2272 Main body ECU IG1 relay Wire harness or connector WIRING DIAGRAM Instrument Panel J/B Main Body ECU IG1 Relay 10 IF 1 2 9 II 3 5 1 IA GAUGE No. 1 ECU IG No. 1 3 E7 IG1D WIP WASH From Battery To Each System A/C No. 2 S-HTR ECU IG No. 2 B137972E01 ST INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. ST–37 2GR-FE STARTING – SMART KEY SYSTEM (b) Turn the engine switch on (IG) and turn the intelligent tester main switch on. (c) Select the item below in the Data List, and read the display on the tester. HINT: When using the intelligent tester with the engine switch off, turn on and off any of the door courtesy light switches repeatedly at 1.5 second intervals or less until communication between the tester and vehicle starts. MAIN BODY: Item Measurement Item / Display (Range) Normal Condition Diagnostic Note IG1 RELAY MON1 Status of IG1 relay monitor (outer) / ON or OFF ON: Engine switch on (IG) (IG1 relay is ON) OFF: Engine switch off (IG1 relay is OFF) - OK: "OK" (engine switch on (IG)) appears on the screen. NG Go to step 3 OK 2 CHECK ENGINE SWITCH CONDITION (a) Check the power source mode change. (1) When the key is inside the vehicle and the shift lever is in the P position, check that pressing the engine switch causes the power source mode to change as follows: OK: off → on (ACC) → on (IG) → off HINT: • If power mode does not change to ON (IG and ACC) (See page ST-114). • If power mode does not change to ON (IG) (See page ST-122). NG GO TO OTHER PROBLEM OK ST ST–38 3 2GR-FE STARTING – SMART KEY SYSTEM INSPECT RELAY (IG1 RELAY) (a) Remove the IG1 relay from the instrument panel J/B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance A092673E23 Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) NG REPLACE RELAY OK 4 CHECK WIRE HARNESS (INSTRUMENT PANEL J/B - MAIN BODY ECU) (a) Disconnect the Il J/B connector. Wire Harness Side: Main Body ECU II E7 IG1D B138001E01 (b) Disconnect the E7 ECU connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance ST Terminal No. (Symbol) Condition Specified Condition II-9 - E7-3 (IG1D) Always Below 1 Ω E7-3 (IG1D) - Body ground Always 10 kΩ or higher NG OK REPAIR OR REPLACE HARNESS OR CONNECTOR ST–39 2GR-FE STARTING – SMART KEY SYSTEM 5 CHECK WIRE HARNESS (INSTRUMENT PANEL J/B - BATTERY AND BODY GROUND) (a) Disconnect the IF and IA J/B connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side: Terminal No. Condition Specified value IF-10 - Body ground Always Below 1 Ω (c) Measure the voltage according to the value(s) in the table below. Standard voltage IA Terminal No. Condition Specified value IA-1 - Body ground Always 10 to 14 V NG IF REPAIR OR REPLACE HARNESS OR CONNECTOR A128037E02 OK 6 INSPECT INSTRUMENT PANEL J/B (a) Measure the resistance according to the value(s) in the table below. Instrument Panel J/B: IF II IG1 Relay Terminal ST A128038E02 ST–40 2GR-FE STARTING – SMART KEY SYSTEM Standard resistance Terminal No. Condition Specified value IF-10 - IG1 relay terminal-1 Always Below 1 Ω Il-9 - IG1 relay terminal-2 Always Below 1 Ω IF-10 - Body ground Always 10 kΩ or higher Il-9 - Body ground Always 10 kΩ or higher NG OK REPLACE MAIN BODY ECU ST REPLACE INSTRUMENT PANEL J/B ST–41 2GR-FE STARTING – SMART KEY SYSTEM DTC B2273 Ignition 2 Monitor Malfunction DESCRIPTION This DTC is output when there is a problem in the IG2D output circuit, which is from the inside of the main body ECU to the IG2 relay. HINT: When the main body ECU is replaced with a new one and the negative (-) battery terminal is connected, the power source mode becomes the IG-ON mode. When the battery is removed and reinstalled, the power source mode that was selected when the battery was removed is restored. After the main body ECU is replaced, perform the registration procedures for the engine immobiliser system (See page EI-8). DTC No. B2273 DTC Detection Condition Trouble Area IG2 relay actuation circuit inside main body ECU or other related circuit is malfunctioning • • • Main body ECU IG2 relay Wire harness or connector WIRING DIAGRAM Engine Room R/B Main Body ECU IG2 Relay 1 1 2 1 3 5 11 E6 1 1 IG2D From Battery Instrument Panel J/B 7 I1 GAUGE No. 2 IGN To Each System INJ B137973E01 ST INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. ST–42 2GR-FE STARTING – SMART KEY SYSTEM (b) Turn the engine switch on (IG) and turn the intelligent tester main switch on. (c) Read the Data List according to the displays on the tester. HINT: When using the intelligent tester with the engine switch off, turn on and off any of the door courtesy light switches repeatedly at 1.5 second intervals or less until communication between the tester and vehicle starts. MAIN BODY: Item Measurement Item / Display (Range) Normal Condition Diagnostic Note IG2 RELAY MON1 Status of IG2 relay monitor (outer) / ON or OFF ON: Engine switch on (IG) (IG2 relay is ON) OFF: Engine switch off (IG2 relay is OFF) - OK: "ON" (Engine switch on (IG)) appears on the screen. NG Go to step 3 OK 2 CHECK ENGINE SWITCH CONDITION (a) Check the power source mode change. (1) When the key is inside the vehicle and the shift lever is in the P position, check that pressing the engine switch causes the power source mode to change as follows: OK: off → on (ACC) → on (IG) → off HINT: • If power mode does not change to ON (IG and ACC) (See page ST-114). • If power mode does not change to ON (IG) (See page ST-122). • If power mode does not change to ON (ACC) (See page ST-131). NG OK ST GO TO OTHER PROBLEM ST–43 2GR-FE STARTING – SMART KEY SYSTEM 3 INSPECT RELAY (IG2 RELAY) 2 3 1 5 5 1 (a) Remove the IG2 relay from the engine room R/B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 2 3 B060778E89 NG REPLACE RELAY OK 4 CHECK WIRE HARNESS (ENGINE ROOM R/B - MAIN BODY ECU AND BODY GROUND) (a) Remove the IG2 relay from the engine room R/B. Wire Harness Side: E6 Main Body ECU Engine Room R/B IG2D IG2 Relay Terminal B138002E01 (b) Disconnect the E6 ECU connector. (c) Measure the resistance according to the value(s) in the table below. ST ST–44 2GR-FE STARTING – SMART KEY SYSTEM Standard resistance Terminal No. (Symbol) Condition Specified Condition Engine Room R/B IG2 relay terminal 1 E6-11 (IG2D) Always Below 1 Ω Engine Room R/B IG2 relay terminal 2 Body ground Always Below 1 Ω E6-11 (IG2D) - Body ground Always 10 kΩ or higher NG OK REPLACE MAIN BODY ECU ST REPAIR OR REPLACE HARNESS OR CONNECTOR ST–45 2GR-FE STARTING – SMART KEY SYSTEM DTC B2274 ACC Monitor Malfunction DESCRIPTION This DTC is output when there is a problem in the ACCD output circuit, which is from the inside of the main body ECU to the ACC relay. HINT: When the main body ECU is replaced with a new one and the negative (-) battery terminal is connected, the power source mode becomes the IG-ON mode. When the battery is removed and reinstalled, the power source mode that was selected when the battery was removed is restored. After the main body ECU is replaced, perform the registration procedures for the engine immobiliser system (See page EI-8). DTC No. B2274 DTC Detection Condition Trouble Area • • • ACC relay actuation circuit inside main body ECU or other related circuit is malfunctioning Main body ECU ACC relay Wire harness or connector WIRING DIAGRAM Instrument Panel J/B Main Body ECU ACC Relay 10 IF 1 2 3 II 3 5 1 IA PWR OUTLET 22 E7 ACCD ECU-ACC To Each System From Battery RADIO No. 2 B137974E01 ST INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. ST–46 2GR-FE STARTING – SMART KEY SYSTEM (b) Turn the engine switch on (IG) and turn the intelligent tester main switch on. (c) Read the Data List according to the displays on the tester. HINT: When using the intelligent tester with the engine switch off, turn on and off any of the door courtesy light switches repeatedly at 1.5 second intervals or less until communication between the tester and vehicle starts. MAIN BODY: Item Measurement Item / Display (Range) ACC RELAY MON Status of ACC Relay Monitor / ON or OFF Normal Condition ON: Engine switch on (ACC) OFF: Engine switch off Diagnostic Note - OK: "ON" (engine switch on (ACC)) appears on the screen. NG Go to step 3 OK 2 CHECK ENGINE SWITCH CONDITION (a) Check the power source mode change. (1) When the key is inside the vehicle and the shift lever is in the P position, check that pressing the engine switch causes the power source mode to change as follows: OK: off → on (ACC) → on (IG) → off HINT: • If power mode does not change to ON (IG and ACC) (See page ST-114). • If power mode does not change to ON (IG) (See page ST-122). • If power mode does not change to ON (ACC) (See page ST-131). NG OK ST GO TO OTHER PROBLEM ST–47 2GR-FE STARTING – SMART KEY SYSTEM 3 INSPECT RELAY (ACC RELAY) (a) Remove the ACC relay from the instrument panel J/B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance A092673 Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) NG REPLACE RELAY OK 4 CHECK WIRE HARNESS (INSTRUMENT PANEL J/B - MAIN BODY ECU) (a) Disconnect the E7 ECU connector. Wire Harness Side: Main Body ECU II E7 ACCD B138001E02 (b) Disconnect the II J/B connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Terminal No. (Symbol) Condition Specified Condition II-3 - E7-22 (ACCD) Always Below 1 Ω E7-22 or II-3 - Body ground Always 10 kΩ or higher NG OK REPAIR OR REPLACE HARNESS OR CONNECTOR ST ST–48 5 2GR-FE STARTING – SMART KEY SYSTEM CHECK WIRE HARNESS (INSTRUMENT PANEL J/B - BATTERY AND BODY GROUND) (a) Disconnect the IF and IA J/B connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side: Terminal No. Condition Specified Condition IF-10 - Body ground Always Below 1 Ω (c) Measure the voltage according to the value(s) in the table below. Standard voltage IA Terminal No. Condition Specified Condition IA-1 - Body ground Always 10 to 14 V NG IF REPAIR OR REPLACE HARNESS OR CONNECTOR A128037E03 OK 6 INSPECT INSTRUMENT PANEL J/B (a) Measure the resistance according to the value(s) in the table below. Wire Harness Side: IF Front Side: ST Back Side: II ACC Relay Terminal B138003E01 ST–49 2GR-FE STARTING – SMART KEY SYSTEM Standard resistance Terminal No. Condition Specified Condition ACC relay terminal 1 IF-10 Always Below 1 Ω ACC relay terminal 2 - II3 Always Below 1 Ω IF-10 - Body ground Always 10 kΩ or higher II-3 - Body ground Always 10 kΩ or higher NG REPLACE INSTRUMENT PANEL J/B OK REPLACE MAIN BODY ECU ST ST–50 2GR-FE STARTING – SMART KEY SYSTEM DTC B2275 STSW Monitor Malfunction DESCRIPTION This DTC is output when there is an open, short, or any other problem in the engine start request output circuit inside the main body ECU or in the external circuit. HINT: When the main body ECU is replaced with a new one and the negative (-) battery terminal is connected, the power source mode becomes the IG-ON mode. When the battery is removed and reinstalled, the power source mode that was selected when the battery was removed is restored. After the main body ECU is replaced, perform the registration procedures for the engine immobiliser system (See page EI-8). DTC No. DTC Detection Condition B2275 ST output circuit (engine starting request signal circuit) inside main body ECU or other related circuit is malfunctioning Trouble Area • • • Main body ECU ECM Wire harness or connector WIRING DIAGRAM Main Body ECU ECM STSW 14 A55 4 E9 STSW B137975E01 INSPECTION PROCEDURE 1 ST CHECK DTC OUTPUT (a) Delete the DTCs (See page ST-26). HINT: After all DTCs are cleared, turn the engine switch on (IG) and depress the brake pedal. After 15 seconds have elapsed, check if the trouble occurs again. (b) Check for DTCs again. OK: No DTC is output. NG Go to step 2 ST–51 2GR-FE STARTING – SMART KEY SYSTEM OK CHECK INTERMITTENT PROBLEMS 2 CHECK WIRE HARNESS (MAIN BODY ECU - ECM) (a) Disconnect the E9 ECU connector. Wire Harness Side: ECM E9 Main Body ECU STSW A55 STSW B137996E02 (b) Disconnect the A55 ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Terminal No. (Symbol) Condition Specified Condition E9-4 (STSW) - A55-14 (STSW) Always Below 1 Ω E9-4 (STSW) - Body ground Always 10 kΩ or higher NG OK REPAIR OR REPLACE HARNESS OR CONNECTOR ST ST–52 3 2GR-FE STARTING – SMART KEY SYSTEM INSPECT MAIN BODY ECU (a) Reconnect the connectors. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Main Body ECU E9 STSW Terminal No. (Symbol) Condition Specified Condition E9-4 (STSW) - Body ground Brake pedal depressed, Engine switch hold on (ST) Output voltage at terminal AM1 or AM2 is -2 V or more. NG REPLACE MAIN BODY ECU B138004E01 OK 4 CHECK MAIN BODY ECU OPERATION (a) After replacing the main body ECU with a normally functioning ECU, check that the engine can start. OK: Engine can start normally. NG OK END (MAIN BODY ECU DEFECTIVE) ST GO TO ENGINE CONTROL SYSTEM ST–53 2GR-FE STARTING – SMART KEY SYSTEM DTC B2276 ACCR Signal Circuit Malfunction DESCRIPTION This DTC is output when the ACCR output circuit inside the main body ECU is open or shorted. HINT: When the main body ECU is replaced with a new one and the negative (-) battery terminal is connected, the power source mode becomes the IG-ON mode. When the battery is removed and reinstalled, the power source mode that was selected when the battery was removed is restored. After the main body ECU is replaced, perform the registration procedures for the engine immobiliser system (See page EI-8). DTC No. DTC Detection Condition ACCR output circuit inside main body ECU or other related circuit is malfunctioning B2276 Trouble Area • • • Main body ECU ECM Wire harness or connector WIRING DIAGRAM Main Body ECU ECM ACCR 13 A55 3 E6 ACCR B137975E02 INSPECTION PROCEDURE 1 CHECK DTC OUTPUT (a) Delete the DTCs (See page ST-26). HINT: After all DTCs are cleared, check if the trouble occurs again 50 seconds after the engine switch is turned on (IG). (b) Check for DTCs again. OK: No DTC B2276 is output. NG OK CHECK INTERMITTENT PROBLEMS Go to step 2 ST ST–54 2 2GR-FE STARTING – SMART KEY SYSTEM CHECK WIRE HARNESS (MAIN BODY ECU - ECM) (a) Disconnect the E6 ECU connector. Wire Harness Side: ECM E6 Main Body ECU A55 ACCR ACCR B138005E01 (b) Disconnect the A55 ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Terminal No. (Symbol) Condition Specified Condition E6-3 (ACCR) - A55-13 (ACCR) Always Below 1 Ω E6-3 (ACCR) - Body ground Always 10 kΩ or higher NG ST OK REPAIR OR REPLACE HARNESS OR CONNECTOR ST–55 2GR-FE STARTING – SMART KEY SYSTEM 3 INSPECT MAIN BODY ECU (a) Reconnect the connectors. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Main Body ECU E6 Terminal No. (Symbol) Condition Specified Condition E6-3 (ACCR) - Body ground Brake pedal depressed, shift P position, engine switch is pushed once → on (IG) 0.1 to 0.8 V → output voltage at terminal AM1 or AM2 is -2 V or more. HINT: Voltage is output only when the engine is cranking. ACCR NG REPLACE MAIN BODY ECU B138007E01 OK 4 CHECK MAIN BODY ECU OPERATION (a) After replacing the main body ECU with a normally functioning ECU, check that the engine starts. OK: Engine can start normally. NG REPLACE ECM OK END (MAIN BODY ECU DEFECTIVE) ST ST–56 2GR-FE STARTING – SMART KEY SYSTEM DTC B2277 Detecting Vehicle Submersion DESCRIPTION This DTC is output when the submersion circuit monitor inside the main body ECU detects that the vehicle is submerged in water. HINT: When the main body ECU is replaced with a new one and the negative (-) battery terminal is connected, the power source mode becomes the IG-ON mode. When the battery is removed and reinstalled, the power source mode that was selected when the battery was removed is restored. After the main body ECU is replaced, perform the registration procedures for the engine immobiliser system (See page EI-8). DTC No. B2277 DTC Detection Condition Trouble Area Submersion circuit monitor inside main body ECU detects that vehicle is submerged in water Main body ECU INSPECTION PROCEDURE 1 CHECK FOR WATER DAMAGE (a) Check the main body ECU, peripheral components, and wire harnesses for traces of water. OK: There are no traces of water. NG TAKE APPROPRIATE MEASURES AGAINST CAUSE OF WATER DAMAGE AND REPLACE MAIN BODY ECU OK 2 CHECK DTC OUTPUT (a) Delete the DTCs (See page ST-26). HINT: After all DTCs are cleared, check if the trouble occurs again 30 seconds after the engine switch is turned on (IG). (b) Check for DTCs again. OK: No DTC is output. NG ST OK END REPLACE MAIN BODY ECU ST–57 2GR-FE STARTING – SMART KEY SYSTEM DTC B2278 Engine Switch Circuit Malfunction DESCRIPTION This DTC is output when 1) a malfunction is detected between the main body ECU and the engine switch; or 2) either of the switches inside the engine switch is malfunctioning. HINT: When the main body ECU is replaced with a new one and the negative (-) battery terminal is connected, the power source mode becomes the IG-ON mode. When the battery is removed and reinstalled, the power source mode that was selected when the battery was removed is restored. After the main body ECU is replaced, perform the registration procedures for the engine immobiliser system (See page EI-8). DTC No. B2278 DTC Detection Condition Communication is abnormal between the main body ECU and engine switch or the engine switch is defective Trouble Area • • • Engine switch Main body ECU Wire harness or connector ST ST–58 2GR-FE STARTING – SMART KEY SYSTEM WIRING DIAGRAM E7 Main Body ECU E52 Engine Switch SS1 7 17 SS2 2 16 SSW1 SSW2 SS1 GND SS2 Free Full Travelling GND 5 B112447E03 INSPECTION PROCEDURE 1 ST READ VALUE OF INTELLIGENT TESTER (START SWITCH) (a) Connect the intelligent tester to the DLC3. (b) Check the DATA LIST for proper functioning of the start switch. HINT: When using the intelligent tester with the engine switch off, turn on and off any of the door courtesy light switches repeatedly at 1.5 second intervals or less until communication between the tester and vehicle starts. ST–59 2GR-FE STARTING – SMART KEY SYSTEM MAIN BODY: Measurement Item/Display (Range) Item Normal Condition Diagnostic Note STSW1 Start Switch 1/ON or OFF ON: Engine switch on (IG) OFF: Engine switch off - START SW2 Start Switch 2/ON or OFF ON: Engine switch on (IG) OFF: Engine switch off - OK: ON (engine switch on (IG)) and OFF (engine switch off) appear on the screen. OK Go to step 3 NG 2 CHECK ENGINE SWITCH CONDITION (a) Check the power source mode change. (1) When the key is inside the vehicle and the shift lever is in the P position, check that pressing the engine switch causes the power source mode to change as follows: OK: off → on (ACC) → on (IG) → off HINT: • If power mode does not change to ON (IG and ACC) (See page ST-114). • If power mode does not change to ON (IG) (See page ST-122). • If power mode does not change to ON (ACC) (See page ST-131). NG GO TO OTHER PROBLEM OK END 3 INSPECT ENGINE SWITCH (a) Remove the engine switch. SS1 GND SS2 ST START STOP 7 6 5 4 3 2 1 14 13 12 11 10 9 8 A109252E01 (b) Disconnect the switch connector. ST–60 2GR-FE STARTING – SMART KEY SYSTEM (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection (Symbols) Switch Condition Specified Condition 7 (SS1) - 5 (GND) Pushed Below 1 Ω 2 (SS2) - 5 (GND) Pushed Below 1 Ω 7 (SS1) - 5 (GND) Not pushed 10 kΩ or higher 2 (SS2) - 5 (GND) Not pushed 10 kΩ or higher HINT: This switch is a momentary type switch. NG REPLACE ENGINE SWITCH OK 4 CHECK WIRE HARNESS (ENGINE SWITCH - MAIN BODY ECU AND BODY GROUND) (a) Disconnect the E7 ECU connector. Wire Harness Side: E7 Main Body ECU E52 Engine Switch SS1 SS2 SSW1 GND SSW2 B137980E01 (b) Disconnect the E52 switch connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance ST Tester Connection (Symbols) Condition Specified Condition E52-7 (SS1) - E7-17 (SSW1) Always Below 1 Ω E52-2 (SS2) - E7-16 (SSW2) Always Below 1 Ω E52-5 (GND) - Body ground Always Below 1 Ω E52-7 (SS1) or E7-17 (SSW1) - Body ground Always 10 kΩ or higher E52-2 (SS2) or E7-16 (SSW2) - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR 2GR-FE STARTING – SMART KEY SYSTEM ST–61 OK REPLACE MAIN BODY ECU ST ST–62 2GR-FE STARTING – SMART KEY SYSTEM DTC B2281 "P" Signal Malfunction DESCRIPTION The main body ECU and the shift lock control ECU are connected by a cable and the CAN. If the cable information and CAN information are inconsistent, this DTC will be output. HINT: After the main body ECU is replaced, perform the registration procedures for the engine immobiliser system (See page EI-8). DTC No. DTC Detection Condition Trouble Area Cable information and CAN information between main body ECU and shift lock control ECU are inconsistent B2281 • • • Main body ECU Shift lock control ECU Wire harness or connector WIRING DIAGRAM Shift Lock Control ECU Main Body ECU ECM From PNP Switch P CAN CAN CAN P2 2 E9 11 E57 P B137990E01 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Turn the engine switch on (IG) and turn the intelligent tester main switch on. (c) Read the DATA LIST according to the displays on the tester. ST MAIN BODY: Item SHIFT P SIG Measurement Item / Range (Display) Shift P Signal / ON or OFF Normal Condition ON: Shift P signal ON (Shift position is P) OFF: Shift P signal OFF (Shift position is not P) Diagnostic Note - ST–63 2GR-FE STARTING – SMART KEY SYSTEM OK: "ON" (P signal is ON) and "OFF" (P signal is OFF) appear on the screen. NG Go to step 2 OK GO TO SHIFT CONTROL SYSTEM 2 CHECK WIRE HARNESS (MAIN BODY ECU - SHIFT LOCK CONTROL ECU) (a) Disconnect the E9 and E57 ECU connectors. Wire Harness Side: E57 Shift Lock Control ECU E9 Main Body ECU P P2 B138006E01 (b) Measure the resistance according to the value(s) in the table below. Standard resistance Terminal No. (Symbol) Condition Specified Condition E9-2 (P) - E57-11 (P2) Always Below 1 Ω E9-2 (P) - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 CHECK MAIN BODY ECU OPERATION (a) After replacing the main body ECU with a normally functioning ECU, check that the engine can start normally. ST ST–64 2GR-FE STARTING – SMART KEY SYSTEM OK: Engine can start normally. NG OK END (MAIN BODY ECU DEFECTIVE) ST GO TO SHIFT CONTROL SYSTEM ST–65 2GR-FE STARTING – SMART KEY SYSTEM DTC B2282 Vehicle Speed Signal Malfunction DESCRIPTION The main body ECU and the combination meter are connected by a cable and the CAN. DTC B2282 is output when: 1) the cable information and CAN information are inconsistent; and 2) a malfunction is detected between the vehicle speed sensor and combination meter. HINT: When the main body ECU is replaced with a new one and the negative (-) battery terminal is connected, the power source mode becomes the IG-ON mode. When the battery is removed and reinstalled, the power source mode that was selected when the battery was removed is restored. After the main body ECU is replaced, perform the registration procedures for the engine immobiliser system (See page EI-8). DTC No. DTC Detection Condition B2282 When both conditions below are met: • Cable information and CAN information between the main body ECU and the combination meter are inconsistent • Malfunction is detected between the vehicle speed sensor and the combination meter Skid Control ECU 4 pulses Combination Meter (Meter ECU) Front Speed Sensor Trouble Area • • • • CAN communication system Combination meter system Main body ECU Wire harness or connector 4 pulses Main Body ECU CAN B2282 Detection Area B2283 Detection Area A109248E08 ST ST–66 2GR-FE STARTING – SMART KEY SYSTEM WIRING DIAGRAM F2 Combination Meter E8 Main Body ECU CAN CAN CAN +S 12 9 F19 Stereo Component Amplifier SPD 11 E60 Tire Pressure Warning ECU SPD 2 F8 Radio Receiver 3 3 SPD F13 Radio and Display 3 C56 Transmission Control ECU SPD1 SPD SPD A55 ECM 8 SPD B137981E01 ST HINT: • A voltage of 12 V or 5 V is output from each ECU and then input to the combination meter. The signal is changed to a pulse signal at the transistor in the combination meter. Each ECU controls the respective system based on the pulse signal. • If a short occurs in an ECU, all systems in the diagram above will not operate normally. 2GR-FE STARTING – SMART KEY SYSTEM ST–67 INSPECTION PROCEDURE 1 CHECK OPERATION OF SPEEDOMETER (a) Drive the vehicle and check if the function of the speedometer in the combination meter is normal. OK: Actual vehicle speed and the speed indicated on the speedometer are the same. HINT: The vehicle speed sensor is functioning normally when the indication on the speedometer is normal. NG GO TO COMBINATION METER SYSTEM OK 2 CHECK DTC OUTPUT (CAN COMMUNICATION SYSTEM) (a) Delete the DTCs (See page ST-26). (b) Check for CAN communication system DTCs. HINT: If the DTCs for the CAN communication system malfunction are output, inspect those DTCs first (See page CA-31). OK: No DTC is output. NG GO TO CAN COMMUNICATION SYSTEM OK 3 CHECK WIRE HARNESS (MAIN BODY ECU - COMBINATION METER) (a) Disconnect the E8 ECU connector. ST ST–68 2GR-FE STARTING – SMART KEY SYSTEM Wire Harness Side: Combination Meter E8 Main Body ECU F2 SPD +S B137982E01 (b) Disconnect the F2 meter connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection (Symbols) Condition Specified Condition E8-9 (SPD) - F2-12 (+S) Body ground Always Below 1 Ω NG OK ST REPAIR OR REPLACE HARNESS OR CONNECTOR ST–69 2GR-FE STARTING – SMART KEY SYSTEM 4 CHECK WIRE HARNESS (MAIN BODY ECU - BODY GROUND) (a) Wire Harness Side: E8 Main Body ECU Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection (Symbols) Condition Specified Condition E8-9 (SPD) - Body ground Always 10 kΩ or higher HINT: If the result of the inspection for a short circuit is not as specified, there may be a short in the ECU. SPD NG REPAIR OR REPLACE HARNESS, CONNECTOR OR EACH ECU B137983E01 OK 5 READ VALUE OF INTELLIGENT TESTER (VEHICLE SPEED SIGNAL) (a) (b) (c) (d) Reconnect the connectors. Connect the intelligent tester to the DLC3. Turn the engine switch on (IG). Check the DATA LIST for proper functioning of the vehicle speed signal. MAIN BODY: Item VEHICLE SPD SIG Measurement Item/Display (Range) Vehicle speed signal/STOP or RUN Normal Condition STOP: Vehicle is stopped RUN: Vehicle is running Diagnostic Note - OK: STOP (vehicle is stopped) and RUN (vehicle is running) appear on the screen. OK NG CHECK INTERMITTENT PROBLEMS ST ST–70 6 2GR-FE STARTING – SMART KEY SYSTEM INSPECT MAIN BODY ECU (SPEED SIGNAL) (a) Check the input signal waveform. (1) Reconnect the connectors. (2) Remove the combination meter assembly with the connector(s) still connected. (3) Connect an oscilloscope to terminal E8-9 (SPD) and body ground. (4) Turn the engine switch on (IG). (5) Turn the wheel slowly. Main Body ECU E8 SPD B137984E01 (6) Check the signal waveform according to the condition(s) in the table below. Item GND NG REPLACE MAIN BODY ECU ST Tool setting 5 V/DIV., 10 ms./DIV. Vehicle condition Driving at approx. 20 km/h (12 mph) OK: The waveform is displayed as shown in the illustration. HINT: As the vehicle speed increases, the cycle of the signal waveform narrows. I042329E01 OK Condition REPLACE COMBINATION METER ST–71 2GR-FE STARTING – SMART KEY SYSTEM DTC B2283 Vehicle Speed Sensor Malfunction DESCRIPTION The skid control ECU converts these signals into 4-pulse signals and sends them to the combination meter. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the main body ECU. The main body ECU determines the vehicle speed based on the frequency of these pulse signals. HINT: When the main body ECU is replaced with a new one and the negative (-) battery terminal is connected, the power source mode becomes the IG-ON mode. When the battery is removed and reinstalled, the power source mode that was selected when the battery was removed is restored. After the main body ECU is replaced, perform the registration procedures for the engine immobiliser system (See page EI-8). DTC No. B2283 DTC Detection Condition When both conditions below are met: • Over-deceleration in vehicle speed • Vehicle speed and engine speed do not match Skid Control ECU 4 pulses Combination Meter (Meter ECU) Front Speed Sensor Trouble Area • • • • • • B2282 detection area Combination meter Speed sensor Skid control ECU Main body ECU Wire harness or connector 4 pulses Main Body ECU CAN B2282 Detection Area B2283 Detection Area A109248E08 ST ST–72 2GR-FE STARTING – SMART KEY SYSTEM INSPECTION PROCEDURE 1 CHECK DTC OUTPUT (SMART KEY SYSTEM) (a) Delete the DTCs (See page ST-26). (b) After all DTCs are cleared, check if the trouble occurs again 320 seconds after the engine switch is turned on (IG). (c) Check for DTC B2282 and DTC B2283. Result Display (DTC output) Proceed to "DTC B2283" only A "DTC B2283" and "DTC B2282" B No DTC C HINT: If DTC B2282 and DTC B2283 are output, perform troubleshooting for DTC B2282 first (See page ST-63). B GO TO DTC B2282 C CHECK INTERMITTENT PROBLEMS A 2 CHECK OPERATION OF SPEEDOMETER (a) Drive the vehicle and check if the function of the speedometer in the combination meter is normal. OK: Actual vehicle speed and the speed indicated on the speedometer are the same. HINT: The vehicle speed sensor is functioning normally when the indication on the speedometer is normal. NG GO TO COMBINATION METER SYSTEM OK 3 ST CHECK DTC OUTPUT (BRAKE CONTROL) (a) Delete the DTCs (See page ST-26). (b) Check for DTCs. (w/o VSC: See page BC-27) (for BOSCH made w/ VSC: See page BC-311) (for ADVICS made w/ VSC: See page BC-151) OK: No DTC is output. NG GO TO BRAKE CONTROL SYSTEM 2GR-FE STARTING – SMART KEY SYSTEM ST–73 OK REPLACE MAIN BODY ECU ST ST–74 2GR-FE STARTING – SMART KEY SYSTEM DTC B2284 Brake Signal Malfunction DESCRIPTION This DTC is output when: 1) the brake signal circuit between the main body ECU and the stop light switch is malfunctioning; and 2) the CAN information is inconsistent. HINT: When the main body ECU is replaced with a new one and the negative (-) battery terminal is connected, the power source mode becomes the IG-ON mode. When the battery is removed and reinstalled, the power source mode that was selected when the battery was removed is restored. After the main body ECU is replaced, perform the registration procedures for the engine immobiliser system (See page EI-8). DTC No. B2284 ST DTC Detection Condition Communication or communication line is abnormal between the main body ECU and the stop light switch Trouble Area • • • • • Stop light switch CAN communication system ECM Main body ECU Wire harness or connector ST–75 2GR-FE STARTING – SMART KEY SYSTEM WIRING DIAGRAM Main Body ECU A19 Stop Light Switch To ECM 2 1 4 3 Instrument Panel J/B 7 IL 23 STP From Battery Instrument Panel J/B 8 IC STOP SW 10 IF From Battery ECM CAN CAN CAN Line B137985E01 INSPECTION PROCEDURE 1. EMERGENCY ENGINE START CONTROL (a) If there is a malfunction in the stop light switch or STOP fuse, their signals may not be correctly transmitted to the main body ECU. This may result in the engine not starting even if the engine switch is pressed while the brake pedal is depressed and the shift lever is in the P position. To activate the starter: (1) Turn the engine switch from off to on (ACC). (2) Press and hold the engine switch for 15 seconds. ST ST–76 2GR-FE STARTING – SMART KEY SYSTEM HINT: Before performing the inspection, depress the brake pedal and check that the stop lights come on. If the stop lights do not come on when the brake pedal is depressed, refer to the page shown in the brackets (See page LI-12). 1 READ VALUE OF INTELLIGENT TESTER (STOP LIGHT SWITCH) (a) Connect the intelligent tester to the DLC3. (b) Turn the engine switch on (IG). (c) Check the DATA LIST for proper functioning of the stop light switch. MAIN BODY: Item STOP LAMP SW Measurement Item/Display (Range) Normal Condition ON: Brake pedal depressed OFF: Brake pedal released Stop light switch / ON or OFF Diagnostic Note - OK: ON (brake pedal depressed) and OFF (brake pedal released) appear on the screen. NG Go to step 4 OK 2 CHECK DTC OUTPUT (CAN COMMUNICATION SYSTEM) (a) Delete the DTCs (See page ST-26). (b) Check for CAN communication system DTCs (See page CA-31). HINT: If the DTCs for the CAN communication system malfunction are output, inspect those DTCs first (See page CA-31). OK: No DTC is output. NG GO TO CAN COMMUNICATION SYSTEM OK 3 CHECK DTC OUTPUT (ENGINE CONTROL SYSTEM) (a) Delete the DTCs (See page ST-26). (b) Check for DTC P0500 and P0503 (See page ES-63). OK: No DTC is output. ST NG OK REPLACE MAIN BODY ECU GO TO ENGINE CONTROL SYSTEM ST–77 2GR-FE STARTING – SMART KEY SYSTEM 4 INSPECT FUSE (STOP SW) (a) Remove the STOP SW fuse from the instrument panel J/ B. (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω NG REPLACE FUSE OK 5 CHECK WIRE HARNESS (BATTERY - MAIN BODY ECU) Wire Harness Side: IL Main Body ECU (a) Disconnect the IL ECU connector. (b) Measure the volage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition IL-7 - Body ground Brake pedal released Below 1 V IL-7 - Body ground Brake pedal depressed 10 to 14 V OK REPAIR OR REPLACE HARNESS OR CONNECTOR B137986E01 NG 6 INSPECT STOP LIGHT SWITCH Stop Light Switch: Pushed in 2 Free 4 (a) Remove the switch. (b) Measure the resistance of the switch. Standard resistance 1 Tester Connection Condition Specified Condition 1-2 Switch pin free Below 1 Ω 3-4 Switch pin free 10 kΩ or higher 1-2 Switch pin pushed in 10 kΩ or higher 3-4 Switch pin pushed in Below 1 Ω 3 I038520E04 NG REPLACE STOP LIGHT SWITCH ST ST–78 OK REPLACE MAIN BODY ECU ST 2GR-FE STARTING – SMART KEY SYSTEM ST–79 2GR-FE STARTING – SMART KEY SYSTEM DTC Steering Lock Position Signal Circuit Malfunction B2285 DESCRIPTION This DTC is output when serial communication signals and LIN communication signals in the circuit between the main body ECU and steering lock actuator (steering lock ECU) are inconsistent. HINT: When the main body ECU is replaced with a new one and the negative (-) battery terminal is connected, the power source mode becomes the IG-ON mode. When the battery is removed and reinstalled, the power source mode that was selected when the battery was removed is restored. After the main body ECU or steering lock ECU is replaced, perform the registration procedures for the engine immobiliser system (See page EI-8). DTC No. DTC Detection Condition Cable and LIN information between the main body ECU and the steering lock ECU are inconsistent B2285 Trouble Area • • • Main body ECU Steering lock ECU Wire harness or connector WIRING DIAGRAM E51 Steering Lock ECU SLP1 Main Body ECU 18 E7 4 SLP Instrument Panel J/B LIN LIN Line 5 9 IR 14 LIN1 B137987E01 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. ST ST–80 2GR-FE STARTING – SMART KEY SYSTEM (b) Check the DATA LIST for proper functioning of the steering lock function. HINT: When using the intelligent tester with the engine switch off, turn on and off any of the door courtesy light switches repeatedly at 1.5 second intervals or less until communication between the tester and vehicle starts. MAIN BODY: Measurement Item/Display (Range) Item STR UNLOCK SW Steering lock condition / ON or OFF Normal Condition Diagnostic Note ON: Steering is unlocked OFF: Steering is locked - OK: ON (steering is unlocked) and OFF (steering is locked) appear on the screen. NG Go to step 3 OK 2 CHECK FOR DTCS (a) Delete the DTCs (See page ST-26). (b) Check for DTC B2285, DTC B2287 and DTC B2785. Result Display (DTC output) Proceed to "DTC B2285" only A "DTC B2287" and/or "DTC B2785" B No DTC C HINT: • If DTC B2287 is output (See page ST-85). • If DTC B2785 is output (See page EI-29). B GO TO DTC CHART C CHECK INTERMITTENT PROBLEMS A REPLACE MAIN BODY ECU 3 ST CHECK WIRE HARNESS (MAIN BODY ECU - STEERING LOCK ECU) (a) Disconnect the E7 and E51 ECU connectors. ST–81 2GR-FE STARTING – SMART KEY SYSTEM Wire Harness Side: E7 Main Body ECU IR Main Body ECU SLP LIN1 E51 Steering Lock ECU LIN SLP1 B137995E01 (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection (Symbols) Condition Specified Condition E7-18 (SLP) - E51-4 (SLP1) Always Below 1 Ω IR-9 (LIN1) - E51-5 (LIN) Always Below 1 Ω E7-18 (SLP) or E51-4 (SLP1) - Body ground Always 10 kΩ or higher IR-9 (LIN1) or E51-5 (LIN) - Body ground Always 10 kΩ or higher NG OK REPAIR OR REPLACE HARNESS OR CONNECTOR ST ST–82 4 2GR-FE STARTING – SMART KEY SYSTEM CHECK MAIN BODY ECU OPERATION (a) After replacing the main body ECU with a normally functioning ECU, check that the engine starts (See page ST-30). OK: Engine can start normally. NG OK END (MAIN BODY ECU DEFECTIVE) ST REPLACE STEERING LOCK ECU ST–83 2GR-FE STARTING – SMART KEY SYSTEM DTC B2286 Runnable Signal Malfunction DESCRIPTION This DTC is output when serial communication signals and CAN communication signals in the circuit between the main body ECU and ECM are inconsistent. HINT: When the main body ECU is replaced with a new one and the negative (-) battery terminal is connected, the power source mode becomes the IG-ON mode. When the battery is removed and reinstalled, the power source mode that was selected when the battery was removed is restored. After the main body ECU is replaced, perform the registration procedures for the engine immobiliser system (See page EI-8). DTC No. DTC Detection Condition B2286 Serial communication signals and CAN communication signals in the circuit between the main body ECU and ECM are inconsistent. Trouble Area • • • • CAN communication system ECM Main body ECU Wire harness or connector ST ST–84 2GR-FE STARTING – SMART KEY SYSTEM WIRING DIAGRAM E8 Main Body ECU E10 DLC3 TAC 9 A55 ECM TACH 15 8 CAN TACH CAN CAN B137988E01 INSPECTION PROCEDURE 1 ST CHECK OPERATION OF TACHOMETER (a) Run the engine and check if the function of the tachometer in the combination meter is normal. OK: Actual engine revolution speed and the revolution indicated on the tachometer are the same. NG GO TO COMBINATION METER SYSTEM ST–85 2GR-FE STARTING – SMART KEY SYSTEM OK 2 CHECK DTC OUTPUT (CAN COMMUNICATION SYSTEM) (a) Delete the DTCs (See page ST-26). (b) Check for CAN communication system DTC U0146. HINT: If the DTCs for the CAN communication system malfunction are output, inspect those DTCs first (See page CA-31). OK: No DTC is output. NG GO TO CAN COMMUNICATION SYSTEM OK 3 CHECK WIRE HARNESS (MAIN BODY ECU - ECM) (a) Disconnect the A55 ECM connector. Wire Harness Side: E8 Main Body ECU ECM TACH A55 TACH ST B138064E01 (b) Disconnect the E8 ECU connector. (c) Measure the resistance according to the value(s) in the table below. ST–86 2GR-FE STARTING – SMART KEY SYSTEM Standard resistance Tester Connection (Symbols) Condition Specified Condition E8-8 (TACH) - A55-15 (TACH) Always Below 1 Ω E8-8 (TACH) or A55-15 (TACH) - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 4 READ VALUE OF INTELLIGENT TESTER (a) Reconnect the connectors. (b) Connect the intelligent tester to the DLC3. (c) Check the DATA LIST for proper functioning of the engine. HINT: When using the intelligent tester with the engine switch off, turn on and off any of the door courtesy light switches repeatedly at 1.5 second intervals or less until communication between the tester and vehicle starts. MAIN BODY: Item E/G COND Measurement Item/Display (Range) Engine condition/STOP or RUN Normal Condition STOP: Engine is stopped RUN: Engine is running Diagnostic Note - OK: STOP (engine is stopped) and RUN (engine is running) appear on the screen. NG OK REPLACE MAIN BODY ECU ST REPLACE ECM ST–87 2GR-FE STARTING – SMART KEY SYSTEM DTC B2287 LIN Communication Master Malfunction DESCRIPTION This DTC is output when there is a LIN communication problem between the main body ECU and certification ECU. HINT: When the main body ECU is replaced with a new one and the negative (-) battery terminal is connected, the power source mode becomes the IG-ON mode. When the battery is removed and reinstalled, the power source mode that was selected when the battery was removed is restored. After the main body ECU or certification ECU is replaced, perform the registration procedures for the engine immobiliser system (See page EI-8). DTC No. DTC Detection Condition Trouble Area B2287 Communication or communication line is abnormal between the main body ECU and the certification ECU • • • Main body ECU Certification ECU Wire harness or connector B2785 Detection Area Main Body ECU CAN CAN Line B2287 Detection Area Certification ECU MPX1 LIN Line Steering Lock ECU ID Code ECU SSW1 SSW2 Engine Switch ST B137997E01 ST–88 2GR-FE STARTING – SMART KEY SYSTEM WIRING DIAGRAM E58 Certification ECU Main Body ECU Instrument Panel J/B 9 LIN IR 10 14 LIN1 B137989E01 INSPECTION PROCEDURE 1 CHECK FOR DTCS (a) Delete the DTCs (See page ST-26). (b) Check for DTC B2287 and B2785. Result Display (DTC output) Proceed to "DTC B2287" only A "DTC B2287" and "DTC B2785" B No DTC C HINT: If DTC B2785 is output, perform troubleshooting for DTC B2785 first (See page EI-29). B GO TO DTC B2785 C CHECK INTERMITTENT PROBLEMS A ST 2 CHECK WIRE HARNESS (MAIN BODY ECU - CERTIFICATION ECU) (a) Disconnect the E58 and IR ECU connectors. ST–89 2GR-FE STARTING – SMART KEY SYSTEM Wire Harness Side: E58 Certification ECU IR Main Body ECU LIN LIN1 B137998E01 (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection (Symbols) Condition Specified Condition IR-9 (LIN1) - E58-10 (LIN) Always Below 1 Ω IR-9 (LIN1) or E58-10 (LIN) - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 CHECK MAIN BODY ECU OPERATION (a) After replacing the main body ECU with a normally functioning ECU, check that the engine starts (See page ST-30). OK: Engine can start normally. NG OK END (MAIN BODY ECU DEFECTIVE) REPLACE CERTIFICATION ECU ST ST–90 2GR-FE STARTING – SMART KEY SYSTEM DTC B2288 Steering Lock Signal Circuit Malfunction DESCRIPTION This DTC is output when the main body ECU cannot detect the unlock condition of the steering lock within a specified time. HINT: When the main body ECU is replaced with a new one and the negative (-) battery terminal is connected, the power source mode becomes the IG-ON mode. When the battery is removed and reinstalled, the power source mode that was selected when the battery was removed is restored. After the main body ECU is replaced, perform the registration procedures for the engine immobiliser system (See page EI-8). DTC No. DTC Detection Condition B2288 After turning engine switch from off to on (IG), the steering wheel does not unlock for a certain period of time (ECU unlocks steering wheel only when it receives an unlock signal from LIN communication and cable) Trouble Area • • • Main body ECU Steering lock ECU Wire harness or connector WIRING DIAGRAM E51 Steering Lock ECU SLP1 4 E7 Main Body ECU 18 SLP B112452E04 INSPECTION PROCEDURE ST 1 CHECK FOR DTCS (a) Delete the DTCs (See page ST-26). (b) After all DTCs are cleared, check if the trouble occurs again 5 seconds after the engine switch is turned on (IG). (c) Check for DTCs again. ST–91 2GR-FE STARTING – SMART KEY SYSTEM OK: DTC B2785, DTC B2287 and DTC B2781 are not output. HINT: • If DTC B2785 is output (See page EI-29). • If DTC B2287 is output (See page ST-85). • If DTC B2271 is output (See page ST-31). NG GO TO DTC CHART OK 2 CHECK WIRE HARNESS (MAIN BODY ECU - STEERING LOCK ECU) (a) Disconnect the E7 and E51 ECU connectors Wire Harness Side: E7 Main Body ECU SLP E51 Steering Lock ECU SLP1 B137999E01 (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition E7-18 (SLP) - E51-4 (SLP1) Always Below 1 Ω E7-18 (SLP) or E51-4 (SLP1) - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR ST ST–92 2GR-FE STARTING – SMART KEY SYSTEM OK 3 CHECK MAIN BODY ECU OPERATION (a) After replacing the main body ECU with a normally functioning ECU, check that the steering lock/unlock function operates normally. OK: Steering lock/unlock function operates normally. HINT: If steering lock/unlock function does not operate, refer to PROBLEM SYMPTOMS TABLE of the electrical steering lock (steering wheel cannot be unlocked) (See page SR10). NG OK END (MAIN BODY ECU DEFECTIVE) ST GO TO ELECTRIC STEERING LOCK ST–93 2GR-FE STARTING – SMART KEY SYSTEM DTC B2289 Key Collation Waiting Time Over DESCRIPTION This DTC is output when there is a LIN communication problem between the main body ECU and certification ECU or when there is a problem in the engine immobiliser system. HINT: After the main body ECU is replaced, perform the registration procedures for the engine immobiliser system (See page EI-8). DTC No. B2289 DTC Detection Condition Either condition below is met: • Cable and CAN are abnormal between the main body ECU and the engine immobiliser system • The engine immobiliser system is malfunctioning Trouble Area • • • • Main body ECU Engine immobiliser system Wire harness or connector Certification ECU B2785 Detection Area Main Body ECU CAN CAN Line B2289 Detection Area Certification ECU MPX1 LIN Line Steering Lock ECU ID Code ECU SSW1 SSW2 Engine Switch B137997E02 ST ST–94 2GR-FE STARTING – SMART KEY SYSTEM WIRING DIAGRAM E58 Certification ECU Main Body ECU Instrument Panel J/B 9 LIN IR 10 14 LIN1 B137989E02 INSPECTION PROCEDURE 1 CHECK FOR DTCS (a) Delete the DTCs (See page ST-26). (b) Check for DTC B2289 and B2785. Result Display (DTC output) Proceed to "DTC B2289" only A "DTC B2785" only B No DTC C HINT: • If DTC B2785 is output, perform troubleshooting for DTC B2785 first (See page EI-29). B GO TO DTC B2785 C CHECK INTERMITTENT PROBLEMS A ST 2 CHECK WIRE HARNESS (MAIN BODY ECU - CERTIFICATION ECU) (a) Disconnect the E58 and IR ECU connectors. ST–95 2GR-FE STARTING – SMART KEY SYSTEM Wire Harness Side: E58 Certification ECU IR Main Body ECU LIN LIN1 B137998E01 (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection (Symbols) Condition Specified Condition IR-9 (LIN1) - E58-10 (LIN) Always Below 1 Ω IR-9 (LIN1) or E58-10 (LIN) - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 CHECK MAIN BODY ECU OPERATION (a) After replacing the main body ECU with a normally functioning ECU, check that the engine starts. OK: Engine can start normally. HINT: If the engine does not start, refer to PROBLEM SYMPTOMS TABLE of the smart key system (entry) (matching for the inside of the cabin cannot be performed) (See page DL-147). NG GO TO SMART KEY SYSTEM (ENTRY) ST ST–96 2GR-FE STARTING – SMART KEY SYSTEM OK END (MAIN BODY ECU DEFECTIVE) ST ST–97 2GR-FE STARTING – SMART KEY SYSTEM Engine does not Start DESCRIPTION 1. ENGINE START SYSTEM FUNCTION (a) If the engine switch is pressed with the shift lever in the P or N position and the brake pedal depressed, the main body ECU determines that it is an engine start request. (b) The certification ECU and other ECUs perform key verification via the LIN communication line. (c) The main body ECU activates the ACC relay. (d) The main body ECU activates the IG1 and IG2 relays. (e) The certification ECU outputs a steering UNLOCK signal. The signal is sent to the main body ECU via the steering lock ECU. (f) The main body ECU sends an engine start request signal to the ECM. (g) The ECM sends an ACC cut request signal to the main body ECU. (h) The ECM and main body ECU activate the ST relay. (i) The main body ECU deactivates the ACC relay until the ECU detects an engine start. (j) When engine revolution speed reaches 200 rpm, the main body ECU determines that the engine has been started. The ECU reactivates the ACC relay and turns off the engine switch indicator light. Symbols of main body ECU Signals STP Stop light switch ON signal SSW1/SSW2 Engine switch ON signal ACCD ACC relay operation signal IG2D IG2 relay operation signal STR2 ST relay operation signal STR Park/neutral position switch signal TACH Engine start detection signal STSW Starter activation request signal ACCR ACC cut request signal ST ST–98 2GR-FE STARTING – SMART KEY SYSTEM Engine Switch MAIN BODY ECU AM2 AM1 AM2 From Battery SSW1 SSW2 CAN Line CAN Stop Light Switch STP Shift Lock Control ECU P Combination Meter SPD IG1 SLP Steering Lock ECU LIN1 IG1D IG2 ID Code Box IG2D Certification ECU ACC ACCD Key ST CUT STR2 LIN CAN ST A B B137946E01 2GR-FE STARTING – SMART KEY SYSTEM A ST–99 B STR STSW Park / Neutral Position Switch TACH GND1 GND2 ACCR Transmission Control ECU MAIN BODY ECU STA NSW ECM NSW ST STAR ACCR STA TACH Starter STSW Crankshaft Position Sensor NE+ NEBattery ST B137970E02 WIRING DIAGRAM See CRANKING HOLDING FUNCTION CIRCUIT (See page ES-455). ST–100 2GR-FE STARTING – SMART KEY SYSTEM INSPECTION PROCEDURE 1. EMERGENCY ENGINE START CONTROL (a) If there is a malfunction in the stop light switch or STOP fuse, their signals may not be correctly transmitted to the main body ECU. This may result in the engine not starting even if the engine switch is pressed while the brake pedal is depressed and the shift lever is in the P position. To activate the starter: (1) Turn the engine switch from off to on (ACC). (2) Press and hold the engine switch for 15 seconds. HINT: After the main body ECU, certification ECU, steering lock ECU, ID code box and/or ECM are/is replaced, perform the registration procedures for the engine immobiliser system (See page EI-8). 1 CHECK ENTRY FUNCTION DETECTION AREA Inspection Point B137958E01 (a) Inspect entry detection area. (1) When the electrical key is in either of the 2 inspection points in the illustration, the shift lever is in the P position and the brake pedal is depressed, check that the engine switch indicator illuminates in green. OK: Engine switch illuminates in green. HINT: If the engine switch does not illuminate, perform troubleshooting according to the PROBLEM SYMPTOMS TABLE (See page ST-17). NG GO TO OTHER PROBLEM OK 2 CHECK IF ENGINE STARTS (INITIALIZE STEERING LOCK) (a) Make sure that the shift lever is in the P position. (b) Open and close the driver's door with the engine switch off. Check if the engine can be started. OK: Engine can be started. HINT: After the battery is discharged and then recharged, the engine may not start unless the steering lock is initialized using the above procedure (See page SR-9). OK ST END NG 3 CHECK FOR DTC (a) Delete the DTCs (See page ST-26). (b) Check for DTCs again. OK: No DTC is output. 2GR-FE STARTING – SMART KEY SYSTEM ST–101 HINT: • If smart key system (start) DTCs are output (See page ST-28). • If smart key system (entry) DTCs are output (See page DL-159). • If electrical steering lock DTCs are output (See page EI-25). • If engine immobiliser system DTCs are output (See page SR-15). • If engine control system DTCs are output (See page ES-63). NG GO TO DTC CHART OK 4 CHECK ENGINE SWITCH CONDITION (a) Check the power source mode change. (1) When the key is inside the vehicle and the shift lever is in the P position, check that pressing the engine switch causes the power source mode to change as follows: OK: off → on (ACC) → on (IG) → off HINT: • If power mode does not change to ON (IG and ACC) (See page ST-114). • If power mode does not change to ON (IG) (See page ST-122). • If power mode does not change to ON (ACC) (See page ST-131). NG GO TO OTHER PROBLEM OK 5 CHECK CRANKING FUNCTION (a) Check the engine cranking function. (1) When there is fuel in the fuel tank, the key is inside the vehicle, and the shift lever is in the P position, check that depressing the brake pedal and pressing the engine switch crank the engine. OK: Engine cranks. OK Go to step 21 NG 6 READ VALUE OF INTELLIGENT TESTER (P SIGNAL) (a) Connect the intelligent tester to the DLC3. ST ST–102 2GR-FE STARTING – SMART KEY SYSTEM (b) Turn the engine switch on (IG). (c) Read the DATA LIST according to the displays on the tester screen. MAIN BODY: Item SHIFT P SIG Measurement Item/Range (Display) Normal Condition Diagnostic Note ON: Shift position is P OFF: Shift position is not P Shift P signal / ON or OFF - OK: ON (P signal is ON) and OFF (P signal is OFF) appear on the screen. HINT: If the result is not as specified, perform troubleshooting for DTC B2281 first (See page ST-60). NG GO TO DTC B2281 OK 7 READ VALUE OF INTELLIGENT TESTER (STOP LIGHT SWITCH) (a) Connect the intelligent tester to the DLC3. (b) Turn the engine switch on (IG). (c) Check the DATA LIST for proper functioning of the stop light switch. MAIN BODY: Item STOP LAMP SW Measurement Item/Display (Range) Stop light Switch / ON or OFF Normal Condition Diagnostic Note ON: Brake pedal depressed OFF: Brake pedal released - OK: ON (brake pedal depressed) and OFF (brake pedal released) appear on the screen. HINT: If the result is not as specified, perform troubleshooting for DTC B2284 first (See page ST-72). NG GO TO DTC B2284 OK 8 READ VALUE OF INTELLIGENT TESTER (STEERING LOCK) (a) Connect the intelligent tester to the DLC3. (b) Turn the engine switch on (IG). ST MAIN BODY: Item STR UNLOCK SW Measurement Item/Display (Range) Steering lock condition / ON or OFF Normal Condition ON: Steering is unlocked OFF: Steering is locked Diagnostic Note - OK: ON (steering is unlocked) and OFF (steering is locked) appear on the screen. ST–103 2GR-FE STARTING – SMART KEY SYSTEM HINT: If the result is not as specified, perform troubleshooting for DTCs B2285 and B2288 first (See page ST-28). NG GO TO DTC B2285 OK 9 CHECK STEERING LOCK (a) Check if the steering lock is released when turning the engine switch on (ACC). OK: The steering lock is released. NG GO TO STEERING LOCK SYSTEM OK 10 INSPECT MAIN BODY ECU (STSW VOLTAGE) (a) Disconnect the A55 ECM connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Main Body ECU E9 STSW Tester Connection (Symbols) Condition Specified Condition E9-4 (STSW) - Body ground Brake pedal depressed, engine switch held on (ST) Output voltage at terminal AM1 or AM2 is 2 V or more. HINT: If the result is not as specified, perform troubleshooting for DTC B2275 first (See page ST-48). NG GO TO DTC B2275 B138004E01 OK ST ST–104 11 2GR-FE STARTING – SMART KEY SYSTEM INSPECT ECM (ACCR VOLTAGE) (a) Reconnect the connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Main Body ECU E6 Tester Connection (Symbols) Condition Specified Condition ACCR (E6-3) - GND2 (IM-9) Brake pedal depressed, shift lever P position, engine switch is pushed once → on (IG) 0.1 to 0.8 V*1 → Output voltage at terminal AM1 or AM2 is -2 V or more. *1: Voltage is output only when the engine is cranking. HINT: If the result is not as specified, perform troubleshooting for DTC B2276 first (See page ST-51). ACCR B138007E01 NG GO TO DTC B2276 OK 12 INSPECT ECM (STR2 VOLTAGE) (a) Measure the voltage according to the value(s) in the table below. Standard voltage Main Body ECU E9 Tester Connection (Symbols) Condition Specified Condition STR2 (E9-6) - GND2 (IM9) Brake pedal depressed, shift lever P or N position, engine switch on (ST) Output voltage at terminal AM1 or AM2 is 3.5 V or more.*1 *1: Voltage is output for 0.3 seconds when the engine is cranking to start. STR2 NG REPLACE ECM B138004E02 ST OK 13 CHECK WIRE HARNESS (MAIN BODY ECU -ECM - ENGINE ROOM R/B) (a) Remove the ST CUT relay from the engine room R/B. ST–105 2GR-FE STARTING – SMART KEY SYSTEM Wire Harness Side: E9 Main Body ECU Engine Room R/B ECM STR2 C55 ST CUT Relay Terminal STAR B138009E01 (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection (Symbols) Condition Specified Condition C55-63 (STAR) - E9-6 (STR2) Always Below 1 Ω C55-63 (STAR) - ST CUT relay terminal - 3 Always Below 1 Ω C55-63 (STAR) - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK ST ST–106 14 2GR-FE STARTING – SMART KEY SYSTEM INSPECT RELAY (ST CUT) (a) Measure the resistance of the ST CUT relay. Standard resistance Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) NG REPLACE RELAY B016200E23 OK 15 INSPECT PARK/NEUTRAL POSITION SWITCH (a) Disconnect the park/neutral position (PNP) switch connector. (b) Measure the resistance according the the value(s) in the table below. Standard resistance Component Side: PNP Switch Shift Position Tester Connection Specified Condition P 4-9 Below 1 Ω N 4-9 Below 1 Ω Except P and N 4-9 10 kΩ or higher NG REPLACE PARK/NEUTRAL POSITION SWITCH B138018E01 OK 16 CHECK HARNESS AND CONNECTOR (PARK/NEUTRAL POSITION SWITCH - ECM) (a) Disconnect the C55 ECM connector. ST ST–107 2GR-FE STARTING – SMART KEY SYSTEM Wire Harness Side: ECM C1 PNP Switch C55 NSW B138010E01 (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection (Symbols) Condition Specified Condition C55-62 (NSW) - C1-4 Always Below 1 Ω C55-62 (NSW) - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 17 INSPECT RELAY (ST) (a) Remove the starter relay from the engine room R/B. (b) Measure the resistance of the starter relay. Standard resistance Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) NG B016200E23 OK ST REPLACE RELAY ST–108 18 2GR-FE STARTING – SMART KEY SYSTEM CHECK HARNESS AND CONNECTOR (ECM AND STARTER - ST RELAY) (a) Disconnect the A55 ECM connector. ECM Engine Room R/B Starter C3 A55 ST Relay Terminal STA B138011E01 (b) Disconnect the C3 starter connector. (c) Measure the resistance according the the value(s) in the table below. Standard resistance Tester Connection (Symbols) Condition Specified Condition A55-48 (STA) - ST relay terminal - 1 Always Below 1 Ω A55-48 (STA) - Body ground Always 10 kΩ or higher C3-1 - ST relay terminal -3 Always Below 1 Ω C3-1 - Body ground Always 10 kΩ or higher NG OK ST REPAIR OR REPLACE HARNESS OR CONNECTOR ST–109 2GR-FE STARTING – SMART KEY SYSTEM 19 INSPECT ENGINE ROOM RELAY BLOCK (ST RELAY VOLTAGE) (a) Measure the voltage according to the value(s) in the table below. Standard voltage Engine Room R/B Tester Connection Condition Specified Condition ST relay terminal - 5 Body ground Always 9 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR ST Relay Terminal B138012E01 OK 20 INSPECT STARTER ASSEMBLY HINT: See page ST-143. NG REPAIR OR REPLACE STARTER ASSEMBLY OK REPAIR OR REPLACE HARNESS OR CONNECTOR (PNP SWITCH - ST RELAY, STARTER BATTERY) 21 READ VALUE OF INTELLIGENT TESTER (L CODE) (a) Reconnect the connectors. (b) Connect the intelligent tester to the DLC3. HINT: When using the intelligent tester with the engine switch off, turn on and off any of the door courtesy light switches repeatedly at 1.5 second intervals or less until communication between the tester and vehicle starts. ST ST–110 2GR-FE STARTING – SMART KEY SYSTEM (c) Turn the engine switch on (IG). SMART ACCESS (Certification ECU): Item L CODE CHK Measurement Item/Display (Range) Normal Condition OK: Normal NG: Malfunction L code check / ON or NG Diagnostic Note Electrical key in the cabin OK: OK is displayed on the screen. HINT: If the result is not as specified, there may be a malfunction with the steering lock ECU or the ID code box. NG GO TO ENGINE IMMOBILISER SYSTEM OK 22 READ VALUE OF INTELLIGENT TESTER (ENGINE START REQUEST) (a) Connect the intelligent tester to the DLC3. HINT: When using the intelligent tester with the engine switch off, turn on and off any of the door courtesy light switches repeatedly at 1.5 second intervals or less until communication between the tester and vehicle starts. (b) Turn the engine switch on (IG). SMART ACCESS (Certification ECU): Item START RQST Measurement Item/Display (Range) Start request signal response / OK or NG Normal Condition Diagnostic Note OK: Received NG: Not received - OK: OK (received) and NG (not received) appear on the screen. NG REPLACE CERTIFICATION ECU OK 23 READ VALUE OF INTELLIGENT TESTER (S CODE) (a) Connect the intelligent tester to the DLC3. HINT: When using the intelligent tester with the engine switch off, turn on and off any of the door courtesy light switches repeatedly at 1.5 second intervals or less until communication between the tester and vehicle starts. (b) Turn the engine switch on (IG). ST SMART ACCESS (Certification ECU): Item S CODE CHK Measurement Item/Display (Range) S code check / OK or NG Normal Condition OK: Normal NG: Malfunction Diagnostic Note - ST–111 2GR-FE STARTING – SMART KEY SYSTEM OK: OK is displayed on the screen. HINT: If the result is not as specified, there may be a malfunction with the certification ECU or the ID code box. NG GO TO ENGINE IMMOBILISER SYSTEM OK 24 INSPECT ID CODE BOX (a) Check the input signal waveform. (1) Connect an oscilloscope to terminal E50-6 (EFIO) and body ground. (2) Turn the engine switch on (IG). (3) Check the signal waveform according to the condition(s) in the table below. E50 ID Code Box 8 7 6 5 4 3 2 1 Item EFIO Tool setting 10 V/DIV., 100 ms./DIV. Vehicle condition Engine switch on (IG) NG GND Condition REPLACE ID CODE BOX HI LOW B138013E01 OK END ST ST–112 2GR-FE STARTING – SMART KEY SYSTEM Engine Switch Indicator Circuit DESCRIPTION Engine start conditions or system malfunctions can be checked by the status of the engine switch indicator light. Engine switch indicator light condition: Power Source Mode/Condition ST Indicator Light Condition Brake pedal released Brake pedal depressed, shift lever in P or N off OFF ON (Green) (When key and vehicle IDs match) on (ACC, IG) ON (Amber) ON (Green) Engine running OFF OFF Steering lock not unlocked Flashes (Green) for 15 sec. Flashes (Green) for 15 sec. System malfunction Flashes (Amber) for 15 sec. Flashes (Amber) for 15 sec. ST–113 2GR-FE STARTING – SMART KEY SYSTEM WIRING DIAGRAM E7 Main Body ECU E52 Engine Switch 5 GND INDS 12 15 INDW 13 14 SWIL 11 25 INDS Indicator Light 4 COM INDW Indicator Light SWIL Illumination B112453E04 INSPECTION PROCEDURE 1 INSPECT ENGINE SWITCH (a) Remove the engine switch. ST ST–114 2GR-FE STARTING – SMART KEY SYSTEM Indicator Light INDS GND COM START STOP 7 Illumination 6 5 4 3 2 1 14 13 12 11 10 9 8 INDW SWIL A109252E10 (b) Apply battery voltage between the terminals of the switch, and check the illumination condition of the switch. NOTICE: • If the positive (+) lead and the negative (-) lead are incorrectly connected, the engine switch indicator will not illuminate. • If the voltage is too low, the indicator will not illuminate. OK Measurement Condition Specified Condition Battery positive (+) → Terminal 11 (SWIL) Battery negative (-) → Terminal 4 (COM) or 5 (GND) Illuminates Battery positive (+) → Terminal 12 (INDS) Battery negative (-) → Terminal 4 (COM) or 5 (GND) Illuminates Battery positive (+) → Terminal 13 (INDW) Battery negative (-) → Terminal 4 (COM) or 5 (GND) Illuminates NG REPLACE ENGINE SWITCH OK 2 CHECK WIRE HARNESS (ENGINE SWITCH - MAIN BODY ECU AND BODY GROUND) (a) Disconnect the E52 switch connector. Wire Harness Side: E7 Main Body ECU SWIL COM ST INDS E52 Engine Switch INDW SWIL INDS GND INDW B137980E02 (b) Disconnect the E7 ECU connector. (c) Measure the resistance according to the value(s) in the table below. ST–115 2GR-FE STARTING – SMART KEY SYSTEM Standard resistance Tester Connection Condition Specified Condition E52-11 (SWIL) - E7-25 (SWIL) Always Below 1 Ω E52-12 (INDS) - E7-15 (INDS) Always Below 1 Ω E52-13 (INDW) - E7-14 (INDW) Always Below 1 Ω E52-5 (GND) - Body ground Always Below 1 Ω E52-4 (COM) - Body ground Always Below 1 Ω E52-11 (SWIL) or E7-25 (SWIL) - Body ground Always 10 kΩ or higher E52-12 (INDS) or E7-15 (INDS) - Body ground Always 10 kΩ or higher E52-13 (INDW) or E7-14 (INDW) - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE MAIN BODY ECU ST ST–116 2GR-FE STARTING – SMART KEY SYSTEM Power Source Mode does not Change to ON (IG and ACC) DESCRIPTION When the engine switch is pushed with the electrical key in the cabin, the main body ECU receives signals to switch the power source mode. HINT: To allow use of the intelligent tester to inspect the push-button start function when the engine switch is off, repeat opening and closing any of the doors. Opening and closing a door establishes communication between the intelligent tester and the main body ECU. (Opening and closing a door can also be simulated by operating a door courtesy light switch.) ST ST–117 2GR-FE STARTING – SMART KEY SYSTEM WIRING DIAGRAM Main Body ECU Engine Room J/B AM2 1 1G From Battery From IG2 Fuse 6 E7 AM1 1 E6 AM2 11 E6 IG2D SS1 7 17 E7 SSW1 SS2 2 16 E7 SSW2 1 Engine Room R/B IG2 1 1 5 3 1 2 1 1 To Each System E52 Engine Switch 5 GND Instrument Panel J/B E50 ID Code Box 8 GND LIN1 3 E58 Certification ECU 17 E LIN 10 9 IR 14 10 IF 5 9 IM 4 LIN1 GND1 GND2 ST B137991E01 ST–118 2GR-FE STARTING – SMART KEY SYSTEM IG1 To Each Fuse From ALT Fuse 3 5 1 2 9 II 1 IA ACC To Each Fuse 10 IF 3 5 1 2 3 II Instrument Panel J/B 22 E7 ACCD 3 E7 IG1D B137992E01 INSPECTION PROCEDURE 1 CHECK ENTRY FUNCTION DETECTION AREA Inspection Point ST B137958E01 (a) Inspect entry detection area. (1) When the electrical key is in either of the 2 inspection points in the illustration, the shift lever is in the P position and the brake pedal is depressed, check that the engine switch indicator illuminates in green. OK: Engine switch illuminates in green. HINT: If the engine switch does not illuminate, perform troubleshooting according to the PROBLEM SYMPTOMS TABLE (See page ST-17). NG GO TO OTHER PROBLEM 2GR-FE STARTING – SMART KEY SYSTEM ST–119 OK 2 INSPECT FUSE (AM2) (a) Remove the AM2 fuse from the engine room J/B. (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω NG REPLACE FUSE OK 3 CHECK CONNECTORS (a) Check that the connectors are securely connected and the terminals are not deformed or loose. OK: The connectors are securely connected and the terminals are not deformed or loose. NG REPAIR OR REPLACE CONNECTORS OK ST ST–120 4 2GR-FE STARTING – SMART KEY SYSTEM CHECK WIRE HARNESS (MAIN BODY ECU - BATTERY) (a) Disconnect the E6 and E7 ECU connectors. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness Side: E7 Main Body ECU AM1 Tester Connection (Symbols) Condition Specified Condition E7-6 (AM1) - Body ground Always 10 to 14 V E6-1 (AM2) - Body ground Always 10 to 14 V NG E6 AM2 B138000E01 OK ST REPAIR OR REPLACE HARNESS OR CONNECTOR ST–121 2GR-FE STARTING – SMART KEY SYSTEM 5 CHECK WIRE HARNESS (MAIN BODY ECU - BODY GROUND) (a) Disconnect the IF and IM ECU connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side: IM Main Body ECU GND2 Tester Connection (Symbols) Condition Specified Condition IF-10 (GND1) - Body ground Always Below 1 Ω IM-9 (GND2) - Body ground Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR IF GND1 B138008E01 OK 6 CHECK FOR DTCS (a) Delete the DTCs (See page ST-26). HINT: After all the DTCs are cleared, check if the trouble occurs again 5 seconds after the engine switch is turned on (IG). (b) Check for DTCs again. OK: No DTC is output. NG GO TO DTC CHART OK 7 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Turn the engine switch on (IG). (c) Check the DATA LIST for proper functioning of the start switches 1 and 2. HINT: When using the intelligent tester with the engine switch off, turn on and off any of the door courtesy light switches repeatedly at 1.5 second intervals or less until communication between the tester and vehicle starts. ST ST–122 2GR-FE STARTING – SMART KEY SYSTEM MAIN BODY: Measurement Item/Display (Range) Item Normal Condition Diagnostic Note STSW1 Start Switch 1/ON or OFF ON: Engine switch on (IG) OFF: Engine switch off - START SW2 Start Switch 2/ON or OFF ON: Engine switch on (IG) OFF: Engine switch off - OK: ON (engine switch on (IG)) and OFF (engine switch off) appear on the screen. OK REPLACE MAIN BODY ECU NG 8 INSPECT ENGINE SWITCH (a) Remove the engine switch. SS1 GND SS2 START STOP 7 6 5 4 3 2 1 14 13 12 11 10 9 8 A109252E14 (b) Measure the resistance of the switch. Standard resistance Tester Connection Switch Condition Specified Condition 7 (SS1) - 5 (GND) Pushed Below 1 Ω 2 (SS2) - 5 (GND) Pushed Below 1 Ω 7 (SS1) - 5 (GND) Not pushed 10 kΩ or higher 2 (SS2) - 5 (GND) Not pushed 10 kΩ or higher NG REPLACE ENGINE SWITCH OK 9 CHECK WIRE HARNESS (MAIN BODY ECU AND BODY GROUND - ENGINE SWITCH) (a) Disconnect the E7 ECU connector. ST ST–123 2GR-FE STARTING – SMART KEY SYSTEM Wire Harness Side: E7 Main Body ECU E52 Engine Switch SS1 SS2 SSW1 GND SSW2 B137980E01 (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection (Symbols) Condition Specified Condition E52-7 (SS1) - E7-17 (SSW1) Always Below 1 Ω E52-2 (SS2) - E7-16 (SSW2) Always Below 1 Ω E52-5 (GND) - Body ground Always Below 1 Ω E52-7 (SS1) or E7-17 (SSW1) - Body ground Always 10 kΩ or higher E52-2 (SS2) or E7-16 (SSW2) - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE MAIN BODY ECU ST ST–124 2GR-FE STARTING – SMART KEY SYSTEM Power Source Mode does not Change to ON (IG) DESCRIPTION When the engine switch is pushed with the electrical key in the cabin, the main body ECU receives signals to switch the power source mode. HINT: To allow use of the intelligent tester to inspect the push-button start function when the engine switch is off, repeat opening and closing any of the doors. Opening and closing a door establishes communication between the intelligent tester and the main body ECU. (Opening and closing a door can also be simulated by operating a door courtesy light switch.) ST ST–125 2GR-FE STARTING – SMART KEY SYSTEM WIRING DIAGRAM Main Body ECU Engine Room J/B AM2 1 1G From Battery 1 Engine Room R/B 6 E7 AM1 1 E6 AM2 11 E6 IG2D From IG2 Fuse IG2 1 1 5 3 2 1 To Each System 1 1 Instrument Panel J/B From ALT Fuse 10 IF 5 9 IM 4 GND1 GND2 1 IA IG1 To Each System 10 IF 3 5 1 2 9 II 3 E7 IG1D ST B137993E01 ST–126 2GR-FE STARTING – SMART KEY SYSTEM INSPECTION PROCEDURE 1 INSPECT FUSE (AM2) (a) Remove the AM2 fuse from the engine room J/B. (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω NG REPLACE FUSE OK 2 CHECK CONNECTORS (a) Check that the connectors are securely connected and the terminals are not deformed or loose. OK: The connectors are securely connected and the terminals are not deformed or loose. NG OK ST REPAIR OR REPLACE CONNECTORS ST–127 2GR-FE STARTING – SMART KEY SYSTEM 3 CHECK WIRE HARNESS (MAIN BODY ECU - BATTERY) (a) Disconnect the E6 and E7 ECU connectors. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness Side: E7 Main Body ECU AM1 Tester Connection (Symbols) Condition Specified Condition E7-6 (AM1) - Body ground Always 10 to 14 V E6-1 (AM2) - Body ground Always 10 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR E6 AM2 B138000E01 OK ST ST–128 4 2GR-FE STARTING – SMART KEY SYSTEM CHECK WIRE HARNESS (MAIN BODY ECU - BODY GROUND) (a) Disconnect the IF and IM ECU connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side: IM Main Body ECU GND2 Tester Connection (Symbols) Condition Specified Condition IF-10 (GND1) - Body ground Always Below 1 Ω IM-9 (GND2) - Body ground Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR IF GND1 B138008E01 OK 5 INSPECT RELAY (IG2 RELAY) 1 3 1 5 2 5 (a) Remove the IG2 relay from the engine room R/B No. 2. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (When battery voltage is applied to terminals 1 and 2) 2 3 B060778E73 NG REPLACE RELAY OK ST 6 CHECK WIRE HARNESS (ENGINE ROOM R/B - MAIN BODY ECU AND BODY GROUND) (a) Remove the IG2 relay from the engine room R/B. ST–129 2GR-FE STARTING – SMART KEY SYSTEM Wire Harness Side: E6 Main Body ECU Engine Room R/B IG2D IG2 Relay Terminal B138002E01 (b) Disconnect the E6 ECU connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Terminal No. (Symbol) Specified Condition Engine room R/B IG2 relay terminal 1 - E6-11 (IG2D) Below 1 Ω Engine room R/B IG2 relay terminal 2 - Body ground Below 1 Ω E6-11 (IG2D) - Body ground 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK ST ST–130 7 2GR-FE STARTING – SMART KEY SYSTEM INSPECT RELAY (IG1 RELAY) (a) Remove the IG1 relay from the instrument panel J/B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance A092673E23 Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) NG REPLACE RELAY OK 8 CHECK WIRE HARNESS (INSTRUMENT PANEL J/B - MAIN BODY ECU) (a) Disconnect the Il J/B connector. Wire Harness Side: Main Body ECU II E7 IG1D B138001E01 (b) Disconnect the E7 ECU connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance ST Terminal No. (Symbol) Condition Specified Condition II-9 - E7-3 (IG1D) Always Below 1 Ω E7-3 (IG1D) - Body ground Always 10 kΩ or higher NG OK REPAIR OR REPLACE HARNESS OR CONNECTOR ST–131 2GR-FE STARTING – SMART KEY SYSTEM 9 CHECK WIRE HARNESS (INSTRUMENT PANEL J/B - BATTERY AND BODY GROUND) (a) Disconnect the IF and IA J/B connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side: Terminal No. Condition Specified Condition IF-10 - Body ground Always Below 1 Ω (c) Measure the voltage according to the value(s) in the table below. Standard voltage IA Terminal No. Condition Specified Condition IA-1 - Body ground Always 10 to 14 V NG IF REPAIR OR REPLACE HARNESS OR CONNECTOR A128037E02 OK 10 INSPECT INSTRUMENT PANEL J/B (a) Measure the resistance according to the value(s) in the table below. Instrument Panel J/B: IF II IG1 Relay Terminal ST A128038E02 ST–132 2GR-FE STARTING – SMART KEY SYSTEM Standard resistance Terminal No. Condition Specified Condition IF-10 - IG1 relay terminal-1 Always Below 1 Ω II-9 - IG1 relay terminal2 Always Below 1 Ω IF-10 - Body ground Always 10 kΩ or higher II-9 - Body ground Always 10 kΩ or higher NG OK REPLACE INSTRUMENT PANEL J/B ST REPLACE MAIN BODY ECU 2GR-FE STARTING – SMART KEY SYSTEM ST–133 Power Source Mode does not Change to ON (ACC) DESCRIPTION When the engine switch is pushed with the electrical key in the cabin, the main body ECU receives signals to switch the power source mode. HINT: To allow use of the intelligent tester to inspect the push-button start function when the engine switch is off, repeat opening and closing any of the doors. Opening and closing a door establishes communication between the intelligent tester and the main body ECU. (Opening and closing a door can also be simulated by operating a door courtesy light switch.) ST ST–134 2GR-FE STARTING – SMART KEY SYSTEM WIRING DIAGRAM Main Body ECU Engine Room J/B AM2 1 From Battery 1 1G 6 E7 AM1 1 E6 AM2 Instrument Panel J/B 10 5 IF 9 4 IM GND1 GND2 1 From ALT Fuse IA ACC To Each System 3 5 1 2 10 IF 3 II 22 E7 ACCD ST B137994E01 2GR-FE STARTING – SMART KEY SYSTEM ST–135 INSPECTION PROCEDURE 1 INSPECT FUSE (AM2) (a) Remove the AM2 fuse from the engine room J/B. (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω NG REPLACE FUSE OK 2 CHECK CONNECTORS (a) Check that the connectors are securely connected and the terminals are not deformed or loose. OK: The connectors are securely connected and the terminals are not deformed or loose. NG REPAIR OR REPLACE CONNECTORS OK ST ST–136 3 2GR-FE STARTING – SMART KEY SYSTEM CHECK WIRE HARNESS (MAIN BODY ECU - BATTERY) (a) Disconnect the E6 and E7 ECU connectors. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness Side: E7 Main Body ECU AM1 Tester Connection (Symbols) Condition Specified Condition E7-6 (AM1) - Body ground Always 10 to 14 V E6-1 (AM2) - Body ground Always 10 to 14 V NG E6 AM2 B138000E01 OK ST REPAIR OR REPLACE HARNESS OR CONNECTOR ST–137 2GR-FE STARTING – SMART KEY SYSTEM 4 CHECK WIRE HARNESS (MAIN BODY ECU - BODY GROUND) (a) Disconnect the IF and IM ECU connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side: IM Main Body ECU GND2 Tester Connection (Symbols) Condition Specified Condition IF-10 (GND1) - Body ground Always Below 1 Ω IM-9 (GND2) - Body ground Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR IF GND1 B138008E01 OK 5 INSPECT RELAY (ACC RELAY) (a) Remove the ACC relay from the instrument panel J/B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection A092673 NG Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) REPLACE RELAY OK 6 CHECK WIRE HARNESS (INSTRUMENT PANEL J/B - MAIN BODY ECU) (a) Disconnect the E7 ECU connector. ST ST–138 2GR-FE STARTING – SMART KEY SYSTEM Wire Harness Side: Main Body ECU II E7 ACCD B138001E02 (b) Disconnect the II J/B connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Terminal No. (Symbol) Condition Specified Condition II-3 - E7-22 (ACCD) Always Below 1 Ω E7-22 or II-3 - Body ground Always 10 kΩ or higher NG OK ST REPAIR OR REPLACE HARNESS OR CONNECTOR ST–139 2GR-FE STARTING – SMART KEY SYSTEM 7 CHECK WIRE HARNESS (INSTRUMENT PANEL J/B - BATTERY AND BODY GROUND) (a) Disconnect the IF and IA J/B connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side: Terminal No. Condition Specified Condition IF-10 - Body ground Always Below 1 Ω (c) Measure the voltage according to the value(s) in the table below. Standard voltage IA Terminal No. Condition Specified Condition IA-1 - Body ground Always 10 to 14 V NG IF REPAIR OR REPLACE HARNESS OR CONNECTOR A128037E03 OK 8 INSPECT INSTRUMENT PANEL J/B (a) Measure the resistance according to the value(s) in the table below. Wire Harness Side: IF Front Side: Back Side: ST II ACC Relay Terminal B138003E01 ST–140 2GR-FE STARTING – SMART KEY SYSTEM Standard resistance Terminal No. Condition Specified Condition ACC relay terminal 1 IF-10 Always Below 1 Ω ACC relay terminal 2 - II3 Always Below 1 Ω IF-10 - Body ground Always 10 kΩ or higher II-3 - Body ground Always 10 kΩ or higher NG OK REPLACE MAIN BODY ECU ST REPLACE INSTRUMENT PANEL J/B ST–139 2GR-FE STARTING – STARTER STARTER 2GR-FE STARTING ENGINE COMPONENTS AIR CLEANER CAP SUB-ASSEMBLY V-BANK COVER SUB-ASSEMBLY AIR CLEANER INLET ASSEMBLY 5.0 (51, 44 in.*lbf) NO. 1 AIR CLEANER INLET 5.0 (51, 44 in.*lbf) AIR CLEANER FILTER ELEMENT 9.8 (100, 87 in.*lbf) x2 COOL AIR INTAKE DUCT SEAL 37 (380, 28) 5.0 (51, 44 in.*lbf) x3 STARTER ASSEMBLY AIR CLEANER CASE SUB-ASSEMBLY ST N*m (kgf*cm, ft.*lbf) : Specified torque A133821E01 ST–140 2GR-FE STARTING – STARTER STARTER ARMATURE ASSEMBLY STARTER COMMUTATOR END FRAME ASSEMBLY STARTER COMMUTATOR END FRAME COVER 6.0 (61, 53 in.*lbf) SNAP RING REPAIR SERVICE STARTER KIT WASHER -PLUNGER -RETURN SPRING 6.0 (61, 53 in.*lbf) -MAGNETIC SWITCH 7.5 (76, 66 in.*lbf) 10 (102, 7) MOTOR TERMINAL STARTER KIT PLANETARY GEAR ST N*m (kgf*cm, ft.*lbf) : Specified torque STARTER ARMATURE PLATE Non-reusable part STARTER YOKE ASSEMBLY Apply High-temperature grease A134900E01 2GR-FE STARTING – STARTER ST–141 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE COOL AIR INTAKE DUCT SEAL (See page EM-23) 3. REMOVE V-BANK COVER SUB-ASSEMBLY (See page EM-23) 4. REMOVE AIR CLEANER INLET ASSEMBLY (See page EM-24) 5. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-503) 6. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (See page EM-24) 7. REMOVE NO. 1 AIR CLEANER INLET (See page EM24) 8. REMOVE STARTER ASSEMBLY (a) Disconnect the terminal 50 connector from the starter assembly. (b) Remove the nut and disconnect the wire harness from terminal 30. (c) Remove the 2 bolts and starter assembly. A133864 DISASSEMBLY 1. REMOVE REPAIR SERVICE STARTER KIT (a) Remove the nut and disconnect the lead wire from terminal C. A079718E05 (b) Remove the 2 screws that hold the magnetic switch to the motor terminal starter kit. (c) Remove the repair service starter kit. (d) Remove the return spring and the plunger from the repair service starter kit. ST A079719E05 ST–142 2GR-FE STARTING – STARTER 2. REMOVE STARTER YOKE ASSEMBLY (a) Remove the 2 through bolts and pull out the starter yoke assembly together with the starter commutator end frame assembly. A079720E05 (b) Remove the starter yoke assembly from the starter commutator end frame assembly. A079721E03 3. REMOVE STARTER ARMATURE PLATE (a) Remove the starter armature plate from the starter yoke assembly. 4. REMOVE STARTER COMMUTATOR END FRAME COVER (a) Using a screwdriver, remove the starter commutator end frame cover. 5. REMOVE STARTER ARMATURE ASSEMBLY (a) Using snap ring pliers, remove the snap ring and plate washer. (b) Remove the starter armature assembly from the commutator end frame assembly. A079722E04 A079723E03 ST Snap Ring Pliers A082440E07 2GR-FE STARTING – STARTER 6. ST–143 REMOVE PLANETARY GEAR (a) Remove the 3 planetary gears from the motor terminal starter kit. A081167E03 ST ST–144 2GR-FE STARTING – STARTER INSPECTION 1. INSPECT STARTER ASSEMBLY CAUTION: Make sure to complete each of the following tests within 5 seconds to prevent the coil from burning out. (a) Perform pull-in test: (1) Disconnect the lead wire from terminal C. Terminal C A133511E01 (2) Connect the battery to the magnetic switch as shown in the illustration. Check that the clutch pinion gear moves outward. If the clutch pinion gear does not move outward, replace the repair service starter kit. Terminal C Body Terminal 50 A133512E01 (b) Perform hold-in test: (1) Disconnect the negative (-) terminal lead from terminal C under the conditions for pull-in test. Check that the pinion gear remains out. If the clutch pinion gear moves inward, replace the repair service starter kit. Terminal C Body Terminal 50 A133513E01 Terminal C ST Body Terminal 50 A133514E01 (c) Inspect clutch pinion gear return: (1) Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear moves inward. If the clutch pinion gear does not move inward, replace the repair service starter kit. (d) Perform no-load performance test: (1) Connect the field coil wire to terminal C with the nut. Make sure that the lead is not grounded. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) (2) Clamp the starter in a vise. ST–145 2GR-FE STARTING – STARTER (3) Connect the battery and an ammeter to the starter as shown in the illustration. (4) Check that the starter rotates smoothly and steadily with the clutch pinion gear extended. Check that the ammeter reads the specified current. Specified current Ammeter Terminal 30 Condition Specified condition at 11.5 V 90 A or less If the result is not as specified, overhaul the starter assembly. Body Terminal 50 A133510E01 2. INSPECT REPAIR SERVICE STARTER KIT (a) Check the plunger. (1) Push in the plunger and check that it returns quickly to its original position. If necessary, replace the repair service starter kit. A058586E04 (b) Inspect the resistance of the pull-in coil. (1) Using an ohmmeter, measure the resistance between terminals 50 and C. Standard resistance Terminal C Terminal 50 Tester connection Specified condition Terminal 50 - Terminal C Below 1 Ω If the resistance is not as specified, replace the repair service starter kit. Below 1 Ω A079725E08 (c) Inspect the resistance of the hold-in coil. (1) Using an ohmmeter, measure the resistance between terminal 50 and the switch body. Standard resistance Body Below 2 Ω Tester connection Specified condition Terminal 50 - Switch body Below 2 Ω If the resistance is not as specified, replace the repair service starter kit. Terminal 50 A079726E07 3. INSPECT STARTER ARMATURE ASSEMBLY (a) Check the commutator surface for dirt or burning. If the surface is dirty or burnt, smooth the surface with 400-grit sandpaper or leather. ST ST–146 2GR-FE STARTING – STARTER (b) Inspect the resistance of the commutator. (1) Using an ohmmeter, measure the resistance between the segments of the commutator. Standard resistance Below 1 Ω Tester connection Specified condition Segment - Segment Below 1 Ω If the resistance is not as specified, replace the starter armature assembly. Segment A058372E04 (2) Using an ohmmeter, measure the resistance between the commutator and armature coil core. Standard resistance 10 kΩ or Higher Commutator Coil Core Tester connection Specified condition Commutator - Armature coil core 10 kΩ or higher If the resistance is not as specified, replace the starter armature assembly. A058373E04 (c) Using vernier calipers, measure the commutator depth. Specified depth: 3.1 mm (0.122 in.) Maximum depth: 3.8 mm (0.150 in.) If the depth is greater than the maximum, replace the starter armature assembly. Depth A058584E09 4. Length A076677E10 ST INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY (a) Check the brush length. (1) Using vernier calipers, measure the brush length. Specified length: 9.0 mm (0.354 in.) Maximum length: 4.0 mm (0.157 in.) If the length is less than the minimum, replace the starter commutator end frame assembly. (b) Check the resistance. (1) Using an ohmmeter, measure the resistance between the positive (+) and negative (-) brushes. Resistance: 10 kΩ or higher If the resistance is not as specified, repair or replace the starter commutator end frame assembly. 10 kΩ or Higher A079766E10 2GR-FE STARTING – STARTER 5. Lock Free ST–147 INSPECT MOTOR TERMINAL STARTER KIT (a) Check the starter clutch. (1) Rotate the clutch pinion gear counterclockwise and check that it turns freely. Try to rotate the clutch pinion gear clockwise and check that it locks. If necessary, replace the motor terminal starter kit. A081655E05 REASSEMBLY 1. INSTALL PLANETARY GEAR (a) Apply high-temperature grease to the planetary gears and pin parts of the planetary shaft. (b) Install the 3 planetary gears to the motor terminal starter kit. 2. INSTALL STARTER ARMATURE ASSEMBLY (a) Apply high-temperature grease to the plate washer and the armature shaft. (b) Install the starter armature assembly to the starter commutator end frame assembly. (c) Using snap ring pliers, install the plate washer and a new snap ring. Apply Grease A081656E06 Snap Ring Pliers A082440E08 (d) Using vernier calipers, measure the snap ring. Maximum length: 5.0 mm (0.197 in.) If the length is greater than the maximum, replace the snap ring with a new one. Length A058810E14 3. A081178E03 INSTALL STARTER COMMUTATOR END FRAME COVER (a) Install the starter commutator end frame cover to the starter commutator end frame assembly. ST ST–148 Claw 2GR-FE STARTING – STARTER 4. INSTALL STARTER ARMATURE PLATE (a) Align the claw of the armature plate with the groove inside the starter yoke assembly, and install the starter armature plate. 5. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY (a) Align the starter commutator end frame rubber with the groove of the starter yoke assembly. (b) Install the starter commutator end frame assembly to the starter yoke assembly. NOTICE: The magnet of the starter yoke assembly may attract the starter armature assembly when the starter commutator end frame assembly is installed, causing the magnet to break. 6. INSTALL STARTER YOKE ASSEMBLY (a) Align the claw of the starter yoke with the groove inside the motor terminal starter kit. Groove A073991E14 Rubber Groove A079727E08 Claw Groove A079728E07 (b) Install the starter yoke with the 2 through bolts. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) A079720E06 7. ST A079729E03 INSTALL REPAIR SERVICE STARTER KIT (a) Apply high-temperature grease to the plunger and the hook. (b) Hang the plunger hook of the repair service starter kit to the drive lever hook. (c) Install the plunger and the return spring. 2GR-FE STARTING – STARTER ST–149 (d) Install the repair service starter kit with the 2 screws. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) A079719E06 (e) Connect the lead wire to terminal C with the nut. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) A079718E06 INSTALLATION 1. INSTALL STARTER ASSEMBLY (a) Install the starter assembly with the 2 bolts. Torque: 37 N*m (380 kgf*cm, 28 ft.*lbf) (b) Connect the wire harness to terminal 30 and install the nut. Then, attach the terminal cap. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) (c) Connect the terminal 50 connector to the starter assembly. 2. INSTALL NO. 1 AIR CLEANER INLET (See page EM49) 3. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (See page EM-50) 4. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See page ES-506) 5. INSTALL AIR CLEANER INLET ASSEMBLY (See page EM-50) 6. INSTALL V-BANK COVER SUB-ASSEMBLY (See page EM-52) 7. INSTALL COOL AIR INTAKE DUCT SEAL (See page EM-52) 8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page EM-51) A133864 ST ST–149 2GR-FE STARTING – STARTER RELAY STARTER RELAY ON-VEHICLE INSPECTION 1. INSPECT STARTER RELAY ASSEMBLY (a) Using an ohmmeter, measure the resistance between each terminal. Standard resistance Tester Connection E034090E03 Specified Condition 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the starter relay assembly. ST ST–150 2GR-FE STARTING – STARTER CUT RELAY (w/ Smart Key System) STARTER CUT RELAY (w/ Smart Key System) ON-VEHICLE INSPECTION 1. E034090E19 INSPECT STARTER CUT RELAY (a) Using an ohmmeter, measure the resistance between each terminal. Standard resistance Tester Connection Specified Condition 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the starter cut relay. ST ST–151 2GR-FE STARTING – IGNITION RELAY (w/ Smart Key System) IGNITION RELAY (w/ Smart Key System) ON-VEHICLE INSPECTION 1. E034090E19 INSPECT NO. 2 IGNITION RELAY (a) Using an ohmmeter, measure the resistance between each terminal. Standard resistance Tester Connection Specified Condition 10 kΩ or higher 3-5 Below 1 Ω (Apply battery voltage between terminals 1 and 2) If the result is not as specified, replace the No. 2 ignition relay. ST ST–152 2GR-FE STARTING – ENGINE SWITCH (w/ Smart Key System) ENGINE SWITCH (w/ Smart Key System) 2GR-FE STARTING ENGINE COMPONENTS ENGINE SWITCH LOWER INSTRUMENT PANEL FINISH PANEL A133822E01 ST 2GR-FE STARTING – ENGINE SWITCH (w/ Smart Key System) ST–153 REMOVAL Finish Panel 1. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (See page IP-22) 2. REMOVE ENGINE SWITCH (a) Detach the 2 claws and remove the engine switch from the finish panel. Engine Switch A131544E01 ST ST–154 2GR-FE STARTING – ENGINE SWITCH (w/ Smart Key System) INSPECTION 1. INSPECT ENGINE SWITCH (a) Measure the resistance according to the value(s) in the table below. SS1 GND SS2 START STOP 7 6 5 4 3 2 1 14 13 12 11 10 9 8 A109252E01 Standard resistance Tester Connection Switch Condition Specified Condition 7 (SS1) - 5 (GND) Pushed Below 1 Ω 2 (SS2) - 5 (GND) Pushed Below 1 Ω 7 (SS1) - 5 (GND) Not pushed 10 kΩ or higher 2 (SS2) - 5 (GND) Not pushed 10 kΩ or higher If the result is not as specified, replace the engine switch. (b) Apply battery voltage between the terminals of the switch, and check the illumination condition of the switch. Indicator Light INDS GND COM START STOP 7 Illumination 6 5 4 3 2 1 14 13 12 11 10 9 8 INDW SWIL A109252E10 Standard resistance ST Measurement Condition Specified Condition Battery positive (+) → Terminal 11 (SWIL) Battery negative (-) → Terminal 4 (COM) or 5 (GND) Illuminates Battery positive (+) → Terminal 12 (INDS) Battery negative (-) → Terminal 4 (COM) or 5 (GND) Illuminates Battery positive (+) → Terminal 13 (INDW) Battery negative (-) → Terminal 4 (COM) or 5 (GND) Illuminates If the result is not as specified, replace the engine switch. 2GR-FE STARTING – ENGINE SWITCH (w/ Smart Key System) ST–155 INSTALLATION Finish Panel 1. INSTALL ENGINE SWITCH (a) Attach the 2 claws to install the switch. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (See page IP-57) Engine Switch A131544E01 ST 2GR-FE STARTING – IGNITION SWITCH (w/o Smart Key System) IGNITION SWITCH (w/o Smart Key System) LOCK ACC ON-VEHICLE INSPECTION 1. ON START AM1 ST1 4 ACC IG1 3 2 7 6 INSPECT IGNITION OR STARTER SWITCH ASSEMBLY (a) Check the resistance. (1) Using an ohmmeter, measure the resistance between the terminals. Standard resistance Condition Tester Connection Specified Condition LOCK Between all terminals 10 kΩ or higher ACC 2-4 Below 1 Ω ON 1 5 START ST2 ST–155 IG2 AM2 A119190E04 1-2-4 5-6 1-3-4 5-6-7 Below 1 Ω Below 1 Ω If the result is not as specified, replace the ignition or starter switch. ST BC–1 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM ANTI-LOCK BRAKE SYSTEM PRECAUTION 1. Expression EXPRESSIONS OF IGNITION SWITCH The type of ignition switch used on this model differs according to the specifications of the vehicle. The expressions listed in the table below are used in this section. Switch Type Ignition Switch (Position) Engine Switch (Condition) Ignition switch off LOCK off Ignition switch on (IG) ON on (IG) Ignition switch on (ACC) ACC on (ACC) Engine start START start 2. 3. TROUBLESHOOTING PRECAUTION HINT: The anti-lock brake system includes the ABS and EBD. (a) When there is a malfunction in the terminal contact points or installation problems with parts, removing and installing the suspected problem parts may return the system to normal, either completely or temporarily. (b) In order to determine the malfunctioning area, be sure to check the conditions at the time the malfunction occurred, such as by the DTC output and the freeze frame data output, and record it before disconnecting each connector or removing and installing parts. (c) Be sure to remove and install the brake actuator and each individual sensor with the ignition switch off unless otherwise specified in the inspection procedure. (d) If the brake actuator or a sensor has been removed and installed, it is necessary to check the system for problems after the parts have been reassembled. Check for DTCs using the intelligent tester, also check that system functions and signals received by the ECU are normal using test mode. CAN COMMUNICATION SYSTEM PRECAUTION (a) The CAN communication system is used for data communication between each of the ECUs and sensors. If there is trouble in the CAN communication line, a DTC of the communication line is output. (b) If a DTC of the CAN communication line is output, repair the malfunction in the communication line and troubleshoot the anti-lock brake system. BC BC–2 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM (c) In order to enable CAN communication, a specific type of wiring is used for the CAN communication lines. The wiring used for each communication line is a twisted pair of wires that have an equal length. A bypass wire should not be used, because the data being transmitted will be corrupted. BC BC–3 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM PARTS LOCATION BRAKE MASTER CYLINDER ASSEMBLY - BRAKE FLUID LEVEL WARNING SWITCH BRAKE ACTUATOR SKID CONTROL SENSOR - SKID CONTROL ECU (REAR SPEED SENSOR) REAR SPEED SENSOR ROTOR FRONT SPEED SENSOR ROTOR FRONT SPEED SENSOR ECM (2GR-FE) BC FRONT SPEED SENSOR FRONT SPEED SENSOR ROTOR ECM (2AZ-FE) ENGINE ROOM R/B - FUSIBLE LINK (ABS NO. 1) - FUSIBLE LINK (ABS NO. 2) SKID CONTROL SENSOR (REAR SPEED SENSOR) REAR SPEED SENSOR ROTOR C131985E01 BC–4 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM STOP LIGHT SWITCH COMBINATION METER ASSEMBLY PARKING BRAKE SWITCH (AUTOMATIC TRANSAXLE) - ABS WARNING LIGHT - BRAKE WARNING LIGHT BC DLC3 INSTRUMENT PANEL J/B - ECU IG NO. 2 FUSE PARKING BRAKE SWITCH (MANUAL TRANSAXLE) C131984E01 BC–5 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM SYSTEM DIAGRAM Brake Actuator Assembly (Skid Control ECU with Actuator) Motor Relay Motor Solenoid Relay Solenoid Speed Sensor (On Each Wheel) BC Skid Control ECU Stop Light Switch Combination Meter Assembly Speedometer ABS Warning Light Parking Brake Switch BRAKE Warning Light ECM Main Body ECU CAN Communication System C131987E01 Transmitting ECU Skid control ECU Receiving ECU Combination meter Signals • • ABS warning light signal BRAKE warning light signal Communication method CAN communication system BC–6 BC BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM Transmitting ECU Receiving ECU Signals Communication method ECM Skid control ECU Shift position signal CAN communication system BC–7 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM SYSTEM DESCRIPTION 1. SYSTEM DESCRIPTION HINT: The skid control ECU is located within the brake actuator assembly. (a) ABS (Anti-lock Brake System) The ABS helps prevent the wheels from locking when the brakes are applied firmly or when braking on a slippery surface. Brake Actuator Assembly BC Pump Motor Each Speed Sensor Each Wheel Cylinder Skid Control ECU Solenoid Valves ABS Warning Light Combination Meter Assembly CAN Communication System Hydraulic Pressure C132003E01 BC–8 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM Operation description The skid control ECU detects wheel lock based on speed signals it receives from the wheel speed sensors. Based on this information, the skid control ECU controls the pump motor and solenoid valves. The pump motor and solenoid valves are used to prevent wheel lock by controlling the hydraulic pressure applied to the brakes at each wheel. The ABS warning light will come on when the system is malfunctioning. BC BC–9 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM (b) EBD (Electronic Brake force Distribution) The EBD control utilizes ABS, realizing proper brake force distribution between the front and rear wheels in accordance with driving conditions. In addition, when braking while cornering, it also controls the brake forces of the right and left wheels, helping to maintain vehicle behavior. Brake Actuator Assembly Pump Motor Each Speed Sensor Each Wheel Skid Control ECU BC Solenoid Valves BRAKE Warning Light ABS Warning Light Combination Meter Assembly CAN Communication System Hydraulic Pressure C132004E01 BC–10 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM 2. BC 3. 4. 5. Operation description The skid control ECU receives a speed signal from each wheel speed sensor, and uses these signals to detect locking of the wheels. The ECU uses this information in order to determine appropriate control of the solenoid valves. The solenoid valves control the hydraulic pressure applied to the brake cylinder at each wheel. In this way, the solenoid valves are used to control the brake power split between the front and rear, and left and right wheels. The ABS and BRAKE warning lights come on if there is a malfunction in the EBD system. ABS with EBD OPERATION (a) Based on the signals received from the 4 wheel speed sensors, the skid control ECU calculates the deceleration and speed of each wheel, while monitoring for wheel lock. If wheel lock is occurring, the ECU controls the solenoid valves in the brake actuator in order to adjust the hydraulic pressure applied to the brakes at each wheel. FAIL SAFE FUNCTION (a) When a failure occurs in the anti-lock brake system, the ABS warning light comes on and operation is prohibited. In addition, when a failure which disables EBD operation occurs, the brake warning light also comes on and operation is prohibited (See page BC-24). INITIAL CHECK (a) When the vehicle speed first becomes approximately 4 mph (6 km/h) or more after the ignition switch is turned on (IG), each solenoid valve and motor of the brake actuator is sequentially activated to perform an electrical check. During the initial check, the operating sound of solenoid valve and motor can be heard from the engine compartment, but this is not a malfunction. FUNCTION OF COMPONENTS Components Function • Brake actuator assembly • Composed of the holding solenoid valve, pressure reduction solenoid valve, pump motor, reservoir, etc., and adjusts the hydraulic pressure applied to each wheel cylinder. Houses the skid control ECU. Skid control ECU Processes the signals sent from each sensor to control ABS and EBD. Speed sensor Detects speed of each wheel and inputs the data into the skid control ECU. Master cylinder Generates pressure according to pedal effort. Stop light switch Illuminates the stop light when the brake pedal is depressed. (Sends a brake on signal to the skid control ECU) Solenoid relay • • Supplies power to each solenoid. Housed in the skid control ECU. Motor relay • • Supplies power to the pump motor. Housed in the skid control ECU. • Comes on to inform the driver that a malfunction in the ABS and EBD has occurred. Blinks to output DTC. ABS warning light • BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM Components Function • BRAKE warning light BC–11 • Comes on to inform the driver that the parking brake is on when the system is normal or the brake fluid level has decreased. Comes on to inform the driver that a malfunction in the EBD has occurred. BC BC–12 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS (a) Interview the customer to confirm the trouble. NEXT 3 CHECK CAN COMMUNICATION SYSTEM BC (a) Check for DTCs (See page BC-21). HINT: The skid control ECU is connected to the CAN communication system. Therefore, before starting troubleshooting, make sure to check that there is no trouble in the CAN communication system. Result Result Proceed to DTC is not output A DTC is output B B CHECK CAN COMMUNICATION CIRCUIT A 4 CHECK DTC AND FREEZE FRAME DATA (a) Check for DTCs and Freeze Frame Data (See page BC21 for DTC Check / Clear, BC-23 for Freeze Frame Data). (1) Record the DTCs and Freeze Frame Data. (b) Clear the DTCs. (c) Recheck for DTCs. (1) Reproduce the malfunction and check if the DTCs are output again. Result Result Proceed to DTC is output A DTC is not output (Problem symptom does not occur) B DTC is not output (Problem symptom occurs) C B GO TO STEP 9 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM C BC–13 GO TO STEP 10 A 5 DIAGNOSTIC TROUBLE CODE CHART (a) Go to "DIAGNOSTIC TROUBLE CODE CHART" (See page BC-27). NEXT 6 CIRCUIT INSPECTION NEXT 7 BC REPAIR OR REPLACE NEXT 8 CONFIRMATION TEST NEXT END 9 SYMPTOM SIMULATION NEXT 10 PROBLEM SYMPTOMS TABLE (a) Go to "PROBLEM SYMPTOMS TABLE" (See page BC16). NEXT 11 NEXT CIRCUIT INSPECTION BC–14 12 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM REPAIR OR REPLACE NEXT 13 CONFIRMATION TEST NEXT END TEST MODE PROCEDURE ABS Warning Light: BRAKE Warning Light: 1. BC USA: USA: Canada: Canada: C131966E01 WARNING LIGHT AND INDICATOR LIGHT INITIAL CHECK (a) Release the parking brake. NOTICE: Before releasing the parking brake, move the shift lever to the P position for safety (AT model) or set the chocks to hold the vehicle for safety (MT model). HINT: When the parking brake is applied or the level of the brake fluid is low, the BRAKE warning light comes on. (b) When the ignition switch is turned on (IG), check that the ABS warning light comes on for approximately 3 seconds. HINT: • If the skid control ECU stores any DTCs, the ABS and BRAKE warning lights come on. • If the indicator remains on or does not come on, proceed to troubleshooting for the light circuits listed below. Trouble Area See procedure ABS warning light (Remains on) BC-74 ABS warning light circuit (Does not come on) BC-78 BRAKE warning light (Remains on) BC-81 BRAKE warning light (Does not come on) BC-91 2. SENSOR SIGNAL CHECK USING TEST MODE (SIGNAL CHECK) (INTELLIGENT TESTER) HINT: If the ignition switch is turned from on (IG) to on (ACC) or off during Test Mode (signal check), DTCs recorded during the signal check function will be erased. BC–15 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM (a) Procedure to enter Test Mode. (1) Turn the ignition switch off. (2) Connect the intelligent tester to the DLC3. (3) Check that the steering wheel is centered and move the shift lever to the P position (for Automatic Transaxle) or apply the parking brake (Manual Transaxle). (4) Turn the ignition switch on (IG). DLC3 Intelligent Tester C131977E02 (5) Set the intelligent tester to Test Mode (select "SIGNAL CHECK"). HINT: Refer to the intelligent tester operator's manual for further details. C106533 (6) Check that the ABS warning light comes on for several seconds and then blinks in test mode. HINT: If the ABS warning light does not blink, inspect the ABS warning light circuit. TEST MODE: Blinking Pattern: 0.13 sec. 0.13 sec. Trouble Area ON ABS warning light (Does not come on) See procedure BC-78 (b) Check the sensor signal. (1) Drive the vehicle straight ahead. Accelerate the vehicle to a speed of 28 mph (45 km/h) or more for several seconds and check that the ABS warning light goes off when the brake pedal is depressed. HINT: • The sensor check may not be completed if wheel spin occurs, or if the steering wheel is turned during this check. • The ABS warning light goes off when the sensor signal check has been completed and the brake pedal is depressed. • The ABS warning light comes on immediately after a malfunction has been detected during the speed sensor signal check. OFF Display: USA: Canada: C132874E01 BC BC–16 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM BC 3. DLC3: (3) Using SST, connect terminals TS and CG of the DLC3. SST 09843-18040 (4) Turn the ignition switch on (IG). CG TS (c) Stop the vehicle. NOTICE: • The speed sensor check may not be completed if the speed sensor check is started while turning the steering wheel or spinning the wheels. • If the signal check has not been completed, the ABS warning light will blink while driving and the ABS system will not operate. (d) Read the DTC(s) by following the tester screen. NOTICE: • If only the DTCs are displayed, repair the malfunction area and clear the DTCs. • If the DTCs or Test Mode codes (DTC of signal check function) are displayed, repair the malfunction area, clear the DTCs and perform the Test Mode inspection. HINT: See the list of DTCs (See procedure "A"). SENSOR SIGNAL CHECK BY TEST MODE (SIGNAL CHECK) (SST CHECK WIRE) HINT: If the ignition switch is turned from on (IG) to on (ACC) or off during Test Mode (signal check), DTCs recorded during the signal check will be erased. (a) Procedure for Test Mode. (1) Turn the ignition switch off. (2) Check that the steering wheel is centered and move the shift lever to the P position (Automatic Transaxle) or apply the parking brake (Manual Transaxle). G022987E07 BC–17 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM (5) Check that the ABS warning light comes on for several seconds and then blinks in Test Mode. HINT: If the ABS warning light does not blink, inspect the TS and CG terminal circuit, and ABS warning light circuit. TEST MODE: Blinking Pattern: 0.13 sec. 0.13 sec. ON Trouble Area OFF Display: USA: Canada: C132874E01 DLC3: BC-97 ABS warning light circuit (Does not come on) BC-78 (b) Check the sensor signal. (1) Drive the vehicle straight ahead. Accelerate the vehicle to a speed of 28 mph (45 km/h) or more for several seconds and check that the ABS warning light goes off when the brake pedal is depressed. HINT: • The sensor check may not be completed if wheel spin occurs, or if the steering wheel is turned during this check. • The ABS warning light goes off when the sensor signal check has been completed and the brake pedal is depressed. • The ABS warning light comes on immediately after a malfunction has been detected during the speed sensor signal check. (c) Stop the vehicle. NOTICE: • The speed sensor check may not be completed if the speed sensor check is started while turning the steering wheel or spinning the wheels. • If the signal check has not been completed, the ABS warning light will blink while driving and the ABS system will not operate. (d) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 CG TS See procedure TS and CG terminal circuit TC G022988E01 BC BC–18 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM (e) Count the number of blinks of the ABS warning light. Blinking Pattern of Normal System Code: 0.25 sec. 0.25 sec. ON OFF Blinking Pattern of Trouble Code (Example Codes 71 and 72): 0.5 sec. 0.5 sec. BC 1.5 sec. 2.5 sec. 4 sec. Repeat ON OFF Code 71 Code 72 C132876E01 NOTICE: • If only the DTCs are displayed, repair the malfunction area and clear the DTCs. • If the DTCs or Test Mode codes (DTC of signal check function) are displayed, repair the malfunction area, clear the DTCs and perform the Test Mode inspection. HINT: • If more than 1 malfunction is detected at the same time, the lowest numbered code will be displayed first. • See the list of DTCs (See procedure "A"). (f) After performing the check, disconnect the SST from terminals TS and CG, and TC and CG of the DLC3, and turn the ignition switch off. (g) Turn the ignition switch on (IG) to cancel the test mode. HINT: • If the ignition switch is not turned on (IG) after the SST is removed from the DLC3, the previous Test Mode will continue. • If the ignition switch is turned on (IG) with terminals TS and CG shorted, the previous Test Mode will continue. BC–19 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM 4. DTC OF TEST MODE (SIGNAL CHECK) FUNCTION (Procedure "A") DTC of Test Mode (Signal Check): Code No. Diagnosis Trouble Area C1271/71 Low output signal of front speed sensor RH • • • Front speed sensor RH Sensor installation Speed sensor rotor C1272/72 Low output signal of front speed sensor LH • • • Front speed sensor LH Sensor installation Speed sensor rotor C1273/73 Low output signal of rear speed sensor RH • • • Rear speed sensor RH Sensor installation Speed sensor rotor C1274/74 Low output signal of rear speed sensor LH • • • Rear speed sensor LH Sensor installation Speed sensor rotor C1275/75 Abnormal change in output signal of front speed sensor RH • • • Front speed sensor RH Front speed sensor circuit RH Sensor installation C1276/76 Abnormal change in output signal of front speed sensor LH • • • Front speed sensor LH Front speed sensor circuit LH Sensor installation C1277/77 Abnormal change in output signal of rear speed sensor RH • • • Rear speed sensor RH Rear speed sensor circuit RH Sensor installation C1278/78 Abnormal change in output signal of rear speed sensor LH • • • Rear speed sensor LH Rear speed sensor circuit LH Sensor installation HINT: The codes in this table are output only in Test Mode (signal check). BC BC–20 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM PROBLEM SYMPTOMS TABLE If a normal code is displayed during the DTC check but the problem still occurs, check the circuits for each problem symptom in the order given in the table below and proceed to the relevant troubleshooting page. NOTICE: When replacing the skid control ECU, sensor, etc., turn the ignition switch off. HINT: • Inspect the fuses and relays before investigating the suspected areas as shown in the table below. • Inspect each malfunction circuit in numerical order for the corresponding symptoms. ANTI-LOCK BRAKE SYSTEM: Symptom BC ABS does not operate ABS does not operate efficiently ABS warning light malfunction (Remains on) ABS warning light malfunction (Does not come on) Brake warning light malfunction (Remains on) Brake warning light malfunction (Does not come on) ABS sensor DTC check cannot be done Suspected area See page 1. Check the DTC reconfirming that the normal system code is output BC-21 2. IG power source circuit BC-63 3. Front speed sensor circuit BC-30 4. Rear speed sensor circuit BC-38 5. Check the brake actuator assembly with the intelligent tester (Check brake actuator assembly operation using the active test function) If abnormal, check the hydraulic circuit for leakage BR-42 6. If the symptoms still occur even after the above circuits in suspected areas have been inspected and proved to be normal, replace the brake actuator assembly (skid control ECU) BC-432 1. Check the DTC reconfirming that the normal system code is output. BC-21 2. Front speed sensor circuit BC-30 3. Rear speed sensor circuit BC-38 4. Stop light switch circuit BC-67 5. Check the brake actuator assembly with the intelligent tester (Check brake actuator assembly operation using the active test function) BR-42 6. If the symptoms still occur even after the above circuits in suspected areas have been inspected and proved to be normal, replace the brake actuator assembly (skid control ECU) BC-432 1. ABS warning light circuit BC-74 2. Brake actuator assembly (skid control ECU) BC-432 1. ABS warning light circuit BC-78 1. Brake warning light circuit BC-81 2. Brake actuator assembly (skid control ECU) BC-432 1. Brake warning light circuit BC-91 2. Brake actuator assembly (skid control ECU) BC-432 1. Check the DTC again and make sure that the normal system code is output BC-21 2. TS and CG terminal circuit BC-97 3. TC and CG terminal circuit BC-94 4. If the symptoms still occur even after the above circuits in suspected areas have been inspected and proved to be normal, replace the brake actuator assembly (skid control ECU) BC-432 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM BC–21 TERMINALS OF ECU 1. TERMINALS OF ECU Skid Control ECU (Brake Actuator Assembly): C131974E01 Symbols (Terminal No.) Terminal Description GND2 (1) Actuator pump motor ground +BM (2) Motor relay power supply +BS (3) Solenoid valves power supply GND1 (4) Skid control ground FL+ (5) Front LH (+) wheel speed signal input FL- (6) Front LH (-) wheel speed signal input RL+ (7) Rear LH (+) wheel speed signal input RR- (8) Rear RH (-) wheel speed signal input FR- (9) Front RH (-) wheel speed signal input FR+ (10) Front RH (+) wheel speed signal input D/G (11) Diagnosis tester communication line CANL (15) CAN communication line L RL- (17) Rear LH (-) wheel speed signal input IG1 (18) ECU power supply RR+ (19) Rear RH (+) wheel speed signal input STP (20) Stop light switch input SP1 (23) Speed signal output for speedometer TS (25) Sensor check input CANH (26) CAN communication line H 2. TERMINAL INSPECTION (a) Disconnect the connector and measure the voltage or resistance on the wire harness side. HINT: Voltage cannot be measured with the connector connected to the skid control ECU as the connector is watertight. BC BC–22 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM Skid Control ECU (Harness Side Connector Front View): C131969E01 Symbols (Terminal No.) BC GND2 (1) - Body ground Wiring Color W-B - Body ground Terminal Description Condition Specified Condition Actuator pump motor ground Always Below 1 Ω +BM (2) - Body ground B - Body ground Motor relay power supply Always 10 to 14 V +BS (3) - Body ground L - Body ground Solenoid valves power supply Always 10 to 14 V Skid control ECU ground Always Below 1 Ω IG1 (18) - Body ground P - Body ground ECU power supply Ignition switch on (IG) 10 to 14 V STP (20) - Body ground P - Body ground Stop light switch input Stop light switch ON (Brake pedal depressed) 8 to 14 V STP (20) - Body ground P - Body ground Stop light switch input Stop light switch OFF (Brake pedal released) Below 3 V GND1 (4) - Body ground W-B - Body ground BC–23 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM DIAGNOSIS SYSTEM 1. CG (b) The vehicle's ECU uses the ISO 15765-4 for communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. HINT: Connect the cable of the intelligent tester to the DLC3, turn the ignition switch on (IG) and attempt to use the intelligent tester. If the screen displays a communication error message, a problem exists on either the vehicle side or the tester side. If the communication is normal when the tester is connected to another vehicle, inspect the DLC3 on the original vehicle. If the communication is still impossible when the tester is connected to another vehicle, the problem is probably in the tester itself. Consult the Service Department listed in the tester's instruction manual. SG CANH 1 2 3 4 5 6 7 8 9 10 11 1213141516 CANL BAT Symbols (Terminal No.) CG (4) - Body ground DIAGNOSIS SYSTEM (a) Inspect the battery voltage. Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge the battery before proceeding. A082779E65 Terminal Description Chassis ground Condition Specified Condition Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 9 to 14 V CANH (6) - CANL (14) HIGH-level CAN bus line Ignition switch OFF* 54 to 69 Ω CANH (6) - Battery positive HIGH-level CAN bus line Ignition switch OFF* 6 kΩ or higher CANH (6) - CG (4) HIGH-level CAN bus line Ignition switch OFF* 200 Ω or higher CANL (14) - Battery positive LOW-level CAN bus line Ignition switch OFF* 6 kΩ or higher CANL (14) - CG (4) LOW-level CAN bus line Ignition switch OFF* 200 Ω or higher 2. NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. DIAGNOSIS NOTICE: When releasing the parking brake, set chocks to hold the vehicle for safety. BC BC–24 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM (a) Release the parking brake. (b) Turn the ignition switch on (IG). (c) If the skid control ECU detects a malfunction, the ABS warning light and brake warning light will come on to warn the driver. The table below indicates which light will come on when there is a malfunction in a particular function. USA: USA: Canada: Canada: C131968E01 BC Item/Trouble Area ABS System EBD System Skid Control ECU ABS Warning light { { { Brake Warning light - { { 3. {: Light ON -: Light OFF • The DTCs are simultaneously stored in the memory. The DTCs can be read by connecting the SST (09843-18043) between the TC and CG terminals of the DLC3 and observing the blinking pattern of the ABS warning light, or by connecting an intelligent tester (See page BC21). • This system has a sensor signal check function (See page BC-11). WARNING LIGHT INITIAL CHECK NOTICE: When releasing the parking brake, set chocks to hold the vehicle for safety. HINT: When the parking brake is applied or the level of the brake fluid is low, the brake warning light comes on. (a) Release the parking brake. (b) Check that the ABS warning light and brake warning light come on when the ignition switch is turned on (IG) and go off in approximately 3 seconds. (c) If the warning lights do not come on or remain on, inspect the ABS warning light circuit and/or brake warning light circuit. Trouble Area USA: USA: Canada: Canada: C131968E01 See procedure ABS warning light circuit (Remains on) BC-74 ABS warning light circuit (Does not come on) BC-78 Brake warning light circuit (Remains on) BC-81 Brake warning light circuit (Does not come on) BC-91 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM 4. Shake Slightly DLC3: SYMPTOM SIMULATION HINT: The most difficult case in troubleshooting is when no symptoms occur. In such cases, a thorough customer problem analysis must be carried out. Then the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be reproduced. No matter how experienced or skilled a technician may be, if he proceeds to troubleshoot without confirming the problem symptoms, he will likely overlook something important and make a wrong guess at some points in the repair operation. This leads to a standstill in troubleshooting. (a) Vibration method: When vibration seems to be the major cause. HINT: Perform the simulation method only during the primary check period (for approximately 6 seconds after the ignition switch is turned on (IG)). (1) Slightly vibrate the part of the sensor considered to be the problem cause with your fingers and check whether the malfunction occurs. (2) Slightly shake the connector vertically and horizontally. HINT: Shaking the relays too strongly may result in open relays. (3) Slightly shake the wire harness vertically and horizontally. The connector joint and fulcrum of the vibration are the major areas to be checked thoroughly. Vibrate Slightly Vibrate Slightly BC–25 D025083E13 DTC CHECK / CLEAR CG TC 1. G022986E01 DTC CHECK / CLEAR (SST CHECK WIRE) (a) DTC check (1) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 (2) Turn the ignition switch on (IG). (3) Read the DTCs from the ABS warning light on the combination meter. HINT: If no code appears, inspect the TC and CG terminal circuit and the ABS warning light circuit. Trouble Area See procedure TC and CG terminal circuit BC-94 ABS warning light circuit (Remains on) BC-74 ABS warning light circuit (Does not come on) BC-78 BC BC–26 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM (4) As an example, refer to the chart below for the blinking patterns of the normal system code and trouble codes 11 and 21. Normal System Code: Trouble Code (Example Codes 11 and 21): 0.25 sec. 0.5 sec. 2.5 sec. 1.5 sec. 0.25 sec. 2 sec. 0.5 sec. 4 sec. 4 sec. ON ON OFF OFF Repeat Code 11 BC Code 21 I042843E01 (5) The codes are explained in the code table (See page BC-27). (6) After completing the check, disconnect terminals TC and CG of the DLC3, and turn off the display. If 2 or more DTCs are detected at the same time, the DTCs will be displayed in ascending order. DLC3: (b) DTC clear (1) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 (2) Turn the ignition switch on (IG). CG TC G022986E01 BR03890 (3) Clear the DTCs stored in the ECU by depressing the brake pedal 8 times or more within 5 seconds. (4) Check that the warning light indicates the normal system code. (5) Remove the SST from the terminals of the DLC3. HINT: Clearing the DTCs cannot be performed by disconnecting the battery terminal or the ECU-IG fuse. BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM 2. Intelligent Tester DLC3 CAN VIM C131977E05 3. BC–27 DTC CHECK/CLEAR (WHEN USING INTELLIGENT TESTER:) (a) DTC check (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch on (IG). (3) Read the DTCs by following the prompts on the tester screen. (b) DTC clear (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch on (IG). (3) Operate the intelligent tester to clear the codes. HINT: Refer to the intelligent tester operator's manual for further details. END OF DTC CHECK/CLEAR (a) Turn the ignition switch on (IG). (b) Check that the ABS warning light goes off within approximately 3 seconds. BC BC–28 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM FREEZE FRAME DATA 1. BC (c) (d) (e) (f) Intelligent Tester DLC3 FREEZE FRAME DATA (a) Whenever a DTC is detected or the ABS operates, the skid control ECU stores the current vehicle (sensor) status as Freeze Frame Data. (b) The skid control ECU stores the number of times (maximum: 31) the ignition switch has been turned from off to on (IG) since the last time the ABS was activated. HINT: • Freeze frame data at the time the ABS operates: The skid control ECU stores and updates data whenever the ABS system operates. When the skid control ECU stores data at the time a DTC is detected, the data stored during ABS operation is erased. • Freeze frame data at the time a DTC is detected: When the skid control ECU stores data at the time a DTC is detected, no updates will be performed until the data is cleared. Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Select "DTC INFO" on the tester display. On the DTC data display screen, select the DTC data display with "*". CAN VIM C131977E05 Intelligent Tester Display Measurement Item Reference Value TROUBLE CODE Freeze DTC min.: 0, max.: 65535 #DTC Number of trouble codes min.: 0, max.: 255 FREEZE TIME Elapsed time after freeze trigger Min.: 0 ms, Max.: 500 ms #IG ON Number of operations of ignition switch on (IG) after storing freeze frame data 0 to 31 STOP LAMP SW Stop light switch signal Stop light switch ON: ON, OFF: OFF PARKING BRAKE SW Parking brake condition ON: Parking brake on OFF: Parking brake off OPERATED SYSTEM Operated system ABS operated: ABS FR WHEEL SPD Front right wheel speed Min.: 0 MPH (0 km/h), Max.: 202 MPH (326 km/h) FL WHEEL SPD Front left wheel speed Min.: 0 MPH (0 km/h), Max.: 202 MPH (326 km/h) RR WHEEL SPD Rear right wheel speed Min.: 0 MPH (0 km/h), Max.: 202 MPH (326 km/h) BC–29 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM Intelligent Tester Display Measurement Item Reference Value RL WHEEL SPD Rear left wheel speed Min.: 0 MPH (0 km/h), Max.: 202 MPH (326 km/h) VEHICLE SPD Vehicle speed reading Speed indication on the meter SPD GRADE Vehicle speed grade Min.: -1.869 G, Max.: 1.869 G BC BC–30 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM FAIL-SAFE CHART 1. FAIL SAFE OPERATION If there is a problem with sensor signals or brake actuator systems, the skid control ECU will prohibit power supply to the brake actuator and terminate ABS control. ABS control will be prohibited, but EBD control continues as much as possible. If EBD control is impossible, the brake warning light will come on to warn the driver (See page BC-19). Malfunction Area Control Method ABS system Prohibits the ABS control EBD system Prohibits the ABS and EBD control HINT: If the ABS system has a malfunction, the brake system will operate normally without ABS control. BC BC–31 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM DATA LIST / ACTIVE TEST 1. DATA LIST HINT: According to the DATA LIST displayed by the intelligent tester, the value of the switch, sensor, actuator and other items can be read without removing any parts. Reading the DATA LIST as a first step in troubleshooting is one of the methods to save labor time. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) According to the display on the tester, read the "DATA LIST". Intelligent Tester BC DLC3 CAN VIM C131977E05 DATA LIST: Item Measurement Item / Range (Display) Normal Condition Diagnostic Note ABS MOT RELAY ABS motor relay / ON or OFF ON: During pump motor operation OFF: No pump motor operation - SOL RELAY Solenoid relay / ON or OFF ON: Solenoid relay ON OFF: Solenoid relay OFF - STOP LAMP SW Stop light switch / ON or OFF ON: Brake pedal depressed OFF: Brake pedal released - PARKING BRAKE SW Parking brake switch / ON or OFF ON: Parking brake applied OFF: Parking brake released - FR WHEEL SPD Wheel speed sensor (FR) reading / min.: 0 km/h (0 MPH), max.: 326 km/h (202 MPH) Actual wheel speed Speed indicated on speedometer FL WHEEL SPD Wheel speed sensor (FL) reading / min.: 0 km/h (0 MPH), max.: 326 km/h (202 MPH) Actual wheel speed Speed indicated on speedometer RR WHEEL SPD Wheel speed sensor (RR) reading / min.: 0 km/h (0 MPH), max.: 326 km/h (202 MPH) Actual wheel speed Speed indicated on speedometer RL WHEEL SPD Wheel speed sensor (RL) reading / min.: 0 km/h (0 MPH), max.: 326 km/h (202 MPH) Actual wheel speed Speed indicated on speedometer VEHICLE SPD Vehicle speed reading / min.: 0 km/h (0 MPH), max.: 326 km/h (202 MPH) Actual wheel speed Speed indicated on speedometer IG VOLTAGE ECU power supply voltage / NORMAL or TOO LOW NORMAL: 9.5 V or over TOO LOW: Below 9.5 V - SFRR ABS solenoid (SFRR) ON / OFF ON: Operates - SFRH ABS solenoid (SFRH) ON / OFF ON: Operates - SFLR ABS solenoid (SFLR) ON / OFF ON: Operates - BC–32 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM Item Measurement Item / Range (Display) Normal Condition Diagnostic Note SFLH ABS solenoid (SFLH) ON / OFF ON: Operates - SRRR ABS solenoid (SRRR (SRR)) ON / OFF ON: Operates - SRRH ABS solenoid (SRRH (SRH)) ON / OFF ON: Operates - SRLR ABS solenoid (SRLR) ON / OFF ON: Operates - SRLH ABS solenoid (SRLH) ON / OFF ON: Operates - TEST MODE Test mode / NORMAL or TEST NORMAL: Normal mode TEST: During test mode - #CODES Number of DTCs recorded / min.: 0, max.: 255 Min.: 0, max.: 19 - ABS WARN LAMP ABS warning light ON /OFF ON: ABS warning light ON OFF: ABS warning light off - BRAKE WARN LAMP Brake warning light ON / OFF ON: Brake warning light ON OFF: Brake warning light off - FR WHEEL ACCEL Front right wheel acceleration / Min.: -200.84 m/s, Max.: 199.27 m/s 0 m/s - FL WHEEL ACCEL Front left wheel acceleration / Min.: -200.84 m/s, Max.: 199.27 m/s 0 m/s - RR WHEEL ACCEL Rear right wheel acceleration / Min.: -200.84 m/s, Max.: 199.27 m/s 0 m/s - RL WHEEL ACCEL Rear left wheel acceleration / Min.: -200.84 m/s, Max.: 199.27 m/s 0 m/s - FR ABS STATUS Front right ABS control status / ON or OFF ON: During ABS control OFF: Not ABS control - FL ABS STATUS Front left ABS control status / ON or OFF ON: During ABS control OFF: Not ABS control - RR ABS STATUS Rear right ABS control status / ON or OFF ON: During ABS control OFF: Not ABS control - RL ABS STATUS Rear left ABS control status / ON or OFF ON: During ABS control OFF: Not ABS control - FR EBD STATUS Front right EBD control status / ON or OFF ON: During EBD control OFF: Not EBD control - FL EBD STATUS Front left EBD control status / ON or OFF ON: During EBD control OFF: Not EBD control - RR EBD STATUS Rear right EBD control status / ON or OFF ON: During EBD control OFF: Not EBD control - RL EBD STATUS Rear left EBD control status / ON or OFF ON: During EBD control OFF: Not EBD control - BC 2. ACTIVE TEST HINT: Performing the ACTIVE TEST using the intelligent tester allows the relay, actuator and other items to operate without removing any parts. Performing the ACTIVE TEST as a first step in troubleshooting is one of the methods to save labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). BC–33 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM (c) According to the display on the tester, perform the "ACTIVE TEST". ACTIVE TEST: Item Vehicle Condition / Test Details Diagnostic Note SFRR Turns ABS solenoid (SFRR) ON / OFF Operating sound of solenoid (clicking sound) can be heard SFRH Turns ABS solenoid (SFRH) ON / OFF Operating sound of solenoid (clicking sound) can be heard SFLR Turns ABS solenoid (SFLR) ON / OFF Operating sound of solenoid (clicking sound) can be heard SFLH Turns ABS solenoid (SFLH) ON / OFF Operating sound of solenoid (clicking sound) can be heard SRRR Turns ABS solenoid (SRRR) ON / OFF Operating sound of solenoid (clicking sound) can be heard SRRH Turns ABS solenoid (SRRH) ON / OFF Operating sound of solenoid (clicking sound) can be heard SRLR Turns ABS solenoid (SRLR) ON / OFF Operating sound of solenoid (clicking sound) can be heard SRLH Turns ABS solenoid (SRLH) ON / OFF Operating sound of solenoid (clicking sound) can be heard MOT RELAY Turns ABS motor relay ON / OFF Operating sound of motor can be heard ABS WRN LIGHT Turns ABS warning light ON / OFF Observe combination meter BRAKE WRN LIGHT Turns Brake warning light ON / OFF Observe combination meter BC BC–34 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM DIAGNOSTIC TROUBLE CODE CHART NOTICE: Turn the ignition switch off before removing parts. HINT: • If no abnormality is found when inspecting parts, inspect the skid control ECU and ground points for poor contact. • If a malfunction code is displayed during the DTC check, check the circuit indicated by the DTC. For details of each code, refer to the "See page" for respective "DTC No." in the DTC chart. • When 2 or more DTCs are detected, perform circuit inspection one by one until the problem is identified. ANTI-LOCK BRAKE SYSTEM: DTC No. Detection Item Trouble Area See page C0200/31 Right Front Wheel Speed Sensor Signal Malfunction 1. Front speed sensor RH 2. Front speed sensor RH circuit 3. Front speed sensor rotor RH 4. Sensor installation 5. Brake actuator assembly (skid control ECU) BC-30 C0205/32 Left Front Wheel Speed Sensor Signal Malfunction 1. Front speed sensor LH 2. Front speed sensor LH circuit 3. Front speed sensor rotor LH 4. Sensor installation 5. Brake actuator assembly (skid control ECU) BC-30 C0210/33 Right Rear Wheel Speed Sensor Signal Malfunction 1. Rear speed sensor RH 2. Rear speed sensor RH circuit 3. Rear speed sensor rotor RH 4. Sensor installation 5. Brake actuator assembly (skid control ECU) BC-38 C0215/34 Left Rear Wheel Speed Sensor Signal Malfunction 1. Rear speed sensor LH 2. Rear speed sensor LH circuit 3. Rear speed sensor rotor LH 4. Sensor installation 5. Brake actuator assembly (skid control ECU) BC-38 C0226/21 SFR Solenoid Circuit 1. SFRR or SFRH circuit 2. Brake actuator assembly BC-47 C0236/22 SFL Solenoid Circuit 1. SFLR or SFLH circuit 2. Brake actuator assembly BC-47 C0246/23 SRR Solenoid Circuit 1. SRRR or SRRH circuit 2. Brake actuator assembly BC-47 C0256/24 SRL Solenoid Circuit 1. SRLR or SRLH circuit 2. Brake actuator assembly BC-47 C0273/13 Open or Short Circuit in ABS Motor Relay Circuit 1. Brake actuator assembly (motor relay) 2. ABS No. 1 fuse (Fusible link) 3. Wire harness (+BM circuit) BC-49 C0278/11 Open or Short Circuit in ABS Solenoid Relay Circuit 1. Brake actuator assembly (solenoid relay) 2. ABS No. 2 fuse (Fusible link) 3. Wire harness (+BS circuit) BC-53 BC BC–35 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM Trouble Area See page C1237/37 DTC No. Speed Sensor Rotor Faulty Detection Item 1. Brake actuator assembly (skid control ECU) 2. Speed sensor rotor (Front) 3. Rear axle hub and bearing assembly 4. Speed sensor 5. Speed sensor circuit 6. Tire and wheel size 7. Tire deformation BC-56 C1241/41 Low Battery Positive Voltage or Abnormally High Battery Positive Voltage 1. Battery 2. Charging system 3. Power source circuit 4. Brake actuator assembly (Skid control ECU) BC-63 C1249/49 Open in Stop Light Switch Circuit 1. Stop light switch 2. Stop light switch circuit 3. Brake actuator assembly (Skid control ECU) BC-67 C1271/71 Low Output Signal of Front Speed Sensor RH (Test Mode DTC) 1. Front speed sensor RH 2. Sensor installation 3. Skid control rotor BC-30 C1272/72 Low Output Signal of Front Speed Sensor LH (Test Mode DTC) 1. Front speed sensor LH 2. Sensor installation 3. Skid control rotor BC-30 C1273/73 Low Output Signal of Rear Speed Sensor RH (Test Mode DTC) 1. Rear speed sensor RH 2. Sensor installation 3. Skid control rotor BC-38 C1274/74 Low Output Signal of Rear Speed Sensor LH (Test Mode DTC) 1. Rear speed sensor LH 2. Sensor installation 3. Skid control rotor BC-38 C1275/75 Abnormal Change in Output Signal of Front Speed Sensor RH (Test Mode DTC) 1. Front speed sensor RH 2. Front speed sensor circuit RH 3. Sensor installation BC-30 C1276/76 Abnormal Change in Output Signal of Front Speed Sensor LH (Test Mode DTC) 1. Front speed sensor LH 2. Front speed sensor circuit LH 3. Sensor installation BC-30 C1277/77 Abnormal Change in Output Signal of Rear Speed Sensor RH (Test Mode DTC) 1. Rear speed sensor RH 2. Sensor installation 3. Sensor rotor BC-38 C1278/78 Abnormal Change in Output Signal of Rear Speed Sensor LH (Test Mode DTC) 1. Rear speed sensor LH 2. Sensor installation 3. Sensor rotor BC-38 C1300/62 Skid Control ECU Malfunction Brake actuator assembly (skid control ECU) BC-72 C1330/35 Right Front Speed Sensor Circuit 1. Front speed sensor RH 2. Front speed sensor RH circuit 3. Sensor installation BC-30 C1331/36 Left Front Speed Sensor Circuit 1. Front speed sensor LH 2. Front speed sensor LH circuit 3. Sensor installation BC-30 C1332/38 Right Rear Speed Sensor Circuit 1. Rear speed sensor RH 2. Rear speed sensor RH circuit 3. Sensor installation BC-38 C1333/39 Left Rear Speed Sensor Circuit 1. Rear speed sensor LH 2. Rear speed sensor LH circuit 3. Sensor installation BC-38 U0073/94 Control Module Communication Bus OFF 1. Wire harness (CANL, CANH circuit) 2. Brake actuator assembly (skid control ECU) BC-73 BC BC–36 BC BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM DTC C0200/31 Right Front Wheel Speed Sensor Signal Malfunction DTC C0205/32 Left Front Wheel Speed Sensor Signal Malfunction DTC C1271/71 Low Output Signal of Front Speed Sensor RH (Test Mode DTC) DTC C1272/72 Low Output Signal of Front Speed Sensor LH (Test Mode DTC) DTC C1275/75 Abnormal Change in Output Signal of Front Speed Sensor RH (Test Mode DTC) DTC C1276/76 Abnormal Change in Output Signal of Front Speed Sensor LH (Test Mode DTC) DTC C1330/35 Right Front Speed Sensor Circuit DTC C1331/36 Left Front Speed Sensor Circuit DESCRIPTION The speed sensors detect wheel speed and transmit the signals to the skid control ECU. These signals are used for control of the ABS control system. Each of the front and rear rotors has 48 serrations. When the rotors rotate, the magnetic field generated by the permanent magnet in the speed sensor induces AC voltage. Since the frequency of this AC voltage changes in direct proportion to the speed of the rotor, the frequency is used by the ECU to detect the speed of each wheel. DTCs C1271/71 to C1276/76 can be deleted when the speed sensor sends a wheel speed signal or the test mode ends. DTCs C1271/71 to C1276/76 are output only in the test mode. Speed Sensor Rotor Coil N S Magnet To ECU Low speed High speed +V -V F000010E16 BC–37 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM DTC No. DTC Detecting Condition Trouble Area C0200/31 C0205/32 When either of the following is detected: • Vehicle speed is more than 25 mph (40 km/h), and pulses are not input for 0.03 sec. • When the vehicle speed has reached 8 mph (12 km/h) after the initial start or restart, a wheel speed of 0 mph (0 km/h) is detected. • • • • • Front speed sensor RH and/or LH Front speed sensor circuit RH and/or LH Front speed sensor rotor RH and/or LH Sensor installation Brake actuator assembly (skid control ECU) C1330/35 C1331/36 Abnormality in the resistance value of each speed sensor is detected. • • • Front speed sensor RH and/or LH Front speed sensor circuit RH and/or LH Sensor installation C1271/71 C1272/72 Detected only during test mode. • • • Front speed sensor Sensor installation Sensor rotor C1275/75 C1276/76 Detected only during test mode. • • • Front speed sensor Front speed sensor circuit Sensor installation HINT: DTC No. C0200/31 and C1330/35 are for the front speed sensor RH. DTC No. C0205/32 and C1331/36 are for the front speed sensor LH. BC WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) A14 ABS Speed Sensor Front LH A35 ABS Speed Sensor Front RH 1 2 1 2 5 A25 FL+ 6 A25 FL10 A25 FR+ 9 A25 FR- F040884E12 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). 1 READ VALUE OF INTELLIGENT TESTER (FRONT SPEED SENSOR) (a) Connect the intelligent tester to the DLC3. (b) Start the engine. BC–38 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM (c) Select "DATA LIST" and read the value displayed on the intelligent tester (See page BC-25). DATA LIST: ABS Measurement Item / Range (Display) Item Normal Condition FR WHEEL SPD Wheel speed sensor (FR) reading / min.: 0 MPH (0 km/h), max.: 202 MPH (326 km/h) Actual wheel speed FL WHEEL SPD Wheel speed sensor (FL) reading / min.: 0 MPH (0 km/h), max.: 202 MPH (326 km/h) Actual wheel speed (d) Check that there is no difference between the speed value output from the speed sensor displayed on the intelligent tester and the speed value displayed on the speedometer when driving the vehicle. OK: The speed value output from the speed sensor displayed on the intelligent tester is the same as the actual vehicle speed. NG BC Go to step 5 OK 2 PERFORM TEST MODE INSPECTION (SIGNAL CHECK) (a) Check if test mode (signal check) DTCs are detected (See page BC-11). Result Condition Proceed to Test mode (signal check) DTC is not output A Test mode (signal check) DTC is output B B A Go to step 5 BC–39 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM 3 INSPECT SPEED SENSOR SIGNAL WAVEFORM Front Speed Sensor (Wire Harness Side) Connector Front View: A14 A35 FRFLFL+ Normal Signal Waveform: FR+ GND 1 V/Division, 2 ms./Division C132005E01 (a) Lift up the vehicle. (b) Perform the inspection using an oscilloscope. (1) Disconnect the front speed sensor connector. (2) Connect the oscilloscope to terminals 1 and 2 of the front speed sensor. (3) Check that a waveform is output when the tires are rotated. OK: The same waveform is output from front wheels and there is no noise or interference in the waveform. HINT: • As vehicle speed (wheel rotation speed) increases, the width of the waveform narrows and the output voltage becomes greater. • When noise is identified in the waveform on the oscilloscope, the erratic signals are generated due to rotor scratches, looseness or foreign matter attached to the speed sensor. (c) Connect the connector. NG Go to step 11 OK 4 RECONFIRM DTC (a) Clear the DTCs (See page BC-21). (b) Drive the vehicle at a speed of approximately 25 mph (40 km/h) or more for 60 seconds or more. (c) Check if the same DTCs are recorded (See page BC21). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTCs (C0200/31, C0205/32, C1330/35 and C1331/36) are output A DTCs (C0200/31, C0205/32, C1330/35 and C1331/36) are output (When troubleshooting in accordance with the PROBLEM SYMPTOMS TABLE) B DTCs (C0200/31, C0205/32, C1330/35 and C1331/36) are not output (When troubleshooting in accordance with the DTC CHART) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page BC-16) C END BC BC–40 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM A 5 INSPECT FRONT SPEED SENSOR INSTALLATION (a) Check the front speed sensor installation. OK: The installation bolt is tightened properly. There is no clearance between the sensor and front steering knuckle. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) NOTICE: Check the speed sensor signal after replacement (See page BC-11). 8.0 N*m (82 kgf*cm, 71 in.*lbf) OK No clearance NG BR03795E21 BC NG REPLACE FRONT SPEED SENSOR (See page BC-438) OK 6 INSPECT FRONT SPEED SENSOR 2 (a) Make sure that there is no looseness at the locking part and the connecting part of the connectors. (b) Disconnect the front speed sensor connectors. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: LH 1 C093876E01 Tester Connection Specified Condition A14-1 (FL+) - A14-2 (FL-) 0.92 to 1.22 kΩ at 20 °C (68°F) A14-1 (FL+) - Body ground 10 kΩ or higher A14-2 (FL-) - Body ground 10 kΩ or higher Tester Connection Specified Condition A35-1 (FR+) - A35-2 (FR-) 0.92 to 1.22 kΩ at 20 °C(68°F) A35-1 (FR+) - Body ground 10 kΩ or higher A35-2 (FR-) - Body ground 10 kΩ or higher RH NOTICE: Check the speed sensor signal after replacement (See page BC-11). NG OK REPLACE FRONT SPEED SENSOR (See page BC-438) BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM 7 BC–41 CHECK HARNESS AND CONNECTOR (FRONT SPEED SENSOR TO SKID CONTROL ECU) Skid Control ECU (Wire Harness Side) Connector Front View: FL+ FL- FR- FR+ A25 Front Speed Sensor (Wire Harness Side) Connector Front View: A14 (a) Disconnect the skid control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: LH FL+ FR- FR+ C132908E02 Specified Condition A25-5 (FL+) - A14-1 (FL+) Below 1 Ω A25-6 (FL-) - A14-2 (FL-) Below 1 Ω A14-1 (FL+) - Body ground 10 kΩ or higher A14-2 (FL-) - Body ground 10 kΩ or higher Tester Connection Specified Condition A25-10 (FR+) - A35-1 (FR+) Below 1 Ω RH A35 FL- Tester Connection A25-9 (FR-) - A35-2 (FR-) Below 1 Ω A35-1 (FR+) - Body ground 10 kΩ or higher A35-2 (FR-) - Body ground 10 kΩ or higher (c) Connect the connectors. NG REPAIR OR REPLACE HARNESS OR CONNECTOR (FRONT SPEED SENSOR TO SKID CONTROL ECU) OK 8 INSPECT SPEED SENSOR SIGNAL WAVEFORM Front Speed Sensor (Wire Harness Side) Connector Front View: A14 A35 FRFLFL+ Normal Signal Waveform: FR+ GND 1 V/Division, 2 ms./Division C132005E01 (a) Lift up the vehicle. (b) Perform the inspection using an oscilloscope. (1) Disconnect the front speed sensor connector. (2) Connect the oscilloscope to terminals 1 and 2 of the front speed sensor. (3) Check that a waveform is output when the tires are rotated. OK: The same waveforms is output from front wheels and there is no noise or interference in the waveform. HINT: • As vehicle speed (wheel rotation speed) increases, the width of the waveform narrows and the output voltage becomes greater. • When noise is identified in the waveform on the oscilloscope, the erratic signals are generated due to rotor scratches, looseness or foreign matter attached to the speed sensor. (4) Connect the connector. NG Go to step 11 BC BC–42 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM OK 9 READ VALUE OF INTELLIGENT TESTER (FRONT SPEED SENSOR) (a) Connect the intelligent tester to the DLC3. (b) Start the engine. (c) Select "DATA LIST" and read the value displayed on the intelligent tester (See page BC-25). DATA LIST: ABS Measurement Item / Range (Display) Item Normal Condition FR WHEEL SPD Wheel speed sensor (FR) reading / min.: 0 MPH (0 km/h), max.: 202 MPH (326 km/h) Actual wheel speed FL WHEEL SPD Wheel speed sensor (FL) reading / min.: 0 MPH (0 km/h), max.: 202 MPH (326 km/h) Actual wheel speed (d) Check that there is no difference between the speed value output from the speed sensor displayed on the intelligent tester and the speed value displayed on the speedometer when driving the vehicle. OK: The speed value output from the speed sensor displayed on the intelligent tester is the same as the actual vehicle speed. HINT: If troubleshooting has been carried out according to the "PROBLEM SYMPTOMS TABLE", refer back to the table and proceed to the next step before replacing the part (See page BC-16). BC NG REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) OK 10 RECONFIRM DTC (a) Clear the DTCs (See page BC-21). (b) Drive the vehicle at a speed of approximately 25 mph (40 km/h) or more for 60 seconds or more. (c) Check if the same DTCs are recorded (See page BC21). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTCs (C0200/31, C0205/32, C1330/35 and C1331/36) are output A DTCs (C0200/31, C0205/32, C1330/35 and C1331/36) are not output B B END BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM BC–43 A 11 INSPECT SPEED SENSOR TIP (a) Remove the front speed sensor (See page BC-438). (b) Check the sensor tip. OK: No scratches or foreign matter on the sensor tip. NOTICE: Check the speed sensor signal after cleaning or replacement (See page BC-11). (c) Install the speed sensor. NG CLEAN OR REPLACE SPEED SENSOR OK CLEAN OR REPLACE SPEED SENSOR ROTOR BC BC–44 BC BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM DTC C0210/33 Right Rear Wheel Speed Sensor Signal Malfunction DTC C0215/34 Left Rear Wheel Speed Sensor Signal Malfunction DTC C1273/73 Low Output Signal of Rear Speed Sensor RH (Test Mode DTC) DTC C1274/74 Low Output Signal of Rear Speed Sensor LH (Test Mode DTC) DTC C1277/77 Abnormal Change in Output Signal of Rear Speed Sensor RH (Test Mode DTC) DTC C1278/78 Abnormal Change in Output Signal of Rear Speed Sensor LH (Test Mode DTC) DTC C1332/38 Right Rear Speed Sensor Circuit DTC C1333/39 Left Rear Speed Sensor Circuit DESCRIPTION Refer to DTCs C0200/31, C0205/32, C1330/35, and C1331/36 (See page BC-30). DTCs from C1273/73 to C1278/78 can be deleted when the speed sensor sends a vehicle speed signal or the test mode ends. DTCs from C1273/73 to C1278/78 are output only in the test mode. DTC No. DTC Detecting Condition C0210/33 C0215/34 When either of the following is detected: • Vehicle speed is more than 25 mph (40 km/h), and pulses are not input for 0.03 sec. • When the vehicle speed has reached 8 mph (12 km/h), after the initial start or restart a wheel speed of 0 mph (0 km/h) is detected. Trouble Area • • • • • Rear speed sensor RH and/or LH Rear speed sensor circuit RH and/or LH Rear speed sensor rotor RH and/or LH Sensor installation Brake actuator assembly (skid control ECU) C1332/38 C1333/39 Abnormality in the resistance value of each speed sensor is detected. • • • Rear speed sensor RH and/or LH Rear speed sensor circuit RH and/or LH Sensor installation C1273/73 C1274/74 Detected only during test mode. • • • Rear speed sensor Sensor installation Sensor rotor C1277/77 C1278/78 Detected only during test mode. • • • Rear speed sensor Sensor installation Sensor rotor HINT: DTC No. C0210/33 and C1332/38 are for the rear speed sensor RH. DTC No. C0215/34 and C1333/39 are for the rear speed sensor LH. BC–45 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) 2 g1 Speed Sensor Rear LH 7 A25 RL+ 1 2 17 A25 RL- f1 Speed Sensor Rear RH 8 A25 RR- 19 A25 RR+ 1 BC F040884E16 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). 1 READ VALUE OF INTELLIGENT TESTER (REAR SPEED SENSOR) (a) Connect the intelligent tester to the DLC3. (b) Start the engine. (c) Select "DATA LIST" and read the value displayed on the intelligent tester (See page BC-25). DATA LIST: ABS Item Measurement Item / Range (Display) Normal Condition RR WHEEL SPD Wheel speed sensor (RR) reading / min.: 0 MPH (0 km/h), max.: 202 MPH (326 km/h) Actual wheel speed RL WHEEL SPD Wheel speed sensor (RL) reading / min.: 0 MPH (0 km/h), max.: 202 MPH (326 km/h) Actual wheel speed (d) Check that there is no difference between the speed value output from the speed sensor displayed on the intelligent tester and the speed value displayed on the speedometer when driving the vehicle. OK: The speed value output from the speed sensor displayed on the intelligent tester is the same as the actual vehicle speed. NG OK Go to step 5 BC–46 2 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM PERFORM TEST MODE INSPECTION (SIGNAL CHECK) (a) Check if test mode (signal check) DTCs are detected (See page BC-11). Result Condition Proceed to Test mode (signal check) DTC is not output A Test mode (signal check) DTC is output B B Go to step 5 A 3 BC INSPECT SPEED SENSOR SIGNAL WAVEFORM Skid Control ECU (Harness Side Connector Front View): RL- RL+ RR- RR+ Normal Signal Waveform: GND (a) Lift up the vehicle. (b) Perform the inspection using an oscilloscope. (1) Disconnect the skid control ECU connector. (2) Connect the oscilloscope to terminals of the skid control ECU. (3) Check that a waveform is output when the tires are rotated. OK: The same waveform is output from rear wheels and there is no noise or interference in the waveform. HINT: • As vehicle speed (wheel rotation speed) increases, the width of the waveform narrows and the output voltage becomes greater. • When noise is identified in the waveform on the oscilloscope, the erratic signals are generated due to rotor scratches, looseness or foreign matter attached to the speed sensor. (4) Connect the connector. NG CLEAN OR REPLACE SPEED SENSOR AND SENSOR ROTOR 1 V/Division, 2 ms./Division C132907E02 OK 4 RECONFIRM DTC (a) Clear the DTCs (See page BC-21). (b) Drive the vehicle at a speed of approximately 25 mph (40 km/h) or more for 60 seconds or more. BC–47 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM (c) Check if the same DTCs are recorded (See page BC21). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTCs (C0210/33, C0215/34, C1332/38 and C1333/39) are output A DTCs (C0210/33, C0215/34, C1332/38 and C1333/39) are output (When troubleshooting in accordance with the PROBLEM SYMPTOMS TABLE) B DTCs (C0210/33, C0215/34, C1332/38 and C1333/39) are not output (When troubleshooting in accordance with the DTC CHART) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page BC-16) C END A 5 INSPECT SPEED SENSOR INSTALLATION (a) Check the rear speed sensor installation. OK: There is no clearance between the sensor and rear axle carrier. NOTICE: Check the speed sensor signal after replacement (See page BC-11). No Clearance OK NG NG F010178E07 OK REPLACE REAR SPEED SENSOR (See page BC-443) BC BC–48 6 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM INSPECT REAR SPEED SENSOR (a) Disconnect the rear speed sensor connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: LH Rear Speed Sensor: Tester Connection 2 g1-1 (RL+) - g1-2 (RL-) Below 2.2 kΩ g1-1 (RL+) - Body ground 10 kΩ or higher g1-2 (RL-) - Body ground 10 kΩ or higher Tester Connection Specified Condition RH 1 BC Specified Condition C113377E03 f1-1 (RR+) - f1-2 (RR-) Below 2.2 kΩ f1-1 (RR+) - Body ground 10 kΩ or higher f1-2 (RR-) - Body ground 10 kΩ or higher NOTICE: Check the speed sensor signal after replacement (See page BC-11). NG OK REPLACE REAR SPEED SENSOR (See page BC-443) BC–49 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM 7 CHECK HARNESS AND CONNECTOR (SKID CONTROL SENSOR WIRE TO SKID CONTROL ECU) Skid Control ECU (Wire Harness Side) Connector Front View: RL- RL+ RR- RR+ (a) Check harness and connector. (1) Disconnect the skid control ECU connector. (2) Disconnect the skid control sensor wire. (3) Measure the resistance according to the value(s) in the table below. Standard resistance: LH A25 Front Speed Sensor (Wire Harness Side) Connector Front View: Tester Connection Specified Condition A25-7 (RL+) - g1-1 (RL+) Below 1 Ω A25-17 (RL-) - g1-2 (RL-) Below 1 Ω g1-1 (RL+) - Body ground 10 kΩ or higher g1-2 (RL-) - Body ground 10 kΩ or higher RH Tester Connection Specified Condition A25-19 (RR+) - f1-1 (RR+) Below 1 Ω A25-8 (RR-) - f1-2 (RR-) Below 1 Ω 10 kΩ or higher 10 kΩ or higher g1 f1 f1-1 (RR+) - Body ground LH RH f1-2 (RR-) - Body ground NG RL- RL+ RR- RR+ REPAIR OR REPLACE HARNESS OR CONNECTOR (SKID CONTROL ECU TO SKID CONTROL SENSOR WIRE) C132909E03 OK 8 CHECK HARNESS AND CONNECTOR (SKID CONTROL SENSOR WIRE TO REAR SPEED SENSOR) Skid Control Sensor Wire: Vehicle Side Connector (a) Check harness and connector (skid control sensor wire). (1) Measure the resistance according to the value(s) in the table below. Standard resistance: LH Tester Connection g1 LH f1 RH A Specified Condition g1-1 - A-1 Below 1 Ω g1-1 - A-2 10 kΩ or higher g1-1 - Body ground 10 kΩ or higher g1-2 - A-2 Below 1 Ω g1-2 - A-1 10 kΩ or higher g1-2 - Body ground 10 kΩ or higher Tester Connection Specified Condition f1-1 - A-1 Below 1 Ω RH Sensor Side Connector C113396E04 BC BC–50 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM NG Tester Connection Specified Condition f1-1 - A-2 10 kΩ or higher f1-1 - Body ground 10 kΩ or higher f1-2 - A-2 Below 1 Ω f1-2 - A-1 10 kΩ or higher f1-2 - Body ground 10 kΩ or higher REPAIR OR REPLACE SKID CONTROL SENSOR WIRE OK 9 BC INSPECT SPEED SENSOR SIGNAL WAVEFORM Skid Control ECU (Harness Side Connector Front View): RL- RL+ RR- RR+ Normal Signal Waveform: GND (a) Lift up the vehicle. (b) Perform the inspection using the oscilloscope. (1) Disconnect the skid control ECU connector. (2) Connect the oscilloscope to terminals of the skid control ECU. (3) Check that a waveform is output when the tires are rotated. OK: The same waveforms is output from rear wheels and there is no noise or interference in the waveform. HINT: • As vehicle speed (wheel rotation speed) increases, the width of the waveform narrows and the output voltage becomes greater. • When noise is identified in the waveform on the oscilloscope, the erratic signals are generated due to rotor scratches, looseness or foreign matter attached to the speed sensor. (4) Connect the connectors. NG CLEAN OR REPLACE SPEED SENSOR AND SENSOR ROTOR 1 V/Division, 2 ms./Division C132907E02 OK 10 READ VALUE OF INTELLIGENT TESTER (REAR SPEED SENSOR) (a) Connect the intelligent tester to the DLC3. (b) Start the engine. BC–51 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM (c) Select "DATA LIST" and read the value displayed on the intelligent tester (See page BC-25). DATA LIST: ABS Measurement Item / Range (Display) Item Normal Condition RR WHEEL SPD Wheel speed sensor (RR) reading / min.: 0 MPH (0 km/h), max.: 202 MPH (326 km/h) Actual wheel speed RL WHEEL SPD Wheel speed sensor (RL) reading / min.: 0 MPH (0 km/h), max.: 202 MPH (326 km/h) Actual wheel speed (d) Check that there is no difference between the speed value output from the speed sensor displayed on the intelligent tester and the speed value displayed on the speedometer when driving the vehicle. OK: The speed value output from the speed sensor displayed on the intelligent tester is the same as the actual vehicle speed. HINT: • It is suspected that the DTCs were output due to a bad connection of the connector terminal. • If troubleshooting has been carried out according to the "PROBLEM SYMPTOMS TABLE", refer back to the table and proceed to the next step (See page BC16). NG REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) OK 11 RECONFIRM DTC (a) Clear the DTCs (See page BC-21). (b) Drive the vehicle at a speed of approximately 25 mph (40 km/h) or more for 60 seconds or more. (c) Check if the same DTCs are recorded (See page BC21). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTCs (C0210/33, C0215/34, C1332/38 and C1333/39) are output A DTCs (C0210/33, C0215/34, C1332/38 and C1333/39) are not output B B END A 12 INSPECT SPEED SENSOR ROTOR (a) Turn the ignition switch off. (b) Remove the rear axle (See page AH-15). BC BC–52 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM (c) Check the rotor. OK: No scratches, cracks, oil, or foreign matter on the rotors. NOTICE: Check the speed sensor signal after cleaning or replacement (See page BC-11). (d) Install the rear axle (See page AH-16). NG CLEAN OR REPLACE SPEED SENSOR ROTOR OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC BC–53 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM DTC C0226/21 SFR Solenoid Circuit DTC C0236/22 SFL Solenoid Circuit DTC C0246/23 SRR Solenoid Circuit DTC C0256/24 SRL Solenoid Circuit DESCRIPTION These solenoids turn on when signals are received from the ECU and they control the pressure acting on the wheel cylinders thus controlling braking force. DTC No. DTC Detecting Condition Trouble Area C0226/21 C0236/22 C0246/23 C0256/24 Solenoid valve signal does not match the check result. • • Each solenoid circuit Brake actuator assembly BC WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) ALT ABS No. 2 3 A25 +BS 4 FL MAIN A25 GND1 1 A25 GND2 Battery C131988E01 BC–54 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM INSPECTION PROCEDURE 1 RECONFIRM DTC HINT: These codes are detected when a problem is identified in the brake actuator assembly. The solenoid circuit is in the brake actuator assembly. Therefore, solenoid circuit inspection and solenoid unit inspection cannot be performed. Be sure to check if the DTC is output before replacing the brake actuator assembly. (a) Clear the DTC (See page BC-21). (b) Start the engine. (c) Drive the vehicle at a speed of 12 mph (20 km/h) or more for 30 seconds or more. (d) Check if the same DTC is recorded (See page BC-21). Result BC Condition Proceed to DTC is not output A DTC is output B HINT: • If the normal system code is output (the trouble code is not output), slightly jiggle the connectors, wire harness, and fuses of the brake actuator assembly. Make sure that no DTCs are output. • If any DTCs are output while jiggling a connector or wire harness of the brake actuator (skid control ECU), inspect and repair the connector or wire harness. • It is suspected that the DTCs were output due to a bad connection of the connector terminal. B A END REPAIR BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC–55 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM DTC Open or Short Circuit in ABS Motor Relay Circuit C0273/13 DESCRIPTION The ABS motor relay supplies power to the ABS pump motor. While the ABS is activated, the ECU turns the motor relay on and operates the ABS pump motor. If the voltage supplied to the motor relay (+BM) is below the DTCs detection threshold due to low voltage from the battery or alternator, the DTC may be stored. DTC No. DTC Detecting Condition C0273/13 When any of the following is detected: • When the motor relay is actuated, voltage is not supplied to the pump motor within 0.1 second. • When the motor relay is changed from ON to OFF, the remaining high voltage is more than 2 V for 1 second. • For 30 to 125 msec. after the motor relay is turned from ON to OFF, the remaining high voltage is out of range. The voltage is still out of range when the motor relay is turned from ON to OFF 3 times. Trouble Area • • • ABS No. 1 fuse (Fusible link) Wire harness (+BM circuit) Brake actuator assembly (motor relay) BC WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) ALT ABS No. 1 2 A25 +BM 4 FL MAIN A25 GND1 1 A25 GND2 Battery C131988E02 INSPECTION PROCEDURE HINT: • When C1241/41 is output together with C0273/13, inspect and repair the trouble areas indicated by C1241/41 (See page BC-63). BC–56 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM • Check the condition of each related circuit connector before troubleshooting (See page IN-40). 1 INSPECT FUSIBLE LINK (ABS NO. 1 FUSE) Engine Room R/B (a) Remove the fusible link from the engine room R/B. (b) Check if the fusible link is melted. OK: The fusible link is not melted. (c) Install the fusible link to the engine room R/B with the nut. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) Fusible Link NG REPLACE FUSIBLE LINK ABS No. 1 BC C136500E01 OK 2 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (ABS MOTOR RELAY) (a) Connect the intelligent tester to the DLC3. (b) Start the engine. (c) Select "ACTIVE TEST" on the intelligent tester (See page BC-25). ACTIVE TEST: ABS Item ABS MTR RELAY Measurement Item / Range (Display) Turns ABS motor relay ON / OFF Normal Condition Operating sound of motor is heard (d) Check the operating sound of the ABS motor relay when operating it with the intelligent tester. OK: The operating sound of the ABS motor relay should be heard. Result Result Proceed to The operating sound is not heard A The operating sound is heard B B A Go to step 5 BC–57 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM 3 INSPECT SKID CONTROL ECU CONNECTOR (+BM TERMINAL VOLTAGE) Skid Control ECU (Harness Side Connector Front View): A25 +BM (a) Disconnect the skid control ECU connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition A25-2 (+BM) Body ground Always 10 to 14 V NG C131970E02 REPAIR OR REPLACE HARNESS OR CONNECTOR (+BM CIRCUIT) OK 4 INSPECT SKID CONTROL ECU CONNECTOR (GND TERMINAL CONTINUITY) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU (Harness Side Connector Front View): GND2 BC GND1 Tester Connection Specified Condition A25-4 (GND1) - Body ground Below 1 Ω A25-1 (GND2) - Body ground Below 1 Ω (b) Connect the connector. C131970E03 NG REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) OK 5 RECONFIRM DTC HINT: This code is detected when a problem is identified in the brake actuator assembly. The ABS motor relay is in the brake actuator assembly. Therefore, ABS motor relay inspection and motor relay unit inspection cannot be performed. Be sure to check if the DTC is output before replacing the brake actuator assembly. (a) Clear the DTC (See page BC-21). (b) Start the engine. (c) Drive the vehicle at a speed of 12 mph (20 km/h) or more for 30 seconds or more. (d) Check if the same DTC is recorded (See page BC-21). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition DTC is not output Proceed to A BC–58 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM Condition Proceed to DTC is output B HINT: • If the normal system code is output (the trouble code is not output), slightly jiggle the connectors, wire harness, and fuses of the brake actuator assembly. Make sure that no DTCs are output. • If any DTCs are output while jiggling a connector or wire harness of the brake actuator (skid control ECU), inspect and repair the connector or wire harness. • It is suspected that the DTCs were output due to a bad connection of the connector terminal. B REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) A BC CHECK FOR INTERMITTENT PROBLEMS (SYMPTOM SIMULATION) (See page BC-19) BC–59 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM DTC Open or Short Circuit in ABS Solenoid Relay Circuit C0278/11 DESCRIPTION This relay supplies power to each ABS solenoid. If the ABS initial check is OK after the ignition switch is turned on (IG), the skid control ECU will turn the ABS solenoid relay on. DTC No. C0278/11 DTC Detecting Condition Trouble Area When any of the following is detected: • 3 or more solenoid valves are found faulty and simultaneously valve supply voltage is detected to be abnormal. • Solenoid valve relay is not switched off. • Valve relay is stuck open even through the valve relay supply voltage is high. • • • Wire harness (+BS circuit) ABS No. 2 fuse (Fusible link) Brake actuator assembly (Solenoid relay) WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) ALT ABS No. 2 3 A25 +BS 4 FL MAIN A25 GND1 1 A25 GND2 Battery C131988E01 INSPECTION PROCEDURE HINT: • When C1241/41 is output together with C0278/11, inspect and repair the trouble areas indicated by C1241/41 (See page BC-63). • Check the condition of each related circuit before troubleshooting (See page IN-40). BC BC–60 1 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM INSPECT FUSIBLE LINK (ABS NO. 2 FUSE) (a) Remove the fusible link from the engine room R/B. (b) Check if the fusible link is melted. OK: The fusible link is not melted. (c) Install the fusible link to the engine room R/B with the nut. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) Engine Room R/B ABS No. 2 BC NG REPLACE FUSIBLE LINK C136500E02 OK 2 INSPECT SKID CONTROL ECU CONNECTOR (+BS CIRCUIT) Skid Control ECU (Harness Side Connector Front View): +BS A25 (a) Disconnect the skid control ECU connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition A25-3 (+BS) Body ground Always 10 to 14 V NG C131970E10 REPAIR OR REPLACE HARNESS OR CONNECTOR (+BS CIRCUIT) OK 3 INSPECT SKID CONTROL ECU CONNECTOR (GND TERMINAL CONTINUITY) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU (Harness Side Connector Front View): GND2 GND1 A25 Tester Connection Specified Condition A25-4 (GND1) - Body ground Below 1 Ω A25-1 (GND2) - Body ground Below 1 Ω (b) Connect the connector. C131970E05 OK NG REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) BC–61 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM 4 RECONFIRM DTC HINT: This code is detected when a problem is identified in the brake actuator assembly. The solenoid circuit is in the brake actuator assembly. Therefore, solenoid circuit inspection and solenoid unit inspection cannot be performed. Be sure to check if the DTC is output before replacing the brake actuator assembly. (a) Clear the DTC (See page BC-21). (b) Start the engine. (c) Drive the vehicle at a speed of 12 mph (20 km/h) or more for 30 seconds or more. (d) Check if the same DTC is recorded (See page BC-21). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTC is not output A DTC is output B HINT: • If the normal system code is output (the trouble code is not output), slightly jiggle the connectors, wire harnesses, and fuses of the brake actuator assembly. Make sure that no DTCs are output. • If any DTCs are output while jiggling a connector or wire harness of the brake actuator (skid control ECU), inspect and repair the connector or wire harness. • It is suspected that the DTCs were output due to a bad connection of the connector terminal. B REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) A CHECK FOR INTERMITTENT PROBLEMS (SYMPTOM SIMULATION) (See page BC-19) BC BC–62 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM DTC C1237/37 Speed Sensor Rotor Faulty DESCRIPTION The skid control ECU measures the speed of each wheel by receiving signals from the speed sensor. These signals are used for recognizing that all 4 wheels are operating properly. Therefore, all wheel signals must be equal. DTC No. C1237/37 DTC Detecting Condition When any of the following is detected: • Wheel speed difference between the wheels. • Wheel sensor signal failure. • ABS control continues for 60 sec. or more. Trouble Area • • • • • • • Brake actuator assembly (skid control ECU) Speed sensor rotor (Front) Rear axle hub and bearing assembly Speed sensor Speed sensor circuit Tire and wheel size Tire deformation WIRING DIAGRAM BC Brake Actuator Assembly (Skid Control ECU) A14 ABS Speed Sensor Front LH A35 ABS Speed Sensor Front RH 1 2 1 2 5 A25 FL+ 6 A25 FL10 A25 FR+ 9 A25 FR- F040884E12 BC–63 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM Brake Actuator Assembly (Skid Control ECU) 2 g1 Speed Sensor Rear LH 7 A25 RL+ 1 2 17 A25 RL- f1 Speed Sensor Rear RH 8 A25 RR- 19 A25 RR+ 1 BC F040884E16 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). 1 CHECK TIRES (a) Check the size and condition of all 4 tires (See page TW3). HINT: This DTC is output when tire deformation or a difference in tire size is detected. OK: The diameters of all 4 tires and air pressure are the same. NG OK REPLACE TIRES SO THAT ALL 4 TIRES ARE THE SAME SIZE BC–64 2 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM INSPECT SPEED SENSOR AND SENSOR ROTOR SERRATIONS (a) Disconnect the skid control ECU connector. (b) Connect the oscilloscope to each speed sensor terminal of the skid control ECU connector. Terminals Skid Control ECU (Harness Side Connector Front View): FL+ FL- RL- RL+ RR- RR+ FR- FR+ C131970E06 Normal Signal Waveform: BC GND 1 V / Division, 2 ms. / Division C140980E01 Connector Circuit A25-5 (FL+) - A25-6 (FL-) Front left speed sensor A25-10 (FR+) - A25-9 (FR-) Front right speed sensor A25-7 (RL+) - A25-17 (RL-) Rear left speed sensor A25-19 (RR+) - A25-8 (RR-) Rear right speed sensor (c) Check that a waveform is output when the tires are rotated (by the sensor circuit). OK: A waveform as shown in the figure should be output. HINT: • Each sensor circuit outputs the same waveform without noise. • As vehicle speed (wheel rotation speed) increases, the width of the waveform narrows and the output voltage becomes greater. • When noise is identified in the waveform on the oscilloscope, the erratic signals are generated due to rotor scratches, looseness or foreign matter attached to the speed sensor. (d) Make sure that the waveform does not change while jiggling a connector or a wire harness. OK: The waveform does not change. HINT: If the waveform changes while jiggling a connector or a wire harness, there may be a malfunction in the connector or the wire harness. (e) Connect the connector. NG Go to step 4 OK 3 RECONFIRM DTC (a) Clear the DTC (See page BC-21). (b) Start the engine. (c) Drive the vehicle at a speed of 20 mph (32 km/h) or more for 60 seconds or more. (d) Check if the same DTC is recorded (See page BC-21). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. BC–65 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM Result Condition Proceed to DTC is not output A DTC is output B B REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) A CHECK FOR INTERMITTENT PROBLEMS (SYMPTOM SIMULATION) (See page BC-19) 4 CHECK SPEED SENSOR ROTOR (a) Check the speed sensor rotor. Front Speed Sensor Rotor: (See page DS-25) Rear Speed Sensor Rotor: (See page AH-15) OK: No scratches or foreign matter on the rotors. NOTICE: Check the speed sensor signal after the cleaning/ replacement (See page BC-11). NG CLEAN OR REPLACE SPEED SENSOR ROTOR OK 5 CHECK SPEED SENSOR TIP (a) Remove each speed sensor. (b) Check the speed sensor tip. OK: No scratches or foreign matter on the sensor tip. NOTICE: Check the speed sensor signal after the cleaning/ replacement (See page BC-11). (c) Install speed sensor. NG OK CLEAN OR REPLACE SPEED SENSOR BC BC–66 6 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM INSPECT EACH SPEED SENSOR (a) Disconnect each speed sensor connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: FRONT Front Speed Sensor: 1 BC 2 Rear Speed Sensor: Tester Connection Condition Specified Condition A14-1 (FL+) - A14-2 (FL) Always 1.4 to 1.8 kΩ at 20°C (68°F) A14-1 (FL+) - Body ground Always 10 kΩ or higher A14-2 (FL-) - Body ground Always 10 kΩ or higher A35-1 (FR+) - A35-2 (FR-) Always 1.4 to 1.8 kΩ at 20°C (68°F) A35-1 (FR+) - Body ground Always 10 kΩ or higher A35-2 (FR-) - Body ground Always 10 kΩ or higher REAR 1 2 Tester Connection Condition Specified Condition g1-1 (RL+) - g1-2 (RL-) Always Below 2.2 kΩ g1-1 (RL+) - Body ground Always 10 kΩ or higher g1-2 (RL-) - Body ground Always 10 kΩ or higher f1-1 (RR+) - f1-2 (RR-) Always Below 2.2 kΩ f1-1 (RR+) - Body ground Always 10 kΩ or higher f1-2 (RR-) - Body ground Always 10 kΩ or higher C136027E01 (c) Connect the connector. NOTICE: Check the speed sensor signal after replacement (See page BC-11). NG OK REPLACE EACH SPEED SENSOR BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM 7 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU TO EACH SPEED SENSOR) (a) Disconnect the skid control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: FRONT Skid Control ECU Harness Side Connector Front View: A25 BC–67 FL+ FL- RL+ RR- FR- RL- RR+ FR+ Front Speed Sensor Harness Side Connector Front View: A35 A14 FL- FR- FR+ FL+ Tester Connection Condition Specified Condition A25-5 (FL+) - A14-1 (FL+) Always Below 1 Ω A25-6 (FL-) - A14-2 (FL-) Always Below 1 Ω A25-10 (FR+) - A35-1 (FR+) Always Below 1 Ω A25-9 (FR-) - A35-2 (FR) Always Below 1 Ω A25-5 (FL+) - Body ground Always 10 kΩ or higher A25-6 (FL-) - Body ground Always 10 kΩ or higher A25-10 (FR+) - Body ground Always 10 kΩ or higher A25-9 (FR-) - Body ground Always 10 kΩ or higher Tester Connection Condition Specified Condition A25-7 (RL+) - g1-1 (RL+) Always Below 1 Ω A25-17 (RL-) - g1-2 (RL) Always Below 1 Ω A25-19 (RR+) - f1-1 (RR+) Always Below 1 Ω A25-8 (RR-) - f1-2 (RR-) Always Below 1 Ω A25-7 (RL+) - Body ground Always 10 kΩ or higher A25-17 (RL-) - Body ground Always 10 kΩ or higher A25-19 (RR+) - Body ground Always 10 kΩ or higher A25-8 (RR-) - Body ground Always 10 kΩ or higher REAR Rear Speed Sensor Harness Side Connector Front View: g1 f1 RR- RR+ RL- RL+ C136491E02 (c) Connect the connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR (SKID CONTROL ECU TO EACH SPEED SENSOR) OK 8 RECONFIRM DTC (a) Clear the DTC (See page BC-21). (b) Start the engine. BC BC–68 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM (c) Drive the vehicle at the speed of 20 mph (32 km/h) or more for at least 60 seconds. (d) Check if the same DTC is recorded (See page BC-21). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTC (C1237/37) is not output A DTC (C1237/37) is output B B REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) A BC CHECK FOR INTERMITTENT PROBLEMS (SYMPTOM SIMULATION) (See page BC-19) BC–69 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM DTC C1241/41 Low Battery Positive Voltage or Abnormally High Battery Positive Voltage DESCRIPTION If a malfunction is detected in the power supply circuit of the brake actuator assembly (skid control ECU), the skid control ECU (housed in the actuator assembly) stores this DTC and the fail-safe function prohibits ABS operation (See page BC-24). This DTC is output when the IG1 terminal voltage deviates from the normal condition due to a malfunction in the power supply or charging circuit such as the battery or alternator circuit, etc. This DTC is cancelled when the IG1 terminal voltage returns to normal (only when the voltage returns to normal from a voltage lower than the specified value). DTC No. DTC Detecting Condition C1241/41 With vehicle speed more than 4 mph (6 km/h), when any of the following is detected: • Battery voltage is 16.9 V or more. • Battery voltage is 9.4 V or less when ABS does not operate. • Battery voltage is 9.2 V or less when ABS operates. Trouble Area • • • • Battery Charging system Power source circuit Brake actuator assembly (Skid control ECU) BC BC–70 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) IG1 ECU IG No. 2 5 3 2 1 18 A25 IG1 E23 Ignition SW BC (*2) AM1 (*2) IG1 1 4 AM1 (*1) Main Body ECU ALT 6 E7 1 E6 (*1) AM2 AM1 IG1D 3 E7 AM2 4 FL MAIN A25 GND1 1 A25 Battery GND2 *1: with Smart Key System *2: without Smart Key System C136502E01 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). BC–71 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM 1 INSPECT FUSE (ECU-IG NO. 2 FUSE) (a) Remove the ECU-IG No. 2 fuse from the instrument panel J/B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Instrument Panel J/B: ECU-IG No. 2 Fuse Tester Connection Specified Condition ECU-IG No. 2 fuse Below 1 Ω (Continuity) (c) Install the fuse. C136048E01 NG REPLACE FUSE OK 2 INSPECT BATTERY BC (a) Check the battery voltage. Standard voltage: 11 to 14 V NG INSPECT CHARGING SYSTEM OK 3 INSPECT SKID CONTROL ECU CONNECTOR (IG1 TERMINAL VOLTAGE) Skid Control ECU (Harness Side Connector Front View): A25 IG1 OK C131970E07 (a) Disconnect the skid control ECU connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition A25-18 (IG1) Body ground Ignition switch on (IG) 10 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR (IG1 CIRCUIT) BC–72 4 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM INSPECT SKID CONTROL ECU CONNECTOR (GND TERMINAL CONTINUITY) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU (Harness Side Connector Front View): GND2 GND1 A25 Tester Connection Specified Condition A25-4 (GND1) - Body ground Below 1 Ω A25-1 (GND2) - Body ground Below 1 Ω (b) Connect the connector. C131970E05 NG REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) OK BC 5 RECONFIRM DTC (a) Clear the DTC (See page BC-21). (b) Turn the ignition switch on (IG). (c) Check if the same DTC is recorded (See page BC-21). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTC (C1241/41) is output A DTC (C1241/41) is output (When troubleshooting in accordance with the PROBLEM SYMPTOMS TABLE) B DTC (C1241/41) is not output (When troubleshooting in accordance with the DTC CHART) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page BC-16) C END A REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC–73 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM DTC C1249/49 Open in Stop Light Switch Circuit DESCRIPTION This circuit recognizes brake operation by sending a stop light signal to the skid control ECU. The skid control ECU has an open detection circuit, which outputs this DTC when detecting an open in the stop light signal input line (STP terminal) or the ground line of the stop light circuit with the stop light switch off (brake pedal not depressed). DTC No. C1249/49 DTC Detecting Condition Stop light switch circuit is open, and stop light switch voltage is 40% or more and less than 67% of the battery voltage. Trouble Area • • • Stop light switch Stop light switch circuit Brake actuator assembly (Skid Control ECU) BC BC–74 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) A19 Stop Light SW STOP 2 1 20 A25 STP N16 Center Stop Light 2 1 BC S12 Rear Combination Light (RH) Tail 3 ALT Stop FL MAIN Tail 2 Mutiplex Communication System (CAN) 2 Stop Battery 3 N15 Noise Filter (Dome and Stop) S11 Rear Combination Light (LH) C131990E01 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). BC–75 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM 1 CHECK STOP LIGHT SWITCH OPERATION (STOP LIGHT SWITCH CIRCUIT) (a) Check that the stop lights come on when the brake pedal is depressed and goes off when the brake pedal is released. OK Pedal Condition Illumination Condition Brake pedal depressed ON Brake pedal released OFF NG Go to step 5 OK 2 INSPECT SKID CONTROL ECU CONNECTOR (STP TERMINAL) Skid Control ECU (Harness Side Connector Front View): STP A25 (a) Disconnect the skid control ECU connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Switch Condition Specified Condition A25-20 (STP) - Body ground Brake pedal depressed 8 to 14 V A25-20 (STP) - Body ground Brake pedal released Below 4.0 V C131970E08 NG Go to step 7 OK 3 INSPECT SKID CONTROL ECU CONNECTOR (GND TERMINAL CONTINUITY) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU (Harness Side Connector Front View): GND2 GND1 A25 Tester Connection Specified Condition A25-4 (GND1) - Body ground Below 1 Ω A25-1 (GND2) - Body ground Below 1 Ω (b) Connect the connector. C131970E05 NG REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) OK 4 RECONFIRM DTC (a) Clear the DTC (See page BC-21). (b) Start the engine. BC BC–76 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM (c) Depress the brake pedal several times to test the stop light circuit. (d) Check if the same DTC is recorded (See page BC-21). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTC is not output A DTC is output (When troubleshooting in accordance with the DTC CHART) B DTC is output (When troubleshooting in accordance with the PROBLEM SYMPTOMS TABLE) C B REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) C PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page BC-16) BC A CHECK FOR INTERMITTENT PROBLEMS (SYMPTOM SIMULATION) (See page BC-19) 5 INSPECT STOP LIGHT SWITCH ASSEMBLY (POWER SOURCE TERMINAL VOLTAGE) Stop Light Switch (Wire Harness Side) Connector Front View: (a) Disconnect the stop light switch connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition A19-2 - Body ground Always 10 to 14 V A19 NG I042363E17 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (POWER SOURCE CIRCUIT) BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM 6 BC–77 INSPECT STOP LIGHT SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance Stop Light Switch Assembly Tester Connection Condition Specified Condition Switch pin free 1-2 Below 1 Ω Switch pin pushed in 1-2 10 kΩ or higher NG Free REPLACE STOP LIGHT SWITCH ASSEMBLY (See page BR-71) Pushed In BC C113379E01 OK 7 CHECK HARNESS AND CONNECTOR (STOP LIGHT SWITCH TO SKID CONTROL ECU) Skid Control ECU (Wire Harness Side) Connector Front View: STP A25 (a) Disconnect the stop light switch connector and skid control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition A25-20 (STP) - A19-1 (STP) Below 1 Ω (c) Connect the connector. Stop Light Switch (Wire Harness Side) Connector Front View: NG REPAIR OR REPLACE HARNESS OR CONNECTOR (STOP LIGHT SWITCH TO SKID CONTROL ECU) A19 STP C132984E02 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (STOP LIGHT CIRCUIT) BC–78 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM DTC C1300/62 Skid Control ECU Malfunction DESCRIPTION The skid control ECU outputs this DTC, if malfunctions are found in the circuit inside the computer by self diagnosis. DTC No. C1300/62 DTC Detecting Condition Internal failure of the skid control ECU control unit Trouble Area Brake actuator assembly (skid control ECU) INSPECTION PROCEDURE 1 REPLACE BRAKE ACTUATOR ASSEMBLY (a) Replace the brake actuator assembly (skid control ECU) (See page BC-432). HINT: This DTC is output when the skid control ECU detects a malfunction in the internal circuit. (b) Clear the DTC (See page BC-21). BC NEXT END BC–79 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM DTC U0073/94 Control Module Communication Bus OFF DESCRIPTION • The skid control ECU receives the signal sent from the ECM via the CAN communication system. • When DTCs indicating a CAN communication system malfunction are output, repair the CAN communication system before repairing each corresponding sensor. DTC No. U0073/94 DTC Detecting Condition When any of the following is detected: 1. The skid control ECU cannot send a signal (30 cycles). 2. The condition that bus OFF state occurs for 300 msec. Trouble Area • • Wire harness (CANL, CANH circuit) Brake actuator assembly (Skid control ECU) INSPECTION PROCEDURE Proceed to CAN communication system troubleshooting (See page CA-8). HINT: When DTCs indicating a CAN communication system malfunction are output, repair the CAN communication system before repairing each corresponding sensor. BC BC–80 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM ABS Warning Light Remains ON DESCRIPTION The skid control ECU sends the indicator signals to the combination meter assembly via the CAN communication system. If any of the following is detected, the ABS warning light remains on. • The skid control ECU connectors are disconnected from the skid control ECU. • There is a malfunction in the skid control ECU internal circuit. • There is an open in the wire harness between the combination meter and the skid control ECU. • The ABS and/or EBD is defective. HINT: The intelligent tester may not be used when the skid control ECU is abnormal. BC BC–81 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM WIRING DIAGRAM F1 Combination Meter Brake Actuator Assembly (Skid Control ECU) CANH 17 ABS IG+ DRIVER IC 26 A25 CANH 15 MICRO COMPUTER CANL 18 A25 CANL IG1 ECU IG No. 2 5 3 2 1 BC 18 A25 IG1 E23 Ignition SW (*2) AM1 (*2) IG1 4 AM1 1 Main Body ECU E7 (*1) (*1) 6 ALT AM1 IG1D 1 AM2 E6 3 E7 AM2 4 A25 GND1 FL MAIN 1 Battery *1: with Smart Key System A25 GND2 *2: without Smart Key System C136510E01 INSPECTION PROCEDURE HINT: Check the condition of each related circuit before troubleshooting (See page IN-40). BC–82 1 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM INSPECT CAN COMMUNICATION SYSTEM (a) Check if a CAN communication system DTC is output (See page BC-21). Result Condition Proceed to CAN communication system DTC is not output A CAN communication system DTC is output B B INSPECT CAN COMMUNICATION SYSTEM (See page CA-8) A 2 CHECK SKID CONTROL ECU CONNECTOR SECURELY CONNECTED BC (a) Check if the skid control ECU connector is connected. OK: The connector is securely connected. NG CONNECT CONNECTOR TO ECU CORRECTLY OK 3 CHECK BATTERY (a) Check the battery voltage. Standard voltage: 11 to 14 V NG INSPECT CHARGING SYSTEM OK 4 INSPECT SKID CONTROL ECU CONNECTOR (IG1 TERMINAL VOLTAGE) Skid Control ECU (Harness Side Connector Front View): A25 IG1 OK C131970E07 (a) Disconnect the skid control ECU connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition A25-18 (IG1) - Body ground Ignition switch on (IG) 10 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR (IG1 CIRCUIT) BC–83 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM 5 INSPECT SKID CONTROL ECU CONNECTOR (GND TERMINAL CONTINUITY) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU (Harness Side Connector Front View): GND2 GND1 A25 Tester Connection Specified Condition A25-4 (GND1) - Body ground Below 1 Ω A25-1 (GND2) - Body ground Below 1 Ω (b) Connect the connector. C131970E05 NG REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) OK 6 BC INSPECT COMBINATION METER ASSEMBLY (a) Connect the intelligent tester to the DLC3. (b) Select the "ACTIVE TEST" on the tester (See page BC25). ACTIVE TEST: ABS Item Vehicle Condition / Test Details Diagnostic Note ABS WRN LIGHT Turn ABS warning light ON / OFF Observe combination meter (c) Check the ABS warning light operation. OK: The ABS warning light turns on or off in accordance with the intelligent tester. Result Condition Proceed to OK A OK (When troubleshooting in accordance with the PROBLEM SYMPTOMS TABLE) B NG C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page BC-16) C REPLACE COMBINATION METER ASSEMBLY (See page ME-63) A REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC–84 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM ABS Warning Light does not Come ON WIRING DIAGRAM F1 Combination Meter Brake Actuator Assembly (Skid Control ECU) CANH 17 ABS IG+ DRIVER IC 26 A25 CANH 15 MICRO COMPUTER CANL 18 A25 CANL BC IG1 ECU IG No. 2 5 3 2 1 18 A25 IG1 E23 Ignition SW (*2) AM1 (*2) IG1 4 AM1 1 Main Body ECU E7 (*1) (*1) 6 ALT AM2 AM1 IG1D 1 E6 3 E7 AM2 4 A25 GND1 FL MAIN 1 Battery *1: with Smart Key System A25 GND2 *2: without Smart Key System C136510E01 BC–85 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). 1 INSPECT CAN COMMUNICATION SYSTEM (a) Check if a CAN communication system DTC is output (See page BC-21). Result Condition Proceed to CAN communication system DTC is not output A CAN communication system DTC is output B B REPAIR CAN COMMUNICATION SYSTEM (See page CA-8) A 2 BC INSPECT ABS WARNING LIGHT HINT: When disconnecting the skid control ECU connector, the ABS warning light comes on. (a) Turn the ignition switch off. (b) Disconnect the skid control ECU connector. (c) Turn the ignition switch on (IG). (d) Check that the ABS warning light comes on. OK: The ABS warning light comes on. (e) Connect the connector. NG Go to step 3 OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) 3 INSPECT COMBINATION METER ASSEMBLY (a) Connect the intelligent tester to the DLC3. (b) Select the "ACTIVE TEST" on the tester (See page BC25). ACTIVE TEST: METER Item Vehicle Condition / Test Details Diagnostic Note ABS WRN LIGHT Turn ABS warning light ON / OFF Observe combination meter (c) Check the ABS warning light operation. OK: The ABS warning light turns on or off in accordance with the intelligent tester. BC–86 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM NG REPLACE COMBINATION METER ASSEMBLY (See page ME-63) OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM BC–87 Brake Warning Light Remains ON DESCRIPTION The skid control ECU sends the indicator signals to the combination meter assembly via the CAN communication system. If any of the following is detected, the brake warning light remains on: • The skid control ECU connector is disconnected from the skid control ECU. • The brake fluid level is insufficient. • The parking brake is applied. • EBD operation is not possible. BC BC–88 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) Main Body ECU 5 CANH E8 6 CANL E8 Combination Meter CANH BC MICRO COMPUTER CANL 17 26 F1 A25 18 15 F1 A25 CANH CANL BRAKE DRIVER IC 6 F2 IG+ B/LE A16 Brake Fluid Level Warning SW 1 2 E33 (*1) A18 (*2) Parking Brake SW PKB 2 IM 14 IC (*1) (*2) 1 4 A25 GND1 1 A25 GND2 (*1): M/T (*2): A/T C136504E01 BC–89 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM IG1 18 ECU IG No. 2 5 3 2 1 A25 IG1 E23 Ignition SW (*2) AM1 (*2) 4 AM1 IG1 1 BC Main Body ECU ALT 6 E7 (*1) (*1) AM2 AM1 3 IG1D 1 E6 E7 AM2 FL MAIN Battery *1: with Smart Key System *2: without Smart Key System C136505E01 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). 1 CHECK DTC (a) Check if an ABS DTC is output (See page BC-21). Result Condition Proceed to CAN communication system DTC is not output A CAN communication system DTC is output B BC–90 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM B REPAIR CIRCUITS INDICATED BY OUTPUT DTCS (See page BC-27) A 2 INSPECT CAN COMMUNICATION SYSTEM (a) Check if a CAN communication system DTC is output (See page BC-21). Result Condition Proceed to DTC is not output A DTC is output B B BC REPAIR CAN COMMUNICATION SYSTEM (See page CA-8) A 3 CHECK IF SKID CONTROL ECU CONNECTOR SECURELY CONNECTED (a) Check if the skid control ECU connector is connected securely. OK: The connector should be securely connected. NG CONNECT CONNECTOR TO ECU CORRECTLY OK 4 CHECK BATTERY (a) Check the battery voltage. Standard voltage: 11 to 14 V NG OK INSPECT CHARGING SYSTEM BC–91 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM 5 INSPECT SKID CONTROL ECU CONNECTOR (IG1 TERMINAL VOLTAGE) Skid Control ECU (Harness Side Connector Front View): A25 IG1 C131970E07 (a) Disconnect the skid control ECU connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition A25-18 (IG1) - Body ground Ignition switch on (IG) 10 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR (IG1 CIRCUIT) OK 6 (a) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU (Harness Side Connector Front View): GND2 GND1 A25 NG C131970E05 OK BC INSPECT SKID CONTROL ECU CONNECTOR (GND TERMINAL CONTINUITY) Tester Connection Specified Condition A25-4 (GND1) - Body ground Below 1 Ω A25-1 (GND2) - Body ground Below 1 Ω REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) BC–92 7 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM INSPECT PARKING BRAKE SWITCH (a) Remove the parking brake switch. (b) Disconnect the parking brake switch connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Automatic Transaxle Parking Brake Switch: Automatic Transaxle: Free Pushed in Tester Connection Condition Specified Condition (A18-1) - Ground part Free Below 1 Ω (A18-1) - Ground part Pushed in 10 kΩ or higher Condition Specified Condition Manual Transaxle Tester Connection Manual Transaxle: Free BC Pushed in Free Below 1 Ω (E33-1) - Ground part Pushed in 10 kΩ or higher NG C109430E03 OK (E33-1) - Ground part REPLACE PARKING BRAKE SWITCH BC–93 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM 8 CHECK HARNESS AND CONNECTOR (MAIN BODY ECU TO PARKING BRAKE SWITCH) (a) Disconnect the main body ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: Automatic Transaxle Main Body ECU Wire Harness View: IC : Automatic Transaxle Tester Connection Specified Condition IC-14 - A18-1 (PKB) Below 1 Ω A18-1 (PKB) - Body ground 10 kΩ or higher Manual Transaxle IM : Manual Transaxle Specified Condition Below 1 Ω E33-1 (PKB) - Body ground 10 kΩ or higher (c) Connect the connector. NG Parking Brake Switch Harness Side Connector Front View: A18 : Automatic Transaxle E33 : Manual Transaxle C136418E03 OK Tester Connection IM-2 (PKB) - E33-1 (PKB) REPAIR OR REPLACE HARNESS OR CONNECTOR (MAIN BODY ECU TO PARKING BRAKE SWITCH) BC BC–94 9 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM INSPECT BRAKE FLUID LEVEL WARNING SWITCH ASSEMBLY Brake Fluid Level Warning Switch (a) Remove the reservoir tank cap. (b) Disconnect the brake fluid level warning switch connector. (c) Measure the resistance according to the value(s) in the table below. HINT: A float is located inside the reservoir. Its position can be changed by increasing or decreasing the level of brake fluid. Standard resistance A16 MAX Level MIN Level BC Tester Connection Condition Specified Condition (A16-1) - (A16-2) Float UP 10 kΩ or higher (No Continuity) (A16-1) - (A16-2) Float DOWN Below 1 Ω (Continuity) C139740E01 HINT: If there is no problem after finishing the above check, adjust the brake fluid level to the MAX level. NG OK REPLACE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY (BRAKE FLUID LEVEL WARNING SWITCH) BC–95 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM 10 CHECK HARNESS AND CONNECTOR (BRAKE FLUID LEVEL WARNING SWITCH TO COMBINATION METER) (a) Disconnect the combination meter assembly connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Combination Meter Wire Harness View: Tester Connection Specified Condition A16-1 - F2-6 (B/LE) Below 1 Ω F2-6 (B/LE) - Body ground 10 kΩ or higher A16-2 - Body ground Below 1 Ω (c) Connect the connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR (BRAKE FLUID LEVEL WARNING SWITCH TO COMBINATION METER) F2-6 (B/LE) Brake Fluid Level Warning Switch Harness Side Connector Front View: A16 C136033E01 OK 11 INSPECT COMBINATION METER ASSEMBLY (a) Connect the intelligent tester to the DLC3. (b) Select the "ACTIVE TEST" on the tester (See page BC25). ACTIVE TEST: ABS Item Vehicle Condition / Test Details Diagnostic Note BRAKE WARN LIGHT Turn brake warning light ON / OFF Observe combination meter (c) Check the ABS warning light operation. OK: The BRAKE warning light turns on or off in accordance with the intelligent tester. Result Condition Proceed to OK A OK (When troubleshooting in accordance with the PROBLEM SYMPTOMS TABLE) B NG C BC BC–96 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page BC-16) C REPLACE COMBINATION METER ASSEMBLY (See page ME-63) A REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC BC–97 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM Brake Warning Light does not Come ON WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) Main Body ECU 5 CANH E8 6 CANL E8 Combination Meter CANH MICRO COMPUTER CANL 17 26 F1 A25 18 15 F1 A25 BC CANH CANL BRAKE DRIVER IC 6 F2 IG+ B/LE A16 Brake Fluid Level Warning SW 1 2 E33 (*1) A18 (*2) Parking Brake SW PKB 2 IM 14 IC (*1) (*2) 1 4 A25 GND1 1 A25 GND2 (*1): M/T (*2): A/T C136504E01 BC–98 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM IG1 18 ECU IG No. 2 5 3 2 1 A25 IG1 E23 Ignition SW (*2) AM1 (*2) 4 AM1 IG1 1 BC Main Body ECU ALT 6 E7 (*1) (*1) AM2 AM1 IG1D 1 E6 3 E7 AM2 FL MAIN Battery *1: with Smart Key System *2: without Smart Key System C136505E01 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). 1 INSPECT CAN COMMUNICATION SYSTEM (a) Check if a CAN communication system DTC is output (See page BC-21). Result Condition Proceed to CAN communication system DTC is not output A CAN communication system DTC is output B BC–99 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM B REPAIR CAN COMMUNICATION SYSTEM (See page CA-8) A 2 INSPECT BRAKE WARNING LIGHT HINT: When disconnecting the skid control ECU connector, the brake warning light comes on. (a) Turn the ignition switch off. (b) Disconnect the skid control ECU connector. (c) Turn the ignition switch on (IG). (d) Check that the brake warning light comes on. OK: The brake warning light comes on. NG Go to step 3 BC OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) 3 INSPECT COMBINATION METER ASSEMBLY (a) Connect the intelligent tester to the DLC3. (b) Select the "ACTIVE TEST" on the tester (See page BC25). ACTIVE TEST: METER Item Vehicle Condition / Test Details Diagnostic Note BRAKE WARN LIGHT Turn brake warning light ON / OFF Observe combination meter (c) Check the ABS warning light operation. OK: The BRAKE warning light turns on or off in accordance with the intelligent tester. NG REPLACE COMBINATION METER ASSEMBLY (See page ME-63) OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC–100 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM TC and CG Terminal Circuit DESCRIPTION DTC output mode is set by connecting terminals TC and CG of the DLC3. DTCs are indicated by the blinking pattern of the ABS warning light. WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) ECM CANH BC CANL 41 41 A55 *1 A24 *2 49 A55 *1 49 A55 *2 26 A25 CANH 15 A25 CANL E10 DLC3 27 TC A55 *1 27 A24 *2 13 *1: 2GR-FE *2: 2AZ-FE 4 TC CG C136513E01 HINT: When warning lights continue to blink, a ground short in the wiring of terminal TC of the DLC3 or an internal ground short in one or more ECUs is suspected. INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). 1 CHECK CAN COMMUNICATION SYSTEM (a) Check if a CAN communication DTC is output (See page BC-21). Result Result Proceed to CAN communication system DTC is output A CAN communication system DTC is not output B BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM B BC–101 Go to step 2 A GO TO CAN COMMUNICATION SYSTEM (See page CA-8) 2 CHECK HARNESS AND CONNECTOR (ECM TO DLC3) (a) Disconnect the ECM connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance 2GR-FE DLC3: E10 Tester Connection Specified Condition A55-27 (TC) - E10-13 (TC) Below 1 Ω E10-13 (TC) - Body ground 10 kΩ or higher 2AZ-FE TC ECM Wire Harness View: Tester Connection Specified Condition A24-27 (TC) - E10-13 (TC) Below 1 Ω E10-13 (TC) - Body ground 10 kΩ or higher (c) Connect the connector. NG A55-27 (TC) (*1) A24-27 (TC) (*2) (*1): 2GR-FE (*2): 2AZ-FE C136035E02 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (TC TERMINAL CIRCUIT) BC BC–102 3 DLC3: BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM CHECK HARNESS AND CONNECTOR (DLC3 CG CIRCUIT) (a) Measure the resistance according to the value(s) in the table below. Standard resistance CG E10 NG Tester Connection Specified Condition E10-4 (CG) - Body ground Below 1 Ω REPAIR OR REPLACE HARNESS OR CONNECTOR (CG TERMINAL CIRCUIT) G022986E25 OK BC 4 REPAIR OR REPLACE HARNESS OR CONNECTOR (TC TERMINAL CIRCUIT) (a) Measure the resistance according to the value(s) in the table below. Standard resistance DLC3: E10 NG Tester Connection Specified Condition E10-13 (TC) - Body ground 10 kΩ or higher CHECK HARNESS AND CONNECTOR (TC TERMINAL CIRCUIT) G022986E26 OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC–103 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM TS and CG Terminal Circuit DESCRIPTION In the Test Mode (signal check), a malfunction of the speed sensor that cannot be detected when the vehicle is stopped can be detected while driving. Transition to the sensor check mode can be performed by connecting terminals TS and CG of the DLC3 and turning the ignition switch from off to on (IG). WIRING DIAGRAM A25 Brake Actuator Assembly E10 DLC3 TS CG (Skid Control ECU) 12 25 BC TS 4 C109400E11 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). BC–104 1 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU TO DLC3) (a) Disconnect the skid control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Contorl ECU (Harness Side Connector Front View): A25 Tester Connection Condition Specified Condition A25-25 (TS) - E10-12 (TS) Always Below 1 Ω (c) Connect the connector. NG TS DLC3: REPAIR OR REPLACE HARNESS OR CONNECTOR (SKID CONTROL ECU TO DLC3) BC E10 TS C133301E02 OK 2 DLC3: CHECK HARNESS AND CONNECTOR (DLC3 TO BODY GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance CG Tester Connection Condition Specified Condition E10-4 (CG) - Body ground Always Below 1 Ω E10 NG G022987E23 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (DLC3 TO BODY GROUND) BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM 3 BC–105 CHECK HARNESS AND CONNECTOR (DLC3 TO BODY GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance DLC3: Tester Connection Condition Specified Condition E10-12 (TS) - Body ground Always 10 kΩ or higher E10 NG TS REPAIR OR REPLACE HARNESS OR CONNECTOR (DLC3 TO BODY GROUND) G022987E24 OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC BC–100 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) PRECAUTION 1. Expression BC EXPRESSIONS OF IGNITION SWITCH The type of ignition switch used on this model differs according to the specifications of the vehicle. The expressions listed in the table below are used in this section. Switch Type Ignition Switch (Position) Engine Switch (Condition) Ignition switch off LOCK off Ignition switch on (IG) ON on (IG) Ignition switch on (ACC) ACC on (ACC) Engine start START start 2. 3. TROUBLESHOOTING PRECAUTIONS (a) When there is a malfunction with terminal contact points or part installation problems, removal and installation of the suspected problem parts may return the system to the normal condition either completely or temporarily. (b) In order to determine the malfunctioning area, be sure to check the conditions at the time the malfunction occurred, such as DTC output and the Freeze Frame Data, and record it before disconnecting each connector or removing and installing parts. (c) Since the system may be influenced by malfunctions in systems other than the brake control system, be sure to check for DTCs in other systems. HANDLING PRECAUTIONS (a) Do not remove or install VSC parts such as the steering angle sensor or yaw rate sensor (acceleration sensor included) except when required, as they cannot be adjusted correctly after removal or installation. (b) Be sure to perform preparation before work and confirmation after work is completed by following the direction in the repair manual when working on the VSC system. (c) Be sure to remove and install the ECU, actuator, each sensor, etc. with the ignition switch off unless it is not specified in the inspection procedure. (d) If the ECU, brake actuator, or a sensor has been removed and installed, it is necessary to check the system for problems after the parts have been reassembled. Check for DTCs using the intelligent tester, also check that system functions and signals received by the ECU are normal using Test Mode. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 4. 5. 6. BC–101 DTC PRECAUTION (a) Warnings for some DTCs cannot be cleared only by repairing the malfunctioning parts. If the warning is displayed after repair work, the DTC should be cleared after turning the ignition switch off. NOTICE: If a DTC for a malfunctioning part reappears after it was cleared, then it has been stored again. CHASSIS DYNAMOMETER PRECAUTION (a) Enter Test Mode to disable TRAC and VSC control when using a chassis dynamometer. HINT: The vehicle may move unexpectedly out of the dynamometer because of TRAC and VSC operations. NOTICE: • Make sure that the VSC warning light is blinking (for vehicles without the multi information display) or "CHECK VSC SYSTEM" is displayed on the multi information display (for vehicles with the multi information display) (Test Mode is achieved). • Secure the vehicle with the lock chain for safety. CAN COMMUNICATION SYSTEM PRECAUTIONS (a) The CAN communication system is used for the data communication between the skid control ECU, the steering angle sensor, the yaw rate sensor (acceleration sensor included) and other ECUs. If there is trouble in the CAN communication line, corresponding DTCs in the communication line are output. (b) If the DTC in the CAN communication line is output, repair the malfunction in the communication line and troubleshoot the VSC system while data communication is normal. (c) In order to enable CAN communication, a specific type of wiring is used for the CAN communication lines. The wiring used for each communication line is a twisted pair of wires that have an equal length. A bypass wire should not be used, because the data being transmitted will be corrupted. BC BC–102 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) PARTS LOCATION SKID CONTROL SENSOR (REAR SPEED SENSOR) BRAKE ACTUATOR - SKID CONTROL ECU ECM (*2) ECM (*1) BC BRAKE MASTER CYLINDER - BRAKE FLUID LEVEL WARNING SWITCH ENGINE ROOM R/B - ABS MOTOR RELAY FRONT SPEED SENSOR (VSC NO. 1 (FAIL SAFE) RELAY) (VSC NO. 2 RELAY) - ABS NO. 1 FUSE - ABS NO. 2 FUSE (*1): 2GR-FE (*2): 2AZ-FE C135800E01 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–103 COMBINATION METER - ABS WARNING LIGHT - BRAKE WARNING LIGHT - VSC WARNING LIGHT (*3) - MULTI INFORMATION DISPLAY (*4) - SLIP INDICATOR LIGHT - MASTER CAUTION INDICATOR LIGHT PARKING BRAKE SWITCH (*5) BC PARKING BRAKE SWITCH (*6) SKID CONTROL BUZZER DLC3 STEERING ANGLE SENSOR YAW RATE AND ACCELERATION SENSOR STOP LIGHT SWITCH MAIN BODY ECU (INSTRUMENT PANEL J/B) - ECU-IG NO. 2 FUSE - STOP FUSE (*3): Models without Multi Information Display (*5): A/T (*4): Models with Multi Information Display (*6): M/T C135801E04 BC–104 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) SYSTEM DIAGRAM Brake Actuator Assembly Speed Sensor (on Each Wheel) Master Cylinder Pressure Sensor Solenoid Relay BC Switching Solenoid Valve Stop Light Switch Control Solenoid Valve Skid Control ECU Pump Motor Stop Light VSC NO. 2 Relay Skid Control Buzzer VSC NO. 1 (Fail Safe) Relay C109461E02 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–105 Combination Meter Skid Control ECU Speedometer ABS Warning Light BRAKE Warning Light Steering Angle Sensor BC VSC Warning Light (*1) Multi Information Display (*2) Yaw Rate and Acceleration Sensor SLIP Indicator Light ECM Master Caution Indicator Light Main Body ECU DLC3 (*1): Models without Multi Information Display (*2): Models with Multi Information Display CAN Communication System C140724E01 BC–106 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) Transmitting ECU (transmitter) Receiving ECU ECM Skid control ECU Skid control ECU Yaw rate and acceleration sensor Skid control ECU Steering angle sensor Skid control ECU ECM Signals • • • • • • Combination meter BC CAN communication system Steering angle sensor request signal CAN communication system • • Wheel speed signal VSC data signal CAN communication system • • ABS warning light ON signal BRAKE warning light ON signal VSC warning light ON signal (*1) Multi information display ON signal (*2) SLIP indicator light ON signal Master caution indicator light ON signal Wheel speed signal CAN communication system • • • • Main body ECU Skid control ECU CAN communication system Yaw rate and acceleration request signal • Skid control ECU Shift position signal Throttle position signal Engine revolution signal Intake air temperature signal Engine torque request signal Accelerator pedal position signal Communication method Parking brake switch signal CAN communication system (*1): Models without multi information display (*2): Models with multi information display BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–107 SYSTEM DESCRIPTION 1. FUNCTION DESCRIPTION HINT: • The skid control ECU is located within the brake actuator assembly. • The yaw rate sensor and acceleration sensor are combined in a single unit. This unit communicates with the skid control ECU through CAN communication. (a) ABS (Anti-lock Brake System) The ABS helps prevent the wheels from locking when the brakes are applied firmly or when braking on a slippery surface. Brake Actuator Assembly BC Pump Motor Each Speed Sensor Each Wheel Cylinder Skid Control ECU Solenoid Valve Combination Meter ABS Warning Light : CAN Communication System : Hydraulic Pressure C109467E01 BC–108 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) (1) Operation description The skid control ECU detects wheel lock based on speed signals it receives from the wheel speed sensors. Based on this information, the skid control ECU controls the pump motor and solenoid valves. The pump motor and solenoid valves are used to prevent wheel lock by controlling the hydraulic pressure applied to the brakes at each wheel. The ABS warning light will come on when the system is malfunctioning. (b) EBD (Electronic Brake force Distribution) The EBD control utilizes ABS, and performs proper brake force distribution between the front and rear wheels in accordance with driving conditions. When braking while cornering, it also controls the brake forces of the right and left wheels, helping to maintain vehicle behavior. BC Brake Actuator Assembly Each Speed Sensor Skid Control ECU Solenoid Valves Each Wheel Cylinder Combination Meter BRAKE Warning Light : CAN Communication System : Hydraulic Pressure C109468E02 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–109 (1) Operation description The skid control ECU receives a speed signal from each wheel speed sensor, and uses these signals to detect locking of the wheels. The ECU uses this information in order to determine appropriate control of the solenoid valves. The solenoid valves control the hydraulic pressure applied to the brake cylinder at each wheel. In this way, the solenoid valves are used to control the brake power split between the front and rear, and left and right wheels. The BRAKE warning light will come on if there is a malfunction in the EBD system. BC BC–110 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) (c) BA (Brake Assist) The primary purpose of the brake assist system is to provide auxiliary brake force to assist the driver who cannot generate a large enough brake force during emergency braking, thus helping to maximize the brake performance of the vehicle. Brake Actuator Assembly Pump Motor Each Wheel Cylinder Each Speed Sensor Skid Control ECU Solenoid Valve BC Master Cylinder Pressure Sensor ECM Combination Meter ABS Warning Light : CAN Communication System : Hydraulic Pressure C109469E01 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–111 (1) Operation description The skid control ECU receives the speed signal from each speed sensor and the fluid pressure signal from the master cylinder pressure sensor to determine whether brake assist is necessary. If brake assist is necessary, the skid control ECU sends control signals to the pump motor and solenoid. The pump and the solenoid valve then control the pressure applied to each wheel cylinder. The ABS warning light comes on to indicate a malfunction in the BA system. BC BC–112 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) (d) TRAC (Traction Control) The TRAC system helps prevent the drive wheels from slipping when the driver depresses the accelerator pedal excessively when starting off or accelerating on a slippery surface. Brake Actuator Assembly Pump Motor Each Speed Sensor Skid Control ECU Each Wheel Cylinder Solenoid Valve BC Yaw Rate and Acceleration Sensor Combination Meter VSC Warning Light (*1) Steering Angle Sensor Multi Information Display (*2) ECM SLIP Indicator Light : CAN Communication System (*1): Models without Multi Information Display : Hydraulic Pressure (*2): Models with Multi Information Display C109470E03 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–113 (1) Operation description The skid control ECU detects wheelspin by receiving signals from each speed sensor and the ECM via CAN communication. The skid control ECU controls engine torque with the ECM via CAN communication and brake hydraulic pressure through the pump and solenoid valve. The SLIP indicator light blinks when the system is operating. When there is a malfunction in the TRAC system, both VSC warning light (models without multi information display) and SLIP indicator light will come on and the DTC will be displayed on the multi information display (models with multi information display). BC BC–114 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) (e) VSC (Vehicle Stability Control) The VSC system helps prevent the vehicle from slipping sideways as a result of strong front or rear wheel skid during cornering. Brake Actuator Assembly Pump Motor Each Speed Sensor Each Wheel Cylinder Skid Control ECU Solenoid Valves Skid Control Buzzer BC Yaw Rate and Acceleration Sensor Combination Meter VSC Warning Light (*1) Steering Angle Sensor Multi Information Display (*2) ECM SLIP Indicator Light : CAN Communication System (*1): Models without Multi Information Display : Hydraulic Pressure (*2): Models with Multi Information Display C109471E03 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 2. 3. BC–115 (1) Operation description The skid control ECU determines the vehicle operating conditions based on signals received from the wheel speed sensors, yaw rate and acceleration sensor, and steering angle sensor. The skid control ECU sends signals via CAN communication to the ECM in order to control engine torque. The skid control ECU controls brake hydraulic pressure using the pump and solenoid valves. The SLIP indicator light will blink, and the skid control buzzer will sound when the system is operating. If a malfunction occurs in the VSC system, both the VSC warning light (models without multi information display) and the SLIP indicator light will come on. In addition, the DTC will appear on the multi information display (models with multi information display). ABS with EBD, BA, TRAC and VSC OPERATION (a) The skid control ECU calculates vehicle stability tendency based on the signals from the speed sensor, yaw rate and acceleration sensor, and steering angle sensor. In addition, it evaluates the results of the calculations to determine whether any control actions (control of the engine output torque by electronic throttle control and of the wheel brake pressure by the brake actuator assembly) should be implemented. (b) The SLIP indicator blinks and the skid control buzzer sounds to inform the driver that the VSC system is operating. The SLIP indicator also blinks when traction control is operating, and the operation being performed is displayed. FAIL SAFE (a) When a failure occurs in the ABS with BA, TRAC and VSC systems, the ABS warning, VSC warning (models without multi information display), and SLIP indicator lights come on or the DTC will be displayed on the multi information display (models with multi information display) and ABS with BA, TRAC and VSC operations are prohibited. In addition, when there is a failure that disables the EBD operation, the BRAKE warning light also comes on and the EBD operation is prohibited. (b) If control is prohibited due to a malfunction during operation, control will be disabled gradually. This is to avoid sudden vehicle instability. BC BC–116 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 4. INITIAL CHECK (a) When the vehicle speed first becomes approximately 4 mph (6 km/h) or more after the ignition switch is turned on (IG), each solenoid valve and motor of the brake actuator is sequentially activated to perform an electrical check. During the initial check, the operating sound of solenoid valve and motor can be heard from the engine compartment, but this is not a malfunction. INSPECTION MODE (a) VSC operation can be disabled by operating the intelligent tester. HINT: Refer to the intelligent tester operator's manual for further details. FUNCTION OF COMPONENTS 5. 6. Components BC Speed sensor Function Detects the wheel speed and sends the signal to the skid control ECU. • Skid control ECU (housed in brake actuator assembly) • • • Consists of the master cylinder cut solenoid valve, retention solenoid valve, pressure reduction solenoid valve, pump motor, and reservoir, and adjusts the brake fluid pressure applied to each wheel cylinder. Houses the skid control ECU. • • Supplies power to each solenoid. Housed in the skid control ECU. Brake actuator assembly Solenoid relay Processes the signals sent from each sensor to control the ABS, BA, TRAC, and VSC. Sends and receives the control signals to or from the ECM, yaw rate and acceleration sensor, and steering angle sensor, etc. via CAN communication. Motor relay (VSC NO. 2 relay) Supplies power to the pump motor. Fail safe relay (VSC NO. 1 relay) Cuts off power to the motor when the pump motor circuit malfunctions. • • Steering angle sensor • • Installed in the combination switch. Detects the steering amount and direction and sends the signals to the skid control ECU via CAN communication. Has the magnetic resistance element which detects the rotation of the magnet housed in the detection gear in order to detect the changes of magnetic resistance and the steering amount and direction. • Acceleration sensor measures the capacity of the condenser that changes the distance between the electrodes depending on G force, which occurs when the vehicle is accelerated, and converts the measured value into electrical signals. Yaw rate sensor detects the vehicle's angular velocity (yaw rate) in the vertical direction based on the amount and direction of the piezoelectric ceramics deflection. Sends signals to the skid control ECU via CAN communication. Master cylinder pressure sensor • • Detects the fluid pressure in the master cylinder. Housed in the brake actuator assembly. Stop light switch Detects the brake operating conditions and inputs the results to the skid control ECU. ECM Controls the engine output when TRAC and VSC are operating with the skid control ECU via CAN communication. Yaw rate and acceleration sensor Skid control buzzer • Intermittently sounds to inform the driver that the VSC is operating. • ABS warning light • • BRAKE warning light • Comes on to inform the driver that a malfunction in the ABS or BA has occurred. Blinks to output DTC. Comes on to inform the driver that the parking brake is ON when the system is normal, or the brake fluid has decreased. Comes on to inform the driver that a malfunction in the EBD has occurred. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) Components BC–117 Function • VSC warning light (*1) • • Multi information display (*2) • Comes on to inform the driver that a malfunction in the VSC system has occurred. Blinks to output DTC. Displays to inform the driver that a malfunction in the VSC system has occurred. Displays to output DTC. SLIP indicator light Blinks to inform the driver that TRAC and VSC are operating. Master caution indicator light Comes on to inform the driver that a malfunction. (*1): Models without multi information display (*2): Models with multi information display BC BC–118 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) HOW TO PROCEED WITH TROUBLESHOOTING HINT: The intelligent tester can be used at steps 3, 7, and 10. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS (a) Interview the customer and confirm the trouble (See page IN-45). NEXT BC 3 CHECK DTC AND FREEZE FRAME DATA (a) Check and record a DTC and Freeze Frame Data. (b) Clear the DTC and Freeze Frame Data (See page BC141). (c) Reconfirm the DTC. (1) Reconfirm the DTC based on the recorded DTC and Freeze Frame Data (See page BC-141 for DTC Check/Clear, and BC-144 for Freeze Frame Data). HINT: If any of the DTCs U0100/65, U0123/62, U0124/95, and U0126/63 is output together with a CAN communication DTC, first check the appropriate sensor for a momentary open circuit (See page BC118). Result Condition Proceed to DTC is output A DTC is not output (Problem symptom does not occur) B DTC is not output (Problem symptom occurs) C B GO TO STEP 5 C GO TO STEP 6 A 4 DIAGNOSTIC TROUBLE CODE CHART (a) Proceed to Diagnostic Trouble Code Chart (See page BC-151). BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–119 NEXT GO TO STEP 7 5 SYMPTOM SIMULATION (a) Proceed to Diagnosis System (See page BC-138). NEXT 6 PROBLEM SYMPTOMS TABLE (a) Proceed to Problem Symptoms Table (See page BC134). NEXT 7 BC CIRCUIT INSPECTION NEXT 8 IDENTIFICATION OF PROBLEM NEXT 9 REPAIR OR REPLACEMENT NEXT 10 NEXT END CONFIRMATION TEST BC–120 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) CHECK FOR INTERMITTENT PROBLEMS 1. CHECK FOR INTERMITTENT PROBLEMS HINT: A momentary interruption (open circuit) in the connectors and/or wire harness between the sensors and ECUs can be detected using the ECU Data List function of the intelligent tester. (a) Turn the ignition switch off and connect the intelligent tester to the DLC3. BC DLC3 Intelligent Tester C131977E06 Harness Signal: OK Momentary interruption 1 sec. 1 sec. 1 sec. Intelligent Tester Display: ERROR NORMAL (b) Turn the ignition switch on (IG). Follow the directions on the intelligent tester to display the Data List and select areas where momentary interruption should be monitored. HINT: • A momentary interruption (open circuit) cannot be detected for 3 seconds after the ignition switch is turned on (IG) (initial check). • If the status remains on (ERROR displayed), check the continuity between the ECU and the sensors, or between ECUs. • The ERROR display on the intelligent tester remains on for 1 second after the harness signal changes from momentary interruption (open circuit) to normal condition. C106657E02 Item (Display) Measurement Item / Range (Display) Normal Condition Diagnostic Note FR SPD OPN FR speed sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - FL SPD OPN FL speed sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - RR SPD OPN RR speed sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - RL SPD OPN RL speed sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - EFI COM OPN EFI communication open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–121 Item (Display) Measurement Item / Range (Display) Normal Condition Diagnostic Note YAW RATE OPN Yaw rate sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - DECELERAT OPN Acceleration sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - STEERING OPN Steering angle sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - M/C OPN Master cylinder pressure sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - (c) While observing the screen, gently jiggle the connector or wire harness between the ECU and sensors, or between ECUs. Result: ERROR display does not change. HINT: The connector and/or wire harness will be in momentary interruption (open circuit) if the display changes. Repair or replace the connector and/or wire harness as one of them is faulty. F047126 BC BC–122 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) CALIBRATION 1. Replacing Parts / Operation DESCRIPTION • After replacing the VSC relevant components or performing "Front wheel alignment adjustment", clear and read the sensor calibration data. • Follow the chart to perform calibration. Necessary Operation Skid control ECU Yaw rate and acceleration sensor zero point calibration. Yaw rate and acceleration sensor 1. Clearing zero point calibration data. 2. Yaw rate and acceleration sensor zero point calibration. Front wheel alignment adjustment 1. Clearing zero point calibration data. 2. Yaw rate and acceleration sensor zero point calibration. 2. BC OBTAIN ZERO POINT OF YAW RATE AND ACCELERATION SENSOR (INTELLIGENT TESTER) NOTICE: • While obtaining the zero point, keep the vehicle stationary and do not vibrate, tilt, move, or shake it. (Do not start the engine.) • Be sure to perform this procedure on a level surface (with an inclination of less than 1 degree). (a) Clear the zero point calibration data. (1) Turn the ignition switch off. (2) Connect the intelligent tester to the DLC3. (3) Check that the steering wheel is centered and move the shift lever to the P position (A/T) or apply the parking brake (M/T). (4) Turn the ignition switch on (IG). DLC3 Intelligent Tester C131977E06 (5) Operate the intelligent tester to erase the codes (select "RESET MEMORY"). HINT: Refer to the intelligent tester operator's manual for further details. C106531 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–123 (6) Turn the ignition switch off. NOTICE: If the ignition switch is turned on (IG) for more than 15 seconds with the shift lever in the P position (A/T) or the parking brake applied (M/T) after zero point of the yaw rate and acceleration sensor has been cleared, only the zero point of the yaw rate sensor will be stored. If the vehicle is driven under these conditions, the skid control ECU will store the zero point calibration for the acceleration sensor as not being completed. The skid control ECU will then also indicate this as a malfunction of the VSC system using the indicator lights (models without multi information display) or multi information display (models with multi information display). (b) Perform zero point calibration of the yaw rate and acceleration sensor. (1) Turn the ignition switch off. (2) Check that the steering wheel is centered and move the shift lever to the P position (A/T) or apply the parking brake (M/T). NOTICE: DTCs C1210/36 and C1336/39 will be recorded if the shift lever is not in the P position (A/T) or the parking brake is not applied (M/T) (See page BC-188). (3) Connect the intelligent tester to the DLC3. (4) Turn the ignition switch on (IG). DLC3 Intelligent Tester C131977E06 BC BC–124 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) (5) Set the intelligent tester to Test Mode (select "TEST MODE"). HINT: Refer to the intelligent tester operator's manual for further details. (6) After the Test Mode has been entered, keep the vehicle stationary on a level surface for 2 seconds or more. C106532 TEST MODE Blinking Pattern: 0.13 sec. BC 0.13 sec. ON OFF Display: C135802E01 DLC3: CG TS G022987E07 3. (7) Check that the VSC warning light blinks (models without multi information display) or "CHECK VSC SYSTEM" is displayed on the multi information display (models with multi information display) (Test Mode). HINT: • The SLIP indicator light remains on during Test Mode because TRAC is prohibited. • If the VSC warning light does not blink (models without multi information display) or "CHECK VSC SYSTEM" is not displayed on the multi information display (models with multi information display), perform zero point calibration again. • The zero point calibration is performed only once after the system enters the Test Mode. • Calibration cannot be performed again until the stored data is cleared. (8) Turn the ignition switch off and disconnect the intelligent tester. OBTAIN ZERO POINT OF YAW RATE AND ACCELERATION SENSOR (SST CHECK WIRE) NOTICE: • While obtaining the zero point, keep the vehicle stationary and do not vibrate, tilt, move, or shake it. (Do not start the engine.) • Be sure to perform the procedure on a level surface (with an inclination of less than 1 degree). (a) Clear the zero point calibration data. (1) Turn the ignition switch off. (2) Check that the steering wheel is centered and move the shift lever to the P position (A/T) or apply the parking brake (M/T). (3) Turn the ignition switch on (IG). (4) The warning light and indicator light come on for 3 seconds to indicate that the initial check is completed. (5) Using SST, connect and disconnect terminals TS and CG of the DLC3 4 times or more within 8 seconds. SST 09843-18040 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–125 NOTICE: If the ignition switch is turned on (IG) for more than 15 seconds with the shift lever in the P position (A/T) or the parking brake applied (M/T) after zero point of the yaw rate and acceleration sensor has been cleared, only the zero point of the yaw rate sensor will be stored. If the vehicle is driven under these conditions, the skid control ECU will store the zero point calibration for the acceleration sensor as not being completed. The skid control ECU will then also indicate this as a malfunction of the VSC system using the indicator lights (models without multi information display) or multi information display (models with multi information display). (b) Perform zero point calibration of the yaw rate and acceleration sensor. (1) Turn the ignition switch off. (2) Check that the steering wheel is centered and move the shift lever to the P position (A/T) or apply the parking brake (M/T). NOTICE: DTCs C1210/36 and C1336/39 will be recorded if the shift lever is not in the P position (A/T) or the parking brake is not applied (M/T) (See page BC-188). DLC3: (3) Using SST, connect terminals TS and CG of the DLC3. SST 09843-18040 (4) Turn the ignition switch on (IG). (5) Keep the vehicle stationary on a level surface for 2 seconds or more. CG TS G022987E07 BC BC–126 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) (6) Check that the VSC warning light blinks (models without multi information display) or "CHECK VSC SYSTEM" is displayed on the multi information display (models with multi information display) (Test Mode). HINT: • The SLIP indicator light remains on during Test Mode because TRAC is prohibited. • If the VSC warning light does not blink (models without multi information display) or "CHECK VSC SYSTEM" is not displayed on the multi information display (models with multi information display), perform zero point calibration again. • The zero point calibration is performed only once after the system enters the Test Mode. • Calibration cannot be performed again until the stored data is cleared. (7) Turn the ignition switch off and disconnect the SST from the DLC3. TEST MODE Blinking Pattern: 0.13 sec. 0.13 sec. ON OFF Display: BC C135802E01 TEST MODE PROCEDURE ABS Warning Light: BRAKE Warning Light: VSC Warning Light (*1): SLIP Indicator Light: Master Caution Indicator Light: (*1): Models without Multi Information Display C140885E01 1. WARNING LIGHT AND INDICATOR LIGHT INITIAL CHECK (a) Release the parking brake. NOTICE: Before releasing the parking brake, move the shift lever to the P position for safety (A/T) or set the chocks to hold the vehicle for safety (M/T). HINT: When the parking brake is applied or the level of the brake fluid is low, the BRAKE warning light comes on. (b) When the ignition switch is turned on (IG), check that the ABS warning, BRAKE warning, SLIP indicator, and master caution indicator lights come on for approximately 3 seconds. Vehicles equipped with VSC, which are not equipped with a multi information display, the VSC warning light will illuminate instead of the master caution indicator light. HINT: If the ECU stores a DTC, the ABS warning, BRAKE warning, VSC warning and SLIP indicator lights will come on. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–127 If the vehicle is equipped with a multi information display, and the vehicle stores a DTC, the master caution indicator light will illuminate, and the multi information display will indicate the malfunction instead of the VSC warning light. In this case, the ABS warning, BRAKE warning, and SLIP indicator lights will also come on. If the indicator remains on or does not come on, proceed to troubleshooting for the light circuits listed below. Trouble Area ABS warning light circuit See procedure BC-229 or BC-233 BRAKE warning light circuit BC-244 or BC-252 VSC warning light circuit BC-236 or BC-240 SLIP indicator light circuit BC-255 or BC-259 2. SENSOR CHECK USING TEST MODE (SIGNAL CHECK) (INTELLIGENT TESTER) NOTICE: After replacement of the brake actuator assembly and/or yaw rate and acceleration sensor, perform zero point calibration of the yaw rate and acceleration sensor. HINT: • If the ignition switch is turned from on (IG) to on (ACC) or off during Test Mode (signal check), DTCs of the signal check function will be erased. • During Test Mode (signal check), the skid control ECU records all DTCs of the signal check function. By performing the Test Mode (signal check), the codes are erased if a normal condition is confirmed. The remaining codes are the codes where an abnormality was found. (a) Procedure to enter Test Mode. (1) Turn the ignition switch off. (2) Connect the intelligent tester to the DLC3. (3) Check that the steering wheel is centered and move the shift lever to the P position (A/T) or apply the parking brake (M/T). (4) Turn the ignition switch on (IG). DLC3 Intelligent Tester C131977E06 BC BC–128 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) (5) Set the intelligent tester to Test Mode (select "SIGNAL CHECK"). HINT: Refer to the intelligent tester operator's manual for further details. C106533 (6) Check that the ABS and VSC (models without multi information display) warning lights blink or "CHECK VSC SYSTEM" is displayed on the multi information display (models with multi information display) (Test Mode). HINT: • The SLIP indicator light remains on during Test Mode because TRAC is prohibited. • If the ABS and VSC (models without multi information display) warning lights do not blink or "CHECK VSC SYSTEM" is not displayed on the multi information display (models with multi information display), inspect the TS and CG terminal circuit, and ABS and VSC warning light circuits. TEST MODE Blinking Pattern: 0.13 sec. BC 0.13 sec. ON OFF Display: Trouble Area See procedure TS and CG terminal circuit BC-269 ABS warning light circuit BC-233 VSC warning light circuit BC-240 C135802E01 Blinking Pattern in TEST MODE: 0.13 sec. 0.13 sec. ON 3. OFF BR03904E16 4. (7) Check the ABS sensor. HINT: Check that the ABS warning light is blinking in Test Mode and perform the check. ACCELERATION SENSOR CHECK (INTELLIGENT TESTER) (a) Keep the vehicle stationary on a level surface for 1 second or more. HINT: Acceleration sensor check can be performed with the master cylinder pressure sensor check below. MASTER CYLINDER PRESSURE SENSOR CHECK (INTELLIGENT TESTER) (a) Leave the vehicle in a stationary condition and release the brake pedal for 1 second or more, and quickly and continuously depress the brake pedal with a force of 98 N (10 kgf, 22 lbf) or more for 1 second. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 5. BC–129 (b) Check that the ABS warning light stays on for 3 seconds. HINT: • Ensure that the ABS warning light comes on. • While the ABS warning light stays on, continue to depress the brake pedal with a force of 98 N (10 kgf, 22 lbf) or more. • The ABS warning light comes on for 3 seconds every time brake pedal operation above is performed. • If the check of the master cylinder pressure sensor is not completed, depressing the brake pedal causes further decrease in the negative pressure, making the sensor check difficult to be completed. • If the negative pressure is insufficient, the master cylinder pressure sensor check may not be completed. In this case, run the engine at idle to obtain sufficient negative pressure. • If the brake pedal is strongly depressed when the negative pressure is insufficient, the BRAKE warning light may come on in accordance with the booster pressure control. In this case, run the engine at idle to obtain sufficient negative pressure. SPEED SENSOR CHECK (INTELLIGENT TESTER) (a) Check the speed sensor signal. (1) Drive the vehicle straight ahead. Accelerate the vehicle to a speed of 28 mph (45 km/h) or more for several seconds and check that the ABS warning light goes off. HINT: The sensor check may not be completed if wheelspin occurs. (b) Stop the vehicle. NOTICE: • Before performing the speed sensor check, complete the acceleration sensor and master cylinder pressure sensor checks. • The speed sensor check may not be completed if the speed sensor check is started while turning the steering wheel or spinning the wheels. • After the ABS warning light goes off and if the vehicle speed exceeds 50 mph (80 km/h), a signal check code will be stored again. Accelerate or stop the vehicle before the speed reaches 50 mph (80 km/h). • If the signal check has not been completed, the ABS warning light blinks while driving and the ABS system does not operate. BC BC–130 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) HINT: When the sensor check has been completed, the ABS warning light goes off while driving and blinks in the Test Mode pattern while stationary. (c) Check the VSC sensor. Check that the VSC warning light (models without multi information display) blinks or "CHECK VSC SYSTEM" is displayed on the multi information display (models with multi information display), and perform the check. TEST MODE Blinking Pattern: 0.13 sec. 0.13 sec. ON OFF Display: BC C135802E01 6. Start Position Within +- 5 deg. End Position C137757E01 YAW RATE SENSOR CHECK (INTELLIGENT TESTER) (a) Check the output of the yaw rate sensor. (1) Keep the vehicle in a stationary condition on a level surface for 1 second or more. (2) Move the shift lever from P to the D position (A/ T) or release the parking brake (M/T) and drive the vehicle at a speed of approximately 3 mph (5 km/h), and turn the steering wheel either to the left or right 90° or more until the vehicle makes a 180° turn. (3) Stop the vehicle and move the shift lever to the P position (A/T) or apply the parking brake (M/T). Check that the skid control buzzer sounds for 3 seconds. HINT: • If the skid control buzzer sounds, the sensor check is completed normally. • If the skid control buzzer does not sound, check the skid control buzzer circuit (See page BC-263), then perform the sensor check again. • If the skid control buzzer still does not sound, there is a malfunction in the yaw rate sensor, so check the DTC. • Make a 180° turn. At the end of the turn, the direction of the vehicle should be within 180° +- 5° of its start position. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–131 • Do not spin the wheels. • Do not turn the ignition switch off while turning. • Do not move the shift lever to the P position (A/T) or do not apply the parking brake (M/T) while turning, but changing in the vehicle speed, stopping, or driving in reverse is possible. • Complete the turn within 20 seconds. 7. Blinking Pattern in TEST MODE: 0.13 sec. 0.13 sec. ON OFF BR03904E16 8. 9. END OF SENSOR CHECK (INTELLIGENT TESTER) (a) If the sensor check is completed, the ABS warning light blinks (Test Mode) when the vehicle stops and the ABS warning light is off while the vehicle is driving. NOTICE: • When the yaw rate sensor, acceleration sensor, speed sensor, and master cylinder pressure sensor checks are completed, the sensor check is completed. • If the sensor check is not completed, the ABS warning light blinks even while the vehicle is driving and the ABS does not operate. READ DTC OF SIGNAL CHECK FUNCTION (INTELLIGENT TESTER) (a) Read the DTC(s) by following the tester screen. NOTICE: • If only the DTCs are displayed, repair the malfunction area and clear the DTCs. • If the DTCs or Test Mode codes (DTC of signal check function) are displayed, repair the malfunction area, clear the DTCs and perform the Test Mode inspection. HINT: See the list of DTC (See procedure "A"). SENSOR CHECK USING TEST MODE (SIGNAL CHECK) (SST CHECK WIRE) NOTICE: After replacement of the brake actuator assembly and/or yaw rate and acceleration sensor, perform zero point calibration of the yaw rate and acceleration sensor. HINT: • If the ignition switch is turned from on (IG) to on (ACC) or off during Test Mode (signal check), DTCs of the signal check function will be erased. • During Test Mode (signal check), the skid control ECU records all DTCs of the signal check function. By performing the Test Mode (signal check), the codes are erased if a normal condition is confirmed. The remaining codes are the codes where an abnormality was found. (a) Procedure to enter Test Mode. (1) Turn the ignition switch off. BC BC–132 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) (2) Check that the steering wheel is centered and move the shift lever to the P position (A/T) or apply the parking brake (M/T). DLC3: (3) Using SST, connect terminals TS and CG of the DLC3. SST 09843-18040 (4) Turn the ignition switch on (IG). CG TS G022987E07 (5) Check that the ABS and VSC (models without multi information display) warning lights blink or "CHECK VSC SYSTEM" is displayed on the multi information display (models with multi information display) (Test Mode). HINT: • The SLIP indicator light remains on during Test Mode because TRAC is prohibited. • If the ABS and VSC (models without multi information display) warning lights do not blink or "CHECK VSC SYSTEM" is not displayed on the multi information display (models with multi information display), inspect the TS and CG terminal circuit, and ABS and VSC warning light circuits. TEST MODE Blinking Pattern: BC 0.13 sec. 0.13 sec. ON OFF Display: Trouble Area See procedure TS and CG terminal circuit BC-269 ABS warning light circuit BC-233 VSC warning light circuit BC-240 C135802E01 Blinking Pattern in TEST MODE: 0.13 sec. 0.13 sec. ON OFF BR03904E16 (6) Check the ABS sensor. HINT: Check that the ABS warning light is blinking in Test Mode and perform the check. 10. ACCELERATION SENSOR CHECK (SST CHECK WIRE) (a) Keep the vehicle stationary on a level surface for 1 second or more. HINT: Acceleration sensor check can be performed with the master cylinder pressure sensor check below. 11. MASTER CYLINDER PRESSURE SENSOR CHECK (SST CHECK WIRE) (a) Leave the vehicle in a stationary condition and release the brake pedal for 1 second or more, and quickly and continuously depress the brake pedal with a force of 98 N (10 kgf, 22 lbf) or more for 1 second. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–133 (b) Check that the ABS warning light stays on for 3 seconds. HINT: • Ensure that the ABS warning light comes on. • While the ABS warning light stays on, continue to depress the brake pedal with a force of 98 N (10 kgf, 22 lbf) or more. • The ABS warning light comes on for 3 seconds every time the brake pedal operation above is performed. • If the check of the master cylinder pressure sensor is not completed, depressing the brake pedal causes further decrease in the negative pressure, making the sensor check difficult to be completed. • If the negative pressure is insufficient, the master cylinder pressure sensor check may not be completed. In this case, run the engine at idle to obtain sufficient negative pressure. • If the brake pedal is strongly depressed when the negative pressure is insufficient, the BRAKE warning light may come on in accordance with the booster pressure control. In this case, run the engine at idle to obtain sufficient negative pressure. 12. SPEED SENSOR CHECK (SST CHECK WIRE) (a) Check the speed sensor signal. (1) Drive the vehicle straight ahead. Accelerate the vehicle to a speed of 28 mph (45 km/h) or more for several seconds and check that the ABS warning light goes off. HINT: The sensor check may not be completed if wheelspin occurs. (b) Stop the vehicle. NOTICE: • Before performing the speed sensor check, complete the acceleration sensor and master cylinder pressure sensor checks. • The speed sensor check may not be completed if the speed sensor check is started while turning the steering wheel or spinning the wheels. • After the ABS warning light goes off, if vehicle speed exceeds 50 mph (80 km/h), a signal check code will be stored again. Accelerate or stop the vehicle before the speed reaches 50 mph (80 km/h). • If the signal check has not been completed, the ABS warning light blinks while driving and the ABS system does not operate. BC BC–134 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) HINT: When the sensor check has been completed, the ABS warning light goes off while driving and blinks in the Test Mode pattern while stationary. (c) Check the VSC sensor. Check that the VSC warning light (models without multi information display) blinks or "CHECK VSC SYSTEM" is displayed on the multi information display (models with multi information display), and perform the check. TEST MODE Blinking Pattern: 0.13 sec. 0.13 sec. ON OFF Display: BC C135802E01 Start Position Within +- 5 deg. End Position C137757E01 13. YAW RATE SENSOR CHECK (SST CHECK WIRE) (a) Check the output of the yaw rate sensor. (1) Keep the vehicle stationary on a level surface for 1 second or more. (2) Move the shift lever from P to the D position (A/ T) or release the parking brake (M/T) and drive the vehicle at a vehicle speed of approximately 3 mph (5 km/h) and turn the steering wheel either to the left or right 90° or more and until the vehicle makes a 180° turn. (3) Stop the vehicle and move the shift lever to the P position (A/T) or apply the parking brake (M/T). Check that the skid control buzzer sounds for 3 seconds. HINT: • If the skid control buzzer sounds, the sensor check is completed normally. • If the skid control buzzer does not sound, check the skid control buzzer circuit (See page BC-263), then perform the sensor check again. • If the skid control buzzer still does not sound, there is a malfunction in the yaw rate sensor, so check the DTC. • Make a 180° turn. At the end of the turn, the direction of the vehicle should be within 180° +- 5° of its start position. • Do not spin the wheels. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–135 • Do not turn the ignition switch off while turning. • Do not move the shift lever to the P position (A/T) or do not apply the parking brake (M/T) while turning, but changing in the vehicle speed, stopping, or driving in reverse is possible. • Complete the turn within 20 seconds. Blinking Pattern in TEST MODE: 0.13 sec. 0.13 sec. ON OFF BR03904E16 DLC3: 15. READ DTC OF SIGNAL CHECK FUNCTION (SST CHECK WIRE) (a) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 CG TS 14. END OF SENSOR CHECK (SST CHECK WIRE) (a) If the sensor check is completed, the ABS warning light blinks (Test Mode) when the vehicle stops and the ABS warning light is off while the vehicle is driving. NOTICE: • When the yaw rate sensor, acceleration sensor, speed sensor, and master cylinder pressure sensor checks are completed, the sensor check is completed. • If the sensor check is not completed, the ABS warning light blinks even while the vehicle is driving and the ABS does not operate. TC G022988E01 BC BC–136 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) (b) Count the number of blinks of the ABS and VSC (models without multi information display) warning lights or read "DIAG VSC" on the multi information display (models with multi information display). Blinking Pattern in Normal System Code: 0.25 sec. Display of Normal System Code: 0.25 sec. ON OFF BC Blinking Pattern in Trouble Code (Example Codes 71 and 72): 0.5 sec. 0.5 sec. 2.5 sec. 1.5 sec. 4 sec. Repeat ON OFF Code 71 Code 72 Display of Trouble Code (Example Code 71): C135803E02 NOTICE: • If only the DTCs are displayed, repair the malfunction area and clear the DTCs. • If the DTCs or Test Mode codes (DTC of signal check function) are displayed, repair the malfunction area, clear the DTCs and perform the Test Mode inspection. HINT: • If more than 1 malfunction is detected at the same time, the lowest numbered code will be displayed first. • See the list of DTC (See procedure "A"). BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–137 (c) After performing the check, disconnect the SST from terminals TS and CG, and TC and CG of the DLC3 and turn the ignition switch off. (d) Turn the ignition switch on (IG). HINT: • If the ignition switch is not turned on (IG) after the SST is removed from the DLC3, the previous Test Mode will continue. • If the ignition switch is turned on (IG) with terminals TS and CG shorted, the previous Test Mode will continue. 16. DTC OF TEST MODE (SIGNAL CHECK) FUNCTION (Procedure "A") ABS sensor: Code No. Diagnosis Trouble Area C1271/71 Low output signal of front speed sensor RH • • • Front speed sensor RH Sensor installation Speed sensor rotor C1272/72 Low output signal of front speed sensor LH • • • Front speed sensor LH Sensor installation Speed sensor rotor C1273/73 Low output signal of rear speed sensor RH • • • Rear speed sensor RH Sensor installation Speed sensor rotor C1274/74 Low output signal of rear speed sensor LH • • • Rear speed sensor LH Sensor installation Speed sensor rotor C1275/75 Abnormal change in output signal of front speed sensor RH Speed sensor rotor C1276/76 Abnormal change in output signal of front speed sensor LH Speed sensor rotor C1277/77 Abnormal change in output signal of rear speed sensor RH Speed sensor rotor C1278/78 Abnormal change in output signal of rear speed sensor LH Speed sensor rotor C1279/79 Acceleration sensor output voltage malfunction • • Yaw rate and acceleration sensor Sensor installation C1281/81 Master cylinder pressure sensor output malfunction • • Stop light switch Master cylinder pressure sensor VSC sensor: Code No. C0371/71 Diagnosis Yaw rate sensor Trouble Area Yaw rate and acceleration sensor HINT: The codes in this table are output only in Test Mode (signal check). BC BC–138 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) PROBLEM SYMPTOMS TABLE If there are no DTCs output and the problem still occurs, check the circuits for each problem symptom in the order given in the table below and proceed to the relevant troubleshooting page. HINT: • Inspect the fuse and relay before investigating the suspected areas as shown in the table below. • Inspect each malfunction circuit in numerical order for the corresponding symptom. Vehicle Stability Control System: Symptom BC ABS, BA and/or EBD does not operate ABS, BA and/or EBD does not operate efficiently ABS sensor DTC check cannot be done ABS warning light abnormal (Remains on) ABS warning light abnormal (Does not come on) BRAKE warning light abnormal (Remains on) BRAKE warning light abnormal (Does not come on) Suspected Area See page 1. Check the DTC again and make sure that the normal system code is output. BC-141 2. IG power source circuit BC-207 3. Front speed sensor circuit BC-156 4. Rear speed sensor circuit BC-164 5. Check the brake actuator assembly with the intelligent tester. (Check brake actuator assembly operation using the Active Test function.) If abnormal, check the hydraulic circuit for leakage. BC-425 6. If the symptoms still occur even after the above circuits in suspected areas have been inspected and proved to be normal, replace the brake actuator assembly (skid control ECU). BC-426 1. Check the DTC again and make sure that the normal system code is output. BC-141 2. Front speed sensor circuit BC-156 3. Rear speed sensor circuit BC-164 4. Stop light switch circuit BC-213 5. Check the brake actuator assembly with the intelligent tester. (Check brake actuator assembly operation using the Active Test function.) If abnormal, check the hydraulic circuit for leakage. BC-425 6. If the symptoms still occur even after the above circuits in suspected areas have been inspected and proved to be normal, replace the brake actuator assembly (skid control ECU). BC-426 1. Check the DTC again and make sure that the normal system code is output. BC-141 2. TC and CG terminal circuit BC-266 3. If the symptoms still occur even after the above circuit in suspected areas has been inspected and proved to be normal, replace the brake actuator assembly (skid control ECU). BC-426 1. ABS warning light circuit BC-229 2. Brake actuator assembly (Skid control ECU) BC-426 1. ABS warning light circuit BC-233 2. Brake actuator assembly (Skid control ECU) BC-426 1. BRAKE warning light circuit BC-244 2. Brake actuator assembly (Skid control ECU) BC-426 1. BRAKE warning light circuit BC-252 2. Brake actuator assembly (Skid control ECU) BC-426 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) Symptom Suspected Area VSC sensor DTC check cannot be done VSC warning light abnormal (Remains on) (*1) VSC warning light abnormal (Does not come on) (*1) Multi information display abnormal (Remains on) (*2) Multi information display abnormal (Does not come on) (*2) SLIP indicator light abnormal (Remains on) SLIP indicator light abnormal (Does not come on) Sensor check cannot be done Skid control buzzer abnormal See page 1. Check the DTC again and make sure that the normal system code is output. BC-141 2. IG power source circuit BC-207 3. Check the hydraulic circuit for leakage VSC and/or TRAC does not operate BC–139 - 4. Front speed sensor circuit BC-156 5. Rear speed sensor circuit BC-164 6. Yaw rate and acceleration sensor circuit BC-193 7. Steering angle sensor circuit BC-190 8. If the symptoms still occur even after the above circuits in suspected areas have been inspected and proved to be normal, replace the brake actuator assembly (skid control ECU). BC-426 1. Check the DTC again and make sure that the normal system code is output. BC-141 2. TC and CG terminal circuit BC-266 3. If the symptoms still occur even after the above circuit in suspected areas has been inspected and proved to be normal, replace the brake actuator assembly (skid control ECU). BC-426 1. VSC warning light circuit BC-236 2. Brake actuator assembly (Skid control ECU) BC-426 1. VSC warning light circuit BC-240 2. Brake actuator assembly (Skid control ECU) BC-426 1. VSC warning light circuit BC-236 2. Brake actuator assembly (Skid control ECU) BC-426 1. VSC warning light circuit BC-240 2. Brake actuator assembly (Skid control ECU) BC-426 1. SLIP indicator light circuit BC-255 2. Brake actuator assembly (Skid control ECU) BC-426 1. SLIP indicator light circuit BC-259 2. Brake actuator assembly (Skid control ECU) BC-426 1. TS and CG terminal circuit BC-269 2. Brake actuator assembly (Skid control ECU) BC-426 1. Skid control buzzer circuit BC-263 2. Brake actuator assembly (Skid control ECU) BC-426 (*1): Models without multi information display (*2): Models with multi information display BC BC–140 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) TERMINALS OF ECU 1. Terminal of ECU Skid Control ECU: F045080E06 BC Symbols (Terminal No.) Terminal Description GND2 (1) Pump motor ground BM (2) Motor relay input FR+ (3) Front wheel speed RH signal power supply output FL- (4) Front wheel speed LH signal input RR+ (5) Rear wheel speed RH signal power supply output RL- (6) Rear wheel speed LH signal input CANH (11) CAN communication line H SP1 (12) Speed signal output for combination meter D/G (13) Diagnosis tester communication line MRF (14) Fail safe motor relay output MR (15) Motor relay output FR- (17) Front wheel speed RH signal input FL+ (18) Front wheel speed LH signal power supply output RR- (19) Rear wheel speed RH signal input RL+ (20) Rear wheel speed LH signal power supply output TS (24) Test mode (signal check) input CANL (25) CAN communication line L STP (27) Stop light switch input BZ (30) Skid control buzzer output +BS (31) Solenoid relay power supply GND1 (32) Skid control ECU ground WFSE (42) WFSE input R+ (45) Power supply for motor relay IG1 (46) IG1 power supply BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 2. BC–141 Terminal Inspection (a) Disconnect the connector and measure the voltage or resistance on the wire harness side. Skid Control ECU Harness Side Connector Front View: A26 F049377E11 HINT: Voltage cannot be measured with the connector connected to the skid control ECU because the connector is watertight. Standard BC Symbols (Terminal No.) Wiring Color GND2 (A26-1) - Body ground W-B - Body ground STP (A26-27) - Body ground Terminal Description Condition Specified Condition Below 1 Ω Pump motor ground Ignition switch off P - Body ground Stop light switch input Stop light switch ON → OFF (Brake pedal depressed → released) 8 to 14 V → Below 1.5 V BZ (A26-30) - Body ground R - Body ground Buzzer output Ignition switch on (IG), when buzzer not sounding 6 to 10 V +BS (A26-31) - Body ground L - Body ground Solenoid relay power supply Always 10 to 14 V GND1 (A26-32) - Body ground W-B - Body ground Skid control ECU ground Always Below 1 Ω IG1 (A26-46) - Body ground P - Body ground IG1 power supply Ignition switch on (IG) 10 to 14 V BC–142 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DIAGNOSIS SYSTEM 1. BC DLC3: CG SG CANH SIL CANL BAT G022986E35 DESCRIPTION When troubleshooting a vehicle with the diagnosis system, the only difference from the usual troubleshooting procedure is connecting the intelligent tester to the vehicle and reading various data output from the vehicle's skid control ECU. The skid control ECU records DTCs when the computer detects a malfunction in the computer itself or in its circuits. To check the DTCs, connect the intelligent tester to the DLC3 on the vehicle. The intelligent tester enables you to erase the DTCs, activate the various actuators, and check the Freeze Frame Data and Data List. (a) Check the battery voltage. Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge the battery before proceeding. (b) Check the DLC3. The ECU uses ISO 15765-4 for communication. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. Verify the conditions listed in the table below. Symbols (Terminal No.) Terminal Description Condition Specified condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 11 to 14 V CANH (6) - CANL (14) CAN bus line *Ignition switch off 54 to 69 Ω CANH (6) - CG (4) HIGH-level CAN bus line *Ignition switch off 200 Ω or higher CANL (14) - CG (4) LOW-level CAN bus line *Ignition switch off 200 Ω or higher CANH (6) - BAT (16) HIGH-level CAN bus line *Ignition switch off 6 kΩ or higher CANL (14) - BAT (16) LOW-level CAN bus line *Ignition switch off 6 kΩ or higher NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. HINT: Connect the cable of the intelligent tester to the DLC3, turn the ignition switch on (IG) and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. BC–143 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 on the original vehicle. • If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's operator's manual. 2. ABS Warning Light: BRAKE Warning Light: VSC Warning Light (*1): SLIP Indicator Light: DIAGNOSIS (a) If the skid control ECU detects a malfunction, the ABS, BRAKE, and VSC (models without multi information display) warning lights, and SLIP indicator light will come on and the multi information display (models with multi information display) shows warning messages in order to warn the driver. The table below indicates which lights will come on when there is a malfunction in a particular function. Master Caution Indicator Light: (*1): Models without Multi Information Display C140885E01 Item / Trouble Area ABS EBD BA TRAC VSC ABS warning light { { { - - BRAKE warning light - { - - - VSC warning light (*1) { { { { { Multi information display (*2) { { { { { SLIP indicator light { { { { { BC BC–144 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) {: Light ON -: Light OFF (*1): Models without multi information display (*2): Models with multi information display • The DTCs are simultaneously stored in the memory. The DTCs can be read by connecting the SST between terminals TC and CG of the DLC3 and observing the blinking pattern of the ABS and VSC (models without multi information display) warning lights, by reading the multi information display (models with multi information display), or by connecting the intelligent tester. • This system has a Test Mode (signal check) function (See page BC-123). The DTC can be read by connecting the intelligent tester and observing the blinking pattern of the ABS and VSC (models without multi information display) warning lights or by reading the multi information display (models with multi information display). BC 3. ABS Warning Light: BRAKE Warning Light: VSC Warning Light (*1): SLIP Indicator Light: Master Caution Indicator Light: WARNING LIGHT AND INDICATOR LIGHT CHECK (a) Release the parking brake. NOTICE: When releasing the parking brake, move the shift lever to the P position for safety (A/T) or set the chocks to hold the vehicle for safety (M/T). HINT: When the parking brake is applied or the level of the brake fluid is low, the BRAKE warning light comes on. (b) When the ignition switch is turned on (IG), check that the ABS, BRAKE and VSC (models without multi information display) warning lights, and SLIP, and master caution indicator lights come on for approximately 3 seconds. HINT: If the warning light and indicator light check result is not normal, proceed to troubleshooting for the ABS, BRAKE and VSC warning light circuits and SLIP indicator light circuit. If the indicator remains on, proceed to troubleshooting for the light circuit below. Trouble Area (*1): Models without Multi Information Display C140885E01 See procedure ABS warning light circuit BC-229 BRAKE warning light circuit BC-244 VSC warning light circuit BC-236 SLIP indicator light circuit BC-255 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 4. SYMPTOM SIMULATION HINT: The most difficult case in troubleshooting is when no symptoms occur. In such cases, a thorough customer problem analysis must be carried out. Then the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be reproduced. No matter how experienced or skilled a technician may be, if he proceeds to troubleshoot without confirming the problem symptoms, he will likely overlook something important and make a wrong guess at some points in the repair operation. This leads to a standstill in troubleshooting. (a) Vibration method: When vibration seems to be the major cause. HINT: Perform the simulation method only during the primary check period (for approximately 6 seconds after the ignition switch is on (IG)). (1) Slightly vibrate the part of the sensor considered to be the problem cause with your fingers and check whether the malfunction occurs. (2) Slightly shake the connector vertically and horizontally. HINT: Shaking the relays too strongly may result in open relays. (3) Slightly shake the wire harness vertically and horizontally. The connector joint and fulcrum of the vibration are the major areas to be checked thoroughly. Vibrate Slightly Shake Slightly Vibrate Slightly BC–145 D025083E14 DTC CHECK / CLEAR 1. DLC3 Intelligent Tester C131977E06 DTC CHECK/CLEAR (INTELLIGENT TESTER) (a) Check the DTC. (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch on (IG). (3) Read the DTCs following the prompts on the tester screen. (b) Clear the DTC. (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch on (IG). (3) Operate the intelligent tester to clear the codes. HINT: Refer to the intelligent tester operator's manual for further details. BC BC–146 DLC3: BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 2. CG TC G022986E01 DTC CHECK/CLEAR (SST CHECK WIRE) (a) Check the DTC. (1) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 (2) Turn the ignition switch on (IG). (3) Observe the blinking pattern of the ABS and VSC (models without multi information display) warning lights or read the multi information display (models with multi information display) in order to identify the DTC. HINT: If no code appears, inspect the TC and CG terminal circuit, and ABS and VSC warning light circuits. Trouble Area TC and CG terminal circuit BC See procedure BC-266 ABS warning light circuit BC-229 or BC-233 VSC warning light circuit BC-236 or BC-240 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–147 (4) As an example, the illustration below shows the blinking patterns of the normal system code and trouble codes 11 and 21 for ABS and VSC (models without multi information display) warning lights or display of the normal system code and trouble code 43 for the VSC on the multi information display (models with multi information display). Blinking Pattern in Normal System Code: Blinking Pattern in Trouble Code (Example Codes 11 and 21): 0.25 sec. 0.25 sec. 2 sec. ON ON 2.5 sec. 0.5 sec. 0.5 sec. 1.5 sec. 4 sec. 4 sec. Repeat BC OFF OFF Code 11 Code 21 Display of Trouble Code (Example Code 43): Display of Normal System Code: C135804E02 (5) The codes are explained in the code table (See page BC-151). (6) After completing the check, disconnect terminals TC and CG of the DLC3, and turn off the display. If 2 or more DTCs are detected at the same time, the DTCs will be displayed in ascending order. DLC3: (b) Clear the DTC. (1) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 (2) Turn the ignition switch on (IG). CG TC G022986E01 BC–148 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BR03890 3. BC (3) Clear the DTCs stored in the ECU by depressing the brake pedal 8 times or more within 5 seconds. (4) Check that the warning light or multi information display indicates the normal system code. (5) Remove the SST from the terminals of the DLC3. HINT: Clearing the DTCs cannot be performed by disconnecting the battery terminal or the ECU-IG NO. 2 fuse. END OF DTC CHECK/CLEAR (a) Turn the ignition switch on (IG). (b) Check that the ABS warning light goes off within approximately 3 seconds. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–149 FREEZE FRAME DATA 1. Item (Display) FREEZE FRAME DATA (a) Whenever an ABS DTC is detected, the skid control ECU stores the current vehicle (sensor) state as Freeze Frame Data. The skid control ECU stores the number of times (maximum: 31) the ignition switch has been turned from off to on (IG) since the last time the ABS was activated. HINT: • However, if the vehicle is stopped or at a low speed (4.3 mph (7 km/h) or less), or if a DTC is detected, the skid control ECU will stop counting the number. • Freeze Frame Data at the time the ABS operates: The skid control ECU stores and updates data whenever the ABS system operates. When the ECU stores data at the time a DTC is detected, the data stored during ABS operation is erased. • Freeze Frame Data at the time a DTC is detected: When the skid control ECU stores data at the time a DTC is detected, no updates will be performed until the data is cleared. (b) Connect the intelligent tester to the DLC3. (c) Turn the ignition switch on (IG). (d) On the tester display, select the Freeze Frame Data. Measurement Item Reference Value VEHICLE SPD Vehicle speed reading Min.: 0 mph (0 km/h), Max.: 202 mph (326.4 km/ h) STOP LAMP SW Stop light switch signal Stop light switch ON: ON, OFF: OFF #IG ON Number of operations of ignition switch on (IG) after storing Freeze Frame Data 0 to 31 MAS CYL PRESS 1 Master cylinder pressure sensor reading Brake pedal released: 0.3 to 0.5 V M/C PRESS GRADE Master cylinder pressure sensor change Min.: -30 MPa/s, Max.: 225 MPa/s YAW RATE Yaw rate sensor reading Min.: -128 deg/s, Max.: 127 deg/s STEERING SEN Steering angle sensor reading Left turn: Increase Right turn: Decrease FORWARD & REA G Forward and backward G Min.: -25.11 m/s2, Max.: 24.91 m/s2 SPD GRADE Vehicle speed grade Min.: -25.11 m/s2, Max.: 24.91 m/s2 BUZZER Skid control buzzer signal Skid control buzzer ON: ON, OFF: OFF ACCELERATOR % Accelerator opening angle % Min.: 0 %, Max.: 128 % PARKING BRAKE SW Parking brake switch signal Parking brake switch ON: ON, OFF: OFF ENGINE TORQUE Real engine torque Min.: -1,024 Nm, Max.: 1,023 Nm FR WHEEL SPD FR wheel speed Min.: 0 mph (0 km/h), Max.: 202 mph (326.4 km/ h) FL WHEEL SPD FL wheel speed Min.: 0 mph (0 km/h), Max.: 202 mph (326.4 km/ h) RR WHEEL SPD RR wheel speed Min.: 0 mph (0 km/h), Max.: 202 mph (326.4 km/ h) BC BC–150 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) Item (Display) Measurement Item Reference Value RL WHEEL SPD RL wheel speed Min.: 0 mph (0 km/h), Max.: 202 mph (326.4 km/ h) LATERAL G Lateral G Min.: -25.11 m/s2, Max.: 24.91 m/s2 Gear position information FAIL 1st 2nd 3rd 4th 5th 6th P, N R NOT R Shift lever position information FAIL 1st 2nd 3rd 4th 5th 6th/B D/M P, N R Operated system status ABS activated: ABS VSC activated: VSC TRAC activated: TRAC BA activated: BA Fail safe mode activated: FAIL No system activated: NON System prohibited: SYS GEAR POSITION LEVER POSITION BC OPERATED SYSTEM FREEZE TIME Elapsed time after freeze trigger Min.: 0 ms, Max.: 500 ms TROUBLE CODE Freeze frame DTC Displays to output DTC INSPECTION MODE Inspection mode OTHER: Normal, INSPECT: Service BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–151 FAIL-SAFE CHART 1. FAIL SAFE OPERATION • If there is a problem with sensor signals or actuator systems, the skid control ECU prohibits power supply to the brake actuator assembly and informs the ECM of VSC system failure. The brake actuator assembly turns off each solenoid and the ECM shuts off VSC control (traction control signal) from the skid control ECU accordingly, which turns out to be as if the ABS, TRAC and VSC systems were not installed. The ABS control will be prohibited, but EBD control continues as much as possible. If EBD control is impossible, the BRAKE warning light comes on to warn the driver (See page BC-138). • If system components have any malfunction before starting control, immediately stop the operation. If system components have any malfunction during control, gradually stop the control so as not to trigger a sudden change in vehicle conditions. If it is impossible to control the systems, the warning light comes on to inform the driver of termination of the systems (See page BC-138). HINT: If the hydraulic brake booster encounters a malfunction, brake performance is gradually lost and ABS, BA, TRAC and VSC systems are prohibited. ABS, EBD and BA system: Malfunction Area Control Method ABS system ABS, BA, TRAC and VSC control prohibited BA system ABS, BA, TRAC and VSC control prohibited EBD system ABS, EBD, BA, TRAC and VSC control prohibited HINT: A malfunction in either the ABS or BA system will result in an identical operation, with ABS, BA, TRAC and VSC system control prohibited. TRAC and VSC system: Malfunction Area Control Method Engine control system (TRAC and VSC systems) Before control: Disables control During control: Uses only the brakes to effect control Brake control system (VSC system) Before control: Disables control During control: Uses only the engine to effect control Brake control system (TRAC system) Before control: Disables control During control: Disables control (by gradually ending control) HINT: As for the TRAC and VSC systems, different systems prohibit different controls depending on a malfunctioning part. BC BC–152 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DATA LIST / ACTIVE TEST 1. Item (Display) BC DATA LIST HINT: With the intelligent tester connected to the DLC3 and the ignition switch on (IG), the ABS, TRAC and VSC Data List can be displayed. Follow the prompts on the tester screen to access the Data List. Measurement Item / Range (Display) Normal Condition Diagnostic Note ABS MTR RELAY ABS motor relay / ON or OFF ON: Motor relay ON OFF: Motor relay OFF - SOL RELAY Solenoid relay / ON or OFF ON: Solenoid relay ON OFF: Solenoid relay OFF - FAIL MTR RELAY Fail safe motor relay / ON or OFF ON: Motor relay ON OFF: Motor relay OFF - IDLE SW Main idle switch / ON or OFF ON: Accelerator pedal released OFF: Accelerator pedal depressed - STOP LAMP SW Stop light switch / ON or OFF ON: Brake pedal depressed OFF: Brake pedal released - PARKING BRAKE SW Parking brake switch / ON or OFF ON: Parking brake applied OFF: Parking brake released - ENG REVOLUTIONS Engine revolutions / min.: 0 r/min, max.: 65535 r/min - - GEAR POSITION Gear position information / P/N, R, 1st-6th, FAIL, NOT R - - LEVER POSITION Shift lever position information / P/N, R, D/M, 1st-6th/B, FAIL - - SHIFT INFO Shift information / ON or OFF ON: During gear change - FR WHEEL SPD FR wheel speed sensor reading / min.: 0 mph (0 km/h), max.: 202 mph (326 km/h) Actual wheel speed Similar speed as indicated on speedometer FL WHEEL SPD FL wheel speed sensor reading / min.: 0 mph (0 km/h), max.: 202 mph (326 km/h) Actual wheel speed Similar speed as indicated on speedometer RR WHEEL SPD RR wheel speed sensor reading / min.: 0 mph (0 km/h), max.: 202 mph (326 km/h) Actual wheel speed Similar speed as indicated on speedometer RL WHEEL SPD RL wheel speed sensor reading / min.: 0 mph (0 km/h), max.: 202 mph (326 km/h) Actual wheel speed Similar speed as indicated on speedometer DECELERAT SEN Acceleration sensor 1 reading / min.: -1.889 G, max.: 1.875 G Approximately 0+-0.13 G while stationary Reading changes when vehicle is bounced DECELERAT SEN 2 Acceleration sensor 2 reading / min.: -1.889 G, max.: 1.875 G Approximately 0+-0.13 G while stationary Reading changes when vehicle is bounced SFRR ABS solenoid (SFRR) / ON or OFF ON: Operates - SFRH ABS solenoid (SFRH) / ON or OFF ON: Operates - SFLR ABS solenoid (SFLR) / ON or OFF ON: Operates - SFLH ABS solenoid (SFLH) / ON or OFF ON: Operates - SRRR ABS solenoid (SRRR) / ON or OFF ON: Operates - SRRH ABS solenoid (SRRH) / ON or OFF ON: Operates - BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) Item (Display) Measurement Item / Range (Display) Normal Condition BC–153 Diagnostic Note SRLR ABS solenoid (SRLR) / ON or OFF ON: Operates - SRLH ABS solenoid (SRLH) / ON or OFF ON: Operates - SM1 Master cut solenoid (SM1) / ON or OFF ON: Operates - SM2 Master cut solenoid (SM2) / ON or OFF ON: Operates - VEHICLE SPD Maximum wheel speed sensor reading / min.: 0 mph (0 km/h), max.: 202 mph (326 km/h) Actual vehicle speed Speed indicated on speedometer YAW RATE SENS 1 Yaw rate sensor 1 / min.: -128 deg/s, max.: 127 deg/s Min.: -128 deg/s Max.: 127 deg/s - ZERO YAW RATE Memorized zero value / min.: 128 deg/s, max.: 127 deg/s Min.: -128 deg/s Max.: 127 deg/s - STEERING SEN Steering angle sensor / min.: 3,276.8 deg, max.: 3,276.7 deg Left turn: Increase Right turn: Decrease - MAS CYL PRESS 1 Master cylinder pressure sensor 1 reading / min.: 0 V, max.: 5 V When brake pedal is released: 0.3 to 0.5 V Reading increases when brake pedal is depressed ACCELERATOR % The difference of a present accelerator / min.: 0%, max.: 128% - - ENGINE TORQUE Real engine torque / min.: -1,024 N*m, max.: 1,023 N*m - - FR SPD OPN FR speed sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - FL SPD OPN FL speed sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - RR SPD OPN RR speed sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - RL SPD OPN RL speed sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - YAW RATE OPN Yaw rate sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - DECELERAT OPN Acceleration sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - STEERING OPN Steering angle sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - M/C OPN Master cylinder pressure sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - EFI COM OPN EFI communication open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - #DTC Number of DTC / min.: 0, max.: 255 - - ABS WARN LAMP ABS warning light / ON or OFF ON: Warning light ON OFF: Warning light OFF - BRAKE WARN LAMP BRAKE warning light / ON or OFF ON: Warning light ON OFF: Warning light OFF - SLIP INDI LAMP SLIP indicator light / ON or OFF ON: Indicator light ON OFF: Indicator light OFF - BUZZER Skid control buzzer / ON or OFF ON: Buzzer ON OFF: Buzzer OFF - VSC WARN LAMP VSC warning light (*1) or multi information display (*2) / ON or OFF ON: Indicator ON OFF: Indicator OFF - ZERO M/C SEN Memorized zero value / min.: 12.5 MPa, max.: 12.4 MPa Min.: -12.5 MPa Max.: 12.4 MPa - BC BC–154 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) Item (Display) FR WHEEL ACCEL FL WHEEL ACCEL RR WHEEL ACCEL RL WHEEL ACCEL ZERO DECELERAT ZERO DECELERAT 2 ZERO STEERING BC LATERAL G Measurement Item / Range (Display) Min.: -200.84 m/s2 FR wheel acceleration / min.: 2 Normal Condition 2 200.84 m/s , max.: 199.27 m/s Max.: 199.27 m/s2 FL wheel acceleration / min.: - Min.: -200.84 m/s2 200.84 m/s 2, max.: 199.27 m/s2 Min.: -200.84 m/s2 RR wheel acceleration / min.: m/s2 Max.: 199.27 m/s2 2 , max.: 199.27 m/s Max.: 199.27 m/s2 RL wheel acceleration / min.: - Min.: -200.84 m/s2 200.84 m/s2, max.: 199.27 m/s2 Max.: 199.27 m/s2 Memorized zero value / min.: - Min.: -25.11 m/s2 25.11 m/s2, max.: 24.91 m/s2 Max.: 24.91 m/s2 Memorized zero value / min.: - Min.: -25.11 m/s2 25.11 m/s2, max.: 24.91 m/s2 Max.: 24.91 m/s2 Memorized zero value / min.: 3,276.8 deg, max.: 3,276.7 deg Min.: -3,276.8 deg Max.: 3,276.7 deg Lateral G / min.: -25.11 m/s2, Min.: -25.11 m/s2 200.84 Diagnostic Note - - - - - - 2 Max.: 24.91 m/s2 Forward and rearward G / min.: - Min.: -25.11 m/s2 25.11 m/s2, max.: 24.91 m/s2 Max.: 24.91 m/s2 YAW RATE VALUE Yaw rate value / min.: -128 deg/s, max.: 127 deg/s Min.: -128 deg/s Max.: 127 deg/s - STEERING ANGLE Steering angle value / min.: 3,276.8 deg, max.: 3,276.7 deg Min.: -3,276.8 deg Max.: 3,276.7 deg - TRAC STATUS TRAC control status / ON or OFF ON: During the control - TRAC ENG STATUS TRAC engine control status / ON or OFF ON: During the control - TRAC BRK STATUS TRAC brake control status / ON or OFF ON: During the control - FR VSC STATUS FR wheel VSC control status / ON or OFF ON: During the control - FL VSC STATUS FL wheel VSC control status / ON or OFF ON: During the control - RR VSC STATUS RR wheel VSC control status / ON or OFF ON: During the control - RL VSC STATUS RL wheel VSC control status / ON or OFF ON: During the control - FR ABS STATUS FR wheel ABS control status / ON or OFF ON: During the control - FL ABS STATUS FL wheel ABS control status / ON or OFF ON: During the control - RR ABS STATUS RR wheel ABS control status / ON or OFF ON: During the control - RL ABS STATUS RL wheel ABS control status / ON or OFF ON: During the control - RR EBD STATUS RR wheel EBD control status / ON or OFF ON: During the control - RL EBD STATUS RL wheel EBD control status / ON or OFF ON: During the control - BA STATUS BA control status / ON or OFF ON: During the control - PBA STATUS PBA control status / ON or OFF ON: During the control - INSPECTION MODE Inspection mode / OTHER or INSPECT - - #IG ON2 Number of ignition switch on (IG) after entering the inspection mode / min.: 0, max.: 255 - - FORWARD&REA G max.: 24.91 m/s - BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) Item (Display) TROUBLE CODE Measurement Item / Range (Display) Normal Condition Freeze frame DTC / min.:0, max.: 65,535 - 2. Item (Display) BC–155 Diagnostic Note - (*1): Models without multi information display (*2): Models with multi information display ACTIVE TEST HINT: Performing the Active Test using the intelligent tester allows the relay, actuator, and other items to operate without removing any parts. Performing the Active Test as the first step in troubleshooting is one of the methods to save labor time. It is possible to display the Data List during the Active Test. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) On the tester display, select the Active Test. HINT: The ignition switch must be turned on (IG) to proceed to the Active Test using the intelligent tester. Vehicle Condition / Test Details Diagnostic Note SFRR Turns ABS solenoid (SFRR) ON / OFF Operating sound of solenoid (clicking sound) can be heard SFRH Turns ABS solenoid (SFRH) ON / OFF Operating sound of solenoid (clicking sound) can be heard SFLR Turns ABS solenoid (SFLR) ON / OFF Operating sound of solenoid (clicking sound) can be heard SFLH Turns ABS solenoid (SFLH) ON / OFF Operating sound of solenoid (clicking sound) can be heard SRRR Turns ABS solenoid (SRRR) ON / OFF Operating sound of solenoid (clicking sound) can be heard SRRH Turns ABS solenoid (SRRH) ON / OFF Operating sound of solenoid (clicking sound) can be heard SRLR Turns ABS solenoid (SRLR) ON / OFF Operating sound of solenoid (clicking sound) can be heard SRLH Turns ABS solenoid (SRLH) ON / OFF Operating sound of solenoid (clicking sound) can be heard SMF Turns master cut solenoid (SM1) ON / OFF Operating sound of solenoid (clicking sound) can be heard SMR Turns master cut solenoid (SM2) ON / OFF Operating sound of solenoid (clicking sound) can be heard SOL RELAY Turns ABS solenoid relay ON / OFF - MOTOR RELAY Turns ABS motor relay ON / OFF Operating sound of relay (clicking sound) and motor can be heard ABS WARN LAMP Turns ABS warning light ON / OFF Observe combination meter VSC WARN LAMP Turns VSC warning light (*1) or multi information display (*2) ON / OFF Observe combination meter SLIP INDI LAMP Turns SLIP indicator light ON / OFF Observe combination meter BRAKE WARN LAMP Turns BRAKE warning light ON / OFF Observe combination meter BUZZER Turns skid control buzzer ON / OFF Buzzer can be heard (*1): Models without multi information display (*2): Models with multi information display BC BC–156 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DIAGNOSTIC TROUBLE CODE CHART • If a trouble code is displayed during the DTC check, check the circuit indicated by the DTC. For details of each code, refer to the page for the respective "DTC No." in the DTC chart. • Inspect the fuse and relay before investigating the trouble areas as shown in the table below. DTC chart of ABS: DTC No. Trouble Area See page Front Speed Sensor RH Circuit 1. Front speed sensor RH 2. Speed sensor circuit 3. Speed sensor rotor 4. Sensor installation 5. Brake actuator assembly (Skid control ECU) BC-156 Front Speed Sensor LH Circuit 1. Front speed sensor LH 2. Speed sensor circuit 3. Speed sensor rotor 4. Sensor installation 5. Brake actuator assembly (Skid control ECU) BC-156 Rear Speed Sensor RH Circuit 1. Rear speed sensor RH 2. Speed sensor circuit 3. Speed sensor rotor 4. Sensor installation 5. Brake actuator assembly (Skid control ECU) BC-164 Rear Speed Sensor LH Circuit 1. Rear speed sensor LH 2. Speed sensor circuit 3. Speed sensor rotor 4. Sensor installation 5. Brake actuator assembly (Skid control ECU) BC-164 C0226/21 SFR Solenoid Circuit 1. Brake actuator assembly 2. SFRH or SFRR circuit BC-172 C0236/22 SFL Solenoid Circuit 1. Brake actuator assembly 2. SFLH or SFLR circuit BC-172 C0246/23 SRR Solenoid Circuit 1. Brake actuator assembly 2. SRRH or SRRR circuit BC-172 C0256/24 SRL Solenoid Circuit 1. Brake actuator assembly 2. SRLH or SRLR circuit BC-172 C0273/13 (*1) Open in ABS Motor Relay Circuit 1. ABS NO. 1 fuse 2. VSC NO. 2 relay 3. VSC NO. 2 relay circuit 4. Brake actuator assembly BC-175 C0274/14 Short to B+ in ABS Motor Relay Circuit 1. ABS NO. 1 fuse 2. VSC NO. 2 relay 3. VSC NO. 2 relay circuit 4. Brake actuator assembly BC-175 C0278/11 Open in ABS Solenoid Relay Circuit 1. ABS NO. 2 fuse 2. ABS solenoid relay 3. ABS solenoid relay circuit 4. Brake actuator assembly BC-181 C0279/12 Short to B+ in ABS Solenoid Relay Circuit Brake actuator assembly BC-181 C1225/25 SM Solenoid Circuit 1. Brake actuator assembly 2. SM1 or SM2 circuit BC-172 C1235/35 Foreign Object is Attached on Tip of Front Speed Sensor RH 1. Front speed sensor RH 2. Speed sensor rotor 3. Sensor installation 4. Brake actuator assembly (Skid control ECU) BC-197 C0200/31 (*1) C0205/32 (*1) Detection Item BC C0210/33 (*1) C0215/34 (*1) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DTC No. Detection Item Trouble Area See page C1236/36 Foreign Object is Attached on Tip of Front Speed Sensor LH 1. Front speed sensor LH 2. Speed sensor rotor 3. Sensor installation 4. Brake actuator assembly (Skid control ECU) BC-197 C1238/38 Foreign Object is Attached on Tip of Rear Speed Sensor RH 1. Rear speed sensor RH 2. Speed sensor rotor 3. Sensor installation 4. Brake actuator assembly (Skid control ECU) BC-197 Foreign Object is Attached on Tip of Rear Speed Sensor LH 1. Rear speed sensor LH 2. Speed sensor rotor 3. Sensor installation 4. Brake actuator assembly (Skid control ECU) BC-197 Low Battery Positive Voltage 1. ECU-IG NO. 2 fuse 2. Battery 3. Charging system 4. Power source circuit 5. Internal power supply circuit of the skid control ECU BC-207 Acceleration Sensor Stuck Malfunction 1. Yaw rate and acceleration sensor 2. Yaw rate and acceleration sensor circuit BC-193 Open or Short in Acceleration Sensor Circuit 1. Yaw rate and acceleration sensor 2. Yaw rate and acceleration sensor circuit BC-193 Acceleration Sensor Output Malfunction 1. Yaw rate and acceleration sensor 2. Yaw rate and acceleration sensor circuit BC-193 Master Cylinder Pressure Sensor Malfunction 1. Master cylinder pressure sensor 2. Master cylinder pressure sensor circuit 3. Stop light switch circuit 4. Brake actuator assembly BC-210 Open in Stop Light Switch Circuit 1. STOP fuse 2. Stop light switch 3. Stop light switch circuit 4. Brake actuator assembly (Skid control ECU) BC-213 Open in Pump Motor Circuit 1. Brake actuator assembly (GND circuit) 2. Brake actuator assembly (Motor circuit) BC-219 C1361/91 Short Circuit in ABS Motor Fail Safe Relay Circuit 1. ABS NO. 1 fuse 2. VSC NO. 1 (fail safe) relay 3. VSC NO. 1 (fail safe) relay circuit 4. Brake actuator assembly BC-175 C1381/97 Yaw Rate and / or Acceleration Sensor Power Supply Voltage Malfunction 1. Yaw rate and acceleration sensor 2. Yaw rate and acceleration sensor power source circuit BC-193 U0073/94 Control Module Communication Bus OFF CAN communication system BC-224 U0124/95 Lost Communication with Lateral Acceleration Sensor Module CAN communication system (Skid control ECU to yaw rate and acceleration sensor) BC-224 C1239/39 C1241/41 C1243/43 (*1) C1244/44 C1245/45 (*1) C1246/46 (*2) C1249/49 C1251/51 (*1) (*1, *2): BC–157 BC BC–158 BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) Even after the trouble areas are repaired, the ABS warning light will not go off unless the following operations are performed: • (*1): (a)Drive the vehicle at 12 mph (20 km/h) for 30 seconds or more and check that the ABS warning light goes off. (b)Clear the DTC. • (*2): (a)Keep the vehicle stationary for 5 seconds or more and depress the brake pedal lightly 2 or 3 times. (b)Drive the vehicle at the vehicle speed of 31 mph (50 km/h) and keep depressing the brake pedal strongly for approximately 3 seconds. (c) Repeat the above operation 3 times or more and check that the ABS warning light goes off. (d)Clear the DTC. HINT: In some cases, the intelligent tester cannot be used when the ABS warning light remains on. DTC chart of VSC: DTC No. 43 Detection Item Trouble Area See page ABS Control System Malfunction ABS control system BC-155 C1201/51 Engine Control System Malfunction Engine control system BC-186 C1203/53 ECM Communication Circuit Malfunction ECM BC-187 Zero Point Calibration of Yaw Rate Sensor Undone 1. Brake actuator assembly (Skid control ECU) 2. Yaw rate and acceleration sensor 3. Zero point calibration undone BC-188 C1231/31 Steering Angle Sensor Circuit Malfunction 1. Steering angle sensor 2. Steering angle sensor circuit 3. Steering angle sensor power supply 4. Brake actuator assembly (Skid control ECU) BC-190 C1232/32 Stuck in Acceleration Sensor 1. Yaw rate and acceleration sensor 2. Yaw rate and acceleration sensor circuit BC-193 C1234/34 Yaw Rate Sensor Malfunction 1. Yaw rate and acceleration sensor 2. Yaw rate and acceleration sensor circuit BC-193 C1290/66 Steering Angle Sensor Zero Point Malfunction 1. Yaw rate and acceleration sensor zero point calibration incomplete 2. Poor adjustment of the centered position of the steering wheel 3. Poor adjustment of front wheel alignment BC-222 C1336/39 Zero Point Calibration of Acceleration Sensor Undone 1. Brake actuator assembly (Skid control ECU) 2. Yaw rate and acceleration sensor 3. Zero point calibration undone BC-188 U0100/65 Lost Communication with ECM / PCM CAN communication system (Skid control ECU to ECM) BC-224 C1210/36 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DTC No. Detection Item Trouble Area See page BC-224 BC-224 U0123/62 Lost Communication with Yaw Rate Sensor Module CAN communication system (Skid control ECU to yaw rate and acceleration sensor) U0126/63 Lost Communication with Steering Angle Sensor Module CAN communication system (Skid control ECU to steering angle sensor) BC–159 HINT: In some cases, the intelligent tester cannot be used when the VSC warning light (models without multi information display) or multi information display (models with multi information display) remains on. Test Mode DTC of ABS: DTC No. Detection Item Trouble Area See page C1271/71 Low Output Signal of Front Speed Sensor RH (Test Mode DTC) 1. Front speed sensor RH 2. Sensor installation 3. Speed sensor rotor BC-156 C1272/72 Low Output Signal of Front Speed Sensor LH (Test Mode DTC) 1. Front speed sensor LH 2. Sensor installation 3. Speed sensor rotor BC-156 C1273/73 Low Output Signal of Rear Speed Sensor RH (Test Mode DTC) 1. Rear speed sensor RH 2. Sensor installation 3. Speed sensor rotor BC-164 C1274/74 Low Output Signal of Rear Speed Sensor LH (Test Mode DTC) 1. Rear speed sensor LH 2. Sensor installation 3. Speed sensor rotor BC-164 C1275/75 Abnormal Change in Output Signal of Front Speed Sensor RH (Test Mode DTC) Speed sensor rotor BC-197 C1276/76 Abnormal Change in Output Signal of Front Speed Sensor LH (Test Mode DTC) Speed sensor rotor BC-197 C1277/77 Abnormal Change in Output Signal of Rear Speed Sensor RH (Test Mode DTC) Speed sensor rotor BC-197 C1278/78 Abnormal Change in Output Signal of Rear Speed Sensor LH (Test Mode DTC) Speed sensor rotor BC-197 C1279/79 Acceleration Sensor Output Voltage Malfunction (Test Mode DTC) 1. Yaw rate and acceleration sensor 2. Sensor installation BC-193 C1281/81 Master Cylinder Pressure Sensor Output Malfunction (Test Mode DTC) 1. Stop light switch 2. Master cylinder pressure sensor BC-210 Test Mode DTC of VSC: DTC No. C0371/71 Detection Item Yaw Rate Sensor (Test Mode DTC) Trouble Area See page Yaw rate and acceleration sensor BC-193 BC BC–160 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DTC 43 ABS Control System Malfunction DESCRIPTION This DTC is output when the VSC system detects a malfunction in the ABS control system. DTC No. 43 DTC Detection Condition Malfunction in the ABS control system. Trouble Area ABS control system INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). 1 BC CHECK ABS CONTROL SYSTEM (a) Clear the DTC (See page BC-141). (b) Turn the ignition switch on (IG). (c) Check if the same DTC is recorded (See page BC-141). Result Condition Proceed to DTC (ABS control system DTC) is not output A DTC (ABS control system DTC) is output B B REPAIR CIRCUIT INDICATED BY OUTPUT DTC (See page BC-151) A 2 RECONFIRM DTC (a) Clear the DTC (See page BC-141). (b) Turn the ignition switch on (IG). (c) Check if the same DTC is recorded (See page BC-141). Result Condition Proceed to DTC (43) is not output A DTC (43) is output B B A USE SIMULATION METHOD TO CHECK REPLACE BRAKE ACTUATOR ASSEMBLY BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–161 DTC C0200/31 Front Speed Sensor RH Circuit DTC C0205/32 Front Speed Sensor LH Circuit DTC C1271/71 Low Output Signal of Front Speed Sensor RH (Test Mode DTC) DTC C1272/72 Low Output Signal of Front Speed Sensor LH (Test Mode DTC) DESCRIPTION The speed sensors detect wheel speed and transmit the signals to the ECU. These signals are used for control of the ABS control system. Each of the front and rear rotors have 48 serrations. When the rotors rotate, the magnetic field generated by the permanent magnet in the speed sensor induces an AC voltage. Since the frequency of this AC voltage changes in direct proportion to the speed of the rotor, the frequency is used by the ECU to detect the speed of each wheel. DTCs C1271/71 and C1272/72 can be deleted when the speed sensor sends a wheel speed signal or the Test Mode ends. DTCs C1271/71 and C1272/72 are output only in the Test Mode. Speed Sensor Rotor Coil N S Magnet To ECU Low speed High speed +V -V F000010E04 DTC No. DTC Detection Condition C0200/31 C0205/32 When any of the following is detected: 1. At a vehicle speed of 6 mph (10 km/h) or more, an open or short in the sensor signal circuit continues for 1 second or more. 2. Momentary interruption of the sensor signal from the abnormal wheel occurs 7 times or more. 3. An open in the speed sensor signal circuit continues for 0.5 seconds or more. HINT: • DTC C0200/31 is for the front speed sensor RH. • DTC C0205/32 is for the front speed sensor LH. Trouble Area • • • • • Front speed sensor RH/LH Speed sensor circuit Speed sensor rotor Sensor installation Brake actuator assembly (Skid control ECU) BC BC–162 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) WIRING DIAGRAM Brake Actuator Assembly - Skid Control ECU Front Speed Sensor RH 2 3 1 17 FR+ FR- Front Speed Sensor LH BC 2 18 1 4 FL+ FL- C132772E05 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). 1 CHECK HARNESS AND CONNECTOR (MOMENTARY INTERRUPTION) (a) Using the intelligent tester, check for any momentary interruption in the wire harness and connector corresponding to a DTC (See page BC-118). ABS / VSC: Item (Display) Measurement Item / Range (Display) Normal Condition FR SPD OPN FR speed sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal FL SPD OPN FL speed sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal Result Condition Proceed to There are no momentary interruptions A There are momentary interruptions B There is a constant open circuit C HINT: Perform the above inspection before removing the sensor and connector. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) B Go to step 11 C Go to step 5 BC–163 A 2 READ VALUE OF INTELLIGENT TESTER (FRONT SPEED SENSOR) (a) (b) (c) (d) Turn the ignition switch off. Connect the intelligent tester to the DLC3. Start the engine. Select the Data List mode on the intelligent tester. ABS / VSC: Item (Display) Measurement Item / Range (Display) Normal Condition FR WHEEL SPD FR wheel speed sensor reading / min.: 0 mph (0 km/ h), max.: 202 mph (326 km/h) Actual wheel speed FL WHEEL SPD FL wheel speed sensor reading /min.: 0 mph (0 km/h), max.: 202 mph (326 km/h) Actual wheel speed (e) Check that there is no difference between the speed value output from the speed sensor displayed on the intelligent tester and the speed value displayed on the speedometer when driving the vehicle. OK: The speed value output from the speed sensor displayed on the intelligent tester is the same as the actual vehicle speed. NG Go to step 5 OK 3 PERFORM TEST MODE (SIGNAL CHECK) (a) Perform sensor check in the Test Mode procedure (See page BC-123). OK: All Test Mode DTCs are erased. NG Go to step 5 OK 4 RECONFIRM DTC (a) (b) (c) (d) Turn the ignition switch off. Clear the DTC (See page BC-141). Start the engine. Drive the vehicle at the speed of 20 mph (32 km/h) or more for at least 60 seconds. (e) Check if the same DTC is recorded (See page BC-141). BC BC–164 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) Result Condition Proceed to DTCs (C0200/31 and/or C0205/32) are not output A DTCs (C0200/31 and/or C0205/32) are output B HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step (See page BC-134). B Go to step 7 A USE SIMULATION METHOD TO CHECK BC 5 CHECK FRONT SPEED SENSOR INSTALLATION (a) Turn the ignition switch off. (b) Check the speed sensor installation. OK: There is no clearance between the sensor and the front steering knuckle. The installation bolt is tightened properly. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) Front Speed Sensor: 8.0 N*m (82 kgf*cm, 71 in.*lbf) OK No clearance NG BR03795E52 NG INSTALL FRONT SPEED SENSOR CORRECTLY OK 6 CHECK FRONT SPEED SENSOR TIP (a) Remove the front speed sensor (See page BC-438). (b) Check the speed sensor tip. OK: No scratches or foreign matter on the sensor tip. NOTICE: Check the speed sensor signal after cleaning or replacement (See page BC-123). NG OK CLEAN OR REPLACE FRONT SPEED SENSOR BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 7 BC–165 INSPECT FRONT SPEED SENSOR (a) (b) (c) (d) Front Speed Sensor: 1 2 Turn the ignition switch off. Install the front speed sensor. Disconnect the front speed sensor connector. Measure the resistance according to the value(s) in the table below. Standard resistance: RH Tester Connection Condition Specified Condition 1 (FR+) - 2 (FR-) Always 1.4 to 1.8 kΩ at 20°C (68 °F) 1 (FR+) - Body ground Always 10 kΩ or higher 2 (FR-) - Body ground Always 10 kΩ or higher Tester Connection Condition Specified Condition 1 (FL+) - 2 (FL-) Always 1.4 to 1.8 kΩ at 20°C (68 °F) 1 (FL+) - Body ground Always 10 kΩ or higher 2 (FL-) - Body ground Always 10 kΩ or higher LH C136017E01 NOTICE: Check the speed sensor signal after replacement (See page BC-123). NG OK REPLACE FRONT SPEED SENSOR BC BC–166 8 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - FRONT SPEED SENSOR) (a) Disconnect the skid control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: RH Skid Control ECU Harness Side Connector Front View: A26 FR+ FL- Tester Connection Condition Specified Condition A26-3 (FR+) - A35-1 (FR+) Always Below 1 Ω A26-3 (FR+) - Body ground Always 10 kΩ or higher A26-17 (FR-) - A35-2 (FR-) Always Below 1 Ω A26-17 (FR-) - Body ground Always 10 kΩ or higher Tester Connection Condition Specified Condition A26-18 (FL+) - A14-1 (FL+) Always Below 1 Ω A26-18 (FL+) - Body ground Always 10 kΩ or higher A26-4 (FL-) - A14-2 (FL-) Always Below 1 Ω A26-4 (FL-) - Body ground Always 10 kΩ or higher LH FR- BC FL+ Front Speed Sensor Harness Side Connector Front View: A35 A14 NG FR- FR+ FL- FL+ C136018E01 OK REPAIR OR REPLACE HARNESS OR CONNECTOR BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 9 CHECK SPEED SENSOR AND SPEED SENSOR ROTOR SERRATIONS (a) Reconnect the front speed sensor connector. (b) Connect the oscilloscope to the front speed sensor terminal of the skid control ECU. (c) Check that a waveform is output when the tires are rotated. OK: The same waveform is output from all the 4 wheels and there is no noise or interference in the waveform. HINT: • As the vehicle speed (wheel revolution speed) increases, a cycle of the waveform narrows and the output voltage becomes greater. • When noise is identified in the waveform on the oscilloscope, the erratic signals are generated due to speed sensor rotor's scratches, looseness or foreign matter attached to it. Skid Control ECU Harness Side Connector Front View: A26 BC–167 FR+ FR- FL- FL+ Normal Signal Waveform: NG REPLACE BRAKE ACTUATOR ASSEMBLY GND 1 V/Division, 2 ms/Division C136019E04 OK 10 RECONFIRM DTC (a) (b) (c) (d) Reconnect the skid control ECU connector. Clear the DTC (See page BC-141). Start the engine. Drive the vehicle at the speed of 20 mph (32 km/h) or more for at least 60 seconds. (e) Check if the same DTC is recorded (See page BC-141). Result Condition Proceed to DTCs (C0200/31 and/or C0205/32) are output A DTCs (C0200/31 and/or C0205/32) are not output B HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step (See page BC-134). B USE SIMULATION METHOD TO CHECK BC BC–168 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) A REPLACE BRAKE ACTUATOR ASSEMBLY 11 REPAIR OR REPLACE HARNESS OR CONNECTOR (SKID CONTROL ECU - FRONT SPEED SENSOR) (a) Turn the ignition switch off. (b) Repair or replace the harness or connector. (c) Check for any momentary interruption between the skid control ECU and front speed sensor (See page BC-118). (d) Check that there is no momentary interruption. NEXT BC 12 RECONFIRM DTC (a) Clear the DTC (See page BC-141). (b) Start the engine. (c) Drive the vehicle at the speed of 20 mph (32 km/h) or more for at least 60 seconds. (d) Check if the same DTC is recorded (See page BC-141). Result Condition Proceed to DTCs (C0200/31 and/or C0205/32) are not output A DTCs (C0200/31 and/or C0205/32) are output B HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step (See page BC-134). B A END Go to step 2 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–169 DTC C0210/33 Rear Speed Sensor RH Circuit DTC C0215/34 Rear Speed Sensor LH Circuit DTC C1273/73 Low Output Signal of Rear Speed Sensor RH (Test Mode DTC) DTC C1274/74 Low Output Signal of Rear Speed Sensor LH (Test Mode DTC) DESCRIPTION The speed sensors detect wheel speed and transmit the signals to the ECU. These signals are used for control of the ABS control system. Each of the front and rear rotors have 48 serrations. When the rotors rotate, the magnetic field generated by the permanent magnet in the speed sensor induces an AC voltage. Since the frequency of this AC voltage changes in direct proportion to the speed of the rotor, the frequency is used by the ECU to detect the speed of each wheel. DTCs C1273/73 and C1274/74 can be deleted when the speed sensor sends a wheel speed signal or the Test Mode ends. DTCs C1273/73 and C1274/74 are output only in the Test Mode. Speed Sensor Rotor Coil N S Magnet To ECU Low speed High speed +V -V F000010E04 DTC No. DTC Detection Condition C0210/33 C0215/34 When any of the following is detected: 1. At a vehicle speed of 6 mph (10 km/h) or more, an open or short in the sensor signal circuit continues for 1 second or more. 2. Momentary interruption of the sensor signal from the abnormal wheel occurs 7 times or more. 3. An open in the speed sensor signal circuit continues for 0.5 seconds or more. HINT: • DTC C0210/33 is for the rear speed sensor RH. • DTC C0215/34 is for the rear speed sensor LH. Trouble Area • • • • • Rear speed sensor RH/LH Speed sensor circuit Speed sensor rotor Sensor installation Brake actuator assembly (Skid control ECU) BC BC–170 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) WIRING DIAGRAM Brake Actuator Assembly - Skid Control ECU Rear Speed Sensor RH 2 5 1 19 RR+ RR- Rear Speed Sensor LH BC 2 20 1 6 RL+ RL- C132772E06 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). 1 CHECK HARNESS AND CONNECTOR (MOMENTARY INTERRUPTION) (a) Using the intelligent tester, check for any momentary interruption in the wire harness and connector corresponding to a DTC (See page BC-118). ABS / VSC: Item (Display) Measurement Item / Range (Display) Normal Condition RR SPD OPN RR speed sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal RL SPD OPN RL speed sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal Result Condition Proceed to There are no momentary interruptions A There are momentary interruptions B There is a constant open circuit C HINT: Perform the above inspection before removing the sensor and connector. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) B Go to step 11 C Go to step 5 BC–171 A 2 READ VALUE OF INTELLIGENT TESTER (REAR SPEED SENSOR) (a) (b) (c) (d) Turn the ignition switch off. Connect the intelligent tester to the DLC3. Start the engine. Select the Data List mode on the intelligent tester. ABS / VSC: Item (Display) Measurement Item / Range (Display) Normal Condition RR WHEEL SPD RR wheel speed sensor reading / min.: 0 mph (0 km/ h), max.: 202 mph (326 km/h) Actual wheel speed RL WHEEL SPD RL wheel speed sensor reading / min.: 0 mph (0 km/ h), max.: 202 mph (326 km/h) Actual wheel speed (e) Check that there is no difference between the speed value output from the speed sensor displayed on the intelligent tester and the speed value displayed on the speedometer when driving the vehicle. OK: The speed value output from the speed sensor displayed on the intelligent tester is the same as the actual vehicle speed. NG Go to step 5 OK 3 PERFORM TEST MODE (SIGNAL CHECK) (a) Perform sensor check in the Test Mode procedure (See page BC-123). OK: All Test Mode DTCs are erased. NG Go to step 5 OK 4 RECONFIRM DTC (a) (b) (c) (d) Turn the ignition switch off. Clear the DTC (See page BC-141). Start the engine. Drive the vehicle at the speed of 20 mph (32 km/h) or more for at least 60 seconds. (e) Check if the same DTC is recorded (See page BC-141). BC BC–172 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) Result Condition Proceed to DTCs (C0210/33 and/or C0215/34) are not output A DTCs (C0210/33 and/or C0215/34) are output B HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step (See page BC-134). B Go to step 6 A USE SIMULATION METHOD TO CHECK BC 5 CHECK REAR SPEED SENSOR INSTALLATION (a) Turn the ignition switch off. (b) Check the speed sensor installation. OK: There is no clearance between the sensor and rear axle carrier. Rear Speed Sensor: NG No Clearance OK INSTALL REAR SPEED SENSOR CORRECTLY NG F010178E22 OK 6 INSPECT REAR SPEED SENSOR (a) Turn the ignition switch off. (b) Disconnect the rear speed sensor connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: RH Rear Speed Sensor: Tester Connection 1 Condition Specified Condition 2 (RR+) - 1 (RR-) Always 0.9 to 2.1 kΩ 2 (RR+) - Body ground Always 10 kΩ or higher 1 (RR-) - Body ground Always 10 kΩ or higher Tester Connection Condition Specified Condition LH 2 C113377E02 2 (RL+) - 1 (RL-) Always 0.9 to 2.1 kΩ 2 (RL+) - Body ground Always 10 kΩ or higher 1 (RL-) - Body ground Always 10 kΩ or higher BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–173 NOTICE: Check the speed sensor signal after replacement (See page BC-123). NG REPLACE REAR SPEED SENSOR OK 7 CHECK HARNESS AND CONNECTOR (SKID CONTROL SENSOR WIRE) Skid Control Sensor Wire: f1 :RH Vehicle Side Connector "B" (a) Disconnect the skid control sensor wire. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: RH g1 :LH Sensor Side Connector "A" Tester Connection Condition Specified Condition f1 ("A"-1) - f1 ("B"-2) Always Below 1 Ω f1 ("A"-1) - f1 ("B"-1) Always 10 kΩ or higher f1 ("A"-1) - Body ground Always 10 kΩ or higher f1 ("A"-2) - f1 ("B"-1) Always Below 1 Ω f1 ("A"-2) - f1 ("B"-2) Always 10 kΩ or higher f1 ("A"-2) - Body ground Always 10 kΩ or higher LH C136026E01 Tester Connection Condition Specified Condition g1 ("A"-1) - g1 ("B"-2) Always Below 1 Ω g1 ("A"-1) - g1 ("B"-1) Always 10 kΩ or higher g1 ("A"-1) - Body ground Always 10 kΩ or higher g1 ("A"-2) - g1 ("B"-1) Always Below 1 Ω g1 ("A"-2) - g1 ("B"-2) Always 10 kΩ or higher g1 ("A"-2) - Body ground Always 10 kΩ or higher NOTICE: Check the speed sensor signal after replacement (See page BC-123). NG OK REPLACE SKID CONTROL SENSOR WIRE BC BC–174 8 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - REAR SPEED SENSOR) (a) Disconnect the skid control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: RH Skid Control ECU Harness Side Connector Front View: RR+ A26 RL- RR- BC Tester Connection Condition A26-5 (RR+) - f1-1 (RR+) Always Below 1 Ω A26-5 (RR+) - Body ground Always 10 kΩ or higher A26-19 (RR-) - f1-2 (RR-) Always Below 1 Ω A26-19 (RR-) - Body ground Always 10 kΩ or higher Tester Connection Condition Specified Condition A26-20 (RL+) - g1-1 (RL+) Always Below 1 Ω A26-20 (RL+) - Body ground Always 10 kΩ or higher A26-6 (RL-) - g1-2 (RL-) Always Below 1 Ω A26-6 (RL-) - Body ground Always 10 kΩ or higher LH RL+ Rear Speed Sensor Harness Side Connector Front View: g1 f1 NG RR- RR+ RL- RL+ C136020E01 OK Specified Condition REPAIR OR REPLACE HARNESS OR CONNECTOR BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 9 CHECK SPEED SENSOR AND SPEED SENSOR ROTOR SERRATIONS (a) Reconnect the skid control sensor wire. (b) Reconnect the rear speed sensor connector. (c) Connect the oscilloscope to the rear speed sensor terminal of the skid control ECU. (d) Check that a waveform is output when the tires are rotated. OK: The same waveform is output from all the 4 wheels and there is no noise or interference in the waveform. HINT: • As the vehicle speed (wheel revolution speed) increases, a cycle of the waveform narrows and the output voltage becomes greater. • When noise is identified in the waveform on the oscilloscope, the erratic signals are generated due to speed sensor rotor's scratches, looseness or foreign matter attached to it. Skid Control ECU Harness Side Connector Front View: A26 BC–175 RR+ RL- RR- RL+ Normal Signal Waveform: NG REPLACE BRAKE ACTUATOR ASSEMBLY GND 1 V/Division, 2 ms/Division C136019E02 OK 10 RECONFIRM DTC (a) (b) (c) (d) Reconnect the skid control ECU connector. Clear the DTC (See page BC-141). Start the engine. Drive the vehicle at the speed of 20 mph (32 km/h) or more for at least 60 seconds. (e) Check if the same DTC is recorded (See page BC-141). Result Condition Proceed to DTCs (C0210/33 and/or C0215/34) are output A DTCs (C0210/33 and/or C0215/34) are not output B HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step (See page BC-134). B USE SIMULATION METHOD TO CHECK BC BC–176 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) A REPLACE BRAKE ACTUATOR ASSEMBLY 11 REPAIR OR REPLACE HARNESS OR CONNECTOR (SKID CONTROL ECU - REAR SPEED SENSOR) (a) Turn the ignition switch off. (b) Repair or replace the harness or connector. (c) Check for any momentary interruption between the skid control ECU and rear speed sensor (See page BC-118). (d) Check that there is no momentary interruption. NEXT BC 12 RECONFIRM DTC (a) Clear the DTC (See page BC-141). (b) Start the engine. (c) Drive the vehicle at the speed of 20 mph (32 km/h) or more for at least 60 seconds. (d) Check if the same DTC is recorded (See page BC-141). Result Condition Proceed to DTCs (C0210/33 and/or C0215/34) are not output A DTCs (C0210/33 and/or C0215/34) are output B HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step (See page BC-134). B A END Go to step 2 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DTC C0226/21 SFR Solenoid Circuit DTC C0236/22 SFL Solenoid Circuit DTC C0246/23 SRR Solenoid Circuit DTC C0256/24 SRL Solenoid Circuit DTC C1225/25 SM Solenoid Circuit BC–177 DESCRIPTION These solenoids turn on when signals are received from the skid control ECU and they control the pressure acting on the wheel cylinders to control the braking force. DTC No. DTC Detection Condition C0226/21 C0236/22 C0246/23 C0256/24 Trouble Area Open or short in the solenoid circuit continues for 0.05 seconds or more. • • Brake actuator assembly Solenoid circuit C1225/25 When any of the following is detected: • While outputting switching solenoid (SM1 or SM2) ON, overcurrent continues for 0.05 seconds or more. • While outputting switching solenoid (SM1 or SM2) OFF, an open circuit continues for 0.05 seconds or more. • While outputting switching solenoid (SM1 or SM2) ON, an open circuit continues for 0.1 second or more. • While outputting switching solenoid (SM1 or SM2) OFF, current continues to be applied for 0.1 second or more. • Short to GND in the switching solenoid (SM1 or SM2) continues for 0.1 second or more. • Switching solenoids SM1 and SM2 are shorted for 0.1 second or more. • • Brake actuator assembly SM1 or SM2 circuit BC BC–178 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) WIRING DIAGRAM Brake Actuator Assembly Skid Control ECU ALT ABS NO. 2 Solenoid Relay 31 +BS SFRH SFLH BC SRRH SRLH SFRR SFLR 32 GND1 SRRR SRLR FL MAIN 1 Battery GND2 SM1 SM2 C136021E01 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 1 BC–179 RECONFIRM DTC HINT: These codes are detected when a problem is determined in the brake actuator assembly. The solenoid circuits are in the brake actuator assembly. Therefore, solenoid circuit inspection and solenoid unit inspection cannot be performed. Be sure to check if any DTC code is output before replacing the brake actuator assembly. (a) Clear the DTC (See page BC-141). (b) Start the engine. (c) Drive the vehicle at the speed of 4 mph (6 km/h) or more. (d) Check if the same DTC is recorded (See page BC-141). Result Condition Proceed to DTCs (C0226/21, C0236/22, C0246/23, C0256/24 and/or C1225/25) are not output A DTCs (C0226/21, C0236/22, C0246/23, C0256/24 and/or C1225/25) are output B HINT: • If a speed signal of 4 mph (6 km/h) or more is input to the skid control ECU, with the ignition switch on (IG) and the stop light switch off, the ECU performs self diagnosis of the motor and solenoid circuits. • If the normal system code is output (the trouble code is not output), slightly jiggle the connectors, wire harness, and fuses of the brake actuator assembly. Make sure that no DTCs are output. • If any DTCs are output while jiggling a connector or wire harness of the brake actuator assembly (skid control ECU), inspect and repair the connector or wire harness. B A USE SIMULATION METHOD TO CHECK REPLACE BRAKE ACTUATOR ASSEMBLY BC BC–180 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DTC C0273/13 Open in ABS Motor Relay Circuit DTC C0274/14 Short to B+ in ABS Motor Relay Circuit DTC C1361/91 Short Circuit in ABS Motor Fail Safe Relay Circuit DESCRIPTION If a DTC of the motor line is stored, the VSC NO. 1 (fail safe) relay cuts off the power supply to the VSC NO. 2 relay and performs fail safe. While any of the ABS, TRAC, VSC, or BA is operating, the skid control ECU (housed in the actuator assembly) turns the VSC NO. 2 relay on and activates the pump motor in the brake actuator. This code may be stored if the motor relay (BM) voltage becomes lower than the DTC detecting condition due to insufficient output from the battery or alternator. DTC No. DTC Detection Condition C0273/13 When any of the following (1 or 2) is detected: 1. All of the following conditions continue for 0.12 seconds or more. • The IG1 terminal voltage is between 9.5 and 17.2 V. • During initial check and ABS, BA, TRAC, or VSC are operating. • Relay contact is open when the relay is ON. 2. All of the following conditions continue for 0.12 seconds. • The IG1 terminal voltage is 9.5 V or less. • Relay contact remains open when the relay is ON. • • • • ABS NO. 1 fuse VSC NO. 2 relay VSC NO. 2 relay circuit Brake actuator assembly C0274/14 When the motor relay is OFF, the VSC NO. 2 relay remains closed for 4 seconds or more. • • • • ABS NO. 1 fuse VSC NO. 2 relay VSC NO. 2 relay circuit Brake actuator assembly C1361/91 Immediately after the ignition switch is turned on (IG), the relay contact is closed for 4 seconds when the VSC NO. 1 (fail safe) relay is OFF. • • • • ABS NO. 1 fuse VSC NO. 1 (fail safe) relay VSC NO. 1 (fail safe) relay circuit Brake actuator assembly BC Trouble Area BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–181 WIRING DIAGRAM Brake Actuator Assembly R+ VSC NO. 1 (Fail Safe) 45 MRF 1 2 5 3 14 BC VSC NO. 2 MR ABS NO. 1 1 2 3 5 ALT 15 BM 2 Pump Motor FL MAIN Battery Skid Control ECU GND2 1 C136022E01 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). BC–182 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) INSPECT ABS NO. 1 FUSE (a) Remove the fusible link from the engine room R/B. Engine Room R/B: Fusible Link ABS NO. 1 (50 A) Fuse BC C136500E06 (b) Check if the fusible link is melted. OK: The fusible link is melted. (c) Install the fusible link to the engine room R/B with the nut. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) Fusible Link: NG ABS NO. 1 E130412E02 OK REPLACE FUSIBLE LINK (ABS NO. 1 FUSE) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 2 BC–183 INSPECT VSC NO. 2 RELAY (a) Remove the VSC NO. 2 relay. (b) Measure the resistance according to the value(s) in the table below. Standard resistance VSC NO. 2 Relay: F050240E07 Tester Connection Condition Specified Condition 3-5 Always 10 kΩ or higher 3-5 Apply B+ between terminals 1 and 2 Below 1 Ω NG REPLACE VSC NO. 2 RELAY OK 3 INSPECT VSC NO. 1 (FAIL SAFE) RELAY BC (a) Remove the VSC NO. 1 (fail safe) relay. (b) Measure the resistance according to the value(s) in the table below. Standard resistance VSC NO. 1 (Fail Safe) Relay: F050241E11 Tester Connection Condition Specified Condition 3-5 Always 10 kΩ or higher 3-5 Apply B+ between terminals 1 and 2 Below 1 Ω NG REPLACE VSC NO. 1 (FAIL SAFE) RELAY OK 4 INSPECT ENGINE ROOM RELAY BLOCK (POWER SOURCE TERMINAL) Engine Room R/B: VSC NO. 1 (Fail Safe) Relay (a) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition VSC NO. 1 (fail safe) relay terminal 5 Body ground Always 10 to 14 V NG C135809E01 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (POWER SOURCE CIRCUIT) BC–184 5 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) INSPECT ENGINE ROOM RELAY BLOCK Engine Room R/B: VSC NO. 1 (Fail Safe) Relay (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition VSC NO. 1 (fail safe) relay terminal 3 VSC NO. 2 relay terminal 5 Always Below 1 Ω VSC NO. 1 (fail safe) relay terminal 3 Body ground Always 10 kΩ or higher VSC NO. 2 Relay NG BC REPAIR OR REPLACE ENGINE ROOM RELAY BLOCK C135809E02 OK 6 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - ENGINE ROOM RELAY BLOCK) (a) Disconnect the skid control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: A26 BM Engine Room R/B: MRF R+ MR VSC NO. 1 (Fail Safe) Relay Tester Connection Condition Specified Condition A26-2 (BM) - VSC NO. 2 relay terminal 3 Always Below 1 Ω A26-2 (BM) - Body ground Always 10 kΩ or higher A26-14 (MRF) - VSC NO. 1 (fail safe) relay terminal 2 Always Below 1 Ω A26-14 (MRF) - Body ground Always 10 kΩ or higher A26-15 (MR) - VSC NO. 2 relay terminal 2 Always Below 1 Ω A26-15 (MR) - Body ground Always 10 kΩ or higher A26-45 (R+) - VSC NO. 1 (fail safe) relay terminal 1 Always Below 1 Ω A26-45 (R+) - Body ground Always 10 kΩ or higher NG VSC NO. 2 Relay C136023E03 REPAIR OR REPLACE HARNESS OR CONNECTOR BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–185 OK 7 RECONFIRM DTC (a) (b) (c) (d) Clear the DTC (See page BC-141). Start the engine. Drive the vehicle at the speed of 4 mph (6 km/h) or more. Check if the same DTC is recorded (See page BC-141). HINT: Reinstall the relays, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTCs (C0273/13, C0274/14 and/or C1361/91) are not output A DTCs (C0273/13, C0274/14 and/or C1361/91) are output B HINT: • If a speed signal of 4 mph (6 km/h) or more is input to the skid control ECU, with the ignition switch on (IG) and the stop light switch off, the ECU performs self diagnosis of the motor and solenoid circuits. • If the normal system code is output (the trouble code is not output), slightly jiggle the connectors, wire harness, and fuses of the brake actuator assembly. Make sure that no DTCs are output. • If any DTCs are output while jiggling a connector or wire harness of the brake actuator assembly (skid control ECU), inspect and repair the connector or wire harness. B A USE SIMULATION METHOD TO CHECK REPLACE BRAKE ACTUATOR ASSEMBLY BC BC–186 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DTC C0278/11 Open in ABS Solenoid Relay Circuit DTC C0279/12 Short to B+ in ABS Solenoid Relay Circuit DESCRIPTION The ABS solenoid relay supplies power to the ABS solenoid and TRAC solenoid. The solenoid relay is turned on 1.5 seconds after the ignition switch is turned on (IG), and is turned off if an open or short in the solenoid is detected by self diagnosis performed when the vehicle starts running. The ABS solenoid relay is housed in the skid control ECU in the actuator assembly. HINT: If a speed signal of 4 mph (6 km/h) or more is input to the skid control ECU, with the ignition switch on (IG) and the stop light switch off, the ECU performs self diagnosis of the motor and solenoid circuits. DTC No. BC DTC Detection Condition Trouble Area C0278/11 When any of the following (1 or 2) is detected: 1. Both of the following conditions continue for 0.2 seconds or more. • The IG1 terminal voltage is between 9.5 and 17.2 V. • The solenoid relay contact is open when the relay is ON. 2. Both of the following conditions continue for 0.2 seconds or more. • IG1 terminal voltage becomes lower than 9.5 V or less when the relay is turned on. • The relay contact remains open. • • • • C0279/12 Immediately after the ignition switch is turned on (IG), the solenoid relay contact is closed for 0.2 seconds when the relay is turned off. Brake actuator assembly ABS NO. 2 fuse ABS solenoid relay ABS solenoid relay circuit Brake actuator assembly BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–187 WIRING DIAGRAM Brake Actuator Assembly Skid Control ECU ALT ABS NO. 2 Solenoid Relay 31 +BS SFRH SFLH BC SRRH SRLH SFRR SFLR 32 GND1 SRRR SRLR FL MAIN 1 Battery GND2 SM1 SM2 C136021E01 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). BC–188 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) INSPECT ABS NO. 2 FUSE (a) Remove the fusible link from the engine room R/B. Engine Room R/B: Fusible Link ABS NO. 2 (30 A) Fuse BC C136500E07 (b) Check if the fusible link is melted. OK: The fusible link is melted. (c) Install the fusible link to the engine room R/B with the nut. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) Fusible Link: NG ABS NO. 2 E130412E03 OK REPLACE FUSIBLE LINK (ABS NO. 2 FUSE) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 2 BC–189 INSPECT SKID CONTROL ECU (+BS TERMINAL) (a) Disconnect the skid control ECU connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control ECU Harness Side Connector Front View: A26 Tester Connection Condition Specified Condition A26-31 (+BS) - Body ground Always 10 to 14 V NG +BS F049362E96 REPAIR OR REPLACE HARNESS OR CONNECTOR (+BS CIRCUIT) OK 3 INSPECT SKID CONTROL ECU (GND TERMINAL) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: A26 Tester Connection Condition Specified Condition A26-32 (GND1) - Body ground Always Below 1 Ω A26-1 (GND2) - Body ground Always Below 1 Ω NG GND2 GND1 F049362E97 REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) OK 4 RECONFIRM DTC (a) (b) (c) (d) (e) Reconnect the skid control ECU connector. Clear the DTC (See page BC-141). Start the engine. Drive the vehicle at the speed of 4 mph (6 km/h) or more. Check if the same DTC is recorded (See page BC-141). Result Condition Proceed to DTCs (C0278/11 and/or C0279/12) are not output A DTCs (C0278/11 and/or C0279/12) are output B HINT: • If a speed signal of 4 mph (6 km/h) or more is input to the skid control ECU, with the ignition switch on (IG) and the stop light switch off, the ECU performs self diagnosis of the motor and solenoid circuits. • If the normal system code is output (the trouble code is not output), slightly jiggle the connectors, wire harnesses, and fuses of the brake actuator assembly. Make sure that no DTCs are output. BC BC–190 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) • If any DTCs are output while jiggling a connector or wire harness of the brake actuator assembly (skid control ECU), inspect and repair the connector or wire harness. B A USE SIMULATION METHOD TO CHECK BC REPLACE BRAKE ACTUATOR ASSEMBLY BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DTC BC–191 C1201/51 Engine Control System Malfunction DESCRIPTION If a malfunction in the engine control system is detected, the operations of VSC and TRAC are prohibited by the fail safe function. When the signals from the engine are input normally, the fail safe is cancelled and the DTC is not stored. DTC No. C1201/51 DTC Detection Condition Trouble Area Engine control system malfunction signal continues for 5 seconds. Engine control system INSPECTION PROCEDURE 1 CHECK ENGINE CONTROL SYSTEM (a) Check if the engine control system DTC is output (See page ES-45 for 2GR-FE, or ES-38 for 2AZ-FE). Result Condition Proceed to DTC is not output A DTC is output B B A REPLACE ECM INSPECT ENGINE CONTROL SYSTEM BC BC–192 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DTC C1203/53 ECM Communication Circuit Malfunction DESCRIPTION The circuit is used to send TRAC and VSC control information from the skid control ECU to the ECM, and engine control information from the ECM to the skid control ECU. DTC No. DTC Detection Condition C1203/53 Engine, drive source and destination variations that are sent from the ECM do not match the ones of the skid control ECU. Trouble Area ECM INSPECTION PROCEDURE 1 CHECK PART NUMBER (ECM AND BRAKE ACTUATOR ASSEMBLY) (a) Check that the proper ECM and brake actuator assembly (skid control ECU) are installed. OK: Proper ECUs are installed. BC NG OK REPLACE ECM REPLACE ECUS WITH PROPER ONES BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–193 DTC C1210/36 Zero Point Calibration of Yaw Rate Sensor Undone DTC C1336/39 Zero Point Calibration of Acceleration Sensor Undone DESCRIPTION The skid control ECU receives signals from the yaw rate and acceleration sensor via the CAN communication system. The yaw rate sensor has the built in acceleration sensor and detects the vehicle's condition using 2 circuits (GL1, GL2). If there is trouble in the bus lines between the yaw rate and acceleration sensor and the CAN communication system, the DTCs U0123/62 (yaw rate sensor communication trouble) and U0124/95 (acceleration sensor communication trouble) are output. The DTCs are also output when the calibration has not been completed. DTC No. DTC Detection Condition C1210/36 Zero point calibration of yaw rate sensor undone. C1336/39 When either of the following is detected: 1. The vehicle runs in the normal mode with zero point calibration undone. 2. After the zero point has been obtained, the zero point voltage of the sensor is not between 2.38 and 2.62 V. Trouble Area • • • Brake actuator assembly (Skid control ECU) Yaw rate and acceleration sensor Zero point calibration undone (Perform zero point calibration and check DTC. If DTC is not output again, the sensor is normal) • • • Brake actuator assembly (Skid control ECU) Yaw rate and acceleration sensor Zero point calibration undone (Perform zero point calibration and check DTC. If DTC is not output again, the sensor is normal) INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). HINT: When U0123/62, U0124/95 or U0126/63 is output along with C1210/36 or C1336/39, inspect and repair trouble areas indicated by U0123/62, U0124/95 or U0126/63 first. 1 PERFORM ZERO POINT CALIBRATION OF YAW RATE AND ACCELERATION SENSOR (a) Perform zero point calibration of the yaw rate and acceleration sensor (See page BC-119). NEXT 2 RECONFIRM DTC (a) Clear the DTC (See page BC-141). (b) Check if the same DTCs are recorded (See page BC141). Result Condition Proceed to DTCs (C1210/36 and/or C1336/39) are output A DTCs (C1210/36 and/or C1336/39) are not output B BC BC–194 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) HINT: • The DTCs are recorded because zero point calibration has not been completed. • End the procedure as the same DTCs are not recorded after completion of zero point calibration. B END A 3 CHECK YAW RATE AND ACCELERATION SENSOR INSTALLATION (a) Turn the ignition switch off. (b) Check that the yaw rate and acceleration sensor has been installed properly (See page BC-448). OK: The sensor should be tightened to the specified torque. The sensor should not be tilted. BC NG OK REPLACE BRAKE ACTUATOR ASSEMBLY INSTALL YAW RATE AND ACCELERATION SENSOR CORRECTLY BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DTC BC–195 C1231/31 Steering Angle Sensor Circuit Malfunction DESCRIPTION The steering angle sensor signal is sent to the skid control ECU via the CAN communication system. When there is a malfunction in the CAN communication system, it will be detected by the steering angle sensor zero point malfunction diagnostic function. DTC No. DTC Detection Condition Trouble Area When ECU IG1 terminal voltage is 9.5 V or more, the steering angle sensor malfunction signal is received. C1231/31 • • • • Steering angle sensor Steering angle sensor circuit Steering angle sensor power supply Brake actuator assembly (Skid control ECU) WIRING DIAGRAM Brake Actuator Assembly CANL CANH BAT BC - Skid Control ECU Steering Angle Sensor 9 25 10 11 CANL CANH ECU-B NO. 1 3 2 1 From Battery IG1 IG ESS ECU-IG NO. 2 1 3 5 2 1 2 (*1): without Smart Key System From Ignition Switch (*1), Main Body ECU (*2) (*2): with Smart Key System C136024E04 INSPECTION PROCEDURE HINT: • When U0073/94, U0123/62, U0124/95 or U0126/63 is output together with C1231/31, inspect and repair the trouble areas indicated by U0073/94, U0123/62, U0124/95 or U0126/63 first. BC–196 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) • When the speed sensor or the yaw rate sensor has trouble, DTCs for the steering angle sensor may be output even when the steering angle sensor is normal. When DTCs for the speed sensor or yaw rate sensor are output together with other DTCs for the steering angle sensor, inspect and repair the speed sensor and yaw rate sensor first, and then inspect and repair the steering angle sensor. 1 CHECK DTC (a) Clear the DTC (See page BC-141). (b) Turn the ignition switch off. (c) Turn the ignition switch on (IG) again and check that no CAN communication system DTC is output. (d) Drive the vehicle and turn the steering wheel to the right and left at the speed of 22 mph (35 km/h) and check that no speed sensor and yaw rate sensor DTCs are output. Result BC Condition Proceed to No CAN communication system DTC and the speed sensor or yaw rate sensor DTC are output A CAN communication system DTC is output B Speed sensor or yaw rate sensor DTC is output C HINT: • If there is a malfunction in the speed sensor or the yaw rate sensor, an abnormal value may be output although the steering angle sensor is normal. • If the speed sensor and the yaw rate sensor DTCs are output simultaneously, repair the sensors and inspect the steering angle sensor. B INSPECT CAN COMMUNICATION SYSTEM C REPAIR CIRCUIT INDICATED BY OUTPUT DTC (See page BC-151) A 2 INSPECT STEERING ANGLE SENSOR (POWER SOURCE TERMINAL) (a) (b) (c) (d) Steering Angle Sensor Wire Harness View: E17-1 (IG) Turn the ignition switch off. Remove the steering wheel and the column cover lower. Disconnect the steering angle sensor connector. Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition E17-1 (IG) - Body ground Ignition switch on (IG) 10 to 14 V E17-3 (BAT) - Body ground Always 10 to 14 V NG E17-3 (BAT) G030156E15 REPAIR OR REPLACE HARNESS OR CONNECTOR (POWER SOURCE CIRCUIT) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–197 OK 3 INSPECT STEERING ANGLE SENSOR (GROUND TERMINAL) (a) Turn the ignition switch off. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Steering Angle Sensor Wire Harness View: Tester Connection Condition Specified Condition E17-2 (ESS) - Body ground Always Below 1 Ω HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step (See page BC-134). NG E17-2 (ESS) G030156E16 OK REPLACE STEERING ANGLE SENSOR REPAIR OR REPLACE HARNESS OR CONNECTOR (GROUND CIRCUIT) BC BC–198 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DTC C1232/32 Stuck in Acceleration Sensor DTC C0371/71 Yaw Rate Sensor (Test Mode DTC) DTC C1234/34 Yaw Rate Sensor Malfunction DTC C1243/43 Acceleration Sensor Stuck Malfunction DTC C1244/44 Open or Short in Acceleration Sensor Circuit DTC C1245/45 Acceleration Sensor Output Malfunction DTC C1279/79 Acceleration Sensor Output Voltage Malfunction (Test Mode DTC) DTC C1381/97 Yaw Rate and / or Acceleration Sensor Power Supply Voltage Malfunction BC DESCRIPTION The skid control ECU receives signals from the yaw rate and acceleration sensor via the CAN communication system. The yaw rate sensor has a built in acceleration sensor and detects the vehicle's condition using 2 circuits (GL1, GL2). If there is trouble in the bus lines between the yaw rate and acceleration sensor and the CAN communication system, the DTC U0123/62 (malfunction in CAN communication with the yaw rate sensor) and U0124/95 (malfunction in CAN communication with the acceleration sensor) are output. These DTCs are also output when calibration has not been completed. DTCs C0371/71 and C1279/79 can be deleted when the yaw rate and acceleration sensor sends a yaw rate and/or acceleration signal or the Test Mode ends. DTCs C0371/71 and C1279/79 are output only in the Test Mode. DTC No. DTC Detection Condition C1232/32 At a vehicle speed of 6 mph (10 km/h) or more, either GL1 or GL2 (input signal) does not change for 30 seconds or more. • • Yaw rate and acceleration sensor Yaw rate and acceleration sensor circuit Trouble Area C1234/34 Sensor malfunction signal is received from the yaw rate sensor. • • Yaw rate and acceleration sensor Yaw rate and acceleration sensor circuit C1243/43 While the vehicle speed changes from 19 mph (30 km/h) to 0 mph (0 km/h), the condition that the values of GL1 and GL2 do not change occurs 16 times or more. • • Yaw rate and acceleration sensor Yaw rate and acceleration sensor circuit C1244/44 When either of the following is detected: 1. A data malfunction signal is received from the acceleration sensor. 2. After the difference between GL1 and GL2 becomes 0.6 G or more with the vehicle stationary, the difference remains 0.4 G or more for 60 seconds or more. • • Yaw rate and acceleration sensor Yaw rate and acceleration sensor circuit C1245/45 At a vehicle speed of 19 mph (30 km/h) or more, the difference between the forward and backward G calculated from the acceleration sensor value and that calculated from the vehicle speed sensor exceeds 0.35 G for 60 seconds or more. • • Yaw rate and acceleration sensor Yaw rate and acceleration sensor circuit C1381/97 At a vehicle speed of more than 2 mph (3 km/h), the acceleration sensor power source malfunction signal is received for 10 seconds or more. • • Yaw rate and acceleration sensor Yaw rate and acceleration sensor power source circuit BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–199 WIRING DIAGRAM Brake Actuator Assembly Yaw Rate and Acceleration Sensor CANL CANH IG GND - Skid Control ECU 2 25 3 11 5 3 5 1 1 2 (*1): without Smart Key System CANH BC From Battery IG1 ECU-IG NO. 2 CANL From Ignition Switch (*1), Main Body ECU (*2) (*2): with Smart Key System C136028E04 INSPECTION PROCEDURE NOTICE: When replacing the yaw rate and acceleration sensor, perform zero point calibration (See page BC-119). HINT: When U0123/62, U0124/95 or U0126/63 is output together with C1232/32, C1234/34, C1243/43, C1244/ 44, C1245/45, or C1381/97, inspect and repair the trouble areas indicated by U0123/62, U0124/95 or U0126/63 first. 1 CHECK DTC (a) Clear the DTC (See page BC-141). (b) Turn the ignition switch off. (c) At a speed of 19 mph (30 km/h) or more, drive the vehicle, turn the steering wheel, and decelerate the vehicle (depress the brake pedal). BC–200 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) (d) Turn the ignition switch on (IG) again and check that no CAN communication system DTC is output. (e) Check if DTCs for zero point calibration of the yaw rate sensor undone (C1210/36) or for zero point calibration of the acceleration sensor undone (C1336/39) are output. Result Condition Proceed to DTCs (C1210/36, C1336/39 and/or CAN communication system DTC) are not output A CAN communication system DTC is output B DTCs (C1210/36 and/or C1336/39) are output C B INSPECT CAN COMMUNICATION SYSTEM C REPAIR CIRCUIT INDICATED BY OUTPUT DTC (See page BC-151) A BC 2 CHECK YAW RATE AND ACCELERATION SENSOR INSTALLATION (a) Turn the ignition switch off. (b) Check that the yaw rate and acceleration sensor has been installed properly (See page BC-448). OK: The sensor is tightened to the specified torque. The sensor is not tilted. NG INSTALL YAW RATE AND ACCELERATION SENSOR CORRECTLY OK 3 INSPECT YAW RATE AND ACCELERATION SENSOR (IG TERMINAL) Yaw Rate and Acceleration Sensor Harness Side Connector Front View: E34 IG (a) Disconnect the yaw rate and acceleration sensor connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition E34-5 (IG) - Body ground Ignition switch on (IG) 10 to 14 V G026359E61 NG OK REPAIR OR REPLACE HARNESS OR CONNECTOR (IG CIRCUIT) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 4 BC–201 INSPECT YAW RATE AND ACCELERATION SENSOR (GND TERMINAL) Yaw Rate and Acceleration Sensor Harness Side Connector Front View: E34 GND G026359E62 (a) Turn the ignition switch off. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition E34-1 (GND) - Body ground Always Below 1 Ω NOTICE: Check the yaw rate and acceleration sensor signal after replacement (See page BC-123). HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step (See page BC-134). NG REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) OK REPLACE YAW RATE AND ACCELERATION SENSOR BC BC–202 BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DTC C1235/35 Foreign Object is Attached on Tip of Front Speed Sensor RH DTC C1236/36 Foreign Object is Attached on Tip of Front Speed Sensor LH DTC C1238/38 Foreign Object is Attached on Tip of Rear Speed Sensor RH DTC C1239/39 Foreign Object is Attached on Tip of Rear Speed Sensor LH DTC C1275/75 Abnormal Change in Output Signal of Front Speed Sensor RH (Test Mode DTC) DTC C1276/76 Abnormal Change in Output Signal of Front Speed Sensor LH (Test Mode DTC) DTC C1277/77 Abnormal Change in Output Signal of Rear Speed Sensor RH (Test Mode DTC) DTC C1278/78 Abnormal Change in Output Signal of Rear Speed Sensor LH (Test Mode DTC) DESCRIPTION The speed sensors detect wheel speed and transmit the signals to the ECU. These signals are used for control of the ABS control system. Each of the front and rear rotors have 48 serrations. When the rotors rotate, the magnetic field generated by the permanent magnet in the speed sensor induces an AC voltage. Since the frequency of this AC voltage changes in direct proportion to the speed of the rotor, the frequency is used by the ECU to detect the speed of each wheel. DTCs C1275/75 to C1278/78 can be deleted when the speed sensor sends a vehicle speed signal or the Test Mode ends. DTCs from C1275/75 to C1278/78 are output only in the Test Mode. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–203 Speed Sensor Rotor Coil N S Magnet To ECU Low speed High speed +V -V F000010E04 DTC No. C1235/35 C1236/36 C1238/38 C1239/39 DTC Detection Condition At a vehicle speed of 12 mph (20 km/h) or more, noise occurs in the sensor signal from the abnormal wheel for 5 seconds or more. HINT: • DTC C1235/35 is for the front speed sensor RH. • DTC C1236/36 is for the front speed sensor LH. • DTC C1238/38 is for the rear speed sensor RH. • DTC C1239/39 is for the rear speed sensor LH. Trouble Area • • • • Speed sensor Speed sensor rotor Sensor installation Brake actuator assembly (Skid control ECU) BC BC–204 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) WIRING DIAGRAM Front Speed Sensor Circuit: Brake Actuator Assembly - Skid Control ECU Front Speed Sensor RH 2 1 3 17 BC FR+ FR- Front Speed Sensor LH 2 1 18 4 FL+ FL- C132772E07 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) Rear Speed Sensor Circuit: BC–205 Brake Actuator Assembly - Skid Control ECU Rear Speed Sensor RH 2 1 5 19 RR+ RR- Rear Speed Sensor LH 2 1 20 6 BC RL+ RL- C132772E08 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). HINT: When C0200/31, C0205/32, C0210/33, or C0215/34 is output together with C1235/35, C1236/36, C1238/ 38, or C1239/39, inspect and repair the trouble areas indicated by C0200/31, C0205/32, C0210/33, or C0215/34 first. BC–206 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) CHECK SPEED SENSOR AND SPEED SENSOR ROTOR SERRATIONS Skid Control ECU Harness Side Connector Front View: A26 FR+ FL- RR+ RL- FR- FL+ RR- RL+ Normal Signal Waveform: BC GND (a) Disconnect the skid control ECU connector. (b) Connect the oscilloscope to each speed sensor terminal of the skid control ECU. (c) Check that a waveform is output when the tires are rotated (by the sensor circuit). OK: The same waveform is output from all the 4 wheels and there is no noise or interference in the waveform. (d) Check that the waveform does not change while jiggling a connector or a wire harness. OK: The waveform does not change. HINT: • As the vehicle speed (wheel revolution speed) increases, a cycle of the waveform narrows and the output voltage becomes greater. • When noise is identified in the waveform on the oscilloscope, the erratic signals are generated due to speed sensor rotor's scratches, looseness or foreign matter attached to it. NG Go to step 3 1 V/Division, 2 ms/Division C136019E05 OK 2 RECONFIRM DTC (a) (b) (c) (d) Reconnect the skid control ECU connector. Clear the DTC (See page BC-141). Start the engine. Drive the vehicle at the speed of 12 mph (20 km/h) or more for at least 60 seconds. (e) Check if the same DTC is recorded (See page BC-141). Result Condition Proceed to DTCs (C1235/35, C1236/36, C1238/38 and/or C1239/39) are not output A DTCs (C1235/35, C1236/36, C1238/38 and/or C1239/39) are output B B A USE SIMULATION METHOD TO CHECK REPLACE BRAKE ACTUATOR ASSEMBLY BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 3 INSPECT EACH SPEED SENSOR (a) Disconnect each speed sensor connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: RH Front Speed Sensor: 1 2 Rear Speed Sensor: Tester Connection Condition Specified Condition 1 (FR+) - 2 (FR-) Always 1.4 to 1.8 kΩ at 20°C (68 °F) 1 (FR+) - Body ground Always 10 kΩ or higher 2 (FR-) - Body ground Always 10 kΩ or higher 2 (RR+) - 1 (RR-) Always 0.9 to 2.1 kΩ 2 (RR+) - Body ground Always 10 kΩ or higher 1 (RR-) - Body ground Always 10 kΩ or higher Tester Connection Condition Specified Condition 1 (FL+) - 2 (FL-) Always 1.4 to 1.8 kΩ at 20°C (68 °F) 1 (FL+) - Body ground Always 10 kΩ or higher 2 (FL-) - Body ground Always 10 kΩ or higher LH 1 2 2 (RL+) - 1 (RL-) Always 0.9 to 2.1 kΩ 2 (RL+) - Body ground Always 10 kΩ or higher 1 (RL-) - Body ground Always 10 kΩ or higher C136027E01 Result Result Proceed to OK (for rear) A OK (for front) B NG C B C A BC–207 Go to step 5 REPLACE EACH SPEED SENSOR BC BC–208 4 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) CHECK HARNESS AND CONNECTOR (SKID CONTROL SENSOR WIRE) Skid Control Sensor Wire: f1 :RH Vehicle Side Connector "B" (a) Disconnect the skid control sensor wire. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: RH g1 :LH Sensor Side Connector "A" Tester Connection Condition Specified Condition f1 ("A"-1) - f1 ("B"-2) Always Below 1 Ω f1 ("A"-1) - f1 ("B"-1) Always 10 kΩ or higher f1 ("A"-1) - Body ground Always 10 kΩ or higher f1 ("A"-2) - f1 ("B"-1) Always Below 1 Ω f1 ("A"-2) - f1 ("B"-2) Always 10 kΩ or higher f1 ("A"-2) - Body ground Always 10 kΩ or higher Tester Connection Condition Specified Condition g1 ("A"-1) - g1 ("B"-2) Always Below 1 Ω LH BC C136026E01 g1 ("A"-1) - g1 ("B"-1) Always 10 kΩ or higher g1 ("A"-1) - Body ground Always 10 kΩ or higher g1 ("A"-2) - g1 ("B"-1) Always Below 1 Ω g1 ("A"-2) - g1 ("B"-2) Always 10 kΩ or higher g1 ("A"-2) - Body ground Always 10 kΩ or higher NOTICE: Check the speed sensor signal after replacement (See page BC-123). NG OK REPLACE SKID CONTROL SENSOR WIRE BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 5 BC–209 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - EACH SPEED SENSOR) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: RH Skid Control ECU Harness Side Connector Front View: FR+ FL- RR+ RL- A26 RL+ FRFL+ RRFront Speed Sensor Harness Side Connector Front View: Tester Connection Condition Specified Condition A26-3 (FR+) - A35-1 (FR+) Always Below 1 Ω A26-3 (FR+) - Body ground Always 10 kΩ or higher A26-17 (FR-) - A35-2 (FR-) Always Below 1 Ω A26-17 (FR-) - Body ground Always 10 kΩ or higher A26-5 (RR+) - f1-1 (RR+) Always Below 1 Ω A26-5 (RR+) - Body ground Always 10 kΩ or higher A26-19 (RR-) - f1-2 (RR-) Always Below 1 Ω A26-19 (RR-) - Body ground Always 10 kΩ or higher Tester Connection Condition Specified Condition BC LH A35 A14 FLFRFR+ FL+ Rear Speed Sensor Harness Side Connector Front View: A26-18 (FL+) - A14-1 (FL+) Always Below 1 Ω A26-18 (FL+) - Body ground Always 10 kΩ or higher A26-4 (FL-) - A14-2 (FL-) Always Below 1 Ω A26-4 (FL-) - Body ground Always 10 kΩ or higher A26-20 (RL+) - g1-1 (RL+) Always Below 1 Ω A26-20 (RL+) - Body ground Always 10 kΩ or higher A26-6 (RL-) - g1-2 (RL-) Always Below 1 Ω A26-6 (RL-) - Body ground Always 10 kΩ or higher g1 f1 NG RR- RR+ RL- REPAIR OR REPLACE HARNESS OR CONNECTOR RL+ C136025E01 OK 6 RECONFIRM DTC (a) Reconnect the skid control sensor wire. (b) Reconnect the skid control ECU connector and the speed sensor connector. (c) Clear the DTC (See page BC-141). (d) Start the engine. (e) Drive the vehicle at the speed of 12 mph (20 km/h) or more for at least 60 seconds. (f) Check if the same DTC is recorded (See page BC-141). Result Condition Proceed to DTCs (C1235/35, C1236/36, C1238/38 and/or C1239/39) are output (for front) A DTCs (C1235/35, C1236/36, C1238/38 and/or C1239/39) are output (for rear) B BC–210 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) Condition Proceed to DTCs (C1235/35, C1236/36, C1238/38 and/or C1239/39) are not output B C C Go to step 8 USE SIMULATION METHOD TO CHECK A 7 CHECK FRONT SPEED SENSOR TIP (a) Turn the ignition switch off. (b) Remove the front speed sensor (See page BC-438). (c) Check the speed sensor tip. OK: No scratches or foreign matter on the sensor tip. NOTICE: Check the speed sensor signal after cleaning or replacement (See page BC-123). BC NG CLEAN OR REPLACE FRONT SPEED SENSOR OK 8 CHECK EACH SPEED SENSOR ROTOR (a) Turn the ignition switch off. (b) Remove each speed sensor rotor. (c) Check the speed sensor rotor. OK: No scratches, missing teeth, or foreign matter on the rotors. NOTICE: Check the speed sensor signal after cleaning or replacement (See page BC-123). NG CLEAN OR REPLACE EACH SPEED SENSOR ROTOR OK 9 RECONFIRM DTC (a) Install the front speed sensor and the speed sensor rotor. (b) Clear the DTC (See page BC-141). (c) Start the engine. (d) Drive the vehicle at the speed of 12 mph (20 km/h) or more for at least 60 seconds. (e) Check if the same DTC is recorded (See page BC-141). BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–211 Result Condition Proceed to DTCs (C1235/35, C1236/36, C1238/38 and/or C1239/39) are output A DTCs (C1235/35, C1236/36, C1238/38 and/or C1239/39) are not output B B USE SIMULATION METHOD TO CHECK A REPLACE BRAKE ACTUATOR ASSEMBLY BC BC–212 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DTC C1241/41 Low Battery Positive Voltage DESCRIPTION If a malfunction is detected in the power supply circuit, the skid control ECU (housed in the actuator assembly) stores this DTC and the fail safe function prohibits ABS operation. This DTC is stored when the IG1 terminal voltage deviates from the DTC detection condition due to a malfunction in the power supply or charging circuit such as the battery or alternator circuit, etc. The DTC is cancelled when the IG1 terminal voltage returns to normal. DTC No. DTC Detection Condition C1241/41 When any of the following is detected: 1. At a vehicle speed of 2 mph (3 km/h) or more, the IG1 terminal voltage is 9.5 V or less for 10 seconds or more. 2. When the solenoid relay remains ON and the IG1 terminal voltage is 9.5 V or less, the relay contact is open for 0.2 seconds or more. 3. While the VSC NO. 1 (fail safe) relay is ON after VSC NO. 2 relay ON, the IG1 terminal voltage is 9.5 V or less and the actuator pump drive motor is OFF for 0.1 second or more. BC Trouble Area • • • • • ECU-IG NO. 2 fuse Battery Charging system Power source circuit Internal power supply circuit of the skid control ECU WIRING DIAGRAM Brake Actuator Assembly - Skid Control ECU IG1 Ignition Switch (*1) AM1 (*1) 4 AM1 ALT ECU-IG NO. 2 5 3 2 1 46 IG1 IG1 1 Main Body ECU (*2) (*2) 3 FL MAIN IG1D 6 32 AM2 1 AM1 2 1 Battery GND1 GND2 (*1): without Smart Key System (*2): with Smart Key System C136029E03 BC–213 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). 1 INSPECT ECU-IG NO. 2 FUSE (a) Remove the ECU-IG NO. 2 fuse from the main body ECU. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Main Body ECU: Tester Connection Condition Specified Condition ECU-IG NO. 2 (7.5 A) fuse Always Below 1 Ω NG REPLACE ECU-IG NO. 2 FUSE BC ECU-IG NO. 2 Fuse C135806E01 OK 2 CHECK BATTERY (a) Install the ECU-IG NO. 2 fuse. (b) Check the battery voltage. Standard voltage: 10 to 14 V NG CHECK AND REPLACE CHARGING SYSTEM OR BATTERY OK 3 INSPECT SKID CONTROL ECU (IG1 TERMINAL) (a) Disconnect the skid control ECU connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control ECU Harness Side Connector Front View: A26 IG1 Tester Connection Condition Specified Condition A26-46 (IG1) - Body ground Ignition switch on (IG) 10 to 14 V F049362E98 NG REPAIR OR REPLACE HARNESS OR CONNECTOR (IG1 CIRCUIT) BC–214 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) OK 4 INSPECT SKID CONTROL ECU (GND TERMINAL) (a) Turn the ignition switch off. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: A26 GND2 GND1 F049362E97 Tester Connection Condition Specified Condition A26-32 (GND1) - Body ground Always Below 1 Ω A26-1 (GND2) - Body ground Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) OK BC 5 RECONFIRM DTC (a) (b) (c) (d) Reconnect the skid control ECU connector. Clear the DTC (See page BC-141). Turn the ignition switch on (IG). Check if the same DTC is recorded (See page BC-141). Result Condition Proceed to DTC (C1241/41) is not output A DTC (C1241/41) is output B HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step (See page BC-134). B A USE SIMULATION METHOD TO CHECK REPLACE BRAKE ACTUATOR ASSEMBLY BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–215 DTC C1246/46 Master Cylinder Pressure Sensor Malfunction DTC C1281/81 Master Cylinder Pressure Sensor Output Malfunction (Test Mode DTC) DESCRIPTION Master cylinder pressure sensor is connected to the skid control ECU in the brake actuator assembly. DTC C1281/81 can be deleted when the master cylinder pressure sensor sends a master cylinder pressure signal or the Test Mode ends. DTC C1281/81 is output only in the Test Mode. Brake Actuator Assembly Skid Control ECU From Battery IG1 BC VCM Master Cylinder Pressure Sensor From Stop Light Switch STP PMC To Body Ground GND E2 VCM: Power Supply for Master Cylinder Pressure Sensor PMC: Master Cylinder Pressure Sensor Input E2: Master Cylinder Pressure Sensor Ground C106656E05 BC–216 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DTC No. DTC Detection Condition Trouble Area C1246/46 When any of the following is detected: • At a vehicle speed of 4.3 mph (7 km/h) or more, when the PMC terminal voltage is over 0.86 V, it does not change by 0.005 V or more for 30 seconds. • Noise occurs in the PMC terminal 7 times or more within 5 seconds. • When the stop light switch is OFF, the PMC terminal voltage is more than 0.86 V or less than 0.3 V for 5 seconds or more. • With the IG1 terminal voltage between 9.5 and 17.2 V, the VCM terminal voltage is not between 4.4 and 5.6 V for 1.2 seconds or more. • When the VCM terminal voltage between 4.4 and 5.6 V, the PCM terminal voltage is not between 0.14 and 4.85 V for 1.2 seconds or more. • • • • Master cylinder pressure sensor Master cylinder pressure sensor circuit Stop light switch circuit Brake actuator assembly INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). BC 1 CHECK STOP LIGHT OPERATION (a) Check that the stop light comes on when the brake pedal is depressed, and goes off when the brake pedal is released. OK Condition Illumination Condition Brake pedal depressed ON Brake pedal released OFF NG INSPECT STOP LIGHT CIRCUIT OK 2 READ VALUE OF INTELLIGENT TESTER (MASTER CYLINDER PRESSURE SENSOR) (a) Connect the intelligent tester to the DLC3. (b) Start the engine. (c) Select the Data List mode on the intelligent tester. ABS / VSC: Item (Display) Measurement Item / Range (Display) MAS CYL PRESS 1 Master cylinder pressure sensor 1 reading / min.: 0 V, max.: 5 V Normal Condition When brake pedal is released: 0.3 to 0.5 V (d) Check that the brake fluid pressure value of the master cylinder pressure sensor observed on the intelligent tester changes when the brake pedal is depressed. OK: When the pedal is depressed, voltage displayed on the intelligent tester increases. NG OK REPLACE BRAKE ACTUATOR ASSEMBLY BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 3 BC–217 READ VALUE OF INTELLIGENT TESTER (STOP LIGHT SWITCH) (a) Select the Data List mode on the intelligent tester. ABS / VSC: Item (Display) STOP LAMP SW Measurement Item / Range (Display) Stop light switch / ON or OFF Normal Condition ON: Brake pedal depressed OFF: Brake pedal released (b) Check that the stop light condition observed on the intelligent tester changes when the brake pedal is depressed. OK: When the brake pedal is depressed, the intelligent tester displays "ON". NG REPLACE BRAKE ACTUATOR ASSEMBLY OK 4 BC RECONFIRM DTC (a) (b) (c) (d) Turn the ignition switch off. Clear the DTC (See page BC-141). Start the engine. At a speed of 18 mph (30 km/h) or more, drive the vehicle and perform braking test (decelerate the vehicle by depressing the brake pedal). (e) Check if the same DTC is recorded (See page BC-141). Result Condition Proceed to DTC (C1246/46) is not output A DTC (C1246/46) is output B B A USE SIMULATION METHOD TO CHECK REPLACE BRAKE ACTUATOR ASSEMBLY BC–218 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DTC C1249/49 Open in Stop Light Switch Circuit DESCRIPTION The skid control ECU (housed in the actuator assembly) inputs the stop light switch signal and the condition of brake operation. The skid control ECU has an open detection circuit, which outputs this DTC when detecting an open in the stop light input line while the stop light switch is OFF. BC DTC No. DTC Detection Condition C1249/49 When IG1 terminal voltage is 9.5 to 17.2 V, an open circuit of the stop light switch continues for 0.3 seconds or more. Trouble Area • • • • STOP fuse Stop light switch Stop light switch circuit Brake actuator assembly (Skid control ECU) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–219 WIRING DIAGRAM Brake Actuator Assembly - Skid Control ECU ECU-IG NO. 2 From IG1 Relay 46 IG1 Stop Light Switch STOP 2 From Battery 1 27 STP Open Detection Circuit BC Rear Combination Light LH 1 Stop 3 Rear Combination Light RH 1 3 Stop Center Stop Light 1 2 32 GND1 1 GND2 C136030E01 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). BC–220 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) INSPECT STOP FUSE (a) Remove the STOP fuse from the main body ECU. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Main Body ECU: Tester Connection Condition Specified Condition STOP (10 A) fuse Always Below 1 Ω NG REPLACE STOP FUSE STOP Fuse BC C135806E02 OK 2 CHECK STOP LIGHT OPERATION (a) Install the STOP fuse. (b) Check that the stop light comes on when the brake pedal is depressed, and goes off when the brake pedal is released. OK Condition Illumination Condition Brake pedal depressed ON Brake pedal released OFF NG Go to step 7 OK 3 INSPECT SKID CONTROL ECU (STP TERMINAL) (a) Disconnect the skid control ECU connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control ECU Harness Side Connector Front View: A26 Tester Connection Condition Specified Condition A26-27 (STP) - Body ground Stop light switch ON (Brake pedal depressed) 8 to 14 V A26-27 (STP) - Body ground Stop light switch OFF (Brake pedal released) Below 1.5 V STP F049362E99 NG REPAIR OR REPLACE HARNESS OR CONNECTOR (STP CIRCUIT) BC–221 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) OK 4 INSPECT SKID CONTROL ECU (IG1 TERMINAL) (a) Turn the ignition switch on (IG). (b) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control ECU Harness Side Connector Front View: Tester Connection Condition Specified Condition A26-46 (IG1) - Body ground Ignition switch on (IG) 10 to 14 V A26 IG1 NG F049362E98 REPAIR OR REPLACE HARNESS OR CONNECTOR (IG1 CIRCUIT) OK 5 BC INSPECT SKID CONTROL ECU (GND TERMINAL) (a) Turn the ignition switch off. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: Tester Connection A26 GND2 GND1 F049362E97 Condition Specified Condition A26-32 (GND1) - Body ground Always Below 1 Ω A26-1 (GND2) - Body ground Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) OK 6 RECONFIRM DTC (a) (b) (c) (d) Reconnect the skid control ECU connector. Clear the DTC (See page BC-141). Start the engine. Depress the brake pedal several times to test the stop light circuit. (e) Check if the same DTC is recorded (See page BC-141). Result Condition Proceed to DTC (C1249/49) is not output A DTC (C1249/49) is output B HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step (See page BC-134). B REPLACE BRAKE ACTUATOR ASSEMBLY BC–222 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) A USE SIMULATION METHOD TO CHECK 7 INSPECT STOP LIGHT SWITCH (POWER SOURCE TERMINAL) (a) Disconnect the stop light switch connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Stop Light Switch Harness Side Connector Front View: Tester Connection Condition Specified Condition A19-2 - Body ground Always 10 to 14 V A19 NG BC REPAIR OR REPLACE HARNESS OR CONNECTOR (POWER SOURCE CIRCUIT) I042363E16 OK 8 INSPECT STOP LIGHT SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard resistance Stop Light Switch: Tester Connection 2 1 NG Free Pushed in C124796E03 OK Condition Specified Condition 1-2 Switch pin free Below 1 Ω 1-2 Switch pin pushed in 10 kΩ or higher REPLACE STOP LIGHT SWITCH BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 9 BC–223 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - STOP LIGHT SWITCH) (a) Disconnect the skid control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: A26 Stop Light Switch Harness Side Connector Front View: STP Tester Connection Condition Specified Condition A26-27 (STP) - A19-1 Always Below 1 Ω A26-27 (STP) - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR BC A19 F049379E08 OK 10 RECONFIRM DTC (a) Reconnect the skid control ECU connector and the stop light switch connector. (b) Clear the DTC (See page BC-141). (c) Start the engine. (d) Depress the brake pedal several times to test the stop light circuit. (e) Check if the same DTC is recorded (See page BC-141). Result Condition Proceed to DTC (C1249/49) is not output A DTC (C1249/49) is output B HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step (See page BC-134). B REPLACE BRAKE ACTUATOR ASSEMBLY A INSPECT LIGHTING SYSTEM (STOP LIGHT CIRCUIT) BC–224 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DTC C1251/51 Open in Pump Motor Circuit DESCRIPTION DTC No. DTC Detection Condition • • C1251/51 Trouble Area Actuator pump motor does not operate properly. Open in actuator pump motor circuit continues for at least 2 seconds. • • Brake actuator assembly (GND circuit) Brake actuator assembly (Motor circuit) WIRING DIAGRAM Brake Actuator Assembly BC R+ VSC NO. 1 (Fail Safe) 45 MRF 1 2 5 3 14 VSC NO. 2 MR ABS NO. 1 ALT 1 2 3 5 15 BM 2 Pump Motor FL MAIN Battery Skid Control ECU GND2 1 C136022E01 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–225 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (ABS MOTOR RELAY) (a) Connect the intelligent tester to the DLC3. (b) Start the engine. (c) Select the Active Test mode on the intelligent tester. ABS / VSC: Item (Display) MOTOR RELAY Vehicle Condition / Test Details Diagnostic Note Operating sound of relay (clicking sound) and motor can be heard Turns ABS motor relay ON / OFF (d) Check the operating sound of the ABS motor relay and motor when operating it with the intelligent tester. OK: The operating sound of the ABS motor relay and motor can be heard. OK Go to step 3 NG 2 INSPECT SKID CONTROL ECU (GND2 TERMINAL) (a) Turn the ignition switch off. (b) Disconnect the skid control ECU connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: A26 GND2 C141143E01 Tester Connection Condition Specified Condition A26-1 (GND2) - Body ground Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR (GND2 CIRCUIT) OK 3 RECONFIRM DTC (a) (b) (c) (d) Reconnect the skid control ECU connector. Clear the DTC (See page BC-141). Start the engine. Drive the vehicle at the speed of 4.3 mph (7 km/h) or more. (e) Check if the same DTC is recorded (See page BC-141). Result Condition Proceed to DTC (C1251/51) is not output A DTC (C1251/51) is output B BC BC–226 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) HINT: • If a speed signal of 4 mph (6 km/h) or more is input to the skid control ECU, with the ignition switch on (IG) and the stop light switch off, the ECU performs self diagnosis of the motor and solenoid circuits. • If a normal system code is output (the trouble code is not output), slightly jiggle the connectors, wire harness, and fuses of the brake actuator assembly. Make sure that no DTCs are output. • If any DTCs are output while jiggling a connector or wire harness of the brake actuator assembly (skid control ECU), inspect and repair the connector or wire harness. B A BC USE SIMULATION METHOD TO CHECK REPLACE BRAKE ACTUATOR ASSEMBLY BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DTC BC–227 C1290/66 Steering Angle Sensor Zero Point Malfunction DESCRIPTION The skid control ECU acquires steering angle sensor zero point every time the ignition switch is turned on (IG) and the vehicle is driven at 22 mph (35 km/h) or more for approximately 5 seconds. The ECU also stores the previous zero point. If front wheel alignment or steering wheel position is adjusted without disconnecting the negative battery terminal, or if yaw rate and acceleration sensor zero point is not acquired after the adjustments have been completed, the skid control ECU detects the difference between the previous zero point and newly acquired zero point and outputs this DTC to indicate a poor adjustment. Warning of the steering angle sensor zero point malfunction will be cancelled by turning the ignition switch off. DTC No. DTC Detection Condition Trouble Area • C1290/66 The steering angle sensor zero point calibration position vastly differs from the recorded value • • Yaw rate and acceleration sensor zero point calibration incomplete Poor adjustment of the centered position of the steering wheel Poor adjustment of front wheel alignment INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). 1 PERFORM ZERO POINT CALIBRATION OF YAW RATE AND ACCELERATION SENSOR (a) Perform zero point calibration of the yaw rate and acceleration sensor (See page BC-119). HINT: • When the stored zero point of the yaw rate and acceleration sensor is erased, steering angle sensor zero point will also be erased. • If the zero point and output value of the yaw rate and acceleration sensor and the output value of the speed sensors are not normal, steering angle sensor zero point cannot be acquired normally even if the vehicle is driven straight ahead at 22 mph (35 km/h) or more. NEXT 2 CHECK STEERING ANGLE SENSOR ZERO POINT CALIBRATION (a) Drive the vehicle straight ahead at 22 mph (35 km/h) or more for at least 5 seconds. (b) Check that the centered position of the steering wheel is correctly set while driving straight ahead. HINT: If front wheel alignment and steering position are adjusted as a result of abnormal centered position of the steering wheel, acquire yaw rate and acceleration sensor zero point again after the adjustments are completed. BC BC–228 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) OK: The centered position of the steering wheel is correctly set. NG ADJUST FRONT WHEEL ALIGNMENT OR STEERING POSITION OK 3 RECONFIRM DTC (a) (b) (c) (d) Turn the ignition switch off. Clear the DTC (See page BC-141). Start the engine. Drive the vehicle and turn the steering wheel to the right and left at the speed of 22 mph (35 km/h) or more. (e) Check if the same DTC is recorded (See page BC-141). BC Result Condition Proceed to DTC (C1290/66) is not output A DTC (C1290/66) is output B B A END REPLACE BRAKE ACTUATOR ASSEMBLY BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–229 DTC U0073/94 Control Module Communication Bus OFF DTC U0100/65 Lost Communication with ECM / PCM DTC U0123/62 Lost Communication with Yaw Rate Sensor Module DTC U0124/95 Lost Communication with Lateral Acceleration Sensor Module DTC U0126/63 Lost Communication with Steering Angle Sensor Module DESCRIPTION The skid control ECU receives the signals from the ECM, steering angle sensor, and yaw rate and acceleration sensor via the CAN communication system. DTC No. DTC Detection Condition Trouble Area U0073/94 When any of the following is detected: 1. With the IG1 terminal voltage 10 V or more, after the output of data from the skid control ECU is completed, the sending continues for 5 seconds or more. 2. With the IG1 terminal voltage 10 V or more, the condition that bus OFF state occurs once or more within 100 ms occurs 10 times in succession. (Sent signals cannot be received.) 3. With the IG1 terminal voltage 10 V or more, a delay in receiving data from the yaw rate and acceleration sensor and steering angle sensor continues for 1 second or more. 4. With the IG1 terminal voltage 10 V or more, the condition that a delay in receiving data from the yaw rate and acceleration sensor and steering angle sensor occurs more than once within 5 seconds occurs 10 times in succession within 60 seconds. CAN communication system U0100/65 When either of the following is detected: 1. With the IG1 terminal voltage 10 V or more and the vehicle speed 9 mph (15 km/h) or more, data cannot be sent to the ECM for 2 seconds or more. 2. The IG1 terminal voltage 10 V or more and the vehicle speed 9 mph (15 km/h) or more for 2 seconds or more. CAN communication system (Skid control ECU to ECM) U0123/62 When either of the following is detected: 1. With the IG1 terminal voltage 10 V or more, data from the yaw rate sensor cannot be received for 1 second or more. 2. With the IG1 terminal voltage 10 V or more, the following occurs 10 times in succession within 60 seconds. • The condition that data from the yaw rate sensor cannot be received occurs once or more within 5 seconds. CAN communication system (Skid control ECU to yaw rate and acceleration sensor) U0124/95 When either of the following is detected: 1. With the IG1 terminal voltage 10 V or more, data from the acceleration sensor cannot be received for 1 second or more. 2. With the IG1 terminal voltage 10 V or more, the following occurs 10 times in succession within 60 seconds. • The condition that data from the acceleration sensor cannot be received occurs once or more within 5 seconds. CAN communication system (Skid control ECU to yaw rate and acceleration sensor) BC BC–230 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) DTC No. DTC Detection Condition U0126/63 When either of the following is detected: 1. With the IG1 terminal voltage 10 V or more, data from the steering angle sensor cannot be received for 1 second or more. 2. With the IG1 terminal voltage 10 V or more, the following occurs 10 times in succession within 60 seconds. • The condition that data from the steering angle sensor cannot be received occurs once or more within 5 seconds. Trouble Area CAN communication system (Skid control ECU to steering angle sensor) WIRING DIAGRAM Brake Actuator Assembly BC ECM CANH CANL 41 1 2 11 49 7 8 25 Yaw Rate and Acceleration Sensor CANL 1 CANH CANL 10 4 CANH - Skid Control ECU J/C J/C Steering Angle Sensor 2 3 1 1 10 2 2 2 9 CANH CANL C136031E01 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–231 INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (MOMENTARY INTERRUPTION) (a) Using the intelligent tester, check for any momentary interruption in the wire harness and connector corresponding to a DTC (See page BC-118). ABS / VSC: Item (Display) Measurement Item / Range (Display) Normal Condition EFI communication open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal STEERING OPN Steering sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal YAW RATE OPN Yaw rate sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal EFI COM OPN Result Condition Proceed to There is a constant open circuit A There are no momentary interruptions B There are momentary interruptions C HINT: Perform the above inspection before removing the sensor and connector. B Go to step 3 C Go to step 4 A 2 CHECK IF EACH SENSOR AND ECM CONNECTOR IS SECURELY CONNECTED (a) Turn the ignition switch off. (b) Check if each sensor or ECM connector is securely connected. OK: The connector should be securely connected. NG CONNECT CONNECTOR TO EACH SENSOR OR ECM CORRECTLY OK 3 RECONFIRM DTC (a) Turn the ignition switch off. (b) Record the output DTCs (for ABS, VSC, and CAN communication) (See page BC-141). BC BC–232 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) HINT: If the CAN communication system DTC and the relevant sensor DTCs are output simultaneously, troubleshoot the relevant sensor DTCs (for ABS and VSC) after the CAN communication system returns to normal. Result Condition Proceed to DTC (CAN communication system DTC) is output A DTC (ABS and/or VSC DTC) is output B DTC is not output C B REPAIR CIRCUIT INDICATED BY OUTPUT DTC (See page BC-151) C USE SIMULATION METHOD TO CHECK A BC INSPECT CAN COMMUNICATION SYSTEM 4 REPAIR OR REPLACE HARNESS OR CONNECTOR (a) Turn the ignition switch off. (b) Repair or replace the harness or connector. (c) Check for any momentary interruption between the skid control ECU and each sensor or ECM (See page BC118). (d) Check that there is no momentary interruption. NEXT 5 RECONFIRM DTC (a) (b) (c) (d) Turn the ignition switch off. Clear the DTC (See page BC-141). Start the engine. Drive the vehicle and turn the steering wheel to the right and left at a speed of 9 mph (15 km/h) or more. (e) Check that no CAN communication system DTC is output. (f) If ABS and VSC DTCs are output, record them. Result Condition Proceed to DTC output for the CAN communication system A No DTC is output (ABS and/or VSC DTC is output) B No DTC is output (No ABS and/or VSC DTC is output) C HINT: The CAN communication system must be normal when repairing each sensor DTC (for ABS and VSC). BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–233 B REPAIR CIRCUIT INDICATED BY OUTPUT DTC (See page BC-151) C END A INSPECT CAN COMMUNICATION SYSTEM BC BC–234 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) ABS Warning Light Remains ON DESCRIPTION The skid control ECU is connected to the combination meter via CAN communication. If any of the following is detected, the ABS warning light remains on. • The skid control ECU connectors are disconnected from the skid control ECU. • There is a malfunction in the skid control ECU internal circuit. • There is an open in the harness between the combination meter and the skid control ECU. HINT: In some cases, the intelligent tester cannot be used when the skid control ECU is abnormal. BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–235 WIRING DIAGRAM Brake Actuator Assembly - Skid Control ECU Combination Meter CANL CANL 18 25 CANH 17 11 CANH MPX+B IG1 BC ECU-IG NO. 2 From Battery 5 3 2 1 46 IG1 ES 24 From Ignition Switch (*3), Main Body ECU (*4) IG+ ABS From IG2 Relay (*1), Ignition Switch (*2) Power Supply Circuit 32 GND1 GAUGE NO. 2 IG+ 13 (*1): 2GR-FE (*2): 2AZ-FE 1 GND2 (*3): without Smart Key System (*4): with Smart Key System C109474E03 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). BC–236 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) CHECK CAN COMMUNICATION SYSTEM (a) Check if the CAN communication system DTC is output (See page CA-25). Result Condition Proceed to DTC is not output A DTC is output B B INSPECT CAN COMMUNICATION SYSTEM A 2 CHECK IF SKID CONTROL ECU CONNECTOR IS SECURELY CONNECTED (a) Check if the skid control ECU connector is securely connected. OK: The connector should be securely connected. BC NG CONNECT CONNECTOR TO ECU CORRECTLY OK 3 CHECK BATTERY (a) Check the battery voltage. Standard voltage: 11 to 14 V NG CHECK AND REPLACE CHARGING SYSTEM OR BATTERY OK 4 INSPECT SKID CONTROL ECU (IG1 TERMINAL) (a) Disconnect the skid control ECU connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control ECU Harness Side Connector Front View: A26 Tester Connection Condition Specified Condition A26-46 (IG1) - Body ground Ignition switch on (IG) 10 to 14 V IG1 F049362E98 NG REPAIR OR REPLACE HARNESS OR CONNECTOR (IG1 CIRCUIT) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–237 OK 5 INSPECT SKID CONTROL ECU (GND TERMINAL) (a) Turn the ignition switch off. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: Tester Connection GND1 F049362E97 Specified Condition A26-32 (GND1) - Body ground Always Below 1 Ω A26-1 (GND2) - Body ground Always Below 1 Ω A26 GND2 Condition NG REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) OK BC 6 INSPECT COMBINATION METER ASSEMBLY (a) Reconnect the skid control ECU connector. (b) Perform Active Test of the combination meter (meter CPU) using the intelligent tester (See page ME-32). OK: The ABS warning light turns on or off in accordance with the intelligent tester. HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step before replacing the part (See page BC-134). NG OK REPLACE BRAKE ACTUATOR ASSEMBLY REPLACE COMBINATION METER ASSEMBLY BC–238 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) ABS Warning Light does not Come ON DESCRIPTION The skid control ECU is connected to the combination meter via CAN communication. BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–239 WIRING DIAGRAM Brake Actuator Assembly - Skid Control ECU Combination Meter CANL CANL 18 25 CANH 17 11 CANH MPX+B IG1 BC ECU-IG NO. 2 From Battery 5 3 2 1 46 IG1 ES 24 From Ignition Switch (*3), Main Body ECU (*4) IG+ ABS From IG2 Relay (*1), Ignition Switch (*2) Power Supply Circuit 32 GND1 GAUGE NO. 2 IG+ 13 (*1): 2GR-FE (*2): 2AZ-FE 1 GND2 (*3): without Smart Key System (*4): with Smart Key System C109474E03 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). BC–240 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) CHECK CAN COMMUNICATION SYSTEM (a) Check if the CAN communication system DTC is output (See page CA-25). Result Condition Proceed to DTC is not output A DTC is output B B INSPECT CAN COMMUNICATION SYSTEM A 2 CHECK ABS WARNING LIGHT (a) Disconnect the skid control ECU connector. (b) Turn the ignition switch on (IG). (c) Check that the ABS warning light comes on. OK: The ABS warning light comes on. HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step before replacing the part (See page BC-134). BC OK REPLACE BRAKE ACTUATOR ASSEMBLY NG 3 INSPECT COMBINATION METER ASSEMBLY (a) Turn the ignition switch off. (b) Reconnect the skid control ECU connector. (c) Perform Active Test of the combination meter (meter CPU) using the intelligent tester (See page ME-32). OK: The ABS warning light turns on or off in accordance with the intelligent tester. HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step (See page BC-134). NG OK REPLACE BRAKE ACTUATOR ASSEMBLY REPLACE COMBINATION METER ASSEMBLY BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–241 VSC Warning Light Remains ON DESCRIPTION The skid control ECU communicates with the combination meter via CAN communication. If the ECU stores a DTC, the DTC will be displayed on the multi information display in the combination meter (models with multi information display). On models without a multi information display, the VSC warning light will come on when the skid control ECU stores a DTC. BC BC–242 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) WIRING DIAGRAM Brake Actuator Assembly - Skid Control ECU Combination Meter CANL CANL 18 25 CANH 17 11 CANH MPX+B BC ES 24 From IG2 Relay (*1), Ignition Switch (*2) (*4) Power Supply Circuit GAUGE NO. 2 IG+ 13 (*1): 2GR-FE VSC (*3) IG+ (*2): 2AZ-FE (*3): Models without Multi Information Display (*4): Models with Multi Information Display C109475E02 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 1 BC–243 CHECK CAN COMMUNICATION SYSTEM (a) Check if the CAN communication system DTC is output (See page CA-25). Result Condition Proceed to DTC is not output A DTC is output B B INSPECT CAN COMMUNICATION SYSTEM A 2 CHECK IF SKID CONTROL ECU CONNECTOR IS SECURELY CONNECTED (a) Check if the skid control ECU connector is securely connected. OK: The connector should be securely connected. NG CONNECT CONNECTOR TO ECU CORRECTLY OK 3 CHECK BATTERY (a) Check the battery voltage. Standard voltage: 11 to 14 V NG CHECK AND REPLACE CHARGING SYSTEM OR BATTERY OK 4 INSPECT COMBINATION METER ASSEMBLY (a) Perform Active Test of the combination meter (meter CPU) using the intelligent tester (See page ME-32). OK: The VSC warning light (models without multi information display) or multi information display (models with multi information display) turns on or off in accordance with the intelligent tester. HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step before replacing the part (See page BC-134). BC BC–244 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) NG OK REPLACE BRAKE ACTUATOR ASSEMBLY BC REPLACE COMBINATION METER ASSEMBLY BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–245 VSC Warning Light does not Come ON DESCRIPTION The skid control ECU communicates with the combination meter via CAN communication. If the ECU stores a DTC, the DTC will be displayed on the multi information display in the combination meter (models with multi information display). On models without a multi information display, the VSC warning light will come on when the skid control ECU stores a DTC. BC BC–246 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) WIRING DIAGRAM Brake Actuator Assembly - Skid Control ECU Combination Meter CANL CANL 18 25 CANH 17 11 CANH MPX+B BC ES 24 From IG2 Relay (*1), Ignition Switch (*2) (*4) Power Supply Circuit GAUGE NO. 2 IG+ 13 (*1): 2GR-FE VSC (*3) IG+ (*2): 2AZ-FE (*3): Models without Multi Information Display (*4): Models with Multi Information Display C109475E02 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 1 BC–247 CHECK CAN COMMUNICATION SYSTEM (a) Check if the CAN communication system DTC is output (See page CA-25). Result Condition Proceed to DTC is not output A DTC is output B B INSPECT CAN COMMUNICATION SYSTEM A 2 CHECK VSC WARNING LIGHT (a) Connect the intelligent tester to the DLC3. (b) Start the engine. (c) Select "VSC WARN LAMP" in the Active Test and operate the VSC warning light (models without multi information display) or multi information display (models with multi information display) using the intelligent tester. ABS / VSC: Item (Display) VSC WARN LAMP Vehicle Condition / Test Details Turn VSC warning light (*1) or multi information display (*2) ON / OFF Diagnostic Note Observe combination meter (*1): Models without multi information display (*2): Models with multi information display (d) Check that "ON" and "OFF" of the VSC warning light (models without multi information display) or multi information display (models with multi information display) are indicated on the combination meter when using the intelligent tester. OK: The VSC warning light (models without multi information display) or multi information display (models with multi information display) turns on or off in accordance with the intelligent tester. HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step before replacing the part (See page BC-134). OK REPLACE BRAKE ACTUATOR ASSEMBLY NG 3 INSPECT COMBINATION METER ASSEMBLY (a) Turn the ignition switch off. BC BC–248 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) (b) Perform Active Test of the combination meter (meter CPU) using the intelligent tester (See page ME-32). OK: The VSC warning light (models without multi information display) or multi information display (models with multi information display) turns on or off in accordance with the intelligent tester. HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step (See page BC-134). NG OK BC REPLACE BRAKE ACTUATOR ASSEMBLY REPLACE COMBINATION METER ASSEMBLY BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–249 Brake Warning Light Remains ON DESCRIPTION The skid control ECU is connected to the combination meter via CAN communication. If any of the following is detected, the BRAKE warning light remains on: • The skid control ECU connector is disconnected from the skid control ECU. • The brake fluid level is insufficient. • The parking brake is applied. • EBD operation is not possible. BC BC–250 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) WIRING DIAGRAM Brake Actuator Assembly Combination Meter - Skid Control ECU CANL CANL 18 25 CANH 17 11 CANH MPX+B Parking Brake Switch 5 6 CANH 1 BC 14 (*5) 2 (*6) 19 CANL PKB Main Body ECU From IG2 Relay (*1), Ignition Switch (*2) Power Supply Circuit From Ignition Switch (*3), Main Body ECU (*4) IG+ GAUGE NO. 2 13 From Battery ES IG1 24 ECU-IG NO. 2 IG+ BRAKE 5 3 2 1 46 IG1 B/LE 6 (*1): 2GR-FE 1 Brake Fluid Level Warning Switch (*2): 2AZ-FE (*3): without Smart Key System (*4): with Smart Key System (*5): A/T (*6): M/T 32 1 GND1 GND2 2 C135799E03 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). BC–251 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 1 CHECK CAN COMMUNICATION SYSTEM (a) Check if the CAN communication system DTC is output (See page CA-25). Result Condition Proceed to DTC is not output A DTC is output B B INSPECT CAN COMMUNICATION SYSTEM A 2 CHECK IF SKID CONTROL ECU CONNECTOR IS SECURELY CONNECTED (a) Check if the skid control ECU connector is securely connected. OK: The connector should be securely connected. NG CONNECT CONNECTOR TO ECU CORRECTLY OK 3 CHECK BATTERY (a) Check the battery voltage. Standard voltage: 11 to 14 V NG CHECK AND REPLACE CHARGING SYSTEM OR BATTERY OK 4 INSPECT SKID CONTROL ECU (IG1 TERMINAL) (a) Disconnect the skid control ECU connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control ECU Harness Side Connector Front View: A26 IG1 Tester Connection Condition Specified Condition A26-46 (IG1) - Body ground Ignition switch on (IG) 10 to 14 V F049362E98 NG REPAIR OR REPLACE HARNESS OR CONNECTOR (IG1 CIRCUIT) BC BC–252 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) OK 5 INSPECT SKID CONTROL ECU (GND TERMINAL) (a) Turn the ignition switch off. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: A26 GND2 GND1 F049362E97 Tester Connection Condition Specified Condition A26-32 (GND1) - Body ground Always Below 1 Ω A26-1 (GND2) - Body ground Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) OK BC 6 INSPECT PARKING BRAKE SWITCH (a) Disconnect the parking brake switch connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Parking Brake Switch A/T: Free Pushed in Tester Connection Condition Specified Condition 1 - Body ground Parking brake switch ON (Switch pin free) Below 1 Ω 1 - Body ground Parking brake switch OFF (Switch pin pushed in) 10 kΩ or higher NG M/T: Free Pushed in C109430E02 OK REPLACE PARKING BRAKE SWITCH BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 7 BC–253 CHECK HARNESS AND CONNECTOR (MAIN BODY ECU - PARKING BRAKE SWITCH) (a) Disconnect the main body ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: A/T Main Body ECU Harness Side Connector Front View A/T: IC Tester Connection Condition Specified Condition IC-14 (PKB) - A18-1 Always Below 1 Ω IC-14 (PKB) - Body ground Always 10 kΩ or higher Tester Connection Condition Specified Condition IM-2 (PKB) - E33-1 Always Below 1 Ω IM-2 (PKB) - Body ground Always 10 kΩ or higher M/T M/T: NG IM Parking Brake Switch Harness Side Connector Front View: A18 : A/T E33 : M/T C136418E01 OK REPAIR OR REPLACE HARNESS OR CONNECTOR BC BC–254 8 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) INSPECT BRAKE FLUID LEVEL WARNING SWITCH (a) Remove the reservoir tank cap and strainer. (b) Disconnect the brake fluid level warning switch connector. (c) Measure the resistance according to the value(s) in the table below. HINT: A float is located inside the reservoir. Its position can be changed by increasing or decreasing the level of brake fluid. Standard resistance Brake Fluid Level Warning Switch: Tester Connection BC C140953E01 Specified Condition 1-2 Float up (Switch OFF) 1.9 to 2.1 kΩ 1-2 Float down (Switch ON) Below 1 Ω HINT: If there is no problem after finishing the above check, adjust the brake fluid level to the MAX level. NG OK Condition REPLACE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY (BRAKE FLUID LEVEL WARNING SWITCH) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 9 BC–255 CHECK HARNESS AND CONNECTOR (COMBINATION METER - BRAKE FLUID LEVEL WARNING SWITCH) (a) Disconnect the combination meter connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Combination Meter Wire Harness View: Tester Connection Condition Specified Condition F2-6 (B/LE) - A16-1 Always Below 1 Ω F2-6 (B/LE) - Body ground Always 10 kΩ or higher A16-2 - Body ground Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR BC F2-6 (B/LE) Brake Fluid Level Warning Switch Harness Side Connector Front View: A16 C136033E01 OK 10 INSPECT COMBINATION METER ASSEMBLY (a) Perform Active Test of the combination meter (meter CPU) using the intelligent tester (See page ME-32). OK: The BRAKE warning light turns on or off in accordance with the intelligent tester. HINT: • Reinstall the connectors and restore the vehicle to its prior condition before checking the combination meter. • If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step before replacing the part (See page BC-134). NG REPLACE COMBINATION METER ASSEMBLY BC–256 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) OK REPLACE BRAKE ACTUATOR ASSEMBLY BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–257 Brake Warning Light does not Come ON DESCRIPTION The skid control ECU is connected to the combination meter via CAN communication. BC BC–258 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) WIRING DIAGRAM Brake Actuator Assembly Combination Meter - Skid Control ECU CANL CANL 18 25 CANH 17 11 CANH MPX+B Parking Brake Switch 5 6 CANH 1 BC 14 (*5) 2 (*6) 19 CANL PKB Main Body ECU From IG2 Relay (*1), Ignition Switch (*2) Power Supply Circuit From Ignition Switch (*3), Main Body ECU (*4) IG+ GAUGE NO. 2 13 From Battery ES IG1 24 ECU-IG NO. 2 IG+ BRAKE 5 3 2 1 46 IG1 B/LE 6 (*1): 2GR-FE 1 Brake Fluid Level Warning Switch (*2): 2AZ-FE (*3): without Smart Key System (*4): with Smart Key System (*5): A/T (*6): M/T 32 1 GND1 GND2 2 C135799E03 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 1 BC–259 CHECK CAN COMMUNICATION SYSTEM (a) Check if the CAN communication system DTC is output (See page CA-25). Result Condition Proceed to DTC is not output A DTC is output B B INSPECT CAN COMMUNICATION SYSTEM A 2 CHECK BRAKE WARNING LIGHT (a) Disconnect the skid control ECU connector. (b) Turn the ignition switch on (IG). (c) Check that the BRAKE warning light comes on. OK: The BRAKE warning light comes on. HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step before replacing the part (See page BC-134). OK REPLACE BRAKE ACTUATOR ASSEMBLY NG 3 INSPECT COMBINATION METER ASSEMBLY (a) Turn the ignition switch off. (b) Reconnect the skid control ECU connector. (c) Perform Active Test of the combination meter (meter CPU) using the intelligent tester (See page ME-32). OK: The BRAKE warning light turns on or off in accordance with the intelligent tester. HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step (See page BC-134). NG OK REPLACE BRAKE ACTUATOR ASSEMBLY REPLACE COMBINATION METER ASSEMBLY BC BC–260 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) Slip Indicator Light Remains ON DESCRIPTION The skid control ECU is connected to the combination meter via CAN communication. The SLIP indicator light blinks during VSC and/or TRAC operation. When the system fails, the SLIP indicator light comes on to warn the driver (See page BC-138). BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–261 WIRING DIAGRAM Brake Actuator Assembly Combination Meter - Skid Control ECU CANL 18 25 CANH 17 11 CANL CANH MPX+B BC ES 24 IG+ SLIP Power Supply Circuit From IG2 Relay (*1), Ignition Switch (*2) GAUGE NO. 2 IG+ 13 (*1): 2GR-FE (*2): 2AZ-FE C109476E03 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). BC–262 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) CHECK CAN COMMUNICATION SYSTEM (a) Check if the CAN communication system DTC is output (See page CA-25). Result Condition Proceed to DTC is not output A DTC is output B B INSPECT CAN COMMUNICATION SYSTEM A 2 CHECK IF SKID CONTROL ECU CONNECTOR IS SECURELY CONNECTED (a) Check if the skid control ECU connector is securely connected. OK: The connector should be securely connected. BC NG CONNECT CONNECTOR TO ECU CORRECTLY OK 3 CHECK BATTERY (a) Check the battery voltage. Standard voltage: 11 to 14 V NG CHECK AND REPLACE CHARGING SYSTEM OR BATTERY OK 4 INSPECT COMBINATION METER ASSEMBLY (a) Perform Active Test of the combination meter (meter CPU) using the intelligent tester (See page ME-32). OK: The SLIP indicator light turns on or off in accordance with the intelligent tester. HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step before replacing the part (See page BC-134). NG REPLACE COMBINATION METER ASSEMBLY BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–263 OK REPLACE BRAKE ACTUATOR ASSEMBLY BC BC–264 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) Slip Indicator Light does not Come ON DESCRIPTION The skid control ECU is connected to the combination meter via CAN communication. The SLIP indicator light blinks during VSC and/or TRAC operation. When the system fails, the SLIP indicator light comes on to warn the driver (See page BC-138). BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–265 WIRING DIAGRAM Brake Actuator Assembly Combination Meter - Skid Control ECU CANL 18 25 CANH 17 11 CANL CANH MPX+B BC ES 24 IG+ SLIP Power Supply Circuit From IG2 Relay (*1), Ignition Switch (*2) GAUGE NO. 2 IG+ 13 (*1): 2GR-FE (*2): 2AZ-FE C109476E03 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). BC–266 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) CHECK CAN COMMUNICATION SYSTEM (a) Check if the CAN communication system DTC is output (See page CA-25). Result Condition Proceed to DTC is not output A DTC is output B B INSPECT CAN COMMUNICATION SYSTEM A 2 CHECK SLIP INDICATOR LIGHT (a) Connect the intelligent tester to the DLC3. (b) Start the engine. (c) Select "SLIP INDI LAMP" in the Active Test and operate the SLIP indicator light using the intelligent tester. BC ABS / VSC: Item (Display) SLIP INDI LAMP Vehicle Condition / Test Details Turn SLIP indicator light ON / OFF Diagnostic Note Observe combination meter (d) Check that "ON" and "OFF" of the SLIP indicator light are indicated on the combination meter when using the intelligent tester. OK: The SLIP indicator light turns on or off in accordance with the intelligent tester. HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step before replacing the part (See page BC-134). OK REPLACE BRAKE ACTUATOR ASSEMBLY NG 3 INSPECT COMBINATION METER ASSEMBLY (a) Turn the ignition switch off. (b) Perform Active Test of the combination meter (meter CPU) using the intelligent tester (See page ME-32). OK: The SLIP indicator light turns on or off in accordance with the intelligent tester. HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step (See page BC-134). BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) NG BC–267 REPLACE COMBINATION METER ASSEMBLY OK REPLACE BRAKE ACTUATOR ASSEMBLY BC BC–268 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) Skid Control Buzzer Circuit DESCRIPTION The skid control buzzer sounds while the accumulator pressure is abnormally low or when an abnormality causing low fluid pressure occurs, and then the VSC is activated. WIRING DIAGRAM Brake Actuator Assembly Skid Control Buzzer IG1 - Skid Control ECU ECU-IG NO. 2 BC 5 3 2 1 2 30 1 BZ From Ignition Switch (*1), Main Body ECU (*2) From Battery (*1): without Smart Key System (*2): with Smart Key System C136034E03 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SKID CONTROL BUZZER) (a) Connect the intelligent tester to the DLC3. (b) Start the engine. (c) Select the Active Test mode on the intelligent tester. ABS / VSC: Item (Display) BUZZER Vehicle Condition / Test Details Turns skid control buzzer ON / OFF Diagnostic Note Buzzer can be heard (d) Check that the buzzer sounds/stops when turning the skid control buzzer on/off by using the intelligent tester. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–269 Result Condition Proceed to Buzzer does not sound or sounds constantly A Buzzer sounds/stops B HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step (See page BC-134). B END A 2 INSPECT SKID CONTROL BUZZER (POWER SOURCE TERMINAL) (a) (b) (c) (d) Skid Control Buzzer Harness Side Connector Front View: E13 C107604E17 Turn the ignition switch off. Disconnect the skid control buzzer connector. Turn the ignition switch on (IG). Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition E13-2 - Body ground Ignition switch on (IG) 10 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR (POWER SOURCE CIRCUIT) OK 3 INSPECT SKID CONTROL BUZZER (a) Apply battery negative voltage to terminal 1, and battery positive voltage to terminal 2 of the skid control buzzer, and then check that the buzzer sounds. OK: The skid control buzzer sounds. Skid Control Buzzer: NG (+) (-) 1 2 C125130E01 OK REPLACE SKID CONTROL BUZZER BC BC–270 4 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - SKID CONTROL BUZZER) (a) Turn the ignition switch off. (b) Disconnect the skid control ECU connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: A26 Condition Specified Condition A26-30 (BZ) - E13-1 Always Below 1 Ω A26-30 (BZ) - Body ground Always 10 kΩ or higher HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step before replacing the part (See page BC-134). BZ Skid Control Buzzer Harness Side Connector Front View: BC Tester Connection NG E13 I045407E11 OK REPLACE BRAKE ACTUATOR ASSEMBLY REPAIR OR REPLACE HARNESS OR CONNECTOR BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) BC–271 TC and CG Terminal Circuit DESCRIPTION Connecting terminals TC and CG of the DLC3 causes the ECU to display the DTC by blinking the ABS warning light. WIRING DIAGRAM Brake Actuator Assembly ECM DLC3 - Skid Control ECU CANH TC 27 13 11 CANH TC CANL CG 41 49 BC CANL 25 4 C109399E05 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). 1 CHECK CAN COMMUNICATION SYSTEM (a) Check if the CAN communication system DTC is output (See page CA-25). Result Condition Proceed to DTC is not output A DTC is output B B A INSPECT CAN COMMUNICATION SYSTEM BC–272 2 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) INSPECT DLC3 DLC3: (a) Turn the ignition switch on (IG). (b) Measure the voltage according to the value(s) in the table below. Standard voltage CG E10 TC Tester Connection Condition Specified Condition E10-13 (TC) - E10-4 (CG) Ignition switch on (IG) 10 to 14 V OK Go to step 5 G022986E20 NG BC 3 CHECK HARNESS AND CONNECTOR (TC of DLC3 - ECM) (a) Turn the ignition switch off. (b) Disconnect the ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: 2GR-FE DLC3: E10 TC Tester Connection Condition E10-13 (TC) - A55-27 (TC) Always Below 1 Ω E10-13 (TC) - Body ground Always 10 kΩ or higher 2AZ-FE ECM Wire Harness View: Tester Connection Condition Specified Condition E10-13 (TC) - A24-27 (TC) Always Below 1 Ω E10-13 (TC) - Body ground Always 10 kΩ or higher NG A55-27 (TC) (*1) A24-27 (TC) (*2) (*1): 2GR-FE (*2): 2AZ-FE C136035E02 OK Specified Condition REPAIR OR REPLACE HARNESS OR CONNECTOR BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 4 DLC3: BC–273 CHECK HARNESS AND CONNECTOR (CG of DLC3 - BODY GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance CG E10 Tester Connection Condition Specified Condition E10-4 (CG) - Body ground Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR G022986E21 OK 5 DLC3: CHECK ECM (TC of DLC3 INPUT) (a) (b) (c) (d) (e) CG Turn the ignition switch off. Reconnect the ECM connector. Using SST, connect terminals TC and CG of the DLC3. Turn the ignition switch on (IG). Check that the check engine warning light is blinking. E10 TC G022986E20 Result Condition Proceed to Check engine warning light is blinking A Check engine warning light is not blinking B HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step before replacing the part (See page BC-134). B A REPLACE BRAKE ACTUATOR ASSEMBLY REPAIR OR REPLACE WIRE HARNESS OR ECM (TC of ECM CIRCUIT) BC BC–274 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) TS and CG Terminal Circuit DESCRIPTION In the Test Mode (signal check), a malfunction of the speed sensor that cannot be detected when the vehicle is stopped can be detected while driving. Transition to the sensor check mode can be performed by connecting terminals TS and CG of the DLC3 and turning the ignition switch from off to on (IG). WIRING DIAGRAM Brake Actuator Assembly DLC3 BC TS CG - Skid Control ECU 12 24 TS 4 C109400E06 INSPECTION PROCEDURE NOTICE: When replacing the brake actuator assembly, perform zero point calibration (See page BC-119). BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) 1 BC–275 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - TS of DLC3) (a) Disconnect the skid control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: A26 Tester Connection Condition Specified Condition A26-24 (TS) - E10-12 (TS) Always Below 1 Ω NG TS REPAIR OR REPLACE HARNESS OR CONNECTOR DLC3: BC E10 TS C128347E08 OK 2 DLC3: CHECK HARNESS AND CONNECTOR (CG of DLC3 - BODY GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance CG E10 Condition Specified Condition Always Below 1 Ω NG G022987E21 OK Tester Connection E10-4 (CG) - Body ground REPAIR OR REPLACE HARNESS OR CONNECTOR BC–276 3 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for ADVICS Made) CHECK HARNESS AND CONNECTOR (TS of DLC3 - BODY GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance DLC3: Condition Specified Condition Always 10 kΩ or higher HINT: If troubleshooting has been carried out according to the Problem Symptoms Table, refer back to the table and proceed to the next step before replacing the part (See page BC-134). E10 TS Tester Connection E10-12 (TS) - Body ground G022987E22 NG BC OK REPLACE BRAKE ACTUATOR ASSEMBLY REPAIR OR REPLACE HARNESS OR CONNECTOR BC–272 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) PRECAUTION 1. Expression BC EXPRESSIONS OF IGNITION SWITCH The type of ignition switch used on this model differs according to the specifications of the vehicle. The expressions listed in the table below are used in this section. Switch Type Ignition Switch (Position) Engine Switch (Condition) Ignition switch off LOCK off Ignition switch on (IG) ON on (IG) Ignition switch on (ACC) ACC on (ACC) Engine start START start 2. 3. TROUBLESHOOTING PRECAUTION (a) When there is a malfunction in the contact point of the terminals or installation problems with parts, the removal and installation of the suspected problem parts may return the system to the normal condition either completely or temporarily. (b) In order to determine the malfunctioning area, be sure to check the conditions at the time the malfunction occurred, such as by DTC output and freeze frame data output, and record it before disconnecting each connector or removing and installing parts. (c) Since the vehicle stability control system may be influenced by a malfunction in the other systems, be sure to check for DTCs in the other systems. (d) Be sure to remove and install the brake actuator assembly and each sensor with the ignition switch off unless specified in the inspection procedure. (e) If the brake actuator or a sensor has been removed and installed, it is necessary to check the system for problems after the parts have been reassembled. Check for DTCs using the intelligent tester, also check that system functions and signals received by the ECU are normal using test mode. CAN COMMUNICATION SYSTEM PRECAUTION (a) The CAN communication system is used for data communication between the skid control ECU, the steering angle sensor, and the yaw rate and acceleration sensor. If there is trouble in the CAN communication line, a DTC of the communication line is output. (b) If a DTC of the CAN communication line is output, repair the malfunction in the communication line and troubleshoot the vehicle stability control system under the condition that data communication is normal. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 4. 5. BC–273 (c) In order to enable CAN communication, a specific type of wiring is used for the CAN communication lines. The wiring used for each communication line is a twisted pair of wires that have an equal length. A bypass wire should not be used, because the data being transmitted will be corrupted. DTC PRECAUTION (a) Warnings for some DTCs cannot be cleared by only repairing the malfunctioning parts. If the warning is displayed after repair work, the DTC should be cleared after turning the ignition switch off. NOTICE: If a DTC for a malfunctioning part reappears after it was cleared, then it has been stored again. CHASSIS DYNAMOMETER PRECAUTION (a) Enter Test Mode to disable TRAC and VSC control when using a chassis dynamometer. HINT: The vehicle may move unexpectedly out of the dynamometer because of TRAC and VSC operations. NOTICE: • Make sure that the VSC warning (multi information display and master caution indicator light) light is blinking (TEST Mode is achieved). • Secure the vehicle with the lock chain for safety. BC BC–274 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) PARTS LOCATION BRAKE ACTUATOR ASSEMBLY BRAKE MASTER CYLINDER ASSEMBLY - SKID CONTROL ECU FRONT SPEED SENSOR ROTOR FRONT SPEED SENSOR - BRAKE FLUID LEVEL WARNING SWITCH REAR SPEED SENSOR SKID CONTROL SENSOR ECM (2GR-FE) (REAR SPEED SENSOR ROTOR) BC ECM (2AZ-FE) ENGINE ROOM R/B SKID CONTROL SENSOR - FUSIBLE LINK (ABS NO. 1 ) (REAR SPEED SENSOR) - FUSIBLE LINK (ABS NO. 2) REAR SPEED SENSOR ROTOR FRONT SPEED SENSOR ROTOR FRONT SPEED SENSOR C131985E02 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) STOP LIGHT SWITCH BC–275 COMBINATION METER ASSEMBLY SKID CONTROL BUZZER - ABS WARNING LIGHT PARKING BRAKE SWITCH - SLIP INDICATOR LIGHT - MASTER CAUTION INDICATOR - VSC WARNING LIGHT - BRAKE WARNING LIGHT - MULTI-INFORMATION DISPLAY (Automatic Transaxle) BC DLC3 INSTRUMENT PANEL J/B - ECU-IG NO. 2 FUSE YAW RATE AND ACCELERATION SENSOR PARKING BRAKE SWITCH STEERING ANGLE SENSOR (Manual Transaxle) C131986E01 BC–276 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) SYSTEM DIAGRAM Brake Actuator Assembly Motor Relay Pump Motor Solenoid Relay Solenoid (Control) Stop Light Switch BC Speed Sensor (for Each Wheel) Skid Control (VSC Warning) Buzzer Skid Control ECU Solenoid (Linear) Master Cylinder Pressure Sensor C131981E02 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) Brake Actuator Assembly BC–277 Combination Meter Assembly Skid Control ECU Speedometer ABS Warning Light Brake Warning Light Steering Angle Sensor SLIP Indicator Light BC VSC Warning (MultiInformation Display) Yaw Rate and Acceleration Sensor VSC Warning Light (without Multi-Information Display) Body ECU Shift Position Switch Parking Brake Switch ECM CAN Communication System Accelerator Pedal Position Sensor Engine Revolution Sensor C132007E02 BC–278 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) Transmitting ECU (transmitter) Receiving ECU ECM Skid control ECU Skid control ECU Yaw rate and acceleration sensor Skid control ECU Steering angle sensor Skid control ECU ECM Signals • • • • • • CAN communication system Steering angle sensor request signal CAN communication system • • Wheel speed signal VSC data signal CAN communication system • • • Wheel speed signal ABS warning light ON signal BRAKE warning light ON signal VSC warning light ON signal (*1) Multi information display ON signal (*2) SLIP indicator light ON signal Master caution indicator light ON signal CAN communication system Combination meter • BC • • Main body ECU Skid control ECU CAN communication system Yaw rate and acceleration request signal • Skid control ECU Shift position signal Throttle position signal Engine revolution signal Intake air temperature signal Engine torque request signal Accelerator pedal position signal Communication method Parking brake switch signal CAN communication system (*1): without multi-information display (Combination meter) (*2): with multi-information display (Combination meter) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–279 SYSTEM DESCRIPTION 1. SYSTEM DESCRIPTION HINT: • The skid control ECU is located within the brake actuator assembly. • The yaw rate sensor and acceleration sensor are combined in a single unit. This unit communicates with the skid control ECU through the CAN communication system. (a) ABS operation (1) Based on the signals received from the 4 wheel speed sensors, the skid control ECU calculates the deceleration and speed of each wheel, while monitoring for wheel lock. If wheel lock is occurring, the ECU controls the solenoid valves in the brake actuator in order to adjust the hydraulic pressure applied to the brakes at each wheel. BC BC–280 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 2. FUNCTION DESCRIPTION (a) ABS (Anti-lock Brake System) The ABS helps prevent the wheels from locking when the brakes are applied firmly or when braking on a slippery surface. Brake Actuator Assembly Pump Motor Each Speed Sensor Each Wheel Cylinder Skid Control ECU Solenoid Valves BC Combination Meter ABS Warning Light CAN Communication System Hydraulic Pressure C132008E02 (1) Operation description The skid control ECU detects wheel lock condition by receiving vehicle speed signals from each speed sensor, and sends control signals to the pump motor and solenoid valves. The pump motor and solenoid valves avoid wheel lock by controlling the hydraulic pressure of each wheel cylinder. The ABS warning light comes on when the ABS system is malfunctioning. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–281 (b) EBD (Electronic Brake force Distribution) The EBD control utilizes ABS, which ensures proper brake force distribution between the front and rear wheels in accordance with driving conditions. In addition, when braking while cornering, it also controls the brake forces of the right and left wheels, helping to maintain vehicle behavior. Brake Actuator Assembly Each Speed Sensor Skid Control ECU Solenoid Valves Each Wheel Cylinder BC Combination Meter BRAKE Warning Light CAN Communication System Hydraulic Pressure C132009E02 (1) Operation description The skid control ECU receives a speed signal from each speed sensor, and uses these signals to detect locking of the wheels. The ECU uses this information in order to determine appropriate control of the solenoid valves. The solenoid valves control the hydraulic pressure applied to the brake cylinder at each wheel. In this way, the solenoid valves are used to control the brake power split between the front and rear, and left and right wheels. The BRAKE warning light comes on if there is a malfunction in the EBD system. BC–282 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) (c) BA (Brake Assist) The primary purpose of the brake assist system is to provide auxiliary brake force to assist a driver who cannot generate a large enough brake force during emergency braking. This system helps to maximize the brake performance of the vehicle. Brake Actuator Assembly Each Speed Sensor Pump Motor Skid Control ECU Each Wheel Cylinder Solenoid Valves BC Master Cylinder Pressure Sensor Combination Meter ECM ABS Warning Light CAN Communication System Hydraulic Pressure C132010E01 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–283 (1) Operation description The skid control ECU receives the speed signal from each speed sensor and the hydraulic pressure signal from the master cylinder pressure sensor to determine whether brake assist is necessary. If brake assist is considered to be necessary, the skid control ECU sends control signals to the pump motor and solenoid valve. The pump and solenoid valve then control the pressure applied to each wheel cylinder. The ABS warning light comes on to indicate a malfunction in the BA (brake assist) system. BC BC–284 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) (d) TRAC (Traction Control) The TRAC system helps prevent the drive wheel from slipping if the driver depresses the accelerator pedal excessively when starting off or accelerating on a slippery surface. Brake Actuator Assembly Each Speed Sensor Pump Motor Skid Control ECU Each Wheel Cylinder Solenoid Valves BC Yaw Rate and Acceleration Sensor Combination Meter Steering Angle Sensor VSC Warning (Multi-Information Display) SLIP Indicator Light ECM Master Caution Indicator Light CAN Communication System Hydraulic Pressure C132011E01 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–285 (1) Operation description The skid control ECU detects wheelspin condition by receiving signals from each speed sensor and the ECM via CAN communication. The skid control ECU controls engine torque with the ECM via CAN communication and brake hydraulic pressure through the pump and solenoid valve. The SLIP indicator light blinks when the system is operating. If a malfunction occurs in the TRAC system, both master caution and SLIP indicator lights will come on and the DTC will be displayed on the multi-information display. BC BC–286 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) (e) VSC (Vehicle Stability Control) The VSC system helps prevent the vehicle from slipping sideways as a result of a strong front or rear wheel skid during cornering. Brake Actuator Assembly Each Speed Sensor Pump Motor Each Wheel Cylinder Skid Control ECU Solenoid Valves Skid Control Buzzer BC Yaw Rate and Acceleration Sensor Combination Meter Steering Angle Sensor ECM VSC Warning (Multi-Information Display) SLIP Indicator Light Master Caution Indicator Light CAN Communication System Hydraulic Pressure C132012E02 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 3. 4. BC–287 (1) Operation description The skid control ECU determines the vehicle operating conditions based on signals received from the wheel speed sensors, yaw rate and acceleration sensor, and steering angle sensor. The skid control ECU sends signals via CAN communication to the ECM in order to control engine torque. The skid control ECU controls brake hydraulic pressure using the pump and solenoid valves. The SLIP indicator light will blink, and the skid control system buzzer will sound when the system is operating. If a malfunction occurs in the VSC system, both the master caution indicator light and the SLIP indicator light will come on. In addition to this, the DTC will appear on the multi-information display. Vehicles without a multi-information display will illuminate the VSC warning light and SLIP indicator light if a malfunction occurs. ABS with EBD, BA, TRAC and VSC OPERATION (a) The skid control ECU calculates vehicle stability tendency based on the signals from the speed sensor, yaw rate and acceleration sensor, and steering angle sensor. In addition, it evaluates the results of the calculations to determine whether any control actions (control of the engine output torque by electronic throttle control and of the wheel brake pressure by the brake actuator assembly) should be implemented. (b) The SLIP indicator blinks and the skid control buzzer sounds to inform the driver that the VSC system is operating. The SLIP indicator also blinks when traction control is operating, and the operation being performed is displayed. FAIL SAFE (a) When a failure occurs in the ABS with BA, TRAC and VSC systems, the ABS and VSC warning (with multi-information display) lights, and SLIP indicator light come on and ABS with BA, TRAC and VSC operations are prohibited. In addition, when there is a failure that disables the EBD operation, the BRAKE warning light also comes on and the EBD operation is prohibited. (b) If control is prohibited due to a malfunction during operation, control will be disabled gradually. This is to avoid sudden vehicle instability. BC BC–288 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 5. 6. INITIAL CHECK (a) When the vehicle speed first becomes approximately 4 mph (6 km/h) or more after the ignition switch is turned on (IG), each solenoid valve and motor of the brake actuator assembly is sequentially activated to perform an electrical check. During the initial check, the operating sound of solenoid valve and motor can be heard from the engine compartment, but this is not a malfunction. FUNCTION OF COMPONENTS Components Function • Brake actuator assembly • • Skid control ECU (housed in brake actuator assembly) BC • Changes the fluid path based on the signals from the skid control ECU during the operation of the ABS with EBD & Brake Assist & TRAC & VSC system, in order to control the fluid pressure that is applied to the wheel cylinders. Houses the skid control ECU. Judges the vehicle driving condition based on the signals from each sensor, and controls the brake actuator assembly. Sends and receives the control signals to or from the ECM, yaw rate and acceleration sensor, and steering angle sensor via CAN communication. Master cylinder pressure sensor • • Speed sensor Detects speed of each wheel and inputs the data into the skid control ECU. Stop light switch Illuminates the brake light when the brake pedal is depressed. (Sends a brake on signal to the skid control ECU) Motor relay • • Supplies power to the pump motor. Housed in the skid control ECU. Solenoid relay • • Supplies power to each solenoid. Housed in the skid control ECU. • • Controls the engine output based on the signals received from the skid control ECU. Sends the accelerator pedal position signal and the engine speed signal to the skid control ECU. • • Comes on to inform the driver that a malfunction in the ABS, EBD or BA (Brake Assist) has occurred. Blinks to output DTC. BRAKE warning light • • Comes on to inform the driver that the parking brake is ON when the system is normal. Comes on to inform the driver that a malfunction in the EBD has occurred. VSC warning light Comes on to inform the driver that a malfunction in the VSC system has occurred. SLIP indicator light Blinks to inform the driver that TRC and VSC are operating. Brake fluid level warning switch Detects the brake fluid level. ECM ABS warning light Skid control buzzer Intermittently sounds to inform the driver that the VSC is operating. • Yaw rate and acceleration sensor • • • • Steering angle sensor Detects the fluid pressure in the master cylinder. Housed in the brake actuator assembly. • Acceleration sensor measures the capacity of the condenser that changes the distance between the electrodes depending on G force, which occurs when the vehicle is accelerated, and converts the measured value into electrical signals. Yaw rate sensor detects the vehicle's angular velocity (yaw rate) in the vertical direction based on the amount and direction of the piezoelectric ceramics deflection. Sends signals to the skid control ECU via CAN communication. Installed in the steering column. Detects the steering amount and direction and sends the signals to the skid control ECU via CAN communication. Has the magnetic resistance element, which detects the rotation of the magnet housed in the detection gear in order to detect the changes in magnetic resistance and the steering amount and direction. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–289 HOW TO PROCEED WITH TROUBLESHOOTING 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS (a) Interview the customer to confirm the trouble. NEXT 3 CHECK CAN COMMUNICATION SYSTEM (a) Check for DTCs (See page BC-302). HINT: The skid control ECU is connected to the CAN communication system. Therefore, before starting troubleshooting, make sure to check that there is no trouble in the CAN communication system. Result Result Proceed to DTC is not output A DTC is output B B CHECK CAN COMMUNICATION CIRCUIT A 4 CHECK DTC AND FREEZE FRAME DATA (a) Check for DTCs and Freeze Frame Data (See page BC302 for DTC Check / Clear, BC-305 for Freeze Frame Data). (1) Record the DTCs and Freeze Frame Data. (b) Clear the DTCs. (c) Recheck for DTCs. (1) Reproduce the malfunction and check if the DTCs are output again. Result Result Proceed to DTC is output A DTC is not output (Problem symptom does not occur) B DTC is not output (Problem symptom occurs) C B GO TO STEP 9 BC BC–290 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) C GO TO STEP 10 A 5 DIAGNOSTIC TROUBLE CODE CHART (a) Go to "DIAGNOSTIC TROUBLE CODE CHART" (See page BC-311). NEXT 6 CIRCUIT INSPECTION NEXT BC 7 REPAIR OR REPLACE NEXT 8 CONFIRMATION TEST NEXT END 9 SYMPTOM SIMULATION NEXT 10 PROBLEM SYMPTOMS TABLE (a) Go to "PROBLEM SYMPTOMS TABLE" (See page BC295). NEXT 11 NEXT CIRCUIT INSPECTION BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 12 BC–291 REPAIR OR REPLACE NEXT 13 CONFIRMATION TEST NEXT END TEST MODE PROCEDURE ABS Warning Light: USA: CANADA: Master Caution Indicator Light: BRAKE Warning Light: USA: CANADA: SLIP Indicator Light: VSC Warning Light (without multi-information display) C137469E01 1. WARNING LIGHT AND INDICATOR LIGHT INITIAL CHECK (a) Release the parking brake. NOTICE: Before releasing the parking brake, move the shift lever to the P position for safety (Automatic Transaxle model) or set the chocks to hold the vehicle for safety (Manual Transaxle model). HINT: When the parking brake is applied or the level of the brake fluid is low, the BRAKE warning light comes on. (b) When the ignition switch is turned on (IG), check that the ABS, VSC (without multi-information display), BRAKE warning lights, and master caution, SLIP indicator lights come on for approximately 3 seconds. HINT: If the ECU stores any DTCs, the ABS, BRAKE, VSC warning (without multi-information display and master caution indicator light) lights, and SLIP indicator light come on. If the indicator remains on or does not come on, proceed to troubleshooting for the light circuits listed below. Trouble Area See procedure ABS warning light (Remains on) BC-380 ABS warning light (Does not come on) BC-385 BRAKE warning light (Remains on) BC-395 BRAKE warning light (Does not come on) BC-404 VSC warning light (Remains on) BC-388 VSC warning light (Does not come on) BC-392 SLIP indicator light (Remains on) BC-408 SLIP indicator light (Does not come on) BC-412 BC BC–292 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 2. (a) Procedure to enter Test Mode. (1) Turn the ignition switch off. (2) Connect the intelligent tester to the DLC3. (3) Check that the steering wheel is centered and move the shift lever to the P position (Automatic Transaxle) or apply the parking brake (Manual Transaxle). (4) Turn the ignition switch on (IG). Intelligent Tester BC DLC3 SENSOR SIGNAL CHECK BY TEST MODE (SIGNAL CHECK) (INTELLIGENT TESTER) HINT: If the ignition switch is turned from on (IG) to on (ACC) or off during Test Mode (signal check), DTCs recorded during the signal check function will be erased. CAN VIM C131977E05 (5) Set the intelligent tester to Test Mode (select "SIGNAL CHECK"). HINT: Refer to the intelligent tester operator's manual for further details. C106533 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) (6) Check that the ABS warning light comes on for several seconds and then blinks in Test Mode. HINT: If the ABS warning light does not blink, inspect the ABS warning light circuit. TEST MODE: Blinking Pattern: 0.13 sec. BC–293 0.13 sec. Trouble Area ON ABS warning light (Does not come on) OFF Display: USA: Canada: C132874E01 3. See procedure BC-404 (b) Check the sensor signal. (1) Drive the vehicle straight ahead. Accelerate the vehicle to a speed of 28 mph (45 km/h) or more for several seconds and check that the ABS warning light goes off when the brake pedal is depressed. HINT: • The sensor check may not be completed if wheelspin occurs, or if the steering wheel is turned during this check. • The ABS warning light goes off when the sensor signal check has been completed and the brake pedal is depressed. • The ABS warning light comes on immediately after a malfunction has been detected during the speed sensor signal check. (c) Stop the vehicle. NOTICE: • The speed sensor check may not be completed if the speed sensor check is started while turning the steering wheel or spinning the wheels. • If the signal check has not been completed, the ABS warning light will blink while driving and the ABS system will not operate. (d) Read the DTC(s) by following the tester screen. NOTICE: • If only the DTCs are displayed, repair the malfunction area and clear the DTCs. • If the DTCs or Test Mode codes (DTC of signal check function) are displayed, repair the malfunction area, clear the DTCs and perform the Test Mode inspection. HINT: See the list of DTCs (See procedure "A"). SENSOR SIGNAL CHECK BY TEST MODE (SIGNAL CHECK) (SST CHECK WIRE) HINT: If the ignition switch is turned from on (IG) to on (ACC) or off during Test Mode (signal check), DTCs recorded during the signal check will be erased. (a) Procedure to enter Test Mode. (1) Turn the ignition switch off. BC BC–294 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) (2) Check that the steering wheel is centered and move the shift lever to the P position (Automatic Transaxle) or apply the parking brake (Manual Transaxle). DLC3: (3) Using SST, connect terminals TS and CG of the DLC3. SST 09843-18040 (4) Turn the ignition switch on (IG). CG TS G022987E07 (5) Check that the ABS warning light comes on for several seconds and then blinks in Test Mode. HINT: If the ABS warning light does not blink, inspect the TS and CG terminal circuit, and ABS warning light circuit. TEST MODE: BC Blinking Pattern: 0.13 sec. 0.13 sec. ON Trouble Area OFF Display: USA: Canada: C132874E01 See procedure TS and CG terminal circuit BC-421 ABS warning light circuit (Does not come on) BC-385 (b) Check the sensor signal. (1) Drive the vehicle straight ahead. Accelerate the vehicle to a speed of 28 mph (45 km/h) or more for several seconds and check that the ABS warning light goes off when the brake pedal is depressed. HINT: • The sensor check may not be completed if wheelspin occurs, or if the steering wheel is turned during this check. • The ABS warning light goes off when the sensor signal check has been completed and the brake pedal is depressed. • The ABS warning light comes on immediately after a malfunction has been detected during the speed sensor signal check. (c) Stop the vehicle. NOTICE: • The speed sensor check may not be completed if the speed sensor check is started while turning the steering wheel or spinning the wheels. • If the signal check has not been completed, the ABS warning light will blink while driving and the ABS system will not operate. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DLC3: (d) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 (e) Count the number of blinks of the ABS warning light. CG TS BC–295 TC G022988E01 Blinking Pattern of Normal System Code: 0.25 sec. 0.25 sec. ON BC OFF Blinking Pattern of Trouble Code (Example Codes 71 and 72): 0.5 sec. 0.5 sec. 1.5 sec. 2.5 sec. 4 sec. Repeat ON OFF Code 71 Code 72 C132876E01 (f) NOTICE: • If only the DTCs are displayed, repair the malfunction area and clear the DTCs. • If the DTCs or Test Mode codes (DTC of signal check function) are displayed, repair the malfunction area, clear the DTCs and perform the Test Mode inspection. HINT: • If more than 1 malfunction is detected at the same time, the lowest numbered code will be displayed first. • See the list of DTCs (See procedure "A"). After performing the check, disconnect the SST from terminals TS and CG, and TC and CG of the DLC3, and turn the ignition switch off. BC–296 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 4. (g) Turn the engine switch on (IG) to cancel the Test Mode. HINT: • If the ignition switch is not turned on (IG) after the SST is removed from the DLC3, the previous Test Mode will continue. • If the ignition switch is turned on (IG) with terminals TS and CG shorted, the previous Test Mode will continue. DTC OF TEST MODE (SIGNAL CHECK) FUNCTION (Procedure "A") DTC of Test Mode (Signal Check): Code No. Diagnosis Trouble Area C1271/71 Low output signal of front speed sensor RH • • • C1272/72 Low output signal of front speed sensor LH • • • Front speed sensor LH Sensor installation Speed sensor rotor C1273/73 Low output signal of rear speed sensor RH • • • Rear speed sensor RH Sensor installation Speed sensor rotor C1274/74 Low output signal of rear speed sensor LH • • • Rear speed sensor LH Sensor installation Speed sensor rotor C1275/75 Abnormal change in output signal of front speed sensor RH • • • Front speed sensor RH Sensor installation Sensor rotor C1276/76 Abnormal change in output signal of front speed sensor LH • • • Front speed sensor LH Sensor installation Sensor rotor C1277/77 Abnormal change in output signal of rear speed sensor RH • • • Rear speed sensor RH Sensor installation Sensor rotor C1278/78 Abnormal change in output signal of rear speed sensor LH • • • Rear speed sensor LH Sensor installation Sensor rotor BC 5. Front speed sensor RH Sensor installation Speed sensor rotor HINT: The codes in this table are output only in Test Mode (signal check). ENGINE VARIANT LEARNING • Engine variant learning is automatically performed immediately after the Test Mode is entered. • The ABS, VSC, BRAKE, and SLIP indicators come on for 3 seconds after learning. BC–297 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) PROBLEM SYMPTOMS TABLE If there are no DTCs output but the problem still occurs, check the circuits for each problem symptom in the order given in the table below, and proceed to the relevant troubleshooting page. NOTICE: Before replacing the brake actuator assembly, sensor, or other related parts, turn the ignition switch off. Vehicle stability control system: Symptom ABS, BA and/or EBD does not operate ABS, BA and/or EBD does not operate efficiently VSC and/or TRACTION does not operate ABS sensor DTC check cannot be done Suspected area See page 1. Check for the DTC again and make sure that the normal system code is output. BC-302 2. IG power source circuit BC-361 3. Front speed sensor circuit BC-316 4. Rear speed sensor circuit BC-324 5. Check the brake actuator assembly with the intelligent tester (Check brake actuator assembly operation using the active test function). If abnormal, check the hydraulic circuit for leakage. BC-431 6. If the symptoms still occur even after the above circuits in suspected areas have been inspected and proved to be normal, replace the brake actuator assembly (skid control ECU). BC-432 1. Check for the DTC again and make sure that the normal system code is output. BC-302 2. Front speed sensor circuit BC-316 3. Rear speed sensor circuit BC-324 4. Stop light switch circuit BC-368 5. Check the brake actuator assembly with the intelligent tester (Check brake actuator assembly operation using the active test function). If abnormal, check the hydraulic circuit for leakage. BC-431 6. If the symptoms still occur even after the above circuits in suspected areas have been inspected and proved to be normal, replace the brake actuator assembly (skid control ECU). BC-432 1. Check for the DTC again and make sure that the normal system code is output. BC-302 2. IG power source circuit BC-361 3. Check the hydraulic circuit for leakage. - 4. Front speed sensor circuit BC-316 5. Rear speed sensor circuit BC-324 6. Yaw rate and deceleration sensor circuit BC-343 7. Steering angle sensor circuit BC-350 8. If the symptoms still occur even after the above circuits in suspected areas have been inspected and proved to be normal, replace the brake actuator assembly (skid control ECU). BC-432 1. Check for the DTC again and make sure that the normal system code is output. BC-302 2. TC and CG terminal circuit BC-418 3. If the symptoms still occur even after the above circuits in suspected areas have been inspected and proved to be normal, replace the brake actuator assembly (skid control ECU). BC-432 BC BC–298 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) Symptom See page BC-302 2. TC and CG terminal circuit BC-418 3. If the symptoms still occur even after the above circuits in suspected areas have been inspected and proved to be normal, replace the brake actuator assembly (skid control ECU). BC-432 1. TS and CG terminal circuit BC-421 2. Brake actuator assembly (skid control ECU) BC-432 ABS warning light abnormal (Remains on) ABS warning light circuit BC-380 ABS warning light abnormal (Does not come on) ABS warning light circuit BC-385 VSC sensor DTC check cannot be done Sensor signal check cannot be done BC Suspected area 1. Check for the DTC again and make sure that the normal system code is output. VSC warning light abnormal (Remains on) VSC warning light circuit BC-388 VSC warning light abnormal (Does not come on) VSC warning light circuit BC-392 Brake warning light abnormal (Remains on) Brake warning light circuit BC-395 Brake warning light abnormal (Does not come on) Brake warning light circuit BC-404 SLIP indicator light abnormal (Remains on) SLIP indicator light circuit BC-408 SLIP indicator light abnormal (Does not come on) SLIP indicator light circuit BC-412 Skid control buzzer abnormal Skid control buzzer circuit BC-415 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–299 TERMINALS OF ECU 1. TERMINALS OF ECU Skid Control ECU: A60 C113404E05 Symbols (Terminal No.) Terminal Description GND2 (1) Skid control ECU ground +BM (2) Power supply for motor +BS (3) Power supply for solenoid GND1 (4) Skid control ECU ground FL+ (5) Front left wheel speed sensor input FL- (6) Front left wheel speed sensor ground RL+ (7) Rear left wheel speed sensor input RR- (8) Rear right wheel speed sensor ground FR- (9) Front right wheel speed sensor ground FR+ (10) Front right wheel speed sensor input D/G (11) Diagnosis tester communication line CANL (14) CAN communication line L BZ (23) Buzzer output RL- (27) Rear left wheel speed sensor ground IG1 (28) ECU power supply RR+ (29) Rear right wheel speed sensor input STP1 (30) Stop light switch input SP1 (33) Speed signal output CANH (35) CAN communication line H TS (39) Sensor check switch input BC BC–300 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 2. TERMINAL INSPECTION (a) Disconnect the connector and measure the voltage and resistance according to the value(s) in the table below. Skid Control ECU (Harness Side Connector Front View): A60 BC C137467E01 HINT: Voltage cannot be measured with the connector connected to the skid control ECU, as the connector is watertight. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition GND2 (A60-1) - Body ground W-B - Body ground Actuator pump motor ground Always Below 1 Ω +BM (A60-2) - Body ground B - Body ground Power supply for motor Always 10 to 14 V +BS (A60-3) - Body ground L - Body ground Power supply for solenoid Always 10 to 14 V GND1 (A60-4) - Body ground W-B - Body ground Skid control ECU ground Always Below 1 Ω BZ (A60-23) - Body ground R - Body ground Buzzer warning light output Ignition switch on (IG), Buzzer does not sound 6 to 10 V IG1 (A60-28) - Body ground P - Body ground IG1 power supply Ignition switch on (IG) 10 to 14 V STP1 (A60-30) - Body ground P - Body ground Stop light switch input Stop light switch ON →OFF (Brake pedal depressed → released) 5 to 14 V → Below 3 V BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–301 DIAGNOSIS SYSTEM 1. CG (b) The vehicle's ECU uses the ISO 15765-4 for communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. HINT: Connect the cable of the intelligent tester to the DLC3, turn the ignition switch on (IG) and attempt to use the intelligent tester. If the screen displays a communication error message, a problem exists on either the vehicle side or the tester side. If the communication is normal when the tester is connected to another vehicle, inspect the DLC3 on the original vehicle. If the communication is still impossible when the tester is connected to another vehicle, the problem is probably in the tester itself. Consult the Service Department listed in the tester's instruction manual. SG CANH 1 2 3 4 5 6 7 8 9 10 11 1213141516 CANL BAT Symbols (Terminal No.) CG (4) - Body ground DIAGNOSIS SYSTEM (a) Inspect the battery voltage. Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge the battery before proceeding. A082779E65 Terminal Description Chassis ground Condition Specified Condition Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 9 to 14 V CANH (6) - CANL (14) HIGH-level CAN bus line Ignition switch OFF* 54 to 69 Ω CANH (6) - Battery positive HIGH-level CAN bus line Ignition switch OFF* 6 kΩ or higher CANH (6) - CG (4) HIGH-level CAN bus line Ignition switch OFF* 200 Ω or higher CANL (14) - Battery positive LOW-level CAN bus line Ignition switch OFF* 6 kΩ or higher CANL (14) - CG (4) LOW-level CAN bus line Ignition switch OFF* 200 Ω or higher 2. NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. DESCRIPTION NOTICE: When releasing the parking brake, set chocks to hold the vehicle for safety. BC BC–302 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) ABS Warning Light: USA: CANADA: Master Caution Indicator Light: (a) If the skid control ECU detects a malfunction, the ABS, VSC (without multi-information display), and BRAKE warning lights, and master caution and SLIP indicator lights will come on and the multiinformation display shows a warning message in order to warn the driver. The table below indicates which lights will come on when there is a malfunction in a particular function. BRAKE Warning Light: USA: CANADA: SLIP Indicator Light: BC VSC Warning Light (without multi-information display) C137469E01 Item/Trouble Area ABS EBD BA TRAC VSC ABS Warning Light { { { - - BRAKE Warning Light - { - - - VSC Warning Light (without multi-information display) { { { { { SLIP Indicator Light { { { { { {: Light ON -: Light OFF • The DTCs are simultaneously stored in the memory. The DTCs can be read by connecting the SST between terminals TC and CG of the DLC3 and observing the blinking pattern of the ABS warning light by connecting the intelligent tester (See page BC-302). • This system has a signal check function (TEST MODE) (See page BC-290). The DTC can be read by connecting the intelligent tester and observing the blinking pattern of the ABS warning. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 3. ABS Warning Light: USA: CANADA: Master Caution Indicator Light: BRAKE Warning Light: USA: CANADA: SLIP Indicator Light: VSC Warning Light (without multi-information display) WARNING LIGHT AND INDICATOR LIGHT INITIAL CHECK (a) Release the parking brake. NOTICE: Before releasing the parking brake, move the shift lever to the P position for safety (Automatic Transaxle model) or set the chocks to hold the vehicle for safety (Manual Transaxle model). HINT: When the parking brake is applied or the level of the brake fluid is low, the BRAKE warning light comes on. (b) When the ignition switch is turned on (IG), check that the ABS, VSC (without multi-information display), and BRAKE warning lights, and master caution and SLIP indicator lights come on for approximately 3 seconds. HINT: If the ECU stores any DTCs, the ABS, BRAKE, and VSC warning (multi-information display and master caution indicator light) lights, and SLIP indicator light come on. If the indicator remains on or does not come on, proceed to troubleshooting for the light circuits listed below. Trouble Area C137469E01 BC–303 See procedure ABS warning light (Remains on) BC-380 ABS warning light (Does not come on) BC-385 BRAKE warning light (Remains on) BC-395 BRAKE warning light (Does not come on) BC-404 VSC warning light (Remains on) BC-388 VSC warning light (Does not come on) BC-392 SLIP indicator light (Remains on) BC-408 SLIP indicator light (Does not come on) BC-412 4. SYMPTOM SIMULATION HINT: The most difficult case in troubleshooting is when no symptoms occur. In such cases, a thorough customer problem analysis must be carried out. Then the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be reproduced. No matter how experienced or skilled a technician may be, if he proceeds to troubleshoot without confirming the problem symptoms, he will likely overlook something important and make a wrong guess at some points in the repair operation. This leads to a standstill in troubleshooting. BC BC–304 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) (a) Vibration method: When vibration seems to be the major cause. HINT: Perform the simulation method only during the primary check period (for approximately 6 seconds after the ignition switch is turned on (IG)). (1) Slightly vibrate the part of the sensor considered to be the problem cause with your fingers and check whether the malfunction occurs. (2) Slightly shake the connector vertically and horizontally. HINT: Shaking the relays too strongly may result in open relays. (3) Slightly shake the wire harness vertically and horizontally. The connector joint and fulcrum of the vibration are the major areas to be checked thoroughly. Vibrate Slightly Shake Slightly BC Vibrate Slightly DLC3: D025083E14 DTC CHECK / CLEAR CG TC 1. G022986E01 DTC CHECK/CLEAR (WHEN USING SST CHECK WIRE:) (a) DTC check (1) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 (2) Turn the ignition switch on (IG). BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–305 (3) Observe the blinking pattern of the ABS and VSC (without multi-information display) warning lights or read the multi information display (with multi-information display) in order to identify the DTC. with Multi-Information Display Normal System Code of ABS and VSC: Trouble Code of ABS and VSC (Example Codes 11 and 21): 0.5 sec. 0.25 sec. 2 sec. 0.25 sec. ON ON OFF OFF with Multi-Information Display Normal System Code of VSC: 4 sec. 1.5 sec. 2.5 sec. Code 11 0.5 sec. 4 sec. Repeat BC Code 21 Trouble Code of VSC (Example Code 43): C137468E03 HINT: If no code appears, inspect the TC and CG terminal circuit, the ABS warning light circuit, and the VSC warning light circuit. Trouble Area See procedure ABS warning light (Remains on) BC-380 ABS warning light (Does not come on) BC-385 VSC warning light (Remains on) BC-388 VSC warning light (Does not come on) BC-392 TC and CG Terminal Circuit BC-418 • As an example, the blinking patterns for a normal system code and trouble codes 11 and 21 are shown in the illustration. (4) Codes are explained in the code table (See page BC-311). (5) After completing the check, disconnect terminals TC and CG of the DLC3, and turn off the display. If 2 or more DTCs are detected at the same time, the DTCs will be displayed in ascending order. BC–306 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DLC3: (b) DTC clear (1) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 (2) Turn the ignition switch on (IG). CG TC G022986E01 (3) Clear the DTCs stored in the ECU by depressing the brake pedal 8 times or more within 5 seconds. (4) Check that the warning light indicates a normal system code. (5) Remove the SST. HINT: Clearing the DTCs cannot be performed by disconnecting the battery terminal or the ECU-IG fuse. BC BR03890 2. Intelligent Tester DLC3 CAN VIM C131977E05 3. DTC CHECK/CLEAR (WHEN USING INTELLIGENT TESTER:) (a) DTC check (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch on (IG). (3) Read the DTCs by following the prompts on the tester screen. (b) DTC clear (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch on (IG). (3) Operate the intelligent tester to clear the codes. HINT: Refer to the intelligent tester operator's manual for further details. END OF DTC CHECK/CLEAR (a) Turn the ignition switch on (IG). (b) Check that the ABS warning light goes off within approximately 3 seconds. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–307 FREEZE FRAME DATA 1. Item (Display) FREEZE FRAME DATA (a) Whenever an ABS DTC is detected, the skid control ECU stores the current vehicle (sensor) state as Freeze Frame Data. The skid control ECU stores the number of times (maximum: 31) the ignition switch has been turned from off to on (IG) since the last time the ABS was activated. HINT: • However, if the vehicle is stopped or at a low speed (4.3 mph (7 km/h) or less), or if a DTC is detected, the skid control ECU will stop counting the number. • Freeze Frame Data at the time the ABS operates: The skid control ECU stores and updates data whenever the ABS system operates. When the ECU stores data at the time a DTC is detected, the data stored during ABS operation is erased. • Freeze Frame Data at the time a DTC is detected: When the skid control ECU stores data at the time a DTC is detected, no updates will be performed until the data is cleared. (b) Connect the intelligent tester to the DLC3. (c) Turn the ignition switch on (IG). (d) Select the "DTC INFO" on the tester display. (e) On the DTC data display screen, select the DTC data display with "*". Measurement Item Reference Value VEHICLE SPD Vehicle speed reading Min.: 0 mph (0 km/h), Max.: 202 mph (326.4 km/ h) STOP LAMP SW Stop light switch signal Stop light switch ON: ON, OFF: OFF #IG ON Number of operations of engine switch on (IG) after storing freeze frame data 0 to 31 MAS CYL PRESS 1 Master cylinder pressure sensor reading Brake pedal released: 0.3 to 0.5 V M/C PRESS GRADE Master cylinder pressure sensor change Min.: -30 MPa/s, Max.: 225 MPa/s YAW RATE Yaw rate sensor reading Min.: -128 deg/s, Max.: 127 deg/s STEERING SEN Steering angle sensor reading Left turn: Increase Right turn: Decrease SPD GRADE Vehicle speed grade Min.: -25.11 m/s2, Max.: 24.91 m/s2 BUZZER Skid control buzzer signal Skid control buzzer ON: ON, OFF: OFF PARKING BRAKE SW Parking brake switch signal Parking brake switch ON: ON, OFF: OFF ENGINE TORQUE Real engine torque Min.: -1024 Nm, Max.: 1023 Nm FR WHEEL SPD FR wheel speed Min.: 0 mph (0 km/h), Max.: 202 mph (326.4 km/ h) FL WHEEL SPD FL wheel speed Min.: 0 mph (0 km/h), Max.: 202 mph (326.4 km/ h) RR WHEEL SPD RR wheel speed Min.: 0 mph (0 km/h), Max.: 202 mph (326.4 km/ h) RL WHEEL SPD RL wheel speed Min.: 0 mph (0 km/h), Max.: 202 mph (326.4 km/ h) BC BC–308 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) Item (Display) Measurement Item Reference Value Lateral G Min.: -25.11 m/s2, Max.: 24.91 m/s2 Gear position information FAIL 1st 2nd 3rd 4th 5th 6th P, N R NOT R Shift lever position information FAIL 1st 2nd 3rd 4th 5th 6th/B D/M P, N R OPERATED SYSTEM Operated system status ABS activated: ABS VSC activated: VSC TRAC activated: TRAC BA activated: BA PB activated: PB Fail safe mode activated: FAIL No system activated: NON System prohibited: SYS FREEZE TIME Elapsed time after freeze trigger Min.: 0 ms, Max.: 500 ms TROUBLE CODE Freeze frame DTC Displays to output DTC INSPECTION MODE Inspection mode OTHER: Normal, INSPECT: Service LATERAL G GEAR POSITION * LEVER POSITION * BC *: Automatic Transaxle BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–309 FAIL-SAFE CHART 1. Malfunction FAIL SAFE OPERATION (a) If there is a problem with sensor signals or actuator systems, the skid control ECU prohibits power supply to the brake actuator assembly and informs the ECM of the VSC system failure. (b) The brake actuator assembly turns off each solenoid and the ECM shuts off the VSC control (traction control signal) from the skid control ECU accordingly, which turns out to be as if the vehicle stability control system was not installed. (c) ABS, VSC, and TRAC control will be prohibited, but EBD control continues as much as possible. If EBD control is impossible, the brake warning light comes on to warn the driver (See page BC-298). Symptom ABS system Prohibits the ABS, BA, TRAC, and VSC control BA system Prohibits the ABS, BA, TRAC, and VSC control EBD system Prohibits the ABS, EBD, BA, TRAC, and VSC control TRAC system Prohibits the TRAC and VSC control VSC system Prohibits the TRAC and VSC control HINT: • A malfunction in either the ABS or BA system results in an identical operation, with ABS, BA, TRAC, and VSC system control prohibited. • If control is prohibited due to a malfunction during operation, control will be disabled gradually to prevent the vehicle from becoming unstable suddenly. BC BC–310 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DATA LIST / ACTIVE TEST 1. Measurement Item / Range (Display) Item (Display) BC DATA LIST HINT: With the intelligent tester connected to the DLC3 and the ignition switch on (IG), the ABS, TRAC and VSC Data List can be displayed. Follow the prompts on the tester screen to access the Data List. Normal Condition Diagnostic Note MTR RELAY ABS motor relay / ON or OFF ON: Motor relay ON OFF: Motor relay OFF - SOL RELAY Solenoid relay / ON or OFF ON: Solenoid relay ON OFF: Solenoid relay OFF - IDLE SW Main idle switch / ON or OFF ON: Accelerator pedal released OFF: Accelerator pedal depressed - STOP LAMP SW Stop light switch / ON or OFF ON: Brake pedal depressed OFF: Brake pedal released - PARKING BRAKE SW Parking brake switch / ON or OFF ON: Parking brake applied OFF: Parking brake released - ENG REVOLUTIONS Engine revolutions / min.: 0 r/min, max.: 65,535 r/min - - GEAR POSITION * Gear position information / P/N, R, 1st-6th, FAIL, NOT R - - LEVER POSITION * Shift lever position information / P/N, R, D/M, 1st-6th/B, FAIL - - SHIFT INFO Shift information / ON or OFF ON: During gear change - FR WHEEL SPD FR wheel speed sensor reading / min.: 0 mph (0 km/h), max.: 202 mph (326 km/h) Actual wheel speed Similar speed as indicated on speedometer FL WHEEL SPD FL wheel speed sensor reading / min.: 0 mph (0 km/h), max.: 202 mph (326 km/h) Actual wheel speed Similar speed as indicated on speedometer RR WHEEL SPD RR wheel speed sensor reading / min.: 0 mph (0 km/h), max.: 202 mph (326 km/h) Actual wheel speed Similar speed as indicated on speedometer RL WHEEL SPD RL wheel speed sensor reading / min.: 0 mph (0 km/h), max.: 202 mph (326 km/h) Actual wheel speed Similar speed as indicated on speedometer Approximately 0+-0.13 G while stationary Reading changes when vehicle is bounced Acceleration sensor 1 reading / DECELERAT SEN min.: -18.52 m/s2, max.: 18.39 m/ s2 SFRR ABS solenoid (SFRR) / ON or OFF ON: Operates - SFRH ABS solenoid (SFRH) / ON or OFF ON: Operates - SFLR ABS solenoid (SFLR) / ON or OFF ON: Operates - SFLH ABS solenoid (SFLH) / ON or OFF ON: Operates - SRRR ABS solenoid (SRRR) / ON or OFF ON: Operates - SRRH ABS solenoid (SRRH) / ON or OFF ON: Operates - SRLR ABS solenoid (SRLR) / ON or OFF ON: Operates - SRLH ABS solenoid (SRLH) / ON or OFF ON: Operates - BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) Item (Display) Measurement Item / Range (Display) Normal Condition BC–311 Diagnostic Note SRM2 Master cut solenoid (SRM2) / ON or OFF ON: Operates - SRM1 Master cut solenoid (SRM1) / ON or OFF ON: Operated - SRC2 Master cut solenoid (SMC2) / ON or OFF ON: Operates - SRC1 Master cut solenoid (SRC1) / ON or OFF ON: Operates - VEHICLE SPD Maximum wheel speed sensor reading / min.: 0 mph (0 km/h), max.: 202 mph (326 km/h) Actual vehicle speed Speed indicated on speedometer YAW RATE SENS 1 Yaw rate sensor 1 / min.: -128 deg/s, max.: 127 deg/s Min.: -128 deg/s Max.: 127 deg/s - ZERO YAW RATE Memorized zero value / min.: 128 deg/s, max.: 127 deg/s Min.: -128 deg/s Max.: 127 deg/s - STEERING SEN Steering angle sensor / min.: 3,276.8 deg, max.: 3,276.7 deg Left turn: Increase Right turn: Decrease - MAS CYL PRESS 1 Master cylinder pressure sensor 1 reading / min.: 0 V, max.: 5 V When brake pedal is released: 0.3 to 0.5 V Reading increases when brake pedal is depressed ENGINE TORQUE Real engine torque / min.: -1024 N*m, max.: 1023 N*m - - FR SPD OPN FR speed sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - FL SPD OPN FL speed sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - RR SPD OPN RR speed sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - RL SPD OPN RL speed sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - YAW RATE OPN Yaw rate sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - DECELERAT OPN Acceleration sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - STEERING OPN Steering angle sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - EFI COM OPN EFI communication open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal - #DTC Number of DTC / min.: 0, max.: 255 - - ABS WARN LAMP ABS warning light / ON or OFF ON: Warning light ON OFF: Warning light OFF - BRAKE WARN LAMP BRAKE warning light / ON or OFF ON: Warning light ON OFF: Warning light OFF - SLIP INDI LAMP SLIP indicator light / ON or OFF ON: Indicator light ON OFF: Indicator light OFF - BUZZER Skid control buzzer / ON or OFF ON: Buzzer ON OFF: Buzzer OFF - VSC WARN LAMP VSC warning (multi-information display and master caution indicator light) light / ON or OFF ON: Indicator ON OFF: Indicator OFF - FR wheel acceleration / min.: - Min.: -200.84 m/s2 FR WHEEL ACCEL FL WHEEL ACCEL RR WHEEL ACCEL 200.84 m/s2, max.: 199.27 m/s2 Min.: -200.84 m/s2 FL wheel acceleration / min.: 2 Max.: 199.27 m/s2 2 200.84 m/s , max.: 199.27 m/s Max.: 199.27 m/s2 RR wheel acceleration / min.: - Min.: -200.84 m/s2 2 2 200.84 m/s , max.: 199.27 m/s Max.: 199.27 m/s2 - - - BC BC–312 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) Item (Display) RL WHEEL ACCEL ZERO DECELERAT ZERO STEERING LATERAL G Normal Condition Min.: -200.84 m/s2 RL wheel acceleration / min.: 2 2 200.84 m/s , max.: 199.27 m/s Max.: 199.27 m/s2 Memorized zero value / min.: - Min.: -25.11 m/s2 25.11 m/s 2, max.: 24.91 m/s2 Max.: 24.91 m/s2 Memorized zero value / min.: 3,276.8 deg, max.: 3,276.7 deg Min.: -3,276.8 deg Max.: 3,276.7 deg Lateral G / min.: -25.11 m/s2, Min.: -25.11 m/s2 Diagnostic Note - - 2 Max.: 24.91 m/s2 Forward and rearward G / min.: - Min.: -25.11 m/s2 25.11 m/s2, max.: 24.91 m/s2 Max.: 24.91 m/s2 YAW RATE VALUE Yaw rate value / min.: -128 deg/s, max.: 127 deg/s Min.: -128 deg/s Max.: 127 deg/s - STEERING ANGLE Steering angle value / min.: 3,276.8 deg, max.: 3,276.7 deg Min.: -3,276.8 deg Max.: 3,276.7 deg - TRAC STATUS TRAC control status / ON or OFF ON: During the control - TRAC ENG STATUS TRAC engine control status / ON or OFF ON: During the control - TRAC BRK STATUS TRAC brake control status / ON or OFF ON: During the control - FR VSC STATUS FR wheel VSC control status / ON or OFF ON: During the control - FL VSC STATUS FL wheel VSC control status / ON or OFF ON: During the control - RR VSC STATUS RR wheel VSC control status / ON or OFF ON: During the control - RL VSC STATUS RL wheel VSC control status / ON or OFF ON: During the control - FR ABS STATUS FR wheel ABS control status / ON or OFF ON: During the control - FL ABS STATUS FL wheel ABS control status / ON or OFF ON: During the control - RR ABS STATUS RR wheel ABS control status / ON or OFF ON: During the control - RL ABS STATUS RL wheel ABS control status / ON or OFF ON: During the control - FR EBD STATUS FR wheel EBD control status / ON or OFF ON: During the control - FL EBD STATUS FL wheel EBD control status / ON or OFF ON: During the control - RR EBD STATUS RR wheel EBD control status / ON or OFF ON: During the control - RL EBD STATUS RL wheel EBD control status / ON or OFF ON: During the control - BA STATUS BA control status / ON or OFF ON: During the control - INSPECTION MODE Inspection mode / OTHER or INSPECT - - #IG ON2 Number of ignition switch on (IG) after entering the inspection mode / min.: 0, max.: 255 - - TROUBLE CODE Freeze frame DTC / min.: 0, max.: 65,535 - - FORWARD&REA G BC Measurement Item / Range (Display) max.: 24.91 m/s *: Automatic Transaxle - BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 2. Item (Display) BC–313 ACTIVE TEST HINT: Performing the Active Test using the intelligent tester allows the relay, actuator, and other items to operate without removing any parts. Performing the Active Test as the first step in troubleshooting is one of the methods to save labor time. It is possible to display the Data List during the Active Test. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) From the display on the tester, select the Active Test. HINT: The ignition switch must be turned on (IG) to proceed to the Active Test using the intelligent tester. Vehicle Condition / Test Details Diagnostic Note SFRR Turns ABS solenoid (SFRR) ON / OFF Operating sound of solenoid (clicking sound) can be heard SFRH Turns ABS solenoid (SFRH) ON / OFF Operating sound of solenoid (clicking sound) can be heard SFLR Turns ABS solenoid (SFLR) ON / OFF Operating sound of solenoid (clicking sound) can be heard SFLH Turns ABS solenoid (SFLH) ON / OFF Operating sound of solenoid (clicking sound) can be heard SRRR Turns ABS solenoid (SRRR) ON / OFF Operating sound of solenoid (clicking sound) can be heard SRRH Turns ABS solenoid (SRRH) ON / OFF Operating sound of solenoid (clicking sound) can be heard SRLR Turns ABS solenoid (SRLR) ON / OFF Operating sound of solenoid (clicking sound) can be heard SRLH Turns ABS solenoid (SRLH) ON / OFF Operating sound of solenoid (clicking sound) can be heard SRM2 Turns master cut solenoid (SRM2) ON / OFF Operating sound of solenoid (clicking sound) can be heard SRM1 Turns master cut solenoid (SRM1) ON / OFF Operating sound of solenoid (clicking sound) can be heard SRC2 Turns master cut solenoid (SRC2) ON / OFF Operating sound of solenoid (clicking sound) can be heard SRC1 Turns master cut solenoid (SRC1) ON / OFF Operating sound of solenoid (clicking sound) can be heard MOTOR RELAY Turns ABS motor relay ON / OFF Operating sound of relay (clicking sound) and motor can be heard ABS WARN LAMP Turns ABS warning light ON / OFF Observe combination meter VSC WARN LAMP Turns VSC warning (master caution indicator) light ON / OFF Observe combination meter SLIP INDI LAMP Turns SLIP indicator light ON / OFF Observe combination meter BRAKE WARN LAMP Turns BRAKE warning light ON / OFF Observe combination meter BUZZER Turns skid control buzzer ON / OFF Buzzer can be heard BC BC–314 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DIAGNOSTIC TROUBLE CODE CHART • If a trouble code is displayed during the DTC check, check the circuit indicated by the DTC. For details of each code, refer to the page for the respective "DTC No." in the DTC chart. • Inspect the fuse and relay before investigating the trouble areas as shown in the table below. DTC chart of ABS: DTC No. Detection Item Trouble Area See page C0200/31 Right Front Wheel Speed Sensor Signal Malfunction 1. Front speed sensor RH 2. Front speed sensor circuit RH 3. Front speed sensor rotor RH 4. Sensor installation 5. Brake actuator assembly (skid control ECU) BC-316 C0205/32 Left Front Wheel Speed Sensor Signal Malfunction 1. Front speed sensor LH 2. Front speed sensor circuit LH 3. Front speed sensor rotor LH 4. Sensor installation 5. Brake actuator assembly (skid control ECU) BC-316 C0210/33 Right Rear Wheel Speed Sensor Signal Malfunction 1. Rear speed sensor RH 2. Rear speed sensor circuit RH 3. Rear speed sensor rotor RH 4. Sensor installation 5. Brake actuator assembly (skid control ECU) BC-324 C0215/34 Left Rear Wheel Speed Sensor Signal Malfunction 1. Rear speed sensor LH 2. Rear speed sensor circuit LH 3. Rear speed sensor rotor LH 4. Sensor installation 5. Brake actuator assembly (skid control ECU) BC-324 C0226/21 SFR Solenoid Circuit 1. Each solenoid circuit 2. Brake actuator assembly BC-333 C0236/22 SFL Solenoid Circuit 1. Each solenoid circuit 2. Brake actuator assembly BC-333 C0246/23 SRR Solenoid Circuit 1. Each solenoid circuit 2. Brake actuator assembly BC-333 C0256/24 SRL Solenoid Circuit 1. Each solenoid circuit 2. Brake actuator assembly BC-333 C0273/13 Open or Short Circuit in ABS Motor Relay Circuit 1. ABS No. 1 fuse (Fusible link) 2. Brake actuator assembly (skid control ECU) 3. Motor relay circuit BC-335 C0278/11 Open or Short Circuit in ABS Solenoid Relay Circuit 1. ABS No. 2 fuse (Fusible link) 2. Brake actuator assembly (skid control ECU) 3. Solenoid relay circuit BC-339 C1225/25 SMC Solenoid Circuit 1. Brake actuator assembly (skid control ECU) 2. SMC1 solenoid circuit BC-348 C1226/26 SMC Solenoid Circuit 1. Brake actuator assembly (skid control ECU) 2. SMC2 circuit BC-348 C1227/27 SRC Solenoid Circuit 1. Brake actuator assembly (skid control ECU) 2. SRC1 circuit BC-348 C1228/28 SRC Solenoid Circuit 1. Brake actuator assembly (skid control ECU) 2. SRC2 circuit BC-348 BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) Trouble Area See page C1237/37 DTC No. Tires of Different Size Detection Item 1. Brake actuator assembly (skid control ECU) 2. Speed sensor 3. Speed sensor rotor (front) 4. Rear axle hub and bearing assembly 5. Speed sensor circuit 6. Tire and wheel circuit 7. Tire deformation BC-354 C1241/41 Low Battery Positive Voltage or Abnormally High Battery Positive Voltage 1. Battery 2. ECU-IG No. 2 fuse 3. Charging system 4. Power source circuit 5. Brake actuator assembly (internal power source circuit) BC-361 C1246/46 Master Cylinder Pressure Sensor Malfunction 1. Master cylinder pressure sensor 2. Master cylinder pressure sensor circuit 3. Stop light switch circuit 4. Brake actuator assembly (skid control ECU) BC-365 C1249/49 Open in Stop Light Switch Circuit 1. Stop light switch 2. Stop light switch circuit 3. Brake actuator assembly (skid control ECU) BC-368 C1271/71 Low Output Signal of Front Speed Sensor RH (Test Mode DTC) 1. Front speed sensor RH 2. Sensor installation 3. Speed sensor rotor BC-316 C1272/72 Low Output Signal of Front Speed Sensor LH (Test Mode DTC) 1. Front speed sensor LH 2. Sensor installation 3. Speed sensor rotor BC-316 C1273/73 Low Output Signal of Rear Speed Sensor RH (Test Mode DTC) 1. Rear speed sensor RH 2. Sensor installation 3. Speed sensor rotor BC-324 C1274/74 Low Output Signal of Rear Speed Sensor LH (Test Mode DTC) 1. Rear speed sensor LH 2. Sensor installation 3. Speed sensor rotor BC-324 C1275/75 Abnormal Change in Output Signal of Front Speed Sensor RH (Test Mode DTC) 1. Front speed sensosr RH 2. Sensor installation 3. Sensor rotor BC-316 C1276/76 Abnormal Change in Output Signal of Front Speed Sensor LH (Test Mode DTC) 1. Front speed sensosr LH 2. Sensor installation 3. Sensor rotor BC-316 C1277/77 Abnormal Change in Output Signal of Rear Speed Sensor RH (Test Mode DTC) 1. Rear speed sensosr RH 2. Sensor installation 3. Sensor rotor BC-324 C1278/78 Abnormal Change in Output Signal of Rear Speed Sensor LH (Test Mode DTC) 1. Rear speed sensosr LH 2. Sensor installation 3. Sensor rotor BC-324 C1288/88 ECU Version Miss Match ECM BC-374 C1300/62 Skid Control ECU Malfunction Brake actuator assembly (skid control ECU) BC-375 C1330/35 Right Front Speed Sensor Circuit 1. Front speed sensor RH 2. Front speed sensor circuit RH 3. Sensor installation BC-316 C1331/36 Left Front Speed Sensor Circuit 1. Front speed sensor LH 2. Front speed sensor circuit LH 3. Sensor installation BC-316 C1332/38 Right Rear Speed Sensor Circuit 1. Rear speed sensor RH 2. Rear speed sensor circuit RH 3. Sensor installation BC-324 BC–315 BC BC–316 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DTC No. Detection Item Trouble Area See page C1333/39 Left Rear Speed Sensor Circuit 1. Rear speed sensor LH 2. Rear speed sensor circuit LH 3. Sensor installation BC-324 U0073/94 Control Module Communication Bus OFF CAN communication system BC-377 (*1, *2): Even after the trouble areas are repaired, the ABS warning light will not go off unless the following operations are performed: • (*1): (a)Drive the vehicle at 12 mph (20 km/h) for 30 seconds or more and check that the ABS warning light goes off. (b)Clear the DTC. • (*2): (a)Keep the vehicle stationary for 5 seconds or more and depress the brake pedal lightly 2 or 3 times. (b)Drive the vehicle at the vehicle speed of 31 mph (50 km/h) and keep depressing the brake pedal strongly for approximately 3 seconds. (c) Repeat the above operation 3 times or more and check that the ABS warning light goes off. (d)Clear the DTC. HINT: In some cases, the intelligent tester cannot be used when the ABS warning light remains on. BC DTC chart of VSC: DTC No. 43 Detection Item Trouble Area See page ABS Control System Malfunction ABS control system BC-315 C0365/28 Malfunction in Deceleration Sensor 1. Yaw rate and acceleration sensor 2. Yaw rate and acceleration sensor circuit 3. Sensor installation 4. Brake actuator assembly (skid control ECU) BC-343 C1201/51 Engine Control System Malfunction Engine control system BC-347 C1231/31 Steering Angle Sensor Circuit Malfunction 1. Steering angle sensor 2. Steering angle sensor circuit 3. Steering angle sensor power supply BC-350 C1234/34 Yaw Rate Sensor Malfunction 1. Yaw rate and acceleration sensor 2. Yaw rate and acceleration sensor circuit BC-343 U0100/65 Lost Communication with ECM / PCM CAN communication system (skid control ECU to ECM) BC-377 U0123/62 Lost Communication with Yaw Rate Sensor Module CAN communication system (skid control ECU to yaw rate and acceleration sensor) BC-377 U0126/63 Lost Communication with Steering Angle Sensor Module CAN communication system (skid control ECU to steering angle sensor) BC-377 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DTC 43 BC–317 ABS Control System Malfunction DESCRIPTION This DTC is output when the VSC system detects a malfunction in the ABS control system. DTC No. 43 DTC Detection Condition Malfunction in the ABS control system Trouble Area ABS control system INSPECTION PROCEDURE 1 CHECK ABS CONTROL SYSTEM (a) Clear the DTC (See page BC-302). (b) Turn the ignition switch on (IG). (c) Check if the same DTC is recorded (See page BC-302). Result Condition Proceed to DTC (ABS control system DTC) is not output A DTC (ABS control system DTC) is output B B REPAIR CIRCUITS INDICATED BY OUTPUT DTCS (BRAKE CONTROL SYSTEM) (See page BC-311) A 2 CONFIRM DTC (a) Clear the DTC (See page BC-302). (b) Turn the ignition switch on (IG). (c) Check if the same DTC is recorded (See page BC-302). Result Condition Proceed to DTC (43) is not output A DTC (43) is output B B A END REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC BC–318 BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DTC C0200/31 Right Front Wheel Speed Sensor Signal Malfunction DTC C0205/32 Left Front Wheel Speed Sensor Signal Malfunction DTC C1271/71 Low Output Signal of Front Speed Sensor RH (Test Mode DTC) DTC C1272/72 Low Output Signal of Front Speed Sensor LH (Test Mode DTC) DTC C1275/75 Abnormal Change in Output Signal of Front Speed Sensor RH (Test Mode DTC) DTC C1276/76 Abnormal Change in Output Signal of Front Speed Sensor LH (Test Mode DTC) DTC C1330/35 Right Front Speed Sensor Circuit DTC C1331/36 Left Front Speed Sensor Circuit DESCRIPTION The speed sensors detects wheel speed and transmit the signals to the skid control ECU. These signals are used for control of the ABS control system. Each of the front and rear rotors has 48 serrations. When the rotors rotate, the magnetic field generated by the permanent magnet in the speed sensor induces AC voltage. Since the frequency of this AC voltage changes in direct proportion to the speed of the rotor, the frequency is used by the ECU to detect the speed of each wheel. DTCs C1271/71 to C1276/76 can be deleted when the speed sensor sends a wheel speed signal or the test mode ends. DTCs C1271/71 to C1276/76 are output only in the test mode. Speed Sensor Rotor Coil N S Magnet To ECU Low speed High speed +V -V F000010E16 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–319 DTC No. DTC Detecting Condition Trouble Area C0200/31 C0205/32 When either of the following is detected: • Vehicle speed is more than 25 mph (40 km/h), and pulses are not input for 0.03 sec. • When the vehicle speed has reached 8 mph (12 km/h) after the initial start or restart, a wheel speed of 0 mph (0 km/h) is detected. • • • • • Front speed sensor RH and/or LH Front speed sensor circuit RH and/or LH Front speed sensor rotor RH and/or LH Sensor installation Brake actuator assembly (skid control ECU) C1330/35 C1331/36 Abnormality in the resistance value of each speed sensor is detected. • • • Front speed sensor RH and/or LH Front speed sensor circuit RH and/or LH Sensor installation C1271/71 C1272/72 Detected only during test mode. • • • Front speed sensor Sensor installation Sensor rotor C1275/75 C1276/76 Detected only during test mode. • • • Front speed sensor Sensor installation Sensor rotor HINT: DTC No. C0200/31 and C1330/35 are for the front speed sensor RH. DTC No. C0205/32 and C1331/36 are for the front speed sensor LH. BC WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU with Actuator) A14 Front Speed Sensor LH 1 2 1 A35 Front Speed Sensor RH 2 5 A60 FL+ 6 A60 FL- 10 A60 FR+ 9 A60 FR- C122979E02 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). BC–320 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) READ VALUE OF INTELLIGENT TESTER (FRONT SPEED SENSOR) (a) Connect the intelligent tester to the DLC3. (b) Start the engine. (c) Select "DATA LIST" and read the value displayed on the intelligent tester (See page BC-307). DATA LIST: ABS/TRAC/VSC Measurement Item / Range (Display) Item Normal Condition FR WHEEL SPD Wheel speed sensor (FR) reading / min.: 0 MPH (0 km/h), max.: 202 MPH (326 km/h) Actual wheel speed FL WHEEL SPD Wheel speed sensor (FL) reading / min.: 0 MPH (0 km/h), max.: 202 MPH (326 km/h) Actual wheel speed (d) Check that there is no difference between the speed value output from the speed sensor displayed on the intelligent tester and the speed value displayed on the speedometer when driving the vehicle. OK: The speed value output from the speed sensor displayed on the intelligent tester is the same as the actual vehicle speed. BC NG Go to step 5 OK 2 PERFORM TEST MODE INSPECTION (SIGNAL CHECK) (a) Check if test mode (signal check) DTCs are detected (See page BC-290). Result Condition Proceed to Test mode (signal check) DTC is not output A Test mode (signal check) DTC is output B B A Go to step 5 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 3 BC–321 INSPECT SPEED SENSOR SIGNAL WAVEFORM A14 :LH FL+ FL- A35 :RH FR+ FR- Normal Signal Waveform: GND (a) Lift up the vehicle. (b) Perform the inspection using an oscilloscope. (1) Disconnect the front speed sensor connector. (2) Connect the oscilloscope to terminals 1 and 2 of the front speed sensor. (3) Check that a waveform is output when the tires are rotated. OK: The same waveform is output from front wheels and there is no noise or interference in the waveform. HINT: • As vehicle speed (wheel rotation speed) increases, the width of the waveform narrows and the output voltage becomes greater. • When noise is identified in the waveform on the oscilloscope, the erratic signals are generated due to rotor scratches, looseness or foreign matter attached to the speed sensor. (4) Connect the connector. NG 1 V/Division, 2 ms./Division Go to step 11 C136488E02 OK 4 RECONFIRM DTC (a) Clear the DTCs (See page BC-302). (b) Drive the vehicle at a speed of approximately 25 mph (40 km/h) or more for 60 seconds or more. (c) Check if the same DTCs are recorded (See page BC302). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTCs (C0200/31, C0205/32, C1330/35 and C1331/36) are output A DTCs (C0200/31, C0205/32, C1330/35 and C1331/36) are output (When troubleshooting in accordance with the PROBLEM SYMPTOMS TABLE) B DTCs (C0200/31, C0205/32, C1330/35 and C1331/36) are not output (When troubleshooting in accordance with the DTC CHART) C BC BC–322 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page BC-295) C END A 5 INSPECT FRONT SPEED SENSOR INSTALLATION (a) Check the front speed sensor installation. OK: The installation bolt is tightened properly. There is no clearance between the sensor and front steering knuckle. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) NOTICE: Check the speed sensor signal after replacement (See page BC-290). 8.0 N*m (82 kgf*cm, 71 in.*lbf) BC OK No clearance NG BR03795E21 NG INSTALL FRONT SPEED SENSOR CORRECTLY (See page BC-440) OK 6 INSPECT FRONT SPEED SENSOR 2 (a) Make sure that there is no looseness at the locking part and the connecting part of the connectors. (b) Disconnect the front speed sensor connectors. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: LH 1 C093876E01 Tester Connection Specified Condition A14-1 (FL+) - A14-2 (FL-) 0.92 to 1.22 kΩ at 20°C A14-1 (FL+) - Body ground 10 kΩ or higher A14-2 (FL-) - Body ground 10 kΩ or higher RH Tester Connection Specified Condition A35-1 (FR+) - A35-2 (FR-) 0.92 to 1.22 kΩ at 20°C A35-1 (FR+) - Body ground 10 kΩ or higher A35-2 (FR-) - Body ground 10 kΩ or higher NOTICE: Check the speed sensor signal after replacement (See page BC-290). NG REPLACE FRONT SPEED SENSOR (See page BC-438) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–323 OK 7 CHECK HARNESS AND CONNECTOR (FRONT SPEED SENSOR TO SKID CONTROL ECU) (a) Disconnect the skid control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: LH Skid Control ECU (Harness Side Connector Front View): FL+ FL- A60 Tester Connection Specified Condition A60-5 (FL+) - A14-1 (FL+) Below 1 Ω A60-6 (FL-) - A14-2 (FL-) Below 1 Ω A60-5 (FL+) - Body ground 10 kΩ or higher A60-6 (FL-) - Body ground 10 kΩ or higher Tester Connection Specified Condition A60-10 (FR+) - A35-1 (FR+) Below 1 Ω A60-9 (FR-) - A35-2 (FR-) Below 1 Ω RH FR- FR+ Front Speed Sensor (Harness Side Connecotor Front View): A14 A35 A60-10 (FR+) - Body ground 10 kΩ or higher A60-9 (FR-) - Body ground 10 kΩ or higher (c) Connect the connectors. NG FL- FL+ FR- FR+ C139143E01 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (FRONT SPEED SENSOR TO SKID CONTROL ECU) BC BC–324 8 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) INSPECT SPEED SENSOR SIGNAL WAVEFORM A14 :LH FL+ FL- (a) Lift up the vehicle. (b) Perform the inspection using an oscilloscope. (1) Disconnect the front speed sensor connector. (2) Connect the oscilloscope to terminals 1 and 2 of the front speed sensor. (3) Check that a waveform is output when the tires are rotated. OK: The same waveform is output from all the 4 wheels and there is no noise or interference in the waveform. HINT: • As vehicle speed (wheel rotation speed) increases, the width of the waveform narrows and the output voltage becomes greater. • When noise is identified in the waveform on the oscilloscope, the erratic signals are generated due to rotor scratches, looseness or foreign matter attached to the speed sensor. (4) Connect the connector. A35 :RH FR+ FR- Normal Signal Waveform: BC GND 1 V/Division, 2 ms./Division C136488E02 NG Go to step 11 OK 9 READ VALUE OF INTELLIGENT TESTER (FRONT SPEED SENSOR) (a) Connect the intelligent tester to the DLC3. (b) Start the engine. (c) Select "DATA LIST" and read the value displayed on the intelligent tester (See page BC-307). DATA LIST: ABS/TRAC/VSC Item Measurement Item / Range (Display) Normal Condition FR WHEEL SPD Wheel speed sensor (FR) reading / min.: 0 MPH (0 km/h), max.: 202 MPH (326 km/h) Actual wheel speed FL WHEEL SPD Wheel speed sensor (FL) reading / min.: 0 MPH (0 km/h), max.: 202 MPH (326 km/h) Actual wheel speed (d) Check that there is no difference between the speed value output from the speed sensor displayed on the intelligent tester and the speed value displayed on the speedometer when driving the vehicle. OK: The speed value output from the speed sensor displayed on the intelligent tester is the same as the actual vehicle speed. HINT: If troubleshooting has been carried out according to the "PROBLEM SYMPTOMS TABLE", refer back to the table and proceed to the next step before replacing the part (See page BC-295). BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) NG BC–325 REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) OK 10 RECONFIRM DTC (a) Clear the DTCs (See page BC-302). (b) Drive the vehicle at a speed of approximately 25 mph (40 km/h) or more for 60 seconds or more. (c) Check if the same DTCs are recorded (See page BC302). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTCs (C0200/31, C0205/32, C1330/35 and C1331/36) are output A DTCs (C0200/31, C0205/32, C1330/35 and C1331/36) are output (When troubleshooting in accordance with the PROBLEM SYMPTOMS TABLE) B DTCs (C0200/31, C0205/32, C1330/35 and C1331/36) are not output (When troubleshooting in accordance with the DTC CHART) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page BC-295) C END A 11 INSPECT SPEED SENSOR TIP Speed Sensor Rotor R000948E03 (a) Remove the front speed sensor. (b) Check the sensor tip. OK: No scratches or foreign matter on the sensor tip. NOTICE: Check the speed sensor signal after cleaning or replacement (See page BC-290). (c) Install the speed sensor. NG OK CLEAN OR REPLACE SPEED SENSOR ROTOR CLEAN OR REPLACE SPEED SENSOR BC BC–326 BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DTC C0210/33 Right Rear Wheel Speed Sensor Signal Malfunction DTC C0215/34 Left Rear Wheel Speed Sensor Signal Malfunction DTC C1273/73 Low Output Signal of Rear Speed Sensor RH (Test Mode DTC) DTC C1274/74 Low Output Signal of Rear Speed Sensor LH (Test Mode DTC) DTC C1277/77 Abnormal Change in Output Signal of Rear Speed Sensor RH (Test Mode DTC) DTC C1278/78 Abnormal Change in Output Signal of Rear Speed Sensor LH (Test Mode DTC) DTC C1332/38 Right Rear Speed Sensor Circuit DTC C1333/39 Left Rear Speed Sensor Circuit DESCRIPTION Refer to DTCs C0200/31, C0205/32, C1330/35, and C1331/36 (See page BC-316). DTCs from C1273/73 to C1278/78 can be deleted when the speed sensor sends a vehicle speed signal or the test mode ends. DTCs from C1273/73 to C1278/78 are output only in the test mode. DTC No. DTC Detecting Condition C0210/33 C0215/34 When either of the following is detected: • Vehicle speed is more than 25 mph (40 km/h) and pulses are not input for 0.03 sec. • When the vehicle speed has reached 8 mph (12 km/h), after the initial start or restart, a wheel speed of 0 mph (0 km/h) is detected. Trouble Area • • • • • Rear speed sensor RH and/or LH Rear speed sensor circuit RH and/or LH Rear speed sensor rotor RH and/or LH Sensor installation Brake actuator assembly (skid control ECU) C1332/38 C1333/39 Abnormality in the resistance value of each speed sensor is detected. • • • Rear speed sensor RH and/or LH Rear speed sensor circuit RH and/or LH Sensor installation C1273/73 C1274/74 Detected only during test mode. • • • Rear speed sensor Sensor installation Sensor rotor C1277/77 C1278/78 Detected only during test mode. • • • Rear speed sensor Sensor installation Sensor rotor HINT: DTC No. C0210/33 and C1332/38 are for the rear speed sensor RH. DTC No. C0215/34 and C1333/39 are for the rear speed sensor LH. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–327 WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU with Actuator) 1 7 A60 RL+ g1 Rear Speed Sensor LH 27 A60 RL- 2 BC 29 A60 RR+ 1 f1 Rear Speed Sensor RH 8 A60 RR- 2 C122948E03 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). 1 READ VALUE OF INTELLIGENT TESTER (REAR SPEED SENSOR) (a) Connect the intelligent tester to the DLC3. (b) Start the engine. (c) Select "DATA LIST" and read the value displayed on the intelligent tester (See page BC-307). DATA LIST: ABS/TRAC/VSC Item Measurement Item / Range (Display) Normal Condition RR WHEEL SPD Wheel speed sensor (RR) reading / min.: 0 MPH (0 km/h), max.: 202 MPH (326 km/h) Actual wheel speed RL WHEEL SPD Wheel speed sensor (RL) reading / min.: 0 MPH (0 km/h), max.: 202 MPH (326 km/h) Actual wheel speed (d) Check that there is no difference between the speed value output from the speed sensor displayed on the intelligent tester and the speed value displayed on the speedometer when driving the vehicle. BC–328 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) OK: The speed value output from the speed sensor displayed on the intelligent tester is the same as the actual vehicle speed. NG Go to step 5 OK 2 PERFORM TEST MODE INSPECTION (SIGNAL CHECK) (a) Check if test mode (signal check) DTCs are detected (See page BC-290). Result Condition Proceed to Test mode (signal check) DTC is not output A Test mode (signal check) DTC is output B BC B Go to step 5 A 3 INSPECT SPEED SENSOR SIGNAL WAVEFORM Skid Control ECU (Harness Side Connector Front View): A60 RL+ RR- RL- RR+ Normal Signal Waveform: GND (a) Lift up the vehicle. (b) Perform the inspection using an oscilloscope. (1) Disconnect the skid control ECU connector. (2) Connect the oscilloscope to the rear speed sensor terminals of the skid control ECU. (3) Check that a waveform is output when the tires are rotated. OK: The same waveform is output from all the 4 wheels and there is no noise or interference in the waveform. HINT: • As vehicle speed (wheel rotation speed) increases, the width of the waveform narrows and the output voltage becomes greater. • When noise is identified in the waveform on the oscilloscope, the erratic signals are generated due to rotor scratches, looseness or foreign matter attached to the speed sensor. (4) Connect the connector. NG 1 V/Division, 2 ms./Division C139144E01 REPAIR OR REPLACE SPEED SENSOR AND SENSOR ROTOR BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–329 OK 4 RECONFIRM DTC (a) Clear the DTCs (See page BC-302). (b) Drive the vehicle at a speed of approximately 25 mph (40 km/h) or more for 60 seconds or more. (c) Check if the same DTCs are recorded (See page BC302). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTCs (C0210/33, C0215/34, C1332/38 and C1333/39) are output A DTCs (C0210/33, C0215/34, C1332/38 and C1333/39) are output (When troubleshooting in accordance with the PROBLEM SYMPTOMS TABLE) B DTCs (C0210/33, C0215/34, C1332/38 and C1333/39) are not output (When troubleshooting in accordance with the DTC CHART) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page BC-295) C END A 5 INSPECT SPEED SENSOR INSTALLATION (a) Check the rear speed sensor installation. OK: There is no clearance between the sensor and rear axle carrier. NOTICE: Check the speed sensor signal after replacement (See page BC-290). No Clearance OK NG NG F010178E07 OK INSTALL REAR SPEED SENSOR CORRECTLY BC BC–330 6 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) INSPECT REAR SPEED SENSOR (a) Disconnect the rear speed sensor connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: LH Rear Speed Sensor: Tester Connection 2 g1-1 (RR+) - g1-2 (RR-) Below 2.2 kΩ g1-1 (RR+) - Body ground 10 kΩ or higher g1-2 (RR-) - Body ground 10 kΩ or higher Tester Connection Specified Condition RH 1 BC Specified Condition C113377E01 f1-1 (RL+) - f1-2 (RL-) Below 2.2 kΩ f1-1 (RL+) - Body ground 10 kΩ or higher f1-2 (RL-) - Body ground 10 kΩ or higher NOTICE: Check the speed sensor signal after replacement (See page BC-290). NG OK REPLACE REAR SPEED SENSOR (See page BC-443) BC–331 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 7 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU TO SKID CONTROL SENSOR WIRE) (a) Check the harness and connector. (1) Disconnect the skid control ECU connector and the rear speed sensor connector. (2) Disconnect the skid control sensor wire. (3) Measure the resistance according to the value(s) in the table below. Standard resistance: LH Skid Control ECU (Harness Side Connector Front View): A60 RL+ RL- RR- RR+ RL- f1 :RH RL+ RR- Specified Condition A60-7 (RL+) - g1-1 (RL+) Below 1 Ω A60-27 (RL-) - g1-2 (RL-) Below 1 Ω A60-7 (RL+) - Body ground 10 kΩ or higher A60-27 (RL-) - Body ground 10 kΩ or higher BC RH Rear Speed Sensor (Harness Side Connector Front View): g1 :LH Tester Connection RR+ NG Tester Connection Specified Condition A60-29 (RR+) - f1-1 (RR+) Below 1 Ω A60-8 (RR-) - f1-2 (RR-) Below 1 Ω A60-29 (RR+) - Body ground 10 kΩ or higher A60-8 (RR-) - Body ground 10 kΩ or higher REPAIR OR REPLACE HARNESS OR CONNECTOR (SKID CONTROL ECU TO SKID CONTROL SENSOR WIRE) C139145E02 OK 8 CHECK HARNESS AND CONNECTOR (SKID CONTROL SENSOR WIRE TO REAR SPEED SENSOR) Skid Control Sensor Wire: Vehicle Side Connector (a) Check harness and connector (skid control sensor wire). (1) Measure the resistance according to the value(s) in the table below. Standard resistance: LH Tester Connection g1 LH f1 RH A Specified Condition g1-1 - A-1 Below 1 Ω g1-1 - A-2 10 kΩ or higher g1-1 - Body ground 10 kΩ or higher g1-2 - A-2 Below 1 Ω g1-2 - A-1 10 kΩ or higher g1-2 - Body ground 10 kΩ or higher Tester Connection Specified Condition f1-1 - A-1 Below 1 Ω RH Sensor Side Connector C113396E05 BC–332 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) Tester Connection Specified Condition f1-1 - A-2 10 kΩ or higher f1-1 - Body ground 10 kΩ or higher f1-2 - A-2 Below 1 Ω f1-2 - A-1 10 kΩ or higher f1-2 - Body ground 10 kΩ or higher (2) Connect the connector. NG REPAIR OR REPLACE SKID CONTROL SENSOR WIRE OK 9 BC INSPECT SPEED SENSOR SIGNAL WAVEFORM Skid Control ECU (Harness Side Connector Front View): A60 RL+ RR- RL- RR+ Normal Signal Waveform: GND (a) Lift up the vehicle. (b) Perform the inspection using an oscilloscope. (1) Disconnect the skid control ECU connector. (2) Connect the oscilloscope to the rear speed sensor terminals of the skid control ECU. (3) Check that a waveform is output when the tires are rotated. OK: The same waveforms is output from rear wheels and there is no noise or interference in the waveform. HINT: • As vehicle speed (wheel rotation speed) increases, the width of the waveform narrows and the output voltage becomes greater. • When noise is identified in the waveform on the oscilloscope, the erratic signals are generated due to rotor scratches, looseness or foreign matter attached to the speed sensor. (4) Connect the connector. NG CLEAN OR REPLACE SPEED SENSOR AND SENSOR ROTOR 1 V/Division, 2 ms./Division C139144E01 OK 10 READ VALUE OF INTELLIGENT TESTER (REAR SPEED SENSOR) (a) Connect the intelligent tester to the DLC3. (b) Start the engine. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–333 (c) Select "DATA LIST" and read the value displayed on the intelligent tester (See page BC-307). DATA LIST: ABS/TRAC/VSC Measurement Item / Range (Display) Item Normal Condition RR WHEEL SPD Wheel speed sensor (RR) reading / min.: 0 MPH (0 km/h), max.: 202 MPH (326 km/h) Actual wheel speed RL WHEEL SPD Wheel speed sensor (RL) reading / min.: 0 MPH (0 km/h), max.: 202 MPH (326 km/h) Actual wheel speed (d) Check that there is no difference between the speed value output from the speed sensor displayed on the intelligent tester and the speed value displayed on the speedometer when driving the vehicle. OK: The speed value output from the speed sensor displayed on the intelligent tester is the same as the actual vehicle speed. HINT: • It is suspected that the DTCs were output due to a bad connection of the connector terminal. • If troubleshooting has been carried out according to the "PROBLEM SYMPTOMS TABLE", refer back to the table and proceed to the next step (See page BC295). NG REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) OK 11 RECONFIRM DTC (a) Clear the DTCs (See page BC-302). (b) Drive the vehicle at a speed of approximately 25 mph (40 km/h) or more for 60 seconds or more. (c) Check if the same DTCs are recorded (See page BC302). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTCs (C0210/33, C0215/34, C1332/38 and C1333/39) are output A DTCs (C0210/33, C0215/34, C1332/38 and C1333/39) are output (When troubleshooting in accordance with the PROBLEM SYMPTOMS TABLE) B DTCs (C0210/33, C0215/34, C1332/38 and C1333/39) are not output (When troubleshooting in accordance with the DTC CHART) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page BC-295) C END BC BC–334 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) A 12 INSPECT SPEED SENSOR ROTOR (a) Turn the ignition switch off. (b) Remove the rear axle. (c) Check the rotor. OK: No scratches, cracks, oil, or foreign matter on the rotors. NOTICE: Check the speed sensor signal after cleaning or replacement (See page BC-290). (d) Install the rear axle. NG BC CLEAN OR REPLACE SPEED SENSOR ROTOR OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DTC C0226/21 SFR Solenoid Circuit DTC C0236/22 SFL Solenoid Circuit DTC C0246/23 SRR Solenoid Circuit DTC C0256/24 SRL Solenoid Circuit BC–335 DESCRIPTION These solenoids turn on when signals are received from the skid control ECU and they control the pressure acting on the wheel cylinders to control the braking force. DTC No. DTC Detection Condition Trouble Area C0226/21 C0236/22 C0246/23 C0256/24 Solenoid valve signal does not match the check result. • • Each solenoid circuit Brake actuator assembly BC WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) ALT FL MAIN ABS No. 2 3 A60 +BS 4 A60 GND1 1 A60 GND2 Battery C131988E04 BC–336 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) INSPECTION PROCEDURE 1 RECONFIRM DTC HINT: These codes are detected when a problem is identified in the brake actuator assembly. The solenoid circuits are located in the brake actuator assembly. Therefore, solenoid circuit inspection and solenoid unit inspection cannot be performed. Be sure to check if the DTC is output before replacing the brake actuator assembly. (a) Clear the DTC (See page BC-302). (b) Start the engine. (c) Drive the vehicle at a speed of 12 mph (20 km/h) or more for 30 seconds or more. (d) Check if the same DTC is recorded (See page BC-302). BC Result Condition Proceed to DTC is not output A DTC is output B HINT: • If the normal system code is output (the trouble code is not output), slightly jiggle the connectors, wire harness, and fuses of the brake actuator assembly (skid control ECU). Make sure that no DTCs are output. • If any DTCs are output while jiggling a connector or wire harness of the brake actuator (skid control ECU), inspect and repair the connector or wire harness. • It is suspected that the DTCs were output due to a bad connection of the connector terminal. B A END REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DTC BC–337 Open or Short Circuit in ABS Motor Relay Circuit C0273/13 DESCRIPTION The ABS motor relay supplies power to the ABS pump motor. While the ABS is activated, the ECU switches the motor relay on and operates the ABS pump motor. If the voltage supplied to the motor relay (+BM) is below the DTCs detection threshold due to low voltage from the battery or alternator, the DTC may be stored. DTC No. DTC Detection Condition C0273/13 When any of the following is detected: • When the motor relay is actuated, voltage is not supplied to the pump motor within 0.1 seconds. • For 30 to 125 ms after the motor relay is turned from ON to OFF, the remaining high voltage is out of range. The motor relay is turned from ON to OFF 3 times. If the voltage is still out of range in the 3rd operation, this failure is detected. • When the motor relay is changed from ON to OFF, the remaining high voltage is more than 2 V for 1 second. Trouble Area • • • ABS No. 1 fuse (Fusible link) Brake actuator assembly (skid control ECU) Motor relay circuit BC WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) ALT ABS No. 1 2 A60 +BM 4 FL MAIN A60 GND1 1 A60 GND2 Battery C131988E05 INSPECTION PROCEDURE HINT: • When C1241/41 is output together with C0273/13, inspect and repair the trouble areas indicated by C1241/41 (See page BC-361). BC–338 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) • Check the condition of each related circuit connector before troubleshooting (See page IN-40). 1 INSPECT FUSIBLE LINK (ABS NO. 1 FUSE) Engine Room R/B Fusible Link (a) Remove the fusible link from the engine room R/B. (b) Check if the fusible link is malted. OK: The fusible link is not melted. (c) Install the fusible link to the engine room R/B with the nut. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) NG REPLACE FUSIBLE LINK ABS No. 1 BC C136500E04 OK 2 INSPECT SKID CONTROL ECU (+BM TERMINAL VOLTAGE) (a) Disconnect the skid control ECU connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control ECU (Harness Side Connector Front View): A60 Tester Connection Condition Specified Condition A60-2 (+BM) - Body ground Always 10 to 14 V NG +BM C136493E01 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (+BM CIRCUIT) BC–339 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 3 INSPECT SKID CONTROL ECU (GND TERMINAL CONTINUITY) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU (Harness Side Connector Front View): A60 Tester Connection Specified Condition A60-4 (GND1) - Body ground Below 1 Ω A60-1 (GND2) - Body ground Below 1 Ω (b) Connect the connector. NG GND2 REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) GND1 BC C136493E02 OK 4 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (ABS MOTOR RELAY) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Select "ACTIVE TEST" on the intelligent tester (See page BC-307). ACTIVE TEST: ABS/TRAC/VSC Item ABS MTR RELAY Measurement Item/Range (Display) Turns ABS motor relay ON/OFF Normal Condition Operating sound of motor is heard. (d) Check the operating sound of the ABS motor relay when operating it with the intelligent tester. OK: The operating sound of the ABS motor relay is heard. NG REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) OK 5 RECONFIRM DTC HINT: This code is detected when a problem is identified in the brake actuator assembly. The ABS motor relay is located in the brake actuator assembly. Therefore, ABS motor relay inspection and motor relay unit inspection cannot be performed. Be sure to check if the DTC is output before replacing the brake actuator assembly. (a) Clear the DTC (See page BC-302). BC–340 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) (b) Start the engine. (c) Drive the vehicle at a speed of 12 mph (20 km/h) or more for 30 seconds or more. (d) Check if the same DTC is recorded (See page BC-302). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTC is not output A DTC is output B HINT: • If the normal system code is output (the trouble code is not output), slightly jiggle the connectors, wire harness, and fuses of the brake actuator assembly (skid control ECU). Make sure that no DTCs are output. • If any DTCs are output while jiggling a connector or wire harness of the brake actuator assembly (skid control ECU), inspect and repair the connector or wire harness. • It is suspected that the DTCs were output due to a bad connection of the connector terminal. BC B REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) A CHECK FOR INTERMITTENT PROBLEMS (SYMPTOM SIMULATION) (See page BC-298) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DTC C0278/11 BC–341 Open or Short Circuit in ABS Solenoid Relay Circuit DESCRIPTION The ABS solenoid relay supplies power to the ABS solenoid. The solenoid relay is turned on 1.5 seconds after the ignition switch is turned on (IG), and is turned off if an open or short in the solenoid is detected by self diagnosis performed when the vehicle starts running. The ABS solenoid relay is housed in the skid control ECU in the brake actuator assembly. HINT: If a speed signal of 4 mph (6 km/h) or more is input to the skid control ECU, with the ignition switch on (IG) and the stop light switch off, the skid control ECU performs self diagnosis of the motor and solenoid circuits. DTC No. C0278/11 DTC Detection Condition Trouble Area When any of the following is detected: • When the relay is ON, the voltage is less than IG terminal voltage x 0.8 V for 0.5 seconds. • When the relay is OFF, the voltage is out of range (IG terminal voltage x 0.1 to IG terminal voltage x 0.8). • • • ABS No. 2 fuse (Fusible link) Brake actuator assembly (skid control ECU) Solenoid relay circuit WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) ALT FL MAIN ABS No. 2 3 A60 +BS 4 A60 GND1 1 A60 GND2 Battery C131988E04 BC BC–342 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) INSPECTION PROCEDURE HINT: • When C1241/41 is output together with C0278/11, inspect and repair the trouble areas indicated by C1241/41 (See page BC-361). • Check the condition of each related circuit connector before troubleshooting (See page IN-40). 1 INSPECT FUSIBLE LINK (ABS NO. 2 FUSE) (a) Remove the fusible link from the engine room R/B. (b) Check if the fusible link is melted. OK: The fusible link is not melted. (c) Install the fusible link to the engine room R/B with the nut. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) Engine Room R/B NG REPLACE FUSIBLE LINK BC ABS No. 2 C136500E05 OK 2 INSPECT SKID CONTROL ECU (+BS TERMINAL VOLTAGE) (a) Disconnect the skid control ECU connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control ECU (Harness Side Connector Front View): A60 Tester Connection Condition Specified Condition A60-3 (+BS) - Body ground Always 10 to 14 V NG +BS C136493E03 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (+BS CIRCUIT) BC–343 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 3 INSPECT SKID CONTROL ECU (GND TERMINAL CONTINUITY) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU (Harness Side Connector Front View): A60 Tester Connection Specified Condition A60-4 (GND1) - Body ground Below 1 Ω A60-1 (GND2) - Body ground Below 1 Ω (b) Connect the connector. NG GND2 REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) GND1 BC C136493E02 OK 4 RECONFIRM DTC HINT: This code is detected when a problem is identified in the brake actuator assembly. The solenoid circuit is located in the brake actuator assembly. Therefore, solenoid circuit inspection and solenoid unit inspection cannot be performed. Be sure to check if the DTC code is output before replacing the brake actuator assembly. (a) Clear the DTC (See page BC-302). (b) Start the engine. (c) Drive the vehicle at a speed of 12 mph (20 km/h) or more for 30 seconds or more. (d) Check if the same DTC is recorded (See page BC-302). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTC is not output A DTC is output B HINT: • If the normal system code is output (the trouble code is not output), slightly jiggle the connectors, wire harnesses, and fuses of the brake actuator assembly. Make sure that no DTCs are output. • If any DTCs are output while jiggling a connector or wire harness of the brake actuator (skid control ECU), inspect and repair the connector or wire harness. • It is suspected that the DTCs were output due to a bad connection of the connector terminal. BC–344 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) B REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) A CHECK FOR INTERMITTENT PROBLEMS (SYMPTOM SIMULATION) (See page BC-298) BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DTC C0365/28 Malfunction in Deceleration Sensor DTC C1234/34 Yaw Rate Sensor Malfunction BC–345 DESCRIPTION The deceleration sensor is combined with the yaw rate and acceleration sensor. The brake actuator receives signals from the yaw rate and acceleration sensor via the CAN communication system. If there is trouble in the CAN communication system, DTCs U0073/94 and U0123/62 are output. DTC No. C0365/28 DTC Detection Condition When any of the following is detected: • Lateral acceleration difference between sensor signal and reference value is large. • Offset value of sensor signal is higher than the standard value. • C1234/34 Trouble Area • • • • Yaw rate and acceleration sensor Yaw rate and acceleration sensor circuit Sensor installation Brake actuator assembly (skid control ECU) • • Yaw rate and acceleration sensor Yaw rate and acceleration sensor circuit Sensor signal is out of range (2.25 m/s2). Sensor malfunction signal is received from the yaw rate sensor. BC BC–346 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) E65 Yaw Rate and Acceleration Sensor CANH ECU IG No. 2 1 IG 35 A60 2 CANH 14 CANL GND A60 3 CANL 4 IG1 BC 5 3 2 1 E23 Ignition SW (*2) AM1 (*2) 4 AM1 IG1 1 (*1) Main Body ECU ALT (*1) 6 E7 AM1 IG1D 1 AM2 E6 3 E7 AM2 FL MAIN Battery *1: with Smart Key System *2: without Smart Key System C136507E01 INSPECTION PROCEDURE HINT: • Check the condition of each related circuit connector before troubleshooting (See page IN-40). BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–347 • When U0073/94, U0100/65, U0123/62 and/or U0126/63 is output together with C0365/28, inspect and repair the trouble areas indicated by U0073/94, U0100/65, U0123/62 and/or U0126/63 first. 1 CHECK DTC (a) Clear the DTCs (See page BC-302). (b) Start the engine. (c) At a speed of 18 mph (30 km/h) or more, drive the vehicle, turn the steering wheel, and decelerate (depress the brake pedal) the vehicle. (d) Turn the ignition switch on (IG) again and check that no CAN communication system DTC is output (See page BC-302). Result Condition Proceed to CAN communication system DTC is not output A CAN communication system DTC is output B B INSPECT CAN COMMUNICATION SYSTEM (See page CA-8) A 2 INSPECT YAW RATE AND ACCELERATION SENSOR INSTALLATION (a) Check that the yaw rate and acceleration sensor has been installed properly (See page BC-448). OK: The sensor should be tightened to the specified torque. The sensor should not be titled. NG INSTALL YAW RATE AND ACCELERATION SENSOR CORRECTLY OK 3 INSPECT YAW RATE AND ACCELERATION SENSOR (IG TERMINAL) (a) Disconnect the yaw rate and acceleration sensor connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Yaw Rate and Acceleration Sensor (Harness Side Connector Front View): E65 IG Tester Connection Condition Specified Condition E65-1 (IG) - Body ground Ignition switch on (IG) 10 to 14 V F048983E13 NG REPAIR OR REPLACE HARNESS OR CONNECTOR (IG CIRCUIT) BC BC–348 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) OK 4 INSPECT YAW RATE AND ACCELERATION SENSOR (GND TERMINAL) (a) Turn the ignition switch off. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Yaw Rate and Acceleration Sensor (Harness Side Connector Front View): E65 GND Tester Connection Condition Specified Condition E65-4 (GND) - Body ground Always Below 1 Ω NG F048983E12 REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) OK BC 5 RECONFIRM DTC (a) Clear the DTCs (See page BC-302). (b) Start the engine. (c) At a speed of 18 mph (30 km/h) or more, drive the vehicle, turn the steering wheel, and decelerate (depress the brake pedal) the vehicle. (d) Turn the ignition switch on (IG) again and check that no CAN communication system DTC is output (See page BC-302). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTC is output A DTC is output (When troubleshooting in accordance with the PROBLEM SYMPTOMS TABLE) B DTC is not output (When troubleshooting in accordance with the DTC CHART) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page BC-295) C CHECK FOR INTERMITTENT PROBLEMS (SYMPTOM SIMULATION) (See page BC-298) A REPLACE YAW RATE AND ACCELERATION SENSOR (See page BC-447) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DTC BC–349 C1201/51 Engine Control System Malfunction DESCRIPTION If a malfunction in the engine control system is detected, the operations of VSC and TRAC are prohibited by the fail safe function (See page BC-306). When the signals from the engine are input normally, the fail safe is cancelled and the DTC is not stored. DTC No. C1201/51 DTC Detecting Condition Trouble Area A trouble signal in the engine control system is input. Engine control system INSPECTION PROCEDURE 1 CHECK DTC (ENGINE CONTROL SYSTEM) (a) Clear the DTC (engine control system) (See page ES-38 for 2AZ-FE, ES-45 for 2GR-FE). (b) Perform a road test. (c) Check for the DTC (engine control system). Result Display (DTC Output) Proceed to DTC (engine control system) is not output A DTC (engine control system) is output B B A REPLACE ECM REPAIR CIRCUITS INDICATED BY OUTPUT DTCS (ENGINE CONTROL SYSTEM) BC BC–350 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DTC C1225/25 SMC Solenoid Circuit DTC C1226/26 SMC Solenoid Circuit DTC C1227/27 SRC Solenoid Circuit DTC C1228/28 SRC Solenoid Circuit DESCRIPTION These solenoids turn on when signals are received from the skid control ECU and they control the pressure acting on the wheel cylinders to control the braking force. DTC No. BC DTC Detecting Condition Trouble Area C1225/25 Solenoid valve signal does not match the check result • • Brake actuator assembly (skid control ECU) SMC1 circuit C1226/26 Solenoid valve signal does not match the check result • • Brake actuator assembly (skid control ECU) SMC2 circuit C1227/27 Solenoid valve signal does not match the check result • • Brake actuator assembly (skid control ECU) SRC1 circuit C1228/28 Solenoid valve signal does not match the check result • • Brake actuator assembly (skid control ECU) SRC2 circuit WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) ALT FL MAIN ABS No. 2 3 A60 +BS 4 A60 GND1 1 A60 GND2 Battery C131988E04 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–351 INSPECTION PROCEDURE 1 RECONFIRM DTC HINT: These codes are detected when a problem is identified in the brake actuator assembly. The solenoid circuits are located in the brake actuator assembly. Therefore, solenoid circuit inspection and solenoid unit inspection cannot be performed. Be sure to check if the DTC is output before replacing the brake actuator assembly. (a) Clear the DTC (See page BC-302). (b) Start the engine. (c) Drive the vehicle at a speed of 12 mph (20 km/h) or more for 30 seconds or more. (d) Check if the same DTC is recorded (See page BC-302). Result Condition Proceed to DTC is not output A DTC is output B HINT: • If the normal system code is output (the trouble code is not output), slightly jiggle the connectors, wire harness, and fuses of the brake actuator assembly (skid control ECU). Make sure that no DTCs are output. • If any DTCs are output while jiggling a connector or wire harness of the brake actuator (skid control ECU), inspect and repair the connector or wire harness. • It is suspected that the DTCs were output due to a bad connection of the connector terminal. B A END REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC BC–352 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DTC C1231/31 Steering Angle Sensor Circuit Malfunction DESCRIPTION The steering angle sensor signal is sent to the skid control ECU via the CAN communication system. When there is a malfunction in the CAN communication system, it will be detected by the steering angle sensor zero point malfunction diagnostic function. BC DTC No. DTC Detection Condition C1231/31 When any of the following is detected: • With ECU terminal IG1 voltage 9.8 V or more, the condition that the ECU does not receive data from the steering angle sensor continues. • Internal sensor failure • The offset value is out of range. • Sensor signal changes too rapidly. • Steering angle value difference between measured and reference is out of range. • Steering angle sensor signal is out of range. Trouble Area • • • Steering angle sensor Steering angle sensor circuit Steering angle sensor power supply BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–353 WIRING DIAGRAM E17 Steering Angle Sensor Brake Actuator Assembly (Skid Control ECU) 35 SHORT 1 ECU IB No. 1 3 2 ECU IG No. 2 1 BATT A60 CANH CANH 10 14 A60 CANL CANL 9 IG ESS 2 IG1 BC 5 3 2 1 E23 Ignition SW (*2) AM1 (*2) 4 AM1 ALT (*1) Main Body ECU 6 E7 (*1) IG1 1 AM2 1 E6 AM1 IG1D 3 E7 AM2 FL MAIN Battery *1: with Smart Key System *2: without Smart Key System C136508E01 BC–354 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) INSPECTION PROCEDURE HINT: • When U0073/94, U0100/63, U0123/62 and/or U0126/63 is output together with C1231/31, inspect and repair the trouble areas indicated by U0073/94, U0100/65, U0123/62 and/or U0126/63 first. • When the speed sensor or the yaw rate and acceleration sensor has trouble, DTCs for the steering angle sensor may be output even when the steering angle sensor is normal. When DTCs for the speed sensor or yaw rate and acceleration sensor are output together with other DTCs for the steering angle sensor, inspect and repair the speed sensor and yaw rate and acceleration sensor first, and then inspect and repair the steering angle sensor. • Check the condition of each related circuit connector before troubleshooting (See page IN-40). 1 CHECK DTC (a) Clear the DTC (See page BC-302). (b) Turn the ignition switch off. (c) Turn the ignition switch on (IG) again and check that no CAN communication system DTC is output. (d) Drive the vehicle and turn the steering wheel to the right and left at the speed of 22 mph (35 km/h) and check that no speed sensor and yaw rate and acceleration sensor DTCs are output (See page BC-302). BC Result Condition Proceed to No CAN communication system DTC and the speed sensor or yaw rate and acceleration sensor DTC are output A CAN communication system DTC is output B Speed sensor or yaw rate and acceleration sensor DTC is output C HINT: • If there is a malfunction in the speed sensor or the yaw rate and acceleration sensor, an abnormal value may be output although the steering angle sensor is normal. • If the speed sensor and the yaw rate and acceleration sensor DTCs are output simultaneously, repair the sensors and inspect the steering angle sensor. A B INSPECT CAN COMMUNICATION SYSTEM (See page CA-8) C REPAIR CIRCUITS INDICATED BY OUTPUT DTCS (See page BC-311) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 2 BC–355 INSPECT STEERING ANGLE SENSOR (POWER SOURCE TERMINAL) (a) Remove the column cover lower. (b) Disconnect the steering angle sensor connector. (c) Measure the voltage according to the value(s) in the table below. Standard voltage Steering Angle Sensor Wire Harness View: E17 IG Tester Connection Condition Specified Condition E17-1 (IG) - Body ground Ignition switch on (IG) 10 to 14 V E17-3 (BAT) - Body ground Always 10 to 14 V NG BATT REPAIR OR REPLACE HARNESS OR CONNECTOR (POWER SOURCE CIRCUIT) BC G030156E17 OK 3 INSPECT STEERING ANGLE SENSOR (GROUND TERMINAL) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Steering Angle Sensor Wire Harness View: E17 Tester Connection Condition Specified Condition E17-2 (ESS) - Body ground Always Below 1 Ω (b) Connect the connector. (c) Install the column cover lower. NG REPAIR OR REPLACE HARNESS OR CONNECTOR (GROUND CIRCUIT) ESS G030156E18 OK REPLACE STEERING ANGLE SENSOR (See page BC-450) BC–356 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DTC C1237/37 Tires of Different Size DESCRIPTION The skid control ECU measures the speed of each wheel by receiving signals from the speed sensor. These signals are used for recognizing that all 4 wheels are operating properly. Therefore, all wheel signals must be equal. DTC No. C1237/37 DTC Detecting Condition When any of the following is detected: • Wheel speed difference between the wheels. • Wheel sensor signal failure. • ABS control continues for 60 sec. or more. Trouble Area • • • • • • • Brake actuator assembly (skid control ECU) Speed sensor rotor (Front) Rear axle hub and bearing assembly Speed sensor Speed sensor circuit Tire and wheel size Tire deformation WIRING DIAGRAM BC Brake Actuator Assembly (Skid Control ECU with Actuator) A14 Front Speed Sensor LH 1 2 1 A35 Front Speed Sensor RH 2 5 A60 FL+ 6 A60 FL- 10 A60 FR+ 9 A60 FR- C122979E02 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–357 Brake Actuator Assembly (Skid Control ECU with Actuator) 1 g1 Rear Speed Sensor LH 2 1 f1 Rear Speed Sensor RH 2 7 A60 RL+ 27 A60 RL- 29 A60 RR+ BC 8 A60 RR- C122948E04 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). 1 CHECK TIRES (a) Check the size and condition of all 4 wheels (See page TW-3). HINT: The DTC is output when tire deformation or a difference in tire size is detected. OK: The diameter of all 4 tires and air pressure are the same. NG OK REPLACE TIRES SO THAT ALL 4 TIRES ARE THE SAME SIZE BC–358 2 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) INSPECT SPEED SENSOR AND SENSOR ROTOR SERRATIONS Skid Control ECU (Harness Side Connector Front View): A60 FL- RL+ FL+ RL- RRFR- (a) Lift up the vehicle. (b) Disconnect the skid control ECU connector. (c) Connect the oscilloscope to each speed sensor terminal of the skid control ECU connector. Terminals Connector FR+ Circuit A60-5 (FL+) - A60-6 (FL-) Front left speed sensor A60-10 (FR+) - A60-9 (FR-) Front right speed sensor A60-7 (RL+) - A60-27 (RL-) Rear left speed sensor A60-29 (RR+) - A60-8 (RR-) Rear right speed sensor RR+ BC C136493E04 Normal Signal Waveform: GND 1 V/Division, 2 ms./Division C140980E03 (d) Check that a waveform is output when the tires are rotated (by the sensor circuit). OK: A waveform as shown in the figure is output. HINT: • Each sensor circuit outputs the same waveform without noise. • As vehicle speed (wheel rotation speed) increases, the width of the waveform narrows and the fluctuation in the output voltage becomes greater. • When noise is identified in the waveform on the oscilloscope, the erratic signals are generated due to rotor scratches, looseness or foreign matter attached to the speed sensor. (e) Make sure that the waveform does not change while jiggling a connector or a wire harness. OK: The waveform does not change. HINT: If the waveform changes while jiggling a connector or a wire harness, there may be a malfunction in the connector or the wire harness. (f) Connect the connector. NG Go to step 4 OK 3 RECONFIRM DTC (a) Clear the DTC (See page BC-302). (b) Start the engine. (c) Drive the vehicle at a speed of 20 mph (32 km/h) or more for 60 seconds or more. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–359 (d) Check if the same DTC is recorded (See page BC-302). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTC is not output A DTC is output B B REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) A CHECK FOR INTERMITTENT PROBLEMS (SYMPTOM SIMULATION) (See page BC-298) 4 BC CHECK SPEED SENSOR ROTOR (a) Check the speed sensor rotor. Front Speed Sensor Rotor (Front drive outboard joint shaft assembly): (See page DS-23) Rear Speed Sensor Rotor (Rear axle hub and bearing assembly): (See page AH-14) OK: No scratches or foreign matter on the rotors. NOTICE: Check the speed sensor signal after the cleaning/ replacement (See page BC-290). NG CLEAN OR REPLACE SPEED SENSOR ROTOR OK 5 CHECK SPEED SENSOR TIP (a) Remove each speed sensor (See page BC-438 for front, BC-443 for rear). (b) Check the speed sensor tip. OK: No scratches or foreign matter on the sensor tip. NOTICE: Check the speed sensor signal after the cleaning/ replacement (See page BC-290). (c) Install the speed sensor. NG OK CLEAN OR REPLACE SPEED SENSOR BC–360 6 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) INSPECT SPEED SENSOR (a) Disconnect each speed sensor connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: FRONT Front Speed Sensor: 1 BC 2 Rear Speed Sensor: Tester Connection Condition Specified Condition A14-1 (FL+) - A14-2 (FL) Always 0.92 to 1.22 kΩ at 20°C A14-1 (FL+) - Body ground Always 10 kΩ or higher A14-2 (FL-) - Body ground Always 10 kΩ or higher A35-1 (FR+) - A35-2 (FR-) Always 0.92 to 1.22 kΩ at 20°C A35-1 (FR+) - Body ground Always 10 kΩ or higher A35-2 (FR-) - Body ground Always 10 kΩ or higher REAR 2 1 Tester Connection Condition Specified Condition g1-1 (RL+) - g1-2 (RL-) Always Below 2.2 kΩ g1-1 (RL+) - Body ground Always 10 kΩ or higher g1-2 (RL-) - Body ground Always 10 kΩ or higher f1-1 (RR+) - f1-2 (RR-) Always Below 2.2 kΩ f1-1 (RR+) - Body ground Always 10 kΩ or higher f1-2 (RR-) - Body ground Always 10 kΩ or higher C136027E02 NOTICE: Check the speed sensor signal after replacement (See page BC-290). NG OK REPLACE EACH SPEED SENSOR BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 7 BC–361 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU TO EACH SPEED SENSOR) Skid Control ECU (Harness Side Connector Front View): A60 RRFL- RL+ FRFR+ FL+ RL- RR+ Front Speed Sensor Harness Side Connector Front View: A14 A35 FL- FL+ FR- FR+ (a) Disconnect the skid control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: FRONT Tester Connection Condition Specified Condition A60-5 (FL+) - A14-1 (FL+) Always Below 1 Ω A60-5 (FL+) - Body ground Always 10 kΩ or higher A60-6 (FL-) - A14-2 (FL-) Always Below 1 Ω A60-6 (FL-) - Body ground Always 10 kΩ or higher A60-10 (FR+) - A35-1 (FR+) Always Below 1 Ω A60-10 (FR+) - Body ground Always 10 kΩ or higher A60-9 (FR-) - A35-2 (FR) Always Below 1 Ω A60-9 (FR-) - Body ground Always 10 kΩ or higher Tester Connection Condition Specified Condition A60-7 (RL+) - g1-1 (RL+) Always Below 1 Ω A60-7 (RL+) - Body ground Always 10 kΩ or higher A60-27 (RL-) - g1-2 (RL) Always Below 1 Ω A60-27 (RL-) - Body ground Always 10 kΩ or higher A60-29 (RR+) - f1-1 (RR+) Always Below 1 Ω A60-29 (RR+) - Body ground Always 10 kΩ or higher A60-8 (RR-) - f1-2 (RR-) Always Below 1 Ω A60-8 (RR-) - Body ground Always 10 kΩ or higher REAR Rear Speed Sensor Harness Side Connector Front View: g1 f1 RL- RL+ RR- RR+ C139146E02 (c) Connect the connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR (SKID CONTROL ECU TO EACH SPEED SENSOR) OK 8 RECONFIRM DTC (a) Clear the DTC (See page BC-302). (b) Start the engine. BC BC–362 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) (c) Drive the vehicle at a speed of 20 mph (32 km/h) or more for at least 60 seconds. (d) Check if the same DTC is recorded (See page BC-302). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTC (C1237/37) is not output A DTC (C1237/37) is output B B REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) A BC CHECK FOR INTERMITTENT PROBLEMS (SYMPTOM SIMULATION) (See page BC-298) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DTC C1241/41 BC–363 Low Battery Positive Voltage or Abnormally High Battery Positive Voltage DESCRIPTION If a malfunction is detected in the power supply circuit of the brake actuator assembly (skid control ECU), the skid control ECU (housed in the actuator assembly) stores this DTC and the fail-safe function prohibits ABS operation. This DTC is output when the IG1 terminal voltage deviates from the normal condition due to a malfunction in the power supply or charging circuit such as the battery or alternator circuit. This DTC is cancelled when the IG1 terminal voltage returns to normal (only when the voltage returns to normal from a voltage lower than the specified value). DTC No. C1241/41 DTC Detection Condition When either of the following is detected: • Battery voltage is 16.8 V or more. • Battery voltage is 9.2 V or less. Trouble Area • • • • • Battery ECU-IG No. 2 fuse Charging system Power source circuit Brake actuator assembly (internal power source circuit) BC BC–364 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) IG1 ECU IG No. 2 5 3 2 1 28 A60 IG1 4 A60 GND1 1 A60 GND2 E23 Ignition SW BC (*2) AM1 (*2) 4 AM1 IG1 1 Main Body ECU ALT (*1) 6 E7 (*1) AM2 AM1 IG1D 1 E6 3 AM2 FL MAIN Battery E7 *1: with Smart Key System *2: without Smart Key System C136502E02 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–365 INSPECTION PROCEDURE 1 INSPECT FUSE (ECU-IG NO. 2 FUSE) (a) Remove the ECU-IG No. 2 fuse from the instrument panel J/B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Instrument Panel J/B: ECU-IG No. 2 Fuse Tester Connection Specified Condition ECU-IG No. 2 fuse Below 1 Ω (Continuity) (c) Install the fuse. C136048E01 NG REPLACE FUSE OK 2 BC INSPECT BATTERY (a) Check the battery voltage. Standard voltage: 11 to 14 V NG INSPECT CHARGING SYSTEM OK 3 INSPECT SKID CONTROL ECU (IG1 TERMINAL VOLTAGE) (a) Disconnect the skid control ECU connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control ECU (Harness Side Connector Front View): A60 Tester Connection Condition Specified Condition A60-28 (IG1) - Body ground Ignition switch on (IG) 10 to 14 V NG IG1 C136493E05 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (IG1 CIRCUIT) BC–366 4 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) INSPECT SKID CONTROL ECU (GND TERMINAL CONTINUITY) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU (Harness Side Connector Front View): A60 Tester Connection Specified Condition A60-4 (GND1) - Body ground Below 1 Ω A60-1 (GND2) - Body ground Below 1 Ω (b) Connect the connector. NG GND2 REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) GND1 BC C136493E02 OK 5 RECONFIRM DTC (a) Clear the DTC (See page BC-302). (b) Start the engine. (c) Check if the same DTC is recorded (See page BC-302). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTC is not output A DTC is output (When troubleshooting in accordance with the PROBLEM SYMPTOMS TABLE) B DTC is output (When troubleshooting in accordance with the DTC CHART) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page BC-295) C REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) A CHECK FOR INTERMITTENT PROBLEMS (SYMPTOM SIMULATION) (See page BC-298) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DTC BC–367 C1246/46 Master Cylinder Pressure Sensor Malfunction DESCRIPTION The master cylinder pressure sensor is connected to the skid control ECU in the brake actuator assembly. Brake Actuator Assembly Skid Control ECU From Battery IG1 VCM Master Cylinder Pressure Sensor From Stop Light Switch STP PMC To Body ground GND E2 BC VCM: Power Supply for Master Cylinder Pressure Sensor PMC: Master Cylinder Pressure Sensor Input E2: Master Cylinder Pressure Sensor Ground C106656E03 DTC No. C1246/46 DTC Detection Condition When any of the following is detected: • The voltage of the sensor signal is out of range (less than 0.3 V, more than 4.86 V). • The sensor supply voltage is out of range (above 5.3 V, below 4.7 V). • The sensor signal offset value is out of range. • The sum of signal 1 and signal 2 is out of range (above 5.5 V, below 4.5 V). Trouble Area • • • • Master cylinder pressure sensor Master cylinder pressure sensor circuit Stop light switch circuit Brake actuator assembly (skid control ECU) INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). BC–368 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) CHECK STOP LIGHT OPERATION (a) Check that the stop light comes on when the brake pedal is depressed, and goes off when the brake pedal is released. OK Condition Illumination Condition Brake pedal depressed ON Brake pedal released OFF NG INSPECT STOP LIGHT CIRCUIT OK 2 READ VALUE OF INTELLIGENT TESTER (MASTER CYLINDER PRESSURE SENSOR) BC (a) Connect the intelligent tester to the DLC3. (b) Start the engine. (c) Select the "DATA LIST" mode on the intelligent tester (See page BC-307). DATA LIST: ABS/TRAC/VSC Item (Display) Measurement Item / Range (Display) MAS CYL PRESS 1 Master cylinder pressure sensor 1 reading / min.: 0 V, max.: 5 V Normal Condition When brake pedal is released: 0.3 to 0.5 V (d) Check that the hydraulic pressure value of the master cylinder pressure sensor observed on the intelligent tester changes when the brake pedal is depressed. OK: When the pedal is depressed, voltage displayed on the intelligent tester increases. NG REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) OK 3 READ VALUE OF INTELLIGENT TESTER (STOP LIGHT SWITCH) (a) Select the "DATA LIST" mode on the intelligent tester (See page BC-307). DATA LIST: ABS/TRAC/VSC Item (Display) STOP LAMP SW Measurement Item / Range (Display) Stop light switch / ON or OFF Normal Condition ON: Brake pedal depressed OFF: Brake pedal released (b) Check that the stop light condition observed on the intelligent tester changes when the brake pedal is depressed. OK: When the brake pedal is depressed, the intelligent tester displays "ON". BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) NG BC–369 REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) OK 4 RECONFIRM DTC (a) Clear the DTC (See page BC-302). (b) Start the engine. (c) At a speed of 18 mph (30 km/h) or more, drive the vehicle and perform braking test (decelerate the vehicle by depressing the brake pedal). (d) Check if the same DTC is recorded (See page BC-302). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTC (C1246/46) is not output A DTC (C1246/46) is output B B REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) A CHECK FOR INTERMITTENT PROBLEMS (SYMPTOM SIMULATION) (See page BC-298) BC BC–370 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DTC C1249/49 Open in Stop Light Switch Circuit DESCRIPTION This circuit recognizes brake operation by sending a stop light signal to the skid control ECU. The skid control ECU has an open detection circuit, which outputs this DTC when detecting an open in the stop light signal input line (STP terminal) or the ground line of the stop light circuit with the stop light switch off (brake pedal not depressed). BC DTC No. DTC Detection Condition C1249/49 When either of the following is detected: • After the ignition switch is turned on (IG), the STP terminal voltage of the ECU is 40% to 67% of its supplied voltage for 0.5 seconds. • When STP signal is OFF (release the brake pedal), the pressure sensor value exceeds 725 bar for 1 second. Trouble Area • • • Stop light switch Stop light switch circuit Brake actuator assembly (skid control ECU) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–371 WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) A19 Stop Light Switch STOP 1 2 30 A60 STP1 N16 Center Stop Light 2 1 BC S12 Rear Combination Light (RH) Tail 3 Stop 2 Multiplex Communication System (CAN) Tail ALT 3 Stop FL MAIN 2 S11 Rear Combination Light (LH) Battery 4 A60 GND1 1 A60 GND2 N15 Noise Filter (Dome and Stop) C131998E02 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). BC–372 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) CHECK STOP LIGHT SWITCH OPERATION (STOP LIGHT SWITCH CIRCUIT) (a) Check that the stop lights come on when the brake pedal is depressed and go off when the brake pedal is released. OK Pedal Condition Illumination Condition Brake pedal depressed ON Brake pedal released OFF NG Go to step 5 OK 2 INSPECT SKID CONTROL ECU (STP TERMINAL) BC (a) Disconnect the skid control ECU connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control ECU (Harness Side Connector Front View): A60 Tester Connection Switch Condition Specified Condition A60-30 (STP1) - Body ground Brake pedal depressed 8 to 14 V A60-30 (STP1) - Body ground Brake pedal released Below 4.0 V NG STP1 C136493E06 OK Go to step 7 BC–373 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 3 INSPECT SKID CONTROL ECU (GND TERMINAL CONTINUITY) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU (Harness Side Connector Front View): A60 Tester Connection Specified Condition A60-4 (GND1) - Body ground Below 1 Ω A60-1 (GND2) - Body ground Below 1 Ω (b) Connect the connector. NG GND2 REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) GND1 BC C136493E02 OK 4 RECONFIRM DTC (a) Clear the DTC (See page BC-302). (b) Start the engine. (c) Depress the brake pedal several times to test the stop light circuit. (d) Check if the same DTC is recorded (See page BC-302). HINT: Reinstall the sensors, connectors, etc. and restore the vehicle to its prior condition before rechecking for DTCs. Result Condition Proceed to DTC is not output A DTC is output B HINT: It is suspected that the DTCs were output due to a bad connection of the connector terminal. B REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) A CHECK FOR INTERMITTENT PROBLEMS (SYMPTOM SIMULATION) (See page BC-298) BC–374 5 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) CHECK HARNESS AND CONNECTOR (STOP LIGHT SWITCH POWER SOURCE TERMINAL VOLTAGE) (a) Disconnect the stop light switch connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Stop Light Switch (Harness Side Connector Front View): Tester Connection Condition Specified Condition A19-2 - Body ground Always 10 to 14 V A19 NG REPAIR OR REPLACE HARNESS OR CONNECTOR (STOP LIGHT SWITCH POWER SOURCE CIRCUIT) I042363E18 OK BC 6 INSPECT STOP LIGHT SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance Stop Light Switch Assembly: Free Switch Condition Specified Condition 1-2 Switch pin free Below 1 Ω 1-2 Switch pin pushed in 10 kΩ or higher (b) Connect the connector. Pushed In F047752E04 OK Tester Connection NG REPLACE STOP LIGHT SWITCH ASSEMBLY BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 7 BC–375 CHECK HARNESS AND CONNECTOR (STOP LIGHT SWITCH TO SKID CONTROL ECU) (a) Disconnect the stop light switch connector and skid control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU (Harness Side Connector Front View): A60 Tester Connection Specified Condition A60-30 (STP1) - A19-1 (STP1) Below 1 Ω (c) Connect the connectors. NG STP1 REPAIR OR REPLACE HARNESS OR CONNECTOR (STOP LIGHT SWITCH TO SKID CONTROL ECU) Stop Lignt Switch (Harness Side Connector Front View): BC A19 STP C139147E01 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (STOP LIGHT CIRCUIT) BC–376 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DTC C1288/88 ECU Version Miss Match DESCRIPTION DTC No. C1288/88 DTC Detection Condition ECM does not match Trouble Area ECM INSPECTION PROCEDURE 1 CHECK CAN COMMUNICATION SYSTEM (a) Check if a CAN communication system DTC is output (See page BC-302). Result Condition BC Proceed to CAN communication system DTC is not output A CAN communication system DTC is output B B INSPECT CAN COMMUNICATION SYSTEM (See page CA-8) A 2 PERFORM ENGINE VARIANT LEARNING (a) Perform engine variant learning (See page BC-290). NEXT 3 CONFIRM RECONFIRM DTC (a) Clear the DTC (See page BC-302). (b) Start the engine. (c) Check if the same DTC is recorded (See page BC-302). Result Condition Proceed to DTC is not output A DTC is output B B A END REPLACE ECM BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) DTC BC–377 C1300/62 Skid Control ECU Malfunction DESCRIPTION The skid control ECU is housed in the brake actuator assembly. The skid control ECU judges the vehicle driving condition based on the signals from each sensor, and controls the brake actuator assembly. DTC No. DTC Detection Condition C1300/62 Trouble Area Internal failure of the skid control ECU control unit Brake actuator assembly (skid control ECU) INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). 1 CHECK DTC (a) Check the DTC (See page BC-302). BC Result Condition Proceed to DTC C1300/62 is output (only C1300/62) A Other DTCs are output B B REPAIR CIRCUITS INDICATED BY OUTPUT DTCS (See page BC-302) A 2 INSPECT SKID CONTROL ECU (IG1 TERMINAL VOLTAGE) (a) Disconnect the skid control ECU connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control ECU (Harness Side Connector Front View): A60 Tester Connection Condition Specified Condition A60-28 (IG1) - Body ground Ignition switch on (IG) 10 to 14 V NG IG1 C136493E05 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (IG1 CIRCUIT) BC–378 3 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) INSPECT SKID CONTROL ECU (GND TERMINAL CONTINUITY) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU (Harness Side Connector Front View): A60 Tester Connection Specified Condition A60-4 (GND1) - Body ground Below 1 Ω A60-1 (GND2) - Body ground Below 1 Ω (b) Connect the connector. NG GND2 BC REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) GND1 C136493E02 OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–379 DTC U0073/94 Control Module Communication Bus OFF DTC U0100/65 Lost Communication with ECM / PCM DTC U0123/62 Lost Communication with Yaw Rate Sensor Module DTC U0126/63 Lost Communication with Steering Angle Sensor Module DESCRIPTION The skid control ECU receives the signals from the ECM, steering angle sensor, and yaw rate and acceleration sensor via the CAN communication system. DTC No. DTC Detection Condition Trouble Area U0073/94 When either of the following is detected: 1. Bus OFF state continues for 300 msec. 2. The ECU detects that it cannot send a signal. CAN communication system U0100/65 When either of the following is detected: 1. At a vehicle speed of 4 mph (6 km/h) or more, the skid control ECU receives data that is out of range from the engine. 2. At a vehicle speed of 4 mph (6 km/h) or more, the skid control ECU receives abnormal data from the engine (5 cycles). CAN communication system (Skid control ECU to ECM) U0123/62 When any r of the following is detected: 1. The skid control ECU receives an abnormal signal from the yaw rate sensor (5 cycles). 2. The skid control ECU receives a signal that has a shorter message than normal. 3. The skid control ECU cannot receive a signal from the yaw rate sensor. CAN communication system (Skid control ECU to yaw rate and acceleration sensor) U0126/63 When any of the following is detected: 1. The skid control ECU receives an abnormal signal from the steering angle sensor (5 cycles). 2. The skid control ECU receives a signal that has a shorter message than normal. 3. The skid control ECU cannot receive a signal from the steering angle sensor. CAN communication system (Skid control ECU to steering angle sensor) BC BC–380 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) WIRING DIAGRAM A60 Brake Actuator Assembly (Skid Control ECU) E38 A/C Amplifier CANH CANL 11 35 12 14 E61 Option Connector (Bus Buffer) BC CAN+ CAN- CANL 1 (*1) 41 2 (*1) 49 CANL CANH CANL A24 ECM 13 (*2) 41 22 (*2) 49 CANH CANL E17 Steering Sensor E65 Yaw Rate Sensor CANH CANL A55 ECM E30 Airbag Sensor Assembly Center CANH CANH 2 10 3 9 CANH CANL *1: 2GR-FE *2: 2AZ-FE C136509E01 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) E10 DLC3 F1 Combination Meter CANH 6 CANL BC–381 14 17 18 CANH CANL E8 Main Body ECU 5 6 CANH BC CANL C132000E01 INSPECTION PROCEDURE Proceed to CAN communication system troubleshooting (See page CA-8). HINT: When a DTC indicating a CAN communication system malfunction is output, repair the CAN communication system before repairing each corresponding sensor. BC–382 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) ABS Warning Light Remains ON DESCRIPTION The skid control ECU is connected to the combination meter assembly via CAN communication. If any of the following is detected, the ABS warning light remains on. • The skid control ECU connectors are disconnected from the skid control ECU. • There is a malfunction in the skid control ECU internal circuit. • There is an open in the wire harness between the combination meter assembly and the skid control ECU. HINT: In some cases, the intelligent tester cannot be used when the skid control ECU is abnormal. BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–383 WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) F1 Combination Meter CANH 17 ABS MICRO COMPUTER DRIVER IC IG+ CANL 18 35 A60 CANH 14 A60 CANL IG1 ECU IG No. 2 5 3 2 1 BC 28 A60 IG1 4 A60 GND1 1 A60 GND2 E23 Ignition SW (*2) AM1 (*2) IG1 1 4 AM1 Main Body ECU ALT (*1) 6 E7 AM2 1 E6 (*1) AM1 IG1D AM2 FL MAIN Battery 3 E7 *1: with Smart Key System *2: without Smart Key System C136510E02 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). BC–384 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) CHECK CAN COMMUNICATION SYSTEM (a) Check if a CAN communication system DTC is output (See page BC-302). Result Condition Proceed to CAN communication system DTC is not output A CAN communication system DTC is output B B INSPECT CAN COMMUNICATION SYSTEM (See page CA-8) A 2 CHECK IF SKID CONTROL ECU CONNECTOR IS SECURELY CONNECTED BC (a) Check if the skid control ECU connector is securely connected. OK: The connector is securely connected. NG CONNECT CONNECTOR TO ECU CORRECTLY OK 3 CHECK BATTERY (a) Check the battery voltage. Standard voltage: 11 to 14 V NG OK CHECK AND REPLACE CHARGING SYSTEM OR BATTERY BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 4 BC–385 INSPECT SKID CONTROL ECU (IG1 TERMINAL) (a) Disconnect the skid control ECU connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control ECU (Harness Side Connector Front View): A60 Tester Connection Condition Specified Condition A60-28 (IG1) - Body ground Ignition switch on (IG) 10 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR (IG1 CIRCUIT) IG1 BC C136493E05 OK 5 INSPECT SKID CONTROL ECU (GND TERMINAL) (a) Turn the ignition switch off. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU (Harness Side Connector Front View): A60 Tester Connection Condition Specified Condition A60-4 (GND1) - Body ground Always Below 1 Ω A60-1 (GND2) - Body ground Always Below 1 Ω (c) Connect the connector. NG GND2 GND1 REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) C136493E02 OK 6 INSPECT COMBINATION METER ASSEMBLY (a) Connect the intelligent tester to the DLC3. (b) Perform "ACTIVE TEST" of the combination meter assembly using the intelligent tester (See page ME-32). (c) Check the ABS warning light operation. OK: The ABS warning light turns on or off in accordance with the intelligent tester. BC–386 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) NG REPLACE COMBINATION METER ASSEMBLY (See page ME-63) OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–387 ABS Warning Light does not Come ON DESCRIPTION The skid control ECU is connected to the combination meter assembly via CAN communication. BC BC–388 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) F1 Combination Meter CANH 17 ABS MICRO COMPUTER DRIVER IC IG+ CANL 18 35 A60 CANH 14 A60 CANL 28 A60 IG1 4 A60 GND1 1 A60 GND2 IG1 BC ECU IG No. 2 5 3 2 1 E23 Ignition SW (*2) AM1 (*2) IG1 1 4 AM1 Main Body ECU ALT (*1) 6 E7 AM2 1 E6 (*1) AM1 IG1D AM2 FL MAIN Battery 3 E7 *1: with Smart Key System *2: without Smart Key System C136510E02 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 1 BC–389 CHECK CAN COMMUNICATION SYSTEM (a) Check if a CAN communication system DTC is output (See page BC-302). Result Condition Proceed to CAN communication system DTC is not output A CAN communication system DTC is output B B INSPECT CAN COMMUNICATION SYSTEM (See page CA-8) A 2 CHECK ABS WARNING LIGHT (a) Disconnect the skid control ECU connector. (b) Turn the ignition switch on (IG). (c) Check that the ABS warning light comes on. OK: The ABS warning light comes on. (d) Connect the connector. OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) NG 3 INSPECT COMBINATION METER ASSEMBLY (a) Connect the intelligent tester to the DLC3. (b) Perform "ACTIVE TEST" of the combination meter assembly using the intelligent tester (See page ME-32). (c) Check ABS warning light operation. OK: The ABS warning light turns on or off in accordance with the intelligent tester. NG REPLACE COMBINATION METER ASSEMBLY (See page ME-63) OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC BC–390 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) VSC Warning Light Remains ON DESCRIPTION The skid control ECU communicates with the combination meter assembly via CAN communication. If the ECU stores a DTC, the master caution indicator light will illuminate, and the DTC will be displayed on the multi-information display in the combination meter (models with multi-information display). On models without a multi-information display, the VSC warning light will come on when the skid control ECU stores a DTC. BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–391 WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) F1 Combination Meter (*3) VSC IG+ CANH 17 MICRO COMPUTER Multi-display (*4) CANL 18 35 A60 CANH 14 A60 CANL IG1 ECU IG No. 2 5 3 2 1 BC 28 A60 IG1 E23 Ignition SW (*2) AM1 (*2) 4 AM1 IG1 1 Main Body ECU ALT (*1) 6 E7 1 E6 AM2 AM1 IG1D 3 E7 AM2 4 A60 GND1 FL MAIN *1: with Smart Key System Battery (*1) *2: without Smart Key System 1 A60 GND2 *3: without Multi-Information Display *4: with Multi-Information Display C136510E03 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). BC–392 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) CHECK CAN COMMUNICATION SYSTEM (a) Check if a CAN communication system DTC is output (See page BC-302). Result Condition Proceed to CAN communication system DTC is not output A CAN communication system DTC is output B B INSPECT CAN COMMUNICATION SYSTEM (See page CA-8) A 2 CHECK IF SKID CONTROL ECU CONNECTOR IS SECURELY CONNECTED BC (a) Check if the skid control ECU connector is securely connected. OK: The connector is securely connected. NG CONNECT CONNECTOR TO ECU CORRECTLY OK 3 CHECK BATTERY (a) Check the battery voltage. Standard voltage: 11 to 14 V NG CHECK AND REPLACE CHARGING SYSTEM OR BATTERY OK 4 INSPECT COMBINATION METER ASSEMBLY (a) Connect the intelligent tester to the DLC3. (b) Perform "ACTIVE TEST" of the combination meter assembly using the intelligent tester (See page ME-32). (c) Check VSC warning (multi-information display)/VSC warning light (without multi-information display) operation. OK: The VSC warning (multi-information display) or VSC warning light turns on or off in accordance with the intelligent tester. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) NG BC–393 REPLACE COMBINATION METER ASSEMBLY (See page ME-63) OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC BC–394 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) VSC Warning Light does not Come ON DESCRIPTION The skid control ECU communicates with the combination meter assembly via CAN communication. If the ECU stores a DTC, the master caution indicator light will illuminate, and the DTC will be displayed on the multi-information display in the combination meter (models with multi-information display). On models without a multi-information display, the VSC warning light will come on when the skid control ECU stores a DTC. BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–395 WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) F1 Combination Meter (*3) VSC IG+ CANH 17 MICRO COMPUTER Multi-display (*4) CANL 18 35 A60 CANH 14 A60 CANL IG1 ECU IG No. 2 5 3 2 1 BC 28 A60 IG1 E23 Ignition SW (*2) AM1 (*2) 4 AM1 IG1 1 Main Body ECU ALT (*1) 6 E7 1 E6 AM2 AM1 IG1D 3 E7 AM2 4 A60 GND1 FL MAIN *1: with Smart Key System Battery (*1) *2: without Smart Key System 1 A60 GND2 *3: without Multi-Information Display *4: with Multi-Information Display C136510E03 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). BC–396 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) CHECK CAN COMMUNICATION SYSTEM (a) Check if a CAN communication system DTC is output (See page BC-302). Result Condition Proceed to CAN communication system DTC is not output A CAN communication system DTC is output B B INSPECT CAN COMMUNICATION SYSTEM (See page CA-8) A 2 BC INSPECT COMBINATION METER ASSEMBLY (a) Connect the intelligent tester to the DLC3. (b) Perform "ACTIVE TEST" of the combination meter assembly using the intelligent tester (See page ME-32). (c) Check that "ON" and "OFF" of the VSC warning (multiinformation display) or VSC warning light are indicated on the combination meter assembly when using the intelligent tester. OK: The VSC warning (multi-information display) turns on or off in accordance with the intelligent tester. NG REPLACE COMBINATION METER ASSEMBLY (See page ME-63) OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–397 Brake Warning Light Remains ON DESCRIPTION The skid control ECU is connected to the combination meter assembly via CAN communication. If any of the following is detected, the BRAKE warning light remains on: • The skid control ECU connector is disconnected from the skid control ECU. • The brake fluid level is insufficient. • The parking brake is applied. • EBD operation is not possible. BC BC–398 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) Main Body ECU CANH 5 E8 CANL 6 E8 Combination Meter 17 CANH BC MICRO COMPUTER CANL F1 35 A60 CANH 18 14 F1 A60 CANL BRAKE DRIVER IC IG+ 6 F2 B/LE A16 Brake Fluid Level Warning SW 1 2 E33 (*1) A18 (*2) Parking Brake SW PKB 2 14 IM (*1) IC (*2) 1 4 A60 GND1 1 A60 GND2 *1: M/T *2: A/T C136504E02 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–399 IG1 ECU IG No. 2 5 3 2 1 28 A60 IG1 E23 Ignition SW (*2) AM1 (*2) IG1 1 4 AM1 BC Main Body ECU ALT E7 (*1) (*1) 6 AM1 1 AM2 E6 3 IG1D E7 AM2 FL MAIN Battery *1: with Smart Key System *2: without Smart Key System C136505E02 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). 1 CHECK CAN COMMUNICATION SYSTEM (a) Check if a CAN communication system DTC is output (See page BC-302). Result Condition Proceed to CAN communication system DTC is not output A CAN communication system DTC is output B BC–400 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) B INSPECT CAN COMMUNICATION SYSTEM (See page CA-8) A 2 CHECK IF SKID CONTROL ECU CONNECTOR IS SECURELY CONNECTED (a) Check if the skid control ECU connector is securely connected. OK: The connector is securely connected. NG CONNECT CONNECTOR TO ECU CORRECTLY OK BC 3 CHECK BATTERY (a) Check the battery voltage. Standard voltage: 11 to 14 V NG CHECK AND REPLACE CHARGING SYSTEM OR BATTERY OK 4 INSPECT SKID CONTROL ECU (IG1 TERMINAL) (a) Disconnect the skid control ECU connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control ECU (Harness Side Connector Front View): A60 Tester Connection Condition Specified Condition A60-28 (IG1) - Body ground Ignition switch on (IG) 10 to 14 V NG IG1 C136493E05 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (IG1 CIRCUIT) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 5 BC–401 INSPECT SKID CONTROL ECU (GND TERMINAL) (a) Turn the ignition switch off. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU (Harness Side Connector Front View): A60 Tester Connection Condition Specified Condition A60-4 (GND1) - Body ground Always Below 1 Ω A60-1 (GND2) - Body ground Always Below 1 Ω (c) Connect the connector. NG GND2 GND1 REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) BC C136493E02 OK 6 INSPECT PARKING BRAKE SWITCH (a) Disconnect the parking brake switch connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Parking Brake Switch: Automatic Transaxle: Free Pushed in Manual Transaxle: Condition Specified Condition 1 - Body ground Parking brake switch ON (Switch pin free) Below 1 Ω 1 - Body ground Parking brake switch OFF (Switch pin pushed in) 10 kΩ or higher NG Free Pushed in C109430E03 OK Tester Connection REPLACE PARKING BRAKE SWITCH BC–402 7 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) CHECK HARNESS AND CONNECTOR (MAIN BODY ECU TO PARKING BRAKE SWITCH) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: Automatic Transaxle Main Body ECU Wire Harness View: IC : Automatic Transaxle Tester Connection Condition Specified Condition IC-14 (PKB) - A18-1 Always Below 1 Ω IC-14 (PKB) - Body ground Always 10 kΩ or higher Tester Connection Condition Specified Condition IM-2 (PKB) - E33-1 Always Below 1 Ω IM-2 (PKB) - Body ground Always 10 kΩ or higher Manual Transaxle IM : Manual Transaxle BC (b) Connect the connector. NG Parking Brake Switch Harness Side Connector Front View: A18 : Automatic Transaxle E33 : Manual Transaxle C136418E03 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (MAIN BODY ECU TO PARKING BRAKE SWITCH) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 8 INSPECT BRAKE FLUID LEVEL WARNING SWITCH Brake Fluid Level Warning Switch (a) Remove the reservoir tank cap and strainer. (b) Disconnect the brake fluid level warning switch connector. (c) Measure the resistance according to the value(s) in the table below. HINT: A float is located inside the reservoir. Its position can be changed by increasing or decreasing the level of brake fluid. Standard resistance A16 MAX Level Tester Connection MIN Level C139740E01 Condition Specified Condition 1-2 Float up (Switch OFF) 1.9 to 2.1 kΩ 1-2 Float down (Switch ON) Below 1 Ω HINT: If there is no problem after finishing the above check, adjust the brake fluid level to the MAX level. NG OK BC–403 REPLACE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY (BRAKE FLUID LEVEL WARNING SWITCH) BC BC–404 9 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) CHECK HARNESS AND CONNECTOR (COMBINATION METER TO BRAKE FLUID LEVEL WARNING SWITCH) (a) Disconnect the combination meter connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Combination Meter Wire Harness View: Tester Connection Condition Specified Condition F2-6 (B/LE) - A16-1 Always Below 1 Ω F2-6 (B/LE) - Body ground Always 10 kΩ or higher A16-2 - Body ground Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR (COMBINATION METER TO BRAKE FLUID LEVEL WARNING SWITCH) BC F2-6 (B/LE) Brake Fluid Level Warning Switch Harness Side Connector Front View: A16 C136033E01 OK 10 INSPECT COMBINATION METER ASSEMBLY (a) Connect the intelligent tester to the DLC3. (b) Select the "ACTIVE TEST" on the tester (See page BC307). ACTIVE TEST: ABS/TRAC/VSC Item BRAKE WRN LIGHT Vehicle Condition/Test Details Turns brake warning light on / off Diagnostic Note Observe combination meter (c) Check BRAKE warning light operation. OK: The BRAKE warning light turns on or off in accordance with the intelligent tester. NG REPLACE COMBINATION METER ASSEMBLY (See page ME-63) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–405 OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC BC–406 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) Brake Warning Light does not Come ON DESCRIPTION The skid control ECU is connected to the combination meter assembly via CAN communication. BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–407 WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) Main Body ECU CANH 5 E8 CANL 6 E8 Combination Meter 17 CANH MICRO COMPUTER CANL F1 35 A60 CANH 18 14 F1 A60 CANL BC BRAKE DRIVER IC IG+ 6 F2 B/LE A16 Brake Fluid Level Warning SW 1 2 E33 (*1) A18 (*2) Parking Brake SW PKB 2 14 IM (*1) IC (*2) 1 4 A60 GND1 1 A60 GND2 *1: M/T *2: A/T C136504E02 BC–408 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) IG1 ECU IG No. 2 5 3 2 1 28 A60 IG1 E23 Ignition SW (*2) AM1 (*2) IG1 1 4 AM1 BC Main Body ECU ALT E7 (*1) (*1) 6 AM1 1 AM2 E6 3 IG1D E7 AM2 FL MAIN Battery *1: with Smart Key System *2: without Smart Key System C136505E02 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). 1 CHECK CAN COMMUNICATION SYSTEM (a) Check if a CAN communication system DTC is output (See page BC-302). Result Condition Proceed to CAN communication system DTC is not output A CAN communication system DTC is output B BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) B BC–409 INSPECT CAN COMMUNICATION SYSTEM (See page CA-8) A 2 CHECK BRAKE WARNING LIGHT (a) Disconnect the skid control ECU connector. (b) Turn the ignition switch on (IG). (c) Check that the BRAKE warning light comes on. OK: The BRAKE warning light comes on. (d) Connect the connector. OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) NG 3 BC INSPECT COMBINATION METER ASSEMBLY (a) Connect the intelligent tester to the DLC3. (b) Perform "ACTIVE TEST" of the combination meter assembly using the intelligent tester (See page ME-32). (c) Check BRAKE warning light operation. OK: The BRAKE warning light turns on or off in accordance with the intelligent tester. NG REPLACE COMBINATION METER ASSEMBLY (See page ME-63) OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC–410 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) Slip Indicator Light Remains ON DESCRIPTION The skid control ECU is connected to the combination meter assembly via CAN communication. The SLIP indicator light blinks during VSC and/or TRAC operation. When the system fails, the SLIP indicator light comes on to warn the driver (See page BC-278). BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–411 WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) F1 Combination Meter CANH 17 SLIP IG+ DRIVER IC MICRO COMPUTER CANL 18 35 A60 CANH 14 A60 CANL IG1 ECU IG No. 2 5 3 2 1 BC 28 A60 IG1 E23 Ignition SW (*2) AM1 (*2) 4 AM1 IG1 1 Main Body ECU ALT (*1) 6 E7 AM1 IG1D 1 AM2 E6 3 E7 AM2 4 A60 GND1 FL MAIN *1: with Smart Key System Battery (*1) *2: without Smart Key System 1 A60 GND2 C136510E05 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). BC–412 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) CHECK CAN COMMUNICATION SYSTEM (a) Check if a CAN communication system DTC is output (See page BC-302). Result Condition Proceed to CAN communication system DTC is not output A CAN communication system DTC is output B B INSPECT CAN COMMUNICATION SYSTEM (See page CA-8) A 2 CHECK IF SKID CONTROL ECU CONNECTOR IS SECURELY CONNECTED BC (a) Check if the skid control ECU connector is securely connected. OK: The connector is securely connected. NG CONNECT CONNECTOR TO ECU CORRECTLY OK 3 CHECK BATTERY (a) Check the battery voltage. Standard voltage: 11 to 14 V NG CHECK AND REPLACE CHARGING SYSTEM OR BATTERY OK 4 INSPECT COMBINATION METER ASSEMBLY (a) Connect the intelligent tester to the DLC3. (b) Perform "ACTIVE TEST" of the combination meter assembly using the intelligent tester (See page ME-32). (c) Check SLIP indicator light operation. OK: The SLIP indicator light turns on or off in accordance with the intelligent tester. NG REPLACE COMBINATION METER ASSEMBLY (See page ME-63) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–413 OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC BC–414 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) Slip Indicator Light does not Come ON DESCRIPTION The skid control ECU is connected to the combination meter assembly via CAN communication. The SLIP indicator light blinks during VSC and/or TRAC operation. When the system fails, the SLIP indicator light comes on to warn the driver (See page BC-278). BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–415 WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) F1 Combination Meter CANH 17 SLIP IG+ DRIVER IC MICRO COMPUTER CANL 18 35 A60 CANH 14 A60 CANL IG1 ECU IG No. 2 5 3 2 1 BC 28 A60 IG1 E23 Ignition SW (*2) AM1 (*2) 4 AM1 IG1 1 Main Body ECU ALT (*1) 6 E7 AM1 IG1D 1 AM2 E6 3 E7 AM2 4 A60 GND1 FL MAIN *1: with Smart Key System Battery (*1) *2: without Smart Key System 1 A60 GND2 C136510E05 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). BC–416 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) CHECK CAN COMMUNICATION SYSTEM (a) Check if a CAN communication system DTC is output (See page BC-302). Result Condition Proceed to CAN communication system DTC is not output A CAN communication system DTC is output B B INSPECT CAN COMMUNICATION SYSTEM (See page CA-8) A 2 BC INSPECT COMBINATION METER ASSEMBLY (a) Connect the intelligent tester to the DLC3. (b) Perform "ACTIVE TEST" of the combination meter assembly using the intelligent tester (See page ME-32). (c) Check the SLIP indicator light operation. OK: The SLIP indicator light turns on or off in accordance with the intelligent tester. NG REPLACE COMBINATION METER ASSEMBLY (See page ME-63) OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–417 Skid Control Buzzer Circuit DESCRIPTION The skid control buzzer sounds and the SLIP indicator light blinks during VSC operation. WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) E13 VSC Warning Buzzer IG1 ECU IG No. 2 5 2 3 Buzzer 1 23 A60 BZ 28 BC A60 IG1 2 1 E23 Ignition SW (*2) AM1 (*2) 4 AM1 IG1 1 Main Body ECU ALT (*1) 6 E7 (*1) AM2 1 E6 AM1 IG1D AM2 4 A60 GND1 FL MAIN *1: with Smart Key System Battery 3 E7 *2: without Smart Key System 1 A60 GND2 C136511E01 BC–418 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SKID CONTROL BUZZER) (a) Connect the intelligent tester to the DLC3. (b) Select the "ACTIVE TEST" on the intelligent tester (See page BC-307). ACTIVE TEST: ABS/TRAC/VSC Item (Display) BUZZER Vehicle Condition / Test Details Turns skid control buzzer ON / OFF Diagnostic Note Buzzer can be heard (c) Check that the buzzer sounds/stops when turning the skid control buzzer on/off by using the intelligent tester. Result Condition BC Proceed to Buzzer does not sound or sounds constantly A Buzzer sounds/stops B B CHECK FOR INTERMITTENT PROBLEMS (SYMPTOM SIMULATION) (See page BC-298) A 2 INSPECT SKID CONTROL BUZZER (POWER SOURCE TERMINAL) (a) Disconnect the skid control buzzer connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control Buzzer (Harness Side Connector Front View): E13 C107604E18 OK Tester Connection Condition Specified Condition E13-2 - Body ground Ignition switch on (IG) 10 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR (POWER SOURCE CIRCUIT) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 3 BC–419 INSPECT SKID CONTROL BUZZER (a) Apply battery negative voltage to terminal 1, and battery positive voltage to terminal 2 of the skid control buzzer, and then check that the buzzer sounds. OK: The skid control buzzer sounds. Skid Control Buzzer: NG (+) REPLACE SKID CONTROL BUZZER (See page BC-453) (-) 1 2 BC C125130E01 OK 4 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU TO SKID CONTROL BUZZER) (a) Disconnect the skid control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU (Harness Side Connector Front View): A60 BZ Tester Connection Condition Specified Condition A60-23 (BZ) - E13-1 Always Below 1 Ω A60-23 (BZ) - Body ground Always 10 kΩ or higher (c) Connect the connectors. NG Skid Control Buzzer (Harness Side Connector Front View): REPAIR OR REPLACE HARNESS OR CONNECTOR (SKID CONTROL ECU TO SKID CONTROL BUZZER) E13 C139149E01 OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC–420 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) TC and CG Terminal Circuit DESCRIPTION DTC output mode is set by connecting terminals TC and CG of the DLC3. DTCs are indicated by the blinking pattern of the ABS warning light. WIRING DIAGRAM Brake Actuator Assembly (Skid Control ECU) ECM BC 41 CANH A55 *1 41 A24 *2 26 A60 CANH 49 CANL A55 *1 49 A24 *2 15 A60 CANL E10 DLC3 27 TC A55 *1 27 A24 *2 13 *1: 2GR FE *2: 2AZ-FE 4 TC CG C136514E01 HINT: When warning lights continue to blink, a ground short in the wiring of terminal TC of the DLC3 or an internal ground short in one or more ECUs is suspected. INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). 1 CHECK CAN COMMUNICATION SYSTEM (a) Check if a CAN communication DTC is output (See page BC-302). Result Result Proceed to CAN communication system DTC is output A CAN communication system DTC is not output B BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) B BC–421 Go to step 2 A GO TO CAN COMMUNICATION SYSTEM (See page CA-8) 2 CHECK HARNESS AND CONNECTOR (ECM TO DLC3) (a) Disconnect the ECM connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: 2GR-FE DLC3: E10 Tester Connection Specified Condition E10-13 (TC) - A55-27 (TC) Below 1 Ω E10-13 (TC) - Body ground 10 kΩ or higher 2AZ-FE TC Tester Connection ECM Wire Harness View: Specified Condition E10-13 (TC) - A24-27 (TC) Below 1 Ω E10-13 (TC) - Body ground 10 kΩ or higher (c) Connect the connector. NG A55-27 (TC) (*1) A24-27 (TC) (*2) (*1): 2GR-FE (*2): 2AZ-FE C136035E02 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (TC TERMINAL CIRCUIT) BC BC–422 3 DLC3: BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) CHECK HARNESS AND CONNECTOR (DLC3 TO CG CIRCUIT) (a) Measure the resistance according to the value(s) in the table below. Standard resistance CG Tester Connection Specified Condition E10-4 (CG) - Body ground Below 1 Ω E10 NG REPAIR OR REPLACE HARNESS OR CONNECTOR (CG TERMINAL CIRCUIT) G022986E27 OK BC 4 CHECK HARNESS AND CONNECTOR (TC TERMINAL CIRCUIT) (a) Measure the resistance according to the value(s) in the table below. Standard resistance DLC3: Tester Connection Specified Condition E10-13 (TC) - Body ground 10 kΩ or higher E10 NG TC REPAIR OR REPLACE HARNESS OR CONNECTOR (TC TERMINAL CIRCUIT) G022986E28 OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) BC–423 TS and CG Terminal Circuit DESCRIPTION In the Test Mode (signal check), a malfunction of the speed sensor that cannot be detected when the vehicle is stopped can be detected while driving. Transition to the sensor check mode can be performed by connecting terminals TS and CG of the DLC3 and turning the ignition switch from off to on (IG). WIRING DIAGRAM Brake Actuator Assembly E10 DLC3 - Skid Control ECU 24 TS CG 12 BC A60 TS 4 C136515E01 INSPECTION PROCEDURE HINT: Check the condition of each related circuit connector before troubleshooting (See page IN-40). BC–424 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU TO DLC3) (a) Disconnect the skid control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU (Harness Side Connector Front View): A60 TS Tester Connection Condition Specified Condition A60-24 (TS) - E10-12 (TS) Always Below 1 Ω (c) Connect the connector. NG DLC3: E10 REPAIR OR REPLACE HARNESS OR CONNECTOR (SKID CONTROL ECU TO DLC3) BC TS C139177E01 OK 2 DLC3: CHECK HARNESS AND CONNECTOR (DLC3 TO BODY GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance CG Tester Connection Condition Specified Condition E10-4 (CG) - Body ground Always Below 1 Ω E10 NG G022987E25 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (DLC3 TO BODY GROUND) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (for BOSCH Made) 3 BC–425 CHECK HARNESS AND CONNECTOR (TS TERMINAL CIRCUIT) (a) Measure the resistance according to the value(s) in the table below. Standard resistance DLC3: Tester Connection Condition Specified Condition E10-12 (TS) - Body ground Always 10 kΩ or higher E10 NG TS REPAIR OR REPLACE HARNESS OR CONNECTOR (TS TERMINAL CIRCUIT) G022987E26 OK REPLACE BRAKE ACTUATOR ASSEMBLY (See page BC-432) BC BC–424 BRAKE CONTROL – BRAKE ACTUATOR (for ADVICS Made) BRAKE ACTUATOR (for ADVICS Made) BRAKE CONTROL COMPONENTS 15 (155, 11) *14 (143, 10) 15 (155, 11) *14 (143, 10) RADIATOR RESERVE TANK ASSEMBLY BC 5.4 (55, 48 in.*lbf) BRAKE ACTUATOR 19 (195, 14) 5.4 (55, 48 in.*lbf) BRAKE ACTUATOR BRACKET ASSEMBLY 19 (195, 14) N*m (kgf*cm, ft.*lbf) : Specified torque * For use with SST C133321E01 BRAKE CONTROL – BRAKE ACTUATOR (for ADVICS Made) BC–425 ON-VEHICLE INSPECTION DLC3 1. CONNECT INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Start the engine and run it at idle . (c) Select the Active Test mode on the intelligent tester. HINT: Refer to the intelligent tester operator's manual for further details. 2. INSPECT ACTUATOR MOTOR OPERATION NOTICE: Do not keep a motor relay on continuously for more than 5 seconds. When operating it continuously, set an interval of more than 20 seconds. (a) With the motor relay on, check the actuator motor operation sounds. (b) Turn the motor relay off. (c) Depress the brake pedal and hold it for approximately 15 seconds. Check that the brake pedal cannot be depressed farther. (d) With the motor relay on, check that the pedal does not pulsate. (e) Turn the motor relay off and release the brake pedal. Intelligent Tester C131977E08 3. INSPECT RIGHT FRONT WHEEL OPERATION NOTICE: Do not turn on a solenoid in a manner different than described below. (a) Depress the brake pedal and hold it. (b) Turn the SFRH and SFRR solenoids on simultaneously, and check that the pedal cannot be depressed. (c) Turn the SFRH and SFRR solenoids off simultaneously, and check that the pedal can be depressed. NOTICE: Do not keep the motor relay on continuously for more than 5 seconds. When operating them continuously, set an interval of more than 20 seconds. (d) Turn the motor relay on and check that the pedal returns. NOTICE: Do not keep the motor relay on continuously for more than 5 seconds. When operating it continuously, set an interval of more than 20 seconds. (e) Turn the motor relay off and release the brake pedal. BC BC–426 BRAKE CONTROL – BRAKE ACTUATOR (for ADVICS Made) 4. BC INSPECT OTHER WHEEL OPERATION (a) Using the same procedure, check the solenoids of the other wheels. HINT: • Left front wheel: SFLH, SFLR • Right rear wheel: SRRH, SRRR • Left rear wheel: SRLH, SRLR BRAKE CONTROL – BRAKE ACTUATOR (for ADVICS Made) BC–427 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE RADIATOR RESERVE TANK ASSEMBLY (a) Separate the radiator reserve tank hose. (b) Remove the radiator reserve tank assembly. 3. DRAIN BRAKE FLUID NOTICE: If brake fluid leaks onto any painted surface, immediately clean it off completely. 4. REMOVE BRAKE ACTUATOR (a) Release the lock lever and disconnect the actuator connector. Connector BC C133326E01 (b) Using SST, disconnect the 6 brake lines from the actuator assembly with bracket. SST 09023-00101 SST C133324E01 (c) Use tags or make a memo to identify the places to reconnect. HINT: • *1: To Front Wheel Cylinder RH • *2: To Front Wheel Cylinder LH • *3: To Rear Wheel Cylinder RH • *4: To Rear Wheel Cylinder LH • *5: From 1st Master Cylinder • *6: From 2nd Master Cylinder *6 *2 *3 *4 *5 *1 C133323E01 BC–428 BRAKE CONTROL – BRAKE ACTUATOR (for ADVICS Made) (d) Remove the 3 bolts and brake actuator assembly with bracket from the body. NOTICE: Do not damage the brake tubes and wire harness. C133325E01 DISASSEMBLY 1. REMOVE BRAKE ACTUATOR BRACKET ASSEMBLY (a) Remove the 2 nuts and the brake actuator assembly from the actuator bracket assembly. BC C133322 REASSEMBLY 1. C133322 INSTALL BRAKE ACTUATOR BRACKET ASSEMBLY (a) Install the actuator assembly to the brake actuator bracket assembly with the 2 nuts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) NOTICE: Do not remove the hole plug before installing a new brake actuator because the brake actuator assembly is filled with brake fluid. INSTALLATION 1. C133325E01 INSTALL BRAKE ACTUATOR (a) Install the brake actuator assembly with bracket to the body with the 3 bolts. Torque: 19 N*m (195 kgf*cm, 14 ft.*lbf) NOTICE: Do not damage the brake tubes and wire harness. BRAKE CONTROL – BRAKE ACTUATOR (for ADVICS Made) (b) Temporarily tighten each brake tube to the correct positions of the brake actuator assembly with bracket as shown in the illustration. HINT: • *1: To Front Wheel Cylinder RH • *2: To Front Wheel Cylinder LH • *3: To Rear Wheel Cylinder RH • *4: To Rear Wheel Cylinder LH • *5: From 1st Master Cylinder • *6: From 2nd Master Cylinder *6 *2 *3 *4 BC–429 *5 *1 C133323E01 (c) Using SST, fully tighten each brake tube. SST 09023-00101 Torque: without SST 15 N*m (155 kgf*cm, 11 ft.*lbf) with SST 14 N*m (143 kgf*cm, 10 ft.*lbf) NOTICE: • Use a torque wrench with a fulcrum length of 300 mm (11.81 in.). • This torque value is effective when SST is parallel to a torque wrench. SST C133324E01 (d) Connect the actuator connector. NOTICE: Make sure that the connector is locked securely. 2. INSTALL RADIATOR RESERVE TANK ASSEMBLY (a) Install the radiator reserve tank assembly. (b) Connect the radiator reservoir tank hose. 3. FILL RESERVOIR WITH BRAKE FLUID (See page BR6) 4. BLEED BRAKE LINE (See page BR-7) 5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 6. BLEED BRAKE ACTUATOR (See page BR-8) 7. INSPECT BRAKE FLUID LEVEL (See page BR-10) 8. INSPECT FOR BRAKE FLUID LEAKAGE 9. PERFORM YAW RATE SENSOR ZERO POINT CALIBRATION HINT: (See page BC-119) Connector C133335E01 10. INSPECT ACTUATOR WITH INTELLIGENT TESTER HINT: (See page BC-425) BC BC–430 BRAKE CONTROL – BRAKE ACTUATOR (for BOSCH Made) BRAKE ACTUATOR (for BOSCH Made) BRAKE CONTROL COMPONENTS with VSC: 15 (155, 11) *14 (143, 10) 15 (155, 11) *14 (143, 10) 15 (155, 11) *14 (143, 10) BC 8.0 (82, 71 in.*lbf) 19 (194, 14) *17 (173, 13) 15 (155, 11) *14 (143, 10) 19 (195, 14) BRAKE ACTUATOR 8.0 (82, 71 in.*lbf) BRAKE ACTUATOR 19 (195, 14) RADIATOR RESERVE TANK ASSEMBLY BRAKE ACTUATOR BRACKET ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque *For use with SST C133318E01 BRAKE CONTROL – BRAKE ACTUATOR (for BOSCH Made) BC–431 ON-VEHICLE INSPECTION DLC3 1. CONNECT INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Start the engine and run it at idle. (c) Select the Active Test mode on the intelligent tester. HINT: Refer to the intelligent tester operator's manual for further details. 2. INSPECT ACTUATOR MOTOR OPERATION NOTICE: Do not keep a motor relay on continuously for more than 5 seconds. When operating it continuously, set an interval of more than 20 seconds. (a) With the motor relay on, check the actuator motor operation sounds. (b) Turn the motor relay off. (c) Depress the brake pedal and hold it for approximately 15 seconds. Check that the brake pedal cannot be depressed farther. (d) With the motor relay on, check that the pedal does not pulsate. (e) Turn the motor relay off and release the brake pedal. Intelligent Tester C131977E07 3. INSPECT RIGHT FRONT WHEEL OPERATION NOTICE: Do not turn on a solenoid in a manner different than described below. (a) Depress the brake pedal and hold it. (b) Turn the SFRH and SFRR solenoids on simultaneously, and check that the pedal cannot be depressed. (c) Turn the SFRH and SFRR solenoids off simultaneously, and check that the pedal can be depressed. NOTICE: Do not keep the motor relay on continuously for more than 5 seconds. When operating them continuously, set an interval of more than 20 seconds. (d) Turn the motor relay on and check that the pedal returns. NOTICE: Do not keep the motor relay on continuously for more than 5 seconds. When operating it continuously, set an interval of more than 20 seconds. (e) Turn the motor relay off and release the brake pedal. BC BC–432 BRAKE CONTROL – BRAKE ACTUATOR (for BOSCH Made) 4. BC INSPECT OTHER WHEEL OPERATION (a) Using the same procedure, check the solenoids of the other wheels. HINT: • Left front wheel: SFLH, SFLR • Right rear wheel: SRRH, SRRR • Left rear wheel: SRLH, SRLR BRAKE CONTROL – BRAKE ACTUATOR (for BOSCH Made) BC–433 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE RADIATOR RESERVE TANK ASSEMBLY (a) Separate the radiator reserve tank hose. (b) Remove the radiator reserve tank assembly. 3. DRAIN BRAKE FLUID NOTICE: If brake fluid leaks onto any painted surface, immediately clean it off completely. 4. REMOVE BRAKE ACTUATOR (a) Release the lock lever and disconnect the actuator connector. BC C132775E01 (b) Using SST, disconnect the 6 brake lines from the actuator assembly with bracket. SST 09023-00101 SST C132776E01 (c) Use tags or make a memo to identify the places to reconnect. HINT: • *1: To Front Wheel Cylinder RH • *2: To Front Wheel Cylinder LH • *3: To Rear Wheel Cylinder RH • *4: To Rear Wheel Cylinder LH • *5: From 2nd Master Cylinder • *6: From 1st Master Cylinder *2 *5 *3 *6 *4 *1 C132777E01 BC–434 BRAKE CONTROL – BRAKE ACTUATOR (for BOSCH Made) (d) Remove the 3 bolts and actuator assembly from the body with bracket. NOTICE: Do not damage the brake tubes and wire harness. C132778 DISASSEMBLY 1. BC REMOVE BRAKE ACTUATOR BRACKET ASSEMBLY (a) Remove the 2 nuts and the brake actuator assembly from the actuator bracket assembly. C132779E01 REASSEMBLY 1. C132779E01 INSTALL BRAKE ACTUATOR BRACKET ASSEMBLY (a) Install the actuator assembly to the actuator bracket assembly with the 2 nuts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) NOTICE: Do not remove the hole plug before installing a new brake actuator because the brake actuator assembly is filled with brake fluid. INSTALLATION 1. C132778 INSTALL BRAKE ACTUATOR (w/o VSC) (a) Install the actuator assembly with bracket to the body with the 3 bolts. Torque: 19 N*m (195 kgf*cm, 14 ft.*lbf) NOTICE: Do not damage the brake tubes and wire harness. BRAKE CONTROL – BRAKE ACTUATOR (for BOSCH Made) BC–435 (b) Temporarily tighten each brake tube to the correct positions of the actuator assembly with bracket as shown in the illustration. HINT: • *1: To Front Wheel Cylinder RH • *2: To Front Wheel Cylinder LH • *3: To Rear Wheel Cylinder RH • *4: To Rear Wheel Cylinder LH • *5: From 2nd Master Cylinder • *6: From 1st Master Cylinder *2 *5 *3 *6 *4 *1 C132777E01 (c) Using SST, fully tighten each brake tube. SST 09023-00101 Torque: without SST 15 N*m (155 kgf*cm, 11 ft.*lbf) with SST 14 N*m (143 kgf*cm, 10 ft.*lbf) NOTICE: • Use a torque wrench with a fulcrum length of 300 mm (11.81 in.). • This torque value is effective when SST is parallel to a torque wrench. SST C132776E01 (d) Connect the actuator connector. NOTICE: Make sure that the connector is locked securely. C133319 2. C132778 INSTALL BRAKE ACTUATOR (w/ VSC) (a) Install the actuator assembly with bracket to the body with the 3 bolts. Torque: 19 N*m (195 kgf*cm, 14 ft.*lbf) NOTICE: Do not damage the brake tubes. BC BC–436 BRAKE CONTROL – BRAKE ACTUATOR (for BOSCH Made) (b) Temporarily tighten each brake tube to the correct positions of the actuator assembly with bracket as shown in the illustration. HINT: • *1: To Front Wheel Cylinder RH • *2: To Front Wheel Cylinder LH • *3: To Rear Wheel Cylinder RH • *4: To Rear Wheel Cylinder LH • *5: From 2nd Master Cylinder • *6: From 1st Master Cylinder *2 *5 *3 *6 *4 *1 C132777E01 (c) Using SST, fully tighten each brake tube. SST 09023-00101, 09023-38200 Torque: bolt A M10 without SST 15 N*m (155 kgf*cm, 11 ft.*lbf) bolt A M10 with SST 14 N*m (143 kgf*cm, 10 ft.*lbf) bolt B M12 without SST 19 N*m (194 kgf*cm, 14 ft.*lbf) bolt B M12 with SST 17 N*m (173 kgf*cm, 13 ft.*lbf) NOTICE: • Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). • This torque value is effective when SST is parallel to a torque wrench. BC A B A A B A SST C132776E04 (d) Connect the actuator connector. NOTICE: Make sure that the connector is locked securely. C133319 3. INSTALL RADIATOR RESERVE TANK ASSEMBLY (a) Install the radiator reserve tank assembly. (b) Connect the radiator reservoir tank hose. 4. FILL RESERVOIR WITH BRAKE FLUID (See page BR6) 5. BLEED BRAKE LINE (See page BR-7) 6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 7. BLEED BRAKE ACTUATOR ASSEMBLY (w/ VSC) (See page BR-8) 8. INSPECT BRAKE FLUID LEVEL (See page BR-10) 9. INSPECT FOR BRAKE FLUID LEAKAGE 10. INSPECT ACTUATOR WITH INTELLIGENT TESTER HINT: (See page BC-431) BRAKE CONTROL – BRAKE ACTUATOR (for BOSCH Made) BC–437 11. PERFORM YAW RATE SENSOR ZERO POINT CALIBRATION (w/ VSC) HINT: (See page BC-278) 12. INSPECT SENSOR SIGNAL HINT: • without VSC (see page BC-11) • with VSC (see page BC-290) 13. INSPECT DTC AND CLEAR HINT: • without VSC (See page BC-21) • with VSC (See page BC-302) BC BC–437 BRAKE CONTROL – FRONT SPEED SENSOR FRONT SPEED SENSOR BRAKE CONTROL COMPONENTS FRONT SPEED SENSOR 5.0 (51, 44 in.*lbf) BC 19 (194, 14) 8.0 (82, 71 in.*lbf) FRONT FENDER LINER FRONT WHEEL OPENING EXTENSION PAD N*m (kgf*cm, ft.*lbf) : Specified torque C132784E01 BC–438 BRAKE CONTROL – FRONT SPEED SENSOR REMOVAL 1. REMOVE FRONT WHEEL 2. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH (See page ED-6) 3. REMOVE FRONT FENDER LINER (See page ED-6) 4. REMOVE FRONT SPEED SENSOR (a) Disconnect the front speed sensor connector and clamp. Clamp C132783E01 (b) Remove the 2 bolts from the body and the shock absorber assembly. (c) Disengage the 2 claws from the steering knuckle and body. BC C132781E01 (d) Remove the bolt and the front speed sensor. NOTICE: • Prevent foreign matter from attaching to the sensor tip. • Clean the installation hole and the surface for the speed sensor every time the speed sensor is removed. C132782 BRAKE CONTROL – FRONT SPEED SENSOR BC–439 INSPECTION 1. 2 INSPECT FRONT SPEED SENSOR (for BOSCH Made) (a) Inspect the front speed sensor. If any of the following occurs, replace the front speed sensor with a new one: • The surface of the front speed sensor is cracked, dented, or chipped off. • The connector or wire harness is scratched, cracked, or damaged. • The front speed sensor has been dropped. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: LH 1 Tester Connection Specified Condition 1 (FL+) - 2 (FL-) 0.92 to 1.22 kΩ at 20 °C (68°F) 1 (FL+) - Body ground 10 kΩ or higher 2 (FL-) - Body ground 10 kΩ or higher C093876E01 RH Tester Connection Specified Condition 1 (FR+) - 2 (FR-) 0.92 to 1.22 kΩ at 20 °C(68°F) 1 (FR+) - Body ground 10 kΩ or higher 2 (FR-) - Body ground 10 kΩ or higher If the value is not as specified, replace the front speed sensor. 2. INSPECT FRONT SPEED SENSOR (for ADVICS Made) (a) Inspect the front speed sensor. If any of the following occurs, replace the front speed sensor with a new one: • The surface of the front speed sensor is cracked, dented, or chipped off. • The connector or wire harness is scratched, cracked, or damaged. • The front speed sensor has been dropped. BC BC–440 BRAKE CONTROL – FRONT SPEED SENSOR (b) Measure the resistance according to the value(s) in the table below. Standard resistance: RH Front Speed Sensor: 1 2 Tester Connection Condition Specified Condition 1 (FR+) - 2 (FR-) Always 1.4 to 1.8 kΩ at 20°C (68 °F) 1 (FR+) - Body ground Always 10 kΩ or higher 2 (FR-) - Body ground Always 10 kΩ or higher LH Tester Connection C136017E01 Condition Specified Condition 1 (FL+) - 2 (FL-) Always 1.4 to 1.8 kΩ at 20°C (68 °F) 1 (FL+) - Body ground Always 10 kΩ or higher 2 (FL-) - Body ground Always 10 kΩ or higher If the value is not as specified, replace the front speed sensor. BC INSTALLATION 1. INSTALL FRONT SPEED SENSOR (a) Install the front speed sensor with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) NOTICE: Prevent foreign matter from attaching to the sensor tip. C132782 (b) Install the front speed sensor with the 2 bolts and engage the 2 claws. Torque: Bolt A 5.0 N*m (51 kgf*cm, 44 in.*lbf) Bolt B 19 N*m (194 kgf*cm, 14 ft.*lbf) NOTICE: Do not twist the wire harness for the front speed sensor when installing the speed sensor. A B C132781E03 BRAKE CONTROL – FRONT SPEED SENSOR BC–441 (c) Connect the front speed sensor connector and clamp. Clamp C132783E01 2. INSTALL FRONT FENDER LINER (See page ED-10) 3. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH (See page ED-10) 4. INSTALL FRONT WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 5. CHECK SPEED SENSOR SIGNAL HINT: • for BOSCH without VSC (See page BC-11) • for BOSCH with VSC (See page BC-290) • for ADVICS (See page BC-123) BC BC–442 BRAKE CONTROL – SKID CONTROL SENSOR SKID CONTROL SENSOR BRAKE CONTROL COMPONENTS 62 (632, 46) REAR DISC BRAKE CALIPER ASSEMBLY BC 80 (816, 59) REAR AXLE HUB AND BEARING ASSEMBLY WITH SKID CONTROL SENSOR 80 (816, 59) REAR DISC REAR AXLE HUB AND BEARING ASSEMBLY WITH SKID CONTROL SENSOR: REAR AXLE HUB AND BEARING ASSEMBLY SKID CONTROL SENSOR N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C132788E02 BRAKE CONTROL – SKID CONTROL SENSOR BC–443 REMOVAL C132787 SST Bolt Bolt SST SST C111530E01 1. REMOVE REAR WHEEL 2. DISCONNECT SKID CONTROL SENSOR WIRE (a) Disconnect the connector from the skid control sensor. NOTICE: Be careful not to damage the speed sensor. 3. REMOVE REAR DISC BRAKE CALIPER ASSEMBLY (See page AH-18) 4. REMOVE REAR DISC (See page BR-62) 5. REMOVE REAR AXLE HUB AND BEARING ASSEMBLY WITH SKID CONTROL SENSOR (See page AH-15) 6. REMOVE SKID CONTROL SENSOR (a) Mount the rear axle hub in a vise using aluminum plates. NOTICE: Replace the hub and bearing assembly if it is dropped or receives a strong shock. (b) Using a pin punch and hammer, drive out the 2 pins and remove the 2 attachments from SST. SST 09520-00031 (09521-00010, 09520-00040), 09521-00020 (c) Using SST and 2 bolts (Diameter: 12 mm, pitch: 1.5 mm), remove the skid control sensor from the hub and bearing assembly. SST 09520-00031 (09521-00010, 09520-00040), 09521-00020, 09950-00020 NOTICE: • Keep the sensor away from magnets. • Pull the skid control sensor off straight, taking care not to make contact with the skid control sensor rotor. • If the speed sensor rotor is damaged or deformed, replace the hub and bearing assembly. • Do not scratch the contact surface between the axle hub and the skid control sensor. • Do not attach foreign matter to the speed sensor rotor and tip. BC BC–444 BRAKE CONTROL – SKID CONTROL SENSOR INSPECTION 1. INSPECT SKID CONTROL SENSOR (for BOSCH Made) (a) Inspect the skid control sensor. If any of the following occurs, replace the skid control sensor with a new one: • The surface of the skid control sensor is cracked, dented, or chipped off. • The connector is scratched, cracked, or damaged. • The skid control sensor has been dropped. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: LH Rear Speed Sensor: Tester Connection BC Specified Condition 1 (RR+) - 2 (RR-) Below 2.2 kΩ 1 (RR+) - Body ground 10 kΩ or higher 2 (RR-) - Body ground 10 kΩ or higher Tester Connection Specified Condition RH 2 1 1 (RL+) - 2 (RL-) Below 2.2 kΩ 1 (RL+) - Body ground 10 kΩ or higher 2 (RL-) - Body ground 10 kΩ or higher C113377E01 If the value is not as specified, replace the skid control sensor. 2. INSPECT SKID CONTROL SENSOR (for ADVICS Made) (a) Inspect the skid control sensor. If any of the following occurs, replace the skid control sensor with a new one: • The surface of the skid control sensor is cracked, dented, or chipped off. • The connector is scratched, cracked, or damaged. • The skid control sensor has been dropped. BC–445 BRAKE CONTROL – SKID CONTROL SENSOR (b) Measure the resistance according to the value(s) in the table below. Standard resistance: RH Rear Speed Sensor: Tester Connection Condition Specified Condition 2 (RR+) - 1 (RR-) Always 0.9 to 2.1 kΩ 2 (RR+) - Body ground Always 10 kΩ or higher 1 (RR-) - Body ground Always 10 kΩ or higher Condition Specified Condition LH 2 Tester Connection 1 2 (RL+) - 1 (RL-) Always 0.9 to 2.1 kΩ 2 (RL+) - Body ground Always 10 kΩ or higher 1 (RL-) - Body ground Always 10 kΩ or higher C113377E01 If the value is not as specified, replace the skid control sensor. RH: INSTALLATION LH: 1. CONNECTOR C132785E01 INSTALL SKID CONTROL SENSOR (a) Clean the contact surface between the axle hub and a new skid control sensor. NOTICE: Prevent foreign matter from attaching to the sensor rotor. (b) Place the skid control sensor on the axle hub so that the connector is positioned as shown in the illustration. (c) Using SST, a press, 2 V-blocks, and 2 steel plates, install the skid control sensor to the axle hub. SST 09309-36010, 09213-58013 NOTICE: • Keep the sensor away from magnets. • Do not use a hammer on the skid control sensor. • Check that there is no foreign matter such as iron chips on the detecting portion of the skid control sensor. • Slowly press the skid control sensor straight. SST SST C132786E01 2. INSTALL REAR AXLE HUB AND BEARING ASSEMBLY WITH SKID CONTROL SENSOR (See page AH-16) 3. INSPECT REAR AXLE HUB BEARING LOOSENESS (See page AH-15) 4. INSPECT REAR AXLE HUB RUNOUT (See page AH15) 5. INSTALL REAR DISC (See page BR-63) 6. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY (See page AH-20) BC BC–446 BRAKE CONTROL – SKID CONTROL SENSOR C132787 BC 7. CONNECT SKID CONTROL SENSOR WIRE (a) Connect the connector to the skid control sensor. 8. INSTALL REAR WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 9. INSPECT AND ADJUST REAR WHEEL ALIGNMENT HINT: (See page SP-13) 10. CHECK SPEED SENSOR SIGNAL HINT: • for BOSCH without VSC (See page BC-11) • for BOSCH with VSC (See page BC-290) • for ADVICS (See page BC-123) BC–446 BRAKE CONTROL – YAW RATE AND ACCELERATION SENSOR (w/ VSC) YAW RATE AND ACCELERATION SENSOR (w/ VSC) BRAKE CONTROL COMPONENTS NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH NO. 2 INSTRUMENT for Manual Transaxle: CLUSTER FINISH PANEL GARNISH SHIFT LEVER KNOB SUB-ASSEMBLY UPPER CONSOLE PANEL FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY BC UPPER REAR CONSOLE PANEL SUB-ASSEMBLY SHIFT LEVER KNOB SUB-ASSEMBLY Bosch Type: UPPER REAR CONSOLE PANEL SUB-ASSEMBLY YAW RATE AND ACCELERATION SENSOR 13 (133, 10) BRACKET 5.0 (51, 44 in.*lbf) YAW RATE AND ACCELERATION SENSOR N*m (kgf*cm, ft.*lbf) : Specified torque C133327E01 BRAKE CONTROL – YAW RATE AND ACCELERATION SENSOR (w/ VSC) BC–447 REMOVAL 1. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-24) 2. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) (See page IP-24) 3. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-24) 4. REMOVE NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-25) 5. REMOVE FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-25) 6. REMOVE UPPER CONSOLE PANEL (for Manual Transaxle) (See page IP-25) 7. REMOVE UPPER REAR CONSOLE PANEL SUBASSEMBLY (for Manual Transaxle) (See page IP-26) 8. REMOVE UPPER REAR CONSOLE PANEL SUBASSEMBLY (for Automatic Transaxle) (See page IP26) 9. REMOVE YAW RATE AND ACCELERATION SENSOR (a) Disconnect the yaw rate sensor connector. (b) Remove the 2 bolts and yaw rate sensor. NOTICE: Do not remove the sensor from the bracket. C133329 10. REMOVE YAW RATE AND ACCELERATION SENSOR (for BOSCH Made) (a) Remove the 2 nuts and yaw rate sensor from the bracket. C133328 BC BC–448 BRAKE CONTROL – YAW RATE AND ACCELERATION SENSOR (w/ VSC) INSPECTION 1. INSPECT YAW RATE AND ACCELERATION SENSOR (a) Inspect the yaw rate sensor. If any of the following occurs, replace the yaw rate sensor with a new one: • The surface of the yaw rate sensor is cracked, dented, or chipped off. • The connector is scratched, cracked, or damaged. • The yaw rate sensor has been dropped. INSTALLATION BC 1. INSTALL YAW RATE AND ACCELERATION SENSOR (for BOSCH Made) (a) Install the yaw rate and acceleration sensor to the bracket with the 2 nuts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 2. INSTALL YAW RATE AND ACCELERATION SENSOR (a) Install the yaw rate sensor and acceleration with the 2 bolts. NOTICE: • Do not damage the yaw rate and acceleration sensor. • Make sure that the yaw rate and acceleration sensor is installed securely. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) (b) Connect the yaw rate and acceleration sensor connector. 3. INSTALL UPPER REAR CONSOLE PANEL SUBASSEMBLY (for Automatic Transaxle) (See page IP53) 4. INSTALL UPPER REAR CONSOLE PANEL SUBASSEMBLY (for Manual Transaxle) (See page IP-53) 5. INSTALL UPPER CONSOLE PANEL (for Manual Transaxle) (See page IP-54) 6. INSTALL FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (See page IP-53) 7. INSTALL NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-54) 8. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-55) 9. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) (See page IP-55) C133328 C133329 10. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-55) BRAKE CONTROL – YAW RATE AND ACCELERATION SENSOR (w/ VSC) BC–449 11. PERFORM YAW RATE SENSOR ZERO POINT CALIBRATION HINT: • for BOSCH (See page BC-278) • for ADVICS (See page BC-119) 12. INSPECT SENSOR SIGNAL HINT: • for BOSCH (See page BC-290) • for ADVICS (See page BC-123) BC BRAKE CONTROL – STEERING ANGLE SENSOR (w/ VSC) BC–449 STEERING ANGLE SENSOR (w/ VSC) BRAKE CONTROL COMPONENTS 3 Spoke Type: 50 (510, 37) STEERING PAD 8.8 (90, 78 in.*lbf) BC STEERING WHEEL ASSEMBLY STEERING COLUMN COVER STEERING WHEEL ASSEMBLY STEERING PAD 50 (510, 37) SPIRAL CABLE 8.8 (90, 78 in.*lbf) NO. 3 LOWER STEERING WHEEL COVER NO. 2 LOWER STEERING WHEEL COVER with VSC: SPIRAL CABLE SPIRAL CABLE SUB-ASSEMBLY WITH STEERING ANGLE SENSOR STEERING ANGLE SENSOR N*m (kgf*cm, ft.*lbf) : Specified torque C133868E04 BC–450 BRAKE CONTROL – STEERING ANGLE SENSOR (w/ VSC) REMOVAL BC 1. PRECAUTION CAUTION: Be sure to read "PRECAUTION" thoroughly before servicing (See page RS-1). 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment. 3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD NOTICE: When reconnecting the cable to the negative battery terminal after installing the steering sensor, check that the front tires and steering wheel are kept aligned straight ahead before and after connecting the cable to the negative battery terminal. 4. REMOVE NO. 2 STEERING WHEEL COVER LOWER (See page RS-349) 5. REMOVE NO. 3 STEERING WHEEL COVER LOWER (See page RS-349) 6. REMOVE STEERING PAD (See page RS-350) 7. REMOVE STEERING WHEEL ASSEMBLY (See page SR-38) 8. REMOVE STEERING COLUMN COVER (See page SR-39) 9. REMOVE SPIRAL CABLE SUB-ASSEMBLY WITH STEERING ANGLE SENSOR (See page RS-364) 10. REMOVE STEERING ANGLE SENSOR (a) Disengage the claws and remove the steering angle sensor from the spiral cable. C104804E04 BRAKE CONTROL – STEERING ANGLE SENSOR (w/ VSC) BC–451 INSPECTION 1. INSPECT STEERING ANGLE SENSOR (a) Inspect the steering angle sensor. If any of the following occurs, replace the steering angle sensor with a new one: • The surface of the steering angle sensor is cracked, dented, or chipped off. • The connector is scratched, cracked, or damaged. • The steering angle sensor has been dropped. INSTALLATION C104804E04 1. INSTALL STEERING ANGLE SENSOR (a) Align the locating pins, engage the claws, and install the steering angle sensor to the spiral cable subassembly. 2. INSTALL SPIRAL CABLE SUB-ASSEMBLY WITH STEERING ANGLE SENSOR (See page RS-366) 3. INSTALL STEERING COLUMN COVER (See page SR50) 4. ADJUST SPIRAL CABLE (See page RS-367) 5. INSTALL STEERING WHEEL ASSEMBLY (See page SR-51) 6. INSPECT STEERING WHEEL CENTER POINT (See page SR-47) 7. INSTALL STEERING PAD (See page RS-350) 8. INSTALL NO. 2 STEERING WHEEL COVER LOWER (See page RS-352) 9. INSTALL NO. 3 STEERING WHEEL COVER LOWER (See page RS-351) 10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 11. INSPECT STEERING PAD (See page RS-347) 12. INSPECT SRS WARNING LIGHT HINT: (See page RS-32) BC BC–452 BRAKE CONTROL – SKID CONTROL BUZZER (w/ VSC) SKID CONTROL BUZZER (w/ VSC) BRAKE CONTROL COMPONENTS for TMMK Made: with Smart Key System: LOWER INSTRUMENT PANEL FINISH PANEL BC LOWER INSTRUMENT PANEL FINISH PANEL NO. 1 INSTRUMENT PANEL SUB-ASSEMBLY SKID CONTROL BUZZER or

COWL SIDE TRIM SUB-ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL LH FRONT DOOR SCUFF PLATE C133330E01 BC–453 BRAKE CONTROL – SKID CONTROL BUZZER (w/ VSC) for TMC Made: with Smart Key System: LOWER INSTRUMENT PANEL FINISH PANEL LOWER INSTRUMENT PANEL FINISH PANEL NO. 1 INSTRUMENT PANEL SUB-ASSEMBLY BC SKID CONTROL BUZZER or COWL SIDE TRIM SUB-ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL LH FRONT DOOR SCUFF PLATE C133330E03 BC–454 BRAKE CONTROL – SKID CONTROL BUZZER (w/ VSC) REMOVAL BC 1. PRECAUTION (See page IP-20) 2. REMOVE FRONT DOOR SCUFF PLATE (See page IR24) 3. REMOVE COWL SIDE TRIM SUB-ASSEMBLY (See page IR-25) 4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (See page IP-20) 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (See page IP-21) 6. REMOVE NO. 1 INSTRUMENT PANEL SUBASSEMBLY (See page IP-22) 7. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (w/o Smart Key System) (See page IP-22) 8. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (w/ Smart Key System) (See page IP-22) 9. REMOVE SKID CONTROL BUZZER (a) Disconnect the skid control buzzer connector. (b) Remove the clip and skid control buzzer assembly. C133331E01 INSPECTION 1. (+) (-) Skid Control Buzzer 1 2 F002192E03 INSPECT SKID CONTROL BUZZER (a) Apply battery negative voltage to terminal 1, and battery positive voltage to terminal 2 of the skid control buzzer, and then check that the buzzer sounds. OK: The skid control buzzer sounds. If the skid control buzzer does not sound, replace the skid control buzzer. BRAKE CONTROL – SKID CONTROL BUZZER (w/ VSC) BC–455 INSTALLATION 1. INSTALL SKID CONTROL BUZZER (a) Attach the claw and install the skid control buzzer. (b) Connect the skid control buzzer assembly connector. 2. INSTALL NO. 1 INSTRUMENT PANEL SUBASSEMBLY (See page IP-57) 3. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/ Smart Key System) (See page IP-57) 4. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/o Smart Key System) (See page IP-57) 5. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (See page IP-58) 6. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (See page IP-59) 7. INSTALL COWL SIDE TRIM SUB-ASSEMBLY (See page IR-54) 8. INSTALL FRONT DOOR SCUFF PLATE (See page IR54) C133331E01 BC BC–456 BRAKE CONTROL – ABS MOTOR RELAY (w/ VSC) ABS MOTOR RELAY (w/ VSC) ON-VEHICLE INSPECTION 1. INSPECT VSC NO. 1 (FAIL SAFE) RELAY (a) Remove the VSC NO. 1 (fail safe) relay. (b) Measure the resistance according to the value(s) in the table below. Standard resistance VSC NO. 1 (Fail Safe) Relay: Tester Connection Specified Condition 3-5 Always 10 kΩ or higher 3-5 Apply B+ between terminals 1 and 2 Below 1 Ω If the value is not as specified, replace the VSC NO. 1 (fail safe) relay. F050241E11 2. BC Condition INSPECT VSC NO. 2 RELAY (a) Remove the VSC NO. 2 relay. (b) Measure the resistance according to the value(s) in the table below. Standard resistance VSC NO. 2 Relay: Tester Connection F050240E07 Condition Specified Condition 3-5 Always 10 kΩ or higher 3-5 Apply B+ between terminals 1 and 2 Below 1 Ω If the value is not as specified, replace the VSC NO. 2 relay. BRAKE – BRAKE SYSTEM BR–1 BRAKE SYSTEM PRECAUTION 1. TROUBLESHOOTING PRECAUTION NOTICE: • Care must be taken to replace each part properly as it could affect the performance of the brake system and result in a driving hazard. Replace the parts with those having the same part number or equivalent. • It is very important to keep parts and the area clean when repairing the brake system. • If the vehicle is equipped with a mobile communication system, refer to the precaution in the INTRODUCTION section. • Care must be taken when using magnets as it could affect the performance of the speed sensors. • Since the brake line is classified as one of the critical safety related parts, be sure to disassemble the components if a brake fluid leak is found. If any abnormality is found, replace the component with a new one. • When removing brake components, cover the brake tube connections to prevent foreign matter such as dust or dirt from entering the tubes. • Do not damage or deform the brake tubes when removing or installing them. • When installing a grommet to the body, ensure that the brake tube passes through the center of the grommet. • When installing a brake tube or flexible hose, ensure that they are free from twisting or bending. • If the cap of the flexible hose does not match the groove on the bracket, twist the hose slightly to insert it. • Flexible hoses must be free from absorber oil, grease, etc. • When installing a brake tube to a plastic clamp, ensure that the brake tube is not loose or being pinched. • Do not reuse a clip or plastic clamp removed from a flexible hose. • After installing a brake tube and flexible hose, ensure that they do not interfere with any other components. • Do not allow brake fluid to adhere to any painted surface such as the vehicle body. If brake fluid leaks onto any painted surface, immediately wash it off. BR BR–2 BRAKE – BRAKE SYSTEM • Disconnect and connect the flexible hose and brake tube: (a) Hold the flexible hose with a wrench and disconnect the brake tube with a union nut wrench without deforming the tube. (b) Remove the clip. (c) Install a new clip. (d) Connect the brake tube with a union nut wrench without deforming the tube. Separating: Connecting: BR C102779E06 C133437 • Connect the brake tube and way: (a) Support the way to prevent deformation of the brake tube and connect the brake tube to the way with a union nut wrench. (b) Support the way to prevent deformation of the brake tube and install the bolt to fix the way to the body. 2. EXPRESSIONS OF IGNITION SWITCH The type of ignition switch used on this model differs according to the specifications of the vehicle. The expressions listed in the table below are used in this section. Switch Type Ignition Switch off Expression Ignition Switch on (IG) Ignition Switch on (ACC) Engine Start Ignition Switch (position) Engine Switch (condition) LOCK Off ON On (IG) ACC On (ACC) START Start BR–3 BRAKE – BRAKE SYSTEM SYSTEM DIAGRAM HINT: See the layout drawing to confirm the locations and tightening torque of flexible hoses and brake tubes. Brake Actuator C D A A FRONT A A A A A A B A A A A BR B B A B C B A B D Brake Booster Assembly Brake Master Cylinder Assembly Brake Tube A Torque : 15 N*m (155 kgf*cm, 11 ft.*lbf) Flexible Hose Brake Tube Way Union Nut : 14 N*m (143 kgf*cm, 10 ft.*lbf)* B Union Nut Torque : 15 N*m (155 kgf*cm, 11 ft.*lbf) : 14 N*m (143 kgf*cm, 10 ft.*lbf)* : 19 N*m (194 kgf*cm, 14 ft.*lbf) (for TMMK made with VSC) : 17 N*m (173 kgf*cm, 13 ft.*lbf) (for TMMK made with VSC)* C Union Bolt Torque : 30 N*m (306 kgf*cm, 22 ft.*lbf) D Union Bolt Torque : 33 N*m (337 kgf*cm, 24 ft.*lbf) * For use with SST C131909E01 BR–4 BRAKE – BRAKE SYSTEM PROBLEM SYMPTOMS TABLE Use the table below to help determine the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. BRAKE SYSTEM Symptom Suspected area 1. Fluid leaks in brake system Low pedal or spongy pedal BR Brake drag Brake pull See page BR-6 2. Air in brake system BR-6 3. Piston seals (Worn or damaged) (FRONT) BR-47 4. Piston seals (Worn or damaged) (REAR) BR-59 5. Master cylinder (Faulty) BR-28 6. Booster push rod (Out of adjustment) BR-31 1. Brake pedal free play (Insufficient) BR-19 2. Parking brake lever travel (Out of adjustment) PB-2 3. Parking brake pedal travel (Out of adjustment) PB-1 4. Parking brake cable (Sticking) PB-48 5. Parking brake shoe clearance (Out of adjustment) PB-1 6. Pad (Cracked or distorted) (FRONT) BR-47 7. Pad (Cracked or distorted) (REAR) BR-59 8. Piston (Stuck) (FRONT) BR-47 9. Piston (Stuck) (REAR) BR-59 10. Piston (Seized) (FRONT) BR-47 11. Piston (Seized) (REAR) BR-59 12. Booster push rod (Out of adjustment) BR-31 13. Vacuum leaks in booster systems BR-42 14. Master cylinder (Faulty) BR-28 1. Piston (Stuck) (FRONT) BR-47 2. Piston (Stuck) (REAR) BR-59 3. Pad (Oily) (FRONT) BR-47 4. Pad (Oily) (REAR) BR-59 5. Piston (Seized) (FRONT) BR-47 6. Piston (Seized) (REAR) BR-59 7. Disc (Scored) (FRONT) BR-50 8. Disc (Scored) (REAR) BR-62 9. Pad (Cracked or distorted) (FRONT) BR-50 10. Pad (Cracked or distorted) (REAR) BR-62 BR–5 BRAKE – BRAKE SYSTEM Symptom Suspected area 1. Fluid leaks in brake systems Hard pedal but brake inefficient Noise from brakes See page BR-6 2. Air in brake system BR-6 3. Pad (Worn) (FRONT) BR-50 4. Pad (Worn) (REAR) BR-62 5. Pad (Cracked or distorted) (FRONT) BR-50 6. Pad (Cracked or distorted) (REAR) BR-62 7. Pad (Oily) (FRONT) BR-50 8. Pad (Oily) (REAR) BR-62 9. Pad (Glazed) (FRONT) BR-50 10. Pad (Glazed) (REAR) BR-62 11. Disc (Scored) (FRONT) BR-50 12. Disc (Scored) (REAR) BR-62 13. Booster push rod (Out of adjustment) BR-31 14. Vacuum leaks in booster system BR-42 1. Pad (Cracked or distorted) (FRONT) BR-50 2. Pad (Cracked or distorted) (REAR) BR-62 3. Cylinder mounting bolt (Loose) (FRONT) BR-47 4. Caliper support bolt (Loose) (REAR) PB-58 5. Disc (Scored) (FRONT) BR-50 6. Disc (Scored) (REAR) BR-62 7. Pad support plate (Loose) (FRONT) BR-50 8. Pad support plate (Loose) (REAR) BR-62 9. Sliding pin (Worn) (FRONT) BR-47 10. Sliding pin (Worn) (REAR) BR-59 11. Pad (Dirty) (FRONT) BR-47 12. Pad (Dirty) (REAR) BR-59 13. Pad (Glazed) (FRONT) BR-47 14. Pad (Glazed) (REAR) BR-59 15. Anti-squeal shim (Damaged) (FRONT) BR-47 16. Anti-squeal shim (Damaged) (REAR) BR-59 BR BR–6 BRAKE – BRAKE FLUID BRAKE FLUID ON-VEHICLE INSPECTION MAX 1. MIN C133306E01 BR INSPECT FLUID LEVEL IN RESERVOIR (a) Inspect the fluid level. If brake fluid level is lowered, check for leakage and inspect the disc brake pad. If necessary, refill the reservoir with brake fluid after repair and replacement. Fluid: SAE J1703 or FMVSS No. 116 DOT 3 BRAKE – BRAKE FLUID BR–7 BLEEDING HINT: If any work is performed on the brake system or if air in the brake lines is suspected, bleed the air from the brake system. NOTICE: • Move the shift lever to the P position and apply the parking brake before bleeding the brakes. • Add brake fluid to keep the level between MIN and MAX lines of the reservoir while bleeding the brakes. • If brake fluid leaks onto any painted surface, wash or remove it completely. C132849 1. FILL RESERVOIR WITH BRAKE FLUID (a) Fill the reservoir with brake fluid. Fluid: SAE J1703 or FMVSS No. 116 DOT3 2. BLEED MASTER CYLINDER HINT: • If the master cylinder is reinstalled or if the reservoir becomes empty, bleed the air from the master cylinder. • To avoid brake fluid from adhering, cover the painted surface with a shop rag or piece of cloth. (a) Disconnect the 2 brake lines from the master cylinder. (b) Slowly depress the brake pedal and hold it (*1). C133316 (c) Cover the 2 outer holes with fingers, and release the brake pedal (*2). (d) Repeat (*1) and (*2) 3 or 4 times. C133317 BR BR–8 BRAKE – BRAKE FLUID (e) SST Fulcrum Length C141971E01 3. BR Using SST, connect the brake lines to the master cylinder. SST 09023-00101, 09023-38200 Torque: without SST 15 N*m (155 kgf*cm, 11 ft.*lbf) with SST 14 N*m (143 kgf*cm, 10 ft.*lbf) for TMMK made with VSC without SST 19 N*m (194 kgf*cm, 14 ft.*lbf) for TMMK made with VSC with SST 17 N*m (173 kgf*cm, 13 ft.*lbf) NOTICE: • Use a torque wrench with a fulcrum length of 300 mm (11.81 in.). • This torque value is effective when SST is parallel to a torque wrench. BLEED BRAKE LINE NOTICE: Bleed the air from the brake line of the wheel furthest from the master cylinder. (a) Connect a vinyl tube to the bleeder plug. (b) Depress the brake pedal several times, then loosen the bleeder plug with the pedal depressed (*3). C132853 (c) When fluid stops coming out, tighten the bleeder plug, then release the brake pedal (*4). (d) Repeat (*3) and (*4) until all the air in the fluid is completely bled out. (e) Tighten the bleeder plug completely. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (f) Repeat the above procedures for each wheel to bleed the air from the brake line. 4. C132852 BLEED BRAKE ACTUATOR ASSEMBLY (w/ VSC) NOTICE: After bleeding the air from the brake system, if the height or feel of the brake pedal cannot be obtained, bleed the air from the brake actuator assembly with the intelligent tester by following the procedures below. (a) Depress the brake pedal more than 20 times with the ignition switch off. BRAKE – BRAKE FLUID DLC3 Intelligent Tester C131977E01 BR–9 (b) Connect the intelligent tester to the DLC3, then turn the ignition switch on (IG). NOTICE: Do not start the engine. (c) Turn the intelligent tester power on and select "AIR BLEEDING" on the screen. NOTICE: • Refer to the intelligent tester operator's manual for further details. • Bleed the air by following the steps displayed on the intelligent tester. (d) Bleed the air according to "Step 1: Increase" on the intelligent tester display. NOTICE: Make sure that the master cylinder reservoir tank does not become empty of brake fluid. (1) Connect a vinyl tube to either one of the bleeder plugs. (2) Depress the brake pedal several times, then loosen the bleeder plug connected to the vinyl tube with the pedal depressed (*5). C132853 C132852 C132854 (3) When fluid stops coming out, tighten the bleeder plug, then release the brake pedal (*6). (4) Repeat (*5) and (*6) until all the air in the fluid is completely bled out. (5) Tighten the bleeder plug completely. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (6) Repeat the above procedures for the rest of the wheels to bleed the air from the brake line. (e) Bleed the air from the suction line according to "Step 2: Inhalation" on the intelligent tester display. NOTICE: • Bleed the suction line by following the steps displayed on the intelligent tester. • Make sure that the master cylinder reservoir tank does not become empty of brake fluid. (1) Connect a vinyl tube to the bleeder plug at the right front wheel or the right rear wheel and loosen the bleeder plug. (2) Operate the brake actuator assembly to bleed the air using the intelligent tester (*7). NOTICE: • The operation stops automatically in 4 seconds. • At this time, be sure to release the brake pedal. BR BR–10 BRAKE – BRAKE FLUID C133305 BR C132850 C132852 (f) (3) Check that the operation has stopped by referring to the intelligent tester display and tighten the bleeder plug (*8). (4) Repeat (*7) and (*8) until all the air in the fluid is completely bled out. (5) Tighten the bleeder plug completely. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (6) For the rest of the wheels, bleed the air in the same way as stated in the above procedures. Bleed the air from the pressure reduction line according to "Step 3: Decrease" on the intelligent tester display. NOTICE: • Bleed the pressure reduction line by following the steps displayed on the intelligent tester. • Make sure that the master cylinder reservoir tank does not become empty of brake fluid. (1) Connect a vinyl tube to either one of the bleeder plugs. (2) Loosen the bleeder plug (*9). (3) Using the intelligent tester, operate the brake actuator assembly, completely depress the brake pedal, and hold it. NOTICE: • The operation stops automatically in 4 seconds. When performing this procedure continuously, an interval of at least 20 seconds is required. • When the operation is completed, the brake pedal slightly goes down. This is a normal phenomenon when the solenoid opens. • During this procedure, the pedal seems heavy, but completely depress it so that the brake fluid comes out from the bleeder plug. • Be sure to keep the brake pedal depressed. Never depress and release the pedal repeatedly. (4) Tighten the bleeder plug, then release the brake pedal (*10). (5) Repeat steps (*9) to (*10) until all the air in the fluid is completely bled out. (6) Tighten the bleeder plug completely. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (7) Repeat the above procedures for the rest of the brakes to bleed the air from the brake line. (g) Bleed the air from the brake line again according to "Step 4: Increase" on the intelligent tester display. NOTICE: • Bleed the air by following the steps displayed on the intelligent tester. BRAKE – BRAKE FLUID BR–11 • Make sure that the master cylinder reservoir tank does not become empty of brake fluid. (1) Connect a vinyl tube to either one of the bleeder plugs. (2) Depress the brake pedal several times, then loosen the bleeder plug connected to the vinyl tube with the pedal depressed (*11). C132850 (3) When fluid stops coming out, tighten the bleeder plug, then release the brake pedal (*12). (4) Repeat (*11) and (*12) until all the air in the fluid is completely bled out. (5) Tighten the bleeder plug completely. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (6) Repeat the above procedures for each brake to bleed the air from the brake line. (h) Finish "AIR BLEEDING" on the intelligent tester and turn off the power. (i) Disconnect the intelligent tester from the DLC3. (j) Turn the ignition switch off. C132852 5. INSPECT FLUID LEVEL IN RESERVOIR (a) Check the fluid level and add fluid if necessary. Fluid: SAE J1703 or FMVSS No. 116 DOT3 If fluid leaks, tighten or replace the leaking part. BR BR–11 BRAKE – BRAKE PEDAL BRAKE PEDAL BRAKE COMPONENTS 20 (204, 15) FRONT WIPER ARM AND BLADE ASSEMBLY RH FRONT WIPER ARM AND BLADE ASSEMBLY LH 20 (204, 15) FRONT FENDER TO COWL SIDE SEAL RH COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY FRONT FENDER TO COWL SIDE SEAL LH 85 (867, 63) 5.0 (51, 44 in.*lbf) 7.5 (77, 66 in.*lbf) 85 (867, 63) BR 5.0 (51, 44 in.*lbf) WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY COWL TOP OUTER FRONT PANEL SUB-ASSEMBLY AIR CLEANER CAP SUB-ASSEMBLY AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C132703E02 BR–12 BRAKE – BRAKE PEDAL for TMC made: for Automatic Transaxle: BR 13 (133, 10) CONNECTOR BRAKE MASTER CYLINDER SUB-ASSEMBLY 15 (155, 11) *14 (143, 10) CLIP CLUTCH RESERVOIR TUBE 13 (133, 10) 15 (155, 11) *14 (143, 10) FRONT BRAKE TUBE WAY N*m (kgf*cm, ft.*lbf) : Specified torque 15 (155, 11) *14 (143, 10) O-RING BRAKE MASTER CYLINDER TO WAY TUBE Non-reusable part * For use with SST C133461E01 BR–13 BRAKE – BRAKE PEDAL for TMMK made without VSC: for Automatic Transaxle: 15 (155, 11) *14 (143, 11) BR BRAKE MASTER CYLINDER SUB-ASSEMBLY CONNECTOR 15 (155, 11) *14 (143, 11) O-RING CLIP CLUTCH RESERVOIR TUBE 13 (133, 10) FRONT BRAKE TUBE WAY 15 (155, 11) *14 (143, 11) N*m (kgf*cm, ft.*lbf) : Specified torque 15 (155, 11) *14 (143, 11) Non-reusable part BRAKE MASTER CYLINDER TO WAY TUBE * For use with SST C132705E02 BR–14 BRAKE – BRAKE PEDAL for TMMK made with VSC: for Automatic Transaxle: BR BRAKE MASTER CYLINDER SUB-ASSEMBLY CONNECTOR 19 (194, 14) *17 (173, 13) O-RING 15 (155, 11) *14 (143, 11) CLIP CLUTCH RESERVOIR TUBE 13 (133, 10) FRONT BRAKE TUBE WAY 15 (155, 11) *14 (143, 11) N*m (kgf*cm, ft.*lbf) : Specified torque 19 (194, 14) *17 (173, 13) Non-reusable part BRAKE MASTER CYLINDER TO WAY TUBE * For use with SST C132705E03 BR–15 BRAKE – BRAKE PEDAL for TMC made: BRAKE PEDAL RETURN SPRING CLIP NO. 2 VACUUM HOSE PUSH ROD PIN 26 (265, 19) 13 (133, 10) BRAKE BOOSTER ASSEMBLY BRAKE MASTER CYLINDER PUSH ROD CLEVIS BRAKE BOOSTER GASKET BR for TMMK made: BRAKE PEDAL RETURN SPRING NO. 2 VACUUM HOSE CLIP PUSH ROD PIN 26 (265, 19) 13 (133, 10) BRAKE MASTER CYLINDER PUSH ROD CLEVIS BRAKE BOOSTER ASSEMBLY BRAKE BOOSTER GASKET N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Apply lithium soap base glycol grease C132704E03 BR–16 BRAKE – BRAKE PEDAL with Smart Key System: LOWER INSTRUMENT PANEL FINISH PANEL COMBINATION METER ASSEMBLY INSTRUMENT CLUSTER FINISH PANEL BR NO. 1 INSTRUMENT PANEL SUB-ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL BRAKE PEDAL SUPPORT ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL LH COWL SIDE TRIM CAP COWL SIDE TRIM SUB-ASSEMBLY LH FRONT DOOR SCUFF PLATE LH C133445E02 BR–17 BRAKE – BRAKE PEDAL 13 (133, 10) 19 (194, 14) NO. 1 BRAKE PEDAL SUPPORT PLATE 1.5 (15, 13 in.*lbf) STOP LIGHT SWITCH ASSEMBLY 19 (194, 14) STOP LIGHT SWITCH MOUNTING ADJUSTER BRAKE PEDAL SUPPORT ASSEMBLY BRAKE PEDAL BUSHING BR 13 (133, 10) 19 (194, 14) 13 (133, 10) PUSH ROD PIN BRAKE PEDAL SHAFT COLLAR 37 (377, 27) for Manual Transaxle: CLIP BRAKE PEDAL RETURN SPRING BRAKE PEDAL SUB-ASSEMBLY BRAKE PEDAL SUB-ASSEMBLY BRAKE PEDAL PAD N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Lithium soap base glycol grease C132706E01 BR–18 BRAKE – BRAKE PEDAL REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-24) 3. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-25) 4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (See page ME-63) 5. REMOVE NO. 1 INSTRUMENT PANEL SUBASSEMBLY (See page IP-22) 6. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (w/o Smart Key System) (See page IP-22) 7. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (w/ Smart Key System) (See page IP-22) 8. REMOVE INSTRUMENT CLUSTER FINISH PANEL (See page ME-65) 9. REMOVE COMBINATION METER ASSEMBLY (See page ME-65) BR 10. REMOVE BRAKE BOOSTER ASSEMBLY HINT: Refer to the procedures up to "REMOVE BRAKE BOOSTER". (See page BR-42) 11. REMOVE BRAKE PEDAL SUPPORT ASSEMBLY (a) Disconnect the stop light switch connector and disengage the 2 clamps. Clamp C132710E01 Bolt (A) Bolt (A) Bolt (B) C132711E01 (b) Remove 2 bolts (A), bolt (B) and the No. 1 brake pedal support plate. BR–19 BRAKE – BRAKE PEDAL (c) Remove the bolt and the brake pedal support assembly. C132712 DISASSEMBLY 1. REMOVE STOP LIGHT SWITCH ASSEMBLY (a) Turn the stop light switch assembly and remove it as shown in the illustration. 2. REMOVE STOP LIGHT SWITCH MOUNTING ADJUSTER (a) Remove the stop light switch mounting adjuster. BR C132725 3. REMOVE BRAKE PEDAL SUB-ASSEMBLY (a) Remove the bolt and the nut. (b) Remove the 2 brake pedal bushings, the brake pedal shaft collar, and the brake pedal subassembly. 4. REMOVE BRAKE PEDAL PAD (a) Remove the brake pedal pad. C132727 ADJUSTMENT 1. Stop Light Switch INSPECT AND ADJUST BRAKE PEDAL HEIGHT (a) Inspect the brake pedal height. Pedal height from dash panel Transaxle Clevis Lock Nut Dash Panel Pedal Height C132713E01 Specified condition Automatic 129.9 to 139.9 mm (5.114 to 5.508 in.) Manual 131.9 to 141.9 mm (5.193 to 5.587 in.) (b) Adjust the brake pedal height. (1) Disconnect the connector from the stop light switch assembly. (2) Remove the stop light switch. (3) Loosen the push rod clevis lock nut. (4) Adjust the pedal height by turning the push rod. (5) Tighten the clevis lock nut. Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) BR–20 BRAKE – BRAKE PEDAL (6) Insert the switch into the adjuster until the switch body touches the pedal. NOTICE: Do not depress the pedal. (7) Rotate the switch a quarter turn clockwise. Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf) or less NOTICE: Do not depress the pedal. (8) Connect the connector. Adjuster Switch Body Brake Pedal Stop Light Switch C111301E03 (9) Check the switch clearance. Standard stop light switch clearance: 1.5 to 2.5 mm (0.059 to 0.098 in.) Cushion Stop Light Switch Assembly BR 1.5 to 2.5 mm (0.059 to 0.098 in.) F043108E08 2. INSPECT PEDAL FREE PLAY (a) Stop the engine. Press the pedal several times until no vacuum is left in the booster. Then release the pedal. (b) Depress the pedal until a slight resistance is felt. Measure the distance as shown in the illustration. Pedal free play: 1.0 to 6.0 mm (0.039 to 0.236 in.) If the pedal free play is not as specified, check the switch clearance in the next step. If the pedal free play is as specified, proceed to the "CHECK PEDAL RESERVE DISTANCE" procedure. (c) Check the switch clearance. Standard stop light clearance: 1.5 to 2.5 mm (0.059 to 0.098 in.) If the clearance is not as specified, reinstall the switch and recheck the pedal free play. If the clearance is as specified, troubleshoot the brake system and proceed to the "CHECK PEDAL RESERVE DISTANCE" procedure. 3. INSPECT PEDAL RESERVE DISTANCE (a) Release the parking brake pedal or parking brake lever. (b) With the engine running, depress the brake pedal and measure the pedal reserve distance as shown in the illustration. Pedal reserve distance from the dash panel at 500 N (51 kgf, 112 lbf) Pedal Free Play C132708E01 Dash Panel Pedal Reserve Distance Transaxle C138215E01 Specified condition Automatic 61 mm (2.402 in.) Manual 63 mm (2.480 in.) BRAKE – BRAKE PEDAL BR–21 If the distance is not as specified, troubleshoot the brake system. BR BR–22 BRAKE – BRAKE PEDAL REASSEMBLY 1. INSTALL BRAKE PEDAL PAD (a) Install the brake pedal pad. 2. INSTALL BRAKE PEDAL SUB-ASSEMBLY (a) Apply lithium soap base glycol grease to 2 new brake pedal bushings. (b) Install the brake pedal sub-assembly, the 2 brake pedal bushings, and the brake pedal shaft collar to the brake pedal support assembly with the bolt and the nut as shown in the illustration. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) 3. INSTALL STOP LIGHT SWITCH MOUNTING ADJUSTER (a) Install the stop light switch mounting adjuster. 4. TEMPORARILY TIGHTEN STOP LIGHT SWITCH ASSEMBLY (a) Temporarily tighten the stop light switch assembly as shown in the illustration. Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf) or less HINT: Completely install the stop light switch assembly after adjusting the brake pedal height. C132723 BR C132726 INSTALLATION 1. INSTALL BRAKE PEDAL SUPPORT ASSEMBLY (a) Temporarily install the brake pedal support assembly with the bolt. NOTICE: Fully tighten the bolt after installing the brake booster assembly. C132712 Bolt (A) Bolt (A) Bolt (B) C132711E01 (b) Temporarily install the No. 1 brake pedal support plate with 2 bolts (A) and bolt (B). NOTICE: Fully tighten 2 bolts (A) and bolt (B) after installing the brake booster assembly. BRAKE – BRAKE PEDAL BR–23 (c) Temporarily install the brake booster assembly and the gasket with the 4 nuts. C132719 (d) Fully tighten the bolt. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) BR C132712 (e) Fully tighten 2 bolts (A) and bolt (B). Torque: Bolt (A) 19 N*m (194 kgf*cm, 14 ft.*lbf) Bolt (B) 13 N*m (133 kgf*cm, 10 ft.*lbf) Bolt (A) Bolt (A) Bolt (B) C132711E01 (f) 2. INSTALL BRAKE BOOSTER ASSEMBLY HINT: Refer to the procedures up to "INSTALL BRAKE BOOSTER ASSEMBLY". (See page BR-43) 3. INSTALL COMBINATION METER ASSEMBLY (See page ME-67) 4. INSTALL INSTRUMENT CLUSTER FINISH PANEL (See page ME-68) 5. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/o Smart Key System) (See page IP-57) 6. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/ Smart Key System) (See page IP-57) 7. INSTALL NO. 1 INSTRUMENT PANEL SUBASSEMBLY (See page IP-57) 8. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (See page ME-68) Clamp C132710E01 Engage the 2 clamps and connect the stop light switch connector. BR–24 BRAKE – BRAKE PEDAL 9. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-54) 10. INSTALL FRONT DOOR SCUFF PLATE LH (See page IR-54) 11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL BR BR–24 BRAKE – BRAKE MASTER CYLINDER BRAKE MASTER CYLINDER BRAKE COMPONENTS 20 (204, 15) FRONT WIPER ARM AND BLADE ASSEMBLY RH FRONT WIPER ARM AND BLADE ASSEMBLY LH 20 (204, 15) FRONT FENDER TO COWL SIDE SEAL RH COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY FRONT FENDER TO COWL SIDE SEAL LH 85 (867, 63) BR 5.0 (51, 44 in.*lbf) 7.5 (77, 66 in.*lbf) 85 (867, 63) 5.0 (51, 44 in.*lbf) WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY COWL TOP OUTER FRONT PANEL SUB-ASSEMBLY AIR CLEANER CAP SUB-ASSEMBLY AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C132703E02 BR–25 BRAKE – BRAKE MASTER CYLINDER for TMC made: for Automatic Transaxle: BR 13 (133, 10) CONNECTOR BRAKE MASTER CYLINDER SUB-ASSEMBLY 15 (155, 11) *14 (143, 10) CLIP CLUTCH RESERVOIR TUBE 13 (133, 10) 15 (155, 11) *14 (143, 10) FRONT BRAKE TUBE WAY N*m (kgf*cm, ft.*lbf) : Specified torque 15 (155, 11) *14 (143, 10) O-RING BRAKE MASTER CYLINDER TO WAY TUBE Non-reusable part * For use with SST C133461E01 BR–26 BRAKE – BRAKE MASTER CYLINDER for TMMK made without VSC: for Automatic Transaxle: BR 15 (155, 11) *14 (143, 11) BRAKE MASTER CYLINDER SUB-ASSEMBLY CONNECTOR 15 (155, 11) *14 (143, 11) O-RING CLIP CLUTCH RESERVOIR TUBE 13 (133, 10) FRONT BRAKE TUBE WAY 15 (155, 11) *14 (143, 11) N*m (kgf*cm, ft.*lbf) : Specified torque 15 (155, 11) *14 (143, 11) Non-reusable part BRAKE MASTER CYLINDER TO WAY TUBE * For use with SST C132705E02 BR–27 BRAKE – BRAKE MASTER CYLINDER for TMMK made with VSC: for Automatic Transaxle: CONNECTOR 19 (194, 14) *17 (173, 13) BR BRAKE MASTER CYLINDER SUB-ASSEMBLY O-RING 15 (155, 11) *14 (143, 11) CLIP CLUTCH RESERVOIR TUBE 13 (133, 10) FRONT BRAKE TUBE WAY 15 (155, 11) *14 (143, 11) N*m (kgf*cm, ft.*lbf) : Specified torque 19 (194, 14) *17 (173, 13) Non-reusable part BRAKE MASTER CYLINDER TO WAY TUBE * For use with SST C132705E03 BR–28 BRAKE – BRAKE MASTER CYLINDER REMOVAL BR NOTICE: • The structure of the master cylinder allows the piston to pop out, so observe the following: (a) for TMC made: (1)The master cylinder requires careful handling. Do not allow the master cylinder to receive any impact, such as from being dropped. Do not reuse a master cylinder that has been dropped. (2)Do not scratch or damage the circumference of the piston. For the seal to function correctly, all sliding surfaces must not have any damage. (3)Do not pull out the master cylinder piston. (4)Make sure to release the vacuum from the brake booster (by removing a vacuum hose, etc.) before removing the master cylinder from the brake booster. (5)When installing the master cylinder, remove the protectors for the piston and the discharge port. (6)Apply the supplied grease to the outer diameter of the piston and the inner diameter of the brake booster. (b) for TMMK made: (1)Do not hold the master cylinder by the piston. (Hold the master cylinder by its body or its reservoir while transporting it.) (2)Do not pull out the master cylinder piston. (3)Do not strike or pinch the master cylinder piston, and do not cause any damage to the master cylinder piston by any other means. (4)Make sure to release the vacuum from the brake booster before removing the master cylinder from the brake booster. (5)When installing the master cylinder to the brake booster, or when removing the master cylinder from the brake booster, make sure that the master cylinder is kept horizontal or its tip faces downward (the piston faces upward) to prevent the master cylinder piston from falling off. (6)Do not allow any foreign objects to contaminate the master cylinder piston. If a foreign object gets on the piston, remove it by using a shop rag or a piece of cloth and then apply an even layer of lithium soap based glycol grease around the circumference (sliding part) of the piston (7)Do not use any other type of grease. 1. DRAIN BRAKE FLUID NOTICE: • Stop the engine and depress the brake pedal several times until no vacuum is left in the brake booster. • If the brake fluid leaks onto any painted surface, wash off or remove the brake fluid completely. BRAKE – BRAKE MASTER CYLINDER BR–29 2. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-416) 3. REMOVE AIR CLEANER FILTER ELEMENT SUBASSEMBLY 4. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH (See page WW-9) 5. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH (See page WW-9) 6. REMOVE FRONT FENDER TO COWL SIDE SEAL LH (See page WW-9) 7. REMOVE FRONT FENDER TO COWL SIDE SEAL RH (See page WW-9) 8. REMOVE COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See page WW-10) 9. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (See page WW-10) 10. REMOVE COWL TOP OUTER FRONT PANEL SUBASSEMBLY (a) Disengage the clamp. (b) Remove the 4 nuts, the 4 bolts and the cowl top outer front panel sub-assembly. 11. DISCONNECT CLUTCH RESERVOIR TUBE (for Manual Transaxle) (a) Move the clip and disconnect the clutch reservoir tube from the brake master cylinder sub-assembly. Clamp Nut Nut C132714E01 12. REMOVE BRAKE MASTER CYLINDER SUBASSEMBLY (for TMC Made) (a) Disconnect the connector. C132716 BR BR–30 BRAKE – BRAKE MASTER CYLINDER (b) Using SST, disconnect the 6 brake lines and remove the brake master cylinder to way tube. SST 09023-00101 SST C138468E01 (c) Remove the 2 nuts, the front brake tube way, the Oring and the brake master cylinder sub-assembly. BR C132717 13. REMOVE BRAKE MASTER CYLINDER SUBASSEMBLY (for TMMK Made without VSC) (a) Disconnect the connector. C138202 (b) Using SST, disconnect the 6 brake lines and remove the brake master cylinder to way tube. SST 09023-00101 SST C138468E01 BRAKE – BRAKE MASTER CYLINDER BR–31 (c) Remove the 2 nuts, the front brake tube way, the Oring and the brake master cylinder sub-assembly. C138204 14. REMOVE BRAKE MASTER CYLINDER SUBASSEMBLY (for TMMK Made with VSC) (a) Disconnect the connector. BR C138202 (b) Using SST, disconnect the 6 brake lines and remove the brake master cylinder to way tube. SST 09023-38200, 09023-00101 SST C138468E01 (c) Remove the 2 nuts, the front brake tube way, the Oring and the brake master cylinder sub-assembly. C138204 BR–32 BRAKE – BRAKE MASTER CYLINDER INSPECTION 1. BR Accessory Tool C132707E01 INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD (for TMMK Made) NOTICE: • Make an adjustment with no vacuum in the brake booster assembly. (Depress the brake pedal several times with the engine stopped.) • The brake booster made by TMC does not need adjustment. HINT: • Adjustment of the brake booster push rod is required when the brake master cylinder sub-assembly is replaced with a new one. • Adjustment is not necessary when the removed brake master cylinder sub-assembly is reused and the brake booster assembly is replaced with a new one. (a) Apply chalk to the tip of the accessory tool. HINT: An accessory tool is enclosed with a new brake master cylinder sub-assembly. (b) Place the accessory tool on the brake booster assembly. (c) Measure the clearance between the brake booster push rod and accessory tool. Standard clearance: 0 mm (0 in.) HINT: Adjust the clearance in the following cases: • If there is a clearance between the accessory tool and the shell of the brake booster (floating accessory tool), the push rod is protruding too far. • If the chalk does not stick on the tip of the brake booster push rod, the push rod protrusion is insufficient. (d) If the clearance is not as specified, adjust the push rod length by holding the rod using SST and turning the tip of the rod using a socket driver (7 mm, 0.28 in.). SST 09737-00020 HINT: Check the push rod clearance again after adjustment. SST C132720E01 BRAKE – BRAKE MASTER CYLINDER BR–33 INSTALLATION 1. INSTALL BRAKE MASTER CYLINDER SUBASSEMBLY (for TMC Made) (a) Install the O-ring, the brake master cylinder subassembly and the front brake tube way with the 2 nuts . Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) C132717 (b) Connect the connector. (c) Install the brake master cylinder to way tube and temporarily tighten the 6 brake lines. BR C132716 (d) Using the SST, fully tighten the 6 brake lines. SST 09023-00101 Torque: without SST 15 N*m (155 kgf*cm, 11 ft.*lbf) with SST 14 N*m (143 kgf*cm, 10 ft.*lbf) NOTICE: • Use a torque wrench with a fulcrum length of 300 mm (11.81 in.). • This torque value is effective when SST is parallel to a torque wrench. SST Fulcrum Length C141971E01 2. C138204 INSTALL BRAKE MASTER CYLINDER SUBASSEMBLY (for TMMK Made without VSC) (a) Install the O-ring, the brake master cylinder subassembly and the front brake tube way with the 2 nuts . Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) BR–34 BRAKE – BRAKE MASTER CYLINDER (b) Connect the connector. (c) Install the brake master cylinder to way tube and temporarily tighten the 6 brake lines. C138202 BR (d) Using the SST, fully tighten the 6 brake lines. SST 09023-00101 Torque: without SST 15 N*m (155 kgf*cm, 11 ft.*lbf) with SST 14 N*m (143 kgf*cm, 10 ft.*lbf) NOTICE: • Use a torque wrench with a fulcrum length of 300 mm (11.81 in.). • This torque value is effective when SST is parallel to a torque wrench. SST Fulcrum Length C141971E01 3. C138204 INSTALL BRAKE MASTER CYLINDER SUBASSEMBLY (for TMMK Made with VSC) (a) Install the O-ring, the brake master cylinder subassembly and the front brake tube way with the 2 nuts . Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) BRAKE – BRAKE MASTER CYLINDER BR–35 (b) Connect the connector. (c) Install the brake master cylinder to way tube and temporarily tighten the 6 brake lines. (B) (A) (B) C138203E01 (d) Using the SST, fully tighten the 6 brake lines. SST 09023-00101, 09023-38200 Torque: (A) without SST 15 N*m (155 kgf*cm, 11 ft.*lbf) (A) with SST 14 N*m (143 kgf*cm, 10 ft.*lbf) (B) without SST 19 N*m (194 kgf*cm, 14 ft.*lbf) (B) with SST 17 N*m (173 kgf*cm, 13 ft.*lbf) NOTICE: • Use a torque wrench with a fulcrum length of 300 mm (11.81 in.). • This torque value is effective when SST is parallel to a torque wrench. SST Fulcrum Length C141971E01 4. CONNECT CLUTCH RESERVOIR TUBE (for Manual Transaxle) (a) Connect the clutch reservoir tube to the brake master cylinder sub-assembly and move the clip. 5. FILL RESERVOIR WITH BRAKE FLUID (See page BR6) 6. BLEED CLUTCH PIPE LINE (for Manual Transaxle) (See page CL-19) 7. BLEED MASTER CYLINDER (See page BR-6) 8. BLEED BRAKE LINE (See page BR-7) 9. BLEED BRAKE ACTUATOR ASSEMBLY (w/ VSC) (See page BR-8) 10. INSPECT FLUID LEVEL IN RESERVOIR (See page BR-10) 11. INSPECT FOR BRAKE FLUID LEAKAGE BR BR–36 BRAKE – BRAKE MASTER CYLINDER 12. INSTALL COWL TOP OUTER FRONT PANEL SUBASSEMBLY (a) Install the cowl top outer front panel sub-assembly with the 4 nuts, the 4 bolts and the clamp. Torque: Nut 85 N*m (867 kgf*cm, 63 ft.*lbf) Bolt 5.0 N*m (51 kgf*cm, 44 in.*lbf) 13. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (See page WW-14) Clamp 14. INSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See page WW-15) Nut Nut C132714E01 15. INSTALL FRONT FENDER TO COWL SIDE SEAL LH (See page WW-15) 16. INSTALL FRONT FENDER TO COWL SIDE SEAL RH (See page WW-15) BR 17. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH (See page WW-15) 18. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH (See page WW-16) 19. INSTALL AIR CLEANER FILTER ELEMENT SUBASSEMBLY 20. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See page ES-419) BR–37 BRAKE – BRAKE BOOSTER BRAKE BOOSTER BRAKE COMPONENTS 20 (204, 15) FRONT WIPER ARM AND BLADE ASSEMBLY RH FRONT WIPER ARM AND BLADE ASSEMBLY LH 20 (204, 15) FRONT FENDER TO COWL SIDE SEAL RH COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY FRONT FENDER TO COWL SIDE SEAL LH 85 (867, 63) 5.0 (51, 44 in.*lbf) 7.5 (77, 66 in.*lbf) 85 (867, 63) BR 5.0 (51, 44 in.*lbf) WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY COWL TOP OUTER FRONT PANEL SUB-ASSEMBLY AIR CLEANER CAP SUB-ASSEMBLY AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C132703E02 BR–38 BRAKE – BRAKE BOOSTER for TMC made: for Automatic Transaxle: BR 13 (133, 10) CONNECTOR BRAKE MASTER CYLINDER SUB-ASSEMBLY 15 (155, 11) *14 (143, 10) CLIP CLUTCH RESERVOIR TUBE 13 (133, 10) 15 (155, 11) *14 (143, 10) FRONT BRAKE TUBE WAY N*m (kgf*cm, ft.*lbf) : Specified torque 15 (155, 11) *14 (143, 10) O-RING BRAKE MASTER CYLINDER TO WAY TUBE Non-reusable part * For use with SST C133461E01 BR–39 BRAKE – BRAKE BOOSTER for TMMK made without VSC: for Automatic Transaxle: 15 (155, 11) *14 (143, 11) BR BRAKE MASTER CYLINDER SUB-ASSEMBLY CONNECTOR 15 (155, 11) *14 (143, 11) O-RING CLIP CLUTCH RESERVOIR TUBE 13 (133, 10) FRONT BRAKE TUBE WAY 15 (155, 11) *14 (143, 11) N*m (kgf*cm, ft.*lbf) : Specified torque 15 (155, 11) *14 (143, 11) Non-reusable part BRAKE MASTER CYLINDER TO WAY TUBE * For use with SST C132705E02 BR–40 BRAKE – BRAKE BOOSTER for TMMK made with VSC: for Automatic Transaxle: BR BRAKE MASTER CYLINDER SUB-ASSEMBLY CONNECTOR 19 (194, 14) *17 (173, 13) O-RING 15 (155, 11) *14 (143, 11) CLIP CLUTCH RESERVOIR TUBE 13 (133, 10) FRONT BRAKE TUBE WAY 15 (155, 11) *14 (143, 11) N*m (kgf*cm, ft.*lbf) : Specified torque 19 (194, 14) *17 (173, 13) Non-reusable part BRAKE MASTER CYLINDER TO WAY TUBE * For use with SST C132705E03 BRAKE – BRAKE BOOSTER BR–41 for TMC made: BRAKE PEDAL RETURN SPRING CLIP NO. 2 VACUUM HOSE PUSH ROD PIN 26 (265, 19) 13 (133, 10) BRAKE BOOSTER ASSEMBLY BRAKE MASTER CYLINDER PUSH ROD CLEVIS BRAKE BOOSTER GASKET BR for TMMK made: BRAKE PEDAL RETURN SPRING NO. 2 VACUUM HOSE CLIP PUSH ROD PIN 26 (265, 19) 13 (133, 10) BRAKE MASTER CYLINDER PUSH ROD CLEVIS BRAKE BOOSTER ASSEMBLY BRAKE BOOSTER GASKET N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Apply lithium soap base glycol grease C132704E03 BR–42 BRAKE – BRAKE BOOSTER CORRECT ON-VEHICLE INSPECTION INCORRECT 1. 1st 2nd 3rd C132722E01 INSPECT BRAKE BOOSTER ASSEMBLY (a) Airtightness check. (1) Start the engine and stop it after 1 or 2 minutes. Slowly depress the brake pedal several times. HINT: If the pedal can be depressed to the floor the first time, but on the 2nd and 3rd time cannot be depressed as far, the booster is airtight. (2) Depress the brake pedal while the engine is running, and stop the engine with the pedal depressed. HINT: If there is no change in the pedal reserve distance while holding the pedal for 30 seconds, the booster is airtight. (b) Operation check. (1) Depress the brake pedal several times with the ignition switch off and check that there is no change in the pedal reserve distance when the pedal is depressed. BR C128542 (2) Depress and hold down the pedal, and start the engine. HINT: If the pedal goes down slightly, operation is normal. C128543 REMOVAL C133454 1. REMOVE BRAKE PEDAL RETURN SPRING (a) Remove the brake pedal return spring. 2. SEPARATE BRAKE MASTER CYLINDER PUSH ROD CLEVIS BRAKE – BRAKE BOOSTER BR–43 3. DISCONNECT NO. 2 VACUUM HOSE (a) Move the clip and disconnect the No. 2 vacuum hose. 4. REMOVE BRAKE MASTER CYLINDER SUBASSEMBLY HINT: Refer to the procedures up to "REMOVE MASTER CYLINDER". (See page BR-28) 5. REMOVE BRAKE BOOSTER ASSEMBLY (a) Remove the 4 nuts and the brake booster assembly. NOTICE: Do not damage the brake lines. C132715 BR C132719 C132835E02 6. REMOVE BRAKE BOOSTER GASKET (a) Remove the brake booster gasket. 7. REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS (a) Loosen the lock nut and remove the brake master cylinder push rod clevis. BR–44 BRAKE – BRAKE BOOSTER INSPECTION 1. Ventilation No ventilation C133436E01 BR INSPECT VACUUM CHECK VALVE (a) Inspect the vacuum check valve. (1) Slide the clip and disconnect the vacuum hose. (2) Remove the vacuum check valve. (3) Check that there is ventilation from the booster to the engine, and no ventilation from the engine to the booster. If the results are not as specified, replace the brake booster assembly. BRAKE – BRAKE BOOSTER BR–45 INSTALLATION 1. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS (a) Temporarily install the lock nut and the brake master cylinder push rod clevis to the brake booster assembly. NOTICE: Fully tighten the lock nut after adjusting the pedal height. Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) 2. INSTALL BRAKE BOOSTER GASKET (a) Install a new brake booster gasket. BR C132835E02 3. INSTALL BRAKE BOOSTER ASSEMBLY (a) Install the brake booster assembly and the gasket with the 4 nuts. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) NOTICE: Do not damage the brake lines. 4. CONNECT BRAKE MASTER CYLINDER PUSH ROD CLEVIS (a) Apply lithium soap base glycol grease to the push rod pin. (b) Connect the brake master cylinder push rod clevis to the brake pedal with the push rod pin and a new clip as shown in the illustration. 5. INSTALL BRAKE PEDAL RETURN SPRING (a) Install the brake pedal return spring. 6. INSPECT AND ADJUST BRAKE PEDAL HEIGHT (See page BR-19) 7. INSTALL BRAKE MASTER CYLINDER SUBASSEMBLY HINT: Refer to the procedures up to "INSTALL BRAKE MASTER CYLINDER". (See page BR-32) C132719 Lithium Soap Base Glycol Grease C133452E01 C133454 BR–46 BRAKE – BRAKE BOOSTER 8. C132715 BR CONNECT NO. 2 VACUUM HOSE (a) Connect the No. 2 vacuum hose and move the clip. BR–45 BRAKE – FRONT BRAKE FRONT BRAKE BRAKE COMPONENTS FRONT DISC BRAKE BLEEDER PLUG CAP 8.3 (85, 73 in.*lbf) FRONT DISC BRAKE BLEEDER PLUG FRONT DISC FRONT BRAKE FLEXIBLE HOSE BR 29 (300, 21) FRONT DISC BRAKE BUSHING DUST BOOT 107 (1,090, 79) NO. 1 FRONT DISC BRAKE CYLINDER SLIDE PIN GASKET 34 (350, 25) FRONT DISC BRAKE CYLINDER MOUNTING DISC BRAKE CYLINDER ASSEMBLY NO. 2 FRONT DISC BRAKE CYLINDER SLIDE PIN FRONT DISC BRAKE CYLINDER SLIDE BUSHING FRONT DISC BRAKE BUSHING DUST BOOT FRONT DISC BRAKE PAD SUPPORT PLATE N*m (kgf*cm, ft.*lbf) : Specified torque Lithium soap base glycol grease Non-reusable part C132811E01 BR–46 BRAKE – FRONT BRAKE DISC BRAKE CYLINDER ASSEMBLY for TMMK made: CYLINDER BOOT PISTON SEAL BR FRONT DISC BRAKE PISTON CYLINDER BOOT SET RING PAD WEAR INDICATOR FRONT ANTI-SQUEAL SHIM FRONT BRAKE PAD FRONT ANTI-SQUEAL SHIM Lithium soap base glycol grease Non-reusable part Disc brake grease C132812E01 BR–56 BRAKE – FRONT BRAKE FLEXIBLE HOSE FRONT BRAKE FLEXIBLE HOSE BRAKE COMPONENTS 15 (155, 11) *14 (143, 10) 19 (194, 14) CLIP FRONT BRAKE FLEXIBLE HOSE 29 (300, 21) BR GASKET N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part * For use with SST C132792E01 BRAKE – FRONT BRAKE FLEXIBLE HOSE BR–57 REMOVAL SST 1. REMOVE FRONT WHEEL 2. DRAIN BRAKE FLUID 3. REMOVE FRONT BRAKE FLEXIBLE HOSE (a) Remove the clip. (b) Remove the brake tube with SST while holding the front brake flexible hose with a wrench. SST 09023-00101 NOTICE: • Do not bend or damage the brake tube. • Do not allow any foreign matter such as dirt and dust to enter the brake tube from the connecting points. (c) Remove the bolt, and separate the front brake flexible hose and the speed sensor from the shock absorber. (d) Remove the union bolt, the front brake flexible hose and gasket. C133341E01 INSTALLATION SST 1. C133342E01 INSTALL FRONT BRAKE FLEXIBLE HOSE (a) Connect the front brake flexible hose with the union bolt and a new gasket. Torque: 29 N*m (300 kgf*cm, 21 ft.*lbf) (b) Connect the front flexible hose and the speed sensor to the shock absorber with the bolt. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) NOTICE: When installing the front flexible hose and the speed sensor, the bracket must face toward the exterior of the vehicle. (c) Connect the brake tube to the front brake flexible hose with SST while holding the flexible hose with a wrench. SST 09023-00101 Torque: Without SST 15 N*m (155 kgf*cm, 11 ft.*lbf) With SST 14 N*m (143 kgf*cm, 10 ft.*lbf) NOTICE: • Do not bend or damage the brake tube. • Do not allow any foreign matter such as dirt and dust to enter the brake tube from the connecting points. • Use a torque wrench with a fulcrum length of 300 mm (11.81 in.). • This torque value is effective when SST is parallel to a torque wrench. BR BR–58 BRAKE – FRONT BRAKE FLEXIBLE HOSE (d) Install the front brake flexible hose with a new clip. NOTICE: • When installing the front brake flexible hose, face the identification mark toward the exterior of the vehicle and minimize twisting of the hose. • Install the clip as far as it will go. BR 2. FILL RESERVOIR WITH BRAKE FLUID (See page BR6) 3. BLEED MASTER CYLINDER (See page BR-6) 4. BLEED BRAKE LINE (See page BR-7) 5. BLEED BRAKE ACTUATOR ASSEMBLY (w/ VSC) (See page BR-8) 6. INSPECT BRAKE FLUID LEVEL IN RESERVOIR (See page BR-10) 7. INSPECT FOR BRAKE FLUID LEAKAGE 8. INSTALL FRONT WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) BR–58 BRAKE – REAR BRAKE REAR BRAKE BRAKE COMPONENTS REAR BRAKE FLEXIBLE HOSE 33 (337, 24) REAR DISC BRAKE BLEEDER PLUG CAP 27 (275, 20) 8.3 (85, 73 in.*lbf) BR REAR DISC BRAKE BLEEDER PLUG GASKET REAR DISC BRAKE CYLINDER ASSEMBLY REAR DISC BRAKE BUSHING DUST BOOT NO. 1 REAR DISC BRAKE PAD SUPPORT PLATE 62 (632, 46) REAR DISC BRAKE CYLINDER MOUNTING REAR DISC BRAKE CYLINDER SLIDE PIN REAR DISC NO. 2 REAR DISC BRAKE PAD SUPPORT PLATE N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part PARKING BRAKE SHOE ADJUSTING HOLE PLUG Lithium soap base glycol grease C132830E01 BR–59 BRAKE – REAR BRAKE REAR DISC BRAKE CYLINDER ASSEMBLY PISTON SEAL REAR DISC BRAKE PISTON REAR ANTI-SQUEAL SHIM BRAKE CYLINDER BOOT SET RING REAR DISC BRAKE PAD KIT (PAD ONLY) REAR ANTI-SQUEAL SHIM PAD WEAR INDICATOR Disc brake grease CYLINDER BOOT Non-reusable part Lithium soap base glycol grease C132829E01 BR BRAKE – FRONT BRAKE BR–47 REMOVAL HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. REMOVE FRONT WHEEL 2. DRAIN BRAKE FLUID NOTICE: If brake fluid leaks onto any painted surface of the vehicle, wash or remove it completely. 3. REMOVE DISC BRAKE CYLINDER ASSEMBLY (a) Remove the union bolt and gasket from the disc brake cylinder assembly, then disconnect the flexible hose. BR C133332 (b) Hold the front disc brake cylinder slide pin and remove the 2 bolts and disc brake cylinder assembly. Hold Turn C132794E02 BR–48 BRAKE – FRONT BRAKE DISASSEMBLY 1. REMOVE FRONT BRAKE PAD (a) Remove the 2 brake pads from the front disc brake cylinder mounting. 2. REMOVE FRONT ANTI-SQUEAL SHIM (a) Remove the 2 anti-squeal shims and the 2 pad wear indicator plates from each pad. 3. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE (a) Remove the 4 front disc brake pad support plates. 4. REMOVE FRONT DISC BRAKE CYLINDER MOUNTING (a) Remove the 2 bolts and front disc brake cylinder mounting. 5. REMOVE NO. 1 FRONT DISC BRAKE CYLINDER SLIDE PIN (a) Remove the No. 1 front disc brake cylinder slide pin from the front disc brake cylinder mounting. 6. REMOVE NO. 2 FRONT DISC BRAKE CYLINDER SLIDE PIN (a) Remove the No. 2 front disc brake cylinder slide pin from the front disc brake cylinder mounting. 7. REMOVE FRONT DISC BRAKE CYLINDER SLIDE BUSHING (a) Using a screwdriver, remove the cylinder slide bushing from the No. 2 front disc brake cylinder slide pin. NOTICE: Do not damage the No. 2 front disc brake cylinder slide pin. HINT: Tape the screwdriver tip before use. BR C132796 No. 1 Slide Pin No. 2 Slide Pin C132798E03 C132797 BRAKE – FRONT BRAKE BR–49 8. REMOVE FRONT DISC BRAKE BUSHING DUST BOOT (a) Remove the 2 bushing dust boots from the front disc brake cylinder mounting. 9. REMOVE CYLINDER BOOT (for TMC Made) (a) Using a screwdriver, remove the cylinder boot set ring and the cylinder boot. NOTICE: Be careful not to damage the brake piston and cylinder. C132799E03 BR C132808 10. REMOVE CYLINDER BOOT (for TMMK Made) (a) Using a screwdriver, remove the cylinder boot. NOTICE: Be careful not to damage the brake piston and cylinder. C132808 170 mm (6.70 in.) 50 mm (1.97 in.) 11. REMOVE FRONT DISC BRAKE PISTON (a) Prepare a wooden plate to hold the pistons. (b) Place the wooden plate between the piston and the disc brake cylinder assembly. 30 mm (1.18 in.) C111364E08 (c) Use compressed air to remove the piston from the disc brake cylinder assembly. CAUTION: Do not place your fingers in front of the piston when using compressed air. NOTICE: Do not spatter the brake fluid. C132795 BR–50 BRAKE – FRONT BRAKE 12. REMOVE PISTON SEAL (a) Using a screwdriver, remove the piston seal from the disc brake cylinder assembly. NOTICE: Do not damage the inner cylinder or cylinder groove. HINT: Tape the screwdriver tip before use. C132807 13. REMOVE FRONT DISC BRAKE BLEEDER PLUG CAP (a) Remove the front disc brake bleeder plug cap. 14. REMOVE FRONT DISC BRAKE BLEEDER PLUG 15. REMOVE FRONT DISC (a) Remove the front disc. HINT: Put matchmarks on the disc and the axle hub. Matchmarks BR C132801E01 INSPECTION 1. INSPECT PAD LINING THICKNESS (a) Using a ruler, measure the pad lining thickness. Standard thickness: 12.0 mm (0.472 in.) Minimum thickness: 1.0 mm (0.039 in.) If the pad lining thickness is less than the minimum, replace the brake pads. HINT: Be sure to check wear of the front disc after replacing the brake pad with a new one. 2. INSPECT DISC THICKNESS (a) Using a micrometer, measure the disc thickness. Standard thickness: 28.0 mm (1.102 in.) Minimum thickness : 25.0 mm ( 0.983 in.) If the disc thickness is less than the minimum, replace the front disc. 3. INSPECT BRAKE CYLINDER AND PISTON (a) Check the cylinder bore and piston for rust or scoring. If necessary, replace the disc brake cylinder assembly. 4. INSPECT FRONT DISC BRAKE PAD SUPPORT PLATE (a) Make sure that the pad support plate has sufficient rebound, has no deformation, cracks or wear, and that all rust and dirt are cleaned off. If necessary, replace the brake pad support plate. C132802 Micrometer C132803E01 BRAKE – FRONT BRAKE 5. SST BR–51 INSPECT DISC RUNOUT (a) Using SST to hold the disc, tighten the disc with the 3 hub nuts. SST 09330-00021 Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) HINT: Use the SST to hold the disc while torquing the nuts. C132804E02 (b) Using a dial indicator, measure the disc runout 10 mm (0.39 in.) away from the outer edge of the disc. Maximum disc runout: 0.05 mm (0.0020 in) NOTICE: • Keep the magnet of the dial indicator away from the axle hub and speed sensor. • Install the dial indicator to the shock absorber. (c) If the runout exceeds the maximum value, change the installation positions of the disc and axle so that the runout will become minimal. If the runout exceeds the maximum even after the installation positions are changed, check the bearing play in the axial direction and the axle hub runout (See page AH-16). If the bearing play and the axle hub runout are normal and if the disc thickness is not within the specified range, grind the disc. If the disc thickness is less than the minimum, replace the disc. (d) Remove the front disc. Dial Indicator C132800E02 REASSEMBLY 1. INSTALL FRONT DISC (a) Align the matchmarks and install the front disc. NOTICE: When replacing the disc with a new one, select the installation position where the front disc has the minimum runout. 2. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG (a) Temporarily tighten the front disc brake bleeder plug to the disc brake cylinder sub-assembly. 3. INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP (a) Install the bleeder plug cap to the front disc brake bleeder plug. 4. INSTALL PISTON SEAL (a) Apply lithium soap base glycol grease to a new piston seal. (b) Install the piston seal to the disc brake cylinder assembly. Matchmarks C132801E01 BR BR–52 BRAKE – FRONT BRAKE 5. INSTALL FRONT DISC BRAKE PISTON (for TMC Made) (a) Apply lithium soap base glycol grease to the piston and a new cylinder boot. (b) Install the cylinder boot to the piston. (c) Install the piston to the disc brake cylinder assembly. NOTICE: Do not install the piston forcibly in the cylinder assembly. Lithium soap base glycol grease C132810E02 BR Set Ring 6. INSTALL CYLINDER BOOT (for TMC Made) (a) Install the cylinder boot to the disc brake cylinder assembly. NOTICE: Install the boot securely to the grooves of the cylinder and piston. (b) Using a screwdriver, install a new set ring. NOTICE: • Install the set ring securely to the grooves of the cylinder boot. • Do not damage the cylinder boot. HINT: Tape the screwdriver tip before use. 7. INSTALL CYLINDER BOOT (for TMMK Made) (a) Apply lithium soap base glycol grease to the piston and a new cylinder boot. Cylinder Piston Cylinder Boot C132809E05 (b) Piston Cylinder boot : Lithium soap base glycol grease C109126E06 Install the cylinder boot to the piston as shown in the illustration. BRAKE – FRONT BRAKE BR–53 8. INSTALL FRONT DISC BRAKE PISTON (for TMMK Made) (a) Install the cylinder boot to the cylinder assembly. NOTICE: Install the boot securely to the grooves of the cylinder. (b) Push in the piston by hand and install the boot seal onto the grooves of the piston. NOTICE: Install the boot securely to the grooves of the piston. 9. INSTALL FRONT DISC BRAKE BUSHING DUST BOOT (a) Apply lithium soap base glycol grease to the seal surface of 2 new bushing dust boots. (b) Install the 2 bushing dust boots to the front disc brake cylinder mounting. Cylinder Boot Piston Cylinder C141192E01 Lithium soap base glycol grease C132799E05 10. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSHING (a) Apply lithium soap base glycol grease to a new front disc brake cylinder slide bushing. (b) Install the front disc brake cylinder slide bushing to the No. 2 front disc brake cylinder slide pin. Lithium soap base glycol grease C132805E02 11. INSTALL NO. 2 FRONT DISC BRAKE CYLINDER SLIDE PIN (a) Apply lithium soap base glycol grease to the sliding part and the seal surface of the No. 2 front disc brake cylinder slide pin. (b) Install the No. 2 front disc brake cylinder slide pin to the bottom side of the cylinder mounting. No. 2 Slide Pin Lithium soap base glycol grease C142647E02 BR BR–54 BRAKE – FRONT BRAKE 12. INSTALL NO. 1 FRONT DISC BRAKE CYLINDER SLIDE PIN (a) Apply lithium soap base glycol grease to the sliding part and the seal surface of the No. 1 front disc brake cylinder slide pin. Lithium soap base glycol grease C132826E02 (b) Install the No. 1 front disc brake cylinder slide pin. No. 1 Slide Pin BR C142648E02 13. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING (a) Install the cylinder mounting with the 2 bolts. Torque: 107 N*m (1,090 kgf*cm, 79 ft.*lbf) 14. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE C132796 Area for disc brake grease application C141886E01 15. INSTALL FRONT ANTI-SQUEAL SHIM (a) Apply disc brake grease to the anti-squeal shims. NOTICE: • When replacing worn pads, the anti-squeal shims must be replaced together with the pads. • Install the shims in the correct positions and directions. • Apply disc brake grease to the area that contacts the anti-squeal shim. • Disc brake grease can come out slightly from the area where the anti-squeal shim is installed. • Make sure that disc brake grease is not applied onto the lining surface. BRAKE – FRONT BRAKE BR–55 (b) Install the 2 anti-squeal shims and the 2 pad wear indicators to each pad. NOTICE: Install the pad wear indicators in the correct positions and directions. Pad Wear Indicator 16. INSTALL FRONT BRAKE PAD (a) Install the 2 brake pads with anti-squeal shims to the disc brake cylinder mounting. Anti-squeal Shim Disc Brake Pad Anti-squeal Shim Disc brake grease C132806E01 INSTALLATION Hold 1. Turn INSTALL DISC BRAKE CYLINDER ASSEMBLY (a) Install the disc brake cylinder assembly with the 2 bolts. Torque: 34 N*m (350 kgf*cm, 25 ft.*lbf) C132794E02 (b) Connect the flexible hose with the union bolt and the new gasket. NOTICE: Install the flexible hose lock securely in the lock hole in the disc brake cylinder. Torque: 29 N*m (300 kgf*cm, 21 ft.*lbf) C133332 2. FILL RESERVOIR WITH BRAKE FLUID (See page BR6) 3. BLEED MASTER CYLINDER (See page BR-6) 4. BLEED BRAKE LINE (See page BR-7) 5. BLEED BRAKE ACTUATOR ASSEMBLY (w/ VSC) (See page BR-8) 6. INSPECT BRAKE FLUID LEVEL IN RESERVOIR (See page BR-10) 7. INSPECT FOR BRAKE FLUID LEAKAGE 8. INSTALL FRONT WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) BR BR–60 BRAKE – REAR BRAKE REMOVAL 1. REMOVE REAR WHEEL 2. DRAIN BRAKE FLUID NOTICE: If brake fluid leaks onto any painted surface, wash or remove it completely. 3. DISCONNECT REAR BRAKE FLEXIBLE HOSE (a) Remove the union bolt and the gasket from the rear disc brake cylinder assembly, then disconnect the flexible hose. 4. REMOVE REAR DISC BRAKE CYLINDER ASSEMBLY (a) Hold the 2 front disc brake cylinder slide pins and remove the 2 bolts and rear disc brake cylinder assembly. C132824 BR Hold Turn C132823E01 BRAKE – REAR BRAKE BR–61 DISASSEMBLY 1. REMOVE REAR DISC BRAKE PAD KIT (PAD ONLY) (a) Remove the 2 brake pads with the anti-squeal shims. 2. REMOVE REAR ANTI-SQUEAL SHIM KIT (a) Remove the 2 anti-squeal shims and the 2 pad wear indicator plates from each pad. 3. REMOVE NO. 1 REAR DISC BRAKE PAD SUPPORT PLATE (a) Remove the No. 1 rear disc brake pad support plate from the rear disc brake cylinder mounting. 4. REMOVE NO. 2 REAR DISC BRAKE PAD SUPPORT PLATE (a) Remove the No. 2 rear disc brake pad support plate from the rear disc brake cylinder mounting. 5. REMOVE REAR DISC BRAKE CYLINDER MOUNTING (a) Remove the 2 bolts and the rear disc brake cylinder mounting. C132822 6. REMOVE REAR DISC BRAKE CYLINDER SLIDE PIN (a) Remove the 2 pins (upper and lower) from the rear brake cylinder mounting. 7. REMOVE REAR DISC BRAKE BUSHING DUST BOOT (a) Remove the 2 rear disc brake bushing dust boots from the rear disc brake cylinder mounting. C132821 C132820 BR BR–62 BRAKE – REAR BRAKE 8. REMOVE CYLINDER BOOT (a) Using a screwdriver, pry out the set ring and cylinder boot. NOTICE: Be careful not to damage the brake piston and cylinder. HINT: Tape the screwdriver tip before use. 9. REMOVE REAR DISC BRAKE PISTON (a) Prepare a wooden plate to hold the brake pistons. (b) Place the wooden plate between the brake piston and the rear disc brake cylinder sub-assembly. C132814 170 mm (6.70 in.) BR 50 mm (1.97 in.) 30 mm (1.18 in.) C111364E06 (c) Use compressed air to remove the piston from the disc brake cylinder assembly. CAUTION: Do not place your fingers in front of the brake piston when using compressed air. NOTICE: Be careful not to spatter the brake fluid. C132816 10. REMOVE PISTON SEAL (a) Using a screwdriver, remove the piston seal from the rear disc brake cylinder sub-assembly. NOTICE: Be careful not to damage the inner cylinder and cylinder groove. HINT: Tape the screwdriver tip before use. C132817 11. REMOVE REAR DISC BRAKE BLEEDER PLUG CAP (a) Remove the bleeder plug cap from the rear disc brake bleeder plug. 12. REMOVE REAR DISC BRAKE BLEEDER PLUG (a) Remove the rear disc brake bleeder plug from the rear disc brake cylinder sub-assembly. 13. REMOVE PARKING BRAKE SHOE ADJUSTING HOLE PLUG (a) Remove the parking brake shoe adjusting hole plug. BRAKE – REAR BRAKE BR–63 14. REMOVE REAR DISC (a) Put matchmarks on the rear disc and the axle hub. Matchmarks C132813E01 (b) Release the parking brake and remove the rear disc. HINT: If the disc cannot be removed easily, turn and press firmly the shoe adjuster until the wheel comes free. D028126 BR BR–64 BRAKE – REAR BRAKE INSPECTION 1. INSPECT BRAKE CYLINDER AND PISTON (a) Inspect the cylinder bore and the piston for rust or scoring. If necessary, replace the rear disc brake cylinder assembly and piston. 2. INSPECT PAD LINING THICKNESS (a) Using a ruler, measure the pad lining thickness. Standard thickness: 11.0 mm (0.433 in.) Minimum thickness: 1.0 mm (0.039 in.) If the pad lining thickness is less than the minimum, replace the brake pads. HINT: Be sure to check wear of the front disc after replacing the brake pad with a new one. 3. INSPECT NO. 1 REAR DISC BRAKE PAD SUPPORT PLATE (a) Inspect the No. 1 rear disc brake pad support plate. HINT: Make sure that they have sufficient rebound, and have no deformation, cracks or wear, and all rust and dirt are cleaned off. 4. INSPECT NO. 2 REAR DISC BRAKE PAD SUPPORT PLATE HINT: Inspect the No. 2 rear disc brake pad support plate using the same procedure with the No. 1 rear disc brake pad support plate. 5. INSPECT DISC THICKNESS (a) Using a micrometer, measure the disc thickness. Standard thickness: 10.0 mm (0.390 in.) Minimum thickness: 8.5 mm (0.334 in.) If the disc thickness is less than the minimum, replace the rear disc. 6. INSPECT DISC RUNOUT (a) Install the rear disc. (b) Temporarily fasten the rear disc with the 3 hub nuts. Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) C132815 BR Micrometer C132819E01 (c) Using a dial indicator, measure the disc runout 10 mm (0.39 in.) away from the outer edge of the rear disc. Maximum disc runout: 0.15 mm (0.0059 in.) Dial Indicator C132818E01 BRAKE – REAR BRAKE BR–65 (d) If the runout exceeds the maximum value, change the installation positions of the disc and axle so that the runout will become minimal. If the runout exceeds the maximum even after the installation positions are changed, check the bearing play in the axial direction and the axle hub runout (See page AH-16). If the bearing play and the axle hub runout are normal and if the disc thickness is not within the specified range, grind the disc. If the disc thickness is less than the minimum, replace the disc. (e) Remove the 3 hub nuts. (f) Remove the rear disc. REASSEMBLY Matchmarks 1. INSTALL REAR DISC (a) Aligning the matchmarks, install the rear disc. HINT: When replacing the rear disc with a new one, select the installation position where the rear disc has the minimum runout. 2. ADJUST PARKING BRAKE SHOE CLEARANCE (See page PB-63) HINT: Hold the rear disc with hub nuts by applying parking brake before adjusting the parking brake shoe clearance. 3. INSTALL PARKING BRAKE SHOE ADJUSTING HOLE PLUG (a) Install the parking brake shoe adjusting hole plug. 4. TEMPORARILY TIGHTEN REAR DISC BRAKE BLEEDER PLUG (a) Temporarily install the rear disc brake bleeder plug to the rear disc brake cylinder sub-assembly. 5. INSTALL REAR DISC BRAKE BLEEDER PLUG CAP (a) Install the rear disc brake bleeder plug cap to the rear disc brake bleeder plug. 6. INSTALL PISTON SEAL (a) Apply lithium soap base glycol grease to a new piston seal. (b) Install the piston seal to the rear disc brake cylinder sub-assembly. C132813E01 BR BR–66 BRAKE – REAR BRAKE 7. INSTALL REAR DISC BRAKE PISTON (a) Apply lithium soap base glycol grease to the rear disc brake piston and a new cylinder boot. (b) Install the cylinder boot to the rear disc brake piston. (c) Install the piston to the rear disc brake cylinder subassembly. NOTICE: Do not install the piston forcibly in the disc brake cylinder. 8. INSTALL CYLINDER BOOT (a) Install the cylinder boot to the rear disc brake cylinder sub-assembly. NOTICE: • Install the boot securely onto the grooves of the cylinder and the piston. • Do not damage the cylinder boot. (b) Using a screwdriver, install the set ring. CAUTION: Be careful not to damage the boot. 9. INSTALL REAR DISC BRAKE BUSHING DUST BOOT (a) Apply lithium soap base glycol grease to the seal surface of 2 new rear disc brake bushing dust boots. :Lithium soap base glycol grease C132827E01 Set Ring Piston BR Cylincer Cylinder Boot C133333E01 (b) Install the 2 rear disc brake bushing dust boots to the rear disc brake cylinder mounting. Lithium soap base glycol grease C132828E01 BRAKE – REAR BRAKE BR–67 10. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN (a) Apply lithium soap base glycol grease to the pins. Lithium soap base glycol grease C132826E01 (b) Install the 2 pins (upper and lower) to the rear brake cylinder mounting. BR C132821 11. INSTALL REAR DISC BRAKE CYLINDER MOUNTING (a) Install the rear disc brake cylinder mounting with the 2 bolts. Torque: 62 N*m (632 kgf*cm, 46 ft.*lbf) 12. INSTALL NO. 1 REAR DISC BRAKE PAD SUPPORT PLATE (a) Install the No. 1 rear disc brake pad support plate to the rear disc brake cylinder mounting. C132822 Area for disc brake grease application C141885E01 13. INSTALL NO. 2 REAR DISC BRAKE PAD SUPPORT PLATE (a) Install the No. 2 rear disc brake pad support plate to the rear disc brake cylinder mounting. 14. INSTALL REAR ANTI-SQUEAL SHIM KIT (a) Apply disc brake grease to the inside of the antisqueal shims. NOTICE: • When replacing worn pads, the anti-squeal shims must be replaced together with the pads. • Apply disc brake grease to the area that contacts the anti-squeal shim. • Disc brake grease can come out slightly from the area where the anti-squeal shim is installed. • Make sure that disc brake grease is not applied onto the lining surface. BR–68 BRAKE – REAR BRAKE (b) Install the 2 anti-squeal shims and the pad wear indicators to each of the 2 brake pads. NOTICE: Install the pad wear indicator and anti-squeal shims in the correct positions and directions. Disc brake pad 15. INSTALL REAR DISC BRAKE PAD KIT (PAD ONLY) (a) Install the 2 brake pads with anti-squeal shims to the rear disc brake cylinder mounting. Anti-squeal shim Pad wear indicator Anti-squeal shim Disc brake grease C132825E01 Hold INSTALLATION Turn 1. INSTALL REAR DISC BRAKE CYLINDER ASSEMBLY (a) Install the disc brake cylinder assembly with the 2 bolts. Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) NOTICE: Install the rear disc brake bushing dust boot onto the groove of the rear disc brake cylinder. 2. CONNECT REAR BRAKE FLEXIBLE HOSE (a) Connect the flexible hose with the union bolt and a new gasket. Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf) 3. FILL RESERVOIR WITH BRAKE FLUID (See page BR6) 4. BLEED MASTER CYLINDER (See page BR-6) 5. BLEED BRAKE LINE (See page BR-7) 6. BLEED BRAKE ACTUATOR ASSEMBLY (w/ VSC) (See page BR-8) 7. INSPECT FLUID LEVEL IN RESERVOIR (See page BR-10) 8. CHECK FOR BRAKE FLUID LEAKAGE 9. INSTALL REAR WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) BR C132823E01 C132824 BR–67 BRAKE – REAR BRAKE FLEXIBLE HOSE REAR BRAKE FLEXIBLE HOSE BRAKE COMPONENTS 19 (194, 14) CLIP 15 (155, 11) *14 (143, 10) BR GASKET REAR BRAKE FLEXIBLE HOSE 33 (337, 24) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part * For use with SST C132789E02 BR–68 BRAKE – REAR BRAKE FLEXIBLE HOSE REMOVAL 1. DRAIN BRAKE FLUID 2. REMOVE REAR WHEEL 3. REMOVE REAR BRAKE FLEXIBLE HOSE (a) Remove the union bolt, the rear brake flexible hose and gasket. C132824 (b) Remove the bolt and separate the rear brake flexible hose. BR C132791E02 (c) Using SST, remove the brake line while holding the rear brake flexible hose with a wrench. SST 09023-00101 NOTICE: • Do not bend or damage the brake line. • Do not allow any foreign matter such as dirt and dust to enter the brake tube from the connecting points. (d) Remove the clip. SST C133343E02 INSTALLATION 1. C132824 INSTALL REAR BRAKE FLEXIBLE HOSE (a) Connect the rear brake flexible hose with the union bolt and a new gasket. Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf) (b) Install the rear brake flexible hose with a new clip. NOTICE: • When installing the rear brake flexible hose, face the identification mark toward the exterior of the vehicle and minimize twisting of the hose. • Install the clip as far as it will go. BRAKE – REAR BRAKE FLEXIBLE HOSE BR–69 (c) Using SST, connect the brake line to the rear brake flexible hose while holding the flexible hose with a wrench. SST 09023-00101 Torque: Without SST 15 N*m (155 kgf*cm, 11 ft.*lbf) With SST 14 N*m (143 kgf*cm, 10 ft.*lbf) NOTICE: • Do not bend or damage the brake tube. • Do not allow any foreign matter such as dirt and dust to enter the brake tube from the connecting points. • Use a torque wrench with a fulcrum length of 300 mm (11.81 in.). • This torque value is effective when SST is parallel to a torque wrench. SST C133344E01 (d) Connect the rear flexible hose and the speed sensor to the shock absorber with the bolt. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) NOTICE: When installing the rear flexible hose and the speed sensor, the bracket must face toward the exterior of the vehicle. 2. FILL RESERVOIR WITH BRAKE FLUID (See page BR6) 3. BLEED BRAKE LINE (See page BR-7) 4. BRAKE ACTUATOR ASSEMBLY (w/ VSC) (See page BR-8) 5. INSPECT BRAKE FLUID LEVEL IN RESERVOIR (See page BR-10) 6. CHECK FOR BRAKE FLUID LEAKAGE 7. INSTALL REAR WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) C132791E02 BR BR–70 BRAKE – STOP LIGHT SWITCH STOP LIGHT SWITCH BRAKE COMPONENTS COMBINATION METER with Smart Key System: LOWER INSTRUMENT PANEL FINISH PANEL INSTRUMENT CLUSTER FINISH PANEL BR NO. 1 INSTRUMENT PANEL SUB-ASSEMBLY STOP LIGHT SWITCH LOWER INSTRUMENT PANEL FINISH PANEL CONNECTOR LOWER INSTRUMENT PANEL FINISH PANEL LH without Driver Side Airbag: COWL SIDE TRIM SUB-ASSEMBLY FRONT DOOR SCUFF PLATE INSTRUMENT PANEL SUB-ASSEMBLY C133310E01 BRAKE – STOP LIGHT SWITCH BR–71 ON-VEHICLE INSPECTION Cushion 1. Stop Light Switch Assembly 1.5 to 2.5 mm (0.059 to 0.098 in.) F043108E08 INSPECT STOP LIGHT SWITCH (a) Check the protrusion of the rod. Protrusion of the rod: 1.5 to 2.5 mm (0.059 to 0.098 in.) If the protrusion is not within the specified range, adjust it. CAUTION: Do not depress the brake pedal. BR BR–72 BRAKE – STOP LIGHT SWITCH REMOVAL BR 1. REMOVE FRONT DOOR SCUFF PLATE (See page IR24) 2. REMOVE COWL SIDE TRIM SUB-ASSEMBLY (See page IR-25) 3. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (See page IP-20) 4. REMOVE NO. 1 INSTRUMENT PANEL SUBASSEMBLY (See page IP-22) 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (w/ Smart Key System) (See page IP-22) 6. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (w/o Smart Key System) (See page IP-22) 7. REMOVE INSTRUMENT CLUSTER FINISH PANEL (See page IP-22) 8. REMOVE COMBINATION METER (See page IP-32) 9. REMOVE STOP LIGHT SWITCH (a) Disconnect the stop light switch assembly connector from the stop light switch assembly. C133309E01 (b) Turn the stop light switch assembly counterclockwise and remove the stop light switch assembly. C133307 INSPECTION Stop Light Switch: 1. Free Pushed In INSPECT STOP LIGHT SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Switch Condition Specified Condition 1-2 Switch pin free Below 1 Ω 1-2 Switch pin pushed in 10 kΩ or higher F047752E05 If the measurement result is not normal, replace the stop light switch assembly. BRAKE – STOP LIGHT SWITCH BR–73 INSTALLATION 1. INSTALL STOP LIGHT SWITCH (a) Insert the stop light switch assembly until the body hits the cushion. NOTICE: When inserting the stop light switch assembly, support the pedal from behind so that the pedal is not pushed in. C133308 (b) Make a quarter turn clockwise to install the stop light switch assembly. Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf) or less NOTICE: When inserting the stop light switch assembly, support the pedal from behind so that the pedal is not pushed in. Stop Light Switch 1.5 to 2.5 mm (0.060 to 0.098 in.) BR C131701E02 (c) Connect the stop light switch connector to the stop light switch assembly. (d) Check the protrusion of the rod (See page BR-71). 2. INSTALL COMBINATION METER (See page IP-56) 3. INSTALL INSTRUMENT CLUSTER FINISH PANEL (See page IP-57) 4. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/ Smart Key System) (See page IP-57) 5. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/o Smart Key System) (See page IP-57) 6. INSTALL NO. 1 INSTRUMENT PANEL SUBASSEMBLY (See page IP-57) 7. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (See page IP-58) 8. INSTALL COWL SIDE TRIM SUB-ASSEMBLY (See page IR-54) 9. INSTALL FRONT DOOR SCUFF PLATE (See page IR54) C133309E01 PB–1 PARKING BRAKE – PARKING BRAKE SYSTEM PARKING BRAKE SYSTEM PROBLEM SYMPTOMS TABLE Use the table below to help determine the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. Symptom Brake drag Suspected area See page 1. Parking brake lever travel (Out of adjustment) PB-1 2. Parking brake pedal travel (Out of adjustment) PB-1 3. Parking brake wire (Sticking) [No. 1 cable] PB-48 4. Parking brake wire (Sticking) [No. 2/No. 3 cable] PB-48 5. Parking brake shoe clearance (Out of adjustment) PB-1 6. Parking brake shoe lining (Cracked or distorted) PB-60 7. Tension or return spring (Damaged) PB-58 PB PB–2 PARKING BRAKE – PARKING BRAKE SYSTEM ADJUSTMENT 1. REMOVE REAR WHEEL 2. ADJUST PARKING BRAKE SHOE CLEARANCE (a) Temporarily install the hub nuts. (b) Remove the shoe adjusting hole plug. (c) Turn the shoe adjuster and expand the shoe until the disc locks. (d) Turn and contract the shoe adjuster until the disc can rotate smoothly. Standard: Return 8 notches (e) Check that there is no brake drag against the shoe. (f) Install the shoe adjusting hole plug. (g) Remove the hub nuts. Expand Contract C131914E01 3. INSTALL REAR WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 4. INSPECT PARKING BRAKE PEDAL TRAVEL (for Automatic Transaxle) (a) Fully depress the parking brake pedal and release it to engage the parking brake. (b) Depress the pedal to the floor again, and release it to disengage the parking brake. PB (c) Slowly depress the parking brake pedal to the floor, and count the number of clicks. Parking brake pedal travel: 7 to 10 notches at 300 N (31 kgf, 67 lbf) 5. C107204 ADJUST PARKING BRAKE PEDAL TRAVEL (for Automatic Transaxle) (a) Depress the parking brake pedal. Hold the No. 1 wire adjusting nut using a wrench and loosen the lock nut. (b) Release the parking brake pedal. (c) Turn the No. 1 wire adjusting nut until the parking brake pedal travel meets the above specification. (d) Hold the No. 1 wire adjusting nut using a wrench or an equivalent tool and tighten the lock nut. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) (e) Count the number of clicks after depressing and releasing the parking brake pedal 3 or 4 times. (f) Check whether the parking brake drags. (g) When operating the parking brake pedal, check that the parking brake indicator light comes on. No. 1 Wire Adjusting Nut Lock Nut C133443E01 6. INSPECT PARKING BRAKE LEVER TRAVEL (for Manual Transaxle) (a) Pull the parking brake lever firmly. (b) Release the parking brake lock, and return the parking brake lever to its off position. PARKING BRAKE – PARKING BRAKE SYSTEM PB–3 (c) Slowly pull the parking brake lever all the way up, and count the number of clicks. Parking brake lever travel: 7 to 9 notches at 200 N (20 kgf, 45 lbf) 7. C131910 Wire Adjusting No. 1 Nut Lock Nut C131913E01 ADJUST PARKING BRAKE LEVER TRAVEL (for Manual Transaxle) (a) Pull up the parking brake lever. Hold the No. 1 wire adjusting nut using a wrench and loosen the lock nut. (b) Release the parking brake lever. (c) Turn the No. 1 wire adjusting nut until the parking brake lever travel meets the above specification. (d) Hold the No. 1 wire adjusting nut using a wrench or an equivalent tool and tighten the lock nut. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) (e) Count the number of clicks after depressing and releasing the parking brake lever 3 or 4 times. (f) Check whether the parking brake drags. (g) When operating the parking brake lever, check that the parking brake indicator light comes on. PB PB–3 PARKING BRAKE – PARKING BRAKE LEVER PARKING BRAKE LEVER PARKING BRAKE BRAKE COMPONENTS for Manual Seat: FRONT SEAT HEADREST ASSEMBLY SEAT TRACK COVER RH 37 (377, 27) INNER SEAT TRACK BRACKET COVER RH PB 37 (377, 27) FRONT SEAT ASSEMBLY RH FRONT SEAT HEADREST ASSEMBLY INNER SEAT TRACK BRACKET COVER LH SEAT TRACK COVER LH 37 (377, 27) 37 (377, 27) FRONT SEAT ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque B132048E01 PB–4 PARKING BRAKE – PARKING BRAKE LEVER for Power Seat: FRONT SEAT HEADREST ASSEMBLY SEAT TRACK COVER RH INNER SEAT TRACK BRACKET COVER LH 37 (377, 27) 37 (377, 27) PB FRONT SEAT ASSEMBLY RH FRONT SEAT HEADREST ASSEMBLY INNER SEAT TRACK BRACKET COVER RH 37 (377, 27) SEAT TRACK COVER LH 37 (377, 27) FRONT SEAT ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque B132047E01 PB–5 PARKING BRAKE – PARKING BRAKE LEVER for TMC made: DRIVER SIDE KNEE AIRBAG ASSEMBLY INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY 10 (102, 7) PB or LOWER INSTRUMENT PANEL FINISH PANEL LH LOWER INSTRUMENT PANEL SUB-ASSEMBLY UPPER CONSOLE PANEL SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C133459E01 PB–6 PARKING BRAKE – PARKING BRAKE LEVER for TMMK made: DRIVER SIDE KNEE AIRBAG ASSEMBLY INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY 10 (102, 7) PB or

or

LOWER INSTRUMENT PANEL FINISH PANEL LH LOWER INSTRUMENT PANEL SUB-ASSEMBLY UPPER CONSOLE PANEL SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C133459E02 PARKING BRAKE – PARKING BRAKE LEVER PB–7 NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH SHIFT LEVER KNOB SUB-ASSEMBLY UPPER CONSOLE PANEL PB UPPER CONSOLE REAR PANEL SUB-ASSEMBLY FLOOR CARPET BRACKET RH FLOOR CARPET BRACKET LH C133456E01 PB–8 PARKING BRAKE – PARKING BRAKE LEVER for TMC made: CONSOLE BOX POCKET CONSOLE BOX CARPET for Manual Air Conditioning System: NO. 1 CONSOLE BOX INSERT FRONT PB NO. 2 CONSOLE BOX INSERT FRONT CONSOLE BOX ASSEMBLY for Automatic Air Conditioning System: CONSOLE BOX ASSEMBLY C141955E01 PB–9 PARKING BRAKE – PARKING BRAKE LEVER for TMMK made: CONSOLE BOX POCKET CONSOLE BOX CARPET for Manual Air Conditioning System: NO. 1 CONSOLE BOX INSERT FRONT or or PB NO. 2 CONSOLE BOX INSERT FRONT CONSOLE BOX ASSEMBLY for Automatic Air Conditioning System: or or CONSOLE BOX ASSEMBLY C141955E02 PB–10 PARKING BRAKE – PARKING BRAKE LEVER FRONT DOOR OPENING TRIM WEATHERSTRIP RH REAR DOOR OPENING TRIM WEATHERSTRIP RH REAR DOOR SCUFF PLATE RH LOWER CENTER PILLAR GARNISH RH FRONT DOOR SCUFF PLATE RH COWL SIDE TRIM SUB-ASSEMBLY RH LUGGAGE DOOR LOCK OPEN LEVER SUB-ASSEMBLY PB FRONT FLOOR CARPET ASSEMBLY CROSS MEMBER FLOOR NO. 4 REINFORCEMENT SUB-ASSEMBLY REAR DOOR OPENING TRIM WEATHERSTRIP LH LOWER CENTER PILLAR GARNISH LH FRONT DOOR OPENING TRIM WEATHERSTRIP LH COWL SIDE TRIM SUB-ASSEMBLY LH REAR DOOR SCUFF PLATE LH FRONT DOOR SCUFF PLATE LH C132673E01 PARKING BRAKE – PARKING BRAKE LEVER PB–11 5.0 (51, 44 in.*lbf) 21 (214, 15)* 22 (224, 16)** NO. 1 WIRE ADJUSTING NUT PARKING BRAKE LEVER SUB-ASSEMBLY 1.0 (10, 9.0 in.*lbf) PARKING BRAKE SWITCH ASSEMBLY NO. 2 PARKING BRAKE CABLE ASSEMBLY NO. 1 PARKING BRAKE CABLE ASSEMBLY NO. 3 PARKING BRAKE CABLE ASSEMBLY PB 21 (214, 15)* 22 (224, 16)** PARKING BRAKE EQUALIZER N*m (kgf*cm, ft.*lbf) : Specified torque * For TMC made ** For TMMK made C132672E01 PB–12 PARKING BRAKE – PARKING BRAKE LEVER REMOVAL 1. PRECAUTION (See page IP-1) 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (for Manual Seat) CAUTION: Wait for 90 seconds after disconnecting the cable to prevent the airbag working. (See page RS-1) 3. REMOVE FRONT SEAT ASSEMBLY LH (for Manual Seat) HINT: Refer to the procedures up to "REMOVE FRONT SEAT ASSEMBLY (for Manual Seat)". (See page SE-16) 4. REMOVE FRONT SEAT ASSEMBLY RH (for Manual Seat) HINT: Use the same procedures for the RH side and the LH side. 5. REMOVE FRONT SEAT ASSEMBLY LH (for Power Seat) HINT: Refer to the procedures up to "REMOVE FRONT SEAT ASSEMBLY (for Power Seat)". (See page SE-30) 6. REMOVE FRONT SEAT ASSEMBLY RH (for Power Seat) HINT: Use the same procedures for the RH side and the LH side. 7. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-25) 8. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH (See page IR-26) 9. REMOVE INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY (See page IP-23) PB 10. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (See page IP-20) 11. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (See page IP-21) 12. REMOVE DRIVER SIDE KNEE AIRBAG ASSEMBLY (See page RS-370) 13. REMOVE LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMC Made) (See page IP-23) 14. REMOVE LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMMK Made) (See page IP-24) 15. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (See page IP-24) PARKING BRAKE – PARKING BRAKE LEVER PB–13 16. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-24) 17. REMOVE NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-25) 18. REMOVE UPPER CONSOLE PANEL (See page IP-25) 19. REMOVE UPPER CONSOLE REAR PANEL SUBASSEMBLY (See page IP-26) 20. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMC Made) (See page IP-27) 21. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMMK Made) (See page IP-27) 22. REMOVE CONSOLE BOX POCKET (See page IP-28) 23. REMOVE CONSOLE BOX CARPET (See page IP-28) 24. REMOVE CONSOLE BOX ASSEMBLY (for TMC Made) (See page IP-28) 25. REMOVE CONSOLE BOX ASSEMBLY (for TMMK Made) (See page IP-29) 26. REMOVE NO. 2 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-29) 27. REMOVE NO. 2 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-30) 28. REMOVE NO. 1 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-30) 29. REMOVE NO. 1 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-30) 30. REMOVE FLOOR CARPET BRACKET LH (See page AC-155) 31. REMOVE FLOOR CARPET BRACKET RH (See page AC-155) 32. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-24) 33. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH 34. REMOVE REAR DOOR SCUFF PLATE LH (See page IR-24) 35. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH 36. REMOVE LOWER CENTER PILLAR GARNISH LH (See page IR-25) 37. REMOVE FRONT DOOR SCUFF PLATE RH (See page IR-26) 38. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH PB PB–14 PARKING BRAKE – PARKING BRAKE LEVER 39. REMOVE REAR DOOR SCUFF PLATE RH (See page IR-24) 40. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH 41. REMOVE LOWER CENTER PILLAR GARNISH RH (See page IR-26) 42. REMOVE LUGGAGE DOOR LOCK OPEN LEVER SUB-ASSEMBLY (a) Remove the screw. (b) Disengage the claw and remove the luggage door open lever sub-assembly. 43. REMOVE FRONT FLOOR CARPET ASSEMBLY (a) Disengage the 6 clamps and the 2 claws. C132659 PB Clamp Clamp C132661E01 (b) Turn back the front floor carpet assembly until the bolts of the cross member floor No. 4 reinforcement sub-assembly can be seen. 44. REMOVE CROSS MEMBER FLOOR NO. 4 REINFORCEMENT SUB-ASSEMBLY (a) Remove the 8 bolts and the cross member floor No. 4 reinforcement sub-assembly. C132658 PARKING BRAKE – PARKING BRAKE LEVER PB–15 45. SEPARATE NO. 3 PARKING BRAKE CABLE ASSEMBLY (a) Separate the No. 3 parking brake cable assembly from the parking brake equalizer. C138184 46. SEPARATE NO. 2 PARKING BRAKE CABLE ASSEMBLY Separate the No. 2 parking brake cable assembly from the parking brake equalizer. C138185 47. REMOVE PARKING BRAKE EQUALIZER (a) Slide the rubber boot as shown in the illustration. C138196 (b) Remove the parking brake equalizer from the No. 1 parking brake cable assembly. C132657 48. REMOVE PARKING BRAKE LEVER SUB-ASSEMBLY (a) Disconnect the parking brake switch connector. (b) Remove the 2 bolts, the clip, and the parking brake lever. C131911 PB PB–16 PARKING BRAKE – PARKING BRAKE LEVER DISASSEMBLY 1. REMOVE NO. 1 PARKING BRAKE CABLE ASSEMBLY (a) Using a screwdriver, pull up the parking brake lever claw. C131912 (b) Remove the lock nut, the No. 1 wire adjusting nut, and the No. 1 parking brake cable assembly from the parking brake lever sub-assembly. Lock Nut No. 1 Wire Adjusting Nut C132670E01 PB 2. REMOVE PARKING BRAKE SWITCH ASSEMBLY (a) Remove the screw and the parking brake switch assembly. C132654 REASSEMBLY 1. INSTALL PARKING BRAKE SWITCH ASSEMBLY (a) Install the parking brake switch assembly with the screw. Torque: 1.0 N*m (10 kgf*cm, 9.0 in.*lbf) 2. INSTALL NO. 1 PARKING BRAKE CABLE ASSEMBLY (a) Pass the No. 1 parking brake cable assembly through the parking brake lever sub-assembly. C132654 Lock Nut No. 1 Wire Adjusting Nut C132670E01 (b) Temporarily tighten the lock nut and the No. 1 wire adjusting nut. NOTICE: Fully tighten the lock nut when adjusting the parking brake lever travel. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) PARKING BRAKE – PARKING BRAKE LEVER PB–17 (c) Bend the parking brake lever claw. C132671 INSTALLATION 1. INSTALL PARKING BRAKE LEVER SUB-ASSEMBLY (a) Install the parking brake lever sub-assembly with the 2 bolts and the clip. Torque: for TMC made 21 N*m (214 kgf*cm, 15 ft.*lbf) for TMMK made 22 N*m (224 kgf*cm, 16 ft.*lbf) (b) Connect the parking brake switch connector. 2. INSTALL PARKING BRAKE EQUALIZER (a) Install the parking brake equalizer to the No. 1 parking brake cable assembly. C131911 C132657 (b) Slide the rubber boot back as shown in the illustration. C132656 3. C138185 INSTALL NO. 2 PARKING BRAKE CABLE ASSEMBLY (a) Connect the No. 2 parking brake cable assembly to the parking brake equalizer. PB PB–18 PARKING BRAKE – PARKING BRAKE LEVER 4. INSTALL NO. 3 PARKING BRAKE CABLE ASSEMBLY (a) Connect the No. 3 parking brake cable assembly to the parking brake equalizer. 5. INSTALL CROSS MEMBER FLOOR NO. 4 REINFORCEMENT SUB-ASSEMBLY (a) Install the cross member floor No. 4 reinforcement sub-assembly with the 8 bolts. 6. INSTALL FRONT FLOOR CARPET ASSEMBLY (a) Engage the 6 clamps and the 2 claws and install the front floor carpet assembly. C138184 C132658 PB Clamp Clamp C132661E01 C132659 7. INSTALL LUGGAGE DOOR LOCK OPEN LEVER SUB-ASSEMBLY (a) Engage the claw and install the luggage door open lever sub-assembly with the screw. 8. INSTALL LOWER CENTER PILLAR GARNISH LH (See page IR-53) 9. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (See page IR-55) 10. INSTALL REAR DOOR SCUFF PLATE LH (See page IR-56) PARKING BRAKE – PARKING BRAKE LEVER PB–19 11. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH (See page IR-54) 12. INSTALL FRONT DOOR SCUFF PLATE LH (See page IR-54) 13. INSTALL LOWER CENTER PILLAR GARNISH RH (See page IR-54) 14. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH (See page IR-56) 15. INSTALL REAR DOOR SCUFF PLATE RH (See page IR-56) 16. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH (See page IR-55) 17. INSTALL FRONT DOOR SCUFF PLATE RH (See page IR-55) 18. INSTALL FLOOR CARPET BRACKET LH 19. INSTALL FLOOR CARPET BRACKET RH 20. INSTALL NO. 2 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-50) 21. INSTALL NO. 2 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-50) 22. INSTALL NO. 1 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-49) 23. INSTALL NO. 1 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-50) 24. INSTALL CONSOLE BOX ASSEMBLY (for TMC Made) (See page IP-51) 25. INSTALL CONSOLE BOX ASSEMBLY (for TMMK Made) (See page IP-51) 26. INSTALL CONSOLE BOX CARPET (See page IP-51) 27. INSTALL CONSOLE BOX POCKET (See page IP-51) 28. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMC Made) (See page IP-52) 29. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMMK Made) (See page IP-52) 30. INSTALL UPPER CONSOLE REAR PANEL SUBASSEMBLY (See page IP-53) 31. INSTALL UPPER CONSOLE PANEL (See page IP-54) 32. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-55) 33. INSTALL NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-54) 34. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (See page IP-55) PB PB–20 PARKING BRAKE – PARKING BRAKE LEVER 35. INSTALL LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMC Made) (See page IP-55) 36. INSTALL LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMMK Made) (See page IP-56) 37. INSTALL INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY (See page IP-56) 38. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY (See page RS-370) 39. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (See page IP-58) 40. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (See page IP-59) 41. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-54) 42. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH (See page IR-55) PB 43. INSTALL FRONT SEAT ASSEMBLY LH (for Manual Seat) HINT: Refer to the procedures up to "INSTALL FRONT SEAT ASSEMBLY (for Manual Seat)". (See page SE-24) 44. INSTALL FRONT SEAT ASSEMBLY RH (for Manual Seat) HINT: Use the same procedures for the RH side and the LH side. 45. INSTALL FRONT SEAT ASSEMBLY LH (for Power Seat) HINT: Refer to the procedures up to "INSTALL FRONT SEAT ASSEMBLY (for Power Seat)". (See page SE-41) 46. INSTALL FRONT SEAT ASSEMBLY RH (for Power Seat) HINT: Use the same procedures for the RH side and the LH side. 47. INSPECT PARKING BRAKE LEVER TRAVEL (See page PB-2) 48. ADJUST PARKING BRAKE LEVER TRAVEL (See page PB-2) 49. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (for Manual Seat) 50. PERFORM ZERO POINT CALIBRATION AND SENSITIVITY CHECK (See page RS-242) 51. INSPECT SRS WARNING LIGHT 52. INSPECT SLIDE ADJUSTER LOCK (for Manual Seat) PARKING BRAKE – PARKING BRAKE LEVER PB–21 53. INSPECT FRONT SEAT ASSEMBLY (for Power Seat) (See page SE-42) PB PB–21 PARKING BRAKE – PARKING BRAKE PEDAL PARKING BRAKE PEDAL PARKING BRAKE BRAKE COMPONENTS for TMC made: DRIVER SIDE KNEE AIRBAG ASSEMBLY 10 (102, 7) LOWER INSTRUMENT PANEL FINISH PANEL LH INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY or LOWER INSTRUMENT PANEL SUB-ASSEMBLY COWL SIDE TRIM SUB-ASSEMBLY RH COWL SIDE TRIM SUB-ASSEMBLY LH FRONT DOOR SCUFF PLATE LH FRONT DOOR SCUFF PLATE RH UPPER CONSOLE PANEL SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C133466E01 PB PB–22 PARKING BRAKE – PARKING BRAKE PEDAL for TMMK made: DRIVER SIDE KNEE AIRBAG ASSEMBLY 10 (102, 7) or

PB LOWER INSTRUMENT PANEL FINISH PANEL LH INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY or

LOWER INSTRUMENT PANEL SUB-ASSEMBLY COWL SIDE TRIM SUB-ASSEMBLY RH COWL SIDE TRIM SUB-ASSEMBLY LH FRONT DOOR SCUFF PLATE LH FRONT DOOR SCUFF PLATE RH UPPER CONSOLE PANEL SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C133466E02 PB–23 PARKING BRAKE – PARKING BRAKE PEDAL for TMC made: CONSOLE BOX POCKET NO. 1 CONSOLE BOX INSERT FRONT CONSOLE BOX CARPET NO. 2 CONSOLE BOX INSERT FRONT for Manual Air Conditioning System: PB 18 (184, 13) CENTER AIRBAG SENSOR ASSEMBLY CONSOLE BOX ASSEMBLY for Automatic Air Conditioning System: with VSC: 13 (133, 10) YAW RATE AND ACCELERATION SENSOR CONSOLE BOX ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C141956E01 PB–24 PARKING BRAKE – PARKING BRAKE PEDAL for TMMK made: CONSOLE BOX POCKET NO. 1 CONSOLE BOX INSERT FRONT CONSOLE BOX CARPET for Manual Air Conditioning System: or or PB NO. 2 CONSOLE BOX INSERT FRONT 18 (184, 13) CONSOLE BOX ASSEMBLY CENTER AIRBAG SENSOR ASSEMBLY for Automatic Air Conditioning System: with VSC: or or 13 (133, 10) YAW RATE AND ACCELERATION SENSOR CONSOLE BOX ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C141957E01 PARKING BRAKE – PARKING BRAKE PEDAL PB–25 NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH SHIFT LEVER KNOB SUB-ASSEMBLY NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY PB UPPER CONSOLE REAR PANEL SUB-ASSEMBLY FLOOR CARPET BRACKET RH for Automatic Air Conditioning System: 12 (122, 9) FLOOR CARPET BRACKET LH FLOOR SHIFT LEVER ASSEMBLY NO. 1 CONSOLE BOX DUCT 12 (122, 9) N*m (kgf*cm, ft.*lbf) : Specified torque C133457E02 PB–26 PARKING BRAKE – PARKING BRAKE PEDAL 39 (398, 29) 1.0 (10, 9.0 in.*lbf) PARKING BRAKE SWITCH ASSEMBLY PARKING PEDAL PAD PARKING BRAKE PEDAL ASSEMBLY 39 (398, 29) PB CLIP 5.4 (55, 48 in.*lbf) NO. 1 WIRE ADJUSTING NUT NO. 1 PARKING BRAKE CABLE CLAMP 15 (153, 11) 5.4 (55, 48 in.*lbf) NO. 4 PARKING BRAKE CABLE ASSEMBLY NO. 1 PARKING BRAKE CABLE ASSEMBLY 5.4 (55, 48 in.*lbf) CLIP PARKING BRAKE EQUALIZER TMMK made: NO. 2 PARKING BRAKE CABLE ASSEMBLY NO. 1 PARKING BRAKE CABLE ASSEMBLY NO. 4 PARKING BRAKE CABLE ASSEMBLY NO. 3 PARKING BRAKE CABLE ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque 5.4 (55, 48 in.*lbf) Non-reusable part C133442E02 PARKING BRAKE – PARKING BRAKE PEDAL PB–27 REMOVAL 1. PRECAUTION (See page IP-1) 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait for 90 seconds after disconnecting the cable to prevent the airbag working. (See page RS-1) 3. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-24) 4. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-25) 5. REMOVE FRONT DOOR SCUFF PLATE RH (See page IR-26) 6. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH (See page IR-26) 7. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (See page IP-58) 8. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (See page IP-21) 9. REMOVE DRIVER SIDE KNEE AIRBAG ASSEMBLY (See page RS-370) 10. REMOVE INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY (See page IP-23) 11. REMOVE LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMC Made) (See page IP-23) 12. REMOVE LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMMK Made) (See page IP-24) 13. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (See page IP-24) 14. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-24) 15. REMOVE NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-25) 16. REMOVE FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (See page IP-25) 17. REMOVE UPPER CONSOLE REAR PANEL SUBASSEMBLY (See page IP-26) 18. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMC Made) (See page IP-27) 19. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMMK Made) (See page IP-27) 20. REMOVE CONSOLE BOX POCKET (See page IP-28) 21. REMOVE CONSOLE BOX CARPET (See page IP-28) PB PB–28 PARKING BRAKE – PARKING BRAKE PEDAL 22. REMOVE CONSOLE BOX ASSEMBLY (for TMC Made) (See page IP-28) 23. REMOVE CONSOLE BOX ASSEMBLY (for TMMK Made) (See page IP-29) 24. REMOVE NO. 2 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-29) 25. REMOVE NO. 2 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-30) 26. REMOVE NO. 1 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-30) 27. REMOVE NO. 1 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-30) 28. REMOVE NO. 1 CONSOLE BOX DUCT (for Automatic Air Conditioning System) (See page AC-154) 29. REMOVE FLOOR CARPET BRACKET LH (See page AC-155) 30. REMOVE FLOOR CARPET BRACKET RH (See page AC-155) PB 31. REMOVE YAW RATE AND ACCELERATION SENSOR (w/ VSC) (See page BC-447) 32. REMOVE FLOOR SHIFT LEVER ASSEMBLY (a) Remove the 4 bolts and the floor shift lever assembly. 33. REMOVE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-442) C132691 34. DISCONNECT NO. 4 PARKING BRAKE CABLE ASSEMBLY (a) Using a wrench, hold the lock nut and loosen the turnbuckle. (b) Disconnect the No. 4 parking brake cable assembly from the No. 1 parking brake cable assembly. Hold Turn C132693E01 PARKING BRAKE – PARKING BRAKE PEDAL PB–29 35. REMOVE PARKING BRAKE PEDAL ASSEMBLY (a) Using needle-nose pliers, remove the clip from the No. 1 parking brake cable assembly. (b) Remove the bolt, nut, and the No. 1 parking brake cable clamp. C132692 PB C132694 (c) Separate the No. 1 parking brake cable assembly from the body. (d) Disconnect the parking brake switch connector. (e) Remove the bolt, 2 nuts, and the parking brake pedal assembly with the No. 1 parking brake cable assembly from the body. C132695 PB–30 PARKING BRAKE – PARKING BRAKE PEDAL DISASSEMBLY 1. REMOVE NO. 1 PARKING BRAKE CABLE ASSEMBLY (a) Using a screwdriver, pull up the parking brake pedal claw. C132698 (b) Remove the lock nut and the No. 1 wire adjusting nut. C132697 PB (c) Using needle nose pliers, remove the clip and the No. 1 parking brake cable from the parking brake pedal assembly. C132696 2. REMOVE PARKING BRAKE SWITCH ASSEMBLY (a) Remove the screw and the parking brake switch assembly. 3. REMOVE PARKING PEDAL PAD (a) Remove the parking pedal pad. C132700 C132702 PARKING BRAKE – PARKING BRAKE PEDAL PB–31 REASSEMBLY 1. INSTALL PARKING PEDAL PAD (a) Install the parking pedal pad to the parking brake pedal assembly. 2. INSTALL PARKING BRAKE SWITCH ASSEMBLY (a) Install the parking brake switch assembly with the screw. Torque: 1.0 N*m (10 kgf*cm, 9.0 in.*lbf) 3. INSTALL NO. 1 PARKING BRAKE CABLE ASSEMBLY (a) Pass the No. 1 parking brake cable assembly through the pedal guide. C132702 C132700 (b) Using a brass bar and a hammer, install the clip to the No. 1 parking brake cable assembly. C133439 (c) Temporarily tighten the the lock nut and No. 1 wire adjusting nut. NOTICE: Fully tighten the lock nut and the No. 1 wire adjusting nut when adjusting the parking brake pedal travel. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) C132697 (d) Bend the parking brake pedal claw. C132699 PB PB–32 PARKING BRAKE – PARKING BRAKE PEDAL INSTALLATION 1. INSTALL PARKING BRAKE PEDAL ASSEMBLY (a) Install the parking brake pedal assembly with the bolt and 2 nuts. Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf) (b) Connect the parking brake switch connector. (c) Install the No. 1 parking brake cable assembly to the body with the bolt, the nut, and a new No. 1 parking brake cable clamp. C132695 PB C133453 Torque: Bolt 15 N*m (153 kgf*cm, 11 ft.*lbf) Nut 5.4 N*m (55 kgf*cm, 48 in.*lbf) (d) Using a brass bar and a hammer, install the clip to the No. 1 parking brake cable assembly. 2. C133438 CONNECT NO. 4 PARKING BRAKE CABLE ASSEMBLY (a) Connect the No. 4 parking brake cable assembly to the No. 1 parking brake cable assembly. PARKING BRAKE – PARKING BRAKE PEDAL PB–33 (b) Using a wrench, hold the lock nut and tighten the turnbuckle. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) Hold 3. INSTALL CENTER AIRBAG SENSOR ASSEMBLY (See page RS-442) 4. INSTALL FLOOR SHIFT LEVER ASSEMBLY (a) Install the floor shift lever assembly with the 4 bolts. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 5. INSTALL YAW RATE AND ACCELERATION SENSOR (w/ VSC) (See page BC-448) 6. INSTALL FLOOR CARPET BRACKET LH 7. INSTALL FLOOR CARPET BRACKET RH 8. INSTALL NO. 1 CONSOLE BOX DUCT (for Automatic Air Conditioning System) (See page AC-177) 9. INSTALL NO. 2 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-50) Turn C132693E01 C132691 10. INSTALL NO. 2 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-50) 11. INSTALL NO. 1 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-49) 12. INSTALL NO. 1 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-50) 13. INSTALL CONSOLE BOX ASSEMBLY (for TMC Made) (See page IP-51) 14. INSTALL CONSOLE BOX ASSEMBLY (for TMMK Made) (See page IP-51) 15. INSTALL CONSOLE BOX CARPET (See page IP-51) 16. INSTALL CONSOLE BOX POCKET (See page IP-51) 17. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMC Made) (See page IP-52) 18. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMMK Made) (See page IP-52) 19. INSTALL UPPER CONSOLE REAR PANEL SUBASSEMBLY (See page IP-53) 20. INSTALL FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (See page IP-53) 21. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-55) 22. INSTALL NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-54) PB PB–34 PARKING BRAKE – PARKING BRAKE PEDAL 23. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (See page IP-55) 24. INSTALL LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMC Made) (See page IP-55) 25. INSTALL LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMMK Made) (See page IP-56) 26. INSTALL INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY (See page IP-56) 27. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY (See page RS-370) 28. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (See page IP-58) 29. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (See page IP-59) 30. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-54) PB 31. INSTALL FRONT DOOR SCUFF PLATE LH (See page IR-54) 32. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH (See page IR-55) 33. INSTALL FRONT DOOR SCUFF PLATE RH (See page IR-55) 34. INSPECT PARKING BRAKE PEDAL TRAVEL (See page PB-1) 35. ADJUST PARKING BRAKE PEDAL TRAVEL (See page PB-1) 36. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 37. INSPECT SENSOR SIGNAL (See page BC-448) PB–35 PARKING BRAKE – PARKING BRAKE CABLE PARKING BRAKE CABLE PARKING BRAKE BRAKE COMPONENTS for Manual Seat: FRONT SEAT HEADREST ASSEMBLY SEAT TRACK COVER RH 37 (377, 27) INNER SEAT TRACK BRACKET COVER RH PB 37 (377, 27) FRONT SEAT ASSEMBLY RH FRONT SEAT HEADREST ASSEMBLY INNER SEAT TRACK BRACKET COVER LH SEAT TRACK COVER LH 37 (377, 27) 37 (377, 27) FRONT SEAT ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque B132048E01 PB–36 PARKING BRAKE – PARKING BRAKE CABLE for Power Seat: FRONT SEAT HEADREST ASSEMBLY SEAT TRACK COVER RH INNER SEAT TRACK BRACKET COVER LH 37 (377, 27) 37 (377, 27) PB FRONT SEAT ASSEMBLY RH FRONT SEAT HEADREST ASSEMBLY INNER SEAT TRACK BRACKET COVER RH 37 (377, 27) SEAT TRACK COVER LH 37 (377, 27) FRONT SEAT ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque B132047E01 PB–37 PARKING BRAKE – PARKING BRAKE CABLE for TMC made: DRIVER SIDE KNEE AIRBAG ASSEMBLY INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY 10 (102, 7) PB or LOWER INSTRUMENT PANEL FINISH PANEL LH LOWER INSTRUMENT PANEL SUB-ASSEMBLY UPPER CONSOLE PANEL SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C133459E01 PB–38 PARKING BRAKE – PARKING BRAKE CABLE for TMMK made: DRIVER SIDE KNEE AIRBAG ASSEMBLY INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY 10 (102, 7) PB or

or

LOWER INSTRUMENT PANEL FINISH PANEL LH LOWER INSTRUMENT PANEL SUB-ASSEMBLY UPPER CONSOLE PANEL SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C133459E02 PB–39 PARKING BRAKE – PARKING BRAKE CABLE for TMC made: NO. 1 CONSOLE BOX INSERT FRONT CONSOLE BOX POCKET NO. 2 CONSOLE BOX INSERT FRONT CONSOLE BOX CARPET for Manual Air Conditioning System: PB for Automatic Transaxle: 18 (184, 13) CENTER AIRBAG SENSOR ASSEMBLY for Automatic Transaxle with VSC: CONSOLE BOX ASSEMBLY for Automatic Air Conditioning System: 13 (133, 10) YAW RATE AND ACCELERATION SENSOR CONSOLE BOX ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C141956E02 PB–40 PARKING BRAKE – PARKING BRAKE CABLE for TMMK made: CONSOLE BOX POCKET NO. 1 CONSOLE BOX INSERT FRONT NO. 2 CONSOLE BOX INSERT FRONT CONSOLE BOX CARPET for Manual Air Conditioning System: or or PB for Automatic Transaxle: 18 (184, 13) CONSOLE BOX ASSEMBLY CENTER AIRBAG SENSOR ASSEMBLY for Automatic Transaxle with VSC: for Automatic Air Conditioning System: or or 13 (133, 10) YAW RATE AND ACCELERATION SENSOR CONSOLE BOX ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C141957E02 PARKING BRAKE – PARKING BRAKE CABLE PB–41 for Manual Transaxle: NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH SHIFT LEVER KNOB SUB-ASSEMBLY UPPER CONSOLE PANEL PB UPPER CONSOLE REAR PANEL SUB-ASSEMBLY FLOOR CARPET BRACKET RH FLOOR CARPET BRACKET LH C133456E02 PB–42 PARKING BRAKE – PARKING BRAKE CABLE for Automatic Transaxle: NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH SHIFT LEVER KNOB SUB-ASSEMBLY NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY PB UPPER CONSOLE REAR PANEL SUB-ASSEMBLY FLOOR CARPET BRACKET RH for Automatic Air Conditioning System: 12 (122, 9) FLOOR CARPET BRACKET LH FLOOR SHIFT LEVER ASSEMBLY NO. 1 CONSOLE BOX DUCT 12 (122, 9) N*m (kgf*cm, ft.*lbf) : Specified torque C133457E03 PB–43 PARKING BRAKE – PARKING BRAKE CABLE FRONT DOOR OPENING TRIM WEATHERSTRIP RH REAR DOOR OPENING TRIM WEATHERSTRIP RH REAR DOOR SCUFF PLATE RH LOWER CENTER PILLAR GARNISH RH FRONT DOOR SCUFF PLATE RH COWL SIDE TRIM SUB-ASSEMBLY RH LUGGAGE DOOR LOCK OPEN LEVER SUB-ASSEMBLY PB FRONT FLOOR CARPET ASSEMBLY CROSS MEMBER FLOOR NO. 4 REINFORCEMENT SUB-ASSEMBLY REAR DOOR OPENING TRIM WEATHERSTRIP LH LOWER CENTER PILLAR GARNISH LH FRONT DOOR OPENING TRIM WEATHERSTRIP LH COWL SIDE TRIM SUB-ASSEMBLY LH REAR DOOR SCUFF PLATE LH FRONT DOOR SCUFF PLATE LH C132673E01 PB–44 PARKING BRAKE – PARKING BRAKE CABLE for Manual Transaxle: NO. 1 WIRE ADJUSTING NUT 5.0 (51, 44 in.*lbf) 21 (214, 15)* 22 (224, 16)** PARKING BRAKE LEVER SUB-ASSEMBLY NO. 2 PARKING BRAKE CABLE ASSEMBLY PB NO. 3 PARKING BRAKE CABLE ASSEMBLY 21 (214, 15)* 22 (224, 16)** NO. 1 PARKING BRAKE CABLE ASSEMBLY PARKING BRAKE EQUALIZER N*m (kgf*cm, ft.*lbf) : Specified torque * For TMC made ** For TMMK made C138181E01 PB–45 PARKING BRAKE – PARKING BRAKE CABLE for Automatic Transaxle: 39 (398, 29) PARKING BRAKE PEDAL ASSEMBLY 39 (398, 29) 5.4 (55, 48 in.*lbf) NO. 1 WIRE ADJUSTING NUT PB CLIP NO. 1 PARKING BRAKE CABLE ASSEMBLY 15 (153, 11) NO. 1 PARKING BRAKE CABLE CLAMP 5.4 (55, 48 in.*lbf) NO. 4 PARKING BRAKE CABLE ASSEMBLY 5.4 (55, 48 in.*lbf) CLIP PARKING BRAKE EQUALIZER TMMK made: 5.4 (55, 48 in.*lbf) NO. 2 PARKING BRAKE CABLE ASSEMBLY NO. 3 PARKING BRAKE CABLE ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque NO. 1 PARKING BRAKE CABLE ASSEMBLY NO. 4 PARKING BRAKE CABLE ASSEMBLY Non-reusable part C138178E01 PB–46 PARKING BRAKE – PARKING BRAKE CABLE PARKING BRAKE SHOE HOLD DOWN SPRING NO. 2 PIN 62 (632, 46) REAR DISC BRAKE CALIPER ASSEMBLY REAR DISC PARKING BRAKE SHOE HOLD DOWN SPRING NO. 1 PIN PARKING BRAKE SHOE RETURN TENSION NO. 1 SPRING PARKING BRAKE SHOE STRUT PB PARKING BRAKE SHOE STRUT COMPRESSION SPRING NO. 2 PARKING BRAKE SHOE ASSEMBLY NO. 1 PARKING BRAKE SHOE ASSEMBLY SHOE ADJUSTING HOLE PLUG PARKING BRAKE SHOE HOLD DOWN SPRING NO. 2 CUP PARKING BRAKE SHOE HOLD DOWN SPRING PARKING BRAKE SHOE HOLD DOWN SPRING NO. 1 CUP PARKING BRAKE SHOE HOLD DOWN SPRING NO. 2 CUP PARKING BRAKE SHOE HOLD DOWN SPRING N*m (kgf*cm, ft.*lbf) : Specified torque PARKING BRAKE SHOE HOLD DOWN SPRING NO. 1 CUP PARKING BRAKE SHOE RETURN TENSION NO. 2 SPRING PARKING BRAKE SHOE ADJUSTING SCREW SET Apply high temperature grease C138182E01 PB–47 PARKING BRAKE – PARKING BRAKE CABLE for 2AZ-FE: GASKET TAILPIPE ASSEMBLY 43 (438, 32) EXHAUST PIPE SUPPORT NO. 4 43 (438, 32) 56 (571, 41) CENTER EXHAUST PIPE ASSEMBLY EXHAUST PIPE SUPPORT NO. 4 GASKET PB 56 (571, 41) for 2GR-FE: EXHAUST PIPE SUPPORT NO. 4 EXHAUST TAIL PIPE ASSEMBLY EXHAUST CENTER PIPE ASSEMBLY GASKET 43 (438, 32) 43 (438, 32) GASKET 56 (571, 41) 43 (438, 32) GASKET 56 (571, 41) EXHAUST TAIL EXHAUST PIPE SUPPORT NO. 4 PIPE ASSEMBLY 43 (438, 32) N*m (kgf*cm, ft.*lbf) : Specified torque EXHAUST PIPE SUPPORT NO. 4 Non-reusable part C138183E01 PB–48 PARKING BRAKE – PARKING BRAKE CABLE PARKING BRAKE EQUALIZER NO. 3 PARKING BRAKE CABLE ASSEMBLY 8.0 (82, 71 in.*lbf) 8.5 (87, 75 in.*lbf) 6.0 (61, 53 in.*lbf) PARKING BRAKE CABLE CLAMP for 2AZ-FE: PB NO. 2 FRONT FLOOR HEAT LOWER INSULATOR 4.9 (50, 43 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque C131895E01 PARKING BRAKE – PARKING BRAKE CABLE PB–49 REMOVAL HINT: • Use the same procedures for the No. 2 parking brake cable assembly and No. 3 parking brake cable assembly. • The procedures listed below are for the No. 3 parking brake cable assembly. 1. PRECAUTION (See page IP-20) 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (for Manual Seat) CAUTION: Wait for 90 seconds after disconnecting the cable to prevent the airbag working. (See page RS-1) 3. REMOVE FRONT SEAT ASSEMBLY LH (for Manual Seat) HINT: Refer to the procedures up to "REMOVE FRONT SEAT ASSEMBLY (for Manual Seat)". (See page SE-16) 4. REMOVE FRONT SEAT ASSEMBLY RH (for Manual Seat) HINT: Use the same procedures for the RH side and the LH side. 5. REMOVE FRONT SEAT ASSEMBLY LH (for Power Seat) HINT: Refer to the procedures up to "REMOVE FRONT SEAT ASSEMBLY (for Power Seat)". (See page SE-30) 6. REMOVE FRONT SEAT ASSEMBLY RH (for Power Seat) HINT: Use the same procedures for the RH side and the LH side. 7. REMOVE PARKING BRAKE LEVER SUB-ASSEMBLY (for Manual Transaxle) HINT: Refer to the procedures up to "REMOVE PARKING BRAKE LEVER". (See page PB-11) 8. REMOVE NO. 1 PARKING BRAKE CABLE ASSEMBLY (for Manual Transaxle) (See page PB-15) 9. REMOVE PARKING BRAKE PEDAL ASSEMBLY (for Automatic Transaxle) HINT: Refer to the procedures up to "REMOVE PARKING BRAKE PEDAL". (See page PB-27) 10. REMOVE NO. 1 PARKING BRAKE CABLE ASSEMBLY (for Automatic Transaxle) (See page PB30) PB PB–50 PARKING BRAKE – PARKING BRAKE CABLE 11. REMOVE LUGGAGE DOOR LOCK OPEN LEVER SUB-ASSEMBLY (for Automatic Transaxle) (See page PB-13) 12. REMOVE FRONT FLOOR CARPET ASSEMBLY (for Automatic Transaxle) (See page PB-14) 13. REMOVE CROSS MEMBER FLOOR NO. 4 REINFORCEMENT SUB-ASSEMBLY (for Automatic Transaxle) (See page PB-14) 14. SEPARATE NO. 3 PARKING BRAKE CABLE ASSEMBLY (for Automatic Transaxle) (a) Separate the No. 3 parking brake cable assembly from the parking brake equalizer. C133446 15. SEPARATE NO. 2 PARKING BRAKE CABLE ASSEMBLY (for Automatic Transaxle) (a) Separate the No. 2 parking brake cable assembly from the parking brake equalizer. PB C133455 16. REMOVE NO. 4 PARKING BRAKE CABLE ASSEMBLY (for Automatic Transaxle) (a) Slide the rubber boot as shown in the illustration. C132655 (b) Remove the No. 4 parking brake cable assembly from the parking brake equalizer as shown in the illustration. 17. REMOVE CENTER EXHAUST PIPE ASSEMBLY (for 2AZ-FE) (See page EX-2) 18. REMOVE EXHAUST TAIL PIPE ASSEMBLY (for 2GRFE) (See page EX-2) C132657 19. REMOVE EXHAUST CENTER PIPE ASSEMBLY (for 2GR-FE) (See page EX-2) PARKING BRAKE – PARKING BRAKE CABLE PB–51 20. REMOVE NO. 2 FRONT FLOOR HEAT LOWER INSULATOR (for 2AZ-FE) (a) Remove the 3 nuts and the No. 2 front floor heat lower insulator. 21. REMOVE REAR WHEEL 22. SEPARATE REAR DISC BRAKE CALIPER ASSEMBLY (See page PB-58) 23. REMOVE REAR DISC (See page PB-58) C132669 24. REMOVE PARKING BRAKE SHOE RETURN TENSION NO. 1 SPRING (See page PB-58) 25. REMOVE PARKING BRAKE SHOE STRUT (See page PB-58) 26. REMOVE NO. 1 PARKING BRAKE SHOE ASSEMBLY (See page PB-58) 27. REMOVE PARKING BRAKE SHOE ADJUSTING SCREW SET (See page PB-59) 28. REMOVE NO. 2 PARKING BRAKE SHOE ASSEMBLY (See page PB-59) 29. REMOVE NO. 3 PARKING BRAKE CABLE ASSEMBLY (a) Remove the 2 bolts and separate the No. 3 parking brake cable assembly from the backing plate. C132666 (b) Using needle-nose pliers, remove the clip from the No. 3 parking brake cable assembly. for Manual Transaxle: for Automatic Transaxle: C138186E01 PB PB–52 PARKING BRAKE – PARKING BRAKE CABLE (c) Remove the 3 bolts (A), the bolt (B), and the nut (C), and disengage each claw. Nut (C) Bolt (A) Bolt (B) PB Bolt (A) C132668E03 (d) Remove the No. 3 parking brake cable assembly from the body. (e) Remove the parking brake cable clamp. Axle Carrier Side C132667E01 PB–53 PARKING BRAKE – PARKING BRAKE CABLE INSTALLATION 1. Axle Carrier Side C132667E01 INSTALL NO. 3 PARKING BRAKE CABLE ASSEMBLY (a) Install the parking brake cable clamp to the No. 3 parking brake cable assembly. (b) Install the No. 3 parking brake cable assembly with the 3 bolts (A), the bolt (B) and the nut (C), and engage each claw. Torque: Bolt (A) 8.5 N*m (87 kgf*cm, 75 in.*lbf) Bolt (B) and Nut (C) 6.0 N*m (61 kgf*cm, 53 in.*lbf) Nut (C) PB Bolt (A) Bolt (B) Bolt (A) C132668E03 PB–54 PARKING BRAKE – PARKING BRAKE CABLE (c) Install the No. 3 parking brake cable assembly to the backing plate with the 2 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) C132666 (d) Using a brass bar and a hammer, install the clip to the No. 3 parking brake cable assembly. for Manual Transaxle: PB 2. INSTALL NO. 2 PARKING BRAKE SHOE ASSEMBLY (See page PB-61) 3. INSTALL PARKING BRAKE SHOE ADJUSTING SCREW SET (See page PB-62) 4. INSTALL NO. 1 PARKING BRAKE SHOE ASSEMBLY (See page PB-62) 5. INSTALL PARKING BRAKE SHOE STRUT (See page PB-62) 6. INSTALL PARKING BRAKE SHOE RETURN TENSION NO. 1 SPRING (See page PB-62) 7. CHECK PARKING BRAKE INSTALLATION (See page PB-63) 8. INSTALL REAR DISC (See page PB-63) 9. ADJUST PARKING BRAKE SHOE CLEARANCE (See page PB-63) for Automatic Transaxle: C138187E01 10. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY (See page PB-63) 11. INSTALL REAR WHEEL 12. INSTALL NO. 2 FRONT FLOOR HEAT LOWER INSULATOR (for 2AZ-FE) (a) Install the No. 2 front floor heat lower insulator with the 3 nuts. Torque: 4.9 N*m (50 kgf*cm, 43 in.*lbf) 13. INSTALL CENTER EXHAUST PIPE ASSEMBLY (for 2AZ-FE) (See page EX-4) C132669 14. INSTALL EXHAUST CENTER PIPE ASSEMBLY (for 2GR-FE) (See page EX-4) 15. INSTALL EXHAUST TAIL PIPE ASSEMBLY (for 2GRFE) (See page EX-5) PARKING BRAKE – PARKING BRAKE CABLE PB–55 16. INSTALL NO. 4 PARKING BRAKE CABLE ASSEMBLY (for Automatic Transaxle) (a) Install the No. 4 parking brake cable assembly to the parking brake equalizer. C132657 (b) Slide the rubber boot back as shown in the illustration. Rubber Boot C132656E01 17. CONNECT NO. 2 PARKING BRAKE CABLE ASSEMBLY (for Automatic Transaxle) (a) Connect the No. 2 parking brake cable assembly to the parking brake equalizer. C133455 18. CONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY (for Automatic Transaxle) (a) Connect the No. 3 parking brake cable assembly to the parking brake equalizer. 19. INSTALL CROSS MEMBER FLOOR NO. 4 REINFORCEMENT SUB-ASSEMBLY (for Automatic Transaxle) (See page PB-18) C133446 20. INSTALL FRONT FLOOR CARPET ASSEMBLY (for Automatic Transaxle) (See page PB-18) 21. INSTALL LUGGAGE DOOR LOCK OPEN LEVER SUB-ASSEMBLY (for Automatic Transaxle) (See page PB-18) 22. INSTALL NO. 1 PARKING BRAKE CABLE ASSEMBLY (for Manual Transaxle) (See page PB-16) 23. INSTALL PARKING BRAKE LEVER SUB-ASSEMBLY (for Manual Transaxle) HINT: Refer to the procedures up to "INSTALL PARKING BRAKE LEVER". (See page PB-17) PB PB–56 PARKING BRAKE – PARKING BRAKE CABLE 24. INSTALL NO. 1 PARKING BRAKE CABLE ASSEMBLY (for Automatic Transaxle) (See page PB-31) 25. INSTALL PARKING BRAKE PEDAL ASSEMBLY (for Automatic Transaxle) HINT: Refer to the procedures up to "INSTALL PARKING BRAKE PEDAL". (See page PB-32) 26. INSTALL FRONT SEAT ASSEMBLY LH (for Manual Seat) HINT: Refer to the procedures up to "INSTALL FRONT SEAT ASSEMBLY (for Manual Seat)". (See page SE-24) 27. INSTALL FRONT SEAT ASSEMBLY RH (for Manual Seat) HINT: Use the same procedures for the RH side and the LH side. PB 28. INSTALL FRONT SEAT ASSEMBLY LH (for Power Seat) HINT: Refer to the procedures up to "INSTALL FRONT SEAT ASSEMBLY (for Power Seat)". (See page SE-41) 29. INSTALL FRONT SEAT ASSEMBLY RH (for Power Seat) HINT: Use the same procedures for the RH side and the LH side. 30. INSPECT PARKING BRAKE LEVER TRAVEL (for Manual Transaxle) (See page PB-2) 31. INSPECT PARKING BRAKE PEDAL TRAVEL (for Automatic Transaxle) (See page PB-1) 32. ADJUST PARKING BRAKE LEVER TRAVEL (for Manual Transaxle) (See page PB-2) 33. ADJUST PARKING BRAKE PEDAL TRAVEL (for Automatic Transaxle) (See page PB-1) 34. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (for Manual Seat) 35. PERFORM ZERO POINT CALIBRATION AND SENSITIVITY CHECK HINT: (See page RS-242) 36. INSPECT SRS WARNING LIGHT 37. INSPECT SLIDE ADJUSTER LOCK (for Manual Seat) 38. INSPECT FRONT SEAT ASSEMBLY (for Power Seat) (See page SE-42) 39. CHECK FOR EXHAUST GAS LEAKS (See page EX-5) PB–57 PARKING BRAKE – PARKING BRAKE ASSEMBLY PARKING BRAKE ASSEMBLY PARKING BRAKE BRAKE COMPONENTS PARKING BRAKE SHOE HOLD DOWN SPRING NO. 2 PIN REAR DISC BRAKE CALIPER ASSEMBLY 62 (632, 46) PARKING BRAKE SHOE HOLD DOWN SPRING NO. 1 PIN REAR DISC PARKING BRAKE SHOE GUIDE PLATE PARKING BRAKE SHOE RETURN TENSION NO. 1 SPRING 18 (184, 13) PARKING BRAKE SHOE GUIDE PLATE SET BOLT PB PARKING BRAKE SHOE STRUT C-WASHER NO. 2 PARKING BRAKE SHOE ASSEMBLY PARKING BRAKE SHOE HOLD DOWN SPRING NO. 2 CUP PARKING BRAKE SHOE STRUT COMPRESSION SPRING NO. 1 PARKING BRAKE SHOE ASSEMBLY SHOE ADJUSTING HOLE PLUG SHIM PARKING BRAKE SHOE HOLD DOWN SPRING PARKING BRAKE SHOE LEVER PARKING BRAKE SHOE HOLD DOWN SPRING NO. 2 CUP PARKING BRAKE SHOE ADJUSTING SCREW SET PARKING BRAKE SHOE HOLD DOWN SPRING N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part PARKING BRAKE SHOE HOLD DOWN SPRING NO. 1 CUP PARKING BRAKE SHOE RETURN TENSION NO. 2 SPRING High temperature grease C131896E01 PB–58 PARKING BRAKE – PARKING BRAKE ASSEMBLY DISASSEMBLY HINT: • Use the same procedures for the RH side and the LH side. • The procedures listed below are for the LH side. 1. REMOVE REAR WHEEL 2. SEPARATE REAR DISC BRAKE CALIPER ASSEMBLY (a) Remove the 2 bolts and separate the rear disc brake caliper assembly. HINT: Do not disconnect the flexible hose from the disc brake caliper assembly. 3. REMOVE REAR DISC (a) Release the parking brake and place the matchmarks on the rear disc and the axle hub. (b) Remove the rear disc. HINT: If the disc cannot be removed easily, turn the shoe adjuster until the wheel turns freely. 4. REMOVE PARKING BRAKE SHOE RETURN TENSION NO. 1 SPRING (a) Using needle-nose pliers, remove the 2 parking brake shoe return tension No. 1 springs. 5. REMOVE PARKING BRAKE SHOE STRUT (a) Remove the parking brake shoe strut and the parking brake shoe strut compression spring. 6. REMOVE NO. 1 PARKING BRAKE SHOE ASSEMBLY (a) Release the claw of the parking brake shoe hold down spring No. 1 cup. (b) Remove the No. 1 parking brake shoe assembly as shown in the illustration. (c) Remove the parking brake shoe hold down spring No. 1 cup, the parking brake shoe hold down spring, the parking brake shoe hold down spring No. 2 cup, and the parking brake shoe hold down spring No. 1 pin. C132653 Matchmarks PB C132813E02 C132651 C133469 PARKING BRAKE – PARKING BRAKE ASSEMBLY PB–59 7. REMOVE PARKING BRAKE SHOE ADJUSTING SCREW SET (a) Remove the parking brake shoe adjusting screw set. (b) Remove the parking brake shoe return tension No. 2 spring. 8. REMOVE NO. 2 PARKING BRAKE SHOE ASSEMBLY (a) Release the claw of the the parking brake shoe hold down spring No. 1 cup. (b) Remove the No. 2 parking brake shoe assembly as shown in the illustration. (c) Remove the parking brake shoe hold down spring No. 1 cup, the parking brake shoe hold down spring, the parking brake shoe hold down spring No. 2 cup, and the parking brake shoe hold down spring No. 2 pin. Adjusting Screw Set Return Tension No. 2 Spring C133473E01 C133471 (d) Using needle-nose pliers, disconnect the No. 3 parking brake cable assembly from the parking brake shoe lever. NOTICE: Be careful not to damage the No. 3 parking brake cable assembly. C108700 9. REMOVE PARKING BRAKE SHOE LEVER (a) Using a screwdriver, remove the C-washer, shim and the parking brake shoe lever. C132646 10. REMOVE PARKING BRAKE SHOE GUIDE PLATE (a) Remove the parking brake shoe guide plate set bolt and the parking brake shoe guide plate. C141958 PB PB–60 PARKING BRAKE – PARKING BRAKE ASSEMBLY INSPECTION 1. INSPECT BRAKE DISC INSIDE DIAMETER (a) Using a brake drum gauge or an equivalent tool, measure the inside diameter of the disc. Standard inside diameter: 170 mm (6.69 in.) Maximum inside diameter: 171 mm (6.73 in.) If the inside diameter is more than the maximum, replace the disc. 2. INSPECT PARKING BRAKE SHOE LINING THICKNESS (a) Using a ruler, measure the thickness of the shoe lining. Standard thickness: 2.0 mm (0.079 in.) Minimum thickness: 1.0 mm (0.039 in.) If the lining thickness is less than the minimum, or if there is severe or uneven wear, replace the brake shoe. NOTICE: Always replace both the right and left parking brake shoes together. 3. INSPECT BRAKE DISC AND PARKING BRAKE SHOE LINING FOR PROPER CONTACT (a) Apply chalk to the inside surface of the disc, then grind down the brake shoe lining to fit the disc. If the contact between the disc and the brake shoe lining is improper, repair it using a brake shoe grinder or replace the brake shoe. C132647 R000311 PB BR00828 PB–61 PARKING BRAKE – PARKING BRAKE ASSEMBLY REASSEMBLY 1. APPLY HIGH TEMPERATURE GREASE (a) Apply high temperature grease to the backing plate which makes contact with the shoe. 2. INSTALL PARKING BRAKE SHOE GUIDE PLATE (a) Apply adhesive to the threads of the parking brake shoe guide plate set bolt. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent (b) Install the parking brake shoe guide plate with the parking brake shoe guide plate set bolt. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) C141958 3. INSTALL PARKING BRAKE SHOE LEVER (a) Install the parking brake shoe lever and shim to the No. 2 parking brake shoe assembly with a new Cwasher. C132646 (b) Using a feeler gauge, measure the clearance between the No. 2 parking brake shoe assembly and parking brake shoe lever. Standard clearance: Less than 0.35 mm (0.014 in.) If the clearance is not as specified, replace the shim with one of the correct size. C132648 4. C108700 Shim Thickness Shim Thickness 0.3 mm (0.012 in.) 0.9 mm (0.035 in.) 0.6 mm (0.024 in.) - INSTALL NO. 2 PARKING BRAKE SHOE ASSEMBLY (a) Using needle-nose pliers, connect the No. 3 parking brake cable assembly to the parking brake shoe lever. PB PB–62 PARKING BRAKE – PARKING BRAKE ASSEMBLY (b) Install the No. 2 parking brake shoe assembly with the parking brake shoe hold down spring No. 2 pin, the parking brake shoe hold down spring No. 2 cup, the parking brake shoe hold down spring and the parking brake shoe hold down spring No. 1 cup. (c) Engage the claw of the parking brake shoe hold down spring No. 1 cup to the No. 2 parking brake shoe assembly. C133472 5. INSTALL PARKING BRAKE SHOE ADJUSTING SCREW SET (a) Apply high temperature grease to the parking brake adjusting screw as shown in the illustration. C132649 PB (b) Install the parking brake shoe return tension No. 2 spring to the No. 1 parking brake shoe assembly and the No. 2 parking brake shoe assembly. (c) Install the parking brake shoe adjusting screw set to the No. 1 parking brake shoe assembly and the No. 2 parking brake shoe assembly. Return Tension No. 2 Spring Adjusting Screw Set C133474E01 C133470 6. INSTALL NO. 1 PARKING BRAKE SHOE ASSEMBLY (a) Install the No. 1 parking brake shoe assembly with the parking brake shoe hold down spring No. 1 pin, parking brake shoe hold down spring No. 2 cup, parking brake shoe hold down spring and parking brake shoe hold down spring No. 1 cup. 7. INSTALL PARKING BRAKE SHOE STRUT (a) Attach the parking brake shoe strut and the parking brake shoe strut compression spring to the No. 1 parking brake shoe assembly and No. 2 parking brake shoe assembly. PB–63 PARKING BRAKE – PARKING BRAKE ASSEMBLY 8. INSTALL PARKING BRAKE SHOE RETURN TENSION NO. 1 SPRING (a) Using needle-nose pliers, install the 2 parking brake shoe return tension No. 1 springs. HINT: First install the front side spring and then the rear side spring. 9. CHECK PARKING BRAKE INSTALLATION (a) Check that each part is installed properly. C132651 LH: RH: PB Front Front C132644E01 NOTICE: There should be no oil or grease on the friction surface of the shoe lining and disc. 10. INSTALL REAR DISC (a) Align the matchmarks and install the rear disc. 11. ADJUST PARKING BRAKE SHOE CLEARANCE (a) Temporarily install the hub nuts. (b) Remove the shoe adjusting hole plug. (c) Turn the adjuster and expand the shoes until the disc locks. (d) Contract the shoe adjuster until the disc rotates smoothly. Standard: Return 8 notches (e) Check that the shoe has no brake drag. (f) Install the shoe adjusting hole plug. Contract C108703E01 PB–64 PARKING BRAKE – PARKING BRAKE ASSEMBLY 12. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY (a) Install the rear disc brake caliper assembly with the 2 bolts. Torque: 62 N*m (632 kgf*cm, 46 ft.*lbf) 13. INSTALL REAR WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 14. INSPECT PARKING BRAKE PEDAL TRAVEL (for Automatic Transaxle) (See page PB-1) C132653 15. INSPECT PARKING BRAKE LEVER TRAVEL (for Manual Transaxle) (See page PB-2) 16. ADJUST PARKING BRAKE PEDAL TRAVEL (for Automatic Transaxle) (See page PB-1) 17. ADJUST PARKING BRAKE LEVER TRAVEL (for Manual Transaxle) (See page PB-2) PB ENGINE HOOD / DOOR – HOOD ED–1 HOOD ON-VEHICLE INSPECTION 1. INSPECT HOOD SUB-ASSEMBLY (a) Check that the clearance measurements of areas A to C are within each standard range. C A B ED B132821E01 Standard clearance Area Measurement A 2.3 to 5.3 mm (0.091 to 0.209 in.) B 2.0 to 5.0 mm (0.079 to 0.197 in.) C -1.4 to 1.6 mm (-0.055 to 0.063 in.) ED–2 ENGINE HOOD / DOOR – HOOD ADJUSTMENT TMC made: Centering Bolt TMMK made: Standard Bolt Centering Bolt Standard Bolt B146065E01 HINT: • Centering bolts are used to mount the hood hinge and hood lock. The hood and hood lock cannot be adjusted with the centering bolts on. Substitute the centering bolts with standard bolts (with washers) when making adjustments. • A bolt without a torque specification is shown in the standard bolt chart (See page SS-2). ED 1. REMOVE COOL AIR INTAKE DUCT SEAL (for 2GRFE) (See page ET-4) 2. REMOVE FRONT BUMPER ASSEMBLY (w/o Fog Light) (See page ET-5) 3. REMOVE FRONT BUMPER ASSEMBLY (w/ Fog Light) (See page ET-6) 4. ADJUST HOOD SUB-ASSEMBLY (a) Horizontally and vertically adjust the hood. (1) Loosen the hood's 4 hinge bolts. (2) Move the hood and adjust the clearance between the hood and front fender. (3) Tighten the hood's 4 hinge bolts after the adjustment. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) B132829 (b) Adjust the height of the hood front end using the cushion rubber. (1) Adjust the cushion rubber so that the height of the hood and fender are aligned. HINT: Raise or lower the hood's front end by turning the cushion rubber. B132830 ENGINE HOOD / DOOR – HOOD ED–3 (c) Adjust the hood lock. (1) Loosen the 3 bolts. (2) Tighten the bolts after the adjustment. Torque: 7.5 N*m (77 kgf*cm, 66 in.*lbf) (3) Adjust the hood lock position so that the striker can enter it smoothly. B132832 5. INSTALL FRONT BUMPER ASSEMBLY (w/o Fog Light) (See page ET-13) 6. INSTALL FRONT BUMPER ASSEMBLY (w/ Fog Light) (See page ET-14) 7. INSTALL COOL AIR INTAKE DUCT SEAL (for 2GRFE) (See page ET-14) 8. VEHICLE PREPARATION FOR FOG LIGHT AIM (w/ Fog Light) (See page LI-79) 9. PREPARATION FOR FOG LIGHT AIMING (w/ Fog Light) (See page LI-80) 10. FOG LIGHT AIMING INSPECTION (w/ Fog Light) (See page LI-81) 11. FOG LIGHT AIMING ADJUSTMENT (w/ Fog Light) (See page LI-82) ED ENGINE HOOD / DOOR – HOOD SUPPORT ROD ED–3 HOOD SUPPORT ROD ENGINE HOOD / DOOR BODY COMPONENTS ED HOOD SUPPORT ASSEMBLY B136842E01 ED–4 ENGINE HOOD / DOOR – HOOD SUPPORT ROD REMOVAL NOTICE: • Avoid touching the stroke portions of the rod as much as possible to prevent foreign matter from attaching to it. Be sure to hold the cylinders while servicing. • Do not wear cotton gloves or other similar materials when handling the rod. Fibers may attach to the rod and result in gas leaks. • Do not apply any load to the cylinders in the horizontal direction in order to prevent the rod from being deformed. 1. ED B132831 REMOVE HOOD SUPPORT ASSEMBLY (a) Using a screwdriver, remove the hood support assembly while releasing the 2 clips. NOTICE: Remove the hood support assembly while supporting the hood with hand. ENGINE HOOD / DOOR – HOOD SUPPORT ROD ED–5 INSTALLATION NOTICE: • Avoid touching the stroke portions of the rod as much as possible to prevent foreign matter from attaching to it. Be sure to hold the cylinders while servicing. • Do not wear cotton gloves or other similar materials when handling the rod. Fibers may attach to the rod and result in gas leaks. • Do not apply any load to the cylinders in the horizontal direction in order to prevent the rod from being deformed. 1. INSTALL HOOD SUPPORT ASSEMBLY (a) Install the hood support assembly. NOTICE: • Install the hood support assembly while supporting the hood with hand. • Check that the hood support assembly is engaged in the ball joint and it cannot be pulled out. DISPOSAL 1. A 80 mm B (3.150 in.) B127037E01 DISPOSE OF HOOD SUPPORT ASSEMBLY (a) Horizontally fix the hood support in a vise with the piston-rod pulled out. (b) Wear safety glasses. Gradually cut a part between A and B shown in the illustration using a metal saw and gradually release the gas. NOTICE: Although the gas inside the hood support is colorless, odorless and harmless, there is a possibility that metal debris could scatter. Therefore, cover it with a piece of cloth or other material. ED ENGINE HOOD / DOOR – HOOD LOCK CONTROL CABLE ASSEMBLY ED–5 HOOD LOCK CONTROL CABLE ASSEMBLY ENGINE HOOD / DOOR BODY COMPONENTS for 2GR-FE: ED COOL AIR INTAKE DUCT SEAL 7.5 (77, 66 in.*lbf) 20 (204, 15) HOOD LOCK CONTROL HOOD LOCK CONTROL LEVER SUB-ASSEMBLY CABLE ASSEMBLY HOOD LOCK ASSEMBLY HIGH PITCHED HORN ASSEMBLY FRONT FENDER LINER GROMMET FRONT WHEEL OPENING EXTENSION PAD FRONT BUMPER ASSEMBLY Non-reusable part N*m (kgf*cm, ft.*lbf) : Specified torque B136867E01 ED–6 ENGINE HOOD / DOOR – HOOD LOCK CONTROL CABLE ASSEMBLY REMOVAL B138883 ED 1. REMOVE FRONT WHEEL 2. REMOVE FRONT WHEEL OPENING EXTENSION PAD (a) Remove the 3 screws and the front wheel opening extension pad. 3. REMOVE COOL AIR INTAKE DUCT SEAL (for 2GRFE) (See page ET-4) 4. REMOVE FRONT BUMPER ASSEMBLY (w/o Fog Light) (See page ET-5) 5. REMOVE FRONT BUMPER ASSEMBLY (w/ Fog Light) (See page ET-6) 6. REMOVE FRONT FENDER LINER (a) Remove the 5 clips and bolt. (b) Remove the 4 screws, grommet and the front fender liner. 7. REMOVE HIGH PITCHED HORN ASSEMBLY (See page HO-7) 8. REMOVE HOOD LOCK ASSEMBLY (w/o Engine Hood Courtesy Switch) (a) Remove the 3 bolts. B136871 B136821 (b) Disconnect the hood lock control cable. (c) Remove the hood lock assembly. B136827 ED–7 ENGINE HOOD / DOOR – HOOD LOCK CONTROL CABLE ASSEMBLY 9. REMOVE HOOD LOCK ASSEMBLY (w/ Engine Hood Courtesy Switch) (a) Disconnect the connector. (b) Remove the 3 bolts. B136822 (c) Disconnect the hood lock control cable. (d) Remove the hood lock assembly. ED B136827 10. REMOVE HOOD LOCK CONTROL LEVER SUBASSEMBLY (a) Disconnect the hood lock control cable and remove the hood lock control lever. 11. REMOVE HOOD LOCK CONTROL CABLE ASSEMBLY (a) Using a screwdriver, disconnect the clamps shown in the illustration. B136909 A H D A L B I C A B F K K F E B A J A F B A F F M A A G B136828E01 ED–8 ENGINE HOOD / DOOR – HOOD LOCK CONTROL CABLE ASSEMBLY Area ED Part Name Area Part Name A Hood lock control cable H Grommet B Clamp I Side member outer C Wire harness J Radiator D Pillar K Radiator support cover E Nut L Front fender apron F Radiator support upper M Brace G Hood lock protector - - HINT: Tape the screwdriver tip before use. (b) Pull the cable from the engine compartment and remove it. ED–9 ENGINE HOOD / DOOR – HOOD LOCK CONTROL CABLE ASSEMBLY INSTALLATION 1. INSTALL HOOD LOCK CONTROL CABLE ASSEMBLY (a) Pass the hood lock control cable assembly into the engine compartment. A H D A L B I C A B F ED K K F E B A J A F B A F F M A A G B136828E01 Area Part Name Area Part Name A Hood lock control cable H Grommet B Clamp I Side member outer C Wire harness J Radiator D Pillar K Radiator support cover E Nut L Front fender apron F Radiator support upper M Brace G Hood lock protector - - (b) Pass the cable front side through the upper radiator support. (c) Connect the clamps as shown in the illustration. 2. B136826 INSTALL HOOD LOCK CONTROL LEVER SUBASSEMBLY (a) Install the hood lock control lever and connect the hood lock control cable. ED–10 ENGINE HOOD / DOOR – HOOD LOCK CONTROL CABLE ASSEMBLY 3. INSTALL HOOD LOCK ASSEMBLY (w/o Engine Hood Courtesy Switch) (a) Apply MP grease to the sliding areas of the lock. B136830 (b) Connect the hood lock control cable. ED B136827 (c) Install the hood lock assembly with the 3 bolts. Torque: 7.5 N*m (77 kgf*cm, 66 in.*lbf) B136821 4. INSTALL HOOD LOCK ASSEMBLY (w/ Engine Hood Courtesy Switch) (a) Apply MP grease to the sliding areas of the lock. B136830 (b) Connect the hood lock control cable. B136827 ENGINE HOOD / DOOR – HOOD LOCK CONTROL CABLE ASSEMBLY ED–11 (c) Install the hood lock assembly with the 3 bolts. Torque: 7.5 N*m (77 kgf*cm, 66 in.*lbf) (d) Connect the connector. 5. INSTALL HIGH PITCHED HORN ASSEMBLY (See page HO-7) 6. INSTALL FRONT FENDER LINER (a) Install the front fender liner with the grommet and 4 screws. (b) Install the bolt and 5 clips. B136822 7. INSPECT HOOD SUB-ASSEMBLY (See page ED-1) 8. ADJUST HOOD SUB-ASSEMBLY (See page ED-2) 9. INSTALL FRONT BUMPER ASSEMBLY (w/o Fog Light) (See page ET-13) 10. INSTALL FRONT BUMPER ASSEMBLY (w/ Fog Light) (See page ET-14) 11. INSTALL COOL AIR INTAKE DUCT SEAL (for 2GRFE) (See page ET-14) B136871 12. INSTALL FRONT WHEEL OPENING EXTENSION PAD (a) Install the front wheel opening extension pad with the 3 screws. 13. INSTALL FRONT WHEEL (See page SP-22) 14. VEHICLE PREPARATION FOR FOG LIGHT AIM (w/ Fog Light) (See page LI-79) 15. PREPARATION FOR FOG LIGHT AIMING (w/ Fog Light) (See page LI-80) B138883 16. FOG LIGHT AIMING INSPECTION (w/ Fog Light) (See page LI-81) 17. FOG LIGHT AIMING ADJUSTMENT (w/ Fog Light) (See page LI-82) ED ED–11 ENGINE HOOD / DOOR – FRONT DOOR FRONT DOOR ENGINE HOOD / DOOR BODY COMPONENTS OUTER REAR VIEW MIRROR ASSEMBLY ED 5.5 (56, 49 in.*lbf) FRONT DOOR INNER GLASS WEATHERSTRIP FRONT DOOR INSIDE HANDLE BEZEL PLUG FRONT DOOR LOWER FRAME BRACKET GARNISH FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY ASSIST GRIP COVER FRONT ARMREST BASE PANEL UPPER COURTESY LIGHT ASSEMBLY FRONT DOOR WIRE FRONT DOOR TRIM BOARD SUB-ASSEMBLY POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B146077E01 ED–12 ENGINE HOOD / DOOR – FRONT DOOR FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY FRONT DOOR LOCK CYLINDER FRONT DOOR OUTSIDE HANDLE COVER FRONT DOOR LOCK OPEN ROD FRONT DOOR OUTSIDE HANDLE ASSEMBLY FRONT DOOR REAR OUTSIDE HANDLE PAD FRONT DOOR LOCK ASSEMBLY ED FRONT DOOR FRONT OUTSIDE HANDLE PAD 5.0 (51, 44 in.*lbf) FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY with Smart Key System: DOOR LOCK WIRING HARNESS SEAL 4.0 (41, 35 in.*lbf) FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY DOOR ELECTRICAL KEY OSCILLATOR HOLE PLUG FRONT NO. 1 DOOR STIFFENER CUSHION FRONT DOOR SERVICE HOLE COVER BUTYL TAPE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY 5.5 (56, 49 in.*lbf) 5.4 (55, 48 in.*lbf) 8.0 (82, 71 in.*lbf) FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY FRONT NO. 1 SPEAKER ASSEMBLY Apply MP grease Non-reusable part N*m (kgf*cm, ft.*lbf) : Specified torque B146078E01 ED–13 ENGINE HOOD / DOOR – FRONT DOOR FRONT DOOR UPPER WINDOW FRAME MOULDING RIVET FRONT DOOR STRIPE FRONT DOOR REAR WINDOW FRAME MOULDING DOOR FRAME GARNISH FRONT DOOR LOWER OUTSIDE STRIPE ED FRONT DOOR GLASS SUB-ASSEMBLY FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY FRONT DOOR GLASS RUN FRONT DOOR BELT MOULDING ASSEMBLY TMC made: 8.0 (82, 71 in.*lbf) 26 (265, 19) FRONT DOOR WEATHERSTRIP Non-reusable part FRONT DOOR CHECK ASSEMBLY TMMK made: 8.0 (82, 71 in.*lbf) 26 (265, 19) FRONT DOOR CHECK ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B146081E01 ED–14 ENGINE HOOD / DOOR – FRONT DOOR ON-VEHICLE INSPECTION 1. INSPECT FRONT DOOR PANEL SUB-ASSEMBLY (a) Check that the clearance measurements of areas A to L are within each standard range. G E C H F J D ED I L B K A B132823E01 Standard clearance Area Measurement Area Measurement A 2.7 to 5.7 mm (0.106 to 0.224 in.) G 3.3 to 6.3 mm (0.130 to 0.248 in.) B -1.5 to 1.5 mm (-0.059 to 0.059 in.) H -0.3 to 2.7 mm (-0.012 to 0.106 in.) C 3.3 to 6.3 mm (0.130 to 0.248 in.) I 2.3 to 6.3 mm (0.091 to 0.248 in.) D 6.4 to 9.4 mm (0.252 to 0.370 in.) J -2.0 to 2.0 mm (-0.079 to 0.079 in.) E 3.3 to 6.3 mm (0.130 to 0.248 in.) K 2.7 to 5.7 mm (0.106 to 0.224 in.) F 0.9 to 3.9 mm (0.035 to 0.154 in.) L -1.5 to 1.5 mm (-0.059 to 0.059 in.) DISASSEMBLY 1. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH (a) Disengage the 2 clips and remove the front door lower frame bracket garnish. 2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG (a) Using a screwdriver wrapped with protective tape, disengage the 3 claws, and remove the front door inside handle bezel plug. B132833 Protective tape B132834E01 ENGINE HOOD / DOOR – FRONT DOOR ED–15 3. REMOVE ASSIST GRIP COVER (a) Using a screwdriver wrapped with protective tape, disengage the 6 claws and remove the assist grip cover. 4. REMOVE COURTESY LIGHT ASSEMBLY (a) Using a screwdriver wrapped with protective tape, disengage the claw and remove the courtesy light assembly. (b) Disconnect the connector. Protective tape B132836E01 Protective tape B132838E01 5. (A) REMOVE FRONT DOOR TRIM BOARD SUBASSEMBLY (a) Remove the 3 screws and clip (A). (b) Using the clip remover, disengage the 9 clips. B132840E01 (c) Pull out the front door trim board in the direction indicated by the arrow. (d) Remove the reference bosses from the front door panel. (e) Raise the front door trim board to disengage the 4 claws and remove the front door trim board together with the front door inner glass weatherstrip. Reference Boss B136401E01 ED ED–16 ENGINE HOOD / DOOR – FRONT DOOR (f) Disengage the 2 claws and disconnect the front door inside handle sub-assembly. B136403 6. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (a) Disconnect the connector. (b) Remove the 3 screws and the power window regulator master switch assembly. 7. REMOVE FRONT DOOR WIRE (for Driver Side) (a) Disengage the clamp and remove the 2 screws and front door wire. 8. REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP (a) Using a screwdriver, disengage the 4 clips as shown in the illustration and remove the front door inner glass weatherstrip from the front door trim board. ED B136405 Clamp B136406E01 B136404 ENGINE HOOD / DOOR – FRONT DOOR 9. ED–17 REMOVE FRONT ARMREST BASE PANEL UPPER (a) Remove the 7 screws. (b) Disengage the 4 claws and remove the front armrest base panel upper. B136407 10. REMOVE FRONT DOOR INSIDE HANDLE SUBASSEMBLY (a) Disconnect the front door lock remote control cable and front door inside locking cable and remove the front door inside handle sub-assembly. 11. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY (See page AV-155) B136408 12. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY (See page MI-15) 13. REMOVE FRONT DOOR SERVICE HOLE COVER (a) Disconnect the connector and each clamp, and remove the front door service hole cover. HINT: Remove the remaining butyl tape on the door side. Clamp B146069E01 14. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY (a) Connect the front power window regulator motor assembly connector. (b) Connect the power window regulator master switch assembly and move the front door glass subassembly so that the door glass bolts can be seen. (c) Remove the 2 bolts. NOTICE: After the bolts are removed, the door glass may fall and become deformed. B136412 ED ED–18 (1) ENGINE HOOD / DOOR – FRONT DOOR (d) Remove the front door glass sub-assembly as shown in the illustration. NOTICE: Do not damage the door glass. (e) Disconnect the power window regulator master switch assembly and front power window regulator motor assembly connector. (2) B136413E01 ED Temporary Bolt B136415E01 15. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY (a) Loosen the temporary bolt. NOTICE: If the temporary bolt is removed, the front door window regulator may fall and become deformed. (b) Remove the 5 bolts. (c) Remove the front door window regulator subassembly and the power window regulator motor assembly front as a unit. (d) Remove the temporary bolt from the front door window regulator sub-assembly. 16. REMOVE FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY (a) Using a "torx" driver (T25), remove the 3 screws and the front power window regulator motor assembly. B136416 17. REMOVE FRONT NO. 1 DOOR STIFFENER CUSHION (a) Disengage the 2 claws. (b) Remove the double-sided tape and the front No. 1 door stiffener cushion. Double-sided Tape B136417E01 ENGINE HOOD / DOOR – FRONT DOOR ED–19 18. REMOVE FRONT DOOR GLASS RUN (a) Remove the front door glass run. B136418 19. REMOVE DOOR FRAME GARNISH (a) Disengage the clip and remove the door frame garnish. B136435 20. REMOVE FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY (a) Remove the 2 bolts and the front door front lower frame sub-assembly as shown in the illustration. B136419E01 21. REMOVE FRONT DOOR REAR LOWER FRAME SUBASSEMBLY (a) Remove the bolt and the front door rear lower frame sub-assembly as shown in the illustration. B136420E01 22. REMOVE FRONT DOOR OUTSIDE HANDLE COVER (a) Remove the hole plug. (b) Using a "torx" socket wrench (T30), loosen the screw and remove the front door outside handle cover and the door lock key cylinder as a unit. HINT: The screw cannot be removed because it is integrated into the front door outside handle frame sub-assembly. B136421 ED ED–20 ENGINE HOOD / DOOR – FRONT DOOR (c) Using a screwdriver, disengage the 2 claws and remove the front door outside handle cover. B136424 23. REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY (w/o Smart Key System) (a) Remove the front door outside handle assembly as shown in the illustration. ED B136858 24. REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY (w/ Smart Key System) (a) Disconnect the connector. B136857 (b) Remove the front door outside handle assembly as shown in the illustration. B136422 25. REMOVE FRONT DOOR FRONT OUTSIDE HANDLE PAD (a) Disengage the 3 claws and remove the front door front outside handle pad. B136426 ENGINE HOOD / DOOR – FRONT DOOR ED–21 26. REMOVE FRONT DOOR REAR OUTSIDE HANDLE PAD (a) Disengage the 2 claws and remove the front door rear outside handle pad. B136427 27. REMOVE FRONT DOOR LOCK ASSEMBLY (a) Disconnect the connector. (b) Using a "torx" socket wrench (T30), remove the 3 screws. (c) Slide the front door lock assembly downward, pull out the front door lock open rod from the outside handle frame, and remove the front door lock assembly and cables as a unit. (d) Remove the front door lock open rod from the front door lock assembly. (e) Remove the door lock wiring harness sealing from the front door lock assembly. B136428 28. REMOVE FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY (a) Remove the front door lock remote control cable assembly. B136430 29. REMOVE FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY (a) Using a screwdriver, disengage the 3 claws. HINT: Tape the screwdriver tip before use. B136431 ED ED–22 ENGINE HOOD / DOOR – FRONT DOOR (b) Remove the front door inside locking cable assembly. B136432 30. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY (w/o Smart Key System) (a) Using a "torx" socket wrench (T30), remove the screw. (b) Disengage the claws and remove the front door outside handle frame sub-assembly. ED B136433 31. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY (w/ Smart Key System) (a) Using a "torx" socket wrench (T30), remove the screw. (b) Disconnect the connector. (c) Disengage the 2 clamps. (d) Disengage the claws and remove the front door outside handle frame sub-assembly. B136856 ENGINE HOOD / DOOR – FRONT DOOR ED–23 32. REMOVE DOOR ELECTRICAL KEY OSCILLATOR (w/ Smart Key System) (a) Remove the screw and door electrical key oscillator. B136877 33. REMOVE FRONT DOOR CHECK ASSEMBLY (for TMC Made) (a) Remove the 3 bolts and the front door check assembly. B136436 34. REMOVE FRONT DOOR CHECK ASSEMBLY (for TMMK Made) (a) Remove the bolt, 2 nuts, and the front door check assembly. B146083 35. REMOVE FRONT DOOR WEATHERSTRIP (a) Using the clip remover, disengage the 19 clips and remove the front door weatherstrip. 36. REMOVE FRONT DOOR BELT MOULDING ASSEMBLY (See page ET-34) 37. REMOVE FRONT DOOR REAR WINDOW FRAME MOULDING (See page ET-48) 38. REMOVE FRONT DOOR UPPER WINDOW FRAME MOULDING (See page ET-49) 39. REMOVE FRONT DOOR STRIPE (See page ET-67) 40. REMOVE FRONT DOOR LOWER OUTSIDE STRIPE (See page ET-67) B136437 ED ED–24 ENGINE HOOD / DOOR – FRONT DOOR ADJUSTMENT Centering Bolt Standard Bolt B146066E01 ED B136438 HINT: • Before adjusting the door position for vehicles equipped with side airbags and curtain shield airbags, be sure to disconnect the battery. After adjustment, inspect the SRS warning light, the side airbag system, and the curtain shield airbag system for normal operation. Then initialize both airbag systems. • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. • Centering bolts are used to mount the door hinge to the vehicle body and door. The door cannot be adjusted with the centering bolts on. Substitute the centering bolts with standard bolts (with washers) when making adjustment. • A bolt without a torque specification is shown in the standard bolt chart (See page SS-2). 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment (See page IR-22). 2. ADJUST FRONT DOOR (a) Using SST, loosen the body's hinge bolts and adjust the door position. SST 09812-00010 (b) Tighten the body's hinge bolts after the adjustment. Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) (c) Loosen the door's hinge bolts and adjust the door position. (d) Tighten the door's hinge bolts after the adjustment. Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) ENGINE HOOD / DOOR – FRONT DOOR ED–25 (e) Using a "torx" socket wrench (T40), adjust the striker position by slightly loosening the striker mounting screws and hitting the striker with a plastic hammer. (f) Using a "torx" socket wrench (T40), tighten the striker mounting screws after the adjustment. Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf) 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 4. INSPECT SRS WARNING LIGHT (See page IR-58) B136440 ED ED–26 ENGINE HOOD / DOOR – FRONT DOOR REASSEMBLY ED 1. REPAIR INSTRUCTION (See page ET-68) 2. INSTALL FRONT DOOR LOWER OUTSIDE STRIPE (See page ET-71) 3. INSTALL FRONT DOOR STRIPE (See page ET-71) 4. INSTALL FRONT DOOR UPPER WINDOW FRAME MOULDING (See page ET-49) 5. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING (See page ET-50) 6. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY (See page ET-34) 7. INSTALL FRONT DOOR WEATHERSTRIP (a) Engage the 19 clips to install a new front door weatherstrip. 8. INSTALL FRONT DOOR CHECK ASSEMBLY (for TMC Made) (a) Install the front door check assembly with the 3 bolts. Torque: Bolt (A) 26 N*m (265 kgf*cm, 19 ft.*lbf) Torque: Bolt (B) 8.0 N*m (82 kgf*cm, 71 in.*lbf) 9. INSTALL FRONT DOOR CHECK ASSEMBLY (for TMMK Made) (a) Install the front door check assembly with the bolt and 2 nuts. Torque: Bolt 26 N*m (265 kgf*cm, 19 ft.*lbf) Torque: Nut 8.0 N*m (82 kgf*cm, 71 in.*lbf) B136437 (B) (B) (A) B136436E01 B146083 ENGINE HOOD / DOOR – FRONT DOOR ED–27 10. INSTALL DOOR ELECTRICAL KEY OSCILLATOR (w/ Smart Key System) (a) Install the door electrical key oscillator with the screw. 11. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY (w/o Smart Key System) (a) Apply MP grease to the sliding parts on the front door outside handle frame sub-assembly. B136878 (b) Install the front door outside handle frame subassembly with the claw. (c) Using a "torx" socket wrench (T30), install the front door outside handle frame sub-assembly with the screw. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 12. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY (w/ Smart Key System) (a) Apply MP grease to the sliding parts on the front door outside handle frame sub-assembly. B136434 (b) Install the front door outside handle frame subassembly with the claw. (c) Using a "torx" socket wrench (T30), install the front door outside handle frame sub-assembly with the screw. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) (d) Engage the 2 clamps. (e) Connect the connector. B136886 ED ED–28 ENGINE HOOD / DOOR – FRONT DOOR 13. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY (a) Install the front door inside locking cable assembly. B136432 (b) Engage the 3 claws. ED B136431 14. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY (a) Install the front door lock remote control cable assembly. B136430 15. INSTALL FRONT DOOR LOCK ASSEMBLY NOTICE: • When reusing the removed front door lock assembly, replace the door lock wire harness sealing on the connector with a new one. • Do not allow grease or dust to adhere on the door lock wiring harness sealing surface of the connector. • Reusing the door lock wiring harness sealing and/ or using damaged door lock wiring harness sealing may cause water intrusion to the connection. This may result in a malfunction in the front door lock assembly. (a) Apply MP grease to the sliding parts on the front door lock assembly. (b) Install a new door lock wiring harness sealing to front door lock assembly. ENGINE HOOD / DOOR – FRONT DOOR ED–29 (c) Insert the front door lock open rod to the front door lock assembly, and set it to the front door outside handle frame. (d) Make sure that the front door lock open rod is securely connected to the front door lock assembly. (e) Using a "torx" socket wrench (T30), install the front door lock assembly with the 3 screws. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) (f) Connect the connector. ED B136429 16. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD (a) Attach the 2 claws to install the front door rear outside handle pad. B136427 17. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD (a) Attach the 3 claws to install the front door front outside handle pad. B136426 18. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY (w/o Smart Key System) (a) Insert the front end of the front door outside handle assembly into the front door outside handle frame. (b) Insert the rear end of the front door outside handle assembly into the front door outside handle frame. Next slide the front door outside handle assembly to the front of the vehicle to install it. B136859 ED–30 ENGINE HOOD / DOOR – FRONT DOOR 19. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY (w/ Smart Key System) (a) Insert the front end of the front door outside handle assembly into the front door outside handle frame. (b) Insert the rear end of the front door outside handle assembly into the front door outside handle frame. Next slide the front door outside handle assembly to the front of the vehicle to install it. B136423 (c) Connect the connector. ED B136857 20. INSTALL FRONT DOOR OUTSIDE HANDLE COVER (a) Engage the 2 claws of the front door outside handle cover to the front door lock cylinder to install the cover. B136425 (b) Install the front door lock cylinder. HINT: Make sure that the front door lock cylinder rod is inserted into the front door lock assembly. B136441 (c) Using a "torx" socket wrench (T30), install the front door lock cylinder with the screw. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) (d) Install the hole plug. B136421 ENGINE HOOD / DOOR – FRONT DOOR ED–31 21. INSTALL FRONT DOOR REAR LOWER FRAME SUBASSEMBLY (a) Install the front door rear lower frame sub-assembly with the bolt. B136420 22. INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY (a) Install the front door front lower frame sub-assembly with the 2 bolts. B136419 23. INSTALL DOOR FRAME GARNISH (a) Engage the clip and install a new door frame garnish. B136435 24. INSTALL FRONT DOOR GLASS RUN (a) Install the front door glass run. B136418 25. INSTALL FRONT NO. 1 DOOR STIFFENER CUSHION (a) Engage the 2 claws and install a new front No. 1 door stiffener cushion with the double-sided tape. Double-sided Tape 26. INSTALL FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY NOTICE: The regulator arm must be below the intermediate position when installing the power window regulator motor. B136417E01 ED ED–32 ENGINE HOOD / DOOR – FRONT DOOR (a) Using a "torx" driver (T25), install the front power window regulator motor sub-assembly with the 3 screws. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) HINT: A new front window regulator adopts a self-tapping method. The installation position of the regulator will be threaded when the self-tapping screw is inserted. B112321 ED (4) (2) (3) (5) (6) 27. INSTALL FRONT DOOR WINDOW REGULATOR SUBASSEMBLY (a) Apply MP grease to the sliding parts on the front door window regulator sub-assembly. (b) Install the temporary bolt to the front door window regulator sub-assembly. (c) Temporarily install the window regulator. (d) Tighten the 6 bolts in the order shown in the illustration to install the front window regulator. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (1) B136415E02 28. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY (a) Insert the front door glass sub-assembly into the front door panel along the front door glass run as indicated by the arrows in the illustration. (1) (2) B136414E01 (b) Install the front door glass sub-assembly with the 2 bolts. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 29. INSTALL FRONT DOOR SERVICE HOLE COVER (a) Apply butyl tape to the front door panel. (b) Pass the front door lock remote control cable and rear door inside locking cable through a new front door service hole cover. B136412 ENGINE HOOD / DOOR – FRONT DOOR ED–33 (c) Install a new service hole cover. NOTICE: Securely install the front door service hole cover avoiding wrinkles and air bubbles. (d) Connect each connector and each clamp. Reference Point 30. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY (See page MI-17) Clamp B146070E01 31. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY (See page AV-157) 32. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP (a) Engage the 4 claws and install the front door inner glass weatherstrip. B136876 33. INSTALL FRONT ARMREST BASE PANEL UPPER (a) Engage the 4 claws and install the front armrest base panel upper. (b) Install the 7 screws. B136407 34. INSTALL FRONT DOOR WIRE (for Driver Side) (a) Install the front door wire with the 2 screws. (b) Engage the clamp. Clamp B136406E01 35. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (a) Connect the connector. (b) Install the power window regulator master switch assembly with the 3 screws. B136405 ED ED–34 ENGINE HOOD / DOOR – FRONT DOOR 36. INSTALL FRONT DOOR INSIDE HANDLE SUBASSEMBLY (a) Connect the front door lock remote control cable and front door inside locking cable to the front door inside handle sub-assembly. B136409 (b) Engage the 2 claws and install the front door inside handle sub-assembly. ED 37. INSTALL FRONT DOOR TRIM BOARD SUBASSEMBLY (a) Connect each connector. B136403 (b) Engage the front door trim board with the 4 clips of the front door inner glass weatherstrip. B136402 (c) Engage the 9 clips and install the front door trim board to the front door panel. (d) Install the 3 screws and clip (A). (A) B132840E01 38. INSTALL COURTESY LIGHT ASSEMBLY (a) Connect the connector. ENGINE HOOD / DOOR – FRONT DOOR ED–35 (b) Engage the claw and install the courtesy light assembly. B132839 39. INSTALL ASSIST GRIP COVER (a) Engage the 6 claws and install the assist grip cover. B132837 40. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG (a) Engage the 3 claws and install the front door inside handle bezel plug. B132835 41. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH (a) Engage the 2 clips and install the front door lower frame bracket garnish. 42. INITIALIZE POWER WINDOW CONTROL SYSTEM (See page WS-8) B132833 ED ED–35 ENGINE HOOD / DOOR – REAR DOOR REAR DOOR ENGINE HOOD / DOOR BODY COMPONENTS NO. 1 DOOR SCUFF PLATE CLAMP REAR DOOR INNER GLASS WEATHERSTRIP ED REAR DOOR INSIDE PANEL REINFORCE REAR DOOR INSIDE HANDLE BEZEL PLUG GROMMET GROMMET REAR DOOR INSIDE HANDLE SUB-ASSEMBLY DOOR ASSIST GRIP COVER REAR DOOR TRIM BOARD SUB-ASSEMBLY REAR DOOR ARMREST BASE PANEL UPPER REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY Non-reusable part B146079E01 ED–36 ENGINE HOOD / DOOR – REAR DOOR REAR DOOR OUTSIDE HANDLE ASSEMBLY REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY REAR DOOR LOCK ASSEMBLY ED REAR DOOR OUTSIDE HANDLE COVER REAR DOOR REAR OUTSIDE HANDLE PAD 5.0 (51, 44 in.*lbf) REAR DOOR FRONT OUTSIDE HANDLE PAD 4.0 (41, 35 in.*lbf) DOOR LOCK WIRING HARNESS SEAL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY REAR DOOR INSIDE LOCKING CABLE ASSEMBLY REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY REAR DOOR SERVICE HOLE COVER BUTYL TAPE 5.4 (55, 48 in.*lbf) REAR POWER WINDOW REGULATOR MOTOR ASSEMBLY 8.0 (82, 71 in.*lbf) Apply MP grease Non-reusable part N*m (kgf*cm, ft.*lbf) : Specified torque B146068E01 ED–37 ENGINE HOOD / DOOR – REAR DOOR RIVET REAR DOOR UPPER WINDOW FRAME MOULDING REAR DOOR GLASS RUN REAR DOOR FRAME GARNISH REAR DOOR OUTSIDE STRIPE REAR DOOR QUARTER WINDOW GLASS ED REAR DOOR QUARTER WINDOW WEATHERSTRIP REAR DOOR LOWER OUTSIDE STRIPE REAR DOOR GLASS SUB-ASSEMBLY REAR DOOR FRONT WINDOW FRAME MOULDING REAR DOOR BELT MOULDING ASSEMBLY TMMK made: 8.0 (82, 71 in.*lbf) 26 (265, 19) REAR DOOR CHECK ASSEMBLY TMC made: 8.0 (82, 71 in.*lbf) 26 (265, 19) REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY Non-reusable part REAR DOOR WEATHERSTRIP REAR DOOR CHECK ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B146082E01 ED–38 ENGINE HOOD / DOOR – REAR DOOR ON-VEHICLE INSPECTION 1. INSPECT REAR DOOR PANEL SUB-ASSEMBLY (a) Check that the clearance measurements of areas A to L are within each standard range. G E D I F H J C ED L B K A B132825E01 Standard clearance Area Measurement Area Measurement A 2.7 to 5.7 mm (0.106 to 0.224 in.) G 3.3 to 6.3 mm (0.130 to 0.248 in.) B -1.5 to 1.5 mm (-0.059 to 0.059 in.) H 0 to 3.0 mm (0 to 0.118 in.) C 2.3 to 6.3 mm (0.091 to 0.248 in.) I 3.3 to 6.3 mm (0.130 to 0.248 in.) D -2.0 to 2.0 mm (-0.079 to 0.079 in.) J 5.7 to 8.7 mm (0.224 to 0.343 in.) E 3.3 to 6.3 mm (0.130 to 0.248 in.) K 2.7 to 5.7 mm (0.106 to 0.224 in.) F -0.3 to 2.7 mm (0.012 to 0.106 in.) L -1.5 to 1.5 mm (-0.059 to 0.059 in.) DISASSEMBLY 1. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG (a) Using a screwdriver wrapped with protective tape, disengage the 3 claws and remove the rear door inside handle bezel plug. 2. REMOVE DOOR ASSIST GRIP COVER (a) Using a screwdriver wrapped with protective tape, disengage the 6 claws and remove the door assist grip cover. B136443 B136448 ENGINE HOOD / DOOR – REAR DOOR 3. ED–39 REMOVE REAR DOOR TRIM BOARD SUBASSEMBLY (a) Remove the 3 screws. (b) Using the clip remover, disengage the 7 clips. B136451 (c) Raise the rear door trim board to disengage the 4 claws and remove the rear door trim board together with the rear door inner glass weatherstrip. (d) Disconnect the connector. B136452 (e) Disengage the 2 claws and disconnect the rear door inside handle sub-assembly. B136453 (f) 4. B141704 Disengage the clip as shown in the illustration and remove the No. 1 door scuff plate clamp from the rear door trim board. REMOVE REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY (a) Disconnect the connector. ED ED–40 ENGINE HOOD / DOOR – REAR DOOR (b) Using a screwdriver wrapped with protective tape, disengage the 2 claws and remove the rear power window regulator switch assembly. B136457 5. REMOVE REAR DOOR INNER GLASS WEATHERSTRIP (a) Disengage the 3 clips as shown in the illustration and remove the rear door inner glass weatherstrip from the rear door trim board. 6. REMOVE REAR DOOR ARMREST BASE PANEL UPPER (a) Remove the 7 screws. (b) Disengage the 4 claws and remove the rear door armrest base panel upper. 7. REMOVE REAR DOOR INSIDE HANDLE SUBASSEMBLY (a) Disconnect the cables and remove the rear door inside handle sub-assembly. ED B136456 B136454 B136459 ENGINE HOOD / DOOR – REAR DOOR ED–41 8. REMOVE REAR DOOR INSIDE PANEL REINFORCE (a) Remove the 4 screws and the rear door inside panel reinforce. (b) Remove the 4 grommets. 9. REMOVE REAR DOOR SERVICE HOLE COVER (a) Disconnect the connector. (b) Remove the rear door service hole cover. HINT: Remove the remaining tape on the door side. B136463 B146071 10. REMOVE REAR DOOR CHECK ASSEMBLY (for TMC Made) (a) Remove the 3 bolts and the rear door check assembly. B136464 11. REMOVE REAR DOOR CHECK ASSEMBLY (for TMMK Made) (a) Remove the bolt, 2 nuts, and the rear door check assembly. B146084 ED ED–42 ENGINE HOOD / DOOR – REAR DOOR 12. REMOVE REAR DOOR WEATHERSTRIP (a) Using the clip remover, disengage the 20 clips and remove the rear door weatherstrip. ED B136465 13. REMOVE REAR DOOR GLASS RUN (a) Remove the rear door glass run. B136466 14. REMOVE REAR DOOR FRAME GARNISH (a) Disengage the clip and remove the rear door frame garnish. B136882 15. REMOVE REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY (a) Remove the 2 bolts, the screw, and the rear door lower window frame sub-assembly. B136467 ENGINE HOOD / DOOR – REAR DOOR ED–43 16. REMOVE REAR DOOR QUARTER WINDOW GLASS (a) Remove the rear door quarter window glass and the rear door quarter window weatherstrip as a unit as shown in the illustration. (b) Remove the rear door quarter window glass from the rear door quarter window weatherstrip. B136468 17. REMOVE REAR DOOR GLASS SUB-ASSEMBLY (a) Remove the rear door glass sub-assembly from the rear door window regulator sub-assembly as shown in the illustration. NOTICE: Do not damage the door glass. B136470 Temporary Bolt B136472E01 18. REMOVE REAR DOOR WINDOW REGULATOR SUBASSEMBLY (a) Disconnect the connector. (b) Loosen the temporary bolt. NOTICE: If the temporary bolt is removed, the rear door window regulator may fall and become deformed. (c) Remove the 3 bolts. (d) Remove the rear door window regulator subassembly and the power window regulator motor assembly rear as a unit. (e) Remove the temporary bolt from the rear door window regulator. 19. REMOVE REAR POWER WINDOW REGULATOR MOTOR ASSEMBLY (a) Using a "torx" driver (T25), remove the 3 screws and the rear power window regulator motor assembly. B124520 ED ED–44 ENGINE HOOD / DOOR – REAR DOOR 20. REMOVE REAR DOOR LOCK ASSEMBLY (a) Using a "torx" socket wrench (T30), remove the 3 screws. (b) Move the rear door lock assembly downward and pull the release plate out of the rear door outside handle frame. (c) Remove the door lock wiring harness sealing from the rear door lock assembly. ED B136473 21. REMOVE REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY (a) Using a screwdriver, disengage the claw. HINT: Tape the screwdriver tip before use. B136475 (b) Remove the rear door lock remote control cable assembly. B136476 22. REMOVE REAR DOOR INSIDE LOCKING CABLE ASSEMBLY (a) Using a screwdriver, disengage the 3 claws. HINT: Tape the screwdriver tip before use. B136477 ENGINE HOOD / DOOR – REAR DOOR ED–45 (b) Remove the rear door inside locking cable assembly. B136478 23. REMOVE REAR DOOR OUTSIDE HANDLE COVER (a) Using a "torx" socket wrench (T30), loosen the screw. HINT: The screw cannot be removed because it is integrated into the rear door outside handle frame sub-assembly. B136479 (b) Disengage the 2 claws and remove the rear door outside handle cover. B136480 24. REMOVE REAR DOOR OUTSIDE HANDLE ASSEMBLY (a) Pull and hold the release plate of the outside handle frame as shown in the illustration. NOTICE: The release plate may interfere with the outside handle and may be damaged when removing the handle, unless the release plate of the outside handle frame is pulled and held. B124528 (b) Remove the rear door outside handle assembly as shown in the illustration. B136481 ED ED–46 ENGINE HOOD / DOOR – REAR DOOR 25. REMOVE REAR DOOR FRONT OUTSIDE HANDLE PAD (a) Disengage the 3 claws and remove the rear door front outside handle pad. B136483 26. REMOVE REAR DOOR REAR OUTSIDE HANDLE PAD (a) Disengage the 2 claws and remove the rear door rear outside handle pad. ED B136484 27. REMOVE REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY (a) Using a "torx" socket wrench (T30), remove the screw. (b) Disengage the claws and remove the rear door outside handle frame sub-assembly. 28. REMOVE REAR DOOR BELT MOULDING ASSEMBLY (See page ET-37) 29. REMOVE REAR DOOR FRONT WINDOW FRAME MOULDING (See page ET-55) 30. REMOVE REAR DOOR UPPER WINDOW FRAME MOULDING (See page ET-56) 31. REMOVE REAR DOOR OUTSIDE STRIPE (See page ET-76) 32. REMOVE REAR DOOR LOWER OUTSIDE STRIPE (See page ET-76) B136485 ADJUSTMENT Centering Bolt Standard Bolt B146066E01 HINT: • Before adjusting the door position for vehicles equipped with side airbags and curtain shield airbags, be sure to disconnect the battery. After adjustment, inspect the SRS warning light, the side airbag system, and the curtain shield airbag system for normal operation. Then initialize both airbag systems. • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. ENGINE HOOD / DOOR – REAR DOOR ED–47 • Centering bolts are used to mount the door hinge to the vehicle body and door. The door cannot be adjusted with the centering bolts on. Substitute the centering bolts with standard bolts (with washers) when making adjustments. • A bolt without a torque specification is shown in the standard bolt chart (See page SS-2). 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment (See page RS-363). 2. ADJUST REAR DOOR (a) Loosen the body's hinge bolts and adjust the door position. SST 09812-00010 (b) Tighten the body's hinge bolts after the adjustment. Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) (c) Loosen the door's hinge bolts and adjust the door position. (d) Tighten the door's hinge bolts after the adjustment. Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) B136487 (e) Using a "torx" socket wrench (T40), adjust the striker position by slightly loosening the striker mounting screws and hitting the striker with a plastic hammer. (f) Using a "torx" socket wrench (T40), tighten the striker mounting screws after the adjustment. Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf) 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 4. INSPECT SRS WARNING LIGHT (See page ED-25) B136489 ED ED–48 ENGINE HOOD / DOOR – REAR DOOR REASSEMBLY ED 1. REPAIR INSTRUCTION (See page ET-77) 2. INSTALL REAR DOOR LOWER OUTSIDE STRIPE (See page ET-80) 3. INSTALL REAR DOOR OUTSIDE STRIPE (See page ET-80) 4. INSTALL REAR DOOR UPPER WINDOW FRAME MOULDING (See page ET-56) 5. INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING (See page ET-57) 6. INSTALL REAR DOOR BELT MOULDING ASSEMBLY (See page ET-37) 7. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY (a) Apply MP grease to the sliding parts on the rear door outside handle frame sub-assembly. (b) Using a "torx" socket wrench (T30), install the rear door outside handle frame sub-assembly with the screw. B136486 8. B136484 INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD (a) Attach the 2 claws to install the rear door rear outside handle pad. ENGINE HOOD / DOOR – REAR DOOR 9. ED–49 INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD (a) Attach the 3 claws to install the rear door front outside handle pad. B136483 B136482 10. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY (a) Insert the front end of the rear door outside handle assembly into the rear door outside handle frame. NOTICE: If the bellcrank lever is not pulled and held when installing the outside handle, the bellcrank lever will interfere with the outside handle and it will damage the release plate. (b) Insert the rear end of the rear door outside handle assembly into the rear door outside handle frame. Next slide the rear door outside handle assembly to the front of the vehicle to install it. 11. INSTALL REAR DOOR OUTSIDE HANDLE COVER (a) Install the rear door outside handle cover with the claw. B136480 (b) Using a "torx" socket wrench (T30), install the rear door outside handle cover with the screw. B136479 ED ED–50 ENGINE HOOD / DOOR – REAR DOOR 12. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY (a) Install the rear door inside locking cable assembly. B136478 (b) Engage the 3 claws. ED B136477 13. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY (a) Install the rear door lock remote control cable assembly. B136476 (b) Engage the claw. B136475 14. INSTALL REAR DOOR LOCK ASSEMBLY NOTICE: • When reusing the removed rear door lock assembly, replace the door lock wire harness sealing on the connector with a new one. • Do not allow grease or dust to adhere on the door lock wiring harness sealing surface of the connector. • Reusing the door lock wiring harness sealing and/ or using damaged door lock wiring harness sealing may cause water intrusion to the connection. This may result in a malfunction in the rear door lock assembly. (a) Apply MP grease to the sliding parts on the rear door lock assembly. (b) Install a new door lock wiring harness sealing to the rear door lock assembly. ENGINE HOOD / DOOR – REAR DOOR ED–51 (c) Insert the rear door lock assembly to the rear door outside handle release plate, and set it to the rear door panel. (d) Make sure that the rear door outside handle frame release plate is securely connected to the rear door lock assembly. (e) Using a "torx" socket wrench (T30), install the rear door lock assembly with the 3 screws. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) (f) Connect the connector. B136474 15. INSTALL REAR POWER WINDOW REGULATOR MOTOR ASSEMBLY NOTICE: The regulator arm must be below the intermediate position when installing the power window regulator motor. (a) Using a "torx" driver (T25), install the power window regulator motor assembly with the 3 screws. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) HINT: The new rear window regulator adopts a selftapping method. The installation position of the regulator will be threaded when the self-tapping screw is inserted. B124520 (4) (2) 16. INSTALL REAR DOOR WINDOW REGULATOR SUBASSEMBLY (a) Apply MP grease to the sliding parts on the rear door window regulator sub-assembly. (b) Install the temporary bolt to the rear door window regulator sub-assembly. (c) Temporarily install the window regulator. (d) Tighten the 4 bolts in the order shown in the illustration to install the rear door window regulator. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (e) Connect the connector. (3) (1) B136472E02 17. INSTALL REAR DOOR FRAME GARNISH (a) Engage the clip and install a new rear door frame garnish. B136882 ED ED–52 ENGINE HOOD / DOOR – REAR DOOR 18. INSTALL REAR DOOR GLASS RUN (a) Install the rear door glass run. B136466 19. INSTALL REAR DOOR GLASS SUB-ASSEMBLY (a) Slide the rear door glass sub-assembly to install it as shown in the illustration. ED 20. INSTALL REAR DOOR QUARTER WINDOW GLASS (a) Install the rear door quarter window glass to the rear door quarter weatherstrip. B136471 (b) Install the rear door quarter window glass together with the rear door quarter window glass weatherstrip in the direction indicated by the arrow in the illustration. B136469 21. INSTALL REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY (a) Insert the rear door lower window frame subassembly from up above. (b) Install the rear door glass run to the rear door lower window frame sub-assembly. (c) Install the rear door lower window frame subassembly with the 2 bolts and screw. B136467 ENGINE HOOD / DOOR – REAR DOOR ED–53 22. INSTALL REAR DOOR WEATHERSTRIP (a) Engage the 20 clips and install the rear door weatherstrip. ED B136465 23. INSTALL REAR DOOR CHECK ASSEMBLY (for TMC Made) (a) Install the rear door check assembly with the 3 bolts. Torque: Bolt (A) 26 N*m (265 kgf*cm, 19 ft.*lbf) Torque: Bolt (B) 8.0 N*m (82 kgf*cm, 71 in.*lbf) (B) (B) (A) B136464E01 24. INSTALL REAR DOOR CHECK ASSEMBLY (for TMMK Made) (a) Install the rear door check assembly with the bolt and 2 nuts. Torque: Bolt 26 N*m (265 kgf*cm, 19 ft.*lbf) Torque: Nut 8.0 N*m (82 kgf*cm, 71 in.*lbf) B146084 25. INSTALL REAR DOOR SERVICE HOLE COVER (a) Apply butyl tape to the rear door panel. (b) Pass the rear door lock remote control cable, rear door inside locking cable and each connector through a new rear door service hole cover. (c) Install a new rear door service hole cover. NOTICE: Securely install the rear door service hole cover avoiding wrinkles and air bubbles. (d) Connect the connector and clamp. Reference Point 26. INSTALL REAR DOOR INSIDE PANEL REINFORCE (a) Install 4 new grommets. B146072E01 ED–54 ENGINE HOOD / DOOR – REAR DOOR (b) Install a new rear door inside panel reinforce with the 4 screws. B136463 27. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP (a) Engage the 3 claws to install the rear door inner glass weatherstrip. ED B146073 28. INSTALL REAR DOOR ARMREST BASE PANEL UPPER (a) Engage the 4 claws. (b) Install the rear door armrest base panel upper with the 7 screws. B136454 29. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY (a) Engage the 2 claws and install the rear power window regulator switch assembly. B136457 ENGINE HOOD / DOOR – REAR DOOR ED–55 30. INSTALL REAR DOOR INSIDE HANDLE SUBASSEMBLY (a) Connect the rear door lock remote control cable and rear door inside locking cable to the rear inside handle. B136460 (b) Engage the 2 claws and install the rear door inside handle sub-assembly. B136453 31. INSTALL REAR DOOR TRIM BOARD SUBASSEMBLY (a) Engage the claw to install the No. 1 door scuff plate clamp. (b) Connect each connector. B146074 (c) Engage the rear door trim board with the 4 clips of the rear door inner glass weatherstrip. B136452 ED ED–56 ENGINE HOOD / DOOR – REAR DOOR (d) Engage the 7 clips to install the rear door trim board to the rear door panel. (e) Install the 3 screws. B136451 32. INSTALL DOOR ASSIST GRIP COVER (a) Engage the 6 claws and install the door assist grip cover. ED B136448 33. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG (a) Engage the 3 claws to install the rear door inside handle bezel plug. 34. INITIALIZATION POWER WINDOW CONTROL SYSTEM (See page WS-8) B136444 ENGINE HOOD / DOOR – LUGGAGE COMPARTMENT DOOR ED–57 LUGGAGE COMPARTMENT DOOR ENGINE HOOD / DOOR BODY COMPONENTS ED LUGGAGE COMPARTMENT DOOR COVER 5.5 (56, 49 in.*lbf) 5.5 (56, 49 in.*lbf) LUGGAGE COMPARTMENT DOOR LOCK CYLINDER ASSEMBLY LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY for SE Grade: REAR SPOILER N*m (kgf*cm, ft.*lbf) : Specified torque B136851E01 ED–58 ENGINE HOOD / DOOR – LUGGAGE COMPARTMENT DOOR ED LICENSE PLATE LIGHT ASSEMBLY RH LICENSE PLATE LIGHT ASSEMBLY LH REAR LIGHT ASSEMBLY RH LUGGAGE COMPARTMENT OUTSIDE DOOR GARNISH SUB-ASSEMBLY REAR LIGHT ASSEMBLY LH with Smart Key System: LUGGAGE DOOR OPENING SWITCH ASSEMBLY B136881E01 ED–59 ENGINE HOOD / DOOR – LUGGAGE COMPARTMENT DOOR ON-VEHICLE INSPECTION 1. A B INSPECT LUGGAGE COMPARTMENT DOOR PANEL SUB-ASSEMBLY (a) Check that the clearance measurements of areas A to F are within each standard range. C D ED E F B132827E01 Standard clearance Area Measurement Area Measurement A 7.6 mm (0.299 in.) D 3.8 to 7.8 mm (0.146 to 0.307 in.) B 2.0 to 5.0 mm (0.079 to 0.197 in.) E 2.0 to 5.0 mm (0.079 to 0.197 in.) C -1.5 to 1.5 mm (-0.059 to 0.059 in.) F -1.5 to 1.5 mm (-0.059 to 0.059 in.) ED–60 ENGINE HOOD / DOOR – LUGGAGE COMPARTMENT DOOR DISASSEMBLY 1. REMOVE LUGGAGE COMPARTMENT DOOR COVER (See page ET-61) 2. REMOVE LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY (See page ED-63) 3. REMOVE LUGGAGE COMPARTMENT DOOR LOCK CYLINDER ASSEMBLY (a) Disconnect the cable and connector. ED B136496 (b) Remove the 2 nuts and the luggage compartment door lock cylinder assembly. 4. REMOVE REAR SPOILER (for SE Grade) (See page ET-30) 5. REMOVE LUGGAGE DOOR OPENING SWITCH ASSEMBLY (w/ Smart Key System) (See page DL246) 6. REMOVE LUGGAGE COMPARTMENT OUTSIDE DOOR GARNISH SUB-ASSEMBLY (See page ET-61) 7. REMOVE REAR LIGHT ASSEMBLY LH (See page LI87) 8. REMOVE REAR LIGHT ASSEMBLY RH 9. REMOVE LICENSE PLATE LIGHT ASSEMBLY LH (See page LI-94) B136497 10. REMOVE LICENSE PLATE LIGHT ASSEMBLY RH ADJUSTMENT Centering Bolt Standard Bolt B146067E01 HINT: • Centering bolts are used to mount the door hinge to the door. The door cannot be adjusted with the centering bolts on. Substitute the centering bolts with standard bolts (with washers) when making adjustments. • A bolt without a torque specification is shown in the standard bolt chart (See page SS-2). 1. REMOVE LUGGAGE COMPARTMENT DOOR COVER (See page ET-61) 2. REMOVE LUGGAGE COMPARTMENT FLOOR MAT 3. REMOVE SPARE WHEEL COVER CLAMP 4. REMOVE SPARE WHEEL COVER ASSEMBLY 5. REMOVE LUGGAGE COMPARTMENT SIDE TRAY ASSEMBLY (See page ED-66) ENGINE HOOD / DOOR – LUGGAGE COMPARTMENT DOOR ED–61 6. REMOVE NO. 1 LUGGAGE COMPARTMENT TRIM HOOK (See page ED-66) 7. REMOVE REAR FLOOR FINISH PLATE (See page ED-66) 8. ADJUST LUGGAGE COMPARTMENT DOOR (a) Horizontally and vertically adjust the door by loosening the door side hinge bolts. Torque: 7.5 N*m (77 kgf*cm, 66 in.*lbf) ED B136494 (b) Adjust the striker position by slightly loosening the striker mounting screws and hitting the striker with a plastic hammer. (c) Tighten the striker mounting screws after the adjustment. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 9. B136495 INSTALL REAR FLOOR FINISH PLATE (See page ED72) 10. INSTALL NO. 1 LUGGAGE COMPARTMENT TRIM HOOK (See page ED-72) 11. INSTALL LUGGAGE COMPARTMENT SIDE TRAY ASSEMBLY (See page ED-72) 12. INSTALL SPARE WHEEL COVER ASSEMBLY 13. INSTALL SPARE WHEEL COVER CLAMP 14. INSTALL LUGGAGE COMPARTMENT FLOOR MAT 15. INSTALL LUGGAGE COMPARTMENT DOOR COVER (See page ET-64) ED–62 ENGINE HOOD / DOOR – LUGGAGE COMPARTMENT DOOR REASSEMBLY ED 1. INSTALL LICENSE PLATE LIGHT ASSEMBLY LH (See page LI-95) 2. INSTALL LICENSE PLATE LIGHT ASSEMBLY RH 3. INSTALL REAR LIGHT ASSEMBLY LH (See page LI91) 4. INSTALL REAR LIGHT ASSEMBLY RH 5. INSTALL LUGGAGE COMPARTMENT OUTSIDE DOOR GARNISH SUB-ASSEMBLY (See page ET-63) 6. INSTALL LUGGAGE DOOR OPENING SWITCH ASSEMBLY (w/ Smart Key System) (See page DL246) 7. INSTALL REAR SPOILER (for SE Grade) (See page ET-31) 8. INSTALL LUGGAGE COMPARTMENT DOOR LOCK CYLINDER ASSEMBLY (a) Install the luggage compartment door lock cylinder with the 2 nuts. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) B136497 (b) Connect the cable and connector. 9. INSTALL LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY (See page ED-64) 10. INSTALL LUGGAGE COMPARTMENT DOOR COVER (See page ET-64) B136496 ENGINE HOOD / DOOR – LUGGAGE COMPARTMENT DOOR LOCK ED–63 LUGGAGE COMPARTMENT DOOR LOCK ENGINE HOOD / DOOR BODY COMPONENTS ED LUGGAGE COMPARTMENT DOOR COVER 5.5 (56, 49 in.*lbf) LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B136883E01 ED–64 ENGINE HOOD / DOOR – LUGGAGE COMPARTMENT DOOR LOCK REMOVAL ED 1. REMOVE LUGGAGE COMPARTMENT DOOR COVER (See page ET-61) 2. REMOVE LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY (a) Disconnect the rod. B136491 (b) Disconnect the connector. (c) Remove the 2 bolts and luggage compartment door lock assembly. B136880 INSTALLATION 1. INSTALL LUGGAGE COMPARTMENT DOOR LOCK ASSEMBLY (a) Install the luggage compartment door lock assembly with the 2 bolts. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) (b) Connect the connector. B136880 (c) Connect the rod. 2. B136492 INSTALL LUGGAGE COMPARTMENT DOOR COVER (See page ET-64) ED–65 ENGINE HOOD / DOOR – LUGGAGE DOOR HINGE TORSION BAR LUGGAGE DOOR HINGE TORSION BAR ENGINE HOOD / DOOR BODY COMPONENTS LUGGAGE DOOR HINGE TORSION BAR LH LUGGAGE COMPARTMENT DOOR TORSION BAR SUPPORT LUGGAGE DOOR HINGE TORSION BAR RH LUGGAGE COMPARTMENT FLOOR MAT LUGGAGE COMPARTMENT INNER TRIM COVER RH SPARE WHEEL COVER CLAMP SPARE WHEEL COVER ASSEMBLY NO. 1 LUGGAGE COMPARTMENT TRIM HOOK REAR FLOOR FINISH PLATE LUGGAGE COMPARTMENT INNER TRIM COVER LH LUGGAGE COMPARTMENT SIDE TRAY ASSEMBLY NO. 1 LUGGAGE COMPARTMENT TRIM HOOK B136850E01 ED ED–66 ENGINE HOOD / DOOR – LUGGAGE DOOR HINGE TORSION BAR REMOVAL 1. REMOVE LUGGAGE COMPARTMENT FLOOR MAT 2. REMOVE SPARE WHEEL COVER CLAMP 3. REMOVE SPARE WHEEL COVER ASSEMBLY 4. REMOVE LUGGAGE COMPARTMENT SIDE TRAY ASSEMBLY (a) Remove the bolt. (b) Disengage the clip and remove the luggage compartment side tray assembly. 5. REMOVE NO. 1 LUGGAGE COMPARTMENT TRIM HOOK (a) Remove the 2 screws and the 2 No. 1 luggage compartment trim hooks. 6. REMOVE REAR FLOOR FINISH PLATE (a) Disengage the 7 clips and remove the rear floor finish plate. 7. REMOVE LUGGAGE COMPARTMENT INNER TRIM COVER LH (a) Remove the 2 clips and the luggage compartment inner trim cover LH. ED B136853 B136879 B136852 B136854 ENGINE HOOD / DOOR – LUGGAGE DOOR HINGE TORSION BAR ED–67 8. REMOVE LUGGAGE COMPARTMENT INNER TRIM COVER RH (a) Remove the 2 clips and the luggage compartment inner trim cover RH. 9. REMOVE LUGGAGE DOOR HINGE TORSION BAR RH (a) Disconnect the luggage door hinge torsion bar RH from the luggage compartment door torsion bar support as shown in the illustration. B136855 B136498 (b) Using SST, disconnect the luggage door hinge torsion bar RH from the luggage door hinge and body RH side as shown in the illustration. SST 09804-24010 B136813 (c) Remove the luggage door hinge torsion bar RH from the body LH side as shown in the illustration. B136817 ED ED–68 ENGINE HOOD / DOOR – LUGGAGE DOOR HINGE TORSION BAR 10. REMOVE LUGGAGE DOOR HINGE TORSION BAR LH (a) Disconnect the luggage door hinge torsion bar LH from the luggage compartment door torsion bar support as shown in the illustration. B136500 (b) Using SST, disconnect the luggage door hinge torsion bar LH from the luggage door hinge and body LH side as shown in the illustration. SST 09804-24010 ED B136811 (c) Remove the luggage door hinge torsion bar LH from the body RH side as shown in the illustration. B136815 11. REMOVE LUGGAGE COMPARTMENT DOOR TORSION BAR SUPPORT (a) Remove the luggage compartment door torsion bar support as shown in the illustration. B136819 ENGINE HOOD / DOOR – LUGGAGE DOOR HINGE TORSION BAR ED–69 INSTALLATION HINT: • The installation should be performed in the order of LH to RH. • After installing the torsion bar, use your hand to open and close the luggage door. Make sure the luggage door can open and close smoothly. 1. INSTALL LUGGAGE COMPARTMENT DOOR TORSION BAR SUPPORT (a) Install the luggage compartment door torsion bar support as shown in the illustration. ED B136820 2. Installation Hole (For Adjustment) INSTALL LUGGAGE DOOR HINGE TORSION BAR LH (a) Set the tip of the luggage door hinge torsion bar LH in the installation hole placed in the center part. Holes placed in the upper and lower parts are used for adjustment. Installation Hole B136875E01 (b) Connect the luggage door hinge torsion bar LH to the body RH side as shown in the illustration. B136816 (c) Connect the luggage door hinge torsion bar LH to the luggage compartment door torsion bar support as shown in the illustration. B136810 ED–70 ENGINE HOOD / DOOR – LUGGAGE DOOR HINGE TORSION BAR (d) Using SST, install the luggage door hinge torsion bar LH to the luggage door hinge and body LH side as shown in the illustration. SST 09804-24010 ED B136812 3. Installation Hole (For Adjustment) INSTALL LUGGAGE DOOR HINGE TORSION BAR RH (a) Set the tip of the luggage door hinge torsion bar RH in the installation hole placed in the center part. Holes placed in the upper and lower parts are used for adjustment. Installation Hole B136874E01 (b) Connect the luggage door hinge torsion bar RH to the body LH side as shown in the illustration. B136818 (c) Connect the luggage door hinge torsion bar RH to the luggage compartment door torsion bar support as shown in the illustration. B136499 ENGINE HOOD / DOOR – LUGGAGE DOOR HINGE TORSION BAR ED–71 (d) Using SST, install the luggage door hinge torsion bar RH to the luggage door hinge and body LH side as shown in the illustration. SST 09804-24010 ED B136814 4. INSTALL LUGGAGE COMPARTMENT INNER TRIM COVER LH (a) Install the luggage compartment inner trim cover LH with the 2 clips. 5. INSTALL LUGGAGE COMPARTMENT INNER TRIM COVER RH (a) Install the luggage compartment inner trim cover RH with the 2 clips. B136854 B136855 ED–72 ENGINE HOOD / DOOR – LUGGAGE DOOR HINGE TORSION BAR 6. INSTALL REAR FLOOR FINISH PLATE (a) Engage the 7 clips and install the rear floor finish plate. 7. INSTALL NO. 1 LUGGAGE COMPARTMENT TRIM HOOK (a) Install the 2 No. 1 luggage compartment trim hooks with the 2 screws. 8. INSTALL LUGGAGE COMPARTMENT SIDE TRAY ASSEMBLY (a) Engage the clip and install the luggage compartment side tray assembly. (b) Install the bolt. 9. INSTALL SPARE WHEEL COVER ASSEMBLY ED B136852 B136879 10. INSTALL SPARE WHEEL COVER CLAMP 11. INSTALL LUGGAGE COMPARTMENT FLOOR MAT B136853 2GR-FE CHARGING – CHARGING SYSTEM CH–1 CHARGING SYSTEM PRECAUTION 1. 2. 3. 4. 5. Check that the battery cables are connected to the correct terminals. Disconnect the battery cables when the battery is given a quick charge. Do not perform tests with a high voltage insulation resistance tester. Never disconnect the battery while the engine is running. Check that the charging cable nut is tightened on terminal B of the generator and the engine room R/B. CH CH–2 2GR-FE CHARGING – CHARGING SYSTEM PARTS LOCATION COMBINATION METER -CHARGE WARNING LIGHT GENERATOR INSTRUMENT PANEL J/B -GAUGE NO. 1 FUSE ENGINE ROOM R/B -GAUGE NO. 2 FUSE -ALT-S FUSE -ALT FUSE A135521E01 CH CH–3 2GR-FE CHARGING – CHARGING SYSTEM SYSTEM DIAGRAM ALT-S From Battery From IG1 Relay GAUGE No. 1 Combination Meter GAUGE No. 2 From IG2 Relay 13 F1 IG+ IG+ CHG- 23 F1 L 4 C18 IG 2 C18 S 1 C18 Charge Generator ALT 1 B C19 IC Regulator FL MAIN Battery A138773E01 CH CH–4 2GR-FE CHARGING – CHARGING SYSTEM PROBLEM SYMPTOMS TABLE Result Symptom Charge Warning Light Comes ON while Driving Suspected area 1. Clutch pulley 2. Generator assembly See page CH-7 1. V-ribbed belt Noise Occurs from Generator while Engine is Running 2. Clutch pulley 3. Generator assembly CH CH-8 CH–5 2GR-FE CHARGING – CHARGING SYSTEM ON-VEHICLE INSPECTION Green Dark 1. CHECK BATTERY ELECTROLYTE LEVEL (a) Check the electrolyte level. (1) If the electrolyte level is low, replace the battery (or add distilled water) and check the charging system. 2. CHECK BATTERY SPECIFIC GRAVITY (a) Check the color of the indicator. Result Clear or Light Yellow 3. A115815E01 Indicator color Condition Green Good Dark Charging necessary Clear or light yellow Replacement necessary CHECK BATTERY VOLTAGE (a) If it has not been 20 minutes since you drove the vehicle or since the engine was stopped, turn the ignition switch on (IG) and turn on the electrical systems (headlight, blower motor, rear defogger, etc.) for 60 seconds. This will remove the surface charge from the battery. (b) Turn off the ignition switch and the electrical systems. (c) Measure the battery voltage between the negative () and positive (+) terminals of the battery. Standard voltage: 12.5 to 12.9 V at 20°C (68°F) HINT: If the voltage is below the specification, charge the battery. 4. CHECK BATTERY TERMINAL (a) Check that the battery terminals are not loose or corroded. If the terminals are corroded, clean them. 5. CHECK FUSES (a) Measure the resistance of the ALT fuse, ALT-S fuse, GAUGE No. 1 fuse and GAUGE No. 2 fuse. Standard resistance: Below 1 Ω If the result is not as specified, replace the fuses as necessary. 6. CHECK V-RIBBED BELT (a) Check the belt for wear, cracks or other signs of damage. If any of the following defects is found, replace the V-ribbed belt. • The belt is worn out, cracked, or the cords are exposed. • The cracks reach the cords in more than one place. • The belt has chunks missing from the ribs. A081052E01 B000543 CH CH–6 2GR-FE CHARGING – CHARGING SYSTEM CORRECT (b) Check that the belt fits properly in the ribbed grooves. HINT: Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley. If it has slipped out, replace the V-ribbed belt. Install a new V-ribbed belt correctly. INCORRECT 7. VISUALLY CHECK GENERATOR WIRING (a) Check that the generator wiring is in good condition. If the condition is not good, repair or replace the generator wire. 8. LISTEN FOR ABNORMAL NOISES FROM GENERATOR (a) Check that there is no abnormal noise from the generator while the engine is running. If there is abnormal noise, replace the pulley or generator. 9. CHECK CHARGE WARNING LIGHT CIRCUIT (a) Turn the ignition switch on (IG). Check that the charge warning light comes on. (b) Start the engine and check that the light goes off. If the light does not operate as specified, troubleshoot the charge warning light circuit. B000540E03 Disconnect Wire from Terminal B Ammeter A  Battery Generator Voltmeter Battery V  CH A110265E04 10. CHECK CHARGING CIRCUIT WITHOUT LOAD (a) According to the following procedure, connect an ammeter and voltmeter as shown in the illustration. (1) Disconnect the wire from terminal B of the generator and connect it to the negative (-) lead of the ammeter. (2) Connect the positive (+) lead of the ammeter to terminal B of the generator. (3) Connect the positive (+) lead of the voltmeter to positive (+) terminal of the battery. (4) Ground the negative (-) lead of the voltmeter. (b) Check the charging circuit. (1) While keeping the engine speed at 2,000 rpm, check the readings on the ammeter and voltmeter. Standard amperage: 10 A or less Standard voltage: 13.2 to 14.8 V If the results are not as specified, replace the generator assembly. HINT: • If the battery is not fully charged, the ammeter reading may be more than the standard amperage. In this case, increase electrical load by operating devices such as the wiper motor and rear window defogger. Then, recheck the reading on the ammeter. 2GR-FE CHARGING – CHARGING SYSTEM CH–7 11. CHECK CHARGING CIRCUIT WITH LOAD (a) Keep the engine speed at 2,000 rpm, turn on the high beam headlights, and turn the heater blower switch to the "HI" position. (b) Check the reading on the ammeter. Standard amperage: 30 A or more If the ammeter reading is less than the standard amperage, replace the generator assembly. HINT: • If the battery is fully charged, the ammeter reading may be less than the standard amperage. In this case, increase electrical load by operating devices such as the wiper motor and rear window defogger. Then, recheck the reading on the ammeter. CH CH–8 2GR-FE CHARGING – CHARGING SYSTEM Charge Warning Light Comes ON while Driving INSPECTION PROCEDURE 1 CHECK LOCK FUNCTION OF CLUTCH PULLEY Free (a) Check the lock function with the pulley installed in the vehicle. (1) Visually check that the rotor in the generator operates with the engine started. (b) Check the lock function with the pulley removed from the vehicle. (1) Remove the generator pulley cap. Using SST, hold the generator rotor. (2) Turn the clutch pulley clockwise and check that the outer ring locks. OK: The outer ring locks. SST 09820-63020 Lock NG REPLACE CLUTCH PULLEY A128078E01 OK 2 CHECK LOCK OF CLUTCH PULLEY (a) Start the engine and visually check looseness of the clutch pulley. OK: The clutch pulley is not loose. NG OK REPLACE GENERATOR ASSEMBLY CH TIGHTEN CLUTCH PULLEY TO THE SPECIFIED TORQUE 2GR-FE CHARGING – CHARGING SYSTEM CH–9 Noise Occurs from Generator while Engine is Running INSPECTION PROCEDURE 1 CHECK LOOSENESS OF V-RIBBED BELT (a) Check the tension of the belt by pushing it down with a finger. OK: The tension of the belt is enough. NG REPLACE V-RIBBED BELT TENSIONER ASSEMBLY OK 2 CHECK V-RIBBED BELT FOR WEAR (a) Check the V-ribbed belt for wear. OK: The V-ribbed belt is not worn. NG REPLACE V-RIBBED BELT OK 3 CHECK CLUTCH PULLEY FOR WEAR (a) Check the clutch pulley groove for wear or other defects. OK: The clutch pulley groove is not damaged. NG REPLACE CLUTCH PULLEY OK 4 CHECK FOR NOISE WHILE CLUTCH PULLEY IS OPERATING (a) Perform a driving test and check if noise occurs when decelerating. OK: Noise does not occur. NG REPLACE CLUTCH PULLEY OK REPLACE GENERATOR ASSEMBLY CH 2GR-FE CHARGING – GENERATOR CH–9 GENERATOR 2GR-FE CHARGING ENGINE COMPONENTS V-BANK COVER SUB-ASSEMBLY 5.0 (51, 44 in.*lbf) x2 AIR CLEANER INLET ASSEMBLY 5.0 (51, 44 in.*lbf) NO. 1 AIR CLEANER INLET AIR CLEANER CAP SUB-ASSEMBLY AIR CLEANER FILTER ELEMENT COOL AIR INTAKE DUCT SEAL CH N*m (kgf*cm, ft.*lbf) : Specified torque A134975E01 CH–10 2GR-FE CHARGING – GENERATOR 7.0 (71, 62 in.*lbf) x4 RADIATOR SUPPORT UPPER HOOD LOCK ASSEMBLY 7.5 (77, 66 in.*lbf) x2 HORN CONNECTOR 7.0 (71, 62 in.*lbf) RADIATOR GRILLE PROTECTOR 7.5 (77, 66 in.*lbf) x2 x2 FRONT BUMPER ENERGY ABSORBER x2 ENGINE UNDER COVER LH FRONT BUMPER ASSEMBLY x9 ENGINE UNDER COVER RH FRONT WHEEL OPENING EXTENSION PAD RH FRONT WHEEL OPENING EXTENSION PAD LH CH N*m (kgf*cm, ft.*lbf) : Specified torque A133359E05 CH–11 2GR-FE CHARGING – GENERATOR V-RIBBED BELT FRONT FENDER APRON SEAL RH 9.8 (100, 87 in.*lbf) 8.4 (86, 74 in.*lbf) WIRE HARNESS CLAMP STAY 43 (438, 32) RADIATOR INLET HOSE RADIATOR OUTLET HOSE 20 (204, 15) 43 (438, 32) 20 (204, 15) GENERATOR BRACKET GENERATOR ASSEMBLY FAN MOTOR CONNECTOR RADIATOR ASSEMBLY FAN SHROUD 5.0 (51, 44 in.*lbf) x4 CH N*m (kgf*cm, ft.*lbf) : Specified torque A133878E01 CH–12 2GR-FE CHARGING – GENERATOR GENERATOR DRIVE END FRAME BEARING RETAINER GENERATOR PULLEY CAP x4 GENERATOR WASHER 2.3 (23, 20 in.*lbf) GENERATOR ROTOR ASSEMBLY 111 (1,125, 81) GENERATOR DRIVE END FRAME BEARING GENERATOR CLUTCH PULLEY GENERATOR REAR END COVER GENERATOR TERMINAL INSULATOR x3 x2 4.6 (47, 41 in.*lbf) 1.8 (18, 16 in.*lbf) x4 5.8 (59, 51 in.*lbf) GENERATOR BRUSH HOLDER ASSEMBLY GENERATOR COIL ASSEMBLY CH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A135482E01 2GR-FE CHARGING – GENERATOR CH–13 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE FRONT WHEEL RH 3. REMOVE FRONT FENDER APRON SEAL RH 4. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH 5. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH 6. REMOVE ENGINE UNDER COVER RH 7. REMOVE ENGINE UNDER COVER LH 8. DRAIN ENGINE COOLANT (See page CO-5) 9. REMOVE V-BANK COVER SUB-ASSEMBLY (See page EM-23) 10. REMOVE COOL AIR INTAKE DUCT SEAL (See page EM-23) 11. REMOVE AIR CLEANER INLET ASSEMBLY (See page EM-24) 12. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-503) 13. REMOVE NO. 1 AIR CLEANER INLET (See page EM24) 14. REMOVE FRONT BUMPER ASSEMBLY (w/o Fog Light) (See page ET-5) 15. REMOVE FRONT BUMPER ASSEMBLY (w/ Fog Light) (See page ET-6) 16. REMOVE FRONT BUMPER ENERGY ABSORBER (See page ET-9) 17. SEPARATE RADIATOR RESERVE TANK HOSE (See page CO-24) 18. SEPARATE RADIATOR INLET HOSE (See page CO24) 19. SEPARATE RADIATOR OUTLET HOSE (See page CO-24) 20. SEPARATE NO. 1 OIL COOLER INLET HOSE (See page CO-25) 21. SEPARATE NO. 1 OIL COOLER OUTLET HOSE (See page CO-25) 22. REMOVE RADIATOR SUPPORT UPPER (See page CO-25) 23. REMOVE FAN SHROUD (See page CO-26) 24. REMOVE RADIATOR ASSEMBLY (See page CO-26) 25. REMOVE V-RIBBED BELT (See page EM-6) CH CH–14 2GR-FE CHARGING – GENERATOR 26. REMOVE GENERATOR ASSEMBLY (a) Remove the terminal cap. (b) Remove the nut and disconnect the wire harness from terminal B. (c) Disconnect the generator connector from the generator assembly. (d) Disconnect the connector from the compressor and magnetic clutch. (e) Disconnect the 2 wire harness clamps. A133865 (f) Remove the 2 bolts. A133866 (g) Remove the bolt from the cylinder block. (h) Disconnect the wire harness clamp and remove the generator assembly. A133867 (i) Remove the bolt and wire harness clamp stay. (j) Remove the bolt and bracket. A128066 CH A135391 2GR-FE CHARGING – GENERATOR CH–15 DISASSEMBLY 1. REMOVE GENERATOR CLUTCH PULLEY (a) Using a screwdriver, remove the generator pulley cap. A128068E01 (b) Set SST (A) and (B). SST 09820-63020 (c) Clamp SST (A) in a vise. SST (A) SST (B) A128069E01 (d) Place the rotor shaft end into SST (A). SST (A) Rotor Shaft SST (B) A135194E01 (e) Fit SST (B) to the clutch pulley. Clutch Pulley SST (B) SST (B) A135195E01 (f) Loosen the pulley by turning SST (B) in the direction shown in the illustration. (g) Remove the generator assembly from the SST. (h) Remove the clutch pulley from the rotor shaft. SST (B) A135196E01 CH CH–16 2GR-FE CHARGING – GENERATOR 2. REMOVE GENERATOR REAR END COVER (a) Place the generator assembly on the clutch pulley. A135197 (b) Remove the 3 nuts and generator rear end cover. A128071 3. REMOVE GENERATOR TERMINAL INSULATOR (a) Remove the terminal insulator from the generator coil. 4. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY (a) Remove the 2 screws and brush holder from the generator coil. 5. REMOVE GENERATOR COIL ASSEMBLY (a) Remove the 4 bolts. A128072 A128073 CH A128074 2GR-FE CHARGING – GENERATOR (b) Using SST, remove the generator coil assembly. SST 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011) Turn SST CH–17 SST Hold A118275E01 6. REMOVE GENERATOR ROTOR ASSEMBLY (a) Remove the generator washer. A118365E01 (b) Remove the generator rotor assembly. A118367E01 7. REMOVE GENERATOR DRIVE END FRAME BEARING (a) Remove the 4 screws and retainer plate from the drive end frame. A128076 (b) Using SST and a hammer, tap out the drive end frame bearing from the drive end frame. SST 09950-60010 (09951-00250), 09950-70010 (09951-07100) SST CH A128077E01 CH–18 2GR-FE CHARGING – GENERATOR INSPECTION Free 1. INSPECT GENERATOR CLUTCH PULLEY (a) Hold the center of the pulley, and confirm that the outer ring turns counterclockwise and does not turn clockwise. If the result is not as specified, replace the clutch pulley. 2. INSPECT GENERATOR BRUSH HOLDER ASSEMBLY (a) Using vernier calipers, measure the length of the exposed brushes. Standard exposed length: 9.5 to 11.5 mm (0.374 to 0.453 in.) Minimum exposed length: 4.5 mm (0.177 in.) If the exposed length is less than the minimum, replace the brush holder assembly. 3. INSPECT GENERATOR ROTOR ASSEMBLY (a) Check that the generator rotor bearing is not rough or worn. If necessary, replace the generator rotor assembly. Lock A128078E01 Length A128079E01 A079306E02 Slip Rings (b) Check the generator rotor for an open circuit. (1) Using an ohmmeter, measure the resistance between the slip rings. Standard resistance Ohmmeter Condition Specified condition Approx. 20°C (68°F) 2.3 to 2.7 Ω If the result is not as specified, replace the generator rotor assembly. B012264E08 (c) Check the rotor for a short to ground. (1) Using an ohmmeter, measure the resistance between the slip ring and rotor. Standard resistance Ohmmeter Rotor CH Slip Ring Tester condition Specified condition Slip ring - Rotor 1 MΩ or higher If the result is not as specified, replace the generator rotor assembly. B012265E01 2GR-FE CHARGING – GENERATOR CH–19 (d) Using vernier calipers, measure the slip ring diameter. Standard diameter: 14.2 to 14.4 mm (0.559 to 0.567 in.) Minimum diameter: 14.0 mm (0.551 in.) If the diameter is less than the minimum, replace the generator rotor assembly. Diameter A124106E01 4. INSPECT GENERATOR DRIVE END FRAME BEARING (a) Check that the drive end frame bearing is not rough or worn. If necessary, replace the drive end frame bearing. A128080 REASSEMBLY 1. SST INSTALL GENERATOR DRIVE END FRAME BEARING (a) Using SST and a press, press in a new generator drive end frame bearing. SST 09950-60010 (09951-00470), 09950-70010 (09951-07100) A128081E01 (b) Fit the tabs on the retainer plate into the cutouts on the drive end frame to install the retainer plate. (c) Install the 4 screws. Torque: 2.3 N*m (23 kgf*cm, 20 in.*lbf) Tab 2. INSTALL GENERATOR ROTOR ASSEMBLY (a) Place the drive end frame on the clutch pulley. Cutout A137712E01 (b) Install the generator rotor assembly to the drive end frame. CH A118367E01 CH–20 2GR-FE CHARGING – GENERATOR (c) Place a new generator washer on the generator rotor. A118365E01 3. Deep socket wrench (21 mm) INSTALL GENERATOR COIL ASSEMBLY (a) Using a deep socket wrench (21 mm) and a press, slowly press in the generator coil assembly. A128082E01 (b) Install the 4 bolts. Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf) A128074 4. Pin INSTALL GENERATOR BRUSH HOLDER ASSEMBLY (a) While pushing the 2 brushes into the generator brush holder assembly, insert a φ1.0 mm (0.039 in.) pin into the brush holder hole. A079315E04 (b) Install the brush holder assembly to the generator coil with the 2 screws. Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf) (c) Pull out the pin from the generator brush holder. CH Pin A079316E02 2GR-FE CHARGING – GENERATOR CH–21 5. INSTALL GENERATOR TERMINAL INSULATOR (a) Install the terminal insulator to the generator coil. NOTICE: Pay attention to installation direction of the terminal insulator. 6. INSTALL GENERATOR REAR END COVER (a) Install the generator rear end cover to the generator coil with the 3 nuts. Torque: 4.6 N*m (47 kgf*cm, 41 in.*lbf) 7. REMOVE GENERATOR CLUTCH PULLEY (a) Temporarily install the clutch pulley onto the rotor shaft. A128083E01 A128071 (b) Set SST (A) and (B). SST 09820-63020 SST (A) SST (B) A128084E01 (c) Clamp SST (A) in a vise. (d) Place the rotor shaft end into SST (A). SST (A) Rotor Shaft SST (B) A135194E01 (e) Fit SST (B) to the clutch pulley. Clutch Pulley SST (B) SST (B) A135195E01 CH CH–22 2GR-FE CHARGING – GENERATOR (f) Tighten the pulley by turning SST (B) in the direction shown in the illustration. Torque: 111 N*m (1,125 kgf*cm, 81 ft.*lbf) NOTICE: The torque shown above should be used for tightening without using the SST. When the SST is used for tightening, the torque should be calculated based on the length of the SST (See page IN-6). (g) Remove the generator assembly from the SST. (h) Check that the clutch pulley rotates smoothly. (i) Install a new clutch pulley cap to the clutch pulley. SST (B) 100 mm (3.937 in.) A135208E01 INSTALLATION 1. INSTALL GENERATOR ASSEMBLY (a) Install the bracket with the bolt. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) A135391 (b) Install the wire harness clamp stay. Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) A128066 (c) Connect the wire harness clamp. (d) Install the generator assembly to the cylinder block with the bolt. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) A133867 CH 2GR-FE CHARGING – GENERATOR CH–23 (e) Install the 2 bolts. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) A133866 (f) Connect the generator connector to the generator assembly. (g) Install the generator wire with the nut. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) (h) Install the terminal cap. (i) Connect the 2 wire harness clamps. (j) Connect the magnetic clutch connector to the compressor and magnetic clutch. 2. INSTALL V-RIBBED BELT (See page EM-7) 3. INSTALL RADIATOR ASSEMBLY (See page CO-31) 4. INSTALL FAN SHROUD (See page CO-32) 5. INSTALL RADIATOR SUPPORT UPPER (See page CO-32) 6. CONNECT NO. 1 OIL COOLER OUTLET TUBE (See page CO-33) 7. CONNECT NO. 1 OIL COOLER INLET TUBE (See page CO-33) 8. CONNECT RADIATOR OUTLET HOSE (See page CO33) 9. CONNECT RADIATOR INLET HOSE (See page CO33) A133865 10. CONNECT RADIATOR RESERVE TANK HOSE (See page CO-34) 11. INSTALL FRONT BUMPER ENERGY ABSORBER (See page ET-10) 12. INSTALL FRONT BUMPER ASSEMBLY (w/o Fog Light) (See page ET-13) 13. INSTALL FRONT BUMPER ASSEMBLY (w/ Fog Light) (See page ET-14) 14. INSTALL NO. 1 AIR CLEANER INLET (See page EM49) 15. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See page ES-506) 16. INSTALL AIR CLEANER INLET ASSEMBLY (See page EM-50) CH CH–24 2GR-FE CHARGING – GENERATOR 17. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page EM-51) 18. ADD ENGINE COOLANT (See page CO-6) 19. CHECK FOR ENGINE COOLANT LEAKS (See page CO-1) 20. INSTALL V-BANK COVER SUB-ASSEMBLY (See page EM-52) 21. INSTALL COOL AIR INTAKE DUCT SEAL (See page EM-52) 22. INSTALL FRONT FENDER APRON SEAL RH 23. INSTALL ENGINE UNDER COVER RH 24. INSTALL ENGINE UNDER COVER LH 25. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH 26. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH 27. INSTALL FRONT WHEEL RH (See page EM-7) CH SEAT BELT – SEAT BELT WARNING SYSTEM SB–1 SEAT BELT WARNING SYSTEM SEAT BELT RESTRAINTS PARTS LOCATION CLOCK ASSEMBLY: FRONT PASSENGER SEAT BELT WARNING LIGHT COMBINATION METER ASSEMBLY CENTER AIRBAG SENSOR ASSEMBLY - DRIVER SIDE SEAT BELT WARNING LIGHT SB MAIN BODY ECU (INSTRUMENT PANEL J/B) FRONT SEAT INNER BELT ASSEMBLY (FRONT RH) - GAUGE NO. 2 FUSE FRONT SEAT INNER BELT ASSEMBLY (FRONT LH) B137076E01 SB–2 SEAT BELT – SEAT BELT WARNING SYSTEM SYSTEM DIAGRAM F1 Combination Meter Assembly CANH 9 Center Airbag Sensor Assembly Occupant Detection ECU CANH BSW CANL BGN Front Seat Inner Belt RH P/BE CANL FSP+ FSR+ FSP- FSR- Front Seat Inner Belt LH Road Sensor FL SV1 DBE+ SIG1 DBE- Road Sensor RL SGD1 SV3 SB SIG3 Road Sensor FR SGD3 SV2 SIG2 F3 Clock Assembly 10 SGD2 SV4 PBEW IG 19 Road Sensor RR 3 from GAUGE No. 2 fuse GND1 SIG4 SGD4 : CAN B137075E01 SEAT BELT – SEAT BELT WARNING SYSTEM SB–3 SYSTEM DESCRIPTION 1. 2. Driver seat belt warning light (a) When the driver seat belt is not fastened with the ignition switch on (IG), the driver seat belt warning light on the combination meter assembly comes on to inform the driver. The center airbag assembly detects the driver seat belt status and sends signals to the combination meter assembly using CAN. Passenger seat belt warning (a) When the passenger seat belt is not fastened with the ignition switch on (IG) and the passenger seat occupied, check that the passenger seat belt warning light on the clock display blinks. The combination meter assembly displays the passenger seat belt status and whether the passenger seat is occupied. SB SB–4 SEAT BELT – SEAT BELT WARNING SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use the following procedures to troubleshoot the seat belt warning system. • *: Use the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding to the next step. NEXT 3 CHECK COMMUNICATION FUNCTION OF CAN COMMUNICATION SYSTEM (CAN)* (a) Use the intelligent tester to check if the CAN Communication System (CAN) is functioning normally. Result SB B Result Proceed to CAN DTC is not output A CAN DTC is output B GO TO CAN COMMUNICATION SYSTEM A 4 PROBLEM SYMPTOMS TABLE HINT: See page SB-4. NEXT 5 OVERALL ANALYSIS AND TROUBLESHOOTING* (a) DATA LIST / ACTIVE TEST (See page SB-7) (b) Terminals of ECU (See page SB-4) (c) On-vehicle Inspection (See page SB-7) NEXT SEAT BELT – SEAT BELT WARNING SYSTEM 6 SB–5 REPAIR OR REPLACE NEXT 7 CONFIRMATION TEST NEXT END SB SB–6 SEAT BELT – SEAT BELT WARNING SYSTEM PROBLEM SYMPTOMS TABLE SEAT BELT WARNING SYSTEM Symptom Driver side seat belt warning light does not operate Front passenger seat belt warning light does not operate SB Suspected area See page 1. Front seat inner belt LH SB-9 2. Center airbag sensor assembly SB-9 3. Combination meter assembly SB-9 4. Wire harness SB-9 1. Front seat inner belt RH SB-11 2. Occupant detection ECU SB-11 3. Road sensor SB-11 4. Center airbag sensor assembly SB-11 5. Combination meter assembly SB-11 6. Clock assembly SB-11 7. Wire harness SB-11 SB–7 SEAT BELT – SEAT BELT WARNING SYSTEM TERMINALS OF ECU 1. CLOCK ASSEMBLY F3 B140734E01 Standard voltage Terminal No. (Symbols) Terminal Description Condition Specified Condition F3-3 (IG) - Body ground Power supply Ignition switch OFF → ON (IG) Below 1 V → 10 to 14 V Terminal No. (Symbols) Terminal Description Condition Specified Condition F3-10 (PBEW) - Body ground Passenger seat belt signal The passenger seat is occupied, seat belt is fastened → unfastened Below 1 Ω → 10 kΩ or higher F3-19 (GND1) - Body ground Ground Always Below 1 Ω Standard resistance SB SB–8 SEAT BELT – SEAT BELT WARNING SYSTEM DIAGNOSIS SYSTEM 1. DESCRIPTION (a) The seat belt warning system data can be read from the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the intelligent tester to check for malfunctions and perform repairs. 2. CHECK DLC3 CG SG CANH SIL BAT CANL H100769E16 (a) The ECU uses ISO 15765-4 communication. The terminal arrangement of the DLC3 complies with SAE J 1962 and matches the ISO 15765-4 format. SB DLC3 Intelligent Tester C131977E01 Symbols (Terminals No.) Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 10 to 14 V CANH (6) - CANL (14) CAN bus line Ignition switch OFF* 54 to 69 Ω CANH (6) - CG (4) HIGH-level CAN bus line Ignition switch OFF* 200 Ω or more CANL (14) - CG (4) LOW-level CAN bus line Ignition switch OFF* 200 Ω or more CANH (6) - BAT (16) HIGH-level CAN bus line Ignition switch OFF* 6 kΩ or more CANL (14) - BAT (16) LOW-level CAN bus line Ignition switch OFF* 6 kΩ or more NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the door. SEAT BELT – SEAT BELT WARNING SYSTEM SB–9 If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of the intelligent tester to the DLC3, turn the ignition switch on (IG) and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. • If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. SB SB–10 SEAT BELT – SEAT BELT WARNING SYSTEM DATA LIST / ACTIVE TEST 1. ACTIVE TEST Performing the ACTIVE TEST using the intelligent tester allows the meters, indicators and so on to operate without removing any parts. Performing the ACTIVE TEST as the first step in troubleshooting is one way to shorten labor time. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) From the display on the tester, select the "ACTIVE TEST". METER: Item SB Test Details Diagnostic Note D-BELT REMIND D-SEAT BELT indicator light (OFF/ON) Confirm that the vehicle is stopped with the engine idling P-BELT REMIND P-SEAT BELT indicator light (OFF/ON) Confirm that the vehicle is stopped with the engine idling SEAT BELT – SEAT BELT WARNING SYSTEM SB–11 ON-VEHICLE INSPECTION 1. INSPECT DRIVER SIDE SEAT BELT WARNING (a) Turn the ignition switch on (IG). (b) When the driver seat belt is not fastened, check that the driver seat belt warning light on the combination meter blinks. (c) When the driver seat belt is fastened, check that the driver seat belt warning light on the combination meter is off. 2. INSPECT PASSENGER SIDE SEAT BELT WARNING (a) Turn the ignition switch on (IG). (b) When the front passenger seat belt is not fastened with the passenger seat occupied, check that the front passenger seat belt warning light on the clock display blinks. (c) When the front passenger seat belt is fastened with the passenger seat occupied, check that the front passenger seat belt warning light on the clock display is off. 3. INSPECT SEAT BELT WARNING BUZZER HINT: If the buzzer does not sound, the buzzer cancel setting may be set to ON. (a) Turn the ignition switch on (IG). (b) When the vehicle is driven at approximately 25 km/h (16 mph) or more while the driver or front passenger seat belt is not being fastened, check that the buzzer in the combination meter assembly sounds at an interval of 1.2 seconds for 30 seconds. (c) Check that the buzzer sounds at an interval of 0.4 seconds for 90 seconds. (d) Check that the buzzer stops 2 minutes after the buzzer starts sounding. (e) After the buzzer has stopped, turn the ignition switch off and then start the engine again. Drive the vehicle at approximately 25 km/h (16 mph) or more while the driver or front passenger seat belt is not being fastened, and then check that the buzzer sounds again. (f) After the buzzer has stopped, fasten the driver and front passenger seat belts. Drive the vehicle at approximately 25 km/h (16 mph) or more and unfasten the driver or front passenger seat belt, and then check that the buzzer sounds again. (g) After the buzzer has stopped, move the shift lever to the R position, and then move it to the D position. Drive the vehicle at approximately 25 km/h (16 mph) or more, and then check that the buzzer sounds again. SB SB–12 SEAT BELT – SEAT BELT WARNING SYSTEM Driver Side Seat Belt Warning Light does not Operate DESCRIPTION When the ignition switch is on (IG), the center airbag sensor assembly transmits front seat inner belt state signals to the combination meter assembly through CAN. If the driver seat belt is not fastened, the combination meter assembly blinks the driver seat belt warning light. If the seat belt is fastened, the warning light goes off. NOTICE: The seat belt warning system uses CAN. Before troubleshooting the seat belt warning system, perform "COMMUNICATION FUNCTION CHECK" by following "HOW TO PROCEED WITH TROUBLESHOOTING" to confirm that the communication systems are normal. WIRING DIAGRAM F1 Combination Meter Assembly CANH CANL 12 17 13 18 22 CANH DBE+ CANL DBE- 11 1 12 3 E2 IG+ SB N3 Front Seat Inner Belt Assembly LH Center Airbag Sensor Assembly 13 from GAUGE No. 2 fuse : CAN B137085E01 INSPECTION PROCEDURE 1 CHECK FOR DTCs (a) Check for DTCs. Result Result Proceed to Output DTC (CAN communication) A Output DTC (Airbag system) B No output DTC C A GO TO CAN COMMUNICATION SYSTEM B GO TO AIRBAG SYSTEM SB–13 SEAT BELT – SEAT BELT WARNING SYSTEM C 2 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (a) Operate the intelligent tester according to the steps on the display and select "ACTIVE TEST". METER Item Test Details Diagnostic Note D-BELT REMIND D-SEAT BELT indicator light (OFF/ON) Confirm that the vehicle is stopped with the engine idling OK: Switch condition (ON/OFF) can be switched by "ACTIVE TEST". NG REPLACE COMBINATION METER ASSEMBLY OK END SB SB–14 SEAT BELT – SEAT BELT WARNING SYSTEM Front Passenger Side Seat Belt Warning Light Malfunction DESCRIPTION The occupant detection ECU detects the state of the front seat inner belt assembly RH and road sensor when the front passenger seat is occupied with the ignition switch on (IG). If the front passenger seat belt is not fastened, the front seat belt warning light on the clock display blinks. If the seat belt is fastened, the warning light goes off. WIRING DIAGRAM F1 Combination Meter Assembly CANH 9 Center Airbag Sensor Assembly Occupant Detection ECU CANH P/SB BSW FSP+ FSR+ CANL CANL Front Seat Inner Belt RH BGN FSP- FSRRoad Sensor FL SV1 SIG1 F3 Clock Assembly SB 10 PBEW SGD1 SV3 IG 19 Road Sensor RL 3 from GAUGE No. 2 fuse Road Sensor FR SIG3 GND1 SGD3 SV2 SIG2 Road Sensor RR SGD2 SV4 SIG4 SGD4 : CAN B140735E01 SB–15 SEAT BELT – SEAT BELT WARNING SYSTEM INSPECTION PROCEDURE 1 CHECK FOR DTCs (a) Check for DTCs. Result Result Proceed to No output DTC A Output DTC (CAN communication) B Output DTC (Occupant detection) C B GO TO CAN COMMUNICATION SYSTEM C GO TO OCCUPANT CLASSIFICATION SYSTEM A 2 CHECK WIRE HARNESS (BATTERY POSITIVE AND BODY GROUND) (a) Disconnect the clock assembly connector. (b) Measure the voltage and resistance according to the value(s) in the table below. Standard voltage F3 Tester Connection Condition Specified Condition F3-3 (IG) - Body ground Ignition switch on (IG) 10 to 14 V Standard resistance B137073E01 Tester Connection Condition Specified Condition F3-19 (GND1) - Body ground Always Below 1 Ω NG REPAIR OR REPLACE GAUGE NO. 2 FUSE, HARNESS OR CONNECTOR OK 3 CHECK CLOCK ASSEMBLY (a) Disconnect the clock assembly connector. (b) Apply battery voltage to the connector according to the table below. Standard F3 Condition Battery positive (+) → Terminal 3 (IG) Battery negative (-) → Terminal 10 (PBEW), 19 (GND1) B137074E01 NG Specified Condition Lights up (Seat belt warning light) REPLACE CLOCK ASSEMBLY SB SB–16 SEAT BELT – SEAT BELT WARNING SYSTEM OK 4 CHECK WIRE HARNESS (CLOCK ASSEMBLY - COMBINATION METER ASSEMBLY) (a) Disconnect the combination meter assembly and clock assembly connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Clock Assembly: F3 PBEW Tester Connection Condition Specified Condition F1-9 (P/SB) - F3-10 (PBEW) Always Below 1 Ω F1-9 (P/SB) - Body ground Always 10 kΩ or higher NG Combination Meter Assembly: P/SB F1 B137077E01 OK SB REPLACE COMBINATION METER ASSEMBLY REPAIR OR REPLACE HARNESS OR CONNECTOR SB–14 SEAT BELT – FRONT SEAT INNER BELT ASSEMBLY FRONT SEAT INNER BELT ASSEMBLY SEAT BELT RESTRAINTS COMPONENTS for Manual Seat: FRONT SEAT HEADREST ASSEMBLY 42 (428, 31) INNER SEAT TRACK BRACKET COVER FRONT SEAT INNER BELT ASSEMBLY 37 (377, 27) SEAT TRACK COVER 37 (377, 27) FRONT SEAT ASSEMBLY for Power Seat: SB FRONT SEAT HEADREST ASSEMBLY 42 (428, 31) INNER SEAT TRACK BRACKET COVER FRONT SEAT INNER BELT ASSEMBLY 37 (377, 27) SEAT TRACK COVER 37 (377, 27) FRONT SEAT ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B132031E01 SEAT BELT – FRONT SEAT INNER BELT ASSEMBLY SB–15 REMOVAL for Driver seat: for Passenger seat: Clamp B132032E02 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (for Manual Seat) CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment (See page RS-1). 2. REMOVE FRONT SEAT HEADREST ASSEMBLY 3. REMOVE SEAT TRACK COVER (for Manual Seat) (See page SE-16) 4. REMOVE INNER SEAT TRACK BRACKET COVER (for Manual Seat) (See page SE-16) 5. REMOVE FRONT SEAT ASSEMBLY (for Manual Seat) (See page SE-16) 6. REMOVE SEAT TRACK COVER (for Power Seat) (See page SE-30) 7. REMOVE INNER SEAT TRACK BRACKET COVER (for Power Seat) (See page SE-30) 8. REMOVE FRONT SEAT ASSEMBLY (for Power Seat) (See page SE-30) 9. REMOVE FRONT SEAT INNER BELT ASSEMBLY (for Manual Seat) (a) for Driver seat: (1) Disconnect the connectors and disengage the 4 clamps. (b) for Passenger seat: (1) Disconnect the connector and disengage the 3 clamps. SB SB–16 SEAT BELT – FRONT SEAT INNER BELT ASSEMBLY (c) Remove the nut and front seat inner belt assembly. B132034 10. REMOVE FRONT SEAT INNER BELT ASSEMBLY (for Power Seat) (a) for Driver seat: (1) Disconnect the connectors and disengage the 4 clamps. (b) for Passenger seat: (1) Disconnect the connector and disengage the 3 clamps. for Driver seat: for Passenger seat: SB Clamp B132033E01 (c) Remove the nut and front seat inner belt assembly. B132034 INSTALLATION 1. Protruding Parts B132035E01 INSTALL FRONT SEAT INNER BELT ASSEMBLY (for Manual Seat) (a) Install the front seat inner belt assembly with the nut. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) NOTICE: Do not allow the anchor part of the front seat inner belt assembly to overlap the protruding parts of the front seat adjuster. SEAT BELT – FRONT SEAT INNER BELT ASSEMBLY SB–17 (b) for Driver seat: (1) Connect the connectors and engage the 4 clamps. (c) for Passenger seat: (1) Connect the connector and engage the 3 clamps. for Driver seat: for Passenger seat: Clamp B132032E02 2. Protruding Parts INSTALL FRONT SEAT INNER BELT ASSEMBLY (for Power Seat) (a) Install the front seat inner belt assembly with the nut. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) NOTICE: Do not allow the anchor part of the front seat inner belt assembly to overlap the protruding parts of the front seat adjuster. B132035E01 (b) for Driver seat: (1) Connect the connectors and engage the 4 clamps. (c) for Passenger seat: (1) Connect the connector and engage the 3 clamps. for Driver seat: 3. INSTALL FRONT SEAT ASSEMBLY (for Manual Seat) (See page SE-24) 4. INSTALL INNER SEAT TRACK BRACKET COVER (for Manual Seat) (See page SE-25) 5. INSTALL SEAT TRACK COVER (for Manual Seat) (See page SE-25) 6. INSTALL FRONT SEAT ASSEMBLY (for Power Seat) (See page SE-41) 7. INSTALL INNER SEAT TRACK BRACKET COVER (for Power Seat) (See page SE-42) 8. INSTALL SEAT TRACK COVER (for Power Seat) (See page SE-42) for Passenger seat: Clamp B132033E01 SB SB–18 SEAT BELT – FRONT SEAT INNER BELT ASSEMBLY 9. INSTALL FRONT SEAT HEADREST ASSEMBLY 10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (for Manual Seat) 11. PERFORM ZERO POINT CALIBRATION AND SENSITIVITY CHECK (for Front Passenger Seat) (See page RS-242) 12. INSPECT SLIDE ADJUSTER LOCK (for Manual Seat) 13. INSPECT FRONT SEAT ASSEMBLY (for Power Seat) (See page SE-42) 14. INSPECT SRS WARNING LIGHT (See page RS-32) SB SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY SB–19 FRONT SEAT OUTER BELT ASSEMBLY SEAT BELT RESTRAINTS COMPONENTS UPPER CENTER PILLAR GARNISH REAR DOOR OPENING TRIM WEATHERSTRIP FRONT DOOR OPENING TRIM WEATHERSTRIP REAR DOOR SCUFF PLATE LOWER CENTER PILLAR GARNISH 42 (428, 31) FRONT SHOULDER BELT ANCHOR ADJUSTER ASSEMBLY 42 (428, 31) FRONT DOOR SCUFF PLATE 42 (428, 31) FRONT SEAT OUTER BELT ASSEMBLY 7.5 (77, 66 in.*lbf) 42 (428, 31) LAP BELT OUTER ANCHOR COVER 42 (428, 31) N*m (kgf*cm, ft.*lbf) : Specified torque B132005E01 SB SB–20 SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment (See page RS-1). 2. REMOVE LAP BELT OUTER ANCHOR COVER (a) Disengage the 3 claws and remove the lap belt outer anchor cover. 3. DISCONNECT FRONT SEAT OUTER BELT ASSEMBLY (a) Remove the bolt and disconnect the floor end of the front seat outer belt assembly. 4. REMOVE FRONT DOOR SCUFF PLATE (See page IR24) 5. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP 6. REMOVE REAR DOOR SCUFF PLATE (See page IR24) 7. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP 8. REMOVE LOWER CENTER PILLAR GARNISH (See page IR-25) 9. REMOVE UPPER CENTER PILLAR GARNISH (See page IR-26) B131995 B131996 SB 10. DISCONNECT FRONT SEAT OUTER BELT ASSEMBLY (a) Remove the nut and disconnect the shoulder anchor of the front seat outer belt assembly. B131997 SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY SB–21 11. REMOVE FRONT SHOULDER BELT ANCHOR ADJUSTER ASSEMBLY (a) Remove the 2 bolts and the front shoulder belt anchor adjuster assembly. B132001 12. REMOVE FRONT SEAT OUTER BELT ASSEMBLY (a) Using a screwdriver, pull out the locking button in the direction shown by the arrow to release the lock, and disconnect the connector as shown in the illustration. HINT: Tape the screwdriver tip before use. B132002 (b) Remove the 2 bolts and the front seat outer belt assembly. SB B131998 INSTALLATION 1. 45° B132004E01 (b) Temporarily install the front seat outer belt assembly with the 2 bolts. (c) Fully tighten the upper side bolt first, then the lower side bolt to install the front seat outer belt assembly. Torque: For upper bolt 7.5 N*m (77 kgf*cm, 66 in.*lbf) For lower bolt 42 N*m (428 kgf*cm, 31 ft.*lbf) (1) (2) INSTALL FRONT SEAT OUTER BELT ASSEMBLY (a) Check the degree of tilt when the ELR begins to lock. (1) Check that the belt does not lock at less than 15 degrees of tilt in any direction but locks at over 45 degrees of tilt while gently pulling the belt. NOTICE: Do not disassemble the retractor. B131998E01 SB–22 SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (d) Connect the connector and lock the locking button as shown in the illustration. NOTICE: Securely lock the locking button. B132003 2. INSTALL FRONT SHOULDER BELT ANCHOR ADJUSTER ASSEMBLY (a) Install the front shoulder belt anchor adjuster assembly with the 2 bolts. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) 3. CONNECT FRONT SEAT OUTER BELT ASSEMBLY (a) Connect the shoulder anchor of the front seat outer belt assembly with the nut. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) 4. INSTALL UPPER CENTER PILLAR GARNISH (See page IR-53) 5. INSTALL LOWER CENTER PILLAR GARNISH (See page IR-53) 6. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP (See page IR-55) 7. INSTALL REAR DOOR SCUFF PLATE (See page IR56) 8. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP (See page IR-54) 9. INSTALL FRONT DOOR SCUFF PLATE (See page IR54) B132001 SB B131997 B131996 10. CONNECT FRONT SEAT OUTER BELT ASSEMBLY (a) Install the floor end of the front seat outer belt assembly with the bolt. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) (b) Check if the ELR locks. NOTICE: The check should be performed with the outer belt assembly installed. (1) With the belt assembly installed, check that the belt locks when it is pulled out quickly. SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY SB–23 11. INSTALL LAP BELT OUTER ANCHOR COVER (a) Engage the 3 claws and install the lap belt outer anchor cover. 12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 13. INSPECT SRS WARNING LIGHT (See page RS-32) B131995 SB SB–24 SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY DISPOSAL HINT: When scrapping vehicles equipped with a seat belt pretensioner or disposing of a front seat outer belt (with a seat belt pretensioner), always deploy the seat belt pretensioner first in accordance with the procedures described below. If any abnormality occurs during deployment of the seat belt pretensioner, contact the SERVICE DEPT. of the TOYOTA MOTOR SALES, U.S.A., INC. 1. SB DISPOSE OF FRONT SEAT OUTER BELT ASSEMBLY (WHEN INSTALLED IN VEHICLE) NOTICE: • Never dispose of a front seat outer belt assembly with a pretensioner that has not been deployed. • The seat belt pretensioner produces an exploding sound when it deploys, so perform the operation outdoors where it will not disturb local residents. • When deploying a front seat outer belt (with a seat belt pretensioner), perform the operation at least 10 m (33 ft) away from the front seat outer belt. • Use gloves and safety glasses when handling a front seat belt with a deployed pretensioner. • Always wash your hands with water after completing the operation. • Do not apply water, etc. to a front seat outer belt with a deployed pretensioner. • When deploying the seat belt pretensioner, always use the specified SST (SRS airbag deployment tool). Perform the operation in a place away from electrical interference. • Be sure to follow the procedures listed below when deploying the seat belt pretensioner. (a) Check the function of SST. SST 09082-00700, 09082-00770 CAUTION: When deploying the seat belt pretensioner, always use the specified SST. SST B050515E11 SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY Battery SST SB–25 (1) Connect the red clip of the SST to the battery positive (+) terminal, and the black clip to the battery negative (-) terminal. HINT: At this time, do not connect the yellow connector that will later be connected to the seat belt pretensioner. B050511E10 (2) Press the SST deployment switch, and check that the LED of the SST deployment switch lights up. CAUTION: If the LED is lit when the deployment switch is not pressed, the SST may be malfunctioning. Therefore, do not use the SST. SST B050514E10 SST (b) Connect SST. (1) Connect 2 SST, and then connect them to the front seat outer belt pretensioner. SST 09082-00700, 09082-00770 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the pretensioner connector. SST SB B124247E03 SST 10 m (33 ft) or more B050513E05 (2) Move the SST at least 10 m (33 ft) away from the front of the vehicle. (3) Close all the doors and windows of the vehicle. NOTICE: Do not damage the SST wire harness. (c) Deploy the front seat outer belt pretensioner. (1) Confirm that no one is inside the vehicle or within a 10 m (33 ft) radius of the vehicle. (2) Connect the red clip of the SST to the battery positive (+) terminal, and the black clip to the negative (-) terminal. (3) Press the SST deployment switch to deploy the front seat outer belt pretensioner. HINT: The seat belt pretensioner will deploy at the same time as the LED of the SST illuminates. SB–26 SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (d) Dispose of the front seat outer belt assembly. (1) Remove the front seat outer belt assembly and SST. (2) Place the outer belt in a plastic bag, tie the end tightly, and dispose of it in the same way as other general parts. CAUTION: • The outer belt becomes very hot when the front seat outer belt pretensioner is deployed, so leave it untouched for at least 30 minutes after it has been deployed. • Use gloves and safety glasses when handling an outer belt with a pretensioner that has been deployed. • Always wash your hands with water after completing the operation. • Do not apply water, etc. to a front seat outer belt assembly with a pretensioner that has been deployed. HINT: When scrapping a vehicle, deploy the front seat outer belt pretensioners, and then scrap the vehicle with the deployed outer belt installed. B121579 2. SB DISPOSE OF FRONT SEAT OUTER BELT ASSEMBLY (WHEN NOT INSTALLED IN VEHICLE) NOTICE: • Never dispose of a front seat outer belt assembly with a pretensioner that has not been deployed. • The seat belt pretensioner produces an exploding sound when it deploys, so perform the operation outdoors where it will not disturb local residents. • When deploying a front seat outer belt (with a seat belt pretensioner), perform the operation at least 10 m (33 ft) away from the front seat outer belt. • Use gloves and safety glasses when handling a front seat belt with a deployed pretensioner. • Always wash your hands with water after completing the operation. • Do not apply water, etc. to a front seat outer belt with a deployed pretensioner. • When disposing of a pretensioner equipped front seat outer belt, never deploy the belt in the customer's vehicle. • Be sure to follow the procedures listed below when deploying the seat belt pretensioner. SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY SB–27 (a) Check the function of SST. SST 09082-00700, 09082-00770 CAUTION: When deploying the seat belt pretensioner, always use the specified SST. SST B050515E12 Battery SST (1) Connect the red clip of the SST to the battery positive (+) terminal, and the black clip to the battery negative (-) terminal. HINT: At this time, do not connect the yellow connector that will later be connected to the seat belt pretensioner. B050511E10 (2) Press the SST deployment switch, and check that the LED of the SST deployment switch lights up. CAUTION: If the LED is lit when the deployment switch is not pressed, the SST may be malfunctioning. Therefore, do not use the SST. SST SB B050514E10 SST (b) Connect SST. (1) Connect 2 SST, and then connect them to the front seat outer belt pretensioner. SST 09082-00700, 09082-00770 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the pretensioner connector. SST B124247E03 SST SST B124248E02 (2) Place the outer belt on the ground and cover it with a tire and wheel assembly. NOTICE: Position the front seat outer belt assembly as shown in the illustration. (3) Position and hold the SST at least 10 m (33 ft) away from the wheel. NOTICE: Do not damage the SST wire harness. SB–28 SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY SST 10 m (33 ft) or more B050541E07 B121579 SB (c) Deploy the front seat outer belt pretensioner. (1) Check that no one is within a 10 m (33 ft) radius of the wheel. (2) Connect the red clip of the SST to the battery positive (+) terminal, and the black clip to the battery negative (-) terminal. (3) Press the SST deployment switch to deploy the front seat outer belt pretensioner. HINT: The seat belt pretensioner will deploy at the same time as the LED of the SST illuminates. (d) Dispose of the front seat outer belt assembly. (1) Remove the wheel and SST. (2) Place the outer belt in a plastic bag, tie the end tightly, and dispose of it in the same way as other general parts. CAUTION: • The outer belt becomes very hot when the front seat outer belt pretensioner is deployed, so leave it untouched for at least 30 minutes after it has been deployed. • Use gloves and safety glasses when handling an outer belt with a pretensioner that has been deployed. • Always wash your hands with water after completing the operation. • Do not apply water, etc. to a front seat outer belt assembly with a pretensioner that has been deployed. HINT: When scrapping a vehicle, deploy the front seat outer belt pretensioners, and then scrap the vehicle with the deployed outer belt installed. SB–28 SEAT BELT – REAR SEAT INNER BELT ASSEMBLY REAR SEAT INNER BELT ASSEMBLY SEAT BELT RESTRAINTS COMPONENTS for Fixed Seat Type: REAR SEAT HEADREST ASSEMBLY REAR CENTER SEAT HEADREST ASSEMBLY REAR SEAT BACK ASSEMBLY SB 18 (184, 13) 18 (184, 13) REAR SEAT CUSHION ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B136589E02 SB–29 SEAT BELT – REAR SEAT INNER BELT ASSEMBLY for Fold Down Seat Type: REAR SEAT HEADREST ASSEMBLY REAR CENTER SEAT HEADREST ASSEMBLY 18 (184, 13) 18 (184, 13) 18 (184, 13) REAR SIDE SEAT BACK ASSEMBLY RH SB SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH 18 (184, 13) REAR SEAT CUSHION ASSEMBLY REAR SIDE SEAT BACK ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque B136564E02 SB–30 SEAT BELT – REAR SEAT INNER BELT ASSEMBLY for Reclining Seat Type: REAR SEAT HEADREST ASSEMBLY 18 (184, 13) REAR CENTER SEAT HEADREST ASSEMBLY CENTER SEAT BACK ASSEMBLY REAR SEAT BACK COVER 18 (184, 13) 18 (184, 13) SB 18 (184, 13) SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH REAR SEAT BACK COVER 18 (184, 13) SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH REAR SEAT CUSHION ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B139095E03 SEAT BELT – REAR SEAT INNER BELT ASSEMBLY SB–31 ROOF SIDE INNER GARNISH RH REAR DOOR OPENING TRIM WEATHERSTRIP RH for Reclining Seat Type: 18 (184, 13) RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY RH REAR DOOR SCUFF PLATE RH ROOF SIDE INNER GARNISH LH for Reclining Seat Type: SB REAR DOOR OPENING TRIM WEATHERSTRIP LH 18 (184, 13) RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY LH REAR DOOR SCUFF PLATE LH N*m (kgf*cm, ft.*lbf) : Specified torque B132018E01 SB–32 SEAT BELT – REAR SEAT INNER BELT ASSEMBLY for TMC made: for Reclining Seat Type: PACKAGE TRAY TRIM PANEL ASSEMBLY PACKAGE TRAY TRIM PANEL ASSEMBLY REAR SEAT SHOULDER BELT COVER CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY RH REAR SEAT OUTER BELT ASSEMBLY REAR SEAT SHOULDER BELT COVER 42 (428, 31) 18 (184, 13) REAR SEAT SHOULDER BELT HOLE COVER 18 (184, 13) 42 (428, 31) CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH 42 (428, 31) 42 (428, 31) SB REAR SEAT INNER WITH CENTER BELT ASSEMBLY RH REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH REAR SEAT OUTER BELT ASSEMBLY for Fold Down Seat Type: 42 (428, 31) CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY RH 18 (184, 13) CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque B132019E02 SB–33 SEAT BELT – REAR SEAT INNER BELT ASSEMBLY for TMMK made: for Reclining Seat Type: PACKAGE TRAY TRIM PANEL ASSEMBLY PACKAGE TRAY TRIM PANEL ASSEMBLY REAR SEAT SHOULDER BELT COVER CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY RH REAR SEAT OUTER BELT ASSEMBLY REAR SEAT SHOULDER BELT COVER 42 (428, 31) 18 (184, 13) REAR SEAT SHOULDER BELT HOLE COVER 18 (184, 13) 42 (428, 31) CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH 42 (428, 31) 42 (428, 31) SB REAR SEAT INNER WITH CENTER BELT ASSEMBLY RH REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH REAR SEAT OUTER BELT ASSEMBLY for Fold Down Seat Type: 42 (428, 31) CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY RH 18 (184, 13) CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque B142737E01 SB–34 SEAT BELT – REAR SEAT INNER BELT ASSEMBLY REMOVAL 1. REMOVE REAR SEAT CUSHION ASSEMBLY (See page SE-77) 2. REMOVE REAR SEAT HEADREST ASSEMBLY 3. REMOVE REAR CENTER SEAT HEADREST ASSEMBLY 4. REMOVE REAR SEAT BACK ASSEMBLY (for Fixed Seat Type) (See page SE-77) 5. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-47) 6. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) (See page SE-47) 7. REMOVE REAR SIDE SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-48) 8. REMOVE REAR SIDE SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) (See page SE-48) 9. REMOVE REAR SEAT BACK COVER (for Reclining Seat Type) (See page SE-63) 10. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Reclining Seat Type) (See page SE-63) SB 11. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Reclining Seat Type) (See page SE-64) 12. REMOVE CENTER SEAT BACK ASSEMBLY (for Reclining Seat Type) (See page SE-64) 13. REMOVE REAR DOOR SCUFF PLATE LH (See page IR-24) 14. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH 15. REMOVE REAR DOOR SCUFF PLATE RH (See page IR-24) 16. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH 17. REMOVE RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY LH (for Reclining Seat Type) (See page SE-68) 18. REMOVE RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY RH (for Reclining Seat Type) HINT: Use the same procedures for the RH side and the LH side. 19. REMOVE CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH (See page SB-66) SEAT BELT – REAR SEAT INNER BELT ASSEMBLY SB–35 20. REMOVE CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY RH HINT: Use the same procedures for the RH side and the LH side. 21. REMOVE REAR SEAT INNER WITH CENTER BELT ASSEMBLY RH (for TMC Made) (a) Remove the bolt and the rear seat inner with center belt assembly RH. B132015 22. REMOVE REAR SEAT INNER WITH CENTER BELT ASSEMBLY RH (for TMMK Made) (a) Remove the nut and the rear seat inner with center belt assembly RH. B142738 23. DISCONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH (for TMC Made) (a) Remove the bolt and disconnect the floor end of the rear seat inner with center belt assembly LH. B132000 24. DISCONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH (for TMMK Made) (a) Remove the nut and disconnect the floor end of the rear seat inner with center belt assembly LH. 25. REMOVE ROOF SIDE INNER GARNISH LH (See page IR-26) 26. REMOVE ROOF SIDE INNER GARNISH RH (See page IR-26) B142739 SB SB–36 SEAT BELT – REAR SEAT INNER BELT ASSEMBLY 27. DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) (a) Remove the bolt and disconnect the floor end of the rear seat outer belt assembly. B132006 28. DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) (a) Remove the bolt and disconnect the floor end of the rear seat outer belt assembly. B132007 29. REMOVE REAR SEAT SHOULDER BELT COVER (a) Using a screwdriver, disengage the 4 claws and remove the rear seat shoulder belt cover. HINT: • Tape the screwdriver tip before use. • Use the same procedures for the RH side and the LH side. Protective Tape SB B132011E01 30. REMOVE REAR SEAT SHOULDER BELT HOLE COVER (a) Using a screwdriver, disengage the 4 claws and remove the rear seat shoulder belt hole cover. HINT: Tape the screwdriver tip before use. Protective Tape B132013E02 SEAT BELT – REAR SEAT INNER BELT ASSEMBLY SB–37 31. REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY (a) Disconnect the connector. (b) Disengage the 4 clips and the 5 claws. (c) Pass the 3 rear seat belt floor anchors through the package tray trim panel assembly then remove the package tray trim panel assembly. B132022 32. REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY (for Reclining Seat Type) (a) Disconnect the connector. (b) Disengage the 4 clips and the 5 claws. (c) Pass the 3 rear seat belt floor anchors through the package tray trim panel assembly then remove the package tray trim panel assembly. SB B132139 33. REMOVE REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH (a) Remove the bolt and the rear seat inner with center belt assembly LH. B132025 SB–38 SEAT BELT – REAR SEAT INNER BELT ASSEMBLY INSTALLATION 1. 45° B132023E01 INSTALL REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH (a) Check the degree of the tilt when the ELR begins to lock. (1) Check that the belt does not lock at less than 15 degrees of tilt in any direction but locks at over 45 degrees of tilt while gently pulling the belt. NOTICE: Do not disassemble the retractor. (b) Align the claw with the seat belt positioning hole and install the rear seat inner with center belt assembly LH with the bolt. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) Claw B132026E01 2. SB B132022 INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY (a) Pass the 3 rear seat belt floor anchors through the package tray trim panel assembly. (b) Engage the 4 clips and 5 claws and install the package tray trim panel assembly. (c) Connect the connector. SEAT BELT – REAR SEAT INNER BELT ASSEMBLY SB–39 3. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY (for Reclining Seat Type) (a) Pass the 3 rear seat belt floor anchors through the package tray trim panel assembly. (b) Engage the 4 clips and 5 claws and install the package tray trim panel assembly. (c) Connect the connector. 4. INSTALL REAR SEAT SHOULDER BELT HOLE COVER (a) Engage the 4 claws and install the rear seat shoulder belt hole cover. 5. INSTALL REAR SEAT SHOULDER BELT COVER (a) Engage the 4 claws and install the rear seat shoulder belt cover. HINT: Use the same procedures for the RH side and the LH side. B132139 B132014 B132012 6. Protruding Parts B132008E01 CONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) (a) Connect the floor end of the rear seat outer belt assembly with the bolt. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) NOTICE: Do not allow the anchor part of the rear seat outer belt assembly to overlap the protruding parts of the floor panel. (b) Check if the ELR locks. NOTICE: The check should be performed with the outer belt assembly installed. (1) With the belt assembly installed, check that the belt locks when it is pulled out quickly. SB SB–40 SEAT BELT – REAR SEAT INNER BELT ASSEMBLY 7. CONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) (a) Connect the floor end of the rear seat outer belt assembly with the bolt. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) NOTICE: Do not allow the anchor part of the rear seat outer belt assembly to overlap the protruding parts of the floor panel. (b) Check if the ELR locks. NOTICE: The check should be performed with the outer belt assembly installed. (1) With the belt assembly installed, check that the belt locks when it is pulled out quickly. 8. INSTALL ROOF SIDE INNER GARNISH LH (See page IR-52) 9. INSTALL ROOF SIDE INNER GARNISH RH (See page IR-52) Protruding Parts B132009E01 Protruding Parts B132010E01 SB Protruding Parts B142740E01 10. CONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH (for TMC Made) (a) Connect the floor end of the rear seat inner with center belt assembly LH with the bolt. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) NOTICE: Do not allow the anchor part of the rear seat inner with center belt assembly LH to overlap the protruding parts of the floor panel. (b) Check if the ELR locks. NOTICE: The check should be performed with the outer belt assembly installed. (1) With the belt assembly installed, check that the belt locks when it is pulled out quickly. 11. CONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH (for TMMK Made) (a) Connect the floor end of the rear seat inner with center belt assembly LH with the nut. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) NOTICE: Do not allow the anchor part of the rear seat inner with center belt assembly LH to overlap the protruding parts of the floor panel. (b) Check if the ELR locks. NOTICE: The check should be performed with the outer belt assembly installed. (1) With the belt assembly installed, check that the belt locks when it is pulled out quickly. SEAT BELT – REAR SEAT INNER BELT ASSEMBLY SB–41 12. INSTALL REAR SEAT INNER WITH CENTER BELT ASSEMBLY RH (for TMC Made) (a) Install the rear seat inner with center belt assembly RH with the bolt. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) NOTICE: Do not allow the anchor part of the rear seat inner with center belt assembly RH to overlap the protruding parts of the floor panel. Protruding Parts B131999E01 13. INSTALL REAR SEAT INNER WITH CENTER BELT ASSEMBLY RH (for TMMK Made) (a) Install the rear seat inner with center belt assembly RH with the nut. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) NOTICE: Do not allow the anchor part of the rear seat inner with center belt assembly RH to overlap the protruding parts of the floor panel. Protruding Parts B142741E01 14. INSTALL CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH (See page SB-66) 15. INSTALL CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY RH HINT: Use the same procedures for the RH side and the LH side. 16. INSTALL RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY LH (for Reclining Seat Type) (See page SE-69) 17. INSTALL RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY RH (for Reclining Seat Type) HINT: Use the same procedures for the RH side and the LH side. 18. CONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH (See page IR-55) 19. INSTALL REAR DOOR SCUFF PLATE LH (See page IR-56) 20. CONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH (See page IR-56) 21. INSTALL REAR DOOR SCUFF PLATE RH (See page IR-56) 22. INSTALL CENTER SEAT BACK ASSEMBLY (for Reclining Seat Type) (See page SE-71) 23. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Reclining Seat Type) (See page SE-72) SB SB–42 SEAT BELT – REAR SEAT INNER BELT ASSEMBLY 24. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Reclining Seat Type) (See page SE-71) 25. INSTALL REAR SEAT BACK COVER (for Reclining Seat Type) 26. INSTALL REAR SIDE SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-57) 27. INSTALL REAR SIDE SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) HINT: Use the same procedures for the RH side and the LH side. 28. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-57) 29. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) (See page SE-57) 30. INSTALL REAR SEAT BACK ASSEMBLY (for Fixed Seat Type) (See page SE-84) 31. INSTALL REAR CENTER SEAT HEADREST ASSEMBLY 32. INSTALL REAR SEAT HEADREST ASSEMBLY 33. INSTALL REAR SEAT CUSHION ASSEMBLY (See page SE-84) SB SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY SB–43 REAR SEAT OUTER BELT ASSEMBLY SEAT BELT RESTRAINTS COMPONENTS for Fixed Seat Type: REAR SEAT HEADREST ASSEMBLY REAR CENTER SEAT HEADREST ASSEMBLY REAR SEAT BACK ASSEMBLY SB 18 (184, 13) 18 (184, 13) REAR SEAT CUSHION ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B136589E02 SB–44 SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY for Fold Down Seat Type: REAR SEAT HEADREST ASSEMBLY REAR CENTER SEAT HEADREST ASSEMBLY 18 (184, 13) 18 (184, 13) 18 (184, 13) REAR SIDE SEAT BACK ASSEMBLY RH SB SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH 18 (184, 13) REAR SEAT CUSHION ASSEMBLY REAR SIDE SEAT BACK ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque B136564E02 SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY SB–45 for Reclining Seat Type: REAR SEAT HEADREST ASSEMBLY 18 (184, 13) REAR CENTER SEAT HEADREST ASSEMBLY CENTER SEAT BACK ASSEMBLY REAR SEAT BACK COVER 18 (184, 13) 18 (184, 13) 18 (184, 13) SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH SB REAR SEAT BACK COVER 18 (184, 13) SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH REAR SEAT CUSHION ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B139095E03 SB–46 SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY ROOF SIDE INNER GARNISH RH REAR DOOR OPENING TRIM WEATHERSTRIP RH for Reclining Seat Type: 18 (184, 13) RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY RH REAR DOOR SCUFF PLATE RH ROOF SIDE INNER GARNISH LH for Reclining Seat Type: SB REAR DOOR OPENING TRIM WEATHERSTRIP LH 18 (184, 13) RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY LH REAR DOOR SCUFF PLATE LH N*m (kgf*cm, ft.*lbf) : Specified torque B132018E01 SB–47 SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY for TMC made: for Reclining Seat Type: PACKAGE TRAY TRIM PANEL ASSEMBLY PACKAGE TRAY TRIM PANEL ASSEMBLY REAR SEAT SHOULDER BELT COVER REAR SEAT SHOULDER BELT HOLE COVER REAR SEAT SHOULDER BELT COVER REAR SEAT OUTER BELT ASSEMBLY 42 (428, 31) 18 (184, 13) SB 42 (428, 31) 42 (428, 31) REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH for Fold Down Seat Type: CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH 18 (184, 13) CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH 42 (428, 31) REAR SEAT OUTER BELT ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B132113E02 SB–48 SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY for TMMK made: for Reclining Seat Type: PACKAGE TRAY TRIM PANEL ASSEMBLY PACKAGE TRAY TRIM PANEL ASSEMBLY REAR SEAT SHOULDER BELT COVER REAR SEAT SHOULDER BELT HOLE COVER REAR SEAT SHOULDER BELT COVER REAR SEAT OUTER BELT ASSEMBLY 42 (428, 31) 18 (184, 13) SB 42 (428, 31) 42 (428, 31) REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH for Fold Down Seat Type: CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH 18 (184, 13) CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH 42 (428, 31) REAR SEAT OUTER BELT ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B142742E01 SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY SB–49 REMOVAL 1. REMOVE REAR SEAT CUSHION ASSEMBLY (See page SE-77) 2. REMOVE REAR SEAT HEADREST ASSEMBLY 3. REMOVE REAR CENTER SEAT HEADREST ASSEMBLY 4. REMOVE REAR SEAT BACK ASSEMBLY (for Fixed Seat Type) (See page SE-77) 5. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-47) 6. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) (See page SE-47) 7. REMOVE REAR SIDE SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-48) 8. REMOVE REAR SIDE SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) (See page SE-48) 9. REMOVE REAR SEAT BACK COVER (for Reclining Seat Type) (See page SE-63) 10. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Reclining Seat Type) (See page SE-63) 11. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Reclining Seat Type) (See page SE-64) 12. REMOVE CENTER SEAT BACK ASSEMBLY (for Reclining Seat Type) (See page SE-64) 13. REMOVE REAR DOOR SCUFF PLATE LH (See page IR-24) 14. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH 15. REMOVE REAR DOOR SCUFF PLATE RH (See page IR-24) 16. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH 17. REMOVE RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY LH (for Reclining Seat Type) (See page SE-68) 18. REMOVE RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY RH (for Reclining Seat Type) HINT: Use the same procedures for the RH side and the LH side. 19. REMOVE CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH (See page SB-66) SB SB–50 SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY 20. DISCONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH (for TMC Made) (See page SB35) 21. DISCONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH (for TMMK Made) (See page SB-35) 22. REMOVE ROOF SIDE INNER GARNISH LH (See page IR-26) 23. REMOVE ROOF SIDE INNER GARNISH RH (See page IR-26) 24. DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) (a) Remove the bolt and disconnect the floor end of the rear seat outer belt assembly. B132006 25. DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) (a) Remove the bolt and disconnect the floor end of the rear seat outer belt assembly. SB B132007 26. REMOVE REAR SEAT SHOULDER BELT COVER (a) Using a screwdriver, disengage the 4 claws and remove the rear seat shoulder belt cover. HINT: • Tape the screwdriver tip before use. • Use the same procedures for the RH side and the LH side. Protective Tape B132011E01 SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY SB–51 27. REMOVE REAR SEAT SHOULDER BELT HOLE COVER (a) Using a screwdriver, disengage the 4 claws and remove the rear seat shoulder hole belt cover. HINT: Tape the screwdriver tip before use. Protective Tape B132013E02 28. REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY (See page SB-37) 29. REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY (for Reclining Seat Type) (See page SB-37) 30. REMOVE REAR SEAT OUTER BELT ASSEMBLY (a) Remove the bolt and the rear seat outer belt assembly. B132016 INSTALLATION 1. 45° B132024E01 INSTALL REAR SEAT OUTER BELT ASSEMBLY (a) Check the degree of the tilt when the ELR begins to lock. (1) Check that the belt does not lock at less than 15 degrees of tilt in any direction but locks at over 45 degrees of tilt while gently pulling the belt. NOTICE: Do not disassemble the retractor. (b) Align the claw with the seat belt positioning hole and install the rear seat outer belt assembly with the bolt. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) Claw 2. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY (See page SB-38) 3. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY (for Reclining Seat Type) (See page SB-39) 4. INSTALL REAR SEAT SHOULDER BELT HOLE COVER (a) Engage the 4 claws and install the rear seat shoulder belt hole cover. B132017E01 B132014 SB SB–52 SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY 5. INSTALL REAR SEAT SHOULDER BELT COVER (a) Engage the 4 claws and install the rear seat shoulder belt cover. HINT: Use the same procedures for the RH side and the LH side. 6. CONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) (a) Connect the floor end of the rear seat outer belt assembly with the bolt. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) NOTICE: Do not allow the anchor part of the rear seat outer belt assembly to overlap protruding parts of the floor panel. (b) Check if the ELR locks. NOTICE: The check should be performed with the outer belt assembly installed. (1) With the belt assembly installed, check that the belt locks when it is pulled out quickly. 7. CONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) (a) Connect the floor end of the rear seat outer belt assembly with the bolt. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) NOTICE: Do not allow the anchor part of the rear seat outer belt assembly to overlap protruding parts of the floor panel. (b) Check if the ELR locks. NOTICE: The check should be performed with the outer belt assembly installed. (1) With the belt assembly installed, check that the belt locks when it is pulled out quickly. 8. INSTALL ROOF SIDE INNER GARNISH LH (See page IR-52) 9. INSTALL ROOF SIDE INNER GARNISH RH (See page IR-52) B132012 Protruding Parts B132008E01 Protruding Parts SB B132009E01 10. CONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH (for TMC Made) (See page SB-40) 11. CONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH (for TMMK Made) (See page SB-40) 12. INSTALL CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH (See page SB-66) SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY SB–53 13. INSTALL RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY LH (for Reclining Seat Type) (See page SE-69) 14. INSTALL RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY RH (for Reclining Seat Type) HINT: Use the same procedures for the RH side and the LH side. 15. CONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH (See page IR-55) 16. INSTALL REAR DOOR SCUFF PLATE LH (See page IR-56) 17. CONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH (See page IR-56) 18. INSTALL REAR DOOR SCUFF PLATE RH (See page IR-56) 19. INSTALL CENTER SEAT BACK ASSEMBLY (for Reclining Seat Type) (See page SE-71) 20. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Reclining Seat Type) (See page SE-72) 21. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Reclining Seat Type) (See page SE-71) 22. INSTALL REAR SEAT BACK COVER (for Reclining Seat Type) 23. INSTALL REAR SIDE SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-57) 24. INSTALL REAR SIDE SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) HINT: Use the same procedures for the RH side and the LH side. 25. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-57) 26. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) (See page SE-57) 27. INSTALL REAR SEAT BACK ASSEMBLY (for Fixed Seat Type) (See page SE-84) 28. INSTALL REAR CENTER SEAT HEADREST ASSEMBLY 29. INSTALL REAR SEAT HEADREST ASSEMBLY 30. INSTALL REAR SEAT CUSHION ASSEMBLY (See page SE-84) SB SB–54 SEAT BELT – CHILD RESTRAINT SEAT TETHER ANCHOR CHILD RESTRAINT SEAT TETHER ANCHOR SEAT BELT RESTRAINTS COMPONENTS for Fixed Seat Type: REAR SEAT HEADREST ASSEMBLY REAR CENTER SEAT HEADREST ASSEMBLY REAR SEAT BACK ASSEMBLY SB 18 (184, 13) 18 (184, 13) REAR SEAT CUSHION ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B136589E02 SB–55 SEAT BELT – CHILD RESTRAINT SEAT TETHER ANCHOR for Fold Down Seat Type: REAR SEAT HEADREST ASSEMBLY REAR CENTER SEAT HEADREST ASSEMBLY 18 (184, 13) 18 (184, 13) 18 (184, 13) REAR SIDE SEAT BACK ASSEMBLY RH SB SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH 18 (184, 13) REAR SEAT CUSHION ASSEMBLY REAR SIDE SEAT BACK ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque B136564E02 SB–56 SEAT BELT – CHILD RESTRAINT SEAT TETHER ANCHOR for Reclining Seat Type: REAR SEAT HEADREST ASSEMBLY 18 (184, 13) REAR CENTER SEAT HEADREST ASSEMBLY CENTER SEAT BACK ASSEMBLY REAR SEAT BACK COVER 18 (184, 13) 18 (184, 13) SB 18 (184, 13) SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH REAR SEAT BACK COVER 18 (184, 13) SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH REAR SEAT CUSHION ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B139095E03 SEAT BELT – CHILD RESTRAINT SEAT TETHER ANCHOR SB–57 ROOF SIDE INNER GARNISH RH REAR DOOR OPENING TRIM WEATHERSTRIP RH for Reclining Seat Type: 18 (184, 13) RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY RH REAR DOOR SCUFF PLATE RH ROOF SIDE INNER GARNISH LH for Reclining Seat Type: SB REAR DOOR OPENING TRIM WEATHERSTRIP LH 18 (184, 13) RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY LH REAR DOOR SCUFF PLATE LH N*m (kgf*cm, ft.*lbf) : Specified torque B132018E01 SB–58 SEAT BELT – CHILD RESTRAINT SEAT TETHER ANCHOR for TMC made: for Reclining Seat Type: PACKAGE TRAY TRIM PANEL ASSEMBLY REAR SEAT SHOULDER BELT COVER PACKAGE TRAY TRIM PANEL ASSEMBLY 21 (214, 16) 21 (214, 16) CHILD RESTRAINT SEAT TETHER ANCHOR BRACKET CHILD RESTRAINT SEAT TETHER ANCHOR BRACKET REAR SEAT OUTER BELT ASSEMBLY REAR SEAT SHOULDER BELT HOLE COVER 21 (214, 16) CHILD RESTRAINT SEAT TETHER ANCHOR BRACKET 18 (184, 13) SB REAR SEAT SHOULDER BELT COVER 42 (428, 31) 42 (428, 31) REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH for Fold Down Seat Type: 42 (428, 31) 18 (184, 13) CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque B132114E03 SEAT BELT – CHILD RESTRAINT SEAT TETHER ANCHOR for TMMK made: SB–59 for Reclining Seat Type: PACKAGE TRAY TRIM PANEL ASSEMBLY REAR SEAT SHOULDER BELT COVER PACKAGE TRAY TRIM PANEL ASSEMBLY 21 (214, 16) 21 (214, 16) CHILD RESTRAINT SEAT TETHER ANCHOR BRACKET CHILD RESTRAINT SEAT TETHER ANCHOR BRACKET REAR SEAT OUTER BELT ASSEMBLY REAR SEAT SHOULDER BELT HOLE COVER 21 (214, 16) CHILD RESTRAINT SEAT TETHER ANCHOR BRACKET 18 (184, 13) SB 42 (428, 31) REAR SEAT SHOULDER BELT COVER 42 (428, 31) REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH for Fold Down Seat Type: 42 (428, 31) 18 (184, 13) CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque B142743E01 SB–60 SEAT BELT – CHILD RESTRAINT SEAT TETHER ANCHOR REMOVAL 1. REMOVE REAR SEAT CUSHION ASSEMBLY (See page SE-77) 2. REMOVE REAR SEAT HEADREST ASSEMBLY 3. REMOVE REAR CENTER SEAT HEADREST ASSEMBLY 4. REMOVE REAR SEAT BACK ASSEMBLY (for Fixed Seat Type) (See page SE-77) 5. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-47) 6. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) (See page SE-47) 7. REMOVE REAR SIDE SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-48) 8. REMOVE REAR SIDE SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) (See page SE-48) 9. REMOVE REAR SEAT BACK COVER (for Reclining Seat Type) (See page SE-63) 10. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Reclining Seat Type) (See page SE-63) SB 11. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Reclining Seat Type) (See page SE-64) 12. REMOVE CENTER SEAT BACK ASSEMBLY (for Reclining Seat Type) (See page SE-64) 13. REMOVE REAR DOOR SCUFF PLATE LH (See page IR-24) 14. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH 15. REMOVE REAR DOOR SCUFF PLATE RH (See page IR-24) 16. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH 17. REMOVE RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY LH (for Reclining Seat Type) (See page SE-68) 18. REMOVE RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY RH (for Reclining Seat Type) HINT: Use the same procedures for the RH side and the LH side. 19. REMOVE CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH (See page SB-66) SEAT BELT – CHILD RESTRAINT SEAT TETHER ANCHOR SB–61 20. DISCONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH (for TMC Made) (See page SB35) 21. DISCONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH (for TMMK Made) (See page SB-35) 22. REMOVE ROOF SIDE INNER GARNISH LH (See page IR-26) 23. REMOVE ROOF SIDE INNER GARNISH RH (See page IR-26) 24. DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) (See page SB-36) 25. DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) (See page SB-36) 26. REMOVE REAR SEAT SHOULDER BELT COVER (See page SB-36) 27. REMOVE REAR SEAT SHOULDER BELT HOLE COVER (See page SB-36) 28. REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY (See page SB-37) 29. REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY (for Reclining Seat Type) (See page SB-37) 30. REMOVE CHILD RESTRAINT SEAT TETHER ANCHOR BRACKET (a) Remove the 3 bolts and the 3 child restraint seat tether anchor brackets. B132027 SB SB–62 SEAT BELT – CHILD RESTRAINT SEAT TETHER ANCHOR INSTALLATION B132027 1. INSTALL CHILD RESTRAINT SEAT TETHER ANCHOR BRACKET (a) Install the 3 child restraint seat tether anchor brackets with the 3 bolts. Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf) 2. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY (See page SB-38) 3. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY (for Reclining Seat Type) (See page SB-39) 4. INSTALL REAR SEAT SHOULDER BELT HOLE COVER (See page SB-39) 5. INSTALL REAR SEAT SHOULDER BELT COVER (See page SB-39) 6. CONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) (See page SB-39) 7. CONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) (See page SB-40) 8. INSTALL ROOF SIDE INNER GARNISH LH (See page IR-52) 9. INSTALL ROOF SIDE INNER GARNISH RH (See page IR-52) 10. CONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH (for TMC Made) (See page SB-40) SB 11. CONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH (for TMMK Made) (See page SB-40) 12. INSTALL CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH (See page SB-66) 13. INSTALL RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY LH (for Reclining Seat Type) (See page SE-69) 14. INSTALL RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY RH (for Reclining Seat Type) HINT: Use the same procedures for the RH side and the LH side. 15. CONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH (See page IR-55) 16. INSTALL REAR DOOR SCUFF PLATE LH (See page IR-56) 17. CONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH (See page IR-56) 18. INSTALL REAR DOOR SCUFF PLATE RH (See page IR-56) 19. INSTALL CENTER SEAT BACK ASSEMBLY (for Reclining Seat Type) (See page SE-71) SEAT BELT – CHILD RESTRAINT SEAT TETHER ANCHOR SB–63 20. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Reclining Seat Type) (See page SE-72) 21. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Reclining Seat Type) (See page SE-71) 22. INSTALL REAR SEAT BACK COVER (for Reclining Seat Type) 23. INSTALL REAR SIDE SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-57) 24. INSTALL REAR SIDE SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) HINT: Use the same procedures for the RH side and the LH side. 25. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-57) 26. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) (See page SE-57) 27. INSTALL REAR SEAT BACK ASSEMBLY (for Fixed Seat Type) (See page SE-84) 28. INSTALL REAR CENTER SEAT HEADREST ASSEMBLY 29. INSTALL REAR SEAT HEADREST ASSEMBLY 30. INSTALL REAR SEAT CUSHION ASSEMBLY (See page SE-84) SB SB–64 SEAT BELT – CHILD RESTRAINT SEAT ANCHOR BRACKET CHILD RESTRAINT SEAT ANCHOR BRACKET SEAT BELT RESTRAINTS COMPONENTS for Fixed Seat Type: REAR SEAT HEADREST ASSEMBLY REAR CENTER SEAT HEADREST ASSEMBLY REAR SEAT BACK ASSEMBLY 18 (184, 13) SB 18 (184, 13) CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY REAR SEAT CUSHION ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B147622E01 SB–65 SEAT BELT – CHILD RESTRAINT SEAT ANCHOR BRACKET for Fold Down Seat Type: for Reclining Seat Type: REAR SEAT HEADREST ASSEMBLY REAR SEAT HEADREST ASSEMBLY 18 (184, 13) 18 (184, 13) 18 (184, 13) SEPARATE TYPE REAR SEAT BACK ASSEMBLY REAR SEAT BACK COVER 18 (184, 13) SEPARATE TYPE REAR SEAT BACK ASSEMBLY 18 (184, 13) CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY SB CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY REAR SEAT CUSHION ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B142840E01 SB–66 SEAT BELT – CHILD RESTRAINT SEAT ANCHOR BRACKET REMOVAL 1. REMOVE REAR SEAT CUSHION ASSEMBLY (See page SE-77) 2. REMOVE REAR SEAT HEADREST ASSEMBLY 3. REMOVE REAR CENTER SEAT HEADREST ASSEMBLY (for Fixed Seat Type) 4. REMOVE REAR SEAT BACK ASSEMBLY (for Fixed Seat Type) (See page SE-77) 5. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY (for Fold Down Seat Type) (See page SE47) 6. REMOVE REAR SEAT BACK COVER (for Reclining Seat Type) (See page SE-63) 7. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY (for Reclining Seat Type) (See page SE63) 8. REMOVE CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY (a) Remove the 2 nuts and child restraint seat anchor bracket sub-assembly. B132028 SB INSTALLATION 1. INSTALL CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY (a) Install the child restraint seat anchor bracket subassembly with the 2 nuts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 2. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY (for Reclining Seat Type) (See page SE72) 3. INSTALL REAR SEAT BACK COVER (for Reclining Seat Type) 4. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY (for Fold Down Seat Type) (See page SE57) 5. INSTALL REAR SEAT BACK ASSEMBLY (for Fixed Seat Type) (See page SE-84) 6. INSTALL REAR CENTER SEAT HEADREST ASSEMBLY (for Fixed Seat Type) 7. INSTALL REAR SEAT HEADREST ASSEMBLY B132028 SEAT BELT – CHILD RESTRAINT SEAT ANCHOR BRACKET 8. SB–67 INSTALL REAR SEAT CUSHION ASSEMBLY (See page SE-84) SB CL–1 CLUTCH – CLUTCH SYSTEM CLUTCH SYSTEM PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the ranked order of probability of each of the possible causes. Check each part in order. Replace parts as necessary. CLUTCH SYSTEM Symptom Clutch grabs/chatters Clutch pedal is spongy Clutch is noisy Clutch slips Clutch does not disengage Suspected area See page 1. Engine mounting (Loosen) - 2. Clutch disc (Runout is excessive) CL-32 3. Clutch disc (Oily) CL-32 4. Clutch disc (Worn out) CL-32 5. Clutch disc torsion rubber (Damaged) CL-32 6. Clutch disc (Glazed) CL-32 7. Diaphragm spring (Out of tip alignment) CL-32 1. Clutch Line (Air in line) CL-25 2. Master cylinder cup (Damaged) CL-15 3. Release cylinder rubber (Damaged) CL-24 1. Release bearing (Worn, dirty, or damaged) CL-33 1. Clutch pedal (Free play is out of adjustment) CL-4 2. Clutch disc (Oily) CL-32 3. Clutch disc (Worn out) CL-32 4. Diaphragm spring (Damaged) CL-33 5. Pressure plate (Distortion) CL-32 6. Flywheel (Distortion) CL-33 1. Clutch pedal (Free play is out of adjustment) CL-4 2. Clutch line (Air in line) CL-25 3. Master cylinder cup (Damaged) CL-15 4. Release cylinder cup (Damaged) CL-24 5. Clutch disc (Out of true) CL-32 6. Clutch disc (Runout is excessive) CL-32 7. Clutch disc (Lining broken) CL-32 8. Clutch disc (Dirty or burned) CL-32 9. Clutch disc (Oily) CL-32 10. Clutch disc (Lack of spline grease) CL-32 CL CL–2 CLUTCH – CLUTCH PEDAL CLUTCH PEDAL CLUTCH TRANSMISSION COMPONENTS for TMC Made: CL with Smart Key System: LOWER INSTRUMENT PANEL FINISH PANEL COMBINATION METER ASSEMBLY without Smart Key System: INSTRUMENT CLUSTER FINISH PANEL LOWER INSTRUMENT PANEL FINISH PANEL NO. 1 INSTRUMENT PANEL SUB-ASSEMBLY COWL SIDE TRIM SUB-ASSEMBLY LH COWL SIDE TRIM CLIP LOWER INSTRUMENT PANEL FINISH PANEL LH FRONT DOOR SCUFF PLATE LH C138372E01 CL–3 CLUTCH – CLUTCH PEDAL for TMMK Made: with Smart Key System: CL LOWER INSTRUMENT PANEL FINISH PANEL COMBINATION METER ASSEMBLY without Smart Key System: INSTRUMENT CLUSTER FINISH PANEL LOWER INSTRUMENT PANEL FINISH PANEL NO. 1 INSTRUMENT PANEL SUB-ASSEMBLY COWL SIDE TRIM SUB-ASSEMBLY LH COWL SIDE TRIM CLIP or

LOWER INSTRUMENT PANEL FINISH PANEL LH FRONT DOOR SCUFF PLATE LH C138372E02 CL–4 CLUTCH – CLUTCH PEDAL PUSH ROD CLEVIS 19 (195, 14) 37 (375, 27) CL CLUTCH PEDAL SPRING HOLDER PEDAL SHAFT 12 (120, 9) CLUTCH PEDAL SUPPORT SUB-ASSEMBLY TORSION SPRING CLUTCH PEDAL SHAFT COLLAR NO. 1 CLUTCH PEDAL CUSHION CLUTCH PEDAL BUSHING CLUTCH PEDAL BUSHING CLIP PEDAL WITH HOOK SPRING CLUTCH PEDAL TURNOVER BUSHING CLUTCH MASTER CYLINDER PUSH ROD CLEVIS PIN CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSHING NO. 1 CLUTCH PEDAL CUSHION CLUTCH PEDAL PAD CLUTCH PEDAL SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Apply MP grease C132965E01 CLUTCH – CLUTCH PEDAL CL–5 ON-VEHICLE INSPECTION 1. INSPECT AND ADJUST CLUTCH PEDAL HEIGHT (a) Turn back the floor carpet. (b) Check the pedal height. Pedal height from asphalt sheet: 148.0 to 158.0 mm (5.8268 to 6.2205 in.) If necessary, adjust the pedal height. (c) Adjust the pedal height. (1) Loosen the lock nut and turn the clutch switch until the height is correct. Tighten the lock nut. Torque: 16 N*m (160 kgf*cm, 12 ft.*lbf) Pedal Height Adjustment Point Push Rod Play and Free Play Adjustment Point Pedal Height C138378E01 2. INSPECT CLUTCH PEDAL FREE PLAY AND PUSH ROD PLAY (a) Check that the pedal free play and push rod play are correct. (1) Depress the pedal until clutch resistance is felt. Pedal free play: 5.0 to 15.0 mm (0.197 to 0.591 in.) (2) Gently depress the pedal until the resistance begins to increase a little. Push rod play at pedal top: 1.0 to 5.0 mm (0.039 to 0.197 in.) (b) Adjust the pedal free play and push rod play. (1) Loosen the lock nut and turn the push rod until the free play and push rod play are correct. (2) Tighten the lock nut. Torque: 12 N*m (120 kgf*cm, 9 ft.*lbf) (3) After adjusting the pedal free play, check the pedal height. 3. INSPECT CLUTCH RELEASE POINT (a) Check the clutch release point. (1) Pull the parking brake lever and install the wheel stopper. (2) Start and idle the engine. (3) Without depressing the clutch pedal, slowly move the shift lever to the reverse position until the gears are engaged. Push Rod Play Pedal Free Play C102627E01 25 mm (0.98 in.) or more Full Stroke End Position Release Point CL00512E07 CL CL–6 CL CLUTCH – CLUTCH PEDAL (4) Gradually depress the clutch pedal and measure the stroke distance from the point that the gear noise stops (release point) to the full stroke end position. Standard distance: 25 mm (0.98 in.) or more (From pedal stroke end position to release point) If the distance is not as specified, perform the following operations: • Check the pedal height. • Check push rod play and pedal free play. • Bleed the clutch line. • Check the clutch cover assembly and disc assembly. CLUTCH – CLUTCH PEDAL CL–7 REMOVAL 1. PRECAUTION See page IP-1. 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 3. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-24) 4. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-25) 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (See page IP-20) 6. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (See page IP-21) 7. REMOVE NO. 1 INSTRUMENT PANEL SUBASSEMBLY (See page IP-22) 8. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (w/o Smart Key System) (See page IP-22) 9. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (w/ Smart Key System) (See page IP-22) 10. REMOVE INSTRUMENT CLUSTER FINISH PANEL (See page IP-22) 11. REMOVE COMBINATION METER ASSEMBLY (for TMC Made) (See page IP-23) 12. REMOVE COMBINATION METER ASSEMBLY (for TMMK Made) (See page IP-23) 13. DISCONNECT CONNECTORS (a) Disconnect the clutch start switch connector. (b) Disconnect the clutch switch connector (with cruise control). 14. REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS PIN (a) Remove the clip and pin. C135429 CL CL–8 CLUTCH – CLUTCH PEDAL 15. REMOVE CLUTCH PEDAL SUPPORT SUBASSEMBLY (a) Remove the bolt, 2 nuts and clutch pedal support assembly. 16. REMOVE TORSION SPRING (a) While the clutch pedal is fully depressed, remove the torsion spring. CL 17. REMOVE PEDAL WITH HOOK SPRING (a) Remove the pedal with hook spring. C132956 18. REMOVE CLUTCH PEDAL SUB-ASSEMBLY (a) Remove the pedal shaft and nut. (b) Remove the clutch pedal from the clutch pedal support. 19. REMOVE CLUTCH PEDAL SPRING HOLDER (a) Remove the clutch pedal spring holder from the clutch pedal support. C135394 20. REMOVE CLUTCH PEDAL PAD (a) Remove the clutch pedal pad from the clutch pedal. 21. REMOVE CLUTCH PEDAL BUSHING (a) Remove the 2 pedal bushings and pedal shaft collar from the clutch pedal. C135422 22. REMOVE NO. 1 CLUTCH PEDAL CUSHION (a) Using needle-nose pliers, remove the 2 No. 1 clutch pedal cushions from the clutch pedal. C135423 CLUTCH – CLUTCH PEDAL CL–9 23. REMOVE CLUTCH PEDAL TURNOVER BUSHING (a) Remove the turnover bushing from the clutch pedal. CL C135424 24. REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSHING (a) Using an 8 mm hexagon wrench and a hammer, remove the clevis bushing from the clutch pedal. C135430 INSTALLATION 1. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSHING (a) Apply MP grease to the inside of a new clevis bushing. (b) Install the clevis bushing to the clutch pedal. HINT: Install the clevis bushing from the left side of the vehicle. 2. INSTALL CLUTCH PEDAL TURNOVER BUSHING (a) Apply MP grease to the inside of the turnover bushing. (b) Install the turnover bushing to the clutch pedal. 3. INSTALL NO. 1 CLUTCH PEDAL CUSHION (a) Using needle-nose pliers, install the 2 No. 1 clutch pedal cushions to the clutch pedal. MP grease C135431E01 MP grease C135424E01 C135423 CL–10 CL CLUTCH – CLUTCH PEDAL 4. INSTALL CLUTCH PEDAL BUSHING (a) Apply MP grease to the inner, outer and end surfaces of 2 new pedal bushings. (b) Install the clutch pedal shaft collar and 2 pedal bushings to the clutch pedal. 5. INSTALL CLUTCH PEDAL PAD (a) Install the clutch pedal pad to the clutch pedal. 6. INSTALL CLUTCH PEDAL SPRING HOLDER (a) Apply MP grease to the inside of a new clutch pedal spring holder. (b) Install the clutch pedal spring holder. 7. INSTALL CLUTCH PEDAL SUB-ASSEMBLY (a) Install the clutch pedal to the clutch pedal support with the bolt and nut. Torque: 37 N*m (375 kgf*cm, 27 ft.*lbf) HINT: Install the bolt from the right side of the vehicle. 8. INSTALL PEDAL WITH HOOK SPRING (a) Apply MP grease to the sliding portion of the spring. (b) Install the hook spring. 9. INSTALL TORSION SPRING (a) Apply MP grease to the sliding portion of the spring. (b) Install the torsion spring. MP grease C135422E01 MP grease C135433E01 C135394 MP grease C132964E01 MP grease C125952E02 CLUTCH – CLUTCH PEDAL CL–11 10. INSTALL CLUTCH PEDAL SUPPORT SUBASSEMBLY (a) Install the clutch pedal support to the vehicle with the 2 nuts and bolt. Torque: Bolt 19 N*m (195 kgf*cm, 14 ft.*lbf) Nut 12 N*m (120 kgf*cm, 9 ft.*lbf) C132956 11. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS PIN (a) Apply MP grease to the contact surface of the pin and clevis bushing. (b) Connect the clevis to the clutch pedal with the pin and a new clip. HINT: Install the pin from the left side of the vehicle. MP grease C135428E01 12. CONNECT CONNECTORS (a) Connect the clutch start switch connector. (b) Connect the clutch switch connector (with cruise control). 13. INSTALL COMBINATION METER ASSEMBLY (for TMC Made) (See page IP-56) 14. INSTALL COMBINATION METER ASSEMBLY (for TMMK Made) (See page IP-56) 15. INSTALL INSTRUMENT CLUSTER FINISH PANEL (See page IP-57) 16. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/o Smart Key System) (See page IP-57) 17. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/ Smart Key System) (See page IP-57) 18. INSTALL NO. 1 INSTRUMENT PANEL SUBASSEMBLY (See page IP-57) 19. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (See page IP-58) 20. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (See page IP-59) CL CL–12 CLUTCH – CLUTCH PEDAL 21. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-54) 22. INSTALL FRONT DOOR SCUFF PLATE LH (See page IR-54) 23. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL CL 24. INSPECT AND ADJUST CLUTCH PEDAL SUBASSEMBLY See page CL-4. CL–12 CLUTCH – CLUTCH MASTER CYLINDER CLUTCH MASTER CYLINDER CLUTCH TRANSMISSION COMPONENTS FRONT WIPER ARM AND BLADE ASSEMBLY RH 20 (204, 15) CL FRONT FENDER TO COWL SIDE SEAL RH FRONT WIPER ARM AND BLADE ASSEMBLY LH COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 7.5 (77, 66 in.*lbf) 85 (867, 63) FRONT FENDER TO COWL SIDE SEAL LH 5.0 (51, 44 in.*lbf) WINDSHIELD WIPER LINK ASSEMBLY COWL TOP PANEL OUTER SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque A136912E01 CLUTCH – CLUTCH MASTER CYLINDER CL–13 for TMC Made: with Smart Key System: CL LOWER INSTRUMENT PANEL FINISH PANEL COMBINATION METER ASSEMBLY without Smart Key System: INSTRUMENT CLUSTER FINISH PANEL LOWER INSTRUMENT PANEL FINISH PANEL NO. 1 INSTRUMENT PANEL SUB-ASSEMBLY COWL SIDE TRIM SUB-ASSEMBLY LH COWL SIDE TRIM CLIP LOWER INSTRUMENT PANEL FINISH PANEL LH FRONT DOOR SCUFF PLATE LH C138372E01 CL–14 CLUTCH – CLUTCH MASTER CYLINDER for TMMK Made: with Smart Key System: CL LOWER INSTRUMENT PANEL FINISH PANEL COMBINATION METER ASSEMBLY without Smart Key System: INSTRUMENT CLUSTER FINISH PANEL LOWER INSTRUMENT PANEL FINISH PANEL NO. 1 INSTRUMENT PANEL SUB-ASSEMBLY COWL SIDE TRIM SUB-ASSEMBLY LH COWL SIDE TRIM CLIP or

LOWER INSTRUMENT PANEL FINISH PANEL LH FRONT DOOR SCUFF PLATE LH C138372E02 CL–15 CLUTCH – CLUTCH MASTER CYLINDER CLUTCH LINE CL 15 (155, 11) 12 (120, 9) CLIP x2 GASKET 12 (120, 9) CLUTCH RESERVOIR TUBE CLUTCH MASTER CYLINDER ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C132968E01 CL–16 CLUTCH – CLUTCH MASTER CYLINDER REMOVAL CL 1. PRECAUTION See page IP-1. 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 3. DRAIN BRAKE FLUID (See page BR-28) 4. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-416) 5. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (See page EM-95) 6. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH (See page WW-9) 7. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH (See page WW-9) 8. REMOVE FRONT FENDER TO COWL SIDE SEAL LH (See page WW-9) 9. REMOVE FRONT FENDER TO COWL SIDE SEAL RH (See page WW-9) 10. REMOVE COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See page WW-10) 11. REMOVE WINDSHIELD WIPER LINK ASSEMBLY (See page WW-10) 12. REMOVE COWL TOP PANEL OUTER SUBASSEMBLY (See page ES-424) 13. REMOVE BRAKE BOOSTER ASSEMBLY See page BR-42. 14. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-24) 15. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-25) 16. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (See page IP-20) 17. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (See page IP-21) 18. REMOVE NO. 1 INSTRUMENT PANEL SUBASSEMBLY (See page IP-22) 19. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (w/o Smart Key System) (See page IP-22) 20. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (w/ Smart Key System) (See page IP-22) 21. REMOVE INSTRUMENT CLUSTER FINISH PANEL (See page IP-22) 22. REMOVE COMBINATION METER ASSEMBLY (for TMC Made) (See page IP-23) CLUTCH – CLUTCH MASTER CYLINDER CL–17 23. REMOVE COMBINATION METER ASSEMBLY (for TMMK Made) (See page IP-23) 24. DISCONNECT CLUTCH MASTER CYLINDER PUSH ROD CLEVIS (a) Remove the clip and pin, and disconnect the push rod clevis from the clutch pedal. 25. DRAIN BRAKE FLUID NOTICE: Wash brake fluid off immediately if it is spilled on any painted surface. C135429 26. DISCONNECT CLUTCH RESERVOIR TUBE (a) Using pliers, grip the claws of the clip and slide the clip to disconnect the tube from the clutch master cylinder. HINT: Use a container to catch the fluid. C135418 27. DISCONNECT CLUTCH LINE (a) Using SST, disconnect the clutch line. SST 09023-00101 HINT: Use a container to catch the fluid. SST C135419E01 CL CL–18 CLUTCH – CLUTCH MASTER CYLINDER 28. REMOVE CLUTCH MASTER CYLINDER ASSEMBLY (a) Remove the 2 nuts and clutch master cylinder. (b) Remove the gasket from the clutch master cylinder assembly. CL C135416 INSTALLATION 1. INSTALL CLUTCH MASTER CYLINDER ASSEMBLY (a) Install a new gasket to the clutch master cylinder assembly. (b) Install the clutch master cylinder with the 2 nuts. Torque: 12 N*m (120 kgf*cm, 9 ft.*lbf) 2. CONNECT CLUTCH LINE (a) Using SST, connect the clutch line. SST 09023-00101 Torque: 15 N*m (155 kgf*cm, 11 ft.*lbf) C135416 SST C135419E01 CLUTCH – CLUTCH MASTER CYLINDER 3. Green Mark CL–19 CONNECT CLUTCH RESERVOIR TUBE (a) Connect the clutch reservoir tube to the clutch master cylinder with the clip. NOTICE: • Connect the clutch reservoir tube so that it will not be twisted. • Make sure that the green mark is positioned as shown in the illustration. C135418E01 MP grease 4. CONNECT CLUTCH MASTER CYLINDER PUSH ROD CLEVIS (a) Apply MP grease to the contact surface of the pin and clevis bushing. (b) Connect the clevis to the clutch pedal with the pin and a new clip. HINT: Install the pin from the left side of the vehicle. 5. INSTALL BRAKE BOOSTER ASSEMBLY See page BR-43. 6. INSTALL COMBINATION METER ASSEMBLY (for TMC Made) (See page IP-56) 7. INSTALL COMBINATION METER ASSEMBLY (for TMMK Made) (See page IP-56) 8. INSTALL INSTRUMENT CLUSTER FINISH PANEL (See page IP-57) 9. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/o Smart Key System) (See page IP-57) C135428E01 10. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/ Smart Key System) (See page IP-57) 11. INSTALL NO. 1 INSTRUMENT PANEL SUBASSEMBLY (See page IP-57) 12. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (See page IP-58) 13. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (See page IP-59) 14. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-54) 15. INSTALL FRONT DOOR SCUFF PLATE LH (See page IR-54) 16. INSTALL COWL TOP PANEL OUTER SUBASSEMBLY (See page ES-426) 17. INSTALL WINDSHIELD WIPER LINK ASSEMBLY (See page WW-14) 18. INSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See page WW-15) CL CL–20 CLUTCH – CLUTCH MASTER CYLINDER 19. INSTALL FRONT FENDER TO COWL SIDE SEAL LH (See page WW-15) 20. INSTALL FRONT FENDER TO COWL SIDE SEAL RH (See page WW-15) 21. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH (See page WW-15) CL 22. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH (See page WW-16) 23. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (See page EM-120) 24. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See page ES-419) 25. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 26. BLEED CLUTCH PIPE LINE (a) Fill the brake reservoir with brake fluid and bleed the clutch system. Torque: 8.3 N*m (85 kgf*cm, 74 in.*lbf) 27. CHECK BRAKE FLUID (a) Check the brake fluid (See page BR-6). HINT: • Check for leakage in the brake system. • Check for leakage in the clutch system. 28. CHECK FLUID LEVEL IN RESERVOIR (See page BR6) 29. INSPECT AND ADJUST CLUTCH PEDAL SUBASSEMBLY See page CL-4. CLUTCH – CLUTCH RELEASE CYLINDER CL–21 CLUTCH RELEASE CYLINDER CLUTCH TRANSMISSION COMPONENTS CL AIR CLEANER CAP SUB-ASSEMBLY 5.0 (51, 44 in.*lbf) 5.0 (51, 44 in.*lbf) AIR CLEANER CASE SUB-ASSEMBLY AIR CLEANER INLET ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C138373E01 CL–22 CLUTCH – CLUTCH RELEASE CYLINDER 12 (120, 9) CLUTCH ACCUMULATOR BRACKET CL 37 (380, 28) CLUTCH ACCUMULATOR ASSEMBLY 12 (120, 9) 15 (155, 11) 15 (155, 11) 12 (120, 9) CLUTCH LINE CLUTCH LINE 15 (155, 11) 12 (120, 9) RELEASE CYLINDER HEAT INSULATOR CLUTCH RELEASE CYLINDER ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C135413E01 CLUTCH – CLUTCH RELEASE CYLINDER CL–23 12 (120, 9) CL 8.3 (85, 74 in.*lbf) RELEASE CYLINDER BLEEDER PLUG BLEEDER PLUG CAP CLUTCH RELEASE CYLINDER BODY PISTON SPRING PUSH ROD BOOT N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Lithium soap base glycol grease C135414E01 CL–24 CLUTCH – CLUTCH RELEASE CYLINDER REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE AIR CLEANER INLET ASSEMBLY (See page EM-94) 3. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-416) 4. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (See page EM-95) 5. REMOVE CLUTCH ACCUMULATOR BRACKET (See page CL-28) 6. REMOVE RELEASE CYLINDER HEAT INSULATOR (See page CL-28) 7. DISCONNECT CLUTCH LINE (See page CL-28) 8. REMOVE CLUTCH ACCUMULATOR ASSEMBLY (See page CL-28) 9. REMOVE CLUTCH RELEASE CYLINDER ASSEMBLY (a) Remove the 2 bolts and clutch release cylinder assembly. CL C135415 CLUTCH – CLUTCH RELEASE CYLINDER CL–25 DISASSEMBLY 1. 2. REMOVE CLUTCH RELEASE CYLINDER KIT (a) Remove the boot from the cylinder body. (b) Remove the push rod from the cylinder body. (c) Remove the piston from the cylinder body. NOTICE: Be careful not to damage the inside of the cylinder body. (d) Remove the spring from the cylinder body. (e) Remove the bleeder plug cap from the bleeder plug. REMOVE RELEASE CYLINDER BLEEDER PLUG (a) Remove the bleeder plug from the cylinder body. CL CL–26 CLUTCH – CLUTCH RELEASE CYLINDER REASSEMBLY 1. INSTALL RELEASE CYLINDER BLEEDER PLUG (a) Install the bleeder plug to the cylinder body. Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf) 2. INSTALL CLUTCH RELEASE CYLINDER KIT (a) Install the bleeder plug cap to the bleeder plug. (b) Install a new spring to the cylinder body. CL (c) Coat the piston with lithium soap base glycol grease as shown in the illustration. (d) Install the piston to the cylinder body. NOTICE: Be careful not to damage the inside of the cylinder body. (e) Install the push rod to the cylinder body. (f) Install the boot to the cylinder body. C128485 INSTALLATION C135415 1. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (a) Install the clutch release cylinder and clutch line bracket with the 2 bolts. Torque: 12 N*m (120 kgf*cm, 9 ft.*lbf) 2. INSTALL CLUTCH ACCUMULATOR ASSEMBLY (See page CL-29) 3. CONNECT CLUTCH LINE (See page CL-29) 4. INSTALL RELEASE CYLINDER HEAT INSULATOR (See page CL-29) 5. INSTALL CLUTCH ACCUMULATOR BRACKET (See page CL-29) 6. BLEED CLUTCH LINE (a) Fill the brake reservoir with brake fluid and bleed the clutch system. Torque: 8.3 N*m (85 kgf*cm, 74 in.*lbf) 7. CHECK FOR BRAKE FLUID LEAKAGE HINT: Check for leakage in the clutch system. 8. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (See page EM-120) 9. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See page ES-419) 10. INSTALL AIR CLEANER INLET ASSEMBLY (See page EM-120) 11. CHECK FLUID LEVEL IN RESERVOIR 12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL CL–26 CLUTCH – CLUTCH ACCUMULATOR CLUTCH ACCUMULATOR CLUTCH TRANSMISSION COMPONENTS CL AIR CLEANER CAP SUB-ASSEMBLY 5.0 (51, 44 in.*lbf) 5.0 (51, 44 in.*lbf) AIR CLEANER CASE SUB-ASSEMBLY AIR CLEANER INLET ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C138373E01 CL–27 CLUTCH – CLUTCH ACCUMULATOR 12 (120, 9) CLUTCH ACCUMULATOR BRACKET CL 37 (380, 28) CLUTCH ACCUMULATOR ASSEMBLY 12 (120, 9) 15 (155, 11) 15 (155, 11) 12 (120, 9) CLUTCH LINE CLUTCH LINE 15 (155, 11) 12 (120, 9) RELEASE CYLINDER HEAT INSULATOR CLUTCH RELEASE CYLINDER ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C135413E01 CL–28 CLUTCH – CLUTCH ACCUMULATOR REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE AIR CLEANER INLET ASSEMBLY (See page EM-94) 3. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-416) 4. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (See page EM-95) 5. REMOVE CLUTCH ACCUMULATOR BRACKET (a) Remove the 2 bolts and clutch accumulator bracket. 6. REMOVE RELEASE CYLINDER HEAT INSULATOR (a) Remove the 2 bolts and release cylinder heat insulator. 7. DISCONNECT CLUTCH LINE (a) Using SST, disconnect the clutch lines. SST 09023-00101 HINT: Use a container to catch the fluid. 8. REMOVE CLUTCH ACCUMULATOR ASSEMBLY (a) Remove the 2 nuts and clutch accumulator assembly. CL C132974 C132975 SST C132976E01 C132977 CLUTCH – CLUTCH ACCUMULATOR CL–29 INSTALLATION 1. INSTALL CLUTCH ACCUMULATOR ASSEMBLY (a) Install the clutch accumulator assembly with the 2 nuts. Torque: 12 N*m (120 kgf*cm, 9 ft.*lbf) CL C132977 2. CONNECT CLUTCH LINE (a) Using SST, connect the clutch lines to the clutch accumulator assembly. SST 09023-00101 Torque: 15 N*m (155 kgf*cm, 11 ft.*lbf) 3. INSTALL RELEASE CYLINDER HEAT INSULATOR (a) Install the release cylinder heat insulator with the 2 bolts. Torque: 12 N*m (120 kgf*cm, 9 ft.*lbf) 4. INSTALL CLUTCH ACCUMULATOR BRACKET (a) Install the clutch accumulator bracket with the 2 bolts. Torque: Bolt A 12 N*m (120 kgf*cm, 9 ft.*lbf) Bolt B 37 N*m (380 kgf*cm, 28 ft.*lbf) 5. BLEED CLUTCH PIPE LINE (a) Fill the brake reservoir with brake fluid and bleed the clutch system. Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) 6. CHECK FOR BRAKE FLUID LEAKAGE HINT: Check for leakage in the clutch system. 7. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (See page EM-120) 8. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See page ES-419) SST C132976E01 C132975 A B C132974E01 CL–30 CLUTCH – CLUTCH ACCUMULATOR 9. INSTALL AIR CLEANER INLET ASSEMBLY (See page EM-120) 10. CHECK BRAKE FLUID LEVEL IN RESERVOIR 11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL CL CL–36 CLUTCH – CLUTCH START SWITCH CLUTCH START SWITCH CLUTCH TRANSMISSION COMPONENTS CL CLUTCH START SWITCH ASSEMBLY 16 (160, 12) N*m (kgf*cm, ft.*lbf) : Specified torque C135420E01 CLUTCH – CLUTCH START SWITCH CL–37 ON-VEHICLE INSPECTION 1. Clutch Start Switch Assembly C135434E01 INSPECT CLUTCH START SWITCH ASSEMBLY (a) Check that the engine does not start when the clutch pedal is released. (b) Check that the engine starts when the clutch pedal is fully depressed. If necessary, replace the clutch start switch assembly. CL CLUTCH – CLUTCH UNIT CL–31 CLUTCH UNIT CLUTCH TRANSMISSION COMPONENTS FLYWHEEL SUB-ASSEMBLY CL RELEASE BEARING HUB CLIP x6 19 (195, 14) CLUTCH DISC ASSEMBLY CLUTCH COVER ASSEMBLY CLUTCH RELEASE BEARING ASSEMBLY CLUTCH RELEASE FORK SUB-ASSEMBLY 47 (480, 35) RELEASE FORK SUPPORT CLUTCH RELEASE FORK BOOT N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Clutch spline grease Release hub grease C132969E01 CL–32 CLUTCH – CLUTCH UNIT DISASSEMBLY CL 1. REMOVE MANUAL TRANSAXLE ASSEMBLY See page MX-24. 2. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY (a) Remove the clutch release fork with the clutch release bearing from the transaxle assembly. 3. REMOVE CLUTCH RELEASE BEARING ASSEMBLY (a) Remove the release bearing hub clip and clutch release bearing assembly from the clutch release fork. 4. REMOVE RELEASE FORK SUPPORT (a) Remove the release fork support from the manual transaxle assembly. 5. REMOVE CLUTCH RELEASE FORK BOOT 6. REMOVE CLUTCH COVER ASSEMBLY (a) Put matchmarks on the clutch cover assembly and flywheel sub-assembly. (b) Loosen the 6 bolts one turn at a time until spring tension is released. (c) Remove the 6 bolts and pull off the clutch cover assembly. NOTICE: Do not drop the clutch disc assembly. 7. REMOVE CLUTCH DISC ASSEMBLY NOTICE: Keep the lining part of the clutch disc assembly, the pressure plate and surface of the flywheel subassembly away from oil and foreign matter. C069774 C083809 Matchmarks D008941E02 INSPECTION 1. C104164 INSPECT CLUTCH DISC ASSEMBLY (a) Using vernier calipers, measure the rivet head depth. Minimum rivet depth: 0.3 mm (0.012 in.) If necessary, replace the clutch disc assembly. CLUTCH – CLUTCH UNIT CL–33 (b) Install the clutch disc assembly to the transaxle assembly. NOTICE: Take care not to insert the clutch disc assembly in the wrong direction. (c) Using a dial indicator with a roller instrument, measure the clutch disc assembly runout. Maximum runout: 0.8 mm (0.031 in.) If necessary, replace the clutch disc assembly. Transaxle Side C127504E02 2. INSPECT CLUTCH COVER ASSEMBLY (a) Using vernier calipers, inspect the diaphragm spring for depth and width of wear. Maximum: A (Depth): 0.5 mm (0.020 in.) B (Width): 6.0 mm (0.236 in.) If necessary, replace the clutch cover assembly. 3. INSPECT FLYWHEEL SUB-ASSEMBLY (a) Using a dial indicator, measure the flywheel runout. Maximum runout: 0.1 mm (0.004 in.) If necessary, replace the flywheel sub-assembly. 4. INSPECT CLUTCH RELEASE BEARING ASSEMBLY (a) Check that the bearing moves smoothly without abnormal resistance by turning the sliding parts of the bearing (contact surfaces with the clutch cover) while applying force in the axial direction. (b) Inspect the bearing for damage or wear. If necessary, replace the release bearing assembly. B A D025281E01 C127506 N000414E01 CL CL–34 CLUTCH – CLUTCH UNIT 5. SST CL INSPECT AND ADJUST CLUTCH COVER ASSEMBLY (a) Using a dial indicator with a roller instrument, check the diaphragm spring tip alignment. Maximum variation: 0.5 mm (0.020 in.) If alignment is not as specified, adjust the diaphragm spring tip alignment with SST. SST 09333-00013 D008946E01 REASSEMBLY 1. INSTALL CLUTCH DISC ASSEMBLY (a) Insert SST into the clutch disc assembly, then insert them into the flywheel sub-assembly. SST 09301-00220 NOTICE: Take care not to insert the clutch disc assembly in the wrong direction. 2. REMOVE AND INSTALL CLUTCH COVER ASSEMBLY (a) Align the matchmarks on the clutch cover assembly with the one on the flywheel sub-assembly. (b) Following the procedures shown in the illustration, tighten the 6 bolts in order, starting with the bolt located near the knock pin on the top. Torque: 19 N*m (195 kgf*cm, 14 ft.*lbf) HINT: • Following the order in the illustration, evenly tighten the bolts one turn at a time. • Lightly move SST up and down, and right and left after checking that the disc is in the center to tighten the bolts. SST 09301-00210 SST Flywheel Side C127508E01 7 3 SST 1 (Temporarily), 4 6 2 5 Matchmarks C127509E02 CLUTCH – CLUTCH UNIT CL–35 3. INSTALL RELEASE FORK SUPPORT (a) Install the release fork support to the manual transaxle assembly. Torque: 47 N*m (480 kgf*cm, 35 ft.*lbf) 4. INSTALL RELEASE BEARING HUB CLIP (a) Install the release bearing hub clip to the release bearing assembly. CL C083809 5. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY (a) Apply release hub grease to the contact surfaces between the release fork and release bearing, fork and push rod, and fork and fork support. Sealant: Part No. 08887-01806, RELEASE HUB GREASE or equivalent (b) Install the release fork to the release bearing assembly. 6. INSTALL CLUTCH RELEASE BEARING ASSEMBLY (a) Apply clutch spline grease to the input shaft spline as shown in the illustration. Sealant: Part No. 08887-01706, CLUTCH SPLINE GREASE or equivalent Release Hub Grease C128464E01 C133434 (b) Install the release fork with the release bearing assembly to the manual transaxle assembly. NOTICE: After installation, move the fork back and forth to check that the release bearing slides smoothly. C069774 7. INSTALL CLUTCH RELEASE FORK BOOT 8. INSTALL MANUAL TRANSAXLE ASSEMBLY See page MX-27. CL–38 CLUTCH – CLUTCH START SWITCH REMOVAL 1. 4.5 to 5.5 mm (0.1772 to 0.2165 in.) CL INSPECTION 1. 1 2 CL00477E02 REMOVE CLUTCH START SWITCH ASSEMBLY (a) Disconnect the clutch start switch assembly connector. (b) Remove the nut and clutch start switch assembly from the clutch pedal support. INSPECT CLUTCH START SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance Terminal connection Switch position Condition 1-2 ON (pushed) Below 1 Ω 1-2 OFF (free) 10 kΩ or higher CLUTCH – CLUTCH START SWITCH CL–39 INSTALLATION 1. INSTALL CLUTCH START SWITCH ASSEMBLY (a) Install the clutch start switch assembly with the nut. Torque: 16 N*m (160 kgf*cm, 12 ft.*lbf) (b) Connect the clutch start switch assembly connector. 2. INSPECT CLUTCH START SWITCH ASSEMBLY See page CL-37. CL EX–1 2GR-FE EXHAUST – EXHAUST PIPE EXHAUST PIPE 2GR-FE EXHAUST ENGINE COMPONENTS EXHAUST PIPE SUPPORT NO. 4 EXHAUST FRONT PIPE ASSEMBLY 56 (571, 41) HEATED OXYGEN SENSOR (BANK 1 SENSOR 2) GASKET GASKET 56 (571, 41) 62 (632, 46) EXHAUST TAIL PIPE ASSEMBLY GASKET 62 (632, 46) 33 (337, 24) EXHAUST PIPE SUPPORT NO. 4 REAR EXHAUST PIPE NO. 1 SUPPORT BRACKET 44 (449, 32) EXHAUST PIPE SUPPORT NO. 4 44 (449, 32) GASKET FRONT EXHAUST PIPE NO. 1 SUPPORT BRACKET HEATED OXYGEN SENSOR (BANK 2 SENSOR 2) 33 (337, 24) 43 (438, 32) 43 (438, 32) FRONT EXHAUST PIPE SUPPORT BRACKET EXHAUST PIPE SUPPORT NO. 4 EX EXHAUST PIPE DAMPER EXHAUST CENTER PIPE ASSEMBLY 19 (194, 14) EXHAUST PIPE SUPPORT NO. 4 43 (438, 32) GASKET EXHAUST PIPE SUPPORT NO. 4 EXHAUST PIPE SUPPORT NO. 4 43 (438, 32) N*m (kgf*cm, ft.*lbf) : Specified torque EXHAUST TAIL PIPE ASSEMBLY Non-reusable part A135661E01 EX–2 2GR-FE EXHAUST – EXHAUST PIPE REMOVAL 1. REMOVE EXHAUST TAIL PIPE ASSEMBLY (a) Remove the 4 nuts and 2 exhaust tail pipes. A135718 (b) Remove the 2 gaskets from the exhaust center pipe assembly. 2. REMOVE EXHAUST CENTER PIPE ASSEMBLY (a) Remove the 2 bolts, 2 nuts and exhaust center pipe assembly. EX A135719 2GR-FE EXHAUST – EXHAUST PIPE EX–3 (b) Remove the gasket from the exhaust pipe assembly. 3. REMOVE FRONT EXHAUST PIPE NO. 1 SUPPORT BRACKET (a) Remove the 2 nuts and front support brackets. 4. REMOVE EXHAUST FRONT PIPE ASSEMBLY (a) Disconnect the 2 heated oxygen sensor (bank 1, 2 sensor 2) connectors. (b) Remove the 2 nuts from the exhaust front pipe (left bank exhaust manifold side). A085549E01 EX A135720 (c) Remove the 2 nuts from the exhaust front pipe (right bank exhaust pipe manifold side). (d) Remove the exhaust front pipe. (e) Remove the 2 gaskets from the exhaust front pipe. Bracket A132948E01 5. REMOVE HEATED OXYGEN SENSOR (See page EC21) 6. REMOVE REAR EXHAUST PIPE NO. 1 SUPPORT BRACKET (a) Remove the 2 bolts and rear support bracket. EX–4 2GR-FE EXHAUST – EXHAUST PIPE INSTALLATION Pipe Assembly Front 1. INSTALL REAR EXHAUST PIPE NO. 1 SUPPORT BRACKET (a) Install the rear support bracket with the 2 bolts. Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf) NOTICE: Be sure to install the bracket in the correct direction. 2. INSTALL HEATED OXYGEN SENSOR (See page EC21) 3. INSTALL EXHAUST FRONT PIPE ASSEMBLY (a) Install 2 new gaskets to the exhaust front pipe. (b) Install the exhaust front pipe to the exhaust manifolds with the 4 nuts. Bracket A060823E04 EX A135720 Torque: 62 N*m (632 kgf*cm, 46 ft.*lbf) A085549E01 4. INSTALL FRONT EXHAUST PIPE NO. 1 SUPPORT BRACKET (a) Install the front support brackets with the 2 nuts. Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf) NOTICE: Be sure to install the support brackets in the correct direction. 5. INSTALL EXHAUST CENTER PIPE ASSEMBLY (a) Install a new gasket to the exhaust center pipe assembly. 2GR-FE EXHAUST – EXHAUST PIPE EX–5 (b) Install the exhaust center pipe to the exhaust front pipe with the 2 nuts and 2 bolts. A135719 Torque: 56 N*m (571 kgf*cm, 41 ft.*lbf) 6. INSTALL EXHAUST TAIL PIPE ASSEMBLY (a) Install 2 new gaskets to the exhaust tail pipes. (b) Install the 2 exhaust tail pipes with the 4 nuts. EX A135718 Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 7. CHECK FOR EXHAUST GAS LEAKS If gas is leaking, tighten the areas necessary to stop the leak. Replace the damaged parts as necessary. POWER STEERING – POWER STEERING SYSTEM PS–1 POWER STEERING SYSTEM PRECAUTION 1. 2. HANDLING PRECAUTIONS FOR SRS AIRBAG SYSTEM (a) The vehicle is equipped with an SRS (Supplemental Restraint System) such as airbags. Failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing. This may cause a serious accident. Before servicing (including inspection, replacement, removal and installation of parts), be sure to read the precautionary notices for the Supplemental Restraint System (See page RS-1). PRECAUTIONS FOR REMOVAL, INSTALLATION AND REPLACEMENT OF POWER STEERING COMPONENTS (a) Be sure to turn the front wheels straight ahead when removing and installing the power steering link assembly. (b) If disconnecting the steering sliding yoke and the pinion shaft of the power steering link assembly, be sure to put matchmarks before starting the operation. PS PS–2 POWER STEERING – POWER STEERING SYSTEM PARTS LOCATION VANE PUMP PS POWER STEERING LINK C139138E01 PS–3 POWER STEERING – POWER STEERING SYSTEM PROBLEM SYMPTOMS TABLE HINT: Use the table below to help determine the cause of the problem. The numbers indicate likely causes of the problem in descending order. Check each part in order. If necessary, repair or replace faulty parts. POWER STEERING SYSTEM Symptom Suspected area 1. Tire (Improperly inflated) Hard steering PS-3 3. Drive belt (Loose) (for 2AZ-FE) EM-6 4. Drive belt (Loose) (for 2GR-FE) EM-6 5. Front wheel alignment (Incorrect) SP-4 SP-28 8. Steering column (Binding) SR-38 9. Power steering vane pump (for 2AZ-FE) PS-10 10. Power steering vane pump (for 2GR-FE) PS-24 11. Power steering gear PS-40 1. Tire (Improperly inflated) TW-3 2. Front wheel alignment (Incorrect) SP-4 3. Steering column (Binding) SR-38 4. Power steering gear PS-40 2. Suspension arm ball joints (Worn) SP-28 3. Front wheel bearing (Worn) AH-5 4. Power steering gear PS-40 1. Power steering fluid level (Low) PS-3 2. Steering system joints (Worn) Abnormal noise - 7. Suspension arm ball joints (Worn) 1. Steering system joints (Worn) Excessive free play TW-3 2. Power steering fluid level (Low) 6. Steering system joints (Worn) Poor return See page - 3. Power steering vane pump (for 2AZ-FE) PS-10 4. Power steering vane pump (for 2GR-FE) PS-24 5. Power steering gear PS-40 ON-VEHICLE INSPECTION Example: 1. INSPECT DRIVE BELT (a) Visually check the drive belt for excessive wear, frayed cords, etc. If any defect is found, replace the drive belt. HINT: Cracks on the rib side of a belt are considered acceptable. Replace the belt if there are any missing ribs. 2. CHECK POWER STEERING FLUID LEVEL (a) Keep the vehicle level. F040449E03 PS PS–4 POWER STEERING – POWER STEERING SYSTEM HOT Range (b) With the engine stopped, check the fluid level in the fluid reservoir. If necessary, add fluid. Fluid: ATF DEXRON II or III, or equivalent HINT: If the fluid is hot, check that the fluid level is within the HOT range on the fluid reservoir. If the fluid is cold, check that the fluid level is within the COLD range. (c) Start the engine and run it at idle. (d) Turn the steering wheel from lock to lock several times to raise fluid temperature. Fluid temperature: 70 to 80°C (158 to 176°F) COLD Range C133502E01 Normal (e) Check for foaming or emulsification. If foaming or emulsification is identified, bleed the power steering system (See page PS-7). Abnormal C137876E01 PS Engine Idling (f) With the engine idling, measure the fluid level in the fluid reservoir. (g) Stop the engine. (h) Wait a few minutes and remeasure the fluid level in the fluid reservoir. Maximum fluid level rise: 5 mm (0.20 in.) If a problem is found, bleed the power steering system (See page PS-7). (i) Check the fluid level. Engine Stopped 5 mm (0.20 in.) or less C137875E01 3. INSPECT STEERING FLUID PRESSURE (a) Disconnect the pressure feed tube assembly from the vane pump assembly (See page PS-10 for 2AZFE, PS-24 for 2GR-FE). POWER STEERING – POWER STEERING SYSTEM SST Attachment OUT IN PS–5 (b) Connect SST as shown in the illustration. SST 09640-10010 (09641-01010, 09641-01060, 09641-01030) NOTICE: Check that the valve of the SST is in the open position. (c) Bleed the power steering system (See page PS-7). (d) Start the engine and run it at idle. (e) Turn the steering wheel from lock to lock several times to raise fluid temperature. Fluid temperature: 70 to 80°C (158 to 176°F) Attachment C133506E01 (f) Power Steering Fluid Reservoir Power Steering Gear Assembly SST Power Steering Vane Pump Assembly Valve Closed C106309E03 With the engine idling, close the valve of the SST and observe the reading on the SST. Minimum fluid pressure: 7,800 to 8,300 kPa (79.5 to 84.6 kgf/cm2, 1,131 to 1,204 psi) NOTICE: • Do not keep the valve closed for more than 10 seconds. • Do not allow the fluid temperature to become too high. PS PS–6 POWER STEERING – POWER STEERING SYSTEM (g) With the engine idling, open the valve fully. (h) Measure the fluid pressure at engine speeds of 1,000 rpm and 3,000 rpm. Fluid pressure difference: 490 kPa (5 kgf/cm2, 71 psi) or less NOTICE: Do not turn the steering wheel. Power Steering Fluid Reservoir Power Steering Gear Assembly SST Power Steering Vane Pump Assembly Valve Open C106310E03 (i) With the engine idling and the valve fully opened, turn the steering wheel left or right to the full lock position. Observe the reading on the SST. Minimum fluid pressure: 7,800 to 8,300 kPa (79.5 to 84.6 kgf/cm2, 1,131 to 1,204 psi) NOTICE: • Do not keep the steering wheel in the full lock position for more than 10 seconds. • Do not allow the fluid temperature to become too high. (j) Disconnect the SST. (k) Connect the pressure feed tube assembly to the vane pump assembly (See page PS-20 for 2AZ-FE, PS-34 for 2GR-FE). (l) Bleed the power steering system (See page PS-7). Power Steering Fluid Reservoir PS Power Steering Gear Assembly (Lock Position) SST Power Steering Vane Pump Assembly Valve Open C106311E03 4. CHECK STEERING EFFORT (a) Stop the vehicle on a level, paved surface and turn the wheels straight ahead. (b) Disconnect the negative (-) battery cable from the battery (See page RS-1). (c) Remove the steering pad (See page RS-349). (d) Connect the negative (-) battery cable to the battery. (e) Using a torque wrench, check if the steering wheel set nut is properly tightened. Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf) (f) Start the engine and run it at idle. POWER STEERING – POWER STEERING SYSTEM C132536 PS–7 (g) Turn the steering wheel 90 degrees to the right and check steering effort (torque) while turning the wheel. Check the opposite direction in the same manner. Torque: Steering effort (Reference) 6.0 N*m (61 kgf*cm, 53 in.*lbf) (LE Grade, XLE Grade) Steering effort (Reference) 6.8 N*m (69 kgf*cm, 60 in.*lbf) (SE Grade) HINT: Check tire type, pressure, and the road surface before making your diagnosis. (h) Disconnect the negative (-) battery cable from the battery. (i) Torque the steering wheel set nut. Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf) (j) Install the steering pad (See page RS-350). (k) Connect the negative (-) battery cable to the battery. (l) Clear the DTCs (See page RS-41). (m) Inspect the airbag warning light (See page RS-32). PS POWER STEERING – POWER STEERING FLUID PS–7 POWER STEERING FLUID BLEEDING 1. Normal BLEED POWER STEERING SYSTEM (a) Check the fluid level (See page PS-3). (b) Jack up the front of the vehicle and support it with stands. (c) Turn the steering wheel. (1) With the engine stopped, turn the steering wheel slowly from lock to lock several times. (d) Lower the vehicle. (e) Start the engine. (1) Run the engine at idle for a few minutes. (f) Turn the steering wheel. (1) With the engine idling, turn the steering wheel left or right to the full lock position and keep it in that position for 2 to 3 seconds, then turn the steering wheel to the opposite full lock position and keep it there for 2 to 3 seconds. (2) Repeat this procedure several times. (g) Stop the engine. (h) Check for foaming or emulsification. If the system has to be bled twice because of forming or emulsification, be sure to check for fluid leaks in the system. (i) Check the fluid level (See page PS-3). Abnormal C137876E01 PS PS–8 POWER STEERING – VANE PUMP (for 2AZ-FE) VANE PUMP (for 2AZ-FE) POWER STEERING STEERING COMPONENTS PRESSURE FEED TUBE ASSEMBLY 50 (510, 37) UNION BOLT POWER STEERING FLUID PRESSURE SWITCH CONNECTOR VANE PUMP ASSEMBLY 43 (439, 32) *29 (294, 21) GASKET PS NO. 1 FLUID RESERVOIR TO PUMP HOSE FAN AND GENERATOR V BELT N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part * For use with SST C133504E01 PS–9 POWER STEERING – VANE PUMP (for 2AZ-FE) 69 (704, 51) PRESSURE PORT UNION O-RING FLOW CONTROL VALVE ASSEMBLY FLOW CONTROL VALVE COMPRESSION SPRING 21 (214, 16) POWER STEERING FLUID PRESSURE SWITCH POWER STEERING SUCTION PORT UNION VANE PUMP FRONT HOUSING 12 (122, 9) O-RING VANE PUMP HOUSING OIL SEAL PS 22 (224, 16) VANE PUMP SHAFT WITH PULLEY VANE PUMP REAR HOUSING O-RING VANE PUMP ROTOR VANE PUMP FRONT SIDE PLATE x 10 22 (224, 16) VANE PUMP SHAFT SNAP RING VANE PUMP PLATE O-RING VANE PUMP CAM RING Apply power steering fluid Non-reusable part N*m (kgf*cm, ft.*lbf) : Specified torque C133505E02 PS–10 POWER STEERING – VANE PUMP (for 2AZ-FE) REMOVAL Front PS 1. DRAIN POWER STEERING FLUID 2. REMOVE FRONT WHEEL RH 3. REMOVE ENGINE UNDER COVER RH 4. REMOVE FRONT FENDER APRON SEAL RH 5. REMOVE FAN AND GENERATOR V BELT (See page EM-6) 6. DISCONNECT NO. 1 FLUID RESERVOIR TO PUMP HOSE (a) Slide the clip and disconnect the No. 1 fluid reservoir to pump hose from the vane pump assembly. 7. DISCONNECT PRESSURE FEED TUBE ASSEMBLY (a) Remove the union bolt and disconnect the pressure feed tube assembly from the vane pump assembly. (b) Remove the gasket from the pressure feed tube assembly. 8. DISCONNECT POWER STEERING FLUID PRESSURE SWITCH CONNECTOR (a) Disconnect the power steering fluid pressure switch connector. C135224E02 C135226 C135234 POWER STEERING – VANE PUMP (for 2AZ-FE) 9. PS–11 REMOVE VANE PUMP ASSEMBLY (a) Using SST, loosen the 2 bolts and remove the vane pump assembly. SST 09249-63010 SST C135228E01 (b) Remove the 2 bolts from the vane pump assembly. PS C135233 DISASSEMBLY 1. HOLD VANE PUMP ASSEMBLY (a) Using SST, hold the vane pump assembly in a vise. SST 09630-00014 (09631-00132) 2. REMOVE POWER STEERING SUCTION PORT UNION (a) Remove the bolt and power steering suction port union from the vane pump assembly. (b) Using a screwdriver, remove the O-ring from the power steering suction port union. SST C135230E01 C135231 PS–12 POWER STEERING – VANE PUMP (for 2AZ-FE) 3. REMOVE POWER STEERING FLUID PRESSURE SWITCH (a) Remove the power steering fluid pressure switch from the vane pump assembly. NOTICE: Perform this procedure only when the power steering fluid pressure switch is replaced. 4. REMOVE FLOW CONTROL VALVE ASSEMBLY (a) Remove the pressure port union. (b) Remove the O-ring from the pressure port union. (c) Remove the flow control valve assembly and the flow control valve compression spring. 5. REMOVE VANE PUMP REAR HOUSING (a) Remove the 4 bolts and vane pump rear housing from the vane pump front housing. C133180 C132033 PS C107024 (b) Using a screwdriver, remove the O-ring from the vane pump rear housing. HINT: Tape the screwdriver tip before use. Protective Tape C107025E02 6. C057767 REMOVE VANE PUMP SHAFT WITH PULLEY (a) Using 2 screwdrivers, remove the vane pump shaft snap ring from the vane pump shaft with pulley. (b) Remove the vane pump shaft with pulley. POWER STEERING – VANE PUMP (for 2AZ-FE) PS–13 7. REMOVE VANE PUMP ROTOR (a) Remove the 10 vane pump plates. (b) Remove the vane pump rotor. 8. REMOVE VANE PUMP CAM RING (a) Remove the vane pump cam ring from the vane pump front housing. 9. REMOVE VANE PUMP FRONT SIDE PLATE (a) Remove the vane pump front side plate from the vane pump front housing. C114697 C114698 PS C114699 Protective Tape (b) Using a screwdriver, remove the O-ring from the vane pump front side plate. HINT: Tape the screwdriver tip before use. C107029E02 (c) Remove the O-ring from the vane pump front housing. C114700 PS–14 POWER STEERING – VANE PUMP (for 2AZ-FE) Cloth 10. REMOVE VANE PUMP HOUSING OIL SEAL (a) Using a screwdriver and a shop rag or a piece of cloth, remove the vane pump housing oil seal. NOTICE: Be careful not to damage the vane pump front housing. C114701E02 INSPECTION [b] 1. INSPECT VANE PUMP SHAFT AND BUSHING IN VANE PUMP FRONT HOUSING (a) Using a micrometer, measure the outer diameter [a] of the vane pump shaft with pulley. (b) Using a vernier caliper, measure the inner diameter [b] of the vane pump front housing bushing. (c) Calculate the oil clearance. Oil clearance = Inner diameter of the bushing [b] Outer diameter of the shaft [a]. Maximum oil clearance: 0.07 mm (0.0028 in.) If oil clearance exceeds the maximum, replace the vane pump assembly. 2. INSPECT VANE PUMP ROTOR AND VANE PUMP PLATE CLEARANCE (a) Using a micrometer, measure the thickness of the vane pump plates. Standard thickness: 1.405 to 1.411 mm (0.05531 to 0.05555 in.) If the thickness is not within the specified range, replace the vane pump assembly. [a] C132029E04 PS Thickness C101977E01 (b) Using a feeler gauge, measure the clearance between the side face of the vane pump rotor groove and the vane pump plates. Maximum clearance: 0.03 mm (0.0012 in.) If clearance exceeds the maximum, replace the vane pump assembly. Feeler Gauge C101978E01 POWER STEERING – VANE PUMP (for 2AZ-FE) 3. PS–15 INSPECT FLOW CONTROL VALVE ASSEMBLY (a) Coat the flow control valve assembly with power steering fluid and check that it falls smoothly into the flow control valve due to its own weight. If the control valve does not fall into the hole smoothly, replace the vane pump assembly. C132030 (b) Check the flow control valve assembly for leakage. Close one of the holes and apply compressed air, 392 to 490 kPa (4 to 5 kgf/cm2, 57 to 71 psi), into the opposite side hole, and confirm that air does not come out from the end holes. If air leaks, replace the vane pump assembly. Compressed Air C132031E01 4. Vernier Caliper 5. INSPECT PRESSURE PORT UNION If the union seat in the pressure port union is severely damaged, replace the vane pump assembly. 6. INSPECT TOTAL PRELOAD (a) Check that the pump rotates smoothly without abnormal noise. (b) Temporarily install the service bolt. Recommended service bolt: Thread diameter: 10 mm (0.39 in.) Thread pitch: 1.25 mm (0.0492 in.) Bolt length: 50 mm (1.97 in.) (c) Using a torque wrench, check the pump rotating torque. Rotating torque: 0.27 N*m (2.8 kgf*cm, 2.4 in.*lbf) or less If the rotating torque is not as specified, check the vane pump housing oil seal. C132032E01 Service Bolt C053369E10 INSPECT FLOW CONTROL VALVE COMPRESSION SPRING (a) Using a vernier caliper, measure the free length of the flow control valve compression spring. Minimum free length: 29.2 mm (1.150 in.) If the length is less than the minimum, replace the vane pump assembly. PS PS–16 POWER STEERING – VANE PUMP (for 2AZ-FE) REASSEMBLY NOTICE: When installing parts, coat the parts indicated by arrows with power steering fluid (See page PS-8). 1. INSTALL VANE PUMP HOUSING OIL SEAL (a) Coat a new vane pump housing oil seal lip with power steering fluid. (b) Using SST and a press, install the vane pump housing oil seal. SST 09950-60010 (09951-00280), 09950-70010 (09951-07100) NOTICE: Make sure that the oil seal is installed facing in the correct direction as shown in the illustration. 2. INSTALL VANE PUMP SHAFT WITH PULLEY (a) Coat the inside surface of the bushing in the vane pump front housing with power steering fluid. (b) Gradually insert the vane pump shaft with pulley. NOTICE: Do not damage the oil seal lip in the front housing. HINT: Wrap protective tape around the spline of the vane pump shaft with pulley in order to prevent damage to the oil seal. 3. INSTALL VANE PUMP FRONT SIDE PLATE (a) Coat a new O-ring with power steering fluid and install it into the vane pump front housing. SST SST C114702E01 Protective Tape PS C114703E01 C132035 (b) Coat a new O-ring with power steering fluid and install it onto the vane pump front side plate. C107035 POWER STEERING – VANE PUMP (for 2AZ-FE) PS–17 (c) Align the notch of the vane pump front side plate with that of the vane pump front housing, and install the vane pump front side plate. NOTICE: Make sure that the vane pump front side plate is installed facing in the correct direction. Match C132040E01 Inscribed Mark 4. Match INSTALL VANE PUMP CAM RING (a) Align the notch of the cam ring with that of the vane pump front side plate, and install the vane pump cam ring with the inscribed mark facing upward. NOTICE: Make sure that the vane pump cam ring is installed facing in the correct direction. C139139E01 5. C107038 INSTALL VANE PUMP ROTOR (a) Install the vane pump rotor. HINT: Vane pump rotor can be installed in both directions. (b) Coat the 10 vane pump plates with power steering fluid. PS PS–18 POWER STEERING – VANE PUMP (for 2AZ-FE) (c) Install the vane pump plates with the round end facing outward. NOTICE: Make sure that the vane pump plates are installed facing in the correct direction. Round End Outward C141370E01 PS 6. INSTALL VANE PUMP SHAFT SNAP RING (a) Using a screwdriver and a snap ring expander, install a new vane pump shaft snap ring onto the vane pump shaft with pulley. 7. INSTALL VANE PUMP REAR HOUSING (a) Coat a new O-ring with power steering fluid and install it onto the vane pump rear housing. D030336E01 C107040 Match C136780E01 (b) Align the straight pin of the vane pump rear housing with the notches of the vane pump cam ring, vane pump front side plate, and vane pump front housing. POWER STEERING – VANE PUMP (for 2AZ-FE) PS–19 (c) Install the vane pump rear housing with the 4 bolts. Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf) 8. INSPECT TOTAL PRELOAD (See page PS-15) 9. INSTALL FLOW CONTROL VALVE ASSEMBLY (a) Coat the flow control valve assembly with power steering fluid. (b) Install the flow control valve compression spring and the flow control valve assembly to the vane pump front housing. (c) Coat a new O-ring with power steering fluid and install it onto the pressure port union. (d) Install the pressure port union to the vane pump front housing. Torque: 69 N*m (704 kgf*cm, 51 ft.*lbf) C107024 C132033 10. INSTALL POWER STEERING FLUID PRESSURE SWITCH (a) Coat the new O-ring attached to the new power steering fluid pressure switch with power steering fluid. (b) Install the power steering fluid pressure switch to the vane pump assembly. Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf) NOTICE: Do not use a power steering fluid pressure switch that has been subjected an impact; for example, due to it having been dropped. C133180 11. INSTALL POWER STEERING SUCTION PORT UNION (a) Coat a new O-ring with power steering fluid and install it to the power steering suction port union. (b) Install the power steering suction port union to the vane pump assembly with the bolt. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) C135231 PS PS–20 POWER STEERING – VANE PUMP (for 2AZ-FE) INSTALLATION 1. INSTALL VANE PUMP ASSEMBLY (a) Temporarily install the 2 bolts to the vane pump assembly. (b) Install the vane pump assembly. C135233 (c) Using SST, tighten the 2 bolts. SST 09249-63010 Torque: Without SST 43 N*m (439 kgf*cm, 32 ft.*lbf) With SST 29 N*m (294 kgf*cm, 21 ft.*lbf) NOTICE: • Use a torque wrench with a fulcrum length of 300 mm (11.81 in.). • This torque value is accurate when SST is parallel to the torque wrench. SST PS Fulcrum Length C135229E01 C135234 2. CONNECT POWER STEERING FLUID PRESSURE SWITCH CONNECTOR (a) Connect the connector to the power steering fluid pressure switch. 3. CONNECT PRESSURE FEED TUBE ASSEMBLY (a) Install a new gasket to the pressure feed tube assembly. POWER STEERING – VANE PUMP (for 2AZ-FE) PS–21 (b) Connect the pressure feed tube assembly to the vane pump assembly with the union bolt. Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf) NOTICE: Make sure that the stopper of the pressure feed tube assembly contacts the vane pump assembly securely as shown in the illustration. C135227 4. Paint Mark 2 to 7 mm (0.08 to 0.28 in.) CONNECT NO. 1 FLUID RESERVOIR TO PUMP HOSE (a) Connect the No. 1 fluid reservoir to pump hose to the vane pump assembly with the clip. NOTICE: • Connect the No. 1 oil reservoir to pump hose with the paint mark facing toward the rear of the vehicle. • Push the No. 1 oil reservoir to pump hose as far as it will go as shown in the illustration. • Install the clip at the position specified in the illustration. 5. INSTALL FAN AND GENERATOR V BELT (See page EM-6) 6. ADD POWER STEERING FLUID 7. BLEED POWER STEERING FLUID (See page PS-7) 8. CHECK POWER STEERING FLUID LEVEL (See page PS-3) 9. CHECK FOR POWER STEERING FLUID LEAKS C135225E01 10. INSTALL FRONT FENDER APRON SEAL RH 11. INSTALL ENGINE UNDER COVER RH 12. INSTALL FRONT WHEEL RH Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) PS PS–22 POWER STEERING – VANE PUMP (for 2GR-FE) VANE PUMP (for 2GR-FE) POWER STEERING STEERING COMPONENTS POWER STEERING FLUID PRESSURE SWITCH CONNECTOR 50 (510, 37) UNION BOLT PRESSURE FEED TUBE ASSEMBLY FAN AND GENERATOR V BELT GASKET 9.8 (100, 87 in.*lbf) PS VANE PUMP ASSEMBLY NO. 1 FLUID RESERVOIR TO PUMP HOSE 43 (439, 32) *29 (294, 21) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part * For use with SST C133489E01 PS–23 POWER STEERING – VANE PUMP (for 2GR-FE) 69 (704, 51) PRESSURE PORT UNION O-RING FLOW CONTROL VALVE COMPRESSION SPRING FLOW CONTROL VALVE ASSEMBLY 21 (214, 16) POWER STEERING FLUID PRESSURE SWITCH POWER STEERING SUCTION PORT UNION VANE PUMP FRONT HOUSING 12 (122, 9) O-RING VANE PUMP HOUSING OIL SEAL VANE PUMP REAR HOUSING 22 (224, 16) 22 (224, 16) VANE PUMP SHAFT WITH PULLEY O-RING VANE PUMP ROTOR VANE PUMP FRONT SIDE PLATE x 10 VANE PUMP SHAFT SNAP RING VANE PUMP PLATE O-RING VANE PUMP CAM RING Apply power steering fluid Non-reusable part N*m (kgf*cm, ft.*lbf) : Specified torque C133490E04 PS PS–24 POWER STEERING – VANE PUMP (for 2GR-FE) REMOVAL Front PS 1. DRAIN POWER STEERING FLUID 2. REMOVE FRONT WHEEL RH 3. REMOVE FRONT FENDER APRON SEAL RH 4. REMOVE V-BANK COVER SUB-ASSEMBLY 5. REMOVE FAN AND GENERATOR V BELT (See page EM-6) 6. DISCONNECT NO. 1 FLUID RESERVOIR TO PUMP HOSE (a) Slide the clip and disconnect the No. 1 fluid reservoir to pump hose from the vane pump assembly. 7. DISCONNECT PRESSURE FEED TUBE ASSEMBLY (a) Remove the union bolt and disconnect the pressure feed tube assembly from the vane pump assembly. (b) Remove the bolt and separate the pressure feed tube clamp. (c) Remove the gasket from the pressure feed tube assembly. 8. DISCONNECT POWER STEERING FLUID PRESSURE SWITCH CONNECTOR (a) Disconnect the power steering fluid pressure switch connector. C133174E02 C133175 C133176 POWER STEERING – VANE PUMP (for 2GR-FE) 9. (A) PS–25 REMOVE VANE PUMP ASSEMBLY (a) Using SST, loosen bolt (A) and remove bolt (B), and then remove the vane pump assembly. SST 09249-63010 (B) SST C133177E01 (b) Remove the bolt from the vane pump assembly. PS C135238 DISASSEMBLY 1. HOLD VANE PUMP ASSEMBLY (a) Using SST, hold the vane pump assembly in a vise. SST 09630-00014 (09631-00132) 2. REMOVE POWER STEERING SUCTION PORT UNION (a) Remove the bolt and the power steering suction port union from the vane pump assembly. (b) Using a screwdriver, remove the O-ring from the power steering suction port union. SST C141305E01 C133179 PS–26 POWER STEERING – VANE PUMP (for 2GR-FE) 3. REMOVE POWER STEERING FLUID PRESSURE SWITCH (a) Remove the power steering fluid pressure switch from the vane pump assembly. NOTICE: Perform this procedure only when the power steering fluid pressure switch is replaced. 4. REMOVE FLOW CONTROL VALVE ASSEMBLY (a) Remove the pressure port union. (b) Remove the O-ring from the pressure port union. (c) Remove the flow control valve assembly and the flow control valve compression spring. 5. REMOVE VANE PUMP REAR HOUSING (a) Remove the 4 bolts and vane pump rear housing from the vane pump front housing. C133180 C132033 PS C107024 (b) Using a screwdriver, remove the O-ring from the vane pump rear housing. HINT: Tape the screwdriver tip before use. Protective Tape C107025E02 6. C057767 REMOVE VANE PUMP SHAFT WITH PULLEY (a) Using 2 screwdrivers, remove the vane pump shaft snap ring from the vane pump shaft with pulley. (b) Remove the vane pump shaft with pulley. POWER STEERING – VANE PUMP (for 2GR-FE) PS–27 7. REMOVE VANE PUMP ROTOR (a) Remove the 10 vane pump plates. (b) Remove the vane pump rotor. 8. REMOVE VANE PUMP CAM RING (a) Remove the vane pump cam ring from the vane pump front housing. 9. REMOVE VANE PUMP FRONT SIDE PLATE (a) Remove the vane pump front side plate from the vane pump front housing. C114697 C114698 PS C114699 Protective Tape (b) Using a screwdriver, remove the O-ring from the vane pump front side plate. HINT: Tape the screwdriver tip before use. C107029E02 (c) Remove the O-ring from the vane pump front housing. C114700 PS–28 POWER STEERING – VANE PUMP (for 2GR-FE) Cloth 10. REMOVE VANE PUMP HOUSING OIL SEAL (a) Using a screwdriver and a shop rag or a piece of cloth, remove the vane pump housing oil seal. NOTICE: Be careful not to damage the vane pump front housing. C114701E02 INSPECTION [b] 1. INSPECT VANE PUMP SHAFT AND BUSHING IN VANE PUMP FRONT HOUSING (a) Using a micrometer, measure the outer diameter [a] of the vane pump shaft with pulley. (b) Using a vernier caliper, measure the inner diameter [b] of the vane pump front housing bushing. (c) Calculate the oil clearance. Oil clearance = Inner diameter of the bushing [b] Outer diameter of the shaft [a]. Maximum oil clearance: 0.07 mm (0.0028 in.) If oil clearance exceeds the maximum, replace the vane pump assembly. 2. INSPECT VANE PUMP ROTOR AND VANE PUMP PLATE CLEARANCE (a) Using a micrometer, measure the thickness of the vane pump plates. Standard thickness: 1.405 to 1.411 mm (0.05531 to 0.05555 in.) If the thickness is not within the specified range, replace the vane pump assembly. [a] C132029E04 PS Thickness C101977E01 (b) Using a feeler gauge, measure the clearance between the side face of the vane pump rotor groove and the vane pump plates. Maximum clearance: 0.03 mm (0.0012 in.) If clearance exceeds the maximum, replace the vane pump assembly. Feeler Gauge C101978E01 POWER STEERING – VANE PUMP (for 2GR-FE) 3. PS–29 INSPECT FLOW CONTROL VALVE ASSEMBLY (a) Coat the flow control valve assembly with power steering fluid and check that it falls smoothly into the flow control valve due to its own weight. If the control valve does not fall into the hole smoothly, replace the vane pump assembly. C132030 (b) Check the flow control valve assembly for leakage. Close one of the holes and apply compressed air, 392 to 490 kPa (4 to 5 kgf/cm2, 57 to 71 psi), into the opposite side hole, and confirm that air does not come out from the end holes. If air leaks, replace the vane pump assembly. C132031 4. Vernier Caliper 5. INSPECT PRESSURE PORT UNION If the union seat in the pressure port union is severely damaged, replace the vane pump assembly. 6. INSPECT TOTAL PRELOAD (a) Check that the pump rotates smoothly without abnormal noise. (b) Temporarily install the service bolt. Recommended service bolt: Thread diameter: 10 mm (0.39 in.) Thread pitch: 1.25 mm (0.0492 in.) Bolt length: 50 mm (1.97 in.) (c) Using a torque wrench, check the pump rotating torque. Rotating torque: 0.27 N*m (2.8 kgf*cm, 2.4 in.*lbf) or less If the rotating torque is not as specified, check the vane pump housing oil seal. C132032E01 Service Bolt C053369E10 INSPECT FLOW CONTROL VALVE COMPRESSION SPRING (a) Using a vernier caliper, measure the free length of the flow control valve compression spring. Minimum free length: 29.2 mm (1.150 in.) If the length is less than the minimum, replace the vane pump assembly. PS PS–30 POWER STEERING – VANE PUMP (for 2GR-FE) REASSEMBLY NOTICE: When installing parts, coat the parts indicated by arrows with power steering fluid (See page PS-22). 1. INSTALL VANE PUMP HOUSING OIL SEAL (a) Coat a new vane pump housing oil seal lip with power steering fluid. (b) Using SST and a press, install the vane pump housing oil seal. SST 09950-60010 (09951-00280), 09950-70010 (09951-07100) NOTICE: Make sure that the oil seal is installed facing in the correct direction as shown in the illustration. 2. INSTALL VANE PUMP SHAFT WITH PULLEY (a) Coat the inside surface of the busing in the vane pump front housing with power steering fluid. (b) Gradually insert the vane pump shaft with pulley. NOTICE: Do not damage the oil seal lip in the front housing. HINT: Wrap protective tape around the spline of the vane pump shaft with pulley in order to prevent damage to the oil seal. 3. INSTALL VANE PUMP FRONT SIDE PLATE (a) Coat a new O-ring with power steering fluid and install it into the vane pump front housing. SST SST C114702E01 Protective Tape PS C114703E01 C132035 (b) Coat a new O-ring with power steering fluid and install it onto the vane pump front side plate. C107035 POWER STEERING – VANE PUMP (for 2GR-FE) PS–31 (c) Align the notch of the vane pump front side plate with that of the vane pump front housing, and install the vane pump front side plate. NOTICE: Make sure that the vane pump front side plate is installed facing in the correct direction. Match C132040E01 Inscribed Mark 4. Match INSTALL VANE PUMP CAM RING (a) Align the notch of the cam ring with that of the vane pump front side plate, and install the vane pump cam ring with the inscribed mark facing upward. NOTICE: Make sure that the vane pump cam ring is installed facing in the correct direction. C139139E01 5. C107038 INSTALL VANE PUMP ROTOR (a) Install the vane pump rotor. HINT: Vane pump rotor can be installed in both directions. (b) Coat the 10 vane pump plates with power steering fluid. PS PS–32 POWER STEERING – VANE PUMP (for 2GR-FE) (c) Install the vane pump plates with the round end facing outward. NOTICE: Make sure that the vane pump plates are installed facing in the correct direction. Round End Outward C141370E01 PS 6. INSTALL VANE PUMP SHAFT SNAP RING (a) Using a screwdriver and a snap ring expander, install a new vane pump shaft snap ring onto the vane pump shaft with pulley. 7. INSTALL VANE PUMP REAR HOUSING (a) Coat a new O-ring with power steering fluid and install it onto the vane pump rear housing. D030336E01 C107040 Match C136780E01 (b) Align the straight pin of the vane pump rear housing with the notches of the vane pump cam ring, vane pump front side plate, and vane pump front housing. POWER STEERING – VANE PUMP (for 2GR-FE) PS–33 (c) Install the vane pump rear housing with the 4 bolts. Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf) 8. INSPECT TOTAL PRELOAD (See page PS-29) 9. INSTALL FLOW CONTROL VALVE ASSEMBLY (a) Coat the flow control valve assembly with power steering fluid. (b) Install the flow control valve compression spring and the flow control valve assembly to the vane pump front housing. (c) Coat a new O-ring with power steering fluid and install it onto the pressure port union. (d) Install the pressure port union to the vane pump front housing. Torque: 69 N*m (704 kgf*cm, 51 ft.*lbf) C107024 C132033 10. INSTALL POWER STEERING FLUID PRESSURE SWITCH (a) Coat the new O-ring attached to the new power steering fluid pressure switch with power steering fluid. (b) Install the power steering fluid pressure switch to the vane pump assembly. Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf) NOTICE: Do not use a power steering fluid pressure switch that has been subjected an impact; for example, due to it having been dropped. C133180 11. INSTALL POWER STEERING SUCTION PORT UNION (a) Coat a new O-ring with power steering fluid and install it to the power steering suction port union. (b) Install the power steering suction port union to the vane pump assembly with the bolt. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) C133179 PS PS–34 POWER STEERING – VANE PUMP (for 2GR-FE) INSTALLATION 1. INSTALL VANE PUMP ASSEMBLY (a) Temporarily install the bolt to the vane pump assembly. (b) Install the vane pump assembly. C135238 (c) Using SST, install bolt (B) and tighten the 2 bolts. SST 09249-63010 Torque: Without SST 43 N*m (439 kgf*cm, 32 ft.*lbf) With SST 29 N*m (294 kgf*cm, 21 ft.*lbf) NOTICE: • Use a torque wrench with a fulcrum length of 300 mm (11.81 in.). • This torque value is accurate when SST is parallel to the torque wrench. (B) SST PS Fulcrum Length C133181E01 C133176 2. CONNECT POWER STEERING FLUID PRESSURE SWITCH CONNECTOR (a) Connect the connector to the power steering fluid pressure switch. 3. CONNECT PRESSURE FEED TUBE ASSEMBLY (a) Install a new gasket to the pressure feed tube assembly. POWER STEERING – VANE PUMP (for 2GR-FE) PS–35 (b) Temporarily connect the pressure feed tube assembly to the vane pump assembly with the union bolt. (c) Install the pressure feed tube assembly clamp with the bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) NOTICE: Install the pressure feed tube assembly clamp in the correct position. (d) Fully tighten the union bolt. Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf) NOTICE: Make sure that the stopper of the pressure feed tube assembly contacts the vane pump assembly securely as shown in the illustration. C133182 4. Paint Mark 5. INSTALL FAN AND GENERATOR V BELT (See page EM-7) 6. ADD POWER STEERING FLUID 7. BLEED POWER STEERING FLUID (See page PS-7) 8. CHECK POWER STEERING FLUID LEVEL (See page PS-3) 9. CHECK FOR POWER STEERING FLUID LEAKS 2 to 7 mm (0.08 to 0.28 in.) C133183E01 CONNECT NO. 1 FLUID RESERVOIR TO PUMP HOSE (a) Connect the No. 1 fluid reservoir to pump hose to the vane pump assembly with the clip. NOTICE: • Connect the No. 1 fluid reservoir to pump hose with the paint mark facing toward the rear of the vehicle. • Push the No. 1 fluid reservoir to pump hose as far as it will go as shown in the illustration. • Install the clip at the position specified in the illustration. 10. INSTALL V-BANK COVER SUB-ASSEMBLY 11. INSTALL FRONT FENDER APRON SEAL RH 12. INSTALL FRONT WHEEL RH Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) PS PS–36 POWER STEERING – POWER STEERING LINK POWER STEERING LINK POWER STEERING STEERING COMPONENTS 35 (360, 26) STEERING SLIDING YOKE 9.8 (100, 87 in.*lbf) 25 (250, 18) *22 (227, 16) PRESSURE FEED TUBE ASSEMBLY for 2GR-FE: POWER STEERING LINK ASSEMBLY PS 70 (714, 52) POWER STEERING RACK HOUSING HEAT INSULATOR 49 (500, 36) COTTER PIN 49 (500, 36) COTTER PIN N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part * For use with SST C140706E01 PS–37 POWER STEERING – POWER STEERING LINK 84 (852, 62) TIE ROD ASSEMBLY RH *60 (613, 44) STEERING RACK END SUB-ASSEMBLY 74 (755, 55) STEERING RACK BOOT CLIP NO. 1 STEERING RACK BOOT 13 (128, 9) NO. 2 STEERING RACK BOOT CLAMP *11 (114, 8) CLAW WASHER STEERING LEFT TURN PRESSURE TUBE O-RING O-RING O-RING RACK GUIDE SPRING CAP 13 (128, 9) O-RING *11 (114, 8) STEERING RIGHT TURN PRESSURE TUBE O-RING COMPRESSION SPRING PS RACK GUIDE RACK GUIDE BASE CLAW WASHER 84 (852, 62) *60 (613, 44) STEERING RACK END SUB-ASSEMBLY STEERING RACK BOOT CLIP NO. 2 STEERING RACK BOOT CLAMP Apply power steering fluid 74 (755, 55) NO. 2 STEERING RACK BOOT Apply silicon grease Apply molybdenum disulfide lithium base grease Non-reusable part N*m (kgf*cm, ft.*lbf) : Specified torque TIE ROD ASSEMBLY LH * For use with SST C132524E01 PS–38 POWER STEERING – POWER STEERING LINK 21 (214, 16) DUST COVER CONTROL VALVE HOUSING SUB-ASSEMBLY POWER STEERING CONTROL VALVE UPPER OIL SEAL POWER STEERING CONTROL VALVE UPPER BEARING POWER STEERING CONTROL VALVE SUB-ASSEMBLY PS POWER STEERING CONTROL VALVE LOWER OIL SEAL GASKET POWER STEERING CONTROL VALVE SPACER 25 (250, 18) NUT 54 (546, 40) RACK HOUSING CAP Precoated part Apply MP grease Apply power steering fluid Apply molybdenum disulfide lithium base grease Non-reusable part N*m (kgf*cm, ft.*lbf) : Specified torque C132525E01 PS–39 POWER STEERING – POWER STEERING LINK CYLINDER END STOPPER HOLE SNAP RING CYLINDER END STOPPER O-RING RACK BUSHING OIL SEAL POWER STEERING RACK BUSHING O-RING POWER PISTON OIL SEAL PS POWER STEERING RACK POWER STEERING CYLINDER TUBE OIL SEAL POWER STEERING RACK HOUSING Apply power steering fluid Apply molybdenum disulfide lithium base grease Non-reusable part C132526E01 PS–40 POWER STEERING – POWER STEERING LINK REMOVAL 1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 3. REMOVE FRONT WHEELS 4. SEPARATE STEERING SLIDING YOKE (a) Secure the steering wheel with the seat belt in order to prevent rotation. HINT: This operation is useful to prevent damage to the spiral cable. C133501 (b) Remove the bolt and slide the steering sliding yoke. NOTICE: Do not separate the steering sliding yoke from the power steering link assembly. PS Front C132548E02 (c) Put matchmarks on the steering sliding yoke and the power steering link assembly. (d) Separate the steering sliding yoke from the power steering link assembly. 5. Matchmarks C132549E01 SEPARATE TIE ROD ASSEMBLY LH (a) Remove the cotter pin and the nut. POWER STEERING – POWER STEERING LINK PS–41 (b) Using SST, separate the tie rod assembly LH from the steering knuckle. SST 09628-00011 NOTICE: • Hang SST with a string, etc. to prevent it from falling. • Do not damage the front disc brake dust cover. • Do not damage the ball joint dust cover. • Do not damage the steering knuckle. SST Hold Turn 6. SEPARATE TIE ROD ASSEMBLY RH HINT: Perform the same procedure as for the LH side. 7. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE HINT: Refer to the instructions for removal of the engine assembly (See page EM-94 for 2AZ-FE, EM-23 for 2GRFE). 8. DISCONNECT PRESSURE FEED TUBE ASSEMBLY (a) Using SST, disconnect the pressure feed tube assembly (return tube side) from the power steering link assembly. SST 09023-12701 C133488E01 SST PS C133184E01 (b) Using SST, disconnect the pressure feed tube assembly (pressure feed tube side) from the power steering link assembly. SST 09023-12701 SST C133185E01 (c) Remove the 2 bolts and separate the pressure feed tube clamp. C140652 PS–42 POWER STEERING – POWER STEERING LINK 9. REMOVE POWER STEERING LINK ASSEMBLY (a) Remove the 2 bolts, 2 nuts, and the power steering link assembly. NOTICE: Because the nut has its own stopper, do not turn the nut. Loosen the bolt with the nut fixed. C133187 10. REMOVE POWER STEERING RACK HOUSING HEAT INSULATOR (for 2GR-FE) (a) Remove the power steering rack housing heat insulator from the power steering link assembly. C133188 DISASSEMBLY SST 1. SECURE POWER STEERING LINK ASSEMBLY (a) Using SST, secure the power steering link assembly. SST 09612-00012 HINT: Tape the SST before use. 2. REMOVE STEERING LEFT TURN PRESSURE TUBE (a) Using SST, remove the steering left turn pressure tube. SST 09023-38201 (b) Remove the 2 O-rings from the steering left turn pressure tube. PS Protective Tape C132044E01 SST C132046E01 POWER STEERING – POWER STEERING LINK PS–43 3. REMOVE STEERING RIGHT TURN PRESSURE TUBE (a) Using SST, remove the steering right turn pressure tube. SST 09023-38201 (b) Remove the 2 O-rings from the steering right turn pressure tube. 4. REMOVE TIE ROD ASSEMBLY LH (a) Put matchmarks on the tie rod assembly LH and the steering rack end sub-assembly. (b) Loosen the lock nut, and remove the tie rod assembly LH and the lock nut. 5. REMOVE TIE ROD ASSEMBLY RH HINT: Perform the same procedure as for the LH side. 6. REMOVE STEERING RACK BOOT CLIP (a) Using pliers, remove the 2 steering rack boot clips. 7. REMOVE NO. 2 STEERING RACK BOOT CLAMP (a) Using pliers, remove the 2 No. 2 steering rack boot clamps as shown in the illustration. NOTICE: Be careful not to damage the No. 2 steering rack boot. 8. REMOVE NO. 2 STEERING RACK BOOT (a) Remove the No. 2 steering rack boot. 9. REMOVE NO. 1 STEERING RACK BOOT (a) Remove the No. 1 steering rack boot. SST C132047E01 Matchmarks C132045E01 C132048 PS PS–44 POWER STEERING – POWER STEERING LINK 10. REMOVE STEERING RACK END SUB-ASSEMBLY (a) Using a screwdriver and a hammer, unstake the RH and LH claw washers. NOTICE: Avoid any impact to the steering rack. C132049 (b) Using SST, remove the steering rack end subassembly (RH side) and the claw washer. SST 09922-10010 NOTICE: Use SST 09922-10010 as shown in the illustration. Turn Hold SST PS SST C132050E01 POWER STEERING – POWER STEERING LINK (c) Using SST, remove the steering rack end subassembly (LH side) and the claw washer. SST 09922-10010 NOTICE: Use SST 09922-10010 as shown in the illustration. HINT: Using SST, hold the rack and remove the steering rack end sub-assembly. Hold Turn PS–45 SST SST C132051E01 11. REMOVE RACK GUIDE (a) Using a straight hexagon wrench (24 mm (0.94 in.)), remove the rack guide spring cap. Straight Hexagon Wrench PS C132052E01 (b) Remove the compression spring and the rack guide sub-assembly. C132054 (c) Remove the rack guide base from the rack guide. C132055 PS–46 POWER STEERING – POWER STEERING LINK (d) Remove the O-ring from the rack guide spring cap. C139140E01 12. REMOVE DUST COVER (a) Wrap protective tape around the spline of the control valve in order to prevent damaging the dust cover. (b) Remove the dust cover. Protective Tape C132058E01 13. REMOVE POWER STEERING CONTROL VALVE ASSEMBLY (a) Using a socket wrench (27 mm (1.06 in.)), remove the rack housing cap. Socket Wrench PS C132056E01 (b) Using SST, hold the control valve shaft and remove the nut. SST 09616-00011 Hold Turn SST C132057E01 (c) Remove the 2 bolts and the power steering control valve assembly. (d) Remove the gasket. C132318 POWER STEERING – POWER STEERING LINK PS–47 14. REMOVE POWER STEERING CONTROL VALVE SUB-ASSEMBLY (a) Using a press, remove the power steering control valve sub-assembly. C132319 15. REMOVE POWER STEERING CONTROL VALVE LOWER OIL SEAL (a) Remove the power steering control valve lower oil seal from the power steering control valve subassembly. C132320 Protective Tape C132321E01 SST 16. REMOVE POWER STEERING CONTROL VALVE SPACER (a) Using a screwdriver, remove the 4 power steering control valve spacers from the power steering control valve sub-assembly. NOTICE: Be careful not to damage the spacer grooves on the control valve. HINT: Tape the screwdriver tip before use. 17. REMOVE POWER STEERING CONTROL VALVE UPPER OIL SEAL (a) Using SST and a press, press out the power steering control valve upper oil seal and the power steering control valve upper bearing from the control valve housing sub-assembly. SST 09950-70010 (09951-07150), 09950-60010 (09951-00250, 09951-00180, 09952-06010) C132515E01 18. REMOVE CYLINDER END STOPPER HOLE SNAP RING (a) Using needle-nose pliers, remove the cylinder end stopper hole snap ring from the power steering rack housing. 19. REMOVE POWER STEERING RACK SUB-ASSEMBLY (a) Remove the power steering rack sub-assembly with the cylinder end stopper and power steering rack bushing. C140649 PS PS–48 POWER STEERING – POWER STEERING LINK 20. REMOVE CYLINDER END STOPPER (a) Remove the cylinder end stopper from the power steering rack sub-assembly. C132323E01 21. REMOVE POWER STEERING RACK BUSHING (a) Remove the power steering rack bushing from the power steering rack sub-assembly. C132324E01 Protective Tape PS (b) Using a screwdriver, remove the O-ring from the power steering rack bushing. HINT: Tape the screwdriver tip before use. C132325E01 (c) Using SST, remove the rack bushing oil seal from the power steering rack bushing. SST 09527-21011, 09612-24014 (09613-22011) NOTICE: Be careful not to drop the power steering rack bushing. Hold Turn SST C132510E01 POWER STEERING – POWER STEERING LINK SST SST PS–49 22. REMOVE POWER STEERING CYLINDER TUBE OIL SEAL (a) Using SST and a press, remove the power steering cylinder tube oil seal. SST 09950-70010 (09951-07360), 09950-60010 (09951-00290, 09951-00250) NOTICE: Be careful not to damage the inside surface of the power steering rack housing. SST C132511E01 Protective Tape 23. REMOVE POWER PISTON OIL SEAL (a) Using a screwdriver, remove the power piston oil seal and the O-ring from the power steering rack. NOTICE: Be careful not to damage the power piston oil seal groove on the power steering rack. HINT: Tape the screwdriver tip before use. PS C132326E01 INSPECTION 1. INSPECT POWER STEERING RACK (a) Using a dial indicator, check for runout of the steering rack. Maximum runout: 0.3 mm (0.0118 in.) NOTICE: Make sure that the steering rack is placed horizontally. If runout exceeds the maximum, replace the power steering link assembly. (b) Check the rack surface for wear and damage. 2. INSPECT TIE ROD ASSEMBLY LH (a) Secure the tie rod assembly LH in a vise. (b) Install the nut to the stud bolt. (c) Flip the ball joint back and forth 5 times or more. (d) Using a torque wrench, turn the nut continuously at a rate of 3 to 5 seconds per turn and take the torque reading on the 5th turn. Torque: Turning torque 0.98 to 3.92 N*m (10 to 40 kgf*cm, 8.7 to 34.7 in.*lbf) If turning torque is not within the specified range, replace the tie rod assembly LH. C132328 C132329 PS–50 POWER STEERING – POWER STEERING LINK 3. INSPECT TIE ROD ASSEMBLY RH HINT: Perform the same procedure as for the LH side. 4. INSPECT TOTAL PRELOAD (a) Temporarily install the 2 steering rack ends to the power steering rack. NOTICE: Do not fully turn the power steering rack without the steering rack ends as it may damage the oil seal in the rack housing. (b) Using SST, fully turn the power steering rack right and left 10 times to settle it. SST 09616-00011 SST C132341E01 PS SST C140705E01 (c) Using SST, turn the control valve and measure the preload. SST 09616-00011 Torque: Standard preload (turning) 1.5 N*m (15.3 kgf*cm, 13.3 in.*lbf) or less If the preload exceeds the specified value, proceed to INSTALL RACK GUIDE (See page PS-56). (d) Remove the 2 steering rack ends from the power steering rack. POWER STEERING – POWER STEERING LINK PS–51 REASSEMBLY NOTICE: When installing parts, coat the parts indicated by arrows with power steering fluid, molybdenum disulfide lithium base grease, MP grease or silicon grease (See page PS36). 1. INSTALL POWER PISTON OIL SEAL (a) Coat a new O-ring with power steering fluid and install it to the steering rack. (b) Expand a new power piston oil seal with your fingers. NOTICE: Be careful not to expand the oil seal excessively. (c) Coat the power piston oil seal with power steering fluid. C132330 (d) Install the power piston oil seal to the steering rack, and adjust it with your fingers. 2. INSTALL POWER STEERING CYLINDER TUBE OIL SEAL (a) Apply power steering fluid to the lip of a new power steering cylinder tube oil seal. (b) Install the power steering cylinder tube oil seal to the rack housing at a slant. C132331 SST C140650E01 (c) Using SST, insert the power steering cylinder tube oil seal by pushing the SST in by hand until the oil seal passes the 2 ports. SST 09950-70010 (09951-07360), 09631-00200 NOTICE: • Ensure that the power steering cylinder tube oil seal is installed in the correct direction as shown in the illustration. • Install the power steering cylinder tube oil seal at an angle of approximately 15° so that the lowermost part comes to the point, indicated by the arrow in the illustration, to prevent damage to the side of the oil seal when it passes the 2 ports. • Do not turn the SST when inserting the oil seal. (d) Install SST (09631-00200) to SST (09951-07360) upside down. PS PS–52 POWER STEERING – POWER STEERING LINK (e) Using SST, level the power steering cylinder tube oil seal by pushing the SST in by hand. Using SST and a press, install the oil seal. SST 09950-70010 (09951-07360), 09631-00200 SST 3. INSTALL POWER STEERING RACK SUB-ASSEMBLY (a) Apply molybdenum disulfide lithium base grease to the rack teeth ends. SST C132522E01 (b) Connect SST to the power steering rack subassembly. SST 09631-33010 (c) Coat SST with power steering fluid. (d) Install the power steering rack sub-assembly to the power steering rack housing. (e) Remove SST. Rack Teeth Ends PS SST C132332E01 4. SST SST SST C132512E01 INSTALL POWER STEERING RACK BUSHING (a) Using SST and a press, install the rack bushing oil seal to the power steering rack bushing. SST 09950-70010 (09951-07100), 09950-60010 (09951-00400, 09951-00250, 09952-06010) NOTICE: Ensure that the rack bushing oil seal is installed in the correct direction as shown in the illustration. (b) Coat a new O-ring with power steering fluid and install it to the rack bushing. (c) Coat the rack bushing oil seal lip with power steering fluid. POWER STEERING – POWER STEERING LINK PS–53 (d) Install the power steering rack bushing to the power steering rack housing. NOTICE: Do not damage the rack bushing oil seal. HINT: Wrap protective tape around the end of the steering rack in order to prevent damage to the rack bushing oil seal. Protective Tape C132333E01 5. INSTALL CYLINDER END STOPPER (a) Install the cylinder end stopper to the power steering rack housing. 6. INSTALL CYLINDER END STOPPER HOLE SNAP RING (a) Using needle nose pliers, install the cylinder end stopper hole snap ring to the power steering rack housing. NOTICE: • Make sure that the cylinder end stopper hole snap ring is securely installed in the power steering rack housing groove. • Make sure that the cylinder end stopper hole snap ring claws are aligned with the cylinder end stopper notch. C140651 C140649 7. AIR TIGHTNESS TEST (a) Install SST to the power steering rack housing. SST 09631-12071 (09633-00010) (b) Apply a vacuum of 53 kPa (398 mmHg, 15.65 in.Hg) for approximately 30 seconds. (c) Check that there is no change in the vacuum pressure. If there is a change in the vacuum pressure, check the installation of the oil seals. 8. INSTALL POWER STEERING CONTROL VALVE UPPER OIL SEAL (a) Coat a new power steering control valve upper oil seal lip with power steering fluid. SST C132335E01 PS PS–54 POWER STEERING – POWER STEERING LINK (b) Using SST and a press, press in the power steering control valve upper oil seal. SST 09950-70010 (09951-07150), 09950-60010 (09951-00180, 09952-06010, 09951-00320) NOTICE: Make sure that the power steering control valve upper oil seal is installed in the correct direction as shown in the illustration. SST SST 9. C132516E01 INSTALL POWER STEERING CONTROL VALVE UPPER BEARING (a) Coat the power steering control valve upper bearing with molybdenum disulfide lithium base grease. (b) Using SST and a press, press in the power steering control valve upper bearing. SST 09950-70010 (09951-07150), 09950-60010 (09951-00180, 09951-00340) NOTICE: Make sure that the power steering control valve upper bearing is installed in the correct direction as shown in the illustration. SST SST PS Narrow Oil Seal Side Wide Control Valve Side C133498E01 10. INSTALL POWER STEERING CONTROL VALVE SPACER (a) Expand 4 new power steering control valve spacers with your fingers. NOTICE: Be careful not to expand the power steering control valve spacers excessively. (b) Coat the 4 power steering control valve spacers with power steering fluid. C132330 POWER STEERING – POWER STEERING LINK PS–55 (c) Install the 4 power steering control valve spacers to the control valve, and adjust them with your fingers. 11. INSTALL POWER STEERING CONTROL VALVE SUBASSEMBLY (a) Coat the power steering control valve sub-assembly with power steering fluid. C132336 Protective Tape C132520E01 (b) Install the power steering control valve subassembly into the control valve housing subassembly. NOTICE: Be careful not to damage the power steering control valve spacers and power steering control valve upper oil seal lip. HINT: Wrap protective tape around the spline of the power steering control valve sub-assembly in order to prevent damage to the oil seal. 12. INSTALL POWER STEERING CONTROL VALVE LOWER OIL SEAL (a) Coat a new power steering control valve lower oil seal lip with power steering fluid. SST C132514E01 (b) Using SST and a press, install the power steering control valve lower oil seal to the control valve assembly. SST 09612-22011 NOTICE: • Make sure that the power steering control valve lower oil seal is installed in the correct direction as shown in the illustration. • Do not damage the power steering control valve lower oil seal. 13. INSTALL POWER STEERING CONTROL VALVE ASSEMBLY (a) Install the power steering control valve assembly and a new gasket to the power steering rack housing with the 2 bolts. Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf) C132318 PS PS–56 POWER STEERING – POWER STEERING LINK Turn Hold SST (b) Using SST, hold the control valve shaft and install a new nut. SST 09616-00011 Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) (c) Apply sealant to 2 or 3 threads of the rack housing cap. Sealant: TOYOTA genuine adhesive 1344, THREE BOND 1344 or equivalent C132337E01 (d) Using a socket wrench (27 mm (1.06 in.)), install the rack housing cap. Torque: 54 N*m (546 kgf*cm, 40 ft.*lbf) Socket Wrench C132338E01 (e) Using a punch and a hammer, stake the rack housing cap and the power steering rack housing. PS C140704 C139140E01 14. INSTALL RACK GUIDE (a) Coat a new O-ring with molybdenum disulfide lithium base grease and install it to the rack guide spring cap. NOTICE: Make sure that no foreign matter, such as aluminum dust, is on the power steering rack housing and rack guide spring cap. (b) Apply molybdenum disulfide lithium base grease to the rack guide base and rack guide. POWER STEERING – POWER STEERING LINK PS–57 (c) Install the rack guide base to the rack guide. (d) Apply molybdenum disulfide lithium base grease to the compression spring and the contact surface of the rack guide sub-assembly and the power steering rack. C132055 (e) Install the compression spring and rack guide subassembly to the power steering rack housing. C132054 Straight Hexagon Wrench (f) Using a straight hexagon wrench (24 mm (0.94 in.)), install the rack guide spring cap to the power steering rack housing. Torque: 50 to 70 N*m (514 to 714 kgf*cm, 37 to 52 ft.*lbf) C140653E01 (g) Using SST, turn the control valve and measure the turning torque. Torque: 6.0 N*m (61 kgf*cm, 54 in.*lbf) or more SST C140654E01 PS PS–58 POWER STEERING – POWER STEERING LINK (h) Put matchmarks on the power steering rack housing and the rack guide spring cap. Matchmarks [a] C140655E01 Matchmarks [b] (i) Put matchmarks 30° counterclockwise from matchmarks on the power steering rack housing. (j) Using a straight hexagon wrench (24 mm (0.94 in.)), loosen the rack guide spring cap until matchmarks and matchmarks on the rack guide spring cap are aligned. Measure the rotating torque required when loosening the rack guide spring cap. Torque: 10 N*m (102 kgf*cm, 7.4 ft.*lbf) or more Matchmarks [a] C140656E01 PS Matchmarks [a] Matchmarks [b] C140657E01 POWER STEERING – POWER STEERING LINK Straight Hexagon Wrench PS–59 (k) If the rotating torque required when loosening is below the specified value, perform the following procedure to achieve the specified value. (1) Using a straight hexagon wrench (24 mm (0.94 in.)), re-tighten the rack guide spring cap. Torque: 50 to 70 N*m (510 to 714 kgf*cm, 37 to 52 ft.*lbf) C140653E01 (2) Using a punch and hammer, stake the power steering rack housing and rack guide spring cap at 3 equally spaced positions. HINT: Tap the power steering rack housing and rack guide spring cap strongly and repeatedly to stake them securely. PS C140658 (3) Using a straight hexagon wrench (24 mm (0.94 in.)), loosen the rack guide spring cap until matchmarks and matchmarks on the rack guide spring cap are aligned. Measure the rotating torque required when loosening the rack guide spring cap. Torque: 10 N*m (102 kgf*cm, 7.4 ft.*lbf) or more 15. INSPECT TOTAL PRELOAD (See page PS-50) Matchmarks [a] Matchmarks [b] C140657E01 PS–60 POWER STEERING – POWER STEERING LINK 16. INSTALL DUST COVER (a) Apply MP grease around the control valve shaft as shown in the illustration. MP Grease C132518E01 (b) Wrap vinyl tape around the spline of the control valve. (c) Install the dust cover to the control valve assembly. Protective Tape 17. INSTALL STEERING RACK END SUB-ASSEMBLY (a) Install 2 new claw washers. HINT: Align the claws of the claw washer with the steering rack grooves. C132058E01 Turn Hold PS Fulcrum Length SST SST C132343E01 (b) Using SST, install the steering rack end subassembly (LH side). SST 09922-10010 Torque: Without SST 84 N*m (852 kgf*cm, 62 ft.*lbf) With SST 60 N*m (613 kgf*cm, 44 ft.*lbf) NOTICE: • Use SST 09922-10010 as shown in the illustration. • Use a torque wrench with a fulcrum length of 345 mm (13.58 in.) • This torque value is effective when SST is parallel to the torque wrench. HINT: Using SST, hold the steering rack and install the steering rack end sub-assembly (LH side). POWER STEERING – POWER STEERING LINK Turn Hold SST SST Fulcrum Length PS–61 (c) Using SST, install the steering rack end subassembly (RH side). SST 09922-10010 Torque: Without SST 84 N*m (852 kgf*cm, 62 ft.*lbf) With SST 60 N*m (613 kgf*cm, 44 ft.*lbf) NOTICE: • Use SST 09922-10010 as shown in the illustration. • Use a torque wrench with a fulcrum length of 345 mm (13.58 in.) • This torque value is effective when SST is parallel to the torque wrench. HINT: Using SST, hold the steering rack end subassembly (LH side) and install the steering rack end sub-assembly (RH side). C132344E01 (d) Using a brass bar and a hammer, stake the 2 claw washers. NOTICE: Avoid any impact to the steering rack. C132519 (e) Ensure that the holes of the rack ends are not clogged with grease. HINT: If the hole is clogged, the pressure inside the boot will change after it is assembled and the steering wheel is turned. C133499 18. INSTALL NO. 2 STEERING RACK BOOT (a) Apply silicon grease to the inside of the small opening of the No. 2 steering rack boot. (b) Install the No. 2 steering rack boot to the groove on the rack housing. NOTICE: Be careful not to damage or twist the No. 2 steering rack boot. C100988 PS PS–62 POWER STEERING – POWER STEERING LINK 19. INSTALL NO. 1 STEERING RACK BOOT HINT: Perform the same procedure as for the No. 2 steering rack boot. SST 20. INSTALL NO. 2 STEERING RACK BOOT CLAMP (a) Using SST, tighten the 2 No. 2 steering rack boot clamps as shown in the illustration. SST 09521-24010 Clearance: 2.0 mm (0.079 in.) or less NOTICE: Be careful not to damage the No. 2 steering rack boot. C132345E01 21. INSTALL STEERING RACK BOOT CLIP (a) Using pliers, install the 2 steering rack boot clips. NOTICE: Make sure that each clip claw is positioned within the area shown in the illustration. Upward Front of the vehicle PS C132523E01 (b) Using SST, turn the pinion and check that the rack boots expand and contract smoothly. SST 09616-00011 SST C133500E01 22. INSTALL TIE ROD ASSEMBLY LH (a) Install the lock nut and the tie rod assembly LH to the steering rack end sub-assembly until the matchmarks are aligned. HINT: After adjusting toe-in, torque the lock nut. 23. INSTALL TIE ROD ASSEMBLY RH HINT: Perform the same procedure as for the LH side. Matchmarks C132045E01 POWER STEERING – POWER STEERING LINK PS–63 24. INSTALL STEERING RIGHT TURN PRESSURE TUBE (a) Coat 2 new O-rings with power steering fluid and install them to the steering right turn pressure tube. (b) Using SST, install the right turn pressure tube to the power steering link assembly. SST 09023-38201 Torque: Without SST 13 N*m (128 kgf*cm, 9 ft.*lbf) With SST 11 N*m (114 kgf*cm, 8 ft.*lbf) NOTICE: • Use a torque wrench with a fulcrum length of 250 mm (9.84 in.). • This torque value is effective when SST is parallel to the torque wrench. SST Fulcrum Length C132346E01 25. INSTALL STEERING LEFT TURN PRESSURE TUBE (a) Coat 2 new O-rings with power steering fluid and install them to the steering left turn pressure tube. (b) Using SST, install the left turn pressure tube to the power steering link assembly. SST 09023-38201 Torque: Without SST 13 N*m (128 kgf*cm, 9 ft.*lbf) With SST 11 N*m (114 kgf*cm, 8 ft.*lbf) NOTICE: • Use a torque wrench with a fulcrum length of 250 mm (9.84 in.). • This torque value is effective when SST is parallel to the torque wrench. SST Fulcrum Length C132347E01 INSTALLATION 1. C133188 INSTALL POWER STEERING RACK HOUSING HEAT INSULATOR (for 2GR-FE) (a) Install the power steering rack housing heat insulator to the power steering link assembly. PS PS–64 POWER STEERING – POWER STEERING LINK 2. INSTALL POWER STEERING LINK ASSEMBLY (a) Install the power steering link assembly with the 2 bolts and 2 nuts. Torque: 70 N*m (714 kgf*cm, 52 ft.*lbf) 3. CONNECT PRESSURE FEED TUBE ASSEMBLY (a) Temporarily connect the pressure feed tube assembly to the power steering link assembly. C133187 C133189 (b) Install the pressure feed tube assembly clamp with the 2 bolts. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) PS C140652 (c) Using SST, tighten the pressure feed tube assembly (pressure feed tube side). SST 09023-12701 Torque: Without SST 25 N*m (250 kgf*cm, 18 ft.*lbf) With SST 22 N*m (227 kgf*cm, 16 ft.*lbf) NOTICE: • Use a torque wrench with a fulcrum length of 300 mm (11.81 in.). • This torque value is effective when SST is parallel to the torque wrench. SST Fulcrum Length C133190E01 POWER STEERING – POWER STEERING LINK PS–65 (d) Using SST, tighten the pressure feed tube assembly (return tube side). SST 09023-12701 Torque: Without SST 25 N*m (250 kgf*cm, 18 ft.*lbf) With SST 22 N*m (227 kgf*cm, 16 ft.*lbf) NOTICE: • Use a torque wrench with a fulcrum length of 300 mm (11.81 in.). • This torque value is effective when SST is parallel to a torque wrench. SST Fulcrum Length 4. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE HINT: Refer to the instructions for installation of the engine assembly (See page EM-107 for 2AZ-FE, EM-37 for 2GR-FE). 5. CONNECT TIE ROD ASSEMBLY LH (a) Connect the tie rod assembly LH to the steering knuckle with the nut. Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) (b) Install a new cotter pin. NOTICE: Further tighten the nut up to 60° if the holes for the cotter pin are not aligned. 6. CONNECT TIE ROD ASSEMBLY RH HINT: Perform the same procedure on the other side. 7. CONNECT STEERING SLIDING YOKE (a) Align the matchmarks on the steering sliding yoke and the steering link assembly. C133191E01 Matchmarks C132549E01 PS PS–66 POWER STEERING – POWER STEERING LINK (b) Install the bolt. Torque: 35 N*m (360 kgf*cm, 26 ft.*lbf) 8. INSTALL FRONT WHEELS Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 10. BLEED POWER STEERING FLUID (See page PS-7) 11. CHECK POWER STEERING FLUID LEVEL (See page PS-3) 12. CHECK FOR POWER STEERING FLUID LEAKAGE Front 13. CHECK FOR EXHAUST GAS LEAKS C132548E02 14. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 15. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT HINT: (See page SP-4) PS THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) TD–1 THEFT DETERRENT SYSTEM (w/ Smart Key System) THEFT DETERRENT SECURITIES PARTS LOCATION HAZARD WARNING LIGHT ENGINE HOOD LOCK ASSEMBLY - ENGINE HOOD COURTESY SWITCH PERSONAL LIGHT ASSEMBLY SECURITY HORN ASSEMBLY HEADLIGHT TD LOW PITCHED HORN ENGINE ROOM R/B AND J/B HIGH PITCHED HORN HAZARD WARNING LIGHT - S-HORN RELAY - HORN RELAY - H-LP(RL) RELAY - H-LP(LL) RELAY HEADLIGHT B128403E01 TD–2 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) SECURITY INDICATOR CLOCK ENGINE SWITCH TURN SIGNAL FLASHER ASSEMBLY CERTIFICATION ECU TD MAIN BODY ECU (INSTRUMENT PANEL J/B) DLC3 - TAIL RELAY B128406E01 TD–3 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) REAR DOOR LOCK RH LUGGAGE COMPARTMENT DOOR LOCK CYLINDER REAR DOOR COURTESY SWITCH RH FRONT DOOR LOCK RH FRONT DOOR COURTESY SWITCH RH FRONT DOOR LOCK LH TD FRONT DOOR COURTESY SWITCH LH HAZARD WARNING LIGHT HAZARD WARNING LIGHT REAR DOOR LOCK LH TAILLIGHT TAILLIGHT REAR DOOR COURTESY SWITCH LH LUGGAGE COMPARTMENT DOOR LOCK - LUGGAGE COMPARTMENT DOOR COURTESY SWITCH B128405E01 TD–4 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) SYSTEM DIAGRAM DLC3 Engine Hood Lock Assembly (Engine Hood Courtesy Switch) Main Body ECU Turn Signal Flasher Certification ECU Hazard Warning Light Clock Personal Light Assembly (Security Indicator) Security Horn Head Relay Luggage Compartment Door Lock Cylinder Tail Relay Horn Relay Engine Switch TD Front Door Courtesy Switch (LH, RH) Front Door Lock Position Switch (LH, RH) Rear Door Courtesy Switch (LH, RH) Luggage Compartment Door Lock Assembly (Luggage Compartment Door Courtesy Switch) Rear Door Lock Position Switch (LH, RH) CAN B139449E01 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) TD–5 SYSTEM DESCRIPTION 1. OUTLINE OF THEFT DETERRENT SYSTEM • The theft deterrent system will operate when somebody attempts to forcibly enter the vehicle, unlock any door or luggage compartment door, or open the engine hood or the luggage compartment door without using the key. This system causes the lights to light up or blink and the horns to sound in order to deter break-in and theft. • The theft deterrent system has 2 modes; one is the active arming mode (see ACTIVE ARMING MODE) and the other is passive arming mode (see PASSIVE ARMING MODE). The passive arming mode can be switched ON/OFF using the specified method. • Each mode has 4 states; a disarmed state, an arming preparation state, an armed state and an alarm sounding state. (a) Disarmed state: • The alarm function is not operating. • The theft deterrent system is not operating. (b) Arming preparation state: • The time until the system goes into the armed state. • The theft deterrent system is not operating. (c) Armed state: • The theft deterrent system is operating. (d) Alarm sounding state: • Alarm function is operating. Alarm time: Approx. 60 sec. Refer to table below for alarm method and time: Alarm Method Alarm Time Headlight Blinking Taillight Blinking Hazard Warning Light Blinking Interior Light Illuminating Vehicle Horn Sounding (approx. 0.4 second cycles) Security Horn Sounding (approx. 0.4 second cycles) Approx. 60 sec. 2. Component HINT: If any of the doors are unlocked when the key is not in the actuation area during the armed state, a forced door lock signal will be output (see FORCED DOOR LOCK CONTROL). FUNCTION OF MAIN COMPONENT Function Security indicator Informs driver of theft deterrent system status. Security horn Sounds when attempted brake-in or theft is detected. Headlights Blink when attempted break-in or theft is detected. Taillights Blink when attempted break-in or theft is detected. Hazard warning lights Blinking when attempted break-in or theft is detected. TD TD–6 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) Component Function Interior light Lights up when attempted break-in or theft is detected. Vehicle horns Sounds when attempted break-in or theft is detected. Door courtesy light switch Detects door status (open or closed). Door lock position switch Detects door status (locked or unlocked). Engine hood courtesy switch Detects engine hood status (open or closed). Luggage compartment door courtesy switch Detects luggage compartment door status (open or closed). Luggage compartment door lock cylinder Detects luggage compartment door status (locked or unlocked). Certification ECU • • 3. TD Receives engine hood courtesy switch status. Sends operation signal to security indicator and security horn. ACTIVE ARMING MODE HINT: Active arming mode starts the alarm control immediately after the doors are locked. THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) TD–7 (a) Active arming mode: This system activates as described in the diagram below when one of items for each condition is met. Disarmed State Disarmed State 1 Condition (10) *1 Disarmed State 2 *2 Condition (9) Condition (3) Condition (1) Condition (8) Arming Preparation State Condition (7) Condition (2) Condition (5) Condition (7) Armed State Condition (6) Condition (4) TD Condition (5) Condition (7) Alarm Sounding State B144373E01 HINT: • *1: Disarmed state 1 is the normal disarmed state. • *2: Disarmed state 2 is set from either the disarmed state 1 or the arming preparation state. Condition Item Condition (1) In the disarmed state 1, when the key is not in the actuation area, the system state is switched if one of the following conditions is met. 1. With all doors, engine hood and luggage compartment door closed, lock all doors by key operation. 2. With all doors, engine hood and luggage compartment door closed, lock all doors by wireless operation. 3. With engine hood and luggage compartment door closed and all doors locked with any door still opened, close the open door. TD–8 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) Condition Item Condition (2) After condition (1) is met, allow approx. 30 seconds to elapse. Condition (3) 1. 2. 3. 4. Unlock any door. Open any door, engine hood, or luggage compartment door. Turn the engine switch on (IG or ACC). Reconnect battery. Condition (4) 1. 2. 3. 4. 5. Open engine hood. Open luggage compartment door. Reconnect battery. Open any door. Unlock any door when all doors are locked without wireless operation. Condition (5) 1. Unlock only driver's door or all doors by wireless operation. 2. Unlock only driver's door or all doors by key operation. 3. Turn the engine switch on (IG) and run the engine more than 2 seconds. Condition (6) After approx. 60 seconds, alarm stops and system returns to armed state. Condition (7) 1. Open the luggage compartment door by wireless operation. 2. Unlock the luggage compartment door by key operation. Condition (8) 1. Close the engine hood when the luggage compartment door is closed. 2. Close the luggage compartment door when the engine hood is closed. Condition (9) 1. 2. 3. 4. Condition (10) In the disarmed state 1, when the key is not in the actuation area, the system state is switched if one of the following conditions is met. 1. With all doors closed, and the engine hood or luggage compartment door is opened, lock all doors by wireless operation. 2. With all doors closed, and the engine hood or luggage compartment door is opened, lock all doors by key operation. 3. With the engine hood or luggage compartment door is opened and all doors locked with any door still opened, close the open door. Unlock any door. Open any door. Turn the engine switch from off to on (IG or ACC). Reconnect the battery. 4. TD PASSIVE ARMING MODE HINT: • Passive arming mode starts the alarm control after the key is out of the actuation area and doors are closed. • Passive arming mode can be switched ON/OFF by the specified method. • The alarm is initially set (when shipped from factory) to active arming mode (not passive arming mode). • During passive arming mode, the theft deterrent system goes into the armed state even if the doors are not locked. • Detecting that the doors are unlocked does not set off the alarm during passive arming mode. • A forced door lock signal is not output during passive arming mode (see FORCED DOOR LOCK CONTROL). • Although the theft deterrent system detects that the doors are opened during passive arming mode, the alarm will not go off immediately because an entry delay time is set. • If the condition (1) of active arming mode is met during passive arming mode, the theft deterrent system will switch to active arming mode. TD–9 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) (a) Passive arming mode: This system activates as described in the diagram below when one of items for each condition is met. Disarmed State Disarmed State 1 *1 Condition (1) Disarmed State 2 *2 Condition (3) Condition (3) Condition (2) Arming Preparation State Condition (5) Condition (4) Condition (7) Condition (8) Armed State Condition (9) Condition (6) Condition (7) Alarm Sounding State TD Condition (8) B112143E02 HINT: • *1: Disarmed state 1 is the normal disarmed state. • *2: Disarmed state 2 is set from either the disarmed state 1 or the arming preparation state. Condition Item Condition (1) 1. With any door open, turn the engine switch off. 2. With the engine switch off, open any door. Condition (2) All doors, engine hood and luggage compartment door are closed. Condition (3) 1. 2. 3. 4. Unlock only driver's door or all doors by wireless operation. Unlock only driver's door or all doors by key operation. Reconnect battery. Turn the engine switch on (IG or ACC). TD–10 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) Condition Item Condition (4) After condition (1) is met, allow approx. 30 seconds to elapse. Condition (5) 1. 2. 3. 4. Open any door. Open engine hood. Open luggage compartment door. Unlock luggage compartment door. Condition (6) 1. 2. 3. 4. 5. Open any door and allow entry delay time*1 to elapse. Open engine hood. Open luggage compartment door. Reconnect battery. Turn the engine switch off. After 5 seconds or more elapsed, turn the engine switch on (IG). Condition (7) 1. Unlock only driver's door or all doors by wireless operation. 2. Unlock only driver's door or all doors by key operation. 3. Turn the engine switch on (IG) and run the engine more than 2 seconds. Condition (8) 1. Open luggage compartment door by wireless operation. 2. Unlock luggage compartment door by key operation. Condition (9) After approx. 60 sec., alarm stops and system returns to armed state. 5. TD HINT: *1: When any door is opened while all the doors are closed during passive arming mode, the entry delay time starts. If the switch condition (armed state → disarmed state 1 or 2) is met during the entry delay time, the theft deterrent system will return to disarmed state 1 or 2. However, if the switch condition for disarmed state 1 or 2 is not met, the theft deterrent system will recognize it as a theft and set off the alarm. Entry delay time of 0, 14 or 30 sec. can be selected by the customizing function. FORCED DOOR LOCK CONTROL (a) The forced door lock control prevents the vehicle from being tampered with. Immediately after a door is unlocked (alarm starts), the door is forced to lock by a forced door lock signal. (1) Conditions that force the doors to lock: When the key is not in the actuation area and both of the following conditions are met. • The theft deterrent system is in the alarm sounding state of active arming mode. • Any door is unlocked. THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) 6. 7. TD–11 ALARM MEMORY FUNCTION (a) If the alarm is set off (tampering is detected) while the theft deterrent system is armed, it will be recorded by the alarm memory function. Whenever the theft deterrent system is cancelled, the alarm memory function causes the taillights to light up for 2 seconds in order to inform you that the alarm has been set off. (1) Conditions of the alarm memory function that cause the taillights to light up: When the theft deterrent system has entered into the alarm sounding state (tampering has been detected) even once, the taillights will light up for 2 seconds if any of the following conditions is met. • Switched to the disarmed state from the armed state during active arming mode. • Switched to the disarmed state 1 from the armed state during passive arming mode. HINT: Active arming mode: See ACTIVE ARMING MODE. Passive arming mode: See PASSIVE ARMING MODE. PANIC ALARM CONTROL (a) The panic alarm control makes it possible to voluntarily set off the panic alarm by pressing the PANIC switch on the wireless transmitter. (1) Conditions that cause the panic alarm control to set off the panic alarm: The panic alarm control sets off the panic alarm by pressing the PANIC switch on the wireless transmitter under the following conditions: • The engine switch off. • The theft deterrent system is not in the alarm sounding state. (This condition is common both to active arming mode and to passive arming mode.) (2) Conditions that cause the panic alarm control to shut off the alarm: The panic alarm control shuts off the panic alarm when any of the following conditions is met during panic alarm operation: • The engine switch on (IG). • The panic alarm switch is turned on again. • Any of the switches on the wireless transmitter (LOCK/UNLOCK or LUGGAGE OPEN) is pressed. • The panic alarm ends (approx. 60 sec. have passed). TD TD–12 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) 8. • The theft deterrent system switches to the alarm sounding state. Under this condition, the theft deterrent system is controlling the alarm rather than the panic alarm control. In order to cancel this alarm, refer to the theft deterrent system alarm sounding state cancellation procedure. (This condition is common both to active arming mode to passive arming mode.) HINT: Active arming mode: See ACTIVE ARMING MODE. Passive arming mode: See PASSIVE ARMING MODE. SECURITY INDICATOR OUTPUT (a) The certification ECU outputs a signal to light up the security indicator, according to the state of the theft deterrent system. However, some of the actual lighting conditions of the security indicator are different from the output signals of the certification ECU. Output: State of Theft Deterrent System* Security Indicator Output Signals from certification ECU Actual Lighting Condition Disarmed state 1, 2 OFF OFF (Immobiliser system unset) BLINKING (Immobiliser system set) Arming preparation state ON ON Armed state OFF BLINKING Alarm sounding state ON ON Blinking cycle: Time TD Security Indicator 0.2 sec. ON 1.8 sec. OFF HINT: • *: The above condition is common both to active arming mode and to passive arming mode. • When the immobiliser system is set, the security indicator blinks during both the disarmed state and the armed state, due to the output signals from the immobiliser system. THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) TD–13 HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use this procedure to troubleshoot the theft deterrent system. • The intelligent tester should be used in step 3. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS (a) Interview the customer to confirm the trouble (See page IN-45). NEXT 3 INSPECT COMMUNICATION FUNCTION OF CAN COMMUNICATION SYSTEM (a) Use the intelligent tester to check for normal function of the multiplex communication system. (1) (ECU unconnected, communication line malfunctioning) If no code is output, proceed to A. (2) (ECU unconnected, communication line malfunctioning) If any code is output, proceed to B. B Go To CAN COMMUNICATION SECTION TD A 4 SYMPTOM SIMULATION NEXT 5 PROBLEM SYMPTOMS TABLE (a) If the fault is not listed in the problem symptoms table, proceed to A. (b) If the fault is listed in the problem symptoms table, proceed to B. B Go to step 7 A 6 PERFORM TROUBLESHOOTING ACCORDING TO MALFUNCTION SYMPTOM (a) System description (See page TD-5) TD–14 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) (b) Terminals of ECU (See page TD-17) 7 ADJUST, REPAIR OR REPLACE NEXT 8 NEXT END TD CONFIRMATION TEST THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) TD–15 CUSTOMIZE PARAMETERS HINT: The following items can be customized. NOTICE: • After confirming whether the items requested by the customer are applicable or not for customization, perform customizing operations. • Be sure to record the current settings before customization. • When troubleshooting, make sure that the item in question is not set to "OFF" as a result of customization (Example: For the system, "the wireless function does not operate", first check that the wireless function is not set to "OFF", then perform troubleshooting). THEFT DETERRENT SYSTEM DISPLAY (ITEM) DEFAULT CONTENTS SETTING PASSIVE MODE (Passive Arming Mode) OFF PASSIVE MODE is a function that switches theft deterrent system from arming preparation state to armed state 30 seconds after key is not in the actuation area and all doors, engine hood and luggage compartment door are closed, even if doors are not locked by wireless or door key lock operation In PASSIVE MODE, if you do not perform following operations within 14 seconds after door is opened during armed state, theft deterrent system will judge that condition as a theft and switch to alarm sounding state – Unlock any door by key or wireless operation – Turn the engine switch on (IG) – Open luggage compartment door by key or wireless operation ON/OFF WARN BY HORN (Warning by horn) ON Function that makes vehicle horn and theft deterrent horn be able to be used as a warning device ON/OFF ENTRY DELAY (Entry delay time) 14 s Function that changes entry delay time (time before warning starts) for PASSIVE MODE 0 s/14 s/30 s TD TD–16 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) PROBLEM SYMPTOMS TABLE HINT: • Troubleshooting of the theft deterrent system is based on the premise that the door lock control system and the wireless door lock control system are operating normally. Accordingly, before troubleshooting the theft deterrent system, first make certain that the door lock control system and the wireless door lock control system are operating normally. • The following is the troubleshooting procedure for the theft deterrent system of a vehicle with the smart key system. • Inspect the fuse and relay before investigating the suspected areas shown in the table below. Theft deterrent system: Symptom Theft deterrent system cannot be set Security indicator does not blink when theft deterrent system is set TD Alarm sounding state cannot be canceled when engine switch turned on (IG) Theft deterrent system can be set even when a door is open Vehicle horns (low pitched, high pitched) do not sound while theft deterrent system is in warning operation Hazard warning lights do not flash while theft deterrent system is in warning operation Interior light does not light up while theft deterrent system is in warning operation Security horn does not sound while theft deterrent system is in warning operation Suspected area See page 1. Security indicator light circuit TD-34 2. ECU power source circuit TD-37 3. Door key lock / unlock switch circuit DL-53 4. Door courtesy switch circuit LI-52 5. Luggage compartment door courtesy switch circuit DL-44 6. Engine hood courtesy switch circuit TD-22 7. Replace certification ECU - 8. If the symptom(s) still occur after the above areas are inspected and proved to be normal, replace the main body ECU (Instrument panel J/B) - 1. Security indicator light circuit TD-34 2. Replace certification ECU - 3. If the symptom(s) still occur after the above areas are inspected and proved to be normal, replace the main body ECU (Instrument panel J/B) - 1. Ignition switch circuit TD-30 2. If the symptom(s) still occur after the above areas are inspected and proved to be normal, replace the main body ECU (Instrument panel J/B) - 1. Door courtesy switch circuit LI-52 2. If the symptom(s) still occur after the above areas are inspected and proved to be normal, replace the main body ECU (Instrument panel J/B) - 1. Horn circuit TD-25 2. If the symptom(s) still occur after the above areas are inspected and proved to be normal, replace the main body ECU (Instrument panel J/B) - 1. Wire harness - 2. Turn signal flasher LI-138 3. If the symptom(s) still occur after the above areas are inspected and proved to be normal, replace the main body ECU (Instrument panel J/B) - 1. Interior light circuit LI-57 2. If the symptom(s) still occur after the above areas are inspected and proved to be normal, replace the main body ECU (Instrument panel J/B) - 1. Security horn circuit TD-27 2. If the symptom(s) still occur after the above areas are inspected and proved to be normal, replace the main body ECU (Instrument panel J/B) - TD–17 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) Symptom Hazard warning lights flash even when theft deterrent system is not set Interior light comes on even when theft deterrent system is not set Suspected area See page 1. Wire harness - 2. Turn signal flasher LI-138 3. If the symptom(s) still occur after the above areas are inspected and proved to be normal, replace the main body ECU (Instrument panel J/B) - 1. Interior light circuit LI-57 2. If the symptom(s) still occur after the above areas are inspected and proved to be normal, replace the main body ECU (Instrument panel J/B) - TD TD–18 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) TERMINALS OF ECU 1. CHECK MAIN BODY ECU (INSTRUMENT PANEL J/B) (a) Disconnect the main body ECU (instrument panel J/ B) connectors. IM IF ID IO IA TD E7 E8 E6 E9 IG Main Body ECU B139428E01 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) TD–19 (b) Measure the resistance and voltage between each terminal of the wire harness side connectors and body ground. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition GR - Body ground Rear courtesy light switch RH input Rear door RH CLOSED (OFF) → OPEN (ON) 10 kΩ or higher → Below 1Ω PCTY (E6-21) - Body ground Y - Body ground Passenger side courtesy light switch input Passenger side door CLOSED (OFF) → OPEN (ON) 10 kΩ or higher → Below 1Ω LGCY (E6-25) - Body ground W - Body ground Luggage compartment door courtesy light switch input Luggage compartment door CLOSED (OFF) → OPEN (ON) 10 kΩ or higher → Below 1Ω DCTY (E7-24) - Body ground L - Body ground Driver side door courtesy light switch input Driver side door CLOSED (OFF) → OPEN (ON) 10 kΩ or higher → Below 1Ω ACC (IA-1) - Body ground B - Body ground Ignition power supply (ACC signal) Ignition switch on (ACC) → off 10 to 14 V → Below 1 V IG (IA-1) - Body ground B - Body ground Ignition power supply (IG signal) Ignition switch on (IG) → off 10 to 14 V → Below 1 V BATB (IA-1) - Body ground B - Body ground +B (power battery system) power supply Always 10 to 14 V ALTB (ID-16) - Body ground W - Body ground +B (power system alternator system) power supply Always 10 to 14 V GND1 (IF-10) - Body ground W-B - Body ground Ground Always Below 1 Ω GND2 (IM-9) - Body ground W-B - Body ground Ground Always Below 1 Ω LCTY (IO-7) - Body ground LG - Body ground Rear courtesy light switch LH input Rear door LH CLOSED (OFF) → OPEN (ON) 10 kΩ or higher → Below 1Ω RCTY (E6-5) - Body ground If the result is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the main body ECU (instrument panel J/ B) connectors. (d) Measure the voltage between each terminal of the wire harness side connectors and body ground. Symbols (Terminal No.) Wiring Color Terminal Description Condition System is in alarm sounding state Below 1 V Vehicle horn is sounding (Theft deterrent system is in alarm sounding state) Pulse generation (0 V ← → 12 V) HAZ (E8-4) - Body ground W - Body ground Turn signal flasher relay signal HORN (ID-11) - Body ground B - Body ground Vehicle horn drive 2. E58 Specified Condition If the result is not as specified, the ECU may have a malfunction. CHECK CERTIFICATION ECU ASSEMBLY (a) Disconnect the E58 and E59 ECU connectors. E59 E125964E02 TD TD–20 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) (b) Measure the voltage and resistance of the wire harness side connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition +B (E58-1) - E (E58-17) W - W-B Battery power supply Always 10 to 14 V E (E58-17) - Body ground W-B - Body ground Ground Always Below 1 Ω R - Body ground Engine hood courtesy switch Engine hood OPEN (OFF) → CLOSED (ON) 10 kΩ or higher → Below 1Ω HSW (E59-24) - Body ground If the result is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the E58 and E59 ECU connectors. (d) Measure the voltage of the connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition 3 to 6 V Pulse generation (0 V ← → 12 V) IND (E58-2) - Body ground Y - Body ground Security indicator output Security indicator light up (It lights up only in arming preparation state or alarm sounding state. It flashes when immobiliser is operating.) SH (E59-20) - Body ground P - Body ground Security horn drive Security horn is sounding (Theft deterrent system is in alarm sounding state) If the result is not as specified, the ECU may have a malfunction. DIAGNOSIS SYSTEM CG SG CANH SIL TD CANL 1. CHECK DLC3 (a) The main body ECU uses ISO 15765-4 for communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. BAT H100769E16 Symbols (Terminal No.) Terminal Description Condition Specified condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 10 to 14 V CANH (6) - CANL (14) CAN bus line Engine switch off* 54 to 67 Ω CANH (6) - CG (4) HIGH-level CAN bus line Engine switch off* 200 Ω or higher CANL (14) - CG (4) LOW-level CAN bus line Engine switch off* 200 Ω or higher CANH (6) - BAT (16) HIGH-level CAN bus line Engine switch off* 6 kΩ or higher CANL (14) - BAT (16) LOW-level CAN bus line Engine switch off* 6 kΩ or higher NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the engine switch, any other switches or the doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) TD–21 (b) Connect the cable of the intelligent tester (with CAN VIM) to the DLC3, turn the engine switch on (IG) and attempt to use the intelligent tester. If the screen displays a communication error message, a problem exists in the vehicle or in the tester. • If communication is normal when the tool is connected to another vehicle, inspect the DLC3 on the original vehicle. • If communication is still impossible when the tool is connected to another vehicle, the problem is probably in the tool itself. Consult the Service Department listed in the tool's instruction manual. DLC3 Intelligent Tester C131977E01 TD TD–22 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) DATA LIST / ACTIVE TEST 1. DATA LIST HINT: Using the intelligent tester DATA LIST allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to shorten labor time. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the ignition switch on ON. (c) Enter the following menus: DIAGNOSIS / OBD/ MOBD / MAIN BODY or SMART / DATA LIST. (d) Read the DATA LIST according to the display on the tester. MAIN BODY (Main body ECU): TD Normal Condition Diagnostic Note Item Measurement Item / Display (Range) ACC SW Engine switch signal / ON or OFF ON: Engine switch is on (ACC) OFF: Engine switch is off - IG SW Engine switch signal / ON or OFF ON: Engine switch is on (IG) OFF: Engine switch is off - D DOOR CTY SW D door courtesy switch / ON or OFF ON: Driver side door is OPEN OFF: Driver side door is CLOSED - P DOOR CTY SW P door courtesy switch / ON or OFF ON: Front passenger side door is OPEN OFF: Front passenger side door is CLOSED - RR DOR CTY SW Rear right door courtesy switch / ON or OFF ON: Rear right door is OPEN OFF: Rear right door is CLOSED - RL DOR CTY SW Rear left door courtesy switch / ON or OFF ON: Rear left door is OPEN OFF: Rear left door is CLOSED - LUGG COURTSY SW Luggage compartment door courtesy switch / ON or OFF ON: Luggage compartment door is OPEN OFF: Luggage compartment door is CLOSED - D LOCK POS SW Driver's door lock position switch / ON or OFF ON: Driver's door is UNLOCKED OFF: Driver's door is LOCKED - P LOCK POS SW Passenger door lock position switch / ON or OFF ON: Passenger door is UNLOCKED OFF: Passenger door is LOCKED - RR LOCK POS SW Rear right door lock position switch / ON or OFF ON: Rear right door is UNLOCKED OFF: Rear right door is LOCKED - RL LOCK POS SW Rear left door lock position switch / ON or OFF ON: Rear left door is UNLOCKED OFF: Rear left door is LOCKED - SMART (Certification ECU): Normal Condition Diagnostic Note Item Measurement Item / Display (Range) PASSIVE MODE Passive mode/ON or OFF ON: Passive mode ON OFF: Passive mode OFF - WARN BY HORN Warning by horn/ON or OFF ON: Vehicle horns sound during alarm sounding state OFF: Vehicle horns do not sound during alarm sounding state - ENTRY DELAY Entry delay time during passive mode 0s: Entry delay time is 0 sec. 14s: Entry delay time is 14 sec. 30s: Entry delay time is 30 sec. - THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) 2. TD–23 ACTIVE TEST HINT: Performing the intelligent tester ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to shorten the labor time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the ignition switch on ON. (c) Enter the following menus: DIAGNOSIS / OBD/ MOBD / MAIN BODY or SMART / ACTIVE TEST. (d) Perform the ACTIVE TEST according to the display on the tester. MAIN BODY (Main body ECU): Item Tester Detail Diagnostic Note HAZARD Hazard warning light ON/OFF - VEHICLE HORN Vehicle horn ON/OFF - SMART (Certification ECU): Item Tester Detail Diagnostic Note SECURITY INDIC Security indicator ON/OFF - SECURITY HORN Security horn ON/OFF - TD TD–24 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) Engine Hood Courtesy Switch Circuit DESCRIPTION The engine hood courtesy switch is installed together with the hood lock. This switch turns off when the engine hood is opened and turns on when the engine hood is closed. WIRING DIAGRAM Certification ECU A5 Engine Hood Courtesy Switch 1 24 E59 2 HSW B144359E01 TD INSPECTION PROCEDURE 1 INSPECT ENGINE HOOD COURTESY SWITCH Free (ON) A5 Engine Hood Courtesy Switch (a) Remove the courtesy switch from the hood lock. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection 1-2 Pushed (OFF) B144360E01 Switch Position Specified Condition Free (ON) Below 1 Ω Pushed (OFF) 10 kΩ or higher THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) TD–25 Result Result Proceed to NG (TMC made) A NG (TMMK made) B OK C A REPLACE HOOD LOCK ASSEMBLY B REPLACE ENGINE HOOD COURTESY SWITCH C 2 CHECK HARNESS AND CONNECTOR (ENGINE HOOD COURTESY SWITCH - BODY GROUND) (a) Disconnect the A5 switch connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side Connector Front View: Engine Hood Courtesy Switch NG A5 B144361E01 OK Tester Connection Specified Condition A5-1 - Body ground Below 1 Ω REPAIR OR REPLACE HARNESS OR CONNECTOR TD TD–26 3 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) CHECK HARNESS AND CONNECTOR (CERTIFICATION ECU - ENGINE HOOD COURTESY SWITCH) (a) Disconnect the E59 ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Connector Wire Harness View: (Symbol) Tester Connection Certification ECU E59 Specified Condition HSW (E59-24) - (A5-2) Below 1 Ω HSW (E59-24) - Body ground 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR HSW Wire Harness Side Connector Front View: Engine Hood Courtesy Switch A5 B144362E01 TD OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE TD–27 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) Horn Circuit DESCRIPTION When the theft deterrent system is switched from the armed state to the alarm sounding state, the main body ECU transmits a signal to cause the horn to sound at intervals of 0.4 seconds. WIRING DIAGRAM Instrument Panel J/B Assembly Engine Room R/B and J/B HORN 1 1G 10 1D 11 ID HORN 5 II 6 1B HORN Main Body ECU From Streeting Pad Switch From Battery A4 Low Pitched 1 Horn 25 1 TD A3 High Pitched Horn B139444E01 INSPECTION PROCEDURE 1 INSPECT HORNS (a) Press the horn switch and check if the horns sound. TD–28 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) Result Result Go to Horns sound A Horns do not sound B B GO TO HORN SYSTEM A PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE TD THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) TD–29 Security Horn Circuit DESCRIPTION When the theft deterrent system is changed from the armed state to the alarm sounding state, the certification ECU can control the security horn. WIRING DIAGRAM Certification ECU Engine Room R/B and J/B S-HORN 11 1D 1 1G 20 E59 SH- S-HORN 5 1A TD From Battery 1 A23 Low Pitched Horn B139452E01 TD–30 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) INSPECTION PROCEDURE 1 INSPECT SECURITY HORN ASSEMBLY (a) Remove the security horn assembly. (b) Check operation of the horn. Standard Measurement Condition Battery positive (+) → Terminal 1 Battery negative (-) → Horn body NG B139440 Specified Condition Horn sounds REPAIR OR REPLACE SECURITY HORN ASSEMBLY OK 2 CHECK HARNESS AND CONNECTOR (ENGINE ROOM J/B - SECURITY HORN ASSEMBLY) Wire Harness Side Connector Front View: Engine Room J/B (a) Disconnect the 1A J/B connector and the A23 horn connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance 1A NG TD Security Horn Assembly A23 B139441E01 OK Terminal Connection Specified Condition 1A-5 - A23-1 Below 1 Ω 1A-5 - Body ground 10 kΩ or higher REPAIR OR REPLACE HARNESS OR CONNECTOR THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) 3 TD–31 CHECK HARNESS AND CONNECTOR (CERTIFICATION ECU - ENGINE ROOM J/B) (a) Disconnect the E59 ECU connector and 1D J/B connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Connector Wire Harness View: Certification ECU E59 Symbol (Terminal Connection) SH- (E59-20) - (1D-11) Below 1 Ω SH- (E59-20) - Body ground 10 kΩ or higher NG SH- Specified Condition REPAIR OR REPLACE HARNESS OR CONNECTOR Wire Harness Side Connector Front View: Engine Room J/B 1D B139453E01 OK 4 CHECK HARNESS AND CONNECTOR (ENGINE ROOM J/B - BATTERY) (a) Disconnect the 1G J/B connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness Side: Engine Room J/B 1 Terminal Connection Specified Condition 1G-1 - Body ground 10 to 14 V 1G NG B074501E16 REPAIR OR REPLACE HARNESS OR CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE TD TD–32 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) Ignition Switch Circuit DESCRIPTION The main body ECU determines the ignition position (OFF, ACC, ON) based on signals from the IG or ACC circuit. WIRING DIAGRAM Main Body ECU Instrument Panel J/B 1 IA 5 3 II 2 ACC 3 ECU-ACC 22 ACC 1 10 IF 5 ALT 9 II IG1 2 FL MAIN ECU IG No. 1 15 IG 1 AM2 TD 3 6 E7 AM1 22 E7 ACCD 3 E7 IG1D Battery B139457E01 TD–33 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the ignition switch ON. (c) Turn the intelligent tester main switch on. (d) Select the item below in the DATA LIST and read the display on the intelligent tester. MAIN BODY (Main Body ECU): Item Test Details Diagnostic Note IG SW ignition switch ON signal ON/OFF - ACC SW ignition switch ACC signal ON/OFF - OK: When the ignition switch is operated, the display changes as shown in the table. NG Go to step 2 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE 2 CHECK HARNESS AND CONNECTOR (BATTERY - INSTRUMENT PANEL J/B) (a) Disconnect the IA J/B connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Connector Wire Harness View: Instrument Panel J/B Assembly (Vehicle Rear Side) Tester Connection Condition Specified Condition IA-1 - Body ground Ignition switch ON 10 to 14 V NG IA 1 B110530E02 OK REPAIR OR REPLACE HARNESS OR CONNECTOR TD TD–34 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) 3 CHECK HARNESS AND CONNECTOR (BATTERY - MAIN BODY ECU) (a) Disconnect the E7 ECU connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Connector Wire Harness View: E7 Main Body ECU Symbol (Tester Connection) Specified Condition AM1 (E7-6) - Body ground 10 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR AM1 B139448E01 OK 4 CHECK HARNESS AND CONNECTOR (INSTRUMENT PANEL J/B - MAIN BODY ECU) (a) Remain the E7 ECU connector still disconnected. Connector Wire Harness View: E7 Main Body ECU TD IG1D ACCD B139448E02 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) (b) Disconnect the II J/B connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Connector Wire Harness View: Instrument Panel J/B Assembly (Vehicle Rear Side) Symbol (Tester Connection) NG II TD–35 Specified Condition (II-3) - ACCD (E7-22) Below 1 Ω (II-9) - IG1D (E7-3) Below 1 Ω REPAIR OR REPLACE HARNESS OR CONNECTOR 9 3 B110531E10 OK 5 CHECK HARNESS AND CONNECTOR (INSTRUMENT PANEL J/B - BODY GROUND) Connector Wire Harness Side View: Instrument Panel J/B Assembly (Vehicle Rear Side) (a) Disconnect the IF J/B connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance NG Tester Connection Specified Condition IF-10 - Body ground Below 1 Ω REPAIR OR REPLACE HARNESS OR CONNECTOR IF 10 B110542E03 OK REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY TD TD–36 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) Security Indicator Light Circuit DESCRIPTION Even when the theft deterrent system is in the disarmed state, the security indicator blinks due to a signal output from the immobiliser system. The security indicator blinks continuously due to a continuous signal received from the immobiliser system while in the armed state. The certification ECU causes the security indicator to light up or blink only during the arming preparation state and alarm sounding states. WIRING DIAGRAM Certification ECU F3 Clock Assembly 19 GND1 LP 8 2 E58 IND Security Indicator TD B139455E02 TD–37 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) INSPECTION PROCEDURE 1 INSPECT CLOCK ASSEMBLY (a) Disconnect the F3 clock connector. (b) Apply battery voltage between the terminals of the indicator, and check the lighting condition of the security indicator. Standard F3 Clock Assembly LP GND1 B139454E01 Measurement Condition Specified Condition Battery positive (+) → Terminal F3-8 (LP) Battery negative (-) → Terminal F3-19 (GND1) Lights up NOTICE: • If the positive (+) lead and the negative (-) lead are incorrectly connected, the security indicator will not light up. • Voltage of more than 12 V will damage the security indicator. • If the voltage is too low, the security indicator will not light up. NG REPLACE CLOCK ASSEMBLY OK 2 CHECK HARNESS AND CONNECTOR (CLOCK ASSEMBLY - CERTIFICATION ECU) (a) Disconnect the E58 ECU connector. (b) Disconnect the F3 clock connector. (c) Measure the resistance according to the value(s) table below. Standard resistance Connector Wire Harness View: Certification ECU E58 LP B139456E01 OK Specified Condition IND (E58-2) - LP (F3-8) Below 1 Ω IND (E58-2) - Body ground 10 kΩ or higher NG IND F3 Clock Assembly Symbol (Tester Connection) REPAIR OR REPLACE HARNESS OR CONNECTOR TD TD–38 3 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) CHECK HARNESS AND CONNECTOR (CLOCK ASSEMBLY - BODY GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Connector Wire Harness View: F3 Clock Assembly Symbol (Tester Connection) Specified Condition GND1 (F3-19) - Body ground Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR GND1 E128063E06 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE TD THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) TD–39 ECU Power Source Circuit DESCRIPTION This circuit provides power for main body ECU operation. WIRING DIAGRAM Instrument Panel J/B Assembly Engine Room R/B and J/B ALT DOOR NO. 1 1 2 1 1G Main Body ECU 1 1F 1 IA 1 16 ID DOOR NO. 2 2 6 BATB ALTB From Battery 10 IF 5 TD GND1 9 GND2 IM 4 B144363E01 TD–40 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) INSPECTION PROCEDURE 1 CHECK INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY (MAIN BODY ECU) (POWER SOURCE) (a) Disconnect the ID and IA J/B connectors. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Connector Wire Harness Side: Instrument Panel J/B Assembly (Vehicle Rear Side) NG ID 16 IA 1 B144364E01 TD OK Tester Connection Specified Condition ID-16 - Body ground 10 to 14 V IA-1 - Body ground 10 to 14 V REPAIR OR REPLACE HARNESS OR CONNECTOR THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/ Smart Key System) 2 TD–41 CHECK HARNESS AND CONNECTOR (INSTRUMENT PANEL J/B - BODY GROUND) (a) Disconnect the IF and IM J/B connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Connector Wire Harness View: Instrument Panel J/B Assembly (Vehicle Rear Side) Symbol (Tester Connection) IF-10 - Body ground IM-9 - Body ground Specified Condition Below 1 Ω 9 NG IM REPAIR OR REPLACE HARNESS OR CONNECTOR IF 10 B110543E02 OK REPLACE PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE TD TD–40 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) THEFT DETERRENT SYSTEM (w/o Smart Key System) THEFT DETERRENT SECURITIES PARTS LOCATION HAZARD WARNING LIGHT ENGINE HOOD LOCK ASSEMBLY - ENGINE HOOD COURTESY SWITCH PERSONAL LIGHT ASSEMBLY SECURITY HORN ASSEMBLY HEADLIGHT TD LOW PITCHED HORN ENGINE ROOM R/B AND J/B HIGH PITCHED HORN HAZARD WARNING LIGHT - S-HORN RELAY - HORN RELAY - H-LP(RL) RELAY - H-LP(LL) RELAY HEADLIGHT B128403E01 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) TD–41 SECURITY INDICATOR CLOCK IGNITION SWITCH TURN SIGNAL FLASHER ASSEMBLY TD DLC3 MAIN BODY ECU (INSTRUMENT PANEL J/B) UNLOCK WARNING SWITCH - TAIL RELAY B128404E01 TD–42 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) REAR DOOR LOCK RH LUGGAGE COMPARTMENT DOOR LOCK CYLINDER REAR DOOR COURTESY SWITCH RH FRONT DOOR LOCK RH FRONT DOOR COURTESY SWITCH RH FRONT DOOR LOCK LH TD FRONT DOOR COURTESY SWITCH LH HAZARD WARNING LIGHT HAZARD WARNING LIGHT REAR DOOR LOCK LH TAILLIGHT TAILLIGHT REAR DOOR COURTESY SWITCH LH LUGGAGE COMPARTMENT DOOR LOCK - LUGGAGE COMPARTMENT DOOR COURTESY SWITCH B128405E01 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) TD–43 SYSTEM DIAGRAM Front Door Courtesy Switch (LH, RH) Rear Door Courtesy Switch (LH, RH) Main Body ECU Turn Signal Flasher Hazard Warning Light Personal Light Assembly Front Door Lock Position Switch (LH, RH) Head Relay Rear Door Lock Position Switch (LH, RH) Luggage Compartment Door Lock Assembly (Luggage Compartment Door Courtesy Switch) Tail Relay Horn Relay Security Horn TD Clock Luggage Compartment Door Lock Cylinder (Security Indicatror) DLC3 Unlock Warning Switch Engine Hood Lock Assembly (Engine Hood Courtesy Switch) Ignition Switch CAN B139458E01 TD–44 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) SYSTEM DESCRIPTION 1. OUTLINE OF THEFT DETERRENT SYSTEM • The theft deterrent system will operate when somebody attempts to forcibly enter the vehicle, unlock any door or luggage compartment door or open the engine hood or the luggage compartment door without using the key. This system causes the lights to light up or blink and the horns to sound in order to deter break-in and theft. • The theft deterrent system has 2 modes; one is the active arming mode (see ACTIVE ARMING MODE) and the other is passive arming mode (see PASSIVE ARMING MODE). The passive arming mode can be switched ON/OFF using the specified method. • Each mode has 4 states; a disarmed state, an arming preparation state, an armed state and an alarm sounding state. (a) Disarmed state: • The alarm function is not operating. • The theft deterrent system is not operating. (b) Arming preparation state: • The time until the system goes into the armed state. • The theft deterrent system is not operating. (c) Armed state: • The theft deterrent system is operating. (d) Alarm sounding state: • Alarm function is operating. Alarm time: Approx. 60 sec. Refer to table below for alarm method and time: TD Alarm Method Alarm Time Headlight Blinking Taillight Blinking Hazard Warning Light Blinking Interior Light Illuminating Vehicle Horn Sounding (approx. 0.4 second cycles) Security Horn Sounding (approx. 0.4 second cycles) Approx. 60 sec. 2. Component HINT: If any of the doors are unlocked when the key is not in the key cylinder during the armed state, a forced door lock signal will be output (see FORCED DOOR LOCK CONTROL). FUNCTION OF MAIN COMPONENT Function Security indicator Informs driver of theft deterrent system status. Security horn Sounds when attempted brake-in or theft is detected. Headlights Blink when attempted break-in or theft is detected. Taillights Blink when attempted break-in or theft is detected. Hazard warning lights Blinking when attempted break-in or theft is detected. THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) Component TD–45 Function Interior light Lights up when attempted break-in or theft is detected. Vehicle horns Sounds when attempted break-in or theft is detected. Door courtesy light switch Detects door status (open or closed). Door lock position switch Detects door status (locked or unlocked). Engine hood courtesy switch Detects engine hood status (open or closed). Luggage compartment door courtesy switch Detects luggage compartment door status (open or closed). Luggage compartment door lock cylinder Detects luggage compartment door status (locked or unlocked). 3. ACTIVE ARMING MODE HINT: Active arming mode starts the alarm control immediately after the doors are locked. (a) Active arming mode: This system activates as described in the diagram below when one of items for each condition is met. Disarmed State Disarmed State 1 Condition (10) *1 Disarmed State 2 *2 Condition (9) Condition (3) Condition (1) Condition (8) TD Arming Preparation State Condition (7) Condition (2) Condition (5) Condition (7) Armed State Condition (6) Condition (5) Alarm Sounding State Condition (4) Condition (7) B144373E01 TD–46 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) HINT: • *1: Disarmed state 1 is the normal disarmed state. • *2: Disarmed state 2 is set from either the disarmed state 1 or the arming preparation state. Condition Item Condition (1) TD In the disarmed state 1, when the key is not in the key cylinder, the system state is switched if one of the following conditions is met. 1. With all doors, engine hood and luggage compartment door closed, lock all doors by key operation. 2. With all doors, engine hood and luggage compartment door closed, lock all doors by wireless operation. 3. With engine hood and luggage compartment door closed, close and lock the open door without using key. Condition (2) After condition (1) is met, allow approx. 30 seconds to elapse. Condition (3) 1. 2. 3. 4. 5. Unlock any door. Open any door, engine hood, and luggage compartment door. Insert key into ignition key cylinder. Turn the ignition switch ON or ACC. Reconnect battery. Condition (4) 1. 2. 3. 4. 5. 6. Open engine hood. Open luggage compartment door. Reconnect battery. Open any door. Unlock any door when all doors are locked. Turn the ignition switch ON without using key. Condition (5) 1. Unlock only driver's door or all doors by wireless operation. 2. Unlock only driver's door or all doors by key operation. 3. Turn the ignition switch ON and run the engine for more than 2 seconds. Condition (6) After approx. 60 seconds, alarm stops and system returns to armed state. Condition (7) 1. Open the luggage compartment door by wireless operation. 2. Unlock the luggage compartment door by key operation. Condition (8) 1. Close the engine hood when the luggage compartment door is closed. 2. Close the luggage compartment door when the engine hood is closed. Condition (9) 1. 2. 3. 4. 5. Condition (10) In the disarmed state 1, when the key is not in the key cylinder, the system state is switched if one of the following conditions is met. 1. With all doors closed, and the engine hood or luggage compartment door is opened, lock all doors by wireless operation. 2. With all doors closed, and the engine hood or luggage compartment door is opened, lock all doors by key operation. 3. With the engine hood or luggage compartment door is opened and all doors locked with any door still opened, close the open door. Unlock any door. Open any door. Insert key into ignition key cylinder. Turn the ignition switch ON or ACC. Reconnect the battery. 4. PASSIVE ARMING MODE HINT: • Passive arming mode starts the alarm control after the key is out of the actuation area and doors are closed. • Passive arming mode can be switched ON/OFF by the specified method. • The alarm is initially set (when shipped from factory) to active arming mode (not passive arming mode). • During passive arming mode, the theft deterrent system goes into the armed state even if the doors are not locked. THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) TD–47 • Detecting that the doors are unlocked does not set off the alarm during passive arming mode. • A forced door lock signal is not output during passive arming mode (see FORCED DOOR LOCK CONTROL). • Although the theft deterrent system detects that the doors are opened during passive arming mode, the alarm will not go off immediately because an entry delay time is set. • If the condition (1) of active arming mode is met during passive arming mode, the theft deterrent system will switch to active arming mode. (a) Passive arming mode: This system activates as described in the diagram below when one of items for each condition is met. Disarmed State Disarmed State 1 *1 Condition (1) Disarmed State 2 *2 Condition (3) Condition (3) Condition (2) TD Arming Preparation State Condition (5) Condition (4) Condition (7) Condition (8) Armed State Condition (9) Condition (7) Alarm Sounding State Condition (6) Condition (8) B112143E02 TD–48 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) HINT: • *1: Disarmed state 1 is the normal disarmed state. • *2: Disarmed state 2 is set from either the disarmed state 1 or the arming preparation state. Condition Item Condition (1) 1. With ignition switch OFF, open any door and pull the key out of the ignition key cylinder. 2. With ignition switch OFF, pull the key out of the ignition key cylinder and open any door. Condition (2) All doors, engine hood and luggage compartment door are closed. Condition (3) 1. 2. 3. 4. 5. Unlock only driver's door or all doors by wireless operation. Unlock only driver's door or all doors by key operation. Reconnect battery. Insert key into ignition key cylinder. Turn the ignition switch ON or ACC. Condition (4) After condition (1) is met, allow approx. 30 seconds to elapse. Condition (5) 1. 2. 3. 4. Open any door. Open engine hood. Open luggage compartment door. Unlock luggage compartment door. Condition (6) 1. 2. 3. 4. 5. Open any door and allow entry delay time*1 to elapse. Open engine hood. Open luggage compartment door. Reconnect battery. Turn the ignition switch ON without using key. Condition (7) 1. 2. 3. 4. Unlock only driver's door or all doors by wireless operation. Unlock only driver's door or all doors by key operation. Turn the ignition switch ON and run the engine more than 2 seconds. Turn the ignition switch ON with key operation. Condition (8) 1. Open luggage compartment door by wireless operation. 2. Unlock luggage compartment door by key operation. Condition (9) After approx. 60 sec., alarm stops and system returns to armed state. TD 5. HINT: *1: When any door is opened while all the doors are closed during passive arming mode, the entry delay time starts. If the switch condition (armed state → disarmed state 1 or 2) is met during the entry delay time, the theft deterrent system will return to disarmed state 1 or 2. However, if the switch condition for disarmed state 1 or 2 is not met, the theft deterrent system will recognize it as a theft and set off the alarm. Entry delay time of 0, 14 or 30 sec. can be selected by the customizing function. FORCED DOOR LOCK CONTROL (a) The forced door lock control prevents the vehicle from being tampered with. Immediately after a door is unlocked (alarm starts), the door is forced to lock by a forced door lock signal. (1) Conditions that force the doors to lock: When the key is not in the key cylinder and both of the following conditions are met. • The theft deterrent system is in the alarm sounding state of active arming mode. • Any door is unlocked. THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) 6. 7. TD–49 ALARM MEMORY FUNCTION (a) If the alarm is set off (tampering is detected) while the theft deterrent system is armed, it will be recorded by the alarm memory function. Whenever the theft deterrent system is cancelled, the alarm memory function causes the taillights to light up for 2 seconds in order to inform you that the alarm has been set off. (1) Conditions of the alarm memory function that cause the taillights to light up: When the theft deterrent system has entered into the alarm sounding state (tampering has been detected) even once, the taillights will light up for 2 seconds if any of the following conditions is met. • Switched to the disarmed state from the armed state during active arming mode. • Switched to the disarmed state 1 from the armed state during passive arming mode. HINT: Active arming mode: See ACTIVE ARMING MODE. Passive arming mode: See PASSIVE ARMING MODE. PANIC ALARM CONTROL (a) The panic alarm control makes it possible to voluntarily set off the panic alarm by pressing the PANIC switch on the wireless transmitter. (1) Conditions that cause the panic alarm control to set off the panic alarm: The panic alarm control sets off the panic alarm by pressing the PANIC switch on the wireless transmitter under the following conditions: • The ignition switch is OFF. • The theft deterrent system is not in the alarm sounding state. (This condition is common both to active arming mode and to passive arming mode.) (2) Conditions that cause the panic alarm control to shut off the alarm: The panic alarm control shuts off the panic alarm when any of the following conditions is met during panic alarm operation: • The ignition switch is ON. • The panic alarm switch is turned on again. • Any of the switches on the wireless transmitter (LOCK/UNLOCK or LUGGAGE OPEN) is pressed. • The panic alarm ends (approx. 60 sec. have passed). TD TD–50 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) 8. • The theft deterrent system switches to the alarm sounding state. Under this condition, the theft deterrent system is controlling the alarm rather than the panic alarm control. In order to cancel this alarm, refer to the theft deterrent system alarm sounding state cancellation procedure. (This condition is common both to active arming mode to passive arming mode.) HINT: Active arming mode: See ACTIVE ARMING MODE. Passive arming mode: See PASSIVE ARMING MODE. SECURITY INDICATOR OUTPUT (a) The main body ECU outputs a signal to light up the security indicator, according to the state of the theft deterrent system. However, some of the actual lighting conditions of the security indicator are different from the output signals of the main body ECU. Output: State of Theft Deterrent System* Security Indicator Output Signals from Main Body ECU Actual Lighting Condition Disarmed state 1, 2 OFF OFF (Immobiliser system unset) BLINKING (Immobiliser system set) Arming preparation state ON ON Armed state OFF BLINKING Alarm sounding state ON ON Blinking cycle: Time TD Security Indicator 0.2 sec. ON 1.8 sec. OFF HINT: • *: The above condition is common both to active arming mode and to passive arming mode. • When the immobiliser system is set, the security indicator blinks during both the disarmed state and the armed state, due to the output signals from the immobiliser system. THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) TD–51 HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use this procedure to troubleshoot the theft deterrent system. • The intelligent tester should be used in step 3. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS (a) Interview the customer to confirm the trouble (See page IN-45). NEXT 3 INSPECT COMMUNICATION FUNCTION OF CAN COMMUNICATION SYSTEM (a) Use the intelligent tester to check for normal function of the multiplex communication system. (1) (ECU unconnected, communication line malfunctioning) If no code is output, proceed to A. (2) (ECU unconnected, communication line malfunctioning) If any code is output, proceed to B. B Go To CAN COMMUNICATION SECTION TD A 4 SYMPTOM SIMULATION NEXT 5 PROBLEM SYMPTOMS TABLE (a) If the fault is not listed in the problem symptoms table, proceed to A. (b) If the fault is listed in the problem symptoms table, proceed to B. B Go to step 7 A 6 PERFORM TROUBLESHOOTING ACCORDING TO MALFUNCTION SYMPTOM (a) System description (See page TD-44) TD–52 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) (b) Terminals of ECU (See page TD-55) 7 ADJUST, REPAIR OR REPLACE NEXT 8 NEXT END TD CONFIRMATION TEST THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) TD–53 CUSTOMIZE PARAMETERS HINT: The following items can be customized. NOTICE: • After confirming whether the items requested by the customer are applicable or not for customization, perform customizing operations. • Be sure to record the current settings before customization. • When troubleshooting, make sure that the item in question is not set to "OFF" as a result of customization (Example: For the system, "the wireless function does not operate", first check that the wireless function is not set to "OFF", then perform troubleshooting). THEFT DETERRENT SYSTEM DISPLAY (ITEM) DEFAULT CONTENTS SETTING PASSIVE MODE (Passive Arming Mode) OFF PASSIVE MODE is a function that switches theft deterrent system from arming preparation state to armed state 30 seconds after key is not in the key cylinder and all doors, engine hood and luggage compartment door are closed, even if doors are not locked by wireless or door key lock operation In PASSIVE MODE, if you do not perform following operations within 14 seconds after door is opened during armed state, theft deterrent system will judge that condition as a theft and switch to alarm sounding state – Unlock any door by key or wireless operation – Turn the ignition switch ON – Open luggage compartment door by key or wireless operation ON/OFF WARN BY HORN (Warning by horn) ON Function that makes vehicle horn and theft deterrent horn be able to be used as a warning device ON/OFF ENTRY DELAY (Entry delay time) 14 s Function that changes entry delay time (time before warning starts) for PASSIVE MODE 0 s/14 s/30 s TD TD–54 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) PROBLEM SYMPTOMS TABLE HINT: • Troubleshooting of the theft deterrent system is based on the premise that the door lock control system and the wireless door lock control system are operating normally. Accordingly, before troubleshooting the theft deterrent system, first make certain that the door lock control system and the wireless door lock control system are operating normally. • The following is the troubleshooting procedure for the theft deterrent system of a vehicle without the smart key system. • Inspect the fuse and relay before investigating the suspected areas shown in the table below. Theft deterrent system: Symptom Theft deterrent system cannot be set Security indicator does not blink when theft deterrent system is set TD Alarm sounding state cannot be canceled when ignition switch turned ON Theft deterrent system can be set even when a door is open Vehicle horns (low pitched, high pitched) do not sound while theft deterrent system is in warning operation Hazard warning lights do not flash while theft deterrent system is in warning operation Interior light does not light up while theft deterrent system is in warning operation Security horn does not sound while theft deterrent system is in warning operation Suspected area See page 1. Security indicator light circuit TD-72 2. ECU power source circuit TD-75 3. Unlock warning switch circuit DL-205 4. Door key lock / unlock switch DL-53 5. Door courtesy switch circuit LI-52 6. Luggage compartment door courtesy switch circuit DL-44 7. Engine hood courtesy switch circuit TD-60 8. If the symptom(s) still occur after the above areas are inspected and proved to be normal, replace the main body ECU (Instrument panel J/B) - 1. Security indicator light circuit TD-72 2. If the symptom(s) still occur after the above area is inspected and proved to be normal, replace the main body ECU RH (Instrument Panel J/B) - 1. Ignition switch circuit TD-68 2. Unlock warning switch circuit DL-205 3. If the symptom(s) still occur after the above areas are inspected and proved to be normal, replace the main body ECU (Instrument panel J/B) - 1. Door courtesy switch circuit LI-52 2. If the symptom(s) still occur after the above area is inspected and proved to be normal, replace the main body ECU (Instrument panel J/B) - 1. Horn circuit TD-62 2. If the symptom(s) still occur after the above area is inspected and proved to be normal, replace the main body ECU (Instrument panel J/B) - 1. Wire harness - 2. Turn signal flasher LI-138 3. If the symptom(s) still occur after the above area is inspected and proved to be normal, replace the main body ECU (Instrument panel J/B) - 1. Interior light circuit LI-57 2. If the symptom(s) still occur after the above area is inspected and proved to be normal, replace the main body ECU (Instrument panel J/B) - 1. Security horn circuit TD-64 2. If the symptom(s) still occur after the above area is inspected and proved to be normal, replace the main body ECU (Instrument panel J/B) - TD–55 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) Symptom Hazard warning lights flash even when theft deterrent system is not set Interior light comes on even when theft deterrent system is not set Suspected area See page 1. Wire harness - 2. Turn signal flasher LI-138 3. If the symptom(s) still occur after the above area is inspected and proved to be normal, replace the main body ECU (Instrument panel J/B) - 1. Interior light circuit LI-57 2. If the symptom(s) still occur after the above area is inspected and proved to be normal, replace the main body ECU (Instrument panel J/B) - TD TD–56 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) TERMINALS OF ECU 1. CHECK MAIN BODY ECU (INSTRUMENT PANEL J/B) (a) Disconnect the main body ECU (instrument panel J/ B) connectors. IM IF ID IO IA TD E7 E8 E6 E9 IG Main Body ECU B139428E01 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) TD–57 (b) Measure the resistance and voltage between each terminal of the wire harness side connectors and body ground. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition GR - Body ground Rear courtesy light switch RH input Rear door RH CLOSED (OFF) → OPEN (ON) 10 kΩ or higher → Below 1Ω PCTY (E6-21) - Body ground Y - Body ground Passenger side courtesy light switch input Passenger side door CLOSED (OFF) → OPEN (ON) 10 kΩ or higher → Below 1Ω LGCY (E6-25) - Body ground W - Body ground Luggage compartment door courtesy light switch input Luggage compartment door CLOSED (OFF) → OPEN (ON) 10 kΩ or higher → Below 1Ω HCTY (E7-16) - Body ground R - Body ground Engine hood courtesy switch Engine hood CLOSED (OFF) → OPEN (ON) 10 kΩ or higher → Below 1Ω DCTY (E7-24) - Body ground L - Body ground Driver side door courtesy light switch input Driver side door CLOSED (OFF) → OPEN (ON) 10 kΩ or higher → Below 1Ω KSW (E9-5) - Body ground L - Body ground Unlock warning switch input No key in ignition key cylinder (OFF) → Key inserted (ON) 10 kΩ or higher → Below 1Ω ACC (IA-1) - Body ground B - Body ground Ignition power supply (ACC signal) Ignition switch on (ACC) → off 10 to 14 V → Below 1 V IG (IA-1) - Body ground B - Body ground Ignition power supply (IG signal) Ignition switch on (IG) → off 10 to 14 V → Below 1 V ALTB (ID-16) - Body ground W - Body ground +B (power system alternator system) power supply Always 10 to 14 V GND1 (IF-10) - Body ground W-B - Body ground Ground Always Below 1 Ω BECU (ID-10) - Body ground O - Body ground +B power supply Always 10 to 14 V GND2 (IM-9) - Body ground W-B - Body ground Ground Always Below 1 Ω LCTY (IO-7) - Body ground LG - Body ground Rear courtesy light switch LH input Rear door LH CLOSED (OFF) → OPEN (ON) 10 kΩ or higher → Below 1Ω RCTY (E6-5) - Body ground If the result is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the main body ECU (instrument panel J/ B) connectors. (d) Measure the voltage between each terminal of the wire harness side connectors and body ground. Symbols (Terminal No.) HAZ (E8-4) - Body ground Wiring Color W - Body ground Terminal Description Condition Specified Condition Turn signal flasher relay signal System is in alarm sounding state Below 1 V 3 to 6 V IND (E9-4) - Body ground Y - Body ground Security indicator output Security indicator light up (It lights up only in arming preparation state or alarm sounding state. It flashes when immobiliser is operating.) SH (E9-6) - Body ground P - Body ground Security horn drive Security horn is sounding (Theft deterrent system is in alarm sounding state) Pulse generation (0 V ← → 12 V) HORN (ID-11) - Body ground B - Body ground Vehicle horn drive Vehicle horn is sounding (Theft deterrent system is in alarm sounding state) Pulse generation (0 V ← → 12 V) If the result is not as specified, the main body ECU (instrument panel J/B) may have a malfunction. TD TD–58 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) DIAGNOSIS SYSTEM CG SG CANH SIL CANL 1. CHECK DLC3 (a) The main body ECU uses ISO 15765-4 for communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. BAT H100769E16 Symbols (Terminal No.) Terminal Description Condition Specified condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always CANH (6) - CANL (14) CANH (6) - CG (4) CANL (14) - CG (4) CANH (6) - BAT (16) CANL (14) - BAT (16) CAN bus line HIGH-level CAN bus line LOW-level CAN bus line HIGH-level CAN bus line LOW-level CAN bus line 10 to 14 V * 54 to 67 Ω * 200 Ω or higher * 200 Ω or higher * 6 kΩ or higher OFF* 6 kΩ or higher Ignition switch OFF Ignition switch OFF Ignition switch OFF Ignition switch OFF Ignition switch NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. (b) Connect the cable of the intelligent tester (with CAN VIM) to the DLC3, turn the ignition switch ON and attempt to use the intelligent tester. If the screen displays a communication error message, a problem exists in the vehicle or in the tester. • If communication is normal when the tool is connected to another vehicle, inspect the DLC3 on the original vehicle. • If communication is still impossible when the tool is connected to another vehicle, the problem is probably in the tool itself. Consult the Service Department listed in the tool's instruction manual. TD DLC3 Intelligent Tester C131977E01 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) TD–59 DATA LIST / ACTIVE TEST 1. DATA LIST HINT: Using the intelligent tester DATA LIST allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to shorten labor time. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the ignition switch on ON. (c) Enter the following menus: DIAGNOSIS / OBD/ MOBD / MAIN BODY / DATA LIST. (d) Read the DATA LIST according to the display on the tester. MAIN BODY (Main body ECU): Item Measurement Item / Display (Range) KEY UNLK WRN SW Unlock warning switch signal / ON or OFF ACC SW Normal Condition Diagnostic Note ON: Key is inserted in the ignition key cylinder OFF: Key is removed from the ignition key cylinder - Ignition switch signal / ON or OFF ON: Ignition switch is ACC OFF: Ignition switch is OFF - IG SW Ignition switch signal / ON or OFF ON: Ignition switch is ON OFF: Ignition switch is OFF - D DOOR CTY SW D door courtesy switch / ON or OFF ON: Driver side door is OPEN OFF: Driver side door is CLOSED - P DOOR CTY SW P door courtesy switch / ON or OFF ON: Front passenger side door is OPEN OFF: Front passenger side door is CLOSED - RR DOR CTY SW Rear right door courtesy switch / ON or OFF ON: Rear right door is OPEN OFF: Rear right door is CLOSED - RL DOR CTY SW Rear left door courtesy switch / ON or OFF ON: Rear left door is OPEN OFF: Rear left door is CLOSED - LUGG COURTSY SW Luggage compartment door courtesy switch / ON or OFF ON: Luggage compartment door is OPEN OFF: Luggage compartment door is CLOSED - D LOCK POS SW Driver's door lock position switch / ON or OFF ON: Driver's door is UNLOCKED OFF: Driver's door is LOCKED - P LOCK POS SW Passenger door lock position switch / ON or OFF ON: Passenger door is UNLOCKED OFF: Passenger door is LOCKED - HOOD COURTESY SW Engine hood courtesy switch signal / ON or OFF ON: Engine hood is OPEN OFF: Engine hood is CLOSED - PASSIVE MODE Passive mode/ON or OFF ON: Passive mode ON OFF: Passive mode OFF - WARN BY HORN Warning by horn/ON or OFF ON: Vehicle horns sound during alarm sounding state OFF: Vehicle horns do not sound during alarm sounding state - ENTRY DELAY Entry delay time during passive mode 0s: Entry delay time is 0 sec. 14s: Entry delay time is 14 sec. 30s: Entry delay time is 30 sec. - 2. ACTIVE TEST HINT: Performing the intelligent tester ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to shorten the labor time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. TD TD–60 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) (b) Turn the ignition switch on ON. (c) Enter the following menus: DIAGNOSIS / OBD/ MOBD / MAIN BODY / ACTIVE TEST. (d) Perform the ACTIVE TEST according to the display on the tester. MAIN BODY (Main body ECU): Item SECURITY INDIC TD Tester Detail Security indicator ON/OFF Diagnostic Note - SECURITY HORN Security horn ON/OFF - HAZARD Hazard warning light ON/OFF - VEHICLE HORN Vehicle horn ON/OFF - TD–61 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) Engine Hood Courtesy Switch Circuit DESCRIPTION The engine hood courtesy switch is installed together with the hood lock. This switch turns off when the engine hood is opened and turns on when the engine hood is closed. WIRING DIAGRAM Instrument Panel J/B Assembly E7 Main Body ECU A5 Engine Hood Courtesy Switch 1 16 2 HCTY B144365E01 INSPECTION PROCEDURE 1 TD INSPECT ENGINE HOOD COURTESY SWITCH Free (ON) A5 Engine Hood Courtesy Switch (a) Remove the courtesy switch from the hood lock. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection 1-2 Pushed (OFF) NG B144360E01 OK Switch Position Specified Condition Free (ON) Below 1 Ω Pushed (OFF) 10 kΩ or higher REPLACE HOOD LOCK ASSEMBLY TD–62 2 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) CHECK HARNESS AND CONNECTOR (ENGINE HOOD COURTESY SWITCH - BODY GROUND) (a) Disconnect the A5 switch connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side Connector Front View: Engine Hood Courtesy Switch NG A5 Tester Connection Specified Condition A5-1 - Body ground Below 1 Ω REPAIR OR REPLACE HARNESS OR CONNECTOR B144361E01 OK 3 CHECK HARNESS AND CONNECTOR (MAIN BODY ECU - ENGINE HOOD COURTESY SWITCH) (a) Disconnect the E7 ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Connector Wire Harness View: Main Body ECU TD E7 (Symbol) Tester Connection Specified Condition HCTY (E7-16) - (A5-2) Below 1 Ω HCTY (E7-16) - Body ground 10 kΩ or higher NG HCTY REPAIR OR REPLACE HARNESS OR CONNECTOR Wire Harness Side Connector Front View: Engine Hood Courtesy Switch A5 B144366E01 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) TD–63 Horn Circuit DESCRIPTION When the theft deterrent system is switched from the armed state to the alarm sounding state, the main body ECU transmits a signal to cause the horn to sound at intervals of 0.4 seconds. WIRING DIAGRAM Instrument Panel J/B Assembly Engine Room R/B and J/B HORN 1 1G 10 1D 11 ID HORN 5 II 6 1B HORN Main Body ECU From Streeting Pad Switch From Battery A4 Low Pitched 1 Horn 25 1 TD A3 High Pitched Horn B139444E01 INSPECTION PROCEDURE 1 INSPECT HORNS (a) Press the horn switch and check if the horns sound. TD–64 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) Result Result Go to Horns sound A Horns do not sound B B GO TO HORN SYSTEM A PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE TD THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) TD–65 Security Horn Circuit DESCRIPTION When the theft deterrent system is changed from the armed state to the alarm sounding state, the main body ECU can control the security horn. WIRING DIAGRAM Instrument Panel J/B Assembly Engine Room R/B and J/B S-HORN 1 1G 11 1D 6 E9 SH Main Body ECU S-HORN 5 1A TD From Battery 1 A23 Security Horn B139446E01 INSPECTION PROCEDURE 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (a) Connect the intelligent tester (with CAN VIM) to the DLC3. TD–66 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) (b) Turn the ignition switch ON. (c) Turn the intelligent tester main switch on. (d) Select the item below in the ACTIVE TEST and then check that the horn sounds. MAIN BODY (Main Body ECU): Item Test Details Diagnostic Note SECURITY HORN Security horn ON/OFF - OK: The security horn sounds or stops correctly when operating it through the intelligent tester. NG Go to step 2 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE 2 INSPECT SECURITY HORN ASSEMBLY (a) Remove the security horn assembly. (b) Check operation of the horn. Standard Measurement Condition Battery positive (+) → Terminal 1 Battery negative (-) → Horn body NG B139440 TD OK Specified Condition Horn sounds REPAIR OR REPLACE SECURITY HORN ASSEMBLY THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) 3 TD–67 CHECK HARNESS AND CONNECTOR (ENGINE ROOM J/B - SECURITY HORN ASSEMBLY) Wire Harness Side Connector Front View: Engine Room J/B (a) Disconnect the 1A J/B connector and the A23 horn connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance 1A NG Terminal Connection Specified Condition 1A-5 - A23-1 Below 1 Ω 1A-5 - Body ground 10 kΩ or higher REPAIR OR REPLACE HARNESS OR CONNECTOR Security Horn Assembly A23 B139441E01 OK 4 CHECK HARNESS AND CONNECTOR (MAIN BODY ECU - ENGINE ROOM J/B) (a) Disconnect the E9 ECU connector and 1D J/B connector connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Connector Wire Harness View: Main Body ECU Symbol (Terminal Connection) Specified Condition SH (E9-6) - (1D-11) Below 1 Ω SH (E9-6) - Body ground 10 kΩ or higher E9 SH Wire Harness Side Connector Front View: Engine Room J/B 1D B139442E01 NG REPAIR OR REPLACE HARNESS OR CONNECTOR TD TD–68 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) OK 5 CHECK HARNESS AND CONNECTOR (ENGINE ROOM J/B - BATTERY) (a) Disconnect the 1G J/B connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness Side: Engine Room J/B 1 Terminal Connection Specified Condition 1G-1 - Body ground 10 to 14 V 1G NG B074501E16 REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ENGINE ROOM JUNCTION BLOCK ASSEMBLY TD THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) TD–69 Ignition Switch Circuit DESCRIPTION The main body ECU determines the ignition position (OFF, ACC, ON) based on signals from the IG or ACC circuit. WIRING DIAGRAM Main Body ECU Instrument Panel J/B 1 IA From Battery 3 II ACC 5 3 2 1 4 II IG1 ACC 2 IG1 1 9 II 22 ACC AM1 E23 Ignition Switch 4 AM1 ECU-ACC ECU IG NO. 1 5 3 2 1 15 IG TD 10 IF B139443E01 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester (with CAN VIM) to the DLC3. TD–70 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) (b) Turn the ignition switch ON. (c) Turn the intelligent tester main switch on. (d) Select the item below in the DATA LIST and read the display on the intelligent tester. MAIN BODY (Main Body ECU): Item Test Details Diagnostic Note IG SW ignition switch ON signal ON/OFF - ACC SW ignition switch ACC signal ON/OFF - OK: When the ignition switch is operated, the display changes as shown in the table. NG Go to step 2 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE 2 CHECK HARNESS AND CONNECTOR (BATTERY - INSTRUMENT PANEL J/B) (a) Disconnect the IA J/B connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Connector Wire Harness View: Instrument Panel J/B Assembly (Vehicle Rear Side) Tester Connection Condition Specified Condition IA-1 - Body ground Ignition switch ON 10 to 14 V NG TD IA 1 B110530E02 OK REPAIR OR REPLACE HARNESS OR CONNECTOR TD–71 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) 3 INSPECT IGNITION OR STARTER SWITCH ASSEMBLY E23 Ignition or Starter Switch Assembly (a) Disconnect the E23 switch connector from the ignition switch. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection No Pin NG Condition Specified Condition 1-4 Ignition switch ON Below 1 Ω 2-4 Ignition switch ACC Below 1 Ω REPLACE IGNITION OR STARTER SWITCH ASSEMBLY ACC ON LOCK START B125076E02 OK 4 CHECK HARNESS AND CONNECTOR (INSTRUMENT PANEL J/B - INSTRUMENT PANEL J/B) (a) Disconnect the II J/B connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Connector Wire Harness View: Instrument Panel J/B Assembly (Vehicle Rear Side) Tester Connection Condition Specified Condition II-4 - II-9 Ignition switch ON Below 1 Ω II-4 - II-3 Ignition switch ACC Below 1 Ω NG II 9 3 B110531E10 REPAIR OR REPLACE HARNESS OR CONNECTOR TD TD–72 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) OK 5 CHECK HARNESS AND CONNECTOR (INSTRUMENT PANEL J/B - BODY GROUND) Connector Wire Harness Side View: Instrument Panel J/B Assembly (Vehicle Rear Side) (a) Disconnect the IF J/B connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance NG Tester Connection Specified Condition IF-10 - Body ground Below 1 Ω REPAIR OR REPLACE HARNESS OR CONNECTOR IF 10 B110542E03 OK REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY TD THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) TD–73 Security Indicator Light Circuit DESCRIPTION Even when the theft deterrent system is in the disarmed state, the security indicator blinks due to a signal output from the immobiliser system. The security indicator blinks continuously due to a continuous signal received from the immobiliser system while in the armed state. The main body ECU causes the security indicator to light up or blink only during the arming preparation state and alarm sounding states. WIRING DIAGRAM Instrument Panel J/B F3 Clock Assembly Main Body ECU Security Indicator 19 GND1 LP 8 4 E9 IND B139445E01 TD TD–74 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) INSPECTION PROCEDURE 1 INSPECT CLOCK ASSEMBLY (a) Disconnect the F3 clock connector. (b) Apply battery voltage between the terminals of the indicator, and check the lighting condition of the security indicator. Standard F3 Clock Assembly LP GND1 B139454E01 Measurement Condition Specified Condition Battery positive (+) → Terminal F3-8 (LP) Battery negative (-) → Terminal F3-19 (GND1) Lights up NOTICE: • If the positive (+) lead and the negative (-) lead are incorrectly connected, the security indicator will not light up. • Voltage of more than 12 V will damage the security indicator. • If the voltage is too low, the security indicator will not light up. NG REPLACE CLOCK ASSEMBLY OK 2 CHECK HARNESS AND CONNECTOR (CLOCK ASSEMBLY - MAIN BODY ECU) (a) Disconnect the E9 ECU connector. (b) Disconnect the F3 clock connector. (c) Measure the resistance according to the value(s) table below. Standard resistance Connector Wire Harness View: TD Main Body ECU E9 Symbol (Tester Connection) Specified Condition IND (E9-4) - LP (F3-8) Below 1 Ω IND (E9-4) - Body ground 10 kΩ or higher IND NG Clock Assembly F3 LP B139459E01 OK REPAIR OR REPLACE HARNESS OR CONNECTOR THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) 3 TD–75 CHECK HARNESS AND CONNECTOR (CLOCK ASSEMBLY - BODY GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Connector Wire Harness View: F3 Clock Assembly Symbol (Tester Connection) Specified Condition GND1 (F3-19) - Body ground Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR GND1 E128063E06 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE TD TD–76 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) ECU Power Source Circuit DESCRIPTION This circuit provides power for main body ECU operation. WIRING DIAGRAM Instrument Panel J/B Assembly Engine Room R/B and J/B Main Body ECU DOOR NO. 1 1 1 1G 2 SHORT ECU-B NO. 1 1 2 1 2 1 16 ID 1 10 ID 6 26 ALTB BECU From Battery TD 10 IF 5 GND1 9 IM 4 GND2 B139447E02 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) TD–77 INSPECTION PROCEDURE 1 CHECK INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY (MAIN BODY ECU) (POWER SOURCE) (a) Disconnect the ID J/B connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Connector Wire Harness View: Instrument Panel J/B Assembly (Vehicle Rear Side) NG Tester Connection Specified Condition ID-10 - Body ground 10 to 14 V ID-16 - Body ground 10 to 14 V REPAIR OR REPLACE HARNESS OR CONNECTOR ID 10 16 B110545E04 OK 2 CHECK HARNESS AND CONNECTOR (INSTRUMENT PANEL J/B - BODY GROUND) (a) Disconnect the IF and IM J/B connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Connector Wire Harness View: Instrument Panel J/B Assembly (Vehicle Rear Side) Symbol (Tester Connection) IF-10 - Body ground IM-9 - Body ground Specified Condition Below 1 Ω 9 NG IM IF 10 B110543E02 REPAIR OR REPLACE HARNESS OR CONNECTOR TD TD–78 THEFT DETERRENT – THEFT DETERRENT SYSTEM (w/o Smart Key System) OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE TD TD–78 THEFT DETERRENT – ENGINE HOOD COURTESY SWITCH ENGINE HOOD COURTESY SWITCH THEFT DETERRENT SECURITIES COMPONENTS for 2GR-FE: COOL AIR INTAKE DUCT SEAL HOOD LOCK ASSEMBLY 7.5 (77, 66 in.*lbf) HOOD LOCK CONTROL CABLE ASSEMBLY TD 20 (204, 15) HIGH PITCHED HORN ASSEMBLY FRONT BUMPER ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B136674E01 THEFT DETERRENT – ENGINE HOOD COURTESY SWITCH TD–79 TMMK Made: HOOD LOCK TENSION SPRING A HOOD LOCK TENSION SPRING B ENGINE HOOD COURTESY SWITCH HOOD LOCK ASSEMBLY B136692E01 TD TD–80 THEFT DETERRENT – ENGINE HOOD COURTESY SWITCH REMOVAL 1. REMOVE COOL AIR INTAKE DUCT SEAL (for 2GRFE) (See page ET-4) 2. REMOVE FRONT BUMPER ASSEMBLY (w/o Fog Light) (See page ET-5) 3. REMOVE FRONT BUMPER ASSEMBLY (w/ Fog Light) (See page ET-6) 4. REMOVE HIGH PITCHED HORN ASSEMBLY (See page HO-7) 5. REMOVE HOOD LOCK ASSEMBLY (See page ED-7) 6. REMOVE HOOD LOCK TENSION SPRING A (for TMMK Made) (a) Remove tension spring A. 7. REMOVE HOOD LOCK TENSION SPRING B (for TMMK Made) (a) Remove tension spring B. Tension Spring A B136678E01 TD Tension Spring B B136679E04 THEFT DETERRENT – ENGINE HOOD COURTESY SWITCH 8. TD–81 REMOVE ENGINE HOOD COURTESY SWITCH (for TMMK Made) (a) Remove the 2 screws and the engine hood courtesy switch. B136690 INSPECTION 1. Free (ON) INSPECT ENGINE HOOD COURTESY SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection 1-2 Pushed (OFF) Switch Position Specified Condition Free (ON) Below 1 Ω Pushed (OFF) 10 kΩ or higher If the result is not as specified, replace the hood lock assembly. B144360E02 INSTALLATION 1. B136690 INSTALL ENGINE HOOD COURTESY SWITCH (for TMMK Made) (a) Install the engine hood courtesy switch with the 2 screws. TD TD–82 THEFT DETERRENT – ENGINE HOOD COURTESY SWITCH 2. INSTALL HOOD LOCK TENSION SPRING B (for TMMK Made) (a) Install tension spring B. 3. INSTALL HOOD LOCK TENSION SPRING A (for TMMK Made) (a) Install tension spring A. 4. INSTALL HOOD LOCK ASSEMBLY (See page ED-9) 5. INSTALL HIGH PITCHED HORN ASSEMBLY (See page HO-7) 6. INSTALL FRONT BUMPER ASSEMBLY (w/o Fog Light) (See page ET-13) 7. INSTALL FRONT BUMPER ASSEMBLY (w/ Fog Light) (See page ET-14) 8. INSTALL COOL AIR INTAKE DUCT SEAL (for 2GRFE) (See page ET-14) Tension Spring B B136679E04 Tension Spring A B136678E01 TD THEFT DETERRENT – SECURITY HORN ASSEMBLY TD–83 SECURITY HORN ASSEMBLY THEFT DETERRENT SECURITIES COMPONENTS SECURITY HORN ASSEMBLY 31 (316, 23) TD N*m (kgf*cm, ft.*lbf) : Specified torque B136675E01 REMOVAL 1. B136677 REMOVE SECURITY HORN ASSEMBLY (a) Remove the bolt. (b) Disconnect the connector and remove the security horn assembly. TD–84 THEFT DETERRENT – SECURITY HORN ASSEMBLY INSPECTION 1. INSPECT SECURITY HORN ASSEMBLY (a) Check operation of the horn. Standard Measurement Condition Battery positive (+) → Terminal 1 Battery negative (-) → Horn body B139440 TD Specified Condition Horn sounds If the result is not as specified, replace the security horn assembly. THEFT DETERRENT – SECURITY HORN ASSEMBLY TD–85 INSTALLATION 1. INSTALL SECURITY HORN ASSEMBLY (a) Connect the connector. (b) Install the security horn assembly with the bolt. Torque: 31 N*m (316 kgf*cm, 23 ft.*lbf) B136677 TD IG–1 2GR-FE IGNITION – IGNITION SYSTEM IGNITION SYSTEM 2GR-FE IGNITION ENGINE PARTS LOCATION ECM ENGINE ROOM R/B - IG2 FUSE - ST/AM FUSE IGNITION COIL NOISE FILTER IG NOISE FILTER A137458E01 IG–2 2GR-FE IGNITION – IGNITION SYSTEM SYSTEM DIAGRAM C11 Ignition Coil (No. 1) ECM IG2 IG2 From Battery 5 3 1 1 2 4 E23 Ignition Switch *2 6 IG2 1 AM2 5 *2 From Battery 4 GND IGT1 3 IGF 2 C13 Ignition Coil (No. 2) +B GND IGT2 3 39 C55 IGT2 IGF 2 C12 Ignition Coil (No. 3) ST/AM2 1 E6 Main Body ECU 4 11 E6 IG2D *1 +B 40 C55 IGT1 1 4 +B GND IGT3 3 38 C55 IGT3 IGF 2 C14 Ignition Coil (No. 4) +B GND IGT4 IGF 3 37 C55 IGT4 2 C38 Ignition Coil (No. 5) 1 C16 Noise Filter (Ignition RH) 1 C49 Noise Filter (Ignition LH) 1 4 IG *1: with Smart Key System *2: without Smart Key System 1 4 +B GND IGT5 3 IGF 2 C39 Ignition Coil (No. 6) +B GND 36 C55 IGT5 IGT6 IGF 3 35 C55 IGT6 106 C55 IGF1 2 A136999E01 2GR-FE IGNITION – IGNITION SYSTEM IG–3 ON-VEHICLE INSPECTION NOTICE: In this section, the terms "cold" and "hot" refer to the temperature of the coils. "Cold" means approximately 10°C (14°F) to 50°C (122°F). "HOT" means approximately 50°C (122°F) to 100°C (212°F). 1. INSPECT IGNITION COIL ASSEMBLY (a) Check for DTCs. NOTICE: If any DTC is present, perform troubleshooting in accordance with the procedures for that DTC. (b) Check that sparks occur. (1) Remove the intake air surge tank (See page FU-13). (2) Remove the No. 1 surge tank stay (see page IG-10). (3) Disconnect the 6 ignition coil connectors and remove the 6 bolts and 6 ignition coils. A133896 (4) Using a 16 mm (0.63 in.) plug wrench, remove the 6 spark plugs. A137604 (5) Disconnect the 6 fuel injector connectors. (6) Install the spark plugs to each ignition coil, and connect the ignition coil connectors. IG A133895 IG–4 2GR-FE IGNITION – IGNITION SYSTEM (7) Ground the spark plugs. (8) Check if a spark occurs at each spark plug while the engine is being cranked. NOTICE: • Be sure to ground the spark plugs when checking. • Replace the ignition coil if it receives an impact. • Do not crank the engine for more than 2 seconds. (c) Perform the spark test according to the flowchart below. (1) Check that the ignition coil connector is securely connected. Result A133897 Result Proceed to NG Connect securely OK Go to next step (2) Perform a speak test on each ignition coil. 1. Replace the ignition coil with a normal one. 2. Perform the spark test again. Result Result Proceed to OK Replace ignition coil NG Go to next step (3) Check the power supply to the ignition coil. 1. Turn the ignition switch on (IG). 2. Check that there is battery voltage at the ignition coil positive (+) terminal. Result Result Proceed to NG Check wiring between ignition switch and ignition coil OK Go to next step (4) Check the VVT sensor output voltage. Result Result Proceed to NG Check that there is resistance between ECM and VVT sensor. If there is no resistance, replace VVT sensor. If there is resistance, repair wiring between VVT sensor and ECM. OK Go to next step IG (5) Measure the resistance of the crankshaft position sensor. Standard resistance Temperature Specified Condition Cold 1,630 to 2,740 Ω Hot 2,065 to 3,225 Ω IG–5 2GR-FE IGNITION – IGNITION SYSTEM Result Result Proceed to NG Replace crankshaft position sensor OK Go to next step (6) Check the IGT signal from the ECM. Result Result Proceed to NG Check ECM (See page ES-234) OK Repair wiring between ignition coil and ECM (d) Using a 16 mm (0.63 in.) plug wrench, install the spark plugs. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) (e) Install the 6 ignition coils with the 6 bolts and connect the 6 ignition coil connectors. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) (f) Connect the 6 fuel injector connectors. (g) Install the No. 1 surge tank stay (See page IG-11). (h) Install the intake air surge tank (See page FU-18). 2. Ground I039522E10 INSPECT SPARK PLUG NOTICE: • Never use a wire brush for cleaning. • Never attempt to adjust the electrode gap on a used spark plug. (a) Check the electrode. (1) Using a megohmmeter, measure the insulation resistance. Standard insulation resistance: 10 MΩ or higher HINT: • If the result is 10 MΩ or less, clean the plug and measure the resistance again. • If a megohmmeter is not available, perform the following simple inspection instead. (b) Alternative inspection method: (1) Quickly accelerate the engine to 4,000 rpm 5 times. (2) Remove the spark plugs. (3) Visually check the spark plug. If the electrode is dry, the spark plug is functioning properly. If the electrode is damp, proceed to the next step. (c) Check the spark plug for any damage to its threads and insulator. If there is damage, replace the spark plug. Require spark plug Manufacturer Spark plug type DENSO made FK20HR11 IG IG–6 2GR-FE IGNITION – IGNITION SYSTEM NOTICE: Use only the listed spark plug or equivalent to ensure engine performance and smooth driveability. (d) Check the spark plug electrode gap. Maximum electrode gap for used spark plug: 1.4 mm (0.055 in.) If the gap is greater than the maximum, replace the spark plug. Electrode gap for new spark plug: 1.0 to 1.1 mm (0.039 to 0.043 in.) 1.0 to 1.1 mm A126880E01 B062019 IG (e) Clean the spark plugs. If the electrode has traces of wet carbon, clean the electrode with a spark plug cleaner and then dry it. Standard air pressure: 588 kPa (6 kgf*cm2, 85 psi) Standard duration: 20 seconds or less HINT: Only use the spark plug cleaner when the electrode is free of oil. If the electrode has traces of oil, use gasoline to clean off the oil before using the spark plug cleaner. IG–7 2GR-FE IGNITION – IGNITION COIL IGNITION COIL 2GR-FE IGNITION ENGINE COMPONENTS FRONT WIPER ARM AND BLADE ASSEMBLY RH 20 (204, 15) FRONT FENDER TO COWL SIDE SEAL RH FRONT WIPER ARM AND BLADE ASSEMBLY LH COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 85 (867, 63) 7.5 (77, 66 in.*lbf) 5.0 (51, 44 in.*lbf) FRONT FENDER TO COWL SIDE SEAL LH WINDSHIELD WIPER LINK ASSEMBLY COWL TOP PANEL OUTER SUB-ASSEMBLY IG N*m (kgf*cm, ft.*lbf) : Specified torque A134938E01 IG–8 2GR-FE IGNITION – IGNITION COIL UNION TO CHECK VALVE HOSE * 21 (214, 15) 5.4 (55, 48 in.*lbf) VACUUM HOSE CLAMP THROTTLE BODY BRACKET * VENTILATION HOSE 21 (214, 15) NO. 1 SURGE TANK STAY 16 (163, 12) x4 NO. 3 WATER BY-PASS HOSE NO. 2 WATER BY-PASS HOSE * 18 (184, 13) INTAKE AIR SURGE TANK AIR SURGE TANK TO INTAKE MANIFOLD GASKET IG N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part * DO NOT apply oil A141148E01 2GR-FE IGNITION – IGNITION COIL IG–9 V-BANK COVER SUB-ASSEMBLY 10 (102, 10) IGNITION COIL ASSEMBLY AIR CLEANER CAP SUB-ASSEMBLY IGNITION COIL CONNECTOR N*m (kgf*cm, ft.*lbf) : Specified torque A134977E01 IG IG–10 2GR-FE IGNITION – IGNITION COIL REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. DRAIN ENGINE COOLANT (See page CO-5) 3. REMOVE WINDSHIELD WIPER LINK ASSEMBLY (See page WW-9) 4. REMOVE COWL TOP PANEL OUTER SUBASSEMBLY (See page ES-424) 5. REMOVE V-BANK COVER SUB-ASSEMBLY (See page EM-23) 6. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-503) 7. REMOVE INTAKE AIR SURGE TANK ASSEMBLY (See page EM-31) 8. REMOVE NO. 1 SURGE TANK STAY (a) Remove the bolt and disconnect the harness clamp. A136114 (b) Remove the bolt and No. 1 surge tank stay. A134967 IG 2GR-FE IGNITION – IGNITION COIL 9. LH Bank: IG–11 REMOVE IGNITION COIL ASSEMBLY (a) Disconnect the 6 ignition coil connectors. (b) Remove the 6 bolts and 6 ignition coils. RH Bank: A134966E01 INSTALLATION LH Bank: 1. INSTALL IGNITION COIL ASSEMBLY (a) Install the 6 ignition coils with the 6 bolts. Torque: 10 N*m (102 kgf*cm, 10 ft.*lbf) (b) Connect the 6 ignition coil connectors. 2. INSTALL NO. 1 SURGE TANK STAY (a) Install the No. 1 surge tank stay with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) NOTICE: Make sure that there is no oil on the bolt threads. RH Bank: A134966E01 A134967 IG IG–12 2GR-FE IGNITION – IGNITION COIL (b) Install the bolt and clamp. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) 3. INSTALL INTAKE AIR SURGE TANK ASSEMBLY (See page EM-42) 4. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See page ES-506) 5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page EM-51) 6. ADD ENGINE COOLANT (See page CO-6) 7. CHECK FOR ENGINE COOLANT LEAKS (See page CO-1) 8. INSTALL COWL TOP PANEL OUTER SUBASSEMBLY (See page ES-426) 9. INSTALL WINDSHIELD WIPER LINK ASSEMBLY (See page WW-13) A136114 10. INSTALL V-BANK COVER SUB-ASSEMBLY (See page EM-52) IG 2GR-FE ENGINE MECHANICAL – ENGINE EM–1 ENGINE ON-VEHICLE INSPECTION Intelligent Tester DLC3 CAN VIM C110200E02 1. INSPECT ENGINE COOLANT (a) Inspect the engine coolant (See page CO-1). 2. INSPECT ENGINE OIL (a) Inspect the engine oil (See page LU-1). 3. INSPECT BATTERY (a) Inspect the battery (See page CH-4). 4. INSPECT SPARK PLUGS (a) Inspect the spark plugs (See page IG-5). 5. INSPECT AIR CLEANER FILTER ELEMENT SUBASSEMBLY (a) Remove the air cleaner filter element sub-assembly. (b) Visually check that there is no dirt, blockage, and/or damage to the air cleaner filter element. HINT: • If there is any dirt or a blockage in the air cleaner filter element, clean it with compressed air. • If any dirt or a blockage remains even after cleaning the air cleaner filter element with compressed air, replace it. 6. INSPECT VALVE LASH ADJUSTER NOISE (a) Rev up the engine several times. Check that the engine does not emit unusual noises. If unusual noises occur, warm up the engine and idle it for over 30 minutes. Then repeat this procedure. HINT: If any defects or problems are found during the inspection above, perform lash adjuster inspection (See page EM-87). 7. INSPECT IGNITION TIMING (a) Warm up the engine. (b) When using the intelligent tester: Check the ignition timing. (1) Connect the intelligent tester to the DLC3. (2) Enter DATA LIST mode with the intelligent tester. Ignition timing: 8 to 12° BTDC at idle HINT: Refer to the intelligent tester operator's manual for help when selecting the DATA LIST. EM EM–2 2GR-FE ENGINE MECHANICAL – ENGINE (c) When not using the intelligent tester: Check the ignition timing. (1) Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3. SST 09843-18040 NOTICE: • Confirm the terminal numbers before connecting them. Connection with a wrong terminal can damage the engine. • Turn off all electrical systems before connecting the terminals. • Perform this inspection after the cooling fan motor is turned off. (2) Remove the V-bank cover. DLC3 CG 1 2 3 4 5 6 7 8 9 1011 1213 141516 TC A122830E14 (3) Pull out the red lead wire harness. (4) Connect the tester terminal of the timing light to the red lead wire as shown in the illustration. NOTICE: Use a timing light which can detect the first signal. (5) Check the ignition timing at idle. Ignition timing: 8 to 12° BTDC at idle NOTICE: When checking the ignition timing, the transmission should be in neutral. HINT: Run the engine at 1,000 to 1,300 rpm for 5 seconds, and then check that the engine rpm returns to idle speed. (6) Disconnect terminals 13 (TC) and 4 (CG) of the DLC3. (7) Check the ignition timing at idle. Ignition timing: 12 to 22° BTDC at idle (8) Confirm that the ignition timing moves to the advanced angle side when the engine rpm is increased. (9) Remove the timing light. Red Lead Wire EM Tester Terminal A129620E01 8. Intelligent Tester DLC3 CAN VIM C110200E02 INSPECT ENGINE IDLE SPEED (a) Warm up the engine. (b) When using the intelligent tester: Check the idle speed. (1) Connect the intelligent tester to the DLC3. (2) Enter DATA LIST mode with the intelligent tester. Idle speed: 600 to 700 rpm NOTICE: • When checking the idle speed, the transmission should be in neutral. • Check the idle speed with the cooling fan off. 2GR-FE ENGINE MECHANICAL – ENGINE EM–3 • Switch off all accessories and air conditioning before connecting the intelligent tester. HINT: Refer to the intelligent tester operator's manual for further details. (c) When not using the intelligent tester: Check the idle speed. (1) Using SST, connect the tachometer test probe to terminal 9 (TAC) of the DLC3. SST 09843-18030 (2) Check the idle speed. Idle speed: 600 to 700 rpm DLC3 1 2 3 4 5 6 7 8 TAC 9 1011 1213 141516 9. A122830E15 INSPECT COMPRESSION (a) Warm up and stop the engine. (b) Disconnect the injector connectors. (c) Remove the intake air surge tank (See page FU13). (d) Remove the 6 ignition coils. (e) Remove the 6 spark plugs. (f) A129621 Check the cylinder compression pressure. (1) Insert a compression gauge into the spark plug hole. (2) While cranking the engine, measure the compression pressure. Compression pressure: 1.4 MPa (14 kgf/cm2, 199 psi) Minimum pressure: 0.98 MPa (10 kgf/cm2, 142 psi) Difference between each cylinder: 0.1 MPa (1.0 kgf/cm2, 15 psi) NOTICE: • Always use a fully charged battery to obtain an engine speed of 250 rpm or more. • Check the other cylinders' compression pressure in the same way. • This measurement must be done as quickly as possible. (3) If the cylinder compression is low, pour a small amount of engine oil into the cylinder through the spark plug hole and inspect again. HINT: • If adding oil increases the compression, the piston rings and/or cylinder bore may be worn or damaged. • If pressure stays low, a valve may be stuck or seated improperly, or there may be leakage in the gasket. (g) Install the 6 spark plugs. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) EM EM–4 2GR-FE ENGINE MECHANICAL – ENGINE (h) Install the 6 ignition coils. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) (i) Install the intake air surge tank. (See page FU-17). 10. INSPECT CO/HC (a) Start the engine. (b) Run the engine at 2,500 rpm for approximately 180 seconds. (c) Insert the CO/HC meter testing probe at least 40 cm (1.3 ft) into the tailpipe during idling. (d) Check CO/HC concentration at idle and/or 2,500 rpm. HINT: Check regulations and restrictions in your area when performing 2 mode CO/HC concentration testing (engine check at both idle speed and at 2,500 rpm). If the CO/HC concentration does not comply with regulations, perform troubleshooting in the order given below. (1) Check A/F sensor and heated oxygen sensor operation. (2) See the table below for possible causes, and then inspect and repair. EM CO Normal Low High HC High High High Problems Causes Rough idle 1. Faulty ignitions: – Incorrect timing – Fouled, shorted or improperly gapped plugs 2. Incorrect valve clearance 3. Leaks in intake and exhaust valves 4. Leaks in cylinders Rough idle (fluctuating HC reading) 1. Vacuum leaks: – PCV hoses – Intake manifold – Throttle body – Brake booster line 2. Lean mixture causing misfire Rough idle (black smoke from exhaust) 1. Restricted air filter 2. Plugged PCV valve 3. Faulty SFI system: – Faulty fuel pressure regulator – Defective ECT sensor – Defective MAF meter – Faulty ECM – Faulty injectors – Faulty throttle position sensor 2GR-FE ENGINE MECHANICAL – DRIVE BELT EM–5 DRIVE BELT 2GR-FE ENGINE MECHANICAL ENGINE COMPONENTS V-BANK COVER SUB-ASSEMBLY EM FRONT FENDER APRON SEAL RH V-RIBBED BELT A134931E01 EM–6 2GR-FE ENGINE MECHANICAL – DRIVE BELT REMOVAL 1. REMOVE FRONT WHEEL RH 2. REMOVE FRONT FENDER APRON SEAL RH 3. REMOVE V-BANK COVER SUB-ASSEMBLY (See page EM-23) 4. REMOVE V-RIBBED BELT (a) Using SST, release the belt tension by turning the belt tensioner counterclockwise, and remove the Vribbed belt from the belt tensioner. SST 09249-63010 SST EM A129622E01 (b) While turning the belt tensioner counterclockwise, align with its holes, and then insert the 5 mm bihexagon wrench into the holes to fix the V-ribbed belt tensioner. A095070 2GR-FE ENGINE MECHANICAL – DRIVE BELT INSPECTION REPLACE CORRECT EM–7 INCORRECT 1. INSPECT V-RIBBED BELT (a) Visually check the V-ribbed belt for excessive wear, frayed cords, etc. If any defect has been found, replace the V-ribbed belt. HINT: Cracks on the rib side of a V-ribbed belt are considered acceptable. If the drive belt has chunks missing from its ribs, it should be replaced. HINT: • A "new belt" is a belt which has been used for less than 5 minutes with the engine running. • A "used belt" is a belt which has been used for 5 minutes or more with the engine running. 2. INSPECT V-RIBBED BELT TENSIONER ASSEMBLY (a) Check that nothing gets caught in the tensioner by turning it clockwise and counterclockwise. If a malfunction exitsts, replace the tensioner. A131418E01 INSTALLATION 1. INSTALL V-RIBBED BELT (a) Install the V-ribbed belt. (b) Using SST, turn the belt tensioner counterclockwise and remove the bar. SST 09249-63010 SST A129622E01 Generator Water Pump Idler Tensioner Idler A/C Compressor Vane Pump Crankshaft A129623E01 (c) If it is difficult to install the V-ribbed belt, perform the following procedure: (1) Put the V-ribbed belt on every pulley except the tensioner pulley as shown in the illustration. (2) While releasing the belt tension by turning the belt tensioner counterclockwise, put the Vribbed belt on the tensioner pulley. NOTICE: • Put the backside of the V-ribbed belt on the tensioner pulley and idler pulley. • Check that the V-ribbed belt is properly set to each pulley. (3) After installing the V-ribbed belt, check that it fits properly in the ribbed grooves. Confirm that the belt has not slipped out of the grooves on the bottom of the crank pulley by hand. EM EM–8 EM 2GR-FE ENGINE MECHANICAL – DRIVE BELT 2. INSTALL V-BANK COVER SUB-ASSEMBLY (See page EM-52) 3. INSTALL FRONT FENDER APRON SEAL RH 4. INSTALL FRONT WHEEL RH Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) EM–8 2GR-FE ENGINE MECHANICAL – ENGINE FRONT OIL SEAL ENGINE FRONT OIL SEAL 2GR-FE ENGINE MECHANICAL ENGINE COMPONENTS 250 (2,550, 184) TIMING CHAIN CASE OIL SEAL EM V-BANK COVER SUB-ASSEMBLY CRANKSHAFT PULLEY V-RIBBED BELT FRONT FENDER APRON SEAL RH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A134932E01 2GR-FE ENGINE MECHANICAL – ENGINE FRONT OIL SEAL EM–9 REMOVAL 1. REMOVE FRONT WHEEL RH 2. REMOVE FRONT FENDER APRON SEAL RH 3. REMOVE V-BANK COVER SUB-ASSEMBLY (See page EM-23) 4. REMOVE V-RIBBED BELT (See page EM-6) 5. REMOVE CRANKSHAFT PULLEY (a) Using SST, loosen the crankshaft pulley bolt. SST 09213-70011 (09213-70020), 09330-00021 SST SST EM A119083E01 (b) Using SST, remove the crankshaft pulley bolt and crankshaft pulley. SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021) SST SST A119085E01 6. Cut Position Protective Tape A132241E01 REMOVE TIMING CHAIN CASE OIL SEAL (a) Using a screwdriver, pry out the oil seal. HINT: Tape the screwdriver tip before use. NOTICE: After the removal, check the crankshaft for damage. If it is damaged, smooth the surface with 400-grit sandpaper. EM–10 2GR-FE ENGINE MECHANICAL – ENGINE FRONT OIL SEAL INSTALLATION Chain Cover 1. INSTALL TIMING CHAIN CASE OIL SEAL (a) Apply MP grease to a new oil seal lip. (b) Using SST and a hammer, tap in the oil seal until its surface is flush with the timing chain cover edge. SST 09316-60011 (09316-00011) NOTICE: • Keep the lip free of foreign matter. • Do not tap the oil seal at an angle. 2. INSTALL CRANKSHAFT PULLEY (a) Align the pulley set key with the key groove of the pulley, and slide on the pulley. SST A132242E01 (b) Using SST, install the pulley bolt. SST 09213-70011 (09213-70020), 09330-00021 Torque: 250 N*m (2,550 kgf*cm, 184 ft.*lbf) EM SST A119084E01 3. INSTALL V-RIBBED BELT (See page EM-7) 4. INSTALL V-BANK COVER SUB-ASSEMBLY (See page EM-52) 5. INSTALL FRONT FENDER APRON SEAL RH 6. INSTALL FRONT WHEEL RH Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) EM–11 2GR-FE ENGINE MECHANICAL – ENGINE REAR OIL SEAL ENGINE REAR OIL SEAL 2GR-FE ENGINE MECHANICAL ENGINE COMPONENTS EM ENGINE REAR OIL SEAL FRONT SPACER 83 (850, 61) x8 DRIVE PLATE AND RING GEAR SUB-ASSEMBLY REAR SPACER N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A134930E01 EM–12 2GR-FE ENGINE MECHANICAL – ENGINE REAR OIL SEAL REMOVAL 1. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY HINT: See page AX-207. 2. REMOVE DRIVE PLATE AND RING GEAR SUBASSEMBLY (a) Using SST, hold the crankshaft. SST 09213-70011 (09213-70020), 09330-00021 SST A129631E01 (b) Remove the 8 bolts, front spacer, drive plate and rear spacer. EM A132243 3. Cut Position REMOVE ENGINE REAR OIL SEAL (a) Using a knife, cut off the oil seal lip. (b) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. Tape the screwdriver tip before use. Protective Tape A132244E01 INSTALLATION 1. SST -0.5 to 0.5 mm Retainer SST A132245E01 INSTALL ENGINE REAR OIL SEAL (a) Apply MP grease to a new oil seal lip. (b) Using SST and a hammer, tap in the oil seal. SST 09223-15030, 09950-70010 (09951-07150) Oil seal tap in depth: -0.5 to 0.5 mm (-0.020 to 0.020 in.) 2GR-FE ENGINE MECHANICAL – ENGINE REAR OIL SEAL 2. EM–13 INSTALL DRIVE PLATE AND RING GEAR SUBASSEMBLY (a) Using SST, hold the crankshaft. SST 09213-70011 (09213-70020), 09330-00021 SST A129631E01 (b) Apply adhesive to 2 or 3 threads of the mounting bolt end. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent Adhesive EM P000601E04 (1) Install the front spacer, drive plate and rear spacer on the crankshaft. (2) Install and tighten the 8 mounting bolts uniformly in several steps. Torque: 83 N*m (850 kgf*cm, 61 ft.*lbf) 1 5 7 4 3 3. 8 6 2 A132243E01 INSTALL AUTOMATIC TRANSAXLE ASSEMBLY HINT: See page AX-214. EM–14 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY ENGINE ASSEMBLY 2GR-FE ENGINE MECHANICAL ENGINE COMPONENTS FRONT WIPER ARM AND BLADE ASSEMBLY RH 20 (204, 15) FRONT FENDER TO COWL SIDE SEAL RH FRONT WIPER ARM AND BLADE ASSEMBLY LH COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY EM 85 (867, 63) 7.5 (77, 66 in.*lbf) 5.0 (51, 44 in.*lbf) FRONT FENDER TO COWL SIDE SEAL LH WINDSHIELD WIPER LINK ASSEMBLY COWL TOP PANEL OUTER SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque A134938E01 EM–15 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY AIR CLEANER CAP SUB-ASSEMBLY V-BANK COVER SUB-ASSEMBLY AIR CLEANER FILTER ELEMENT COOL AIR INTAKE DUCT SEAL 5.0 (51, 44 in.*lbf) 5.0 (51, 44 in.*lbf) AIR CLEANER INLET ASSEMBLY EM RELAY BLOCK COVER UPPER AIR CLEANER CASE SUB-ASSEMBLY 5.0 (51, 44 in.*lbf) NO. 1 AIR CLEANER INLET 3.5 (36, 31 in.*lbf) 9.0 (92, 80 in.*lbf) ENGINE UNDER COVER RH 5.0 (51, 44 in.*lbf) BATTERY BATTERY TRAY INTAKE AIR RESONATOR SUB-ASSEMBLY ENGINE UNDER COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque A132994E01 EM–16 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY FRONT FENDER APRON SEAL RH 38 (388, 28) V-RIBBED BELT 23 (235, 17) ENGINE MOVING CONTROL ROD SUB-ASSEMBLY 9.8 (100, 87 in.*lbf) NO. 2 ENGINE MOUNTING STAY RH 43 (438, 32) NO. 1 FUEL VAPOR FEED HOSE GENERATOR ASSEMBLY 10 (102, 7) EM NO. 1 VACUUM SWITCHING VALVE ASSEMBLY NO. 1 OIL RESERVOIR TO PUMP HOSE FUEL TUBE SUB-ASSEMBLY 43 (438, 32) HEATER INLET WATER HOSE RADIATOR HOSE INLET RADIATOR HOSE OUTLET RETURN TUBE SUB-ASSEMBLY NO. 1 FUEL PIPE CLAMP NO. 1 OIL COOLER INLET HOSE 25 (250, 18) HEATER OUTLET WATER HOSE NO. 1 OIL COOLER OUTLET HOSE CLIP 13 (130, 9) 25 (250, 18) COOLER COMPRESSOR ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque TRANSMISSION CONTROL CABLE ASSEMBLY Non-reusable part A132995E01 EM–17 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY STEERING SLIDING YOKE FRONT STABILIZER LINK ASSEMBLY LH 35 (360, 26) EM TIE ROD ASSEMBLY LH 74 (755, 55) 49 (500, 36) COTTER PIN FRONT SPEED SENSOR LH 8.0 (85, 71 in.*lbf) 294 (3,000, 217) FRONT SUSPENSION LOWER NO. 1 ARM LH FRONT AXLE HUB NUT LH 75 (765, 55) 62 (632, 46) GASKET GASKET GASKET 56 (571, 41) 62 (632, 46) NO. 1 EXHAUST PIPE SUPPORT BRACKET 33 (337, 24) EXHAUST PIPE ASSEMBLY FRONT 21 (214, 15) EXHAUST PIPE NO. 1 SUPPORT BRACKET N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A132996E01 EM–18 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 87 (887, 64) ENGINE ASSEMBLY WITH TRANSAXLE ENGINE WIRE 95 (969, 70) 95 (969, 70) VANE PUMP ASSEMBLY EM NO. 2 FUEL PIPE CLAMP FUEL TUBE SUB-ASSEMBLY STARTER ASSEMBLY 43 (439, 32) 37 (380, 26) 37 (380, 26) FRONT FRAME ASSEMBLY 9.8 (100, 87 in.*lbf) 7.8 (80, 69 in.*lbf) FRONT SUSPENSION MEMBER BRACE REAR RH FRAME SIDE RAIL PLATE RH 32 (329, 24) 85 (867, 63) 32 (329, 24) 85 (867, 63) FRAME SIDE RAIL PLATE LH 32 (329, 24) 32 (329, 24) 32 (329, 24) N*m (kgf*cm, ft.*lbf) : Specified torque 85 (867, 63) 85 (867, 63) FRONT SUSPENSION MEMBER BRACE REAR LH 32 (329, 24) A134929E01 EM–19 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 54 (551, 40) ENGINE MOUNTING BRACKET RH DRIVE SHAFT BEARING BRACKET HOLE SNAP RING FRONT DRIVE SHAFT ASSEMBLY RH DRIVE SHAFT BEARING BRACKET 64 (650, 47) EM 32 (334, 30) FRONT DRIVE SHAFT INNER LH SHAFT SNAP RING NO. 1 DRIVE SHAFT BEARING BRACKET SETTING BOLT 46 (469, 34) 7.8 (80, 69 in.*lbf) FRONT DRIVE SHAFT ASSEMBLY LH FLYWHEEL HOUSING UNDER COVER 64 (653, 47) 43 (438, 32) 64 (653, 47) EXHAUST PIPE SUPPORT BRACKET 41 (413, 30) DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT AUTOMATIC TRANSAXLE ASSEMBLY ENGINE MOUNTING BRACKET FR N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A134940E01 EM–20 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY UNION TO CHECK VALVE HOSE * 21 (214, 15) 5.4 (55, 48 in.*lbf) VACUUM HOSE CLAMP * 21 (214, 15) THROTTLE BODY BRACKET VENTILATION HOSE * 21 (214, 15) EM NO. 1 SURGE TANK STAY 16 (163, 12) x4 NO. 3 WATER BY-PASS HOSE NO. 2 WATER BY-PASS HOSE * 18 (184, 13) INTAKE AIR SURGE TANK AIR SURGE TANK TO INTAKE MANIFOLD GASKET N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part * DO NOT apply oil A134939E01 EM–21 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 8.5 (87, 75 in.*lbf) EXHAUST MANIFOLD TO HEAD GASKET NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 21 (214, 15) EXHAUST MANIFOLD TO HEAD LH GASKET x6 10 (102, 7) 8.5 (87, 75 in.*lbf) IGNITION COIL ASSEMBLY 21 (214, 15) x6 EM 10 (102, 7) EXHAUST MANIFOLD SUB-ASSEMBLY RH IGNITION COIL ASSEMBLY 34 (347, 25) NO. 2 IDLER PULLEY SUBASSEMBLY (RR SIDE) NO. 2 MANIFOLD STAY EXHAUST MANIFOLD SUB-ASSEMBLY LH 43 (438, 32) PLATE V-RIBBED BELT TENSIONER ASSEMBLY 21 (214, 15) WATER PUMP PULLEY 43 (438, 32) 43 (438, 32) PLATE NO. 2 IDLER PULLEY SUB-ASSEMBLY (FR SIDE) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A134941E01 EM–22 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 21 (214, 15) NO. 2 ENGINE MOUNTING STAY RH INTAKE MANIFOLD x4 x6 NO. 2 INTAKE MANIFOLD TO HEAD GASKET 20 (200, 14) ENGINE COOLANT TEMPERATURE SENSOR NO. 1 INTAKE MANIFOLD TO HEAD GASKET RADIO SETTING CONDENSER RADIO SETTING CONDENSER 10 (102, 7) EM NO. 1 ENGINE HANGER GASKET 10 (102, 7) 20 (204, 15) NO. 2 ENGINE HANGER KNOCK CONTROL SENSOR 33 (337, 24) 33 (337, 24) 83 (846, 61) x8 DRIVE PLATE SPACER REAR DRIVE PLATE SPACER FRONT 6.0 (61, 53 in.*lbf) NO. 2 TIMING GEAR COVER DRIVE PLATE AND RING GEAR SUB-ASSEMBLY OIL LEVEL GAUGE 21 (214, 15) ENGINE OIL PRESSURE SWITCH ASSEMBLY 54 (551, 40) 21 (214, 15) O-RING x3 NO. 2 OIL LEVEL GAUGE GUIDE x2 NO. 1 ENGINE MOUNTING BRACKET FRONT LH N*m (kgf*cm, ft.*lbf) : Specified torque 21 (214, 15) NO. 1 OIL LEVEL GAUGE GUIDE Non-reusable part Precoated Part O-RING A134942E01 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–23 REMOVAL 1. DISCHARGE FUEL SYSTEM PRESSURE HINT: See page FU-1. 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 4. REMOVE FRONT WHEELS 5. REMOVE ENGINE UNDER COVER LH 6. REMOVE ENGINE UNDER COVER RH 7. REMOVE FRONT FENDER APRON SEAL RH 8. DRAIN ENGINE OIL (See page LU-4) 9. DRAIN ENGINE COOLANT (See page CO-5) 10. DRAIN AUTOMATIC TRANSAXLE FLUID (See page AX-207) 11. REMOVE WINDSHIELD WIPER LINK ASSEMBLY See page WW-9. 12. REMOVE COWL TOP PANEL OUTER SUBASSEMBLY (See page ES-481) 13. REMOVE COOL AIR INTAKE DUCT SEAL (a) Remove the 7 clips and intake duct seal. A132967 14. REMOVE V-BANK COVER SUB-ASSEMBLY (a) Hold the front of the V-bank cover and raise it to disengage the 2 clips on the front of the cover. Continue to raise the cover to disengage the clip on the rear of the cover and remove the cover. NOTICE: Attempting to disengage both front and rear clips at the same time may cause the cover to break. A132968 15. REMOVE V-RIBBED BELT (See page EM-6) EM EM–24 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 16. REMOVE AIR CLEANER INLET ASSEMBLY (a) Remove the 2 bolts, clamp and air cleaner inlet. 17. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-503) A132969 18. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (a) Disconnect the vacuum hose and hose clamp. (b) Remove the 3 bolts and air cleaner case. EM A132971 19. REMOVE NO. 1 AIR CLEANER INLET (a) Remove the bolt and No. 1 air cleaner inlet. A132970 20. REMOVE BATTERY (a) Loosen the bolt and nut, and remove the battery clamp. (b) Remove the battery and battery tray. A132972 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–25 21. REMOVE INTAKE AIR RESONATOR SUB-ASSEMBLY (a) Remove the clip, bolt and intake air resonator. A133928 22. REMOVE NO. 2 ENGINE MOUNTING STAY RH (a) Remove the bolt, 2 nuts, and No. 2 mounting stay RH. EM A132985 23. REMOVE ENGINE MOVING CONTROL ROD SUBASSEMBLY (a) Remove the 4 bolts and engine moving control rod. A132986 24. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE (a) Remove the clamp and disconnect the No. 1 fuel vapor feed hose. A132983 25. DISCONNECT CHECK VALVE TO BRAKE BOOSTER HOSE (a) Remove the clamp and disconnect the check valve to brake booster hose. A132982 EM–26 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 26. REMOVE RADIATOR HOSE INLET (a) Remove the clamp and disconnect the radiator hose inlet. A132979 27. REMOVE RADIATOR HOSE OUTLET (a) Remove the clamp and disconnect the radiator hose outlet. EM A132980 28. DISCONNECT NO. 1 OIL COOLER INLET HOSE (a) Remove the clamp and disconnect the oil cooler inlet hose. 29. DISCONNECT NO. 1 OIL COOLER OUTLET HOSE (a) Remove the clamp and disconnect the oil cooler outlet hose. A133003 30. DISCONNECT HEATER INLET WATER HOSE (a) Disconnect the heater inlet water hose. 31. DISCONNECT HEATER OUTLET WATER HOSE (a) Disconnect the heater outlet water hose. 32. REMOVE ECM HINT: See page ES-518. 33. REMOVE RELAY BLOCK COVER UPPER A132978 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–27 34. DISCONNECT ENGINE WIRE (a) Disconnect the engine wire from the engine room junction block. (1) Remove the nut and separate the wire harness. (2) Using a screwdriver, unlock the engine room J/ B. Pull the engine room J/B upward. (3) Disconnect the engine wire connectors. A132975 (b) Remove the 2 bolts and 2 clamps from the body. EM A132976 (c) Remove the bolt and clamp from the bracket. A132981 35. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (a) Remove the clip and nut, and separate the cable from the transaxle. A132973 EM–28 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 36. SEPARATE FUEL TUBE SUB-ASSEMBLY (a) Remove the No. 1 fuel pipe clamp. A129626 A EM A B012941E15 (b) Disconnect the connector from the tube while pinching part A with your fingers as shown in the illustration. NOTICE: • Check for contamination in the pipe and around the connector. Clean if necessary and then disconnect the connector. • Disconnect the connector by hand. • Do not bend, fold or rotate the nylon tube. • If the pipe and connector are stuck together, push and pull the connector until it becomes free. • Put the pipe and connector ends in vinyl bags to prevent damage and contamination. 37. DISCONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE (a) Disconnect the No. 1 oil reservoir to pump hose. A129629 38. DISCONNECT RETURN TUBE SUB-ASSEMBLY (a) Disconnect the return tube sub-assembly. 39. REMOVE EXHAUST PIPE NO. 1 SUPPORT BRACKET (See page EX-3) 40. REMOVE EXHAUST PIPE ASSEMBLY FRONT (See page EX-2) 41. REMOVE FRONT AXLE HUB NUT LH (See page DS7) A132984 42. REMOVE FRONT AXLE HUB NUT RH HINT: Use the same procedures described for the LH side. 43. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH (See page DS-7) 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–29 44. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH HINT: Use the same procedures described for the LH side. 45. DISCONNECT FRONT SPEED SENSOR LH (See page DS-7) 46. DISCONNECT FRONT SPEED SENSOR RH HINT: Use the same procedures described for the LH side. 47. DISCONNECT TIE ROD ASSEMBLY LH (See page DS-8) 48. DISCONNECT TIE ROD ASSEMBLY RH HINT: Use the same procedures described for the LH side. 49. DISCONNECT FRONT SUSPENSION LOWER NO. 1 ARM LH (See page DS-8) 50. DISCONNECT FRONT SUSPENSION LOWER NO. 1 ARM RH HINT: Use the same procedures described for the LH side. 51. SEPARATE FRONT AXLE ASSEMBLY LH (See page DS-8) 52. SEPARATE FRONT AXLE ASSEMBLY RH HINT: Use the same procedures described for the LH side. 53. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET (a) Remove the No. 1 exhaust pipe support bracket with the 2 bolts. 54. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (See page AX-211) 55. DISCONNECT STEERING SLIDING YOKE (See page PS-40) 56. REMOVE GENERATOR ASSEMBLY (See page CH-14) 57. SEPARATE COOLER COMPRESSOR ASSEMBLY (a) Remove the 2 connector clamps. (b) Remove the 4 bolts and separate the compressor. HINT: Hang up the hoses instead of detaching them. 58. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (a) Set the engine lifter. A132977 EM EM–30 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY (b) Remove the 4 bolts, 2 nuts, and frame side rail plates RH and LH. (c) Remove the 4 bolts, 2 nuts, and front suspension member brace rear RH and LH. (d) Operate the engine lifter, then remove the engine assembly from the vehicle. NOTICE: Make sure that the engine is clear of all wiring and hoses. 59. REMOVE VANE PUMP ASSEMBLY (a) Disconnect the power steering oil pressure switch connector. A129634 (b) Remove the pressure feed tube clamp bolt. (c) Loosen the bolt A. (d) Remove the bolt B and vane pump. EM A B A138331E01 LH side : RH side : No. 1 No. 2 A129635E03 60. INSTALL ENGINE HANGERS (a) Install the 2 engine hangers with the 4 bolts as shown in the illustration. Part No.: No. 1 Engine hanger 12281-31070 No. 2 Engine hanger 12282-31050 Bolts 91671-10825 Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf) (b) Attach the engine sling device and hang the engine with the chain block. 61. REMOVE FRONT FRAME ASSEMBLY (a) Disconnect the connector and clamp. A132990 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–31 (b) Disconnect the 2 clamps. A132989 RH Side: (c) Remove the 2 nuts and disconnect the engine mounting insulators RH and LH. LH Side: EM A078403E05 (d) Remove the bolt and disconnect the engine mounting insulator FR. 62. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (See page DS-9) 63. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (See page DS-9) 64. REMOVE ENGINE WIRE A132988 65. REMOVE STARTER ASSEMBLY (See page ST-141) 66. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY HINT: See page AX-207. 67. REMOVE DRIVE PLATE AND RING GEAR SUBASSEMBLY (See page EM-12) 68. SECURE ENGINE (a) Secure the engine onto an engine stand with the bolts. (b) (c) (a) (a) (c) A129464E01 69. REMOVE INTAKE AIR SURGE TANK ASSEMBLY (a) Disconnect the 2 water by-pass hoses from the throttle with motor body assembly. (b) Disconnect the vapor feed hose. (c) Disconnect the throttle with motor body assembly connector and clamp. (d) Disconnect the No. 1 ventilation hose. EM–32 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY (e) Remove the bolt and vacuum hose clamp. A129466 (f) Disconnect the connector. (g) Remove the 4 bolts, No. 1 surge tank stay and throttle body bracket. EM A129467 (h) Using a 5 mm socket hexagon wrench, remove the 4 bolts. (i) Remove the 2 nuts and intake air surge tank. (j) Remove the gasket from the intake air surge tank. (i) 70. REMOVE IGNITION COIL ASSEMBLY (a) Remove the 6 bolts and 6 ignition coils. (h) (h) (h) (h) (i) A139209E01 71. REMOVE NO. 2 ENGINE MOUNTING STAY RH (a) Remove the bolt and No. 2 engine mounting stay RH. 72. REMOVE INTAKE MANIFOLD (a) Uniformly loosen and remove the 6 bolts and 4 nuts. (b) Remove the intake manifold and 2 gaskets. 73. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH (a) Disconnect the A/F sensor connector clamp. A134933 (b) Uniformly loosen and remove the 6 nuts. (c) Remove the manifold and gasket. A129637 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–33 74. REMOVE OIL LEVEL GAUGE GUIDE SUBASSEMBLY (a) Remove the oil level gauge. (b) Remove the 2 bolts, oil level gauge guides No. 1 and No. 2. (c) Remove the O-rings from the oil level gauge guide. A129638 75. REMOVE NO. 2 MANIFOLD STAY (a) Remove the 2 bolts and No. 2 manifold stay. EM A129639 76. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR (a) Remove the 3 bolts and No. 2 insulator. A129640 77. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH (a) Uniformly loosen and remove the 6 nuts. (b) Remove the manifold and gasket. A129641 78. REMOVE ENGINE MOUNTING BRACKET RH (a) Remove the 3 bolts and engine mounting bracket RH. A129642 EM–34 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 79. REMOVE DRIVE SHAFT BEARING BRACKET (a) Remove the 3 bolts and drive shaft bearing bracket. A129643 80. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (a) Remove the 5 bolts and V-ribbed belt tensioner assembly. EM A129644 81. REMOVE NO. 2 TIMING GEAR COVER (a) Remove the 2 bolts and No. 2 timing gear cover. A132987 82. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY (a) Remove the bolt, plate and No. 2 idler pulley subassembly. FR Side: 83. REMOVE WATER PUMP PULLEY (See page CO-8) RR Side: A129645E01 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–35 84. REMOVE NO. 1 ENGINE MOUNTING BRACKET FRONT LH (a) Remove the 6 bolts and No. 1 engine mounting bracket front LH. A129646 85. REMOVE RADIO SETTING CONDENSER (a) Remove the 2 bolts and 2 radio setting condensers. EM A132991 86. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY (a) Remove the bolt and No. 1 vacuum switching valve. A132992 87. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY (a) Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly. 88. REMOVE KNOCK CONTROL SENSOR (See page ES511) A129647 EM–36 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 89. REMOVE ENGINE COOLANT TEMPERATURE SENSOR (a) Using a 19 mm deep socket wrench, remove the EFI engine coolant temperature sensor and gasket. A129648 INSPECTION 1. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY LH (a) Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head. Maximum warpage: 0.7 mm (0.028 in.) HINT: The maximum allowable warpage of each installation surface is 0.3 mm (0.012 in.). If the warpage is greater than the maximum, replace the manifold. 2. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH (a) Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head. Maximum warpage: 0.7 mm (0.028 in.) HINT: The maximum allowable warpage of each installation surface is 0.3 mm (0.012 in.). If the warpage is greater than the maximum, replace the manifold. 3. INSPECT INTAKE AIR SURGE TANK ASSEMBLY (a) Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the intake manifold. Maximum warpage: 2.5 mm (0.098 in.) If the warpage is greater than the maximum, replace the surge tank. EM A134936 A134937 A134935 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 4. Cylinder head side: Surge tank side: EM–37 INSPECT INTAKE MANIFOLD (a) Cylinder head side: (1) Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.1 mm (0.003 in.) If the warpage is greater than the maximum, replace the intake manifold. (b) Surge tank side: (1) Using a precision straightedge and feeler gauge, measure the surface contacting the surge tank for warpage. Maximum warpage: 0.1 mm (0.003 in.) If the warpage is greater than the maximum, replace the intake manifold. EM A134934E01 INSTALLATION 1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR (a) Using a 19 mm deep socket wrench, install the engine coolant temperature sensor and a new gasket. Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf) 2. INSTALL KNOCK CONTROL SENSOR (See page ES511) 3. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY (a) Clean the threads of the oil pressure switch. Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive: Part No. 08833-00080 THREE BOND 1344, LOCTITE 242 or equivalent A129648 Adhesive P012478E01 (b) Using a 24 mm deep socket wrench, install the oil pressure switch. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) NOTICE: Do not start the engine within 1 hour after installation to prevent oil leaks. A129647 EM–38 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 4. INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY (a) Install the bolt and No. 1 vacuum switching valve. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 5. INSTALL RADIO SETTING CONDENSER (a) Install the 2 bolts and 2 radio setting condensers. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 6. INSTALL NO. 1 ENGINE MOUNTING BRACKET FRONT LH (a) Install the No. 1 engine mounting bracket front LH with the 6 bolts. Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) 7. INSTALL WATER PUMP PULLEY (See page CO-10) A132992 EM A132991 A129646 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 8. FR Side: EM–39 INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY (a) Install the No. 2 idler pulley sub-assembly and cover plate with the bolt. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) RR Side: EM A129645E01 9. INSTALL NO. 2 TIMING GEAR COVER (a) Install the No. 2 timing gear cover with the 2 bolts. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) A132987 A B B B 1 B 2 A129644E01 10. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (a) Temporarily install the V-ribbed belt tensioner with the 5 bolts. HINT: Each bolt length is as follows: A: 70 mm (2.76 in.) B: 33 mm (1.30 in.) (b) Install the V-ribbed belt tensioner by tightening the bolt 1 and bolt 2 in the order shown in the illustration. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) (c) Tighten the other bolts. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) EM–40 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 11. INSTALL DRIVE SHAFT BEARING BRACKET (a) Install the drive shaft bearing bracket with the 3 bolts. Torque: 64 N*m (650 kgf*cm, 47 ft.*lbf) A129643 12. INSTALL ENGINE MOUNTING BRACKET RH (a) Install the engine mounting bracket RH with the 3 bolts. Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) EM A129642 13. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH (a) Install a new gasket as shown in the illustration. Front A129649E01 (b) Install the exhaust manifold sub-assembly LH with the 6 nuts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) A129641 14. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR (a) Install the No. 2 insulator with the 3 bolts. Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) A129640 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–41 15. INSTALL NO. 2 MANIFOLD STAY (a) Install the No. 2 manifold stay with the 2 bolts. Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf) A129639 No. 2 No. 1 A129638E01 16. INSTALL OIL LEVEL GAUGE GUIDE SUBASSEMBLY (a) Install 2 new O-rings to the oil level gauge guide. (b) Apply a light coat of engine oil to the O-rings. (c) Push in the oil level gauge guide end into the guide hole. (d) Install the oil level gauge guide No. 1 with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) (e) Install the oil level gauge guide No. 2 with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) (f) Install the oil level gauge. 17. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH (a) Install a new gasket as shown in the illustration. Front A129650E01 (b) Install the exhaust manifold sub-assembly RH with the 6 nuts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) A129637 18. INSTALL INTAKE MANIFOLD (a) Set a new gasket on each cylinder head. NOTICE: • Align the port holes of the gasket and cylinder head. • Make sure that the gasket is installed in the correct direction. (b) Set the intake manifold on the cylinder heads. A134933 EM EM–42 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY (c) Install and tighten the 6 bolts and 4 nuts uniformly in several steps. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 19. INSTALL NO. 2 ENGINE MOUNTING STAY RH (a) Install the No. 2 mounting stay RH with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 20. INSTALL IGNITION COIL ASSEMBLY (a) Install the 6 ignition coil assemblies with the 6 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 21. INSTALL INTAKE AIR SURGE TANK ASSEMBLY NOTICE: DO NOT apply oil to the bolts as listed below Tightening Parts EM Torque N*m (kgf*cm, ft.*lbf) QTY Surge Tank and Intake Manifold 18 (184, 13) 4 No. 1 Surge Tank Stay and Cylinder Head Cover 21 (214, 15) 1 No. 1 Surge Tank Stay and Surge Tank 21 (214, 15) 1 Throttle Body Bracket and Cylinder Head Cover 21 (214, 15) 1 Throttle Body Bracket and Surge Tank 21 (214, 15) 1 (a) Install a new gasket to the intake air surge tank. (b) Using a 5 mm hexagon socket wrench, install the 4 bolts and 2 nuts. Torque: Bolt 18 N*m (184 kgf*cm, 13 ft.*lbf) Nut 16 N*m (163 kgf*cm, 12 ft.*lbf) (c) Install the throttle body bracket, No. 1 surge tank stay and 4 bolts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) A139209 (d) Connect the connector. A129467 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–43 (e) Install the vacuum hose clamp with the bolt. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) (f) Connect the No. 1 ventilation hose. A129466 (g) Install the clamp and connect the throttle with motor body assembly connector. (h) Connect the vapor feed hose. (i) Connect the 2 water by-pass hoses to the throttle with motor body assembly. (h) (g) (i) 22. REMOVE ENGINE STAND (i) (g) 23. INSTALL DRIVE PLATE AND RING GEAR SUBASSEMBLY (See page EM-13) A129464E04 24. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY HINT: See page AX-214. 25. INSTALL STARTER ASSEMBLY (See page ST-148) 26. INSTALL ENGINE WIRE 27. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (See page DS-20) 28. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (See page DS-21) RH Side: 29. INSTALL FRONT FRAME ASSEMBLY (a) Install the engine mounting insulators RH and LH with the 2 nuts. Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) LH Side: A078403E06 (b) Install the engine mounting insulator FR with the bolt. Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) A132988 EM EM–44 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY (c) Connect the connector and clamp. A132990 (d) Connect the 2 clamps. EM A132989 30. INSTALL VANE PUMP ASSEMBLY (a) Install the vane pump with the 2 bolts. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) (b) Install the pressure feed tube clamp bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) (c) Connect the power steering oil pressure switch connector. A138331 B B B B A A D C D D C D A129634E01 31. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (a) Set the engine assembly with transaxle on the engine lifter. (b) Install the engine assembly to the vehicle. (c) Install the frame side rail plates RH and LH with the 4 bolts and 2 nuts. Torque: A 85 N*m (867 kgf*cm, 63 ft.*lbf) B 32 N*m (329 kgf*cm, 24 ft.*lbf) (d) Install the front suspension member brace rear RH and LH with the 4 bolts and 2 nuts. Torque: C 85 N*m (867 kgf*cm, 63 ft.*lbf) D 32 N*m (329 kgf*cm, 24 ft.*lbf) 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–45 32. INSTALL COOLER COMPRESSOR ASSEMBLY (a) Temporarily install the cooler compressor with the 4 bolts. (b) Install the compressor with the 4 bolts by tightening the bolts in the order shown in the illustration. Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) (c) Install the 2 connector clamps. 3 2 4 33. INSTALL GENERATOR ASSEMBLY (See page CH-22) 1 A132977E01 34. INSTALL STEERING SLIDING YOKE (See page PS65) 35. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (See page AX-218) 36. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET (a) Install the No. 1 exhaust pipe support bracket with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 37. INSTALL FRONT AXLE ASSEMBLY LH (See page DS21) 38. INSTALL FRONT AXLE ASSEMBLY RH HINT: Use the same procedures described for the LH side. 39. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM LH (See page DS-21) 40. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM RH HINT: Use the same procedures described for the LH side. 41. INSTALL TIE ROD ASSEMBLY LH (See page DS-21) 42. INSTALL TIE ROD ASSEMBLY RH HINT: Use the same procedures described for the LH side. 43. INSTALL FRONT SPEED SENSOR LH (See page DS21) 44. INSTALL FRONT SPEED SENSOR RH HINT: Use the same procedures described for the LH side. 45. INSTALL FRONT STABILIZER LINK ASSEMBLY LH (See page DS-22) 46. INSTALL FRONT STABILIZER LINK ASSEMBLY RH HINT: Use the same procedures described for the LH side. 47. INSTALL FRONT AXLE HUB NUT LH (See page DS22) 48. INSTALL FRONT AXLE HUB NUT RH HINT: Use the same procedures described for the LH side. EM EM–46 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 49. INSTALL EXHAUST PIPE ASSEMBLY FRONT (See page EX-4) 50. INSTALL EXHAUST PIPE NO. 1 SUPPORT BRACKET (See page EX-4) 51. CONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE (a) Connect the No. 1 oil reservoir to pump hose. A129629 52. CONNECT RETURN TUBE SUB-ASSEMBLY (a) Connect the return tube sub-assembly. EM A132984 B012944 53. CONNECT FUEL TUBE SUB-ASSEMBLY (a) Push in the fuel tube connector to the fuel pipe until the connector makes a "click" sound. NOTICE: • Check for damage or contamination on the connected part of the pipe. • Check if the pipe and the connector are securely connected by trying to pull them apart. (b) Install the No. 1 fuel pipe clamp. 54. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (a) Install the clip and nut, and connect the cable to the transaxle. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) A132973 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–47 55. CONNECT ENGINE WIRE (a) Install the bolt and clamp to the bracket. Torque: 8.4 N*m (85 kgf*cm, 74 in.*lbf) A132981 (b) Install the 2 bolts and 2 clamps to the body. Torque: Bolt A 12 N*m (123 kgf*cm, 9 ft.*lbf) Bolt B 8.4 N*m (85 kgf*cm, 74 in.*lbf) B A EM A132976E01 (c) Connect the wire to the engine room junction block. Then, install it with the nut and 3 connectors. Torque: 8.4 N*m (85 kgf*cm, 74 in.*lbf) 56. INSTALL RELAY BLOCK COVER UPPER 57. INSTALL ECM (See page ES-519) A132975 58. CONNECT HEATER INLET WATER HOSE (a) Connect the heater inlet water hose. 59. CONNECT HEATER OUTLET WATER HOSE (a) Connect the heater outlet water hose. A132978 EM–48 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 60. CONNECT NO. 1 OIL COOLER INLET HOSE (a) Install the clamp and connect the oil cooler inlet hose. 61. CONNECT NO. 1 OIL COOLER OUTLET HOSE (a) Install the clamp and connect the oil cooler outlet hose. A133003 62. INSTALL RADIATOR HOSE INLET (a) Install the clamp and connect the radiator hose inlet. EM A132979 63. INSTALL RADIATOR HOSE OUTLET (a) Install the clamp and connect the radiator hose outlet. A132980 64. CONNECT CHECK VALVE TO BRAKE BOOSTER HOSE (a) Install the clamp and connect the check valve to brake booster hose. A132982 65. CONNECT NO. 1 FUEL VAPOR FEED HOSE (a) Install the clamp and connect the No. 1 fuel vapor feed hose. A132983 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY B A A A EM–49 66. INSTALL ENGINE MOVING CONTROL ROD SUBASSEMBLY (a) Temporarily install the engine moving control rod with the 4 bolts. (b) First install the bolts A, and then the remaining bolt B. Torque: 38 N*m (388 kgf*cm, 28 ft.*lbf) A132986E01 67. INSTALL NO. 2 ENGINE MOUNTING STAY RH (a) Temporarily install the No. 2 engine mounting stay RH with the bolt. Torque: 38 N*m (388 kgf*cm, 28 ft.*lbf) (b) Tighten the 2 nuts. Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf) EM A132985 68. INSTALL INTAKE AIR RESONATOR SUB-ASSEMBLY (a) Install the intake air resonator with the bolt and clip. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) A133928 69. INSTALL BATTERY (a) Install the battery and battery tray. (b) Install the battery clamp with the bolt and nut. Torque: Bolt 9.0 N*m (92 kgf*cm, 80 in.*lbf) Nut 3.5 N*m (36 kgf*cm, 31 in.*lbf) A132972 70. INSTALL NO. 1 AIR CLEANER INLET (a) Install the No. 1 air cleaner inlet with the bolt. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) A132970 EM–50 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 71. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (a) Install the air cleaner case with the 3 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) (b) Connect the vacuum hose and hose clamp. 72. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See page ES-506) A132971 73. INSTALL AIR CLEANER INLET ASSEMBLY (a) Install the air cleaner inlet with the clamp and 2 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) EM A132969 EM–51 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 74. CONNECT VACUUM HOSES Vacuum Hose Routing Diagram : Throttle Body Intake Air Surge Tank Vacuum Tank From Canister VSV VSV EM Actuator Air Cleaner Engine Mounting Insulator FR VSV for Active Control Engine Mount (ACM) A132993E01 75. INSTALL V-RIBBED BELT (See page EM-7) 76. INSTALL COWL TOP PANEL OUTER SUBASSEMBLY (See page ES-485) 77. INSTALL WINDSHIELD WIPER LINK ASSEMBLY HINT: See page WW-13. 78. INSTALL FRONT WHEELS Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 79. ADD ENGINE OIL 80. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf) 81. ADD ENGINE COOLANT (See page CO-6) 82. ADD AUTOMATIC TRANSAXLE FLUID (See page AX220) 83. ADD POWER STEERING FLUID EM–52 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 84. BLEED POWER STEERING FLUID (See page PS-7) 85. CHECK FOR FUEL LEAKS (See page FU-8) 86. CHECK FOR ENGINE OIL LEAKS 87. CHECK FOR ENGINE COOLANT LEAKS (See page CO-1) 88. CHECK FOR EXHAUST GAS LEAKS 89. CHECK SHIFT LEVER POSITION (See page AX-191) 90. CHECK AND ADJUST FRONT WHEEL ALIGNMENT HINT: See page SP-4. 91. CHECK IGNITION TIMING (See page EM-1) 92. CHECK ENGINE IDLE SPEED (See page EM-2) 93. CHECK CO/HC (See page EM-4) 94. CHECK FUNCTION OF THROTTLE BODY (See page ES-503) EM 95. INSTALL FRONT FENDER APRON SEAL RH 96. INSTALL ENGINE UNDER COVER LH 97. INSTALL ENGINE UNDER COVER RH 98. INSTALL V-BANK COVER SUB-ASSEMBLY (a) Fit the 3 retainers and install the V-bank cover. A132968 99. INSTALL COOL AIR INTAKE DUCT SEAL (a) Install the intake duct seal with the 7 clips. 100. CHECK ABS SPEED SENSOR SIGNAL (a) ABS: (See page BC-11). (b) VSC (for BOSCH): (See page BC-290). (c) VSC (for ADVICS): (See page BC-123). A132967 EM–53 2GR-FE ENGINE MECHANICAL – ENGINE UNIT ENGINE UNIT 2GR-FE ENGINE MECHANICAL ENGINE COMPONENTS RH SIDE: CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 18 (184, 13) SPARK PLUG 10 (102, 7) 10 (102, 7) x3 O-RING SEAL WASHER 10 (102, 7) 10 (102, 7) 21 (214, 15) EM O-RING CYLINDER HEAD COVER SUB-ASSEMBLY 10 (102, 7) x9 10 (102, 7) CAMSHAFT POSITION SENSOR CAMSHAFT POSITION SENSOR CYLINDER HEAD COVER GASKET GASKET 65 (663, 48) OIL PIPE GASKET 10 (102, 7) 65 (663, 48) OIL CONTROL VALVE FILTER RH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A132493E01 EM–54 2GR-FE ENGINE MECHANICAL – ENGINE UNIT LH SIDE: CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 18 (184, 13) SPARK PLUG O-RING 10 (102, 7) OIL FILLER CAP SUB-ASSEMBLY 10 (102, 7) CAMSHAFT POSITION SENSOR x3 10 (102, 7) OIL FILLER CAP GASKET SEAL WASHER 10 (102, 7) 10 (102, 7) 27 (275, 20) x8 VENTILATION VALVE SUB-ASSEMBLY O-RING EM 21 (214, 15) CYLINDER HEAD COVER SUB-ASSEMBLY 10 (102, 7) CAMSHAFT POSITION SENSOR CYLINDER HEAD COVER GASKET OIL CONTROL VALVE FILTER LH NO. 1 OIL PIPE GASKET GASKET N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part 65 (663, 48) Precoated part A132494E01 EM–55 2GR-FE ENGINE MECHANICAL – ENGINE UNIT O-RING 10 (102, 7) FRONT ENGINE MOUNTING BRACKET NO. 1 LH 10 (103, 7) x4 10 (102, 7) x3 x2 GASKET x2 WATER OUTLET 13 (130, 9) CYLINDER BLOCK WATER DRAIN COCK PLUG 54 (551, 40) 25 (255, 18) CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY 13 (130, 9) 13 (130, 9) CYLINDER BLOCK WATER DRAIN COCK PLUG DRAIN COCK PLUG 30 (306, 22) DRAIN COCK ASSEMBLY 10 (102, 7) O-RING WATER INLET HOUSING 10 (102, 7) CRANKSHAFT POSITION SENSOR x2 25 (255, 18) CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY ENGINE REAR OIL SEAL 10 (102, 7) 4.0 (41, 35 in.*lbf) GASKET THERMOSTAT WATER INLET 10 (102, 7) N*m (kgf*cm, ft.*lbf) : Specified torque x4 ENGINE REAR OIL SEAL RETAINER x2 10 (102, 7) x2 Non-reusable part Precoated part A132495E01 EM EM–56 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 10 (102, 7) 10 (102, 7) 4.0 (41, 35 in.*lbf) GASKET x7 OIL PAN BAFFLE PLATE OIL STRAINER SUB-ASSEMBLY 10 (102, 7) EM 10 (102, 7) 10 (102, 7) 21 (214, 15) O-RING OIL PAN SUB-ASSEMBLY 4.0 (41, 35 in.*lbf) x2 21 (214, 15) 10 (102, 7) 4.0 (41, 35 in.*lbf) x14 21 (214, 15) OIL FILTER ELEMENT OIL PAN DRAIN PLUG GASKET 25 (255, 18) O-RING OIL FILTER CAP SUB-ASSEMBLY 40 (408, 30) 21 (214, 15) OIL PAN DRAIN PLUG DRAIN PLUG NO. 2 OIL PAN SUB-ASSEMBLY x16 10 (102, 7) 10 (102, 7) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A132496E01 EM–57 2GR-FE ENGINE MECHANICAL – ENGINE UNIT CHAIN COVER PLATE x10 9.1 (93, 81 in.*lbf) 21 (214, 15) x4 CHAIN COVER PLATE GASKET EM 43 (438, 32) TIMING CHAIN COVER SUB-ASSEMBLY x4 TIMING CHAIN CASE OIL SEAL 250 (2,550, 184) 21 (214, 15) CRANKSHAFT PULLEY 9.1 (93, 81 in.*lbf) x6 WATER PUMP GASKET 9.1 (93, 81 in.*lbf) WATER PUMP ASSEMBLY x8 21 (214, 15) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Precoated part A132497E01 EM–58 2GR-FE ENGINE MECHANICAL – ENGINE UNIT NO. 1 CHAIN TENSIONER ASSEMBLY NO. 2 CHAIN VIBRATION DAMPER 10 (102, 7) CHAIN TENSIONER SLIPPER EM 60 (612, 44) NO. 2 IDLE GEAR SHAFT NO. 1 IDLE GEAR SHAFT IDLE SPROCKET ASSEMBLY GASKET CRANKSHAFT TIMING SPROCKET KEY CHAIN SUB-ASSEMBLY NO. 1 CHAIN VIBRATION DAMPER 23 (230, 17) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A132498E01 EM–59 2GR-FE ENGINE MECHANICAL – ENGINE UNIT RH SIDE: 1st: 10 (102, 7) 2nd: 16 (163, 12) CAMSHAFT GASKET x8 NO. 2 CHAIN SUB-ASSEMBLY GASKET 28 (286, 21) CAMSHAFT TIMING GEAR ASSEMBLY x8 CAMSHAFT BEARING CAP EM 100 (1,020, 74) NO. 2 CAMSHAFT 21 (214, 15) CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY RH 28 (286, 21) 28 (286, 21) CAMSHAFT HOUSING SUB-ASSEMBLY RH NO. 2 CHAIN TENSIONER ASSEMBLY NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY x12 x12 VALVE LASH ADJUSTER ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A132499E01 EM–60 2GR-FE ENGINE MECHANICAL – ENGINE UNIT LH SIDE: NO. 3 CAMSHAFT 1st: 10 (102, 7) 2nd: 16 (163, 12) NO. 2 CHAIN SUB-ASSEMBLY x8 GASKET GASKET 28 (286, 21) x8 CAMSHAFT TIMING GEAR ASSEMBLY 100 (1,020, 74) EM CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY LH CAMSHAFT BEARING CAP 21 (214, 15) NO. 3 CHAIN TENSIONER ASSEMBLY 28 (286, 21) NO. 4 CAMSHAFT 28 (286, 21) CAMSHAFT HOUSING SUB-ASSEMBLY LH NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY x12 x12 VALVE LASH ADJUSTER ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A132500E01 EM–61 2GR-FE ENGINE MECHANICAL – ENGINE UNIT CYLINDER HEAD SUB-ASSEMBLY RH 1st: 36 (367, 27) 2nd: Turn 90° 3rd: Turn 90° 1st: 36 (367, 27) PLATE WASHER 2nd: Turn 90° 3rd: Turn 90° 30 (306, 22) x8 x8 x8 x2 PLATE WASHER x8 EM CYLINDER HEAD SUB-ASSEMBLY LH CLAMP CYLINDER HEAD GASKET 10 (102, 7) NO. 1 WATER BY-PASS HOSE NO. 2 CYLINDER HEAD GASKET CLAMP WATER INLET PIPE N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A132501E01 EM–62 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 44 (449, 32) NO. 1 STRAIGHT SCREW PLUG VALVE STEM CAP VALVE SPRING RETAINER LOCK VALVE STEM CAP VALVE SPRING RETAINER VALVE SPRING RETAINER LOCK INNER COMPRESSION SPRING VALVE STEM OIL SEAL VALVE SPRING RETAINER VALVE SPRING SEAT INTAKE VALVE GUIDE BUSH GASKET EM INNER COMPRESSION SPRING STRAIGHT PIN VALVE STEM OIL SEAL RING PIN VALVE SPRING SEAT 10 (102, 7) STUD BOLT EXHAUST VALVE GUIDE BUSH x2 4.0 (41, 35 in.*lbf) STUD BOLT GASKET 80 (816, 59) NO. 2 STRAIGHT SCREW PLUG 10 (102, 7) STUD BOLT EXHAUST VALVE N*m (kgf*cm, ft.*lbf) : Specified torque INTAKE VALVE Non-reusable part A132502E01 EM–63 2GR-FE ENGINE MECHANICAL – ENGINE UNIT PISTON RING SET PISTON PIN HOLE SNAP RING PISTON PISTON PIN PISTON PIN HOLE SNAP RING CONNECTING ROD SUB-ASSEMBLY CONNECTING ROD BEARING CONNECTING ROD CAP STRAIGHT PIN 1st: 25 (255, 18) EM 2nd: Turn 90° x2 CYLINDER BLOCK SUB-ASSEMBLY x4 STRAIGHT PIN x4 SEAL WASHER 17 (173, 13) STUD BOLT x4 52 (525, 38) x4 10 (102, 7) STUD BOLT NO. 1 OIL NOZZLE SUB-ASSEMBLY x2 STRAIGHT PIN 9.0 (92, 80 in.*lbf) UPPER CRANKSHAFT THRUST WASHER STRAIGHT PIN x4 x4 UPPER CRANKSHAFT BEARING 52 (525, 38) SEAL WASHER CRANKSHAFT LOWER CRANKSHAFT BEARING CRANKSHAFT BEARING CAP x4 1st: 61 (622, 45) 2nd: Turn 90° N*m (kgf*cm, ft.*lbf) : Specified torque x8 x8 Non-reusable part A132503E01 EM–64 2GR-FE ENGINE MECHANICAL – ENGINE UNIT DISASSEMBLY 1. REMOVE OIL FILLER CAP SUB-ASSEMBLY (a) Remove the oil filler cap and gasket. 2. REMOVE SPARK PLUG (a) Remove the spark plugs. 3. REMOVE OIL PAN DRAIN PLUG (a) Remove the drain plug and gasket. 4. REMOVE VENTILATION VALVE SUB-ASSEMBLY (a) Remove the ventilation valve. 5. REMOVE CAMSHAFT POSITION SENSOR (a) Remove the 4 bolts and 4 sensors. A129654 EM A129655 LH Bank: RH Bank: A129656E01 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 6. LH Bank: EM–65 REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Remove the 4 bolts and 4 oil control valves. RH Bank: EM A129662E01 7. REMOVE CRANKSHAFT POSITION SENSOR (a) Remove the bolt and sensor. 8. REMOVE NO. 1 OIL PIPE (a) Remove the 2 oil pipe unions and oil pipe. (b) Remove the oil control valve filter LH and gaskets. 9. REMOVE OIL PIPE (a) Remove the bolt. (b) Remove the 2 oil pipe unions and oil pipe. (c) Remove the oil control valve filter RH and gaskets. A129663 Oil Pipe Union Oil Pipe Union A135726E01 Oil Pipe Union Oil Pipe Union A134878E01 EM–66 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 10. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY (a) Remove the water drain cocks from the cylinder block. (b) Remove the water drain cock plugs from the water drain cocks. RH Side: LH Side: A135829E01 11. REMOVE OIL FILTER ELEMENT (a) Remove the drain plug. NOTICE: Do not remove the O-ring from the oil filter cap. EM A129666 (b) Connect the hose to the pipe. (c) Insert the pipe with the hose into the oil filter cap. (d) Make sure that the oil is completely drained and remove the pipe and O-ring. Pipe Hose O-Ring Pipe Hose A129667E01 2GR-FE ENGINE MECHANICAL – ENGINE UNIT EM–67 (e) Using SST, remove the oil filter cap. SST 09228-06501 SST A129668E01 (f) Oil Filter Element Remove the oil filter element and O-ring from the oil filter cap. NOTICE: Do not use any tools when removing the O-ring to prevent the O-ring groove from being damaged. EM O-Ring A106167E01 12. REMOVE CRANKSHAFT PULLEY (a) Using SST, loosen the crankshaft pulley bolt. SST 09213-70011 (09213-70020), 09330-00021 SST Hold Turn A120690E02 (b) Using SST, remove the crankshaft pulley bolt and crankshaft pulley. SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021) SST Hold Turn A120691E02 EM–68 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 13. REMOVE FRONT ENGINE MOUNTING BRACKET NO. 1 LH (a) Remove the 6 bolts and engine mounting bracket. (b) Using "Torx" socket wrench E8, remove the 2 stud bolts. A129672 14. REMOVE WATER INLET HOUSING (a) Remove the 2 nuts, water inlet and thermostat. (b) Remove the gasket. (c) Remove the housing plug. (d) Remove the housing drain cock. (e) Remove the 2 stud bolts. (f) Separate the water by-pass hose No. 1. EM A129673 (g) Remove the 2 bolts, nut, and water inlet housing. Nut A134879E01 (h) Remove the 2 O-rings. A129675 15. REMOVE WATER OUTLET (a) Remove the 2 bolts, 4 nuts and water outlet. Nut Nut Nut Nut A129676E01 2GR-FE ENGINE MECHANICAL – ENGINE UNIT EM–69 (b) Remove the 2 gaskets and O-ring. A129677 16. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1) (a) Remove the 12 bolts, seal washer, head cover and gasket. EM A129679 (b) Remove the 3 gaskets. A129699 17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2) (a) Remove the 12 bolts, seal washer, head cover and gasket. NOTICE: The baffle plate is located on the back of the portion shown in the illustration. Do not damage the baffle plate when removing the head cover. Baffle Plate A129678E02 (b) Remove the 3 gaskets. A129705 EM–70 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 18. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY (a) Remove the 16 bolts and 2 nuts. Nut Nut A129680E01 SST SST EM (b) Insert the blade of SST between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan sub-assembly. SST 09032-00100 NOTICE: Be careful not to damage the contact surfaces of the oil pans. (c) Using "Torx" socket wrench E6, remove the 2 stud bolts. A120816E01 19. REMOVE OIL STRAINER SUB-ASSEMBLY (a) Remove the bolt, 2 nuts, oil strainer and gasket. (b) Using "Torx" socket wrench E6, remove the 2 stud bolts. A129681 20. REMOVE OIL PAN SUB-ASSEMBLY (a) Remove the 16 bolts and 2 nuts. HINT: Be sure to clean the bolts and stud bolts and check the threads for cracks or other damage. Nut Nut A129682E02 2GR-FE ENGINE MECHANICAL – ENGINE UNIT EM–71 (b) Remove the oil pan by prying between the oil pan and cylinder block with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the cylinder block and oil pan. HINT: Tape the screwdriver tip before use. Protective Tape Protective Tape A129683E01 (c) Remove the 2 O-rings. (d) Using "Torx" socket wrench E8, remove the 2 stud bolts. A129684 21. REMOVE OIL PAN BAFFLE PLATE (a) Remove the 7 bolts and baffle plate. A129685 22. REMOVE ENGINE REAR OIL SEAL RETAINER (a) Remove the 6 bolts. A129686 EM EM–72 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Using a screwdriver, pry out the oil seal retainer. NOTICE: Be careful not to damage the engine rear oil seal retainer. HINT: Tape the screwdriver tip before use. Pry A129687E01 23. REMOVE ENGINE REAR OIL SEAL (a) Place the oil seal retainer on wooden blocks. NOTICE: Be careful not to damage the engine rear oil seal retainer. (b) Using a screwdriver and a hammer, tap out the oil seal. HINT: Tape the screwdriver tip before use. Wooden Block EM A131834E02 24. REMOVE WATER PUMP ASSEMBLY (a) Remove the 16 bolts, water pump and gasket. A129688 25. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY (a) Remove the 15 bolts and 2 nuts as shown in the illustration. Nut Nut A129689E01 2GR-FE ENGINE MECHANICAL – ENGINE UNIT EM–73 (b) Remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the cylinder head, cylinder block and chain cover. HINT: Tape the screwdriver tip before use. (c) Remove the 4 bolts, chain cover plate and gasket. Protective Tape EM Protective Tape A129690E02 (d) Remove the gasket. A128006E01 26. REMOVE TIMING CHAIN CASE OIL SEAL (a) Using a screwdriver, pry out the oil seal. HINT: Tape the screwdriver tip before use. Protective Tape 27. SET NO. 1 CYLINDER TO TDC / COMPRESSION (a) Temporarily tighten the pulley set bolt. Wooden Block A108818E01 (b) Set the timing mark on the crank angle sensor plate to the RH block bore center line (TDC / compression). Center Line Timing Marks Sensor Plate A129691E01 EM–74 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (c) Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing cap as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the timing marks as above. Timing Marks EM Timing Marks A129692E02 Plunger 28. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY (a) Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner. (b) Move the stopper plate downward to set the lock, and insert a pin of φ1.27 mm (0.05 in.) into the stopper plate's hole. Plunger Stopper Plate Pin A124589E02 (c) Remove the 2 bolts and chain tensioner. 29. REMOVE CHAIN TENSIONER SLIPPER (a) Remove the chain tensioner slipper. A095165 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 10° Timing MarkU EM–75 30. REMOVE CHAIN SUB-ASSEMBLY (a) Turn the crankshaft counterclockwise 10° to loosen the chain of the crankshaft timing sprocket. (b) Remove the pulley set bolt. Center Line Sensor Plate A134897E01 (c) Remove the chain from the crankshaft timing sprocket and place it on the crankshaft. EM A134890 (d) Turn the camshaft timing gear assembly on the RH bank clockwise (approximately 60°) and set it as shown in the illustration. Be sure to loosen the chain between the banks. (e) Remove the chain. RH Bank: A095682E03 31. REMOVE IDLE SPROCKET ASSEMBLY (a) Using a 10 mm hexagon wrench, remove the No. 2 idle gear shaft, sprocket and No. 1 idle gear shaft. A129695 32. REMOVE NO. 1 CHAIN VIBRATION DAMPER (a) Remove the 2 bolts and vibration damper. 33. REMOVE NO. 2 CHAIN VIBRATION DAMPER (a) Remove the 2 vibration dampers. A129696 EM–76 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 34. REMOVE CRANKSHAFT TIMING SPROCKET (a) Remove the crankshaft timing sprocket from the crankshaft. (b) Remove the 2 pulley set keys from the crankshaft. A109720 35. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) (a) While raising the No. 2 chain tensioner, insert a pin of φ 1.0 mm (0.039 in.) into the hole to fix the No. 2 chain tensioner. Push EM Pin Plunger A120651E01 (b) Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts and 2 camshaft timing gear assemblies. NOTICE: • Be careful not to damage the cylinder head with the wrench. • Do not disassemble the camshaft timing gear assemblies. (c) Remove the No. 2 chain. Hold Turn A120652E01 36. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY (a) Remove the bolt and No. 2 chain tensioner. A109721 2GR-FE ENGINE MECHANICAL – ENGINE UNIT EM–77 37. REMOVE CAMSHAFT BEARING CAP (for Bank 1) (a) Check that the camshafts are positioned as shown in the illustration. Front View 45° Knock Pin A129700E01 2 6 8 4 1 5 7 3 (b) Uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration. A129701E03 4 6 7 10 9 12 5 8 1 3 2 11 A129702E01 (c) Uniformly loosen and remove the 12 bearing cap bolts in the sequence shown in the illustration. NOTICE: Uniformly loosen the bolts while keeping the camshaft level. (d) Remove the 5 bearing caps. 38. REMOVE CAMSHAFT (a) Remove the camshaft. 39. REMOVE NO. 2 CAMSHAFT (a) Remove the No. 2 camshaft. EM EM–78 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 40. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH (a) Remove the camshaft housing sub-assembly RH by prying between the cylinder head and camshaft housing sub-assembly RH with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing. HINT: Tape the screwdriver tip before use. Protective Tape Protective Tape EM A129703E01 41. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) (a) While pushing down the No. 3 chain tensioner, insert a pin of φ 1.0 mm (0.039 in.) into the hole to fix the No. 3 chain tensioner. Push Pin Plunger A120657E01 Turn Hold A120658E01 (b) Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts and 2 camshaft timing gear assemblies. NOTICE: • Be careful not to damage the cylinder head with the wrench. • Do not disassemble the camshaft timing gear assemblies. (c) Remove the No. 2 chain. 2GR-FE ENGINE MECHANICAL – ENGINE UNIT EM–79 42. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY (a) Remove the bolt and No. 3 chain tensioner. A109722 43. REMOVE CAMSHAFT BEARING CAP (for Bank 2) (a) Check that the camshafts are positioned as shown in the illustration. EM Front View Knock Pin A129706E01 (b) Uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration. 4 8 6 2 3 7 5 1 A134891E03 5 8 11 7 13 2 10 4 1 6 12 9 3 A129708E01 (c) Uniformly loosen and remove the 13 bearing cap bolts in the sequence shown in the illustration. NOTICE: Uniformly loosen the bolts while keeping the camshaft level. (d) Remove the 5 bearing caps. 44. REMOVE NO. 3 CAMSHAFT (a) Remove the No. 3 camshaft. 45. REMOVE NO. 4 CAMSHAFT (a) Remove the No. 4 camshaft. EM–80 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 46. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH (a) Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing. HINT: Tape the screwdriver tip before use. 47. REMOVE NO. 1 VALVE ROCKER ARM SUBASSEMBLY (a) Remove the 24 valve rocker arms. HINT: Arrange the removed parts in the correct order. Protective Tape EM Protective Tape 48. REMOVE VALVE LASH ADJUSTER ASSEMBLY (a) Remove the 24 valve lash adjusters from the cylinder head. HINT: Arrange the removed parts in the correct order. A129709E01 2 4 7 5 3 6 8 1 A129712E01 49. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH (a) Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers. NOTICE: • Be careful not to drop washers into the cylinder head. • Cylinder head warpage or cracking could result from removing bolts in an incorrect order. HINT: Be sure to keep separate the removed parts for each installation position. (b) Remove the cylinder head and gasket. 50. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH (a) Uniformly loosen and remove the bolts in the sequence shown in the illustration. 2 1 A129710E01 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 1 3 8 6 4 5 7 2 A129711E01 EM–81 (b) Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers. NOTICE: • Be careful not to drop washers into the cylinder head. • Cylinder head warpage or cracking could result from removing bolts in an incorrect order. HINT: Be sure to keep separate the removed parts for each installation position. (c) Remove the cylinder head and gasket. 51. REMOVE WATER INLET PIPE (a) Separate the No. 1 water by-pass hose. (b) Remove the 2 bolts and water inlet pipe. 52. REMOVE VALVE STEM CAP (a) Remove the valve stem caps from the cylinder heads. HINT: Arrange the removed parts in the correct order. A129713 53. REMOVE INTAKE VALVE (a) Using SST, compress the compression spring and remove the valve spring retainer locks. SST 09202-70020 (09202-00010) (b) Remove the retainer, compression spring and valve. HINT: Arrange the removed parts in the correct order. SST A129714E01 54. REMOVE EXHAUST VALVE (a) Using SST, compress the compression spring and remove the valve spring retainer locks. SST 09202-70020 (09202-00010) (b) Remove the retainer, compression spring and valve. HINT: Arrange the removed parts in the correct order. SST A129715E01 EM EM–82 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 55. REMOVE VALVE STEM OIL SEAL (a) Using needle-nose pliers, remove the oil seals. A120701E01 56. REMOVE VALVE SPRING SEAT (a) Using compressed air and a magnetic finger, remove the valve spring seats by blowing air onto them. EM A120702E01 57. REMOVE NO. 1 STRAIGHT SCREW PLUG (a) Using a 10 mm hexagon wrench, remove the 4 screw plugs and 4 gaskets. NOTICE: If water leaks from the straight screw plug or the plug corrodes, replace it. RH Bank: LH Bank: A129718E01 2GR-FE ENGINE MECHANICAL – ENGINE UNIT EM–83 58. REMOVE NO. 2 STRAIGHT SCREW PLUG (a) Using a 14 mm hexagon wrench, remove the screw plugs and gaskets. NOTICE: If water leaks from the straight screw plug or the plug corrodes, replace it. LH Bank: 59. REMOVE RING PIN NOTICE: It is not necessary to remove the ring pin unless it is being replaced. 60. REMOVE STUD BOLT NOTICE: If the stud bolt is deformed or the threads are damaged, replace it. RH Bank: 61. REMOVE INTAKE VALVE GUIDE BUSH (a) Heat the cylinder head to 80 to 100°C (176 to 212°F). (b) Place the cylinder head on wooden blocks. A129719E01 (c) Using SST and a hammer, tap out the guide bushes. SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) SST 62. REMOVE EXHAUST VALVE GUIDE BUSH (a) Heat the cylinder head to 80 to 100°C (176 to 212°F). (b) Place the cylinder head on wooden blocks. SST A121839E02 (c) Using SST and a hammer, tap out the guide bushes. SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) SST SST A120709E02 63. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD (a) Check that the matchmarks on the connecting rod and cap are aligned. HINT: The matchmarks on the connecting rods and caps are for ensuring the correct reassembly. EM EM–84 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Remove the 2 connecting rod cap bolts. Engine Front A129760E01 (c) Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left. HINT: Keep the lower bearing inserted to the connecting rod cap. EM A129761 (d) Using a ridge reamer, remove all the carbon from the top of the cylinder. (e) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. HINT: • Keep the bearing, connecting rod and cap together. • Arrange the piston and connecting rod assemblies in the correct order. Ridge Reamer A129720E01 64. REMOVE CONNECTING ROD BEARING NOTICE: Arrange the removed parts in the correct order. 65. REMOVE CRANKSHAFT (a) Uniformly loosen and remove the 8 main bearing cap bolts and seal washers in the several steps and in the sequence shown in the illustration. 5 8 7 6 2 3 4 1 A129721E03 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 2 6 10 9 8 4 14 16 12 13 15 11 7 3 1 5 EM–85 (b) Uniformly loosen the 16 bearing cap bolts, in several steps and in the sequence shown in the illustration. A134892E01 (c) Using a screwdriver, pry out the main bearing caps. Remove the 4 main bearing caps and lower bearings. NOTICE: • Push up on the cap little by little, from the right and left side alternately so that the cap can be removed. • Be careful not to damage the joint surface of the cylinder block and the main bearing cap. (d) Remove the crankshaft. Protective Tape Cylinder Block 66. REMOVE CRANKSHAFT BEARING HINT: Arrange the removed parts in the correct order. Bearing Cap Joint Surface A122567E01 67. REMOVE CRANKSHAFT THRUST WASHER SET (a) Remove the upper bearings and upper thrust washers from the cylinder block. A109726 68. REMOVE PISTON RING SET (a) Using a piston ring expander, remove the 2 compression rings. (b) Remove the oil ring expander and 2 side rails by hand. HINT: Arrange the removed parts in the correct order. Piston Ring Expander A129724E01 EM EM–86 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 69. REMOVE PISTON SUB-ASSEMBLY WITH PIN (a) Check the fitting condition between the piston and piston pin. (1) Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set. A129725 (b) Disconnect the connecting rod from the piston. (1) Using a screwdriver, pry off the snap rings from the piston. EM A129726 (2) Gradually heat the piston to approximately 80°C (176°F). 80°C (176°F) A109729E02 (3) Using a brass bar and plastic hammer, lightly tap out the piston pin and remove the connecting rod. HINT: • The piston and pin are a matched set. • Arrange the pistons, pins, rings, connecting rods and bearings in the correct order. A129728 (c) Using a gasket scraper, remove the carbon from the piston top. A129729 2GR-FE ENGINE MECHANICAL – ENGINE UNIT EM–87 (d) Using a groove cleaning tool or broken ring, clean the piston ring grooves. A129730 (e) Using solvent and a brush, thoroughly clean the piston. NOTICE: Do not use a wire brush. EM A129731 70. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY (a) Using a 5 mm hexagon wrench, remove the bolts and oil nozzles. (b) Check the 3 oil nozzles for damage or clogging. If necessary, replace the oil nozzle. 71. CLEAN CYLINDER BLOCK A120734 INSPECTION A125485 1. INSPECT NO. 1 VALVE ROCKER ARM SUBASSEMBLY (a) Turn the roller by hand to check that it turns smoothly. HINT: If the roller does not turn smoothly, replace the valve rocker arm sub-assembly. 2. INSPECT VALVE LASH ADJUSTER ASSEMBLY NOTICE: • Keep the lash adjuster free of dirt and foreign objects. • Only use clean engine oil. (a) Place the lash adjuster into a container filled with engine oil. EM–88 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Insert the SST's tip into the lash adjuster's plunger and use the tip to press down on the check ball inside the plunger. SST 09276-75010 (c) Squeeze the SST and lash adjuster together to move the plunger up and down 5 to 6 times. (d) Check the movement of the plunger and bleed the air. OK: Plunger moves up and down. NOTICE: When bleeding air from the high-pressure chamber, make sure that the tip of the SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, air will not bleed. (e) After bleeding the air, remove the SST. Then try to quickly and firmly press the plunger with a finger. OK: Plunger is very difficult to move. If the result is not as specified, replace the lash adjuster. INCORRECT CORRECT SST Taper Part Plunger Low Pressure Chamber Check Ball EM High Pressure Chamber SST High Pressure Chamber 3. INSPECT CAMSHAFT (a) Inspect the camshaft for runout. (1) Place the camshaft on V-blocks. A109630E01 (2) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.04 mm (0.0016 in.) If the circle runout is greater than the maximum, replace the camshaft. HINT: Check the oil clearance after replacing the camshaft. A120669 (b) Using a micrometer, measure the cam lobe height. Standard cam lobe height Item Specification Intake camshaft 44.316 to 44.416 mm (1.7447 to 1.7487 in.) Exhaust camshaft 44.262 to 44.362 mm (1.7426 to 1.7465 in.) Maximum cam lobe height Item Specification Intake camshaft 44.166 mm (1.7388 in.) Exhaust camshaft 44.112 mm (1.7367 in.) A109632 EM–89 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (c) Using a micrometer, measure the journal diameter. Standard journal diameter Item Specification No. 1 journal 35.946 to 35.960 mm (1.4152 to 1.4157 in.) Other journals 25.959 to 25. 975 mm (1.0220 to 1.0226 in.) If the journal diameter is not as specified, check the oil clearance. A109633 Key Groove Straight Pin A109635E02 4. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY (a) Clamp the camshaft in a vise. NOTICE: Be careful not to damage the camshaft in the vise. (b) Put the camshaft timing gear and camshaft together by aligning the key groove and straight pin. (c) Lightly press the gear against the camshaft, and turn the gear. Push further at the position where the pin enters the groove. NOTICE: Be sure not to turn the camshaft timing gear in the retard direction (the right angle). (d) Check that there is no clearance between the gear's flange and the camshaft. (e) Tighten the flange bolt with the camshaft timing gear fixed. Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf) (f) Check the lock of the camshaft timing gear. (1) Clamp the camshaft in a vise, and confirm that the camshaft timing gear is locked. NOTICE: Be careful not to damage the camshaft. A109634 EM EM–90 Advance Side Path 2GR-FE ENGINE MECHANICAL – ENGINE UNIT Retard Side Path Close Open Open Close (g) Release the lock pin. (1) Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration. HINT: 2 advance side paths are provided in the groove of the camshaft. Plug one of the paths with a rubber piece. (2) Break through the tape of the advance side path and the retard side path on the opposite side to the hole of the advance side path, as shown in the illustration. EM Vinyl Tape Rubber A106100E02 Advance Side Path Retard Side Path (3) Apply approximately 200 kPa (2.0 kgf/cm2, 28 psi) of air pressure to the 2 broken paths. CAUTION: Cover the paths with a piece of cloth when applying pressure to keep oil from splashing. A106101E03 Advance Side Path Hold Pressure Retard Side Path Decompress A106102E02 (4) Check that the camshaft timing gear revolves in the advance direction when reducing the air pressure applied to the retard side path. HINT: This operation releases the lock pin for the most retarded position. (5) When the camshaft timing gear reaches the most advanced position, release the air pressure from the retard side path and advance side path, in that order. NOTICE: Do not release the air pressure from the advance side path first. The gear may abruptly shift in the retard direction and break the lock pin. 2GR-FE ENGINE MECHANICAL – ENGINE UNIT EM–91 (h) Check for smooth rotation. (1) Turn the camshaft timing gear within its movable range (21°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the gear turns smoothly. NOTICE: Do not use air pressure to perform the smooth operation check. (i) Check the lock in the most retarded position. (1) Confirm that the camshaft timing gear is locked at the most retarded position. Do Not Remove (j) Straight Pin 5. Do Not Remove Flange Bolt A095160E02 Key Groove Straight Pin A109635E02 Remove the flange bolt and camshaft timing gear. NOTICE: • Do not remove the other 3 bolts. • If planning to reuse the gear, be sure to release the straight pin lock before installing the gear. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY (a) Clamp the camshaft in a vise. NOTICE: Be careful not to damage the camshaft in the vise. (b) Put the camshaft timing exhaust gear and camshaft together by aligning the key groove and straight pin. (c) Lightly press the gear against the camshaft, and turn the gear. Push further at the position where the pin enters the groove. NOTICE: Be sure not to turn the camshaft timing exhaust gear in the retard direction (the right angle). (d) Check that there is no clearance between the gear's flange and the camshaft. (e) Tighten the flange bolt with the camshaft timing exhaust gear fixed. Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf) (f) Check the camshaft timing exhaust gear lock. (1) Make sure that the camshaft timing exhaust gear is locked. A107564 EM EM–92 Retard Side Path Open Close 2GR-FE ENGINE MECHANICAL – ENGINE UNIT Advance Side Path (g) Release the lock pin. (1) Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration. HINT: 4 oil paths are provided in the groove. Plug 2 paths with rubber pieces. (2) Prick a hole in the tape placed on the advance side path. Prick a hole in the tape placed on the retard side path, on the opposite side to that of the advance side path, as shown in the illustration. Close Open EM Rubber Vinyl Tape A106103E01 Advance Side Path Retard Side Path (3) Apply approximately 200 kPa (2.0 kgf/cm2, 28 psi) of air pressure to the 2 broken paths (the advance side path and the retard side path). CAUTION: Cover the paths with a piece of cloth when applying pressure to keep oil from splashing. A106104E01 Advance Side Path Decompress Retard Side Path Hold Pressure A106105E02 (4) Make sure that the camshaft timing exhaust gear turns in the retard direction when reducing the air pressure applied to the advance side path. HINT: The lock pin is released and the camshaft timing exhaust gear turns in the retard direction. (5) When the camshaft timing exhaust gear moves to the most retarded position, release the air pressure from the advance side path, and then release the air pressure from the retard side path. NOTICE: Be sure to release the air pressure from the advance side path first. If the air pressure of the retard side path is released first, the camshaft timing exhaust gear may abruptly shift in the advance direction and break the lock pin or other parts. 2GR-FE ENGINE MECHANICAL – ENGINE UNIT EM–93 (h) Check for smooth rotation. (1) Turn the camshaft timing exhaust gear within its movable range (18.5°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the gear turns smoothly. NOTICE: When the air pressure is released from the advance side path and then from the retard side path, the gear automatically returns to the most advanced position due to the advance assist spring operation and locks. Gradually release the air pressure from the retard side path before performing the smooth rotation check. (i) Check the lock at the most advanced position. (1) Make sure that the camshaft timing exhaust gear is locked at the most advanced position. (j) Straight Pin Do Not Remove Remove the flange bolt and camshaft timing exhaust gear. NOTICE: • Be sure not to remove the other 4 bolts. • If planning to reuse the gear, be sure to release the straight pin lock before installing the gear. Do Not Remove Flange Bolt A095162E02 6. Measuring Point 103 mm (4.06 in.) A122880E03 INSPECT CYLINDER HEAD SET BOLT (a) Using vernier calipers, measure the minimum diameter of the elongated thread at the measuring point. Standard outside diameter: 10.85 to 11.00 mm (0.4272 to 0.4331 in.) Minimum outside diameter: 10.70 mm (0.4213 in.) Measuring Point: 103 mm (4.06 in.) HINT: If a visual check reveals no excessively thin areas, check the center of the bolt and find the area that has the lowest diameter. If the diameter is less than the minimum, replace the cylinder head bolt. EM EM–94 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 7. INSPECT CHAIN SUB-ASSEMBLY (a) Pull the chain with a force of 147 N (15 kgf, 33 lbf) as shown in the illustration. (b) Using vernier calipers, measure the length of 15 links. Maximum chain elongation: 136.9 mm (5.390 in.) NOTICE: Perform the measurement at 3 random places. Use the average of the measurements. If the elongation is greater than the maximum, replace the chain. 8. INSPECT NO. 2 CHAIN SUB-ASSEMBLY (a) Pull the chain with a force of 147 N (15 kgf, 33 lbf) as shown in the illustration. (b) Using vernier calipers, measure the length of 15 links. Maximum chain elongation: 137.6 mm (5.417 in.) NOTICE: Perform the measurement at 3 random places. Use the average of the measurements. If the elongation is greater than the maximum, replace the chain. 9. INSPECT CRANKSHAFT TIMING SPROCKET (a) Wrap the chain around the sprocket. Measuring Area 123456 15 A135727E01 EM Measuring Area 123456 15 A135727E04 (b) Using vernier calipers, measure the sprocket diameter with the chain. Minimum sprocket diameter (with chain): 61.4 mm (2.417 in.) HINT: The vernier calipers must contact the chain rollers for the measurement. If the diameter is less than the minimum, replace the chain and sprocket. A109646 10. INSPECT IDLE SPROCKET ASSEMBLY (a) Wrap the chain around the sprocket. (b) Using vernier calipers, measure the sprocket diameter with the chain. Minimum sprocket diameter (with chain): 61.4 mm (2.417 in.) HINT: The vernier calipers must contact the chain rollers for the measurement. If the diameter is less than the minimum, replace the chain and sprocket. A109647 2GR-FE ENGINE MECHANICAL – ENGINE UNIT EM–95 11. INSPECT IDLE GEAR SHAFT OIL CLEARANCE (a) Using a micrometer, measure the idle gear shaft diameter. Idle gear shaft diameter: 22.987 to 23.000 mm (0.9050 to 0.9055 in.) A109648 A120673 Plunger (b) Using a caliper gauge, measure the inside diameter of the idle gear. Idle gear inside diameter: 23.020 to 23.030 mm (0.9063 to 0.9067 in.) (c) Subtract the idle gear shaft diameter measurement from the idle gear inside diameter measurement. Standard oil clearance: 0.020 to 0.043 mm (0.0008 to 0.0017 in.) Maximum oil clearance: 0.093 mm (0.0037 in.) If the thrust oil clearance is greater than the maximum, replace the idle gear shaft and idle gear. 12. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY (a) Move the stopper plate upward to release the lock. Push the plunger and check that it moves smoothly. If necessary, replace the chain tensioner assembly. Stopper Plate A097905E06 Depth Depth A106108E01 13. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY (a) Check that the plunger moves smoothly. (b) Measure the worn depth of the chain tensioner. Maximum depth: 0.9 mm (0.035 in.) If the depth is greater than the maximum, replace the chain tensioner assembly. EM EM–96 2GR-FE ENGINE MECHANICAL – ENGINE UNIT Depth 14. INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY (a) Check that the plunger moves smoothly. (b) Measure the worn depth of the chain tensioner. Maximum depth: 0.9 mm (0.035 in.) If the depth is greater than the maximum, replace the chain tensioner assembly. Depth A106109E01 Depth 15. INSPECT CHAIN TENSIONER SLIPPER (a) Measure the worn depth of the chain tensioner slipper. Maximum depth: 1.0 mm (0.039 in.) If the depth is greater than the maximum, replace the chain tensioner slipper. EM A106110E01 Depth 16. INSPECT NO. 1 CHAIN VIBRATION DAMPER (a) Measure the worn depth of the chain vibration damper. Maximum depth: 1.0 mm (0.039 in.) If the depth is greater than the maximum, replace the chain vibration damper. A106111E01 Y 17. INSPECT NO. 2 CHAIN VIBRATION DAMPER (a) Measure the worn depth of the chain vibration damper. Maximum depth: 1.0 mm (0.039 in.) If the depth is greater than the maximum, replace the chain vibration damper. Depth A106112E01 EM–97 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 18. INSPECT CYLINDER HEAD ASSEMBLY (a) Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of the cylinder block and manifolds. Standard warpage Item Cylinder head lower side: Warpage Cylinder head lower 0.05 mm (0.0020 in.) Intake 0.08 mm (0.0031 in.) Exhaust 0.08 mm (0.0031 in.) Maximum warpage Item Warpage Cylinder head lower 0.10 mm (0.0039 in.) Intake 0.10 mm (0.0039 in.) Exhaust 0.10 mm (0.0039 in.) If the warpage is greater than the maximum, replace the cylinder head assembly. Intake side: Exhaust side: A129747E01 (b) Using a dye penetrant, check the intake ports, exhaust ports and cylinder surface for cracks. If cracked, replace the cylinder head assembly. A120706 19. INSPECT INTAKE VALVE (a) Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: 5.470 to 5.485 mm (0.2154 to 0.2159 in.) If the valve stem is not as specified, check the oil clearance. A121378 EM EM–98 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Using vernier calipers, measure the valve head margin thickness. Standard margin thickness: 1.0 mm (0.03937 in.) Minimum margin thickness: 0.5 mm (0.0197 in.) If the margin thickness is less than the minimum, replace the intake valve. Margin Thickness A121379E01 (c) Using vernier calipers, measure the valve's overall length. Standard overall length: 105.85 mm (4.1673 in.) Minimum overall length: 105.35 mm (4.1476 in.) If the overall length is less than the minimum, replace the intake valve. Overall Length EM A121380E01 20. INSPECT EXHAUST VALVE (a) Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: 5.465 to 5.480 mm (0.2151 to 0.2157 in.) If the valve stem is not as specified, check the oil clearance. A124001 (b) Using vernier calipers, measure the valve head margin thickness. Standard margin thickness: 1.0 mm (0.0397 in.) Minimum margin thickness: 0.5 mm (0.0197 in.) If the margin thickness is less than the minimum, replace the exhaust valve. Margin Thickness A121382E01 Overall Length A121383E01 (c) Using vernier calipers, measure the valve's overall length. Standard overall length: 110.40 mm (4.3464 in.) Minimum overall length: 109.90 mm (4.3268 in.) If the overall length is less than the minimum, replace the exhaust valve. 21. INSPECT INTAKE VALVE SEAT (a) Apply a light coat of Prussian blue to the valve face. 2GR-FE ENGINE MECHANICAL – ENGINE UNIT EM–99 (b) Lightly press the valve face against the valve seat. Width A094929E01 (c) Check the valve face and valve seat by using the following procedure. (1) If Prussian blue appears around the entire valve face, the valve face is concentric. If not, replace the valve. (2) If Prussian blue appears around the entire valve seat, the guide and valve face are concentric. If not, resurface the valve seat. (3) Check that the valve seat contacts in the middle of the valve face with the width between 1.1 and 1.5 mm (0.043 and 0.059 in.). 22. INSPECT EXHAUST VALVE SEAT (a) Apply a light coat of Prussian blue to the valve face. (b) Lightly press the valve face against the valve seat. Width A094929E01 (c) Check the valve face and valve seat by using the following procedure. (1) If Prussian blue appears around the entire valve face, the valve face is concentric. If not, replace the valve. (2) If Prussian blue appears around the entire valve seat, the guide and valve face are concentric. If not, resurface the valve seat. (3) Check that the valve seat contacts in the middle of the valve face with the width between 1.1 and 1.5 mm (0.043 and 0.059 in.). 23. REPAIR INTAKE VALVE SEAT NOTICE: • Repair the seat while checking the seating position. • Keep the lip free of foreign matter. (a) Using a 45° cutter, resurface the valve seat so that the valve seat width is more than the specification. A127139 60° 45° 30° Width A124254E01 (b) Using 30° and 60° cutters, correct the valve seat so that the valve contacts the entire circumference of the seat. The contact should be in the center of the valve seat, and the valve seat width should be maintained within the specified range around the entire circumference of the seat. Width: 1.1 to 1.5 mm (0.043 to 0.059 in.) (c) Handrub the valve and valve seat with an abrasive compound. (d) Check the valve seating position. EM EM–100 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 24. REPAIR EXHAUST VALVE SEAT NOTICE: • Repair the seat while checking the seating position. • Keep the lip free of foreign matter. (a) Using a 45° cutter, resurface the valve seat so that the valve seat width is more than the specification. A127140 75° EM 45° 30° Width A124255E01 (b) Using 30° and 75° cutters, correct the valve seat so that the valve contacts the entire circumference of the seat. The contact should be in the center of the valve seat, and the valve seat width should be maintained within the specified range around the entire circumference of the seat. Width: 1.1 to 1.5 mm (0.043 to 0.059 in.) (c) Handrub the valve and valve seat with an abrasive compound. (d) Check the valve seating position. 25. INSPECT COMPRESSION SPRING (a) Using vernier calipers, measure the free length of the compression spring. Free length: 45.46 mm (1.7898 in.) If the free length is not as specified, replace the spring. A109669 (b) Using a steel square, measure the deviation of the inner compression spring. Maximum deviation: 1.0 mm (0.039 in.) Maximum angle (reference): 2° If the deviation is greater than the maximum, replace the spring. Deviation A094933E01 EM–101 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 26. INSPECT VALVE GUIDE BUSH OIL CLEARANCE (a) Using a caliper gauge, measure the inside diameter of the guide bush. Bush inside diameter: 5.510 to 5.530 mm (0.2169 to 0.2177 in.) (b) Subtract the valve stem diameter measurement from the guide bush inside diameter measurement. Standard clearance Item A120707 Clearance Intake 0.025 to 0.060 mm (0.0010 to 0.0024 in.) Exhaust 0.030 to 0.065 mm (0.0012 to 0.0026 in.) Maximum oil clearance Item Clearance Intake 0.08 mm (0.0032 in.) Exhaust 0.10 mm (0.0039 in.) For intake side: If the clearance is greater than the maximum, replace the intake valve and intake guide bush. For exhaust side: If the clearance is greater than the maximum, replace the exhaust valve and exhaust guide bush. 27. INSPECT CAMSHAFT THRUST CLEARANCE (a) Inspect the RH bank camshaft thrust clearance. (1) Install the RH bank camshafts (See page EM113). A109682 (2) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: 0.08 to 0.13 mm (0.0031 to 0.0051 in.) Maximum thrust clearance: 0.15 mm (0.006 in.) If the thrust clearance is greater than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft. (b) Inspect the LH bank camshaft thrust clearance. (1) Install the LH bank camshafts (See page EM113). (2) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: 0.08 to 0.13 mm (0.0031 to 0.0051 in.) Maximum thrust clearance: 0.15 mm (0.006 in.) If the thrust clearance is greater than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft. EM EM–102 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 28. INSPECT CAMSHAFT OIL CLEARANCE (a) Clean the bearing caps, camshaft housing and camshaft journals. (b) Place the camshafts on the camshaft housing. (c) Lay a strip of Plastigage across each of the camshaft journals. (d) Install the bearing caps (See page EM-113). NOTICE: Do not turn the camshaft. (e) Remove the bearing caps (See page EM-64). Plastigage A120715E01 (f) Measure the Plastigage at its widest point. Standard oil clearance Item EM Oil Clearance No. 1 journal 0.040 to 0.079 mm (0.0016 to 0.0031 in.) Other journals 0.025 to 0.062 mm (0.00098 to 0.0024 in.) Maximum oil clearance Plastigage Other Journals Item Oil Clearance No. 1 journal 0.10 mm (0.0039 in.) Other journals 0.09 mm (0.0035 in.) No. 1 Journal If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the camshaft housing. (g) Clean the bearing caps, camshaft housing and camshaft journals. (h) Place the camshafts on the camshaft housing. Other Journals A129756E03 (i) Lay a strip of Plastigage across each of the camshaft journals. (j) Install the bearing caps (See page EM-113). NOTICE: Do not turn the camshaft. (k) Remove the bearing caps (See page EM-64). Plastigage A120717E01 EM–103 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (l) Plastigage Measure the Plastigage at its widest point. Standard oil clearance Item Oil Clearance No. 1 journal 0.040 to 0.079 mm (0.0016 to 0.0031 in.) Other journals 0.025 to 0.062 mm (0.00098 to 0.0024 in.) Maximum oil clearance Item No. 1 Journal Oil Clearance No. 1 journal 0.10 mm (0.0039 in.) Other journals 0.09 mm (0.0035 in.) Other Journals If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the camshaft housing. 29. INSPECT CONNECTING ROD THRUST CLEARANCE (a) Install the connecting rod cap (See page EM-113). EM Other Journals A129758E03 (b) Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.15 to 0.40 mm (0.0059 to 0.0157 in.) Maximum thrust clearance: 0.50 mm (0.020 in.) If the thrust clearance is greater than the maximum, replace the connecting rod assemblies as necessary. If necessary, replace the crankshaft. A120723 30. INSPECT CONNECTING ROD OIL CLEARANCE (a) Clean the crank pin and bearing. (b) Check the crank pin and bearing for pitting and scratches. (c) Lay a strip of Plastigage on the crank pin. Plastigage A131814E01 EM–104 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (d) Check that the front mark of the connecting rod cap is facing forward. (e) Install the connecting rod cap (See page EM-113). NOTICE: Do not turn the crankshaft. (f) Remove the 2 bolts and connecting rod cap (See page EM-64). Engine Front Front Mark A131815E01 (g) Measure the Plastigage at its widest point. Standard oil clearance: 0.045 to 0.067 mm (0.0018 to 0.0026 in.) Maximum oil clearance: 0.070 mm (0.0028 in.) If the oil clearance is greater than the maximum, replace the connecting rod bearings. If necessary, inspect the crankshaft. HINT: If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap. Each bearing's standard thickness is indicated by a 1, 2, 3 or 4 mark on its surface. Connecting rod diameter Plastigage EM 1, 2, 3, or 4 Mark A131817E02 Mark Diameter 1 56.000 to 56.006 mm (2.2047 to 2.2050 in.) 2 56.007 to 56.012 mm (2.2050 to 2.2052 in.) 3 56.013 to 56.018 mm (2.2052 to 2.2054 in.) 4 56.019 to 56.024 mm (2.2055 to 2.2057 in.) Connecting rod bearing center wall thickness Mark Thickness 1 1.481 to 1.484 mm (0.0583 to 0.0584 in.) 2 1.484 to 1.487 mm (0.0584 to 0.0585 in.) 3 1.487 to 1.490 mm (0.0585 to 0.0587 in.) 4 1.490 to 1.493 mm (0.0587 to 0.0588 in.) Crankshaft pin diameter: 52.992 to 53.000 mm (2.0863 to 2.0866 in.) NOTICE: Completely remove the Plastigage after the measurement. 31. INSPECT CRANKSHAFT THRUST CLEARANCE (a) Install the main bearing cap (See page EM-113). 2GR-FE ENGINE MECHANICAL – ENGINE UNIT A131818 EM–105 (b) Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.04 to 0.24 mm (0.0016 to 0.0094 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.) If the thrust clearance is greater than the maximum, replace the thrust washers as a set. If necessary, replace the crankshaft. Thrust washer thickness: 2.43 to 2.48 mm (0.0957 to 0.0976 in.) 32. INSPECT CYLINDER BLOCK FOR WARPAGE (a) Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of the cylinder head gasket. Maximum warpage: 0.07 mm (0.0028 in.) If the warpage is greater than the maximum, replace the cylinder block. A131819 33. INSPECT CYLINDER BORE (a) Visually check the cylinder for vertical scratches. If deep scratches are present, rebore all the 6 cylinders. If necessary, replace the cylinder block. A131820 EM EM–106 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions. Standard diameter: 94.000 to 94.012 mm (3.7008 to 3.7013 in.) Maximum diameter: 94.200 mm (3.7087 in.) If the average diameter of 4 positions is greater than the maximum, replace the cylinder block. Axial Direction Engine Front EM Thrust Direction A 10 (0.39) B Center mm (in.) A130802E03 Distance 9.8 mm (0.3858 in.) A131821E02 34. INSPECT PISTON SUB-ASSEMBLY WITH PIN (a) Using a micrometer, measure the piston diameter at right angles to the piston center line where the distance from the piston end is as specified. Distance: 9.8 mm (0.3858 in.) Standard diameter: 93.960 to 93.980 mm (3.6992 to 3.7000 in.) Maximum diameter: 93.830 mm (3.6941 in.) 35. INSPECT PISTON OIL CLEARANCE (a) Measure the cylinder bore diameter in the thrust directions. (b) Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.020 to 0.052 mm (0.0008 to 0.0020 in.) Maximum oil clearance: 0.060 mm (0.0024 in.) If the oil clearance is greater than the maximum, replace all the pistons. If necessary, replace the cylinder block. EM–107 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 36. INSPECT RING GROOVE CLEARANCE (a) Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove. Ring groove clearance Item Clearance No. 1 0.020 to 0.070 mm (0.0008 to 0.0028 in.) No. 2 0.020 to 0.060 mm (0.0008 to 0.0024 in.) Oil 0.070 to 0.150 mm (0.0028 to 0.0059 in.) A131822 If the clearance is not as specified, replace the piston. 37. INSPECT PISTON RING END GAP (a) Insert the piston ring into the cylinder bore. (b) Using a piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block. EM 110 mm (4.33 in.) Piston Ring A106218E02 (c) Using a feeler gauge, measure the end gap. Standard end gap Item End Gap No. 1 0.25 to 0.35 mm (0.0098 to 0.0138 in.) No. 2 0.50 to 0.60 mm (0.0197 to 0.0236 in.) Oil 0.10 to 0.40 mm (0.0039 to 0.0157 in.) Maximum end gap Item End Gap No. 1 0.50 mm (0.0197 in.) No. 2 0.85 mm (0.0335 in.) Oil 0.60 mm (0.0236 in.) A109687 If the end gap is greater than the maximum, replace the piston ring. If the end gap is greater than the maximum even with a new piston ring, rebore all the 6 cylinders or replace the cylinder block. 38. INSPECT PISTON PIN OIL CLEARANCE (a) Using a caliper gauge, measure the inside diameter of the piston pin hole. Piston pin hole inside diameter A131823 Mark Diameter A 22.001 to 22.004 mm (0.8662 to 0.8663 in.) B 22.004 to 22.007 mm (0.8663 to 0.8664 in.) C 22.007 to 22.010 mm (0.8664 to 0.8665 in.) EM–108 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Using a micrometer, measure the piston pin diameter. Piston pin diameter 5 mm (0.20 in.) 28 mm (1.10 in.) 5 mm (0.20 in.) A106219E02 Mark Diameter A 21.997 to 22.000 mm (0.8660 to 0.8661 in.) B 22.000 to 22.003 mm (0.8661 to 0.8663 in.) C 22.003 to 22.006 mm (0.8663 to 0.8664 in.) (c) Subtract the piston pin diameter measurement from the piston pin hole diameter measurement. Standard oil clearance: 0.001 to 0.007 mm (0.00004 to 0.00028 in.) Maximum oil clearance: 0.015 mm (0.0006 in.) If the oil clearance is greater than the maximum, replace the piston and piston pin as a set. (d) Using a caliper gauge, measure the inside diameter of the connecting rod bushing. Bushing inside diameter EM Mark Diameter A 22.005 to 22.008 mm (0.8663 to 0.8665 in.) B 22.009 to 22.011 mm (0.8665 to 0.8666 in.) C 22.012 to 22.014 mm (0.8666 to 0.8667 in.) A109689 Piston Pin Hole Inside Diameter Mark Front Mark Connecting Rod Bushing Inside Diameter Mark Front Mark A131824E01 (e) Subtract the piston pin diameter measurement from the bushing inside diameter measurement. Standard oil clearance: 0.005 to 0.011 mm (0.0002 to 0.0004 in.) Maximum oil clearance: 0.030 mm (0.0012 in.) If the oil clearance is greater than the maximum, replace the bushing. If necessary, replace the connecting rod and piston pin as a set. 2GR-FE ENGINE MECHANICAL – ENGINE UNIT EM–109 39. INSPECT CONNECTING ROD (a) Using a rod aligner and feeler gauge, check the connecting rod alignment. (1) Check for out-of-alignment. Maximum out-of-alignment: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If the out-of-alignment is greater than the maximum, replace the connecting rod assembly. A109690 (2) Check for twist. Maximum twist: 0.15 mm (0.0059 in.) per 100 mm (3.94 in.) If the twist is greater than the maximum, replace the connecting rod assembly. EM A109691E01 40. INSPECT CONNECTING ROD BOLT (a) Using vernier calipers, measure the tension portion diameter of the bolt. Standard diameter: 7.2 to 7.3 mm (0.284 to 0.287 in.) Minimum diameter: 7.0 mm (0.276 in.) If the diameter is less than the minimum, replace the bolt. A109692 41. INSPECT CRANKSHAFT (a) Inspect for circle runout. (1) Clean the crank journal. (2) Place the crankshaft on V-blocks. (3) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.06 mm (0.0024 in.) If the circle runout is greater than the maximum, replace the crankshaft. A109693 EM–110 2GR-FE ENGINE MECHANICAL – ENGINE UNIT A109694 EM A109695 (b) Inspect the main journals. (1) Using a micrometer, measure the diameter of each main journal. Standard journal diameter: 60.988 to 61.000 mm (2.4011 to 2.4016 in.) If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft. (2) Check each main journal for taper and out-ofround as shown in the illustration. Maximum taper and out-of-round: 0.02 mm (0.0008 in.) If the taper and out-of-round is greater than the maximum, replace the crankshaft. (c) Inspect the crank pin. (1) Using a micrometer, measure the diameter of each crank pin. Crankshaft pin diameter: 52.992 to 53.000 mm (2.0863 to 2.0866 in.) If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft. (2) Check each crank pin for taper and out-ofround as shown in the illustration. Maximum taper and out-of-round: 0.02 mm (0.0008 in.) If the taper and out-of-round is greater than the maximum, replace the crankshaft. 42. INSPECT CRANKSHAFT OIL CLEARANCE (a) Check the crank journal and bearing for pitting and scratches. (b) Install the crankshaft bearing (See page EM-113). (c) Place the crankshaft on the cylinder block. Plastigage A122109E01 Plastigage A131830E01 (d) Lay a strip of Plastigage across each journal. (e) Examine the front marks and numbers and install the bearing caps on the cylinder block. HINT: A number is marked on each main bearing cap to indicate the installation position. (f) Install the main bearing cap (See page EM-113). NOTICE: Do not turn the crankshaft. (g) Remove the main bearing caps (See page EM-64). (h) Measure the Plastigage at its widest point. Standard oil clearance: 0.026 to 0.047 mm (0.0010 to 0.0019 in.) Maximum oil clearance: 0.050 mm (0.0020 in.) If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft. NOTICE: Completely remove the Plastigage after the measurement. EM–111 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (i) No. 1 No. 2 No. 3 No. 4 Number Mark Cylinder block + Crankshaft 0-5 6 - 11 12 - 17 18 - 23 24 - 28 Bearing to be used "1" "2" "3" "4" "5" HINT: EXAMPLE: Cylinder block "11" + Crankshaft "06" = Total number 17 (Use bearing "3") Crankshaft main journal diameter Number Mark No. 1 No. 2 No. 3 No. 1 and No. 4 Journal Bearing 21.0 mm (0.827 in.) If replacing a bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then refer to the table below for the appropriate bearing number. There are 5 sizes of standard bearings, marked "1", "2", "3", "4" and "5" accordingly. Journal bearings: No. 4 No. 2 and No. 3 Journal Bearing 18.0 mm (0.709 in.) A125230E02 Mark Diameter "00" 60.999 to 61.000 mm (2.4015 to 2.4016 in.) "01" 60.998 to 60.999 mm (2.4015 to 2.4015 in.) "02" 60.997 to 60.998 mm (2.4015 to 2.4015 in.) "03" 60.996 to 60.997 mm (2.4014 to 2.4015 in.) "04" 60.995 to 60.996 mm (2.4014 to 2.4014 in.) "05" 60.994 to 60.995 mm (2.4013 to 2.4014 in.) "06" 60.993 to 60.994 mm (2.4013 to 2.4013 in.) "07" 60.992 to 60.993 mm (2.4013 to 2.4013 in.) "08" 60.991 to 60.992 mm (2.4012 to 2.4013 in.) "09" 60.990 to 60.991 mm (2.4012 to 2.4012 in.) "10" 60.989 to 60.990 mm (2.4011 to 2.4012 in.) "11" 60.988 to 60.989 mm (2.4011 to 2.4011 in.) Standard upper bearing center wall thickness (No. 1 and No. 4 journal) Mark Thickness "1" 2.500 to 2.503 mm (0.0984 to 0.0985 in.) "2" 2.503 to 2.506 mm (0.0985 to 0.0987 in.) "3" 2.506 to 2.509 mm (0.0987 to 0.0988 in.) "4" 2.509 to 2.512 mm (0.0988 to 0.0989 in.) "5" 2.512 to 2.515 mm (0.0989 to 0.0990 in.) Standard lower bearing center wall thickness (No. 1 and No. 4 journal) Mark Thickness "1" 2.478 to 2.481 mm (0.0976 to 0.0977 in.) "2" 2.481 to 2.484 mm (0.0977 to 0.0978 in.) "3" 2.484 to 2.487 mm (0.0978 to 0.0979 in.) "4" 2.487 to 2.490 mm (0.0979 to 0.0980 in.) "5" 2.490 to 2.493 mm (0.0980 to 0.0981 in.) EM EM–112 2GR-FE ENGINE MECHANICAL – ENGINE UNIT Standard upper bearing center wall thickness (No. 2 and No. 3 journal) Mark Thickness "1" 2.478 to 2.481 mm (0.0976 to 0.0977 in.) "2" 2.481 to 2.484 mm (0.0977 to 0.0978 in.) "3" 2.484 to 2.487 mm (0.0978 to 0.0979 in.) "4" 2.487 to 2.490 mm (0.0979 to 0.0980 in.) "5" 2.490 to 2.493 mm (0.0980 to 0.0981 in.) Standard lower bearing center wall thickness (No. 2 and No. 3 journal) EM Measuring Point 40 mm (1.57 in.) A125160E02 Mark Thickness "1" 2.500 to 2.503 mm (0.0984 to 0.0985 in.) "2" 2.503 to 2.506 mm (0.0985 to 0.0987 in.) "3" 2.506 to 2.509 mm (0.0987 to 0.0988 in.) "4" 2.509 to 2.512 mm (0.0988 to 0.0989 in.) "5" 2.512 to 2.515 mm (0.0989 to 0.0990 in.) 43. INSPECT CRANKSHAFT BEARING CAP SET BOLT (a) Using vernier calipers, measure the minimum diameter of the compressed thread at the measuring point. Standard diameter: 10.8 to 11.0 mm (0.4252 to 0.4331 in.) Minimum diameter: 10.7 mm (0.4213 in.) Measuring Point: 40 mm (1.57 in.) If the diameter is less than the minimum, replace the bolt. EM–113 2GR-FE ENGINE MECHANICAL – ENGINE UNIT REASSEMBLY 1. INSTALL STRAIGHT PIN (a) Using a plastic hammer, tap in new straight pins to the cylinder block. Front Cylinder Block: Rear Cylinder Block: C C A B B EM Upper Cylinder Block: Lower Cylinder Block: B D D B Cylinder Block RH Side: 23 mm (0.906 in.) 6 mm (0.236 in.) A B 11 mm (0.433 in.) 9 mm (0.354 in.) B C D Standard protrusion Item Protrusion Pin A 23 mm (0.906 in.) Pin B 6 mm (0.236 in.) Pin C 11 mm (0.433 in.) A131842E02 EM–114 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 2. Front Cylinder Block: Item Protrusion Pin D 9 mm (0.354 in.) INSTALL STUD BOLT (a) Using E8 and E10 "torx" sockets, install the stud bolts. LH Side: A A B EM 12 mm (0.472 in.) 23 mm (0.906 in.) 52 mm (2.047 in.) 15 mm (0.591 in.) 12 mm (0.472 in.) A 40 mm (1.575 in.) B A134958E01 Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) for bolt A 17 N*m (173 kgf*cm, 13 ft.*lbf) for bolt B 3. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY (a) Using a 5 mm hexagon wrench, install the oil nozzles. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 4. INSTALL PISTON SUB-ASSEMBLY WITH PIN (a) Using a screwdriver, install a new snap ring at one end of the piston pin hole. HINT: Be sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston. A120734 Service Hole A131876E01 2GR-FE ENGINE MECHANICAL – ENGINE UNIT EM–115 (b) Gradually heat the piston to approximately 80°C (176°F). (c) Coat the piston pin with engine oil. 80°C (176°F) A125895E02 (d) Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb. HINT: The piston and pin are a matched set. Front Mark EM A131878E01 (e) Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin. A107551 (f) Service Hole 5. A131879E01 Using a screwdriver, install a new snap ring at the other end of the piston pin hole. HINT: Be sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston. INSTALL PISTON RING SET (a) Install the oil ring expander and 2 side rails by hand. EM–116 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Using a piston ring expander, install the oil ring rail as shown in the illustration. Piston Ring Expander Side Rail Upper No. 1 Ring EM No. 2 Ring Oil Ring Expander Oil Ring Side Rail Lower A131880E01 (c) Position the piston rings so that the ring ends are as shown in the illustration. NOTICE: Do not align the ring ends. Side Rail Lower No. 2 Ring Front Mark Oil Ring Expander No. 1 Ring Side Rail Upper A131881E01 6. No. 1 and No. 4 Journal Bearing 21.0 mm (0.827 in.) No. 2 and No. 3 Journal Bearing 18.0 mm (0.709 in.) A124282E02 INSTALL CRANKSHAFT BEARING (a) Clean the main journal and both surfaces of the bearing. NOTICE: Main bearings come in widths between 18.0 mm (0.709 in.) and 21.0 mm (0.827 in.). Install the 21.0 mm (0.827 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 18.0 mm (0.709 in.) bearings in the No. 2 and No. 3 positions. 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Install the upper bearing. (1) Install the upper bearings to the cylinder block as shown in the illustration. NOTICE: • Do not apply engine oil to the bearings and the contact surfaces. • Both sides of the oil groove in the cylinder block should be visible through the oil feed holes in the bearing. The amount visible on each side of the holes should be equal. Upper Bearing CORRECT EM–117 INCORRECT EM A094746E04 (c) Install the lower bearing. (1) Install the lower bearings to the bearing caps. (2) Using vernier calipers, measure the distance between the bearing cap's edge and the lower bearing's edge. Dimension (A - B): 0.7 mm (0.0276 in.) or less NOTICE: Do not apply engine oil to the bearings and the contact surfaces. Vernier Calipers Mark 1, 2, 3, 4 or 5 7. INSTALL CRANKSHAFT THRUST WASHER SET (a) Apply engine oil to the crankshaft thrust washer. A131826E01 (b) Install the 2 thrust washers under the No. 2 journal position of the cylinder block with the oil grooves facing outward. 8. Oil Grooves A106233E02 INSTALL CRANKSHAFT (a) Apply engine oil to the upper bearing, then place the crankshaft on the cylinder block. EM–118 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Confirm the projection and numbers of the main bearing caps and install the bearing caps on the cylinder block. HINT: A number is marked on each main bearing cap to indicate the installation position. (c) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts. (d) Temporarily install the 8 main bearing cap bolts to the inside positions. Projection Number Mark A121711E02 (e) Insert the main bearing cap with your hand until the clearance between the main bearing cap and the cylinder block is less than 6 mm (0.23 in.) by marking the 2 internal bearing cap bolts as a guide. Bolt length: 100 to 102 mm (3.94 to 4.02 in.) EM Less than 6 mm (0.23 in.) Bolt Length 100 to 102 mm (3.94 to 4.02 in.) A134893E01 (f) Using a plastic hammer, lightly tap the bearing cap to ensure a proper fit. (g) Apply a light coat of engine oil to the threads and under the heads of the 8 main bearing cap bolts. A131829 EM–119 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (h) Install the 8 main bearing cap bolts to the outside positions. (i) Install the crankshaft bearing cap bolts. HINT: The main bearing cap bolts are tightened in 2 progressive steps. Bolt Length 105.5 to 107.5 mm (4.15 to 4.23 in.) EM A134894E01 (j) 15 11 9 13 7 3 1 5 8 4 2 6 16 12 10 14 Step 1 (1) Install and uniformly tighten the 16 main bearing cap bolts in the sequence shown in the illustration. Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf) If any of the main bearing cap bolts does not meet the torque specified, replace it. A134892E02 Paint Mark 90° Engine Front (k) Step 2 (1) Mark the front of the bearing cap bolts with paint. (2) Retighten the bearing cap bolts by 90° in the order above. (3) Check that the painted mark is now at a 90° angle to the front. A051462E03 (l) 4 (A) 1 2 3 7 6 5 8 A129721E05 Install 8 new seal washers and uniformly tighten the 8 main bearing cap bolts in several steps and in the sequence shown in the illustration. Torque: 52 N*m (525 kgf*cm, 38 ft.*lbf) Bolt length Item Length Bolt A 45 mm (1.77 in.) Except bolt A 30 mm (1.18 in.) (m) Check that the crankshaft turns smoothly. EM–120 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (n) Check the crankshaft thrust clearance (See page EM-104). 9. INSTALL CONNECTING ROD BEARING (a) Install the connecting rod bearing to the connecting rod and bearing cap. (b) Using vernier calipers, measure the distance between the connecting rod's and bearing cap's edges and the connecting rod bearing's edge. Dimension (A - B): 0.7 mm (0.0276 in.) or less NOTICE: Do not apply engine oil to the bearings and the contact surfaces. 10. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD (a) Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings. Vernier Calipers EM A B A094752E02 (b) Position the piston rings so that the ring ends are as shown in the illustration. NOTICE: Do not align the ring ends. Side Rail Lower No. 2 Ring Front Mark Oil Ring Expander No. 1 Ring Side Rail Upper A131881E01 2GR-FE ENGINE MECHANICAL – ENGINE UNIT EM–121 (c) Using a piston ring compressor, push the correctly numbered piston and connecting rod assembly into the cylinder with the front mark of the piston facing forward. NOTICE: Match the numbered connecting rod cap with the connecting rod. Engine Front Front Mark A131886E01 (d) Check that the front mark of the connecting rod cap is facing forward. (e) Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts. (f) Install the connecting cap bolts. HINT: The connecting cap bolts are tightened in 2 progressive steps. Engine Front Front Mark A129760E02 (g) Step 1 (1) Install and alternately tighten the bolts of the connecting rod cap in several steps. Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) A131887 Painted Mark 90° Front A101478E07 (h) Step 2 (1) Mark the front side of each connecting cap bolt with paint. (2) Retighten the cap bolts by 90° as shown in the illustration. (3) Check the painted mark is now at a 90° angle to the front. (i) Check that the crankshaft turns smoothly. (j) Check the connecting rod thrust clearance (See page EM-103 ). EM EM–122 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 11. INSTALL INTAKE VALVE GUIDE BUSH (a) Using a caliper gauge, measure the bush bore diameter of the cylinder head. Cylinder bore diameter: 10.285 to 10.306 mm (0.4049 to 0.4057 in.) Select a new guide bush (STD or O/S 0.05) Bush size Bush bore diameter STD 10.285 to 10.306 mm (0.4049 to 0.4057 in.) O/S 0.05 10.335 to 10.356 mm (0.4069 to 0.4077 in.) A109626 If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 in.) to install a O/S 0.05 valve guide bush. If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head. (b) Heat the cylinder head to 80 to 100°C (176 to 212°F). (c) Place the cylinder head on wooden blocks. EM (d) Using SST, tap in new valve guide bushes to the specified protrusion height. SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) Protrusion height: 9.30 to 9.70 mm (0.3661 to 0.3819 in.) SST Protrusion Height A120710E03 (e) Using a sharp 5.5 mm reamer, ream the valve guide bushings to obtain the specified clearance. Standard oil clearance: 0.025 to 0.060 mm (0.0010 to 0.0023 in.) A131839 12. INSTALL EXHAUST VALVE GUIDE BUSH (a) Using a caliper gauge, measure the bush bore diameter of the cylinder head. Cylinder bore diameter: 10.285 to 10.306 mm (0.4049 to 0.4057 in.) Select a new guide bush (STD or O/S 0.05) Bush size A109628 Bush bore diameter STD 10.285 to 10.306 mm (0.4049 to 0.4057 in.) O/S 0.05 10.335 to 10.356 mm (0.4069 to 0.4077 in.) 2GR-FE ENGINE MECHANICAL – ENGINE UNIT EM–123 If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 in.) to install a O/S 0.05 valve guide bush. If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head. (b) Heat the cylinder head to 80 to 100°C (176 to 212°F). (c) Place the cylinder head on wooden blocks. (d) Using SST, tap in new valve guide bushes to the specified protrusion height. SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) Protrusion height: 9.30 to 9.70 mm (0.3661 to 0.3819 in.) Protrusion Height SST EM A120712E04 (e) Using a sharp 5.5 mm reamer, ream the valve guide bushings to obtain the specified clearance. Standard oil clearance: 0.030 to 0.065 mm (0.0012 to 0.0026 in.) A096429 13. INSTALL RING PIN (a) Using a plastic hammer, tap in new ring pins to the specified protrusion height. Specified protrusion height: 2.5 to 3.5 mm (0.098 to 0.138 in.) RH Bank: LH Bank: 2.5 to 3.5 mm (0.098 to 0.138 in.) A131888E01 EM–124 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 14. INSTALL NO. 1 STRAIGHT SCREW PLUG (a) Using a 10 mm hexagon wrench, install 4 new gaskets and the straight screw plugs. Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf) RH Bank: LH Bank: EM A129718E01 15. INSTALL NO. 2 STRAIGHT SCREW PLUG (a) Using a 14 mm hexagon wrench, install 2 new gaskets and the 2 straight screw plugs. Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf) LH Bank: 16. INSTALL STUD BOLT NOTICE: If the stud bolt is deformed or the threads are damaged, replace it. RH Bank: A129719E01 EM–125 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (a) Using E6 and E8 "torx" sockets, install the stud bolts. Rear Side RH: Intake Side RH: B B C Intake Side LH: Exhaust Side RH: EM B B Exhaust Side LH: Rear Side LH: A 20 mm (0.79 in.) 13 mm (0.51 in.) A A A C A 16 mm (0.63 in.) 35 mm (1.38 in.) 12 mm (0.47 in.) B 16 mm (0.63 in.) 34 mm (1.34 in.) 9 mm (0.35 in.) 27 mm (1.06 in.) C A134987E01 Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) for bolts A and B 4.0 N*m (41 kgf*cm, 35 in.*lbf) for bolt C EM–126 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 17. INSTALL STRAIGHT PIN (a) Using a plastic hammer, tap in new straight pins as shown in the illustration. LH Bank: RH Bank: 34 mm (1.34 in.) 17.5 to 19.5 mm (0.69 to 0.77 in.) A131890E01 Protrusion height: 17.5 to 19.5 mm (0.689 to 0.768 in.) 18. INSTALL VALVE SPRING SEAT (a) Install the valve spring seats to the cylinder head. EM Gray Intake Side Black Exhaust Side A094934E04 19. INSTALL VALVE STEM OIL SEAL (a) Apply a light coat of engine oil to new oil seals. NOTICE: Pay attention when installing the intake and exhaust oil seals. For example, installing the intake oil seal into the exhaust side or installing the exhaust oil seal to the intake side can cause installation problems later. HINT: The intake valve oil seals are gray and the exhaust valve oil seals are black. (b) Using SST, push in the oil seals. SST 09201-41020 NOTICE: Failure to use SST will cause the seal to be damaged or improperly seated. SST CORRECT INCORRECT A124592E02 2GR-FE ENGINE MECHANICAL – ENGINE UNIT EM–127 20. INSTALL EXHAUST VALVE (a) Apply a sufficient coat of engine oil to the tip area of the intake valve shown in the illustration. (b) Install the valve, compression spring and spring retainer to the cylinder head. NOTICE: Install the same parts in the same combination to the original locations. 30 mm (1.18 in.) or more A094936E04 (c) Using SST, compress the spring and install the 2 retainer locks. SST 09202-70020 (09202-00010) SST EM A129715E01 (d) Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit. NOTICE: Be careful not to damage the retainer. A131896 30 mm (1.18 in.) or more 21. INSTALL INTAKE VALVE (a) Apply a sufficient coat of engine oil to the tip area of the intake valve shown in the illustration. (b) Install the valve, compression spring and spring retainer to the cylinder head. NOTICE: Install the same parts in the same combination to the original locations. A094935E05 (c) Using SST, compress the spring and install the 2 retainer locks. SST 09202-70020 (09202-00010) SST A129714E01 EM–128 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (d) Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit. NOTICE: Be careful not to damage the retainer. 22. INSTALL VALVE STEM CAP (a) Apply a light coat of engine oil to the valve stem caps. (b) Install the valve stem caps on the valves. A131894 23. INSTALL ENGINE REAR OIL SEAL (a) Place the oil seal retainer on wooden blocks. (b) Using SST, tap in a new oil seal until its surface is flush with the oil seal retainer edge. SST 09223-15030, 09950-70010 (09951-07100) NOTICE: • Keep the lip free of foreign matter. • Do not tap on the oil seal at an angle. SST EM A120675E01 24. INSTALL ENGINE REAR OIL SEAL RETAINER (a) Apply seal packing in a continuous line as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal Diameter: 2.0 to 3.0 mm (0.079 to 0.118 in.) NOTICE: • Remove any oil from the contact surface. • Install the oil seal retainer within 3 minutes after applying seal packing. • Do not start the engine for at least 2 hours after installation. 2.0 to 3.0 (0.079 to 0.118) mm (in.) : Seal Packing A131897E02 (b) Install the oil seal retainer with the 6 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTICE: Be sure to apply adhesive 1324 to the bolts in the places indicated by A before installing them. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent A A A129686E01 2GR-FE ENGINE MECHANICAL – ENGINE UNIT EM–129 25. INSTALL WATER INLET PIPE (a) Install the water inlet pipe with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) (b) Install the water by-pass hose No. 1. A120668 Lot No. Engine Front A131898E01 7 2 4 6 5 3 1 8 26. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH (a) Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward. NOTICE: • Be careful of the installation direction. • Gently place the cylinder head in order not to damage the gasket with the bottom part of the head. (b) Place the cylinder head on the cylinder block. NOTICE: Be careful not to allow oil to adhere to the bottom part of the cylinder head. HINT: The cylinder head bolts are tightened in 3 progressive steps. (c) Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts. (d) Step 1 (1) Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps and in the sequence shown in the illustration. Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) A129712E02 90° 90° Engine Front Painted Mark A035289E02 (e) Step 2 (1) Mark the cylinder head bolt head with paint as shown in the illustration. (2) Tighten the cylinder head bolts another 90°. (f) Step 3 (1) Tighten the cylinder head bolts by an additional 90°. (2) Check that the painted mark is now facing rearward. EM EM–130 2GR-FE ENGINE MECHANICAL – ENGINE UNIT Engine Front Lot No. A131900E01 EM 8 1 6 4 3 2 5 27. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH (a) Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward. NOTICE: • Be careful of the installation direction. • Gently place the cylinder head in order not to damage the gasket with the bottom part of the head. (b) Place the cylinder head on the cylinder block. NOTICE: Be careful not to allow oil to adhere to the bottom part of the cylinder head. HINT: The cylinder head bolts are tightened in 3 progressive steps. (c) Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts. (d) Step 1 (1) Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps in the sequence shown in the illustration. Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) 7 A129711E02 90° 90° Engine Front Painted Mark (e) Step 2 (1) Mark the cylinder head bolt head with paint as shown in the illustration. (2) Tighten the cylinder head bolts by 90°. (f) Step 3 (1) Tighten the cylinder head bolts by an additional 90°. (2) Check that the painted mark is now facing rearward. A035289E02 (g) Tighten the 2 bolts in the order shown in the illustration. Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 1 2 A129710E02 28. INSTALL VALVE LASH ADJUSTER ASSEMBLY NOTICE: • Keep the lash adjuster free of dirt and foreign objects. • Only use clean engine oil. (a) Place the lash adjuster into a container filled with engine oil. 2GR-FE ENGINE MECHANICAL – ENGINE UNIT INCORRECT CORRECT SST Taper Part Plunger Low Pressure Chamber Check Ball High Pressure Chamber SST High Pressure Chamber EM–131 (b) Insert the SST's tip into the lash adjuster's plunger and use the tip to press down on the check ball inside the plunger. SST 09276-75010 (c) Squeeze the SST and lash adjuster together to move the plunger up and down 5 to 6 times. (d) Check the movement of the plunger and bleed the air. OK: Plunger moves up and down. NOTICE: When bleeding air from the high-pressure chamber, make sure that the tip of the SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, air will not bleed. (e) After bleeding the air, remove the SST. Then, try to press the plunger quickly and firmly with a finger. OK: Plunger is very difficult to move. If the result is not as specified, replace the lash adjuster. (f) Install the lash adjusters. NOTICE: Install the lash adjuster to the same place it was removed from. 29. INSTALL NO. 1 VALVE ROCKER ARM SUBASSEMBLY (a) Apply engine oil to the lash adjuster tip and valve stem cap end. A109630E01 (b) Make sure that the valve rocker arms are installed as shown in the illustration. Valve Rocker Arm 30. INSTALL CAMSHAFT BEARING CAP (for Bank 1) (a) Apply engine oil to the camshaft journals, camshaft housing and bearing caps. (b) Install the camshaft and No. 2 camshaft to the camshaft housing RH. Lash Adjuster Valve Stem Valve Stem Cap A131901E01 (c) Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction. A131902 EM EM–132 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 7 3 (d) Temporarily tighten the 8 bolts in the order shown in the illustration. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 1 5 4 8 6 2 A131903E01 31. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH (a) Make sure that the valve rocker arm is installed as shown in the illustration. Valve Rocker Arm Lash Adjuster EM Valve Stem Cap Valve Stem A131901E01 (b) Apply seal packing in a continuous line as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter: 3.5 to 4.5 mm (0.138 to 0.177 in.) NOTICE: • Remove any oil from the contact surface. • Install the camshaft housing sub-assembly RH within 3 minutes. • Do not start the engine for at least 2 hours after installing. 3.5 to 4.5 (0.138 to 0.177) mm (in.) : Seal Packing 9 6 7 4 8 A131904E01 3 12 1 5 10 2 Front View 11 45° Knock Pin A131905E01 (c) Install the camshaft housing RH and tighten the 12 bolts in the order shown in the illustration. Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) NOTICE: • When installing the camshaft housing RH, it is necessary to correctly position the camshafts as shown in the illustration. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur. • If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing. 2GR-FE ENGINE MECHANICAL – ENGINE UNIT EM–133 • If the camshaft housing is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages. 4 8 3 7 2 6 (d) Tighten the 8 bolts in the order shown in the illustration. Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) 1 32. INSTALL CAMSHAFT BEARING CAP (for Bank 2) (a) Apply engine oil to the camshaft journals, camshaft housing and bearing caps. (b) Install the No. 3 camshaft and No. 4 camshaft to the camshaft housing LH. 5 A129701E02 (c) Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction. A134960 1 3 5 7 6 8 2 (d) Temporarily tighten the 8 bolts in the order shown in the illustration. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 4 A132217E01 33. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH (a) Make sure that the valve rocker arm is installed as shown in the illustration. Valve Rocker Arm Lash Adjuster Valve Stem Valve Stem Cap A131901E01 EM EM–134 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Apply seal packing in a continuous line as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter: 3.5 to 4.5 mm (0.138 to 0.177 in.) NOTICE: • Remove any oil from the contact surface. • Install the camshaft housing sub-assembly LH within 3 minutes. • Do not start the engine for at least 2 hours after installing. 3.5 to 4.5 (0.138 to 0.177) mm (in.) : Seal Packing A132218E01 EM 9 7 8 3 1 6 4 2 12 13 10 5 11 Front View Knock Pin A132219E01 (c) Install the camshaft housing LH and tighten the 13 bolts in the order shown in the illustration. Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) NOTICE: • When installing the camshaft housing LH, it is necessary to correctly position the camshafts as shown in the illustration. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur. • If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing. • If the camshaft housing is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages. (d) Tighten the 8 bolts in the order shown in the illustration. Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) 1 2 3 4 5 6 7 8 A134891E02 2GR-FE ENGINE MECHANICAL – ENGINE UNIT Push EM–135 34. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY (a) Install the No. 2 chain tensioner with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) (b) While pushing in the tensioner, insert a pin of φ 1.0 mm (0.039 in.) into the hole to fix it. Pin Plunger A121265E02 35. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) (a) Align the mark plate (yellow) with the timing marks (1-dot mark) of the camshaft timing gears as shown in the illustration. (b) Apply a light coat of engine oil to the bolt threads and bolt-seating surface. (c) Align the knock pin of the camshaft with the pin hole of the camshaft timing gear. Install the camshaft timing gear and camshaft timing exhaust gear RH with the No. 2 chain installed. Timing Marks Mark Plate A124048E02 (d) Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts. Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf) (e) Remove the pin from the chain tensioner. Hold Turn A121640E01 EM EM–136 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 36. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY (a) Install the chain tensioner with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) (b) While pushing in the tensioner, insert a pin of φ 1.0 mm (0.039 in.) into the hole to hold it. Plunger Pin Push A121266E02 37. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) (a) Align the mark plate (yellow) with the timing marks (2-dot mark) of the camshaft timing gears as shown in the illustration. (b) Apply a light coat of engine oil to the bolt threads and bolt-seating surface. (c) Align the knock pin of the camshaft with the pin hole of the camshaft timing gear. Install the camshaft timing gear and camshaft timing exhaust gear LH with the No. 2 chain installed. Timing Marks EM Mark Plate A124049E03 Turn Hold (d) Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts. Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf) (e) Remove the pin from the chain tensioner. A121641E02 38. INSTALL NO. 1 CHAIN VIBRATION DAMPER (a) Install the chain vibration damper with the 2 bolts. Torque: 23 N*m (230 kgf*cm, 17 ft.*lbf) 39. INSTALL NO. 2 CHAIN VIBRATION DAMPER (a) Install the 2 chain vibration dampers. A120649 2GR-FE ENGINE MECHANICAL – ENGINE UNIT EM–137 40. INSTALL CRANKSHAFT TIMING SPROCKET (a) Install the 2 timing gear set keys and timing sprocket as shown in the illustration. A109720 Knock Pin A132222E01 41. INSTALL IDLE SPROCKET ASSEMBLY (a) Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft. (b) Temporarily install the No. 1 idle gear shaft and idle sprocket with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear with the knock pin groove of the cylinder block. NOTICE: Be careful of the idle gear direction. HINT: Check that no foreign objects are on the idle gear shafts No. 1 and No. 2. (c) Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft. Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf) HINT: After installing the idle sprocket assembly, check that the idle sprocket turns smoothly. 42. INSTALL CHAIN SUB-ASSEMBLY (a) Align the mark plate and timing marks as shown in the illustration and install the chain. HINT: The camshaft mark plate is orange. Mark Plate Mark Plate Timing Mark A132223E02 EM EM–138 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Do not pass the chain over the crankshaft, just put it on it. A134890 (c) Turn the camshaft timing gear assembly on the RH bank counterclockwise to tighten the chain between the banks. NOTICE: When the idle sprocket is reused, align the chain plate with the mark where the plate had been in order to tighten the chain between the banks. Turn EM When the idle sprocket is reused: Mark Align Chain Plate A122184E04 (d) Align the mark plate and timing mark as shown in the illustration and install the chain onto the crankshaft timing sprocket. HINT: The crankshaft mark plate is yellow. (e) Temporarily tighten the pulley set bolt. Mark Plate Timing Marks A132224E01 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (f) Center Line EM–139 Turn the crankshaft clockwise to set it to the RH block bore center line (TDC / compression). 43. INSTALL CHAIN TENSIONER SLIPPER (a) Install the chain tensioner slipper. Timing Marks A129691E02 44. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (a) Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner. (b) Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate. Stopper Plate EM Plunger A132225E01 (c) Install the chain tensioner with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) A095165 EM–140 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (d) Remove the hexagon wrench of the chain tensioner. Check that each timing mark is aligned with the crankshaft at the TDC / compression. (e) Remove the pulley set bolt. Timing Marks Timing Marks EM Center Line Timing Mark A134895E01 45. INSTALL TIMING CHAIN CASE OIL SEAL (a) Using SST, tap in a new oil seal until its surface is flush with the timing gear case edge. SST 09223-22010, 09506-35010 NOTICE: • Keep the lip free of foreign matter. • Do not tap on the oil seal at an angle. • Make sure that the oil seal edge does not stick out of the timing chain case. SST A125109E04 46. INSTALL WATER PUMP ASSEMBLY (a) Install a new gasket and the water pump with the 8 bolts. Torque: 9.1 N*m (93 kgf*cm, 81 in.*lbf) NOTICE: Be sure to replace the bolts indicated by A with new ones or reuse them after applying adhesive 1344. A A A132227E03 EM–141 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 47. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY (a) Apply seal packing in a continuous line to the engine unit as shown in the following illustration. C C A A A C C C A EM : Seal Packing 3.0 mm or more (0.118 in.) A132228E01 Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter: 3.0 mm (0.118 in.) NOTICE: • Be sure to clean and degrease the contact surfaces, especially the surfaces indicated by C in the illustration. • When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing. • Install the chain cover within 3 minutes. • Do not start the engine for at least 2 hours after installing. EM–142 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Apply seal packing in a continuous line to the timing chain cover as shown in the following illustration. Be sure to apply seal packing C C 20 mm (0.787 in.) 20 mm (0.787 in.) A A B B EM Be sure to apply seal packing A-A 5.0 mm (0.197 in.) 3.0 to 4.0 mm (0.118 to 0.158 in.) B-B 1.0 to 2.0 mm (0.039 to 0.079 in.) C-C 2.0 to 3.0 mm (0.079 to 0.118 in.) Dashed line area (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent) Continuous line area (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent) Alternate long and short dashed line area (Seal packing: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or Equivalent) Diagonal line area (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent) A134901E01 Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Toyota Genuine Seal Packing Black 1282B, Three Bond 1282B or equivalent EM–143 2GR-FE ENGINE MECHANICAL – ENGINE UNIT NOTICE: • When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing. • Install the chain cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing. • Do not start the engine for at least 2 hours after installing. Apply seal packing as follows Area Seal Packing Diameter Application Position from Inside Seal Line Continuous Line Area 4.5 mm or more (0.177 in.) 3.0 to 4.0 mm (0.118 to 0.158 in.) Alternate Long and Dashed Line Area 3.5 mm or more (0.138 in.) 2.0 to 3.0 mm (0.079 to 0.118 in.) Dashed Line Area 3.5 mm or more (0.138 in.) 3.0 to 4.0 mm (0.118 to 0.158 in.) Diagonal Line Area 6.0 mm or more (0.236 in.) 5.0 mm (0.197 in.) (c) Install a new gasket. EM A128017E01 (d) Align the oil pump's drive rotor spline and the crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft. (e) Temporarily tighten the timing chain cover with the 23 bolts and 2 nuts. Crankshaft Drive Rotor Spline A132229E02 Area 4 C A C C C C B B B C C B C B B B B B B C Nut Area 4 Area 4 B Area 2 C Area 1 Area 1 Area 3 B Area 3 Nut A128019E02 EM–144 2GR-FE ENGINE MECHANICAL – ENGINE UNIT Bolt length Item Length Bolt A 40 mm (1.57 in.) Bolt B 55 mm (2.17 in.) Bolt C 25 mm (0.98 in.) NOTICE: Make sure that there is no oil on the bolt threads. (f) Fully tighten the bolts in this order: Area 1 and Area 2. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) (g) Fully tighten the bolts and nuts in this order: Area 3. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) HINT: Tighten the bolts and nuts in the order of upper to lower as shown in the illustration. (h) Fully tighten the bolts in this order: Area 4. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) for bolt A 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolts except bolt A HINT: Tighten the bolts in the order of lower to upper as shown in the illustration. (i) Install a new gasket and the chain cover plate with the 4 bolts. Torque: 9.1 N*m (93 kgf*cm, 81 in.*lbf) EM 48. INSTALL WATER INLET HOUSING (a) Install 2 new O-rings. HINT: Apply a small amount of water or soapy water to Oring (A) in the illustration before installing it. A A129675E01 2GR-FE ENGINE MECHANICAL – ENGINE UNIT EM–145 (b) Install the stud bolts. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 9 mm (0.35 in.) 25 mm (0.98 in.) 9 mm (0.35 in.) EM A137975E01 Nut A134879E01 10° (c) Install the water inlet with the 2 bolts and nut. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTICE: Be careful that the O-ring does not get caught between the parts. (d) Connect the water by-pass hose No. 1. (e) Apply adhesive around the drain cock. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent (f) Install the housing drain cock to the water inlet housing. Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) (g) Install the housing plug to the water drain cock. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) (h) Install a new gasket to the thermostat. (i) 10° A134896E01 Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat in the water inlet housing. HINT: The jiggle valve may be set within 10° of either side of the prescribed positions. EM–146 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (j) Install the water inlet with the 2 nuts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) A129673 Stud Bolt EM 14 mm (0.55 in.) 13 mm (0.51 in.) 49. INSTALL FRONT ENGINE MOUNTING BRACKET NO. 1 LH (a) Install the engine mounting bracket with the 6 bolts. Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) NOTICE: • Install the water inlet and mounting bracket within 15 minutes after installing the chain cover. • Do not start the engine for at least 2 hours after installation. (b) When replacing a stud bolt, install it by using an E8 "torx" socket wrench. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 29 mm (1.14 in.) A134961E01 50. INSTALL OIL PAN BAFFLE PLATE (a) Install the oil pan baffle plate with the 7 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) HINT: Temporarily tighten the 7 bolts. Fully tighten 2 bolts A as shown in the illustration before tightening the other bolts. A A A129685E01 EM–147 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 51. INSTALL OIL PAN SUB-ASSEMBLY (a) When replacing a stud bolt, install it by using an E8 "torx" socket wrench. Timing Chain Cover: Lower Cylinder Block: 16 mm (0.63 in.) 34 mm (1.34 in.) 12 mm (0.47 in.) A134962E01 Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) (b) Install 2 new O-rings. A129684 3.0 to 4.0 mm (0.118 to 0.156 in.) : Seal Packing A132232E01 (c) Apply seal packing in a continuous line as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter: 3.0 to 4.0 mm (0.118 to 0.156 in.) NOTICE: • Remove any oil from the contact surface. • Install the oil pan within 3 minutes after applying seal packing. • Do not start the engine for at least 2 hours after installing. EM EM–148 2GR-FE ENGINE MECHANICAL – ENGINE UNIT Nut A (d) Install the oil pan with the 16 bolts and 2 nuts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) for bolt A 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolts except A A Nut A129682E01 52. INSTALL OIL STRAINER SUB-ASSEMBLY (a) Using an E6 "torx" socket, install the stud bolts as shown in the illustration. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) Timing Chain Cover: EM 16 mm (0.63 in.) 27 mm (1.06 in.) 9 mm (0.35 in.) A134963E01 (b) Install a new gasket and the oil strainer with the bolt and 2 nuts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Nut Nut A129681E01 53. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY (a) Using an E6 "torx" socket, install the stud bolts as shown in the illustration. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 9 mm (0.35 in.) 20 mm 9 mm (0.35 in.) (0.79 in.) A134964E01 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 3.0 to 4.0 mm (0.118 to 0.156 in.) : Seal Packing A132234E02 EM–149 (b) Apply seal packing in a continuous line as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter: 3.0 to 4.0 mm (0.118 to 0.156 in.) NOTICE: • Remove any oil from the contact surface. • Install the oil pan No. 2 within 3 minutes after applying seal packing. • Do not start the engine for at least 2 hours after installing. (c) Install the oil pan with the 16 bolts and 2 nuts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Nut EM Nut A129680E01 54. INSTALL OIL PAN DRAIN PLUG (a) Install a new gasket and the drain plug. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) A129654 : Seal Packing A132236E01 55. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1) (a) Apply seal packing as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent NOTICE: • Remove any oil from the contact surface. • Install the head cover within 3 minutes after applying seal packing. • Do not start the engine for at least 2 hours after installing. EM–150 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Install 3 new gaskets as shown in the illustration. (c) Install a new gasket to the head cover. A129699 5 2 6 7 4 1 8 12 EM A (d) Install a head cover with the 12 bolts and a new washer. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolt A 10 N*m (102 kgf*cm, 7 ft.*lbf) for bolts except A HINT: Make sure the tightening torque of bolt 1. 9 11 3 10 A129679E01 : Seal Packing A132237E01 56. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2) (a) Apply seal packing as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent NOTICE: • Remove any oil from the contact surface. • Install the head cover within 3 minutes after applying seal packing. • Do not start the engine for at least 2 hours after installing. (b) Install 3 new gaskets as shown in the illustration. (c) Install a new gasket to the head cover. A129705 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 2 7 8 9 6 1 5 A 10 12 11 EM–151 (d) Install the head cover with the 12 bolts and a new washer. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolt A 10 N*m (102 kgf*cm, 7 ft.*lbf) for bolts except A HINT: Make sure the tightening torque of bolts 1 and 10. 3 4 A129678E03 57. INSTALL WATER OUTLET (a) Install 2 new gaskets and a new O-ring. HINT: Apply soapy water to the O-ring. EM A129677 (b) Install the water by-pass joint with the 2 bolts and 4 nuts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) for bolts 10 N*m (103 kgf*cm, 7 ft.*lbf) for nuts NOTICE: Be careful that the O-ring does not get caught between the parts. Nut Nut Nut Nut A129676E01 58. INSTALL CRANKSHAFT PULLEY (a) Align the pulley set key with the key groove of the pulley, and slide on the pulley. (b) Using SST, install the pulley bolt. SST 09213-70011 (09213-70020), 09330-00021 Torque: 250 N*m (2,550 kgf*cm, 184 ft.*lbf) SST Hold Turn SST A122396E01 EM–152 2GR-FE ENGINE MECHANICAL – ENGINE UNIT Oil Filter Element O-Ring A106167E01 59. INSTALL OIL FILTER ELEMENT (a) Clean the inside of the oil filter cap, the threads and O-ring groove. (b) Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap. (c) Set a new oil filter element to the oil filter cap. (d) Remove dirt or foreign matter from the installation surface of the engine. (e) Apply a light coat of engine oil to the O-ring again and install the oil filter cap. NOTICE: • Be careful that the O-ring does not get caught between the parts. • The O-ring must not be twisted on the groove. (f) SST EM No clearance Using SST, tighten the oil filter cap. SST 09228-06501 Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) NOTICE: Make sure that the oil filter is installed securely as shown in the illustration. A132239E01 O-Ring A128003E02 (g) Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap. NOTICE: Remove all dirt and foreign matter from the installation surface. (h) Install the oil filter drain plug to the oil filter cap. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) NOTICE: Make sure that the O-ring does not get caught between the parts. 60. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY (a) Apply adhesive around the drain cocks. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent Adhesive A076531E01 2GR-FE ENGINE MECHANICAL – ENGINE UNIT RH Side: 20° 12° LH Side: 45° 15° A135830E01 Oil Pipe Union Oil Pipe Union A135726E01 EM–153 (b) Install the water drain cocks as shown in the illustration. Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) NOTICE: Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks with the specified torque. (c) Install the water drain cock plugs to the water drain cocks. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) 61. INSTALL NO. 1 OIL PIPE (a) Make sure that there is no foreign matter on the mesh of the oil control valve filter LH. NOTICE: Do not touch the mesh when installing the oil control valve filter. (b) Install the oil control valve filter LH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side). (c) Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt. (d) Tighten the oil pipe union (on the head cover side). Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf) (e) Tighten the oil pipe union (on the cylinder head side). Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf) NOTICE: If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools. 62. INSTALL OIL PIPE (a) Make sure that there is no foreign matter on the mesh of the oil control valve filter RH. NOTICE: Do not touch the mesh when installing the oil control valve filter. Oil Pipe Union (A) Oil Pipe Union A134878E02 (b) Install the oil control valve filter RH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side). (c) Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt. (d) Install the bolt (A) to the cylinder head. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) (e) Tighten the oil pipe union (on the head cover side). Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf) (f) Tighten the oil pipe union (on the cylinder head side). Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf) EM EM–154 2GR-FE ENGINE MECHANICAL – ENGINE UNIT NOTICE: If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools. 63. INSTALL CRANKSHAFT POSITION SENSOR (a) Install the sensor with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) A129663 64. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Install the 4 oil control valves with the 4 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) LH Bank: EM RH Bank: A129662E01 2GR-FE ENGINE MECHANICAL – ENGINE UNIT EM–155 65. INSTALL CAMSHAFT POSITION SENSOR (a) Install the 4 sensors with the 4 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) LH Bank: 66. INSTALL VENTILATION VALVE SUB-ASSEMBLY (a) Apply adhesive around the ventilation valve. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent RH Bank: EM A129656E01 (b) Install the ventilation valve. Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) 67. INSTALL SPARK PLUG (a) Install the 6 spark plugs. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 68. INSTALL OIL FILLER CAP SUB-ASSEMBLY (a) Install a new gasket. (b) Install the oil filler cap. A129655 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–1 POWER WINDOW CONTROL SYSTEM WINDSHIELD / WINDOWGLASS BODY PARTS LOCATION MAIN BODY ECU (INSTRUMENT PANEL J/B) WS POWER WINDOW REGULATOR SWITCH ASSEMBLY (FRONT RH) - POWER FUSE - RR DOOR LH FUSE - RR DOOR RH FUSE POWER WINDOW REGULATOR SWITCH ASSEMBLY (REAR RH) POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY POWER WINDOW REGULATOR SWITCH ASSEMBLY (REAR LH) B137050E01 WS–2 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM POWER WINDOW REGULATOR MOTOR (FRONT RH) DOOR COURTESY SWITCH (FRONT RH) WS POWER WINDOW REGULATOR MOTOR (FRONT LH) DOOR COURTESY SWITCH (REAR RH) DOOR COURTESY SWITCH (FRONT LH) POWER WINDOW REGULATOR MOTOR (REAR LH) POWER WINDOW REGULATOR MOTOR (REAR RH) DOOR COURTESY SWITCH (REAR LH) B137082E01 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–3 SYSTEM DIAGRAM Power Window Regulator Switch Assembly (Front RH) Power Window Regulator Master Switch Assembly from POWER fuse B SU SD PU PD from POWER fuse B U D Power Window Regulator Switch Assembly (Rear RH) from RR DOOR RH fuse B SU SD RRU RRD B SU SD RLU RLD (*1) DN B UP1 (*2) (*2) AUTO E LED U D DWN1 (*2) UP Main Body ECU (*2) (*2) (*1) Power Window Regulator Motor Power Window Regulator Motor (Front LH) Power Window Regulator Motor (Front LH) from PWR fuse Power Window Regulator Motor U D Power Window Regulator Switch Assembly (Rear LH) from RR DOOR LH fuse Power Window Regulator Motor AUTO LED *1: without Jam Protection *2: with Jam Protection LIN (*2) (*2) LIN E : LIN Communication Line B137051E01 WS WS–4 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM SYSTEM DESCRIPTION 1. WS POWER WINDOW CONTROL SYSTEM DESCRIPTION (a) The power window control system controls the power window operation using the power window regulator motors. The main controls of this system are the power window regulator master switch, which is mounted on the driver side door, and the power window regulator switches, which are mounted on the passenger side door and rear doors. Operating a window switch results in electrical power being transmitted to the corresponding power window regulator motor. (b) The power window control system has the following functions: Function Outline Manual up-and-down function Function that causes window to go up while power window switch is being pulled halfway up and to go down while pushed halfway down. Window stops as soon as the switch is released. Driver's door auto up-and-down function * Function that enables windows of driver's doors to be fully opened or closed by one press of power window switch. Jam protection function Function that automatically stops power window and moves it downward if a foreign object gets jammed in door window during autoup operation. Remote control function Function that allows power window master switch to control MANUAL up-and-down operations of front passenger door window and rear door windows. Key-off operation function Function that makes it possible to operate power window for approx. 45 seconds after ignition switch is turned on (ACC) or off, if either front door is not opened. Key-linked up-and-down function Function that causes window to go up while driver's door key is turned to lock side for more than 1.5 seconds and to go down while turned to unlock side for more than 1.5 seconds. Window stops as soon as the key is returned to original position. Diagnosis Function that allows the power window switch to make a diagnosis for failed section when power window switch detects a malfunction in power window system. Power window switch light comes on or blinks to inform driver. Fail-safe A fail-safe function to disable a part of power window functions if pulse sensor in power window motor has a malfunction: Driver's door auto up-and-down function and remote control function are disabled. *: with Jam Protection WS–5 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use the following procedure to troubleshoot the power window control system. • The intelligent tester should be used in steps 3 and 5. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS CHECK AND SYMPTOM CHECK NEXT 3 CHECK COMMUNICATION FUNCTION OF LIN COMMUNICATION SYSTEM (a) Use the intelligent tester, inspect the LIN communication function to ensure there are no malfunctions in the communication system. Result B Result Proceed to No DTCs output A DTCs output B GO TO DIAGNOSIS TROUBLE CODE CHART A 4 PROBLEM SYMPTOMS TABLE HINT: See page WS-9. NEXT 5 OVERALL ANALYSIS AND TROUBLESHOOTING (a) Data list/Active test HINT: See page WS-17. (b) Circuit inspection (c) Terminal of ECU HINT: See page WS-9. NEXT WS WS–6 6 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM ADJUST, REPAIR OR REPLACE NEXT WS 7 RESET POWER WINDOW MOTOR HINT: See page WS-8. NEXT END OPERATION CHECK 1. B140183 2. CHECK WINDOW LOCK SWITCH (a) Check that the front passenger side power window and rear power windows operation are disabled when the window lock switch of the power window master switch is pressed. Standard: Front passenger side power window and rear power windows operation are disabled. (b) Check that the front passenger side power window and rear power windows can be operated when the window lock switch is pressed again. Standard: Front passenger side power window and rear power windows can be operated. CHECK MANUAL UP/DOWN FUNCTION (a) Check that the driver side power window operates as follows: Standard Condition Ignition switch on (IG) Master Switch Driver side Switch Operation Power Window Pulled halfway up UP (Closed) Pushed halfway down DOWN (Open) (b) Check that the power windows except the driver side power window operate as follows: Standard Condition Switch Passenger side • • Ignition switch on (IG) Window lock switch OFF Rear LH Rear RH Switch Operation Power Window Pulled up UP (Closed) Pushed down DOWN (Open) Pulled up UP (Closed) Pushed down DOWN (Open) Pulled up UP (Closed) Pushed down DOWN (Open) WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM 3. WS–7 CHECK AUTO UP/DOWN FUNCTION (a) Check that the driver side power window operates as follows: Standard Condition Master Switch Ignition switch on (IG) Driver side 4. Switch Operation Power Window Pulled up fully UP (Closed) Pushed down fully DOWN (Open) CHECK REMOTE MANUAL UP/DOWN FUNCTION (a) Check that the power windows except the driver side power window operate as follows: Standard Condition Master Switch Passenger side • • Ignition switch on (IG) Window lock switch OFF Rear LH Rear RH 5. Check Jig B051853E05 Switch Operation Power Window Pulled up UP (Closed) Pushed down DOWN (Open) Pulled up UP (Closed) Pushed down DOWN (Open) Pulled up UP (Closed) Pushed down DOWN (Open) CHECK JAM PROTECTION FUNCTION NOTICE: • The jam protection function can activate when either the AUTO UP function or MANUAL UP function is used. • Limbs, fingers or other body parts should not be used to test the jam protection function. Do not allow any body parts to get caught by the moving window or regulator. HINT: The jam protection function can activate when either the AUTO UP function or MANUAL UP function are used with the ignition switch ON. The jam protection function can also activate as long as the driver's door remains closed, within 45 seconds after the ignition switch is turned off. (a) Check the reversing distance. (1) Fully open the door glass. (2) Place a check jig measuring 4 to 10 mm (0.16 to 0.40 in.) thick near the window fully closed position. (3) When the door glass is closed using AUTO or MANUAL operation, check that the door glass goes down after contacting the check jig. The glass should go 200 to 240 mm (7.90 to 9.44 in.) away from the position where it contacted the check jig. (4) While the door glass is going down, verify that the window switch can not be used to make the glass go up. (b) Check the reversing distance. (1) Fully open the door glass. WS WS–8 WS WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM (2) Place a check jig measuring 200 to 250 mm (7.90 to 9.84 in.) thick near the window fully closed position. (3) When the door glass is closed using AUTO or MANUAL operation, check that the door glass goes down after contacting the check jig. The door glass should go 80 to 100 mm away from the position where it contacted the check jig. (4) While the door glass is going down, verify that the window switch can not be used to make the glass go up. WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–9 INITIALIZATION 1. 2. INITIALIZE POWER WINDOW REGULATOR MOTOR FRONT LH (WITH JAM PROTECTION) NOTICE: • If the power window motor or power window regulator assembly is replaced, initialization is required (initialization is not necessary when the negative battery terminal is disconnected and reconnected). • No other electrical systems should be operated during initialization. Initialization will be interrupted if a voltage drop occurs in the power being supplied to the power window motor. • Replacing the door glass or door glass run may cause a difference to exist between the current door glass position and the position memorized in the ECU. In this case, the jam protection function may work improperly. Return the system to the pre-initialized condition and reinitialize the system. HINT: • The AUTO UP function will not work unless initialization is completed. • The indicator on the power window master switch will blink when the ignition switch is ON, until initialization has been completed. The indicator will remain on after initialization is successfully completed. (a) Connect the negative battery terminal. (b) Turn the ignition switch on (IG). The indicator on the power window master switch will blink. (c) Fully close the door glass by operating the power window master switch. After the door glass stops, hold the power window master switch in the AUTO UP position for 1 second or more. (d) Check that the indicator on the power window master switch remains on. HINT: If the indicator does not remain on, this means that initialization has not been completed successfully. In this case, lower the door glass at least 50 mm (1.96 in.) and hold the power window master switch in the AUTO UP position for 1 second after the window closes fully. TO RETURN THE SYSTEM TO THE PRE-INITIALIZES CONDITION Disconnect the power window regulator motor connector during power window operation. This will return the motor to the pre-initialized condition. WS WS–10 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM PROBLEM SYMPTOMS TABLE POWER WINDOW CONTROL SYSTEM Symptom Suspected area 1. PWR, POWER, RR DOOR LH/RH fuses WS Power window does not operate with power window regulator master switch Front passenger side power window does not operate with power window regulator switch WS-26 3. Power window regulator motor circuit WS-33 4. Power window regulator master switch - 1. Power window master switch circuit (power source) - 2. Power window regulator motor circuit (front passenger side) WS-36 3. Power window regulator switch (front LH side) WS-30 AUTO UP/DOWN function does not operate on driver side (Only jam protection assistant) WS-38 3. Power window regulator switch (rear LH side) WS-31 WS-40 3. Power window regulator switch (rear RH side) WS-32 1. Diagnosis check WS-14 2. Power window regulator motor reset WS-8 3. Power window regulator master switch - 4. Wire harness - 2. Power window regulator master switch 3. Wire harness Power window can be operated after ignition switch is turned off even if operated conditions are not met 1. Front door courtesy switch 2. Wire harness (LIN communication line) 1. Power window regulator motor reset AUTO UP operation does not fully close power window (Jam protection function is activated) WS-17 LI-109 WS-8 2. Check & clean glass run - 3. Power window regulator master switch - 1. Power window regulator master switch AUTO DOWN function does not operate on driver side (only DOWN AUTO) - 2. Power window regulator motor circuit (rear RH side) 1. DATA LIST/ACTIVE TEST Remote UP/DOWN function does not operate - 2. Power window regulator motor circuit (rear LH side) 1. Power window regulator switch circuit (power source) Rear RH side power window does not operate with power window regulator switch - 2. Power window master switch circuit (power source) 1. Power window regulator switch circuit (power source) Rear LH side power window does not operate with power window regulator switch See page 2. Power window regulator motor circuit (driver side) 3. Wire harness WS-33 - WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–11 TERMINALS OF ECU 1. POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY M1 WS B137056E01 (a) Disconnect the M1 switch connector. (b) Measure the voltage and resistance of each terminal according to the value(s) in the table below. Standard resistance Symbols (Terminal No.) Wiring Color E (M1-1) - Body ground W-B - Body ground Terminal Description Condition Specified Condition Ground Always Below 1 Ω Terminal Description Condition Specified Condition Ignition switch on (IG) 10 to 14 V Standard voltage Symbols (Terminal No.) Wiring Color B (M1-6) - E (M1-1) GR - W-B Power supply If the result is not as specified, there may be a malfunction in the wire harness. (c) Reconnect the M1 switch connector and reset the power window motor. (d) Measure the voltage according to the value(s) in the table below. Standard voltage: with Jam protection Symbols (Terminal No.) UP (M1-8) - E (M1-1) AUTO (M1-4) - E (M1-1) Wiring Color G - W-B Condition Specified Condition Power window motor UP output Ignition switch on (IG), driver side power window switch OFF → UP (Manual operation) 10 to 14 V → 0 V Power window motor AUTO UP output Ignition switch on (IG), driver side power window fully open → driver side power window switch UP (AUTO UP position) → driver side power window fully closed 10 to 14 V → 0 V → 10 to 14 V Power window motor AUTO DOWN output Ignition switch on (IG), driver side power window fully closed → driver side power window switch DOWN (AUTO UP position) → driver side power window fully open 10 to 14 V → 0 V → 10 to 14 V Terminal Description B - W-B WS–12 WS WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM Wiring Color DN (M1-5) - E (M1-1) R - W-B Power window motor DOWN output Ignition switch on (IG), driver side power window switch OFF → DOWN (Manual operation) 10 to 14 V → 0 V PU (M1-16) - E (M1-1) W - W-B Power window motor UP output Ignition switch on (IG), front passenger side power window switch OFF → UP (Manual operation) 0 V → 10 to 14 V R - W-B Power window motor DOWN output Ignition switch on (IG), front passenger side power window switch OFF → DOWN (Manual operation) 0 V → 10 to 14 V L - W-B Power window motor UP output Ignition switch on (IG), rear LH side power window switch OFF → UP (Manual operation) 0 V → 10 to 14 V B - W-B Power window motor DOWN output Ignition switch on (IG), rear LH side power window switch OFF → UP (Manual operation) 0 V → 10 to 14 V Y - W-B Power window motor UP output Ignition switch on (IG), rear RH side power window switch OFF → UP (Manual operation) 0 V → 10 to 14 V LG - W-B Power window motor DOWN output Ignition switch on (IG), rear RH side power window switch OFF → UP (Manual operation) 0 V → 10 to 14 V PD (M1-15) - E (M1-1) RLU (M1-12) - E (M1-1) RLD (M1-13) - E (M1-1) RRU (M1-10) - E (M1-1) RRD (M1-18) - E (M1-1) Terminal Description Condition Specified Condition Symbols (Terminal No.) without Jam protection Symbols (Terminal No.) UP (M1-3) - E (M1-1) DN (M1-4) - E (M1-1) PU (M1-16) - E (M1-1) PD (M1-15) - E (M1-1) RLU (M1-12) - E (M1-1) Condition Specified Condition Power window motor UP output Ignition switch on (IG), driver side power window switch OFF → UP (Manual operation) 0 V → 10 to 14 V Power window motor DOWN output Ignition switch on (IG), driver side power window switch OFF → DOWN (Manual operation) 0 V → 10 to 14 V Power window motor AUTO DOWN output Ignition switch on (IG), driver side power window fully closed → driver side power window switch DOWN (AUTO operation) → driver side power window fully open 10 to 14 V → 0 V → 10 to 14 V Power window motor UP output Ignition switch on (IG), front passenger side power window switch OFF → UP (Manual operation) 0 V → 10 to 14 V R - W-B Power window motor DOWN output Ignition switch on (IG), front passenger side power window switch OFF → DOWN (Manual operation) 0 V → 10 to 14 V L - W-B Power window motor UP output Ignition switch on (IG), rear LH side power window switch OFF → UP (Manual operation) 0 V → 10 to 14 V Wiring Color G - W-B Terminal Description G - W-B W - W-B WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–13 Condition Specified Condition Power window motor DOWN output Ignition switch on (IG), rear LH side power window switch OFF → DOWN (Manual operation) 0 V → 10 to 14 V Y - W-B Power window motor UP output Ignition switch on (IG), rear RH side power window switch OFF → UP (Manual operation) 0 V → 10 to 14 V LG - W-B Power window motor DOWN output Ignition switch on (IG), rear RH side power window switch OFF → DOWN (Manual operation) 0 V → 10 to 14 V Symbols (Terminal No.) Wiring Color RLD (M1-13) - E (M1-1) B - W-B RRU (M1-10) - E (M1-1) RRD (M1-18) - E (M1-1) Terminal Description 2. If the result is not as specified, there may be a malfunction in the wire harness. CHECK POWER WINDOW REGULATOR SWITCH ASSEMBLY (FRONT RH) H6 B137057E01 (a) Disconnect the H6 switch connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Symbols (Terminal No.) Wiring Color B (H6-3) - Body ground GR - Body ground Terminal Description Power supply Condition Specified Condition Ignition switch on (IG) 10 to 14 V If the result is not as specified, there may be a malfunction in the wire harness. (c) Reconnect the H6 switch connector and reset the power window motor. (d) Measure the voltage according to the value(s) in the table below. Standard voltage Symbols (Terminal No.) Wiring Color U (H6-4) - Body ground G - Body ground Y - Body ground D (H6-1) - Body ground Condition Specified Condition Power window motor UP output Ignition switch on (IG), front passenger side power window switch OFF → UP (Manual operation) 0 V → 10 to 14 V Power window motor DOWN output Ignition switch on (IG), front passenger side power window switch OFF → DOWN (Manual operation) 0 V → 10 to 14 V Terminal Description If the result is not as specified, the power window regulator switch assembly may have a malfunction. WS WS–14 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM 3. CHECK POWER WINDOW REGULATOR SWITCH ASSEMBLY (REAR LH) K1 WS B137057E02 (a) Disconnect the K1 switch connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Symbols (Terminal No.) Wiring Color B (K1-3) - Body ground V - Body ground Terminal Description Power supply Condition Specified Condition Ignition switch on (IG) 10 to 14 V If the result is not as specified, there may be a malfunction in the wire harness. (c) Reconnect the K1 switch connector and reset the power window motor. (d) Measure the voltage according to the value(s) in the table below. Standard voltage Symbols (Terminal No.) Wiring Color U (K1-4) - Body ground G - Body ground R - Body ground D (K1-1) - Body ground Condition Specified Condition Power window motor UP output Ignition switch on (IG), front passenger side power window switch OFF → UP (Manual operation) 0 V → 10 to 14 V Power window motor DOWN output Ignition switch on (IG), front passenger side power window switch OFF → DOWN (Manual operation) 0 V → 10 to 14 V Terminal Description 4. If the result is not as specified, the power window regulator switch assembly may have a malfunction. CHECK POWER WINDOW REGULATOR SWITCH ASSEMBLY (REAR RH) J1 B137057E03 (a) Disconnect the J1 switch connector. WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–15 (b) Measure the voltage according to the value(s) in the table below. Standard voltage Symbols (Terminal No.) Wiring Color B (J1-3) - Body ground G - Body ground Terminal Description Power supply Condition Specified Condition Ignition switch on (IG) 10 to 14 V If the result is not as specified, there may be a malfunction in the wire harness. (c) Reconnect the J1 switch connector and reset the power window motor. (d) Measure the voltage according to the value(s) in the table below. Standard voltage Symbols (Terminal No.) Wiring Color U (J1-4) - Body ground V - Body ground R - Body ground D (J1-1) - Body ground Condition Specified Condition Power window motor UP output Ignition switch on (IG), front passenger side power window switch OFF → UP (Manual operation) 0 V → 10 to 14 V Power window motor DOWN output Ignition switch on (IG), front passenger side power window switch OFF → DOWN (Manual operation) 0 V → 10 to 14 V Terminal Description If the result is not as specified, the power window regulator switch assembly may have a malfunction. WS WS–16 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM DIAGNOSIS SYSTEM 1. DESCRIPTION (a) The power window control system data can be read from the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the intelligent tester to check for malfunctions and perform repairs. 2. CHECK DLC3 WS CG SG CANH SIL BAT CANL H100769E16 (a) The ECU uses ISO 15765-4 communication. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. DLC3 Intelligent Tester C131977E01 Symbols (Terminal No.) Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 10 to 14 V CANH (6) - CANL (14) CAN bus line Ignition switch OFF* 54 to 69 Ω CANH (6) - CG (4) HIGH-level CAN bus line Ignition switch OFF* 200 Ω or more CANL (14) - CG (4) LOW-level CAN bus line Ignition switch OFF* 200 Ω or more CANH (6) - BAT (16) HIGH-level CAN bus line Ignition switch OFF* 6 kΩ or more CANL (14) - BAT (16) LOW-level CAN bus line Ignition switch OFF* 6 kΩ or more NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the door. WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–17 If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of the intelligent tester to the DLC3, turn the ignition switch on (IG) and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. • If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. 3. B140750 CHECK DIAGNOSIS (WITH JAM PROTECTION) HINT: If there is a malfunction in the pulse sensor, manually operating the power window switch will cause the power window switch light to blink. (a) Turn the ignition switch on (IG). (b) Manually operate the power window master switch or power window switch on each door. (c) Check the blinking pattern of the AUTO light as shown in the illustration. Brinking Pattern of Light: (A): LIN communication fail (B): - Initial fail (Window position) - Palse sensor fail Normal ON OFF (Light) 1.5 0.5 2.0 (sec.) 1.0 (sec.) B145472E01 (1) If pattern (A) is displayed, check the wire harness or power window ECU. (2) If pattern (B) is displayed, check the power window regulator motor or power window ECU. (3) If the normal pattern is displayed, replace the power window regulator master switch. WS WS–18 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM DTC CHECK / CLEAR WS DLC3 Intelligent Tester C131977E01 1. CHECK DTC (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Check the DTC(s). 2. CLEAR DTC (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) . (c) Clear the DTCs. (d) Check that "DTCs are cleared" is displayed. NOTICE: If any DTCs are output, troubleshoot those DTCs again. WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–19 FAIL-SAFE CHART 1. POWER WINDOW OPERATION IN FAIL-SAFE MODE HINT: If the pulse sensor built into the power window regulator motor (on the driver side) malfunctions, the power window control system enters fail-safe mode. Fail mode Fail Detection Condition With the door glass going up or down, the pulse that indicates door glass operation in the opposite direction is detected for 400 msec. Pulse direction error With the door glass going up or down, no pulse is detected for 350 to 450 msec. Pulse stop error (a) The power window control system prohibits the following power window operation when the pulse sensor for the jam protection function has problems and the window position or the learned value is abnormal. Power window control system Power window operation Ignition switch on (IG) Key-off (Within approx. 45 seconds after ignition switch turned off) Key-off (After approx. 45 seconds elapsed after ignition switch turned off) Manual UP Operation prohibited Operation prohibited Operation prohibited Manual DOWN Operative (Jam protection not operative) Operation prohibited Operation prohibited AUTO UP (hold switch at AUTO UP position) Operative (in MANUAL mode) (Jam protection not operative) Operation prohibited Operation prohibited AUTO UP Operation prohibited Operation prohibited Operation prohibited AUTO DOWN Operation prohibited Operation prohibited Operation prohibited HINT: When the pulse sensor is normal, the AUTO UP / DOWN function can be resumed by deactivating fail-safe mode. To deactivate fail-safe mode, pull up the driver door power window switch to the AUTO UP position and hold it for at least 1 second to fully close the window from the fully open position. (b) If the LIN communication system malfunctions (communication blackout), the power window control system prohibits the following operations. LIN communication system Power window operation Ignition switch on (IG) MANUAL UP Operative (Jam protection operative) MANUAL DOWN Operative (Jam protection not operative) AUTO UP (hold switch at AUTO UP position) Operative (Jam protection operative) AUTO UP Operative (Jam protection operative) AUTO DOWN Operative (Jam protection not operative) WS WS–20 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM DATA LIST / ACTIVE TEST 1. WS 2. USING INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Monitor the ECU data by following the prompts on the tester screen. HINT: The intelligent tester has a "Snapshot" function which records the monitored data. Refer to the intelligent tester operator's manual for further details. DATA LIST HINT: Using the DATA LIST displayed on the intelligent tester, the value of the switches, sensors, actuators, etc. can be read without part removal. Reading the DATA LIST as the first step in troubleshooting is one way to shorten the labor time. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Read the DATA LIST according to the display on the tester. Body: Item Measurement Item/Display (Range) Communication Master SW Master switch communication signal OK/STOP Normal Condition Diagnostic Note OK: Communication is normal STOP: Communication is stop - Ignition Switch Ignition switch signal/ON or OFF ON: Power source mode is (IG) OFF: Power source mode is off or on (ACC) - D Door Courtesy SW Driver side door courtesy switch signal/ON or OFF ON: Driver side door is open OFF: Driver side door is closed - P Door Courtesy SW Front passenger side door courtesy switch signal/ON or OFF ON: Front passenger side door is open OFF: Front passenger side door is closed - 3. ACTIVE TEST HINT: Performing the ACTIVE TEST using the intelligent tester allows you to operate the relay, VSV, actuator, etc. without parts removal. Performing the ACTIVE TEST as the first step in troubleshooting is one way to shorten the labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Perform the ACTIVE TEST according to the display on the tester. Body: Item Test Detail Diagnostic Note IG OFF P/W Control Permission Output Operates power window ON/OFF (After ignition OFF) - WS–21 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM DIAGNOSTIC TROUBLE CODE CHART POWER WINDOW CONTROL SYSTEM DTC No. Detection Item Trouble Area See page Driver Door Motor Malfunction 1. Battery disconnection when the ignition switch is on (IG) 2. Power window regulator motor (on driver side) 3. Incorrect installation of power window components 4. Overheated power window regulator motor (on driver side) WS-19 B2312 Driver Side Door Master Switch Malfunction 1. Power window regulator motor (on driver side) 2. Power window regulator master switch 3. Wire harness 4. Power window regulator master switch is held same position for more than 20 seconds WS-21 B2313 Glass Position Initialization Incomplete 1. Power window regulator motor (on driver side) 2. Power window regulator motor (on driver side) not initialized WS-24 B2311 WS WS–22 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM DTC B2311 Driver Door Motor Malfunction DESCRIPTION WS The portion of the power window control system that is located in the driver door consists of a power window master switch, regulator, and a motor with an integrated ECU. The driver door power window regulator motor is controlled by the ECU when the power window master switch is operated (models with jam protection). DTC B2311 is set when the ECU for the driver door power window regulator motor assembly malfunctions. NOTICE: The power window control system uses a serial communication protocol (LIN) to communicate with the main body ECU. Inspect the communication function by following HOW TO PROCEED WITH TROUBLESHOOTING. Troubleshoot the power window control system after confirming that the communication system is functioning properly. HINT: • Initialization is required only when the power window regulator motor is replaced. However, replacing the motor may cause the motor gear to be engaged in a different position. This can cause a difference to exist between the current door glass position and the position memorized in the ECU. In this case, the jam protection function may work improperly. Return the system to the pre-initialized condition and reinitialize the system. • To return the system to the pre-initialized condition: Disconnect the power window regulator motor connector during power window operation. This will return the motor to the pre-initialized condition. DTC No. DTC Detection Condition Trouble Area B2311 When either condition below is met: • The power window regulator motor (on driver side) malfunctions • When the ECU in the power widow regulator motor (on driver side) determines that the fully closed window position has deviated approximately 20 mm (0.79 in.) or more from the normal position • • • • Battery disconnection when the ignition switch is on (IG) Power window regulator motor (on driver side) Incorrect installation of power window components Overheated power window regulator motor (on driver side) INSPECTION PROCEDURE 1 INITIALIZE POWER WINDOW CONTROL SYSTEM (a) Initialize the power window regulator motor assembly (on the driver side) (see page WS-8). (b) Check that the power window operates normally by opening and closing the window. OK: Driver side power window operates normally. NG OK REPLACE POWER WINDOW REGULATOR MOTOR ASSEMBLY (for Driver Side) WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM 2 WS–23 CHECK WHETHER PARTS HAVE BEEN INSTALLED CORRECTLY (a) Check that the power window components (on the driver side) are installed correctly. OK: Power window components (on driver side) are installed correctly. HINT: When the power window components are installed correctly, the problem has been caused by battery disconnection while the ignition switch is on (IG), improper installation of the power window components or the motor being overheated. NG OK END INSTALL PARTS CORRECTLY WS WS–24 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM DTC B2312 Driver Side Door Master Switch Malfunction DESCRIPTION WS The portion of the power window control system that is located in the driver door consists of a power window master switch, regulator, and a motor with an integrated ECU. The driver door power window regulator motor is controlled by the ECU when the power window master switch is operated (models with jam protection). When the ECU determines that the power window master switch is stuck, DTC B2312 is set. NOTICE: The power window control system uses a serial communication protocol (LIN) to communicate with the main body ECU. Inspect the communication function by following HOW TO PROCEED WITH TROUBLESHOOTING. Troubleshoot the power window control system after confirming that the communication system is functioning properly. DTC No. DTC Detection Condition Trouble Area • B2312 The power window regulator master switch is stuck • • • Power window regulator motor (on driver side) Power window regulator master switch Wire harness Power window regulator master switch is held in same position for more than 20 seconds WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–25 WIRING DIAGRAM with Jam Protection: I5 Power Window Regulator Motor Assembly (Front LH) M1 Power Window Master Switch 6 from POWER fuse B UP LED AUTO DN 1 WS 8 10 3 5 4 4 5 7 18 LED AUTO DWN1 E from PWR fuse Main Body ECU to PWR Relay UP1 2 B PWS LIN2 10 9 1 LIN E : LIN Communication Line B140744E01 WS–26 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM INSPECTION PROCEDURE 1 INSPECT POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance WS B108710 Tester Connection Condition Specified Condition 8 (UP) - 1 (E) - 4 (AUTO) Auto UP Below 1 Ω 5 (DN) - 6 (B) Auto UP Below 1 Ω 8 (UP) - 1 (E) Manual UP Below 1 Ω 5 (DN) - 6 (B) Manual UP Below 1 Ω 8 (UP) - 5 (DN) - 6 (B) OFF Below 1 Ω 5 (DN) - 1 (E) Manual DOWN Below 1 Ω 8 (UP) - 6 (B) Manual DOWN Below 1 Ω 4 (AUTO) - 5 (DN) - 1 (E) Auto DOWN Below 1 Ω 8 (UP) - 6 (B) Auto DOWN Below 1 Ω NG REPLACE POWER WINDOW REGULATOR MASTER SWITCH OK 2 CHECK WIRE HARNESS (WINDOW REGULATOR MASTER SWITCH - WINDOW REGULATOR MOTOR) (a) Disconnect the M1 and I5 connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance M1 Power Window Regulator Master Switch Assembly: LED DN UP AUTO I5 Power Window Regulator Motor (Front LH): AUTO DWN1 LED UP1 B137046E02 Tester Connection Condition Specified Condition M1-8 (UP) - I5-10 (UP1) Always Below 1 Ω M1-3 (LED) - I5-5 (LED) Always Below 1 Ω M1-4 (AUTO) - I5-4 (AUTO) Always Below 1 Ω M1-5 (DN) - I5-7 (DWN1) Always Below 1 Ω M1-8 (UP) - Body ground Always 10 kΩ or higher M1-3 (LED) - Body ground Always 10 kΩ or higher M1-4 (AUTO) - Body ground Always 10 kΩ or higher M1-5 (DN) - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE DRIVER SIDE POWER WINDOW REGULATOR MOTOR ASSEMBLY WS–27 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM DTC B2313 Glass Position Initialization Incomplete DESCRIPTION The portion of the power window control system that is located in the driver door consists of a power window master switch, regulator, and a motor with an integrated ECU. The driver door power window regulator motor is controlled by the ECU when the power window master switch is operated (models with jam protection). When the ECU determines that the driver's door power window regulator motor assembly has not been initialized, DTC B2313 is set. NOTICE: The power window control system uses a serial communication protocol (LIN) to communicate with the main body ECU. Inspect the communication function by following HOW TO PROCEED WITH TROUBLESHOOTING. Troubleshoot the power window control system after confirming that the communication system is functioning properly. HINT: • Replacing the door glass or door glass run may cause a difference to exist between the current door glass position and the position memorized in the ECU. In this case, the jam protection function may work improperly. Return the system to the pre-initialized condition and reinitialize the system. • To return the system to the pre-initialized condition: Disconnect the power window regulator motor connector during power window operation. This will return the motor to the pre-initialized condition. DTC No. B2313 DTC Detection Condition Trouble Area • • • The power window regulator motor (on driver side) is not initialized The power window regulator motor (on driver side) malfunctions • Power window regulator motor (on driver side) Power window regulator motor (on driver side) not initialized INSPECTION PROCEDURE NOTICE: When using the intelligent tester to troubleshoot the LIN communication line: Connect the intelligent tester to the vehicle, and turn the courtesy light switch on and off at 1.5 second intervals until communication between the tester and vehicle begins. 1 CHECK DTC OUTPUT (a) Turn the ignition switch off. (b) Wait for at least 10 seconds, and then turn the ignition switch on (IG). (c) Check whether the DTC output recurs. Result B A Display (DTC Output) Proceed to B2313 A No output B END WS WS–28 2 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM SYSTEM INITIALIZE (POWER WINDOW CONTROL SYSTEM) (a) Turn the ignition switch on (IG) and initialize the power window regulator motor (on the driver side) (see page WS-8). (b) Turn the ignition switch off. (c) Wait for at least 10 seconds, and then turn the ignition switch on (IG). (d) Check whether the DTC output recurs. WS B A END Display (DTC Output) Proceed to No output A B2313 B REPLACE POWER WINDOW REGULATOR MOTOR ASSEMBLY FRONT LH WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–29 Power Window Master Switch Circuit DESCRIPTION This circuit transmits signal from the power window regulator master switch assembly to the power window regulator switch. WS WIRING DIAGRAM M1 Power Window Regulator Master Switch PU PD B RLU RLD RRU RRD H6 Power Window Regulator Switch (Front RH) H4 Power Window Regulator Motor (Front RH) 3 from POWER fuse B 5 4 SU U 2 1 SD D 16 15 K1 Power Window Regulator Switch (Rea LH) K3 from POWER fuse Power Window Regulator Motor (Rear LH) 3 B from RR DOOR LH fuse 5 SU U 4 2 SD D 1 6 12 13 J1 Power Window Regulator Switch (Rear RH) J3 Power Window Regulator Motor (Rear RH) 3 from RR DOOR RH fuse B 5 4 U SU 2 1 D SD 10 18 I5 Power Window Regulator Motor (Front LH) I4 Power Window Regulator Motor (Front LH) *1 5 (4) DN UP 4 AUTO 3 LED E 1 1 2 from PWR fuse *1 *2 8 (3) *1: without Jam Protection *2: with Jam Protection *2 *2 *2 2 *2 B 7 DWN1 10 UP1 4 AUTO 5 LED 1 E *2 ( ): without Jam Protection B140723E01 WS–30 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM INSPECTION PROCEDURE 1 CHECK DTC OUTPUT (a) Turn the ignition switch off. (b) Wait for at least 10 seconds, and then turn the ignition switch on (IG). (c) Check whether the DTC output recurs. Result WS Display (DTC output) B Proceed to No output A Output DTCs B GO TO DTC CHART A 2 INSPECT POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY M1 E (a) Disconnect the M1 connector. (b) Measure the voltage and resistance according to the value(s) in the table below. Standard voltage B Tester Connection Condition Specified Condition 6 (B) - Body ground Ignition switch on (IG) 10 to 14 V Standard resistance B137060E01 Tester Connection Condition Specified Condition 1 (E) - Body ground Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 INSPECT POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (with Jam Protection) Tester Connection 8 (UP) - 1 (E) - 4 (AUTO) 5 (DN) - 6 (B) 8 (UP) - 1 (E) B050518E04 5 (DN) - 6 (B) 8 (UP) - 5 (DN) - 6 (B) 5 (DN) - 1 (E) 8 (UP) - 6 (B) Condition Auto UP Manual UP OFF Manual DOWN Specified Condition Below 1 Ω Below 1 Ω Below 1 Ω Below 1 Ω Below 1 Ω Below 1 Ω Below 1 Ω WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM Tester Connection 4 (AUTO) - 5 (DN) - 1 (E) 8 (UP) - 6 (B) Condition Auto DOWN WS–31 Specified Condition Below 1 Ω Below 1 Ω 1 (E) - 10 (RRU) 1 (E) - 12 (RLU) 1 (E) - 13 (RLD) 1 (E) - 15 (PD) Lock/Unlock switch UNLOCK (Below 1 Ω) →LOCK (10 kΩ or higher) 1 (E) - 16 (PU) 1 (E) - 18 (RRD) (without Jam Protection) Tester Connection 1 (E) - 3 (UP) 1 (E) - 4 (DN) Condition OFF Specified Condition Below 1 Ω Below 1 Ω 1 (E) - 10 (RRU) 1 (E) - 12 (RLU) 1 (E) - 13 (RLD) 1 (E) - 15 (PD) Lock/Unlock switch UNLOCK (Below 1 Ω) →LOCK (10 kΩ or higher) 1 (E) - 16 (PU) 1 (E) - 18 (RRD) NG REPLACE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY OK 4 CHECK WIRE HARNESS (POWER WINDOW MASTER SWITCH - FRONT LH, REAR LH/RH SWITCH) M1 Power Window Regulator Master Switch Assembly: RLU RRU RLD PD RRD PU H6 (K1, J1) Power Window Switch (Front RH, Rear LH/RH): (a) Disconnect the M1 and H6 (K1, J1) connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: Front RH side Tester Connection Condition Specified Condition M1-16 (PU) - H6-5 (SU) Always Below 1 Ω M1-15 (PD) - H6-2 (SD) Always Below 1 Ω M1-16 (PU) - Body ground Always 10 kΩ or higher M1-15 (PD) - Body ground Always 10 kΩ or higher Rear LH side B137067E01 Tester Connection Condition Specified Condition M1-12 (RLU) - K1-5 (SU) Always Below 1 Ω M1-13 (RLD) - K1-2 (SD) Always Below 1 Ω M1-12 (RLU) - Body ground Always 10 kΩ or higher M1-13 (RLD) - Body ground Always 10 kΩ or higher Rear RH side WS WS–32 WS WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM Tester Connection Condition Specified Condition M1-10 (RRU) - J1-5 (SU) Always Below 1 Ω M1-18 (RRD) - J1-2 (SD) Always Below 1 Ω M1-10 (RRU) - Body ground Always 10 kΩ or higher M1-18 (RRD) - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE WS–33 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM Front Passenger Side Power Window Switch Power Source Circuit DESCRIPTION This circuit supplies power to operate the power window regulator switch assembly (Front RH). WS WIRING DIAGRAM H6 Power Window Regulator Switch Assembly (Front RH) 3 from POWER fuse B C B137059E01 INSPECTION PROCEDURE 1 CHECK WIRE HARNESS (POWER WINDOW REGULATOR SWITCH - BATTERY AND BODY GROUND) (a) Disconnect the H6 connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage H6 B Tester Connection Condition Specified Condition 3 (B) - Body ground Ignition switch on (IG) 10 to 14 V NG B137048E01 REPAIR OR REPLACE HARNESS OR CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE WS–34 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM Rear Power Window Switch LH Circuit DESCRIPTION This circuit supplies power to operate the power window regulator switch assembly (Rear LH). WS WIRING DIAGRAM K1 Power Window Regulator Switch Assembly (Rear LH) 3 from RR DOOR LH fuse B C B137059E02 INSPECTION PROCEDURE 1 CHECK WIRE HARNESS (POWER WINDOW REGULATOR SWITCH - BATTERY AND BODY GROUND) (a) Disconnect the K1 connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage K1 B Tester Connection Condition Specified Condition 3 (B) - Body ground Ignition switch on (IG) 10 to 14 V NG B137048E02 REPAIR OR REPLACE HARNESS OR CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE WS–35 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM Rear Power Window Switch RH Circuit DESCRIPTION This circuit supplies power to operate the power window regulator switch (Rear RH). WS WIRING DIAGRAM J1 Power Window Regulator Switch Assembly (Rear RH) 3 from RR DOOR RH fuse B C B137059E03 INSPECTION PROCEDURE 1 CHECK WIRE HARNESS (POWER WINDOW REGULATOR SWITCH - BATTERY AND BODY GROUND) (a) Disconnect the J1 connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage J1 B Tester Connection Condition Specified Condition 3 (B) - Body ground Ignition switch on (IG) 10 to 14 V NG B137048E03 REPAIR OR REPLACE HARNESS OR CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE WS–36 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM Driver Side Power Window Motor Circuit DESCRIPTION WS This circuit transmits signals from the power window regulator master switch assembly to the power window regulator motor (Front LH). WIRING DIAGRAM with Jam Protection: I5 Power Window Regulator Motor (Front LH) from PWR fuse 2 M1 Power Window Regulator Master Switch Assembly B UP1 DWN1 AUTO E 10 8 7 5 4 4 UP DN AUTO 1 C B137064E01 without Jam Protection: M1 Power Window Regulator Master Switch Assembly I4 Power Window Regulator Motor (Front LH) C 2 3 1 4 UP DN B137065E04 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–37 INSPECTION PROCEDURE 1 INSPECT POWER WINDOW REGULATOR MOTOR Motor Gear Counterclockwise Clockwise B127535E01 Measurement Condition Specified Condition Battery positive (+) → Terminal 2 Battery negative (-) → Terminal 1 Motor gear rotates clockwise Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 2 Motor gear rotates counterclockwise (b) with Jam protection: Remove the power window motor. (1) Apply battery voltage to the motor connector according to the table below. NOTICE: Do not apply battery voltage to any terminals except terminals 1, 2, 4, 7 and 10. Standard Counterclockwise Motor Gear without Jam protection: (a) Remove the power window motor. (1) Apply battery voltage to the motor connector according to the table below. NOTICE: Do not apply battery voltage to any terminals except terminals 1 and 2. Standard Clockwise Switch Condition B137055E01 Manual Operation Auto Operation NG OK Measurement Condition Specified Condition Battery positive (+) → Terminal 2 (PWR) Battery negative (-) → Terminal 1 (E), 7 (DN) Motor gear rotates clockwise Battery positive (+) → Terminal 2 (PWR) Battery negative (-) → Terminal 1 (E), 10 (UP) Motor gear rotates counterclockwise Battery positive (+) → Terminal 2 (PWR) Battery negative (-) → Terminal 1 (E), 4 (AUTO), 7 (DN) Motor gear rotates clockwise Battery positive (+) → Terminal 2 (PWR) Battery negative (-) → Terminal 1 (E), 4 (AUTO), 10 (UP) Motor gear rotates counterclockwise REPLACE POWER WINDOW REGULATOR MOTOR WS WS–38 2 WS WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM CHECK WIRE HARNESS (WINDOW REGULATOR MOTOR - WINDOW REGULATOR MASTER SWITCH) (a) without Jam protection: Disconnect the M1 and I4 connectors. (1) Measure the resistance according to the value(s) in the table below. Standard resistance M1 Power Window Regulator Master Switch Assembly: UP DN I4 Power Window Regulator Motor (Front LH): Tester Connection Condition Specified Condition M1-3 (UP) - I4-2 Always Below 1 Ω M1-4 (DN) - I4-1 Always Below 1 Ω M1-3 (UP) - Body ground Always 10 kΩ or higher M1-4 (DN) - Body ground Always 10 kΩ or higher B137061E01 (b) with Jam protection: Disconnect the M1 and I5 connectors. (1) Measure the resistance according to the value(s) in the table below. Standard resistance M1 Power Window Regulator Master Switch Assembly: DN UP I5 Power Window Regulator Motor (Front LH): Tester Connection Condition Specified Condition M1-8 (UP) - I5-10 Always Below 1 Ω M1-5 (DN) - I5-7 Always Below 1 Ω M1-8 (UP) - Body ground Always 10 kΩ or higher M1-5 (DN) - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR B137046E01 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE WS–39 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM Front Passenger Side Power Window Motor Circuit DESCRIPTION This circuit transmits signals from the power window regulator switch assembly (Front RH) to the power window regulator motor (Front RH). WIRING DIAGRAM H6 Power Window Regulator Switch Assembly (Front RH) H4 Power Window Regulator Motor (Front RH) 2 4 1 1 U D C B137065E01 INSPECTION PROCEDURE 1 INSPECT POWER WINDOW REGULATOR MOTOR Motor Gear Clockwise (a) Remove the power window motor. (b) Apply battery voltage to the motor connector according to the table below. NOTICE: Do not apply battery voltage to any terminals except terminals 1 and 2. Standard Couterclockwise B127536E02 Measurement Condition Specified Condition Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 2 Motor gear rotates clockwise Battery positive (+) → Terminal 2 Battery negative (-) → Terminal 1 Motor gear rotates counterclockwise NG OK REPLACE POWER WINDOW REGULATOR MOTOR WS WS–40 2 WS WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM CHECK WIRE HARNESS (WINDOW REGULATOR MOTOR - POWER WINDOW REGULATOR SWITCH) (a) Disconnect the H6 and H4 connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance H6 Power Window Regulator Switch Assembly (Front RH): D Tester Connection Condition Specified Condition H6-4 (U) - H4-2 Always Below 1 Ω H6-1 (D) - H4-1 Always Below 1 Ω H6-4 (U) - Body ground Always 10 kΩ or higher H6-1 (D) - Body ground Always 10 kΩ or higher U H4 Power Window Regulator Motor (Front RH): NG REPAIR OR REPLACE HARNESS OR CONNECTOR B137066E01 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE WS–41 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM Rear Power Window Motor LH Circuit DESCRIPTION This circuit transmits signals from the power window regulator switch assembly (Rear LH) to the power window regulator motor (Rear LH). WIRING DIAGRAM K1 Power Window Regulator Switch Assembly (Rear LH) K3 Power Window Regulator Motor (Rear LH) 1 4 2 1 U D C B137065E02 INSPECTION PROCEDURE 1 INSPECT POWER WINDOW REGULATOR MOTOR Motor Gear Clockwise (a) Remove the power window motor. (b) Apply battery voltage to the motor connector according to the table below. NOTICE: Do not apply battery voltage to any terminals except terminals 1 and 2. Standard Couterclockwise B127536E02 Measurement Condition Specified Condition Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 2 Motor gear rotates clockwise Battery positive (+) → Terminal 2 Battery negative (-) → Terminal 1 Motor gear rotates counterclockwise NG OK REPLACE POWER WINDOW REGULATOR MOTOR WS WS–42 2 WS WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM CHECK WIRE HARNESS (WINDOW REGULATOR MOTOR - WINDOW REGULATOR SWITCH) (a) Disconnect the K1 and K3 connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance K1 Power Window Regulator Switch Assembly (Rear LH): D Tester Connection Condition Specified Condition K1-4 (U) - K3-1 Always Below 1 Ω K1-1 (D) - K3-2 Always Below 1 Ω K1-4 (U) - Body ground Always 10 kΩ or higher K1-1 (D) - Body ground Always 10 kΩ or higher U NG K3 Power Window Regulator Motor (Rear LH): REPAIR OR REPLACE HARNESS OR CONNECTOR B137066E02 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE WS–43 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM Rear Power Window Motor RH Circuit DESCRIPTION This circuit transmits signals from the power window regulator switch assembly (Rear RH) to the power window regulator motor (Rear RH). WIRING DIAGRAM J1 Power Window Regulator Switch Assembly (Rear RH) J3 Power Window Regulator Motor (Rear RH) 1 4 2 1 U D C B137065E05 INSPECTION PROCEDURE 1 INSPECT POWER WINDOW REGULATOR MOTOR Motor Gear Counterclockwise Clockwise B127535E01 (a) Remove the power window motor. (b) Apply battery voltage to the motor connector according to the table below. NOTICE: Do not apply battery voltage to any terminals except terminals 1 and 2. Standard Measurement Condition Specified Condition Battery positive (+) → Terminal 2 Battery negative (-) → Terminal 1 Motor gear rotates clockwise Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 2 Motor gear rotates counterclockwise NG OK REPLACE POWER WINDOW REGULATOR MOTOR WS WS–44 2 WS WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM CHECK WIRE HARNESS (WINDOW REGULATOR MOTOR - WINDOW REGULATOR SWITCH) (a) Disconnect the J1 and J3 connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance J1 Power Window Regulator Switch Assembly (Rear RH): Tester Connection D Condition Specified Condition J1-4 (U) - J3-1 Always Below 1 Ω J1-1 (D) - J3-2 Always Below 1 Ω J1-4 (U) - Body ground Always 10 kΩ or higher J1-1 (D) - Body ground Always 10 kΩ or higher U NG J3 Power Window Regulator Motor (Rear RH): REPAIR OR REPLACE HARNESS OR CONNECTOR B137066E03 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE WS–42 WINDSHIELD / WINDOWGLASS – POWER WINDOW MASTER SWITCH POWER WINDOW MASTER SWITCH INSPECTION WS 1. B050518E04 INSPECT POWER WINDOW MASTER SWITCH (w/ Jam Protection Function) (a) Measure the resistance when the switch is operated according to the value(s) in the table below. Standard resistance Tester Connection 8 (UP) - 1 (E) - 4 (AUTO) 5 (DN) - 6 (B) 8 (UP) - 1 (E) 5 (DN) - 6 (B) 8 (UP) - 5 (DN) - 6 (B) 5 (DN) - 1 (E) 8 (UP) - 6 (B) 4 (AUTO) - 5 (DN) - 1 (E) 8 (UP) - 6 (B) Switch Condition Auto UP Manual UP OFF Manual DOWN Auto DOWN Specified Condition Below 1 Ω Below 1 Ω Below 1 Ω Below 1 Ω Below 1 Ω Below 1 Ω Below 1 Ω Below 1 Ω Below 1 Ω 1 (E) - 10 (RRU) 1 (E) - 12 (RLU) 1 (E) - 13 (RLD) 1 (E) - 15 (PD) Lock/Unlock switch UNLOCK (Below 1 Ω) → LOCK (10 kΩ or higher) 1 (E) - 16 (PU) 1 (E) - 18 (RRD) 2. INSPECT POWER WINDOW MASTER SWITCH (w/o Jam Protection Function) (a) Measure the resistance when the switch is operated according to the value(s) in the table below. Standard resistance Tester Connection 1 (E) - 3 (DU) 1 (E) - 4 (DD) Switch Condition OFF Specified Condition Below 1 Ω Below 1 Ω 1 (E) - 10 (RRU) B050518E04 1 (E) - 12 (RLU) 1 (E) - 13 (RLD) 1 (E) - 15 (PD) 1 (E) - 16 (PU) 1 (E) - 18 (RRD) Lock/Unlock switch UNLOCK (Below 1 Ω) → LOCK (10 kΩ or higher) WINDSHIELD / WINDOWGLASS – FRONT PASSENGER SIDE POWER WINDOW SWITCH WS–43 FRONT PASSENGER SIDE POWER WINDOW SWITCH INSPECTION 1. B102538E01 INSPECT POWER WINDOW SWITCH (a) Remove the power window switch. (b) Measure the resistance when the switch is operated according to the value(s) in the table below. Standard resistance Tester Connection 1 (D) - 2 (SD) 3 (B) - 4 (U) 1 (D) - 2 (SD) 4 (U) - 5 (SU) 4 (U) - 5 (SU) 1 (D) - 3 (B) Switch Condition UP OFF DOWN Specified Condition Below 1 Ω Below 1 Ω Below 1 Ω Below 1 Ω Below 1 Ω Below 1 Ω WS WS–44 WINDSHIELD / WINDOWGLASS – REAR POWER WINDOW SWITCH REAR POWER WINDOW SWITCH INSPECTION 1. WS B102538E01 INSPECT POWER WINDOW SWITCH (for Rear RH) (a) Remove the power window switch. (b) Measure the resistance when the switch is operated according to the value(s) in the table below. Standard resistance Tester Connection 1 (D) - 2 (SD) 3 (B) - 4 (U) 1 (D) - 2 (SD) 4 (U) - 5 (SU) 4 (U) - 5 (SU) 1 (D) - 3 (B) 2. Switch Condition UP OFF DOWN Specified Condition Below 1 Ω Below 1 Ω Below 1 Ω Below 1 Ω Below 1 Ω Below 1 Ω REMOVE POWER WINDOW SWITCH (for Rear LH) (a) Remove the power window switch. (b) Measure the resistance when the switch is operated according to the value(s) in the table below. Standard resistance Tester Connection 1 (D) - 2 (SD) 3 (B) - 4 (U) 1 (D) - 2 (SD) B102538E01 4 (U) - 5 (SU) 4 (U) - 5 (SU) 1 (D) - 3 (B) Switch Condition UP OFF DOWN Specified Condition Below 1 Ω Below 1 Ω Below 1 Ω Below 1 Ω Below 1 Ω Below 1 Ω WINDSHIELD / WINDOWGLASS – POWER WINDOW REGULATOR MOTOR WS–45 POWER WINDOW REGULATOR MOTOR WINDSHIELD / WINDOWGLASS BODY COMPONENTS for Front Door: FRONT DOOR GLASS SUB-ASSEMBLY WS FRONT DOOR LOWER FRAME BRACKET GARNISH FRONT DOOR INNER GLASS WEATHERSTRIP FRONT DOOR SERVICE HOLE COVER BUTYL TAPE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY FRONT DOOR INSIDE HANDLE BEZEL PLUG 5.5 (56, 49 in.*lbf) 8.0 (82, 71 in.*lbf) 5.4 (55, 48 in.*lbf) FRONT NO. 1 SPEAKER ASSEMBLY ASSIST GRIP COVER COURTESY LIGHT ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY FRONT DOOR TRIM BOARD SUB-ASSEMBLY Non-reusable part Apply MP grease B142333E01 WS–46 WINDSHIELD / WINDOWGLASS – POWER WINDOW REGULATOR MOTOR for Rear Door: NO. 1 DOOR SCUFF PLATE CLAMP REAR DOOR GLASS RUN REAR DOOR INNER GLASS WEATHERSTRIP WS REAR DOOR QUARTER WINDOW GLASS REAR DOOR GLASS SUB-ASSEMBLY REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY BUTYL TAPE REAR DOOR INSIDE HANDLE BEZEL PLUG REAR DOOR SERVICE HOLE COVER REAR DOOR TRIM BOARD SUB-ASSEMBLY DOOR ASSIST GRIP COVER 5.4 (55, 48 in.*lbf) 8.0 (82, 71 in.*lbf) REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque REAR POWER WINDOW REGULATOR MOTOR ASSEMBLY Non-reusable part Apply MP grease B142334E01 WINDSHIELD / WINDOWGLASS – POWER WINDOW REGULATOR MOTOR WS–47 REMOVAL 1. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH (See page ED-14) 2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG (See page ED-14) 3. REMOVE ASSIST GRIP COVER (See page ED-15) 4. REMOVE COURTESY LIGHT ASSEMBLY (See page ED-15) 5. REMOVE FRONT DOOR TRIM BOARD SUBASSEMBLY (See page ED-15) 6. REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP (See page ED-16) 7. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY (See page AV-155) 8. REMOVE FRONT DOOR SERVICE HOLE COVER (See page ED-17) 9. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY (See page ED-17) 10. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY (See page ED-18) 11. REMOVE FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY (See page ED-18) 12. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG (See page ED-38) 13. REMOVE DOOR ASSIST GRIP COVER (See page ED38) 14. REMOVE REAR DOOR TRIM BOARD SUBASSEMBLY (See page ED-39) 15. REMOVE REAR DOOR INNER GLASS WEATHERSTRIP (See page ED-40) 16. REMOVE REAR DOOR SERVICE HOLE COVER (See page ED-41) 17. REMOVE REAR DOOR GLASS RUN (See page ED42) 18. REMOVE REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY (See page ED-42) 19. REMOVE REAR DOOR QUARTER WINDOW GLASS (See page ED-43) 20. REMOVE REAR DOOR GLASS SUB-ASSEMBLY (See page ED-43) 21. REMOVE REAR DOOR WINDOW REGULATOR SUBASSEMBLY (See page ED-43) 22. REMOVE REAR POWER WINDOW REGULATOR MOTOR ASSEMBLY (See page ED-43) WS WS–48 WINDSHIELD / WINDOWGLASS – POWER WINDOW REGULATOR MOTOR Motor Gear INSPECTION 1. Clockwise WS Couterclockwise B127536E02 2. Motor Gear Counterclockwise Clockwise B127535E01 Measurement Condition Specified Condition Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 2 Motor gear rotates clockwise Battery positive (+) → Terminal 2 Battery negative (-) → Terminal 1 Motor gear rotates counterclockwise INSPECT POWER WINDOW REGULATOR MOTOR (FRONT LH) (a) without Jam protection: Apply battery voltage to the motor connector according to the table below. NOTICE: Do not apply battery voltage to any terminals except terminals 1 and 2. Standard Measurement Condition Specified Condition Battery positive (+) → Terminal 2 Battery negative (-) → Terminal 1 Motor gear rotates clockwise Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 2 Motor gear rotates counterclockwise (b) with Jam protection: Apply battery voltage to the motor connector according to the table below. NOTICE: Do not apply battery voltage to any terminals except terminals 1, 2, 4, 7 and 10. Standard Counterclockwise Motor Gear INSPECT POWER WINDOW REGULATOR MOTOR (FRONT RH) (a) Apply battery voltage to the motor connector according to the table below. NOTICE: Do not apply battery voltage to any terminals except terminals 1 and 2. Standard Clockwise Switch Condition B137055E01 Manual Operation Auto Operation Measurement Condition Specified Condition Battery positive (+) → Terminal 2 (PWR) Battery negative (-) → Terminal 1 (E), 7 (DN) Motor gear rotates clockwise Battery positive (+) → Terminal 2 (PWR) Battery negative (-) → Terminal 1 (E), 10 (UP) Motor gear rotates counterclockwise Battery positive (+) → Terminal 2 (PWR) Battery negative (-) → Terminal 1 (E), 4 (AUTO), 7 (DN) Motor gear rotates clockwise Battery positive (+) → Terminal 2 (PWR) Battery negative (-) → Terminal 1 (E), 4 (AUTO) 10 (UP) Motor gear rotates counterclockwise WINDSHIELD / WINDOWGLASS – POWER WINDOW REGULATOR MOTOR 3. Motor Gear Clockwise Couterclockwise B127536E02 4. Motor Gear Counterclockwise Clockwise B127535E01 WS–49 INSPECT POWER WINDOW REGULATOR MOTOR (REAR RH) (a) Apply battery voltage to the motor connector according to the table below. NOTICE: Do not apply battery voltage to any terminals except terminals 1 and 2. Standard Measurement Condition Specified Condition Battery positive (+) → Terminal 2 Battery negative (-) → Terminal 1 Motor gear rotates clockwise Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 2 Motor gear rotates counterclockwise INSPECT POWER WINDOW REGULATOR MOTOR (REAR LH) (a) Apply battery voltage to the motor connector according to the table below. NOTICE: Do not apply battery voltage to any terminals except terminals 1 and 2. Standard Measurement Condition Specified Condition Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 2 Motor gear rotates clockwise Battery positive (+) → Terminal 2 Battery negative (-) → Terminal Motor gear rotates counterclockwise WS WS–50 WINDSHIELD / WINDOWGLASS – POWER WINDOW REGULATOR MOTOR INSTALLATION WS 1. INSTALL REAR POWER WINDOW REGULATOR MOTOR ASSEMBLY (See page ED-51) 2. INSTALL REAR DOOR WINDOW REGULATOR SUBASSEMBLY (See page ED-51) 3. INSTALL REAR DOOR GLASS RUN (See page ED-52) 4. INSTALL REAR DOOR GLASS SUB-ASSEMBLY (See page ED-52) 5. INSTALL REAR DOOR QUARTER WINDOW GLASS (See page ED-52) 6. INSTALL REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY (See page ED-52) 7. INSTALL REAR DOOR SERVICE HOLE COVER (See page ED-53) 8. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP (See page ED-54) 9. INSTALL REAR DOOR TRIM BOARD SUBASSEMBLY (See page ED-55) 10. INSTALL DOOR ASSIST GRIP COVER (See page ED56) 11. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG (See page ED-56) 12. INITIALIZATION POWER WINDOW CONTROL SYSTEM (See page WS-8) 13. INSTALL FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY (See page ED-31) 14. INSTALL FRONT DOOR WINDOW REGULATOR SUBASSEMBLY (See page ED-31) 15. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY (See page ED-31) 16. INSTALL FRONT DOOR SERVICE HOLE COVER (See page ED-32) 17. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY (See page AV-157) 18. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP (See page ED-32) 19. INSTALL FRONT DOOR TRIM BOARD SUBASSEMBLY (See page ED-33) 20. INSTALL COURTESY LIGHT ASSEMBLY (See page ED-34) 21. INSTALL ASSIST GRIP COVER (See page ED-34) 22. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG (See page ED-34) WINDSHIELD / WINDOWGLASS – POWER WINDOW REGULATOR MOTOR WS–51 23. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH (See page ED-34) 24. INITIALIZE POWER WINDOW CONTROL SYSTEM (See page WS-8) WS WS–51 WINDSHIELD / WINDOWGLASS – WINDSHIELD GLASS WINDSHIELD GLASS WINDSHIELD / WINDOWGLASS BODY COMPONENTS ROOF HEADLINING ASSEMBLY FRONT ASSIST GRIP SUB-ASSEMBLY WS ASSIST GRIP COVER VISOR BRACKET COVER VISOR ASSEMBLY RH FRONT PILLAR GARNISH CLIP VISOR HOLDER ROOF CONSOLE BOX ASSEMBLY FRONT ASSIST GRIP SUB-ASSEMBLY ASSIST GRIP COVER VISOR HOLDER VISOR ASSEMBLY LH VISOR BRACKET COVER FRONT DOOR OPENING TRIM WEATHERSTRIP RH FRONT PILLAR GARNISH RH FRONT PILLAR GARNISH CLIP FRONT WIPER ARM AND BLADE ASSEMBLY RH 20 (204, 15) FRONT PILLAR GARNISH LH 20 (204, 15) FRONT DOOR OPENING TRIM WEATHERSTRIP LH FRONT WIPER ARM AND BLADE ASSEMBLY LH FRONT FENDER TO COWL SIDE SEAL RH FRONT FENDER TO COWL SIDE SEAL LH N*m (kgf*cm, ft.*lbf) : Specified torque COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Non-reusable part B142346E01 WS–52 WINDSHIELD / WINDOWGLASS – WINDSHIELD GLASS without EC Mirror: TMC made: with EC Mirror: without EC Mirror: TMMK made: INNER REAR VIEW MIRROR STAY HOLDER COVER WS 1.8 (18, 16 in.*lbf) INNER REAR VIEW MIRROR ASSEMBLY INNER REAR VIEW MIRROR ASSEMBLY 1.8 (18, 16 in.*lbf) INNER REAR VIEW MIRROR ASSEMBLY NO. 1 WINDSHIELD GLASS STOPPER *2 NO. 2 WINDSHIELD GLASS STOPPER *1 NO. 2 WINDSHIELD GLASS STOPPER *2 WINDSHIELD GLASS WINDSHIELD MOULDING WINDOW GLASS ADHESIVE DAM WINDSHIELD GLASS RETAINER WINDSHIELD GLASS RETAINER *1: 1-Piece type *2: 2-Piece type WINDSHIELD GLASS ASSEMBLY Non-reusable part N*m (kgf*cm, ft.*lbf) : Specified torque B136128E01 WINDSHIELD / WINDOWGLASS – WINDSHIELD GLASS WS–53 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH (See page WW-9) 3. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH (See page WW-9) 4. REMOVE FRONT FENDER TO COWL SIDE SEAL LH (See page WW-9) 5. REMOVE FRONT FENDER TO COWL SIDE SEAL RH (See page WW-9) 6. REMOVE COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See page WW-10) 7. REMOVE INNER REAR VIEW MIRROR ASSEMBLY (for TMC Made without EC Mirror) (See page MI-11) 8. REMOVE INNER REAR VIEW MIRROR ASSEMBLY (for TMMK Made without EC Mirror) (See page MI-11) 9. REMOVE INNER REAR VIEW MIRROR STAY HOLDER COVER (w/ EC Mirror) (See page MI-11) 10. REMOVE INNER REAR VIEW MIRROR ASSEMBLY (w/ EC Mirror) (See page MI-12) 11. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH 12. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH 13. REMOVE FRONT PILLAR GARNISH LH (See page IR27) 14. REMOVE FRONT PILLAR GARNISH RH (See page IR27) 15. REMOVE ROOF CONSOLE BOX ASSEMBLY (See page IR-28) 16. REMOVE VISOR ASSEMBLY LH (See page IR-28) 17. REMOVE VISOR ASSEMBLY RH (See page IR-29) 18. REMOVE VISOR HOLDER (See page IR-29) 19. REMOVE FRONT ASSIST GRIP SUB-ASSEMBLY (See page IR-29) 20. REMOVE ROOF HEADLINING ASSEMBLY (w/o Sliding Roof) It is not necessary to completely remove the roof headlining assembly. Slightly lower the front section of the roof headlining assembly so that the windshield glass can be removed (See page IR-31). WS WS–54 WINDSHIELD / WINDOWGLASS – WINDSHIELD GLASS 21. REMOVE ROOF HEADLINING ASSEMBLY (w/ Sliding Roof) It is not necessary to completely remove the roof headlining assembly. Slightly lower the front section of the roof headlining assembly so that the windshield glass can be removed (See page IR-32). WS Windshield Glass Cut Body Moulding B136131E01 22. REMOVE WINDSHIELD MOULDING (a) Using a knife, cut off the moulding, as shown in the illustration. NOTICE: • Do not damage the vehicle body with the knife. • If the vehicle body is damaged, repair the damaged portion by applying an anti-rust coating after removing the windshield glass. (b) Remove the remaining moulding from the windshield glass. HINT: When removing the moulding, make a partial cut, then pull and remove it by hand. 23. REMOVE WINDSHIELD GLASS ASSEMBLY NOTICE: • There are No. 1 and No. 2 stoppers on the windshield glass as shown in the illustration. Be careful not to damage the windshield glass when cutting off the adhesive. • To prevent the windshield glass from dropping when performing this operation, be sure to hold the windshield glass using suction cups. HINT: Depending on vehicles, a 1-piece or 2-piece type stopper is used. 1-piece type: No. 2 2-piece type: No. 1 No. 2 B136132E01 WINDSHIELD / WINDOWGLASS – WINDSHIELD GLASS Protective Tape WS–55 (a) Apply protective tape to the installation position of the windshield glass assembly on the vehicle body. HINT: Apply protective tape to the installation surface to prevent it from being scratched. WS B136130E01 Plastic Sheet Protective Tape Wooden Blocks Piano Wire Stopper (b) Pass a piano wire between the vehicle body and glass from the interior. (c) Tie both wire ends to wooden blocks or similar objects. (d) Cut off the adhesive by pulling the piano wire around the windshield glass. NOTICE: • When separating the windshield glass, take care not to damage the paint or the interior and exterior ornaments. • To prevent the safety pad from being scratched when removing the windshield glass, place a plastic sheet between the piano wire and safety pad. Piano Wire Retainer B136134E01 Mark B136133E01 (e) Place matchmarks on the windshield glass and vehicle body on the locations indicated in the illustration. HINT: Matchmarks do not need to be placed if the windshield glass is not going to be reused. (f) Using a suction cup, remove the windshield glass assembly. NOTICE: • Be careful not to drop the windshield glass. • Leave as much adhesive on the vehicle body as possible when removing the windshield glass. 24. REMOVE WINDOW GLASS ADHESIVE DAM (a) Using a scraper, remove the adhesive dam. NOTICE: • Be careful not to damage the windshield glass. • Be sure to replace the adhesive dam with a new one. WS–56 WINDSHIELD / WINDOWGLASS – WINDSHIELD GLASS 25. REMOVE NO. 2 WINDSHIELD GLASS STOPPER (a) Using a scraper, remove the 2 No. 2 stoppers. NOTICE: • Be careful not to damage the windshield glass. • Be sure to replace the No. 2 stoppers with new ones. WS 26. REMOVE WINDSHIELD GLASS RETAINER (a) Using a scraper, remove the 2 retainers. NOTICE: • Be careful not to damage the windshield glass. • Be sure to replace the retainer with a new one. 27. REMOVE NO. 1 WINDSHIELD GLASS STOPPER (for 2 Piece Type) (a) Remove the 2 No. 1 stoppers. NOTICE: Be sure to replace the No. 1 stoppers with new ones. B136135 B106929 28. CLEAN WINDSHIELD GLASS (a) Using a scraper, remove the adhesive tape and adhesive sticking to the windshield glass. NOTICE: Be careful not to damage the windshield glass. (b) Clean the outer circumference of the windshield glass with a non-residue solvent. NOTICE: • Do not touch the windshield glass surface after cleaning it. • Even if using a new windshield glass, clean the windshield glass with a non-residue solvent. WINDSHIELD / WINDOWGLASS – WINDSHIELD GLASS Adhesive Adhesive Body B106934E04 WS–57 29. CLEAN VEHICLE BODY (a) Clean and shape the contact surface of the vehicle body. (1) Using a knife, cut away any rough adhesive on the contact surface of the vehicle body to ensure the appropriate surface shape. NOTICE: Be careful not to damage the vehicle body. HINT: Leave as much adhesive on the vehicle body as possible. (2) Clean the contact surface of the vehicle body with a piece of cloth saturated with cleaner. HINT: Even if all the adhesive has been removed, clean the vehicle body. WS WS–58 WINDSHIELD / WINDOWGLASS – WINDSHIELD GLASS INSTALLATION 1. WS INSTALL NO. 2 WINDSHIELD GLASS STOPPER (a) Using a brush or sponge, coat the application area of the No. 2 stoppers with Primer G. NOTICE: • Do not apply too much primer. • Allow the primer coating to dry for 3 minutes or more. • Do not keep any of the opened Primer G for later use. HINT: If an area other than that specified is coated by accident, wipe off the primer with a clean piece of cloth before it dries. (b) Install 2 new No. 2 stoppers onto the windshield glass, as shown in the illustration. HINT: Only 2-piece type No. 1 stoppers are supplied. Use the 2-piece type stoppers even if a 1-piece type was used. Standard dimension Area Dimension A 13.2 mm (0.519 in.) Back Side: Ceramic Notch Ceramic Notch A A B136136E01 2. INSTALL WINDSHIELD GLASS RETAINER (a) Using a brush or sponge, coat the application area of the retainers with Primer G. NOTICE: • Do not apply too much primer. • Allow the primer coating to dry for 3 minutes or more. • Do not keep any of the opened Primer G for later use. HINT: If an area other than that specified is coated by accident, wipe off the primer with a clean piece of cloth before it dries. WINDSHIELD / WINDOWGLASS – WINDSHIELD GLASS WS–59 (b) Install 2 new retainers onto the windshield glass, as shown in the illustration. Back Side: WS Ceramic Notch Ceramic Notch B136137E01 Stopper 3. INSTALL NO. 1 WINDSHIELD GLASS STOPPER (a) Install 2 new No. 1 stoppers to the vehicle body, as shown in the illustration. HINT: Only 2-piece type No. 1 stoppers are supplied. Use the 2-piece type stoppers even if a 1-piece type was used. 4. INSTALL WINDSHIELD MOULDING (a) Using a brush or sponge, coat the application area of moulding with Primer G. NOTICE: • Do not apply too much primer. • Allow the primer coating to dry for 3 minutes or more. • Do not keep any of the opened Primer G for later use. HINT: If an area other than that specified is coated by accident, wipe off the primer with a clean piece of cloth before it dries. Body B144518E01 WS–60 WINDSHIELD / WINDOWGLASS – WINDSHIELD GLASS (b) Install a new moulding, as shown in the illustration. Back Side: WS Ceramic Notch Ceramic Notch B136139E01 5. INSTALL WINDOW GLASS ADHESIVE DAM (a) Using a brush or sponge, coat the application area of adhesive dam with Primer G. NOTICE: • Do not apply too much primer. • Allow the primer coating to dry for 3 minutes or more. • Do not keep any of the opened Primer G for later use. HINT: If an area other than that specified is coated by accident, wipe off the primer with a clean piece of cloth before it dries. (b) Install a new adhesive dam onto the windshield glass, as shown in the illustration. NOTICE: Install the new adhesive dam along the ceramic notches. Standard dimension Area Dimension A 6.5 mm (0.255 in.) WS–61 WINDSHIELD / WINDOWGLASS – WINDSHIELD GLASS Back Side: WS A Ceramic Notch Ceramic Notch B136138E01 6. Mark B136133E01 Brush Primer M CORRECT WRONG Primer M Adhesive Primer M B136140E01 INSTALL WINDSHIELD GLASS ASSEMBLY (a) Position the windshield glass assembly. (1) Using a suction cup, place the windshield glass assembly in the correct position. (2) Check that the whole contact surface of the windshield glass rim is perfectly even. (3) Align the matchmarks on the windshield glass and vehicle body. NOTICE: Check that the windshield glass stoppers are attached to the vehicle body correctly. (4) Remove the windshield glass assembly. (b) Using a brush, coat the installation surface on the vehicle body with Primer M. NOTICE: • Do not coat the adhesive with Primer M. • Do not apply too much primer. • Allow the primer coating to dry for 3 minutes or more. • Do not keep any of the opened Primer M for later use. HINT: If an area other than that specified is coated by accident, wipe off the primer with a clean piece of cloth before it dries. (c) Using a brush or sponge, coat the application area of adhesive with Primer G. NOTICE: • Do not apply too much primer. • Allow the primer coating to dry for 3 minutes or more. • Do not keep any of the opened Primer G for later use. HINT: • Apply Primer G onto the ceramic notches. • If an area other than that specified is coated by accident, wipe off the primer with a clean piece of cloth before it dries. WS–62 WINDSHIELD / WINDOWGLASS – WINDSHIELD GLASS Standard dimension WS Area Dimension a 8.7 mm (0.342 in.) b 7.0 mm (0.275 in.) c 6.5 mm (0.255 in.) Back Side: Ceramic Notch Ceramic Notch A-A b a Adhesive Center A B B B-B b a A Adhesive Center C-C C c b C Adhesive Center Ceramic Notch Ceramic Notch B136141E01 (d) Apply adhesive (Adhesive: TOYOTA genuine windshield glass adhesive or equivalent). (1) Cut off the tip of the cartridge nozzle, as shown in the illustration. HINT: After cutting off the tip, use all adhesive within the time described in the table below. Usage time frame Temperature Tack-free Time 35°C (95°F) 15 minutes 20°C (68°F) 1 hour and 40 minutes 5°C (41°F) 8 hours (2) Load the sealer gun with cartridge. (3) Apply adhesive to the windshield glass, as shown in the illustration. HINT: Apply adhesive onto the ceramic notches. WS–63 WINDSHIELD / WINDOWGLASS – WINDSHIELD GLASS Standard dimension Area Dimension a 8.7 mm (0.342 in.) b 6.5 mm (0.255 in.) c 12.0 mm (0.472 in.) d 8.0 mm (0.315 in.) WS Back Side: Ceramic Notch Ceramic Notch A-A a Adhesive Center A B B B-B a A Adhesive Center c d C-C C b C d Ceramic Notch Adhesive Ceramic Notch Adhesive Center c B136142E01 Mark B136143E01 (e) Install the windshield glass assembly. (1) Using a suction cup, position the windshield glass so that the matchmarks are aligned, and press it in gently along the rim. NOTICE: • Check that the windshield glass stoppers are attached to the vehicle body correctly. • Check the clearance between the vehicle body and windshield glass. (2) Lightly press the front surface of the windshield glass to ensure a close fit. HINT: Press the glass with force of 98 N (10 kgf, 22 lb) or more. WS–64 WINDSHIELD / WINDOWGLASS – WINDSHIELD GLASS (3) If necessary, use a scraper to correct the level or position of adhesive that has been applied. HINT: Apply adhesive onto the windshield glass rim. (4) Hold the windshield glass using protective tape until the applied adhesive becomes hard. NOTICE: Do not drive the vehicle for the time described in the table below. Minimum time Windshield WS Dam Dam Adhesive B106940E02 Temperature Minimum time prior to driving vehicle 35°C (95°F) 1 hour and 30 minutes 20°C (68°F) 5 hours 5°C (41°F) 24 hours 7. CHECK FOR LEAKS AND REPAIR (a) After the adhesive has hardened, apply water from the outside of the vehicle. Check that no water leaks into the cabin. (b) If water leaks into the cabin, allow the water to dry and add adhesive. (c) Remove the protective tape. 8. INSTALL ROOF HEADLINING ASSEMBLY (w/o Sliding Roof) (See page IR-45) 9. INSTALL ROOF HEADLINING ASSEMBLY (w/ Sliding Roof) (See page IR-46) 10. INSTALL FRONT ASSIST GRIP SUB-ASSEMBLY (See page IR-49) 11. INSTALL VISOR HOLDER (See page IR-49) 12. INSTALL VISOR ASSEMBLY LH (See page IR-50) 13. INSTALL VISOR ASSEMBLY RH (See page IR-50) 14. INSTALL ROOF CONSOLE BOX ASSEMBLY (See page IR-50) 15. INSTALL FRONT PILLAR GARNISH LH (See page IR51) 16. INSTALL FRONT PILLAR GARNISH RH (See page IR52) 17. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH (See page IR-54) 18. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH (See page IR-55) 19. INSTALL INNER REAR VIEW MIRROR ASSEMBLY (for TMC Made without EC Mirror) (See page MI-13) 20. INSTALL INNER REAR VIEW MIRROR ASSEMBLY (for TMMK Made without EC Mirror) (See page MI-13) 21. INSTALL INNER REAR VIEW MIRROR ASSEMBLY (w/ EC Mirror) (See page MI-13) WINDSHIELD / WINDOWGLASS – WINDSHIELD GLASS WS–65 22. INSTALL INNER REAR VIEW MIRROR STAY HOLDER COVER (w/ EC Mirror) (See page MI-14) 23. INSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See page WW-15) 24. INSTALL FRONT FENDER TO COWL SIDE SEAL RH (See page WW-15) 25. INSTALL FRONT FENDER TO COWL SIDE SEAL LH (See page WW-15) 26. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 27. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH (See page WW-15) 28. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH (See page WW-16) 29. INSPECT SRS WARNING LIGHT (See page RS-32) WS WS–74 WINDSHIELD / WINDOWGLASS – BACK WINDOW GLASS REMOVAL WS 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE REAR SEAT CUSHION ASSEMBLY 3. REMOVE REAR SEAT HEADREST ASSEMBLY 4. REMOVE REAR CENTER SEAT HEADREST ASSEMBLY 5. REMOVE REAR SEAT BACK ASSEMBLY (for Fixed Seat Type) (See page SE-77) 6. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-47) 7. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) (See page SE-47) 8. REMOVE REAR SIDE SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-48) 9. REMOVE REAR SIDE SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) (See page SE-48) 10. REMOVE REAR SEAT BACK COVER (for Reclining Seat Type) (See page SE-63) 11. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Reclining Seat Type) (See page SE-63) 12. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Reclining Seat Type) (See page SE-64) 13. REMOVE CENTER SEAT BACK ASSEMBLY (for Reclining Seat Type) (See page SE-64) 14. REMOVE REAR DOOR SCUFF PLATE LH (See page IR-24) 15. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH 16. REMOVE REAR DOOR SCUFF PLATE RH (See page IR-24) 17. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH 18. REMOVE RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY LH (for Reclining Seat Type) (See page SE-68) 19. REMOVE RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY RH (for Reclining Seat Type) 20. REMOVE ROOF SIDE INNER GARNISH LH (See page IR-26) WINDSHIELD / WINDOWGLASS – BACK WINDOW GLASS WS–75 21. REMOVE ROOF SIDE INNER GARNISH RH (See page IR-26) 22. REMOVE CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH (See page SB-66) 23. DISCONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH (for TMC Made) (See page SB35) 24. DISCONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH (for TMMK Made) (See page SB-35) 25. DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) (See page SB-50) 26. DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) (See page SB-50) 27. REMOVE REAR SEAT SHOULDER BELT COVER (See page SB-36) 28. REMOVE REAR SEAT SHOULDER BELT HOLE COVER (See page SB-36) 29. REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY (See page SB-37) 30. REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY (for Reclining Seat Type) (See page SB-37) 31. REMOVE REAR ASSIST GRIP SUB-ASSEMBLY (See page IR-29) 32. REMOVE SPOT LIGHT ASSEMBLY (w/ Sliding Roof) (See page IR-30) 33. REMOVE SUNSHADE TRIM HOLDER (w/ Rear Sunshade) (See page IR-31) 34. REMOVE ROOF HEADLINING ASSEMBLY (w/o Sliding Roof) It is not necessary to completely remove the roof headlining. Slightly lower the rear section of the roof headlining so that the back window glass can be removed (See page IR-31). 35. REMOVE ROOF HEADLINING ASSEMBLY (w/ Sliding Roof) It is not necessary to completely remove the roof headlining. Slightly lower the rear section of the roof headlining so that the back window glass can be removed (See page IR-32). WS WS–76 WINDSHIELD / WINDOWGLASS – BACK WINDOW GLASS Back Window Glass 36. REMOVE BACK WINDOW MOULDING (a) Using a knife, cut off the moulding, as shown in the illustration. NOTICE: • Do not damage the vehicle body with the knife. • If the vehicle body is damaged, repair the damaged portion by applying an anti-rust coating after removing the back window glass assembly. (b) Remove the remaining moulding from the back window glass. HINT: When removing the moulding, make a partial cut, then pull and remove it by hand. Cut Body Moulding WS B136145E01 37. REMOVE BACK WINDOW GLASS ASSEMBLY NOTICE: • There are No. 1 and No. 2 stoppers on the back window glass as shown in the illustration. Be careful not to damage the back window glass when cutting off the adhesive. • To prevent the back window glass from dropping when performing this operation, be sure to hold the back window glass using suction cups. HINT: Depending on vehicles, a 1-piece or 2-piece type stopper is used. 1-piece type: 2-piece type: No. 1 No. 2 No. 2 B136146E01 (a) Disconnect the connector. B136148 WINDSHIELD / WINDOWGLASS – BACK WINDOW GLASS WS–77 (b) Disconnect the connectors. WS for Diversity Antenna Only B146381E01 (c) Apply protective tape to the installation position of the back window glass assembly on the vehicle body. HINT: Apply protective tape to the installation surface to prevent it from being scratched. Protective Tape B136144E01 Protective Tape Plastic Sheet Wooden Blocks Piano Wire Stopper (d) Pass a piano wire between the vehicle body and glass from the interior. (e) Tie both wire ends to wooden blocks or similar objects. (f) Cut off the adhesive by pulling the piano wire around the back window glass. NOTICE: • When separating the back window glass, take care not to damage the paint or the interior and exterior ornaments. • To prevent the package tray trim panel from being scratched when removing the back window glass, place a plastic sheet between the piano wire and package tray trim panel. Piano Wire B136150E01 Mark B136147E01 (g) Place matchmarks on the back window glass and vehicle body on the locations indicated in the illustration. HINT: Matchmarks do not need to be placed if the back window glass is not going to be reused. (h) Using a suction cup, remove the back window glass assembly. NOTICE: • Be careful not to drop the back window glass. WS–78 WINDSHIELD / WINDOWGLASS – BACK WINDOW GLASS • Leave as much adhesive on the vehicle body as possible when removing the back window glass. 38. REMOVE NO. 2 BACK WINDOW GLASS STOPPER (a) Using a scraper, remove the 2 No. 2 stoppers. NOTICE: • Be careful not to damage the back window glass. • Be sure to replace the No. 2 stoppers with new ones. WS 39. REMOVE NO. 1 BACK WINDOW GLASS STOPPER (for 2 Piece Type) (a) Using a scraper, remove the 2 No. 1 stoppers. NOTICE: Be sure to replace the No. 1 stoppers with new ones. B136151 B106929 Adhesive Adhesive Body B106934E04 40. CLEAN BACK WINDOW GLASS (a) Using a scraper, remove the adhesive tape and adhesive sticking to the back window glass. NOTICE: Be careful not to damage the windshield glass. (b) Clean the outer circumference of the back window glass with a non-residue solvent. NOTICE: • Do not touch the back window glass surface after cleaning it. • Even if using a new back window glass, clean the back window glass with a non-residue solvent. 41. CLEAN VEHICLE BODY (a) Clean and shape the contact surface of the vehicle body. (1) Using a knife, cut away any rough adhesive on the contact surface of the vehicle body to ensure the appropriate surface shape. NOTICE: Be careful not to damage the vehicle body. HINT: Leave as much adhesive on the vehicle body as possible. WINDSHIELD / WINDOWGLASS – BACK WINDOW GLASS WS–79 (2) Clean the contact surface of the vehicle body with a piece of cloth saturated with cleaner. HINT: Even if all the adhesive has been removed, clean the vehicle body. WS WS–66 WINDSHIELD / WINDOWGLASS – BACK WINDOW GLASS BACK WINDOW GLASS WINDSHIELD / WINDOWGLASS BODY COMPONENTS WS for Fixed Seat Type: REAR SEAT HEADREST ASSEMBLY REAR CENTER SEAT HEADREST ASSEMBLY REAR SEAT BACK ASSEMBLY 18 (184, 13) 18 (184, 13) REAR SEAT CUSHION ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B136589E02 WINDSHIELD / WINDOWGLASS – BACK WINDOW GLASS WS–67 for Fold Down Seat Type: REAR SEAT HEADREST ASSEMBLY WS REAR CENTER SEAT HEADREST ASSEMBLY 18 (184, 13) 18 (184, 13) 18 (184, 13) REAR SIDE SEAT BACK ASSEMBLY RH SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH 18 (184, 13) REAR SEAT CUSHION ASSEMBLY REAR SIDE SEAT BACK ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque B136564E02 WS–68 WINDSHIELD / WINDOWGLASS – BACK WINDOW GLASS for Reclining Seat Type: REAR SEAT HEADREST ASSEMBLY WS 18 (184, 13) REAR CENTER SEAT HEADREST ASSEMBLY CENTER SEAT BACK ASSEMBLY REAR SEAT BACK COVER 18 (184, 13) 18 (184, 13) 18 (184, 13) SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH REAR SEAT BACK COVER 18 (184, 13) SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH REAR SEAT CUSHION ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B139095E03 WINDSHIELD / WINDOWGLASS – BACK WINDOW GLASS WS–69 ROOF SIDE INNER GARNISH RH REAR DOOR OPENING TRIM WEATHERSTRIP RH WS for Reclining Seat Type: 18 (184, 13) RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY RH REAR DOOR SCUFF PLATE RH ROOF SIDE INNER GARNISH LH for Reclining Seat Type: REAR DOOR OPENING TRIM WEATHERSTRIP LH 18 (184, 13) RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY LH REAR DOOR SCUFF PLATE LH N*m (kgf*cm, ft.*lbf) : Specified torque B132018E01 WS–70 WINDSHIELD / WINDOWGLASS – BACK WINDOW GLASS for TMC made: for Reclining Seat Type: WS PACKAGE TRAY TRIM PANEL ASSEMBLY PACKAGE TRAY TRIM PANEL ASSEMBLY REAR SEAT SHOULDER BELT COVER REAR SEAT SHOULDER BELT HOLE COVER REAR SEAT SHOULDER BELT COVER REAR SEAT OUTER BELT ASSEMBLY 18 (184, 13) 42 (428, 31) 42 (428, 31) REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH for Fold Down Seat Type: CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH 18 (184, 13) CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH 42 (428, 31) REAR SEAT OUTER BELT ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B132113E03 WINDSHIELD / WINDOWGLASS – BACK WINDOW GLASS WS–71 for TMMK made: for Reclining Seat Type: WS PACKAGE TRAY TRIM PANEL ASSEMBLY PACKAGE TRAY TRIM PANEL ASSEMBLY REAR SEAT SHOULDER BELT COVER REAR SEAT SHOULDER BELT HOLE COVER REAR SEAT SHOULDER BELT COVER REAR SEAT OUTER BELT ASSEMBLY 18 (184, 13) 42 (428, 31) 42 (428, 31) REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH for Fold Down Seat Type: CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH 18 (184, 13) CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH 42 (428, 31) REAR SEAT OUTER BELT ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B142742E02 WS–72 WINDSHIELD / WINDOWGLASS – BACK WINDOW GLASS without Sliding Roof: REAR ASSIST GRIP SUB-ASSEMBLY WS ASSIST GRIP COVER ROOF HEADLINING ASSEMBLY REAR ASSIST GRIP SUB-ASSEMBLY ASSIST GRIP COVER with Sliding Roof: REAR ASSIST GRIP SUB-ASSEMBLY ASSIST GRIP COVER ROOF HEADLINING ASSEMBLY REAR ASSIST GRIP SUB-ASSEMBLY with Rear Sunshade: ASSIST GRIP COVER SUNSHADE TRIM HOLDER SPOT LIGHT ASSEMBLY B142347E01 WINDSHIELD / WINDOWGLASS – BACK WINDOW GLASS WS–73 NO. 1 BACK WINDOW GLASS STOPPER *2 NO. 2 BACK WINDOW GLASS STOPPER *1 NO. 2 BACK WINDOW GLASS STOPPER *2 BACK WINDOW GLASS BACK WINDOW MOULDING *1: 1-Piece type *2: 2-Piece type BACK WINDOW GLASS ASSEMBLY Non-reusable part B136129E01 WS WS–80 WINDSHIELD / WINDOWGLASS – BACK WINDOW GLASS INSTALLATION 1. WS INSTALL NO. 2 BACK WINDOW GLASS STOPPER (a) Using a brush or sponge, coat the application area of the No. 2 stoppers with Primer G. NOTICE: • Do not apply too much primer. • Allow the primer coating to dry for 3 minutes or more. • Do not keep any of the opened Primer G for later use. HINT: If an area other than that specified is coated by accident, wipe off the primer with a clean piece of cloth before it dries. (b) Install 2 new No. 2 stoppers onto the windshield glass, as shown in the illustration. HINT: Only 2-piece type No. 2 stoppers are supplied. Use the 2-piece type stoppers even if a 1-piece type was used. Standard dimension Area Dimension A 16.4 mm (0.645 in.) Back Side: Ceramic Notch A Ceramic Notch A B136152E01 WINDSHIELD / WINDOWGLASS – BACK WINDOW GLASS 2. Stopper Body WS–81 INSTALL NO. 1 BACK WINDOW GLASS STOPPER (a) Install 2 new No. 1 stoppers to the vehicle body, as shown in the illustration. HINT: Only 2-piece type No. 1 stoppers are supplied. Use the 2-piece type stoppers even if a 1-piece type was used. B144549E01 Back Side: 3. INSTALL BACK WINDOW MOULDING (a) Using a brush or sponge, coat the application area of moulding with Primer G. NOTICE: • Do not apply too much primer. • Allow the primer coating to dry for 3 minutes or more. • Do not keep any of the opened Primer G for later use. HINT: If an area other than that specified is coated by accident, wipe off the primer with a clean piece of cloth before it dries. (b) Install a new moulding, as shown in the illustration. NOTICE: Align the joint of the new moulding with the ceramic notch. 4. INSTALL BACK WINDOW GLASS ASSEMBLY (a) Position the back window glass assembly. (1) Using a suction cup, place the back window glass in the correct position. (2) Check that the whole contact surface of the back window glass rim is perfectly even. (3) Align the matchmarks on the back window glass and vehicle body. NOTICE: Check that the back window glass stoppers are attached to the vehicle body correctly. (4) Remove the back window glass assembly. Ceramic Notch B136153E01 Mark B136147E01 WS WS–82 WINDSHIELD / WINDOWGLASS – BACK WINDOW GLASS Brush Primer M WS CORRECT WRONG Primer M Adhesive Primer M B136154E01 Back Side: B Area Dimension a 10.75 mm (0.423 in.) b 7.0 mm (0.275 in.) c 10.25 mm (0.403 in.) d 8.0 mm (0.315 in.) B-B A-A A B (b) Using a brush, coat the installation surface on the vehicle body with Primer M. NOTICE: • Do not coat the adhesive with Primer M. • Do not apply too much primer. • Allow the primer coating to dry for 3 minutes or more. • Do not keep any of the opened Primer M for later use. HINT: If an area other than that specified is coated by accident, wipe off the primer with a clean piece of cloth before it dries. (c) Using a brush or sponge, coat the application area of adhesive with Primer G. NOTICE: • Do not apply too much primer. • Allow the primer coating to dry for 3 minutes or more. • Do not keep any of the opened Primer G for later use. HINT: If an area other than that specified is coated by accident, wipe off the primer with a clean piece of cloth before it dries. Standard dimension a a A Adhesive Center C c D D Adhesive Center D-D C-C C b b Adhesive Center c d b Adhesive Center B136155E01 WS–83 WINDSHIELD / WINDOWGLASS – BACK WINDOW GLASS (d) Apply adhesive (Adhesive: TOYOTA genuine windshield glass adhesive or equivalent). (1) Cut off the tip of the cartridge nozzle, as shown in the illustration. HINT: After cutting off the tip, use all adhesive within the time described in the table below. Usage time frame Temperature Tack-free Time 35°C (95°F) 15 minutes 20°C (68°F) 1 hour and 40 minutes 5°C (41°F) 8 hours (2) Load the sealer gun with cartridge. (3) Apply adhesive to the back window glass, as shown in the illustration. Standard dimension Back Side: A B B C e Adhesive C Dimension a 10.75 mm (0.423 in.) b 10.25 mm (0.403 in.) c 8.0 mm (0.315 in.) d 12.0 mm (0.472 in.) e 8.0 mm (0.315 in.) A-A a B-B a A Adhesive Center C-C b d e Area Adhesive Center D-D b c D D Adhesive Center Adhesive Center d B136156E01 Mark B136277E01 (e) Install the back window glass assembly. (1) Using a suction cup, position the back window glass so that the matchmarks are aligned, and press it in gently along the rim. NOTICE: • Check that the back window glass stoppers are attached to the vehicle body correctly. • Check the clearance between the vehicle body and back window glass. WS WS–84 WINDSHIELD / WINDOWGLASS – BACK WINDOW GLASS (2) Lightly press the front surface of the back window glass to ensure a close fit. HINT: Press the glass with force of 98 N (10 kgf, 22 lb) or more. (3) Hold the back window glass using protective tape until applied adhesive becomes hard. NOTICE: Do not drive the vehicle for the time described in the table below. Minimum time WS (f) Temperature Minimum time prior to driving vehicle 35°C (95°F) 1 hour and 30 minutes 20°C (68°F) 5 hours 5°C (41°F) 24 hours Connect the connectors. for Diversity Antenna Only B146381E01 (g) Connect the connector. B136148 5. CHECK FOR LEAKS AND REPAIR (a) After the adhesive has hardened, apply water from the outside of the vehicle. Check that no water leaks into the cabin. (b) If water leaks into the cabin, allow the water to dry and add adhesive. (c) Remove the protective tape. 6. INSTALL ROOF HEADLINING ASSEMBLY (w/o Sliding Roof) (See page IR-45) 7. INSTALL ROOF HEADLINING ASSEMBLY (w/ Sliding Roof) (See page IR-46) 8. INSTALL SUNSHADE TRIM HOLDER (w/ Rear Sunshade) (See page IR-47) 9. INSTALL SPOT LIGHT ASSEMBLY (w/ Sliding Roof) (See page IR-48) 10. INSTALL REAR ASSIST GRIP SUB-ASSEMBLY (See page IR-49) 11. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY (See page SB-38) 12. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY (for Reclining Seat Type) (See page SB-39) WINDSHIELD / WINDOWGLASS – BACK WINDOW GLASS WS–85 13. INSTALL REAR SEAT SHOULDER BELT HOLE COVER (See page SB-39) 14. INSTALL REAR SEAT SHOULDER BELT COVER (See page SB-39) 15. CONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) (See page SB-52) 16. CONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) (See page SB-52) 17. CONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH (for TMC Made) (See page SB-40) 18. CONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH (for TMMK Made) (See page SB-40) 19. INSTALL CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH (See page SB-66) 20. INSTALL ROOF SIDE INNER GARNISH LH (See page IR-52) 21. INSTALL ROOF SIDE INNER GARNISH RH (See page IR-52) 22. INSTALL RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY LH (for Reclining Seat Type) (See page SE-69) 23. INSTALL RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY RH (for Reclining Seat Type) 24. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (See page IR-55) 25. INSTALL REAR DOOR SCUFF PLATE LH (See page IR-56) 26. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH (See page IR-56) 27. INSTALL REAR DOOR SCUFF PLATE RH (See page IR-56) 28. INSTALL CENTER SEAT BACK ASSEMBLY (for Reclining Seat Type) (See page SE-71) 29. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Reclining Seat Type) (See page SE-72) 30. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Reclining Seat Type) (See page SE-71) 31. INSTALL REAR SEAT BACK COVER (for Reclining Seat Type) 32. INSTALL REAR SIDE SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-57) 33. INSTALL REAR SIDE SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) WS WS–86 WINDSHIELD / WINDOWGLASS – BACK WINDOW GLASS 34. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-57) WS 35. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) (See page SE-57) 36. INSTALL REAR SEAT BACK ASSEMBLY (for Fixed Seat Type) (See page SE-84) 37. INSTALL REAR CENTER SEAT HEADREST ASSEMBLY 38. INSTALL REAR SEAT HEADREST ASSEMBLY 39. INSTALL REAR SEAT CUSHION ASSEMBLY 40. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 41. INSPECT SRS WARNING LIGHT (See page RS-32) WS–86 WINDSHIELD / WINDOWGLASS – WINDOW DEFOGGER SYSTEM WINDOW DEFOGGER SYSTEM WINDSHIELD / WINDOWGLASS BODY PARTS LOCATION WS ENGINE ROOM R/B, J/B - RR DEFOG RELAY NOISE FILTER AUTO A/C: MANUAL A/C: WINDOW DEFOGGER WIRE REAR WINDOW DEFOGGER SWITCH MAIN BODY ECU (INSTRUMENT PANEL J/B) A/C AMPLIFIER ASSEMBLY - A/C NO. 2 FUSE B137054E01 WS–87 WINDSHIELD / WINDOWGLASS – WINDOW DEFOGGER SYSTEM SYSTEM DIAGRAM WS Engine Room R/B, J/B A/C Amplifier Assembly RR DEF Relay from A/C No. 2 fuse 1 from RR DEF fuse 1 1 2 1 38 E38 RDFG 37 E38 LIN1 14 E38 GND 5 3 4 1 N18 Noise Filter Defogger Wire 1 P1 1 1 N19 1 2 F16 A/C Controller Assembly TX+ : LIN Communication Line 4 B137053E01 WS–88 WINDSHIELD / WINDOWGLASS – WINDOW DEFOGGER SYSTEM SYSTEM DESCRIPTION 1. WS 2. GENERAL The defogger system's thin heater wires are attached to the inside of the rear window and defog the window surface quickly. The indicator light illuminates while the system is operating. The system automatically turns off after approximately 15 minutes. HINT: The rear window defogger is linked with the mirror defogger. FUNCTION OF MAIN COMPONENT Component Outline Receives rear defogger activation request signals from A/C amplifier assembly (A/C ECU) and supplies power to rear window defogger. RR DEF Relay Rear Window Defogger Receives power from RR DEF relay and heats defogger wire. 3. DESCRIPTION Function Outline • Defogs the rear window surface • Receives rear defogger activation request signals from A/C amplifier assembly (A/C ECU) and supplies power to rear window defogger. Receives power from DEFOG relay and heats defogger wire. WINDSHIELD / WINDOWGLASS – WINDOW DEFOGGER SYSTEM WS–89 HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use the following procedure to troubleshoot the defogger system. • The intelligent tester should be used in step 4. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding to the next step. NEXT 3 PROBLEM SYMPTOMS TABLE HINT: (See page WS-89) NEXT 4 OVERALL ANALYSIS AND TROUBLESHOOTING (a) Terminals of ECU (See page WS-89) (b) Data List/Active Test (See page WS-91) (c) On-vehicle inspection (See page WS-92) NEXT 5 REPAIR OR REPLACE NEXT 6 NEXT END CONFIRMATION TEST WS WS–90 WINDSHIELD / WINDOWGLASS – WINDOW DEFOGGER SYSTEM PROBLEM SYMPTOMS TABLE WINDOW DEFOGGER SYSTEM: Symptom Suspected area 1. A/C No. 2, RR DEF fuses WS Rear window defogger does not operate See page - 2. RR DEF relay WS-94 3. A/C controller assembly WS-94 4. A/C amplifier assembly WS-94 5. Rear window defogger wire WS-92 6. Wire harness - WS–91 WINDSHIELD / WINDOWGLASS – WINDOW DEFOGGER SYSTEM TERMINALS OF ECU 1. CHECK A/C AMPLIFIER ASSEMBLY E38 WS B126304E02 (a) Measure the voltage and resistance of each terminal of the connectors. Standard voltage Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition RDFG (E38-38) - GND (E38-14) G - W-B Rear Defogger Signal Ignition switch on (IG), Rear defogger switch OFF 10 to 14 V Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition GND (E38-14) - Body ground W-B - Body ground Ground Always Below 1 Ω Standard resistance WS–92 WINDSHIELD / WINDOWGLASS – WINDOW DEFOGGER SYSTEM DIAGNOSIS SYSTEM 1. DESCRIPTION (a) The defogger system data can be read from the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the intelligent tester to check for malfunctions and perform repairs. 2. CHECK DLC3 WS CG SG CANH SIL BAT CANL H100769E16 (a) The ECU uses ISO 15765-4 communication. The terminal arrangement of the DLC3 complies with SAE J 1962 and matches the ISO 15765-4 format. DLC3 Intelligent Tester C131977E01 Symbols (Terminal No.) Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 10 to 14 V CANH (6) - CANL (14) CAN bus line Ignition switch OFF* 54 to 69 Ω CANH (6) - CG (4) HIGH-level CAN bus line Ignition switch OFF* 200 Ω or more CANL (14) - CG (4) LOW-level CAN bus line Ignition switch OFF* 200 Ω or more CANH (6) - BAT (16) HIGH-level CAN bus line Ignition switch OFF* 6 kΩ or more CANL (14) - BAT (16) LOW-level CAN bus line Ignition switch OFF* 6 kΩ or more NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the door. WINDSHIELD / WINDOWGLASS – WINDOW DEFOGGER SYSTEM WS–93 If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of the intelligent tester to the DLC3, turn the ignition switch on (IG) and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. • If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. WS WS–94 WINDSHIELD / WINDOWGLASS – WINDOW DEFOGGER SYSTEM DATA LIST / ACTIVE TEST 1. WS PERFORM ACTIVE TEST HINT: Performing the intelligent tester's ACTIVE TEST allows a relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the ignition switch on (IG). (c) Perform the ACTIVE TEST according to the display on the tester. Air Conditioner: Item Test Details Diagnostic Note Defogger Relay (Rear) Turns rear window defogger OFF/ON - WS–95 WINDSHIELD / WINDOWGLASS – WINDOW DEFOGGER SYSTEM ON-VEHICLE INSPECTION 1. 2. Defogger Wire Tester Probe CHECK REAR WINDOW DEFOGGER SYSTEM OPERATION (a) When the ignition switch is turned on (IG) and the defogger switch is pressed, check that the rear window defogger operates. HINT: After 15 minutes, check that the defogger automatically turns off. INSPECT BACK WINDOW (DEFOGGER WIRE) NOTICE: • When cleaning the glass, wipe the glass along the wire using a soft and dry cloth. Take care not to damage the wires. • Do not use detergents or glass cleaners that have abrasive ingredients. Tin Foil B106755E01 • When measuring voltage, wrap a piece of tin foil around the tip of the negative tester probe and press the foil against the wire with your finger, as shown in the illustration. (a) Turn the ignition switch on (IG). (b) Turn the defogger switch on. At Center B106756E01 0V Foil Strip Ground Side (-) (+) Less than 10 V Battery Side Broken Wire B106757E06 (c) Check the voltage at the center of each defogger wire, as shown in the illustration. Standard voltage Voltage Criteria Approx. 5 V Wire is not broken Approx. 10 or 0 V Wire is broken HINT: If there is approximately 10 V, the wire may be faulty between the center of the wire and the wire end on the battery side. If there is no voltage, the wire may be faulty between the center of the wire and the wire end on the ground side. (d) Place the voltmeter's positive (+) lead against the defogger wire on the battery side. (e) Place the voltmeter's negative (-) lead with the foil strip against the wire on the ground side. (f) Slide the positive (+) lead from the battery side to the ground side. WS WS–96 WINDSHIELD / WINDOWGLASS – WINDOW DEFOGGER SYSTEM (g) The point where the voltage drops from approximately 10 V to 0 V is the place where the defogger wire is broken. HINT: If the defogger wire is not broken, the voltmeter should indicate 0 V at the positive (+) end of the defogger wire but gradually increase to approximately 12 V as the meter probe moves to the other end. WS REPAIR 1. Masking Tape Repair Point REPAIR WINDOW DEFOGGER WIRE (a) Clean the broken wire tips with a grease, wax and silicone remover. (b) Place the masking tape along both sides of the wire. Broken Wire B106758E03 (c) Thoroughly mix the repair agent (Dupont paste No. 4817 or equivalent). (d) Using a fine tip brush, apply a small amount of the agent to the wire. (e) After a few minutes, remove the masking tape. NOTICE: Do not repair the defogger wire again for at least 24 hours. B106759 WS–97 WINDSHIELD / WINDOWGLASS – WINDOW DEFOGGER SYSTEM Rear Window Defogger System does not Operate DESCRIPTION When the rear window defogger switch, which is built into the heater control assembly, is operated, the operation signals are transmitted to the A/C amplifier assembly through LIN. When the A/C amplifier assembly receives the signals, it turns on the DEFOG relay to operate the rear window defogger. WIRING DIAGRAM Engine Room R/B, J/B A/C Amplifier Assembly RR DEF Relay from A/C No. 2 fuse 1 from RR DEF fuse 1 1 2 1 38 E38 RDFG 37 E38 LIN1 14 E38 GND 5 3 4 1 N18 Noise Filter Defogger Wire 1 P1 1 1 N19 1 2 F16 A/C Controller Assembly TX+ : LIN Communication Line 4 B137053E01 WS WS–98 WINDSHIELD / WINDOWGLASS – WINDOW DEFOGGER SYSTEM INSPECTION PROCEDURE 1 WS CHECK FOR DTCs (a) Select the DTC check on the intelligent tester to check for communication errors. Result Result Proceed to Not output DTC codes A Output DTC codes (LIN communication) B B GO TO MULTIPLEX COMMUNICATION SYSTEM A 2 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (a) Select the ACTIVE TEST, use the intelligent tester to issue a control command, and then check the window defogger operation. Air Conditioner Item Test Details Defogger Relay (Rear) Turns rear window defogger OFF/ON OK Go to step 5 NG 3 REPLACE AIR CONDITIONER CONTROL ASSEMBLY (a) Replace the air conditioner control assembly. NEXT 4 CONFIRM REAR WINDOW DEFOGGER OPERATION (a) Turn the ignition switch on (IG), press the defogger switch, and check that the window defogger operates. OK: System operates normally NG OK END REPLACE A/C AMPLIFIER ASSEMBLY WINDSHIELD / WINDOWGLASS – WINDOW DEFOGGER SYSTEM 5 WS–99 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (a) Select the ACTIVE TEST, use the intelligent tester to issue a control command, and then check the DEFOG relay operation. (b) Check that operation sound of the RR DEF relay is heard. Result Proceed to Relay operating sound is heard OK Relay operating sound is not heard NG OK Go to step 9 NG 6 INSPECT RR DEF RELAY See page WS-100. NG REPLACE RR DEF RELAY OK 7 CHECK WIRE HARNESS (RR DEF RELAY - BATTERY POSITIVE) (a) Disconnect the RR DEF relay. (b) Measure the voltage according to the value(s) in the table below. Standard voltage: Engine room R/B, J/B B137052E01 OK Tester Connection Condition Specified Condition 1 - Body ground Ignition switch on (IG) 10 to 14 V NG REPAIR OR REPLACE A/C NO. 2 FUSE, HARNESS OR CONNECTOR WS WS–100 8 WINDSHIELD / WINDOWGLASS – WINDOW DEFOGGER SYSTEM CHECK WIRE HARNESS (RR DEF RELAY - A/C AMPLIFIER ASSEMBLY) (a) Disconnect the RR DEF relay and A/C amplifier assembly connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Engine Room R/B, J/B: WS Condition 2 - E38-38 Always Below 1 Ω 2 - Body ground Always 10 kΩ or higher NG A/C Amplifier Assembly: E38 Tester Connection Specified Condition REPAIR OR REPLACE HARNESS OR CONNECTOR RDEF B140724E02 OK REPLACE A/C AMPLIFIER ASSEMBLY 9 INSPECT RR DEF RELAY See page WS-100. NG REPLACE RR DEF RELAY OK 10 CHECK WIRE HARNESS (RR DEF RELAY - BATTERY POSITIVE AND BODY GROUND) (a) Disconnect the RR DEF relay. (b) Measure the voltage and resistance according to the value(s) in the table below. Standard resistance: Engine room R/B, J/B B137052E01 Tester Connection Condition Specified Condition 4 - Body ground Always Below 1 Ω Tester Connection Condition Specified Condition 5 - Body ground Always 10 to 14 V Standard voltage: Engine room R/B, J/B WS–101 WINDSHIELD / WINDOWGLASS – WINDOW DEFOGGER SYSTEM NG REPAIR OR REPLACE RR DEF FUSE, HARNESS OR CONNECTOR OK 11 WS INSPECT NOISE FILTER (a) Disconnect the noise filter connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance N18 B140726E01 Tester Connection Condition Specified Condition N18-1 - N18-2 Always Below 1 Ω N18-1 - Body ground Always 10 kΩ or higher NG REPLACE NOISE FILTER OK 12 CHECK WIRE HARNESS (RR DEF RELAY - NOISE FILTER) (a) Disconnect the RR DEF relay and defogger wire connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Engine Room R/B, J/B: Tester Connection Condition Specified Condition 3 - N18-2 Always Below 1 Ω 3 - Body ground Always 10 kΩ or higher NG Noise Filter: N18 B140738E01 OK REPAIR OR REPLACE HARNESS OR CONNECTOR WS–102 13 WINDSHIELD / WINDOWGLASS – WINDOW DEFOGGER SYSTEM CHECK WIRE HARNESS (NOISE FILTER - DEFOGGER WIRE CONNECTOR) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Noise Filter: WS N18 Tester Connection Condition Specified Condition N18-1 - N19-1 Always Below 1 Ω N18-1 - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR Defogger Wire Connector: N19 B140737E01 OK 14 CHECK WIRE HARNESS (DEFOGGER WIRE CONNECTOR - BODY GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance P1 Tester Connection Condition Specified Condition P1-1 - Body ground Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR B127529E02 OK REPAIR OR REPLACE REAR WINDOW DEFOGGER WIRE WS–100 WINDSHIELD / WINDOWGLASS – DEFOGGER RELAY DEFOGGER RELAY 4 ON-VEHICLE INSPECTION 1 5 3 1. 4 5 WS 1 2 3 2 INSPECT DEFOGGER RELAY (Marking: DEFOG) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Condition Specified Condition 3-4 Below 1 Ω (when battery voltage is not applied between terminals) 3-5 10 kΩ or higher (when battery voltage is not applied between terminals) 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) B106753E01 If the result is not as specified, replace the relay. 2AZ-FE FUEL – FUEL SYSTEM FU–1 FUEL SYSTEM PRECAUTION 1. 2. A129607 3. PRECAUTION (a) Before inspecting and repairing the fuel system, disconnect the negative (-) battery terminal. (b) Do not smoke or work near fire when handling the fuel system. (c) Keep gasoline away from rubber or leather parts. DISCHARGE FUEL SYSTEM PRESSURE CAUTION: • Perform the following procedures to prevent fuel from spilling out before removing any fuel system parts. • Pressure will still remain in the fuel line even after performing the following procedures. When disconnecting the fuel line, cover it with a shop rag or a piece of cloth to prevent fuel from spraying or coming out. (a) Disconnect the fuel pump connector. (1) Remove the rear seat cushion assembly. (2) Remove the rear floor service hole cover. (3) Disconnect the fuel pump connector. (4) Start the engine. (5) After the engine stops, turn the ignition switch off. HINT: DTC P0171/25 (fuel problem) and/or P0191/49 (fuel pressure sensor signal error) may be detected. (6) Crank the engine again. Check that the engine does not start. (7) Remove the fuel tank cap to discharge pressure from the fuel tank. (8) Disconnect the negative (-) battery terminal. (9) Reconnect the fuel pump connector. (10)Install the rear floor service hole cover. (11)Install the rear seat. FUEL SYSTEM (a) When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe the following procedures: (1) Discharge the fuel system pressure. (step 2) (2) Disconnect the fuel pump tube (See page FU23). (3) Drain the fuel that remains inside the fuel pump tube. FU FU–2 2AZ-FE FUEL – FUEL SYSTEM (4) To protect the disconnected fuel pump tube from damage and contamination, cover it with a plastic bag. (5) Put a container under the connection part. Plastic Bag B000679E07 (b) Observe the following precautions when removing and installing the fuel injectors: (1) Never reuse an O-ring. (2) When placing a new O-ring on the injector, do not damage the O-ring. (3) Coat a new O-ring with gasoline before installing it. NOTICE: Do not use engine oil, gear oil or brake fluid. CORRECT INCORRECT FU O-Ring Delivery Pipe A131629E01 O-Ring Fuel Injector Insulator Fuel Delivery Pipe (c) Install the injector to the delivery pipe and cylinder head, as shown in the illustration. NOTICE: Before installing the injector, be sure to apply grease or gasoline to the place where the delivery pipe or cylinder head contacts the Oring of the injector. A097444E02 O-ring Nylon Tube Retainer Pipe Housing A050709E01 (d) Observe the following precautions when disconnecting the fuel delivery pipe (metallic type): HINT: The structure of the metallic connector is shown on the left. 2AZ-FE FUEL – FUEL SYSTEM FU–3 (1) Remove the No. 2 fuel pipe clamp. HINT: The No. 2 fuel pipe clamp cannot be reused. Fuel Pipe A136248E01 (2) Find the metallic connector of the fuel tube assembly. (3) Assemble SST to the connection as shown in the illustration. SST 09268-21010 (4) Turn the SST, align the retainers inside the connector with the SST chamfered parts and insert SST into the connector. (5) Slide the SST and the connector together towards the fuel tube assembly. Retainer (at 4 places) SST A130371E01 (e) Observe the following precautions when connecting the fuel tube connector (metallic type): (1) Check if there is any damage or foreign objects on the connecting part of the pipe. (2) Match the axis of the connector with the axis of the pipe, and push into the connector until the connector makes a "click" sound. If the connection is tight, apply a small amount of fresh engine oil to the tip of the pipe. Push B084645E01 (3) After finishing the connection, check if the pipe and the connector are securely connected by pulling on them. (4) Check for fuel leaks. Pull B084645E04 FU FU–4 2AZ-FE FUEL – FUEL SYSTEM (5) Install a new No. 2 fuel pipe clamp. Fuel Pipe A136248E02 (f) No. 1 Fuel Pipe Clamp FU Observe the following precautions when disconnecting the fuel tube connectors (Quick type A): (1) Remove the No. 1 fuel pipe clamp from the tube connector. (2) Check that there is no dirt or other foreign objects on the pipe and around the connector before disconnecting them. Clean them if necessary. A060083E16 (3) Disconnect the connector from the pipe by hand. (4) When the connector and the pipe are stuck, push in and pull on the connector to release it. Pull the connector out of the pipe carefully. (5) Check that there is no dirt or other foreign objects on the sealing surface of the disconnected pipe. Clean it away if necessary. Quick Type A A088336E10 (6) Do not damage the disconnected pipe and connector, and prevent entry of foreign objects by covering them with a plastic bag. Quick Type A Plastic Bag B009222E04 2AZ-FE FUEL – FUEL SYSTEM FU–5 (g) Observe the following precautions when connecting the fuel tube connectors (Quick Type A): (1) Check if there is any damage or foreign objects on the connecting parts of the pipes. (2) Line up the two parts of the pipes to be connected, and push them together until the connector makes a "click" sound. If the pipe is difficult to push into the connector, apply a small amount of clean engine oil to the tip of the pipe and reinsert it. (3) After connecting the pipes, check that the pipe and connector are securely connected by pulling on them. (4) Check for fuel leaks. Quick Type A Push Pull FU A121423E01 Quick Type B A129459E01 (h) Observe the following precautions when disconnecting the fuel tube connector (Quick type B): (1) Before disconnecting the connector, clean off any dirt that may be present. (2) Pinch the tabs of the fuel tube retainer to disengage the 2 claws. Push the retainer down as shown in the illustration. HINT: Be sure to disconnect the connector by hand. (3) If the connector and pipe are stuck, hold the fuel pipe by hand and push and pull on the connector. Pull the two pipes apart to separate the connector. (4) If there is any dirt or any other foreign objects on the sealing surfaces of the disconnected pipes, clean them if necessary. Quick Type B A091246E06 (5) Do not damage the disconnected pipe and connector, and prevent entry of foreign objects by covering them with a plastic bag. Quick Type B Plastic Bag A093309E03 FU–6 2AZ-FE FUEL – FUEL SYSTEM (i) Quick Type B A132390E01 FU 4. Observe the following precautions when connecting the fuel tube connector (Quick Type B): (1) Line up the two parts of the pipes to be connected, and fully push the fuel tube connector and pipe together until they are fully seated. Next, push the retainer into the connector until its claws lock. If the pipe is difficult to push in to the connector, apply a small amount of clean engine oil to the tip of the pipe and reinsert it. (2) After connecting the pipes, check that the pipe and connector are securely connected by pulling on them. (3) Check for fuel leaks. (j) Observe the following precautions when handling a nylon tube: CAUTION: • Do not twist the connection part of the nylon tube and the quick connector when connecting them. • Do not bend or twist the nylon tube. • Do not remove the EPDM protector on the outside of the nylon tube. • Do not close the piping by bending the nylon tube. CHECK FOR FUEL LEAKS (a) Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs (See page FU-9). FU–7 2AZ-FE FUEL – FUEL SYSTEM PARTS LOCATION FU FUEL PUMP ECM ENGINE ROOM RELAY BLOCK FUEL INJECTOR A136012E01 FU–8 2AZ-FE FUEL – FUEL SYSTEM SYSTEM DIAGRAM ECM C7 Fuel Injector (No. 1) INJ 1 2 108 C24 #10 107 C24 #20 106 C24 #30 105 C24 #40 44 A24 MREL 7 A24 FC C9 Fuel Injector (No. 2) E23 Ignition Switch 1 6 IG2 AM2 2 5 C8 Fuel Injector (No. 3) ST/AM2 1 From Battery FU 2 C10 Fuel Injector (No. 4) 1 2 EFI MAIN From Battery EFI N10 Fuel Suction Pump and Gauge Assembly 5 Pump IGN 4 C/OPN A136724E01 2AZ-FE FUEL – FUEL SYSTEM FU–9 ON-VEHICLE INSPECTION 1. 2. No. 1 Fuel Pipe Clamp A060083E16 CHECK FUEL PUMP OPERATION AND FOR FUEL LEAKS (a) Check fuel pump operation. (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch to the ON position and push the intelligent tester main switch on. NOTICE: Do not start the engine. (3) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / FUEL PUMP / SPD. (4) Check for pressure in the fuel inlet tube from the fuel line. Check that sound of fuel flowing in the fuel tank can be heard. If no sound can be heard, check the integration relay, fuel pump, ECM and wiring connector. (b) Check for fuel leaks. (1) Check that there are no fuel leaks anywhere on the system after performing maintenance. If there is a fuel leak, repair or replace parts as necessary. (c) Turn the ignition switch off. (d) Disconnect the intelligent tester from the DLC3. CHECK FUEL PRESSURE (a) Using a voltmeter, measure the battery voltage. Standard voltage: 11 to 14 V (b) Discharge the fuel system pressure (See page FU1). (c) Disconnect the cable from the negative (-) battery terminal. (d) Remove the No. 1 fuel pipe clamp from the fuel tube connector. (e) Disconnect the fuel hose from the fuel main tube. CAUTION: • Always read the precautions (See page FU-1) before disconnecting the fuel tube connector (quick type). • The fuel pipe line may spray fuel as a result of retained pressure that remains in it. Do not allow fuel to be sprayed in the engine compartment. FU FU–10 SST (Clip) 2AZ-FE FUEL – FUEL SYSTEM (f) SST (Pressure Gauge) (g) (h) SST (T-joint) (i) SST (Tube) (j) SST (Hose) FU SST (Tube Connector) A105669E04 (k) (l) (m) (n) (o) (p) (q) (r) (s) Install SST (pressure gauge) and the fuel tube connector using SST as shown in the illustration. SST 09268-31011 (09268-41500, 90467-13001, 95336-08070), 09268-45014 (09268-41200, 09268-41220, 09268-41250) Wipe up any gasoline. Reconnect the cable to the negative (-) battery terminal. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / FUEL PUMP / SPD. Measure the fuel pressure. Fuel pressure: 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44.1 to 49.7 psi) If the pressure is high, replace the fuel pressure regulator. If the pressure is low, check the fuel hoses and connections, fuel pump, fuel filter and fuel pressure regulator. Disconnect the intelligent tester from the DLC3. Start the engine. Measure the fuel pressure at idle. Fuel pressure: 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44.1 to 49.7 psi) Stop the engine. Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Fuel pressure: 147 kPa (1.5 kgf/cm2, 21 psi) or more If the pressure is not as specified, check the fuel pump, pressure regulator and/or injectors. After checking the fuel pressure, disconnect the cable from the negative battery terminal and carefully remove the SST to prevent gasoline from splashing. Reconnect the fuel main tube (fuel tube connector). CAUTION: Always read the precautions (See page FU-1) before connecting the fuel tube connector (quick type). Install the No. 1 fuel pipe clamp to the fuel tube connector. Check for fuel leaks (Step 1). FU–11 2AZ-FE FUEL – FUEL INJECTOR FUEL INJECTOR 2AZ-FE FUEL ENGINE COMPONENTS PURGE VSV VACUUM HOSE NO. 2 VENTILATION HOSE AIR CLEANER CAP SUB-ASSEMBLY ENGINE WIRE FUEL DELIVERY PIPE WITH INJECTOR 20 (204, 15) FU SPACER PURGE VSV VACUUM HOSE O-RING INSULATOR FUEL INJECTOR ASSEMBLY 7.0 (71, 62 in.*lbf) NO. 2 VENTILATION HOSE NO. 1 FUEL PIPE CLAMP NO. 1 ENGINE COVER SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A136019E01 FU–12 2AZ-FE FUEL – FUEL INJECTOR REMOVAL 1. DISCHARGE FUEL SYSTEM PRESSURE HINT: See page FU-1. 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 3. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-416) 4. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (See page EM-94) 5. DISCONNECT FUEL TUBE SUB-ASSEMBLY (a) Remove the No. 1 fuel pipe clamp. NOTICE: Check for foreign matter on the pipe and around the connector before disconnecting the quick connector. Clean the connector if necessary. FU A136015E01 (b) If the connector and pipe are stuck, pinch the connector, and push and pull the pipe to disconnect them. NOTICE: • Do not use any tools in this procedure. • Check for foreign matter on the sealing surface of the disconnected pipe. Clean it if necessary. Pull Pinch Pinch A136016E01 (c) Separate the fuel tube from the fuel hose clamp. A136017E01 2AZ-FE FUEL – FUEL INJECTOR FU–13 6. DISCONNECT NO. 2 VENTILATION HOSE (a) Disconnect the No. 2 ventilation hose from the ventilation valve. 7. REMOVE FUEL DELIVERY PIPE WITH INJECTOR (a) Remove the 2 wire harness clamps. (b) Disconnect the 4 fuel injector connectors. A097786 FU A136750 (c) Remove the 2 bolts, then remove the fuel delivery pipe together with the 4 fuel injectors. NOTICE: Be careful not to drop the fuel injectors when removing the fuel delivery pipe. A136751 (d) Remove the 2 delivery pipe spacers from the cylinder head. (e) Remove the 4 insulators from the cylinder head. A128737 8. Pull Out A097399E02 REMOVE FUEL INJECTOR ASSEMBLY (a) Pull out the 4 injectors from the delivery pipe. (b) Remove the 4 O-rings from the injectors. FU–14 2AZ-FE FUEL – FUEL INJECTOR Ohmmeter INSPECTION 1. A116182E01 SST (Clip) FU Fuel Tube INSPECT FUEL INJECTOR ASSEMBLY (a) Measure the resistance between the injector terminals. Standard resistance: 11.6 to 12.4 Ω at 20°C (68°F) If the result is not as specified, replace the injector. (b) Inspect the injector injection volume. CAUTION: Keep the injector away from sparks during this test. (1) Connect SST (fuel tube connector) to SST (hose), then connect them to the fuel pipe (vehicle side). SST 09268-31011 (09268-41500, 9046713001, 95336-08070) (2) Install the O-ring to the fuel injector. SST (Tube Connector) SST (Hose) A088228E08 SST SST Tube A116183E02 Connect SST (Wire) A075915E04 (3) Connect SST (adapter and hose) to the injector, and hold the injector and union with SST (clamp). SST 09268-31011 (09268-41110, 0926841300, 90467-13001) (4) Put the injector into the graduated cylinder. CAUTION: Install a suitable vinyl tube onto the injector to contain gasoline spray. (5) Operate the fuel pump. (6) Connect SST (wire) to the injector and the battery for 15 seconds, and measure the injection volume with the graduated cylinder. Test each injector 2 or 3 times. SST 09842-30080 Standard injection volume: 76 to 92 cm3 (4.6 to 5.6 cu in.) per 15 seconds Standard difference between each injector: 16 cm3 (0.98 cu in.) or less 2AZ-FE FUEL – FUEL INJECTOR FU–15 (c) Inspect the fuel leakage. (1) Disconnect the SST (wire) tester probes from the battery and check the fuel leakage from the injector. Standard fuel drop: 1 drop or less per 12 minutes (2) Turn the ignition switch off. (3) Disconnect the cable from the negative (-) battery terminal. (4) Remove the SST. (5) Disconnect the intelligent tester from the DLC3. (6) Reconnect the fuel inlet hose (rear fuel pipe) to the fuel main tube. A116184 INSTALLATION 1. INSTALL FUEL INJECTOR ASSEMBLY (a) Apply a light coat of gasoline or spindle oil to new Orings, then install one onto each fuel injector. FU New O-Ring A097400E02 (b) Apply a light coat of gasoline or spindle oil to the part of the fuel delivery pipe which comes into contact with the O-ring of the fuel injector. (c) Apply a light coat of gasoline or spindle oil to the Oring again, then install the right and left fuel injectors onto the fuel delivery pipe. NOTICE: Make sure that the O-ring is not cracked or jammed before installing the injector. (d) Check that the fuel injector rotates smoothly. If the fuel injector does not rotate, replace the O-ring. CORRECT INCORRECT O-Ring Delivery Pipe A131629E01 2. A128737 INSTALL FUEL DELIVERY PIPE WITH INJECTOR (a) Install 4 new insulators into the cylinder head. (b) Install the 2 delivery pipe spacers onto the cylinder head. FU–16 2AZ-FE FUEL – FUEL INJECTOR (c) Install the fuel delivery pipe together with the 4 fuel injectors, then temporarily tighten the 2 bolts. NOTICE: Be careful not to drop the fuel injectors when installing the fuel delivery pipe. (d) Check that the fuel injector rotates smoothly. If the fuel injector does not rotate smoothly, replace the O-ring. O-Ring Fuel Injector Insulator Fuel Delivery Pipe A097444E02 (e) Tighten the 2 bolts to the specified torque. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) FU A136751 (f) Connect the 4 fuel injector connectors. (g) Install the 2 wire harness clamps. A136750 White Paint Mark UP “A” 3. INSTALL NO. 2 VENTILATION HOSE (a) Connect the ventilation hose to the ventilation valve. NOTICE: Make sure that the paint mark and hose clamp are positioned as shown in the illustration after connecting the hose. 4. CONNECT FUEL TUBE SUB-ASSEMBLY (a) Install the fuel tube to the fuel hose clamp. LH View: “A” A095428E03 A136017E01 2AZ-FE FUEL – FUEL INJECTOR FU–17 (b) Push the fuel tube connector until it makes a "click" sound. Push A103968E03 (c) Install the No. 1 fuel pipe clamp. 5. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See page ES-419) 6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 7. CHECK FOR FUEL LEAKS HINT: See page FU-9. 8. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (See page EM-121) A136015E01 FU FU–18 2AZ-FE FUEL – FUEL PRESSURE PULSATION DAMPER FUEL PRESSURE PULSATION DAMPER 2AZ-FE FUEL ENGINE COMPONENTS NO. 1 ENGINE COVER SUB-ASSEMBLY PURGE VSV VACUUM HOSE 9.0 (92, 80 in.*lbf) AIR CLEANER CAP SUB-ASSEMBLY NO. 2 VENTILATION HOSE NO. 2 FUEL PIPE CLAMP FU FUEL PRESSURE PULSATION DAMPER ASSEMBLY AIR CLEANER FILTER ELEMENT 9.0 (92, 80 in.*lbf) PURGE VSV VACUUM HOSE FUEL TUBE SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A141106E01 2AZ-FE FUEL – FUEL PRESSURE PULSATION DAMPER FU–19 REMOVAL 1. DISCHARGE FUEL SYSTEM PRESSURE HINT: See page FU-1. 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 3. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (See page EM-94) 4. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-416) 5. DISCONNECT FUEL TUBE SUB-ASSEMBLY HINT: Disconnect the metallic type connector (See page FU-1). 6. REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY (a) Remove the 2 bolts and fuel pressure pulsation damper. FU A125338 INSTALLATION O-Ring 1. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY (a) Apply a light coat of gasoline or spindle oil to the Oring of the fuel pressure pulsation damper. A125339E01 (b) Install the fuel pressure pulsation damper with the 2 bolts. Torque: 9.0 N*m (90 kgf*cm, 80 in.*lbf) NOTICE: Make sure that the O-ring is not cracked or jammed before installing the damper. 2. INSTALL FUEL TUBE SUB-ASSEMBLY HINT: Connect the metallic type connector (See page FU-1). 3. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See page ES-419) 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL A125338 FU–20 FU 2AZ-FE FUEL – FUEL PRESSURE PULSATION DAMPER 5. CHECK FOR FUEL LEAKS HINT: See page FU-9. 6. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (See page EM-121) 2AZ-FE FUEL – FUEL PUMP FU–21 FUEL PUMP 2AZ-FE FUEL ENGINE COMPONENTS REAR SEAT CUSHION ASSEMBLY FU REAR FLOOR SERVICE HOLE COVER FUEL PUMP TUBE SUB-ASSEMBLY CLIP 5.9 (60, 52 in.*lbf) x8 FUEL TANK VENT TUBE SET PLATE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE GASKET N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A136244E01 FU–22 2AZ-FE FUEL – FUEL PUMP FUEL NO. 1 SUCTION SUPPORT FUEL SUCTION PLATE SUB-ASSEMBLY FU SPRING FUEL PUMP HARNESS O-RING E-RING O-RING FUEL PRESSURE REGULATOR ASSEMBLY FUEL PUMP FUEL NO. 1 TANK BAND BRACKET FUEL SENDER GAUGE ASSEMBLY Non-reusable part A136245E01 2AZ-FE FUEL – FUEL PUMP FU–23 REMOVAL 1. DISCHARGE FUEL SYSTEM PRESSURE HINT: See page FU-1. 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 3. REMOVE REAR SEAT CUSHION ASSEMBLY (for Fixed Seat Type) (See page SE-77) 4. REMOVE REAR SEAT CUSHION ASSEMBLY (for Fold Down Seat Type) (See page SE-47) 5. REMOVE REAR SEAT CUSHION ASSEMBLY (for Reclining Seat Type) (See page SE-62) 6. REMOVE REAR FLOOR SERVICE HOLE COVER (a) Remove the rear floor service hole cover. (b) Disconnect the fuel pump connector. FU A129478 Tube Joint Clip Nylon Tube Fuel Tube Joint O-Ring Tube Joint Clip A129479E02 7. SEPARATE FUEL PUMP TUBE SUB-ASSEMBLY (a) Remove the tube joint clip, and pull out the fuel pump tube. NOTICE: • Check that there is no dirt around the fuel tube joint before this work and clean any dirt away. • It is necessary to prevent mud or dirt from entering the fuel tube joint. If mud enters the joint, the O-rings may not seal the fuel tube connector and fuel suction plate properly. • Do not use any tools in this work. • Do not bend or twist the nylon tube. • After disconnecting, cover the fuel tube joint with a plastic bag. • If the fuel tube joint and fuel suction plate are stuck, pinch the fuel tank tube between fingers, and turn it carefully to release. Disconnect the fuel tank tube. FU–24 2AZ-FE FUEL – FUEL PUMP 8. REMOVE FUEL TANK VENT TUBE SET PLATE (a) Remove the 8 bolts and set plate. 9. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE (a) Pull out the fuel suction tube from the fuel tank. NOTICE: • Do not damage the fuel pump filter. • Be careful that the arm of the sender gauge does not bend. A129480 FU A139190 (b) Remove the gasket from the fuel suction tube. Gasket A136023E01 DISASSEMBLY 1. A136021 REMOVE FUEL SENDER GAUGE ASSEMBLY (a) Disconnect the fuel sender gauge connector. 2AZ-FE FUEL – FUEL PUMP FU–25 (b) Unlock the fuel sender gauge, and slide it to remove. A136022 2. REMOVE FUEL NO. 1 TANK BAND BRACKET (a) Using needle nozzle pliers, remove the E-ring. FU E-Ring A136234E01 (b) Disengage the 4 claws of the fuel No. 1 suction support and remove the fuel No. 1 tank band bracket from the fuel suction plate with the fuel filter. (c) Remove the spring from the fuel suction plate. A136232 3. A136233 REMOVE FUEL NO. 1 SUCTION SUPPORT (a) Using a screwdriver with the tip taped, disengage the claw and remove the fuel No. 1 suction support. FU–26 2AZ-FE FUEL – FUEL PUMP 4. DISCONNECT FUEL PUMP HARNESS (a) Disconnect the fuel pump harness connector from the fuel suction plate. 5. REMOVE FUEL PUMP (a) Using a screwdriver with its tip taped, disengage the 5 claws and pull out the fuel pump from the fuel filter assembly. NOTICE: • Do not damage the fuel pump filter. • Do not remove the suction filter. A136231 FU A136239E01 (b) Remove the fuel pump harness connector. A136237 (c) Remove the O-ring from the fuel pump. O-Ring A136238E01 2AZ-FE FUEL – FUEL PUMP 6. FU–27 REMOVE FUEL PRESSURE REGULATOR ASSEMBLY (a) Using a screwdriver with its tip taped, remove the fuel pressure regulator from the fuel filter. A136235 (b) Remove the 2 O-rings from the fuel pressure regulator. O-Ring FU A096585E03 INSPECTION 1. A126943 INSPECT FUEL PUMP (a) Check the fuel pump resistance. (1) Measure the resistance between terminals 1 and 2. Standard resistance: 0.2 to 3.0 Ω at 20°C (68°F) If the result is not as specified, replace the fuel pump. (b) Check fuel pump operation. (1) Apply battery voltage to terminals 1 and 2. Check that the pump operates. NOTICE: • These tests must be completed within 10 seconds to prevent the coil from burning out. • Keep the fuel pump as far away from the battery as possible. • Always switch the voltage on and off on the battery side, not on the fuel pump side. If the pump does not operate, replace the fuel pump. FU–28 2AZ-FE FUEL – FUEL PUMP REASSEMBLY O-Ring 1. INSTALL FUEL PRESSURE REGULATOR ASSEMBLY (a) Apply a light coat of gasoline to 2 new O-rings, and install them to the fuel pressure regulator. A096585E03 (b) Install the fuel pressure regulator to the fuel filter. Pressure Regulator FU A136236E01 2. INSTALL FUEL PUMP (a) Apply gasoline to a new O-ring and install it to the fuel filter. New O-Ring A131633E01 (b) Connect the fuel pump harness connector. A126130 2AZ-FE FUEL – FUEL PUMP FU–29 (c) Engage the 5 claws on the fuel filter and install the fuel pump with the pump filter. A136240 3. CONNECT FUEL PUMP HARNESS (a) Connect the fuel pump harness connector from the fuel suction plate. FU A136231 4. INSTALL FUEL NO. 1 SUCTION SUPPORT (a) Install the fuel No. 1 suction support to the fuel filter. 5. INSTALL FUEL NO. 1 TANK BAND BRACKET (a) Install the spring to the fuel suction plate shaft and install them to the fuel No. 1 tank band bracket. (b) Engage the 4 claws of the fuel No. 1 suction support and install the fuel No. 1 tank band bracket to the fuel suction plate with the fuel filter. A136233 (c) Install a new E-ring. E-Ring A136234E01 FU–30 2AZ-FE FUEL – FUEL PUMP 6. INSTALL FUEL SENDER GAUGE ASSEMBLY (a) Slide the fuel sender gauge to engage the claw. A136241 (b) Connect the fuel sender gauge connector. FU A136021 INSTALLATION 1. Gasket INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE (a) Install a new gasket to the fuel suction tube. A136023E01 (b) Install the fuel suction tube. NOTICE: • Do not damage the fuel pump filter. • Be careful that the arm of the sender gauge does not bend. A139190 2AZ-FE FUEL – FUEL PUMP FU–31 2. INSTALL FUEL TANK VENT TUBE SET PLATE (a) Align the mark of the set plate with the fuel suction tube. (b) Install the set plate with the 8 bolts. Torque: 5.9 N*m (60 kgf*cm, 52 in.*lbf) 3. CONNECT FUEL PUMP TUBE SUB-ASSEMBLY (a) Install the fuel pump tube with the tube joint clip. NOTICE: • Check that there are no scratches or foreign objects on the connecting part. • Check that the fuel tube joint is inserted securely. • Check that the tube joint clip is on the collar of the fuel tube joint. • After installing the tube joint clip, check that the fuel tube joint is pulled off. Mark A129480E01 Fuel Main Tube Fuel Tube Joint Fuel Tube O-Ring 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 5. CHECK FOR FUEL LEAKS (See page FU-8) 6. INSTALL REAR FLOOR SERVICE HOLE COVER (a) Connect the fuel pump connector. (b) Install the rear floor service hole cover with new butyl tape. 7. INSTALL REAR SEAT CUSHION ASSEMBLY (for Fixed Seat Type) (See page SE-84) 8. INSTALL REAR SEAT CUSHION ASSEMBLY (for Fold Down Seat Type) (See page SE-58) 9. INSTALL REAR SEAT CUSHION ASSEMBLY (for Reclining Seat Type) (See page SE-73) Tube Joint Clip Tube Joint Clip Collars Collars CORRECT INCORRECT A139189E01 A129478 FU FU–32 2AZ-FE FUEL – FUEL TANK FUEL TANK 2AZ-FE FUEL ENGINE COMPONENTS REAR SEAT CUSHION ASSEMBLY FU REAR FLOOR SERVICE HOLE COVER FUEL PUMP TUBE SUB-ASSEMBLY CLIP 5.9 (60, 52 in.*lbf) x8 FUEL TANK VENT TUBE SET PLATE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE GASKET N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A136244E01 FU–33 2AZ-FE FUEL – FUEL TANK NO. 1 FUEL TUBE FUEL TANK ASSEMBLY FUEL TANK TO FILLER PIPE HOSE For SE Grade: FUEL TANK PROTECTOR LOWER CENTER FUEL TANK PROTECTOR LOWER CENTER x4 FU 5.4 (55, 48 in.*lbf) 39 (400, 29) PIN FUEL TANK BAND NO. 2 PARKING BRAKE CABLE ASSEMBLY 39 (400, 29) FUEL TANK BAND PIN 6.0 (61, 53 in.*lbf) 8.5 (87, 75 in.*lbf) GASKET NO. 3 PARKING BRAKE CABLE ASSEMBLY 6.0 (61, 53 in.*lbf) 8.5 (87, 75 in.*lbf) GASKET 43 (438, 32) CENTER EXHAUST PIPE ASSEMBLY 56 (571, 41) Non-reusable part N*m (kgf*cm, ft.*lbf) : Specified torque A136747E01 FU–34 2AZ-FE FUEL – FUEL TANK FUEL PUMP TUBE SUB-ASSEMBLY FUEL TANK ASSEMBLY NO. 2 FUEL TANK CUSHION X7 FUEL TANK VENT HOSE FU CLIP NUT X4 5.4 (55, 48 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part FUEL MAIN TUBE SUPPORT A109012E08 2AZ-FE FUEL – FUEL TANK FU–35 REMOVAL 1. DISCHARGE FUEL SYSTEM PRESSURE HINT: See page FU-1. 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 3. REMOVE REAR SEAT CUSHION ASSEMBLY (for Fixed Seat Type) (See page SE-77) 4. REMOVE REAR SEAT CUSHION ASSEMBLY (for Fold Down Seat Type) (See page SE-47) 5. REMOVE REAR SEAT CUSHION ASSEMBLY (for Reclining Seat Type) (See page SE-62) 6. REMOVE REAR FLOOR SERVICE HOLE COVER (See page FU-27) 7. SEPARATE FUEL PUMP TUBE SUB-ASSEMBLY (See page FU-27) 8. REMOVE FUEL TANK VENT TUBE SET PLATE (See page FU-28) 9. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE (See page FU-28) 10. DRAIN FUEL 11. REMOVE CENTER EXHAUST PIPE ASSEMBLY (See page EX-2) 12. DISCONNECT NO. 2 PARKING BRAKE CABLE ASSEMBLY (a) Remove the set bolt and set nut of the No. 2 parking brake cable assembly. A135222 13. DISCONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY (a) Remove the set bolt and set nut of the No. 3 parking brake cable assembly. A135223 FU FU–36 2AZ-FE FUEL – FUEL TANK 14. REMOVE REAR STABILIZER BAR NO. 1 BRACKET (a) Remove the 4 bolts and 2 rear stabilizer bar No. 1 brackets. A136008E01 15. REMOVE FUEL TANK PROTECTOR LOWER CENTER (a) Remove the 4 bolts and fuel tank protector (Except SE Grade). FU A135224 (b) Remove the 4 bolts and 2 clips (for SE Grade). (c) Remove the fuel tank protector (for SE Grade). Clip A135225E01 Pinch Retainer Pull Pull Pinch Fuel Tube Connector Retainer Pipe O-Ring A121573E02 16. REMOVE FUEL TANK ASSEMBLY (a) Disconnect the fuel pump tube. (1) Pinch the tab of the retainer to disengage the lock claws and pull it down as shown in the illustration. (2) Pull out the fuel tank main tube. NOTICE: • Check that there is no dirt or other foreign objects around the connector before this operation and clean the connector as necessary. • It is necessary to prevent mud or dirt from entering the quick connector. If mud enters the connector, the O-rings may not seal properly. • Remove the quick connector by hand. • Do not bend or twist the nylon tube. Protect the connector by covering it with a plastic bag. 2AZ-FE FUEL – FUEL TANK FU–37 • If the pipe and connector are stuck, try wiggling or pushing and pulling the connector to release it and pull the connector off of the pipe carefully. Pinch Pull Pinch Nylon Tube Tube Connector O-Ring Pipe (b) Disconnect the No. 1 fuel tube. (1) Pinch the tube connector and then pull out the No. 1 fuel tube. NOTICE: • Check that there is no dirt or other foreign objects around the connector before this operation and clean the connector if necessary. • It is necessary to prevent mud or dirt from entering the quick connector. If mud enters the connector, the O-rings may not seal properly. • Remove the quick connector by hand. • Do not bend or twist the nylon tube. Protect the connector by covering it with a plastic bag. • If the pipe and connector are stuck, try wiggling or pushing and pulling the connector to release it and pull the connector off of the pipe carefully. A121576E01 (c) Place a engine lifter under the fuel tank assembly. A136009 FU FU–38 2AZ-FE FUEL – FUEL TANK (*1) Pinch (d) Remove the 2 set bolts of the fuel tank bands. (*1) (e) Remove the hose clamp and disconnect the fuel tank to filter pipe hose. (*2) (f) Slightly lower the transmission jack. (g) Disconnect the fuel tank vent hose from the charcoal canister. (*3) (1) Push the connector deep into the charcoal canister to release the locking pin. (2) Pinch portion A. (3) Pull out the connector. (h) Remove the fuel tank. (*1) (*3) Push Pinch A (*2) A FU A091352E05 (i) Remove the 2 pins and 2 fuel tank bands as shown in the illustration. (j) Remove the 4 clip nuts (Except SE Grade). A079478 A136004 (k) Remove the 4 clip nuts (for SE Grade). A136005 2AZ-FE FUEL – FUEL TANK Push A FU–39 17. REMOVE FUEL TANK VENT HOSE (a) Push the connector deep into the charcoal canister to release the locking pin. (b) Pinch portion A. (c) Pull out the connector. A Pinch Pinch A079479E03 18. REMOVE FUEL PUMP TUBE SUB-ASSEMBLY (a) Remove the fuel pump tube from the fuel main tube support. FU A079480 19. REMOVE FUEL MAIN TUBE SUPPORT (a) Remove the bolt and tube support. A079481 20. REMOVE NO. 2 FUEL TANK CUSHION (a) Remove the 7 No. 2 fuel tank cushions. A079484 INSTALLATION 1. A079484 INSTALL NO. 2 FUEL TANK CUSHION (a) Install 7 new No. 2 fuel tank cushions to the fuel tank. FU–40 2AZ-FE FUEL – FUEL TANK 2. INSTALL FUEL MAIN TUBE SUPPORT (a) Install the fuel main tube support with the bolt. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 3. INSTALL FUEL PUMP TUBE SUB-ASSEMBLY (a) Install the fuel pump tube to the fuel main tube support. 4. INSTALL FUEL TANK VENT HOSE (a) Install the fuel tank vent hose. 5. INSTALL FUEL TANK ASSEMBLY (a) Install the 4 clip nuts (Except SE Grade). A079481 FU A079480 A129490 A136004 (b) Install the 4 clip nuts (for SE Grade). A136005 2AZ-FE FUEL – FUEL TANK FU–41 (c) Install the 2 fuel tank bands with the 2 pins. (d) Set the fuel tank assembly onto the transmission jack. A129491 (e) Raise the transmission jack so that the fuel tank vent hose can be connected. (*1) NOTICE: Slowly raise the jack to prevent the fuel tank assembly from dropping. (f) Connect the fuel tank inlet pipe with the fuel filter pipe clamp. (*2) (g) Tighten the 2 set bolts of the fuel tank bands. (*3) Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) (*3) (*1) (*3) (*2) A129492E02 Fuel Tube Connector Pipe A091572E03 (h) Connect the No. 1 fuel tube. (1) Push the fuel tube connector into the pipe until the fuel tube connector makes a "click" sound. NOTICE: • Before connecting the tube, make sure that it is not damaged. Make sure that there is no dirt present on the connecting surfaces. • After connecting, check if the fuel tube connector and the pipe are securely connected by pulling on them. (i) Retainer A081598E03 Connect the fuel pump tube. (1) Push the fuel connector into the pipe and push up the retainer so that the claws engage. NOTICE: • Before connecting the tube, make sure that it is not damaged. Make sure that there is no dirt present on the connecting surfaces. FU FU–42 2AZ-FE FUEL – FUEL TANK • After connecting, check if the fuel tube connector and the pipe are securely connected by pulling on them. 6. INSTALL FUEL TANK PROTECTOR LOWER CENTER (a) Install the 4 bolts and fuel tank protector (Except SE Grade). Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) A135224 (b) Install the fuel tank protector with the 4 bolts and 2 clips (for SE Grade). Torque: Bolt 5.4 N*m (55 kgf*cm, 48 in.*lbf) FU Clip A135225E01 7. INSTALL REAR STABILIZER BAR NO. 1 BRACKET (a) Install the 2 rear stabilizer bar No. 1 brackets with the 4 bolts. Torque: 31 N*m (316 kgf*cm, 23 ft.*lbf) 8. INSTALL NO. 3 PARKING BRAKE CABLE ASSEMBLY (a) Install the No. 3 parking brake cable assembly with the bolt and nut. Torque: Bolt 6.0 N*m (61 kgf*cm, 53 in.*lbf) Nut 8.5 N*m (87 kgf*cm, 75 in.*lbf) A136008E01 A135223 2AZ-FE FUEL – FUEL TANK 9. FU–43 INSTALL NO. 2 PARKING BRAKE CABLE ASSEMBLY (a) Install the No. 2 parking brake cable assembly with the bolt and nut. Torque: Bolt 6.0 N*m (61 kgf*cm, 53 in.*lbf) Nut 8.5 N*m (87 kgf*cm, 75 in.*lbf) 10. INSTALL CENTER EXHAUST PIPE ASSEMBLY (See page EX-4) A135222 11. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE (See page FU-32) 12. INSTALL FUEL TANK VENT TUBE SET PLATE (See page FU-32) 13. CONNECT FUEL PUMP TUBE SUB-ASSEMBLY (See page FU-33) 14. ADD FUEL 15. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 16. CHECK FOR FUEL LEAKS (See page FU-8) 17. CHECK FOR EXHAUST GAS LEAKS 18. INSTALL REAR FLOOR SERVICE HOLE COVER 19. INSTALL REAR SEAT CUSHION ASSEMBLY (for Fixed Seat Type) (See page SE-84) 20. INSTALL REAR SEAT CUSHION ASSEMBLY (for Fold Down Seat Type) (See page SE-58) 21. INSTALL REAR SEAT CUSHION ASSEMBLY (for Reclining Seat Type) (See page SE-73) FU ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) EI–1 ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) PRECAUTION 1. 2. PRECAUTIONS WHEN USING INTELLIGENT TESTER (a) When using the intelligent tester to troubleshoot the smart access system: Connect the intelligent tester to the DLC3 while the engine switch off, and turn a door courtesy light switch on and off at 1.5-second intervals until communication between the tester and vehicle begins. PRECAUTIONS FOR EACH FUNCTION (a) Precautions for the electrical key: The electrical key is a precision instrument. Be sure to observe the following: (1) Do not drop or strike the electrical key. (2) Do not allow the electrical key to be kept in a high temperature place for a long time. (3) Do not use an ultrasonic washing machine to clean the electrical key. (4) Keep the electrical key away from magnets or magnetized items during use. (5) Do not attach any stickers to the electrical key. (b) Precautions for the engine start function: (1) Before starting the engine, firmly depress the brake pedal until the indicator of the engine switch illuminates in green. (2) Be sure to turn the engine switch off before disconnecting the negative (-) battery terminal. When the battery terminal is disconnected, the power source mode (off, on (ACC), on (IG)) will remain in memory. When the vehicle's battery becomes discharged, be careful to remember the power source mode. (3) After the battery is removed and reinstalled, be sure to wait 10 seconds or more before the next engine start. The engine may not start immediately after the battery is reinstalled. (c) Precautions for the battery built into the electrical key and the vehicle battery: (1) When the doors are locked (locked state), signals are emitted by the vehicle at a predetermined interval. If the vehicle were to remain parked for a long time, the vehicle battery could become discharged. To prevent this, periodically charge the vehicle battery, or disable the entry and start system. EI EI–2 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) (2) When the doors are locked (locked state), and the electrical key remains in the door oscillator detection area, the system will maintain periodic communication with the electrical key. If the vehicle remains parked in this state for a long time, the vehicle and key batteries could become discharged. If the vehicle is not being used, keep the electrical key at least 2 m (6.56 ft) from the vehicle. EI ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) EI–3 PARTS LOCATION ECM SECURITY INDICATOR LIGHT: ENGINE SWITCH CLOCK ID CODE BOX EI CERTIFICATION ECU DLC3 MAIN BODY ECU STREEING LOCK ECU B128351E01 EI–4 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) SYSTEM DIAGRAM Enigine Switch - Transponder Key Amplifier (with Key Coil) Certification ECU Main Body ECU ID Code Box Steering Lock ECU ECM LIN Communication Line EI B128344E02 Communication table: Transmitting ECU (Transmitter) Receiving ECU (Receiver) Main body ECU Certification ECU Key code recognition signal Signals LIN ID code box Certification ECU DTC (B2791) signal LIN ID code box Steering lock ECU • • LIN ID code box Certification ECU Steering lock release signal Matching request random number signal Matching request random number signal Communication method LIN ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) EI–5 SYSTEM DESCRIPTION 1. 2. Component ENGINE IMMOBILISER SYSTEM DESCRIPTION (a) The immobiliser system is a theft deterrent system that determines whether to disable starting of the SFI system based on a comparison of the key's ID codes and the vehicle's pre-registered code. The immobiliser system compares the vehicle certification ECU's pre-registered ID code with the ID of the key-embedded transponder chip. If the ID codes do not match, the immobiliser system activates and the SFI system cannot be started. The certification ECU manages communication with the ECM, main body ECU, steering lock ECU and ID code box. When the ID codes of the transponder chip and certification ECU match, the certification ECU authorizes the SFI system to start. FUNCTION OF MAIN COMPONENT Outline Transponder key coil/amplifier (built into engine switch) Receives key ID code, amplifies ID code and outputs the code to the certification ECU. Indoor electrical key oscillator Transmits key detection signals within the detection area in the vehicle interior upon receiving a transmission request signal from the certification ECU. Certification ECU request signal is activated when the key is brought into the vehicle interior and the engine switch is pushed. Door control receiver Receives an ID code from the key in the actuation area and transmits it to the certification ECU. Security indicator Illuminates or starts flashing. Illumination is controlled by the certification ECU. 3. SYSTEM FUNCTION (a) Using entry function (1) When the driver (or passenger) is sitting in the vehicle while carrying the key, and the engine switch is pressed while the brake pedal is depressed, the main body ECU recognizes that the engine start operation has occurred and sends a certification request signal to the certification ECU. Upon receipt of the certification request signal, the certification ECU sends a request signal to the indoor electrical key oscillator. Upon receipt of the request signal, the indoor electrical key oscillator sends a request signal to detect if the key is inside the vehicle. When the key receives this request signal, it answers by sending an ID code containing a response code through the glass antenna to the door control receiver. Upon receipt of the ID code, the certification ECU analyzes the code. If the interior certification passes, then the main body ECU sends a certification pass response signal. When the main body ECU receives this signal, the ACC relay is switched on and the IG1 and IG2 relays are switched on in sequence. At this time, the EI EI–6 EI ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) engine switch indicator illuminates in green. Then the certification ECU checks that the power source mode has been changed and sends a steering lock command signal to the main body ECU. After receiving this signal, the main body ECU supplies power to the steering lock actuator. Then (via the ID code box) the steering lock ECU confirms that the certification ECU is certified and drives the steering actuator motor until the steering lock is unlocked. After unlocking the steering lock, an unlock completed signal is sent to the certification ECU. Upon receipt of this signal, the certification ECU sends an unset command signal to the ID code box. Once this signal is received, the ID code box confirms that the certification ECU is certified, sends an immobiliser unset command signal to the ECM and sends a security indicator light off signal to the certification ECU. (b) Not using the entry function (when key battery is depleted) (1) When the driver is sitting in the vehicle while carrying the key and the brake pedal is depressed, the main body ECU recognizes that the stop light switch is on and sends a key confirmation request signal to the certification ECU. Upon receipt of this signal, the certification ECU drives the immobiliser amplifier built in the engine switch. At this time, the engine switch sends an RF wave communication signal to the immobiliser. If the driver holds the key up to the engine switch at this time, the engine switch receives the immobiliser RF wave signal and responds by sending a radio wave signal. When the engine switch receives the radio wave signal from the key, it duplicates the signal and sends an ID code to the certification ECU. Upon receipt of the ID code, the code is analyzed. If the certification passes, a key certification pass response signal is sent to the main body ECU while simultaneously sending a sound buzzer request signal to the meter ECU. When the main body ECU receives this signal, the ACC relay is switched on and the IG1 and IG2 relays are switched on in sequence. At this time, the engine switch indicator illuminates in green. Then the certification ECU checks that the power source mode has been changed and sends a steering lock command signal to the main body ECU. After receiving this signal, the main body ECU supplies power to the steering lock actuator. Then (via the ID code box) the steering lock ECU confirms that the certification ECU is certified and drives the steering actuator ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) EI–7 motor until the steering lock is unlocked. After unlocking the steering lock, an unlock completed signal is sent to the certification ECU. Upon receipt of this signal, the certification ECU sends an unset command signal to the ID code box. Once this signal is received, the ID code box confirms that the certification ECU is certified, sends an immobiliser unset command signal to the ECM and sends a security indicator light off signal to the certification ECU. EI EI–8 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use the following procedures to troubleshoot the engine immobiliser system. • The intelligent tester should be used in steps 3 and 5. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CRANK ENGINE FOR MORE THAN 10 SECONDS NEXT 3 CHECK FOR DTCS (a) Check for DTCs and note any codes that are output (see page EI-24). (b) Delete the DTCs. (c) Recheck for DTCs. Based on the DTCs output above, try to duplicate the SFI system DTC or engine immobiliser system DTC by simulating the symptoms indicated by the DTC. Result Result EI Proceed to DTC output does not reoccur A SFI system DTC output reoccurs B Engine immobiliser system DTC output reoccurs C B GO TO SFI SYSTEM C GO TO DTC CHART A 4 PROBLEM SYMPTOMS TABLE (a) If the fault is not listed on the problem symptoms table, proceed to A. (b) If the fault is listed on the problem symptoms table, proceed to B. B A GO TO STEP 6 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) 5 EI–9 OVERALL ANALYSIS AND TROUBLESHOOTING (a) DATA LIST/ACTIVE TEST (See page EI-24) (b) TERMINALS OF ECU (See page EI-15) NEXT 6 ADJUST, REPAIR OR REPLACE NEXT 7 CONFIRMATION TEST NEXT END EI EI–10 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) REGISTRATION 1. DESCRIPTION OF CODE REGISTRATION HINT: • ID codes are the same as recognition codes for the wireless transmitter and the engine immobiliser function. Registering an ID code enables the smart access system with push-button start, the wireless door lock control function and the engine immobiliser function to be operated. • Code registration is needed when the certification ECU, ID code box, steering lock ECU or key is replaced with a new one. (a) PROCEDURE "1" The vehicle with the smart access system with push-button start system does not have a key slot. Therefore, hold the key close to the engine switch to register the key, as shown in the illustration below. Hold the key with its ornament surface within a range of 10 mm (0.39 in.) or less from the engine switch. Communication distance: 10 mm (0.39 in.) or less from the engine switch. Engine Switch Key Key EI TOYOTA Mark (Ornament Surface) TOYOTA Mark (Ornament Surface) B139204E01 EI–11 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) 2. Part to be replaced PART REPLACEMENT KEY REGISTRATION (a) The following table shows ECU replacement and key registration procedures in case the malfunctioning ECU has been identified after troubleshooting the smart access system with pushbutton start. HINT: • The following procedures indicated in the table below require the use of the intelligent tester: New key ID registration Additional key ID registration Key ID erasure ECU code registration • If all of the registered keys are not available, replacement of the ID code box is also required. • A maximum of 7 keys can be registered. Condition Procedure 1. Replace certification ECU Customer has brought all keys Certification ECU Some keys are lost Key ID codes cannot be either registered or erased PROCEDURE "B" 1. Erase key codes (key ID erasure) PROCEDURE "D" 2. Perform additional key registration procedure (additional key ID registration) PROCEDURE "C" 4. Reregister all keys (new key ID registration) HINT: If some keys are not registered during above steps, they will be disabled because they cannot be registered later ID code box All keys are lost - PROCEDURE "B" 1. Replace certification ECU - 2. Replace ID code box - 3. Reregister all keys (new key ID registration) HINT: If key codes cannot be erased or additional keys cannot be registered due to a malfunction in certification ECU, replace ID code box and certification ECU. If some keys are not registered during above steps, they will be disabled because they cannot be registered later PROCEDURE "A" 4. ECU communication ID registration PROCEDURE "F" 1. Replace ID code box At least 1 key is available - 2. Reregister all keys (new key ID registration) 3. Replace certification ECU Key ID codes can be registered and erased Reference - 2. Register recognition codes in ECUs (ECU code registration) PROCEDURE "E" 3. ECU communication ID registration PROCEDURE "F" 1. Replace ID code box - 2. Replace certification ECU - 3. Reregister all keys (new key ID registration) HINT: If some keys are not registered during above steps, they will be disabled because they cannot be registered later PROCEDURE "A" 4. ECU communication ID registration PROCEDURE "F" EI EI–12 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) Part to be replaced Condition Procedure Reference 1. Replace steering lock ECU Customer has brought at least 1 key Steering lock ECU All keys are lost Main body ECU ECM No condition required No condition required Customer has brought at least 1 key Key All keys are lost 3. EI Process 2. Register recognition codes in ECUs (ECU code registration) PROCEDURE "E" 1. Replace steering lock ECU - 2. Replace certification ECU - 3. Replace ID code box - 4. Reregister all keys (new key ID registration) HINT: If some keys are not registered during above steps, they will be disabled because they cannot be registered later PROCEDURE "A" 5. ECU communication ID registration PROCEDURE "F" Replace main body ECU - 1. Replace ECM - 2. ECU communication ID registration PROCEDURE "F" 1. Using remaining key, erase lost key code (key ID erasure) PROCEDURE "D" 2. Register additional keys as necessary (additional key ID registration) PROCEDURE "E" 1. Replace certification ECU - 2. Replace ID code box - 3. Register all keys (new key ID registration) HINT: If customer brings lost keys at later date, they can be registered using additional key ID registration function PROCEDURE "A" 4. ECU communication ID registration PROCEDURE "F" KEY REGISTRATION (a) PROCEDURE "A" New key ID registration (when replacing certification ECU and ID code box, or certification ECU, ID code box and steering lock ECU) Procedure 1. Start of registration 1. Connect intelligent tester (with CAN VIM) to DLC3 2. Turn engine switch on (IG) 3. Select "SMART ACCESS / ID UTILITY / SMART CODE REG" from tester menu HINT: The engine switch cannot be turned on (IG) more than 10 times. After connecting tester, turn tester on while turning driver's side door courtesy light switch on and off repeatedly at 1.5-second intervals or less to continue key registration procedure 2. Confirmation of ECU code Perform operation according to prompts on tester screen HINT: The mode is automatically selected by tester, new registration mode or add mode 3. Verification of unregistered key *1 Hold unregistered key close to engine switch (For details, refer to PROCEDURE "1") Confirm that wireless door lock buzzer sounds. Place unregistered key on front passenger's side seat Confirm that wireless door lock buzzer sounds 4. Registration of ID code Perform operation according to prompts on tester screen 5. End of registration Finish new key ID code registration ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) EI–13 *1: Repeat this process for each key which is to be registered for the vehicle. Finish the procedure for each key within 30 seconds. If the procedure for any of the keys has not been finished within the specified time, perform registration procedures from process 1 again. Make sure that only 1 key is in the cabin during registration procedures. If 2 or more keys are in the cabin simultaneously, electric waves will interfere with each other, preventing normal registration. (b) PROCEDURE "B" New key ID registration (when replacing certification ECU) Process Procedure 1. Start of registration 1. Connect intelligent tester (with CAN VIM) to DLC3 2. Turn engine switch on (IG) 3. Select "SMART ACCESS / ID UTILITY / SMART CODE REG" from tester menu HINT: The engine switch cannot be turned on (IG) more than 10 times. After connecting tester, turn tester on while turning driver's side door courtesy light switch on and off repeatedly at 1.5-second intervals or less to continue key registration procedure 2. Confirmation of ECU code Perform operation according to prompts on tester screen HINT: The mode is automatically selected by tester, new registration mode or add mode 3. Confirmation of all registered keys *1 Hold unregistered key close to engine switch (For details, refer to PROCEDURE "1") Confirm that wireless door lock buzzer sounds 4. Confirmation of ECU code Perform operation according to prompts on tester screen 5. Verification of unregistered key *2 Hold unregistered key close to engine switch (For details, refer to PROCEDURE "1") Confirm that wireless door lock buzzer sounds. Place unregistered key on front passenger side seat Confirm that wireless door lock buzzer sounds 5. Registration of ID code Perform operation according to prompts on tester screen 6. End of registration Finish new key ID code registration *1: Repeat this process for each key registered for the vehicle. Finish the procedure for each key within 30 seconds. If the procedure for any of the keys has not been finished within the specified time, perform registration procedures from process 1 again. If performing the key confirmation procedure for a key, the security indicator comes on and remains on until all the keys are confirmed. *2: Repeat this process for each key which is to be registered for the vehicle. Finish the procedure for each key within 30 seconds. If the procedure for any of the keys has not been finished within the specified time, perform registration procedures from 1 again. Make sure that only 1 key is in the cabin during registration procedures. If 2 or more keys are in the cabin simultaneously, electric waves will interfere with each other, preventing normal registration. EI EI–14 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) (c) PROCEDURE "C" Additional key ID registration Process Procedure 1. Start of registration 1. Connect intelligent tester (with CAN VIM) to DLC3 2. Turn engine switch on (IG) 3. Select "SMART ACCESS / ID UTILITY / SMART CODE REG" from tester menu 2. Confirmation of registered key *1 Perform operation according to prompts on intelligent tester screen HINT: The mode is automatically selected by tester, new registration mode or add mode Hold unregistered key close to engine switch (For details, refer to PROCEDURE "1") Confirm that wireless door lock buzzer sounds once 3. Confirmation of ECU code Perform operation according to prompts on tester screen 4. Verification of unregistered key *2 Hold unregistered key close to engine switch (For details, refer to PROCEDURE "1") Confirm that wireless door lock buzzer sounds. Place unregistered key on front passenger's side seat Confirm that wireless door lock buzzer sounds 5. Registration of ID code Perform operation according to prompts on tester screen 6. End of registration Finish key ID code registration *1: Perform this process for one of the keys registered for the vehicle. Finish the procedure within 30 seconds. If the procedure has not been finished within the specified time, perform registration procedures from process 1 again. *2: Repeat this process for each key which is to be registered for the vehicle. Finish the procedure for each key within 30 seconds. If the procedure for any of the keys has not been finished within the specified time, perform registration procedures from 1 again. Make sure that only 1 key is in the cabin during registration procedures. If 2 or more keys are in the cabin simultaneously, electric waves will interfere with each other, preventing normal registration. (d) PROCEDURE "D" Key ID erasure HINT: Erase all registered key codes except one. EI Process Procedure 1. Start of erasure 1. Connect intelligent tester (with CAN VIM) to DLC3 2. Turn engine switch on (IG) 3. Select "SMART ACCESS / ID UTILITY / SMART CODE ERS" from tester menu 2. Confirmation of registered key *1 Perform operation according to prompts on intelligent tester screen Hold unregistered key close to engine switch (For details, refer to PROCEDURE "1") Confirm that wireless door lock buzzer sounds once 3. Confirmation of ECU code Perform operation according to prompts on tester screen 4. Erasure of ID code Perform operation according to prompts on tester screen 5. End of erasure Finish key ID code erasure ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) EI–15 *1: Perform this process for one of the keys registered for the vehicle. Finish the procedure within 30 seconds. If the procedure has not been finished within the specified time, perform erasure procedures from process 1 again. (e) PROCEDURE "E" ECU code registration Process Procedure 1. Start of registration 1. Connect intelligent tester (with CAN VIM) to DLC3 2. Turn engine switch on (IG) 3. Select "SMART ACCESS / ID UTILITY / ECU COMM ID REG / ID Code Box and Steering Lock" from tester menu 2. Confirmation of registered key *1 Hold unregistered key close to engine switch (For details, refer to PROCEDURE "1") Confirm that wireless door lock buzzer sounds once 3. Registration of ECU code Perform operation according to prompts on tester screen 4. End of registration Finish ECU code registration (f) *1: Perform this process for one of the keys registered for the vehicle. Finish the procedure within 30 seconds. If the procedure has not been finished within the specified time, perform erasure procedures from process 1 again. PROCEDURE "F" ECU communication ID registration NOTICE: • The ECU communication ID should be registered when the ID code box and/or the ECM is replaced in order to match these ECM communication ID. • The engine cannot be started unless the ECM communication ID matches. Register the ECU communication ID. EI CG TC SST B139171E01 (1) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 EI–16 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) (2) Turn the engine switch on (IG) and leave it for 30 minutes. HINT: Do not start the engine. (3) Turn the engine switch off and disconnect terminals TC and CG. (4) Check that the engine starts. EI EI–17 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) PROBLEM SYMPTOMS TABLE HINT: Use the table below to help determine the cause of the problem symptom. The potential cases of the symptoms are listed in order of probability in the "Suspected Area" column of the table. Check each symptom by checking the suspected area in the order they are listed. Replace parts as necessary. Engine Immobiliser System: Symptom Engine does not start Suspected area See page 1. Key EI-24 2. ID code box power source circuit EI-45 3. Certification ECU power source circuit EI-48 4. Steering lock ECU power source circuit SR-30 5. Smart access system DL-142 6. SFI system ES-15 EI EI–18 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) TERMINALS OF ECU 1. CHECK ENGINE SWITCH E52               B146454E01 (a) Disconnect the E52 switch connector. (b) Measure the resistance according to the value(s) in the table below. Symbols (Terminal No.) AGND (E52-8) - Body ground Wiring Color G - Body ground Terminal Description Ground Condition Specified Condition Below 1 Ω Always If the result is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the E52 switch connector. (d) Measure the resistance and voltage according to the value(s) in the table below. Symbols (Terminal No.) Wiring Color Terminal Description AGND (E52-8) - Body ground G - Body ground Ground VC5 (E52-14) - AGND (E52-8) R-G Power supply W-G Demodulated signal of key code data Condition Always Key is not in cabin Press engine switch Key is not in cabin CODE (E52-10) - AGND (E52-8) Press engine switch and hold key close to engine switch* Key is not in cabin EI TXCT (E52-9) - AGND (E52-8) GR - G Key code output signal Press engine switch and hold key close to engine switch* Specified Condition Below 1 Ω Below 1 V 4.6 to 5.4 V Below 1 V Pulse generation (see waveform 1) Below 1 V Pulse generation (see waveform 2) HINT: *: Remove the key battery before performing this inspection. If the result is not as specified, the switch may have a malfunction. EI–19 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) (e) Inspect using an oscilloscope. (1) Waveform 1 (Reference) Item GND Content Symbols (Terminal No.) CODE (E52-10) - AGND (E52-8) Tool Setting 2 V/DIV., 20 ms./DIV. Condition Press engine switch and hold key close to engine switch* HINT: *: Remove the key battery before performing this inspection. Tool Setting: 2 V/DIV., 20 ms./DIV. B139211E01 (2) Waveform 2 (Reference) Item GND Content Symbols (Terminal No.) TXCT (E52-9) - AGND (E52-8) Tool Setting 2 V/DIV., 20 ms./DIV. Condition Press engine switch and hold key close to engine switch* 2. HINT: *: Remove the key battery before performing this inspection. CHECK CERTIFICATION ECU Tool Setting: 2 V/DIV., 20 ms./DIV. B139212E01 EI E58 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 B106648E23 (a) Disconnect the E58 ECU connector. (b) Measure the resistance and voltage according to the value(s) in the table below. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition Ground Always Below 1 Ω +B (E58-1) - E (E58-17) W - W-B +B power supply Always 10 to 14 V IG (E58-18) - E (E58-17) LG - W-B Ignition power supply Engine switch off Below 1 V E (E58-17) - Body ground W-B - Body ground If the result is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the E58 ECU connector. EI–20 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) (d) Measure the resistance and voltage according to the value(s) in the table below. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition Below 1 Ω AGND (E58-40) - Body ground G - Body ground Engine switch ground Always VC5 (E58-30) - AGND (E58-40) R-G Engine switch power supply Key is not in cabin Press engine switch* Below 1 V 4.6 to 5.4 V Key is not in cabin CODE (E58-9) - AGND (E58-40) W-G Engine switch CODE input GR - G Engine switch TXCT output Press engine switch and hold key close to engine switch* Below 1 V Pulse generation (see waveform 1) Key is not in cabin TXCT (E58-8) - AGND (E58-40) Press engine switch and hold key close to engine switch* Below 1 V Pulse generation (see waveform 2) HINT: *: Remove the key battery before performing this inspection. If the result is not as specified, the ECU may have a malfunction. (e) Inspect using an oscilloscope. (1) Waveform 1 (Reference) Item Symbols (Terminal No.) GND Content CODE (E58-9) - AGND (E58-40) Tool Setting 2 V/DIV., 20 ms./DIV. Condition Press engine switch and hold key close to engine switch* HINT: *: Remove the key battery before performing this inspection. Tool Setting: 2 V/DIV., 20 ms./DIV. EI B139211E01 (2) Waveform 2 (Reference) Item Symbols (Terminal No.) GND Content TXCT (E58-8) - AGND (E58-40) Tool Setting 2 V/DIV., 20 ms./DIV. Condition Press engine switch and hold key close to engine switch* HINT: *: Remove the key battery before performing this inspection. Tool Setting: 2 V/DIV., 20 ms./DIV. B139212E01 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) 3. EI–21 CHECK ID CODE BOX E50 B118534E03 (a) Disconnect the E50 ECU connector. (b) Measure the resistance and voltage according to the value(s) in the table below. Symbols (Terminal No.) GND (E50-8) - Body ground +B (E50-1) - GND (E50-8) Wiring Color W-B - Body ground W - W-B Terminal Description Condition Specified Condition Ground Always Below 1 Ω +B power supply Always 10 to 14 V If the result is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the E50 ECU connector. (d) Measure the voltage according to the value(s) in the table below. Symbols (Terminal No.) Wiring Color Terminal Description Condition Engine switch off EFII (E50-5) - GND (E50-8) G - W-B ECM input signal EFIO (E50-6) - GND (E50-8) L - W-B ECM output signal Engine switch on (IG) Engine switch off Engine switch on (IG) Specified Condition Below 1 V Pulse generation (see waveform 1) Below 1 V Pulse generation (see waveform 2) If the result is not as specified, the ECU may have a malfunction. EI (e) Inspect using an oscilloscope. (1) Waveform 1 (Reference) Item GND Tool Setting: 10 V/DIV., 100 ms./DIV. B139209E01 Content Symbols (Terminal No.) EFII (E50-5) - GND (E50-8) Tool Setting 10 V/DIV., 100 ms./DIV. Condition Engine switch on (IG) EI–22 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) (2) Waveform 2 (Reference) Item Content Symbols (Terminal No.) GND EFIO (E50-6) - GND (E50-8) Tool Setting 10 V/DIV., 100 ms./DIV. Condition Engine switch on (IG) 4. CHECK STEERING CONTROL ECU Tool Setting: 10 V/DIV., 100 ms./DIV. B139210E01 E51 B118684E03 (a) Disconnect the E51 ECU connector. (b) Measure the resistance and voltage according to the value(s) in the table below. Symbols (Terminal No.) EI Wiring Color SGND (E51-2) - Body ground W-B - Body ground GND (E51-1) - Body ground W-B - Body ground Terminal Description Ground Condition Specified Condition Always Below 1 Ω Ground Always Below 1 Ω B (E51-7) - Body ground P - Body ground +B power supply Always 10 to 14 V IG2 (E51-6) - Body ground B - Body ground Ignition power supply Engine switch off Engine switch on (IG) 0V 10 to 14 V If the result is not as specified, there may be a malfunction on the wire harness side. EI–23 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) 5. CHECK ECM A55 C55                                                                                                                                                                                           A107881E14 (a) Measure the resistance and voltage according to the value(s) in the table below. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition E1 (C55-81) - Body ground W-B - Body ground Ground Always Below 1 Ω E01 (C55-22) - Body ground W-B - Body ground Ground Always Below 1 Ω E02 (C55-21) - Body ground B-W - Body ground Ground Always Below 1 Ω E03 (C55-104) - Body ground B - Body ground Ground Always Below 1 Ω E04 (C55-23) - Body ground W - Body ground Ground Always Below 1 Ω E05 (C55-46) - Body ground W - Body ground Ground Always Below 1 Ω ME01 (C55-20) - Body ground B - Body ground Ground Always Below 1 Ω Always 10 to 14 V BATT (A55-20) - E1 (C55-81) Y - W-B Battery (for measuring battery voltage and for ECM memory) +B (A55-2) - E1 (C55-81) R - W-B Power source of ECM IMI (A55-11) - E1 (C55-81) Y - W-B Immobiliser code ECU input signal IMO (A55-10) - E1 (C55-81) G - W-B Immobiliser code ECU output signal Engine switch off Below 1 V Engine switch on (IG) 10 to 14 V Engine switch off Engine switch on (IG) Engine switch off Engine switch on (IG) Below 1 V Pulse generation (see waveform 1) Below 1 V Pulse generation (see waveform 2) If the result is not as specified, the ECM may have a malfunction. EI EI–24 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) (b) Inspect using an oscilloscope. (1) Waveform 1 (Reference) Item GND Content Symbols (Terminal No.) IMI (A55-11) - E1 (C55-81) Tool Setting 10 V/DIV., 100 ms./DIV. Condition Engine switch on (IG) Tool Setting: 10 V/DIV., 100 ms./DIV. B139210E01 (2) Waveform 2 (Reference) Item Symbols (Terminal No.) GND Tool Setting 10 V/DIV., 100 ms./DIV. Condition Engine switch on (IG) 6. Tool Setting: 10 V/DIV., 100 ms./DIV. B139209E01 EI Content IMO (A55-10) - E1 (C55-10) CHECK MAIN BODY ECU (INSTRUMENT PANEL J/B) (a) Disconnect the IF and IM junction block connectors. ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) EI–25 (b) Disconnect the E8, E7 and E6 main body ECU connectors. Vehicle Rear Side IM IF Vehicle Front Side E8 E7 EI E6 B128347E01 (c) Measure the resistance and voltage according to the value(s) in the table below. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition GND1 (IF-10) - Body ground W-B - Body ground Ground Always Below 1 Ω GND2 (IM-9) - Body ground W-B - Body ground Ground Always Below 1 Ω GND3 (E8-1) - Body ground W-B - Body ground Ground Always Below 1 Ω AM1 (E7-6) - Body ground L - Body ground +B power supply Always 10 to 14 V AM2 (E6-1) - Body ground L - Body ground +B power supply Always 10 to 14 V EI–26 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) If the result is not as specified, there may be a malfunction on the wire harness side. DIAGNOSIS SYSTEM 1. CG SG CANH SIL CANL CHECK DLC3 (a) The vehicle's ECU uses ISO 15765-4 for communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. BAT H100769E16 Symbols (Terminal No.) Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 10 to 14 V CANH (6) - CANL (14) CAN bus line Engine switch off* 54 to 69 Ω CANH (6) - CG (4) HIGH-level CAN bus line Engine switch off* 200 Ω or higher CANL (14) - CG (4) LOW-level CAN bus line Engine switch off* 200 Ω or higher CANH (6) - BAT (16) HIGH-level CAN bus line Engine switch off* 6 kΩ or higher CANL (14) - BAT (16) LOW-level CAN bus line Engine switch off* 6 kΩ or higher NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the engine switch, any other switches or the doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. EI (b) Connect the cable of the intelligent tester (with CAN VIM) to the DLC3, turn the engine switch on (IG) and attempt to use the intelligent tester. If the screen displays a communication error message, a problem exists in the vehicle side or tester side. HINT: • If communication is normal when the tool is connected to another vehicle, inspect the DLC3 on the original vehicle. • If communication is still impossible when the tool is connected to another vehicle, the problem is probably in the tool itself. Consult the Service Department listed in the tool's instruction manual. DLC3 Intelligent Tester C131977E01 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) EI–27 DTC CHECK / CLEAR 1. 2. DLC3 Intelligent Tester C131977E01 CHECK DTC (a) Connect the intelligent tester to the Controller Area Network Vehicle Interface Module (CAN VIM). Then connect the CAN VIM to the DLC3. (b) Turn the engine switch on (IG). (c) Read the DTCs by following the directions on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. CLEAR DTC (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the engine switch on (IG). (c) Erase the DTCs by following the directions on the tester's screen. HINT: Refer to the intelligent tester operator's manual for further details. EI EI–28 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) DATA LIST / ACTIVE TEST 1. READ DATA LIST HINT: Using the intelligent tester to read the DATA LIST allows the values or states of switches, sensors, actuators and other items to be read without removing any parts. This non-intrusive inspection can be very useful as intermittent conditions or signals may be discovered before parts or wiring is disturbed. Reading the DATA LIST information early in troubleshooting is one way to save diagnostic time. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the engine switch on (IG). (c) Read the DATA LIST. SMART: Item EI Measurement Item / Display (Range) Normal Condition Diagnostic Note IG SW Engine switch on (IG) signal / ON or OFF ON: Engine switch on (ACC, IG) or start OFF: Engine switch off - ACC SW Engine switch on (ACC) signal / ON or OFF ON: Engine switch on (ACC, IG) or start OFF: Engine switch off - IMMOBILISER Immobiliser system status / SET or UNSET SET: Key is not in cabin UNSET: Key is in cabin - MASTER KEY Master key code signal / MATCH or NO MATCH MATCH: Master key code is sent NO MATCH: Unmatched master key code is sent - SUB KEY Sub-key (Master key) code signal / MATCH or NO MATCH MATCH: Sub-key (master key) code is sent NO MATCH: Unmatched sub-key (master key) code is sent - BCC Transponder chip signal / OK or NG OK: Correct data sent NG: Incorrect data sent - STATUS Transponder chip data / OK or NG OK: Data OK NG: Data error - ENCRYPT CODE Transponder chip signal / OK or NG OK: Correct data sent NG: Incorrect data sent - SERIAL NUMBER Transponder chip signal / OK or NG OK: Correct data sent NG: Incorrect data sent - FRAME Transponder chip signal / OK or NG OK: Correct data sent NG: Incorrect data sent - 2. PERFORM ACTIVE TEST HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the engine switch on (IG). (c) Perform the ACTIVE TEST by following the directions on the tester screen. ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) EI–29 SMART: Item SECURITY INDIC Test Details Turn security indicator ON/OFF Diagnostic Note - EI EI–30 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) DIAGNOSTIC TROUBLE CODE CHART Certification ECU Diagnostic Trouble Code Chart: DTC No. Detection Item Trouble Area See page B2784 Antenna Coil Open / Short 1. Wire harness 2. Engine switch 3. Certification ECU EI-27 B2785 Communication Malfunction between ECUs Connected by LIN 1. Wire harness 2. Certification ECU 3. Main body ECU 4. Steering lock ECU 5. ID code box EI-29 B2786 No Response from Steering Lock ECU 1. Wire harness 2. Certification ECU 3. Steering lock ECU EI-32 B2789 No Response from ID BOX 1. Wire harness 2. Certification ECU 3. ID code box EI-34 B278A Short to GND in Immobiliser System Power Source Circuit 1. Wire harness 2. Engine switch 3. Certification ECU EI-36 B2790 ID BOX EEPROM Malfunction ID code box EI-39 B2791 Communication Condition Failure between ECM 1. Wire harness 2. ID code box 3. ECM EI-40 ECM Diagnostic Trouble Code Chart: DTC No. B2799 Detection Item Engine Immobiliser System Trouble Area 1. Wire harness 2. ECM 3. ID code box See page EI-42 HINT: The DTCs for the engine immobiliser system are specified above. If other codes are output, check the DTC chart for the SFI system. EI ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) DTC B2784 EI–31 Antenna Coil Open / Short DESCRIPTION This DTC is output when there is an open or short malfunction in the key coil (built into engine switch). DTC No. DTC Detection Condition B2784 Antenna coil is open/short Trouble Area • • • Wire harness Engine switch Certification ECU WIRING DIAGRAM Engine Switch Certification ECU 10 CODE 9 W E52 9 TXCT E52 GR E58 CODE 8 E58 TXCT B128331E01 EI INSPECTION PROCEDURE NOTICE: If the certification ECU is replaced, register the key and ECU communication ID (See page EI-8). 1 CHECK DTC OUTPUT (a) Delete the DTCs (See page EI-24). (b) Recheck for DTCs (See page EI-24). Result Result A B2784 output does not reoccur B B A Proceed to B2784 output reoccurs END EI–32 2 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) CHECK HARNESS AND CONNECTOR (CERTIFICATION ECU - ENGINE SWITCH) Wire Harness Side Connector Front View: E58 Certification ECU (a) Disconnect the E58 ECU and E52 switch connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection E58-9 (CODE) - E52-10 (CODE) 10 11 12 13 14 15 16 17 E58-8 (TXCT) - E52-9 (TXCT) 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 E58-9 (CODE) - Body ground 1 2 3 4 5 6 7 8 9 E58-8 (TXCT) - Body ground TXCT Specified Condition Below 1 Ω 10 kΩ or higher CODE NG REPAIR OR REPLACE HARNESS OR CONNECTOR E52 Engine Switch 1 2 3 4 5 6 7 TXCT 8 9 10 11 12 13 14 CODE B119109E06 OK 3 CHECK ENGINE SWITCH (a) After replacing the engine switch (See page ST-152) with a normal one, check that the engine starts. OK: The engine starts. EI NG OK END REPLACE CERTIFICATION ECU ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) DTC EI–33 Communication Malfunction between ECUs Connected by LIN B2785 DESCRIPTION This DTC is output when LIN communication from the certification ECU stops for a certain amount of time. DTC No. DTC Detection Condition Trouble Area LIN communication from certification ECU stops for a certain amount of time • Open or short in wire harness between ECUs B2785 • • • • • Wire harness Certification ECU Main body ECU Steering lock ECU ID code box WIRING DIAGRAM Steering Lock ECU Certification ECU No. 4 J/B 5 E51 LIN O 8 7 4A 4F O 10 E58 Main Body ECU LIN ID Code Box Instrument Panel J/B LIN1 14 9 IR O 1 4M 8 4F O 3 E50 EI LIN1 B128332E01 INSPECTION PROCEDURE NOTICE: • If the certification ECU or ID code box is replaced, register the key and ECU communication ID (See page EI-8). • If the steering lock ECU or main body ECU is replaced, register the ECU code and ECU communication ID (See page EI-8). 1 CHECK DTC OUTPUT (a) Delete the DTCs (See page EI-24). (b) Recheck for DTCs (See page EI-24). EI–34 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) Result Result Proceed to B2785 output reoccurs A B2785 output does not reoccur B B END A 2 CHECK HARNESS AND CONNECTOR (LIN COMMUNICATION LINE) (a) Disconnect the E58, E51, IR and E50 ECU connectors. Wire Harness Side Connector Front View: E50 ID Code Box E58 Certification ECU LIN LIN1 E51 Steering Lock ECU IR Main Body ECU LIN LIN1 EI B128348E01 (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition E58-10 (LIN) - E50-3 (LIN1) E58-10 (LIN) - IR-9 (LIN1) Below 1 Ω E58-10 (LIN) - E51-5 (LIN) E58-10 (LIN) - Body ground NG 10 kΩ or higher REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 CHECK CERTIFICATION ECU (a) After replacing the certification ECU with a normal one, check for DTCs (See page EI-24). ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) EI–35 Result Result Proceed to B2785 output reoccurs A B2785 output does not reoccur B B END A 4 CHECK MAIN BODY ECU (a) After replacing the main body ECU with a normal one, check for DTCs (See page EI-24). Result Result Proceed to B2785 output reoccurs A B2785 output does not reoccur B B END A 5 CHECK STEERING LOCK ECU (a) After replacing the steering lock ECU with a normal one, check for DTCs (See page EI-24). Result Result A B2785 output does not reoccur B B A REPLACE ID CODE BOX Proceed to B2785 output reoccurs END EI EI–36 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) DTC B2786 No Response from Steering Lock ECU DESCRIPTION This DTC is output when the certification ECU does not receive LIN communication from the steering lock ECU for 10 seconds. DTC No. DTC Detection Condition Trouble Area Certification ECU does not receive LIN communication from steering lock ECU for 10 seconds B2786 • • • Wire harness Certification ECU Steering lock ECU WIRING DIAGRAM Steering Lock ECU Certification ECU No. 4 J/B 5 LIN O E51 8 4A 7 4F O 10 E58 LIN B128333E01 EI INSPECTION PROCEDURE NOTICE: • If the certification ECU is replaced, register the key and ECU communication ID (See page EI-8). • If the steering lock ECU is replaced, register the ECU code and ECU communication ID (See page EI-8). 1 CHECK DTC OUTPUT (a) Delete the DTCs (See page EI-24). (b) Recheck for DTCs (See page EI-24). Result Result Proceed to B2786 output reoccurs A B2786 output does not reoccur B B END ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) EI–37 A 2 CHECK HARNESS AND CONNECTOR (CERTIFICATION ECU - STEERING LOCK ECU) Wire Harness Side Connectro Front View: E58 Certification ECU (a) Disconnect the E58 and E51 ECU connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Specified Condition E58-10 (LIN) - E51-5 (LIN) Below 1 Ω E58-10 (LIN) - Body ground 10 kΩ or higher 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 NG LIN REPAIR OR REPLACE HARNESS OR CONNECTOR E51 Steering Lock ECU 1 2 3 4 5 6 7 LIN B118667E01 OK 3 CHECK CERTIFICATION ECU (a) After replacing the certification ECU with a normal one, check for DTCs (See page EI-24). Result Result B2786 output reoccurs A B2786 output does not reoccur B B A REPLACE STEERING LOCK ECU Proceed to END EI EI–38 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) DTC B2789 No Response from ID BOX DESCRIPTION This DTC is output when the certification ECU does not receive LIN communication from the ID code box for 10 seconds. DTC No. DTC Detection Condition B2789 Certification ECU does not receive LIN communication from ID code box • Open or short in wire harness between ECUs Trouble Area • • • Wire harness Certification ECU ID code box WIRING DIAGRAM ID Code BOX Certification ECU No. 4 J/B LIN1 3 E50 O 8 4F 7 4F O 10 E58 LIN B128333E02 EI INSPECTION PROCEDURE NOTICE: If the certification ECU or ID code box is replaced, register the key and ECU communication ID (See page EI-8). 1 CHECK DTC OUTPUT (a) Delete the DTCs (See page EI-24). (b) Recheck for DTCs (See page EI-24). Result Result Proceed to B2789 output reoccurs A B2789 output does not reoccur B B END ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) EI–39 A 2 CHECK HARNESS AND CONNECTOR (CERTIFICATION ECU - ID CODE BOX) Wire Harness Side Connector Front View: E58 Certification ECU 1 2 3 4 5 6 7 8 9 (a) Disconnect the E58 ECU and E50 ID code box connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance 10 11 12 13 14 15 16 17 Tester Connection Specified Condition E58-10 (LIN) - E50-3 (LIN1) Below 1 Ω E58-10 (LIN) - Body ground 10 kΩ or higher 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 NG LIN REPAIR OR REPLACE HARNESS OR CONNECTOR E50 ID Code Box 1 2 3 4 5 6 7 8 LIN1 B113404E02 OK 3 CHECK CERTIFICATION ECU (a) After replacing the certification ECU with a normal one, check for DTCs (See page EI-24). Result Result B2789 output reoccurs A B2789 output does not reoccur B B A REPLACE ID CODE BOX Proceed to END EI EI–40 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) DTC Short to GND in Immobiliser System Power Source Circuit B278A DESCRIPTION This DTC is output when the engine switch power source supply line is open or shorted. DTC No. B278A DTC Detection Condition Engine switch power source supply line is open or shorted Trouble Area • • • Wire harness Engine switch Certification ECU WIRING DIAGRAM Engine Switch Certification ECU 14 VC5 R E52 8 AGND E52 30 E58 G VC5 40 E58 AGND B128331E02 EI INSPECTION PROCEDURE NOTICE: If the certification ECU is replaced, register the key and ECU communication ID (See page EI-8). ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) 1 EI–41 CHECK WIRE HARNESS (CERTIFICATION ECU - ENGINE SWITCH) Wire Harness Side Connector Front View: E58 Certification ECU (a) Disconnect the E58 ECU and E52 switch connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition E58-30 (VC5) - E52-14 (VC5) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 E58-40 (AGND) - E52-8 (AGND) E58-30 (VC5) - Body ground E58-40 (AGND) - Body ground VC5 AGND NG Below 1 Ω 10 kΩ or higher REPAIR OR REPLACE HARNESS OR CONNECTOR E52 Engine Switch 1 2 3 4 5 6 7 8 9 10 11 12 13 14 AGND VC5 B119109E07 OK 2 CHECK HARNESS AND CONNECTOR (ENGINE SWITCH POWER SOURCE) Wire Harness Side Connector Rear View: E58 Certification ECU (a) Reconnect the E58 ECU and E52 switch connectors. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition E58-30 (VC5) - Body ground Key is not in cabin Below 1 V Press engine switch 4.6 to 5.4 V NG VC5 B128349E01 OK Specified Condition REPAIR OR REPLACE HARNESS OR CONNECTOR EI EI–42 3 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) CHECK HARNESS AND CONNECTOR (ENGINE SWITCH BODY GROUND) Wire Harness Side Connector Rear View: (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition E58-40 (AGND) - Body ground Below 1 Ω E58 Certification ECU NG REPAIR OR REPLACE HARNESS OR CONNECTOR AGND B128349E03 OK 4 CHECK ENGINE SWITCH (a) After replacing the engine switch (See page ST-152) with a normal one, check that the engine starts. OK: The engine starts. NG OK EI END REPLACE CERTIFICATION ECU ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) DTC B2790 EI–43 ID BOX EEPROM Malfunction DESCRIPTION This DTC is output when the ID code box detects an internal malfunction. DTC No. B2790 DTC Detection Condition ID code box detects internal malfunction Trouble Area ID code box INSPECTION PROCEDURE NOTICE: If the ID code box is replaced, register the key and ECU communication ID (See page EI-8). 1 REPLACE ID CODE BOX NEXT END EI EI–44 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) DTC Communication Condition Failure between ECM B2791 DESCRIPTION This DTC is output when the ID code box does not respond to a verification request signal from the ECM. HINT: • If the engine switch is turned off immediately after an engine start, this DTC is also detected. • If this DTC is detected simultaneously with DTC B2799, troubleshoot DTC B2799 first. DTC No. DTC Detection Condition Trouble Area ID code box does not respond to a verification request signal from ECM B2791 • • • Wire harness ID code box ECM WIRING DIAGRAM ID Code Box ECM No. 4 J/B IMI 11 A55 Y 7 AE5 L 11 4C 10 4F L 6 E50 EFIO EI B128335E03 INSPECTION PROCEDURE NOTICE: • If the ID code box is replaced, register the key and ECU communication ID (See page EI-8). • If the ECM is replaced, register the ECU communication ID (See page EI-8). • If the engine can be started even when DTC B2791 is output, the ID code box can be considered normal. Be sure to recheck for DTCs after clearing the DTCs (See page EI-24). 1 CHECK DTC OUTPUT (a) Delete the DTCs (See page EI-24). (b) Recheck for DTCs (See page EI-24). Result Result B2791 and other DTC output Proceed to A ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) Result No DTC output B EI–45 Proceed to B END A REPAIR CIRCUITS INDICATED BY OUTPUT DTCS EI EI–46 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) DTC B2799 Engine Immobiliser System DESCRIPTION This DTC is output when one of the following occurs: 1) the ECM detects errors in its own communications with the ID code box; 2) the ECM detects errors in the communication lines; or 3) the ECU communication ID between the ID code box and ECM is different and an engine start is attempted. Before troubleshooting for this DTC, make sure no certification ECU DTCs are present. If present, troubleshoot the certification ECU DTCs first. DTC No. DTC Detection Condition Trouble Area B2799 One of following conditions is met: • Error in communication between ECM and ID code box • Error in communication lines • Communication ID is different with ID code box during communication • • • Wire harness ECM ID code box WIRING DIAGRAM ECM ID Code Box No. 4 J/B 11 IMI A55 10 IMO A55 Y G 7 AE5 13 AE5 L G 11 10 4C 4F 4 5 4C 4F L G 6 E50 EFIO 5 E50 EFII EI B128336E03 INSPECTION PROCEDURE NOTICE: • If the ID code box is replaced, register the key and ECU communication ID (See page EI-8). • If the ECM is replaced, register the ECU communication ID (See page EI-8). 1 CHECK DTC OUTPUT (a) Delete the DTCs (See page EI-24). (b) Recheck for DTCs (See page EI-24). Result Result B2799 output reoccurs Proceed to A ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) Result B2799 output does not reoccur B EI–47 Proceed to B END A 2 RE-REGISTER ECU COMMUNICATION ID (a) Re-register the ECU communication ID (See page EI-8) between the ID code box and ECM. (b) Check that the engine starts. OK: Engine starts. OK END NG 3 CHECK HARNESS AND CONNECTOR (ID CODE BOX - ECM) Wire Harness Side Connecter Front View: E50 ID Code Box (a) Disconnect the E50 ID code box and A55 ECM connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection E50-5 (EFII) - A55-10 (IMO) E50-6 (EFIO) - A55-11 (IMI) E50-5 (EFII) - Body ground E50-6 (EFIO) - Body ground EFII EFIO NG A55 ECM IMO IMI B128354E01 OK Specified Condition Below 1 Ω 10 kΩ or higher REPAIR OR REPLACE HARNESS OR CONNECTOR EI EI–48 4 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) CHECK ECM (a) After replacing the ECM (See page ES-518) with a normal one, check for DTCs (See page EI-8). Result Result A B2799 output does not reoccur B A B END EI Proceed to B2799 output reoccurs REPLACE ID CODE BOX ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) EI–49 ID Code Box Power Source Circuit DESCRIPTION This circuit provides power to operate the ID code box. WIRING DIAGRAM ID Code Box No. 4 J/B No. 3 J/B W 1 1 3J 3C 1 2 4D W W 4F 1 E50 +B Engine Room R/B 21 AE2 LG 3 A42 J/C 8 A41 EFI NO. 1 2 W 1 1A 1G W FL MAIN No. 4 J/B E49 J/C 1 W-B 3 3 4D 4F W-B 8 E50 EI GND 2 W-B BATTERY E2 B128353E01 INSPECTION PROCEDURE NOTICE: If the ID code box is replaced, register the key and ECU communication ID (See page EI-8). EI–50 1 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) INSPECT FUSE (EFI NO. 1) (a) Remove the EFI No. 1 fuse from the No. 1 engine room R/B. (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω NG REPLACE FUSE OK 2 CHECK HARNESS AND CONNECTOR (ID CODE BOX - BATTERY) Wire Harness Side Connector Front View: (a) Disconnect the E50 ID code box connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage E50 ID Code Box NG Tester Connection Specified Condition E50-1 (+B) - Body ground 10 to 14 V REPAIR OR REPLACE HARNESS OR CONNECTOR 1 2 3 4 5 6 7 8 +B B107455E17 OK EI 3 CHECK HARNESS AND CONNECTOR (ID CODE BOX - BODY GROUND) Wire Harness Side Connector Front View: E50 ID Code Box (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition E50-8 (GND) - Body ground Below 1 Ω NG 1 2 3 4 5 6 7 8 GND B107455E18 REPAIR OR REPLACE HARNESS OR CONNECTOR ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) EI–51 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE EI EI–52 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) Certification ECU Power Source Circuit DESCRIPTION This circuit provides power to operate the certification ECU. WIRING DIAGRAM Certification ECU No. 4 J/B No. 3 J/B W 1 1 3J 3C 2 2 4D W W 4F 1 E58 +B 17 E58 E Engine Room R/B 21 AE2 LG 3 A42 J/C 8 A41 EFI NO. 1 2 W 1 1A 1G W EI FL MAIN No. 4 J/B E49 J/C 1 W-B 3 4D 4 4F W-B 2 W-B BATTERY E2 B128353E02 INSPECTION PROCEDURE NOTICE: If the certification ECU is replaced, register the key and ECU communication ID (See page EI-8). ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) 1 EI–53 INSPECT FUSE (EFI NO. 1) (a) Remove the EFI No. 1 fuse from the No. 1 engine room R/B. (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω NG REPLACE FUSE OK 2 CHECK WIRE HARNESS (CERTIFICATION ECU - BATTERY) Wire Harness Side Connector Front View: (a) Disconnect the E58 ECU connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage E58 Certification ECU NG 1 2 3 4 5 6 7 8 9 1011 121314151617 Tester Connection Specified Condition E58-1 (+B) - Body ground 10 to 14 V REPAIR OR REPLACE HARNESS OR CONNECTOR 1819202122232425262728293031323334353637383940 +B B107456E47 OK 3 EI CHECK HARNESS AND CONNECTOR (CERTIFICATION ECU - BODY GROUND) Wire Harness Side Connector Front View: (a) Measure the resistance according to the value(s) in the table below. Standard resistance E58 Certification ECU NG 1 2 3 4 5 6 7 8 9 1011 121314151617 1819202122232425262728293031323334353637383940 E B107456E40 Tester Connection Specified Condition E58-17 (E) - Body ground Below 1 Ω REPAIR OR REPLACE HARNESS OR CONNECTOR EI–54 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE EI ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) EI–51 ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) PRECAUTION 1. PRECAUTIONS FOR THE KEY (a) The key is a precision instrument. Be sure to observe the following: (1) Do not drop or strike the key. (2) Do not allow the key to be kept in a high temperature place for a long time. (3) Do not use an ultrasonic washing machine to clean the key. (4) Keep the key away from magnets or magnetized items during use. (5) Do not attach any stickers to the key. EI EI–52 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) PARTS LOCATION ECM (2GR-FE) ECM (2AZ-FE) FRONT DOOR COURTESY SWITCH SECURITY INDICATOR LIGHT: - DRIVER’S DOOR TRANSPONDER KEY AMPLIFIER TRANSPONDER KEY ECU ASSEMBLY CLOCK EI DLC3 UNLOCK WARNING SWITCH B128352E01 EI–53 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) SYSTEM DIAGRAM Transponder Key ECU Assembly ECM EFI NO. 1 from Battery EFIO IMI +B EFII IMO IGN from Ignition Switch IG Unlock Warning Switch Assembly KSW Transponder Key Amplifier VC5 Front Door Courtesy Light Switch Assembly (Driver’s Door) VC5 CTY CODE CODE TXCT TXCT AGND AGND Clock Assembly (Security Indicator Light) IND LP EI GND1 Data Link Connector 3 GND D SIL B128345E02 EI–54 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) SYSTEM DESCRIPTION 1. 2. Component Outline Transponder key coil/amplifier When key is inserted in ignition key cylinder, key coil receives key code. Then amplifier amplifies ID code and outputs it to transponder key ECU assembly. Unlock warning switch assembly Detects if key is in ignition key cylinder and outputs results to transponder key ECU assembly. ECM ECM receives ID verification results from transponder key ECU assembly. ECM also verifies ECUs. Then judgement of whether to immobilise engine is made. Security indicator Depending on operation of transponder key ECU assembly, interior security indicator light comes on or starts blinking. 3. Security Indicator Light: B128350E02 EI ENGINE IMMOBILISER SYSTEM DESCRIPTION The engine immobiliser system is designed to prevent the vehicle from being stolen. This system uses the transponder key ECU assembly that stores the key codes of authorized ignition keys. If an attempt is made to start the engine using an unauthorized key, the ECU sends a signal to the ECM to prohibit fuel delivery and ignition, effectively disabling the engine. FUNCTION OF MAIN COMPONENT SYSTEM FUNCTION (a) When the transponder key ECU assembly detects that the key unlock warning switch is ON, the ECU provides current to the transponder key coil and produces an electric wave. A transponder chip in the key grip receives the electric wave. Upon receiving the electric wave, the transponder chip outputs a key ID code signal. The transponder key coil receives this signal, the signal is amplified by the transponder key amplifier, and the signal is transmitted to the ECU. The ECU matches the key's ID code with the vehicle's ID code, which was previously registered in the ECU, and communicates the results to the ECM. After the identification results show that the key's ID code matches the vehicle's ID code and the ECU has confirmed their match: 1) the immobiliser system does not immobilise the engine and the engine starting controls (fuel injection control and ignition control) enter standby mode; and 2) the ECU transmits a security indicator signal that communicates "indicator off" to the clock. Then, the clock turns off the security indicator light. (b) The security indicator pattern is as shown below (when changing from the immobiliser set status to the unset status): ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) EI–55 Security Indicator: 1.8 sec. 0.2 sec. 0.2 sec. Lights up for 2 sec. (Sub key is in ignition key cylinder) 1.8 sec. Normal (Immobiliser system is operating normally) ON OFF Immobiliser set status Immobiliser unset status Registration key recognition B118503E03 EI EI–56 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) HOW TO PROCEED WITH TROUBLESHOOTING HINT: Use this procedure to troubleshoot the engine immobiliser system. The intelligent tester should be used in steps 3, 4, and 6. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CRANK ENGINE FOR MORE THAN 10 SECONDS NEXT 3 CHECK FOR DTCS (a) Check for DTCs and note any codes that are output. (b) Delete the DTCs. (c) Recheck for DTCs. Try to duplicate the DTC (SFI system and engine immobiliser system) by simulating the symptoms indicated by the DTC. (1) If the DTC does not reoccur, proceed to A. (2) If the DTC (SFI system) reoccurs, proceed to B. (3) If the DTC (engine immobiliser system) reoccurs, proceed to C. EI B GO TO SFI SYSTEM C GO TO DTC CHART A 4 READ VALUE ON INTELLIGENT TESTER (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the ignition switch to the ON position and turn the intelligent tester on. (c) Read the DATA LIST according to the display on the tester. IMMOBILISER: Item Measurement Item/Display (Range) Normal Condition Diagnostic Note KEY SW Unlock warning switch signal/ON or OFF ON: Key is in ignition key cylinder OFF: No key is in ignition key cylinder - OK: ON (Key is in ignition key cylinder) appears on the screen. ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) NG EI–57 GO TO DTC B2780 OK 5 PROBLEM SYMPTOMS TABLE (a) If the fault is not listed on the problem symptoms table, proceed to A. (b) If the fault is listed on the problem symptoms table, proceed to B. B GO TO STEP 7 A 6 OVERALL ANALYSIS AND TROUBLESHOOTING (a) Inspection with the intelligent tester (DATA LIST). (b) Inspection with the intelligent tester (ACTIVE TEST). (c) TERMINALS OF ECU (See page EI-63). NEXT 7 ADJUST, REPAIR OR REPLACE NEXT 8 CONFIRMATION TEST NEXT EI END EI–58 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) REGISTRATION 1. DESCRIPTION OF CODE REGISTRATION HINT: The key has 2 codes: The key code (immobiliser code) and the wireless code. Both of these codes need to be registered. Refer to page for the wireless code registration procedures. (a) When adding master keys or sub keys (Additional registration): (1) Register key code (immobiliser code) in the transponder key ECU. Target ECU See Procedure Transponder key ECU Procedure "A" (b) When replacing the transponder key ECU (New registration): (1) Register the key code (immobiliser code) in the transponder key ECU. Target ECU See Procedure Transponder key ECU Procedure "B" (2) Register the ECU communication ID between the ECM and the transponder key ECU. Target ECU See Procedure Transponder key ECU Procedure "C" (c) When replacing the ECM: (1) Register the ECU communication ID between the ECM and the transponder key ECU. Target ECU See Procedure Transponder key ECU Procedure "C" 2. EI KEY REGISTRATION (a) Automatic registration (Procedure "B"): The new registration of the key codes (immobiliser codes) is made automatically. HINT: • When installing a new transponder key ECU, the key codes (immobiliser codes) must be registered. • A new transponder key ECU starts in the automatic key code registration mode. In this mode, a maximum of 4 key codes for 3 master keys and 1 sub key can be registered. Since the transponder key ECU can distinguish types of keys, any registration order is acceptable. Automatic Key Code Registration (New Registration): Procedure Security Indicator Condition 1. Start (Procedure "D") Blinking occurs until the first key is inserted. 2. Insert the key into the ignition key cylinder. ON 3. Registration begins. HINT: The registration will be completed approx. 1 sec. after the key is inserted. OFF HINT: Approx. 1 sec. ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) Procedure 4. Remove the key. 5. Register another key ? Yes: Go to procedure "D" No: Go to procedure "E" EI–59 Security Indicator Condition ON HINT: When the maximum number of the key codes is registered, the security indicator remains off until the last key registered is removed. After it is removed, the security indicator starts blinking. 6. End (Procedure "E") HINT: • When no key is inserted in the key cylinder while the system is in automatic key code registration mode, the security indicator remains on. • When the immobiliser system is operating normally and the key is pulled out, the security indicator blinks continuously. • If the key code registration has failed in the automatic key code registration mode, code 2-1 will be output from the security indicator. Trying to register an already registered key will cause code 2-2 to be output when the key is inserted. If the number of registered key codes exceeds the limit, code 2-3 will be output from the security indicator. The output details are shown below. EI EI–60 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) Security Indicator: 0.2 sec. ON Normal (Immobiliser system is operating normally) OFF 1.8 sec. 0.25 sec. 1 sec. ON Code 2 - 1 OFF 0.25 sec. 0.5 sec. 0.25 sec. 1 sec. ON Code 2 - 2 OFF EI 0.25 sec. 0.5 sec. 0.25 sec. 1 sec. ON Code 2 - 3 OFF 0.25 sec. 0.5 sec. B111593E14 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) EI–61 (b) Finish the automatic key code registration mode. The automatic key code registration mode can be forced to end, when at least 1 key code (immobiliser code) for the master key has been registered. (1) Turn the ignition switch on and off 5 times within 10 seconds using the master key that has already been registered. 3. REGISTRATION OF ADDITIONAL KEY (a) Additional registration (Procedure "A"): Register an additional key by using the intelligent tester. HINT: • A maximum of 5 key codes and 3 sub key codes can be registered. • Registration mode will end if any step is not completed within the specified time. • When the ignition cylinder or the key cylinder set is replaced, remove the transmitter module from the original master key. Then install this transmitter module to a new key and use it as the master key. If necessary, use this master key to register other keys. NOTICE: When only the ignition key cylinder has been replaced, you can lock or unlock doors by wireless operation using the new key with built in transmitter but not by inserting it in the door key cylinder. Therefore, keep the original key for the door lock or unlock operation in order to avoid malfunctions caused by a dead transmitter battery in the new key. Additional Registration: Procedure Time (Completion of operation) Security Indicator Condition - Indicator blinks until the first key is inserted. Within 120 sec. OFF EI 1. Start 2. Insert the already registered master key in the ignition key cylinder and turn the ignition switch on. 3. Intelligent tester operation (1) Select IMMOBILISER (2) Select ID UTILITY (3) Select IMMOB CODE REG HINT: After completing the above operation, proceed to the next step in accordance with the prompts on the tester screen. 4. Remove the master key. 5. Insert the key to be registered in the ignition key cylinder. 6. After 60 sec. the key is registered. HINT: The security indicator goes off. 7. Next 8. End Within 20 sec. of the instruction on the tester Within 10 sec. - ON Blinking OFF EI–62 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) NOTICE: If the key code registration has failed in automatic key code registration mode, code 2-1 will be output from the security indicator. Trying to register an already registered key will cause code 2-2 to be output when the key is inserted. If the number of registered key codes exceeds the limit, code 2-3 will be output from the security indicator. The output details are shown in procedure "B". HINT: • A brief outline of procedures for key code registration is shown above. For detailed information, refer to the screen of the intelligent tester. • When the immobiliser system is operating normally and the key is pulled out, the security indicator will blink. 4. ERASURE OF KEY CODE (a) Erase the key codes by using the intelligent tester. HINT: • All key codes will be erased except for the master key which is used for erasing the key codes. In order to use a key for which the code has been erased, it is necessary to register the key code again. • The registration operation will be cancelled if any step is not completed within the specified time. Erasing Key Code: Procedure Time (Operation Completion Time) Security Indicator Condition - Indicator blinks until the first key is inserted. Within 120 sec. OFF Within 10 sec. of the instruction on the tester ON for 1 sec. then OFF - Blinking 1. Start EI 2. Insert the already registered master key in the ignition key cylinder and turn the ignition switch on. 3. Intelligent tester operation (1) Select IMMOBILISER (2) Select ID UTILITY (3) Select IMMOB CODE ERA HINT: After completing the above operation, proceed to the next step in accordance with the prompts on the tester screen. 4. Remove the master key. 5. Next 6. End HINT: • A brief outline of procedures for key code registration is shown above. For detailed information, refer to the screen of the intelligent tester. • When the immobiliser system is operating normally and the key is pulled out, the security indicator will blink. ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) 5. EI–63 ECU COMMUNICATION ID REGISTRATION NOTICE: • The ECU communication ID should be registered when the transponder key ECU and/or the ECM is replaced in order to match it to the ECM communication ID. • The SFI system cannot be started unless the ECM communication ID matches. (a) ECU communication ID registration (Procedure "C"): Register the ECU communication ID, after the transponder key ECU and/or the ECM is replaced. CG TC SST B139171E01 (1) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 (2) Turn the ignition switch to the ON position and leave the vehicle as is for 30 minutes. (3) Check that the engine starts. EI EI–64 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) PROBLEM SYMPTOMS TABLE HINT: Use the table below to help determine the cause of the problem symptom. The potential cases of the symptoms are listed in order of probability in the "Suspected Area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. ENGINE IMMOBILISER SYSTEM: Symptom Unable to register the key. Suspected area 1. Door courtesy switch circuit EI-92 2. ECU power source circuit EI-94 3. Transponder key ECU assembly Engine does not start. Security indicator is always ON. EI-70 2. ECU power source circuit EI-94 3. Transponder key ECU assembly No code is output. ES-11 5. SFI system (2GR-FE) ES-15 1. Security indicator light circuit EI-89 2. ECU power source circuit EI-94 - 1. Security indicator light circuit EI-89 2. ECU power source circuit EI-94 Transponder key ECU assembly - 1. Diagnosis circuit EI-98 2. ECU power source circuit EI-94 3. Transponder key ECU assembly EI - 4. SFI system (2AZ-FE) 3. Transponder key ECU assembly Security indicator is blinking abnormally. - 1. Key 3. Transponder key ECU assembly Security indicator is OFF. See page - HINT: • If the engine does not start, check that the key which did not start the engine control system has been registered, and that it is possible to start with another registered key. • If the security indicator is always ON, finish the automatic registration mode in case the mode still operates. EI–65 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) TERMINALS OF ECU 1. CHECK TRANSPONDER KEY AMPLIFIER (a) Disconnect the E25 amplifier connector and measure the resistance between the terminal of the wire harness side connector and body ground. E25 B065593E20 Symbols (Terminal No.) AGND (E25-7) - Body ground Wiring Color V - Body ground Terminal Description Ground Condition Specified Condition Below 1 Ω Always If the result is not as specified, there may be a malfunction on the wire harness side. (b) Reconnect the E25 amplifier connector and measure the resistance and voltage of each terminal of the connector. Symbols (Terminal No.) VC5 (E25-1) - AGND (E25-7) Wiring Color O-V CODE (E25-4) - AGND (E25-7) BR - V TXCT (E25-5) - AGND (E25-7) R-V AGND (E25-7) - Body ground V - Body ground Terminal Description Condition Specified Condition No key is in ignition key cylinder Power source Key is in ignition key cylinder Demodulated signal of key code data No key is in ignition key cylinder Key code output signal No key is in ignition key cylinder Ground Always Key is in ignition key cylinder Key is in ignition key cylinder Below 1 V 4.6 to 5.4 V Below 1 V Waveform 1 Below 1 V Waveform 2 Below 1 Ω If the result is not as specified, the amplifier may have a malfunction. (c) Inspect using an oscilloscope. (1) Waveform 1 (Reference) GND Tool Setting: 2 V/DIV., 20 ms./DIV. B139208E01 Terminal CODE (E25-4) - AGND (E25-7) Tool Setting 2 V/DIV., 20 ms./DIV. Condition Key is in ignition key cylinder EI EI–66 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) (2) Waveform 2 (Reference) 2. Terminal TXCT (E25-5) - AGND (E25-7) Tool Setting 2 V/DIV., 10 ms./DIV. Condition Key is in ignition key cylinder CHECK TRANSPONDER KEY ECU ASSEMBLY (a) Disconnect the E15 ECU connector and measure the resistance and voltage between each terminal of the wire harness side connector. GND Tool Setting: 2 V/DIV., 10 ms./DIV. B139205E01 E15 B088367E04 Symbols (Terminal No.) Terminal Description Condition Specified Condition W-B - Body ground Ground Always Below 1 Ω +B (E15-1) - GND (E15-16) W - W-B Battery Always 10 to 14 V IG (E15-2) - GND (E15-16) LG - W-B Ignition switch signal GND (E15-16) - Body ground EI Wiring Color KSW (E15-3) - GND (E15-16) B - W-B Unlock warning switch signal Ignition switch OFF Below 1 V Ignition switch ON 10 to 14 V No key is in ignition key cylinder Key is in ignition key cylinder 10 kΩ or higher Below 1 Ω If the result is not as specified, there may be a malfunction on the wire harness side. (b) Reconnect the E15 ECU connector and measure the voltage of each terminal of the connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Ground Always Below 1 Ω Unlock warning switch signal No key is in ignition key cylinder 10 to 14 V Key is in ignition key cylinder Below 1 V AGND (E15-5) - Body ground V - Body ground KSW (E15-3) - GND (E15-16) B - W-B VC5 (E15-14) - AGND (E15-5) O-V Power source R-V Transponder key amplifier communication signal No key is in ignition key cylinder TXCT (E15-4) - AGND (E15-5) Transponder key amplifier communication signal No key is in ignition key cylinder BR - V CODE (E15-15) - AGND (E15-5) Specified Condition No key is in ignition key cylinder Key is in ignition key cylinder Key is in ignition key cylinder Key is in ignition key cylinder Below 1 V 4.6 to 5.4 V Below 1 V Waveform 1 Below 1 V Waveform 2 EI–67 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) Symbols (Terminal No.) Wiring Color Terminal Description EFIO (E15-13) - GND (E15-16) L - W-B ECM output signal EFII (E15-12) - GND (E15-16) G - W-B ECM input signal GR - W-B Diagnostic tester communication D (E15-9) - GND (E15-16) CTY (E15-7) - GND (E15-16) Y - W-B Door courtesy signal IND (E15-8) - GND (E15-16) P - W-B Security indicator signal Condition Specified Condition Ignition switch OFF Below 1 V Ignition switch ON Waveform 3 Ignition switch OFF Below 1 V Ignition switch ON Waveform 4 Without communication Below 1 V During communication Pules generation Switch pushed 10 to 14 V Switch free Below 1 V Security indicator light is on 10 to 14 V Security indicator light is off Below 1 V If the result is not as specified, the ECU may have a malfunction. (c) Inspect using an oscilloscope. (1) Waveform 1 (Reference) Terminal TXCT (E15-4) - AGND (E15-5) Tool Setting 2 V/DIV., 10 ms./DIV. Condition Key is in ignition key cylinder GND Tool Setting: 2 V/DIV., 10 ms./DIV. B139205E01 (2) Waveform 2 (Reference) GND Tool Setting: 2 V/DIV., 20 ms./DIV. B139208E01 Terminal CODE (E15-15) - AGND (E15-5) Tool Setting 2 V/DIV., 20 ms./DIV. Condition Key is in ignition key cylinder EI EI–68 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) (3) Waveform 3 (Reference) Terminal EFIO (E15-13) - GND (E15-16) Tool Setting 2 V/DIV., 1 s./DIV. Condition Ignition switch ON GND Tool Setting: 2 V/DIV., 1 s./DIV. B139206E01 (4) Waveform 4 (Reference) 3. Terminal EFII (E15-12) - GND (E15-16) Tool Setting 2 V/DIV., 1 s./DIV. Condition Ignition switch ON CHECK ECM (a) Disconnect the C24*1 or C55*2 ECM connector and measure the resistance between the terminal of the wire harness side connector and body ground. GND Tool Setting: 2 V/DIV., 1 s./DIV. B139207E01 EI *1: for 2AZ-FE *2: for 2GR-FE                         C24 *1 A24 *1 C55 *2 A55 *2                                                                                                                                                                   A107881E15 Symbols (Terminal No.) E1 (C24-104)*1 - Body ground E1 (C55-81)*2 - Body ground Wiring Color W-B - Body ground Terminal Description Ground Condition Always Specified Condition Below 1 Ω EI–69 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) *1: for 2AZ-FE *2: for 2GR-FE If the result is not as specified, there may be a malfunction on the wire harness side. (b) Reconnect the C24*1 or C55*2 ECM connector. Measure the voltage between each terminal of the connector according to the value(s) in the table below. Symbols (Terminal No.) IMI (A24-11)*1 - E1 (C24-104)*1 IMI (A55-11)*2 - E1 (C55-81)*2 IMO (A24-10)*1 - E1 (C24-104)*1 IMO (A55-10)*2 - E1 (C55-81)*2 Wiring Color Terminal Description Y - W-B Transponder key ECU input signal Ignition switch OFF Below 1 V Ignition switch ON Waveform 1 Transponder key ECU output signal Ignition switch OFF Below 1 V Ignition switch ON Waveform 2 G - W-B Condition Specified Condition *1: for 2AZ-FE *2: for 2GR-FE If the result is not as specified, the ECM may have a malfunction. (c) Inspect using an oscilloscope. (1) Waveform 1 (Reference) Terminal IMI (A24-11)*1 - E1 (C24-104)*1 IMI (A55-11)*2 - E1 (C55-81)*2 Tool Setting 2 V/DIV., 1 s./DIV. Condition Ignition switch ON *1: for 2AZ-FE *2: for 2GR-FE GND Tool Setting: 2 V/DIV., 1 s./DIV. EI B139206E01 (2) Waveform 2 (Reference) Terminal Tool Setting: 2 V/DIV., 1 s./DIV. B139207E01 IMO (A55-10)*2 - E1 (C55-81)*2 Tool Setting 2 V/DIV., 1 s./DIV. Condition Ignition switch ON *1: for 2AZ-FE *2: for 2GR-FE GND IMO (A24-10)*1 - E1 (C24-104)*1 EI–72 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) DATA LIST / ACTIVE TEST 1. READ DATA LIST HINT: Using the DATA LIST displayed on the intelligent tester, the values of the switches, sensors, actuators, etc. can be checked without part removal. Reading the DATA LIST as the first step in troubleshooting is one way to shorten labor time. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the ignition switch to the ON position. (c) Read the DATA LIST according to the display on the tester. IMMOBILISER: EI Item Measurement Item/Display (Range) Normal Condition Diagnostic Note KEY SW Unlock warning switch signal/ON or OFF ON: Key is in ignition key cylinder OFF: No key is in ignition key cylinder - IG SW Ignition switch signal/ON or OFF ON: Ignition switch ON or START OFF: Ignition switch ACC or OFF - IMMOBILISER Immobiliser system status/SET or UNSET UNSET: Ignition switch ON SET: Without key - PERMIT (START) Permit (Start) signal/OK or NG NG: No permission for engine start OK: Engine start permission - RESPONSE Transponder chip data/NG or OK NG: Data error OK: Data OK - FRAME Transponder chip data/NG or OK NG: Data error OK: Data OK - SERIAL NUMBER Transponder chip data/NG or OK NG: Data error OK: Data OK - ENCRYPT CODE Transponder chip data/NG or OK NG: Data error OK: Data OK - STATUS Transponder chip data/NG or OK NG: Data error OK: Data OK - BCC Transponder chip data/NG or OK NG: Incorrect data being sent OK: Correct data being sent - SUB KEY Sub key code signal/NOMATCH or MATCH NOMATCH: Non-matching sub key code is sent MATCH: Sub key code is sent - MASTER KEY Master key code signal/ NOMATCH or MATCH NOMATCH: Non-matching master key code is sent MATCH: Master key code is sent - REGIST SUB CODE Number of registered sub key/ min. 0, max. 15 Number of registered sub key - REGIST MAS CODE Number of registered master key/ min. 0, max. 15 Number of registered master key - REG CODE SPACE Memory space for key codes registration/NOT FULL or FULL NOT FULL: More key code registration possible FULL: No more key code registration possible - +B Power source/BRAKE or NORMAL BRAKE: Power source open NORMAL: Power source normal - ANTENNA COIL Antenna coil condition/NORMAL or FAIL NORMAL: Antenna coil is normal FAIL: Antenna coil is malfunctioning - ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) 2. EI–73 PERFORM ACTIVE TEST HINT: Performing the intelligent tester ACTIVE TEST allows a relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to shorten labor time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the ignition switch to the ON position. (c) Perform the ACTIVE TEST according to the display on the tester. IMMOBILISER: Item Test Details Diagnostic Note SECURITY INDIC Turn security indicator ON/OFF - EI EI–74 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) DIAGNOSTIC TROUBLE CODE CHART TRANSPONDER KEY ECU DIAGNOSTIC TROUBLE CODE CHART: DTC No. Detection Item Trouble Area See page B2780 Push Switch / Key Unlock Warning Switch Malfunction 1. Wire harness 2. Unlock warning switch assembly 3. Transponder key ECU assembly EI-72 B2784 Antenna Coil Open / Short 1. Wire harness 2. Transponder key amplifier 3. Transponder key ECU assembly EI-76 B2793 Transponder Chip Malfunction Key EI-79 B2794 Unmatched Encryption Code Key EI-80 B2795 Unmatched Key Code Key EI-81 B2796 No Communication in Immobiliser System 1. Key 2. Transponder key amplifier 3. Transponder key ECU assembly EI-82 B2797 Communication Malfunction No. 1 1. Key 2. Transponder key amplifier 3. Transponder key ECU assembly EI-84 B2798 Communication Malfunction No. 2 1. Key 2. Transponder key amplifier 3. Transponder key ECU assembly EI-82 ECM DIAGNOSTIC TROUBLE CODE CHART: DTC No. B2799 EI Detection Item Engine Immobiliser System Trouble Area 1. Wire harness 2. Transponder key ECU assembly 3. ECM See page EI-86 HINT: The DTCs for the engine immobiliser system are specified above. If other codes are output, check the DTC chart for the SFI system. ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) DTC EI–75 Push Switch / Key Unlock Warning Switch Malfunction B2780 DESCRIPTION This DTC will be output if the transponder key ECU assembly does not detect that the unlock warning switch is ON even when the ignition switch is ON. Under normal conditions, the unlock warning switch assembly is ON when the ignition switch is ON. DTC No. DTC Detection Condition Trouble Area • • • "Unlock warning switch ON" is not detected when ignition switch is ON. B2780 Unlock warning switch assembly Wire harness Transponder key ECU assembly WIRING DIAGRAM Transponder Key ECU Assembly E22 Unlock Warning Switch Assembly 2 1 W-B No. 3 J/B L 7 7 3A 3B 2 3 3A 3C 3 B E49 J/C W-B W-B 9 12 2 E15 4 FE3 KSW W-B W-B E2 F1 EI B128326E04 INSPECTION PROCEDURE NOTICE: If the transponder key ECU assembly is replaced, register the key and ECU communication ID (See page EI-57). 1 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the ignition switch to the ON position and turn the intelligent tester main switch on. EI–76 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) (c) Select KEY SW in the DATA LIST and read the value displayed on the tester. IMMOBILISER: Item Measurement Item/Display (Range) Normal Condition Diagnostic Note KEY SW Unlock warning switch signal/ON or OFF OFF: Key is in ignition key cylinder ON: No key is in ignition key cylinder - OK: ON (Key is in ignition key cylinder) appears on the screen. OK REPAIR OR REPLACE HARNESS OR CONNECTOR NG 2 INSPECT UNLOCK WARNING SWITCH ASSEMBLY (a) Remove the unlock warning switch assembly (See page DL-225). (b) Measure the resistance according to the value(s) in the table below. Standard resistance Unlock Warning Switch Assembly: Free Push Tester Connection 1-2 NG EI B118535E02 OK Switch Position Specified Condition Switch pushed (Key set) Below 1 Ω Switch free (Key removed) 10 kΩ or higher REPLACE UNLOCK WARNING SWITCH ASSEMBLY ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) 3 EI–77 CHECK HARNESS AND CONNECTOR (UNLOCK WARNING SWITCH - BODY GROUND) Wire Harness Side Connector Rear View: (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition E22-2 - Body ground Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR E22 Unlock Warning Switch Assembly B124194E02 OK 4 CHECK HARNESS AND CONNECTOR (TRANSPONDER KEY ECU - UNLOCK WARNING SWITCH) Wire Harness Side Connector Rear View: E15 Transponder Key ECU Assembly (a) Disconnect the E15 ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection E15-3 (KSW) - E22-1 E22-1 - Body ground NG KSW E22 Unlock Warning Switch Assembly B128340E02 Condition Always Specified Condition Below 1 Ω 10 kΩ or higher REPAIR OR REPLACE HARNESS OR CONNECTOR EI EI–78 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) OK REPLACE TRANSPONDER KEY ECU ASSEMBLY EI EI–70 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) DIAGNOSIS SYSTEM 1. CG SG CANH SIL CANL CHECK DLC3 (a) The vehicle's ECU uses ISO 15765-4 for communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. BAT H100769E16 Symbols (Terminal No.) Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always CANH (6) - CANL (14) CANH (6) - CG (4) CANL (14) - CG (4) CANH (6) - BAT (16) CANL (14) - BAT (16) CAN bus line HIGH-level CAN bus line LOW-level CAN bus line HIGH-level CAN bus line LOW-level CAN bus line 10 to 14 V * 54 to 69 Ω * 200 Ω or higher * 200 Ω or higher * 6 kΩ or higher OFF* 6 kΩ or higher Ignition switch OFF Ignition switch OFF Ignition switch OFF Ignition switch OFF Ignition switch NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. (b) Connect the cable of the intelligent tester (with CAN VIM) to the DLC3, turn the ignition switch to the ON position and attempt to use the intelligent tester. If the screen displays a communication error message, a problem exists in the vehicle side of the tester side. HINT: • If communication is normal when the tool is connected to another vehicle, inspect the DLC3 on the original vehicle. • If communication is still impossible when the tool is connected to another vehicle, the problem is probably in the tool itself. Consult the Service Department listed in the tool's instruction manual. EI DLC3 Intelligent Tester C131977E01 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) EI–71 DTC CHECK / CLEAR 1. 2. DLC3 Intelligent Tester C131977E01 CHECK DTC (a) Connect the intelligent tester to the Controller Area Network Vehicle Interface Module (CAN VIM). Then connect the CAN VIM to the DLC3. (b) Turn the ignition switch to the ON position. (c) Read the DTCs by following the directions on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. CLEAR DTC (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the ignition switch to the ON position. (c) Erase the DTCs by following the directions on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. EI ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) DTC B2784 EI–79 Antenna Coil Open / Short DESCRIPTION The transponder key coil is built into the transponder key amplifier and receives a key code signal from the transponder chip in the key. This signal is amplified by the amplifier, then it is output to the transponder key ECU assembly. DTC No. DTC Detection Condition B2784 Trouble Area • • • Antenna coil is open/shorted Wire harness Transponder key amplifier Transponder key ECU assembly WIRING DIAGRAM E15 Transponder Key ECU Assembly E25 Transponder Key Amplifier Amplifier ANT1 VC5 1 O 14 CODE 4 BR 15 TXCT 5 R 4 AGND 7 V 5 Coil ANT2 VC5 CODE TXCT AGND B111588E13 INSPECTION PROCEDURE NOTICE: If the transponder key ECU assembly is replaced, register the key and ECU communication ID (See page EI-57). 1 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the ignition switch to the ON position and turn the intelligent tester on. EI EI–80 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) (c) Select ANTENNA COIL in the DATA LIST and read the value displayed on the intelligent tester. IMMOBILISER: Item Measurement Item/Display (Range) Normal Condition Diagnostic Note ANTENNA COIL Transponder key amplifier coil condition/NORMAL or FAIL NORMAL: Antenna coil is normal FAIL: Antenna coil is malfunctioning - OK: NORMAL (Antenna coil is normal) appears on the screen. OK REPLACE TRANSPONDER KEY ECU ASSEMBLY NG 2 CHECK HARNESS AND CONNECTOR (TRANSPONDER KEY ECU - TRANSPONDER KEY AMPLIFIER) Wire Harness Side Connector Rear View: E15 Transponder Key ECU Assembly (a) Disconnect the E15 ECU and E25 amplifier connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition E15-4 (TXCT) - E25-5 (TXCT) E15-5 (AGND) - E25-7 (AGND) E15-15 (CODE) - E25-4 (CODE) TXCT CODE EI Below 1 Ω E15-14 (VC5) - E25-1 (VC5) AGND E15-4 (TXCT) - Body ground VC5 E15-5 (AGND) - Body ground E25 Transponder Key Amplifier E15-14 (VC5) - Body ground Always 10 kΩ or higher E15-15 (CODE) - Body ground NG AGND TXCT VC5 CODE B124193E03 OK REPAIR OR REPLACE HARNESS OR CONNECTOR ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) 3 EI–81 INSPECT TRANSPONDER KEY ECU ASSEMBLY (TRANSPONDER KEY AMPLIFIER POWER SOURCE) Wire Harness Side Connector Rear View: E15 Transponder Key ECU Assembly (a) Reconnect the E15 ECU and E25 amplifier connectors. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection E15-14 (VC5) - Body ground NG Condition Specified Condition No key is in ignition key cylinder Below 1 V Key is in ignition key cylinder 4.6 to 5.4 V REPLACE TRANSPONDER KEY ECU ASSEMBLY VC5 B128338E01 OK 4 INSPECT TRANSPONDER KEY ECU ASSEMBLY (TRANSPONDER KEY AMPLIFIER GROUND) Wire Harness Side Connector Rear View: E15 Transponder Key ECU Assembly (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition E15-5 (AGND) - Body ground Always Below 1 Ω NG AGND B128338E02 OK REPLACE TRANSPONDER KEY AMPLIFIER REPLACE TRANSPONDER KEY ECU ASSEMBLY EI EI–82 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) DTC B2793 Transponder Chip Malfunction DESCRIPTION This DTC is output when a malfunction is found in the key during key code registration or a key code is not registered normally. Replace the key if the key code registration is not performed normally and this DTC is detected. DTC No. B2793 DTC Detection Condition Trouble Area Transponder chip malfunction Key INSPECTION PROCEDURE NOTICE: If the key is replaced, register the key (See page EI-57). 1 RE-REGISTER KEY (a) Delete the DTCs (See page EI-69). (b) Re-register the key (See page EI-57) and insert this key into the ignition key cylinder. Check that the engine starts with this key. OK: The engine starts. NG OK END EI REPLACE KEY ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) DTC B2794 EI–83 Unmatched Encryption Code DESCRIPTION This DTC is output when a key with an incomplete key code is inserted into the ignition key cylinder. DTC No. B2794 DTC Detection Condition Key with incomplete key code is inserted Trouble Area Key INSPECTION PROCEDURE NOTICE: If the key is replaced, register the key (See page EI-57). 1 REPLACE KEY NEXT END EI EI–84 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) DTC B2795 Unmatched Key Code DESCRIPTION This DTC is output when a key with a key code that has not been registered in the ECU is inserted into the ignition key cylinder. DTC No. B2795 DTC Detection Condition Trouble Area Key with unregistered key code is inserted Key INSPECTION PROCEDURE NOTICE: If the key is replaced, register the key (See page EI-57). 1 RE-REGISTER KEY (a) Delete the DTCs (See page EI-69). (b) Re-register the key (See page EI-57) and insert this key into the ignition key cylinder. Check that the engine starts with this key. OK: The engine starts. NG OK END EI REPLACE KEY ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) DTC B2796 No Communication in Immobiliser System DTC B2798 Communication Malfunction No. 2 EI–85 DESCRIPTION These DTCs are output if a key that does not have a transponder chip is inserted into the ignition key cylinder or if communication between the key and transponder key ECU assembly is impossible. DTC No. DTC Detection Condition Trouble Area B2796 The key code cannot be transmitted • • • B2798 Key code identification cannot be completed within the specified time • • • Key Transponder key amplifier Transponder key ECU assembly Key Transponder key amplifier Transponder key ECU assembly WIRING DIAGRAM E25 Transponder Key Amplifier E15 Transponder Key ECU Assembly Amplifier ANT1 VC5 1 O 14 CODE 4 BR 15 TXCT 5 R 4 AGND 7 V 5 Coil ANT2 VC5 CODE TXCT EI AGND B111588E13 INSPECTION PROCEDURE NOTICE: • If the transponder key ECU assembly is replaced, register the key and ECU communication ID (See page EI-57). • If the key is replaced, register the key (See page EI-57). 1 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the ignition switch to the ON position and turn the intelligent tester on. EI–86 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) (c) Select IMMOBILISER in the DATA LIST and read the value displayed on the intelligent tester. IMMOBILISER: Item Measurement Item/Display (Range) Normal Condition Diagnostic Note IMMOBILISER Immobiliser system status/SET or UNSET UNSET: Ignition switch ON SET: Without key - OK: UNSET (Ignition switch ON) appears on the screen. OK REPLACE TRANSPONDER KEY ECU ASSEMBLY NG 2 CHECK KEYS (a) Insert the vehicle's other key into the ignition key cylinder. (b) Check that the engine starts with this key. OK: The engine starts. OK RE-REGISTER OR REPLACE KEY THAT CANNOT START ENGINE NG 3 CHECK TRANSPONDER KEY AMPLIFIER (a) After replacing the transponder key amplifier (See page LI-112) with a normally functioning amplifier, check that the engine starts. OK: The engine starts. EI NG OK END REPLACE TRANSPONDER KEY ECU ASSEMBLY EI–87 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) DTC B2797 Communication Malfunction No. 1 DESCRIPTION This DTC is output when an error occurs in communication between the transponder key amplifier and the transponder key ECU. HINT: Some noise is found in the communication line. DTC No. B2797 DTC Detection Condition Trouble Area Keys are positioned too close to each other, or noise occurred in communication line • • • Key Transponder key amplifier Transponder key ECU assembly WIRING DIAGRAM E25 Transponder Key ECU Assembly E15 Transponder Key Amplifier CODE 4 15 BR CODE B052550E15 INSPECTION PROCEDURE NOTICE: If the transponder key ECU assembly is replaced, register the key and ECU communication ID (See page EI-57). 1 CHECK KEYS (a) Check whether the ignition key being used is near other ignition keys, as shown in the illustration. Also, check whether the key ring is in contact with the key grip. Result Example: Result Proceed to Key is near other keys and/or key ring is in contact with key grip. A Key is not near other keys and/or key ring is not in contact with key grip. B B072873E02 B A Go to step 3 EI EI–88 2 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) CHECK DTC OUTPUT (a) Separate the keys from each other, or remove the key ring. (b) Delete the DTCs (See page EI-69). (c) Insert a key into the ignition key cylinder and remove the key. Repeat for all the other keys of the vehicle. OK: No code is output. OK END NG 3 CHECK TRANSPONDER KEY AMPLIFIER (a) After replacing the transponder key amplifier (See page LI-112) with a normally functioning amplifier, check that the engine starts. OK: The engine starts. NG OK END EI REPLACE TRANSPONDER KEY ECU ASSEMBLY ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) DTC B2799 EI–89 Engine Immobiliser System DESCRIPTION This DTC is output when the ECM detects errors in communication with the transponder key ECU, and in the communication lines. This DTC is also output when an engine start is attempted while the ECU communication ID between the transponder key ECU and the ECM is different. Before troubleshooting for this DTC, make sure that there is no DTC detected in the transponder key ECU. If there is any key code related DTC detected in the transponder key ECU, repair it first. DTC No. DTC Detection Condition B2799 Error in communication between ECM and transponder key ECU assembly, and in communication line Communication ID is different during communication with transponder key ECU Trouble Area • • • Wire harness Transponder key ECU assembly ECM WIRING DIAGRAM E15 Transponder Key ECU Assembly ECM 10 10 IMO A55*2 A24*1 11 A24*1 IMI A55*2 G 13 AE5 G 12 Y 7 AE5 L 13 11 EFII EFIO EI *1: for 2AZ-FE *2: for 2GR-FE B128330E05 INSPECTION PROCEDURE NOTICE: • If the transponder key ECU assembly is replaced, register the key and ECU communication ID (See page EI-57). • If the ECM is replaced, register the ECU communication ID (See page EI-57). 1 RE-REGISTER ECU COMMUNICATION ID (a) Re-register the ECU communication ID (See page EI-57) between the transponder key ECU assembly and ECM. (b) Check that the engine starts. OK: The engine starts. EI–90 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) OK END NG 2 CHECK HARNESS AND CONNECTOR (TRANSPONDER KEY ECU - ECM) (a) Disconnect the E15 ECU and A24*1 or A55*2 ECM connectors. Wire Harness Side Connector Front View: Wire Harness Side Connector Rear View: E15 Transponder Key ECU Assembly A24*1 A55*2 ECM *1: for 2AZ-FE EFIO IMO IMI *2: for 2GR-FE EFII B139202E01 (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition E15-12 (EFII) - A24*1, A55*2-10 (IMO) E15-13 (EFIO) - A24*1, A55*2-11 (IMI) EI E15-12 (EFII) - Body ground E15-13 (EFIO) - Body ground Specified Condition Below 1 Ω Always 10 kΩ or higher *1: for 2AZ-FE *2: for 2GR-FE NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 REPLACE TRANSPONDER KEY ECU ASSEMBLY (a) After replacing the transponder key ECU assembly with a normally functioning transponder key ECU assembly, check that the engine starts. OK: The engine starts. ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) NG EI–91 REPLACE ECM OK END EI EI–92 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) Security Indicator Light Circuit DESCRIPTION When the transponder key is registered, the transponder key ECU assembly outputs the key registration condition by lighting up, blinking or turning off the security indicator. WIRING DIAGRAM Clock Assembly (Security Indicator Light) Transponder Key ECU Assembly No. 3 J/B 8 LP F3 GND1 19 F3 Y W-B 11 3R 6 3B 8 2 3R 3U P 8 E15 IND W-B F1 B128327E01 INSPECTION PROCEDURE EI NOTICE: If the transponder key ECU assembly is replaced, register the key and ECU communication ID (See page EI-57). 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the ignition switch to the ON position. (c) Perform the ACTIVE TEST according to the display on the tester. IMMOBILISER: Item Tester Details Diagnostic Note SECURITY INDIC Turn security indicator ON/OFF - OK: Security indicator turns on and off. OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) EI–93 NG 2 CHECK HARNESS AND CONNECTOR (TRANSPONDER KEY ECU - SECURITY INDICATOR LIGHT) Wire Harness Side Connector Rear View: E15 Transponder Key ECU Assembly (a) Disconnect the E15 ECU and F3 combination meter connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Below 1 Ω E15-8 (IND) - F3-8 (LP) E15-8 (IND) - Body ground NG Specified Condition Always 10 kΩ or higher REPAIR OR REPLACE HARNESS OR CONNECTOR IND F3 Clock Assembly (Security Indicator Light) LP B128342E01 EI OK 3 CHECK HARNESS AND CONNECTOR (SECURITY INDICATOR LIGHT - BODY GROUND) Wire Harness Side Connector Rear View: F3 Clock Assembly (Security Indicator Light) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition F3-19 (GND1) - Body ground Always Below 1 Ω NG GND1 B128343E01 REPAIR OR REPLACE HARNESS OR CONNECTOR EI–94 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) OK 4 INSPECT TRANSPONDER KEY ECU ASSEMBLY Wire Harness Side Connector Rear View: E15 Transponder Key ECU Assembly (a) Reconnect the E15 ECU and F3 combination meter connectors. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition E15-8 (IND) - Body ground Immobiliser set state (No key is in ignition key cylinder) Repeats 10 to 14 V and below 1 V NG IND B128338E03 OK REPLACE CLOCK ASSEMBLY EI REPLACE TRANSPONDER KEY ECU ASSEMBLY ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) EI–95 Door Courtesy Switch Circuit DESCRIPTION When an additional transponder key is registered, the transponder key ECU assembly detects the front door courtesy light switch open/close condition, and enters the key registration mode. WIRING DIAGRAM Transponder Key ECU Assembly N6 Door Courtesy Light Switch Assembly (Driver’s Side) No. 3 J/B 1 L 13 EN2 L 12 3O 12 3A Y 7 E15 CTY B128328E01 INSPECTION PROCEDURE NOTICE: If the transponder key ECU assembly is replaced, register the key and ECU communication ID (See page EI-57). EI EI–96 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) 1 CHECK HARNESS AND CONNECTOR (FRONT DOOR COURTESY LIGHT SWITCH CIRCUIT) Wire Harness Side Connector Rear View: E15 Transponder Key ECU Assembly (a) Disconnect the E15 ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection E15-7 (CTY) - Body ground OK Condition Specified Condition Courtesy switch pushed (Door closed) 10 kΩ or higher Courtesy switch free (Door open) Below 1 Ω PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE CTY B128337E01 NG 2 INSPECT FRONT DOOR COURTESY LIGHT SWITCH ASSEMBLY Front Door Courtesy Light Switch Side Connector Front View: Free (a) Remove the driver side front door courtesy light switch (See page LI-128). (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition 10 kΩ or higher 1 - Switch body Courtesy switch pushed (Door closed) Courtesy switch free (Door open) Below 1 Ω Pushed EI NG Switch Body REPLACE FRONT DOOR COURTESY LIGHT SWITCH ASSEMBLY B111600E02 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (TRANSPONDER KEY ECU - FRONT DOOR COURTESY LIGHT SWITCH) ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) EI–97 ECU Power Source Circuit DESCRIPTION This circuit provides power to operate the transponder key ECU assembly. EI EI–98 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) WIRING DIAGRAM 2AZ-FE: Transponder Key ECU Assembly No. 3 J/B 8 J/C 3 A41 A42 LG 21 W EA2 E23 Ignition Switch B 5 AM2 1 1 3J 3B W 1 E15 LG 2 +B Instrument Panel J/B IGN 7 II Y IG2 6 13 IM E15 IG 16 E15 GND Engine Room R/B 1 AE7 W B ST/AM2 1 EFI NO. 1 2 1 1G 1A EI W No. 3 J/B FL MAIN E49 J/C 9 W-B 3 3C 2 3B W-B 2 W-B BATTERY E2 B128324E02 EI–99 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) 2GR-FE: Transponder Key ECU Assembly No. 3 J/B J/C 8 W 3 A42 A41 LG 21 W EA2 1 1 3J 3B W 1 E15 +B Engine Room R/B Instrument Panel J/B IG2 Relay 1 B 1 5 3 1 2 1 18 BR EA1 BR IGN 7 II Y 6 IG2 2 E15 IG BR 1 AM2 5 LG IM E23 Ignition Switch 10 EA1 13 Engine Room R/B ST/AM2 1 B AE7 B 1 IG2 Y 1 2 1A EFI NO. 1 1 1G EI W No. 3 J/B E49 J/C FL MAIN 9 W-B 3 3C 2 3B W-B 16 E15 GND 2 W-B BATTERY A2 E2 B128325E01 INSPECTION PROCEDURE NOTICE: If the transponder key ECU assembly is replaced, register the key and ECU communication ID (See page EI-57). EI–100 1 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) CHECK HARNESS AND CONNECTOR (TRANSPONDER KEY ECU - BATTERY) Wire Harness Side Connector Rear View: E15 Transponder Key ECU Assembly (a) Disconnect the E15 ECU connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition E15-1 (+B) - Body ground Always 10 to 14 V Ignition switch OFF Below 1 V Ignition switch ON 10 to 14 V E15-2 (IG) - Body ground NG REPAIR OR REPLACE HARNESS OR CONNECTOR, OR REPLACE FUSE IG +B B128337E02 OK 2 CHECK HARNESS AND CONNECTOR (TRANSPONDER KEY ECU - BODY GROUND) Wire Harness Side Connector Rear View: E15 Transponder Key ECU Assembly (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition E15-16 (GND) - Body ground Always Below 1 Ω NG EI REPAIR OR REPLACE HARNESS OR CONNECTOR GND B128337E03 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) EI–101 Diagnosis Circuit DESCRIPTION This circuit is used to read the DTCs that are output from the transponder key ECU assembly with the intelligent tester. WIRING DIAGRAM Data Link Connector 3 Transponder Key ECU Assembly Instrument Panel J/B 7 SIL CG E10 4 E10 GR 12 3 IM IF W-B No. 3 J/B GR 7 3L 3 3H 8 3B 3 3C 9 GR E15 D E49 J/C W-B 9 2 W-B E2 B128329E01 INSPECTION PROCEDURE NOTICE: If the transponder key ECU assembly is replaced, register the key and ECU communication ID (See page EI-57). EI EI–102 1 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) CHECK HARNESS AND CONNECTOR (TRANSPONDER KEY ECU - DLC3) Wire Harness Side Connector Rear View: E15 Transponder Key ECU Assembly (a) Disconnect the E15 ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection E15-9 (D) - E10-7 (SIL) E15-9 (D) - Body ground NG Condition Always Specified Condition Below 1 Ω 10 kΩ or higher REPAIR OR REPLACE HARNESS OR CONNECTOR D Wire Harness Side Connector Front View: E10 Data Link Connector 3 SIL B128341E01 OK EI 2 CHECK HARNESS AND CONNECTOR (DLC3 - BODY GROUND) Wire Harness Side Connector Front View: E10 Data Link Connector 3 (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition E10-4 (CG) - Body ground Always Below 1 Ω NG CG B124215E08 REPAIR OR REPLACE HARNESS OR CONNECTOR ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) EI–103 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE EI EXTERIOR – FRONT BUMPER ET–1 FRONT BUMPER EXTERIOR BODY COMPONENTS for 2GR-FE: ET COOL AIR INTAKE DUCT SEAL RADIATOR GRILLE PROTECTOR RADIATOR GRILLE PROTECTOR FRONT BUMPER ASSEMBLY B137228E01 ET–2 EXTERIOR – FRONT BUMPER with Cover: FRONT BUMPER LOWER COVER HOOD TO FRONT END PANEL SEAL FRONT BUMPER UPPER RETAINER RADIATOR GRILLE EMBLEM ET LOWER RADIATOR GRILLE RADIATOR GRILLE with Bracket: FRONT BUMPER EXTENSION MOUNTING BRACKET with Fog light: FOG LIGHT ASSEMBLY RH FRONT BUMPER HOLE COVER RH FRONT BUMPER HOLE COVER LH FOG LIGHT ASSEMBLY LH FRONT BUMPER HOLE COVER RH FRONT BUMPER HOLE COVER LH B137744E01 ET–3 EXTERIOR – FRONT BUMPER with Front Spoiler: FRONT BUMPER EXTENSION RH ET FRONT BUMPER EXTENSION LH FRONT SPOILER B137745E01 ET–4 ET EXTERIOR – FRONT BUMPER FRONT BUMPER SIDE RETAINER RH 34 (347, 25) FRONT BUMPER REINFORCEMENT SUB-ASSEMBLY 34 (347, 25) FRONT BUMPER ENERGY ABSORBER FRONT BUMPER SIDE RETAINER LH N*m (kgf*cm, ft.*lbf) : Specified torque B137743E01 REMOVAL 1. B138886 REMOVE COOL AIR INTAKE DUCT SEAL (for 2GRFE) (a) Remove the 7 clips and cool air intake duct seal. EXTERIOR – FRONT BUMPER 2. Protective Tape ET–5 REMOVE FRONT BUMPER ASSEMBLY (w/o Fog Light) (a) Put protective tape around the front bumper assembly. B140157E01 (b) Using a screwdriver, turn the pin 90 degrees and remove the pin hold clip. HINT: Use the same procedures for the RH side and LH side. 90q B138884E01 (c) Remove the 8 screws, 2 clips, 2 radiator grille protectors and bolt. B140155 (d) Disengage the 2 claws and disconnect the front bumper assembly as shown in the illustration. HINT: Use the same procedures for the RH side and LH side. (e) Remove the front bumper assembly. B140158 ET ET–6 EXTERIOR – FRONT BUMPER 3. Protective Tape REMOVE FRONT BUMPER ASSEMBLY (w/ Fog Light) (a) Put protective tape around the front bumper assembly. B138887E01 ET (b) Using a screwdriver, turn the pin 90 degrees and remove the pin hold clip. HINT: Use the same procedures for the RH side and LH side. 90q B138884E01 (c) Remove the 8 screws, 2 clips, 2 radiator grille protectors and bolt. B137230 (d) Disengage the 2 claws and disconnect the front bumper assembly as shown in the illustration. HINT: Use the same procedures for the RH side and LH side. (e) Disconnect each connector, and then remove the front bumper assembly. B137231 EXTERIOR – FRONT BUMPER ET–7 DISASSEMBLY 1. REMOVE FOG LIGHT ASSEMBLY LH (w/ Fog Light) (See page LI-79) 2. REMOVE FOG LIGHT ASSEMBLY RH (w/ Fog Light) 3. REMOVE FRONT SPOILER (w/ Front Spoiler) (a) Remove the 2 screws and 25 clips. ET B137739 (b) Disengage the 17 claws and remove the front spoiler. 4. REMOVE FRONT BUMPER EXTENSION LH (w/ Front Spoiler) (a) Remove the 2 nuts and front bumper extension LH. 5. REMOVE FRONT BUMPER EXTENSION RH (w/ Front Spoiler) 6. REMOVE FRONT BUMPER EXTENSION MOUNTING BRACKET (w/ Bracket) (a) Remove the 2 screws. B137753 B137741E01 ET–8 EXTERIOR – FRONT BUMPER (b) Disengage the 2 claws and remove the front bumper extension mounting bracket. 7. REMOVE FRONT BUMPER LOWER COVER (w/ Cover) (a) Disengage the 2 claws and remove the front bumper lower cover. 8. REMOVE FRONT BUMPER HOLE COVER LH (w/o Fog Light) (a) Disengage the 5 claws and remove the front bumper hole cover LH. 9. REMOVE FRONT BUMPER HOLE COVER RH (w/o Fog Light) B137730 ET B137732 10. REMOVE FRONT BUMPER HOLE COVER LH (w/ Fog Light) (a) Disengage the 5 claws and remove the front bumper hole cover LH. 11. REMOVE FRONT BUMPER HOLE COVER RH (w/ Fog Light) B137733 12. REMOVE LOWER RADIATOR GRILLE (a) Disengage the 14 claws and remove the lower radiator grille. B137731 EXTERIOR – FRONT BUMPER ET–9 13. REMOVE RADIATOR GRILLE (a) Remove the 2 screws. (b) Disengage the 16 claws and remove the radiator grille. B137232 14. REMOVE HOOD TO FRONT END PANEL SEAL (a) Remove the 10 clips and hood to front end panel seal. ET B137233 15. REMOVE FRONT BUMPER UPPER RETAINER (a) Remove the 3 clips and front bumper upper retainer. B137234 16. REMOVE RADIATOR GRILLE EMBLEM (a) Disengage the 4 claws and remove the radiator grille emblem. B137235 17. REMOVE FRONT BUMPER ENERGY ABSORBER (a) Remove the front bumper energy absorber from the front bumper reinforcement sub-assembly. B137728 ET–10 EXTERIOR – FRONT BUMPER 18. REMOVE FRONT BUMPER REINFORCEMENT SUBASSEMBLY (a) Disengage each clamp. (b) Remove the 6 bolts and front bumper reinforcement sub-assembly. Clamp B137729E01 19. REMOVE FRONT BUMPER SIDE RETAINER LH (a) Remove the screw. (b) Disengage the claw and remove the front bumper side retainer LH. ET 20. REMOVE FRONT BUMPER SIDE RETAINER RH B137727 REASSEMBLY 1. INSTALL FRONT BUMPER SIDE RETAINER LH (a) Engage the claw and install the front bumper side retainer LH. (b) Install the screw. 2. INSTALL FRONT BUMPER SIDE RETAINER RH 3. INSTALL FRONT BUMPER REINFORCEMENT SUBASSEMBLY (a) Install the front bumper reinforcement sub-assembly with the 6 bolts. Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf) (b) Engage each clamp. 4. INSTALL FRONT BUMPER ENERGY ABSORBER (a) Install the front bumper energy absorber to the front bumper reinforcement sub-assembly. B137727 Clamp B137729E01 B137728 EXTERIOR – FRONT BUMPER ET–11 5. INSTALL RADIATOR GRILLE EMBLEM (a) Engage the 4 claws and install the radiator grille emblem. 6. INSTALL FRONT BUMPER UPPER RETAINER (a) Install the front bumper upper retainer with the 3 clips. B137235 ET B137234 7. INSTALL HOOD TO FRONT END PANEL SEAL (a) Apply new double-sided tape to the hood to front end panel seal. (b) Remove the release paper from the hood to front end panel seal. (c) Install the hood to front end panel seal with the 10 clips. 8. INSTALL RADIATOR GRILLE (a) Engage the 16 claws and install the radiator grille. (b) Install the 2 screws. 9. INSTALL LOWER RADIATOR GRILLE (a) Engage the 14 claws and install the lower radiator grille. B137233 B137232 B137731 ET–12 EXTERIOR – FRONT BUMPER 10. INSTALL FRONT BUMPER HOLE COVER LH (w/o Fog Light) (a) Engage the 5 claws and install the front bumper hole cover LH. 11. INSTALL FRONT BUMPER HOLE COVER RH (w/o Fog Light) B137732 12. INSTALL FRONT BUMPER HOLE COVER LH (w/ Fog Light) (a) Engage the 5 claws and install the front bumper hole cover LH. ET 13. INSTALL FRONT BUMPER HOLE COVER RH (w/ Fog Light) B137733 14. INSTALL FRONT BUMPER LOWER COVER (w/ Cover) (a) Engage the 2 claws and install the front bumper lower cover. 15. INSTALL FRONT BUMPER EXTENSION MOUNTING BRACKET (w/ Bracket) (a) Engage the 2 claws and install the front bumper extension mounting bracket. B137730 B137741E01 (b) Install the 2 screws. 16. INSTALL FRONT BUMPER EXTENSION LH (w/ Front Spoiler) (a) Install the front bumper extension LH with the 2 nuts. 17. INSTALL FRONT BUMPER EXTENSION RH (w/ Front Spoiler) B137753 EXTERIOR – FRONT BUMPER ET–13 18. INSTALL FRONT SPOILER (w/ Front Spoiler) (a) Engage the 17 claws and install the front spoiler. ET B137739 (b) Install the 25 clips and 2 screws. 19. INSTALL FOG LIGHT ASSEMBLY LH (w/ Fog Light) (See page LI-82) 20. INSTALL FOG LIGHT ASSEMBLY RH (w/ Fog Light) INSTALLATION 1. B140155 INSTALL FRONT BUMPER ASSEMBLY (w/o Fog Light) (a) Engage each claw. (b) Install the front bumper assembly with the 8 screws, 2 clips, 2 radiator grille protectors and bolt. ET–14 EXTERIOR – FRONT BUMPER (c) Install the pin hold clip. HINT: Use the same procedures for the RH side and LH side. B137229 2. ET INSTALL FRONT BUMPER ASSEMBLY (w/ Fog Light) (a) Connect each connector. (b) Engage each claw. (c) Install the front bumper assembly with the 8 screws, 2 clips, 2 radiator grille protectors and bolt. B137230 (d) Install the pin hold clip. HINT: Use the same procedures for the RH side and LH side. B137229 3. INSTALL COOL AIR INTAKE DUCT SEAL (for 2GRFE) (a) Install the cool air intake duct seal with the 7 clips. 4. VEHICLE PREPARATION FOR FOG LIGHT AIMING (w/ Fog Light) (See page LI-79) 5. PREPARATION FOR FOG LIGHT AIMING (w/ Fog Light) (See page LI-80) 6. INSPECT FOG LIGHT AIMING (w/ Fog Light) (See page LI-81) 7. ADJUST FOG LIGHT AIMING (w/ Fog Light) (See page LI-82) B138886 ET–15 EXTERIOR – REAR BUMPER REAR BUMPER EXTERIOR BODY COMPONENTS ET REAR BUMPER ASSEMBLY with Rear Lower Spoiler: REAR BUMPER ASSEMBLY REAR FLOOR BOARD CLIP CLIP NUT B137224E01 ET–16 EXTERIOR – REAR BUMPER REAR BUMPER SIDE SUPPORT RH REAR BUMPER SIDE RETAINER RH ET REAR BUMPER REINFORCEMENT SUB-ASSEMBLY REAR BUMPER SIDE RETAINER LH WHEEL HOUSE REINFORCEMENT RH 68 (693, 50) REAR BUMPER SIDE SUPPORT LH 68 (693, 50) REAR BUMPER BAR WHEEL HOUSE REINFORCEMENT LH REAR BUMPER PAD REAR BUMPER ENERGY ABSORBER REAR BUMPER PLATE LH REAR BUMPER PAD REAR BUMPER PLATE RH N*m (kgf*cm, ft.*lbf) : Specified torque B137225E01 ET–17 EXTERIOR – REAR BUMPER with Rear Lower Spoiler: REAR BUMPER EXTENSION RH ET REAR BUMPER EXTENSION LH REAR LOWER SPOILER B140152E01 REMOVAL Protective Tape 1. REMOVE REAR BUMPER ASSEMBLY (w/o Rear Lower Spoiler) (a) Put protective tape around the rear bumper assembly. B137211E01 (b) Using a screwdriver, open the 2 rear bumper plates. HINT: Tape the screwdriver tip before use. B137212 ET–18 EXTERIOR – REAR BUMPER (c) Remove the 6 screws and 2 clips. B137214 (d) Disengage the 12 claws and disconnect the rear bumper assembly as shown in the illustration. HINT: Use the same procedures for the RH side and LH side. (e) Remove the rear bumper assembly. ET B137215 2. REMOVE REAR FLOOR BOARD (w/ Rear Lower Spoiler) (a) Remove the 4 screws, 2 clips, 3 nuts and rear floor board. 3. REMOVE REAR BUMPER ASSEMBLY (w/ Rear Lower Spoiler) (a) Put protective tape around the rear bumper assembly. Clip Nut B138885E01 Protective Tape B146330E01 EXTERIOR – REAR BUMPER ET–19 (b) Using a screwdriver, open the 2 rear bumper plates. HINT: Tape the screwdriver tip before use. B146331 (c) Remove the 6 screws. ET B140154 (d) Disengage the 12 claws and disconnect the rear bumper assembly as shown in the illustration. HINT: Use the same procedures for the RH side and LH side. (e) Remove the rear bumper assembly. B146332 ET–20 EXTERIOR – REAR BUMPER DISASSEMBLY 1. REMOVE REAR LOWER SPOILER (w/ Rear Lower Spoiler) (a) Remove the 2 screws, 4 nuts and 16 clips. ET B137223 (b) Disengage the 16 claws and remove the rear lower spoiler. 2. REMOVE REAR BUMPER EXTENSION LH (w/ Rear Lower Spoiler) (a) Remove the 2 nuts and rear bumper extension LH. 3. REMOVE REAR BUMPER EXTENSION RH (w/ Rear Lower Spoiler) 4. REMOVE REAR BUMPER PLATE LH 5. REMOVE REAR BUMPER PLATE RH 6. REMOVE REAR BUMPER PAD (a) Remove the rear bumper pad. HINT: Use the same procedures for the RH side and LH side. B137222 B146333 EXTERIOR – REAR BUMPER ET–21 7. REMOVE REAR BUMPER SIDE SUPPORT LH (a) Remove the 2 screws. (b) Disengage the 3 claws and remove the rear bumper side support LH. 8. REMOVE REAR BUMPER SIDE SUPPORT RH 9. REMOVE REAR BUMPER SIDE RETAINER LH (a) Remove the 2 screws. (b) Disengage the 3 claws and remove the rear bumper side retainer LH. B137219 10. REMOVE REAR BUMPER SIDE RETAINER RH B137220 11. REMOVE WHEEL HOUSE REINFORCEMENT LH (a) Remove the nut and wheel house reinforcement LH. 12. REMOVE WHEEL HOUSE REINFORCEMENT RH B137221 13. REMOVE REAR BUMPER ENERGY ABSORBER (a) Remove the 4 bolts. (b) Disengage the 4 claws and remove the rear bumper energy absorber. B137216 14. REMOVE REAR BUMPER BAR (a) Remove the rear bumper bar from the rear bumper energy absorber. B137218 ET ET–22 EXTERIOR – REAR BUMPER 15. REMOVE REAR BUMPER REINFORCEMENT SUBASSEMBLY (a) Remove the 6 nuts and rear bumper reinforcement sub-assembly. B137217 REASSEMBLY 1. INSTALL REAR BUMPER REINFORCEMENT SUBASSEMBLY (a) Install the rear bumper reinforcement sub-assembly with the 6 nuts. Torque: 68 N*m (693 kgf*cm, 50 ft.*lbf) 2. INSTALL REAR BUMPER BAR (a) Install the rear bumper bar on the rear bumper energy absorber. 3. INSTALL REAR BUMPER ENERGY ABSORBER (a) Engage the 4 claws and install the rear bumper energy absorber. (b) Install the 4 bolts. 4. INSTALL WHEEL HOUSE REINFORCEMENT LH (a) Install the wheel house reinforcement LH with the nut. 5. INSTALL WHEEL HOUSE REINFORCEMENT RH ET B137217 B137218 B137216 B137221 EXTERIOR – REAR BUMPER ET–23 6. INSTALL REAR BUMPER SIDE RETAINER LH (a) Engage the 3 claws and install the rear bumper side retainer LH. (b) Install the 2 screws. 7. INSTALL REAR BUMPER SIDE RETAINER RH 8. INSTALL REAR BUMPER SIDE SUPPORT LH (a) Engage the 3 claws and install the rear bumper side support LH. (b) Install the 2 screws. 9. INSTALL REAR BUMPER SIDE SUPPORT RH B137220 B137219 10. INSTALL REAR BUMPER PAD (a) Apply new double-sided tape to the rear bumper pad. (b) Remove the release paper from the rear bumper pad. (c) Install the rear bumper pad. HINT: Use the same procedures for the RH side and LH side. B146333 11. INSTALL REAR BUMPER PLATE LH 12. INSTALL REAR BUMPER PLATE RH 13. INSTALL REAR BUMPER EXTENSION LH (w/ Rear Lower Spoiler) (a) Install the rear bumper extension LH with the 2 nuts. 14. INSTALL REAR BUMPER EXTENSION RH (w/ Rear Lower Spoiler) B137222 ET ET–24 EXTERIOR – REAR BUMPER 15. INSTALL REAR LOWER SPOILER (w/ Rear Lower Spoiler) (a) Engage the 16 claws and install the rear lower spoiler. ET B137223 (b) Install the 16 clips, 4 nuts and 2 screws. INSTALLATION 1. INSTALL REAR BUMPER ASSEMBLY (w/o Rear Lower Spoiler) (a) Engage each claw. (b) Install the rear bumper assembly with the 6 screws and 2 clips. B137214 (c) Install the 2 rear bumper plates. B137213 2. B140154 INSTALL REAR BUMPER ASSEMBLY (w/ Rear Lower Spoiler) (a) Engage each claw. (b) Install the rear bumper assembly with the 6 screws. EXTERIOR – REAR BUMPER ET–25 (c) Install the 2 rear bumper plates. B147905 3. Clip Nut B138885E01 INSTALL REAR FLOOR BOARD (w/ Rear Lower Spoiler) (a) Install the rear floor board with the 3 nuts, 2 clips and 4 screws. ET ET–25 EXTERIOR – NAME PLATE NAME PLATE EXTERIOR BODY COMPONENTS <1> <2> ET <1> NO. 2 LUGGAGE COMPARTMENT DOOR NAME PLATE <2> NO. 3 LUGGAGE COMPARTMENT DOOR NAME PLATE B137020E01 ET–26 EXTERIOR – NAME PLATE REMOVAL HINT: When removing the name plate, heat the vehicle body and name plate using a heat light. Heating temperature Item Vehicle Body Name Plate Temperature 40 to 60°C (104 to 140°F) 20 to 30°C (68 to 86°F) NOTICE: Do not heat the vehicle body and name plate excessively. Wooden Blocks 1. REMOVE NO. 2 LUGGAGE COMPARTMENT DOOR NAME PLATE (a) Put protective tape around the name plate. (b) Insert a piano wire between the vehicle body and name plate. (c) Tie objects that can serve as handles (for example, wooden blocks) to both wire ends. (d) Pull the piano wire and scrape off the double-sided tape that holds the name plate to the vehicle body. NOTICE: • If reusing the name plate, take care not to damage the name plate. • Be careful not to damage the vehicle body. (e) Remove the name plate. 2. REMOVE NO. 3 LUGGAGE COMPARTMENT DOOR NAME PLATE (a) Put protective tape around the name plate. (b) Insert a piano wire between the vehicle body and name plate. (c) Tie objects that can serve as handles (for example, wooden blocks) to both wire ends. (d) Pull the piano wire and scrape off the double-sided tape that holds the name plate to the vehicle body. NOTICE: • If reusing the name plate, take care not to damage the name plate. • Be careful not to damage the vehicle body. (e) Remove the name plate. ET Protective Tape B137022E01 Wooden Blocks Protective Tape B137023E01 ET–27 EXTERIOR – NAME PLATE INSTALLATION HINT: When installing the name plate, heat the vehicle body and name plate using a heat light. Heating temperature Item Vehicle Body Name Plate Temperature 40 to 60°C (104 to 140°F) 20 to 30°C (68 to 86°F) NOTICE: Do not heat the vehicle body and name plate excessively. 1. INSTALL NO. 2 LUGGAGE COMPARTMENT DOOR NAME PLATE (a) Clean the vehicle body surface. (1) Using a heat light, heat the vehicle body surface. (2) Remove the double-sided tape from the vehicle body. (3) Wipe off any tape adhesive residue with cleaner. (b) Clean the name plate. (If reusing the name plate) (1) Using a heat light, heat the name plate. (2) Remove the double-sided tape from the name plate. (3) Wipe off any tape adhesive residue with cleaner. (4) Apply new double-sided tape to the name plate. (c) Install the name plate. 16.0 mm (0.630 in.) 8.1 mm (0.319 in.) 5.5 mm (0.217 in.) B137027E01 (1) Using a heat light, heat the vehicle body and name plate. (2) Remove the release paper from the name plate. HINT: After removing the release paper, keep the exposed adhesive free from foreign matter. (3) Install the name plate. ET ET–28 EXTERIOR – NAME PLATE 2. ET INSTALL NO. 3 LUGGAGE COMPARTMENT DOOR NAME PLATE (a) Clean the vehicle body surface. (1) Using a heat light, heat the vehicle body surface. (2) Remove the double-sided tape from the vehicle body. (3) Wipe off any tape adhesive residue with cleaner. (b) Clean the name plate. (If reusing the name plate) (1) Using a heat light, heat the name plate. (2) Remove the double-sided tape from the name plate. (3) Wipe off any tape adhesive residue with cleaner. (4) Apply new double-sided tape to the name plate. (c) Install the name plate. (1) Using a heat light, heat the vehicle body and name plate. (2) Remove the release paper from the name plate. HINT: After removing the release paper, keep the exposed adhesive free from foreign matter. (3) Install the name plate. For name plate LE: 134.7 mm (5.303 in.) 66.8 mm (2.630 in.) 64.3 mm (2.532 in.) B137028E01 For name plate XLE: ET–29 EXTERIOR – NAME PLATE 162.2 mm (6.386 in.) 69.6 mm (2.740 in.) 66.6 mm (2.622 in.) B137029E01 For name plate SE: 136.7 mm (5.382 in.) 66.9 mm (2.634 in.) 64.3 mm (2.532 in.) B137030E01 ET ET–30 EXTERIOR – REAR SPOILER REAR SPOILER EXTERIOR BODY COMPONENTS LUGGAGE COMPARTMENT DOOR COVER ET REAR SPOILER B148216E01 ET–31 EXTERIOR – REAR SPOILER REMOVAL 1. REMOVE LUGGAGE COMPARTMENT DOOR COVER (See page ET-61) 2. REMOVE REAR SPOILER HINT: When removing the rear spoiler, heat the vehicle body and rear spoiler using a heat light. Heating temperature Item Vehicle Body Spoiler Temperature 40 to 60°C (104 to 140°F) 20 to 30°C (68 to 86°F) NOTICE: Do not heat the vehicle body and spoiler excessively. (a) Put protective tape around the rear spoiler. Protective Tape B137019E01 (b) Remove the 2 nuts. B137014 Wooden Blocks B137015E01 (c) Insert a piano wire between the vehicle body and rear spoiler. (d) Tie objects that can serve as handles (for example, wooden blocks) to both wire ends. ET ET–32 EXTERIOR – REAR SPOILER (e) Pull the piano wire and scrape off the double-sided tape that holds the spoiler to the vehicle body. Double-sided Tape Clip Stud Bolt Clip Clip Stud Bolt Clip B137016E01 ET (f) NOTICE: • If reusing the spoiler, take care not to damage the spoiler. • Be careful not to damage the vehicle body. Disengage the 4 clips and remove the rear spoiler. ET–33 EXTERIOR – REAR SPOILER INSTALLATION 1. INSTALL REAR SPOILER HINT: When installing the spoiler, heat the vehicle body and spoiler using a heat light. Heating temperature Item Vehicle Body Temperature 40 to 60°C (104 to 140°F) Spoiler 20 to 30°C (68 to 86°F) NOTICE: Do not heat the vehicle body and rear spoiler excessively. (a) Clean the vehicle body surface. (1) Using a heat light, heat the vehicle body surface. (2) Remove the double-sided tape from the vehicle body. (3) Wipe off any tape adhesive residue with cleaner. (b) Clean the rear spoiler. (If reusing the rear spoiler) (1) Using a heat light, heat the rear spoiler. (2) Remove the double-sided tape from the rear spoiler. (3) Wipe off any tape adhesive residue with cleaner. (4) Apply new double-sided tape to the rear spoiler. Double-sided Tape 1.2 mm (0.047 in.) B137017E01 ET ET–34 EXTERIOR – REAR SPOILER (c) Install the rear spoiler. (1) Using a heat light, heat the vehicle body and rear spoiler. (2) Remove the release paper from the rear spoiler. HINT: After removing the release paper, keep the exposed adhesive free from foreign matter. (3) Engage the 4 clips and install the rear spoiler with the 2 nuts. B137018 2. ET INSTALL LUGGAGE COMPARTMENT DOOR COVER (See page ET-64) ET–33 EXTERIOR – FRONT DOOR BELT MOULDING FRONT DOOR BELT MOULDING EXTERIOR BODY COMPONENTS OUTER REAR VIEW MIRROR ASSEMBLY FRONT DOOR BELT MOULDING ASSEMBLY ET 8.0 (80, 71 in.*lbf) FRONT DOOR INNER GLASS WEATHERSTRIP FRONT DOOR INSIDE HANDLE BEZEL PLUG FRONT DOOR LOWER FRAME BRACKET GARNISH FRONT DOOR TRIM BOARD SUB-ASSEMBLY ASSIST GRIP COVER COURTESY LIGHT ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B137749E01 ET–34 EXTERIOR – FRONT DOOR BELT MOULDING REMOVAL ET 1. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH (See page ED-14) 2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG (See page ED-14) 3. REMOVE ASSIST GRIP COVER (See page ED-15) 4. REMOVE COURTESY LIGHT ASSEMBLY (See page ED-15) 5. REMOVE FRONT DOOR TRIM BOARD SUBASSEMBLY (See page ED-15) 6. REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP (See page ED-16) 7. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY (See page MI-15) 8. REMOVE FRONT DOOR BELT MOULDING ASSEMBLY (a) Fully open the front door glass. (b) Put protective tape around the front door belt moulding assembly. Protective Tape B137001E01 (c) Using a moulding remover, disengage the 2 clips and 5 claws, and remove the front door belt moulding assembly. HINT: Tape the remover tip before use. NOTICE: Be careful when removing the moulding as there are claws attached to the front and rear ends of the moulding. B137002 INSTALLATION B137002 1. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY (a) Engage the 2 clips and 5 claws, and install the front door belt moulding assembly. 2. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY (See page MI-17) 3. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP (See page ED-32) 4. INSTALL FRONT DOOR TRIM BOARD SUBASSEMBLY (See page ED-33) 5. INSTALL COURTESY LIGHT ASSEMBLY (See page ED-34) EXTERIOR – FRONT DOOR BELT MOULDING ET–35 6. INSTALL ASSIST GRIP COVER (See page ED-34) 7. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG (See page ED-34) 8. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH (See page ED-34) ET ET–36 EXTERIOR – REAR DOOR BELT MOULDING REAR DOOR BELT MOULDING EXTERIOR BODY COMPONENTS REAR DOOR BELT MOULDING ASSEMBLY ET REAR DOOR INNER GLASS WEATHERSTRIP NO. 1 DOOR SCUFF PLATE CLAMP REAR DOOR INSIDE HANDLE BEZEL PLUG DOOR ASSIST GRIP COVER REAR DOOR TRIM BOARD SUB-ASSEMBLY B137751E01 EXTERIOR – REAR DOOR BELT MOULDING ET–37 REMOVAL Protective Tape 1. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG (See page ED-38) 2. REMOVE DOOR ASSIST GRIP COVER (See page ED38) 3. REMOVE REAR DOOR TRIM BOARD SUBASSEMBLY (See page ED-39) 4. REMOVE REAR DOOR INNER GLASS WEATHERSTRIP (See page ED-40) 5. REMOVE REAR DOOR BELT MOULDING ASSEMBLY (a) Fully open the rear door glass. (b) Put protective tape around the rear door belt moulding assembly. B137003E01 (c) Using a moulding remover, disengage the clip and 6 claws, and remove the rear door belt moulding assembly. HINT: Tape the remover tip before use. NOTICE: Be careful when removing the moulding as there are claws attached to the front end of the moulding. B137004 INSTALLATION 1. INSTALL REAR DOOR BELT MOULDING ASSEMBLY (a) Engage the clip and 6 claws, and install the rear door belt moulding assembly. 2. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP (See page ED-54) 3. INSTALL REAR DOOR TRIM BOARD SUBASSEMBLY (See page ED-55) 4. INSTALL DOOR ASSIST GRIP COVER (See page ED56) 5. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG (See page ED-56) B137004 ET ET–38 EXTERIOR – ROOF DRIP SIDE FINISH MOULDING ROOF DRIP SIDE FINISH MOULDING EXTERIOR BODY COMPONENTS ROOF DRIP SIDE FINISH MOULDING CENTER ROOF DRIP SIDE FINISH MOULDING CLIP ET ROOF DRIP SIDE FINISH MOULDING CLIP Non-reusable part B135477E01 ET–39 EXTERIOR – ROOF DRIP SIDE FINISH MOULDING REMOVAL 1. REMOVE ROOF DRIP SIDE FINISH MOULDING CENTER HINT: When removing the roof drip side finish moulding center, heat the body and roof drip side finish moulding center using a heat light. Heating temperature Item Vehicle Body Moulding Temperature 40 to 60°C (104 to 140°F) 20 to 30°C (68 to 86°F) NOTICE: Do not heat the vehicle body and moulding excessively. (a) Put protective tape around the roof drip side finish moulding center. Protective Tape B135478E01 (b) Using a moulding remover, disengage the 2 clips and remove the roof drip side finish moulding center. NOTICE: • Do not remove the clips. • If the clips are damaged or dropped off, replace them with new ones. 2. B135479E01 REMOVE ROOF DRIP SIDE FINISH MOULDING CLIP HINT: Perform the following procedure if replacing the roof drip side finish moulding clips. (a) Remove the 2 roof drip side finish moulding clips. B135480 ET ET–40 EXTERIOR – ROOF DRIP SIDE FINISH MOULDING INSTALLATION 1. 2 to 3 mm (0.07 to 0.11 in.) Bead of Adhesive Adhesive ET B140153E01 INSTALL ROOF DRIP SIDE FINISH MOULDING CLIP NOTICE: If installing new clips, remove the double-sided tape remaining where the clips will be installed on the body and clean the body with a non-residue type solvent. (a) Apply a 2 to 3 mm (0.07 to 0.11 in.) bead of adhesive (3M DP-105 or equivalent) to new roof drip side finish moulding clips. HINT: Adhesive strength (tensile strength): 13.7 MPa (140 kgf/cm2) or more (when the temperature is 23°C) (b) Install the roof drip side finish moulding clips to the positions on the roof panel shown in the illustration. Determine the locations and firmly press and install the roof drip side finish moulding clips after lightly rubbing up adhesive (3M DP-105 or equivalent). A B D C B136999E01 Standard dimension Area Dimension A 1.4 mm (0.055 in.) B 12.4 mm (0.488 in.) C 1.1 mm (0.043 in.) D 12.1 mm (0.476 in.) HINT: • Initial hardening time: 20 minutes • Complete hardening time: 48 hours EXTERIOR – ROOF DRIP SIDE FINISH MOULDING 2. ET–41 INSTALL ROOF DRIP SIDE FINISH MOULDING CENTER (a) Install the roof drip side finish moulding center when 20 minutes or more have elapsed after pressing and installing the roof drip side finish moulding clips. Installation Datum ET B137000E01 NOTICE: • Install the roof drip side finish moulding center in the proper direction. • Set the front clip to the installation datum. Make sure that the front clip and roof drip side finish moulding center are fit each other. ET–42 EXTERIOR – ROCKER PANEL MOULDING ROCKER PANEL MOULDING EXTERIOR BODY COMPONENTS ET ROCKER PANEL MOULDING ROCKER PANEL MOULDING PROTECTOR GROMMET Non-reusable part B135469E01 REMOVAL 1. B135471 REMOVE ROCKER PANEL MOULDING PROTECTOR (a) Remove the 2 screws and rocker panel moulding protector. ET–43 EXTERIOR – ROCKER PANEL MOULDING 2. REMOVE ROCKER PANEL MOULDING (a) Put protective tape around the rocker panel moulding. Protective Tape Protective Tape B135470E01 (b) Remove the 2 screws and grommet. B135472 (c) Remove the screw. B135473 (d) Remove the 7 clips. B135475 ET ET–44 EXTERIOR – ROCKER PANEL MOULDING (e) Remove the 2 screws. B135474 (f) Disengage the 8 clips and remove the rocker panel moulding. ET B135476 INSTALLATION 1. INSTALL ROCKER PANEL MOULDING (a) Engage the 8 clips and install the rocker panel moulding. B135476 (b) Install the 2 screws. B135474 (c) Install the 7 clips. B135475 EXTERIOR – ROCKER PANEL MOULDING ET–45 (d) Install the screw. B135473 (e) Install a new grommet and 2 screws. ET B135472 2. B135471 INSTALL ROCKER PANEL MOULDING PROTECTOR (a) Install the rocker panel moulding protector with the 2 screws. ET–46 EXTERIOR – FRONT DOOR WINDOW FRAME MOULDING FRONT DOOR WINDOW FRAME MOULDING EXTERIOR BODY COMPONENTS OUTER REAR VIEW MIRROR ASSEMBLY FRONT DOOR BELT MOULDING ASSEMBLY ET 8.0 (80, 71 in.*lbf) FRONT DOOR INNER GLASS WEATHERSTRIP FRONT DOOR INSIDE HANDLE BEZEL PLUG FRONT DOOR LOWER FRAME BRACKET GARNISH FRONT DOOR TRIM BOARD SUB-ASSEMBLY ASSIST GRIP COVER COURTESY LIGHT ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B137749E01 EXTERIOR – FRONT DOOR WINDOW FRAME MOULDING FRONT DOOR UPPER WINDOW FRAME MOULDING ET–47 RIVET FRONT DOOR REAR WINDOW FRAME MOULDING ET FRONT DOOR GLASS RUN FRONT DOOR GLASS SUB-ASSEMBLY FRONT DOOR WEATHERSTRIP BUTYL TAPE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY FRONT DOOR SERVICE HOLE COVER FRONT NO. 1 SPEAKER ASSEMBLY Non-reusable part B137750E01 ET–48 EXTERIOR – FRONT DOOR WINDOW FRAME MOULDING REMOVAL ET 1. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH (See page ED-14) 2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG (See page ED-14) 3. REMOVE ASSIST GRIP COVER (See page ED-15) 4. REMOVE COURTESY LIGHT ASSEMBLY (See page ED-15) 5. REMOVE FRONT DOOR TRIM BOARD SUBASSEMBLY (See page ED-15) 6. REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP (See page ED-16) 7. REMOVE FRONT DOOR INSIDE HANDLE SUBASSEMBLY (See page ED-17) 8. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY (See page AV-155) 9. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY (See page MI-15) 10. REMOVE FRONT DOOR SERVICE HOLE COVER (See page ED-17) 11. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY (See page ED-17) 12. REMOVE FRONT DOOR GLASS RUN (See page ED19) 13. REMOVE FRONT DOOR WEATHERSTRIP (a) Using a clip remover, disengage the clip and remove the front door weatherstrip. B129816 14. REMOVE FRONT DOOR REAR WINDOW FRAME MOULDING HINT: When removing the front door rear window frame moulding, heat the vehicle body and front door rear window frame moulding using a heat light. Heating temperature Item Vehicle Body Moulding Temperature 40 to 60°C (104 to 140°F) 20 to 30°C (68 to 86°F) NOTICE: Do not heat the vehicle body and moulding excessively. (a) Using a heat light, heat the front door rear window frame moulding. EXTERIOR – FRONT DOOR WINDOW FRAME MOULDING ET–49 (b) Disengage the clip. B137005 (c) Using a moulding remover, remove the front door rear window frame moulding. ET Double-sided Tape B137006E01 5 mm (0.20 in.) B137008E01 15. REMOVE FRONT DOOR UPPER WINDOW FRAME MOULDING (a) Put a 4 mm (0.16 in.) drill bit into a drill. (b) Tape the drill bit without the portion of 5 mm (0.20 in.) from the tip covered. HINT: Tape the drill bit to prevent the drill bit from going too deep. (c) Lightly press the drill against the rivets, drill off the flanges of the rivets, and remove the 7 rivets. NOTICE: • Pressing the drill too firmly will cause the rivet to turn and result in the rivet not being drilled through. • Do not pry the rivets with the drill, because this may cause damage to the installation holes of the rivets or the drill bit. • Be careful when touching the drilled rivets as they may become hot. (d) Using a vacuum cleaner, remove the rivet fragments and shavings from the drilled areas. (e) Remove the front door upper window frame moulding from the door frame. ET–50 EXTERIOR – FRONT DOOR WINDOW FRAME MOULDING INSTALLATION 1. INSTALL FRONT DOOR UPPER WINDOW FRAME MOULDING (a) Install the front door upper window frame moulding to the door frame. (b) Using an air riveter or hand riveter with a nose piece, install the front door upper window frame moulding with 7 new rivets. HINT: If the rivet cannot be cut, pull it once and cut it. ET B105049 Riveter NOTICE: • Do not pry the rivet with the riveter, as this will cause damage to the riveter and mandrel. INCORRECT Mandrel B125583E01 • Confirm that the rivets are seated properly against the moulding. Do not tilt the riveter when installing the rivet to the moulding. Do not leave any space between the rivet head and moulding. INCORRECT Riveter INCORRECT Riveter B125584E01 • Do not leave any space between the moulding and door frame. Firmly hold together the 2 items while installing the rivet. INCORRECT Riveter 2. B125585E01 INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING HINT: When installing the front door rear window frame moulding, heat the vehicle body and front door rear window frame moulding using a heat light. Heating temperature Item Vehicle Body Moulding Temperature 40 to 60°C (104 to 140°F) 20 to 30°C (68 to 86°F) EXTERIOR – FRONT DOOR WINDOW FRAME MOULDING ET–51 NOTICE: Do not heat the vehicle body and front door window frame moulding excessively. (a) Clean the vehicle body surface. (1) Using a heat light, heat the vehicle body surface. (2) Remove the double-sided tape from the vehicle body. (3) Wipe off any tape adhesive residue with cleaner. Double-sided Tape 0.8 mm (0.032 in.) (b) Clean the front door rear window frame moulding. (If reusing the front door rear window frame moulding) (1) Using a heat light, heat the front door rear window frame moulding. (2) Remove the double-sided tape from the front door rear window frame moulding. (3) Wipe off any tape adhesive residue with cleaner. (4) Apply new double-sided tape to the front door rear window frame moulding. 5.0 mm (0.197 in.) B137007E01 (c) Install the front door rear window frame moulding. (1) Using a heat light, heat the vehicle body and front door rear window frame moulding. (2) Remove the release paper from the front door rear window frame moulding. HINT: After removing the release paper, keep the exposed adhesive free from foreign matter. B137754 (3) Engage the clip and install the front door rear window frame moulding. B137005 ET ET–52 EXTERIOR – FRONT DOOR WINDOW FRAME MOULDING 3. INSTALL FRONT DOOR WEATHERSTRIP (a) Engage the clip and install the front door weatherstrip. 4. INSTALL FRONT DOOR GLASS RUN (See page ED30) 5. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY (See page ED-31) 6. INSTALL FRONT DOOR SERVICE HOLE COVER (See page ED-32) 7. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY (See page MI-17) 8. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY (See page AV-157) 9. INSTALL FRONT DOOR INSIDE HANDLE SUBASSEMBLY (See page ED-33) B129818 ET 10. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP (See page ED-32) 11. INSTALL FRONT DOOR TRIM BOARD SUBASSEMBLY (See page ED-33) 12. INSTALL COURTESY LIGHT ASSEMBLY (See page ED-34) 13. INSTALL ASSIST GRIP COVER (See page ED-34) 14. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG (See page ED-34) 15. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH (See page ED-34) EXTERIOR – REAR DOOR WINDOW FRAME MOULDING ET–53 REAR DOOR WINDOW FRAME MOULDING EXTERIOR BODY COMPONENTS REAR DOOR BELT MOULDING ASSEMBLY ET REAR DOOR INNER GLASS WEATHERSTRIP NO. 1 DOOR SCUFF PLATE CLAMP REAR DOOR INSIDE HANDLE BEZEL PLUG DOOR ASSIST GRIP COVER REAR DOOR TRIM BOARD SUB-ASSEMBLY B137751E01 ET–54 EXTERIOR – REAR DOOR WINDOW FRAME MOULDING RIVET REAR DOOR FRONT WINDOW FRAME MOULDING REAR DOOR UPPER WINDOW FRAME MOULDING ET REAR DOOR QUARTER WINDOW GLASS REAR DOOR GLASS SUB-ASSEMBLY REAR DOOR GLASS RUN REAR DOOR WEATHERSTRIP REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY BUTYL TAPE REAR DOOR SERVICE HOLE COVER REAR DOOR INSIDE HANDLE SUB-ASSEMBLY Non-reusable part B137752E01 ET–55 EXTERIOR – REAR DOOR WINDOW FRAME MOULDING REMOVAL 1. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG (See page ED-38) 2. REMOVE DOOR ASSIST GRIP COVER (See page ED38) 3. REMOVE REAR DOOR TRIM BOARD SUBASSEMBLY (See page ED-39) 4. REMOVE REAR DOOR INNER GLASS WEATHERSTRIP (See page ED-40) 5. REMOVE REAR DOOR INSIDE HANDLE SUBASSEMBLY (See page ED-40) 6. REMOVE REAR DOOR SERVICE HOLE COVER (See page ED-41) 7. REMOVE REAR DOOR GLASS RUN (See page ED42) 8. REMOVE REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY (See page ED-42) 9. REMOVE REAR DOOR QUARTER WINDOW GLASS (See page ED-43) 10. REMOVE REAR DOOR GLASS SUB-ASSEMBLY (See page ED-43) 11. REMOVE REAR DOOR WEATHERSTRIP (a) Using a clip remover, disengage the clip and remove the rear door weatherstrip. B129819 12. REMOVE REAR DOOR FRONT WINDOW FRAME MOULDING HINT: When removing the rear door front window frame moulding, heat the vehicle body and rear door front window frame moulding using a heat light. Heating temperature Item Vehicle Body Moulding Temperature 40 to 60°C (104 to 140°F) 20 to 30°C (68 to 86°F) NOTICE: Do not heat the vehicle body and moulding excessively. (a) Using a heat light, heat the rear door front window frame moulding. ET ET–56 EXTERIOR – REAR DOOR WINDOW FRAME MOULDING (b) Disengage the clip. B137009 (c) Using a moulding remover, remove the rear door front window frame moulding. ET Double-sided Tape B137010E01 5 mm (0.20 in.) B137012E01 13. REMOVE REAR DOOR UPPER WINDOW FRAME MOULDING (a) Put a 4 mm (0.16 in.) drill bit into a drill. (b) Tape the drill bit without the portion of 5 mm (0.20 in.) from the tip covered. HINT: Tape the drill bit to prevent the drill bit from going too deep. (c) Lightly press the drill bit against the rivets, drill off the flanges of the rivets, and remove the 7 rivets. NOTICE: • Pressing the drill too firmly will cause the rivet to turn and result in the rivet not being drilled through. • Do not pry the rivets with the drill, as this may cause damage to the installation holes of the rivets or the drill bit. • Be careful when touching the drilled rivets, as they may become hot. (d) Using a vacuum cleaner, remove the rivet fragments and shavings from the drilled areas. (e) Remove the rear door upper window frame moulding from the door frame. ET–57 EXTERIOR – REAR DOOR WINDOW FRAME MOULDING INSTALLATION 1. INSTALL REAR DOOR UPPER WINDOW FRAME MOULDING (a) Install the rear door upper window frame moulding to the door frame. (b) Using an air riveter or hand riveter with a nose piece, install the rear door upper window frame moulding with 7 new rivets. HINT: If the rivet cannot be cut, pull it once and cut it. ET B105050 Riveter NOTICE: • Do not pry the rivet with the riveter, as this will cause damage to the riveter and mandrel. INCORRECT Mandrel B125583E01 • Confirm that the rivets are seated properly against the moulding. Do not tilt the riveter when installing the rivet to the moulding. Do not leave any space between the rivet head and moulding. INCORRECT Riveter INCORRECT Riveter B125584E01 • Do not leave any space between the moulding and door frame. Firmly hold together the 2 items while installing the rivet. INCORRECT Riveter 2. B125585E01 INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING HINT: When installing the rear door front window frame moulding, heat the vehicle body and rear door front window frame using a heat light. Heating temperature Item Vehicle Body Moulding Temperature 40 to 60°C (104 to 140°F) 20 to 30°C (68 to 86°F) ET–58 EXTERIOR – REAR DOOR WINDOW FRAME MOULDING NOTICE: Do not heat the vehicle body and rear door window frame moulding excessively. (a) Clean the vehicle body surface. (1) Using a heat light, heat the vehicle body surface. (2) Remove the double-sided tape from the vehicle body. (3) Wipe off any tape adhesive residue with cleaner. Double-sided Tape (A) ET 0.8 mm (0.032 in.) 5.0 mm (0.197 in.) Double-sided Tape (B) 1.2 mm (0.047 in.) (b) Clean the rear door front window frame moulding. (If reusing the rear door front window frame moulding) (1) Using a heat light, heat the rear door front window frame moulding. (2) Remove the double-sided tape from the rear door front window frame moulding. (3) Wipe off any tape adhesive residue with cleaner. (4) Apply new double-sided tape to the rear door front window frame moulding. 5.0 mm (0.197 in.) Double-sided Tape (B) Double-sided Tape (A) B137011E01 (c) Install the rear door front window frame moulding. (1) Using a heat light, heat the vehicle body and rear door front window frame moulding. (2) Remove the release paper from the rear door front window frame moulding. HINT: After removing the release paper, keep the exposed adhesive free from foreign matter. B137755 (3) Engage the clip and install the rear door front window frame moulding. B137009 EXTERIOR – REAR DOOR WINDOW FRAME MOULDING ET–59 3. INSTALL REAR DOOR WEATHERSTRIP (a) Engage the clip and install the rear door weatherstrip. 4. INSTALL REAR DOOR GLASS SUB-ASSEMBLY (See page ED-52) 5. INSTALL REAR DOOR QUARTER WINDOW GLASS (See page ED-52) 6. INSTALL REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY (See page ED-52) 7. INSTALL REAR DOOR GLASS RUN (See page ED-52) 8. INSTALL REAR DOOR SERVICE HOLE COVER (See page ED-53) 9. INSTALL REAR DOOR INSIDE HANDLE SUBASSEMBLY (See page ED-55) B129820 10. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP (See page ED-54) 11. INSTALL REAR DOOR TRIM BOARD SUBASSEMBLY (See page ED-55) 12. INSTALL DOOR ASSIST GRIP COVER (See page ED56) 13. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG (See page ED-56) ET ET–60 EXTERIOR – LUGGAGE COMPARTMENT DOOR GARNISH LUGGAGE COMPARTMENT DOOR GARNISH EXTERIOR BODY COMPONENTS LUGGAGE COMPARTMENT DOOR LOCK CYLINDER ASSEMBLY ET LUGGAGE COMPARTMENT DOOR COVER LUGGAGE COMPARTMENT DOOR OUTSIDE GARNISH with Smart Key System: LUGGAGE DOOR OPENING SWITCH ASSEMBLY SYMBOL EMBLEM B135463E01 EXTERIOR – LUGGAGE COMPARTMENT DOOR GARNISH ET–61 REMOVAL 1. REMOVE LUGGAGE COMPARTMENT DOOR COVER (a) Using a clip remover, remove the 13 clips and luggage compartment door cover. 2. REMOVE LUGGAGE DOOR OPENING SWITCH ASSEMBLY (w/ Smart Key System) (See page DL246) 3. REMOVE LUGGAGE COMPARTMENT DOOR LOCK CYLINDER ASSEMBLY (a) Disconnect the rod. B135458 ET B136491 (b) Disconnect the cable and connector. B136496 (c) Remove the 2 nuts and luggage compartment door lock cylinder assembly. B136497 4. Protective Tape B135459E01 REMOVE LUGGAGE COMPARTMENT DOOR OUTSIDE GARNISH (a) Put protective tape around the luggage compartment door outside garnish. ET–62 EXTERIOR – LUGGAGE COMPARTMENT DOOR GARNISH (b) Remove the 3 nuts. B135460 (c) Using a moulding remover, disengage the 2 clips and remove the luggage compartment door outside garnish. 5. ET REMOVE SYMBOL EMBLEM HINT: When removing the symbol emblem, heat the luggage compartment door outside garnish and symbol emblem using a heat light. Heating temperature B135461 Item Temperature Luggage compartment door outside garnish 40 to 60°C (104 to 140°F) Symbol emblem 20 to 30°C (68 to 86°F) NOTICE: Do not heat the luggage compartment door outside garnish and symbol emblem excessively. (a) Put protective tape around the symbol emblem. Location Pin Wooden Block Protective Tape B137025E01 (b) Insert a piano wire between the luggage compartment door outside garnish and symbol emblem. (c) Tie objects that can serve as handles (for example, wooden blocks) to both wire ends. (d) Pull the piano wire and scrape off the double-sided tape that holds the symbol emblem to the luggage compartment door outside garnish. NOTICE: • If reusing the symbol emblem, take care not to damage the symbol emblem. • Be careful not to damage the luggage compartment door outside garnish. (e) Remove the symbol emblem. ET–63 EXTERIOR – LUGGAGE COMPARTMENT DOOR GARNISH INSTALLATION 1. INSTALL SYMBOL EMBLEM HINT: When installing the symbol emblem, heat the luggage compartment door outside garnish and symbol emblem using a heat light. Heating temperature Item Temperature Luggage compartment door outside garnish 40 to 60°C (104 to 140°F) Symbol emblem 20 to 30°C (68 to 86°F) NOTICE: Do not heat the luggage compartment door outside garnish and symbol emblem excessively. (a) Clean the luggage compartment door outside garnish surface. (1) Using a heat light, heat the luggage compartment door outside garnish surface. (2) Remove the double-sided tape from the luggage compartment door outside garnish. (3) Wipe off any tape adhesive residue with cleaner. (b) Clean the symbol emblem. (If reusing the symbol emblem) (1) Using a heat light, heat the symbol emblem. (2) Remove the double-sided tape from the symbol emblem. (3) Wipe off any tape adhesive residue with cleaner. (4) Apply new double-sided tape to the symbol emblem. (c) Install the symbol emblem. (1) Using a heat light, heat the luggage compartment door outside garnish and symbol emblem. (2) Remove the release paper from the symbol emblem. HINT: After removing the release paper, keep the exposed adhesive free from foreign matter. (3) Install the symbol emblem. B137026 2. B135462 INSTALL LUGGAGE COMPARTMENT DOOR OUTSIDE GARNISH (a) Engage the 2 clips and install the luggage compartment door outside garnish. ET ET–64 EXTERIOR – LUGGAGE COMPARTMENT DOOR GARNISH (b) Install the 3 nuts. B135460 3. ET INSTALL LUGGAGE COMPARTMENT DOOR LOCK CYLINDER ASSEMBLY (a) Install the luggage compartment door lock cylinder with the 2 nuts. B136497 (b) Connect the cable and connector. B136496 (c) Connect the rod. 4. INSTALL LUGGAGE DOOR OPENING SWITCH ASSEMBLY (w/ Smart Key System) (See page DL246) 5. INSTALL LUGGAGE COMPARTMENT DOOR COVER (a) Install the luggage compartment door cover with the 13 clips. B136492 B135458 ET–65 EXTERIOR – FRONT DOOR BLACK OUT TAPE FRONT DOOR BLACK OUT TAPE EXTERIOR BODY COMPONENTS OUTER REAR VIEW MIRROR ASSEMBLY ET 8.0 (80, 71 in.*lbf) FRONT DOOR INNER GLASS WEATHERSTRIP FRONT DOOR INSIDE HANDLE BEZEL PLUG FRONT DOOR LOWER FRAME BRACKET GARNISH FRONT DOOR TRIM BOARD SUB-ASSEMBLY ASSIST GRIP COVER COURTESY LIGHT ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B146673E01 ET–66 EXTERIOR – FRONT DOOR BLACK OUT TAPE FRONT DOOR GLASS SUB-ASSEMBLY FRONT DOOR GLASS RUN ET DOOR FRAME GARNISH FRONT DOOR STRIPE FRONT DOOR WEATHERSTRIP FRONT DOOR LOWER OUTSIDE STRIPE BUTYL TAPE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY FRONT DOOR SERVICE HOLE COVER FRONT NO. 1 SPEAKER ASSEMBLY Non-reusable part B146674E01 ET–67 EXTERIOR – FRONT DOOR BLACK OUT TAPE REMOVAL 1. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH (See page ED-14) 2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG (See page ED-14) 3. REMOVE ASSIST GRIP COVER (See page ED-15) 4. REMOVE COURTESY LIGHT ASSEMBLY (See page ED-15) 5. REMOVE FRONT DOOR TRIM BOARD SUBASSEMBLY (See page ED-15) 6. REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP (See page ED-16) 7. REMOVE FRONT DOOR INSIDE HANDLE SUBASSEMBLY (See page ED-17) 8. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY (See page AV-155) 9. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY (See page MI-15) 10. REMOVE FRONT DOOR SERVICE HOLE COVER (See page ED-17) 11. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY (See page ED-17) 12. REMOVE FRONT DOOR GLASS RUN (See page ED19) 13. REMOVE FRONT DOOR WEATHERSTRIP (See page ET-48) 14. REMOVE DOOR FRAME GARNISH (See page ED-19) 15. REMOVE FRONT DOOR STRIPE (a) Using a heat light, heat the front door stripe. Heating temperature Item Vehicle Body Temperature 40 to 60°C (104 to 140°F) NOTICE: Do not heat the vehicle body excessively. (b) Pull back an edge of the front door stripe and pull it parallel to the vehicle body to pull it off. 16. REMOVE FRONT DOOR LOWER OUTSIDE STRIPE (a) Using a heat light, heat the front door lower outside stripe. Heating temperature Item Vehicle Body Temperature 40 to 60°C (104 to 140°F) NOTICE: Do not heat the vehicle body excessively. ET ET–68 EXTERIOR – FRONT DOOR BLACK OUT TAPE (b) Pull back an edge of the front door lower outside stripe and pull it parallel to the vehicle body to pull it off. ET ET–69 EXTERIOR – FRONT DOOR BLACK OUT TAPE INSTALLATION 1. REPAIR INSTRUCTION (a) Clean the vehicle body surface. (1) Using a heat light, heat the vehicle body surface. Heating temperature Item Vehicle Body (b) (c) (d) (e) Temperature 40 to 60°C (104 to 140°F) NOTICE: Do not heat the vehicle body excessively. (2) Wipe off any tape adhesive residue with cleaner. Installation temperature (1) When ambient temperature is below 15°C, perform the installation procedure after warming the vehicle body surface (installation surface of the door frame) and tape up to between 20 to 30°C using a heat light. When ambient temperature is above 35°C, cool the vehicle body surface (installation surface of the door frame) and tape down to between 20 to 30°C prior to installation. HINT: • The most appropriate temperature for installing the tape is 25°C. • When the temperature is low, the tape turns stiff and comes off easily. When the temperature is high, the tape looses elasticity. Before installation (1) Remove any roughness of coating and dirt on and around the vehicle body surface where the tape will be installed (installation surface of the door frame). If any roughness or dirt remains when pressing the tape onto the surface, air will be trapped under the tape and result in a poor appearance. HINT: Spray water on the shop floor to settle any dust. Key points for handling the tape (1) The tape bends and rolls up easily. Store the tape between flat pieces of cardboard or other similar objects and keep it dry and level. NOTICE: Do not bend the tape or leave it in high temperature places. Key points for installation of the tape (how to use a squeegee and installation procedure for flat surfaces) NOTICE: • Conduct positioning of the tape with a high accuracy to achieve a neat finish and to avoid peeling. ET ET–70 EXTERIOR – FRONT DOOR BLACK OUT TAPE • The tape cannot be reused because it deforms or does not fit any more after being removed. (1) To avoid air bubbles, slightly raise the part of the tape that are going to be applied so that its adhesive surface does not touch the vehicle body while applying the tape. Tilt the squeegee at a 40 to 50° (for pressing forward) or 30 to 45° (for pulling) to the vehicle body surface and press the tape onto the vehicle body surface with a force of 20 to 30 N (2 to 3 kgf) at a constant slow speed of 3 to 7 cm per second. ET Sectional View Non-padded Side Squeegee Padded Side 40 to 50° For pressing forward: 3 to 7 cm/sec. For pulling: 3 to 7 cm/sec. Squeegee Squeegee Stripe Tape Release Paper 10 to 20 mm (0.393 to 0.787 in.) 30 to 45° 10 to 20 mm (0.393 to 0.787 in.) Stripe Tape Release Paper B147252E01 NOTICE: Be sure to observe the specified pressing speed, force, and angle of the squeegee to avoid wrinkles or air bubbles. HINT: • Either angle of the squeegee (for pressing forward or for pulling) is acceptable. • Be sure to apply the tape while removing the release paper 10 to 20 mm from the edge of the squeegee. EXTERIOR – FRONT DOOR BLACK OUT TAPE ET–71 (f) Squeegee Second First Third Hem B147253E01 Key points for installation of the tape (how to use a squeegee and installation procedure for hemming surfaces) (1) If it is difficult to press the tape, press it in several steps as shown in the illustration. Use your fingers or the padded surface of a squeegee to slowly apply the tape to the hem of the vehicle, especially for a small hem. HINT: When applying the tape to the backside of a hem, remove the release paper and use your fingers or the padded surface of a squeegee. (g) Key points for installation of the tape (how to use a squeegee and installation procedure for corners) (1) Remove the release paper and apply the tape carefully with your fingers. (2) Before applying the tape to each corner, heat the tape using a heat light and gradually apply it, to avoid wrinkles on the tape and achieve a neat finish. (h) Check after installation (1) After completing the application, check if the tape is applied neatly. If the tape is not applied neatly, reapply using new tape. NOTICE: Do not reuse the tape. ET ET–72 EXTERIOR – FRONT DOOR BLACK OUT TAPE 2. INSTALL FRONT DOOR LOWER OUTSIDE STRIPE (a) Refer to the illustration to position the front door lower outside stripe. Identification notch (upper) Align the edge of the tape to the door frame +1.5 mm (+0.059 in.) R End -1.0 mm (-0.039 in.) ET LH Side: RH Side: Square Round B146668E01 (b) Remove the release paper and apply the stripe. 3. INSTALL FRONT DOOR STRIPE NOTICE: Be sure to install the front door stripe after applying the front door lower outside stripe. ET–73 EXTERIOR – FRONT DOOR BLACK OUT TAPE (a) Refer to the illustration to position the front door stripe. Align the edge of the tape to the claw position of the door frame garnish R End Claw position of door frame garnish +1.5 mm (+0.059 in.) -1.0 mm (-0.039 in.) ET Identification notch LH Side: RH Side: Round Square B146669E01 (b) Remove the release paper and apply the stripe. 4. INSTALL DOOR FRAME GARNISH (See page ED-30) 5. INSTALL FRONT DOOR WEATHERSTRIP (See page ET-51) 6. INSTALL FRONT DOOR GLASS RUN (See page ED30) 7. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY (See page ED-31) 8. INSTALL FRONT DOOR SERVICE HOLE COVER (See page ED-32) 9. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY (See page MI-17) 10. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY (See page AV-157) 11. INSTALL FRONT DOOR INSIDE HANDLE SUBASSEMBLY (See page ED-33) 12. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP (See page ED-32) 13. INSTALL FRONT DOOR TRIM BOARD SUBASSEMBLY (See page ED-33) ET–74 EXTERIOR – FRONT DOOR BLACK OUT TAPE 14. INSTALL COURTESY LIGHT ASSEMBLY (See page ED-34) 15. INSTALL ASSIST GRIP COVER (See page ED-34) 16. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG (See page ED-34) 17. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH (See page ED-34) ET ET–74 EXTERIOR – REAR DOOR BLACK OUT TAPE REAR DOOR BLACK OUT TAPE EXTERIOR BODY COMPONENTS NO. 1 DOOR SCUFF PLATE CLAMP REAR DOOR INNER GLASS WEATHERSTRIP ET REAR DOOR INSIDE HANDLE BEZEL PLUG REAR DOOR TRIM BOARD SUB-ASSEMBLY DOOR ASSIST GRIP COVER B146675E01 ET–75 EXTERIOR – REAR DOOR BLACK OUT TAPE REAR DOOR GLASS SUB-ASSEMBLY REAR DOOR GLASS RUN REAR DOOR QUARTER WINDOW GLASS ET REAR DOOR OUTSIDE STRIPE REAR DOOR WEATHERSTRIP REAR DOOR FRAME GARNISH REAR DOOR LOWER OUTSIDE STRIPE REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY BUTYL TAPE REAR DOOR SERVICE HOLE COVER REAR DOOR INSIDE HANDLE SUB-ASSEMBLY Non-reusable part B146676E01 ET–76 EXTERIOR – REAR DOOR BLACK OUT TAPE REMOVAL ET 1. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG (See page ED-38) 2. REMOVE DOOR ASSIST GRIP COVER (See page ED38) 3. REMOVE REAR DOOR TRIM BOARD SUBASSEMBLY (See page ED-39) 4. REMOVE REAR DOOR INNER GLASS WEATHERSTRIP (See page ED-40) 5. REMOVE REAR DOOR INSIDE HANDLE SUBASSEMBLY (See page ED-40) 6. REMOVE REAR DOOR SERVICE HOLE COVER (See page ED-41) 7. REMOVE REAR DOOR GLASS RUN (See page ED42) 8. REMOVE REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY (See page ED-42) 9. REMOVE REAR DOOR QUARTER WINDOW GLASS (See page ED-43) 10. REMOVE REAR DOOR GLASS SUB-ASSEMBLY (See page ED-43) 11. REMOVE REAR DOOR WEATHERSTRIP (See page ET-55) 12. REMOVE REAR DOOR OUTSIDE STRIPE (a) Using a heat light, heat the rear door outside stripe. Heating temperature Item Vehicle Body Temperature 40 to 60°C (104 to 140°F) NOTICE: Do not heat the vehicle body excessively. (b) Pull back an edge of the rear door outside stripe and pull it parallel to the vehicle body to pull it off. 13. REMOVE REAR DOOR LOWER OUTSIDE STRIPE (a) Using a heat light, heat the rear door lower outside stripe. Heating temperature Item Vehicle Body Temperature 40 to 60°C (104 to 140°F) NOTICE: Do not heat the vehicle body excessively. (b) Pull back an edge of the rear door lower outside stripe and pull it parallel to the vehicle body to pull it off. ET–77 EXTERIOR – REAR DOOR BLACK OUT TAPE INSTALLATION 1. REPAIR INSTRUCTION (a) Clean the vehicle body surface. (1) Using a heat light, heat the vehicle body surface. Heating temperature Item Vehicle Body (b) (c) (d) (e) Temperature 40 to 60°C (104 to 140°F) NOTICE: Do not heat the vehicle body excessively. (2) Wipe off any tape adhesive residue with cleaner. Installation temperature (1) When ambient temperature is below 15°C, perform the installation procedure after warming the vehicle body surface (installation surface of the door frame) and tape up to between 20 to 30°C using a heat light. When ambient temperature is above 35°C, cool the vehicle body surface (installation surface of the door frame) and tape down to between 20 to 30°C prior to installation. HINT: • The most appropriate temperature for installing the tape is 25°C. • When the temperature is low, the tape turns stiff and comes off easily. When the temperature is high, the tape looses elasticity. Before installation (1) Remove any roughness of coating and dirt on and around the vehicle body surface where the tape will be installed (installation surface of the door frame). If any roughness or dirt remains when pressing the tape onto the surface, air will be trapped under the tape and result in a poor appearance. HINT: Spray water on the shop floor to settle any dust. Key points for handling the tape (1) The tape bends and rolls up easily. Store the tape between flat pieces of cardboard or other similar objects and keep it dry and level. NOTICE: Do not bend the tape or leave it in high temperature places. Key points for installation of the tape (how to use a squeegee and installation procedure for flat surfaces) NOTICE: • Conduct positioning of the tape with a high accuracy to achieve a neat finish and to avoid peeling. ET ET–78 EXTERIOR – REAR DOOR BLACK OUT TAPE • The tape cannot be reused because it deforms or does not fit any more after being removed. (1) To avoid air bubbles, slightly raise the part of the tape that are going to be applied so that its adhesive surface does not touch the vehicle body while applying the tape. Tilt the squeegee at a 40 to 50° (for pressing forward) or 30 to 45° (for pulling) to the vehicle body surface and press the tape onto the vehicle body surface with a force of 20 to 30 N (2 to 3 kgf) at a constant slow speed of 3 to 7 cm per second. ET Sectional View Non-padded Side Squeegee Padded Side 40 to 50° For pressing forward: 3 to 7 cm/sec. For pulling: 3 to 7 cm/sec. Squeegee Squeegee Stripe Tape Release Paper 10 to 20 mm (0.393 to 0.787 in.) 30 to 45° 10 to 20 mm (0.393 to 0.787 in.) Stripe Tape Release Paper B147252E01 NOTICE: Be sure to observe the specified pressing speed, force, and angle of the squeegee to avoid wrinkles or air bubbles. HINT: • Either angle of the squeegee (for pressing forward or for pulling) is acceptable. • Be sure to apply the tape while removing the release paper 10 to 20 mm from the edge of the squeegee. EXTERIOR – REAR DOOR BLACK OUT TAPE ET–79 (f) Squeegee Second First Third Hem B147253E01 Key points for installation of the tape (how to use a squeegee and installation procedure for hemming surfaces) (1) If it is difficult to press the tape, press it in several steps as shown in the illustration. Use your fingers or the padded surface of a squeegee to slowly apply the tape to the hem of the vehicle, especially for a small hem. HINT: When applying the tape to the backside of a hem, remove the release paper and use your fingers or the padded surface of a squeegee. (g) Key points for installation of the tape (how to use a squeegee and installation procedure for corners) (1) Remove the release paper and apply the tape carefully with your fingers. (2) Before applying the tape to each corner, heat the tape using a heat light and gradually apply it, to avoid wrinkles on the tape and achieve a neat finish. (h) Check after installation (1) After completing the application, check if the tape is applied neatly. If the tape is not applied neatly, reapply using new tape. NOTICE: Do not reuse the tape. ET ET–80 EXTERIOR – REAR DOOR BLACK OUT TAPE 2. INSTALL REAR DOOR LOWER OUTSIDE STRIPE (a) Refer to the illustration to position the rear door lower outside stripe. Align the edge of the tape to the door frame ET Identification notch (upper) +1.5 mm (+0.059 in.) LH Side: RH Side: R End -1.0 mm (-0.039 in.) Straight line Triangle B146670E01 (b) Remove the release paper and apply the stripe. 3. INSTALL REAR DOOR OUTSIDE STRIPE NOTICE: Be sure to install the rear door outside stripe after applying the rear door lower outside stripe. ET–81 EXTERIOR – REAR DOOR BLACK OUT TAPE (a) Refer to the illustration to position the rear door outside stripe. Align the edge of the tape to the claw position of the door frame garnish ET R End -1.0 mm (-0.039 in.) +1.5 mm (+0.059 in.) LH Side: RH Side: Identification notch Straight line Claw position of door frame garnish Triangle B146671E01 (b) Remove the release paper and apply the stripe. 4. INSTALL REAR DOOR FRAME GARNISH (See page ED-51) 5. INSTALL REAR DOOR WEATHERSTRIP (See page ET-59) 6. INSTALL REAR DOOR GLASS SUB-ASSEMBLY (See page ED-52) 7. INSTALL REAR DOOR QUARTER WINDOW GLASS (See page ED-52) 8. INSTALL REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY (See page ED-52) 9. INSTALL REAR DOOR GLASS RUN (See page ED-52) 10. INSTALL REAR DOOR SERVICE HOLE COVER (See page ED-53) 11. INSTALL REAR DOOR INSIDE HANDLE SUBASSEMBLY (See page ED-55) 12. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP (See page ED-54) 13. INSTALL REAR DOOR TRIM BOARD SUBASSEMBLY (See page ED-55) ET–82 EXTERIOR – REAR DOOR BLACK OUT TAPE 14. INSTALL DOOR ASSIST GRIP COVER (See page ED56) 15. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG (See page ED-56) ET 2GR-FE EMISSION CONTROL – EMISSION CONTROL SYSTEM EC–1 EMISSION CONTROL SYSTEM 2GR-FE EMISSION CONTROL ENGINE PARTS LOCATION FUEL TANK CAP CANISTER ECM HEATED OXYGEN SENSOR (BANK 1 SENSOR 2) EC HEATED OXYGEN SENSOR (BANK 2 SENSOR 2) AIR FUEL RATIO SENSOR (BANK 1 SENSOR 1) AIR FUEL RATIO SENSOR (BANK 2 SENSOR 1) VACUUM SWITCHING VALVE A135647E03 EC–2 2GR-FE EMISSION CONTROL – EMISSION CONTROL SYSTEM SYSTEM DIAGRAM VSV for EVAP to Charcoal Canister EC ECM Air Fuel Ratio Sensor (Bank 1) Air Fuel Ratio Sensor (Bank 2) Engine Coolant Temperature Sensor Heated Oxygen Sensor (Bank 2) Heated Oxygen Sensor (Bank 1) A113656E02 EC–3 2GR-FE EMISSION CONTROL – EMISSION CONTROL SYSTEM EVAP System Circuit : ECM Air Cleaner Intake Manifold Soak Timer Air Filter Canister EVAP VSV Service Port Fuel Cap Pump Module Roll-over Valve Cut-off Valve Fuel Tank A128936E03 EC EC–4 2GR-FE EMISSION CONTROL – EMISSION CONTROL SYSTEM C15 Air Fuel Ratio Sensor (Bank 1 Sensor 1) A/F 86 C55 HA1A A/F 2 4 +B A1A- HA1A A1A+ 1 ECM (*1) 3 93 C55 A1A+ 116 C55 A1A- C35 Air Fuel Ratio Sensor (Bank 2 Sensor 1) 2 4 +B A2A- HA2A A2A+ 1 109 C55 HA2A (*1) 3 120 C55 A2A+ 119 C55 A2A- C52 Heated Oxgen Sensor (Bank 1 Sensor 2) EC 2 3 +B E2 OX1B HT1B 65 C55 EX1B 4 1 48 C55 HT1B (*1) 88 C55 OX1B C51 Heated Oxgen Sensor (Bank 2 Sensor 2) 2 3 +B OX2B E2 HT2B 64 C55 EX2B 4 1 47 C55 HT2B (*1) 87 C55 OX2B *1 : Shielded A135721E02 EC–5 2GR-FE EMISSION CONTROL – EMISSION CONTROL SYSTEM C6 VSV (Purge) 1 108 C55 PRG 2 N17 Canister Pump Module Vent Valve VGND VLVB 1 9 VCC Canister Pressure Sensor 4 VOUT 3 SGND 2 MGND 6 MTRB Leak Detection Pump 8 34 A55 MPMP 75 C55 VCPP 77 C55 PPMP 76 C55 EPPM 42 A55 VPMP EC EFI EFI MAIN EFI No. 3 From Battery FL MAIN 44 A55 MREL Battery A135722E01 EC–6 2GR-FE EMISSION CONTROL – EMISSION CONTROL SYSTEM ON-VEHICLE INSPECTION 1. INSPECT FUEL CUT-OFF RPM (a) Increase the engine speed to at least 3,500 rpm. (b) Use a sound scope to check for injector operating sounds. (c) Check that when the throttle lever is released, injector operating sounds stop momentarily (at 2,500 rpm) and then resume (at 1,400 rpm). Standard Item Specified Condition Fuel cut off rpm 2,500 rpm Fuel return rpm 1,400 rpm 2. CHECK AIR TIGHTNESS IN FUEL TANK AND FILLER PIPE (a) Disconnect the vent line hose from the fuel tank. (b) Connect the pressure gauge to the fuel tank. (c) Apply pressure to the fuel tank to create an internal pressure of 4 kPa (41 gf/cm2, 0.58 psi). (d) Check that the internal pressure of the fuel tank is maintained for 1 minute. (e) Check the connected portions of each hose and pipe. (f) Check the installed parts on the fuel tank. If any malfunctions, damage or other problems are found, replace the fuel tank and filler pipe. (g) Reconnect the vent line hose to the fuel tank. 3. INSPECT FUEL CUT OFF VALVE AND FUEL CHECK VALVE (a) Disconnect the vent line hose from the fuel tank. (b) Connect the pressure gauge to the fuel tank. (c) Fill the fuel tank with fuel. (d) Apply pressure of 4 kPa (41 gf/cm2, 0.58 psi) to the vent port of the fuel tank. HINT: Check the amount of fuel in the fuel tank. When the fuel tank is full, the float valve of the fill check valve is closed and no air can pass through. (e) Remove the fuel tank cap, and check that the pressure drops. If the pressure does not drop, replace the fuel tank assembly. (f) Reconnect the vent line hose to the fuel tank. EC A128092 Fuel Tank Cap A126204E01 2GR-FE EMISSION CONTROL – EMISSION CONTROL SYSTEM EC–7 4. CHECK AIR INLET LINE (a) Disconnect the air inlet line hose from the charcoal canister. (b) Check that air can flow freely into the air inlet line. If air cannot flow freely into the air inlet line, repair or replace it. (c) Reconnect the air inlet line hose to the charcoal canister. 5. VISUALLY INSPECT HOSES, CONNECTIONS AND GASKETS (a) Check for cracks, leaks or damage. HINT: Removal or problems with the engine oil dipstick, oil filler cap, PCV hose and other components may cause the engine to run improperly. Disconnection, looseness or cracks in the parts of the air induction system between the throttle body and cylinder head will allow air suction and cause the engine to run improperly. If necessary, replace any damaged parts. Air Inlet Hose Air A128093E02 A094394 EC EC–8 2GR-FE EMISSION CONTROL – CANISTER CANISTER 2GR-FE EMISSION CONTROL ENGINE COMPONENTS EC CHARCOAL CANISTER ASSEMBLY 39 (398, 29) N*m (kgf*cm, ft.*lbf) : Specified torque A135648E04 2GR-FE EMISSION CONTROL – CANISTER EC–9 REMOVAL 1. REMOVE FUEL TANK ASSEMBLY HINT: (See page FU-36) 2. REMOVE CHARCOAL CANISTER ASSEMBLY (a) Disconnect the fuel tank vent hose from the charcoal canister. (1) Push the connector deep inside. (2) Pinch portion A. (3) Pull out the connector. Pinch A A Pinch A Push A A132954E01 (b) Disconnect the charcoal canister filter sub-assembly from the charcoal canister. (1) Push the connector deep inside. (2) Pinch portion A. (3) Pull out the connector. (c) Disconnect the vapor pressure sensor connector. (d) Disconnect the wire harness clamp. (e) Disconnect the purge line hose from the charcoal canister. A Pinch A Pinch Push EC A128095E01 (f) Remove the 2 bolts, clip and charcoal canister. A128096 INSPECTION 1. A128097 INSPECT CHARCOAL CANISTER ASSEMBLY (a) Visually check the charcoal canister for cracks or damage. If cracks or damage are found, replace the charcoal canister assembly. EC–10 2GR-FE EMISSION CONTROL – CANISTER (b) Check charcoal canister operation. (1) With the purge port closed, blow 1.67 kPa (17.0 gf/cm2, 0.24 psi) of air into the vent port, and check that air flows from the air inlet port. If the result is not as specified, replace the charcoal canister assembly. Purge Port Air Vent Port Air Inlet Port A128098E01 Air Inlet Port Purge Port Air (2) With the vent port closed, blow 1.10 kPa (11.2 gf/cm2, 0.16 psi) of air to the air inlet port, and check that air flows from the purge port. If the result is not as specified, replace the charcoal canister assembly. Vent Port A128099E02 EC Port B Purge Port Air Inlet Port Port A (c) Check for air leakage. (1) Remove the air hose between ports A and B. (2) Connect the SST (pressure gauge) to the vent port of the charcoal canister. SST 09992-00242 (3) While holding port B, with the purge port and the air inlet port closed and port A open, apply 19.6 kPa (0.2 kgf/cm2, 2.81 psi) of pressurized air into the vent port, then confirm that pressure is retained for 1 minute. If the result is not as specified, replace the charcoal canister assembly. Vent Port SST Pressure Gauge A128100E02 (d) Check the leak detection pump. (1) Remove the detection pump from the charcoal canister. (2) Check that air flows from port A to B and then C. If the result is not as specified, replace the charcoal canister assembly. C A Air B A128108E01 2GR-FE EMISSION CONTROL – CANISTER Valve 7 EC–11 (3) Connect the positive (+) lead to terminal 7 and the negative (-) lead to terminal 6. (4) Check that the valve is closed. If the result is not as specified, replace the charcoal canister assembly. (5) Install the detection pump. Closed 6 A128109E01 INSTALLATION A128096 1. INSTALL CHARCOAL CANISTER ASSEMBLY (a) Install the 2 bolts, clip and charcoal canister. Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf) (b) Connect the purge line hose to the charcoal canister. (c) Connect the wire harness clamp. (d) Connect the vapor pressure sensor connector. (e) Connect the charcoal canister filter sub-assembly to the charcoal canister. (f) Connect the fuel tank vent hose to the charcoal canister. 2. INSTALL FUEL TANK ASSEMBLY HINT: (See page FU-41) EC EC–12 2GR-FE EMISSION CONTROL – VACUUM SWITCHING VALVE (for EVAP) VACUUM SWITCHING VALVE (for EVAP) 2GR-FE EMISSION CONTROL ENGINE COMPONENTS V-BANK COVER SUB-ASSEMBLY VACUUM HOSE 5.0 (51, 44 in.*lbf) VACUUM HOSE EC NO. 1 VACUUM SWITCHING VALVE N*m (kgf*cm, ft.*lbf) : Specified torque A135653E03 2GR-FE EMISSION CONTROL – VACUUM SWITCHING VALVE (for EVAP) EC–13 REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY (See page EM-23) 2. REMOVE NO. 1 VACUUM SWITCHING VALVE (a) Disconnect the 2 vacuum hoses and No. 1 vacuum switching valve connector. A132952E01 (b) Remove the bolt and No. 1 vacuum switching valve. A132953 EC INSPECTION 1. 2 1 INSPECT EVAP VSV (a) Check the VSV for an open circuit. (1) Measure the resistance. Standard resistance Tester Connection Specified Condition 1-2 23 to 26Ω at 20°C (68°F) 1 - Body ground 2 - Body ground 10 kΩ or higher If the resistance is not as specified, replace the VSV assembly. 2 1 A128939E02 EC–14 2GR-FE EMISSION CONTROL – VACUUM SWITCHING VALVE (for EVAP) (b) Check VSV operation. (1) Check that air does not flow from the port as shown in the illustration. F E Air A128937E01 F (2) Apply battery positive voltage across the terminals. (3) Check that air flows from the ports. If the result is not as specified, replace the VSV assembly. E Air A128938E01 INSTALLATION 1. EC INSTALL NO. 1 VACUUM SWITCHING VALVE (a) Install the No. 1 vacuum switching valve with the bolt. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) A132953 (b) Disconnect the 2 vacuum hoses and No. 1 vacuum switching valve connector. 2. A132952E01 INSTALL V-BANK COVER SUB-ASSEMBLY (See page EM-52) 2GR-FE EMISSION CONTROL – VENTILATION VALVE EC–15 VENTILATION VALVE 2GR-FE EMISSION CONTROL ENGINE COMPONENTS V-BANK COVER SUB-ASSEMBLY 27(275, 20) VENTILATION HOSE VENTILATION VALVE EC N*m (kgf*cm, ft.*lbf) : Specified torque Precoated part A135651E03 EC–16 2GR-FE EMISSION CONTROL – VENTILATION VALVE REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY (See page EM-23) 2. DISCONNECT VENTILATION HOSE (a) Disconnect the ventilation hose from the ventilation valve. 3. REMOVE VENTILATION VALVE (a) Remove the ventilation valve. A135715E01 A138519E01 EC INSPECTION 1. Cylinder Head Side Clean Hose Air A113429E01 INSPECT VENTILATION VALVE (a) Install a clean hose to the ventilation valve. (b) Check the ventilation valve operation. (1) Blow air into the cylinder head side, and check that air passes through easily. NOTICE: Do not suck air through the valve. Petroleum substances inside the valve are hazardous to your health. (2) Blow air into the intake manifold side, and check that air passes through with difficulty. If the result is not as specified, replace the ventilation valve. (c) Remove the clean hose from the ventilation valve. Intake Manifold Side Air Clean Hose A105281E01 2GR-FE EMISSION CONTROL – VENTILATION VALVE EC–17 INSTALLATION Adhesive 1. INSTALL VENTILATION VALVE (a) Install the ventilation valve. (1) Apply adhesive to 2 or 3 threads. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent. A105280E01 (2) Install the ventilation valve. Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) A138519E01 A135715E01 2. CONNECT VENTILATION HOSE (a) Connect the ventilation hose to the ventilation valve. 3. INSTALL V-BANK COVER SUB-ASSEMBLY (See page EM-52) EC EC–18 2GR-FE EMISSION CONTROL – AIR FUEL RATIO SENSOR AIR FUEL RATIO SENSOR 2GR-FE EMISSION CONTROL ENGINE COMPONENTS AIR FUEL RATIO SENSOR 44 (449, 33) 44 (449, 33) AIR FUEL RATIO SENSOR EC N*m (kgf*cm, ft.*lbf) : Specified torque A135655E03 EC–19 2GR-FE EMISSION CONTROL – AIR FUEL RATIO SENSOR REMOVAL Bank 1: 1. Bank 2: REMOVE AIR FUEL RATIO SENSOR (a) Disconnect the 2 air fuel ratio sensor connectors. (b) Using SST, remove the 2 air fuel ratio sensors from the front pipe assembly. SST 09224-00010 SST A128101E02 +B INSPECTION HT 1. AF- AF+ Specified Condition 1.8 to 3.4 Ω INSTALLATION Fulcrum Length 1. SST Bank 2: Condition 20 °C (68°F) If the result is not as specified, replace the sensor. A075325E04 Bank 1: INSPECT AIR FUEL RATIO SENSOR (a) Measure the resistance between terminals 1 (HT) and 2 (+B). Standard resistance Fulcrum Length SST A128102E03 INSTALL AIR FUEL RATIO SENSOR (a) Using SST, install the 2 air fuel ratio sensors to the front pipe assembly. SST 09224-00010 Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf) (b) Connect the 2 air fuel ratio sensor connectors. EC EC–20 2GR-FE EMISSION CONTROL – HEATED OXYGEN SENSOR HEATED OXYGEN SENSOR 2GR-FE EMISSION CONTROL ENGINE COMPONENTS FRONT EXHAUST PIPE ASSEMBLY GASKET 56 (571, 41) HEATED OXYGEN SENSOR (BANK 1 SENSOR 2) GASKET 56 (571, 41) 62 (632, 46) GASKET 62 (632, 46) 33 (337, 24) 44 (449, 32) EC REAR EXHAUST PIPE NO. 1 SUPPORT BRACKET 44 (449, 32) FRONT EXHAUST PIPE NO. 1 SUPPORT BRACKET HEATED OXYGEN SENSOR (BANK 2 SENSOR 2) 33 (337, 24) FRONT EXHAUST PIPE SUPPORT BRACKET ENGINE UNDER COVER RH N*m (kgf*cm, ft.*lbf) : Specified torque ENGINE UNDER COVER LH Non-reusable part A135657E03 EC–21 2GR-FE EMISSION CONTROL – HEATED OXYGEN SENSOR REMOVAL 1. REMOVE ENGINE UNDER COVER LH 2. REMOVE ENGINE UNDER COVER RH 3. REMOVE FRONT EXHAUST PIPE ASSEMBLY (See page EX-2) 4. REMOVE HEATED OXYGEN SENSOR (for Bank 1) (a) Using SST, remove the oxygen sensor. SST 09224-00010 5. REMOVE HEATED OXYGEN SENSOR (for Bank 2) (a) Using SST, remove the oxygen sensor. SST 09224-00010 SST A135716E01 SST EC A135724E01 INSPECTION HT +B E1 2 1 4 3 1. OX INSPECT HEATED OXYGEN SENSOR (a) Measure the resistance between terminals 1 (HT) and 2 (+B). Standard resistance Condition Specified Condition 20°C (68°F) 11 to 16 Ω If the result is not as specified, replace the sensor. A091027E03 INSTALLATION 1. SST A135725E01 INSTALL HEATED OXYGEN SENSOR (for Bank 2) (a) Using SST, install the heated oxygen sensor. SST 09224-00010 Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf) EC–22 2GR-FE EMISSION CONTROL – HEATED OXYGEN SENSOR 2. INSTALL HEATED OXYGEN SENSOR (for Bank 1) (a) Using SST, install the heated oxygen sensor. SST 09224-00010 3. INSTALL FRONT EXHAUST PIPE ASSEMBLY (See page EX-4) 4. INSTALL ENGINE UNDER COVER LH 5. INSTALL ENGINE UNDER COVER RH SST A135717E01 EC 2GR-FE EMISSION CONTROL – FUEL TANK CAP EC–23 FUEL TANK CAP INSPECTION 1. REMOVE FUEL TANK CAP ASSEMBLY (a) Visually check if the cap and gasket are deformed or damaged. If necessary, replace the cap. A126203 EC INTERIOR – REAR SUNSHADE ASSEMBLY IR–1 REAR SUNSHADE ASSEMBLY INTERIOR BODY COMPONENTS REAR SEAT HEADREST ASSEMBLY IR 18 (184, 13) REAR CENTER SEAT HEADREST ASSEMBLY CENTER SEAT BACK ASSEMBLY REAR SEAT BACK COVER 18 (184, 13) 18 (184, 13) 18 (184, 13) SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH REAR SEAT BACK COVER 18 (184, 13) SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH REAR SEAT CUSHION ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B139095E02 IR–2 INTERIOR – REAR SUNSHADE ASSEMBLY ROOF SIDE INNER GARNISH RH REAR DOOR OPENING TRIM WEATHERSTRIP RH IR 18 (184, 13) RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY RH REAR DOOR SCUFF PLATE RH ROOF SIDE INNER GARNISH LH REAR DOOR OPENING TRIM WEATHERSTRIP LH 18 (184, 13) RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY LH REAR DOOR SCUFF PLATE LH N*m (kgf*cm, ft.*lbf) : Specified torque B132018E06 INTERIOR – REAR SUNSHADE ASSEMBLY IR–3 PACKAGE TRAY TRIM PANEL ASSEMBLY REAR SEAT SHOULDER BELT COVER REAR SEAT SHOULDER BELT HOLE COVER IR REAR SEAT OUTER BELT ASSEMBLY for TMC made: REAR SEAT SHOULDER BELT COVER 18 (184, 13) 42 (428, 31) 42 (428, 31) REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH for TMMK made: 42 (428, 31) REAR SEAT OUTER BELT ASSEMBLY REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque B142736E01 IR–4 INTERIOR – REAR SUNSHADE ASSEMBLY CURTAIN RAIL END CAP RH CURTAIN RAIL END CAP LH IR REAR WINDOW SHADE ASSEMBLY B132127E01 INTERIOR – REAR SUNSHADE ASSEMBLY IR–5 REMOVAL 1. REMOVE REAR SEAT CUSHION ASSEMBLY (See page SE-62) 2. REMOVE REAR SEAT HEADREST ASSEMBLY 3. REMOVE REAR CENTER SEAT HEADREST ASSEMBLY 4. REMOVE REAR SEAT BACK COVER (See page SE63) 5. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (See page SE-63) 6. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (See page SE-64) 7. REMOVE CENTER SEAT BACK ASSEMBLY (See page SE-64) 8. REMOVE REAR DOOR SCUFF PLATE LH (See page IR-24) 9. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH 10. REMOVE REAR DOOR SCUFF PLATE RH (See page IR-24) 11. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH 12. REMOVE RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY LH (See page SE-68) 13. REMOVE RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY RH HINT: Use the same procedures for the RH side and the LH side. 14. REMOVE CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH (See page SB-66) 15. DISCONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH (for TMC Made) (See page SB35) 16. DISCONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH (for TMMK Made) (See page SB-35) 17. REMOVE ROOF SIDE INNER GARNISH LH (See page IR-26) 18. REMOVE ROOF SIDE INNER GARNISH RH (See page IR-26) 19. DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) (See page SB-36) 20. DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) (See page SB-36) IR IR–6 INTERIOR – REAR SUNSHADE ASSEMBLY 21. REMOVE REAR SEAT SHOULDER BELT COVER (See page SB-36) 22. REMOVE REAR SEAT SHOULDER BELT HOLE COVER (See page SB-36) 23. REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY (See page SB-37) 24. REMOVE CURTAIN RAIL END CAP LH (a) Disengage the 2 claws and remove the curtain rail end cap LH. 25. REMOVE CURTAIN RAIL END CAP RH HINT: Use the same procedures for the RH side and the LH side. IR B132125 26. REMOVE REAR WINDOW SHADE ASSEMBLY (a) Remove the rear window shade assembly as shown in the illustration. B132126 INTERIOR – REAR SUNSHADE ASSEMBLY IR–7 INSTALLATION 1. INSTALL REAR WINDOW SHADE ASSEMBLY (a) Install the rear window shade assembly as shown in the illustration. IR B132128 B132125 2. INSTALL CURTAIN RAIL END CAP LH (a) Engage the 2 claws and install the curtain rail end cap LH. 3. INSTALL CURTAIN RAIL END CAP RH HINT: Use the same procedures for the RH side and the LH side. 4. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY (See page SB-39) 5. INSTALL REAR SEAT SHOULDER BELT HOLE COVER (See page SB-39) 6. INSTALL REAR SEAT SHOULDER BELT COVER (See page SB-39) 7. CONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side) (See page SB-39) 8. CONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side) (See page SB-40) 9. INSTALL ROOF SIDE INNER GARNISH LH (See page IR-52) 10. INSTALL ROOF SIDE INNER GARNISH RH (See page IR-52) 11. CONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH (for TMC Made) (See page SB-40) 12. CONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH (for TMMK Made) (See page SB-40) 13. INSTALL CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH (See page SB-66) IR–8 INTERIOR – REAR SUNSHADE ASSEMBLY 14. INSTALL RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY LH (See page SE-69) 15. INSTALL RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY RH HINT: Use the same procedures for the RH side and the LH side. 16. CONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH (See page IR-55) 17. INSTALL REAR DOOR SCUFF PLATE LH (See page IR-56) 18. CONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH (See page IR-56) IR 19. INSTALL REAR DOOR SCUFF PLATE RH (See page IR-56) 20. INSTALL CENTER SEAT BACK ASSEMBLY (See page SE-71) 21. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (See page SE-72) 22. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (See page SE-71) 23. INSTALL REAR SEAT BACK COVER 24. INSTALL REAR CENTER SEAT HEADREST ASSEMBLY 25. INSTALL REAR SEAT HEADREST ASSEMBLY 26. INSTALL REAR SEAT CUSHION ASSEMBLY (See page SE-73) IR–9 INTERIOR – ROOF HEADLINING ROOF HEADLINING INTERIOR BODY COMPONENTS for Manual Seat: FRONT SEAT HEADREST ASSEMBLY SEAT TRACK COVER RH IR 37 (377, 27) INNER SEAT TRACK BRACKET COVER RH 37 (377, 27) FRONT SEAT ASSEMBLY RH FRONT SEAT HEADREST ASSEMBLY INNER SEAT TRACK BRACKET COVER LH SEAT TRACK COVER LH 37 (377, 27) 37 (377, 27) FRONT SEAT ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque B132048E01 IR–10 INTERIOR – ROOF HEADLINING for Power Seat: FRONT SEAT HEADREST ASSEMBLY SEAT TRACK COVER RH INNER SEAT TRACK BRACKET COVER LH 37 (377, 27) IR 37 (377, 27) FRONT SEAT ASSEMBLY RH FRONT SEAT HEADREST ASSEMBLY INNER SEAT TRACK BRACKET COVER RH 37 (377, 27) SEAT TRACK COVER LH 37 (377, 27) FRONT SEAT ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque B132047E01 IR–11 INTERIOR – ROOF HEADLINING for Fixed Seat Type: REAR SEAT HEADREST ASSEMBLY REAR CENTER SEAT HEADREST ASSEMBLY IR REAR SEAT BACK ASSEMBLY 18 (184, 13) 18 (184, 13) REAR SEAT CUSHION ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B136589E02 IR–12 INTERIOR – ROOF HEADLINING for Fold Down Seat Type: REAR SEAT HEADREST ASSEMBLY REAR CENTER SEAT HEADREST ASSEMBLY 18 (184, 13) IR 18 (184, 13) 18 (184, 13) REAR SIDE SEAT BACK ASSEMBLY RH SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH 18 (184, 13) REAR SEAT CUSHION ASSEMBLY REAR SIDE SEAT BACK ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque B136564E02 IR–13 INTERIOR – ROOF HEADLINING for Reclining Seat Type: REAR SEAT HEADREST ASSEMBLY REAR CENTER SEAT HEADREST ASSEMBLY 18 (184, 13) SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH REAR SEAT BACK COVER CENTER SEAT BACK ASSEMBLY 18 (184, 13) 18 (184, 13) 18 (184, 13) REAR SEAT BACK COVER RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY RH 18 (184, 13) SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH 18 (184, 13) REAR SEAT CUSHION ASSEMBLY RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque B139577E01 IR IR–14 INTERIOR – ROOF HEADLINING NO. 1 DOOR SCUFF PLATE CLAMP IR REAR DOOR INNER GLASS WEATHERSTRIP LH REAR DOOR INSIDE HANDLE BEZEL PLUG LH DOOR ASSIST GRIP COVER LH REAR DOOR TRIM BOARD SUB-ASSEMBLY LH B139576E01 IR–15 INTERIOR – ROOF HEADLINING FRONT DOOR OPENING TRIM WEATHERSTRIP RH FRONT PILLAR GARNISH RH FRONT PILLAR GARNISH CLIP UPPER CENTER PILLAR GARNISH RH IR ROOF SIDE INNER GARNISH RH REAR DOOR OPENING TRIM WEATHERSTRIP RH REAR DOOR SCUFF PLATE RH FRONT SEAT OUTER BELT ASSEMBLY RH COWL SIDE TRIM CLIP FRONT DOOR SCUFF PLATE RH 42 (428, 31) LAP BELT OUTER ANCHOR COVER LOWER CENTER PILLAR GARNISH RH COWL SIDE TRIM SUB-ASSEMBLY RH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part B132050E01 IR–16 INTERIOR – ROOF HEADLINING UPPER CENTER PILLAR GARNISH LH FRONT PILLAR GARNISH LH FRONT PILLAR GARNISH CLIP REAR DOOR OPENING TRIM WEATHERSTRIP LH FRONT DOOR OPENING TRIM WEATHERSTRIP LH IR ROOF SIDE INNER GARNISH LH 42 (428, 31) LAP BELT OUTER ANCHOR COVER REAR DOOR SCUFF PLATE LH LOWER CENTER PILLAR GARNISH LH COWL SIDE TRIM CLIP FRONT SEAT OUTER BELT ASSEMBLY LH FRONT DOOR SCUFF PLATE LH COWL SIDE TRIM SUB-ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part B132049E01 IR–17 INTERIOR – ROOF HEADLINING without Sliding Roof: REAR ASSIST GRIP SUB-ASSEMBLY FRONT ASSIST GRIP SUB-ASSEMBLY ASSIST GRIP COVER ASSIST GRIP COVER IR ROOF HEADLINING ASSEMBLY REAR ASSIST GRIP SUB-ASSEMBLY NO. 1 ROOM LIGHT ASSEMBLY LENS COVER VISOR BRACKET COVER FRONT ASSIST GRIP SUB-ASSEMBLY ASSIST GRIP COVER VISOR ASSEMBLY RH VISOR HOLDER ASSIST GRIP COVER ROOF CONSOLE BOX ASSEMBLY VISOR ASSEMBLY LH VISOR HOLDER VISOR BRACKET COVER B132051E01 IR–18 INTERIOR – ROOF HEADLINING with Sliding Roof: FRONT ASSIST GRIP SUB-ASSEMBLY REAR ASSIST GRIP SUB-ASSEMBLY ASSIST GRIP COVER ASSIST GRIP COVER IR ROOF HEADLINING ASSEMBLY with Rear Sunshade: SUNSHADE TRIM HOLDER SPOT LIGHT ASSEMBLY VISOR BRACKET COVER REAR ASSIST GRIP SUB-ASSEMBLY VISOR ASSEMBLY RH ASSIST GRIP COVER ROOF CONSOLE BOX ASSEMBLY FRONT ASSIST GRIP SUB-ASSEMBLY ASSIST GRIP COVER VISOR HOLDER VISOR ASSEMBLY LH VISOR HOLDER VISOR BRACKET COVER SUN ROOF OPENING TRIM MOULDING B132052E01 IR–19 INTERIOR – ROOF HEADLINING without Sliding Roof: NO. 4 ROOF SILENCER PAD NO. 2 ROOF SILENCER PAD ROOF SIDE RAIL SILENCER PAD RH ROOF SIDE RAIL SILENCER PAD LH NO. 3 REAR SIDE RAIL SPACER RH NO. 2 REAR SIDE RAIL SPACER RH NO. 3 REAR SIDE RAIL SPACER LH NO. 2 REAR SIDE RAIL SPACER LH IR ROOF HEADLINING ASSEMBLY RIVET RADIO SETTING CONDENSER with Sliding Roof: FASTENER HOOK NO. 2 REAR SIDE RAIL SPACER RH NO. 2 REAR SIDE RAIL SPACER LH ROOF HEADLINING ASSEMBLY RIVET RADIO SETTING CONDENSER VANITY LIGHT ASSEMBLY Non-reusable part B132053E01 IR–20 INTERIOR – ROOF HEADLINING without Sliding Roof: for TMC made: ANTENNA CORD SUB-ASSEMBLY NO. 1 ROOF WIRE IR for TMMK made: ANTENNA CORD SUB-ASSEMBLY NO. 1 ROOF WIRE DOUBLE-SIDED TAPE ADHESIVE TAPE B132131E01 IR–21 INTERIOR – ROOF HEADLINING with Sliding Roof: for TMC made: NO. 1 ROOF WIRE ANTENNA CORD SUB-ASSEMBLY IR for TMMK made: NO. 1 ROOF WIRE ANTENNA CORD SUB-ASSEMBLY DOUBLE-SIDED TAPE ADHESIVE TAPE B132130E01 IR–22 INTERIOR – ROOF HEADLINING REMOVAL IR 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (for Manual Seat) CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment (See page RS-1). 2. REMOVE FRONT SEAT HEADREST ASSEMBLY (for Manual Seat) 3. REMOVE SEAT TRACK COVER LH (for Manual Seat) (See page SE-16) 4. REMOVE INNER SEAT TRACK BRACKET COVER LH (for Manual Seat) (See page SE-16) 5. REMOVE FRONT SEAT ASSEMBLY LH (for Manual Seat) (See page SE-16) 6. REMOVE FRONT SEAT HEADREST ASSEMBLY (for Power Seat) 7. REMOVE SEAT TRACK COVER LH (for Power Seat) (See page SE-30) 8. REMOVE INNER SEAT TRACK BRACKET COVER RH (for Power Seat) (See page SE-30) 9. REMOVE FRONT SEAT ASSEMBLY LH (for Power Seat) (See page SE-30) 10. REMOVE FRONT SEAT HEADREST ASSEMBLY (for Manual Seat) 11. REMOVE SEAT TRACK COVER RH (for Manual Seat) HINT: Use the same procedures for the RH side and the LH side. 12. REMOVE INNER SEAT TRACK BRACKET COVER RH (for Manual Seat) HINT: Use the same procedures for the RH side and the LH side. 13. REMOVE FRONT SEAT ASSEMBLY RH (for Manual Seat) HINT: Use the same procedures for the RH side and the LH side. 14. REMOVE FRONT SEAT HEADREST ASSEMBLY (for Power Seat) 15. REMOVE SEAT TRACK COVER RH (for Power Seat) HINT: Use the same procedures for the RH side and the LH side. INTERIOR – ROOF HEADLINING IR–23 16. REMOVE INNER SEAT TRACK BRACKET COVER LH (for Power Seat) HINT: Use the same procedures for the RH side and the LH side. 17. REMOVE FRONT SEAT ASSEMBLY RH (for Power Seat) HINT: Use the same procedures for the RH side and the LH side. 18. REMOVE REAR SEAT CUSHION ASSEMBLY (See page SE-77) 19. REMOVE REAR SEAT HEADREST ASSEMBLY 20. REMOVE REAR CENTER SEAT HEADREST ASSEMBLY 21. REMOVE REAR SEAT BACK ASSEMBLY (for Fixed Seat Type) (See page SE-77) 22. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-47) 23. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) (See page SE-47) 24. REMOVE REAR SIDE SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-48) 25. REMOVE REAR SIDE SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) (See page SE-48) 26. REMOVE REAR SEAT BACK COVER (for Reclining Seat Type) (See page SE-63) 27. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Reclining Seat Type) (See page SE-63) 28. REMOVE SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Reclining Seat Type) (See page SE-64) 29. REMOVE CENTER SEAT BACK ASSEMBLY (for Reclining Seat Type) (See page SE-64) IR IR–24 INTERIOR – ROOF HEADLINING 30. REMOVE REAR DOOR SCUFF PLATE LH (a) Disengage the 5 claws and 2 clips, and remove the rear door scuff plate LH. 31. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH 32. REMOVE REAR DOOR SCUFF PLATE RH HINT: Use the same procedures for the RH side and the LH side. 33. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH B132068 IR 34. REMOVE RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY LH (for Reclining Seat Type) (See page SE-68) 35. REMOVE RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY RH (for Reclining Seat Type) HINT: Use the same procedures for the RH side and the LH side. 36. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG LH (See page ED-38) 37. REMOVE DOOR ASSIST GRIP COVER LH (See page ED-38) 38. REMOVE REAR DOOR TRIM BOARD SUBASSEMBLY LH (See page ED-39) 39. REMOVE REAR DOOR INNER GLASS WEATHERSTRIP LH (See page ED-40) 40. REMOVE FRONT DOOR SCUFF PLATE LH (a) Disengage the 7 claws and 3 clips, and remove the front door scuff plate LH. B132067 INTERIOR – ROOF HEADLINING IR–25 41. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH (a) Remove the cowl side trim clip. (b) Disengage the 2 clips and remove the cowl side trim sub-assembly LH. Cowl Side Trim Clip 42. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH B132116E01 43. REMOVE LAP BELT OUTER ANCHOR COVER (for LH Side) (a) Disengage the 3 claws and remove the lap belt outer anchor cover. IR B131995 44. DISCONNECT FRONT SEAT OUTER BELT ASSEMBLY LH (a) Remove the bolt and disconnect the floor end of the front seat outer belt assembly. B131996 45. REMOVE LOWER CENTER PILLAR GARNISH LH (a) Disengage the 2 claws and 2 clips, and remove the lower center pillar garnish LH. B132057 IR–26 INTERIOR – ROOF HEADLINING 46. REMOVE UPPER CENTER PILLAR GARNISH LH (a) Remove the bolt. (b) Disengage the clip and remove the upper center pillar garnish LH. 47. REMOVE FRONT DOOR SCUFF PLATE RH HINT: Use the same procedures for the RH side and the LH side. B132059 48. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH HINT: Use the same procedures for the RH side and the LH side. 49. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH 50. REMOVE LAP BELT OUTER ANCHOR COVER (for RH Side) HINT: Use the same procedures for the RH side and the LH side. IR 51. DISCONNECT FRONT SEAT OUTER BELT ASSEMBLY RH HINT: Use the same procedures for the RH side and the LH side. 52. REMOVE LOWER CENTER PILLAR GARNISH RH HINT: Use the same procedures for the RH side and the LH side. 53. REMOVE UPPER CENTER PILLAR GARNISH RH HINT: Use the same procedures for the RH side and the LH side. 54. REMOVE ROOF SIDE INNER GARNISH LH (a) Disengage the 5 clips and 2 claws, and remove the roof side inner garnish LH. 55. REMOVE ROOF SIDE INNER GARNISH RH HINT: Use the same procedures for the RH side and the LH side. B132063 INTERIOR – ROOF HEADLINING IR–27 56. REMOVE FRONT PILLAR GARNISH LH (a) Pull the upper part of the garnish toward the inside of the cabin and disengage the 2 clips. (b) Cut off the clip . (c) Disengage the 2 claws and remove the front pillar garnish LH. (d) Remove the clip from the vehicle body. Cut B132056E01 120 mm (4.72 in.) 700 mm (27.56 in.) Adhesive Tape (e) Protect the curtain shield airbag assembly. (1) Cover the airbag with a 700 mm (27.56 in.) x 120 mm (4.72 in.) cloth or piece of nylon and fix the ends of the cover with tape, as shown in the illustration. NOTICE: Cover the curtain shield airbag with a protective cover as soon as the front pillar garnish is removed. Protective Cover Curtain Shield Airbag Assembly B132100E01 Cut 57. REMOVE FRONT PILLAR GARNISH RH (a) Pull the upper part of the garnish toward the inside of the cabin and disengage the 2 clips. (b) Cut off the clip . (c) Disengage the 2 claws and remove the front pillar garnish RH. (d) Remove the clip from the vehicle body. B132055E01 IR IR–28 INTERIOR – ROOF HEADLINING 120 mm (4.72 in.) 700 mm (27.56 in.) Adhesive Tape (e) Protect the curtain shield airbag assembly. (1) Cover the airbag with a 700 mm (27.56 in.) x 120 mm (4.72 in.) cloth or piece of nylon and fix the ends of the cover with tape, as shown in the illustration. NOTICE: Cover the curtain shield airbag with a protective cover as soon as the front pillar garnish is removed. Protective Cover IR Curtain Shield Airbag Assembly B132099E01 58. REMOVE ROOF CONSOLE BOX ASSEMBLY (a) Using a moulding remover, disengage the 2 clips and 2 claws. (b) Disconnect the connectors and remove the roof console box assembly. B132064 59. REMOVE VISOR ASSEMBLY LH (a) Using a moulding remover, disengage the 4 claws and remove the visor bracket cover. B132069 INTERIOR – ROOF HEADLINING IR–29 (b) Disengage the 2 clips and remove the visor assembly LH. 60. REMOVE VISOR ASSEMBLY RH HINT: Use the same procedures for the RH side and the LH side. B132070 61. REMOVE VISOR HOLDER (a) Turn the visor holder approximately 45° and pull it out as shown in the illustration. (b) Disengage the 2 claws and remove the visor holder. 45° IR B132066E01 HINT: Use the same procedures for the RH side and the LH side. 62. REMOVE FRONT ASSIST GRIP SUB-ASSEMBLY (a) Using a screwdriver, disengage the 6 claws and remove the 2 assist grip covers. HINT: Tape the screwdriver tip before use. Protective Tape B132061E01 (b) Disengage the 2 clips and remove the front assist grip sub-assembly. HINT: Use the same procedures for the RH side and the LH side. 63. REMOVE REAR ASSIST GRIP SUB-ASSEMBLY HINT: Use the same procedures for the rear side and the front side. B132062 IR–30 INTERIOR – ROOF HEADLINING 64. REMOVE NO. 1 ROOM LIGHT ASSEMBLY (w/o Sliding Roof) (a) Using a screwdriver, disengage the 4 claws and remove the lens cover. HINT: Tape the screwdriver tip before use. Protective Tape B132140E02 (b) Using a screwdriver, disengage the 2 claws as shown in the illustration. HINT: Tape the screwdriver tip before use. (c) Disengage the 2 claws and remove the No. 1 room light assembly. (d) Disconnect the room light connector. Claw IR Claw Protective Tape Claw Claw Protective Tape B132142E01 A C B C B132093E01 65. REMOVE SPOT LIGHT ASSEMBLY (w/ Sliding Roof) (a) Using a screwdriver, disengage the 2 claws labeled A and 2 claws labeled B from the vehicle body. HINT: Tape the screwdriver tip before use. (b) Using a screwdriver, disengage the 2 claws labeled C and remove the spot light assembly from the headlining. HINT: Tape the screwdriver tip before use. INTERIOR – ROOF HEADLINING IR–31 (c) Using a screwdriver, disengage the 4 claws. HINT: Tape the screwdriver tip before use. (d) Pull the light bulb holder in the direction indicated by the arrow in the illustration to detach the claw. Then remove the spot light assembly from the light bulb holder. Protective Tape Light Bulb Holder 66. REMOVE SUN ROOF OPENING TRIM MOULDING (w/ Sliding Roof) (a) Remove the sun roof opening trim moulding. IR B132095E01 67. REMOVE SUNSHADE TRIM HOLDER (w/ Rear Sunshade) (a) Using a screwdriver, turn the pin of each sunshade trim holder 90°. B132091 (b) Disengage the 2 claws and remove the sunshade trim holder. B132143 68. REMOVE ROOF HEADLINING ASSEMBLY (w/o Sliding Roof) (a) Disconnect the No. 1 roof wire connector and disengage each clamp from the front pillar LH. (b) Remove the bolt and disconnect the radio setting condenser from the front pillar RH. (c) Disconnect the antenna cord sub-assembly connector and disengage each clamp from the front pillar RH. (d) Disconnect the antenna cord sub-assembly connector and disengage the clamp from the rear pillar RH. IR–32 INTERIOR – ROOF HEADLINING (e) Disengage the 4 clips. Clamp Clamp IR Clip Clamp B132072E02 (f) B132073 Remove the roof headlining assembly from the vehicle through the rear left door. 69. REMOVE ROOF HEADLINING ASSEMBLY (w/ Sliding Roof) (a) Disconnect the No. 1 roof wire connector and disengage each clamp from the front pillar LH. (b) Remove the bolt and disconnect the radio setting condenser from the front pillar RH. (c) Disconnect the antenna cord sub-assembly connector and disengage each clamp from the front pillar RH. (d) Disconnect the antenna cord sub-assembly connector and disengage the clamp from the rear pillar RH. IR–33 INTERIOR – ROOF HEADLINING (e) Disconnect the sliding roof drive gear connector. (f) Disengage the hook, 4 clips, and 2 fasteners. Clip Clamp Clamp Fastener IR Clamp B132071E01 (g) Remove the roof headlining assembly from the vehicle through the rear left door. B132074 IR–34 INTERIOR – ROOF HEADLINING 70. REMOVE RADIO SETTING CONDENSER (a) Remove the rivet and radio setting condenser. Rivet B132075E01 71. REMOVE NO. 2 REAR SIDE RAIL SPACER LH (w/o Sliding Roof) (a) Remove the No. 2 rear side rail spacer LH. 72. REMOVE NO. 2 REAR SIDE RAIL SPACER RH (w/o Sliding Roof) HINT: Use the same procedures for the RH side and the LH side. IR B132076 73. REMOVE NO. 3 REAR SIDE RAIL SPACER LH (w/o Sliding Roof) (a) Remove the No. 3 rear side rail spacer LH. 74. REMOVE NO. 3 REAR SIDE RAIL SPACER RH (w/o Sliding Roof) HINT: Use the same procedures for the RH side and the LH side. B132077 75. REMOVE ROOF SIDE RAIL SILENCER PAD LH (w/o Sliding Roof) (a) Remove the roof side rail silencer pad LH. 76. REMOVE ROOF SIDE RAIL SILENCER PAD RH (w/o Sliding Roof) HINT: Use the same procedures for the RH side and the LH side. B132138 77. REMOVE NO. 2 ROOF SILENCER PAD (w/o Sliding Roof) (a) Remove the No. 2 roof silencer pad. B132078 INTERIOR – ROOF HEADLINING IR–35 78. REMOVE NO. 4 ROOF SILENCER PAD (w/o Sliding Roof) (a) Remove the 5 No. 4 roof silencer pads. B132104 79. REMOVE NO. 2 REAR SIDE RAIL SPACER LH (w/ Sliding Roof) (a) Remove the No. 2 rear side rail spacer LH. 80. REMOVE NO. 2 REAR SIDE RAIL SPACER RH (w/ Sliding Roof) HINT: Use the same procedures for the RH side and the LH side. B132079 81. REMOVE FASTENER HOOK (w/ Sliding Roof) 82. REMOVE ANTENNA CORD SUB-ASSEMBLY (See page AV-199) Claw Claw Claw Bulb Holder B126815E01 83. REMOVE VANITY LIGHT ASSEMBLY (w/ Sliding Roof) (a) Disengage the 2 claws and separate the bulb holder from the vanity light assembly as shown in the illustration. (b) Disengage the claw and remove the vanity light assembly. HINT: Use the same procedure to remove the light on the other side. 84. REMOVE NO. 1 ROOF WIRE (w/o Sliding Roof) (a) Remove the adhesive tape from the roof headlining assembly. (b) Remove the No. 1 roof wire from the roof headlining assembly. IR IR–36 INTERIOR – ROOF HEADLINING (c) Remove the double-sided tape from the roof headlining assembly. for TMC made: IR for TMMK made: Adhesive Tape B132085E01 85. REMOVE NO. 1 ROOF WIRE (w/ Sliding Roof) (a) Turn the visor connectors clockwise approximately 90° and separate the connectors from the roof headlining assembly. (b) Remove the adhesive tape from the roof headlining assembly. (c) Remove the No. 1 roof wire from the roof headlining assembly. (d) Remove the double-sided tape from the roof headlining assembly. INTERIOR – ROOF HEADLINING IR–37 for TMC made: for TMMK made: IR Adhesive Tape B132086E04 IR–38 INTERIOR – ROOF HEADLINING INSTALLATION 1. Reference: Tape Attachment Locations INSTALL NO. 1 ROOF WIRE (w/o Sliding Roof) (a) Apply new double-sided tape to locations shown in the illustration while aligning the tape with the markings on the roof headlining. Double-sided Tape 1 mm (0.039 in.) 10 mm (0.394 in.) IR B132087E01 NOTICE: Securely apply the double-sided tape to prevent it from being out of alignment and peeling off. (b) Peel off the release paper from the double-sided tape. (c) Attach the No. 1 roof wire along the double-sided tape so that the marking surface of the wire harness faces downward. NOTICE: • Securely attach the No. 1 roof wire. • Failure to do so may cause abnormal noise. IR–39 INTERIOR – ROOF HEADLINING (d) Apply adhesive tape to locations shown in the illustration. Reference: Tape Attachment Locations for TMC made: IR for TMMK made: A A Adhesive Tape A: 80 mm (3.150 in.) 1 mm (0.039 in.) 20 mm (0.787 in.) B132089E01 HINT: As shown at point A in the illustration, line up and secure the reference tape of the wire harness to the tip of the roof headlining assembly. IR–40 INTERIOR – ROOF HEADLINING 2. Reference: Tape Attachment Locations INSTALL NO. 1 ROOF WIRE (w/ Sliding Roof) (a) Apply new double-sided tape to locations shown in the illustration while aligning the tape with the markings on the roof headlining. Double-sided Tape 1 mm (0.039 in.) 10 mm (0.394 in.) IR B132088E01 NOTICE: Securely apply the double-sided tape to prevent it from being out of alignment and peeling off. (b) Peel off the release paper from the double-sided tape. (c) Attach the No. 1 roof wire along the double-sided tape so that the marking surface of the wire harness faces downward. NOTICE: • Securely attach the No. 1 roof wire. • Failure to do so may cause abnormal noise. (d) Turn the visor connectors clockwise approximately 90° to install the connectors to the roof headlining. IR–41 INTERIOR – ROOF HEADLINING (e) Apply adhesive tape to locations shown in the illustration. Reference: Tape Attachment Locations for TMC made: IR for TMMK made: A A Adhesive Tape A: 80 mm (3.150 in.) 1 mm (0.039 in.) 20 mm (0.787 in.) B132090E01 HINT: As shown at point A in the illustration, line up and secure the reference tape of the wire harness to the tip of the roof headlining assembly. 3. INSTALL ANTENNA CORD SUB-ASSEMBLY (See page AV-202) IR–42 INTERIOR – ROOF HEADLINING 4. INSTALL VANITY LIGHT ASSEMBLY (w/ Sliding Roof) (a) Engage the 3 claws and install the vanity light assembly. HINT: Use the same procedure to install the light on the other side. 5. INSTALL FASTENER HOOK (w/ Sliding Roof) (a) Align the markings on the roof headlining assembly with the fastener hooks and install the fastener hooks using hot melt glue as shown in the illustration. 6. INSTALL NO. 2 REAR SIDE RAIL SPACER LH (w/ Sliding Roof) (a) Align the markings on the roof headlining assembly with the No. 2 rear side rail spacer LH and install the spacer using hot melt glue as shown in the illustration. 7. INSTALL NO. 2 REAR SIDE RAIL SPACER RH (w/ Sliding Roof) HINT: Use the same procedures for the RH side and the LH side. 8. INSTALL NO. 4 ROOF SILENCER PAD (w/o Sliding Roof) (a) Align the markings on the roof headlining assembly with the No. 4 roof silencer pads and install the silencer pads using hot melt glue or double-sided tape as shown in the illustration. B126818E01 IR B139637 B132079 B132104 INTERIOR – ROOF HEADLINING 9. IR–43 INSTALL NO. 2 ROOF SILENCER PAD (w/o Sliding Roof) (a) Align the markings on the roof headlining assembly with the No. 2 roof silencer pad and install the silencer pad using hot melt glue or double-sided tape as shown in the illustration. B132078 10. INSTALL ROOF SIDE RAIL SILENCER PAD LH (w/o Sliding Roof) (a) Align the markings on the roof headlining assembly with the roof side rail silencer pad LH and install the silencer pad using hot melt glue as shown in the illustration. B132138 11. INSTALL ROOF SIDE RAIL SILENCER PAD RH (w/o Sliding Roof) HINT: Use the same procedures for the RH side and the LH side. 12. INSTALL NO. 3 REAR SIDE RAIL SPACER LH (w/o Sliding Roof) (a) Align the markings on the roof headlining assembly with the No. 3 rear side rail spacer LH and install the spacer using hot melt glue as shown in the illustration. B132077 13. INSTALL NO. 3 REAR SIDE RAIL SPACER RH (w/o Sliding Roof) HINT: Use the same procedures for the RH side and the LH side. 14. INSTALL NO. 2 REAR SIDE RAIL SPACER LH (w/o Sliding Roof) (a) Align the markings on the roof headlining assembly with the No. 2 rear side rail spacer LH and install the spacer using hot melt glue as shown in the illustration. B132076 15. INSTALL NO. 2 REAR SIDE RAIL SPACER RH (w/o Sliding Roof) HINT: Use the same procedures for the RH side and the LH side. IR IR–44 INTERIOR – ROOF HEADLINING 16. INSTALL RADIO SETTING CONDENSER (a) Using an air riveter or hand riveter with a nose piece, install the radio setting condenser with a new rivet. INCORRECT Riveter Mandrel IR Rivet INCORRECT INCORRECT Riveter Riveter Riveter INCORRECT B139559E01 NOTICE: • Do not pry the rivet with the riveter, as this will cause damage to the riveter and mandrel. • Confirm that the rivet is seated properly against the moulding. Do not tilt the riveter when installing the rivet to the moulding. Do not leave any space between the rivet head and moulding. • Do not leave any space between the moulding and door frame. Firmly hold the 2 items together while installing the rivet. HINT: If the rivet cannot be cut, pull it once and cut it. IR–45 INTERIOR – ROOF HEADLINING B139560 17. INSTALL ROOF HEADLINING ASSEMBLY (w/o Sliding Roof) (a) Pull the roof headlining assembly into the vehicle through the rear left door. (b) Engage the 4 clips. (c) Connect the antenna cord sub-assembly connector and engage the clamp to the rear pillar RH. (d) Connect the antenna cord sub-assembly connector and engage each clamp to the front pillar RH. (e) Install the radio setting condenser to the front pillar RH with the bolt. (f) Connect the No. 1 roof wire connector and engage each clamp to the front pillar LH. IR Clamp Clamp Clip Clamp B132072E02 IR–46 INTERIOR – ROOF HEADLINING B139561 18. INSTALL ROOF HEADLINING ASSEMBLY (w/ Sliding Roof) (a) Pull the roof headlining assembly into the vehicle through the rear left door. (b) Engage the hook, 4 clips, and 2 fasteners. (c) Connect the sliding roof drive gear connector. (d) Connect the antenna cord sub-assembly connector and engage the clamp to the rear pillar RH. (e) Connect the antenna cord sub-assembly connector and engage each clamp to the front pillar RH. (f) Install the radio setting condenser to the front pillar RH with the bolt. (g) Connect the No. 1 roof wire connector and engage each clamp to the front pillar LH. IR Clip Clamp Clamp Fastener Clamp B132071E01 INTERIOR – ROOF HEADLINING IR–47 19. INSTALL SUNSHADE TRIM HOLDER (w/ Rear Sunshade) (a) Engage the 2 claws. B132143 (b) Using a screwdriver, turn the pin of each sunshade trim holder 90° to install the sunshade trim holders. IR B132092 20. INSTALL SUN ROOF OPENING TRIM MOULDING (w/ Sliding Roof) (a) Align the joining point of the moulding with the notch of the roof headlining assembly, and install the sun roof opening trim moulding. NOTICE: After installation, check that the corners fit correctly. Joining Point Notch B132124E01 IR–48 INTERIOR – ROOF HEADLINING 21. INSTALL SPOT LIGHT ASSEMBLY (w/ Sliding Roof) (a) Push the light bulb holder in the direction indicated by the arrow in the illustration to engage the claw. (b) Engage the 4 claws. IR B132096 (c) Engage the 6 claws and install the spot light assembly. B132094 22. INSTALL NO. 1 ROOM LIGHT ASSEMBLY (w/o Sliding Roof) (a) Engage the 4 claws and install the room light switch base to the No. 1 room light assembly. B139562 INTERIOR – ROOF HEADLINING IR–49 (b) Engage the 4 claws. IR B139563 (c) Engage the 4 claws and install the lens cover. B139564 23. INSTALL FRONT ASSIST GRIP SUB-ASSEMBLY (a) Assemble the front assist grip sub-assembly as shown in the illustration. B132101 (b) Install the front assist grip sub-assembly. HINT: Use the same procedures for the RH side and the LH side. 24. INSTALL REAR ASSIST GRIP SUB-ASSEMBLY HINT: Use the same procedures for the rear side and the front side. B132102 25. INSTALL VISOR HOLDER (a) Engage the 2 claws. IR–50 INTERIOR – ROOF HEADLINING (b) Push in the visor holder and turn it approximately 45°as shown in the illustration. 45° B132103E01 HINT: Use the same procedures for the RH side and the LH side. IR 26. INSTALL VISOR ASSEMBLY LH (a) Engage the 2 clips and install the visor assembly LH. B139565 (b) Engage the 4 claws and install the visor bracket cover. 27. INSTALL VISOR ASSEMBLY RH HINT: Use the same procedures for the RH side and the LH side. B139566 28. INSTALL ROOF CONSOLE BOX ASSEMBLY (a) Connect the connectors. (b) Engage the 2 claws and 2 clips, and then install the roof console box assembly. B132065 INTERIOR – ROOF HEADLINING IR–51 29. INSTALL FRONT PILLAR GARNISH LH (a) Remove the protective cover. 120 mm (4.72 in.) 700 mm (27.56 in.) Adhesive Tape Protective Cover IR Curtain Shield Airbag Assembly B132100E01 (b) Install a new clip on the front pillar garnish LH. (c) Engage the 2 claws and 2 clips, then install the front pillar garnish LH. (2) (1) B132098E01 IR–52 INTERIOR – ROOF HEADLINING 30. INSTALL FRONT PILLAR GARNISH RH (a) Remove the protective cover. 120 mm (4.72 in.) 700 mm (27.56 in.) Adhesive Tape Protective Cover IR Curtain Shield Airbag Assembly B132099E01 (b) Install a new clip on the front pillar garnish RH. (c) Engage the 2 claws and 2 clips, then install the front pillar garnish RH. (2) (1) B132097E01 31. INSTALL ROOF SIDE INNER GARNISH LH (a) Engage the 5 clips and 2 claws, then install the roof side inner garnish LH. 32. INSTALL ROOF SIDE INNER GARNISH RH HINT: Use the same procedures for the RH side and the LH side. B132063 INTERIOR – ROOF HEADLINING IR–53 33. INSTALL UPPER CENTER PILLAR GARNISH LH (a) Engage the clip. (b) Install the upper center pillar garnish LH with the bolt. B132060 34. INSTALL LOWER CENTER PILLAR GARNISH LH (a) Engage the 2 claws and 2 clips, then install the lower center pillar garnish LH. IR B132058 35. CONNECT FRONT SEAT OUTER BELT ASSEMBLY LH (a) Install the floor end of the front seat outer belt assembly with the bolt. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) B131996 36. INSTALL LAP BELT OUTER ANCHOR COVER (for LH Side) (a) Engage the 3 claws and install the lap belt outer anchor cover. B131995 IR–54 INTERIOR – ROOF HEADLINING 37. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH (a) Install the front door opening trim weatherstrip LH as shown in the illustration. NOTICE: After installation, check that the corners fit correctly. Yellow Paint Mark Marking Position B132081E01 IR 38. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH (a) Engage the 2 clips. (b) Install the cowl side trim sub-assembly LH with the cowl side trim clip. Cowl Side Trim Clip B132116E01 39. INSTALL FRONT DOOR SCUFF PLATE LH (a) Engage the 7 claws and 3 clips, then install the front door scuff plate LH. 40. INSTALL UPPER CENTER PILLAR GARNISH RH HINT: Use the same procedures for the RH side and the LH side. 41. INSTALL LOWER CENTER PILLAR GARNISH RH HINT: Use the same procedures for the RH side and the LH side. B132067 42. CONNECT FRONT SEAT OUTER BELT ASSEMBLY RH HINT: Use the same procedures for the RH side and the LH side. 43. INSTALL LAP BELT OUTER ANCHOR COVER (for RH Side) HINT: Use the same procedures for the RH side and the LH side. INTERIOR – ROOF HEADLINING IR–55 44. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH (a) Install the front door opening trim weatherstrip RH as shown in the illustration. NOTICE: After installation, check that the corners fit correctly. White Paint Mark Marking Position B132083E01 45. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH HINT: Use the same procedures for the RH side and the LH side. 46. INSTALL FRONT DOOR SCUFF PLATE RH HINT: Use the same procedures for the RH side and the LH side. 47. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP LH (See page ED-54) 48. INSTALL REAR DOOR TRIM BOARD SUBASSEMBLY LH (See page ED-55) 49. INSTALL DOOR ASSIST GRIP COVER LH (See page ED-56) 50. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG LH (See page ED-56) 51. INSTALL RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY LH (for Reclining Seat Type) (See page SE-69) 52. INSTALL RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY RH (for Reclining Seat Type) HINT: Use the same procedures for the RH side and the LH side. 53. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (a) Install the rear door opening trim weatherstrip LH as shown in the illustration. NOTICE: After installation, check that the corners fit correctly. Red Paint Mark Marking Position B132080E01 IR IR–56 INTERIOR – ROOF HEADLINING 54. INSTALL REAR DOOR SCUFF PLATE LH (a) Engage the 5 claws and 2 clips, then install the rear door scuff plate LH. B132068 IR 55. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH (a) Install the rear door opening trim weatherstrip RH as shown in the illustration. NOTICE: After installation, check that the corners fit correctly. Blue Paint Mark 56. INSTALL REAR DOOR SCUFF PLATE RH HINT: Use the same procedures for the RH side and the LH side. 57. INSTALL CENTER SEAT BACK ASSEMBLY (for Reclining Seat Type) (See page SE-71) Marking Position B132082E01 58. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Reclining Seat Type) (See page SE-72) 59. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Reclining Seat Type) (See page SE-71) 60. INSTALL REAR SEAT BACK COVER (for Reclining Seat Type) 61. INSTALL REAR SIDE SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-57) 62. INSTALL REAR SIDE SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) HINT: Use the same procedures for the RH side and the LH side. 63. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-57) 64. INSTALL SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH (for Fold Down Seat Type) (See page SE-57) INTERIOR – ROOF HEADLINING IR–57 65. INSTALL REAR SEAT BACK ASSEMBLY (for Fixed Seat Type) (See page SE-84) 66. INSTALL REAR CENTER SEAT HEADREST ASSEMBLY 67. INSTALL REAR SEAT HEADREST ASSEMBLY 68. INSTALL REAR SEAT CUSHION ASSEMBLY (See page SE-84) 69. INSTALL FRONT SEAT ASSEMBLY LH (for Power Seat) (See page SE-41) 70. INSTALL INNER SEAT TRACK BRACKET COVER RH (for Power Seat) (See page SE-42) 71. INSTALL SEAT TRACK COVER LH (for Power Seat) (See page SE-42) 72. INSTALL FRONT SEAT HEADREST ASSEMBLY (for Power Seat) 73. INSTALL FRONT SEAT ASSEMBLY LH (for Manual Seat) (See page SE-24) 74. INSTALL INNER SEAT TRACK BRACKET COVER LH (for Manual Seat) (See page SE-25) 75. INSTALL SEAT TRACK COVER LH (for Manual Seat) (See page SE-25) 76. INSTALL FRONT SEAT HEADREST ASSEMBLY (for Manual Seat) 77. INSTALL FRONT SEAT ASSEMBLY RH (for Power Seat) HINT: Use the same procedures for the RH side and the LH side. 78. INSTALL INNER SEAT TRACK BRACKET COVER LH (for Power Seat) HINT: Use the same procedures for the RH side and the LH side. 79. INSTALL SEAT TRACK COVER RH (for Power Seat) HINT: Use the same procedures for the RH side and the LH side. 80. INSTALL FRONT SEAT HEADREST ASSEMBLY (for Power Seat) 81. INSTALL FRONT SEAT ASSEMBLY RH (for Manual Seat) HINT: Use the same procedures for the RH side and the LH side. IR IR–58 INTERIOR – ROOF HEADLINING 82. INSTALL INNER SEAT TRACK BRACKET COVER RH (for Manual Seat) HINT: Use the same procedures for the RH side and the LH side. 83. INSTALL SEAT TRACK COVER RH (for Manual Seat) HINT: Use the same procedures for the RH side and the LH side. 84. INSTALL FRONT SEAT HEADREST ASSEMBLY (for Manual Seat) 85. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (for Manual Seat) IR 86. PERFORM ZERO POINT CALIBRATION AND SENSITIVITY CHECK (for Front Passenger Seat) (See page RS-242) 87. INSPECT SRS WARNING LIGHT (See page RS-32) 88. INSPECT FRONT SEAT ASSEMBLY (for Power Seat) (See page SE-42) 89. INSPECT SLIDE ADJUSTER LOCK (for Manual Seat) U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–1 AUTOMATIC TRANSAXLE SYSTEM PRECAUTION NOTICE: • Perform the RESET MEMORY (AT initialization) when replacing the automatic transaxle assembly, engine assembly or ECM (See page AX-16). • Perform the REGISTRATION (VIN registration) when replacing the ECM (See page ES-16). HINT: RESET MEMORY can not be completed by only disconnecting the battery cable. 1. EXPRESSION OF IGNITION SWITCH The type of ignition switch used on this model differs according to the specifications of the vehicle. The expressions listed in the table below are used in this section. Switch Type Ignition Switch (Position) Engine Switch (Condition) Ignition switch off LOCK Off Ignition switch on (IG) ON On (IG) Ignition switch on (ACC) ACC On (ACC) Engine start START Start Expression E116900E03 2. The automatic transaxle is composed of highly precision-finished parts which need careful inspection before reassembly. Even a small nick could cause fluid leakage or affect the performance. The instructions here are organized so that you work on only one component group at a time. This will help avoid confusion caused by similar-looking parts of different sub-assemblies being on your workbench at the same time. The component groups are inspected and repaired from the converter housing side. Complete the inspection, repair and AX AX–2 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. AX reassembly before proceeding to the next component group as much as possible. If a defect is found in a certain component group during reassembly, inspect and repair this group immediately. If a component group cannot be assembled because some parts are being ordered, be sure to keep all parts of the group in a separate container while proceeding with disassembly, inspection, repair and reassembly of other component groups. Recommended: ATF WS All disassembled parts should be washed clean and any fluid passages and holes should be blown through with compressed air. Dry all parts with compressed air. Never use a shop rag or a piece of cloth to dry them. When using compressed air, always aim away from yourself to prevent accidentally spraying ATF or kerosene in your face. Only recommended automatic transaxle fluid or kerosene should be used for cleaning. After cleaning, the parts should be arranged in the correct order for efficient inspection, repair, and reassembly. When disassembling a valve body, be sure to match each valve together with the corresponding spring. New discs for the brakes and clutches that are to be used for replacement must be soaked in ATF for at least 15 minutes before reassembly. All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be coated with ATF prior to reassembly. All gaskets and rubber O-rings should be replaced with new ones. Do not apply adhesive cements to gaskets and similar parts. Make sure that the ends of a snap ring are not aligned with one of the cutouts and are installed in the groove correctly. When replacing a worn bushing, the sub-assembly containing the bushing must also be replaced. Check thrust bearings and races for wear or damage. Replace them as necessary. When working with FIPG material, you must observe the following: • Using a razor blade and a gasket scraper, remove all the old packing (FIPG) material from the gasket surface. • Thoroughly clean all components to remove any loose material. • Clean both sealing surfaces with a non-residue solvent. U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–3 • Parts must be reassembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied. AX AX–4 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DEFINITION OF TERMS Term AX Definition Monitor description Description of what the ECM monitors and how it detects malfunctions (monitoring purpose and its details). Related DTCs Diagnostic code Typical enabling condition Preconditions that allow the ECM to detect malfunctions. With all preconditions satisfied, the ECM sets the DTC when the monitored value(s) exceeds the malfunction threshold(s). Sequence of operation The priority order that is applied to monitoring, if multiple sensors and components are used to detect the malfunction. While another sensor is being monitored, the next sensor or component will not be monitored until the previous monitoring has concluded. Required sensor/components The sensors and components that are used by the ECM to detect malfunctions. Frequency of operation The number of times that the ECM checks for malfunctions per driving cycle. "Once per driving cycle" means that the ECM detects malfunction only one time during a single driving cycle. "Continuous" means that the ECM detects malfunction every time when enabling condition is met. Duration The minimum time that the ECM must sense a continuous deviation in the monitored value(s) before setting a DTC. This timing begins after the "typical enabling conditions" are met. Malfunction thresholds Beyond this value, the ECM will conclude that there is a malfunction and set a DTC. MIL operation MIL illumination timing after a defect is detected. "Immediately" means that the ECM illuminates MIL the instant the ECM determines that there is a malfunction. "2 driving cycle" means that the ECM illuminates MIL if the same malfunction is detected again in the 2nd driving cycle. Component operating range Normal operation range of sensors and solenoids under normal driving conditions. Use these ranges as a reference. They cannot be used to judge if a sensor or solenoid is defective or not. U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–5 PARTS LOCATION COMBINATION METER - MIL (MALFUNCTION INDICATOR LAMP) TRANSMISSION CONTROL SWITCH STOP LIGHT SWITCH ASSEMBLY DLC3 (DATA LINK CONNECTOR 3) SPEED SENSOR (NC) SPEED SENSOR (NT) SHIFT SOLENOID VALVE SLT ECM SHIFT SOLENOID VALVE SL3 SHIFT SOLENOID VALVE SL1 SHIFT SOLENOID VALVE SR TRANSMISSION WIRE PARK / NEUTRAL POSITION SWITCH (ATF TEMPERATURE SENSOR) SHIFT SOLENOID VALVE DSL SHIFT SOLENOID VALVE S4 SHIFT SOLENOID VALVE SL2 C136787E01 AX AX–6 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM SYSTEM DIAGRAM The configuration of the electronic control system in the U250E automatic transaxles is as shown in the following chart. Crankshaft Position Sensor NE SL1 Shift Solenoid Valve SL1 Engine Coolant Temperature THW Throttle Position Sensor Transmission Control Switch (D ←→ 4 and 2 ←→ L Position) Park/Neutral Position Switch SL2 Shift Solenoid Valve SL2 SL3 Shift Solenoid Valve SL3 SLT Shift Solenoid Valve SLT S4 Shift Solenoid Valve S4 DSL Shift Solenoid Valve DSL SR Shift Solenoid Valve SR VTA1, 2 VC 4, L NSW, P R, D, 3, 2 Speed Sensor ECM Skid Control ECU Combination Meter SPD Speed Sensor NC NC Speed Sensor NT NT Stop Light Switch Assembly ATF (Automatic Transmission Fluid) STP TH01 W TC AX MIL (Malfunction Indicator Light) DLC3 (Data Link Connector 3) CAN C136788E01 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–7 SYSTEM DESCRIPTION 1. SYSTEM DESCRIPTION (a) The ECT (Electronic controlled automatic transmission/transaxle) is an automatic transmission/transaxle that electronically controls shift timing using the ECM. The ECM detects electrical signals that indicate engine and driving conditions, and controls the shift point, based on driver habits and road conditions. As a result, fuel efficiency and power transmission performance are improved. Shift shock has been reduced by controlling the engine and transmission simultaneously. In addition, the ECT has features such as follows: • Diagnostic function. • Fail-safe function when a malfunction occurs. AX AX–8 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: • The ECM of this system is connected to the CAN and multiplex communication system. Therefore, before starting troubleshooting, make sure to check that there is no trouble in the CAN and multiplex communication systems. • The intelligent tester can be used at steps 3, 4, 6, and 9. 1 Vehicle Brought to Workshop NEXT 2 Customer Problem Analysis NEXT 3 Connect the OBD II scan tool or intelligent tester to DLC3 NEXT 4 Check and Clear DTCs and Freeze Frame Data HINT: (See page AX-28). NEXT 5 Visual Inspection NEXT 6 Setting the Check Mode Diagnosis HINT: (See page AX-29). NEXT 7 AX Problem Symptom Confirmation HINT: (See page AX-9). Symptom does not occur: Go to step 8 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–9 Symptom occurs: Go to step 9 8 Symptom Simulation HINT: (See page IN-45). NEXT 9 DTC Check HINT: (See page AX-28). DTC is not output: Go to step 10 DTC is output: Go to step 17 10 Basic Inspection HINT: (See page AX-123, AX-129 and AX-182). NG Go to step 19 OK 11 Mechanical System Test HINT: (See page AX-12). NG Go to step 16 OK 12 Hydraulic Test HINT: (See page AX-14). NG Go to step 16 OK 13 Manual Shifting Test HINT: (See page AX-15). NG Go to step 15 AX AX–10 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM OK 14 Problem Symptoms Table Chapter 1 HINT: (See page AX-19). NG Go to step 18 OK 15 Problem Symptoms Table Chapter 2 HINT: (See page AX-19). NEXT 16 Part Inspection Go to step 19 17 DTC Chart HINT: (See page AX-35). NEXT 18 Circuit Inspection NEXT 19 Repair or Replace NEXT 20 NEXT End AX Confirmation Test U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–11 ROAD TEST 1. 2. PROBLEM SYMPTOM CONFIRMATION (a) Based on the result of the customer problem analysis, try to reproduce the symptoms. If the problem is that the transaxle does not shift up, shift down, or the shift point is too high or too low, conduct the following road test referring to the automatic shift schedule and simulate the problem symptoms. ROAD TEST NOTICE: Perform the test at the ATF (Automatic Transmission Fluid) temperature 50 to 80°C (122 to 176°F) in the normal operation. (a) D position test: Shift into the D position and fully depress the accelerator pedal and check the following points. (1) Check up-shift operation. Check that 1 → 2, 2 → 3, 3 → 4 and 4 → 5th upshifts take place, and that the shift points conform to the automatic shift schedule (See page SS-40). HINT: 5th Gear Up-shift Prohibition Control • Engine coolant temperature is 55°C (131°F) or less and vehicle speed is at 70 km/h (43 mph) or less. • ATF temperature is -2°C (28°F) or less. 5th and 4th Gear Lock-up Prohibition Control • Brake pedal is depressed. • Accelerator pedal is released. • Engine coolant temperature is 60°C (140°F) or less. (2) Check for shift shock and slip. Check for shock and slip at the 1 → 2, 2 → 3, 3 → 4 and 4 → 5th up-shifts. (3) Check for abnormal noise and vibration. Check for abnormal noise and vibration when up-shifting from 1 → 2, 2 → 3, 3 → 4, and 4 → 5 while driving with the shift lever in the D position, and also check while driving in the lock-up condition. HINT: The check for the cause of abnormal noise and vibration must be done thoroughly as it could also be due to loss of balance in the differential, torque converter clutch, etc. (4) Check kick-down operation. Check vehicle speeds when the 2nd to 1st, 3rd to 2nd, 4th to 3rd, and 5th to 4th kick-downs take place while driving with the shift lever in the D position. Confirm that each speed is within the applicable vehicle speed range indicated in the automatic shift schedule (See page SS-40). AX AX–12 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM (5) Check abnormal shock and slip at kick-down. (6) Check the lock-up mechanism. • Drive in D position (5th gear), at a steady speed (lock-up ON). • Lightly depress the accelerator pedal and check that the engine speed does not change abruptly. HINT: • There is no lock-up in the 1st and 2nd gear. • 4th lock-up operates while uphill-downhill is active in the D position. • If there is a big jump in engine speed, there is no lock-up. (b) 4 (O/D OFF) position test: Shift into the 4 position and fully depress the accelerator pedal and check the following points. (1) Check up-shift operation. Check that the 1 → 2, 2 → 3 and 3 → 4 up-shift take place and that the shift point conforms to the automatic shift schedule (See page SS-40). HINT: There is no 5th up-shift in the 4 position. (2) Check engine braking. While driving in the 4 position and 4th gear, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noise during acceleration and deceleration, and for shock at up-shift and down-shift. (c) 3 position test: Shift into the 3 position and fully depress the accelerator pedal and check the following points. (1) Check up-shift operation. Check that the 1 → 2 and 2 → 3 up-shift take place and that the shift point conforms to the automatic shift schedule (See page SS-40). HINT: There is no 4th up-shift and lock-up in the 3 position. (2) Check engine braking. While running in the 3 position and 3rd gear, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noise during acceleration and deceleration, and for shock at up-shift and down-shift. AX U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–13 (d) 2 position test: Shift into the 2 position and fully depress the accelerator pedal and check the following points. (1) Check up-shift operation. Check that the 1 →2 up-shift takes place and that the shift point conforms to the automatic shift schedule (See page SS-40). HINT: There is no 3rd up-shift and lock-up in the 2 position. (2) Check engine braking. While running in the 2 position and 2nd gear, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noise during acceleration and deceleration, and for shock at up-shift and down-shift. (e) L position test: Shift into the L position and fully depress the accelerator pedal and check the following points. (1) Check no up-shift. While running in the L position, check that there is no up-shift to 2nd gear. HINT: There is no lock-up in the L position. (2) Check engine braking. While running in the L position, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noise during acceleration and deceleration. (f) R position test: Shift into the R position, lightly depress the accelerator pedal, and check that the vehicle moves backward without any abnormal noise or vibration. CAUTION: Before conducting this test ensure that the test area is free from people and obstruction. (g) P position test: Stop the vehicle on the grade (more than 5°) and after shifting into the P position, release the parking brake. Then, check that the parking lock pawl holds the vehicle in place. (h) Uphill/downhill control function test: (1) Check that the gear does not up-shift to the 4th or 5th gear while the vehicle is driving uphill. (2) Check that the gear automatically down-shifts from 5th to 4th or from the 4th to 3rd gear when brake is applied while the vehicle is driving downhill. AX AX–14 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM MECHANICAL SYSTEM TESTS 1. PERFORM MECHANICAL SYSTEM TESTS (a) Measure the stall speed. The object of this test is to check the overall performance of the transaxle and engine by measuring the stall speeds in the D position. NOTICE: • Driving test should be done on a paved road (a nonskid road). • Perform the test at the normal operating ATF (Automatic Transmission Fluid) temperature 50 to 80°C (122 to 176°F). • Do not continuously run this test for longer than 10 seconds. • To ensure safety, do this test in a wide, clear level area which provides good traction. • The stall test should always be carried out in pairs. One technician should observe the conditions of wheels or wheel stoppers outside the vehicle while the other is doing the test. (1) Chock the 4 wheels. (2) Connect the intelligent tester to the DLC3. (3) Fully apply the parking brake. (4) Keep your left foot pressed firmly on the brake pedal. (5) Start the engine. (6) Shift into the D position. Press all the way down on the accelerator pedal with your right foot. (7) Quickly read the stall speed at this time. Stall speed: 2,310 +- 150 rpm Evaluation: Problem AX Possible cause (a) Stall engine speed is low in D position • Engine power output may be insufficient • Stator one-way clutch not operating properly HINT: If the value is less than the specified value by 600 rpm or more, the torque converter could be faulty. (b) Stall engine speed is high in D position • • • • • • Line pressure is too low Forward clutch slipping U/D (Underdrive) brake slipping U/D (Underdrive) one-way clutch is not operating properly No.1 one-way clutch not operating properly Improper fluid level (b) Measure the time lag. (1) When the shift lever is shifted while the engine is idling, there will be a certain time lapse or lag before the shock can be felt. This is used for checking the condition of the clutch and brake. NOTICE: • Perform the test at the normal operating ATF (Automatic Transmission Fluid) temperature: 50 to 80°C (122 to 176°F). U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–15 • Be sure to allow 1 minute interval between tests. • Perform the test three times, and measure the time lags. Calculate the average value of the three time lags. (2) Connect the intelligent tester to the DLC3. (3) Fully apply the parking brake. (4) Start and warm up the engine and check idle speed. Idle speed: approx. 700 rpm (In N position and A/C OFF) (5) Shift the lever from N to D position. Using a stop watch, measure the time from when the lever is shifted until the shock is felt. Time lag: N → D less than 1.2 seconds (6) In the same way, measure the time lag for N → R. Time lag: N → R less than 1.5 seconds Evaluation (If N → D or N → R time lag is longer than the specified): Problem Possible cause N → D time lag is longer • • • • • Line pressure is too low Forward clutch worn No.1 one-way clutch is not operating properly U/D (Underdrive) one-way clutch is not operating U/D (Underdrive) brake worn N → R time lag is longer • • • • Line pressure is too low Reverse clutch worn 1st and reverse brake worn U/D (Underdrive) brake worn AX AX–16 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM HYDRAULIC TEST 1. Test Plug A: Test Plug B: D Position (CO) R Position (C2) SST SST C109078E01 PERFORM HYDRAULIC TEST (a) Measure the line pressure. NOTICE: • Perform the test at the normal operating ATF (Automatic Transmission Fluid) temperature: 50 to 80°C (122 to 176°F). • The line pressure test should always be carried out in pairs. One technician should observe the conditions of wheels or wheel stoppers outside the vehicle while the other is performing the test. • Be careful to prevent SST hose from interfering with the exhaust pipe. • This Check must be conducted after checking and adjusting engine. • Perform under condition that A/C is OFF. • When conducting stall test, do not continue more than 10 seconds. (1) Warm up the ATF (Automatic Transmission Fluid). (2) Lift the vehicle up. (3) Remove the engine under cover. (4) Connect intelligent tester to DLC3. (5) Remove the test plug A on the transaxle case front left side and install the SST. SST 09992-00095 (09992-00231, 0999200271) NOTICE: There is a difference in installation point between D position and R position. (6) Start the engine. (7) Using intelligent tester, shift to D position and hold 3rd gear by active test, and measure the line pressure in idling. Specified line pressure: Condition Idling D position kPa (kgf / cm2, psi) 372 to 412 kPa (3.8 to 4.2 kgf/cm2, 54 to 60 psi) (8) Turn the ignition switch off. AX U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–17 (9) Disconnect the connector of the transmission wire. HINT: Disconnect the connector only when performing the D position stall test. (10)Start the engine. (11)Firmly depress the brake pedal, shift to the D position, depress the accelerator pedal all the way down and check the line pressure while the stall test is performed. Specified line pressure: Condition Stall test Transmission Wire C109079E01 D position kPa (kgf / cm2, psi) 931 to 1,031 kPa (9.5 to 10.5 kgf/cm2, 135 to 150 psi) (12)Turn the ignition switch off. (13)Remove the SST, install the test plug A. (14)Remove the test plug B, install the SST and start engine. SST 09992-00095 (09992-00231, 0999200271) (15)Connect the transmission wire connector, depress the brake pedal firmly, shift to the R position and check that the line pressure while the engine is idling and during the stall test. Specified line pressure: Condition Idling Stall test R position kPa (kgf / cm2, psi) 672 to 742 kPa (6.9 to 7.6 kgf/cm2, 97 to 108 psi) 1,768 to 1,968 kPa (18.0 to 20.1 kgf/cm2, 256 to 285 psi) (16)Remove the SST, install the test plug B. (17)Clear the DTC. Evaluation: Problem Possible cause Measured values are higher than specified in all positions • • Shift solenoid valve (SLT) defective Regulator valve defective Measured values are lower than specified in all positions • • • • Shift solenoid valve (SLT) defective Regulator valve defective Oil pump defective U/D (Underdrive) direct clutch defective Pressure is low in the D position only • • D position circuit fluid leak Forward clutch defective Pressure is low in the R position only • • • R position circuit fluid leak Reverse clutch defective 1st and reverse brake defective AX AX–18 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM MANUAL SHIFTING TEST 1. PERFORM MANUAL SHIFTING TEST HINT: • With this test, it can be determined whether the trouble occurs in the electrical circuit or is a mechanical problem in the transaxle. • If any abnormalities are found in the following test, the problem is in the transaxle itself. (a) Disconnect the connector of the transmission wire. (b) Drive with the transmission wire disconnected. Shifting the shift lever in the order of L, 2, 3, 4 and D position to check whether the shifting condition changes the table below. Shift Position Shifting Condition L ←→ 2 No Shift (Not Change) 2 ←→ 3 Down Shift ←→ Up Shift 3 ←→ 4 ←→ D No Shift (Not Change) HINT: When driving with the transmission wire disconnected, the shift lever position is in L or 2, the gear position is held in 3rd and the shift lever position is in 3, 4 or D, the gear position is held in 4th. However, when the shift position is in R or P, the operation is same as usual. (c) Connect the connector of the transmission wire. (d) Clear the DTC. Transmission Wire C109079E01 AX U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–19 INITIALIZATION 1. RESET MEMORY NOTICE: • Perform the RESET MEMORY (AT initialization) when replacing the automatic transaxle assembly, engine assembly or ECM. • The RESET MEMORY can be performed only with the Intelligent tester. HINT: The ECM memorizes the condition that the ECT controls the automatic transaxle assembly and engine assembly according to those characteristics. Therefore, when the automatic transaxle assembly, engine assembly, or ECM has been replaced, it is necessary to reset the memory so that the ECM can memorize the new information. Reset procedure is as follows. (a) Turn the ignition switch off. (b) Connect the intelligent tester to the DLC3. (c) Turn the ignition switch on (IG) position and push the intelligent tester main switch on. (d) Select the item "DIAGNOSIS / ENHANCED OBD II". (e) Perform the reset memory procedure from the ENGINE menu. CAUTION: After performing the RESET MEMORY, be sure to perform the ROAD TEST (See page AX-9) described earlier. HINT: The ECM is learned by performing the ROAD TEST. (1) Tester menu flow: AX AX–20 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM G023367 AX U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–21 MONITOR DRIVE PATTERN 1. MONITOR DRIVE PATTERN FOR ECT TEST (a) Perform this drive pattern as one method to simulate the detection conditions of the ECT malfunctions. (The DTCs may not be detected due the actual driving conditions. And some codes may not be detected through this drive pattern.) HINT: Preparation for driving • Warm up the engine sufficiently. (Engine coolant temperature is 60°C (140°F) or higher) • Drive the vehicle when the atmospheric temperature is -10°C (14°F) or higher. (Malfunction is not detected when the atmospheric temperature is less than -10°C (14°F)) Driving note • Drive the vehicle through all gears. Stop → 1st → 2nd → 3rd → 4th → 5th → 5th (lock-up ON). • Repeat the above driving pattern three times or more. NOTICE: • The monitor status can be checked using the OBD II scan tool or intelligent tester. When using the intelligent tester, monitor status can be found in the "ENHANCED OBD II / DATA LIST" or under "CARB OBD II". • In the event that the drive pattern must be interrupted (possibly due to traffic conditions or other factors), the drive pattern can be resumed and, in most cases, the monitor can be completed. • Perform this drive pattern on a level road as much as possible and strictly observe the posted speed limits and traffic laws while driving. AX AX–22 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Vehicle Speed Maintain a constant speed or gradual acceleration (with the throttie open) for 3 minutes or more.*1 Approx. 100 km/h (62mph) Lock-up ON Vehicle Speed Approx. 80 km/h (50mph) 0 Warmed up sufficiently Stop (Idling) Normal acceleration through all the gears from 1st to 5th G031593E12 HINT: *1: Drive at such a speed in the uppermost gear, to engage lock-up. The vehicle can be driven at a speed lower than that in the above diagram under the lock-up condition. NOTICE: If necessary to drive the vehicle for approximately 30 minutes to detect DTC P0711 (ATF temperature sensor malfunction). AX AX–23 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM PROBLEM SYMPTOMS TABLE HINT: • If a normal code is displayed during the diagnostic trouble code check although the trouble still occurs, check the electrical circuits for each symptom in the order given in the charts on the following pages and proceed to the page given for troubleshooting. • The Matrix Chart is divided into 2 chapters. • When the circuit on which mark *1 is attached is a malfunction, DTC could be output. Chapter 1: Refer to the table below when the trouble cause is considered to be electrical the instruction "Proceed to next circuit inspection shown on matrix chart" is given in the flow chart of each circuit, proceed to the circuit with the next highest number in the table to continue the check. If the trouble still occurs even though there are no abnormalities in any of the other circuits, check and replace the ECM. 1. Chapter 1: Electronic Circuit Matrix Chart Symptom No down-shift (A particular gear, from 1st to 4th gear, is not down-shifted) Suspected area See page ECM IN-40 1. Transmission control switch (4 <--> D position) circuit *1 AX-39 2. Shift solenoid valve (S4) circuit *1 AX-106 3. ECM IN-40 No up-shift (A particular gear, from 1st to 4th gear, is not up-shifted) ECM IN-40 1. Transmission control switch (4 <--> D position) circuit *1 AX-39 No up-shift (4th -> 5th) 2. Shift solenoid valve (S4) circuit *1 AX-106 3. ECM IN-40 1. Stop light switch circuit *1 AX-60 2. Engine coolant temp. sensor circuit *1 ES-53 3. ECM IN-40 ECM IN-40 1. Throttle position sensor circuit *1 ES-53 2. ECM IN-40 1. Transmission control switch (4 <--> D position) circuit *1 AX-39 2. ECM IN-40 1. Engine coolant temp. sensor circuit *1 ES-53 2. ECM IN-40 1. Transmission control switch (2 <--> L position) circuit *1 AX-39 2. ECM IN-40 1. Shift solenoid valve (SL1) circuit *1 AX-73 No down-shift (5th -> 4th) No lock-up No lock-up off Shift point too high or too low Up-shift to 5th from 4th while shift lever is in 4 position Up-shift to 5th from 4th while engine is cold Up-shift to 2nd from 1st while shift lever is in L position Harsh engagement (N -> D) 2. ECM IN-40 Harsh engagement (Lock-up) ECM IN-40 Harsh engagement (Any driving position) ECM IN-40 Poor acceleration ECM IN-40 No kick-down ECM IN-40 Engine stalls when starting off or stopping ECM IN-40 1. Park/neutral position switch circuit *1 AX-39 2. ECM IN-40 Malfunction in shifting AX AX–24 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM 2. Chapter 2: On-Vehicle Repair and Off-Vehicle Repair Symptom Vehicle does not move in any forward position and in reverse positions See page 1. Valve body assembly AX-138 2. U/D brake (B3) AX-204 3. Torque converter clutch AX-193 1. Valve body assembly AX-138 2. Reverse clutch (C2) AX-204 3. 1st and reverse brake (B2) AX-204 1. Valve body assembly AX-138 2. 2nd and O/D brake (B1) AX-204 1. Valve body assembly AX-138 2. Direct and O/D clutch (C0) AX-204 1. Valve body assembly AX-138 2. 2nd and O/D brake (B1) AX-204 1. Shift solenoid valve (S4) AX-295 2. Valve body assembly AX-138 3. U/D clutch (C3) AX-204 1. Shift solenoid (S4) AX-295 2. Valve body assembly AX-138 Valve body assembly AX-138 No down-shift (3rd -> 2nd) Valve body assembly AX-138 No down-shift (2nd -> 1st) Valve body assembly AX-138 1. Shift solenoid valve (DSL) AX-295 2. Valve body assembly AX-138 3. Torque converter clutch AX-193 1. Shift solenoid valve (SL1) AX-295 2. Valve body assembly AX-138 3. C1 accumulator AX-204 4. Forward clutch (C1) AX-204 5. One-way clutch No.1 (F1) AX-204 6. U/D one-way clutch (F2) AX-204 1.Shift solenoid valve (SL2) AX-295 2. Valve body assembly AX-138 3. Torque converter clutch AX-193 1. Valve body assembly AX-138 2. C2 accumulator AX-204 3. Reverse clutch (C2) AX-204 4. 1st and reverse brake (B2) AX-204 1. Shift solenoid valve (SLT) AX-295 2. Valve body assembly AX-138 1. Valve body assembly AX-138 2. 2nd and O/D brake (B1) AX-204 1. Valve body assembly AX-138 2. C0 accumulator AX-204 Vehicle does not move in R position No up-shift (1st -> 2nd) No up-shift (2nd -> 3rd) No up-shift (3rd -> 4th) No up-shift (4th -> 5th) No down-shift (5th -> 4th) No down-shift (4th -> 3rd) No lock-up or No lock-up off Harsh engagement (N -> D) Harsh engagement (Lock-up) Harsh engagement (N -> R) Harsh engagement (1st -> 2nd -> 3rd -> 4th -> 5th) Harsh engagement (1st -> 2nd) Harsh engagement (2nd -> 3rd) Harsh engagement (3rd -> 4th) AX Suspected area Harsh engagement (4th -> 5th) 3. Direct and O/D clutch (C0) AX-204 1. Valve body assembly AX-138 2. 2nd and O/D brake (B1) AX-204 1. Valve body assembly AX-138 2. C3 accumulator AX-204 3. U/D clutch (B3) AX-204 AX–25 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Symptom Suspected area See page 1. Valve body assembly AX-138 2. B3 accumulator AX-204 1. Valve body assembly AX-138 2. Oil strainer AX-138 3. Direct and O/D clutch (C0) AX-204 4. Forward clutch (C1) AX-204 5. U/D clutch (C3) AX-204 6. 2nd and brake (B1) AX-204 7. U/D brake (B3) AX-204 8. One-way clutch No.1 (F1) AX-204 9. U/D one-way clutch (F2) AX-204 10. Torque converter clutch AX-193 Torque converter clutch AX-193 1. Reverse clutch (C2) AX-204 2. 1st and reverse brake (B2) AX-204 1. Forward clutch (C1) AX-204 2. One-way clutch No. 1 (F1) AX-204 3. U/D one-way clutch (F2) AX-204 Slip or shudder (2nd) 2nd and O/D brake (B1) AX-204 Slip or shudder (3rd) Direct and O/D clutch (C0) AX-204 Slip or shudder (4th) 2nd and O/D brake (B1) AX-204 Slip or shudder (5th) U/D clutch (C3) AX-204 Shift position too high or too low Shift solenoid valve (SLT) AX-295 No engine braking (1st +- 4th: D position) U/D brake (B3) AX-204 Harsh engagement (5th -> 4th) Slip or shudder (Forward and reverse: After warm-up) Slip or shudder (Particular position: Just after engine starts) Slip or shudder (R position) Slip or shudder (1st) No engine braking (1st: L (1) position) 1. Valve body assembly AX-138 2. 1st and reverse brake (B2) AX-204 1. Valve body assembly AX-138 2. 2nd and O/D brake (B1) AX-204 No engine braking (3rd: 3 position) U/D brake (B3) AX-204 No kick-down Valve body assembly AX-138 No engine braking (2nd: 2 position) Poor acceleration (All positions) Poor acceleration (5th) Engine stalls when starting off or stopping 1. Shift solenoid valve (SLT) AX-295 2. Torque converter clutch AX-193 1. U/D clutch (C3) AX-204 2. U/D planetary gear unit AX-204 1. Shift solenoid valve (DSL) AX-295 2. Torque converter clutch AX-193 AX AX–26 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM TERMINALS OF ECM 1. ECM C24                         A24                                                                                                                                                                   A107881E12 HINT: Each ECM terminal's standard voltage is shown in the table below. In the table, first follow the information under "Condition". Look under "Symbols (Terminal No.)" for the terminals to inspected. The standard voltage between the terminals is shown under "Specific Condition". Use the illustration above as a reference for the ECM terminals. Symbols (Terminals No.) D (C24-56) - E1 (C24-104) R (C24-53) - E1 (C24-104) Terminal Description G - W-B D shift position switch signal P - W-B R shift position switch signal SPD (A24-8) - E1 (C24-104) L - W-B Speed signal STP (A24-36) - E1 (C24-104) W - W-B Stop light switch signal G - W-B 4 shift position switch signal 4 (A24-25) - E1 (C24-104) 3 (A24-26) - E1 (C24-104) AX Wiring Color 2 (C24-55) - E1 (C24-104) G - W-B V - W-B 3 shift position switch signal 2 shift position switch signal Condition Specified Condition Ignition switch on (IG) and shift lever D and 4 position 10 to 14 V Ignition switch on (IG) and shift lever except D and 4 position Below 1 V Ignition switch on (IG) and shift lever R position 10 to 14 V Ignition switch on (IG) and shift lever except R position Below 1 V Vehicle speed 20 km/h (12mph) Pulse generation (See waveform 8) Brake pedal is depressed 7.5 to 14 V Brake pedal is released Below 1.5 V Ignition switch on (IG) and shift lever 4 position 10 to 14 V Ignition switch on (IG) and shift lever except 4 position Below 1 V Ignition switch on (IG) and shift lever 3 position 10 to 14 V Ignition switch on (IG) and shift lever except 3 position Below 1 V Ignition switch on (IG) and shift lever 2 and L position 10 to 14 V Ignition switch on (IG) and shift lever except 2 and L position Below 1 V U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Symbols (Terminals No.) L (C24-74) - E1 (C24-104) P (C24-73) - E1 (C24-104) Wiring Color Terminal Description BR - W-B L shift position switch signal GR - W-B N (C24-54) - E1 (C24-104) SB - W-B NSW (C24-52) - E1 (C24-104) SB - W-B Park position switch signal Neutral position switch signal Park neutral switch signal DSL (C24-79) - E1 (C24-104) BR - W-B DSL solenoid signal SR (C24-80) - E1 (C24-104) G - W-B SR solenoid signal S4 (C24-78) - E1 (C24-104) GR - W-B S4 solenoid signal Condition Specified Condition Ignition switch on (IG) and shift lever L position 10 to 14 V Ignition switch on (IG) and shift lever except L position Below 1 V Ignition switch on (IG) and shift lever P position 10 to 14 V Ignition switch on (IG) and shift lever except P position Below 1 V Ignition switch on (IG) and shift lever N position 10 to 14 V Ignition switch on (IG) and shift lever except N position Below 1 V Ignition switch on (IG) and shift lever P and N position Below 2 V Ignition switch on (IG) and shift lever except P and N position 10 to 14 V Vehicle speed 65 km/h (40mph), lock-up (ON to OFF) Pulse generation (See waveform 2) Ignition switch on (IG) Below 1 V 3rd, 4th or 5th gear 10 to 14 V 1st or 2nd gear Below 1 V Ignition switch on (IG) Below 1 V 5th gear 10 to 14 V Except 5th gear Below 1 V SL3+ (C24-60) - SL3- (C24-61) O-Y SL3 solenoid signal Engine idle speed Pulse generation (See waveform 3) SL2+ (C24-58) - SL2- (C24-59) G-R SL2 solenoid signal Engine idle speed Pulse generation (See waveform 4) SL1+ (C24-57) - SL1- (C24-77) L - L-G SL1 solenoid signal Engine idle speed Pulse generation (See waveform 5) NC+ (C24-101) - NC- (C24-102) LG - P Speed sensor (NC) signal Vehicle speed 30 km/h (19mph): (3rd gear) Engine speed 1,400 rpm Pulse generation (See waveform 6) NT+ (C24-125) - NT- (C24-124) G-W Speed sensor (NT) signal Vehicle speed 20 km/h (12mph) Pulse generation (See waveform 7) SLT+ (C24-76) - SLT- (C24-75) L-W SLT solenoid signal Engine idle speed Pulse generation (See waveform 1) THO1 (C24-72) - ETHO (C24-95) Y - BR ATF temperature sensor signal ATF temperature: 115°C (239°F) or more Below 1.5 V 5 V/DIV AX–27 (a) Waveform 1 Reference: Terminal SLT+ - SLT- Tool setting 5 V/DIV, 1ms/DIV Vehicle condition Engine idle speed GND 1 ms/DIV G023426E01 AX AX–28 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM 10 V/DIV GND (b) Waveform 2 Reference: Terminal DSL - E1 Tool setting 10 V/DIV, 100ms/DIV Vehicle condition Vehicle speed 65 km/h (40 mph), lock-up (ON to OFF) 100 ms/DIV C053420E07 5 V/DIV (c) Waveform 3 Reference: Terminal SL3+ - SL3- Tool setting 5 V/DIV, 1ms/DIV Vehicle condition Engine idle speed GND 1 ms/DIV G023426E01 5 V/DIV (d) Waveform 4 Reference: Terminal SL2+ - SL2- Tool setting 5 V/DIV, 1ms/DIV Vehicle condition Engine idle speed GND 1 ms/DIV G023426E01 5 V/DIV (e) Waveform 5 Reference: Terminal SL1+ - SL1- Tool setting 5 V/DIV, 1ms/DIV Vehicle condition Engine idle speed GND 1 ms/DIV G023426E07 (f) 1 V/DIV GND AX 1 ms/DIV C093866E08 Waveform 6 Reference: Terminal NC+ - NC- Tool setting 1 V/DIV, 1ms/DIV Vehicle condition Vehicle speed 30 km/h (19 mph): (3rd gear) Engine speed 1.400 rpm U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM 5 V/DIV GND AX–29 (g) Waveform 7 Reference: Terminal NT+ - NT- Tool setting 5 V/DIV, 0.5ms/DIV Vehicle condition Vehicle speed 20 km/h (12 mph) 0.5 ms/DIV C053419E12 5 V/DIV (h) Waveform 8 Reference: Terminal GND 20 ms/DIV C053421E08 SPD - E1 Tool setting 5 V/DIV, 20ms/DIV Vehicle condition Vehicle speed 20 km/h (12 mph) HINT: Depending on the vehicle, the output waveform voltage, influenced by optionally installed systems, may become 5V. AX AX–30 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DIAGNOSIS SYSTEM 1. FI00534 Intelligent Tester DLC3 CAN VIM C131977E05 AX DESCRIPTION (a) When troubleshooting OBD II vehicles, the only difference from the usual troubleshooting procedure is to connect an OBD II scan tool complying with SAE J1987 or a intelligent tester to the vehicle, and read off various data output from the vehicle's ECM. (b) OBD II regulations require that the vehicle's onboard computer illuminate the Malfunction Indicator Lamp (MIL) on the instrument panel when the computer detects a malfunction in the computer itself or in the drive system components which affect the vehicle emissions. In addition to illuminating the MIL when a malfunction is detected, the applicable DTCs prescribed by SAE J2012 are recorded in the ECM memory (See page AX-35). If the malfunction does not occur in 3 consecutive trips, the MIL goes off but the DTCs remain in the ECM memory. (c) To check the DTCs, connect the OBD II scan tool or intelligent tester to the DLC3 of the vehicle. The OBD II scan tool or intelligent tester also enables you to erase the DTCs and check freeze frame data and various forms of engine data (For operating instructions, see the instruction book). (d) The DTCs include SAE controlled codes and Manufacturer controlled codes. SAE controlled codes must be set as prescribed by the SAE, while Manufacturer controlled codes can be set freely by a manufacturer within the prescribed limits (See page AX-35). (e) The diagnosis system operates in "normal mode" during the normal vehicle use. In normal mode, "2trip detection logic" is used to ensure accurate detection of malfunction. "Check mode" is also available to technicians as an option. In check mode, "1-trip detection logic" is used for simulating malfunction symptoms and increasing the system's ability to detect malfunctions, including intermittent malfunction. (f) *2 trip detection logic: When a malfunction is first detected, the malfunction is temporarily stored in the ECM memory (1st trip). IF the ignition switch is turned off and then turned on (IG) again, and same malfunction is detected again, the MIL will illuminate. U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–31 (g) The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. (h) The intelligent tester displays freeze frame data recorded at five different points: 1) 3 times before the DTC is set, 2) once when the DTC is set, and 3) once after the DTC is set. The data can be used to simulate the vehicle's condition around the time of the malfunction. The data may be helpful in determining the cause of a malfunction. It may also be helpful in determining whether a DTC is being caused by a temporary malfunction. DTC set point 0.5 sec. 0.5 sec. 0.5 sec. Freeze frame data recorded point A092901E15 2. D1 INSPECT THE DLC3 (a) The vehicle's ECM uses ISO 15765-4for communication. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4format. 1 2 3 4 5 6 7 8 9 10 11 1213141516 DLC3 A082779E62 Terminals of DLC 3 Symbol Terminal No. Name Reference Terminal Result Condition SIL 7 Bus "+" line 5 - Signal ground Pulse generation During transmission CG 4 Chassis ground Body ground Below 1 Ω Always SG 5 Signal ground Body ground Below 1 Ω Always BAT 16 Battery positive Body ground 11 to 14 V Always CANH 6 CAN bus line CANL 54 to 69 Ω IG switch OFF* CANH 6 HIGH-level CAN bus line Battery positive 6 kΩ or higher IG switch OFF* CANH 6 HIGH-level CAN bus lineCG CG 200 Ω or higher IG switch OFF* CANL 14 LOW-level CAN bus line Battery positive 6 kΩ or higher IG switch OFF* CANL 14 LOW-level CAN bus line CG 200 Ω or higher IG switch OFF* CAUTION: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. AX AX–32 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM 3. 4. AX If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: The DLC3 is the interface prepared for reading various data from the vehicle's ECM. After connecting the cable of the intelligent tester to the CAN VIM, turn the ignition switch ON and turn the tester ON. If a communication failure message is displayed on the tester screen (on the tester: UNABLE TO CONNECT TO VEHICLE), a problem exists in either the vehicle or tester. In order to identify the location of the problem, connect the tester to another vehicle. • If the communication is normal when the tool is connected to another vehicle, inspect the DLC3 on the original vehicle. • If the communication is still impossible when the tool is connected to another vehicle, the problem is probably in the tool itself, so consult the Service Department listed in the tool's instruction manual. CHECK BATTERY VOLTAGE (a) Measure the battery voltage. Battery voltage: 11 to 14 V If voltage is below 11 V, replace the battery before proceeding. CHECK MIL (a) Check that the MIL illuminates when turning the ignition switch on (IG). HINT: If the MIL does not light up, troubleshoot the combination meter. (b) When the engine is started, the MIL should go off. If the lamp remains on, it means that the diagnosis system has detected a malfunction or abnormality in the system. U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–33 DTC CHECK / CLEAR 1. Intelligent Tester DLC3 CAN VIM C131977E05 2. DTC CHECK (NORMAL MODE) NOTICE: When the diagnostic system is switched from the normal mode to the check mode, all the DTCs and freeze frame data recorded in the normal mode will be erased. So before switching modes, always check the DTCs and freeze frame data, and note them down. DTCs which are stored in the ECM can be displayed with the intelligent tester or generic OBD II scan tool. These scan tools can display pending DTCs and current DTCs. Some DTC aren't stored if the ECM doesn't detect a malfunction during consecutive driving. However, the detected malfunction during once driving is stored as pending DTC. (a) Checking DTCs using the OBD II scan tool or intelligent tester. (1) Connect the intelligent tester to the Controller Area Network Vehicle Interface Module (CAN VIM). Then connect the CAN VIM to the Data Link Connector 3 (DLC3). (2) Turn the ignition switch on (IG). (3) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES (or PENDING CODE). (4) Use the OBD II scan tool or intelligent tester to check the DTCs and freeze frame data and note them down (For operating instructions, see the OBD II scan tool's instruction book). NOTICE: When simulating symptoms with an OBD II scan tool (excluding intelligent tester) to check the DTCs, use the normal mode. For codes on the DTCs chart which are subject to "2 trip detection logic", Turn the engine switch off after the symptom is simulated once. Then repeat the simulation process again. When the problem has been simulated twice, the MIL illuminates and the DTCs are recorded in the ECM. DTC CLEAR (a) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (b) Turn the ignition switch on (IG). (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CLEAR CODES and press YES. AX AX–34 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM CHECK MODE PROCEDURE HINT: Check mode has a higher sensitivity to malfunctions and can detect malfunction that normal mode cannot detect. Check mode can also detect all the malfunctions that normal mode can detect. In check mode, DTCs are detected with 1-trip detection logic. 1. DTC CHECK (CHECK MODE) HINT: Intelligent tester only: Compared to the normal mode, the check mode is more sensitive for detecting malfunctions. Furthermore, the same diagnostic items which are detected in the normal mode can also be detected in the check mode. (a) Procedure for Check Mode using the intelligent tester. (1) Check the initial conditions. • Battery positive voltage 11 V or more • Throttle valve fully closed • Transaxle in the P or N position • A/C switch is off (2) Turn the ignition switch off. (3) Connect the intelligent tester together with the Controller Area Network Vehicle Interface Module (CAN VIM) to the DLC3. Intelligent Tester DLC3 CAN VIM C131977E05 0.13 sec. 0.13 sec. ON OFF BR03904E17 AX (4) Turn the ignition switch on (IG) and turn the intelligent tester main switch on. (5) Select the item "DIAGNOSIS/ENHANCED OBD II/CHECK MODE" (Check that the MIL flashes). NOTICE: All DTCs and freeze frame data recorded will be erased if: 1) the intelligent tester is used to change the ECM from normal mode to check mode or vice-versa; or 2) during check mode, the ignition switch is turned from the on (IG) to ACC position or turned OFF. (6) Start the engine (the MIL goes off after the engine starts). (7) Perform "MONITOR DRIVE PATTERN" for the ECT test (See page AX-17). (Or, simulate the conditions of the malfunction described by the customer). NOTICE: Leave the ignition switch on (IG) until you have checked the DTCs, etc. (8) After simulating malfunction conditions, use the intelligent tester diagnosis selector to check the DTCs and freeze frame data, etc. U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM 2. AX–35 (9) When you use intelligent tester: Select the item "DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES". (10)After checking the DTC, inspect the applicable circuit. (11)(See page AX-35) to confirm the details of the DTCs. DTC CLEAR (a) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (b) Turn the ignition switch on (IG). (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CLEAR CODES and press YES. AX AX–36 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM FAIL-SAFE CHART 1. Normal Solenoid Valve SL1 ON OFF ON OFF OFF SL2 ON ON OFF FL FL SL3 OFF OFF OFF ON ON S4 OFF OFF OFF OFF ON 1st 2nd 3rd 4th 5th Gear Position SL1 Malfunction (During driving at 1st or 2nd) Solenoid Valve SL1 OFF SL2 ON ON OFF to ON FL to ON FL to ON SL3 OFF OFF OFF ON to OFF ON to OFF S4 Gear Position SL1 Malfunction (During driving at 3rd) Solenoid Valve AX Solenoid Valve OFF OFF OFF ON to OFF 2nd 3rd to 2nd 4th to 2nd 5th to 2nd ON to FL OFF to FL FL FL OFF SL2 ON to FL SL3 OFF OFF OFF ON to FL ON to FL S4 OFF to ON OFF to ON OFF to ON OFF to ON ON 1st to 4th 2nd to 4th 3rd to 4th 4th 5th to 4th SL1 OFF SL2 ON to FL ON to FL OFF to FL FL FL SL3 OFF to ON OFF to ON OFF to ON ON ON S4 Gear Position OFF 1st to 2nd SL1 Gear Position SL1 Malfunction (During driving at 4th or 5th) FAIL-SAFE This function minimizes the loss of the ECT functions when any malfunction occurs in a sensor or solenoid. (a) ATF (Automatic Transmission Fluid) temperature sensor: When the ATF temperature sensor has a malfunction, 5th upshift is prohibited. (b) Counter gear speed sensor NC (Speed sensor NC): When the counter gear speed sensor has a malfunction, 5th upshift is prohibited. (c) Shift solenoid valve DSL: When the solenoid valve DSL has a malfunction, the current to the solenoid valve is stopped. This stops lock-up control, then fuel economy decreases. (d) Shift solenoid valve SL1, SL2, SL3 and S4: Fail safe function: If either of the shift solenoid valve circuits develops an open or short, the ECM turns the other shift solenoid "ON" and "OFF" in order to shift into the gear positions shown in the table below. Manual shifting as shown in the following table must be done (In case of a short circuit, the ECM stops sending the current to the short circuited solenoid). Even if starting the engine in the fail-safe mode, the gear position remains in the same position. HINT: FL: Flex Lock-up OFF OFF OFF OFF ON 1st to 4th 2nd to 4th 3rd to 4th 4th 5th to 4th AX–37 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM SL2 Malfunction Solenoid Valve SL1 ON SL2 OFF OFF to ON ON SL3 S4 OFF OFF OFF to ON OFF to ON 1st to 4th 2nd to 4th 3rd to 4th 4th 5th to 4th ON OFF ON OFF to ON OFF to ON SL2 ON ON OFF FL FL SL3 OFF Gear Position SL1 SL3 Malfunction Solenoid Valve S4 S4 Malfunction Solenoid Valve ON to OFF ON to OFF OFF to ON OFF to ON ON OFF OFF OFF to ON ON 2nd 3rd 4th 5th to 4th SL1 ON OFF ON OFF OFF SL2 ON ON OFF FL FL SL3 OFF OFF OFF ON ON S4 OFF 2nd 3rd 4th 5th to 4th 2nd to 4th 3rd to 4th 4th 5th to 4th 1st SL1 OFF SL2 OFF SL3 OFF S4 Gear Position OFF OFF Gear Position SL1, SL2, SL3, and S4 Malfunction OFF to ON 1st Gear Position Solenoid Valve OFF to ON OFF 1st to 4th AX AX–38 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DATA LIST / ACTIVE TEST 1. AX Item Measurement Item/ Range (display) STOP LIGHT SW Stop light switch Status/ ON or OFF DATA LIST HINT: According to the DATA LIST displayed by the intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the on position. (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". (g) According to the display on the tester, read the "DATA LIST". Normal Condition • • Brake Pedal is depressed: ON Brake Pedal is released: OFF Diagnostic Note - PNP SW [NSW] PNP switch Status/ ON or OFF Shift lever position is; P and N: ON Except P and N: OFF When the shift lever position displayed on the Intelligent tester differs from the actual position, adjustment of the PNP switch or the shift cable may be incorrect. HINT: When the failure still occurs even after adjusting these parts, See page AX-39. REVERSE PNP switch Status/ ON or OFF Shift lever position is; R: ON Except R: OFF ↑ DRIVE PNP switch Status/ ON or OFF Shift lever position is; D and 4 : ON Except D and 4: OFF ↑ 2ND PNP SW Status/ ON or OFF Shift lever position is; 2 and L : ON Except 2 and L: OFF ↑ LOW PNP SW Status/ ON or OFF Shift lever position is; L : ON Except L: OFF ↑ 4TH/DRIVE PNP SW Status/ ON or OFF Shift lever position is; 4 : ON Except 4: OFF ↑ 3RD PNP SW Status/ ON or OFF Shift lever position is; 3 : ON Except 3: OFF ↑ AX–39 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Item Measurement Item/ Range (display) Normal Condition Diagnostic Note - SHIFT Actual Gear Position/ 1st, 2nd, 3rd, 4th or 5th (O/D) Shift Lever Position is; • L: 1st • 2: 1st or 2nd • 3: 1st, 2nd or 3rd • 4: 1st, 2nd, 3rd or 4th • D (O/D ON): 1st, 2nd, 3rd, 4th or 5th LOCK UP SOL Lock Up Solenoid Status/ ON or OFF • • Lock Up: ON Except Lock Up: OFF - • SOLENOID (SLT) Shift Solenoid SLT Status/ ON or OFF Accelerator pedal is depressed: OFF Accelerator pedal is released: ON - AT FLUID TEMP ATF Temp. Sensor Value/ min.: -40°C (-40°F) max.: 215°C (419°F) After Stall Test; Approx. 80°C (176°F) Equal to ambient temperature when cold soak If the value is "-40°C (-40°F)" or "215°C (419°F)", ATF temp. sensor circuit is opened or shorted. SPD (NC) SHIFT • • HINT: 3rd when shift lever position is D position (After warming up the engine); • Intermediate shaft speed (NC) becomes close to the engine speed. Counter Gear Speed/ display: 50 r/min 2. Item • - ACTIVE TEST HINT: Performing the ACTIVE TEST using the intelligent tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Push the "ON" button of the intelligent tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST". (g) According to the display on tester, perform the "ACTIVE TEST". Test Details [Test Details] Operate the shift solenoid valve and set the each shift position by yourself. [Vehicle Condition] • IDL: ON • Less than 50 km/h (31 mph) [Others] • Press "→" button: Shift up • Press "←" button: Shift down Diagnostic Note Possible to check the operation of the shift solenoid valves. AX AX–40 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Item Test Details LOCK UP [Test Details] Control the shift solenoid DSL to set the automatic transaxle to the lock-up condition. [Vehicle Condition] • Vehicle Speed: 60 km/h (37 mph) or more Diagnostic Note Possible to check the DSL operation. SOLENOID (SL1) [Test Details] Operate the shift solenoid SL1 [Vehicle Condition] • Vehicle Stopped. • Shift lever P or N position - SOLENOID (SL2) [Test Details] Operate the shift solenoid SL2 [Vehicle Condition] • Vehicle Stopped. • Shift lever P or N position - SOLENOID (SL3) [Test Details] Operate the shift solenoid SL3 [Vehicle Condition] • Vehicle Stopped. • Shift lever P or N position - SOLENOID (S4) [Test Details] Operate the shift solenoid S4 [Vehicle Condition] • Vehicle Stopped. • Shift lever P or N position - SOLENOID (SR) [Test Details] Operate the shift solenoid SR [Vehicle Condition] • Vehicle Stopped. • Shift lever P or N position - SOLENOID (DSL) [Test Details] Operate the shift solenoid DSL [Vehicle Condition] • Vehicle Stopped. • Shift lever P or N position - SOLENOID (SLT)* [Test Details] Operate the shift solenoid SLT and raise the line pressure. [Vehicle Condition] • Vehicle Stopped. • IDL: ON HINT: OFF: Line pressure up (When the active test of "SOLENOID (SLT)" is performed, the ECM commands the SLT solenoid to turn off). ON: No action (normal operation) - *: "SOLENOID (SLT)" in the ACTIVE TEST is performed to check the line pressure changes by connecting the SST to the automatic transaxle, which is used in the HYDRAULIC TEST (See page AX-14) as well. HINT: The pressure values in ACTIVE TEST and HYDRAULIC TEST are different from each other. AX U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–41 DIAGNOSTIC TROUBLE CODE CHART If a DTC is displayed during the DTC check, check the parts listed in the table below and proceed to the page given. HINT: • *1: Comes on MIL (Malfunction Indicator Lamp) light up • *2: "DTC stored" mark means ECM memorizes the malfunction code if the ECM detects the DTC detection condition. • This DTC may be output when the clutch, brake and gear components etc. inside the automatic transmission are damaged. AUTOMATIC TRANSMISSION SYSTEM DTC No. Detection Item Trouble Area MIL *1 Memory *2 See page P0705 Transmission Range Sensor Circuit Malfunction (PRNDL Input) 1. Open or short in park/neutral position switch circuit 2. Park/neutral position switch 3. ECM Comes on DTC stored AX-39 P0710 Transmission Fluid Temperature Sensor "A" Circuit 1. Open or short in ATF temperature sensor circuit 2. Transmission wire (ATF temperature sensor) 3. ECM Comes on DTC stored AX-48 P0711 Transmission Fluid Temperature Sensor "A" Performance 1. Transmission wire (ATF temperature sensor) Comes on DTC stored AX-53 P0712 Transmission Fluid Temperature Sensor "A" Circuit Low Input 1. Short in ATF temperature sensor circuit 2. Transmission wire (ATF temperature sensor) 3. ECM Comes on DTC stored AX-48 P0713 Transmission Fluid Temperature Sensor "A" Circuit High Input 1. Open in ATF temperature sensor circuit 2. Transmission wire (ATF temperature sensor) 3. ECM Comes on DTC stored AX-48 P0717 Turbine Speed Sensor Circuit No Signal 1. Open or short in transmission revolution sensor NT (speed sensor NT) circuit 2. Transmission revolution sensor NT (speed sensor NT) 3. ECM 4. Automatic transaxle assembly Comes on DTC stored AX-57 P0724 Brake Switch "B" Circuit High 1. Short in stop light switch circuit 2. Stop light switch 3. ECM Comes on DTC stored AX-60 AX AX–42 AX U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC No. Detection Item P0741 Torque Converter Clutch Solenoid Performance (Shift Solenoid Valve DSL) 1. Shift solenoid valve DSL remains open or closed 2. Valve body is blocked 3. Torque converter clutch 4. Automatic transaxle (clutch, brake or gear etc.) 5. Line pressure is too low Trouble Area Comes on MIL *1 DTC stored Memory *2 See page AX-63 P0746 Pressure Control Solenoid "A" Performance (Shift Solenoid Valve SL1) 1. Shift solenoid valve SL1 remains open or closed 2. Valve body is blocked 3. Automatic transaxle (clutch, brake or gear etc.) Comes on DTC stored AX-69 P0748 Pressure Control Solenoid "A" Electrical (Shift Solenoid Valve SL1) 1. Open or short in shift solenoid valve SL1 circuit 2. Shift solenoid valve SL1 3. ECM Comes on DTC stored AX-73 P0766 Shift Solenoid "D" Performance (Shift Solenoid Valve S4) 1. Shift solenoid valve S4 remains open or closed 2. Valve body is blocked (Brake control valve) 3. Automatic transmission (clutch, brake or gear, etc.) Comes on DTC stored AX-77 P0771 Shift Solenoid "E" Performance (Shift Solenoid Valve SR) 1. Shift solenoid valve SR remains open or closed 2. Valve body is blocked 3. Automatic transaxle (clutch, brake or gear etc.) Comes on DTC stored AX-81 P0776 Pressure Control Solenoid "B" Performance (Shift Solenoid Valve SL2) 1. Shift solenoid valve SL2 remains open or closed 2. Valve body is blocked 3. Automatic transaxle (clutch, brake or gear etc.) Comes on DTC stored AX-85 P0778 Pressure Control Solenoid "B" Electrical (Shift Solenoid Valve SL2) 1. Open or short in shift solenoid valve SL2 circuit 2. Shift solenoid valve SL2 3. ECM Comes on DTC stored AX-90 P0793 Intermediate Shaft Speed Sensor "A" 1. Open or short in transmission revolution sensor NC (speed sensor NC) circuit 2. Transmission revolution sensor NC (speed sensor NC) 3. ECM Comes on DTC stored AX-94 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC No. Detection Item Trouble Area MIL *1 Memory *2 AX–43 See page P0796 Pressure Control Solenoid "C" Performance (Shift Solenoid Valve SL3) 1. Shift solenoid valve SL3 remains open or closed 2. Valve body is blocked 3. Automatic transaxle (clutch, brake or gear etc.) Comes on DTC stored AX-98 P0798 Pressure Control Solenoid "C" Electrical (Shift Solenoid Valve SL3) 1. Open or short in shift solenoid valve SL3 circuit 2. Shift solenoid valve SL3 3. ECM Comes on DTC stored AX-102 P0982 Shift Solenoid "D" Control Circuit Low (Shift Solenoid Valve S4) 1. Short in shift solenoid valve S4 circuit 2. Shift solenoid valve S4 3. ECM Comes on DTC stored AX-106 P0983 Shift Solenoid "D" Control Circuit High (Shift Solenoid Valve S4) 1. Open in shift solenoid valve S4 circuit 2. Shift solenoid valve S4 3. ECM Comes on DTC stored AX-106 P0985 Shift Solenoid "E" Control Circuit Low (Shift Solenoid Valve SR) 1. Short in shift solenoid valve SR circuit 2. Shift solenoid valve SR 3. ECM Comes on DTC stored AX-109 P0986 Shift Solenoid "E" Control Circuit High (Shift Solenoid Valve SR) 1. Open in shift solenoid valve SR circuit 2. Shift solenoid valve SR 3. ECM Comes on DTC stored AX-109 P2714 Pressure Control Solenoid "D" Performance (Shift Solenoid Valve SLT) 1. Shift solenoid valve SLT remains closed 2. Valve body is blocked 3. Automatic transaxle (clutch, brake or gear etc.) Comes on DTC stored AX-112 P2716 Pressure Control Solenoid "D" Electrical (Shift Solenoid Valve SLT) 1. Open or short in shift solenoid valve SLT circuit 2. Shift solenoid valve SLT 3. ECM Comes on DTC stored AX-116 P2769 Torque Converter Clutch Solenoid Circuit Low (Shift Solenoid Valve DSL) 1. Short in shift solenoid valve DSL circuit 2. Shift solenoid valve DSL 3. ECM Comes on DTC stored AX-120 P2770 Torque Converter Clutch Solenoid Circuit High (Shift Solenoid Valve DSL) 1. Open in shift solenoid valve DSL circuit 2. Shift solenoid valve DSL 3. ECM Comes on DTC stored AX-120 AX AX–44 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC P0705 Transmission Range Sensor Circuit Malfunction (PRNDL Input) DESCRIPTION The park/neutral position switch detects the shift lever position and sends signals to the ECM. DTC No. DTC Detection Condition P0705 (A) Any 2 or more signals of the following are ON simultaneously (2-trip detection logic) • P input signal is ON. • N input signal is ON. • R input signal is ON. • D input signal is ON. • 3 input signal is ON. • 2 input signal is ON. (B) Any 2 or more signals of the following are ON simultaneously (2-trip detection logic) • NSW input signal is ON. • R input signal is ON. • D input signal is ON. • 3 input signal is ON. • 2 input signal is ON. (C) All switches are OFF simultaneously for NSW, P, R, N, D, 3 and 2 positions (2-trip detection logic). (D) Both 1 and 2 are met (2-trip detection logic) 1. One of the following is met (a) NSW input signal is ON. (b) P input signal is ON. (c) N input signal is ON. (d) R input signal is ON 2. One of the following is met (a) 4 input signal is ON. (b) L input signal is ON. Trouble Area • • • Open or short in park / neutral position switch circuit Park / neutral position switch ECM MONITOR DESCRIPTION These DTCs indicate a problem with the park/neutral position switch and the wire harness in the park/ neutral position switch circuit. The park/neutral position switch detects the shift lever position and sends a signal to the ECM. For security, the park/neutral position switch detects the shift lever position so that engine can be started only when the shift lever is in the P or N position The park/neutral position switch sends a signal to the ECM according to the shift position (P, R, N or D). The ECM determines that there is a problem with the switch or related parts if in receives more than 1 position signal simultaneously. The ECM will turn on the MIL and store the DTC. MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0705: Park/neutral position switch/Verify switch input Park/neutral position switch Continuous 2 sec. 2 driving cycles None TYPICAL ENABLING CONDITIONS AX All: The monitor will run whenever this DTC is not present. None Ignition switch ON Battery voltage 10.5 V or more U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–45 TYPICAL MALFUNCTION THRESHOLDS 1. One of the following conditions is met: Condition (A), (B), (C) and (D) Condition (A) If 2 or more of the following signal outputs exist at the same time P switch ON N switch ON R switch ON D switch ON 3 switch ON 2 switch ON Condition (B) If 2 or more of the following signal outputs exist at the same time NSW switch ON R switch ON D switch ON 3 switch ON 2 switch ON Condition (C) All of following conditions are met NSW switch OFF P switch OFF N switch OFF R switch OFF D switch OFF 3 switch OFF 2 switch OFF Condition (D) Both (i) and (ii) are met (i) One of the following is met NSW switch ON P switch ON N switch ON R switch ON (ii) One of the following is met 4 switch ON L switch ON COMPONENT OPERATING RANGE Park/neutral Position switch The park/neutral position switch sends only one signal to the ECM. AX AX–46 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM WIRING DIAGRAM ECM To ST Relay 48 A24 STA C1 Park / Neutral Position Switch N 52 C24 NSW P 5 4 55 C24 2 LL 8 26 A24 3 2L 3 56 C24 D DL 7 5 1 NSSL NSSD 25 A24 4 AT4 2 RB 2 74 C24 L ATL 6 E31 Transmission Control Switch NL 54 C24 N 9 53 C24 R RL 1 73 C24 P PL 6 GAUGE No. 1 IG1 FL MAIN ALT 3 2 1 AM1 4 AM1 Battery 5 IG1 1 E23 Ignition Switch C125005E01 AX U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–47 INSPECTION PROCEDURE HINT: According to the DATA LIST displayed by the intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. 1. READ DATA LIST (a) Turn the ignition switch off. (b) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (c) Turn the ignition switch on (IG). (d) Turn on the tester. (e) Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". (f) According to the display on the tester, read the "DATA LIST". Item PNP SW [NSW] REVERSE DRIVE 2ND LOW 4TH/DRIVE 3RD Measurement Item / Range (Display) Normal Condition Diagnostic Note PNP SW Status / ON or OFF Shift lever position is; P and N: ON Except P or N: OFF When the shift lever position displayed on the intelligent tester differs from the actual position, adjustment of the PNP switch or the shift cable may be incorrect. PNP SW Status / ON or OFF Shift lever position is; R: ON Except R: OFF When the shift lever position displayed on the intelligent tester differs from the actual position, adjustment of the PNP switch or the shift cable may be incorrect. PNP SW Status / ON or OFF Shift lever position is; D and 4: ON Except D and 4: OFF When the shift lever position displayed on the intelligent tester differs from the actual position, adjustment of the PNP switch or the shift cable may be incorrect. PNP SW Status / ON or OFF Shift lever position is; 2 and L: ON Except 2 and L: OFF When the shift lever position displayed on the intelligent tester differs from the actual position, adjustment of the PNP switch or the shift cable may be incorrect. PNP SW Status / ON or OFF Shift lever position is; L: ON Except L: OFF When the shift lever position displayed on the intelligent tester differs from the actual position, adjustment of the PNP switch or the shift cable may be incorrect. PNP SW Status / ON or OFF Shift lever position is; 4: ON Except 4: OFF When the shift lever position displayed on the intelligent tester differs from the actual position, adjustment of the PNP switch or the shift cable may be incorrect. PNP SW Status / ON or OFF Shift lever position is; 3: ON Except 3: OFF When the shift lever position displayed on the intelligent tester differs from the actual position, adjustment of the PNP switch or the shift cable may be incorrect. AX AX–48 1 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM CHECK HARNESS AND CONNECTOR (BATTERY - PARK/NEUTRAL POSITION) (a) Disconnect the park/neutral position switch connector. (b) Turn the ignition switch on (IG). (c) Measure voltage according to the value(s) in the table below. Standard voltage Wire Harness Side: (Connector Front View): RB 1 C1 5 6 2 7 3 4 8 9 NG Tester Connection Specified Condition 2 - Body ground 10 to 14 V REPAIR OR REPLACE HARNESS OR CONNECTOR C117645E06 OK 2 CHECK HARNESS AND CONNECTOR (OUTPUT SIGNAL) (a) Turn the ignition switch on (IG). (b) Measure voltage according to the value(s) in the table below. Standard voltage Wire Harness Side: (Connector Front View): B 1 C1 5 6 2 7 3 4 8 9 NG C117645E07 OK AX Tester Connection Specified Condition 4 - Body ground 10 to 14 V Go to step 8 AX–49 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM 3 INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Measure resistance according to the value(s) in the table below when the shift lever is moved to each position. Standard resistance Switch Side: (Connector Front View): Shift Position P Except P R C1 Except R N Except N D and 4 Except D and 4 3 Except 3 Tester Connection 2 - 6 and 4 - 5 2-1 2 - 9 and 4 - 5 2-7 2-3 C110340E34 2 and L Except 2 and L NG 2-8 Specified Condition Below 1 Ω 10 kΩ or higher Below 1 Ω 10 kΩ or higher Below 1 Ω 10 kΩ or higher Below 1 Ω 10 kΩ or higher Below 1 Ω 10 kΩ or higher Below 1 Ω 10 kΩ or higher REPLACE PARK/NEUTRAL POSITION SWITCH ASSEMBLY OK 4 CHECK HARNESS AND CONNECTOR (PARK/NEUTRAL POSITION SWITCH - ECM) (a) Connect the park/neutral position switch connector. (b) Disconnect the ECM connectors. (c) Turn the ignition switch on (IG), and measure the voltage according to the value(s) in the table below when the shift lever is moved to each position. Wire Harness Side: (Connector Front View): C24 ECM R N 2 P D A24 3 C136857E03 AX AX–50 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Standard voltage Shift Position P Except P N Except N R Tester Connection Specified Condition 10 to 14 V C24-73 (P) - Body ground Below 1 V 10 to 14 V C24-54 (N) - Body ground Below 1 V 10 to 14 V* C24-53 (R) - Body ground Except R D and 4 Except D and 4 3 Except 3 2 and L Except 2 and L Below 1 V 10 to 14 V C24-56 (D) - Body ground Below 1 V 10 to 14 V A24-26 (3) - Body ground Below 1 V 10 to 14 V C24-55 (2) - Body ground Below 1 V HINT: *: The voltage will drop slightly due to lighting up of the back up light. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 5 CHECK HARNESS AND CONNECTOR (PARK/NEUTRAL POSITION SWITCH TRANSMISSION CONTROL SWITCH) (a) Disconnect the transmission control switch connector of shift lock control unit assembly. (b) Measure the voltage according to the value(s) in the table below when the shift lever is moved to each position. Standard voltage Wire Harness Side: (Connector Front View): Shift Position E31 D and 4 Except D and 4 2 and L Except 2 and L NG C110345E17 OK AX Tester Connection 1 - Body ground 5 - Body ground Specified Condition 10 to 14 V Below 1 V 10 to 14 V Below 1 V REPAIR OR REPLACE HARNESS OR CONNECTOR AX–51 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM 6 INSPECT TRANSMISSION CONTROL SWITCH (a) Measure the resistance according to the value(s) in the table below when the shift lever is moved to each position. Standard resistance Switch Side: Shift Position (Connector Front View): 4 and 3 Except 4 and 3 L E31 Except L NG Tester Connection 1-2 5-6 Specified Condition Below 1 Ω 10 kΩ or higher Below 1 Ω 10 kΩ or higher REPLACE TRANSMISSION CONTROL SWITCH C136860E01 OK 7 CHECK HARNESS AND CONNECTOR (TRANSMISSION CONTROL SWITCH - ECM) (a) Connect the transmission control switch connector of shift lock control unit assembly. (b) Turn the ignition switch to the ON position, and measure the voltage according to the value(s) in the table below when the shift lever is moved to each position. Wire Harness Side: (Connector Front View): C24 ECM L A24 4 C136857E02 Standard voltage Shift Position 4 Except 4 L Except L Tester Connection A24-25 (4) - Body ground C24-74 (L) - Body ground Specified Condition 10 to 14 V Below 1 V 10 to 14 V Below 1 V AX AX–52 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM 8 CHECK HARNESS AND CONNECTOR (PARK/NEUTRAL POSITION SWITCH - ECM) (a) Disconnect the ECM connectors. (b) Turn the ignition switch off. (c) Measure resistance according to the value(s) in the table below. Standard resistance (Check for open) Wire Harness Side: (Connector Front View): Park/Neutral Position Switch C1 1 2 5 6 7 Tester Connection Specified Condition B (C1-4) - NSW (C24-52) Below 1 Ω 3 4 Standard resistance (Check for short) 8 9 B Tester Connection Specified Condition B (C1-4) or NSW (C24-52) - Body ground 10 kΩ or higher C24 ECM NG NSW OK REPLACE ECM AX C136861E02 REPAIR OR REPLACE HARNESS OR CONNECTOR U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–53 DTC P0710 Transmission Fluid Temperature Sensor "A" Circuit DTC P0712 Transmission Fluid Temperature Sensor "A" Circuit Low Input DTC P0713 Transmission Fluid Temperature Sensor "A" Circuit High Input DESCRIPTION The ATF (Automatic Transmission Fluid) temperature sensor converts the fluid temperature into a resistance value which is input into the ECM. The ECM applies a voltage to the temperature sensor through ECM terminal THO1. The sensor resistance changes with the transmission fluid temperature. As the temperature becomes higher, the sensor resistance decreases. One terminal of the sensor is grounded so that the sensor resistance decreases and the voltage goes down as the temperature becomes higher. The ECM calculates the fluid temperature based on the voltage signal. Resistance Acceptable Temperature G031389E12 DTC No. DTC Detection Condition Trouble Area P0710 (a) and (b) are detected momentarily within 0.5 sec. when neither P0712 nor P0713 is detected (1-trip detection logic) (a) ATF temperature sensor resistance is less than 79 Ω. (b) ATF temperature sensor resistance is more than 156 kΩ. HINT: Within 0.5 sec., the malfunction switches from (a) to (b) or from (b) to (a) • • • Open or short in ATF temperature sensor circuit Transmission wire (ATF temperature sensor) ECM P0712 ATF temperature sensor resistance is less than 79 Ω for 0.5 sec. or more (1-trip detection logic) • • • Short in ATF temperature sensor circuit Transmission wire (ATF temperature sensor) ECM AX AX–54 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC No. DTC Detection Condition P0713 ATF temperature sensor resistance is more than 156 kΩ when 15 minutes or more have elapsed after the engine start DTC is detected for 0.5 sec. or more (1-trip detection logic) Trouble Area • • • Open in ATF temperature sensor circuit Transmission wire (ATF temperature sensor) ECM MONITOR DESCRIPTION These DTCs indicate an open or short in the automatic transmission fluid (ATF) temperature sensor (TFT sensor) circuit. The automatic transmission fluid (ATF) temperature sensor converts ATF temperature to an electrical resistance value. Based on the resistance, the ECM determines the ATF temperature, and the ECM detects an opens or shorts in the ATF temperature circuit. If the resistance value of the ATF temperature is less than 79 Ω *1or more than 156 kΩ *2, the ECM interprets this as a fault in the ATF sensor or wiring. The ECM will turn on the MIL and store the DTC. *1: 150°C (302°F) or more is indicated regardless of the actual ATF temperature. *2: -40°C (-40°F) is indicated regardless of the actual ATF temperature. HINT: The ATF temperature can be checked on the intelligent tester display. MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0710: ATF temperature sensor/Range check (Chattering) P0712: ATF temperature sensor/Range check (Low resistance) P0713: ATF temperature sensor/Range check (High resistance) ATF temperature sensor (TFT sensor) Continuous 0.5 sec. Immediate None TYPICAL ENABLING CONDITIONS P0710: Range check (Chattering) P0712: Range check (Low resistance) The monitor will run whenever these DTCs are not present. None The typical enabling condition is not available. - P0713: Range check (High resistance) The monitor will run whenever this DTC is not present. None Time after engine start 15 min. or more TYPICAL MALFUNCTION THRESHOLDS P0710: Range check (Chattering) TFT (Transmission fluid temperature) sensor resistance Less than 79 Ω or More than 156 kΩ P0712: Range check (Low resistance) TFT sensor resistance Less than 79 Ω P0713: Range check (High resistance) TFT sensor resistance AX More than 156 kΩ COMPONENT OPERATING RANGE TFT sensor. Atmospheric temperature to approx. 130°C (266°F) AX–55 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM WIRING DIAGRAM C25 Electronically Controlled Transmission Solenoid ECM 72 1 C24 THO 95 C24 7 E2 THO1 ETHO C C131059E04 INSPECTION PROCEDURE HINT: According to the DATA LIST displayed by the OBD II scan tool or intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. NOTICE: In the table below, the value listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether apart is faulty or not. 1. READ DATA LIST (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch on (IG). (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". (g) According to the display on the tester, read the "DATA LIST". Item Measurement Item/ Range (display) Normal Condition AT FLUID TEMP ATF Temp. Sensor Value/ min.: -40°C (-40°F) max.: 215°C (419°F) Approx. 80°C (176°F) (After Stall Test) HINT: When DTC P0712 is output and OBD II scan tool or intelligent tester output is 150°C (302°F), there is a short circuit. When DTC P0713 is output and OBD II scan tool or intelligent tester output is -40°C (-40°F), there is an open circuit. AX AX–56 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Measure the resistance between terminal THO1 (THO) and body ground. Temperature Displayed Malfunction -40°C (-40°F) Open circuit 150°C (302°F) or more Short circuit HINT: If a circuit related to the ATF temperature sensor become open, P0713 is immediately set (in 0.5 second). When P0713 is set, P0711 cannot be detected. It is not necessary to inspect the circuit when P0711 is set. 1 INSPECT TRANSMISSION WIRE (ATF TEMPERATURE SENSOR) (a) Disconnect the transmission wire connector from the transaxle. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Transmission Wire Side: (Connector Front View): THO C25 E2 NG AX Specified Condition 1 (THO) - 7 (E2) 79 Ω to 156 kΩ 1 (THO) - Body ground 10 kΩ or higher 7 (E2) - Body ground 10 kΩ or higher HINT: If the resistance is out of the specified range with either the ATF temperature shown in the table below, the driveability of the vehicle may decrease. C113969E24 OK Tester Connection ATF Temperature Specified Condition 20°C (68°F) 3 to 5 kΩ 110°C (230°F) 0.22 to 0.28 kΩ REPAIR OR REPLACE TRANSMISSION WIRE U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM 2 AX–57 CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) Wire Harness Side: (Connector Front View): C24 ECM (a) Connect the transmission wire connector to the transaxle. (b) Disconnect the ECM connectors. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition C24-72 (THO1) - C24-95 (ETHO) 79 Ω to 156 kΩ (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short) THO1 ETHO Tester Connection C24-72 (THO1) - Body ground A136781E01 C24-95 (ETHO) - Body ground NG Specified Condition 10 kΩ or higher REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM AX AX–58 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC P0711 Transmission Fluid Temperature Sensor "A" Performance DESCRIPTION The ATF (Automatic Transmission Fluid) temperature sensor converts the fluid temperature into a resistance value which is input into the ECM. DTC No. DTC Detection Condition Trouble Area P0711 (A) Both (a) and (b) are detected: (2-trip detection logic) (a) Intake air and engine coolant temperatures are more than 10°C (14°F) at engine start (b) After normal driving for over 19 min. and 9 km (6 mile) or more, ATF temp. is less than 20°C (68°F) (B) When engine coolant temp. is less that 35°C (95°F) at engine start, the ATF temp. is 110°C (230°F) or more after 17 min. of engine start (2-trip detection logic). Transmission wire (ATF temperature sensor) MONITOR DESCRIPTION The ATF temperature sensor converts the ATF temperature to an electrical resistance value. Based on the resistance, the ECM determines the ATF temperature and detects an open or short in the ATF temperature circuit or a fault in the ATF temperature sensor. After running the vehicle for a certain period, the ATF temperature should increase. If the ATF temperature is below 20°C (68°F) after running the vehicle for a certain period, the ECM interprets this as a fault, and turns on the MIL. When the ATF temperature is 110°C (230°F) or more after 17 minutes of engine cold start, the ECM also determines this as a fault, turns on the MIL, and stores the DTC. MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0711: ATF temperature sensor/Rationality check ATF temperature sensor (TFT sensor) Continuous 3 sec.: Condition (A) 10 sec.: Condition (B) 2 driving cycles None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever this DTC is not present. Time after engine start ECT (Engine coolant temperature) None 16 min. and 40 sec. or more -15°C (5°F) or more ATF sensor circuit Not circuit malfunction ECT sensor circuit Not circuit malfunction IAT sensor circuit Not circuit malfunction ETCS Not circuit malfunction Condition (A): Time After engine start Driving distance after engine start AX 18 min. and 20 sec. 9 km (5.6 mile) or more IAT (Intake air temperature) (12 sec. after starting engine) -10°C (14°F) or more ECT (12 sec. after starting engine) -10°C (14°F) or more AX–59 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Condition (B): ECT (Current temperature) 60°C (140°F) or more ECT (12 sec. after engine start) Less than 35°C (95°F) TYPICAL MALFUNCTION THRESHOLDS Condition (A): ATF temperature sensor Less than 20°C (68°F) Condition (B): ATF temperature sensor 110°C (230°F) or more COMPONENT OPERATING RANGE ATF temperature sensor Atmospheric temperature to approx. 130°C (266°F) WIRING DIAGRAM C25 Electronically Controlled Transmission Solenoid ECM 1 72 C24 THO 7 E2 C 95 C24 THO1 ETHO C131059E04 INSPECTION PROCEDURE HINT: According to the DATA LIST displayed by the OBD II scan tool or intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. NOTICE: In the table below, the value listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether apart is faulty or not. 1. READ DATA LIST (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. AX AX–60 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM (d) (e) (f) (g) Turn the ignition switch on (IG). Turn on the tester. Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". According to the display on the tester, read the "DATA LIST". Item Measurement Item/ Range (display) Normal Condition AT FLUID TEMP ATF Temp. Sensor Value/ min.: -40°C (-40°F) max.: 215°C (419°F) Approx. 80°C (176°F) (After Stall Test) HINT: When DTC P0712 is output and OBD II scan tool or intelligent tester output is 150°C (302°F), there is a short circuit. When DTC P0713 is output and OBD II scan tool or intelligent tester output is -40°C (-40°F), there is an open circuit. Measure the resistance between terminal THO1 (THO) and body ground. Temperature Displayed Malfunction -40°C (-40°F) Open circuit 150°C (302°F) or more Short circuit HINT: If a circuit related to the ATF temperature sensor becomes open, P0713 is immediately set (in 0.5 second). When P0713 is set, P0711 cannot be detected. It is not necessary to inspect the circuit when P0711 is set. 1 CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0711) (a) Connect the OBD II scan tool or the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and push the OBD II scan tool or the intelligent tester main switch ON. (c) When you use intelligent tester: Select the item "DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES". (d) Read the DTCs using the OBD II scan tool or the intelligent tester. Result Display (DTC output) Proceed to Only "P0711" is output A "P0711" and other DTCs B HINT: If any other codes besides "P0711" are output, perform troubleshooting for those DTCs first. B GO TO DTC CHART A AX 2 CHECK TRANSMISSION FLUID LEVEL OK: Automatic transmission fluid level is correct. U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM NG AX–61 ADD FLUID OK REPLACE TRANSMISSION WIRE (ATF TEMPERATURE SENSOR) AX AX–62 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC P0717 Turbine Speed Sensor Circuit No Signal DESCRIPTION This sensor detects the rotation speed of the input turbine. By comparing the input turbine speed signal (NT) with the counter gear speed sensor signal (NC), the ECM detects the shift timing of the gears and appropriately controls the engine torque and hydraulic pressure according to various conditions. Thus, providing smooth gear shift. DTC No. DTC Detection Condition Trouble Area P0717 ECM detects conditions (a), (b) and (c) continuously for 5 sec. or more: (1-trip detection logic) (a) Vehicle speed: 50 km/h (31 mph) or more (b) Park/neutral position switch (STAR and R) is OFF (c) Speed sensor (NT): less than 300 rpm • • • • Open or short in transmission revolution sensor NT (speed sensor NT) circuit Transmission revolution sensor NT (speed sensor NT) ECM Automatic transaxle assembly 5 V/DIV 0.5 ms/DIV C053419E01 Reference (Using an oscilloscope): Check the waveform between terminals NT+ and NT- of the ECM connector. Standard: Refer to the illustration. Terminal Tool setting Vehicle condition NT+ - NT- 5 V/DIV, 0.5ms/DIV Vehicle speed 20 km/h (12 mph) MONITOR DESCRIPTION The NT terminal of the ECM detects a revolution signal from the speed sensor (NT) (input RPM). The ECM calculates a gearshift comparing the speed sensor (NT) with the speed sensor (NC). While the vehicle is operating in 2nd, 3rd, 4th or 5th gear in the shift position of D, if the input shaft revolution is less than 300 rpm *1although the output shaft revolution is more than 1,000 rpm *2, the ECM detects the trouble, illuminates the MIL and stores the DTC. *1: Pulse is not output or is irregularly output. *2: The vehicle speed is 50 km/h (31 mph) or more. MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation AX P0717: Speed sensor (NT) / Verify pulse input Speed sensor (NT), Speed sensor (NC) Continuous 5 sec. Immediate None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present. P0500 (VSS) P0748, P0778, P0798 (Shift solenoid valve (range)) AX–63 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Shift change Shift change is completed and before starting next shift change operation ECM selected gear 2nd, 3rd, 4th or 5th Output shaft rpm 1,000 rpm or more NSW switch OFF R switch OFF L switch OFF Engine Running Battery voltage 8 V or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Sensor signal rpm Less than 300 rpm COMPONENT OPERATING RANGE Speed sensor (NT) Turbine speed is equal to engine speed with lock-up ON WIRING DIAGRAM C26 ECM Speed Sensor (Tur bine) 1 125 NT+ C24 2 5V 124 C24 NTE1 G031763E44 INSPECTION PROCEDURE 1 INSPECT SPEED SENSOR INSTALLATION (a) Check the speed sensor installation. OK: The installation bolt is tightened properly and there is no clearance between the sensor and transaxle case. NG OK REPLACE SPEED SENSOR (NT) AX NG BR03795E36 AX–64 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM OK 2 INSPECT SPEED SENSOR (NT) (a) Disconnect the speed sensor connector from the transaxle. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Sensor Side: (Connector Front View): Tester Connection Specified Condition 20 °C (68 °F) 1-2 560 to 680 Ω C26 NG REPLACE SPEED SENSOR (NT) 1 2 C110343E37 OK 3 CHECK HARNESS AND CONNECTOR (SPEED SENSOR - ECM) (a) Connect the speed sensor connector. (b) Disconnect the ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side: (Connector Front View): C24 ECM Tester Connection Specified Condition 20°C (68°F) C24-125 (NT+) - C24-124 (NT-) 560 to 680 Ω (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short) NT- Tester Connection NT+ C24-125 (NT+) - Body ground A136781E02 C24-124 (NT-) - Body ground NG OK REPLACE ECM AX Specified Condition 10 kΩ or higher REPAIR OR REPLACE HARNESS OR CONNECTOR U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC P0724 AX–65 Brake Switch "B" Circuit High DESCRIPTION The purpose of this circuit is to prevent the engine from stalling while driving in lock-up condition when brakes are suddenly applied. When the brake pedal is depressed, this switch sends a signals to the ECM. Then the ECM cancels the operation of the lock-up clutch while braking is in progress. DTC No. DTC Detecting Condition Trouble Area P0724 The stop light switch remains ON even when the vehicle is driven in a STOP (less than 3 km/h (2 mph) and GO (30 km/h (19 mph) or more) fashion 5 times. (2-trip detection logic). • • • Short in stop light switch circuit Stop light switch ECM MONITOR DESCRIPTION This DTC indicates that the stop light switch remains on. When the stop light switch remains ON during "stop and go" driving, the ECM interprets this as a fault in the stop light switch and the MIL comes on and the ECM stores the DTC. The vehicle must stop (less than 3 km/h (2 mph)) and go (30 km/h (19 mph) or more) 5 times for two driving cycles in order to detect a malfunction. MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0724: Stop light switch/Rationality Stop light switch, Vehicle speed sensor Continuous GO and STOP 5 times 2 driving cycles None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present. None Ignition switch ON Starter OFF Battery voltage 8 V or more GO (Vehicle speed is 30 km/h (18.63 mph) or more) Once STOP (Vehicle speed is less than 3 km/h (1.86 mph)) Once TYPICAL MALFUNCTION THRESHOLDS Brake switch Remain ON during GO and STOP 5 times WIRING DIAGRAM See page ES-234. AX AX–66 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM INSPECTION PROCEDURE 1 READ VALUE OF DATA LIST HINT: According to the DATA LIST displayed by the OBD II scan tool or intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the OBD II scan tool or intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch on (IG). (e) Turn on the tester.. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". (g) According to the display on the tester, read the "DATA LIST". DATA LIST Item Measurement Item/ Range (display) STOP LIGHT SW Stop light SW Status/ ON or OFF Normal Condition • • Brake pedal is depressed: ON Brake pedal is released: OFF NOTICE: In the table below, the value listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether apart is faulty or not. OK Go to step 3 NG 2 INSPECT STOP LIGHT SWITCH ASSEMBLY 2 1 (a) Remove the stop light switch assembly. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Switch position Switch pin free 4 3 Switch pin pushed in Switch pin free Free Pushed In E065594E45 Switch pin pushed in NG AX OK Tester Connection 1-2 3-4 Specified Condition Below 1 Ω 10 kΩ or higher 10 kΩ or higher Below 1 Ω REPLACE STOP LIGHT SWITCH ASSEMBLY AX–67 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM 3 CHECK HARNESS AND CONNECTOR (STOP LIGHT SWITCH ASSEMBLY - ECM) (a) Install the stop light switch assembly. (b) Measure the voltage according to the value(s) in the table below when the brake pedal is depressed and released. Standard voltage Wire Harness Side: (Connector Front View): Condition ECM Brake pedal is depressed A24 Brake pedal is released NG STP Tester Connection Specified Condition A24-36 (STP) Body ground 10 to 14 V Below 1 V REPAIR OR REPLACE HARNESS OR CONNECTOR A115671E29 OK REPLACE ECM AX AX–68 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC P0741 Torque Converter Clutch Solenoid Performance (Shift Solenoid Valve DSL) SYSTEM DESCRIPTION The ECM uses the signals from the throttle position sensor, air-flow meter, turbine (input) speed sensor, intermediate (counter) shaft speed sensor and crankshaft position sensor to monitor the engagement condition of the lock-up clutch. Then the ECM compares the engagement condition of the lock-up clutch with the lock-up schedule in the ECM memory to detect a mechanical problems of the shift solenoid valve DSL, valve body and torque converter clutch. DTC No. DTC Detection CondS1ition P0741 Lock-up does not occur when driving in the lock-up range (normal driving at 80 km/h [50 mph]), or lock up remains ON in the lock-up OFF range. (2-trip detection logic) Trouble Area • • • • • Shift solenoid valve DSL remains open or closed Valve body is blocked Torque converter clutch Automatic transaxle (clutch, brake or gear etc.) Line pressure is too low MONITOR DESCRIPTION Torque converter lock-up is controlled by the ECM based on the speed sensor (NT), speed sensor (NC), engine rpm, engine load, engine temperature, vehicle speed, transmission temperature, and gear selection. The ECM determines the lock-up status of the torque converter by comparing the engine rpm (NE) to the input turbine rpm (NT). The ECM calculates the actual transmission gear by comparing input turbine rpm (NT) to counter gear rpm (NC). When conditions are appropriate, the ECM requests "lock-up" by applying control voltage to the shift solenoid DSL. When the DSL is turned on, it applies pressure to the lock-up relay valve and locks the torque converter clutch. If the ECM detects no lock-up after lock-up has been requested or if it detects lock-up when it is not requested, the ECM interprets this as a fault in the shift solenoid valve DSL or lock-up system performance. The ECM will turn on the MIL and store the DTC. HINT: Example: When any of the following is met, the system judges it as a malfunction. • There is a difference in rotation between the input side (engine speed) and output side (input turbine speed) of the torque converter when the ECM commands lock-up. (Engine speed is at least 75 rpm greater than input turbine speed.) • There is no difference in rotation between the input side (engine speed) and output side (input turbine speed) of the torque converter when the ECM commands lock-up off. (The difference between engine speed and input turbine speed is less than 35 rpm.) MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation AX P0741: Shift solenoid valve DSL/OFF malfunction Shift solenoid valve DSL/ON malfunction Shift solenoid valve DSL, Speed sensor (NT), Speed sensor (NC), Crankshaft position sensor (NE), Throttle position sensor (VPA1), Mass air flow sensor (MAF), Transmission temperature sensor (THO1), Engine coolant temperature sensor (ECT) Continuous Duration OFF malfunction 3.5 sec. ON malfunction 1.8 sec. MIL operation 2 driving cycles Sequence of operation None U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–69 TYPICAL ENABLING CONDITIONS ALL: The monitor will run whenever this DTC is not present. ECT (Engine coolant temperature) Transmission range TFT (Transmission fluid temperature) P0115 - P0118 (ECT sensor) P0125 (Insufficient ECT for closed loop) P0500 (VSS) P0748, P0778, P0798 (Shift solenoid valve (range)) 10°C (50°F) or more "D" -20°C (-4°F) or more TFT sensor circuit Not circuit malfunction ECT sensor circuit Not circuit malfunction Turbine speed sensor circuit Not circuit malfunction Intermediate shaft speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction Shift solenoid valve SL3 circuit Not circuit malfunction Shift solenoid valve S4 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve DSL circuit Not circuit malfunction Electronic throttle system Not circuit malfunction OFF malfunction ECM lock-up command ECM selected gear Vehicle speed ON 3rd, 4th or 5th 25 km/h (15.5 mph) or more ON malfunction ECM lock-up command OFF ECM selected gear 3rd, 4th or 5th Throttle valve opening angle 8.5% or more Vehicle speed 25 to 60 km/h (15.5 to 37.3 mph) TYPICAL MALFUNCTION THRESHOLDS Either of the following conditions is met: OFF malfunction or ON malfunction OFF malfunction: Engine Speed - Input (turbine) speed 100 rpm or more ON malfunction: Difference between engine speed and input (turbine) speed Less than 35 rpm INSPECTION PROCEDURE HINT: Performing the ACTIVE TEST using the intelligent tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. 1. PERFORM ACTIVE TEST (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. AX AX–70 (d) (e) (f) (g) U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Turn the ignition switch on (IG). Turn on the tester. Select the item "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST". According to the display on the tester, perform the "ACTIVE TEST". Item LOCK UP Test Details Diagnostic Note [Test Details] Control the shift solenoid DSL to set the automatic transaxle to the lock-up condition. [Vehicle Condition] Vehicle Speed: 60 km/h (37 mph) or more Possible to check the DSL operation. HINT: • This test can be conducted when the vehicle speed is 60 km/h (37 mph) or more. • This test can be conducted in the 5th gear. (h) Lightly depress the accelerator pedal and check that the engine speed does not change abruptly. HINT: • When changing the accelerator pedal opening angle while driving, if the engine speed does not change, lock-up is on. • Slowly release, but not fully, the accelerator pedal in order to decelerate. (Fully releasing the pedal will close the throttle valve and lock-up may be turned off.) Accelerator Pedal Opening Angel Accelerator Pedal Fully Released Lock-up OFF Engine speed Lock-up ON time G029214E02 1 CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0741) (a) Connect the OBD II scan tool or the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (b) Turn the ignition switch on (IG) and turn the OBD II scan tool or the intelligent tester main switch ON. (c) When you use intelligent tester: Select the item "DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES". (d) Read the DTCs using the OBD II scan tool or the intelligent tester. Result AX Display (DTC output) Proceed to Only "P0741" is output A "P0741" and other DTCs B U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–71 HINT: If any other codes besides "P0741" are output, perform the troubleshooting for those DTCs first. B GO TO DTC CHART A 2 INSPECT TRANSMISSION WIRE (DSL) (a) Disconnect the transmission wire connector from the transaxle. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Transmission Wire Side: (Connector Front View): DSL C25 NG Tester Connection Specified Condition 20°C (68°F) 10 - Body ground 11 to 13 Ω Go to step 4 C113969E25 OK 3 CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission wire connector. (b) Disconnect the ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side: (Connector Front View): C24 ECM Tester Connection Specified Condition 20°C (68°F) C24-79 (DSL) - Body ground 11 to 13 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR DSL A136781E03 OK AX AX–72 4 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM INSPECT SHIFT SOLENOID VALVE (DSL) (a) Remove the shift solenoid valve DSL. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Shift Solenoid Valve DSL: (-) Tester Connection Specified Condition 20°C (68°F) Solenoid Connector (DSL) - Solenoid Body (DSL) 11 to 13 Ω (c) Connect the positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. OK: The solenoid valve makes an operating sound. (+) C113970E01 NG REPLACE SHIFT SOLENOID VALVE (DSL) OK 5 CHECK TRANSMISSION WIRE OK: The connectors and pins are securely installed. There is no open or short on the wire harness. NG REPAIR OR REPLACE TRANSMISSION WIRE OK 6 INSPECT TRANSMISSION VALVE BODY ASSEMBLY OK: There are no foreign objects on each valve. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK 7 INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY OK: The torque converter clutch operates normally. NG AX REPLACE TORQUE CONVERTER CLUTCH ASSEMBLY U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–73 OK REPAIR AUTOMATIC TRANSAXLE ASSEMBLY AX AX–74 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC P0746 Pressure Control Solenoid "A" Performance (Shift Solenoid Valve SL1) SYSTEM DESCRIPTION The ECM uses signals from the vehicle speed sensor to detect the actual gear position (1st, 2nd, 3rd, 4th or 5th gear). Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical problems of the shift solenoid valves, valve body or automatic transaxle (clutch, brake or gear etc.). DTC No. P0746 DTC Detecting Condition Trouble Area The gear required by the ECM does not match the actual gear when driving (2-trip detection logic) • • • Shift solenoid valve SL1 remains open or closed Valve body is blocked Automatic transaxle (clutch, brake or gear etc.) MONITOR DESCRIPTION The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF". According to the input shaft revolution, intermediate (counter) shaft revolution and output shaft revolution, the ECM detects the actual gear position (1st, 2nd, 3rd, 4th or 5th gear position). When the gear position commanded by the ECM and the actual gear position are not the same, the ECM illuminates the MIL. HINT: Example: When either condition (a) or (b) is met, the ECM detects a malfunction. (a) The ECM commands the 1st gear, but the actual gear is 2nd. (b) The ECM commands the 2nd gear, but the actual gear is 1st. MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0746: Shift solenoid valve SL1/OFF malfunction Shift solenoid valve SL1/ON malfunction Shift solenoid valve SL1, Speed sensor (NT), Speed sensor (NC), Crankshaft position sensor (NE) Continuous 0.8 sec. 2 driving cycles None TYPICAL ENABLING CONDITIONS ALL: The monitor will run whenever this DTC is not present. ECT (Engine coolant temperature) Transmission range TFT (Transmission fluid temperature) AX P0115 - P0118 (ECT sensor) P0125 (Insufficient ECT for closed loop) P0500 (VSS) P0748, P0778, P0798 (Shift solenoid valve (range)) 10°C (50°F) or more "D" -20°C (-4°F) or more TFT sensor circuit Not circuit malfunction ECT sensor circuit Not circuit malfunction Turbine speed sensor circuit Not circuit malfunction Intermediate shaft speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Shift solenoid valve SL3 circuit Not circuit malfunction Shift solenoid valve S4 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve DSL circuit Not circuit malfunction Electronic throttle system Not circuit malfunction AX–75 OFF malfunction: ECM selected gear Vehicle speed Throttle valve opening angle 1st Less than 40 km/h (24.9 mph) 4.5% or more at engine speed 1,900 rpm (Varies with engine speed) ON malfunction: ECM selected gear Throttle valve opening angle 2nd 4.5% or more at engine speed 1,900 rpm (Varies with engine speed) TYPICAL MALFUNCTION THRESHOLDS Either of the following conditions is met: OFF malfunction or ON malfunction OFF malfunction: 2 detections are necessary per driving cycle: 1st detection; temporary flag ON 2nd detection; pending fault code ON Input (turbine) speed/Intermediate shaft speed 1.49 to 1.63 ON malfunction: Input (turbine) speed/Intermediate shaft speed 2.72 to 2.86 INSPECTION PROCEDURE HINT: Performing the ACTIVE TEST using the intelligent tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. 1. PERFORM ACTIVE TEST (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the OBD II scan tool or intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch on (IG). (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST / SHIFT". (g) According to the display on the tester, perform the "ACTIVE TEST". HINT: While driving, the shift position can be forcibly changed with the intelligent tester. AX AX–76 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem (See page AX-30). Item SHIFT Test Details Diagnostic Note [Test Details] Operate the shift solenoid valve and set each shift position by yourself. [Vehicle Condition] Less than 50 km/h (31 mph) [Others] • Press "←" button: Shift up • Press "→" button: Shift down Possible to check the operation of the shift solenoid valves. HINT: • This test can be conducted when the vehicle speed is 50 km/h (31 mph) or less. • The shift position commanded by the ECM is shown in the DATA LIST/SHIFT display on the intelligent tester. 1 CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0746) (a) Connect the OBD II scan tool or intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (b) Turn the ignition switch on (IG) and turn the OBD II scan tool or the intelligent tester main switch ON. (c) When you use intelligent tester: Select the item "DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES". (d) Read the DTCs using the OBD II scan tool or the intelligent tester. Result Display (DTC output) Proceed to Only "P0746" is output A "P0746" and other DTCs B HINT: If any other codes besides "P0746" are output, perform the troubleshooting for those DTCs first. B A AX GO TO DTC CHART U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM 2 AX–77 INSPECT SHIFT SOLENOID VALVE (SL1) (a) Remove the shift solenoid valve SL1. (b) Measure the resistance according to the value(s) in the table below. Resistance Shift Solenoid Valve SL1: 2 1 NG (-) Specified Condition 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. 2 1 Tester Connection REPLACE SHIFT SOLENOID VALVE (SL1) (+) G020767E05 OK 3 INSPECT TRANSMISSION VALVE BODY ASSEMBLY OK: There are no foreign objects on each valve. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK 4 INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY OK: The torque converter clutch operates normally. NG REPLACE TORQUE CONVERTER CLUTCH ASSEMBLY OK REPAIR OR REPLACE AUTOMATIC TRANSAXLE ASSEMBLY AX AX–78 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC P0748 Pressure Control Solenoid "A" Electrical (Shift Solenoid Valve SL1) DESCRIPTION Shifting from 1st to 5th is performed in combination with "ON" and "OFF" operation of the shift solenoid valves SL1, SL2, SL3, S4 and SR which are controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valves to allow the vehicle to be operated smoothly (Fail safe function). DTC No. DTC Detection Condition Trouble Area The ECM checks for an open or short in the shift solenoid valve SL1 circuit while driving and shift gears. (1-trip detection logic) • Output signal duty equals to 100 %. (NOTE: SL1 output signal duty is less than 100 % under normal condition.) P0748 • • • Open or short in shift solenoid valve SL1 circuit Shift solenoid valve SL1 ECM MONITOR DESCRIPTION The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF". When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. And the ECM performs the fail-safe function and turns the other normal shift solenoid valves "ON/OFF" (In case of an open or short circuit, the ECM stops sending current to the circuit.) (See page AX-30). MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0748: Shift solenoid valve SL1/Range check Shift solenoid valve SL1 Continuous 1 sec. Immediate None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present. Battery voltage None 11 V or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Solenoid status from MIC Fail (Open or Short) COMPONENT OPERATING RANGE Output signal duty AX Less than 100% AX–79 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM WIRING DIAGRAM C25 Electronically Controlled Transmission Solenoid SL1+ 57 C24 6 ECM +B CPU SL1+ 77 SL1C24 SL1- 13 G031765E34 INSPECTION PROCEDURE 1 INSPECT TRANSMISSION WIRE (SL1) (a) Disconnect the transmission wire connector from the transaxle. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Transmission Wire Side: (Connector Front View): C25 SL1+ Tester Connection Specified Condition 20°C (68°F) 6 (SL1+) - 13 (SL1-) 5.0 to 5.6 Ω (c) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short) SL1C113969E26 NG Tester Connection Specified Condition SL1+ - Body ground 10 kΩ or higher SL1- - Body ground 10 kΩ or higher Go to step 3 OK AX AX–80 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM 2 CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission connector to the transaxle. (b) Disconnect the connector from the ECM. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side: (Connector Front View): C24 ECM Tester Connection Specified Condition 20°C (68°F) C24-57 (SL1+) - C24-77 (SL1-) 5.0 to 5.6 Ω (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short) SL1+ SL1- Tester Connection C24-57 (SL1+) - Body ground A136781E04 C24-77 (SL1-) - Body ground NG Specified Condition 10 kΩ or higher REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM 3 INSPECT SHIFT SOLENOID VALVE (SL1) (a) Remove the shift solenoid valve SL1. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Shift Solenoid Valve SL1: 2 1 NG (-) AX Specified Condition 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. 2 1 Tester Connection (+) G020767E05 REPLACE SHIFT SOLENOID VALVE (SL1) U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–81 OK REPAIR OR REPLACE TRANSMISSION WIRE AX AX–82 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC P0766 Shift Solenoid "D" Performance (Shift Solenoid Valve S4) SYSTEM DESCRIPTION The ECM uses signals from the vehicle speed sensor to detect the actual gear position (1st, 2nd, 3rd, 4th or 5th gear). Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical problems of the shift solenoid valves, valve body or automatic transaxle (clutch, brake or gear etc.). DTC No. P0766 DTC Detecting Condition Trouble Area The gear required by the ECM does not match the actual gear when driving (2-trip detection logic) • • • Shift solenoid valve S4 remains open or closed Valve body is blocked Automatic transaxle (clutch, brake or gear etc.) MONITOR DESCRIPTION The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF". According to the input shaft revolution, intermediate (counter) shaft revolution and output shaft revolution, the ECM detects the actual gear position (1st, 2nd, 3rd, 4th or 5th gear position). When the gear position commanded by the ECM and the actual gear position are not the same, the ECM illuminates the MIL and stores the DTC. MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0766: Shift solenoid valve S4/OFF malfunction Shift solenoid valve S4/ON malfunction Shift solenoid valve S4, Speed sensor (NT), Speed sensor (NC), Crankshaft position sensor (NE) Continuous OFF malfunction (A) and ON malfunction (B) 1 sec. OFF malfunction (B) 1.2 sec. ON malfunction (A) 0.8 sec. 2 driving cycles None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever this DTC is not present. ECT (Engine coolant temperature) Transmission range TFT (Transmission fluid temperature) AX P0115 - P0118 (ECT sensor) P0125 (Insufficient ECT for closed loop) P0500 (VSS) P0748, P0778, P0798 (Shift solenoid valve (range)) 10°C (50°F) or more "D" -20°C (-4°F) or more TFT sensor circuit Not circuit malfunction ECT sensor circuit Not circuit malfunction Turbine speed sensor circuit Not circuit malfunction Intermediate shaft speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction Shift solenoid valve SL3 circuit Not circuit malfunction U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Shift solenoid valve S4 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve DSL circuit Not circuit malfunction Electronic throttle system Not circuit malfunction AX–83 OFF malfunction (A): ECM selected gear Throttle valve opening angle Vehicle speed 5th 5% or more 10 km/h (6.2 mph) or more OFF malfunction (B): ECM lock-up command ON ECM selected gear 3rd, 4th or 5th Throttle valve opening angle 10% or more Vehicle speed 25 to 100 km/h (15.5 to 62.1 mph) ON malfunction (A): ECM selected gear Throttle valve opening angle 4th or 5th 4.5% or more at engine speed 1,900 rpm (Varies with engine speed) ON malfunction (B): ECM selected gear Throttle valve opening angle Vehicle speed 4th 5% or more 10 km/h (6.2 mph) or more TYPICAL MALFUNCTION THRESHOLDS Either of the following conditions is met: OFF malfunction (A) and (B), or ON malfunction (A) and (B) 2 detections are necessary per driving cycle: 1st detection; temporary flag ON 2nd detection; pending fault code ON OFF malfunction (A): Intermediate shaft speed/Output speed 1.34 to 1.48 OFF malfunction (B): Difference between engine speed and input (turbine) speed Less than 35 rpm ON malfunction (A): Input (turbine) speed/Intermediate shaft speed 0.64 to 0.74 ON malfunction (B): Intermediate shaft speed/Output speed 0.95 to 1.09 INSPECTION PROCEDURE HINT: Performing the ACTIVE TEST using the intelligent tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. 1. PERFORM ACTIVE TEST (a) Warm up the engine. (b) Turn the ignition switch off. AX AX–84 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM (c) Connect the OBD II scan tool or intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch on (IG). (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST / SHIFT". (g) According to the display on the tester, perform the "ACTIVE TEST". HINT: While driving, the shift position can be forcibly changed with the intelligent tester. Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem (See page AX-30). Item SHIFT Test Details Diagnostic Note [Test Details] Operate the shift solenoid valve and set each shift position by yourself. [Vehicle Condition] Less than 50 km/h (31 mph) [Others] • Press "→" button: Shift up • Press "←" button: Shift down Possible to check the operation of the shift solenoid valves. HINT: • This test can be conducted when the vehicle speed is 50 km/h (31 mph) or less. • The shift position commanded by the ECM is shown in the DATA LIST/SHIFT display on the intelligent tester. 1 CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0766) (a) Connect the OBD II scan tool or intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (b) Turn the ignition switch on (IG) and turn the OBD II scan tool or the intelligent tester main switch ON. (c) Select the item "DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES". (d) Read the DTCs using the OBD II scan tool or the intelligent tester. Result Display (DTC output) Proceed to Only "P0766" is output A "P0766" and other DTCs B HINT: If any other codes besides "P0766" are output, perform the troubleshooting for those DTCs first. B A AX GO TO DTC CHART U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM 2 AX–85 INSPECT SHIFT SOLENOID VALVE S4 (a) Remove the shift solenoid valve S4. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Shift Solenoid Valve S4: (-) (+) Tester Connection Specified Condition 20°C (68°F) Solenoid Connector (S4) - Solenoid Body (S4) 11 to 15 Ω (c) Connect the positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. OK: The solenoid makes an operating sound. C113971E01 NG REPLACE SHIFT SOLENOID VALVE (S4) OK 3 INSPECT TRANSMISSION VALVE BODY ASSEMBLY OK: There are no foreign objects on each valve. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK 4 INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY OK: The torque converter clutch operates normally. NG REPLACE TORQUE CONVERTER CLUTCH ASSEMBLY OK REPAIR OR REPLACE AUTOMATIC TRANSAXLE ASSEMBLY AX AX–86 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC P0771 Shift Solenoid "E" Performance (Shift Solenoid Valve SR) SYSTEM DESCRIPTION The ECM uses signals from the vehicle speed sensor to detect the actual gear position (1st, 2nd, 3rd, 4th or 5th gear). Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical problems of the shift solenoid valves, valve body or automatic transaxle (clutch, brake or gear etc.). DTC No. P0771 DTC Detecting Condition Trouble Area The gear required by the ECM does not match the actual gear when driving (2-trip detection logic) • • • Shift solenoid valve SR remains open or closed Valve body is blocked Automatic transaxle (clutch, brake or gear etc.) MONITOR DESCRIPTION The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF". According to the input shaft revolution, intermediate (counter) shaft revolution and output shaft revolution, the ECM detects the actual gear position (1st, 2nd, 3rd, 4th or 5th gear position). When the gear position commanded by the ECM and the actual gear position are not the same, the ECM illuminates the MIL and stores the DTC. MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0771: Shift solenoid valve SR/Rationality check Shift solenoid valve SR, Speed sensor (NT), Speed sensor (NC), Crankshaft position sensor (NE) Continuous OFF malfunction (A) 1 sec. OFF malfunction (B) 3.5 sec. ON malfunction (A) Continuous ON malfunction (B) and (C) 0.8 sec. 2 driving cycles None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever this DTC is not present ECT (Engine coolant temperature) Transmission range TFT (Transmission fluid temperature) AX P0115 - P0118 (ECT sensor) P0125 (Insufficient ECT for closed loop) P0500 (VSS) P0748, P0778, P0798 (Shift solenoid valve (range)) 10°C (50°F) or more "D" -20°C (-4°F) or more TFT sensor circuit Not circuit malfunction ECT sensor circuit Not circuit malfunction Turbine speed sensor circuit Not circuit malfunction Intermediate shaft speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Shift solenoid valve SL3 circuit Not circuit malfunction Shift solenoid valve S4 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve DSL circuit Not circuit malfunction Electronic throttle system Not circuit malfunction AX–87 OFF malfunction (A): ECM selected gear Throttle valve opening angle Vehicle speed 5th 5% or more 10 km/h (6.2 mph) or more OFF malfunction (B): ECM lock-up command ECM selected gear Vehicle speed ON 3rd, 4th or 5th 25 km/h (15.5 mph) or more ON malfunction (A): ECM lock-up command OFF ON malfunction (B): ECM selected gear Vehicle speed Throttle valve opening angle 1st Less than 40 km/h (24.9 mph) 4.5% or more at engine speed 1,900 rpm (Varies with engine speed) ON malfunction (C): ECM selected gear Throttle valve opening angle 3rd 4.5% or more at engine speed 1,900 rpm (Varies with engine speed) ON malfunction (D): Duration time from shift command of ECM ECM selected gear 15 sec. or more 4th or 5th TYPICAL MALFUNCTION THRESHOLDS Either of the following conditions is met: OFF malfunction (A) and (B), or ON malfunction (A), (B), (C) and (D) OFF malfunction (A): Intermediate shaft speed/Output speed 1.34 to 1.48 OFF malfunction (B): Engine speed - Input (turbine) speed 75 rpm or more ON malfunction (A): Difference between engine speed and input (turbine) speed 150 rpm or more ON malfunction (B): Input (turbine) speed/Intermediate shaft speed 0.93 to 1.07 ON malfunction (C): Input (turbine) speed/Intermediate shaft speed 0.93 to 1.07 ON malfunction (D): Input (turbine) speed/Intermediate shaft speed 0.64 to 0.74 AX AX–88 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM INSPECTION PROCEDURE HINT: Performing the ACTIVE TEST using the intelligent tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. 1. PERFORM ACTIVE TEST (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the OBD II scan tool or intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch on (IG). (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST / SHIFT". (g) According to the display on the tester, perform the "ACTIVE TEST". HINT: While driving, the shift position can be forcibly changed with the intelligent tester. Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem (See page AX-30). Item SHIFT Test Details [Test Details] Operate the shift solenoid valve and set each shift position by yourself. [Vehicle Condition] Less than 50 km/h (31 mph) [Others] • Press "→" button: Shift up • Press "←" button: Shift down Diagnostic Note Possible to check the operation of the shift solenoid valves. HINT: • This test can be conducted when the vehicle speed is 50 km/h (31 mph) or less. • The shift position commanded by the ECM is shown in the DATA LIST/SHIFT display on the intelligent tester. 1 CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0771) (a) Connect the OBD II scan tool or intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (b) Turn the ignition switch on (IG) and turn the OBD II scan tool or the intelligent tester main switch ON. (c) When you use intelligent tester: Select the item "DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES". (d) Read the DTCs using the OBD II scan tool or the intelligent tester. Result AX Display (DTC output) Proceed to Only "P0771" is output A "P0771" and other DTCs B HINT: If any other codes besides "P0771" are output, perform the troubleshooting for those DTCs first. U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM B AX–89 GO TO DTC CHART A 2 INSPECT SHIFT SOLENOID VALVE (SR) (a) Remove the shift solenoid valve SR. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Shift Solenoid Valve SR: (+) Tester Connection Specified Condition 20°C (68°F) Solenoid Connector (SR) - Solenoid Body (SR) 11 to 15 Ω (-) (c) Connect positive (+) lead to the terminal of solenoid connector, negative (-) lead to the solenoid body. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID VALVE (SR) C113977E01 OK 3 INSPECT TRANSMISSION VALVE BODY ASSEMBLY OK: There are no foreign objects on each valve. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK 4 INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY OK: The torque converter clutch operates normally. NG REPLACE TORQUE CONVERTER CLUTCH ASSEMBLY OK REPAIR OR REPLACE AUTOMATIC TRANSAXLE ASSEMBLY AX AX–90 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC P0776 Pressure Control Solenoid "B" Performance (Shift Solenoid Valve SL2) SYSTEM DESCRIPTION The ECM uses signals from the vehicle speed sensor to detect the actual gear position (1st, 2nd, 3rd, 4th or 5th gear). Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical problems of the shift solenoid valves, valve body or automatic transaxle (clutch, brake or gear etc.). DTC No. P0776 DTC Detecting Condition Trouble Area The gear required by the ECM does not match the actual gear when driving (2-trip detection logic) • • • Shift solenoid valve SL2 remains open or closed Valve body is blocked Automatic transaxle (clutch, brake or gear etc.) MONITOR DESCRIPTION The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF". According to the input shaft revolution, intermediate (counter) shaft revolution and output shaft revolution, the ECM detects the actual gear position (1st, 2nd, 3rd, 4th or 5th gear position). When the gear position commanded by the ECM and the actual gear position are not the same, the ECM illuminates the MIL and stores the DTC. MONITOR STRATEGY Related DTCs P0776: Shift solenoid valve SL2/OFF malfunction Shift solenoid valve SL2/ON malfunction Required sensors/Components Shift solenoid valve SL2, Speed sensor (NT), Speed sensor (NC), Crankshaft position sensor (NE) Frequency of operation Continuous Duration OFF malfunction (A) 1.8 sec. OFF malfunction (B) and (C) 0.8 sec. ON malfunction (A) and (B) 0.8 sec. ON malfunction (C) 0.4 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever this DTC is not present. ECT (Engine coolant temperature) Transmission range TFT (Transmission fluid temperature) AX P0115 - P0118 (ECT sensor) P0125 (Insufficient ECT for closed loop) P0500 (VSS) P0748, P0778, P0798 (Shift solenoid valve (range)) 10°C (50°F) or more "D" -20°C (-4°F) or more TFT sensor circuit Not circuit malfunction ECT sensor circuit Not circuit malfunction Turbine speed sensor circuit Not circuit malfunction Intermediate shaft speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Shift solenoid valve SL3 circuit Not circuit malfunction Shift solenoid valve S4 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve DSL circuit Not circuit malfunction Electronic throttle system Not circuit malfunction AX–91 OFF malfunction (A): ECM lock-up command Vehicle speed Throttle valve opening angle OFF Less than 60 km/h (37.3 mph) 8.5% or more OFF malfunction (B): ECM selected gear Vehicle speed Throttle valve opening angle 1st Less than 40 km/h (24.9 mph) 4.5% or more at engine speed 1,900 rpm (Varies with engine speed) OFF malfunction (C): ECM selected gear Throttle valve opening angle 3rd 4.5% or more at engine speed 1,900 rpm (Varies with engine speed) OFF malfunction (D): Duration time from shift command of ECM ECM selected gear 15 sec. or more 4th or 5th ON malfunction (A): ECM selected gear Vehicle speed Throttle valve opening angle 1st Less than 40 km/h (24.9 mph) 4.5% or more at engine speed 1,900 rpm (Varies with engine speed) ON malfunction (B): ECM selected gear Throttle valve opening angle Malfunction of pressure control solenoid "B" (SL2) and "C" (SL3) 3rd 7.0% or more at output speed 1,400 rpm (Varies with engine speed) Not detected ON malfunction (C): Throttle valve opening angle Malfunction of pressure control solenoid "B" (SL2) 7.0% or more at output speed 1,050 rpm (Varies with engine speed) Not detected TYPICAL MALFUNCTION THRESHOLDS Either of the following conditions is met: OFF malfunction (A), (B), (C) and (D), or ON malfunction (A), (B) and (C) OFF malfunction (A): Difference between engine speed and input (turbine) speed Less than 35 rpm OFF malfunction (B) and (C): Input (turbine) speed/Intermediate shaft speed 0.93 to 1.07 OFF malfunction (D): Input (turbine) speed/Intermediate shaft speed 0.64 to 0.74 AX AX–92 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM ON malfunction (A): Input (turbine) speed/Intermediate shaft speed 2.72 to 2.86 ON malfunction (B): Input (turbine) speed - Intermediate shaft speed 700 rpm or more ON malfunction (C): Less than -500 rpm or 700 rpm or more Input (turbine) speed - Intermediate shaft speed INSPECTION PROCEDURE HINT: Performing the ACTIVE TEST using the intelligent tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. 1. PERFORM ACTIVE TEST (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the OBD II scan tool or intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch on (IG). (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST / SHIFT". (g) According to the display on the tester, perform the "ACTIVE TEST". HINT: While driving, the shift position can be forcibly changed with the intelligent tester. Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem (See page AX-30). Item SHIFT Test Details [Test Details] Operate the shift solenoid valve and set the each shift position by yourself. [Vehicle Condition] Less than 50 km/h (31 mph) [Others] • Press "→" button: Shift up • Press "←" button: Shift down Diagnostic Note Possible to check the operation of the shift solenoid valves. HINT: • This test can be conducted when the vehicle speed is 50 km/h (31 mph) or less. • The shift position commanded by the ECM is shown in the DATA LIST/SHIFT display on the intelligent tester. 1 AX CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0776) (a) Connect the OBD II scan tool or intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (b) Turn the ignition switch on (IG) and turn the OBD II scan tool or the intelligent tester main switch ON. (c) When you use intelligent tester: Select the item "DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES". U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–93 (d) Read the DTCs using the OBD II scan tool or the intelligent tester. Result Display (DTC output) Proceed to Only "P0776" is output A "P0776" and other DTCs B HINT: If any other codes besides "P0776" are output, perform the troubleshooting for those DTCs first. B GO TO DTC CHART A 2 INSPECT SHIFT SOLENOID VALVE (SL2) (a) Remove the shift solenoid valve SL2. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Shift Solenoid Valve SL2: 2 1 NG (-) Specified Condition 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. 2 1 Tester Connection REPLACE SHIFT SOLENOID VALVE (SL2) (+) G020767E28 OK 3 INSPECT TRANSMISSION VALVE BODY ASSEMBLY OK: There are no foreign objects on each valve. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK AX AX–94 4 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY OK: The torque converter clutch operates normally. NG REPLACE TORQUE CONVERTER CLUTCH ASSEMBLY OK REPAIR OR REPLACE AUTOMATIC TRANSAXLE ASSEMBLY AX U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC P0778 AX–95 Pressure Control Solenoid "B" Electrical (Shift Solenoid Valve SL2) DESCRIPTION Shifting from 1st to 5th is performed in combination with "ON" and "OFF" operation of the shift solenoid valves SL1, SL2, SL3, S4 and SR which are controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valves to allow the vehicle to be operated smoothly (Fail safe function). DTC No. DTC Detection Condition Trouble Area ECM checks for an open or short circuit in shift solenoid valves SL2 (1-trip detection logic) Hybrid IC for solenoid indicates fail. P0778 • • • Open or short in shift solenoid valve SL2 circuit Shift solenoid valve SL2 ECM MONITOR DESCRIPTION The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF". When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. And the ECM performs the fail-safe function and turns the other normal shift solenoid valves "ON/OFF" (In case of an open or short circuit, the ECM stops sending current to the circuit.) (See page AX-30). MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0778: Shift solenoid valve SL2/Range check Shift solenoid valve SL2 Continuous 1 sec. Immediate None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present. Solenoid current cut status Battery voltage None Not cut 11 V or more Ignition switch ON Starter OFF CPU commanded duty ratio to SL2 19% or more TYPICAL MALFUNCTION THRESHOLDS Solenoid status from MIC Fail (Open or short) COMPONENT OPERATING RANGE Output signal duty Less than 100% AX A X–96 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM WIRING DIAGRAM C25 Electronically Controlled Transmission Solenoid ECM +B CPU 58 SL2+ C24 5 SL2+ 59 SL2- C24 SL2- 12 G031765E35 INSPECTION PROCEDURE 1 INSPECT TRANSMISSION WIRE (SL2) (a) Disconnect the transmission wire connector from the transaxle. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Transmission Wire Side: (Connector Front View): SL2+ C25 Tester Connection Specified Condition 20°C (68°F) 5 (SL2+) - 12 (SL2-) 5.0 to 5.6 Ω (c) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short) SL2C113969E27 NG OK AX Tester Connection Specified Condition 5 (SL2+) - Body ground 10 kΩ or higher 12 (SL2-) - Body ground 10 kΩ or higher Go to step 3 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM 2 AX–97 CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission connector to the transaxle. (b) Disconnect the connector from the ECM. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side: (Connector Front View): C24 ECM Tester Connection Specified Condition 20°C (68°F) C24-58 (SL2+) - C24-59 (SL2-) 5.0 to 5.6 Ω (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short) SL2+ SL2- Tester Connection C24-58 (SL2+) - Body ground A136781E05 C24-59 (SL2-) - Body ground NG Specified Condition 10 kΩ or higher REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM 3 INSPECT SHIFT SOLENOID VALVE (SL2) (a) Remove the shift solenoid valve SL2. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Shift Solenoid Valve SL2: 2 1 NG (-) Specified Condition 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. 2 1 Tester Connection REPLACE SHIFT SOLENOID VALVE (SL2) (+) G020767E28 AX AX–98 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM OK REPAIR OR REPLACE TRANSMISSION WIRE AX U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC P0793 AX–99 Intermediate Shaft Speed Sensor "A" DESCRIPTION This sensor detects the rotation speed of the counter gear. By comparing the counter gear speed signal (NC) with the direct clutch speed sensor signal (NT), the ECM detects the shift timing of the gears and appropriately controls the engine torque and hydraulic pressure according to various conditions. Thus smooth gear shifting is performed. DTC No. DTC Detection Condition Trouble Area P0793 ECM detects conditions (a), (b) and (c) continuously for 5 sec. or more: (1-trip detection logic) (a) Vehicle speed: 50 km/h (31 mph) or more (b) Park/neutral position switch (STAR) is OFF (c) Speed sensor (NC): less than 300 rpm • • • Open or short in transmission revolution sensor NC (speed sensor NC) circuit Transmission revolution sensor NC (speed sensor NC) ECM Reference (Using an oscilloscope): Check the waveform between terminals NC+ and NC- of the ECM connector. 1 V/DIV 1 ms/DIV C093866E01 Standard: Refer to the illustration. Terminal NC+ - NC- Tool setting 1 V/DIV, 1ms/DIV Vehicle condition Vehicle speed 30 km/h (19 mph): (3rd gear) Engine speed 1,400 rpm MONITOR DESCRIPTION The NC terminal of the ECM detects a revolution signal from the speed sensor (NC) (counter gear rpm). The ECM calculates a gearshift comparing the speed sensor (NT) with the speed sensor (NC). While the vehicle is operating in 2nd, 3rd, 4th or 5th gear in the shift position of D, if the counter gear revolution is less than 300 rpm *1although the output shaft revolution is more than 1,000 rpm *2, the ECM detects the trouble, illuminates the MIL and stores the DTC. *1: Pulse is not output or is irregularly output. *2: The vehicle speed is 50 km/h (31 mph) or more. MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0793: Speed sensor (NC)/Verify pulse input Speed sensor (NC), Speed sensor (NT), Park/neutral position switch Continuous 5 sec. Immediate None AX AX–100 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM TYPICAL ENABLING CONDITIONS P0500 (VSS) P0748, P0778, P0798 (Shift solenoid valve(range)) The monitor will run whenever this DTC is not present. Engine Running NSW switch OFF Output shaft rpm 1,000 rpm or more Battery voltage 8 V or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Sensor signal rpm Less than 300 rpm COMPONENT OPERATING RANGE HINT: 3rd when shift lever position is D position (After warming up the engine); • Intermediate shaft speed (NC) becomes close to the engine speed. Counter gear speed sensor (NC) WIRING DIAGRAM C27 Speed Sensor (Counter Gear) ECM 101 1 2 C24 NC+ 5V 102 C24 NCE1 G031763E45 INSPECTION PROCEDURE AX HINT: According to the DATA LIST displayed by the OBD II scan tool or intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. 1. READ DATA LIST (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the OBD II scan tool or intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch on (IG). (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". (g) According to the display on the tester, read the "DATA LIST". U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Measurement Item/ Range (display) Item Counter Gear Speed/ display: 50 r/min SPD (NC) AX–101 Normal Condition [HINT] 3rd when shift lever position is D position (After warming up the engine); • Intermediate shaft speed (NC) becomes close to the engine speed. HINT: • SPD (NC) is always 0 while driving: Open or short in the sensor or circuit. • SPD (NC) is always more than 0 and less than 300 rpm while driving the vehicle at 50 km/h (31 mph) or more: Sensor trouble, improper installation, or intermittent connection trouble of the circuit. 1 INSPECT SPEED SENSOR INSTALLATION (a) Check the speed sensor installation. OK: The installation bolt is tightened properly and there is no clearance between the sensor and transaxle case. NG OK REPLACE SPEED SENSOR (NC) NG BR03795E35 OK 2 INSPECT SPEED SENSOR (NC) (a) Disconnect the speed sensor connector from the transaxle. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Sensor Side: (Connector Front View): Tester Connection Specified Condition 20 °C (68 °F) 1-2 560 to 680 Ω C27 NG 2 REPLACE SPEED SENSOR (NC) 1 C110343E38 OK AX AX–102 3 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM CHECK HARNESS AND CONNECTOR (SPEED SENSOR - ECM) (a) Connect the speed sensor connector. (b) Disconnect the ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side: (Connector Front View): C24 ECM Tester Connection Specified Condition 20 °C (68 °F) C24-101 (NC+) - C24-102 (NC-) 560 to 680 Ω (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short) NC+ Tester Connection NC- C24-101 (NC+) - Body ground A136781E06 C24-102 (NC-) - Body ground NG OK REPLACE ECM AX Specified Condition 10 kΩ or higher REPAIR OR REPLACE HARNESS OR CONNECTOR U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC P0796 AX–103 Pressure Control Solenoid "C" Performance (Shift Solenoid Valve SL3) SYSTEM DESCRIPTION The ECM uses signals from the vehicle speed sensor to detect the actual gear position (1st, 2nd, 3rd, 4th or 5th gear). Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical troubles of the shift solenoid valves and valve body. DTC No. P0796 DTC Detecting Condition Trouble Area The gear required by the ECM does not match the actual gear when driving (2-trip detection logic) • • • Shift solenoid valve SL3 remains open or closed Valve body is blocked Automatic transaxle (clutch, brake or gear etc.) MONITOR DESCRIPTION The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF". According to the input shaft revolution, intermediate (counter) shaft revolution and output shaft revolution, the ECM detects the actual gear position (1st, 2nd, 3rd, 4th or 5th gear position). When the gear position commanded by the ECM and the actual gear position are not the same, the ECM illuminates the MIL and stores the DTC. MONITOR STRATEGY Related DTCs P0796: Shift solenoid valve SL3/OFF malfunction Shift solenoid valve SL3/ON malfunction Required sensors/Components Shift solenoid valve SL3, Speed sensor (NT), Speed sensor (NC), Crankshaft position sensor (NE) Frequency of operation Continuous Duration OFF malfunction (A) 0.8 sec. OFF malfunction (B) 1 sec. ON malfunction (A) and (B) 0.8 sec. ON malfunction (C) 0.4 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever this DTC is not present. ECT (Engine coolant temperature) Transmission range TFT (Transmission fluid temperature) P0115 - P0118 (ECT sensor) P0125 (Insufficient ECT for closed loop) P0500 (VSS) P0748, P0778, P0798 (Shift solenoid valve (range)) 10°C (50°F) or more "D" -20°C (-4°F) or more TFT sensor circuit Not circuit malfunction ECT sensor circuit Not circuit malfunction Turbine speed sensor circuit Not circuit malfunction Intermediate shaft speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction AX AX–104 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Shift solenoid valve SL3 circuit Not circuit malfunction Shift solenoid valve S4 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve DSL circuit Not circuit malfunction Electronic throttle system Not circuit malfunction OFF malfunction (A): ECM selected gear Throttle valve opening angle 4th or 5th 4.5% or more at engine speed 1,900 rpm (Varies with engine speed) OFF malfunction (B): ECM selected gear Throttle valve opening angle Vehicle speed 4th 5% or more 10 km/h (6.2 mph) or more ON malfunction (A): ECM selected gear Vehicle speed Throttle valve opening angle 1st Less than 40 km/h (24.9 mph) 4.5% or more at engine speed 1,900 rpm (Varies with engine speed) ON malfunction (B): ECM selected gear Throttle valve opening angle Malfunction of pressure control solenoid "B" (SL2) and "C" (SL3) 3rd 7.0% or more at output speed 1,400 rpm (Varies with engine speed) Not detected ON malfunction (C): Throttle valve opening angle Malfunction of pressure control solenoid "B" (SL2) 7.0% or more at output speed 1,050 rpm (Varies with engine speed) Not detected TYPICAL MALFUNCTION THRESHOLDS Either of the following conditions is met: OFF malfunction (A) and (B), or ON malfunctions (A), (B) and (C) 2 detections are necessary per driving cycle: 1st detection; temporary flag ON 2nd detection; pending fault code ON OFF malfunction (A): Input (turbine) speed/Intermediate shaft speed 0.93 to 1.07 OFF malfunction (B): Intermediate shaft speed/Output speed 0.95 to 1.09 ON malfunction (A): Input (turbine) speed/Intermediate shaft speed 0.93 to 1.07 ON malfunction (B): Input (turbine) speed - Intermediate shaft speed 700 rpm or more ON malfunction (C): AX Input (turbine) speed - Intermediate shaft speed Less than -500 rpm or 700 rpm or more U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–105 INSPECTION PROCEDURE HINT: Performing the ACTIVE TEST using the intelligent tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. 1. PERFORM ACTIVE TEST (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the OBD II scan tool or intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch on (IG). (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST / SHIFT". (g) According to the display on the tester, perform the "ACTIVE TEST". HINT: While driving, the shift position can be forcibly changed with the intelligent tester. Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem (See page AX-30). Item Test Details Diagnostic Note SHIFT [Test Details] Operate the shift solenoid valve and set each shift position by yourself. [Vehicle Condition] Less than 50 km/h (31 mph) [Others] • Press "→" button: Shift up • Press "←" button: Shift down Possible to check the operation of the shift solenoid valves. HINT: • This test can be conducted when the vehicle speed is 50 km/h (31 mph) or less. • The shift position commanded by the ECM is shown in the DATA LIST/SHIFT display on the intelligent tester. 1 CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0796) (a) Connect the OBD II scan tool or intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (b) Turn the ignition switch on (IG) and turn the OBD II scan tool or the intelligent tester main switch ON. (c) When you use intelligent tester: Select the item "DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES". (d) Read the DTCs using the OBD II scan tool or the intelligent tester. Result Display (DTC output) Proceed to Only "P0796" is output A "P0796" and other DTCs B HINT: If any other codes besides "P0796" are output, perform the troubleshooting for those DTCs first. AX AX–106 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM B GO TO DTC CHART A 2 INSPECT SHIFT SOLENOID VALVE (SL3) (a) Remove the shift solenoid valve SL3. (b) Measure the resistance according to the value(s) in the table below. Resistance Shift Solenoid Valve SL3: 2 1 NG (-) Specified Condition 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. 2 1 Tester Connection REPLACE SHIFT SOLENOID VALVE (SL3) (+) G020767E29 OK 3 INSPECT TRANSMISSION VALVE BODY ASSEMBLY OK: There are no foreign objects on each valve. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK 4 INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY OK: The torque converter clutch operates normally. NG REPLACE TORQUE CONVERTER CLUTCH ASSEMBLY OK AX REPAIR OR REPLACE AUTOMATIC TRANSAXLE ASSEMBLY U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC P0798 AX–107 Pressure Control Solenoid "C" Electrical (Shift Solenoid Valve SL3) DESCRIPTION Shifting from 1st to 5th is performed in combination with "ON" and "OFF" operation of the shift solenoid valves SL1, SL2, SL3, S4 and SR which are controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valves to allow the vehicle to be operated smoothly (Fail safe function). DTC No. DTC Detection Condition Trouble Area The ECM checks for an open or short in the shift solenoid valve SL3 circuit while driving and shifting gears. (1-trip detection logic) – Output signal duty equals to 100 %. (NOTE: SL3 output signal duty is less than 100 % under normal condition.) P0798 • • • Open or short in shift solenoid valve SL3 circuit Shift solenoid valve SL3 ECM MONITOR DESCRIPTION The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF". When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. And the ECM performs the fail-safe function and turns the other normal shift solenoid valves "ON/OFF" (In case of an open or short circuit, the ECM stops sending current to the circuit.) (See page AX-30). MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0798: Shift solenoid valve SL3/Range check Shift solenoid valve SL3 Continuous 1 sec. Immediate None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present. Battery voltage None 11 V or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Solenoid status from MIC Fail (Open or short) COMPONENT OPERATING RANGE Output signal duty Less than 100% AX AX–108 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM WIRING DIAGRAM C25 Electronically Controlled Transmission Solenoid ECM +B CPU 60 SL3+ SL3- C24 4 SL3+ 61 SL3C24 11 G031765E36 INSPECTION PROCEDURE 1 INSPECT TRANSMISSION WIRE (SL3) (a) Disconnect the transmission wire connector from the transaxle. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Transmission Wire Side: (Connector Front View): SL3+ C25 Tester Connection Specified Condition 20°C (68°F) 4 (SL3+) - 11 (SL3-) 5.0 to 5.6 Ω (c) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short) Tester Connection 4 (SL3+) - Body ground SL3- 11 (SL3-) - Body ground C113969E28 NG OK AX Go to step 3 Specified Condition 10 kΩ or higher U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM 2 AX–109 CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission connector to the transaxle. (b) Disconnect the connector from the ECM. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side: (Connector Front View): C24 ECM Tester Connection Specified Condition 20°C (68°F) C24-60 (SL3+) - C24-61 (SL3-) 5.0 to 5.6 Ω (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short) SL3+ SL3- Tester Connection C24-60 (SL3+) - Body ground A136781E07 C24-61 (SL3-) - Body ground NG Specified Condition 10 kΩ or higher REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM 3 INSPECT SHIFT SOLENOID VALVE (SL3) (a) Remove the shift solenoid valve SL3. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Shift Solenoid Valve SL3: 2 1 NG (-) Specified Condition 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. 2 1 Tester Connection REPLACE SHIFT SOLENOID VALVE (SL3) (+) G020767E29 AX AX–110 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM OK REPAIR OR REPLACE TRANSMISSION WIRE AX U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–111 DTC P0982 Shift Solenoid "D" Control Circuit Low (Shift Solenoid Valve S4) DTC P0983 Shift Solenoid "D" Control Circuit High (Shift Solenoid Valve S4) DESCRIPTION Shifting from 1st to 5th is performed in combination with "ON" and "OFF" operation of the shift solenoid valves SL1, SL2, SL3, S4 and SR which are controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valves to allow the vehicle to be operated smoothly (Fail safe function). DTC No. DTC Detection Condition Trouble Area P0982 ECM detects short in solenoid valve S4 circuit 2 times when solenoid valve S4 is operated (1-trip detection logic) • • • Short in shift solenoid valve S4 circuit Shift solenoid valve S4 ECM P0983 ECM detects open in solenoid valve S4 circuit 2 times when solenoid valve S4 is not operated (1-trip detection logic) • • • Open in shift solenoid valve S4 circuit Shift solenoid valve S4 ECM MONITOR DESCRIPTION The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF". When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. And the ECM performs the fail-safe function and turns the other normal shift solenoid valves "ON/OFF" (In case of an open or short circuit, the ECM stops sending current to the circuit.) (See page AX-30). MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0982: Shift solenoid valve S4/Range check (Low resistance) P0983: Shift solenoid valve S4/Range check (High resistance) Shift solenoid valve S4 Continuous 0.064 sec. or more Immediate None TYPICAL ENABLING CONDITIONS P0982: Range check (Low resistance): The monitor will run whenever this DTC is not present. Shift solenoid valve S4 Battery voltage None ON 8 V or more Ignition switch ON Starter OFF P0983: Range check (High resistance): The monitor will run whenever this DTC is not present. None Shift solenoid valve S4 OFF Battery voltage 8 V or more Ignition switch ON Starter OFF AX AX–112 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM TYPICAL MALFUNCTION THRESHOLDS P0982: Range check (Low resistance): 8 Ω or less Shift solenoid valve S4 resistance P0983: Range check (High resistance): Shift solenoid valve S4 resistance 100 kΩ or more COMPONENT OPERATING RANGE Resistance: 11 to 15 Ω at 20°C (68°F) Shift solenoid valve S4 WIRING DIAGRAM ECM C25 Electronically Controlled Transmission Solenoid +B 78 S4 C24 3 S4 CPU G031165E57 INSPECTION PROCEDURE 1 INSPECT TRANSMISSION WIRE (S4) (a) Disconnect the transmission wire connector from the transaxle. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Transmission Wire Side: (Connector Front View): C25 S4 NG C113969E29 AX OK Tester Connection Specified Condition 20°C (68°F) 3 - Body ground 11 to 15 Ω Go to step 3 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM 2 AX–113 CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission connector to the transaxle. (b) Disconnect the connector from the ECM. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side: (Connector Front View): C24 ECM Tester Connection Specified Condition 20°C (68°F) C24-78 (S4) - Body ground 11 to 15 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR S4 A136781E08 OK REPLACE ECM 3 INSPECT SHIFT SOLENOID VALVE (S4) (a) Remove the shift solenoid valve S4. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Shift Solenoid Valve S4: (-) (+) Tester Connection Specified Condition 20°C (68°F) Solenoid Connector (S4) - Solenoid Body (S4) 11 to 15 Ω (c) Connect the positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. OK: The solenoid makes an operating sound. C113971E01 NG REPLACE SHIFT SOLENOID VALVE (S4) OK REPAIR OR REPLACE TRANSMISSION WIRE AX AX–114 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC P0985 Shift Solenoid "E" Control Circuit Low (Shift Solenoid Valve SR) DTC P0986 Shift Solenoid "E" Control Circuit High (Shift Solenoid Valve SR) DESCRIPTION Shifting from 1st to 5th is performed in combination with "ON" and "OFF" operation of the shift solenoid valves SL1, SL2, SL3, S4 and SR which are controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valves to allow the vehicle to be operated smoothly (Fail safe function). DTC No. DTC Detection Condition Trouble Area P0985 ECM detects short in solenoid valve SR circuit 2 times when solenoid valve SR is operated (1-trip detection logic) • • • Short in shift solenoid valve SR circuit Shift solenoid valve SR ECM P0986 ECM detects open in solenoid valve SR circuit 2 times when solenoid valve SR is not operated (1-trip detection logic) • • • Open in shift solenoid valve SR circuit Shift solenoid valve SR ECM MONITOR DESCRIPTION The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF". When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. And the ECM performs the fail-safe function and turns the other normal shift solenoid valves "ON/OFF" (In case of an open or short circuit, the ECM stops sending current to the circuit.) (See page AX-30). MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0985: Shift solenoid valve SR/Range check (Low resistance) P0986: Shift solenoid valve SR/Range check (High resistance) Shift solenoid valve SR Continuous 0.064 sec. or more Immediate None TYPICAL ENABLING CONDITIONS P0985: Range check (Low resistance): The monitor will run whenever this DTC is not present. Shift solenoid valve SR Battery voltage None ON 8 V or more Ignition switch ON Starter OFF P0986: Range check (High resistance): AX The monitor will run whenever this DTC is not present. None Shift solenoid valve SR OFF Battery voltage 8 V or more Ignition switch ON Starter OFF AX–115 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM TYPICAL MALFUNCTION THRESHOLDS P0985: Range check (Low resistance): 8 Ω or less Shift solenoid valve SR resistance P0986: Range check (High resistance): Shift solenoid valve SR resistance 100 kΩ or more COMPONENT OPERATING RANGE Resistance: 11 to 15 Ω at 20°C (68°F) Shift solenoid valve SR WIRING DIAGRAM ECM C25 Electronically Controlled Transmission Solenoid +B 80 SR C24 9 SR CPU G031165E58 INSPECTION PROCEDURE 1 INSPECT TRANSMISSION WIRE (SR) (a) Disconnect the transmission wire connector from the transaxle. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Transmission Wire Side: (Connector Front View): C25 NG Tester Connection Specified Condition 20°C (68°F) 9 - Body ground 11 to 15 Ω Go to step 3 SR C113969E30 OK AX AX–116 2 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission connector to the transaxle. (b) Disconnect the connector from the ECM. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side: (Connector Front View): C24 ECM Tester Connection Specified Condition 20°C (68°F) C24-80 (SR) - Body ground 11 to 15 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR SR A136781E09 OK REPLACE ECM 3 INSPECT SHIFT SOLENOID VALVE (SR) (a) Remove the shift solenoid valve SR. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Shift Solenoid Valve SR: (+) Tester Connection Specified Condition 20°C (68°F) Solenoid Connector (SR) - Solenoid Body (SR) 11 to 15 Ω (-) (c) Connect the positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. OK: The solenoid makes an operating sound. C113977E01 NG OK REPAIR OR REPLACE TRANSMISSION WIRE AX REPLACE SHIFT SOLENOID VALVE (SR) U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC P2714 AX–117 Pressure Control Solenoid "D" Performance (Shift Solenoid Valve SLT) SYSTEM DESCRIPTION The linear solenoid valve (SLT) controls the transmission line pressure for smooth transmission operation based on signals from the throttle position sensor and the vehicle speed sensor. The ECM adjusts the duty ratio (*) of the SLT solenoid valve to control hydraulic line pressure coming from the primary regulator valve. Appropriate line pressure assures smooth shifting with varying engine outputs. (*): Duty Ratio The duty ratio is the ratio of the period of continuity in one cycle. For example, if A is the period of continuity in one cycle, and B is the period of non-continuity, then Duty Ratio= A/(A+B) x 100(%) Line Pressure Control Pressure Current Flow to Solenoid ON OFF 1 cycle C108924E02 DTC No. P2714 DTC Detection Condition ECM detects a malfunction on SLT (ON side) according to the revolution difference of the turbine, intermediate and the output shaft, and also by the oil pressure. (2-trip detection logic) Trouble Area • • • Shift solenoid valve SLT remains closed Valve body is blocked Automatic transaxle (clutch, brake or gear, etc.) AX AX–118 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM MONITOR DESCRIPTION In any forward position, when the difference between the revolutions of the turbine, Intermediate and output shaft exceeds the specified value (varies with Intermediate, output speed) determined by the ECM, the ECM illuminates the MIL and outputs the DTC. When shift solenoid valve SLT remains on, the oil pressure goes down and the clutch engagement force decreases. NOTICE: If you continue driving under these conditions, the clutch will burn out and the vehicle will no longer be drivable. MONITOR STRATEGY Related DTCs P2714: Shift solenoid valve SLT/ON malfunction Required sensors/Components Shift solenoid valve SLT, Speed sensor (NT), Speed sensor (NC), Crankshaft position sensor (NE) Frequency of operation Continuous Duration 1 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS ON malfunction: The monitor will run whenever this DTC is not present. Transmission range TFT (Transmission fluid temperature) None "D" -20°C (-4°F) or more TFT sensor circuit Not circuit malfunction ECT sensor circuit Not circuit malfunction Turbine speed sensor circuit Not circuit malfunction Intermediate shaft speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction Shift solenoid valve SL3 circuit Not circuit malfunction Shift solenoid valve S4 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve DSL circuit Not circuit malfunction Electronic throttle system Not circuit malfunction ON malfunction (a): ECM selected gear Temporary MAIN gear NT - NC x Temporary MAIN gear ratio NT: Input (turbine) speed NC: Intermediate shaft speed Temporary U/D gear NC - NO x Temporary U/D gear ratio NO: Output speed AX 4th 1st or 2nd or 3rd or 4th 100 rpm or more at Intermediate shaft speed 1,000 rpm Low or High 300 rpm or more at Output speed 1,000 rpm TT TT: Turbine Torque 142 Nm or more NT 250 rpm or more NC 250 rpm or more NO 250 rpm or more U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–119 ON malfunction (b): ECM selected gear 5th Temporary MAIN gear 1st or 2nd or 3rd or 4th NT - NC x Temporary MAIN gear ratio NT: Input (turbine) speed NC: Intermediate shaft speed 100 rpm or more at Intermediate shaft speed 1,000 rpm Temporary U/D gear Low or High NC - NO x Temporary U/D gear ratio NO: Output speed 300 rpm or more at Output speed 1,000 rpm TT TT: Turbine Torque 142 Nm or more NT 250 rpm or more NC 250 rpm or more NO 250 rpm or more TYPICAL MALFUNCTION THRESHOLDS [ON malfunction] Detection condition: Total accumulated time of ON malfunctions (a) and (b) is 1 second or more ON malfunction (a): NT - NC x 4th gear ratio NC - NO x Low gear ratio Duration 100 rpm or more at Intermediate shaft speed 1,000 rpm 300 rpm or more at Output speed 1,000 rpm 0.85 sec. or more Shift Solenoid valve SL1 Performance Not performance malfunction ON malfunction (b): NT - NC x 4th gear ratio NC - NO x High gear ratio Duration 100 rpm or more at Intermediate shaft speed 1,000 rpm 300 rpm or more at Output speed 1,000 rpm 0.85 sec. or more Shift Solenoid valve SL1 Performance Not performance malfunction INSPECTION PROCEDURE 1 CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P2714) (a) Connect the OBD II scan tool or intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (b) Turn the ignition switch on (IG) and turn the OBD II scan tool or the intelligent tester main switch ON. (c) When you use intelligent tester: Select the item "DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES" (d) Read the DTCs using the OBD II scan tool or the intelligent tester. Result Display (DTC output) Proceed to Only P2714 is output A P2714 and other DTCs B HINT: If any other codes besides "P2714" are output, perform the troubleshooting for those DTCs first. AX AX–120 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM B GO TO DTC CHART A 2 INSPECT SHIFT SOLENOID VALVE SLT (a) Remove the shift solenoid valve SLT. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Shift Solenoid Valve SLT: 2 1 NG (-) Specified Condition 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. 2 1 Tester Connection REPLACE SHIFT SOLENOID VALVE SLT (+) G020767E43 OK 3 INSPECT TRANSMISSION VALVE BODY ASSEMBLY OK: There are no foreign objects on each valve. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK 4 INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY OK: The torque converter clutch operates normally. NG REPLACE TORQUE CONVERTER CLUTCH ASSEMBLY OK AX REPAIR OR REPLACE AUTOMATIC TRANSAXLE ASSEMBLY U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC AX–121 Pressure Control Solenoid "D" Electrical (Shift Solenoid Valve SLT) P2716 DESCRIPTION The linear solenoid valve (SLT) controls the transmission line pressure for smooth transmission operation based on signals from the throttle position sensor and the vehicle speed sensor. The ECM adjusts the duty cycle of the SLT solenoid valve to control hydraulic line pressure coming from the primary regulator valve. Appropriate line pressure assures smooth shifting with varying engine outputs. (*): Duty Ratio The duty ratio is the ratio of the period of continuity in one cycle. For example, if A is the period of continuity in one cycle, and B is the period of non-continuity, then Duty Ratio=A/(A + B) x 100(%) DTC No. P2716 DTC Detection Condition Trouble Area Open or short is detected in shift solenoid valve SLT circuit for 1 second or more while driving (1-trip detecting logic). • • • Open or short in shift solenoid valve SLT circuit Shift solenoid valve SLT ECM Line Pressure Control Pressure Current Flow to Solenoid ON OFF 1 cycle C114295E01 MONITOR DESCRIPTION When an open or short in the linear solenoid valve (SLT) circuit is detected, the ECM interprets this as a fault. The ECM will turn on the MIL and store the DTC. MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P2716: Shift solenoid valve SLT/Range check Shift solenoid valve SLT Continuous 1 sec. Immediate None AX AX–122 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present. Solenoid current cut status None Not cut Battery voltage 11 V or more Ignition switch ON Starter OFF CPU commanded duty ratio to SLT 19% or more TYPICAL MALFUNCTION THRESHOLDS Solenoid status from IC Fail (Open or short) COMPONENT OPERATING RANGE Resistance: 5.0 to 5.6 Ω at 20°C (68°F) Shift solenoid valve SLT WIRING DIAGRAM C25 Electronically Controlled Transmission Solenoid ECM 76 SLT+ 2 C24 75 SLT- 8 C24 +B SLT+ SLT- G031770E27 AX U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–123 INSPECTION PROCEDURE 1 INSPECT TRANSMISSION WIRE (SLT) (a) Disconnect the transmission wire connector from the transaxle. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Transmission Wire Side: (Connector Front View): C25 SLT+ Tester Connection Specified Condition 20°C (68°F) 2 (SLT+) - 8 (SLT-) 5.0 to 5.6 Ω (c) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short) Tester Connection Specified Condition 2 (SLT+) - Body ground SLT- 10 kΩ or higher 8 (SLT-) - Body ground C113969E31 NG Go to step 3 OK 2 CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) Wire Harness Side: (Connector Front View): C24 ECM SLT- (a) Connect the transmission wire connector to the transaxle. (b) Disconnect the ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition 20°C (68°F) C24-76 (SLT+) - C24-75 (SLT-) 5.0 to 5.6 Ω (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short) SLT+ Tester Connection A136781E10 C24-76 (SLT+) - Body ground C24-75 (SLT-) - Body ground NG Specified Condition 10 kΩ or higher REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM AX AX–124 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM 3 INSPECT SHIFT SOLENOID VALVE (SLT) (a) Remove the shift solenoid valve (SLT). (b) Measure the resistance according to the value(s) in the table below. Standard resistance Shift Solenoid Valve SLT: 2 1 NG (-) (+) G020767E08 OK REPAIR OR REPLACE TRANSMISSION WIRE AX Specified Condition 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. 2 1 Tester Connection REPLACE SHIFT SOLENOID VALVE (SLT) U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–125 DTC P2769 Torque Converter Clutch Solenoid Circuit Low (Shift Solenoid Valve DSL) DTC P2770 Torque Converter Clutch Solenoid Circuit High (Shift Solenoid Valve DSL) DESCRIPTION The shift solenoid valve DSL is turned "ON" and "OFF" by signals from the ECM in order to control the hydraulic pressure operation, the lock-up relay valve, which then controls operation of the lock-up clutch. DTC No. DTC Detection Condition Trouble Area P2769 ECM detects short in solenoid valve DSL circuit (0.1 sec.) when solenoid valve DSL is operated (2-trip detection logic) • • • P2770 ECM detects open in solenoid valve DSL circuit (0.1 sec.) when solenoid valve DSL is not operated (2-trip detection logic) • • • Short in shift solenoid valve DSL circuit Shift solenoid valve DSL ECM Open in shift solenoid valve DSL circuit Shift solenoid valve DSL ECM MONITOR DESCRIPTION Torque converter lock-up is controlled by the ECM based on engine rpm, engine load, engine temperature, vehicle speed, transmission temperature, and shift range selection. The ECM determines the lock-up status of the torque converter by comparing the engine rpm (NE) to the input turbine rpm (NT). The ECM calculates the actual transmission gear by comparing input turbine rpm (NT) to counter gear rpm (NC). When conditions are appropriate, the ECM requests "lock-up" by applying control voltage to the shift solenoid DSL. When the DSL is opened, it applies pressure to the lock-up relay valve and locks the torque converter clutch. If the ECM detects an open or short in the DSL solenoid circuit, the ECM interprets this as a fault in the DSL solenoid or circuit. The ECM will turn on the MIL and store the DTC. MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P2769: Shift solenoid valve DSL/Range check (Low resistance) P2770: Shift solenoid valve DSL/Range check (High resistance) Shift solenoid valve DSL Continuous 0.064 sec. or more 2 driving cycles None TYPICAL ENABLING CONDITIONS P2769: Range check (Low resistance): The monitor will run whenever this DTC is not present. Shift solenoid valve DSL Solenoid current cut status None ON Not cut Battery voltage 8 V or more Ignition switch ON Starter OFF P2770: Range check (High resistance): The monitor will run whenever this DTC is not present. Shift solenoid valve DSL None ON Battery voltage 8 V or more Ignition switch ON AX AX–126 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Starter OFF TYPICAL MALFUNCTION THRESHOLDS P2769: Range check (Low resistance): 8 Ω or less Shift solenoid valve DSL resistance P2770: Range check (High resistance): Shift solenoid valve DSL resistance 100 kΩ or more COMPONENT OPERATING RANGE Resistance: 11 to 13 Ω at 20°C (68°F) Shift solenoid valve DSL WIRING DIAGRAM ECM C25 Electronically Controlled Transmission Solenoid +B DSL 79 DSL C24 10 CPU G031165E59 INSPECTION PROCEDURE 1 INSPECT TRANSMISSION WIRE (DSL) (a) Disconnect the transmission wire connector from the transaxle. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Transmission Wire Side: (Connector Front View): C25 NG AX DSL C113969E32 Tester Connection Specified Condition 20°C (68°F) 10 - Body ground 11 to 13 Ω Go to step 3 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–127 OK 2 CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission wire connector. (b) Disconnect the ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side: (Connector Front View): C24 ECM Tester Connection Specified Condition 20°C (68°F) C24-79 (DSL) - Body ground 11 to 13 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR DSL A136781E03 OK REPLACE ECM 3 INSPECT SHIFT SOLENOID VALVE (DSL) (a) Remove the shift solenoid valve DSL. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Shift Solenoid Valve DSL: (-) Tester Connection Specified Condition 20°C (68°F) Solenoid Connector (DSL) - Solenoid Body (DSL) 11 to 13 Ω (c) Connect the positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. OK: The solenoid valve makes an operating sound. (+) C113970E02 NG REPLACE SHIFT SOLENOID VALVE (DSL) OK REPAIR OR REPLACE TRANSMISSION WIRE AX U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE FLUID AX–123 AUTOMATIC TRANSAXLE FLUID ON-VEHICLE INSPECTION 1. OK if hot Add if hot D025120E03 CHECK FLUID LEVEL HINT: Drive the vehicle so that the engine and transaxle are at normal operating temperature. Fluid temperature: 70 to 80°C (158 to 176°F) (a) Park the vehicle on a level surface and set the parking brake. (b) With the engine idling and the brake pedal depressed, move the shift lever to all positions from P to L. Then return it to P. (c) Pull out the dipstick and wipe it clean. (d) Push it back fully into the pipe. (e) Pull it out again and check that the fluid level is within the HOT range. If the fluid level is below the HOT range, add new fluid and recheck the fluid level. If the fluid level exceeds the HOT range, drain the fluid once, add proper amount of new fluid and recheck the fluid level. AX AX–124 U250E AUTOMATIC TRANSAXLE – SPEED SENSOR SPEED SENSOR U250E AUTOMATIC TRANSAXLE TRANSMISSION COMPONENTS AIR CLEANER CAP SUB-ASSEMBLY 5.0 (51, 44 in.*lbf) 5.0 (51, 44 in.*lbf) AIR CLEANER INLET ASSEMBLY 5.0 (51, 44 in.*lbf) 9.0 (92, 80 in.*lbf) 3.5 (36, 31 in.*lbf) SPEED SENSOR (NT SENSOR) AIR CLEANER CASE SUB-ASSEMBLY 8.8 (90, 78 in.*lbf) SPEED SENSOR (NC SENSOR) 8.8 (90, 78 in.*lbf) O-RING O-RING BATTERY BATTERY TRAY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part AX Apply ATF WS C135104E02 AX–125 U250E AUTOMATIC TRANSAXLE – SPEED SENSOR REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE BATTERY (See page EM-95) 3. REMOVE AIR CLEANER INLET ASSEMBLY (See page EM-94) 4. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-416) 5. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (See page EM-95) 6. REMOVE SPEED SENSOR (NT SENSOR) (a) Disconnect the speed sensor connector. (b) Remove the bolt and speed sensor. (c) Remove the O-ring from the speed sensor. 7. REMOVE SPEED SENSOR (NC SENSOR) (a) Disconnect the speed sensor connector. (b) Remove the bolt and speed sensor. (c) Remove the O-ring from the speed sensor. C135106 C135107 INSPECTION Sensor Side: 1. (Connector Front View) INSPECT SPEED SENSOR (NT SENSOR) (a) Disconnect the speed sensor connector from the transaxle. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition (20°C (68°F)) 1-2 560 to 680 Ω If the resistance value is not as specified, replace the speed sensor. 2 1 C113863E05 AX AX–126 U250E AUTOMATIC TRANSAXLE – SPEED SENSOR 2. Sensor Side: (Connector Front View) INSPECT SPEED SENSOR (NC SENSOR) (a) Disconnect the speed sensor connector from the transaxle. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition (20°C (68°F)) 1-2 560 to 680 Ω If the resistance value is not as specified, replace the speed sensor. 2 1 C113863E05 AX U250E AUTOMATIC TRANSAXLE – SPEED SENSOR AX–127 INSTALLATION 1. INSTALL SPEED SENSOR (NC SENSOR) (a) Coat a new O-ring with ATF WS and install it to the speed sensor. (b) Install the speed sensor with the bolt. Torque: 8.8 N*m (90 kgf*cm, 78 in.*lbf) (c) Connect the speed sensor connector. 2. INSTALL SPEED SENSOR (NT SENSOR) (a) Coat a new O-ring with ATF WS and install it to the speed sensor. C135107 (b) Install the speed sensor with the bolt. Torque: 8.8 N*m (90 kgf*cm, 78 in.*lbf) (c) Connect the speed sensor connector. 3. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (See page EM-120) 4. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See page ES-419) 5. INSTALL AIR CLEANER INLET ASSEMBLY (See page EM-120) 6. INSTALL BATTERY (See page EM-119) 7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf) C135106 AX U250E AUTOMATIC TRANSAXLE – PARK / NEUTRAL POSITION SWITCH AX–127 PARK / NEUTRAL POSITION SWITCH U250E AUTOMATIC TRANSAXLE TRANSMISSION COMPONENTS 9.0 (92, 80 in.*lbf) 3.5 (36, 31 in.*lbf) BATTERY BATTERY TRAY TRANSMISSION CONTROL CABLE ASSEMBLY 5.4 (55, 48 in.*lbf) CLIP 15 (150, 11) CONTROL SHAFT LEVER 13 (130, 9) 5.4 (55, 48 in.*lbf) PARK/NEUTRAL POSITION SWITCH ASSEMBLY LOCK PLATE 6.9 (70, 61 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C135108E04 AX AX–128 U250E AUTOMATIC TRANSAXLE – PARK / NEUTRAL POSITION SWITCH REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE BATTERY (See page EM-95) 3. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (a) Remove the nut from the control shaft lever. (b) Disconnect the transmission control cable assembly from the control shaft lever. C135109 (c) Remove the clip and disconnect the transmission control cable assembly from the No. 1 control cable bracket. NOTICE: Do not hold the resin guide pipe. C135705 4. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Disconnect the park/neutral position switch connector. C135706 (b) Remove the nut, washer and control shaft lever. C135707 AX U250E AUTOMATIC TRANSAXLE – PARK / NEUTRAL POSITION SWITCH AX–129 (c) Using a screwdriver, pry up the lock plate. C135708 (d) Remove the lock nut and the lock plate. C135709 (e) Remove the 2 bolts and pull out the park/neutral position switch. C135710 AX AX–130 U250E AUTOMATIC TRANSAXLE – PARK / NEUTRAL POSITION SWITCH INSPECTION 1. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY OPERATION (a) Apply the parking brake and turn the ignition switch to the ON position. (b) Depress the brake pedal and check that the engine starts only when the shift lever is set in the N or P position. (c) Check that the back-up light comes on and the reverse warning buzzer sounds only when the shift lever is set in the R position and the light and buzzer do not operate when the shift lever is in other positions. If a failure is found, check the park/neutral position switch. 2. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Jack up the vehicle. (b) Disconnect the park/neutral position switch connector. (c) Measure the resistance according to the value(s) in the table below when the shift lever is moved to each position. Standard resistance Switch Side: (Connector Front View): Shift Position P Except P R Except R N C110340E36 Except N D and 4 Except D and 4 3 Except 3 2 and L Except 2 and L Tester Connection 2 - 6 and 4 - 5 2-1 2 - 9 and 4 - 5 2-7 2-3 2-8 Specified Condition Below 1 Ω 10 kΩ or higher Below 1 Ω 10 kΩ or higher Below 1 Ω 10 kΩ or higher Below 1 Ω 10 kΩ or higher Below 1 Ω 10 kΩ or higher Below 1 Ω 10 kΩ or higher If operation cannot be done as specified, replace the park/neutral position switch. Neutral Basic Line ADJUSTMENT 1. Groove AX D025514E01 ADJUST PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Loosen the 2 bolts of the park/neutral position switch and move the shift lever to the N position. (b) Align the groove with the neutral basic line. (c) Hold the switch in position and tighten the 2 bolts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) (d) After adjustment, perform the inspection (See page AX-129). U250E AUTOMATIC TRANSAXLE – PARK / NEUTRAL POSITION SWITCH AX–131 INSTALLATION 1. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Install the park/neutral position switch to the manual valve shaft. (b) Temporarily install the 2 bolts. C135710 (c) Place a new lock plate and tighten the nut. Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf) (d) Temporarily install the control shaft lever. C135709 (e) Turn the lever counterclockwise until it stops, then turn it clockwise 2 notches. (f) Remove the control shaft lever. C135711 (g) Align the groove with the neutral basic line. (h) Hold the switch in position and tighten the 2 bolts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) Groove Neutral Basic Line C099456E01 (i) Using a screwdriver, stake the nut with the lock plate. AX C135708 AX–132 U250E AUTOMATIC TRANSAXLE – PARK / NEUTRAL POSITION SWITCH (j) Install the control shaft lever, washer and nut. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) C135707 (k) Connect the park/neutral position switch connector. C135706 2. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (a) Connect the transmission control cable to the bracket with a new clip. C135705 (b) Connect the transmission control cable assembly to the control shaft lever with the nut. Torque: 15 N*m (150 kgf*cm, 11 ft.*lbf) 3. INSTALL BATTERY (See page EM-119) 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf) 5. INSPECT SHIFT LEVER POSITION (See page AX-146) 6. ADJUST SHIFT LEVER POSITION (See page AX-146) 7. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY HINT: See page AX-129. C135109 AX AX–133 U250E AUTOMATIC TRANSAXLE – TRANSMISSION WIRE TRANSMISSION WIRE U250E AUTOMATIC TRANSAXLE TRANSMISSION COMPONENTS TRANSMISSION WIRE 5.4 (55, 48 in.*lbf) TEMPERATURE SENSOR LOCK PLATE O-RING 6.6 (67, 58 in.*lbf) AUTOMATIC TRANSAXLE ASSEMBLY MAGNET GASKET AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY x18 7.8 (80, 69 in.*lbf) GASKET N*m (kgf*cm, ft.*lbf) : Specified torque 49 (500, 36) Non-reusable part Apply ATF WS Precoated part C137673E03 AX AX–134 U250E AUTOMATIC TRANSAXLE – TRANSMISSION WIRE REMOVAL 1. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY HINT: See page AX-162. 2. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUBASSEMBLY (a) Remove the 18 bolts, oil pan and gasket. NOTICE: Some fluid will remain in the oil pan. Remove all the pan bolts, and carefully remove the oil pan assembly. C091925 (b) Remove the 2 magnets from the oil pan. D030865E01 (c) Examine particles in the pan. (1) Collect any steel chips with the removed magnets. Look carefully at the chips and particles in the pan and on the magnets to see the type of wear which might be found in the transaxle. Steel (magnetic): bearing, gear and plate wear Brass (non-magnetic): bearing wear Result: Steel (magnetic): bearing, gear and plate wear Brass (non-magnetic): bearing wear AT00103 3. C135717 AX DISCONNECT TRANSMISSION WIRE (a) Disconnect the 7 shift solenoid valve connectors. (b) Remove the bolt and lock plate, and disconnect the ATF temperature sensor. U250E AUTOMATIC TRANSAXLE – TRANSMISSION WIRE 4. AX–135 REMOVE TRANSMISSION WIRE (a) Disconnect the transmission wire connector. (b) Remove the bolt and transmission wire. D030866 (c) Remove the O-ring from the transmission wire. D030867 INSTALLATION 1. INSTALL TRANSMISSION WIRE (a) Coat a new O-ring of the transmission wire connector with ATF WS and install it to the transmission wire. D030867 (b) Install the transmission wire with the bolt. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) (c) Connect the transmission wire connector. D030866 2. CONNECT TRANSMISSION WIRE (a) Coat the O-ring of the ATF WS temperature sensor with ATF. (b) Install the ATF temperature sensor with the lock plate and bolt. Torque: 6.6 N*m (67 kgf*cm, 58 in.*lbf) (c) Connect the 7 shift solenoid valve connectors. AX C135717 AX–136 U250E AUTOMATIC TRANSAXLE – TRANSMISSION WIRE 3. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUBASSEMBLY (a) Install the 2 magnets in the oil pan. (b) Apply adhesive or equivalent to new 18 bolts. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent D030865E01 (c) Using a new gasket, install the oil pan to the transaxle case with the 18 bolts. Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) NOTICE: Since the bolts should be seal bolts, apply adhesive to the bolts and tighten them within 10 minutes of application. 4. C091925 AX INSTALL AUTOMATIC TRANSAXLE ASSEMBLY HINT: See page AX-168. U250E AUTOMATIC TRANSAXLE – VALVE BODY ASSEMBLY AX–137 VALVE BODY ASSEMBLY U250E AUTOMATIC TRANSAXLE TRANSMISSION COMPONENTS TEMPERATURE SENSOR AUTOMATIC TRANSAXLE ASSEMBLY LOCK PLATE TRANSMISSION WIRE 6.6 (67, 58 in.*lbf) SPRING CHECK BALL BODY MANUAL VALVE TRANSMISSION VALVE BODY ASSEMBLY 11 (110, 8) x17 VALVE BODY OIL STRAINER ASSEMBLY O-RING 11 (110, 8) 11 (110, 8) MAGNET AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY GASKET x18 7.8 (80, 69 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque GASKET Non-reusable part Apply ATF WS 49 (500, 36) Precoated part C139866E02 AX AX–138 U250E AUTOMATIC TRANSAXLE – VALVE BODY ASSEMBLY REMOVAL 1. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY HINT: See page AX-162. 2. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUBASSEMBLY (a) Remove the 18 bolts, oil pan and gasket. NOTICE: Some fluid will remain in the oil pan. Remove all the pan bolts, and carefully remove the oil pan assembly. C091925 (b) Remove the 2 magnets from the oil pan. D030865E01 (c) Examine particles in the pan. (1) Collect any steel chips with the removed magnets. Look carefully at the chips and particles in the pan and on the magnets to see the type of wear which might be found in the transaxle. Result: Steel (magnetic): bearing, gear and plate wear Brass (non-magnetic): bearing wear AT00103 3. C135717 AX DISCONNECT TRANSMISSION WIRE (a) Disconnect the 7 shift solenoid valve connectors. (b) Remove the bolt and lock plate, and disconnect the ATF temperature sensor. U250E AUTOMATIC TRANSAXLE – VALVE BODY ASSEMBLY 4. AX–139 REMOVE VALVE BODY OIL STRAINER ASSEMBLY (a) Remove the 3 bolts and oil strainer. NOTICE: Be careful that some fluid will come out of the oil strainer. C135715 (b) Remove the O-ring from the oil strainer. C135716 5. REMOVE TRANSMISSION VALVE BODY ASSEMBLY (a) Support the valve body assembly and remove the 17 bolts and the valve body assembly. NOTICE: Be careful not to drop the check ball, spring and accumulator piston. C091933 (b) Remove the check ball body and spring. 6. REMOVE MANUAL VALVE (a) Remove the manual valve from the valve body assembly. C050017 AX AX–140 U250E AUTOMATIC TRANSAXLE – VALVE BODY ASSEMBLY INSTALLATION 1. INSTALL MANUAL VALVE (a) Install the manual valve to the valve body assembly. 2. INSTALL TRANSMISSION VALVE BODY ASSEMBLY (a) Install the spring and check ball body. C050017 (b) Align the groove of the manual valve with the pin of the lever. (c) Install the valve body with the 17 bolts. Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf) NOTICE: • Push the valve body against the accumulator piston spring and the check ball body to install it. • First, temporarily tighten the bolts marked by (1) in the illustration because they are positioning bolts. Bolt length: Bolt A: 25 mm (0.984 in.) Bolt B: 57 mm (2.244 in.) Bolt C: 41 mm (1.614 in.) A B (1) B A (1) C B C C C091933E02 3. INSTALL VALVE BODY OIL STRAINER ASSEMBLY (a) Coat a new O-ring with ATF WS. (b) Install the O-ring to the oil strainer. C135716 (c) Install the oil strainer with the 3 bolts. Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf) C135715 AX U250E AUTOMATIC TRANSAXLE – VALVE BODY ASSEMBLY AX–141 4. INSTALL TRANSMISSION WIRE (a) Coat the O-ring with ATF WS. (b) Install the ATF temperature sensor with the lock plate and bolt. Torque: 6.6 N*m (67 kgf*cm, 58 in.*lbf) (c) Connect the 7 shift solenoid valve connectors. 5. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUBASSEMBLY (a) Install the 2 magnets in the oil pan. (b) Apply adhesive or equivalent to new 18 bolts. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent C135717 D030865E01 (c) Using a new gasket, install the oil pan to the transaxle case with the 18 bolts. Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) NOTICE: Since the bolts should be seal bolts, apply adhesive to the bolts and tighten them within 10 minutes of application. 6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf) 7. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY HINT: See page AX-168. C091925 AX AX–142 U250E AUTOMATIC TRANSAXLE – SHIFT LOCK SYSTEM SHIFT LOCK SYSTEM ON-VEHICLE INSPECTION Wire Harness Side: (Connector Rear View): STP E IG ACC 1. CHECK SHIFT LOCK OPERATION (a) Move the shift lever to the P position. (b) Turn the ignition switch to the LOCK position. (c) Check that the shift lever cannot be moved to any position other than P. (d) Turn the ignition switch to the on position, depress the brake pedal and check that the shift lever can be moved to another position. If operation cannot be done as specified, inspect the shift lock control unit. 2. CHECK SHIFT LOCK RELEASE BUTTON OPERATION (a) Using a screwdriver, remove the shift lock release cover. (b) When operating the shift lever with the shift lock release button pressed, check that the lever can be moved to any position other than P. If operation cannot be done as specified, check the shift lever assembly installation condition. 3. CHECK KEY INTERLOCK OPERATION (a) Turn the ignition switch to the ON position. (b) Depress the brake pedal and move the shift lever to any position other than P. (c) Check that the ignition key cannot be turned to the LOCK position. (d) Move the shift lever to the P position, turn the ignition key to the LOCK position and check that the ignition key can be removed. If operation cannot be done as specified, inspect the shift lock control unit. 4. INSPECT SHIFT LOCK CONTROL ECU (a) Measure the voltage according to the value(s) in the table below. HINT: Do not disconnect the shift lock control ECU connector. KLS+ C127833E05 AX Standard voltage Terminal Measuring Condition Voltage (V) 6 (ACC) - 1 (E) Ignition switch ON 10 to 14 6 (ACC) - 1 (E) Ignition switch ACC 10 to 14 AX–143 U250E AUTOMATIC TRANSAXLE – SHIFT LOCK SYSTEM Terminal Measuring Condition Voltage (V) 6 (ACC) - 1 (E) Ignition switch OFF Below 1 4 (STP) - 1 (E) Depress brake pedal 10 to 14 4 (STP) - 1 (E) Release brake pedal Below 1 5 (KLS+) - 1 (E) 1. Ignition switch ACC and shift lever P position 2. Ignition switch ACC and shift lever except P position 3. Ignition switch ACC and shift lever P position (After approx. 1 second) 7.5 to 11 Below 1 6 to 9 8 (IG) - 1 (E) Ignition switch ON 10 to 14 8 (IG) - 1 (E) Ignition switch OFF Below 1 (b) Measure the resistance according to the value(s) in the table below. HINT: Do not disconnect the shift lock control ECU connector. If the result is not as specified, replace the shift lock control ECU. Wire Harness Side: (Connector Rear View): E C127833E06 Standard resistance Terminal Measuring Condition Specified Value 1 (E) - Body ground Always Below 1 Ω AX AX–144 U250E AUTOMATIC TRANSAXLE – TRANSMISSION CONTROL CABLE ASSEMBLY TRANSMISSION CONTROL CABLE ASSEMBLY U250E AUTOMATIC TRANSAXLE TRANSMISSION COMPONENTS 5.0 (51, 44 in.*lbf) NO. 2 SHIFT CABLE GROMMET RETAINER TRANSMISSION CONTROL CABLE ASSEMBLY 5.0 (51, 44 in.*lbf) 3.5 (36, 31 in.*lbf) AIR CLEANER CAP SUB-ASSEMBLY 9.0 (92, 80 in.*lbf) 5.0 (51, 44 in.*lbf) 5.0 (51, 44 in.*lbf) BATTERY AIR CLEANER INLET ASSEMBLY AIR CLEANER CASE SUB-ASSEMBLY BATTERY TRAY CLIP 12 (150, (125, 11) 10) 15 TRANSMISSION CONTROL CABLE ASSEMBLY AX N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C137675E04 U250E AUTOMATIC TRANSAXLE – TRANSMISSION CONTROL CABLE ASSEMBLY AX–145 REMOVAL 1. REMOVE AIR CONDITIONING UNIT HINT: See page AC-151. 2. REMOVE BATTERY (See page EM-95) 3. REMOVE AIR CLEANER INLET ASSEMBLY (See page EM-94) 4. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-416) 5. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (See page EM-95) 6. DISCONNECT NO. 2 SHIFT CABLE GROMMET RETAINER (a) Disconnect the transmission control cable assembly from the transmission floor shift assembly while pushing the 2 claws of the floor shift cable. (b) Turn back the carpet. C135015 (c) Remove the 2 bolts and disconnect the No. 2 shift cable grommet retainer. (d) Remove the No. 2 shift cable grommet retainer. C132234 7. REMOVE TRANSMISSION CONTROL CABLE ASSEMBLY (a) Remove the nut from the control shaft lever. (b) Disconnect the transmission control cable assembly from the control shaft lever. C135109 AX AX–146 U250E AUTOMATIC TRANSAXLE – TRANSMISSION CONTROL CABLE ASSEMBLY (c) Remove the clip and disconnect the transmission control cable assembly from the No. 1 control cable bracket. C135705 (d) Disconnect the transmission control cable assembly from the control cable clamp. (e) Pull out the transmission control cable assembly from the body. C090579 AX U250E AUTOMATIC TRANSAXLE – TRANSMISSION CONTROL CABLE ASSEMBLY AX–147 ADJUSTMENT 1. INSPECT SHIFT LEVER POSITION (a) When shifting from the P to the R position with the ignition switch on and brake pedal depressed, make sure that the shift lever moves smoothly and moves correctly into position. (b) Start the engine and make sure that the vehicle moves forward when shifting from the N to the D position and moves rearward when shifting to the R position. If operation cannot be done as specified, inspect the park/neutral position switch assembly and check the shift lever assembly installation condition. 2. ADJUST SHIFT LEVER POSITION (a) Move the shift lever to the N position. (b) Remove the nut from the control shaft lever. (c) Disconnect the transmission control cable assembly from the control shaft lever. C135109 (d) Push the control shaft fully downward. (e) Return the control shaft lever 2 notches to the N position. C135711 AX AX–148 U250E AUTOMATIC TRANSAXLE – TRANSMISSION CONTROL CABLE ASSEMBLY (f) Slider Lock Piece Move the slider in the directions indicated by the arrows and pull up the lock piece. NOTICE: Do not damage the boot. C135734E02 (g) Install the transmission control cable to the control shaft lever with the nut. Torque: 15 N*m (150 kgf*cm, 11 ft.*lbf) NOTICE: • If the control cable end is excessively pushed up, the shift lever cannot be adjusted. • When tightening the nut, confirm that the control cable is properly stretched. C135109 C138300E01 AX (h) Push in the lock piece. NOTICE: Firmly push in the lock piece until the slider lock is engaged. (i) Start the engine and make sure that the vehicle moves forward when moving the lever from the N to the D position and moves rearward when moving it to the R position. If it becomes hard to move the shift lever, readjust the shift lever position. U250E AUTOMATIC TRANSAXLE – TRANSMISSION CONTROL CABLE ASSEMBLY AX–149 INSTALLATION 1. INSTALL NO. 2 SHIFT CABLE GROMMET RETAINER (a) Pass the transmission control cable assembly from the cabin to the engine compartment. (b) Install the No. 2 shift cable grommet retainer to the transmission control cable assembly. (c) Install the No. 2 shift cable grommet retainer with the 2 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) C132234 2. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (a) Install the transmission control cable assembly as shown in the illustration. HINT: • Install the floor shift cable with the uneven surface facing up. • Securely engage the claws of the floor shift cable. C135020 (b) Connect the control cable to the control cable clamp. C090579 AX AX–150 U250E AUTOMATIC TRANSAXLE – TRANSMISSION CONTROL CABLE ASSEMBLY (c) Connect the control cable to the bracket with a new clip. C135705 (d) Install the transmission control cable to the control shaft lever with the nut. Torque: 15 N*m (150 kgf*cm, 11 ft.*lbf) C135109 (e) Push in the lock piece of the transmission control cable. NOTICE: Firmly push in the lock piece until the slider lock is engaged. HINT: After pushing in the lock piece, make sure that the boot is not deformed. 3. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (See page EM-120) 4. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See page ES-419) 5. INSTALL AIR CLEANER INLET ASSEMBLY (See page EM-120) 6. INSTALL BATTERY (See page EM-119) 7. INSTALL AIR CONDITIONING UNIT HINT: See page AC-173. 8. INSPECT SHIFT LEVER POSITION (See page AX-146) 9. ADJUST SHIFT LEVER POSITION (See page AX-146) C138300E02 AX AX–150 U250E AUTOMATIC TRANSAXLE – DIFFERENTIAL OIL SEAL DIFFERENTIAL OIL SEAL U250E AUTOMATIC TRANSAXLE TRANSMISSION COMPONENTS FRONT DRIVE SHAFT ASSEMBLY RH HOLE SNAP RING FRONT DRIVE SHAFT LH HOLE SNAP RING 32 (330, 24) FRONT DRIVE SHAFT ASSEMBLY LH TIE ROD ASSEMBLY LH FRONT STABILIZER LINK ASSEMBLY LH FRONT SPEED SENSOR LH 19 (192, 14) 74 (755, 55) 8.0 (82, 71 in.*lbf) FRONT FLEXIBLE HOSE FRONT AXLE ASSEMBLY LH 294 (3000, 217) FRONT AXLE HUB NUT LH FRONT SUSPENSION LOWER NO. 1 ARM LH 49 (500, 36) COTTER PIN 75 (765, 55) AX N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C137676E04 U250E AUTOMATIC TRANSAXLE – DIFFERENTIAL OIL SEAL AX–151 GASKET 49 (500, 36) DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL TRANSAXLE HOUSING OIL SEAL N*m (kgf*cm, ft.*lbf) : Specified torque Apply MP grease Non-reusable part C135731E04 AX AX–152 U250E AUTOMATIC TRANSAXLE – DIFFERENTIAL OIL SEAL REMOVAL 1. DRAIN AUTOMATIC TRANSAXLE FLUID (See page AX-162) 2. REMOVE FRONT WHEEL 3. REMOVE FRONT AXLE HUB NUT LH (See page DS7) 4. REMOVE FRONT AXLE HUB NUT RH HINT: Use the same procedures described for the LH side. 5. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH (See page DS-7) 6. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH HINT: Use the same procedures described for the LH side. 7. SEPARATE FRONT SPEED SENSOR LH (See page DS-7) 8. SEPARATE FRONT SPEED SENSOR RH 9. SEPARATE TIE ROD ASSEMBLY LH (See page DS-8) 10. SEPARATE TIE ROD ASSEMBLY RH HINT: Use the same procedures described for the LH side. 11. SEPARATE FRONT SUSPENSION LOWER NO. 1 ARM LH (See page DS-8) 12. SEPARATE FRONT SUSPENSION LOWER NO. 1 ARM RH HINT: Use the same procedures described for the LH side. 13. SEPARATE FRONT AXLE ASSEMBLY LH (See page DS-8) 14. SEPARATE FRONT AXLE ASSEMBLY RH HINT: Use the same procedures described for the LH side. 15. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (See page DS-9) 16. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (See page DS-9) 17. FIX FRONT AXLE ASSEMBLY LH (See page DS-9) 18. FIX FRONT AXLE ASSEMBLY RH HINT: Use the same procedures described for the LH side. AX U250E AUTOMATIC TRANSAXLE – DIFFERENTIAL OIL SEAL AX–153 19. REMOVE TRANSAXLE HOUSING OIL SEAL (a) Using SST, pull out the oil seal. SST 09308-00010 SST C083057E01 20. REMOVE DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL (a) Using SST, pull out the oil seal. SST 09308-00010 SST C083058E01 INSTALLATION SST 1. INSTALL TRANSAXLE HOUSING OIL SEAL (a) Using SST and a hammer, install a new oil seal. SST 09316-60011 (09316-00011) Oil seal installation depth: -0.5 to 0.5 mm (-0.020 to 0.020 in.) (b) Coat the lip of the oil seal with MP grease. 2. INSTALL DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL (a) Using SST and a hammer, install a new oil seal. SST 09649-17010, 09950-70010 (09951-07150) Oil seal installation depth: -0.5 to 0.5 mm (-0.020 to 0.020 in.) (b) Coat the lip of the oil seal with MP grease. 3. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (See page DS-20) 4. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (See page DS-21) 5. INSTALL FRONT AXLE ASSEMBLY LH (See page DS21) 6. INSTALL FRONT AXLE ASSEMBLY RH HINT: Use the same procedures described for the LH side. 7. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM LH (See page DS-21) D025829E02 SST D025830E02 AX AX–154 U250E AUTOMATIC TRANSAXLE – DIFFERENTIAL OIL SEAL 8. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM RH HINT: Use the same procedures described for the LH side. 9. INSTALL TIE ROD ASSEMBLY LH (See page DS-21) 10. INSTALL TIE ROD ASSEMBLY RH HINT: Use the same procedures described for the LH side. 11. INSTALL FRONT SPEED SENSOR LH (See page DS21) 12. INSTALL FRONT SPEED SENSOR RH HINT: Use the same procedures described for the LH side. 13. INSTALL FRONT STABILIZER LINK ASSEMBLY LH (See page DS-22) 14. INSTALL FRONT STABILIZER LINK ASSEMBLY RH HINT: Use the same procedures described for the LH side. 15. INSTALL FRONT AXLE HUB NUT LH (See page DS22) 16. INSTALL FRONT AXLE HUB NUT RH HINT: Use the same procedures described for the LH side. 17. INSTALL FRONT WHEEL (See page DS-22) 18. ADD AUTOMATIC TRANSAXLE FLUID (See page AX175) 19. INSPECT AUTOMATIC TRANSAXLE FLUID (See page AX-123) 20. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT See page SP-4. 21. CHECK ABS SPEED SENSOR SIGNAL HINT: See page BC-11. AX U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY AX–155 AUTOMATIC TRANSAXLE ASSEMBLY U250E AUTOMATIC TRANSAXLE TRANSMISSION COMPONENTS FRONT WIPER ARM AND BLADE ASSEMBLY RH 20 (204, 15) FRONT FENDER TO COWL SIDE SEAL RH FRONT WIPER ARM AND BLADE ASSEMBLY LH COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 7.5 (77, 66 in.*lbf) 85 (867, 63) FRONT FENDER TO COWL SIDE SEAL LH 5.0 (51, 44 in.*lbf) WINDSHIELD WIPER LINK ASSEMBLY COWL TOP PANEL OUTER SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque A136912E01 AX AX–156 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY ENGINE MOVING CONTROL ROD SUB-ASSEMBLY NO. 2 ENGINE MOUNTING BRACKET RH 64 (653, 47) 9.0 (92, 80 in.*lbf) 52 (531, 38) 64 (653, 47) NO. 1 ENGINE COVER SUB-ASSEMBLY NO. 2 ENGINE MOUNTING STAY RH V-RIBBED BELT 9.8 (100, 87 in.*lbf) 52 (531, 38) 21 (214, 15) GENERATOR ASSEMBLY FRONT FENDER APRON SEAL RH N*m (kgf*cm, ft.*lbf) : Specified torque A134948E01 AX U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY 5.0 (51, 44 in.*lbf) AX–157 AIR CLEANER CAP SUB-ASSEMBLY AIR CLEANER INLET ASSEMBLY 9.0 (92, 80 in.*lbf) BATTERY 5.0 (51, 44 in.*lbf) AIR CLEANER CASE SUB-ASSEMBLY BATTERY TRAY 7.8 (80, 69 in.*lbf) COMPRESSOR AND MAGNETIC CLUTCH AIR CLEANER BRACKET NO. 1 VACUUM HOSE CONNECTOR HEATER INLET WATER HOSE 25 (255, 18) NO. 1 OIL RESERVOIR TO PUMP HOSE J/B COVER RADIATOR HOSE OUTLET RETURN TUBE SUB-ASSEMBLY TRANSMISSION CONTROL CABLE ASSEMBLY ENGINE UNDER COVER RH 15 (150,11 ) HEATER OUTLET WATER HOSE CLIP OIL COOLER OUTLET HOSE ENGINE UNDER COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque OIL COOLER INLET HOSE Non-reusable part RADIATOR HOSE INLET AX C138301E04 AX–158 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY TIE ROD ASSEMBLY LH STEERING SLIDING YOKE 35 (357, 26) 74 (755, 55) 49 (500, 36) COTTER PIN 8.0 (82, 71 in.*lbf) FRONT SPEED SENSOR LH DRIVE SHAFT ASSEMBLY LH 294 (3,000, 217) FRONT AXLE HUB NUT LH 75 (755, 55) FRONT SUSPENSION LOWER NO. 1 ARM LH EXHAUST PIPE GASKET 56 (571, 41) EXHAUST PIPE GASKET 62 (633, 46) FRONT EXHAUST PIPE NO. 1 SUPPORT BRACKET 33 (337, 24) 33 (337, 24) REAR EXHAUST PIPE NO. 1 SUPPORT BRACKET FRONT EXHAUST PIPE ASSEMBLY AX N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C143322E01 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY AX–159 43 (439, 32) 54 (551, 40) VANE PUMP ASSEMBLY x3 95 (969, 70) ENGINE MOUNTING BRACKET RH 95 (969, 70) 87 (888, 64) FRONT FRAME ASSEMBLY FRAME SIDE RAIL PLATE SUB-ASSEMBLY RH FRAME SUSPENSION MEMBER BRACE REAR RH 32 (326, 24) 85 (867, 63) FRAME SIDE RAIL PLATE SUB-ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque FRAME SUSPENSION MEMBER BRACE REAR LH 32 (326, 24) 85 (867, 63) AX A109016E07 AX–160 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY FRONT DRIVE SHAFT ASSEMBLY RH HOLE SNAP RING x6 TORQUE CONVERTER CLUTCH ASSEMBLY 41 (418, 30) 44 (449, 33) x4 64 (653, 47) FLYWHEEL HOUSING UNDER COVER 46 (469, 34) 46 (469, 34) STARTER ASSEMBLY SNAP RING 39 (398, 29) N*m (kgf*cm, ft.*lbf) : Specified torque AX Non-reusable part FRONT DRIVE SHAFT ASSEMBLY LH Precoated part C138302E06 AX–161 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY 8.4 (86, 74 in.*lbf) 8.4 (86, 74 in.*lbf) WIRE HARNESS CLAMP BRACKET WIRE HARNESS CLAMP BRACKET NO. 2 TRANSMISSION CONTROL CABLE BRACKET 12 (122, 9) ENGINE WIRE 5.5 (56, 49 in.*lbf) SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY O-RING 12 (130, 9) ENGINE MOUNTING FRONT BRACKET WIRE HARNESS 12 (122, 9) NO. 1 TRANSMISSION CONTROL CABLE BRACKET 12 (122, 9) OIL COOLER TUBE CLAMP 64 (653, 47) TRANSAXLE CASE UPPER COVER 5.4 (55, 48 in.*lbf) GASKET ATF LEVEL GAUGE 49 (500, 36) NO. 1 OIL COOLER INLET TUBE 34 (350, 25) *32 (322, 24) 12 (122, 9) TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY 34 (350, 25) *32 (322, 24) 5.5 (56, 49 in.*lbf) NO. 1 OIL COOLER OUTLET TUBE N*m (kgf*cm, ft.*lbf) : Specified torque O-RING Non-reusable part * For use with SST Apply ATF WS C138303E06 AX AX–162 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY REMOVAL 1. DISCHARGE FUEL SYSTEM PRESSURE HINT: See page FU-1. 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 4. REMOVE FRONT WHEELS 5. REMOVE ENGINE UNDER COVER LH 6. REMOVE ENGINE UNDER COVER RH 7. REMOVE FRONT FENDER APRON SEAL RH 8. DRAIN ENGINE OIL (See page LU-4) 9. DRAIN ENGINE COOLANT (See page CO-5) 10. DRAIN AUTOMATIC TRANSAXLE FLUID (a) Using a 6 mm socket hexagon wrench, remove the drain plug and gasket, and drain ATF. (b) Install a new gasket and the drain plug. Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) 11. REMOVE WINDSHIELD WIPER LINK ASSEMBLY HINT: See page WW-9. 12. REMOVE COWL TOP PANEL OUTER SUBASSEMBLY (See page ES-424) 13. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (See page EM-94) 14. REMOVE V-RIBBED BELT (See page EM-6) 15. REMOVE AIR CLEANER INLET ASSEMBLY (See page EM-94) 16. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-416) 17. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (See page EM-95) 18. REMOVE BATTERY (See page EM-95) 19. REMOVE NO. 2 ENGINE MOUNTING STAY RH (See page EM-95) 20. REMOVE ENGINE MOVING CONTROL ROD SUBASSEMBLY (See page EM-95) 21. REMOVE NO. 2 ENGINE MOUNTING BRACKET RH (See page EM-96) AX 22. DISCONNECT NO. 1 VACUUM HOSE CONNECTOR (See page EM-96) 23. DISCONNECT RADIATOR HOSE INLET (See page EM-96) U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY AX–163 24. DISCONNECT RADIATOR HOSE OUTLET (See page EM-96) 25. DISCONNECT OIL COOLER INLET HOSE (See page CO-22) 26. DISCONNECT OIL COOLER OUTLET HOSE (See page CO-23) 27. DISCONNECT HEATER INLET WATER HOSE (See page EM-97) 28. DISCONNECT HEATER OUTLET WATER HOSE (See page EM-97) 29. REMOVE ECM (See page EM-97) 30. DISCONNECT ENGINE WIRE (See page EM-97) 31. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (a) Remove the nut from the control shaft lever. (b) Disconnect the transmission control cable assembly from the control shaft lever. C135109 (c) Remove the clip and disconnect the transmission control cable assembly from the No. 1 control cable bracket. C135705 (d) Disconnect the transmission control cable assembly from the control cable clamp. 32. DISCONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE (See page EM-98) 33. DISCONNECT RETURN TUBE SUB-ASSEMBLY (See page EM-99) 34. DISCONNECT FUEL TUBE SUB-ASSEMBLY (See page EM-99) C090579 35. REMOVE GENERATOR ASSEMBLY (See page CH-11) 36. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (See page EM-99) 37. REMOVE FRONT EXHAUST PIPE ASSEMBLY (See page EX-3) AX AX–164 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY 38. REMOVE FRONT AXLE HUB NUT LH (See page DS7) 39. REMOVE FRONT AXLE HUB NUT RH HINT: Use the same procedures described for the LH side. 40. REMOVE FRONT STABILIZER LINK ASSEMBLY LH (See page DS-7) 41. REMOVE FRONT STABILIZER LINK ASSEMBLY RH HINT: Use the same procedures described for the LH side. 42. REMOVE FRONT SPEED SENSOR LH (See page DS7) 43. REMOVE FRONT SPEED SENSOR RH HINT: Use the same procedures described for the LH side. 44. DISCONNECT TIE ROD ASSEMBLY LH (See page DS-8) 45. DISCONNECT TIE ROD ASSEMBLY RH HINT: Use the same procedures described for the LH side. 46. DISCONNECT FRONT SUSPENSION LOWER NO. 1 ARM LH (See page DS-8) 47. DISCONNECT FRONT SUSPENSION LOWER NO. 1 ARM RH HINT: Use the same procedures described for the LH side. 48. SEPARATE FRONT AXLE ASSEMBLY LH (See page DS-8) 49. SEPARATE FRONT AXLE ASSEMBLY RH HINT: Use the same procedures described for the LH side. 50. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (a) Remove the flywheel housing under cover. C092289 AX U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY AX–165 (b) Turn the crankshaft to gain access and remove the 6 bolts while holding the crankshaft pulley bolt with a wrench. HINT: There will be one green colored bolt. 51. SEPARATE STEERING SLIDING YOKE (See page PS40) C092290 52. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (See page EM-100) 53. REMOVE VANE PUMP ASSEMBLY (See page EM101) 54. REMOVE FRONT FRAME ASSEMBLY (See page EM101) 55. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (See page DS-9) 56. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (See page DS-9) 57. REMOVE ENGINE WIRE 58. REMOVE STARTER ASSEMBLY (See page ST-5) 59. REMOVE ENGINE MOUNTING FRONT BRACKET (a) Remove the 3 bolts and engine mounting front bracket. D025420 60. SEPARATE AUTOMATIC TRANSAXLE ASSEMBLY (a) Remove the 5 bolts. C127822 AX AX–166 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY (b) Remove the 4 lower side mounting bolts. (c) Separate and remove the automatic transaxle. 61. REMOVE TORQUE CONVERTER CLUTCH ASSEMBLY C127820 62. REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY (a) Remove the bolt and hole cover from the transaxle case. (b) Remove the O-ring from the hole cover. C135002 63. REMOVE NO. 2 TRANSMISSION CONTROL CABLE BRACKET (a) Remove the bolt and No. 2 transmission control cable bracket. Front C092391E01 64. REMOVE WIRE HARNESS CLAMP BRACKET (a) Disconnect the wire harnesses from the 2 brackets. (b) Remove the 2 bolts and 2 clamps. Front C092392E02 65. DISCONNECT WIRE HARNESS (a) Remove the bolt and disconnect the wire harness. AX Front C092393E03 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY Transmission Wire Connector AX–167 66. DISCONNECT CONNECTORS (a) Disconnect the transmission wire connector. (b) Disconnect the park/neutral position switch connector. (c) Disconnect the 2 speed sensor connectors. Park/Neutral Position Switch Connector Speed Sensor Connector D030864E09 67. REMOVE NO. 1 TRANSMISSION CONTROL CABLE BRACKET (a) Remove the bolt and oil cooler tube clamp. (b) Remove the 2 bolts and No. 1 transmission control cable bracket. 68. REMOVE TRANSMISSION OIL FILLER TUBE SUBASSEMBLY (a) Remove the ATF level gauge. C091736 Transmission Oil Filler Tube Sub-assembly (b) Remove the bolt and transmission oil filler tube subassembly. (c) Remove the O-ring from the oil filler tube subassembly. C091737E02 69. REMOVE NO. 1 OIL COOLER INLET TUBE (a) Using SST and a wrench, disconnect the No. 1 oil cooler inlet tube. SST 09023-12701 SST 70. REMOVE NO. 1 OIL COOLER OUTLET TUBE (a) Using SST and a wrench, disconnect the No. 1 oil cooler outlet tube. SST 09023-12701 C088047E01 AX AX–168 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY 71. REMOVE TRANSAXLE CASE UPPER COVER (a) Remove the 3 bolts and transaxle case upper cover. C088136 INSTALLATION 1. INSTALL TRANSAXLE CASE UPPER COVER (a) Install the transmission case upper cover with the 3 bolts. Torque: 12 N*m (117 kgf*cm, 8 ft.*lbf) 2. INSTALL ENGINE MOUNTING FRONT BRACKET (a) Install the engine mounting front bracket to the automatic transaxle with the 3 bolts. Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) 3. INSTALL TRANSMISSION OIL FILLER TUBE SUBASSEMBLY (a) Coat a new O-ring with ATF, and install it to the oil filler tube. C088136 D025420 (b) Install the oil filler tube to the automatic transaxle with the bolt. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) (c) Install the ATF level gauge. C088135 AX C088278 4. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET (a) Install the No. 1 control cable bracket with the 2 bolts. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 5. INSTALL NO. 1 OIL COOLER INLET TUBE (a) Temporarily install the No. 1 oil cooler outlet tube. (b) Temporarily install the No. 1 oil cooler inlet tube. U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY AX–169 (c) Install the oil cooler tube clamp with the bolt. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) HINT: Install the oil cooler tube clamp so that the oil cooler tube cushions are positioned as shown in the illustration. C091745 (d) Using SST and a wrench, tighten the No. 1 oil cooler inlet tube. SST 09023-12701 Torque: For use without SST 34 N*m (350 kgf*cm, 25 ft.*lbf) For use with SST 32 N*m (322 kgf*cm, 24 ft.*lbf) HINT: Use a torque wrench with a fulcrum length of 345 mm (13.58 in.). SST C092540E02 Transmission Wire Connector 6. INSTALL NO. 1 OIL COOLER OUTLET TUBE (a) Using SST and a wrench, tighten the No. 1 oil cooler outlet tube. SST 09023-12701 Torque: For use without SST 34 N*m (350 kgf*cm, 25 ft.*lbf) For use with SST 32 N*m (322 kgf*cm, 24 ft.*lbf) HINT: Use a torque wrench with a fulcrum length of 345 mm (13.58 in.). 7. CONNECT CONNECTORS (a) Connect the transmission wire connector. (b) Connect the park/neutral position switch connector. (c) Connect the 2 speed sensor connectors. Park/Neutral Position Switch Connector Speed Sensor Connector AX D030864E09 AX–170 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY 8. CONNECT WIRE HARNESS (a) Connect the wire harness with the bolt. Torque: 12 N*m (130 kgf*cm, 9 ft.*lbf) 9. INSTALL WIRE HARNESS CLAMP BRACKET (a) Install the 2 brackets with the 2 bolts. Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) (b) Connect the wire harnesses to the clamps. Front C092393E03 Front C092392E02 10. INSTALL NO. 2 TRANSMISSION CONTROL CABLE BRACKET (a) Install the No. 2 transmission control cable bracket with the bolt. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) Front 11. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY (a) Coat a new O-ring with ATF WS, and install it to the hole cover. C092394E03 (b) Install the hole cover to the transaxle case with the bolt. Torque: 5.5 N*m (56 kgf*cm, 47 in.*lbf) C135002 12. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY (a) Using vernier calipers and a straight edge, measure dimension "A" between the transaxle fitting part of the engine and the converter fitting part of the drive plate (#1). AX A D031087E01 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY AX–171 (b) Set the key of the front oil pump drive gear to the top and put a mark on the housing. G034557 (c) Put a mark on the torque converter clutch so that its groove can be clearly indicated. C057914 (d) Align the 2 marks on the transaxle case and torque converter clutch and fit the splined part of the input shaft to the spline part of the turbine runner. C088330 (e) Rotating the torque converter clutch, fit the spline part of the stator shaft to the spline part of the stator. HINT: Rotate it about 180 degrees. C088300 (f) Rotating the torque converter clutch, align the 2 marks on the case and the torque converter clutch again and fit the key of the oil pump drive gear into the key way of the torque converter clutch. CAUTION: When rotating the torque converter clutch, do not push it with excessive force. AX C088301 AX–172 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY (g) Using vernier calipers and a straight edge, measure dimension "B" shown in the illustration and check that "B" is greater than "A" (measured in step (#1)). Standard: A + 1 (0.04 in.) mm or more NOTICE: Remember to minus the thickness of the straight edge. Dimension B C065911E01 13. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (a) Install the automatic transaxle to the engine with the 5 bolts. Torque: Bolt A 64 N*m (653 kgf*cm, 47 ft.*lbf) Bolt B 46 N*m (469 kgf*cm, 34 ft.*lbf) Bolt C 46 N*m (469 kgf*cm, 34 ft.*lbf) A A C A B C127822E02 (b) Install the 4 lower side mounting bolts. Torque: Bolt D 44 N*m (449 kgf*cm, 32 ft.*lbf) 14. INSTALL STARTER ASSEMBLY (See page ST-13) 15. INSTALL ENGINE WIRE D D D D C127820E01 16. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (See page DS-20) 17. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (See page DS-21) 18. INSTALL FRONT FRAME ASSEMBLY (See page EM112) 19. INSTALL VANE PUMP ASSEMBLY (See page EM-113) 20. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (See page EM-114) 21. INSTALL STEERING SLIDING YOKE (See page PS65) 22. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (a) Apply a few drops of adhesive to 2 threads on the tip of the 6 torque converter clutch mounting bolts. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent. AX U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY AX–173 (b) Install the 6 torque converter clutch mounting bolts. Torque: 41 N*m (418 kgf*cm, 30 ft.*lbf) NOTICE: First install the black colored bolt, and then the remaining 5 bolts. C092290 (c) Install the flywheel housing under cover. 23. INSTALL FRONT AXLE ASSEMBLY LH (See page DS21) 24. INSTALL FRONT AXLE ASSEMBLY RH HINT: Use the same procedures described for the LH side. 25. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM LH (See page DS-21) C094159 26. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM RH HINT: Use the same procedures described for the LH side. 27. INSTALL TIE ROD ASSEMBLY LH (See page DS-21) 28. INSTALL TIE ROD ASSEMBLY RH HINT: Use the same procedures described for the LH side. 29. INSTALL FRONT SPEED SENSOR LH (See page DS21) 30. INSTALL FRONT SPEED SENSOR RH HINT: Use the same procedures described for the LH side. 31. INSTALL FRONT STABILIZER LINK ASSEMBLY LH (See page DS-22) 32. INSTALL FRONT STABILIZER LINK ASSEMBLY RH HINT: Use the same procedures described for the LH side. 33. INSTALL FRONT AXLE HUB NUT LH (See page DS22) 34. INSTALL FRONT AXLE HUB NUT RH HINT: Use the same procedures described for the LH side. 35. INSTALL FRONT EXHAUST PIPE ASSEMBLY (See page EX-3) 36. CONNECT COMPRESSOR AND MAGNETIC CLUTCH (See page EM-115) 37. INSTALL GENERATOR ASSEMBLY (See page CH-19) AX AX–174 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY 38. CONNECT FUEL TUBE SUB-ASSEMBLY (See page EM-115) 39. CONNECT RETURN TUBE SUB-ASSEMBLY (See page EM-116) 40. CONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE (See page EM-116) 41. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (a) Connect the transmission control cable assembly to the control cable clamp. C090579 (b) Connect the transmission control cable to the bracket with a new clip. C135705 (c) Connect the transmission control cable assembly to the control shaft lever with the nut. Torque: 15 N*m (150 kgf*cm, 11 ft.*lbf) 42. CONNECT ENGINE WIRE (See page EM-117) 43. INSTALL ECM (See page EM-117) 44. CONNECT HEATER INLET WATER HOSE (See page EM-117) C135109 45. CONNECT HEATER OUTLET WATER HOSE (See page EM-118) 46. CONNECT OIL COOLER INLET HOSE (See page CO30) 47. CONNECT OIL COOLER OUTLET HOSE (See page CO-30) 48. CONNECT RADIATOR HOSE INLET (See page EM118) 49. CONNECT RADIATOR HOSE OUTLET (See page EM118) AX 50. CONNECT NO. 1 VACUUM HOSE CONNECTOR (See page EM-118) 51. INSTALL NO. 2 ENGINE MOUNTING BRACKET RH (See page EM-118) U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY AX–175 52. INSTALL ENGINE MOVING CONTROL ROD SUBASSEMBLY (See page EM-119) 53. INSTALL NO. 2 ENGINE MOUNTING STAY RH (See page EM-119) 54. INSTALL BATTERY (See page EM-119) 55. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (See page EM-120) 56. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See page ES-419) 57. INSTALL AIR CLEANER INLET ASSEMBLY (See page EM-120) 58. INSTALL V-RIBBED BELT (See page EM-6) 59. INSTALL COWL TOP PANEL OUTER SUBASSEMBLY (See page ES-426) 60. INSTALL WINDSHIELD WIPER LINK ASSEMBLY HINT: See page WW-13. 61. INSTALL FRONT WHEEL (See page EM-120) 62. ADD ENGINE OIL 63. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page EM-120) 64. ADD ENGINE COOLANT (See page CO-5) 65. ADD AUTOMATIC TRANSAXLE FLUID Fluid type: Toyota Genuine ATF WS 66. ADD POWER STEERING FLUID 67. BLEED POWER STEERING FLUID (See page PS-7) 68. INSPECT AUTOMATIC TRANSAXLE FLUID (See page AX-123) 69. CHECK FOR FUEL LEAKS (See page FU-9) 70. CHECK FOR ENGINE OIL LEAKS 71. CHECK FOR ENGINE COOLANT LEAKS (See page CO-1) 72. CHECK FOR EXHAUST GAS LEAKS 73. CHECK FOR SHIFT LEVER POSITION (See page AX179) 74. ADJUST SHIFT LEVER POSITION (See page AX-182) 75. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT HINT: See page SP-4. 76. CHECK IGNITION TIMING (See page EM-1) 77. CHECK ENGINE IDLE SPEED (See page EM-2) AX AX–176 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY 78. INSPECT CO/HC (See page EM-3) 79. INSTALL FRONT FENDER APRON SEAL RH 80. INSTALL ENGINE UNDER COVER LH 81. INSTALL ENGINE UNDER COVER RH 82. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (See page EM-121) 83. CHECK ABS SPEED SENSOR SIGNAL HINT: See page BC-11. AX AX–177 U250E AUTOMATIC TRANSAXLE – SHIFT LEVER SHIFT LEVER U250E AUTOMATIC TRANSAXLE TRANSMISSION COMPONENTS for TMC Made: NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH UPPER CONSOLE PANEL SUB-ASSEMBLY SHIFT LEVER KNOB SUB-ASSEMBLY CONSOLE BOX POCKET NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY UPPER CONSOLE REAR PANEL SUB-ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL CONSOLE BOX CARPET NO. 2 CONSOLE BOX INSERT FRONT LOWER INSTRUMENT PANEL FINISH PANEL LH FLOOR CARPET BRACKET LH COWL SIDE TRIM SUB-ASSEMBLY LH FRONT DOOR SCUFF PLATE LH CONSOLE BOX ASSEMBLY C137677E02 AX AX–178 U250E AUTOMATIC TRANSAXLE – SHIFT LEVER for TMMK Made: NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH UPPER CONSOLE PANEL SUB-ASSEMBLY SHIFT LEVER KNOB SUB-ASSEMBLY CONSOLE BOX POCKET NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY UPPER CONSOLE REAR PANEL SUB-ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL CONSOLE BOX CARPET or

LOWER INSTRUMENT PANEL FINISH PANEL LH NO. 2 CONSOLE BOX INSERT FRONT or or FLOOR CARPET BRACKET LH COWL SIDE TRIM SUB-ASSEMBLY LH FRONT DOOR SCUFF PLATE LH CONSOLE BOX ASSEMBLY C137677E03 AX AX–179 U250E AUTOMATIC TRANSAXLE – SHIFT LEVER 12 (122, 9) 12 (122, 9) SHIFT LOCK CONTROL UNIT TRANSMISSION CONTROL CABLE ASSEMBLY SHIFT LOCK CONTROL ECU INDICATOR LIGHT WIRE SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C135729E04 AX AX–180 U250E AUTOMATIC TRANSAXLE – SHIFT LEVER ON-VEHICLE INSPECTION 1. AX INSPECT SHIFT LEVER POSITION (a) When shifting from the P to the R position with the ignition switch on and the brake pedal depressed, make sure that the shift lever moves smoothly and moves correctly into the position. (b) Start the engine and make sure that the vehicle moves forward when shifting from the N to the D position and moves rearward when shifting to the R position. If operation cannot be done as specified, inspect the park/neutral position switch assembly and check the shift lever assembly installation condition. U250E AUTOMATIC TRANSAXLE – SHIFT LEVER AX–181 REMOVAL B133990 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-24) 3. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-25) 4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (See page IP-20) 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (See page IP-21) 6. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (See page IP-22) 7. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (a) Turn the shift lever knob counterclockwise and remove the shift lever knob sub-assembly. 8. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-24) 9. REMOVE NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-25) 10. REMOVE FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (See page IP-25) 11. REMOVE UPPER CONSOLE REAR PANEL SUBASSEMBLY (See page IP-26) 12. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMC Made) (See page IP-27) 13. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMMK Made) (See page IP-27) 14. REMOVE CONSOLE BOX POCKET (See page IP-28) 15. REMOVE CONSOLE BOX CARPET (See page IP-28) 16. REMOVE CONSOLE BOX ASSEMBLY (for TMC Made) (See page IP-28) 17. REMOVE CONSOLE BOX ASSEMBLY (for TMMK Made) (See page IP-29) 18. REMOVE NO. 2 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-29) 19. REMOVE NO. 2 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-30) 20. REMOVE FLOOR CARPET BRACKET LH (See page AC-155) 21. REMOVE TRANSMISSION CONTROL CABLE ASSEMBLY (a) Disconnect the end of the transmission control cable assembly from the shift lock control unit. AX AX–182 U250E AUTOMATIC TRANSAXLE – SHIFT LEVER (b) Disconnect the transmission control cable assembly from the shift lock control unit. C135015 22. REMOVE SHIFT LOCK CONTROL UNIT (a) Disconnect the shift lock control ECU connector and transmission control switch wire connector. C135016 (b) Remove the 4 bolts and shift lever. C135017 DISASSEMBLY Connector Front View: Stopper G028933E01 AX 1. REMOVE INDICATOR LIGHT WIRE SUB-ASSEMBLY (a) Using a screwdriver, release the stopper. (b) Using a screwdriver, disengage the locking lug of terminals (4) and (8), and pull the terminals out from the rear of the connector. U250E AUTOMATIC TRANSAXLE – SHIFT LEVER AX–183 (c) Release the indicator light wire from the clamp on the shift lock control unit. (d) Turn the indicator light guide counterclockwise. (e) Align the indicator light guide key with the groove on the shift lock control unit to remove the indicator light wire. Groove Key C135019E01 2. REMOVE SHIFT LOCK CONTROL ECU (a) Remove the shift lock control ECU from the shift lock control unit. C135730 INSPECTION Switch Side: (Connector Front View) 1. INSPECT TRANSMISSION CONTROL SWITCH (a) Measure the resistance according to the value(s) in the table below when the shift lever is moved to each position. Standard resistance Shift Position 4 and 3 G028380E11 Except 4 and 3 L Except L Tester Connection 1-2 5-6 Specified Condition Below 1 Ω 10 kΩ or higher Below 1 Ω 10 kΩ or higher If the resistance value is not as specified, replace the transmission control switch. AX AX–184 U250E AUTOMATIC TRANSAXLE – SHIFT LEVER ADJUSTMENT 1. ADJUST SHIFT LEVER POSITION (a) Move the shift lever to the N position. (b) Remove the nut from the control shaft lever. (c) Disconnect the transmission control cable assembly from the control shaft lever. C135109 (d) Push the control shaft fully downward. (e) Return the control shaft lever 2 notches to the N position. C135711 (f) Slider Lock Piece C135734E02 AX Move the slider in the directions indicated by the arrows and pull up the lock piece. NOTICE: Do not damage the boot. U250E AUTOMATIC TRANSAXLE – SHIFT LEVER AX–185 (g) Connect the transmission control cable assembly to the control shaft lever with the nut. Torque: 15 N*m (150 kgf*cm, 11 ft.*lbf) C135109 (h) Push in the lock piece. NOTICE: Firmly push in the lock piece until the slider lock is engaged. (i) Start the engine and make sure that the vehicle moves forward when moving the lever from the N to the D position and moves rearward when moving it to the R position. If it becomes hard to move the shift lever, readjust the shift lever position. C138300E01 REASSEMBLY 1. INSTALL SHIFT LOCK CONTROL ECU (a) Install the shift lock control ECU to the shift lever. 2. INSTALL INDICATOR LIGHT WIRE SUB-ASSEMBLY (a) Insert the indicator light wire into the shift lock control unit while aligning the groove on the unit with the indicator light guide key. (b) Install the indicator light guide by turning it clockwise until it securely locks. (c) Install the indicator light wire to the clamp on the shift lock control unit. C135730 Groove Key C135019E02 AX AX–186 U250E AUTOMATIC TRANSAXLE – SHIFT LEVER (d) Connect terminals (4) and (8) of the indicator light wire. (e) Push the stopper. Connector Front View: Stopper G028933E01 INSTALLATION 1. INSTALL SHIFT LOCK CONTROL UNIT (a) Connect the shift lock ECU connector and transmission control switch wire connector. (b) Install the 4 bolts and shift lock control unit. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 2. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (a) Install the transmission control cable assembly as shown in the illustration. HINT: • Install the floor shift cable with the uneven surface facing up. • Securely engage the claws of the floor shift cable. 3. INSTALL FLOOR CARPET BRACKET LH 4. INSTALL NO. 2 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-50) 5. INSTALL NO. 2 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-50) 6. INSTALL CONSOLE BOX ASSEMBLY (for TMC Made) (See page IP-51) 7. INSTALL CONSOLE BOX ASSEMBLY (for TMMK Made) (See page IP-51) 8. INSTALL CONSOLE BOX CARPET (See page IP-51) 9. INSTALL CONSOLE BOX POCKET (See page IP-51) C135016 C135020 AX 10. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMC Made) (See page IP-52) U250E AUTOMATIC TRANSAXLE – SHIFT LEVER AX–187 11. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMMK Made) (See page IP-52) 12. INSTALL UPPER CONSOLE REAR PANEL SUBASSEMBLY (See page IP-53) 13. INSTALL FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (See page IP-53) 14. INSTALL NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-54) 15. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-55) 16. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (a) Install the shift lever knob sub-assembly. 17. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (See page IP-57) 18. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (See page IP-58) 19. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (See page IP-59) B133991 20. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-54) 21. INSTALL FRONT DOOR SCUFF PLATE LH (See page IR-54) 22. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf) 23. INSPECT SHIFT LEVER POSITION (See page AX-146) 24. ADJUST SHIFT LEVER POSITION (See page AX-146) AX U250E AUTOMATIC TRANSAXLE – TORQUE CONVERTER CLUTCH AND DRIVE PLATE AX–187 TORQUE CONVERTER CLUTCH AND DRIVE PLATE U250E AUTOMATIC TRANSAXLE TRANSMISSION COMPONENTS FRONT WIPER ARM AND BLADE ASSEMBLY RH 20 (204, 15) FRONT FENDER TO COWL SIDE SEAL RH FRONT WIPER ARM AND BLADE ASSEMBLY LH COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 7.5 (77, 66 in.*lbf) 85 (867, 63) FRONT FENDER TO COWL SIDE SEAL LH 5.0 (51, 44 in.*lbf) WINDSHIELD WIPER LINK ASSEMBLY COWL TOP PANEL OUTER SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque A136912E01 AX AX–188 U250E AUTOMATIC TRANSAXLE – TORQUE CONVERTER CLUTCH AND DRIVE PLATE ENGINE MOVING CONTROL ROD SUB-ASSEMBLY NO. 2 ENGINE MOUNTING BRACKET RH 64 (653, 47) 9.0 (92, 80 in.*lbf) 52 (531, 38) 64 (653, 47) NO. 1 ENGINE COVER SUB-ASSEMBLY NO. 2 ENGINE MOUNTING STAY RH V-RIBBED BELT 9.8 (100, 87 in.*lbf) 52 (531, 38) 21 (214, 15) GENERATOR ASSEMBLY FRONT FENDER APRON SEAL RH N*m (kgf*cm, ft.*lbf) : Specified torque AX A134948E01 U250E AUTOMATIC TRANSAXLE – TORQUE CONVERTER CLUTCH AND DRIVE PLATE AX–189 5.0 (51, 44 in.*lbf) AIR CLEANER CAP SUB-ASSEMBLY AIR CLEANER INLET ASSEMBLY 9.0 (92, 80 in.*lbf) BATTERY 5.0 (51, 44 in.*lbf) AIR CLEANER CASE SUB-ASSEMBLY BATTERY TRAY 7.8 (80, 69 in.*lbf) COMPRESSOR AND MAGNETIC CLUTCH AIR CLEANER BRACKET NO. 1 VACUUM HOSE CONNECTOR HEATER INLET WATER HOSE 25 (255, 18) NO. 1 OIL RESERVOIR TO PUMP HOSE J/B COVER RADIATOR HOSE OUTLET RETURN TUBE SUB-ASSEMBLY TRANSMISSION CONTROL CABLE ASSEMBLY ENGINE UNDER COVER RH 15 (150,11 ) HEATER OUTLET WATER HOSE CLIP OIL COOLER OUTLET HOSE ENGINE UNDER COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque OIL COOLER INLET HOSE Non-reusable part RADIATOR HOSE INLET AX C138301E04 AX–190 U250E AUTOMATIC TRANSAXLE – TORQUE CONVERTER CLUTCH AND DRIVE PLATE TIE ROD ASSEMBLY LH STEERING SLIDING YOKE 35 (357, 26) 74 (755, 55) 49 (500, 36) COTTER PIN 8.0 (82, 71 in.*lbf) FRONT SPEED SENSOR LH DRIVE SHAFT ASSEMBLY LH 294 (3,000, 217) FRONT AXLE HUB NUT LH 75 (755, 55) FRONT SUSPENSION LOWER NO. 1 ARM LH EXHAUST PIPE GASKET 56 (571, 41) EXHAUST PIPE GASKET 62 (633, 46) FRONT EXHAUST PIPE NO. 1 SUPPORT BRACKET 33 (337, 24) 33 (337, 24) REAR EXHAUST PIPE NO. 1 SUPPORT BRACKET FRONT EXHAUST PIPE ASSEMBLY AX N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C143322E01 U250E AUTOMATIC TRANSAXLE – TORQUE CONVERTER CLUTCH AND DRIVE PLATE AX–191 43 (439, 32) 54 (551, 40) VANE PUMP ASSEMBLY x3 95 (969, 70) ENGINE MOUNTING BRACKET RH 95 (969, 70) 87 (888, 64) FRONT FRAME ASSEMBLY FRAME SIDE RAIL PLATE SUB-ASSEMBLY RH FRAME SUSPENSION MEMBER BRACE REAR RH 32 (326, 24) 85 (867, 63) FRAME SIDE RAIL PLATE SUB-ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque FRAME SUSPENSION MEMBER BRACE REAR LH 32 (326, 24) 85 (867, 63) AX A109016E07 AX–192 U250E AUTOMATIC TRANSAXLE – TORQUE CONVERTER CLUTCH AND DRIVE PLATE FRONT DRIVE SHAFT ASSEMBLY RH HOLE SNAP RING x6 TORQUE CONVERTER CLUTCH ASSEMBLY 41 (418, 30) 44 (449, 33) x4 64 (653, 47) FLYWHEEL HOUSING UNDER COVER 46 (469, 34) 46 (469, 34) STARTER ASSEMBLY SNAP RING 39 (398, 29) N*m (kgf*cm, ft.*lbf) : Specified torque AX Non-reusable part FRONT DRIVE SHAFT ASSEMBLY LH Precoated part C138302E06 U250E AUTOMATIC TRANSAXLE – TORQUE CONVERTER CLUTCH AND DRIVE PLATE AX–193 REMOVAL 1. INSPECTION SST 1. AT00953E02 INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY (a) Inspect the one-way clutch. (1) Set SST into the inner race of the one-way clutch. SST 09350-32014 (09351-32010) (2) Install SST so that it fits in the notch of the converter hub and outer race of the one-way clutch. SST 09350-32014 (09351-32010, 0935132020) (3) Stand the torque converter up and turn the SST. Standard: If the one-way clutch is turned clockwise, it rotates freely and if turned counterclockwise, it locks. Hold Lock Turn REMOVE TORQUE CONVERTER CLUTCH ASSEMBLY HINT: See page AX-162. Free AT03306E02 Sample showing minimum amount of powders in ATF Actual Size D025367E07 (b) Determine the condition of the torque converter clutch assembly. (1) If the inspection result of the torque converter clutch assembly satisfies the following conditions, replace the torque converter clutch assembly. Malfunction item: A metallic sound is emitted from the torque converter clutch assembly during the stall test or when the shift lever is moved to the N position. The one-way clutch is free or locked in both directions. The amount of powder in the ATF is greater than the sample shown in the illustration (see the sample). HINT: The sample shows the auto fluid of approximately 0.25 liters (0.26 US qts, 0.22 Imp. qts) that is taken out from the removed torque converter clutch. (c) Exchange the ATF in the torque converter clutch. (1) If the ATF is discolored and/or has a foul odor, completely stir the ATF in the torque converter clutch and drain it. AX AX–194 U250E AUTOMATIC TRANSAXLE – TORQUE CONVERTER CLUTCH AND DRIVE PLATE (d) Clean and check the oil cooler and oil pipe line. (1) If the torque converter clutch is inspected or the ATF is exchanged, clean the oil cooler and oil pipe line. HINT: • Spray compressed air of 196 kPa (2 kgf/ cm2, 28 psi) from the inlet hose. • If plenty of fine powders are identified in the ATF, add new ATF using a bucket pump and clean it again. (2) If the ATF is cloudy, inspect the oil cooler (radiator). C135012 OK (e) Prevent deformation of the torque converter clutch and damage to the oil pump gear. (1) When there is any damage to the end of the bolt for the torque converter clutch and to the bottom of the bolt hole, replace the bolt and the torque converter clutch. (2) All of the bolts must be the same length. (3) Bolts with washers must be used. NG The Bottom is Damaged D025368E08 2. C135090 AX INSPECT DRIVE PLATE & RING GEAR SUBASSEMBLY (a) Set up a dial indicator with a roller instrument and measure the drive plate runout. (b) Check for damage of the ring gear. Maximum runout: 0.20 mm (0.0079 in.) If runout is not within specification or the ring gear is damaged, replace the drive plate. U250E AUTOMATIC TRANSAXLE – TORQUE CONVERTER CLUTCH AND DRIVE PLATE AX–195 INSTALLATION 1. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY HINT: See page AX-168. AX AX–195 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AUTOMATIC TRANSAXLE UNIT U250E AUTOMATIC TRANSAXLE TRANSMISSION COMPONENTS 8.8 (90, 78 in.*lbf) BREATHER PLUG HOSE SPEED SENSOR 8.8 (90, 78 in.*lbf) 5.4 (55, 48 in.*lbf) O-RING NO. 2 BREATHER PLUG 7.4 (75, 65 in.*lbf) NO. 1 TRANSAXLE CASE PLUG TRANSMISSION WIRE O-RING 7.4 (75, 65 in.*lbf) NO. 1 TRANSAXLE CASE PLUG LOCK PLATE 6.6 (67, 58 in.*lbf) 27 (275, 20) O-RING OIL COOLER TUBE UNION (INLET OIL COOLER UNION) O-RING O-RING 7.4 (75, 65 in.*lbf) NO. 1 TRANSAXLE CASE PLUG 7.4 (75, 65 in.*lbf) NO. 1 TRANSAXLE CASE PLUG O-RING 27 (276, 20) DRAIN PLUG GASKET OIL COOLER TUBE UNION (OUTLET OIL COOLER UNION) N*m (kgf*cm, ft.*lbf) : Specified torque 49 (500, 36) DRAIN PLUG Non-reusable part Apply ATF WS Precoated part C132380E01 AX AX–196 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT UNDERDRIVE OUTPUT SHAFT OIL SEAL RING 7.4 (75, 65 in.*lbf) TRANSAXLE REAR COVER SUB-ASSEMBLY NO. 1 TRANSAXLE CASE PLUG UNDERDRIVE CYLINDRICAL ROLLER BEARING 7.4 (75, 65 in.*lbf) Bolt A: 19 (190,14) Other bolt: 25 (250,18) AUTOMATIC TRANSAXLE CASE SUB-ASSEMBLY NO. 1 TRANSAXLE CASE PLUG x11 29 (296, 21) O-RING O-RING 9.8 (100, 87 in.*lbf) x8 x4 7.4 (75, 65 in.*lbf) NO. 1 TRANSAXLE CASE PLUG O-RING NO. 1 GOVERNOR APPLY GASKET TRANSAXLE APPLY TUBE CLAMP x3 29 (296, 21) x5 22 (225, 16) TRANSAXLE CASE 2ND BRAKE GASKET DIFFERENTIAL GEAR LUBE APPLY TUBE TRANSAXLE HOUSING BRAKE DRUM GASKET MANUAL VALVE LEVER SHAFT RETAINER SPRING SLOTTED SPRING PIN SPACER MANUAL VALVE LEVER SHAFT MANUAL VALVE LEVER SUB-ASSEMBLY MANUAL VALVE LEVER SHAFT OIL SEAL 5.4 (55, 48 in.*lbf) PARK/NEUTRAL POSITION SWITCH ASSEMBLY 6.9 (70, 61 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque CONTROL SHAFT LEVER Non-reusable part Precoated part LOCK PLATE 13 (130, 9) Apply ATF WS Apply MP grease WASHER C132381E01 AX U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–197 TRANSMISSION VALVE BODY ASSEMBLY PARKING LOCK ROD SUB-ASSEMBLY 11 (110, 8) x17 PARKING LOCK PAWL BRACKET VALVE BODY OIL STRAINER ASSEMBLY 20 (205, 15) O-RING MANUAL DETENT SPRING SUB-ASSEMBLY COMPRESSION SPRING 12 (120, 9) 11 (110, 8) 20 (205, 15) AUTOMATIC TRANSAXLE OIL PAN GASKET TRANSMISSION OIL CLEANER MAGNET C-3 ACCUMULATOR PISTON SPRING CHECK BALL BODY COMPRESSION SPRING O-RING REVERSE CLUTCH ACCUMULATOR PISTON x18 AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY COMPRESSION SPRING 7.8 (80, 69 in.*lbf) O-RING B-3 ACCUMULATOR PISTON N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Precoated part Apply ATF WS C132382E01 AX AX–198 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT FORWARD CLUTCH ASSEMBLY OIL PUMP ASSEMBLY 22 (225, 16) THRUST NEEDLE ROLLER BEARING x7 OVERDRIVE BRAKE GASKET WASHER 185 (1,886, 136) to 350 (3,569, 258) NUT NO. 1 THRUST BEARING RACE COUNTER DRIVE GEAR COUNTER DRIVE ANGULAR BALL BEARING (FRONT SIDE) THRUST NEEDLE ROLLER BEARING MULTIPLE DISC CLUTCH HUB N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Apply ATF WS C132383E01 AX AX–199 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT FLANGE 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY PLATE 1ST AND REVERSE BRAKE PISTON O-RING SNAP RING 1ST AND REVERSE BRAKE DISC SNAP RING COUNTER DRIVE ANGULAR BALL BEARING (REAR SIDE) BRAKE HUB SNAP RING PLATE FRONT PLANETARY GEAR ASSEMBLY FRONT PLANETARY RING GEAR SNAP RING REAR PLANETARY SUN GEAR ASSEMBLY FLANGE 2ND BRAKE DISC NO. 2 PLANETARY CARRIER THRUST WASHER ONE-WAY CLUTCH ASSEMBLY SECOND BRAKE PISTON ASSEMBLY REAR PLANETARY GEAR ASSEMBLY ONE-WAY CLUTCH SLEEVE NO. 3 THRUST BEARING RACE THRUST BEARING RACE NO. 2 THRUST BEARING RACE THRUST NEEDLE ROLLER BEARING INPUT SUN GEAR SNAP RING THRUST NEEDLE ROLLER BEARING ONE-WAY CLUTCH INNER RACE NO. 1 PLANETARY CARRIER THRUST WASHER NO. 2 THRUST BEARING RACE THRUST BEARING THRUST BEARING OVERDRIVE DIRECT CLUTCH REAR CLUTCH OIL SEAL RING HUB SUB-ASSEMBLY THRUST BEARING RACE NEEDLE ROLLER BEARING DIRECT CLUTCH ASSEMBLY Non-reusable part TRANSAXLE REAR COVER SUB-ASSEMBLY AX Apply ATF WS C132384E01 AX–200 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT NO. 2 UNDERDRIVE CLUTCH DISC FLANGE UNDERDRIVE ONE-WAY CLUTCH ASSEMBLY UNDERDRIVE CLUTCH ASSEMBLY UNDERDRIVE PLANETARY GEAR ASSEMBLY PLATE SNAP RING OUTER RACE RETAINER THRUST BEARING RACE THRUST NEEDLE ROLLER BEARING THRUST NEEDLE ROLLER BEARING NO. 2 THRUST BEARING UNDERDRIVE RACE NEEDLE ROLLER BEARING UNDERDRIVE BRAKE PISTON UNDERDRIVE CLUTCH DRUM OIL SEAL RING O-RING SNAP RING UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY Non-reusable part Apply ATF WS C132385E01 AX U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–201 DIFFERENTIAL GEAR ASSEMBLY PARKING LOCK PAWL PARKING LOCK PAWL SHAFT TENSION SPRING PARKING LOCK PAWL PIN 9.8 (100, 87 in.*lbf) PAWL SHAFT CLAMP CLUTCH APPLY TUBE BRAKE APPLY TUBE 5.4 (55, 48 in.*lbf) TRANSAXLE APPLY TUBE CLAMP N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part NO. 1 GOVERNOR APPLY GASKET C132386E01 AX AX–202 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT DIRECT MULTIPLE DISC CLUTCH DISC DIRECT MULTIPLE DISC CLUTCH CUSHION PLATE DIRECT CLUTCH FLANGE DIRECT CLUTCH FLANGE HOLE SNAP RING DIRECT MULTIPLE DISC CLUTCH PLATE OVERDRIVE CLUTCH PLATE OVERDRIVE DIRECT CLUTCH HOLE SNAP RING OVERDRIVE DIRECT CLUTCH DISC OVERDRIVE CLUTCH FLANGE OVERDRIVE DIRECT CLUTCH O-RING OVERDRIVE DIRECT CLUTCH PISTON OVERDRIVE DIRECT CLUTCH BALANCER INTERMEDIATE SHAFT SUB-ASSEMBLY OVERDRIVE DIRECT CLUTCH RETURN SPRING SHAFT SNAP RING Non-reusable part Apply ATF WS OVERDRIVE DIRECT CLUTCH DRUM SUB-ASSEMBLY OVERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY C132387E01 AX U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–203 2ND BRAKE CYLINDER 2ND BRAKE PISTON 2ND BRAKE PISTON O-RING 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY 2ND BRAKE PISTON RETURN SPRING SEAT SHAFT SNAP RING Non-reusable part Apply ATF WS C132388E01 AX AX–204 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT DISASSEMBLY 1. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Remove the nut, washer, and control shaft lever. C135707 (b) Using a screwdriver, unstake the lock plate, and remove the lock nut and nut stopper. C135708 (c) Remove the 2 bolts and pull out the park/neutral position switch. C135710 2. REMOVE NO. 2 BREATHER PLUG (a) Remove the No. 2 breather plug from the transaxle case. C134833 No. 2 Breather Plug AX O-Ring C134834E01 (b) Remove the hose and O-ring from the No. 2 breather plug. U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–205 3. REMOVE OIL COOLER TUBE UNION (INLET OIL COOLER UNION) (a) Remove the union. (b) Remove the O-ring from the union. 4. REMOVE OIL COOLER TUBE UNION (OUTLET OIL COOLER UNION) (a) Remove the union. (b) Remove the O-ring from the union. 5. REMOVE SPEED SENSOR (a) Remove the 2 bolts and the 2 speed sensors from the transaxle assembly. 6. REMOVE NO. 1 TRANSAXLE CASE PLUG (a) Remove the 4 No. 1 transaxle case plugs from the transaxle case. (b) Remove the 4 O-rings from the 4 No. 1 transaxle case plugs. 7. FIX AUTOMATIC TRANSAXLE ASSEMBLY (a) Fix the transaxle assembly. 8. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUBASSEMBLY (a) Remove the drain plug and drain plug gasket from the oil pan. Union O-Ring C083143E03 Union O-Ring C083144E04 Speed Sensor D030672E04 C134835 AX C134836 AX–206 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT (b) Remove the 18 bolts, oil pan, and gasket. C091925 (c) Remove the 2 transmission oil cleaner magnets from the oil pan. Magnet C134837E01 9. Magnet AT00103E03 INSPECT TRANSMISSION OIL CLEANER MAGNET (a) Remove the magnets and use them to collect any steel chips. Examine the chips and particles in the pan and on the magnet to determine what type of wear has occurred in the transaxle: Result: Steel (magnetic): bearing, gear, and plate wear Brass (non-magnetic): bushing wear 10. DISCONNECT TRANSMISSION WIRE (a) Disconnect the 7 connectors from the shift solenoid valves. (b) Remove the bolt, lock plate, and ATF temperature sensor. Temperature Sensor C134838E01 11. REMOVE TRANSMISSION WIRE (a) Remove the bolt and transmission wire from the transaxle case. AX Transmission Wire D003547E05 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–207 12. REMOVE VALVE BODY OIL STRAINER ASSEMBLY (a) Remove the 3 bolts and oil strainer. C134839 (b) Remove the O-ring from the oil strainer. O-Ring C091932E02 13. REMOVE TRANSMISSION VALVE BODY ASSEMBLY (a) Support the valve body assembly and remove the 17 bolts and valve body assembly. C091933 14. REMOVE NO. 1 GOVERNOR APPLY GASKET (a) Remove the No. 1 governor apply gasket from the transaxle case. C083127 15. REMOVE TRANSAXLE CASE 2ND BRAKE GASKET (a) Remove the transaxle case 2nd brake gasket from the transaxle case. AX C083128 AX–208 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT 16. REMOVE BRAKE DRUM GASKET (a) Remove the brake drum gasket from the transaxle case. C083129 17. REMOVE CHECK BALL BODY (a) Remove the check ball body and spring from the transaxle case. Check Ball D003554E01 18. REMOVE C-3 ACCUMULATOR PISTON (a) Remove the spring from the C-3 accumulator piston. D003555 (b) Using needle-nose pliers, remove the the C-3 accumulator piston from the transaxle case. C134840 (c) Remove the O-ring from the C-3 accumulator piston. O-Ring C-3 Accumulator Piston AX C134841E01 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT D026401 AX–209 19. REMOVE REVERSE CLUTCH ACCUMULATOR PISTON (a) Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil hole and remove the reverse accumulator piston and spring. NOTICE: • Applying compressed air may cause the piston to jump-out. When removing the piston, hold it by hand using a waste cloth. • Take care not to splash ATF when applying the air. (b) Remove the 2 O-rings from the reverse clutch accumulator piston. Reverse Clutch Accumulator Piston O-Ring O-Ring D026402E07 D003558E01 20. REMOVE B-3 ACCUMULATOR PISTON (a) Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil hole and remove the B-3 accumulator piston and 2 springs. NOTICE: • Applying compressed air may cause the piston to jump-out. When removing the piston, hold it by hand using a waste cloth. • Take care not to splash ATF when applying the air. (b) Remove the O-ring from the B-3 accumulator piston. B-3 Accumulator Piston O-Ring D003904E06 21. REMOVE MANUAL VALVE LEVER SHAFT RETAINER SPRING (a) Using needle-nose pliers, remove the manual valve lever shaft retainer spring. AX D003559 AX–210 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT 22. REMOVE MANUAL DETENT SPRING SUBASSEMBLY (a) Remove the 2 bolts and manual detent spring subassembly. D003560 23. REMOVE PARKING LOCK PAWL BRACKET (a) Remove the 2 bolts and parking lock pawl bracket. C056727 24. REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY (a) Using a screwdriver, slide the spacer. Spacer C134842E01 (b) Using a pin punch (φ3 mm) and hammer, drive out the pin. HINT: Slowly drive out the pin so that it will not fall into the transaxle case. C134843 (c) Remove the manual valve lever shaft, manual valve lever, and spacer. AX C134844 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–211 25. REMOVE PARKING LOCK ROD SUB-ASSEMBLY (a) Remove the parking lock rod sub-assembly from the manual valve lever sub-assembly. HINT: Align the dial with the notches on the manual valve lever sub-assembly to remove the parking lock rod sub-assembly. Parking Lock Rod Sub-assembly C134845E01 26. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL (a) Using a screwdriver, remove the oil seal from the transaxle case. 27. FIX AUTOMATIC TRANSAXLE ASSEMBLY (a) Fix the transaxle case with the oil pump side facing up. 28. INSPECT INPUT SHAFT END PLAY (See page AX231) D003566 29. REMOVE TRANSAXLE HOUSING (a) Remove the 16 bolts. (b) Tap on the circumference of the transaxle housing with a plastic hammer to remove the transaxle housing from the transaxle case. NOTICE: The differential may be accidentally removed when the transaxle housing is removed. C115282 30. REMOVE OIL PUMP ASSEMBLY (a) Remove the 7 bolts and oil pump from the transaxle case. D003569E03 Differential Gear Assembly 31. REMOVE THRUST NEEDLE ROLLER BEARING (a) Remove the thrust needle roller bearing from the underdrive planetary gear assembly. Thrust Needle Roller Bearing Forward Clutch Assembly AX D025505E04 AX–212 Differential Gear Assembly U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT No. 2 Thrust Bearing Underdrive Race Forward Clutch Assembly 32. REMOVE NO. 2 THRUST BEARING UNDERDRIVE RACE (a) Remove the No. 2 thrust bearing underdrive race from the underdrive planetary gear assembly. Underdrive Planetary Gear Assembly D025506E05 Differential Gear Assembly 33. REMOVE DIFFERENTIAL GEAR ASSEMBLY (a) Remove the differential gear assembly from the transaxle case. D026450E07 34. REMOVE OVERDRIVE BRAKE GASKET (a) Remove the 2 overdrive brake gaskets from the transaxle case. D003573 Forward Clutch Assembly 35. REMOVE FORWARD CLUTCH ASSEMBLY (a) Remove the forward clutch assembly from the transaxle case. D003574E04 Thrust Needle Roller Bearing AX D003906E03 (b) Remove the thrust needle roller bearing from the forward clutch. U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT Thrust Needle Roller Bearing Multiple Disc Clutch Hub Thrust Needle Roller Bearing No. 1 Thrust Bearing Race AX–213 36. REMOVE MULTIPLE DISC CLUTCH HUB (a) Remove the thrust needle roller bearing, multiple disc clutch hub, thrust needle roller bearing and No. 1 thrust bearing race from the transaxle case. 37. INSPECT MULTIPLE DISC CLUTCH HUB (See page AX-228) D026787E05 38. REMOVE UNDERDRIVE PLANETARY GEAR ASSEMBLY (a) Remove the bolt and pawl shaft clamp from the transaxle case. Pawl Shaft Clamp D003576E04 (b) Remove the parking lock pawl shaft from the transaxle case. D009652 (c) Push the parking lock pawl. HINT: Failure to do so will cause interference when the underdrive planetary gear is removed. D009689 Underdrive Planetary Gear Assembly (d) Remove the underdrive planetary gear assembly from the transaxle case. NOTICE: Do not drop the underdrive planetary gear assembly. AX D003579E05 AX–214 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT 39. REMOVE PARKING LOCK PAWL (a) Remove the spring, pawl pin and parking lock pawl. D026386 40. REMOVE UNDERDRIVE CLUTCH ASSEMBLY (a) Remove the underdrive clutch assembly, thrust bearing, and bearing race from the transaxle case. Thrust Bearing Bearing Race D003580E03 41. REMOVE UNDERDRIVE ONE-WAY CLUTCH ASSEMBLY (a) Using a screwdriver, remove the snap ring from the transaxle case. Snap Ring D003581E03 (b) Remove the underdrive one-way clutch from the transaxle case. Underdrive One-way Clutch Assembly C134846E01 (c) Remove the outer race retainer from the one-way clutch. AX Outer Race Retainer D003907E01 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT Snap Ring AX–215 42. REMOVE NO. 2 UNDERDRIVE CLUTCH DISC (a) Using a screwdriver, remove the snap ring. D026466E01 (b) Remove the flange, 3 discs and 3 plates from the transaxle case. Flange 43. INSPECT NO. 2 UNDERDRIVE CLUTCH DISC (See page AX-228) C134847E01 44. REMOVE TRANSAXLE REAR COVER SUBASSEMBLY (a) Remove the 11 bolts. (b) Tap on the circumference of the rear cover with a plastic hammer to remove the transaxle rear cover from the transaxle case. C134848 45. REMOVE NO. 1 TRANSAXLE CASE PLUG (a) Remove the 4 No. 1 transaxle case plugs from the transaxle rear cover. (b) Remove the 4 O-rings from the 4 No. 1 transaxle case plugs. C134849 Rear Clutch Oil Seal Ring 46. REMOVE REAR CLUTCH OIL SEAL RING (a) Remove the 3 rear clutch oil seal rings from the transaxle rear cover. AX D026389E02 AX–216 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT 47. REMOVE NEEDLE ROLLER BEARING (a) Using SST, remove the needle roller bearing from the transaxle rear cover. SST 09387-00041 (09387-01021, 09387-01030, 09387-01040) SST D026472E01 48. REMOVE NO. 1 GOVERNOR APPLY GASKET (a) Using a screwdriver, remove the 3 apply gaskets. D026390 49. REMOVE BRAKE APPLY TUBE (a) Remove the bolt, clamp and brake apply tube. (b) Remove the clutch apply tube. (c) Remove the brake apply tube from the clamp. Brake Apply Tube Clutch Apply Tube C134851E01 50. REMOVE DIRECT CLUTCH ASSEMBLY (a) Remove the thrust bearing and the direct clutch assembly from the transaxle case. Direct Clutch Assembly 51. INSPECT PACK CLEARANCE OF DIRECT CLUTCH (See page AX-232) 52. INSPECT PACK CLEARANCE OF OVERDRIVE CLUTCH (See page AX-232) Thrust Bearing D026403E04 53. REMOVE DIRECT MULTIPLE DISC CLUTCH DISC (a) Using a screwdriver, remove the snap ring from the intermediate shaft. Snap Ring AX D026419E01 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–217 (b) Remove the flange, 3 discs, 3 plates and cushion plate from the intermediate shaft. 54. INSPECT DIRECT MULTIPLE DISC CLUTCH DISC (See page AX-231) D026420 55. REMOVE OVERDRIVE DIRECT CLUTCH DISC (a) Using a screwdriver, remove the snap ring from the intermediate shaft. (b) Remove the flange, 3 discs and 3 plates from the intermediate shaft. 56. INSPECT OVERDRIVE DIRECT CLUTCH DISC (See page AX-231) C134887 SST D003677E01 Direct Clutch Drum Clutch Balancer 57. REMOVE OVERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY (a) Place SST on the clutch balancer and compress the spring with a press. SST 09387-00020 (b) Using a snap ring expander, remove the snap ring from the direct clutch drum. NOTICE: • Stop the press when the spring seat is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove. This prevents the spring seat from being deformed. • Do not expand the snap ring excessively. (c) Remove the clutch balancer from the overdrive direct clutch drum. D026424E02 AX AX–218 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT Direct Clutch Drum Overdrive Clutch Return Spring (d) Remove the overdrive clutch return spring from the overdrive direct clutch drum. 58. INSPECT OVERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY (See page AX-231) D026423E05 59. REMOVE OVERDRIVE DIRECT CLUTCH PISTON (a) Install the intermediate shaft on the transaxle rear cover. (b) Holding the direct clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the transaxle rear cover to remove the direct clutch piston. D026463 60. REMOVE OVERDRIVE DIRECT CLUTCH DRUM SUBASSEMBLY (a) Holding the direct clutch drum by hand, apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the transaxle rear cover to remove the direct clutch drum. D026425 O-Ring 61. REMOVE OVERDRIVE DIRECT CLUTCH O-RING (a) Using a screwdriver, remove the O-ring from the direct clutch drum. D026464E01 62. REMOVE OVERDREVE DIRECT CLUTCH HUB SUBASSEMBLY (a) Remove the thrust bearing race, thrust bearing, and overdrive direct clutch hub from the planetary gear assembly. Overdrive Direct Clutch Hub Thrust Bearing AX Thrust Bearing Race D026392E05 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–219 63. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY (a) Remove the rear planetary sun gear assembly from the transaxle case. Rear Planetary Sun Gear Assembly D026714E04 (b) Remove the thrust needle roller bearing and thrust bearing race from the rear planetary sun gear assembly. C134852 (c) Remove the No. 2 planetary carrier thrust washer from the rear planetary sun gear assembly. No. 2 Planetary Carrier Thrust Washer Rear Planetary Sun Gear D026393E02 64. REMOVE ONE-WAY CLUTCH ASSEMBLY (a) Remove the one-way clutch assembly and the thrust needle roller bearing from the transaxle case. One-way Clutch Assembly Thrust Needle Roller Bearing D026598E04 One-way Clutch Inner Race (b) Remove the one-way clutch inner race from the one-way clutch assembly. AX D003909E05 AX–220 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT 65. REMOVE ONE-WAY CLUTCH SLEEVE (a) Remove the one-way clutch sleeve from the transaxle case. One-way Clutch Sleeve D003589E06 66. REMOVE NO. 1 PLANETARY CARRIER THRUST WASHER (a) Remove the No. 1 planetary carrier thrust washer from the planetary gear assembly. No. 1 Planetary Carrier Thrust Washer C134853E01 67. REMOVE 2ND BRAKE DISC (a) Using a screwdriver, remove the snap ring. (b) Remove the flange, 3 discs and 3 plates from the transaxle case. Snap Ring 68. INSPECT 2ND BRAKE DISC (See page AX-228) C134854E01 69. REMOVE SECOND BRAKE PISTON ASSEMBLY (a) Using a screwdriver, remove the snap ring. Snap Ring D008058E04 (b) Remove the second brake piston assembly from the transaxle case. AX Second Brake Piston Assembly D026396E05 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–221 70. REMOVE 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY (a) Place SST on the return spring and compress it with a press. SST 09387-00060 (b) Using a screwdriver, remove the snap ring. SST D026703E01 (c) Remove the 2nd brake piston return spring subassembly. 2nd Brake Piston Return Spring Sub-assembly 71. INSPECT 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY (See page AX-234) D026704E03 72. REMOVE 2ND BRAKE PISTON (a) Hold the 2nd brake piston and apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the 2nd brake cylinder to remove the 2nd brake piston. D026705 73. REMOVE 2ND BRAKE PISTON O-RING (a) Remove the 2 O-rings from the 2nd brake piston. O-Ring O-Ring D026706E04 74. REMOVE REAR PLANETARY GEAR ASSEMBLY (a) Using a screwdriver, remove the snap ring. Snap Ring AX D003616E01 AX–222 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT (b) Remove the rear planetary gear assembly from the transaxle case. Rear Planetary Gear Assembly D026591E03 No. 2 Thrust Bearing Race Input Sun Gear No. 3 Thrust Bearing Race 75. REMOVE INPUT SUN GEAR (a) Remove the 2 thrust needle roller bearings, No. 2 thrust bearing races, No. 3 thrust bearing race, and input sun gear from the transaxle case. Thrust Needle Roller Bearing No. 2 Thrust Bearing Race C134855E01 76. REMOVE 1ST AND REVERSE BRAKE DISC (a) Remove the flange, 5 discs and 5 plates from the transaxle case. 77. INSPECT 1ST AND REVERSE BRAKE DISC (See page AX-229) C134856 78. REMOVE FRONT PLANETARY GEAR ASSEMBLY (a) Using a chisel and hammer, unstake the lock washer. NOTICE: Push down all claws of the washer. Otherwise SST cannot be fully pressed against the nut, and the nut cannot be loosened. Lock Washer D003595E03 (b) Using SST, remove the nut and washer. SST 09387-00030, 09387-00080 SST AX D003596E01 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT SST AX–223 (c) Using SST and a press, remove the front planetary gear assembly from the counter drive gear. SST 09950-60010 (09951-00450), 09950-70010 (09951-07100) D026398E01 (d) Remove the front planetary gear assembly from the brake hub. Brake Hub Front Planetary Gear Assembly D026763E02 79. REMOVE FRONT PLANETARY RING GEAR (a) Using a screwdriver, remove the snap ring and front planetary ring gear from the brake hub. Front Planetary Ring Gear Snap Ring Brake Hub D003615E04 SST D003600E01 80. REMOVE 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY (a) Place SST on the return spring, and compress the return spring with a press. SST 09387-00070 (b) Using a snap ring expander, remove the snap ring. NOTICE: • Stop the press when the spring seat is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring seat from being deformed. • Do not expand the snap ring excessively. (c) Remove the return spring. 81. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY (See page AX-229) AX AX–224 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT 1st And Reverse Brake Piston D026405E02 82. REMOVE 1ST AND REVERSE BRAKE PISTON (a) Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the transaxle case to remove the 1st and reverse brake piston. NOTICE: • Applying compressed air may cause the piston to jump-out. When removing the piston, hold it by hand using a waste cloth. • Take care not to splash ATF when applying the air. (b) Remove the 2 O-rings from the 1st and reverse brake piston. O-Ring O-Ring D026713E02 83. REMOVE COUNTER DRIVE GEAR (a) Using SST and a press, remove the counter drive gear from the transaxle case. SST 09950-60010 (09951-00590), 09950-70010 (09951-07100) SST SST C134861E01 (b) Tighten the 2 bolts evenly and make clearance of approx. 20.0 mm (0.797 in.) between the counter drive gear and the inner race. D003602E01 Turn Hold SST AX C134858E01 (c) Using SST, remove the tapered roller bearing inner race. SST 09950-00020, 09950-00030, 09950-60010 (09951-00590) U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–225 84. REMOVE COUNTER DRIVE ANGULAR BALL BEARING (a) Remove the bearing inner race (rear side) and angular ball (rear side). Inner Race Angular Ball C134859E01 (b) Using SST, remove the bearing outer race (rear side) from the transaxle case. SST 09308-00010 SST C134860E01 (c) Remove the angular ball (front side). C134925 (d) Using SST and a press, remove the bearing outer race (front side) from the transaxle case. SST 09950-60020 (09951-00810), 09950-70010 (09951-07200) SST C134862E01 (e) Using a screwdriver, remove the snap ring from the transaxle case. AX C134863 AX–226 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT SST Snap Ring D026407E01 85. REMOVE UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY (a) Place SST on the return spring, and compress the return spring with a press. SST 09387-00020 (b) Using a snap ring expander, remove the snap ring. NOTICE: • Stop the press when the spring seat is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring seat from being deformed. • Do not expand the snap ring excessively. (c) Remove the return spring. 86. INSPECT UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY (See page AX-229) Underdrive Brake Piston 87. REMOVE UNDERDRIVE BRAKE PISTON (a) Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the transaxle case to remove the underdrive brake piston. D026406E02 (b) Remove the 2 O-rings from the underdrive brake piston. O-Ring O-Ring D003794E03 Hold SST Turn D003605E03 AX 88. REMOVE NEEDLE ROLLER BEARING (a) Using SST, remove the needle roller bearing from the transaxle case. SST 09387-00041 (09387-01010, 09387-01030, 09387-01040) U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–227 89. REMOVE UNDERDRIVE CLUTCH DRUM OIL SEAL RING (a) Remove the 2 oil seal rings from the transaxle case. Underdrive Clutch Drum Oil Seal Ring D003914E05 90. REMOVE NO. 1 TRANSAXLE CASE PLUG (a) Remove the 2 No. 1 transaxle case plugs. (b) Remove the 2 O-rings from the 2 No. 1 transaxle case plugs. D026383 Hold Turn SST 91. REMOVE UNDERDRIVE CYLINDRICAL ROLLER BEARING (a) Using SST, remove the underdrive cylindrical roller bearing from the transaxle case. SST 09820-00031, 09950-40011 (09952-04010, 09954-04010, 09955-04061, 09957-04010), 09950-50013 (09951-05010, 09953-05020) C134864E01 92. REMOVE UNDERDRIVE OUTPUT SHAFT OIL SEAL RING (a) Remove the oil seal ring from the transaxle housing. Underdrive Output Shaft Oil Seal Ring D003915E08 Transaxle Apply Tube Clamp Differential Gear Lube Apply Tube 93. REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE (a) Remove the bolt, transaxle apply tube clamp and differential gear lube apply tube from the transaxle housing. AX C134866E01 AX–228 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT INSPECTION 1. INSPECT MULTIPLE DISC CLUTCH HUB (a) Using a dial indicator, measure the inside diameter of the multiple disc clutch hub bushing. Standard inside diameter: 23.025 to 23.046 mm (0.9065 to 0.9073 in.) Maximum inside diameter: 23.09 mm (0.9091 in.) If the diameter is greather than the maximum, replace the multiple disc clutch hub with a new one. NOTICE: Check the contact surface of the bushing in the direct clutch shaft. If any scratch or discolor is identified, replace the direct clutch subassembly with a new one. 2. INSPECT NO. 2 UNDERDRIVE CLUTCH DISC (a) Check if the sliding surfaces of the discs, plates and flange are worn or burnt. If necessary, replace them. NOTICE: • If the linings of the discs are peeled off or discolored, or even if a part of the groove is damaged, replace all discs. • Before assembling new discs, soak them in ATF for at least 15 minutes. 3. INSPECT OVERDRIVE DIRECT CLUTCH DRUM SUBASSEMBLY (a) Using a dial indicator, measure the inside diameter of the overdrive direct clutch drum sub-assembly bushing. Standard inside diameter: 23.025 to 23.046 mm (0.9065 to 0.9073 in.) Maximum inside diameter: 23.09 mm (0.9091 in.) If the diameter is greather than the maximum, replace the overdrive direct clutch drum subassembly. NOTICE: Check the contact surface of the bushing in the direct clutch shaft. If any scratch or discolor is identified, replace the direct clutch subassembly with a new one. 4. INSPECT 2ND BRAKE DISC (a) Check if the sliding surfaces of the discs, plates and flange are worn or burnt. If necessary, replace them. NOTICE: • If the linings of the discs are peeled off or discolored, or even if a part of the groove is damaged, replace all discs. • Before assembling new discs, soak them in ATF for at least 15 minutes. Multiple Disc Clutch Hub Dial Indicator D003829E06 D009196 Overdrive Direct Clutch Drum Sub-assembly Dial Indicator D003829E05 AX D026717 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–229 5. INSPECT 1ST AND REVERSE BRAKE DISC (a) Check if the sliding surfaces of the discs, plates and flange are worn or burnt. If necessary, replace them. NOTICE: • If the linings of the discs are peeled off or discolored, or even if a part of the groove is damaged, replace all discs. • Before assembling new discs, soak them in ATF for at least 15 minutes. 6. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY (a) Using vernier calipers, measure the free length of the spring together with the spring seat. Standard free length: 17.63 mm (0.6941 in.) If the free length is shorter than the standard free length, replace the 1st and reverse brake return spring sub-assembly. 7. INSPECT UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY (a) Using vernier calipers, measure the free length of the spring together with the spring seat. Standard free length: 13.24 mm (0.5213 in.) If the free length is shorter than the standard free length, replace the under drive brake return spring sub-assembly. 8. INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE (a) Using vernier calipers, measure the distance between the disc surface and the contact surface of the 2nd brake cylinder and transaxle case (Dimension A). (b) Select an appropriate flange so that the pack clearance will be within the specified range. Pack clearance: 0.745 to 1.21 mm (0.0293 to 0.0476 in.) HINT: Piston stroke = Dimension A - Flange thickness Flange thickness: mm (in.) D009189 C141534 C141534 A C134874E01 Mark Thickness Mark Thickness 1 1.8 (0.071) 5 2.2 (0.087) 2 1.9 (0.075) 6 2.3 (0.091) 3 2.0 (0.079) 7 2.4 (0.094) 4 2.1 (0.083) 8 2.5 (0.098) (c) Install the flange. AX AX–230 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT 9. B C134877E01 INSPECT PACK CLEARANCE OF SECOND BRAKE (a) Using vernier calipers, measure the distance between the disc surface and snap ring surface (Dimension B). (b) Select an appropriate flange so that the pack clearance will be within the specified range. Pack clearance: 0.53 to 0.91 mm (0.0209 to 0.0358 in.) HINT: Piston stroke = Dimension B - Flange thickness Snap ring thickness 1.6 mm (0.063 in.) Flange thickness: mm (in.) Mark Thickness Mark Thickness 0 2.9 (0.114) 5 3.4 (0.134) 1 3.0 (0.118) 6 3.5 (0.138) 2 3.1 (0.122) 7 3.6 (0.142) 3 3.2 (0.126) 8 3.7 (0.146) 4 3.3 (0.130) - - (c) Install the flange. D008082 10. INSPECT PACK CLEARANCE OF NO. 2 UNDERDRIVE CLUTCH (a) Using a dial indicator, measure the underdrive clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi). Pack clearance: 1.645 to 2.20 mm (0.0648 to 0.0866 in.) (b) Select an appropriate flange from the table below so that the pack clearance will be within the specified range. Flange thickness: mm (in.) Mark Thickness Mark Thickness Y 2.8 (0.110) C 3.4 (0.134) A 3.0 (0.118) D 3.6 (0.142) B 3.2 (0.126) - - (c) Temporarily remove the snap ring and attach the flange to the transaxle case. (d) Reinstall the snap ring to the transaxle case. 11. INSPECT UNDERDRIVE ONE-WAY CLUTCH ASSEMBLY (a) Install the underdrive clutch assembly to the oneway clutch. (b) Rotate the underdrive clutch assembly to check the rotating direction for the lock or free operation. (c) Remove the underdrive clutch assembly from the one-way clutch. Free Free D003925E01 AX U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–231 12. INSPECT INPUT SHAFT END PLAY (a) Using a dial indicator, measure the input shaft end play. End play: 0.262 to 1.244 mm (0.01 to 0.049 in.) D008091 13. INSPECT DIRECT MULTIPLE DISC CLUTCH DISC (a) Check if the sliding surfaces of the discs, plates, and flange are worn or burnt. If necessary, replace them. NOTICE: • If the lining of a disc comes off or discolors, or a groove is damaged, replace all discs. • Before assembling new discs, soak them in ATF for at least 15 minutes. C134886 14. INSPECT OVERDRIVE DIRECT CLUTCH DISC (a) Check if the sliding surfaces of the discs, plates, and flange are worn or burnt. If necessary, replace them. NOTICE: • If the lining of a disc comes off or discolors, or a groove is damaged, replace all discs. • Before assembling new discs, soak them in ATF for at least 15 minutes. D026719 15. INSPECT OVERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY (a) Using vernier calipers, measure the free length of the spring together with the spring seat. Standard free length: 25.91 mm (1.0201 in.) If the free length is shorter than the standard free length, replace the overdrive clutch return spring sub-assembly. Overdrive Clutch Return Spring D009211E02 AX AX–232 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT 16. INSPECT PACK CLEARANCE OF DIRECT CLUTCH (a) Install the intermediate shaft and needle roller bearing on the transaxle rear cover. NOTICE: Be careful not to damage the oil seal ring outers. (b) Using a dial indicator, measure the direct clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi). Pack clearance: 0.60 to 0.82 mm (0.02362 to 0.03228 in.) If the pack clearance is not as specified, inspect the discs, plates and flange. C134884 17. INSPECT PACK CLEARANCE OF OVERDRIVE CLUTCH (a) Using a dial indicator, measure the overdrive clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi). Pack clearance: 0.52 to 0.83 mm (0.02047 to 0.03268 in.) If the pack clearance is not as specified, inspect the discs, plates and flange. C134885 AX AX–233 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT 18. INSPECT PACK CLEARANCE OF DIRECT CLUTCH (a) Install the intermediate shaft on the transaxle rear cover. (b) Using a dial indicator, measure the direct clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi). Pack clearance: 0.60 to 0.82 mm (0.02362 to 0.03228 in.) If the pack clearance is less than the minimum, parts may have been assembled incorrectly, so check and reassemble. If the clearance is not as specified, select another flange. HINT: There are 8 different thicknesses of flanges available. Flange thickness: mm (in.) C134884 Mark Thickness Mark Thickness 0 2.9 (0.114) 4 3.3 (0.130) 1 3.0 (0.118) 5 3.4 (0.134) 2 3.1 (0.122) 6 3.5 (0.138) 3 3.2 (0.126) 7 3.6 (0.142) 19. INSPECT PACK CLEARANCE OF OVERDRIVE CLUTCH (a) Using a dial indicator, measure the overdrive clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi). Pack clearance: 0.52 to 0.83 mm (0.02047 to 0.03268 in.) If the pack clearance is less than the minimum, parts may have been assembled incorrectly, so check and reassemble. If the clearance is not as specified, select another flange. HINT: There are 7 different thicknesses of flanges available. Flange thickness: mm (in.) C134885 Mark Thickness Mark Thickness 0 2.5 (0.098) 4 2.9 (0.114) 1 2.6 (0.102) 5 3.0 (0.118) 2 2.7 (0.106) 6 3.1 (0.122) 3 2.8 (0.110) - - AX AX–234 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT (b) Check that the disc rotates when rotating the disc after inserting the rear planetary sun gear. NOTICE: Do not place the rear planetary sun gear in a vise. D026428 20. INSPECT 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY (a) Using vernier calipers, measure the free length of the spring together with the spring seat. Standard free length: 16.61 mm (0.6539 in.) If the free length is shorter than the standard free length, replace the 2nd brake piston return spring sub-assembly. 2nd Brake Piston Return Spring C089124E02 AX AX–235 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT REASSEMBLY 1. BEARING POSITION B A E D C F J G K I H C110530E01 AX AX–236 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT Mar k Front Race Diameter Inside / Outside (mm (in.)) Thrust Bearing Diameter Inside / Outside (mm (in.)) Rear Race Diameter Inside / Outside (mm (in.)) A - 53.0 (2.087) / 78.2 (3.079) 52.1 (2.051) / 75.5 (2.972) B - 37.73 (1.4854) / 58.0 (2.284) 29.9 (1.177) / 55.5 (2.185) C - 33.85 (1.3327) / 52.2 (2.055) - D - 23.5 (0.925) / 44.0 (1.732) - E - 36.3 (1.429) / 52.2 (2.055) 34.5 (1.358) / 48.5 (1.909) F 34.5 (1.358) / 56.82 (2.2370) 32.4 (1.276) / 56.62 (2.2291) - G 40.3 (1.587) / 58.0 (2.284) 38.6 (1.520) / 60.0 (2.362) 38.6 (1.520) / 58.0 (2.284) H - 53.6 (2.110) / 69.6 (2.740) - I 33.1 (1.303) / 45.4 (1.787) 31.85 (1.2539) / 45.2 (1.780) - J - 25.0 (0.984) / 39.5 (1.555) 23.6 (0.929) / 36.6 (1.441) K - 55.9 (2.201) / 76.0 (2.992) or 76.6 (3.016) - Transaxle Apply Tube Clamp Differential Gear Lube Apply Tube 2. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE (a) Install the differential gear lube apply tube and transaxle apply tube clamp to the transaxle housing with the bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) NOTICE: Make sure to insert the pipe to the stopper. 3. INSTALL NO. 1 TRANSAXLE CASE PLUG (a) Install 2 new O-rings to the 2 No. 1 transaxle case plugs. (b) Install the 2 No. 1 transaxle case plugs to the transaxle rear housing. Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf) 4. INSTALL UNDERDRIVE OUTPUT SHAFT OIL SEAL RING (a) Coat a new oil seal ring with ATF and install it to the transaxle housing. C134866E01 D026383 Underdrive Output Shaft Oil Seal Ring D003915E08 AX U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–237 5. INSTALL UNDERDRIVE CYLINDRICAL ROLLER BEARING (a) Coat the underdrive cylindrical roller bearing with ATF. (b) Using SST and a press, install the underdrive cylindrical roller bearing. SST 09950-60020, 09950-70010 (09951-00780, 09951-07100) NOTICE: Do not apply excessive pressure to it. 6. INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL RING (a) Coat 2 new oil seal rings with ATF, and install them to the transaxle rear cover. NOTICE: • Do not expand the gap of the oil seal ring excessively. • Securely engage the hooks. Confirm the smooth rotation. 7. INSTALL NEEDLE ROLLER BEARING (a) Wind vinyl tape around SST at the place 4.0 mm (0.157 in.) above the bottom end until the thickness of the wound tape is about 5.0 mm (0.197 in.). NOTICE: Clean SST to remove deposited oil before winding vinyl tape. (b) Coat a new needle roller bearing with ATF. SST D003807E01 Underdrive Clutch Drum Oil Seal Ring D003914E05 5.0 mm (0.197 in.) Vinyl Tape SST 4.0 mm (0.157 in.) D003809E08 (c) Using SST and a press, install the needle roller bearing to the transaxle case. SST 09950-60010 (09951-00320), 09950-70010 (09951-07100) NOTICE: When the wound vinyl tape contacts the transaxle case, stop press-fitting. SST D003810E01 AX AX–238 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT 8. O-Ring O-Ring INSTALL UNDERDRIVE BRAKE PISTON (a) Coat 2 new O-rings with ATF, and install them to the underdrive brake piston. NOTICE: • Install the the O-rings carefully not to have a twist or a pinching. • Apply enough ATF to the O-rings prior to installation. (b) Coat the underdrive brake piston with ATF. D003794E03 (c) Install the underdrive brake piston to the transaxle case. NOTICE: Be careful not to damage the O-rings. Underdrive Brake Piston D026764E01 9. SST Snap Ring D026407E01 INSTALL UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY (a) Place SST on the return spring and compress the return spring with a press. SST 09387-00020 (b) Using a snap ring expander, install the snap ring to the transaxle case. NOTICE: • Stop the press when the spring seat is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring seat from being deformed. • Do not expand the snap ring excessively. • After installing the spring sub-assembly, check all of the springs are fitted in the piston correctly. • The snap ring should be securely engaged in the groove of the transaxle case. 10. INSTALL COUNTER DRIVE GEAR BEARING (a) Install the snap ring to the transaxle case. C134867 AX U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT SST AX–239 (b) Using SST and a press, install the bearing outer race (rear side) to the transaxle case. SST 09316-12010, 09950-60020 (09951-00810), 09950-70010 (09951-07150) NOTICE: • Ensure that the snap ring is securely installed. • Do not apply excessive pressure to the bearing outer race. C134868E01 SST C134869E01 (c) Using SST and a press, install the bearing outer race (front side) to the transaxle case. SST 09316-12010, 09502-24010, 09523-36010, 09950-60020 (09951-00810), 09950-70010 (09951-07150) NOTICE: • Do not apply excessive pressure to the bearing outer race. • Install the bearing outer race with a press while holding the bearing outer race with SST (09502-24010, 09523-36010). (d) Install the 2 angular balls to the transaxle case. 11. INSTALL COUNTER DRIVE GEAR (a) Coat the counter drive gear with ATF. (b) Using SST and a press, install the tapered roller bearing inner race (front side) to the counter drive gear. SST 09649-17010, 09950-70010 (09951-07150) NOTICE: Do not apply excessive pressure to the bearing inner race. SST C134870E01 AX AX–240 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT Counter Drive Gear (c) Using SST and a press, install the counter drive gear and bearing inner race (rear side) to the transaxle case. SST 09223-15030, 09527-17011, 09950-60020 (09951-00720), 09950-70010 (09951-07150) NOTICE: Do not apply excessive pressure to the counter drive gear and bearing inner race. SST Bearing SST C134871E01 O-Ring O-Ring 12. INSTALL 1ST AND REVERSE BRAKE PISTON (a) Coat 2 new O-rings with ATF. (b) Install the 2 O-rings to the 1st and reverse brake piston. NOTICE: • Install the O-rings carefully not to have a twist or a pinching. • Apply enough ATF to the O-rings prior to installation. D026713E02 (c) Coat the 1st and reverse brake piston with ATF, and install it to the transaxle case. NOTICE: Be careful not to damage the O-rings. 1st And Reverse Brake Piston 13. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY (a) Install the return spring. D026593E02 SST AX D003600E01 (b) Place SST on the return spring and compress the return spring with a press. SST 09387-00070 (c) Using a snap ring expander, install the snap ring to the transaxle case. NOTICE: • Stop the press when the spring seat is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring seat from being deformed. • Do not expand the snap ring excessively. U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–241 • After installing the spring sub-assembly, check all of the springs are fitted in the piston correctly. • The snap ring should be securely engaged in the groove of the cylinder. 14. INSTALL FRONT PLANETARY RING GEAR (a) Using a screwdriver, install the front planetary ring gear and snap ring to the brake hub. NOTICE: Confirm that the snap ring is engaged in the groove of the brake hub correctly. Front Planetary Ring Gear Snap Ring Brake Hub D003615E04 15. INSTALL FRONT PLANETARY GEAR ASSEMBLY (a) Install the front planetary gear assembly to the brake hub. Brake Hub Front Planetary Gear Assembly D026763E02 SST Brake Hub with Front Planetary Gear Assembly (b) Using SST and a press, press-fit the front planetary gear assembly. SST 09950-60010 (09951-00500), 09950-70010 (09951-07100) NOTICE: • Do not apply excessive pressure to the front planetary gear assembly. • Press the inner race of the LH tapered roller bearing, counter gear, and front planetary gear assembly to the position where no preload is applied to one pair of tapered roller bearings (left and right). SST Counter Drive Gear Transaxle Case C134872E01 AX AX–242 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT (c) Install a new washer as shown in the illustration. Washer D003917E02 (d) Using SST, install the nut. SST 09387-00030, 09387-00080 Torque: 185 N*m (1,886 kgf*cm, 136 ft.*lbf) SST D003596E01 SST D003918E01 (e) Using SST and a torque wrench, measure the turning torque of the bearing while rotating SST at 60 rpm. If the measured value is not within the specified range, gradually tighten the nut until the turning torque falls within the specified range. SST 09387-00080 Torque: 350 N*m (3,569 kgf*cm, 258 ft.*lbf) (a limit) Bearing Turning Torque: 0.19 to 0.4 N*m (1.9 to 4.1 kgf*cm, 1.7 to 3.5 in.*lbf) HINT: Use a torque wrench with a fulcrum length of 160 mm (6.3 in.) to measure the turning torque. (f) C134873 AX Using a chisel and hammer, stake the front lock washer. AX–243 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT E D C B A Input Sun Gear C134855E02 16. INSTALL INPUT SUN GEAR (a) Coat the 2 thrust bearings with ATF. (b) Install the input sun gear, 2 thrust needle roller bearings, 2 No. 2 thrust bearing races, and No. 3 thrust bearings to the transaxle case. NOTICE: Ensure that the parts are installed in the correct order and direction. Thrust bearing and bearing race diameter: mm (in.) Inside Outside 34.5 (1.358) 56.82 (2.2370) Thrust Bearing, B 32.4 (1.276) 56.62 (2.2291) Bearing Race, C 40.3 (1.587) 58.0 (2.284) Bearing Race, A Thrust Bearing, D 38.6 (1.520) 60.0 (2.362) Bearing Race, E 38.6 (1.520) 58.0 (2.284) 17. INSTALL REAR PLANETARY GEAR ASSEMBLY (a) Install the rear planetary gear assembly to the brake hub. Rear Planetary Gear Assembly D026591E03 Snap Ring (b) Using a screwdriver, install the snap ring. NOTICE: Confirm that the snap ring is engaged in the groove of the 1st and reverse brake hub correctly. D003616E01 Disc Plate 18. INSTALL 1ST AND REVERSE BRAKE DISC (a) Coat the 5 discs with ATF. (b) Install the 5 plates and 5 discs. NOTICE: Be careful about the order of discs and plates. 19. INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE (See page AX-229) C134875E01 AX AX–244 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT 20. INSTALL 2ND BRAKE PISTON (a) Coat the 2nd brake piston with ATF, and install it to the 2nd brake cylinder. D026775 21. INSTALL 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY (a) Install the 2nd brake piston return spring subassembly. NOTICE: Ensure that all springs are fitted in the piston correctly. 2nd Brake Piston Return Spring Sub-assembly D026704E03 (b) Place SST on the piston return spring, and compress it with a press. SST 09387-00060 (c) Using a screwdriver, install the snap ring. NOTICE: Stop the press when the spring seat is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove. This prevents the spring seat from being deformed. SST D026703E01 22. INSTALL SECOND BRAKE PISTON ASSEMBLY (a) Install the second brake piston assembly to the transaxle case. Second Brake Piston Assembly D026396E05 Snap Ring AX D008058E04 (b) Install the snap ring and measure the inside diameter. Inside diameter: More than 167 mm (6.57 in.) NOTICE: • Make sure to install the tapered snap ring in the correct direction. • When the diameter does not meet the specified value, replace the snap ring with a new one. U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–245 • After installing the snap ring, confirm that there is no clearance between the second brake cylinder and the fitting surface of the cylinder in the transaxle case. 23. INSTALL ONE-WAY CLUTCH SLEEVE (a) Install the one-way clutch sleeve to the 2nd brake cylinder assembly. NOTICE: Check the positioning direction of the outer sleeve. One-way Clutch Sleeve C092977E02 24. INSTALL NO. 1 PLANETARY CARRIER THRUST WASHER (a) Coat the No. 1 planetary carrier thrust washer with ATF, and install it onto the planetary sun gear assembly. NOTICE: After installing the washer, confirm that the projections on the washer are securely fitted in the holes of the planetary sun gear assembly. No. 1 Planetary Carrier Thrust Washer D026394E04 One-way Clutch Inner Race 25. INSTALL ONE-WAY CLUTCH ASSEMBLY (a) Install the one-way clutch inner race to the one-way clutch. NOTICE: • Check the direction of the inner race. • Confirm that the discrimination mark can be seen. D003909E05 (b) Check the rotating direction of the one-way clutch inner race for the lock or free operation, as shown in the illustration. Free Lock C134926E01 AX AX–246 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT (c) Install the one-way clutch and thrust needle roller bearing to the one-way clutch sleeve outer. Bearing diameter: mm (in.) One-way Clutch Assembly Bearing Inside Outside 53.6 (2.110) 69.4 (2.732) NOTICE: Install the thrust bearing properly so that noncolored race will be visible. Thrust Needle Roller Bearing D026598E04 26. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY (a) Coat the No. 2 planetary carrier thrust washer with ATF, and install it onto the rear planetary sun gear. No. 2 Planetary Carrier Thrust Washer Rear Planetary Sun Gear D026393E02 B (b) Coat the bearing with yellow petrolatum, and install it onto the rear planetary sun gear. Bearing diameter: mm (in.) A Inside Outside Race, A 33.1 (1.303) 45.4 (1.787) Bearing, B 31.85 (1.254) 45.2 (1.78) D026404E06 (c) Install the rear planetary sun gear assembly to the rear planetary gear. NOTICE: After installing the rear planetary sun gear assembly, confirm that the B1 discs engage. Rear Planetary Sun Gear Assembly D026714E04 27. INSTALL 2ND BRAKE CLUTCH DISC (a) Coat the 3 discs with ATF. (b) Install the 3 discs and 3 plates to the transaxle case. (c) Install the snap ring. Disc 28. INSPECT PACK CLEARANCE OF SECOND BRAKE HINT: See page Plate AX C134876E01 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT Overdrive Direct Clutch Hub B A D026392E06 O-Ring AX–247 29. INSTALL OVERDRIVE DIRECT CLUTCH HUB SUBASSEMBLY (a) Install the direct clutch hub to the planetary gear assembly. NOTICE: Be careful not to damage the bushing inside the overdrive clutch hub during installation. (b) Coat the thrust bearing with ATF. (c) Install the bearing race and the thrust bearing to the direct clutch hub. NOTICE: When installing the bearing, hold the side of the overdrive clutch hub. Bearing and race diameter: mm (in.) Inside Outside Bearing, A 25.0 (0.984) 39.5 (1.555) Race, B 23.6 (0.929) 36.6 (1.441) 30. INSTALL OVERDRIVE DIRECT CLUTCH O-RING (a) Coat a new O-ring with ATF, and install it to the direct clutch drum. NOTICE: Ensure that the O-ring is not twisted or pinched. D026464E01 Intermediate Shaft Sub-assembly Overdrive Direct Clutch Drum Sub-assembly 31. INSTALL OVERDRIVE DIRECT CLUTCH DRUM SUBASSEMBLY (a) Coat the direct clutch drum with ATF, and install it to the intermediate shaft. NOTICE: • Be careful not to damage the O-ring. • Be careful not to damage the lip seal of the direct clutch drum. D026462E03 Overdrive Direct Clutch Piston 32. INSTALL OVERDRIVE DIRECT CLUTCH PISTON (a) Coat the overdrive direct clutch piston with ATF, and install it to the overdrive direct clutch drum subassembly. NOTICE: Be careful not to damage the lip seal of the direct clutch piston. D026461E01 AX AX–248 Direct Clutch Drum U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT Overdrive Clutch Return Spring D026423E05 Overdrive Direct Clutch Drum Sub-assembly Clutch Balancer D026424E03 SST D003677E01 33. INSTALL OVERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY (a) Install the overdrive clutch return spring subassembly to the overdrive direct clutch drum subassembly. NOTICE: When installing the spring sub-assembly, ensure that all springs are fitted in the piston correctly. (b) Coat the clutch balancer with ATF. (c) Install the clutch balancer to the overdrive direct clutch drum sub-assembly. NOTICE: • Be careful not to damage the lip seal of the direct clutch balancer. • Ensure that the clutch balancer is not pinched and there are no other defects at the sealing lip. • Apply enough ATF to the sealing lip prior to installation. (d) Place SST on the clutch balancer and compress the piston return spring with a press. SST 09387-00020 (e) Using a snap ring expander, install the snap ring to the direct clutch drum. NOTICE: • Stop the press when the spring seat is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove. This prevents the spring seat from being deformed. • Do not expand the snap ring excessively. (f) Stopper Stopper Position the end gap of the snap ring in the piston as shown in the illustration. NOTICE: Ensure that the end gap of the snap ring is not aligned with any of the stoppers. D025588E03 Flange Disc Plate AX C134928E01 34. INSTALL OVERDRIVE DIRECT CLUTCH DISC (a) Coat the 3 discs with ATF. (b) Install the 3 plates, 3 discs and flange to the intermediate shaft. NOTICE: Be careful about the order of the discs, plates and flange. U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–249 (c) Using a screwdriver, install the snap ring. NOTICE: The snap ring should be securely engaged in the groove of the drum. Snap Ring Drum D026421E02 Flange Disc Plate Cushion Plate 35. INSTALL DIRECT MULTIPLE DISC CLUTCH DISC (a) Coat the 3 discs with ATF. (b) Install the cushion plate, 3 plates, 3 discs and flange to the intermediate shaft. NOTICE: • Install the cushion plate with the mark on the white surface facing the plate. • Be careful about the order of discs, plates and flange. D026416E01 (c) Using a screwdriver, install the snap ring. NOTICE: The snap ring should be securely engaged in the groove of the drum. Snap Ring 36. INSPECT PACK CLEARANCE OF DIRECT CLUTCH (See page AX-232) 37. INSPECT PACK CLEARANCE OF OVERDRIVE CLUTCH (See page AX-232) Drum D026419E04 38. INSTALL DIRECT CLUTCH ASSEMBLY (a) Coat the thrust bearing with ATF. (b) Install the direct clutch assembly and thrust bearing to the rear planetary sun gear assembly. NOTICE: The disc in the direct clutch should completely match with the hub attached outside the rear planetary sun gear. Otherwise, the rear cover cannot be installed. Direct Clutch Assembly Thrust Bearing D026403E04 (c) Clean the contact surfaces of the transaxle case and the rear cover. (d) As shown in the illustration, place a straight edge on the direct clutch drum and measure the distance between the transaxle case and the straight edge using vernier calipers (Dimension C). C AX C134878E01 AX–250 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT D D026470E02 (e) Using vernier calipers and a simple straight edge, measure the dimension shown in the illustration. (f) Calculate the end play value using the following formula. Select a thrust bearing which satisfies the specified end play value and install it. End play: 0.199 to 0.970 mm (0.0078 to 0.0382 in.) NOTICE: Make sure that the non-colored race side is facing the direct clutch assembly. HINT: End play = Dimension D - Dimension C Bearing thickness and diameter: mm (in.) Thickness Inside Outside 3.6 (0.1417) 55.9 (2.201) 76.0 (2.992) 3.8 (0.150) 55.9 (2.201) 76.6 (3.016) 39. INSTALL NO. 1 GOVERNOR APPLY GASKET (a) Install 3 new No. 1 governor apply gaskets to the transaxle case. D026390 40. INSTALL BRAKE APPLY TUBE (a) Install the clamp to the brake apply tube. NOTICE: Make sure to install the clamp to the apply tube before installing the apply tube to the transaxle case. This prevents the apply tube from being deformed or damaged. (b) Install the clutch apply tube. D003923 (c) Install the brake apply tube to the transaxle case with the bolt. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) NOTICE: Each pipe should be securely inserted until it reaches the stopper. Brake Apply Tube Clutch Apply Tube C134851E01 AX U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT SST D026766E01 Rear Clutch Oil Seal Ring AX–251 41. INSTALL NEEDLE ROLLER BEARING (a) Using SST and a press, install the needle roller bearing to the transaxle rear cover. SST 09950-60010 (09951-00230, 09952-06010, 09951-00360) Press fit depth: 20.55 to 21.25 mm (0.8091 to 0.8366 in.) NOTICE: • Face the inscribed mark side of the bearing race up. • Keep pressing until the specified value is obtained. (b) Coat the needle roller bearing with ATF. 42. INSTALL REAR CLUTCH OIL SEAL RING OUTER (a) Coat 3 new rear clutch oil seal rings with ATF, and install them to the transaxle rear cover. NOTICE: The rear clutch oil seal rings should be securely engaged in the grooves of the drum. D026389E02 43. INSTALL NO. 1 TRANSAXLE CASE PLUG (a) Install 4 new O-rings to the 4 No. 1 transaxle case plugs. (b) Install the 4 No. 1 transaxle case plugs to the transaxle rear cover. Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf) C134849 FIPG D026454E01 44. INSTALL TRANSAXLE REAR COVER SUBASSEMBLY (a) Remove any packing material and keep the contact surfaces of the transaxle rear cover and the transaxle case away from oil. (b) Apply FIPG to the cover. FIPG: Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent NOTICE: Apply FIPG in a continuous line (width 1.2 mm (0.047 in.)) along the sealing surface. AX AX–252 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT (c) Apply liquid sealer to the threads of bolt A. Sealant: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent (d) Install the 11 bolts. Torque: Bolt A 19 N*m (190 kgf*cm, 14 ft.*lbf) Other bolts 25 N*m (250 kgf*cm, 18 ft.*lbf) A A A A A C134848E01 Flange Disc Plate 45. INSTALL NO. 2 UNDERDRIVE CLUTCH DISC (a) Coat the 3 discs with ATF. (b) Install the 3 discs, 3 plates and flange to the transaxle case. NOTICE: Be careful about the order of discs, plates and flange. C134879E01 Snap Ring (c) Using a screwdriver, install the snap ring. NOTICE: The snap ring should be securely engaged in the groove of the drum. 46. INSPECT PACK CLEARANCE OF NO. 2 UNDERDRIVE CLUTCH (See page AX-230) 47. INSPECT UNDERDRIVE ONE-WAY CLUTCH ASSEMBLY (See page AX-230) D026466E01 48. INSTALL UNDERDRIVE ONE-WAY CLUTCH ASSEMBLY (a) Install the outer race retainer to the one-way clutch. NOTICE: Securely install the outer race retainer onto the external tooth of the one-way clutch. Outer Race Retainer D003907E01 AX U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–253 (b) Install the one-way clutch to the transaxle case. NOTICE: Ensure that the outer race retainer and the mark on the transaxle case are aligned. Mark Outer Race Retainer C134880E01 (c) Using a screwdriver, install the snap ring to the transaxle case. NOTICE: The snap ring should be securely engaged in the groove of the transaxle case. Snap Ring D003581E01 49. INSTALL UNDERDRIVE CLUTCH ASSEMBLY (a) Coat the bearing and bearing race with ATF, and install them onto the underdrive clutch. Bearing and bearing race diameter: mm (in.) D003580 Inside Outside Bearing 37.73 (1.4854) 58.0 (2.284) Race 29.9 (1.177) 55.5 (2.185) (b) Install the underdrive clutch assembly to the transaxle case. NOTICE: When installing the underdrive clutch drum subassembly, do not damage the oil seal ring. AX AX–254 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT 50. INSTALL PARKING LOCK PAWL (a) Install the pawl pin and spring to the parking lock pawl. Parking Lock Pawl Spring Pawl Pin D009691E01 (b) Temporarily install the parking lock pawl, pin and spring to the transaxle case as shown in the illustration. D026386 Underdrive Planetary Gear Assembly 51. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY (a) Install the underdrive planetary gear assembly to the transaxle case. NOTICE: Firmly engage all the discs of the underdrive clutch with the hub splines of the underdrive planetary gear assembly and securely assemble them. D003579E05 (b) Install the parking lock pawl shaft. D009693 (c) Install the pawl shaft clamp with the bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) AX Pawl Shaft Clamp D003576E04 AX–255 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT (d) Using a straight edge and vernier calipers as shown in the illustration, measure the gap between the top of the differential drive pinion in the underdrive planetary gear and contact surface of the transaxle case and housing (Dimension E). NOTICE: Note down dimension E because it is necessary for the following process. E D003875E03 Dimension (1) Dimension (2) (e) As shown in the illustration, measure the 2 places of the transaxle housing, and calculate dimension F using the following formula. NOTICE: Note down dimension F because it is necessary for the following process. HINT: Dimension F = Dimension (1) - Dimension (2) D025511E03 52. INSTALL MULTIPLE DISC CLUTCH HUB (a) Install the No. 1 thrust bearing race to the transaxle case while checking its direction. Bearing race diameter: mm (in.) No. 1 Thrust Bearing Race Bearing Race Inside Outside 34.5 (1.359) 48.5 (1.909) D008087E04 Thrust Needle Roller Bearing Multiple Disc Clutch Hub (b) Coat the thrust needle roller bearing and race with ATF, and install them onto the multiple disc clutch hub. Thrust bearing and race diameter: mm (in.) Thrust Bearing Inside Outside 36.4 (1.433) 52.2 (2.055) (c) Coat the needle roller bearing with ATF. D026710E03 Thrust Needle Roller Bearing Multiple Disc Clutch Hub (d) Install the needle roller bearing to the multiple disc clutch hub. Bearing diameter: mm (in.) Bearing Inside Outside 23.5 (0.925) 44.0 (1.732) (e) Install the multiple disc clutch hub to the transaxle case. D026711E03 AX AX–256 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT Thrust Needle Roller Bearing 53. INSTALL FORWARD CLUTCH ASSEMBLY (a) Coat the thrust needle roller bearing with ATF. (b) Install the thrust needle roller bearing to the forward clutch. Thrust bearing diameter: mm (in.) Thrust Bearing D003820E01 Forward Clutch Assembly Inside Outside 33.85 (1.3327) 52.2 (2.0551) NOTICE: Install the thrust bearing properly so that the temper colored side of the race will be visible. (c) Install the forward clutch to the forward clutch assembly. NOTICE: • Align the splines of all discs in the forward clutch with those of the multiple clutch hub to assemble them securely. • Be careful not to damage the bush inside the forward clutch hub during installation. D003574E04 54. INSTALL OVERDRIVE BRAKE GASKET (a) Install 2 new overdrive brake gaskets. D003573 Differential Gear Assembly 55. INSTALL DIFFERENTIAL GEAR ASSEMBLY (a) Install the differential gear assembly to the transaxle case. D026450E07 Differential Gear Assembly No. 2 Thrust Bearing Underdrive Race Forward Clutch Assembly AX Underdrive Planetary Gear Assembly D025506E05 56. INSTALL NO. 2 THRUST BEARING UNDERDRIVE RACE (a) Install the No. 2 thrust bearing underdrive race to the underdrive planetary gear assembly. AX–257 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT Differential Gear Assembly Thrust Needle Roller Bearing Forward Clutch Assembly D025505E04 57. INSTALL THRUST NEEDLE ROLLER BEARING (a) Coat the thrust needle roller bearing with ATF. (b) Calculate the end play value using the following formula and values of Dimensions E and F that ware measured when installing the cylindrical roller bearing and underdrive planetary gear. Select an appropriate underdrive planetary gear thrust bearing race No. 2 which satisfies the specified end play value, and install it. End play: 0.198 to 0.693 mm (0.00779 to 0.02728 in.) HINT: End play = Dimension F - Dimension E - Thrust bearing thickness 2.5 mm (0.0984 in.) - Underdrive thrust bearing race No. 2 thickness. Race thickness: mm (in.) F-E Thickness Less than 7.339 (0.28894) 3.5 (0.138) 7.339 (0.28894) or more 3.8 (0.150) Bearing and bearing race diameter: mm (in.) Inside Outside Bearing 53.0 (2.087) 78.2 (3.079) Bearing race 52.1 (2.051) 75.5 (2.972) 58. INSTALL OIL PUMP ASSEMBLY (a) Install the oil pump to the transaxle case with the 7 bolts. Torque: 22 N*m (225 kgf*cm, 16 ft.*lbf) D003569E03 O-Ring (b) Coat the O-ring of the oil pump with ATF. NOTICE: Confirm the input shaft rotates smoothly with the manual operation after installing the oil pump. D003629E04 AX AX–258 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT 59. INSTALL TRANSAXLE HOUSING (a) Remove any parking material and keep the contact surfaces of the transaxle case and transaxle housing away from oil. (b) Apply FIPG to the transaxle case. FIPG: Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent FIPG Seal Width 1.2 mm (0.047 in.) D003630E09 B C B A C C A C115282E02 (c) Install the transaxle housing to the transaxle case with the 16 bolts. Torque: Bolt A 22 N*m (225 kgf*cm, 16 ft.*lbf) Bolt B 29 N*m (296 kgf*cm, 21 ft.*lbf) Bolt C 29 N*m (296 kgf*cm, 21 ft.*lbf) HINT: Apply seal packing or equivalent to bolts A and C. Seal packing: Toyota Genuine Seal Packing 1344, Three Bond 1344 or Equivalent Bolt length Bolt A: 50 mm (1.969 in.) Bolt B: 50 mm (1.969 in.) Bolt C: 42 mm (1.654 in.) NOTICE: Apply seal packing to new bolts and tighten them within 10 minutes of application. 60. INSPECT INPUT SHAFT END PLAY (See page AX231) 61. FIX AUTOMATIC TRANSAXLE ASSEMBLY (a) Fix the transaxle assembly. D003631 AX U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–259 62. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL (a) Coat a new oil seal with MP grease. (b) Using SST, install the oil seal to the transaxle case. SST 09950-60010 (09951-00230), 09950-70010 (09951-07100) Oil seal drive in depth: -0.5 to 0.5 mm (-0.0197 to 0.0197 in. ) SST D026468E01 63. INSTALL PARKING LOCK ROD SUB-ASSEMBLY (a) Install the parking lock rod to the manual valve lever. HINT: Align the dial with the notches on the manual valve lever and turn the dial 90° to install the parking lock rod. C134844E01 64. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY (a) Install a new spacer and the manual valve lever shaft to the transaxle case. NOTICE: Do not damage the oil seal while installing the shaft to the transaxle case. C134881 (b) Using a pin punch and hammer, drive in a new pin. C134843 Pin Pin Punch (c) Turn the spacer and the lever shaft to align the smaller hole of the spacer with the staking position mark on the lever shaft. (d) Using a pin punch, stake the spacer through the small hole. (e) Check that the spacer does not turn. AX D026765E02 AX–260 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT 65. INSTALL MANUAL VALVE LEVER SHAFT RETAINER SPRING (a) Using needle-nose pliers, install the retainer spring. NOTICE: Hang the spring on the shaft securely. D003559 66. INSTALL PARKING LOCK PAWL BRACKET (a) Install the parking lock pawl bracket with the 2 bolts. Torque: 20 N*m (205 kgf*cm, 15 ft.*lbf) Bolt length: 25 mm (0.98 in.) NOTICE: Be sure the parking rod is placed between the parking pawl and the guide of the parking bracket after the parking bracket is installed. D003561E01 B A D003560E04 B-3 Accumulator Piston O-Ring D003904E06 AX 67. INSTALL MANUAL DETENT SPRING SUBASSEMBLY (a) Install the manual detent spring sub-assembly with the 2 bolts. NOTICE: Make sure to install the manual detent spring and cover in this order. HINT: Tighten the bolts in the order of A and B. Torque: Bolt A 20 N*m (205 kgf*cm, 15 ft.*lbf) Bolt B 12 N*m (120 kgf*cm, 9 ft.*lbf) Bolt length: Bolt A: 27 mm (1.06 in.) Bolt B: 16 mm (0.63 in.) 68. INSTALL B-3 ACCUMULATOR PISTON (a) Coat a new O-ring with ATF, and install it to the B-3 accumulator piston. NOTICE: Install the O-ring to the accumulator piston not to have a twist or a pinching. Apply enough ATF to the O-ring prior to installation. Be sure about the installation position. U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–261 (b) Coat the piston and springs with ATF, and install them to the transaxle case. NOTICE: Install the correct springs to the B-3 accumulator piston by checking the color or dimension of the springs. Accumulator spring: ATF D025512E01 Free length / Outer diameter (mm (in.)) Color Inner: 62.00 (2.4409) / 15.50 (0.610) Purple Outer: 74.23 (2.9224) / 21.70 (0.854) Purple 69. INSTALL REVERSE CLUTCH ACCUMULATOR PISTON (a) Coat 2 new O-rings with ATF, and install them to the reverse clutch accumulator piston. NOTICE: Install the O-rings to the accumulator piston not to have a twist or a pinching. Apply enough ATF to the O-rings prior to installation. Be sure about the installation positions. Reverse Clutch Accumulator Piston O-Ring O-Ring D026402E06 (b) Coat the piston and spring with ATF, and install them to the transaxle case. NOTICE: Install the correct spring to the reverse clutch accumulator piston by checking the color or dimension of the spring. Accumulator spring: Free length / Outer diameter (mm (in.)) Color 60.96 (2.3999) / 14.10 (0.555) Yellow C092978 O-Ring C-3 Accumulator Piston 70. INSTALL C-3 ACCUMULATOR PISTON (a) Coat a new O-ring with ATF, and install it to the C-3 accumulator piston. NOTICE: Install the O-ring to the accumulator piston not to have a twist or a pinching. Apply enough ATF to the O-ring prior to installation. Be sure about the installation position. C134841E01 (b) Coat the piston with ATF, and install it to the transaxle case. AX C083146 AX–262 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT (c) Install the spring to the C-3 accumulator piston. NOTICE: Install the correct spring to the C-3 accumulator piston by checking the color or dimension of the spring. Accumulator spring: Free length / Outer diameter (mm (in.)) Color 72.20 (2.8425) / 19.0 (0.748) Colorless D003555 Check Ball 71. INSTALL CHECK BALL BODY (a) Coat the check ball body with ATF. (b) Install the check ball body and spring. NOTICE: Regarding the installation of the spring for the check ball body, be sure to place the spring in the hole in the ball body. Be careful about the orientation of the parts. D003554E01 72. INSTALL BRAKE DRUM GASKET (a) Coat a new brake drum gasket with ATF, and install it to the transaxle case. NOTICE: Do not damage the lip portion of the brake drum gasket when inserting the gasket to the case. Apply enough ATF to the gasket prior to installation. Be careful about the orientation of the parts. C083129 73. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET (a) Coat a new transaxle case 2nd brake gasket with ATF, and install it to the transaxle case. NOTICE: Do not damage the lip portion of the transaxle case 2nd brake gasket when inserting the gasket to the case. Apply enough ATF to the gasket prior to installation. Be careful about the orientation of the parts. C083128 74. INSTALL NO. 1 GOVERNOR APPLY GASKET (a) Coat a new No. 1 governor apply gasket with ATF, and install it to the transaxle case. NOTICE: Do not damage the lip portion of the No. 1 governor apply gasket when inserting the gasket to the case. Apply enough ATF to the gasket prior to installation. Be careful about the orientation of the parts. AX C083127 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT A B (1) B B A (1) C C C C091933E05 AX–263 75. INSTALL TRANSMISSION VALVE BODY ASSEMBLY (a) Check the manual valve lever position. Install the valve body to the transaxle case with the 17 bolts. Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf) Bolt length: Bolt A: 25 mm (0.984 in.) Bolt B: 57 mm (2.244 in.) Bolt C: 41 mm (1.614 in.) NOTICE: • Push the valve body against the accumulator piston spring and the check ball body to install it. • When installing the valve body to the transaxle case, do not hold the solenoids. • Temporarily tighten the bolts marked by (1) in the illustration first because they are positioning bolts. 76. INSTALL VALVE BODY OIL STRAINER ASSEMBLY (a) Coat a new O-ring with ATF, and install it to the oil strainer. NOTICE: Install the O-ring carefully not to have a twist or a pinching. Apply enough ATF to the O-ring prior to installation. O-Ring C091932E02 (b) Install the oil strainer to the valve body with the 3 bolts. Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf) NOTICE: Apply ATF to the bolts prior to installation. C134839 77. INSTALL TRANSMISSION WIRE (a) Coat a new O-ring with ATF, and install it to the transmission wire. NOTICE: Install the O-ring not to have a twist or pinching. Apply enough ATF to the O-ring prior to installation. O-Ring D003636E06 AX AX–264 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT (b) Install the transmission wire retaining bolt. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) Transmission Wire D003547E05 G F E D C B A C091927E06 Magnet 78. CONNECT TRANSMISSION WIRE (a) Coat an O-ring of the ATF temperature sensor with ATF. (b) Install the ATF temperature sensor with the lock plate and bolt. Torque: 6.6 N*m (67 kgf*cm, 58 in.*lbf) (c) Connect the 7 solenoid connectors. NOTICE: • Connect the connectors to A, B, C, D, E, F and G, starting with the shorter ones. • Apply ATF to the bolt prior to installation. 79. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUBASSEMBLY (a) Install the 2 magnets in the oil pan. (b) Apply seal packing or equivalent to the 18 bolts. Seal packing: Toyota Genuine Seal Packing 1344, Three Bond 1344 or Equivalent C134837E01 C091925 AX (c) Install a new oil pan gasket and the oil pan to the transaxle case with the 18 bolts. Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) NOTICE: • Apply seal packing to new bolts and tighten them within 10 minutes of application. • Remove any oil or grease from the contact surface of the transaxle case and the oil pan with the gasket completely before installing the oil pan to the case. (d) Install a new gasket to the drain plug. (e) Install the drain plug. Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–265 80. INSTALL NO. 1 TRANSAXLE CASE PLUG (a) Coat 4 new O-rings with ATF, and install them to the 4 No. 1 transaxle case plugs. (b) Install the 4 No. 1 transaxle case plugs to the transaxle case. Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf) D026716 81. INSTALL SPEED SENSOR (a) Apply liquid sealer to the "A" bolt threads. Sealant: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent (b) Install the 2 sensors to the transaxle case with the 2 bolts. Torque: 8.8 N*m (90 kgf*cm, 78 in.*lbf) Speed Sensor D030672E04 82. INSTALL OIL COOLER TUBE UNION (OUTLET OIL COOLER UNION) (a) Coat a new O-ring with ATF, and install it to the union. (b) Install the union to the transaxle case. Torque: 27 N*m (276 kgf*cm, 20 ft.*lbf) Union O-Ring C083144E04 83. INSTALL OIL COOLER TUBE UNION (INLET OIL COOLER UNION) (a) Coat a new O-ring with ATF, and install it to the union. (b) Install the union to the transaxle case. Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) Union O-Ring 84. INSTALL NO. 2 BREATHER PLUG (a) Coat a new O-ring with ATF. C083143E03 No. 2 Breather Plug (b) Install the hose and a new O-ring to the breather plug. (c) Install the No. 2 breather plug hose to the transaxle case. AX O-Ring C134834E01 AX–266 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT 85. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Install the park/neutral position switch onto the manual valve lever shaft and temporarily install the 2 adjusting bolts. (b) Install a new nut stopper and nut. Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf) C135710 (c) Temporarily install the control shaft lever. C135709 (d) Turn the lever counterclockwise until it stops, and then turn it clockwise 2 notches. (e) Remove the control shaft lever. C135711 (f) Align the groove with the neutral basic line. (g) Hold the switch in position and tighten the 2 bolts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) Groove Neutral Basic Line C099456E01 (h) Using a screwdriver, stake the nut with the nut stopper. AX C135708 U250E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT (i) AX–267 Install the control shaft lever, washer and nut. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) C135707 AX AX–268 U250E AUTOMATIC TRANSAXLE – OIL PUMP OIL PUMP U250E AUTOMATIC TRANSAXLE TRANSMISSION COMPONENTS FRONT OIL PUMP DRIVEN GEAR FRONT OIL PUMP BODY O-RING 9.8 (100, 87 in.*lbf) x11 CLUTCH DRUM OIL SEAL RING STATOR SHAFT ASSEMBLY FRONT OIL PUMP DRIVE GEAR FRONT OIL PUMP AND GEAR BODY SUB-ASSEMBLY FRONT OIL PUMP OIL SEAL Non-reusable part Apply MP grease Apply ATF WS C132389E01 AX U250E AUTOMATIC TRANSAXLE – OIL PUMP AX–269 REMOVAL 1. REMOVE OIL PUMP ASSEMBLY (See page AX-211) AX AX–270 U250E AUTOMATIC TRANSAXLE – OIL PUMP DISASSEMBLY 1. INSPECT OIL PUMP ASSEMBLY (See page AX-270) 2. REMOVE CLUTCH DRUM OIL SEAL RING (a) Remove the 2 clutch drum oil seal rings. 3. REMOVE STATOR SHAFT ASSEMBLY (a) Using a torx socket (T30), remove the 11 bolts and stator shaft. (b) Keep the gears in assembling order. 4. INSPECT CLEARANCE OF OIL PUMP ASSEMBLY (See page AX-270) 5. REMOVE FRONT OIL PUMP DRIVE GEAR (a) Remove the front oil pump drive gear. 6. REMOVE FRONT OIL PUMP DRIVEN GEAR (a) Remove the front oil pump driven gear. Clutch Drum Oil Seal Ring D003650E01 D003651E01 D009206E02 D009206E01 AX U250E AUTOMATIC TRANSAXLE – OIL PUMP AX–271 7. REMOVE FRONT OIL PUMP BODY O-RING (a) Using a screwdriver, remove the O-ring. HINT: Tape the screwdriver tip before use. 8. REMOVE FRONT OIL PUMP OIL SEAL (a) Mount the oil pump in a soft jaw vise. (b) Using SST, remove the oil seal from the oil pump body. SST 09308-00010 O-Ring D025586E03 SST D003647E01 INSPECTION 1. INSPECT OIL PUMP ASSEMBLY (a) Turn the drive gear with 2 screwdrivers and make sure that it rotates smoothly. NOTICE: Be careful not to damage the oil seal lip. 2. INSPECT CLEARANCE OF OIL PUMP ASSEMBLY (a) Push the driven gear to one side of the body. (b) Using a feeler gauge, measure the clearance. Standard body clearance: 0.10 to 0.17 mm (0.0039 to 0.0067 in.) Side clearance: 0.02 to 0.05 mm (0.001 to 0.002 in.) Maximum body clearance: 0.17 mm (0.0067 in.) If the body clearance is greater than the maximum, replace the oil pump body sub-assembly. C134883 Oil Pump Drive Gear Oil Pump Driven Gear D009207E01 (c) Using a feeler gauge, measure the tip clearance between the driven gear teeth and drive gear teeth. Standard tip clearance: 0.07 to 0.15 mm (0.0028 to 0.0059 in.) Maximum tip clearance: 0.15 mm (0.0059 in.) If the tip clearance is greater than the maximum, replace the oil pump body sub-assembly. D009208 AX AX–272 U250E AUTOMATIC TRANSAXLE – OIL PUMP (d) Using a straight edge and feeler gauge, measure the side clearance of both gears. Standard side clearance: 0.02 to 0.05 mm (0.0008 to 0.0020 in.) Maximum side clearance: 0.05 mm (0.0020 in.) Drive gear thickness: mm (in.) D009209 Mark Thickness A 11.690 to 11.699 (0.4602 to 0.4606) B 11.700 to 11.709 (0.4606 to 0.4610) C 11.710 to 11.720 (0.4610 to 0.4614) D 11.721 to 11.730 (0.4615 to 0.4618) E 11.731 to 11.740 (0.4619 to 0.4622) Driven gear thickness: mm (in.) Mark Thickness A 11.690 to 11.699 (0.4602 to 0.4606) B 11.700 to 11.709 (0.4606 to 0.4610) C 11.710 to 11.720 (0.4610 to 0.4614) D 11.721 to 11.730 (0.4615 to 0.4618) E 11.731 to 11.740 (0.4619 to 0.4622) 3. INSPECT FRONT OIL PUMP AND GEAR BODY SUBASSEMBLY (a) Using a dial indicator, measure the inside diameter of the oil pump body bushing. Standard inside diameter: 38.113 to 38.138 mm (1.50051 to 1.50149 in.) Maximum inside diameter: 38.188 mm (1.50346 in.) If the inside diameter is greater than the maximum, replace the oil pump body sub-assembly. 4. INSPECT STATOR SHAFT ASSEMBLY (a) Using a dial indicator, measure the inside diameter of the stator shaft. Standard inside diameter: 21.500 to 21.526 mm (0.84646 to 0.84748 in.) Maximum inside diameter: 21.57 mm (0.8492 in.) If the inside diameter is greater than the maximum, replace the stator shaft. D003648 D003653 REASSEMBLY 1. SST AX D003654E01 INSTALL FRONT OIL PUMP OIL SEAL (a) Using SST and a hammer, install a new oil seal to the oil pump body. SST 09350-32014 (09351-32140) HINT: The seal end should be flush with the outer edge of the oil pump. (b) Coat the lip of the oil seal with MP grease. U250E AUTOMATIC TRANSAXLE – OIL PUMP AX–273 2. INSTALL FRONT OIL PUMP BODY O-RING (a) Coat a new O-ring with ATF, and install it to the oil pump body. NOTICE: • Install the O-ring carefully not to have a twist or a pinching. • Apply enough ATF to the O-ring prior to installation. 3. INSTALL FRONT OIL PUMP DRIVEN GEAR (a) Coat the front oil pump driven gear with ATF, and install it to the oil pump body with the marked side up. 4. INSTALL FRONT OIL PUMP DRIVE GEAR (a) Coat the front oil pump drive gear with ATF, and install it to the oil pump body with the marked side up. 5. INSTALL STATOR SHAFT ASSEMBLY (a) Align the bolt holes in the stator shaft assembly with those in the front oil pump and gear body subassembly. (b) Using a torx socket (T30), install the 11 bolts. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 6. INSTALL CLUTCH DRUM OIL SEAL RING (a) Coat 2 new clutch drum oil seal rings with ATF. (b) Install the 2 clutch drum oil seal rings. NOTICE: Do not expand the ring ends excessively. O-Ring C055817E04 Oil Pump Driven Gear Mark D009206E14 Oil Pump Drive Gear Mark D009206E15 D003651E01 Clutch Drum Oil Seal Ring AX D026627E01 AX–274 U250E AUTOMATIC TRANSAXLE – OIL PUMP INSTALLATION 1. AX INSTALL OIL PUMP ASSEMBLY (See page AX-257) AX–273 U250E AUTOMATIC TRANSAXLE – FORWARD CLUTCH FORWARD CLUTCH U250E AUTOMATIC TRANSAXLE TRANSMISSION COMPONENTS FORWARD CLUTCH PISTON RETURN SPRING SHAFT SNAP RING FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY FORWARD CLUTCH PISTON SUB-ASSEMBLY NO. 1 CLUTCH BALANCER INPUT SHAFT OIL SEAL RING INPUT SHAFT SUB-ASSEMBLY FORWARD CLUTCH FLANGE FORWARD CLUTCH PLATE FORWARD CLUTCH FLANGE HOLE SNAP RING FORWARD MULTIPLE DISC CLUTCH DISC Non-reusable part Apply ATF WS C132390E01 AX AX–274 U250E AUTOMATIC TRANSAXLE – FORWARD CLUTCH DISASSEMBLY 1. INSPECT PACK CLEARANCE OF FORWARD CLUTCH (See page AX-275) 2. REMOVE FORWARD MULTIPLE DISC CLUTCH DISC (a) Using a screwdriver, remove the snap ring. Snap Ring D026753E01 (b) Remove the flange, 5 discs and 5 plates from the input shaft assembly. D026754 3. SST Snap Ring D026418E01 REMOVE FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY (a) Place SST on the spring retainer and compress the return spring with a press. SST 09387-00020 (b) Using a snap ring expander, remove the snap ring. NOTICE: • Stop the press when the spring seat is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove. This prevents the spring seat from bearing deformed. • Do not expand the snap ring excessively. (c) Remove the clutch balancer from the input shaft. Clutch Balancer Input Shaft D026709E03 AX U250E AUTOMATIC TRANSAXLE – FORWARD CLUTCH AX–275 (d) Remove the forward clutch return spring from the input shaft. Forward Clutch Return Spring Input Shaft D026708E02 4. REMOVE FORWARD CLUTCH PISTON SUBASSEMBLY (a) Place the forward clutch drum onto the oil pump. (b) Holding the forward clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil pump to remove the forward clutch piston. HINT: When the piston cannot be removed as it is slanted, either blow the air again with the protruding side pushed, or remove the piston using needle nose pliers with the tips taped. 5. REMOVE INPUT SHAFT OIL SEAL RING (a) Remove the input shaft oil seal ring from the input shaft. D003664 C056374 INSPECTION 1. D026715 INSPECT PACK CLEARANCE OF FORWARD CLUTCH (a) Install the forward clutch on the oil pump. NOTICE: Be careful not to damage the oil seal ring of the oil pump. (b) Using a dial indicator, measure the forward clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi). Pack clearance: 1.00 to 1.25 mm (0.0394 to 0.04921 in.) If the clearance is not within the standard, inspect the discs, plates and flange. If the piston stroke is less than the minimum, parts may have been assembled incorrectly. Check and reassemble again. HINT: • As the opening is large, cover it with a piece of cloth or shop rag to prevent the compressed air from being released. AX AX–276 U250E AUTOMATIC TRANSAXLE – FORWARD CLUTCH • There are 5 different thicknesses of flanges available. Flange thickness: mm (in.) No. Thickness No. Thickness 1 3.00 (0.1181) 4 3.45 (0.1358) 2 3.15 (0.1240) 5 3.60 (0.1417) 3 3.30 (0.1299) - - 2. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC (a) Check if the sliding surfaces of the discs, plates, and flange are worn or burnt. If necessary, replace them. HINT: • If the lining of a disc comes off or discolors, or even if a part of the groove is damaged, replace all discs. • Before assembling new discs, soak them in ATF for at least 15 minutes. 3. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY (a) Using vernier calipers, measure the free length of the spring together with the spring seat. Standard free length: 26.74 mm (1.0528 in.) If the free length is shorter than the standard free length, replace the forward clutch return spring subassembly. 4. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC (a) Check if the disc lightly rotates when rotating the forward clutch assembly after inserting the multiple disc clutch into it. NOTICE: Do not place the forward clutch assembly in a vise. D009189 Forward Clutch Return Spring D009211E01 D003672 REASSEMBLY A 1. D025587E01 AX INSTALL INPUT SHAFT OIL SEAL RING (a) Compress a new input shaft oil seal ring from both sides to adjust dimension A. Dimension A: 5 mm (0.197 in.) (b) Coat the oil seal ring with ATF and install it to the input shaft. NOTICE: Do not expand the gap of the oil seal ring too much. Securely engage the hooks. U250E AUTOMATIC TRANSAXLE – FORWARD CLUTCH AX–277 2. INSTALL FORWARD CLUTCH PISTON SUBASSEMBLY (a) Coat the forward clutch piston with ATF, and install it to the input shaft. NOTICE: Be careful not to damage the lip seal of the forward clutch piston. 3. INSTALL FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY (a) Install the return spring to the input shaft. NOTICE: After installing the spring sub-assembly, check all of the springs are fitted in the piston correctly. (b) Coat the clutch balancer with ATF. Forward Clutch Piston D026707E01 Forward Clutch Return Spring Input Shaft D026708E02 (c) Install the clutch balancer to the input shaft. NOTICE: • Be careful not to damage the lip seal of the forward clutch balancer. • Install the clutch balancer carefully not to have a pinching or any other defects at the sealing lip. • Apply enough ATF to the sealing lip prior to installation. Clutch Balancer Input Shaft D026709E03 (d) Place SST on the clutch balancer, and compress the clutch balancer with a press. SST 09387-00020 (e) Install the snap ring with a snap ring expander. NOTICE: • Stop the press when the spring seat is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove. This prevents the spring seat from being deformed. • Do not expand the snap ring excessively. SST Snap Ring D026418E01 (f) Stopper Stopper 4. Position the end gap of the snap ring in the piston as shown in the illustration. NOTICE: The end gap of the snap ring should not be aligned with any of the stoppers. INSTALL FORWARD MULTIPLE DISC CLUTCH DISC (a) Coat the 5 discs with ATF. AX D026788E02 AX–278 U250E AUTOMATIC TRANSAXLE – FORWARD CLUTCH (b) Install the 5 plates, 5 discs, and flange to the input shaft. NOTICE: Be careful about the order of discs, plates, and flange. Flange Disc Plate D026415E01 (c) Using a screwdriver, install the snap ring. (d) Check that the end gap of the snap ring is not aligned with one of the cutouts. NOTICE: The snap ring should be securely engaged in the groove of the drum. Snap Ring D026753E01 AX 5. INSPECT PACK CLEARANCE OF FORWARD CLUTCH (See page AX-275) 6. INSPECT FORWARD MULTIPLE CLUTCH DISC (See page AX-276) U250E AUTOMATIC TRANSAXLE – UNDERDRIVE PLANETARY GEAR AX–279 UNDERDRIVE PLANETARY GEAR U250E AUTOMATIC TRANSAXLE TRANSMISSION COMPONENTS DIFFERENTIAL DRIVE PINION CYLINDRICAL ROLLER BEARING RACE INNER PARKING LOCK GEAR 280 (2,855, 207) FRONT PLANETARY GEAR NUT UNDERDRIVE ANGULAR BALL BEARING (REAR SIDE) UNDERDRIVE ANGULAR BALL BEARING OUTER RACE UNDERDRIVE ANGULAR BALL BEARING (FRONT SIDE) COUNTER DRIVE GEAR HOLE SNAP RING UNDERDRIVE ANGULAR BALL BEARING INNER RACE (FRONT SIDE) COUNTER DRIVEN GEAR UNDERDRIVE ANGULAR BALL BEARING INNER RACE (REAR SIDE) UNDERDRIVE PLANETARY RING GEAR UNDERDRIVE PLANETARY GEAR ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque UNDERDRIVE PLANETARY RING HOLE SNAP RING Non-reusable part C132391E01 AX AX–280 U250E AUTOMATIC TRANSAXLE – UNDERDRIVE PLANETARY GEAR DISASSEMBLY 1. SST REMOVE FRONT PLANETARY GEAR NUT (a) Using SST and a hammer, loosen the staked part of the lock nut. SST 09930-00010 (09931-00010, 09931-00020), 09387-00050, 09495-65040 D003686E01 (b) Clamp the underdrive planetary gear in a soft jaw vise. NOTICE: Be careful not to damage the differential drive pinion. Underdrive Planetary Gear C134896E01 (c) Using a socket wrench, remove the lock nut. Underdrive Planetary Gear C134897E01 2. REMOVE CYLINDRICAL ROLLER BEARING RACE INNER (a) Using SST, remove the cylindrical roller bearing race inner. SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00320) 3. REMOVE UNDERDRIVE PLANETARY GEAR ASSEMBLY (a) Using SST and a press, remove the differential drive pinion, parking lock gear, counter driven gear with underdrive planetary ring gear, and angular ball bearing. SST 09387-00050, 09495-65040, 09950-60010 (09951-00320), 09950-70010 (09951-07100) Turn Hold SST D003689E01 SST AX C134898E01 U250E AUTOMATIC TRANSAXLE – UNDERDRIVE PLANETARY GEAR (b) Clamp the underdrive planetary gear in a soft jaw vise. (c) Using SST, remove the rear angular ball bearing from the underdrive planetary gear. SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00320) Turn Hold SST AX–281 SST C134899E01 4. REMOVE UNDERDRIVE PLANETARY RING GEAR (a) Using snap ring pliers, remove the snap ring. Snap Ring C134900E01 (b) Remove the underdrive planetary ring gear from the counter driven gear. Underdrive Planetary Ring Gear Counter Driven Gear C137499E01 INSPECTION Underdrive Planetary Gear 1. SST INSPECT UNDERDRIVE PLANETARY GEAR PRELOAD (a) Using SST, fix the underdrive planetary gear assembly. SST 09387-00050, 09495-65040 C134894E01 AX AX–282 U250E AUTOMATIC TRANSAXLE – UNDERDRIVE PLANETARY GEAR (b) Using SST and a torque wrench, measure the turning torque of the underdrive planetary gear assembly while turning the torque wrench at 60 rpm. SST 09387-00050, 09495-65040 Turning torque at 60 rpm: 0.28 to 0.89 N*m (2.9 to 9.1 kgf*cm, 2.478 to 7.877 in.*lbf) HINT: Use a torque wrench with a fulcrum length of 160 mm (6.3 in.). SST C134895E01 REASSEMBLY 1. INSTALL UNDERDRIVE PLANETARY RING GEAR (a) Install a new snap ring to the outer race of the tapered roller bearing. HINT: If replacing the bearing, also replace the counter driven gear with a new one. Snap Ring D008112E01 (b) Using a piston ring compressor, squeeze the snap ring. D008113 SST SST C134902E01 AX (c) Using SST and a press, press in the outer race of the angular ball bearing. SST 09950-60020 (09951-00890), 09950-70010 (09951-07100) NOTICE: Do not damage the snap ring during installation of the outer race. U250E AUTOMATIC TRANSAXLE – UNDERDRIVE PLANETARY GEAR AX–283 (d) Install the underdrive planetary ring gear to the counter driven gear. Underdrive Planetary Ring Gear Counter Driven Gear C137499E01 (e) Using snap ring pliers, install the snap ring. Snap Ring C134900E01 2. SST INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY (a) Using a press, press the angular ball bearing inner race (rear side) into the underdrive planetary gear. SST 09950-60010 (09951-00260), 09950-70010 (09951-07100), 09726-40010 C134903E01 (b) Install the counter driven gear with planetary ring gear to the underdrive planetary gear. C134904 AX AX–284 U250E AUTOMATIC TRANSAXLE – UNDERDRIVE PLANETARY GEAR (c) Using SST and a press, press in the angular ball bearing inner race (front side). SST 09950-60010 (09951-00260), 09950-70010 (09951-07100), 09726-40010 NOTICE: Press the counter driven gear while rotating it. SST C134905E01 (d) Using a press, press in the parking lock gear. SST 09950-60010 (09951-00260), 09950-70010 (09951-07100), 09316-20011 NOTICE: Press the counter driven gear while rotating it. SST C134906E01 Differential Drive Pinion 3. INSTALL DIFFERENTIAL DRIVE PINION (a) Using a press, press in the differential drive pinion. SST 09726-40010, 09950-60010 (09951-00260), 09950-70010 (09951-07100) NOTICE: Press the counter driven gear while rotating it. 4. INSTALL CYLINDRICAL ROLLER BEARING RACE INNER (a) Using a press, press in the cylindrical roller bearing race inner. SST 09515-21010, 09950-60010 (09951-00260), 09950-70010 (09951-07100) NOTICE: Press the counter driven gear while rotating it. 5. INSTALL FRONT PLANETARY GEAR NUT (a) Clamp the underdrive planetary gear in a soft jaw vise. NOTICE: Be careful not to damage the differential drive pinion. (b) Using a socket wrench, install a new lock nut. Torque: 280 N*m (2,855 kgf*cm, 207 ft.*lbf) HINT: Use a torque wrench with a fulcrum length of 750 mm (29.53 in.). SST D026434E01 SST C134907E01 Underdrive Planetary Gear AX C134897E01 U250E AUTOMATIC TRANSAXLE – UNDERDRIVE PLANETARY GEAR AX–285 (c) Using a chisel and hammer, stake the lock nut. CAUTION: Be sure that there are no cracks on the nut. C056809 AX AX–286 U250E AUTOMATIC TRANSAXLE – UNDERDRIVE CLUTCH UNDERDRIVE CLUTCH U250E AUTOMATIC TRANSAXLE TRANSMISSION COMPONENTS NO. 1 UNDERDRIVE CLUTCH PLATE NO. 1 UNDERDRIVE CLUTCH FLANGE NO. 2 UNDERDRIVE CLUTCH FLANGE HOLE SNAP RING NO. 1 UNDERDRIVE CLUTCH DISC UNDERDRIVE CLUTCH PISTON SET CLUTCH BALANCER UNDERDRIVE CLUTCH DRUM O-RING UNDERDRIVE RETURN SPRING SHAFT SNAP RING UNDERDRIVE CLUTCH DRUM SUB-ASSEMBLY UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY Non-reusable part AX Apply ATF WS C132392E01 U250E AUTOMATIC TRANSAXLE – UNDERDRIVE CLUTCH AX–287 DISASSEMBLY 1. REMOVE NO. 2 UNDERDRIVE CLUTCH FLANGE HOLE SNAP RING (a) Using a screwdriver, remove the No. 2 underdrive clutch flange hole snap ring. 2. REMOVE NO. 1 UNDERDRIVE CLUTCH DISC (a) Remove the flange, 3 discs, and 3 plates from the underdrive clutch drum. 3. REMOVE UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY (a) Place SST on the clutch balancer and compress the spring with a press. SST 09350-32014 (09351-32070) (b) Using a snap ring expander, remove the snap ring. NOTICE: • Stop the press when the spring seat is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove. This prevents the spring seat from being deformed. • Do not expand the snap ring excessively. Snap Ring D003701E01 Underdrive Clutch Drum C134892E01 SST Snap Ring D003703E01 (c) Remove the clutch balancer from the underdrive clutch drum. Clutch Balancer Underdrive Clutch Drum C056359E01 AX AX–288 U250E AUTOMATIC TRANSAXLE – UNDERDRIVE CLUTCH (d) Remove the return spring from the underdrive clutch drum. Underdrive Clutch Return Spring Underdrive Clutch Drum C056360E04 4. REMOVE UNDERDRIVE CLUTCH PISTON SET (a) Remove the underdrive clutch from the transaxle case. NOTICE: Be careful not to damage the oil seal ring. (b) Holding the underdrive clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm 2, 57 psi) to the transaxle case to remove the underdrive clutch piston. 5. REMOVE UNDERDRIVE CLUTCH DRUM O-RING (a) Using a screwdriver, remove the O-ring from the underdrive clutch drum. D003705 O-Ring D026465E03 INSPECTION 1. AX C134891 INSPECT UNDERDRIVE PACK CLEARANCE (a) Install the underdrive clutch to the transaxle case. NOTICE: Be careful not to damage the oil seal rings. (b) Install a dial indicator as shown in the illustration. (c) Measure the underdrive clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi). Pack clearance: 1.51 to 1.71 mm (0.0594 to 0.0673 in.) If the pack clearance is not within the specified range, inspect the discs, plates, and flange. U250E AUTOMATIC TRANSAXLE – UNDERDRIVE CLUTCH AX–289 2. INSPECT NO. 1 UNDERDRIVE CLUTCH DISC (a) Check if the sliding surfaces of the discs, plates and flange are worn or burnt. If necessary, replace them. HINT: • If the lining of a disc comes off or discolors, or even if a part of the groove is damaged, replace all discs. • Before assembling new discs, soak them in ATF for at least 15 minutes. 3. INSPECT UNDERDRIVE CLUTCH DRUM SUBASSEMBLY (a) Using a dial indicator, measure the inside diameter of the underdrive clutch drum bushing. Standard inside diameter: 32.56 to 32.58 mm (1.2818 to 1.2826 in.) Maximum inside diameter: 32.63 mm (1.2846 in.) If the inside diameter is greater than the maximum, replace the underdrive clutch drum. 4. INSPECT UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY (a) Using vernier calipers, measure the free length of the spring together with the spring seat. Standard free length: 17.14 mm (0.6748 in.) If the free length is shorter than the standard free length, replace the underdrive clutch return spring sub-assembly. D004077 D008129 D003824 REASSEMBLY O-Ring 1. INSTALL UNDERDRIVE CLUTCH DRUM O-RING (a) Coat a new O-ring with ATF, and install it to the underdrive clutch drum. NOTICE: Install the O-ring carefully not to have a twist or a pinching. 2. INSTALL UNDERDRIVE CLUTCH PISTON SET (a) Coat the underdrive clutch piston with ATF, and install it to the underdrive clutch piston drum. NOTICE: • Be careful not to damage the O-ring. • Be careful not to damage the lip seal of the piston. D026465E03 AX D003860 AX–290 U250E AUTOMATIC TRANSAXLE – UNDERDRIVE CLUTCH 3. Underdrive Clutch Return Spring Underdrive Clutch Drum INSTALL UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY (a) Install the return spring to the underdrive clutch drum. NOTICE: After installing the spring sub-assembly, check all of the springs are fitted in the piston correctly. (b) Coat the clutch balancer with ATF. C056360E02 (c) Install the clutch balancer to the underdrive clutch drum. NOTICE: Be careful not to damage the lip seal of the clutch balancer. Clutch Balancer Underdrive Clutch Drum C056359E01 (d) Place SST on the clutch balancer and compress the piston return spring with a press. SST 09350-32014 (09351-32070) (e) Using a snap ring expander, install the snap ring to the underdrive clutch drum. NOTICE: • Stop the press when the spring seat is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove. This prevents the spring seat from being deformed. • Do not expand the snap ring excessively. SST Snap Ring D003703E01 (f) Stopper Stopper Position the end gap of the snap ring in the underdrive clutch drum as shown in the illustration. NOTICE: The end gap of the snap ring should not be aligned with any of the stoppers. D025592E01 4. Disc Flange Plate AX C134893E01 INSTALL NO. 1 UNDERDRIVE CLUTCH DISC (a) Coat the 3 discs with ATF. (b) Install the 3 plates, 3 discs, and flange to the underdrive clutch drum. NOTICE: Be careful about the order of discs, plates, and flange. U250E AUTOMATIC TRANSAXLE – UNDERDRIVE CLUTCH 5. AX–291 INSTALL NO. 2 UNDERDRIVE CLUTCH FLANGE HOLE SNAP RING (a) Using a screwdriver, install the No. 2 underdrive clutch flange hole snap ring. (b) Check that the end gap of the snap ring is not aligned with one of the cutouts. NOTICE: The snap ring should be securely engaged in the groove of the drum. D003701 AX AX–292 U250E AUTOMATIC TRANSAXLE – SHIFT SOLENOID VALVE SHIFT SOLENOID VALVE U250E AUTOMATIC TRANSAXLE TRANSMISSION COMPONENTS AUTOMATIC TRANSAXLE ASSEMBLY TEMPERATURE SENSOR LOCK PLATE TRANSMISSION WIRE 6.6 (67, 58 in.*lbf) SPRING CHECK BALL BODY TRANSMISSION VALVE BODY ASSEMBLY 11 (112, 8) x17 VALVE BODY OIL STRAINER ASSEMBLY O-RING 11 (112, 8) 11 (112, 8) MAGNET AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY GASKET 7.8 (80, 69 in.*lbf) x18 49 (500, 36) GASKET AX N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Apply ATF Precoated part C137674E05 AX–293 U250E AUTOMATIC TRANSAXLE – SHIFT SOLENOID VALVE SHIFT SOLENOID VALVE SR SHIFT SOLENOID VALVE S4 11 (112, 8) SHIFT SOLENOID VALVE SLT 11 (112, 8) 6.6 (67, 58 in.*lbf) LOCK PLATE LOCK PLATE SHIFT SOLENOID VALVE SL2 6.6 (67, 58 in.*lbf) 11 (112, 8) SHIFT SOLENOID VALVE SL3 LOCK PLATE SHIFT SOLENOID VALVE SL1 SHIFT SOLENOID VALVE DSL AX N*m (kgf*cm, ft.*lbf) : Specified torque C139867E01 AX–294 U250E AUTOMATIC TRANSAXLE – SHIFT SOLENOID VALVE REMOVAL 1. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY HINT: See page AX-162. 2. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUBASSEMBLY (See page AX-138) 3. DISCONNECT TRANSMISSION WIRE (See page AX138) 4. REMOVE VALVE BODY OIL STRAINER ASSEMBLY (See page AX-139) 5. REMOVE TRANSMISSION VALVE BODY ASSEMBLY (See page AX-139) DISASSEMBLY 1. REMOVE SHIFT SOLENOID VALVE SL3 (a) Remove the bolt and lock plate from the valve body assembly. (b) Remove the shift solenoid valve SL3 from the valve body assembly. 2. REMOVE SHIFT SOLENOID VALVE SLT (a) Remove the shift solenoid valve SLT from the valve body assembly. 3. REMOVE SHIFT SOLENOID VALVE S4 (a) Remove the bolt and shift solenoid valve S4 from the valve body assembly. 4. REMOVE SHIFT SOLENOID VALVE SR (a) Remove the shift solenoid valve SR from the valve body assembly. Lock Plate SL3 SLT C089112E01 D026442 D026438 AX AX–295 U250E AUTOMATIC TRANSAXLE – SHIFT SOLENOID VALVE 5. REMOVE SHIFT SOLENOID VALVE DSL (a) Remove the bolt and shift solenoid valve DSL from the valve body assembly. 6. REMOVE SHIFT SOLENOID VALVE SL2 (a) Remove the bolt, lock plate and shift solenoid valve SL2 from the valve body assembly. 7. REMOVE SHIFT SOLENOID VALVE SL1 (a) Remove the bolt, lock plate and shift solenoid valve SL1 from the valve body assembly. D026443 C089113 C089115 INSPECTION Shift Solenoid Valve SL3: 1. 2 1 (-) Tester Connection Specified Condition 20°C (68°F) 1-2 5.0 to 5.6 Ω If the value is not as specified, replace the shift solenoid valve. (b) Connect the positive (+) lead to terminal 2 of the solenoid connector, and the negative (-) lead to terminal 1 of the solenoid connector. OK: The solenoid valve makes an operating sound. If the result is not as specified, replace the shift solenoid valve. 2 1 INSPECT SHIFT SOLENOID VALVE SL3 (a) Measure the resistance according to the value(s) in the table below. Standard resistance AX (+) G020767E29 AX–296 U250E AUTOMATIC TRANSAXLE – SHIFT SOLENOID VALVE 2. Shift Solenoid Valve SLT: 2 1 (-) Tester Connection Specified Condition 20°C (68°F) 1-2 5.0 to 5.6 Ω If the value is not as specified, replace the shift solenoid valve. (b) Connect the positive (+) lead to terminal 2 of the solenoid connector, and the negative (-) lead to terminal 1 of the solenoid connector. OK: The solenoid valve makes an operating sound. If the result is not as specified, replace the shift solenoid valve. 2 1 INSPECT SHIFT SOLENOID VALVE SLT (a) Measure the resistance according to the value(s) in the table below. Standard resistance (+) G020767E08 3. Shift Solenoid Valve S4: (-) (+) C113971E01 AX INSPECT SHIFT SOLENOID VALVE S4 (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition 20°C (68°F) Solenoid Connector (S4) - Solenoid Body (S4) 11 to 15 Ω If the value is not as specified, replace the shift solenoid valve. (b) Connect the positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. OK: The solenoid valve makes an operating sound. If the result is not as specified, replace the shift solenoid valve. AX–297 U250E AUTOMATIC TRANSAXLE – SHIFT SOLENOID VALVE 4. Shift Solenoid Valve SR: (+) Tester Connection Specified Condition 20°C (68°F) Solenoid Connector (SR) - Solenoid Body (SR) 11 to 15 Ω (-) If the value is not as specified, replace the shift solenoid valve. (b) Connect the positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. OK: The solenoid valve makes an operating sound. If the result is not as specified, replace the shift solenoid valve. C113977E01 5. Shift Solenoid Valve DSL: (-) INSPECT SHIFT SOLENOID VALVE SR (a) Measure the resistance according to the value(s) in the table below. Standard resistance (+) C113970E01 INSPECT SHIFT SOLENOID VALVE DSL (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition 20°C (68°F) Solenoid Connector (DSL) - Solenoid Body (DSL) 11 to 15 Ω If the value is not as specified, replace the shift solenoid valve. (b) Connect the positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. OK: The solenoid valve makes an operating sound. If the result is not as specified, replace the shift solenoid valve. AX AX–298 U250E AUTOMATIC TRANSAXLE – SHIFT SOLENOID VALVE 6. Shift Solenoid Valve SL2: 2 1 (-) Tester Connection Specified Condition 20°C (68°F) 1-2 5.0 to 5.6 Ω If the value is not as specified, replace the shift solenoid valve. (b) Connect the positive (+) lead to terminal 2 of the solenoid connector, and the negative (-) lead to terminal 1 of the solenoid connector. OK: The solenoid valve makes an operating sound. If the result is not as specified, replace the shift solenoid valve. 2 1 INSPECT SHIFT SOLENOID VALVE SL2 (a) Measure the resistance according to the value(s) in the table below. Standard resistance (+) G020767E28 7. Shift Solenoid Valve SL1: 2 1 (-) Tester Connection Specified Condition 20°C (68°F) 1-2 5.0 to 5.6 Ω If the value is not as specified, replace the shift solenoid valve. (b) Connect the positive (+) lead to terminal 2 of the solenoid connector, and the negative (-) lead to terminal 1 of the solenoid connector. OK: The solenoid valve makes an operating sound. If the result is not as specified, replace the shift solenoid valve. 2 1 INSPECT SHIFT SOLENOID VALVE SL1 (a) Measure the resistance according to the value(s) in the table below. Standard resistance (+) G020767E46 REASSEMBLY 1. AX C089115 INSTALL SHIFT SOLENOID VALVE SL1 (a) Install the shift solenoid valve SL1 and lock plate to the valve body assembly with the bolt. Torque: 6.6 N*m (67 kgf*cm, 58 in.*lbf) U250E AUTOMATIC TRANSAXLE – SHIFT SOLENOID VALVE AX–299 2. INSTALL SHIFT SOLENOID VALVE SL2 (a) Install the shift solenoid valve SL2 and lock plate to the valve body assembly with the bolt. Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) 3. INSTALL SHIFT SOLENOID VALVE DSL (a) Install the shift solenoid valve DSL to the valve body assembly with the bolt. Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) 4. INSTALL SHIFT SOLENOID VALVE SR (a) Install the shift solenoid valve SR to the valve body assembly. 5. INSTALL SHIFT SOLENOID VALVE S4 (a) Install the shift solenoid valve S4 to the valve body assembly with the bolt. Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) 6. INSTALL SHIFT SOLENOID VALVE SL3 (a) Install the shift solenoid valve SL3 to the valve body assembly. 7. INSTALL SHIFT SOLENOID VALVE SLT (a) Install the shift solenoid valve SLT and lock plate to the valve body assembly with the bolt. Torque: 6.6 N*m (67 kgf*cm, 58 in.*lbf) C089113E01 D026443 D026438 D026442 Lock Plate SL3 SLT AX C089112E01 AX–300 U250E AUTOMATIC TRANSAXLE – SHIFT SOLENOID VALVE INSTALLATION AX 1. INSTALL TRANSMISSION VALVE BODY ASSEMBLY (See page AX-139) 2. INSTALL VALVE BODY OIL STRAINER ASSEMBLY (See page AX-140) 3. INSTALL TRANSMISSION WIRE (See page AX-140) 4. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUBASSEMBLY (See page AX-141) 5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page AX-141) 6. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (See page AX-168) AX–301 U250E AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE DIFFERENTIAL CASE U250E AUTOMATIC TRANSAXLE TRANSMISSION COMPONENTS FRONT DIFFERENTIAL PINION THRUST WASHER TRANSAXLE HOUSING OIL SEAL FRONT NO. 1 DIFFERENTIAL PINION SHAFT FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN FRONT DIFFERENTIAL SIDE GEAR TRANSAXLE HOUSING FRONT DIFFERENTIAL PINION FRONT NO. 1 DIFFERENTIAL SIDE GEAR THRUST WASHER FRONT DIFFERENTIAL RING GEAR FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING OUTER RACE x10 95 (970, 70) FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING FRONT DIFFERENTIAL CASE FRONT DIFFERENTIAL CASE REAR SHIM DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING OUTER RACE N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Apply MP grease Apply ATF WS C132393E01 AX AX–302 U250E AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE REMOVAL 1. Matchmarks Front Dfferential Ring Gear REMOVE DIFFERENTIAL GEAR ASSEMBLY (See page AX-212) DISASSEMBLY 1. REMOVE FRONT DIFFERENTIAL RING GEAR (a) Put matchmarks on the front differential ring gear and differential case. C134908E01 (b) Remove the 10 bolts. Front Differential Ring Gear C134909E01 (c) Using a plastic hammer, tap on the front differential ring gear to remove it from the case. Front Differential Ring Gear C134910E01 2. Turn Hold SST SST C134911E01 AX REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING (a) Using SST, remove the front differential case front tapered roller bearing from the differential case. SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00480) U250E AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE AX–303 (b) Using SST, remove the front differential case front tapered roller bearing outer race. SST 09308-00010 SST D025596E02 3. Hold Turn SST SST C134912E01 REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING (a) Using SST, remove the front differential case rear tapered roller bearing from the differential case. SST 09950-00020, 09950-00030, 09950-40011 (09955-04061, 09957-04010, 0995804011), 09950-50013 (09951-05010, 0995205010, 09953-05020, 09954-05021, 0995505010), 09950-60010 (09951-00480), 09950-70010 (09951-07100) (b) Using SST, remove the front differential case rear tapered roller bearing outer race. SST 09308-00010 SST D025598E01 4. REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN (a) Using a pin punch and hammer, remove the straight pin. NOTICE: Before removing the straight pin, unstake it with a pin punch. 5. REMOVE FRONT NO. 1 DIFFERENTIAL PINION SHAFT (a) Remove the front No. 1 differential pinion shaft from the differential case. C134913 Differential Case AX Front No. 1 Differential Pinion Shaft C134914E02 AX–304 U250E AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE Front Differential Side Gear 6. REMOVE FRONT DIFFERENTIAL SIDE GEAR (a) Remove the 2 front differential pinions, 2 pinion thrust washers, 2 front differential side gears and 2 side gear thrust washers from the differential case. 7. REMOVE TRANSAXLE HOUSING OIL SEAL (a) Using SST and a hammer, remove the oil seal. SST 09950-70010 (09951-07200), 09950-60010 (09951-00630) 8. REMOVE DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL (a) Using SST and a hammer, remove the oil seal. SST 09950-70010 (09951-07100), 09608-10010 Front Differential Side Gear C134915E01 SST C134916E01 SST C134917E01 INSPECTION 1. C050252 AX INSPECT BACKLASH (a) Using a dial indicator, inspect the backlash of the side gear. Standard backlash: 0.05 to 0.20 mm (0.0020 to 0.0079 in.) Thrust washer thickness Mark Thickness 1 1.000 mm (0.0394 in.) 2 1.100 mm (0.0433 in.) 3 1.200 mm (0.0472 in.) 4 1.300 mm (0.0512 in.) U250E AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE AX–305 REASSEMBLY Front Differential Side Gear 1. INSTALL FRONT DIFFERENTIAL SIDE GEAR (a) Coat the 2 front differential side gears, 2 side gear thrust washers, 2 front differential pinions and 2 pinion thrust washers with ATF and install them to the differential case. 2. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT (a) Coat the front No. 1 differential pinion shaft with ATF, and install it to the differential case. 3. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN (a) Using a pin punch and hammer, install the pinion shaft straight pin. Front Differential Side Gear C134915E01 Differential Case Front No. 1 Differential Pinion Shaft C134914E02 C134918 (b) Using a chisel and hammer, stake the differential case. NOTICE: Stake it after adjusting the backlash. C134919 4. SST C134920E01 INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING (a) Using SST and a press, install the front differential case front tapered roller bearing to the differential case. SST 09550-60010 (09951-00480), 09950-70010 (09951-07100), 09710-04081 NOTICE: Do not damage the bearing cage during installation of the bearing inner race. AX AX–306 U250E AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE (b) Using SST and a hammer, install the front differential case front tapered roller bearing outer race to the transaxle housing. SST 09950-60020 (09951-00750), 09950-70010 (09951-07200) C083736 5. SST C134921E01 INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING (a) Using SST and a press, install the front differential case rear tapered roller bearing to the differential case. SST 09710-04081, 09550-60010 (09951-00480), 09950-70010 (09951-07100) NOTICE: Do not damage the bearing cage during installation of the bearing inner race. (b) Using SST and a hammer, install the front differential case rear tapered roller bearing outer race to the transaxle housing. SST 09550-60010 (09951-00790), 09950-70010 (09951-00710) NOTICE: Clearance is not allowed between the bearing and transaxle housing. SST D026449E01 6. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD (a) Install the differential assembly to the transaxle case. C134922 C C B C A AX C C A D026384E03 (b) Clean the matching surfaces of the transaxle case and transaxle housing. (c) Install the transaxle housing to the transaxle case and tighten them with the 16 bolts. Torque: Bolt A 22 N*m (225 kgf*cm, 16 ft.*lbf) Bolt B, C 29 N*m (299 kgf*cm, 22 ft.*lbf) Bolt length: Bolt A: 50 mm (1.969 in.) AX–307 U250E AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE Bolt B: 50 mm (1.969 in.) Bolt C: 42 mm (1.654 in.) (d) Using SST, turn the differential assembly right and left 2 or 3 times to settle the bearing. SST 09564-32011 (e) Using SST and a torque wrench, measure the turning torque of the differential. SST 09564-32011 Turning torque at 60 rpm: New bearing: 0.20 to 0.69 N*m (2.0 to 7.0 kgf*cm, 1.8 to 6.1 in.*lbf) Used bearing: 0.10 to 0.35 N*m (1.0 to 3.6 kgf*cm, 0.9 to 3.1 in.*lbf) HINT: If the turning torque is not within the specified range, refer to the table below to select a thrust washer so that the turning torque is within the specified range. Flange thickness: mm (in.) SST D025604E01 Mark Thickness Mark Thickness 0 1.90 (0.0748) A 2.40 (0.0945) 1 1.95 (0.0768) B 2.45 (0.0965) 2 2.00 (0.0787) C 2.50 (0.0984) 3 2.05 (0.0807) D 2.55 (0.1004) 4 2.10 (0.0827) E 2.60 (0.1024) 5 2.15 (0.0846) F 2.65 (0.1043) 6 2.20 (0.0866) G 2.70 (0.1063) 7 2.25 (0.0886) H 2.75 (0.1083) 8 2.30 (0.0906) J 2.80 (0.1102) 9 2.35 (0.0925) - - (f) Remove the 16 bolts and the transaxle housing. D026384 AX AX–308 U250E AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE (g) Remove the differential assembly. C134922 7. 90 to 110°C (194 to 230°F) INSTALL FRONT DIFFERENTIAL RING GEAR (a) Using ATF and a heater, heat the front differential ring gear to 90 to 110°C (194.0 to 230.0°F). NOTICE: Do not overheat the ring gear over 110°C (230.0°F). (b) Clean the contact surface of the front differential case. D025215E04 Matchmarks (c) Align the matchmarks, and install the front differential ring gear case quickly. NOTICE: Do not install the bolts while the ring gear is hot. Front Dfferential Ring Gear C134908E01 (d) Tighten the 10 bolts. Torque: 95 N*m (970 kgf*cm, 70 ft.*lbf) NOTICE: Tighten the bolts a little at a time in diagonal order. Front Differential Ring Gear C134909E01 8. AX SST D026451E01 INSTALL TRANSAXLE HOUSING OIL SEAL (a) Using SST and a hammer, drive in a new oil seal. SST 09608-32010, 09950-70010 (09951-07150) (b) Coat the lip of the oil seal with a small amount of MP grease. Oil seal drive in depth: -0.5 to 0.5 mm (-0.0197 to 0.0197 in.) U250E AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE 9. SST AX–309 INSTALL DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL (a) Using SST and a hammer, drive in a new oil seal. SST 09726-36010, 09950-70010 (09951-07150) (b) Coat the lip of the oil seal with a small amount of MP grease. Oil seal drive in depth: -0.5 to 0.5 mm (-0.0197 to 0.0197 in.) C134923E01 AX AX–310 U250E AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE INSTALLATION 1. AX INSTALL DIFFERENTIAL GEAR ASSEMBLY (See page AX-256) AH–1 AXLE – AXLE SYSTEM AXLE SYSTEM PROBLEM SYMPTOMS TABLE Use the table below to help find the cause of the problem. Check each part. If necessary, replace these parts. Symptom Wander Front wheel shimmy Suspected area See page 1. Wheel alignment (Front) SP-4 2. Wheel alignment (Rear) SP-13 3. Steering linkage PS-49 4. Hub bearing (Front) AH-5 5. Hub bearing (Rear) AH-14 6. Stabilizer bar (Front) SP-33 7. Stabilizer bar (Rear) SP-69 1. Shock absorber SP-18 2. Lower ball joint SP-28 3. Hub bearing AH-5 AH AH–2 AXLE – FRONT AXLE HUB BOLT FRONT AXLE HUB BOLT SUSPENSION & AXLE AXLE COMPONENTS 107 (1,090, 79) AH FRONT DISC FRONT AXLE HUB BOLT FRONT DISC BRAKE CALIPER ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C137195E01 AXLE – FRONT AXLE HUB BOLT AH–3 REPLACEMENT 1. REMOVE FRONT WHEEL 2. SEPARATE FRONT DISC BRAKE CALIPER ASSEMBLY (See page AH-6) 3. REMOVE FRONT DISC (See page BR-49) 4. REMOVE FRONT AXLE HUB BOLT (a) Temporarily install the 2 nuts and washers to the front axle hub bolt as shown in the illustration. (b) Using SST and a brass bar or an equivalent tool to hold the front axle, remove the front axle hub bolt. SST 09628-10011 SST SST Hold Turn C112993E02 5. INSTALL FRONT AXLE HUB BOLT (a) Install a washer and nut to a new front axle hub bolt as shown in the illustration. (b) Using a brass bar to hold the front axle, install the hub bolt by torquing the nut. 6. INSTALL FRONT DISC (See page BR-51) 7. INSTALL FRONT DISC BRAKE CALIPER ASSEMBLY (See page AH-10) 8. INSTALL FRONT WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) Nut Washer Hold Turn C108165E02 AH AH–4 AXLE – FRONT AXLE HUB FRONT AXLE HUB SUSPENSION & AXLE AXLE COMPONENTS FRONT SHOCK ABSORBER ASSEMBLY 19 (192, 14) 210 (2,140, 155) AH 8.0 (82, 71 in.*lbf) FRONT SPEED SENSOR FRONT DRIVE SHAFT ASSEMBLY TIE ROD END SUB-ASSEMBLY 107 (1,090, 79) FRONT AXLE ASSEMBLY FRONT DISC FRONT DISC BRAKE CALIPER ASSEMBLY 294 (3,000, 217) FRONT AXLE HUB NUT FRONT SUSPENSION LOWER NO. 1 ARM 75 (765, 55) 49 (500, 36) COTTER PIN N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C137840E01 AH–5 AXLE – FRONT AXLE HUB NO. 1 FRONT WHEEL BEARING DUST DEFLECTOR FRONT AXLE HUB HOLE SNAP RING FRONT AXLE HUB BEARING STEERING KNUCKLE COTTER PIN 8.3 (85, 73 in.*lbf) AH 123 (1,250, 91) FRONT LOWER BALL JOINT ASSEMBLY 8.3 (85, 73 in.*lbf) FRONT AXLE HUB SUB-ASSEMBLY FRONT DISC BRAKE DUST COVER N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C137841E01 AH–6 AXLE – FRONT AXLE HUB ON-VEHICLE INSPECTION 1. REMOVE FRONT WHEEL 2. SEPARATE FRONT DISC BRAKE CALIPER ASSEMBLY (See page AH-6) 3. REMOVE FRONT DISC (See page BR-49) 4. INSPECT FRONT AXLE HUB BEARING LOOSENESS (a) Using a dial indicator, check for looseness near the center of the axle hub. Maximum: 0.05 mm (0.0020 in.) NOTICE: Ensure that the dial indicator is set perpendicular to the measurement surface. HINT: If looseness exceeds the maximum, replace the bearing. 5. INSPECT FRONT AXLE HUB RUNOUT (a) Using a dial indicator, check for runout on the surface of the axle hub outside the hub bolt. Maximum: 0.05 mm (0.0020 in.) NOTICE: Ensure that the dial indicator is set perpendicular to the measurement surface. HINT: If runout exceeds the maximum, replace the axle hub. 6. INSTALL FRONT DISC (See page BR-51) 7. INSTALL FRONT DISC BRAKE CALIPER ASSEMBLY (See page AH-10) 8. INSTALL FRONT WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) AH C108155 C108156 AXLE – FRONT AXLE HUB AH–7 REMOVAL HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. C067088E04 Matchmarks 1. REMOVE FRONT WHEEL 2. REMOVE FRONT AXLE HUB NUT (See page DS-7) 3. SEPARATE FRONT SPEED SENSOR (See page DS-7) 4. SEPARATE FRONT DISC BRAKE CALIPER ASSEMBLY (a) Remove the 2 bolts and separate the front disc brake caliper assembly from the steering knuckle. NOTICE: Use wire or an equivalent tool to keep the brake caliper from hanging down by the flexible hose. 5. REMOVE FRONT DISC (See page BR-49) 6. SEPARATE TIE ROD END SUB-ASSEMBLY (See page DS-8) 7. SEPARATE FRONT SUSPENSION LOWER NO. 1 ARM (See page DS-8) 8. REMOVE FRONT AXLE ASSEMBLY (a) Put matchmarks on the front drive shaft assembly and the front axle hub sub-assembly. (b) Using a plastic hammer, separate the front drive shaft assembly from the front axle assembly. NOTICE: Be careful not to damage the drive shaft boot and speed sensor rotor. C129150E01 (c) Remove the 2 bolts, 2 nuts, and front axle assembly. C132414 AH AH–8 AXLE – FRONT AXLE HUB 9. Vinyl Tape REMOVE NO. 1 FRONT WHEEL BEARING DUST DEFLECTOR (a) Using a screwdriver with its tip wrapped with vinyl tape, remove the No. 1 front wheel bearing dust deflector. NOTICE: Be careful not to damage the steering knuckle. C108161E02 10. REMOVE FRONT AXLE HUB HOLE SNAP RING (a) Using snap ring pliers, remove the front axle hub hole snap ring. AH C108210 11. REMOVE FRONT AXLE HUB SUB-ASSEMBLY (a) Hold the front axle assembly between aluminium plates in a vise. NOTICE: Do not overtighten the vise. (b) Using SST, remove the front axle hub subassembly. SST 09520-00031 SST SST C108162E02 (c) Using SST and a press, remove the bearing inner race (outside) from the front axle hub sub-assembly. SST 09555-55010, 09950-60010 (09951-00430), 09950-70010 (09951-07100) NOTICE: Be careful not to drop the front axle hub subassembly. SST SST 12. REMOVE FRONT DISC BRAKE DUST COVER (a) Remove the 4 bolts and disc brake dust cover from the steering knuckle. 13. REMOVE FRONT LOWER BALL JOINT ASSEMBLY (See page SP-28) C108211E02 AXLE – FRONT AXLE HUB AH–9 14. REMOVE FRONT AXLE HUB BEARING (a) Place the bearing inner race (outside) on the front axle hub bearing. (b) Using SST and a press, press the front axle hub bearing until it contacts the SST. SST 09527-17011, 09950-60010 (09951-00600, 09951-00400, 09952-06010), 09950-70010 (09951-07100) SST SST SST AH SST C108212E02 (c) Using SST to make the steering knuckle horizontal, fix it to the V-block as shown in the illustration. SST 09527-20011, 09950-60010 (09951-00600, 09951-00400, 09952-06010), 09950-70010 (09951-07100) (d) Using SST and a press, remove the front axle hub bearing from the steering knuckle. SST SST SST SST C108213E02 INSTALLATION 1. INSTALL FRONT AXLE HUB BEARING (a) Using SST and a press, install a new front axle hub bearing to the steering knuckle. SST 09950-60020 (09951-00810), 09950-70010 (09951-07100) 2. INSTALL FRONT LOWER BALL JOINT ASSEMBLY (See page SP-29) 3. INSTALL FRONT DISC BRAKE DUST COVER (a) Install the disc brake dust cover to the steering knuckle with the 4 bolts. Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf) SST SST C108214E03 AH–10 AXLE – FRONT AXLE HUB 4. INSTALL FRONT AXLE HUB SUB-ASSEMBLY (a) Using SST and a press, install the front axle hub sub-assembly. SST 09608-32010, 09950-60020 (09951-00810), 09950-70010 (09951-07100) 5. INSTALL FRONT AXLE HUB HOLE SNAP RING (a) Using snap ring pliers, install a new front axle hub hole snap ring. 6. INSTALL NO. 1 FRONT WHEEL BEARING DUST DEFLECTOR (a) Using SST and a hammer, install a new No. 1 front wheel bearing dust deflector. SST 09316-60011 (09316-00011, 09316-00031), 09608-32010 HINT: Align the hole for the speed sensor in the No. 1 front wheel bearing dust deflector with the steering knuckle. 7. INSTALL FRONT AXLE ASSEMBLY (a) Align the matchmarks and install the front drive shaft assembly to the front axle hub sub-assembly. SST SST SST AH SST C108445E02 C108210 SST SST SST SST C108163E03 Matchmarks C129153E01 AXLE – FRONT AXLE HUB AH–11 (b) Install the steering knuckle with the front axle assembly to the front shock absorber with the 2 bolts and 2 nuts. Torque: 210 N*m (2,140 kgf*cm, 155 ft.*lbf) NOTICE: • Only when reusing the bolts and nuts, apply a small amount of engine oil to the threads of the nuts. • Be careful not to damage the drive shaft boot and speed sensor rotor. C132414 8. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM (See page DS-21) 9. INSTALL TIE ROD END SUB-ASSEMBLY (See page DS-21) 10. INSTALL FRONT DISC 11. INSTALL FRONT DISC BRAKE CALIPER ASSEMBLY (a) Install the front disc brake caliper assembly to the steering knuckle with the 2 bolts. Torque: 107 N*m (1,090 kgf*cm, 79 ft.*lbf) NOTICE: Do not twist the brake hose when installing the front disc brake caliper assembly. C067088E05 12. INSTALL FRONT AXLE HUB NUT (a) Using a socket wrench (30 mm), install a new axle hub nut. Torque: 294 N*m (3,000 kgf*cm, 217 ft.*lbf) HINT: Stake the nut after inspecting for looseness and runout in the following steps. 13. SEPARATE FRONT DISC BRAKE CALIPER ASSEMBLY (a) Remove the 2 bolts and separate the front disc brake caliper assembly from the steering knuckle. NOTICE: Use wire or an equivalent tool to keep the brake caliper from hanging down by the flexible hose. 14. REMOVE FRONT DISC 15. INSPECT FRONT AXLE HUB BEARING LOOSENESS (See page AH-5) 16. INSPECT FRONT AXLE HUB RUNOUT (See page AH6) 17. INSTALL FRONT DISC (See page BR-51) 18. INSTALL FRONT DISC BRAKE CALIPER ASSEMBLY (a) Install the front disc brake caliper assembly with the 2 bolts to the steering knuckle. Torque: 107 N*m (1,090 kgf*cm, 79 ft.*lbf) NOTICE: Do not twist the brake hose when installing the front disc brake caliper assembly. AH AH–12 AXLE – FRONT AXLE HUB 19. INSTALL FRONT SPEED SENSOR (See page DS-21) 20. INSTALL FRONT AXLE HUB NUT (a) Using a chisel and hammer, stake the axle hub nut. 21. INSTALL FRONT WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 22. ADJUST FRONT WHEEL ALIGNMENT HINT: See page SP-4 C068609E03 AH 23. CHECK ABS SPEED SENSOR SIGNAL (a) ABS: See page BC-11 (b) VSC (for BOSCH): See page BC-290 (c) VSC (for ADVICS): See page BC-123 AH–12 AXLE – REAR AXLE HUB BOLT REAR AXLE HUB BOLT SUSPENSION & AXLE AXLE COMPONENTS 62 (630, 46) AH 19 (192, 14) REAR DISC BRAKE CALIPER ASSEMBLY REAR AXLE HUB BOLT REAR DISC N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C140859E01 AXLE – REAR AXLE HUB BOLT AH–13 REPLACEMENT 1. REMOVE REAR WHEEL 2. REMOVE REAR DISC BRAKE CALIPER ASSEMBLY (See page AH-18) 3. REMOVE REAR DISC (See page PB-58) 4. REMOVE REAR AXLE HUB BOLT (a) Temporarily install the 2 nuts and washers to the rear axle hub bolt as shown in the illustration. (b) Using SST and a brass bar or an equivalent tool to hold the hub and bearing assembly, remove the rear axle hub bolt. SST 09628-10011 SST Turn Hold C140758E01 5. INSTALL REAR AXLE HUB BOLT (a) Install a washer and nut to a new bolt as shown in the illustration. (b) Using a brass bar or an equivalent tool to hold the hub and bearing assembly, install the rear axle hub bolt by tightening the nut. 6. INSTALL REAR DISC (See page BR-63) 7. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY (See page AH-20) 8. INSTALL REAR WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) Washer Nut Hold Turn C140759E01 AH AH–14 AXLE – REAR AXLE HUB AND BEARING REAR AXLE HUB AND BEARING SUSPENSION & AXLE AXLE COMPONENTS 62 (630, 46) SKID CONTROL SENSOR CONNECTOR 62 (630, 46) AH 19 (192, 14) 80 (816, 59) REAR DISC BRAKE CALIPER ASSEMBLY 80 (816, 59) REAR AXLE HUB AND BEARING ASSEMBLY 80 (816, 59) REAR DISC N*m (kgf*cm, ft.*lbf) : Specified torque C140830E01 AXLE – REAR AXLE HUB AND BEARING AH–15 ON-VEHICLE INSPECTION 1. REMOVE REAR WHEEL 2. SEPARATE REAR DISC BRAKE CALIPER ASSEMBLY (See page AH-18) 3. REMOVE REAR DISC (See page PB-58) 4. INSPECT REAR AXLE HUB BEARING LOOSENESS (a) Using a dial indicator, check for looseness near the center of the axle hub. Maximum: 0.05 mm (0.0020 in.) NOTICE: Ensure that the dial indicator is set perpendicular to the measurement surface. If looseness exceeds the maximum, replace the axle hub assembly. C119285 5. INSPECT REAR AXLE HUB RUNOUT (a) Using a dial indicator, check for runout on the surface of the axle hub outside the hub bolt. Maximum: 0.07 mm (0.0027 in.) NOTICE: Ensure that the dial indicator is set perpendicular to the measurement surface. If runout exceeds the maximum, replace the axle hub assembly. 6. INSTALL REAR DISC (See page BR-63) 7. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY (See page AH-20) 8. INSTALL REAR WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) C119286 AH AH–16 AXLE – REAR AXLE HUB AND BEARING REMOVAL HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. REMOVE REAR WHEEL 2. SEPARATE REAR DISC BRAKE CALIPER ASSEMBLY (See page AH-18) 3. REMOVE REAR DISC (See page PB-58) 4. REMOVE REAR AXLE HUB AND BEARING ASSEMBLY (a) Disconnect the skid control sensor connector. AH (b) Remove the 4 bolts and hub and bearing assembly. C083035E01 INSTALLATION 1. INSTALL REAR AXLE HUB AND BEARING ASSEMBLY (a) Install the hub and bearing assembly with the 4 bolts. Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf) (b) Connect the skid control sensor connector. NOTICE: Do not twist the sensor wire when connecting it. 2. INSPECT REAR AXLE HUB BEARING LOOSENESS (See page AH-15) 3. INSPECT REAR AXLE HUB RUNOUT (See page AH15) 4. INSTALL REAR DISC (See page BR-63) 5. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY (See page AH-20) 6. INSTALL REAR WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 7. CHECK ABS SPEED SENSOR SIGNAL (a) ABS: See page BC-11 (b) VSC (for BOSCH): See page BC-290 (c) VSC (for ADVICS): See page BC-123 C083035E02 AH–17 AXLE – REAR AXLE CARRIER REAR AXLE CARRIER SUSPENSION & AXLE AXLE COMPONENTS 180 (1,836, 133) REAR SHOCK ABSORBER ASSEMBLY REAR NO. 2 SUSPENSION ARM REAR NO. 1 SUSPENSION ARM 100 (1,020, 74) SKID CONTROL SENSOR CONNECTOR AH 62 (630, 46) 19 (192, 14) 100 (1,020, 74) 62 (630, 46) 113 (1,150, 83) REAR AXLE CARRIER SUB-ASSEMBLY REAR DISC BRAKE CALIPER ASSEMBLY PARKING BRAKE ASSEMBLY REAR STRUT ROD 80 (816, 59) REAR AXLE HUB AND BEARING ASSEMBLY REAR DISC 80 (816, 59) N*m (kgf*cm, ft.*lbf) : Specified torque C140831E01 AH–18 AXLE – REAR AXLE CARRIER REMOVAL HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. REMOVE REAR WHEEL 2. SEPARATE REAR DISC BRAKE CALIPER ASSEMBLY (a) Remove the bolt and separate the flexible hose from the shock absorber. AH C083014E02 (b) Remove the 2 bolts and separate the rear disc brake caliper assembly. NOTICE: Use wire or an equivalent tool to keep the brake caliper from hanging down by the flexible hose. C083008E02 3. REMOVE REAR DISC (See page PB-58) 4. REMOVE REAR AXLE HUB AND BEARING ASSEMBLY (See page AH-15) 5. SEPARATE REAR STRUT ROD (a) Remove the bolt and nut, and separate the rear strut rod (rear axle carrier side) from the rear axle carrier sub-assembly. HINT: When removing the bolt, keep the nut from rotating. 6. SEPARATE REAR NO. 2 SUSPENSION ARM (a) Remove the bolt and nut, and separate the rear No. 2 suspension arm (rear axle carrier side) from the rear axle carrier sub-assembly. HINT: When removing the bolt, keep the nut from rotating. 7. SEPARATE REAR NO. 1 SUSPENSION ARM (a) Remove the bolt and nut, and separate the rear No. 1 suspension arm (rear axle carrier side) from the rear axle carrier sub-assembly. HINT: When removing the bolt, keep the nut from rotating. G024053 G025995 AXLE – REAR AXLE CARRIER 8. AH–19 REMOVE REAR AXLE CARRIER SUB-ASSEMBLY (a) Remove the 2 bolts and 2 nuts, and remove the rear axle carrier sub-assembly from the shock absorber. C129156 INSTALLATION 1. INSTALL REAR AXLE CARRIER SUB-ASSEMBLY (a) Install the rear axle carrier sub-assembly to the shock absorber with the 2 bolts and 2 nuts. Torque: 180 N*m (1,836 kgf*cm, 133 ft.*lbf) 2. TEMPORARILY TIGHTEN REAR NO. 1 SUSPENSION ARM (a) Temporarily tighten the rear No. 1 suspension arm with the bolt and nut. HINT: Insert the bolt from the rear side of the vehicle and temporarily tighten the bolt. 3. TEMPORARILY TIGHTEN REAR NO. 2 SUSPENSION ARM (a) Temporarily tighten the rear No. 2 suspension arm with the bolt and nut. HINT: Insert the bolt from the rear side of the vehicle and temporarily tighten the bolt. 4. TEMPORARILY TIGHTEN REAR STRUT ROD (a) Temporarily tighten the rear strut rod with the bolt and nut. HINT: Insert the bolt from the inside of the vehicle and temporarily tighten the bolt. 5. INSTALL REAR AXLE HUB AND BEARING ASSEMBLY (See page AH-16) 6. INSPECT REAR AXLE HUB BEARING LOOSENESS (See page AH-15) 7. INSPECT REAR AXLE HUB RUNOUT (See page AH15) 8. INSTALL REAR DISC (See page BR-63) C129156 G025995 G024053 AH AH–20 AXLE – REAR AXLE CARRIER 9. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY (a) Install the rear disc brake caliper with the 2 bolts. Torque: 62 N*m (630 kgf*cm, 46 ft.*lbf) NOTICE: Do not twist the brake hose when installing the rear disc brake caliper assembly LH. C083008E03 (b) Install the rear flexible hose with the bolt. Torque: 19 N*m (192 kgf*cm, 14 ft.*lbf) AH 10. INSTALL REAR WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 11. STABILIZE SUSPENSION (See page SP-50) C083014E03 12. FULLY TIGHTEN REAR NO. 1 SUSPENSION ARM (a) Fully tighten the bolt. Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf) C132483 13. FULLY TIGHTEN REAR NO. 2 SUSPENSION ARM (a) Fully tighten the bolt. Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf) C132492 14. FULLY TIGHTEN REAR STRUT ROD (a) Fully tighten the bolt. Torque: 113 N*m (1,150 kgf*cm, 83 ft.*lbf) 15. ADJUST REAR WHEEL ALIGNMENT HINT: See page SP-13 C132476 16. CHECK ABS SPEED SENSOR SIGNAL (a) ABS: See page BC-11 (b) VSC (for BOSCH): See page BC-290 (c) VSC (for ADVICS): See page BC-123 SS–1 SERVICE SPECIFICATIONS – STANDARD BOLT STANDARD BOLT HOW TO DETERMINE BOLT STRENGTH Bolt Type Hexagon Head Bolt Stud Bolt Normal Recess Bolt Weld Bolt Class Deep Recess Bolt No Mark No Mark No Mark 4T 5T w/ Washer w/ Washer 6T 7T 8T 9T 10T 11T SS SS–2 SERVICE SPECIFICATIONS – STANDARD BOLT SPECIFIED TORQUE FOR STANDARD BOLTS Class 4T SS 5T 6T 7T 8T 9T 10T 11T Diameter (mm) Pitch (mm) Specified torque N*m kgf*cm ft.*lbf N*m kgf*cm ft.*lbf 6 1 5 55 48 in.*lbf 6 60 52 in.*lbf 8 1.25 12.5 130 9 14 145 10 10 1.25 26 260 19 29 290 21 12 1.25 47 480 35 53 540 39 14 1.5 74 760 55 84 850 61 Hexagon head bolt Hexagon flange bolt 16 1.5 115 1,150 83 - - - 6 1 6.5 65 56 in.*lbf 7.5 75 65 in.*lbf 8 1.25 15.5 160 12 17.5 175 13 10 1.25 32 330 24 36 360 26 12 1.25 59 600 43 65 670 48 14 1.5 91 930 67 100 1,050 76 16 1.5 140 1,400 101 - - - 6 1 8 80 69 in.*lbf 9 90 78 in.*lbf 8 1.25 19 195 14 21 210 15 10 1.25 39 400 29 44 440 32 12 1.25 71 730 53 80 810 59 14 1.5 110 1,100 80 125 1,250 90 16 1.5 170 1,750 127 - - - 6 1 10.5 110 8 12 120 9 8 1.25 25 260 19 28 290 21 10 1.25 52 530 38 58 590 43 12 1.25 95 970 70 105 1,050 76 14 1.5 145 1,500 108 165 1,700 123 16 1.5 230 2,300 166 - - - 8 1.25 29 300 22 33 330 24 10 1.25 61 620 45 68 690 50 12 1.25 110 1,100 80 120 1,250 90 8 1.25 34 340 25 37 380 27 10 1.25 70 710 51 78 790 57 12 1.25 125 1,300 94 140 1,450 105 8 1.25 38 390 28 42 430 31 10 1.25 78 800 58 88 890 64 12 1.25 140 1,450 105 155 1,600 116 8 1.25 42 430 31 47 480 35 10 1.25 87 890 64 97 990 72 12 1.25 155 1,600 116 175 1,800 130 SS–3 SERVICE SPECIFICATIONS – STANDARD BOLT HOW TO DETERMINE NUT STRENGTH Nut Type Present Standard Hexagon Nut Old Standard Hexagon Nut Cold Forging Nut Class Cutting Processed Nut No Mark No Mark (w/ Washer) 4N No Mark (w/ Washer) No Mark 5N (4T) 6N 7N (5T) 8N No Mark 10N (7T) 11N 12N HINT: • *: Nut with 1 or more marks on one side surface of the nut. • Use the nut with the same number of the nut strength classification or greater than the bolt strength classification number when tightening parts with a bolt and nut. Example: • Bolt = 4T • Nut = 4N or more SS SS–4 SERVICE SPECIFICATIONS – 2AZ-FE ENGINE CONTROL SYSTEM 2AZ-FE ENGINE CONTROL SYSTEM SERVICE DATA Camshaft timing oil control valve assembly Resistance at 20°C (68°F) 6.9 to 7.9 Ω Camshaft position sensor SS Standard resistance 1 (G+) - 2(G-) 835 to 1,400 Ω at Cold 1 (G+) - 2(G-) 1,060 to 1,645 Ω at Hot Crankshaft position sensor Standard resistance Cold Hot 985 to 1,600 Ω 1,265 to 1,890 Ω Throttle body assembly Resistance at 20°C (68°F) 2 (M+) - 1 (M-) 0.3 to 100 kΩ E.F.I. engine coolant temperature sensor Resistance Approx. 20°C (68°F) Approx. 80°C (176°F) 2.32 to 2.59 kΩ 0.310 to 0.326 kΩ Knock sensor Resistance at 20°C (68°F) 120 to 280 kΩ Circuit opening relay (engine room R/B Unit D) Specified condition 1E-8 - 1E-12 Below 1 Ω 1E-7 - 1E-13 10 kΩ or higher 1E-7 - 1E-13 Below 1 Ω (when battery voltage is applied to terminals 1G-5 and 1H-9) 1E-9 - 1E-10 Below 1 Ω 1E-7 - 1E-12 10 kΩ or higher 1E-7 - 1E-12 Below 1 Ω (when battery voltage is applied to terminals 1H-10 and 1H-2) 1E-7 - 1E-10 Below 1 Ω EFI relay (engine room R/B Unit D) Specified condition A/F relay (engine room R/B Unit D) Specified condition 1A-3 - 1A-4 10 kΩ or higher 1A-3 - 1A-4 Below 1 Ω (when battery voltage is applied to terminals 1D-5 and 1H-2) Accelerator pedal rod Standard voltage (ACCEL POS #1) Standard voltage (ACCEL POS #2) Released 0.5 to 1.1 V Depressed 2.5 to 4.5 V Released 1.2 to 2.0 V Depressed 3.4 to 5.0 V SS–5 SERVICE SPECIFICATIONS – 2AZ-FE ENGINE CONTROL SYSTEM TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Throttle body assembly x Intake manifold 30 305 22 Knock sensor x Cylinder block sub-assembly 20 204 15 ECM x ECM bracket 3.0 30 27 ECM x Body 6.5 66 57 Accelerator pedal rod assembly x Body 5.4 55 48 in.*lbf Camshaft timing oil control valve assembly x Cylinder head subassembly 9.0 92 80 in.*lbf Vacuum hose clamp x Intake manifold 5.0 51 44 in.*lbf Camshaft position sensor x Cylinder head sub-assembly 9.0 92 80 in.*lbf Crankshaft position sensor x Timing chain cover sub-assembly 9.0 92 80 in.*lbf Engine coolant temperature sensor x Cylinder head sub-assembly 20 204 15 Intake manifold x Cylinder head sub-assembly 30 306 22 Intake manifold x Cylinder block sub-assembly 30 306 22 Cowl top panel outer sub-assembly x Body 5.0 51 44 in.*lbf SS SS–6 SERVICE SPECIFICATIONS – 2GR-FE ENGINE CONTROL SYSTEM 2GR-FE ENGINE CONTROL SYSTEM SERVICE DATA Throttle body Standard throttle valve opening percentage SS 60% or more Camshaft timing oil control valve assembly Resistance at 20°C (68°F) 6.9 to 7.9 Ω Crankshaft position sensor -10 to 50 °C (14 to 122 °F) 1,630 to 2,740 Ω 50 to 100 °C (122 to 212 °F) 2,065 to 3,225 Ω Throttle body Resistance at 20°C (68°F) 2 (M+) - 1 (M-) 0.3 to 100 kΩ 5 (VC) - 3 (E2) 1.2 to 3.2 kΩ E.F.I. engine coolant temperature sensor Resistance Approx. 20°C (68°F) Approx. 80°C (176°F) 2.32 to 2.59 kΩ 0.310 to 0.326 kΩ Knock sensor Resistance at 20°C (68°F) 120 to 280 kΩ Circuit opening relay (engine room R/B Unit D) Specified condition 1E-8 - 1E-12 Below 1 Ω 1E-7 - 1E-13 10 kΩ or higher 1E-7 - 1E-13 Below 1 Ω (when battery voltage is applied to terminals 1G-5 and 1H-9) 1E-9 - 1E-10 Below 1 Ω EFI relay (engine room R/B Unit D) Specified condition 1E-7 - 1E-12 10 kΩ or higher 1E-7 - 1E-12 Below 1 Ω (when battery voltage is applied to terminals 1H-10 and 1H-2) 1E-7 - 1E-10 Below 1 Ω A/F relay (engine room R/B Unit D) Specified condition 1A-3 - 1A-4 10 kΩ or higher 1A-3 - 1A-4 Below 1 Ω (when battery voltage is applied to terminals 1D-5 and 1H-2) IG2 Relay Standard resistance 3-5 10 kΩ or higher 3-5 Below 1 Ω (Battery voltage applied between terminals 1 and 2) Acceleration pedal rod Standard voltage (ACCEL POS #1) Standard voltage (ACCEL POS #2) Released 0.5 to 1.1 V Depressed 2.5 to 4.5 V Released 1.2 to 2.0 V Depressed 3.4 to 5.0 V SS–7 SERVICE SPECIFICATIONS – 2GR-FE ENGINE CONTROL SYSTEM TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Throttle body assembly x Intake air surge tank 10 102 7 Knock sensor x Cylinder block sub-assembly 20 199 14 Water outlet x Cylinder head sub-assembly 15 153 11 ECM x Instrument panel reinforcement 5.5 56 49 in.*lbf ECM x Blower assembly 5.5 56 49 in.*lbf Accelerator pedal rod assembly x Body 5.4 55 48 in.*lbf Camshaft timing oil control valve assembly x Cylinder head cover subassembly 10 102 7 VVT sensor x Cylinder head cover sub-assembly 10 102 7 Crankshaft position sensor x Cylinder block sub-assembly 10 102 7 Engine coolant temperature sensor x Cylinder head sub-assembly 20 204 15 SS SS–8 SERVICE SPECIFICATIONS – 2AZ-FE ENGINE MECHANICAL 2AZ-FE ENGINE MECHANICAL SERVICE DATA Ignition timing SS Idle speed Compression Valve clearance (cold) with Terminals TC and CG of DLC3 connected 8 to 12°BTC at idle with Terminals TC and CG of DLC3 disconnected 5 to 15°BTC at idle M/T 650 to 750 rpm A/T 610 to 710 rpm Compression pressure 1.360 MPa (13.9 kgf/cm2, 198 psi) Minimum pressure 0.98 MPa (10 kgf/cm2, 142 psi) Difference between each cylinder 100 kPa (1.0 kgf/cm2, 14 psi) Intake 0.19 to 0.29 mm (0.0075 to 0.0114 in.) Exhaust 0.38 to 0.48 mm (0.0150 to 0.0189 in.) Balanceshaft Standard thrust clearance 0.050 to 0.090 mm (0.0020 to 0.0035 in.) Maximum thrust clearance 0.09 mm (0.0035 in.) Standard oil clearance 0.004 to 0.049 mm (0.0002 to 0.0019 in.) Maximum oil clearance Housing journal bore diameter Journal diameter Bearing center wall thickness 0.049 mm (0.0019 in.) Mark 1 26.000 to 26.006 mm (1.0236 to 1.0239 in.) Mark 2 26.007 to 26.012 mm (1.0239 to 1.0241 in.) Mark 3 26.013 to 26.018 mm (1.0241 to 1.0243 in.) Mark 1 22.985 to 23.000 mm (0.9049 to 0.9055 in.) Mark 2 22.985 to 23.000 mm (0.9049 to 0.9055 in.) Mark 3 22.985 to 23.000 mm (0.9049 to 0.9055 in.) Standard bolt length 58.3 to 59.7 mm (2.295 to 2.350 in.) Maximum bolt length 60.3 mm (2.374 in.) Mark 1 1.486 to 1.489 mm (0.0585 to 0.0586 in.) Mark 2 1.490 to 1.492 mm (0.0586 to 0.0587 in.) Mark 3 1.493 to 1.495 mm (0.0587 to 0.0589 in.) Oil pump drive sprocket Minimum sprocket diameter (with chain) 48.2 mm (1.898 in.) Oil pump drive shaft sprocket Minimum sprocket diameter (with chain) 48.2 mm (1.898 in.) Crankshaft timing sprocket Minimum sprocket diameter (with chain) 51.6 mm (2.031 in.) Chain tensioner slipper Maximum wear 1.0 mm (0.039 in.) Chain vibration damper No. 1 Maximum wear 1.0 mm (0.039 in.) Chain tensioner plate Maximum wear 0.5 mm (0.020 in.) Cylinder head set bolt Standard bolt length 141.3 to 142.7 mm (5.563 to 5.618 in.) Maximum bolt length 144.2 mm (5.677 in.) Chain sub-assembly Maximum chain elongation 114.5 mm (4.508 in.) No. 2 Chain sub-assembly Maximum chain elongation 102.2 mm (4.024 in.) Camshaft timing gear assembly Minimum gear or sprocket diameter (with chain) 97.3 mm (3.831 in.) Camshaft timing sprocket Minimum gear or sprocket diameter (with chain) 97.3 mm (3.831 in.) Camshaft (Intake) Maximum circle runout 0.03 mm (0.0012 in.) Standard cam lobe height 47.306 to 47.406 mm (1.8624 to 1.8664 in.) Maximum cam lobe height 47.196 mm (1.8581 in.) No. 1 journal diameter 35.971 to 35.985 mm (1.4162 to 1.4167 in.) Outer journal diameter 22.959 to 22.975 mm (0.9039 to 0.9045 in.) SERVICE SPECIFICATIONS – 2AZ-FE ENGINE MECHANICAL Standard thrust clearance Maximum thrust clearance Standard oil clearance Intake Standard bearing center wall thickness Camshaft journal diameter 0.040 to 0.095 mm (0.0016 to 0.0037 in.) 0.110 mm (0.0043 in.) No. 1 journal bearing mark 1 0.007 to 0.038 mm (0.0003 to 0.0015 in.) No. 1 journal bearing mark 2 0.008 to 0.038 mm (0.0003 to 0.0015 in.) No. 1 journal bearing mark 3 0.008 to 0.038 mm (0.0003 to 0.0015 in.) Other journals 0.025 to 0.062 mm (0.0010 to 0.0024 in.) Mark 1 40.000 to 40.008 mm (1.5748 to 1.5752 in.) Mark 2 40.009 to 40.017 mm (1.5752 to 1.5755 in.) Mark 3 40.018 to 40.025 mm (1.5755 to 1.5758 in.) Mark 1 2.000 to 2.004 mm (0.0787 to 0.0789 in.) Mark 2 2.005 to 2.008 mm (0.0789 to 0.0791 in.) Mark 3 2.009 to 2.012 mm (0.0791 to 0.0792 in.) Mark 1 35.971 to 35.985 mm (1.4162 to 1.4167 in.) Mark 2 35.971 to 35.985 mm (1.4162 to 1.4167 in.) Mark 3 35.971 to 35.985 mm (1.4162 to 1.4167 in.) Maximum oil clearance Cylinder head journal bore diameter SS–9 0.070 mm (0.0028 in.) Camshaft No. 2 (Exhaust) Maximum circle runout 0.03 mm (0.0012 in.) Standard cam lobe height 45.983 to 46.083 mm (1.8104 to 1.8143 in.) Minimum cam lobe height 45.873 mm (1.8060 in.) No. 1 journal diameter 35.971 to 35.985 mm (1.4162 to 1.4167 in.) Other journal diameter 22.959 to 22.975 mm (0.9039 to 0.9045 in.) Standard thrust clearance Maximum thrust clearance Exhaust 0.080 to 0.135 mm (0.0032 to 0.0053 in.) 0.150 mm (0.0059 in.) No. 1 journal 0.015 to 0.054 mm (0.0006 to 0.0021 in.) Other journals 0.025 to 0.062 mm (0.0010 to 0.0024 in.) Mark 1 40.000 to 40.008 mm (1.5748 to 1.5752 in.) Mark 2 40.009 to 40.017 mm (1.5752 to 1.5755 in.) Mark 3 40.018 to 40.025 mm (1.5755 to 1.5758 in.) Mark 1 2.000 to 2.004 mm (0.00787 to 0.0789 in.) Mark 2 2.005 to 2.008 mm (0.0789 to 0.0791 in.) Mark 3 2.009 to 2.012 mm (0.0791 to 0.0792 in.) Mark 1 35.971 to 35.985 mm (1.4162 to 1.4167 in.) Mark 2 35.971 to 35.985 mm (1.4162 to 1.4167 in.) Mark 3 35.971 to 35.985 mm (1.4162 to 1.4167 in.) Intake manifold Maximum warpage 0.20 mm (0.0079 in.) Exhaust manifold Maximum warpage 0.70 mm (0.0276 in.) Cylinder block side 0.05 mm (0.0020 in.) Intake manifold side 0.08 mm (0.0031 in.) Exhaust manifold side 0.08 mm (0.0031 in.) Standard oil clearance Maximum oil clearance Cylinder head journal bore diameter Standard bearing center wall thickness Camshaft journal diameter 0.100 mm (0.0039 in.) Cylinder head Maximum warpage Inner compression spring Intake valve Free length 47.43 mm (1.867 in.) Maximum deviation 1.6 mm (0.063 in.) Standard overall length 101.71 mm (4.0043 in.) Minimum overall length 101.21 mm (3.9846 in.) Valve stem diameter 5.470 to 5.485 mm (0.2154 to 0.2159 in.) Standard margin thickness 1.05 to 1.45 mm (0.0413 to 0.0571 in.) Minimum margin thickness 0.50 mm (0.0197 in.) SS SS–10 SERVICE SPECIFICATIONS – 2AZ-FE ENGINE MECHANICAL Exhaust valve Intake valve guide bush SS Bush bore diameter Standard overall length 101.15 mm (3.9823 in.) Minimum overall length 100.70 mm (3.9646 in.) Valve stem diameter 5.465 to 5.480 mm (0.2152 to 0.2157 in.) Standard margin thickness 1.20 to 1.60 mm (0.0472 to 0.0630 in.) Minimum margin thickness 0.50 mm (0.0197 in.) Bush inside diameter 5.510 to 5.530 mm (0.2169 to 0.2177 in.) Standard bush oil clearance 0.025 to 0.060 mm (0.0010 to 0.0024 in.) Minimum bush oil clearance 0.080 mm (0.0031 in.) Use STD 10.285 to 10.306 mm (0.4049 to 0.4057 in.) Use O/S 0.05 10.335 to 10.356 mm (0.4069 to 0.4077 in.) Protrusion height 9.6 to 10.0 mm (0.3779 to 0.3937 in.) Standard oil clearance 0.025 to 0.060 mm (0.0010 to 0.0024 in.) Exhaust valve guide bush Bush bore diameter Bush inside diameter 5.510 to 5.530 mm (0.2169 to 0.2177 in.) Standard oil clearance 0.030 to 0.065 mm (0.0012 to 0.0026 in.) Minimum oil clearance 0.100 mm (0.0039 in.) Use STD 10.285 to 10.306 mm (0.4049 to 0.4057 in.) Use O/S 0.05 10.335 to 10.356 mm (0.4069 to 0.4077 in.) Protrusion height 9.6 to 10.0 mm (0.3779 to 0.3937 in.) Standard oil clearance 0.030 to 0.065 mm (0.0012 to 0.0026 in.) Lifter diameter Valve lifter 30.966 to 30.976 mm (1.2191 to 1.2195 in.) Lifter bore diameter 31.009 to 31.025 mm (1.2208 to 1.2215 in.) Standard oil clearance 0.033 to 0.059 mm (0.0013 to 0.0023 in.) Maximum oil clearance 0.070 mm (0.0028 in.) Connecting rod Standard thrust clearance 0.160 to 0.362 mm (0.0063 to 0.0143 in.) Maximum thrust clearance 0.362 mm (0.0143 in.) Standard oil clearance 0.032 to 0.063 mm (0.0013 to 0.0025 in.) Maximum oil clearance 0.063 mm (0.0025 in.) Connecting rod bearing center wall thickness (Reference) Mark 1 1.485 to 1.488 mm (0.0585 to 0.0586 in.) Mark 2 1.489 to 1.491 mm (0.0586 to 0.0587 in.) Mark 3 Connecting rod small end bore diameter Connecting rod small end bore diameter (Reference) 1.492 to 1.494 mm (0.0587 to 0.0588 in.) 22.005 to 22.014 mm (0.8663 to 0.8667 in.) Mark A 22.005 to 22.008 mm (0.8663 to 0.8665 in.) Mark B 22.009 to 22.011 mm (0.8665 to 0.8666 in.) Mark C 22.012 to 22.014 mm (0.8666 to 0.8667 in.) Standard oil clearance 0.005 to 0.011 mm (0.0002 to 0.0004 in.) Maximum oil clearance 0.011 mm (0.0004 in.) Maximum rod out-of alignment per 100 mm (3.94 in.) 0.05 mm (0.0020 in.) Maximum rod twist per 100 mm (3.94 in.) Cylinder block 0.15 mm (0.0059 in.) Maximum warpage 0.05 mm (0.0020 in.) Standard cylinder bore diameter 88.500 to 88.513 mm (3.4843 to 3.4847 in.) Maximum cylinder bore diameter 88.633 mm (3.4894 in.) Piston Standard piston diameter 88.469 to 88.479 mm (3.4830 to 3.4834 in.) Standard piston oil clearance 0.021 to 0.044 mm (0.0008 to 0.0017 in.) Maximum piston oil clearance 0.10 mm (0.0039 in.) Piston pin bore diameter 22.001 to 22.010 mm (0.8662 to 0.8665 in.) Mark A Piston pin bore diameter (Reference) 22.001 to 22.004 mm (0.8662 to 0.8663 in.) Mark B 22.005 to 22.007 mm (0.8663 to 0.8664 in.) Mark C 22.008 to 22.010 mm (0.8664 to 0.8665 in.) SERVICE SPECIFICATIONS – 2AZ-FE ENGINE MECHANICAL SS–11 Piston ring Ring groove clearance Standard end gap Maximum end gap No. 1 Ring 0.020 to 0.070 mm (0.0008 to 0.0028 in.) No. 2 Ring 0.020 to 0.060 mm (0.0008 to 0.0024 in.) Oil Ring 0.020 to 0.070 mm (0.0008 to 0.0028 in.) No. 1 Ring 0.24 to 0.31 mm (0.0094 to 0.0122 in.) No. 2 Ring 0.33 to 0.43 mm (0.0130 to 0.0169 in.) Oil Ring 0.10 to 0.30 mm (0.0040 to 0.0119 in.) No. 1 Ring 0.89 mm (0.0350 in.) No. 2 Ring 1.37 mm (0.0539 in.) Oil Ring 0.73 mm (0.0287 in.) Piston pin Standard piston pin diameter Piston pin diameter (Reference) 21.997 to 22.006 mm (0.8660 to 0.8664 in.) Mark A 21.997 to 22.000 mm (0.8660 to 0.8661 in.) Mark B 22.001 to 22.003 mm (0.8662 to 0.8663 in.) Mark C 22.004 to 22.006 mm (0.8663 to 0.8664 in.) Mark A 21.997 to 22.000 mm (0.8660 to 0.8661 in.) Mark B 22.001 to 22.003 mm (0.8662 to 0.8663 in.) Mark C 22.004 to 22.006 mm (0.8663 to 0.8664 in.) Standard oil clearance 0.001 to 0.007 mm (0.0004 to 0.0003 in.) Maximum oil clearance 0.010 mm (0.0004 in.) Connecting rod bolt Standard diameter 7.0 to 7.3 mm (0.276 to 0.287 in.) Maximum diameter 7.0 mm (0.276 in.) Crankshaft Standard thrust clearance 0.040 to 0.240 mm (0.0016 to 0.0095 in.) Maximum thrust clearance 0.30 mm (0.0118 in.) Thrust washer thickness 1.930 to 1.980 mm (0.0760 to 0.0780 in.) Cylinder block main journal bore diameter (Reference) Mark 0 59.000 to 59.002 mm (2.3228 to 2.3229 in.) Mark 1 59.003 to 59.004 mm (2.3230 to 2.3230 in.) Mark 2 59.005 to 59.006 mm (2.3230 to 2.3231 in.) Mark 3 59.007 to 59.009 mm (2.3231 to 2.3232 in.) Mark 4 59.010 to 59.011 mm (2.3232 to 2.3233 in.) Mark 5 59.012 to 59.013 mm (2.3233 to 2.3234 in.) Mark 6 59.014 to 59.016 mm (2.3234 to 2.3235 in.) Main journal diameter Main journal diameter (Reference) Standard main bearing center wall thickness (Reference) 54.988 to 55.000 mm (2.1648 to 2.1654 in.) Mark 0 54.999 to 55.000 mm (2.1653 to 2.1654 in.) Mark 1 54.997 to 54.998 mm (2.1652 to 2.1653 in.) Mark 2 54.995 to 54.996 mm (2.1652 to 2.1652 in.) Mark 3 54.993 to 54.994 mm (2.1651 to 2.1651 in.) Mark 4 54.991 to 54.992 mm (2.1650 to 2.1650 in.) Mark 5 54.988 to 54.990 mm (2.1649 to 2.1650 in.) Mark 1 1.993 to 1.996 mm (0.0785 to 0.0786 in.) Mark 2 1.997 to 1.999 mm (0.0786 to 0.0787 in.) Mark 3 2.000 to 2.002 mm (0.0787 to 0.0788 in.) Mark 4 2.003 to 2.005 mm (0.0789 to 0.0789 in.) Maximum circle runout 0.03 mm (0.0012 in.) Standard oil clearance 0.017 to 0.040 mm (0.0007 to 0.0016 in.) Maximum oil clearance 0.060 mm (0.0024 in.) Maximum main journal taper and out-of-round 0.003 mm (0.0001 in.) Maximum crank pin taper and out-of round 0.003 mm (0.0001 in.) Crank pin diameter 47.990 to 48.000 mm (1.8894 to 1.8898 in.) SS SS–12 SERVICE SPECIFICATIONS – 2AZ-FE ENGINE MECHANICAL Crankshaft bearing cap set bolt SS Standard diameter 7.3 to 7.5 mm (0.287 to 0.295 in.) Minimum diameter 7.2 mm (0.284 in.) SS–13 SERVICE SPECIFICATIONS – 2AZ-FE ENGINE MECHANICAL TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Engine mounting bracket No. 2 RH x Timing chain cover 52 531 38 Engine mounting bracket RH x Cylinder block 54 551 40 Engine moving control rod with bracket x Engine mounting bracket No. 2 RH 64 653 47 Engine moving control rod with bracket x Fender apron RH 64 653 47 Engine mounting stay No. 2 RH x Cylinder head 64 653 47 Engine mounting stay No. 2 RH x Engine mounting bracket No. 2 RH 64 653 47 Engine hanger No. 1 x Cylinder head 38 387 28 Engine hanger No. 2 x Cylinder head 38 387 28 ECT sensor x Cylinder head 20 204 15 Knock sensor x Cylinder block 20 204 15 Engine oil pressure switch assembly x Cylinder head 15 153 11 Water by-pass pipe No. 1 x Cylinder block 9.0 92 80 in.*lbf Oil cooler pipe x Cylinder block 9.0 92 80 in.*lbf Transverse engine engine mounting bracket x Cylinder block 54 551 40 Drive shaft bearing bracket x Cylinder block 64 653 47 V-ribbed belt tensioner assembly x Timing chain cover 60 607 44 Ignition coil assembly x Cylinder head 9.0 92 80 in.*lbf Engine cover x Cylinder head cover 7.0 71 62 in.*lbf 37 378 27 Exhaust manifold converter x Cylinder head Except PZEV 37 378 27 Exhaust manifold stay x Exhaust manifold converter For PZEV 44 449 32 Manifold converter insulator No. 1 x Exhaust manifold converter 12 122 9 Oil level gauge guide x Water by-pass pipe No. 1 9.0 92 80 in.*lbf Intake manifold x Cylinder head 30 306 22 Drive plate and ring gear (A/T) x Crankshaft 98 1,000 72 Flywheel sub-assembly (M/T) x Crankshaft 130 1,330 96 Engine mounting insulator LH x Automatic transaxle assembly 95 969 70 143 1,459 105 95 969 70 Engine mounting insulator LH x Manual transaxle assembly Engine mounting insulator RH x Engine mounting bracket RH Nut A Engine mounting insulator RH x Frame Nut B Engine mounting insulator FR x Engine mounting bracket FR 87 888 64 87 888 64 Engine mounting bracket rear No. 2 x Engine lateral control rod (M/T) 89 910 66 Vane pump assembly x Timing chain cover 43 439 32 Frame side plate x Front frame assembly Bolt A 85 867 63 Frame side plate x Body Bolt B 32 326 24 Front suspension member brace rear x Front frame assembly Bolt C 85 867 63 Front suspension member brace rear x Body Bolt D 32 326 24 Steering return tube clamp x Frame 8.0 80 69 in.*lbf Compressor and magnetic clutch x Cylinder block 25 250 18 Bolt 9.0 92 80 in.*lbf Nut 3.5 36 31 in.*lbf Speed sensor front LH (with ABS) x Steering knuckle 8.0 82 71 in.*lbf Speed sensor front RH (with ABS) x Steering knuckle 8.0 82 71 in.*lbf Air cleaner assembly x Body 5.0 51 44 in.*lbf Air cleaner inlet assembly x Body 5.0 51 44 in.*lbf 1st 22 220 16 2nd Turn 90° Turn 90° Turn 90° Battery clamp x Body Balanceshaft housing x Stiffening crankcase assembly SS SS–14 SERVICE SPECIFICATIONS – 2AZ-FE ENGINE MECHANICAL Part Tightened N*m Stiffening crankcase assembly x Cylinder block kgf*cm 245 ft.*lbf 18 with head taper screw plug No. 1 x Cylinder block 26 265 19 No. 1 oil nozzle sub-assembly x Cylinder block 7.0 71 62 in.*lbf Oil control valve filter x Cylinder block 30 306 22 Cylinder block water drain cock x Stiffening crankcase assembly 25 13 255 130 18 9 1st 79 806 58 2nd Cylinder head x Cylinder block SS 24 Turn 90° Turn 90° Turn 90° Camshaft timing gear assembly x Camshaft 54 551 40 Camshaft timing sprocket x Camshaft 54 551 40 Camshaft bearing cap No. 1 x Cylinder head 30 301 22 Camshaft bearing cap No. 2 x Cylinder head 30 301 22 Camshaft bearing cap No. 3 x Cylinder head 9.0 92 80 in.*lbf Oil pump assembly x Stiffening crankcase assembly 19 194 14 Chain tensioner plate x Stiffening crankcase assembly 12 122 9 Oil pump drive sprocket x Oil pump 30 301 22 Chain vibration damper No. 1 x Cylinder head 9.0 92 80 in.*lbf Chain vibration damper No. 1 x Cylinder block 9.0 92 80 in.*lbf Chain tensioner slipper x Cylinder block 19 194 14 Timing chain guide x Crankshaft bearing cap No. 1 9.0 92 80 in.*lbf Oil pan x Stiffening crankcase assembly 9.0 92 80 in.*lbf 25 255 18 9.0 92 80 in.*lbf Oil pan drain plug x Oil pan Timing chain cover x Cylinder block, Cylinder head Bolt A Bolt B 25 255 18 Bolt C 55 561 41 Nut Crankshaft position sensor x Timing chain cover Crankshaft pulley x Crankshaft TMMK made TMC made 11 112 8 9.0 92 80 in.*lbf 170 1,733 125 180 1,835 133 Chain tensioner assembly No. 1 x Timing chain cover 9.0 92 80 in.*lbf Camshaft position sensor x Cylinder head 9.0 92 80 in.*lbf Radio setting condenser x Cylinder head 10 102 7 Cylinder head cover x Cylinder head Bolt A 11 112 8 Bolt B 14 143 10 Nut Cylinder head cover x Engine wire Oil filter union x Stiffening crankcase assembly Oil filter union x Stiffening crankcase assembly (with Oil cooler) 11 112 8 8.4 86 74 in.*lbf 30 306 22 Oil filter union 79 806 58 Nut 9.0 92 80 in.*lbf Union bolt Oil filter x Oil filter union 25 255 18 13 133 10 Spark plug x Cylinder head 19 194 14 Ventilation valve x Cylinder head cover 19 194 14 No. 1 exhaust pipe support bracket x Body Bolt A Stud bolt 19 194 14 5 51 44 in.*lbf Bolt B 5 51 44 in.*lbf Bolt C 9.5 97 84 in.*lbf Bolt D 9.5 97 84 in.*lbf SS–15 SERVICE SPECIFICATIONS – 2AZ-FE ENGINE MECHANICAL Part Tightened Stud bolt Crankshaft bearing cap x Cylinder block Connecting rod cap x Connecting rod N*m kgf*cm ft.*lbf Bolt A 5.0 51 44 in.*lbf Bolt B 22 220 16 Bolt C 9.5 97 84 in.*lbf Bolt D 5.0 51 44 in.*lbf 1st 20 204 15 2nd 40 408 29 3rd Turn 90° Turn 90° Turn 90° 1st 25 250 18 2nd Turn 90° Turn 90° Turn 90° SS SERVICE SPECIFICATIONS – 2GR-FE ENGINE MECHANICAL SS–15 2GR-FE ENGINE MECHANICAL SERVICE DATA Ignition timing Terminals TC and CG of DLC3 connected 8 to 12° BTDC at idle (Transmission in neutral) Terminals TC and CG of DLC3 5 to 15° BTDC at idle (Transmission in neutral) disconnected Idle speed Compression 600 to 700 rpm (Transmission in neutral) Compression pressure Minimum pressure Difference between each cylinder 1.4 MPa (14 kgf/cm2, 199 psi) or more 0.98 MPa (10 kgf/cm2, 142 psi) 0.1 MPa (1.0 kgf/cm2, 15 psi) or less Cylinder head set bolt Outside diameter Standard 10.85 to 11.00 mm (0.4272 to 0.4331 in.) Minimum 10.70 mm (0.4213 in.) Maximum 136.9 mm (5.390 in.) Maximum 137.6 mm (5.417 in.) Minimum 61.4 mm (2.417 in.) Minimum 61.4 mm (2.417 in.) Chain Elongation No. 2 chain Elongation Crankshaft timing gear Diameter (w/ chain) Idle sprocket Diameter (w/ chain) Idle gear shaft Idle gear shaft diameter 22.987 to 23.000 mm (0.9050 to 0.9055 in.) Idle gear inside diameter Oil clearance 23.020 to 30.030 mm (0.9063 to 0.9067 in.) Standard 0.020 to 0.043 mm (0.0008 to 0.0017 in.) Maximum 0.093 mm (0.0037 in.) Maximum 0.9 mm (0.035 in.) Maximum 0.9 mm (0.035 in.) Maximum 1.0 mm (0.039 in.) Maximum 1.0 mm (0.039 in.) Maximum 1.0 mm (0.039 in.) Chain tensioner assembly No. 2 Worn depth Chain tensioner assembly No. 3 Worn depth Chain tensioner slipper Worn depth Chain vibration damper No. 1 Worn depth Chain vibration damper No. 2 Worn depth Cylinder head sub-assembly Warpage Cylinder head lower 0.05 mm (0.0020 in.) Intake 0.08 mm (0.0031 in.) Exhaust 0.08 mm (0.0031 in.) Maximum 0.10 mm (0.0039 in.) Intake valve Valve stem diameter Margin thickness Overall length 5.470 to 5.485 mm (0.2154 to 0.2159 in.) Standard 1.0 mm (0.039 in.) Maximum 0.5 mm (0.0197 in.) Standard 105.85 mm (4.1673 in.) Maximum 105.35 mm (4.1476 in.) Exhaust valve Valve stem diameter 5.465 to 5.480 mm (0.2152 to 0.2158 in.) SS SS–16 Margin thickness Overall length SERVICE SPECIFICATIONS – 2GR-FE ENGINE MECHANICAL Standard 1.0 mm (0.0394 in.) Maximum 0.5 mm (0.0197 in.) Standard 111.40 mm (4.3858 in.) Maximum 109.90 mm (4.3268 in.) Inner compression spring Free length SS 45.46 mm (1.7898 in.) Deviation Maximum 1.0 mm (0.039 in.) Angle (reference) Maximum 2° Intake valve guide bush Inside diameter Oil clearance Bush bore diameter 5.510 to 5.530 mm (0.2169 to 0.2177 in.) Standard 0.025 to 0.060 mm (0.0010 to 0.0024 in.) Maximum 0.08 mm (0.0031 in.) Use STD 10.285 to 10.306 mm (0.4049 to 0.4057 in.) Use O/S 0.05 10.335 to 10.356 mm (0.4069 to 0.4077 in.) Protrusion height 9.3 to 9.7 mm (0.3661 to 0.3819 in.) Exhaust valve guide bush Inside diameter Oil clearance Bush bore diameter 5.510 to 5.530 mm (0.2169 to 0.2177 in.) Standard 0.030 to 0.065 mm (0.0012 to 0.0026 in.) Maximum 0.10 mm (0.0039 in.) Use STD 10.285 to 10.306 mm (0.4049 to 0.4057 in.) Use O/S 0.05 10.335 to 10.356 mm (0.4069 to 0.4077 in.) Protrusion height 9.30 to 9.70 mm (0.3661 to 0.3819 in.) No. 1 camshaft Journal diameter Circuit runout Cam lobe height No. 1 journal 35.946 to 35.960 mm (1.4152 to 1.4157 in.) Other journals 25.959 to 25.975 mm (1.0220 to 1.0226 in.) Maximum Standard Maximum Oil clearance Thrust clearance 0.04 mm (0.0016 in.) 44.316 to 44.416 mm (1.7447 to 1.7487 in.) 44.166 mm (1.7388 in.) Standard No. 1 journal 0.040 to 0.079 mm (0.0016 to 0.0031 in.) Other journals 0.025 to 0.062 mm (0.0010 to 0.0024 in.) Maximum No. 1 journal 0.10 mm (0.0039 in.) Other journals 0.09 mm (0.0035 in.) Standard Maximum 0.08 to 0.13 mm (0.0031 to 0.0051 in.) 0.15 mm No. 2 camshaft Journal diameter Circuit runout Cam lobe height No. 1 journal 35.946 to 35.960 mm (1.4152 to 1.4157 in.) Other journals 25.959 to 25.975 mm (1.0220 to 1.0226 in.) Maximum Standard Maximum Oil clearance Thrust clearance 0.04 mm (0.0016 in.) 44.262 to 44.362 mm (1.7426 to 1.7465 in.) 44.112 mm (1.7367 in.) Standard No. 1 journal 0.040 to 0.079 mm (0.0016 to 0.0031 in.) Other journals 0.025 to 0.062 mm (0.0010 to 0.0024 in.) Maximum No. 1 journal 0.10 mm (0.0039 in.) Other journals 0.09 mm (0.0035 in.) Standard Maximum 0.08 to 0.13 mm (0.0031 to 0.0051 in.) 0.15 mm No. 3 camshaft Journal diameter Circuit runout No. 1 journal 35.946 to 35.960 mm (1.4152 to 1.4157 in.) Other journals 25.959 to 25.975 mm (1.0220 to 1.0226 in.) Maximum 0.04 mm (0.0016 in.) SERVICE SPECIFICATIONS – 2GR-FE ENGINE MECHANICAL Cam lobe height Standard Maximum Oil clearance SS–17 44.316 to 44.416 mm (1.7447 to 1.7487 in.) 44.166 mm (1.7388 in.) Standard No. 1 journal 0.040 to 0.079 mm (0.0016 to 0.0031 in.) Other journals 0.025 to 0.062 mm (0.0010 to 0.0024 in.) Maximum No. 1 journal 0.10 mm (0.0039 in.) Other journals Thrust clearance Standard Maximum 0.09 mm (0.0035 in.) 0.08 to 0.13 mm (0.0031 to 0.0051 in.) 0.15 mm No. 4 camshaft Journal diameter Circuit runout Cam lobe height No. 1 journal 35.946 to 35.960 mm (1.4152 to 1.4157 in.) Other journals 25.959 to 25.975 mm (1.0220 to 1.0226 in.) Maximum Standard Maximum Oil clearance 0.04 mm (0.0016 in.) 44.262 to 44.362 mm (1.7426 to 1.7465 in.) 44.112 mm (1.7367 in.) Standard No. 1 journal 0.040 to 0.079 mm (0.0016 to 0.0031 in.) Other journals 0.025 to 0.062 mm (0.0010 to 0.0024 in.) Maximum No. 1 journal 0.10 mm (0.0039 in.) Other journals Thrust clearance Standard Maximum 0.09 mm (0.0035 in.) 0.08 to 0.13 mm (0.0031 to 0.0051 in.) 0.15 mm Ring pin for cylinder head sub-assembly Protrusion height 2.5 to 3.5 mm (0.098 to 0.138 in.) Straight pin for cylinder head sub-assembly Protrusion height Connecting rod thrust clearance 17.5 to 19.5 mm (0.689 to 0.768 in.) Standard Maximum Connecting rod oil clearance Standard Maximum Crankshaft thrust clearance Standard Maximum Thrust washer thickness Cylinder block warpage Cylinder bore diameter Maximum Standard Maximum 0.15 to 0.40 mm (0.0059 to 0.0157 in.) 0.50 mm (0.020 in.) 0.045 to 0.067 mm (0.0018 to 0.0026 in.) 0.070 mm (0.0028 in.) 0.04 to 0.24 mm (0.0016 to 0.0094 in.) 0.30 mm (0.0118 in.) 2.43 to 2.48 mm (0.0957 to 0.0976 in.) 0.07 mm (0.0028 in.) 94.000 to 94.012 mm (3.7008 to 3.7013 in.) 94.200 mm (3.7087 in.) Piston diameter Distance Standard Maximum Oil clearance Standard 9.8 mm (0.3858 in.) 93.960 to 93.980 mm (3.6992 to 3.7000 in.) 93.830 mm (3.6941 in.) 0.02 to 0.052 mm (0.0008 to 0.0020 in.) Maximum 0.06 mm Connecting rod out-of alignment Maximum 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) Connecting rod twist Maximum 0.15 mm (0.0059 in.) per 100 mm (3.94 in.) Piston pin hole inside diameter 22.001 to 22.010 mm (0.8662 to 0.8665 in.) Piston pin diameter 21.997 to 22.006 mm (0.8660 to 0.8664 in.) Oil clearance Standard Maximum Connecting rod bushing inside diameter Oil clearance 0.001 to 0.007 mm (0.00004 to 0.00028 in.) 0.015 mm (0.0006 in.) 22.005 to 22.014 mm (0.8663 to 0.8667 in.) Standard Maximum 0.005 to 0.011 mm (0.0002 to 0.0004 in.) 0.03 mm (0.0012 in.) SS SS–18 SERVICE SPECIFICATIONS – 2GR-FE ENGINE MECHANICAL Piston ring groove clearance Piston ring end gap SS No. 1 0.020 to 0.070 mm (0.0008 to 0.0028 in.) No. 2 0.020 to 0.060 mm (0.0008 to 0.0024 in.) Oil 0.070 to 0.150 mm (0.0028 to 0.0059 in.) Standard No. 1 No. 2 0.50 to 0.60 mm (0.0197 to 0.0236 in.) Oil (Side rail) 0.10 to 0.40 mm (0.0039 to 0.0157 in.) Maximum No. 1 0.50 mm (0.0197 in.) No. 2 0.85 mm (0.0335 in.) Oil (Side rail) Connecting rod bolt diameter Standard Maximum Crankshaft bearing cap set bolt diameter Crankshaft circle runout Standard Crankshaft oil clearance 7.0 mm (0.276 in.) 10.8 to 11.0 mm (0.4252 to 0.4331 in.) Maximum 10.7 mm (0.4213 in.) 0.06 mm (0.0024 in.) 60.988 to 61.000 mm (2.4011 to 2.4016 in.) Maximum Crank pin diameter Crank pin taper and out-of-round 0.60 mm (0.0236 in.) 7.2 to 7.3 mm (0.283 to 0.287 in.) Maximum Main journal diameter Main journal taper and out-of-round 0.25 to 0.35 mm (0.0098 to 0.0138 in.) 0.02 mm (0.0008 in.) 52.992 to 53.000 mm (2.0863 to 2.0866 in.) Maximum Standard Maximum 0.02 mm (0.0008 in.) 0.026 to 0.047 mm (0.0010 to 0.0019 in.) 0.050 mm (0.0020 in.) Straight pin for cylinder block sub-assembly Protrusion height Pin A 23 mm (0.906 in.) Pin B 6 mm (0.236 in.) Pin C 11 mm (0.433 in.) Pin D 9 mm (0.354 in.) SS–19 SERVICE SPECIFICATIONS – 2GR-FE ENGINE MECHANICAL TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Ignition coil assembly x Cylinder head cover sub-assembly 10 102 7 Engine hanger No. 1 x Cylinder head sub-assembly RH 33 337 24 Engine hanger No. 2 x Cylinder head sub-assembly LH 33 337 24 Engine mounting bracket RH x Cylinder block sub-assembly 54 551 40 Oil level gauge guide x Cylinder head sub-assembly 21 214 15 Idler pulley sub-assembly No. 2 x Timing chain cover sub-assembly 43 438 32 V-ribbed belt tensioner assembly x Cylinder block sub-assembly 43 438 32 Intake manifold x Cylinder head sub-assembly 21 214 15 Exhaust manifold sub-assembly RH x Cylinder head sub-assembly RH 21 214 15 Exhaust manifold sub-assembly LH x Cylinder head sub-assembly LH 21 214 15 Drive plate & ring gear sub-assembly x Crankshaft 83 850 61 Air cleaner case x Body 5.0 51 44 in.*lbf E.F.I engine coolant temperature x water by-pass joint RR 20 200 14 Bolt A 85 867 63 Bolt B 32 329 24 Bolt C 85 867 63 Bolt D 32 329 24 Manifold stay No. 2 x Exhaust manifold sub-assembly LH 34 347 25 Air cleaner inlet No. 1 x Body 5.0 51 44 in.*lbf Engine assembly w/ Transaxle x Body Air cleaner inlet assembly x Body Battery clamp x Body 5.0 51 44 in.*lbf Bolt 9.0 92 80 in.*lbf Nut 3.5 36 31 Steering intermediate shaft x Steering gear 35 360 26 Stabilizer link x Shock absorber 74 755 55 Tie rod assembly x Steering gear 49 500 36 Speed sensor front x Front axle 8.0 82 71 in.*lbf Front axle hub nut x Front drive shaft 294 2,998 217 Cooler compressor x V-ribbed belt tensioner 25 250 18 Bolt A 44 450 32 Bolt B 38 387 28 Engine mounting control bracket x Engine mounting bracket front No. 1 LH Engine assembly w/ Transaxle x Front frame assembly Nut 23 235 17 Bolt 87 887 64 Nut 95 969 70 Drive shaft bearing bracket x Cylinder block sub-assembly 64 650 47 Exhaust manifold heat insulator No. 2 x Exhaust manifold subassembly LH 8.5 87 75 in.*lbf Oil pressure switch x Oil pan sub-assembly 21 210 15 Engine mounting stay No. 2 RH x Intake manifold 21 214 15 Timing gear cover No. 2 x Chain cover sub-assembly 6.0 61 53 in.*lbf Engine mounting bracket front No. 1 LH x Chain cover 54 551 40 1st 10 102 7 2nd 16 163 12 Camshaft housing x Cylinder head sub-assembly 28 286 21 Chain tensioner No. 1 x Cylinder head sub-assembly 10 102 7 Chain tensioner No. 2 x Cylinder head sub-assembly 21 214 15 Chain tensioner No. 3 x Cylinder head sub-assembly 21 214 15 Camshaft bearing cap x Camshaft housing SS SS–20 SERVICE SPECIFICATIONS – 2GR-FE ENGINE MECHANICAL N*m kgf*cm ft.*lbf Camshaft timing gear assembly x Camshaft Part Tightened 100 1,020 74 Camshaft timing exhaust gear assembly x Camshaft 100 1,020 74 Engine rear oil seal retainer x Cylinder block sub-assembly 10 102 7 Knock sensor x Cylinder block sub-assembly 20 204 15 Water inlet pipe x Cylinder block sub-assembly 10 102 7 Cylinder head RH x Cylinder block subassembly SS Cylinder head sub-assembly LH x Cylinder block sub-assembly 1st 36 367 27 2nd Turn 90° Turn 90° Turn 90° 3nd Turn 90° Turn 90° Turn 90° Recessed head 1st 36 367 27 2nd Turn 90° Turn 90° Turn 90° 3nd Turn 90° Turn 90° Turn 90° 30 306 22 23 230 17 Idle gear No. 1 x Cylinder block sub-assembly 60 612 44 Timing chain cover plate x Timing chain cover sub-assembly 9.1 93 81 in.*lbf Areas 1: Bolt 21 214 15 14 mm (0.55 in.) head Chain vibration damper No. 1 x Cylinder block sub-assembly Timing chain cover sub-assembly x Cylinder head and block Areas 2: Bolt 21 214 15 Areas 3: Bolt and Nut 21 214 15 Areas 4: Bolt A 43 438 32 Areas 4: Except Bolt A 21 214 15 Water pump assembly x Timing chain cover sub-assembly 9.1 93 81 in.*lbf Oil pan baffle plate x Cylinder block sub-assembly 10 102 7 Oil pan stud bolt x Cylinder block and timing chain cover subassembly 10 102 7 Oil pan stud bolt x No. 2 oil pan sub-assembly 4.0 41 35 in.*lbf Oil strainer stud bolt x Timing chain cover sub-assembly 4.0 41 35 in.*lbf Oil strainer sub-assembly x Cylinder block and timing chain cover subassembly 10 102 7 10 102 7 21 214 15 10 102 7 Oil pan sub-assembly x Cylinder block and timing chain cover sub-assembly bolt A except bolt A Oil pan sub-assembly No. 2 x Oil pan sub-assembly Oil pan drain plug x Oil pan sub-assembly No. 2 40 408 30 Crankshaft pulley x Crankshaft 250 2,550 184 bolt A 21 214 15 except bolt A 10 102 7 Cylinder head cover sub-assembly x Cylinder head sub-assembly RH Cylinder head cover sub-assembly LH x Cylinder head sub-assembly LH Water outlet x Cylinder head sub-assembly bolt A 21 214 15 except bolt A 10 102 7 bolt 10 102 7 nut 10 104 8 Water inlet housing set nut 10 102 7 Water inlet set bolt and nut 10 102 7 Oil filter cap x Oil pan 25 255 18 Camshaft position sensor 10 102 7 SS–21 SERVICE SPECIFICATIONS – 2GR-FE ENGINE MECHANICAL Part Tightened Ventilation valve x Cylinder head cover sub-assembly LH N*m kgf*cm ft.*lbf 27 275 20 Oil pipe union x Cylinder block sub-assembly 65 663 48 Oil pipe union x Cylinder head cover sub-assembly 65 663 48 Oil pipe x Cylinder head sub-assembly 10 102 7 Crankshaft position sensor x Cylinder block sub-assembly 10 102 7 Camshaft timing oil control valve assembly x Cylinder head cover 10 102 7 Cylinder block water drain cock sub-assembly x Cylinder block subassembly 25 255 18 Drain cock sub-assembly x Water inlet housing 30 306 22 Water drain cock plug x Water drain cock sub-assembly 13 130 9 Drain cock plug x Drain cock sub-assembly 13 130 9 Spark plug x Cylinder head sub-assembly Stud bolt x Cylinder head sub-assembly 25 254 18 For A and B bolts 10 102 7 For C bolts 4.0 41 35 in.*lbf 44 449 32 80 816 59 61 622 45 Turn 90° Turn 90° Turn 90° 14 mm head 52 525 38 1st 25 255 18 2nd Turn 90° Turn 90° Turn 90° 10 102 7 17 173 13 9.0 92 80 in.*lbf W/ head screw plug x Cylinder head sub-assembly W/ head screw plug No. 2 x Cylinder head sub-assembly Main bearing cap x Cylinder block sub-assembly 16 pointed head 1st 2nd Connecting rod cap x Connecting rod Stud bolt x Cylinder block sub-assembly bolt A bolt B Sub-assembly oil nozzle No. 1 x Cylinder block sub-assembly SS SERVICE SPECIFICATIONS – 2AZ-FE FUEL SS–21 2AZ-FE FUEL SERVICE DATA Fuel pressure 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44.1 to 49.7 psi) Fuel pressure : at fuel pressure remains for 5 minutes after engine has stopped 147 kPa (1.5 kgf/cm3, 21 psi) or more Fuel injector Resistance at 20°C (68°F) 11.6 to 12.4 Ω 76 to 92 cm2 (4.6 to 5.6 cu in.) per 15 seconds Injection volume 2 Difference between each injector 16 cm (0.98 cu in.) or less Fuel drop 1 drop or less per 12 minutes Fuel pump Resistance at 20°C (68°F) 0.2 to 3.0 Ω SS SS–22 SERVICE SPECIFICATIONS – 2AZ-FE FUEL TORQUE SPECIFICATIONS Part Tightened Fuel delivery pipe x Cylinder head SS N*m kgf*cm ft.*lbf 20 204 15 Fuel pressure pulsation damper x Fuel delivery pipe 9.0 90 80 in.*lbf Fuel tank bent tube set plate x Fuel tank assembly 5.9 60 52 in.*lbf Fuel main tube support x Fuel tank assembly 5.4 55 48 in.*lbf Fuel tank band sub-assembly No. 1 x Body 39 400 29 Fuel tank protector lower center x Fuel tank assembly 5.4 55 48 in.*lbf 6.0 61 53 in.*lbf Parking brake cable assembly No. 2 x Body Bolt Nut 8.5 87 75 in.*lbf Parking brake cable assembly No. 3 x Body Bolt 6.0 61 53 in.*lbf Nut 8.5 87 75 in.*lbf 31 316 23 Stabilizer bar bracket x Suspension member SS–22 SERVICE SPECIFICATIONS – 2GR-FE FUEL 2GR-FE FUEL SERVICE DATA Fuel pressure 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44.1 to 49.7 psi) Fuel pressure : at fuel pressure remains for 5 minutes after engine has stopped 147 kPa (1.5 kgf/cm2, 21 psi) or more Fuel injector SS Resistance at 20°C (68°F) 11.6 to 12.4 Ω Injection volume 84 to 100 cm2 (5.1 to 6.0 cu in.) per 15 seconds Difference between each injector 16 cm3 (0.98 cu in.) or less Fuel drop 1 drop or less per 16 minutes Fuel pump Resistance at 20°C (68°F) 0.2 to 3.0 Ω SS–23 SERVICE SPECIFICATIONS – 2GR-FE FUEL TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf 21 214 15 Bolt 18 184 13 Nut 16 163 12 Intake air surge tank x Cylinder head 21 214 15 Vacuum hose clamp set bolt 5.4 55 48 in.*lbf Fuel delivery pipe sub-assembly x Intake manifold Intake air surge tank x Intake manifold Fuel tank bent tube set plate x Fuel tank assembly 5.9 60 52 in.*lbf Fuel main tube support x Fuel tank assembly 5.4 55 48 in.*lbf Fuel tank band sub-assembly No. 1 x Body 39 400 29 Fuel tank protector lower center x Fuel tank assembly 5.4 55 48 in.*lbf Bolt 6.0 61 53 in.*lbf Nut 8.5 87 75 in.*lbf Bolt 6.0 61 53 in.*lbf Nut 8.5 87 75 in.*lbf 31 316 23 Parking brake cable assembly No. 2 x Body Parking brake cable assembly No. 3 x Body Stabilizer bar bracket x Suspension member SS SERVICE SPECIFICATIONS – 2AZ-FE EMISSION CONTROL SS–23 2AZ-FE EMISSION CONTROL SERVICE DATA VSV for EVAP Resistance 1-2 26 to 30 Ω at 20°C (68°F) 1 - Body ground 10 MΩ or higher 2 - Body ground 10 MΩ or higher Air fuel ratio sensor Resistance 1 (HT) - 2 (+B) 1.8 to 3.4 Ω at 20°C (68°F) 1 (HT) - 2 (+B) 11 to 16 Ω at 20°C (68°F) Oxygen sensor Resistance SS SS–24 SERVICE SPECIFICATIONS – 2AZ-FE EMISSION CONTROL TORQUE SPECIFICATIONS Part Tightened SS N*m kgf*cm ft.*lbf Charcoal canister assembly x Body 39 398 29 Air fuel ratio sensor x Front pipe assembly 44 449 32 Oxygen sensor x Front pipe assembly 44 449 32 SS–24 SERVICE SPECIFICATIONS – 2GR-FE EMISSION CONTROL 2GR-FE EMISSION CONTROL SERVICE DATA VSV for EVAP Resistance SS 1-2 26 to 30 Ω at 20°C (68°F) 1 - Body ground 10 MΩ or higher 2 - Body ground 10 MΩ or higher Air fuel ratio sensor Resistance 1 (HT) - 2 (+B) 1.8 to 3.4 Ω at 20°C (68°F) 1 (HT) - 2 (+B) 11 to 16 Ω at 20°C (68°F) Oxygen sensor Resistance SS–25 SERVICE SPECIFICATIONS – 2GR-FE EMISSION CONTROL TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Charcoal canister assembly x Body 39 398 29 No. 1 Vacuum switching valve x Head cover 5.0 51 44 in.*lbf Air fuel ratio sensor x Front pipe assembly 44 449 32 Oxygen sensor x Front pipe assembly 44 449 32 SS SERVICE SPECIFICATIONS – 2GR-FE INTAKE SS–25 2GR-FE INTAKE SERVICE DATA Vacuum switching valve Resistance 1-2 37 to 44 Ω at 20°C (68°F) 1 - Body ground 10 kΩ or higher 2 - Body ground 10 kΩ or higher SS SS–26 SERVICE SPECIFICATIONS – 2AZ-FE EXHAUST 2AZ-FE EXHAUST SERVICE DATA Compression spring SS Minimum length: 38.5 mm (1.515 in.) SS–27 SERVICE SPECIFICATIONS – 2AZ-FE EXHAUST TORQUE SPECIFICATIONS 2AZ-FE: Part Tightened Center exhaust pipe assembly x Tail exhaust pipe assembly N*m kgf*cm ft.*lbf 43 438 32 Front exhaust pipe assembly x Exhaust manifold RH 62 632 46 Front exhaust pipe assembly x Exhaust manifold LH 62 632 46 Front exhaust pipe assembly x Center exhaust pipe assembly 56 571 41 Exhaust pipe damper x Center exhaust pipe assembly 19 194 14 Exhaust pipe No. 1 support bracket x Body 33 337 24 Front exhaust pipe No. 1 support bracket x Body 33 337 24 Rear exhaust pipe No. 1 support bracket x Body 33 337 24 Exhaust pipe support No. 4 x Body 33 337 24 Exhaust pipe No. 4 support bracket sub-assembly x Body 39 398 29 Exhaust pipe No. 4 support bracket sub-assembly x Body 39 398 29 Heated oxygen sensor (Bank 1 Sensor 2) x Front exhaust pipe assembly 44 449 32 Heated oxygen sensor (Bank 2 Sensor 2) x Front exhaust pipe assembly 44 449 32 SS SERVICE SPECIFICATIONS – 2GR-FE EXHAUST SS–27 2GR-FE EXHAUST SERVICE DATA Compression spring Minimum length: 38.5 mm (1.515 in.) SS SS–28 SERVICE SPECIFICATIONS – 2GR-FE EXHAUST TORQUE SPECIFICATIONS 2GR-FE: Part Tightened Center exhaust pipe assembly x Tail pipe assembly SS N*m kgf*cm ft.*lbf 43 438 32 Front exhaust pipe assembly x Exhaust manifold RH 62 632 46 Front exhaust pipe assembly x Exhaust manifold LH 62 632 46 Front exhaust pipe assembly x Center exhaust pipe assembly 56 571 41 Exhaust pipe damper x Center exhaust pipe assembly 19 194 14 Exhaust pipe No. 1 support bracket x Body 33 337 24 Front exhaust pipe No. 1 support bracket x Body 33 337 24 Rear exhaust pipe No. 1 support bracket x Body 33 337 24 Exhaust pipe support No. 4 x Body 33 337 24 Exhaust pipe No. 4 support bracket sub-assembly x Body 39 398 29 Exhaust pipe No. 4 support bracket sub-assembly x Body 39 398 29 Heated oxygen sensor (Bank 1 Sensor 2) x Front exhaust pipe assembly 44 449 32 Heated oxygen sensor (Bank 2 Sensor 2) x Front exhaust pipe assembly 44 449 32 SS–28 SERVICE SPECIFICATIONS – 2AZ-FE COOLING 2AZ-FE COOLING SERVICE DATA THERMOSTAT Condition SS Specified Condition Standard valve opening temperature 80 to 84 °C (176 to 183 °F) Standard valve lift 10 mm (0.39 in.) or more at 95 °C (203 °F) COOLING FAN MOTOR Item Condition Specified Condition Cooling fan motor (w/o Trailer hitch) at 20°C (68 °F) 7.9 to 10.9 A Cooling fan motor (w/ Trailer hitch) at 20°C (68 °F) 11.8 to 14.8 A No. 2 cooling fan motorr (w/o Trailer hitch) at 20°C (68 °F) 7.9 to 10.9 A No. 2 cooling fan motor (w/ Trailer hitch) at 20°C (68 °F) 7.9 to 10.9 A Item Tester Connection Specified Condition No. 1 fan relay 3-5 10 Ωor higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 3-4 Below 1 Ω 3-5 10 Ωor higher 3-4 10 Ωor higher (when battery voltage is applied to terminals 1 and 2) 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 3-5 10 Ωor higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) Item Condition Specified Condition Radiator reservoir cap For brand-new cap 93.3 to 122.7 kPa (0.95 to 1.25 kgf/cm2, 13.5 to 17.8 psi) After using cap 78.5 kPa (0.8 kgf/cm2, 11.4 psi) COOLING FAN RELAY No. 2 fan relay No. 3 fan relay RADIATOR SS–29 SERVICE SPECIFICATIONS – 2AZ-FE COOLING TORQUE SPECIFICATIONS COOLANT Part Tightened N*m kgf*cm ft.*lbf Cylinder block drain cock plug x Cylinder block 13 130 9 N*m kgf*cm ft.*lbf WATER PUMP Part Tightened Water pump x Cylinder block 9.0 92 80 in.*lbf Water pump pulley x Water pump 26 265 19 Part Tightened N*m kgf*cm ft.*lbf Water inlet x Cylinder block 9.0 92 80 in.*lbf THERMOSTAT RADIATOR Part Tightened Oil cooler assembly x Cooler pipe N*m kgf*cm ft.*lbf for Bolt A 15 150 11 for Nut B 8.3 85 73 in.*lbf Condenser assembly x Radiator assembly 5.4 55 48 in.*lbf Upper radiator support x Radiator support LH and RH 7.0 71 62 in.*lbf Upper radiator support x Hood lock assembly 7.5 77 66 in.*lbf SS SS–30 SERVICE SPECIFICATIONS – 2GR-FE COOLING 2GR-FE COOLING SERVICE DATA THERMOSTAT SS Condition Specified Condition Standard valve opening temperature 80 to 84°C (176 to 183°F) Standard valve lift 7.7 mm (0.3031 in.) or more at 95°C (203°F) COOLING FAN MOTOR Item Condition Specified Condition Cooling fan motor (w/o Trailer hitch) at 20°C (68°F) 6.8 to 9.8 A Cooling fan motor (w/ Trailer towing system) at 20°C (68°F) 11.8 to 14.8 A No. 2 cooling fan motor (w/o Trailer hitch) at 20°C (68°F) 6.8 to 9.8 A No. 2 cooling fan motor (w/ Trailer hitch) at 20°C (68°F) 6.8 to 9.8 A Item Condition Specified Condition Cooling fan ECU Ignition switch on (IG). Turn the ignition switch to the ON position. 9 to 14 V Item Tester Connection Specified Condition Cooling fan relay 3-5 10 Ω or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) Item Tester Connection Specified Condition Radiator reservoir cap For brand-new cap 93.3 to 122.7 kPa (0.95 to 1.25 kgf/cm2, 13.5 to 17.8 psi) After using cap 78.5 kPa (0.8 kgf/cm2, 11.4 psi) COOLING FAN ECU COOLING FAN RELAY RADIATOR SS–31 SERVICE SPECIFICATIONS – 2GR-FE COOLING TORQUE SPECIFICATIONS COOLANT Part Tightened N*m kgf*cm ft.*lbf Cylinder block drain cock plug x Cylinder block 13 130 9 WATER PUMP Part Tightened N*m kgf*cm ft.*lbf for bolt A 21 214 15 for bolt B 9.1 93 81 in.*lbf for bolt C 9.1 93 81 in.*lbf V-ribbed belt tensioner assembly x Cylinder block 43 438 32 No. 2 idler pulley sub-assembly x Cylinder block 43 438 32 Water pump pulley x Water pump 21 214 15 Water inlet housing x Cylinder block 10 102 7 Radiator reservoir tank x Body 5.0 51 44 in.*lbf Water pump x Cylinder block THERMOSTAT Part Tightened N*m kgf*cm ft.*lbf Water inlet x Water inlet housing 10 102 7 RADIATOR Part Tightened Oil cooler assembly x Cooler pipe N*m kgf*cm ft.*lbf for Bolt A 15 150 11 for Nut B 8.3 85 73 in.*lbf Condenser assembly x Radiator assembly 5.0 51 44in.*lbf Radiator support upper x Radiator support LH and RH 7.0 71 62 in.*lbf Radiator support upper x Hood lock assembly 7.5 77 66 in.*lbf SS SS–32 SERVICE SPECIFICATIONS – 2AZ-FE LUBRICATION 2AZ-FE LUBRICATION SERVICE DATA OIL PRESSURE SS Condition Specified Condition Idle 29 kPa (0.3 kgf/cm2, 4.3 psi) or more 3,000 rpm 170 to 300 kPa (1.7 to 3.1 kgf/cm2, 24 to 44 psi) OIL PUMP Item Condition Specified Condition Oil pump rotor Standard side clearance 0.030 to 0.085 mm (0.0012 to 0.0033 in.) Maximum side clearance 0.16 mm (0.0063 in.) Standard tip clearance 0.080 to 0.160 mm (0.0031 to 0.0063 in.) Maximum tip clearance 0.35 mm (0.0138 in.) Standard body clearance 0.100 to 0.170 mm (0.0039 to 0.0067 in.) Maximum body clearance 0.325 mm (0.01128 in.) Oil pump drive chain Maximum chain elongation 52.4 mm (2.063 in.) Oil pump sprocket Minimum crankshaft sprocket diameter (with chain) 48.2 mm (1.898 in.) Minimum oil pump drive shaft sprocket 48.2 mm (1.898 in.) Maximum wear 0.5 mm (0.020 in.) Chain tensioner plate SS–33 SERVICE SPECIFICATIONS – 2AZ-FE LUBRICATION TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Oil filter x Stiffening crankcase 13 133 10 Oil drain plug x Oil pan 25 255 18 Oil pump cover x Oil pump 8.8 90 78 in.*lbf Oil pump relief valve x Oil pump 49 500 36 Oil pump strainer x Oil pump 8.8 90 78 in.*lbf Oil pump X Cylinder block 19 194 14 15 153 11 9.0 92 80 in.*lbf Oil pressure switch x Cylinder block Timing chain cover x Cylinder block, Cylinder head Bolt A Bolt B 25 255 18 Bolt C 55 561 41 Nut 11 112 8 22 220 16 Stud bolt x Cylinder block Oil cooler x Cylinder block Union bolt 79 800 58 Nut 9.0 92 80 in.*lbf SS SERVICE SPECIFICATIONS – 2GR-FE LUBRICATION SS–33 2GR-FE LUBRICATION SERVICE DATA OIL PRESSURE Condition Specified Condition Idle 80 kPa (0.8 kgf/cm2, 11.6 psi) or more 3,000 rpm 380 kPa (3.9 kgf/cm2, 55.5 psi) or more OIL PUMP Item Condition Specified Condition Oil pump rotor Standard side clearance 0.030 to 0.090 mm (0.0012 to 0.0035 in.) Maximum side clearance 0.090 mm (0.0035 in.) Standard tip clearance 0.060 to 0.160 mm (0.0024 to 0.0063 in.) Maximum tip clearance 0.16 mm (0.0063 in.) Standard body clearance 0.250 to 0.325 mm (0.0098 to 0.0128 in.) Maximum body clearance 0.325 mm (0.01128 in.) SS SS–34 SERVICE SPECIFICATIONS – 2GR-FE LUBRICATION TORQUE SPECIFICATIONS Part Tightened SS N*m kgf*cm ft.*lbf Oil pressure switch x Oil pan 15 153 11 Oil filter cap x Oil pan 25 255 18 Oil filter drain plug x Oil filter cap 13 127 10 Oil pan drain plug x No. 2 oil pan 40 408 30 Oil pump cover x Timing chain cover 9.1 93 81 in.*lbf Plug X Oil pump cover 49 500 37 Timing chain cover x Cylinder block, Cylinder head, Oil pan Area 1, 2 Bolt 21 214 15 Area 3 bolt, nut 21 214 15 Area 4 Bolt A 43 438 32 Area 4 except bolt A 21 214 15 SS–34 SERVICE SPECIFICATIONS – 2AZ-FE IGNITION 2AZ-FE IGNITION SERVICE DATA Spark Plug SS Standard electrode gap 1.0 to 1.1 mm (0.039 to 0.043 in.) for new spark plug Maximum electrode gap 1.3 mm (0.051 in.) for used spark plug SS–35 SERVICE SPECIFICATIONS – 2AZ-FE IGNITION TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Spark plug x Cylinder head subassembly 19 194 14 Ignition coil assembly x Cylinder head cover 9.0 92 80 in.*lbf SS SERVICE SPECIFICATIONS – 2GR-FE IGNITION SS–35 2GR-FE IGNITION SERVICE DATA Spark plug Standard electrode gap 1.0 to 1.1 mm (0.039 to 0.043 in.) for new spark plug Maximum electrode gap 1.4 mm (0.055 in.) for used spark plug SS SS–36 SERVICE SPECIFICATIONS – 2GR-FE IGNITION TORQUE SPECIFICATIONS Part Tightened SS N*m kgf*cm ft.*lbf Spark plug x Cylinder head subassembly 18 184 13 Ignition coil assembly x Cylinder head cover 7.5 76 66 in.*lbf SS–36 SERVICE SPECIFICATIONS – 2AZ-FE STARTING 2AZ-FE STARTING SERVICE DATA Starter assembly Rated voltage and output power 12 V 1.7 kW Specified current 90 A or less at 11.5 V Starter armature assembly SS Brush length Starter relay Specified condition Standard depth 3.1 mm (0.122 in.) Minimum depth 3.8 mm (0.150 in.) Standard length 9.0 mm (0.354 in.) Minimum length 4.0 mm (0.157 in.) 1-2 Below 1 Ω 3-5 10 kΩ or higher LOCK: Between all terminals 10 kΩ or higher ACC: 2 (ACC) - 4 (AM1) ON: 1 (IG1) - 2 (ACC) - 4 (AM1) Ignition switch Resistance ON: 5 (AM2) - 6 (IG2) START: 1 (ST1) - 3 (ST1) - 4 (AM1) START: 5 (AM2) - 6 (IG2) - 7 (ST2) Below 1 Ω SS–37 SERVICE SPECIFICATIONS – 2AZ-FE STARTING TORQUE SPECIFICATIONS Part Tightened Starter x Engine N*m kgf*cm ft.*lbf Bolt 37 380 28 Terminal 30 9.8 100 87 in.*lbf Terminal C 10 102 7 Starter x Clutch flexible hose bracket Bolt 12 120 9 Starter commutator end frame assembly x Starter yoke assembly Bolt 6.0 61 53 in.*lbf Magnetic switch x Starter drive housing Screw 7.5 76 66 in.*lbf SS SS–37 SERVICE SPECIFICATIONS – 2GR-FE STARTING 2GR-FE STARTING SERVICE DATA Starter assembly Rated voltage and output power 12 V 1.7 kW Specified current 90 A or less at 11.5 V Starter armature assembly Brush length Starter relay Specified condition Standard depth 3.1 mm (0.122 in.) Minimum depth 3.8 mm (0.150 in.) Standard length 9.0 mm (0.354 in.) Minimum length 4.0 mm (0.157 in.) 1-2 Below 1 Ω 3-5 10 kΩ or higher LOCK: Between all terminals 10 kΩ or higher ACC: 2 (ACC) - 4 (AM1) ON: 1 (IG1) - 2 (ACC) - 4 (AM1) Ignition switch Resistance ON: 5 (AM2) - 6 (IG2) START: 1 (ST1) - 3 (ST1) - 4 (AM1) Below 1 Ω START: 5 (AM2) - 6 (IG2) - 7 (ST2) Pushed: 7 (SS1) - 5 (GND) Engine switch Resistance Pushed: 2 (SS2) - 5 (GND) Not pushed: 7 (SS1) - 5 (GND) Not pushed: 2 (SS2) - 5 (GND) Below 1 Ω 10 kΩ or higher SS SS–38 SERVICE SPECIFICATIONS – 2GR-FE STARTING TORQUE SPECIFICATIONS Part Tightened Starter x Engine SS N*m kgf*cm ft.*lbf Bolt 37 380 28 Terminal 30 9.8 100 87 in.*lbf Terminal C 10 102 7 Starter commutator end frame assembly x Starter yoke assembly Bolt 6.0 61 53 in.*lbf Magnetic switch x Starter drive housing Screw 7.5 76 66 in.*lbf SS–38 SERVICE SPECIFICATIONS – 2AZ-FE CHARGING 2AZ-FE CHARGING SERVICE DATA Charging circuit without load Charging circuit with load Brush length SS Standard amperage: 10 A or less Standard voltage: 13.2 to 14.8 V Standard amperage: 30 A or more Standard exposed length: 9.5 to 11.5 mm (0.374 to 0.453 in.) Minimum exposed length: 4.5 mm (0.177 in.) Slip rings resistance: 2.3 to 2.7 kΩ at 20°C (68°F) Generator rotor assembly Standard slip ring diameter: 14.2 to 14.4 mm (0.559 to 0.567 in.) Minimum slip ring diameter: 14.0 mm (0.551 in.) SS–39 SERVICE SPECIFICATIONS – 2AZ-FE CHARGING TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Bearing retainer plate x Generator drive end frame 2.3 23 20 in.*lbf Generator coil assembly x Generator drive end frame 5.8 59 51 in.*lbf Generator brush holder assembly x Generator coil assembly 1.8 18 16 in.*lbf Generator rear end cover x Generator coil assembly 4.6 47 41 in.*lbf Clutch pulley x Generator rotor assembly 111 1,125 81 Generator assembly x Cord clip 4.6 47 41 in.*lbf Generator assembly x Wire harness bracket 8.4 86 74 in.*lbf Bolt A: Generator assembly x Cylinder block 21 215 16 Bolt B: Generator assembly x Cylinder block 52 530 38 Generator wire x Terminal B 9.8 100 87 in.*lbf SS SERVICE SPECIFICATIONS – 2GR-FE CHARGING SS–39 2GR-FE CHARGING SERVICE DATA Charging circuit without load Charging circuit with load Brush length Standard amperage: 10 A or less Standard voltage: 12.1 to 15.4 V Standard amperage: 30 A or more Standard exposed length: 9.5 to 11.5 mm (0.374 to 0.453 in.) Minimum exposed length: 4.5 mm (0.177 in.) Slip rings resistance: 2.3 to 2.7 kΩ at 20°C (68°F) Generator rotor assembly Standard slip ring diameter: 14.2 to 14.4 mm (0.559 to 0.567 in.) Minimum slip ring diameter: 14.0 mm (0.551 in.) SS SS–40 SERVICE SPECIFICATIONS – 2GR-FE CHARGING TORQUE SPECIFICATIONS Part Tightened SS N*m kgf*cm ft.*lbf Bearing retainer plate x Generator drive end frame 2.3 23 20 in.*lbf Generator coil assembly x Generator drive end frame 5.8 59 51 in.*lbf Generator brush holder assembly x Generator coil assembly 1.8 18 16 in.*lbf Generator rear end cover x Generator coil assembly 4.6 47 41 in.*lbf Clutch pulley x Generator rotor assembly 111 1,125 81 Generator assembly x Generator bracket 20 204 15 Cylinder block x Generator bracket 20 204 15 Generator assembly x wire harness clamp stay 8.4 86 74 in.*lbf Generator assembly x Cylinder block 43 438 32 Bolt B: Generator assembly x Cylinder block 52 530 38 Generator wire x Terminal B 9.8 100 87 in.*lbf SS–40 SERVICE SPECIFICATIONS – U250E AUTOMATIC TRANSAXLE U250E AUTOMATIC TRANSAXLE SERVICE DATA Line pressure (Wheel locked) D position 372 to 412 kPa (3.8 to 4.2 kgf*cm2, 54 to 60 psi) R position 672 to 742 kPa (6.8 to 7.5 kgf*cm2, 97 to 108 psi) D position 931 to 1,031 kPa (9.5 to 10.5 kgf*cm2, 135 to 150 psi) R position 1,768 to 1,968 kPa (18.0 to 20.0 kgf*cm2, 256 to 285 psi) D position 2,160 to 2,460 rpm N → D position Less than 1.2 seconds N → R position Less than 1.5 seconds Engine idle speed (A/C OFF) N position 650 to 750 rpm Drive plate runout Maximum 0.20 mm (0.0079 in.) Engine idling SS AT stall (Throttle valve fully open) Engine stall revolution Time lag Torque converter runout Differential oil seal drive in depth Maximum 0.30 mm (0.0118 in.) Transaxle housing oil seal - 0.5 to 0.5 mm (-0.020 to 0.020 in.) Differential side bearing retainer oil seal - 0.5 to 0.5 mm (-0.020 to 0.020 in.) 1→2 47 to 54 km/h (29 to 34 mph) 2→3 92 to 101 km/h (57 to 63 mph) 3→4 145 to 160 km/h (90 to 99 mph) 4→5 208 to 226 km/h (129 to 140 mph) 5→4 201 to 218 km/h (125 to 135 mph) 4→3 137 to 151 km/h (85 to 94 mph) 3→2 84 to 93 km/h (52 to 58 mph) 2→1 34 to 40 km/h (21 to 25 mph) 4→5 68 to 75 km/h (42 to 47 mph) 5→4 36 to 42 km/h (22 to 26 mph) 1→2 47 to 54 km/h (29 to 34 mph) 2→3 92 to 101 km/h (57 to 63 mph) 4→3 141 to 155 km/h (85 to 94 mph) 3→2 84 to 93 km/h (52 to 58 mph) 2→1 34 to 40 km/h (21 to 25 mph) 1→2 47 to 54 km/h (29 to 34 mph) 3→2 89 to 98 km/h (52 to 58 mph) 2→1 34 to 40 km/h (21 to 25 mph) 2→1 40 to 46 km/h (25 to 29 mph) Lock-up ON 76 to 84 km/h (47 to 52 mph) Shift schedule D position (Normal) Throttle valve fully open Throttle valve fully closed 3 position Throttle valve fully open 2 position Throttle valve fully open L position Throttle valve fully open Lock-up point (Throttle valve opening 5%) D position 5th gear 4th gear Flex lock-up point (Throttle valve opening 5%) D position Lock-up OFF 75 to 82 km/h (47 to 51 mph) Lock-up ON 76 to 85 km/h (47 to 53 mph) Lock-up OFF 75 to 82 km/h (47 to 51 mph) SERVICE SPECIFICATIONS – U250E AUTOMATIC TRANSAXLE 5th gear 4th gear Lock-up ON 56 to 63 km/h (35 to 39 mph) Lock-up OFF 55 to 62 km/h (34 to 39 mph) Lock-up ON 41 to 47 km/h (25 to 29 mph) Lock-up OFF 40 to 46 km/h (25 to 29 mph) STD 0.10 to 0.17 mm (0.0039 to 0.0067 in.) Maximum 0.17 mm (0.0067 in.) STD 0.07 to 0.15 mm (0.0028 to 0.0059 in.) Maximum 0.15 mm (0.0059 in.) STD 0.02 to 0.05 mm (0.0008 to 0.0020 in.) SS–41 Oil pump Body clearance Tip clearance Side clearance Drive gear thickness Driven gear thickness Pump body bushing inside diameter Stator shaft bushing inside diameter Maximum 0.05 mm (0.0020 in.) Mark A 11.690 to 11.699 mm (0.4602 to 0.4606 in.) Mark B 11.700 to 11.709 mm (0.4606 to 0.4610 in.) Mark C 11.710 to 11.720 mm (0.4610 to 0.4614 in.) Mark D 11.721 to 11.730 mm (0.4615 to 0.4618 in.) Mark E 11.731 to 11.740 mm (0.4619 to 0.4622 in.) Mark A 11.690 to 11.699 mm (0.4602 to 0.4606 in.) Mark B 11.700 to 11.709 mm (0.4606 to 0.4610 in.) Mark C 11.710 to 11.720 mm (0.4610 to 0.4614 in.) Mark D 11.721 to 11.730 mm (0.4615 to 0.4618 in.) Mark E 11.731 to 11.740 mm (0.4619 to 0.4622 in.) STD 38.113 to 38.138 mm (1.50050 to 1.50149 in.) Maximum 38.188 mm (1.50346 in.) STD 21.500 to 21.526 mm (0.84646 to 0.84748 in.) Maximum 21.57 mm (0.8492 in.) Multiple disc clutch hub Inside diameter STD 23.025 to 23.046 mm (0.9065 to 0.9073 in.) Maximum 23.09 mm (0.9091 in.) STD 23.025 to 23.046 mm (0.9065 to 0.9073 in.) Maximum 23.09 mm (0.9091 in.) Over direct clutch drum sub-assembly Inside diameter Forward clutch Pack clearance 0.85 to 1.25 mm (0.0335 to 0.0492 in.) Return spring free length 26.74 mm (1.0528 in.) Flange thickness Mark 0 2.85 mm (0.1122 in.) Mark 1 3.00 mm (0.1181 in.) Mark 2 3.15 mm (0.1240 in.) Mark 3 3.30 mm (0.1299 in.) Mark 4 3.45 mm (0.1358 in.) Mark 5 3.60 mm (0.1417 in.) Mark 6 3.75 mm (0.1476 in.) Reverse clutch Pack clearance 0.60 to 0.82 mm (0.02362 to 0.03228 in.) SS SS–42 SERVICE SPECIFICATIONS – U250E AUTOMATIC TRANSAXLE Flange thickness SS Mark 0 2.9 mm (0.114 in.) Mark 1 3.0 mm (0.118 in.) Mark 2 3.1 mm (0.122 in.) Mark 3 3.2 mm (0.126 in.) Mark 4 3.3 mm (0.130 in.) Mark 5 3.4 mm (0.134 in.) Mark 6 3.5 mm (0.138 in.) Mark 7 3.6 mm (0.142 in.) Direct clutch and O/D clutch Pack clearance 0.52 mm (0.02047 in.) Return spring free length Flange thickness 25.91 mm (1.0201 in.) Mark 0 2.5 mm (0.098 in.) Mark 1 2.6 mm (0.102 in.) Mark 2 2.7 mm (0.106 in.) Mark 3 2.8 mm (0.110 in.) Mark 4 2.9 mm (0.114 in.) Mark 5 3.0 mm (0.118 in.) Mark 6 3.1 mm (0.122 in.) 2nd brake Pack clearance 0.53 to 0.91 mm (0.0209 to 0.0358 in.) Return spring free length Flange thickness 16.61 mm (0.6539 in.) Mark 0 2.9 mm (0.114 in.) Mark 1 3.0 mm (0.118 in.) Mark 2 3.1 mm (0.122 in.) Mark 3 3.2 mm (0.126 in.) Mark 4 3.3 mm (0.130 in.) Mark 5 3.4 mm (0.134 in.) Mark 6 3.5 mm (0.138 in.) Mark 7 3.6 mm (0.142 in.) Mark 8 3.7 mm (0.146 in.) 2nd brake piston Inside diameter More than 167 mm (6.57 in.) U/D clutch Pack clearance U/D clutch drum bushing inside diameter 1.42 to 1.71 mm (0.0559 to 0.0673 in.) STD 32.56 to 32.58 mm (1.2818 to 1.2826 in.) Max. 32.63 mm (1.2846 in.) Return spring free length Flange thickness 17.14 mm (0.6748 in.) Mark K 2.9 mm (0.114 in.) Mark A 3.0 mm (0.118 in.) Mark G 3.1 mm (0.122 in.) Mark B 3.2 mm (0.126 in.) Mark H 3.3 mm (0.130 in.) Mark C 3.4 mm (0.134 in.) Mark J 3.5 mm (0.138 in.) U/D clutch No. 2 Pack clearance 1.645 to 2.20 mm (0.0648 to 0.0866 in.) Return spring free length 13.24 mm (0.5213 in.) SERVICE SPECIFICATIONS – U250E AUTOMATIC TRANSAXLE Flange thickness Mark Y 2.8 mm (0.110 in.) Mark A 3.0 mm (0.118 in.) Mark B 3.2 mm (0.126 in.) Mark C 3.4 mm (0.134 in.) Mark D 3.6 mm (0.142 in.) SS–43 1st & reverse brake Pack clearance 0.745 to 1.21 mm (0.0293 to 0.0476 in.) Return spring free length 17.63 mm (0.6941 in.) Flange thickness Mark 1 1.8 mm (0.071 in.) Mark 2 1.9 mm (0.075 in.) Mark 3 2.0 mm (0.079 in.) Mark 4 2.1 mm (0.083 in.) Mark 5 2.2 mm (0.087 in.) Mark 6 2.3 mm (0.091 in.) Mark 7 2.4 mm (0.094 in.) Mark 8 2.5 mm (0.098 in.) U/D planetary gear 0.28 to 0.89 N*m (2.9 to 9.1 kgf*cm, 2.478 to 7.877 in.*lbf) Preload (at 60 rpm) Front planetary gear 0.19 to 0.4 N*m (1.9 to 4.1 kgf*cm, 1.7 to 3.5 in.*lbf) Turning torque (at 60 rpm) Input shaft End play 0.262 to 1.249 mm (0.0103 to 0.0492 in.) Direct clutch to transaxle rear cover End play 0.199 to 0.970 mm (0.0078 to 0.0382 in.) U/D planetary gear assembly to U/D cyindrical roller bearing End play Race thickness 0.198 to 0.693 mm (0.00780 to 0.02728 in.) Less than 7.339 mm (9.2890 in.) 3.5 mm (0.138 in.) 7.339 mm (0.2890 in.) or more 3.8 mm (0.150 in.) Transaxle rear cover Bearing press fit depth 20.55 to 21.25 mm (0.8091 to 0.8366 in.) Transmission valve body A Valve body installation bolt length 25 mm (0.984 in.) B 57 mm (2.244 in.) C 41 mm (1.614 in.) Manual valve lever shaft oil seal Oil seal drive in depth -0.5 to 0.5 mm (-0.0197 to 0.0197 in.) Front differential Backlash Thrust washer thickness 0.05 to 0.20 mm (0.0020 to 0.0079 in.) Mark 1 1.000 mm (0.0394 in.) Mark 2 1.100 mm (0.0433 in.) Mark 3 1.200 mm (0.0472 in.) Mark 4 1.3 mm (0.0512 in.) New bearing 0.20 to 1.0 N*m (2.0 to 10.2 kgf*cm, 1.8 to 8.9 in.*lbf) Used bearing 0.10 to 0.35 N*m (1.0 to 3.6 kgf*cm, 0.9 to 3.1 in.*lbf) Preload (at 60 rpm) SS SS–44 SS Flange thickness SERVICE SPECIFICATIONS – U250E AUTOMATIC TRANSAXLE Mark 0 1.90 mm (0.0748 in.) Mark 1 1.95 mm (0.0768 in.) Mark 2 2.00 mm (0.0787 in.) Mark 3 2.05 mm (0.0807 in.) Mark 4 2.10 mm (0.0827 in.) Mark 5 2.15 mm (0.0846 in.) Mark 6 2.20 mm (0.0866 in.) Mark 7 2.25 mm (0.0886 in.) Mark 8 2.30 mm (0.0906 in.) Mark 9 2.35 mm (0.0925 in.) Mark A 2.40 mm (0.0945 in.) Mark B 2.45 mm (0.0965 in.) Mark C 2.50 mm (0.0984 in.) Mark D 2.55 mm (0.1004 in.) Mark E 2.60 mm (0.1024 in.) Mark F 2.65 mm (0.1043 in.) Mark G 2.70 mm (0.1063 in.) Mark H 2.75 mm (0.1083 in.) Mark J 2.80 mm (0.1102 in.) SS–45 SERVICE SPECIFICATIONS – U250E AUTOMATIC TRANSAXLE TORQUE SPECIFICATIONS Part Tightened Park/neutral position switch N*m kgf*cm ft.*lbf Bolt 5.4 55 48 in.*lbf Nut 6.9 70 61 in.*lbf Control shaft lever x Control shaft 13 130 9 Shift control cable x Control shaft lever 15 150 11 Bolt A 64 653 47 Bolt B 46 470 34 Bolt C 46 470 34 Bolt D 44 449 32 Torque converter clutch x Drive plate 41 418 30 Engine mounting bracket FR x Transaxle 64 653 47 Transaxle housing x Engine block Oil filler tube x Transaxle 5.5 56 49 in.*lbf No. 1 transmission control cable bracket x Transaxle 12 122 9 No. 2 transmission control cable bracket x Transaxle 12 122 9 Oil cooler tube clamp x Control cable bracket 5.4 55 48 in.*lbf Oil cooler inlet tube x Transaxle 34 350 25 Oil cooler outlet tube x Transaxle 34 350 25 Wire harness x Transaxle 12 130 9 Wire harness clamp x Transaxle 8.4 85 74 in.*lbf Revolution sensor NC sensor x Transaxle 5.4 55 49 in.*lbf Revolution sensor NT sensor x Transaxle 5.4 55 49 Drain plug x Oil pan 49 500 36 Transmission wire x Transaxle 5.4 55 48 in.*lbf ATF temperature sensor x Valve body 6.6 67 58 in.*lbf Oil pan x Transaxle 7.8 80 69 in.*lbf Bolt A, B 11 110 8 Bolt C, D 6.6 67 58 in.*lbf Solenoid valve x Valve body Valve body x Transaxle 11 110 8 Oil strainer x Valve body 11 110 8 Floor shift assembly x Body 12 122 9 Control cable x Body 5.0 51 43 in.*lbf Front planetary gear lock nut 185 to 350 1,886 to 3,569 136 to 258 Brake apply tube clamp x Transaxle case 5.4 55 48 in.*lbf Transaxle case No.1 plug x Transaxle rear cover 7.4 75 65 in.*lbf Transaxle case No.1 plug x Transaxle housing 7.4 75 65 in.*lbf 7.4 75 65 in.*lbf 19 190 14 Transaxle case No.1 plug x Transaxle case Transaxle rear cover x Transaxle case Bolt A Other bolt Pawl shaft clamp x Transaxle case Oil pump assembly x Transaxle case Bolt A Transaxle housing x Transaxle case Transmission wire x Transaxle housing 250 18 100 87 in.*lbf 22 225 16 22 225 16 Bolt B 29 296 21 Bolt C 29 296 21 20 205 15 20 205 15 Parking lock pawl bracket x Transaxle case Manual detent spring x Transaxle case 25 9.8 Bolt A Bolt B 12 120 9 5.4 55 48 in.*lbf Transmission valve body x Transaxle case 11 110 8 ATF temperature sensor clamp x Transmission valve body 6.6 67 58 in.*lbf SS SS–46 SERVICE SPECIFICATIONS – U250E AUTOMATIC TRANSAXLE Part Tightened SS N*m kgf*cm ft.*lbf Valve body oil strainer assembly x Transmission valve body 11 110 8 Speed sensor x Transaxle case 8.8 90 79 in.*lbf Oil cooler tube union (Outlet oil cooler union) x Transaxle case 27 276 20 Oil cooler tube union (Inlet oil cooler union) x Transaxle case 25 255 18 Oil pump body x Stator shaft assembly 9.8 100 87 in.*lbf Line pressure control solenoid assembly x Transmission valve body assembly 6.6 67 58 in.*lbf Shift solenoid valve SL1 x Transmission valve body assembly 6.6 67 58 in.*lbf Shift solenoid valve SL2 x Transmission valve body assembly 11 110 8 Shift solenoid valve SL3 x Transmission valve body assembly 6.6 67 58 in.*lbf Shift solenoid valve S4 x Transmission valve body assembly 11 110 8 Shift solenoid valve DSL x Transmission valve body assembly 11 110 8 Front differential case x Front differential ring gear 95 970 70 Front planetary gear nut 280 2,855 207 SS–46 SERVICE SPECIFICATIONS – U660E AUTOMATIC TRANSAXLE U660E AUTOMATIC TRANSAXLE SERVICE DATA Line pressure (Wheel locked) D position 372 to 412 kPa (3.8 to 4.2 kgf*cm2, 54 to 60 psi) R position 672 to 742 kPa (6.8 to 7.5 kgf*cm2, 97 to 108 psi) D position 1,160 to 1,350 kPa (11.8 to 13.8 kgf*cm2, 168 to 196 psi) R position 1,900 to 2,200 kPa (19.4 to 22.4 kgf*cm2, 276 to 319 psi) D position 2,370 to 2,670 rpm N → D position Less than 1.2 seconds N → R position Less than 1.5 seconds Engine idle speed (A/C OFF) N position 600 to 700 rpm Drive plate runout Maximum 0.20 mm (0.0079 in.) Engine idling SS AT stall (Throttle valve fully open) Engine stall revolution Time lag Torque converter runout Differential oil seal drive in depth Maximum 0.30 mm (0.0118 in.) LH side -0.5 to 0.5 mm (-0.020 to 0.020 in.) RH side -0.5 to 0.5 mm (-0.020 to 0.020 in.) 1→2 50 to 56 km/h (31 to 35 mph) 2→3 93 to 103 km/h (58 to 64 mph) 3→4 128 to 141 km/h (80 to 88 mph) 4→5 174 to 193 km/h (108 to 120 mph) 5→6 258 to 285 km/h (160 to 177 mph 6→5 252 to 278 km/h (157 to 173 mph 5→4 169 to 187 km/h (105 to 116 mph)) 4→3 121 to 134 km/h (75 to 83 mph)) 3→2 87 to 96km/h (54 to 60 mph) 2→1 33 to 37 km/h (21 to 23 mph) 1→2 37 to 41 km/h (23 to 25 mph) 2→3 72 to 79 km/h (45 to 47 mph) 3→4 110 to 122 km/h (68 to 76 mph) 4→5 174 to 192 km/h (108 to 119 mph) 5→6 258 to 285 km/h (160 to 177 mph 6→5 252 to 278 km/h (157 to 173 mph 5→4 169 to 187 km/h (105 to 116 mph)) 4→3 104 to 115 km/h (65 to 71 mph)) 3→2 65 to 72km/h (40 to 45 mph) 2→1 33 to 37 km/h (21 to 23 mph) 1→3 27 to 30 km/h (17 to 19 mph) 3→1 6 to 8 km/h (4 to 5 mph) 4→5 48 to 54 km/h (30 to 34 mph) 5→6 65 to 72 km/h (40 to 45 mph) 6→5 58 to 65 km/h (36 to 40 mph) 5→4 46 to 51 km/h (29 to 32 mph) Shift schedule D position Throttle valve fully open (Normal) Throttle valve fully open (Cold) Throttle valve fully open (Failure) Throttle valve fully closed (Normal) 5, 4, 3, 2, 1 position SERVICE SPECIFICATIONS – U660E AUTOMATIC TRANSAXLE Manual down shift speed →5 252 to 278 km/h (156 to 172 mph) →4 169 to 187 km/h (105 to 116 mph) →3 121 to 134 km/h (75 to 83 mph) →2 87 to 96km/h (54 to 60 mph) →1 38 to 42 km/h (23 to 26 mph) Lock-up ON 69 to 76 km/h (43 to 47 mph) SS–47 Lock-up schedule (Throttle valve opening 5%) D position 6th gear 5th gear 4th gear 3rd gear 2nd gear Lock-up OFF 67 to 74 km/h (42 to 46 mph) Lock-up ON 59 to 66 km/h (37 to 41 mph) Lock-up OFF 57 to 63 km/h (35 to 39 mph) Lock-up ON 43 to 47 km/h (27 to 29 mph) Lock-up OFF 41 to 45 km/h (25 to 28 mph) Lock-up ON 30 to 33 km/h (19 to 21 mph) Lock-up OFF 28 to 31 km/h (17 to 19 mph) Lock-up ON 23 to 25 km/h (14 to 16 mph) Lock-up OFF 22 to 24 km/h (14 to 15 mph) Flex lock-up schedule (Throttle valve opening 5%) D position 6th gear 5th gear 4th gear 3rd gear 2nd gear Lock-up ON 62 to 68 km/h (39 to 42 mph) Lock-up OFF 60 to 67 km/h (38 to 42 mph) Lock-up ON 50 to 55 km/h (31 to 34 mph) Lock-up OFF 50 to 55 km/h (31 to 34 mph) Lock-up ON 37 to 41 km/h (23 to 25 mph) Lock-up OFF 35 to 39 km/h (22 to 24 mph) Lock-up ON 27 to 30 km/h (17 to 19 mph) Lock-up OFF 25 to 28 km/h (16 to 17 mph) Lock-up ON 20 to 22 km/h (12 to 14 mph) Lock-up OFF 18 to 20 km/h (11 to 12 mph) Oil pump Body clearance Side clearance STD 0.08 to 0.15 mm (0.0031 to 0.0059 in.) Maximum 0.15 mm (0.0059 in.) STD 0.025 to 0.04 mm (0.0010 to 0.0016 in.) Maximum 0.04 mm (0.0016 in.) 11.547 to 11.555 mm (0.4546 to 0.4549 in.) 11.555 to 11.563 mm (0.4549 to 0.4552 in.) Drive gear thickness 11.564 to 11.571 mm (0.4553 to 0.4556 in.) 11.572 to 11.579 mm (0.4556 to 0.4559 in.) 11.580 to 11.587 mm (0.4559 to 0.4562 in.) 11.547 to 11.555 mm (0.4546 to 0.4549 in.) 11.555 to 11.563 mm (0.4549 to 0.4552 in.) Driven gear thickness 11.564 to 11.571 mm (0.4553 to 0.4556 in.) 11.572 to 11.579 mm (0.4556 to 0.4559 in.) 11.580 to 11.587 mm (0.4559 to 0.4562 in.) Pump body bushing inside diameter Stator shaft bushing inside diameter STD 43.113 to 43.138 mm (1.6974 to 1.6983 in.) Maximum 43.188 mm (1.7003 in.) STD 22.500 to 22.526 mm (0.8858 to 0.8868 in.) Maximum 22.57 mm (0.8886 in.) STD 25.580 to 25.601 mm (1.0071 to 1.0079 in.) Maximum 25.601 mm (1.0079 in.) Rear planetary sun gear Inside diameter SS SS–48 SERVICE SPECIFICATIONS – U660E AUTOMATIC TRANSAXLE Under drive planetary gear Clearance 0.18 to 0.54 mm (0.0071 to 0.0213 in.) Planetary sun gear Inside diameter STD 25.525 to 25.546 mm (1.0049 to 1.0058 in.) Maximum 25.546 mm (1.0058 in.) 2nd brake piston return spring Return spring free length 23.85 mm (0.9390 in.) Planetary gear SS Clearance A point 0.23 to 0.59 mm (0.0091 to 0.0232 in.) B point 0.16 to 0.66 mm (0.0063 to 0.0260 in.) 1st and reverse brake return spring Return spring free length 15.79 mm (0.6217 in.) No. 2 brake Piston stroke Flange thickness 0.884 to 1.196 mm (0.0348 to 0.0471 in.) Mark 40 4.0 mm (0.157 in.) Mark 41 4.1 mm (0.161 in.) Mark 42 4.2 mm (0.165 in.) Mark 43 4.3 mm (0.169 in.) Mark 44 4.4 mm (0.173 in.) Mark 30 3.0 mm (0.118 in.) Mark 31 3.1 mm (0.122 in.) Mark 32 3.2 mm (0.126 in.) Mark 33 3.3 mm (0.130 in.) Mark 34 3.4 mm (0.134 in.) Mark 35 3.5 mm (0.138 in.) Mark 38 3.8 mm (0.150 in.) Mark 39 3.9 mm (0.154 in.) Mark 40 4.0 mm (0.157 in.) Mark 41 4.1 mm (0.161 in.) Mark 42 4.2 mm (0.165 in.) Mark 43 4.3 mm (0.169 in.) Mark 30 3.0 mm (0.118 in.) Mark 31 3.1 mm (0.122 in.) Mark 32 3.2 mm (0.126 in.) Mark 33 3.3 mm (0.130 in.) Mark 34 3.4 mm (0.134 in.) Mark 35 3.5 mm (0.138 in.) No. 1 brake Piston stroke Flange thickness 0.807 to 0.974 mm (0.0318 to 0.0383 in.) No. 3 brake Clearance Flange thickness 0.599 to 0.761 mm (0.0024 to 0.0300 in.) No. 1 clutch disc Piston stroke Flange thickness 0.806 to 0.974 mm (0.0317 to 0.0383 in.) No. 2 clutch disc Pack clearance 0.544 to 0.744 mm (0.0214 to 0.0293 in.) SERVICE SPECIFICATIONS – U660E AUTOMATIC TRANSAXLE Flange thickness Mark 30 3.0 mm (0.118 in.) Mark 31 3.1 mm (0.122 in.) Mark 32 3.2 mm (0.126 in.) Mark 33 3.3 mm (0.130 in.) Mark 34 3.4 mm (0.134 in.) Mark 35 3.5 mm (0.138 in.) SS–49 Input shaft End play 0.012 to 1.250 mm (0.0005 to 0.0492 in.) Intermediate shaft End play 0.007 to 1.113 mm (0.0003 to 0.0438 in.) Transaxle rear cover Bearing press fit depth 21.5 to 21.9 mm (0.8464 to 0.8622 in.) Transmission valve body A Valve body installation bolt length 25 mm (0.98 in.) B 30 mm (1.18 in.) C 35 mm (1.38 in.) D 45 mm (1.77 in.) E 55 mm (2.17 in.) Manual valve lever shaft oil seal Oil seal drive in depth -0.5 to 0.5 mm (-0.0197 to 0.0197 in.) Front differential Backlash 0 to 0.15 mm (0 to 0.0059 in.) 1.50 mm (0.0591 in.) 1.55 mm (0.0610 in.) 1.60 mm (0..0630 in.) 1.65 mm (0.0650 in.) Thrust washer thickness 1.70 mm (0.0669 in.) 1.75 mm (0.0689 in.) 1.80 mm (0.0709 in.) 1.85 mm (0.0728 in.) 1.90 mm (0.0748 in.) Preload (at 10 rpm) 1.05 to 1.93 N*m (10.7 to 19.67 kgf*cm, 9.29 to 17.08 in.*lbf) SS SS–50 SERVICE SPECIFICATIONS – U660E AUTOMATIC TRANSAXLE 2.000 mm (0.0787 in.) 2.025 mm (0.0797 in.) 2.050 mm (0.0807 in.) 2.075 mm (0.0817 in.) 2.100 mm (0.0827 in.) 2.125 mm (0.0837 in.) 2.150 mm (0.0847 in.) 2.175 mm (0.0856 in.) 2.200 mm (0.0866 in.) SS 2.225 mm (0.0876 in.) 2.250 mm (0.0886 in.) 2.275 mm (0.0896 in.) 2.300 mm (0.0906 in.) 2.325 mm (0.0915 in.) 2.350 mm (0.0925 in.) 2.375 mm (0.0935 in.) 2.400 mm (0.0945 in.) Shim thickness 2.425 mm (0.0935 in.) 2.450 mm (0.0965 in.) 2.475 mm (0.0974 in.) 2.500 mm (0.0984 in.) 2.525 mm (0.0994 in.) 2.550 mm (0.1004 in.) 2.575 mm (0.1014 in.) 2.600 mm (0.1024 in.) 2.625 mm (0.1034 in.) 2.650 mm (0.1043 in.) 2.675 mm (0.1053 in.) 2.700 mm (01063 in.) 2.725 mm (0.1073 in.) 2.750 mm (0.1083 in.) 2.775 mm (0.1093 in.) 2.800 mm (0.1102 in.) 2.825 mm (0.1112 in.) 2.850 mm (0.1122 in.) 2.875 mm (0.1132 in.) Counter driven gear Preload (at 10 rpm) 3.29 to 6.07 N*m (35.35 to 61.86 kgf*cm, 2.42 to 4.46 in.*lbf) SERVICE SPECIFICATIONS – U660E AUTOMATIC TRANSAXLE SS–51 2.000 mm (0.0787 in.) 2.025 mm (0.0797 in.) 2.050 mm (0.0807 in.) 2.075 mm (0.0817 in.) 2.100 mm (0.0827 in.) 2.125 mm (0.0837 in.) 2.150 mm (0.0847 in.) 2.175 mm (0.0856 in.) 2.200 mm (0.0866 in.) 2.225 mm (0.0876 in.) 2.250 mm (0.0886 in.) 2.275 mm (0.0896 in.) 2.300 mm (0.0906 in.) 2.325 mm (0.0915 in.) 2.350 mm (0.0925 in.) 2.375 mm (0.0935 in.) 2.400 mm (0.0945 in.) 2.425 mm (0.0935 in.) 2.450 mm (0.0965 in.) 2.475 mm (0.0974 in.) Shim thickness 2.500 mm (0.0984 in.) 2.525 mm (0.0994 in.) 2.550 mm (0.1004 in.) 2.575 mm (0.1014 in.) 2.600 mm (0.1024 in.) 2.625 mm (0.1034 in.) 2.650 mm (0.1043 in.) 2.675 mm (0.1053 in.) 2.700 mm (01063 in.) 2.725 mm (0.1073 in.) 2.750 mm (0.1083 in.) 2.775 mm (0.1093 in.) 2.800 mm (0.1102 in.) 2.825 mm (0.1112 in.) 2.850 mm (0.1122 in.) 2.875 mm (0.1132 in.) 2.900 mm (0.1141 in.) 2.925 mm (0.1152 in.) 2.950 mm (0.1161 in.) 2.975 mm (0.1171 in.) 3.000 mm (0.1181 in.) SS SS–52 SERVICE SPECIFICATIONS – U660E AUTOMATIC TRANSAXLE TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Park/neutral position switch 5.4 55 48 in.*lbf Control shaft lever x Control shaft 13 130 9 13 130 9 64 653 47 Transmission control cable x Control shaft lever Bolt A Transaxle housing x Engine block SS Bolt B 64 653 47 Bolt C 46 469 34 43 439 32 Torque converter clutch x Drive plate Bolt D 41 418 30 Engine mounting front bracket x Transaxle case 64 653 47 Refill plug x Transaxle case 49 500 36 Over flow plug x Transaxle case 40 408 30 Control cable bracket No. 1 x Transaxle case 12 122 9 Oil cooler tube union (inlet oil cooler union) x Transaxle case 27 275 20 Oil cooler tube union (outlet oil cooler union) x Transaxle case 27 275 20 Wire harness x Transaxle case 12 122 9 Wire harness clamp bracket x Transaxle case 8.4 86 74 in.*lbf Transmission revolution sensor x Valve body 11 112 8 No. 1 transmission oil filler tube x Oil pan 1.7 17 15 in.*lbf Speedometer driven hole cover x Transaxle case 5.5 56 49 in.*lbf Transmission wire (ATF temperature sensor) x Valve body 11 112 8 Oil pan x Transaxle case 7.5 76 66 in.*lbf Transmission wire x Valve body 11 112 8 Valve body x Transaxle case 11 112 8 Oil strainer x Valve body 11 112 8 Breather bracket x Camshaft housing sub-assembly LH 5.5 56 49 in.*lbf Air cleaner bracket x Body 7.8 80 69 in.*lbf No. 2 shift cable grommet retainer x Body 5.0 51 44 in.*lbf Flywheel housing under cover x Transaxle housing 7.8 80 69 in.*lbf TCM x Transaxle case 11 112 8 Shift lock control unit x Body 12 122 9 Differential gear lube apply tube x Transaxle housing 23 234 17 Lock nut x Transaxle case 120 1,223 88 Transaxle case No. 1 plug x Transaxle rear cover 7.4 75 65 in.*lbf Transaxle case No. 1 plug x Transaxle housing 7.4 75 65 in.*lbf Transaxle case No. 1 plug x Transaxle case Transaxle rear cover x Transaxle case Bolt A Bolt B Transaxle rear cover plate x Transaxle case Oil pump assembly x Transaxle case Transaxle housing x Transaxle case Bolt A Bolt B 29 296 20 23 234 17 17 173 12 7.5 76 66 in.*lbf 23 234 17 31 316 23 23 234 17 Pawl shaft clamp x Transaxle case 23 234 17 Pawl stopper plate x Transaxle case 23 234 17 Manual detent spring x Transaxle case 23 234 17 Oil pump body x Stator shaft assembly 9.3 95 82 in.*lbf Shift solenoid valve SL3 x Transmission valve body assembly 11 110 8 Shift solenoid valve SL4 x Transmission valve body assembly 11 110 8 Front differential case x Front differential ring gear 120 1,223 88 SS–53 SERVICE SPECIFICATIONS – CLUTCH CLUTCH SERVICE DATA Pedal height from asphalt sheet 148.0 to 158.0 mm (5.8268 to 6.2205 in.) Clutch pedal free play 5.0 to 15.0 mm (0.197 to 0.591 in.) Clutch pedal push rod play at pedal top 1.0 to 5.0 mm (0.039 to 0.197 in.) Clutch release point from pedal full stroke end position 25 mm (0.98 in.) or more Disc rivet head depth Minimum 0.3 mm (0.012 in.) Disc runout Maximum 0.8 mm (0.031 in.) Maximum depth: 0.5 mm (0.020 in.) Maximum width: 6.0 mm (0.236 in.) Flywheel runout Maximum 0.1 mm (0.004 in.) Diaphragm spring tip alignment Maximum variation: 0.5 mm (0.020 in.) Clutch start switch assembly Specified condition Diaphragm spring finger wear SS Switch position ON (pushed) Below 1 Ω Switch position OFF (not pushed) 10 kΩ or higher SS–54 SERVICE SPECIFICATIONS – CLUTCH TORQUE SPECIFICATIONS Part Tightened SS N*m kgf*cm ft.*lbf Clutch pedal sub-assembly x Clutch pedal support 37 375 27 Clutch pedal support set bolt x Body 19 195 14 Clutch pedal support set nut x Body 12 120 9 Cylinder push rod clevis lock nut 12 120 9 Clutch master cylinder assembly x Clutch pedal support 12 120 9 Clutch master cylinder assembly x Flexible hose tube 15 155 11 Release cylinder bleeder plug 8.3 85 74 in.*lbf Clutch release cylinder assembly x Transaxle housing 12 120 9 Clutch accumulator assembly set nut 12 120 9 Clutch release cylinder assembly x Flexible hose tube 15 155 11 Clutch accumulator assembly x Flexible hose tube 15 155 11 Release cylinder heat insulator set bolt 12 120 9 Clutch accumulator bracket set bolt A 12 120 9 Clutch accumulator bracket set bolt B 37 380 28 Clutch cover assembly x Flywheel 19 195 14 Release fork support x Transaxle assembly 47 480 35 Clutch start switch assembly set nut 16 160 12 SS–54 SERVICE SPECIFICATIONS – E351 MANUAL TRANSAXLE E351 MANUAL TRANSAXLE SERVICE DATA MANUAL TRANSAXLE ASSEMBLY: Transmission case oil seal driven in depth 3.0 to 4.0 mm (0.1181 to 0.1575 in.) Front transaxle case cover oil seal drive in depth -0.5 to 0.5 mm (-0.020 to 0.020 in.) MANUAL TRANSAXLE UNIT: SS 5th gear thrust clearance Standard clearance 0.10 to 0.65 mm (0.0039 to 0.0256 in.) 5th gear radial clearance Standard clearance 0.009 to 0.050 mm (0.0004 to 0.0020 in.) Reverse idler gear sub-assembly inside diameter Standard inside diameter 20.056 to 20.074 mm (0.7896 to 0.7903 in.) Maximum inside diameter 20.074 (0.7903 in.) Standard outer diameter 19.984 to 20.000 mm (0.7868 to 0.7874 in.) Minimum outer diameter 19.984 mm (0.7868 in.) Standard clearance 0.15 to 0.35 mm (0.0059 to 0.0138 in.) Standard inside diameter 34.981 to 34.997 mm (1.3772 to 1.3778 in.) Maximum inside diameter 34.997 mm (1.3778 in.) Reverse idler gear shaft outer diameter No. 3 transmission hub sleeve groove thickness of the claw part on No. 3 gear shift fork 5th gear inside diameter Front transaxle case cover oil seal driven in depth -0.5 to 0.5 mm (-0.020 to 0.020 in.) Transmission case oil seal driven in depth 3.0 to 4.0 mm (0.1181 to 0.1575 in.) Output shaft rear bearing clearance 3.8 to 4.4 mm (0.150 to 0.173 in.) New bearing 0.8 to 1.6 N*m (8.16 to 16.32 kgf*cm, 7.1 to 14.2 in.*lbf) Used bearing 0.5 to 1.0 N*m (5.10 to 10.20 kgf*cm, 4.4 to 8.9 in.*lbf) 0 1.30 mm (0.0512 in.) 1 1.35 mm (0.0531 in.) 2 1.40 mm (0.0551 in.) 3 1.45 mm (0.0571 in.) 4 1.50 mm (0.0591 in.) 5 1.55 mm (0.0610 in.) 6 1.60 mm (0.0630 in.) 7 1.65 mm (0.0650 in.) 8 1.70 mm (0.0669 in.) 9 1.75 mm (0.0689 in.) A 1.80 mm (0.0709 in.) Output shaft bearing preload Output shaft rear bearing shim thickness B 1.85 mm (0.0728 in.) C 1.90 mm (0.0748 in.) D 1.95 mm (0.0768 in.) E 2.00 mm (0.0787 in.) F 2.05 mm (0.0807 in.) G 2.10 mm (0.0827 in.) H 2.15 mm (0.0846 in.) J 2.20 mm (0.0866 in.) K 2.25 mm (0.0886 in.) L 2.30 mm (0.0906 in.) M 2.35 mm (0.0925 in.) N 2.40 mm (0.0945 in.) P 2.45 mm (0.0965 in.) Q 2.50 mm (0.0984 in.) SERVICE SPECIFICATIONS – E351 MANUAL TRANSAXLE Front differential case tapered roller bearing preload Front differential case shim rear thickness SS–55 New bearing 0.8 to 1.6 N*m (8.16 to 16.32 kgf*cm, 7.1 to 14.2 in.*lbf) Used bearing 0.5 to 1.0 N*m (5.10 to 10.20 kgf*cm, 4.4 to 8.9 in.*lbf) 0 2.00 mm (0.0787 in.) 1 2.05 mm (0.0807 in.) 2 2.10 mm (0.0827 in.) 3 2.15 mm (0.0846 in.) 4 2.20 mm (0.0866 in.) 5 2.25 mm (0.0886 in.) 6 2.30 mm (0.0906 in.) 7 2.35 mm (0.0925 in.) 8 2.40 mm (0.0945 in.) 9 2.45 mm (0.0965 in.) A 2.50 mm (0.0984 in.) B 2.55 mm (0.1004 in.) C 2.60 mm (0.1024 in.) D 2.65 mm (0.1043 in.) E 2.70 mm (0.1063 in.) F 2.75 mm (0.1083 in.) G 2.80 mm (0.1102 in.) H 2.85 mm (0.1122 in.) Front differential case oil seal clearance 1.0 to 2.0 mm (0.0394 to 0.0.787 in.) Input shaft front bearing clearance 4.28 to 4.60 mm (0.1685 to 0.1811 in.) Reverse restrict pin clearance 12.5 to 13.5 mm (0.492 to 0.531 in.) No. 3 transmission clutch hub snap ring clearance 0.1 mm or less (0.0039 in. or less) a 1.75 to 1.80 mm (0.0689 to 0.0709 in.) b 1.80 to 1.85 mm (0.0709 to 0.0728 in.) c 1.85 to 1.90 mm (0.0728 to 0.0748 in.) d 1.90 to 1.95 mm (0.0748 to 0.0768 in.) e 1.95 to 2.00 mm (0.0768 to 0.0787 in.) f 2.00 to 2.05 mm 0.0787 to 0.0807 in.) g 2.05 to 2.10 mm (0.0807 to 0.0827 in.) h 2.10 to 2.15 mm (0.0827 to 0.0846 in.) j 2.15 to 2.20 mm (0.0846 to 0.0866 in.) 4th gear thrust clearance Standard clearance 0.10 to 0.57 mm (0.0039 to 0.0224 in.) 3rd gear thrust clearance Standard clearance 0.10 to 0.35 mm (0.0039 to 0.0138 in.) KOYO made 0.009 to 0.053 mm (0.0004 to 0.0021 in.) NSK made 0.009 to 0.051 mm (0.0004 to 0.0020 in.) KOYO made 0.009 to 0.053 mm (0.0004 to 0.0021 in.) NSK made 0.009 to 0.051 mm (0.0004 to 0.0020 in.) No. 3 transmission clutch hub snap ring thickness INPUT SHAFT ASSEMBLY: 4th gear radial clearance 3rd gear radial clearance Input shaft run out Input shaft standard outer diameter Input shaft minimum outer diameter 4th gear inside diameter Maximum run out 0.03 mm (0.0012 in.) A 35.984 to 36.000 mm (1.4167 to 1.4173 in.) B 35.984 to 36.000 mm (1.4167 to 1.4173 in.) C 27.957 to 27.972 mm (1.1007 to 1.1013 in.) A 35.984 mm (1.4167 in.) B 35.984 mm (1.4167 in.) C 27.957 mm (1.1007 in.) Standard inside diameter 42.009 to 42.025 mm (1.6539 to 1.6545 in.) Maximum inside diameter 42.025 mm (1.6545 in.) SS SS–56 SERVICE SPECIFICATIONS – E351 MANUAL TRANSAXLE 3rd gear inside diameter Standard inside diameter 43.009 to 43.025 mm (1.6933 to 1.6939 in.) Maximum inside diameter 43.025 mm (1.6939 in.) Between the 4th gear spline end and synchronizer outer ring back clearance 0.75 to 1.65 mm (0.0295 to 0.0650 in.) Between the 3rd gear spline end and synchronizer outer ring back clearance 0.65 to 1.75 mm (0.0256 to 0.0689 in.) No. 2 transmission hub sleeve groove thickness of the claw part on No.1 gear shift fork Standard clearance 0.11 to 0.69 mm (0.0043 to 0.0272 in.) No. 2 transmission clutch hub snap ring clearance Standard clearance 0.1 mm or less (0.0039 in. or less) H 2.30 to 2.35 mm (0.0906 to 0.0925 in.) J 2.35 to 2.40 mm (0.0925 to 0.0945 in.) K 2.40 to 2.45 mm (0.0945 to 0.0965 in.) L 2.45 to 2.50 mm (0.0965 to 0.0984 in.) M 2.50 to 2.55 mm (0.0984 to 0.1004 in.) N 2.55 to 2.60 mm (0.1004 to 0.1024 in.) P 2.60 to 2.65 mm (0.1024 to 0.1043 in.) Standard clearance 0.1 mm or less (0.0039 in. or less) 1 2.35 to 2.40 mm (0.0925 to 0.0945 in.) 2 2.40 to 2.45 mm (0.0945 to 0.0965 in.) 3 2.45 to 2.50 mm (0.0965 to 0.0984 in.) 4 2.50 to 2.55 mm (0.0984 to 0.1004 in.) 5 2.55 to 2.60 mm (0.1004 to 0.1024 in.) 6 2.60 to 2.65 mm (0.1024 to 0.1043 in.) 7 2.65 to 2.70 mm (0.1043 to 0.1063 in.) 8 2.70 to 2.75 mm (0.1063 to 0.1083 in.) Standard clearance 0.25 to 0.40 mm (0.0098 to 0.0157 in.) SS No. 2 transmission clutch hub snap ring thickness Input shaft rear radial ball bearing snap ring clearance Input shaft rear radial ball bearing snap ring thickness OUTPUT SHAFT ASSEMBLY: 1st gear thrust clearance 2nd gear thrust clearance 1st gear radial clearance 2nd gear radial clearance Output shaft run out Output shaft standard outer diameter Output shaft minimum outer diameter 2nd gear inside diameter 1st gear inside diameter Standard clearance 0.10 to 0.35 mm (0.0039 to 0.0138 in.) KOYO made 0.009 to 0.053 mm (0.0004 to 0.0021 in.) NSK made 0.009 to 0.051mm (0.0004 to 0.0020in.) KOYO made 0.009 to 0.053 mm (0.0004 to 0.0021 in.) NSK made 0.009 to 0.051mm (0.0004 to 0.0020in.) Maximum run out 0.03 mm (0.0012 in.) A 37.610 to 37.626 mm (1.4807 to 1.4813 in.) B 34.502 to 34.512 mm (1.3583 to 1.3587 in.) A 37.610 mm (1.4807 in.) B 34.502 mm (1.3583 in.) Standard inside diameter 50.009 to 50.025 mm (1.9689 to 1.9695 in.) Maximum inside diameter 50.025 mm (1.9695 in.) Standard inside diameter 51.009 to 51.025 mm (2.0082 to 2.0089 in.) Maximum inside diameter 51.025 mm (2.0089 in.) Between the 2nd gear while and No. 2 synchronizer ring back clearance 0.70 to 1.45 mm (0.0276 to 0.0571 in.) Between the 1st gear while and No. 1 synchronizer ring set back clearance 0.70 to 1.45 mm (0.0276 to 0.0571 in.) Reverse gear groove - thickness of the claw part on No .1 gear shift fork clearance Standard clearance 0.15 to 0.35 mm (0.0059 to 0.0138 in.) KOYO made 0.009 to 0.053 mm (0.0004 to 0.0021 in.) NSK made 0.009 to 0.051 mm (0.0004 to 0.0020 in.) KOYO made 0.009 to 0.053 mm (0.0004 to 0.0021 in.) NSK made 0.009 to 0.051 mm (0.0004 to 0.0020 in.) Standard clearance 0.10 to 0.35 mm (0.0039 to 0.0138 in.) 2nd gear radial clearance 1st gear radial clearance 2nd gear thrust clearance SERVICE SPECIFICATIONS – E351 MANUAL TRANSAXLE 1st gear thrust clearance Standard clearance SS–57 0.25 to 0.40 mm (0.0098 to 0.0157 in.) SHIFT AND SELECT LEVER SHAFT ASSEMBLY: Control shaft cover oil seal drive in depth 28.0 to 29.0 mm (1.1022 to 1.142 in.) Shift lever slotted pin clearance to the No. 1 shift lever inner assembly 0.4 to 0.5 mm (-0.0157 to 0.0197 in.) Shift lever slotted pin clearance to the No. 2 shift lever inner 5.8 to 6.8 mm (0.228 to 0.268 in.) DIFFERENTIAL CASE ASSEMBLY: Front differential side gear backlash Standard backlash 0.05 to 0.20 mm (0.0020 to 0.0079 in.) Front differential pinion thrust washer thickness Minimum thickness 0.9 mm (0.035 in.) Front differential No. 1 pinion shaft thickness Minimum diameter 17.975 mm (0.70768 in.) Front differential side gear backlash Front differential side gear thrust washer thickness Standard backlash 0.05 to 0.20 mm (0.0020 to 0.0079 in.) 1 1.00 mm (0.0394 in.) 2 1.10 mm (0.0433 in.) 3 1.20 mm (0.0472 in.) 4 1.30 mm (0.0512 in.) SS SS–58 SERVICE SPECIFICATIONS – E351 MANUAL TRANSAXLE TORQUE SPECIFICATIONS Part Tightened SS N*m kgf*cm ft.*lbf Floor shift lever assembly x Body 12 122 9 Floor shift cable transmission control shift retainer x Body 5.0 51 44 in.*lbf Clutch tube bracket set bolt 17 173 13 Reverse idler gear shaft bolt 30 306 22 Gear shift fork No. 3 shift fork bolt 24 244 17 Manual transmission output shaft rear set nut 123 1,250 90 Control shaft cover set bolt 20 204 15 Control shift lever x Shift and select lever shaft 6.4 65 57 in.*lbf Selecting bellcrank assembly x Manual transmission case 20 200 14 Release fork support x manual transaxle case 47 480 35 Bolt A 64 653 47 Bolt B 46 470 34 Manual transaxle x Engine Bolt C Engine mounting insulator LH x Manual transaxle 44 449 32 64 653 47 Manual transmission case protector x Manual transaxle 18 184 13 Engine mounting bracket FR x Manual transaxle 64 653 47 Bolt A 12 122 9 Bolt B 7.0 71 62 in.*lbf Wire harness clamp bracket x Manual transaxle 8.4 86 74 in.*lbf Ground cable x Manual transaxle 12 122 9 Clutch line x Manual transaxle Transmission case x Manual transaxle case 29 296 21 Manual transaxle case x Transmission case 29 296 21 Bearing retainer rear x Transmission case 43 438 32 Manual transaxle case receiver x Manual transaxle case 7 71 62 in.*lbf No. 1 gear shift head x No. 2 gear shift fork shaft 24 245 18 No. 1 gear shift fork x No. 1 gear shift fork shaft 24 245 18 Reverse shift arm bracket x Manual transaxle case 17 173 13 Reverse restrict pin plug x Transmission case 13 133 9.6 No. 1 oil receiver pipe x Transmission case 17 173 13 No. 2 oil receiver pipe x Transmission case 17 173 13 Clutch tube bracket x Transmission case 17 173 13 Reverse idler gear shaft bolt x Transmission case 30 306 22 No. 3 transmission clutch hub gear shift fork shaft x input shaft 24 245 18 Manual transmission output rear set nut x Output shaft 123 1,254 91 Drain plug sub-assembly x Transmission case 49 500 36 Manual transmission filler plug x Transmission case 49 500 36 Back up light switch assembly x Transmission case 40 408 30 Manual Transmission breather plug x Transmission case 49 500 36 No. 1 lock ball assembly x Transmission case 29 296 21 Speedometer driven hole cover sub-assembly set bolt 5.5 56 48 in.*lbf Selecting bellcrank support x Selecting bellcrank No. 2 plate washer 12 122 9 Front differential ring gear x Front differential case 106 1,081 78 SS–59 SERVICE SPECIFICATIONS – DRIVE SHAFT DRIVE SHAFT TORQUE SPECIFICATIONS Part Tightened Front wheel set nut N*m kgf*cm ft.*lbf 103 1,050 76 Lower ball joint x Front suspension lower No. 1 arm 75 765 55 Tie rod end x Steering knuckle 49 500 36 Axle hub x Front drive shaft 294 3,000 217 Front drive shaft center bearing set bolt 32 330 24 Front speed sensor set bolt 8.0 82 71 in.*lbf Front flexible hose and speed sensor wire harness x Shock absorber 19 192 14 Front stabilizer link x Front shock absorber 74 755 55 SS SS–60 SERVICE SPECIFICATIONS – AXLE AXLE SERVICE DATA SS Front axle hub bearing for looseness Maximum: 0.05 mm (0.0020 in.) Front axle hub for runout Maximum: 0.05 mm (0.0020 in.) Rear axle hub bearing for looseness Maximum: 0.05 mm (0.0020 in.) Rear axle hub for runout Maximum: 0.07 mm (0.0027 in.) SS–61 SERVICE SPECIFICATIONS – AXLE TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Front wheel set nut 103 1,050 76 Front disc brake caliper x Steering knuckle 107 1,090 79 Front axle assembly x Front shock absorber 210 2,140 155 Axle hub x Front drive shaft 294 3,000 217 Front disc brake dust cover x Steering knuckle 8.3 85 73 in.*lbf Rear wheel set nut 103 1,050 76 Rear axle carrier x Rear disc brake caliper 62 630 46 Rear flexible hose x Rear shock absorber 19 192 14 Rear shock absorber x Rear axle carrier 180 1,836 133 Rear axle hub and bearing set bolt 80 816 59 Rear strut rod x Rear axle carrier 113 1,150 83 Rear No. 2 suspension arm x Rear axle carrier 100 1,020 74 Rear No. 1 suspension arm x Rear axle carrier 100 1,020 74 SS SS–61 SERVICE SPECIFICATIONS – SUSPENSION SUSPENSION SERVICE DATA Toe-in (total) Front wheel alignment A-B 0 +- 2 mm (0 - 0.08 in.) Rack end length difference 1.5 mm (0.06 in.) or less for USA and Canada: Vehicle height ACV40L-CEAGKA GSV40L-CETGKA ACV40L-AEAGKA GSV40L-AETGKA ACV40L-CEANKA ACV40L-CEMNKA Front wheel alignment GSV40L-CETNKA ACV40L-AEANKA ACV40L-AEMNKA GSV40L-AETNKA ACV40L-CEASKA ACV40L-CEMSKA GSV40L-CETSKA Front A - B 125 mm (4.92 in.) Rear C - D 54 mm (2.13 in.) Front A - B 126 mm (4.96 in.) Rear C - D 55 mm (2.17 in.) Front A - B 125 mm (4.92 in.) Rear C - D 53 mm (2.09 in.) Front A - B 126 mm (4.96 in.) Rear C - D 54 mm (2.13 in.) Front A - B 125 mm (4.92 in.) Rear C - D 54 mm (2.13 in.) Front A - B 125 mm (4.92 in.) Rear C - D 53 mm (2.09 in.) Front A - B 126 mm (4.96 in.) Rear C - D 55 mm (2.17 in.) Front A - B 125 mm (4.92 in.) Rear C - D 53 mm (2.09 in.) Front A - B 125 mm (4.92 in.) Rear C - D 52 mm (2.05 in.) Front A - B 126 mm (4.96 in.) Rear C - D 54 mm (2.13 in.) Front A - B 128 mm (5.04 in.) Rear C - D 57 mm (2.24 in.) Front A - B 127 mm (5.00 in.) Rear C - D 55 mm (2.17 in.) Front A - B 129 mm (5.08 in.) Rear C - D 58 mm (2.28 in.) for Mexico: Vehicle height ACV40L-CEAGKA Front wheel alignment GSV40L-CETGKA ACV40L-CEANKA Front A - B 115 mm (4.53 in.) Rear C - D 40 mm (1.57 in.) Front A - B 116 mm (4.57 in.) Rear C - D 41mm (1.61 in.) Front A - B 115 mm (4.53 in.) Rear C - D 40 mm (1.57 in.) SS SS–62 SERVICE SPECIFICATIONS – SUSPENSION for USA and Canada: Wheel turning angle ACV40L-CEAGKA GSV40L-CETGKA ACV40L-AEAGKA SS GSV40L-AETGKA ACV40L-CEANKA ACV40L-CEMNKA Front wheel alignment GSV40L-CETNKA ACV40L-AEANKA ACV40L-AEMNKA GSV40L-AETNKA ACV40L-CEASKA ACV40L-CEMSKA GSV40L-CETSKA Inside wheel 38°22'+-2° (38.37°+-2°) Outside wheel reference 33°33' (33.55°) Inside wheel 38°22'+-2° (38.37°+-2°) Outside wheel reference 33°33' (33.55°) Inside wheel 38°22'+-2° (38.37°+-2°) Outside wheel reference 33°33' (33.55°) Inside wheel 38°22'+-2° (38.37°+-2°) Outside wheel reference 33°33' (33.55°) Inside wheel 38°22'+-2° (38.37°+-2°) Outside wheel reference 33°33' (33.55°) Inside wheel 38°22'+-2° (38.37°+-2°) Outside wheel reference 33°33' (33.55°) Inside wheel 38°22'+-2° (38.37°+-2°) Outside wheel reference 33°33' (33.55°) Inside wheel 38°22'+-2° (38.37°+-2°) Outside wheel reference 33°33' (33.55°) Inside wheel 38°22'+-2° (38.37°+-2°) Outside wheel reference 33°33' (33.55°) Inside wheel 38°22'+-2° (38.37°+-2°) Outside wheel reference 33°33' (33.55°) Inside wheel 38°42'+-2° (38.70°+-2°) Outside wheel reference 33°46' (33.77°) Inside wheel 38°42'+-2° (38.70°+-2°) Outside wheel reference 33°46' (33.77°) Inside wheel 38°18'+-2° (38.30°+-2°) Outside wheel reference 33°32' (33.53°) for Mexico: Wheel turning angle ACV40L-CEAGKA Front wheel alignment GSV40L-CETGKA ACV40L-CEANKA Inside wheel 38°18'+-2° (38.30°+-2°) Outside wheel reference 33°41' (33.68°) Inside wheel 38°18'+-2° (38.30°+-2°) Outside wheel reference 33°41' (33.68°) Inside wheel 38°18'+-2° (38.30°+-2°) Outside wheel reference 33°41' (33.68°) SS–63 SERVICE SPECIFICATIONS – SUSPENSION for USA and Canada: Camber ACV40L-CEAGKA GSV40L-CETGKA ACV40L-AEAGKA GSV40L-AETGKA ACV40L-CEANKA ACV40L-CEMNKA Front wheel alignment GSV40L-CETNKA ACV40L-AEANKA ACV40L-AEMNKA GSV40L-AETNKA ACV40L-CEASKA ACV40L-CEMSKA GSV40L-CETSKA Camber -0°40'+-45' (-0.67°+-0.75°) Right-left difference 45' (0.75°) or less Camber -0°40'+-45' (-0.67°+-0.75°) Right-left difference 45' (0.75°) or less Camber -0°40'+-45' (-0.67°+-0.75°) Right-left difference 45' (0.75°) or less Camber -0°40'+-45' (-0.67°+-0.75°) Right-left difference 45' (0.75°) or less Camber -0°40'+-45' (-0.67°+-0.75°) Right-left difference 45' (0.75°) or less Camber -0°40'+-45' (-0.67°+-0.75°) Right-left difference 45' (0.75°) or less Camber -0°40'+-45' (-0.67°+-0.75°) Right-left difference 45' (0.75°) or less Camber -0°40'+-45' (-0.67°+-0.75°) Right-left difference 45' (0.75°) or less Camber -0°40'+-45' (-0.67°+-0.75°) Right-left difference 45' (0.75°) or less Camber -0°40'+-45' (-0.67°+-0.75°) Right-left difference 45' (0.75°) or less Camber -0°40'+-45' (-0.67°+-0.75°) Right-left difference 45' (0.75°) or less Camber -0°40'+-45' (-0.67°+-0.75°) Right-left difference 45' (0.75°) or less Camber -0°40'+-45' (-0.67°+-0.75°) Right-left difference 45' (0.75°) or less for Mexico: Camber ACV40L-CEAGKA Front wheel alignment GSV40L-CETGKA ACV40L-CEANKA Camber -0°35'+-45' (-0.58°+-0.75°) Right-left difference 45' (0.75°) or less Camber -0°35'+-45' (-0.58°+-0.75°) Right-left difference 45' (0.75°) or less Camber -0°35'+-45' (-0.58°+-0.75°) Right-left difference 45' (0.75°) or less SS SS–64 SERVICE SPECIFICATIONS – SUSPENSION for USA and Canada: Caster ACV40L-CEAGKA GSV40L-CETGKA ACV40L-AEAGKA SS GSV40L-AETGKA ACV40L-CEANKA ACV40L-CEMNKA Front wheel alignment GSV40L-CETNKA ACV40L-AEANKA ACV40L-AEMNKA GSV40L-AETNKA ACV40L-CEASKA ACV40L-CEMSKA GSV40L-CETSKA Caster 3°00'+-45' (3.00°+-0.75°) Right-left difference 45' (0.75°) or less Caster 2°55'+-45' (2.92°+-0.75°) Right-left difference 45' (0.75°) or less Caster 2°55'+-45' (2.92°+-0.75°) Right-left difference 45' (0.75°) or less Caster 2°55'+-45' (2.92°+-0.75°) Right-left difference 45' (0.75°) or less Caster 3°00'+-45' (3.00°+-0.75°) Right-left difference 45' (0.75°) or less Caster 2°55'+-45' (2.92°+-0.75°) Right-left difference 45' (0.75°) or less Caster 2°55'+-45' (2.92°+-0.75°) Right-left difference 45' (0.75°) or less Caster 2°55'+-45' (2.92°+-0.75°) Right-left difference 45' (0.75°) or less Caster 2°55'+-45' (2.92°+-0.75°) Right-left difference 45' (0.75°) or less Caster 2°55'+-45' (2.92°+-0.75°) Right-left difference 45' (0.75°) or less Caster 3°00'+-45' (3.00°+-0.75°) Right-left difference 45' (0.75°) or less Caster 2°55'+-45' (2.92°+-0.75°) Right-left difference 45' (0.75°) or less Caster 2°55'+-45' (2.92°+-0.75°) Right-left difference 45' (0.75°) or less for Mexico: Caster ACV40L-CEAGKA Front wheel alignment GSV40L-CETGKA ACV40L-CEANKA Caster 2°45'+-45' (2.75°+-0.75°) Right-left difference 45' (0.75°) or less Caster 2°40'+-45' (2.67°+-0.75°) Right-left difference 45' (0.75°) or less Caster 2°45'+-45' (2.75°+-0.75°) Right-left difference 45' (0.75°) or less SS–65 SERVICE SPECIFICATIONS – SUSPENSION for USA and Canada: Steering axis inclination ACV40L-CEAGKA GSV40L-CETGKA ACV40L-AEAGKA GSV40L-AETGKA ACV40L-CEANKA ACV40L-CEMNKA Front wheel alignment GSV40L-CETNKA ACV40L-AEANKA ACV40L-AEMNKA GSV40L-AETNKA ACV40L-CEASKA ACV40L-CEMSKA GSV40L-CETSKA Steering axis inclination 12°15'+-45' (12.25°+-0.75°) Right-left difference 45' (0.75°) or less Steering axis inclination 12°15'+-45' (12.25°+-0.75°) Right-left difference 45' (0.75°) or less Steering axis inclination 12°15'+-45' (12.25°+-0.75°) Right-left difference 45' (0.75°) or less Steering axis inclination 12°15'+-45' (12.25°+-0.75°) Right-left difference 45' (0.75°) or less Steering axis inclination 12°15'+-45' (12.25°+-0.75°) Right-left difference 45' (0.75°) or less Steering axis inclination 12°15'+-45' (12.25°+-0.75°) Right-left difference 45' (0.75°) or less Steering axis inclination 12°15'+-45' (12.25°+-0.75°) Right-left difference 45' (0.75°) or less Steering axis inclination 12°15'+-45' (12.25°+-0.75°) Right-left difference 45' (0.75°) or less Steering axis inclination 12°15'+-45' (12.25°+-0.75°) Right-left difference 45' (0.75°) or less Steering axis inclination 12°15'+-45' (12.25°+-0.75°) Right-left difference 45' (0.75°) or less Steering axis inclination 12°15'+-45' (12.25°+-0.75°) Right-left difference 45' (0.75°) or less Steering axis inclination 12°15'+-45' (12.25°+-0.75°) Right-left difference 45' (0.75°) or less Steering axis inclination 12°15'+-45' (12.25°+-0.75°) Right-left difference 45' (0.75°) or less for Mexico: Steering axis inclination ACV40L-CEAGKA Front wheel alignment GSV40L-CETGKA ACV40L-CEANKA Steering axis inclination 12°00'+-45' (12.00°+-0.75°) Right-left difference 45' (0.75°) or less Steering axis inclination 12°00'+-45' (12.00°+-0.75°) Right-left difference 45' (0.75°) or less Steering axis inclination 12°00'+-45' (12.00°+-0.75°) Right-left difference 45' (0.75°) or less front lower ball joint Lower ball joint turning torque 1.0 to 3.4 N*m (10 to 35 kgf*cm, 9 to 30 in.*lbf) front stabilizer link assembly Stabilizer link ball joint turning torque 0.05 to 2.0 N*m (0.5 to 20 kgf*cm, 0.4 to 18 in.*lbf) Toe-in (total) Rear wheel alignment A +B 0 +- 24mm (0 +- 0.4 in.) C-D 4 +- 2mm (0.16 +- 0.08 in.) Rack end length difference 1.5 mm (0.06 in.) or less SS SS–66 SERVICE SPECIFICATIONS – SUSPENSION for USA and Canada: Camber ACV40L-CEAGKA GSV40L-CETGKA ACV40L-AEAGKA SS GSV40L-AETGKA ACV40L-CEANKA ACV40L-CEMNKA Rear wheel alignment GSV40L-CETNKA ACV40L-AEANKA ACV40L-AEMNKA GSV40L-AETNKA ACV40L-CEASKA ACV40L-CEMSKA GSV40L-CETSKA Camber -1°18'+-45' (-1.30°+-0.75°) Right-left difference 45' (0.75°) or less Camber -1°18'+-45' (-1.30°+-0.75°) Right-left difference 45' (0.75°) or less Camber -1°15'+-45' (-1.25°+-0.75°) Right-left difference 45' (0.75°) or less Camber -1°15'+-45' (-1.25°+-0.75°) Right-left difference 45' (0.75°) or less Camber -1°18'+-45' (-1.30°+-0.75°) Right-left difference 45' (0.75°) or less Camber -1°18'+-45' (-1.30°+-0.75°) Right-left difference 45' (0.75°) or less Camber -1°18'+-45' (-1.30°+-0.75°) Right-left difference 45' (0.75°) or less Camber -1°15'+-45' (-1.25°+-0.75°) Right-left difference 45' (0.75°) or less Camber -1°15'+-45' (-1.25°+-0.75°) Right-left difference 45' (0.75°) or less Camber -1°15'+-45' (-1.25°+-0.75°) Right-left difference 45' (0.75°) or less Camber -1°18'+-45' (-1.30°+-0.75°) Right-left difference 45' (0.75°) or less Camber -1°18'+-45' (-1.30°+-0.75°) Right-left difference 45' (0.75°) or less Camber -1°18'+-45' (-1.30°+-0.75°) Right-left difference 45' (0.75°) or less for Mexico: Camber ACV40L-CEAGKA Rear wheel alignment GSV40L-CETGKA ACV40L-CEANKA Rear stabilizer link assembly Camber -1°06'+-45' (-1.10°+-0.75°) Right-left difference 45' (0.75°) or less Camber -1°06'+-45' (-1.10°+-0.75°) Right-left difference 45' (0.75°) or less Camber -1°06'+-45' (-1.10°+-0.75°) Right-left difference 45' (0.75°) or less Stabilizer link ball joint turning torque 0.05 to 1.0 N*m (0.5 to 10 kgf*cm, 0.4 to 8.9 in.*lbf) SS–67 SERVICE SPECIFICATIONS – SUSPENSION TORQUE SPECIFICATIONS FRONT: N*m kgf*cm ft.*lbf Suspension support x Body Part tighten 85 867 63 Shock absorber x Axle 210 2,141 155 Speed sensor wire harness x Shock absorber 19 194 14 Piston rod x Suspension support 70 714 52 Stabilizer link x Shock absorber 74 755 55 Suspension lower No. 1 arm x Member A 200 B 206 A 2,040 B 2,100 A 148 B 152 Engine mounting insulator x Member 87 887 64 Lower ball joint x Steering knuckle 123 1,250 91 Stabilizer bracket x Member 27 275 20 Stabilizer link x Stabilizer bar 74 755 55 Front wheel set nut 103 1,050 76 Tie rod end lock nut 74 755 55 REAR: N*m kgf*cm ft.*lbf Suspension support x Body Part tighten 39 398 29 Shock absorber x Axle carrier 180 1,840 133 Piston rod x Suspension support 55 561 41 Speed sensor wire harness x Shock absorber 5.0 51 44 in.*lbf Flexible hose x Shock absorber 19 194 14 Stabilizer link x Shock absorber 39 398 29 Strut rod x Axle carrier 113 1,152 83 Strut rod x Body 113 1,152 83 Parking brake No. 3 cable x Body 6.0 61 53 in.*lbf Suspension No. 1 arm x Suspension member 100 1,020 74 Suspension No. 1 arm x Axle carrier 100 1,020 74 Suspension No. 2 arm x Suspension member 100 1,020 74 Suspension No. 2 arm x Axle carrier 100 1,020 74 Stabilizer bracket x Suspension member 31 316 23 Stabilizer link x Stabilizer bar 39 398 29 A 55 B 38 A 561 B 388 A 41 B 28 Suspension member x Body 56 571 41 Rear wheel set nut 103 1,050 76 No. 2 Suspension arm lock nut 56 571 41 Suspension member x Suspension member lower stopper SS SS–68 SERVICE SPECIFICATIONS – TIRE AND WHEEL TIRE AND WHEEL SERVICE DATA Cold tire inflation pressure Tire size Front kgf/cm2 Rear P215/60R16 94V 210 kPa (2.1 , 31 psi) 210 kPa (2.1 kgf/cm2, 31 psi) P215/55R17 93V 220 kPa (2.2 kgf/cm2, 32 psi) 220 kPa (2.2 kgf/cm2, 32 psi) When driving under the above vehicle conditions at sustained high speeds above 160 km/h (100 mph), in countries where such speeds are permitted bylaw, inflate the front and rear tires to 240 kPa (2.4 kgf*cm2, 35 psi) provided that it does not exceed the maximum cold tire inflation pressure molded on the tire sidewall. SS Tire runout 1.4 mm (0.055 in.) or less Imbalance after adjustment 8.0 g (0.018 lb) or less SS–69 SERVICE SPECIFICATIONS – TIRE AND WHEEL TORQUE SPECIFICATIONS TIRE PRESSURE WARNING RECEIVER Part tightened Tire pressure warning receiver set bolt N*m kgf*cm ft.*lbf 7.5 77 66 in.*lbf TIRE PRESSURE WARNING VALVE AND TRANSMITTER N*m kgf*cm ft.*lbf Tire pressure warning valve and transmitter set nut Part tightened 4.0 41 35 in.*lbf Front wheel set nuts 103 1,050 76 Rear wheel set nuts 103 1,050 76 N*m kgf*cm ft.*lbf 7.5 77 66 in.*lbf TIRE PRESSURE WARNING ECU Part tightened Tire pressure warning ECU set nut SS SERVICE SPECIFICATIONS – BRAKE CONTROL SS–69 BRAKE CONTROL SERVICE DATA 1 (FL+) - 2 (FL-) LH for BOSCH RH Front speed sensor LH for ADVICS RH LH for BOSCH RH Skid control sensor LH for ADVICS RH VSC NO. 1 (Fail Safe) relay VSC NO. 1 relay Always 0.92 to 1.22 kΩ at 20 °C(68°F) 1 (FL+) - Body ground Always 10 kΩ or higher 2 (FL-) - Body ground Always 10 kΩ or higher 1 (FR+) - 2 (FR-) Always 0.92 to 1.22 kΩ at 20 °C(68°F) 1 (FR+) - Body ground Always 10 kΩ or higher 2 (FR-) - Body ground Always 10 kΩ or higher 1 (FL+) - 2 (FL-) Always 1.4 to 1.8 kΩ at 20°C (68 °F) 1 (FL+) - Body ground Always 10 kΩ or higher 2 (FL-) - Body ground Always 10 kΩ or higher 1 (FR+) - 2 (FR-) Always 1.4 to 1.8 kΩ at 20°C (68 °F) 1 (FR+) - Body ground Always 10 kΩ or higher 2 (FR-) - Body ground Always 10 kΩ or higher 1 (RR+) - 2 (RR-) Always Below 2.2 kΩ 1 (RR+) - Body ground Always 10 kΩ or higher 2 (RR-) - Body ground Always 10 kΩ or higher 1 (RL+) - 2 (RL-) Below Always Below 2.2 kΩ 1 (RL+) - Body ground 10 Always 10 kΩ or higher 2 (RL-) - Body ground Always 10 kΩ or higher 2 (RL+) - 1 (RL-) Always 0.9 to 2.1 kΩ 2 (RL+) - Body ground Always 10 kΩ or higher 1 (RL-) - Body ground Always 10 kΩ or higher 2 (RR+) - 1 (RR-) Always 0.9 to 2.1 kΩ 2 (RR+) - Body ground Always 10 kΩ or higher 1 (RR-) - Body ground Always 10 kΩ or higher Resistance 3 - 5 Always 10 kΩ or higher Resistance 3 - 5 Apply B+ between terminals 1 and 2 Below 1 Ω Resistance 3 - 5 Always 10 kΩ or higher Resistance 3 - 5 Apply B+ between terminals 1 and 2 Below 1 Ω SS SS–70 SERVICE SPECIFICATIONS – BRAKE CONTROL TORQUE SPECIFICATIONS Part tightened Brake actuator x Brake actuator bracket N*m kgf*cm ft.*lbf BOSCH 8 82 71 in.*lbf ADVICS 5.4 55 48 in.*lbf Brake actuator bracket x Body BOSCH with VSC Brake actuator x Brake tube SS Bolt A Bolt B 19 195 14 15 (14) 155 (143) 11 (10) 19 (17) 194 (173) 14 (13) BOSH without VSC 15 (14) 155 (143) 11 (10) ADVICS 15 (14) 155 (143) 11 (10) 8 82 71 in.*lbf Front speed sensor x Knuckle Front speed sensor x Body 5 51 44 in.*lbf Front speed sensor x Absorber 19 194 14 Yaw rate and acceleration sensor 13 133 10 (): For use with SST SERVICE SPECIFICATIONS – BRAKE SS–71 BRAKE SERVICE DATA Brake pedal height Automatic transaxle 129.9 to 139.9 mm(5.114 to 5.508 in.9 Manual transaxle 131.9 to 141.9 mm (5.193 to 5.587 in.) Standard stop light switch clearance 1.5 to 2.5 mm (0.059 to 0.098 in.) Brake pedal free play 1.0 to 6.0 mm (0.039 to 0.236 in.) Brake pedal reserve distance from dash panel at 500 N (51 kgf, 112 lbf) Brake booster push rod to piston clearance (for TMMK made) Front brake pad lining thickness Front brake disc thickness Front brake disc runout Rear disc brake pad lining thickness Rear brake disc thickness Rear brake disc runout Automatic transaxle 61 mm (2.502 in.) Manual transaxle 63 mm (2.480 in.) Standard clearance 0 mm (0 in.) Standard 12.0 mm (0472 in.) Minimum 1.0 mm (0.039 in.) Standard 28.0 mm (1.102 in.) Minimum 25.0 mm (0.983 in.) Maximum 0.05 mm (0.0020in.) Standard 11.0 mm (0.433 in.) Minimum 1.0 mm (0.039 in.) Standard 10.0 mm (0.390 in.) Minimum 8.5 mm (0.334 in.) Maximum 0.15 mm (0.0059 in.) SS SS–72 SERVICE SPECIFICATIONS – BRAKE TORQUE SPECIFICATIONS Parts tightened Brake master cylinder x Brake tube N*m kgf*cm ft.*lbf for TMC made 15 (14) 155 (143) 11 (11) for TMMK made without VSC 15 (14) 155 (143) 11 (11) Nut (A) 15 (14) 155 (143) 11 (11) Nut (B) for TMMK made with VSC SS 19 (17) 194 (173) 14 (13) Brake booster clevis lock nut 26 265 19 Brake light switch 1.5 15 13 in.*lbf Brake pedal sub-assembly set bolt 37 377 27 Brake pedal support assembly x Body 19 194 14 Brake pedal support assembly x No. 1 brake pedal support plate 13 133 10 No. 1 brake pedal support x Body 19 194 14 Brake master cylinder x Brake booster Cowl top outer front panel sub-assembly x Body 13 133 10 Nut 85 867 63 Bolt 5.0 51 44 in.*lbf Brake booster assembly x Brake pedal support assembly 13 133 10 Front brake cylinder mounting x Steering knuckle 107 1,090 79 Bleeder plug 8.3 85 73 in.*lbf Front disc brake cylinder mounting x Front disc brake cylinder assembly 34 350 25 Front disc brake cylinder assembly x Flexible hose Flexible hose x Tube 29 300 21 15 (14) 155 (143) 11 (10) Front flexible hose x Absorber 19 194 14 Rear disc brake cylinder mounting set bolt 62 632 46 Rear disc brake cylinder mounting x Rear disc brake cylinder assembly 27 275 20 Rear disc brake cylinder assembly x Flexible hose 33 337 24 Rear flexible hose x Absorber 19 194 14 (): For use with SST SS–73 SERVICE SPECIFICATIONS – PARKING BRAKE PARKING BRAKE SERVICE DATA Parking brake pedal travel at 300 N (31 kgf, 68 lbf) 7 to 10 notches Parking brake lever travel at 200 N (20 kgf, 45 lbf) 7 to 9 notches Rear brake disc inside diameter Parking brake shoe lining thickness Clearance between parking brake shoe and parking brake she lever Standard 170 mm (6.69 in.) Maximum 171 mm (6.73 in.) Standard 2.0 mm (0.079 in.) Maximum 1.0 mm (0.039 in.) Less than 0.35 mm (0.014 in.) SS SS–74 SERVICE SPECIFICATIONS – PARKING BRAKE TORQUE SPECIFICATIONS Parts tightened N*m kgf*cm Wheel nut 103 1050 76 Wire adjusting No. 1 nut (for Automatic Transaxle) 5.4 55 48 in.*lbf Wire adjusting No. 1 nut (for Manual Transaxle) 5.0 51 44 in.*lbf Parking brake switch assembly 1.0 10 9.0 in.*lbf Parking brake lever sub-assembly x Body SS for TMC made 21 214 15 for TMMK made 22 224 16 Parking brake pedal assembly x Body No. 1 parking brake cable assembly x Body ft.*lbf 39 398 29 Bolt 15 153 11 Nut 5.4 55 48 in.*lbf No. 1 parking brake cable assembly x No. 4 parking brake cable assembly 5.4 55 48 in.*lbf Floor shift lever assembly x Body 12 122 9 Bolt (A) 8.5 87 75 in.*lbf Bolt (B) 6.0 61 53 in.*lbf No. 3 parking brake cable assembly x Body 6.0 61 53 in.*lbf No. 3 parking brake assembly x Backing plate Nut (C) 8.0 82 71 in.*lbf No. 2 front floor heat lower insulator x Body 4.9 50 43 in.*lbf Rear disc brake caliper set bolt 62 632 46 Parking brake shoe guide plate set bolt 18 184 13 SS–74 SERVICE SPECIFICATIONS – STEERING COLUMN STEERING COLUMN SERVICE DATA Steering free play (Maximum) SS 30 mm (1.18 in.) SS–75 SERVICE SPECIFICATIONS – STEERING COLUMN TORQUE SPECIFICATIONS Part tightened Steering intermediate shaft assembly x Steering column assembly (for TMC made) N*m kgf*cm ft.*lbf 35 360 26 Steering column assembly set nuts (for TMC made) 25 255 18 Steering column assembly set bolt (for TMC made) 25 255 18 Steering intermediate shaft assembly x Power steering link assembly (for TMC made) 35 360 26 Steering post assembly set nuts (for TMMK made) 21 214 16 Steering post assembly set bolt (for TMMK made) 21 214 16 Steering post assembly x Power steering link assembly (for TMMK made) 35 360 26 Steering wheel assembly set nut 50 510 37 SS SERVICE SPECIFICATIONS – POWER STEERING SS–75 POWER STEERING SERVICE DATA POWER STEERING FLUID Fluid level rise (Maximum) 5 mm (0.20 in.) Fluid pressure at idle speed with valve closed 7,800 to 8,300 kPa (79.5 to 84.6 kgf/cm2, 1,131 to 1,204 psi) Fluid pressure at idle speed with valve fully open and turn the steering wheel to the full lock position 7,800 to 8,300 kPa (79.5 to 84.6 kgf/cm2, 1,131 to 1,204 psi) SS STEERING WHEEL Steering effort at idle speed (Reference) LE Grade, XLE Grade 6.0 N*m (61 kgf*cm, 53 in.*lbf) SE Grade 6.8 N*m (69 kgf*cm, 60 in.*lbf) VANE PUMP (for 2AZ-FE) Vane pump shaft and vane pump housing oil clearance (Maximum) 0.07 mm (0.0028 in.) Vane plate thickness (Standard) 1.405 to 1.411 mm (0.05531 to 0.05555 in.) Clearance between the rotor groove and plate (Maximum) 0.03 mm (0.0012 in.) Compression spring free length (Minimum) 29.2 mm (1.150 in.) Vane pump rotating torque 0.27 N*m (2.8 kgf*cm, 2.4 in.*lbf) VANE PUMP (for 2GR-FE) Vane pump shaft and vane pump housing oil clearance (Maximum) 0.07 mm (0.0028 in.) Vane plate thickness (Standard) 1.405 to 1.411 mm (0.05531 to 0.05555 in.) Clearance between the rotor groove and plate (Maximum) 0.03 mm (0.0012 in.) Compression spring free length (Minimum) 29.2 mm (1.150 in.) Vane pump rotating torque 0.27 N*m (2.8 kgf*cm, 2.4 in.*lbf) POWER STEERING LINK Steering rack runout (Maximum) 0.3 mm (0.0118 in.) Tie rod end sub-assembly stud bolt turning torque 0.98 to 3.92 N*m (10 to 40 kgf*cm, 8.7 to 34.7 in.*lbf) Total preload (Control valve rotating torque) 1.5 N*m (15.3 kgf*cm, 13.3 in.*lbf) or less SS–76 SERVICE SPECIFICATIONS – POWER STEERING TORQUE SPECIFICATIONS VANE PUMP (for 2AZ-FE) Part tightened Vane pump rear housing x Vane pump front housing kgf*cm ft.*lbf 22 224 16 Pressure port union x Vane pump front housing 69 704 51 Power steering fluid pressure switch x Vane pump assembly 21 214 16 Power steering suction port union x Vane pump assembly Vane pump assembly set bolts SS N*m 12 122 9 29 (43) 294 (439) 21 (32) Pressure feed tube assembly x Vane pump assembly (union bolt) 50 510 37 Front wheel RH set nuts 103 1,050 76 N*m kgf*cm ft.*lbf 22 224 16 ( ): For use without SST VANE PUMP (for 2GR-FE) Part tightened Vane pump rear housing x Vane pump front housing Pressure port union x Vane pump front housing 69 704 51 Power steering fluid pressure switch x Vane pump assembly 21 214 16 Power steering suction port union x Vane pump assembly Vane pump assembly set bolts 12 122 9 29 (43) 294 (439) 21 (32) Pressure feed tube assembly clamp set bolt 9.8 100 87 in.*lbf Pressure feed tube assembly x Vane pump assembly (union bolt) 50 510 37 Front wheel RH set nuts 103 1,050 76 N*m kgf*cm ft.*lbf Power steering control valve housing x Rack housing 21 214 16 Control valve lock nut 25 250 18 ( ): For use without SST POWER STEERING LINK Part tightened Rack housing cap 54 546 40 Steering rack end sub-assembly 60 (84) 613 (852) 44 (62) Right turn pressure tube x Power steering link assembly (union nut) 11 (13) 114 (128) 8 (9) Left turn pressure tube x Power steering link assembly (union nut) 11 (13) 114 (128) 8 (9) Power steering link assembly set bolts 70 714 52 Pressure feed tube assembly clamp set bolts 9.8 100 87 in.*lbf 22 (25) 227 (250) 16 (18) 49 500 36 Pressure feed tube assembly x Power steering link assembly (union nut) Tie rod assembly x Steering knuckle Steering sliding yoke x Power steering link assembly 35 360 26 Front wheels set nuts 103 1,050 76 ( ): For use without SST SERVICE SPECIFICATIONS – AIR CONDITIONING SS–77 AIR CONDITIONING SERVICE DATA Refrigerant charge volume (Standard:) 450 to 550g (15.9 to 19.4 oz.) Magnetic clutch clearance 0.26 to 0.60 mm (0.010 to 0.024 in.) SS SS–78 SERVICE SPECIFICATIONS – AIR CONDITIONING TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Air conditioning unit assembly x Body 9.8 100 87 in.*lbf Instrument panel reinforcement assembly x Body (Collar) 6.0 61 53 in.*lbf Instrument panel reinforcement assembly x Body (Passenger seat) 20 204 15 Instrument panel reinforcement assembly x Body (Driver seat) 17 175 13 Air conditioning tube assembly x Cooler expansion valve 3.5 35 30 in.*lbf Suction pipe sub-assembly x Air conditioning tube assembly 9.8 100 7 9.8 100 7 Compressor and magnetic clutch x Engine 25 255 18 No. 1 cooler refrigerant discharge hose x Compressor and magnetic clutch 9.8 100 7 No. 1 cooler refrigerant suction hose x Compressor and magnetic clutch 9.8 100 7 Magnet clutch hub x Cooler compressor assembly 18 184 13 AIR CONDITIONING UNIT SS BLOWER UNIT Blower assembly x Instrument panel reinforcement assembly COMPRESSOR AND MAGNETIC CLUTCH (for 2GRFE) COMPRESSOR AND PULLEY (for 2AZ-FE) Compressor and pulley x Engine 25 255 18 No. 1 cooler refrigerant discharge hose x Compressor and pulley 9.8 100 7 No. 1 cooler refrigerant suction hose x Compressor and pulley 9.8 100 7 Cooler condenser assembly x Radiator assembly 5.0 51 44 in.*lbf Cooler refrigerant discharge pipe x Cooler condenser assembly 9.8 100 87 in.*lbf Air conditioner tube and accessory x Cooler condenser assembly 9.8 100 87 in.*lbf Cap x cooler condenser assembly 2.9 30 26 in.*lbf CONDENSER SS–78 SERVICE SPECIFICATIONS – SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM TORQUE SPECIFICATIONS SS Part Tightened N*m kgf*cm ft.*lbf Steering pad x Steering wheel assembly 8.8 90 78 in.*lbf Driver side knee airbag assembly x Instrument panel reinforcement 10 102 7 Curtain shield airbag assembly x Body 11 112 8 Center airbag sensor assembly x Body 17.5 179 13 Front airbag sensor x Body 17.5 179 13 Side airbag sensor x Body 9.0 92 80 in.*lbf Rear airbag sensor x Body 9.0 92 80 in.*lbf Seat position sensor x Front seat assembly 8.0 82 71 in.*lbf SS–79 SERVICE SPECIFICATIONS – SEAT BELT SEAT BELT TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf 42 428 31 Front seat outer belt assembly (Floor anchor) x Body 42 428 31 Front seat outer belt assembly (Shoulder anchor) x Front shoulder belt anchor adjuster assembly 42 428 31 Front shoulder belt anchor adjuster assembly x Body 42 428 31 Front seat outer belt assembly (For upper bolt) x Body 7.5 77 66 in.*lbf Front seat outer belt assembly (For lower bolt) x Body 42 428 31 Rear seat inner with center belt assembly RH (For TMC Made) x Body 42 428 31 Rear seat inner with center belt assembly RH (For TMMK Made) x Body 42 428 31 Rear seat inner with center belt assembly LH floor anchor (For TMC Made) x Body 42 428 31 Rear seat inner with center belt assembly LH floor anchor (For TMMK Made) x Body 42 428 31 Rear seat outer belt assembly floor anchor (For LH side) x Body 42 428 31 Rear seat outer belt assembly floor anchor (For RH side) x Body 42 428 31 Rear seat inner with center belt assembly LH x Body 42 428 31 42 428 31 FRONT SEAT INNER BELT ASSEMBLY Front seat inner belt assembly x Front seat assembly FRONT SEAT OUTER BELT ASSEMBLY REAR SEAT INNER BELT ASSEMBLY REAR SEAT OUTER BELT ASSEMBLY Rear seat outer belt assembly floor anchor (For LH side) x Body Rear seat outer belt assembly floor anchor (For RH side) x Body 42 428 31 Rear seat outer belt assembly x Body 42 428 31 21 214 16 18 184 13 CHILD RESTRAINT SEAT TETHER ANCHOR Child restraint seat tether anchor bracket x Body CHILD RESTRAINT SEAT ANCHOR BRACKET Child restraint seat anchor bracket subassembly x Body SS SS–80 SERVICE SPECIFICATIONS – THEFT DETERRENT SYSTEM THEFT DETERRENT SYSTEM TORQUE SPECIFICATIONS SS Part Tightened N*m kgf*cm ft.*lbf Security horn assembly x Body 31 316 23 SS–81 SERVICE SPECIFICATIONS – CRUISE CONTROL CRUISE CONTROL TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Cruise control main switch x Steering wheel 2.4 24 21 in.*lbf Clutch switch x Clutch Pedal 15.7 160 12 ft.*lbf Main body ECU (Cowl side junction block) x Instrument panel reinforcement 8.0 82 71 in.*lbf SS SS–82 SERVICE SPECIFICATIONS – LIGHTING LIGHTING TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf 3.6 37 32 in.*lbf 1.6 16 14 in.*lbf Rear combination assembly x Body 3.6 37 32 in.*lbf Rear light assembly x Body 3.6 37 32 in.*lbf 1.6 16 14 in.*lbf 12 122 8.9 12 122 8.9 5.5 56 49 in.*lbf HEADLIGHT ASSEMBLY Headlight assembly x Body FOG LIGHT ASSEMBLY SS Fog light assembly x Front bumper assembly REAR COMBINATION LIGHT ASSEMBLY HIGH MOUNTED STOP LIGHT ASSEMBLY High mounted stop light assembly x Package tray trim panel assembly FRONT DOOR COURTESY SWITCH Front door courtesy switch assembly x Body REAR DOOR COURTESY SWITCH Rear door courtesy switch assembly x Body BACK DOOR COURTESY SWITCH Luggage compartment door lock assembly x Body SS–83 SERVICE SPECIFICATIONS – WIPER AND WASHER WIPER AND WASHER TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Front wiper arm and blade assembly LH x Windshield wiper motor and link assembly 20 204 15 Front wiper arm and blade assembly RH x Windshield wiper motor and link assembly 20 204 15 Windshield wiper motor and link assembly x Body 7.5 77 66 in.*lbf Windshield wiper link assembly x Windshield wiper motor assembly 5.4 55 48 in.*lbf FRONT WIPER MOTOR SS SS–84 SERVICE SPECIFICATIONS – DOOR LOCK DOOR LOCK TORQUE SPECIFICATIONS FRONT DOOR LOCK SS Part Tightened N*m kgf*cm ft*lbf Front door lock assembly x Door panel 5.0 51 44 in.*lbf Part Tightened N*m kgf*cm ft*lbf Rear door lock assembly x Door panel 5.0 51 44 in.*lbf REAR DOOR LOCK SS–85 SERVICE SPECIFICATIONS – METER METER TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Steering pad switch x Steering wheel 2.4 24 21 in.*lbf Upper steering column cover x Lower steering column cover 2.0 20 18 in.*lbf SS SS–86 SERVICE SPECIFICATIONS – AUDIO / VISUAL AUDIO / VISUAL TORQUE SPECIFICATIONS SS Part Tightened N*m kgf*cm ft.*lbf Steering pad switch x Steering wheel 2.4 24 21 in.*lbf SS–87 SERVICE SPECIFICATIONS – HORN HORN TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Low pitched horn x Body 20 204 15 High pitched horn x Body 20 204 15 SS SS–88 SERVICE SPECIFICATIONS – WINDSHIELD / WINDOWGLASS WINDSHIELD / WINDOWGLASS TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Front power window regulator motor assembly x Front door window regulator sub-assembly 5.4 55 48 in.*lbf Front door window regulator subassembly x Front door 8.0 82 71 in.*lbf Front door glass sub-assembly x Front door window regulator subassembly 5.5 56 49 in.*lbf Rear power window regulator motor assembly x Rear door window regulator sub-assembly 5.4 55 48 in.*lbf Rear door window regulator subassembly x Rear door 8.0 82 71 in.*lbf Inner rear view mirror assembly x Windshield glass 1.8 18 16 in.*lbf Front wiper arm and blade assembly x Windshield wiper motor and link assembly 20 204 15 Rear seat inner with center belt assembly LH x Body 42 428 31 Child restraint seat anchor bracket sub-assembly LH x Body 18 184 13 Rear seat outer belt assembly x Body 42 428 31 Rear seat back assembly x Body 18 184 13 Rear side seat back assembly x Body 18 184 13 Separate type rear seat back assembly x Body 18 184 13 Reclining remote control lever sub-assembly x Body 18 184 13 Center seat back assembly x Body 18 184 13 POWER WINDOW REGULATOR MOTOR SS WINDSHIELD GLASS BACK WINDOW GLASS SS–89 SERVICE SPECIFICATIONS – MIRROR MIRROR TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Inner rear view mirror x Windshield glass 1.8 18 16 in.*lbf Outer rear view mirror assembly x Door panel 5.5 56 49 in.*lbf SS SS–90 SERVICE SPECIFICATIONS – INSTRUMENT PANEL INSTRUMENT PANEL TORQUE SPECIFICATIONS Part Tightened SS N*m kgf*cm ft.*lbf Instrument Panel Reinforcement x Passenger Airbag 20 204 15 Upper Steering Column Cover x Lower Steering Column Cover 2.0 20 18 in.*lbf SS–91 SERVICE SPECIFICATIONS – SEAT SEAT TORQUE SPECIFICATIONS FRONT SEAT Part Tightened N*m kgf*cm ft.*lbf Front seat back cover bracket x Front seat frame 5.5 56 48 in.*lbf Front seat x Body 37 377 27 SS REAR SEAT (for Fixed Type) Part Tightened N*m kgf*cm ft.*lbf Rear seat back assembly x Body 18 184 13 REAR SEAT (for Fold Down Seat Type) Part Tightened N*m kgf*cm ft.*lbf Separate type rear seat back assembly x Body 18 184 13 Rear side seat back assembly x Body 18 184 13 REAR SEAT (for Reclining Seat Type) Part Tightened N*m kgf*cm ft.*lbf Separate type rear seat back assembly x Body 18 184 13 Center seat back assembly x Body 18 184 13 Rear seat reclining adjuster assembly x Body 18 184 13 Reclining remote control lever sub- assembly x Body 18 184 13 SS–92 SERVICE SPECIFICATIONS – ENGINE HOOD / DOOR ENGINE HOOD / DOOR TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf HOOD SS Hood hinge x Hood panel 13 133 10 Hood lock x Body 7.5 77 66 in.*lbf Door check x Body 26 265 19 Door check x Door panel 8.0 82 71 in.*lbf Door hinge x Body 26 265 19 FRONT DOOR Door hinge x Door panel 26 265 19 Door lock x Door panel 5.0 51 44 in.*lbf Door lock striker x Body 23 235 17 Power window regulator motor x Window regulator 5.4 55 48 in.*lbf Window regulator x Door panel 8.0 82 71 in.*lbf Door glass x Window regulator 5.5 56 49 in.*lbf Outer rear view mirror x Door panel 5.5 56 49 in.*lbf Door outside handle frame x Door panel 4.0 41 35 in.*lbf Door check x Body 26 265 19 Door check x Door panel 8.0 82 71 in.*lbf Door hinge x Body 26 265 19 REAR DOOR Door hinge x Door panel 26 265 19 Door lock x Door panel 5.0 51 44 in.*lbf Door lock striker x Body 23 235 17 Power window regulator motor x Window regulator 5.4 55 48 in.*lbf Window regulator x Door panel 8.0 82 71 in.*lbf Door outside handle frame x Door panel 4.0 41 35 in.*lbf 7.5 77 66 in.*lbf Luggage lock striker x Body 5.5 56 49 in.*lbf Luggage lock x Door panel 5.5 56 49 in.*lbf Luggage lock cylinder x Door panel 5.5 56 49 in.*lbf LUGGAGE DOOR Luggage door hinge x Door panel SS–93 SERVICE SPECIFICATIONS – EXTERIOR EXTERIOR TORQUE SPECIFICATIONS N*m kgf*cm ft.*lbf Front bumper reinforcement sub-assembly set bolt Part tightened 34 347 25 Rear bumper reinforcement sub-assembly set nut 68 693 50 SS SS–94 SERVICE SPECIFICATIONS – INTERIOR INTERIOR TORQUE SPECIFICATIONS Part Tightened SS N*m kgf*cm ft.*lbf Front seat outer belt assembly LH floor anchor x Body 42 428 31 Front seat outer belt assembly RH floor anchor x Body 42 428 31 SS–95 SERVICE SPECIFICATIONS – SLIDING ROOF SLIDING ROOF TORQUE SPECIFICATIONS Part Tightened Sliding roof glass sub-assembly x Sliding roof housing sub-assembly N*m kgf*cm ft.*lbf 4.0 41 35 in.*lbf Sliding roof housing sub-assembly (Bolt) x Body 5.5 56 49 in.*lbf Sliding roof housing sub-assembly (Nut) x Body 5.5 56 49 in.*lbf Sliding roof drive gear sub-assembly x Sliding roof housing sub-assembly 5.4 55 48 in.*lbf Sliding roof piece sub-assembly LH x Sliding roof housing sub-assembly 2.0 20 18 in.*lbf Sliding roof piece sub-assembly RH x Sliding roof housing sub-assembly 2.0 20 18 in.*lbf Sliding roof side stopper x Sliding roof housing sub-assembly 2.0 20 18 in.*lbf SS FOREWORD This repair manual has been prepared to provide essential information on body panel repair methods (including cutting and welding operations, but excluding painting) for the TOYOTA CAMRY. Applicable models: ACV 40 series GSV 40 series This manual consists of body repair methods, exploded diagrams and illustrations of the body components and other information relating to body panel replacement such as handling precautions, etc. However, it should be noted that the front fenders of this TOYOTA model are bolted on and require no welding. When repairing, don’t cut and join areas that are not shown in this manual. Only work on the specified contents to maintain body strength. Body construction will sometimes differ depending on specifications and country of destination. Therefore, please keep in mind that the information contained herein is based on vehicles for general destinations. For the repair procedures and specifications other than collisiondamaged body components of the TOYOTA CAMRY refer to the repair manuals. If you require the above manuals, please contact your TOYOTA dealer. All information contained in this manual is the most up-to-date at the time of publication. However, specifications and procedures are subject to change without prior notice. ABOUT THIS MANUAL Scope of the repair work explanation
This text explains the welding panel replacement instructions from the vehicle’s white body condition. We have abbreviated the explanations of the removal and reinstallation of the equipment parts up to the white body condition and of the installation, inspection, adjustment and final inspection of equipment parts after replacing the weld panel. Section categories
This manual has been divided as shown below. Section Title Contents Examples INTRODUCTION Explanation of general body repair. Views of weld panel replacement instructions. Cautionary items. Views of weld panel replacement instructions. BODY PANEL REPLACEMENT Instructions for replacing the weld panels from the white body condition, from which bolted parts have been removed, with individual supply parts. Front side member replacement. Quarter panel replacement. BODY DIMENSIONS Body aligning measurements. Dimension diagrams. PAINT
COATING Scope and type of anti-rust treatment, etc. together with weld panel replacement. Under coating. Body sealer. Contents omitted in this manual.
Make sure to perform the following essential procedures, although they are omitted in this manual. (1) Clean and wash removed parts, if necessary. (2) Visual inspection. INTRODUCTION IN-1 PRECAUTION GENERAL REPAIR INSTRUCTIONS 1. WORK PRECAUTIONS (a) VEHICLE PROTECTION (1) When welding, protect the painted surfaces, windows, seats and carpet with heat resistant, fireproof covers. Glass Cover Seat Cover F33000 (b) SAFETY (1) Never stand in a direct line with the chain when using a puller on the body or frame, and be sure to attach a safety cable. WRONG F33001 (2) Before performing repair work, check for fuel leaks. If a leak is found, be sure to close the opening completely. (3) If it is necessary to use a flame in the area of the fuel tank, first remove the tank and plug the fuel line. WRONG F33002 (c) F33003 SAFETY WORK CLOTHES (1) In addition to the usual mechanic’s wear, cap and safety shoes, the appropriate gloves, head protector, glasses, ear plugs, face protector, dust-prevention mask, etc. should be worn as the situation demands. Code Name A Dust-Prevention Mask B Face Protector C Eye Protector D Safety Shoes E Welder’s Glasses F Ear Plugs G Head Protector H Welder’s Gloves INTRODUCTION IN-2 PRECAUTIONS FOR REPAIRING BODY STRUCTURE PANELS 1. Toyota prohibits the use of the heat repair method on body structure panels when repairing a vehicle damaged in a collision. Panels that have high strength and rigidity, as well as a long life span for the automobile body are in high demand. At Toyota, in order to fulfill these requirements, we use high tensile strength steel sheets and rust preventive steel sheets on the body. High tensile steel sheets are made with alloy additives and a special heat treatment in order to improve their strength. To prevent the occurrence of rust for a long period of time, the surface of the steel is coated with a zinc alloy. If body structure parts are heat repaired with an acetylene torch or other heating source, the crystalline organization of the steel sheet will change and their strength of the steel sheet will be reduced. The ability of the body to resist rust is significantly lowered as well since the rust resistant zinc coating is destroyed by heat and the steel sheet surface is oxidized. F33014 2. F33015 HEAT REPAIR FOR BODY STRUCTURE PANELS STRUCTURE PANEL KINKS A sharp deformation angle on a panel that cannot be returned to its original shape by pulling or hammering is called a kink. Structural parts are designed to perform in their original shape. If parts are deformed in an accident, or if the deformed parts are repaired and reused, the parts may be unable to perform as intended. It is necessary to replace the part where the kink has occurred. INTRODUCTION 3. F33016 F33017 IN-3 IMPACT BEAM REPAIR The impact beam and bracket are necessary and important parts that help reduce the probability of injury to passengers in side collisions. For impact beams, we use special high tensile strength steel. The high tensile strength steel maintains its special crystalline organization by heat treatment or alloy additives. Structural parts are designed to perform in their original shape. If parts are deformed in an accident, or if the deformed parts are repaired and reused, the parts may be unable to perform as intended. If the impact beam or bracket is damaged, replace the door assembly that has the damaged beam. Also, the bumper reinforcement is a necessary and important part that helps reduce the probability of injury to passengers in front collisions, and for the same reasons explained above, should be replaced if damaged. INTRODUCTION IN-4 PROPER AND EFFICIENT WORK PROCEDURES 1. Body Measument Diagrams REMOVAL (a) PRE-REMOVAL MEASURING (1) Before removal or cutting operations, take measurements in accordance with the dimensions diagram. Always use a puller to straighten a damaged body or frame. F33020 (b) CUTTING AREA (1) Always cut in a straight line and avoid cutting reinforced areas. Cutting Okay Corners Reinforcement F33021 (c) WRONG PRECAUTIONS FOR DRILLING OR CUTTING (1) Check behind any area to be drilled or cut to ensure that there are no hoses, wires, etc., that may be damaged. HINT: See “Handling Precautions on Related Components” on page IN-9. F33022 (d) REMOVAL OF ADJACENT COMPONENTS (1) When removing adjacent components, apply protective tape to the surrounding body and your tools to prevent damage. HINT: See “Handling Precautions on Related Components” on page IN-9. F33007 INTRODUCTION 2. IN-5 PREPARATION FOR INSTALLATION (a) SPOT WELD POINTS (1) When welding panels with a combined thickness of over 3 mm (0.12 in.), use a MIG (Metal Inert Gas) welder for plug welding. HINT: Spot welding does not provide sufficient durability for panels with a combined thickness of over 3 mm (0.12 in.) Less than 3 mm F10011A (b) APPLICATION OF WELD-THROUGH PRIMER (SPOT SEALER) (1) Remove the paint from the portion of the new parts and body to be welded, and apply weld-through primer. F33008 (c) MAKING HOLES FOR PLUG WELDING (1) For areas where a spot welder cannot be used, use a puncher or drill to make holes for plug welding. REFERENCE: mm (in.) Thickness of welded portion Puncher Size of plug hole 1.0 (0.04) under ø 5 (0.20) over 1.0 (0.04) − 1.6 (0.06) ø 6.5 (0.26) over 1.7 (0.07) − 2.3 (0.09) ø 8 (0.31) over 2.4 (0.09) over ø 10 (0.39) over F33009 (d) SAFETY PRECAUTIONS FOR ELECTRICAL COMPONENTS (1) When welding, there is a danger that electrical components will be damaged by the electrical current flowing through the body. (2) Before starting work, disconnect the negative terminal of the battery and ground the welder near the welding location of the body. F33023 Air Saw 20 − 30 mm Overlap F33024 (e) ROUGH CUTTING OF JOINTS (1) For joint areas, rough cut the new parts, leaving 20 − 30 mm (0.79 − 1.18 in.) of overlap. INTRODUCTION IN-6 3. INSTALLATION (a) PRE-WELDING MEASUREMENTS (1) Always take measurements before installing underbody or engine components to ensure correct assembly. After installation, confirm proper fit. F33025 (b) WELDING PRECAUTIONS (1) The number of welding spots should be as follows. Spot weld: 1.3 X No. of manufacturer’s spots. Plug weld: More than No. of manufacturer’s plugs. (2) Plug welding should be done with a MIG (Metal Inert Gas) welder. Do not gas weld or braze panels at areas other than where specified. WRONG F10017A (c) CORRECT POST-WELDING REFINISHING (1) Always check the welded spots to ensure that they are secure. (2) When smoothing out the weld spots with a disc grinder, be careful not to grind off too much as this will weaken the weld. WRONG F10018A (d) SPOT WELD LOCATIONS (1) Avoid welding over previously welded areas. Old Spot Locations New Spot Locations F33010 Tip Cutter F10019A (e) SPOT WELDING PRECAUTIONS (1) The shape of the tip point of the spot welder significantly affects the strength of the weld. Therefore, maintain the tip point in the proper shape, and allow it to cool after every five or six spots. (2) Completely remove the paint from the areas to be spot welded, including the seams and the surfaces that come in contact with the welding tip. (3) Use a sander to remove any burrs that are created during spot welding. INTRODUCTION 4. Sealer Gun IN-7 ANTI-RUST TREATMENT AFTER INSTALLATION (BEFORE PAINTING PROCESS) (a) BODY SEALER APPLICATION (1) For water-proofing and anti-corrosion measures, always apply the body sealer to the body panel seams and hems of the doors, hood, etc. F33011 (b) UNDERCOAT APPLICATION (1) To prevent corrosion and protect the body from damage by flying stones, always apply sufficient under coating to the bottom surface of the under body and inside of the wheel housings. F33012 5. ANTI-RUST TREATMENT AFTER INSTALLATION (AFTER PAINTING PROCESS) (a) ANTI-RUST AGENT (WAX) APPLICATION (1) To preserve impossible to paint areas from corrosion, always apply sufficient anti-rust agent (wax) to the inside of the hemming areas of the doors and hood, and around the hinges, or the welded surfaces inside the box-shaped cross sections of the side members, body pillars, etc. F33013 INTRODUCTION IN-8 6. ANTI-RUST TREATMENT BY PAINTING REFERENCE: Painting prevents corrosion and protects the sheet metal from damage. In this section, anti-chipping paint only for anti-corrosion purposes is described. (a) ANTI-CHIPPING PAINT (1) To prevent corrosion and protect the body from damage by flying stones, etc., apply anti-chipping paint to the rocker panel, wheel arch areas, balance panel, etc. HINT: Depending on the model or the application area, there are cases where the application of anti-chipping paint is necessary before the second coat or after the top coat.
Apply the anti-chipping paint after the top coat.
Apply the anti-chipping paint before the second coat. Anti-Chipping Paint Top Coat Second Coat Top Coat Second Coat Anti-Chipping Paint Under Coat (ED Primer) Under Coat (ED Primer) Steel Metal Steel Metal F10024A INTRODUCTION IN-9 HANDLING PRECAUTIONS ON RELATED COMPONENTS 1. BRAKE SYSTEM The brake system is one of the most important safety components. Always follow the directions and notes given in the brake section of the repair manual for the relevant model year when handling brake system parts. NOTICE: When repairing the brake master cylinder or TRAC system, bleed the air out of the TRAC system. 2. DRIVE TRAIN AND CHASSIS The drive train and chassis are components that can have great effects on the running performance and vibration resistance of the vehicle. After installing components in the sections listed in the table below, perform alignments to ensure correct mounting angles and dimensions. Body repair must be particularly accurate to ensure correct alignment. HINT: Correct procedures and special tools are required for alignment. Always follow the directions given in the repair manual for the relevant model year during alignment and in section DI of this section. 3. Component to be aligned Section of repair manual for relevant model Front Wheels Front Suspension section Rear Wheels Rear Suspension section COMPONENTS ADJACENT TO THE BODY PANELS Various types of component parts are mounted directly on or adjacently to the body panels. Strictly observe the following precautions to prevent damaging these components and the body panels during handling.
Before repairing the body panels, remove their components or apply protective covers over the components.
Before prying components off using a screwdriver or a scraper, etc., attach protective tape to the tool tip or blade to prevent damaging the components and the body paint.
Before removing components from the outer surface of the body, attach protective tape to the body to ensure no damage to painted areas. HINT: Apply touch-up paint to any damaged paint surfaces.
Before drilling or cutting sections, make sure that there are no wires, etc., on the reverse side. 4. ECU (ELECTRONIC CONTROL UNIT) Many ECUs are mounted in this vehicle. Take the following precautions during body repair to prevent damage to the ECUs.
Before starting electric welding operations, disconnect the negative (−) terminal cable from the battery. When the negative (−) terminal cable is disconnected from the battery, the memory of the clock and audio systems will be erased. So, before starting work, make a record of the contents memorized by each memory system. Then when work is finished, reset the clock and audio systems as before. When the vehicle has tilt and telescopic steering, power seats and outside rear view mirrors, which are all equipped with a memory function, it is not possible to make a record of the memory contents. When the operation is finished, it will be necessary to explain this fact to the customer, and request the customer to adjust the features and reset the memory.
Do not expose the ECUs to ambient temperatures above 80C (176F). NOTICE: Since it is possible that the ambient temperature may reach 80C (176F) or more, remove the ECUs from the vehicle before starting work.
Be careful not to drop the ECUs and not to apply physical shocks to them. INTRODUCTION IN-10 DAMAGED VEHICLE DISPOSAL PRECAUTION (SRS AIRBAG SYSTEM) For SRS airbag system adjustment methods, refer to the TOYOTA Repair Manual. (1) When using an electric welder, first remove all airbags and the seat belt pretensioner. (2) If impacts are likely to occur to the front airbag sensor, side airbag sensor, rear airbag sensor or seat position sensor, remove each sensor as necessary beforehand. (3) Do not allow the front airbag sensor, side airbag sensor, rear airbag sensor or seat position sensor to become heated to high temperatures. COMBINATION METER ASSEMBLY: CLOCK ASSEMBLY: SRS WARNING LIGHT PASSENGER AIRBAG ON / OFF INDICATOR CURTAIN SHIELD AIRBAG ASSEMBLY LH FRONT PASSENGER AIRBAG ASSEMBLY CURTAIN SHIELD AIRBAG ASSEMBLY RH FRONT SEAT OUTER BELT ASSEMBLY RH DRIVER SIDE KNEE AIRBAG ASSEMBLY SPIRAL CABLE STEERING PAD CENTER AIRBAG SENSOR ASSEMBLY FRONT SEAT OUTER BELT ASSEMBLY LH C123719 INTRODUCTION IN-11 FRONT SEAT SIDE AIRBAG ASSEMBLY LH REAR AIRBAG SENSOR RH REAR AIRBAG SENSOR LH FRONT SEAT SIDE AIRBAG ASSEMBLY RH SIDE AIRBAG SENSOR RH SIDE AIRBAG SENSOR LH SEAT POSITION SENSOR FRONT SEAT INNER BELT ASSEMBLY LH OCCUPANT CLASSIFICATION ECU FRONT AIRBAG SENSOR LH FRONT AIRBAG SENSOR RH C123718 INTRODUCTION IN-12 HANDLING PRECAUTIONS OF PLASTIC BODY PARTS 1. 2. 3. The repair procedure for plastic body parts must conform with the type of plastic material. Plastic body parts are identified by the codes in the following table. When repairing metal body parts adjoining plastic body parts (by brazing, frame cutting, welding, painting etc.), consideration must be given to the properties of the plastic. Code Material name Heat* resistant temperature limit
C (
F) Resistance to alcohol or gasoline Notes AAS Acrylonitrile Acrylic Styrene 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid gasoline and organic or aromatic solvents. ABS Acrylonitrile Butadiene Styrene 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid gasoline and organic or aromatic solvents. AES Acrylonitrile Ethylene Styrene 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid gasoline and organic or aromatic solvents. ASA Acrylonitrile Styrene Acrylate 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid gasoline and organic or aromatic solvents. EPDM Ethylene Propylene 100 (212) Alcohol is harmless. Gasoline is harmless if applied only for short time in small amounts. Most solvents are harmless but avoid dipping in gasoline, solvents, etc. PA Polyamide (Nylon) 80 (176) Alcohol and gasoline are harmless. Avoid battery acid. PBT Polybutylene Terephthalate 160 (320) Alcohol and gasoline are harmless. Most solvents are harmless. PC Polycarbonate 120 (248) Alcohol is harmless. Avoid gasoline, brake fluid, wax, wax removers and organic solvents. Avoid alkali. Polyoxymethylene (Polyacetal) 100 (212) Alcohol and gasoline are harmless. Most solvents are harmless. Polypropylene 80 (176) Alcohol and gasoline are harmless. Most solvents are harmless. Polymethyl Methacrylate 80 (176) Alcohol is harmless if applied only for short time in small amounts. Avoid dipping or immersing in alcohol, gasoline, solvents, etc. PVC Polyvinylchloride (Vinyl) 80 (176) Alcohol and gasoline are harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid dipping or immersing in alcohol, gasoline, solvents, etc. TPO Thermoplastic Olefine 80 (176) Alcohol is harmless. Gasoline is harmless if applied only for short time in small amounts. Most solvents are harmless but avoid dipping in gasoline, solvents, etc. TOYOTA Super Olefine Polymer 80 (176) Alcohol and gasoline are harmless. Most solvents are harmless. POM PP PMMA TSOP *Temperatures higher than those listed here may result in material deformation during repair. INTRODUCTION IN-13 Door Window Frame Moulding (PP) Emblem (AES) Front Fender To Cowl Side Seal (PP / EPDM) Cowl Top Ventilator Louver (PP / TSOP) Wiper Blade (PBT) Ex. U.S.A: Side Turn Signal Light (ABS / PMMA) Roof Drip Side Finish Moulding (TPO) Outer Rear View Mirror (ABS / PA / AES) Front Door Outside Handle (PC) Foglight (ASA / PBT) Rear Door Outside Handle (PC) Headlight (PC/PP) Radiator Grille (ABS) Front Bumper Extension Mounting Bracket (TSOP) Front Bumper Cover (TSOP) F30269 INTRODUCTION IN-14 97 Door Belt Moulding (POM / PVC) Door Window Frame Moulding (ASA) Emblem (ABS) Luggage Compartment Opening Door Outside Garnish (TSOP) Licence Plate Light (PC) Emblem (TSOP) Rocker Panel Mounting (TSOP) Rear Light (ASA / PMMA) Rear Combination Light (ASA / PMMA) Rear Bumper (TSOP) F30269A INTRODUCTION IN-15 ABOUT THIS VEHICLE STRUCTUAL OUTLINE Laser welding (12points) Adhesive Application Area . . . Over 590Mpa High strength steel . . . Over 440Mpa High strength steel . . . Formed material application areas (refer to PC-8) F30267 INTRODUCTION IN-16 NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP VEHICLE 1. NOTICE FOR USING JACK AND SAFETY STAND Front : JACK POSITION : SUPPORT POSITION, PANTOGRAPH JACK POSITION : CENTER OF VEHICLE GRAVITY (unloaded condition) D100366 INTRODUCTION 2. IN-17 NOTICE FOR USING SWING ARM TYPE LIFT Center of Lift CENTER OF VEHICLE GRAVITY (unloaded condition) Rubber Attachment D100367 3. NOTICE FOR USING PLATE TYPE LIFT Attachment Dimensions 85 mm (3.35 in.) 70 mm (2.76 in.) Attachment 100 mm (3.94 in.) HINT: Right and left set position Place the vehicle over the center of the lift. 200 mm (7.87 in.) mm (in.) HINT: Front and left set position Place the attachments at the ends of the rubber plate surface, under the vehicle lift pad (A and C in the illustration). Raise the plate slightly and reposition the vehicle so the top of the attachment (B in the illustration) is aligned with the front side notch in the vehicle rocker flange. F30268 INTRODUCTION IN-18 DAMAGE DIAGNOSIS Confirmation Point Collision Direction Collision Force Absorption Direction Front Body Pillar Upper Reinforcement Rocker Panel Reinforecement Front Bumper Reinforcement Front Side Member Roof Reinforcement Center Pillar Reinforcement Floor Cross Member Front Body Pillar Reinforcement F30266 INTRODUCTION IN-19 COMPORNENTS 1. Front bumper for 2GR-FE: COOL AIR IN TAKE DUCT SEAL RADIATOR GRILLE PROTECTOR RADIATOR GRILLE PROTECTOR FRONT BUMPER ASSEMBLY B137228 INTRODUCTION IN-20 FRONT BUMPER SIDE RETAINER RH 34 (347, 25) 34 (347, 25) FRONT BUMPER REINFORCEMENT SUB-ASSEMBLY FRONT BUMPER ENERGY ABSORBER FRONT BUMPER SIDE RETAINER LH CAUTION: The bolts and nuts must be tightened to the torque specification, as they are related to vehicle safety during a collision. N.m (kgf.cm, ft..lbf) : Specified torque B137743 INTRODUCTION 2. IN-21 Rear bumper REAR BUMPER SIDE SUPPORT RH REAR BUMPER SIDE RETAINER RH REAR BUMPER REINFORCEMENT SUB-ASSEMBLY REAR BUMPER SIDE RETAINER LH WHEEL HOUSE REINFORCEMENT RH 68 (693, 50) REAR BUMPER SIDE SUPPORT LH 68 (693, 50) REAR BUMPER BAR WHEEL HOUSE REINFORCEMENT LH REAR BUMPER PAD REAR BUMPER PLATE LH REAR BUMPER ENERGY ABSORBER REAR BUMPER PAD REAR BUMPER PLATE RH CAUTION: The bolts and nuts must be tightened to the torque specification, as they are related to vehicle safety during a collision. N.m (kgf.cm, ft..lbf) : Specified torque B137225 INTRODUCTION IN-22 3. Instrument panel INSTRUMENT PANEL NO. 1 SPEAKER PANEL SUB-ASSEMBLY INSTRUMENT PANEL NO. 2 SPEAKER PANEL SUB-ASSEMBLY NO. 1 DEFROSTER NOZZLE GARNISH for LH Side: for RH Side: FRONT NO. 2 SPEAKER ASSEMBLY FRONT NO. 2 SPEAKER ASSEMBLY FRONT PASSENGER AIRBAG ASSEMBLY INSTRUMENT PANEL WIRE ASSEMBLY INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY INSTRUMENT PANEL NO. 3 REGISTER ASSEMBLY FRONT PILLAR GARNISH CLIP FRONT PILLAR GARNISH CLIP FRONT PILLAR GARNISH RH FRONT PILLAR GARNISH LH 20 (204, 15) INSTRUMENT PANEL SAFETY PAD ASSEMBLY COMBINATION METER ASSEMBLY without Smart Key System: LOWER INSTRUMENT PANEL FINISH PANEL INSTRUMENT CLUSTER FINISH PANEL with Smart Key System: NO. 1 INSTRUMENT PANEL SUB-ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL CAUTION: The bolts and nuts must be tightened to the torque specification, as they are related to vehicle safety during a collision. N.m (kgf.cm, ft..lbf) : Specified torque Non-reusable part B137286 INTRODUCTION IN-23 TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY STEERING PAD 2.0 (20, 18 in..lbf) 50 (510, 37) STEERING COLUMN COVER STEERING WHEEL ASSEMBLY LOWER NO. 3 STEERING WHEEL COVER SHIFT LEVER KNOB SUB-ASSEMBLY LOWER NO. 2 STEERING WHEEL COVER 8.8 (90, 78 in..lbf) FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY UPPER CONSOLE REAR PANEL SUB-ASSEMBLY RADIO RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY NO. 1 CONSOLE BOX INSERT FRONT UPPER CONSOLE PANEL SUB-ASSEMBLY NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH NO. 2 CONSOLE BOX INSERT FRONT 17.5 (179, 13) CONSOLE BOX CARPET CENTER AIRBAG SENSOR ASSEMBLY CONSOLE BOX POCKET CONSOLE BOX ASSEMBLY CAUTION: The bolts and nuts must be tightened to the torque specification, as they are related to vehicle safety during a collision. N.m (kgf.cm, ft..lbf) : Specified torque B137285 INTRODUCTION IN-24 with Plasmacluster: NO. 3 INSTRUMENT PANEL STAY GLOVE BOX LIGHT ASSEMBLY DEFROSTER NOZZLE ASSEMBLY PLASMACLUSTER NO. 2 HEATER TO REGISTER DUCT SIDE NO. 2 DEFROSTER NOZZLE DUCT SIDE NO. 1 DEFROSTER NOZZLE DUCT NO. 3 HEATER TO REGISTER DUCT NO. 1 HEATER TO REGISTER DUCT NO. 2 ANTENNA CORD SUB-ASSEMBLY with Navigation System: 7.0 (71, 62 in..lbf) NAVIGATION ANTENNA ASSEMBLY LOWER INSTRUMENT PANEL SUB-ASSEMBLY INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL LH COWL SIDE TRIM SUB-ASSEMBLY RH COWL SIDE TRIM CLIP FRONT DOOR SCUFF PLATE RH CAUTION: The bolts and nuts must be tightened to the torque specification, as they are related to vehicle safety during a collision. N.m (kgf.cm, ft..lbf) : Specified torque B137288 INTRODUCTION 4. IN-25 Interior trim UPPER CENTER PILLAR GARNISH REAR DOOR OPENING TRIM WEATHERSTRIP FRONT DOOR OPENING TRIM WEATHERSTRIP ROOF SIDE INNER GARNISH LH REAR DOOR SCUFF PLATE LOWER CENTER PILLAR GARNISH 42 (428, 31) FRONT SHOULDER BELT ANCHOR ADJUSTER ASSEMBLY 42 (428, 31) FRONT DOOR SCUFF PLATE for Reclining Seat Type: 42 (428, 31) FRONT SEAT OUTER BELT ASSEMBLY 7.5 (77, 66 in..lbf) 18 (184, 13) 42 (428, 31) LAP BELT OUTER ANCHOR COVER 42 (428, 31) RECLINING REMOTE CONTROL LEVER SUB-ASSEMBLY LH CAUTION: The bolts and nuts must be tightened to the torque specification, as they are related to vehicle safety during a collision. N.m (kgf.cm, ft..lbf) : Specified torque B132005 INTRODUCTION IN-26 for Reclining Seat Type: PACKAGE TRAY TRIM PANEL ASSEMBLY PACKAGE TRAY TRIM PANEL ASSEMBLY REAR SEAT SHOULDER BELT COVER CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY RH REAR SEAT OUTER BELT ASSEMBLY REAR SEAT SHOULDER BELT COVER 42 (428, 31) 18 (184, 13) REAR SEAT SHOULDER BELT HOLE COVER 18 (184, 13) 42 (428, 31) CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH 42 (428, 31) 42 (428, 31) REAR SEAT INNER WITH CENTER BELT ASSEMBLY RH REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH REAR SEAT OUTER BELT ASSEMBLY for Fold Down Seat Type: 42 (428, 31) CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY RH 18 (184, 13) CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH CAUTION: The bolts and nuts must be tightened to the torque specification, as they are related to vehicle safety during a collision. N.m (kgf.cm, ft..lbf) : Specified torque B132019 INTRODUCTION IN-27 without Sliding Roof: REAR ASSIST GRIP SUB-ASSEMBLY FRONT ASSIST GRIP SUB-ASSEMBLY ASSIST GRIP COVER ASSIST GRIP COVER ROOF HEADLINING ASSEMBLY REAR ASSIST GRIP SUB-ASSEMBLY NO. 1 ROOM LIGHT ASSEMBLY LENS COVER VISOR BRACKET COVER FRONT ASSIST GRIP SUB-ASSEMBLY ASSIST GRIP COVER VISOR ASSEMBLY RH VISOR HOLDER ASSIST GRIP COVER ROOF CONSOLE BOX ASSEMBLY VISOR ASSEMBLY LH VISOR HOLDER VISOR BRACKET COVER B132051 INTRODUCTION IN-28 with Sliding Roof: FRONT ASSIST GRIP SUB-ASSEMBLY REAR ASSIST GRIP SUB-ASSEMBLY ASSIST GRIP COVER ASSIST GRIP COVER ROOF HEADLINING ASSEMBLY with Rear Sunshade: SUNSHADE TRIM HOLDER SPOT LIGHT ASSEMBLY VISOR BRACKET COVER REAR ASSIST GRIP SUB-ASSEMBLY VISOR ASSEMBLY RH ASSIST GRIP COVER ROOF CONSOLE BOX ASSEMBLY FRONT ASSIST GRIP SUB-ASSEMBLY ASSIST GRIP COVER VISOR HOLDER VISOR ASSEMBLY LH VISOR HOLDER VISOR BRACKET COVER SUN ROOF OPENING TRIM MOULDING B132052 INTRODUCTION 5. IN-29 Front seat for Manual Seat: FRONT SEAT HEADREST ASSEMBLY 42 (428, 31) INNER SEAT TRACK BRACKET COVER FRONT SEAT INNER BELT ASSEMBLY 37 (377, 27) SEAT TRACK COVER 37 (377, 27) FRONT SEAT ASSEMBLY for Power Seat: FRONT SEAT HEADREST ASSEMBLY 37 (377, 27) INNER SEAT TRACK BRACKET COVER FRONT SEAT INNER BELT ASSEMBLY 37 (377, 27) SEAT TRACK COVER 37 (377, 27) FRONT SEAT ASSEMBLY CAUTION: The bolts and nuts must be tightened to the torque specification, as they are related to vehicle safety during a collision. N.m (kgf.cm, ft..lbf) : Specified torque B132031 INTRODUCTION IN-30 6. Rear seat for Fixed Seat Type: REAR SEAT HEADREST ASSEMBLY REAR CENTER SEAT HEADREST ASSEMBLY REAR SEAT BACK ASSEMBLY 18 (184, 13) 18 (184, 13) REAR SEAT CUSHION ASSEMBLY CAUTION: The bolts and nuts must be tightened to the torque specification, as they are related to vehicle safety during a collision. N.m (kgf.cm, ft..lbf) : Specified torque B136589 INTRODUCTION IN-31 for Fold Down Seat Type: REAR SEAT HEADREST ASSEMBLY REAR CENTER SEAT HEADREST ASSEMBLY 18 (184, 13) 18 (184, 13) 18 (184, 13) REAR SIDE SEAT BACK ASSEMBLY RH SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH 18 (184, 13) REAR SEAT CUSHION ASSEMBLY REAR SIDE SEAT BACK ASSEMBLY LH CAUTION: The bolts and nuts must be tightened to the torque specification, as they are related to vehicle safety during a collision. N.m (kgf.cm, ft..lbf) : Specified torque B135415 INTRODUCTION IN-32 for Reclining Seat Type: REAR SEAT HEADREST ASSEMBLY 18 (184, 13) REAR CENTER SEAT HEADREST ASSEMBLY CENTER SEAT BACK ASSEMBLY REAR SEAT BACK COVER 18 (184, 13) 18 (184, 13) 18 (184, 13) SEPARATE TYPE REAR SEAT BACK ASSEMBLY RH REAR SEAT BACK COVER 18 (184, 13) SEPARATE TYPE REAR SEAT BACK ASSEMBLY LH REAR SEAT CUSHION ASSEMBLY CAUTION: The bolts and nuts must be tightened to the torque specification, as they are related to vehicle safety during a collision. N.m (kgf.cm, ft..lbf) : Specified torque B139095 INTRODUCTION IN-33 WHEEL ALIGNMENT STANDARD 1. FRONT WHEEL ALIGNMENT Standard vehicle height: for USA and Canada: Model Front A − B Rear C − D ACV40L-CEAGKA 125 mm (4.92 in.) 54 mm (2.13 in.) GSV40L-CETGKA 126 mm (4.96 in.) 55 mm (2.17 in.) ACV40L-AEAGKA 125 mm (4.92 in.) 53 mm (2.09 in.) GSV40L-AETGKA 126 mm (4.96 in.) 54 mm (2.13 in.) ACV40L-CEANKA 125 mm (4.92 in.) 54 mm (2.13 in.) ACV40L-CEMNKA 125 mm (4.92 in.) 53 mm (2.09 in.) GSV40L-CETNKA 126 mm (4.96 in.) 55 mm (2.17 in.) ACV40L-AEANKA 125 mm (4.92 in.) 53 mm (2.09 in.) ACV40L-AEMNKA 125 mm (4.92 in.) 52 mm (2.05 in.) GSV40L-AETNKA 126 mm (4.96 in.) 54 mm (2.13 in.) ACV40L-CEASKA 128 mm (5.04 in.) 57 mm (2.24 in.) ACV40L-CEMSKA 127 mm (5.00 in.) 55 mm (2.17 in.) GSV40L-CETSKA 129 mm (5.08 in.) 58 mm (2.28 in.) C132408 for Mexico: Model Front A − B Rear C − D ACV40L-CEAGKA 115 mm (4.53 in.) 40 mm (1.57 in.) GSV40L-CETGKA 116 mm (4.57 in.) 41 mm (1.61 in.) ACV40L-CEANKA 115 mm (4.53 in.) 40 mm (1.57 in.) Model Front A − B Rear C − D ACV40L-AEANKW 115 mm (4.53 in.) 38 mm (1.50 in.) ACV40R-AEANKW 115 mm (4.53 in.) 38 mm (1.50 in.) for General export: ACV40L-AEMNKW 117 mm (4.61 in.) 42 mm (1.65 in.) ACV40R-AEMNKW 117 mm (4.61 in.) 42 mm (1.65 in.) GSV40L-AETGKW 117 mm (4.61 in.) 42 mm (1.65 in.) GSV40R-AETGKW 117 mm (4.61 in.) 42 mm (1.65 in.) INTRODUCTION IN-34 Standard wheel angle: for USA and Canada: Model Inside wheel Outside wheel (reference) ACV40L-CEAGKA 38
22’ +−2
(38.37
+−2
) 33
33’ (33.55
) GSV40L-CETGKA 38
22’ +−2
(38.37
+−2
) 33
33’ (33.55
) ACV40L-AEAGKA 38
22’ +−2
(38.37
+−2
) 33
33’ (33.55
) GSV40L-AETGKA 38
22’ +−2
(38.37
+−2
) 33
33’ (33.55
) ACV40L-CEANKA 38
22’ +−2
(38.37
+−2
) 33
33’ (33.55
) ACV40L-CEMNKA 38
22’ +−2
(38.37
+−2
) 33
33’ (33.55
) GSV40L-CETNKA 38
22’ +−2
(38.37
+−2
) 33
33’ (33.55
) ACV40L-AEANKA 38
22’ +−2
(38.37
+−2
) 33
33’ (33.55
) ACV40L-AEMNKA 38
22’ +−2
(38.37
+−2
) 33
33’ (33.55
) GSV40L-AETNKA 38
22’ +−2
(38.37
+−2
) 33
33’ (33.55
) ACV40L-CEASKA 38
42’ +−2
(38.70
+−2
) 33
46’ (33.77
) ACV40L-CEMSKA 38
42’ +−2
(38.70
+−2
) 33
46’ (33.77
) GSV40L-CETSKA 38
18’ +−2
(38.30
+−2
) 33
32’ (33.53
) Model Inside wheel Outside wheel (reference) ACV40L-CEAGKA 38
18’ +−2
(38.30
+−2
) 33
41’ (33.68
) GSV40L-CETGKA 38
18’ +−2
(38.30
+−2
) 33
41’ (33.68
) ACV40L-CEANKA 38
18’ +−2
(38.30
+−2
) 33
41’ (33.68
) for Mexico: for General export: Model Inside wheel Outside wheel (reference) for General export 38
42’ +−2
(38.70
+− 2
) 33
46’ (33.77
) Front A: Inside B: Outside C132439 INTRODUCTION IN-35 Standard camber inclination: for USA and Canada: Alignment Tester Model Camber Right-left difference ACV40L-CEAGKA −0
40’ +−45’ (−0.67
+−0.75
) 45’ (0.75
) or less GSV40L-CETGKA −0
40’ +−45’ (−0.67
+−0.75
) 45’ (0.75
) or less ACV40L-AEAGKA −0
40’ +−45’ (−0.67
+−0.75
) 45’ (0.75
) or less GSV40L-AETGKA −0
40’ +−45’ (−0.67
+−0.75
) 45’ (0.75
) or less ACV40L-CEANKA −0
40’ +−45’ (−0.67
+−0.75
) 45’ (0.75
) or less ACV40L-CEMNKA −0
40’ +−45’ (−0.67
+−0.75
) 45’ (0.75
) or less GSV40L-CETNKA −0
40’ +−45’ (−0.67
+−0.75
) 45’ (0.75
) or less ACV40L-AEANKA −0
40’ +−45’ (−0.67
+−0.75
) 45’ (0.75
) or less ACV40L-AEMNKA −0
40’ +−45’ (−0.67
+−0.75
) 45’ (0.75
) or less GSV40L-AETNKA −0
40’ +−45’ (−0.67
+−0.75
) 45’ (0.75
) or less ACV40L-CEASKA −0
40’ +−45’ (−0.67
+−0.75
) 45’ (0.75
) or less ACV40L-CEMSKA −0
40’ +−45’ (−0.67
+−0.75
) 45’ (0.75
) or less GSV40L-CETSKA −0
40’ +−45’ (−0.67
+−0.75
) 45’ (0.75
) or less Model Camber Right-left difference ACV40L-CEAGKA −0
35’ +−45’ (−0.58
+−0.75
) 45’ (0.75
) or less GSV40L-CETGKA −0
35’ +−45’ (−0.58
+−0.75
) 45’ (0.75
) or less ACV40L-CEANKA −0
35’ +−45’ (−0.58
+−0.75
) 45’ (0.75
) or less Gauge C132440 for Mexico: for General export: Model Camber Right-left difference for General export −0
30’ +−45’ (−0.50
+− 0.75
) 45’ (0.75
) or less INTRODUCTION IN-36 Standard caster inclination: for USA and Canada: Model Caster Right-left difference ACV40L-CEAGKA 3
00’ +−45’ (3.00
+−0.75
) 45’ (0.75
) or less GSV40L-CETGKA 2
55’ +−45’ (2.92
+−0.75
) 45’ (0.75
) or less ACV40L-AEAGKA 2
55’ +−45’ (2.92
+−0.75
) 45’ (0.75
) or less GSV40L-AETGKA 2
55’ +−45’ (2.92
+−0.75
) 45’ (0.75
) or less ACV40L-CEANKA 3
00’ +−45’ (3.00
+−0.75
) 45’ (0.75
) or less ACV40L-CEMNKA 2
55’ +−45’ (2.92
+−0.75
) 45’ (0.75
) or less GSV40L-CETNKA 2
55’ +−45’ (2.92
+−0.75
) 45’ (0.75
) or less ACV40L-AEANKA 2
55’ +−45’ (2.92
+−0.75
) 45’ (0.75
) or less ACV40L-AEMNKA 2
55’ +−45’ (2.92
+−0.75
) 45’ (0.75
) or less GSV40L-AETNKA 2
55’ +−45’ (2.92
+−0.75
) 45’ (0.75
) or less ACV40L-CEASKA 3
00’ +−45’ (3.00
+−0.75
) 45’ (0.75
) or less ACV40L-CEMSKA 2
55’ +−45’ (2.92
+−0.75
) 45’ (0.75
) or less GSV40L-CETSKA 2
55’ +−45’ (2.92
+−0.75
) 45’ (0.75
) or less Model Caster Right-left difference ACV40L-CEAGKA 2
45’ +−45’ (2.75
+−0.75
) 45’ (0.75
) or less GSV40L-CETGKA 2
40’ +−45’ (2.67
+−0.75
) 45’ (0.75
) or less ACV40L-CEANKA 2
45’ +−45’ (2.75
+−0.75
) 45’ (0.75
) or less for Mexico: for General export: Model Caster Right-left difference for General export 2
40’ +− 45’ (2.67
+− 0.75
) 45’ (0.75
) or less INTRODUCTION Steering axis inclination: for USA and Canada: Model Steering axis inclination Right-left difference ACV40L-CEAGKA 12
15’ +−45’ (12.25
+−0.75
) 45’ (0.75
) or less GSV40L-CETGKA 12
15’ +−45’ (12.25
+−0.75
) 45’ (0.75
) or less ACV40L-AEAGKA 12
15’ +−45’ (12.25
+−0.75
) 45’ (0.75
) or less GSV40L-AETGKA 12
15’ +−45’ (12.25
+−0.75
) 45’ (0.75
) or less ACV40L-CEANKA 12
15’ +−45’ (12.25
+−0.75
) 45’ (0.75
) or less ACV40L-CEMNKA 12
15’ +−45’ (12.25
+−0.75
) 45’ (0.75
) or less GSV40L-CETNKA 12
15’ +−45’ (12.25
+−0.75
) 45’ (0.75
) or less ACV40L-AEANKA 12
15’ +−45’ (12.25
+−0.75
) 45’ (0.75
) or less ACV40L-AEMNKA 12
15’ +−45’ (12.25
+−0.75
) 45’ (0.75
) or less GSV40L-AETNKA 12
15’ +−45’ (12.25
+−0.75
) 45’ (0.75
) or less ACV40L-CEASKA 12
15’ +−45’ (12.25
+−0.75
) 45’ (0.75
) or less ACV40L-CEMSKA 12
15’ +−45’ (12.25
+−0.75
) 45’ (0.75
) or less GSV40L-CETSKA 12
15’ +−45’ (12.25
+−0.75
) 45’ (0.75
) or less Model Steering axis inclination Right-left difference ACV40L-CEAGKA 12
00’ +−45’ (12.00
+−0.75
) 45’ (0.75
) or less GSV40L-CETGKA 12
00’ +−45’ (12.00
+−0.75
) 45’ (0.75
) or less ACV40L-CEANKA 12
00’ +−45’ (12.00
+−0.75
) 45’ (0.75
) or less for Mexico: for General export: Model Steering axis inclination Right-left difference for General export 12
00’ +− 45’ (12.00
+− 0.75
) 45’ (0.75
) or less IN-37 INTRODUCTION IN-38 Standard Toe-in (total): A − B: 0 +− 2 mm (0 +− 0.08 in.) Dimension A Front C125226 Dimension B Tread Center Marks C125225 2. REAR WHEEL ALIGNMENT Standard toe-in: Toe−in (total) A + B: C − D: — Front 0
+− 24’ (0
+− 0.4
) 4 +− 2 mm (0.16 +− 0.08 in.) C132438 INTRODUCTION Standard camber: for USA and Canada: Model Camber Right-left difference ACV40L-CEAGKA −1
18’ +−45’ (−1.30
+−0.75
) 45’ (0.75
) or less GSV40L-CETGKA −1
18’ +−45’ (−1.30
+−0.75
) 45’ (0.75
) or less ACV40L-AEAGKA −1
15’ +−45’ (−1.25
+−0.75
) 45’ (0.75
) or less GSV40L-AETGKA −1
15’ +−45’ (−1.25
+−0.75
) 45’ (0.75
) or less ACV40L-CEANKA −1
18’ +−45’ (−1.30
+−0.75
) 45’ (0.75
) or less ACV40L-CEMNKA −1
18’ +−45’ (−1.30
+−0.75
) 45’ (0.75
) or less GSV40L-CETNKA −1
18’ +−45’ (−1.30
+−0.75
) 45’ (0.75
) or less ACV40L-AEANKA −1
15’ +−45’ (−1.25
+−0.75
) 45’ (0.75
) or less ACV40L-AEMNKA −1
15’ +−45’ (−1.25
+−0.75
) 45’ (0.75
) or less GSV40L-AETNKA −1
15’ +−45’ (−1.25
+−0.75
) 45’ (0.75
) or less ACV40L-CEASKA −1
18’ +−45’ (−1.30
+−0.75
) 45’ (0.75
) or less ACV40L-CEMSKA −1
18’ +−45’ (−1.30
+−0.75
) 45’ (0.75
) or less GSV40L-CETSKA −1
18’ +−45’ (−1.30
+−0.75
) 45’ (0.75
) or less Model Camber Right-left difference ACV40L-CEAGKA −1
06’ +−45’ (−1.10
+−0.75
) 45’ (0.75
) or less GSV40L-CETGKA −1
06’ +−45’ (−1.10
+−0.75
) 45’ (0.75
) or less ACV40L-CEANKA −1
06’ +−45’ (−1.10
+−0.75
) 45’ (0.75
) or less for Mexico: for General export: Model Camber Right-left difference for General export −1
00’ +−45’ (−1.00
+−0.75
) 45’ (0.75
) or less IN-39 INTRODUCTION IN-40 HOW TO USE THIS MANUAL 1. BODY PANEL REPLACEMENT THIS MANUAL BODY PANEL REPLACEMENT BP-34 QUARTER PANEL (CUT)
With the body lower back panel removed. Symbol meaning : Remove Weld Points : Cut and Join Location : Cut Location for Supply Parts REMOVAL Fuel Filler Opening Lid 150 (5.91) 150 (5.91) 40 (1.57) mm (in.) REMOVAL POINT 1. Remove the Fuel Filler Opening Lid at the same time. REPLACEMENT PART AND METHOD INSTALLATION OF WELD POINTS QUARTER PANEL (CUT) Weld method and panel position symbols (See page IN-44) Replacement method (ASSY)...Assembly replacement (CUT)...Major cutting (less than 1/2 of part used) (CUT-H)...Half cutting (about 1/2 of part used) (CUT-P)...Partial cutting (most of part used) Replacement part SYMBOLS (See page IN-42) PART LOCATION REMOVAL CONDITIONS SYMBOL MEANING REMOVAL DIAGRAM Describes in detail the removal of the damaged part involving repair by cutting. REMOVAL GUIDE Provides additional information to more efficiently help you perform the removal. F33027 INTRODUCTION IN-41 7 BP-36 BODY PANEL REPLACEMENT Symbol meaning : Mig Plug Weld : Body Sealer : Spot Weld : Butt Weld INSTALLATION Fuel Filler Opening Lid Rivets 5 (0.20) mm (in.) POINT 1.Before temporarily installing the new parts, apply body sealer to the wheel arch. HINT 1) Apply body sealer evenly about 5 mm (0.20 in.) from the flange, avoiding any oozing. 2) Apply sealer evenly, about 3 − 4 mm (0.12 − 0.16 in.) in diameter. 2.Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) 3.After welding, apply body sealer and undercoating to the corresponding parts. SYMBOLS INSTALLATION DIAGRAM Describes in detail the installation to the new parts involving repair by welding and / or cutting, but excluding painting. INSTALLATIOLN GUIDE Provides additional information to more efficiently help you perform the installation. SYMBOLS (See page IN-42) INSTALLATION OF WELD POINTS (See page IN-44) Weld method and panel position symbols PART NAME F33026 INTRODUCTION IN-42 2. SYMBOLS The following symbols are used in the welding diagrams in section BP of this manual to indicate cutting areas and the types of weld required. SYMBOLS MEANING SYMBOLS MEANING ILLUSTRATION CUT AND JOIN LOCATION (Saw Cut) CUT AND JOIN LOCATION (Cut Location for Supply Parts) CUT CUT LOCATION CUT WITH DISC SANDER ETC. BRAZE BRAZE (Removal) BRAZE BRAZE (Installation) WELD POINTS — SPOT WELD OR MIG PLUG WELD CONTINUOUS MIG WELD (BUTT WELD) WELDING CONTINUOUS MIG WELD (TACK WELD) SEALER BODY SEALER F33004 INTRODUCTION SYMBOLS MEANING SYMBOLS — IN-43 MEANING ILLUSTRATION Assembly Mark — BODY SEALER (Flat Finishing) — — — BODY SEALER (Flat Finishing) F33005 INTRODUCTION IN-44 3. ILLUSTRATION OF WELD POINT SYMBOLS EXAMPLE: REMOVAL INSTALLATION Weld points Weld points Remove weld point and panel position SYMBOLS MEANING Remove Weld Points ILLUSTRATION Remove weld point and panel position SYMBOLS MEANING ILLUSTRATION Spot Weld (Outside) MIG Plug Weld (Middle) Spot MIG Weld (Inside) F33006 INTRODUCTION IN-45 ABBREVIATIONS USED IN THIS MANUAL For convenience, the following abbreviations are used in this manual. ABS Antilock Brake System A/C Air Conditioner assy assembly ECT Electronic Controlled Transmission ECU Electronic Control Unit e.g. Exempli Gratia (for Example) Ex. Except FWD Front Wheel Drive Vehicles 2WD Two Wheel Drive Vehicles 4WD Four Wheel Drive Vehicles in. inch LH Left-hand LHD Left-hand Drive MIG Metal Inert Gas M/Y Model Year PPS Progressive Power Steering RH Right-hand RHD Right-hand Drive SRS Supplemental Restraint System SSM Special Service Materials w/ with w/o without BODY PANEL REPLACEMENT BP-1 RADIATOR UPPER SUPPORT (ASSY): TMC made Symbol meaning REMOVAL : Remove Weld Points INSTALLATION : MIG Plug Weld F25701A F25701B REMOVAL.INSTALLATION Front Fender Gusset F25701 INSTALLATION POINT 1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. 2 Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) 3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. BODY PANEL REPLACEMENT BP-2 RADIATOR SUPPORT UPPER BRACE (ASSY): TMC made With the radiator upper support removed. Symbol meaning REMOVAL : Remove Weld Points INSTALLATION : MIG Plug Weld F25702A F25702B REMOVAL.INSTALLATION Front Bumper Upper Arm Radiator Support F25702 REMOVAL POINT 1 Remove the radiator support at the same time. INSTALLATION POINT 1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. 2 Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) 3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. BODY PANEL REPLACEMENT BP-3 522 (20.55) 1,482 (58.35) 1,218 (47.95) 1,462 (57.56) 872 (34.33) 456 (17.95) 978 (38.50) mm (in.) F25704 INSTALLATION POINT 1 Measure the dimensions before installing the headlights. 2 These values are reference values. BODY PANEL REPLACEMENT BP-4 RADIATOR SIDE SUPPORT (ASSY): TMMK made Symbol meaning F25703A REMOVAL : Remove Weld Points INSTALLATION : MIG Plug Weld F25703B REMOVAL.INSTALLATION Front Bumper Upper Arm F25703 INSTALLATION POINT 1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. 2 Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) 3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. BODY PANEL REPLACEMENT BP-5 522 (20.55) 1,482 (58.35) 1,218 (47.95) 1,462 (57.56) 872 (34.33) 456 (17.95) 978 (38.50) mm (in.) F25704 INSTALLATION POINT 1 Measure the dimensions before installing the headlights. 2 These values are reference values. BODY PANEL REPLACEMENT BP-6 FRONT CROSSMEMBER (ASSY) Symbol meaning REMOVAL : Remove Weld Points : Cut with disc sander, etc. INSTALLATION : MIG Plug Weld : Tack Weld F25705A F25705B REMOVAL.INSTALLATION 10 (0.39) mm (in.) F25705 INSTALLATION POINT 1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. 2 Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) 3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. BODY PANEL REPLACEMENT BP-7 RADIATOR SUPPORT (ASSY) Symbol meaning F25706A REMOVAL : Remove Weld Points : Cut with disc sander, etc. INSTALLATION : MIG Plug Weld : Tack Weld F25706B REMOVAL.INSTALLATION 10 (0.39) mm (in.) F25706 INSTALLATION POINT 1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. 2 Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) 3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. BODY PANEL REPLACEMENT BP-8 FRONT FENDER FRONT APRON (ASSY) With the radiator support removed. Symbol meaning F25707A REMOVAL : Remove Weld Points : Cut with disc sander, etc. INSTALLATION : MIG Plug Weld : Tack Weld F25707B REMOVAL.INSTALLATION F25707 INSTALLATION POINT 1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. 2 Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) BODY PANEL REPLACEMENT BP-9 Fender Apron Plate LH: RH: 6 (0.24) Front Fender Apron Front Extension 15 (0.59) 6 (0.24) mm (in.) F25708 REMOVAL POINT 1 Remove the front fender apron front extension at the same time. INSTALLATION POINT 1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. 2 Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) 3 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating) 4 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. BODY PANEL REPLACEMENT BP-10 FRONT APRON TO COWL SIDE UPPER MEMBER (ASSY) With the front fender front apron and front body pillar lower gusset removed. Symbol meaning REMOVAL : Remove Weld Points INSTALLATION : MIG Plug Weld F25709A F25709B REMOVAL.INSTALLATION Front Apron To Cowl Side Lower Front Member F25709 REMOVAL POINT 1 After removing the front apron to cowl side lower front member, remove the front apron to cowl side upper member. INSTALLATION POINT 1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. 2 Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) 3 After welding the to the front apron to cowl side upper member vehicle side, install the front apron to cowl side lower front member. BODY PANEL REPLACEMENT BP-11 F25805 INSTALLATION POINT 1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. 2 Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) 3 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating) 4 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. BODY PANEL REPLACEMENT BP-12 FRONT FENDER APRON (ASSY) With the radiator support and front body pillar lower gusset removed. Symbol meaning REMOVAL : Remove Weld Points : Cut with disc sander, etc. INSTALLATION : MIG Plug Weld : Tack Weld F25710A F25710B REMOVAL.INSTALLATION CAUTION Make sure to attach correctly in accordance with the body dimension diagram as this part affects the front wheel alignment. F25710 INSTALLATION POINT 1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. 2 Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) BODY PANEL REPLACEMENT BP-13 6 (0.24) 15 (0.59) 6 (0.24) CAUTION mm (in.) Make sure to attach correctly in accordance with the body dimension diagram as this part affects the front wheel alignment. F25711 INSTALLATION POINT 1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. 2 Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) 3 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating) 4 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. BODY PANEL REPLACEMENT BP-14 FRONT SIDE MEMBER (CUT-P) With the radiator support removed. Symbol meaning : Remove Weld Points : Cut and Join Location F25712A F25712B REMOVAL 110 (4.33) Front Side Member Extension mm (in.) F25712 REMOVAL POINT 1 Remove the front side member extension at the same time. BODY PANEL REPLACEMENT BP-15 Symbol meaning : MIG Plug Weld : Butt Weld F25713B INSTALLATION Front Side Member Extension F25713 INSTALLATION POINT 1 Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) 2 After welding, apply undercoating to the corresponding parts.(See the paint.coating) 3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. BODY PANEL REPLACEMENT BP-16 FRONT SIDE MEMBER (CUT-H): TMC made With the front fender apron removed. Symbol meaning : Remove Weld Points F25714A F25714B REMOVAL F25714 BODY PANEL REPLACEMENT BP-17 Symbol meaning : MIG Plug Weld F25715B INSTALLATION CAUTION Front Side Member Extension Make sure to attach correctly in accordance with the body dimension diagram as this part affects the front wheel alignment. F25715 INSTALLATION POINT 1 Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) 2 After welding, apply body sealer and undercoating to the corresponding parts.(See the paint.coating) 3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. BODY PANEL REPLACEMENT BP-18 FRONT SIDE MEMBER (CUT-H): TMMK made With the front fender apron removed. Symbol meaning : Remove Weld Points F25716A F25716B REMOVAL F25716 BODY PANEL REPLACEMENT BP-19 Symbol meaning : MIG Plug Weld F25718B INSTALLATION CAUTION Front Side Member Extension Make sure to attach correctly in accordance with the body dimension diagram as this part affects the front wheel alignment. F25718 INSTALLATION POINT 1 Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) 2 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating) 3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. BODY PANEL REPLACEMENT BP-20 COWL TOP SIDE REINFORCEMENT (ASSY) Symbol meaning REMOVAL : Cut with disc sander, etc. INSTALLATION : Tack Weld F25720A F25720B REMOVAL.INSTALLATION 13 (0.51) 15 (0.59) 15 (0.59) 10 (0.39) 25 (0.98) mm (in.) F25720 INSTALLATION POINT 1 After welding, apply body sealer to the corresponding parts. (See the paint.coating) 2 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. BODY PANEL REPLACEMENT BP-21 FRONT BODY PILLAR LOWER GUSSET (ASSY) Symbol meaning F25719A REMOVAL : Remove Weld Points INSTALLATION : MIG Plug Weld F25719B REMOVAL.INSTALLATION F25719 INSTALLATION POINT 1 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. BODY PANEL REPLACEMENT BP-22 COWL TOP OUTER PANEL (ASSY) With the cowl top side reinforcement and front body pillar lower gusset removed. Symbol meaning REMOVAL : Remove Weld Points : Cut with disc sander, etc. INSTALLATION : MIG Plug Weld : Tack Weld F25721A F25721B REMOVAL.INSTALLATION 7 (0.28) mm (in.) F25721 INSTALLATION POINT 1 Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) 2 After welding, apply body sealer to the corresponding parts. (See the paint.coating) 3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. BODY PANEL REPLACEMENT BP-23 FRONT BODY PILLAR (CUT) With the cowl top outer panel removed. Symbol meaning : Cut with disc sander, etc. : Cut and Join Location : Remove Weld Points : Cut Location for Supply Parts F25722A F25722B REMOVAL 200 (7.87) Urethane Foam 160 (6.30) 140 (5.51) 60 (2.36) mm (in.) F25722 BODY PANEL REPLACEMENT BP-24 Symbol meaning : Cut with disc sander, etc. : Cut and Join Location : Remove Weld Points : Cut Location for Supply Parts F25722B F25723 BODY PANEL REPLACEMENT BP-25 Symbol meaning : MIG Plug Weld : Tack Weld : Cut and Join Location : Butt Weld : Body Sealer F25724B INSTALLATION Cowl Side Panel 45 (1.77) Center Body Pillar Lower Reinforce 310 (12.20) Front Body Pillar Lower Reinforce 20 (0.79) mm (in.) F25724 INSTALLATION POINT 1 Before temporarily installing the new parts, weld the center body pillar lower reinforce, front body pillar lower reinforce and cowl side panel with the standard number of welding points. BODY PANEL REPLACEMENT BP-26 Symbol meaning : MIG Plug Weld : Tack Weld : Cut and Join Location : Butt Weld : Body Sealer F25724B Front Body Pillar Lower Reinforce Cowl Side Panel Center Body Pillar Lower Reinforce 10 (0.39) mm (in.) F25725 INSTALLATION POINT 1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. 2 Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) 3 After welding the center body pillar lower reinforce, front body pillar lower reinforce and cowl side panel to the vehicle side, install the front body upper outer pillar and center body outer pillar. BODY PANEL REPLACEMENT BP-27 Front Body Upper Outer Pillar Urethane Foam Center Body Outer Pillar No. 6 Pillar Outer Bracket Center Body Pillar Lower Reinforce F25807 INSTALLATION POINT 1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. 2 Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) 3 Before installing a new part, apply body sealer. HINT: 1) Apply sealer in an even, continuous bead. 4 After welding the center body pillar lower reinforce and front body pillar lower reinforce to the vehicle side, install the front body upper outer pillar, center body outer pillar and No.6 pillar outer bracket. 5 After welding, apply the polyurethane foam to the corresponding parts.(See the paint.coating) 6 After welding, apply body sealer and undercoating to the corresponding parts.(See the paint.coating) 7 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. BODY PANEL REPLACEMENT BP-28 CENTER BODY PILLAR (CUT) Symbol meaning : Remove Weld Points F25726A : Cut with disc sander, etc. : Cut and Join Location : Cut Location for Supply Parts F25726B REMOVAL Urethane Foam 20 (0.79) 90 (3.54) Urethane Foam 80 (3.15) 60 (2.36) mm (in.) F25726 REMOVAL POINT 1 *1: Take care not to damage the internal reinforcement. BODY PANEL REPLACEMENT BP-29 Symbol meaning : MIG Plug Weld : Tack Weld : Cut and Join Location : Butt Weld F25727B INSTALLATION Center Body Pillar Lower Reinforce 310 (12.20) Center Body Pillar Upper Reinforce Center Body Inner Pillar mm (in.) F25727 INSTALLATION POINT 1 Before temporarily installing the new parts, weld the center body pillar lower reinforce, center body pillar upper reinforce and center body inner pillar with the standard number of welding points. BODY PANEL REPLACEMENT BP-30 Symbol meaning : MIG Plug Weld : Tack Weld : Cut and Join Location : Butt Weld F25727B Center Body Pillar Upper Reinforce Center Body Inner Pillar Roof Side Outer No.2 Rail Urethane Foam Urethane Foam 12 (0.47) Center Body Pillar Lower Reinforce Center Body Outer Pillar mm (in.) F25728 INSTALLATION POINT 1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. 2 Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) 3 After welding the center body pillar lower reinforce, center body pillar upper reinforce and center body inner pillar to the vehicle side, install the center body outer pillar and roof side outer No.2 rail. BODY PANEL REPLACEMENT BP-31 20 (0.79) F25808 INSTALLATION POINT 1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. 2 Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) 3 After welding, apply the polyurethane foam to the corresponding parts. (See the paint.coating) 4 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating) 5 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. BODY PANEL REPLACEMENT BP-32 FRONT DOOR OUTER PANEL (ASSY) Symbol meaning : Remove Weld Points F25757A F25757B REMOVAL Positioning Tape Installation Position Hemming Location Disc Sander F25757 REMOVAL POINT 1 Before removing the outer panel, mark the installation position with tape. 2 Before removing the outer panel, establish its exact position in relation to the window frame using a reference marker, etc. 3 After grinding off the hemming location, remove the outer panel. BODY PANEL REPLACEMENT BP-33 Symbol meaning : MIG Plug Weld : Spot MIG Weld : Body Sealer F25758B INSTALLATION Positioning Tape 10 (0.39) Do not close the drain hole. Cloth Tape 30
Hemming Tool mm (in.) F25758 INSTALLATION POINT 1 Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection beam and backside of the new parts. HINT: 1) Apply sealer evenly about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter on the outer panel and apply just enough sealer for the reinforcement and side impact protection beam to make contact. 2 Bend the flange hem about 30
with a hammer and dolly. Then, fasten tightly with a hemming tool. HINT: 1) Perform hemming in three steps, being careful not to warp the panel. 2) If a hemming tool cannot be used, hem with a hammer and dolly. 3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. BODY PANEL REPLACEMENT BP-34 REAR DOOR OUTER PANEL (ASSY) Symbol meaning : Remove Weld Points F25759A F25759B REMOVAL Positioning Tape Installation Position Hemming Location Disc Sander F25759 REMOVAL POINT 1 Before removing the outer panel, mark the installation position with tape. 2 Before removing the outer panel, establish its exact position in relation to the window frame using a reference marker, etc. 3 After grinding off the hemming location, remove the outer panel. BODY PANEL REPLACEMENT BP-35 Symbol meaning : MIG Plug Weld : Spot MIG Weld : Body Sealer F25760B INSTALLATION Positioning Tape 10 (0.39) Do not close the drain hole. Cloth Tape 30
Hemming Tool mm (in.) F25760 INSTALLATION POINT 1 Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection beam and backside of the new parts. HINT: 1) Apply sealer evenly about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter on the outer panel and apply just enough sealer for the reinforcement and side impact protection beam to make contact. 2 Bend the flange hem about 30
with a hammer and dolly. Then, fasten tightly with a hemming tool. HINT: 1) Perform hemming in three steps, being careful not to warp the panel. 2) If a hemming tool cannot be used, hem with a hammer and dolly. 3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. BODY PANEL REPLACEMENT BP-36 ROCKER OUTER PANEL (CUT-P) Symbol meaning : Remove Weld Points : Cut and Join Location : Cut Location for Supply Parts F25729A F25729B REMOVAL 800 (31.50) 60 (2.36) 50 (1.97) mm (in.) F25729 REMOVAL POINT 1 *1: Take care not to damage the internal reinforcement. BODY PANEL REPLACEMENT BP-37 Symbol meaning : MIG Plug Weld : Cut and Join Location : Butt Weld F25730B INSTALLATION Center Body Pillar Lower Reinforce Center Body Outer Pillar mm (in.) F25730 INSTALLATION POINT 1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. 2 Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) 3 After welding the center body pillar lower reinforce to the vehicle side, install the center body outer pillar. 4 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. BODY PANEL REPLACEMENT BP-38 ROCKER OUTER EXTENSION (ASSY): TMC made Symbol meaning : Remove Weld Points : Cut and Join Location F25731A : Cut Location for Supply Parts F25731B REMOVAL Center Body Outer Pillar 280 (11.02) Quarter Panel 260 (10.24) 70 (2.76) Center Body Pillar Lower Reinforce mm (in.) F25731 REMOVAL POINT 1 *1 in illustration above indicates where the adhesive is. 2 After removing the center body outer pillar and quarter panel, remove the rocker outer extension and center body pillar lower reinforce. BODY PANEL REPLACEMENT BP-39 Symbol meaning : MIG Plug Weld : Butt Weld : Body Sealer F25732B INSTALLATION Rocker Panel Reinforcement Center Body Pillar Lower Reinforce Center Body Outer Pillar Quarter Panel F25732 INSTALLATION POINT 1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. 2 Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) 3 Before temporarily installing the new parts, weld the rocker panel reinforcement and rocker outer extension with the standard number of welding points. 4 Before installing a new part, apply body sealer. HINT: 1) Apply sealer in an even, continuous bead. 5 After welding the center body pillar lower reinforce and rocker outer extension to the vehicle side, install the center body outer pillar and quarter panel. 6 After welding, apply body sealer and undercoating to the corresponding parts.(See the paint.coating) 7 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. BODY PANEL REPLACEMENT BP-40 ROCKER OUTER REINFORCE (ASSY): TMMK made Symbol meaning : Remove Weld Points : Cut and Join Location F25733A : Cut Location for Supply Parts F25733B REMOVAL Center Body Outer Pillar 280 (11.02) Quarter Panel 260 (10.24) 70 (2.76) Center Body Pillar Lower Reinforce mm (in.) F25733 INSTALLATION POINT 1 *1 in illustation above indicates where the adhesive is. 2 After removing the center body outer pillar and quarter panel, remove the rocker outer reinforce and center body pillar lower reinforce. BODY PANEL REPLACEMENT BP-41 Symbol meaning : MIG Plug Weld : Butt Weld : Body Sealer F25734B INSTALLATION Center Body Pillar Lower Reinforce Center Body Outer Pillar Quarter Panel F25734 INSTALLATION POINT 1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. 2 Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) 3 Before installing a new part, apply body sealer. HINT: 1) Apply sealer in an even, continuous bead. 4 After welding the rocker outer reinforce to the vehicle side, install the center body outer pillar and quarter panel. 5 After welding, apply body sealer and undercoating to the corresponding parts.(See the paint.coating) 6 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. BODY PANEL REPLACEMENT BP-42 QUARTER PANEL (CUT) Quarter Panel Replacement Using Adhesive F25735A Work Procedure Precaution 1 Cut the wheel arch portion. 2 Heat the quarter panel adhesive area and remove the quarter panel. (1) Using an industrial dryer or oxygen acetylene burner, heat the quarter panel to 110 to 140
C. Make sure the quarter panel does not warp. 3 Clean off any adhesive that remains on the vehicle. (1) Using a gas burner, heat the adhesive to 110 to 140
C. (2) Using a scraper, scrape away the adhesive. (3) If adhesive remains, the strength of any subsequently applied adhesive will be weak. (1) Scuff at a width of approximately 10 mm over the previous adhesive coating. (1) Hardening Time Estimation With dryer or equivalent (60
C) : 60 minutes (complete hardening: 90 minutes) Ambient temperature (25
C) : 12 hours (complete hardening: 24 hours) 4 Using a disc grinder or belt sander, scuff and sand any adhesive that remains on the vehicle. 5 Apply adhesive to the exposed metal areas on the vehicle. Using a spatula, spread the adhesive evenly. 6 Apply adhesive to the vehicle again. 7 Using #60-240 grit sandpaper, scuff the adhesive application area on the new quarter panel. 8 Apply adhesive to the new quarter panel. Using a spatula, spread the adhesive evenly. 9 Using a vise or the palms of your hands, press the quarter panel so that the thickness of the adhesive is even. 10 Complete installation the new quarter panel. 11 Dry the adhesive areas of the new quarter panel. BODY PANEL REPLACEMENT Symbol meaning : Remove Weld Points BP-43 : Cut with disc sander, etc. : Cut Location for Supply Parts : Cut and Join Location : Braze F25735B REMOVAL Urethane Foam 85 (3.35) 260 (10.24) mm (in.) F25735 REMOVAL POINT 1 *1 in illustration above indicates where the adhesive is. 2 Roughly cut open the wheel arch of the panel so that the adhesive can be reached. Cut through the adhesive with a cut chisel to remove the panel. HINT: 1) If the cut chisel cannot reach the adhesive, heat the adhesive with a heat gun, oxygen-acetylene burner. When heating, do not deform the quarter housing outer panel. BODY PANEL REPLACEMENT BP-44 Symbol meaning : Remove Weld Points : Cut with disc sander, etc. : Cut Location for Supply Parts : Cut and Join Location : Braze F25735B F25736 BODY PANEL REPLACEMENT BP-45 Symbol meaning : Spot Weld : MIG Plug Weld : Butt Weld : Body Sealer : Braze F25737B INSTALLATION TMMK made: Urethane Foam Quarter Lock Pillar Reinforcement Fuel Filler Opening Lid Water Proof Rivets 3 (0.12) Spot Tip 5 (0.24) mm (in.) F25737 INSTALLATION POINT 1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. 2 Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) 3 Apply adhesive(3MTM AutomixTM Panel Bonding Adhesive #8115) to the area indicated by *1 in illustration. HINT: 1) Apply enough adhesive for the panels to sick to each other. 4 Perform spot-welding on the flange indicated by *2 in the illustration. Modify/ cut the spot tip as shown in the illustration (*3) so that it can fit into the narrow flange. 5 Before installing a new part, apply body sealer. HINT: 1) Apply sealer in an even, continuous bead. BODY PANEL REPLACEMENT BP-46 Symbol meaning : Spot Weld : MIG Plug Weld : Butt Weld : Body Sealer : Braze F25737B F25738 INSTALLATION POINT 1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. 2 Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) 3 After welding, apply the polyurethane foam to the corresponding parts. (See the paint.coating) 4 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating) 5 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. BODY PANEL REPLACEMENT BP-47 QUARTER WHEEL HOUSING OUTER PANEL (ASSY): TMC made With the quarter panel removed. : Cut with disc sander, etc. Symbol meaning REMOVAL : Remove Weld Points : Cut and Join Location INSTALLATION : MIG Plug Weld : Tack Weld F25739A : Butt Weld F25739B REMOVAL.INSTALLATION [LH] 310 (12.20) Rocker Outer Extension mm (in.) F25739 REMOVAL POINT 1 *1: Take care not to damage the internal reinforcement. 2 After removing the rocker outer extension, remove the quarter wheel housing outer panel. INSTALLATION POINT 1 After welding the quarter wheel housing outer panel to the vehicle side, install the rocker outer extension. BODY PANEL REPLACEMENT BP-48 : Cut with disc sander, etc. Symbol meaning REMOVAL : Remove Weld Points : Cut and Join Location INSTALLATION : MIG Plug Weld : Tack Weld : Butt Weld F25739B [LH] Roof Side Outer Panel F25740 REMOVAL POINT 1 After removing the roof side outer panel, remove the quarter wheel housing outer panel. INSTALLATION POINT 1 After welding the quarter wheel housing outer panel to the vehicle side, install the roof side outer panel. BODY PANEL REPLACEMENT BP-49 [LH] 20 (0.79) mm (in.) F25742 INSTALLATION POINT 1 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating) 2 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. BODY PANEL REPLACEMENT BP-50 : Cut with disc sander, etc. Symbol meaning REMOVAL : Remove Weld Points : Cut and Join Location INSTALLATION : MIG Plug Weld : Tack Weld : Butt Weld F25739B [RH] 310 (12.20) Rocker Outer Extension mm (in.) F25795 REMOVAL POINT 1 *1: Take care not to damage the internal reinforcement. 2 After removing the rocker outer extension, remove the quarter wheel housing outer panel. INSTALLATION POINT 1 After welding the quarter wheel housing outer panel to the vehicle side, install the rocker outer extension. BODY PANEL REPLACEMENT BP-51 [RH] Roof Side Outer Panel F25741 REMOVAL POINT 1 After removing the roof side outer panel, remove the quarter wheel housing outer panel. INSTALLATION POINT 1 After welding the quarter wheel housing outer panel to the vehicle side, install the roof side outer panel. BODY PANEL REPLACEMENT BP-52 : Cut with disc sander, etc. Symbol meaning REMOVAL : Remove Weld Points : Cut and Join Location INSTALLATION : MIG Plug Weld : Tack Weld : Butt Weld F25739B [RH] 20 (0.79) mm (in.) F25796 INSTALLATION POINT 1 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating) 2 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. BODY PANEL REPLACEMENT BP-53 QUARTER WHEEL HOUSING OUTER PANEL (ASSY): TMMK made With the quarter panel removed. : Cut with disc sander, etc. Symbol meaning REMOVAL : Remove Weld Points : Cut and Join Location INSTALLATION : MIG Plug Weld : Tack Weld F25797A : Butt Weld F25797B REMOVAL.INSTALLATION [LH] 310 (12.20) Rocker Outer Reinforce mm (in.) F25797 REMOVAL POINT 1 *1: Take care not to damage the internal reinforcement. 2 After removing the rocker outer reinforce, remove the quarter wheel housing outer panel. INSTALLATION POINT 1 After welding the quarter wheel housing outer panel to the vehicle side, install the rocker outer reinforce. BODY PANEL REPLACEMENT BP-54 : Cut with disc sander, etc. Symbol meaning REMOVAL : Remove Weld Points : Cut and Join Location INSTALLATION : MIG Plug Weld : Tack Weld : Butt Weld F25797B [LH] Roof Side Outer Panel F25798 REMOVAL POINT 1 After removing the roof side outer panel, remove the quarter wheel housing outer panel. INSTALLATION POINT 1 After welding the quarter wheel housing outer panel to the vehicle side, install the roof side outer panel. BODY PANEL REPLACEMENT BP-55 [LH] 20 (0.79) mm (in.) F25799 INSTALLATION POINT 1 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating) 2 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. BODY PANEL REPLACEMENT BP-56 : Cut with disc sander, etc. Symbol meaning REMOVAL : Remove Weld Points : Cut and Join Location INSTALLATION : MIG Plug Weld : Tack Weld : Butt Weld F25797B [RH] 310 (12.20) Rocker Outer Reinforce mm (in.) F25800 REMOVAL POINT 1 *1: Take care not to damage the internal reinforcement. 2 After removing the rocker outer reinforce, remove the quarter wheel housing outer panel. INSTALLATION POINT 1 After welding the quarter wheel housing outer panel to the vehicle side, install the rocker outer reinforce. BODY PANEL REPLACEMENT BP-57 [RH] Roof Side Outer Panel F25801 REMOVAL POINT 1 After removing the roof side outer panel, remove the quarter wheel housing outer panel. INSTALLATION POINT 1 After welding the quarter wheel housing outer panel to the vehicle side, install the roof side outer panel. BODY PANEL REPLACEMENT BP-58 : Cut with disc sander, etc. Symbol meaning REMOVAL : Remove Weld Points : Cut and Join Location INSTALLATION : MIG Plug Weld : Tack Weld : Butt Weld F25797B [RH] 20 (0.79) mm (in.) F25802 INSTALLATION POINT 1 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating) 2 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. BODY PANEL REPLACEMENT BP-59 BODY LOWER BACK PANEL (ASSY) Symbol meaning F25743A REMOVAL : Remove Weld Points INSTALLATION : MIG Plug Weld F25743B REMOVAL.INSTALLATION F25743 INSTALLATION POINT 1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. 2 Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) 3 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating) 4 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. BODY PANEL REPLACEMENT BP-60 QUARTER PANEL END HOUSING (ASSY): TMC made Symbol meaning REMOVAL : Remove Weld Points INSTALLATION : MIG Plug Weld F25744A : Cut with disc sander, etc. F25744B REMOVAL.INSTALLATION Luggage Compartment Opening Trough Luggage Compartment Trim No. 1 Bracket F25744 REMOVAL POINT 1 Remove the luggage compartment opening trough at the same time. INSTALLATION POINT 1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. 2 Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) 3 After welding, apply body sealer to the corresponding parts. (See the paint.coating) 4 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. BODY PANEL REPLACEMENT BP-61 QUARTER PANEL END HOUSING (ASSY): TMMK made Symbol meaning F25745A REMOVAL : Remove Weld Points INSTALLATION : MIG Plug Weld : Cut with disc sander, etc. F25745B REMOVAL.INSTALLATION F25745 INSTALLATION POINT 1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. 2 Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) 3 After welding, apply body sealer to the corresponding parts. (See the paint.coating) 4 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. BODY PANEL REPLACEMENT BP-62 REAR FLOOR NO. 3 CROSSMEMBER (ASSY) With the body lower back panel removed. Symbol meaning F25746A REMOVAL : Remove Weld Points INSTALLATION : Spot Weld : MIG Plug Weld F25746B REMOVAL.INSTALLATION F25746 INSTALLATION POINT 1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. 2 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating) 3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. BODY PANEL REPLACEMENT BP-63 REAR FLOOR PAN (ASSY) With the rear floor no.3 crossmember removed. Symbol meaning : Remove Weld Points F25747A F25747B REMOVAL Rear Floor Pan Reinforcement F25747 REMOVAL POINT 1 Remove the rear floor pan reinforcement at the same time. BODY PANEL REPLACEMENT BP-64 Symbol meaning : Remove Weld Points F25747B [LH] [RH] F285748 BODY PANEL REPLACEMENT BP-65 Symbol meaning : MIG Plug Weld F25749B INSTALLATION Spare Wheel Clamp Bracket Fuel Tube No.3 Bracket Weld Bolts ( ): TMMK made F25749 INSTALLATION POINT 1 Before temporarily installing the new parts, weld the spare wheel clamp bracket and fuel tube No.3 bracket with the standard number of welding points. BODY PANEL REPLACEMENT BP-66 Symbol meaning : MIG Plug Weld : Tack Weld F25749B [LH] [RH] F25804 BODY PANEL REPLACEMENT BP-67 Rear Floor Pan Reinforcement F25803 INSTALLATION POINT 1 After welding, apply body sealer and undercoating to the corresponding parts.(See the paint.coating) 2 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. BODY PANEL REPLACEMENT BP-68 REAR FLOOR SIDE PANEL (ASSY) With the rear floor pan removed. Symbol meaning F25750A REMOVAL : Remove Weld Points INSTALLATION : MIG Plug Weld F25750B REMOVAL.INSTALLATION [LH] F25750 INSTALLATION POINT 1 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating) 2 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. BODY PANEL REPLACEMENT BP-69 [RH] F25751 INSTALLATION POINT 1 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating) 2 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. BODY PANEL REPLACEMENT BP-70 REAR FLOOR SIDE REAR MEMBER (ASSY) With the rear floor no.3 crossmember removed. Symbol meaning F25752A REMOVAL : Remove Weld Points INSTALLATION : MIG Plug Weld F25752B REMOVAL.INSTALLATION LH: RH: F25752 INSTALLATION POINT 1 Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) 2 After welding, apply undercoating to the corresponding parts.(See the paint.coating) 3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. BODY PANEL REPLACEMENT BP-71 REAR FLOOR NO. 2 CROSSMEMBER (ASSY) Symbol meaning F25753A REMOVAL : Remove Weld Points INSTALLATION : MIG Plug Weld F25753B REMOVAL.INSTALLATION F25753 INSTALLATION POINT 1 Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) 2 After welding, apply undercoating to the corresponding parts.(See the paint.coating) 3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. BODY PANEL REPLACEMENT BP-72 ROOF PANEL (ASSY): Nomal Roof Symbol meaning F25754A REMOVAL : Remove Weld Points INSTALLATION : Spot Weld : MIG Plug Weld : Body Sealer F25754B REMOVAL.INSTALLATION F25754 INSTALLATION POINT 1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. 2 Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) 3 After welding, apply body sealer to the corresponding parts.(See the paint.coating) 4 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. BODY PANEL REPLACEMENT BP-73 F25806 INSTALLATION POINT 1 Before temporarily installing the new parts, apply body sealer to the windshield header panel, roof panel reinforcement and back door opening frame. HINT: 1) Apply just enough sealer for the new parts to make contact. BODY PANEL REPLACEMENT BP-74 ROOF PANEL (ASSY): Moon Roof Symbol meaning REMOVAL : Remove Weld Points INSTALLATION : Spot Weld : MIG Plug Weld F25755A : Body Sealer F25755B REMOVAL.INSTALLATION Cloth Tape Wooden Hammer Disc Sander [Removal] [Install] F25755 INSTALLATION POINT 1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish 2 Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) 3 After welding, apply body sealer to the corresponding parts.(See the paint.coating) 4 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. BODY PANEL REPLACEMENT BP-75 F25756 INSTALLATION POINT 1 Before temporarily installing the new parts, apply body sealer to the windshield header panel, roof panel reinforcement and back door opening frame. HINT: 1) Apply just enough sealer for the new parts to make contact. BODY PANEL REPLACEMENT BP-76 OUTER PANEL INSTALLATION TORQUE 13 (133, 10) 13 (133, 10) 13 (133, 10) 13 (133, 10) 6.0 (61, 53 in..lbf) 6.0 (61, 53 in..lbf) 8.0 (82, 71 in..lbf) 8.0 (82, 71 in..lbf) 34 (347, 25) 8.0 (82, 71 in..lbf) N.m (kgf.cm, ft..lbf) : Specified torque F25761 BODY PANEL REPLACEMENT BP-77 26 (265, 19) 26 (265, 19) 26 (265, 19) 26 (265, 19) N.m (kgf.cm, ft..lbf) : Specified torque F25762 BODY PANEL REPLACEMENT BP-78 7.5 (77, 66 in..lbf) 7.5 (77, 66 in..lbf) 7.5 (77, 66 in..lbf) 7.5 (77, 66 in..lbf) 68 (694, 50) 68 (693, 50) N.m (kgf.cm, ft..lbf) : Specified torque F25763 BODY PANEL REPLACEMENT BP-79 FIT STANDARD/ADJUSTMENT METHOD/TORQUE SPECIFICATION HOOD SUB-ASSEMBLY 3.5 (0.138) 3.7 (0.146) 5.1 (0.201) mm (in.) F25764 1. ADJUST HOOD SUB-ASSEMBLY HINT:
Centering bolts are used to mount the hood hinge and hood lock. The hood and hood lock cannot be adjusted with the centering bolts on. Substitute the centering bolts with standard bolts (with washers) when making adjustments. a. Horizontally and vertically adjust the hood. i. Loosen the hood’s 4 hinge bolts. ii. Move the hood and adjust the clearance between the hood and front fender. iii. Tighten the hood’s 4 hinge bolts after the adjustment. Torque: 13 N.m (133 kgf.cm, 10 ft..lbf) B132829 BODY PANEL REPLACEMENT BP-80 b. Adjust the height of the hood front end using the cushion rubber. i. Adjust the cushion rubber so that the height of the hood and fender are aligned. HINT: Raise or lower the hood’s front end by turning the cushion rubber. B132830 c. Adjust the hood lock. i. Loosen the 3 bolts. ii. Tighten the bolts after the adjustment. Torque: 7.5 N.m (77 kgf.cm, 66 in..lbf) iii. Adjust the hood lock position so that the striker can enter it smoothly. B132832 BODY PANEL REPLACEMENT BP-81 FRONT DOOR 4.8 (0.189) 4.8 (0.189) 4.3 (0.169) 4.2 (0.165) 4.2 (0.165) 5.0 (0.197) mm (in.) F25765 1. ADJUST FRONT DOOR HINT:
Before adjusting the door position for vehicles equipped with side airbags and curtain shield airbags, be sure to disconnect the battery. After adjustment, inspect the SRS warning light, the side airbag system, and the curtain shield airbag system for normal operation. Then initialize both airbag systems.
Use the same procedures for the RH side and LH side.
The procedures listed below are for the LH side.
Centering bolts are used to mount the door hinge to the vehicle body and door. The door cannot be adjusted with the centering bolts on. Substitute the centering bolts with standard bolts (with washers) when making adjustment. BODY PANEL REPLACEMENT BP-82 a. Using SST, loosen the body’s hinge bolts and adjust the door position. SST 09812-00010 b. Tighten the body’s hinge bolts after the adjustment. Torque: 26 N.m (265 kgf.cm, 19 ft..lbf) c. Loosen the door’s hinge bolts and adjust the door position. d. Tighten the door’s hinge bolts after the adjustment. Torque: 26 N.m (265 kgf.cm, 19 ft..lbf) B136438 e. Using a “torx” socket wrench (T40), adjust the striker position by slightly loosening the striker mounting screws and hitting the striker with a plastic hammer. f. Using a “torx” socket wrench (T40), tighten the striker mounting screws after the adjustment. Torque: 23 N.m (235 kgf.cm, 17 ft..lbf) B136440 BODY PANEL REPLACEMENT BP-83 REAR DOOR 4.8 (0.189) 4.8 (0.189) 4.3 (0.169) 4.2 (0.165) 4.2 (0.165) 4.2 (0.165) 5.0 (0.197) mm (in.) B25766 1. ADJUST REAR DOOR HINT:
Before adjusting the door position for vehicles equipped with side airbags and curtain shield airbags, be sure to disconnect the battery. After adjustment, inspect the SRS warning light, the side airbag system, and the curtain shield airbag system for normal operation. Then initialize both airbag systems.
Use the same procedures for the RH side and LH side.
The procedures listed below are for the LH side.
Centering bolts are used to mount the door hinge to the vehicle body and door. The door cannot be adjusted with the centering bolts on. Substitute the centering bolts with standard bolts (with washers) when making adjustments. BODY PANEL REPLACEMENT BP-84 a. Loosen the body’s hinge bolts and adjust the door position. SST 09812-00010 b. Tighten the body’s hinge bolts after the adjustment. Torque: 26 N.m (265 kgf.cm, 19 ft..lbf) c. Loosen the door’s hinge bolts and adjust the door position. d. Tighten the door’s hinge bolts after the adjustment. Torque: 26 N.m (265 kgf.cm, 19 ft..lbf) B136487 e. Using a “torx” socket wrench (T40), adjust the striker position by slightly loosening the striker mounting screws and hitting the striker with a plastic hammer. f. Using a “torx” socket wrench (T40), tighten the striker mounting screws after the adjustment. Torque: 23 N.m (235 kgf.cm, 17 ft..lbf) B136489 BODY PANEL REPLACEMENT BP-85 LUGGAGE COMPARTMENT DOOR 3.5 (0.138) 3.5 (0.138) 5.7 (0.224) mm (in.) F25767 1. ADJUST LUGGAGE COMPARTMENT DOOR HINT:
Centering bolts are used to mount the door hinge to the door. The door cannot be adjusted with the centering bolts on. Substitute the centering bolts with standard bolts (with washers) when making adjustments. a. Horizontally and vertically adjust the door by loosening the door side hinge bolts. Torque: 7.5 N.m (77 kgf.cm, 66 in..lbf) B136494 b. Adjust the striker position by slightly loosening the 2 striker mounting screws and hitting the striker with a plastic-faced hammer. c. Tighten the striker mounting screws after the adjustment. Torque: 5.5 N.m (56 kgf.cm, 49 in..lbf) B136495 BODY PANEL REPLACEMENT BP-86 NAME PLATE APPLICATION PROCEDURE (a) (b) (c) Heat the double-sided tape remaining on the body with an infrared lamp or equivalent. HINT: Heat the tape to 40 to 60
C for approximately 1 to 2 minutes. Wipe off the remaining double-sided tape using a clean cloth or equivalent. HINT: If a name plate is installed without thoroughly removing the remaining double-sided tape from the body, the name plate will not adhere properly. Make sure to thoroughly wipe off the double-sided tape. After cleaning the installation area of the body with degreasing agent, attach the name plate to the position shown in the illustration. HINT: The working environment should be 20
C when installing the name plate. If the working environment is below 20
C, heat the installation area of the body to 20 to 30
C and then install the name plate. [GENERAL EXPORT] 14.8 (0.583) 12.4 (0.488) 11.4 (0.449) 13.3 (0.524) 154.5 (6.083) 7.2 (0.283) 64.3 (2.531) 66.5 (2.618) 122.9 (4.839) mm (in.) F25809 BODY PANEL REPLACEMENT BP-87 [U.S.A., CANADA] 16.0 (0.630) 8.1 (0.319) 5.5 (0.217) [For name plate LE] 66.8 (2.630) 64.3 (2.531) [For name plate XLE] 134.7 (5.303) 66.6 (2.622) 69.6 (2.740) 162.2 (6.386) [For name plate SE] 64.3 (2.531) 66.9 (2.634) 136.7 (5.382) mm (in.) F25810 BODY PANEL REPLACEMENT BP-88 CAUTION LABEL ATTACHMENT POSITION After using a degreasing agent to clean the surfaces of the body where the caution labels will be attached, attach the caution labels to the positions shown in the illustration. HINT: 1) Attach each caution label with its orientation the same as the numbers shown in the illustration. 2) Make sure the caution label is not attached over a spot weld. 3) When attaching the caution label, make sure not to touch the label’s adhesive surface. 4) To prevent the edges of the caution label from peeling, apply extra pressure to the label’s periphery. 5) If the work area’s temperature is 5
C or less, the caution label’s adhesive will deteriorate. It is recommended that you heat the label to 20 to 40
C. [GENERAL EXPORT] Long Life Coolant Service Label Cooler Service Caution Label F25768 BODY PANEL REPLACEMENT BP-89 [GENERAL EXPORT] Fuel Infomation Label Name Plate Tire Pressure Information Label Side Air Bag Caution Label Tire Pressure Information Label (EUROPE RHD) Side Air Bag Caution Label F25769 BODY PANEL REPLACEMENT BP-90 [U.S.A., CANADA] Loaded Inspection Maintenance Exemption Emission Control Information Long Life Coolant Service Label Engine Vacuume Hose Information Cooler Service Caution F25770 BODY PANEL REPLACEMENT BP-91 [U.S.A., CANADA] Fuel infomation Label Certification Reguration Information Label Tire Pressure Information Label Side Air Bag Caution Label Mercury Information Label Side Air Bag Caution Label Side Air Bag Caution Label F25771 PAINT
COATING PC-1 BODY PANEL SEALING AREAS Be sure to apply body sealer to the body panel joints and door edges (tip of outer panel folded part), etc., to waterproof and rustproof them. HINT: 1) Apply degreasing agent to a clean cloth and clean the sealer application areas. 2) After removing the applied spot sealer from the sealer application areas using thinner or equivalent, rustproof the areas by applying primer or equivalent. Then apply body sealer. 3) If sealer is unnecessarily applied to an area, apply degreasing agent to a clean cloth and clean off the sealer immediately. Flat Finishing 1. No Flat Finishing ENGINE COMPARTMENT F25781 PC-2 2. PAINT
COATING INSIDE LHD only F25782 PAINT
COATING 3. PC-3 OUTSIDE F25783 PC-4 PAINT
COATING F25784 PAINT
COATING 4. PC-5 DOOR PARTS F25785 PC-6 PAINT
COATING F25786 PAINT
COATING PC-7 BODY PANEL UNDERCOATING AREAS Apply PASTAR UWE or PASTAR UC to the chassis, floor underside, sheet metal fitting weld points of the body, and inside of the wheel house to prevent rust and noise, as well protect the body from flying rocks. HINT: 1) Work must be performed while wearing the appropriate protective gear and in a well-ventilated area. 2) Apply degreasing agent to a clean cloth and clean any dirt and oil from the application areas. 3) Cover the surrounding areas of the application areas with masking paper to avoid coating unnecessary areas. 4) Do not coat high temperature areas, such as the tailpipe, or moving parts, such as the driveshaft. 5) Do not leave any gaps between the panel joints. 6) Apply sealer to the panel joints in advance. HINT: 1) Parts coated using the PASTAR UWE should be left until dry to the touch in a 25
C environment for 60 to 75 minutes. Parts coated using PASTAR UC should be left until dry to the touch in a 25
C environment for 15 to 30 minutes. 2) If using a PASTAR gun, one spray applies a 0.5 mm thick coating. 3) PASTAR UWE: Part number V9240 − 0025 PASTAR UC: Spray type: Part number V9240 − 0008 Aerosol type: Part number V9240 − 0021 [LH] [RH] F25787 REFERENCE The undercoating should be applied according to the specifications for your country while referring to the notes above. PC-8 PAINT
COATING FOAMED MATERIAL APPLICATION AREAS If an increase in temperature or other condition damages the foamed material when repairing or replacing the panel, fill in the insufficient areas with urethane foam. The following illustration shows the areas for one side, but the foamed material must be applied equally to both the left and right sides. HINT: 1) Work must be performed while wearing the appropriate protective gear and in a well-ventilated area. 2) Apply tape or equivalent to any holes, nuts, etc., near the areas to be filled. [Nomal Roof] [Moon Roof] F25788 PAINT
COATING PC-9 BODY PANEL ANTI-RUST AGENT (WAX) APPLICATION AREAS Apply RUSTOP W to the doors and hood edges (tips of outer panel folded parts) and undersides, areas around hinges, etc., to prevent rust. Coat the undersides of the edges using a nozzle and air gun, and coat the areas around the hinges using a brush. HINT: 1) If RUSTOP is unnecessarily applied to an area, apply degreasing agent to a clean cloth and clean off the RUSTOP immediately. F25789 PC-10 PAINT
COATING SILENCER SHEET INSTALLATION AREAS Substitute silencer sheets for the laminate coat application areas. [TMC made] . . . 1.8 (0.071) . . . 2.6 (0.102) ... ... *1 . . 2.6 (0.102) *2 . . 2.6 (0.102)
3.0 (0.118) *3 . . 3.0 (0.118) . . . 3.0 (0.118) ... *4 . . 3.0 (0.118) . . . 3.0 (0.118)
3.9 (0.154) . . . 3.9 (0.154) . . . 3.9 (0.154)
5.3 (0.209) . . . 5.3 (0.209) *1 U.S.A., CANADA, RHD *2 U.S.A., CANADA *3 Ex. U.S.A., CANADA *4 RHD mm (in.) F25790 PAINT
COATING PC-11 Substitute silencer sheets for the laminate coat application areas. [TMMK made] ... 1.3 (0.051) ... 1.8 (0.071) ... 1.8 (0.071)
2.3 (0.091) ... 2.3 (0.091) ... 2.3 (0.091)
3.3 (0.130) ... 3.3 (0.130) ... 3.3 (0.130)
4.7 (0.185) ... 4.7 (0.185) mm (in.) F25791 PC-12 PAINT
COATING BODY PANEL ANTI-CHIPPING PAINT APPLICATION AREAS To protect the body from damage due to flying rocks, apply the anti-chipping paint to the rocker panels, wheel arches, and lower parts of the doors. HINT: 1) Work must be performed while wearing the appropriate protective gear and in a well-ventilated area. 2) Apply anti-chipping paint to the indicated areas first, before applying the top coat. 3) If anti-chipping paint is unnecessarily applied to an area, apply degreasing agent to a clean cloth and clean the paint off immediately. . . . . . . . . SOFT − CHIP PRIMER . . . . . . . . ANTI − CHIPPING PAINT (INTERMEDIATE COAT) . . . . . . . . PROTECTOR SEAL F25792 BODY DIMENSIONS Three-dimensional distance Center-to-center straight-line distance DI-1 GENERAL INFORMATION 1. BASIC DIMENSIONS (a) There are two types of dimensions in the diagram. (1) (Three-dimensional distance)
Straight-line distance between the centers of two measuring points. Center-to-center horizontal distance in forward / rearward direction Two-dimensional distance Vertical distance to center Vertical distance to lower surface Imaginary Standard Line (2) (Two-dimensional distance)
Horizontal distance in forward/rearward between the centers of two measuring points.
The height from an imaginary standard line. (b) In cases in which only one dimension is given, left and right are symmetrical. (c) The dimensions in the following drawing indicate actual distance. Therefore, please use the dimensions as a reference. (d) The line that connects the places listed below is the imaginary standard line when measuring the height. (The dimensions are printed in the text.) Under Surface of The Rocker Panel A mm B mm C mm Imaginary Standard Line SYMBOL Name 1 The place that was lowered A mm from the under surface of the rocker panel centered on the front jack up point. 2 The place that was lowered B mm from the under surface of the rocker panel centered between 1 and 3. 3 The place that was lowered C mm from the under surface of the rocker panel centered on the rear jack up point. BODY DIMENSIONS DI-2 Plate Looseness Body Looseness Pointer Looseness 2. MEASURING (a) Basically, all measurements are to be done with a tracking gauge. For portions where it is not possible to use a tracking gauge, a tape measure should be used. (b) Use only a tracking gauge that has no looseness in the body, measuring plate, or pointers. Pointer Master Gauge Wrong Correct Pointer HINT: 1) The height of the left and right pointers must be equal. 2) Always calibrate the tracking gauge before measuring or after adjusting the pointer height. 3) Take care not to drop the tracking gauge or otherwise shock it. 4) Confirm that the pointers are securely in the holes. (c) When using a tape measure, avoid twists and bends in the tape. BODY DIMENSIONS DI-3 BODY DIMENSION DRAWINGS ENGINE COMPARTMENT (for LHD) (Three-Dimensional Distance) 1,532 (60.31) 706 (27.80) 1,657 (65.24) 588 (23.15) 1,115 (43.90) 439 (17.28) 753 (29.65) 581 (23.15) 1,075 (42.32) 1,467 (57.76) 1,582 (62.28) 1,068 (42.05) 1,502 (59.13) 1,513 (59.57) 832 (32.76) 341 349 (13.43) (13.74) 319 (12.56) 753 (29.65) 1,520 996 (59.84) (39.21) 1,379 (54.29) 454 (17.87) 237 (9.33) 788 (31.02) 239 (9.41) 865 (34.06) 826 (32.52) 911 (35.87) 913 (35.94) 850 (33.46) 453 (17.83) 656 (25.83) 355 (13.98) 1,037 (40.83) 451 (17.76) Height from Imaginary Standard Line A, a C, c K, k 706 (27.80) 794 (31.26) 639 (25.16) Vehicle Dimensions A-M or a-m B-c or b-C B-f D-E D-e G-n or g-N L-l L-m or l-M M-m 475 (18.70) 1,345 (52.95) 1,078 (42.44) 869 (34.21) 1,060 (41.73) 989 (38.94) 1,536 (60.47) 1,562 (61.50) 1,552 (61.10) HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear). Symbol Name A, a Front fender installation nut B, b Front spring support hole-inner C, c Hood hinge installation nut D, d Cowl panel installation nut E, e Front side member standard hole F, f Front side member standard hole G, g Radiator upper support installation nut mm (in.) Hole dia. H, h M6 (0.24) I Radiator support standard hole ø10 (0.39) Hood lock support installation nut M6 (0.24) ø12.5 (0.492) J, j Front fender bracket installation nut M6 (0.24) M8 (0.31) K, k Radiator upper support installation nut M6 (0.24) M6 (0.24) L, l Front fender installation nut M6 (0.24) ø18 (0.71) M, m Front fender installation nut M6 (0.24) ø18 (0.71) N, n Front bumper reinforcement installation nut M10 (0.39) M6 (0.24) — — — BODY DIMENSIONS DI-4 BODY DIMENSION DRAWINGS ENGINE COMPARTMENT (for RHD) (Three-Dimensional Distance) 1,532 (60.31) 706 (27.80) 1,657 (65.24) 579 (22.80) 1,115 (43.90) 443 (17.44) 762 (30.00) 588 (23.15) 1,075 (42.32) 1,467 (57.76) 1,582 (62.28) 1,063 (41.85) 1,502 (59.13) 1,513 (59.57) 832 (32.76) 341 349 (13.43) (13.74) 319 (12.56) 747 (29.41) 1,520 996 (59.84) (39.21) 1,379 (54.29) 458 (18.03) 237 (9.33) 788 (31.02) 239 (9.41) 867 (34.13) 826 (32.52) 911 (35.87) 913 (35.94) 850 (33.46) 453 (17.83) 656 (25.83) 355 (13.98) 1,037 (40.83) 451 (17.76) Height from Imaginary Standard Line A, a C, c K, k 706 (27.80) 794 (31.26) 639 (25.16) Vehicle Dimensions A-M or a-m B-c or b-C B-f D-E D-e G-n or g-N L-l L-m or l-M M-m 475 (18.70) 1,345 (52.95) 1,078 (42.44) 875 (34.45) 1,071 (42.17) 989 (38.94) 1,536 (60.47) 1,562 (61.50) 1,552 (61.10) HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear). Symbol Name A, a Front fender installation nut B, b Front spring support hole-inner C, c Hood hinge installation nut D, d Cowl panel installation nut E, e Front side member standard hole F, f Front side member standard hole G, g Radiator upper support installation nut mm (in.) Hole dia. H, h M6 (0.24) I Radiator support standard hole ø10 (0.39) Hood lock support installation nut M6 (0.24) ø12.5 (0.492) J, j Front fender bracket installation nut M6 (0.24) M8 (0.31) K, k Radiator upper support installation nut M6 (0.24) M6 (0.24) L, l Front fender installation nut M6 (0.24) ø18 (0.71) M, m Front fender installation nut M6 (0.24) ø18 (0.71) N, n Front bumper reinforcement installation nut M10 (0.39) M6 (0.24) — — — BODY DIMENSIONS DI-5 BODY OPENING AREAS (Side View: Front) (Three-Dimensional Distance) 1,139 (44.84) 1,604 (63.15) 761 (29.96) 909 (35.79) 1,532 (60.31) 1,005 (39.57) 856 (33.70) 826 (32.52) 1,191 (46.89) 1,141 (44.92) 1,272 (50.08) 855 (33.66) 1,116 (43.94) Vehicle Dimensions E-e F-f G-g H-h I-i J-j K-k 1,345 (52.95) 1,493 (58.78) 1,491 (58.70) 1,491 (58.70) 1,176 (46.30) 1,288 (50.71) 1,491 (58.70) E-f or e-F E-h or e-H E-j or e-J F-j or f-J F-k or f-K G-q or g-Q H-I or h-i J-k or j-K 1,579 (62.17) 1,640 (64.57) 1,520 (59.84) 1,881 (74.06) 1,720 (67.72) 1,795 (70.67) 1,663 (65.47) 1,579 (62.17) HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear). Symbol Name A, a Roof panel corner mm (in.) Hole dia. H, h Rocker panel assemby mark — — I, i Roof side rail assembly mark — B, b Hood hinge installation nut M8 (0.31) J, i Center body pillar assembly mark — C, c Front door hinge installation nut M8 (0.31) K, k Center body pillar assembly mark — D, d Front door hinge installation nut M8 (0.31) L, l Front door lock striker installation nut M8 (0.31) E, e Front body pillar assembly mark — M, m Rear door hinge installation nut M8 (0.31) F, f Front body pillar assembly mark — N, n Rear door hinge installation nut M8 (0.31) G, g Rocker panel assembly mark — Q, q Rocker panel assembly mark — BODY DIMENSIONS DI-6 BODY OPENING AREAS (Side View: Rear) (Three-Dimensional Distance) 747 (29.41) 883 (34.76) 1,004 (39.53) 1,068 (42.05) 1,080 (42.52) 1,058 (41.65) 742 (29.21) Vehicle Dimensions O-o P-p Q-q R-r S-s T-t U-u 1,311 (51.61) 1,491 (58.70) 1,491 (58.70) 1,172 (46.14) 1,298 (51.10) 1,492 (58.74) 1,576 (62.05) I-r or i-R O-s or o-S O-t or o-T P-t or P-T Q-r or q-R S-t or s-T 1,362 (53.62) 1,503 (59.17) 1,654 (65.12) 1,666 (65.59) 1,584 (62.36) 1,516 (59.69) HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear). Symbol I, i Name Roof side rail assembly mark mm (in.) Hole dia. Q, q Rocker panel assembly mark — — R, r Roof side rail assembly mark — M, m Rear door hinge installation nut M8 (0.31) S, s Quarter panel assembly mark — N, n Rear door hinge installation nut M8 (0.31) T, t Quarter panel assembly mark — O, o Center body pillar assembly mark — U, u Rear door lock striker installation nut P, p Center body pillar assembly mark — — — M8 (0.31) — BODY DIMENSIONS DI-7 BODY OPENING AREAS (Rear View) (Three-Dimensional Distance) 1,020 (40.16) 1,659 (65.31) 724 (28.50) 1,320 (51.97) 1,124 (44.25) 1,196 (47.09) 1,291 (50.83) 587 (23.11) 1,232 (48.50) 1,033 (40.67) 439 (17.28) 1,485 (58.46) 1,123 (44.21) 710 (27.95) Vehicle Dimensions G-g 1,137 (44.76) HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear). Symbol Name mm (in.) Hole dia. D, d Luggage opening trough / Quarter panel adjoining point A, a Roof panel corner — E, e Quarter panel standard hole ø13 (0.51) B, b Upper back reinforcement / Quarter panel adjoining point — C, c Upper back reinforcement / Quarter panel adjoining point — — F, f Luggage trim installation hole ø8.5 (0.335) G, g Rear spring support hole inner-front ø9.5 (0.374) H, h Center body pillar assembly mark — BODY DIMENSIONS DI-8 UNDER BODY (Three-Dimensional Distance) 1,180 (46.46) 734 (28.90) RH 679 (26.73) 1,228 (48.35) (60.08) LH 1,000 1,037 (39.37) 1,007 (40.83) (39.65) 936 (36.85) 1,464 (57.64) 1,224 (48.19) 1,001 (39.41) 1,005 (39.57) 912 (35.91) 658 (25.91) 843 (33.19) 1,131 (44.53) 1,170 (46.06) 922 (36.30) 567 (22.32) 430 (16.93) 1,093 (43.03) 1,088 (42.83) 1,144 (45.04) 1,526 1,203 (47.36) 322 (12.68) 656 (25.83) 1,135 (44.69) 309 (12.17) 803 (31.61) 1,203 (47.36) 1,024 (40.31) 1,190 (46.85) 1,103 (43.43) 410 (16.14) 1,072 (42.20) 588 (23.15) 715 (28.15) Front A, a B, b C, c 94 290 316 (12.44) (3.70) (11.42) F-f F-G or f-g F-g or f-G 1 2 3 1,100 (43.31) 158 (6.22) 1,027 (40.43) 100 (3.94) 100 (3.94) 98 (3.86) D, d 180 (7.09) E, e F, f 120 63 (4.72) (2.48) G, g 29 (1.14) H, h 31 (1.22) 1 2 I, i J, j K, k 125 159 272 (4.92) (6.26) (10.71) l L 285 284 (11.18) (11.22) 3 M, m 259 (10.20) Imaginary Standard Line mm (in.) Symbol Name Hole dia. G, g Front side member standard hole ø18 (0.71) A, a Front bumper reinforcement installation nut M10 (0.39) H, h Front floor under reinforcement standard hole ø15 (0.59) B, b Front crossmember standard hole ø18 (0.71) I, i Strut bar installation hole-inner ø12 (0.47) C, c Front side member standard hole ø18 (0.71) J, j Rear floor side member standard hole ø18 (0.71) D, d Front suspension member installation nut-front M16 (0.63) K, k Rear suspension member installation nut M12 (0.47) E, e Front suspension member installation nut-rear M16 (0.63) L, l Rear floor side member standard hole ø18 (0.71) F, f Torque box front standard hole ø25 (0.98) M, m Rear floor side member standard hole ø18 (0.71) BODY DIMENSIONS DI-9 UNDER BODY (Two-Dimensional Distance) 2,518 2,285 (99.13) (89.96) 1,706 (67.17) 519 500 (20.43) (19.69) 665 (26.18) RH 0 550 (21.65) 456 (17.95) 329 (12.95) 504 (19.84) LH 1,265 (49.80) 630 (24.80) 585 (23.03) 456 (17.95) 468 (18.43) 544 (21.42) 1,090 1,350 (42.91) (53.15) 1,916 (75.43) 662 (26.06) 525 (20.67) 513 (20.20) 503 (19.80) 511 (20.12) 547 (21.54) 1,330 (52.36) 1,916 (75.43) 340 (13.39) 2,395 2,177 (94.29) (85.71) Front 1,395 1,135 (54.92) (44.69) Wheel base A, a B, b C, c D, d 316 94 290 180 (12.44) (3.70) (11.42) (7.09) 0 541 (21.30) 1 2 3 100 (3.94) 100 (3.94) 98 (3.86) 920 (36.22) 2,775 (109.25) E, e F, f 752 120 (29.61) (4.72) G, g 63 1 (2.48) H, h 29 (1.14) I, i 31 (1.22) 2 3 N n J, j K, k L, l M, m O, o 284 285 125 159 272 779 259 (4.92) (6.26) (10.71) (30.67) (11.18) (11.22) (10.20) Imaginary Standard Line mm (in.) Hole dia. H, h Front side member standard hole ø18 (0.71) A, a Front bumper reinforcement installation nut M10 (0.39) I, i Front floor under reinforcement standard hole ø15 (0.59) Symbol Name B, b Front crossmember standard hole ø18 (0.71) J, j Strut bar installation hole-inner ø12 (0.47) C, c Front side member standard hole ø18 (0.71) K, k Rear floor side member standard hole ø18 (0.71) D, d Front suspension member installation nut-front M16 (0.63) L, l Rear suspension member installation nut M12 (0.47) E, e Front spring support hole-outer ø12.5 (0.492) M, m Rear spring support hole-outer ø9.5 (0.374) F, f Front suspension member installation nut-rear M16 (0.63) N, n Rear floor side member standard hole ø18 (0.71) Torque box front standard hole ø25 (0.98) O, o Rear floor side member standard hole ø18 (0.71) G, g BODY DIMENSIONS DI-10 SUSPENSION CROSSMEMBER (Three-Dimensional Distance) Front RH LH 700 (27.56) 920 (36.22) 879 (34.61) 945 (37.20) 1,029 (40.51) 616 (24.25) 520 (20.47) 658 (25.91) 676 (26.61) 486 (19.13) 738 (29.06) 80 74 89 55 72 (3.15) (2.91) (3.50) (2.17) (2.83) 72 55 89 74 80 (2.83) (2.17) (3.50) (2.91) (3.15) Imaginary Standard Line HINT: For sysmbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (Seen from rear). Symbol mm (in.) Name Hole dia. C, c Front frame standard hole ø13 (0.51) A, a Front frame standard hole ø13 (0.51) D, d Front frame standard hole ø13 (0.51) B, b Front frame standard hole ø13 (0.51) E, e Lower arm installation hole-lower ø15 (0.59) BODY DIMENSIONS DI-11 SUSPENSION CROSSMEMBER (Two-Dimensional Distance) Front LH 635 (25.00) 350 (13.78) 505 (19.88) 460 (18.11) 0 14 (0.55) 104 (4.09) 338 (13.31) 243 (9.57) 369 (14.53) 80 74 89 55 72 (3.15) (2.91) (3.50) (2.17) (2.83) RH 350 (13.78) 635 (25.00) 460 (18.11) 338 (13.31) 243 (9.57) 369 (14.53) 72 55 89 74 80 (2.83) (2.17) (3.50)(2.91) (3.15) 505 (19.88) 0 14 (0.55) 104 (4.09) Imaginary Standard Line HINT: For sysmbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (Seen from rear). Symbol mm (in.) Name Hole dia. C, c Front frame standard hole ø13 (0.51) A, a Front frame standard hole ø13 (0.51) D, d Front frame standard hole ø13 (0.51) B, b Front frame standard hole ø13 (0.51) E, e Lower arm installation hole-lower ø15 (0.59) BODY DIMENSIONS DI-12 REFERENCE VALUE ENGINE COMPARTMENT (Three-Dimensional Distance) 1,552 (61.10) 1,582 (62.28) 1,562 (61.50) 633 (24.92) 387 (15.24) 1,595 (62.80) 1,463 (57.60) 1,536 (60.47) 1,520 (59.84) 1,467 (57.76) 1,328 (52.28) 237 (9.33) 848 (33.39) 240 (9.45) 1,216 (47.87) 887 (34.92) 1,203 (47.36) 1,448 (57.01) 422 (16.61) Vehicle Dimensions B-E or b-e C-E or c-e 524 (20.63) 476 (18.74) HINT: 1) For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear). 2) These values are actual measurements made on model. Use these reference values. 3) Measure point with the Front fender to cowl side seal and Cool air intake dust seal removed. mm (in.) Symbol Name Hole dia. C, c Front fender installation bolt — A, a Front bumper cover installation bolt — D, d Front fender installation bolt — B, b Headlight installation bolt — E, e Front fender installation bolt — BODY DIMENSIONS DI-13 UNDER BODY (Three-Dimensional Distance) 679 (26.73) 871 (34.29) 274 (10.79) 1,007 (39.65) 1,205 (47.44) 1,498 (58.98) 1,425 (56.10) 802 (31.57) 1,002 (39.45) 1,268 (49.92) 1,044 (41.10) 658 (25.91) 936 (36.85) HINT: 1) For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear). 2) These values are actual measurements made on model. Use these reference values. 3) Measure point with the Engine under cover removed. mm (in.) Symbol Name A, a Front crossmember reinforcement No.2 standard hole B, b Front suspension member installation bolt Hole dia. C, c Front suspension member installation bolt — ø10 (0.39) D, d Front side member standard hole — — — — — BODY DIMENSIONS DI-14 UNDER BODY (Two-Dimensional Distance) Front bumper reinforcement [RH] 12.9
[LH] 12.9
12.3
12.4
72.9 3
M10 NUT 72.9 3
M10 NUT 25.4 31.4 Rear spring support Front spring support 11.6 9.5 0.6 36.1 36.6 56.5 2.7 22.6 42.3 64.9 2.9 0.6 12.5 2.3 2.4 2.5 4.9 20.2 5.8
3.1
2.2 39.5 37.9 50.4 12.3 62.0 mm WW–1 WIPER AND WASHER – WIPER AND WASHER SYSTEM WIPER AND WASHER SYSTEM PRECAUTION 1. Switch Type Ignition switch off Expression EXPRESSIONS OF IGNITION SWITCH (a) The type of ignition switch used on this model differs according to the specifications of the vehicle. The expressions listed in the table below are used in this section. Ignition Switch (position) Engine Switch (condition) LOCK Off Ignition switch on (IG) ON On (IG) Ignition switch on (ACC) ACC On (ACC) Engine start START Start 2. PRECAUTION OF WASHER NOZZLE ADJUSTMENT (a) Do not clean or adjust the washer nozzle with a safety pin, etc. because; (1) the washer nozzle tip is made of resin and could be damaged. (2) adjustment is not necessary because the washer nozzle is a spray type. If it is necessary to change the nozzle angle, replace the washer nozzle with one that has a different nozzle angle. (See page WW-28) (b) In case the washer nozzle is clogged with wax, etc., remove it and clean the nozzle hole with a soft resin brush, etc. WW WW–2 WIPER AND WASHER – WIPER AND WASHER SYSTEM PARTS LOCATION WASHER NOZZLE FRONT WIPER ARM AND BLADE ASSEMBLY LH FRONT WIPER ARM AND BLADE ASSEMBLY RH WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY - FRONT WIPER MOTOR WINDSHIELD WASHER JAR AND PUMP ASSEMBLY - FRONT WASHER MOTOR - WINDSHIELD WIPER LINK ASSEMBLY ENGINE ROOM J/B AND R/B - ALT FUSE WIPER SWITCH WW MAIN BODY ECU (INSTRUMENT PANEL J/B) - IG1 RELAY - WIP FUSE - WASH FUSE E119081E01 WW–3 WIPER AND WASHER – WIPER AND WASHER SYSTEM SYSTEM DIAGRAM Wiper Control Switch +B +2 +1 +S INT1 INT2 B1 MIST Washer Switch OFF INT W LO OFF HI ON EW Front Wiper Relay Circuit Tr2 Tr1 C1 C2 Washer Motor WW +2 +1 LO +S +B Front Wiper Motor HI B126225E02 WW–4 WIPER AND WASHER – WIPER AND WASHER SYSTEM SYSTEM DESCRIPTION 1. 2. WW WASHER LINKED OPERATION (a) This system operates the front wipers at a low speed immediately after a jet of washer fluid when the front washer switch is turned on for approximately 0.3 seconds or more. If the switch is turned off within approximately 1.5 seconds, the system stops the wipers when the switch is turned off. If the switch is turned on for approximately 1.5 seconds or more, the system stops the wipers approximately 2.2 seconds after the switch is turned off. INTERMITTENT OPERATION (a) The system operates the front wipers once in approximately 1.6 to 10.7 seconds when the front wiper switch is turned to the INT position. The intermittent time can be adjusted between 1.6 and 10.7 seconds. (b) If the wiper control switch is turned to the INT position, current flows from the already charged capacitor C1 to Tr1 (transistor) through terminals INT1 and INT2 of the wiper control switch. When Tr1 turns on, current flows from terminal +S of the wiper control switch to terminal +1 of the wiper control switch, to terminal +1 of the wiper motor, to the wiper motor and finally to the ground, causing the wiper motor to operate. At the same time, current flows from capacitor C1 to terminal INT1 of the wiper control switch and then INT2. When the current flow from capacitor C1 ends, Tr1 turns off to stop the relay contact point and halt the wiper motor. When the relay contact point turns off, capacitor C1 begins to charge again and Tr1 remains off until charging has been completed. This period corresponds to the intermittent time. When capacitor C1 is fully charged, Tr1 turns on and then the relay contact point activates, causing the motor to operate. This cycle is the intermittent operation. The intermittent time can be adjusted by using the intermittent time adjust dial (variable resistor) to change the charge time of capacitor C1. WW–5 WIPER AND WASHER – WIPER AND WASHER SYSTEM Wiper Control Switch +B +2 +1 +S INT1 INT2 B1 MIST Washer Switch OFF INT W LO OFF HI ON EW Front Wiper Relay Circuit Tr2 Tr1 C1 C2 Washer Motor +1 +2 LO +S +B WW Front Wiper Motor HI B126226E02 WW–8 WIPER AND WASHER – FRONT WIPER MOTOR FRONT WIPER MOTOR BODY ELECTRICAL WIPER AND WASHER COMPONENTS FRONT WIPER ARM AND BLADE ASSEMBLY RH 20 (204, 15) 20 (204, 15) FRONT WIPER ARM AND BLADE ASSEMBLY LH FRONT FENDER TO COWL SIDE SEAL RH COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 7.5 (77, 66 in.*lbf) WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY FRONT FENDER TO COWL SIDE SEAL LH 5.4 (55, 48 in.*lbf) WINDSHIELD WIPER LINK ASSEMBLY WW WINDSHIELD WIPER MOTOR ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Apply MP grease E128804E01 WIPER AND WASHER – FRONT WIPER MOTOR WW–9 REMOVAL 1. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH (a) Remove the nut and the front wiper arm and blade assembly LH. 2. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH (a) Remove the nut and the front wiper arm and blade assembly RH. 3. REMOVE FRONT FENDER TO COWL SIDE SEAL LH (a) Disengage the claw and remove the front fender to cowl side seal LH. 4. REMOVE FRONT FENDER TO COWL SIDE SEAL RH (a) Disengage the claw and remove the front fender to cowl side seal RH. E128807 E128808 E128809 WW E128810 WW–10 WIPER AND WASHER – FRONT WIPER MOTOR 5. REMOVE COWL TOP VENTILATOR LOUVER SUBASSEMBLY (a) Remove the 2 clips. (b) Disengage the 4 claws and remove the cowl top ventilator louver sub-assembly. 6. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (a) Disconnect the connector. E128811 E128812 (b) Remove the 4 bolts and the windshield wiper motor and link assembly. E128813 WW 7. Protective Tape E128814E01 REMOVE WINDSHIELD WIPER MOTOR ASSEMBLY (a) Using a screwdriver, separate the No. 2 windshield wiper link rod from the crank arm pivot of the front wiper motor assembly as shown in the illustration. HINT: Tape the screwdriver tip before use. WIPER AND WASHER – FRONT WIPER MOTOR WW–11 (b) Move the crank arm in the direction indicated by the arrow. E128815 (c) Remove the 3 bolts and the windshield wiper motor assembly from the windshield wiper link assembly. E128816 Connector Front View: B1 INSPECTION B 1. +2 +1 +S E E034081E37 INSPECT WINDSHIELD WIPER MOTOR ASSEMBLY (for TMC Made) (a) LO Operation Check (1) Connect a positive (+) battery lead to terminal B1-5 (+1) of the connector, and a negative (-) battery lead to terminal B1-4 (E), and check that the motor operates at low speed (LO). (b) HI Operation Check (1) Connect a positive (+) lead to terminal B1-3 (+2) of the connector, and a negative (-) battery lead to terminal B1-4 (E), and check that the motor operates at high speed (HI). (c) Automatic Stop Operation Check (1) Put matchmarks on the windshield wiper motor assembly. The matchmarks will be used to confirm the return of the motor shaft to the park position. 22° +5° -10° Automatic Stop Position B131458E01 WW WW–12 WIPER AND WASHER – FRONT WIPER MOTOR (2) Connect a positive (+) battery lead to terminal B1-5 (+1) of the connector on the wiper motor and connect a negative battery lead to terminal B1-4 (E) of the wiper motor. With the motor operating at low speed (LO), disconnect terminal B1-5 (+1) to stop the wiper motor at a position where the matchmarks do not line up. HINT: In the following step, connections will be made at the wiper motor to allow verification of the operation of the park contacts that are operated by the cam in the wiper motor. After the connections have been made, when the motor is not in the park position, current will flow from terminal B1-2 (B) through the park contacts in the wiper motor, to terminal B1-1 (+S). The current will then flow through the jumper wire to terminal B1-5 (+1) through the motor to ground (causing it to operate). When the motor reaches the park position, the park contacts should open, stopping the operation of the wiper motor in the correct location. Terminals B1-2 (B) and B1-1 (+S) are connected by the internal cam in the wiper motor when the wiper motor is not in the park position. Terminals B1-1 (+S) and B1-4 (E) are connected by the internal cam in the wiper motor when the wiper motor is in the park position. (3) With the ground wire still attached from the previous step, connect a jumper lead between terminal B1-1 (+S) and terminal B1-5 (+1). Next, connect a positive (+) battery lead to terminal B1-2 (B) to cause the wiper motor to operate at low speed. If the wiper motor is operating correctly, the wiper will operate until it reaches the park position. When it reaches the park position, it will automatically stop. (4) Verify that the matchmarks on the windshield wiper motor assembly are lined up. WW Connector Front View: A59 2. B +2 +1 +S E E034081E38 INSPECT WINDSHIELD WIPER MOTOR ASSEMBLY (for TMMK Made) (a) LO Operation Check (1) Connect a positive (+) battery lead to terminal A59-5 (+1) of the connector, and a negative (-) battery lead to terminal A59-4 (E), and check that the motor operates at low speed (LO). (b) HI Operation Check (1) Connect a positive (+) lead to terminal A59-3 (+2) of the connector, and a negative (-) battery lead to terminal A59-4 (E), and check that the motor operates at high speed (HI). WIPER AND WASHER – FRONT WIPER MOTOR WW–13 (c) Automatic Stop Operation Check (1) Put matchmarks on the windshield wiper motor assembly. The matchmarks will be used to confirm the return of the motor shaft to the park position. (2) Connect a positive (+) battery lead to terminal A59-5 (+1) of the connector on the wiper motor and connect a negative battery lead to terminal A59-4 (E) of the wiper motor. With the motor operating at low speed (LO), disconnect terminal A59-5 (+1) to stop the wiper motor at a position where the matchmarks do not line up. HINT: In the following step, connections will be made at the wiper motor to allow verification of the operation of the park contacts that are operated by the cam in the wiper motor. After the connections have been made, when the motor is not in the park position, current will flow from terminal A59-2 (B) through the park contacts in the wiper motor, to terminal A59-1 (+S). The current will then flow through the jumper wire to terminal A59-5 (+1) through the motor to ground (causing it to operate). When the motor reaches the park position, the park contacts should open, stopping the operation of the wiper motor in the correct location. Terminals A59-2 (B) and A59-1 (+S) are connected by the internal cam in the wiper motor when the wiper motor is not in the park position. Terminals A591 (+S) and A59-4 (E) are connected by the internal cam in the wiper motor when the wiper motor is in the park position. (3) With the ground wire still attached from the previous step, connect a jumper lead between terminal A59-1 (+S) and terminal A59-5 (+1). Next, connect a positive (+) battery lead to terminal A59-2 (B) to cause the wiper motor to operate at low speed. If the wiper motor is operating correctly, the wiper will operate until it reaches the park position. When it reaches the park position, it will automatically stop. (4) Verify that the matchmarks on the windshield wiper motor assembly are lined up. 22° +5° -10° Automatic Stop Position B131458E01 INSTALLATION 1. E128816 INSTALL WINDSHIELD WIPER MOTOR ASSEMBLY (a) Install the windshield wiper motor assembly with the 3 bolts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) WW WW–14 WIPER AND WASHER – FRONT WIPER MOTOR (b) Move the crank arm in the direction indicated by the arrow. E128817 (c) Apply MP grease to the crank arm pivot of the windshield wiper motor assembly. E128818E01 (d) Install the No. 2 windshield wiper link rod to the pivot of the windshield wiper motor assembly. E128819E01 2. (1) (2) WW (4) (3) INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (a) Install the windshield wiper motor and link assembly with the 4 bolts. Torque: 7.5 N*m (77 kgf*cm, 66 in.*lbf) NOTICE: Tighten the bolts in the order shown in the illustration. E128813E01 (b) Connect the connector. E128812 WIPER AND WASHER – FRONT WIPER MOTOR WW–15 3. INSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY (a) Engage the 4 claws and install the cowl top ventilator louver sub-assembly. (b) Install the 2 clips. 4. INSTALL FRONT FENDER TO COWL SIDE SEAL RH (a) Engage the claw and install the front fender to cowl side seal RH. 5. INSTALL FRONT FENDER TO COWL SIDE SEAL LH (a) Engage the claw and install the front fender to cowl side seal LH. 6. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH (a) Operate the wiper and stop the windshield wiper motor at the automatic stop position. E128811 E128810 E128809 WW WW–16 WIPER AND WASHER – FRONT WIPER MOTOR (b) Clean the wiper arm serrations. (c) When reinstalling: (1) Clean the wiper pivot serrations with a wire brush. Wiper Arm Serrations Wire Brush Wiper Pivot Serrations E112237E01 (d) Install the front wiper arm and blade assembly LH with the nut to the position shown in the illustration. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) HINT: Hold the arm hinge by hand to fasten the nut. Ceramic Notch A 7. Louver Edge E128820E01 WW Area Measurement A 37 to 52 mm (1.46 to 2.05 in.) INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH (a) Operate the wiper and stop the windshield wiper motor at the automatic stop position. WW–17 WIPER AND WASHER – FRONT WIPER MOTOR (b) Clean the wiper arm serrations. (c) When reinstalling: (1) Clean the wiper pivot serrations with a wire brush. Wiper Arm Serrations Wire Brush Wiper Pivot Serrations E112237E01 A (d) Install the front wiper arm and blade assembly RH with the nut to the position shown in the illustration. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) HINT: Hold the arm hinge by hand to fasten the nut. Louver Edge Ceramic Notch E128821E01 Area Measurement A 23 to 38 mm (0.90 to 1.49 in.) (e) Operate the front wipers while spraying washer fluid on the windshield glass. Make sure that the front wipers function properly and the wipers do not come into contact with the vehicle body. WW WW–18 WIPER AND WASHER – FRONT WIPER RUBBER FRONT WIPER RUBBER BODY ELECTRICAL WIPER AND WASHER COMPONENTS FRONT WIPER BLADE WIPER RUBBER BACKING PLATE WIPER RUBBER WIPER RUBBER BACKING PLATE E119633E02 WW WIPER AND WASHER – FRONT WIPER RUBBER WW–19 REMOVAL 1. REMOVE FRONT WIPER BLADE (a) Disengage the holder of the front wiper blade. (b) Remove the front wiper blade from the front wiper arm as shown in the illustration. NOTICE: Do not bend the front wiper arm with the front wiper blade removed because the arm tip could damage the windshield surface. Front Wiper Arm Holder Front Wiper Blade E128822E01 2. E125259 REMOVE WIPER RUBBER (a) Remove the wiper rubber and the wiper rubber backing plates from the front wiper blade. WW WW–20 WIPER AND WASHER – FRONT WIPER RUBBER (b) Remove the 2 wiper rubber backing plates from the wiper rubber. E125260E01 INSTALLATION 1. E125260E02 INSTALL WIPER RUBBER (a) Install the 2 wiper rubber backing plates to the wiper rubber. NOTICE: • Align the protrusions on the wiper rubber with the notches in the backing plates. • Align the curves of the backing plates with the curve of the glass. (b) Install the wiper rubber to the front wiper blade with the tip of the rubber (curved end) facing the axis of the wiper arm. NOTICE: Firmly push the wiper rubber into the wiper blade to securely engage them. 2. E112266 WW INSTALL FRONT WIPER BLADE (a) Install the front wiper blade as shown in the illustration. WIPER AND WASHER – FRONT WIPER RUBBER WW–21 (b) Install the holder of the front wiper blade. Front Wiper Arm Holder Front Wiper Blade E128823E01 WW WIPER AND WASHER – WIPER SWITCH WW–21 WIPER SWITCH BODY ELECTRICAL WIPER AND WASHER COMPONENTS WINDSHIELD WIPER SWITCH ASSEMBLY without Smart Key System: with Smart Key System: STEERING COLUMN COVER STEERING COLUMN COVER E128805E01 WW WW–22 WIPER AND WASHER – WIPER SWITCH REMOVAL 1. REMOVE STEERING COLUMN COVER (See page SR-39) 2. REMOVE WINDSHIELD WIPER SWITCH ASSEMBLY (a) Disconnect the 2 connectors. (b) Disengage the claw and remove the windshield wiper switch assembly as shown in the illustration. NOTICE: If the claw is pushed with excessive force, it may break. E128824 INSPECTION Connector Front View: E20 1. E19 E069286E04 INSPECT WINDSHIELD WIPER SWITCH ASSEMBLY (a) Check the continuity of the windshield wiper switch assembly. (1) Measure the resistance according to the value(s) in the table below. Standard resistance: Front Wiper Switch Switch Position Tester Connection Specified Resistance MIST E20-2 (+B) - E20-3 (+1) Below 1 Ω OFF E20-1 (+S) - E20-3 (+1) Below 1 Ω INT E20-1 (+S) - E20-3 (+1) Below 1 Ω LO E20-2 (+B) - E20-3 (+1) Below 1 Ω HI E20-2 (+B) - E20-4 (+2) Below 1 Ω Front Washer Switch Switch Position WW Tester Connection Specified Resistance OFF E19-3 (WF) - E19-2 (EW) 10 kΩ or higher ON E19-3 (WF) - E19-2 (EW) Below 1 Ω (b) Intermittent Operation Check (1) Connect the voltmeter (+) terminal to terminal E20-3 (+1) of the connector and the voltmeter (-) terminal to terminal E19-2 (EW). (2) Connect a positive (+) battery lead to terminal E20-2 (+B) of the connector and a negative (-) battery lead to terminals E19-2 (EW) and E20-1 (+S). (3) Turn the wiper switch to the INT position. (4) Connect a positive (+) battery lead to terminal E20-1 (+S) of the connector for 5 seconds. WIPER AND WASHER – WIPER SWITCH WW–23 (5) Connect a negative (-) battery lead to terminal E20-4 (+2) of the connector. Operate the intermittent wiper adjustment ring and measure the voltage between terminals E20-3 (+1) and E19-2 (EW). FAST: SLOW: 10 to 14 V E20-3 (+1) ←→ E19-2 (EW) Voltage between terminals 0V 1.6 +- 1 seconds 10.7 +- 5 seconds E056399E31 INSTALLATION 1. INSTALL WINDSHIELD WIPER SWITCH ASSEMBLY (a) Engage the claw and install the windshield wiper switch assembly as shown in the illustration. (b) Connect the 2 connectors. 2. INSTALL STEERING COLUMN COVER (See page SR50) E128825 WW WW–24 WIPER AND WASHER – FRONT WASHER MOTOR FRONT WASHER MOTOR BODY ELECTRICAL WIPER AND WASHER COMPONENTS for 2GR-FE: COOL AIR INTAKE DUCT SEAL RADIATOR GRILLE PROTECTOR FRONT BUMPER ASSEMBLY WINDSHIELD WASHER MOTOR AND PUMP ASSEMBLY E128806E01 WW WIPER AND WASHER – FRONT WASHER MOTOR WW–25 REMOVAL 1. REMOVE COOL AIR INTAKE DUCT SEAL (for 2GRFE) (See page ET-4) 2. REMOVE FRONT BUMPER ASSEMBLY (w/o Fog Light) (See page ET-5) 3. REMOVE FRONT BUMPER ASSEMBLY (w/ Fog Light) (See page ET-6) 4. DRAIN WASHER FLUID (a) Disconnect the washer hose from the windshield washer motor and pump assembly, and drain the washer fluid. 5. REMOVE WINDSHIELD WASHER MOTOR AND PUMP ASSEMBLY (a) Disconnect the connector. (b) Remove the windshield washer motor and pump assembly. E128826 E128827 WW WW–26 WIPER AND WASHER – FRONT WASHER MOTOR INSPECTION 1. INSPECT WINDSHIELD WASHER MOTOR AND PUMP ASSEMBLY HINT: This check should be performed with the front washer motor and pump installed to the washer jar. (a) Fill the washer jar with washer fluid. (b) Connect the positive (+) battery lead to terminal A37-1 of the washer motor and pump, and the negative (-) lead to terminal A37-2. (c) Check if washer fluid is pumped from the washer jar. OK: Washer fluid is pumped from the washer jar. A37 2. E065747E07 INSPECT WASHER FLUID LEVEL SENSOR HINT: The following check should be performed with the windshield washer motor and pump installed to the washer jar. (a) Fill the washer jar with washer fluid. (b) Disconnect the connector from the washer fluid level sensor. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Fluid Volume Specified Condition More than 700 to 900 ml 10 kΩ or higher Less than 700 to 900 ml Below 1 Ω INSTALLATION 1. WW E128827 INSTALL WINDSHIELD WASHER MOTOR AND PUMP ASSEMBLY (a) Install the windshield washer motor and pump assembly. (b) Connect the connector. WIPER AND WASHER – FRONT WASHER MOTOR WW–27 2. FILL UP WASHER JAR WITH WASHER FLUID (a) Connect the washer hose to the windshield washer motor and pump assembly and fill the washer jar with washer fluid. 3. INSTALL FRONT BUMPER ASSEMBLY (w/ Fog Light) (See page ET-14) 4. INSTALL FRONT BUMPER ASSEMBLY (w/o Fog Light) (See page ET-13) 5. INSTALL COOL AIR INTAKE DUCT SEAL (for 2GRFE) (See page ET-14) E128828 WW WIPER AND WASHER – WASHER NOZZLE WW–27 WASHER NOZZLE ON-VEHICLE INSPECTION 1. INSPECT WASHER NOZZLE SUB-ASSEMBLY (a) With the engine running, check the position that the washer fluid hits the windshield. Standard: Washer fluid hits the windshield in the areas shown in the illustration. HINT: If the result is not as specified, replace the washer nozzle. 300 (11.81) 300 (11.81) Upper limit Washer fluid spray area Lower limit 140 (5.51) mm (in.) 130 (5.12) 130 (5.12) E128829E01 WW WW–28 WIPER AND WASHER – WASHER NOZZLE ADJUSTMENT 1. (2) (1) ADJUST WASHER NOZZLE SUB-ASSEMBLY (a) Using a screwdriver, disengage the 2 claws and separate the washer nozzle sub-assembly as shown in the illustration. NOTICE: Be careful not to damage the windshield. HINT: Tape the screwdriver tip before use. Protective Tape E128830E01 (b) Disconnect the washer nozzle sub-assembly from the washer hose. NOTICE: Washer nozzles cannot be reused. (c) Select a washer nozzle sub-assembly so that the washer fluid spray area is within the standard. E128831 Available Washer Nozzles: +2° +1° -1° 0° -2° WW Washer Fluid Spray Angle Part Number -2° 85381-30210 -1° 85381-30190 0° 85381-30170 +1° 85381-30180 +2° 85381-30200 E128832E01 WIPER AND WASHER – WASHER NOZZLE WW–29 (d) Connect the selected washer nozzle sub-assembly to the washer hose. (e) Engage the 2 claws and install the washer nozzle sub-assembly. WW NS–1 NAVIGATION – NAVIGATION SYSTEM NAVIGATION SYSTEM BODY ELECTRICAL NAVIGATION PARTS LOCATION FRONT SIDE SPEAKER -FRONT NO. 2 SPEAKER LH SPIRAL CABLE COMBINATION METER GPS ANTENNA RADIO AND NAVIGATION ASSEMBLY STEERING PAD SWITCH MICROPHONE FRONT SIDE SPEAKER -FRONT NO. 2 SPEAKER RH ANTENNA ANTENNA AMPLIFIER FRONT SIDE SPEAKER -FRONT NO. 1 SPEAKER REAR SIDE SPEAKER INSTRUMENT PANEL J/B -REAR SPEAKER -TAIL RELAY -ACC RELAY -RADIO NO. 2 FUSE STEREO COMPONENT AMPLIFIER NS -PANEL FUSE STEREO JACK ADAPTER ENGINE ROOM J/B AND R/B -RADIO NO. 1 FUSE E132176E01 NS–2 NAVIGATION – NAVIGATION SYSTEM SYSTEM DIAGRAM Steering Pad Switch Switch Signal Combination Meter Vehicle Speed Signal Park/Neutral Position Switch Stereo Component Amplifier Speakers Reverse Signal Microphone Assembly Radio and Navigation Assembly Microphone Voice Signal Stereo Jack Adapter External Device Sound Signal Radio Antenna GPS Antenna Antenna Amplifier NS : AVC-LAN : Sound Signal E129832E02 NAVIGATION – NAVIGATION SYSTEM NS–3 SYSTEM DESCRIPTION 1. Radio and navigation assembly outline (a) Conventionally, 2 separate devices, a "radio and display" and a "navigation ECU" are used. This model has adopted a new type, combining these devices into a single unit. Radio and Display Radio and Navigation Assembly Navigation ECU E129826E01 NS NS–4 NAVIGATION – NAVIGATION SYSTEM 2. Navigation system outline (a) Vehicle position tracking methods It is essential that the navigation system correctly tracks the current vehicle position and displays it on the map. There are 2 methods to track the current vehicle position: autonomous (dead reckoning) and GPS* (satellite) navigation. Both navigation methods are used in conjunction with each other. *GPS (Global Positioning System) GPS satellite Location by autonomous navigation Navigation Gyro Sensor GPS Antenna Location by GPS navigation Vehicle Speed Sensor Radio and Navigation Assembly GPS Antenna Receive satellite radio wave ECU Detect the measurement position GPS correction Vehicle Speed Sensor Detect vehicle running distance Create the current vehicle position tracking data Navigation screen Detect direction change Gyro Sensor Map matching correction NS Map disc Map and current vehicle position data processing Map scrolling Map scale switching E120052E01 NS–5 NAVIGATION – NAVIGATION SYSTEM Operation Description Vehicle Position Calculation The radio and navigation assembly calculates the current vehicle position (direction and current position) using the direction deviation signal from the gyro sensor and the running distance signal from the vehicle speed sensor and creates the driving route. Map Display Processing The radio and navigation assembly displays the vehicle track on the map by processing the vehicle position data, vehicle running track, and map data from the map disc. Map Matching The map data from the map disc is compared to the vehicle position and running track data. Then, the vehicle position is matched with the nearest road. GPS Correction The vehicle position is matched to the position measured by GPS. Then, the measurement position data from the GPS unit is compared with the vehicle position and running track data. If the position is widely different, the GPS measurement position is used. Distance Correction The running distance signal from the vehicle speed sensor includes the error caused by tire wear and slippage between the tires and road surface. Distance correction is performed to account for this. The radio and navigation assembly automatically offsets the running distance signal to make up for the difference between it and the distance data of the map. The offset is automatically updated. Navigation is performed even where the GPS radio wave does not reach. GPS Satellite In a tunnel In an indoor parking lot Between tall buildings Under an overpass On a forest or tree-lined path Autonomous Navigation Autonomous Navigation and GPS Wave Navigation NS I100028E07 NS–6 NAVIGATION – NAVIGATION SYSTEM HINT: The combination of autonomous and GPS navigation makes it possible to display the vehicle position even when the vehicle is in places where the GPS radio wave cannot receive a signal. When only autonomous navigation is used, however, the mapping accuracy may slightly decline. (b) Autonomous navigation This method determines the relative vehicle position based on the running track determined by the gyro and vehicle speed sensors located in the radio and navigation assembly. (1) Gyro sensor Calculates the direction by detecting angular velocity. It is located in the radio and navigation assembly. (2) Vehicle speed sensor Used to calculate the vehicle running distance. NS NS–7 NAVIGATION – NAVIGATION SYSTEM (c) GPS navigation (Satellite navigation) This method detects the absolute vehicle position using radio waves from a GPS satellite. * GPS satellites were launched by the U.S. Department of Defence for military purposes. Current longitude/latitude/altitude is determined using the radio wave arrival time from four satellites. GPS I100029E03 Number of satellites Measurement Description 2 or less Measurement impossible Vehicle position cannot be obtained because the number of satellites is not enough. 3 2-dimensional measurement is possible Vehicle position is obtained based on the current longitude and latitude. (This is less precise than 3-dimensional measurement.) 4 3-dimensional measurement is possible Vehicle position is obtained based on the current longitude, latitude and altitude. NS NS–8 NAVIGATION – NAVIGATION SYSTEM (d) Map matching The current driving route is calculated by autonomous navigation (according to the gyro sensor and vehicle speed sensor) and GPS navigation. This information is then compared with possible road shapes from the map data in the map disc and the vehicle position is set onto the most appropriate road. Start Actual driving route Driving route on the display (Route by estimation) L1 L 1 A L 2 L2 L3 Roads L 3 The system compares the shape of the roads L1, L2 and L3 to the estimated running track after the vehicle makes a right turn. At point A, the vehicle position differs enough from the shape of L1 that the display switches to the road L2. Map Matching NS I100030E07 NS–9 NAVIGATION – NAVIGATION SYSTEM (e) Touch switch Touch switches are touch-sensitive (interactive) switches operated by touching the screen. When a switch is pressed, the outer glass bends in to contact the inner glass at the pressed position. By doing this, the voltage ratio is measured and the pressed position is detected. Outer Glass Inner Vx1 (Vy1) Vy1 Contact Vx1 Vx2 Vx2 (Vy2) Vy2 Touch-sensitive switch position The touch switch detects the voltage ratio and calculates the position on the screen. E106414E03 3. DVD (Digital Versatile Disc) player outline (for navigation map) (a) The radio and navigation assembly (built-in navigation ECU) uses a laser pickup to read the digital signals recorded on a DVD. HINT: • Do not disassemble any part of the radio and navigation assembly (built-in navigation ECU). • Do not apply oil to the radio and navigation assembly (built-in navigation ECU). • Do not insert anything but a DVD into the radio and navigation assembly (built-in navigation ECU). NS NS–10 NAVIGATION – NAVIGATION SYSTEM 4. CAUTION: Do not look directly at the laser pickup because the radio and navigation assembly (built-in navigation ECU) uses an invisible laser beam. Be sure to only operate the navigation system as instructed. CD (Compact Disc) player outline (a) A compact disc player uses a laser pickup to read digital signals recorded on a compact disc (CD). By converting the digital signals to analog, it can play music and other content. NOTICE: • Do not disassemble any part of the CD player. • Do not apply oil to the CD player. • Do not insert anything but a CD into the CD player. CAUTION: Do not look directly at the laser pickup because the CD player uses an invisible laser beam. Be sure to only operate the player as instructed. (b) Usable discs (1) This player can only play audio CDs, CD-Rs (CD-Recordable), and CD-RWs (CDReWritable) that have any of the following marks: E119759 NS (c) Precautions for use of discs NOTICE: • Copy-protected CDs cannot be played. • CD-Rs and CD-RWs may not be played depending on the recording conditions or characteristics of the discs, or due to damage, dirt, or deterioration caused by leaving the discs in the cabin for a long time. • Unfinalized CD-Rs and CD-RWs cannot be played. • DualDiscs that mate DVD recorded material on one side with CD digital audio material on the other cannot be played. • Keep the discs away from dirt. Be careful not to damage the discs or leave your fingerprints on them. • Hold discs by the outer edge and center hole with the label side up. NAVIGATION – NAVIGATION SYSTEM NS–11 • Leaving the disc exposed halfway out of the slot for a long time after pressing the disc eject button may cause deformation of the disc, making the disc unusable. • If discs have adhesive tape, stickers, CDR labels, or any traces of such labels attached, the discs may not be ejected or player malfunctions may result. • Keep the discs away from direct sunlight. (Exposure to direct sunlight may cause deformation of the disc, making the disc unusable.) • Do not use odd-shaped CDs because these may cause player malfunctions. • Do not use discs whose recording portion is transparent or translucent because they may not be inserted, ejected, or played normally. HINT: • When it is cold or it is raining, if the windows mist up, mist and also dew may form in the player. In such a case, the CD may skip or the CD may stop in the middle of play. Ventilate or dehumidify the cabin for a while before using the player. • The CD may skip if the player experiences strong vibrations when the vehicle is driven on rough road or similar uneven surface(s). I100151 5. (d) Cleaning NOTICE: Do not use a lens cleaner because it may cause a malfunction in the pickup portion of the player. (1) If dirt is on the disc surface, wipe it clean with a soft dry cloth such as an eyeglass cleaner for plastic lenses from the inside to the outside in a radial direction. NOTICE: • Pressing on the disc by hand or rubbing the disc with a hard cloth may scratch the disc surface. • Use of solvent such as a record spray, antistatic agent, alcohol, benzine, and thinner, or a chemical cloth may cause damage to the disc, making the disc unusable. MP3/WMA OUTLINE (a) Playable MP3 file standards Compatible standard Compatible sampling frequency Compatible bit rate Compatible channel mode MP3 (MPEG1 LAYER3, MPEG2 LSF LAYER 3) • • MPEG1 LAYER3: 32, 44.1, 48 (kHz) MPEG2 LSF LAYER3: 16, 22.05, 24 (kHz) • MPEG1 LAYER3: 64, 80, 96, 112, 128, 160, 192, 224, 256, 320 (kbps) MPEG2 LSF LAYER3: 64, 80, 96, 112, 128, 144, 160 (kbps) Compatible with VBR • • Stereo, joint stereo, dual channel, monaural NS NS–12 NAVIGATION – NAVIGATION SYSTEM (b) Playable WMA file standards Compatible standard WMA Ver. 7, 8, and 9 Compatible sampling frequency 32, 44.1, 48 (kHz) Compatible bit rate • • • Ver. 7, 8: CBR48, 64, 80, 96, 128, 160, 192 (kbps) Ver. 9: CBR48, 64, 80, 96, 128, 160, 192, 256, 320 (kbps) Compatible with playback of channel 2 only (c) ID3 tag and WMA tag (1) Additional textual information called ID3 tag can be input to MP3 files. Information such as song titles and artist names can be stored. HINT: This player is compatible with the ID3 tags of ID3 Ver. 1.0 and 1.1, and ID3 Ver. 2.2 and 2.3. (Number of characters complies with ID3 Ver. 1.0 and 1.1.) (2) Additional textual information called WMA tag can be input to WMA files. Information such as song titles and artist names can be stored. (d) Usable media (1) Only CD-ROMs, CD-Rs (CD-Recordable), and CD-RWs (CD-ReWritable) can be used to play MP3/WMA files. NOTICE: • CD-Rs and CD-RWs are more easily affected by a hot and humid environment than discs used for normal audio CDs. For this reason, some CD-Rs and CD-RWs may not be played. • If there are fingerprints or scratches on the disc, the disc may not be played or the CD may skip. • Some CD-Rs and CD-RWs deteriorate if they are left in the cabin for a long time. • Keep CD-Rs and CD-RWs in a storage case that is impenetrable to light. (e) Usable media format (1) Usable media format NS Disc format CD-ROM Mode 1, CD-ROM XA Mode 2 Form 1 File format ISO9660 Level 1 and Level 2 (Joliet, Romeo) HINT: • As for MP3/WMA files written in any format other than those above, the contents of the files may not be played normally or the file names or folder names may not be displayed correctly. • This player is compatible with multi-session discs and can play CD-Rs and CD-RWs on which MP3/WMA files are added. However, only the first session can be played. • Discs whose first session includes both music data and MP3 or WMA format data cannot be played. NAVIGATION – NAVIGATION SYSTEM NS–13 (2) Standard and restrictions Maximum directory levels 8 levels Maximum number of characters for a folder name/file name 32 characters Maximum number of folders 192 (Including empty folders, route folders, and folders that do not contain MP3/WMA files) Maximum number of files in a disc 255 (Including non-MP3/WMA files) (f) 6. File names (1) Only files with an extension of ".mp3" or ".wma" can be recognized and played as MP3 or WMA files. (2) Save MP3 or WMA files with an extension of ".mp3" or ".wma". NOTICE: If saving non-MP3 or non-WMA files with an extension of ".mp3" or ".wma", those files are wrongly recognized as MP3 or WMA files and played. A loud noise may occur and damage to the speaker may result. AVC-LAN Description (a) What is AVC-LAN? AVC-LAN, an abbreviation for "Audio Visual Communication Local Area Network", is a united standard developed by the manufacturers in affiliation with Toyota Motor Corporation. This standard pertains to audio and visual signals as well as switch and communication signals. Example: Radio Receiver (Resistor 60 to 80 Ω) AVC-LAN Stereo Component Amplifier I100032E09 NS NS–14 NAVIGATION – NAVIGATION SYSTEM 7. NS 8. (b) Purpose: Recently, car audio systems have rapidly developed and the functions have vastly changed. The conventional car audio system is being integrated with multi-media interfaces similar to those in navigation systems. At the same time, customers are demanding higher quality from their audio systems. This is merely an overview of the standardization background. The specific purposes are as follows: (1) To solve sound problems, etc. caused by using components of different manufacturers through signal standardization. (2) To allow each manufacturer to concentrate on developing products they do best. From this, reasonably priced products can be produced. HINT: • If a short to +B or short to ground is detected in the AVC-LAN circuit, communication is interrupted and the audio system will stop functioning. • If the audio system has a navigation system installed, the multi-display unit acts as the master unit. If the navigation system is not installed, the audio head unit acts as the master unit instead. If the radio and navigation assembly is installed, it is the master unit. • The radio and navigation assembly contains a resistor that is necessary to enable communication on the different AVC-LAN circuits. • The car audio system with an AVC-LAN circuit has a diagnostic function. • Each component has a specified number (3digit) called a physical address. Each function has a number (2-digit) called a logical address. Communication system outline (a) Components of the navigation system communicate with each other via the AVC-LAN. (b) The radio and navigation assembly has enough resistance (60 to 80 Ω) necessary for communication. (c) If a short circuit or open circuit occurs in the AVCLAN circuit, communication is interrupted and the navigation system will stop functioning. Diagnostic function outline (a) The audio system has a diagnostic function (the result is indicated on the master unit). (b) A 3-digit hexadecimal component code (physical address) is allocated to each component on the AVC-LAN. Using this code, the component in the diagnostic function can be displayed. NAVIGATION – NAVIGATION SYSTEM 9. E100921 Example: NS–15 "Bluetooth" outline (a) "Bluethooth" is a trademark owned by Bluetooth SIG. Inc. (b) "Bluetooth" is a new wireless connection technology that uses the 2.4 GHz frequency band. This makes it possible to connect a cellular phone ("Bluetooth" compatible phone *1) to the radio and navigation assembly (the "Bluetooth" system is built in), and use the handsfree function of the cellular phone, even if it is in a pocket or bag. As a result, it is not necessary to use a connector attached directly to the cellular phone. *1: Some versions of "Bluetooth" compatible cellular phones may not function. Radio and Navigation Assembly (Built-in “Bluetooth” receiver antenna) Cellular Phone (”Bluetooth” type) Cellular Tower E121227E02 HINT: The communication performance of "Bluetooth" may vary depending on obstructions or radio wave conditions between communication devices, electromagnetic radiation, communication device sensitivity, or antenna capacity. NS NS–16 NAVIGATION – NAVIGATION SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING 1 VEHICLE BROUGHT INTO A WORKSHOP NEXT 2 DIAGNOSTIC QUESTIONING AND SYMPTOM CONFIRMATION (a) Ask the customer about symptoms and confirm malfunctions. THE SCREEN DISPLAYS NOTHING (GO TO STEP 8, AND PROCEED TO "BLACK SCREEN") OTHER SYMPTOMS (GO TO STEP 3) 3 CONFIRM THE SYSTEM NORMAL CONDITION APPLICABLE (THIS IS NOT A MALFUNCTION) NOT APPLICABLE (GO TO STEP 4) 4 CHECK DTC HINT: If the system cannot enter the diagnostic mode, inspect the AVC-LAN and all the components that connect to the AVCLAN for short circuits and repair or replace the problem part. A CODE IS OUTPUT (GO TO STEP 5) A CODE IS NOT OUTPUT (GO TO STEP 8) 5 DTC CLEAR (a) Clear the DTCs and finish the diagnostic mode. HINT: The currently output DTCs may not indicate actual malfunctions depending on the vehicle conditions. NS NEXT NAVIGATION – NAVIGATION SYSTEM 6 NS–17 RECHECK DTC HINT: • If the system cannot enter the diagnostic mode, inspect the AVC-LAN and all the components that connect to the AVC-LAN for short circuits. • Even if the malfunction symptom is not confirmed, check for diagnostic trouble codes. This is because the system stores past diagnostic trouble codes. • Refer to the detailed description on the diagnostic screen as necessary (See page NS-30). • Check the diagnostic trouble code and inspect the area the code indicates. A CODE IS OUTPUT (GO TO STEP 7) A CODE IS NOT OUTPUT (GO TO STEP 8) 7 DIAGNOSTIC TROUBLE CODE CHART (a) Find the output code in the diagnostic trouble code chart (See page NS-52). NEXT 8 GO TO STEP 10 PROBLEM SYMPTOMS TABLE (a) Find the applicable symptom code in the problem symptoms table (See page NS-41). HINT: If the symptom does not recur and no code is output, perform the symptom reproduction method (See page IN-40). THERE IS AN APPLICABLE SYMPTOM CODE IN THE TABLE (GO TO STEP 10) THERE IS NO APPLICABLE SYMPTOM CODE IN THE TABLE (GO TO STEP 9) 9 CHECK THE ECU TERMINAL ARRANGEMENT BASED ON THE MALFUNCTION SYMPTOM NS NEXT 10 CHECK THE CIRCUIT (a) Adjust, repair, or replace as necessary. NS–18 NAVIGATION – NAVIGATION SYSTEM NEXT 11 RECHECK THE DIAGNOSTIC TROUBLE CODE HINT: After deleting the DTCs, recheck for diagnostic trouble codes. NEXT 12 NEXT END NS PERFORM CONFIRMATION TEST NS–19 NAVIGATION – NAVIGATION SYSTEM IDENTIFICATION OF NOISE SOURCE 1. Frequency 300 kHz 30 kHz Designation Radio Description (a) Radio frequency band (1) Radio broadcasts use the radio frequency bands shown in the table below. LF MF Modulation HF VHF FM Amplitude modulation MF: Medium Frequency 300 MHz 30 MHz AM Radio Wave LF: Low Frequency 30 MHz HF: High Frequency Frequency modulation VHF: Very High Frequency E108734E01 (b) Service area (1) The service areas of AM and FM broadcasts are vastly different. Sometimes an AM broadcast can be received very clearly but an FM stereo cannot. FM stereo has the smallest service area, and is prone to pick up static and other types of interference such as noise. (c) Radio reception problems HINT: In addition to static, other problems such as "phasing", "multipath", and "fade out" exist. These problems are not caused by electrical noise, but by the radio signal propagation method itself. FM (Stereo) FM (Monaural) AM E108735E01 Phasing Ionosphere I100011E02 (1) Phasing AM broadcasts are susceptible to electrical interference and another kind of interference called phasing. Occurring only at night, phasing is the interference created when a vehicle receives 2 radio wave signals from the same transmitter. One signal is reflected off the ionosphere and the other signal is received directly from the transmitter. NS NS–20 NAVIGATION – NAVIGATION SYSTEM (2) Multipath Multipath is a type of interference created when a vehicle receives 2 radio wave signals from the same transmitter. One signal is reflected off buildings or mountains and the other signal is received directly from the transmitter. Multipath I100012E02 (3) Fade out Fade out is caused by objects (buildings, mountains, and other such large obstacles) that deflect away part of a signal, resulting in a weaker signal when the object is between the transmitter and vehicle. High frequency radio waves, such as FM broadcasts, are easily deflected by obstructions. Low frequency radio waves, such as AM broadcasts, are much more difficult to deflect. (d) Noise problem Technicians must have a clear understanding about each customer's noise complaint. Use the following table to diagnose noise problems. Fade Out I100013E02 Radio Frequency Noise Occurrence Condition Presumable Cause AM Noise occurs in a specified area Foreign noise AM Noise occurs when listening to an intermittent broadcast An identical program transmitted from multiple towers can cause noise where the signals overlap AM Noise occurs only at night Music beat from a distant broadcast FM Noise occurs while driving in a specified area Multipath or phasing noise resulting from a change in FM frequency HINT: If the noise does not match the examples above, refer to the descriptions about phasing and multipath. NS NS–21 NAVIGATION – NAVIGATION SYSTEM SYSTEM NORMAL CONDITION CHECK 1. CHECK NORMAL CONDITION (a) If the symptom is applicable to any of the following, it is intended behavior, and not a malfunction. Symptom Answer A longer route than expected is chosen. Depending on the road conditions, the radio and navigation assembly may determine that a longer route is quicker. Even when distance priority is high, the shortest route is not shown. Some paths may not be advised due to safety concerns. When the vehicle is put into motion immediately after the engine starts, the navigation system deviates from the actual position. If the vehicle starts before the navigation system activates, the system may not react. When running on certain types of roads, especially new roads, the vehicle position deviates from the actual position. When the vehicle is driving on new roads not available on the map disc, the system attempts to match it to another nearby road, causing the position mark to deviate. (b) The following symptoms are not a malfunction, but are caused by errors inherent in the GPS, gyro sensor, speed sensor, and radio and navigation assembly. (1) The current position mark may be displayed on a nearby parallel road. I100066 (2) Immediately after a fork in the road, the current vehicle position mark may be displayed on the wrong road. I100067 (3) When the vehicle turns right or left at an intersection, the current vehicle position mark may be displayed on a nearby parallel road. I100068 NS NS–22 NAVIGATION – NAVIGATION SYSTEM (4) When the vehicle is carried, such as on a ferry, and the vehicle itself is not running, the current vehicle position mark may be displayed in the position where the vehicle was until a measurement can be performed by GPS. I100069 (5) When the vehicle runs on a steep hill, the current vehicle position mark may deviate from the correct position. I100070 (6) When the vehicle makes a continuous turn of 360, 720, 1,080, etc. degrees, the current vehicle position mark may deviate from the correct position. I100071 (7) When the vehicle moves erratically, such as constant lane changes, the current vehicle position mark may deviate from the correct position. I100072 (8) When the ignition switch is turned on (ACC or IG) on a turntable before parking, the current vehicle position mark may not point in the correct direction. The same will occur when the vehicle comes out of parking. NS I038146 NAVIGATION – NAVIGATION SYSTEM NS–23 (9) When the vehicle runs on a snowy road or a mountain path with the chains installed or using a spare tire, the current vehicle position mark may deviate from the correct position. I100074 (10)When a tire is changed, the current vehicle position mark may deviate from the correct position. HINT: • Diameter of the tire may change, causing a speed sensor error. • Performing the "tire change" in calibration mode will allow the system to correct the current vehicle position faster. I100075 NS NS–24 NAVIGATION – NAVIGATION SYSTEM DISPLAY CHECK MODE HINT: • This mode checks the color display on the display. • Illustrations may differ from the actual vehicle depending on the device settings and options. Therefore, some detailed areas may not be shown exactly the same as on the actual vehicle. 1. ENTER DIAGNOSTIC MODE (See page NS-46) 2. DISPLAY CHECK (a) Select "Display Check" from the "Diagnosis MENU" screen. 3. COLOR BAR CHECK (a) Select "Color Bar Check" from the "Display Check" screen. E120055E02 E120053E07 (b) Select a color bar from the "Color Bar Check Mode" screen. (c) Check the display color. HINT: • The entire screen turns to the color or stripe selected. • Touching the display will return to the "Color Bar Check" screen. NS E120102 NS–25 NAVIGATION – NAVIGATION SYSTEM 4. TOUCH SWITCH CHECK (a) Select "Touch Switch Check" from the "Display Check" screen. E125809E02 (b) Touch the display anywhere in the open area to perform the check when the "Touch Switch Check" screen is displayed. HINT: • A "+" mark is displayed where the display is touched. • The "+" mark remains on the display even after the finger is removed. E120103 5. PANEL SWITCH CHECK (a) Select "Panel Switch Check" from the "Display Check" screen. E125809E03 (b) Operate each switch and check that the switch name and condition are correctly displayed. *1 *2 *3 I100041E07 Display Push switch name/*1 Rotary switch name/*2 Rotary switch direction/*3 Contents • • Name of the pressed switch is displayed. If more than one switch is pressed, "MULTIPLE" is displayed. Name of the rotary switch is displayed. Direction of the rotary switch is displayed. NS NS–26 NAVIGATION – NAVIGATION SYSTEM 6. VEHICLE SIGNAL CHECK (a) Select "Vehicle Signal Check" from the "Display Check" screen. E125809E04 E125810 7. (b) When the "Vehicle Signal Check Mode" screen is displayed, check all the vehicle signal conditions. HINT: • Only conditions having inputs are displayed. • This screen is updated once per second when input signals to the vehicle are changed. • For details of this function, refer to DIAGNOSIS DISPLAY DETAILED DESCRIPTION (See page NS-30). CAN CHECK NOTICE: This function operates only for the systems connected to the CAN system. (a) Select "CAN Check" from the "Display Check" screen. E125809E05 (b) Check the CAN connection check result. HINT: For details of this function, refer to DIAGNOSIS DISPLAY DETAILED DESCRIPTION (See page NS-30). E120057 NS NAVIGATION – NAVIGATION SYSTEM NS–27 BLUETOOTH TEL CHECK MODE HINT: Illustrations may differ from the actual vehicle depending on the device settings and options. Therefore, some detailed areas may not be shown exactly the same as on the actual vehicle. 1. ENTER DIAGNOSTIC MODE (See page NS-46) 2. "BLUETOOTH" TEL CHECK (a) Select "'Bluetooth' TEL Check" from the "Diagnosis MENU" screen. 3. "BLUETOOTH" CHECK (a) Select "'Bluetooth' Check" from the "'Bluetooth' Handsfree Check Menu" screen. E120062E01 E120063 (b) Select "Serial Communication Log" from the "'Bluetooth' Check Menu" screen. E120064 (1) The communication log data in the display ECU are displayed on this screen. HINT: The displayed data can be used as a reference. NS E120065 NS–28 NAVIGATION – NAVIGATION SYSTEM (c) Select "Software Version" from the "'Bluetooth' Check Menu" screen. E120066 (1) Check the software version of the "Bluetooth" module. *1 *2 *3 *4 E120067E02 Screen Description: Display Contents General Version/*1 • • General software version of "Bluetooth" module If any of the API version, upper stack version, and low stack version is updated, the general version is upgraded. API Version/*2 API software version is displayed. Upper Stack Version/*3 Upper Stack version is displayed. Lower Stack Version/*4 Lower Stack version is displayed. HINT: This function is controlled by the built-in display ECU. 4. E120068 NS HANDSFREE VOICE QUALITY SET (a) Select "Handsfree Voice Quality Set" from the "'Bluetooth' Handsfree Check Menu" screen. NS–29 NAVIGATION – NAVIGATION SYSTEM (b) Check the handsfree voice level. *1 *2 E120069E01 Screen Description: Display Contents Received voice level adjustment/*1 Setting possible for the voice level received from "Bluetooth" compatible phones. Sent voice level adjustment/*2 Setting possible for the voice level sent to "Bluetooth" compatible phones. HINT: This function is controlled by the built-in display ECU. NOTICE: "Voice Quality Type" should not be changed. NS NS–30 NAVIGATION – NAVIGATION SYSTEM NAVIGATION CHECK MODE HINT: • This mode displays GPS satellite information. • Illustrations may differ from the actual vehicle depending on the device settings and options. Therefore, some detailed areas may not be shown exactly the same as on the actual vehicle. 1. ENTER DIAGNOSTIC MODE (See page NS-46 ) 2. NAVIGATION CHECK (a) Select "Navigation Check" from the "Diagnosis MENU" screen. 3. GPS INFORMATION (a) Select "GPS Information" from the "Navigation Check" screen. E120058E01 E120059E15 (b) When GPS information is displayed, check the GPS conditions. HINT: • This screen is updated once per second when input signals to the vehicle are changed. • For details of this function, refer to DIAGNOSIS DISPLAY DETAILED DESCRIPTION (See page NS-30). I102403 4. NS E120059E16 VEHICLE SENSORS (a) Select "Vehicle Sensors" from the "Navigation Check" screen. NAVIGATION – NAVIGATION SYSTEM NS–31 (b) Check all the signals and sensors when vehicle signal information is displayed. HINT: • This screen is updated once per second when input signals to the vehicle are changed. • This screen displays vehicle signals input to the built-in navigation ECU. • For details of this function, refer to DIAGNOSIS DISPLAY DETAILED DESCRIPTION (See page NS-30). E120060 5. COLOR BAR CHECK (a) Select "Color Bar Check" from the "Navigation Check" screen. E120059E17 (b) Check each color of the color bar when the "NAVI Color Bar Check" screen is displayed. HINT: • Colors will not be displayed full-screen as in "Display Check Mode". • This screen displays the built-in navigation ECU display color. I100050 6. MEMORY COPY/PASTE CHECK HINT: This function cannot be used. 7. PARTS INFORMATION (a) Select "Parts Information" from the "Navigation Check" screen. E120059E18 E120059E19 NS NS–32 NAVIGATION – NAVIGATION SYSTEM (b) Check the navigation and disc information when the "Parts Information" screen is displayed. *1 *2 *3 *4 I100052E02 Screen Description: Display Contents Navigation Manufacturer/*1 Radio and navigation assembly manufacturer is displayed. Navigation Version/*2 Radio and navigation assembly version is displayed. Disc Manufacturer/*3 Map disc manufacturer is displayed. Disc Version/*4 Map disc version is displayed. 8. MIC & VOICE RECOGNITION CHECK (a) Select "Mic & Voice Recognition Check" on the "Display Check" screen to display the "MICROPHONE & VOICE RECOGNITION CHECK" screen. E120059E20 Microphone Input Level Meter Recording Switch Play Switch Recording Indicator Stop Switch E120056E03 NS (b) When voice is input into the microphone, check that the microphone input level meter changes according to the input voice. (c) Push the recording switch and perform voice recording. (d) Check that the recording indicator remains on while recording and that the recorded voice is played normally. HINT: • For details of this function, refer to DIAGNOSIS DISPLAY DETAILED DESCRIPTION (See page NS-30). • This function is controlled by the built-in navigation ECU. NAVIGATION – NAVIGATION SYSTEM 9. NS–33 DVD PLAYER INFORMATION CHECK (a) Select "DVD Player Information" from the "Navigation Check" screen. E120059E21 (b) Check for DTCs. HINT: • This is a DVD player check function in the radio and navigation assembly (built-in navigation ECU). • For details of this function, refer to DIAGNOSIS DISPLAY DETAILED DESCRIPTION (See page NS-30). Trouble code E120061E01 NS NS–34 NAVIGATION – NAVIGATION SYSTEM DIAGNOSIS DISPLAY DETAILED DESCRIPTION HINT: • This section contains a detailed description of displays within diagnostic mode. • Illustrations may differ from the actual vehicle depending on the device settings and options. Therefore, some detailed areas may not be shown exactly the same as on the actual vehicle. 1. SYSTEM CHECK (a) System Check Mode Screen *1 *2 *3 *1 *2 *4 I100055E08 (1) Device Names and Hardware Address/*1 HINT: • Registered device names are displayed. • If a device name is unknown to the system, its physical address is shown instead. Address No. NS Name Address No. Name 110 EMV 120 AVX 128 1DIN TV 140 AVN 144 G-BOOK 178 NAVI 17C MONET 190 AUDIO H/U 1AC CAMERA-C 1B0 Rr-TV 1C0 Rr-CONT 19D BT-HF 1C4 PANEL 1C6 G/W 1C8 FM-M-LCD 1D8 CONT-SW 1EC Body 118 EMVN 1F1 XM 1F2 SIRIUS 230 TV-TUNER 240 CD-CH2 250 DVD-CH 280 CAMERA 360 CD-CH1 3A0 MD-CH NS–35 NAVIGATION – NAVIGATION SYSTEM Address No. 17D Name Address No. TEL 440 Name DSP-AMP 530 ETC 1F6 RSE 1A0 DVD-P 1D6 CLOCK 238 DTV 480 AMP (2) Check Result/*2 HINT: Result codes for all devices are displayed. Result Meaning Action OK The device did not respond with a DTC (excluding communication DTCs from the AVC-LAN). EXCH The device responds with a "replace"-type DTC. Look up the DTC in "Unit Check Mode" and replace the device. CHEK The device responds with a "check"-type DTC. Look up the DTC in "Unit Check Mode". NCON The device was previously present, but does not respond in diagnostic mode. 1. Check power supply wire harness of the device. 2. Check the AVC-LAN of the device. Old The device responds with an "old"-type DTC. Look up the DTC in "Unit Check Mode". The device responds in diagnostic mode, but gives no DTC information. 1. Check power supply wire harness of the device. 2. Check the AVC-LAN of the device. NRES - (3) Code Clear/*3 • Present DTCs are cleared. • Press the "Code CLR" switch for 3 seconds. (4) Memory Clear/*4 • Present and past DTCs and registered connected device names are cleared. • Press the "Memory CLR" switch for 3 seconds. (b) Diagnosis MENU Screen NS E120070E01 NS–36 NAVIGATION – NAVIGATION SYSTEM HINT: Each item is grayed out or not displayed based on the device settings. (c) Unit Check Mode Screen *1 *6 *5 *2 *3 *4 *7 E120071E03 Screen Description: Display Device name/*1 Segment/*2 DTC/*3 Timestamp/*4 Present code/*5 Past code/*6 Diagnosis clear switch/*7 NS Contents Target device Target device logical address DTC (Diagnostic Trouble Code) The time and date of past DTCs are displayed. (The year is displayed in 2-digit format.) DTCs output at the service check are displayed. Diagnostic memory results and recorded DTCs are displayed. Pushing this switch for 3 seconds clears the diagnostic memory data of the target device. (Both response to diagnostic system check result and the displayed data are cleared.) NS–37 NAVIGATION – NAVIGATION SYSTEM (d) LAN Monitor (Original) Screen *1 I100058E04 (1) Check Result/*1 HINT: Check results of all the devices are displayed. Result No Err (OK) Meaning There are no communication DTCs. Action - CHEK The device responds with a "check"-type DTC. Look up the DTC in "Unit Check Mode". NCON The device was previously present, but does not respond in diagnostic mode. 1. Check power supply wire harness of the device. 2. Check the AVC-LAN of the device. Old The device responds with an "old"-type DTC. Look up the DTC in "Unit Check Mode". NRES The device responds in diagnostic mode, but gives no DTC information. 1. Check power supply wire harness of the device. 2. Check the AVC-LAN of the device. NS NS–38 NAVIGATION – NAVIGATION SYSTEM (e) LAN Monitor (Individual) Screen *1 *2 *3 *4 *5 *7 *6 E120072E01 Screen Description: Display Device name/*1 Segment/*2 DTC/*3 Sub-code (device address)/*4 Connection check No./*5 DTC occurrence/*6 Diagnosis clear switch/*7 NS Contents Target device Target logical address DTC (Diagnostic Trouble Code) Physical address stored with DTC (If there is no address, nothing is displayed.) Connection check number stored with DTC Number of times the same DTC has been recorded Pushing this switch for 3 seconds clears the diagnostic memory data of the target device. (Both response to diagnostic system check result and the displayed data are cleared.) NS–39 NAVIGATION – NAVIGATION SYSTEM 2. DISPLAY CHECK (a) Vehicle Signal Check Mode Screen E120073 Screen Description: Name Battery Contents Battery voltage is displayed. PKB Parking brake ON/OFF state is displayed. REV Reverse signal ON/OFF state is displayed. IG TAIL SPEED IG switch ON/OFF state is displayed. TAIL signal (Light control switch) ON/OFF state is displayed. Vehicle speed is displayed in km/h. HINT: • Only items sending a vehicle signal will be displayed. • This screen is updated once per second when input signals to the vehicle are changed. NS NS–40 NAVIGATION – NAVIGATION SYSTEM (b) CAN Connection Check Screen *1 E120075E01 Screen Description: Name Contents • • CAN connection check result/*1 • • For systems connected to the CAN system, the results of the CAN connection check are displayed. "NG" - The ignition switch is on (ACC or IG) and the CAN communication lines are malfunctioning or the CAN bus lines are not connected. "OK" - The ignition switch is on (ACC or IG) and the CAN communication lines are normal. Blank - CAN connection check is performed with the ignition switch on (ACC) or off. HINT: • This function operates only for the systems connected to the CAN system. • When the ignition switch is turned off, the bus lines are disconnected, or a malfunction occurs in the bus lines while the CAN connection check result is being displayed, the problem will be reflected on the screen in real time. NS NS–41 NAVIGATION – NAVIGATION SYSTEM 3. NAVIGATION CHECK (a) Navigation Check Screen E120076E01 HINT: Each item is grayed out or not displayed based on the device settings. (b) GPS Information Screen *1 *1 *2 *2 *5 *3 NS *4 I102405E01 (1) Satellite information/*1 Information from a maximum of 12 satellites is displayed on the screen. This information includes the target GPS satellite number, elevation angle, direction, and signal level. NS–42 NAVIGATION – NAVIGATION SYSTEM (2) Receiving condition/*2 (DENSO model): Display Contents T The system is receiving a GPS signal, but is not using it for location. P The system is using the GPS signal for location. - The system cannot receive a GPS signal. (AISIN AW model): Display Contents 01H The system cannot receive a GPS signal. 02H The system is tracing a satellite. 03H The system is receiving a GPS signal, but is not using it for location. 04H The system is using the GPS signal for location. Measurement information/*3: Display Contents 2D 2-dimensional location method is being used. 3D 3-dimensional location method is being used. NG Location data cannot be used. Error - Reception error has occurred. Any other state. Position information/*4 Display Contents Position Latitude and longitude information on the current position is displayed. Display Contents Date information/*5: Date The date/time information obtained from GPS signal is displayed in Greenwich mean time (GMT). The last 4 digits are displayed. (c) Vehicle Sensors Screen *1 *2 *3 NS E120077E01 NS–43 NAVIGATION – NAVIGATION SYSTEM Vehicle signal: Display Contents REV/*1 REV signal ON/OFF state is displayed. SPD/*2 SPD signal condition is displayed. Sensor signal: Display Contents Gyro sensor output condition is displayed (when the vehicle runs straight or is stationary, the voltage is approximately 2.5 V). Gyro sensor/*3 HINT: Signals are updated once per second only when vehicle sensor signals are changed. (d) Microphone & Voice Recognition Check Screen *1 *2 *3 *4 *5 E125119E01 Screen Description: Display Microphone input level meter/*1 Contents Monitors the microphone input level every 100 ms and displays the results in 8 different levels. Recording switch/*2 Starts recording. Stop switch/*3 Stops recording. Play switch/*4 Plays the recorded voice. Recording indicator/*5 Comes on while recording. HINT: • The microphone input function is on at all times when this screen is displayed. • While recording or playing, the switches other than the stop switch cannot be pushed. • When no voice is recorded, the play switch cannot be pushed. • Recording will stop after 5 seconds or by pushing the stop switch. NS NS–44 NAVIGATION – NAVIGATION SYSTEM (e) DVD Player Information Screen *2 *1 *3 *4 *5 E120078E01 Screen Description: Display Contents Trouble code/*1 Each code corresponding to the malfunctions is displayed. For details, refer to "Trouble Code Description". • Occurrence time/*2 • The date (year, month, day) and time (hour, minute, second) when the trouble code was detected are displayed as a time stamp. (Greenwich mean time) The time data to be displayed are received from the GPS receiver. All code data being displayed are cleared by pushing this switch for 3 seconds. Trouble code clear switch/*3 Returning switch/*4 The previous page is displayed. If the current displayed page is the first page, this switch cannot be operated. Proceeding switch/*5 The next page is displayed. If the current displayed page is the last page, this switch cannot be operated. Trouble Code Description: Code 01 03 Malfunction Countermeasure Cannot be recognized Replace radio and navigation assembly. Cannot be read Follow the inspection procedure for DTC 58-42 (See page NS-83). HINT: This is a DVD player check function in the radio and navigation assembly (built-in navigation ECU). NS NS–45 NAVIGATION – NAVIGATION SYSTEM PROBLEM SYMPTOMS TABLE HINT: • Before inspecting the suspected areas listed in the table below, check the fuse and relay. • Before inspecting the suspected areas listed in the table below, check the DTCs. • Methods used to verify the cause of the problem are listed in order of probability in the suspected area column. Display function: Symptom Pressing PWR switch does not turn on system. Black screen (No image appears on navigation/audio screen). Illumination for panel switch does not come on with TAIL switch on. Display does not dim (Night Screen) with TAIL switch on. Power does not turn off (The screen remains on). Panel switches do not function. Touch panel switch does not function. Display panel does not open, tilt, or tilts improperly. Screen is distorted. Screen flicker or color distortion. Navigation function switches can be operated while vehicle is running. Suspected area See page 1. Proceed to "Pressing Power Switch does not Turn on System" NS-101 2. Radio and navigation assembly power source circuit NS-191 3. AVC-LAN circuit NS-175 4. Radio and navigation assembly NS-194 1. Proceed to "Black Screen" NS-146 2. Illumination circuit NS-156 3. AVC-LAN circuit NS-175 4. Radio and navigation assembly NS-194 1. Proceed to "Illumination for Panel Switch does not Come on with TAIL Switch ON" NS-111 2. Illumination circuit NS-156 3. Radio and navigation assembly NS-194 1. Proceed to "Display does not DIM when Light Control Switch is Turned ON" NS-112 2. Illumination circuit NS-156 3. Radio and navigation assembly NS-194 1. Radio and navigation assembly power source circuit NS-191 2. Radio and navigation assembly NS-194 1. Proceed to "Panel Switches do not Function" NS-113 2. Steering pad switch circuit NS-151 3. Radio and navigation assembly power source circuit NS-191 4. Radio and navigation assembly NS-194 1. Proceed to "Touch Panel Switch does not Function" NS-114 2. Steering pad switch circuit NS-151 3. Radio and navigation assembly power source circuit NS-191 4. Radio and navigation assembly NS-194 1. Proceed to "Display Panel does not Open, Tilt, or Tilts Improperly" NS-115 2. Radio and navigation assembly power source circuit NS-191 3. Radio and navigation assembly NS-194 1. Radio and navigation assembly power source circuit NS-191 2. Radio and navigation assembly NS-194 1. Proceed to "Screen Flicker or Color Distortion" NS-116 2. Radio and navigation assembly power source circuit NS-191 3. Radio and navigation assembly NS-194 Proceed to "Vehicle Speed Signal Circuit between Radio and Navigation Assembly and Combination Meter" NS-147 NS NS–46 NAVIGATION – NAVIGATION SYSTEM Audio function: Symptom No sound can be heard from speakers (audio is mute). Suspected area See page 1. Proceed to "No Sound can be Heard from Speakers" NS-102 2. Stereo component amplifier power source circuit AV-142 3. Proceed to "Mute Signal Circuit between Radio and Navigation Assembly and Stereo Component Amplifier" NS-172 4. Proceed to "Sound Signal Circuit between Radio and Navigation Assembly and Stereo Component Amplifier" NS-168 5. Speaker circuit NS-163 6. Stereo component amplifier AV-150 7. Radio and navigation assembly NS-194 Radio broadcast cannot be received or poor reception. Proceed to "Radio Broadcast cannot be Received or Poor Reception" NS-108 CD cannot be inserted / played or CD is ejected right after insertion. Proceed to "CD cannot be Inserted / Played or CD is Ejected Right After Insertion" NS-104 CD cannot be ejected. Proceed to "CD cannot be Ejected" NS-103 CD sound skips. Proceed to "CD Sound Skips" NS-106 Abnormal noise occurs. Proceed to "Noise Occurs" NS-99 1. Proceed to "Poor Sound Quality in All Modes (Low Volume)" NS-118 2. Proceed to "Mute Signal Circuit between Radio and Navigation Assembly and Stereo Component Amplifier" NS-172 3. Stereo component amplifier power source circuit AV-142 4. Radio and navigation assembly power source circuit NS-191 5. Stereo component amplifier AV-150 6. Radio and navigation assembly NS-194 1. Proceed to "Sound Signal Circuit between Radio and Navigation Assembly and Stereo Jack Adapter" NS-170 2. Stereo jack adapter AV-223 3. Radio and navigation assembly NS-194 Proceed to "Vehicle Speed Signal Circuit between Stereo Component Amplifier and Combination Meter" AV-120 Poor sound quality in all modes (low volume). External device sound cannot be heard or sound quality is bad (Stereo jack is used). ASL does not function. Navigation function: Symptom Map disc cannot be inserted. Map disc cannot be ejected. Vehicle position mark deviates. Cursor or map rotates when vehicle is stopped. NS Vehicle position mark is not updated. Current position display does not appear. Suspected area See page 1. Proceed to "Map Disc cannot be Inserted" NS-119 2. Radio and navigation assembly power source circuit NS-191 3. Radio and navigation assembly NS-194 1. Radio and navigation assembly power source circuit NS-191 2. Radio and navigation assembly NS-194 1. Proceed to "Vehicle Position Mark Deviates Greatly" NS-120 2. GPS antenna NS-210 3. Radio and navigation assembly NS-194 1. Proceed to "Cursor or Map Rotates When Vehicle is Stopped" NS-122 2. Radio and navigation assembly NS-194 1. Proceed to "Vehicle Position Mark is not Updated" NS-123 2. Map disc - 3. Radio and navigation assembly NS-194 1. Proceed to "Current Position Display does not Appear" NS-124 2. Map disc - 3. GPS antenna NS-210 4. Radio and navigation assembly NS-194 NS–47 NAVIGATION – NAVIGATION SYSTEM Symptom GPS mark is not displayed. Voice guidance does not function. Map display incomplete. Route cannot be calculated. Voice recognition difficulty. Suspected area See page 1. Proceed to "GPS Mark is not Displayed" NS-125 2. GPS antenna NS-210 3. Radio and navigation assembly NS-194 1. Proceed to "Voice Guidance does not Function" NS-128 2. Proceed to "Mute Signal Circuit between Radio and Navigation Assembly and Stereo Component Amplifier" NS-172 3. Navigation voice circuit NS-180 4. Speaker circuit NS-163 5. Map disc - 6. Radio and navigation assembly NS-194 7. Stereo component amplifier AV-150 1. Proceed to "Map Display Incomplete" NS-131 2. Map disc - 3. Radio and navigation assembly NS-194 1. Proceed to "Route cannot be Calculated" NS-132 2. Map disc - 3. Radio and navigation assembly NS-194 1. Proceed to "Voice Recognition Difficulty" NS-133 2. Radio and navigation assembly NS-194 1. Proceed to "Voice is not Recognized" NS-135 2. Proceed to "Microphone Circuit between Microphone and Radio and Navigation Assembly" NS-182 3. Steering pad switch circuit NS-151 4. Microphone AV-232 5. Radio and navigation assembly NS-194 Speed signal does not change in the navigation check mode. Proceed to "Vehicle Speed Signal Circuit between Radio and Navigation Assembly and Combination Meter" NS-147 Reverse signal does not change in the navigation check mode. Reverse signal circuit NS-177 Voice is not recognized. Steering pad switch function: Symptom Suspected area See page The system cannot be operated by the steering pad switch. 1. Steering pad switch circuit NS-151 2. Radio and navigation assembly NS-194 Illumination for steering pad switch does not come on with TAIL switch on. 1. Illumination circuit NS-156 2. Radio and navigation assembly NS-194 "Bluetooth" function: Symptom Cellular phone registration failure, phone directory transfer failure. Suspected area See page Proceed to "Cellular Phone Registration Failure, Phone Directory Transfer Failure" NS-137 1. Proceed to "Cellular Phone cannot Send / Receive" NS-139 Cellular phone cannot send / receive. 2. Steering pad switch circuit NS-151 3. Radio and navigation assembly NS-194 Cannot call in a certain place. Proceed to "Cannot Call in a Certain Place" NS-141 1. Proceed to "The Other Caller's Voice cannot be Heard, is too Quiet, or Distorted" NS-142 2. Navigation voice circuit NS-180 3. Radio and navigation assembly NS-194 4. Stereo component amplifier AV-150 The other caller's voice cannot be heard, is too quiet, or distorted. NS NS–48 NAVIGATION – NAVIGATION SYSTEM Symptom The other caller cannot hear your voice, or your voice is too quiet or distorted. NS Suspected area See page 1. Proceed to "The Other Caller cannot Hear Your Voice, or Your Voice is too Quiet or Distorted" NS-144 2. Proceed to "Microphone Circuit between Microphone and Radio and Navigation Assembly" NS-182 3. Microphone AV-232 4. Radio and navigation assembly NS-194 NS–49 NAVIGATION – NAVIGATION SYSTEM TERMINALS OF ECU 1. RADIO AND NAVIGATION ASSEMBLY F9 F10 F13 F12 F14 E126216E01 Symbols (Terminal No.) Wiring Color Terminal Description Condition Specification See "Vehicle Signal Check" (See page NS-22) - SPD (F13-3) - GND (F9-20) V - BR Speed signal from combination meter REV (F13-5) - GND (F9-20) R - BR Reverse signal See "Vehicle Signal Check" (See page NS-22) SWG (F10-6) - Body ground P - Body ground Steering pad switch ground Always Steering pad switch signal No switch is pushed → SEEK+ switch pushed → SEEK- switch pushed → VOL+ switch pushed → VOL- switch pushed 4 V or more → Approx. 0.5 V → Approx. 0.9 V → Approx. 2.0 V → Approx. 3.4 V Steering pad switch signal No switch is pushed → MODE switch pushed → ON HOOK switch pushed → OFF HOOK switch pushed → VOICE switch pushed 4 V or more → Approx. 0.5 V → Approx. 0.9 V → Approx. 2.0 V → Approx. 3.4 V SW1 (F10-7) - SWG (F10-6) O-P Below 1 V SW2 (F10-8) - SWG (F10-6) Y-P IVO+ (F10-11) - GND (F9-20) R - BR Voice guidance signal Voice guidance is playing A waveform synchronized with sounds is output IVO- (F10-12) - GND (F9-20) G - BR Voice guidance signal Voice guidance is playing A waveform synchronized with sounds is output SLD1 (F10-13) - Body ground Shielded - Body ground Voice sound signal shielded ground Always Below 1 V Battery Always 10 to 14 V G - BR Illumination signal Turn ignition switch on (IG) Light control switch OFF → TAIL or ON ATX+ (F9-5) - GND (F9-20) R - BR AVC-LAN communication signal Turn ignition switch on (ACC) MUTE (F9-7) - GND (F9-20) O - BR Mute signal Audio system is playing → Changing R+ (F9-8) - GND (F9-20) R - BR Sound signal (Right) Audio system is playing B (F9-1) - GND (F9-20) ILL+ (F9-2) - GND (F9-20) L-Y - BR Below 1V → 10 to 14 V 2 to 3 V Above 3.5 V → Below 1 V A waveform synchronized with sounds is output NS NS–50 Symbols (Terminal No.) L+ (F9-9) - GND (F9-20) NAVIGATION – NAVIGATION SYSTEM Wiring Color B - BR Terminal Description Sound signal (Left) Audio system is playing Specification A waveform synchronized with sounds is output SLD (F9-10) - Body ground Shielded - Body ground Shielded ground Always ACC (F9-11) - GND (F9-20) GR - BR Accessory (ON) Turn ignition switch off → on (ACC or IG) Below 1 V → 10 to 14 V ILL- (F9-12) - GND (F9-20) W-B - BR Illumination signal Turn ignition switch on (IG) Light control switch OFF → TAIL or ON Below 1 V →10 to 14 V ANT (F9-13) - GND (F9-20) O - BR Power source of antenna Radio switch ON and AM or FM 10 to 14 V ATX- (F9-15) - GND (F9-20) G - BR AVC-LAN communication signal Turn ignition switch on (ACC) 2 to 3 V R- (F9-18) - GND (F9-20) G - BR Sound signal (Right) Audio system is playing A waveform synchronized with sounds is output L- (F9-19) - GND (F9-20) W - BR Sound signal (Left) Audio system is playing A waveform synchronized with sounds is output GND (F9-20) - Body ground Always R - Body ground Microphone voice signal See "Microphone Check" (See page NS-27) TSW- (F12-12) - GND (F9 -20) P - BR Telephone relation switch signal Always MACC (F12-17) - GND (F9-20) LG - BR Microphone AMP power supply Turn ignition switch off → on (IG) SGND (F12-18) - GND (F9-20) P - BR Ground Always MIC+ (F12-19) - GND (F9-20) G - BR Microphone voice signal See "Microphone Check" (See page NS-27) VAR+ (F14-2) - GND (F9-20) G - BR Sound signal (Right) External device is playing (When stereo jack is used) A waveform synchronized with sounds is output VAL+ (F14-3) - GND (F9-20) R - BR Sound signal (Left) External device is playing (When stereo jack is used) A waveform synchronized with sound is output Shielded ground Always Below 1 V External device connection detection signal External device is connected Below 1 V VA- (F14-5) - Body ground ADPG (F14 - 6) - GND (F9-20) BR - Body ground Below 1 V Ground MIC- (F12-9) - Body ground BR - Body ground G - BR 2. NS Condition Below 1 V Below 1 V Below 1 V → 5 V Below 1 V - STEREO COMPONENT AMPLIFIER (See page AV-15) NAVIGATION – NAVIGATION SYSTEM NS–51 DTC CHECK / CLEAR HINT: • Illustrations may differ from the actual vehicle depending on the device settings and options. Therefore, some detailed areas may not be shown exactly the same as on the actual vehicle. • If the system cannot enter the diagnostic mode, inspect all AVC-LAN communication components and repair or replace problem parts (See page NS-175). • After the ignition switch is turned on (IG), check that the map is displayed before starting the diagnostic mode. Otherwise, some items cannot be checked. 1. START DIAGNOSTIC MODE (a) There are 2 methods to start diagnostic mode. Start the mode by using one of them. (b) Method 1 (1) Start the engine. (2) While pressing and holding the "INFO" switch, operate the light control switch: OFF → Turn ON → Turn OFF → Turn ON → Turn OFF → Turn ON → Turn OFF. (3) The diagnostic mode starts and the "System Check Mode" screen will be displayed. Service inspection starts automatically and the result will be displayed. “INFO” Switch E129827E01 (c) 2. E109432 Method 2 (1) Start the engine. (2) Switch to the "Display Check" screen. (3) From the display quality adjustment screen, touch the corners of the screen in the following order: upper left → lower left → upper left → lower left → upper left → lower left. (4) The diagnostic mode starts and the "System Check Mode" screen will be displayed. Service inspection starts automatically and the result will be displayed. FINISH DIAGNOSTIC MODE (a) There are 2 methods to end diagnostic mode. Use one of them. (1) Turn the ignition switch off. (2) Press and hold the "DISP" switch for 3 seconds. NS NS–52 NAVIGATION – NAVIGATION SYSTEM 3. E120083E01 NS DIAGNOSIS MENU (a) The "Diagnosis MENU" screen will be displayed by pressing the "Menu" switch on the "System Check Mode" screen. NAVIGATION – NAVIGATION SYSTEM 4. NS–53 CHECK DTC (a) Read the system check result. (1) If the check result is "EXCH", "CHEK" or "Old", touch the displayed check result to view the results on the "Unit Check Mode" screen and record them. HINT: • If all check results are "OK", go to communication DTC check. • If a device name is not known, its physical address is displayed. HINT: When proceeding to view the results of another device, press the "Service" switch to return to the "System Check Mode" screen. Repeat this step. Diagnostic Code Logical Address Diagnostic Code Logical Address NS E111721E02 NS–54 NAVIGATION – NAVIGATION SYSTEM (b) Read the communication diagnostic check result. (1) Return to the "System Check Mode" screen, and press the "LAN Mon" switch to enter the "LAN Monitor" screen. I038208E05 NS NAVIGATION – NAVIGATION SYSTEM NS–55 (2) If the check result is "CHEK" or "Old", touch the displayed check result to view the results on the individual communication diagnostic screen and record them. HINT: • If all check results are "No Err", the system judges that no DTC exists. • The sub-code (relevant device) will be indicated by its physical address. • When proceeding to view the results of another device, press the "Service" switch to return to the original "LAN Monitor" screen. Repeat this step. Sub-code Logical Address Diagnosis Code NS E120084E01 NS–56 NAVIGATION – NAVIGATION SYSTEM 5. DTC CLEAR/RECHECK (a) Clear DTC (1) Press the "Code CLR" switch for 3 seconds. (2) The check results are cleared. I038211E02 (b) Recheck (1) Press the "Recheck" switch. I038212E01 (2) Confirm that all diagnostic codes are "OK" when the check results are displayed. If a code other than "OK" is displayed, troubleshoot again. I038213E01 (3) Press the "LAN Mon" switch to change to the "LAN Monitor" screen. I038213E02 (4) Confirm that all diagnostic codes are "No Err". If a code other than "No Err" is displayed, troubleshoot again. NS I038214E01 NS–57 NAVIGATION – NAVIGATION SYSTEM DIAGNOSTIC TROUBLE CODE CHART COMMUNICATION DIAGNOSIS: DTC No. 01-21 Detection Item Trouble Area See page ROM Error Radio and navigation assembly NS-56 01-22 RAM Error Radio and navigation assembly NS-56 01-D5 Absence of Registration Unit 1. Power source circuit of the component shown by the subcode 2. AVC-LAN circuit between the radio and navigation assembly and the component shown by the sub-code 3. Component shown by the subcode NS-57 01-D6 No Master 1. Radio and navigation assembly power source circuit 2. Power source circuit of the component which has stored this code 3. AVC-LAN circuit between the radio and navigation assembly and the component which has stored this code 4. Component which has stored this code 5. Radio and navigation assembly NS-59 01-D7 Connection Check Error 1. Radio and navigation assembly power source circuit 2. Power source circuit of the component which has stored this code 3. AVC-LAN circuit between the radio and navigation assembly and the component which has stored this code 4. Component which has stored this code 5. Radio and navigation assembly NS-59 01-D8 No Response for Connection Check 1. Power source circuit of the component shown by the subcode 2. AVC-LAN circuit between the radio and navigation assembly and the component shown by the sub-code 3. Component shown by the subcode NS-57 01-D9 Last Mode Error 1. Power source circuit of the component shown by the subcode 2. AVC-LAN circuit between the radio and navigation assembly and the component shown by the sub-code 3. Component shown by the subcode NS-57 01-DA No Response Against ON / OFF Command 1. Power source circuit of the component shown by the subcode 2. AVC-LAN circuit between the radio and navigation assembly and the component shown by the sub-code 3. Component shown by the subcode NS-57 NS NS–58 NAVIGATION – NAVIGATION SYSTEM DTC No. NS Trouble Area See page 01-DB Mode Status Error Detection Item 1. Power source circuit of the component shown by the subcode 2. AVC-LAN circuit between the radio and navigation assembly and the component shown by the sub-code 3. Component shown by the subcode NS-57 01-DC Transmission Error If the same sub-code is recorded in other components, check harness for power supply and communication system of all components shown by code NS-63 01-DD Master Reset 1. Radio and navigation assembly power source circuit 2. AVC-LAN circuit between the radio and navigation assembly and the component which has stored this code 3. Radio and navigation assembly 4. Component which has stored this code NS-66 01-DE Slave Reset 1. Power source circuit of the component shown by the subcode 2. AVC-LAN circuit between the radio and navigation assembly and the component shown by the sub-code 3. Component shown by the subcode NS-57 01-DF Master Error 1. Radio and navigation assembly power source circuit 2. AVC-LAN circuit between the radio and navigation assembly and the component which has stored this code 3. AVC-LAN circuit between the master unit and the sub-master unit (radio receiver) 4. Radio and navigation assembly 5. Component which has stored this code NS-70 01-E0 Registration Complete Indication Error - NS-74 01-E1 Voice Processing Device ON Error 1. Radio and navigation assembly power source circuit 2. AVC-LAN circuit between the radio and navigation assembly and the component which has stored this code 3. Radio and navigation assembly 4. Component which has stored this code NS-66 01-E2 ON / OFF Indication Parameter Error Radio and navigation assembly NS-75 01-E3 Registration Demand Transmission - NS-74 01-E4 Multiple Frame Incomplete - NS-74 SW: DTC No. 21-10 Detection Item Panel Switch Error Trouble Area Radio and navigation assembly See page NS-76 NS–59 NAVIGATION – NAVIGATION SYSTEM DTC No. 21-11 Detection Item Touch Switch Error Trouble Area Radio and navigation assembly See page NS-76 SW WITH NAME: DTC No. Detection Item Trouble Area See page 23-10 Panel Switch Error Radio and navigation assembly NS-76 23-11 Touch Switch Error Radio and navigation assembly NS-76 SW CONVERTING: DTC No. Detection Item Trouble Area See page 24-10 Panel Switch Error Radio and navigation assembly NS-76 24-11 Touch Switch Error Radio and navigation assembly NS-76 COMMAND SW: DTC No. Detection Item Trouble Area See page 25-10 Panel Switch Error Radio and navigation assembly NS-76 25-11 Touch Switch Error Radio and navigation assembly NS-76 FRONT MONITOR: DTC No. 34-10 Detection Item Trouble Area See page Error in Picture Circuit Radio and navigation assembly NS-77 34-11 No Current in Back-light Radio and navigation assembly NS-77 34-12 Excess Current in Back-light Radio and navigation assembly NS-77 TELEPHONE: DTC No. 57-47 Detection Item Bluetooth Module Initialization Failed Trouble Area Radio and navigation assembly See page NS-78 NAVI: DTC No. Trouble Area See page 58-10 Gyro Error Detection Item 1. Gyro sensor 2. Radio and navigation assembly NS-79 58-11 GPS Receiver Error Radio and navigation assembly NS-81 58-40 GPS Antenna Error 1. Wire harness 2. GPS antenna 3. Radio and navigation assembly NS-82 58-41 GPS Antenna Power Source Error 1. Wire harness 2. GPS antenna 3. Radio and navigation assembly NS-82 58-42 Map Disc Read Error 1. Map Disc 2. Radio and navigation assembly NS-83 58-43 SPD Signal Error 1. Speed signal circuit 2. Radio and navigation assembly NS-85 58-44 Player Error Radio and navigation assembly NS-86 58-45 High Temperature Radio and navigation assembly NS-87 IN-DASH CD CHANGER: DTC No. 63-10 Detection Item CD Changer Mechanical Error Trouble Area See page Radio and navigation assembly NS-88 63-11 CD Insertion and Ejection Error Radio and navigation assembly NS-88 63-12 CD Reading Abnormal Radio and navigation assembly NS-88 63-41 Wrong Disc 1. CD 2. Radio and navigation assembly NS-89 63-42 Disc cannot be Read 1. CD 2. Radio and navigation assembly NS-89 NS NS–60 NAVIGATION – NAVIGATION SYSTEM DTC No. Trouble Area See page 63-43 CD-ROM Abnormal Detection Item 1. CD 2. Radio and navigation assembly NS-91 63-44 CD Abnormal Radio and navigation assembly NS-92 63-45 Eject Error Radio and navigation assembly NS-93 63-46 Scratched / Reversed Disc 1. CD 2. Radio and navigation assembly NS-94 63-47 High Temperature Radio and navigation assembly NS-96 63-48 Excess Current Radio and navigation assembly NS-92 63-50 Tray Insertion / Ejection Error Radio and navigation assembly NS-92 63-51 Elevator Error Radio and navigation assembly NS-93 63-52 Clamp Error Radio and navigation assembly NS-93 63-78 DSP Error - NS-97 63-7D Disc cannot be Played 1. CD 2. Radio and navigation assembly NS-98 63-7E No Playable Files 1. CD 2. Radio and navigation assembly NS-98 63-7F Copyright Protection Error 1. CD 2. Radio and navigation assembly NS-98 GPS: DTC No. NS Trouble Area See page 80-10 Gyro Error Detection Item 1. Gyro sensor 2. Radio and navigation assembly NS-79 80-11 GPS Receiver Error Radio and navigation assembly NS-81 80-40 GPS Antenna Error 1. Wire harness 2. GPS antenna 3. Radio and navigation assembly NS-82 80-41 GPS Antenna Power Source Error 1. Wire harness 2. GPS antenna 3. Radio and navigation assembly NS-82 80-42 Map Disc Read Error 1. Map disc 2. Radio and navigation assembly NS-83 80-43 SPD Signal Error 1. Speed signal circuit 2. Radio and navigation assembly NS-85 80-44 Player Error Radio and navigation assembly NS-86 80-45 High Temperature Radio and navigation assembly NS-87 NS–61 NAVIGATION – NAVIGATION SYSTEM DTC 01-21 ROM Error DTC 01-22 RAM Error DESCRIPTION DTC No. DTC Detection Condition 01-21 A malfunction exists in ROM. 01-22 A malfunction exists in RAM. Trouble Area Radio and navigation assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 REPLACE RADIO AND NAVIGATION ASSEMBLY NEXT END NS NS–62 NAVIGATION – NAVIGATION SYSTEM DTC 01-D5 Absence of Registration Unit DTC 01-D8 No Response for Connection Check DTC 01-D9 Last Mode Error DTC 01-DA No Response Against ON / OFF Command DTC 01-DB Mode Status Error DTC 01-DE Slave Reset DESCRIPTION DTC No. DTC Detection Condition • A component shown by the sub-code is (was) disconnected from the system when turning the ignition switch on (ACC or IG). The communication condition with the device that the code shows cannot be obtained when the engine starts. 01-D5 *1, *4 • 01-D8 *2, *4 A component shown by the sub-code is (was) disconnected from the system after engine start. 01-D9 *1, *4 The device that had functioned before the engine stopped is (was) disconnected from the system when turning the ignition switch is on (ACC or IG). • • • • 01-DA *4 NS Trouble Area No response is identified when changing mode. Detected when sound and image do not change by switch operation. 01-DB *1, *4 A dual alarm is detected. 01-DE *3, *4 A slave device has been disconnected after engine start. • Power source circuit of the component shown by the sub-code AVC-LAN circuit between the radio and navigation assembly and the component shown by the subcode Component shown by the sub-code HINT: • *1: Even if no fault is present, this trouble code may be stored depending on the battery condition or engine start voltage. • *2: If the power connector is disconnected after the engine starts, this code is stored after 180 seconds. • *3: This code may be stored if the engine is started and then the ignition switch is turned to the START position again. (Key type ignition switch only) • *4: If it is reported that the device does not exist during verification, check the power source circuit and AVC-LAN circuit for the device. NOTICE: • Before starting troubleshooting, be sure to clear DTCs to erase codes stored due to the reasons described in the HINT above. Then, check for DTCs and troubleshoot according to the output DTCs. • The radio and navigation assembly is the master unit. • Be sure to clear and recheck DTCs after the inspection is completed to confirm that no DTCs are output. INSPECTION PROCEDURE NOTICE: Be sure to read DESCRIPTION before performing the following procedures. NAVIGATION – NAVIGATION SYSTEM 1 NS–63 CHECK "RADIO AND NAVIGATION ASSEMBLY COMMUNICATION ERROR" IN FLOW CHART Refer to the radio and navigation assembly communication error (See page NS-188). NEXT END NS NS–64 NAVIGATION – NAVIGATION SYSTEM DTC 01-D6 No Master DTC 01-D7 Connection Check Error DESCRIPTION DTC No. DTC Detection Condition 01-D6 *1 When either of the following conditions is met: • The component which has stored the code has (had) been disconnected when the ignition switch is turned on (ACC or IG). • The master device has (had) been disconnected when this code is stored. 01-D7 *2 When either of the following conditions is met: • The component which has stored the code has (had) been disconnected after the engine starts (started). • The master device has (had) been disconnected when this code is (was) stored. Trouble Area • • • • • Radio and navigation assembly power source circuit Power source circuit of the component which has stored this code AVC-LAN circuit between the radio and navigation assembly and the component which has stored this code Component which has stored this code Radio and navigation assembly HINT: • *1: Even if no fault is present, this trouble code may be stored depending on the battery condition or engine start voltage. • *2: When 210 seconds have elapsed after disconnecting the power supply connector of the master component with the ignition switch on (ACC or IG), this code is stored. NOTICE: • Before starting troubleshooting, be sure to clear DTCs to erase codes stored due to the reasons described in the HINT above. Then, check for DTCs and troubleshoot according to the output DTCs. • The radio and navigation assembly is the master unit. • Be sure to clear and recheck DTCs after the inspection is completed to confirm that no DTCs are output. INSPECTION PROCEDURE NOTICE: Be sure to read DESCRIPTION before performing the following procedures. 1 CHECK RADIO AND NAVIGATION ASSEMBLY POWER SOURCE CIRCUIT Refer to the radio and navigation assembly power source circuit (See page NS-191). If the power source circuit is operating normally, proceed to the next step. NEXT NS NS–65 NAVIGATION – NAVIGATION SYSTEM 2 IDENTIFY THE COMPONENT WHICH HAS STORED THIS CODE (a) Enter the diagnostic mode. (b) Press the "LAN Mon" switch to change to "LAN Monitor" mode. (c) Identify the component which has stored this code. Component Table: Example: Display DSP-AMP Component Stereo component amplifier HINT: "NAVI" is the component which has stored this code in the example shown in the illustration. Component which has stored this code DTC E121199E01 NEXT 3 CHECK POWER SOURCE CIRCUIT OF COMPONENT WHICH HAS STORED THIS CODE (a) Inspect the power source circuit of the component which has stored this code. If the power source circuit is operating normally, proceed to the next step. Component Table: Component Stereo component amplifier (DSP-AMP) NEXT Proceed to Stereo component amplifier power source circuit (See page AV-142) NS NS–66 4 NAVIGATION – NAVIGATION SYSTEM CHECK RADIO AND NAVIGATION ASSEMBLY (a) Disconnect the radio and navigation assembly connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness View: Tester connection Condition Specified condition ATX+ (F9-5) ATX- (F9-15) Always 60 to 80 Ω F9 NG REPLACE RADIO AND NAVIGATION ASSEMBLY ATX+ ATXE120099E03 OK 5 CHECK HARNESS AND CONNECTOR HINT: For details of the connectors, refer to "TERMINALS OF ECU" (See page NS-45). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the radio and navigation assembly and the component which has stored this code. (1) Disconnect all connectors between the radio and navigation assembly and the component which has stored this code. (2) Check for an open or short in the AVC-LAN circuit between the radio and navigation assembly and the component which has stored this code. OK: There is no open or short circuit. NS NS–67 NAVIGATION – NAVIGATION SYSTEM AVC-LAN WIRING DIAGRAM Stereo Component Amplifier (*2) Radio and Navigation Assembly (*1) 8 TX+ F19 5 F9 7 TX- F19 15 F9 ATX- ATX+ *1: Master Unit *2: Slave Unit E111831E09 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 6 REPLACE COMPONENT WHICH HAS STORED THIS CODE (a) Replace the component which has stored this code with a normal one and check if the same problem occurs again. OK: Same problem does not occur. NG REPLACE RADIO AND NAVIGATION ASSEMBLY OK END NS NS–68 NAVIGATION – NAVIGATION SYSTEM DTC 01-DC Transmission Error DESCRIPTION DTC No. 01-DC *1 DTC Detection Condition Trouble Area Transmission to component shown by sub-code failed. (Detecting this DTC does not always mean actual failure.) If the same sub-code is recorded in other components, check harness for power supply and communication system of all components shown by code HINT: *1: This code may be stored if the engine is started, idled for 60 seconds and then the ignition switch is turned to the START position again. (Key type ignition switch only) NOTICE: • Before starting troubleshooting, be sure to clear DTCs to erase codes stored due to the reasons described in the HINT above. Then, check for DTCs and troubleshoot according to the output DTCs. • The radio and navigation assembly is the master unit. • Be sure to clear and recheck DTCs after the inspection is completed to confirm that no DTCs are output. INSPECTION PROCEDURE NOTICE: Be sure to read DESCRIPTION before performing the following procedures. 1 CHECK FOR DTC OF OTHER COMPONENTS (a) Check if the component shown by the sub-code is displayed in the check result of the other components. (1) Check if "01-DC" is output for the other components. (2) If "01-DC" is output for any other components, check if the same physical address is displayed. HINT: For the list of the components shown by sub-codes, refer to the table in step 2. Result Result Proceed to "01-DC" is output and the same physical address is displayed A "01-DC" is not output or the same physical address is not displayed B B A NS Go to step 4 NS–69 NAVIGATION – NAVIGATION SYSTEM 2 IDENTIFY THE COMPONENT WHICH HAS STORED THIS CODE (a) Enter the diagnostic mode. (b) Press the "LAN Mon" switch to change to "LAN Monitor" mode. (c) Identify the component which has stored this code. Component Table: Example: Display Component DSP-AMP (440) Stereo component amplifier AVN (140) Radio and navigation assembly HINT: "NAVI" is the component which has stored this code in the example shown in the illustration. Component which has stored this code DTC Component shown by sub-code E121199E02 NEXT 3 CHECK COMPONENT WHICH HAS STORED THIS CODE (a) Select the component which has stored this code. Component Table: Component Proceed to Radio and navigation assembly (AVN) Radio and navigation assembly communication error (See page NS-188) Stereo component amplifier (DSP-AMP) Stereo component amplifier communication error (See page NS-185) NEXT END NS NS–70 4 NAVIGATION – NAVIGATION SYSTEM CLEAR DTC (a) Clear the DTCs (See page NS-46). HINT: If "01-DC" is output for only one component, this may not indicate a malfunction. NEXT 5 RECHECK DTC (a) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. NG OK END NS Go to step 3 NS–71 NAVIGATION – NAVIGATION SYSTEM DTC 01-DD Master Reset DTC 01-E1 Voice Processing Device ON Error DESCRIPTION DTC No. 01-DD *1 DTC Detection Condition The device that should be the master has been disconnected after the engine starts. Trouble Area • • 01-E1 *2 The AMP device records that the AMP output does not function even while the source device is operating. • • Radio and navigation assembly power source circuit AVC-LAN circuit between the radio and navigation assembly and the component which has stored this code Radio and navigation assembly Component which has stored this code HINT: • *1: This code may be stored if the engine is started and the ignition switch is turned to the START position again. (Key type ignition switch only) • *2: Even if no fault is present, this trouble code may be stored depending on the battery condition or engine start voltage. NOTICE: • Before starting troubleshooting, be sure to clear DTCs to erase codes stored due to the reasons described in the HINT above. Then, check for DTCs and troubleshoot according to the output DTCs. • The radio and navigation assembly is the master unit. • Be sure to clear and recheck DTCs after the inspection is completed to confirm that no DTCs are output. INSPECTION PROCEDURE NOTICE: Be sure to read DESCRIPTION before performing the following procedures. 1 CHECK RADIO AND NAVIGATION ASSEMBLY POWER SOURCE CIRCUIT Refer to the radio and navigation assembly power source circuit (See page NS-191). If the power source circuit is operating normally, proceed to the next step. NEXT NS NS–72 2 NAVIGATION – NAVIGATION SYSTEM INSPECT RADIO AND NAVIGATION ASSEMBLY (a) Disconnect the radio and navigation assembly connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness View: Tester connection Condition Specified condition ATX+ (F9-5) ATX- (F9-15) Always 60 to 80 Ω F9 NG ATX+ ATXE120099E03 OK NS REPLACE RADIO AND NAVIGATION ASSEMBLY NS–73 NAVIGATION – NAVIGATION SYSTEM 3 IDENTIFY THE COMPONENT WHICH HAS STORED THIS CODE (a) Enter the diagnostic mode. (b) Press the "LAN Mon" switch to change to "LAN Monitor" mode. (c) Identify the component which has stored this code. Component Table: Example: Display DSP-AMP Component Stereo component amplifier HINT: "NAVI" is the component which has stored this code in the example shown in the illustration. Component which has stored this code DTC E111829E03 NEXT 4 CHECK HARNESS AND CONNECTOR HINT: For details of the connectors, refer to "TERMINALS OF ECU" (See page NS-45). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the radio and navigation assembly and the component which has stored this code. (1) Disconnect all connectors between the radio and navigation assembly and the component which has stored this code. (2) Check for an open or short in the AVC-LAN circuit between the radio and navigation assembly and the component which has stored this code. NS NS–74 NAVIGATION – NAVIGATION SYSTEM OK: There is no open or short circuit. AVC-LAN WIRING DIAGRAM Stereo Component Amplifier (*2) Radio and Navigation Assembly (*1) 8 TX+ F19 5 F9 7 TX- F19 15 F9 ATX- ATX+ *1: Master Unit *2: Slave Unit E111831E09 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 5 REPLACE RADIO AND NAVIGATION ASSEMBLY (a) Replace the radio and navigation assembly with a normal one and check if the same problem occurs again. OK: Same problem does not occur. NG OK END NS REPLACE COMPONENT WHICH HAS STORED THIS CODE NS–75 NAVIGATION – NAVIGATION SYSTEM DTC 01-DF Master Error DESCRIPTION DTC No. DTC Detection Condition Trouble Area • • 01-DF *1 • The device with a display fails and the master is switched to the audio device. A communication error between the sub-master (radio receiver) and master occurs. • • • • Radio and navigation assembly power source circuit AVC-LAN circuit between the radio and navigation assembly and the component which has stored this code AVC-LAN circuit between the radio and navigation assembly and the radio receiver Radio and navigation assembly Component which has stored this code HINT: *1: When 210 seconds have elapsed after disconnecting the power supply connector of the master component with the ignition switch on (ACC or IG), this code is stored. NOTICE: • Before starting troubleshooting, be sure to clear DTCs to erase codes stored due to the reasons described in the HINT above. Then, check for DTCs and troubleshoot according to the output DTCs. • The radio and navigation assembly is the master unit. • Be sure to clear and recheck DTCs after the inspection is completed to confirm that no DTCs are output. INSPECTION PROCEDURE NOTICE: Be sure to read DESCRIPTION before performing the following procedures. 1 CHECK RADIO AND NAVIGATION ASSEMBLY POWER SOURCE CIRCUIT Refer to the radio and navigation assembly power source circuit (See page NS-191). If the power source circuit is operating normally, proceed to the next step. NEXT NS NS–76 2 NAVIGATION – NAVIGATION SYSTEM INSPECT RADIO AND NAVIGATION ASSEMBLY (a) Disconnect the radio and navigation assembly connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness View: Tester connection Condition Specified condition ATX+ (F9-5) ATX- (F9-15) Always 60 to 80 Ω F9 NG ATX+ ATXE120099E03 OK NS REPLACE RADIO AND NAVIGATION ASSEMBLY NS–77 NAVIGATION – NAVIGATION SYSTEM 3 IDENTIFY THE COMPONENT WHICH HAS STORED THIS CODE (a) Enter the diagnostic mode. (b) Press the "LAN Mon" switch to change to "LAN Monitor" mode. (c) Identify the component which has stored this code. Component Table: Example: Display DSP-AMP Component Stereo component amplifier HINT: "NAVI" is the component which has stored this code in the example shown in the illustration. Component which has stored this code DTC E121199E04 NEXT 4 CHECK HARNESS AND CONNECTOR HINT: For details of the connectors, refer to "TERMINALS OF ECU" (See page NS-45). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the radio and navigation assembly and the component which has stored this code. (1) Disconnect all connectors between the radio and navigation assembly and the component which has stored this code. (2) Check for an open or short in the AVC-LAN circuit between the radio and navigation assembly and the component which has stored this code. NS NS–78 NAVIGATION – NAVIGATION SYSTEM OK: There is no open or short circuit. AVC-LAN WIRING DIAGRAM Stereo Component Amplifier (*2) Radio and Navigation Assembly (*1) 8 TX+ F19 5 F9 7 TX- F19 15 F9 ATX- ATX+ *1: Master Unit *2: Slave Unit E111831E09 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 5 REPLACE RADIO AND NAVIGATION ASSEMBLY (a) Replace the radio and navigation assembly with a normal one and check if the same problem occurs again. OK: Same problem does not occur. NG OK END NS REPLACE COMPONENT WHICH HAS STORED THIS CODE NS–79 NAVIGATION – NAVIGATION SYSTEM DTC 01-E0 Registration Complete Indication Error DTC 01-E3 Registration Demand Transmission DTC 01-E4 Multiple Frame Incomplete DESCRIPTION DTC No. DTC Detection Condition Trouble Area 01-E0 "Registration complete" signal from the master device cannot be received. - 01-E3 The registration demand signal from the slave device is output. Or the registration demand signal is output by receiving connection confirmation signal from the submaster device. - 01-E4 The multiple frame transmission is incomplete. - HINT: Even if no fault is present, this trouble code may be stored depending on the battery condition or engine start voltage. INSPECTION PROCEDURE HINT: • After the inspection is completed, clear the DTCs. • These DTCs do not indicate a malfunction. NS NS–80 NAVIGATION – NAVIGATION SYSTEM DTC 01-E2 ON / OFF Indication Parameter Error DESCRIPTION DTC No. 01-E2 DTC Detection Condition The signal for ON/OFF control from the master device has a problem. INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 NEXT END NS REPLACE RADIO AND NAVIGATION ASSEMBLY Trouble Area Radio and navigation assembly NS–81 NAVIGATION – NAVIGATION SYSTEM DTC 21-10 Panel Switch Error DTC 21-11 Touch Switch Error DTC 23-10 Panel Switch Error DTC 23-11 Touch Switch Error DTC 24-10 Panel Switch Error DTC 24-11 Touch Switch Error DTC 25-10 Panel Switch Error DTC 25-11 Touch Switch Error DESCRIPTION DTC No. DTC Detection Condition 21-10 The panel switch detection circuit has a problem. 21-11 The touch panel switch has a problem. 23-10 The panel switch detection circuit has a problem. 23-11 The touch panel switch has a problem. 24-10 The panel switch detection circuit has a problem. 24-11 The touch panel switch has a problem. 25-10 The panel switch detection circuit has a problem. 25-11 The touch panel switch has a problem. Trouble Area Radio and navigation assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 REPLACE RADIO AND NAVIGATION ASSEMBLY NEXT END NS NS–82 NAVIGATION – NAVIGATION SYSTEM DTC 34-10 Error in Picture Circuit DTC 34-11 No Current in Back-light DTC 34-12 Excess Current in Back-light DESCRIPTION DTC No. DTC Detection Condition 34-10 Error in power supply system for picture circuit 34-11 Decline in power output from inverter circuit for backlight 34-12 Excess power output from inverter circuit for back-light INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 NEXT END NS REPLACE RADIO AND NAVIGATION ASSEMBLY Trouble Area Radio and navigation assembly NS–83 NAVIGATION – NAVIGATION SYSTEM DTC 57-47 Bluetooth Module Initialization Failed DESCRIPTION DTC No. 57-47 DTC Detection Condition • • • "Bluetooth" module is not installed. Problem with "Bluetooth" module Problem in communication line to "Bluetooth" module Trouble Area Radio and navigation assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 REPLACE RADIO AND NAVIGATION ASSEMBLY NEXT END NS NS–84 NAVIGATION – NAVIGATION SYSTEM DTC 58-10 Gyro Error DTC 80-10 Gyro Error DESCRIPTION DTC No. DTC Detection Condition Trouble Area 58-10 Ground short, power supply short, or open circuit in the gyro signal 80-10 Ground short, power supply short, or open circuit in the gyro signal • • Gyro sensor Radio and navigation assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK VEHICLE SENSOR (NAVIGATION CHECK MODE) (a) Enter the "Navigation Check" mode (Vehicle Sensors) (See page NS-27). (b) Check the gyro voltage. Standard voltage: 0.1 to 4.5 V NG REPLACE RADIO AND NAVIGATION ASSEMBLY E120088 OK 2 CLEAR DTC (a) Clear the DTCs (See page NS-46). NEXT 3 NS RECHECK DTC (a) Recheck for DTCs and check if the same trouble occurs again. HINT: If DTCs are detected frequently, replace the radio and navigation assembly. OK: Malfunction disappears. NG REPLACE RADIO AND NAVIGATION ASSEMBLY NAVIGATION – NAVIGATION SYSTEM NS–85 OK END NS NS–86 NAVIGATION – NAVIGATION SYSTEM DTC 58-11 GPS Receiver Error DTC 80-11 GPS Receiver Error DESCRIPTION DTC No. DTC Detection Condition • 58-11 • • 80-11 • RTC, ROM, and RAM of the GPS receiver and TCXO error GPS receiver is failed. RTC, ROM, and RAM of the GPS receiver and TCXO error GPS receiver is failed. INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 NEXT END NS REPLACE RADIO AND NAVIGATION ASSEMBLY Trouble Area Radio and navigation assembly NS–87 NAVIGATION – NAVIGATION SYSTEM DTC 58-40 GPS Antenna Error DTC 58-41 GPS Antenna Power Source Error DTC 80-40 GPS Antenna Error DTC 80-41 GPS Antenna Power Source Error DESCRIPTION DTC No. DTC Detection Condition 58-40 GPS antenna error 58-41 Error of the power source to the GPS antenna 80-40 GPS antenna error 80-41 Error of the power source to the GPS antenna Trouble Area • • • Wire harness GPS antenna Radio and navigation assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK HARNESS AND CONNECTOR (GPS ANTENNA - RADIO AND NAVIGATION ASSEMBLY) (a) Check that the GPS antenna cord is securely connected to the radio and navigation assembly connector. OK: The cord is securely connected. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 2 REPLACE GPS ANTENNA (a) Replace the GPS antenna with a normal one and check if the same problem occurs again. (1) Clear the DTCs (See page NS-46). (2) Recheck for DTCs and check if the same trouble occurs again. OK: Same problem does not occur. NG OK END REPLACE RADIO AND NAVIGATION ASSEMBLY NS NS–88 NAVIGATION – NAVIGATION SYSTEM DTC 58-42 Map Disc Read Error DTC 80-42 Map Disc Read Error DESCRIPTION DTC No. DTC Detection Condition 58-42 • • • Player error Scratches or dirt on the disc Access to an invalid address due to software error 80-42 • • • Player error Scratches or dirt on the disc Access to an invalid address due to software error Trouble Area • • Map disc Radio and navigation assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK MAP DISC (a) Check that the map disc is not deformed or cracked. OK: No deformations or cracks on the map disc. NG Go to step 4 I100152 OK 2 DISC CLEANING (a) Disc cleaning (1) If dirt is on the disc surface, wipe it clean with a soft cloth from the inside to the outside in a radial direction. NOTICE: Do not use a conventional record cleaner or anti-static preservative. NS I100201E04 NEXT 3 DTC CLEAR AND RECHECK (a) Clear the DTCs (See page NS-46). NAVIGATION – NAVIGATION SYSTEM NS–89 (b) Recheck for DTCs and check if the same trouble occurs again. OK: Same problem does not occur. OK END NG 4 REPLACE MAP DISC (a) Replace the map disc. (b) Clear the DTCs and recheck for DTCs. (c) Check if the same trouble occurs again. OK: Same problem does not occur. OK END NG REPLACE RADIO AND NAVIGATION ASSEMBLY NS NS–90 NAVIGATION – NAVIGATION SYSTEM DTC 58-43 SPD Signal Error DTC 80-43 SPD Signal Error DESCRIPTION DTC No. DTC Detection Condition Trouble Area 58-43 A difference between the GPS speed and SPD pulse is detected. 80-43 A difference between the GPS speed and SPD pulse is detected. • • Speed signal circuit Radio and navigation assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK VEHICLE SENSOR (NAVIGATION CHECK MODE) (a) Enter the "Navigation Check" mode (Vehicle Sensors) (See page NS-27). (b) While driving the vehicle, compare the "SPD" indicator to the reading on the speedometer. Check if these readings are almost equal. OK: The readings are almost equal. OK E120089 REPLACE RADIO AND NAVIGATION ASSEMBLY NG 2 PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE Refer to "Speed signal does not change in the navigation check mode" in the problem symptoms table (See page NS41). NEXT END NS NS–91 NAVIGATION – NAVIGATION SYSTEM DTC 58-44 Player Error DTC 80-44 Player Error DESCRIPTION DTC No. DTC Detection Condition 58-44 Map player error is detected. 80-44 Map player error is detected. Trouble Area Radio and navigation assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK RADIO AND NAVIGATION ASSEMBLY (a) Check if a disc can be inserted or ejected normally. OK: A disc can be inserted or ejected normally. NG REPLACE RADIO AND NAVIGATION ASSEMBLY OK 2 DTC CLEAR AND RECHECK (a) Clear the DTCs (See page NS-46). (b) Recheck for DTCs and check if the same trouble occurs again. OK: Same problem does not occur. OK END NG REPLACE RADIO AND NAVIGATION ASSEMBLY NS NS–92 NAVIGATION – NAVIGATION SYSTEM DTC 58-45 High Temperature DTC 80-45 High Temperature DESCRIPTION DTC No. DTC Detection Condition Trouble Area 58-45 High map disc player temperature is detected (Over 80°C). 80-45 High map disc player temperature is detected (Over 80°C). Radio and navigation assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK RADIO AND NAVIGATION ASSEMBLY (a) Park the vehicle in a cool place. (b) Check that the temperature of the radio and navigation assembly has becomes sufficiently low, then start the engine to verify the malfunction symptom. OK: Same problem does not occur. NG OK END NS REPLACE RADIO AND NAVIGATION ASSEMBLY NS–93 NAVIGATION – NAVIGATION SYSTEM DTC 63-10 CD Changer Mechanical Error DTC 63-11 CD Insertion and Ejection Error DTC 63-12 CD Reading Abnormal DESCRIPTION DTC No. DTC Detection Condition 63-10 A mechanical error in the CD changer is detected while the CD is not being inserted or ejected. 63-11 CD insertion or ejection is failed. 63-12 CD read problem occurs. Trouble Area Radio and navigation assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 REPLACE RADIO AND NAVIGATION ASSEMBLY NEXT END NS NS–94 NAVIGATION – NAVIGATION SYSTEM DTC 63-41 Wrong Disc DTC 63-42 Disc cannot be Read DESCRIPTION DTC No. DTC Detection Condition 63-41 An unsuitable disc is inserted. 63-42 The disc cannot be read. Trouble Area • • CD Radio and navigation assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK DISC (a) Check that the disc is not deformed or cracked. OK: No deformations or cracks on the disc. NG CHANGE DISC I100152 OK 2 DISC CLEANING (a) Disc cleaning (1) If dirt is on the disc surface, wipe it clean with a soft cloth from the inside to the outside in a radial direction. NOTICE: Do not use a conventional record cleaner or anti-static preservative. I100151 NS NEXT 3 CLEAR DTC (a) Clear the DTCs (See page NS-46). NEXT NAVIGATION – NAVIGATION SYSTEM 4 NS–95 RECHECK DTC (a) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. OK END NG 5 REPLACE DISC WITH ANOTHER AND RECHECK (a) Replace the disc with another and recheck. (1) Replace the disc with another normal one. (2) Clear the DTCs (See page NS-46). (3) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. NG REPLACE RADIO AND NAVIGATION ASSEMBLY OK END NS NS–96 NAVIGATION – NAVIGATION SYSTEM DTC 63-43 CD-ROM Abnormal DESCRIPTION DTC No. 63-43 DTC Detection Condition Trouble Area • • CD-ROM operation is abnormal. CD Radio and navigation assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK IF A PROPER CD IS INSERTED (a) Make sure that the CD is an audio CD or a CD with an MP3 or WMA file, and that it is not deformed, flawed, stained, burred, or otherwise defective. OK: Normal CD HINT: • Translucent or uniquely-shaped CDs cannot be played. • CD with adhesive paper labels should not be played. • Commercial audio CDs can be played. • CD-DA files on CD-ROMs, CD-Rs, and CD-RWs can be played. • MP3 and WMA files on CD-ROMs, CD-Rs, and CDRWs can be played. • For details on playable CDs, refer to the Owner's Manual. NG CD IS FAULTY OK 2 REPLACE CD WITH ANOTHER AND RECHECK (a) Replace the CD with another and recheck. (1) Replace the CD with another normal one. (2) Clear the DTCs (See page NS-46). (3) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. NS NG OK END REPLACE RADIO AND NAVIGATION ASSEMBLY NS–97 NAVIGATION – NAVIGATION SYSTEM DTC 63-44 CD Abnormal DTC 63-48 Excess Current DTC 63-50 Tray Insertion / Ejection Error DESCRIPTION DTC No. 63-44 DTC Detection Condition Trouble Area Operation error in the CD mechanism 63-48 Excess current is present in the CD changer. 63-50 Malfunction in insertion/ejection system Radio and navigation assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CLEAR DTC (a) Clear the DTCs (See page NS-46). NEXT 2 RECHECK DTC (a) Recheck for DTCs and check if the same trouble occurs again. HINT: If DTCs are detected frequently, replace the radio and navigation assembly. OK: Malfunction disappears. NG REPLACE RADIO AND NAVIGATION ASSEMBLY OK END NS NS–98 NAVIGATION – NAVIGATION SYSTEM DTC 63-45 Eject Error DTC 63-51 Elevator Error DTC 63-52 Clamp Error DESCRIPTION DTC No. DTC Detection Condition Trouble Area 63-45 Magazine cannot be ejected. 63-51 Mechanical error occurs during elevator operation. 63-52 Error occurs in CD changer clamp. Radio and navigation assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK RADIO AND NAVIGATION ASSEMBLY (a) Check if a disc can be changed, inserted, or ejected normally. OK: Malfunction disappears. NG OK END NS REPLACE RADIO AND NAVIGATION ASSEMBLY NS–99 NAVIGATION – NAVIGATION SYSTEM DTC 63-46 Scratched / Reversed Disc DESCRIPTION DTC No. 63-46 DTC Detection Condition Trouble Area Scratches or dirt is found on CD surface or CD is set upside down. • • CD Radio and navigation assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK THAT CD IS INSERTED PROPERLY (a) Check that the CD is not inserted upside down. OK: CD is properly inserted. NG INSERT CD PROPERLY OK 2 CHECK DISC (a) Check that the disc is not deformed or cracked. OK: No deformations or cracks on the disc. NG CHANGE DISC I100152 OK 3 DISC CLEANING (a) Disc cleaning (1) If dirt is on the disc surface, wipe it clean with a soft cloth from the inside to the outside in a radial direction. NOTICE: Do not use a conventional record cleaner or anti-static preservative. I100151 NEXT NS NS–100 4 NAVIGATION – NAVIGATION SYSTEM CLEAR DTC (a) Clear the DTCs (See page NS-46). NEXT 5 RECHECK DTC (a) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. OK END NG 6 REPLACE DISC WITH ANOTHER AND RECHECK (a) Replace the disc with another and recheck. (1) Replace the disc with another normal one. (2) Clear the DTCs (See page NS-46). (3) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. NG OK END NS REPLACE RADIO AND NAVIGATION ASSEMBLY NS–101 NAVIGATION – NAVIGATION SYSTEM DTC 63-47 High Temperature DESCRIPTION DTC No. 63-47 DTC Detection Condition Trouble Area Sensor detects that CD unit temperature is high (Over 80°C). Radio and navigation assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK RADIO AND NAVIGATION ASSEMBLY (a) Park the vehicle in a cool place. (b) Check that the temperature of the radio and navigation assembly becomes sufficiently low, then start the engine. Check that the malfunction disappears. OK: Malfunction disappears. NG REPLACE RADIO AND NAVIGATION ASSEMBLY OK END NS NS–102 NAVIGATION – NAVIGATION SYSTEM DTC 63-78 DSP Error DESCRIPTION DTC No. 63-78 DTC Detection Condition Trouble Area An error occurs during the decode process (MP3/ WMA). - INSPECTION PROCEDURE HINT: After the inspection completed, clear the DTCs. NOTICE: • This code may be output even if there is no malfunction. • If this code is output frequently, replace the radio and navigation assembly. 1 CLEAR DTC (a) Clear the DTCs (See page NS-46). HINT: These DTCs do not indicate a malfunction. NEXT 2 RECHECK DTC (a) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. NG OK END NS REPLACE RADIO AND NAVIGATION ASSEMBLY NS–103 NAVIGATION – NAVIGATION SYSTEM DTC 63-7D Disc cannot be Played DTC 63-7E No Playable Files DTC 63-7F Copyright Protection Error DESCRIPTION DTC No. DTC Detection Condition Trouble Area • • An incompatible MP3/WMA file is used. Although the file has an extension of ".mp3" or ".wma", the header information cannot be read. 63-7E • • A disc with no music data is used. Playable files are not on the disc (MP3/WMA). 63-7F A copy-protected file, which cannot be played, is used. 63-7D • • CD Radio and navigation assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHANGE DISC (a) Insert a disc with a playable file and check if the disc can be played correctly. HINT: For details on playable files and discs, refer to the Owner's Manual. OK: The disc can be played correctly. NG REPLACE RADIO AND NAVIGATION ASSEMBLY OK DISC IS FAULTY NS NS–104 NAVIGATION – NAVIGATION SYSTEM Noise Occurs INSPECTION PROCEDURE 1 NOISE CONDITION (a) Check from which direction the noise comes (front left or right, or rear left or right). (1) Check from which direction the noise comes. OK: The location of the noise source can be determined. NG Go to step 3 OK 2 CHECK SPEAKERS (a) Check the installation conditions of the speaker units that are located near the noise source and that there are no cracks, scratches, deformation, or other failures. Result Condition Proceed to A speaker is installed incorrectly A Foreign objects are in the speaker B A speaker cone paper is broken C No malfunction is found D A REINSTALL SPEAKER B REMOVE FOREIGN OBJECT C REPLACE SPEAKER D 3 CHECK NOISE CONDITIONS (a) Check the noise condition. HINT: The radio has a noise prevention function to reduce noise when listening to the radio. If a loud noise occurs, check whether the ground at the antenna mounting base and the noise prevention unit are installed and wired correctly. NS Conditions under which noise occurs Noise increases when the accelerator pedal is depressed, but stops when the engine is stopped. Noise occurs during A/C or heater operation. Noise occurs when the vehicle accelerates rapidly on an unpaved road or after the ignition switch is turned on (IG or ACC). Noise source Generator Blower motor Fuel pump NS–105 NAVIGATION – NAVIGATION SYSTEM Conditions under which noise occurs Noise source Noise occurs when the horn switch is pressed and released or when pressed and held. Horn Noise occurs synchronously with the blink of the turn signal. Flasher Noise occurs during window washer operation. Washer Noise occurs while the engine is running, and continues even after the engine is stopped. Noise occurs during wiper operation. Water temperature sensor Wiper Noise occurs when the brake pedal is depressed. Stop light switch Others Static electricity HINT: • In the chart's left column, find the situation that matches the customer's complaint. Then, in the right column, find the part that is causing the noise. Check the noise filter on or for the part. • To save time and avoid a misdiagnosis, first make sure that the noise is not coming from outside the vehicle. • Noise should be removed in descending order of loudness. • Setting the radio to a frequency where no signal is received may make recognition of the noise problem easier. OK: The noise source cannot be determined. NG REPAIR OR REPLACE NOISE SOURCE OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–106 NAVIGATION – NAVIGATION SYSTEM Pressing Power Switch does not Turn on System INSPECTION PROCEDURE 1 CHECK CABIN (a) Check that conditions in the cabin are not likely to cause condensation. HINT: This problem occurs when the cabin is humid and the temperature rapidly changes. This condition may produce condensation, resulting in a short circuit. OK: Condensation is not likely to occur. NG DRY CABIN AND RECHECK CONDITIONS OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NAVIGATION – NAVIGATION SYSTEM NS–107 No Sound can be Heard from Speakers INSPECTION PROCEDURE 1 CHECK AUDIO SETTINGS (a) Enter the sound adjustment screen by pressing the "SOUND" switch on the AUDIO display. (b) Set volume, fader, and balance to the initial values and check that sound is normal. OK: Audio system returns to normal. HINT: Sound quality adjustment items vary depending on the type of the amplifier. E120098 OK END NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–108 NAVIGATION – NAVIGATION SYSTEM CD cannot be Ejected INSPECTION PROCEDURE 1 CHECK OPERATION (a) Press the disc eject switch of the radio receiver for 5 seconds or more and check that the CD is ejected. OK: CD is ejected. NG REPLACE RADIO AND NAVIGATION ASSEMBLY OK 2 REPLACE CD WITH ANOTHER AND RECHECK (a) Insert another CD and check if it is ejected. OK: CD is ejected. NG OK CD IS FAULTY NS REPLACE RADIO AND NAVIGATION ASSEMBLY NAVIGATION – NAVIGATION SYSTEM NS–109 CD cannot be Inserted / Played or CD is Ejected Right After Insertion INSPECTION PROCEDURE 1 CHECK IF A PROPER CD IS INSERTED (a) Make sure that the CD is an audio CD or a CD with an MP3 or WMA file, and that it is not deformed, flawed, stained, burred, or otherwise defective. OK: Normal CD HINT: • Translucent or uniquely-shaped CDs cannot be played. • Commercial audio CDs can be played. • CD-DA files on CD-ROMs, CD-Rs, and CD-RWs can be played. • MP3 and WMA files on CD-ROMs, CD-Rs and CDRWs can be played. • For details on playable CDs, refer to the Owner's Manual. NG CD IS FAULTY OK 2 CHECK THAT CD IS INSERTED PROPERLY (a) Check whether or not the CD is inserted upside down. OK: CD is properly inserted. NG SET CD PROPERLY OK 3 CHECK CD (a) Clean the disc by wiping it with a soft cloth from the inside to the outside in a radial direction. OK: Malfunction disappears. NOTICE: Do not use a conventional record cleaner or antistatic preservative. OK I100151 NG CD WAS DIRTY NS NS–110 4 NAVIGATION – NAVIGATION SYSTEM REPLACE CD WITH ANOTHER AND RECHECK (a) Replace the CD with a normal one and check that the malfunction disappears. OK: Malfunction disappears. NG OK CD IS FAULTY NS REPLACE RADIO AND NAVIGATION ASSEMBLY NAVIGATION – NAVIGATION SYSTEM NS–111 CD Sound Skips INSPECTION PROCEDURE 1 CHECK CD (a) Check the CD. OK: The CD is clean. HINT: If dirt is on the CD surface, wipe it clean with a soft cloth from the inside to the outside in a radial direction. NOTICE: Do not use a conventional record cleaner or antistatic preservative. I100151 NG CLEAN CD OK 2 CHECK CD (a) Check that the CD is not deformed or cracked. OK: No deformation or cracks on the CD. NG CD IS FAULTY I100152 OK 3 CHECK OPERATION OF ANOTHER CD (a) Check using another CD. (1) Check if the problem recurs using another CD. OK: The problem does not occur. OK CD IS FAULTY NS NG 4 CHECK RADIO AND NAVIGATION ASSEMBLY (a) Check the radio and navigation assembly installation condition. (1) Check that the radio and navigation assembly is properly installed. NS–112 NAVIGATION – NAVIGATION SYSTEM OK: Radio and navigation assembly is properly installed. NG OK REPLACE RADIO AND NAVIGATION ASSEMBLY NS REINSTALL RADIO AND NAVIGATION ASSEMBLY NS–113 NAVIGATION – NAVIGATION SYSTEM Radio Broadcast cannot be Received or Poor Reception INSPECTION PROCEDURE 1 CHECK RADIO AND NAVIGATION ASSEMBLY (a) Check the radio's automatic station search function. (1) Check the radio's automatic station search function by activating it. OK: The radio's automatic station search function works properly. OK REPLACE RADIO AND NAVIGATION ASSEMBLY NG 2 INSPECT RADIO AND NAVIGATION ASSEMBLY (a) Disconnect the radio and navigation assembly connector F9. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness View: Tester connection Condition Specified condition ANT - Body ground Ignition SW on (IG) Radio SW ON 10 to 14 V F9 NG REPLACE RADIO AND NAVIGATION ASSEMBLY ANT E120099E04 OK 3 CHECK OPTIONAL COMPONENTS (a) Check optional components (sun-shade film, telephone antenna, etc.). (1) Check if any optional components, such as sunshade film or telephone antenna that may decrease reception capacity, are installed. OK: Optional components are installed. NOTICE: Do not remove any optional components installed by the customer without his or her consent. NS NS–114 NAVIGATION – NAVIGATION SYSTEM OK REMOVE AND RECHECK OPTIONAL COMPONENTS (SEE NOTICE ABOVE) NG 4 CHECK RADIO AND NAVIGATION ASSEMBLY E050367E01 (a) Preparation for check (1) Remove the antenna plug from the radio and navigation assembly. (b) Check for noise (1) Turn the ignition switch on (ACC) with the radio and navigation assembly connector connected. (2) Turn the radio on and put into AM mode. (3) Place a screwdriver, thin wire, or other metal object on the radio receiver's antenna jack and check that noise can be heard from the speaker. OK: Noise occurs. NG REPLACE RADIO AND NAVIGATION ASSEMBLY OK 5 CHECK GLASS ANTENNA (a) Check for continuity of the antenna. HINT: Check for continuity at the center of each antenna wire as shown in the illustration. NOTICE: When cleaning the glass, wipe it in the direction of the wire with a soft dry cloth. Take care not to damage the wire. Do not use detergents or glass cleaners with abrasive ingredients. When measuring voltage, wrap a piece of tin foil around the tip of the negative probe and press the foil against the wire with your finger, as shown in the illustration. OK: There is continuity in the antenna. Tester Probe Tin Foil Antenna Wire NG NS E111994E02 OK REPAIR GLASS ANTENNA NAVIGATION – NAVIGATION SYSTEM 6 NS–115 REPLACE ANTENNA AMPLIFIER (a) Replace the antenna amplifier and check that it operates normally. OK: The antenna amplifier operates normally. OK END NG REPLACE RADIO AND NAVIGATION ASSEMBLY NS NS–116 NAVIGATION – NAVIGATION SYSTEM Illumination for Panel Switch does not Come on with Tail Switch ON INSPECTION PROCEDURE 1 CHECK VEHICLE SIGNAL (DISPLAY CHECK MODE) (a) Enter the "Display Check" mode (Vehicle Signal Check Mode) (See page NS-22). (b) Check that the display changes between ON and OFF according to the light control switch operation. OK Light Control Switch I038223E01 TAIL or ON ON OFF OFF HINT: This display is updated once per second. As a result, it is normal for the display to lag behind the actual change in the switch. NG OK REPLACE RADIO AND NAVIGATION ASSEMBLY NS Display PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS–117 NAVIGATION – NAVIGATION SYSTEM Display does not Dim when Light Control Switch is Turned ON INSPECTION PROCEDURE 1 CHECK IMAGE QUALITY SETTING (a) Enter the display adjustment screen by pressing the "DISP" switch. (b) Turn the light control switch to the TAIL position. (c) Check if "DAY MODE" on the display adjustment is ON. OK: "DAY MODE" is ON. NG Go to step 2 E125813E01 OK TURN "DAY MODE" SETTING OFF 2 CHECK VEHICLE SIGNAL (DISPLAY CHECK MODE) (a) Enter the "Display Check" mode (Vehicle Signal Check) (See page NS-22). (b) Check that the display changes between ON and OFF according to the light control switch operation. OK Light Control Switch E125810E01 Display TAIL or ON ON OFF OFF HINT: The display is updated once per second. It is normal for the display to lag behind the actual switch operation. NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE OK REPLACE RADIO AND NAVIGATION ASSEMBLY NS NS–118 NAVIGATION – NAVIGATION SYSTEM Panel Switches do not Function INSPECTION PROCEDURE 1 CHECK PANEL SWITCH (a) Check for foreign matter around the switches that might prevent operation. OK: No foreign matter is found. NG REMOVE ANY FOREIGN MATTER FOUND OK 2 CHECK PANEL SWITCH (DISPLAY CHECK MODE) (a) Enter the "Display Check" mode (Panel Switch Check) (See page NS-22). (b) Operate the abnormal switch and check if the switch name and status are correctly displayed. OK: The switch name and status are correctly displayed as operated. NG I100041 OK REPLACE RADIO AND NAVIGATION ASSEMBLY NS PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NAVIGATION – NAVIGATION SYSTEM NS–119 Touch Panel Switch does not Function INSPECTION PROCEDURE 1 CHECK TOUCH PANEL (a) Check for foreign matter on the display. OK: The display is clean. NG CLEAN DISPLAY AND RECHECK TOUCH PANEL OK 2 CHECK TOUCH SWITCH (DISPLAY CHECK MODE) (a) Enter the "Display Check" mode (Touch Switch Check) (See page NS-22). (b) Touch the display in the area where the switch malfunction occurs. OK: A "+" mark appears at the touched position. NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE I100039E04 OK REPLACE RADIO AND NAVIGATION ASSEMBLY NS NS–120 NAVIGATION – NAVIGATION SYSTEM Display Panel does not Open, Tilt or Tilts Improperly INSPECTION PROCEDURE 1 CHECK RADIO AND NAVIGATION ASSEMBLY (a) Check for foreign matter or obstructions caught in the moving parts of the panel. OK: No obstruction or foreign matter found. NG REMOVE ANY OBSTRUCTION OR FOREIGN MATTER FOUND E120094 OK 2 CHECK OPERATION (a) Check if the navigation and audio systems function properly. OK: Navigation and audio systems function properly. OK REPLACE RADIO AND NAVIGATION ASSEMBLY NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NAVIGATION – NAVIGATION SYSTEM NS–121 Screen Flicker or Color Distortion INSPECTION PROCEDURE 1 CHECK DISPLAY SETTING (a) Enter the display adjustment screen by pressing the "DISPLAY" switch. (b) Reset display settings (contrast, brightness) and check that the screen appears normal. E120095E01 (c) Press the "INFO" switch and then select "Screen Setting." E120096E04 (d) Set the "Switch Color" to "Green" (initial setting) and check if the display returns to normal. OK: Returns to normal. NG Go to step 2 E120097 OK END 2 NS CHECK CABIN (a) Check that the cabin temperature is warmer than -20°C (-4.0°F). OK: Cabin is warmer than -20°C (-4.0°F). NG HEAT CABIN AND RECHECK TEMPERATURE NS–122 NAVIGATION – NAVIGATION SYSTEM OK 3 CHECK COLOR BAR (DISPLAY CHECK MODE) (a) Enter the "Display Check" mode (Color Bar Check) (See page NS-22). (b) Check that the color bars match the displayed names. OK: Color bars match the displayed names. NG REPLACE RADIO AND NAVIGATION ASSEMBLY I100037E05 OK 4 CHECK NAVI COLOR BAR (NAVIGATION CHECK MODE) (a) Enter the "Navigation Check" mode (NAVI Color Bar Check) (See page NS-27). (b) Check that the color bars match the displayed names. OK: Color bars match the displayed names. NG REPLACE RADIO AND NAVIGATION ASSEMBLY I100050E04 OK NS PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NAVIGATION – NAVIGATION SYSTEM NS–123 Poor Sound Quality in All Modes (Low Volume) INSPECTION PROCEDURE 1 CHECK AUDIO SETTINGS (a) Set "BASS", "MID" and "TREB" to the initial values and check that sound is normal. OK: Malfunction disappears. OK END NG 2 COMPARE WITH ANOTHER VEHICLE OF SAME MODEL (a) Compare with another vehicle of the same model. (1) Compare with another vehicle of the same model which does not have trouble to see if there is any difference in the sound quality. OK: No difference is found. OK END NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–124 NAVIGATION – NAVIGATION SYSTEM MAP Disc cannot be Inserted INSPECTION PROCEDURE 1 CHECK RADIO AND NAVIGATION ASSEMBLY (a) Check if a disc is inserted into the MAP disc slot. (1) Check if "DISC IN" is displayed. OK: "DISC IN" is displayed. NG EJECT DISC E125111 OK 2 CHECK MAP DISC (a) Check that the map disc is not deformed or cracked. OK: No deformations or cracks on map disc. NG REPLACE MAP DISC I100152E12 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–125 NAVIGATION – NAVIGATION SYSTEM Vehicle Position Mark Deviates Greatly INSPECTION PROCEDURE 1 CHECK GPS MARK (a) Check that the GPS mark is displayed. OK: GPS mark is displayed. NG GO TO "GPS MARK IS NOT DISPLAYED" IN PROBLEM SYMPTOMS TABLE E125110E01 OK 2 CHECK VEHICLE SENSOR (NAVIGATION CHECK MODE) (a) Enter the "Navigation Check" mode (Vehicle Sensors) (See page NS-27). (b) While driving the vehicle, compare the "Speed" indicator to the reading on the speedometer. Check that these readings are almost equal. OK: The readings are almost equal. NG E120089 GO TO "SPEED SIGNAL DOES NOT CHANGE IN NAVIGATION CHECK MODE" IN PROBLEM SYMPTOMS TABLE OK 3 CHECK VEHICLE SENSOR (NAVIGATION CHECK MODE) (a) Check that the display changes between ON and OFF according to the shift lever operation. OK E120101E01 Shift Lever Position Display Except Reverse OFF Reverse ON HINT: The display is updated once per second. It is normal for the display to lag behind the actual switch operation. NG GO TO "REVERSE SIGNAL DOES NOT CHANGE IN NAVIGATION CHECK MODE" IN PROBLEM SYMPTOMS TABLE NS NS–126 NAVIGATION – NAVIGATION SYSTEM OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NAVIGATION – NAVIGATION SYSTEM NS–127 Cursor or MAP Rotates when Vehicle Stopped INSPECTION PROCEDURE 1 CHECK CONDITION (a) Check with the customer if the vehicle has been turned by a turntable. OK: Vehicle has not been turned by turntable. HINT: If the vehicle is turned on a turntable with the ignition switch on (IG), the system may store the angular velocity. As a result, the vehicle position cursor may deviate. E106418 NG TURN IGNITION SWITCH ON (IG) WHEN VEHICLE IS COMPLETELY STOPPED OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–128 NAVIGATION – NAVIGATION SYSTEM Vehicle Position Mark is not Updated INSPECTION PROCEDURE 1 CHECK MAP DISC (a) Check that the map disc is not deformed or cracked. OK: No deformations or cracks on map disc. NG REPLACE MAP DISC I100152E12 OK 2 CHECK NAVIGATION DISPLAY (a) Check if a touch scroll can be performed on the map display. OK: Touch scroll can be performed. NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE OK 3 CHECK VEHICLE SENSOR (NAVIGATION CHECK MODE) (a) Enter the "Navigation Check" mode (Vehicle Sensors) (See page NS-27). (b) While driving the vehicle, compare the "Speed" indicator to the reading on the speedometer. Check if these readings are almost equal. OK: The readings are almost equal. NG E120089 NS GO TO "SPEED SIGNAL DOES NOT CHANGE IN NAVIGATION CHECK MODE" IN PROBLEM SYMPTOMS TABLE OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NAVIGATION – NAVIGATION SYSTEM NS–129 Current Position Display does not Appear INSPECTION PROCEDURE 1 CHECK RADIO AND NAVIGATION ASSEMBLY (a) Check if a map disc is inserted into the map disc slot. OK: A map disc is inserted. NG INSERT MAP DISC IN MAP SIDE SLOT E125111 OK 2 CHECK MAP DISC (a) Check that the map disc is not deformed or cracked. OK: No deformations or cracks on map disc. NG REPLACE MAP DISC I100152E12 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–130 NAVIGATION – NAVIGATION SYSTEM GPS Mark is not Displayed INSPECTION PROCEDURE 1 CHECK CABIN (a) Check the cabin for any object that might interrupt radio reception on the instrument panel. If such an object exists, remove it and check if the GPS mark reappears. HINT: The GPS uses extremely faint radio waves originating from satellites. If the signal is interrupted by obstructions or other radio waves, the GPS may not be able to properly receive the signal. OK: Mark appears. NG Go to step 2 OK NORMAL OPERATION 2 CHECK SURROUNDINGS (a) Check if the vehicle is in a location where GPS signal reception is poor. If the vehicle is in such a place, relocate the vehicle and check if the GPS mark reappears. HINT: The GPS uses 24 satellites in 6 orbits. At any point in time, 4 satellites should be able to pinpoint your vehicle. However, GPS signals may not reach the vehicle due to influence from the surroundings, vehicle direction, and time. For illustrated examples, see below. NS NS–131 NAVIGATION – NAVIGATION SYSTEM In a tunnel In a building Under an overpass Between tall buildings On a forest or tree-lined path Under a cliff, overhang I100196E03 OK: GPS mark is displayed. NG Go to step 3 OK SYSTEM RETURNS TO NORMAL 3 CHECK GPS INFORMATION (NAVIGATION CHECK MODE) I102403E01 (a) Enter the "Navigation Check" mode (GPS Information) (See page NS-27). (b) Check how many of the following codes appear in the "STS" column. For DENSO Made: T, P For AISIN AW Made: 08H, 04H OK: At least 3 codes appear. NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–132 NAVIGATION – NAVIGATION SYSTEM OK REPLACE RADIO AND NAVIGATION ASSEMBLY NS NAVIGATION – NAVIGATION SYSTEM NS–133 Voice Guidance does not Function INSPECTION PROCEDURE 1 CHECK NAVIGATION SETTING (a) Enter the "Menu" screen by pressing the "MENU" switch. (b) Select "Volume". E120104E02 (c) Check that "OFF" is not selected. OK: "OFF" is not selected. NG TURN VOICE GUIDANCE VOLUME UP TO 4 USING VOICE ADJUSTMENT SWITCHES E120106 OK 2 CHECK NAVIGATION SETTING (a) Enter the "Menu" screen by pressing the "MENU" switch. (b) Select "Set up". E120104E03 NS NS–134 NAVIGATION – NAVIGATION SYSTEM (c) Check that "Voice Guidance in All Modes" is not OFF. OK: Voice guidance in all modes is not OFF. NG TURN VOICE GUIDANCE IN ALL MODES "ON" E120105E01 OK 3 CHECK NAVIGATION SETTING (a) Enter the "Menu" screen by pressing the "MENU" switch. (b) Select "Setup". E120104E03 (c) Check that "Auto Voice Guidance" is not OFF. OK: Auto voice guidance is not OFF. NG TURN AUTO VOICE GUIDANCE "ON" E120107 OK 4 CHECK MAP DISC (a) Check that the map disc is not deformed or cracked. OK: No deformations or cracks on map disc. NG NS I100152E12 REPLACE MAP DISC NAVIGATION – NAVIGATION SYSTEM NS–135 OK 5 CHECK RADIO AND NAVIGATION ASSEMBLY (a) Check that audio sound can be heard from the driver side speaker. OK: Audio sound can be heard. NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE OK REPLACE RADIO AND NAVIGATION ASSEMBLY NS NS–136 NAVIGATION – NAVIGATION SYSTEM MAP Display Incomplete INSPECTION PROCEDURE 1 CHECK MAP DISC (a) Check that the map disc is not deformed or cracked. OK: No deformations or cracks on map disc. NG REPLACE MAP DISC I100152E12 OK 2 CHECK NAVIGATION DISPLAY (a) Check that displays other than the navigation display are complete. OK: No other incomplete displays are found. OK NG REPLACE RADIO AND NAVIGATION ASSEMBLY NS PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NAVIGATION – NAVIGATION SYSTEM NS–137 Route cannot be Calculated INSPECTION PROCEDURE 1 CHECK MAP DISC (a) Check that the map disc is not deformed or cracked. OK: No deformations or cracks on map disc. NG REPLACE MAP DISC I100152E12 OK 2 SET DESTINATION (a) Set another destination and check if the system can calculate the route correctly. OK: Route can be correctly calculated. NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE OK NORMAL OPERATION NS NS–138 NAVIGATION – NAVIGATION SYSTEM Voice Recognition Difficulty INSPECTION PROCEDURE 1 CHECK CONDITION (a) Check if the system's voice recognition level is low by using only one particular voice. OK: System's voice recognition level is low with any voice. HINT: System's voice recognition level varies depending on voice and pronunciation. This is not a malfunction. NG END OK 2 CHECK MAP DISC (a) Check that the map disc is not deformed or cracked. OK: No deformations or cracks on map disc. NG REPLACE MAP DISC I100152E12 OK 3 CHECK MAP DISC (a) Check for dirt on the map disc surface. OK: No dirt is on map disc surface. NOTICE: Do not use a conventional record cleaner or antistatic preservative. HINT: If the disc is dirty, clean the disc by wiping the disc's surface radially with a soft cloth. NS I100201E04 OK NG CLEAN MAP DISC NAVIGATION – NAVIGATION SYSTEM 4 NS–139 CHECK MICROPHONE (NAVIGATION CHECK MODE) Microphone Input Level Meter Recording Switch Play Switch Recording Indicator Stop Switch (a) Enter the "MICROPHONE & VOICE RECOGNITION CHECK" mode (See page NS-27). (b) When voice is input into the microphone, check that the microphone input level meter changes according to the input voice. (c) Push the recording switch and perform voice recording. HINT: Voice can be recorded up to 5 seconds. (d) Check that the recording indicator remains on while recording and that the recorded voice is played normally without noise or distortion. OK: All check results are normal. NG E120056E03 PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE OK END NS NS–140 NAVIGATION – NAVIGATION SYSTEM Voice is not Recognized INSPECTION PROCEDURE 1 CHECK NAVIGATION SETTING (a) Enter the "Menu" screen by pressing the "MENU" switch. (b) Select "Setup". E120104E03 (c) Check that "Voice Recognition Guidance" is not OFF. OK: Voice Recognition Guidance is not OFF. NG TURN VOICE RECOGNITION GUIDANCE "ON" E120105E02 OK 2 CHECK MAP DISC (a) Check that the map disc is not deformed or cracked. OK: No deformations or cracks on map disc. NG I100152E12 OK NS REPLACE MAP DISC NAVIGATION – NAVIGATION SYSTEM 3 NS–141 CHECK MAP DISC (a) Check for dirt on the map disc surface. OK: No dirt is on the map disc surface. NOTICE: Do not use a conventional record cleaner or antistatic preservative. HINT: If the disc is dirty, clean the disc by wiping the disc's surface radially with a soft cloth. I100201E04 NG CLEAN MAP DISC OK 4 CHECK MICROPHONE (NAVIGATION CHECK MODE) Microphone Input Level Meter Recording Switch Play Switch Recording Indicator Stop Switch (a) Enter the "MICROPHONE & VOICE RECOGNITION CHECK" mode (See page NS-27). (b) When voice is input into the microphone, check that the microphone input level meter changes according to the input voice. (c) Push the recording switch and perform voice recording. HINT: Voice can be recorded up to 5 seconds. (d) Check that the recording indicator remains on while recording and that the recorded voice is played normally without noise or distortion. OK: All check results are normal. NG E120056E03 PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE OK REPLACE RADIO AND NAVIGATION ASSEMBLY NS NS–142 NAVIGATION – NAVIGATION SYSTEM Cellular Phone Registration Failure, Phone Directory Transfer Failure INSPECTION PROCEDURE 1 CHECK CURRENT CONDITIONS (a) Proceed to the next step according to the table below. Result Conditions Proceed to Another "Bluetooth" compatible cellular phone is present. A Another "Bluetooth" compatible vehicle is present. B None of the above C B Go to step 3 C Go to step 4 A 2 CHECK USING ANOTHER CELLULAR PHONE (a) Check if the system functions using another "Bluetooth" compatible cellular phone. HINT: • Confirm that either the same or a different version of another "Bluetooth" compatible cellular phone complies with the system. • Depending on the version, some "Bluetooth" compatible cellular phones cannot be used. OK: The system functions. NG REPLACE RADIO AND NAVIGATION ASSEMBLY OK USE A "BLUETOOTH" COMPATIBLE CELLULAR PHONE 3 NS CHECK USING ANOTHER "BLUETOOTH" COMPATIBLE VEHICLE (a) Register the cellular phone with another vehicle and check if the system functions normally. HINT: Depending on the version, some "Bluetooth" compatible cellular phones cannot be used. OK: The system functions. NAVIGATION – NAVIGATION SYSTEM OK NS–143 REPLACE RADIO AND NAVIGATION ASSEMBLY NG USE A "BLUETOOTH" COMPATIBLE CELLULAR PHONE 4 CHECK CELLULAR PHONE (a) Check if the cellular phone is "Bluetooth" compatible. HINT: Some versions of "Bluetooth" compatible cellular phones may not function. OK: The phone is "Bluetooth" compatible. NG USE A "BLUETOOTH" COMPATIBLE CELLULAR PHONE OK 5 CHECK CELLULAR PHONE (a) Check if a call can be made from the cellular phone. HINT: When the battery is low, registration or directory transfer cannot be done. OK: A call can be made from the cellular phone. NG REPAIR OR REPLACE CELLULAR PHONE OK REPLACE RADIO AND NAVIGATION ASSEMBLY NS NS–144 NAVIGATION – NAVIGATION SYSTEM Cellular Phone cannot Send / Receive INSPECTION PROCEDURE 1 CHECK "BLUETOOTH" SETTINGS (a) Check if the "Bluetooth" settings are correct. OK: "Bluetooth" settings are correct. NG SET SETTINGS CORRECTLY OK 2 CHECK CELLULAR PHONE (a) Check if the cellular phone is "Bluetooth" compatible. HINT: Some versions of "Bluetooth" compatible cellular phones may not function. OK: Phone is "Bluetooth" compatible. NG END (ONLY A "BLUETOOTH" COMPATIBLE CELLULAR PHONE CAN BE USED) OK 3 CHECK SETTINGS (a) Check if the cellular phone functions. HINT: The cellular phone is unable to call under any of the following conditions. • The cellular phone is locked. • The directory is being transferred. • The line is crossed. • Transmission is regulated. • The power is off. • The cellular phone is not connected to "Bluetooth" ("BT" is displayed while connected). OK: None of the above conditions exist. NG NS SET CORRECTLY OK 4 CHECK CELLULAR PHONE (a) Check if the cellular phone can make a call. NAVIGATION – NAVIGATION SYSTEM NS–145 HINT: When the battery is low, calls cannot be made or received. OK: Cellular phone can make a call. NG REPAIR OR REPLACE CELLULAR PHONE OK 5 CHECK RECEPTION (a) Set the cellular phone so that it can receive calls. (b) Place the cellular phone close to the radio and navigation assembly. (c) Check if the cellular phone has reception according to the radio and navigation assembly. OK: Cellular phone has reception. NG REPLACE RADIO AND NAVIGATION ASSEMBLY OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–146 NAVIGATION – NAVIGATION SYSTEM Cannot Call in a Certain Place INSPECTION PROCEDURE 1 CHECK SURROUNDING CONDITIONS (a) Check if the cellular phone can make calls in a certain place. OK: It can make calls. NG END (CELLULAR PHONES CAN ONLY FUNCTION IN CELLULAR SERVICE AREAS) OK 2 CHECK RECEPTION (a) Enter the "Information" screen by pressing the "INFO" switch. (b) Select "Telephone". E120096E02 (c) Check the "Bluetooth" connection indicator ("BT" indicator). E120108E01 Result NS NEXT END Condition Procedure Yellow color Bring the cellular phone to a location where the "BT" mark turns blue. Blue color Replace radio and navigation assembly. No connection mark is displayed Select a registered cellular phone or register a "Bluetooth" compatible phone. NAVIGATION – NAVIGATION SYSTEM NS–147 The Other Caller's Voice cannot be Heard, is too Quiet, or Distorted INSPECTION PROCEDURE 1 CHECK CELLULAR PHONE (a) Check if the voice on the other side can be heard using a cellular phone. OK: Voice can be heard. NG REPAIR OR REPLACE CELLULAR PHONE OK 2 CHECK NAVIGATION SYSTEM (a) Check that navigation sound can be heard from the driver side speaker. OK: Audio sound can be heard. NG GO TO "VOICE GUIDANCE DOES NOT FUNCTION" IN PROBLEM SYMPTOMS TABLE OK 3 CHECK SETTINGS (a) Check if the volume level is set to low on the CALL screen. OK: The level is not set low. NG SET VOLUME TO HIGH E120109E02 OK NS NS–148 4 NAVIGATION – NAVIGATION SYSTEM CHECK SETTINGS E120069E02 (a) Enter the "Handsfree Voice Quality Set" mode (See page NS-25). (b) Check if the Receive Voice Level is set to "0". HINT: The Receive Voice Level can be set to 11 different levels, -5 to +5, with a 3 dB difference. (c) Check if the Receive Voice Level is set to the minimum or maximum level. HINT: When the Receive Voice Level is set to the minimum or maximum level, the sound may be distorted. OK: The Receive Voice Level is set to "0". NG SET RECEIVE VOICE LEVEL TO "0" OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NAVIGATION – NAVIGATION SYSTEM NS–149 The Other Caller cannot Hear Your Voice, or Your Voice is too Quiet or Distorted INSPECTION PROCEDURE 1 CHECK CELLULAR PHONE (a) Check if the other side can hear your voice properly. OK: Your voice can be heard correctly. NG REPLACE CELLULAR PHONE OK 2 CHECK SETTINGS (a) Check if the mute switch is set to ON. OK: Mute switch is not set to ON. NG TURN MUTE SWITCH OFF E120109E03 OK 3 CHECK SETTINGS E120069E06 (a) Enter the "Handsfree Voice Quality Set" mode (See page NS-25). (b) Check if the Send Voice Level is set to "0". HINT: The Send Voice Level can be set to 11 different levels, -5 to +5, with a 3 dB difference. (c) Check if the Send Voice Level is set to the minimum or maximum level. HINT: When the Send Voice Level is set to the minimum or maximum level, the sound may be distorted. OK: The Send Voice Level is set to "0". NG OK SET SEND VOICE LEVEL TO "0" NS NS–150 4 NAVIGATION – NAVIGATION SYSTEM CHECK MICROPHONE (NAVIGATION CHECK MODE) Microphone Input Level Meter Recording Switch Play Switch Recording Indicator Stop Switch (a) Enter the "MICROPHONE & VOICE RECOGNITION CHECK" mode (See page NS-27). (b) When voice is input into the microphone, check that the microphone input level meter changes according to the input voice. (c) Push the recording switch and perform voice recording. HINT: Voice can be recorded up to 5 seconds. (d) Check that the recording indicator remains on while recording and that the recorded voice is played normally without noise or distortion. OK: All check results are normal. NG E120056E03 OK REPLACE RADIO AND NAVIGATION ASSEMBLY NS PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NAVIGATION – NAVIGATION SYSTEM NS–151 Black Screen INSPECTION PROCEDURE 1 CHECK DISPLAY SETTING (a) Check that the display is not in "Screen OFF" mode. OK: The display setting is not in "Screen OFF" mode. NG CHANGE SCREEN TO "SCREEN ON" MODE OK 2 CHECK IMAGE QUALITY SETTING (a) Check that the screen color quality can be set. OK: Setting is possible. NG Go to step 3 OK PRESS PANEL SWITCH "DISPLAY" AND SET SCREEN COLOR QUALITY TO NORMAL 3 CHECK CABIN (a) Check that condensation is not likely to occur in the cabin, and that the temperature is not high or extremely low in the cabin. HINT: • A humid cabin and a rapid change in temperature may lead to condensation. Condensation in the cabin may short circuit the screen. • The appropriate cabin temperature is 20 to 30°C (68 to 86°F). OK: Condensation is not likely and temperature is not high or extremely low. NG SET CABIN TO APPROPRIATE TEMPERATURE OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–152 NAVIGATION – NAVIGATION SYSTEM Vehicle Speed Signal Circuit between Radio and Navigation Assembly and Combination Meter DESCRIPTION The radio and navigation assembly receives a vehicle speed signal from the combination meter and information about the GPS antenna, and then adjusts vehicle position. HINT: • A voltage of 12 V or 5 V is output from each ECU and then input to the combination meter. The signal is changed to a pulse signal at the transistor in the combination meter. Each ECU controls the respective system based on the pulse signal. • If a short occurs in an ECU, all systems in the diagram below will not operate normally. WIRING DIAGRAM Radio and Navigation Assembly 3 (*1) From Main Body ECU From Stereo Component Amplifier F13 (*2) SPD From Transmission Control ECU From Engine Control Module +S 12 F2 From Tire Pressure Warning ECU Combination Meter From Speed Sensor *1: with Smart Key System *2: 2GR-FE NS E129780E01 NAVIGATION – NAVIGATION SYSTEM NS–153 INSPECTION PROCEDURE 1 CHECK OPERATION OF SPEEDOMETER (a) Drive the vehicle and check if the function of the speedometer on the combination meter is normal. OK: Actual vehicle speed and the speed indicated on the speedometer are the same. HINT: The vehicle speed sensor is functioning normally when the indication on the speedometer is normal. NG GO TO COMBINATION METER SYSTEM OK 2 INSPECT RADIO AND NAVIGATION ASSEMBLY (a) Disconnect the radio and navigation assembly connector F13. (b) Measure the voltage. (1) Jack up either one of the drive wheels. (2) Move the shift lever to the neutral position. (3) Turn the ignition switch on (IG). Radio and Navigation Assembly Wire Harness View: SPD F13 E113510E05 (4) Measure the voltage between terminal SPD of the wire harness connector and body ground when the drive wheels are turned slowly. OK: Voltage pulses as shown in the illustration. OK 4.5 to 14 V NS Below 2 V 0 Turn the wheel E110855E01 NG REPLACE RADIO AND NAVIGATION ASSEMBLY NS–154 3 NAVIGATION – NAVIGATION SYSTEM CHECK HARNESS AND CONNECTOR (COMBINATION METER - RADIO AND NAVIGATION ASSEMBLY) (a) Disconnect the radio and navigation assembly connector F13 and combination meter connector F2. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Radio and Navigation Assembly Wire Harness View: SPD Tester connection Condition Specified condition SPD - +S Ignition switch off Below 1 Ω NG F13 REPAIR OR REPLACE HARNESS OR CONNECTOR Combination Meter Wire Harness View: F2 +S E129818E01 OK 4 CHECK HARNESS AND CONNECTOR (RADIO AND NAVIGATION ASSEMBLY - BODY GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Radio and Navigation Assembly Wire Harness View: SPD Tester connection Condition Specified condition SPD - Body ground Ignition switch off 10 kΩ or higher HINT: If the resistance between terminal SPD and body ground is less than 10 kΩ, there may be a short in a wire harness, connector, or an ECU. NS NG F13 E113510E05 REPAIR OR REPLACE HARNESS OR CONNECTOR OR CHECK EACH ECU NAVIGATION – NAVIGATION SYSTEM NS–155 OK REPLACE COMBINATION METER NS NS–156 NAVIGATION – NAVIGATION SYSTEM Steering Pad Switch Circuit DESCRIPTION This circuit sends an operation signal from the steering pad switch to the radio and navigation assembly. If there is an open in the circuit, the navigation system cannot be operated using the steering pad switch. If there is a short in the circuit, the resulting condition is the same as if the switch were continuously depressed. Therefore, the radio and navigation assembly cannot be operated using the steering pad switch, and the radio and navigation assembly itself cannot function. NS NS–157 NAVIGATION – NAVIGATION SYSTEM WIRING DIAGRAM Radio and Navigation Assembly 3 Spoke Type: Steering Pad Switch LH VOL- VOL+ SEEK- SEEK+ MODE Spiral Cable 10 a1 AU1 6 E18 7 8 a1 EAU 4 E18 F10 SWG 9 a1 AU2 5 E18 8 F10 SW2 F10 SW1 6 Steering Pad Switch RH ON HOOK OFF HOOK VOICE 4 Spoke Type: Radio and Navigation Assembly Steering Pad Switch LH SEEK+ MODE Spiral Cable 10 a1 AU1 6 E18 8 a1 EAU 4 E18 F10 SWG 9 a1 AU2 5 E18 8 F10 SW2 7 F10 SW1 6 Steering Pad Switch RH ON HOOK OFF HOOK SEEK- VOL+ NS VOL- VOICE E129781E02 NS–158 NAVIGATION – NAVIGATION SYSTEM INSPECTION PROCEDURE NOTICE: The vehicle is equipped with an SRS (Supplemental Restraint System) such as the airbags. Before servicing (including removal or installation of parts), be sure to read the precautionary notice for the Supplemental Restraint System (See page RS-1). 1 INSPECT RADIO AND NAVIGATION ASSEMBLY (a) Disconnect the radio and navigation assembly connector F10. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness View: SW1 SW2 F10 SWG Tester connection E113509E03 Condition Specified condition SW1 - SWG No switch is pushed Approx. 100 kΩ SW1 - SWG SEEK+ switch: push 0 to 2.5 Ω SW1 - SWG SEEK- switch: push Approx. 0.3 kΩ SW1 - SWG VOL+ switch: push Approx. 1 kΩ SW1 - SWG VOL- switch: push Approx. 3.1 kΩ SW2 - SWG No switch is pushed Approx. 100 kΩ SW2 - SWG MODE switch: push 0 to 2.5 Ω SW2 - SWG VOICE switch: push Approx. 3.1 kΩ SW2 - SWG ON HOOK switch: push Approx. 0.3 kΩ SW2 - SWG OFF HOOK switch: push Approx. 1 kΩ NG Go to step 2 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE 2 INSPECT STEERING PAD SWITCH ASSEMBLY (a) Disconnect the steering pad switch assembly connector a1. NS NS–159 NAVIGATION – NAVIGATION SYSTEM 3 Spoke Type: a1 AUD IO OFF (HO LD) EAU AU2 AU1 4 Spoke Type: a1 AUDIO OFF (HOLD) EAU AU2 AU1 E129804E01 (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Condition Specified condition AU1 - EAU No switch is pushed Approx. 100 kΩ AU1 - EAU SEEK+ switch: push 0 to 2.5 Ω AU1 - EAU SEEK- switch: push Approx. 0.3 kΩ AU1 - EAU VOL+ switch: push Approx. 1 kΩ AU1 - EAU VOL- switch: push Approx. 3.1 kΩ AU2 - EAU No switch is pushed Approx. 100 kΩ AU2 - EAU MODE switch: push 0 to 2.5 Ω AU2 - EAU VOICE switch: push Approx. 3.1 kΩ AU2 - EAU ON HOOK switch: push Approx. 0.3 kΩ AU2 - EAU OFF HOOK switch: push Approx. 1 kΩ NS NS–160 NAVIGATION – NAVIGATION SYSTEM NG REPLACE STEERING PAD SWITCH ASSEMBLY OK 3 INSPECT SPIRAL CABLE (a) Disconnect the steering pad switch assembly and spiral cable connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Steering Pad Switch Side: AU2 EAU Tester connection Spiral cable position Specified condition Center AU1 EAU - EAU 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right Center AU1 - AU1 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right Center AU2 - AU2 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right Vehicle Side: AU2 EAU AU1 I039337E31 NOTICE: The spiral cable is an important part of the SRS airbag system. Incorrect removal or installation of the spiral cable may prevent the airbag from deploying. Be sure to read the page shown in the brackets. HINT: • Removal (See page RS-363) • Installation (See page RS-366) NG REPLACE SPIRAL CABLE OK REPAIR OR REPLACE HARNESS OR CONNECTOR (SPIRAL CABLE - RADIO AND NAVIGATION ASSEMBLY) NS NS–161 NAVIGATION – NAVIGATION SYSTEM Illumination Circuit DESCRIPTION Power is supplied to the radio and navigation assembly and steering pad switch illumination when the light control switch is in the TAIL or HEAD position. WIRING DIAGRAM Radio and Navigation Assembly Steering Pad Switch Spiral Cable LH 5 IL+2 a1 RH 8 a1 4 From Battery EAU 12 2 E18 F9 4 E18 6 ILL+ F10 SWG PANEL 5 3 1 2 To Main Body ECU TAIL 20 F1 Combination Meter F9 GND 12 12 E2 ILL- 11 F9 ILL- E129819E02 NS INSPECTION PROCEDURE NOTICE: The vehicle is equipped with an SRS (Supplemental Restraint System) such as the airbags. Before servicing (including removal or installation of parts), be sure to read the precautionary notice for the Supplemental Restraint System (See page RS-1). NS–162 1 NAVIGATION – NAVIGATION SYSTEM CHECK ILLUMINATION (a) Check if the illumination for the radio and navigation assembly, steering pad switch, glove box or others (Hazard switch, transmission control switch, etc.) comes on when the light control switch is turned to the HEAD or TAIL position. Result Condition Proceed to Illumination comes on for all components except steering pad switch. A Illumination comes on for all components except radio and navigation assembly. B No illumination comes on (radio receiver, hazard switch, glove box, etc.) C Illumination comes on only for glove box and steering pad switch. D B Go to step 6 C GO TO LIGHTING SYSTEM D GO TO COMBINATION METER SYSTEM A 2 CHECK HARNESS AND CONNECTOR (BATTERY - SPIRAL CABLE) Spiral Cable Connector Front View: (a) Disconnect the spiral cable connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Tester connection Condition Specified condition IL+2 - Body ground Light control switch TAIL or HEAD 10 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR IL+2 E120026E07 OK NS 3 CHECK STEERING PAD SWITCH ASSEMBLY (a) Disconnect the steering pad switch assembly connector. NAVIGATION – NAVIGATION SYSTEM NS–163 3 Spoke Type: a1 AUD IO OFF (HO LD) 4 Spoke Type: a1 AUDIO OFF (HOLD) E129805E01 (b) Connect the positive (+) lead to terminal ILL+ and the negative (-) lead to terminal EAU of the steering pad switch connector. (c) Check if the illumination for the steering pad switch comes on. OK: Illumination for the steering pad switch assembly comes on. NG OK REPLACE STEERING PAD SWITCH ASSEMBLY NS NS–164 4 NAVIGATION – NAVIGATION SYSTEM INSPECT SPIRAL CABLE (a) Disconnect the steering pad switch and spiral cable connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Steering Pad Switch Side: IL+2 EAU Tester Connection Spiral cable position EAU - EAU 2.5 rotations to the left Specified Condition Center Below 1 Ω 2.5 rotations to the right Center ILL+ - ILL+ 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right Vehicle Side: IL+2 NOTICE: The spiral cable is an important part of the SRS airbag system. Incorrect removal or installation of the spiral cable may prevent the airbag from deploying. Be sure to read the page shown in the brackets. HINT: • Removal (See page RS-363) • Installation (See page RS-366) NG EAU I039337E32 OK NS REPLACE SPIRAL CABLE NS–165 NAVIGATION – NAVIGATION SYSTEM 5 CHECK HARNESS AND CONNECTOR (SPIRAL CABLE - RADIO AND NAVIGATION ASSEMBLY) (a) Disconnect the connectors from the radio and navigation assembly and spiral cable. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Radio and Navigation Assembly Wire Harness View: SWG F10 Tester connection Condition Specified condition SWG - EAU Always Below 1 Ω SWG - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR Spiral Cable Connector Front View: E18 EAU E120116E03 OK REPLACE RADIO AND NAVIGATION ASSEMBLY NS NS–166 6 NAVIGATION – NAVIGATION SYSTEM CHECK HARNESS AND CONNECTOR (BATTERY - RADIO AND NAVIGATION ASSEMBLY) (a) Disconnect the radio and navigation assembly connector F9. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness View: ILL+ Tester connection Condition Specified condition ILL+ - Body ground Light control switch TAIL or HEAD 10 to 14 V NG F9 REPAIR OR REPLACE HARNESS OR CONNECTOR E113513E05 OK 7 CHECK HARNESS AND CONNECTOR (RADIO AND NAVIGATION ASSEMBLY COMBINATION METER) (a) Disconnect the radio and navigation assembly and combination meter connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Radio and Navigation Assembly Wire Harness View: ILL- F9 Tester connection Condition Specified condition ILL- - ILL- Always Below 1 Ω ILL- - Body ground Always 10 kΩ or higher NG Combination Meter Wire Harness View: F1 NS ILLE129820E02 REPAIR OR REPLACE HARNESS OR CONNECTOR NAVIGATION – NAVIGATION SYSTEM NS–167 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–168 NAVIGATION – NAVIGATION SYSTEM Speaker Circuit DESCRIPTION The sound signal that has been amplified by the stereo component amplifier is sent to the speakers from the stereo component amplifier through this circuit. If there is a short in this circuit, the stereo component amplifier detects it and stops output to the speakers. Thus sound cannot be heard from the speakers even if there is no malfunction in the stereo component amplifier or speakers. WIRING DIAGRAM Stereo Component Amplifier F21 Front No. 2 Speaker LH 1 2 F23 Front No. 2 Speaker RH 1 2 I1 Front No. 1 Speaker LH 1 2 H1 Front No. 1 Speaker RH 1 2 8 F18 FL+ 7 F18 FL- 2 F18 FR+ 6 F18 FR- 2 F20 WFL+ 1 F20 WFL- 9 F20 WFR+ 3 F20 WFR- E126150E08 NS NS–169 NAVIGATION – NAVIGATION SYSTEM Rear Speaker LH 2 WF1+ O14 4 WF1- O14 1 + O14 4 F20 SL+ 10 F20 SL- 3 F18 RL+ 3 9 O14 F18 RL- 2 WF2+ O15 5 F20 SR+ 12 F20 SR- - Rear Speaker RH 4 WF2- O15 1 + O15 3 - O15 10 F18 RR+ 4 F18 RR- E129782E01 NS NS–170 NAVIGATION – NAVIGATION SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (a) Disconnect the connectors shown in the illustration on the left from the stereo component amplifier and speakers. (b) Measure the resistance between each of the front No. 2 speakers and the stereo component amplifier to check for an open circuit in the wire harness. Standard resistance: Below 1 Ω (c) Measure the resistance between each of the rear speakers and the stereo component amplifier to check for an open circuit in the wire harness. Standard resistance: Below 1 Ω (d) Measure the resistance between each of the front No. 1 speakers and the stereo component amplifier to check for an open circuit in the wire harness. Standard resistance: Below 1 Ω (e) Measure the resistance between each speaker and body ground to check for a short circuit in the wire harness. Standard resistance: 10 kΩ or higher Stereo Component Amplifier Wire Harness View: F18 F20 WFR- WFL- RR- SL+ SR+ SRSLWFR+ RL+ FR+ FRRR+ FLWFL+ RL- FL+ Front No. 1 Speaker Connector Front View: I1 H1 Front No. 2 Speaker Connector Front View: NG REPAIR OR REPLACE HARNESS OR CONNECTOR F21 F23 Rear Speaker Connector Front View: O14 O15 NS E129821E04 OK 2 INSPECT FRONT NO. 1 SPEAKER (a) Resistance check. NS–171 NAVIGATION – NAVIGATION SYSTEM (1) Measure the resistance between the terminals of the speaker. Standard resistance: 1.8 to 2.6 Ω NG REPLACE FRONT NO. 1 SPEAKER OK 3 INSPECT FRONT NO. 2 SPEAKER (a) Check that the malfunction disappears when another speaker in good condition is installed. OK: Malfunction disappears. HINT: • Connect all the connectors to the front No. 2 speakers. • When there is a possibility that either the right or left front speaker is defective, inspect by interchanging the right one with the left one. • Perform the above inspection on both LH and RH sides. OK REPLACE FRONT NO. 2 SPEAKER NG 4 INSPECT REAR SPEAKER Woofer (+) Woofer (-) Tweeter (+) Tweeter (-) (a) Woofer speaker: (1) Measure the resistance according to the value(s) in the table below. NOTICE: The speaker should not be removed for checking. Standard resistance Tester connection Condition Specified condition 2-4 Always 1.8 to 2.6 Ω E129809E01 (b) Tweeter speaker: (1) Check that the malfunction disappears when another rear speaker in good condition is installed. OK: Malfunction appears. HINT: • Connect all the connectors to the rear speaker. • When there is a possibility that either the right or left rear speaker is detective, inspect by interchanging the right one with the left one. NG REPLACE REAR SPEAKER NS NS–172 NAVIGATION – NAVIGATION SYSTEM OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–173 NAVIGATION – NAVIGATION SYSTEM Sound Signal Circuit between Radio and Navigation Assembly and Stereo Component Amplifier DESCRIPTION The radio and navigation assembly sends a sound signal to the stereo component amplifier through this circuit. The sound signal that has been sent is amplified by the stereo component amplifier, and then is sent to the speakers. If there is an open or short in the circuit, sound cannot be heard from the speakers even if there is no malfunction in the stereo component amplifier or speakers. WIRING DIAGRAM Radio and Navigation Assembly Stereo Component Amplifier 6 (Sielded) 10 SLD F19 F9 2 F19 19 F9 3 9 F19 F9 4 18 F19 F9 5 R+ F19 8 L- L+ R- F9 SLD L- L+ R- R+ E129783E01 NS NS–174 NAVIGATION – NAVIGATION SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (RADIO AND NAVIGATION ASSEMBLY - STEREO COMPONENT AMPLIFIER) (a) Disconnect the connectors from the radio and navigation assembly and stereo component amplifier. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Radio and Navigation Assembly Wire Harness View: SLD L+ R+ Tester connection Condition Specified condition L+ - L+ Always Below 1 Ω L- R- Always Below 1 Ω Always Below 1 Ω R- - R- Always Below 1 Ω SLD - SLD Always Below 1 Ω L+ - Body ground Always 10 kΩ or higher L- - Body ground Always 10 kΩ or higher R+ - Body ground Always 10 kΩ or higher R- - Body ground Always 10 kΩ or higher F9 Stereo Component Amplifier Wire Harness View: L- - LR+ - R+ NG REPAIR OR REPLACE HARNESS OR CONNECTOR F19 SLD R+ LR- L+ E129822E01 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–175 NAVIGATION – NAVIGATION SYSTEM Sound Signal Circuit between Radio and Navigation Assembly and Stereo Jack Adapter DESCRIPTION The stereo jack adapter sends an external device sound signal to the radio and navigation assembly through this circuit. The sound signal that has been sent is amplified by the stereo component amplifier and then is sent to the speakers. If there is an open or short in the circuit, sound cannot be heard from the speakers even if there is no malfunction in the stereo component amplifier, radio and navigation assembly, or speakers. WIRING DIAGRAM Radio and Navigation Assembly Stereo Jack Adapter 4 AUXO F17 6 F14 ADPG 3 1 ALO F17 F14 VAL+ 2 ARO F17 2 F14 VAR+ 5 3 ASGN F17 F14 VA(Shielded) E129784E01 NS NS–176 NAVIGATION – NAVIGATION SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (RADIO AND NAVIGATION ASSEMBLY - STEREO JACK ADAPTER) (a) Disconnect the connectors from the stereo jack adapter and radio and navigation assembly. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Radio and Navigation Assembly Wire Harness View: F14 VAR+ VAL+ ADPG Stereo Jack Adapter Connector Front View: VA- Tester connection Condition Specified condition AUXO - ADPG Always Below 1 Ω ASGN - VA- Always Below 1 Ω ARO - VAR+ Always Below 1 Ω ALO - VAL+ Always Below 1 Ω AUXO - Body ground Always 10 kΩ or higher ASGN - Body ground Always 10 kΩ or higher ARO - Body ground Always 10 kΩ or higher ALO - Body ground Always 10 kΩ or higher NG REPLACE HARNESS OR CONNECTOR F17 AUXO ALO ARO ASGN E129823E03 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–177 NAVIGATION – NAVIGATION SYSTEM Mute Signal Circuit between Radio and Navigation Assembly and Stereo Component Amplifier DESCRIPTION This circuit sends a signal to the stereo component amplifier to mute noise. Because of that, the noise produced by changing the sound source ceases. If there is an open in the circuit, noise can be heard from the speakers when changing the sound source. If there is a short in the circuit, even though the stereo component amplifier is normal, no sound, or only an extremely small sound, can be produced. WIRING DIAGRAM Stereo Component Amplifier Radio and Navigation Assembly 7 1 MUTE F19 F9 MUTE E110892E20 INSPECTION PROCEDURE 1 INSPECT STEREO COMPONENT AMPLIFIER (a) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness View: F19 MUTE E126155E02 NG Tester connection Condition Specified condition MUTE - Body ground Turn ignition switch on (ACC), Audio system is playing → Changing Above 3.5 V → Below 1 V OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–178 2 NAVIGATION – NAVIGATION SYSTEM CHECK HARNESS AND CONNECTOR (RADIO AND NAVIGATION ASSEMBLY - STEREO COMPONENT AMPLIFIER) (a) Disconnect the radio and navigation assembly connector F9 and stereo component amplifier connector F19. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Radio and Navigation Assembly Wire Harness View: MUTE Stereo Component Amplifier Wire Harness View: F19 MUTE E129822E02 NS Condition Specified condition Always Below 1 Ω MUTE - Body ground Always 10 kΩ or higher NG F9 OK Tester connection MUTE (F9-7) - MUTE (F19-1) REPAIR OR REPLACE HARNESS OR CONNECTOR NS–179 NAVIGATION – NAVIGATION SYSTEM 3 INSPECT STEREO COMPONENT AMPLIFIER (OUTPUT SIGNAL) (a) Reconnect the stereo component amplifier connector F19. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness View: MUTE F9 Tester connection Condition Specified condition MUTE - Body ground Turn ignition switch on (ACC) Audio system is playing Above 3.5 V NG REPLACE STEREO COMPONENT AMPLIFIER E113513E07 OK REPLACE RADIO AND NAVIGATION ASSEMBLY NS NS–180 NAVIGATION – NAVIGATION SYSTEM AVC-LAN Circuit DESCRIPTION Each unit of the navigation system connected to the AVC-LAN (communication bus) transfers the signal of each switch by communication. When a short to +B or short to ground occurs in this AVC-LAN, the navigation system will not function normally as the communication is discontinued. INSPECTION PROCEDURE 1 INSPECT RADIO AND NAVIGATION ASSEMBLY (a) Disconnect the radio and navigation assembly connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness View: Tester connection Condition Specified condition ATX+ (F19-5) ATX- (F19-15) Always 60 to 80 Ω F9 NG REPLACE RADIO AND NAVIGATION ASSEMBLY ATX+ ATXE120099E03 OK 2 CHECK HARNESS AND CONNECTOR HINT: For details of the connectors, refer to "TERMINALS OF ECU" (See page NS-45). (a) Referring to the AVC-LAN wiring diagram below, check all AVC-LAN circuits. (1) Disconnect all connectors in all AVC-LAN circuits. (2) Check for an open or short in all AVC-LAN circuits. NS NS–181 NAVIGATION – NAVIGATION SYSTEM AVC-LAN WIRING DIAGRAM Stereo Component Amplifier (*2) Radio and Navigation Assembly (*1) 8 TX+ F19 5 F9 7 TX- F19 15 F9 ATX- ATX+ *1: Master Unit *2: Slave Unit E111831E09 OK: There is no open or short circuit. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–182 NAVIGATION – NAVIGATION SYSTEM Reverse Signal Circuit DESCRIPTION The radio and navigation assembly receives a reverse signal from the park/neutral position switch and information about the GPS antenna, and then adjusts vehicle position. WIRING DIAGRAM Radio and Navigation Assembly Park/Neutral Position Switch (A/T) 1 2 C1 C1 RB RL (*1) (*2) 2 1 C1 C1 5 F13 REV (A/T) (*1) (*2) C28 Back-up Light Switch (M/T) (M/T) 2 1 From GAUGE No. 1 Fuse *1: 2GR-FE *2: 2AZ-FE E129828E03 INSPECTION PROCEDURE 1 INSPECT RADIO AND NAVIGATION ASSEMBLY (a) Disconnect the radio and navigation assembly connector F13. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness View: REV NS Tester connection Condition Specified condition REV - Body ground Ignition switch on (IG). Shift lever is moved to R position. 10 to 14 V REV - Body ground Ignition switch on (IG). Shift lever is moved to any position except R. Below 1 V F13 OK E113510E06 NG REPLACE RADIO AND NAVIGATION ASSEMBLY NS–183 NAVIGATION – NAVIGATION SYSTEM 2 CHECK HARNESS AND CONNECTOR (a) Disconnect the radio and navigation assembly connector F13 and park/neutral position switch connector C1 or back-up light switch connector C28. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Radio and Navigation Assembly Wire Harness View: REV F13 Tester connection Condition Specified condition REV - C1-1 (*1) Always Below 1 Ω REV - C1-2 (*2) Always Below 1 Ω REV - C28-1 (*3) Always Below 1 Ω REV - Body ground Always 10 kΩ or higher *1: 2AZ-FE, A/T *2: 2GR-FE, A/T *3: M/T NG Park/Neutral Position Switch Connector Front View: REPAIR OR REPLACE HARNESS OR CONNECTOR C1 Back-up Light Switch Connector Front View: C28 NS E129830E02 OK 3 CHECK VEHICLE TYPE (a) Choose type to be inspected. NS–184 NAVIGATION – NAVIGATION SYSTEM Result Type Go to step A/T A M/T B B Go to step 5 A 4 INSPECT PARK/NEUTRAL POSITION SWITCH Park/Neutral Position Switch: C1 (a) Disconnect the park/neutral position switch connector C1. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Condition Specified condition C1-1 - C1-2 Shift lever is moved to R. Below 1 Ω C1-1 - C1-2 Shift lever is moved to any position except R. 10 kΩ or higher E120122E04 NG REPLACE PARK/NEUTRAL POSITION SWITCH OK REPAIR OR REPLACE HARNESS OR CONNECTOR 5 INSPECT BACK-UP LIGHT SWITCH Back-up Light Switch: C28 C28-2 C28-1 (a) Disconnect the buck-up light switch connector C28. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Condition Specified condition C28-1 - C28-2 Shift lever is moved to R. Below 1 Ω C28-1 - C28-2 Shift lever is moved to any position except R. 10 kΩ or higher I045225E02 NG NS OK REPAIR OR REPLACE HARNESS OR CONNECTOR REPLACE BACK-UP LIGHT SWITCH NS–185 NAVIGATION – NAVIGATION SYSTEM Navigation Voice Circuit DESCRIPTION This circuit is used when the voice guidance in the navigation system is on. WIRING DIAGRAM Radio and Navigation Assembly 13 SLD1 F10 Stereo Component Amplifier (Shielded) 12 IVO- F10 22 F19 INT- 11 IVO+ F10 23 F19 INT+ E119672E03 NS NS–186 NAVIGATION – NAVIGATION SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (RADIO AND NAVIGATION ASSEMBLY - STEREO COMPONENT AMPLIFIER) (a) Disconnect the radio and navigation assembly connector F10 and stereo component amplifier connector F19. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Radio and Navigation Assembly Wire Harness View: Tester connection Condition Specified condition IVO+ - INT+ Always Below 1 Ω IVO+ IVO- F10 IVO- - INT- Always Below 1 Ω IVO+ - Body ground Always 10 kΩ or higher IVO- - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR Stereo Component Amplifier Wire Harness View: F19 INT+ INT- E129824E01 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–187 NAVIGATION – NAVIGATION SYSTEM Microphone Circuit between Microphone and Radio and Navigation Assembly DESCRIPTION This circuit sends a microphone signal from the microphone to the radio and navigation assembly. It also supplies power from the radio and navigation assembly to the microphone. WIRING DIAGRAM Radio and Navigation Assembly Microphone 1 2 Q5 (*1) Q12 (*2) MIC- 5 Q5 (*1) 3 Q12 (*2) MI1+ 3 Q5 (*1) 1 Q12 (*2) ACC 17 F12 MACC 9 F12 MIC19 F12 MIC+ 12 (Shielded) (Shielded) (Shielded) F12 TSW18 *1: TMC Made F12 SGND *2: TMMK Made E129785E02 NS NS–188 NAVIGATION – NAVIGATION SYSTEM INSPECTION PROCEDURE 1 INSPECT RADIO AND NAVIGATION ASSEMBLY (a) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness View: Tester connection Condition Specified condition MACC - Body ground Ignition SW on (ACC) 4 to 6 V NG REPLACE RADIO AND NAVIGATION ASSEMBLY F12 MACC E121195E03 OK 2 CHECK HARNESS AND CONNECTOR (a) Disconnect the radio and navigation assembly connector F12. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness View: TSWE113512E03 OK NS Condition Specified condition SGND - TSW- Always Below 1 Ω NG F12 SGND Tester connection REPAIR OR REPLACE HARNESS OR CONNECTOR NS–189 NAVIGATION – NAVIGATION SYSTEM 3 CHECK HARNESS AND CONNECTOR (MICROPHONE - RADIO AND NAVIGATION ASSEMBLY) (a) Disconnect the microphone connector Q5 or Q12 and radio and navigation assembly connector F12. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Microphone Connector Front View (TMC Made): Q5 ACC Tester connection Condition Specified condition ACC - MACC Always Below 1 Ω MI1+ - MIC+ Always Below 1 Ω MIC- - MIC- Always Below 1 Ω MACC - Body ground Always 10 kΩ or higher MIC+ - Body ground Always 10 kΩ or higher MIC- - Body ground Always 10 kΩ or higher MIC- MI1+ NG Microphone Connector Front View (TMMK Made): ACC REPAIR OR REPLACE HARNESS OR CONNECTOR Q12 MI1+ MICRadio and Navigation Assembly Wire Harness View: F12 MICMIC+ MACC E131896E01 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–190 NAVIGATION – NAVIGATION SYSTEM Stereo Component Amplifier Communication Error INSPECTION PROCEDURE 1 IDENTIFY THE COMPONENT SHOWN BY SUB-CODE (a) Enter the diagnostic mode. (b) Press the "LAN Mon" switch to change to "LAN Monitor" mode. (c) Identify the component shown by the sub-code. HINT: • "110 (multi-display)" is the component shown by the sub-code in the example shown in the illustration. • The sub-code will be indicated by its physical address. • For the component list, refer to "DIAGNOSIS DISPLAY DETAILED DESCRIPTION" (See page NS30). Example: DTC Component shown by sub-code E121199E05 NEXT 2 CHECK POWER SOURCE CIRCUIT OF COMPONENT SHOWN BY SUB-CODE (a) Inspect the power source circuit of the component shown by the sub-code. If the power source circuit is operating normally, proceed to the next step. NS Component Table: Component Radio and navigation assembly (140) Proceed to Radio and navigation assembly power source circuit (See page NS-191) NS–191 NAVIGATION – NAVIGATION SYSTEM NEXT 3 CHECK RADIO AND NAVIGATION ASSEMBLY (a) Disconnect the radio and navigation assembly connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness View: Tester connection Condition Specified condition ATX+ (F9-5) ATX- (F9-15) Always 60 to 80 Ω F9 NG REPLACE RADIO AND NAVIGATION ASSEMBLY ATX+ ATXE120099E03 OK 4 CHECK HARNESS AND CONNECTOR (STEREO COMPONENT AMPLIFIER COMPONENT SHOWN BY SUB-CODE) HINT: • Start the check from the circuit that is near the component shown by the sub-code first. • For details of the connectors, refer to "TERMINALS OF ECU" (See page NS-45). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the stereo component amplifier and the component shown by the sub-code. (1) Disconnect all connectors between the stereo component amplifier and the component shown by the sub-code. (2) Check for an open or short in the AVC-LAN circuit between the stereo component amplifier and the component shown by the sub-code. NS NS–192 NAVIGATION – NAVIGATION SYSTEM AVC-LAN WIRING DIAGRAM Stereo Component Amplifier (*2) Radio and Navigation Assembly (*1) 8 TX+ F19 5 F9 7 TX- F19 15 F9 ATX- ATX+ *1: Master Unit *2: Slave Unit E111831E09 OK: There is no open or short circuit. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 5 REPLACE COMPONENT SHOWN BY SUB-CODE (a) Replace the component shown by the sub-code with a normal one and check if the same problem occurs again. OK: Same problem does not occur. NG OK END NS REPLACE STEREO COMPONENT AMPLIFIER NAVIGATION – NAVIGATION SYSTEM NS–193 Radio and Navigation Assembly Communication Error INSPECTION PROCEDURE 1 IDENTIFY THE COMPONENT SHOWN BY SUB-CODE (a) Enter the diagnostic mode. (b) Press the "LAN Mon" switch to change to "LAN Monitor" mode. (c) Identify the component shown by the sub-code. HINT: • "110 (multi-display)" is the component shown by the sub-code in the example shown in the illustration. • The sub-code will be indicated by its physical address. • For the component list, refer to "DIAGNOSIS DISPLAY DETAILED DESCRIPTION" (See page NS30). Example: DTC Component shown by sub-code E121199E05 NEXT 2 CHECK POWER SOURCE CIRCUIT OF COMPONENT SHOWN BY SUB-CODE (a) Inspect the power source circuit of the component shown by the sub-code. If the power source circuit is operating normally, proceed to the next step. Component Table: Component Stereo component amplifier (440) Proceed to Stereo component amplifier power source circuit (See page AV-142) NS NS–194 NAVIGATION – NAVIGATION SYSTEM NEXT 3 CHECK RADIO AND NAVIGATION ASSEMBLY (a) Disconnect the radio and navigation assembly connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness View: Tester connection Condition Specified condition ATX+ (F9-5) ATX- (F9-15) Always 60 to 80 Ω F9 NG REPLACE RADIO AND NAVIGATION ASSEMBLY ATX+ ATXE120099E03 OK 4 CHECK HARNESS AND CONNECTOR HINT: • Start the check from the circuit that is near the component shown by the sub-code first. • For details of the connectors, refer to "TERMINALS OF ECU" (See page NS-45). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the radio and navigation assembly and the component shown by the sub-code. (1) Disconnect all connectors between the radio and navigation assembly and the component shown by the sub-code. (2) Check for an open or short in the AVC-LAN circuit between the radio and navigation assembly and the component shown by the sub-code. NS NS–195 NAVIGATION – NAVIGATION SYSTEM AVC-LAN WIRING DIAGRAM Stereo Component Amplifier (*2) Radio and Navigation Assembly (*1) 8 TX+ F19 5 F9 7 TX- F19 15 F9 ATX- ATX+ *1: Master Unit *2: Slave Unit E111831E09 OK: There is no open or short circuit. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 5 REPLACE COMPONENT SHOWN BY SUB-CODE (a) Replace the component shown by the sub-code with a normal one and check if the same problem occurs again. OK: Same problem does not occur. NG REPLACE RADIO AND NAVIGATION ASSEMBLY OK END NS NS–196 NAVIGATION – NAVIGATION SYSTEM Radio and Navigation Assembly Power Source Circuit DESCRIPTION This is the power source circuit to operate the radio and navigation assembly. WIRING DIAGRAM Radio and Navigation Assembly RADIO NO. 1 from Battery RADIO NO. 2 from ACC Relay 1 F9 B 11 F9 ACC 20 F9 GND E121223E13 NS NS–197 NAVIGATION – NAVIGATION SYSTEM INSPECTION PROCEDURE 1 INSPECT RADIO AND NAVIGATION ASSEMBLY (a) Disconnect the radio and navigation assembly connector F9. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness View: B ACC Tester connection Condition Specified condition GND - Body ground Always Below 1 Ω (c) Measure the voltage according to the value(s) in the table below. Standard voltage GND F9 Tester connection Condition Specified condition B - GND Always 10 to 14 V ACC - GND Ignition SW on (ACC) 10 to 14 V E113513E06 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–193 NAVIGATION – MULTI-DISPLAY MULTI-DISPLAY BODY ELECTRICAL NAVIGATION COMPONENTS INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY NAVIGATION RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH UPPER CONSOLE PANEL SUB-ASSEMBLY NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH for Automatic Transaxle: for Manual Transaxle: SHIFT LEVER KNOB SUB-ASSEMBLY FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY SHIFT LEVER KNOB SUB-ASSEMBLY UPPER CONSOLE PANEL NS UPPER CONSOLE REAR PANEL SUB-ASSEMBLY UPPER CONSOLE REAR PANEL SUB-ASSEMBLY E129204E01 NS–194 NAVIGATION – MULTI-DISPLAY NAVIGATION RECEIVER ASSEMBLY RADIO NO. 2 BRACKET RADIO NO. 1 BRACKET HEATER CONTROL PANEL E129972E01 NS NAVIGATION – MULTI-DISPLAY NS–195 REMOVAL 1. EJECT MAP DISC (a) Turn the ignition switch on (ACC). (b) Push the "CLOSE" button. (c) Touch "MAP EJECT" on the navigation screen to eject the map disc. 2. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-24) 3. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) (See page IP-24) 4. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-24) 5. REMOVE NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-25) 6. REMOVE FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-25) 7. REMOVE UPPER CONSOLE PANEL (for Manual Transaxle) (See page IP-25) 8. REMOVE UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Automatic Transaxle) (See page IP26) 9. REMOVE UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Manual Transaxle) (See page IP-26) 10. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (See page IP-27) 11. REMOVE INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY (See page IP-27) 12. REMOVE NAVIGATION RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY (a) Remove the 4 bolts. (b) Pull the navigation receiver with heater control panel assembly toward the rear of the vehicle and disengage the 4 clips. (c) Disconnect each connector and remove the navigation receiver with heater control panel assembly. NS E129205 NS–196 NAVIGATION – MULTI-DISPLAY 13. REMOVE RADIO NO. 1 BRACKET (a) Remove the 5 bolts and radio No. 1 bracket. E129206 14. REMOVE RADIO NO. 2 BRACKET (a) Remove the 5 bolts and radio No. 2 bracket. E129207 15. REMOVE NAVIGATION RECEIVER ASSEMBLY (a) Remove the navigation receiver assembly as shown in the illustration. E129208 INSTALLATION 1. INSTALL NAVIGATION RECEIVER ASSEMBLY (a) Install the navigation receiver assembly as shown in the illustration. 2. INSTALL RADIO NO. 2 BRACKET (a) Install the radio No. 2 bracket with the 5 bolts. E129209 NS E129207 NAVIGATION – MULTI-DISPLAY NS–197 3. INSTALL RADIO NO. 1 BRACKET (a) Install the radio No. 1 bracket with the 5 bolts. 4. INSTALL NAVIGATION RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY (a) Connect each connector. E129206 (b) Engage the 4 clips. (c) Install the navigation receiver with heater control panel assembly with the 4 bolts. E129205 5. INSTALL INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY (See page IP-52) 6. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (See page IP-52) 7. INSTALL UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Automatic Transaxle) (See page IP53) 8. INSTALL UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Manual Transaxle) (See page IP-53) 9. INSTALL FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-53) 10. INSTALL UPPER CONSOLE PANEL (for Manual Transaxle) (See page IP-54) 11. INSTALL NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-54) 12. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-55) 13. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-55) 14. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) (See page IP-55) 15. INSERT MAP DISC NS NS–198 NAVIGATION – NAVIGATION ANTENNA CORD NAVIGATION ANTENNA CORD BODY ELECTRICAL NAVIGATION COMPONENTS for TMC Made: TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY 2.0 (20, 18 in.*lbf) STEERING COLUMN COVER 50 (510, 37) STEERING WHEEL ASSEMBLY LOWER NO. 2 STEERING WHEEL COVER LOWER NO. 3 STEERING WHEEL COVER 8.8 (90, 78 in.*lbf) NS STEERING PAD N*m (kgf*cm, ft.*lbf) : Specified torque B137279E01 NS–199 NAVIGATION – NAVIGATION ANTENNA CORD for TMMK Made: TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY 2.0 (20, 18 in.*lbf) STEERING COLUMN COVER for 4 Spoke: 50 (510, 37) STEERING WHEEL ASSEMBLY LOWER NO. 2 STEERING WHEEL COVER LOWER NO. 3 STEERING WHEEL COVER STEERING PAD 8.8 (90, 78 in.*lbf) for 3 Spoke: STEERING WHEEL ASSEMBLY 50 (510, 37) LOWER NO. 2 STEERING WHEEL COVER LOWER NO. 3 STEERING WHEEL COVER STEERING PAD NS 8.8 (90, 78 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque B137280E01 NS–200 NAVIGATION – NAVIGATION ANTENNA CORD for TMC Made: COMBINATION METER ASSEMBLY INSTRUMENT CLUSTER FINISH PANEL without Smart Key System: LOWER INSTRUMENT PANEL FINISH PANEL with Smart Key System: NO. 1 INSTRUMENT PANEL SUB-ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL COWL SIDE TRIM SUB-ASSEMBLY LH COWL SIDE TRIM CLIP LOWER INSTRUMENT PANEL FINISH PANEL LH NS FRONT DOOR SCUFF PLATE LH B137281E01 NS–201 NAVIGATION – NAVIGATION ANTENNA CORD for TMMK Made: COMBINATION METER ASSEMBLY without Smart Key System: INSTRUMENT CLUSTER FINISH PANEL LOWER INSTRUMENT PANEL FINISH PANEL with Smart Key System: NO. 1 INSTRUMENT PANEL SUB-ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL COWL SIDE TRIM SUB-ASSEMBLY LH COWL SIDE TRIM CLIP or

LOWER INSTRUMENT PANEL FINISH PANEL LH NS FRONT DOOR SCUFF PLATE LH B137281E03 NS–202 NAVIGATION – NAVIGATION ANTENNA CORD for TMC Made: LOWER INSTRUMENT PANEL SUB-ASSEMBLY or COWL SIDE TRIM SUB-ASSEMBLY RH COWL SIDE TRIM CLIP FRONT DOOR SCUFF PLATE RH INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY B137282E01 NS NAVIGATION – NAVIGATION ANTENNA CORD NS–203 for TMMK Made: LOWER INSTRUMENT PANEL SUB-ASSEMBLY or

COWL SIDE TRIM SUB-ASSEMBLY RH COWL SIDE TRIM CLIP FRONT DOOR SCUFF PLATE RH INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY B137282E03 NS NS–204 NAVIGATION – NAVIGATION ANTENNA CORD NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH for Automatic Transaxle: SHIFT LEVER KNOB SUB-ASSEMBLY FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY UPPER CONSOLE REAR PANEL SUB-ASSEMBLY for Manual Transaxle: SHIFT LEVER KNOB SUB-ASSEMBLY UPPER CONSOLE PANEL UPPER CONSOLE REAR PANEL SUB-ASSEMBLY NS B137283E01 NAVIGATION – NAVIGATION ANTENNA CORD NS–205 INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY NAVIGATION RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY for TMC Made: UPPER CONSOLE PANEL SUB-ASSEMBLY for TMMK Made: UPPER CONSOLE PANEL SUB-ASSEMBLY NS E133838E01 NS–206 NAVIGATION – NAVIGATION ANTENNA CORD for TMC Made: FRONT PILLAR GARNISH CLIP FRONT PILLAR GARNISH CLIP FRONT PILLAR GARNISH RH FRONT PILLAR GARNISH LH INSTRUMENT PANEL NO. 3 REGISTER ASSEMBLY INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY NO. 1 CONSOLE BOX INSERT FRONT NO. 2 CONSOLE BOX INSERT FRONT CONSOLE BOX CARPET NS CONSOLE BOX ASSEMBLY CONSOLE BOX POCKET Non-reusable part B137285E01 NS–207 NAVIGATION – NAVIGATION ANTENNA CORD for TMMK Made: FRONT PILLAR GARNISH CLIP FRONT PILLAR GARNISH CLIP FRONT PILLAR GARNISH RH FRONT PILLAR GARNISH LH INSTRUMENT PANEL NO. 3 REGISTER ASSEMBLY INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY NO. 1 CONSOLE BOX INSERT FRONT or or NO. 2 CONSOLE BOX INSERT FRONT CONSOLE BOX CARPET NS CONSOLE BOX ASSEMBLY CONSOLE BOX POCKET Non-reusable part B137285E03 NS–208 NAVIGATION – NAVIGATION ANTENNA CORD for TMC Made: INSTRUMENT PANEL NO. 1 SPEAKER PANEL SUB-ASSEMBLY INSTRUMENT PANEL NO. 2 SPEAKER PANEL SUB-ASSEMBLY NO. 1 DEFROSTER NOZZLE GARNISH for RH Side: for LH Side: FRONT NO. 2 SPEAKER ASSEMBLY FRONT NO. 2 SPEAKER ASSEMBLY or or or or 20 (204, 15) INSTRUMENT PANEL SAFETY PAD ASSEMBLY NS N*m (kgf*cm, ft.*lbf) : Specified torque B137286E01 NS–209 NAVIGATION – NAVIGATION ANTENNA CORD for TMMK Made: INSTRUMENT PANEL NO. 1 SPEAKER PANEL SUB-ASSEMBLY INSTRUMENT PANEL NO. 2 SPEAKER PANEL SUB-ASSEMBLY NO. 1 DEFROSTER NOZZLE GARNISH for RH Side: for LH Side: FRONT NO. 2 SPEAKER ASSEMBLY FRONT NO. 2 SPEAKER ASSEMBLY , or , or 20 (204, 15) INSTRUMENT PANEL SAFETY PAD ASSEMBLY NS N*m (kgf*cm, ft.*lbf) : Specified torque B137286E03 NS–210 NAVIGATION – NAVIGATION ANTENNA CORD DEFROSTER NOZZLE ASSEMBLY SIDE NO. 2 DEFROSTER NOZZLE DUCT SIDE NO. 1 DEFROSTER NOZZLE DUCT NO. 2 HEATER TO REGISTER DUCT NO. 1 HEATER TO REGISTER DUCT NO. 3 HEATER TO REGISTER DUCT NAVIGATION ANTENNA ASSEMBLY E129932E01 NS NAVIGATION – NAVIGATION ANTENNA CORD NS–211 REMOVAL 1. PRECAUTION (See page IP-1) 2. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment (See page RS-1). 4. REMOVE LOWER NO. 3 STEERING WHEEL COVER (See page RS-349) 5. REMOVE LOWER NO. 2 STEERING WHEEL COVER (See page RS-349) 6. REMOVE STEERING PAD (See page RS-350) 7. REMOVE STEERING WHEEL ASSEMBLY (See page SR-38) 8. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-24) 9. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-25) 10. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (See page IP-20) 11. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (See page IP-21) 12. REMOVE STEERING COLUMN COVER (for TMC Made) (See page IP-21) 13. REMOVE STEERING COLUMN COVER (for TMMK Made) (See page IP-21) 14. REMOVE TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY (See page SR-39) 15. REMOVE NO. 1 INSTRUMENT PANEL SUBASSEMBLY (See page IP-22) 16. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (w/o Smart Key System) (See page IP-22) 17. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (w/ Smart Key System) (See page IP-22) 18. REMOVE INSTRUMENT CLUSTER FINISH PANEL (See page IP-22) 19. REMOVE COMBINATION METER ASSEMBLY (for TMC Made) (See page IP-23) 20. REMOVE COMBINATION METER ASSEMBLY (for TMMK Made) (See page IP-23) 21. REMOVE FRONT DOOR SCUFF PLATE RH (See page IR-26) NS NS–212 NAVIGATION – NAVIGATION ANTENNA CORD 22. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH 23. REMOVE INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY (See page IP-23) 24. REMOVE LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMC Made) (See page IP-23) 25. REMOVE LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMMK Made) (See page IP-24) 26. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-24) 27. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) (See page IP-24) 28. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-24) 29. REMOVE NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-25) 30. REMOVE FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-25) 31. REMOVE UPPER CONSOLE PANEL (for Manual Transaxle) (See page IP-25) 32. REMOVE UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Automatic Transaxle) (See page IP26) 33. REMOVE UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Manual Transaxle) (See page IP-26) 34. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMC Made) (See page IP-27) 35. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMMK Made) (See page IP-27) 36. REMOVE INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY (See page IP-27) 37. REMOVE NAVIGATION RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY (See page NS-195) 38. REMOVE CONSOLE BOX POCKET (See page IP-28) 39. REMOVE CONSOLE BOX CARPET (See page IP-28) 40. REMOVE CONSOLE BOX ASSEMBLY (for TMC Made) (See page IP-28) NS 41. REMOVE CONSOLE BOX ASSEMBLY (for TMMK Made) (See page IP-29) 42. REMOVE NO. 2 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-29) 43. REMOVE NO. 2 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-30) NAVIGATION – NAVIGATION ANTENNA CORD NS–213 44. REMOVE NO. 1 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-30) 45. REMOVE NO. 1 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-30) 46. REMOVE FRONT PILLAR GARNISH LH (See page IR27) 47. REMOVE INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY (See page IP-31) 48. REMOVE INSTRUMENT PANEL NO. 1 SPEAKER PANEL SUB-ASSEMBLY (See page IP-31) 49. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (for LH Side) (See page AV-156) 50. REMOVE FRONT PILLAR GARNISH RH (See page IR27) 51. REMOVE INSTRUMENT PANEL NO. 3 REGISTER ASSEMBLY (See page IP-31) 52. REMOVE INSTRUMENT PANEL NO. 2 SPEAKER PANEL SUB-ASSEMBLY (See page IP-32) 53. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (for RH Side) HINT: Use the same procedures for the RH side and the LH side (See page AV-156). 54. REMOVE NO. 1 DEFROSTER NOZZLE GARNISH (See page IP-32) 55. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY (for TMC Made) (See page IP-32) 56. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY (for TMMK Made) (See page IP-34) 57. REMOVE SIDE NO. 1 DEFROSTER NOZZLE DUCT (for TMC Made) (See page IP-37) 58. REMOVE SIDE NO. 1 DEFROSTER NOZZLE DUCT (for TMMK Made) (See page IP-37) 59. REMOVE SIDE NO. 2 DEFROSTER NOZZLE DUCT (for TMC Made) (See page IP-38) 60. REMOVE SIDE NO. 2 DEFROSTER NOZZLE DUCT (for TMMK Made) (See page IP-38) 61. REMOVE DEFROSTER NOZZLE ASSEMBLY (for TMC Made) (See page IP-38) 62. REMOVE DEFROSTER NOZZLE ASSEMBLY (for TMMK Made) (See page IP-38) 63. REMOVE NO. 1 HEATER TO REGISTER DUCT (for TMC Made) (See page IP-38) 64. REMOVE NO. 1 HEATER TO REGISTER DUCT (for TMMK Made) (See page IP-39) NS NS–214 NAVIGATION – NAVIGATION ANTENNA CORD 65. REMOVE NO. 3 HEATER TO REGISTER DUCT (for TMC Made) (See page IP-39) 66. REMOVE NO. 3 HEATER TO REGISTER DUCT (for TMMK Made) (See page IP-39) 67. REMOVE NO. 2 HEATER TO REGISTER DUCT (for TMC Made) (See page IP-39) 68. REMOVE NO. 2 HEATER TO REGISTER DUCT (for TMMK Made) (See page IP-39) 69. REMOVE NAVIGATION ANTENNA ASSEMBLY (a) Disengage the 3 clamps. (b) Remove the 2 screws and navigation antenna assembly. Clamp E129192E01 INSTALLATION Clamp E129192E01 NS 1. INSTALL NAVIGATION ANTENNA ASSEMBLY (a) Install the navigation antenna assembly with the 2 screws. (b) Engage the 3 clamps. 2. INSTALL NO. 2 HEATER TO REGISTER DUCT (for TMC Made) (See page IP-41) 3. INSTALL NO. 2 HEATER TO REGISTER DUCT (for TMMK Made) (See page IP-41) 4. INSTALL NO. 3 HEATER TO REGISTER DUCT (for TMC Made) (See page IP-41) 5. INSTALL NO. 3 HEATER TO REGISTER DUCT (for TMMK Made) (See page IP-41) 6. INSTALL NO. 1 HEATER TO REGISTER DUCT (for TMC Made) (See page IP-42) 7. INSTALL NO. 1 HEATER TO REGISTER DUCT (for TMMK Made) (See page IP-42) 8. INSTALL DEFROSTER NOZZLE ASSEMBLY (for TMC Made) (See page IP-42) 9. INSTALL DEFROSTER NOZZLE ASSEMBLY (for TMMK Made) (See page IP-42) 10. INSTALL SIDE NO. 2 DEFROSTER NOZZLE DUCT (for TMC Made) (See page IP-42) 11. INSTALL SIDE NO. 2 DEFROSTER NOZZLE DUCT (for TMMK Made) (See page IP-43) 12. INSTALL SIDE NO. 1 DEFROSTER NOZZLE DUCT (for TMC Made) (See page IP-43) NAVIGATION – NAVIGATION ANTENNA CORD NS–215 13. INSTALL SIDE NO. 1 DEFROSTER NOZZLE DUCT (for TMMK Made) (See page IP-43) 14. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY (for TMC Made) (See page IP-44) 15. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY (for TMMK Made) (See page IP-45) 16. INSTALL NO. 1 DEFROSTER NOZZLE GARNISH (See page IP-48) 17. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (for LH Side) (See page AV-156) 18. INSTALL INSTRUMENT PANEL NO. 1 SPEAKER PANEL SUB-ASSEMBLY (See page IP-48) 19. INSTALL INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY (See page IP-48) 20. INSTALL FRONT PILLAR GARNISH LH (See page IR51) 21. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (for RH Side) HINT: Use the same procedures for the RH side and the LH side (See page AV-156). 22. INSTALL INSTRUMENT PANEL NO. 2 SPEAKER PANEL SUB-ASSEMBLY (See page IP-49) 23. INSTALL INSTRUMENT PANEL NO. 3 REGISTER ASSEMBLY (See page IP-49) 24. INSTALL FRONT PILLAR GARNISH RH (See page IR52) 25. INSTALL NO. 1 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-49) 26. INSTALL NO. 1 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-50) 27. INSTALL NO. 2 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-50) 28. INSTALL NO. 2 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-50) 29. INSTALL CONSOLE BOX ASSEMBLY (for TMC Made) (See page IP-51) 30. INSTALL CONSOLE BOX ASSEMBLY (for TMMK Made) (See page IP-51) 31. INSTALL CONSOLE BOX CARPET (See page IP-51) 32. INSTALL CONSOLE BOX POCKET (See page IP-51) 33. INSTALL NAVIGATION RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY (See page NS-196) 34. INSTALL INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY (See page IP-52) NS NS–216 NAVIGATION – NAVIGATION ANTENNA CORD 35. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMC Made) (See page IP-52) 36. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMMK Made) (See page IP-52) 37. INSTALL UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Automatic Transaxle) (See page IP53) 38. INSTALL UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Manual Transaxle) (See page IP-53) 39. INSTALL FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-53) 40. INSTALL UPPER CONSOLE PANEL (for Manual Transaxle) (See page IP-54) 41. INSTALL NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-54) 42. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-55) 43. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-55) 44. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) (See page IP-55) 45. INSTALL LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMC Made) (See page IP-55) 46. INSTALL LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMMK Made) (See page IP-56) 47. INSTALL INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY (See page IP-56) 48. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH (See page IR-55) 49. INSTALL FRONT DOOR SCUFF PLATE RH (See page IR-55) 50. INSTALL COMBINATION METER ASSEMBLY (for TMC Made) (See page IP-56) 51. INSTALL COMBINATION METER ASSEMBLY (for TMMK Made) (See page IP-56) 52. INSTALL INSTRUMENT CLUSTER FINISH PANEL (See page IP-57) NS 53. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/o Smart Key System) (See page IP-57) 54. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/ Smart Key System) (See page IP-57) 55. INSTALL NO. 1 INSTRUMENT PANEL SUBASSEMBLY (See page IP-57) NAVIGATION – NAVIGATION ANTENNA CORD NS–217 56. INSTALL TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY 57. ADJUST SPIRAL CABLE SUB-ASSEMBLY (See page RS-367) 58. INSTALL STEERING COLUMN COVER (for TMC Made) (See page IP-58) 59. INSTALL STEERING COLUMN COVER (for TMMK Made) (See page IP-58) 60. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (See page IP-58) 61. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (See page IP-59) 62. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-54) 63. INSTALL FRONT DOOR SCUFF PLATE LH (See page IR-54) 64. INSTALL STEERING WHEEL ASSEMBLY (See page SR-51) 65. INSTALL STEERING PAD (See page RS-350) 66. INSTALL LOWER NO. 3 STEERING WHEEL COVER (See page RS-351) 67. INSTALL LOWER NO. 2 STEERING WHEEL COVER (See page RS-352) 68. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 69. INSPECT STEERING PAD (See page RS-352) 70. INSPECT SRS WARNING LIGHT (See page RS-32) NS INTRODUCTION – HOW TO USE THIS MANUAL IN–1 HOW TO USE THIS MANUAL GENERAL INFORMATION 1. 2. 3. 4. GENERAL DESCRIPTION (a) This manual is written in accordance with SAE J2008. (1) Diagnosis (2) Removing / Installing, Replacing, Disassembling / Reassembling, Checking and Adjusting (3) Final Inspection (b) The following procedures are omitted from this manual. However, these procedures must be performed. (1) Use a jack or lift to perform operations (2) Clean all removed parts (3) Perform a visual check INDEX (a) An alphabetical INDEX section is provided at the end of the manual as a reference to help you find the item to be repaired. PREPARATION (a) Use of Special Service Tools (SST) and Special Service Materials (SSM) may be required, depending on the repair procedure. Be sure to use SST and SSM when they are required and follow the working procedure properly. A list of SST and SSM is in the "Preparation" section of this manual. REPAIR PROCEDURES (a) A component illustration is placed under the title where necessary. (b) Non-reusable parts, grease application areas, precoated parts and torque specifications are noted in the component illustrations. The following illustration is an example. IN IN–2 INTRODUCTION – HOW TO USE THIS MANUAL Example: Filter Cap Clevis Pin Float Gasket Reservoir Tank IN Washer Grommet Slotted Spring Pin Clip 12 (120,9) Clevis Lock Nut 15 (155,11) Push Rod Cylinder Boot Snap Ring Piston N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part N017080E11 (c) Torque specifications, grease application areas and non-reusable parts are emphasized in the procedures. HINT: There are cases where such information can only be explained by using an illustration. In these cases, torque, oil and other information are described in the illustration. (d) Only items with key points are described in the text. What to do and other details are explained using illustrations next to the text. Both the text and illustrations are accompanied by standard values and notices. Illustration What to do and where to do it Task heading What work will be performed Explanation text How to perform the task Also has information such as specifications and warnings, which are written in boldface text 5. 6. CAUTION (e) Illustrations of similar vehicle models are sometimes used. In these cases, minor details may be different from the actual vehicle. (f) Procedures are presented in a step-by-step format. SERVICE SPECIFICATIONS (a) SPECIFICATIONS are presented in boldface text throughout the manual. The specifications are also found in the "Service Specifications" section for reference. TERM DEFINITIONS Possibility of injury to you or other people. NOTICE Possibility of damage to components being repaired. HINT Provides additional information to help you perform repairs. INTRODUCTION – HOW TO USE THIS MANUAL 7. IN–3 INTERNATIONAL SYSTEM OF UNITS (a) The units used in this manual comply with the International System of Units (SI UNIT) standard. Units from the metric system and the English systems are also provided. Example: Torque: 30 N*m (310 kgf*cm, 22 ft.*lbf) IN IN–4 INTRODUCTION – IDENTIFICATION INFORMATION IDENTIFICATION INFORMATION VEHICLE IDENTIFICATION AND SERIAL NUMBERS A IN 1. VEHICLE IDENTIFICATION NUMBER (a) The vehicle identification number is stamped on the vehicle body and on the certification label, as shown in the illustration. A: Vehicle Identification Number B: Certification Label 2. ENGINE SERIAL NUMBER AND TRANSAXLE SERIAL NUMBER (a) The engine serial number is stamped on the cylinder block of the engine as shown in the illustration. B D100359E02 2AZ-FE: 2GR-FE: D100360E02 INTRODUCTION – IDENTIFICATION INFORMATION A C B B D100373E01 (b) The transaxle serial number is stamped on the housing as shown in the illustration. A: E351E Transaxle Serial Number B: U250E Transaxle Serial Number C: U660E Transaxle Serial Number IN–5 IN IN–6 INTRODUCTION – REPAIR INSTRUCTION REPAIR INSTRUCTION PRECAUTION 1. IN BASIC REPAIR HINT (a) HINTS ON OPERATIONS D025016E01 1 Attire • • 2 Vehicle protection Prepare a grille cover, fender cover, seat cover and floor mat before starting the operation. 3 Safety operation • • • • • Always wear a clean uniform. Hat and safety shoes must be worn. When working with 2 or more persons, be sure to check safety for one another. When working with the engine running, make sure to provide ventilation for exhaust fumes in the workshop. If working on high temperature, high pressure, rotating, moving, or vibrating parts, wear appropriate safety equipment and take extra care not to injure yourself or others. When jacking up the vehicle, be sure to support the specified location with a safety stand. When lifting up the vehicle, use appropriate safety equipment. 4 Preparation of tools and measuring gauge Before starting operation, prepare a tool stand, SST, gauge, oil and parts for replacement. 5 Removal and installation, disassembly and assembly operations • • • • Diagnose with a thorough understanding of proper procedures and of the reported problem. Before removing the parts, check the general condition of the assembly and for deformation and damage. When the assembly is complicated, take notes. For example, note the total number of electrical connections, bolts, or hoses removed. Add matchmarks to insure reassembly of components in the original positions. Temporarily mark hoses and their fittings if needed. Clean and wash the removed parts if necessary and assemble them after a thorough check. IN–7 INTRODUCTION – REPAIR INSTRUCTION 6 Removed parts • • • Place the removed parts in a separate box to avoid mixing them up with the new parts or contaminating the new parts. For non-reusable parts such as gaskets, O-rings, and self-locking nuts, replace them with new ones as instructed in this manual. Retain the removed parts for customer inspection, if requested. (b) JACKING UP AND SUPPORTING VEHICLE (1) Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations. Seal Lock Adhesive Z011554E03 INCORRECT CORRECT (c) PRECOATED PARTS (1) Precoated parts are bolts and nuts that are coated with a seal lock adhesive at the factory. (2) If a precoated part is retightened, loosened or moved in any way, it must be recoated with the specified adhesive. (3) When reusing a precoated part, clean off the old adhesive and dry the part with compressed air. Then apply new seal lock adhesive appropriate to that part. (4) Some seal lock agents harden slowly. You may have to wait for the seal lock adhesive to harden. (d) GASKETS (1) When necessary, use a sealer on gaskets to prevent leaks. (e) BOLTS, NUTS AND SCREWS (1) Carefully follow all the specifications for tightening torques. Always use a torque wrench. (f) FUSES (1) When inspecting a fuse, check that the wire of the fuse is not broken. (2) When replacing fuses, be sure that the new fuse has the correct amperage rating. Do not exceed the rating or use one with a lower rating. V035007E01 Illustration Symbol Part Name Abbreviation FUSE FUSE IN IN–8 Illustration INTRODUCTION – REPAIR INSTRUCTION Symbol Part Name Abbreviation MEDIUM CURRENT FUSE M-FUSE HIGH CURRENT FUSE H-FUSE FUSIBLE LINK FL CIRCUIT BREAKER CB IN (g) CLIPS (1) The removal and installation methods of typical clips used for vehicle body parts are shown in the table below. HINT: If clips are damaged during work, always replace the damaged clip with a new one. INTRODUCTION – REPAIR INSTRUCTION Shape (Example) IN–9 Removal/Installation Remove clips with clip remover or pliers. IN Remove fasteners with clip remover or screwdriver. Remove clips with wide scraper to prevent panel damage. Remove clips by pushing center pin through and prying out shell. IN–10 INTRODUCTION – REPAIR INSTRUCTION Shape (Example) Removal/Installation Remove clips by unscrewing center pin and prying out shell. IN Remove clips by prying out pin and then prying out shell. (h) CLAWS (1) The removal and installation methods of typical claws used for vehicle body parts are shown in the table below. HINT: If claws are damaged during a procedure, always replace the damaged claws with a new caps or covers. Shape (Example) Illustration Procedures 1. Using a screwdriver, detach the claws and remove the cap or covers. 1. Using a screwdriver, detach the claws and remove the cap or covers. INTRODUCTION – REPAIR INSTRUCTION Shape (Example) Illustration IN–11 Procedures 1. Using a screwdriver, detach the claws and remove the cap or covers. IN (i) INCORRECT CORRECT REMOVAL AND INSTALLATION OF VACUUM HOSES (1) To disconnect a vacuum hose, pull and twist from the end of the hose. Do not pull from the middle of the hose as this may damage the hose. D031750E01 (2) When disconnecting vacuum hoses, use tags to identify where they should be reconnected. (3) After completing any hose related repairs, double check that the vacuum hoses are properly connected. The label under the hood shows the proper layout. (4) When using a vacuum gauge, never force the hose onto a connector that is too large. If a hose has been stretched, air may leak. Use a stepdown adapter if necessary. D025064E01 (j) L1 L2 D002612E02 TORQUE WHEN USING TORQUE WRENCH WITH EXTENSION TOOL IN–12 INTRODUCTION – REPAIR INSTRUCTION L1 (1) Use the formula below to calculate special torque values for situations where SST or an extension tool is combined with the torque wrench. Formula: T' = L2/(L1 + L2) * T L2 IN T' D001201E01 Reading of torque wrench {N*m (kgf*cm, ft.*lbf)} T Torque {N*m (kgf*cm, ft.*lbf)} L1 Length of SST or extension tool {cm (in.)} L2 Length of torque wrench {cm (in.)} 2. NOTICE: If an extension tool or SST is combined with a torque wrench and the wrench is used to tighten to a torque specification in this manual, the actual torque will be excessive and parts will be damaged. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER The CAMRY is equipped with a Supplemental Restraint System (SRS). CAUTION: Failure to carry out the service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing and lead to serious injury. Furthermore, if a mistake is made when servicing SRS, it is possible that the SRS may fail to operate properly. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the following section carefully. (a) GENERAL NOTICE (1) As malfunctions of the SRS are difficult to confirm, the Diagnostic Trouble Codes (DTCs) become the most important source of information when troubleshooting. When troubleshooting the SRS, always check the DTCs before disconnecting the battery. INTRODUCTION – REPAIR INSTRUCTION IN–13 (2) Work must be started at least 90 seconds after the ignition switch is turned off and after the cable is disconnected from the negative (-) battery terminal. The SRS is equipped with a back-up power source. If work is started within 90 seconds after turning the ignition switch off and disconnecting the cable from the negative (-) battery terminal, the SRS may deploy. When the cable is disconnected from the negative (-) battery terminal, clock and audio system memory is erased. Before starting work, make a note of the settings of each memory system. When work is finished, reset the clock and audio system as before. CAUTION: Never use a back-up power source (battery or other) to avoid erasing the system memory. The back-up power source may inadvertently power the SRS and cause it to deploy. (3) In minor collisions where the SRS does not deploy, the steering pad, front passenger airbag assembly, driver side knee airbag assembly, front seat side airbag assembly, curtain shield airbag assembly and front seat outer belt assembly should be inspected before further use of the vehicle. (See page RS-352 for steering pad) (See page RS-399 for front passenger airbag assembly) (See page RS-371 for driver side knee airbag assembly) (See page RS-432 for front seat side airbag assembly) (See page RS-426 for curtain shield airbag assembly) (See page SB-23 for front seat outer belt assembly) (4) Never use SRS parts from another vehicle. When replacing parts, use new parts. (5) Before repairs, remove the airbag sensor assemblies if impacts are likely to be applied to the sensor during repairs. (6) Never disassemble and attempt to repair all airbag sensor assemblies and all airbag assemblies. 1. Steering pad 2. Front passenger airbag assembly 3. Driver side knee airbag assembly 4. Front seat side airbag assembly 5. Curtain shield airbag assembly 6. Front seat outer belt assembly IN IN–14 INTRODUCTION – REPAIR INSTRUCTION (7) Replace the airbag sensor assemblies and the airbag assemblies if: 1) damage has occurred from being dropped, or 2) cracks, dents or other defects in the case, bracket or connector are present. (8) Do not directly expose the airbag sensor assembly or airbag assembly to hot air or flames. (9) Use a voltmeter/ohmmeter with high impedance (minimum=10 kΩ) for troubleshooting electrical circuits. (10)Information labels are attached to the SRS components. Follow the instructions on the labels. (11)After work on the SRS is completed, check the SRS warning light. IN Marks C107194E01 (b) SPIRAL CABLE (1) The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position, as cable disconnection and other problems may occur. Refer to the information about correct installation of the steering wheel (See page RS-366). (c) STEERING PAD (1) Always place a removed or new steering pad surface upward as shown in the illustration. Placing the horn button with the pad surface facing down could cause a serious accident if the airbag inflates. Also, do not place anything on top of the horn button. Example: CORRECT INCORRECT D100362E02 INTRODUCTION – REPAIR INSTRUCTION IN–15 (2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury. Example: IN Z013950E02 (3) Grease or detergents of any kind should not be applied to the horn button. (4) Store the horn button assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise. (5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (4 pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring. (6) When disposing of the vehicle or the horn button assembly by itself, the airbag should be deployed using SST before disposal (See page RS-352). Activate the airbag in a safe place away from electrical noise. (d) FRONT PASSENGER AIRBAG ASSEMBLY (1) Always place a removed or new front passenger airbag assembly with the pad surface facing upward as shown in the illustration. Placing the airbag assembly with the airbag inflation direction facing down could cause a serious accident if the airbag inflates. Example: CORRECT INCORRECT D100363E02 IN–16 INTRODUCTION – REPAIR INSTRUCTION (2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury. Example: IN Z013951E02 (3) Grease or detergents of any kind should not be applied to the front passenger airbag assembly. (4) Store the airbag assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise. (5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (4 pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring. (6) When disposing of the vehicle or the airbag assembly unit by itself, the airbag should be deployed using SST before disposal (See page RS-399). Activate the airbag in a safe place away from electrical noise. (e) DRIVER SIDE KNEE AIRBAG ASSEMBLY (1) Always place a removed or new knee airbag assembly with the airbag inflation direction facing upward. Placing the airbag assembly with the airbag inflation direction facing downward could cause a serious accident if the airbag inflates. Example: CORRECT INCORRECT D100364E01 INTRODUCTION – REPAIR INSTRUCTION IN–17 (2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury. Example: IN D030398E01 (f) (3) Grease or detergents of any kind should not be applied to the knee airbag assembly. (4) Store the knee airbag assembly where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise. (5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (2 pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring. (6) When disposing of a vehicle or knee airbag assembly unit by itself, the airbag should be inflated using SST before disposal (See page RS-371). Activate the airbag in a safe place away from electrical noise. FRONT SEAT SIDE AIRBAG ASSEMBLY (1) Always place a removed or new front seat side airbag assembly with the airbag inflation direction facing up. (2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury. Example: D030924E04 (3) Grease or detergents of any kind should not be applied to the front seat side airbag assembly. (4) Store the airbag assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise. IN–18 INTRODUCTION – REPAIR INSTRUCTION (5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (2 pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring. (6) When disposing of a vehicle or the airbag assembly unit by itself, the airbag should be deployed using SST before disposal (See page RS-432). Activate the airbag in a safe place away from electrical noise. (g) CURTAIN SHIELD AIRBAG ASSEMBLY (1) Always place a removed or new curtain shield airbag assembly in a clear plastic bag, and keep it in a safe place. IN Example: CORRECT INCORRECT Clear Plastic Bag D100325E02 CAUTION: The plastic bag is not reusable. NOTICE: Never disassemble the curtain shield airbag assembly. (2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury. Example: D030931E01 (3) Grease or detergents of any kind should not be applied to the curtain shield airbag assembly. (4) Store the airbag assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise. INTRODUCTION – REPAIR INSTRUCTION IN–19 (5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (4 pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring. (6) When disposing of a vehicle or the airbag assembly unit by itself, the airbag should be deployed using SST before disposal (See page RS-426). Activate the airbag in a safe place away from electrical noise. (h) FRONT SEAT OUTER BELT ASSEMBLY AND REAR SEAT OUTER BELT ASSEMBLY (SEAT BELT PRETENSIONER) (1) Never measure the resistance of the seat outer belt. This may cause the pretensioner of the seat belt to activate, which could cause serious injury. Example: D030370E03 (2) Never disassemble the seat outer belt. (3) Never install the seat outer belt on another vehicle. (4) Store the seat outer belt in an area where the ambient temperature is below 80°C (176°F), the humidity is not high and there is no electrical noise. (5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (2 pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring. (6) When disposing of a vehicle or the seat outer belt unit by itself, the seat outer belt should be activated before disposal (See page SB-23). Activate the seat outer belt in a safe place away from electrical noise. (7) As the seat outer belt is hot after being activated, allow some time for it to cool down sufficiently before disposal. Never apply water to cool down the seat outer belt. (8) Grease, detergents, oil or water should not be applied to the front seat outer belt. IN IN–20 INTRODUCTION – REPAIR INSTRUCTION (i) IN (j) 3. Negative (-) Cable Negative (-) Battery Terminal D033608E03 INCORRECT D031751E02 AIRBAG SENSOR ASSEMBLY (1) Never reuse an airbag sensor assembly that has been involved in a collision where the SRS has deployed. (2) The connectors to the airbag sensor assembly should be connected or disconnected with the sensor placed on the floor. If the connectors are connected or disconnected while the airbag sensor assembly is not placed on the floor, the SRS may activate. (3) Work must be started at least 90 seconds after the ignition switch is turned off and the cable is disconnected from the negative (-) battery terminal, even if only loosening the set bolts of the airbag sensor assembly. WIRE HARNESS AND CONNECTOR (1) The SRS wire harness is integrated with the instrument panel wire harness assembly. All the connectors in the system are a standard yellow color. If the SRS wire harness becomes disconnected or the connector becomes broken, repair or replace it. ELECTRONIC CONTROL (a) REMOVAL AND INSTALLATION OF BATTERY TERMINAL NOTICE: Certain systems need to be initialized after reconnecting the cable to the negative (-) battery terminal. (1) Before performing electronic work, disconnect the cable from the negative (-) battery terminal to prevent component and wire damage caused by accidental short circuits. (2) When disconnecting the cable, turn the ignition switch and headlight dimmer switch off and loosen the cable nut completely. Perform these operations without twisting or prying the cable. Then disconnect the cable. (3) Clock settings, radio settings, audio system memory, DTCs and other data are erased when the cable is disconnected from the negative (-) battery terminal. Write down any necessary data before disconnecting the cable. (b) HANDLING OF ELECTRONIC PARTS (1) Do not open the cover or case of the ECU unless absolutely necessary. If the IC terminals are touched, the IC may be rendered inoperative by static electricity. (2) Do not pull the wires when disconnecting electronic connectors. Pull the connector itself. (3) Do not drop electronic components, such as sensors or relays. If they are dropped on a hard surface, they should be replaced. INTRODUCTION – REPAIR INSTRUCTION 4. 5. D001563E01 IN–21 (4) When cleaning the engine with steam, protect the electronic components, air filter and emission-related components from water. (5) Never use an impact wrench to remove or install temperature switches or temperature sensors. (6) When measuring the resistance between terminals of a wire connector, insert the tester probe carefully to prevent terminals from bending. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS (a) PLACE FOR REMOVING AND INSTALLING FUEL SYSTEM PARTS (1) Work in a location with good air ventilation that does not have welders, grinders, drills, electric motors, stoves, or any other ignition sources. (2) Never work in a pit or near a pit as vaporized fuel will collect in those places. (b) REMOVING AND INSTALLING FUEL SYSTEM PARTS (1) Prepare a fire extinguisher before starting the operation. (2) To prevent static electricity, install a ground wire to the fuel changer, vehicle and fuel tank, do not spray the surrounding area with water. Be careful when performing work in this area, as the work surface will become slippery. Do not clean up gasoline spills with water, as this may cause the gasoline to spread, and possibly create a fire hazard. (3) Avoid using electric motors, working lights and other electric equipments that can cause sparks or high temperatures. (4) Avoid using iron hammers as they may create sparks. (5) Dispose of fuel-contaminated cloth separately using a fire resistant container. REMOVAL AND INSTALLATION OF ENGINE INTAKE PARTS (a) If any metal particles enter inlet system parts, this may damage the engine. (b) When removing and installing inlet system parts, cover the openings of the removed parts and engine openings. Use gummed tape or other suitable materials. (c) When installing inlet system parts, check that no metal particles have entered the engine or the installed parts. IN IN–22 INTRODUCTION – REPAIR INSTRUCTION Spring Type Clamp 6. HANDLING OF HOSE CLAMPS (a) Before removing the hose, check the clamp position so that it can be reinstalled in the same position. (b) Replace any deformed or dented clamps with new ones. (c) When reusing a hose, attach the clamp on the clamp track portion of the hose. (d) For a spring type clamp, you may want to spread the tabs slightly after installation by pushing in the direction of the arrows as shown in the illustration. 7. FOR VEHICLES EQUIPPED WITH MOBILE COMMUNICATION SYSTEMS (a) Install the antenna far away from the ECU and sensors of the vehicle electronic systems as possible. (b) Install an antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the vehicle electronic systems. For details about ECU and sensors locations, refer to the section on the applicable components. (c) Keep the antenna and feeder separate from other wirings as much as possible. This will prevent signals sent from the communication equipment from affecting vehicle equipment and vice-versa. (d) Check that the antenna and feeder are correctly adjusted. (e) Do not install any high-powered mobile communication system. FOR VEHICLES EQUIPPED WITH TRACTION CONTROL (TRAC) AND VEHICLE STABILITY CONTROL (VSC) SYSTEMS When testing with a 2-wheel drum tester such as a speedometer tester, a combination tester for the speedometer and brake, a chassis dynamometer, or when jacking up the front wheels and turning the wheels, perform the following procedure to enter the inspection mode and stop the TRAC and VSC systems. (a) Activating inspection mode (Not using the intelligent tester) HINT: • Perform procedures "D" to "J" within 30 seconds. • Perform procedures "G" and "H" within 15 seconds each. (1) Ensure that the ignition switch is off and the engine is stopped (Procedure "A"). (2) Make sure that the shift lever is in the P position (Procedure "B"). (3) Start the engine (Procedure "C"). (4) Parking Brake Lever Type: Apply the parking brake by pulling the parking brake lever (Procedure "D"). IN Clamp Track B107182E01 D020025E01 8. INTRODUCTION – REPAIR INSTRUCTION IN–23 (5) Parking Brake Pedal Type: Apply the parking brake by depressing the parking brake pedal (Procedure "E"). (6) Depress and release the brake pedal twice (Procedure "F"). (7) While holding the brake pedal down, release and apply the parking brake twice (Procedure "G"). (8) With the parking brake applied, depress and release the brake pedal twice (Procedure "H"). (9) without Multi-information Display: Check that the VSC warning light and SLIP indicator light come on (Procedure "I"). HINT: • If the VSC warning light and SLIP indicator light do not come on in procedure "I", repeat the procedures from "A" to "I". • Turning the ignition switch off ends inspection mode. without Multi-information Display: VSC Warning Light SLIP Indicator Light D100379E01 with Multi-information Display: SLIP Indicator Light Multi-information Display D100380E02 (10)with Multi-information Display: Check that the "CHECK VSC SYSTEM" message appears on the multi-information display and SLIP indicator light come on (Procedure "J"). HINT: • If the "CHECK VSC SYSTEM" message appears on the multi-information display and SLIP indicator light do not come on in procedure "J", repeat the procedures from "A" to "J". • Turning the ignition switch off ends inspection mode. (b) Activating inspection mode (Using the intelligent tester) (1) Ensure that the ignition switch is off and the engine is stopped (Procedure "A"). (2) Make sure that the shift lever is in the P position (Procedure "B"). (3) Connect the intelligent tester to the DLC3 (Procedure "C"). (4) Start the engine (Procedure "D"). (5) Turn the intelligent tester main switch on (Procedure "E"). (6) Select the following menu items: ABS/ INSPECTION MODE (Procedure "F"). IN IN–24 INTRODUCTION – REPAIR INSTRUCTION (7) without Multi-information Display: Check that the VSC warning light and SLIP indicator light come on (Procedure "G"). HINT: • If the VSC warning light and SLIP indicator light do not come on in procedure "G", repeat the procedures from "A" to "G". • Turning the ignition switch off ends inspection mode. without Multi-information Display: IN VSC Warning Light SLIP Indicator Light D100379E01 with Multi-information Display: SLIP Indicator Light 9. Multi-information Display D100380E02 (8) with Multi-information Display: Check that the "CHECK VSC SYSTEM" message appears on the multi-information display and SLIP indicator light come on (Procedure "H"). HINT: • If the "CHECK VSC SYSTEM" message appears on the multi-information display and SLIP indicator light do not come on in procedure "H", repeat the procedures from "A" to "H". • Turning the ignition switch off ends inspection mode. FOR VEHICLES EQUIPPED WITH CATALYTIC CONVERTER CAUTION: If a large amount of unburned gasoline or gasoline vapors flow into the converter, it may cause overheating and create a fire hazard. To prevent this, observe the following precautions. (a) Use only unleaded gasoline. (b) Avoid idling the engine for more than 20 minutes. (c) Avoid performing unnecessary spark jump tests. (1) Perform a spark jump test only when absolutely necessary. Perform this test as rapidly as possible. (2) While testing, never race the engine. (d) Avoid a prolonged engine compression measurement. Engine compression measurements must be performed as rapidly as possible. (e) Do not run the engine when the fuel tank is nearly empty. This may cause the engine to misfire and create an extra load on the converter. INTRODUCTION – REPAIR INSTRUCTION IN–25 VEHICLE LIFT AND SUPPORT LOCATIONS 1. 2. 3. Rubber Attachment D025082E01 NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP (a) As a rule, the vehicle must be unloaded when jacking up. Never jack up or lift up the vehicle loaded with things of heavy weight. (b) When removing any parts of heavy weight like the engine and transaxle, the center of gravity of the vehicle moves. Place a balance weight so as to keep it from rolling, or hold the jacking support location using the mission jack. NOTICE FOR USING 4 POST LIFT (a) Follow the instruction manual for a safety operation. (b) Do not damage tires or wheels with a free wheel beam. (c) Using a wheel stopper, fix the vehicle. NOTICE FOR USING JACK AND SAFETY STAND (a) Work in the flat place using a wheel stopper at all times. (b) Use a safety stand with a rubber attachment, as shown in the illustration. (c) Support the specified location with a jack and safety stand accurately. (d) When jacking up the front wheels, release the parking brake and place wheel stoppers only behind the rear wheels. When jacking up the rear wheels, place wheel stoppers only in front of the front wheels. (e) Do not work or leave the vehicle supported only by a jack. Be sure to support the vehicle with a safety stand. (f) When jacking up only the front wheels or only the rear wheels, place wheel stoppers to both sides of the wheels that contact ground. IN IN–26 INTRODUCTION – REPAIR INSTRUCTION (g) When jacking down the vehicle with its front wheels jacked up, release the parking brake and place wheel stoppers only in front of the rear wheels. When jacking down the vehicle with its rear wheels jacked up, place wheel stoppers only behind the front wheels. IN : JACK POSITION : SUPPORT POSITION, PANTOGRAPH JACK POSITION : CENTER OF VEHICLE GRAVITY (unloaded condition) D100366E01 4. NOTICE FOR USING SWING ARM TYPE LIFT (a) Follow the instruction manual of the lift for a safety operation. (b) Use a cradle with a rubber attachment, as shown in the illustration. (c) Set in the vehicle so as to make its center of gravity as close as possible to the center of the lift. (d) Place the vehicle horizontally by adjusting the height of the cradle, and match the groove of the cradle and the safety stand support location accurately. (e) Be sure to lock the swing arm during the operation. (f) Lift the vehicle up until the tires float, and shake the vehicle to make sure that the vehicle is stable. INTRODUCTION – REPAIR INSTRUCTION 5. IN–27 NOTICE FOR USING PLATE TYPE LIFT (a) Follow the instruction manual of the lift for a safety operation. (b) Use a plate lift attachment. (c) Be sure to set the vehicle to the specified position. Right and left set position • Place the vehicle over the center of the lift. Front and rear set position • Align the cushion gum ends of the plate with the attachment lower ends (A and C). Align the attachment upper end (B) with the rocker flange front side notch. • (d) Lift the vehicle up until the tires float a bit, and shake the vehicle to make sure that the vehicle is stable. IN IN–28 INTRODUCTION – REPAIR INSTRUCTION Center of Lift IN Swing Arm Type Lift: CENTER OF VEHICLE GRAVITY (unloaded condition) Rubber Attachment Plate Type Lift: Attachment Dimensions 85 mm (3.35 in.) B A Attachment 70 mm (2.76 in.) C 100 mm (3.94 in.) 200 mm (7.87 in.) D100367E01 IN–29 INTRODUCTION – REPAIR INSTRUCTION CUSTOMIZE PARAMETERS 1. AIR CONDITIONING SYSTEM HINT: The following items can be customized. NOTICE: • When the customer requests a change in a function, first make sure that the function can be customized. • Be sure to make a note of the current settings before customizing. • When troubleshooting a function, first make sure that the function is set to the default setting. AIR CONDITIONER (AUTO A/C) DISPLAY (ITEM) DEFAULT CONTENTS SETTING NORMAL To shift the temperature against the displayed temperature +2 C / +1 C / NORMAL / -1 C / -2 C AIR INLET MODE (Air Inlet Mode) AUTO In case of turning the A/C ON when you desire to make the compartment cool down quickly, this is the function to change the mode automatically to RECIRCULATION mode MANUAL / AUTO COMPRESSOR MODE (Compressor Mode) AUTO Function to turn the A/C ON automatically by pressing the AUTO button when the blower is ON and the A/C is OFF MANUAL / AUTO COMPRS / DEF OPER (Compressor / Air Inlet DEF Operation) LINK Function to turn the A/C ON automatically linked with the FRONT DEF button when the A/C is OFF NORMAL / LINK EVAP CTRL (Evaporator Control) AUTO Function to set the evaporator control to the AUTOMATIC position (AUTO) to save power, or to the coldest position (MANUAL) to dehumidify the air and to prevent the windows from fogging up MANUAL / AUTO FOOT / DEF MODE (Foot / DEF auto mode) ON Function to turn the airflow from FOOT / DEF ON automatically when AUTO MODE is ON OFF / ON AUTO BLOW UP (Foot / DEF automatic blower up function) ON Function to change the blower level automatically when the defroster is ON OFF / ON AMBIENT TMP SFT (Ambient Temperature Shift) NORMAL SET TEMP SHIFT (Set Temperature Shift) Function to shift the ambient temperature against the displayed ambient temperature 2. +3 C / +2 C / +1 C / NORMAL / -1 C / -2 C / -3 C THEFT DETERRENT SYSTEM (w/o Smart Key System) HINT: The following items can be customized. NOTICE: • After confirming whether the items requested by the customer are applicable or not for customization, perform customizing operations. • Be sure to record the current settings before customization. • When troubleshooting, make sure that the item in question is not set to "OFF" as a result of customization (Example: For the system, "the wireless function does not operate", first check that the wireless function is not set to "OFF", then perform troubleshooting). IN IN–30 INTRODUCTION – REPAIR INSTRUCTION THEFT DETERRENT SYSTEM DISPLAY (ITEM) IN DEFAULT CONTENTS SETTING PASSIVE MODE (Passive Arming Mode) OFF PASSIVE MODE is a function that switches theft deterrent system from arming preparation state to armed state 30 seconds after key is not in the key cylinder and all doors, engine hood and luggage compartment door are closed, even if doors are not locked by wireless or door key lock operation In PASSIVE MODE, if you do not perform following operations within 14 seconds after door is opened during armed state, theft deterrent system will judge that condition as a theft and switch to alarm sounding state – Unlock any door by key or wireless operation – Turn the ignition switch ON – Open luggage compartment door by key or wireless operation ON/OFF WARN BY HORN (Warning by horn) ON Function that makes vehicle horn and theft deterrent horn be able to be used as a warning device ON/OFF ENTRY DELAY (Entry delay time) 14 s Function that changes entry delay time (time before warning starts) for PASSIVE MODE 0 s/14 s/30 s 3. THEFT DETERRENT SYSTEM (w/ Smart Key System) HINT: The following items can be customized. NOTICE: • After confirming whether the items requested by the customer are applicable or not for customization, perform customizing operations. • Be sure to record the current settings before customization. • When troubleshooting, make sure that the item in question is not set to "OFF" as a result of customization (Example: For the system, "the wireless function does not operate", first check that the wireless function is not set to "OFF", then perform troubleshooting). THEFT DETERRENT SYSTEM DISPLAY (ITEM) DEFAULT CONTENTS SETTING PASSIVE MODE (Passive Arming Mode) OFF PASSIVE MODE is a function that switches theft deterrent system from arming preparation state to armed state 30 seconds after key is not in the actuation area and all doors, engine hood and luggage compartment door are closed, even if doors are not locked by wireless or door key lock operation In PASSIVE MODE, if you do not perform following operations within 14 seconds after door is opened during armed state, theft deterrent system will judge that condition as a theft and switch to alarm sounding state – Unlock any door by key or wireless operation – Turn the engine switch on (IG) – Open luggage compartment door by key or wireless operation ON/OFF WARN BY HORN (Warning by horn) ON Function that makes vehicle horn and theft deterrent horn be able to be used as a warning device ON/OFF ENTRY DELAY (Entry delay time) 14 s Function that changes entry delay time (time before warning starts) for PASSIVE MODE 0 s/14 s/30 s 4. LIGHTING SYSTEM HINT: The followings are the possible items to be customized. IN–31 INTRODUCTION – REPAIR INSTRUCTION NOTICE: • Before attempting to customize vehicle settings, confirm whether it is possible to make the change that the customer has requested. • Be sure to record the current value before customizing. • In case of performing the troubleshooting, pay attention because there is a possibility that the function has been disabled by customizing. (Example: In case of the symptom in which "The wireless operation does not function", check that the wireless operation has not been disabled by customizing, then perform the troubleshooting.) ILLUMINATED ENTRY: Display Default Contents Setting LIGHTING TIME 15 s Changes the lighting time of the interior light and ignition key cylinder light. I/L ON / UNLOCK ON Lights up the interior light and ignition key cylinder light when a door is unlocked. ON / OFF ON Lights up the interior light and ignition key cylinder light when the ignition switch is turned from on (ACC) to off ON / OFF I/L ON / ACC OFF 7.5 s / 15 s / 30 s LIGHT CONTROL: Display Default Contents Setting LIGHT OFF DELAY 30 s Keeps the headlights on for a certain period of time after turning the ignition switch off and closing all the doors with the headlights on. OFF / 30 s / 60 s / 90 s SENSITIVITY NORMAL Adjusts the sensitivity of the automatic light control system. *1 LIGHT 2 / LIGHT 1 / NORMAL / DARK 1 / DARK 2 DISP EX ON SEN NORMAL Changes the ambient brightness level required to dim the clock display illumination. *1 LIGHT 2 / LIGHT 1 / NORMAL / DARK 1 / DARK 2 NORMAL Changes the ambient brightness level required to cancel the dimming of the clock display illumination. LIGHT 2 / LIGHT 1 / NORMAL / DARK 1 / DARK 2 DISP EX OFF SEN HINT: Sensitivity adjustment can hardly be confirmed. Check by driving the customer's vehicle. Illustration *1 Ambient Brightness Level Setting Dark Bright DARK2 DARK1 5. NORMAL LIGHT1 LIGHT2 POWER DOOR LOCK CONTROL SYSTEM CUSTOMIZING FUNCTION WITH INTELLIGENT TESTER HINT: The following items can be customized. IN IN–32 INTRODUCTION – REPAIR INSTRUCTION NOTICE: • Before attempting to customize vehicle settings, confirm whether it is possible to make the change that the customer has requested. • Be sure to record the current settings before customizing. • When troubleshooting, make sure that the item in question has not been disabled using the customizing function. IN DOOR LOCK: Display (Item) Default Contents Setting UNLOCK/PARK (Unlock w/ engine switch on (IG), shift P, speed 0 km/h (0 mph)) A/T: ON M/T: OFF (Cannot be changed) Function that unlocks doors when the shift lever is moved to the P position from any other position while the ignition switch is on (IG) ON/OFF ALL UNLK/OPN-CL (All unlock w/ D door open-close) A/T: OFF M/T: ON Function that unlocks all other doors when opening driver side door within 10 seconds after turning the ignition switch off from on (IG) ON/OFF • Function that unlocks only the driver side door when the driver side door key cylinder is turned to unlock once and unlocks all the doors when it is turned to unlock twice In the OFF setting, turning it once unlocks all doors ON/OFF A/T: ON M/T: OFF (Cannot be changed) Function that locks doors when the shift lever is moved from the P position to any other position ON/OFF OFF Function that locks doors when vehicle reaches a vehicle speed 20 km/h (13 mph) ON/OFF UNLK/KEY TWICE (Unlock w/ 2 times D key operation) ON • AUTO LOCK/SHIFT (Auto lock/shift not P) AUTO LOCK WIRELESS D LOCK: Display (Item) AUTO LOCK DELAY Default Contents Function that selects AUTO LOCK time (30 sec. or 60 sec.) 60s 6. Setting 30s/60s WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) HINT: The following items can be customized. NOTICE: • When the customer requests a change in a function, first make sure that customization of the function(s) is possible. • Be sure to record the current settings before customizing. • When troubleshooting a function, first make sure that the function is not set to OFF. WIRELESS DOOR LOCK CONTROL SYSTEM Display (item) Default WIRELESS OPER (Wireless door lock control function) ON Function Function that turns wireless door lock function ON/OFF Setting ON/OFF IN–33 INTRODUCTION – REPAIR INSTRUCTION Display (item) Default • Function Setting When the doors are locked by wireless operation, the hazard warning lights flash once. When the doors are unlocked by wireless operation, the hazard warning lights flash twice. ON/OFF HAZARD ANS BACK (Hazard answer-back for wireless door lock control) ON OPEN DOOR WARN (Door ajar warning) ON The buzzer sounds when LOCK is pressed when any of the doors are ajar. ON/OFF AUTO LOCK DELAY (Auto lock time) 60 s This function regulates the interval between unlocking and automatic relocking of doors. 30 s/60 s UNLOCK /2OPER (Wireless unlock operated twice) ON This function unlocks the driver's door when the UNLOCK switch is pressed once, and unlocks all doors when pressed twice within 3 seconds. If set to OFF, pressing UNLOCK once unlocks all doors. ON/OFF ALARM FUNCTION (Panic function) ON This function operates the theft deterrent system when PANIC is pressed and held for 0.8 seconds. ON/OFF WIRLS BUZZ RESP (Wireless buzzer answer-back) ON Wireless door lock buzzer response/ON or OFF ON/OFF 0.6 s PR ON This function changes operation method of transmitter to open luggage compartment door. 1 TIME: Push 1 time 2 TIMES: Push 2 times 0.6 s PR: Push 0.6 seconds OFF: Does not operate 1 TIME/2 TIMES/0.6 s PR/ OFF TRUNK LID OPER (Wireless trunk opener function setting) • 7. WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) HINT: The following items can be customized. NOTICE: • When the customer requests a change in a function, first make sure that customization of the function(s) is possible. • Be sure to record the current settings before customizing. • When troubleshooting a function, first make sure that the function is not set to OFF. WIRELESS DOOR LOCK CONTROL SYSTEM: Display (item) Default WIRELESS OPER (Wireless door lock control function) ON Function Function that turns wireless door lock function ON/OFF • Setting ON/OFF When the doors are locked by wireless operation, the hazard warning lights flash once. When the doors are unlocked by wireless operation, the hazard warning lights flash twice. ON/OFF HAZARD ANS BACK (Hazard answer-back for wireless door lock control) ON OPEN DOOR WARN (Door ajar warning) ON The buzzer sounds when LOCK is pressed when any of the doors are ajar. ON/OFF AUTO LOCK DELAY (Auto lock time) 60 s This function regulates the interval between unlocking and automatic relocking of doors. 30 s/60 s • IN IN–34 INTRODUCTION – REPAIR INSTRUCTION Display (item) IN Default Function Setting UNLOCK /2OPER (Wireless unlock operated twice) ON This function unlocks the driver's door when the UNLOCK switch is pressed once, and unlocks all doors when pressed twice within 3 seconds. If set to OFF, pressing UNLOCK once unlocks all doors. ALARM FUNCTION (Panic function) ON This function operates the theft deterrent system when PANIC is pressed and held for 0.8 seconds. ON/OFF WIRLS BUZZ RESP (Wireless buzzer answer-back) ON Wireless door lock buzzer response/ON or OFF ON/OFF 0.6 s ON This function changes operation method of transmitter to open luggage compartment door. 1 TIME: Push 1 time 2 TIMES: Push 2 times 0.6 s PR: Push 0.6 seconds OFF: Does not operate 1 TIME/2 TIMES/0.6 s PR/ OFF TRUNK LID OPER (Wireless trunk opener function setting) 8. ON/OFF SMART KEY SYSTEM (Door Lock) (a) CUSTOMIZING FUNCTION WITH INTELLIGENT TESTER HINT: The items in the table below can be customized. NOTICE: • When the customer requests a change in a function, first make sure that the function can be customized. • Be sure to make a note of the current setting before customizing. • When troubleshooting a function, first make sure that the function is set to the default setting. HINT: The following functions' default settings are ON. Part of these functions can be customized. SMART: Display (Item) Default Contents Setting PARK WAIT TIME (Wait time to permit opening door after locking) 2.5s Function that sets waiting time to permit opening door after door is locked with entry lock function. 0.5s / 1.5s / 2.5s / 5.0s SMART UNLOCK D_DOOR Function that switches the entry unlock detection area. ALL / D_DOOR SMART IGNITION (SMART ignition available area) ALL Function to choose the available area for electrical key to start E/G and cancel the steering lock. FRONT / ALL SMART TRUNK (Luggage compartment opening operation) ON Function to open a luggage compartment when the driver has the electrical key and presses the luggage open button. ON / OFF WIRELESS DOOR LOCK: Display (Item) ALARM FUNCTION (Panic function) Default ON Contents Function to operate the theft deterrent system by keeping pressing the lock button of the transmitter for 2.5 seconds. If there is a panic button, press the panic button instead of the lock button. Setting ON / OFF IN–35 INTRODUCTION – REPAIR INSTRUCTION WARNING: Display (Item) KEY LOW-BATT WRN Default ON Contents Function to set a warning function for the time when a key battery becomes weak. Setting ON / OFF (b) Entry Unlock Mode Switching Function (1) To change the vehicle to entry unlock mode switching function, make sure the vehicle power is off and simultaneously press and hold the electrical key's LOCK switch and another electrical key switch for 4.5 seconds. When the switches are pressed and held for 4.5seconds, the entry door unlock mode changes in the following order: driver door mode, all door mode. NOTICE: After pressing and holding the switches for 4.5 seconds, wait 5 seconds before performing the same procedure again. • Driver door unlock mode: When the driver door's touch sensor is touched, only the driver door unlocks. When another touch sensor is touched, all doors unlock. • All door unlock mode: When the touch sensor is touched, all doors unlock. (2) The certification ECU receives this signal from the entry door control receiver and changes the smart key system to the entry unlock mode. IN IN–36 INTRODUCTION – REPAIR INSTRUCTION (3) The certification ECU sounds the buzzers of the wireless door lock buzzer and combination meter to inform the user that the mode has been switched. IN Combination Meter Wireless Door Lock Buzzer Multi-information Display Mode Driver Door (Default) Passenger, rear LH and RH door “open” indication ON OFF Sounds 3 times All Doors (Customized) Buzzer Sounds once Displayed for 5 sec. All door “open” indication ON OFF Sounds 2 times Displayed for 5 sec. Sounds once Multi-information dispaly B137954E01 HINT: The function only changes the entry unlock mode of the smart key system. It does not switch the unlocking of the wireless door lock control. (c) Electrical Key Cancel The electrical key cancel operation disables the following functions: • Entry Ignition • Entry Unlock/Lock • Entry Luggage Compartment Open • Electrical Key Lock-in Prevention • Warning IN–37 INTRODUCTION – REPAIR INSTRUCTION 9. • Memory Call (1) The operation procedures are as follows: Precondition: Engine switch off, driver side door closed and unlocked. 1. Unlock the driver side door once with the UNLOCK switch of the electrical key. 2. Open the driver door within 5 seconds. 3. Unlock the driver side door twice with the UNLOCK switch of the electrical key within 5 seconds. 4. Repeat open → close twice for the driver door within 30 seconds, and open again. (Driver door: Open → Close → Open → Close → Open) 5. Unlock the driver side door twice with the UNLOCK switch of the electrical key within 5 seconds. 6. Repeat open → close once for the driver door within 30 seconds, and open again. (Driver door: Open → Close → Open) 7. Close the driver door within 5 seconds. When electrical key cancel is activated, the wireless door lock buzzer sounds twice. To return to the original condition, perform the procedures again. When the original condition is returned, the wireless door lock buzzer sounds once. KEY REMINDER WARNING SYSTEM PARAMETERS (USING INTELLIGENT TESTER) HINT: The following items can be customized. NOTICE: • Be sure to record current values before customizing. • When performing troubleshooting, be aware that the functions may be set to OFF by customizing. (Example: In case of the symptom in which "The wireless operation does not function", check that the wireless operation is not set to OFF by customizing, then perform the troubleshooting.) METER: Display (Item) Default Contents Setting KEY REMND VOLUM LARGE Function to change volume of the key reminder warning buzzer. LARGE/MEDIUM/SMALL KEY REMND SOUND NORMAL Function to change cycle of the key reminder warning buzzer. FAST/NORMAL/SLOW 10. METER/GAUGE SYSTEM COMBINATION METER ASSEMBLY NOTICE: Be sure to record the current value before customizing. IN IN–38 INTRODUCTION – REPAIR INSTRUCTION HINT: The following items can be customized using intelligent tester. METER: Display (Item) IN Default Contents Setting KEY REMND VOLUM LARGE Function to change the volume of the key remind warning buzzer LARGE, MEDIUM, SMALL KEY REMND SOUND NORMAL Function to change the cycle of the key remind warning buzzer FAST, NORMAL, SLOW SEAT-BELT WARN D/P ON Function to change the setting of the seat belt buzzer. D/P on, D ON, P on, D/P off HINT: This setting is only valid for the buzzer which sounds at the 5 km/h (3 mph) or more. (a) SEAT BELT BUZZER ON/OFF SETTING (Procedure "A") The seat belt buzzer ON/OFF setting, which is a setting of the buzzer function of the combination meter, can disable the driver and front passenger side seat belt buzzers. NOTICE: • These buzzers should be on for safe driving. Perform these procedures only if it is necessary to set the buzzer off (disabled). • When either the battery cable or the combination meter connector is disconnected, these buzzers are set on (enabled). • Odometer returns to 0 after starting this procedure, although it is not displayed. HINT: "b-oFF" indicates that the buzzer is OFF. "b-on" indicates that the buzzer is ON. The seat belt buzzer ON/OFF setting will be finished (the odometer will display "ODO") if the ODO/TRIP switch is not operated for 10 seconds or more. In this case, perform step 11 to check that the buzzer ON/OFF setting is complete. If it is not complete, start from step 1 again. (1) Driver and front passenger side seat belt buzzers 1. Turn the ignition switch on (IG). 2. Press the ODO/TRIP switch until the odometer displays "ODO". 3. Ignition switch off. 4. Turn the ignition switch on (IG). 5. Press the ODO/TRIP switch immediately (within 6 seconds) and hold it down for 10 seconds or more. 6. Continue holding down the ODO/TRIP switch and fasten the driver side seat belt. 7. Check that the odometer displays either "bon" or "b-oFF". 8. Press the ODO/TRIP switch to change the display to "b-oFF". INTRODUCTION – REPAIR INSTRUCTION IN–39 9. Ignition switch off. 10.Turn the ignition switch on (IG). 11.Check that no buzzer sounds. (2) Front passenger side seat belt buzzer 1. Turn the ignition switch on (IG). 2. Press the ODO/TRIP switch until the odometer displays "ODO". 3. Ignition switch off. 4. Turn the ignition switch on (IG). 5. Sit in the front passenger seat. Press the ODO/TRIP switch immediately (within 6 seconds) and hold it down for 10 seconds or more. 6. Sit in the front passenger seat. Continue holding down the ODO/TRIP switch and fasten the front passenger side seat belt. 7. Check that the odometer displays either "bon" or "b-oFF". 8. Press the ODO/TRIP switch to change the display to "b-oFF". 9. Ignition switch off. 10.Turn the ignition switch on (IG). 11.Check that no buzzer sounds. IN IN–40 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS GENERAL INFORMATION IN A large number of ECU controlled systems are used in the CAMRY. In general, ECU controlled systems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures only involve inspecting the ECU controlled system's circuits one by one. An adequate understanding of the system and a basic knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and necessary repairs. FOR USING INTELLIGENT TESTER – Before using the intelligent tester, read the tester operator's manual thoroughly. – If the tester cannot communicate with the ECU controlled systems when the tester is connected to the DLC3 with the ignition switch on and the tester turned on, there is a problem on the vehicle side or tester side. (1)If communication is normal when the tester is connected to another vehicle, inspect the diagnosis data link line (Bus (+) line) or ECU power circuit of the vehicle. (2)If communication is still not possible when the tester is connected to another vehicle, the problem is probably in the tester itself. Perform the Self Test procedures outlined in the tester operator's manual. INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN–41 ELECTRONIC CIRCUIT INSPECTION PROCEDURE 1. INCORRECT INCORRECT CORRECT D032092E01 Looseness of Crimping Core Wire Terminal Deformation Pull Lightly D025087E03 BASIC INSPECTION (a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS (1) Unless otherwise stated, all resistance measurements should be made at an ambient temperature of 20°C (68°F). Resistance measurements may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down. (b) HANDLING CONNECTORS (1) When disconnecting a connector, first squeeze the mating connector housing halves tightly together to release the lock, and then press the lock claw and separate the connector. (2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it. (3) Before connecting a connector, check that there are no deformations, damage, looseness or missing terminals. (4) When connecting a connector, press firmly until it locks with a "click" sound. (5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside (harness side) using a mini test lead. NOTICE: • As a waterproof connector cannot be checked from the backside, check it by connecting a sub-harness. • Do not damage the terminals by moving the inserted tester needle. (c) CHECKING CONNECTORS (1) Checking when a connector is disconnected: Squeeze the connector together to confirm that they are fully connected and locked. (2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the backside of the connector. Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or deformed terminals. IN IN–42 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS (3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, and check for ample tension when inserting and after full engagement. NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal. IN D025088E02 (d) REPAIR METHOD OF CONNECTOR TERMINAL (1) If there is any foreign matter on the terminal, clean the contact point with compressed air or a cloth. Never rub the contact point using sandpaper as the plating may come off. (2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is goldplated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal. (3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock into the housing, the housing may have to be replaced. INCORRECT CORRECT D032093E01 INCORRECT (e) HANDLING OF WIRE HARNESS (1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be restored in the same way. (2) Never twist, pull or slacken the wire harness more than necessary. (3) The wire harness should never come into contact with a high temperature part, or rotating, moving, vibrating or sharp-edged parts. Avoid contact with panel edges, screw tips and other sharp items. (4) When installing parts, never pinch the wire harness. (5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with vinyl tape. INCORRECT INCORRECT D101266E01 Fig. 1 ECU B C OPEN 1 1 2 2 A 1 2 1 2 SENSOR Z017004E02 2. CHECK FOR OPEN CIRCUIT (a) For an open circuit in the wire harness in Fig. 1, the resistance or voltage, as described below. INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Fig. 2 ECU 1 1 1 2 2 2 SENSOR C A B Z017005E02 IN–43 (b) Check the resistance. (1) Disconnect connectors A and C and measure the resistance between the terminals of the connectors. Standard resistance (Fig. 2) Tester Connection Specified Condition Connector A terminal 1 - Connector C terminal 1 10 kΩ or higher Connector A terminal 2 - Connector C terminal 2 Below 1 Ω HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. Fig. 3 ECU SENSOR (2) Disconnect connector B and measure the resistance between the terminals of the connectors. Standard resistance (Fig. 3) Tester Connection 1 2 1 2 C 1 1 2 B2 2 A B1 B004722E03 Fig. 4 ECU 5V SENSOR 0 V 1 2 C 5V 1 2 2 B 1 2 A Z017007E02 Specified Condition Connector A terminal 1 - Connector B1 terminal 1 Below 1 Ω Connector B2 terminal 2 - Connector C terminal 2 10 kΩ or higher If the results match the examples above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. (c) Check the voltage. (1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. With each connector still connected, measure the voltage between the body ground and these terminals (in this order): 1) terminal 1 of connector A, 2) terminal 1 of connector B, and 3) terminal 1 of connector C. Standard voltage (Fig. 4) Tester Connection Specified Condition Connector A terminal 1 - Body ground 5V Connector B terminal 1 - Body ground 5V Connector C terminal 1 - Body ground Below 1 V If the results match the examples above, an open circuit exists in the wire harness between terminal 1 of connector B and terminal 1 of connector C. IN IN–44 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Fig. 5 ECU SHORT 1 2 IN 1 1 2 2 CHECK FOR SHORT CIRCUIT (a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance check with the body ground (below). A B C 3. Z017008E02 (b) Check the resistance with the body ground. (1) Disconnect connectors A and C and measure the resistance. Standard resistance (Fig. 6) Fig. 6 ECU SENSOR Tester Connection 1 1 2 2 C 1 2 A B Specified Condition Connector A terminal 1 - Body ground Below 1 Ω Connector A terminal 2 - Body ground 10 kΩ or higher Z017009E02 HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. If your results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. (2) Disconnect connector B and measure the resistance. Standard resistance (Fig. 7) Fig. 7 Tester Connection ECU SENSOR 1 2 C 1 2 B2 1 2 B1 1 2 Specified Condition Connector A terminal 1 - Body ground 10 kΩ or higher Connector B2 terminal 2 - Body ground Below 1 Ω A Z017808E02 4. If the results match the examples above, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. CHECK AND REPLACE ECU NOTICE: • The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side. • When no measuring condition is specified, perform the inspection with the engine stopped and the ignition switch on. • Check that the connectors are fully seated. Check for loose, corroded or broken wires. INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Example: Ground IN00383E02 ECU Side Wire Harness Side W/H Side Ground Ground IN00384E03 IN–45 (a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Temporarily replace the ECU with a normally functioning one and check if the symptoms occur. If the trouble symptoms disappear, replace the original ECU. (1) Measure the resistance between the ECU ground terminal and body ground. Standard resistance: Below 1 Ω (2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness side for bending, corrosion or foreign matter. Lastly, check the contact pressure of the female terminals. IN IN–46 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS HOW TO PROCEED WITH TROUBLESHOOTING 1. IN 1 OPERATION FLOW HINT: Perform troubleshooting in accordance with the procedures below. The following is an outline of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are working on before beginning troubleshooting. VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS (a) Ask the customer about the conditions and environment when the problem occurred. NEXT 3 INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT 4 SYMPTOM CONFIRMATION AND DTC (AND FREEZE FRAME DATA) CHECK (a) Visually check the wire harnesses, connectors and fuses for open and short circuits. (b) Warm up the engine to the normal operating temperature. (c) Confirm the problem symptoms and conditions, and check for DTCs Result Result Proceed to DTC is output A DTC is not output B B A Go to step 6 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 5 IN–47 DTC CHART (a) Check the results obtained in step 4. Then find the output DTC in the DTC chart. Look at the "Trouble Area" column for a list of potentially malfunctioning circuits and/ or parts. NEXT 6 Go to step 7 PROBLEM SYMPTOMS CHART (a) Check the results obtained in step 4. Then find the problem symptoms in the problem symptoms table. Look at the "Suspected Area" column for a list of potentially malfunctioning circuits and/or parts. NEXT 7 CIRCUIT INSPECTION OR PARTS INSPECTION (a) Identify the malfunctioning circuit or part. NEXT 8 ADJUST, REPAIR OR REPLACE (a) Adjust, repair or replace the malfunctioning circuit or parts. NEXT 9 CONFIRMATION TEST (a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the malfunction does not reoccur, perform a confirmation test under the same conditions and in the same environment as when the malfunction occurred the first time. NEXT END 2. CUSTOMER PROBLEM ANALYSIS IN IN–48 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS HINT: • In troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time the malfunction occurred. • Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases. • The following 5 items are important points in the problem analysis: IN What Vehicle model, system name When Date, time, occurrence frequency Where Road conditions Under what conditions? Running conditions, driving conditions, weather conditions How did it happen? Problem symptoms 3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT: The diagnostic system in the CAMRY has various functions. • The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a previous malfunction's DTC can be checked by a technician during troubleshooting. • Another function is the Input Signal Check, which checks if the signals from various switches are sent to the ECU correctly. By using these functions, the problem areas can be narrowed down and troubleshooting is more effective. Diagnostic functions are incorporated in the following system in the CAMRY. Data List Active Test { { { { { { { { { { { { { { System DTC Check (Normal Mode) DTC Check (Check Mode) Sensor Check/Test Mode (Input Signal Check) 2AZ-FE SFI System { 2GR-FE SFI System { Smart Key System (Starting) { U250E Automatic Transaxle System { U660E Automatic Transaxle System { Tire Pressure Warning System { { { Anti-lock Brake System { { { { Vehicle Stability Control System (for BOSCH made) { { { { INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Sensor Check/Test Mode (Input Signal Check) Data List Active Test { { { { { { { { { System DTC Check (Normal Mode) Vehicle Stability Control System (for ADVICS made) { Electric Steering Lock Air Conditioning System Airbag System { Occupant Classification System { DTC Check (Check Mode) { { { { Seat Belt Warning System Theft Deterrent System (w/ Smart Key System) { { Theft Deterrent System (w/o Smart Key System) { { Engine Immobilizer System (w/ Smart Key System) { { { Engine Immobilizer System (w/o Smart Key System) { { { Cruise Control System { { Lighting System { { { Power Door Lock Control System { { { Wireless Door Lock Control System (w/ Smart Key System) { { { Wireless Door Lock Control System (w/o Smart Key System) { { { Smart Key System (Door Lock) { { { { { { { { { Key Reminder Warning System Meter/Gauge System { Audio and Visual System { Navigation System { Power Window Control System { { Window Defogger System Sliding Roof System { { { IN–49 IN IN–50 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS • In the DTC check, it is very important to determine whether the problem indicated by the DTC either: 1) still occurs, or 2) occurred in the past but has returned to normal. In addition, the DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine current system conditions, as shown in the flowchart below. • Never skip the DTC check. Failing to check DTCs may, depending on the case, result in unnecessary troubleshooting for systems operating normally or lead to repairs not related to the problem. Follow the procedures listed in the flowchart in the correct order. • The following flowchart shows how to proceed with troubleshooting using the DTC check. Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the troubleshooting of each problem symptom. IN 1 DTC CHECK NEXT 2 MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY NEXT 3 SYMPTOM CONFIRMATION Result Result Proceed to No symptoms exist A Symptoms exist B B Go to step 5 A 4 SIMULATION TEST USING SYMPTOM SIMULATION METHODS NEXT 5 DTC CHECK Result Result Proceed to DTC is not output A INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Result Proceed to DTC is output B B IN–51 TROUBLESHOOTING OF PROBLEM INDICATED BY DTC IN A 6 SYMPTOM CONFIRMATION Result Result Proceed to No symptoms exist A Symptoms exist B If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness or connector in that circuit in the past. Check the wire harness and connectors. B SYSTEM NORMAL A TROUBLESHOOTING OF EACH PROBLEM SYMPTOM The problem still occurs in a place other than the diagnostic circuit (the DTC displayed first is either for a past problem or a secondary problem). 4. SYMPTOM SIMULATION HINT: The most difficult case in troubleshooting is when no problem symptoms occur. In such a case, a thorough problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked and mistakes or delays. For example: With a problem that only occurs when the engine is cold or as a result of vibration caused by the road during driving, the problem can never be determined if the symptoms are being checked on a stationary vehicle or a vehicle with a warmed-up engine. Vibration, heat or water penetration (moisture) are difficult to reproduce. The symptom simulation tests below are effective substitutes for the conditions and can be applied to a stationary vehicle. Important points in the symptom simulation test: IN–52 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes. IN Vibrate Slightly Shake Slightly Vibrate Slightly B071602E03 D025085E02 (a) VIBRATION METHOD: When a malfunction seems to occur as a result of vibration. (1) PART AND SENSOR Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the problem, and check whether the malfunction occurs. NOTICE: Applying strong vibration to relays may open relays. (2) CONNECTORS Slightly shake the connector vertically and horizontally. (3) WIRE HARNESS Slightly shake the wire harness vertically and horizontally. HINT: The connector joint and fulcrum of the vibration are the major areas that should be checked thoroughly. (b) HEAT METHOD: When a malfunction seems to occur when the area in question is heated. (1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar device. Check if the malfunction occurs. NOTICE: • Do not heat to more than 60°C (140°F). Exceeding this temperature may damage the components. • Do not apply heat directly to the parts in the ECU. (c) WATER SPRINKLING METHOD: When a malfunction seems to occur on a rainy day or in high-humidity. (1) Sprinkle water onto the vehicle and check if the malfunction occurs. NOTICE: • Never sprinkle water directly into the engine compartment. Indirectly change the temperature and humidity by spraying water onto the front of the radiator. • Never apply water directly onto the electronic components. INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN–53 HINT: If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water tests. AUTO B107149 (d) HIGH ELECTRICAL LOAD METHOD: When a malfunction seems to occur when an electrical load is excessive. (1) Turn on the heater blower, headlight, rear window defogger and all other electrical loads. Check if the malfunction reoccurs. 5. DIAGNOSTIC TROUBLE CODE CHART Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the proper inspection procedure. A description of each of the chart's columns is shown in the table below. Item Description DTC No. Indicates the diagnostic trouble code Detection Item Indicates the system or details of the problem Trouble Area Indicates the suspected areas of the problem See Page Indicates the page where the inspection procedures for each circuit is to be found, or gives instruction for checking and repairs. 6. PROBLEM SYMPTOMS TABLE When a "Normal" code is output during a DTC check but the problem still occurs, use the Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptoms are in the table. The suspected areas are listed in order of probability. A description of each of the chart's columns is shown in the table below. HINT: In some cases, the problem is not detected by the diagnostic system even though a problem symptom occurs. It is possible that the problem occurs outside the detection range of the diagnostic system, or that the problem occurs in a completely different system. Item Description Problem Symptom - Circuit Inspection, Inspection Order Indicates the order in which the circuits need to be checked Circuit or Part Name Indicates the circuit or part which needs to be checked See Page Indicates the page where the flowchart for each circuit is located 7. CIRCUIT INSPECTION A description of the main areas of each circuit inspection is shown in the table below. Item Description Circuit Description The major role, operation of the circuit and its component parts are explained. Diagnostic Trouble Code No. and Detection Item Indicates the diagnostic trouble codes, diagnostic trouble code settings and suspected areas for a problem IN IN–54 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Item Description Wiring Diagram This shows a wiring diagram of the circuit. Use this diagram together with ELECTRICAL WIRING DIAGRAM to thoroughly understand the circuit. Wire colors are indicated by an alphabetical code. B = Black, L = Blue, R = Red, BR = Brown, LG = Light Green, V = Violet, G = Green, O = Orange, W = White, GR = Gray, P = Pink, Y = Yellow, SB = Sky Blue The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Inspection Procedures Use the inspection procedures to determine if the circuit is normal or abnormal. If abnormal, use the inspection procedures to determine whether the problem is located in the sensors, actuators, wire harnesses or ECU. Indicates the condition of the connector of the ECU during the check Connector being checked is connected. Connections of tester are indicated by (+) or (-) after the terminal name. Connector being checked is disconnected. The inspections between a connector and body ground, information about the body ground is not shown in the illustration. IN IN–54 INTRODUCTION – TERMS TERMS ABBREVIATIONS USED IN MANUAL Abbreviations IN ABS Meaning Anti-Lock Brake System A/C Air Conditioner AC Alternating Current ACC Accessory ACIS Acoustic Control Induction System ACM Active Control Engine Mount ACSD Automatic Cold Start Device A.D.D Automatic Disconnecting Differential A/F Air-Fuel Ratio AHC Active Height Control Suspension ALR Automatic Locking Retractor ALT Alternator AMP Amplifier ANT Antenna APPROX. Approximately ASSY Assembly A/T, ATM Automatic Transmission (Transaxle) ATF Automatic Transmission Fluid AUTO Automatic AUX Auxiliary AVG Average AVS Adaptive Variable Suspension AWD All Wheel Drive Vehicle B+ Battery Voltage BA Brake Assist BACS Boost Altitude Compensation System BAT Battery BDC Bottom Dead Center B/L Bi-Level B/S Bore-Stroke Ratio BTDC Before Top Dead Center BVSV Bimetallic Vacuum Switching Valve CAN Controller Area Network CB Circuit Breaker CCo Catalytic Converter For Oxidation CCV Canister Closed Valve CD Compact Disc CF Cornering Force CG Center of Gravity CH Channel CKD Complete Knock Down COMB. Combination CPE Coupe CPS Combustion Pressure Sensor CPU Central Processing Unit CRS Child Restraint System IN–55 INTRODUCTION – TERMS Abbreviations Meaning CTR Center C/V Check Valve CV Control Valve CW Curb Weight DC Direct Current DEF Defogger DFL Deflector DIFF. Differential DIFF. LOCK Differential Lock D/INJ Direct Injection DLC Data Link Connector DLI Distributorless Ignition DOHC Double Overhead Camshaft DP Dash Pot DS Dead Soak DSP Digital Signal Processor DTC Diagnostic Trouble Code DVD Digital Versatile Disc EBD Electric Brake Force Distribution EC Electrochromic ECAM Engine Control And Measurement System ECD Electronically Controlled Diesel ECDY Eddy Current Dynamometer ECT Electronic Controlled Automatic Transmission ECU Electronic Control Unit ED Electro-Deposited Coating EDU Electronic Driving Unit EDIC Electric Diesel Injection Control EFI Electronic Fuel Injection E/G Engine EGR Exhaust Gas Recirculation EGR-VM EGR-Vacuum Modulator ELR Emergency Locking Retractor EPS Electric Power Steering ENG Engine ES Easy & Smooth ESA Electronic Spark Advance ETCS-i Electronic Throttle Control System-intelligent EVAP Evaporative Emission Control EVP Evaporator E-VRV Electric Vacuum Regulating Valve EX Exhaust FE Fuel Economy FF Front-Engine-Front-Wheel-Drive F/G Fuel Gauge FIPG Formed In Place Gasket FL Fusible Link F/P Fuel Pump FPU Fuel Pressure Up IN IN–56 INTRODUCTION – TERMS Abbreviations FR IN Meaning Front F/W Flywheel FW/D Flywheel Damper FWD Front-Wheel-Drive GAS Gasoline GND Ground GPS Global Positioning System GSA Gear Shift Actuator HAC High Altitude Compensator H/B Hatchback H-FUSE High Current Fuse HI High HID High Intensity Discharge (Headlight) HPU Hydraulic Power Unit HSG Housing HT Hard Top HV Hybrid Vehicle HWS Heated Windshield System IC Integrated Circuit IDI Indirect Diesel Injection IFS Independent Front Suspension IG Ignition IIA Integrated Ignition Assembly IN Intake (Manifold, Valve) INT Intermittent I/P Instrument Panel IRS Independent Rear Suspension ISC Idle Speed Control J/B Junction Block J/C Junction Connector KD Kick-Down LAN Local Area Network LB Liftback LCD Liquid Crystal Display LED Light Emitting Diode LH Left-Hand LHD Left-Hand Drive LIN Local Interconnect Network L/H/W Length, Height, Width LLC Long-Life Coolant LNG Liquefied Natural Gas LO Low LPG Liquefied Petroleum Gas LSD Limited Slip Differential LSP & BV Load Sensing Proportioning and Bypass Valve LSPV Load Sensing Proportioning Valve MAP Manifold Absolute Pressure MAX. Maximum MIC Microphone IN–57 INTRODUCTION – TERMS Abbreviations Meaning MIL Malfunction Indicator Lamp MIN. Minimum MG1 Motor Generator No. 1 MG2 Motor Generator No. 2 MMT Multi-mode Manual Transmission MP Multipurpose MPI Multipoint Electronic Injection MPX Multiplex Communication System M/T, MTM Manual Transmission (Transaxle) MT Mount MTG Mounting N Neutral NA Natural Aspiration NO. Number O2S Oxygen Sensor OC Oxidation Catalyst OCV Oil Control Valve O/D Overdrive OEM Original Equipment Manufacturing OHC Overhead Camshaft OHV Overhead Valve OPT Option ORVR On-board Refilling Vapor Recovery O/S Oversize P & BV Proportioning and Bypass Valve PBD Power Back Door PCS Power Control System PCV Positive Crankcase Ventilation PKB Parking Brake PPS Progressive Power Steering PROM Programmable Read Only Memory PS Power Steering PSD Power Slide Door PTC Positive Temperature Coefficient PTO Power Take-Off PZEV Partial Zero Emission Vehicle P/W Power Window R&P Rack and Pinion RAM Random Access Memory R/B Relay Block RBS Recirculating Ball Type Steering R/F Reinforcement RFS Rigid Front Suspension RH Right-Hand RHD Right-Hand Drive RLY Relay ROM Read Only Memory RR Rear RRS Rigid Rear Suspension IN IN–58 INTRODUCTION – TERMS Abbreviations RSE IN Meaning Rear Seat Entertainment RWD Rear-Wheel Drive SC Supercharger SCV Swirl Control Valve SDN Sedan SEN Sensor SICS Starting Injection Control System SOC State Of Charge SOHC Single Overhead Camshaft SPEC Specification SPI Single Point Injection SRS Supplemental Restraint System SSM Special Service Materials SST Special Service Tools STD Standard STJ Cold-Start Fuel Injection SW Switch SYS System T/A Transaxle TACH Tachometer TBI Throttle Body Electronic Fuel Injection TC Turbocharger TCCS TOYOTA Computer-Controlled System TCM Transmission Control Module TCV Timing Control Valve TDC Top Dead Center TEMP. Temperature TFT TOYOTA Free-Tronic TIS Total Information System for Vehicle Development T/M Transmission TMC TOYOTA Motor Corporation TMMIN PT. TOYOTA Motor Manufacturing Indonesia TMMK TOYOTA Motor Manufacturing Kentucky, Inc. TMT TOYOTA Motor Thailand Co. Ltd. TRAC/TRC Traction Control System TURBO Turbocharge TVIP TOYOTA Vehicle Instruction Protection TWC Three-Way Catalyst U/D Underdrive U/S Undersize VCV Vacuum Control Valve VDIM Vehicle Dynamics Integrated Management VENT Ventilator VIM Vehicle Interface Module VGRS Variable Gear Ratio Steering VIN Vehicle Identification Number VPS Variable Power Steering VSC Vehicle Skid Control VSV Vacuum Switching Valve IN–59 INTRODUCTION – TERMS Abbreviations Meaning VTV Vacuum Transmitting Valve VVT-i Variable Valve Timing-intelligent W/ With WGN Wagon W/H Wire Harness W/O Without 1ST First 2ND Second 2WD Two Wheel Drive Vehicle (4 x 2) 3RD Third 4TH Fourth 4WD Four Wheel Drive Vehicle (4 x 4) 4WS Four Wheel Steering System 5TH Fifth IN IN–60 INTRODUCTION – TERMS GLOSSARY OF SAE AND TOYOTA TERMS This glossary lists all SAE-J1930 terms and abbreviations used in this manual in compliance with SAE recommendations, as well as their TOYOTA equivalents. IN SAE ABBREVIATIONS A/C TOYOTA TERMS ( )-ABBREVIATIONS SAE TERMS Air Conditioning Air Conditioner ACL Air Cleaner Air Cleaner, A/CL AIR Secondary Air Injection Air Injection (AI) AP Accelerator Pedal - B+ Battery Positive Voltage +B, Battery Voltage BARO Barometric Pressure HAC CAC Charge Air Cooler Intercooler CARB Carburetor Carburetor CFI Continuous Fuel Injection - CKP Crankshaft Position Crank Angle CL Closed Loop Closed Loop CMP Camshaft Position Cam Angle CPP Clutch Pedal Position - CTOX Continuous Trap Oxidizer - CTP Closed Throttle Position LL ON, Idle ON DFI Direct Fuel Injection Direct Injection (DI./INJ) DI Distributor Ignition - DLC3 Data Link Connector 3 OBD II Diagnostic Connector DTC Diagnostic Trouble Code Diagnostic Trouble Code DTM Diagnostic Test Mode - ECL Engine Coolant Level - ECM Engine Control Module Engine Electronic Control Unit (ECU) ECT Engine Coolant Temperature Coolant Temperature, Water Temperature (THW) EEPROM Electrically Erasable Programmable Read Only Memory Electrically Erasable Programmable Read Only Memory (EEPROM), Erasable Programmable Read Only Memory (EPROM) EFE Early Fuel Evaporation Cold Mixture Heater (CMH), Heat Control Valve (HCV) EGR Exhaust Gas Recirculation Exhaust Gas Recirculation (EGR) EI Electronic Ignition Distributorless Ignition (DLI) EM Engine Modification Engine Modification (EM) EPROM Erasable Programmable Read Only Memory Programmable Read Only Memory (PROM) EVAP Evaporative Emission Evaporative Emission Control (EVAP) FC Fan Control - FEEPROM Flash Electrically Erasable Programmable Read Only Memory - FEPROM Flash Erasable Programmable Read Only Memory - FF Flexible Fuel - FP Fuel Pump Fuel Pump GEN Generator Alternator GND Ground Ground (GND) HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO2S) IAC Idle Air Control Idle Speed Control (ISC) IAT Intake Air Temperature Intake or Inlet Air Temperature ICM Ignition Control Module - IN–61 INTRODUCTION – TERMS SAE ABBREVIATIONS TOYOTA TERMS ( )-ABBREVIATIONS SAE TERMS IFI Indirect Fuel Injection Indirect Injection (IDL) IFS Inertia Fuel-Shutoff - ISC Idle Speed Control - KS Knock Sensor Knock Sensor MAF Mass Airflow Air Flow Meter MAP Manifold Absolute Pressure Manifold Pressure Intake Vacuum MC Mixture Control Electric Bleed Air Control Valve (EBCV) Mixture Control Valve (MCV) Electric Air Control Valve (EACV) MDP Manifold Differential Pressure - MFI Multiport Fuel Injection Electronic Fuel Injection (EFI) MIL Malfunction Indicator Light Check Engine Light MST Manifold Surface Temperature - MVZ Manifold Vacuum Zone - NVRAM Non-Volatile Random Access Memory - O2S Oxygen Sensor Oxygen Sensor, O2 Sensor (O2S) OBD On-Board Diagnostic On-Board Diagnostic System (OBD) OC Oxidation Catalytic Converter Oxidation Catalytic Convert (OC), CCo OL Open Loop Open Loop PAIR Pulsed Secondary Air Injection Air Suction (AS) PCM Powertrain Control Module - PNP Park/Neutral Position - PROM Programmable Read Only Memory - PSP Power Steering Pressure - PTOX Periodic Trap Oxidizer Diesel Particulate Filter (DPF) Diesel Particulate Trap (DPT) RAM Random Access Memory Random Access Memory (RAM) RM Relay Module - ROM Read Only Memory Read Only Memory (ROM) RPM Engine Speed Engine Speed SC Supercharger Supercharger SCB Supercharger Bypass E-ABV SFI Sequential Multiport Fuel Injection Electronic Fuel Injection (EFI), Sequential Injection SPL Smoke Puff Limiter - SRI Service Reminder Indicator - SRT System Readiness Test - ST Scan Tool - TB Throttle Body Throttle Body TBI Throttle Body Fuel Injection Single Point Injection Central Fuel Injection (Ci) TC Turbocharger Turbocharger TCC Torque Converter Clutch Torque Converter TCM Transmission Control Module Transmission ECU, ECT ECU TP Throttle Position Throttle Position TR Transmission Range - TVV Thermal Vacuum Valve Bimetallic Vacuum Switching Valve (BVSV) Thermostatic Vacuum Switching Valve (TVSV) TWC Three-Way Catalytic Converter Three-Way Catalytic (TWC) Manifold Converter CCRO IN IN–62 INTRODUCTION – TERMS SAE ABBREVIATIONS IN TOYOTA TERMS ( )-ABBREVIATIONS SAE TERMS TWC+OC Three-Way + Oxidation Catalytic Converter CCR + CCo VAF Volume Airflow Air Flow Meter VR Voltage Regulator Voltage Regulator VSS Vehicle Speed Sensor Vehicle Speed Sensor WOT Wide Open Throttle Full Throttle WU-OC Warm Up Oxidation Catalytic Converter - WU-TWC Warm Up Three-Way Catalytic Converter - 3GR Third Gear - 4GR Fourth Gear - 2GR-FE INTAKE – INTAKE AIR CONTROL SYSTEM IT–1 INTAKE AIR CONTROL SYSTEM 2GR-FE INTAKE ENGINE PARTS LOCATION INTAKE AIR CONTROL VALVE IT AIR CLEANER CASE SUB-ASSEMBLY VACUUM SWITCHING VALVE A135658E03 IT–2 2GR-FE INTAKE – INTAKE AIR CONTROL SYSTEM SYSTEM DIAGRAM ECM 20 B45 VTA1 23 B45 VC 19 B45 VTA2 G-R Y L-B B30 Throttle Body Assembly 6 VTA 5 4 VC VTA2 5 B45 M+ 4 B45 M- B M+ 2 W M- 1 (*1) 3 E2 B10 Mass Air Flow Meter THA BR 2 W 3 1 W-R 4 +B VG IT 22 B45 THA 29 B45 E2G 30 B45 VG W-L E2 E2G 17 B45 GE01 R B18 VSV (ACIS) 5 W 33 B45 ACIS L 2 1 A13 VSV (AICV) A42 J/C 12 A2 W 19 21 GR 20 G 2 1 GR 5 A2 P 27 B45 AICV GR Engine Room R/B & J/B EFI No. 2 BR A51 J/C W-B 6 A 1 5 1D 2 1H 1 EFI Relay 2 1 EFI No. 1 10 1H V 8 A24 MREL *1: Shielded A129500E01 2GR-FE INTAKE – INTAKE AIR CONTROL SYSTEM IT–3 ON-VEHICLE INSPECTION 1. A129501 INSPECT INTAKE AIR CONTROL VALVE ASSEMBLY (a) Inspection procedure when using the intelligent tester: (1) Warm up the engine. (2) Stop the engine. (3) Connect the intelligent tester to the DLC3. (4) Turn the ignition switch on (IG). (5) Turn the tester on. (6) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / INTAKE CTL VSV1. Press the right or left button. (7) Make sure that a clicking sound is heard from the intake air control valve when current flows. If the result is not as specified, replace the intake air surge tank. INSPECTION 2 1 1. INSPECT INTAKE AIR CONTROL VALVE (a) Inspection procedure when applying voltage between the terminals: (1) Disconnect the connector from the intake air control valve. (2) Apply battery voltage between terminals 1 (-) and 2 (+) of the intake air control valve. Check that a clicking sound is heard from the intake air control valve. If the result is not as specified, replace the intake air surge tank. 2. INSPECT AIR CLEANER ASSEMBLY (a) Apply 26.6 kPa (200 mmHg, 7.9 in. Hg) of vacuum to the actuator. Check if the valve rotates open, as shown in the illustration. (b) Apply vacuum for 1 minute. The actuator should continue to keep the valve open. If the result is not as specified, replace the air cleaner assembly. A129502 A129503 IT IT–4 2GR-FE INTAKE – VACUUM SWITCHING VALVE VACUUM SWITCHING VALVE 2GR-FE INTAKE ENGINE COMPONENTS VACUUM HOSE VACUUM SWITCHING VALVE VACUUM SWITCHING VALVE CONNECTOR VACUUM HOSE IT A135659E02 IT–5 2GR-FE INTAKE – VACUUM SWITCHING VALVE REMOVAL 1. REMOVE VACUUM SWITCHING VALVE (a) Remove the 2 vacuum hoses and vacuum switching valve connector. (b) Remove the screw and vacuum switching valve. A133294E01 INSPECTION Ohmmeter 37 to 44 Ω 1. INSPECT VACUUM SWITCHING VALVE (a) Measure the VSV resistance. Standard resistance Tester Connection Specified Condition 1-2 37 to 44 Ω at 20 °C (68°F) 1 - Body ground 2 - Body ground 10 kΩ or higher If the result is not as specified, replace the VSV. Ohmmeter 10 kΩ or higher IT Body Ground A085570E04 IT–6 2GR-FE INTAKE – VACUUM SWITCHING VALVE (b) Check VSV operation. (1) When vacuum is applied to the E port, check that air is sucked into the filter. If the result is not as specified, replace the VSV. AIR Filter E A128950E01 (2) Apply battery voltage across the terminals. When vacuum is applied to the F port, check that air is sucked into the E port. If the result is not as specified, replace the VSV. IT AIR F E A128951E01 INSTALLATION 1. A133294E01 REMOVE VACUUM SWITCHING VALVE (a) Install the vacuum switching valve with the screw. (b) Install the 2 vacuum hoses and vacuum switching valve. HO–1 HORN – HORN SYSTEM HORN SYSTEM BODY ELECTRICAL HORN PARTS LOCATION STEERING PAD (STEERING PAD SWITCH) MAIN BODY ECU INSTRUMENT PANEL J/B LOW PITCHED HORN HIGH PITCHED HORN ENGINE ROOM R/B ENGINE ROOM J/B - HORN FUSE - HORN RELAY HO B131106E01 HO–2 HORN – HORN SYSTEM SYSTEM DIAGRAM Main Body ECU Instrument Panel J/B HORN 11 ID HORN 25 5 HORN II 8 E18 FL MAIN Spiral Cable HO 1 Steering Pad Switch 1 A4 Horn (Low) 1 A3 Horn (High) a1 L Horn Switch B131104E01 HO HO–3 HORN – HORN SYSTEM PROBLEM SYMPTOMS TABLE HORN SYSTEM Symptom Horn does not sound Suspected area See page 1. HORN fuse HO-3 2. Horn relay HO-3 3. Steering pad switch RS-347 4. Spiral cable RS-364 5. Wire harness - 1. Horn relay HO-3 2. Steering pad switch RS-347 3. Wire harness - Low pitched horn operates but high pitched horn does not operate 1. High pitched horn HO-7 2. Wire harness - High pitched horn operates but low pitched horn does not operate 1. Low pitched horn HO-5 2. Wire harness - Horn blows all the time HO HO–3 HORN – HORN RELAY HORN RELAY INSPECTION 1. INSPECT FUSE (HORN) (a) Check the resistance of the HORN fuse. Standard: Below 1 Ω 2. INSPECT HORN RELAY (a) Remove the engine room R/B and J/B (horn relay). (b) Measure the resistance according to the value(s) in the table below. 1G 1B 6 5 4 3 2 1 1D 5 4 3 2 1 13 12 11 10 9 8 7 6 B131164E01 Standard resistance Tester Connection Condition Specified Condition 1G-1 - 1B-6 Always 10 kΩ or higher 1G-1 - 1B-6 When battery voltage is applied to terminals 1G1 and 1D-10 Below 1 Ω HO HO–4 HORN – LOW PITCHED HORN LOW PITCHED HORN BODY ELECTRICAL HORN COMPONENTS for 2GR-FE: COOL AIR INTAKE DUCT SEAL 20 (204, 15) LOW PITCHED HORN ASSEMBLY HO FRONT BUMPER ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque E127991E01 HO–5 HORN – LOW PITCHED HORN REMOVAL 1. REMOVE COOL AIR INTAKE DUCT SEAL (for 2GRFE) (See page ET-4) 2. REMOVE FRONT BUMPER ASSEMBLY (See page ET-5) 3. REMOVE LOW PITCHED HORN ASSEMBLY (a) Disconnect the connector. (b) Remove the bolt and the low pitched horn assembly. E127994 INSPECTION 1. INSPECT LOW PITCHED HORN (a) Apply battery voltage and check operation of the horn, as shown in the table below. Standard Measurement Condition Battery positive (+) → Terminal 1 Battery negative (-) → Body ground Specified Condition Horn sounds B068846E01 INSTALLATION E127994 1. INSTALL LOW PITCHED HORN ASSEMBLY (a) Install the low pitched horn assembly with the bolt. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) (b) Connect the connector. 2. INSTALL FRONT BUMPER ASSEMBLY (See page ET13) 3. INSTALL COOL AIR INTAKE DUCT SEAL (for 2GRFE) (See page ET-14) HO HO–6 HORN – HIGH PITCHED HORN HIGH PITCHED HORN BODY ELECTRICAL HORN COMPONENTS for 2GR-FE: COOL AIR INTAKE DUCT SEAL 20 (204, 15) HIGH PITCHED HORN ASSEMBLY HO FRONT BUMPER ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque E127990E01 HO–7 HORN – HIGH PITCHED HORN REMOVAL 1. REMOVE COOL AIR INTAKE DUCT SEAL (for 2GRFE) (See page ET-4) 2. REMOVE FRONT BUMPER ASSEMBLY (See page ET-5) 3. REMOVE HIGH PITCHED HORN ASSEMBLY (a) Disconnect the connector. (b) Remove the bolt and the high pitched horn assembly. E127995 INSPECTION 1. INSPECT HIGH PITCHED HORN (a) Apply battery voltage and check operation of the horn, as shown in the table below. Standard Measurement Condition Battery positive (+) → Terminal 1 Battery negative (-) → Body ground Specified Condition Horn sounds B068846E01 INSTALLATION E127995 1. INSTALL HIGH PITCHED HORN ASSEMBLY (a) Install the high pitched horn assembly with the bolt. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) (b) Connect the connector. 2. INSTALL FRONT BUMPER ASSEMBLY (See page ET13) 3. INSTALL COOL AIR INTAKE DUCT SEAL (for 2GRFE) (See page ET-14) HO 2GR-FE COOLING – COOLING SYSTEM CO–1 COOLING SYSTEM ON-VEHICLE INSPECTION 1. CHECK FOR ENGINE COOLANT LEAKS CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. NOTICE: Before performing each inspection, turn the A/C switch OFF. (a) Fill the radiator with coolant and attach a radiator cap tester. (b) Warm up the engine. (c) Using a radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf*cm, 17 psi), and check that the pressure does not drop. If the pressure drops, check the hoses, radiator and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head. A133894 2. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR (a) Check that the engine coolant level is between the LOW and FULL lines when the engine is cold. If the engine coolant level is low, check for leaks and add "TOYOTA Super Long Life Coolant" or similar high quality ethylene glycol based non-silicate, nonamine, non-nitrite and non-borate coolant with longlife hybrid organic acid technology to the FULL line. NOTICE: Do not substitute plain water for engine coolant. 3. INSPECT ENGINE COOLANT QUALITY (a) Remove the radiator cap. CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. (b) Check if there are any excessive deposits of rust or scales around the radiator cap and radiator filler hole. Also, the coolant should be free of oil. If excessively dirty, clean the coolant passage and replace the coolant. (c) Install the radiator cap. CO CO–2 2GR-FE COOLING – COOLING FAN SYSTEM COOLING FAN SYSTEM 2GR-FE COOLING ENGINE PARTS LOCATION ECM INSTRUMENT PANEL JUNCTION BLOCK CO COOLING FAN ASSEMBLY -ECU IG NO. 1 -MAIN FAN MOTOR ENGINE ROOM RELAY BLOCK -SUB FAN MOTOR -FAN MAIN FUSE -COOLING FAN ECM -COOLING FAN RELAY A137457E02 CO–3 2GR-FE COOLING – COOLING FAN SYSTEM SYSTEM DIAGRAM A54 Cooling Fan ECU Main Fan Motor A55 ECM S1 2 43 RFC M+ (M) FAN MAIN M- (M) Sub Fan Motor +B1 3 M+ (S) 5 3 2 1 FAN MAIN From Battery From Battery ECU IG No. 1 M- (S) E1 1 A136998 CO CO–4 2GR-FE COOLING – COOLING FAN SYSTEM ON-VEHICLE INSPECTION 1. INSPECT COOLING FAN SYSTEM (a) Put the vehicle in the following conditions: (1) The ignition switch is off. (2) The coolant temperature is less than 95°C (203°F). (3) The battery voltage is between 9 and 14 V. (4) The A/C switch is OFF. (b) Connect the 400 A probe of the ammeter to terminals M+ (M) and M+ (S) of the cooling fan motor. (c) Turn the ignition switch on (IG) and wait for approximately 10 seconds. Check that the fan stops. (d) Start the engine. Check that the fan stops with the engine idling. HINT: • Make sure that the radiator engine coolant temperature is less than 95°C (203°F). • Turn the A/C switch OFF. (e) Check that the fan operates when the A/C switch is turned ON (MAX COOL and the magnet clutch is operating). Standard current : Without trailer hitch Item Specified Condition Cooling fan motor 2 to 8 A Cooling fan motor No. 2 2 to 8 A Standard current : With trailer hitch Item Specified Condition Cooling fan motor 2 to 11 A Cooling fan motor No. 2 2 to 11 A CO (f) HINT: The coolant temperature is less than 95°C (203°F). Check that the fan operates when the engine coolant temperature sensor connector is disconnected. Standard current : Without trailer hitch Item Specified Condition Cooling fan motor 2 to 11 A Cooling fan motor No. 2 2 to 11 A Standard current : With trailer hitch Item Specified Condition Cooling fan motor 2 to 15 A Cooling fan motor No. 2 2 to 15 A 2GR-FE COOLING – COOLING FAN SYSTEM CO–5 (g) After the engine is warmed up, check that the fan operates as shown in the illustration on the left. HINT: • The coolant temperature at which the fan starts operating is approximately 95°C (203°F). • This system can also be checked using the intelligent tester. • Select the following menu items: Power train / Engine / Data List / Initial Engine Coolant Temp. Operating Diagram A/C OFF MAX HI Fan Speed LO 95 97 100 102 °C 203 207 212 216 °F A139339E02 CO CO–5 2GR-FE COOLING – COOLANT COOLANT ON-VEHICLE INSPECTION 1. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH 2. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH 3. REMOVE ENGINE UNDER COVER RH 4. REMOVE ENGINE UNDER COVER LH 5. REMOVE V-BANK COVER SUB-ASSEMBLY (See page EM-23) 6. REMOVE COOL AIR INTAKE DUCT SEAL (See page EM-23) 7. DRAIN ENGINE COOLANT NOTICE: Do not remove the radiator cap sub-assembly while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. (a) Remove the radiator cap sub-assembly from the radiator assembly. (b) Loosen the radiator drain cock plug and 2 cylinder block drain cock plugs, then drain the coolant. Cylinder Block Drain Cock Plug Radiator Cap Cylinder Block Drain Cock Plug CO Radiator Drain Cock Plug A128117E02 HINT: Collect the coolant in a container and dispose of it according to the regulations in your area. CO–6 2GR-FE COOLING – COOLANT 8. ADD ENGINE COOLANT (a) Close the radiator drain cock plug and 2 cylinder block drain cock plugs. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) for cylinder block drain cock plug (b) Slowly fill the radiator with TOYOTA Super Long Life Coolant (SLLC). Specified capacity: 9.0 liters (9.5 US qts, 7.9 lmp. qts) HINT: • TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids). • Contact your TOYOTA dealer for further details. (c) Slowly pour coolant into the radiator reservoir tank until it reaches the FULL line. (d) Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant. If the coolant level is low, add coolant. (e) Install the radiator cap sub-assembly and reservoir tank cap. (f) Start the engine, and warm it up. HINT: Adjust the air conditioner set temperature to MAX (HOT). (g) Stop the engine, and wait until the engine coolant cools down. (h) Add engine coolant to the FULL line on the radiator reservoir. 9. CHECK FOR ENGINE COOLANT LEAKS (See page CO-1) CO 10. INSTALL V-BANK COVER SUB-ASSEMBLY (See page EM-52) 11. INSTALL ENGINE UNDER COVER RH 12. INSTALL ENGINE UNDER COVER LH 13. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH 14. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH 15. INSTALL COOL AIR INTAKE DUCT SEAL (See page EM-52) CO–7 2GR-FE COOLING – WATER PUMP WATER PUMP 2GR-FE COOLING ENGINE COMPONENTS WATER PUMP ASSEMBLY GASKET 9.1 (93, 81 in.*lbf) ×5 9.1 (93, 81 in.*lbf) 21 (214, 15) ×9 21 (214, 15) 43 (438, 32) 43 (438, 32) NO. 2 IDLER PULLEY SUB-ASSEMBLY WATER PUMP PULLEY 43 (438, 32) NO. 2 IDLER PULLEY SUB-ASSEMBLY NO. 2 IDLER PULLEY COVER PLATE NO. 2 IDLER PULLY COVER PLATE V-RIBBED BELT TENSIONER ASSEMBLY O-RING ×2 10 (102, 7) 43 (438, 32) GASKET WATER INLET HOUSING 54 (551, 40) 54 (551, 40) ×3 ×2 54 (551, 40) NO. 1 ENGINE MOUNTING BRACKET FRONT LH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Precoated part A134976E07 CO CO–8 2GR-FE COOLING – WATER PUMP REMOVAL 1. REMOVE ENGINE ASSEMBLY AND TRANSAXLE HINT: See page EM-23 2. SECURE ENGINE STAND HINT: See page EM-30 3. REMOVE NO. 1 ENGINE MOUNTING BRACKET FRONT LH (See page EM-35) 4. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY (a) Remove the 2 bolts, 2 idler pulley cover plates and 2 idler pulley sub-assemblies. 5. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (a) Remove the 5 bolts and V-ribbed belt tensioner assembly. 6. REMOVE WATER PUMP PULLEY (a) Using SST, hold the water pump pulley. SST 09960-10010 (09962-01000, 09963-00700) (b) Remove the 4 bolts and water pump pulley. FR Side: RR Side: A129645E01 CO A135522 SST A128112E03 2GR-FE COOLING – WATER PUMP 7. Water Hose CO–9 REMOVE WATER INLET HOUSING (a) Disconnect the water hose. (b) Remove the 2 bolts, nut and water inlet housing. Water Inlet Housing A133375E01 (c) Remove the water inlet housing gasket and water outlet pipe O-ring. A128120 8. REMOVE WATER PUMP ASSEMBLY (a) Remove the 16 bolts, water pump assembly and water pump gasket. A094889 Drain Hole INSPECTION Air Hole 1. INSPECT WATER PUMP ASSEMBLY (a) Visually check the drain hole and air hole for coolant leakage. (b) Turn the pulley, and check that the water pump bearing moves smoothly and noiselessly. If the bearing does not move smoothly and noiselessly, replace the water pump. A096655E06 INSTALLATION B A A B A C B B A B C A A A 1. A A A128115E01 INSTALL WATER PUMP ASSEMBLY (a) Install a new water pump gasket and the water pump assembly with the 16 bolts. Torque: Bolt A 21 N*m (214 kgf*cm, 15 ft.*lbf) Bolts B and C 9.1 N*m (93 kgf*cm, 81 in.*lbf) NOTICE: • Make sure that there is no oil on the threads of bolts A. CO CO–10 2GR-FE COOLING – WATER PUMP • Be sure to replace 2 bolts C with new ones or reuse them after applying adhesive 1344. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent 2. INSTALL WATER INLET HOUSING (a) Install a new water inlet housing No. 1 gasket and water outlet pipe O-ring. A128122 (b) Install the water inlet housing with the 2 bolts and nut. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTICE: Be careful not to allow the O-ring to get caught between the parts. (c) Connect the water hose. Water Hose Water Inlet Housing A133375E01 SST CO 3. INSTALL WATER PUMP PULLEY (a) Temporarily install the water pump pulley with the 4 bolts. (b) Using SST, hold the water pump pulley. SST 09960-10010 (09962-01000, 09963-00700) (c) Tighten the 4 bolts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 4. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (a) Install the V-ribbed belt tensioner assembly with the 5 bolts. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) A128112E01 A135522 2GR-FE COOLING – WATER PUMP 5. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY (a) Install the 2 idler pulley cover plates and idler pulley sub-assemblies with the 2 bolts. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 6. INSTALL NO. 1 ENGINE MOUNTING BRACKET FRONT LH (See page EM-38) 7. REMOVE ENGINE STAND 8. INSTALL ENGINE ASSEMBLY AND TRANSAXLE HINT: See page EM-37 9. ADD ENGINE COOLANT (See page CO-6) FR Side: RR Side: CO–11 10. CHECK FOR ENGINE COOLANT LEAKS (See page CO-1) A129645E01 CO CO–12 2GR-FE COOLING – THERMOSTAT THERMOSTAT 2GR-FE COOLING ENGINE COMPONENTS V-BANK COVER SUB-ASSEMBLY 38 (388, 28) V-RIBBED BELT FRONT FENDER APRON SEAL RH 43 (438, 32) THERMOSTAT ENGINE MOVING CONTROL ROD SUB-ASSEMBLY 38 (388, 28) NO. 2 ENGINE MOUNTING STAY RH NO. 2 IDLER PULLEY SUB-ASSEMBLY GASKET 10 (102, 7) 10 (102, 7) WATER INLET CO RADIATOR HOSE OUTLET Non-reusable part N*m (kgf*cm, ft.*lbf) : Specified torque A134965E02 2GR-FE COOLING – THERMOSTAT CO–13 REMOVAL 1. DRAIN ENGINE COOLANT 2. REMOVE V-BANK COVER SUB-ASSEMBLY (See page EM-23) 3. REMOVE FRONT FENDER APRON SEAL RH 4. REMOVE NO. 2 ENGINE MOUNTING STAY RH (See page EM-25) 5. REMOVE ENGINE MOVING CONTROL ROD SUBASSEMBLY (See page EM-25) 6. REMOVE V-RIBBED BELT (See page EM-6) 7. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY (See page EM-34) 8. DISCONNECT RADIATOR HOSE OUTLET (See page EM-26) 9. REMOVE WATER INLET (a) Remove the 2 nuts and water inlet. 10. REMOVE THERMOSTAT (a) Remove the gasket from the thermostat. A133374 INSPECTION 1. INSPECT THERMOSTAT (a) Inspect the thermostat. HINT: The valve opening temperature is inscribed on the thermostat. CO P013560 (b) Immerse the thermostat in water and gradually heat the water. (c) Check the valve opening temperature. Valve opening temperature: 80 to 84°C (176 to 183°F) If the valve opening temperature is not as specified, replace the thermostat. P000436 CO–14 2GR-FE COOLING – THERMOSTAT (d) Check the valve lift. Valve lift: 7.7 mm (0.3031 in.) or more at 95°C (203°F) If the valve lift is not as specified, replace the thermostat. (e) Check that the valve is fully closed when the thermostat is at low temperatures (below 40°C (104°F)). If it is not fully closed, replace the thermostat. 7.7 mm A091387E02 10° INSTALLATION 10° 1. INSTALL THERMOSTAT (a) Install a new gasket to the thermostat. (b) Install the thermostat with the jiggle valve facing up. HINT: The jiggle valve may be set within 10°on either side of the prescribed position. 2. INSTALL WATER INLET (a) Install the water inlet with the 2 nuts . Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 3. CONNECT RADIATOR HOSE OUTLET (See page EM48) 4. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY (See page EM-39) 5. INSTALL V-RIBBED BELT (See page EM-7) 6. INSTALL ENGINE MOVING CONTROL ROD SUBASSEMBLY (See page EM-49) 7. INSTALL NO. 2 ENGINE MOUNTING STAY RH (See page EM-49) 8. INSTALL FRONT FENDER APRON SEAL RH 9. ADD ENGINE COOLANT (See page CO-6) Jiggle Valve A132392E01 A133374 CO 10. CHECK FOR ENGINE COOLANT LEAKS (See page CO-1) 11. INSTALL V-BANK COVER SUB-ASSEMBLY (See page EM-52) 2GR-FE COOLING – COOLING FAN MOTOR CO–15 COOLING FAN MOTOR ON-VEHICLE INSPECTION 1. COOLING FAN MOTOR (a) Check that the motor turns smoothly when the battery is connected to the fan motor connector. (b) Measure the current while the motor is turning. Standard current: With trailer hitch: 11.8 to 14.8 A at 20°C (68°F) Without trailer hitch: 6.8 to 9.8 A at 20°C (68°F) If the result is not as specified, replace the cooling fan motor. 2. NO. 2 COOLING FAN MOTOR (a) Check that the motor turns smoothly when the battery is connected to the fan motor connector. (b) Measure the current while the motor is turning. Standard current: With trailer hitch: 6.8 to 9.8 A at 20°C (68°F) Without trailer hitch: 6.8 to 9.8 A at 20°C (68°F) If the result is not as specified, replace the cooling fan motor No. 2. 1 2 M- (Negative (-)) M+ (Positive (+)) A110241E04 1 S- (Negative (-)) 2 S+ (Positive (+)) A110242E04 CO CO–16 2GR-FE COOLING – COOLING FAN ECU COOLING FAN ECU ON-VEHICLE INSPECTION 1 E1 2 SI 1. 3 +B1 A125060E02 CO INSPECT COOLING FAN ECU (a) Inspect the input voltage. (1) Disconnect the cooling fan ECU connector. (2) Turn the ignition switch on (IG). Check the voltage of the +B terminal of the disconnected wire harness side connector. Standard voltage: 9 to 14 V If the result is not as specified, inspect the power source system (fusible link, fuse, wire harness and relay). (b) Inspect the cooling fan motor (see page CO-15). (c) Measure the resistance between terminals RFC (ECM) and SI (cooling fan ECU) of the wire harness side connectors. HINT: • If the fan does not operate, there may be a short circuit. • If the fan remains operating, there may be an open circuit. (d) Inspect the ECM power source circuit and ground circuit. CO–17 2GR-FE COOLING – COOLING FAN ECU Waveform 1 1 V/DIV 20 ms/DIV GND Waveform 2 1 V/DIV 20 ms/DIV GND Waveform 3 1 V/DIV 20 ms/DIV (e) Inspect the input signal and output current. NOTICE: Be sure to perform the inspection with the radiator coolant temperature less than 95°C (203 °F). (1) Connect the 400 A probe of the ammeter to terminal M+ of the cooling fan motor. (2) Set the intelligent tester to the oscilloscope function. (3) Using the intelligent tester, check the waveform between terminals RFC and E1 of the ECM. Standard waveform Condition Input Signal Output Current Engine stopped (Ignition switch on (IG)) Waveform 1 (Duty ratio 0 %) (Fan stops) Engine idling (A/C OFF) Waveform 1 (0 %) (Fan stops) Engine idling (A/C ON) Waveform 2 (30 to 70 %) 2 to 11 A (Fan operates) Engine idling (Coolant temperature sensor connector disconnected) Waveform 3 (30 to 70 %) 2 to 11 A (Fan operates) HINT: • If the input signal is abnormal, there is a malfunction in the ECM or cooling fan ECU. • If the output current is abnormal even when the input signal is normal, there is a malfunction in the cooling fan ECU (RFC) or motor. GND CO A126255E01 CO–18 2GR-FE COOLING – COOLING FAN RELAY COOLING FAN RELAY ON-VEHICLE INSPECTION 1. A035654 COOLING FAN RELAY (a) Remove the relay from engine room relay block No. 1. (b) Measure the resistance of the relay. Standard resistance Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the cooling fan relay. (c) Install the relay to engine room relay block No. 1. CO 2GR-FE COOLING – RADIATOR CO–19 RADIATOR 2GR-FE COOLING ENGINE COMPONENTS V-BANK COVER SUB-ASSEMBLY 5.0 (51, 44 in.*lbf) x2 AIR CLEANER INLET SUB-ASSEMBLY 5.0 (51, 44 in.*lbf) NO. 1 AIR CLEANER INLET AIR CLEANER CAP SUB-ASSEMBLY AIR CLEANER FILTER ELEMENT COOL AIR INTAKE DUCT SEAL CO N*m (kgf*cm, ft.*lbf) : Specified torque A134975E05 CO–20 2GR-FE COOLING – RADIATOR 7.0 (71, 62 in.*lbf) x4 RADIATOR SUPPORT UPPER HOOD LOCK ASSEMBLY x2 7.5 (77, 66 in.*lbf) HORN CONNECTOR 7.0 (71, 62 in.*lbf) RADIATOR GRILLE PROTECTOR 7.5 (77, 66 in.*lbf) x2 x2 FRONT BUMPER ENERGY ABSORBER CO x2 ENGINE UNDER COVER LH FRONT BUMPER ASSEMBLY x9 ENGINE UNDER COVER RH FRONT WHEEL OPENING EXTENSION PAD RH FRONT WHEEL OPENING EXTENSION PAD LH N*m (kgf*cm, ft.*lbf) : Specified torque A133359E05 CO–21 2GR-FE COOLING – RADIATOR RADIATOR HOSE INLET RADIATOR HOSE OUTLET RADIATOR SUPPORT CUSHION RADIATOR SUPPORT CUSHION FAN MOTOR CONNECTOR RADIATOR ASSEMBLY FAN SHROUD RADIATOR SUPPORT LOWER RADIATOR SUPPORT LOWER 5.0 (51, 44 in.*lbf) CO x4 N*m (kgf*cm, ft.*lbf) : Specified torque A133360E02 CO–22 2GR-FE COOLING – RADIATOR RADIATOR CAP SUB-ASSEMBLY RADIATOR TANK UPPER O-RING FAN SHROUD OIL COOLER PIPE CORE SUB-ASSEMBLY 15 (150, 11) O-RING O-RING 15 (150, 11) With Hose 15 (150, 11) O-RING 8.3 (85, 73 in.*lbf) OIL COOLER ASSEMBLY RADIATOR TANK LOWER O-RING DRAIN PLUG Non-reusable part N*m (kgf*cm, ft.*lbf) : Specified torque A133898E03 ON-VEHICLE INSPECTION 1. CO 1 2 3 4 A107446E01 CHECK RADIATOR CAP SUB-ASSEMBLY (a) Measure the valve opening pressure. (1) If there are water stains or foreign matter on rubber packings 1, 2 or 3, clean the part(s) with water and finger scouring. (2) Check that rubber packings 1, 2 and 3 are not deformed, cracked or swollen. (3) Check that rubber packings 3 and 4 are not stuck together. (4) Apply engine coolant to rubber packings 2 and 3 before using the radiator cap tester. (5) When using the cap tester, tilt it to 30° or more above the horizontal. CO–23 2GR-FE COOLING – RADIATOR (6) Pump the cap tester several times, and check the maximum pressure *1. Pumping speed: 1 pumps every second *1: Even if the cap cannot maintain the maximum pressure, it is not a defect. Judgment Criteria Radiator Cap Tester 30° or more Radiator Cap A104601E03 Item Specified Condition Standard valve (for brand-new cap) 93.3 to 122.7 kPa (0.95 to 1.25 kgf/ Minimum standard valve (after using cap) 78.5 kPa (0.8 kgf/cm2, 11.4 psi) cm2, 13.5 to 17.8 psi) If the maximum pressure is less than the specified pressure for the minimum standard valve, replace the radiator cap sub-assembly. ON-VEHICLE CLEANING 1. A073603 INSPECT FINS BLOCKAGE (a) If the fins are clogged, wash them with water or a steam cleaner. Dry with compressed air. NOTICE: • If the distance between the steam cleaner and the core is too close, the fins may become damaged. Keep the following injection distance. Standard Injection Distance Injection Pressure 300 mm (11.81 in.) (30 to 50 kg/cm2, 427 to 711 psi) 500 mm (19.69 in.) 2,942 to 4,903 kPa 4,903 to 7,845 kPa (50 to 80 kg/cm2, 711 to 1,138 psi) • If the fins are bent, straighten them with a screwdriver or pliers. • Never apply water directly onto the electronic components. CO CO–24 2GR-FE COOLING – RADIATOR REMOVAL 1. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH 2. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH 3. REMOVE ENGINE UNDER COVER RH 4. REMOVE ENGINE UNDER COVER LH 5. DRAIN ENGINE COOLANT (See page CO-5) 6. REMOVE V-BANK COVER SUB-ASSEMBLY (See page EM-23) 7. REMOVE COOL AIR INTAKE DUCT SEAL (See page EM-23) 8. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-503) 9. REMOVE AIR CLEANER INLET SUB-ASSEMBLY (See page EM-24) 10. REMOVE NO. 1 AIR CLEANER INLET (See page EM24) 11. REMOVE FRONT BUMPER ASSEMBLY (w/ Fog Light) (See page ET-6) 12. REMOVE FRONT BUMPER ASSEMBLY (w/o Fog Light) (See page ET-6) 13. REMOVE FRONT BUMPER ENERGY ABSORBER (See page ET-9) 14. SEPARATE RADIATOR RESERVE TANK HOSE (a) Separate the radiator reserve tank hose from the radiator assembly. CO A133362 15. DISCONNECT RADIATOR HOSE INLET (a) Separate the radiator inlet hose from the radiator assembly. A133363 2GR-FE COOLING – RADIATOR CO–25 16. DISCONNECT RADIATOR HOSE OUTLET (a) Separate the radiator outlet hose from the radiator assembly. A133364 17. DISCONNECT NO. 1 OIL COOLER INLET HOSE (a) Separate the No. 1 oil cooler inlet hose from the radiator assembly. A133365 18. DISCONNECT NO. 1 OIL COOLER OUTLET HOSE (a) Separate the No. 1 oil cooler outlet hose from the radiator assembly. 19. REMOVE RADIATOR SUPPORT UPPER (a) Disconnect the horn connector. A133366 (b) Remove the 3 bolts and separate the hood lock assembly from the radiator support upper. CO A133367 (c) Remove the clamp and separate the hood lock control cable from the radiator support upper. A133368E01 CO–26 2GR-FE COOLING – RADIATOR (d) Remove the 5 bolts and radiator support upper. A133369 20. REMOVE FAN SHROUD (a) Remove the 3 clamps and connector. A139341E01 (b) Release the 3 snap fits and lift the fan assembly with motor from the radiator. Guide :Snap Fit Guide A140761E01 21. REMOVE RADIATOR ASSEMBLY (a) Remove the 4 bolts and separate the condenser assembly from the radiator assembly. CO A133370 (b) Remove the radiator assembly from the body. A133373 2GR-FE COOLING – RADIATOR CO–27 22. REMOVE RADIATOR SUPPORT CUSHION (a) Remove the 2 radiator support cushions from the radiator assembly. Radiator Support Cushion A133371E02 23. REMOVE RADIATOR SUPPORT LOWER (a) Remove the 2 radiator support lowers from the radiator assembly. Radiator Support Lower A133371E03 CO CO–28 2GR-FE COOLING – RADIATOR DISASSEMBLY Stopper Bolt Part A Dimension B 0.2 to 0.3 mm SST 1. REMOVE DRAIN PLUG (a) Remove the drain plug. (b) Remove the O-ring. 2. REMOVE RADIATOR TANK UPPER (a) Install the claw to the overhaul handle, inserting it in the hole in part A as shown in the illustration. SST 09230-01010 (09231-01010, 09231-01030) (b) While gripping the handle, adjust the stopper bolt so that dimension B is as shown in the illustration. Dimension B: 0.2 to 0.3 mm (0.008 to 0.012 in.) NOTICE: If the stopper bolt is not adjusted, the claw may be damaged. Claw Overhaul Handle A104619E03 Tank (c) Using SST to release the caulking, grip the handle until stopped by the stopper bolt. SST 09230-01010 (09231-01010, 09231-01030) Lock Plate SST CO Stopper Bolt A128137E02 (d) Lightly tap the bracket of the radiator (or radiator hose inlet or outlet) with a soft-faced hammer and remove the tank. (e) Remove the O-ring. Tap A128138E01 2GR-FE COOLING – RADIATOR CO–29 3. REMOVE RADIATOR TANK LOWER (a) With hose: (1) Remove the 2 clips and hose from the radiator assembly. (b) Removal procedure of the radiator tank lower is the same as that of the radiator tank upper. 4. REMOVE OIL COOLER ASSEMBLY (a) Without hose: (1) Remove the bolt and cooler pipe (A). (2) Remove the nut and plate washer (B). (3) Remove the oil cooler (C). (4) Remove the 2 O-rings from the oil cooler (D). A134968E02 (D) (C) (A) (A) (B) Lower Tank (C) (B) A128140E02 Lock Plate Lock Plate INSPECTION 1. Core A087087E06 INSPECT LOCK PLATE (a) Inspect the lock plate for damage. HINT: • If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible. Therefore, first correct the shape of the lock plate groove with pliers or a similar object, if necessary. • Water leakage will result if the bottom of the lock plate groove is damaged or dented. Repair or replace the locking plate if necessary. NOTICE: The radiator can only be recaulked 2 times. After recaulking 2 times, the radiator core must be replaced. REASSEMBLY (D) (C) (A) 1. (A) (B) Lower Tank (C) (B) A128140E02 INSTALL OIL COOLER ASSEMBLY (a) Without hose (1) Clean the O-ring contact surfaces of the lower tank and oil cooler. (2) Install 2 new O-rings to the oil cooler (D). (3) Install the oil cooler to the lower tank (C). (4) Install the plate washer and nut (B). Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf) (5) Install the cooler pipe with the bolt (A). Torque: 15 N*m (150 kgf*cm, 11 ft.*lbf) CO CO–30 2GR-FE COOLING – RADIATOR 2. Stopper Bolt Part A INSTALL RADIATOR TANK UPPER (a) Install the punch assembly to the overhaul handle, inserting it in the hole in part A as shown in the illustration. SST 09230-01010, 09231-14010 Dimension B SST Punch Assembly Overhaul Handle A104624E02 ○ Normal X Twisted (b) After checking that there are no foreign objects in the lock plate groove, install a new O-ring without twisting it. HINT: When cleaning the lock plate groove, lightly rub it with sand paper without scratching it. CO X Twisted O-Ring A104623E03 CORRECT Tank WRONG Tap Lock Plate A128141E01 (c) Install the tank without damaging the O-ring. 2GR-FE COOLING – RADIATOR 5 3 (d) Lightly press SST against the lock plate in the order shown in the illustration. After repeating this a few times, fully caulk the lock plate by gripping the handle until stopped by the stopper plate. HINT: • Do not tap the areas protruding around the pipes, brackets or tank ribs. • The dotted circles shown in the illustration and parts of the oil cooler near the dotted circles cannot be tapped with the SST. Use pliers or similar objects and be careful not to damage the core plates. 7 2 1 6 SST 4 CO–31 8 Lock Plate Stopper Bolt Tank A129608E02 (e) Check the lock plate height (H) after completing caulking. Plate height (H): 7.40 to 7.80 mm (0.2913 to 0.3071 in.) If not within the specified height range, adjust the stopper bolt of the handle and caulk again. (f) Tap the lock plate with a soft-faced hammer so that there is no gap between the lock plate and the tank. H 3. A128142E01 INSTALL RADIATOR TANK LOWER (a) Installation procedure of the radiator tank lower is the same as that of the radiator tank upper. (b) With hose (1) Install the hose and 2 clips. 4. A134968E02 INSTALL DRAIN PLUG (a) Install a new O-ring to the drain plug. (b) Install the drain plug. CO CO–32 2GR-FE COOLING – RADIATOR 5. SST INSPECT FOR WATER LEAKS (a) Plug the inlet and outlet pipes of the radiator with SST. SST 09230-01010 (b) Using the radiator cap tester, apply pressure to the radiator. Test pressure: 177 kPa (1.8 kgf/cm2, 26 psi) (c) Submerge the radiator in water. A128143E03 (d) Inspect for leaks. HINT: On radiators with resin tanks, there is clearance between the tank and lock plate where a minute amount of air will remain, giving the appearance of an air leak when the radiator is submerged in water. Therefore, before doing the water leak test, first swish the radiator around in the water until all air bubbles disappear. Tank Lock Plate O-Ring A087096E02 INSTALLATION Radiator Support Lower 1. INSTALL RADIATOR SUPPORT LOWER (a) Install the 2 radiator support lowers to the radiator assembly. 2. INSTALL RADIATOR SUPPORT CUSHION (a) Install the 2 radiator support cushions to the radiator assembly. 3. INSTALL RADIATOR ASSEMBLY (a) Install the radiator to the body. A133371E03 CO Radiator Support Cushion A133371E02 A135523 2GR-FE COOLING – RADIATOR CO–33 (b) Install the condenser assembly with the 4 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) A133370 4. Guide :Snap Fit INSTALL FAN SHROUD (a) Install the fan assembly with motor to the radiator with the 2 guides at the bottom and 3 snap fits on the top. Guide A140761E01 (b) Connect the fan motor connector. A139341E01 5. INSTALL RADIATOR SUPPORT UPPER (a) Install the radiator support upper with the 5 bolts. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) A133369 (b) Install the hood lock assembly to the radiator support upper with the 3 bolts. Torque: 7.5 N*m (77 kgf*cm, 66 in.*lbf) A133367 CO CO–34 2GR-FE COOLING – RADIATOR (c) Install the hood lock control cable assembly to the radiator support upper with the clamp. (d) Connect the 2 horn connectors. A133368 6. CONNECT NO. 1 OIL COOLER OUTLET TUBE (a) Connect the No. 1 oil cooler outlet tube to the radiator assembly. 7. CONNECT NO. 1 OIL COOLER INLET TUBE (a) Connect the No. 1 oil cooler inlet tube to the radiator assembly. 8. CONNECT RADIATOR HOSE OUTLET (a) Connect the radiator hose outlet to the radiator assembly. 9. CONNECT RADIATOR HOSE INLET (a) Connect the radiator hose inlet to the radiator assembly. A133366 A133365 CO A133364 A133363 2GR-FE COOLING – RADIATOR CO–35 10. CONNECT RADIATOR RESERVOIR TANK HOSE (a) Connect the radiator reservoir tank hose to the radiator assembly. 11. INSTALL FRONT BUMPER ENERGY ABSORBER (See page ET-10) 12. INSTALL FRONT BUMPER ASSEMBLY (w/ Fog Light) (See page ET-14) A133362 13. REMOVE FRONT BUMPER ASSEMBLY (w/o Fog Light) (See page ET-13) 14. INSTALL NO. 1 AIR CLEANER INLET (See page EM49) 15. INSTALL AIR CLEANER INLET SUB-ASSEMBLY (See page EM-50) 16. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See page ES-506) 17. INSTALL COOL AIR INTAKE DUCT SEAL (See page EM-52) 18. INSTALL V-BANK COVER SUB-ASSEMBLY (See page EM-52) 19. ADD ENGINE COOLANT (See page CO-6) 20. CHECK FOR ENGINE COOLANT LEAKS (See page CO-1) 21. INSTALL ENGINE UNDER COVER RH 22. INSTALL ENGINE UNDER COVER LH 23. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH 24. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH CO TIRE AND WHEEL – TIRE AND WHEEL SYSTEM TW–1 TIRE AND WHEEL SYSTEM PRECAUTION 1. 2. REMOVAL AND INSTALLATION OF THE TIRE PRESSURE WARNING VALVE SUB-ASSEMBLY (a) When installing a tire, make sure that the tire pressure warning valve sub-assembly does not interfere with the tire bead in order to prevent damage to the tire pressure warning valve subassembly. (b) After completing the operation, remove the valve core to rapidly release the air in the tire and check that the warning light comes on. If the warning light does not come on, the system may be defective. (c) If there is air leakage, tighten the nut to a torque of 4.0 N*m (41 kgf*cm, 35 in.*lbf) and push the valve core 2 or 3 times to remove any dirt attached to the valve core. If air continues to leak, replace the grommet, washer, and nut. (d) When installing the tire pressure warning valve subassembly, check whether the rim, grommet, washer, and nut are clean. Use a manufacturer-specified cap. (e) When putting air into the tire, first install the tire pressure valve straight onto the stem of the tire pressure warning valve sub-assembly. TIRE AND WHEEL REPLACEMENT (a) If replacing a tire, be sure to check the grommet of the tire valve for damage. If the grommet is damaged, replace the grommet, washer, and the nut. (b) If tires and wheels are replaced, register the transmitter ID (see page TW-15). TW TW–2 TIRE AND WHEEL – TIRE AND WHEEL SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING 1. Check that the wheel nuts are fully tightened. NG Repair DIAGNOSIS OF TIRE VIBRATION (a) Inspection procedure NG Inspect bearing looseness. Inspect axle hub runout. OK Repair tire(s). TW OK OK Return the vehicle to the customer. Check tire pressure. OK Check wheel balance. OK NG Adjustment NG Inspect bearing looseness. Inspect axle hub runout. Adjustment NG Repair NG OK Check wheel balance. C107882E08 2. DIAGNOSIS OF IRREGULAR TIRE WEAR (a) Inspection procedure TIRE AND WHEEL – TIRE AND WHEEL SYSTEM Check tire pressure. NG Adjustment OK Check wheel alignment. OK TW–3 Rotate or replace the tire(s). NG TW Adjustment NG Check wheel alignment. OK C107883E01 TW–4 TIRE AND WHEEL – TIRE AND WHEEL SYSTEM INSPECTION 1. INSPECT TIRE (a) Check the tires for wear and proper inflation pressure. Cold tire inflation pressure Front kPa (kgf*cm2, psi) Tire size Rear kPa (kgf*cm2, psi) P215/60R16 94V 210 (2.1, 31) 210 (2.1, 31) P215/55R17 93V 220 (2.2, 32) 220 (2.2, 32) When driving under the above vehicle conditions at sustained high speeds above 160 km/h (100 mph), in countries where such speeds are permitted bylaw, inflate the front and rear tires to 240 kPa (2.4 kgf*cm2, 35 psi) provided that it does not exceed the maximum cold tire inflation pressure molded on the tire sidewall. TW (b) Using a dial indicator, check the runout of the tires. Tire runout: 1.4 mm (0.055 in.) or less C137874 2. ROTATE TIRE (a) Rotate the tires as shown in illustration (A). If the vehicle is equipped with a grand spare tire, rotate the tires as shown in illustration (B). 3. INSPECT WHEEL BALANCE (a) Check and adjust the off-the-car balance. (b) Steel wheel (1) If necessary, check and adjust the on-the-car balance. Imbalance after adjustment: 8.0 g (0.018 lb.) or less. (A) Front (B) C135236E01 C080976 TIRE AND WHEEL – TIRE AND WHEEL SYSTEM TW–5 (c) Except for steel wheel (1) If necessary, check and adjust the on-the-car balance. Imbalance after adjustment: 8.0 g (0.018 lb.) or less. NOTICE: • Remove dirt, oil and water from the surface where the balance weight is to be adhered with a cleaning detergent. • Do not touch the sticking surface of the tape. • Adhere the sticking type balance weight to the flat position shown in the illustration. • Push the balance weight securely with a finger to adhere it to the position. • Do not reuse the balance weight. HINT: The inner side balance weight should be installed by clipping it to the rim. Approximately 25 mm (0.984 in.) C110354E03 4. INSPECT BEARING LOOSENESS (See page AH-5 for FRONT AXLE, AH-15 for REAR AXLE) 5. INSPECT AXLE HUB RUNOUT (See page AH-6 for FRONT AXLE, AH-15 for REAR AXLE) TW TW–6 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TIRE PRESSURE WARNING SYSTEM PRECAUTION 1. Switch Type Expression EXPRESSIONS OF IGNITION SWITCH (a) The type of ignition switch used on this model differs according to the specification of the valves Ignition Switch (position) Engine Switch (condition) Ignition switch off LOCK Off Ignition switch on (IG) ON On (IG) Ignition switch on (ACC) ACC On (ACC) Engine start START Start 2. TW Tire Pressure Warning Light E129450E01 TIRE PRESSURE WARNING SYSTEM PRECAUTION (a) When the tire pressure warning light comes on, immediately check the tire pressure of the tire and adjust it to the specified value. (The tire pressure warning light will blink (come on after blinking for 1 minute) if there is an open in the tire pressure warning light circuit.) NOTICE: Check the ground spare tire as well since this system monitors pressure of all tires including the ground spare tire. Cold tire inflation pressure Tire size Front kPa (kgf/cm2, psi) Rear kPa (kgf/cm2, psi) P215/60R16 94W 210 (2.1, 31) *1 240 (2.4, 35)*2 210 (2.1, 31) *1 240 (2.4, 35)*2 P215/55R17 93V 220 (2.2, 32) *1 240 (2.4, 35)*2 220 (2.2, 32) *1 240 (2.4, 35)*2 *1: For driving under 100 mph (160 km/h) *2: For driving at 100 mph (160 km/h) or over (b) When the tire pressure warning light blinks (comes on after blinking for 1 minute), there is a malfunction in the system. Check for DTCs. (c) It is necessary to register the transmitter ID in the tire pressure warning ECU after replacing the tire pressure warning valve and transmitter and/or tire pressure warning ECU (See page TW-15). (d) When replacing the tire pressure warning ECU; (1) Using the DATA LIST, read the transmitter IDs registered in the ECU and make a note of them before removing the tire pressure warning ECU. (2) Register the transmitter IDs after installing a new tire pressure warning ECU. TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TW–7 (e) When replacing the tire pressure warning valve and transmitter; (1) Take a note of the 7 digit number (transmitter ID) written on the tire pressure warning valve and transmitter when replacing it. Register the transmitter IDs in the tire pressure warning ECU after replacing the tire pressure warning valve and transmitter and installing the tires and wheels on the vehicle. Tire pressure warning valve and transmitter: Transmitter ID (7 digit number) TW E128762E02 3. NOTICE: The transmitter ID is written on the tire pressure warning valve and transmitter. It will be unable to be read after installing the tire pressure warning valve and transmitter on the tire and wheel. Therefore, take a note of the transmitter ID before installing the tire pressure warning valve and transmitter. (f) When replacing the tire pressure warning ECU and the tire pressure warning valves and transmitters; It is necessary to perform the initialization (See page TW-18) after the registration (See page TW-15). (g) Precautions about the tire pressure; • The tire pressures decrease naturally. • In winter, tire pressure may decrease due to low ambient temperatures (tire pressure decreases by approximately 10 kPa (0.2 kgf/cm2, 1.45 psi) for every 10°C (50°F) drop in the ambient temperature). Therefore, the tire pressure warning is more likely to operate if the tire pressures are not adjusted appropriately. If the daily temperature variation is large, pressurize the tires high so that the tire pressures are suitable under cold conditions. Incorrect tire pressure warning operation becomes less likely. IN CASE OF TIRE AND WHEEL REPLACEMENT (a) When tires and wheels are replaced, always ensure that each transmitter ID is correctly registered. TW–8 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM 4. 5. TW IN CASE OF REPLACEMENT OF TIRE PRESSURE WARNING ECU, TIRE PRESSURE WARNING VALVE AND TRANSMITTER, OR TIRE(S) WITH DIFFERENT TIRE PRESSURE (a) Initialize the tire pressure warning system after any of the following is performed: • Replacing the tire pressure warning ECU or the tire pressure warning valve and transmitter • Installing tire(s) which require different tire pressure HINT: The tire pressure warning system will not operate properly if it is not initialized (See page TW-18). FAIL-SAFE FUNCTION (a) When a system malfunction occurs in the tire pressure warning system, the tire pressure warning light blinks (comes on after blinking for 1 minute) and informs the driver of the system failure. (b) The result of this diagnosis is stored in the tire pressure warning ECU. TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TW–9 PARTS LOCATION COMBINATION METER ASSEMBLY - TIRE PRESSURE WARNING LIGHT TIRE PRESSURE WARNING RESET SWITCH TIRE PRESSURE WARNING ECU TIRE PRESSURE WARNING VALVE AND TRANSMITTER TIRE PRESSURE WARNING ANTENNA AND RECEIVER TIRE PRESSURE WARNING VALVE AND TRANSMITTER TIRE PRESSURE WARNING VALVE AND TRANSMITTER TIRE PRESSURE WARNING VALVE AND TRANSMITTER (*) TIRE PRESSURE WARNING VALVE AND TRANSMITTER *1: GROUND SPARE TIRE E129453E01 TW TW–10 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM SYSTEM DIAGRAM TW Front Tire Pressure Warning Valve Combination Meter and Transmitter LH (Vehicle Speed Signal) Front Tire Pressure Warning Valve and Transmitter RH Combination Meter (Tire Pressure Warning Light) Tire Pressure Warning Antenna and Receiver Tire Pressure Warning ECU Rear Tire Pressure Warning Valve and Transmitter LH Rear Tire Pressure Warning Valve and Transmitter RH DLC3 Tire Pressure Warning Reset Switch Tire Pressure Warning Valve and Transmitter (Spare Tire) (*) : Radio Signal *: Ground Spare Tire C138248E01 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TW–11 SYSTEM DESCRIPTION 1. Combination Meter Assembly DESCRIPTION OF SYSTEM (a) A tire pressure warning valve and transmitter is equipped with a tire pressure sensor and a transmitter and is installed in a tire wheel assembly. The sensor measures the tire pressure. The measured value and transmitter ID are transmitted to the tire pressure warning antenna and receiver on the body as radio waves and then sent to the tire pressure warning ECU from the tire pressure warning antenna and receiver. If the transmitter ID has already been registered, the ECU compares the measured air pressure value with the standard value. When the value is less than the standard value registered in the tire pressure monitor ECU, the warning light on the combination meter comes on. • For the differences in the air pressure settings by the type of tires, a tire pressure warning reset switch has been adopted. Tire Pressure Warning Valve and Transmitter - Tire Pressure Warning Light Tire Pressure Warning Antenna and Receiver Tire Pressure Warning Reset Switch Tire Pressure Warning Valve and Transmitter (*) Front Tire Pressure Warning ECU Tire Pressure Warning Valve and Transmitter *: Ground Spare Tire E129451E02 2. WHEN TIRE PRESSURE WARNING LIGHT IS LIT (a) When the tire pressure warning light does not go off, or when it comes on during driving, check tire pressure. If the tire pressure warning light comes on within several hours after adjusting the tire pressure, the tire may have a slow air leak. (b) Under the following conditions, the system may not function properly. • Facilities or devices that use similar radio frequencies are located in the vicinity of the vehicle. TW TW–12 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TW 3. Components • A radio device of similar frequency is used in the vehicle. • A large amount of snow or ice is stuck to the vehicle, especially onto the wheels and around the wheel houses. • The battery of the sensor has been depleted. • The tires without tire pressure warning valve and transmitter are used. • Tire chains are used. • When the ground spare tire is not within the receivable range of the electric wave, a signal may not be received because the ground spare tire is fixed. Accordingly, the system may not function properly. If there is a possibility that the tire pressure warning system does not receive a signal from the grounde spare tire, rotate the tire 90°. • If any wheels other than the specified ones are used, the system may not function properly because interference may prevent the radio waves from being correctly transmitted from the tire pressure sensor. • Depending on the tire type, the system may not function properly even though the specified wheels are used. (c) The average usage life of the grommet of the tire pressure warning valve and transmitter is approximately 5 years, at which time it must be replaced. Re-tighten the valve nut if the valve is leaking air, although it is less than 5 years old and there is no problem with grommets. (d) After removing and installing the ECU or a sensor, check for a diagnostic code and verify that it is a normal code. FUNCTION OF COMPONENTS Function Tire pressure warning valve and transmitter Combined as a single unit with a disc wheel air valve, it measures tire pressure and temperature and transmits an ID number for measurement value and identification. Built-in the battery. Tire pressure warning antenna and receiver Receives and transmits a necessary signal from the transmitter to the tire pressure warning ECU. Tire pressure warning ECU Receives the signal from the receiver and identifies it as vehicle's own signal. If the measured value is equal to or lower than the specified value, it transmits a signal so that the air pressure warning light on the combination meter comes on. Tire pressure warning light Located in the combination meter, it informs the driver of lowered tire air pressure and system failure. Tire pressure warning reset switch Enters the initialization mode for tire or wheel replacement. TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM 4. TW–13 TIRE PRESSURE WARNING RESET SWITCH • By operating the tire pressure warning reset switch, the tire pressure warning ECU can be set to issue a warning at an inflation pressure that corresponds to the type of tires. Therefore, the dealer must set the warning threshold to the proper value in order to comply with the local regulations. • Operate the tire pressure warning reset switch only after the inflation pressures of all tires (including the full-size spare tire) have been adjusted on the vehicle. • To initialize the system, press and hold the tire pressure warning reset switch for 3 seconds or longer with the ignition switch on (IG). After the initialization process has started, the warning light blinks 3 times (1 second on, 1 second off). • During initialization, the tire pressure warning valve and transmitter measures the inflation pressure of the tires, and registers the signals that are transmitted into the tire pressure warning ECU at a frequency of once per minute. The initialization process is completed when signals from the all tires (including the ground spare tire) have been received. TW TW–14 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING The intelligent tester can be used at steps 3, 7 and 9. 1 Vehicle Brought to Workshop NEXT 2 Customer Problem Analysis NEXT TW 3 Check Tire Pressure Warning Light and Indicator Condition (a) Turn the ignition switch on (IG). (b) Record the condition of the tire pressure warning light on the combination meter assembly. (c) Refer to the "TIRE PRESSURE WARNING LIGHT AND INDICATOR CHART" section of the DIAGNOSIS SYSTEM for checking the condition of the tire pressure warning light (See page TW-24). NEXT 4 DTC Check and Clear DTC is output: Go to step 5 DTC is not output: Go to step 6 5 DTC Chart Go to step 8 6 Problem Symptom Confirmation Symptom does not occur: Symptom simulation Symptom occurs: Go to step 7 7 Problem Symptoms Table Go to step 9 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM 8 TW–15 Circuit Inspection (a) Refer to PRECAUTION (See page TW-6). (b) Refer to SYSTEM DESCRIPTION (See page TW-11). (c) Set the tire pressures to the appropriate specified values. (d) Perform initialization (See page TW-18). (e) Perform test mode procedure (See page TW-20). (1) Check for a DTC (See page TW-28). (2) Clear the DTC. (3) Identify the transmitter corresponding to a DTC. (f) Perform registration of the transmitter ID (See page TW15). (g) Check the terminals of ECU (See page TW-23). (h) Refer to DATA LIST / ACTIVE TEST (See page TW-29). NEXT 9 Repair NEXT 10 Confirmation Test (a) Check for a DTC (See page TW-28). (b) Perform initialization (See page TW-18). (c) Confirm that the initialization has been completed. NEXT End TW TW–16 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM REGISTRATION 1. READ TRANSMITTER ID Prepare the all transmitter ID data before starting registration. HINT: • Read the registered transmitter IDs that are stored in the ECU using the intelligent tester and note them down. • If reading stored transmitter IDs is impossible due to malfunctions of components such as the tire pressure warning antenna and receiver, remove the tires from the wheels and check the IDs located on the tire pressure warning valves and transmitters (See page TW-6). • When replacing the tire pressure warning ECU, read the IDs stored in the old ECU using the intelligent tester. • When replacing the tire pressure warning valves and transmitters, note down the IDs written on the tire pressure warning valves and transmitters. 2. REGISTER TRANSMITTER ID NOTICE: It is necessary to register the transmitter ID in the tire pressure warning ECU when replacing the tire pressure warning valve and transmitter and/or tire pressure warning ECU. TW (a) Connect the intelligent tester to DLC3 (Procedure "A"). (b) Turn the ignition switch on (IG) (Procedure "B"). (c) Select the REGIST TIRE following the intelligent tester screen (UTILITY - REGIST TIRE) (Procedure "C"). DLC3 Intelligent Tester C131977E09 (d) Input the IDs (ID1 to ID4 or ID5) using the intelligent tester and transmit them to the tire pressure warning ECU (Procedure "D"). F100622 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM C107265 TW–17 (e) Set the ID transmission condition to "ID Registration is complete" (Procedure "E"). HINT: • The previously registered IDs will be deleted from the memory when the registration is completed. • If the procedures "C" to "D" are not completed within 5 min. , the mode will return to the normal operation mode. • When the system is in initialization mode after the tire pressure warning reset switch has been operated, the registration is disabled until the initialization process is canceled or completed. TW TW–18 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM Registration Procedure TW F101083E01 3. CONFIRMATION OF TRANSMITTER ID REGISTRATION (a) Connect the intelligent tester to DLC3 (ignition switch is off). (b) Turn the ignition switch on (IG). (c) Select "TIREPRESS" by following the prompts displayed on the intelligent tester. TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TW–19 (d) Confirm that the data of tire pressure of all tires (including the ground spare tire) are displayed on the intelligent tester screen. NOTICE: • It may take up to 1 minute or more to update the tire pressure data. • If the IDs have not been registered, some of DTC C2171/71 is set in the tire pressure warning ECU after 51 minutes or more. TW TW–20 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM INITIALIZATION 1. TW INITIALIZATION NOTICE: • Perform initialization after the transmitter ID registration is completed. • Initialization is necessary after replacing any of the ECU, tires with different tire pressure, or tire pressure warning valve and transmitter, or when a new vehicle is delivered. • Perform the tire pressure adjustment after the vehicle has sufficiently cooled down. If the vehicle is not sufficiently cooled down, increase the air pressure by 20 to 30 kPa (0.2 to 0.3 kgf/ cm2, 2.9 to 4.3 psi) above the specified value. (a) Set the air pressure of all wheels, including the ground spare tire, to the specified value. Cold tire inflation pressure Front kPa (kgf/cm2, psi) Tire size Rear kPa (kgf/cm2, psi) P215/60R16 94W 210 (2.1, 31) *1 240 (2.4, 35)*2 210 (2.1, 31) *1 240 (2.4, 35)*2 P215/55R17 93V 220 (2.2, 32) *1 240 (2.4, 35)*2 220 (2.2, 32) *1 240 (2.4, 35)*2 *1: For driving under 100 mph (160 km/h) *2: For driving at 100 mph (160 km/h) or over (b) Keep the tire pressure warning reset switch pressed for 3 seconds or more with the ignition switch on (IG). (c) Check that the tire pressure warning light blinks 3 times (1 second ON, 1 second OFF). HINT: • Initialization will be completed if signals are received from all the wheels. Initialization will be canceled if the ignition switch is turned off during initialization. Tire Pressure Warning Reset Switch Tire Pressure Warning Light Output Pattern: 1 sec. ON OFF 1 sec. E129454E01 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM DLC3: CG 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 TC F100115E55 TW–21 (d) Wait for 2 or 3 minutes with the ignition switch on (IG). NOTICE: • The initialization is normally completed within 2 to 3 minutes. • If the initialization has not been completed successfully, DTC C2177/77 is set approximately 20 minutes. • The initialization can be terminated by making a short circuit between terminals TC and CG of the DLC3 connector. (e) Confirm that the initialization has been completed using the intelligent tester. (1) Change the mode to test mode using intelligent tester and check that test DTCs have been stored. • The test DTCs will not be indicated until the system initialization is complete. • After the initialization has been completed successfully, the test DTCs (C2181/81 to C2191/91) are indicated. NOTICE: The following operations can be used instead of above procedure 1. Turn the ignition switch from off to on (IG). 2. Monitor the tire pressure values of all the wheels using intelligent tester. 3. If the tire pressure values cannot be displayed on the intelligent tester screen, the initialization has failed. 4. It takes 2 to 3 minutes to display the tire pressure data. HINT: • In winter, as the tire pressure may decrease depending on the ambient temperature, increase the tire pressure by 20 to 30 kPa (0.2 to 0.3 kgf/cm2, 2.9 to 4.3 psi) above the specified value after confirmation that the initialization has been completed. TW TW–22 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TEST MODE PROCEDURE 1. ENTER TEST MODE HINT: • Operation of the tire pressure warning reset switch can be checked in TEST MODE. • During TEST MODE, the system is not initialized by pushing the tire pressure warning reset switch. The circuit of the tire pressure warning reset switch can be inspected during this mode. (a) (b) (c) (d) (e) TW 2. DLC3 Intelligent Tester C131977E01 Make sure that the ignition switch is off. Connect the intelligent tester to DLC3. Turn the ignition switch on (IG). Select the TEST MODE on intelligent tester. Confirm that the tire pressure warning light in the combination meter blinks at 0.125 second intervals. PERFORM SIGNAL CHECK HINT: • When entering signal check mode, the tire pressure warning ECU sets all the signal check DTCs first. After completing signal check for each inspection item, the DTCs for systems that are determined to be normal by the tire pressure warning ECU will be erased. The DTCs for other inspection items may not be erased when only a certain signal is inspected. • When signal check returns to normal mode, all the signal check DTCs will be erased. (a) Make sure that the ignition switch is off. (b) Connect the intelligent tester to DLC3. (c) Turn the ignition switch on (IG). DLC3 Intelligent Tester C131977E01 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TW–23 (d) Select the SIGNAL CHECK on intelligent tester. TW C110644 (e) Drive the vehicle at 12 mph (20 km/h) or more for 10 seconds or more. For checking the vehicle speed signal (C2191/91). (f) Loosen the valve core and rapidly reduce the pressure (at least 40 kPa (0.41 kg/cm2, 5.8 psi) within 30 seconds or more). For checking the transmitter data (C2181/81 to C2185/85). HINT: The transmitter ID can be transmitted by rapidly reducing the tire pressure. (g) Check that the tire pressure warning system test mode DTCs are erased. SIGNAL CHECK DTC C2181/81 to C2185/85 C2191/91 Test Signal Signal Check DTC Clear Condition Transmitter Data Receive data from the transmitter which has a registered ID in the tire pressure warning ECU Vehicle Speed Signal Vehicle speed of 12 mph (20 km/h) or more is detected for 3 seconds or more (h) Check the tire pressure warning reset switch. (1) Press the tire pressure warning reset switch. (2) Check the tire pressure warning indicator light. Test Signal Tire Pressure Warning Reset Switch Normal Condition • • Switch ON: TPWS indicator comes on Switch OFF: TPWS indicator blinks TW–24 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM (i) TW Result HINT: After the signal check is completed, check for a DTC and signal check DTC to confirm the system status. Condition Procedure SIGNAL CHECK DTC is output Repair the faulty part and enter SIGNAL CHECK again SIGNAL CHECK DTCs are cleared No problem (j) End of SIGNAL CHECK After completing the test mode (SIGNAL CHECK), turn the ignition switch off and disconnect the tester. DTC of SIGNAL CHECK (TEST DIAGNOSIS) function: If a trouble code is displayed during the test mode DTC check, check the circuit listed for that code. For details of each code, refer to the relevant page listed under respective "DTC No." in the chart. DTC No. C2181/81 (TW-38) C2182/82 (TW-38) C2183/83 (TW-38) C2184/84 (TW-38) C2185/85 (TW-38) C2191/91 (TW-61) Detection Item Trouble Area Transmitter ID1 not received • • • • Tire pressure warning valve and transmitter Tire pressure warning antenna and receiver Wire harness or connector Tire pressure warning ECU Transmitter ID2 not received • • • • Tire pressure warning valve and transmitter Tire pressure warning antenna and receiver Wire harness or connector Tire pressure warning ECU Transmitter ID3 not received • • • • Tire pressure warning valve and transmitter Tire pressure warning antenna and receiver Wire harness or connector Tire pressure warning ECU Transmitter ID4 not received • • • • Tire pressure warning valve and transmitter Tire pressure warning antenna and receiver Wire harness or connector Tire pressure warning ECU Transmitter ID5 not received • • • • Tire pressure warning valve and transmitter Tire pressure warning antenna and receiver Wire harness or connector Tire pressure warning ECU Vehicle speed signal error • • • • Vehicle speed sensor Combination meter assembly Wire harness or connector Tire pressure warning ECU TW–25 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM PROBLEM SYMPTOMS TABLE HINT: • Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected Area" column of table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. • Inspect the fuses and relays related to this system before inspecting the suspected areas below. TIRE PRESSURE WARNING SYSTEM: Symptom Tire pressure warning system does not operate. DTC check cannot be done. Tire pressure warning light malfunctions (Remains on). Tire pressure warning light malfunctions (Blinking). Initialization cannot be done. Suspected area See page 1. Tire pressure warning valve and transmitter TW-77 2. Tire pressure warning antenna and receiver TW-73 3. Power source circuit TW-67 4. TC and CG terminal circuit TW-69 5. Combination meter assembly ME-15 6. Tire pressure warning ECU TW-82 1. Power source circuit TW-82 2. TC and CG terminal circuit TW-69 3. Tire pressure warning ECU TW-82 1. Tire pressure check TW-3 2. Initialization TW-18 3. Tire pressure warning ECU connector poorly connected TW-24 4. Tire pressure warning light circuit TW-65 5. Tire pressure warning ECU TW-82 1. Check DTC TW-28 2. Tc and CG terminal circuit TW-69 3. Test mode (SIGNAL CHECK) TW-20 4. Tire pressure warning ECU TW-82 1. Test mode (SIGNAL CHECK) TW-20 2. Tire pressure reset switch TW-85 3. Tire pressure warning ECU TW-82 TW TW–26 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TERMINALS OF ECU HINT: Inspect the connectors from the back side while the connectors are connected. E60 E129452E01 TW Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition IG (E60-7) - GND (E60-9) B - W-B IG power source Ignition switch on (IG) 10 to 16 V SPD (E60-2) - GND (E60-9) V - W-B Vehicle speed signal Ignition switch on (IG) Pulse generation (See waveform 1) SIL (E60-10) - GND (E60-9) GR - W-B Diagnostic communication terminal IND (E60-5) - GND (E60-9) L - W-B Tire pressure warning light signal Ignition switch on (IG) 10 to 16 V Ignition switch on (IG) 4.5 to 5.5 V RF5V (E60-6) - GND (E60-9) LC - W-B Tire pressure warning antenna and receiver power source CLSW (E60-1) - GND (E60-9) O - W-B Tire pressure warning reset switch RDA (E60-12) - GND (E60-9) G - W-B Tire pressure warning antenna and receiver signal GND2 (E60-11) - GND (E60-9) BR - W-B Tire pressure warning antenna and receiver ground 1. GND F047507E05 • • Ignition switch on (IG) Intelligent tester is connected to DLC3 Pulse generation (See waveform 2) • • Ignition switch on (IG) Tire pressure warning reset switch on 8 to 15V • • Ignition switch on (IG) The Tire pressure warning antenna and receiver is not connected 9 to 16 V Always Below 1 Ω Waveform 1 (Reference) (a) Waveform Item Contents Terminal SPD - GND Tool setting 5V/DIV, 200ms/DIV. Vehicle condition While driving at approximately 12 mph (20 km/h). TW–27 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM 2. 5V 1 ms Waveform 2 (Reference) (a) Waveform Item GND Contents Terminal SIL - Body ground Tool setting 5 V/DIV., 1 ms/DIV. Vehicle condition Communicating using intelligent tester C107353E03 TW TW–28 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM DIAGNOSIS SYSTEM 1. CHECK BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge the battery before proceeding. 2. CHECK DLC3 (a) The ECU uses the ISO 15765-4 for communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. CG SG CANH SIL TW CANL BAT H100769E16 Symbols (Terminal NO. ) Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always CANH (6) - CANL (14) CANH (6) - CG (4) CANL (14) - CG (4) CANH (6) - BAT (16) CANL (14) - BAT (16) CAN bus line HIGH-level CAN bus line LOW-level CAN bus line HIGH-level CAN bus line LOW-level CAN bus line 11 to 14 V Ignition switch off * 54 to 69 Ω off* 200 Ω or higher Ignition switch off * 200 Ω or higher Ignition switch off * 6 kΩ or higher Ignition switch off * 6 kΩ or higher Ignition switch NOTICE: measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the power switch, or any other switches or the doors. (b) If the result is not as specified, DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of the intelligent tester to DLC3, turn the ignition switch on (IG) and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. • If communication is normal when the tester is connected to another vehicle, inspect DLC3 of the original vehicle. • If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. *Before TW–29 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM 3. DIAGNOSIS SYSTEM (a) DTCs (Normal mode) (1) DTCs are memorized in the tire pressure warning ECU and read by the blinks of the tire pressure warning light or by using the intelligent tester (See page TW-28). (b) Test mode (1) By switching from normal mode into test mode (input signal check), you can inspect the tire pressure warning antenna and receiver, each tire pressure warning valve and transmitter, and vehicle speed sensor (See page TW-20). 4. CHECK WARNING LIGHT (a) Turn the ignition switch on (IG). (b) Check that the tire pressure warning light comes on for 3 seconds. If the warning check result is not normal, proceed to the troubleshooting for the tire pressure warning light circuit. Tire Pressure Warning Light Trouble Area See procedure Tire pressure warning light circuit TW-65 E129450E01 5. TIRE PRESSURE WARNING LIGHT AND INDICATOR CHART HINT: The table below indicates the state of the tire pressure warning light and indicator after the ignition switch is turned on (IG). Always Immediately after turning the ignition switch on (IG) Warning light output pattern Comes on for 3 sec. Goes off Comes on Blinks (*1) Blinks (*2) Blinks (*3) Outputs DTC Normal { { - - - - - Low tire pressure { - { - - - - System fail { - - { - - - Test mode { - - - { - - Initialization { - - - - { - ECU connector poorly connected - - - { - - - TC ground { - - - - - { *1: Comes on and goes off repeatedly at 0.5 second intervals, and comes on after 1 minute. 0.5 sec. ON OFF 0.5 sec. 1 minute E133091E01 TW TW–30 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM *2: Comes on and goes off repeatedly at 0.125 second intervals. 0.125 sec. ON OFF 0.125 sec. C110635E01 *3: Blinks 3 times (1 second on, 1 second off). 1 sec. ON TW OFF 1 sec. C110636E01 TW–35 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM DIAGNOSTIC TROUBLE CODE CHART HINT: • If no abnormality is found when the parts are inspected, inspect the tire pressure warning ECU. • If a malfunction code is displayed during the DTC check, inspect the circuit listed for that code. For details of each code, refer to the relevant page listed under respective "DTC No." in the DTC chart. TIRE PRESSURE WARNING SYSTEM DTC No. Detection Item Trouble Area See page C2111/11 Transmitter ID1 Operation Stop 1. Tire pressure warning valve and transmitter 2. Tire pressure warning ECU TW-34 C2112/12 Transmitter ID2 Operation Stop 1. Tire pressure warning valve and transmitter 2. Tire pressure warning ECU TW-34 C2113/13 Transmitter ID3 Operation Stop 1. Tire pressure warning valve and transmitter 2. Tire pressure warning ECU TW-34 C2114/14 Transmitter ID4 Operation Stop 1. Tire pressure warning valve and transmitter 2. Tire pressure warning ECU TW-34 C2115/15 Transmitter ID5 Operation Stop 1. Tire pressure warning valve and transmitter 2. Tire pressure warning ECU TW-34 C2121/21 No Signal from Transmitter ID1 in Main Mode 1. Tire pressure warning valve and transmitter 2. Tire pressure warning antenna and receiver 3. Wire harness or connector 4. Tire pressure warning ECU TW-38 C2122/22 No Signal from Transmitter ID2 in Main Mode 1. Tire pressure warning valve and transmitter 2. Tire pressure warning antenna and receiver 3. Wire harness or connector 4. Tire pressure warning ECU TW-38 C2123/23 No Signal from Transmitter ID3 in Main Mode 1. Tire pressure warning valve and transmitter 2. Tire pressure warning antenna and receiver 3. Wire harness or connector 4. Tire pressure warning ECU TW-38 C2124/24 No Signal from Transmitter ID4 in Main Mode 1. Tire pressure warning valve and transmitter 2. Tire pressure warning antenna and receiver 3. Wire harness or connector 4. Tire pressure warning ECU TW-38 C2125/25 No Signal from Transmitter ID5 in Main Mode 1. Tire pressure warning valve and transmitter 2. Tire pressure warning antenna and receiver 3. Wire harness or connector 4. Tire pressure warning ECU TW-38 C2141/41 Transmitter ID1 Error 1. Tire pressure warning valve and transmitter 2. Tire pressure warning ECU TW-46 C2142/42 Transmitter ID2 Error 1. Tire pressure warning valve and transmitter 2. Tire pressure warning ECU TW-46 TW TW–36 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM DTC No. TW Detection Item Trouble Area See page C2143/43 Transmitter ID3 Error 1. Tire pressure warning valve and transmitter 2. Tire pressure waning ECU TW-46 C2144/44 Transmitter ID4 Error 1. Tire pressure warning valve and transmitter 2. Tire pressure warning ECU TW-46 C2145/45 Transmitter ID5 Error 1. Tire pressure warning valve and transmitter 2. Tire pressure warning ECU TW-46 C2165/65 Abnormal Temperature Inside ID1 Tire 1. Tires 2. Tire pressure warning valve and transmitter 3. Tire pressure warning ECU TW-49 C2166/66 Abnormal Temperature Inside ID2 Tire 1. Tires 2. Tire pressure warning valve and transmitter 3. Tire pressure warning ECU TW-49 C2167/67 Abnormal Temperature Inside ID3 Tire 1. Tires 2. Tire pressure warning valve and transmitter 3. Tire pressure warning ECU TW-49 C2168/68 Abnormal Temperature Inside ID4 Tire 1. Tires 2. Tire pressure warning valve and transmitter 3. Tire pressure warning ECU TW-49 C2169/69 Abnormal Temperature Inside ID5 Tire 1. Tires 2. Tire pressure warning valve and transmitter 3. Tire pressure warning ECU TW-49 C2176/76 Receiver Error 1. Tire pressure warning antenna and receiver 2. Wire harness or connector 3. Tire pressure warning ECU TW-55 C2171/71 Transmitter ID not Registered Tire pressure warning ECU TW-53 C2177/77 Initialization not Completed 1. Tire pressure warning valve and transmitter 2. Tire pressure warning ECU 3. Tire pressure warning antenna and receiver 4. Tire pressure warning reset switch 5. Wire harness or connector TW-58 C2181/81 Transmitter ID1 not Received (Test Mode DTC) 1. Tire pressure warning valve and transmitter 2. Tire pressure warning antenna and receiver 3. Wire harness or connector 4. Tire pressure warning ECU TW-38 C2182/82 Transmitter ID2 not Received (Test Mode DTC) 1. Tire pressure warning valve and transmitter 2. Tire pressure warning antenna and receiver 3. Wire harness or connector 4. Tire pressure warning ECU TW-38 C2183/83 Transmitter ID3 not Received (Test Mode DTC) 1. Tire pressure warning valve and transmitter 2. Tire pressure warning antenna and receiver 3. Wire harness or connector 4. Tire pressure warning ECU TW-38 TW–37 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM Trouble Area See page C2184/84 DTC No. Transmitter ID4 not Received (Test Mode DTC) Detection Item 1. Tire pressure warning valve and transmitter 2. Tire pressure warning antenna and receiver 3. Wire harness or connector 4. Tire pressure warning ECU TW-38 C2185/85 Transmitter ID5 not Received (Test Mode DTC) 1. Tire pressure warning valve and transmitter 2. Tire pressure warning antenna and receiver 3. Wire harness or connector 4. Tire pressure warning ECU TW-38 C2191/91 Vehicle Speed Signal Error (Test Mode DTC) 1. Vehicle speed sensor 2. Tire pressure warning ECU 3. Combination meter 4. Wire harness or connector TW-61 TW TW–33 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM DATA LIST / ACTIVE TEST 1. Item DATA LIST (a) Connect the intelligent tester to DLC3. (b) Turn the ignition switch on (IG). (c) Following the display on the intelligent tester, read "DATA LIST". Measurement item/ Range (Display) Normal Condition Diagnostic Note MODE STATUS Tire pressure warning system mode/NORMAL or REG 2nd or REG M or TEST NORMAL: Normal mode TEST: Test mode - MAIN TIRE Number of main tire ID to be registered/ 0 or 1 or 2 or 3 or 4 or 5 0 to 5 should be displayed - INITIAL SW Tire pressure warning reset switch/ON, OFF ON: Switch on OFF: Switch off - VEHICLE SPEED Vehicle speed reading/ min.: 0 km/h (0 mph), max.: 255 km/h (158 mph) Actual vehicle speed Speed indicated on the combination meter REGIT ID1 CODE Registered ID1 code/min.: 0, max.: FFFFFFF The ID No. registered in the transmitter ID1 is displayed - REGIT ID2 CODE Registered ID2 code/min.: 0, max.: FFFFFFF The ID No. registered in the transmitter ID2 is displayed - REGIT ID3 CODE Registered ID3 code/min.: 0, max.: FFFFFFF The ID No. registered in the transmitter ID3 is displayed - REGIT ID4 CODE Registered ID4 code/min.: 0, max.: FFFFFFF The ID No. registered in the transmitter ID4 is displayed - REGIT ID5 CODE Registered ID5 code/min.: 0, max.: FFFFFFF The ID No. registered in the transmitter ID5 is displayed - TRANS STATUS ID code transmission status/ FINISH or NOW FINISH or NOW - Actual tire inflation pressure - Actual tire inflation pressure - Actual tire inflation pressure - Actual tire inflation pressure - Actual tire inflation pressure - ID1 tire inflation pressure/ TIREPRESS1 min.: 0 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/cm2, 92.2 psi) ID2 tire inflation pressure/ TIREPRESS2 min.: 0 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/cm2, 92.2 psi) ID3 tire inflation pressure/ TIREPRESS3 min.: 0 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/cm2, 92.2 psi) ID4 tire inflation pressure/ TIREPRESS4 min.: 0 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/cm2, 92.2 psi) ID5 tire inflation pressure/ TIREPRESS5 min.: 0 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/cm2, 92.2 psi) TIRE TEMP1 ID1 temperature in tire/ min.: -40°C (-40°F), max.: 215°C (419°F) Actual tire temperature - TIRE TEMP2 ID2 temperature in tire/ min.: -40°C (-40°F), max.: 215°C (419°F) Actual tire temperature - TIRE TEMP3 ID3 temperature in tire/ min.: -40°C (-40°F), max.: 215°C (419°F) Actual tire temperature - TIRE TEMP4 ID4 temperature in tire/ min.: -40°C (-40°F), max.: 215°C (419°F) Actual tire temperature - TW TW–34 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM Item TW Measurement item/ Range (Display) Normal Condition Diagnostic Note TIRE TEMP5 ID5 temperature in tire/ min.: -40°C (-40°F), max.: 215°C (419°F) Actual tire temperature - BATT VOLT1 ID1 battery voltage/ OVER or LESS OVER - BATT VOLT2 ID2 battery voltage/ OVER or LESS OVER - BATT VOLT3 ID3 battery voltage/ OVER or LESS OVER - BATT VOLT4 ID4 battery voltage/ OVER or LESS OVER - BATT VOLT5 ID5 battery voltage/ OVER or LESS OVER - SELECT SW INFO Select switch setting information/ WITH or WITHOUT WITH or WITHOUT - INITIAL SW INFO Tire pressure warning reset switch setting information/ WITH or WITHOUT WITH or WITHOUT - Tire pressure after initialization - Tire pressure after initialization - Tire pressure after initialization - Tire pressure after initialization - Tire pressure after initialization - Min.: 0, Max.: - - ID1 initial threshold of low-pressure/ INIT THRESHOLD1 min.: 0 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kpa (6.48 kgf/cm2, 92.2 psi) ID2 initial threshold of low-pressure/ INIT THRESHOLD2 min.: 0 kpa (0 kgf/cm2, 0 psi), max.: 637.5 kpa (6.48 kgf/cm2, 92.2 psi) ID3 initial threshold of low-pressure/ INIT THRESHOLD3 min.: 0 kpa (0 kgf/cm2, 0 psi), max.: 637.5 kpa (6.48 kgf/cm2, 92.2 psi) ID4 initial threshold of low-pressure/ INIT THRESHOLD4 min.: 0 kpa (0 kgf/cm2, 0 psi), max.: 637.5 kpa (6.48 kgf/cm2, 92.2 psi) ID5 initial threshold of low-pressure/ INIT THRESHOLD5 min.: 0 kpa (0 kgf/cm2, 0 psi), max.: 637.5 kpa (6.48 kgf/cm2, 92.2 psi) # CODES Number of DTC recorded/ min.: 0, max.: 255 TW–35 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM DIAGNOSTIC TROUBLE CODE CHART HINT: • If no abnormality is found when the parts are inspected, inspect the tire pressure warning ECU. • If a malfunction code is displayed during the DTC check, inspect the circuit listed for that code. For details of each code, refer to the relevant page listed under respective "DTC No." in the DTC chart. TIRE PRESSURE WARNING SYSTEM DTC No. Detection Item Trouble Area See page C2111/11 Transmitter ID1 Operation Stop 1. Tire pressure warning valve and transmitter 2. Tire pressure warning ECU TW-34 C2112/12 Transmitter ID2 Operation Stop 1. Tire pressure warning valve and transmitter 2. Tire pressure warning ECU TW-34 C2113/13 Transmitter ID3 Operation Stop 1. Tire pressure warning valve and transmitter 2. Tire pressure warning ECU TW-34 C2114/14 Transmitter ID4 Operation Stop 1. Tire pressure warning valve and transmitter 2. Tire pressure warning ECU TW-34 C2115/15 Transmitter ID5 Operation Stop 1. Tire pressure warning valve and transmitter 2. Tire pressure warning ECU TW-34 C2121/21 No Signal from Transmitter ID1 in Main Mode 1. Tire pressure warning valve and transmitter 2. Tire pressure warning antenna and receiver 3. Wire harness or connector 4. Tire pressure warning ECU TW-38 C2122/22 No Signal from Transmitter ID2 in Main Mode 1. Tire pressure warning valve and transmitter 2. Tire pressure warning antenna and receiver 3. Wire harness or connector 4. Tire pressure warning ECU TW-38 C2123/23 No Signal from Transmitter ID3 in Main Mode 1. Tire pressure warning valve and transmitter 2. Tire pressure warning antenna and receiver 3. Wire harness or connector 4. Tire pressure warning ECU TW-38 C2124/24 No Signal from Transmitter ID4 in Main Mode 1. Tire pressure warning valve and transmitter 2. Tire pressure warning antenna and receiver 3. Wire harness or connector 4. Tire pressure warning ECU TW-38 C2125/25 No Signal from Transmitter ID5 in Main Mode 1. Tire pressure warning valve and transmitter 2. Tire pressure warning antenna and receiver 3. Wire harness or connector 4. Tire pressure warning ECU TW-38 C2141/41 Transmitter ID1 Error 1. Tire pressure warning valve and transmitter 2. Tire pressure warning ECU TW-46 C2142/42 Transmitter ID2 Error 1. Tire pressure warning valve and transmitter 2. Tire pressure warning ECU TW-46 TW TW–36 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM DTC No. TW Detection Item Trouble Area See page C2143/43 Transmitter ID3 Error 1. Tire pressure warning valve and transmitter 2. Tire pressure waning ECU TW-46 C2144/44 Transmitter ID4 Error 1. Tire pressure warning valve and transmitter 2. Tire pressure warning ECU TW-46 C2145/45 Transmitter ID5 Error 1. Tire pressure warning valve and transmitter 2. Tire pressure warning ECU TW-46 C2165/65 Abnormal Temperature Inside ID1 Tire 1. Tires 2. Tire pressure warning valve and transmitter 3. Tire pressure warning ECU TW-49 C2166/66 Abnormal Temperature Inside ID2 Tire 1. Tires 2. Tire pressure warning valve and transmitter 3. Tire pressure warning ECU TW-49 C2167/67 Abnormal Temperature Inside ID3 Tire 1. Tires 2. Tire pressure warning valve and transmitter 3. Tire pressure warning ECU TW-49 C2168/68 Abnormal Temperature Inside ID4 Tire 1. Tires 2. Tire pressure warning valve and transmitter 3. Tire pressure warning ECU TW-49 C2169/69 Abnormal Temperature Inside ID5 Tire 1. Tires 2. Tire pressure warning valve and transmitter 3. Tire pressure warning ECU TW-49 C2176/76 Receiver Error 1. Tire pressure warning antenna and receiver 2. Wire harness or connector 3. Tire pressure warning ECU TW-55 C2171/71 Transmitter ID not Registered Tire pressure warning ECU TW-53 C2177/77 Initialization not Completed 1. Tire pressure warning valve and transmitter 2. Tire pressure warning ECU 3. Tire pressure warning antenna and receiver 4. Tire pressure warning reset switch 5. Wire harness or connector TW-58 C2181/81 Transmitter ID1 not Received (Test Mode DTC) 1. Tire pressure warning valve and transmitter 2. Tire pressure warning antenna and receiver 3. Wire harness or connector 4. Tire pressure warning ECU TW-38 C2182/82 Transmitter ID2 not Received (Test Mode DTC) 1. Tire pressure warning valve and transmitter 2. Tire pressure warning antenna and receiver 3. Wire harness or connector 4. Tire pressure warning ECU TW-38 C2183/83 Transmitter ID3 not Received (Test Mode DTC) 1. Tire pressure warning valve and transmitter 2. Tire pressure warning antenna and receiver 3. Wire harness or connector 4. Tire pressure warning ECU TW-38 TW–37 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM Trouble Area See page C2184/84 DTC No. Transmitter ID4 not Received (Test Mode DTC) Detection Item 1. Tire pressure warning valve and transmitter 2. Tire pressure warning antenna and receiver 3. Wire harness or connector 4. Tire pressure warning ECU TW-38 C2185/85 Transmitter ID5 not Received (Test Mode DTC) 1. Tire pressure warning valve and transmitter 2. Tire pressure warning antenna and receiver 3. Wire harness or connector 4. Tire pressure warning ECU TW-38 C2191/91 Vehicle Speed Signal Error (Test Mode DTC) 1. Vehicle speed sensor 2. Tire pressure warning ECU 3. Combination meter 4. Wire harness or connector TW-61 TW TW–38 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM DTC C2111/11 Transmitter ID1 Operation Stop DTC C2112/12 Transmitter ID2 Operation Stop DTC C2113/13 Transmitter ID3 Operation Stop DTC C2114/14 Transmitter ID4 Operation Stop DTC C2115/15 Transmitter ID5 Operation Stop DESCRIPTION TW The tire pressure warning valve and transmitters that are installed in the tire and wheel assemblies measure the air pressures of the tires. The measured values are transmitted to the tire pressure warning antenna and receiver on the body as radio waves and then sent to the tire pressure warning ECU. The ECU compares the measured air pressure values with the air pressure threshold. When the measured air pressure value is less than this threshold, the warning light in the combination meter comes on. The tire pressure warning ECU stores a DTC when the tire pressure warning valve and transmitter stops transmitting signals. At this time, forcibly transmit the signals by releasing the tire pressure rapidly. The stored DTC is cleared when the signal transmission is resumed. DTC No. DTC Detecting Condition C2111/11 C2112/12 C2113/13 C2114/14 C2115/15 Tire pressure warning valve and transmitters stop transmitting signals Trouble Area • • Tire pressure warning valve and transmitter Tire pressure warning ECU HINT: • It is necessary to perform the procedure to identify the tire pressure warning valve and transmitter that is malfunctioning because it cannot be identified by the output DTC. • DTC C2115/15 are used only when the vehicle is equipped with a ground spare tire. TW–39 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM WIRING DIAGRAM Tire Pressure Warning Valve and Transmitter (Front RH) Tire Pressure Warning ECU Tire Pressure Warning Valve and Transmitter (Front LH) Tire Pressure Warning Valve and Transmitter (Rear RH) TW Tire Pressure Warning Valve and Transmitter (Rear LH) Tire Pressure Warning Valve and Transmitter (Ground Spear Tire) 5 N20 *1 1 N20 *1 4 N20 *1 Tire Pressure Warning Antenna and Receiver 5 N34 *2 1 N34 *2 4 N34 *2 6 E60 RF5V 12 E60 RDA 11 E60 GND2 9 E60 GND E53 Tire Pressure Warning Reset Switch 2 *1: TMC Made 1 1 E60 CLSW *2: TMMK Made E130159E01 TW–40 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM INSPECTION PROCEDURE NOTICE: • It is necessary to perform initialization (See page TW-18) after registration (See page TW-15) of the transmitter IDs into the tire pressure warning ECU after the ECU and/or valve and transmitter has been replaced. HINT: Set the tire pressure to the specified value. 1 PERFORM FORCED TRANSMISSION OF TRANSMITTER ID OF ALL WHEELS (a) Set the tire pressure to the specified value. Cold tire Inflation Pressure Tire size Front kPa (kgf/cm2, psi) Rear kPa (kgf / cm2, psi) P215/60R16 94 V 210 (2.1, 31) 210 (2.1, 31) P215/55R17 93 V 220 (2.2, 32) 220 (2.2, 32) TW (b) Connect the intelligent tester to the DLC3. (c) Turn the ignition switch on (IG) and turn the tester ON. (d) Select "TIREPRESS" by following the prompts displayed on the intelligent tester. Item Measurement Item/Range (display) Normal Condition Diagnostic Note Actual tire inflation pressure - Actual tire inflation pressure - Actual tire inflation pressure - Actual tire inflation pressure - Actual tire inflation pressure - ID1 tire inflation pressure / min.:0 TIREPRESS1 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf / cm2, 92.2 psi) ID2 tire inflation pressure / min.:0 TIREPRESS2 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf / cm2, 92.2 psi) ID3 tire inflation pressure / min.:0 TIREPRESS3 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf / cm2, 92.2 psi) ID4 tire inflation pressure / min.:0 TIREPRESS4 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf / cm2, 92.2 psi) ID5 tire inflation pressure / min.:0 TIREPRESS5 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf / cm2, 92.2 psi) (e) Rapidly release the pressures from each wheel by approximately 40 kPa (0.4 kgf / cm2, 5.8 psi) /30 seconds or more. (1) Check that each tire pressure data displayed on the intelligent tester screen has changed. OK: Each tire pressure data displayed on the intelligent tester screen will change to the value of the tire pressure. NOTICE: • It takes about 1 minute or more to display the updated tire pressure data. TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TW–41 • When the "TIREPRESS" data has not changed, reset the tire pressure to the appropriate specified value and rotate the tire 90 to 270 degrees (including the ground spare tire). Then rapidly release the tire pressure and recheck it. (2) After confirming that all of the tire pressure data displayed on the intelligent tester screen have changed, set the tire pressure to the appropriate specified values. HINT: If the tire pressure data displayed on the intelligent tester screen has not changed after rechecking, go to other problem procedure (For malfunction in transmission or reception function (See page TW23) NG OK END INSPECT OTHER PROBLEM (MALFUNCTION IN TRANSMISSION OR RECEPTION FUNCTION) TW TW–42 TW TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM DTC C2121/21 No Signal from Transmitter ID1 in Main Mode DTC C2122/22 No Signal from Transmitter ID2 in Main Mode DTC C2123/23 No Signal from Transmitter ID3 in Main Mode DTC C2124/24 No Signal from Transmitter ID4 in Main Mode DTC C2125/25 No Signal from Transmitter ID5 in Main Mode DTC C2181/81 Transmitter ID1 not Received (Test Mode DTC) DTC C2182/82 Transmitter ID2 not Received (Test Mode DTC) DTC C2183/83 Transmitter ID3 not Received (Test Mode DTC) DTC C2184/84 Transmitter ID4 not Received (Test Mode DTC) DTC C2185/85 Transmitter ID5 not Received (Test Mode DTC) DESCRIPTION The tire pressure warning valve and transmitters that are installed in the tire and wheel assemblies measure the air pressure of the tires. The measured values are transmitted to the tire pressure warning antenna and receiver on the body as radio waves and then sent to the tire pressure warning ECU. The ECU compares the measured air pressure values with the air pressure threshold. When the measured air pressure value is less than this threshold, the warning light in the combination meter comes on. The tire pressure warning valve and transmitters constantly send radio waves to the tire pressure warning antenna and receiver. Under the following conditions below, the tire pressure warning antenna and receiver is unable to receive the signals from the tire pressure warning valves and transmitters, and a DTC is stored. • Facilities or devices that use similar radio frequencies are located in the vicinity of the vehicle. • Devices using similar radio frequencies are used in the vehicle. HINT: When no signals are received for 51 minutes or more, a DTC is output. DTCs from C2121/21 to C2125/25 can only be cleared by using the tester. DTCs from C2181/81 to C2184/84 or C2185/85 can be cleared when the transmitter in the tire pressure warning valve and transmitter sends a forced transmission signal or test mode ends. DTCs from C2181/81 to C2184/84 or C2185/85 are output only in test mode. DTC No. DTC Detecting Condition C2121/21 C2122/22 C2123/23 C2124/24 C2125/25 These DTCs are detected when no signals are received for 51 minutes or more. • • • • Tire pressure warning valve and transmitter Tire pressure warning antenna and receiver Wire harness or connector Tire pressure warning ECU Malfunction in the transmitting/receiving circuit • • • • Tire pressure warning valve and transmitter Tire pressure warning antenna and receiver Wire harness or connector Tire pressure warning ECU C2181/81 C2182/82 C2183/83 C2184/84 C2185/85 Trouble Area TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TW–43 HINT: • It is necessary to perform the procedure to identify the tire pressure warning valve and transmitter that is malfunctioning because it cannot be identified by the output DTC. • DTCs C2125/25 and C2185/85 are used only when the vehicle is equipped with a ground spare tire. TW TW–44 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM WIRING DIAGRAM Tire Pressure Warning Valve and Transmitter (Front RH) Tire Pressure Warning ECU Tire Pressure Warning Valve and Transmitter (Front LH) Tire Pressure Warning Valve and Transmitter (Rear RH) TW Tire Pressure Warning Valve and Transmitter (Rear LH) Tire Pressure Warning Valve and Transmitter (Ground Spear Tire) 5 N20 *1 1 N20 *1 4 N20 *1 Tire Pressure Warning Antenna and Receiver 5 N34 *2 1 N34 *2 4 N34 *2 6 E60 RF5V 12 E60 RDA 11 E60 GND2 9 E60 GND E53 Tire Pressure Warning Reset Switch 2 *1: TMC Made 1 1 E60 CLSW *2: TMMK Made E130159E01 TW–45 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM INSPECTION PROCEDURE NOTICE: • When replacing the tire pressure warning ECU, read the IDs stored in the ECU using the intelligent tester and write them down before removal. • It is necessary to perform initialization (See page TW-18) after registration (See page TW-15) of the transmitter IDs into the tire pressure warning ECU after the ECU and/or valve and transmitter has been replaced. HINT: Set the tire pressure to the specified value. 1 CHECK FREQUENCY RECEIVING CONDITION (a) Check if the vehicle is not located in areas such as described below: (1) Facilities or devices that use similar radio frequencies are located in the vicinity of the vehicle. HINT: If the vehicle is located in areas described above, the tire pressure warning light may come on only in a particular area. (2) Devices using similar radio frequencies are used in the vehicle. OK: Facilities, or devices that use similar radio frequencies are not located in the vicinity of the vehicle. HINT: Radio frequency may be interrupted due to surroundings or devices installed by user. NG CHECK IF ANY DEVICE IS INSTALLED BY USER OK 2 IDENTIFY TRANSMITTER CORRESPONDING TO DTC (a) Set the tire pressure to the appropriate specified values. Cold tire inflation pressure Tire size Front kPa (kgf/cm2, psi) Rear kPa (kgf/cm2, psi) P215/60R16 94V 210 (2.1, 31) 210 (2.1, 31) P215/55R17 93V 220 (2.2, 32) 220 (2.2, 32) (b) Select "Tire inflation Pressure" by following the prompts displayed on the intelligent tester. Item Measurement Item/Range (display) Normal Condition Diagnostic Note Actual tire inflation pressure - Actual tire inflation pressure - ID1 tire inflation pressure/ TIREPRESS1 min.: 0 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/cm2, 92.2 psi) ID2 tire inflation pressure/ TIREPRESS2 min.: 0 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/cm2, 92.2 psi) TW TW–46 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM Item Measurement Item/Range (display) Normal Condition Diagnostic Note Actual tire inflation pressure - Actual tire inflation pressure - Actual tire inflation pressure - ID3 tire inflation pressure/ TIREPRESS3 min.: 0 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/cm2, 92.2 psi) ID4 tire inflation pressure/ TIREPRESS4 min.: 0 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/cm2, 92.2 psi) ID5 tire inflation pressure/ TIREPRESS5 min.: 0 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/cm2, 92.2 psi) (c) Rapidly reduce the tire pressure for each wheel at least 40 kPa (0.41 kg/cm2, 5.8 psi) within 30 seconds. (d) Check the DATA LIST. NOTICE: • It takes about 1 minute or more to display the updated tire pressure data. • When no "Tire Inflation Pressure" data has changed, reset the tire pressure to the appropriate specified value and rotate the tire 90 to 270 degrees. Then rapidly release the tire pressure and recheck it. • Record the transmitter ID of which "Tire Inflation Pressure" data corresponds to each tire. (e) After confirming that one of "Tire Inflation Pressure" data for one tire (ID1 to ID4 or ID5) has changed, repeat this procedure one by one. Identify the transmitter that corresponds to DTC. Result TW Condition Proceed to One or more of transmitters abnormal A All normal B All abnormal C A B C Go to step 4 END TW–47 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM 3 CHECK HARNESS AND CONNECTOR (ECU - RECEIVER) Wire Harness Side Connector Front View: Tire Pressure Warning ECU RF5V E60 (a) (b) (c) (d) Disconnect the E60 ECU connector. Disconnect the N20 receiver connector.*1 Disconnect the N34 receiver connector.*2 Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection RDA E60-12 (RDA) - N20-1 (RDA) GND2 Specified Condition *1 E60-12 (RDA) - N34-1 (RDA)*2 E60-11 (GND2) - N20-4 (GND)*1 Tire Pressure Warning Receiver with Antenna Below 1 Ω E60-6 (RF5V) - N20-5 (+5V)*1 E60-6 (RF5V) - N34-5 (+5V) TW HINT: • *1: TMC Made • *2: TMMK Made *1 N20 +5V *2 N34 E60-11 (GND2) - N34-4 (GND)*2 NG RDA GND REPAIR OR REPLACE HARNESS OR CONNECTOR E129461E03 OK 4 INSPECT TIRE PRESSURE WARNING VALVE AND TRANSMITTER (a) Select REGIT ID CODE by following the prompts displayed on the intelligent tester. Item Measurement Item/Range (Display) Normal Condition Diagnostic Note REGIT ID1 CODE Registered ID1 code/ min.: 0, max.: FFFFFF* The ID No. registered in the transmitter ID1 is displayed *: Displayed only when the ID No. is not registered. REGIT ID2 CODE Registered ID2 code/ min.: 0, max.: FFFFFF* The ID No. registered in the transmitter ID2 is displayed *: Displayed only when the ID No. is not registered. REGIT ID3 CODE Registered ID3 code/ min.: 0, max.: FFFFFF* The ID No. registered in the transmitter ID3 is displayed *: Displayed only when the ID No. is not registered. REGIT ID4 CODE Registered ID4 code/ min.: 0, max.: FFFFFF* The ID No. registered in the transmitter ID4 is displayed *: Displayed only when the ID No. is not registered. REGIT ID5 CODE Registered ID5 code/ min.: 0, max.: FFFFFF* The ID No. registered in the transmitter ID5 is displayed *: Displayed only when the ID No. is not registered. (b) Check the ID number on the identified transmitter by removing it from the tire and wheel. TW–48 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM Tire pressure warning valve and transmitter: Transmitter ID (7 digit number) E128762E01 TW (c) Confirm that the ID number on the transmitter and recorded transmitter ID match. Result Result Proceed to Match A Do nor match B B Go to step 6 A 5 REPLACE TIRE PRESSURE WARNING VALVE AND TRANSMITTER HINT: (See page TW-77) NEXT 6 REGISTRATION OF TRANSMITTER ID (a) Perform registration (See page TW-15). (b) Set the tire air pressure of all wheels to the specified value (For the specified value, See step 2). NEXT 7 PERFORM INITIALIZATION (a) Perform initialization (See page TW-18). NEXT 8 READ VALUE OF DATA LIST (a) Turn the ignition switch off, and then turn it on (IG). TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TW–49 (b) Select "TIREPRESS" by following the prompts displayed on the intelligent tester. HINT: It may take up to 1 minute or more to display the tire pressure data. Result Condition Proceed to All tire pressure readings are equal to specified values. A Tire pressure values are not displayed. B B REPLACE TIRE PRESSURE WARNING ECU A END TW TW–50 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM DTC C2141/41 Transmitter ID1 Error DTC C2142/42 Transmitter ID2 Error DTC C2143/43 Transmitter ID3 Error DTC C2144/44 Transmitter ID4 Error DTC C2145/45 Transmitter ID5 Error DESCRIPTION TW The tire pressure warning valve and transmitters that are installed in the tire and wheel assemblies measure the air pressure of the tires. The measured values are transmitted to the tire pressure warning antenna and receiver on the body as radio waves and then sent to the tire pressure warning ECU. The ECU compares the measured air pressure values with the air pressure threshold. When the measured air pressure value is less than this threshold, the warning light in the combination meter comes on. When the internal circuit of the tire pressure warning valve and transmitter is malfunctioning, this DTC is output. DTC No. C2141/41 C2142/42 C2143/43 C2144/44 C2145/45 DTC Detecting Condition If an "ERROR" signal is received 3 times consecutively, the tire pressure warning valve and transmitter will be judged as defective and a DTC will be output. This will happen in situations where the inflation pressure is outside the range 0 to 637.5 kPa (0 to 6.48 kgf/cm2, 0 psi to 92.2 psi), the temperature inside the tire is outside the specified range -40 to 120°C (-40 to 253°F), or an error occurs in the tire pressure warning valve and transmitter or the surrounding area. Trouble Area • • Tire pressure warning valve and transmitter Tire pressure warning ECU HINT: • It is necessary to perform the procedure to identify the tire pressure warning valve and transmitter that is malfunctioning because it cannot be identified by the output DTC. • DTC 2145/45 is used only when the vehicle is equipped with ground spare tire. INSPECTION PROCEDURE NOTICE: • When replacing the tire pressure warning ECU, read the IDs stored in the ECU using the intelligent tester and write them down before removal. • It is necessary to perform initialization (See page TW-18) after registration (See page TW-15) of the transmitter IDs into the tire pressure warning ECU after the ECU and/or valve and transmitter has been replaced. 1 IDENTIFY TRANSMITTER CORRESPONDING TO DTC (a) Set the tire pressure to the specified value. Cold tire inflation pressure Tire size Front kPa (kgf/cm2, psi) Rear kPa (kgf/cm2, psi) P215/60R16 94W 210 (2.1, 31) *1 240 (2.4, 35)*2 210 (2.1, 31) *1 240 (2.4, 35)*2 P215/55R17 93V 220 (2.2, 32) *1 240 (2.4, 35)*2 220 (2.2, 32) *1 240 (2.4, 35)*2 *1: For driving under 100 mph (160 km/h) *2: For driving at 100 mph (160 km/h) or over TW–51 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM (b) Display the "Tire Inflation Pressure" data for each wheel using the intelligent tester. (c) Rapidly reduce the tire pressure for each wheel at least 40 kPa (0.41 kg/cm2, 5.8 psi) within 30 seconds. If "Tire Inflation Pressure" displayed on the tester (ID1 to ID4 or ID5) does not change, the tire pressure monitor valve corresponds to the DTC that was detected. HINT: • Identify the malfunctioning tire pressure monitor valve by repeatedly decreasing the tire pressure for each tire. • Record which "TIREPRESS" data (ID1 to ID4 or ID5) corresponds to each tire. Measurement Item/Range (display) Item Normal Condition Diagnostic Note Actual tire inflation pressure - Actual tire inflation pressure - Actual tire inflation pressure - Actual tire inflation pressure - Actual tire inflation pressure - ID1 tire inflation pressure/ TIREPRESS1 min.: 0 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/cm2, 92.2 psi) ID2 tire inflation pressure/ TIREPRESS2 min.: 0 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/cm2, 92.2 psi) ID3 tire inflation pressure/ TIREPRESS3 min.: 0 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/cm2, 92.2 psi) ID4 tire inflation pressure/ TIREPRESS4 min.: 0 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/cm2, 92.2 psi) ID5 tire inflation pressure/ TIREPRESS5 min.: 0 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/cm2, 92.2 psi) (d) Check the DATA LIST. Result Condition Detection Condition One of "Tire Inflation Pressure" data (ID1 to ID4 or ID5) changed. Normal "Tire Inflation Pressure" data did not change. Transmitter corresponding to DTC NOTICE: • When "TIREPRESS" data has not changed, reset the tire pressure to the appropriate specified value and rotate the tire 90 to 270 degrees. Then forcibly transmit the transmitter ID and recheck. • Record the transmitter ID and position of transmitters that are normal. (e) When the "TIREPRESS" data (ID1 to ID4 or ID5) has changed, repeat this procedure to identify the tire pressure warning valve and transmitter that corresponds to a DTC. (f) When all of the "TIREPRESS" data (ID1 to ID4 or ID5) have changed, identify the malfunctioning tire pressure warning valve and transmitter using recorded ID numbers and output DTC. (g) Set the tire pressures to the appropriate specified values. TW TW–52 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM NEXT 2 REPLACE TIRE PRESSURE WARNING VALVE AND TRANSMITTER (a) Replace the identified tire pressure warning valve and transmitter with a new one. HINT: • Before installing a new tire pressure warning valve and transmitter, read and write down its transmitter ID. • The IDs for the tire pressure warning valve and transmitter not be replaced should be checked using the tester and recorded. NEXT TW 3 REGISTRATION OF TRANSMITTER ID (a) Register the transmitter ID for all wheels (See page TW15). (b) Set the tire air pressure of all wheels to the specified value (For the specified value, see step 1). NEXT 4 CHECK DTC (a) Check for a DTC (See page TW-28). Result Condition Proceed to Any of the DTCs from C2141/41 to C2144/44 or C2145/45 are output. A Any of the DTCs from C2141/41 to C2144/44 or C2145/45 are not output. B B A REPLACE TIRE PRESSURE WARNING ECU END TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM DTC C2165/65 Abnormal Temperature Inside ID1 Tire DTC C2166/66 Abnormal Temperature Inside ID2 Tire DTC C2167/67 Abnormal Temperature Inside ID3 Tire DTC C2168/68 Abnormal Temperature Inside ID4 Tire DTC C2169/69 Abnormal Temperature Inside ID5 Tire TW–53 DESCRIPTION Each tire pressure warning valve and transmitter measures the internal temperature of its tire as well as tire pressure, and transmits the information to the tire pressure warning ECU along with the transmitter ID. If the measured temperature is out of the specified range, the tire pressure warning ECU recognizes it as a malfunction, outputs DTCs, and blinks the tire pressure warning light. DTC No. C2165/65 C2166/66 C2167/67 C2168/68 C2169/69 DTC Detecting Condition Trouble Area Temperature inside the tire exceeds 119°C (246.2°F) more than once. • • • Tires Tire pressure warning valve and transmitter Tire pressure warning ECU HINT: • It is necessary to perform the procedure to identify the tire pressure warning valve and transmitter that is malfunctioning because it cannot be identified by the output DTC. • DTC 2169/69 is used only when the vehicle is equipped with ground spare tire. INSPECTION PROCEDURE NOTICE: • When replacing the tire pressure warning ECU, read the IDs stored in the ECU using the intelligent tester and note them down before removal. • It is necessary to perform initialization (See page TW-18) after registration (See page TW-15) of the transmitter IDs into the tire pressure warning ECU after the ECU and/or valve and transmitter has been replaced. HINT: Set the tire pressure to the specified value. 1 CHECK TIRES (a) Check the tire is not flat, and there is no indication of air pressure drop. OK: Tire is normal. HINT: If a tire is damaged, the tire pressure warning valve and transmitter may also have been damaged at the same time. NG REPLACE TIRE AND TIRE PRESSURE WARNING VALVE AND TRANSMITTER TW TW–54 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM OK 2 IDENTIFY TRANSMITTER CORRESPONDING TO DTC (a) Set the tire pressure to the specified value. Cold tire inflation pressure Front kPa (kgf/cm2, psi) Tire size Rear kPa (kgf/cm2, psi) P215/60R16 94W 210 (2.1, 31) *1 240 (2.4, 35)*2 210 (2.1, 31) *1 240 (2.4, 35)*2 P215/55R17 93V 220 (2.2, 32) *1 240 (2.4, 35)*2 220 (2.2, 32) *1 240 (2.4, 35)*2 *1: For driving under 100 mph (160 km/h) *2: For driving at 100 mph (160 km/h) or over (b) Display the "TIREPRESS" data for each wheel using the intelligent tester. (c) Rapidly reduce the tire pressure for each wheel at least 40 kPa (0.41 kg/cm2, 5.8 psi) within 30 seconds. (d) Check the DATA LIST TW Measurement Item/Range (display) Item Normal Condition Diagnostic Note Actual tire inflation pressure - Actual tire inflation pressure - Actual tire inflation pressure - Actual tire inflation pressure - Actual tire inflation pressure - ID1 tire inflation pressure/ TIREPRESS1 min.: 0 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/cm2, 92.2 psi) ID2 tire inflation pressure/ TIREPRESS2 min.: 0 kPa (0 kgf/cm2, 0 psi), max.: 2 637.5 kPa (6.48 kgf/cm , 92.2 psi) ID3 tire inflation pressure/ TIREPRESS3 min.: 0 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/cm2, 92.2 psi) ID4 tire inflation pressure/ TIREPRESS4 min.: 0 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/cm2, 92.2 psi) ID5 tire inflation pressure/ TIREPRESS5 min.: 0 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/cm2, 92.2 psi) Result Condition Detection Condition One of "Tire Inflation Pressure" data (ID1 to ID4 or ID5) changed. Normal No "Tire Inflation Pressure" data changed. Transmitter corresponding to DTC NOTICE: • It takes about 1 minute or more to display the updated data. • When no "TIREPRESS" data has changed, reset the tire pressure to the appropriate specified value and rotate the tire 90 to 270 degrees. Then forcibly transmit the transmitter ID and recheck it. • Record the transmitter ID and position that is normal condition. (e) When the "TIREPRESS" data (ID1 to ID4 or ID5) has changed, repeat this procedure to identify the tire pressure warning valve and transmitter that corresponds to a DTC. TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM (f) TW–55 When all of the "TIREPRESS" data (ID1 to ID4 or ID5) has changed, identify the malfunctioning tire pressure warning valve and transmitter based on the recorded ID numbers and output DTC. NEXT 3 REPLACE TIRE PRESSURE WARNING VALVE AND TRANSMITTER (a) Replace the identified tire pressure warning valve and transmitter with a new one. HINT: • Before installing a new tire pressure warning valve and transmitter, read and write down its transmitter ID. • The IDs for the tire pressure warning valve and transmitter not be replaced should be checked using tester and recorded. NEXT 4 CHECK REGISTRATION OF TRANSMITTER ID (a) Register the transmitter ID for 4 or 5 wheels (See page TW-15). (b) Set the tire pressure of all wheels to the specified value. Cold tire inflation pressure Front kPa (kgf/cm2, psi) Tire size Rear kPa (kgf/cm2, psi) P215/60R16 94W 210 (2.1, 31) *1 240 (2.4, 35)*2 210 (2.1, 31) *1 240 (2.4, 35)*2 P215/55R17 93V 220 (2.2, 32) *1 240 (2.4, 35)*2 220 (2.2, 32) *1 240 (2.4, 35)*2 *1: For driving under 100 mph (160 km/h) *2: For driving at 100 mph (160 km/h) or over NEXT 5 PERFORM INITIALIZATION (a) Perform initialization (See page TW-18). NEXT 6 CHECK DTC (a) Check for a DTC (See page TW-18). Result Condition Proceed to Any of the DTCs from C2165/65 to C2168/68 or C2169/69 are output. A Any of the DTCs from C2165/65 to C2168/68 or C2169/69 are not output. B B END TW TW–56 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM A REPLACE TIRE PRESSURE WARNING ECU TW TW–57 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM DTC C2171/71 Transmitter ID not Registered DESCRIPTION The IDs of each tire pressure warning valve and transmitters are registered to the tire pressure warning ECU. When the ECU detects that an ID is not the one of registered IDs, or cannot receive an ID signal, a DTC is output. DTC No. C2171/71 DTC Detection Condition Transmitter ID code is not registered. (When an ID code is unregistered for 51 minutes or more) Trouble Area Tire pressure warning ECU INSPECTION PROCEDURE NOTICE: • When replacing the tire pressure warning ECU, read the IDs stored in the ECU using the intelligent tester and note them down before removal. • It is necessary to perform initialization (See page TW-18) after registration (See page TW-15) the transmitter IDs into the tire pressure warning ECU after the ECU have been replaced. 1 CONFIRM REGISTRATION CONDITION (REGISTERED ID CODES) (a) Connect the intelligent tester to the DLC3 connector. (b) Turn the ignition switch ON (IG) and turn the tester ON. (c) Select REGIT ID CODE by following the prompts displayed on the intelligent tester. OK: The registered transmitter ID codes are displayed on the intelligent tester screen. OK REPLACE TIRE PRESSURE WARNING ECU NG 2 PERFORM REGISTRATION (TRANSMITTER ID) (a) Register the transmitter IDs for all the wheels (See page TW-15). (b) Set the tire pressure of all the wheels to the appropriate specified values. NEXT 3 READ VALUE ON DATA LIST (a) Check the DATA LIST (See page TW-29). (b) Select "TIREPRESS" by following the prompts displayed on the intelligent tester. HINT: It may take up to 1 minute or more to display the tire pressure data. TW TW–58 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM Result Condition Proceed to All tire pressure readings are equal to specified values. A Tire pressure values not display B B A END TW REPLACE TIRE PRESSURE WARNING ECU TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM DTC TW–59 C2176/76 Receiver Error DESCRIPTION The signals are transmitted to the tire pressure warning antenna and receiver on the body as radio waves and then sent to the tire pressure warning ECU. DTC No. DTC Detection Condition C2176/76 DTC is stored when any of the following is detected: • Malfunction in the tire pressure warning ECU internal circuit. • Terminal RF5V is shorted to ground. • Malfunction in the tire pressure warning antenna and receiver internal circuit. Trouble Area • • • Tire pressure warning antenna and receiver Wire harness or connector Tire pressure warning ECU WIRING DIAGRAM TW Tire Pressure Warning Antenna and Receiver Tire Pressure Warning ECU 5 +5V N20 *1 5 N34 6 E60 RF5V *2 1 RDA N20 *1 1 N34 *2 12 E60 RDA 4 GND N20 4 N34 11 E60 GND2 *1 *2 *1: TMC Made *2: TMMK Made E131610E01 INSPECTION PROCEDURE NOTICE: • When replacing the tire pressure warning ECU, read the IDs stored in the ECU using the intelligent tester and write them down before removal. • It is necessary to perform initialization (See page TW-18) after registration (See page TW-15) of the transmitter IDs into the tire pressure warning ECU after the ECU have been replaced. TW–60 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM 1 CHECK TIRE PRESSURE WARNING ECU (a) Measure the voltage according to the value(s) in the table below. Standard voltage Tire Pressure Warning ECU E60 RF5V GND2 Tester Connection Switch Condition Specified Condition E60-6 (RF5V) - E60-11 (GND2) Ignition switch ON (IG) 4.5 to 5.5 V NG Go to step 5 E133090E01 OK TW 2 CHECK WIRE HARNESS (ECU - RECEIVER) Wire Harness Side Connector Front View: Tire Pressure Warning ECU E60 (a) (b) (c) (d) Disconnect the E60 ECU connector. Disconnect the N20 receiver connector.*1 Disconnect the N34 receiver connector.*2 Measure the resistance according to the value(s) in the table below. Standard resistance RDA Tester Connection E60-12 (RDA) - N20-1 (RDA) Specified Condition *1 E60-12 (RDA) - N34-1 (RDA)*2 Tire Pressure Warning Antenna and Receiver HINT: • *1: TMC Made • *2: TMMK Made NG *1 N20 REPAIR OR REPLACE HARNESS OR CONNECTOR *2 N34 RDA E129461E01 OK 3 REPLACE TIRE PRESSURE WARNING ANTENNA AND RECEIVER NEXT 4 Below 1 Ω CHECK DTC (a) Check for DTC (See page TW-28). OK: DTC is not output. TW–61 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM HINT: • It is necessary to register IDs when replacing the tire pressure warning ECU (See page TW-15). • Read the IDs on the DATA LIST before removing the tire pressure warning ECU. Register the ID in the new tire pressure warning ECU. NG REPLACE TIRE PRESSURE WARNING ECU OK END 5 CHECK HARNESS AND CONNECTOR (ECU - RECEIVER) Wire Harness Side Connector Front View: Tire Pressure Warning ECU (a) (b) (c) (d) RF5V E60 Disconnect the E60 ECU connector. Disconnect the N20 receiver connector.*1 Disconnect the N34 receiver connector.*2 Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection E60-11 (GND2) - N20-4 (GND) E60-11 (GND2) - N34-4 (GND)*2 GND2 E60-6 (RF5V) - N20-5 (+5V)*1 Tire Pressure Warning Antenna and Receiver *1 N20 *2 N34 Specified Condition *1 Below 1 Ω E60-6 (RF5V) - N34-5 (+5V)*2 HINT: • *1: TMC Made • *2: TMMK Made Result +5V RDA E129461E02 Result Proceed to OK A OK (When troubleshooting accordance with PROBLEM SYMPTOMS TABLE) B NG C A REPLACE TIRE PRESSURE WARNING ECU C REPAIR OR REPLACE HARNESS OR CONNECTOR AND REPLACE TIRE PRESSURE WARNING ECU B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE TW TW–62 DTC TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM C2177/77 Initialization not Completed DESCRIPTION Initialization is necessary after replacing any of the ECU, tires with different tire pressure, or tire pressure warning valve and transmitter, after rotating the tires or when a new vehicle is delivered. DTC No. C2177/77 TW DTC Detection Condition Initialization is not completed after vehicle speed of 5 mph (8 km/h) or more continues for 20 minutes or more (total). Trouble Area • • • • • Tire pressure warning valve and transmitter Tire pressure warning ECU Tire pressure warning antenna and receiver Tire pressure warning reset switch Wire harness or connector TW–63 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM WIRING DIAGRAM Tire Pressure Warning Valve and Transmitter (Front RH) Tire Pressure Warning ECU Tire Pressure Warning Valve and Transmitter (Front LH) Tire Pressure Warning Valve and Transmitter (Rear RH) TW Tire Pressure Warning Valve and Transmitter (Rear LH) Tire Pressure Warning Valve and Transmitter (Ground Spear Tire) 5 N20 *1 1 N20 *1 4 N20 *1 Tire Pressure Warning Antenna and Receiver 5 N34 *2 1 N34 *2 4 N34 *2 6 E60 RF5V 12 E60 RDA 11 E60 GND2 9 E60 GND E53 Tire Pressure Warning Reset Switch 2 *1: TMC Made 1 1 E60 CLSW *2: TMMK Made E130159E01 TW–64 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM INSPECTION PROCEDURE 1 CHECK DTC (a) Check for a DTC. Result Condition Proceed to Only DTC C2177/77 is output. A DTC C2177/77 and any of the DTCs from C2121/21 to C2125/25 are output. B A TW REPLACE TIRE PRESSURE WARNING ECU B (See page TW-38) REPAIR CIRCUITS INDICATED BY OUTPUT DTCS TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TW–67 Tire Pressure Warning Reset Switch Circuit DESCRIPTION Receiving a signal from the tire pressure warning reset switch, the tire pressure warning ECU and receiver indicates the initialization of the pressure warning system. WIRING DIAGRAM Tire Pressure Warning ECU E53 Tire Pressure Warning Reset Switch 2 1 TW 1 E60 CLSW E129459E03 INSPECTION PROCEDURE 1 CHECK TIRE PRESSURE WARNING RESET SWITCH FUNCTION (a) Perform the tire pressure warning reset switch test in TEST MODE PROCEDURE (See page TW-20). OK: Reset switch ON: Tire pressure warning light comes on. Reset switch OFF: Tire pressure warning light blinks. NG OK END Go to step 2 TW–68 2 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM INSPECT TIRE PRESSURE WARNING RESET SWITCH (a) Disconnect the tire pressure warning reset switch connector. (b) Measure the resistance between terminals 1 and 2 of the tire pressure warning reset switch when the tire pressure warning switch is ON and OFF. Standard resistance Tire Pressure Warning Reset Switch: ON Switch Condition 2 1 OFF Specified Condition ON Below 1 Ω OFF 10 kΩ or higher C107260E01 NG TW REPLACE TIRE PRESSURE WARNING RESET SWITCH OK 3 CHECK HARNESS AND CONNECTOR (TIRE PRESSURE WARNING RESET SW - TIRE PRESSURE WARNING ECU) Tire Pressure Warning Reset Switch: (harness side connector) (a) Disconnect the tire pressure warning reset switch E53 connector and tire pressure warning ECU E60 connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Switch Condition E53 E60-1 (CLSW) - E53-1 Below 1 Ω E60-1 (CLSW) - Body ground 10 kΩ or higher E53-2 - Body ground Below 1Ω NG Tire Pressure Warning ECU: E60 CLSW C111010E06 OK REPLACE TIRE PRESSURE WARNING ECU Specified Condition REPAIR OR REPLACE HARNESS OR CONNECTOR TW–65 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM DTC C2191/91 Vehicle Speed Signal Error (Test Mode DTC) DESCRIPTION The tire pressure warning ECU receives a speed signal from the combination meter. This DTC is stored upon entering test mode, and cleared when a vehicle speed signal of 12 mph (20 km/h) is detected for 3 seconds or more. This DTC is output only in test mode. DTC No. DTC Detecting Condition C2191/91 Trouble Area • • • • Speed sensor circuit malfunction Vehicle speed sensor Tire pressure warning ECU Combination meter Wire harness or connector WIRING DIAGRAM TW F2 Combination Meter E60 Tire Pressure Warning ECU 12 2 +S SPD E115290E29 INSPECTION PROCEDURE NOTICE: • When replacing the tire pressure warning ECU, read the IDs stored in the ECU using the intelligent tester and write them down before removal. • It is necessary to perform initialization (See page TW-18) after registration (See page TW-15) of the transmitter IDs into the tire pressure warning ECU after the ECU have been replaced. 1 READ VALUE ON INTELLIGENT TESTER (a) Connect the intelligent tester to DLC3. (b) Turn the ignition switch on (IG), and turn the intelligent tester on. (c) Select the item below in the Data List, and read the value displayed on the intelligent tester. TW–66 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM HINT: Enter the following menus: DIAGNOSIS / OBD/MOBD / METER / DATA LIST. METER Item Normal Condition VEHICLE SPD Almost same as actual vehicle speed (d) Check that the values indicated on the tester and on the combination meter are the same. OK: Vehicle speed indicated on the intelligent tester indicates the actual speed. NG GO TO METER / GAUGE SYSTEM OK TW 2 CHECK HARNESS AND CONNECTOR (ECU - COMBINATION METER) Wire Harness Side Connector Front View: Tire Pressure Warning ECU (a) Disconnect the E60 ECU connector. (b) Disconnect the F2 meter connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition E60-2 (SPD) - F2-12 (+S) Below 1 Ω E60-2 (SPD) - Body ground 10 kΩ or higher E60 SPD NG Combination Meter F2 +S E129462E01 OK REPLACE TIRE PRESSURE WARNING ECU REPAIR OR REPLACE HARNESS OR CONNECTOR TW–69 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM Tire Pressure Warning Light Circuit DESCRIPTION If the ECU detects trouble, the tire pressure warning light blinks (comes on after blinking for 1 minute) and tire pressure monitor is cancelled at the same time. At this time, the ECU records a DTC in the memory. Connect terminals TC and CG of DLC3 to make the tire pressure warning light blink and output the DTC. WIRING DIAGRAM Combination Meter Tire Pressure Warning ECU TW TIRE 7 F1 5 E60 IND E129599E01 INSPECTION PROCEDURE NOTICE: It is necessary to perform initialization (See page TW-18) after registration (See page TW-15) of the transmitter IDs into the tire pressure warning ECU, after the ECU have been replaced. HINT: This procedure must be performed according to the PROBLEM SYMPTOMS TABLE. TW–70 1 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM CHECK HARNESS AND CONNECTOR (COMBINATION METER - TIRE PRESSURE WARNING ECU) (a) Disconnect the F1 combination meter connector. Combination Meter Assembly Wire Harness View: F1 TW TIRE E123360E03 (b) Disconnect the E60 tire pressure warning ECU connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tire Pressure Warning ECU E60 IND Tester Connection Specified Condition F1-7 (TIRE) - E60-5 (IND) Below 1 Ω F1-7 (TIRE) - Body ground 10 kΩ or higher E133089E01 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 2 INSPECT COMBINATION METER (a) Disconnect the connector from the tire pressure warning ECU. (b) Turn the ignition switch on (IG), check the condition of the tire pressure warning light illumination. Result Tire Pressure Warning ECU E60 Condition Proceed to Illuminates A Does not illuminate B E133089E04 B A REPLACE TIRE PRESSURE WARNING ECU REPLACE COMBINATION METER TW–71 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM ECU Power Source Circuit DESCRIPTION This is the power source for the tire pressure warning ECU. WIRING DIAGRAM E60 Tire Pressrue Warning ECU IG1 ECU-IG NO. 1 From Battery 7 TW IG From Battery 9 GND E130363E01 INSPECTION PROCEDURE NOTICE: It is necessary to register an ID code after replacing the tire pressure warning valve and transmitter and/or the tire pressure warning ECU (See page TW-15). 1 INSPECT FUSE (ECU-IG NO. 1) (a) Remove the ECU-IG NO. 1 fuse from the instrument panel junction block. (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω NG OK REPLACE FUSE TW–72 2 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM INSPECT IG1 RELAY (a) Remove the IG1 relay from the instrument panel junction block. (b) Measure the resistance according to the value(s) in the table below. Standard resistance 1 5 3 5 3 2 Tester Connection 10 kΩ or higher Below 1 Ω (When battery voltage is applied to terminals 1 and 2) 3-5 2 A092673E31 NG TW Specified Condition 1 REPLACE IG1 RELAY OK 3 CHECK HARNESS AND CONNECTOR (ECU - BATTERY AND BODY GROUND) (a) Disconnect the E60 ECU connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness Side: IG E60 GND E129464E01 Tester Connection Switch Condition Specified Condition E60-7 (IG) - Body ground Ignition switch on (IG) 10 to 14 V Ignition switch off Below 1 V (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition E60-9 (GND) - Body ground Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE TW–73 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TC and CG Terminal Circuit DESCRIPTION DTC output mode is set by connecting terminals 13 (TC) and 4 (CG) of the DLC3. The DTCs are indicated by the blinking of the tire pressure warning light. WIRING DIAGRAM E60 Tire Pressure Warning ECU E10 DLC3 TC CG TW 13 3 TC 4 E110507E13 HINT: When each warning light blinks continuously, a ground short in the wiring of terminal TC of the DLC3 or an internal ground short in an ECU connected to this circuit may have occurred. INSPECTION PROCEDURE NOTICE: It is necessary to register an ID code after replacing the tire pressure warning valve and transmitter and/or the tire pressure warning ECU (See page TW-15). TW–74 1 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM CHECK HARNESS AND CONNECTOR (DLC3 - TIRE PRESSURE WARNING ECU) (a) Disconnect the E60 ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side: DLC3 Tester Connection E60-3 (TC) - E10-13 (TC) E10-4 (CG) - Body ground E10 NG CG TC Specified Condition Below 1 Ω REPAIR OR REPLACE HARNESS OR CONNECTOR Tire Pressure Warning ECU TW TC E60 E129465E01 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE TW–74 TIRE AND WHEEL – TIRE PRESSURE WARNING RECEIVER (w/ Antenna) REMOVAL TW 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE REAR SEAT CUSHION ASSEMBLY (for Fixed Seat Type) (See page SE-77) 3. REMOVE REAR SEAT HEADREST ASSEMBLY (for Fixed Seat Type) 4. REMOVE REAR CENTER SEAT HEADREST ASSEMBLY (for Fixed Seat Type) 5. REMOVE REAR SEATBACK ASSEMBLY (for Fixed Seat Type) (See page SE-77) 6. REMOVE REAR SEAT CUSHION ASSEMBLY (for Fold Down Seat Type) (See page SE-47) 7. REMOVE REAR SIDE SEATBACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-48) 8. REMOVE REAR SEAT HEADREST ASSEMBLY (for Reclining Seat Type) 9. REMOVE REAR SEAT CUSHION ASSEMBLY (for Reclining Seat Type) (See page SE-62) 10. REMOVE REAR SEATBACK COVER (for Reclining Seat Type) (See page SE-63) 11. REMOVE SEPARATE TYPE REAR SEATBACK ASSEMBLY LH (for Reclining Seat Type) (See page SE-63) 12. REMOVE INNER ROOF SIDE GARNISH LH (See page IR-26) 13. REMOVE TIRE PRESSURE WARNING RECEIVER ASSEMBLY (a) Remove the bolt. (b) Disconnect the connector and remove the tire pressure warning receiver assembly. C132527 TIRE AND WHEEL – TIRE PRESSURE WARNING RECEIVER (w/ Antenna) TW–75 INSTALLATION C132527 1. INSTALL TIRE PRESSURE WARNING RECEIVER ASSEMBLY (a) Connect the connector to the tire pressure warning receiver assembly. (b) Install the tire pressure warning receiver assembly with the bolt Torque: 7.5 N*m (77 kgf*cm, 66 in.*lbf) 2. INSTALL INNER ROOF SIDE GARNISH LH (See page IR-52) 3. INSTALL REAR SEATBACK ASSEMBLY (for Fixed Seat Type) (See page SE-84) 4. INSTALL REAR CENTER SEAT HEADREST ASSEMBLY (for Fixed Seat Type) 5. INSTALL REAR SEAT HEADREST ASSEMBLY (for Fixed Seat Type) 6. INSTALL REAR SEAT CUSHION ASSEMBLY (for Fixed Seat Type) (See page SE-84) 7. INSTALL REAR SIDE SEATBACK ASSEMBLY LH (for Fold Down Seat Type) (See page SE-57) 8. INSTALL REAR SEAT CUSHION ASSEMBLY (for Fold Down Seat Type) (See page SE-58) 9. INSTALL REAR SEATBACK ASSEMBLY LH (for Reclining Seat Type) (See page SE-72) 10. INSTALL REAR SEATBACK COVER (for Reclining Seat Type) 11. INSTALL REAR SEAT HEADREST ASSEMBLY (for Reclining Seat Type) 12. INSTALL BENCH TYPE REAR SEAT CUSHION ASSEMBLY (for Reclining Seat Type) (See page SE73) 13. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 14. INSPECT TIRE PRESSURE WARNING SYSTEM HINT: (See page TW-20) TW TIRE AND WHEEL – TIRE PRESSURE WARNING RECEIVER (w/ Antenna) TW–71 TIRE PRESSURE WARNING RECEIVER (w/ Antenna) SUSPENSION TIRE AND WHEEL & AXLE COMPONENTS for Fixed Type: REAR SEAT HEADREST ASSEMBLY TW REAR CENTER SEAT HEADREST ASSEMBLY REAR SEATBACK ASSEMBLY 18 (184, 13) 18 (184, 13) REAR SEAT CUSHION ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B136589E05 TW–72 TIRE AND WHEEL – TIRE PRESSURE WARNING RECEIVER (w/ Antenna) for Fold Down Seat Type: REAR SIDE SEATBACK ASSEMBLY LH 18 (184, 13) TW REAR SEAT CUSHION ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C139029E01 for Reclining Seat Type: REAR SEAT HEADREST ASSEMBLY SEPARATE TYPE REAR SEATBACK ASSEMBLY LH REAR SEATBACK COVER 18 (184, 13) 18 (184, 13) REAR SEAT CUSHION ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C135237E01 TIRE AND WHEEL – TIRE PRESSURE WARNING RECEIVER (w/ Antenna) TW–73 TIRE PRESSURE WARNING RECEIVER ASSEMBLY TW 7.5 (77, 66 in.*lbf) INNER ROOF SIDE GARNISH LH N*m (kgf*cm, ft.*lbf) : Specified torque C132530E01 TW–76 TIRE AND WHEEL – TIRE PRESSURE WARNING VALVE AND TRANSMITTER TIRE PRESSURE WARNING VALVE AND TRANSMITTER SUSPENSION TIRE AND WHEEL & AXLE COMPONENTS TW with Grand Spare Tire: TIRE PRESSURE WARNING VALVE SUB-ASSEMBLY (TIRE PRESSURE WARNING VALVE AND TRANSMITTER) INNER GROMMET WASHER NUT 4.0 (41, 35 in.*lbf) VALVE CORE CAP N*m (kgf*cm, ft.*lbf) : Specified torque C132533E01 TIRE AND WHEEL – TIRE PRESSURE WARNING VALVE AND TRANSMITTER TW–77 REMOVAL Tire Shoe 10 to 20 mm (0.39 to 0.79 in.) F046444E01 1. REMOVE FRONT WHEEL 2. REMOVE REAR WHEEL 3. REMOVE GRAND SPARE TIRE (w/ Grand Spare Tire) 4. REMOVE TIRE PRESSURE WARNING VALVE SUBASSEMBLY (a) Remove the valve core and cap, and release the air from the tire. (b) After ensuring that a sufficient amount of air has been released, remove the nut and washer that are used to secure the tire pressure warning valve and transmitter. Drop the tire pressure warning valve and transmitter inside the tire. HINT: Keep the removed cap, valve core, nut, and washer. (c) After dropping the tire pressure warning valve and transmitter into the tire, disengage the bead using the shoe of the tire remover. NOTICE: Be careful not to damage the tire pressure warning valve and transmitter due to interference between the tire pressure warning valve and transmitter and the tire bead. (d) Remove the bead on the upper side in the usual way. (e) Take out the tire pressure warning valve and transmitter from the tire and remove the bead on the lower side in the usual way. HINT: Check that no cracks or damage are identified on the grommet. If any damage is found, replace the grommet, washer, and nut. TW TW–78 TIRE AND WHEEL – TIRE PRESSURE WARNING VALVE AND TRANSMITTER INSTALLATION 1. 7-digit Number Transmitter ID TW Print Surface C137898E01 Rim Nut Washer Tire Pressure Warning Valve and Transmitter Cap Grommet C139137E01 INSTALL TIRE PRESSURE WARNING VALVE SUBASSEMBLY (a) Insert the tire pressure warning valve and transmitter into the valve installation hole. Insert it from the inside of the rim so that the print surface can be seen. NOTICE: • Check that there is no visible deformation, damage, or other abnormalities on the tire pressure warning valve and transmitter. • Check that there is no foreign matter on the inner grommet and around the rim hole. • If the tire pressure warning valve and transmitter is installed in the reverse direction, it may be damaged or fail to transmit signals when running at high speeds. • If installing a new tire pressure warning valve and transmitter, write down the ID number before installation. • It is necessary to register the ID in the ECU after installation (See page TW-15). (b) Install the washer on the tire pressure warning valve and transmitter from the rim side and tighten the nut. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) NOTICE: • Do not tighten the nut further after tightening it to the specified torque. • Check that there is no foreign matter on the washer and nut. • If the tire and tire pressure warning valve and transmitter have been removed, check that there is no damage or cuts visible, and no foreign matter, such as mud, dirt, or sand attached to the grommet. Replace the grommet with a new one if any of the defects mentioned above are found. • Check that there is no oil, water, or lubricant around the rim hole, tire pressure warning valve and transmitter, washer, and nut. Failing to do so may result in improper installation. TIRE AND WHEEL – TIRE PRESSURE WARNING VALVE AND TRANSMITTER (c) Set the wheel disc to the mounting machine and install the lower tire bead. Position the main body of the tire pressure warning valve and transmitter in the shaded area as shown in the illustration. NOTICE: • If the tire pressure warning valve and transmitter is positioned outside this area, it will be interfered with the tire bead, and may cause damage to the tire pressure warning valve and transmitter. • If the use of lubricant is required when installing the bead, do not apply the lubricant directly to the tire pressure warning valve and transmitter. (d) Install the upper bead. NOTICE: Make sure that the tire bead and tool do not interfere with the main body of the tire pressure warning valve and transmitter and that it is not clamped by the bead. (e) After the tire is inflated, the valve nut may be loose. Retighten the nut to the specified torque and then check for air leaks with soapy water. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) NOTICE: Do not tighten the nut further after tightening it to the specified torque. Mount Tool of the Mounting Machine Rim Area for the Tire Pressure Warning Valve and Transmitter TW–79 Rim Rotating Direction Mount Tool of the Mounting Machine Rim Rim Rotating Direction Area for the Tire Pressure Warning Valve and Transmitter C137868E01 2. INSTALL FRONT WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 3. INSTALL REAR WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 4. INSTALL GRAND SPARE TIRE (w/ Grand Spare Tire) 5. INSPECT TIRE HINT: (See page TW-3) 6. REGISTER TRANSMITTER ID HINT: (See page TW-15) 7. INSPECT TIRE PRESSURE WARNING SYSTEM HINT: (See page TW-20) TW TW–80 TIRE AND WHEEL – TIRE PRESSURE WARNING VALVE AND TRANSMITTER DISPOSAL HINT: The tire pressure warning valve sub-assembly is powered by a lithium battery. When disposing of the tire pressure warning valve sub-assembly, remove the battery and dispose of it correctly. 1. TW DISPOSE OF TIRE PRESSURE WARNING VALVE SUB-ASSEMBLY (a) Use the tip of a screwdriver to pry off the back cover. C137865 Lithium Battery (b) The battery and base board covered with resin are exposed. While taking out the battery, cut the 2 terminals that connect the battery to the base board. Terminal Terminal C137866E01 TIRE AND WHEEL – TIRE PRESSURE WARNING ECU TW–81 TIRE PRESSURE WARNING ECU SUSPENSION TIRE AND WHEEL & AXLE COMPONENTS FRONT DOOR SCUFF PLATE RH COWL SIDE TRIM SUB-ASSEMBLY RH TW TIRE PRESSURE WARNING ECU 7.5 (77, 66 in.*lbf) LOWER INSTRUMENT PANEL SUB-ASSEMBLY NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C132532E01 TW–82 TIRE AND WHEEL – TIRE PRESSURE WARNING ECU REMOVAL NOTICE: Before removing the tire pressure warning ECU, read the registered transmitter IDs of all wheels and write them down to use for re-registration of transmitter IDs (See page TW-15). TW 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE FRONT DOOR SCUFF PLATE RH (See page IR-26) 3. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH (See page IR-26) 4. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (See page IP-23) 5. REMOVE LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMC Made) (See page IP-23) 6. REMOVE LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMMK Made) (See page IP-24) 7. REMOVE TIRE PRESSURE WARNING ECU (a) Remove the nut. (b) Disconnect the connector and remove the tire pressure warning ECU. C132528 INSTALLATION C132528 1. INSTALL TIRE PRESSURE WARNING ECU (a) Connect the connector to the tire pressure warning ECU. (b) Install the tire pressure warning ECU with the nut. Torque: 7.5 N*m (77 kgf*cm, 66 in.*lbf) 2. INSTALL LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMC Made) (See page IP-55) 3. INSTALL LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMMK Made) (See page IP-56) 4. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (See page IP-56) 5. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH (See page IR-55) 6. INSTALL FRONT DOOR SCUFF PLATE RH (See page IR-55) 7. CONNECT CABLE TO BATTERY NEGATIVE TERMINAL TIRE AND WHEEL – TIRE PRESSURE WARNING ECU TW–83 8. REGISTER TRANSMITTER ID HINT: (See page TW-15) 9. INITIALIZE SYSTEM NOTICE: • Be sure to register the transmitter IDs of all tires including the grand spare tire in the ECU before initialization. • Be sure to inflate all tires including the grand spare tire to the proper inflation pressure before initialization. HINT: (See page TW-18) 10. INSPECT TIRE PRESSURE WARNING SYSTEM HINT: (See page TW-20) TW TW–84 TIRE AND WHEEL – TIRE PRESSURE WARNING RESET SWITCH TIRE PRESSURE WARNING RESET SWITCH SUSPENSION TIRE AND WHEEL & AXLE COMPONENTS FRONT DOOR SCUFF PLATE RH COWL SIDE TRIM SUB-ASSEMBLY RH TW NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY LOWER INSTRUMENT PANEL SUB-ASSEMBLY TIRE PRESSURE WARNING RESET SWITCH C132531E01 TIRE AND WHEEL – TIRE PRESSURE WARNING RESET SWITCH TW–85 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE FRONT DOOR SCUFF PLATE RH (See page IR-26) 3. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH (See page IR-26) 4. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (See page IP-23) 5. REMOVE LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMC Made) (See page IP-23) 6. REMOVE LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMMK Made) (See page IP-24) 7. REMOVE TIRE PRESSURE WARNING RESET SWITCH (a) Disengage the 2 claws and remove the tire pressure warning reset switch from the lower instrument panel sub-assembly. C132529 INSTALLATION C132529 1. INSTALL TIRE PRESSURE WARNING RESET SWITCH (a) Engage the 2 claws to install the tire pressure warning reset switch. 2. INSTALL LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMC Made) (See page IP-55) 3. INSTALL LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMMK Made) (See page IP-56) 4. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (See page IP-56) 5. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH (See page IR-55) 6. INSTALL FRONT DOOR SCUFF PLATE RH (See page IR-55) 7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 8. INITIALIZE SYSTEM NOTICE: Be sure to inflate all tires including the grand spare tire to the proper inflation pressure before initialization. HINT: (See page TW-18) TW TW–86 TIRE AND WHEEL – TIRE PRESSURE WARNING RESET SWITCH 9. TW INSPECT TIRE PRESSURE WARNING SYSTEM HINT: (See page TW-20) PREPARATION – 2AZ-FE ENGINE CONTROL SYSTEM PP–1 2AZ-FE ENGINE CONTROL SYSTEM PREPARATION RECOMMENDED TOOLS 09082-00040 (09083-00150) TOYOTA Electrical Tester Test Lead Set PP PP–2 EQUIPMENT Ohmmeter Radiator cap tester Service Wire Harness Torque wrench PP PREPARATION – 2AZ-FE ENGINE CONTROL SYSTEM PP–2 PREPARATION – 2GR-FE ENGINE CONTROL SYSTEM 2GR-FE ENGINE CONTROL SYSTEM PREPARATION RECOMMENDED TOOLS 09082-00040 PP (09083-00150) TOYOTA Electrical Tester Test Lead Set PREPARATION – 2GR-FE ENGINE CONTROL SYSTEM PP–3 EQUIPMENT Ohmmeter Radiator cap tester Service Wire Harness Torque wrench PP PREPARATION – 2AZ-FE ENGINE MECHANICAL PP–3 2AZ-FE ENGINE MECHANICAL PREPARATION SST 09032-00100 Oil Pan Seal Cutter 09201-10000 Valve Guide Bushing Remover & Replacer Set (09201-01050) Valve Guide Bushing Remover & Replacer 5 09201-41020 Valve Stem Oil Seal Replacer 09202-70020 Valve Spring Compressor (09202-00010) 09213-54015 (91651-60855) Attachment Crankshaft Pulley Holding Tool Bolt 09216-42010 Belt Tension Wrench Set 09223-15030 Oil Seal & Bearing Replacer 09223-22010 Crankshaft Front Oil Seal Replacer PP PP–4 PREPARATION – 2AZ-FE ENGINE MECHANICAL 09228-06501 Oil Filter Wrench 09309-37010 Transmission Bearing Replacer 09330-00021 Companion Flange Holding Tool 09817-33190 Sensor Socket Wrench 09843-18030 Tacho-pulse Pickup Wire No.2 09843-18040 Diagnosis Check Wire No.2 09950-40011 Puller B Set (09951-04010) Hanger 150 (09952-04010) Slide Arm (09953-04030) Center Bolt 200 (09954-04010) Arm 25 (09955-04041) Claw No.4 PP PREPARATION – 2AZ-FE ENGINE MECHANICAL (09957-04010) Attachment (91111-51014) Bolt 09950-50013 Puller C Set PP–5 PP (09951-05010) Hanger 150 (09952-05010) Slide Arm (09953-05020) Center Bolt 150 (09954-05021) Claw No.2 09950-70010 Handle Set (09951-07100) Handle 100 09960-10010 Variable Pin Wrench Set (09962-01000) Variable Pin Wrench Arm Assembly (09963-01000) Pin 10 PP–8 PREPARATION – 2AZ-FE ENGINE MECHANICAL SSM Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent Toyota Genuine Seal Packing 1282B, Three Bond 1282B or Equivalent Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent PP PP–6 PREPARATION – 2AZ-FE ENGINE MECHANICAL RECOMMENDED TOOLS 09011-12301 Socket Wrench 30 mm 09031-00040 Pin Punch 09040-00011 Hexagon Wrench Set PP (09043-20060) Socket Hexagon Wrench 6 (09043-20100) Socket Hexagon Wrench 10 09043-50100 Bi-hexagon Wrench 10 mm 09090-04020 Engine Sling Device 09200-00010 Engine Adjust Kit PREPARATION – 2AZ-FE ENGINE MECHANICAL PP–7 EQUIPMENT Abrasive compound Valve Brush Piston Caliper gauge Carbide cutter CO/HC meter PP Compression gauge Connecting rod aligner Cylinder gauge Dial indicator Dye penetrant Engine tune-up tester Groove cleaning tool Piston ring groove Heater Hexagon wrench (1.5 mm) Timing belt tensioner Micrometer Pin hole grinder Connecting rod bushing Piston ring compressor Piston ring expander Plastigage Precision straight edge Press Reamer Cylinder Ridge reamer Cylinder Soft brush Cylinder head Cylinder block Solvent Spring tester Valve spring Steel square Valve spring Thermometer Torque wrench Torx socket wrench Valve seat cutter Valve guide bushing brush V-block Vernier calipers Wire brush HINT: Torx is registered trademark of Textron Inc. Valve Cylinder head PP–8 PREPARATION – 2GR-FE ENGINE MECHANICAL 2GR-FE ENGINE MECHANICAL PREPARATION SST PP 09032-00100 Oil Pan Seal Cutter 09201-10000 Valve Guide Bushing Remover & Replacer Set (09201-01050) Valve Guide Bushing Remover & Replacer 5 09201-41020 Valve Stem Oil Seal Replacer 09202-70020 Valve Spring Compressor (09202-00010) 09213-70011 (09213-70020) Attachment Crankshaft Pully Holding Tool Bolt 09223-15030 Oil Seal & Bearing Replacer 09223-22010 Crankshaft Front Oil Seal Replacer 09228-06501 Oil Filter Wrench PREPARATION – 2GR-FE ENGINE MECHANICAL 09249-63010 Torque Wrench Adaptor 09276-75010 Valve Lifter Tool PP–9 PP 09316-60011 Transmission & Transfer Bearing Replacer (09316-00011) Replacer Pipe 09330-00021 Companion Flange Holding Tool 09506-35010 Differential Drive Pinion Rear Bearing Replacer 09843-18030 Tacho-pulse Pickup Wire No.2 09843-18040 Diagnosis Check Wire No.2 09950-50013 Puller C Set (09951-05010) Hanger 150 (09952-05010) Slide Arm (09953-05020) Center Bolt 150 PP–10 PREPARATION – 2GR-FE ENGINE MECHANICAL (09954-05021) Claw No.2 09950-70010 Handle Set (09951-07100) Handle 100 (09951-07150) Handle 150 PP PREPARATION – 2GR-FE ENGINE MECHANICAL PP–11 RECOMMENDED TOOLS 09011-12301 Socket Wrench 30 mm 09040-00011 Hexagon Wrench Set PP (09043-20050) Socket Hexagon Wrench 5 (09043-20060) Socket Hexagon Wrench 6 (09043-20080) Socket Hexagon Wrench 8 (09043-20100) Socket Hexagon Wrench 10 (09043-30140) Straight Hexagon Wrench 14 09043-30190 Straight Hexagon Wrench 19 09043-50100 Bi-hexagon Wrench 10 mm 09090-04020 Engine Sling Device 09200-00010 Engine Adjust Kit PP–12 PREPARATION – 2GR-FE ENGINE MECHANICAL (09857-00031) PP Spark Plug Gap Gauge PREPARATION – 2GR-FE ENGINE MECHANICAL PP–13 EQUIPMENT Abrasive compound Brush Caliper gauge Carbide cutter (30°) Carbide cutter (45°) Carbide cutter (60°) Carbide cutter (75°) Connecting rod aligner Cylinder gauge Dial indicator Dye penetrant Engine tune-up tester Groove cleaning tool Heater Micrometer Piston ring compressor Piston ring expander Plastigage Precision straight edge Press Reamer (5.5 mm) Ridge reamer Soft brush Solvent Spring tester Steel square Thermometer Torque wrench Torx socket wrench Valve seat cutter Valve guide bushing brush V-block Vernier calipers Wire brush Bar Chain Block CO/HC meter Compression gauge Dial indicator with magnetic base Engine Sling Device Feeler gauge Radiator cap tester Slide calipers Tachometer Timing light Wooden block Deep socket wrench 24 mm PP PP–14 PREPARATION – 2GR-FE ENGINE MECHANICAL HINT: Torx is registered trademark of Textron Inc. PP PREPARATION – 2GR-FE ENGINE MECHANICAL PP–15 SSM Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent Toyota Genuine Seal Packing 1282B, Three Bond 1282B or Equivalent Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent PP PREPARATION – 2AZ-FE FUEL PP–13 2AZ-FE FUEL PREPARATION SST 09268-31011 Injection Measuring Tool Set (09268-41110) Adaptor (09268-41300) Clamp (09268-41500) Fuel Tube Connector (90467-13001) Clip (95336-08070) Hose 09268-45014 EFI Fuel Pressure Gauge (09268-41200) Gauge (09268-41220) Hose (09268-41250) T Joint 09842-30080 Wire H EFI Inspection PP PP–14 PREPARATION – 2AZ-FE FUEL RECOMMENDED TOOLS 09082-00040 (09083-00150) PP TOYOTA Electrical Tester Test Lead Set PREPARATION – 2AZ-FE FUEL PP–15 EQUIPMENT Measuring Flask Ohmmeter Service Wire Harness Stopwatch Torque wrench Vernier calipers PP PP–16 PREPARATION – 2AZ-FE FUEL SSM 08850-00065 PP Butyl Tape Set PREPARATION – 2GR-FE FUEL PP–15 2GR-FE FUEL PREPARATION SST 09268-31011 Injection Measuring Tool Set (09268-41500) Fuel Tube Connector (90467-13001) Clip (95336-08070) Hose 09268-41140 Adapter 09268-41400 Clamp 09268-45014 EFI Fuel Pressure Gauge (09268-41200) Gauge (09268-41220) Hose (09268-41250) T Joint 09842-30080 Wire H EFI Inspection PP PP–16 PREPARATION – 2GR-FE FUEL RECOMMENDED TOOLS 09082-00040 (09083-00150) PP TOYOTA Electrical Tester Test Lead Set PREPARATION – 2GR-FE FUEL PP–17 EQUIPMENT Measuring Flask Ohmmeter Service Wire Harness Stopwatch Torque wrench Vernier calipers PP PP–18 PREPARATION – 2GR-FE FUEL SSM 08850-00065 PP Butyl Tape Set PREPARATION – 2AZ-FE EMISSION CONTROL PP–17 2AZ-FE EMISSION CONTROL PREPARATION SST 09224-00010 O2 Sensor Wrench PP PP–18 PREPARATION – 2AZ-FE EMISSION CONTROL RECOMMENDED TOOLS 09082-00040 (09083-00150) PP TOYOTA Electrical Tester Test Lead Set PREPARATION – 2AZ-FE EMISSION CONTROL PP–19 EQUIPMENT Intelligent vacuum pump Ohmmeter Service Wire Harness Torque wrench Vacuum gauge PP PP–18 PREPARATION – 2GR-FE EMISSION CONTROL 2GR-FE EMISSION CONTROL PREPARATION SST PP 09224-00010 O2 Sensor Wrench 09992-00242 Turbocharger Pressure Gauge PREPARATION – 2GR-FE EMISSION CONTROL PP–19 RECOMMENDED TOOLS 09082-00040 (09083-00150) TOYOTA Electrical Tester Test Lead Set PP PP–20 EQUIPMENT Intelligent vacuum pump Ohmmeter Service Wire Harness Torque wrench Vacuum gauge PP PREPARATION – 2GR-FE EMISSION CONTROL PREPARATION – 2AZ-FE INTAKE PP–19 2AZ-FE INTAKE PREPARATION EQUIPMENT Intelligent tester Ohmmeter Intelligent vacuum pump PP PP–20 2GR-FE INTAKE PREPARATION EQUIPMENT Intelligent tester Ohmmeter Intelligent vacuum pump PP PREPARATION – 2GR-FE INTAKE PREPARATION – 2AZ-FE EXHAUST PP–21 2AZ-FE EXHAUST PREPARATION EQUIPMENT Torque wrench PP PP–22 2GR-FE EXHAUST PREPARATION EQUIPMENT Torque wrench PP PREPARATION – 2GR-FE EXHAUST PREPARATION – 2AZ-FE COOLING PP–23 2AZ-FE COOLING PREPARATION SST 09230-01010 Radiator Service Tool Set (09231-01010) Overhaul Handle (09231-01030) Claw 09231-14010 Punch 09960-10010 Variable Pin Wrench Set (09962-01000) Variable Pin Wrench Arm Assembly (09963-00700) Pin 7 PP PP–24 PREPARATION – 2AZ-FE COOLING RECOMMENDED TOOLS 09082-00040 (09083-00150) PP TOYOTA Electrical Tester Test Lead Set PREPARATION – 2AZ-FE COOLING PP–25 EQUIPMENT Ohmmeter Radiator cap tester Thermometer Torque wrench Vernier calipers PP PP–26 PREPARATION – 2AZ-FE COOLING COOLANT PP Capacity Classification 6.2 liters (6.6 US qts, 5.5 Imp. qts) Use only "TOYOTA Super Long Life Coolant" or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids). PREPARATION – 2AZ-FE COOLING PP–27 SSM Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent PP PREPARATION – 2GR-FE COOLING PP–25 2GR-FE COOLING PREPARATION SST 09230-01010 Radiator Service Tool Set (09231-01010) Overhaul Handle (09231-01030) Claw 09231-14010 Punch 09960-10010 Variable Pin Wrench Set (09962-01000) Variable Pin Wrench Arm Assembly (09963-00700) Pin 7 PP PP–26 PREPARATION – 2GR-FE COOLING RECOMMENDED TOOLS 09082-00040 (09083-00150) PP TOYOTA Electrical Tester Test Lead Set PREPARATION – 2GR-FE COOLING PP–27 EQUIPMENT Ohmmeter Radiator cap tester Thermometer Torque wrench Vernier calipers PP PP–28 PREPARATION – 2GR-FE COOLING COOLANT PP Capacity Classification 9.0 liters (9.5 US qts, 7.9 Imp. qts) Use only "TOYOTA Super Long Life Coolant" or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids). PREPARATION – 2GR-FE COOLING PP–29 SSM Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent PP PREPARATION – 2AZ-FE LUBRICATION PP–27 2AZ-FE LUBRICATION PREPARATION SST 09223-22010 Crankshaft Front Oil Seal Replacer 09228-06501 Oil Filter Wrench PP PP–28 PREPARATION – 2AZ-FE LUBRICATION RECOMMENDED TOOLS 09044-00020 Torx Socket E10 09200-00010 Engine Adjust Kit PP HINT: Torx is registered trademark of Textron Inc. PREPARATION – 2AZ-FE LUBRICATION PP–29 EQUIPMENT Precision straight edge Torque wrench Vernier calipers Deep socket wrench (24 mm) Socket wrench (27 mm) Oil pressure gauge PP PP–30 PREPARATION – 2AZ-FE LUBRICATION LUBRICANT PP Item Condition Capacity Classification Oil grade - - Use ILSAC multigrade engine oil. SAE 5W-20 and SAE 0W-20 engine oil may be used. However, SAE0W-20 is the best choice for good fuel economy and good starting in cold weather. Drain and refill with oil filter change 4.3 liters (4.5 US qts, 3.8 Imp. qts) - without oil filter change 4.1 liters (4.3 US qts, 3.6 Imp. qts) - Dry fill 5.0 liters (5.3 US qts, 4.4 Imp. qts) - Dry fill PREPARATION – 2AZ-FE LUBRICATION PP–29 EQUIPMENT Precision straight edge Torque wrench Vernier calipers Deep socket wrench (24 mm) Socket wrench (27 mm) Oil pressure gauge PP PP–30 PREPARATION – 2AZ-FE LUBRICATION LUBRICANT PP Item Condition Capacity Classification Oil grade - - Use ILSAC multigrade engine oil. SAE 5W-20 and SAE 0W-20 engine oil may be used. However, SAE0W-20 is the best choice for good fuel economy and good starting in cold weather. Drain and refill with oil filter change 4.3 liters (4.5 US qts, 3.8 Imp. qts) - without oil filter change 4.1 liters (4.3 US qts, 3.6 Imp. qts) - Dry fill 5.0 liters (5.3 US qts, 4.4 Imp. qts) - Dry fill PREPARATION – 2AZ-FE LUBRICATION PP–31 SSM Toyota Genuine Adhesive 1344, Three Bond 1344B or Equivalent Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent PP PREPARATION – 2GR-FE LUBRICATION PP–29 2GR-FE LUBRICATION PREPARATION SST 09223-22010 Crankshaft Front Oil Seal Replacer 09228-06501 Oil Filter Wrench 09506-35010 Differential Drive Pinion Rear Bearing Replacer PP PP–30 PREPARATION – 2GR-FE LUBRICATION RECOMMENDED TOOLS 09200-00010 PP Engine Adjust Kit PREPARATION – 2GR-FE LUBRICATION PP–31 EQUIPMENT Deep socket wrench (24 mm) Hose Oil pressure gauge Socket wrench (27 mm) Precision straight edge Torque wrench PP PP–32 PREPARATION – 2GR-FE LUBRICATION LUBRICANT PP Item Condition Capacity Classification Oil grade - - Use ILSAC multigrade engine oil. SAE 5W-30 engine oil may be used. However, SAE 5W-30 is the best choice for good fuel economy and good starting in cold weather. Drain and refill with oil filter change 6.1 liters (6.4 US qts, 5.4 Imp. qts) - without oil filter change 5.7 liters (6.0 US qts, 5.0 Imp. qts) - Dry fill 6.5 liters (6.9 US qts, 5.7 Imp. qts) - Dry fill PREPARATION – 2GR-FE LUBRICATION PP–33 SSM Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent Toyota Genuine Seal Packing Block, Three Bond 1207B or Equivalent Toyota Genuine Seal Packing 1282B, Three Bond 1282B or Equivalent PP PREPARATION – 2AZ-FE IGNITION PP–31 2AZ-FE IGNITION PREPARATION RECOMMENDED TOOLS 09082-00040 (09083-00150) TOYOTA Electrical Tester Test Lead Set PP PP–32 EQUIPMENT Spark plug cleaner Torque wrench PP PREPARATION – 2AZ-FE IGNITION PP–32 PREPARATION – 2GR-FE IGNITION 2GR-FE IGNITION PREPARATION RECOMMENDED TOOLS 09082-00040 PP (09083-00150) TOYOTA Electrical Tester Test Lead Set PREPARATION – 2GR-FE IGNITION PP–33 EQUIPMENT Spark plug cleaner Torque wrench PP PREPARATION – 2AZ-FE STARTING PP–33 2AZ-FE STARTING PREPARATION RECOMMENDED TOOLS 09082-00040 (09083-00150) 09905-00013 TOYOTA Electrical Tester Test Lead Set Snap Ring Pliers PP PP–34 EQUIPMENT Torque wrench Service Wire Harness Vernier calipers Sandpaper (#400) PP PREPARATION – 2AZ-FE STARTING PP–34 PREPARATION – 2GR-FE STARTING 2GR-FE STARTING PREPARATION RECOMMENDED TOOLS 09082-00040 PP (09083-00150) 09905-00013 TOYOTA Electrical Tester Test Lead Set Snap Ring Pliers PREPARATION – 2GR-FE STARTING PP–35 EQUIPMENT Torque wrench Service Wire Harness Vernier calipers Sandpaper (#400) PP PREPARATION – 2AZ-FE CHARGING PP–35 2AZ-FE CHARGING PREPARATION SST 09612-70100 (09612-07240) Power Steering Oil Seal Remover Set Collar 09820-63020 Alternator Pulley Wrench Set 09950-40011 Puller B Set (09951-04020) Hanger 200 (09952-04010) Slide Arm (09953-04020) Center Bolt 150 (09954-04010) Arm 25 (09955-04071) Claw No.7 (09957-04010) Attachment (09958-04011) Holder PP PP–36 PREPARATION – 2AZ-FE CHARGING 09950-60010 Replacer Set (09951-00250) Replacer 25 09950-70010 Handle Set (09951-07100) Handle 100 PP PREPARATION – 2AZ-FE CHARGING PP–37 RECOMMENDED TOOLS 09082-00040 (09083-00150) TOYOTA Electrical Tester Test Lead Set PP PP–38 EQUIPMENT Torque wrench Vernier calipers Pin (φ1 mm) PP PREPARATION – 2AZ-FE CHARGING PREPARATION – 2GR-FE CHARGING PP–37 2GR-FE CHARGING PREPARATION SST 09820-63020 Alternator Pulley Wrench Set 09950-40011 Puller B Set (09951-04020) Hanger 200 (09952-04010) Slide Arm (09953-04020) Center Bolt 150 (09954-04010) Arm 25 (09955-04071) Claw No.7 (09957-04010) Attachment (09958-04011) Holder 09950-60010 Replacer Set (09951-00250) Replacer 25 PP PP–38 PREPARATION – 2GR-FE CHARGING (09951-00470) Replacer 47 09950-70010 Handle Set (09951-07100) Handle 100 PP PREPARATION – 2GR-FE CHARGING PP–39 RECOMMENDED TOOLS 09082-00040 (09083-00150) TOYOTA Electrical Tester Test Lead Set PP PP–40 EQUIPMENT Torque wrench Vernier calipers Pin (φ1 mm) PP PREPARATION – 2GR-FE CHARGING PREPARATION – U250E AUTOMATIC TRANSAXLE PP–39 U250E AUTOMATIC TRANSAXLE PREPARATION SST 09023-12701 Union Nut Wrench 17mm 09223-15030 Oil Seal & Bearing Replacer 09308-00010 Oil Seal Puller 09316-12010 Transfer Bearing Replacer 09316-20011 Transfer Bearing Replacer 09316-60011 Transmission & Transfer Bearing Replacer (09316-00011) Replacer Pipe 09350-32014 TOYOTA Automatic Transmission Tool Set (09351-32010) One-way Clutch Test Tool (09351-32020) Stator Stopper (09351-32070) No.2 Piston Spring Compressor PP PP–40 PREPARATION – U250E AUTOMATIC TRANSAXLE (09351-32140) Oil Seal Replacer 09387-00020 Direct Clutch Wrench 09387-00030 Counter Drive Gear Holding Tool 09387-00041 Bearing Puller Assembly PP (09387-01010) Claw No.1 (09387-01021) Claw No.2 (09387-01030) Pin (09387-01040) Bearing Puller Body 09387-00050 Under Drive Gear Puller 09387-00060 Second Brake Wrench 09387-00070 First & Reverse Brake Wrench 09387-00080 Counter Drive Gear Nut Wrench PREPARATION – U250E AUTOMATIC TRANSAXLE 09495-65040 Axle Hub Oil Seal Replacer 09502-24010 Bearing Replacer PP–41 PP 09515-21010 Rear Axle Shaft Bearing Replacer 09523-36010 Rear Axle Hub Guide Tool 09527-17011 Rear Axle Shaft Bearing Remover 09550-60010 Differential Side Bearing Replacer (09951-00480) Replacer 48 (09951-00790) Replacer 79 09564-32011 Differential Preload Adaptor 09608-10010 Steering Knuckle Oil Seal Replacer 09608-32010 Steering Knuckle Oil Seal Replacer 09649-17010 Steering Knuckle Tool PP–42 PREPARATION – U250E AUTOMATIC TRANSAXLE 09710-04081 Base 09726-36010 Lower Control Arm Bushing Replacer 09726-40010 Lower Control Shaft Bearing Replacer 09820-00031 Alternator Rotor Rear Bearing Replacer 09930-00010 Drive Shaft Nut Chisel PP (09931-00010) Handle (09931-00020) Nut Chisel 09950-00020 Bearing Remover 09950-00030 Bearing Remover Attachment 09950-40011 Puller B Set (09952-04010) Slide Arm (09954-04010) Arm 25 PREPARATION – U250E AUTOMATIC TRANSAXLE (09955-04061) Claw No.6 (09957-04010) Attachment PP–43 PP (09958-04011) Holder 09950-50013 Puller C Set (09951-05010) Hanger 150 (09952-05010) Slide Arm (09953-05020) Center Bolt 150 (09954-05021) Claw No.2 (09955-05010) Adapter No.1 09950-60010 Replacer Set (09951-00230) Replacer 23 (09951-00260) Replacer 26 PP–44 PREPARATION – U250E AUTOMATIC TRANSAXLE (09951-00320) Replacer 32 (09951-00360) Replacer 36 (09951-00450) Replacer 45 (09951-00480) Replacer 48 (09951-00500) Replacer 50 (09951-00590) Replacer 59 (09951-00630) Replacer 63 (09952-06010) Adapter PP 09950-60020 Replacer Set No.2 (09951-00720) Replacer 72 (09951-00750) Replacer 75 (09951-00810) Replacer 81 PREPARATION – U250E AUTOMATIC TRANSAXLE (09951-00890) Replacer 89 09950-70010 Handle Set PP–45 PP (09951-00710) Replacer 71 (09951-00780) Replacer 78 (09951-07100) Handle 100 (09951-07150) Handle 150 (09951-07200) Handle 200 PP–46 PREPARATION – U250E AUTOMATIC TRANSAXLE RECOMMENDED TOOLS 09031-00030 Pin Punch 09040-00011 Hexagon Wrench Set PP (09043-20060) Socket Hexagon Wrench 6 (09043-20100) Socket Hexagon Wrench 10 09042-00010 Torx Socket T30 09905-00012 Snap Ring No.1 Expander 09905-00013 Snap Ring Pliers (09904-00090) 09924-12411 HINT: Torx is registered trademark of Textron Inc. Claw Set Deep Socket Wrench 41 PREPARATION – U250E AUTOMATIC TRANSAXLE PP–47 EQUIPMENT Dial indicator with magnetic base Feeler gauge Vernier calipers Torque wrench Plastic hammer Straight edge Press Punch PP PP–48 PREPARATION – U250E AUTOMATIC TRANSAXLE LUBRICANT Automatic transaxle fluid PP Dry fill 8.0 liter (8.5 USqts, 7.0 Imp.qts) Drain and refill 3.5 liter (3.7 USqts, 3.1 Imp.qts) ATF WS PREPARATION – U250E AUTOMATIC TRANSAXLE PP–49 SSM Toyata Genuine Seal Packing 1281, Three Bond 1281 or Equivalent Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent PP PREPARATION – U660E AUTOMATIC TRANSAXLE PP–47 U660E AUTOMATIC TRANSAXLE PREPARATION SST 09223-15030 Oil Seal & Bearing Replacer 09308-00010 Oil Seal Puller 09308-14010 Replacer Pipe A 09316-10010 Remover & Replacer 09319-60020 Output Shaft Needle Roller Bearing Remover 09350-32014 TOYOTA Automatic Transmission Tool Set (09351-32010) One-way Clutch Test Tool (09351-32020) Stator Stopper (09351-32140) Oil Seal Replacer 09387-00020 Direct Clutch Wrench 09387-00060 Second Brake Wrench PP PP–48 PREPARATION – U660E AUTOMATIC TRANSAXLE 09387-00070 First & Reverse Brake Wrench 09387-00130 Counter Drive Gear Nut Wrench 09495-65040 Axle Hub Oil Seal Replacer 09527-17011 Rear Axle Shaft Bearing Remover 09564-33010 Drive Pinion Lock Nut Socket 09710-04081 Base 09843-18040 Diagnosis Check Wire No.2 09930-00010 Drive Shaft Nut Chisel 09950-00020 Bearing Remover 09950-00030 Bearing Remover Attachment 09950-40011 Puller B Set (09951-04010) Hanger 150 PP PREPARATION – U660E AUTOMATIC TRANSAXLE (09952-04010) Slide Arm (09953-04020) Center Bolt 150 PP–49 PP (09954-04010) Arm 25 (09955-04071) Claw No.7 (09957-04010) Attachment (09958-04011) Holder 09950-60010 Replacer Set (09951-00220) Replacer 22 (09951-00230) Replacer 23 (09951-00320) Replacer 32 (09951-00400) Replacer 40 (09951-00420) Replacer 42 PP–50 PREPARATION – U660E AUTOMATIC TRANSAXLE (09951-00480) Replacer 48 (09951-00530) Replacer 53 (09951-00540) Replacer 54 (09951-00580) Replacer 58 (09951-00650) Replacer 65 PP 09950-60020 Replacer Set No.2 (09951-00710) Replacer 71 (09951-00790) Replacer 79 (09951-00810) Replacer 81 (09951-01030) Replacer 103 09950-70010 Handle Set (09951-07100) Handle 100 PREPARATION – U660E AUTOMATIC TRANSAXLE (09951-07150) Handle 150 (09951-07200) Handle 200 PP–51 PP 09951-01100 Replacer 110 09992-00095 Automatic Transmission Oil Pressure Gauge Set (09992-00231) Adaptor C (09992-00271) Gauge Assy PP–52 PREPARATION – U660E AUTOMATIC TRANSAXLE RECOMMENDED TOOLS 09031-00030 Pin Punch 09040-00011 Hexagon Wrench Set PP (09043-20060) Socket Hexagon Wrench 6 (09043-20100) Socket Hexagon Wrench 10 09042-00010 Torx Socket T30 09905-00012 Snap Ring No.1 Expander 09905-00013 Snap Ring Pliers (09904-00090) 09924-12411 HINT: Torx is registered trademark of Textron Inc. Claw Set Deep Socket Wrench 41 PREPARATION – U660E AUTOMATIC TRANSAXLE PP–53 EQUIPMENT Dial indicator with magnetic base Feeler gauge Vernier calipers Torque wrench Plastic hammer Straight edge Press Punch PP PP–54 PREPARATION – U660E AUTOMATIC TRANSAXLE LUBRICANT Automatic transaxle fluid Dry fill PP 6.57 liter (6.94 USqts, 5.78 Imp.qts) ATF WS PREPARATION – U660E AUTOMATIC TRANSAXLE PP–55 SSM Toyata Genuine Seal Packing 1281, Three Bond 1281 or Equivalent Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent PP PREPARATION – CLUTCH PP–53 CLUTCH PREPARATION SST 09023-00101 Union Nut Wrench 10 mm 09301-00210 Clutch Guide Tool 09301-00220 Clutch Guide Tool 09333-00013 Universal Joint Bearing Remover & Replacer PP PP–54 EQUIPMENT Vernier calipers Dial indicator with magnetic base Torque wrench PP PREPARATION – CLUTCH PP–55 PREPARATION – CLUTCH LUBRICANT Item Brake fluid Capacity - Classification SAE J1703 or FMVSS No. 116 DOT3 PP PP–54 PREPARATION – E351 MANUAL TRANSAXLE E351 MANUAL TRANSAXLE PREPARATION SST PP 09229-55010 Oil Cooler Relief Valve Wrench 09308-00010 Oil Seal Puller 09309-12020 5th Driven Gear Replacer 09316-20011 Transfer Bearing Replacer 09316-60011 Transmission & Transfer Bearing Replacer (09316-00031) Replacer B (09316-00041) Replacer C 09387-00041 Bearing Puller Assembly (09387-02010) Oil Seal Replacer (09387-02020) One-way Clutch Test Tool Set 09506-30012 Differential Drive Pinion Rear Bearing Cone Replacer PREPARATION – E351 MANUAL TRANSAXLE 09564-32011 Differential Preload Adaptor 09608-00071 Drive Pinion Rear Bearing Cone Replacer PP–55 PP 09608-06041 Front Hub Inner Bearing Cone Replacer 09608-10010 Steering Knuckle Oil Seal Replacer 09608-32010 Steering Knuckle Oil Seal Replacer 09612-65014 Steering Worm Bearing Puller (09612-01040) Claw D (09612-01050) Hanger Pin with Nut 09631-12090 Seal Ring Tool 09930-00010 Drive Shaft Nut Chisel 09950-00020 Bearing Remover 09950-00030 Bearing Remover Attachment PP–56 PREPARATION – E351 MANUAL TRANSAXLE 09950-30012 Puller A Set (09951-03010) Upper Plate (09953-03010) Center Bolt (09954-03010) Arm (09957-04010) Attachment 09950-40011 Puller B Set (09957-04010) Attachment 09950-50013 Puller C Set (09957-04010) Attachment PP 09950-60010 Replacer Set (09951-00180) Replacer 18 (09951-00280) Replacer 28 PREPARATION – E351 MANUAL TRANSAXLE (09951-00320) Replacer 32 (09951-00420) Replacer 42 PP–57 PP (09951-00430) Replacer 43 (09951-00490) Replacer 49 (09951-00560) Replacer 56 (09951-00570) Replacer 57 (09951-00600) Replacer 60 (09951-00680) Replacer 68 (09955-03011) Claw No.1 09950-60020 Replacer Set No.2 (09951-00680) Replacer 68 (09951-00730) Replacer 73 PP–58 PREPARATION – E351 MANUAL TRANSAXLE (09951-00790) Replacer 79 (09951-00890) Replacer 89 (09951-00910) Replacer 91 09950-70010 Handle Set (09951-07100) Handle 100 (09951-07150) Handle 150 (09951-07200) Handle 200 PP PREPARATION – E351 MANUAL TRANSAXLE PP–59 RECOMMENDED TOOLS 09011-12301 Socket Wrench 30 mm 09031-00040 Pin Punch . PP 09040-00011 (09043-20060) Hexagon Wrench Set Socket Hexagon Wrench 6 09042-00050 Torx Socket T45 09905-00012 Snap Ring No.1 Expander HINT: Torx is registered trademark of Textron Inc. PP–60 EQUIPMENT Dial indicator with magnetic base Torque wrench Slide calipers V-block Micrometer PP Dial indicator Cylinder gauge Feeler gauge Precision straight edge PREPARATION – E351 MANUAL TRANSAXLE PP–61 PREPARATION – E351 MANUAL TRANSAXLE LUBRICANT Item Manual transaxle oil (w/ Differential oil) Capacity 2.5 liters (2.6 US qts, 2.2 lmp. qts) Classification API GL-4 or GL-5 SAE 75W-90 PP PP–62 PREPARATION – E351 MANUAL TRANSAXLE SSM Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent PP PP–60 PREPARATION – DRIVE SHAFT DRIVE SHAFT PREPARATION SST PP 09240-00020 Wire Gauge Set 09520-01010 Drive Shaft Remover Attachment 09520-24010 Differential Side Gear Shaft Puller (09520-32040) Shocker Set 09521-24010 Rear Axle Shaft Puller 09527-10011 Rear Axle Shaft Bearing Remover 09527-30010 Rear Axle Shaft Bearing Remover 09608-16042 Front Hub Bearing Adjusting Tool (09608-02021) Bolt & Nut (09608-02041) Retainer 09628-00011 Ball Joint Puller PREPARATION – DRIVE SHAFT 09726-40010 Lower Control Shaft Bearing Replacer 09930-00010 Drive Shaft Nut Chisel PP–61 PP 09950-00020 Bearing Remover PP–62 PREPARATION – DRIVE SHAFT RECOMMENDED TOOLS 09011-12301 Socket Wrench 30 mm 09040-00011 Hexagon Wrench Set PP (09043-20060) Socket Hexagon Wrench 6 09905-00012 Snap Ring No.1 Expander PREPARATION – DRIVE SHAFT PP–63 EQUIPMENT Torque wrench PP PP–64 PREPARATION – DRIVE SHAFT LUBRICANT Item 2GR-FE Outboard joint grease 164 to 184 g (5.8 to 6.5 oz.) 2AZ-FE (for TMC made) Outboard joint grease 190 to 200 g (6.7 to 7.1 oz.) 2AZ-FE (for TMMK made) Outboard joint grease 100 to 120 g (3.5 to 4.2 oz.) Inboard joint grease 155 to 175 g (5.5 to 6.2 oz.) 2GR-FE PP Capacity 2AZ-FE (for TMC made) Inboard joint grease 175 to 185 g (6.2 to 6.5 oz.) 2AZ-FE (for TMMK made) Inboard joint grease 170 to 190 g (6.0 to 6.7 oz.) PP–62 PREPARATION – AXLE AXLE PREPARATION SST 09316-60011 PP Transmission & Transfer Bearing Replacer (09316-00011) Replacer Pipe (09316-00031) Replacer B 09520-00031 Rear Axle Shaft Puller 09527-17011 Rear Axle Shaft Bearing Remover 09527-20011 Rear Axle Shaft Bearing Remover 09555-55010 Differential Drive Pinion Bearing Replacer 09608-32010 Steering Knuckle Oil Seal Replacer 09628-10011 Ball Joint Puller 09950-60010 Replacer Set (09951-00400) Replacer 40 PREPARATION – AXLE (09951-00430) Replacer 43 (09951-00600) Replacer 60 PP–63 PP (09952-06010) 09950-60020 Adapter Replacer Set No.2 (09951-00810) Replacer 81 09950-70010 Handle Set (09951-07100) Handle 100 PP–64 PREPARATION – AXLE RECOMMENDED TOOLS PP 09011-12301 Socket Wrench 30 mm 09905-00013 Snap Ring Pliers PREPARATION – AXLE PP–65 EQUIPMENT Torque wrench Dial indicator with magnetic base PP PP–64 PREPARATION – SUSPENSION SUSPENSION PREPARATION SST PP 09628-62011 Boll Joint Puller 09727-30021 Coil Spring Compressor (09727-00010) Bolt Set (09727-00021) Arm Set (09727-00031) Compressor PREPARATION – SUSPENSION PP–65 RECOMMENDED TOOLS 09011-12301 Socket Wrench 30 mm 09040-00011 Hexagon Wrench Set PP (09043-20050) Socket Hexagon Wrench 5 (09043-20060) Socket Hexagon Wrench 6 09050-00032 Air Drill PP–66 PREPARATION – SUSPENSION EQUIPMENT Torque wrench Dial indicator with magnetic base Tire pressure gauge Alignment tester Toe-in gauge PP Angle gauge Slide Calipers Wooden block Camber-caster-kingpin gauge Drill (Safety equipment: protective goggles, etc.) Shock absorber disposal PP–66 PREPARATION – TIRE AND WHEEL TIRE AND WHEEL PREPARATION RECOMMENDED TOOLS 09082-00040 PP (09083-00150) TOYOTA Electrical Tester Test Lead Set PREPARATION – TIRE AND WHEEL PP–67 EQUIPMENT Tire pressure gauge Dial indicator with magnetic base Wheel balancer Torque wrench PP PREPARATION – BRAKE CONTROL PP–67 BRAKE CONTROL PREPARATION SST 09023-00101 Union Nut Wrench 10 mm 09023-38200 Union Nut Wrench 12mm 09213-58013 Crankshaft Pulley Holding Tool 09309-36010 Transmission Rear Bearing Replacer 09520-00031 Rear Axle Shaft Puller (09520-00040) Shocker (09521-00010) Rod with Grip 09521-00020 Drive Shaft Boot Clamping Tool 09950-00020 Bearing Remover PP PP–68 EQUIPMENT Torque wrench PP PREPARATION – BRAKE CONTROL PP–69 PREPARATION – BRAKE CONTROL LUBRICANT Item Capacity Classification Brake fluid - SAE J1703 or FMVSS No. 116 DOT 3 PP PP–68 PREPARATION – BRAKE BRAKE PREPARATION SST PP 09023-00101 Union Nut Wrench 10 mm 09023-38200 Union Nut Wrench 12mm 09330-00021 Companion Flange Holding Tool 09737-00020 Brake Booster Push Rod Wrench PREPARATION – BRAKE PP–69 EQUIPMENT Ruler Micrometer Dial indicator with magnetic base Torque wrench PP PP–70 PREPARATION – BRAKE LUBRICANT PP Item Capacity Classification Brake fluid - SAE J1703 or FMVSS No. 116 DOT 3 PREPARATION – PARKING BRAKE PP–69 PARKING BRAKE PREPARATION EQUIPMENT Torque wrench Slide calipers Brake drum gauge Feeler gauge PP PP–70 PREPARATION – PARKING BRAKE SSM Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent PP PP–70 PREPARATION – STEERING COLUMN STEERING COLUMN PREPARATION SST PP 09950-50013 Puller C Set (09951-05010) Hanger 150 (09952-05010) Slide Arm (09953-05020) Center Bolt 150 (09954-05031) Claw No.3 PREPARATION – STEERING COLUMN PP–71 RECOMMENDED TOOLS 09082-00040 (09083-00150) TOYOTA Electrical Tester Test Lead Set PP PP–72 EQUIPMENT Torque wrench PP PREPARATION – STEERING COLUMN PREPARATION – POWER STEERING PP–71 POWER STEERING PREPARATION SST 09023-12701 Union Nut Wrench 17mm 09023-38201 Union Nut Wrench 12mm 09249-63010 Torque Wrench Adaptor 09521-24010 Rear Axle Shaft Puller 09527-21011 Rear Axle Shaft Bearing Remover 09612-00012 Rack & Pinion Steering Rack Housing Stand 09612-22011 Tilt Handle Bearing Replacer 09612-24014 Steering Gear Housing Overhaul Tool Set (09613-22011) Steering Rack Shaft Bushing Puller 09616-00011 Steering Worm Bearing Adjusting Socket 09628-00011 Ball Joint Puller PP PP–72 PREPARATION – POWER STEERING 09630-00014 (09631-00132) Power Steering Gear Housing Overhaul Tool Set Vane Pump Bracket PP 09631-00200 Rack Seal GuIde NO.2 09631-12071 Steering Rack Oil Seal Test Tool (09633-00010) Packing 09631-33010 Steering Rack Cover I 09640-10010 Power Steering Pressure Gauge Set (09641-01010) Gauge Assy (09641-01030) Attachment B (09641-01060) Attachment E 09922-10010 Variable Open Wrench 09950-60010 Replacer Set PREPARATION – POWER STEERING (09951-00180) Replacer 18 (09951-00250) Replacer 25 PP–73 PP (09951-00280) Replacer 28 (09951-00290) Replacer 29 (09951-00320) Replacer 32 (09951-00340) Replacer 34 (09951-00400) Replacer 40 (09952-06010) Adapter 09950-70010 Handle Set (09951-07100) Handle 100 (09951-07150) Handle 150 (09951-07360) Handle 360 PP–74 PREPARATION – POWER STEERING RECOMMENDED TOOLS 09040-00011 (09043-30240) Hexagon Wrench Set Straight Hexagon Wrench 24 PP 09905-00012 Snap Ring No.1 Expander PREPARATION – POWER STEERING PP–75 EQUIPMENT Torque wrench Vernier calipers Dial indicator Feeler gauge Micrometer V-block PP PP–76 PREPARATION – POWER STEERING LUBRICANT Item Power steering fluid (Total) PP Capacity 1.0 liters (1.1 US qts, 0.9 Imp. qts) Classification ATF DEXRON II or III or equivalent PREPARATION – POWER STEERING PP–77 SSM TOYOTA genuine adhesive 1344, THREE BOND 1344, or equivalent PP PREPARATION – AIR CONDITIONING PP–75 AIR CONDITIONING PREPARATION SST 07110-58060 Air Conditioner Service Tool Set (07117-58060) Refrigerant Drain Service Valve (07117-58070) T-Joint (07117-58080) Quick Disconnect Adapter (07117-58090) Quick Disconnect Adapter (07117-78050) Refrigerant Charging Gauge (07117-88060) Refrigerant Charging Hose (07117-88070) Refrigerant Charging Hose (07117-88080) Refrigerant Charging Hose PP PP–76 PREPARATION – AIR CONDITIONING RECOMMENDED TOOLS 09042-00020 TORX Socket T40 09082-00040 TOYOTA Electrical Tester PP (09083-00150) Test Lead Set 09904-00010 Expander Set (09904-00050) No. 4 Claw HINT: TORX is a registered trademark of Textron Inc. PREPARATION – AIR CONDITIONING PP–77 EQUIPMENT Vinyl tape Hexagon wrench 4mm Hexagon wrench 12 mm Gas leak detector Dial indicator with magnetic base Torque wrench PP PP–78 PREPARATION – AIR CONDITIONING LUBRICANT PP Item Capacity Classification Compressor oil - ND-OIL 8 or equivalent PREPARATION – SUPPLEMENTAL RESTRAINT SYSTEM PP–77 SUPPLEMENTAL RESTRAINT SYSTEM PREPARATION SST 09082-00700 SRS Airbag Deployment Tool 09082-00750 Airbag Deployment Wire Sub-harness No.3 09082-00770 Airbag Deployment Wire Sub-harness No.5 09082-00780 Airbag Deployment Wire Sub-harness No.6 09082-00802 Airbag Deployment Wire Sub-Harness No. 8 (09082-10801) Wire A (09082-20801) Wire B (09082-30801) Wire C 09843-18060 SRS Check Wire PP PP–78 PREPARATION – SUPPLEMENTAL RESTRAINT SYSTEM RECOMMENDED TOOLS 09042-00010 PP HINT: Torx is a registered trademark of Textron Inc. Torx Socket T30 PREPARATION – SUPPLEMENTAL RESTRAINT SYSTEM PP–79 EQUIPMENT Torque wrench Feeler gauge Battery Tape Bolt Length: 35.0 mm (1.378 in.) Diameter: 6.0 mm (0.236 in.) Pitch: 1.0 mm (0.039 in.) Airbag disposal Tire Width: 185 mm (7.28 in.) Inner diameter: 360 mm (14.17 in.) Airbag disposal Tire with disc wheel Width: 185 mm (7.28 in.) Inner diameter: 360 mm (14.17 in.) Airbag disposal Wire harness Airbag disposal Plastic bag Airbag disposal PP PREPARATION – SEAT BELT PP–79 SEAT BELT PREPARATION SST 09082-00700 SRS Airbag Deployment Tool 09082-00770 Airbag Deployment Wire Sub-harness No.5 PP PP–80 PREPARATION – SEAT BELT RECOMMENDED TOOLS 09082-00040 (09083-00150) PP TOYOTA Electrical Tester Test Lead Set PREPARATION – SEAT BELT PP–81 EQUIPMENT Torque wrench Protective tape PP PP–80 PREPARATION – THEFT DETERRENT SYSTEM THEFT DETERRENT SYSTEM PREPARATION RECOMMENDED TOOLS 09082-00040 PP (09083-00150) TOYOTA Electrical Tester Test Lead Set PREPARATION – THEFT DETERRENT SYSTEM PP–81 EQUIPMENT Torque wrench PP PREPARATION – ENGINE IMMOBILISER PP–81 ENGINE IMMOBILISER PREPARATION SST 09843-18040 Diagnosis Check Wire No.2 PP PP–82 PREPARATION – ENGINE IMMOBILISER RECOMMENDED TOOLS 09082-00040 (09083-00150) PP TOYOTA Electrical Tester Test Lead Set PP–82 PREPARATION – CRUISE CONTROL CRUISE CONTROL PREPARATION RECOMMENDED TOOLS 09082-00040 PP (09083-00150) TOYOTA Electrical Tester Test Lead Set PREPARATION – CRUISE CONTROL PP–83 EQUIPMENT Torque wrench PP PREPARATION – LIGHTING PP–83 LIGHTING PREPARATION RECOMMENDED TOOLS 09042-00010 TORX Socket T30 09082-00040 TOYOTA Electrical Tester (09083-00150) Test Lead Set PP PP–84 EQUIPMENT Clip remover Torque wrench Tire pressure gage White paper PP PREPARATION – LIGHTING PP–84 PREPARATION – WIPER AND WASHER WIPER AND WASHER PREPARATION RECOMMENDED TOOLS 09082-00040 PP (09083-00150) TOYOTA Electrical Tester Test Lead Set PREPARATION – WIPER AND WASHER PP–85 EQUIPMENT Protective tape Torque wrench Wire brush MP grease PP PREPARATION – DOOR LOCK PP–85 DOOR LOCK PREPARATION RECOMMENDED TOOLS 09042-00010 Torx Socket T30 09082-00040 TOYOTA Electrical Tester (09083-00150) HINT: Torx is a registered trademark of Textron Inc. Test Lead Set PP PP–86 EQUIPMENT MP grease Protective tape Torque wrench PP PREPARATION – DOOR LOCK PP–86 PREPARATION – METER METER PREPARATION RECOMMENDED TOOLS 09082-00050 TOYOTA Electrical Tester Set PP (09083-00150) Test Lead Set PREPARATION – METER PP–87 EQUIPMENT Torque wrench PP PREPARATION – AUDIO / VISUAL PP–87 AUDIO / VISUAL PREPARATION RECOMMENDED TOOLS 09082-00040 (09083-00150) TOYOTA Electrical Tester Test Lead Set PP PP–88 EQUIPMENT Torque wrench Double-sided tape Tape PP PREPARATION – AUDIO / VISUAL PP–88 PREPARATION – NAVIGATION NAVIGATION PREPARATION RECOMMENDED TOOLS 09082-00040 PP (09083-00150) TOYOTA Electrical Tester Test Lead Set PREPARATION – HORN PP–89 HORN PREPARATION RECOMMENDED TOOLS 09082-00040 (09083-00150) TOYOTA Electrical Tester Test Lead Set PP PP–90 EQUIPMENT Torque wrench PP PREPARATION – HORN PP–90 PREPARATION – GARAGE DOOR OPENER GARAGE DOOR OPENER PREPARATION RECOMMENDED TOOLS 09070-20010 PP Moulding Remover PREPARATION – OTHER SYSTEM PP–91 OTHER SYSTEM PREPARATION RECOMMENDED TOOLS 09082-00040 (09083-00150) TOYOTA Electrical Tester Test Lead Set PP PP–92 PREPARATION – WINDSHIELD / WINDOWGLASS WINDSHIELD / WINDOWGLASS PREPARATION RECOMMENDED TOOLS 09082-00040 PP (09083-00150) TOYOTA Electrical Tester Test Lead Set PREPARATION – WINDSHIELD / WINDOWGLASS PP–93 EQUIPMENT Torque wrench Protective Tape Knife Suction cup Piano wire Wooden block or similar object Plastic sheet Scraper Brush or sponge Sealer gun PP PP–94 PREPARATION – WINDSHIELD / WINDOWGLASS SSM Toyota Genuine Windshield Glass Adhesive or Equivalent PP PREPARATION – MIRROR PP–93 MIRROR PREPARATION RECOMMENDED TOOLS 09042-00030 TORX Socket T20 09070-20010 Moulding Remover 09082-00040 TOYOTA Electrical Tester (09083-00150) Test Lead Set HINT: TORX is a registered trademark of Textron Inc. PP PP–94 EQUIPMENT Torque wrench Protective tape PP PREPARATION – MIRROR PP–94 PREPARATION – INSTRUMENT PANEL INSTRUMENT PANEL PREPARATION RECOMMENDED TOOLS 09070-20010 PP Moulding Remover PREPARATION – INSTRUMENT PANEL PP–95 EQUIPMENT Torque wrench Tape To avoid surface damage PP PP–95 PREPARATION – SEAT SEAT PREPARATION RECOMMENDED TOOLS 09082-00040 (09083-00150) TOYOTA Electrical Tester - Test Lead Set - PP PP–96 PREPARATION – SEAT EQUIPMENT PP Hog ring - Hog ring pliers - Tape To avoid surface damage Torque wrench - PP–96 PREPARATION – ENGINE HOOD / DOOR ENGINE HOOD / DOOR PREPARATION SST PP 09804-24010 Luggage Compartment Door Torsion Bar Tool 09812-00010 Door Hinge Set Bolt Wrench PREPARATION – ENGINE HOOD / DOOR PP–97 RECOMMENDED TOOLS 09041-00020 TORX Driver T25 09042-00010 TORX Socket T30 PP 09042-00020 TORX Socket T40 HINT: TORX is a registered trademark of Textron Inc. PP–98 EQUIPMENT Protective goggle Metal saw Torque wrench MP grease Clip remover PP Protective tape PREPARATION – ENGINE HOOD / DOOR PP–98 EQUIPMENT Protective goggle Metal saw Torque wrench MP grease Clip remover PP Protective tape PREPARATION – ENGINE HOOD / DOOR PREPARATION – EXTERIOR PP–97 EXTERIOR PREPARATION RECOMMENDED TOOLS 09050-00032 Air Drill 09050-20010 Air Riveter (09050-02020) 09070-20010 Nose Piece No.1 Moulding Remover PP PP–98 PREPARATION – EXTERIOR EQUIPMENT Torque wrench Protective tape To avoid surface damage Heat light Double-sided tape Piano wire PP Clip remover Wooden block or similar object Drill (Safety equipment: protective goggles, etc.) Drill bit Hand riveter Rivet Vacuum cleaner For tying both piano wire ends PP–98 PREPARATION – INTERIOR INTERIOR PREPARATION RECOMMENDED TOOLS PP 09050-20010 Air Riveter 09070-20010 Moulding Remover PREPARATION – INTERIOR PP–99 EQUIPMENT Clip remover Torque wrench Protective tape Double-sided tape Adhesive tape Drill (Safety equipment: protective goggles, etc.) Hand riveter Rivet PP PREPARATION – SLIDING ROOF PP–99 SLIDING ROOF PREPARATION RECOMMENDED TOOLS 09041-00020 TORX Driver T25 09082-00040 TOYOTA Electrical Tester (09083-00150) Test Lead Set PP PP–100 EQUIPMENT Torque wrench Protective tape PP PREPARATION – SLIDING ROOF 2AZ-FE CHARGING – CHARGING SYSTEM CH–1 CHARGING SYSTEM PRECAUTION 1. 2. 3. 4. 5. Check that the battery cables are connected to the correct terminals. Disconnect the battery cables when the battery is given a quick charge. Do not perform tests with a high voltage insulation resistance tester. Never disconnect the battery while the engine is running. Check that the charging cable nut is tightened on terminal B of the generator and the engine room R/B. CH CH–2 2AZ-FE CHARGING – CHARGING SYSTEM PARTS LOCATION COMBINATION METER -CHARGE WARNING LIGHT GENERATOR ECM INSTRUMENT PANEL J/B ENGINE ROOM R/B -GAUGE NO. 1 FUSE -ALT FUSE -GAUGE NO. 2 FUSE -ALT-S FUSE A135520E01 CH CH–3 2AZ-FE CHARGING – CHARGING SYSTEM SYSTEM DIAGRAM ECM ALT-S From Battery From IG1 Relay GAUGE No. 1 Combination Meter From Ignition Switch GAUGE No. 2 13 F1 IG+ IG+ CHG- 23 F1 L 4 C18 IG 2 C18 S 1 C18 M 3 C18 Charge Generator ALT 1 B C19 IC Regulator FL MAIN 50 C24 ALT Battery A135064E01 CH CH–4 2AZ-FE CHARGING – CHARGING SYSTEM PROBLEM SYMPTOMS TABLE Result Symptom Charge Warning Light Comes ON while Driving Suspected area 1. Clutch pulley 2. Generator assembly See page CH-7 1. V-ribbed belt Noise Occurs from Generator while Engine is Running 2. Clutch pulley 3. Generator assembly CH CH-8 CH–5 2AZ-FE CHARGING – CHARGING SYSTEM ON-VEHICLE INSPECTION Green Dark 1. CHECK BATTERY ELECTROLYTE LEVEL (a) Check the electrolyte level. (1) If the electrolyte level is low, replace the battery (or add distilled water) and check the charging system. 2. CHECK BATTERY SPECIFIC GRAVITY (a) Check the color of the indicator. Result Clear or Light Yellow 3. A115815E01 Indicator color Condition Green Good Dark Charging necessary Clear or light yellow Replacement necessary CHECK BATTERY VOLTAGE (a) If it has not been 20 minutes since you drove the vehicle or since the engine was stopped, turn the ignition switch to the ON position and turn on the electrical systems (headlight, blower motor, rear defogger, etc.) for 60 seconds. This will remove the surface charge from the battery. (b) Turn off the ignition switch and the electrical systems. (c) Measure the battery voltage between the negative () and positive (+) terminals of the battery. Standard voltage: 12.5 to 12.9 V at 20°C (68°F) HINT: If the voltage is below the specification, charge the battery. 4. CHECK BATTERY TERMINAL (a) Check that the battery terminals are not loose or corroded. If the terminals are corroded, clean them. 5. CHECK FUSES (a) Measure the resistance of the ALT fuse, ALT-S fuse, GAUGE No. 1 fuse and GAUGE No. 2 fuse. Standard resistance: Below 1 Ω If the result is not as specified, replace the fuses as necessary. 6. CHECK V-RIBBED BELT (a) Check the belt for wear, cracks or other signs of damage. If any of the following defects is found, replace the V-ribbed belt. • The belt is worn out, cracked, or the cords are exposed. • The cracks reach the cords in more than one place. • The belt has chunks missing from the ribs. A081052E01 B000543 CH CH–6 2AZ-FE CHARGING – CHARGING SYSTEM CORRECT (b) Check that the belt fits properly in the ribbed grooves. HINT: Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley. If it has slipped out, replace the V-ribbed belt. Install a new V-ribbed belt correctly. INCORRECT 7. VISUALLY CHECK GENERATOR WIRING (a) Check that the generator wiring is in good condition. If the condition is not good, repair or replace the generator wire. 8. LISTEN FOR ABNORMAL NOISES FROM GENERATOR (a) Check that there is no abnormal noise from the generator while the engine is running. If there is abnormal noise, replace the pulley or generator. 9. CHECK CHARGE WARNING LIGHT CIRCUIT (a) Turn the ignition switch to the ON position. Check that the charge warning light comes on. (b) Start the engine and check that the light goes off. If the light does not operate as specified, troubleshoot the charge warning light circuit. B000540E03 Disconnect Wire from Terminal B Ammeter A  Battery Generator Voltmeter Battery CH V  A110265E04 10. CHECK CHARGING CIRCUIT WITHOUT LOAD (a) According to the following procedure, connect an ammeter and voltmeter as shown in the illustration. (1) Disconnect the wire from terminal B of the generator and connect it to the negative (-) lead of the ammeter. (2) Connect the positive (+) lead of the ammeter to terminal B of the generator. (3) Connect the positive (+) lead of the voltmeter to positive (+) terminal of the battery. (4) Ground the negative (-) lead of the voltmeter. (b) Check the charging circuit. (1) While keeping the engine speed at 2,000 rpm, check the readings on the ammeter and voltmeter. Standard amperage: 10 A or less Standard voltage: 13.2 to 14.8 V If the results are not as specified, replace the generator assembly. HINT: • If the battery is not fully charged, the ammeter reading may be more than the standard amperage. In this case, increase electrical load by operating devices such as the wiper motor and rear window defogger. Then, recheck the reading on the ammeter. 2AZ-FE CHARGING – CHARGING SYSTEM CH–7 11. CHECK CHARGING CIRCUIT WITH LOAD (a) Keep the engine speed at 2,000 rpm, turn on the high beam headlights, and turn the heater blower switch to the "HI" position. (b) Check the reading on the ammeter. Standard amperage: 30 A or more If the ammeter reading is less than the standard amperage, replace the generator assembly. HINT: • If the battery is fully charged, the ammeter reading may be less than the standard amperage. In this case, increase electrical load by operating devices such as the wiper motor and rear window defogger. Then, recheck the reading on the ammeter. CH CH–8 2AZ-FE CHARGING – CHARGING SYSTEM Charge Warning Light Comes ON while Driving INSPECTION PROCEDURE 1 CHECK LOCK FUNCTION OF CLUTCH PULLEY Free (a) Check the lock function with the pulley installed in the vehicle. (1) Visually check that the rotor in the generator operates with the engine started. (b) Check the lock function with the pulley removed from the vehicle. (1) Remove the generator pulley cap. Using SST, hold the generator rotor. (2) Turn the clutch pulley clockwise and check that the outer ring locks. OK: The outer ring locks. SST 09820-63020 Lock NG REPLACE CLUTCH PULLEY A130538E01 OK 2 CHECK LOCK OF CLUTCH PULLEY (a) Start the engine and visually check looseness of the clutch pulley. OK: The clutch pulley is not loose. NG OK REPLACE GENERATOR ASSEMBLY CH TIGHTEN CLUTCH PULLEY TO THE SPECIFIED TORQUE 2AZ-FE CHARGING – CHARGING SYSTEM CH–9 Noise Occurs from Generator while Engine is Running INSPECTION PROCEDURE 1 CHECK LOOSENESS OF V-RIBBED BELT (a) Check the tension of the belt by pushing it down with a finger. OK: The tension of the belt is enough. NG REPLACE V-RIBBED BELT TENSIONER ASSEMBLY OK 2 CHECK V-RIBBED BELT FOR WEAR (a) Check the V-ribbed belt for wear. OK: The V-ribbed belt is not worn. NG REPLACE V-RIBBED BELT OK 3 CHECK CLUTCH PULLEY FOR WEAR (a) Check the clutch pulley groove for wear or other defects. OK: The clutch pulley groove is not damaged. NG REPLACE CLUTCH PULLEY OK 4 CHECK FOR NOISE WHILE CLUTCH PULLEY IS OPERATING (a) Perform a driving test and check if noise occurs when decelerating. OK: Noise does not occur. NG REPLACE CLUTCH PULLEY OK CH REPLACE GENERATOR ASSEMBLY 2AZ-FE CHARGING – GENERATOR CH–9 GENERATOR 2AZ-FE CHARGING ENGINE COMPONENTS V-RIBBED BELT 8.4 (86, 74 in.*lbf) 9.8 (100, 87 in.*lbf) 52 (530, 38) 21 (215, 16) GENERATOR ASSEMBLY FRONT FENDER APRON SEAL RH ENGINE UNDER COVER RH N*m (kgf*cm, ft.*lbf) : Specified torque A133568E01 CH CH–10 2AZ-FE CHARGING – GENERATOR GENERATOR WASHER GENERATOR ROTOR ASSEMBLY x4 2.3 (23, 20 in.*lbf) BEARING RETAINER PLATE 111 (1,125, 81) GENERATOR CLUTCH PULLEY GENERATOR PULLEY CAP GENERATOR DRIVE END FRAME BEARING GENERATOR DRIVE END FRAME GENERATOR BRUSH HOLDER ASSEMBLY GENERATOR TERMINAL INSULATOR 1.8 (18, 16 in.*lbf) x3 x2 x4 4.6 (47, 41 in.*lbf) 5.8 (59, 51 in.*lbf) GENERATOR REAR END COVER 4.6 (47, 41 in.*lbf) GENERATOR COIL ASSEMBLY CORD CLIP CH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A135515E01 2AZ-FE CHARGING – GENERATOR CH–11 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE FRONT WHEEL RH 3. REMOVE ENGINE UNDER COVER RH 4. REMOVE FRONT FENDER APRON SEAL RH 5. REMOVE V-RIBBED BELT (See page EM-6) 6. REMOVE GENERATOR ASSEMBLY (a) Disconnect the generator connector. (b) Remove the nut and disconnect the wire harness from terminal B. (c) Remove the bolt and wire harness clamp bracket. (d) Remove the wire harness clamps. A135170 (e) Remove the 2 bolts and generator assembly. A133567 DISASSEMBLY 1. REMOVE GENERATOR CLUTCH PULLEY (a) Using a screwdriver, puncture the center of the generator pulley cap and pry it off. NOTICE: Do not reuse the generator pulley cap. A126771 SST (A) (b) Set SST (A) and (B). SST 09820-63020 (c) Clamp SST (A) in a vise. SST (B) CH A124115E01 CH–12 2AZ-FE CHARGING – GENERATOR (d) Place the rotor shaft end into SST (A). Rotor Shaft SST (A) SST (B) A128605E01 (e) Fit SST (B) to the clutch pulley. Clutch Pulley SST (B) SST (B) A128606E01 (f) Loosen the pulley by turning SST (B) in the direction shown in the illustration. (g) Remove the generator assembly from the SST. (h) Remove the clutch pulley from the rotor shaft. SST (B) A128607E01 2. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY (a) Place the generator assembly on the clutch pulley. A128608 (b) Remove the 3 nuts and generator rear end cover. CH A128610 2AZ-FE CHARGING – GENERATOR CH–13 3. REMOVE GENERATOR TERMINAL INSULATOR (a) Remove the terminal insulator. 4. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY (a) Remove the 2 screws and generator brush holder. 5. REMOVE GENERATOR ROTOR ASSEMBLY (a) Remove the 4 bolts. A128609 A128611 A128612 (b) Remove the bolt and cord clip. A128613 Hold Turn (c) Using SST, remove the coil. SST 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011) CH SST SST A128614E01 CH–14 2AZ-FE CHARGING – GENERATOR 6. REMOVE GENERATOR ROTOR ASSEMBLY (a) Remove the washer. A118365E01 (b) Remove the generator rotor. A128615 7. REMOVE GENERATOR DRIVE END FRAME BEARING (a) Remove the 4 screws and bearing retainer. A128617 (b) Using SST and a hammer, tap out the bearing. SST 09950-60010 (09951-00250), 09950-70010 (09951-07100) SST A128618E01 INSPECTION 1. CH Free Lock A130538E01 INSPECT GENERATOR CLUTCH PULLEY (a) Hold the center of the pulley, and confirm that the outer ring turns counterclockwise and does not turn clockwise. If the result is not as specified, replace the generator pulley with clutch. CH–15 2AZ-FE CHARGING – GENERATOR Length 2. INSPECT GENERATOR BRUSH HOLDER ASSEMBLY (a) Using vernier calipers, measure the brush length. Standard length: 9.5 to 11.5 mm (0.374 to 0.453 in.) Minimum length: 4.5 mm (0.177 in.) If the brush length is less than the minimum, replace the generator brush holder assembly. 3. INSPECT GENERATOR ROTOR ASSEMBLY (a) Check the appearance. (1) Check that the bearing is not rough or worn. OK: The bearing rotates smoothly. If the result is not as specified, replace the generator rotor assembly. A079305E04 A097469E01 (b) Check the resistance. (1) Measure the resistance between the slip rings. Standard resistance Slip Ring Condition Specified condition Approx. 20°C (68°F) 2.3 to 2.7 Ω If the result is not as specified, replace the generator rotor assembly. A097476E02 (2) Measure the resistance between the slip ring and rotor core. Standard resistance Slip Ring Tester condition Specified condition Slip ring - Rotor core 1 MΩ or higher If the result is not as specified, replace the generator rotor assembly. Rotor Core A097477E02 (c) Check the slip ring diameter. (1) Using vernier calipers, measure the slip ring diameter. Standard diameter: 14.2 to 14.4 mm (0.559 to 0.567 in.) Minimum diameter: 14 mm (0.551 in.) If the diameter is less than the minimum, replace the generator rotor assembly. A097470E02 CH CH–16 2AZ-FE CHARGING – GENERATOR 4. INSPECT GENERATOR DRIVE END FRAME BEARING (a) Check that the bearing is not rough or worn. OK: The bearing rotates smoothly. If the bearing does not rotate smoothly, replace the bearing. A097471E01 REASSEMBLY 1. SST INSTALL GENERATOR DRIVE END FRAME BEARING (a) Using SST and a press, press in a new generator drive end frame bearing. SST 09950-60010 (09951-00250), 09950-70010 (09951-07100) A128619E01 (b) Fit the tabs on the retainer plate into the cutouts on the drive end frame to install the retainer plate. (c) Install the 4 screws. Torque: 2.3 N*m (23 kgf*cm, 20 in.*lbf) Tab 2. INSTALL GENERATOR ROTOR ASSEMBLY (a) Place the drive end frame on the clutch pulley. Cutout A128620E01 (b) Install the generator rotor onto the generator rectifier end frame. A128615 (c) Place a new generator washer on the generator rotor. CH A118365E01 2AZ-FE CHARGING – GENERATOR 3. SST CH–17 INSTALL GENERATOR COIL ASSEMBLY (a) Using SST and a press, press in the generator coil assembly to the drive end frame. SST 09612-70100 (09612-07240) A128621E01 (b) Tighten the 4 bolts. Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf) A128612 (c) Install the cord clip with the bolt. Torque: 4.6 N*m (47 kgf*cm, 41 in.*lbf) A128613 4. Pin INSTALL GENERATOR BRUSH HOLDER ASSEMBLY (a) While pushing the 2 brushes into the generator brush holder, insert a 1.0 mm (0.039 in.) pin into the generator brush holder. A079315E04 (b) Install the generator brush holder with the 2 screws. Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf) CH A128622 CH–18 2AZ-FE CHARGING – GENERATOR (c) Pull the pin out of the generator brush holder. Pull out Pin A130537E01 5. INSTALL GENERATOR TERMINAL INSULATOR (a) Install the terminal insulator onto the generator rectifier end frame. 6. INSTALL GENERATOR REAR END COVER (a) Install the generator rear end cover with the 3 nuts. Torque: 4.6 N*m (47 kgf*cm, 41 in.*lbf) 7. INSTALL GENERATOR CLUTCH PULLEY (a) Temporarily install the clutch pulley onto the rotor shaft. A128623 A128610 (b) Set SST (A) and (B). SST 09820-63020 (c) Clamp SST (A) in a vise. SST (A) SST (B) A128084E01 (d) Place the rotor shaft end into SST (A). Rotor Shaft CH SST (A) SST (B) A128605E01 2AZ-FE CHARGING – GENERATOR CH–19 (e) Fit SST (B) to the clutch pulley. Clutch Pulley SST (B) SST (B) A128606E01 (f) SST (B) Tighten the pulley by turning SST (B) in the direction shown in the illustration. Torque: 111 N*m (1,125 kgf*cm, 81 ft.*lbf) NOTICE: The torque shown above should be used for tightening without using the SST. When the SST is used for tightening, the torque should be calculated based on the length of the SST (See page IN-6). (g) Remove the generator assembly from the SST. (h) Check that the clutch pulley rotates smoothly. (i) Install a new clutch pulley cap to the clutch pulley. SST (B) 100 mm (3.937 in.) A135051E01 Wire Harness Clamp Bracket Rib INSTALLATION 1. INSTALL GENERATOR ASSEMBLY (a) Confirm that the wire harness of the crankshaft position sensor is secured to the wire harness clamp bracket through the back of the rib of the timing chain cover. A097394E03 (b) Install the generator assembly with the 2 bolts. Torque: Bolt A 21 N*m (215 kgf*cm, 16 ft.*lbf) Bolt B 52 N*m (530 kgf*cm, 38 ft.*lbf) B A A133567E01 CH CH–20 2AZ-FE CHARGING – GENERATOR (c) Install the generator wire to terminal B with the nut. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) (d) Install the clamp bracket with the bolt. Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) (e) Attach the clamp and connect the generator connector to the generator. A135170 CH 2. INSTALL V-RIBBED BELT (See page EM-6) 3. INSTALL FRONT FENDER APRON SEAL RH 4. INSTALL ENGINE UNDER COVER RH 5. INSTALL FRONT WHEEL RH (See page EM-7) 6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page EM-120) U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–1 AUTOMATIC TRANSAXLE SYSTEM PRECAUTION NOTICE: • If the following parts have been replaced, initialize the TCM and perform a road test to allow the TCM to learn (See page AX-25). – Valve body assembly – Shift solenoid SL3 – Shift solenoid SL4 • If the following parts have been replaced, perform a road test to allow the TCM to learn (See page AX-25). – Shift solenoid SL1 – Shift solenoid SL2 • If the TCM or transaxle has been replaced, register the transmission compensation code in the TCM (See page AX-19). • Perform the RESET MEMORY (AT initialization) when replacing the automatic transmission assembly, engine assembly or ECM (See page AX-25). 1. The automatic transaxle is composed of highly precision-finished parts which need careful inspection before reassembly. Even a small nick could cause fluid leakage or affect transmission performance. The instructions here are organized so that you work on only one component group at a time. This will help avoid confusion caused by similar-looking parts of different sub-assemblies being on your workbench at the same time. The component groups are inspected and repaired from the converter housing side. Complete as much as possible of the inspection, repair and reassembly before proceeding to the next component group. If a defect is found in a certain component group during reassembly, inspect and repair this group immediately. If a component group cannot be assembled because some parts are being ordered, be sure to keep all parts of the group in a separate container while proceeding with disassembly, inspection, repair and reassembly of other component groups. Recommended: ATF WS 2. All disassembled parts should be washed clean and any fluid passages and holes should be blown through with compressed air. 3. Dry all parts with compressed air. Never use a shop rag or a piece of cloth to dry them. 4. When using compressed air, always aim away from yourself to prevent accidentally spraying ATF or kerosene in your face. 5. Only recommended automatic transmission fluid or kerosene should be used for cleaning. AX AX–2 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM 6. After cleaning, the parts should be arranged in the correct order for efficient inspection, repair, and reassembly. 7. When disassembling a valve body, be sure to match each valve together with its corresponding spring. 8. New discs for the brakes and clutches must be soaked in ATF for at least 15 minutes before reassembly. 9. All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be coated with ATF prior to reassembly. 10.All gaskets, seals, and rubber O-rings should be replaced with new ones. 11.Do not apply adhesive cements to gaskets and similar parts. 12.Make sure that the ends of a snap ring are not aligned with one of the cutouts and that the snap ring is installed in the groove correctly. 13.When replacing a worn bushing, the sub-assembly containing the bushing must also be replaced. 14.Check thrust bearings and races for wear or damage. If they are damaged, replace them. 15.When working with FIPG material, you must observe the following: – Using a razor blade and a gasket scraper, remove all the old packing (FIPG) material from the gasket surface. – Thoroughly clean all components to remove any loose material. – Clean both sealing surfaces with a non-residue solvent. – Parts must be reassembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied. 1. EXPRESSIONS OF IGNITION SWITCH The type of ignition switch used on this model differs according to the specifications of the vehicle. The expressions listed in the table below are used in this section. AX Expression Ignition switch off Switch Type Ignition Switch (Position) Engine Switch (Condition) LOCK Off Ignition switch on (IG) ON On (IG) Ignition switch on (ACC) ACC ON (ACC) Engine start START Start U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–3 DEFINITION OF TERMS Term Definition Monitor description Description of what the TCM monitors and how it detects malfunctions (monitoring purpose and its details). Related DTCs Diagnostic code Typical enabling condition Preconditions that allow the TCM to detect malfunctions. With all preconditions satisfied, the TCM sets the DTC when the monitored value(s) exceeds the malfunction threshold(s). Sequence of operation The priority order that is applied to monitoring, if multiple sensors and components are used to detect the malfunction. While another sensor is being monitored, the next sensor or component will not be monitored until the previous monitoring has concluded. Required sensor/components The sensors and components that are used by the TCM to detect malfunctions. Frequency of operation The number of times that the TCM checks for malfunctions per driving cycle. "Once per driving cycle" means that the TCM detects malfunction only one time during a single driving cycle. "Continuous" means that the TCM detects malfunction every time when the enabling conditions are met. Duration The minimum time that the TCM must sense a continuous deviation in the monitored value(s) before setting a DTC. This timing begins after the "typical enabling conditions" are met. Malfunction thresholds Beyond this value, the TCM will conclude that there is a malfunction and set a DTC. MIL operation MIL illumination timing after a defect is detected. "Immediately" means that the TCM illuminates MIL the instant the TCM determines that there is a malfunction. "2 driving cycle" means that the TCM illuminates MIL if the same malfunction is detected again in the 2nd driving cycle. Component operating range Normal operation range of sensors and solenoids under normal driving conditions. Use these ranges as a reference. They cannot be used to judge if a sensor or solenoid is defective. AX AX–4 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM PARTS LOCATION COMBINATION METER AX SHIFT LEVER - TRANSMISSION CONTROL SWITCH STOP LIGHT SWITCH DLC3 PARK / NEUTRAL POSITION SWITCH ECM SHIFT SOLENOID VALVE (SL) SPEED SENSOR TCM SHIFT SOLENOID VALVE (SLT) SHIFT SOLENOID VALVE (SLU) SHIFT SOLENOID VALVE (SL2) SHIFT SOLENOID VALVE (SL1) ATF TEMPERATURE SENSOR SHIFT SOLENOID VALVE (SL3) (INCLUDED ATF PRESSURE SWITCHE) SHIFT SOLENOID VALVE (SL4) C133208E01 AX–5 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM SYSTEM DIAGRAM The configuration of the electronic control system in the U660E automatic transaxle is as shown in the following chart. SL1 INPUT TURBINE SPEED SENSOR AX SOLENOID VALVE SL1 NTO COUNTER GEAR SPEED SENSOR SL2 SOLENOID VALVE SL2 SL3 SOLENOID VALVE SL3 SL4 SOLENOID VALVE SL4 NCO ATF PRESSURE SWITCHES ATF TEMP. SENSOR TPS1, 2, 3 THO1 TCM STOP LIGHT SWITCH STP COMBINATION METER SPD STARTER RELAY (Starter Signal) STA PARK / NEUTRAL POSITION SWITCH NSW SLU R,D CAN+ SLT SOLENOID VALVE SLT SL SOLENOID VALVE SL CAN- P,R,N,D MASS AIR FLOW METER Shift Range Indicator Light Shift Position Indicator Light S Mode Indicator Light VG Buzzer THW CRANKSHAFT POSITION SENSOR NE ACCELERATOR PEDAL POSITION SENSOR CANH CANL S,SFTU SFTD ENGINE COOLANT TEMP. SENSOR THROTTLE POSITION SENSOR DLC3 COMBINATION METER NSW TRANSMISSION CONTROL SWITCH SOLENOID VALVE SLU VPA1 VPA2 VPA ECM W #10 to #60 IGT1 to 6 MIL FUEL INJECTORS IGNITION COILS IGF M THROTTLE CONTROL MOTOR VPA2 C133209E01 AX–6 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM with Smart Key System: TCM AX +B Stop Light To ECM STP EFI MAIN Stop Light Switch STOP SPD1 EFI MAIN Combination Meter EFI No. 1 BATT R GAUGE No. 1 D Park / Neutral Position Switch ST/AM2 STA ST FL MAIN Main Body ECU ECM CAN- Park / Neutral Position Switch STR CAN+ NSW S ECU IG No. 2 SFTLI SFTD Transmission Control Switch C133214E05 AX–7 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM without Smart Key System: ALT TCM ST/AM2 AX NSW AM1 Stop Light STP Ignition Switch STA Park / Neutral Position Switch STOP Stop Light Switch SPD1 Combination Meter R GAUGE No. 1 D ST Park / Neutral Position Switch To Starter BATT EFI No. 1 ECM CAN+ CAN- S EFI +B EFI MAIN FL MAIN SFTLI SFTD To ECM ECU IG No. 2 Transmission Control Switch C133213E01 AX–8 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Automatic Transaxle AX SL1+ Shift Solenoid Valve SL1 SL1SL2+ Shift Solenoid Valve SL2 SL2SL3+ Shift Solenoid Valve SL3 SL3SL4+ Shift Solenoid Valve SL4 SL4SL Shift Solenoid Valve SL ATF Pressure Switch 1 TPS1 ATF Pressure Switch 2 TPS2 ATF Pressure Switch 3 TPS3 ATF Temperature Sensor Input Turbine Speed Sensor Counter Gear Speed Sensor THO1 E2 NTB NTO NCB NCO C133215E01 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–9 SYSTEM DESCRIPTION 1. SYSTEM DESCRIPTION (a) The ECT (Electronic controlled automatic transaxle) is an automatic transaxle that has its shift timing electronically controlled by the Transmission Control Module (TCM). The TCM detects electrical signals that indicate engine and driving conditions, and controls the shift point, based on driver's habits and road conditions. As a result, fuel efficiency and transaxle performance are improved. Shift shock has been reduced by controlling the engine and transaxle simultaneously. In addition, the ECT has features such as: • Diagnostic function. • Fail-safe function for use when a malfunction occurs. AX AX–10 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: • The TCM of this system is connected to the CAN communication system. Therefore, before starting troubleshooting, make sure to check that there is no trouble in the CAN communication system. • *: Use the intelligent tester. AX 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS NEXT 3 INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT 4 CONNECT INTELLIGENT TESTER TO DLC3* NEXT 5 CHECK AND CLEAR DTCS AND FREEZE FRAME DATA* (a) Refer to the DTC CHECK / CLEAR (See page AX-38). NEXT 6 VISUAL INSPECTION NEXT 7 SETTING CHECK MODE DIAGNOSIS* (a) Refer to the CHECK MODE PROCEDURE (See page AX-39). NEXT AX–11 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM 8 PROBLEM SYMPTOM CONFIRMATION (a) Refer to the ROAD TEST (See page AX-12). Result B Result Proceed to Symptom does not occur A Symptom occurs B GO TO STEP 10 A 9 SYMPTOM SIMULATION (a) Refer to the ELECTRONIC CIRCUIT INSPECTION PROCEDURE (See page IN-40). NEXT 10 DTC CHECK* (a) Refer to the DTC CHECK / CLEAR (See page AX-38). Result Result B Proceed to DTC is not output A DTC is output B GO TO STEP 18 A 11 BASIC INSPECTION (a) Refer to the AUTOMATIC TRANSMISSION FLUID (See page AX-164). (b) Refer to the PARK/NEUTRAL POSITION SWITCH (See page AX-174). (c) Refer to the SHIFT LEVER ASSEMBLY (See page AX224). NG GO TO STEP 21 OK 12 MECHANICAL SYSTEM TEST (a) Refer to the MECHANICAL SYSTEM TEST (See page AX-15). NG GO TO STEP 17 AX AX–12 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM OK 13 HYDRAULIC TEST (a) Refer to the HYDRAULIC TEST (See page AX-17). AX NG GO TO STEP 17 OK 14 MANUAL SHIFTING TEST (a) Refer to the MANUAL SHIFTING TEST (See page AX18). NG GO TO STEP 16 OK 15 PROBLEM SYMPTOMS TABLE CHAPTER 1 (a) Refer to the PROBLEM SYMPTOMS TABLE (See page AX-29). NG GO TO STEP 19 OK 16 PROBLEM SYMPTOMS TABLE CHAPTER 2 (a) Refer to the PROBLEM SYMPTOMS TABLE (See page AX-29). NEXT 17 PART INSPECTION NEXT 18 GO TO STEP 21 DTC CHART (a) Refer to the DIAGNOSTIC TROUBLE CODE CHART (See page AX-46). NEXT 19 NEXT CIRCUIT INSPECTION U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM 20 AX–13 IDENTIFICATION OF PROBLEM NEXT 21 REPAIR OR REPLACE NEXT 22 NEXT END CONFIRMATION TEST AX AX–14 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM ROAD TEST 1. AX 2. PROBLEM SYMPTOM CONFIRMATION (a) Based on the result of the customer problem analysis, try to reproduce the symptoms. If the problem is that the transaxle does not shift up or down, or the shift point is too high or too low, conduct the following road test referring to the automatic shift schedule and attempt to duplicate the problem symptoms. ROAD TEST NOTICE: Perform the test at the ATF (Automatic Transmission Fluid) temperature 50 to 80°C (122 to 176°F) in the normal operation. (a) D position test: Shift into the D position and fully depress the accelerator pedal and check the following: (1) Check up-shift operation. Check that 1 to 2, 2 to 3, 3 to 4, 4 to 5 and 5 to 6 up-shifts take place, and that the shift points conform to the automatic shift schedule (See page SS-46). HINT: 6th Gear Up-shift Prohibition Control • Engine coolant temperature is 60°C (140°F) or less and vehicle speed is 50 mph (80 km/ h) or less. 5th Gear Up-shift Prohibition Control • Engine coolant temperature is 55°C (131°F) or less and vehicle speed is 32 mph (51 km/ h) or less. 4th Gear Up-shift Prohibition Control • Engine coolant temperature is 47°C (117°F) or less and vehicle speed is 31 mph (49 km/ h) or less. Lock-up Prohibition Control • Brake pedal is depressed. • Accelerator pedal is released. • Engine coolant temperature is 60°C (140°F) or less. (2) Check for shift shock and slip. Check for shock and slip at the 1 to 2, 2 to 3, 3 to 4, 4 to 5 and 5 to 6th up-shifts. (3) Check for abnormal noise and vibration. Check for abnormal noise and vibration when up-shifting from 1 to 2, 2 to 3, 3 to 4, 4 to 5 and 5 to 6 while driving with the shift lever in the D position, and also while driving in the lock-up condition. HINT: The check for the cause of abnormal noise and vibration must be done thoroughly as it could also be due to loss of balance in the differential, torque converter clutch, etc. U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–15 (4) Check kick-down operation. Check vehicle speeds when the 2nd to 1st, 3rd to 2nd, 4th to 3rd, 5th to 4th, and 6th to 5th kickdowns take place while driving with the shift lever in the D position. Confirm that each speed is within the applicable vehicle speed range indicated in the automatic shift schedule (See page SS-46). (5) Check for abnormal shock and slip at kick-down. (6) Check the lock-up mechanism. • Drive the vehicle with the shift lever in the D position (2nd, 3rd, 4th, 5th or 6th gear) at a steady speed (lock-up ON). • Lightly depress the accelerator pedal and check that the engine speed does not change abruptly. HINT: • There is no lock-up function in the 1st gears. • If there is a jump in engine speed, this indicates that lock-up is not operating. (b) S position test Shift to the S position, depress the accelerator pedal and check the following: (1) Check shift operation. • With the shift lever in the S position (while the vehicle is stopped), shift into the "+" position to check that the shift position on the combination meter changes as follows: 1 to 2, 2 to 3, 3 to 4, 4 to 5 and 5 to 6. • While driving in the 5 (S) position and 5th gear (at a vehicle speed of approximately 34 to 40 mph (55 to 65 km/h), shift into the "-" position and check if the 4th gear down-shift occurs and proper engine braking occurs. • While driving in the 4 (S) position and 4th gear (at a vehicle speed of approximately 19 to 25 mph (30 to 40 km/h), shift into the "-" position and check if the 3rd gear down-shift occurs and proper engine braking occurs. • While driving in the 3 (S) position and 3rd gear (at a vehicle speed of approximately 12 to 19 mph (20 to 30 km/h), shift into the "-" position and check if the 2nd gear down-shift occurs and proper engine braking occurs. • While driving in the 2 (S) position and 2nd gear (at a vehicle speed of approximately 6 to 12 mph (10 to 20 km/h), shift into the "-" position and check if the 1st gear down-shift occurs and proper engine braking occurs. HINT: Manual shift (S position) is prohibited under either of the following conditions: • Down-shifting may cause engine overrun. AX AX–16 AX U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM • The driver continuously down-shifts. (Downshifting to 1st gear may not be performed.) (c) R position test: Shift into the R position, lightly depress the accelerator pedal, and check that the vehicle moves backward without any abnormal noise or vibration. CAUTION: Before conducting this test ensure that the test area is free from people and obstruction. (d) P position test: Stop the vehicle on a grade (more than 5°) and after shifting into the P position, release the parking brake. Then, check that the parking lock pawl holds the vehicle in place. U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–17 MECHANICAL SYSTEM TESTS 1. PERFORM MECHANICAL SYSTEM TESTS (a) Measure the stall speed. The object of this test is to check the overall performance of the transaxle and engine by measuring the stall speeds in the D position. NOTICE: • Driving test should be done on a paved road (a nonskid road). • Perform the test at the normal operating ATF (Automatic Transmission Fluid) temperature 50 to 80°C (122 to 176°F). • Do not continuously run this test for longer than 5 seconds. • To ensure safety, perform this test in a wide, clear level area which provides good traction. • The stall test should always be carried out in pairs. One technician should observe the conditions of wheels or wheel stoppers from a safe location outside the vehicle while the other is doing the test. (1) Chock the 4 wheels. (2) Connect the intelligent tester to the DLC3. (3) Fully apply the parking brake. (4) Keep your left foot pressed firmly on the brake pedal. (5) Start the engine. (6) Using the intelligent tester, shift into the D position and hold 3rd gear using active test. Press all the way down on the accelerator pedal with your right foot. (7) Quickly read the stall speed at this time. Stall speed: 2,520 +- 150 rpm Evaluation: Problem Possible cause (a) Stall engine speed is low in D position • Engine power output may be insufficient • Stator one-way clutch is not operating properly HINT: If the value is less than the specified value by 600 rpm or more, the torque converter could be faulty. (b) Stall engine speed is high in D position • • • • Line pressure is too low Clutch No. 1 (C1) slipping One-way clutch (F1) is not operating properly Improper fluid level AX AX–18 AX U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM (b) Measure the time lag. (1) When the shift lever is shifted while the engine is idling, there will be a certain time lapse or lag before the shock can be felt. This is used for checking the condition of the clutches and brakes. NOTICE: • Perform the test at the normal operating ATF (Automatic Transmission Fluid) temperature: 50 to 80°C (122 to 176°F). • Be sure to allow 1 minute interval between tests. • Perform the test three times and measure the time lags. Calculate the average value of the three time lags. (2) Connect the intelligent tester to the DLC3. (3) Fully apply the parking brake. (4) Start and warm up the engine and check idle speed. Idle speed: approx. 650 rpm (In N position and A/C OFF) (5) Shift the lever from N to D position. Using a stop watch, measure the time from when the lever is shifted until the shock is felt. Time lag: N to D less than 1.2 seconds (6) In the same way, measure the time lag for N to R. Time lag: N to R less than 1.5 seconds Evaluation (If N to D or N to R time lag is longer than the specified time): Problem Possible cause N to D time lag is longer • • • Line pressure is too low Clutch No.1 (C1) is worn One-way clutch (F1) is not operating properly N to R time lag is longer • • • Line pressure is too low Brake No. 2 (B2) is worn Brake No. 3 (B3) is worn U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–19 HYDRAULIC TEST 1. SST SST C133223E01 PERFORM HYDRAULIC TEST (a) Measure the line pressure. NOTICE: • Perform the test at the normal operating ATF (Automatic Transmission Fluid) temperature: 50 to 80°C (122 to 176°F). • The line pressure test should always be carried out in pairs. One technician should observe the conditions of wheels or wheel stoppers outside the vehicle while the other is performing the test. • Be sure to prevent SST hose from interfering with the exhaust pipe. • This check must be conducted after checking and adjusting engine. • Perform the test with the A/C is OFF. • When conducting stall test, do not continue more than 5 seconds. (1) Warm up the ATF (Automatic Transmission Fluid). (2) Lift the vehicle up. (3) Remove the engine under cover. (4) Connect the intelligent tester to the DLC3. (5) Remove the test plug on the transaxle case front left side and install the SST. SST 09992-00095 (09992-00231, 0999200271) (6) Start the engine. (7) Shift to the D position, and then use the intelligent tester to hold 3rd gear using active test. Measure the line pressure while the engine is idling. Specified line pressure: Condition Idling D position kPa (kgf/cm2, psi) 362 to 412 kPa (3.7 to 4.2 kgf/cm2, 52 to 60 psi) (8) Turn the ignition switch OFF. AX AX–20 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM (9) Disconnect the connector of the TCM. HINT: Disconnect the connector only when performing the D position stall test. (10)Start the engine. (11)Firmly depress the brake pedal, shift to the D position, depress the accelerator pedal all the way down, and check the line pressure while the stall test is performed. Specified line pressure: AX D position kPa (kgf/cm2, psi) Condition Stall test C133211 1,160 to 1,350 kPa (11.8 to 13.8 kgf/cm2, 168 to 196 psi) (12)Turn the ignition switch OFF. (13)Connect the TCM connector, depress the brake pedal firmly, shift to the R position, and check that the line pressure while the engine is idling and during the stall test. Specified line pressure: R position kPa (kgf/cm2, psi) Condition Idling Stall test 806 to 916 kPa (8.2 to 9.3 kgf/cm2, 117 to 133 psi) 1,890 to 2,000 kPa (19.3 to 20.4 kgf/cm2, 274 to 290 psi) (14)Remove the SST, install the test plug. (15)Clear the DTC. Evaluation: Problem Possible cause Measured values are higher than the specified value in all positions • • Shift solenoid valve (SLT) defective Regulator valve defective Measured values are lower than the specified value in all positions • • • Shift solenoid valve (SLT) defective Regulator valve defective Oil pump defective Pressure is low in the D position only • • D position circuit fluid leak Clutch No. 1 (C1) defective Pressure is low in the R position only • • • R position circuit fluid leak Brake No. 2 (B2) defective Brake No. 3 (B3) defective U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–21 MANUAL SHIFTING TEST 1. PERFORM MANUAL SHIFTING TEST HINT: • With this test, it can be determined whether trouble occurs in the electrical circuit. Also, trouble can be a mechanical problem in the transaxle. • If any abnormalities are found in the following test, the problem is in the transaxle itself. (a) Disconnect the TCM connector. (b) Drive the vehicle with the TCM disconnected. Shifting the shift lever to the D position to check whether the shifting condition changes as shown in the table below. C133211 Shift Position Shifting Condition D No Shift (No Change) HINT: When driving the vehicle with the TCM disconnected, the gear position will be as follows: • When the shift lever is in the D position, the transmission will stay in 3rd gear. • When the shift lever is in the R or the P position, the transmission will also be in the R or P position respectively. (c) Connect the connector of the TCM. (d) Clear the DTC (See page AX-38). AX AX–22 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM REGISTRATION NOTICE: • When the automatic transaxle is replaced, the transaxle's compensation code must be input into the TCM (Proceed to step 1). • When the TCM is replaced, the existing transaxle compensation codes must be input into the new TCM (Proceed to step 2). AX 1. QR Code Label #-          Transmission Compensation Code     QR Code Label INPUT COMPENSATION CODE NOTICE: Transaxle compensation codes are unique, 60-digit alphanumeric values printed on the QR label. If an incorrect transaxle compensation code is input into the TCM, shift shock may occur. (a) Record the transmission compensation code specified on the QR label. HINT: The transaxle compensation code is imprinted on the QR label. (b) Shift the shift lever to N or P position. (c) Connect the intelligent tester to the DLC3. (d) Turn the ignition switch on (IG). (e) Turn the tester on. NOTICE: Do not start the engine. C133268E01 (f) Enter the menu items in this order: DIAGNOSIS / OBD/MOBD / ECT / AT CODE UTILITY. (g) Press "ENTER". M-OBD / OBDΤMENU [Name of system] 1 : DATA LIST 1 : DTC INFO 3 : ACTIVE TEST 4 : SNAPSHOT 6 : RESET MEMORY 8 : CHECK MODE 9 : AT CODE UTILITY C133193 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–23 (h) Select "AT CODE REGIST". (i) Press "ENTER". AT CODE UTILITY [Name of system] 1 : AT CODE REGIST 2 : AT CODE RESET AX C133194 (j) Press "ENTER" again to proceed. NOTICE This function is used to input a compensation code and initialize the ECU after an A/T assembly or ECU has been replaced. PRESS [ENTER] C133195 (k) Press "ENTER" again to proceed. CHECK Gear Selector is in P. Vehicle is stopped. Engine is OFF. Engine switch is ON(IG). PRESS [ENTER] C133196 (l) Press "ENTER" again to proceed. NOTICE This function must not be performed without referring the service manual. PRESS [ENTER] C133197 (m) Select "SET A/T CODE". (n) Press "ENTER". A/T CODE REGIST Select a function. 1. SET A/T CODE 2. READ A/T CODE PRESS [ENTER] C133198 AX–24 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM (o) Select "INPUT A/T CODE". (p) Press "ENTER". A/T CODE REGIST SET A/T CODE Select a way of setting the code. 1. INPUT A/T CODE 2. SAVED A/T CODE AX PRESS [ENTER] C133199 (q) Register the compensation code. (1) Press "ENTER". INPUT A/T CODE code input method Press [] / [ ] to shift the cursor right/left. Press [] / [ ] to shift the cursor up/down. Input alphanumeric with 10 key and * key. PRESS [ENTER] C133200 A/T CODE REGIST Input the code printed on the A/T. (r) PRESS [ENTER] C133201 (2) Manually input the transaxle compensation code. The code is a 60-digit alphanumeric value imprinted on the QR label. Check that the compensation code displayed on the screen is correct by comparing it with the 60-digit alphanumeric value on the QR label. NOTICE: If an incorrect transaxle compensation code is input into the TCM, shift shock will occur. HINT: Input letters by operating the keys from 0 to 5 while pressing the * key. (s) Press "ENTER" to set the compensation code to the TCM. HINT: • If the registration process fails, the compensation code may be incorrect. Check the compensation code again. • If the attempted compensation code is correct, a problem with the wire harness or a bad connection with the DLC3 may cause a registration failure. Check the wire harness and the DLC3 connection. If no problem is found, the TCM may be malfunctioning. Check the TCM and repeat this operation. A/T CODE REGIST SET CODE A/T CODE REGIST is complete. PRESS [EXIT] C133203 2. TRANSFER COMPENSATION CODE NOTICE: Transaxle compensation codes are 60-digit alphanumeric values imprinted on the QR label. If an incorrect transaxle compensation code is input into the TCM, shift shock may occur. U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–25 HINT: The following operation is available for use with TCMs that can transmit the registered transaxle compensation code to the intelligent tester. (a) Shift the shift lever to N or P position. (b) Connect the intelligent tester to the DLC3. (c) Turn the ignition switch on (IG). (d) Turn the tester on. NOTICE: Do not start the engine. HINT: The transaxle compensation code is imprinted on the QR label. (e) Read the transaxle compensation code. (1) Enter the menu items in this order: DIAGNOSIS / OBD/MOBD / ECT / AT CODE UTILITY. (2) Press "ENTER". M-OBD / OBDΤMENU [Name of system] 1 : DATA LIST 1 : DTC INFO 3 : ACTIVE TEST 4 : SNAPSHOT 6 : RESET MEMORY 8 : CHECK MODE 9 : AT CODE UTILITY C133193 (3) Select "AT CODE REGIST". (4) Press "ENTER". AT CODE UTILITY [Name of system] 1 : AT CODE REGIST 2 : AT CODE RESET C133194 (5) Press "ENTER" again to proceed. NOTICE This function is used to input a compensation code and initialize the ECU after an A/T assembly or ECU has been replaced. PRESS [ENTER] C133195 AX AX–26 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM (6) Press "ENTER" again to proceed. CHECK Gear Selector is in P. Vehicle is stopped. Engine is OFF. Engine switch is ON(IG). AX PRESS [ENTER] C133196 (7) Press "ENTER" again to proceed. NOTICE This function must not be performed without referring the service manual. PRESS [ENTER] C133197 (8) Select "READ A/T CODE". (9) Press "ENTER". A/T CODE REGIST Select a function. 1. SET A/T CODE 2. READ A/T CODE PRESS [ENTER] C133198 A/T CODE REGIST READ A/T CODE is completed. PRESS [EXIT] C133206 (10) Press "EXIT". NOTICE: Do not use the code specified on the transaxle QR label even if the transmission compensation code cannot be read using the intelligent tester. The code printed on an in-service transaxle may not match its current characteristics. Replace the TCM with a new one and perform a road test to allow the TCM to learn. (11) Turn the ignition switch off. (f) Replace the TCM. (g) Set the transaxle compensation code. (1) Turn the ignition switch on (IG). (2) Turn the tester on. U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–27 (3) Enter the menu items in this order: DIAGNOSIS / OBD/MOBD / ECT / AT CODE UTILITY. (4) Press "ENTER". M-OBD / OBDΤMENU [Name of system] 1 : DATA LIST 1 : DTC INFO 3 : ACTIVE TEST 4 : SNAPSHOT 6 : RESET MEMORY AX 8 : CHECK MODE 9 : AT CODE UTILITY C133193 (5) Press "ENTER" again to proceed. NOTICE This function is used to input a compensation code and initialize the ECU after an A/T assembly or ECU has been replaced. PRESS [ENTER] C133195 (6) Press "ENTER" again to proceed. CHECK Gear Selector is in P. Vehicle is stopped. Engine is OFF. Engine switch is ON(IG). PRESS [ENTER] C133196 (7) Press "ENTER" again to proceed. NOTICE This function must not be performed without referring the service manual. PRESS [ENTER] C133197 (8) Select "SET A/T CODE". (9) Press "ENTER". A/T CODE REGIST Select a function. 1. SET A/T CODE 2. READ A/T CODE PRESS [ENTER] C133198 AX–28 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM (10) Select "SAVED A/T CODE". (11) Press "ENTER". A/T CODE REGIST SET CODE A/T CODE REGIST is complete. AX PRESS [EXIT] C133203 (12) Press "EXIT". A/T CODE REGIST SET CODE A/T CODE REGIST is complete. PRESS [EXIT] C133203 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–29 INITIALIZATION 1. RESET TRANSAXLE COMPENSATION CODE NOTICE: The transaxle compensation code can be reset only with the intelligent tester. HINT: The TCM memorizes the condition that the ECT controls the automatic transaxle assembly and engine assembly according to those characteristics. Therefore, when the automatic transaxle assembly, engine assembly, or TCM has been replaced, it is necessary to reset the memory so that the TCM can memorize the new information. Reset procedure is as follows. (a) Shift the shift lever to N or P position. (b) Turn the ignition switch off. (c) Connect the intelligent tester to the DLC3. (d) Turn the ignition switch on (IG) and push the intelligent tester main switch on. (e) Enter the menu items in this order: DIAGNOSIS / OBD/MOBD / ECT / AT CODE UTILITY. M-OBD / OBDΤMENU [Name of system] 1 : DATA LIST 1 : DTC INFO 3 : ACTIVE TEST 4 : SNAPSHOT 6 : RESET MEMORY 8 : CHECK MODE 9 : AT CODE UTILITY C133193 AT CODE UTILITY [Name of system] 1 : AT CODE REGIST 2 : AT CODE RESET 2. C133194 (f) Select "AT CODE RESET". (g) Press the "ENTER" CAUTION: After the transaxle compensation code, be sure to perform a road test to allow TCM to learn. PERFORM ROAD TEST TO ALLOW TCM TO LEARN NOTICE: Perform the following procedures while strictly observing all traffic laws and speed limits. (a) From a standstill, achieve highest possible speed with the accelerator pedal opened 15% or less. Keep the accelerator pedal angle steady while driving the vehicle. (b) Repeat the previous step until shift shock no longer occurs. (c) From a standstill, achieve highest possible speed with the accelerator pedal opened 25% or more. Keep the accelerator pedal angle steady while driving the vehicle. (d) Repeat the previous step until shift shock no longer occurs. AX AX–30 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM 3. AX RESET MEMORY NOTICE: • Perform the RESET MEMORY (AT initialization) when replacing the engine assembly. • The RESET MEMORY can be performed only with the intelligent tester. HINT: The ECM memorizes the condition that the ECT controls the automatic transmission assembly and engine assembly according to those characteristics. Therefore, when the automatic transmission assembly, engine assembly, or ECM has been replaced, it is necessary to reset the memory so that the ECM can memorize the new information. (a) Reset procedure is as follows. (1) Turn the engine switch off. (2) Connect the intelligent tester to the DLC3. (3) Turn the ignition switch on (IG) position. (4) Turn the intelligent tester main switch on. (5) Select the item "DIAGNOSIS / OBD/MOBD / ECT / RESET MEMORY". NOTICE: After performing the RESET MEMORY, be sure to perform the ROAD TEST (See page AX-12) described previously. M-OBD / OBDΤMENU [Name of system] 1 : DATA LIST 1 : DTC INFO 3 : ACTIVE TEST 4 : SNAPSHOT 6 : RESET MEMORY 8 : CHECK MODE 9 : AT CODE UTILITY C133193 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–31 MONITOR DRIVE PATTERN 1. MONITOR DRIVE PATTERN FOR ECT TEST (a) Perform this drive pattern as one method to simulate the detection conditions of the ECT malfunctions. (The DTCs may not be detected due to differences from the actual driving conditions. Some codes may not be detected using this drive pattern.) HINT: Preparation for driving • Warm up the engine sufficiently. (Engine coolant temperature should be 60°C (140°F) or higher) • Drive the vehicle when the atmospheric temperature is -10°C (14°F) or higher. (Malfunction may not be detected when the atmospheric temperature is less than -10°C (14°F)) Notice on driving • Drive the vehicle through all gears. Stop to 1st to 2nd to 3rd to 4th to 5th to 6th (lockup ON). • Confirm engine braking using the S position. While driving in the 6 (S) position and 6th gear lock-up, shift to the "-" position to down-shift from 6th to 5th, 5th to 4th, 4th to 3rd, 3rd to 2nd, 2nd to 1st. Check that proper engine braking occurs whenever down-shift takes place. • Repeat the above driving pattern three times or more. NOTICE: • The monitor status can be checked using the intelligent tester. When using the intelligent tester, monitor status can be found in "OBD/ MOBD / ECT / DATA LIST". • In the event that the drive pattern must be interrupted (possibly due to traffic conditions or other factors), the drive pattern can be resumed and, in most cases, the monitor can be completed. • Perform this drive pattern on a road with the fewest hills possible and strictly observe the posted speed limits and traffic laws while driving. AX AX–32 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Vehicle Speed Maintain a constant speed or gradual acceleration (with the throttle open) for 3 minutes or more.*1 AX Approx. 62 mph (100 km/h) Lock-up ON Vehicle Speed Approx. 50 mph (80 km/h) 0 Warmed up sufficiently Normal acceleration through all the gears from 1st to 6th Stop (Idling) G031593E30 HINT: *1: Drive the vehicle at a sufficient speed in the uppermost gear, to allow lock-up to engage. The vehicle can be driven at a speed lower than that in the above diagram under the lock-up condition. NOTICE: It is necessary to drive the vehicle for approximately 30 minutes to detect DTC P0711 (ATF temperature sensor malfunction). AX–33 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM PROBLEM SYMPTOMS TABLE HINT: If a normal code is displayed during the diagnostic trouble code check although the problem or symptom still occurs, check the electrical circuits for each symptom in the order given in the charts on the following pages. Proceed to the page given in the chart and perform troubleshooting. The Matrix Chart is divided into 2 chapters. Chapter 1: Refer to the table below when the trouble cause is considered to be electrical. If the instruction "Proceed to next circuit inspection shown on matrix chart" is given in the flow chart of each circuit, proceed to the circuit with the next highest number in the table to continue the check. If the trouble still occurs even though there are no abnormalities in any of the other circuits, check and replace the TCM. Chapter 2: Chapter 2 covers on and off vehicle repair of the transaxle. Contents specified in the table below may not match while fail-safe control is operating. 1. Chapter 1: Electronic Circuit Matrix Chart Symptom No up-shift (1st to 2nd) No up-shift (2nd to 3rd) No up-shift (3rd to 4th) No up-shift (4th to 5th) No up-shift (5th to 6th) No down-shift (6th to 5th) No down-shift (5th to 4th) No down-shift (4th to 3rd) No down-shift (3rd to 2nd) No down-shift (2nd to 1st) Suspected area See page 1. Shift solenoid valve (SL3) circuit *1 AX-105 2. TCM IN-40 1. Shift solenoid valve (SL4) circuit *1 AX-148 2. TCM IN-40 1. Shift solenoid valve (SL2) circuit *1 AX-92 2. Engine coolant temp. sensor circuit *1 ES-145 3. TCM IN-40 1. Shift solenoid valve (SL1) circuit *1 AX-84 2. Shift solenoid valve (SL4) circuit *1 AX-148 3. Engine coolant temp. sensor circuit ES-145 4. TCM IN-40 1. Engine coolant temp. sensor circuit *1 ES-145 2. Shift solenoid valve (SL3) circuit *1 AX-105 3. Shift solenoid valve (SL4) circuit *1 AX-148 4. TCM IN-40 1. Shift solenoid valve (SL4) circuit *1 AX-148 2. TCM IN-40 1. Shift solenoid valve (SL1) circuit *1 AX-84 2. TCM IN-40 1. Shift solenoid valve (SL2) circuit *1 AX-92 2. Shift solenoid valve (SL4) circuit *1 AX-148 3. TCM IN-40 1. Shift solenoid valve (SL4) circuit *1 AX-148 2. Shift solenoid valve (SL3) circuit *1 AX-105 3. TCM IN-40 1. Shift solenoid valve (SL3) circuit *1 AX-100 2. TCM IN-40 AX AX–34 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Symptom No lock-up AX No lock-up off Shift point too high or too low Up-shift from 3rd to 4th while engine is cold Up-shift from 4th to 5th while engine is cold No gear change by shifting into "+" or "-" while shifting the lever Harsh engagement (N to D) Harsh engagement (Lock-up) Harsh engagement (Any driving position) Poor acceleration Suspected area See page 1. Shift solenoid valve (SLU) circuit *1 AX-136 2. Shift solenoid valve (SL) circuit AX-139 3. Engine coolant temp. sensor circuit *1 ES-145 4. Stop light switch circuit *1 AX-71 5. Speed sensor NT circuit *1 AX-66 6. TCM IN-40 1. TCM IN-40 1. Shift solenoid valve (SLT) circuit *1 AX-128 2. Speed sensor NT circuit *1 AX-66 3. Speed sensor NC circuit *1 AX-95 4. Accelerator pedal position sensor circuit *1 ES-334 5. ATF temperature sensor circuit *1 AX-55 6. TCM IN-40 1. Engine coolant temp. sensor circuit *1 ES-145 2. TCM IN-40 1. Engine coolant temp. sensor circuit *1 ES-145 2. TCM IN-40 1. Transmission control switch circuit AX-154 2. TCM IN-40 1. Shift solenoid valve (SL1) circuit *1 AX-84 2. TCM IN-40 1. Speed sensor NT circuit *1 AX-66 2. Speed sensor NC circuit *1 AX-95 3. Shift solenoid valve (SLU) circuit *1 AX-136 4. TCM IN-40 1. Accelerator pedal position sensor circuit *1 ES-334 2. Shift solenoid valve (SLT) circuit *1 AX-128 3. Speed sensor NC circuit AX-95 4. Speed sensor NT circuit *1 AX-66 5. TCM IN-40 1. Shift solenoid valve (SLT) circuit *1 AX-128 2. TCM IN-40 1. TCM IN-40 No kick-down 1. TCM IN-40 Engine stalls when starting off or stopping 1. TCM IN-40 No engine brake 1. Park/neutral position switch circuit *1 AX-158 Malfunction in shifting 2. Transmission control switch circuit AX-154 3. TCM IN-40 Slip or shudder (5th to 6th and 6th to 5th) 1. Shift solenoid valve (SLT) circuit *1 AX-128 1. Shift solenoid valve (SL1) circuit AX-84 2. Shift solenoid valve (SLT) circuit AX-128 Initial acceleration or subsequent acceleration is improper. Vehicle is stuck in a gear (1st to 6th). Acceleration is improper when the gear is 4th or higher. Initial acceleration or subsequent acceleration is improper. Vehicle does not shift down (from 4th to 3rd). Vehicle is stuck in a gear (1st to 4th). Acceleration is improper when the gear is 6th. 3. TCM IN-40 1. Shift solenoid valve (SL2) circuit AX-92 2. Shift solenoid valve (SLT) circuit AX-128 3. TCM IN-40 1. Shift solenoid valve (SL2) circuit AX-92 2. TCM IN-40 1. Shift solenoid valve (SL3) circuit AX-105 2. TCM IN-40 AX–35 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Symptom Acceleration is improper when the gear is 3rd or 5th. Initial acceleration or subsequent acceleration is improper. Vehicle does not shift down (from 3rd to 2nd). No up-shift (5th to 6th). Suspected area See page 1. Shift solenoid valve (SL4) circuit AX-148 2. Shift solenoid valve (SLT) circuit AX-128 3. TCM IN-40 1. Shift solenoid valve (SL4) circuit AX-148 2. TCM IN-40 HINT: *1: When the circuit is defective, a DTC may be output. 2. Chapter 2: On-Vehicle Repair and Off-Vehicle Repair Symptom Vehicle does not move in any forward and reverse positions. Vehicle does not move in R position. No up-shift (1st to 2nd) No up-shift (2nd to 3rd) No up-shift (3rd to 4th) No up-shift (4th to 5th) No up-shift (5th to 6th) No down-shift (6th to 5th) No down-shift (5th to 4th) No down-shift (4th to 3rd) No down-shift (3rd to 2nd) No down-shift (2nd to 1st) No lock-up or No lock-up off Suspected area See page 1. Valve body assembly AX-181 2. Torque converter clutch AX-239 1. Valve body assembly AX-181 2. Brake No. 2 (B2) AX-274 3. Brake No. 3 (B3) AX-274 4. Shift solenoid valve (SL4)*1 AX-142 1. Valve body assembly AX-181 2. Brake No. 1 (B1) AX-274 3. Shift solenoid valve (SL3)*1 AX-100 1. Valve body assembly AX-181 2. Brake No. 3 (B3) AX-274 3. Shift solenoid valve (SL4)*1 AX-142 1. Valve body assembly AX-181 2. Clutch No. 2 (C2) AX-274 3. Shift solenoid valve (SL2)*1 AX-87 1. Valve body assembly AX-181 2. Brake No. 3 (B3) AX-274 3. Shift solenoid valve (SL3)*1 AX-100 1.Valve body assembly AX-181 2. Brake No. 1 (B1) AX-274 3. Shift solenoid valve (SL3)*1 AX-100 1. Brake No. 3 (B3) AX-274 2. Shift solenid valve (SL4)*1 AX-142 3. Valve body assembly AX-181 1. Shift solenoid valve (SL1)*1 AX-79 2. Clutch No. 1 (C1) AX-274 3. Valve body assembly AX-181 1. Brake No. 3 (B3) AX-274 2. Shift solenid valve (SL4)*1 AX-142 3. Valve body assembly AX-181 1. Brake No. 1 (B1) AX-274 2. Shift solenid valve (SL3)*1 AX-100 3. Valve body assembly AX-181 1. Valve body assembly AX-181 1. Valve body assembly AX-181 2. Torque converter clutch AX-239 AX AX–36 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Symptom Harsh engagement (N to D) AX Harsh engagement (Lock-up) Harsh engagement (N to R) Harsh engagement (1 to 2 to 3 to 4 to 5 to 6) Harsh engagement (1st to 2nd) Harsh engagement (2nd to 3rd) Harsh engagement (3rd to 4th) Harsh engagement (4th to 5th) Harsh engagement (5th to 6th) Harsh engagement (6th to 5th) Slip or shudder (Forward and reverse: After warm-up) Slip or shudder (Particular position: just after engine starts) Slip or shudder (R position) Suspected area See page 1. Valve body assembly AX-181 2. C1 accumulator AX-274 3. One-way clutch No. 1 (F1) AX-274 4. Clutch No. 1 (C1) AX-274 5. Shift solenoid valve (SL1)*1 AX-79 1. Valve body assembly AX-181 2. Torque converter clutch AX-239 3. Shift solenoid valve (SLU)*1 AX-131 1. Valve body assembly AX-181 2. Brake No. 2 (B2) AX-274 3. Brake No. 3 (B3) AX-274 4. Shift solenoid valve (SL4)*1 AX-142 1. Valve body assembly AX-181 2. Shift solenoid valve (SLT)*1 AX-121 1. Valve body assembly AX-181 2. B1 accumulator AX-274 3. Brake No. 1 (B1) AX-274 4. Shift solenoid valve (SL3)*1 AX-100 1. Valve body assembly AX-181 2. B3 accumulator AX-274 3. Brake No. 3 (B3) AX-274 4. Shift solenoid valve (SL4)*1 AX-142 1. Valve body assembly AX-181 2. C2 accumulator AX-274 3. Clutch No. 2 (C2) AX-274 4. Shift solenoid valve (SL2)*1 AX-87 1. Valve body assembly AX-181 2. B3 accumulator AX-274 3. Brake No. 3 (B3) AX-274 4. Shift solenoid valve (SL4)*1 AX-142 1. Valve body assembly AX-181 2. B1 accumulator AX-274 3. Brake No. 1 (B1) AX-274 4. Shift solenoid valve (SL3)*1 AX-100 1. Valve body assembly AX-181 2. B3 accumulator AX-274 3. Brake No. 3 (B3) AX-274 4. Shift solenoid valve (SL4)*1 AX-142 1. Valve body assembly AX-181 2. Oil strainer - 3. Brake No. 1 (B1) AX-274 4. Brake No. 2 (B2) AX-274 5. Brake No. 3 (B3) AX-274 6. One-way clutch No. 1 (F1) AX-274 7. Clutch No. 1 (C1) AX-274 8. Clutch No. 2 (C2) AX-274 1. Torque converter clutch AX-239 1. Brake No. 2 (B2) AX-274 2. Brake No. 3 (B3) AX-274 AX–37 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Symptom Slip or shudder (1 position) Slip or shudder (2 position) Slip or shudder (3 position) Slip or shudder (4 position) Slip or shudder (5 position) Slip or shudder (6 position) No engine braking (1st position) No engine braking (2nd position) No engine braking (3rd position) No engine braking (4th position) No kick-down Shift point too hight or too low Poor acceleration (All positions) Poor acceleration (6th) Engine stalls when starting off or stopping Suspected area See page 1. One-way clutch No. 1 (F1) AX-274 2. Clutch No. 1 (C1) AX-274 1. Brake No. 1 (B1) AX-274 2. Clutch No. 1 (C1) AX-274 1. Brake No. 3 (B3) AX-274 2. Clutch No. 1 (C1) AX-274 1. Clutch No. 1 (C1) AX-274 2. Clutch No. 2 (C2) AX-274 1. Brake No. 3 (B3) AX-274 2. Clutch No. 2 (C2) AX-274 1. Brake No. 3 (B3) AX-274 2. Clutch No. 2 (C2) AX-274 1. Valve body assembly AX-181 2. Brake No. 2 (B2) AX-274 1. Valve body assembly AX-181 2. Brake No. 1 (B1) AX-274 1. Valve body assembly AX-181 2. Brake No. 3 (B3) AX-274 1. Valve body assembly AX-181 2. Clutch No. 2 (C2) AX-274 1. Valve body assembly AX-181 1. Valve body assembly AX-181 1. Valve body assembly AX-181 2. Torque converter clutch AX-239 1. Brake No. 1 (B1) AX-274 2. Clutch No. 2 (C2) AX-274 1. Valve body assembly AX-181 2. Torque converter clutch AX-239 HINT: *1: When the circuit is defective, a DTC may be output. AX AX–38 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM TERMINALS OF ECU 1. TCM C56 AX 7 6 5 4 3 2 1 17 16 15 14 13 12 11 10 9 26 25 24 23 22 21 20 19 8 18 C133222E01 HINT: Each TCM terminal's standard voltage is shown in the table below. In the table, first follow the information under "Condition". Look under "Symbols (Terminals No.)" for the terminals to be inspected. The standard voltage between the terminals is shown under "Specified Condition". Use the illustration above as a reference for the TCM terminals. Symbols (Terminals No.) R (C56-15) - E1 (C56-8) D (C56-16) - E1 (C56-8) STP (C56-12) - E1 (C56-8) NSW (C56-11) - E1 (C56-8) STA (C56-10) - E1 (C56-8) Wiring Color W - B-W R - B-W B - B-W L - B-W Y - B-W Terminal Description R shift position switch signal D shift position switch signal Stop light switch signal Park/neutral switch signal Starter signal Condition Specified Condition IG switch ON (IG) and shift lever in R position 10 to 14 V IG switch ON (IG) and shift lever in any position except R position Below 1 V IG switch ON (IG) and shift lever in D or 3 position 10 to 14 V IG switch ON (IG) and shift lever in any position except D and 3 position Below 1 V Brake pedal is depressed 7.5 to 14 V Brake pedal is released Below 1.5 V IG switch ON (IG) and shift lever in P or N position Below 2 V IG switch ON (IG) and shift lever in any position except P or N position 10 to 14 V Cranking (shift lever position in P or N position, ignition switch START) 10 to 14 V IG switch ON (IG) and shift lever in any position except P or N position Below 2 V Pulse generation (See waveform 1) SPD1 (C56-3) - E1 (C56-8) BR - B-W Speed signal from combination meter Vehicle speed 12 mph (20 km/h) BATT (C56-1) - E1 (C56-8) W-L - B-W Battery (for measuring battery voltage and for TCM memory) Always 9 to 14 V IG2 (C56-13) - E1 (C56-8) L-B - B-W Ignition switch Ignition switch ON (IG) 9 to 14 V +B (C56-18) - E1 (C56-8) W-L - B-W Power source of TCM Ignition switch ON (IG) 9 to 14 V Ignition switch ON (IG) Pulse generation (See waveform 2) CAN+ (C56-6) - E1 (C56-8) B - B-W CAN communication line AX–39 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Symbols (Terminals No.) Wiring Color CAN- (C56-7) - E1 (C56-8) Y - B-W 5 V/DIV. Terminal Description CAN communication line Condition Ignition switch ON (IG) Specified Condition Pulse generation (See waveform 3) (a) Waveform 1 Reference: Terminal SPD1 - E1 Tool setting 2 V/DIV., 20 ms./DIV. Vehicle condition Vehicle speed 12 mph (20 km/h) GND 20 ms./DIV. G034872E02 1 V/DIV (b) Waveform 2 Reference: Terminal CAN+ - E1 Tool setting 1 V/DIV., 10 ms./DIV. Vehicle condition Engine is stopped, ignition ON (IG) GND 10 ms./DIV G036660E06 1 V/DIV GND 10 ms./DIV G036661E05 (c) Waveform 3 Reference: Terminal CAN- - E1 Tool setting 1 V/DIV., 10 ms./DIV. Vehicle condition Engine is stopped, ignition ON (IG) 2. ECM HINT: Each ECM terminal's standard voltage is shown in the table below. In the table, first follow the information under "Condition". Look under "Symbols (Terminals No.)" for the terminals to be inspected. The standard voltage between the terminals is shown under "Specified Condition". Use the illustration below as a reference for the ECM terminals. AX AX–40 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM ECM: C55 AX                                 A55                                                                                                                                                           A107881E27 Symbols (Terminals No.) S (A55-25) - E1 (C55-81) SFTU (A55-16) - E1 (C55-81) SFTD (A55-51) - E1 (C55-81) Wiring Color Y - W-B R - W-B L - W-B Terminal Description S shift position switch signal Up shift switch signal Down shift switch signal Condition Specified Condition IG switch ON (IG) and shift lever in S position 10 to 14 V IG switch ON (IG) and shift lever in any position except S position Below 1 V IG switch ON (IG) and shift lever in S position 10 to 14 V IG switch ON (IG) and shift lever in "+" position (Up shift) Below 1 V IG switch ON (IG) and shift lever in S position 10 to 14 V IG switch ON (IG) and shift lever in "-" position (Down shift) Below 1 V U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–41 DIAGNOSIS SYSTEM 1. (b) OBD II regulations require that the vehicle's onboard computer illuminate the Malfunction Indicator Lamp (MIL) on the instrument panel when the computer detects a malfunction in: (1) The emission control system/components (2) The power train control components (which affect vehicle emissions) (3) The computer In addition, the applicable Diagnostic Trouble Codes (DTCs) prescribed by SAE J2012 are recorded in the TCM memory. If the malfunction does not reoccur in 3 consecutive trips, the MIL turns off automatically but the DTCs remain recorded in the TCM memory. FI00534E01 Intelligent Tester 2. DLC3 DESCRIPTION (a) When troubleshooting On-Board Diagnostic (OBD II) vehicles, the vehicle must be connected to the OBD II scan tool (complying with SAE J1987). Various data output from the vehicle's TCM can be read then. CAN VIM C131977E05 3. 4. (c) To check DTCs, connect the intelligent tester to the Data Link Connector 3 (DLC3) of the vehicle. The intelligent tester displays DTCs, the freeze frame data and a variety of the engine data. The DTCs and freeze frame data can be erased with the intelligent tester (See page AX-38). NORMAL MODE AND CHECK MODE (a) The diagnosis system operates in "normal mode" during normal vehicle use. In normal mode, "2 trip detection logic" is used to ensure accurate detection of malfunctions. "Check mode" is also available to technicians as an option. In check mode, "1 trip detection logic" is used for simulating malfunction symptoms and increasing the system's ability to detect malfunctions, including intermittent malfunctions. 2 TRIP DETECTION LOGIC (a) When a malfunction is first detected, the malfunction is temporarily stored in the TCM memory (1st trip). If the ignition switch is turned off and then on (IG) again, and the same malfunction is detected again, the MIL will illuminate. FREEZE FRAME DATA (a) The TCM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. AX AX–42 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM (b) The intelligent tester displays freeze frame data recorded at five different points: 1) 3 points before the DTC is set, 2) once when the DTC is set, and 3) once after the DTC is set. The data can be used to simulate the vehicle's condition around the time of the malfunction. The data may be helpful in determining the cause of a malfunction. It may also be helpful in determining whether a DTC is being caused by a temporary malfunction. DTC set point 0.5 sec. 0.5 sec. 0.5 sec. AX :Freeze frame data recorded point A092901E07 5. CG SG CANH 1 2 3 4 5 6 7 8 9 10 11 1213141516 CANL BAT Symbols (Terminal No.) A082779E65 DLC3 (Data Link Connector 3) (a) The vehicle's TCM uses the ISO 15765-4 for communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. HINT: Connect the cable of the intelligent tester to the DLC3, turn the ignition switch on (IG) and attempt to use the intelligent tester. If the screen displays a communication error message, a problem exists in the vehicle side or the tester side. If the communication is normal when the tester is connected to another vehicle, inspect the DLC3 on the original vehicle. If the communication is still impossible when the tester is connected to another vehicle, the problem is probably in the tester itself. Consult the Service Department listed in the tester's instruction manual. Terminal Description Condition Specified Condition CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 11 to 14 V CANH (6) - CANL (14) HIGH-level CAN bus line Ignition switch OFF* 54 to 69 Ω CANH (6) - CG (4) HIGH-level CAN bus line Ignition switch OFF* 200 kΩ or higher CANL (14) - CG (4) LOW-level CAN bus line Ignition switch OFF* 200 kΩ or higher CANH (6) - BAT (16) HIGH-level CAN bus line Ignition switch OFF* 6 kΩ or higher 6. 7. NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. CHECK BATTERY VOLTAGE Battery voltage: 11 to 14 V (a) If the voltage is below 11 V, replace or recharge the battery before proceeding. CHECK MIL (a) Check that the MIL illuminates when turning the ignition switch on (IG). If the MIL does not illuminate, there is a problem in the MIL circuit (See page ES-471). (b) When the engine is started, the MIL should turn off. U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC CHECK / CLEAR Intelligent Tester 1. DLC3 AX–43 CAN VIM C131977E05 2. CHECK DTC (a) DTCs which are stored in the TCM can be displayed with the intelligent tester. These scan tools can display pending DTCs and current DTCs. Some DTCs are not stored if the TCM doesn't detect a malfunction during consecutive driving. However, the malfunction detected while a driving is stored as a pending DTC. (1) Connect the intelligent tester to the Controller Area Network Vehicle Interface Module (CAN VIM). Then connect the CAN VIM to the Data Link Connector 3 (DLC3). (2) Turn the ignition switch on (IG). (3) Enter the following menus: DIAGNOSIS / OBD/ MOBD / ECT / DTC INFO / CURRENT CODES (or PENDING CODE). (4) Confirm the DTCs and freeze frame data and then write them down. (5) Confirm the details of the DTCs (See page AX46). NOTICE: When a symptom has been duplicated using normal mode, use the intelligent tester to check for DTCs. For DTCs that are subject to "2-trip detection logic", perform the following steps: Turn the ignition switch OFF after the symptom has occurred once. Repeat the process of attempting to duplicate the symptom. When the problem or symptom happens for the second time and a DTC has been recorded, the MIL will illuminate, and the code will be stored. CLEAR DTC (a) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (b) Turn the ignition switch on (IG). (c) Enter the following menus: DIAGNOSIS / OBD/ MOBD / ECT / DTC INFO / CLEAR CODES and press YES. AX AX–44 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM CHECK MODE PROCEDURE 1. DESCRIPTION (a) Check mode has a higher sensitivity to malfunctions and can detect malfunctions that normal mode cannot detect. Check mode can also detect all the malfunctions that normal mode can detect. In check mode, DTCs are detected with 1-trip detection logic. 2. CHECK MODE PROCEDURE (a) Make sure that the items below are satisfied: (1) Battery positive voltage is 11 V or more (2) Throttle valve is fully closed (3) Transaxle is in the P or N position (4) A/C is switched OFF (b) Turn the ignition switch off. (c) Connect the intelligent tester together with the Controller Area Network Vehicle Interface Module (CAN VIM) to the DLC3. (d) Turn the ignition switch on (IG). (e) Enter the following menus: DIAGNOSIS / OBD/ MOBD / ECT / CHECK MODE. AX Intelligent Tester DLC3 CAN VIM C131977E05 (f) 0.13 seconds ON OFF 0.13 seconds A076900E02 Change the TCM to check mode. Make sure that the MIL flashes as shown in the illustration. NOTICE: All DTCs and freeze frame data recorded will be erased if: 1) the intelligent tester is used to change the TCM from normal mode to check mode or vice-versa; or 2) during check mode, the ignition switch is turned from on (IG) to on (ACC) or off. Before entering check mode, make notes of any DTCs and freeze frame data that are present. (g) Start the engine. The MIL should turn off after the engine starts. (h) Perform "MONITOR DRIVE PATTERN" for the ECT test (See page AX-27). (Or, duplicate the conditions of the malfunction described by the customer). (i) After duplicating the malfunction conditions, use the intelligent tester diagnosis selector to check the DTC and freeze frame data. AX–45 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM FAIL-SAFE CHART 1. Fail-safe This function minimizes the loss of operation when any abnormality occurs in a sensor or solenoid. Fail-safe Control List Malfunction Part Input Turbine Speed Sensor AX Function Shifting to only either the 1st or 3rd gears is allowed. • Counter Gear Speed Sensor • The counter gear speed is determined based on the signals from the skid control ECU (speed sensor signals). Shifting between 1st to 4th gears is allowed. ATF Temp. Sensor Shifting between 1st to 4th gears is allowed. ECT ECU Power Supply (Voltage is Low) When the vehicle is being driven in 6th gear, the transaxle is fixed in 6th gear. When being driven in any of the 1st to 5th gears, the transaxle is fixed in 5th gear. CAN communication Shifting to only either 1st or 3rd gears is allowed. Knock Sensor Shifting between 1st to 4th gears is allowed. Solenoid Valve SL1, SL2, SL3 and SL4 The current to the failed solenoid valve is cut off and operating the other solenoid valves with normal operation performs shift control. (Shift controls in fail-safe mode are described in the table on the next page. For details, refer to Fail-Safe Control Chart) Solenoid Valve Operation when Normal: Gear Position Solenoid 1st 2nd 3rd 4th 5th 6th SL1 ON ON ON ON OFF OFF SL2 OFF OFF OFF ON ON ON SL3 OFF ON OFF OFF OFF ON SL4 OFF OFF ON OFF ON OFF Fail-safe Control Chart: Gear Position in Normal Operation 1st 2nd 3rd 4th 5th 6th 1st 2nd 3rd 4th 5th 6th OFF Malfunction (without Fail-safe Control) 1st to N 2nd to N 3rd to N 4th to N 5th 6th Fail-safe Control during OFF Malfunction Fixed in 3rd or 5th Fail-safe Control during OFF Malfunction (ATF Pressure Switches 1 and 2 Malfunctions) Fixed in 3rd or 5th ON Malfunction (without Fail-safe Control) *1 SL1 ON Malfunction (without Fail-safe 1st to 4th 2nd to 4th 3rd to 4th 4th 5th 6th OFF Malfunction (without Fail-safe Control) 1st 2nd 3rd 4th to 1st 5th to N 6th to N Fail-safe Control during OFF malfunction 1st 2nd 3rd 3rd 3rd 3rd Fail-safe Control during OFF Malfunction (ATF Pressure Switches 1 and 2 Malfunctions) Fixed in 2nd or 3rd Control) *1 SL2 ON Malfunction (without Fail-safe 1st to 2nd 2nd 3rd 4th 5th 6th OFF Malfunction (without Fail-safe Control) 1st 2nd to 1st 3rd 4th 5th 6th to N Fail-safe Control during OFF malfunction 1st 3rd 3rd 4th 5th 5th Fail-safe Control during OFF Malfunction (ATF Pressure Switches 1 and 2 Malfunctions) Fixed in 3rd Control) *1 SL3 AX–46 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Gear Position in Normal Operation 1st 2nd 3rd 4th 5th 6th 3rd 3rd 3rd 4th 5th 5th OFF Malfunction (without Fail-safe Control) 1st 2nd 3rd to 1st 4th 5th to N 6th Fail-safe Control during OFF malfunction 1st *2 2nd *2 4th*2 4th*2 6th 6th Fail-safe Control during OFF Malfunction (ATF Pressure Switches 1 and 2 Malfunctions) Fixed in 2nd ON Malfunction (without Fail-safe Control)*1 SL4 AX *1: Fail-safe control is not actuated when the ON malfunction occurs. *2: Shifting to 5th and 6th gears is prohibited. AX–47 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DATA LIST / ACTIVE TEST 1. DATA LIST HINT: Using the DATA LIST using the intelligent tester allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to save labor time. NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester together with the CAN VIM (Controller Area Network Vehicle Interface Module) to the DLC3. (d) Turn the ignition switch on (IG). (e) Turn the tester on. (f) Enter the following menus: "DIAGNOSIS / OBD/ MOBD / ECT / DATA LIST". (g) According to the display on the tester, read "DATA LIST". Item Measurement Item/ Range (display) CALC LOAD Calculated load by ECM: Min.: 0%, Max.: 100% ENGINE SPD Engine speed: Min.: 0 rpm, Max.: 16,383.75 rpm 550 to 800 rpm: Idling - VEHICLE SPD Vehicle speed: Min.: 0 km/h, Max.: 255 km/h Actual vehicle load - COOLANT TEMP Engine coolant temperature: Min.: -40°C (419°F), Max.: 140°C (258°F) 80 to 105°C (176 to 221°F): After warming up • THROTTLE POS Throttle position: Min.: 0%, Max.: 100% 10 to 22%: Idling Calculated value based on VTA1 THROTTLE POS Throttle position: Min.: 0%, Max.: 100% SPD (NC) Min.: 0 rpm, Max.: 12750 rpm Normal Condition • • Diagnostic Note 15.0 to 35.0%: Idling 10.0 to 30.0%: Running without load (2,000 rpm) - • • • 0%: Accelerator pedal released 64 to 96%: Accelerator pedal fully depressed - SPD (NT) Input turbine speed/ display: 50 r/min HINT: • Lock-up ON (After warming up the engine): Input turbine speed (NT) equal to the engine speed. • Lock-up OFF (Idling at N position): Input turbine speed (NT) nearly equal to the engine speed. CTP SW Closed throttle position switch: ON or OFF • • ON: Throttle fully closed OFF: Throttle open If value -40°C (-40°F): sensor circuit open If value 140°C (284°F): sensor circuit shorted Recognition valve for throttle opening angle on ECM - - - AX AX–48 Item AX U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Measurement Item/ Range (display) PNP SW [NSW] PNP switch status/ ON or OFF STOP LIGHT SW Stop light switch status/ ON or OFF Normal Condition Shift lever position is; P and N: ON Except P and N: OFF • • Brake pedal is depressed: ON Brake pedal is released: OFF Diagnostic Note When the shift lever position displayed on the intelligent tester differs from the actual position, adjustment of the PNP switch or the shift cable may be incorrect. HINT: When the failure still occurs even after adjusting these parts, see page AX-165. - BATTERY VOLTAGE Battery voltage: Min.: 0, Max.: 65.535 V 9 to 14 V: Idling TC/TE1 TC and TE1 terminals of DLC3: ON or OFF - Active Test support data FC IDL Fuel cut idle: ON or OFF ON: Fuel cut operating FC IDL= "ON" when throttle valve fully closed and engine speed over 2,800 rpm FC TAU Fuel cut TAU (Fuel cut during very light load): ON: Fuel cut operating Fuel cut being performed under very light load to prevent engine combustion from becoming incomplete ECM gear shift command/ 1st, 2nd, 3rd, 4th, 5th or 6th Shift lever position is; • D: 1st, 2nd, 3rd, 4th, 5th or 6th • S: 1st, 2nd, 3rd, 4th, 5th or 6th SHIFT REVERSE PARKING NEUTRAL DRIVE PNP switch status/ ON or OFF PNP switch status/ ON or OFF PNP switch status/ ON or OFF PNP switch status/ ON or OFF - - Shift lever position is; R: ON Except R: OFF When the shift lever position displayed on the intelligent tester differs from the actual position, adjustment of the PNP switch or the shift cable may be incorrect. HINT: When the failure still occurs even after adjusting these parts, see page AX-158 Shift lever position is; P: ON Except P: OFF When the shift lever position displayed on the intelligent tester differs from the actual position, adjustment of the PNP switch or the shift cable may be incorrect. HINT: When the failure still occurs even after adjusting these parts, see page AX-158 Shift lever position is; N: ON Except N: OFF When the shift lever position displayed on the intelligent tester differs from the actual position, adjustment of the PNP switch or the shift cable may be incorrect. HINT: When the failure still occurs even after adjusting these parts, see page AX-158 Shift lever position is; D and S: ON Except D and S: OFF When the shift lever position displayed on the intelligent tester differs from the actual position, adjustment of the PNP switch or the shift cable may be incorrect. HINT: When the failure still occurs even after adjusting these parts, see page AX-158 AX–49 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Item Measurement Item/ Range (display) SPORTS UP SW Sport shift up switch status/ ON or OFF SPORTS DOWN SW Sport shift down switch status/ ON or OFF Normal Condition • • • • Diagnostic Note Press continuously "+" (Up shift): ON Release "+" (Up shift): OFF - Press continuously "-" (Down shift): ON Release "-" (Down shift): OFF - MODE SELECT SW Sport mode select switch status/ ON or OFF Shift lever position is; S, "+" and "-": ON Except S, "+" and "-": OFF - TPS 1 SW 0: OFF / 1: ON Gear position 1st, 2nd, 3rd or 4th: ON Gear position 5th or 6th: OFF - TPS 2 SW 0: OFF / 1: ON Gear position 4th, 5th or 6th: ON Gear position 1st, 2nd or 3rd: OFF - TPS 3 SW 0: OFF / 1: ON Shift solenoid valve SLU is ON: ON Shift solenoid valve SLU is OFF: OFF - A/T OIL TEMP 1 ATF temp. sensor value/ min.: -40°C (-40°F) max.: 215°C (419°F) NT SENS VOL Min.: 0 V, Max.: 5 V 0.1 to 1.9 V - NC SENS VOL Min.: 0 V, Max.: 5 V 0.1 to 1.9 V - ATF 0: OFF / 1: ON • • After stall test; Approx. 80°C (176°F) Equal to ambient temperature when cold soak If the value is "-40°C (-40°F)" or "215°C (419°F)", ATF temp. sensor circuit is open or shorted. - LOCK UP 0: OFF / 1: ON Lock up: ON - LOCK UP SOL Lock up solenoid status/ ON or OFF • • Lock up: ON Except lock up: OFF - SOLENOID (SLU) Shift Solenoid SLU Status/ ON or OFF • • Lock up: ON Except lock up: OFF - • SOLENOID (SLT) Shift solenoid SLT status/ ON or OFF Accelerator pedal is depressed: OFF Accelerator pedal is released: ON - ENGINE SPD Engine speed: Min.: 0 rpm, Max.: 16,383.75 rpm 550 to 800 rpm: Idling INTAKE AIR TEMP Intake air temperature Min.: -40°C (-40°F), Max.: 140°C (258°F) Equivalent to ambient air temperature COOLANT TEMP Engine coolant temperature Min.: -40°C (-40°F), Max.: 215°C (419°F) 80 to 105°C (176 to 221°F): After warming up THROTTLE POS Throttle sensor position: Min.: 0%, Max.: 100% THROTTLE POS Whether throttle position sensor detecting idle: ON or OFF ACCEL POS Min.: 0%, Max.: 100% #CODES # of Codes: Min.: 0, Max.: 255 - CHECK MODE Check mode: 0: OFF, 1: ON ON: Check mode ON • • • • • • Accelerator pedal released: 0% Accelerator pedal fully depressed: 64 to 96% ON: Idling • If value -40°C(-40°F): sensor circuit open If value 140°C(284°F): sensor circuit shorted If value -40°C (-40°F): sensor circuit open If value 140°C (284°F): sensor circuit shorted Recognition value for throttle opening angle on ECM Number of detected DTCs - AX AX–50 AX U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Item Measurement Item/ Range (display) SPD TEST Check mode result for vehicle speed sensor: 0: COMPL, 1: INCMPL - - MIL MIL status: ON or OFF ON: MIL ON - MIL ON RUN DIST MIL ON run distance: Min.: 0 mile (65,535 km), Max.: 110,950 mile (65,535 km) Distance after DTC detected - MIL ON RUN TIME Running time from MIL ON: Min.: 0 minute, Max.:65,535 minutes Equivalent to running time after MIL ON - ENG RUN TIME Engine run time: Min.: 0 second, Max.: 65,535 seconds Time after engine start - TIME DTC CLEAR Time after DTC cleared: Min.: 0 minute, Max.: 65,535 minutes Equivalent to time after DTCs erased - DIST DTC CLEAR Distance after DTC cleared: Min.: 0 km/h, Max.: 65,535 km/h Equivalent to time after DTCs erased - WU CYC DTC CLEAR Warm-up cycle after DTC cleared: Min.: 0, Max.: 255 - OBD CERT OBD requirement OBD2 COMP ON Comprehensive component monitor 0: NOT AVL, 1: AVAIL - CCM ENA Comprehensive component monitor UNABLE or ENABLE - - CCM CMPL Comprehensive component monitor COMPL or INCMPL - - FUEL ENA Fuel system monitor UNABLE or ENABLE - - FUEL CMPL Fuel system monitor COMPL or INCMPL - - MISFIRE ENA Misfire monitor UNABLE or ENABLE - - MISFIRE CMPL Misfire monitor COMPL or INCMPL - - HTR ENA O2S (A/FS) heater monitor UNABLE or ENABLE - - HTR CMPL O2S (A/FS) heater monitor COMPL or INCMPL - - O2S(A/FS) ENA O2S (A/FS) monitor UNABLE or ENABLE - - O2S(A/FS) CMPL O2S (A/FS) monitor COMPL or INCMPL - - EVAP ENA EVAP monitor UNABLE or ENABLE - - EVAP CMPL EVAP monitor COMPL or INCMPL - - CAT ENA Catalyst monitor: UNABLE or ENABLE - - CAT CMPL Catalyst monitor COMPL or INCMPL - - Normal Condition Diagnostic Note Number of warm-up cycles after DTC cleared Comprehensive Component Monitor U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–51 Item Measurement Item/ Range (display) TRANSMISSION Transmission type - Identifying transmission type: 6 speed SYSTEM System identification - Identifying engine type: GASOLINE (gasoline engine) Normal Condition 2. Item SHIFT Diagnostic Note ACTIVE TEST HINT: Performing the ACTIVE TEST using the intelligent tester allows relays, VSVs, actuators and other items to be operated without removing any parts. Performing the ACTIVE TEST as the first step in troubleshooting is one method to save labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester together with the CAN VIM (Controller Area Network Vehicle Interface Module) to the DLC3. (d) Turn the ignition switch on (IG). (e) Turn the intelligent tester on. (f) Enter the following items: "DIAGNOSIS / OBD/ MOBD / ECT / ACTIVE TEST". (g) According to the display on tester, perform "ACTIVE TEST". Test Details [Test Details] Operate the shift solenoid valve and set each shift position by yourself. [Vehicle Condition] • IDL: ON [Others] • Press "→" button: Shift up • Press "←" button: Shift down Diagnostic Note Possible to check the operation of the shift solenoid valves. Upshifts and downshifts should be performed consecutively. A 10second interval is required between gear changes. Do not downshift at high speeds. Doing so will damage the automatic transaxle. LOCK UP [Test Details] Control the shift solenoid SLU to set the automatic transaxle to the lock-up condition. [Vehicle Condition] • Throttle valve opening angle: Less than 35% • Vehicle speed: 37 mph (60 km/h) or more, and 6th gear Possible to check the SLU solenoid operation. SOLENOID (SL1) [Test Details] Operate the shift solenoid SL1 [Vehicle Condition] • Vehicle Stopped • Shift lever in P or N position - SOLENOID (SL2) [Test Details] Operate the shift solenoid SL2 [Vehicle Condition] • Vehicle Stopped • Shift lever in P or N position - SOLENOID (SL3) [Test Details] Operate the shift solenoid SLU [Vehicle Condition] • Vehicle Stopped • Shift lever in P or N position - AX AX–52 Item AX U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Test Details Diagnostic Note SOLENOID (SL4) [Test Details] Operate the shift solenoid S1 [Vehicle Condition] • Vehicle Stopped • Shift lever in P or N position - SOLENOID (SL) [Test Details] Operate the shift solenoid S2 [Vehicle Condition] • Vehicle Stopped • Shift lever in P or N position - SOLENOID (SLT) [Test Details] Operate the shift solenoid SLT and raise the line pressure. [Vehicle Condition] • Vehicle Stopped • IDL: ON HINT: OFF: Line pressure up (When the active test of "SOLENOID (SLT)" is performed, the ECM commands the SLT solenoid to turn off). ON: No action (normal operation) - SOLENOID (SLU) [Test Details] Operate the shift solenoid SLU and raise the line pressure. [Vehicle Condition] • Vehicle Stopped. • IDL: ON HINT: OFF: Line pressure up (When the active test of "SOLENOID (SLU)" is performed, the ECM commands the SLU solenoid to turn off). ON: No action (normal operation) - *: "SOLENOID (SLT)" in the ACTIVE TEST is performed to check the line pressure changes by connecting the SST to the automatic transaxle. The same SST is used for the HYDRAULIC TEST (See page AX-17) as well. HINT: The pressure values in ACTIVE TEST and HYDRAULIC TEST will be different from each other. U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–53 DIAGNOSTIC TROUBLE CODE CHART If a DTC is displayed during the DTC check, check the parts listed in the table below and proceed to the page given. HINT: • *1: MIL (Malfunction Indicator Lamp) comes on • *2: "DTC stored" mark means TCM memorizes the trouble code if the TCM detects that the DTC detection condition is satisfied. • A DTC may be output when the clutch, brake and gear components, etc. inside the automatic transaxle are damaged. AUTOMATIC TRANSAXLE SYSTEM DTC No. Detection Item Trouble Area MIL *1 Memory *2 See page P0500 Vehicle Speed Sensor "A" 1. Vehicle speed sensor 2. Vehicle speed sensor signal circuit 3. Combination meter 4. TCM Comes on DTC stored AX-50 P0560 System Voltage 1. Open in back-up power source circuit 2. TCM Comes on DTC stored AX-53 P0710 Transmission Fluid Temperature Sensor "A" Circuit 1. Open or short in ATF temperature sensor circuit 2. Transmission wire (ATF temperature sensor) 3. TCM Comes on DTC stored AX-55 P0711 Transmission Fluid Temperature Sensor "A" Performance Transmission wire (ATF temperature sensor) Comes on DTC stored AX-60 P0712 Transmission Fluid Temperature Sensor "A" Circuit Low Input 1. Short in ATF temperature sensor circuit 2. Transmission wire (ATF temperature sensor) 3. TCM Comes on DTC stored AX-55 P0713 Transmission Fluid Temperature Sensor "A" Circuit High Input 1. Open in ATF temperature sensor circuit 2. Transmission wire (ATF temperature sensor) 3. TCM Comes on DTC stored AX-55 P0715 Input / Turbine Speed Sensor Circuit Malfunction 1. Transmission revolution sensor (speed sensor NT) 2. TCM Comes on DTC stored AX-66 P0717 Input Speed Sensor Circuit No Signal 1. Transmission revolution sensor (speed sensor NT) 2. TCM Comes on DTC stored AX-66 P0724 Brake Switch "B" Circuit High 1. Short in stop light switch signal circuit 2. Stop light switch 3. TCM Comes on DTC stored AX-71 P0741 Torque Converter Clutch Solenoid Performance (Shift Solenoid Valve SL) 1. Shift solenoid valve SL remains closed 2. Valve body is blocked 3. Torque converter clutch 4. Automatic transaxle (clutch, brake or gear etc.) 5. Line pressure is too low Comes on DTC stored AX-74 P0746 Pressure Control Solenoid "A" Performance (Shift Solenoid Valve SL1) 1. Shift solenoid valve SL1 remains open or closed 2. Valve body is blocked 3. Automatic transaxle (clutch, brake or gear etc.) Comes on DTC stored AX-79 AX AX–54 DTC No. U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Detection Item Trouble Area MIL *1 Memory *2 See page P0748 Pressure Control Solenoid "A" Electrical (Shift Solenoid Valve SL1) 1. Open or short in shift solenoid valve SL1 circuit 2. Shift solenoid valve SL1 3. TCM Comes on DTC stored AX-84 P0776 Pressure Control Solenoid "B" Performance (Shift Solenoid Valve SL2) 1. Shift solenoid valve SL2 remains open or closed 2. Valve body is blocked 3. Automatic transaxle (clutch, brake or gear etc.) Comes on DTC stored AX-87 P0778 Pressure Control Solenoid "B" Electrical (Shift Solenoid Valve SL2) 1. Open or short in shift solenoid valve SL2 circuit 2. Shift solenoid valve SL2 3. TCM Comes on DTC stored AX-92 P0791 Intermediate Shaft Speed Sensor "A" Circuit 1. Transmission revolution sensor (speed sensor NC) 2. TCM Comes on DTC stored AX-95 P0793 Intermediate Shaft Speed Sensor "A" 1. Transmission revolution sensor (speed sensor NC) 2. TCM Comes on DTC stored AX-95 P0796 Pressure Control Solenoid "C" Performance (Shift Solenoid Valve SL3) 1. Shift solenoid valve SL3 remains open or closed 2. Valve body is blocked 3. Automatic transaxle (clutch, brake or gear etc.) Comes on DTC stored AX-100 P0798 Pressure Control Solenoid "C" Electrical (Shift Solenoid Valve SL3) 1. Open or short in shift solenoid valve SL3 circuit 2. Shift solenoid valve SL3 3. TCM Comes on DTC stored AX-105 P0872 Transmission Fluid Pressure Switch No.1 Circuit Low 1. ATF temperatuer sensor assembly (ATF pressure switch No. 1) 2. Transmission wire - DTC stored AX-108 P0873 Transmission Fluid Pressure Switch No.1 Circuit High 1. ATF temperatuer sensor assembly (ATF pressure switch No 1) 2. Transmission wire 3. TCM - DTC stored AX-108 P0877 Transmission Fluid Pressure Switch No.2 Circuit Low 1. ATF temperatuer sensor assembly (ATF pressure switch No. 2) 2. Transmission wire - DTC stored AX-112 P0878 Transmission Fluid Pressure Switch No.2 Circuit High 1. ATF temperatuer sensor assembly (ATF pressure switch No. 2) 2. Transmission wire 3. TCM - DTC stored AX-112 P0989 Transmission Fluid Pressure Switch No.3 Circuit Low 1. ATF temperatuer sensor assembly (ATF pressure switch No. 3) 2. Transmission wire Comes on DTC stored AX-116 P0990 Transmission Fluid Pressure Switch No.3 Circuit High 1. ATF temperatuer sensor assembly (ATF pressure switch No. 3) 2. Transmission wire 3. TCM Comes on DTC stored AX-116 P2714 Pressure Control Solenoid "D" Performance (Shift Solenoid Valve SLT) 1. Shift solenoid valve SLT remains open 2. Shift solenoid valve SL1, SL2, SL3 or SL4 remains open or closed 4. Valve body is blocked 5. Automatic transaxle (clutch, brake or gear, etc.) Comes on DTC stored AX-121 AX U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC No. Detection Item Trouble Area MIL *1 Memory *2 AX–55 See page P2716 Pressure Control Solenoid "D" Electrical (Shift Solenoid Valve SLT) 1. Open or short in shift solenoid valve SLT circuit 2. Shift solenoid valve SLT 3. TCM Comes on DTC stored AX-128 P2757 Torque Converter Clutch Pressure Control Solenoid Performance (Shift Solenoid Valve SLU) 1. Shift solenoid valve SLU remains open or closed 2. Valve body is blocked 3. Torque converter clutch 4. Automatic transaxle (clutch, brake or gear, etc.) 5. Line pressure is too low Comes on DTC stored AX-131 P2759 Torque Converter Clutch Pressure Control Solenoid Control Circuit Electrical (Shift Solenoid Valve SLU) 1. Open or short in shift solenoid valve SLU circuit 2. Shift solenoid valve SLU 3. TCM Comes on DTC stored AX-136 P2769 Short in Torque Converter Clutch Solenoid Circuit (Shift Solenoid Valve SL) 1. Short in shift solenoid valve SL circuit 2. Shift solenoid valve SL 3. TCM Comes on DTC stored AX-139 P2770 Open in Torque Converter Clutch Solenoid Circuit (Shift Solenoid Valve SL) 1. Open in shift solenoid valve SL circuit 2. Shift solenoid valve SL 3. TCM Comes on DTC stored AX-139 P2808 Pressure Control Solenoid "D" Performance or Stuck OFF (Shift Solenoid Valve SL4) 1. Shift solenoid valve SL4 remains open or closed 2. Valve body is blocked 3. Automatic transaxle (clutch, brake or gear etc.) Comes on DTC stored AX-142 P2810 Pressure Control Solenoid "D" Electrical (Shift Solenoid Valve SL4) 1. Open or short in shift solenoid valve SL4 circuit 2. Shift solenoid valve SL4 3. TCM Comes on DTC stored AX-148 U0100 Lost Communication with ECM/ PCM "A" TCM Comes on DTC stored AX-151 AX AX–56 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC P0500 Vehicle Speed Sensor "A" DESCRIPTION AX The speed sensors detect the wheel speed and sends the appropriate signals to the skid control ECU. The skid control ECU converts these wheel speed signals into a 4-pulse signal and outputs it to the TCM via the combination meter. The TCM determines the vehicle speed based on the frequency of these pulse signals. 4-Pulse From Speed Sensor 4-Pulse Skid Control ECU TCM Combination Meter A079413E20 DTC No. P0500 DTC Detection Condition When the ECT sensor is normal and the counter gear speed is 300 rpm or more, the vehicle speed signal is not input for 2 seconds or more. Trouble Area • • • • Vehicle speed sensor Vehicle speed sensor signal circuit Combination meter TCM MONITOR DESCRIPTION The TCM assumes that the vehicle is being driven when the transmission counter gear indicates more than 300 rpm and over 30 seconds have passed since the park/neutral position switch was turned off. If there is no signal from the vehicle speed sensor with these conditions satisfied, the TCM concludes that the vehicle speed sensor is malfunctioning. The TCM will turn on the MIL and a DTC will be set. MONITOR STRATEGY Related DTCs P0500: Vehicle Speed Sensor Circuit Required sensors/components (Main) Vehicle speed sensor, Combination meter, ABS ECU Required sensors/components (Sub) Counter gear Speed (CS) sensor, ECT sensor Frequency of operation Continuous Duration 2 seconds MIL operation Immediately Sequence operation None TYPICAL ENABLING CONDITIONS Engine Running Transmission counter gear revolution 300 rpm or more Battery voltage 8 V or more Ignition switch ON Starter OFF U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–57 Either a or b is met (See below) a. All of the following conditions are met ECT 20°C (68°F) or more ECT sensor fail Not detected Time after PNP switch ON to OFF 2 sec. or more AX b. All of the following conditions are met ECT Less than 20°C (68°F) ECT sensor fail Detected Time after PNP switch ON to OFF 30 sec. or more TYPICAL MALFUNCTION THRESHOLDS Vehicle speed sensor signal No pulse input WIRING DIAGRAM TCM F2 Combination Meter 3 SPD1 C56 +S 12 8 C56 E1 A122761E04 INSPECTION PROCEDURE 1 INSPECT SPEEDOMETER (METER OPERATION) (a) Drive the vehicle and check if operation of the speedometer in the combination meter is normal. HINT: The vehicle speed sensor is operating normally if the speedometer display is normal. NG OK CHECK SPEEDOMETER CIRCUIT AX–58 2 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM INSPECT TCM Wire Harness Side: TCM Connector (Front View) AX C56 E1 SPD1 Turn the wheel A062954E07 OK REPLACE TCM Shift the lever to the neutral position. Jack up the vehicle. Disconnect the TCM connector. Turn the ignition switch on (IG). (e) Measure the voltage according to the value(s) in the table below as the wheel is turned slowly. Standard C133210E01 4.5 to 5.5 V 0V (a) (b) (c) (d) Tester Connection Specified Condition C56-3 (SPD1) - C56-8 (E1) Voltage is generated intermittently HINT: The output voltage should fluctuate up and down similarly to the diagram when the wheel is turned slowly. NG REPAIR OR REPLACE HARNESS OR CONNECTOR U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC P0560 AX–59 System Voltage DESCRIPTION The battery supplies electricity to the TCM even when the ignition switch is off. This power allows the TCM to store data such as DTC history, freeze frame data and fuel trim values. If the battery voltage falls below a minimum level, these memories are cleared and the TCM determines that there is a malfunction in the power supply circuit. When the engine is next started, the TCM will illuminate the MIL and set the DTC. DTC No. P0560 DTC Detection Condition Trouble Area Open in TCM back-up power source circuit (1 trip detection logic) • • Open in back-up power source circuit TCM HINT: If DTC P0560 is set, the TCM does not store other DTCs. MONITOR STRATEGY Related DTCs P0560: TCM system voltage Required Sensors/Components (Main) TCM Required Sensors/Components (Sub) - Frequency of Operation Continuous Duration 3 seconds MIL Operation Immediate (MIL illuminated after next engine start) Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present: None Stand-by RAM Initialized TYPICAL MALFUNCTION THRESHOLDS TCM power source Less than 3.5 V AX AX–60 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM WIRING DIAGRAM TCM AX 1 BATT C56 EFI No. 1 FL MAIN 8 C56 E1 Battery A122745E03 INSPECTION PROCEDURE 1 INSPECT TERMINAL VOLTAGE (BATT VOLTAGE OF TCM) (a) Disconnect the TCM connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness Side: TCM Connector (Front View) C56 BATT OK REPLACE TCM C133210E02 NG Tester Connection Specified Condition BATT (C56-1) - E1 (C56-8) 10 to 14 V REPAIR OR REPLACE HARNESS OR CONNECTOR (EFI NO. 1 FUSE - TCM) U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–61 DTC P0710 Transmission Fluid Temperature Sensor "A" Circuit DTC P0712 Transmission Fluid Temperature Sensor "A" Circuit Low Input DTC P0713 Transmission Fluid Temperature Sensor "A" Circuit High Input DESCRIPTION The ATF (Automatic Transmission Fluid) temperature sensor converts the fluid temperature into a resistance value for use by the TCM. Resistance Acceptable range Temperature G031389E14 The TCM applies a voltage to the temperature sensor through terminal OIL of the TCM. The sensor resistance changes with the transmission fluid temperature. As the temperature becomes higher, the sensor resistance decreases. One terminal of the sensor is grounded so that the sensor resistance decreases and the voltage goes down as the temperature becomes higher. The TCM calculates the fluid temperature based on the voltage signal. DTC No. P0710 DTC Detection Condition (a) and (b) are detected momentarily within 0.5 sec. when neither P0712 nor P0713 is detected (1-trip detection logic) (a) ATF temperature sensor resistance is less than 79 Ω. (b) ATF temperature sensor resistance is more than 156 kΩ. HINT: Within 0.5 sec., the malfunction switches from (a) to (b) or from (b) to (a) Trouble Area • • • Open or short in ATF temperature sensor circuit Transmission wire (ATF temperature sensor) TCM AX AX–62 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC No. AX DTC Detection Condition Trouble Area P0712 ATF temperature sensor resistance is less than 79 Ω for 0.5 sec. or more have (1-trip detection logic) • • • P0713 ATF temperature sensor resistance is more than 156 kΩ when 15 minutes or more have elapsed after the engine starts DTC is detected for 0.5 sec. or more (1-trip detection logic) • • • Short in ATF temperature sensor circuit Transmission wire (ATF temperature sensor) TCM Open in ATF temperature sensor circuit Transmission wire (ATF temperature sensor) TCM MONITOR DESCRIPTION These DTCs indicate an open or short in the automatic transmission fluid (ATF) temperature sensor (TFT sensor) circuit. The automatic transmission fluid (ATF) temperature sensor converts ATF temperature into an electrical resistance value. Based on the resistance, the TCM determines the ATF temperature, and the TCM detects an open or short in the ATF temperature circuit. If the resistance value of the ATF temperature is less than 79 Ω*1 or more than 156 kΩ*2, the TCM interprets this as a fault in the ATF sensor or wiring. The TCM will turn on the MIL and store the DTC. *1: 150°C (302°F) or more is indicated regardless of the actual ATF temperature. *2: -40°C (-40°F) is indicated regardless of the actual ATF temperature. HINT: The ATF temperature can be checked on the intelligent tester display. MONITOR STRATEGY Related DTCs P0710: ATF temperature sensor/Range check (Chattering) P0712: ATF temperature sensor/Range check (Low resistance) P0713: ATF temperature sensor/Range check (High resistance) Required sensors/Components ATF temperature sensor (TFT sensor) Frequency of operation Continuous Duration 0.5 sec. MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS P0710: Range check (Chattering) The monitor will run whenever this DTC is not present. None The typical enabling condition is not available. - P0712: Range check (Low resistance) The monitor will run whenever this DTC is not present. None The typical enabling condition is not available. - P0713: Range check (High resistance) The monitor will run whenever this DTC is not present. None Time after engine start 15 min. or more TYPICAL MALFUNCTION THRESHOLDS P0710: Range check (Chattering) TFT (transmission fluid temperature) sensor resistance Less than 79 Ω or more than 156 kΩ U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–63 P0712: Range check (Low resistance) Less than 79 Ω TFT sensor resistance P0713: Range check (High resistance) TFT sensor resistance AX More than 156 kΩ COMPONENT OPERATING RANGE TFT sensor Atmospheric temperature to approx. 130°C (266°F) WIRING DIAGRAM TCM 18 17 THO1 E2 ATF Temperature Sensor Transaxle Assembly C133262E01 INSPECTION PROCEDURE 1. DATA LIST HINT: According to the DATA LIST displayed on the intelligent tester, you can read the value of switches, sensors, actuators and other items without removing any parts. Reading the DATA LIST as the first step in troubleshooting is one method to save labor time. NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty. (a) Warm up the engine. (b) Turn the ignition switch off. AX–64 AX U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM (c) Connect the intelligent tester together with the CAN VIM (Controller Area Network Vehicle Interface Module) to the DLC3. (d) Turn the ignition switch on (IG). (e) Turn on the tester. (f) Enter the following items: "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". (g) According to the display on tester, read "DATA LIST". Item Measurement Item/ Range (display) AT OIL TEMP1 ATF Temp. Sensor Value/ min.: -40°C (-40°F) max.: 215°C (419°F) Normal Condition • • After Stall Test; Approx. 80°C (176°F) Equal to ambient temperature when cold soak HINT: When DTC P0712 is output and intelligent tester indicates 150°C (302°F) or more, there is a short circuit. When DTC P0713 is output and intelligent tester indicates -40°C (-40°F), there is an open circuit. Measure the resistance between terminal OIL and body ground. Temperature Displayed Malfunction -40°C (-40°F) Open circuit 150 °C (302°F) or more Short circuit HINT: If the circuit related to the ATF temperature sensor becomes open, P0713 is immediately set (in 0.5 seconds). When P0713 is set, P0711 cannot be detected. It is not necessary to inspect the circuit when P0711 is set. 1 INSPECT TRANSMISSION WIRE (ATF TEMPERATURE SENSOR) (a) Remove the TCM from the transaxle. (b) Measure the resistance according to the value(s) in the table below. Standard resistance THO1 E2 Tester Connection Specified Condition 17 (E2) - 18 (THO1) 90 Ω to 156 kΩ 17 (E2) - Body ground 10 kΩ or higher 18 (THO1) - Body ground 10 kΩ or higher HINT: If the resistance is out of the specified range with the ATF temperature shown in the table below, the driveability of the vehicle may decrease. Standard resistance C133212E01 OK NG ATF Temperature Specified Condition 10 °C (50°F) 5.8 to 7.1 kΩ 110°C (230°F) 0.23 to 0.26 kΩ REPLACE TCM U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM 2 AX–65 INSPECT ATF TEMPERATURE SENSOR (a) Disconnect the ATF temperature sensor connector from the transmission wire. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection THO1 E2 Specified Condition E2 - THO1 90 Ω to 156 kΩ E2 - Body ground 10 kΩ or higher THO1 - Body ground 10 kΩ or higher HINT: If the resistance is out of the specified range with the ATF temperature shown in the table below, the driveability of the vehicle may decrease. Standard resistance ATF Temperature C133224E01 OK REPLACE TRANSMISSION WIRE NG Specified Condition 10 °C (50°F) 5.8 to 7.1 kΩ 110°C (230°F) 0.22 to 0.28 kΩ REPLACE ATF TEMPERATURE SENSOR ASSEMBLY AX AX–66 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC Transmission Fluid Temperature Sensor "A" Performance P0711 DESCRIPTION AX The ATF (Automatic Transmission Fluid) temperature sensor converts the fluid temperature into a resistance value for use by the TCM. Resistance Acceptabele range Temperature G031389E15 The TCM applies a voltage to the temperature sensor through terminal OIL of the TCM. The sensor resistance changes with the transmission fluid temperature. As the temperature becomes higher, the sensor resistance decreases. One terminal of the sensor is grounded so that the sensor resistance decreases and the voltage goes down as the temperature becomes higher. The TCM calculates the fluid temperature based on the voltage signal. DTC No. P0711 DTC Detection Condition Both (a) and (b) are detected: (2-trip detection logic) (a) Intake air and engine coolant temps. are more than -10°C (14°F) at engine start. (b) After normal driving for over 16 min. and 40 sec. and 5 mile (8 km) or more, ATF temp. is less than 20°C (68°F) Trouble Area Transmission wire (ATF temperature sensor) MONITOR DESCRIPTION This DTC indicates that there is a problem with output signals from the automatic transmission fluid (ATF) temperature sensor (TFT sensor) and that the sensor itself is defective. The ATF temperature sensor converts the ATF temperature into an electrical resistance value. Based on the resistance, the TCM determines the ATF temperature and detects an open or short in the ATF temperature circuit or a fault of the ATF temperature sensor. After running the vehicle for a certain period, the ATF temperature should increase. If the ATF temperature is below 20°C (68°F) after running the vehicle for a certain period, the TCM interprets this as a fault, and turns on the MIL. U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–67 MONITOR STRATEGY Related DTCs P0711: ATF temperature sensor/Rationality check Required sensors/Components ATF temperature sensor (TFT sensor) Frequency of operation Continuous Duration 3 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS ALL: The monitor will run whenever this DTC is not present None TFT (Transmission fluid temperature) sensor circuit Circuit is not malfunctioning ECT (Engine coolant temperature) sensor circuit Circuit is not malfunctioning IAT (Intake air temperature) sensor circuit Circuit is not malfunctioning Turbine speed sensor circuit Circuit is not malfunctioning Intermediate shaft speed sensor Circuit is not malfunctioning Shift solenoid valve SL1 circuit Circuit is not malfunctioning Shift solenoid valve SL2 circuit Circuit is not malfunctioning Shift solenoid valve SL3 circuit Circuit is not malfunctioning Shift solenoid valve SL4 circuit Circuit is not malfunctioning Knock control sensor circuit Circuit is not malfunctioning CAN communication system Circuit is not malfunctioning Electronic throttle system Circuit is not malfunctioning Time after engine start 16 min. and 40 sec. or more ECT (Engine coolant temperature) Above -15°C (5°F) Condition A: Time after engine start 18 min. and 20 sec. Driving distance after engine start 5 miles (8 km) or more IAT (12 sec. after engine start) Above -10°C (14°F) ECT (12 sec. after engine start) Above -10°C (14°F) Accumulated driving time *1 200 sec. or more *1: Following conditions are met Engine speed - Turbine speed 50 rpm or more Output speed 400 rpm or more Throttle valve opening angle 3% or more TFT (Transmission fluid temperature) Less than 20°C (68°F) Shift position Not "N" or "P" Condition B: Time after engine start 30 min. Driving distance after engine start 9.3 miles (15 km) IAT (12 sec. after engine start) -15°C (5°F) or more ECT (12 sec. after engine start) -15°C (5°F) or more TFT (Transmission fluid temperature) Less than 20°C (68°F) Accumulated driving time *1 400 sec. or more Condition C: Time after engine start 40 min. Driving distance after engine start 12.4 miles (20 km) TFT (Transmission fluid temperature) Less than 20°C (68°F) AX AX–68 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Accumulated driving time *1 550 sec. or more Condition D: Time after ECT reaches 60°C (140°F) 10 sec. or more TFT (12 sec. after engine start) 110°C (230°F) or more ECT (12 sec. after engine start) 35°C (95°F) or less AX TYPICAL MALFUNCTION THRESHOLDS Condition A, B and C: Less than 20°C (68°F) (THO = -10°C (14°F) at engine start) (Conditions vary with THO at engine) TFT Condition D: TFT 110°C (230°F) or more COMPONENT OPERATING RANGE TFT Atmospheric temperature - approx. 130°C (266°F) WIRING DIAGRAM TCM 18 17 THO1 E2 ATF Temperature Sensor Transaxle Assembly C133262E01 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–69 INSPECTION PROCEDURE 1. DATA LIST HINT: According to the DATA LIST displayed on the intelligent tester, you can read the value of switches, sensors, actuators and other items without removing any parts. Reading the DATA LIST as the first step in troubleshooting is one method to save labor time. NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester together with the CAN VIM (Controller Area Network Vehicle Interface Module) to the DLC3. (d) Turn the ignition switch on (IG). (e) Turn on the tester. (f) Enter the following items: "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". (g) According to the display on the tester, read "DATA LIST". Item Measurement Item/ Range (display) AT OIL TEMP1 ATF Temp. Sensor Value/ min.: -40°C (-40°F) max.: 215°C (419°F) Normal Condition • • After Stall Test; Approx. 80°C (176°F) Equal to ambient temperature when cold soak HINT: When DTC P0712 is output and the intelligent tester indicates 150°C (302°F) or more, there is a short circuit. When DTC P0713 is output and the intelligent tester indicates -40°C (-40°F), there is an open circuit. Measure the resistance between terminal THO1 (OT) and body ground. Temperature Displayed Malfunction -40°C (-40°F) Open circuit 150°C (302°F) or more Short circuit HINT: If a circuit related to the ATF temperature sensor becomes open, P0713 is immediately set (in 0.5 seconds). When P0713 is set, P0711 cannot be detected. It is not necessary to inspect the circuit when P0711 is set. 1 CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0711) (a) Connect the the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the the intelligent tester on. (c) Select the items: "DIAGNOSIS / OBD/MOBD / ECT / DTC INFO / CURRENT CODES". (d) Read the DTCs using the intelligent tester. Result Display (DTC output) Proceed to Only "P0711" is output A "P0711" and other DTCs B AX AX–70 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM HINT: If any other codes besides "P0711" are output, perform troubleshooting for those DTCs first. B AX GO TO DTC CHART A 2 CHECK TRANSMISSION FLUID LEVEL (a) Check the transmission fluid level (See page AX-164). OK: Automatic transmission fluid level is correct. NG ADD FLUID OK 3 INSPECT TRANSMISSION WIRE (ATF TEMPERATURE SENSOR) (a) Remove the TCM from the transaxle. (b) Measure the resistance according to the value(s) in the table below. Standard resistance THO1 E2 Tester Connection Specified Condition 17 (E2) - 18 (THO1) 90 Ω to 156 kΩ 17 (E2) - Body ground 10 kΩ or higher 18 (THO1) - Body ground 10 kΩ or higher HINT: If the resistance is out of the specified range with the ATF temperature shown in the table below, the driveability of the vehicle may decrease. Standard resistance C133212E01 OK NG ATF Temperature Specified Condition 10 °C (50°F) 5.8 to 7.1 kΩ 110°C (230°F) 0.23 to 0.26 kΩ REPLACE TCM U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM 4 AX–71 CHECK ATF TEMPERATURE SENSOR (a) Disconnect the ATF temperature sensor connector from the transmission wire. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection THO1 E2 Specified Condition E2 - THO1 90 Ω to 156 kΩ E2 - Body ground 10 kΩ or higher THO1 - Body ground 10 kΩ or higher HINT: If the resistance is out of the specified range with the ATF temperature shown in the table below, the driveability of the vehicle may decrease. Standard resistance ATF Temperature C133224E01 OK REPLACE TRANSMISSION WIRE NG Specified Condition 10 °C (50°F) 5.8 to 7.1 kΩ 110°C (230°F) 0.23 to 0.26 kΩ REPLACE ATF TEMPERATURE SENSOR ASSEMBLY AX AX–72 AX U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC P0715 Input / Turbine Speed Sensor Circuit Malfunction DTC P0717 Input Speed Sensor Circuit No Signal SYSTEM DESCRIPTION This sensor detects the rotation speed of the turbine which shows the input revolution of transaxle. By comparing the input turbine speed signal (NT) with the counter gear speed sensor signal (NC), the TCM detects the shift timing of the gears and appropriately controls the engine torque and hydraulic pressure according to various conditions, thus, providing smooth gear shift. Clutch Drum Counter Gear Input Speed Sensor NT Output Speed Sensor NC C133216E01 DTC No. DTC Detection Condition P0715 When the speed sensor input voltage is either more than 1.9 V or less than 0.1 V for 4.5 seconds or more. P0717 ECM detects conditions (a), (b) and (c) continuously for 5 sec. or more: (1-trip detection logic) (a) Vehicle speed: 31 mph (50 km/h) or more (b) Park/neutral position switch (STAR and R) is OFF (c) Speed sensor (NT): less than 300 rpm Trouble Area • • Transmission revolution sensor (speed sensor NT) TCM MONITOR DESCRIPTION The NT terminal of the TCM detects a revolution signal from the speed sensor (NT) (input RPM). The TCM calculates a gearshift comparing the speed sensor (NT) with the speed sensor (NC). While the vehicle is operating in 2nd, 3rd, 4th or 5th gear in the shift position of D, if the input shaft revolution is less than 300 rpm *1although the output shaft revolution is more than 1,000 rpm *2, the TCM interprets this as a fault, illuminates the MIL and stores the DTC. *1: Pulse is not output or is irregularly output. *2: The vehicle speed is 31 mph (50 km/h) or more. MONITOR STRATEGY Related DTCs P0717: Speed sensor (NT)/Verify pulse input U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Required sensors/Components Speed sensor (NT), Speed sensor (NC) Frequency of operation Continuous Duration 5 sec. MIL operation Immediate Sequence of operation None AX TYPICAL ENABLING CONDITIONS P0715: Battery voltage 8 V or more Ignition switch ON Starter OFF P0717: The monitor will run whenever this DTC is not present. P0500 (VSS) P0748, P0778, P0798 (Shift solenoid valve (range)) Shift change Shift change is completed before starting next shift change operation TCM selected gear 2nd, 3rd, 4th, 5th or 6th Output shaft rpm 1,000 rpm or more STAR switch OFF R switch OFF Engine Running Battery voltage 8 V or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS P0715: Sensor voltage Less than 0.1 V or more than 1.9 V P0717: Sensor signal rpm Less than 300 rpm COMPONENT OPERATING RANGE Speed sensor (NT) AX–73 Turbine speed is equal to engine speed with lock-up ON AX–74 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM WIRING DIAGRAM TCM AX NTB NTO Speed Sensor (NT) Transaxle Assembly C133260E02 INSPECTION PROCEDURE 1. DATA LIST NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty. HINT: According to the DATA LIST displayed on the intelligent tester, you can read the value of switches, sensors, actuators and other items without removing any parts. Reading the DATA LIST as the first step in troubleshooting is one method to save labor time. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester together with the CAN VIM (Controller Area Network Vehicle Interface Module) to the DLC3. (d) Turn the ignition switch on (IG). (e) Turn on the tester. (f) Enter the following items: "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". (g) According to the display on the tester, read "DATA LIST". Item SPD (NT) Measurement Item/ Range (display) Input Turbine Speed/display: 50 r/min Normal Condition HINT: • Lock-up ON (after warming up the engine); input turbine speed (NT) is equal to the engine speed. • Lock-up OFF (Idling at N position); input turbine speed (NT) is nearly equal to the engine speed. U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–75 HINT: • SPD (NT) is always 0 while driving: Open or short in the sensor or circuit. • SPD (NT) is always more than 0 and less than 300 rpm while driving the vehicle at 31 mph (50 km/h) or more: Sensor trouble, improper installation, or intermittent connection trouble of the circuit. 1 AX INSPECT SPEED SENSOR (SENSOR INSTALLATION) (a) Make sure that the connector is properly connected, and check the speed sensor installation. OK: The installation bolt is tightened properly and there is no clearance between the sensor and transaxle case. NG REPAIR OR REPLACE SPEED SENSOR C133219 OK 2 CHECK TRANSMISSION WIRE (a) Remove the TCM. (b) Disconnect the speed sensor connector from the transmission wire. (c) Measure the resistance according to the value(s) in the table below. Standard resistance TCM Side Connector NTO NTB Sensor Side Connector NTO NTB OK NEXT Specified Condition NTO - NTO Below 1 Ω NTB - NTB Below 1 Ω NTO - NTB 10 kΩ or higher NG C133270E01 3 Tester Condition REPLACE SPEED SENSOR REPLACE TRANSMISSION WIRE AX–76 4 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM CHECK IF DTC OUTPUT RECURS (SEE IF DTC P0715 AND/OR P0717 OUTPUT AGAIN) (a) Connect the intelligent tester to the DLC3. (b) Start the engine and turn the intelligent tester main switch ON. (c) Perform the monitor drive pattern (See page AX-27) (d) When you use the intelligent tester: Select the item "DIAGNOSIS / OBD/MOBD / ECT / DTC INFO / CURRENT CODES". (e) Read the DTCs using the intelligent tester. AX Result Display (DTC output) Proceed to Only "P0715 or P0717" is output A No output B B A REPLACE TCM END U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC P0724 AX–77 Brake Switch "B" Circuit High DESCRIPTION The purpose of this circuit is to prevent the engine from stalling while driving in lock-up condition when brakes are suddenly applied. When the brake pedal is depressed, this switch sends a signal to the TCM. Then the TCM cancels the operation of the lock-up clutch while braking is in progress. DTC No. P0724 DTC Detection Condition The stop light switch remains ON even when the vehicle is driven in a STOP (less than 2 mph (3 km/h)) and GO (19 mph (30 km/h) or more) fashion 5 times. (2trip detection logic). Trouble Area • • • Short in stop light switch signal circuit Stop light switch TCM MONITOR DESCRIPTION This DTC indicates that the stop light switch remains ON. When the stop light switch remains ON during "stop and go" driving, the TCM interprets this as a fault in the stop light switch, illuminates the MIL, and stores the DTC. The vehicle must stop (less than 2 mph (3 km/h)) and go (19 mph (30 km/h) or more) five times for two consecutive driving cycles in order to set this DTC. MONITOR STRATEGY Related DTCs P0724: Stop light switch/Range check/Rationality Required sensors/Components Stop light switch Frequency of operation Continuous Duration GO and STOP 5 times MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS The stop light switch remains ON during GO and STOP 10 times. GO and STOP are defined as follows; The monitor will run whenever this DTC is not present. None GO: (Vehicle speed is 18.63 mph (30 km/h) or more) 18.7 mph (30 km/h) or more STOP: (Vehicle speed is less than 1.86 mph (3 km/h)) Less than 1.86 mph (3 km/h) Starter OFF Battery voltage 8 V or more Ignition switch ON TYPICAL MALFUNCTION THRESHOLDS Switch status ON stuck AX AX–78 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM WIRING DIAGRAM TCM AX 12 C56 ALT STP STOP A19 Stop Light Switch FL MAIN To Stop Light 8 C56 E1 Battery C133263E01 INSPECTION PROCEDURE 1 READ VALUE OF DATA LIST (STP SIGNAL) HINT: According to the DATA LIST displayed on the intelligent tester, you can read the value of switches, sensors, actuators and other items without removing any parts. Reading the DATA LIST as the first step in troubleshooting is one method to save labor time. (a) Turn the ignition switch off. (b) Connect the intelligent tester together with the CAN VIM (Controller Area Network Vehicle Interface Module) to the DLC3. (c) Turn the ignition switch on (IG). (d) Turn on the tester. (e) Enter the following items: "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". (f) According to the display on the tester, read "DATA LIST". Standard Item Measurement Item/ Range (display) STOP LIGHT SW Stop light switch status/ ON or OFF Normal Condition • • Brake pedal is depressed: ON Brake pedal is released: OFF AX–79 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM NOTICE: In the table above, the conditions listed under "Normal Condition" are reference conditions. Do not depend solely on these reference conditions when deciding whether a part is faulty. OK Go to step 3 AX NG 2 INSPECT STOP LIGHT SWITCH ASSEMBLY 2 Free Pushed In 4 1 3 I013683E16 (a) Remove the stop light switch assembly. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Switch Position Tester Connection Specified Condition Switch pin free 1-2 Below 1 Ω Switch pin pushed in 1-2 10 kΩ or higher Switch pin free 3-4 10 kΩ or higher Switch pin pushed in 3-4 Below 1 Ω NG REPLACE STOP LIGHT SWITCH ASSEMBLY OK 3 CHECK HARNESS AND CONNECTOR (STOP LIGHT SWITCH ASSEMBLY - TCM) (a) Install the stop light switch assembly. (b) Disconnect the TCM connector. (c) Measure the voltage according to the value(s) in the table below when the brake pedal is depressed and released. Standard voltage Wire Harness Side: TCM Connector (Front View) C56 STP Condition Tester Connection Specified Condition Brake pedal is depressed C56-12 (STP) - Body ground 10 to 14 V Brake pedal is released C56-12 (STP) - Body ground Below 1 V C133210E03 NG OK REPLACE TCM REPAIR OR REPLACE HARNESS OR CONNECTOR AX–80 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC P0741 Torque Converter Clutch Solenoid Performance (Shift Solenoid Valve SL) SYSTEM DESCRIPTION AX The TCM uses signals from the throttle position sensor, air-flow meter, turbine (input) speed sensor, intermediate (counter) speed sensor and crankshaft position sensor to help determine the engagement timing of the lock-up clutch. The TCM monitors the engagement of the clutch using the turbine (input) speed sensor, intermediate (counter) speed sensor and crankshaft position sensor. Then the TCM compares the engagement condition of the lock-up clutch with the lock-up schedule in the TCM memory to detect shift solenoid valve SL, valve body and torque converter clutch mechanical problems. DTC No. P0741 DTC Detection Condition When both of the following are detected (2-trip detection logic): • Lock-up does not occur when requested. • Transmission fluid pressure switch No. 3 is ON. Trouble Area • • • • • Shift solenoid valve SL remains closed Valve body is blocked Torque converter clutch Automatic transaxle (clutch, brake or gear etc.) Line pressure is too low MONITOR DESCRIPTION Torque converter lock-up is controlled by the TCM based on the speed sensor (NT), speed sensor (NC), engine rpm, engine load, engine temperature, vehicle speed, transmission fluid temperature, and gear selection. The TCM determines the lock-up status of the torque converter by comparing the engine rpm (NE) to the input turbine rpm (NT). The TCM calculates the actual transmission gear by comparing the input turbine rpm (NT) to the counter gear rpm (NC). When conditions are appropriate, the TCM requests "lock-up" by applying control voltage to the shift solenoid SL. When the SL is turned on, it applies pressure to the lock-up relay valve and locks the torque converter clutch. If the TCM detects no lock-up after lock-up has been requested or if it detects lock-up when it is not requested, the TCM interprets this as a fault in the shift solenoid valve SL or lock-up system performance. The TCM will turn on the MIL and store the DTC. HINT: Example: When any of the following is met, the system judges it as a malfunction. • There is a difference in rotation between the input side (engine speed) and output side (input turbine speed) of the torque converter when the TCM commands lock-up. (Engine speed is at least 70 rpm greater than the input turbine speed.) • There is no difference in rotation between the input side (engine speed) and output side (input turbine speed) of the torque converter when the TCM commands lock-up off. (The difference between the engine speed and input turbine speed is less than 20 rpm.) MONITOR STRATEGY Related DTCs P0741: Shift solenoid valve SL OFF malfunction Shift solenoid valve SL ON malfunction Required sensors/Components Shift solenoid valve SL, Speed sensor (NT), Speed sensor (NC), Crankshaft position sensor (NE), Throttle position sensor (VPA1), Mass air flow sensor (MAF), Transmission temperature sensor (THO1), Engine coolant temperature sensor (ECT) Frequency of operation Continuous Duration OFF malfunction 3.5 sec. MIL operation 2 driving cycles Sequence of operation None U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–81 TYPICAL ENABLING CONDITIONS ALL: The monitor will run whenever this DTC is not present. P0115 - P0118 (ECT sensor) P0125 (Insufficient ECT for closed loop) P0500 (VSS) P0748, P0778, P0798 (Shift solenoid valve (range)) ECT (Engine coolant temperature) 40°C (104°F) or more Transmission range "D" TFT (Transmission fluid temperature) -10°C (-14°F) or more TFT sensor circuit No circuit malfunction ECT sensor circuit No circuit malfunction Turbine speed sensor circuit No circuit malfunction Intermediate shaft speed sensor circuit No circuit malfunction Torque converter clutch circuit No circuit malfunction Knock control sensor circuit No circuit malfunction Shift solenoid valve SL1 circuit No circuit malfunction Shift solenoid valve SL2 circuit No circuit malfunction Shift solenoid valve SL3 circuit No circuit malfunction Shift solenoid valve SL4 circuit No circuit malfunction Shift solenoid valve SLU circuit No circuit malfunction CAN communication circuit No circuit malfunction Electronic throttle system No circuit malfunction TCM selected gear No 1st Vehicle speed 15.5 miles (25 km) Turbine speed/Output speed (NT/NO) with 1st 3.304 to 7.724 Turbine speed/Output speed (NT/NO) with 2nd 1.901 to 2.340 Turbine speed/Output speed (NT/NO) with 3rd 1.399 to 1.649 Turbine speed/Output speed (NT/NO) with 4th 0.998 to 1.138 Turbine speed/Output speed (NT/NO) with 5th 0.705 to 0.836 Turbine speed/Output speed (NT/NO) with 6th 0.568 to 0.695 TYPICAL MALFUNCTION THRESHOLDS OFF malfunction: Following conditions are met (a) and (b) (a) Engine Speed - Turbine speed 70 rpm or more (b) Transmission fluid pressure switch ON INSPECTION PROCEDURE HINT: Performing the ACTIVE TEST using the intelligent tester allows relays, VSVs, actuators and so on to operate without removing any parts. Performing the ACTIVE TEST as the first step in troubleshooting is one method to save labor time. It is possible to display the DATA LIST during the ACTIVE TEST. 1. PERFORM ACTIVE TEST (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester to the DLC3. (d) Turn the ignition switch on (IG). (e) Turn the intelligent tester on. (f) When using the intelligent tester: Enter the following items: "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST". AX AX–82 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM (g) According to the display on the tester, perform "ACTIVE TEST". Item LOCK UP AX Test Details Diagnostic Note [Test Details] Control the shift solenoid SL to set the automatic transaxle to the lockup condition. [Vehicle Condition] Vehicle Speed: 37 mph (60km/h) or more Possible to check the SL operation. HINT: • This test can be conducted when the vehicle speed is 37 mph (60km/h) or more. • This test can be conducted in the 5th gear. (h) Lightly depress the accelerator pedal and check that the engine speed does not change abruptly. HINT: • When changing the accelerator pedal opening angle while driving, if the engine speed does not change, lock-up is on. • Slowly release, but not fully, the accelerator pedal in order to decelerate. (Fully releasing the pedal will close the throttle valve and lock-up may be turned off.) Accelerator Pedal Opening Angle Accelerator Pedal Fully Released Lock-up OFF Engine speed Lock-up ON Time G029214E08 1 CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0741) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the intelligent tester on. (c) Enter the following items: "DIAGNOSIS / OBD/MOBD / ECT / DTC INFO / CURRENT CODES". (d) Read the DTCs using the intelligent tester. Result Display (DTC output) Proceed to Only "P0741" is output A "P0741" and other DTCs B HINT: If any other codes besides "P0741" are output, perform the troubleshooting for those DTCs first. B GO TO DTC CHART U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–83 A 2 CHECK TRANSMISSION WIRE (a) Remove the TCM from the transaxle. (b) Measure the resistance according to the value(s) in the table below. Standard resistance SL Tester Connection Specified Condition 20°C (68°F) 6 (SL) - Body ground 11 to 15 Ω OK Go to step 4 C133212E04 NG 3 CHECK SHIFT SOLENOID VALVE SL (RESISTANCE) (a) Remove the shift solenoid valve SL. (b) Measure the resistance according to the value(s) in the table below. Standard resistance C133217 OK REPLACE TRANSMISSION WIRE Tester Connection Specified Condition 20°C (68°F) Solenoid Connector (SL) - Solenoid Body (SL) 11 to 15 Ω NG REPLACE SHIFT SOLENOID VALVE SL AX AX–84 4 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM CHECK SHIFT SOLENOID VALVE SL (OPERATION) (a) Remove the shift solenoid valve SL. (b) Connect a positive (+) lead to the terminal of the solenoid connector, and a negative (-) lead to the solenoid body. OK: The solenoid valve makes an operating noise. AX NG REPLACE SHIFT SOLENOID VALVE SL C133218 OK 5 CHECK TRANSMISSION VALVE BODY ASSEMBLY OK: There are no foreign objects on each valve and they operate smoothly. NG REPLACE TRANSMISSION WIRE OK 6 CHECK TORQUE CONVERTER CLUTCH ASSEMBLY OK: The torque converter clutch operates normally. NG REPLACE TORQUE CONVERTER CLUTCH ASSEMBLY OK REPAIR OR REPLACE AUTOMATIC TRANSAXLE ASSEMBLY U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC P0746 AX–85 Pressure Control Solenoid "A" Performance (Shift Solenoid Valve SL1) SYSTEM DESCRIPTION The TCM uses the vehicle speed signal to determine the actual gear position (1st, 2nd, 3rd, 4th, 5th or 6th gear). Then the TCM compares the actual gear with the shift schedule in the TCM memory to detect mechanical problems of the shift solenoid valves and valve body. DTC No. P0746 DTC Detecting Condition The engine revs freely when 1st, 2nd, 3rd, or 4th gear is requested (2-trip detection logic). When either of the following is detected twice (2-trip detection logic): • When 5th gear is requested, 4th gear is engaged. • When 6th gear is requested, 4th gear is engaged Trouble Area • • • Shift solenoid valve SL1 remains open or closed Valve body is blocked Automatic transaxle (clutch, brake or gear etc.) MONITOR DESCRIPTION The TCM commands gear shifts by turning the shift solenoid valves on or off. According to the input shaft revolution, intermediate (counter) shaft revolution and output shaft revolution, the TCM detects the actual gear position (1st, 2nd, 3rd, 4th, 5th or 6th gear position). When the gear position commanded by the TCM and the actual gear position are not the same, the TCM illuminates the MIL. MONITOR STRATEGY Related DTCs P0746: Shift solenoid valve SL1 OFF malfunction Shift solenoid valve SL1 ON malfunction Required sensors/Components Shift solenoid valve SL1, Speed sensor (NT), Speed sensor (NC), Crankshaft position sensor (NE) Frequency of operation Continuous Duration ON malfunction: 0.8 sec. OFF malfunction: 0.5 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS ALL: The monitor will run whenever this DTC is not present. P0115 - P0118 (ECT sensor) P0125 (Insufficient ECT for closed loop) P0500 (VSS) P0748, P0778, P0798 (Shift solenoid valve (range)) Transmission range "D" TFT (Transmission fluid temperature) Above -10°C (14°F) ECT sensor circuit Circuit is not malfunctioning Turbine speed sensor circuit Circuit is not malfunctioning Intermediate shaft speed sensor circuit Circuit is not malfunctioning Knock control sensor circuit Circuit is not malfunctioning Shift solenoid valve SL1 circuit Circuit is not malfunctioning Shift solenoid valve SL2 circuit Circuit is not malfunctioning Shift solenoid valve SL3 circuit Circuit is not malfunctioning Shift solenoid valve SL4 circuit Circuit is not malfunctioning CAN communication circuit Circuit is not malfunctioning Electronic throttle system Circuit is not malfunctioning AX AX–86 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM OFF malfunction: TCM selected gear 1st, 2nd, 3rd or 4th TCM indicated pressure value of SL1 1,200 kPa Throttle valve opening angle 3% or more ON malfunction: AX TCM selected gear 5th or 6th Vehicle speed 1.2 mph (2 km/h) or more ETC (Engine coolant temperature) 40°C (104°F) or more Throttle valve opening angle 4.5% or more at engine speed 2,000 rpm (Varies with engine speed) TYPICAL MALFUNCTION THRESHOLDS Either of the following conditions is met: OFF malfunction: Turbine speed - Output speed x Gear ratio 1,000 or more ON malfunction: Input (turbine) speed/Intermediate shaft speed when output speed less than 1,000 rpm 0.998 to 1.138 INSPECTION PROCEDURE 1 CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0746) (a) Connect the intelligent tester to the DLC3. (b) Start the engine and turn the intelligent tester on. (c) Enter the following items: "DIAGNOSIS / OBD/MOBD / ECT / DTC INFO / CURRENT CODES". (d) Read the DTCs using the intelligent tester. Result Display (DTC output) Proceed to Only "P0746" is output A "P0746" and other DTCs B HINT: If a solenoid is stuck OFF, DTCs for several solenoids including the malfunctioning solenoid will be detected. A Go to step 3 B 2 PERFORM ACTIVE TEST BY SHIFT NOTICE: This test should always be performed with at least 2 people. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the intelligent tester on. (c) Enter the following items: "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST / SHIFT". AX–87 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM HINT: Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables confirmation of the problem (See page AX-39). Item Test Details Diagnostic Note SHIFT [Test Details] Operate the shift solenoid valve and set each shift position by yourself. [Others] • Press "←" button: Shift up • Press "→" button: Shift down Possible to check the operation of the shift solenoid valves. NOTICE: • This test can be conducted when the vehicle is stopped. • When shifting gears using the Active Test function, do not operate the accelerator pedal for 2 seconds before and after shifting gears. HINT: The shift position commanded by the TCM is shown in the DATA LIST/SHIFT display on the intelligent tester. (d) Check the vehicle speed and the gear position when the engine speed is 1,000 rpm. HINT: Because the torque converter clutch has not engaged, it may be difficult to obtain the speeds specified in 4th, 5th, and 6th gear, however a difference of speed should still be evident following each gear change. Standard 1st 2nd 3rd 4th 5th 6th 5 to 7.5 mph (8 to 12 km/h) 9.3 to 11.8 mph (15 to 19 km/h) 13.0 to 15.5 mph (21 to 25 km/h) 19.3 to 21.7 mph (31 to 35 km/h) 27.3 to 29.8 mph (44 to 48 km/h) 32.3 to 34.8 mph (52 to 56 km/h) (e) Compare the TCM gear shift command and the actual gear position. Result Actuator gear position under malfunction Shift solenoid SL1 Shift solenoid SL2 Shift solenoid SL3 2nd 3rd 4th Stuck ON 1st 2nd 3rd 4th 4th 4th Stuck OFF N*1 *1 N *1 N *1 N 5th 6th Stuck ON 4th 4th 4th 4th 5th 6th 1st *1 N N*1 Shift solenoid SLT 6th 1st 2nd Stuck ON 2nd 2nd 3rd 4th 5th 6th Stuck OFF 1st 1st 3rd 4th 5th N*1 3rd 3rd 3rd 4th 5th 5th Stuck OFF 1st 2nd 1st 4th N*1 6th Stuck ON N*2 N*2 N*2 N*2 N*2 N*2 1st 2nd 3rd 4th 5th 6th ON*3 Stuck OFF*3 3rd 5th Stuck OFF Stuck Shift solenoid SL4 TCM gear shift command 1st Proceed to A B C D E HINT: • *1: Neutral AX AX–88 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM • *2: If the shift solenoid SLT is stuck on, the line pressure will be low. Therefore, the amount of torque that can be transmitted by each gear is lower than the normal limit. When the engine power exceeds this lowered limit, the engine speed will increase freely. • *3: When shift solenoid SLT is stuck OFF, gear shifting is normal. AX B GO TO DTC CHART (RELATED SHIFT SOLENOID VALVE (SL2) PERFORMANCE DTC P0776) C GO TO DTC CHART (RELATED SHIFT SOLENOID VALVE (SL3) PERFORMANCE DTC P0796) D GO TO DTC CHART (RELATED SHIFT SOLENOID VALVE (SL4) PERFORMANCE DTC P2808) E GO TO DTC CHART (RELATED SHIFT SOLENOID VALVE (SLT) PERFORMANCE DTC P2714) A 3 INSPECT SHIFT SOLENOID VALVE (SL1) (a) Remove the shift solenoid valve SL1. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Shift Solenoid Valve SL1: 2 1 NG (-) (+) G020767E05 OK Specified Condition 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect a positive (+) lead through a 21 W bulb to terminal 2 and a negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating noise. 2 1 Tester Connection REPLACE SHIFT SOLENOID VALVE (SL1) U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM 4 AX–89 INSPECT TRANSMISSION VALVE BODY ASSEMBLY OK: There are no foreign objects on each valve and they operate smoothly. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK 5 INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY OK: The torque converter clutch operates normally. NG REPLACE TORQUE CONVERTER CLUTCH ASSEMBLY OK REPAIR OR REPLACE AUTOMATIC TRANSAXLE ASSEMBLY AX AX–90 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC P0748 Pressure Control Solenoid "A" Electrical (Shift Solenoid Valve SL1) DESCRIPTION AX Shifting from 1st to 6th is performed in combination with "ON" and "OFF" operation of the shift solenoid valves SL1, SL2, SL3, SL4 and SL which is controlled by the TCM. If an open or short circuit occurs in any of the shift solenoid valves, the TCM controls the remaining normal shift solenoid valves to allow the vehicle to be operated smoothly (See page AX-39). DTC No. P0748 DTC Detection Condition The TCM checks for an open or short in the shift solenoid valve SL1 circuit while driving and shifting between 4th and 5th gears. (1-trip detection logic) • Output signal duty equals 100%. (NOTE: SL1 output signal duty is less than 100% under normal condition.) Trouble Area • • • Open or short in shift solenoid valve SL1 circuit Shift solenoid valve SL1 TCM MONITOR DESCRIPTION This DTC indicates an open or short in the shift solenoid valve SL1 circuit. The TCM causes gear shifts to occur by turning the shift solenoid valves on or off. When there is an open or short circuit in any shift solenoid valve circuit, the TCM detects the problem and illuminates the MIL and stores the DTC. The TCM also performs the fail-safe function and turns the other normal shift solenoid valves on or off. (In case of an open or short circuit, the TCM stops sending current to the circuit.) While driving and shifting between 4th and 5th gears, if the TCM detects an open or short in the shift solenoid valve SL1 circuit, the TCM determines there is a malfunction (See page AX-39). MONITOR STRATEGY Related DTCs P0748: Shift solenoid valve SL1/Range check Required sensors/Components Shift solenoid valve SL1 Frequency of operation Continuous Duration 1 sec. MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS ALL: The monitor will run whenever this DTC is not present None Ignition switch ON Starter OFF Malfunction (A): Battery voltage 12 V or more Malfunction (B): Battery voltage 10 V or more and less than 12 V CPU commanded duty Less than 75% TYPICAL MALFUNCTION THRESHOLDS Output signal duty 100% or more AX–91 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM WIRING DIAGRAM TCM AX +B SL1+ Shift Solenoid Valve SL1 SL1- Transaxle Assembly C133261E01 INSPECTION PROCEDURE HINT: The shift solenoid valve SL1 is turned on or off automatically normally when the shift lever is in the D position: TCM command gearshift 1st 2nd 3rd 4th 5th 6th Shift solenoid valve SL1 ON ON ON ON OFF OFF AX–92 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM 1 INSPECT TRANSMISSION WIRE (SL1) SL1+ AX (a) Remove the TCM from the transaxle. (b) Measure the resistance according to the value(s) in the table below. Standard resistance SL1- Tester Connection Specified Condition 20°C (68°F) 14 (SL1+) - 13 (SL1-) 5.0 to 5.6 Ω (c) Measure the resistance according to the value(s) in the table below. Standard resistance: Check for short Tester Connection C133212E02 OK Specified Condition 14 (SL1+) - Body ground 10 kΩ or higher 13 (SL1-) - Body ground 10 kΩ or higher REPLACE TCM NG 2 INSPECT SHIFT SOLENOID VALVE SL1 (a) Remove the shift solenoid valve SL1. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Shift Solenoid Valve SL1: 2 1 NG (-) Specified Condition 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect a positive (+) lead through a 21 W bulb to terminal 2 and a negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. 2 1 Tester Connection (+) G020767E05 OK REPLACE TRANSMISSION WIRE REPLACE SHIFT SOLENOID VALVE SL1 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC P0776 AX–93 Pressure Control Solenoid "B" Performance (Shift Solenoid Valve SL2) SYSTEM DESCRIPTION The TCM uses the vehicle speed signal to detect the actual gear position (1st, 2nd, 3rd, 4th, 5th or 6th gear). Then the TCM compares the actual gear with the shift schedule in the TCM memory to detect shift solenoid valves and valve body mechanical problems. DTC No. DTC Detecting Condition P0776 The engine revs freely when 4th, 5th, or 6th gear is requested (2-trip detection logic). When any of the following is detected twice (2-trip detection logic): • When 1st gear is requested, 4th gear is engaged. • When 2nd gear is requested, 4th gear is engaged. • When 3rd gear is requested, 4th gear is engaged. Trouble Area • • • Shift solenoid valve SL2 remains open or closed Valve body is blocked Automatic transaxle (clutch, brake or gear etc.) MONITOR DESCRIPTION The TCM commands gear shifts by turning the shift solenoid valves on or off. According to the input shaft revolution, intermediate (counter) shaft revolution and output shaft revolution, the TCM detects the actual gear position (1st, 2nd, 3rd, 4th, 5th or 6th gear position). When the gear position commanded by the TCM and the actual gear position are not the same, the TCM illuminates the MIL and stores the DTC. MONITOR STRATEGY Related DTCs P0776: Shift solenoid valve SL2/OFF malfunction Shift solenoid valve SL2/ON malfunction Required sensors/Components Shift solenoid valve SL2, Speed sensor (NT), Speed sensor (NC), Crankshaft position sensor (NE) Frequency of operation Continuous Duration OFF malfunction 0.5 sec. ON malfunction 0.8 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever this DTC is not present. P0115 - P0118 (ECT sensor) P0125 (Insufficient ECT for closed loop) P0500 (VSS) P0748, P0778, P0798 (Shift solenoid valve (range)) Transmission range "D" TFT (Transmission fluid temperature) Above -10°C (-14°F) Knock control sensor circuit Circuit is not malfunctioning ECT sensor circuit Circuit is not malfunctioning Turbine speed sensor circuit Circuit is not malfunctioning Intermediate shaft speed sensor circuit Circuit is not malfunctioning Shift solenoid valve SL1 circuit Circuit is not malfunctioning Shift solenoid valve SL2 circuit Circuit is not malfunctioning Shift solenoid valve SL3 circuit Circuit is not malfunctioning Shift solenoid valve SL4 circuit Circuit is not malfunctioning AX AX–94 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM CAN communication system Circuit is not malfunctioning Electronic throttle system Circuit is not malfunctioning OFF malfunction: TCM selected gear AX 4th, 5th or 6th TCM indicated pressure value of SL2 1,200 kPa Throttle valve opening angle 3% or more ON malfunction (A): TCM selected gear 1st Vehicle speed 1.2 mph (2 km/h) to 25 mph (40 km/h) Vehicle speed 1.2 mph (2 km/h) or more ECT (Engine coolant temperature) Above 40°C (104°F) Engine speed - Turbine speed 50 rpm or more ON malfunction (B): TCM selected gear 2nd Throttle valve opening angle 4.5% or more at engine speed 2,000 rpm (Varies with engine speed) Vehicle speed 1.2 mph (2 km/h) or more ECT (Engine coolant temperature) Above 40°C (104°F) ON malfunction (C): TCM selected gear 3rd Throttle valve opening angle 4.5% or more at engine speed 2,000 rpm (Varies with engine speed) Vehicle speed 1.2 mph (2 km/h) or more ECT (Engine coolant temperature) Above 40°C (104°F) ECT (Engine coolant temperature) 40°C (104°F) or more TYPICAL MALFUNCTION THRESHOLDS OFF malfunction: Input (turbine) speed-Intermediate shaft speed x Gear ratio 1,000 rpm or more ON malfunction: Input (turbine) speed/Intermediate shaft speed when output speed less than 1,000 rpm 0.998 to 1.138 INSPECTION PROCEDURE 1 CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0776) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the intelligent tester on. (c) Enter the following items: "DIAGNOSIS / OBD/MOBD / ECT / DTC INFO / CURRENT CODES". (d) Read the DTCs using the intelligent tester. Result Display (DTC output) Proceed to Only "P0776" is output A "P0776" and other DTCs B AX–95 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM HINT: If a solenoid is stuck OFF, DTCs for several solenoids including the malfunctioning solenoid will be detected. A Go to step 3 B 2 AX PERFORM ACTIVE TEST BY INTELLIGENT TESTER NOTICE: This test should always be performed with at least 2 people. (a) Connect the intelligent tester to the DLC3. (b) Start the engine and turn the intelligent tester on. (c) Enter the following items: "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST / SHIFT". HINT: Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables confirm of the problem (See page AX-39). Item SHIFT Test Details Diagnostic Note [Test Details] Operate the shift solenoid valve and set each shift position by yourself. [Others] • Press "←" button: Shift up • Press "→" button: Shift down Possible to check the operation of the shift solenoid valves. NOTICE: • This test can be conducted when the vehicle is stopped. • When shifting gears using the Active Test function, do not operate the accelerator pedal for 2 seconds before and after shifting gears. HINT: The shift position commanded by the TCM is shown in the DATA LIST/SHIFT display on the intelligent tester. (d) Check the vehicle speed and the gear position when the engine speed is 1,000 rpm. HINT: Because the torque converter clutch has not engaged, it may be difficult to obtain the speeds specified in 4th, 5th, and 6th gear, however a difference of speed should still be evident following each gear change. Standard 1st 2nd 3rd 4th 5th 6th 5 to 7.5 mph (8 to 12 km/h) 9.3 to 11.8 mph (15 to 19 km/h) 13.0 to 15.5 mph (21 to 25 km/h) 19.3 to 21.7 mph (31 to 35 km/h) 27.3 to 29.8 mph (44 to 48 km/h) 32.3 to 34.8 mph (52 to 56 km/h) (e) Compare the TCM gear shift command and the actual gear position. AX–96 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Result Actuator gear position under malfunction Shift solenoid SL1 AX Shift solenoid SL2 Shift solenoid SL3 1st 2nd 3rd 4th 5th 6th Stuck ON 1st 2nd 3rd 4th 4th 4th Stuck OFF N*1 N*1 N*1 N*1 5th 6th Stuck ON 4th 4th 4th 4th 5th 6th *1 N*1 Stuck OFF 1st 2nd 3rd 1st N Stuck ON 2nd 2nd 3rd 4th 5th 6th Stuck OFF 1st 1st 3rd 4th 5th N*1 3rd 3rd 3rd 4th 5th 5th 6th Stuck Shift solenoid SL4 ON*3 Stuck OFF Stuck ON Shift solenoid SLT TCM gear shift command Stuck *3 OFF Proceed to A B C D 1st 2nd 1st 4th N*1 *2 *2 *2 *2 *2 N*2 5th 6th N N N N N E 1st 2nd 3rd 4th HINT: • *1: Neutral • *2: If the shift solenoid SLT is stuck on, the line pressure will be low. Therefore, the amount of torque that can be transmitted by each gear is lower than the normal limit. When the engine power exceeds this lowered limit, the engine speed will increase freely. • *3: When shift solenoid SLT is stuck OFF, gear shifting is normal. B A GO TO DTC CHART (RELATED SHIFT SOLENOID VALVE (SL1) PERFORMANCE DTC P0746) C GO TO DTC CHART (RELATED SHIFT SOLENOID VALVE (SL3) PERFORMANCE DTC P0796) D GO TO DTC CHART (RELATED SHIFT SOLENOID VALVE (SL4) PERFORMANCE DTC P2808) E GO TO DTC CHART (RELATED SHIFT SOLENOID VALVE (SLT) PERFORMANCE DTC P2714) U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM 3 AX–97 INSPECT SHIFT SOLENOID VALVE (SL2) (a) Remove the shift solenoid valve SL2. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Shift Solenoid Valve SL2: 2 1 Specified Condition 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect a positive (+) lead through a 21 W bulb to terminal 2 and a negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating noise. 2 1 Tester Connection NG (-) REPLACE SHIFT SOLENOID VALVE (SL2) (+) G020767E28 OK 4 INSPECT TRANSMISSION VALVE BODY ASSEMBLY OK: There are no foreign objects on each valve and they operate smoothly. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK 5 INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY OK: The torque converter clutch operates normally. NG OK REPLACE AUTOMATIC TRANSAXLE ASSEMBLY REPLACE TORQUE CONVERTER CLUTCH ASSEMBLY AX AX–98 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC P0778 Pressure Control Solenoid "B" Electrical (Shift Solenoid Valve SL2) DESCRIPTION AX Shifting from 1st to 6th is performed in combination with "ON" and "OFF" operation of the shift solenoid valves SL1, SL2, SL3, SL4 and SL which is controlled by the TCM. If an open or short circuit occurs in any of the shift solenoid valves, the TCM controls the remaining normal shift solenoid valve to allow the vehicle to be operated smoothly (See page AX-39). DTC No. P0778 DTC Detection Condition The TCM checks for an open or short in the shift solenoid valve SL2 circuit while driving and shifting gears. (1-trip detection logic) • Output signal duty equals to 100%. (NOTE: SL2 output signal duty is less than 100% under normal condition.) Trouble Area • • • Open or short in shift solenoid valve SL2 circuit Shift solenoid valve SL2 TCM MONITOR DESCRIPTION This DTC indicates an open or short in the shift solenoid valve SL2 circuit. The TCM commands gear shifts by turning the shift solenoid valves on or off. When there is an open or short circuit in any of the shift solenoid valve circuits, the TCM detects the problem and illuminates the MIL and stores the DTC. The TCM also performs the fail-safe function and turns the other normal shift solenoid valves on or off. (In case of an open or short circuit, the TCM stops sending current to the circuit.) While driving and shifting gears, if the TCM detects an open or short in the shift solenoid valve SL2 circuit, the TCM determines there is a malfunction (See page AX-39). MONITOR STRATEGY Related DTCs P0778: Shift solenoid valve SL2/Range check Required sensors/Components Shift solenoid valve SL2 Frequency of operation Continuous Duration 1 sec. MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS ALL: The monitor will run whenever this DTC is not present None Ignition switch ON Starter OFF Malfunction (A): Battery voltage 12 V or more Malfunction (B): Battery voltage 10 V or more and less than 12 V CPU commanded duty Less than 75% TYPICAL MALFUNCTION THRESHOLDS Output signal duty 100% or more AX–99 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM WIRING DIAGRAM TCM AX +B SL2+ Shift Solenoid Valve SL2 SL2- Transaxle Assembly C133261E03 INSPECTION PROCEDURE HINT: The shift solenoid valve SL2 is turned on or off automatically when the shift lever is in the D position: TCM command gearshift 1st 2nd 3rd 4th 5th 6th Shift solenoid valve SL2 OFF OFF OFF ON ON ON AX–100 1 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM INSPECT TRANSMISSION WIRE (SL2) SL2+ AX (a) Remove the TCM from the transaxle. (b) Measure the resistance according to the value(s) in the table below. Standard resistance SL2- Tester Connection Specified Condition 20°C (68°F) 9 (SL2+) - 8 (SL2-) 5.0 to 5.6 Ω (c) Measure the resistance according to the value(s) in the table below. Standard resistance: Check for short C133212E03 OK Tester Connection Specified Condition 9 (SL2+) - Body ground 10 kΩ or higher 8 (SL2-) - Body ground 10 kΩ or higher REPLACE TCM NG 2 INSPECT SHIFT SOLENOID SL2 (a) Remove the shift solenoid valve SL2. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Shift Solenoid Valve SL2: 2 1 NG (-) Specified Condition 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect a positive (+) lead through a 21 W bulb to terminal 2 and a negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. 2 1 Tester Connection (+) G020767E07 OK REPAIR OR REPLACE TRANSMISSION WIRE REPLACE SHIFT SOLENOID SL2 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–101 DTC P0791 Intermediate Shaft Speed Sensor "A" Circuit DTC P0793 Intermediate Shaft Speed Sensor "A" DESCRIPTION This sensor detects the rotation speed of the turbine which shows the input speed of transaxle. By comparing the input turbine speed signal (NC) with the counter gear speed sensor signal (NC), the TCM detects the shift timing of the gears and appropriately controls the engine torque and hydraulic pressure according to various conditions, thus, providing smooth gear shift. Clutch Drum Counter Gear Input Speed Sensor NT Output Speed Sensor NC C133216E01 DTC No. DTC Detection Condition P0791 When the speed sensor input voltage is either more than 1.9 V or less than 0.1 V for 2 seconds or more. P0793 When the vehicle speed is 15.5 mph (25 km/h) or higher, the counter gear speed is less than 300 rpm for 2 seconds or more. Trouble Area • • Transmission revolution sensor (speed sensor NC) TCM MONITOR DESCRIPTION The NT terminal of the TCM detects a revolution signal from the speed sensor (NT) (input RPM). The TCM calculates a gearshift comparing the speed sensor (NT) with the speed sensor (NC). While the vehicle is operating in 2nd, 3rd, 4th or 5th gear in the shift position of D, if the input shaft revolution is less than 300 rpm *1although the output shaft revolution is more than 1,000 rpm *2, the TCM interprets this as a fault, illuminates the MIL and stores the DTC. *1: Pulse is not output or is irregularly output. *2: The vehicle speed is 31 mph (50 km/h) or more. MONITOR STRATEGY Related DTCs P0717: Speed sensor (NT) /Verify pulse input Required sensors/Components Speed sensor (NT), Speed sensor (NC) Frequency of operation Continuous AX AX–102 AX U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Duration 5 sec. MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present. P0500 (VSS) P0748, P0778, P0798 (Shift solenoid valve (range)) Vehicle speed 15.5 mph (25 km/h) or more Battery voltage 8 V or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS P0791: Sensor voltage Less than 0.1 V or more than 1.9 V P0793: Sensor signal rpm Less than 300 rpm WIRING DIAGRAM TCM NCB NCO Speed Sensor (NT) Transaxle Assembly C133260E06 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–103 INSPECTION PROCEDURE 1. DATA LIST NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty. HINT: According to the DATA LIST displayed on the intelligent tester, you can read the value of switches, sensors, actuators and other items without removing any parts. Reading the DATA LIST as the first step in troubleshooting is one method to save labor time. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester together with the CAN VIM (Controller Area Network Vehicle Interface Module) to the DLC3. (d) Turn the ignition switch on (IG). (e) Turn on the tester. (f) Enter the following items: "DIAGNOSIS / ENHANCED OBD / DATA LIST". (g) According to the display on the tester, read "DATA LIST". Item SPD (NC) Measurement Item/ Range (display) Counter Gear Speed/ display: 50 r/min Normal Condition HINT: • Lock-up ON (after warming up the engine); input turbine speed (NC) is equal to the engine speed. • Lock-up OFF (Idling at N position); input turbine speed (NC) is nearly equal to the engine speed. HINT: • SPD (NC) is always 0 while driving: Open or short in the sensor or circuit. • SPD (NC) is always more than 0 and less than 300 rpm while driving the vehicle at 31 mph (50 km/h) or more: Sensor trouble, improper installation, or intermittent connection trouble of the circuit. 1 INSPECT SPEED SENSOR (SENSOR INSTALLATION) (a) Make sure that the connector is properly connected, and check the speed sensor installation. OK: The installation bolts are tightened properly and there is no clearance between the sensor and transaxle case. NG C133219 OK REPAIR OR REPLACE SPEED SENSOR AX AX–104 2 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM CHECK TRANSMISSION WIRE (a) Remove the TCM. (b) Disconnect the speed sensor connector from the transmission wire. (c) Measure the resistance according to the value(s) in the table below. Standard resistance TCM Side Connector AX Tester Condition NCO NCB Sensor Side Connector NCO Specified Condition NCO - NCO Below 1 Ω NCB - NCB Below 1 Ω NCO - NCB 10 kΩ or higher NG REPLACE TRANSMISSION WIRE NCB C133270E02 OK 3 REPLACE SPEED SENSOR NEXT 4 CHECK IF DTC OUTPUT RECURS (SEE IF DTC P0791 AND/OR P0793 IS OUTPUT AGAIN) (a) Connect the intelligent tester to the DLC3. (b) Start the engine and turn the intelligent tester main switch ON. (c) Perform the monitor drive pattern (See page AX-27). (d) When you use the intelligent tester: Select the item "DIAGNOSIS / OBD/MOBD / ECT / DTC INFO / CURRENT CODES". (e) Read the DTCs using the intelligent tester. Result Display (DTC output) Proceed to Only "P0791 or P0793" is output A No outpur B B END U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–105 A REPLACE TCM AX AX–106 DTC U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM P0796 Pressure Control Solenoid "C" Performance (Shift Solenoid Valve SL3) SYSTEM DESCRIPTION AX The TCM uses the vehicle speed signal to determine the actual gear position (1st, 2nd, 3rd, 4th, 5th or 6th gear). Then the TCM compares the actual gear with the shift schedule in the TCM memory to detect shift solenoid valves and valve body mechanical problems. DTC No. DTC Detecting Condition P0796 The engine revs freely when 2nd or 6th gear is requested (2-trip detection logic). When the following is detected twice (2-trip detection logic): • When 1st gear is requested, 2nd gear is engaged. Trouble Area • • • Shift solenoid valve SL3 remains open or closed. Valve body is blocked. Automatic transaxle (clutch, brake or gear etc.) MONITOR DESCRIPTION The TCM commands gear shifts by turning the shift solenoid valves on or off. According to the input shaft revolution, intermediate (counter) shaft revolution and output shaft revolution, the TCM detects the actual gear position (1st, 2nd, 3rd, 4th, 5th or 6th gear position). When the gear position commanded by the TCM and the actual gear position are not the same, the TCM illuminates the MIL and stores the DTC. MONITOR STRATEGY Related DTCs P0796: Shift solenoid valve SL3/OFF malfunction Shift solenoid valve SL3/ON malfunction Required sensors/Components Shift solenoid valve SL3, Speed sensor (NT), Speed sensor (NC), Crankshaft position sensor (NE) Frequency of operation Continuous Duration OFF malfunction (A) and (B) 0.5 sec. OFF malfunction (C) and (D) 0.8 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever this DTC is not present. P0115 - P0118 (ECT sensor) P0125 (Insufficient ECT for closed loop) P0500 (VSS) P0748, P0778, P0798 (Shift solenoid valve (range)) Transmission range "D" TFT (Transmission fluid temperature) Above -10°C (-14°F) Knock control sensor circuit Circuit is not malfunctioning ECT sensor circuit Circuit is not malfunctioning Turbine speed sensor circuit Circuit is not malfunctioning Intermediate shaft speed sensor circuit Circuit is not malfunctioning Shift solenoid valve SL1 circuit Circuit is not malfunctioning Shift solenoid valve SL2 circuit Circuit is not malfunctioning Shift solenoid valve SL3 circuit Circuit is not malfunctioning Shift solenoid valve SL4 circuit Circuit is not malfunctioning CAN communication system Circuit is not malfunctioning U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Electronic throttle system AX–107 Circuit is not malfunctioning OFF malfunction (A): TCM selected gear 2nd Throttle valve opening angle 3% or more TCM indicated pressure value of SL1 1,200 kPa TCM indicated pressure value of SL2 0 kPa TCM indicated pressure value of SL3 1,200 kPa OFF malfunction (B): TCM selected gear 6th Throttle valve opening angle 3% or more TCM indicated pressure value of SL1 0 kPa TCM indicated pressure value of SL2 1,200 kPa TCM indicated pressure value of SL3 1,200 kPa OFF malfunction (C): TCM selected gear 2nd Throttle valve opening angle: (When condition "D" is not detected) 4.5% or more at engine speed 2,000 rpm (condition varies with engine speed) (When condition "D" is detected) 0.5% or more at engine speed 500 rpm (condition varies with engine speed) ECT (engine coolant temperature) 40°C (104°F) or more OFF malfunction (D): Throttle valve opening angle 0.5% or more at engine speed 500 rpm (condition varies with engine speed) ON malfunction: TCM selected gear 1st Vehicle speed 1.2 mph (2 km/h) or more Engine speed - Turbine speed 50 rpm or more ECT (engine coolant temperature) Above 40°C (104°F) TYPICAL MALFUNCTION THRESHOLDS Either of the following conditions is met: OFF malfunction (A) or (B) or ((C) and (D)), or ON malfunctions 2 detections are necessary per driving cycle: 1st detection; temporary flag ON 2nd detection; pending fault code ON OFF malfunction (A): Turbine speed - Output speed x 2nd gear ratio 1,000 rpm or more OFF malfunction (B): Turbine speed - Output speed x 6th gear ratio 1,000 rpm or more OFF malfunction (C): Input (turbine) speed/Intermediate shaft speed 3.304 to 7.724 OFF malfunction (D): Input (turbine) speed/Intermediate shaft speed 3.304 to 7.724 ON malfunction: Input (turbine) speed/Intermediate shaft speed 1.901 to 2.340 AX AX–108 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM INSPECTION PROCEDURE 1 CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0796) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the intelligent tester on. (c) Enter the following items: "DIAGNOSIS / OBD/MOBD / ECT / DTC INFO / CURRENT CODES". (d) Read the DTCs using the intelligent tester. AX Result Display (DTC output) Proceed to Only "P0796" is output A "P0796" and other DTCs B HINT: If a solenoid is stuck OFF , DTCs for several solenoids including the malfunctioning solenoid will be detected. A Go to step 3 B 2 PERFORM ACTIVE TEST BY INTELLIGENT TESTER NOTICE: This test should always be performed with at least 2 people. (a) Connect the intelligent tester to the DLC3. (b) Start the engine and turn the intelligent tester on. (c) Enter the following items: "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST / SHIFT". HINT: Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem (See page AX-39). Item SHIFT Test Details [Test Details] Operate the shift solenoid valve and set each shift position by yourself. [Others] • Press "←" button: Shift up • Press "→" button: Shift down Diagnostic Note Possible to check the operation of the shift solenoid valves. NOTICE: • This test can be conducted when the vehicle is stopped. • When shifting gears using the Active Test function, do not operate the accelerator pedal for 2 seconds before and after shifting gears. HINT: The shift position commanded by the TCM is shown in the DATA LIST/SHIFT display on the intelligent tester. (d) Check the vehicle speed and the gear position when the engine speed is 1,000 rpm. U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–109 HINT: Because the torque converter clutch has not engaged, it may be difficult to obtain the speeds specified in 4th, 5th, and 6th gear, however a difference of speed should still be evident following each gear change. Standard 1st 2nd 3rd 4th 5th 6th 5 to 7.5 mph (8 to 12 km/h) 9.3 to 11.8 mph (15 to 19 km/h) 13.0 to 15.5 mph (21 to 25 km/h) 19.3 to 21.7 mph (31 to 35 km/h) 27.3 to 29.8 mph (44 to 48 km/h) 32.3 to 34.8 mph (52 to 56 km/h) (e) Compare the TCM gear shift command and the actual gear position. Result Actuator gear position under malfunction Shift solenoid SL1 Shift solenoid SL2 Shift solenoid SL3 1st 2nd 3rd 4th 5th 6th Stuck ON 1st 2nd 3rd 4th 4th 4th Stuck OFF N*1 N*1 N*1 N*1 5th 6th Stuck ON 4th 4th 4th 4th 5th 6th N*1 Stuck OFF 1st 2nd 3rd 1st N*1 Stuck ON 2nd 2nd 3rd 4th 5th 6th Stuck OFF 1st 1st 3rd 4th 5th N*1 3rd 3rd 3rd 4th 5th 5th *1 6th *2 Stuck Shift solenoid SL4 ON*3 Stuck OFF Stuck ON Shift solenoid SLT TCM gear shift command Stuck OFF*3 Proceed to A B C D 1st 2nd 1st 4th *2 *2 *2 *2 N N N N N N N*2 1st 2nd 3rd 4th 5th 6th E HINT: • *1: Neutral • *2: If the shift solenoid SLT is stuck on, the line pressure will be low. Therefore, the amount of torque that can be transmitted by each gear is lower than the normal limit. When the engine power exceeds this lowered limit, the engine speed will increase freely. • *3: When shift solenoid SLT is stuck OFF, gear shifting is normal. A GO TO DTC CHART (RELATED SHIFT SOLENOID VALVE (SL1) PERFORMANCE DTC P0746) B GO TO DTC CHART (RELATED SHIFT SOLENOID VAVLE (SL2) PERFORMANCE DTC P0776) D GO TO DTC CHART (RELATED SHIFT SOLENOID VALVE (SL4) PERFORMANCE DTC P2808) E GO TO DTC CHART (RELATED SHIFT SOLENOID VAVLE (SLT) PERFORMANCE DTC P2714) AX AX–110 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM C 3 AX INSPECT SHIFT SOLENOID VALVE (SL3) (a) Remove the shift solenoid valve SL3. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Shift Solenoid Valve SL3: 2 1 Specified Condition 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect a positive (+) lead through a 21 W bulb to terminal 2 and a negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating noise. 2 1 Tester Connection NG (-) REPLACE SHIFT SOLENOID VALVE (SL3) (+) G020767E29 OK 4 INSPECT TRANSMISSION VALVE BODY ASSEMBLY OK: There are no foreign objects on each valve and they operate smoothly. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK 5 INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY OK: The torque converter clutch operates normally. NG OK REPLACE AUTOMATIC TRANSAXLE ASSEMBLY REPLACE TORQUE CONVERTER CLUTCH ASSEMBLY U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC P0798 AX–111 Pressure Control Solenoid "C" Electrical (Shift Solenoid Valve SL3) DESCRIPTION Shifting gears from 1st through 5th is performed in combination with "ON" and "OFF" operation of the shift solenoid valves SL1, SL2, SL3 and SL4 which are controlled by the TCM. If an open or short circuit occurs in any of the shift solenoid valves, the TCM controls the remaining normal shift solenoid valves to allow the vehicle to be operated smoothly (Fail safe function). DTC No. P0798 DTC Detecting Condition The TCM checks for an open or short in the shift solenoid valve SL3 circuit while driving and shifting gears. (1-trip detection logic) • Output signal duty equals to 100%. (NOTE: SL3 output signal duty is less than 100% under normal condition.) Trouble Area • • • Open or short in shift solenoid valve SL3 circuit Shift solenoid valve SL3 TCM MONITOR DESCRIPTION The TCM commands gear shifts by turning the shift solenoid valves on or off. When there is an open or short circuit in any shift solenoid valve circuit, the TCM detects the problem and illuminates the MIL and stores the DTC. And the TCM performs the fail-safe function and turns the other normal shift solenoid valves on or off (In case of an open or short circuit, the TCM stops sending current to the circuit.) (See page AX-39). MONITOR STRATEGY Related DTCs P0798: Shift solenoid valve SL3/Range check Required sensors/Components Shift solenoid valve SL3 Frequency of operation Continuous Duration 1 sec. MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS ALL: The monitor will run whenever this DTC is not present None Ignition switch ON Starter OFF Malfunction (A): Battery voltage 12 V or more Malfunction (B): Battery voltage 10 V or more and less than 12 V CPU commanded duty Less than 75% TYPICAL MALFUNCTION THRESHOLDS Output signal duty 100% COMPONENT OPERATING RANGE Output signal duty Less than 100% AX A X – 11 2 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM WIRING DIAGRAM TCM AX +B SL3+ Shift Solenoid Valve SL3 SL3- Transaxle Assembly C133261E04 INSPECTION PROCEDURE 1 INSPECT TRANSMISSION WIRE (SL3) SL3+ (a) Remove the TCM from the transaxle. (b) Measure the resistance according to the value(s) in the table below. Standard resistance SL3- Tester Connection Specified Condition 20°C (68°F) 16 (SL3+) - 15 (SL3-) 5.0 to 5.6 Ω (c) Measure the resistance according to the value(s) in the table below. Standard resistance: Check for short C133212E05 OK Tester Connection Specified Condition 16 (SL3+) - Body ground 10 kΩ or higher 15 (SL3-) - Body ground 10 kΩ or higher REPLACE TCM U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–113 NG 2 INSPECT SHIFT SOLENOID VALVE (SL3) (a) Remove the shift solenoid valve SL3. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Shift Solenoid Valve SL3: 2 1 NG (-) Specified Condition 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect a positive (+) lead throgh a 21 W bulb to terminal 2 and a negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating noise. 2 1 Tester Connection (+) G020767E29 OK REPLACE TRANSMISSION WIRE REPLACE SHIFT SOLENOID VALVE (SL3) AX AX–114 AX U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC P0872 Transmission Fluid Pressure Switch No.1 Circuit Low DTC P0873 Transmission Fluid Pressure Switch No.1 Circuit High DESCRIPTION ATF pressure switch No. 1 is installed in the shift solenoid valve ATF output passage. This switch is used to identify the malfunctioning part when a fail-safe operation is performed. If the shift solenoid valve malfunctions when the ATF pressure switch has a malfunction, a fail-safe operation will be performed. This fail-safe operation is different from the fail-safe operation performed when the solenoid valve malfunctions and the ATF pressure switch is normal. DTC No. DTC Detecting Condition P0872 ATF pressure switch No. 1 OFF is detected twice when any of the gears from 1st to 4th engages normally. Trouble Area • P0873 ATF pressure switch No. 1 ON is detected twice when 5th or 6th gear engages normally. • • ATF temperature sensor assembly (ATF pressure switch No. 1) Transmission wire TCM WIRING DIAGRAM TCM TSP1 ATF Pressure Switch No.1 Transaxle Assembly C133258E01 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–115 INSPECTION PROCEDURE 1 CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P0872 OR P0873) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the intelligent tester on. (c) Enter the following items: "DIAGNOSIS / OBD/MOBD / ECT / DTC INFO / CURRENT CODES". (d) Read the DTCs using the intelligent tester. Result Display (DTC output) Proceed to Only "P0873" is output A Only "P0872" is output B "P0872 or P0873" and other DTCs C HINT: If a solenoid is stuck OFF, DTCs for several solenoids including the malfunctioning solenoid will be detected. B Go to step 4 C GO TO DTC CHART A 2 CHECK TRANSMISSION WIRE (SHORT TO GROUND) (a) Remove the TCM. (b) Measure the resistance according to the value(s) in the table below. Standard resistance TPS1 Tester Condition Specified Condition 10 (TPS1) - Body ground (Valve body assembly) 10 kΩ or higher OK C133212E10 NG REPLACE TCM AX AX–116 3 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM CHECK ATF TEMPERATURE SENSOR ASSEMBLY (ATF PRESSURE SWITCH NO. 1) (a) Disconnect the transmission wire connector from the ATF temperature sensor assembly. (b) Measure the resistance according to the value(s) in the table below. Standard resistance AX TPS1 Tester Condition Specified Condition 3 (TPS1) - Body ground (Valve body assembly) 10 kΩ or higher NG C142707E01 OK REPLACE TRANSMISSION WIRE REPLACE ATF TEMPERATURE SENSOR ASSEMBLY AX–117 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM 4 CHECK TRANSMISSION WIRE (a) Remove the TCM. (b) Disconnect the connector from the ATF temperature sensor assembly. (c) Measure the resistance according to the value(s) in the table below. Standard resistance TCM Side Connector Tester Condition Specified Condition 10 (TPS1) - 3 (TPS1) Below 1 Ω 10 (TPS1) or 3 (TPS1) - Body ground (Valve body assembly) 10 kΩ or higher TPS1 NG Sensor Side Connector REPLACE TRANSMISSION WIRE TPS1 C133269E01 OK REPLACE ATF TEMPERATURE SENSOR ASSEMBLY AX AX–118 AX U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC P0877 Transmission Fluid Pressure Switch No.2 Circuit Low DTC P0878 Transmission Fluid Pressure Switch No.2 Circuit High DESCRIPTION ATF pressure switch No. 2 is installed in the shift solenoid valve ATF output passage. This switch is used to identify the malfunctioning part when a fail-safe operation is performed. If the shift solenoid valve malfunctions when the ATF pressure switch has a malfunction, a fail-safe operation will be performed. This fail-safe operation is different from the fail-safe operation performed when the solenoid valve malfunctions and the ATF pressure switch is normal. DTC No. DTC Detecting Condition P0877 ATF pressure switch No. 2 OFF is detected twice when any of the gears from 4th to 6th engages normally. Trouble Area • P0878 ATF pressure switch No. 2 ON is detected twice when any of the gears from 1st to 3rd engages normally. • • ATF temperature sensor assembly (ATF pressure switch No. 2) Transmission wire TCM WIRING DIAGRAM TCM TSP2 ATF Pressure Switch No. 2 Transaxle Assembly C133258E02 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–119 INSPECTION PROCEDURE 1 CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P0877 OR P0878) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the intelligent tester on. (c) Enter the following items: "DIAGNOSIS / OBD/MOBD / ECT / DTC INFO / CURRENT CODES". (d) Read the DTCs using the intelligent tester. Result Display (DTC output) Proceed to Only "P0878" is output A Only "P0877" is output B "P0877 or P0878" and other DTCs C HINT: If a solenoid is stuck OFF, DTCs for several solenoids including the malfunctioning solenoid will be detected. B Go to step 4 C GO TO DTC CHART A 2 CHECK TRANSMISSION WIRE (SHORT TO GROUND) (a) Remove the TCM. (b) Measure the resistance according to the value(s) in the table below. Standard resistance TPS2 Tester Condition Specified Condition 20 (TPS2) - Body ground (Valve body assembly) 10 kΩ or higher OK C133212E11 NG REPAIR OR REPLACE TCM AX AX–120 3 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM CHECK ATF TEMPERATURE SENSOR ASSEMBLY (ATF PRESSURE SWITCH NO. 2) (a) Disconnect the transmission wire connector from the ATF temperature sensor assembly. (b) Measure the resistance according to the value(s) in the table below. Standard resistance AX TPS2 Tester Condition Specified Condition 4 (TPS2) - Body ground (Valve body assembly) 10 kΩ or higher NG C142708E01 OK REPLACE TRANSMISSION WIRE REPLACE ATF TEMPERATURE SENSOR ASSEMBLY AX–121 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM 4 CHECK TRANSMISSION WIRE (a) Remove the TCM. (b) Disconnect the connector from the ATF temperature sensor assembly. (c) Measure the resistance according to the value(s) in the table below. Standard resistance TCM Side Connector Tester Condition Specified Condition 20 (TPS2) - 2 (TPS2) Below 1 Ω 20 (TPS2) or 2 (TPS2) - Body ground (Valve body assembly) 10 kΩ or higher TPS2 NG Sensor Side Connector REPLACE TRANSMISSION WIRE TPS2 C133269E02 OK REPLACE ATF TEMPERATURE SENSOR ASSEMBLY AX AX–122 AX U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC P0989 Transmission Fluid Pressure Switch No.3 Circuit Low DTC P0990 Transmission Fluid Pressure Switch No.3 Circuit High DESCRIPTION ATF pressure switch No. 3 is installed in the lock-up solenoid ATF output passage and is used to detect a malfunction in the lock-up solenoid. DTC No. DTC Detection Condition P0989 Transmission fluid pressure switch No. 3 is OFF when lock-up occurs in response to a lock-up request (2 trip detection logic). P0990 When both of the following are detected (2 trip detection logic): • Transmission fluid pressure switch No. 3 is ON when lock-up does not occur. • Lock-up does not occur when shift solenoid valve (SLU) is requested to turn off in the lock-up range. Trouble Area • • • ATF temperature sensor assembly (ATF pressure switch No. 3) Transmission wire TCM MONITOR DESCRIPTION The TCM illuminates the MIL and stores the DTC when the TCM detects that the ATF pressure switch is OFF with the lock-up solenoid ON or when the TCM detects that the ATF pressure switch is ON with the lock-up solenoid OFF. MONITOR STRATEGY Related DTCs P0989: Transmission fluid pressure switch No. 3 OFF malfunction P0990: Transmission fluid pressure switch No. 3 ON malfunction Required sensors/Components Transmission fluid pressure switch No. 3 Frequency of operation Continuous Duration 4 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS ALL: The monitor will run whenever these DTCs are not present None Turbine speed sensor circuit Circuit is not malfunctioning Intermediate shaft speed sensor circuit Circuit is not malfunctioning Shift solenoid valve SL1 circuit Circuit is not malfunctioning Shift solenoid valve SL2 circuit Circuit is not malfunctioning Shift solenoid valve SL3 circuit Circuit is not malfunctioning Shift solenoid valve SL4 circuit Circuit is not malfunctioning Shift solenoid valve SLU circuit Circuit is not malfunctioning TFT sensor circuit Circuit is not malfunctioning Torque converter clutch circuit Circuit is not malfunctioning ECT sensor circuit Circuit is not malfunctioning CAN communication system Circuit is not malfunctioning Electric throttle system Circuit is not malfunctioning TFT (Transmission fluid temperature) Above -10°C (14°F) U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM ECT (Engine coolant temperature) 40°C (104°F) or more Transmission range "D" TCM selected gear Not 1st Vehicle speed 15.5 mph (25 km/h) or more P0989: TCM lock-up command ON Engine speed - Turbine speed Less than 20 rpm Throttle valve opening angle 7% or more Vehicle speed Less than 62 mph (100 km/h) Shift solenoid valve SLU Not ON malfunction P0990: TCM indicated pressure valve of SLU Less than 4 kPa TCM lock-up command OFF Shift solenoid valve SLU Not malfunction Shift solenoid valve SL Not OFF malfunction TYPICAL MALFUNCTION THRESHOLDS P0989: Transmission fluid pressure switch No. 3 OFF P0990: Following conditions are met (a) and (b) (a) Engine speed - Turbine speed Less than 20 rpm (b) Transmission fluid pressure switch No. 3 ON AX–123 AX AX–124 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM WIRING DIAGRAM TCM AX TSP3 ATF Pressure Switch No. 3 Transaxle Assembly C133258E03 INSPECTION PROCEDURE 1 CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P0989 OR P0990) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the intelligent tester on. (c) Enter the following items: "DIAGNOSIS / OBD/MOBD / ECT / DTC INFO / CURRENT CODES". (d) Read the DTCs using the intelligent tester. Result Display (DTC output) Proceed to Only "P0990" is output A Only "P0989" is output B "P0989 or P0990" and other DTCs C HINT: If a solenoid is stuck OFF, DTCs for several solenoids including the malfunctioning solenoid will be detected. B C Go to step 4 GO TO DTC CHART U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–125 A 2 CHECK TRANSMISSION WIRE (SHORT TO GROUND) (a) Remove the TCM. (b) Measure the resistance according to the value(s) in the table below. Standard resistance TPS3 Tester Condition Specified Condition 19 (TPS3) - Body ground (Valve body assembly) 10 kΩ or higher OK REPLACE TCM C133212E12 NG 3 CHECK ATF TEMPERATURE SENSOR ASSEMBLY (ATF PRESSURE SWITCH NO. 3) (a) Disconnect the connector from the ATF temperature sensor assembly. (b) Measure the resistance according to the value(s) in the table below. Standard resistance TPS3 Tester Condition Specified Condition 5 (TPS3) - Body ground (Valve body assembly) 10 kΩ or higher NG C142709E01 OK REPLACE TRANSMISSION WIRE REPLACE ATF TEMPERATURE SENSOR ASSEMBLY AX AX–126 4 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM CHECK TRANSMISSION WIRE (a) Remove the TCM. (b) Disconnect the connector from the ATF temperature sensor assembly. (c) Measure the resistance according to the value(s) in the table below. Standard resistance TCM Side Connector AX Tester Condition Specified Condition 19 (TPS3) - 1 (TPS3) Below 1 Ω 19 (TPS3) or 1 (TPS3) - Body ground (Valve body assembly) 10 kΩ or higher TPS3 NG Sensor Side Connector REPLACE TRANSMISSION WIRE TPS3 C133269E03 OK REPLACE ATF TEMPERATURE SENSOR ASSEMBLY U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC P2714 AX–127 Pressure Control Solenoid "D" Performance (Shift Solenoid Valve SLT) SYSTEM DESCRIPTION The linear solenoid valve (SLT) controls the transmission line pressure for smooth transmission operation based on signals from the throttle position sensor and the vehicle speed sensor. The TCM adjusts the duty ratio (*) of the SLT solenoid valve to control hydraulic line pressure coming from the primary regulator valve. Appropriate line pressure assures smooth shifting with varying engine outputs. (*): Duty Ratio The duty ratio is the ratio of the period of continuity in one cycle. For example, if A is the period of continuity in one cycle, and B is the period of non-continuity, then Duty Ratio= A/(A+B) x 100 (%) Spool Valve Hydraulic Sleeve Solenoid Coil ON A B OFF Current 1 Cycle C133225E01 DTC No. P2714 DTC Detection Condition The ECM detects a malfunction in the shift solenoid valve SLT (ON side) according to the difference in the speed between the turbine and the output shaft, and also by the transmission fluid pressure. (2-trip detection logic) Trouble Area • • • • Shift solenoid valve SLT remains open Shift solenoid valve SL1, SL2, SL3 or SL4 remains open or closed Valve body is blocked Automatic transaxle (clutch, brake or gear, etc.) MONITOR DESCRIPTION The TCM calculates the amount of heat absorbed by the friction material based on the difference in revolution (clutch slippage) between the turbine and output shaft. The TCM turns on the MIL and outputs this DTC when the amount of heat absorption exceeds the specified value. When the shift solenoid valve SLT remains on, oil pressure goes down and clutch engagement force decreases. NOTICE: If driving continues under these conditions, the clutches will burn out and the vehicle will no longer be drivable. MONITOR STRATEGY Related DTCs P2714: Shift solenoid valve SLT/ON malfunction Required sensors/Components Shift solenoid valve SLT Frequency of operation Continuous Duration Immediate MIL operation 2 driving cycles Sequence of operation None AX AX–128 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM TYPICAL ENABLING CONDITIONS ON malfunction: AX The monitor will run whenever this DTC is not present. None Turbine speed sensor circuit Circuit is not malfunctioning TFT sensor circuit Circuit is not malfunctioning Shift solenoid valve SL1 circuit Circuit is not malfunctioning Shift solenoid valve SL2 circuit Circuit is not malfunctioning Shift solenoid valve SL3 circuit Circuit is not malfunctioning Shift solenoid valve SL4 circuit Circuit is not malfunctioning Shift solenoid valve SLT circuit Circuit is not malfunctioning ECT (Engine coolant temperature) sensor circuit Circuit is not malfunctioning Knock control sensor circuit Circuit is not malfunctioning ETCS (Electric throttle control system) System is not down Transmission range "D" Engine Starting TFT -10°C (5°F) or more Input turbine torque 100 N*m or more Turbine speed 250 rpm or more Output speed 250 rpm or more TYPICAL MALFUNCTION THRESHOLDS ON malfunction: Detection criteria Threshold Turbine speed - Output speed x Gear ratio at output speed 1,000 rpm (Condition varies with output speed) 75 rpm or more INSPECTION PROCEDURE 1 CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P2714) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the intelligent tester on. (c) Enter the following items: "DIAGNOSIS / OBD/MOBD / ECT / DTC INFO / CURRENT CODES". (d) Read the DTCs using the intelligent tester. Result Display (DTC output) Proceed to Only "P2714" is output A "P2714" and other DTCs B HINT: If a solenoid is stuck ON, DTCs for several solenoids including the malfunctioning solenoid will be detected. A B INSPECT SHIFT SOLENOID VALVE SLT U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM 2 AX–129 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SHIFT SOLENOID VALVE SLT) NOTICE: • Perform the test at the normal operating ATF (Automatic Transmission Fluid) temperature: 50 to 80°C (122 to 176°F) • Be sure to prevent SST hose from interfering with the exhaust pipe. • This check must be conducted after checking and adjusting the engine. • Perform the test with the A/C OFF. HINT: Performing the ACTIVE TEST using the intelligent tester allows relays, VSVs, actuators and other items to operate without removing any parts. Performing the ACTIVE TEST as the first step in troubleshooting is one method to save labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Turn the ignition switch off. (b) Lift the vehicle up. (c) Remove the test plug on the transmission case center right side and connect SST. SST 09992-00095 (09992-00231, 09992-00271) (d) Lower the vehicle. (e) Fully apply the parking brake and chock the 4 wheels. (f) Connect the intelligent tester together with the CAN VIM (Controller Area Network Vehicle Interface Module) to the DLC3. (g) Start the engine. (h) Warm up the ATF (Automatic Transmission Fluid). (i) Measure the line pressure when the engine is idling. (j) Turn on the tester. (k) Enter the following items: DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST / SOLENOID (SLT)". (l) Follow the instructions on the tester and perform the ACTIVE TEST. (m) Measure the line pressure with SST. SST SST C133223E01 Item SOLENOID (SLT)* Test Details [Test Details] Operate the shift solenoid SLT and raise the line pressure. [Vehicle Condition] • Vehicle Stopped. • IDL: ON HINT: OFF: Line pressure up (When the active test of "SOLENOID (SLT)" is performed, the TCM commands the SLT solenoid to turn off). ON: No action (normal operation) AX AX–130 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM *: "SOLENOID (SLT)" in the ACTIVE TEST is performed to check that the line pressure changes by connecting the SST to the automatic transaxle. The same SST is used in the HYDRAULIC TEST (See page AX-17) as well. HINT: The pressure values in ACTIVE TEST and HYDRAULIC TEST are different from each other. OK: The line pressure changes as specified when performing the ACTIVE TEST. AX NG Go to step 5 OK 3 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SHIFTING TEST) NOTICE: This test should always be performed with at least 2 people. HINT: Performing the ACTIVE TEST using the intelligent tester allows relays, VSVs, actuators and other items to be operated without removing any parts. Performing the ACTIVE TEST as the first step in troubleshooting is one method to save labor time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester together with the CAN VIM (Controller Area Network Vehicle Interface Module) to the DLC3. (d) Start the engine. (e) Turn on the tester. (f) Enter the following items: "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST". (g) Follow the instructions on the tester and read the ACTIVE TEST. Item SHIFT Test Details [Test Details] Operate the shift solenoid valve and set the each shift position by yourself. [Vehicle Condition] • IDL: ON [Others] • Press "→" button: Shift up • Press "←" button: Shift down Diagnostic Note It is possible to check the operation of the shift solenoid valves. NOTICE: • This test can be conducted when the vehicle is stopped. • When shifting gears using the Active Test function, do not operate the accelerator pedal for 2 seconds before and after shifting gears. U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–131 HINT: The shift position commanded by the TCM is shown on the DATA LIST/SHIFT display on the intelligent tester. (h) Check the vehicle speed and the gear position when the engine speed is 1,000 rpm. HINT: Because the torque converter clutch has not engaged, it may be difficult to obtain the speeds specified in 4th, 5th, and 6th gear, however a difference of speed should still be evident following each gear change. Standard 1st 2nd 3rd 4th 5th 6th 5 to 7.5 mph (8 to 12 km/h) 9.3 to 11.8 mph (15 to 19 km/h) 13.0 to 15.5 mph (21 to 25 km/h) 19.3 to 21.7 mph (31 to 35 km/h) 27.3 to 29.8 mph (44 to 48 km/h) 32.3 to 34.8 mph (52 to 56 km/h) (i) Compare the TCM gear shift command and the actual gear position. Result Actuator gear position under malfunction Shift solenoid SL1 Shift solenoid SL2 Shift solenoid SL3 2nd 3rd 4th Stuck ON 1st 2nd 3rd 4th 4th 4th Stuck OFF N*1 N*1 N*1 N*1 5th 6th Stuck ON 4th 4th 4th 4th 5th 6th 1st *1 N N*1 Shift solenoid SLT 6th 1st 2nd Stuck ON 2nd 2nd 3rd 4th 5th 6th Stuck OFF 1st 1st 3rd 4th 5th N*1 3rd 3rd 3rd 4th 5th 5th Stuck OFF 1st 2nd 1st 4th N*1 6th Stuck ON N*2 N*2 N*2 N*2 N*2 N*2 1st 2nd 3rd 4th 5th 6th ON*3 Stuck *3 OFF 3rd 5th Stuck OFF Stuck Shift solenoid SL4 TCM gear shift command 1st Proceed to A B C D E HINT: • *1: Neutral • *2: If the shift solenoid SLT is stuck on, the line pressure will be low. Therefore, the amount of torque that can be transmitted by each gear is lower than the normal limit. When the engine power exceeds this lowered limit, the engine speed will increase freely. • *3: When shift solenoid SLT is stuck OFF, gear shifting is normal. A GO TO DTC CHART (RELATED SHIFT SOLENOID VALVE (SL1) PERFORMANCE DTC P0746) B GO TO DTC CHART (RELATED SHIFT SOLENOID VALVE (SL2) PERFORMANCE DTC P0776) AX AX–132 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM C GO TO DTC CHART (RELATED SHIFT SOLENOID VALVE (SL3) PERFORMANCE DTC P0796) D GO TO DTC CHART (RELATED SHIFT SOLENOID VALVE (SL4) PERFORMANCE DTC P2808) AX E 4 INSPECT SHIFT SOLENOID VALVE SLT (a) Remove the shift solenoid valve SLT. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Shift Solenoid Valve SLT: 2 1 NG (-) Specified Condition 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect a positive (+) lead through a 21 W bulb to terminal 2 and a negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. 2 1 Tester Connection REPLACE SHIFT SOLENOID VALVE SLT (+) G020767E08 OK 5 INSPECT TRANSMISSION VALVE BODY ASSEMBLY OK: There are no foreign objects on each valve. NG REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK 6 INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY (a) Check the torque converter clutch assembly (See page AX-239). OK: The torque converter clutch operates normally. U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM NG AX–133 REPLACE TORQUE CONVERTER CLUTCH ASSEMBLY OK REPLACE AUTOMATIC TRANSMISSION ASSEMBLY AX AX–134 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC P2716 Pressure Control Solenoid "D" Electrical (Shift Solenoid Valve SLT) DESCRIPTION AX Refer to DTC P2714 (See page AX-121). DTC No. P2716 DTC Detection Condition Open or short is detected in shift solenoid valve SLT circuit for 1 second or more while driving (1-trip detection logic). Trouble Area • • • Open or short in shift solenoid valve SLT circuit Shift solenoid valve SLT TCM MONITOR DESCRIPTION When an open or short in the linear solenoid valve (SLT) circuit is detected, the TCM interprets this as a fault. The TCM will turn on the MIL and store the DTC. MONITOR STRATEGY Related DTCs P2716: Shift solenoid valve SLT/Range check Required sensors/Components Shift solenoid valve SLT Frequency of operation Continuous Duration 1 sec. MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS ALL: The monitor will run whenever this DTC is not present None Solenoid current cut status Not cut Ignition switch ON Starter OFF Malfunction (A): Battery voltage 10 V to 12 V Malfunction (B): Battery voltage 10 V or more and less than 12 V Target current 0.75 A Malfunction (C): Battery voltage 8 V or more Target current 1A Malfunction (D): Battery voltage 11 V or more Target current 1 A or more Malfunction (E): Battery voltage 11 V or more Target current 0.1 A or more Commanded voltage - Last commanded voltage Less than 0.02 V U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–135 TYPICAL MALFUNCTION THRESHOLDS Malfunction (A) and (B): Output signal duty 100% or more Malfunction (C): Output signal duty 0% or less AX Malfunction (D): Output signal monitor No signal Malfunction (E): Commanded voltage - Last commanded voltage 0.02 V or more COMPONENT OPERATING RANGE Output signal duty Less than 100% WIRING DIAGRAM TCM +B SLT+ Shift Solenoid Valve SLT SLT- Transaxle Assembly C133261E05 AX–136 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM INSPECTION PROCEDURE 1 INSPECT TRANSMISSION WIRE (SLT) AX (a) Remove the TCM from the transaxle. (b) Measure the resistance according to the value(s) in the table below. Standard resistance SLT- SLT+ Tester Connection Specified Condition 20°C (68°F) 12 (SLT+) - 7 (SLT-) 5.0 to 5.6 Ω (c) Measure the resistance according to the value(s) in the table below. Standard resistance: Check for short C133212E06 OK Tester Connection Specified Condition 12 (SLT+) - Body ground 10 kΩ or higher 7 (SLT-) - Body ground 10 kΩ or higher REPLACE TCM NG 2 INSPECT SHIFT SOLENOID VALVE SLT (a) Remove the shift solenoid valve SLT. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Shift Solenoid Valve SLT: 2 1 NG (-) Specified Condition 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect a positive (+) lead through a 21 W bulb to terminal 2 and a negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. 2 1 Tester Connection (+) G020767E08 OK REPLACE TRANSMISSION WIRE REPLACE SHIFT SOLENOID VALVE SLT U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC P2757 AX–137 Torque Converter Clutch Pressure Control Solenoid Performance (Shift Solenoid Valve SLU) SYSTEM DESCRIPTION The TCM uses the signals from the throttle position sensor, air-flow meter, turbine (input) speed sensor, output speed sensor and crankshaft position sensor to monitor the engagement condition of the lock-up clutch. Spool Valve Hydraulic Pressure Sleeve Solenoid Coil Current C133226E01 The TCM compares the engagement condition of the lock-up clutch with the lock-up schedule in the TCM memory to detect shift solenoid valve SLU, valve body and torque converter clutch mechanical problems. DTC No. P2757 DTC Detection Condition When both of the following are detected (2-trip detection logic): • Lock-up does not occur when requested. • Transmission fluid pressure switch No. 3 is OFF. When both of the following are detected (2-trip detection logic): • Transmission fluid pressure switch No. 3 is ON when lock-up does not occur. • Lock-up occurs when the shift solenoid valve SLU is requested to turn on in the lock-up range. Trouble Area • • • • • Shift solenoid valve SLU remains open or closed Valve body is blocked Torque converter clutch Automatic transaxle (clutch, brake or gear, etc.) Line pressure is too low MONITOR DESCRIPTION Torque converter lock-up is controlled by the TCM based on the turbine (input) speed sensor NT, output speed sensor NC, engine rpm, engine load, engine temperature, vehicle speed, transmission fluid temperature, and gear selection. The TCM determines the lock-up status of the torque converter by comparing the engine rpm (NE) to the input turbine rpm (NT). The TCM calculates the actual transmission gear by comparing input turbine rpm (NT) to output shaft rpm (NC). When conditions are appropriate, the TCM requests "lock-up" by applying control voltage to the shift solenoid SLU. When the SLU is turned on, it applies pressure to the lock-up relay valve and locks the torque converter clutch. If the TCM detects no lock-up after lock-up has been requested or if it detects lock-up when it is not requested, the TCM interprets this as a fault in the shift solenoid valve SLU or lock-up system performance. The TCM will turn on the MIL and store the DTC. Example: When any of the following is met, the system judges it as a malfunction. AX AX–138 AX U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM • There is a difference in rotation between the input side (engine speed) and output side (input turbine speed) of the torque converter when the TCM commands lock-up. (Engine speed is at least 70 rpm greater than input turbine speed.) • There is no difference in rotation between the input side (engine speed) and output side (input turbine speed) of the torque converter when the TCM commands lock-up off. (The difference between engine speed and input turbine speed is less than 20 rpm.) MONITOR STRATEGY Related DTCs P2757: Shift solenoid valve SLU OFF malfunction Shift solenoid valve SLU ON malfunction Required sensors/Components Shift solenoid valve SLU Frequency of operation Continuous Duration OFF malfunction (A): 3.5 sec. OFF malfunction (B): 0.05 sec. ON malfunction: 1.8 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS The following items are common to all conditions below. The monitor will run whenever this DTC is not present. None Turbine speed sensor circuit Circuit is not malfunctioning Intermediate shaft speed sensor circuit Circuit is not malfunctioning Shift solenoid valve SL1 circuit Circuit is not malfunctioning Shift solenoid valve SL2 circuit Circuit is not malfunctioning Shift solenoid valve SL3 circuit Circuit is not malfunctioning Shift solenoid valve SL4 circuit Circuit is not malfunctioning Shift solenoid valve SLU circuit Circuit is not malfunctioning Knock sensor circuit Circuit is not malfunctioning ETCS (Electric throttle control system) System is not down Transmission shift position "D" ECT (Engine coolant temperature) 40°C (104°F) or more Spark advance from Max. retard timing by KCS control 0°CA or more TFT (Transmission fluid temperature) Above -10°C (5°F) TCM selected gear Not 1st Vehicle speed 15.5 mph (25 km/h) or more Torque converter clutch circuit Circuit is not malfunctioning ECT circuit Circuit is not malfunctioning CAN communication system Circuit is not malfunctioning Turbine speed/Output speed (NT/NO) with 1st 3.304 to 7.724 Turbine speed/Output speed (NT/NO) with 2nd 1.901 to 2.340 Turbine speed/Output speed (NT/NO) with 3rd 1.399 to 1.649 Turbine speed/Output speed (NT/NO) with 4th 0.998 to 1.138 Turbine speed/Output speed (NT/NO) with 5th 0.705 to 0.836 Turbine speed/Output speed (NT/NO) with 6th 0.568 to 0.695 OFF malfunction (A): TCM lock-up command ON Duration time from lock-up on command 3 sec. or more Shift solenoid valve SLU ON malfunction not occuring U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–139 ON malfunction: OFF TCM lock-up command (SLU pressure: less than 4 kPa (0.04 kgfcm2, 0.6 psi) Duration time from lock-up on command 0.064 sec. or more Throttle valve opening angle 7% or more Vehicle speed Less than 37.3 mph (60 km/h) AX TYPICAL MALFUNCTION THRESHOLDS OFF malfunction: Following conditions are met (a) and (b) (a) Engine speed - Turbine speed 70 rpm or more (b) Transmission fluid pressure switch OFF ON malfunction: Following conditions are met (a) and (b) (a) Engine speed - Turbine speed Less than 35 rpm (b) Transmission fluid pressure switch ON COMPONENT OPERATING RANGE Speed sensor (NT) Input speed is equal to engine speed when lock-up is ON. INSPECTION PROCEDURE 1. ACTIVE TEST HINT: Performing the ACTIVE TEST using the intelligent tester allows relays, VSVs, actuators and other items to be operated without removing any parts. Performing the ACTIVE TEST as the first step in troubleshooting is one method to save labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester together with the CAN VIM (Controller Area Network Vehicle Interface Module) to the DLC3. (d) Turn the ignition switch on (IG). (e) Turn on the tester. (f) Enter the following items: "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST". (g) According to the display on the tester, perform "ACTIVE TEST". Item LOCK UP Test Details [Test Details] Control the shift solenoid SLU to set the automatic transaxle to the lock-up condition. [Vehicle Condition] • Throttle valve opening angle: Less than 35% • Vehicle Speed: 37 mph (60 km/h) or more Diagnostic Note Possible to check the SLU operation. HINT: • This test can be conducted when the vehicle speed is 36 mph (58 km/h) or more. • This test can be conducted with the 6th gear. AX–140 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM (h) Lightly depress the accelerator pedal and check that the engine speed does not change abruptly. AX Accelerator Pedal Opening Angle Accelerator Pedal Fully Released Lock-up OFF Engine speed Lock-up ON time G029214E09 HINT: • When changing the accelerator pedal opening angle while driving, if the engine speed does not change, lock-up is on. • Slowly release, but not fully, the accelerator pedal in order to decelerate. (Fully releasing the pedal will close the throttle valve and lock-up may be turned off automatically.) 1 CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P2757) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the intelligent tester on. (c) Enter the following items: "DIAGNOSIS / OBD/MOBD / ECT / DTC INFO / CURRENT CODES". (d) Read the DTCs using the intelligent tester. Result Display (DTC output) Proceed to Only "P2757" is output A "P2757" and other DTCs B HINT: If any other codes besides "P2757" are output, perform troubleshooting for those DTCs first. B A GO TO DTC CHART U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM 2 AX–141 INSPECT SHIFT SOLENOID VALVE SLU (a) Remove the shift solenoid valve SLU. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Shift Solenoid Valve SLU: 1 2 NG (-) Specified Condition 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect a positive (+) lead through a 21 W bulb to terminal 2 and a negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. 2 1 Tester Connection REPLACE SHIFT SOLENOID VALVE SLU (+) G020767E09 OK 3 INSPECT TRANSMISSION VALVE BODY ASSEMBLY OK: There are no foreign objects on each valve. NG REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK 4 INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY (a) Check the torque converter clutch assembly (See page AX-239). OK: The torque converter clutch operates normally. NG REPLACE TORQUE CONVERTER CLUTCH ASSEMBLY OK REPLACE AUTOMATIC TRANSMISSION ASSEMBLY AX AX–142 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC AX Torque Converter Clutch Pressure Control Solenoid Control Circuit Electrical (Shift Solenoid Valve SLU) P2759 DESCRIPTION The amount of current flow to the solenoid is controlled by the (*) duty ratio of the TCM output signal. The higher the duty ratio becomes, the higher the lock-up hydraulic pressure becomes during the lock-up operation. Hydraulic Pressure A ON B OFF Current 1 Cycle C133227E01 (*) Duty Ratio The duty ratio is the ratio of the period of continuity in one cycle. For example, if A is the period of continuity in one cycle, and B is the period of non-continuity, then Duty Ratio = A/(A+B) x 100 (%). DTC No. P2759 DTC Detection Condition Open or short is detected in shift solenoid valve SLU circuit for 1 second or more while driving (1-trip detection logic). Trouble Area • • • Open or short in shift solenoid valve SLU circuit Shift solenoid valve SLU TCM MONITOR DESCRIPTION When an open or short in a shift solenoid valve (SLU) circuit is detected, the TCM determines there is a malfunction. The TCM will turn on the MIL and store this DTC. MONITOR STRATEGY Related DTCs P2759: Shift solenoid valve SLU/Range check Required sensors/Components Shift solenoid valve SLU Frequency of operation Continuous Duration 1 sec. MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS ALL: The monitor will run whenever this DTC is not present None Ignition switch ON Starter OFF U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–143 Malfunction (A): Battery voltage 12 V or more Malfunction (A): Battery voltage 10 V or more and less than 12 V CPU commanded duty Less than 75% AX TYPICAL MALFUNCTION THRESHOLDS Output signal duty 100% or more COMPONENT OPERATING RANGE Output signal duty Less than 100% WIRING DIAGRAM TCM +B SLU+ Shift Solenoid Valve SLU SLU- Transaxle Assembly C133261E06 AX–144 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM INSPECTION PROCEDURE 1 INSPECT TRANSMISSION WIRE (SLU) AX (a) Remove the TCM from the transaxle. (b) Measure the resistance according to the value(s) in the table below. Standard resistance SLU- SLU+ Tester Connection Specified Condition 20°C (68°F) 11 (SLU+) - 5 (SLU-) 5.0 to 5.6 Ω (c) Measure the resistance according to the value(s) in the table below. Standard resistance: Check for short C133212E07 OK Tester Connection Specified Condition 11 (SLU+) - Body ground 10 kΩ or higher 5 (SLU-) - Body ground 10 kΩ or higher REPLACE TCM NG 2 INSPECT SHIFT SOLENOID VALVE SLU (a) Remove the shift solenoid valve SLU. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Shift Solenoid Valve SLU: 1 2 NG (-) Specified Condition 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect a positive (+) lead through a 21 W bulb to terminal 2 and a negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. 2 1 Tester Connection (+) G020767E09 OK REPLACE TRANSMISSION WIRE REPLACE SHIFT SOLENOID VALVE SLU U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–145 DTC P2769 Short in Torque Converter Clutch Solenoid Circuit (Shift Solenoid Valve SL) DTC P2770 Open in Torque Converter Clutch Solenoid Circuit (Shift Solenoid Valve SL) DESCRIPTION The shift solenoid valve SL is turned ON or OFF by signals from the TCM to control the hydraulic pressure acting on the lock-up relay valve, which then controls operation of the lock-up clutch. DTC No. DTC Detection Condition Trouble Area P2769 TCM detects a short in the shift solenoid valve SL circuit when the shift solenoid valve SL is operated (2 trip detection logic). • • • Short in shift solenoid valve SL circuit Shift solenoid valve SL TCM P2770 TCM detects an open in the shift solenoid valve SL circuit when the shift solenoid valve SL is not operated (2 trip detection logic). • • • Open in shift solenoid valve SL circuit Shift solenoid valve SL TCM Fail-safe function: If the TCM detects a malfunction, it turns the shift solenoid valve SL OFF. MONITOR DESCRIPTION Based on the signals from the throttle position sensor, the air flow meter and the crankshaft position sensor, the TCM sends a signal to the solenoid valve SL to regulate the hydraulic pressure and provide smoother torque converter clutch engagement. The shift solenoid valve SL responds to commands from the TCM. The valve controls the lock-up relay valve to perform the torque-converter lock-up function. If the TCM detects an open or short circuit for shift solenoid valve SL, it will illuminate the MIL. MONITOR STRATEGY Related DTCs P2769: Shift solenoid valve SL/Range check (Low resistance) P2770: Shift solenoid valve SL/Range check (High resistance) Required sensors/Components Shift solenoid valve SL Frequency of operation Continuous Duration 1 time MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS P2769: Range check (Low resistance): The monitor will run whenever the following DTCs are not present None Solenoid ON Time after solenoid OFF to ON More than 0.008 sec. P2770: Range check (High resistance): The monitor will run whenever the following DTCs are not present None Solenoid ON Time after solenoid ON to OFF More than 0.008 sec. AX AX–146 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM TYPICAL MALFUNCTION THRESHOLDS P2769: Range check (Low resistance): Intelligent power MOS diagnosis fail signals detected while the solenoid is operated Fail at solenoid resistance: 8 Ω or less P2770: Range check (High resistance): AX Intelligent power MOS diagnosis fail signals detected while the solenoid is not operated Fail at solenoid resistance: 100 kΩ or more COMPONENT OPERATING RANGE Resistance: 11 to 15 Ω at 20°C (68°F) Shift solenoid valve SL WIRING DIAGRAM TCM SL Shift Solenoid Valve SL Transaxle Assembly C133259E01 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–147 INSPECTION PROCEDURE 1 INSPECT TRANSMISSION WIRE (SHIFT SOLENOID VALVE SL) (a) Remove the TCM from the transaxle. (b) Measure the resistance of the transmission wire. Standard resistance SL Tester Connection Condition Specified Condition 6 (SL) - Body ground 20°C (68°F) 11 to 15 Ω OK REPLACE TCM C133212E09 NG 2 INSPECT SHIFT SOLENOID VALVE SL (RESISTANCE) (a) Remove the shift solenoid valve SL. (b) Measure the resistance between the solenoid valve terminal and solenoid valve body. Standard resistance: 11 to 15 Ω at 20°C (68°F) NG C133217 OK REPLACE TRANSMISSION WIRE REPLACE SHIFT SOLENOID VALVE SL AX AX–148 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC P2808 Pressure Control Solenoid "D" Performance or Stuck OFF (Shift Solenoid Valve SL4) DESCRIPTION AX The TCM uses the vehicle speed signal to determine the actual gear position (1st, 2nd, 3rd, 4th, 5th or 6th gear). Then the TCM compares the actual gear with the shift schedule in the TCM memory to detect shift solenoid valves and valve body mechanical problems. DTC No. DTC Detecting Condition P2808 The engine revs freely when 3rd or 5th gear is requested. (2-trip detection logic) When any of the following is detected. In addition, the condition that 4th gear is engaged when 4th gear is requested occurs twice. (2-trip detection logic) • When 1st gear is requested, 4th gear is engaged. • When 2nd gear is requested, 4th gear is engaged. • When 6th gear is requested, 4th gear is engaged. Trouble Area • • • Shift solenoid valve SL4 remains open or closed Valve body is blocked Automatic transaxle (clutch, brake or gear etc.) MONITOR DESCRIPTION The TCM commands gear shifts by turning the shift solenoid valves on or off. According to the input shaft revolution, intermediate (counter) shaft revolution and output shaft revolution, the TCM detects the actual gear position (1st, 2nd, 3rd, 4th or 5th gear position). When the gear position commanded by the TCM and the actual gear position are not the same, the TCM illuminates the MIL and stores the DTC. MONITOR STRATEGY Related DTCs P2808: Shift solenoid valve SL4/OFF malfunction Shift solenoid valve SL4/ON malfunction Required sensors/Components Shift solenoid valve SL4, Speed sensor (NT), Speed sensor (NC), Crankshaft position sensor (NE) Frequency of operation Continuous Duration OFF malfunction (A): 0.5 sec. OFF malfunction (B): 0.8 sec. ON malfunction: 0.8 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS All: Turbine speed sensor circuit Circuit is not malfunctioning Intermediate shaft speed sensor circuit Circuit is not malfunctioning Shift solenoid valve SL1 circuit Circuit is not malfunctioning Shift solenoid valve SL2 circuit Circuit is not malfunctioning Shift solenoid valve SL3 circuit Circuit is not malfunctioning Shift solenoid valve SL4 circuit Circuit is not malfunctioning ETC (Engine coolant temperature) sensor circuit Circuit is not malfunctioning Knock control sensor circuit Circuit is not malfunctioning Electronic throttle system Circuit is not malfunctioning CAN communication system Circuit is not malfunctioning Transmission range "D" Transmission fluid temperature Above -10°C (5°F) U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–149 OFF malfunction (A): TCM select gear 3rd or 5th Throttle valve opening angle 3% or more OFF malfunction (B): TCM select gear 3rd Throttle valve opening angle 4.5% or more Vehicle speed 1.2 mph (2 km/h) or more ECT (Engine coolant temperature) 40°C (104°F) or more Turbine speed/Output speed (NT/NO) with 1st 3.304 to 7.724 Turbine speed/Output speed (NT/NO) with 2nd 1.901 to 2.340 Turbine speed/Output speed (NT/NO) with 3rd 1.399 to 1.649 Turbine speed/Output speed (NT/NO) with 4th 0.998 to 1.138 Turbine speed/Output speed (NT/NO) with 5th 0.705 to 0.836 Turbine speed/Output speed (NT/NO) with 6th 0.568 to 0.695 ON malfunction (A): TCM select gear 1st Time after transmission to 1st gear 0.1 sec. or more Vehicle speed 1.2 mph (2 km/h) to 25 mph (40 km/h) ECT (Engine coolant temperature) 40°C (104°F) or more Turbine speed/Output speed (NT/NO) with 1st 3.304 to 7.724 Turbine speed/Output speed (NT/NO) with 2nd 1.901 to 2.340 Turbine speed/Output speed (NT/NO) with 3rd 1.399 to 1.649 Turbine speed/Output speed (NT/NO) with 4th 0.998 to 1.138 Turbine speed/Output speed (NT/NO) with 5th 0.705 to 0.836 Turbine speed/Output speed (NT/NO) with 6th 0.568 to 0.695 ON malfunction (B): TCM select gear 2nd Throttle valve opening angle 4.5% or more at engine speed 2,000 rpm (condition varies with engine speed) Vehicle speed 1.2 mph (2 km/h) or more ECT (Engine coolant temperature) 40°C (104°F) or more Turbine speed/Output speed (NT/NO) with 1st 3.304 to 7.724 Turbine speed/Output speed (NT/NO) with 2nd 1.901 to 2.340 Turbine speed/Output speed (NT/NO) with 3rd 1.399 to 1.649 Turbine speed/Output speed (NT/NO) with 4th 0.998 to 1.138 Turbine speed/Output speed (NT/NO) with 5th 0.705 to 0.836 Turbine speed/Output speed (NT/NO) with 6th 0.568 to 0.695 ON malfunction (C): TCM select gear 6th Throttle valve opening angle 4.5% or more at engine speed 2,000 rpm (condition varies with engine speed) Vehicle speed 1.2 mph (2 km/h) or more ECT (Engine coolant temperature) 40°C (104°F) or more Turbine speed/Output speed (NT/NO) with 1st 3.304 to 7.724 Turbine speed/Output speed (NT/NO) with 2nd 1.901 to 2.340 Turbine speed/Output speed (NT/NO) with 3rd 1.399 to 1.649 Turbine speed/Output speed (NT/NO) with 4th 0.998 to 1.138 Turbine speed/Output speed (NT/NO) with 5th 0.705 to 0.836 Turbine speed/Output speed (NT/NO) with 6th 0.568 to 0.695 AX AX–150 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM ON malfunction (D): TCM select gear AX 4th Throttle valve opening angle 4.5% or more at engine speed 2,000 rpm (condition vary with engine speed) Vehicle speed 1.2 mph (2 km/h) or more ECT (Engine coolant temperature) 40°C (104°F) or more Turbine speed/Output speed (NT/NO) with 1st 3.304 to 7.724 Turbine speed/Output speed (NT/NO) with 2nd 1.901 to 2.340 Turbine speed/Output speed (NT/NO) with 3rd 1.399 to 1.649 Turbine speed/Output speed (NT/NO) with 4th 0.998 to 1.138 Turbine speed/Output speed (NT/NO) with 5th 0.705 to 0.836 Turbine speed/Output speed (NT/NO) with 6th 0.568 to 0.695 TYPICAL MALFUNCTION THRESHOLDS OFF malfunction (A): Engine speed - Turbine speed x Gear ratio 1,000 rpm or more OFF malfunction (B): Turbine speed / Output speed 3.304 to 7.724 ON malfunction (A) and (B): Turbine speed / Output speed 1.399 to 1.649 ON malfunction (C): Turbine speed / Output speed 0.705 to 0.836 ON malfunction (D): Turbine speed / Output speed 0.998 to 1.138 INSPECTION PROCEDURE 1 CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P2808) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the intelligent tester on. (c) Enter the following items: "DIAGNOSIS / OBD/MOBD / DTC INFO / CURRENT CODES". (d) Read the DTCs using the intelligent tester. Result Display (DTC output) Proceed to Only "P2808" is output A "P2808" and other DTCs B HINT: If a solenoid is stuck OFF, DTCs for several solenoids including the malfunctioning solenoid will be detected. A B Go to step 3 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM 2 AX–151 PERFORM ACTIVE TEST BY INTELLIGENT TESTER NOTICE: This test should always be performed with at least 2 people. (a) Connect the intelligent tester to the DLC3. (b) Start the engine and turn the intelligent tester on. (c) Enter the following items: "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST / SHIFT". HINT: While driving, the shift position can be forcibly changed with the intelligent tester. Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem (See page AX-39). Item Test Details Diagnostic Note [Test Details] Operate the shift solenoid valve and set each shift position by yourself. [Others] • Press "←" button: Shift up • Press "→" button: Shift down SHIFT It is possible to check the operation of the shift solenoid valves. NOTICE: • This test can be conducted when the vehicle is stopped. • When shifting gears using the Active Test function, do not operate the accelerator pedal for 2 seconds before and after shifting gears. HINT: The shift position commanded by the TCM is shown on the DATA LIST/SHIFT display on the intelligent tester. (d) Check the vehicle speed and the gear position when the engine speed is 1,000 rpm. HINT: Because the torque converter clutch has not engaged, it may be difficult to obtain the speeds specified in 4th, 5th, and 6th gear, however a difference of speed should still be evident following each gear change. Standard 1st 2nd 3rd 4th 5th 6th 5 to 7.5 mph (8 to 12 km/h) 9.3 to 11.8 mph (15 to 19 km/h) 13.0 to 15.5 mph (21 to 25 km/h) 19.3 to 21.7 mph (31 to 35 km/h) 27.3 to 29.8 mph (44 to 48 km/h) 32.3 to 34.8 mph (52 to 56 km/h) (e) Compare the TCM gear shift command and the actual gear position. Result Actuator gear position under malfunction Shift solenoid SL1 Shift solenoid SL2 TCM gear shift command 1st 2nd 3rd 4th 5th 6th Stuck ON 1st 2nd 3rd 4th 4th 4th Stuck OFF N*1 *1 *1 N *1 N 5th 6th Stuck ON 4th 4th 4th 4th 5th 6th Stuck OFF 1st 2nd 3rd 1st *1 N*1 N N Proceed to A B AX AX–152 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Actuator gear position under malfunction Shift solenoid SL3 2nd 3rd 4th 5th 6th Stuck ON 2nd 2nd 3rd 4th 5th 6th Stuck OFF 1st 1st 3rd 4th 5th N*1 3rd 3rd 3rd 4th 5th 5th Stuck OFF 1st 2nd 1st 4th N*1 6th Stuck ON N*2 N*2 N*2 N*2 N*2 N*2 1st 2nd 3rd 4th 5th 6th Stuck AX Shift solenoid SL4 Shift solenoid SLT TCM gear shift command 1st ON*3 Stuck OFF*3 Proceed to C D E HINT: • *1: Neutral • *2: If the shift solenoid SLT is stuck on, the line pressure will be low. Therefore, the amount of torque that can be transmitted by each gear is lower than the normal limit. When the engine power exceeds this lowered limit, the engine speed will increase freely. • *3: When shift solenoid SLT is stuck OFF, gear shifting is normal. D A GO TO DTC CHART (RELATED SHIFT SOLENOID VALVE (SL1) PERFORMANCE DTC P0746) B GO TO DTC CHART (RELATED SHIFT SOLENOID VALVE (SL2) PERFORMANCE DTC P0776) C GO TO DTC CHART (RELATED SHIFT SOLENOID VALVE (SL3) PERFORMANCE DTC P0796) E GO TO DTC CHART (RELATED SHIFT SOLENOID VALVE (SLT) PERFORMANCE DTC P2714) U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM 3 AX–153 INSPECT SHIFT SOLENOID VALVE SL4 (a) Remove the shift solenoid valve SL4. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Shift Solenoid Valve SL3: 2 1 Specified Condition 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect a positive (+) lead through a 21 W bulb to terminal 2 and a negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating noise. 2 1 Tester Connection NG (-) REPLACE SHIFT SOLENOID VALVE SL4 (+) G020767E29 OK 4 INSPECT TRANSMISSION VALVE BODY ASSEMBLY OK: There are no foreign objects on each valve and they operate smoothly. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK 5 TORQUE CONVERTER CLUTCH ASSEMBLY OK: The torque converter clutch operates normally. NG OK REPLACE AUTOMATIC TRANSAXLE ASSEMBLY REPLACE TORQUE CONVERTER CLUTCH ASSEMBLY AX AX–154 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC P2810 Pressure Control Solenoid "D" Electrical (Shift Solenoid Valve SL4) DESCRIPTION AX Shifting gears from 1st through 5th is performed in combination with "ON" and "OFF" operation of the shift solenoid valves SL1, SL2, SL3 and SL4 which are controlled by the TCM. If an open or short circuit occurs in either of the shift solenoid valve, the TCM controls the remaining normal shift solenoid valves to allow the vehicle to be operated smoothly (Fail safe function). DTC No. P2810 DTC Detecting Condition The TCM checks for an open or short in the shift solenoid valve SL4 circuit while driving and shifting gears. (1-trip detection logic) • Output signal duty equals to 100%. (NOTE: SL4 output signal duty is less than 100% under normal condition.) Trouble Area • • • Open or short in shift solenoid valve SL4 circuit Shift solenoid valve SL4 TCM MONITOR DESCRIPTION The TCM commands gear shifts by turning the shift solenoid valves on or off. When there is an open or short circuit in any shift solenoid valve circuit, the TCM detects the problem and illuminates the MIL and stores the DTC. And the TCM performs the fail-safe function and turns the other normal shift solenoid valves on or off (In case of an open or short circuit, the TCM stops sending current to the circuit.) (See page AX-39). MONITOR STRATEGY Related DTCs P0798: Shift solenoid valve SL3/Range check Required sensors/Components Shift solenoid valve SL3 Frequency of operation Continuous Duration 1 sec. MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS ALL: The monitor will run whenever this DTC is not present None Ignition switch ON Starter OFF Malfunction (A): Battery voltage 12 V or more Malfunction (B): Battery voltage 10 V or more and less than 12 V CPU commanded duty Less than 75% TYPICAL MALFUNCTION THRESHOLDS Output signal duty 100% or more AX–155 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM WIRING DIAGRAM TCM AX +B SL4+ Shift Solenoid Valve SL4 SL4- Transaxle Assembly C133261E07 INSPECTION PROCEDURE 1 INSPECT TRANSMISSION WIRE (SL4 CIRCUIT) SL4+ (a) Remove the TCM from the transaxle. (b) Measure the resistance according to the value(s) in the table below. Standard resistance SL4- Tester Connection Specified Condition 20°C (68°F) 22 (SL4+) - 21 (SL4-) 5.0 to 5.6 Ω (c) Measure the resistance according to the value(s) in the table below. Standard resistance: Check for short C133212E08 OK Tester Connection Specified Condition 22 (SL4+) - Body ground 10 kΩ or higher 21 (SL4-) - Body ground 10 kΩ or higher REPLACE TCM AX–156 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM NG 2 AX INSPECT SHIFT SOLENOID VALVE SL4 (a) Remove the shift solenoid valve SL4. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Shift Solenoid Valve SL4: 2 1 NG (-) Specified Condition 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect a positive (+) lead through a 21 W bulb to terminal 2 and a negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating noise. 2 1 Tester Connection (+) G020767E44 OK REPLACE TRANSMISSION WIRE REPLACE SHIFT SOLENOID VALVE SL4 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM DTC U0100 AX–157 Lost Communication with ECM/PCM "A" DESCRIPTION The engine control unit intercommunicates with the TCM with the Controller Area Network (CAN). If there is a problem in this intercommunication, the TCM sets a DTC. DTC No. DTC Detection Condition U0100 Following conditions are met for 1.25 seconds (1 trip detection logic): • Ignition switch ON (IG) • Battery voltage is 10.5 V or more • No intercommunication between the engine control ECU and TCM Trouble Area TCM MONITOR STRATEGY Related DTCs U0100: Verify communication Required Sensors/Components (Main) TCM Required Sensors/Components (Related) - Frequency of Operation Continuous Duration 1.25 seconds MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs not present None Battery Voltage 10.5 V or more Ignition Switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Communication between TCM and ECM No communication AX AX–158 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM WIRING DIAGRAM ECM AX EFI No.2 To EFI Relay 3 7 1 5 2 E31 Transmission Control Swich CAN- 7 C56 CAN+ 6 C56 25 A55 S 51 A55 SFTD 16 A55 SFTU 1 C55 CAN2 C55 CAN+ TCM C133256E01 INSPECTION PROCEDURE HINT: • Refer to inspection procedure for CAN communication system (See page CA-8). • If the CAN communication malfunctions, the TCM cannot receive the current data from the ECM. In this case, the freeze frame data output from the TCM has not been updated, so the data will not be useful for the inspection. However, reading the Data List as the first step in troubleshooting is effective to find malfunctions. • The malfunction area can be checked using the BUS CHECK function on the intelligent tester (See page CA-25). 1 CHECK ECU TERMINAL VOLTAGE (+B AND E1 TERMINALS) (a) Disconnect the TCM connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage of the TCM connectors. Standard voltage Wire Harness Side: TCM Connector (Front View) C56 +B E1 Tester Connection Specified Condition C56-18 (+B) - C56-8 (E1) 9 to 14 V (d) Turn the ignition switch off. (e) Measure the resistance of the TCM connector. C133210E08 Tester Connection Specified Condition C56-8 (E1) - Body ground Below 1 Ω AX–159 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 2 AX CHECK HARNESS AND CONNECTOR (TCM - ECM) (a) Disconnect the C56 TCM connector. (b) Disconnect the C55 ECM connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side: ECM Connector (Front View) CAN- CAN+ TCM Connector (Front View) CAN- Tester Connection Specified Condition C56-6 (CAN+) - C55-2 (CAN+) Below 1 Ω C56-7 (CAN-) - C55-1 (CAN-) Below 1 Ω C56-6 (CAN+) or C55-2 (CAN+) - Body ground 1 MΩ or more C56-7 (CAN-) or C55-1 (CAN-) - Body ground 1 MΩ or more NG REPAIR OR REPLACE HARNESS OR CONNECTOR CAN+ C133242E01 OK 3 CHECK IF DTC OUTPUT RECURS (a) Connect the intelligent tester to the DLC3. (b) Clear the DTC. (c) Replace the TCM. HINT: Replace the TCM with a TCM from a normally functioning vehicle of the same model. (d) Start the engine. (e) Read the DTCs. Display (DTC Output) Proceed to P0100 A No DTC B B A REPLACE ECM REPLACE TCM AX–160 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Transmission Control Switch Circuit DESCRIPTION AX When moving the shift lever into the S position using the transmission control switch, it is possible to switch the shift range position between "1" (first range) and "6" (sixth range). Shifting up "+" once raises one shift range position, and shifting down "-" lowers one shift range position. WIRING DIAGRAM ECM EFI No.2 To EFI Relay 3 7 1 5 2 E31 Transmission Control Swich CAN- 7 C56 CAN+ 6 C56 25 A55 S 51 A55 SFTD 16 A55 SFTU 1 C55 CAN2 C55 CAN+ TCM C133256E01 AX–161 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (BATTERY - TRANSMISSION CONTROL SWITCH) (a) Disconnect the transmission control switch connector of shift lock control unit assembly. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness Side: (Connector Front View): Switch Condition Ignition switch ON (IG) E31 Ignition switch OFF NG Tester Connection 3 - Body ground Specified Condition 10 to 14 V Below 1 V REPAIR OR REPLACE HARNESS OR CONNECTOR C110345E22 OK 2 CHECK HARNESS AND CONNECTOR (TRANSMISSION CONTROL SWITCH - BODY GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side: (Connector Front View): NG E31 C110345E22 OK Tester Connection Specified Condition 5 - Body ground Below 1 Ω REPAIR OR REPLACE HARNESS OR CONNECTOR AX AX–162 3 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM INSPECT TRANSMISSION CONTROL SWITCH (a) Measure the resistance between each terminal of the shift lock control unit assembly when the shift lever is moved to each position. Standard resistance Switch Side: AX (Connector Front View): Shift Position S, "+" and "-" Except S, "+" and "-" Press continuously "+" (Up shift) E31 Tester Connection 3-7 2-5 S Specified Condition Below 1 Ω 10 kΩ or higher Below 1 Ω 10 kΩ or higher Press continuously "-" (Down shift) 1-5 S Below 1 Ω 10 kΩ or higher C110341E16 NG REPLACE TRANSMISSION CONTROL SWITCH OK 4 CHECK HARNESS AND CONNECTOR (TRANSMISSION CONTROL SWITCH - ECM) Wire Harness Side: SFTD S SFTU ECM Connector (Front view) G100098E12 (a) Connect the transmission control switch connector of the shift lock control unit assembly. (b) Disconnect the A55 ECM connector. (c) Turn the ignition switch on (IG), and measure the voltage according to the value(s) in the table below when the shift lever is moved to each position. Standard voltage Shift Position Tester Connection Specified Condition S, "+" and "-" A55-25 (S) - Body ground Below 1 V Except S, "+" and "-" 10 to 14 V (d) Turn the ignition switch off. (e) Disconnect the ECM connector. (f) Measure the resistance according to the value(s) in the table below when the shift lever is moved to each position. Standard resistance Shift Position Tester Connection Press continuously "+" (Up shift) A55-16 (SFTU) - Body ground S Press continuously "-" (Down shift) S Specified Condition Below 1 Ω 10 kΩ or higher A55-51 (SFTD) - Body ground Below 1 Ω 10 kΩ or higher U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM NG AX–163 REPAIR OR REPLACE HARNESS OR CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AX AX–164 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM Park / Neutral Position Switch Circuit DESCRIPTION The park/neutral position switch detects the shift lever position and sends signals to the TCM. AX WIRING DIAGRAM TCM GAUGE No. 1 16 C56 D To IG1 Relay 15 C56 R 11 C56 NSW To ST Relay C1 Park/Neutral Position Switch 10 C56 STA C133257E01 INSPECTION PROCEDURE 1. DATA LIST HINT: According to the DATA LIST displayed on the intelligent tester, you can read the value of switches, sensors, actuators and other items without removing any parts. Reading the DATA LIST as the first step in troubleshooting is one method to save labor time. NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester together with the CAN VIM (Controller Area Network Vehicle Interface Module) to the DLC3. (d) Turn the ignition switch on (IG). (e) Turn on the tester. (f) Enter the following items: "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". AX–165 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM (g) According to the display on the tester, read "DATA LIST". Measurement Item/ Range (display) Item Normal Condition Diagnostic Note PNP Switch Status/ ON or OFF Shift lever position is; P and N: ON Except P and N: OFF When the shift lever position displayed on the intelligent tester differs from the actual position, adjustment of the PNP switch or the shift cable may be incorrect. PNP Switch Status/ ON or OFF Shift lever position is; R: ON Except R: OFF When the shift lever position displayed on the intelligent tester differs from the actual position, adjustment of the PNP switch or the shift cable may be incorrect. PNP Switch Status/ ON or OFF Shift lever position is; P: ON Except P: OFF When the shift lever position displayed on the intelligent tester differs from the actual position, adjustment of the PNP switch or the shift cable may be incorrect. PNP Switch Status/ ON or OFF Shift lever position is; N: ON Except N: OFF When the shift lever position displayed on the intelligent tester differs from the actual position, adjustment of the PNP switch or the shift cable may be incorrect. DRIVE PNP Switch Status/ ON or OFF Shift lever position is; D and S: ON Except D and S: OFF When the shift lever position displayed on the intelligent tester differs from the actual position, adjustment of the PNP switch or the shift cable may be incorrect. MODE SELECT SW Sport Mode Select Switch Status/ ON or OFF Shift lever position is; S, "+" and "-": ON Except S, "+" and "-": OFF PNP SW [NSW] REVERSE PARKING NEUTRAL 1 - INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Disconnect the park/neutral position switch connector. (b) Measure the resistance according to the value(s) in the table below when the shift lever is moved to each position. Standard resistance Switch Side: (Connector Front View): Shift Position P C1 Except P R Except R N Except N D, S, "+" and "-" Except D, S, "+" and "-" Tester Connection 1 - 3 and 4 - 9 1-2 1 - 8 and 4 - 9 1-7 Specified Condition Below 1 Ω 10 kΩ or higher Below 1 Ω 10 kΩ or higher Below 1 Ω 10 kΩ or higher Below 1 Ω 10 kΩ or higher C110340E42 NG OK REPLACE PARK/NEUTRAL POSITION SWITCH ASSEMBLY AX AX–166 2 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM INSPECT TRANSMISSION CONTROL SWITCH (a) Connect the park/neutral position switch connector. (b) Disconnect the transmission control switch connector of the shift lock control unit assembly. (c) Measure the resistance according to the value(s) in the table below when the shift lever is moved to each position. Standard resistance Switch Side: AX (Connector Front View): Shift Position E31 Tester Connection S, "+" and "-" 3-7 Except S, "+" and "-" NG Specified Condition Below 1 Ω 10 kΩ or higher REPLACE TRANSMISSION CONTROL SWITCH C110341E16 OK 3 CHECK ECU TERMINAL VOLTAGE (STA TERMINAL) (a) Connect the transmission control switch connector of the shift lock control unit assembly. (b) Measure the voltage according to the value(s) in the table below while cranking the engine. Standard voltage Wire Harness Side: TCM Connector (Front View) C56 STA C133210E04 Tester Connection Specified Condition STA (C56-10) - Body ground 9 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR (TCM - ECM) OK 4 CHECK HARNESS AND CONNECTOR (PARK/NEUTRAL POSITION SWITCH - TCM) (a) Disconnect the TCM connector. (b) Turn the ignition switch on (IG), and measure the voltage according to the value(s) in the table below when the shift lever is moved to each position. Standard voltage Wire Harness Side: TCM Connector (Front View) C56 Shift Position Tester Connection Specified Condition R R (C56-15) - Body ground 10 to 14 V * D (C56-16) - Body ground 10 to 14 V Except R R D D C133210E05 Except D Below 1 V Below 1 V U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–167 HINT: *: The voltage will drop slightly because the back up light is turned on. NG OK REPLACE TCM REPAIR OR REPLACE HARNESS OR CONNECTOR (PARK/NEUTRAL POSITION SWITCH - TCM) AX AX–168 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM ECU Power Source Circuit DESCRIPTION AX When the ignition switch is turned on (IG), voltage from the ECM's MREL terminal is applied to the EFI relay. This causes the contacts of the EFI relay to close, which supplies power to terminal +B of the TCM. WIRING DIAGRAM TCM EFI MAIN 18 C56 +B To ECM EFI Relay FL MAIN 8 C56 E1 Battery C133264E01 INSPECTION PROCEDURE 1 INSPECT ECU TERMINAL VOLTAGE (+B TERMINAL) (a) Disconnect the TCM connector. (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness Side: TCM Connector (Front View) C56 +B NG E1 C133210E06 OK Tester Connection Specified Condition +B (C56-18) - E1 (C56-8) 9 to 14 V CHECK FOR INTERMITTENT PROBLEMS U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM 2 AX–169 CHECK HARNESS AND CONNECTOR (TCM - BODY GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side: TCM Connector (Front View) C56 Tester Connection Specified Condition E1 (C56-8) - Body ground Below 1 Ω (b) Reconnect the TCM connector. NG E1 C133210E07 REPAIR OR REPLACE HARNESS OR CONNECTOR (TCM - BODY GROUND) OK REPAIR OR REPLACE HARNESS OR CONNECTOR (TCM - EFI RELAY) AX AX–164 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE FLUID AUTOMATIC TRANSAXLE FLUID ADJUSTMENT 1. BEFORE FILLING TRANSAXLE WITH FLUID • This transaxle requires Genuine ATF WS transmission fluid. • After servicing the transaxle, you must refill the transaxle with the correct amount of fluid. • Maintain the vehicle in a horizontal position while adjusting fluid level. • Proceed to step 2 if the oil pan, valve body, drive shaft, and/or torque converter has been removed or if the oil seal has been replaced. • Proceed to step 3 if oil leakage has been repaired and if the oil cooler and cooler hose have been removed. 2. FILL TRANSAXLE PAN WITH FLUID (a) Remove the engine under cover LH. (b) Remove the engine under cover RH. (c) Remove the under front fender apron seal RH. AX (d) Remove the refill plug and overflow plug. Refill Plug Overflow Plug C132240E01 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE FLUID AX–165 (e) Fill the transaxle through the refill hole until fluid begins to trickle out of the overflow tube. AX C132241 (f) 3. C132242 Temporarily install the overflow plug. FILL TRANSAXLE WITH FLUID (a) Fill the transaxle with the correct amount of fluid as listed in the table below. Standard capacity Performed Repair Fill Amount Replacement of transaxle (a new torque converter is used) 5.3 liters (5.6 US qts, 4.7 lmp. qts) Replacement of transaxle (the torque converter is reused) 3.4 liters (3.6 US qts, 3.0 lmp. qts) Removal & installation of oil pan (including oil drain) Removal & installation of drive shaft 2.8 liters (3.0 US qts, 2.5 lmp. qts) Removal & installation of valve body 3.2 liters (3.4 US qts, 2.8 lmp. qts) Removal & installation of torque converter 4.8 liters (5.1 US qts, 4.2 lmp. qts) Repair of oil leakage and removal of oil cooler and cooler hose 0.5 liters (0.5 US qts, 0.4 lmp. qts) HINT: If you cannot add the listed amount of fluid, do the following: (1) Temporarily install the refill plug. (2) Allow the engine to idle with the air conditioning OFF. (3) Move the shift lever through entire gear range to circulate fluid. (4) Move the shift lever to the P position. (5) Wait for 30 seconds with the engine idling. (6) Stop the engine. (7) Remove the refill plug and add fluid. (8) Reinstall the refill plug. AX–166 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE FLUID (b) Temporarily install the refill plug to avoid fluid splash. 4. CIRCULATE AUTOMATIC TRANSAXLE FLUID (a) Allow the engine to idle with the air conditioning OFF. (b) Move the shift lever through entire gear range to circulate the fluid. 5. CHECK FLUID TEMPERATURE NOTICE: The fluid temperature should be less than 40°C (104°F) before beginning the fluid temperature check. AX (a) With the intelligent tester: (1) Connect the intelligent tester to the DLC3. (2) Select the tester menus: OBD/MOBD, ENGINE, DATA LIST and A/T. (3) Check A/T OIL TEMP. (4) Allow the engine to idle until the fluid temperature reaches 39°C (102°F). Intelligent Tester DLC3 CAN VIM C131977E05 DLC3: (b) Without the intelligent tester (Using D shift indicator): (1) Connect terminals CG (4) and TC (13) of the DLC3 using SST. SST 09843-18040 (2) Move the shift lever back and forth between N and D at 1.5 seconds interval for 6 seconds. (3) The D shift indicator on the combination meter comes on for 2 seconds when the fluid temperature is within the appropriate temperature range. (4) The D shift indicator will come on again when the fluid temperature reaches 40°C (104°F) and will blink when it exceeds 45°C (113°F). (5) After confirming that the D shift indicator turns off, move the shift lever to the P position and remove the SST from terminals CG and TC. CG 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 TC C101492E04 6. CHECK TRANSAXLE FLUID LEVEL NOTICE: The fluid temperature must be between 40°C (104°F) and 45°C (113°F) to accurately check the fluid level. (a) Remove the overflow plug with the engine idling. U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE FLUID AX–167 (b) Check that the fluid comes out of the overflow tube. If fluid does not come out, proceed to step 7. If fluid comes out, wait until the overflow slows to a trickle and proceed to step 8. Specified Fluid Level Overflow Tube 7. C113723E01 8. ADD FLUID (a) Install the overflow plug. (b) Remove the refill plug. (c) Add the fluid until it comes out of the overflow plug. (d) Wait until the overflow slows to a trickle. (e) Install the overflow plug with a new gasket. (f) Install the refill plug with a new gasket. (g) Stop the engine. AFTER FILLING TRANSMISSION (a) Install the overflow plug with a new gasket. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) (b) Install the refill plug with a new gasket. Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) (c) Stop the engine. AX AX–168 U660E AUTOMATIC TRANSAXLE – SPEED SENSOR SPEED SENSOR U660E AUTOMATIC TRANSAXLE TRANSMISSION COMPONENTS AUTOMATIC TRANSAXLE ASSEMBLY AX 11 (112, 8) SPEED SENSOR TRANSMISSION VALVE BODY ASSEMBLY x11 11 (112, 8) O-RING 11 (112, 8) VALVE BODY OIL STRAINER ASSEMBLY GASKET AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY x18 N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Apply ATF WS 7.5 (76, 66 in.*lbf) Precoated part C139853E01 U660E AUTOMATIC TRANSAXLE – SPEED SENSOR AX–169 REMOVAL 1. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY HINT: (See page AX-207) 2. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUBASSEMBLY (See page AX-182) 3. REMOVE VALVE BODY OIL STRAINER ASSEMBLY (See page AX-182) 4. REMOVE TRANSMISSION VALVE BODY ASSEMBLY (See page AX-183) 5. REMOVE SPEED SENSOR (a) Disconnect the connector. (b) Remove the 2 bolts and speed sensor from the valve body. C138516 INSTALLATION 1. INSTALL SPEED SENSOR (a) Coat the 2 bolts with ATF. (b) Install the speed sensor to the valve body with the 2 bolts. Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) (c) Connect the connector. 2. INSTALL TRANSMISSION VALVE BODY ASSEMBLY (See page AX-183) 3. INSTALL VALVE BODY OIL STRAINER ASSEMBLY (See page AX-184) 4. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUBASSEMBLY (See page AX-185) 5. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY HINT: (See page AX-214) C138516E01 AX AX–170 U660E AUTOMATIC TRANSAXLE – ATF TEMPERATURE SENSOR ATF TEMPERATURE SENSOR U660E AUTOMATIC TRANSAXLE TRANSMISSION COMPONENTS AX AUTOMATIC TRANSAXLE ASSEMBLY O-RING ATF TEMPERATURE SENSOR ASSEMBLY CLAMP 11 (112, 8) O-RING VALVE BODY OIL STRAINER ASSEMBLY 11 (112, 8) GASKET AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY x18 7.5 (76, 66 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Apply ATF WS Precoated part C138308E01 AX–171 U660E AUTOMATIC TRANSAXLE – ATF TEMPERATURE SENSOR REMOVAL 1. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY HINT: (See page AX-207) 2. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUBASSEMBLY (See page AX-182) 3. REMOVE VALVE BODY OIL STRAINER ASSEMBLY (See page AX-182) 4. REMOVE ATF TEMPERATURE SENSOR ASSEMBLY (a) Disconnect the connector. (b) Remove the 4 bolts, ATF temperature sensor assembly and clamp from the valve body. C139240 (c) Remove the O-ring from the ATF temperature sensor assembly. O-Ring C138520E01 INSPECTION 1. INSPECT ATF TEMPERATURE SENSOR ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection THO1 E2 C133224E01 Specified Condition E2 - THO1 90 Ω to 156 kΩ E2 - Body ground 10 kΩ or higher THO1 - Body ground 10 kΩ or higher HINT: If the resistance is out of the specified range with the ATF temperature assembly shown in the table below, the driveability of the vehicle may decrease. Standard resistance ATF Temperature Specified Condition 10 °C (50°F) 5.8 to 7.1 kΩ 110°C (230°F) 0.23 to 0.26 kΩ If the result is not specified, replace the ATF temperature sensor assembly. AX AX–172 U660E AUTOMATIC TRANSAXLE – ATF TEMPERATURE SENSOR INSTALLATION O-Ring 1. INSTALL ATF TEMPERATURE SENSOR ASSEMBLY (a) Coat a new O-ring with ATF and install it to the ATF temperature sensor assembly . (b) Coat the 4 bolts with ATF. AX C138520E01 Connector B B (c) Install the ATF temperature sensor assembly and clamp to the valve body with the 4 bolts. Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) Bolt length: Bolt A: 25 mm (0.98 in.) Bolt B: 85 mm (3.35 in.) (d) Connect the connector. B A C139240E01 2. INSTALL VALVE BODY OIL STRAINER ASSEMBLY (See page AX-184) 3. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUBASSEMBLY (See page AX-185) 4. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY HINT: (See page AX-214) U660E AUTOMATIC TRANSAXLE – PARK / NEUTRAL POSITION SWITCH AX–173 PARK / NEUTRAL POSITION SWITCH U660E AUTOMATIC TRANSAXLE TRANSMISSION COMPONENTS COOL AIR INTAKE DUCT SEAL AX 5.0 (51, 44 in.*lbf) AIR CLEANER CAP SUB-ASSEMBLY 5.0 (51, 44 in.*lbf) AIR CLEANER INLET ASSEMBLY AIR CLEANER FILTER ELEMENT NO. 1 AIR CLEANER INLET CLIP 13 (130, 9) CONTROL SHAFT LEVER 5.0 (51, 44 in.*lbf) 13 (130, 9) 5.4 (55, 48 in.*lbf) AIR CLEANER CASE SUB-ASSEMBLY TRANSMISSION CONTROL CABLE PARK/NEUTRAL POSITION SWITCH ASSEMBLY 7.8 (80, 69 in.*lbf) AIR CLEANER BRACKET N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C133596E01 AX–174 U660E AUTOMATIC TRANSAXLE – PARK / NEUTRAL POSITION SWITCH ON-VEHICLE INSPECTION 1. AX INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY OPERATION (a) Apply the parking brake. (b) Turn the ignition switch on (IG). (c) Depress the brake pedal and check that the engine starts when the shift lever is set in the N or P position, but does not start in other positions. (d) Check that the back-up light comes on and the reverse warning buzzer sounds when the shift lever is set in the R position, but the light and buzzer do not operate in other positions. If a failure is found, check the park/neutral position switch for continuity. U660E AUTOMATIC TRANSAXLE – PARK / NEUTRAL POSITION SWITCH AX–175 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE COOL AIR INTAKE DUCT SEAL (See page EM-23) 3. REMOVE AIR CLEANER INLET ASSEMBLY (See page EM-24) 4. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-503) 5. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (See page EM-24) 6. REMOVE NO. 1 AIR CLEANER INLET (See page EM24) 7. REMOVE AIR CLEANER BRACKET (a) Separate the wire harness clamp. (b) Remove the 3 bolts and air cleaner bracket. 8. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Remove the clip from the transmission cable bracket. C132235 C132237 (b) Remove the nut and transmission control cable from the control shaft lever. (c) Disconnect the connector from the park/neutral position switch. C132236 AX AX–176 U660E AUTOMATIC TRANSAXLE – PARK / NEUTRAL POSITION SWITCH (d) Remove the nut, washer and control shaft lever from the control shaft. AX C136685 (e) Remove the 2 bolts and park/neutral position switch from the control shaft. NOTICE: Before removing the park/neutral position switch, remove any dirt or rust on the installation portion of the control shaft. Be sure to remove the switch straight along the shaft while being careful not to deform the plate spring that supports the shaft. If the plate spring is deformed, the park/neutral switch cannot be reinstalled correctly. C135732 INSPECTION Switch Side: 1. (Connector Front View): B L PL NL RL RB DL C110340E41 INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below when the shift lever is moved to each position. Standard resistance: Shift Position Tester Connection Specified Condition P 1 (RB) - 3 (PL) and 4 (B) 9 (L) Below 1 Ω Except P ↑ 10 kΩ or higher R 2 (RL) - 1 (RB) Below 1 Ω Except R ↑ 10 kΩ or higher N 1 (RB) - 8 (NL) and 4 (B) 9 (L) Below 1 Ω Except N ↑ 10 kΩ or higher D, S, "+" and "-" 1 (RB) - 7 (DL) Below 1 Ω Except D, S, "+" and "-" ↑ 10 kΩ or higher If operation cannot be done as specified, replace the park/neutral position switch. U660E AUTOMATIC TRANSAXLE – PARK / NEUTRAL POSITION SWITCH AX–177 INSTALLATION 1. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Move the shift lever to the N position. (b) Align the protrusions of the park/neutral position switch. Protrusions C135733E01 C135732 (c) Install the park/neutral position switch to the control shaft with the 2 bolts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) NOTICE: • Before installing the park/neutral position switch, remove any dirt or rust on the installation portion of the control shaft. Be sure to install the switch straight along the shaft while being careful not to deform the plate spring that supports the shaft. If the plate spring is deformed, the park/neutral switch cannot be reinstalled correctly. • After installing the park/neutral position switch, confirm that the 2 protrusions on the switch are aligned. (d) Install the control shaft lever to the control shaft with the nut and washer. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) (e) Connect the connector to the park/neutral position switch. C136685 (f) C132237 Connect the transmission control cable to the transmission control cable bracket with a new clip. AX AX–178 U660E AUTOMATIC TRANSAXLE – PARK / NEUTRAL POSITION SWITCH (g) Connect the transmission control cable to the control shaft lever with the nut. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) AX C132236 C132235 2. INSTALL AIR CLEANER BRACKET (a) Install the air cleaner bracket with the 3 bolts. Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) (b) Install the wire harness clamp. 3. INSTALL NO. 1 AIR CLEANER INLET (See page EM49) 4. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (See page EM-50) 5. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See page ES-506) 6. INSTALL AIR CLEANER INLET ASSEMBLY (See page EM-50) 7. INSTALL COOL AIR INTAKE DUCT SEAL (See page EM-52) 8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page EM-51) 9. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY OPERATION (See page AX-174) 10. INSPECT SHIFT LEVER POSITION (See page AX-191) 11. ADJUST SHIFT LEVER POSITION (See page AX-191) AX–178 U660E AUTOMATIC TRANSAXLE – TRANSMISSION WIRE TRANSMISSION WIRE U660E AUTOMATIC TRANSAXLE TRANSMISSION COMPONENTS AUTOMATIC TRANSAXLE ASSEMBLY AX TRANSMISSION WIRE TRANSMISSION VALVE BODY ASSEMBLY LOCK PLATE x11 11 (112, 8) 11 (112, 8) O-RING VALVE BODY OIL STRAINER ASSEMBLY 11 (112, 8) GASKET AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY 7.5 (76, 66 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part x18 Apply ATF WS Precoated part C139854E01 U660E AUTOMATIC TRANSAXLE – TRANSMISSION WIRE AX–179 REMOVAL 1. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY HINT: (See page AX-207) 2. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUBASSEMBLY (See page AX-182) 3. REMOVE VALVE BODY OIL STRAINER ASSEMBLY (See page AX-182) 4. REMOVE TRANSMISSION VALVE BODY ASSEMBLY (See page AX-183) 5. REMOVE TRANSMISSION WIRE (a) Disconnect the 9 connectors. (b) Remove the transmission wire from the clamp. C139241 (c) Remove the bolt, lock plate and transmission wire from the valve body. C138518 INSTALLATION 1. C142570E01 INSTALL TRANSMISSION WIRE (a) Coat the O-ring with ATF. (b) Coat the bolt with ATF. AX AX–180 U660E AUTOMATIC TRANSAXLE – TRANSMISSION WIRE (c) Install the transmission wire and lock plate to the valve body with the bolt. Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) AX C138518 (d) Install the transmission wire to the clamp. (e) Connect the 9 connectors. 2. INSTALL TRANSMISSION VALVE BODY ASSEMBLY (See page AX-183) 3. INSTALL VALVE BODY OIL STRAINER ASSEMBLY (See page AX-184) 4. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUBASSEMBLY (See page AX-185) 5. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY HINT: (See page AX-214) C139241 AX–181 U660E AUTOMATIC TRANSAXLE – VALVE BODY ASSEMBLY VALVE BODY ASSEMBLY U660E AUTOMATIC TRANSAXLE TRANSMISSION COMPONENTS AX AUTOMATIC TRANSAXLE ASSEMBLY MANUAL VALVE TRANSMISSION VALVE BODY ASSEMBLY 11 (112, 8) x11 O-RING VALVE BODY OIL STRAINER ASSEMBLY 11 (112, 8) GASKET MAGNET AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY 7.5 (76, 66 in.*lbf) x18 N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Apply ATF WS Precoated part C139875E03 AX–182 U660E AUTOMATIC TRANSAXLE – VALVE BODY ASSEMBLY REMOVAL AX 1. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY HINT: (See page AX-207) 2. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUBASSEMBLY (a) Remove the 18 bolts and oil pan from the transaxle. NOTICE: Some fluid will remain in the oil pan. Remove all the pan bolts, and carefully remove the oil pan assembly. (b) Remove the gasket from the oil pan. C134962 (c) Remove the 2 magnets from the oil pan. Magnet C134963E02 (d) Examine particles in the oil pan. (1) Collect any steel chips with the removed magnets. Lock carefully at the chips and particles in the oil pan and on the magnets to see the type of wear which might be found in the transaxle. Result: Steel (magnetic): Bearing, gear and plate wear Brass (non-magnetic): Bearing wear AT00103 3. C136687 REMOVE VALVE BODY OIL STRAINER ASSEMBLY (a) Remove the 2 bolts and oil strainer from the valve body. U660E AUTOMATIC TRANSAXLE – VALVE BODY ASSEMBLY AX–183 (b) Remove the O-ring from the oil strainer. O-Ring AX C136688E01 4. REMOVE TRANSMISSION VALVE BODY ASSEMBLY (a) Remove the 11 bolts and valve body from the transaxle. NOTICE: When removing the transmission valve body assembly, be careful not to allow the transmission revolution sensor and the transaxle case to interfere each other. 5. REMOVE MANUAL VALVE (a) Remove the manual valve from the valve body. C136689 C138517 INSTALLATION C138517 1. INSTALL MANUAL VALVE (a) Coat the manual valve with ATF and install it to the valve body. 2. INSTALL TRANSMISSION VALVE BODY ASSEMBLY (a) Coat the O-ring of the transmission wire with ATF. AX–184 U660E AUTOMATIC TRANSAXLE – VALVE BODY ASSEMBLY C B (b) Confirm that the manual valve lever is positioned as shown in the illustration and install the valve body assembly to the transaxle case with the 11 bolts. Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) Bolt length: Bolt A: 25 mm (0.98 in.) Bolt B: 30 mm (1.18 in.) Bolt C: 35 mm (1.38 in.) Bolt D: 45 mm (1.77 in.) Bolt E: 55 mm (2.17 in.) NOTICE: • When installing the transmission valve body assembly, be careful not to allow the transmission revolution sensor and transaxle case to interfere each other. • Be sure to insert the pin of the manual valve lever into the groove on the end of the manual valve. • First, temporarily tighten the bolts marked by (*1) in the illustration because they are positioning bolts. A D AX *1 *1 E B B C136689E01 3. O-Ring INSTALL VALVE BODY OIL STRAINER ASSEMBLY (a) Coat a new O-ring with ATF and install it to the oil strainer. NOTICE: Ensure that the O-ring is not twisted or pinched. C136688E01 (b) Install the oil strainer to the valve body with the 2 bolts. Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) C136687 U660E AUTOMATIC TRANSAXLE – VALVE BODY ASSEMBLY 4. Magnet AX–185 INSTALL AUTOMATIC TRANSAXLE OIL PAN SUBASSEMBLY (a) Install the 2 magnets to the oil pan. (b) Install a new gasket to the oil pan. (c) Apply sealant to the 18 bolts. Sealant: Toyota Genuine Seal Packing 1344, Three Bond 1344 or equivalent. C134963E02 (d) Install the oil pan from the automatic transaxle with the 18 bolts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) NOTICE: • In order to ensure proper sealing of the transmission oil pan bolts, apply sealant to the bolts and install them within 10 minutes of sealant application. • Completely remove any oil or grease from the contact surface of the transaxle case and oil pan sub-assembly with the gasket before installation. C134962 5. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY HINT: (See page AX-214) AX AX–186 U660E AUTOMATIC TRANSAXLE – SHIFT LOCK SYSTEM SHIFT LOCK SYSTEM ON-VEHICLE INSPECTION 1. CHECK SHIFT LOCK OPERATION (a) Move the shift lever to the P position. (b) Turn the ignition switch off. (c) Check that the shift lever cannot be moved to any position other than P. (d) Turn the ignition switch on (IG), depress the brake pedal and check that the shift lever can be moved to another position. If operation cannot be done as specified, inspect the shift lock control unit. 2. CHECK SHIFT LOCK RELEASE BUTTON OPERATION (a) Using a screwdriver, remove the shift lock release cover. (b) When operating the shift lever with the shift lock release button pressed, check that the lever can be moved to any position other than P. If operation cannot be done as specified, check the shift lever assembly installation condition. 3. CHECK KEY INTERLOCK OPERATION (w/o Smart Key System) (a) Turn the ignition switch to the ON position. (b) Depress the brake pedal and move the shift lever to any position other than P. (c) Check that the ignition key cannot be turned to the LOCK position. (d) Move the shift lever to the P position, turn the ignition key to the LOCK position and check that the ignition key can be removed. If operation cannot be done as specified, inspect the shift lock control unit. 4. INSPECT SHIFT LOCK CONTROL UNIT ASSEMBLY (w/o Smart Key System) (a) Measure the voltage according to the value(s) in the table below. HINT: Do not disconnect the shift lock control unit assembly connector. AX Wire Harness Side: (Connector Rear View): STP E IG ACC KLS+ C127833E05 AX–187 U660E AUTOMATIC TRANSAXLE – SHIFT LOCK SYSTEM Standard voltage Terminal Measuring Condition Voltage (V) 6 (ACC) - 1 (E) Ignition switch ON 10 to 14 6 (ACC) - 1 (E) Ignition switch ACC 10 to 14 6 (STP) - 1 (E) Ignition switch OFF Below 1 4 (STP) - 1 (E) Brake pedal depressed 10 to 14 4 (STP) - 1 (E) Brake pedal released Below 1 5 (KLS+) - 1 (E) 1. Ignition switch ACC and shift lever P position 2. Ignition switch ACC and shift lever except P position 3. Ignition switch ACC and shift lever P position (After approx. 1 second) 7.5 to 11 Below 1 6 to 9 8 (IG) - 1 (E) Ignition switch ON 10 to 14 8 (IG) - 1 (E) Ignition switch OFF Below 1 (b) Measure the resistance according to the value(s) in the table below. HINT: Do not disconnect the shift lock control unit assembly connector. If the result is not as specified, replace the shift lever assembly. Wire Harness Side: (Connector Rear View): E C127833E06 Standard resistance Terminal Measuring Condition Specified Value 1 (E) - Body ground Always Below 1 Ω 5. Wire Harness Side: (Connector Rear View): STP E INSPECT SHIFT LOCK CONTROL UNIT ASSEMBLY (w/ Smart Key System) (a) Measure the voltage according to the value(s) in the table below. HINT: Do not disconnect the shift lock control unit assembly connector. IG C129009E03 Standard voltage Terminal Measuring Condition Voltage (V) 12 (IG) - 3 (E) Engine switch on (IG) 10 to 14 12 (IG) - 3 (E) Engine switch off Below 1 6 (STP) - 3 (E) Brake pedal depressed 10 to 14 AX AX–188 U660E AUTOMATIC TRANSAXLE – SHIFT LOCK SYSTEM Terminal Measuring Condition Voltage (V) 6 (STP) - 3 (E) Brake pedal released Below 1 (b) Measure the resistance according to the value(s) in the table below. HINT: Do not disconnect the shift lock control unit assembly connector. If the result is not done as specified, replace the shift lever assembly. Wire Harness Side: (Connector Rear View): AX E C129009E04 Standard resistance Terminal Measuring Condition Specified Value 3 (E) - Body ground Always Below 1 Ω U660E AUTOMATIC TRANSAXLE – TRANSMISSION CONTROL CABLE ASSEMBLY AX–189 TRANSMISSION CONTROL CABLE ASSEMBLY U660E AUTOMATIC TRANSAXLE TRANSMISSION COMPONENTS 17.5 (179, 13) 5.0 (51, 44 in.*lbf) AX SHIFT LOCK CONTROL UNIT NO. 2 SHIFT CABLE GROMMET RETAINER CENTER AIRBAG SENSOR ASSEMBLY AIR CLEANER CAP SUB-ASSEMBLY COOL AIR INTAKE DUCT SEAL AIR CLEANER FILTER ELEMENT TRANSMISSION CONTROL CABLE ASSEMBLY CLIP 13 (130, 9) 5.0 (51, 44 in.*lbf) 5.0 (51, 44 in.*lbf) AIR CLEANER CASE SUB-ASSEMBLY AIR CLEANER INLET ASSEMBLY 5.0 (51, 44 in.*lbf) NO. 1 AIR CLEANER INLET N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C141688E01 AX–190 U660E AUTOMATIC TRANSAXLE – TRANSMISSION CONTROL CABLE ASSEMBLY REMOVAL AX 1. REMOVE AIR CONDITIONING UNIT HINT: (See page AC-151) 2. REMOVE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-442) 3. REMOVE COOL AIR INTAKE DUCT SEAL (See page EM-23) 4. REMOVE AIR CLEANER INLET ASSEMBLY (See page EM-24) 5. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-503) 6. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (See page EM-24) 7. REMOVE NO. 1 AIR CLEANER INLET (See page EM24) 8. DISCONNECT NO. 2 SHIFT CABLE GROMMET RETAINER (a) Turn back the carpet. (b) Remove the 2 bolts and disconnect the No. 2 shift cable grommet retainer. (c) Remove the No. 2 shift cable grommet retainer. 9. REMOVE TRANSMISSION CONTROL CABLE ASSEMBLY (a) Disconnect the end of the transmission control cable assembly from the shift lock control unit. (b) Disconnect the transmission control cable assembly from the transmission floor shift assembly while pushing the 2 claws of the floor shift cable. C132234 C135015 (c) Remove the nut and transmission control cable from the control shaft lever. C132236 U660E AUTOMATIC TRANSAXLE – TRANSMISSION CONTROL CABLE ASSEMBLY AX–191 (d) Remove the clip and disconnect the transmission control cable assembly from the No. 1 control cable bracket. (e) Pull out the transmission control cable assembly from the body. AX C132237 AX–192 U660E AUTOMATIC TRANSAXLE – TRANSMISSION CONTROL CABLE ASSEMBLY ADJUSTMENT 1. INSPECT SHIFT LEVER POSITION (a) When shifting from the P to the R position with the ignition switch on (IG) and brake pedal depressed, make sure that the shift lever moves smoothly and moves correctly into position. (b) Start the engine and make sure that the vehicle moves forward when shifting from the N to the D position and moves rearward when shifting to the R position. If operation cannot be done as specified, inspect the park/neutral position switch assembly and check the shift lever assembly installation condition. 2. ADJUST SHIFT LEVER POSITION (a) Move the shift lever to the N position. AX (b) Remove the nut and transmission control cable from the control shaft lever. C132236 (c) Align the protrusions of the park/neutral position switch. Protrusions C135733E01 U660E AUTOMATIC TRANSAXLE – TRANSMISSION CONTROL CABLE ASSEMBLY Slider AX–193 (d) Move the slider in the directions indicated by the arrows and pull up the lock piece. NOTICE: Do not damage the boot. Lock Piece AX C135734E02 (e) Install the control cable to the control shaft with the nut. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) NOTICE: • If the control cable end is excessively pushed up, the shift lever cannot be adjusted. • When tightening the nut, confirm that the control cable is properly stretched. C132236 (f) Push in the lock piece. NOTICE: Firmly push in the lock piece until the slider lock is engaged. (g) Start the engine and make sure that the vehicle moves forward when moving the lever from the N to the D position and moves rearward when moving it to the R position. If it becomes hard to move the shift lever, readjust the shift lever position. C138300E01 AX–194 U660E AUTOMATIC TRANSAXLE – TRANSMISSION CONTROL CABLE ASSEMBLY INSTALLATION 1. INSTALL NO. 2 SHIFT CABLE GROMMET RETAINER (a) Pass the control cable from the cabin to the engine compartment. (b) Install the No. 2 shift cable grommet retainer with the 2 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) AX 2. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (a) Move the shift lever to the N position. C132234 (b) Install the transmission control cable assembly as shown in the illustration. HINT: • Install the floor shift cable with the uneven surface facing up. • Securely engage the claws of the floor shift cable. C135020 (c) Connect the control cable to the bracket with a new clip. C132237 U660E AUTOMATIC TRANSAXLE – TRANSMISSION CONTROL CABLE ASSEMBLY AX–195 (d) Install the control cable to the control shaft lever with the nut. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) AX C132236 (e) Push in the lock piece of the transmission control cable. NOTICE: Firmly push in the lock piece until the slider lock is engaged. HINT: After pushing in the lock piece, make sure that the boot is not deformed. 3. INSTALL CENTER AIRBAG SENSOR ASSEMBLY (See page RS-442) 4. INSTALL AIR CONDITIONING UNIT HINT: (See page AC-173) 5. INSTALL NO. 1 AIR CLEANER INLET (See page EM49) 6. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (See page EM-50) 7. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See page ES-506) 8. INSTALL AIR CLEANER INLET ASSEMBLY (See page EM-50) 9. INSTALL COOL AIR INTAKE DUCT SEAL (See page EM-52) C138300E02 10. INSPECT SHIFT LEVER POSITION (See page AX-191) 11. ADJUST SHIFT LEVER POSITION (See page AX-191) U660E AUTOMATIC TRANSAXLE – DIFFERENTIAL OIL SEAL AX–195 DIFFERENTIAL OIL SEAL U660E AUTOMATIC TRANSAXLE TRANSMISSION COMPONENTS FRONT DRIVE SHAFT ASSEMBLY RH AX HOLE SNAP RING FRONT DRIVE SHAFT LH HOLE SNAP RING 32 (330, 24) FRONT DRIVE SHAFT ASSEMBLY LH TIE ROD ASSEMBLY LH FRONT STABILIZER LINK ASSEMBLY LH FRONT SPEED SENSOR LH 19 (192, 14) 8.0 (82, 71 in.*lbf) 74 (755, 55) FRONT FLEXIBLE HOSE FRONT AXLE ASSEMBLY LH 294 (3,000, 217) FRONT AXLE HUB NUT LH FRONT SUSPENSION LOWER NO. 1 ARM LH 49 (500, 36) COTTER PIN 75 (765, 55) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C137676E03 AX–196 U660E AUTOMATIC TRANSAXLE – DIFFERENTIAL OIL SEAL AX GASKET NO. 1 TRANSMISSION OIL FILLER TUBE 49 (500, 36) REFILL PLUG GASKET 49 (408, 40 (500, 30) 36) OVERFLOW PLUG FRONT TRANSAXLE CASE NO. 1 OIL SEAL TRANSAXLE CASE NO. 2 OIL SEAL N*m (kgf*cm, ft.*lbf) : Specified torque Apply MP grease Non-reusable part C139876E01 U660E AUTOMATIC TRANSAXLE – DIFFERENTIAL OIL SEAL AX–197 REMOVAL 1. DRAIN AUTOMATIC TRANSAXLE FLUID (See page AX-207) 2. REMOVE FRONT WHEELS 3. REMOVE FRONT AXLE HUB NUT LH (See page DS7) 4. REMOVE FRONT AXLE HUB NUT RH (See page EM28) 5. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH (See page DS-7) 6. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH (See page EM-29) 7. SEPARATE FRONT SPEED SENSOR LH (See page DS-7) 8. SEPARATE FRONT SPEED SENSOR RH (See page EM-29) 9. SEPARATE TIE ROD ASSEMBLY LH (See page DS-8) 10. SEPARATE TIE ROD ASSEMBLY RH (See page EM29) 11. SEPARATE FRONT SUSPENSION LOWER NO. 1 ARM LH (See page DS-8) 12. SEPARATE FRONT SUSPENSION LOWER NO. 1 ARM RH (See page EM-29) 13. SEPARATE FRONT AXLE ASSEMBLY LH (See page DS-8) 14. SEPARATE FRONT AXLE ASSEMBLY RH (See page EM-29) 15. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (See page DS-9) 16. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (See page DS-9) 17. SECURE FRONT AXLE HUB SUB-ASSEMBLY (See page DS-9) 18. REMOVE TRANSAXLE CASE NO. 2 OIL SEAL (a) Using SST, remove the oil seal from the transaxle case. SST 09308-00010 SST C133598E01 AX AX–198 U660E AUTOMATIC TRANSAXLE – DIFFERENTIAL OIL SEAL 19. REMOVE FRONT TRANSAXLE CASE NO. 1 OIL SEAL (a) Using SST, remove the oil seal from the transaxle housing. SST 09308-00010 SST AX C133597E01 INSTALLATION 1. INSTALL TRANSAXLE CASE NO. 2 OIL SEAL (a) Using SST and a hammer, install a new oil seal to the transaxle case. SST 09316-10010, 09950-70010 (09951-07100) Oil seal installation depth: -0.5 to 0.5 mm (-0.020 to 0.020 in.) (b) Coat the lip of the oil seal with MP grease. 2. INSTALL FRONT TRANSAXLE CASE NO. 1 OIL SEAL (a) Using SST and a hammer, install a new oil seal to the transaxle housing. SST 09308-14010 Oil seal installation depth: -0.5 to 0.5 mm (-0.020 to 0.020 in.) (b) Coat the lip of the oil seal with MP grease. 3. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (See page DS-20) 4. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (See page DS-21) 5. INSTALL FRONT AXLE ASSEMBLY LH (See page DS21) 6. INSTALL FRONT AXLE ASSEMBLY RH (See page EM-45) 7. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM LH (See page DS-21) 8. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM RH (See page EM-45) 9. INSTALL TIE ROD ASSEMBLY LH (See page DS-21) SST C139870E01 SST C139869E01 10. INSTALL TIE ROD ASSEMBLY RH (See page EM-45) 11. INSTALL FRONT SPEED SENSOR LH (See page DS21) U660E AUTOMATIC TRANSAXLE – DIFFERENTIAL OIL SEAL AX–199 12. INSTALL FRONT SPEED SENSOR RH (See page EM45) 13. INSTALL FRONT STABILIZER LINK ASSEMBLY LH (See page DS-22) 14. INSTALL FRONT STABILIZER LINK ASSEMBLY RH (See page EM-45) 15. INSTALL FRONT AXLE HUB NUT LH (See page DS22) 16. INSTALL FRONT AXLE HUB NUT RH (See page EM45) 17. INSTALL FRONT WHEELS (See page EM-51) 18. ADD AUTOMATIC TRANSAXLE FLUID HINT: (See page AX-164) 19. ADJUST FRONT WHEEL ALIGNMENT HINT: (See page SP-4) 20. CHECK ABS SPEED SENSOR SIGNAL (a) ABS: BC-11 (b) VSC (for BOSCH): BC-290 (c) VSC (for ADVICS): BC-123 AX AX–200 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY AUTOMATIC TRANSAXLE ASSEMBLY U660E AUTOMATIC TRANSAXLE TRANSMISSION COMPONENTS FRONT WIPER ARM AND BLADE ASSEMBLY RH AX 20 (204, 15) FRONT FENDER TO COWL SIDE SEAL RH FRONT WIPER ARM AND BLADE ASSEMBLY LH COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 85 (867, 63) 7.5 (77, 66 in.*lbf) 5.0 (51, 44 in.*lbf) FRONT FENDER TO COWL SIDE SEAL LH WINDSHIELD WIPER LINK ASSEMBLY COWL TOP PANEL OUTER SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque A134938E01 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY AX–201 AIR CLEANER CAP SUB-ASSEMBLY V-BANK COVER SUB-ASSEMBLY AX AIR CLEANER FILTER ELEMENT COOL AIR INTAKE DUCT SEAL 5.0 (51, 44 in.*lbf) 5.0 (51, 44 in.*lbf) AIR CLEANER INLET ASSEMBLY RELAY BLOCK COVER UPPER AIR CLEANER CASE SUB-ASSEMBLY 5.0 (51, 44 in.*lbf) NO. 1 AIR CLEANER INLET 3.5 (36, 31 in.*lbf) 9.0 (92, 80 in.*lbf) ENGINE UNDER COVER RH 5.0 (51, 44 in.*lbf) BATTERY BATTERY TRAY INTAKE AIR RESONATOR SUB-ASSEMBLY ENGINE UNDER COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque A132994E01 AX–202 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY FRONT FENDER APRON SEAL RH 38 (388, 28) V-RIBBED BELT AX 23 (235, 17) ENGINE MOVING CONTROL ROD SUB-ASSEMBLY 9.8 (100, 87 in.*lbf) NO. 2 ENGINE MOUNTING STAY RH 43 (438, 32) GENERATOR ASSEMBLY NO. 1 OIL RESERVOIR TO PUMP HOSE NO. 1 FUEL VAPOR FEED HOSE FUEL TUBE SUB-ASSEMBLY 43 (438, 32) HEATER INLET WATER HOSE RADIATOR HOSE INLET RADIATOR HOSE OUTLET RETURN TUBE SUB-ASSEMBLY NO. 1 FUEL PIPE CLAMP NO. 1 OIL COOLER INLET HOSE 25 (250, 18) NO. 1 OIL COOLER OUTLET HOSE HEATER OUTLET WATER HOSE CLIP 13 (130, 9) 25 (250, 18) COOLER COMPRESSOR ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque TRANSMISSION CONTROL CABLE ASSEMBLY Non-reusable part C142576E01 AX–203 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY STEERING SLIDING YOKE AX FRONT STABILIZER LINK ASSEMBLY LH 35 (360, 26) TIE ROD ASSEMBLY LH 74 (755, 55) 49 (500, 36) COTTER PIN FRONT SPEED SENSOR LH 8.0 (85, 71 in.*lbf) 294 (3,000, 217) FRONT SUSPENSION LOWER NO. 1 ARM LH FRONT AXLE HUB NUT LH 75 (765, 55) 62 (632, 46) GASKET GASKET GASKET 56 (571, 41) 62 (632, 46) NO. 1 EXHAUST PIPE SUPPORT BRACKET 33 (337, 24) EXHAUST PIPE ASSEMBLY FRONT 21 (214, 15) EXHAUST PIPE NO. 1 SUPPORT BRACKET N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A132996E01 AX–204 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY 87 (887, 64) AX ENGINE ASSEMBLY WITH TRANSAXLE ENGINE WIRE 95 (969, 70) 95 (969, 70) VANE PUMP ASSEMBLY NO. 2 FUEL PIPE CLAMP FUEL TUBE SUB-ASSEMBLY STARTER ASSEMBLY 43 (439, 32) 37 (380, 26) FRONT FRAME ASSEMBLY 37 (380, 26) 9.8 (100, 87 in.*lbf) 7.8 (80, 69 in.*lbf) FRONT SUSPENSION MEMBER BRACE REAR RH FRAME SIDE RAIL PLATE RH 32 (329, 24) 85 (867, 63) 32 (329, 24) 85 (867, 63) FRAME SIDE RAIL PLATE LH 32 (329, 24) 32 (329, 24) 32 (329, 24) N*m (kgf*cm, ft.*lbf) : Specified torque 85 (867, 63) 85 (867, 63) FRONT SUSPENSION MEMBER BRACE REAR LH 32 (329, 24) A134929E01 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY AX–205 FRONT DRIVE SHAFT ASSEMBLY RH AX BRACKET HOLE SNAP RING FRONT DRIVE SHAFT LH HOLE SNAP RING 32 (330, 24) FRONT DRIVE SHAFT ASSEMBLY LH 46 (469, 34) TORQUE CONVERTER CLUTCH ASSEMBLY x6 43 (439, 32) 41 (418, 30) x3 x7 7.8 (80, 69 in.*lbf) 64 (653, 47) DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT EXHAUST PIPE SUPPORT BRACKET FLYWHEEL HOUSING UNDER COVER N*m (kgf*cm, ft.*lbf) : Specified torque AUTOMATIC TRANSAXLE ASSEMBLY Non-reusable part Precoated part C139878E01 AX–206 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY NO. 1 TRANSMISSION CONTROL CABLE BRACKET AX ENGINE WIRE 12 (122, 9) 8.4 (86, 74 in.*lbf) 12 (122, 9) 12 (122, 9) 5.5 (56, 49 in.*lbf) WIRE HARNESS O-RING 8.4 (86, 74 in.*lbf) WIRE HARNESS CLAMP BRACKET 5.5 (56, 49 in.*lbf) SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY ENGINE MOUNTING FRONT BRACKET AUTOMATIC TRANSAXLE ASSEMBLY BREATHER BRACKET 8.4 (86, 74 in.*lbf) BREATHER HOSE 64 (653, 47) WIRE HARNESS CLAMP BRACKET 8.4 (86, 74 in.*lbf) WIRE HARNESS CLAMP BRACKET 11 (115, 8) TCM OIL COOLER OUTLET HOSE N*m (kgf*cm, ft.*lbf) : Specified torque OIL COOLER INLET HOSE Non-reusable part Apply ATF WS C133599E01 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY AX–207 REMOVAL NOTICE: • When the automatic transaxle is replaced, the transaxle's compensation code must be input into the TCM (See page AX-19). • When the TCM is replaced, the existing transaxle compensation codes must be input into the new TCM (See page AX-22). • If the following parts have been replaced, initialize the TCM and perform a road test to allow the TCM to learn (See page AX-25). – Valve body assembly – Shift solenoid SL3 – Shift solenoid SL4 • If the following parts have been replaced, perform a road test to allow the TCM to learn (See page AX-25). – Shift solenoid SL1 – Shift solenoid SL2 • If the TCM or transaxle has been replaced, register the transmission compensation code in the TCM (See page AX-19). • Perform the RESET MEMORY (AT initialization) when replacing the automatic transmission assembly, engine assembly or ECM (See page AX-25). 1. DISCHARGE FUEL SYSTEM PRESSURE HINT: (See page FU-1) 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 4. REMOVE FRONT WHEELS 5. REMOVE ENGINE UNDER COVER LH 6. REMOVE ENGINE UNDER COVER RH 7. REMOVE FRONT FENDER APRON SEAL RH 8. DRAIN ENGINE OIL 9. DRAIN ENGINE COOLANT (See page CO-5) 10. DRAIN AUTOMATIC TRANSAXLE FLUID (a) Remove the refill plug and gasket. C142572 AX AX–208 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY (b) Using a 6 mm socket hexagon wrench, remove the overflow plug and gasket. AX C142571 (c) Using a 6 mm socket hexagon wrench, remove the No. 1 transmission oil filler tube. (d) Drain the automatic transaxle fluid. C142574 (e) Using a 6 mm socket hexagon wrench, install the No. 1 transmission oil filler tube. Torque: 1.7 N*m (17 kgf*cm, 15 in.*lbf) C142574 (f) Using a 6 mm socket hexagon wrench, install the overflow plug with a new gasket. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) C142571 (g) Install the refill plug with a new gasket. Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) 11. REMOVE WINDSHIELD WIPER LINK ASSEMBLY HINT: (See page WW-9) 12. REMOVE COWL TOP PANEL OUTER SUBASSEMBLY (See page ES-481) C142572 13. REMOVE COOL AIR INTAKE DUCT SEAL (See page EM-23) U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY AX–209 14. REMOVE V-BANK COVER SUB-ASSEMBLY (See page EM-23) 15. REMOVE V-RIBBED BELT (See page EM-6) 16. REMOVE AIR CLEANER INLET ASSEMBLY (See page EM-24) 17. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-503) 18. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (See page EM-24) 19. REMOVE NO. 1 AIR CLEANER INLET (See page EM24) 20. REMOVE BATTERY (See page EM-24) 21. REMOVE INTAKE AIR RESONATOR SUB-ASSEMBLY (See page EM-25) 22. REMOVE NO. 2 ENGINE MOUNTING STAY RH (See page EM-25) 23. REMOVE ENGINE MOVING CONTROL ROD SUBASSEMBLY (See page EM-25) 24. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE (See page EM-25) 25. DISCONNECT CHECK VALVE TO BRAKE BOOSTER HOSE (See page EM-25) 26. REMOVE RADIATOR HOSE INLET (See page EM-26) 27. REMOVE RADIATOR HOSE OUTLET (See page EM26) 28. DISCONNECT NO. 1 OIL COOLER INLET HOSE (See page EM-26) 29. DISCONNECT NO. 1 OIL COOLER OUTLET HOSE (See page EM-26) 30. DISCONNECT HEATER INLET WATER HOSE (See page EM-26) 31. DISCONNECT HEATER OUTLET WATER HOSE (See page EM-26) 32. REMOVE ECM (See page ES-518) 33. REMOVE RELAY BLOCK COVER UPPER 34. DISCONNECT ENGINE WIRE (See page EM-27) AX AX–210 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY 35. SEPARATE WIRE HARNESS (a) Remove the bolt and disconnect the wire harness. AX C096795 36. DISCONNECT CONNECTOR (a) Disconnect the park/neutral position switch connector. 37. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (See page EM-27) 38. SEPARATE FUEL TUBE SUB-ASSEMBLY (See page EM-28) C132238 39. DISCONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE (See page EM-28) 40. DISCONNECT RETURN TUBE SUB-ASSEMBLY (See page EM-28) 41. REMOVE EXHAUST PIPE NO. 1 SUPPORT BRACKET (See page EX-3) 42. REMOVE EXHAUST PIPE ASSEMBLY FRONT (See page EX-3) 43. REMOVE FRONT AXLE HUB NUT LH (See page DS7) 44. REMOVE FRONT AXLE HUB NUT RH (See page EM28) 45. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH (See page DS-7) 46. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH (See page EM-29) 47. DISCONNECT FRONT SPEED SENSOR LH (See page DS-7) 48. DISCONNECT FRONT SPEED SENSOR RH (See page EM-29) 49. DISCONNECT TIE ROD ASSEMBLY LH (See page DS-8) 50. DISCONNECT TIE ROD ASSEMBLY RH (See page EM-29) 51. DISCONNECT FRONT SUSPENSION LOWER NO. 1 ARM LH (See page DS-8) 52. DISCONNECT FRONT SUSPENSION LOWER NO. 1 ARM RH (See page EM-29) U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY AX–211 53. SEPARATE FRONT AXLE ASSEMBLY LH (See page DS-8) 54. SEPARATE FRONT AXLE ASSEMBLY RH (See page EM-29) 55. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET (See page EM-29) 56. REMOVE FLYWHEEL HOUSING UNDER COVER (a) Remove the 2 bolts, exhaust pipe support bracket and flywheel housing under cover. C135005 57. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (a) Turn the crankshaft to gain access and remove the 6 bolts while holding the crankshaft pulley bolt with a wrench. 58. DISCONNECT STEERING SLIDING YOKE (See page PS-40) 59. REMOVE GENERATOR ASSEMBLY (See page CH-14) D002828 60. SEPARATE COOLER COMPRESSOR ASSEMBLY (See page EM-29) 61. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (See page EM-29) 62. REMOVE VANE PUMP ASSEMBLY (See page EM-30) 63. INSTALL ENGINE HANGERS (See page EM-30) 64. REMOVE FRONT FRAME ASSEMBLY (See page EM30) 65. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (See page DS-9) 66. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (See page DS-9) 67. REMOVE ENGINE WIRE 68. REMOVE STARTER ASSEMBLY (See page ST-141) AX AX–212 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY 69. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (a) Remove the bolt and breather bracket from the camshaft housing sub-assembly LH. (b) Remove the breather hose from the breather bracket. Camshaft Housing Sub-assembly LH AX C142575E01 (c) Remove the 11 bolts. (d) Separate and remove the automatic transaxle. C135007 70. REMOVE TORQUE CONVERTER CLUTCH ASSEMBLY (a) Put matchmarks on the transaxle housing and torque converter clutch assembly. (b) Remove the torque converter clutch assembly from the automatic transaxle assembly. Matchmarks C139850E01 71. REMOVE ENGINE MOUNTING FRONT BRACKET (a) Remove the 3 bolts and engine mounting front bracket. C133601 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY AX–213 72. REMOVE TCM (a) Remove the 2 bolts and TCM from the transaxle. AX C139840E01 73. REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY (a) Remove the bolt and hole cover from the transaxle case. (b) Remove the O-ring from the hole cover. C135002 74. REMOVE WIRE HARNESS CLAMP BRACKET (a) Remove the 4 bolts and 4 clamp brackets. C139880 75. REMOVE NO. 1 TRANSMISSION CONTROL CABLE BRACKET (a) Remove the 2 bolts and No.1 transmission control cable bracket. C139615 AX–214 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY 76. SEPARATE OIL COOLER OUTLET HOSE (a) Separate the oil cooler outlet hose. AX C139881 77. SEPARATE OIL COOLER INLET HOSE (a) Separate the oil cooler inlet hose. C139882 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY AX–215 INSTALLATION 1. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY HINT: (See page AX-239) 2. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY (a) Using vernier calipers and a straightedge, measure dimension "A" between the transaxle fitting part of the engine and the converter fitting part of the drive plate (#). C083051 (b) Aligning the matchmarks on the transaxle case and torque converter clutch assembly, engage the splines of the input shaft and turbine runner. NOTICE: Do not push on the torque converter when aligning the matchmarks. C135008 (c) Engage the splines of the stator shaft and the stator while turning the torque converter clutch assembly. HINT: Turn the torque converter clutch assembly approximately 180°. C135009 (d) Turn the torque converter clutch assembly and align the matchmarks on the torque converter clutch assembly and transaxle case to engage the key of the oil pump drive gear into the slot on the torque converter clutch assembly. C135010 AX AX–216 AX U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY (e) Using vernier calipers and a straightedge, measure dimension "B" shown in the illustration and check that "B" is greater than "A" (measured in step (#)). Standard: A + 1 mm (0.04 in.) or more NOTICE: Make sure to deduct the thickness of the straightedge. B C135011E01 3. INSTALL OIL COOLER INLET HOSE (a) Install the oil cooler inlet hose. 4. INSTALL OIL COOLER OUTLET HOSE (a) Install the oil cooler outlet hose. 5. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET (a) Install the No. 1 transmission control cable bracket with the 2 bolts. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) C139882 C139881 C139615 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY AX–217 6. INSTALL WIRE HARNESS CLAMP BRACKET (a) Install the 4 clamp brackets and 4 bolts. Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) 7. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY (a) Coat a new O-ring with ATF, and install it to the hole cover. C139880 (b) Install the hole cover to the transaxle case with the bolt. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 8. INSTALL TCM (a) Install the TCM to the transaxle. C135002 (b) Install and tighten the 2 bolts in the order shown in the illustration. Torque: 11 N*m (112 kgf*cm, 9 ft.*lbf) 2 1 C139840E05 9. C133601 INSTALL ENGINE MOUNTING FRONT BRACKET (a) Install the engine mounting front bracket to the automatic transaxle with the 3 bolts. Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) AX AX–218 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY A A A B A A AX C A D D D C135007E01 10. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (a) Install the automatic transaxle to the engine with the 11 bolts. Torque: Bolt A 64 N*m (653 kgf*cm, 47 ft.*lbf) Bolt B 64 N*m (653 kgf*cm, 47 ft.*lbf) Bolt C 46 N*m (469 kgf*cm, 34 ft.*lbf) Bolt D 43 N*m (439 kgf*cm, 32 ft.*lbf) (b) Install the breather bracket to the camshaft housing sub-assembly LH with the bolt. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) (c) Install the breather hose to the breather bracket. Camshaft Housing Sub-assembly LH 11. INSTALL STARTER ASSEMBLY (See page ST-148) C142575E01 12. CONNECT CONNECTOR (a) Connect the park/neutral position switch connector. C132238 13. INSTALL WIRE HARNESS (a) Connect the wire harness with the bolt. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 14. INSTALL ENGINE WIRE 15. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (See page DS-20) 16. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (See page DS-21) C096795 17. INSTALL FRONT FRAME ASSEMBLY (See page EM43) 18. INSTALL VANE PUMP ASSEMBLY (See page EM-44) 19. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (See page EM-44) U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY AX–219 20. INSTALL COOLER COMPRESSOR ASSEMBLY (See page EM-45) 21. INSTALL GENERATOR ASSEMBLY (See page CH-22) 22. INSTALL STEERING SLIDING YOKE (See page PS65) D002828 23. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (a) Apply a few drops of adhesive to 2 threads on the tip of the 6 torque converter clutch mounting bolts. Sealant: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent (b) Install the 6 torque converter clutch mounting bolts. Torque: 41 N*m (418 kgf*cm, 30 ft.*lbf) NOTICE: First install the black colored bolt, and then the remaining 5 bolts. 24. INSTALL FLYWHEEL HOUSING UNDER COVER (a) Install the flywheel housing under cover and exhaust pipe support bracket to the automatic transaxle with the 2 bolts. Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) 25. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET (See page EM-45) C135005 26. INSTALL FRONT AXLE ASSEMBLY LH (See page DS21) 27. INSTALL FRONT AXLE ASSEMBLY RH (See page EM-45) 28. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM LH (See page DS-21) 29. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM RH (See page EM-45) 30. INSTALL TIE ROD ASSEMBLY LH (See page DS-21) 31. INSTALL TIE ROD ASSEMBLY RH (See page EM-45) 32. INSTALL FRONT SPEED SENSOR LH (See page DS21) 33. INSTALL FRONT SPEED SENSOR RH (See page EM45) 34. INSTALL FRONT STABILIZER LINK ASSEMBLY LH (See page DS-22) 35. INSTALL FRONT STABILIZER LINK ASSEMBLY RH (See page EM-45) 36. INSTALL FRONT AXLE HUB NUT LH (See page DS22) 37. INSTALL FRONT AXLE HUB NUT RH (See page EM45) AX AX–220 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY 38. INSTALL EXHAUST PIPE ASSEMBLY FRONT (See page EX-4) 39. INSTALL EXHAUST PIPE NO. 1 SUPPORT BRACKET (See page EM-45) AX 40. CONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE (See page EM-46) 41. CONNECT RETURN TUBE SUB-ASSEMBLY (See page EM-46) 42. CONNECT FUEL TUBE SUB-ASSEMBLY (See page EM-46) 43. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (See page EM-46) 44. CONNECT ENGINE WIRE (See page EM-47) 45. INSTALL RELAY BLOCK COVER UPPER 46. INSTALL ECM (See page ES-519) 47. CONNECT HEATER INLET WATER HOSE (See page EM-47) 48. CONNECT HEATER OUTLET WATER HOSE (See page EM-47) 49. CONNECT NO. 1 OIL COOLER INLET HOSE (See page EM-48) 50. CONNECT NO. 1 OIL COOLER OUTLET HOSE (See page EM-48) 51. INSTALL RADIATOR HOSE INLET (See page EM-48) 52. INSTALL RADIATOR HOSE OUTLET (See page EM48) 53. CONNECT CHECK VALVE TO BRAKE BOOSTER HOSE (See page EM-48) 54. CONNECT NO. 1 FUEL VAPOR FEED HOSE (See page EM-48) 55. INSTALL ENGINE MOVING CONTROL ROD SUBASSEMBLY (See page EM-49) 56. INSTALL NO. 2 ENGINE MOUNTING STAY RH (See page EM-49) 57. INSTALL INTAKE AIR RESONATOR SUB-ASSEMBLY (See page EM-49) 58. INSTALL BATTERY (See page EM-49) 59. INSTALL NO. 1 AIR CLEANER INLET (See page EM49) 60. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (See page EM-50) 61. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See page ES-506) U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY AX–221 62. INSTALL AIR CLEANER INLET ASSEMBLY (See page EM-50) 63. CONNECT VACUUM HOSES (See page EM-51) 64. INSTALL V-RIBBED BELT (See page EM-7) 65. INSTALL COWL TOP PANEL OUTER SUBASSEMBLY (See page ES-485) 66. INSTALL WINDSHIELD WIPER LINK ASSEMBLY HINT: (See page WW-13) 67. INSTALL FRONT WHEELS (See page EM-51) 68. ADD ENGINE OIL 69. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page EM-51) 70. ADD ENGINE COOLANT (See page CO-6) 71. ADD AUTOMATIC TRANSAXLE FLUID HINT: (See page AX-164) 72. ADD POWER STEERING FLUID 73. BLEED POWER STEERING FLUID (See page PS-7) 74. CHECK FOR FUEL LEAKS (See page FU-8) 75. CHECK FOR ENGINE OIL LEAKS 76. CHECK FOR ENGINE COOLANT LEAKS (See page CO-1) 77. CHECK FOR EXHAUST GAS LEAKS 78. CHECK SHIFT LEVER POSITION (See page AX-224) 79. CHECK AND ADJUST FRONT WHEEL ALIGNMENT HINT: (See page SP-4) 80. CHECK IGNITION TIMING (See page EM-1) 81. CHECK ENGINE IDLE SPEED (See page EM-2) 82. CHECK CO/HC (See page EM-4) 83. CHECK FUNCTION OF THROTTLE BODY (See page ES-503) 84. INSTALL FRONT FENDER APRON SEAL RH 85. INSTALL ENGINE UNDER COVER LH 86. INSTALL ENGINE UNDER COVER RH 87. INSTALL V-BANK COVER SUB-ASSEMBLY (See page EM-52) 88. INSTALL COOL AIR INTAKE DUCT SEAL (See page EM-52) 89. CHECK ABS SPEED SENSOR SIGNAL (a) ABS: BC-11 AX AX–222 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY (b) VSC (for BOSCH): BC-290 (c) VSC (for ADVICS): BC-123 AX AX–222 U660E AUTOMATIC TRANSAXLE – SHIFT LEVER SHIFT LEVER U660E AUTOMATIC TRANSAXLE TRANSMISSION COMPONENTS AX NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH for TMC Made: UPPER CONSOLE PANEL SUB-ASSEMBLY NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH SHIFT LEVER KNOB SUB-ASSEMBLY CONSOLE BOX POCKET FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY without Smart Key System: with Smart Key System: UPPER CONSOLE REAR PANEL SUB-ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL CONSOLE BOX CARPET NO. 2 CONSOLE BOX INSERT FRONT LOWER INSTRUMENT PANEL FINISH PANEL LH FLOOR CARPET BRACKET LH COWL SIDE TRIM SUB-ASSEMBLY LH FRONT DOOR SCUFF PLATE LH CONSOLE BOX ASSEMBLY C135013E01 AX–223 U660E AUTOMATIC TRANSAXLE – SHIFT LEVER NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH for TMMK Made: UPPER CONSOLE PANEL SUB-ASSEMBLY NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH AX SHIFT LEVER KNOB SUB-ASSEMBLY CONSOLE BOX POCKET FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY without Smart Key System: with Smart Key System: UPPER CONSOLE REAR PANEL SUB-ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL CONSOLE BOX CARPET NO. 2 CONSOLE BOX INSERT FRONT or

LOWER INSTRUMENT PANEL FINISH PANEL LH or or FLOOR CARPET BRACKET LH COWL SIDE TRIM SUB-ASSEMBLY LH FRONT DOOR SCUFF PLATE LH CONSOLE BOX ASSEMBLY C135013E02 AX–224 AX U660E AUTOMATIC TRANSAXLE – SHIFT LEVER 12 (122, 9) 12 (122, 9) SHIFT LOCK CONTROL UNIT TRANSMISSION CONTROL CABLE ASSEMBLY SHIFT LOCK CONTROL ECU INDICATOR LIGHT WIRE SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C135729E03 U660E AUTOMATIC TRANSAXLE – SHIFT LEVER AX–225 ON-VEHICLE INSPECTION 1. INSPECT SHIFT LEVER POSITION (a) When shifting from the P to the R position with the ignition switch on (IG) and the brake pedal depressed, make sure that the shift lever moves smoothly and moves correctly into the position. (b) Start the engine and make sure that the vehicle moves forward when shifting from the N to the D position and moves rearward when shifting to the R position. If operation cannot be done as specified, inspect the park/neutral position switch assembly and check the shift lever assembly installation condition. AX AX–226 U660E AUTOMATIC TRANSAXLE – SHIFT LEVER REMOVAL HINT: (See page IP-1) AX 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-24) 3. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-25) 4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (See page IP-20) 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (See page IP-21) 6. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (without Smart Key System) (See page IP-22) 7. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (with Smart Key System) (See page IP-22) 8. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (a) Turn the shift lever knob counterclockwise and remove the shift lever knob sub-assembly. 9. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-24) 10. REMOVE NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-25) B133990 11. REMOVE FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (See page IP-25) 12. REMOVE UPPER CONSOLE REAR PANEL SUBASSEMBLY (See page IP-26) 13. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMC Made) (See page IP-27) 14. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMMK Made) (See page IP-27) 15. REMOVE CONSOLE BOX POCKET (See page IP-28) 16. REMOVE CONSOLE BOX CARPET (See page IP-28) 17. REMOVE CONSOLE BOX ASSEMBLY (for TMC Made) (See page IP-28) 18. REMOVE CONSOLE BOX ASSEMBLY (for TMMK Made) (See page IP-29) 19. REMOVE NO. 2 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-29) 20. REMOVE NO. 2 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-30) 21. REMOVE FLOOR CARPET BRACKET LH (See page AC-155) U660E AUTOMATIC TRANSAXLE – SHIFT LEVER AX–227 22. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (a) Disconnect the end of the transmission control cable from the shift lock control unit. (b) Disconnect the transmission control cable assembly from the transmission floor shift assembly while pushing the 2 claws of the floor shift cable. C135015 23. REMOVE SHIFT LOCK CONTROL UNIT ASSEMBLY (a) Disconnect the shift lock control ECU connector and indicator light wire connector. C135016 (b) Remove the 4 bolts and shift control unit assembly. C135017 AX AX–228 U660E AUTOMATIC TRANSAXLE – SHIFT LEVER DISASSEMBLY 1. AX REMOVE INDICATOR LIGHT WIRE SUB-ASSEMBLY (a) Using a screwdriver, release the stopper. (b) Using a screwdriver, disengage the locking lug of terminals (4) and (8), and pull the terminals out from the rear of the connector. 2 3 1 Stopper C092376E02 (c) Release the indicator light wire from the clamp on the shift lock control unit assembly. (d) Turn the indicator light guide counterclockwise. (e) Align the indicator light guide key with the groove on the shift lock control unit to remove the indicator light wire. Groove Key C135019E01 2. C135730 REMOVE SHIFT LOCK CONTROL ECU (a) Remove the shift lock control ECU from the shift lock control unit assembly. U660E AUTOMATIC TRANSAXLE – SHIFT LEVER AX–229 INSPECTION Switch Side: 1. (Connector Front View): J43 C110341E15 INSPECT TRANSMISSION CONTROL SWITCH (a) Measure resistance between each terminal of the shift lock control unit assembly when the shift lever is moved to each position. Standard resistance Shift Position Tester Connection Specified Condition S, "+" and "-" 3-7 Below 1 Ω Except S, "+" and "-" 3-7 10 kΩ or higher Press continuously "+" (Up shift) 2-5 Below 1 Ω S 2-5 10 kΩ or higher Press continuously "-" (Down shift) 1-5 Below 1 Ω S 1-5 10 kΩ or higher If the resistance value is not as specified, replace the shift lock control ECU. AX AX–230 U660E AUTOMATIC TRANSAXLE – SHIFT LEVER ADJUSTMENT 1. ADJUST SHIFT LEVER POSITION (a) Move the shift lever to the N position. (b) Remove the nut and transmission control cable from the control shaft lever. AX C132236 (c) Align the protrusions of the park/neutral position switch. Protrusions C135733E01 Slider Lock Piece C135734E02 (d) Move the slider in the directions indicated by the arrows and pull up the lock piece. NOTICE: Do not damage the boot. U660E AUTOMATIC TRANSAXLE – SHIFT LEVER AX–231 (e) Connect the transmission control cable assembly to the control shaft lever with the nut. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) AX C132236 (f) Push in the lock piece. NOTICE: Firmly push in the lock piece until the slider lock is engaged. (g) Start the engine and make sure that the vehicle moves forward when moving the lever from the N to the D position and moves rearward when moving it to the R position. If it becomes hard to move the shift lever, readjust the shift lever position. C138300E01 REASSEMBLY 1. INSTALL SHIFT LOCK CONTROL ECU (a) Install the shift lock control ECU to the shift lever. 2. INSTALL INDICATOR LIGHT WIRE SUB-ASSEMBLY (a) Insert the indicator light wire into the shift lock control unit while aligning the groove on the unit with the indicator light guide key. (b) Install the indicator light guide by turning it clockwise until it securely locks. (c) Install the indicator light wire to the clamp on the shift lock control unit. C135730 Groove Key C135019E02 AX–232 Stopper U660E AUTOMATIC TRANSAXLE – SHIFT LEVER (d) Connect terminals (4) and (8) of the indicator light wire. (e) Push the stopper. Connector Front View: AX G028933E01 INSTALLATION 1. INSTALL SHIFT LOCK CONTROL UNIT (a) Install the 4 bolts and shift lock control unit. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) C135017 (b) Connect the shift lock ECU connector and transmission control switch wire connector. C135016 U660E AUTOMATIC TRANSAXLE – SHIFT LEVER 2. C135020 AX–233 INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (a) Install the transmission control cable assembly as shown in the illustration. HINT: • Install the floor shift cable with the uneven surface facing up. • Securely engage the claws of the floor shift cable. 3. INSTALL FLOOR CARPET BRACKET LH 4. INSTALL NO. 2 CONSOLE BOX INSERT FRONT (for TMC Made) (See page IP-50) 5. INSTALL NO. 2 CONSOLE BOX INSERT FRONT (for TMMK Made) (See page IP-50) 6. INSTALL CONSOLE BOX ASSEMBLY (for TMC Made) (See page IP-51) 7. INSTALL CONSOLE BOX ASSEMBLY (for TMMK Made) (See page IP-51) 8. INSTALL CONSOLE BOX CARPET (See page IP-51) 9. INSTALL CONSOLE BOX POCKET (See page IP-51) 10. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMC Made) (See page IP-52) 11. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMMK Made) (See page IP-52) 12. INSTALL UPPER CONSOLE REAR PANEL SUBASSEMBLY (See page IP-53) 13. INSTALL FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (See page IP-53) 14. INSTALL NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-54) 15. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-55) 16. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (a) Install the shift lever knob sub-assembly. 17. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (without Smart Key System) (See page IP-57) 18. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (with Smart Key System) (See page IP-57) 19. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (See page IP-58) B133991 20. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (See page IP-59) 21. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-54) AX AX–234 U660E AUTOMATIC TRANSAXLE – SHIFT LEVER 22. INSTALL FRONT DOOR SCUFF PLATE LH (See page IR-54) 23. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page EM-51) AX 24. INSPECT SHIFT LEVER POSITION (See page AX-191) 25. ADJUST SHIFT LEVER POSITION (See page AX-191) U660E AUTOMATIC TRANSAXLE – TORQUE CONVERTER CLUTCH AND DRIVE PLATE AX–233 TORQUE CONVERTER CLUTCH AND DRIVE PLATE U660E AUTOMATIC TRANSAXLE TRANSMISSION COMPONENTS FRONT WIPER ARM AND BLADE ASSEMBLY RH 20 (204, 15) FRONT FENDER TO COWL SIDE SEAL RH FRONT WIPER ARM AND BLADE ASSEMBLY LH COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 85 (867, 63) 7.5 (77, 66 in.*lbf) 5.0 (51, 44 in.*lbf) FRONT FENDER TO COWL SIDE SEAL LH WINDSHIELD WIPER LINK ASSEMBLY COWL TOP PANEL OUTER SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque A134938E01 AX AX–234 U660E AUTOMATIC TRANSAXLE – TORQUE CONVERTER CLUTCH AND DRIVE PLATE AIR CLEANER CAP SUB-ASSEMBLY AX V-BANK COVER SUB-ASSEMBLY AIR CLEANER FILTER ELEMENT COOL AIR INTAKE DUCT SEAL 5.0 (51, 44 in.*lbf) 5.0 (51, 44 in.*lbf) AIR CLEANER INLET ASSEMBLY RELAY BLOCK COVER UPPER AIR CLEANER CASE SUB-ASSEMBLY 5.0 (51, 44 in.*lbf) NO. 1 AIR CLEANER INLET 3.5 (36, 31 in.*lbf) 9.0 (92, 80 in.*lbf) ENGINE UNDER COVER RH 5.0 (51, 44 in.*lbf) BATTERY BATTERY TRAY INTAKE AIR RESONATOR SUB-ASSEMBLY ENGINE UNDER COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque A132994E01 U660E AUTOMATIC TRANSAXLE – TORQUE CONVERTER CLUTCH AND DRIVE PLATE AX–235 FRONT FENDER APRON SEAL RH 38 (388, 28) V-RIBBED BELT AX 23 (235, 17) ENGINE MOVING CONTROL ROD SUB-ASSEMBLY 9.8 (100, 87 in.*lbf) NO. 2 ENGINE MOUNTING STAY RH 43 (438, 32) GENERATOR ASSEMBLY NO. 1 OIL RESERVOIR TO PUMP HOSE NO. 1 FUEL VAPOR FEED HOSE FUEL TUBE SUB-ASSEMBLY 43 (438, 32) HEATER INLET WATER HOSE RADIATOR HOSE INLET RADIATOR HOSE OUTLET RETURN TUBE SUB-ASSEMBLY NO. 1 FUEL PIPE CLAMP NO. 1 OIL COOLER INLET HOSE 25 (250, 18) NO. 1 OIL COOLER OUTLET HOSE HEATER OUTLET WATER HOSE CLIP 13 (130, 9) 25 (250, 18) COOLER COMPRESSOR ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque TRANSMISSION CONTROL CABLE ASSEMBLY Non-reusable part C142576E01 AX–236 U660E AUTOMATIC TRANSAXLE – TORQUE CONVERTER CLUTCH AND DRIVE PLATE STEERING SLIDING YOKE AX FRONT STABILIZER LINK ASSEMBLY LH 35 (360, 26) TIE ROD ASSEMBLY LH 74 (755, 55) 49 (500, 36) COTTER PIN FRONT SPEED SENSOR LH 8.0 (85, 71 in.*lbf) 294 (3,000, 217) FRONT SUSPENSION LOWER NO. 1 ARM LH FRONT AXLE HUB NUT LH 75 (765, 55) 62 (632, 46) GASKET GASKET GASKET 56 (571, 41) 62 (632, 46) NO. 1 EXHAUST PIPE SUPPORT BRACKET 33 (337, 24) EXHAUST PIPE ASSEMBLY FRONT 21 (214, 15) EXHAUST PIPE NO. 1 SUPPORT BRACKET N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A132996E01 U660E AUTOMATIC TRANSAXLE – TORQUE CONVERTER CLUTCH AND DRIVE PLATE AX–237 87 (887, 64) ENGINE ASSEMBLY WITH TRANSAXLE ENGINE WIRE AX 95 (969, 70) 95 (969, 70) VANE PUMP ASSEMBLY NO. 2 FUEL PIPE CLAMP FUEL TUBE SUB-ASSEMBLY STARTER ASSEMBLY 43 (439, 32) 37 (380, 26) FRONT FRAME ASSEMBLY 37 (380, 26) 9.8 (100, 87 in.*lbf) 7.8 (80, 69 in.*lbf) FRONT SUSPENSION MEMBER BRACE REAR RH FRAME SIDE RAIL PLATE RH 32 (329, 24) 85 (867, 63) 32 (329, 24) 85 (867, 63) FRAME SIDE RAIL PLATE LH 32 (329, 24) 32 (329, 24) 32 (329, 24) N*m (kgf*cm, ft.*lbf) : Specified torque 85 (867, 63) 85 (867, 63) FRONT SUSPENSION MEMBER BRACE REAR LH 32 (329, 24) A134929E01 AX–238 U660E AUTOMATIC TRANSAXLE – TORQUE CONVERTER CLUTCH AND DRIVE PLATE FRONT DRIVE SHAFT ASSEMBLY RH AX BRACKET HOLE SNAP RING FRONT DRIVE SHAFT LH HOLE SNAP RING 32 (330, 24) FRONT DRIVE SHAFT ASSEMBLY LH 46 (469, 34) TORQUE CONVERTER CLUTCH ASSEMBLY x6 43 (439, 32) 41 (418, 30) x3 x7 7.8 (80, 69 in.*lbf) 64 (653, 47) DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT EXHAUST PIPE SUPPORT BRACKET FLYWHEEL HOUSING UNDER COVER N*m (kgf*cm, ft.*lbf) : Specified torque AUTOMATIC TRANSAXLE ASSEMBLY Non-reusable part Precoated part C139878E01 U660E AUTOMATIC TRANSAXLE – TORQUE CONVERTER CLUTCH AND DRIVE PLATE AX–239 REMOVAL 1. INSPECTION SST 1. AT00953E02 INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY (a) Inspect the one-way clutch. (1) Set SST into the inner race of the one-way clutch. SST 09350-32014 (09351-32010) (2) Install SST so that it fits in the notch of the converter hub and outer race of the one-way clutch. SST 09350-32014 (09351-32010, 0935132020) (3) Stand the torque converter up and turn the SST. Standard: If the one-way clutch is turned clockwise, it rotates freely and if turned counterclockwise, it locks. Hold Lock Turn REMOVE TORQUE CONVERTER CLUTCH ASSEMBLY HINT: (See page AX-207) Free AT03306E02 Sample showing minimum amount of powders in ATF Actual Size D025367E07 (b) Determine the condition of the torque converter clutch assembly. (1) If the inspection result of the torque converter clutch assembly satisfies the following conditions, replace the torque converter clutch assembly. Malfunction item: A metallic sound is emitted from the torque converter clutch assembly during the stall test or when the shift lever is moved to the N position. The one-way clutch is free or locked in both directions. The amount of powder in the ATF is greater than the sample shown in the illustration (see the sample). HINT: The sample shows the auto fluid of approximately 0.25 liters (0.26 US qts, 0.22 Imp. qts) that is taken out from the removed torque converter clutch. (c) Exchange the ATF in the torque converter clutch. (1) If the ATF is discolored and/or has a foul odor, completely stir the ATF in the torque converter clutch and drain it. AX AX–240 U660E AUTOMATIC TRANSAXLE – TORQUE CONVERTER CLUTCH AND DRIVE PLATE (d) Clean and check the oil cooler and oil pipe line. (1) If the torque converter clutch is inspected or the ATF is exchanged, clean the oil cooler and oil pipe line. HINT: • Spray compressed air of 196 kPa (2 kgf/cm, 28 psi) from the inlet hose. • If plenty of fine powders are identified in the ATF, add new ATF using a bucket pump and clean it again. (2) If the ATF is cloudy, inspect the oil cooler (radiator). AX C011090 OK (e) Prevent deformation of the torque converter clutch and damage to the oil pump gear. (1) When there is any damage to the end of the bolt for the torque converter clutch and to the bottom of the bolt hole, replace the bolt and the torque converter clutch. (2) All of the bolts must be the same length. (3) Bolts with washers must be used. NG The Bottom is Damaged D025368E08 2. C135090 INSPECT DRIVE PLATE & RING GEAR SUBASSEMBLY (a) Set up a dial indicator with a roller instrument and measure the drive plate runout. Maximum runout: 0.20 mm (0.0079 in.) (b) Check for damage of the ring gear. If runout is not within specification or the ring gear is damaged, replace the drive plate. U660E AUTOMATIC TRANSAXLE – TORQUE CONVERTER CLUTCH AND DRIVE PLATE AX–241 INSTALLATION 1. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY HINT: (See page AX-214) AX AX–241 U660E AUTOMATIC TRANSAXLE – TCM TCM U660E AUTOMATIC TRANSAXLE TRANSMISSION COMPONENTS AX COOL AIR INTAKE DUCT SEAL 9.0 (92, 80 in.*lbf) BATTERY CLAMP BATTERY 5.0 (51, 44 in.*lbf) 5.0 (51, 44 in.*lbf) BATTERY TRAY INTAKE AIR RESONATOR SUB-ASSEMBLY AIR CLEANER INLET ASSEMBLY CLIP 11 (112, 8) 5.0 (51, 44 in.*lbf) TCM NO. 1 AIR CLEANER INLET N*m (kgf*cm, ft.*lbf) : Specified torque C139868E03 AX–242 U660E AUTOMATIC TRANSAXLE – TCM REMOVAL NOTICE: When the TCM is replaced, the existing transaxle compensation codes must be input into the new TCM (See page AX-22). AX 1. REMOVE COOL AIR INTAKE DUCT SEAL (See page EM-23) 2. REMOVE BATTERY (See page EM-24) 3. REMOVE AIR CLEANER INLET ASSEMBLY (See page EM-24) 4. REMOVE NO. 1 AIR CLEANER INLET (See page EM24) 5. REMOVE INTAKE AIR RESONATOR SUB-ASSEMBLY (See page EM-25) 6. REMOVE TCM (a) Turn the lock lever and disconnect the connector from the TCM. C133604 (b) Remove the 2 bolts and TCM from the transaxle. C139840E01 U660E AUTOMATIC TRANSAXLE – TCM AX–243 INSTALLATION 1. INSTALL TCM (a) Install the TCM to the transaxle. (b) Install and tighten the 2 bolts in the order shown in the illustration. Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) 2 1 C139840E02 (c) Connect the connector to the TCM. (d) Turn the lock lever and secure the connector with the lock lever. C139242 2. INSTALL INTAKE AIR RESONATOR SUB-ASSEMBLY (See page EM-49) 3. INSTALL NO. 1 AIR CLEANER INLET (See page EM49) 4. INSTALL AIR CLEANER INLET ASSEMBLY (See page EM-50) 5. INSTALL BATTERY (See page EM-49) 6. INSTALL COOL AIR INTAKE DUCT SEAL (See page EM-52) 7. PERFORM TCM REGISTRATION HINT: (See page AX-19) AX AX–244 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AUTOMATIC TRANSAXLE UNIT U660E AUTOMATIC TRANSAXLE TRANSMISSION COMPONENTS AX 13 (130, 9) BREATHER PLUG CAP BREATHER PLUG HOSE CONTROL SHAFT LEVER 5.4 (55, 48 in.*lbf) BREATHER PLUG O-RING 7.8 (80, 69 in.*lbf) NO. 1 TRANSAXLE CASE PLUG PARK/NEUTRAL POSITION SWITCH ASSEMBLY O-RING MANUAL VALVE LEVER SHAFT OIL SEAL O-RING 7.8 (80, 69 in.*lbf) NO. 1 TRANSAXLE CASE PLUG O-RING 27 (275, 20) OIL COOLER TUBE UNION (INLET OIL COOLER UNION) GASKET 49 (500, 36) 7.8 (80, 69 in.*lbf) NO. 1 TRANSAXLE CASE PLUG REFILL PLUG O-RING NO. 1 OIL FILLER TUBE 27 (275, 20) OIL COOLER TUBE UNION (OUTLET OIL COOLER UNION) GASKET 40 (408, 30) OVERFLOW PLUG N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Apply MP grease Apply ATF WS C134944E01 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–245 COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING OUTER RACE 29 (296, 21) AX SHIM CLAMP 23 (234, 17) GASKET O-RING DIFFERENTIAL GEAR LUBE APPLY TUBE GASKET 31 (316, 23) O-RING TRANSAXLE HOUSING x17 23 (234, 17) x3 x12 23 (234, 17) TRANSAXLE REAR COVER SUB-ASSEMBLY OIL SEAL RING THRUST NEEDLE ROLLER BEARING x2 THRUST NEEDLE ROLLER RACE NEEDLE ROLLER BEARING 17 (173, 12) O-RING x2 7.4 (75, 65 in.*lbf) x2 7.5 (76, 66 in.*lbf) TRANSAXLE REAR COVER PLATE N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Precoated part Apply ATF WS C134945E01 AX–246 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT O-RING AX TRANSMISSION VALVE BODY ASSEMBLY MANUAL VALVE LEVER SHAFT x11 MANUAL VALVE LEVER SHAFT RETAINER SPRING 11 (112, 8) SPACER O-RING SLOTTED SPRING PIN PARKING LOCK LEVER SUB-ASSEMBLY VALVE BODY OIL STRAINER ASSEMBLY SPACER 11 (112, 8) MANUAL VALVE LEVER SUB-ASSEMBLY AUTOMATIC TRANSAXLE OIL PAN GASKET 23 (234, 17) TRANSMISSION OIL CLEANER MAGNET AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY 7.5 (76, 66 in.*lbf) COVER MANUAL DETENT SPRING SUB-ASSEMBLY x18 N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Precoated part Apply ATF WS C134946E01 AX–247 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT PLANETARY SUN GEAR SUB-ASSEMBLY WASHER UNDERDRIVE PLANETARY RING GEAR AX SNAP RING 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY NO. 3 BRAKE HUB RACE BEARING SNAP RING 23 (234, 17) UNDERDRIVE PLANETARY GEAR ASSEMBLY O-RING NO. 1 BRAKE PISTON x7 NO. 1 BRAKE PLATE O-RING FRONT OIL PUMP AND GEAR BODY SUB-ASSEMBLY UNDERDRIVE PLANETARY SUN GEAR FLANGE NO. 1 BRAKE DISC RACE INPUT SHAFT SUB-ASSEMBLY BEARING OIL SEAL RING BEARING NO. 3 BRAKE PLATE FLANGE SNAP RING SNAP RING FLANGE NO. 3 BRAKE DISC N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Apply MP grease Apply ATF WS C134947E01 AX–248 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT NO. 2 BRAKE PLATE SNAP RING SNAP RING NO. 2 BRAKE PISTON AX FLANGE NO. 2 BRAKE DISC O-RING 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY SNAP RING PLANETARY RING GEAR 120 (1,223, 88) COUNTER DRIVE GEAR NUT BEARING PLANETARY RING GEAR FLANGE RACE BEARING PLANETARY GEAR ASSEMBLY SNAP RING INTERMEDIATE SHAFT OIL SEAL ONE-WAY CLUTCH ASSEMBLY SNAP RING NO. 1 CLUTCH DISC FLANGE O-RING SNAP RING RACE BEARING DIRECT MULTIPLE DISC CLUTCH ASSEMBLY NO. 2 CLUTCH PLATE NO. 1 CLUTCH PLATE BEARING SNAP RING REAR PLANETARY SUN GEAR ASSEMBLY FLANGE NO. 2 CLUTCH DISC NO. 2 DIRECT CLUTCH PISTON N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Apply ATF WS C134948E01 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–249 AX FRONT DIFFERENTIAL CASE PARKING LOCK PAWL PIN SPRING PARKING LOCK PAWL PARKING LOCK PAWL SHAFT PAWL SHAFT CLAMP 23 (234, 17) 23 (234, 17) PARKING LOCK ROD SUB-ASSEMBLY PAWL STOPPER PLATE PARKING LOCK SLEEVE N*m (kgf*cm, ft.*lbf) : Specified torque C134949E01 AX–250 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING OUTER RACE AX COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING COUNTER DRIVEN GEAR COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING NO. 3 BRAKE PISTON BRAKE PISTON RETURN SPRING SNAP RING BEARING INNER RACE (REAR SIDE) SNAP RING BEARING INNER RACE (FRONT SIDE) COUNTER DRIVE GEAR BEARING (#1) COUNTER DRIVE GEAR (#1) The counter drive gear bearing cannot be separated from the transaxle case. When the counter drive gear bearing or transaxle case is replaced, prepare the following: COUNTER DRIVE GEAR BEARING Non-reusable part Apply ATF WS SNAP TRANSAXLE CASE C134950E01 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–251 DISASSEMBLY 1. REMOVE NO. 2 BREATHER PLUG (a) Using a screwdriver, remove the breather plug hose from the transaxle case. AX C134951 (b) Using a screwdriver, remove the breather plug from the breather plug hose. (c) Using a screwdriver, remove the O-ring from the breather plug. (d) Using a screwdriver, remove the breather plug cap from the breather breather plug hose. Breather Plug Cap Breather Plug Hose Breather Plug O-Ring C134952E01 2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Remove the nut, washer, and control shaft lever from the control shaft. C136685 C136686 (b) Remove the 2 bolts and the park/neutral position switch assembly from the transaxle case. NOTICE: Before removing the park/neutral position switch, remove any dirt or rust on the installation portion of the control shaft. Be sure to remove the switch straight along the shaft while being careful not to deform the plate spring that supports the shaft. If the plate spring is deformed, the park/neutral switch cannot be reinstalled correctly. AX–252 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT 3. REMOVE OIL COOLER TUBE UNION (INLET OIL COOLER UNION) (a) Loosen the nut while holding the oil cooler tube union (inlet oil cooler union). (b) Remove the oil cooler tube union (inlet oil cooler union) from the transaxle case. (c) Remove the O-ring from the oil cooler tube union (inlet oil cooler union). 4. REMOVE OIL COOLER TUBE UNION (OUTLET OIL COOLER UNION) (a) Loosen the nut while holding the oil cooler tube union (outlet oil cooler union). (b) Remove the oil cooler tube union (outlet oil cooler union) from the transaxle case. (c) Remove the O-ring from the oil cooler tube union (outlet oil cooler union). 5. REMOVE NO. 1 TRANSAXLE CASE PLUG (a) Remove the 3 No. 1 transaxle case plugs from the transaxle case. (b) Using a screwdriver, remove the 3 O-rings from the 3 No. 1 transaxle case plugs. AX C134956 C134957 C134958 (c) Using a hexagon wrench (6 mm), remove the 3 hexagon bolts from the transaxle housing. (d) Remove the 3 gaskets from the 3 hexagon bolts. C134959 6. C136444 FIX AUTOMATIC TRANSAXLE ASSEMBLY (a) Secure the transaxle assembly on wooden blocks. U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT 7. AX–253 REMOVE AUTOMATIC TRANSAXLE OIL PAN SUBASSEMBLY (a) Using a hexagon wrench (6 mm), remove the overflow plug from the automatic transaxle oil pan sub-assembly. (b) Remove the gasket from the overflow plug. C134961 (c) Using a hexagon wrench (6 mm), remove the No. 1 oil filler tube from the automatic transaxle assembly. C141531 (d) Remove the 18 bolts, automatic transaxle oil pan sub-assembly, and gasket from the automatic transaxle assembly. C134962 (e) Remove the 2 magnets from the automatic transaxle oil pan sub-assembly. Magnet 8. C134963E02 INSPECT TRANSMISSION OIL CLEANER MAGNET (See page AX-274) AX AX–254 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT 9. REMOVE VALVE BODY OIL STRAINER ASSEMBLY (a) Remove the 2 bolts and oil strainer assembly from the valve body assembly. AX C136687 (b) Remove the O-ring from the oil strainer assembly. C136688 10. REMOVE TRANSMISSION VALVE BODY ASSEMBLY (a) Remove the 11 bolts and valve body assembly from the transaxle case. NOTICE: When removing the transmission valve body assembly, be careful not to allow the transmission revolution sensor and the transaxle case to interfere each other. C136689 11. REMOVE TRANSAXLE CASE GASKET (a) Remove the 2 gaskets from the transaxle case. 12. INSPECT INPUT SHAFT SUB-ASSEMBLY (See page AX-274) C136429 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–255 13. REMOVE TRANSAXLE REAR COVER SUBASSEMBLY (a) Remove the refill plug from the transaxle rear cover. (b) Remove the gasket from the refill plug. AX C136430 (c) Remove the 2 No. 1 automatic transaxle case plugs from the transaxle rear cover. (d) Using a screwdriver, remove the 2 O-rings from the 2 No. 1 automatic transaxle case plugs. C134960 (e) Remove the 14 bolts from the transaxle rear cover. (f) Using a brass bar and hammer, tap on the circumference of the rear transaxle cover, to remove the transaxle rear cover from the transaxle case. C136431 (g) Using a screwdriver, remove the 3 O-rings from the transaxle case. C136432 (h) Using a screwdriver, remove the 2 oil seal rings from the transaxle rear cover. (i) Remove the thrust needle roller bearing and thrust needle roller race from the transaxle rear cover. Oil Seal Ring Thrust Needle Roller Bearing Thrust Needle Roller Race C136440E01 AX–256 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT (j) Using a "TORX" wrench (T30), remove the 2 "TORX" screws and transaxle rear cover plate from the transaxle rear cover. AX C136443 (k) Using SST, remove the needle roller bearing from the transaxle rear cover. SST 09319-60020 SST C136690E01 14. REMOVE DIRECT MULTIPLE DISC CLUTCH ASSEMBLY (a) Remove the direct multiple disc clutch assembly from the transaxle case. (b) Remove the thrust needle roller bearing from the direct multiple disc clutch assembly. C136442 15. REMOVE DIRECT MULTIPLE DISC CLUTCH SNAP RING (a) Using 2 screwdrivers, remove the snap ring from the direct multiple disc clutch assembly. C136433 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–257 (b) Remove the No. 2 direct clutch piston from the direct multiple disc clutch assembly. AX C136434 (c) Using a screwdriver, remove the intermediate shaft oil seal ring from the direct No. 2 direct clutch piston. (d) Using a screwdriver, remove the O-ring from the direct multiple disc clutch assembly. O-Ring Intermediate Shaft Oil Seal C136428E01 16. REMOVE NO. 2 DIRECT MULTIPLE DISC CLUTCH FLANGE (a) Remove the flange, 3 clutch discs and 3 clutch plates from the direct multiple disc clutch assembly. Clutch Plate Clutch Disc 17. INSPECT NO. 2 CLUTCH DISC (See page AX-274) Clutch Flange C136435E01 18. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY (a) Using a snap ring expander, remove the snap ring from the direct multiple disc clutch assembly. C136436 AX–258 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT (b) Remove the rear planetary sun gear from the direct multiple disc clutch assembly. AX C136437 (c) Remove the thrust needle roller bearing and thrust needle roller race from the direct multiple disc clutch assembly. Thrust Needle Roller Bearing Thrust Needle Roller Race 19. INSPECT REAR PLANETARY SUN GEAR ASSEMBLY (See page AX-276) C136438E01 20. REMOVE NO. 1 DIRECT MULTIPLE DISC CLUTCH FLANGE (a) Using 2 screwdrivers, remove the 2 snap rings from the direct multiple disc clutch assembly. C136445 Clutch Flange (b) Remove the flange, 4 clutch discs, and 4 clutch plates from the direct multiple disc clutch assembly. 21. INSPECT NO. 1 CLUTCH DISC (See page AX-275) Clutch Plate Clutch Disc Clutch Flange C136446E01 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–259 22. REMOVE TRANSAXLE HOUSING (a) Remove the 20 bolts from the transaxle housing. (b) Using a brass bar and hammer, tap on the circumference of the transaxle housing to remove the transaxle housing from the transaxle case. AX C136447 23. REMOVE COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING OUTER RACE (a) Using SST, remove the counter driven gear front tapered roller bearing outer race and shim from the transaxle housing. SST 09308-00010 SST C136448E01 24. REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE (a) Remove the bolt, clamp, and differential gear lube apply tube from the transaxle housing. C136449 25. REMOVE FRONT OIL PUMP AND GEAR BODY SUBASSEMBLY (a) Remove the 7 bolts and oil pump from the transaxle case. (b) Remove the O-ring from the oil pump assembly. C136450 AX–260 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT (c) Remove the thrust needle roller bearing and thrust needle roller race from the carrier lock nut. (d) Remove the O-ring from the transaxle case. Thrust Needle Roller Race Thrust Needle Roller Bearing AX O-Ring C138729E01 26. REMOVE NO. 3 BRAKE DISC (a) Using a screwdriver, remove the snap ring from the oil pump assembly. C136451 (b) Remove the 2 brake flanges, 3 brake discs, and 2 brake plates from the oil pump assembly. Brake Flange 27. INSPECT NO. 3 BRAKE DISC (See page AX-275) Brake Plate Brake Disc Brake Flange C136452E01 28. REMOVE UNDERDRIVE PLANETARY GEAR ASSEMBLY (a) Remove the underdrive planetary gear assembly from the oil pump assembly. C136458 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–261 29. REMOVE NO. 3 BRAKE HUB (a) Remove the No. 3 brake hub from the underdrive planetary gear assembly. AX C136454 (b) Remove the thrust needle roller bearing and thrust needle roller race from the underdrive planetary gear assembly. Thrust Needle Roller Race Thrust Needle Roller Bearing C136455E01 30. REMOVE UNDERDRIVE PLANETARY RING GEAR (a) Using needle-nose pliers, remove the snap ring from the underdrive planetary ring gear. (b) Remove the underdrive planetary ring gear from the underdrive planetary gear assembly. C136456 31. REMOVE PLANETARY SUN GEAR SUB-ASSEMBLY (a) While expanding the snap ring with snap ring pliers, remove the front planetary sun gear from the underdrive planetary gear assembly. (b) Remove the snap ring from the underdrive planetary gear assembly. 32. INSPECT UNDERDRIVE PLANETARY GEAR ASSEMBLY (See page AX-276) 33. INSPECT PLANETARY SUN GEAR SUB-ASSEMBLY (See page AX-275) C136457 AX–262 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT 34. REMOVE INPUT SHAFT SUB-ASSEMBLY (a) Remove the input shaft from the oil pump assembly. AX C136459 Thrust Needle Roller Race Thrust Needle Roller Bearing (b) Remove the thrust needle roller bearing and thrust needle roller race from the input shaft. (c) Using a screwdriver, remove the 3 input shaft oil seal rings from the input shaft. Input Shaft Input Shaft Oil Seal Ring C136460E01 35. REMOVE UNDERDRIVE PLANETARY SUN GEAR (a) Remove the underdrive planetary sun gear from the oil pump assembly. (b) Remove the thrust needle roller bearing from the oil pump assembly. C136461 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–263 36. REMOVE NO. 1 BRAKE DISC (a) Using a screwdriver, remove the 2 snap rings from the oil pump assembly. AX C136462 (b) Remove the flange, 4 brake discs, and 4 brake plates from the oil pump assembly. Flange Brake Plate 37. INSPECT NO. 1 BRAKE DISC (See page AX-276) Brake Disc C136463E01 38. REMOVE 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY (a) Remove the 3 2nd brake piston return springs from the oil pump assembly. 39. INSPECT 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY (See page AX-277) C136464 40. REMOVE NO. 1 BRAKE PISTON (a) Holding the oil pump assembly by hand, apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil pump assembly to remove the No. 1 brake piston. C136465 AX–264 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT (b) Using a screwdriver, remove the 2 O-rings from the No. 1 brake piston. AX C136466 41. REMOVE FRONT DIFFERENTIAL CASE (a) Remove the differential case sub-assembly from the transaxle case. C136467 42. REMOVE COUNTER DRIVE GEAR NUT (a) Using a SST and hammer, unstake the nut. SST 09930-00010 SST C136698E01 (b) Turn the manual valve lever 2 notches counterclockwise to set it in the P position as shown in the illustration. P C136700E01 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–265 (c) Using SST, remove the nut from the planetary gear assembly. SST 09387-00130 SST AX C136468E01 43. REMOVE COUNTER DRIVEN GEAR (a) Turn the manual valve lever 2 notches clockwise to set it in the N position as shown in the illustration. N C136699E01 (b) Remove the counter driven gear sub-assembly from the transaxle case. C136469 SST C136470E01 44. REMOVE COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING (a) Using SST, remove the counter driven gear front tapered roller bearing from the counter driven gear sub-assembly. SST 09950-00020, 09950-00030, 09950-60010 (09951-00400) AX–266 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT 45. REMOVE COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING (a) Using SST, remove the counter driven gear rear tapered roller bearing and differential drive pinion from the counter driven gear. SST 09950-40011 (09951-04010, 09952-04010, 09954-04010, 09953-04020, 09955-04071, 09957-04010, 09958-04011), 09950-60010 (09951-00320) SST AX SST C138720E01 46. REMOVE PAWL SHAFT CLAMP (a) Remove the bolt and pawl shaft clamp from the transaxle case. C136472 47. REMOVE PAWL STOPPER PLATE (a) Remove the 2 bolts and pawl stopper plate from the transaxle case. C136473 48. REMOVE PARKING LOCK SLEEVE (a) Remove the parking lock sleeve from the transaxle case. C136474 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–267 49. REMOVE PARKING LOCK PAWL (a) Remove the spring, parking lock pawl pin, parking lock pawl shaft, and parking lock pawl from the transaxle case. AX C136475 50. REMOVE COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING OUTER RACE (a) Using SST, remove the counter driven gear rear tapered roller bearing outer race from the transaxle case. SST 09308-00010 SST C136476E01 51. REMOVE ONE-WAY CLUTCH ASSEMBLY (a) Using a screwdriver, remove the snap ring from the transaxle case. C141525 (b) Remove the one-way clutch assembly with planetary ring gear from the transaxle case. (c) Remove the thrust needle roller bearing from the transaxle case. 52. INSPECT ONE-WAY CLUTCH ASSEMBLY (See page AX-277) C141526 AX–268 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT 53. REMOVE PLANETARY RING GEAR (a) Remove the planetary ring gear from the one-way clutch assembly. AX C136479 54. REMOVE PLANETARY RING GEAR FLANGE (a) Using a screwdriver, remove the snap ring from the planetary ring gear. (b) Remove the planetary ring gear flange from the planetary ring gear. C136480 55. REMOVE NO. 2 BRAKE DISC (a) Using a screwdriver, remove the snap ring from the transaxle case. C141524 (b) Remove the brake flange, 5 brake discs, and 5 brake plates from the transaxle case. Brake Flange Brake Plate Brake Disc C136483E01 56. INSPECT NO. 2 BRAKE DISC (See page AX-277) U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–269 57. REMOVE 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY (a) Using a screwdriver, remove the snap ring from the transaxle case. AX C136482 (b) Remove the 1st and reverse brake return spring from the transaxle case. 58. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY (See page AX-278) C136484 59. REMOVE NO. 2 BRAKE PISTON (a) Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the ATF hole indicated by the arrow to remove the No. 2 brake piston assembly from the transaxle case. C136485 (b) Using a screwdriver, remove the 2 O-rings from the No. 2 brake piston. C136673 AX–270 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT 60. REMOVE PLANETARY GEAR ASSEMBLY (a) Using SST and a press, remove the planetary gear assembly from the transaxle case. SST 09950-60010 (09951-00580), 09950-70010 (09951-07100) SST AX C136674E01 61. REMOVE COUNTER DRIVE GEAR (a) Using SST and a press, remove the counter drive gear and bearing inner race (rear side) from the transaxle case. SST 09950-60020 (09951-00710), 09950-70010 (09951-07100) SST SST C136697E01 (b) As shown in the illustration, tighten the 3 bolts evenly and leave a clearance of approximately 20.0 mm (0.797 in.) between the counter drive gear and inner race. C136676 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–271 (c) Using SST, remove the bearing inner race (front side) from the counter drive gear. SST 09950-00020, 09950-00030, 09950-60020 (09951-00710) SST AX C136677E01 62. REMOVE NO. 3 BRAKE PISTON (a) Using a screwdriver, remove the snap ring from the transaxle case. C136678 (b) Remove the brake piston return spring from the transaxle case. (c) Remove the No. 3 brake piston from the transaxle case. C136679 63. REMOVE MANUAL DETENT SPRING SUBASSEMBLY (a) Remove the bolt, cover, and manual detent spring sub-assembly from the transaxle case. C134953 64. REMOVE PARKING LOCK ROD SUB-ASSEMBLY (a) Remove the parking lock rod sub-assembly from the parking lock lever sub-assembly. HINT: Align the dial with the notches on the parking lock lever sub-assembly to remove the parking lock rod sub-assembly. C136683 AX–272 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT 65. REMOVE MANUAL VALVE LEVER SHAFT (a) Using needle-nose pliers, remove the manual valve lever shaft retainer spring from the transaxle case. AX C136680 (b) Using a screwdriver, slide the spacer of the manual valve lever sub-assembly. C136701 (c) Using a pin punch (3 mm) and hammer, drive out the slotted spring pin from the manual valve lever sub-assembly. HINT: Slowly drive out the pin so that it will not fall into the transaxle case. C137417 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–273 (d) Using a screwdriver, slide the spacer of the parking lock lever sub-assembly. AX C137418 (e) Using a pin punch (3 mm) and hammer, drive out the slotted spring pin from the parking lock lever sub-assembly. HINT: Slowly drive out the pin so that it will not fall into the transaxle case. C136702 (f) Remove the manual valve lever shaft, manual valve lever sub-assembly, parking lock lever subassembly and 2 spacers from the transaxle case. C137428 66. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL (a) Using a screwdriver, remove the manual valve lever shaft oil seal from the transaxle case. C136684 AX–274 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT INSPECTION 1. INSPECT TRANSMISSION OIL CLEANER MAGNET (a) Use the removed magnets to collect any steel chips. Examine the chips and particles in the pan and on the magnets to determine what type of wear has occurred in the transaxle: Result: Steel (magnetic): Bearing, gear and plate wear Brass (non-magnetic): Bearing wear 2. INSPECT INPUT SHAFT SUB-ASSEMBLY (a) Using a dial indicator, measure the input shaft end play. End play: 0.012 to 1.250 mm (0.0005 to 0.0492 in.) 3. INSPECT NO. 2 CLUTCH DISC (a) Check if the sliding surfaces of the discs, plates, and flange are worn or burnt. If necessary, replace them. NOTICE: If the linings of the discs are peeled off or discolored, or even if a part of the groove is damaged, replace all discs. AX C138722 C136696 C138267 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT 4. AX–275 INSPECT PLANETARY SUN GEAR SUB-ASSEMBLY (a) Using a dial indicator, measure the inside diameter of the bushings of the planetary sun gear. Standard inside diameter: 25.525 to 25.546 mm (1.0049 to 1.0057 in.) Maximum inside diameter: 25.546 mm (1.0057 in.) If the inside diameter is greater than the maximum, replace the planetary gear sun gear. C138259 5. INSPECT NO. 1 CLUTCH DISC (a) Check if the sliding surfaces of the discs, plates, and flange are worn or burnt. If necessary, replace them. NOTICE: If the linings of the discs are peeled off or discolored, or even if a part of the groove is damaged, replace all discs. 6. INSPECT NO. 3 BRAKE DISC (a) Check if the sliding surfaces of the discs, plates, and flange are worn or burnt. If necessary, replace them. NOTICE: If the linings of the discs are peeled off or discolored, or even if a part of the groove is damaged, replace all discs. C138265 C138255 AX AX–276 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT 7. INSPECT UNDERDRIVE PLANETARY GEAR ASSEMBLY (a) Using a feeler gauge, measure the clearance between the underdrive planetary gear and the pinion gear at 4 points. Standard clearance: 0.18 to 0.54 mm (0.0071 to 0.0213 in.) If the clearance is greater than the standard clearance, replace the underdrive planetary gear sun gear. 8. INSPECT REAR PLANETARY SUN GEAR ASSEMBLY (a) Using a dial indicator, measure the inside diameter of the bushing of the rear planetary sun gear subassembly. Standard inside diameter: 25.580 to 25.601 mm (1.0071 to 1.0079 in.) Maximum inside diameter: 25.601 mm (1.0079 in.) If the inside diameter is greater than the maximum, replace the rear planetary sun gear sub-assembly. 9. INSPECT NO. 1 BRAKE DISC (a) Check if the sliding surfaces of the discs, plates, and flange are worn or burnt. If necessary, replace them. NOTICE: If the linings of the discs are peeled off or discolored, or even if a part of the groove is damaged, replace all discs. AX C138260 C138266 C138255 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–277 10. INSPECT 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY (a) Using vernier calipers, measure the free length of the 3 2nd brake piston return springs including the spring seats. Standard free length: 23.85 mm (0.9390 in.) If the free length is shorter than the standard free length, replace the 2nd brake piston return spring. C138254 11. INSPECT ONE-WAY CLUTCH ASSEMBLY (a) Temporarily install the one-way clutch assembly to the planetary ring gear. (b) Rotate the one-way clutch assembly to check the rotating direction for lock or free operation. If the one-way clutch assembly does not operate normally, replace it. C138723 12. INSPECT PLANETARY GEAR ASSEMBLY (a) Using a feeler gauge, measure the clearance between the planetary gear case and each pinion gear at points A and B. A - Standard Clearance A point 0.23 to 0.59 mm (0.0091 to 0.0232 in.) B point 0.16 to 0.66 mm (0.0063 to 0.02598 in.) If the clearance is greater than the standard clearance, replace the planetary gear assembly. B C137433E01 13. INSPECT NO. 2 BRAKE DISC (a) Check if the sliding surfaces of the discs, plates, and flange are worn or burnt. If necessary, replace them. NOTICE: If the linings of the discs are peeled off or discolored, or even if a part of the groove is damaged, replace all discs. C137438 AX AX–278 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX C141533 14. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY (a) Using vernier calipers, measure the free length of the 1st and reverse brake return spring together with the spring seat. Standard free length: 15.79 mm (0.6217 in.) If the free length is shorter than the standard free length, replace the 1st and reverse brake return spring. 15. INSPECT CLEARANCE OF NO. 2 BRAKE (a) Using a dial indicator, measure the clearance of the No. 2 brake while applying compressed air (200 kPa, 2.0 kgf/cm2, 29 psi). Standard clearance: 0.884 to 1.196 mm (0.0348 to 0.0471 in.) HINT: Measure the clearance at 3 points where the brake piston diameter is approximately 140 mm (5.51 in.) and calculate the average. If the clearance is not as specified, select an appropriate No. 2 brake flange so that the clearance will be within the specified range. HINT: There are 5 different thicknesses of flanges available. No. 2 brake flange thickness: mm (in.) C137439 Thickness Thickness 4.0 (0.157) 4.3 (0.169) 4.1 (0.161) 4.4 (0.173) 4.2 (0.165) - 16. INSPECT CLEARANCE OF NO. 1 BRAKE (a) Using a dial indicator, measure the clearance of the No. 1 brake while applying compressed air (200 kPa, 2.0 kgf/cm2, 29 psi). Standard clearance: 0.807 to 0.974 mm (0.0318 to 0.0383 in.) HINT: Measure the clearance at 3 points where the brake piston diameter is approximately 140 mm (5.51 in.) and calculate the average. If the clearance is not as specified, select an appropriate No. 1 brake flange so that the clearance will be within the specified range. HINT: There are 6 different thicknesses of flanges available. No. 1 brake flange thickness: mm (in.) C138258 Thickness Thickness 3.0 (0.118) 3.3 (0.130) 3.1 (0.122) 3.4 (0.134) 3.2 (0.126) 3.5 (0.138) AX–279 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT Dimension A No. 3 Brake Front Oil Pump Assembly Dimension B Contact Surface of Front Oil Pump Assembly C138724E01 17. INSPECT CLEARANCE OF NO. 3 BRAKE (a) Using vernier calipers and a straight edge, measure the distance shown in the illustration (Dimension A) while a load of 500 N (51 kgf, 112 lbf) is being applied to the flange. HINT: Measure dimension A at 3 points where the flange diameter is approximately 166 mm (6.54 in.) and calculate the average. (b) Using vernier calipers and a straight edge, measure the distance shown in the illustration. (Dimension B). HINT: Measure dimension B at 3 points where the No. 3 brake diameter is approximately 166 mm (6.54 in.) and calculate the average. (c) Calculate the clearance value using the following formula: clearance = Dimension B - Dimension A Standard clearance: 0.599 to 0.761 mm (0.0236 to 0.0300 in.) If the clearance is not as specified, select an appropriate brake flange so that the clearance will be within the specified range. HINT: There are 6 different thicknesses of flanges available. No. 3 brake flange thickness: mm (in.) Thickness Thickness 3.80 (0.150) 4.10 (0.161) 3.90 (0.154) 4.20 (0.165) 4.00 (0.157) 4.30 (0.169) 18. INSPECT CLEARANCE OF NO. 1 CLUTCH DISC (a) Install the direct multiple disc clutch assembly onto the transaxle rear cover. (b) Using a dial indicator, measure the No. 1 clutch pack clearance while applying and releasing compressed air (200 kPa, 2.0 kgf/cm2, 29 psi). HINT: Measure the clearance at 3 points where the flange diameter is approximately 152 mm (5.98 in.) and calculate the average. Pack clearance: 0.806 to 0.974 mm (0.0317 to 0.0383 in.) If the pack clearance is not as specified, inspect the discs, plates and flange. HINT: There are 6 different thicknesses of flanges available. No. 1 clutch flange thickness: mm (in.) C138728 Thickness Thickness 3.0 (0.118) 3.3 (0.130) 3.1 (0.122) 3.4 (0.134) AX AX–280 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT Thickness Thickness 3.2 (0.126) 3.5 (0.138) 19. INSPECT CLEARANCE OF NO. 2 CLUTCH DISC (a) Install the direct multiple disc clutch assembly onto the transaxle rear cover. (b) Using a dial indicator, measure the No. 2 clutch pack clearance while applying and releasing compressed air (200 kPa, 2.0 kgf/cm2, 29 psi). HINT: Measure the clearance at 3 points where the diameter of the No. 2 direct multiple clutch piston is approximately 152 mm (5.98 in.) and calculate the average. Pack clearance: 0.544 to 0.744 mm (0.0214 to 0.0293 in.) If the pack clearance is not as specified, inspect the discs, plates and flange. HINT: There are 6 different thicknesses of flanges available. No. 2 clutch flange thickness: mm (in.) AX C138727 Thickness Thickness 3.0 (0.118) 3.3 (0.130) 3.1 (0.122) 3.4 (0.134) 3.2 (0.126) 3.5 (0.138) U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–281 REASSEMBLY 1. BEARING POSITION AX C B A C138530E01 AX–282 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX E D H F G C138529E01 AX–283 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT Mark Front Race Diameter Inside / Outside mm (in.) Thrust Bearing Diameter Inside / Outside mm (in.) Rear Race Diameter Inside / Outside mm (in.) A - 57.7 (2.271) / 75.2 (2.961) - B - 29.1 (1.146) / 48.6 (1.913) 30.7 (1.209) / 48.3 (1.902) C 65.9 (2.594) / 80.3 (3.161) 62.6 (2.465) / 82.4 (3.244) - D 59.4 (2.339) / 77 (3.032) 53.1 (2.091) / 79 (3.110) - E - 56.1 (2.209) / 80.9 (3.185) - F - 61.2 (2.409) / 79 (3.110) - G - 28 (1.102) / 47.1 (1.854) 26.1 (1.028) / 44 (1.732) H 52.2 (2.055) / 70.4 (2.772) 48.9 (1.925) / 72.0 (2.835) - 2. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL (a) Coat the lip of a new manual valve lever shaft oil seal with MP grease. (b) Using SST and a hammer, install the manual valve lever shaft oil seal to the transaxle case. SST 09950-60010 (09951-00230), 09950-70010 (09951-07100) Oil seal installation depth: -0.5 to 0.5 mm (-0.0197 to 0.0197 in.) 3. INSTALL MANUAL VALVE LEVER SHAFT (a) Install a new spacer to the parking lock lever subassembly. (b) Install the parking lock lever sub-assembly to the manual valve lever shaft. (c) Install a new spacer to the manual valve lever subassembly. (d) Install the manual valve lever sub-assembly to the manual valve lever shaft. SST C137421E01 (e) Install the manual valve lever shaft to the transaxle case. NOTICE: Do not damage the manual valve lever shaft oil seal while installing the manual valve lever shaft to the transaxle case. C137428 AX AX–284 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT (f) Using a pin punch (3 mm) and hammer, install a new slotted spring pin to the parking lock lever subassembly. AX C137417 (g) Turn the spacer and the lever shaft to align the smaller hole of the spacer with the staking position mark on the lever shaft. (h) Using a pin punch, stake the spacer through the small hole. (i) Check that the spacer does not turn. C137429 (j) C136702 Using a pin punch (3 mm) and hammer, install a new slotted spring pin to the manual valve lever sub-assembly. U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–285 (k) Turn the spacer and the lever shaft to align the smaller hole of the spacer with the staking position mark on the lever shaft. (l) Using a pin punch, stake the spacer through the small hole. (m) Check that the spacer does not turn. C137430 (n) Using needle-nose pliers, install the manual valve shaft retainer spring to the transaxle case. C136680 4. INSTALL PARKING LOCK ROD SUB-ASSEMBLY (a) Align the dial with the notches on the parking lock lever sub-assembly and install the parking lock rod sub-assembly. 5. INSTALL MANUAL DETENT SPRING SUBASSEMBLY (a) Install the manual detent spring sub-assembly and cover to the transaxle case with the bolt. Torque: 23 N*m (234 kgf*cm, 17 ft.*lbf) NOTICE: Make sure to install the manual detent spring first and then the cover. C136683 C134953 AX AX–286 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT 6. INSTALL COUNTER DRIVE GEAR BEARING NOTICE: Perform this procedure only when the counter drive gear bearing or transaxle case is replaced. (a) Using SST and a press, install a new counter drive gear bearing and snap ring to the transaxle case. SST 09950-60020 (09951-01030), 09950-70010 (09951-07100) AX SST SST C138721E01 7. INSTALL NO. 3 BRAKE PISTON (a) Coat the contact surface of the transaxle case with ATF. (b) Coat the lip seal of the No. 3 brake piston with ATF. C137432 (c) Temporarily install the pawl stopper plate to the transaxle case with the 2 bolts. C137431 C136679 (d) Press the return spring installation surface to install the No. 3 brake piston to the transaxle case. NOTICE: • Make sure that the lip of the No. 3 brake piston is not twisted and does not get caught in the transaxle case. • After installing, make sure that the protrusions on the No. 3 brake piston and the grooves on the pawl stopper plate are aligned. (e) Install the return spring to the transaxle case. U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT (f) AX–287 Remove the 2 bolts and pawl stopper plate from the transaxle case. AX C137422 (g) Place SST on the brake piston return spring and compress the brake piston return spring with a press. SST 09387-00070 NOTICE: Stop the press when the brake piston return spring is flush with the snap ring groove. This prevents the brake piston return spring from being deformed. (h) Using a screwdriver, install the snap ring to the transaxle case as shown in the illustration. NOTICE: • Confirm that the snap ring is secured in the groove of the transaxle case. • Be sure to align the opening ends of the snap ring with the protrusions on the brake piston return spring as shown in the illustration. SST C138725E01 8. SST C137423E01 INSTALL COUNTER DRIVE GEAR (a) Using SST and a press, install the bearing inner race (front side) to the counter drive gear. SST 09387-00020 AX–288 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT (b) Install the bearing inner race (rear side) and counter drive gear to the transaxle case. SST 09223-15030, 09527-17011, 09950-60020 (09951-00810), 09950-70010 (09951-07100) NOTICE: There should not be any clearance between the bearing inner race (front side) and counter drive gear. AX SST SST SST C137424E01 9. SST SST SST C137425E01 INSTALL FRONT PLANETARY GEAR ASSEMBLY (a) Using SST and a press, press in the planetary gear assembly to the transaxle case. SST 09223-15030, 09527-17011, 09951-01100 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–289 10. INSTALL NO. 2 BRAKE PISTON (a) Coat 2 new O-rings with ATF and install them to the No. 2 brake piston. NOTICE: Ensure that the 2 O-rings are not twisted. AX C136673 (b) Install the No. 2 brake piston to the transaxle case. NOTICE: Be careful not to damage the O-rings. 11. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY (a) Install the 1st and reverse brake return spring to the transaxle case. C138726 SST SST C137434E01 (b) Place SST on the 1st and reverse brake return spring and compress the 1st and reverse brake return spring with a press. SST 09387-00060 NOTICE: Stop the press when the 1st and reverse brake return spring is flush with the snap ring groove. This prevents the 1st and reverse brake return spring from being deformed. (c) Using a screwdriver, install the snap ring to the transaxle case as shown in the illustration. NOTICE: • Confirm that the snap ring is secured in the groove of the transaxle case. • Be sure to align the opening ends of the snap ring with the protrusions on the transaxle case as shown in the illustration. AX–290 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT Brake Flange AX Brake Plate Brake Disc 12. INSTALL NO. 2 BRAKE DISC (a) Install the 5 brake discs, 5 brake plates, and brake flange to the transaxle case. NOTICE: Make sure that the discs, plates, and flange are installed in the correct order. C136483E01 (b) Using a screwdriver, install the snap ring to the transaxle case. NOTICE: • Confirm that the snap ring is secured in the groove of the transaxle case. • Be sure to align the opening ends of the snap ring with the protrusions on the transaxle case as shown in the illustration. 13. INSPECT CLEARANCE OF NO. 2 BRAKE (See page AX-278) C136481 14. INSTALL PLANETARY RING GEAR FLANGE (a) Install the planetary ring gear flange to the planetary ring gear. (b) Using a screwdriver, install the snap ring to the planetary ring gear. NOTICE: Confirm that the snap ring is secured in the groove of the planetary ring gear. C136480 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–291 15. INSTALL PLANETARY RING GEAR (a) Install the planetary ring gear to the one-way clutch assembly. NOTICE: Make sure that the one-way clutch assembly is positioned in the correct direction as shown in the illustration. C136479 16. INSTALL ONE-WAY CLUTCH ASSEMBLY (a) Coat the thrust needle roller bearing with ATF, and install it onto the planetary gear assembly. Bearing diameter: mm (in.) One-way Clutch Assembly Retainer C136478E01 - Inside Outside Bearing 56.1 (2.209) 80.9 (3.185) NOTICE: Install the thrust needle roller bearing properly so that the temper colored side of the race will be visible. (b) Install the one-way clutch assembly to the transaxle case. NOTICE: Make sure that there is no clearance between the retainer and the claw on the one-way clutch assembly. If there is any clearance, the spring of the retainer will be deformed. AX AX–292 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT (c) Using a screwdriver, install the snap ring to the transaxle case. NOTICE: • Confirm that the snap ring is secured in the groove of the transaxle case. • Be sure to align the opening ends of the snap ring with the protrusions on the transaxle case. AX C136477 SST C137443E01 17. INSTALL COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING OUTER RACE (a) Using SST and a hammer, install the counter driven gear rear tapered roller bearing outer race to the transaxle case. SST 09950-60010 (09951-00650), 09950-70010 (09951-07100) NOTICE: Be sure to install the counter driven gear rear tapered roller bearing outer race so that there is no clearance between the bearing outer race and the transaxle case. If there is any clearance, the turning torque of the counter drive gear cannot be measured correctly. 18. INSTALL PARKING LOCK PAWL (a) Install the parking lock pawl to the transaxle case with the parking lock pawl shaft. (b) Install the parking lock pawl pin to the transaxle case. C136475 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–293 (c) Install the torsion spring to the parking lock pawl. NOTICE: Make sure that one end of the spring is fixed in the hole of the transaxle case and the other end is positioned on the parking lock pawl as shown in the illustration. C137444 19. INSTALL PARKING LOCK SLEEVE (a) Install the parking lock sleeve to the transaxle case. C136474 20. INSTALL PAWL STOPPER PLATE (a) Install the pawl stopper plate to the transaxle case with the 2 bolts. Torque: 23 N*m (234 kgf*cm, 17 ft.*lbf) C136473 21. INSTALL PAWL SHAFT CLAMP (a) Install the pawl shaft clamp to the transaxle case with the bolt. Torque: 23 N*m (234 kgf*cm, 17 ft.*lbf) C136472 AX AX–294 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT SST AX C138250E01 SST C138251E01 22. INSTALL COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING (a) Using SST and a press, install a new the counter driven gear front tapered roller bearing to the counter driven gear sub-assembly. SST 09950-60010 (09951-00530) NOTICE: Be sure to install the counter driven gear front tapered roller bearing so that there is no clearance between the bearing and the counter driven gear. If there is any clearance, the turning torque of the counter drive gear cannot be measured correctly. 23. INSTALL COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING (a) Using SST and a press, install a new the counter driven gear rear tapered roller bearing to the counter driven gear sub-assembly. SST 09950-60010 (09951-00420) NOTICE: Be sure to install the counter driven gear rear tapered roller bearing and the differential drive pinion so that there is no clearance between each of them and the counter driven gear. 24. INSTALL COUNTER DRIVEN GEAR (a) Install the counter driven gear sub-assembly to the transaxle case. C136469 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–295 25. INSTALL COUNTER DRIVE GEAR NUT (a) Turn the manual shaft lever 2 notches counterclockwise to set it in the P position as shown in the illustration. AX P C136700E01 (b) Using SST, install a new nut. SST 09387-00130 Torque: 120 N*m (1,223 kgf*cm, 88 ft.*lbf) SST C136468E01 (c) Turn the manual shaft lever 2 notches clockwise to set it in the N position as shown in the illustration. N C136699E01 AX–296 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT (d) Using SST and a torque wrench, measure the turning torque of the bearing while rotating SST at 60 rpm. SST 09387-00130 Turning torque: 0.10 to 0.22 N*m (1.02 to 2.24 kgf*cm, 0.89 to 1.94 in.*lbf) When the measured value is not within the specified range, gradually tighten the nut until the turning toque falls within the specified range. Maximum torque: 180 N*m (1,835 kgf*cm, 132 ft.*lbf) AX SST C138252E01 (e) Using SST and a hammer, stake the planetary gear assembly. SST 09930-00010 SST C136698E01 26. INSTALL FRONT DIFFERENTIAL CASE (a) Install the differential case sub-assembly to the transaxle case. 27. INSPECT DIFFERENTIAL SIDE GEAR (See page AX332) C136467 28. INSTALL NO. 1 BRAKE PISTON (a) Coat 2 new O-rings with ATF and install them to the No. 1 brake piston. NOTICE: Ensure that the 2 O-rings are not twisted. C136466 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–297 (b) Install the No. 1 brake piston to the oil pump assembly. NOTICE: Be careful not to damage the O-rings. AX C138253 29. INSTALL 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY (a) Install the 3 2nd brake piston return springs to the oil pump assembly. NOTICE: Make sure that the 3 2nd brake piston return springs are installed straight through the protrusions on the oil pump assembly. C136464 Flange Brake Plate Brake Disc C136463E01 30. INSTALL NO. 1 BRAKE DISC (a) Install the 4 brake discs, 4 brake plates, and brake flange to the oil pump assembly. NOTICE: • Make sure that the discs, plates, and flange are installed in the correct order. • Be sure to install the flange in the correct direction. AX–298 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT SST AX (#1) (#2) C138256E01 (b) Place SST on the flange and compress the flange with a press. SST 09387-00070, 09495-65040 NOTICE: Stop the press when the brake piston return spring is flush with the snap ring groove. This prevents the brake piston return spring from being deformed. (c) Using a screwdriver, install the snap ring to the transaxle case as shown in the illustration (#1). NOTICE: • Confirm the snap ring is fixed in the groove of the oil pump. • Be sure to align the opening ends of the snap ring with the protrusions on the brake piston return spring as shown in the illustration. (d) Using a screwdriver, install the snap ring to the oil pump assembly as shown in the illustration (#2). NOTICE: • Confirm that the snap ring is secured in the groove of the oil pump. • Be sure to align the opening ends of the snap ring with the protrusions on the brake piston return spring as shown in the illustration. 31. INSPECT CLEARANCE OF NO. 1 BRAKE (See page AX-278) 32. INSTALL UNDERDRIVE PLANETARY SUN GEAR (a) Coat the thrust needle roller bearing with ATF, and install it to the oil pump assembly. Bearing diameter: mm (in.) - Inside Outside Bearing 57.7 (2.272) 75.2 (2.961) NOTICE: Install the thrust needle roller bearing properly so that the temper colored side of the race will be visible. (b) Install the underdrive planetary sun gear to the oil pump assembly. C136461 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT Thrust Needle Roller Race Thrust Needle Roller Bearing Input Shaft Input Shaft Oil Seal Ring C136460E01 AX–299 33. INSTALL INPUT SHAFT SUB-ASSEMBLY (a) Coat the 3 input shaft oil seal rings with ATF and install them to the input shaft. NOTICE: Do not expand the gap of the oil seal ring too much. (b) Coat the thrust needle roller bearing and thrust needle roller race with ATF, and install them on the oil pump assembly. Bearing diameter: mm (in.) - Inside Outside Bearing 29.1 (1.146) 48.6 (1.913) Race 30.7 (1.209) 48.3 (1.902) NOTICE: Be sure to install the thrust needle roller bearing in the correct direction. (c) Install the input shaft to the oil pump assembly. C136459 34. INSTALL PLANETARY SUN GEAR SUB-ASSEMBLY (a) Using a snap ring expander, install the snap ring to the underdrive planetary gear assembly. (b) Using a snap ring expander, install the front planetary sun gear sub-assembly to the underdrive planetary gear assembly with the snap ring expanded. C136457 AX AX–300 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT 35. INSTALL UNDERDRIVE PLANETARY RING GEAR (a) Install the underdrive planetary ring gear to the underdrive planetary gear assembly. (b) Using needle-nose pliers, install the snap ring to the underdrive planetary ring gear. NOTICE: Confirm that the snap ring is secured in the groove of the underdrive planetary ring gear. AX C136456 36. INSTALL NO. 3 BRAKE HUB (a) Coat the thrust needle roller bearing with ATF and install it on the underdrive planetary gear assembly. Bearing diameter: mm (in.) Thrust Needle Roller Race Thrust Needle Roller Bearing C136455E01 - Inside Outside Bearing 62.6 (2.464) 82.9 (3.263) Race 65.9 (2.594) 80.3 (3.161) NOTICE: Install the thrust needle roller bearing properly so that the temper colored side of the race will be visible. (b) Coat the race with MP grease and install it to the No. 3 brake hub. (c) Install the No. 3 brake hub to the underdrive planetary gear assembly. C136454 37. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY (a) Install the underdrive planetary gear assembly to the oil pump assembly. C136458 AX–301 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT Brake Flange Brake Plate Brake Disc 38. INSTALL NO. 3 BRAKE DISC (a) Install the 2 brake flanges, 3 brake discs, and 2 brake plates to the oil pump assembly. NOTICE: Make sure that the discs, plates, and flange are installed in the correct order. Brake Flange C136452E01 (b) Using a screwdriver, install the snap ring to the oil pump assembly. NOTICE: • Confirm the snap ring is fixed in the groove of the oil pump. • Be sure to align the opening ends of the snap ring with the protrusions on the brake piston return spring as shown in the illustration. 39. INSPECT CLEARANCE OF NO. 3 BRAKE C136451E01 Thrust Needle Roller Race Thrust Needle Roller Bearing O-Ring C138729E01 40. INSTALL FRONT OIL PUMP AND GEAR BODY SUBASSEMBLY (a) Coat the O-ring with ATF and install it to the transaxle case. (b) Coat the thrust needle roller bearing and thrust needle roller race with ATF and install them on the underdrive planetary gear assembly. Bearing and race diameter: mm (in.) - Inside Outside Bearing 53.1 (2.091) 79 (3.11) Race 59.4 (2.339) 77 (3.03) NOTICE: Install the thrust needle roller bearing properly so that the temper colored side of the race will be visible. (c) Coat the O-ring with ATF and install it to the oil pump. (d) Install the oil pump assembly to the transaxle case with the 7 bolts. Torque: 23 N*m (234 kgf*cm, 17 ft.*lbf) C136450 AX AX–302 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX C136449 SST C138261E01 41. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE (a) Install the differential gear lube apply tube to the transaxle housing. NOTICE: Insert the differential lube apply tube into the transaxle case until it makes contact with the stopper. (b) Install the apply tube clamp to the differential gear lube apply tube with the bolt. Torque: 23 N*m (234 kgf*cm, 17 ft.*lbf) NOTICE: There should be clearance between the differential lube apply tube and apply tube clamp. 42. INSTALL COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING OUTER RACE (a) Install the shim to the transaxle housing. (b) Using SST, install a new counter driven gear front tapered roller bearing outer race to the transaxle housing. SST 09950-60020 (09951-00810), 09950-70010 (09951-07100) NOTICE: Be sure to install the counter driven gear front tapered roller bearing outer race so that there is no clearance between the shim and the transaxle housing. 43. INSTALL TRANSAXLE HOUSING (a) Remove packing material from the contact surface between the transaxle housing and case. NOTICE: Make sure that there is no ATF on the contact surface. FIPG C138263E01 (b) Apply FIPG to the transaxle case. FIPG: Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent. NOTICE: Apply a bead of FIPG (width 1.2 mm (0.047 in.)) along the sealing surface. U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT A A A AX–303 (c) Install the transaxle housing to the transaxle case with the 20 bolts. Torque: Bolt A 31 N*m (316 kgf*cm, 23 ft.*lbf) Bolt B 23 N*m (234 kgf*cm, 17 ft.*lbf) A A B C136447E01 44. ADJUST COUNTER DRIVEN GEAR PRELOAD (a) Using SST and a torque wrench, measure the turning torque of the counter driven gear while rotating SST at 10 rpm. SST 09564-33010 Turning torque: Differential side bearing preload 3.29 to 6.07 N*m (33.53 to 61.86 kgf*cm, 2.42 to 4.46 ft.*lbf) If the turning torque is not within the specified range, refer to the table below to select a shim of the counter driven gear front tapered roller bearing outer race so that the turning torque is within the specified range. SST C138262E01 Clutch Flange Clutch Plate Clutch Disc Clutch Flange C136446E01 Thickness Thickness Thickness Thickness 2.000 (0.0787) 2.275 (0.0896) 2.525 (0.0994) 2.775 (0.1093) 2.025 (0.0797) 2.300 (0.0906) 2.550 (0.1004) 2.800 (0.1102) 2.050 (0.0807) 2.325 (0.0915) 2.575 (0.1014) 2.825 (0.1112) 2.075 (0.0817) 2.350 (0.0925) 2.600 (0.1024) 2.850 (0.1122) 2.100 (0.0827) 2.375 (0.0935) 2.625 (0.1034) 2.875 (0.1132) 2.125 (0.0837) 2.400 (0.0945) 2.650 (0.1043) 2.900 (0.1142) 2.150 (0.0847) 2.425 (0.0955) 2.675 (0.1053) 2.925 (0.1152) 2.175 (0.0856) 2.450 (0.0965) 2.700 (0.1063) 2.950 (0.1161) 2.200 (0.0866) 2.475 (0.0974) 2.725 (0.1073) 2.975 (0.1171) 2.225 (0.0876) 2.500 (0.0984) 2.750 (0.1083) 3.000 (0.1181) 2.250 (0.0886) - - - 45. INSTALL NO. 1 CLUTCH DISC (a) Install the clutch flange, 4 clutch discs, and 4 clutch plates to the direct multiple disc clutch assembly. NOTICE: Make sure that the flange, discs, and plates are installed in the correct order. AX AX–304 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT (b) Using a screwdriver, install the 2 snap rings to the direct multiple disc clutch assembly. NOTICE: Confirm that the snap ring is secured in the groove of the direct multiple disc clutch assembly. AX 46. INSPECT CLEARANCE OF NO. 1 CLUTCH DISC (See page AX-279) C136445 Thrust Needle Roller Bearing Thrust Needle Roller Race C136438E01 47. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY (a) Coat the thrust needle roller bearing and thrust needle roller race with ATF, and install them to the direct multiple disc clutch assembly. Bearing and race diameter: mm (in.) - Inside Outside Bearing 28 (1.10) 47.1 (1.854) Race 26.1 (1.028) 44 (1.73) NOTICE: Install the thrust needle roller bearing properly so that the temper colored side of the race will be visible. (b) Install the rear planetary sun gear to the direct multiple disc clutch assembly. C136437 (c) Using a snap ring expander, install the snap ring to the direct multiple disc clutch assembly. C136436 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT Clutch Plate Clutch Disc AX–305 48. INSTALL NO. 2 CLUTCH DISC (a) Install the clutch flange, 3 clutch discs, and 3 clutch plates to the direct multiple disc clutch assembly. NOTICE: Make sure that the flange, discs, and plates are installed in the correct order. Clutch Flange C136435E01 49. INSTALL DIRECT MULTIPLE DISC CLUTCH SNAP RING (a) Coat a new O-ring with ATF and install it to the direct multiple disc clutch assembly. (b) Coat a new intermediate shaft oil seal ring with ATF and install it to the intermediate shaft. O-Ring Intermediate Shaft Oil Seal C136428E01 (c) Install the No. 2 direct clutch piston to the direct multiple disc clutch assembly. NOTICE: Be sure to engage the claws on the direct multiple disc clutch assembly to the grooves on the No. 2 direct clutch piston. C136434 (d) Using a screwdriver, install the snap ring to the direct multiple disc clutch assembly. NOTICE: Position the opening of the snap ring as shown in the illustration. 50. INSPECT CLEARANCE OF NO. 2 CLUTCH DISC (See page AX-280) C136433E01 AX AX–306 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT 51. INSTALL REAR MULTIPLE DISC CLUTCH ASSEMBLY (a) Coat the thrust needle roller bearing with ATF and install it on the transaxle case. Bearing diameter: mm (in.) AX - Inside Outside Bearing 61.2 (2.409) 79 (3.11) (b) Install the direct multiple disc clutch assembly to the transaxle case. (c) Clean the contact surface of the transaxle case and transaxle rear cover. C136442 (d) As shown in the illustration, place a straight edge on the multiple direct clutch drum and measure the distance between the transaxle case and the straight edge using vernier calipers (Dimension A). Dimension A C138269E01 (e) Using vernier calipers and a straight edge, measure the distance shown in the illustration. (Dimension B) (f) Calculate the end play value using the following formula: End play = Dimension B - Dimension A End play: 0.007 to 1.113 mm (0.0003 to 0.0438 in.) Dimension B C138268E01 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT SST C138270E01 AX–307 52. INSTALL TRANSAXLE REAR COVER SUBASSEMBLY (a) Using SST and a hammer, install the needle roller bearing into the transaxle rear cover. SST 09950-60010 (09951-00220), 09950-70010 (09951-07100) Press installation depth: 21.5 to 21.9 mm (0.8464 to 08622 in.) (b) Apply sealant to the 2 "TORX" screws. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent (c) Using a "TORX" wrench (T30), install the transaxle rear cover plate to the transaxle rear cover with the 2 "TORX" screws. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) C136443 (d) Coat the thrust needle roller bearing and thrust needle roller race with ATF and install it on the transaxle case. Bearing diameter: mm (in.) Oil Seal Ring Thrust Needle Roller Bearing Thrust Needle Roller Race C136440E01 Inside Outside 48.9 (1.925) 72.0 (2.835) Race 52.2 (2.055) 70.4 (2.772) (e) Coat the 2 new oil seals with ATF and install them to the transaxle rear cover. (f) C136432 Bearing Coat the 3 O-rings with ATF and install them to the transaxle case. NOTICE: Ensure that the 3 O-rings are not twisted. AX AX–308 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT (g) Remove packing material from the contact surfaces between the transaxle rear cover and transaxle case. NOTICE: Make sure that there is no ATF on the contact surface. FIPG: Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent. AX C138271 A A A B A B (h) Install the transaxle rear cover to the transaxle case with the 14 bolts. Torque: Bolt A 23 N*m (234 kgf*cm, 17 ft.*lbf) Bolt B 17 N*m (173 kgf*cm, 12 ft.*lbf) C136431E01 (i) (j) Install a new gasket to the refill plug. Install the refill plug to the transaxle rear cover. Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) C136430 (k) Coat 2 new O-rings with ATF and install them to the 2 No. 1 automatic transaxle case plugs. (l) Install the 2 No. 1 automatic transaxle case plugs to the transaxle rear cover. Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf) 53. INSPECT INPUT SHAFT END PLAY (See page AX274) C134960 54. INSTALL TRANSAXLE CASE GASKET (a) Coat the 2 gaskets with ATF and install them to the transaxle case. C136429 AX–309 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT C B 55. INSTALL TRANSMISSION VALVE BODY ASSEMBLY (a) Install the valve body assembly to the transaxle case with the 11 bolts. Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) A D *1 *1 E B B C136689E01 - Bolt length Bolt A 25 mm (0.98 in.) Bolt B 30 mm (1.18 in.) Bolt C 35 mm (1.38 in.) Bolt D 45 mm (1.77 in.) Bolt E 55 mm (2.17 in.) NOTICE: • When installing the transmission valve body assembly, be careful not to allow the transmission revolution sensor and transaxle case to interfere each other. • Be sure to insert the pin of the manual valve lever into the groove on the end of the manual valve. • First, temporarily tighten the bolts marked by (*1) in the illustration because they are positioning bolts. 56. INSTALL VALVE BODY OIL STRAINER ASSEMBLY (a) Coat a new O-ring with ATF and install it to the oil strainer assembly. NOTICE: Ensure that the O-ring is not twisted or pinched. C136688 (b) Install the oil strainer assembly to the valve body assembly with the 2 bolts. Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) C136687 AX AX–310 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT 57. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUBASSEMBLY (a) Install the 2 magnets in the automatic transaxle oil pan sub-assembly. (b) Apply sealant to the 18 bolts. Sealant: Toyota Genuine Seal Packing 1344, Three Bond 1344 or equivalent. AX C134963 C134962 (c) Install the automatic transaxle oil pan sub-assembly and a new gasket to the transaxle case with the 18 bolts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) NOTICE: • In order to ensure proper sealing of the transmission pan bolts, apply sealant to the bolts and install them within 10 minutes of sealant application. • Completely remove any oil or grease from the contact surface of the transaxle case and oil pan sub-assembly with the gasket before installation. (d) Install the No. 1 oil filler tube from the automatic transaxle assembly. C141531 (e) Install the overflow plug and a new gasket to the oil pun sub-assembly. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) C134961 58. INSTALL NO. 1 TRANSAXLE CASE PLUG (a) Install the 3 gaskets to the 3 hexagon bolts. (b) Apply sealant to the 3 hexagon bolts. Sealant: Toyota Genuine Seal Packing 1344, Three Bond 1344 or equivalent. NOTICE: In order to ensure proper sealing of the hexagon bolts, apply sealant to the bolts and install them within 10 minutes of sealant application. U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX–311 (c) Install the 3 hexagon bolts to the transaxle housing with the gaskets. Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) AX C134959 (d) Coat 3 new O-rings with the ATF and install them to the 3 No. 1 transaxle case plugs. (e) Install the 3 No. 1 transaxle case plugs to the transaxle case. Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf) C134958 59. INSTALL OIL COOLER TUBE UNION (OUTLET OIL COOLER UNION) (a) Coat a new O-ring with ATF and install it to the oil cooler tube union (outlet oil cooler union). (b) Install the oil cooler tube union (outlet oil cooler union) to the transaxle case as shown in the illustration. Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) C134957 60. INSTALL OIL COOLER TUBE UNION (INLET OIL COOLER UNION) (a) Coat a new O-ring with ATF and install it to the oil cooler tube union (inlet oil cooler union). (b) Install the oil cooler tube union (inlet oil cooler union) to the transaxle case. Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) C134956 Protrusions C135733E01 61. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Align the protrusions of the park/neutral position switch. AX–312 U660E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT AX C136686 (b) Install the park/neutral position switch to the control shaft with the 2 bolts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) NOTICE: • Before installing the park/neutral position switch, remove any dirt or rust on the installation portion of the control shaft. Be sure to install the switch straight along the shaft while being careful not to deform the plate spring that supports the shaft. If the plate spring is deformed, the park/neutral switch cannot be reinstalled correctly. • After installing the park/neutral position switch, confirm that the 2 protrusions on the switch are aligned. (c) Install the control shaft lever to the control shaft with the washer and nut. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) C136685 62. INSTALL BREATHER PLUG HOSE (a) Install a new O-ring to the breather plug. (b) Install the breather plug to the breather plug hose. (c) Install the breather plug cap to the breather plug hose. Breather Plug Cap Breather Plug Hose Breather Plug O-Ring C134952E01 (d) Install the breather plug hose to the transaxle case. C134951 AX–313 U660E AUTOMATIC TRANSAXLE – OIL PUMP OIL PUMP U660E AUTOMATIC TRANSAXLE TRANSMISSION COMPONENTS AX STATOR SHAFT ASSEMBLY 9.3 (95, 82 in.*lbf) FR OIL PUMP AND GEAR BODY SUB-ASSEMBLY x7 FRONT OIL PUMP OIL SEAL FRONT OIL PUMP DRIVEN GEAR FRONT OIL PUMP DRIVE GEAR x9 9.3 (95, 82 in.*lbf) FRONT OIL PUMP BODY O-RING N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Apply MP grease Apply ATF WS C134940E01 AX–314 U660E AUTOMATIC TRANSAXLE – OIL PUMP DISASSEMBLY 1. INSPECT FRONT OIL PUMP AND GEAR BODY SUBASSEMBLY (See page AX-315) 2. REMOVE STATOR SHAFT ASSEMBLY (a) Using a "TORX" wrench (T30), remove the 16 bolts and stator shaft assembly from the oil pump body. NOTICE: Keep the gears in the order of installation. 3. INSPECT CLEARANCE OF FRONT OIL PUMP AND GEAR BODY SUB-ASSEMBLY (See page AX-315) 4. REMOVE FRONT OIL PUMP BODY O-RING (a) Remove the O-ring from the oil pump body. 5. REMOVE FRONT OIL PUMP DRIVE GEAR (a) Remove the front oil pump drive gear from the oil pump body. AX C138275 C138278 C138276 AX–315 U660E AUTOMATIC TRANSAXLE – OIL PUMP 6. REMOVE FRONT OIL PUMP DRIVEN GEAR (a) Remove the front oil pump driven gear from the oil pump body. AX C138277 7. SST REMOVE FRONT OIL PUMP OIL SEAL (a) Mount the oil pump in a soft jaw vise. (b) Using SST, remove the oil seal from the oil pump body. SST 09308-00010 C138508E01 INSPECTION 1. INSPECT FRONT OIL PUMP AND GEAR BODY SUBASSEMBLY (a) Turn the drive gear with 2 screwdrivers and make sure that it rotates smoothly. NOTICE: Be careful not to damage the oil seal lip. 2. INSPECT CLEARANCE OF FRONT OIL PUMP AND GEAR BODY SUB-ASSEMBLY (a) Push the driven gear to one side of the body. (b) Using a feeler gauge, measure the clearance. Standard clearance: 0.08 to 0.15 mm (0.0031 to 0.0059 in.) Maximum clearance: 0.15 mm (0.0059 in.) If the clearance is greater than the maximum, replace the oil pump body sub-assembly. C138512 C138509 (c) Using a straight edge and feeler gauge, measure the side clearance of both gears. Standard side clearance: 0.025 to 0.04 mm (0.0010 to 0.0016 in.) Maximum side clearance: 0.04 mm (0.0016 in.) Drive gear thickness: C138511 Mark Thickness - 11.547 to 11.555 mm (0.4546 to 0.4549 in.) - 11.555 to 11.563 mm (0.4549 to 0.4552 in.) - 11.564 to 11.571 mm (0.4553 to 0.4556 in.) AX–316 U660E AUTOMATIC TRANSAXLE – OIL PUMP Mark Thickness - 11.572 to 11.579 mm (0.4556 to 0.4559 in.) - 11.580 to 11.587 mm (0.4559 to 0.4562 in.) Driven gear thickness: AX Mark Thickness - 11.547 to 11.555 mm (0.4546 to 0.4549 in.) - 11.555 to 11.563 mm (0.4549 to 0.4552 in.) - 11.564 to 11.571 mm (0.4553 to 0.4556 in.) - 11.572 to 11.579 mm (0.4556 to 0.4559 in.) - 11.580 to 11.587 mm (0.4559 to 0.4562 in.) 3. INSPECT FRONT OIL PUMP AND GEAR BODY SUBASSEMBLY (a) Using a dial indicator, measure the inside diameter of the oil pump body bushing. Standard inside diameter: 43.113 to 43.138 mm (1.6974 to 1.6983 in.) Maximum inside diameter: 43.188 mm (1.7003 in.) If the inside diameter is greater than the maximum, replace the oil pump body sub-assembly. 4. INSPECT STATOR SHAFT ASSEMBLY (a) Using a dial indicator, measure the inside diameter of the oil pump body bushing. Standard inside diameter: 22.500 to 22.526 mm (0.8858 to 0.8868 in.) Maximum inside diameter: 22.570 mm (0.8886 in.) If the inside diameter is greater than the maximum, replace the oil pump body sub-assembly. C138514 C138513 REASSEMBLY 1. INSTALL FRONT OIL PUMP OIL SEAL (a) Using SST and a hammer, install a new oil seal to the oil pump body. SST 09350-32014 (09351-32140) NOTICE: The seal end should be level with the outer edge of the oil pump. (b) Coat the lip of the oil seal with MP grease. 2. INSTALL FRONT OIL PUMP BODY O-RING (a) Coat a new O-ring with ATF and install it to the oil pump body. NOTICE: Ensure that the O-ring is not twisted. SST C138515E01 C138278 AX–317 U660E AUTOMATIC TRANSAXLE – OIL PUMP 3. INSTALL FRONT OIL PUMP DRIVEN GEAR (a) Coat the front oil pump driven gear with ATF and install it to the oil pump body with the marked side up. AX C138277 4. INSTALL FRONT OIL PUMP DRIVE GEAR (a) Coat the front oil pump drive gear with ATF, and install it to the oil pump body with the marked side up. 5. INSTALL STATOR SHAFT ASSEMBLY (a) Align each knock pin of the stator shaft with the holes in the oil pump body and install the stator shaft to the oil pump body with the 16 bolts. (b) Using a "TORX" socket (T30), install the 11 bolts. Torque: 9.3 N*m (95 kgf*cm, 82 in.*lbf) C138276 A A A A A A A A B A 6. B B B B B B C138275E01 - Bolt length: Bolt A 14 mm (0.55 in) Bolt B 26 mm (1.02 in) INSPECT FRONT OIL PUMP AND GEAR BODY SUBASSEMBLY (See page AX-315) AX–318 U660E AUTOMATIC TRANSAXLE – SHIFT SOLENOID VALVE SHIFT SOLENOID VALVE U660E AUTOMATIC TRANSAXLE TRANSMISSION COMPONENTS AX TRANSMISSION VALVE BODY ASSEMBLY LOCK PLATE O-RING 11 (112, 8) O-RING CLAMP TRANSMISSION WIRE ATF TEMPERATURE SENSOR ASSEMBLY 11 (112, 8) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Apply ATF WS C138274E01 U660E AUTOMATIC TRANSAXLE – SHIFT SOLENOID VALVE AX–319 AX SOLENOID LOCK PLATE 11 (112, 8) 11 (112, 8) SOLENOID LOCK PLATE SHIFT SOLENOID VALVE SL SOLENOID LOCK PLATE SHIFT SOLENOID VALVE SLT SHIFT SOLENOID VALVE SLU SHIFT SOLENOID VALVE SL2 SHIFT SOLENOID VALVE SL1 N*m (kgf*cm, ft.*lbf) : Specified torque SHIFT SOLENOID VALVE SL4 SHIFT SOLENOID VALVE SL3 Apply ATF WS C138719E01 AX–320 U660E AUTOMATIC TRANSAXLE – SHIFT SOLENOID VALVE REMOVAL AX 1. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (See page AX-207) 2. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUBASSEMBLY (See page AX-182) 3. REMOVE VALVE BODY OIL STRAINER ASSEMBLY (See page AX-182) 4. REMOVE TRANSMISSION VALVE BODY ASSEMBLY (See page AX-183) DISASSEMBLY 1. REMOVE TRANSMISSION WIRE (a) Disconnect the connector from the transmission wire. (b) Remove the bolt and lock plate from the valve body assembly. C138518 (c) Disconnect the 8 connectors and remove the transmission wire from the valve body assembly. C138519 2. REMOVE ATF TEMPERATURE SENSOR ASSEMBLY (a) Remove the 4 bolts, ATF temperature sensor assembly and clamp from the valve body assembly. C138522 (b) Remove the O-ring from the ATF temperature sensor assembly. O-ring O-Ring C138520E01 U660E AUTOMATIC TRANSAXLE – SHIFT SOLENOID VALVE 3. AX–321 REMOVE SHIFT SOLENOID VALVE SL (a) Remove the shift solenoid valve SL from the valve body assembly. AX Solenoid Valve SL C138523E01 4. REMOVE SHIFT SOLENOID VALVE SLT (a) Remove the lock plate and shift solenoid valve SLT from the valve body assembly 5. REMOVE SHIFT SOLENOID VALVE SLU (a) Remove the shift solenoid valve SLU from the valve body assembly. 6. REMOVE SHIFT SOLENOID VALVE SL2 (a) Remove the bolt, lock plate and shift solenoid valve SL2 from the valve body assembly. 7. REMOVE SHIFT SOLENOID VALVE SL1 (a) Remove the shift solenoid valve SL1 from the valve body assembly. Lock Plate Solenoid Valve SLT Solenoid Valve SLU C138524E01 Lock Plate Solenoid Valve SL2 Solenoid Valve SL1 C138525E02 AX–322 U660E AUTOMATIC TRANSAXLE – SHIFT SOLENOID VALVE 8. REMOVE SHIFT SOLENOID VALVE SL3 (a) Remove the bolt, lock plate and shift solenoid valve SL3 from the valve body assembly. 9. REMOVE SHIFT SOLENOID VALVE SL4 (a) Remove the bolt, lock plate and shift solenoid valve SL4 from the valve body assembly. Lock Plate AX Solenoid Valve SL3 C138526E01 Lock Plate Solenoid Valve SL4 C138527E02 INSPECTION 1. INSPECT SHIFT SOLENOID VALVE SL (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition 20°C (68°F) Solenoid Connector (SL) - Solenoid Body (SL) 11 to 15 Ω C133217 If the value is not as specified, replace the shift solenoid valve. (b) Connect the positive (+) lead to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the shift solenoid valve. OK: The solenoid makes an operating noise. If the operation is not as specified, replace the shift solenoid valve. C133218 AX–323 U660E AUTOMATIC TRANSAXLE – SHIFT SOLENOID VALVE 2. Shift Solenoid Valve SLT: 2 1 (-) Tester Connection Specified Condition 20°C (68°F) 1-2 5.0 to 5.6 Ω If the value is not as specified, replace the shift solenoid valve. (b) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the shift solenoid valve. OK: The solenoid makes an operating noise. If the operation is not as specified, replace the shift solenoid valve. 2 1 INSPECT SHIFT SOLENOID VALVE SLT (a) Measure the resistance according to the value(s) in the table below. Standard resistance (+) G020767E08 3. Shift Solenoid Valve SLU: 1 2 (-) Tester Connection Specified Condition 20°C (68°F) 1-2 5.0 to 5.6 Ω If the value is not as specified, replace the shift solenoid valve. (b) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the shift solenoid valve. OK: The solenoid makes an operating noise. If the operation is not as specified, replace the shift solenoid valve. 2 1 INSPECT SHIFT SOLENOID VALVE SLU (a) Measure the resistance according to the value(s) in the table below. Standard resistance (+) G020767E09 AX AX–324 U660E AUTOMATIC TRANSAXLE – SHIFT SOLENOID VALVE 4. Shift Solenoid Valve SL2: 2 1 AX (-) Tester Connection Specified Condition 20°C (68°F) 1-2 5.0 to 5.6 Ω If the value is not as specified, replace the shift solenoid valve. (b) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the shift solenoid valve. OK: The solenoid makes an operating noise. If the operation is not as specified, replace the shift solenoid valve. 2 1 INSPECT SHIFT SOLENOID VALVE SL2 (a) Measure the resistance according to the value(s) in the table below. Standard resistance (+) G020767E07 5. Shift Solenoid Valve SL1: 2 1 (-) Tester Connection Specified Condition 20°C (68°F) 1-2 5.0 to 5.6 Ω If the value is not as specified, replace the shift solenoid valve. (b) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the shift solenoid valve. OK: The solenoid makes an operating noise. If the operation is not as specified, replace the shift solenoid valve. 2 1 INSPECT SHIFT SOLENOID VALVE SL1 (a) Measure the resistance according to the value(s) in the table below. Standard resistance (+) G020767E05 AX–325 U660E AUTOMATIC TRANSAXLE – SHIFT SOLENOID VALVE 6. Shift Solenoid Valve SL3: 2 1 (-) Tester Connection Specified Condition 20°C (68°F) 1-2 5.0 to 5.6 Ω If the value is not as specified, replace the shift solenoid valve. (b) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the shift solenoid valve. OK: The solenoid makes an operating noise. If the operation is not as specified, replace the shift solenoid valve. 2 1 INSPECT SHIFT SOLENOID VALVE SL3 (a) Measure the resistance according to the value(s) in the table below. Standard resistance (+) G020767E29 7. Shift Solenoid Valve SL3: 2 1 (-) Tester Connection Specified Condition 20°C (68°F) 1-2 5.0 to 5.6 Ω If the value is not as specified, replace the shift solenoid valve. (b) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the shift solenoid valve. OK: The solenoid makes an operating noise. If the operation is not as specified, replace the shift solenoid valve. 2 1 INSPECT SHIFT SOLENOID VALVE SL4 (a) Measure the resistance according to the value(s) in the table below. Standard resistance (+) G020767E29 REASSEMBLY Lock Plate 1. Solenoid Valve SL4 C138527E01 INSTALL SHIFT SOLENOID VALVE SL4 (a) Coat the shift solenoid valve SL4 and bolt with ATF. (b) Install the shift solenoid valve SL4 and lock plate to the valve body assembly with the bolt. Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) AX AX–326 U660E AUTOMATIC TRANSAXLE – SHIFT SOLENOID VALVE 2. INSTALL SHIFT SOLENOID VALVE SL3 (a) Coat the shift solenoid valve SL3 and bolt with ATF. (b) Install the shift solenoid valve SL3 and lock plate to the valve body assembly with the bolt. Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) 3. INSTALL SHIFT SOLENOID VALVE SL1 (a) Coat the shift solenoid valve SL1 with ATF. (b) Install the shift solenoid valve SL1 to the valve body assembly. 4. INSTALL SHIFT SOLENOID VALVE SL2 (a) Coat the shift solenoid valve SL2 and bolt with ATF. (b) Install the shift solenoid valve SL2 and lock plate to the valve body assembly with the bolt. Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) 5. INSTALL SHIFT SOLENOID VALVE SLU (a) Coat the shift solenoid valve SLU with ATF. (b) Install the shift solenoid valve SLU to the valve body assembly. 6. INSTALL SHIFT SOLENOID VALVE SLT (a) Coat the shift solenoid valve SLT with ATF. (b) Install the shift solenoid valve SLT and lock plate to the valve body assembly. Lock Plate AX Solenoid Valve SL3 C138526E01 Lock Plate Solenoid Valve SL2 Solenoid Valve SL1 C138525E02 Lock Plate Solenoid Valve SLT Solenoid Valve SLU C138524E01 U660E AUTOMATIC TRANSAXLE – SHIFT SOLENOID VALVE 7. AX–327 INSTALL SHIFT SOLENOID VALVE SL (a) Coat the shift solenoid valve SL with ATF. (b) Install the shift solenoid valve SL to the valve body assembly. AX Solenoid Valve SL C138523E01 8. O-Ring INSTALL ATF TEMPERATURE SENSOR ASSEMBLY (a) Coat a new O-ring with ATF and install it to the ATF temperature sensor assembly. C138520E01 (b) Coat the 4 bolts with ATF. (c) Install the ATF temperature sensor assembly and clamp to the valve body assembly with the 4 bolts. Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) C138522 9. INSTALL TRANSMISSION WIRE (a) Connect the 8 connectors to the valve body assembly. C138519 (b) Coat the O-ring with ATF. C142570E01 AX–328 U660E AUTOMATIC TRANSAXLE – SHIFT SOLENOID VALVE (c) Coat the bolt with ATF. (d) Install the transmission wire and lock plate to the valve body assembly with the bolt. Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) AX C138518 U660E AUTOMATIC TRANSAXLE – SHIFT SOLENOID VALVE AX–329 INSTALLATION 1. INSTALL TRANSMISSION VALVE BODY ASSEMBLY (See page AX-183) 2. INSTALL VALVE BODY OIL STRAINER ASSEMBLY (See page AX-184) 3. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUBASSEMBLY (See page AX-185) 4. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (See page AX-214) AX AX–329 U660E AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE DIFFERENTIAL CASE U660E AUTOMATIC TRANSAXLE TRANSMISSION COMPONENTS FRONT DIFFERENTIAL PINION THRUST WASHER AX FRONT DIFFERENTIAL PINION FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN FRONT NO. 1 DIFFERENTIAL PINION SHAFT DIFFERENTIAL SIDE GEAR x12 120 (1,223, 88) DIFFERENTIAL CASE FRONT TRANSAXLE CASE OIL SEAL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING OUTER RACE FRONT DIFFERENTIAL RING GEAR FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING TRANSAXLE CASE OIL SEAL SHIM FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING OUTER RACE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Apply MP grease Apply ATF WS C134941E01 AX–330 U660E AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE DISASSEMBLY 1. Matchmarks REMOVE FRONT DIFFERENTIAL RING GEAR (a) Put matchmarks on the front differential ring gear and differential case. AX C138531E01 (b) Remove the 12 bolts. C138532 (c) Using a plastic hammer, tap on the front differential ring gear to remove it from the case. C138533 2. SST REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING (a) Using SST, remove the front differential case front tapered roller bearing from the differential case. SST 09950-00020, 09950-00030, 09950-60010 (09951-00480) C138534E01 (b) Using SST, remove the front differential case front tapered roller bearing outer race and shim from the transaxle housing. SST 09308-00010 SST C138537E01 U660E AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE 3. AX–331 REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING (a) Using SST, remove the front differential case rear tapered roller bearing from the differential case. SST 09950-00020, 09950-00030, 09950-60010 (09951-00480) SST C138535E01 (b) Using SST, remove the front differential case rear tapered roller bearing outer race from the transaxle case. SST 09308-00010 SST C138536E01 4. REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN (a) Using a pin punch (3 mm) and hammer, remove the straight pin. NOTICE: Before removing the straight pin, unstake it with a pin punch. 5. REMOVE FRONT NO. 1 DIFFERENTIAL PINION SHAFT (a) Remove the front No. 1 differential pinion shaft from the differential case. 6. REMOVE DIFFERENTIAL SIDE GEAR (a) Remove the 2 front differential pinions, 2 pinion thrust washers, 2 front differential side gears, and 2 side gear thrust washers from the differential case. C138710 C138706 C138528 AX AX–332 U660E AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE 7. REMOVE FRONT TRANSAXLE CASE OIL SEAL (a) Using SST and a hammer, remove the front transaxle case oil seal from the transaxle housing. SST 09950-60010 (09951-00540), 09950-70010 (09951-07200) 8. REMOVE TRANSAXLE CASE OIL SEAL (a) Using SST and a hammer, remove the transaxle case oil seal from transaxle case. SST 09950-60010 (09951-00650), 09950-70010 (09951-07100) AX SST C138708E01 SST C138709E01 INSPECTION 1. C083562 INSPECT DIFFERENTIAL SIDE GEAR BACKLASH (a) Hold the differential case in a vise between aluminum plates. NOTICE: Do not overtighten the vise. (b) Place a dial indicator on the tip of the side gear tooth at a right angle. (c) Hold the pinion gear in the differential case and measure the backlash of the side gear. Standard backlash: 0 to 0.15 mm (0 to 0.0059 in.) Thrust washer thickness Thickness Thickness 1.50 mm (0.0591 in.) 1.75 mm (0.0689 in.) 1.55 mm (0.0610 in.) 1.80 mm (0.0709 in.) 1.60 mm (0.0630 in.) 1.85 mm (0.07283 in.) 1.65 mm (0.0650 in.) 1.90 mm (0.07480 in.) 1.70 mm (0.0669 in.) - If the backlash is greater than the standard range, select another side gear thrust washer. REASSEMBLY 1. C138528 INSTALL DIFFERENTIAL SIDE GEAR (a) Coat the 2 front differential side gears, 2 side gear thrust washers, 2 front differential pinions and 2 pinion thrust washers with ATF and install them to the differential case. U660E AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE AX–333 2. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT (a) Coat the front No. 1 differential pinion shaft with ATF, and install it to the differential case. 3. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH (See page AX-332) C138706 4. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN (a) Using a pin punch (3 mm) and hammer, install the pinion shaft straight pin. NOTICE: Align the holes, and install the pinion shaft straight pin. C138707 (b) Using a chisel and hammer, stake the differential case. NOTICE: Stake the differential case after adjusting the backlash. C138711 5. SST C138712E01 INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING (a) Using SST and a press, install the front differential case rear tapered roller bearing to the differential case. SST 09710-04081, 09950-60010 (09951-00480), 09950-70010 (09951-07100) NOTICE: Do not damage the bearing cage during bearing inner race installation. (b) Using SST and a hammer, install the front differential case rear tapered roller bearing outer race to the transaxle case. SST 09950-70010 (09951-07150), 09950-60020 (09951-00790) NOTICE: Ensure that there is no clearance between the bearing and transaxle case. SST C138714E01 AX AX–334 U660E AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE 6. SST AX C138713E01 INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING (a) Using SST and a press, install the front differential case front tapered roller bearing to the differential case. SST 09710-04081, 09950-60010 (09951-00480), 09950-70010 (09951-07100) NOTICE: Do not damage the bearing cage during bearing inner race installation. (b) Install the shim to the transaxle housing. (c) Using SST and a hammer, install the front differential case front tapered roller bearing outer race to the transaxle housing. NOTICE: Ensure that there is no clearance between the bearing and transaxle housing. SST C138715E01 7. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD (a) Install the differential assembly to the transaxle case. (b) Clean the contact surfaces of the transaxle case and transaxle housing. C136467 A A A A A B C136447E01 (c) Install the transaxle housing to the transaxle case with the 20 bolts. Torque: Bolt A 31 N*m (316 kgf*cm, 23 ft.*lbf) Bolt B 23 N*m (234 kgf*cm, 17 ft.*lbf) U660E AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE AX–335 (d) Using SST, turn the differential assembly right and left 2 or 3 times to settle the bearing. SST 09564-33010 (e) Using SST and a torque wrench, measure the turning torque of the differential side bearing while rotating SST at 10 rpm. SST 09564-33010 Turning torque: 1.05 to 1.93 N*m (10.70 to 19.67 kgf*cm, 9.29 to 17.08 in.*lbf) If the turning torque is not within the specified range, refer to the table below to select a shim so that the turning torque is within the specified range. Shim thickness: mm (in.) SST C138262E01 Thickness Thickness Thickness Thickness 2.000 (0.0787) 2.225 (0.0876) 2.450 (0.0965) 2.675 (0.1054) 2.025 (0.0797) 2.250 (0.0886) 2.475 (0.0974) 2.700 (0.1063) 2.050 (0.0807) 2.275 (0.0896) 2.500 (0.0984) 2.725 (0.1073) 2.075 (0.0817) 2.300 (0.0906) 2.525 (0.0994) 2.750 (0.1083) 2.100 (0.0827) 2.325 (0.0915) 2.550 (0.1004) 2.775 (0.1093) 2.125 (0.0837) 2.350 (0.0925) 2.575 (0.1014) 2.800 (0.1102) 2.150 (0.0847) 2.375 (0.0935) 2.600 (0.1024) 2.825 (0.1112) 2.175 (0.0856) 2.400 (0.0945) 2.625 (0.1034) 2.850 (0.1122) 2.200 (0.0866) 2.425 (0.0955) 2.650 (0.1043) 2.875 (0.1132) (f) Remove the 20 bolts and the transaxle housing from the transaxle case. C136447 (g) Remove the differential assembly from the transaxle case. C136467 AX AX–336 U660E AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE 8. 90 to 110°C (194 to 230°F) AX INSTALL FRONT DIFFERENTIAL RING GEAR (a) Using ATF and a heater, heat the front differential ring gear to 90 to 110°C (194.0 to 230.0°F). NOTICE: Do not heat the ring gear to more than 110°C (230.0°F). (b) Clean the contact surface of the front differential case. D025215E05 (c) Align the matchmarks, and install the front differential ring gear case quickly. NOTICE: Do not install the bolts while the ring gear is hot. Matchmarks C138531E01 (d) Tighten the 12 bolts. Torque: 120 N*m (1,223 kgf*cm, 88 ft.*lbf) NOTICE: Tighten the bolts a little at a time in diagonal order. 9. INSTALL TRANSAXLE CASE OIL SEAL (a) Coat the lip of a new oil seal with MP grease. C138532 (b) Using SST and a hammer, install the oil seal. SST 09316-10010, 09950-70010 (09951-07100) Oil seal drive in depth: -0.5 to 0.5 mm (-0.0197 to 0.0197 in.) 10. INSTALL FRONT TRANSAXLE CASE OIL SEAL (a) Coat the lip of a new oil seal with MP grease. SST SST C138716E01 U660E AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE AX–337 (b) Using SST and a hammer, install the oil seal. SST 09308-14010 Oil seal drive in depth: -0.5 to 0.5 mm (-0.0197 to 0.0197 in.) AX SST C138717E01 2AZ-FE COOLING – COOLING SYSTEM CO–1 COOLING SYSTEM ON-VEHICLE INSPECTION 1. CHECK FOR ENGINE COOLANT LEAKS NOTICE: Before performing each inspection, turn the A/C switch OFF. CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. (a) Fill the radiator with coolant and attach a radiator cap tester. (b) Warm up the engine. (c) Using a radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf*cm, 17 psi), and check that the pressure does not drop. If the pressure drops, check the hoses, radiator and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head. 2. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR (a) Check that the engine coolant level is between the LOW and FULL lines when the engine is cold. If the engine coolant level is low, check for leaks and add "TOYOTA Super Long Life Coolant" or similar high quality ethylene glycol based non-silicate, nonamine, non-nitrite and non-borate coolant with longlife hybrid organic acid technology to the FULL line. NOTICE: Do not substitute plain water for engine coolant. 3. INSPECT ENGINE COOLANT QUALITY (a) Remove the radiator cap. CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. (b) Check if there are any excessive deposits of rust or scales around the radiator cap and radiator filler hole. Also, the coolant should be free of oil. If excessively dirty, clean the coolant passage and replace the coolant. (c) Install the radiator cap. A135234 CO CO–2 2AZ-FE COOLING – COOLING FAN SYSTEM COOLING FAN SYSTEM 2AZ-FE COOLING ENGINE PARTS LOCATION COOLING FAN MOTOR ENGINE ROOM RELAY BLOCK CO INSTRUMENT PANEL JUNCTION BLOCK -COOLING FAN RELAY -CDS FAN FUSE -ECU IG FUSE NO. 1 -RDI FAN FUSE A137456E02 CO–3 2AZ-FE COOLING – COOLING FAN SYSTEM SYSTEM DIAGRAM ECM FAN No. 1 From Battery RDI FAN From Ignition Switch ECU IG No. 1 3 5 1 2 22 A24 FANH From Battery CDS FAN A6 A/C Condenser Fan Motor 2 FAN No. 3 5 3 1 2 4 2 1 A7 Radiator Fan Motor FAN No. 2 1 3 5 1 2 21 A24 FANL A137000 CO CO–4 2AZ-FE COOLING – COOLING FAN SYSTEM ON-VEHICLE INSPECTION CO 1. INSPECT COOLING FAN OPERATION AT LOW TEMPERATURES (Below 83°C (181°F)) (a) Turn the ignition switch to the ON position. (b) Check that the cooling fan stops. If not, check the cooling fan relay and engine coolant temperature sensor, and check whether there is disconnection or an open circuit between them. (c) Disconnect the engine coolant temperature sensor connector. (d) Check that the cooling fan rotates. If not, check the fuses, cooling fan relay, ECM and cooling fan, and check for a short circuit between the cooing fan relay and engine coolant temperature sensor. (e) Reconnect the engine coolant temperature sensor connector. 2. INSPECT COOLING FAN OPERATION AT HIGH TEMPERATURES (Above 93°C (199°F)) (a) Start the engine, and raise the engine coolant temperature to above 93°C (199°F). HINT: Engine coolant temperature is detected by the engine coolant temperature sensor on the water outlet. (b) Check that the cooling fan rotates. If not, replace the engine coolant temperature sensor. CO–5 2AZ-FE COOLING – COOLANT COOLANT ON-VEHICLE INSPECTION 1. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH 2. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH 3. REMOVE ENGINE UNDER COVER LH 4. REMOVE ENGINE UNDER COVER RH 5. DRAIN ENGINE COOLANT NOTICE: Do not remove the radiator cap sub-assembly while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. (a) Remove the radiator cap sub-assembly from the radiator assembly. (b) Loosen the radiator drain cock plug and cylinder block drain cock plug, then drain the coolant. Radiator Cap CO Cylinder Block Drain Cock Plug Radiator Drain Cock Plug A136224E04 HINT: Collect the coolant in a container and dispose of it according to the regulations in your area. 6. ADD ENGINE COOLANT (a) Close the radiator drain cock plug and 2 cylinder block drain cock plugs. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) for cylinder block drain cock plug CO–6 2AZ-FE COOLING – COOLANT (b) Slowly fill the radiator with TOYOTA Super Long Life Coolant (SLLC). Specified capacity: 6.2 liters (6.6 US qts, 5.5 lmp. qts) HINT: • TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids). • Contact your TOYOTA dealer for further details. (c) Slowly pour coolant into the radiator reservoir tank until it reaches the FULL line. (d) Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant. If the coolant level is low, add coolant. (e) Install the radiator cap sub-assembly and reservoir tank cap. (f) Start the engine, and warm it up. HINT: Adjust the air conditioner set temperature to MAX (HOT). (g) Stop the engine, and wait until the engine coolant cools down. (h) Add engine coolant to the FULL line on the radiator reservoir. CO 7. CHECK FOR ENGINE COOLANT LEAKS 8. INSTALL ENGINE UNDER COVER RH 9. INSTALL ENGINE UNDER COVER LH 10. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH 11. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH CO–7 2AZ-FE COOLING – WATER PUMP WATER PUMP 2AZ-FE COOLING ENGINE COMPONENTS 64 (653, 47) ENGINE MOVING CONTROL ROD SUB-ASSEMBLY 52 (531, 38) 64 (653, 47) NO. 2 ENGINE MOUNTING BRACKET RH NO. 2 ENGINE MOUNTING STAY RH V-RIBBED BELT 9.8 (100, 7 ) 8.4 (86, 74 in.*lbf) 52 (530, 38) 21 (215, 16) CO GENERATOR ASSEMBLY ENGINE UNDER COVER RH FRONT FENDER APRON SEAL RH ENGINE UNDER COVER LH FRONT WHEEL OPENING EXTENSION PAD LH FRONT WHEEL OPENING EXTENSION PAD RH N*m (kgf*cm, ft.*lbf) : Specified torque A136149E02 CO–8 2AZ-FE COOLING – WATER PUMP CLAMP BRACKET 9.0 (92, 80 in.*lbf) 9.0 (92, 80 in.*lbf) 26 (265, 19) 26 (265, 19) WATER PUMP PULLEY WATER PUMP ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque A136759E05 CO 2AZ-FE COOLING – WATER PUMP CO–9 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH 3. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH 4. REMOVE ENGINE UNDER COVER RH 5. REMOVE ENGINE UNDER COVER LH 6. DRAIN ENGINE COOLANT (See page CO-5) 7. REMOVE FRONT FENDER APRON SEAL RH 8. REMOVE NO. 2 ENGINE MOUNTING STAY RH (See page EM-95) 9. REMOVE ENGINE MOVING CONTROL ROD SUBASSEMBLY (See page EM-95) 10. REMOVE NO. 2 ENGINE MOUNTING BRACKET RH (See page EM-96) 11. REMOVE V-RIBBED BELT (See page EM-6) 12. REMOVE GENERATOR ASSEMBLY (See page CH-11) 13. REMOVE WATER PUMP PULLEY (a) Using SST, remove the 4 bolts and water pump pulley. SST 09960-10010 (09962-01000, 09963-00700) SST CO A098715E03 14. REMOVE WATER PUMP ASSEMBLY (a) Remove the clamp of the crankshaft position sensor from the water pump. (b) Disconnect the wire of the crankshaft position sensor from the clamp bracket. A094516E01 CO–10 2AZ-FE COOLING – WATER PUMP (c) Remove the 4 bolts, 2 nuts and clamp bracket. Clamp Bracket B012052E03 (d) Using a screwdriver, pry between the water pump and cylinder block, and then remove the water pump. HINT: Tape the screwdriver tip before use. NOTICE: Be careful not to damage the contact surfaces of the water pump and cylinder block. A129792 Air Hole INSPECTION Drain Hole 1. INSPECT WATER PUMP ASSEMBLY (a) Visually check the drain hole and air hole for coolant leakage. If leakage is found, replace the water pump assembly. A128603E01 (b) Turn the pulley, and then check that the water pump bearing moves smoothly without making a "click" sound. If it does not move smoothly, replace the water pump assembly. CO A112198 2AZ-FE COOLING – WATER PUMP CO–11 INSTALLATION 1. Seal Diameter 2.2 to 2.5 mm (0.09 to 0.10 in.) A A INSTALL WATER PUMP ASSEMBLY (a) Remove any old seal packing material from the contact surface. (b) Apply a continuous line of seal packing as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent Standard seal diameter: 2.2 to 2.5 mm (0.09 to 0.10 in.) NOTICE: • Remove any oil from the contact surface. • The parts must be set within 3 minutes after applying seal packing. Otherwise, the material must be removed and reapplied. A-A 0.5 to 1.0 mm (0.02 to 0.04 in.) 2.5 mm (0.10 in.) A094495E05 Clamp Bracket (c) Install the water pump and clamp bracket with the 4 bolts and 2 nuts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) CO B012052E03 (d) Install the wire of the crankshaft position sensor onto the clamp bracket. (e) Install the clamp of the crankshaft position sensor onto the water pump. A094516 CO–12 2AZ-FE COOLING – WATER PUMP 2. INSTALL WATER PUMP PULLEY (a) Using SST, install the water pump pulley with the 4 bolts. SST 09960-10010 (09962-01000, 09963-00700) Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) 3. INSTALL GENERATOR ASSEMBLY (See page CH-19) 4. INSTALL V-RIBBED BELT (See page EM-6) 5. INSTALL NO. 2 ENGINE MOUNTING BRACKET RH (See page EM-118) 6. INSTALL ENGINE MOVING CONTROL ROD SUBASSEMBLY (See page EM-119) 7. INSTALL NO. 2 ENGINE MOUNTING STAY RH (See page EM-119) 8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page EM-120) 9. ADD ENGINE COOLANT (See page CO-5) SST A098715E02 10. CHECK FOR ENGINE COOLANT LEAKS (See page CO-1) 11. INSTALL ENGINE UNDER COVER LH 12. INSTALL ENGINE UNDER COVER RH 13. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH 14. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH CO CO–12 2AZ-FE COOLING – THERMOSTAT THERMOSTAT 2AZ-FE COOLING ENGINE COMPONENTS WATER INLET THERMOSTAT 9.0 (92, 80 in.*lbf) GASKET RADIATOR HOSE OUTLET Non-reusable part CO N*m (kgf*cm, ft.*lbf) : Specified torque A134970E03 2AZ-FE COOLING – THERMOSTAT CO–13 REMOVAL 1. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH 2. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH 3. REMOVE ENGINE UNDER COVER LH 4. REMOVE ENGINE UNDER COVER RH 5. DRAIN ENGINE COOLANT (See page CO-5) 6. DISCONNECT RADIATOR HOSE OUTLET (See page EM-96) 7. REMOVE WATER INLET (a) Remove the 2 nuts and disconnect the water inlet from the cylinder block. 8. REMOVE THERMOSTAT (a) Remove the gasket from the thermostat. A112181 INSPECTION 1. INSPECT THERMOSTAT (a) The valve opening temperature is inscribed on the thermostat. P013560E01 (b) Immerse the thermostat in water, and then gradually heat the water. (c) Check the valve opening temperature of the thermostat. Standard valve opening temperature: 80 to 84°C (176 to 183°F) If the valve opening temperature is not as specified, replace the thermostat. P000436E01 CO CO–14 2AZ-FE COOLING – THERMOSTAT Valve Lift A085445E04 CO (d) Check the valve lift. Standard valve lift: 10 mm (0.39 in.) or more at 95°C (203°F) If the valve lift is not as specified, replace the thermostat. (e) Check that the valve is fully closed when the thermostat is at low temperatures (below 77°C (171°F)). If it is not fully closed, replace the thermostat. 2AZ-FE COOLING – THERMOSTAT CO–15 INSTALLATION 1. INSTALL THERMOSTAT (a) Install a new gasket onto the thermostat. (b) Install the thermostat with the jiggle valve upward. HINT: The jiggle valve may be set to within 10° on either side of the prescribed position. Upward 10° 10° Jiggle Valve A112199E02 2. INSTALL WATER INLET (a) Install the water inlet with the 2 nuts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 3. CONNECT RADIATOR HOSE OUTLET (See page EM118) 4. ADD ENGINE COOLANT (See page CO-5) 5. CHECK FOR ENGINE COOLANT LEAKS (See page CO-1) 6. INSTALL ENGINE UNDER COVER LH 7. INSTALL ENGINE UNDER COVER RH 8. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH 9. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH A112181 CO 2AZ-FE COOLING – COOLING FAN MOTOR CO–15 COOLING FAN MOTOR Cooling Fan Motor Side Connector: ON-VEHICLE INSPECTION Positive (+) 1. COOLING FAN MOTOR (a) Check that the motor turns smoothly when the battery is connected to the fan motor connector. (b) Measure the current while the motor is turning. Standard current: With trailer hitch: 11.8 to 14.8 A at 20°C (68°F) Without trailer hitch: 7.9 to 10.9 A at 20°C (68°F) If the result is not as specified, replace the cooling fan motor. 2. NO. 2 COOLING FAN MOTOR (a) Check that the motor turns smoothly when the battery is connected to the fan motor connector. (b) Measure the current while the motor is turning. Standard current: With trailer hitch: 7.9 to 10.9 A at 20°C (68°F) Without trailer hitch: 7.9 to 10.9 A at 20°C (68°F) If the result is not as specified, replace the cooling fan motor No. 2. Negative (-) A103699E02 Cooling Fan Motor Side Connector: Positive (+) Negative (-) A103699E02 CO CO–16 2AZ-FE COOLING – COOLING FAN RELAY 1 COOLING FAN RELAY 2 ON-VEHICLE INSPECTION 5 3 1. 5 1 2 3 B060778E01 COOLING FAN RELAY (a) Remove the relay from the engine room No. 2 relay block. (b) Measure the resistance of the relay. Standard resistance Tester Connection Specified Condition 3-5 10 Ω or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the relay. (c) Install the relay to the engine room relay block No. 2. 2. 1 4 2 4 5 3 5 1 2 3 COOLING FAN RELAY NO. 2 (a) Remove the relay from the engine room No. 2 relay block. (b) Measure the resistance of the relay. Standard resistance Tester Connection Specified Condition 3-4 Below 1 Ω 3-5 10 Ω or higher 3-4 10 Ω or higher (when battery voltage is applied to terminals 1 and 2) 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) A087121E01 If the result is not as specified, replace the relay. (c) Install the relay. CO 3. 3 5 1 2 1 2 5 3 B060778E45 COOLING FAN RELAY NO. 3 (a) Remove the relay from the engine room No. 2 relay block. (b) Measure the resistance of the relay. Standard resistance Tester Connection Specified Condition 3-5 10 Ω or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the relay. (c) Install the relay. CO–17 2AZ-FE COOLING – RADIATOR RADIATOR 2AZ-FE COOLING ENGINE COMPONENTS AIR CLEANER CAP SUB-ASSEMBLY 5.0 (51, 44 in.*lbf) AIR CLEANER FILTER ELEMENT x2 AIR CLEANER INLET ASSEMBLY CO ENGINE UNDER COVER RH ENGINE UNDER COVER LH FRONT WHEEL OPENING EXTENSION PAD RH FRONT WHEEL OPENING EXTENSION PAD LH N*m (kgf*cm, ft.*lbf) : Specified torque A139342E01 CO–18 2AZ-FE COOLING – RADIATOR 7.0 (71, 62 in.*lbf) x4 RADIATOR SUPPORT UPPER HOOD LOCK ASSEMBLY x2 7.5 (77, 66 in.*lbf) HORN CONNECTOR 7.0 (71, 62 in.*lbf) 7.5 (77, 66 in.*lbf) x2 x2 CO FRONT BUMPER ENERGY ABSORBER x2 x9 FRONT BUMPER ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque A134969E02 CO–19 2AZ-FE COOLING – RADIATOR RADIATOR HOSE OUTLET RADIATOR HOSE INLET RADIATOR SUPPORT CUSHION RADIATOR ASSEMBLY FAN MOTOR CONNECTOR FAN MOTOR WITH MOTOR RADIATOR SUPPORT LOWER CO 5.0 (51, 44 in.*lbf) x4 CONDENSER ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque A134972E02 CO–20 2AZ-FE COOLING – RADIATOR RADIATOR CAP SUB-ASSEMBLY FAN ASSEMBLY WITH MOTOR RADIATOR TANK UPPER O-RING CORE SUBASSEMBLY 15 (150, 11) with AUTOMATIC TRANSAXLE O-RING 15 (150, 11) OIL COOLER ASSEMBLY O-RING O-RING RADIATOR TANK LOWER DRAIN PLUG OIL COOLER PIPE 8.3 (85, 73 in.*lbf) O-RING Non-reusable part N*m (kgf*cm, ft.*lbf) : Specified torque A137802E02 ON-VEHICLE INSPECTION CO 1. 1 2 3 4 A107446E01 CHECK RADIATOR CAP SUB-ASSEMBLY (a) Measure the valve opening pressure. (1) If there are water stains or foreign matter on rubber packings 1, 2 or 3, clean the part(s) with water and finger scouring. (2) Check that rubber packings 1, 2 and 3 are not deformed, cracked or swollen. (3) Check that rubber packings 3 and 4 are not stuck together. (4) Apply engine coolant to rubber packings 2 and 3 before using the radiator cap tester. (5) When using the cap tester, tilt it to 30° or more above the horizontal. CO–21 2AZ-FE COOLING – RADIATOR (6) Pump the cap tester several times, and check the maximum pressure *1. Pumping speed: 1 pumps every second *1: Even if the cap cannot maintain the maximum pressure, it is not a defect. Judgment Criteria Radiator Cap Tester 30° or more Radiator Cap A104601E03 Item Specified Condition Standard valve (for brand-new cap) 93.3 to 122.7 kPa (0.95 to 1.25 kgf/ Minimum standard valve (after using cap) 78.5 kPa (0.8 kgf/cm2, 11.4 psi) cm2, 13.5 to 17.8 psi) If the maximum pressure is less than the specified pressure for the minimum standard valve, replace the radiator cap sub-assembly. ON-VEHICLE CLEANING 1. A073603 INSPECT FINS BLOCKAGE (a) If the fins are clogged, wash them with water or a steam cleaner. Dry with compressed air. NOTICE: • If the distance between the steam cleaner and the core is too close, the fins may become damaged. Keep the following injection distance. Standard Injection Distance Injection Pressure 300 mm (11.81 in.) (30 to 50 kg/cm2, 427 to 711 psi) 500 mm (19.69 in.) 2,942 to 4,903 kPa 4,903 to 7,845 kPa (50 to 80 kg/cm2, 711 to 1,138 psi) • If the fins are bent, straighten them with a screwdriver or pliers. • Never apply water directly onto the electronic components. CO CO–22 2AZ-FE COOLING – RADIATOR REMOVAL 1. DRAIN ENGINE COOLANT 2. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH 3. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH 4. REMOVE ENGINE UNDER COVER RH 5. REMOVE ENGINE UNDER COVER LH 6. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-416) 7. REMOVE AIR CLEANER INLET ASSEMBLY (See page EM-94) 8. REMOVE FRONT BUMPER ASSEMBLY (w/o Fog Light) (See page ET-5) 9. REMOVE FRONT BUMPER ASSEMBLY (w/ Fog Light) (See page ET-6) 10. REMOVE FRONT BUMPER ENERGY ABSORBER 11. SEPARATE RADIATOR RESERVE TANK HOSE (a) Separate the radiator reserve tank hose from the radiator assembly. A135233 12. DISCONNECT RADIATOR HOSE INLET (a) Disconnect the radiator hose inlet from the radiator assembly. CO A135240 13. DISCONNECT RADIATOR HOSE OUTLET (a) Disconnect the radiator hose outlet from the radiator assembly. A133364 2AZ-FE COOLING – RADIATOR CO–23 14. DISCONNECT OIL COOLER INLET HOSE (for Automatic Transaxle) (a) Disconnect the oil cooler inlet hose from the radiator assembly. A133365 15. DISCONNECT OIL COOLER OUTLET HOSE (for Automatic Transaxle) (a) Disconnect the oil cooler outlet hose from the radiator assembly. A133366 16. REMOVE RADIATOR SUPPORT UPPER (a) Disconnect the horn connector. (b) Remove the 3 bolts and separate the hood lock assembly from the radiator support upper. A135235 (c) Remove the clamp and separate the hood lock control cable from the radiator support upper. A135236 (d) Remove the 5 bolts and radiator support upper. A135237 CO CO–24 2AZ-FE COOLING – RADIATOR 17. REMOVE RADIATOR ASSEMBLY (a) Remove the 3 clamps and 2 connectors. A135241 (b) Remove the 4 bolts and separate the condenser assembly from the radiator assembly. A135239 (c) Remove the radiator assembly from the body. A135238 18. REMOVE FAN ASSEMBLY WITH MOTOR (a) Release the 3 snap fits and lift the fan assembly with motor from the radiator. CO Guide Snap Fit A136226E01 19. REMOVE RADIATOR SUPPORT CUSHION (a) Remove the 2 radiator support cushions from the radiator assembly. Radiator Support Cushion A133371E02 2AZ-FE COOLING – RADIATOR CO–25 20. REMOVE RADIATOR SUPPORT LOWER (a) Remove the 2 radiator support lowers from the radiator assembly. Radiator Support Lower A133371E03 CO CO–26 2AZ-FE COOLING – RADIATOR DISASSEMBLY 1. REMOVE DRAIN PLUG (a) Remove the drain plug. (b) Remove the O-ring. 2. REMOVE RADIATOR TANK UPPER (a) Install the claw to the overhaul handle, inserting it in the hole in part A as shown in the illustration. SST 09230-01010 (09231-01010, 09231-01030) (b) While gripping the handle, adjust the stopper bolt so that dimension B is as shown in the illustration. Dimension B: 0.2 to 0.3 mm (0.008 to 0.012 in.) NOTICE: If the stopper bolt is not adjusted, the claw may be damaged. Stopper Bolt Part A Dimension B 0.2 to 0.3 mm SST Claw Overhaul Handle A104619E05 (c) Using SST to release the caulking, grip the handle until stopped by the stopper bolt. SST 09230-01010 (09231-01010, 09231-01030) Tank Lock Plate SST CO Stopper Bolt A128137E02 (d) Lightly tap the bracket of the radiator (or radiator hose inlet or outlet) with a soft-faced hammer and remove the tank. (e) Remove the O-ring. 3. Tap A128138E01 REMOVE RADIATOR TANK LOWER HINT: Removal procedure of the radiator tank lower is the same as that of the radiator tank upper. 2AZ-FE COOLING – RADIATOR 4. (D) (C) (A) (A) (B) CO–27 REMOVE OIL COOLER ASSEMBLY (a) Remove the screw and cooler pipe (A). (b) Remove the nut and plate washer (B). (c) Remove the oil cooler (C). (d) Remove the 2 O-rings from the oil cooler (D). (B) Lower Tank (C) A128140E02 Lock Plate Lock Plate INSPECTION 1. Core A087087E06 INSPECT LOCK PLATE (a) Inspect the lock plate for damage. HINT: • If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible. Therefore, first correct the shape of the lock plate groove with pliers or a similar object, if necessary. • Water leakage will result if the bottom of the lock plate groove is damaged or dented. Repair or replace the lock plate if necessary. NOTICE: The radiator can only be recaulked 2 times, After recaulking 2 times, the radiator core must be replaced. REASSEMBLY (D) (C) (A) 1. (A) (B) Lower Tank (B) (C) A128140E02 INSTALL OIL COOLER ASSEMBLY (a) Clean the O-ring contact surfaces of the lower tank and oil cooler (D). (b) Install 2 new O-rings to the oil cooler (C). (c) Install the oil cooler to the lower tank. (d) Install the plate washer and nut (B). Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf) (e) Install the cooler pipe (A). Torque: 15 N*m (150 kgf*cm, 11 ft.*lbf) (f) Install the screw (A). CO CO–28 2AZ-FE COOLING – RADIATOR 2. Stopper Bolt Part A Dimension B INSTALL RADIATOR TANK UPPER (a) Install the punch assembly to the overhaul handle, inserting it in the hole in part A as shown in the illustration. SST 09230-01010, 09231-14010 (b) While gripping the handle, adjust the stopper bolt so that dimension B is as shown in the illustration. Dimension B: 8.4 mm (0.331 in.) SST Punch Assembly Overhaul Handle A104624E02 ○ Normal X Twisted (c) After checking that there are no foreign objects in the lock plate groove, install a new O-ring without twisting it. HINT: When cleaning the lock plate groove, lightly rub it with sand paper without scratching it. CO X Twisted O-Ring A104623E03 CORRECT Tank WRONG Tap Lock Plate A128141E01 (d) Install the tank without damaging the O-ring. (e) Tap the lock plate with a soft-faced hammer so that there is no gap between the lock plate and the tank. 2AZ-FE COOLING – RADIATOR (f) 5 3 7 2 1 6 4 8 SST Lock Plate Stopper Bolt Tank CO–29 Lightly press SST against the lock plate in the order shown in the illustration. After repeating this a few times, fully caulk the lock plate by gripping the handle until stopped by the stopper plate. HINT: • Do not tap the areas protruding around the pipes, brackets or tank ribs. • The dotted circles shown in the illustration and parts of the oil cooler near the dotted circles cannot be tapped with the SST. Use pliers or similar objects and be careful not to damage the core plates. A129608E01 (g) Check the lock plate height (H) after completing caulking. Plate height (H): 7.40 to 7.80 mm (0.2913 to 0.3071 in.) If not within the specified height range, adjust the stopper bolt of the handle and caulk again. H 3. INSTALL RADIATOR TANK LOWER SST 09230-01010, 09231-14010 HINT: Removal procedure of the lower radiator tank is the same as that of the upper radiator tank. 4. INSTALL DRAIN PLUG (a) Install a new O-ring to the drain plug. (b) Install the drain plug. 5. INSPECT FOR WATER LEAKS (a) Plug the inlet and outlet pipes of the radiator with SST. SST 09230-01010 (b) Using the radiator cap tester, apply pressure to the radiator. Test pressure: 177 kPa (1.8 kgf/cm2, 26 psi) (c) Submerge the radiator in water. A128142E02 SST A128143E03 CO CO–30 2AZ-FE COOLING – RADIATOR (d) Inspect for leaks. HINT: On radiators with resin tanks, there is clearance between the tank and lock plate where a minute amount of air will remain, giving the appearance of an air leak when the radiator is submerged in water. Therefore, before doing the water leak test, first swish the radiator around in the water until all air bubbles disappear. Tank Lock Plate O-Ring A087096E02 INSTALLATION Radiator Support Lower 1. INSTALL RADIATOR SUPPORT LOWER (a) Install the 2 radiator support lowers to the radiator assembly. 2. INSTALL RADIATOR SUPPORT CUSHION (a) Install the 2 radiator support cushions to the radiator assembly. 3. INSTALL FAN ASSEMBLY WITH MOTOR (a) Install the fan assembly with motor to the radiator with the 2 guides at the bottom and 3 snap fits on the top. 4. INSTALL RADIATOR ASSEMBLY (a) Install the radiator to the body. A133371E03 Radiator Support Cushion A133371E02 CO Guide Snap Fit A136226E01 A135238 2AZ-FE COOLING – RADIATOR CO–31 (b) Install the condenser assembly with the 4 bolts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) A135239 (c) Connect the 2 fan motor connectors and the 3 clamps. A135241 5. INSTALL RADIATOR SUPPORT UPPER (a) Install the radiator support upper with the 5 bolts. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) A135237 (b) Install the hood lock control cable assembly to the radiator support upper with the clamp. A135236E01 (c) Install the hood lock assembly to the radiator support upper with the 3 bolts. Torque: 7.5 N*m (77 kgf*cm, 66 in.*lbf) (d) Connect the horn connector. A135235 CO CO–32 2AZ-FE COOLING – RADIATOR 6. CONNECT OIL COOLER OUTLET HOSE (for Automatic Transaxle) (a) Connect the oil cooler outlet hose to the radiator assembly. 7. CONNECT OIL COOLER INLET HOSE (for Automatic Transaxle) (a) Connect the oil cooler inlet hose to the radiator assembly. 8. CONNECT RADIATOR HOSE OUTLET (a) Connect the radiator hose outlet to the radiator assembly. 9. CONNECT RADIATOR HOSE INLET (a) Connect the radiator hose inlet to the radiator assembly. A128129 A128128 A128127 CO A135240 10. CONNECT RADIATOR RESERVOIR TANK HOSE (a) Connect the radiator reservoir tank hose to the radiator assembly. 11. INSTALL AIR CLEANER INLET ASSEMBLY (See page EM-120) 12. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See page ES-419) 13. ADD ENGINE COOLANT (See page CO-5) A135233 2AZ-FE COOLING – RADIATOR CO–33 14. CHECK FOR ENGINE COOLANT LEAKS (See page CO-1) 15. INSTALL ENGINE UNDER COVER LH 16. INSTALL ENGINE UNDER COVER RH 17. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH 18. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH CO 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–1 SFI SYSTEM PRECAUTION NOTICE: • Perform RESET MEMORY (AT initialization) when replacing the automatic transmission assembly, engine assembly or ECM (See page AX-16). • Perform REGISTRATION (VIN registration) when replacing the ECM (See page ES-16). HINT: Initialization cannot be completed by removing the battery. ES ES–2 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DEFINITION OF TERMS Terms ES Definition Monitor Description Description of what ECM monitors and how detects malfunctions (monitoring purpose and details). Related DTCs Group of diagnostic trouble codes that are output by ECM based on the same malfunction detection logic. Typical Enabling Condition Preconditions that allow ECM to detect malfunctions. With all preconditions satisfied, ECM sets DTC when monitored value(s) exceeds malfunction threshold(s). Sequence of Operation Order of monitor priority, applied if multiple sensors and components involved in single malfunction detection process. Each sensor and component monitored in turn, when previous detection operation is completed. Required Sensor/Components Sensors and components used by ECM to detect each malfunction. Frequency of Operation Number of times ECM checks for each malfunction during each driving cycle. "Once per driving cycle" means ECM only performs checks for that malfunction once in single driving cycle. "Continuous" means ECM performs checks for that malfunction whenever enabling conditions are met. Duration Minimum time for which ECM must detect continuous deviation in monitored value(s) in order to set DTC. Timing begins when Typical Enabling Conditions are met. Malfunction Thresholds Value, beyond which, ECM determines malfunctions exist and sets DTCs. MIL Operation Timing of MIL illumination after malfunction is detected. "Immediate" means ECM illuminates MIL as soon as malfunction is detected. "2 driving cycle" means ECM illuminates MIL if the same malfunction is detected second time in the next sequential driving cycle. 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–3 PARTS LOCATION PZEV: CANISTER PUMP MODULE PURGE VSV CANISTER MASS AIR FLOW METER ES FUEL PUMP ECM ENGINE ROOM R/B AND ENGINE ROOM J/B EFI NO. 3 FUSE EFI NO. 2 FUSE EFI NO. 1 FUSE EFI MAIN FUSE INTEGRATION RELAY (ENGINE ROOM J/B) - EFI RELAY - CIRCUIT OPENING RELAY A137360E01 ES–4 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM EXCEPT PZEV: PURGE VSV CANISTER CANISTER PUMP MODULE MASS AIR FLOW METER ES FUEL PUMP ECM ENGINE ROOM R/B AND ENGINE ROOM J/B EFI NO. 3 FUSE EFI NO. 2 FUSE EFI NO. 1 FUSE EFI MAIN FUSE INTEGRATION RELAY (ENGINE ROOM J/B) - EFI RELAY - CIRCUIT OPENING RELAY A137361E01 ES–5 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PZEV: CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY FUEL INJECTOR KNOCK SENSOR CAMSHAFT POSITION SENSOR ES THROTTLE BODY IGNITION COIL INTAKE MANIFOLD RUNNER VALVE (IMRV) ENGINE COOLANT TEMPERATURE SENSOR HEATED OXYGEN SENSOR PARK/NEUTRAL POSITION SW AIR-FUEL RATIO SENSOR CRANKSHAFT POSITION SENSOR A135059E01 ES–6 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM EXCEPT PZEV: CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY FUEL INJECTOR KNOCK SENSOR CAMSHAFT POSITION SENSOR THROTTLE BODY ES IGNITION COIL ENGINE COOLANT TEMPERATURE SENSOR HEATED OXYGEN SENSOR PARK/NEUTRAL POSITION SW AIR-FUEL RATIO SENSOR CRANKSHAFT POSITION SENSOR A132270E01 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–7 INSTRUMENT PANEL J/B - IGN FUSE - STOP FUSE CLUTCH START SWITCH COMBINATION METER IGNITION SWITCH DLC3 ES STOP LIGHT SW ACCELERATOR PEDAL ROD A132271E01 ES–8 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM SYSTEM DIAGRAM ECM To IGN EFI No. 1 C/OPN BATT +B EFI EFI MAIN EFI No. 2 FC +B2 ES Purge VSV M MREL Fuel Pump EFI No. 3 PRG IG SW IGSW ST/AM2 ALT AM1 AM2 AM1 TC IGN IG2 To C/OPN DLC3 TACH Generator ALT IG1 To Park/Neutral Position SW ETCS To Battery +BM FL MAIN Combination Meter GAUGE No. 2 IMRV (Intake Manifold Runner Valve) Motor MIL IAC+*1 W Stop Light SW STOP M IAC-*1 E1 STP ST1- To IGN Battery E01 E03 E04 *1: PZEV Only A132314E01 ES–9 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ECM Throttle Actuator M+ Mass Air Flow Meter ME2G VG GE01 THA ETHA No. 4 Fuel Injector ES #40 No. 3 Fuel Injector Engine Coolant Temperature Sensor To INJ #30 No. 2 Fuel Injector THW ETHW #20 No. 1 Fuel Injector Air-fuel Ratio Sensor #10 HA1A Knock Sensor A1A+ KNK1 A1A- EKNK Heated Oxygen Sensor HT1B E02 OX1B ME01 EX1B A132315E01 ES–10 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ECM Crankshaft Position Sensor Camshaft Timing Oil Control Valve NE+ NE- ES OC1+ OC1To INJ Camshaft Position Sensor IGT1 No. 1 Ignition Coil IGT2 No. 2 Ignition Coil IGT3 No. 3 Ignition Coil IGT4 No. 4 Ignition Coil G2G2+ Throttle Position Sensor VCTA VTA1 IGF1 VTA2 Park/Neutral Position SW or Clutch Start SW ETA IMRV Position Sensor To IG SW ST NSW*2 VCIA*1 To IG SW IACA*1 EIA*1 STA To Starter *1: PZEV Only *2: Automatic Transaxle Only A132316E01 ES–11 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ECM FAN No. 3 Combination Meter To IG1 FANL SPD A/C Condenser Fan Motor To Battery M Transponder Key ECU IMO IMI Radiator Fan Motor FAN No. 2 M Accelerator Pedal Position Sensor VCP2 FAN No. 1 VPA2 IC To Battery EPA2 VCPA FANH Canister Pump Module VPA IC EPA Vent Valve VPMP VCPP CANH CANH CANL CANL PPMP Canister Pressure Sensor To EFI No. 3 EPPM MPMP PS Oil Pressure SW M Leak Detection Pump PSW EC EOM A132317E01 ES ES–12 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: *: Use the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT ES 2 CUSTOMER PROBLEM ANALYSIS NEXT 3 CONNECT INTELLIGENT TESTER TO DLC3* HINT: If the display indicates a communication fault in the tester, inspect the DLC3. NEXT 4 CHECK FOR DTC AND FREEZE FRAME DATA* HINT: Record or print DTCs and freeze frame data, if necessary. NEXT 5 CLEAR DTC AND FREEZE FRAME DATA* NEXT 6 CONDUCT VISUAL INSPECTION NEXT 7 NEXT SET CHECK MODE DIAGNOSIS* ES–13 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 8 CONFIRM PROBLEM SYMPTOMS HINT: If the engine does not start, first perform the "CHECK DTC" procedures and "CONDUCT BASIC INSPECTION" procedures below. Result Result Proceed to Malfunction does not occur A Malfunction occurs B B ES GO TO STEP 10 A 9 SIMULATE SYMPTOMS NEXT 10 CHECK FOR DTC* Result B Result Proceed to Trouble code A No code B GO TO STEP 12 A 11 REFER TO DTC CHART NEXT GO TO STEP 14 12 CONDUCT BASIC INSPECTION Result Result Proceed to Malfunctioning parts not confirmed A Malfunctioning parts confirmed B B GO TO STEP 17 ES–14 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM A 13 REFER TO PROBLEM SYMPTOMS TABLE Result Result Proceed to Malfunctioning circuit confirmed A Malfunctioning parts confirmed B B ES GO TO STEP 17 A 14 CHECK ECM POWER SOURCE CIRCUIT NEXT 15 CONDUCT CIRCUIT INSPECTION Result Result Proceed to Malfunction not confirmed A Malfunction confirmed B B A 16 CHECK FOR INTERMITTENT PROBLEMS NEXT GO TO STEP 18 17 CONDUCT PARTS INSPECTION NEXT 18 NEXT IDENTIFY PROBLEM GO TO STEP 18 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 19 ES–15 ADJUST AND/OR REPAIR NEXT 20 CONDUCT CONFIRMATION TEST NEXT END ES ES–16 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK FOR INTERMITTENT PROBLEMS ES HINT: Inspect the vehicle's ECM using check mode. Intermittent problems are easier to detect with the intelligent tester when the ECM is in check mode. In check mode, the ECM uses 1 trip detection logic, which is more sensitive to malfunctions than normal mode (default), which uses 2 trip detection logic. 1. Clear the DTCs (See page ES-38). 2. Switch the ECM from normal mode to check mode using the intelligent tester (See page ES-41). 3. Perform a simulation test. 4. Check and wiggle the harness(es), connector(s) and terminal(s). ES–17 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM BASIC INSPECTION When a malfunction is not confirmed by the DTC check, troubleshooting should be carried out in all circuits considered to be possible causes of the problem. In many cases, by carrying out the basic engine check shown in the following flowchart, the location of the problem can be found quickly and efficiently. Therefore, using this check is essential when engine troubleshooting. 1 CHECK BATTERY VOLTAGE NOTICE: Conduct this check with the engine stopped and ignition switch off. Result NG Result Proceed to 11 V or more OK Below 11 V NG CHARGE OR REPLACE BATTERY OK 2 CHECK WHETHER ENGINE WILL CRANK NG PROCEED TO PROBLEM SYMPTOMS TABLE OK 3 CHECK WHETHER ENGINE STARTS NG GO TO STEP 6 OK 4 CHECK AIR FILTER (a) Visually check that the air filter is not excessively contaminated with dirt or oil. NG REPLACE AIR FILTER NG TROUBLESHOOT IDLING SPEED AND PROCEED TO NEXT STEP OK 5 CHECK IDLING SPEED ES ES–18 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK 6 CHECK FUEL PRESSURE NG TROUBLESHOOT FUEL PRESSURE AND PROCEED TO NEXT STEP NG TROUBLESHOOT SPARK AND PROCEED TO NEXT STEP OK 7 ES CHECK FOR SPARKS OK PROCEED TO PROBLEM SYMPTOMS TABLE 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–19 REGISTRATION NOTICE: The Vehicle Identification Number (VIN) must be input into the replacement ECM. HINT: The VIN is a 17-digit alphanumeric number. The intelligent tester is required to register the VIN. 1. 2. DESCRIPTION This registration section consists of 3 parts: Input Instructions, Read VIN and Write VIN. (a) Input Instructions: Explains the general VIN input instructions when using the intelligent tester. (b) Read VIN: Explains the VIN reading process in a flowchart. This process allows the VIN stored in the ECM to be read in order to confirm that the two VINs, provided with the vehicle and stored in the vehicle's ECM, are the same. (c) Write VIN: Explains the VIN writing process in a flowchart. This process allows the VIN to be input into the ECM. If the ECM is changed, or the vehicle VIN and ECM VIN do not match, the VIN can be registered or overwritten in the ECM by following this procedure. INPUT INSTRUCTIONS (a) Intelligent tester The arrow buttons (UP, DOWN, RIGHT and LEFT) and numerical buttons (0 to 9) are used to input the VIN. (b) Cursor Operation To move the cursor around the tester screen, press the RIGHT and LEFT buttons. (c) Alphabetical Character Input (1) Press the UP and DOWN buttons to select the desired alphabetical character. (2) After selection, the cursor should move. (d) Numeric Character Input (1) Press the numerical button corresponding to the number that you want to input. (2) After input, the cursor should move. HINT: Numerical characters can also be selected by using the UP and DOWN buttons. (e) Correction (1) When correcting the input character(s), put the cursor onto the character using the RIGHT and LEFT buttons. (2) Select or input the correct character using the UP/DOWN buttons, or the numerical buttons. (f) Finishing Input Operation (1) Make sure that the input VIN matches the vehicle VIN after input. (2) Press the ENTER button on the tester. ES ES–20 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 3. READ VIN (a) Confirm the vehicle VIN. (b) Connect the intelligent tester to the DLC3. (c) Turn the ignition switch to the ON position. (d) Turn the tester on. (e) Select the following menu items: DIAGNOSIS / ENHANCED OBD II/ VIN. Menu Screen: Select VIN READ ES VIN Previously Stored DTC P0630 Set VIN Not Stored 17-digit VIN displayed [EXIT] [EXIT] [EXIT] To Menu Screen A103812E03 4. WRITE VIN (a) Confirm the vehicle VIN. (b) Connect the intelligent tester to the DLC3. (c) Turn the ignition switch to the ON position. (d) Turn the tester on. ES–21 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (e) Select the following menu items: DIAGNOSIS / ENHANCED OBD II/ VIN. Menu Screen: Select VIN WRITE ES VIN Previously Stored [NO] [YES] [YES] [YES] To Menu Screen 17-digit VIN displayed [NO] Continue to next illustration To Menu Screen A103813E01 ES–22 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM New Registration Input Instructions [ENTER] ES [ENTER] [ENTER] [ENTER] Input Error [Exit] Continue to next illustration A136113E01 ES–23 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Writing Successful Writing Error Communication Error ES [ENTER] To Menu Screen [EXIT] To Menu Screen [EXIT] To Menu Screen A103815E03 ES–24 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECKING MONITOR STATUS ES The purpose of the monitor result (mode 06) is to allow access to the results of on-board diagnostic monitoring tests of specific components/systems that are not continuously monitored. Examples are catalysts and evaporative emissions (EVAP). The monitor result allows the OBD II scan tool to display the monitor status, test value, minimum test limit and maximum test limit. These data are displayed after the vehicle has been driven to run the monitor. When the test value is not between the minimum test limit and maximum test limit, the ECM (PCM) interprets this as a malfunction. If the test value is on the borderline of the test limits, the component is likely to malfunction in the near future. Perform the following instructions to view the monitor status. Although this instruction refers to the Lexus/Toyota diagnostic tester, it can be checked using a generic OBD II scan tool. Refer to your scan tool operator's manual for specific procedural information. 1. PERFORM MONITOR DRIVE PATTERN (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the tester on. (c) Clear the DTCs (See page ES-38). (d) Run the vehicle in accordance with the applicable drive pattern described in READINESS MONITOR DRIVE PATTERN (See page ES-23). Do not turn the ignition switch off. NOTE: The test results will be lost if the ignition switch is turned off. 2. ACCESS MONITOR RESULT (a) Select the following items from the intelligent tester menus: DIAGNOSIS / ENHANCED OBD II / MONITOR INFO and MONITOR RESULT. The monitor status appears after the component name. • INCMP: The component has not been monitored yet. • PASS: The component is functioning normally. • FAIL: The component is malfunctioning. (b) Confirm that the component is either PASS or FAIL. (c) Select the component and press ENTER. The accuracy test value appears if the monitor status is either PASS or FAIL. 3. CHECK COMPONENT STATUS (a) Compare the test value with the minimum test limit (MIN LIMIT) and maximum test limit (MAX LIMIT). 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 4. (b) If the test value is between the minimum test limits and maximum test limits, the component is functioning normally. If not, the component is malfunctioning. The test value is usually not near the test limit. If the test value is on the borderline of the test limits, the component is likely to malfunction in the near future. HINT: The monitor result might be PASS on rare occasions even if the malfunction indicator lamp (MIL) is illuminated. This indicates the system malfunctioned on a previous driving cycle. This might be caused by an intermittent problem. MONITOR RESULT INFORMATION If you use a generic scan tool, multiply the test value by the scaling value listed below. A/F Sensor (Sensor 1): Monitor ID Test ID Scaling Unit Description $01 $8E Multiply by 0.001 V A/F sensor deterioration level $01 $91 Multiply by 0.004 mA A/F sensor current HO2 Sensor (Sensor 2): Monitor ID Test ID Scaling Unit Description $02 $07 Multiply by 0.001 V Minimum sensor voltage $02 $08 Multiply by 0.001 V Maximum sensor voltage $02 $8F Multiply by 0.0003 g Maximum oxygen storage capacity Catalyst: Monitor ID $21 Test ID $A9 Scaling Multiply by 0.0003 Unit No dimension Description Oxygen storage capacity of catalyst EVAP: Monitor ID Test ID Scaling Unit Description $3D $C9 Multiply by 0.001 kPa Test value for small leak (P0456) $3D $CA Multiply by 0.001 kPa Test value for gross leak (P0455) $3D $CB Multiply by 0.001 kPa Test value for leak detection pump stuck OFF (P2401) $3D $CD Multiply by 0.001 kPa Test value for leak detection pump stuck ON (P2402) $3D $CE Multiply by 0.001 kPa Test value for vent valve stuck OFF (P2420) $3D $CF Multiply by 0.001 kPa Test value for vent valve stuck ON (P2419) $3D $D0 Multiply by 0.001 kPa Test value for reference orifice low flow (P043E) $3D $D1 Multiply by 0.001 kPa Test value for reference orifice high flow (P043F) $3D $D4 Multiply by 0.001 kPa Test value for purge VSV stuck closed (P0441) $3D $D5 Multiply by 0.001 kPa Test value for purge VSV stuck open (P0441) $3D $D7 Multiply by 0.001 kPa Test value for purge flow insufficient (P0441) Rear Oxygen Sensor Heater: Monitor ID $42 Test ID $91 Scaling Multiply by 0.001 Unit Ohm ES–25 Description Oxygen sensor resistance bank 1 sensor 2 ES ES–26 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Misfire: Monitor ID $A1 $A1 $A2 Test ID $0B $0C $0B Scaling Multiply by 1 Multiply by 1 Multiply by 1 Unit Time Exponential Weighted Moving Average (EWMA) misfire for all cylinders: EWMA = Total misfire counts for last driving cycle * 0.1 + Last EWMA * 0.9 Misfire counts for last 10 driving cycles - Total Time Ignition switch to the ON position: Total misfire counts for last driving cycle Engine running: Total misfire counts for current driving cycle Misfire counts for last or current driving cycle - all cylinders Time Exponential Weighted Moving Average (EWMA) misfire for cylinder 1: EWMA = Total misfire counts for last driving cycle * 0.1 + Last EWMA * 0.9 Misfire counts for last 10 driving cycles - Total Time Ignition switch to the ON position: Total misfire counts for last driving cycle Engine running: Total misfire counts for current driving cycle Misfire counts for last or current driving cycle - cylinder 1 Time Exponential Weighted Moving Average (EWMA) misfire for cylinder 2: EWMA = Total misfire counts for last driving cycle * 0.1 + Last EWMA * 0.9 Misfire counts for last 10 driving cycles - Total Time Ignition switch to the ON position: Total misfire counts for last driving cycle Engine running: Total misfire counts for current driving cycle Misfire counts for last or current driving cycle - cylinder 2 Time Exponential Weighted Moving Average (EWMA) misfire for cylinder 3: EWMA = Total misfire counts for last driving cycle * 0.1 + Last EWMA * 0.9 Misfire counts for last 10 driving cycles - Total Time Ignition switch to the ON position: Total misfire counts for last driving cycle Engine running: Total misfire counts for current driving cycle Misfire counts for last or current driving cycle - cylinder 3 Time Exponential Weighted Moving Average (EWMA) misfire for cylinder 4: EWMA = Total misfire counts for last driving cycle * 0.1 + Last EWMA * 0.9 Misfire counts for last 10 driving cycles - Total Time Ignition switch to the ON position: Total misfire counts for last driving cycle Engine running: Total misfire counts for current driving cycle Misfire counts for last or current driving cycle - cylinder 4 ES $A2 $A3 $A3 $A4 $A4 $A5 $A5 $0C $0B $0C $0B $0C $0B $0C Multiply by 1 Multiply by 1 Multiply by 1 Multiply by 1 Multiply by 1 Multiply by 1 Multiply by 1 Description 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–27 READINESS MONITOR DRIVE PATTERN 1. PURPOSE OF READINESS TESTS • The On-Board Diagnostic (OBD II) system is designed to monitor the performance of emission related components, and indicate any detected abnormalities with DTCs (Diagnostic Trouble Codes). Since various components need to be monitored during different driving conditions, the OBD II system is designed to run separate monitoring programs called Readiness Monitors. • The intelligent tester's software must be version 9.0 or newer to view the Readiness Monitor Status. To view the status, select the following menu items: DIAGNOSIS / ENHANCED OBD II / MONITOR INFO / MONITOR STATUS. • When the Readiness Monitor status reads COMPL (complete), the necessary conditions have been met for running the performance tests for that Readiness Monitor. • A generic OBD II scan tool can also be used to view the Readiness Monitor status. HINT: Many state Inspection and Maintenance (I/M) programs require a vehicle's Readiness Monitor status to show COMPL before beginning emission tests. The Readiness Monitor will be reset to INCMPL (incomplete) if: • The ECM has lost battery power or blown a fuse. • DTCs have been cleared. • The conditions for running the Readiness Monitor have not been met. If the Readiness Monitor status shows INCMPL, follow the appropriate Readiness Monitor Drive Pattern to change the status to COMPL. CAUTION: Strictly observe posted speed limits, traffic laws, and road conditions when performing these drive patterns. NOTICE: These drive patterns represent the fastest method of satisfying all conditions necessary to achieve complete status for each specific Readiness Monitor. In the event of a drive pattern being interrupted (possibly due to factors such as traffic conditions), the drive pattern can be resumed. In most cases, the Readiness Monitor will still achieve complete status upon completion of the drive pattern. To ensure completion of the Readiness Monitors, avoid sudden changes in vehicle load and speed (driving up and down hills and/or sudden acceleration). ES ES–28 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2. CATALYST MONITOR (ACTIVE AIR-FUEL RATIO CONTROL TYPE) Vehicle Speed Between 40 mph and 70 mph (64 km/h and 113 km/h) (6) NOTICE: This test will not be completed if the vehicle is driven at absolutely constant speed such as with cruise control activated. ES Idling (5) Ignition Switch OFF Warm up 10 minutes Time (Note: Even when vehicle stops during driving pattern, test can be resumed) A115372E50 3. (a) Preconditions The monitor will not run unless: • The MIL is OFF. (b) Drive Pattern (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch to the ON position. (3) Turn the tester on. (4) Clear the DTCs (if set) (See page ES-38). (5) Start the engine and warm it up. (6) Drive the vehicle at between 40 mph and 70 mph (64 km/h and 113 km/h) for at least 10 minutes. (c) Monitor Status Check the Readiness Monitor status displayed on the tester. If the status does not switch to COMPL (complete), extend the driving time. EVAP SYSTEM MONITOR (KEY OFF TYPE) (a) Preconditions The monitor will not run unless: – The fuel tank is less than 90% full. – The altitude is less than 8,000 ft. (2,450 m). – The vehicle is stationary. – The engine coolant temperature is between 4.4°C and 35°C (40°F and 95°F). – The intake air temperature is between 4.4°C and 35°C (40°F and 95°F). – Vehicle was driven in a city area (or on free-way) for 10 minutes or more. ES–29 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (b) Monitor Conditions (1) Turn the ignition switch off and wait for 6 hours. HINT: Do not start the engine until checking Readiness Monitor status. If the engine is started, the step described above must be repeated. (c) Monitor Status (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch to the ON position. (3) Turn the tester on. (4) Check the Readiness Monitor status displayed on the tester. If the status does not switch to COMPL (complete), restart the engine, make sure that the preconditions have been met, and then perform the Monitor Conditions again. 4. AIR-FUEL RATIO (A/F) AND HEATED OXYGEN (HO2) SENSOR MONITORS (ACTIVE AIR-FUEL RATIO CONTROL TYPE) Monitor Drive Pattern ECT: 75°C (167°F) or more Vehicle Speed Accelerator Pedal Depressed Between 38 and 75 mph (60 and 120 km/h) (6) 40 mph (64 km/h) or more (5) Accelerator Pedal Released (Fuel-cut) At least 3 times (8) (9) (10) 6 mph (10 km/h) (7) Idling Time Warming up 10 minutes or more 10 seconds 4 seconds or more or more A115374E09 (a) Preconditions The monitor will not run unless: – 2 minutes or more have elapsed since the engine was started. – The Engine Coolant Temperature (ECT) is 75°C (167°F) or more. – Cumulative driving time at a vehicle speed of 30 mph (48 km/h) or more exceeds 6 minutes. – Air-fuel ratio feedback control is performed. ES ES–30 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES 5. (b) Drive Pattern for front A/F sensor and HO2 sensor (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch to the ON position. (3) Turn the tester on. (4) Clear the DTCs (See page ES-38). (5) Start the engine, and warm it up until the ECT reaches 75°C (167°F) or higher (6) Drive the vehicle at between 38 mph (60 km/h) and 75 mph (120 km/h) for at least 10 minutes. (7) Change the transmission to the 2nd gear. (8) Accelerate the vehicle to 40 mph (64 km/h) or more by depressing the accelerator pedal for at least 10 seconds. (9) Soon after performing step (8) above, release the accelerator pedal for at least 4 seconds without depressing the brake pedal, in order to execute fuel-cut control. (10)Allow the vehicle to decelerate until the vehicle speed declines to less than 6 mph (10 km/h). (11)Repeat steps from (8) through (10) above at least 3 times in one driving cycle. (c) Monitor Status (1) Check the Readiness Monitor status displayed on the tester. (2) If the status does not switch to COMPL (complete), make sure that the preconditions have been met, and then perform steps from (5) through (11) in the Drive Pattern above. AIR-FUEL RATIO (A/F) AND HEATED OXYGEN (HO2) SENSOR HEATER MONITORS (FRONT A/F AND REAR HO2 SENSOR TYPE) Vehicle Speed (7) 25 mph (40 km/h) Idling (6) Ignition Switch OFF 10 minutes or more 2 minutes or more A121604E07 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–31 (a) Preconditions The monitor will not run unless: – The MIL is OFF. (b) Drive Pattern (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch to the ON position. (3) Turn the tester on. (4) Clear the DTCs (if set) (See page ES-38). (5) Start the engine. (6) Allow the engine to idle for 10 minutes or more. (7) Drive the vehicle at 25 mph (40 km/h) or more for at least 2 minutes. (c) Monitor Status (1) Check the Readiness Monitor status displayed on the tester. If the status does not switch to COMPL (complete), make sure that the preconditions have been met, and repeat steps from (5) to (7) described in the Drive Pattern above. ES ES–32 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PROBLEM SYMPTOMS TABLE HINT: Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. SFI system: Symptom ES Engine does not crank (Does not start) No initial combustion (Does not start) Engine cranks normally but difficult to start Difficult to start with cold engine Difficult to start with warm engine High engine idle speed Low engine idle speed (Poor idling) Rough idling Suspected area See page 1. Battery CH-4 2. Starter ST-7 3. Starter relay ST-14 4. Park / neutral position switch (Automatic transaxle) AX-130 5. Clutch start switch (Manual transaxle) CL-37 6. Immobiliser system EI-55 1. ECM power source circuit ES-380 2. Crankshaft position sensor ES-411 3. Camshaft position sensor ES-409 4. Ignition system IG-3 5. Fuel pump control circuit ES-392 6. ECM ES-29 7. VC output circuit ES-387 1. Fuel pump control circuit ES-392 2. Compression EM-3 1. Ignition system IG-3 2. Spark plug IG-5 3. Fuel pump control circuit ES-392 4. Injector FU-14 1. Injector FU-14 2. Ignition system IG-3 3. Spark plug IG-5 4. Fuel pump control circuit ES-392 1. Electronic throttle control system ES-280 2. A/C signal circuit - 3. ECM power source circuit ES-380 1. Electronic throttle control system ES-280 2. A/C signal circuit - 3. Fuel pump control circuit ES-392 4. Air induction system EC-5 5. PCV hose EC-5 1. Compression EM-3 2. Spark plug IG-5 3. Injector FU-14 4. Ignition system IG-3 5. Fuel pump control circuit ES-392 6. Electronic throttle control system ES-280 7. Air induction system EC-5 8. PCV hose EC-5 9. Mass air flow meter ES-402 ES–33 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Symptom Idle hunting Hesitation/Poor acceleration Surging (Poor driveability) Engine stalls soon after starting Engine stalls only during A/C operation Unable/difficult to refuel Suspected area See page 1. Electronic throttle control system ES-280 2. Air induction system EC-5 3. ECM power source circuit ES-380 1. Fuel pump control circuit ES-392 2. Spark plug IG-5 3. Ignition system IG-3 4. Injector FU-14 5. Mass air flow meter ES-402 6. Electronic throttle control system ES-280 7. Air induction system EC-5 8. Compression EM-3 1. Spark plug IG-5 2. Fuel pump control circuit ES-392 3. Ignition system IG-3 4. Injector FU-14 5. Mass air flow meter ES-402 6. Variable valve timing system ES-69 7. Compression EM-3 1. Fuel pump control circuit ES-392 2. Spark plug IG-5 3. Ignition system IG-3 4. Injector FU-14 5. Variable valve timing system ES-69 6. Electronic throttle control system ES-280 7. Air induction system EC-5 8. PCV hose EC-5 9. Compression EM-3 1. A/C signal circuit - 2. ECM ES-29 1. Refueling valve (canister) - ES ES–34 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TERMINALS OF ECM C24  ES                                A24                                                                                                                                                           A107881E12 HINT: The standard normal voltage between each pair of the ECM terminals is shown in the table below. The appropriate conditions for checking each pair of the terminals are also indicated. The result of checks should be compared with the standard normal voltage for that pair of the terminals, displayed in the Specified Condition column. The illustration above can be used as a reference to identify the ECM terminal locations. Terminal Descriptions Conditions Specified Conditions Symbols (Terminal No.) Wiring Colors BATT (A24-20) - E1 (C24-104) Y - W-B Battery (for measuring battery voltage and for ECM memory) Always 9 to 14 V +BM (A24-3) - E1 (C24-104) LG - W-B Power source of throttle actuator Always 9 to 14 V IGSW (A24-28) - E1 (C24-104) Y - W-B Ignition switch Ignition switch to the ON position 9 to 14 V +B (A24-2) - E1 (C24-104) R - W-B Power source of ECM Ignition switch to the ON position 9 to 14 V +B2 (A24-1) - E1 (C24-104) R - W-B Power source of ECM Ignition switch to the ON position 9 to 14 V OC1+ (C24-100) - OC1- (C24123) W-B Camshaft timing oil control valve (OCV) Idling Pulse generation (see waveform 1) MREL (A24-44) - E1 (C24-104) O - W-B EFI relay Ignition switch to the ON position 9 to 14 V 0.5 to 3.0 V VG (C24-118) - E2G (C24-116) SB - W Mass air flow meter Idling, Shift lever position P or N, A/ C switch OFF THA (C24-65) - ETHA (C24-88) P-Y Intake air temperature sensor Idling, Intake air temperature 20°C (68°F) 0.5 to 3.4 V THW (C24-97) - ETHW (C24-96) B-P Engine coolant temperature sensor Idling, Engine coolant temperature 80°C (176°F) 0.2 to 1.0 V VCTA (C24-67) - ETA (C24-91) B-P Power source of throttle position sensor (specific voltage) Ignition switch to the ON position 4.5 to 5.5 V Ignition switch to the ON position, Throttle valve fully closed 0.5 to 1.1 V Y-P Throttle position sensor (for engine control) Ignition switch to the ON position, Throttle valve fully open 3.3 to 4.9 V VTA1 (C24-115) - ETA (C24-91) ES–35 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Symbols (Terminal No.) VTA2 (C24-114) - ETA (C24-91) VPA (A24-55) - EPA (A24-59) VPA2 (A24-56) - EPA2 (A24-60) Wiring Colors W-L - P G-Y R-O Terminal Descriptions Throttle position sensor (for sensor malfunction detection) Accelerator pedal position sensor (for engine control) Accelerator pedal position sensor (for sensor malfunctioning detection) Conditions Specified Conditions Ignition switch to the ON position, Throttle valve fully closed 2.1 to 3.1 V Ignition switch to the ON position, Throttle valve fully open 4.6 to 5.0 V Ignition switch to the ON position, Accelerator pedal released 0.5 to 1.1 V Ignition switch to the ON position, Accelerator pedal fully depressed 2.6 to 4.5 V Ignition switch to the ON position, Accelerator pedal released 1.2 to 2.0 V Ignition switch to the ON position, Accelerator pedal fully depressed 3.4 to 5.0 V VCPA (A24-57) - EPA (A24-59) B-Y Power source of accelerator pedal position sensor (for VPA) Ignition switch to the ON position 4.5 to 5.5 V VCP2 (A24-58) - EPA2 (A24-60) L-O Power source of accelerator pedal position sensor (for VPA2) Ignition switch to the ON position 4.5 to 5.5 V HA1A (C24-109) - E04 (C24-46) G-W A/F sensor heater Idling Below 3.0 V Ignition switch to the ON position 9 to 14 V A1A+ (C24-112) - E1 (C24-104) L -W-B A/F sensor Ignition switch to the ON position 3.3 V*1 A1A- (C24-113) - E1 (C24-104) P - W-B A/F sensor Ignition switch to the ON position 3.0 V*1 HT1B (C24-47) - E03 (C24-86) LG - B Heated oxygen sensor heater Idling Below 3.0 V Ignition switch to the ON position 9 to 14 V OX1B (C24-64) - EX1B (C24-87) W - BR Heated oxygen sensor Engine speed maintained at 2,500 rpm for 2 minutes after warming up sensor Pulse generation (see waveform 2) #10 (C24-108) - E01 (C24-45) #20 (C24-107) - E01 (C24-45) #30 (C24-106) - E01 (C24-45) #40 (C24-105) - E01 (C24-45) B - W-B R - W-B Y - W-B L - W-B Ignition switch to the ON position 9 to 14 V Injector Idling Pulse generation (see waveform 3) KNK1 (C24-110) - EKNK (C24111) G-R Knock sensor Engine speed maintained at 4,000 after warming up engine Pulse generation (see waveform 4) G2+ (C24-99) - G2- (C24-98) Y - BR Camshaft position sensor Idling Pulse generation (see waveform 5) NE+ (C24-122) - NE- (C24-121) G-R Crankshaft position sensor Idling Pulse generation (see waveform 5) IGT1 (C24-85) - E1 (C24-104) IGT2 (C24-84) - E1 (C24-104) IGT3 (C24-83) - E1 (C24-104) IGT4 (C24-82) - E1 (C24-104) W - W-B G-R - W-B G - W-B LG - W-B Ignition coil (ignition signal) Idling Pulse generation (see waveform 6) 4.5 to 5.5 V BR - W-B Ignition coil (ignition confirmation signal) Ignition switch to the ON position IGF1 (C24-81) - E1 (C24-104) Idling Pulse generation (see waveform 6) Ignition switch to the ON position 9 to 14 V PRG (C24-49) - E1 (C24-104) O - W-B Purge VSV Idling Pulse generation (see waveform 7) SPD (A24-8) - E1 (C24-104) L - W-B Speed signal from combination meter Driving at 12 mph (20 km/h) Pulse generation (see waveform 8) STA (A24-48) - E1 (C24-104) V - W-B Starter signal Cranking 5.5 V or more NSW (C24-52)*2 - E1 (C24-104) SB - W-B Starter relay control Ignition switch to the ON position Below 1.5 V Cranking 5.5 V or more STP (A24-36) - E1 (C24-104) W - W-B Stop light switch Brake pedal depressed 7.5 to 14 V Brake pedal released Below 1.5 V ES ES–36 Symbols (Terminal No.) ST1- (A24-35) - E1 (C24-104) ES 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Wiring Colors GR - W-B Terminal Descriptions Stop light switch (opposite to STP terminal) Conditions Specified Conditions Ignition switch to the ON position, Brake pedal depressed Below 1.5 V Ignition switch to the ON position, Brake pedal released 7.5 to 14 V M+ (C24-42) - ME01 (C24-43) G-B Throttle actuator Idling with warm engine Pulse generation (see waveform 9) M- (C24-41) - ME01 (C24-43) R-B Throttle actuator Idling with warm engine Pulse generation (see waveform 10) FC (A24-7) - E1 (C24-104) Y - W-B Fuel pump control Ignition switch to the ON position 9 to 14 V Idling Below 1.5 V W (A24-24) - E1 (C24-104) BR - W-B MIL Ignition switch to the ON position Below 1.5 V Idling 9 to 14 V TC (A24-27) - E1 (C24-104) P - W-B Terminal TC of DLC3 Ignition switch to the ON position 9 to 14 V TACH (A24-15) - E1 (C24-104) B - W-B Engine speed Idling Pulse generation (see waveform 11) VPMP (A24-42) - E1 (C24-104) W - W-B Vent valve (built into canister pump module) Ignition switch to the ON position 9 to 14 V Below 3 V G - W-B Leak detection pump (built into canister pump module) Leak detection pump OFF MPMP (A24-34) - E1 (C24-104) Leak detection pump ON 9 to 14 V VCPP (C24-70) - EPPM (C24-94) R-G Power source for canister pressure sensor (specific voltage) Ignition switch to the ON position 4.5 to 5.5 V PPMP (C24-71) - EPPM (C24-94) L - G Canister pressure sensor (built into canister pump module) Ignition switch to the ON position 3 to 3.6 V Ignition switch to the ON position 9 to 14 V FANL (A24-21) - E1 (C24-104) R - W-B Fan No. 1 relay Idling with A/C ON, or high engine coolant temperature Below 1.5 V FANH (A24-22) - E1 (C24-104) W - W-B Fan No. 2, 3 relay Idling with high engine coolant temperature Below 1.5 V ALT (C24-50) - E1 (C24-104) L - W-B Generator Ignition switch to the ON position 9 to 14 V CANH (A24-41) - E1 (C24-104) B - W-B CAN communication line Ignition switch to the ON position Pulse generation (see waveform 12) CANL (A24-49) - E1 (C24-104) W - W-B CAN communication line Ignition switch to the ON position Pulse generation (see waveform 13) IAC+ (A24-33)*3 - E1 (C24-104) L - W-B Intake manifold runner valve motor Ignition switch to the ON position Pulse generation IAC- (A24-52)*3 - E1 (C24-104) W - W-B Intake manifold runner valve motor Ignition switch to the ON position Pulse generation VCIA (C24-103)*3 - EIA (C24126)*3 B-L Power source of intake manifold runner valve position sensor (Specific voltage) Ignition switch to the ON position 4.5 to 5.5 V Ignition switch to the ON position, intake manifold runner valve fully closed. 0.2 to 1.0 V Ignition switch to the ON position, intake manifold runner valve fully opened. 3.2 to 4.8 V IACA (C24-93)*3 - EIA (C24126)*3 B-W - L Intake manifold runner valve position sensor HINT: *1: The ECM terminal voltage is constant regardless of the output voltage from the sensor. *2: Automatic transaxle only *3: PZEV only 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 1. 5 V/DIV. ES–37 WAVEFORM 1 Camshaft timing oil control valve (OCV): ECM Terminal Names Between OC1+ and OC1- Tester Ranges 5 V/DIV., 1 ms./DIV. Conditions Idling GND 1 ms./DIV. A093229E11 2. 0.2 V/DIV. ECM Terminal Names Between OX1B and EX1B Tester Ranges 0.2 V/DIV., 200 ms./DIV. Conditions Engine speed maintained at 2,500 rpm for 2 minutes after warming up sensor HINT: In DATA LIST, item O2S B1 S2 shows the ECM input values from the heated oxygen sensor. GND 200 ms./DIV. A088863E15 3. 20 V/DIV. Between #10 (to #40) and E01 Tester Ranges 20 V/DIV., 20 ms./DIV. Conditions Idling HINT: The wavelength becomes shorter as the engine rpm increases. A093279E10 4. 1 V/DIV. GND 1 ms./DIV. WAVEFORM 3 Injector No. 1 (to No. 4) injection signal: ECM Terminal Names GND 20 ms./DIV. WAVEFORM 2 Heated oxygen sensor: A085286E24 WAVEFORM 4 Knock sensor: ECM Terminal Names Between KNK1 and EKNK Tester Ranges 1 V/DIV., 1 ms./DIV. Conditions Engine speed maintained at 4,000 rpm after warming up engine HINT: • The wavelength becomes shorter as the engine rpm increases. • The waveforms and amplitudes displayed differ slightly depending on the vehicle. ES ES–38 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 5. 5 V/DIV CH1 (G2) GND CH2 (NE+) GND 20 ms./DIV ECM Terminal Names 5 V/DIV., 20 ms./DIV. Conditions Idling HINT: The wavelength becomes shorter as the engine rpm increases. A063955E21 2 V/DIV. IGT Ground WAVEFORM 6 Igniter IGT signal (from ECM to igniter) and Igniter IGF signal (from igniter to ECM): ECM Terminal Names IGF Ground 20 ms./DIV. 2 V/DIV., 20 ms./DIV. Conditions Idling HINT: The wavelength becomes shorter as the engine rpm increases. 7. Between PRG and E1 Tester Ranges 5 V/DIV., 50 ms./DIV. Conditions Idling HINT: If the waveform is not similar to the illustration, check the waveform again after idling for 10 minutes or more. A093230E07 8. 2 V/DIV. WAVEFORM 8 Vehicle speed signal: ECM Terminal Names Between SPD and E1 Tester Ranges 2 V/DIV., 20 ms./DIV. Conditions Driving at 12 mph (20 km/h) GND 20 ms./DIV. WAVEFORM 7 Purge VSV: ECM Terminal Names GND 50 ms./DIV. HINT: The wavelength becomes shorter as the vehicle speed increases. A093224E13 9. 5 V/DIV. WAVEFORM 9 Throttle actuator positive terminal: ECM Terminal Names Between M+ and ME01 Tester Ranges 5 V/DIV., 1 ms./DIV. Conditions Idling with warm engine HINT: The duty ratio varies depending on the throttle actuator operation. GND 1 ms./DIV. Between IGT (1 to 4) and E1 Between IGF1 and E1 Tester Ranges A093278E22 5 V/DIV. CH1: Between G2+ and G2CH2: Between NE+ and NE- Tester Ranges 6. ES WAVEFORM 5 Crankshaft position sensor and Camshaft position sensor: A093274E13 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–39 10. WAVEFORM 10 Throttle actuator negative terminal: 5 V/DIV. GND 1 ms./DIV. A093275E12 ECM Terminal Names Between M- and ME01 Tester Ranges 5 V/DIV., 1 ms./DIV. Conditions Idling with warm engine HINT: The duty ratio varies depending on the throttle actuator operation. 11. WAVEFORM 11 Engine speed signal: 5 V/DIV. GND ECM Terminal Names Between TACH and E1 Tester Ranges 5 V/DIV., 10 ms./DIV. Conditions Idling HINT: The wavelength becomes shorter as the engine rpm increases. 10 ms./DIV. A093225E11 1 V/DIV. GND 10 Ǵsec./DIV. A086154E01 1 V/DIV. GND 10 Ǵsec./DIV. A086155E01 12. WAVEFORM 12 CAN communication signal: ECM Terminal Names Between CANH and E1 Tester Ranges 1 V/DIV., 10 µsec./DIV. Conditions Engine stops and ignition switch to the ON position HINT: The waveform varies depending on the CAN communication signal. 13. WAVEFORM 13 CAN communication signal: ECM Terminal Names Between CANL and E1 Tester Ranges 1 V/DIV., 10 µsec./DIV. Conditions Engine stops and ignition switch to the ON position HINT: The waveform varies depending on the CAN communication signal. ES ES–40 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DIAGNOSIS SYSTEM 1. ES FI00534 Intelligent Tester DLC3 CAN VIM C131977E05 2. DESCRIPTION When troubleshooting OBD II (On-Board Diagnostics) vehicles, the intelligent tester (complying with SAE J1987) must be connected to the DLC3 (Data Link Connector 3) of the vehicle. Various data in the vehicle's ECM (Engine Control Module) can be then read. OBD II regulations require that the vehicle's on-board computer illuminates the MIL (Malfunction Indicator Lamp) on the instrument panel when the computer detects a malfunction in: (a)The emission control system components. (b)The powertrain control components (which affect vehicle emissions). (c) The computer itself. In addition, if the applicable DTCs (Diagnostic Trouble Codes) prescribed by SAE J2012 are not recorded on 3 consecutive trips, the MIL turns off automatically but the DTCs remain recorded in the ECM memory. To check DTCs, connect the intelligent tester to the DLC3. The tester displays DTCs, freeze frame data, and a variety of the engine data. The DTCs and freeze frame data can be erased with the tester (See page ES-38). In order to enhance OBD function on vehicles and develop the Off-Board diagnosis system, CAN (Controller Area Network) communication is introduced in this system. It minimizes the gap between technician skills and vehicle technology. CAN is a network, which uses a pair of data transmission lines, spanning multiple computers and sensors. It allows high speed communication between the systems and simplifies the wire harness connection. Since this system is equipped with the CAN communication, connecting the CAN VIM (Vehicle Interface Module) to the intelligent tester is necessary to display any information from the ECM. (Also the communication between the intelligent tester and the ECM uses CAN communication signals.) When confirming the DTCs and any data of the ECM, connect the CAN VIM between the DLC3 and the intelligent tester. NORMAL MODE AND CHECK MODE The diagnosis system operates in normal mode during normal vehicle use. In normal mode, "2 trip detection logic" is used to ensure accurate detection of malfunctions. "Check mode" is also available as an option for technicians. In check mode, "1 trip detection logic" is used for simulating malfunction symptoms and increasing the system's ability to detect malfunctions, including intermittent problems (intelligent tester only) (See page ES-41). ES–41 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 3. 4. 5. CG SG CANH SIL 2 TRIP DETECTION LOGIC When a malfunction is first detected, the malfunction is temporarily stored in the ECM memory (1st trip). If the same malfunction is detected during the next subsequent drive cycle, the MIL is illuminated (2nd trip). FREEZE FRAME DATA The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. DLC3 (Data Link Connector 3) The vehicle's ECM uses the ISO 15765-4 for communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. BAT CANL H100769E16 Symbols Terminal No. Names Reference terminal Results Condition SIL 7 Bus "+" line 5 - Signal ground Pulse generation During transmission CG 4 Chassis ground Body ground 1 Ω or less Always SG 5 Signal ground Body ground 1 Ω or less Always BAT 16 Battery positive Body ground 9 to 14 V Always 14 - CANL 54 to 69 Ω Ignition switch OFF* CANH 6 CAN "High" line Battery positive 6 kΩ or higher Ignition switch OFF* CANL 14 CAN "Low" line 4 - CG 200 Ω or higher Ignition switch OFF* Battery positive 6 kΩ or higher Ignition switch OFF* 4 - CG 200 Ω or higher Ignition switch OFF* CAUTION: *: Before measuring the resistance, leave the vehicle as it is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: The DLC3 is the interface prepared for reading various data from the vehicle's ECM. After connecting the cable of the intelligent tester to the CAN VIM, turn the ignition switch to the ON position and turn the tester on. If a communication failure message is displayed on the tester screen (on the tester: UNABLE TO CONNECT TO VEHICLE), a problem exists in either the vehicle or tester. In order to identify the location of the problem, connect the tester to another vehicle. If communication is normal: Inspect the DLC3 on the original vehicle. ES ES–42 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 6. 7. ES 8. If communication is still not possible: The problem is probably in the tester itself. Consult the Service Department listed in the instruction manual. BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, replace or recharge the battery before proceeding to the next step. MIL (Malfunction Indicator Lamp) (a) The MIL is illuminated when the ignition switch is first turned ON position (the engine is not running). (b) The MIL should turn OFF when the engine is started. If the MIL remains illuminated, the diagnosis system has detected a malfunction or abnormality in the system. HINT: If the MIL is not illuminated when the ignition switch is first turned ON position, check the MIL circuit (See page ES-397). ALL READINESS For the vehicle, using the intelligent tester allows readiness codes corresponding to all DTCs to be read. When diagnosis (normal or malfunctioning) has been complete, readiness codes are set. Select the following menu items on the intelligent tester: ENHANCED OBD II / MONITOR STATUS. 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–43 DTC CHECK / CLEAR NOTICE: When the diagnosis system is changed from normal mode to check mode or vice versa, all DTCs and freeze frame data recorded in normal mode are erased. Before changing modes, always check and make a note of any DTCs and freeze frame data. HINT: • DTCs which are stored in the ECM can be displayed on the intelligent tester. The intelligent tester can display current and pending DTCs. • Some DTCs are not set if the ECM does not detect the same malfunction again during a second consecutive driving cycle. However, such malfunctions, detected on only one occasion, are stored as pending DTCs. 1. Intelligent Tester 2. DLC3 CAN VIM C131977E05 3. CHECK FOR DTC (Using intelligent tester) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position. (c) Turn the tester on. (d) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES or PENDING CODES. (e) Check the DTC(s) and freeze frame data, and then write them down. (f) Check the details of the DTC(s) (See page ES-53). CLEAR DTC (Using intelligent tester) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position. (c) Turn the tester on. (d) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CLEAR CODES. (e) Press the YES button. CLEAR DTC (Without using intelligent tester) (a) Perform either of the following operations: (1) Disconnect the cable from the negative (-) battery terminal for more than 1 minute. (2) Remove the EFI No. 1 and ETCS fuses from the engine room R/B (located inside the engine compartment) for more than 1 minute. ES ES–44 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM FREEZE FRAME DATA 1. ES DTC set 0.5 seconds 0.5 seconds 0.5 seconds Freeze frame data which can be read 2. DESCRIPTION The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. HINT: If it is impossible to duplicate the problem even though a DTC is detected, confirm the freeze frame data. The ECM records engine conditions in the form of freeze frame data every 0.5 seconds. Using the intelligent tester, 5 separate sets of freeze frame data can be checked. – 3 data set before the DTC was set. – 1 data set when the DTC was set. – 1 data set after the DTC was set. These data sets can be used to simulate the condition of the vehicle around the time of the occurrence of the malfunction. The data may assist in identifying the cause of the malfunction, and in judging whether it was temporary or not. LIST OF FREEZE FRAME DATA A103809E12 LABEL (Intelligent Tester Display) INJECTOR IGN ADVANCE CALC LOAD VEHICLE LOAD MAF Measurement Item Diagnostic Note Injection period of No. 1 cylinder - Ignition advance - Calculated load Vehicle load Mass air flow volume Calculated load by ECM If approximately 0.0 g/sec.: • Mass air flow meter power source circuit open or short • VG circuit open or short If 160.0 g/sec. or more: • E2G circuit open ENGINE SPD Engine speed VEHICLE SPD Vehicle speed Speed indicated on speedometer Engine coolant temperature If -40°C (-40°F), sensor circuit open If 140°C (284°F) or more, sensor circuit shorted Intake air temperature If -40°C (-40°F), sensor circuit open If 140°C (284°F) or more, sensor circuit shorted COOLANT TEMP INTAKE AIR - AIR-FUEL RATIO Ratio compared to stoichiometric level - PURGE DENSITY Learning value of purge density - Ratio of evaporative purge flow to intake air volume - EVAP PURGE FLOW EVAP PURGE VSV EVAP purge VSV duty ratio - KNOCK CRRT VAL Correction learning value of knocking - Feedback value of knocking - KNOCK FB VAL ES–45 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM LABEL (Intelligent Tester Display) ACCEL POS #1 Measurement Item Diagnostic Note Absolute Accelerator Pedal Position (APP) No. 1 - ACCEL POS #2 Absolute APP No. 2 - THROTTLE POS Throttle position - THROTTLE POS Throttle sensor positioning - Throttle sensor positioning #2 - THROTTLE POS #2 THROTTLE MOT Throttle motor - O2S B1 S2 Heated oxygen sensor output Performing INJ VOL or A/F CONTROL function of ACTIVE TEST enables technician to check output voltage of sensor AFS B1 S1 A/F sensor output Performing INJ VOL or A/F CONTROL function of ACTIVE TEST enables technician to check output voltage of sensor TOTAL FT #1 Total fuel trim - SHORT FT #1 Short-term fuel trim Short-term fuel compensation used to maintain air-fuel ratio at stoichiometric air-fuel ratio LONG FT #1 Long-term fuel trim Overall fuel compensation carried out in longterm to compensate for a continual deviation of short-term fuel trim from central valve • • FUEL SYS #1 Fuel system status • • • OL (Open Loop): Has not yet satisfied conditions to go closed loop CL (Closed Loop): Using A/F sensor as feedback for fuel control OL DRIVE: Open loop due to driving conditions (fuel enrichment) OL FAULT: Open loop due to detected system fault CL FAULT: Closed loop but A/F sensor, which used for fuel control malfunctioning O2FT B1 S2 Fuel trim at heated oxygen sensor - AF FT B1 S1 Fuel trim at A/F sensor - A/F sensor current - CAT TEMP B1S1 AFS B1 S1 Estimated catalyst temperature (sensor 1) - CAT TEMP B1S2 Estimated catalyst temperature (sensor 2) - Sub heated oxygen sensor impedance (sensor 2) - Engine coolant temperature at engine start - Intake air temperature at engine start - Injection volume - S O2S B1S2 INI COOL TEMP INI INTAKE TEMP INJ VOL STARTER SIG PS SW PS SIGNAL CTP SW Starter switch (STSW) signal - Power steering signal - Power steering signal (history) Signal status usually ON until ignition switch turned OFF Closed throttle position switch - A/C signal - Park/Neutral Position (PNP) switch signal - Electrical load signal - STOP LIGHT SW Stop light switch - BATTERY VOLTAGE Battery voltage - A/C SIGNAL PNP SW (NSW) ELECT LOAD SIG Atmosphere pressure - EVAP (Purge) VSV ATM PRESSURE EVAP Purge VSV - FUEL PUMP/SPD Fuel pump/speed status - VVT control status - VVT CTRL B1 ES ES–46 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM LABEL (Intelligent Tester Display) VACUUM PUMP EVAP VENT VAL FAN MOTOR TC/TE1 ES Measurement Item Key-off EVAP system leak detection pump status Diagnostic Note (see page ES-344) Key-off EVAP system vent valve status - Electric fan motor - TC and CG (TE1) terminals of DLC3 - ENG SPEED #1 Engine rpm during No. 1 cylinder fuel cut Output only when FUEL CUT #1 is performed using ACTIVE TEST ENG SPEED #2 Engine rpm during No. 2 cylinder fuel cut Output only when FUEL CUT #2 is performed using ACTIVE TEST ENG SPEED #3 Engine rpm during No. 3 cylinder fuel cut Output only when FUEL CUT #3 is performed using ACTIVE TEST ENG SPEED #4 Engine rpm during No. 4 cylinder fuel cut Output only when FUEL CUT #4 is performed using ACTIVE TEST ENG SPEED ALL VVTL AIM ANGL#1 Average of engine rpm values during fuel cut of No. 1 to No. 4 cylinders Output only when ACTIVE TEST is performed VVT aim angle - VVT CHNG ANGL#1 VVT angle - VVT OCV DUTY B1 VVT OCV operation duty - FC IDL Fuel cut idle ON: when throttle valve fully closed and engine speed over 3,500 rpm FC TAU Fuel cut with a very light load Fuel cut being performed with a very light load to prevent incomplete engine combustion IGNITION Ignition counter - CYL #1 Cylinder #1 misfire Displayed only during idling CYL #2 Cylinder #2 misfire Displayed only during idling CYL #3 Cylinder #3 misfire Displayed only during idling CYL #4 Cylinder #4 misfire Displayed only during idling CYL ALL All cylinders misfire Displayed only during idling MISFIRE RPM Engine speed when misfire occurred - MISFIRE LOAD Engine load when misfire occurred - MISFIRE MARGIN Margin to detect engine misfire - MIL ON RUN DIST Distance after DTC is detected - ENG RUN TIME Accumulated engine running time - TIME DTC CLEAR Cumulative time after DTC cleared - DIST DTC CLEAR WU CYC DTC CLEAR Accumulated distance from DTC cleared - Warm-up cycle after DTC cleared - 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–47 CHECK MODE PROCEDURE HINT: Intelligent tester only: Compared to normal mode, check mode is more sensitive to malfunctions. Therefore, check mode can detect the malfunctions that cannot be detected by normal mode. NOTICE: All the stored DTCs and freeze frame data are erased if: 1) the ECM is changed from normal mode to check mode or vice versa; or 2) the ignition switch is turned from ON position to ACC position or off while in check mode. Before changing modes, always check and make a note of any DTCs and freeze frame data. 1. Intelligent Tester DLC3 CAN VIM CHECK MODE PROCEDURE (Using intelligent tester) (a) Check and ensure the following conditions: (1) Battery positive voltage 11 V or more. (2) Throttle valve fully closed. (3) Transmission in the P or N position. (4) A/C switch OFF. (b) Turn the ignition switch off. (c) Connect the intelligent tester to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn the tester on. (f) Select the following menu items: DIAGNOSIS / ENHANCED OBD II/ CHECK MODE. (g) Switch the ECM from normal mode to check mode. C131977E05 0.13 seconds ON OFF 0.13 seconds A076900E04 (h) Make sure that the MIL flashes as shown in the illustration. (i) Start the engine. (j) Make sure that the MIL turns off. (k) Simulate the conditions of the malfunction described by the customer. (l) Check for DTCs and freeze frame data using the tester. ES ES–48 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM FAIL-SAFE CHART If any of the following DTCs are set, the ECM enters fail-safe mode to allow the vehicle to be driven temporarily. DTCs ES Components Fail-Safe Operations Fail-Safe Deactivation Conditions P0031 and P0032 Air-Fuel Ratio (A/F) Sensor Heater ECM turns off A/F sensor heater. Ignition switch OFF P0037 and P0038 Heated Oxygen (HO2) Sensor Heater ECM turns off HO2 sensor heater. Ignition switch OFF P0100, P0102 and P0103 Mass Air Flow (MAF) Meter ECM calculates ignition timing according to engine speed and throttle valve position. Pass condition detected P0110, P0112 and P0113 Intake Air Temperature (IAT) Sensor ECM estimates IAT to be 20°C (68°F). Pass condition detected P0115, P0117 and P0118 Engine Coolant Temperature (ECT) Sensor ECM estimates ECT to be 80°C (176°F). Pass condition detected P0120, P0121, P0122, P0123, P0220, P0222, P0223, P0604, P0606, P0607, P0657, P2102, P2103, P2111, P2112, P2118, P2119 and P2135 Electronic Throttle Control System (ETCS) ECM cuts off throttle actuator current and throttle valve is returned to 6° throttle position by return spring. ECM then adjusts engine output by controlling fuel injection (intermittent fuel-cut) and ignition timing in accordance with accelerator pedal opening angle to allow vehicle to continue at minimal speed*. Pass condition detected and then ignition switch turned off P0327 and P0328 Knock Sensor ECM sets ignition timing to maximum retard. Ignition switch off P0351 to P0354 Igniter ECM cuts fuel. Pass condition detected Accelerator Pedal Position (APP) Sensor APP sensor has 2 sensor circuits: Main and Sub. If either circuit malfunctions, ECM controls engine using the other circuit. If both circuits malfunction, ECM regards accelerator pedal as being released. As a result, throttle valve is closed and engine idles. Pass condition detected and then ignition switch turned off P2120, P2121, P2122, P2123, P2125, P2127, P2128 and P2138 HINT: *: The vehicle can be driven slowly when the accelerator pedal is depressed firmly and slowly. If the accelerator pedal is depressed quickly, the vehicle may speed up and slow down erratically. ES–49 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DATA LIST / ACTIVE TEST 1. DATA LIST HINT: By reading the DATA LIST displayed on an intelligent tester, values can be checked, including those of the switches, sensors, and actuators, without removing any parts. Reading the DATA LIST as the first step in troubleshooting is one method to shorten diagnostic time. NOTICE: In the table below, the values listed under Normal Condition are for reference only. Do not depend solely on these values when determining whether or not a part is faulty. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn the tester on. (f) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST. (g) Check the values by referring to the table below. ECM: Intelligent Tester Display Measurement Item: Range (Display) Normal Condition*1 Diagnostic Note INJECTOR Injection period of No. 1 cylinder: Min.: 0 ms, Max.: 32.64 ms 1.0 to 3.0 ms: Idling - IGN ADVANCE Ignition timing advance for No. 1 cylinder: Min.: -64 deg, Max.: 63.5 deg BTDC 8 to 12 deg: Idling - CALC LOAD Calculated load by ECM: Min.: 0 %, Max.: 100 % VEHICLE LOAD Vehicle load: Min.: 0 %, Max.: 25,700 % • • 10 to 30 %: Idling 10 to 30 %: Running without load at 2,500 rpm Load value Load percentage in terms of maximum intake air flow amount Actual vehicle load MAF Air flow rate from Mass Air Flow (MAF) meter: Min.: 0 g/sec., Max.: 655.35 g/sec. 1 to 3 g/sec.: Idling 2 to 6 g/sec.: Running without load at 2,500 rpm ENGINE SPD Engine speed: Min.: 0 rpm, Max.: 16,383.75 rpm 650 to 750 rpm: Idling (Manual transaxle) 610 to 710 rpm: Idling (Automatic transaxle) VEHICLE SPD Vehicle speed: Min.: 0 km/h, Max.: 255 km/h Actual vehicle speed COOLANT TEMP Engine coolant temperature: Min.: -40°C, Max.: 140°C 80 to 100°C (176 to 212°F): After warming up INTAKE AIR Intake air temperature: Min.: -40°C, Max.: 140°C Equivalent to ambient air temperature If value is approximately 0.0 g/ sec.: • MAF meter power source circuit open • VG circuit open or shorted If value is 160.0 g/sec. or more: • E2G circuit open - Speed indicated on speedometer • • • • If -40°C (-40°F): sensor circuit open If 140°C (284°F) or more: sensor circuit shorted If -40°C (-40°F): sensor circuit open If 140°C (284°F) or more: sensor circuit shorted ES ES–50 Intelligent Tester Display 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Measurement Item: Range (Display) Normal Condition*1 Diagnostic Note • ES Less than 1 (0 to 0.999) = Lean Stoichiometric air-fuel ratio = 1 Greater than 1 (1.001 to 1.999) = Rich AIR-FUEL RATIO Ratio compared to stoichiometric level: Min.: 0, Max.: 1.999 0.8 to 1.2: Idling PURGE DENSITY Learning value of purge density: Min.: -50, Max.: 350 -40 to 10: Idling - EVAP PURGE FLOW Ratio of evaporative purge flow to intake air volume: Min.: 0 %, Max.: 102.4 % 0 to 10 %: Idling - EVAP PURGE VSV EVAP (PURGE) VSV control duty: Min.: 0 %, Max.: 100 % 10 to 50 %: Idling Order signal from ECM VAPOR PRES PUMP Vapor pressure: Min.: 33.853 kPa, Max.: 125.596 kPa Approximately 100 kPa: Ignition switch to the ON position EVAP system pressure monitored by canister pressure sensor VAPOR PRES CALC Vapor pressure (calculated): Min.: -5.632 kPa, Max.: 715.264 kPa Approximately 100 kPa: Ignition switch to the ON position EVAP system pressure monitored by canister pressure sensor KNOCK CRRT VAL Knock correction learning value: Min: -64°CA, Max.: 1,984°CA 0 to 20°CA: Driving at 44 mph (70 km/h) Service data KNOCK FB VAL Knock feedback value: Min: -64°CA, Max.: 1,984°CA -20 to 0°CA: Driving at 44 mph (70 km/h) Service data ACCEL POS #1 Absolute Accelerator Pedal Position (APP) No. 1: Min.: 0 %, Max.: 100 % 10 to 22 %: Accelerator pedal released 52 to 90 %: Accelerator pedal fully depressed Read value with ignition switch to the ON position (Do not start engine) ACCEL POS #2 Absolute APP No. 2: Min.: 0 %, Max.: 100 % 24 to 40 %: Accelerator pedal released 68 to 100 %: Accelerator pedal fully depressed Read value with ignition switch to the ON position (Do not start engine) ACCEL POS #1 APP sensor No. 1 voltage: Min.: 0 V, Max.: 5 V 0.5 to 1.1 V: Accelerator pedal released 2.6 to 4.5 V: Accelerator pedal fully depressed Read value with ignition switch to the ON position (Do not start engine) ACCEL POS #2 APP sensor No. 2 voltage: Min.: 0 V, Max.: 5 V 1.2 to 2.0 V: Accelerator pedal released 3.4 to 5.0 V: Accelerator pedal fully depressed Read value with ignition switch to the ON position (Do not start engine) ACCEL IDL POS Whether or not accelerator pedal position sensor detecting idle: ON or OFF ON: Idling - THRTL LEARN VAL Throttle valve fully closed (learned value): Min.: 0 V, Max.: 5 V 0.4 to 0.8 V - ACCEL SSR #1 AD APP sensor No. 1 voltage (AD): Min.: 0 V, Max.: 4.9804 V - ETCS service data ACCEL LRN VAL#1 Accelerator fully closed learning value No. 1: Min.: 0 deg, Max.: 124.512 deg - ETCS service data ACCEL LRN VAL#2 Accelerator fully closed learning value No. 2: Min.: 0 deg, Max.: 124.512 deg - ETCS service data FAIL #1 Whether or not fail safe function executed: ON or OFF ON: ETCS has failed - FAIL #2 Whether or not fail safe function executed: ON or OFF ON: ETCS has failed - ST1 Brake pedal signal: ON or OFF ON: Brake pedal depressed - • • ES–51 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Intelligent Tester Display Measurement Item: Range (Display) Normal Condition*1 Diagnostic Note SYS GUARD JUDGE System guard: ON or OFF - ETCS service data OPN MALFUNCTION Open side malfunction: ON or OFF - ETCS service data THROTTLE POS Throttle position sensor: Min.: 0%, Max.: 100 % THROTTL IDL POS Whether or not throttle position sensor detecting idle: ON or OFF ON: Idling - THRTL REQ POS Throttle requirement position: Min.: 0 V, Max.: 5 V 0.5 to 1.0 V: Idling - THROTTLE POS Throttle position: Min.: 0 %, Max.: 100 % • • 10 to 22 %: Throttle fully closed 66 to 98 %: Throttle fully open • • • • • 0 %: Throttle fully closed 50 to 80 %: Throttle fully open • 42 to 62 %: Throttle fully closed 92 to 100 %: Throttle fully open • • Calculated value based on VTA1 Read value with ignition switch to the ON position (Do not start engine) Recognition value for throttle opening angle on ECM Read value with ignition switch to the ON position (Do not start engine) Calculated value based on VTA2 Read value with ignition switch to the ON position (Do not start engine) THROTTLE POS #2 Throttle position No. 2 sensor: Min.: 0 %, Max.: 100 % THROTTLE POS #1 Throttle position sensor No. 1 output voltage: Min.: 0 V, Max.: 5 V THROTTLE POS #2 Throttle position sensor No. 2 output voltage: Min.: 0 V, Max.: 5 V THRTL COMND VAL Throttle position command value: Min.: 0 V, Max.: 4.9804 V THROTTLE SSR #1 Throttle sensor opener position No. 1: Min.: 0 V, Max.: 4.9804 V - ETCS service data THROTTLE SSR #2 Throttle sensor opener position No. 2: Min.: 0 V, Max.: 4.9804 V - ETCS service data THRTL SSR #1 AD Throttle position sensor No. 1 output voltage (AD): Min.: 0 V, Max.: 4.9804 V 0.5 to 4.9 V Read value with ignition switch to the ON position (Do not start engine) THROTTLE MOT Whether or not throttle actuator control permitted: ON or OFF ON: Idling Read value with ignition switch to the ON position (Do not start engine) THROTTLE MOT Throttle actuator current: Min.: 0 A, Max.: 80 A 0 to 3.0 A: Idling - THROTTLE MOT Throttle actuator: Min.: 0 %, Max.: 100 % 0.5 to 40 %: Idling - THRTL MOT (OPN) Throttle actuator duty ratio (open): Min.: 0 %, Max.: 100 % 0 to 40 %: Idling ETCS service data THRTL MOT (CLS) Throttle actuator duty ratio (closed): Min.: 0 %, Max.: 100 % 0 to 40 %: Idling ETCS service data O2S B1 S2 Heated oxygen sensor output voltage for sensor 2: Min.: 0 V Max.: 1.275 V 0.1 to 0.9 V: Driving at 44 mph (70 km/h) Performing INJ VOL or A/F CONTROL function of ACTIVE TEST enables technician to check output voltage of sensor • • • • • • 0.5 to 1.1 V: Throttle fully closed 3.3 to 4.9 V: Throttle fully open Read value with ignition switch to the ON position (Do not start engine) 2.1 to 3.1 V: Throttle fully closed 4.6 to 5.0 V: Throttle fully open Read value with ignition switch to the ON position (Do not start engine) Read value with ignition switch to the ON position (Do not start engine) 0.5 to 4.9 V ES ES–52 Intelligent Tester Display 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Measurement Item: Range (Display) Normal Condition*1 Diagnostic Note Performing INJ VOL or A/F CONTROL function of ACTIVE TEST enables technician to check output voltage of sensor AFS B1 S1 A/F sensor output voltage for sensor 1: Min.: 0 V Max.: 7.999 V 2.8 to 3.8 V: Idling TOTAL FT #1 Total fuel trim value for fuel system: Min.: -0.5, Max.: 0.496 -0.2 to 0.2 SHORT FT #1 Short-term fuel trim: Min.: -100 %, Max.: 99.2 % -20 to 20 % Short-term fuel compensation used to maintain air-fuel ratio at stoichiometric air-fuel ratio LONG FT #1 Long-term fuel trim: Min.: -100 %, Max.: 99.2 % -20 to 20 % Overall fuel compensation carried out in long-term to compensate for a continual deviation of short-term fuel trim from central value ES - • • FUEL SYS #1 Fuel system status: OL or CL or OL DRIVE or OL FAULT or CL FAULT CL: Idling after warming up • • • O2FT B1 S2 Short-term fuel trim associated with sensor 2: Min.: -100 %, Max.: 99.2 % • AF FT B1 S1 Short-term fuel trim associated with sensor 1: Min.: 0, Max.: 1.999 • • Value less than 1 (0.000 to 0.999) =Lean Stoichiometric air-fuel ratio=1 Value greater than 1 (1.001 to 1.999) = Rich OL (Open Loop): Has not yet satisfied conditions to go closed loop CL (Closed Loop): Using A/F sensor as feedback for fuel control OL DRIVE: Open loop due to driving conditions (fuel enrichment) OL FAULT: Open loop due to detected system fault CL FAULT: Closed loop but A/ F sensor, which used for fuel control malfunctioning - - AFS B1 S1 A/F sensor current: Min.: -128 mA, Max.: 127.99 mA - - CAT TEMP B1S1 Estimated catalyst temperature (sensor 1): Min.: -40°C, Max.: 6,513.5°C - - CAT TEMP B1S2 Estimated catalyst temperature (sensor 2): Min.: -40°C, Max.: 6,513.5°C - - S O2S B1S2 Sub heated oxygen sensor impedance (sensor 2): Min.: 0 Ω, Max.: 21247.68 Ω - - INI COOL TEMP Engine coolant temperature at engine start: Min.: -40°C, Max.: 120°C Close to ambient air temperature - INI INTAKE TEMP Intake air temperature at engine start: Min.: -40°C, Max.: 120°C Close to ambient air temperature - INJ VOL Injection volume (Cylinder 1): Min.: 0 ml, Max.: 2.048 ml 0 to 0.15 ml: Idling STARTER SIG Starter switch (STSW) signal: ON or OFF ON: Cranking - PS SW Power steering signal: ON or OFF ON: Power steering operation - Quantity of fuel injection volume for 10 times ES–53 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Intelligent Tester Display Measurement Item: Range (Display) Normal Condition*1 Diagnostic Note PS SIGNAL Power steering signal (history): ON or OFF ON: When steering wheel first turned after battery terminals connected CTP SW Closed throttle position switch: ON or OFF • • A/C SIGNAL A/C signal: ON or OFF ON: A/C ON - PNP SW [NSW] PNP switch status: ON or OFF ON: P or N position - ELECT LOAD SIG Electrical load signal: ON or OFF ON: Headlights or defogger turned ON - STOP LIGHT SW Stop light switch: ON or OFF ON: Brake pedal depressed - +BM Whether or not electric throttle control system power inputted: ON or OFF ON: Ignition switch to the ON position and system normal - +BM VOLTAGE +BM voltage: Min.: 0, Max.: 19.2182 9 to 14 (V): Ignition switch to the ON position and system normal BATTERY VOLTAGE Battery voltage: Min.: 0 V, Max.: 65.535 V 9 to 14 V: Ignition switch to the ON position ACTUATOR POWER Actuator power supply: ON or OFF ON: Idling ATM PRESSURE Atmospheric pressure: Min.: 0 kPa, Max.: 255 kPa Approximately 100 kPa: Ignition switch to the ON position - EVAP (Purge) VSV Purge VSV status: ON or OFF - - FUEL PUMP / SPD Fuel pump status: ON or OFF VVT CTRL B1 VVT control (bank 1) status: ON or OFF - VACUUM PUMP Key-off EVAP system leak detection pump status: ON or OFF - Active Test support data EVAP VENT VAL Key-off EVAP system vent valve status: ON or OFF - Active Test support data FAN MOTOR Electric fan motor: ON or OFF TC/TE1 TC and CG (TE1) terminals of DLC3: ON or OFF - Active Test support data ENG SPEED #1 Engine rpm during No. 1 cylinder fuel cut: Min.: 0 rpm, Max.: 25,600 rpm - Output only when FUEL CUT #1 is performed using ACTIVE TEST ENG SPEED #2 Engine rpm during No. 2 cylinder fuel cut: Min.: 0 rpm, Max.: 25,600 rpm - Output only when FUEL CUT #2 is performed using ACTIVE TEST ENG SPEED #3 Engine rpm during No. 3 cylinder fuel cut: Min.: 0 rpm, Max.: 25,600 rpm - Output only when FUEL CUT #3 is performed using ACTIVE TEST ENG SPEED #4 Engine rpm during No. 4 cylinder fuel cut: Min.: 0 rpm, Max.: 25,600 rpm - Output only when FUEL CUT #4 is performed using ACTIVE TEST ENG SPEED ALL Average of engine rpm values during fuel cut of No. 1 to No. 4 cylinders: Min.: 0 rpm, Max.: 25,600 rpm - Output only when ACTIVE TEST is performed VVTL AIM ANGL#1*2 VVT aim angle: Min.: 0 %, Max.: 100 % ON: Throttle fully closed OFF: Throttle open - ETCS service data ETCS service data ON: Engine running ON: Electric fan motor operating 0 to 100 % Signal status usually ON until battery terminals disconnected Active Test support data - - VVT duty signal value during intrusive operation ES ES–54 Intelligent Tester Display ES 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Measurement Item: Range (Display) Normal Condition*1 Diagnostic Note VVT CHNG ANGL#1*2 VVT angle: Min.: 0°FR, Max.: 60°FR 0 to 56°FR Displacement angle during intrusive operation VVT OCV DUTY B1*2 VVT OCV operation duty: Min.: 0 %, Max.: 100 % 0 to 100 % Requested duty value for intrusive operation FC IDL Fuel cut idle: ON or OFF ON: Fuel cut operation FC IDL = "ON" when throttle valve fully closed and engine speed over 3,500 rpm FC TAU Fuel cut TAU (Fuel cut with a very light load): ON or OFF ON: Fuel cut operating Fuel cut being performed with a very light load to prevent incomplete engine combustion IGNITION Ignition counter: Min.: 0, Max.: 800 0 to 800 - CYL #1, #2, #3, #4 Misfire of cylinder 1 to 4: Min.: 0, Max.: 255 0 - CYL ALL All cylinders misfire: Min.: 0, Max.: 255 0 - MISFIRE RPM Engine speed when misfire occurs: Min.: 0 rpm, Max.: 6,375 rpm - - MISFIRE LOAD Engine load when misfire occurs: Min.: 0 g/rev, Max.: 3.98 g/rev - - MISFIRE MARGIN Margin to detect engine misfire: Min.: -100 %, Max.: 99.22 % #CODES Number of codes: Min.: 0, Max.: 255 CHECK MODE Check mode: ON or OFF SPD TEST Check mode result for vehicle speed sensor: COMPL or INCMPL - - MISFIRE TEST Check mode result for misfire monitor: COMPL or INCMPL - - OXS1 TEST Check mode result for HO2 sensor: COMPL or INCMPL - - A/F SSR TEST B1 Check mode result for air-fuel ratio sensor: COMPL or INCMPL - - MIL MIL status: ON or OFF ON: MIL ON - MIL ON RUN DIST MIL ON run distance: Min.: 0 km, Max.: 65,535 km Distance after DTC detected - MIL ON RUN TIME Running time from MIL ON: Min.: 0 minutes, Max.: 65,535 minutes Equivalent to running time after MIL ON - ENG RUN TIME Engine run time: Min.: 0 seconds, Max.: 65,535 seconds Time after engine start - TIME DTC CLEAR Time after DTC cleared: Min.: 0 minutes, Max.: 65,535 minutes Equivalent to time after DTCs erased - DIST DTC CLEAR Distance after DTC cleared: Min.: 0 km, Max.: 65,535 km Equivalent to drive distance after DTCs erased - WU CYC DTC CLEAR Warm-up cycle after DTC cleared: Min.: 0, Max.: 255 OBD CERT OBD requirement -100 to 99.22 % ON: Check mode ON OBD2 Misfire detecting margin Number of detected DTCs (See page ES-41) Number of warm-up cycles after DTC cleared - ES–55 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Intelligent Tester Display Measurement Item: Range (Display) Normal Condition*1 Diagnostic Note COMP MON Comprehensive component monitor: NOT AVL or AVAIL - - FUEL MON Fuel system monitor: NOT AVL or AVAIL - - MISFIRE MON Misfire monitor: NOT AVL or AVAIL - - O2S (A/FS) HTR O2S (A/FS) heater monitor: NOT AVL or AVAIL - - O2S (A/FS) MON O2S (A/FS) monitor: NOT AVL or AVAIL - - EVAP MON EVAP monitor: NOT AVL or AVAIL - - CAT MON Catalyst monitor: NOT AVL or AVAIL - - EGR ENA EGR monitor: UNABLE or ENABLE UNABLE - EGR CMPL EGR monitor: COMPL or INCMPL INCMPL - HTR ENA O2S (A/FS) heater monitor: UNABLE or ENABLE ENABLE - HTR CMPL O2S (A/FS) heater monitor: COMPL or INCMPL INCMPL - O2S (A/FS) ENA O2S (A/FS) monitor: UNABLE or ENABLE ENABLE - O2S (A/FS) CMPL O2S (A/FS) monitor: COMPL or INCMPL INCMPL - ACRF ENA A/C monitor: UNABLE or ENABLE UNABLE - ACRF CMPL A/C monitor: COMPL or INCMPL INCMPL - AIR ENA Secondary air injection system monitor: UNABLE or ENABLE UNABLE - AIR CMPL Secondary air injection system monitor: COMPL or INCMPL INCMPL - EVAP ENA EVAP monitor: UNABLE or ENABLE ENABLE - EVAP CMPL EVAP monitor: COMPL or INCMPL INCMPL - HCAT ENA Heated catalyst monitor: UNABLE or ENABLE UNABLE - HCAT CMPL Heated catalyst monitor: COMPL or INCMPL INCMPL - CAT ENA Catalyst monitor: UNABLE or ENABLE ENABLE - CAT CMPL Catalyst monitor: COMPL or INCMPL COMPL - MODEL CODE Identifying model code ACA3# - ENGINE TYPE Identifying engine type 2AZFE - CYLINDER NUMBER Identifying cylinder number: Min.: 0, Max.: 255 4 - TRANSMISSION Identifying transmission type 5AT or M/T - DESTINATION Identifying destination A (America) - MODEL YEAR Identifying model year: Min.: 1,900, Max.: 2,155 2007 - ES ES–56 Intelligent Tester Display SYSTEM 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Measurement Item: Range (Display) Identifying engine system Normal Condition*1 Diagnostic Note GASLIN (gasoline engine) - HINT: • *1: If no idling conditions are specified, the transmission gear selector lever should be in the N or P position, and the A/C switch and all accessory switches should be OFF. • *2: DATA LIST values are only displayed when performing the following ACTIVE TEST: VVT B1. For other ACTIVE TESTs, the DATA LIST value will be 0. 2. ACTIVE TEST HINT: Performing an ACTIVE TEST enables components including the relays, VSV (Vacuum Switching Valve) and actuators, to be operated without removing any parts. The ACTIVE TEST can be performed with the intelligent tester. Performing the ACTIVE TEST as the first step in troubleshooting is one method to shorten diagnostic time. DATA LIST can be displayed during ACTIVE TEST. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position. (c) Turn the tester on. (d) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST. (e) Perform the ACTIVE TEST by referring to the table below. ES ECM: Intelligent Tester Displays Test Details Control Ranges Diagnostic Notes • • INJ VOL Change injection volume Between -12.5 and 24.8 % • • • All injectors tested at same time Perform test at less than 3,000 rpm Injection volume can be changed in 0.1 % graduations within control range Perform test at less than 3,000 rpm A/F CONTROL enables checking and graphing of A/F (Air-Fuel Ratio) sensor and Heated Oxygen (HO2) sensor voltage outputs To conduct test, select following menu items: ACTIVE TEST / A/F CONTROL / USER DATA / AFS B1S1 and O2S B1S2; then press YES and ENTER followed by F4. A/F CONTROL Change injection volume Decrease by 12.5 % or increase by 24.8 % EVAP VSV (ALONE) Activate purge VSV control ON/OFF FUEL PUMP / SPD Activate fuel pump (C/OPN Relay) ON/OFF TC/TE1 Turn on and off TC and TE1 connection ON/OFF FC IDL PROHBT Prohibit idling fuel cut control ON/OFF - COOLING FAN Control electric cooling fan ON/OFF - • Test is possible when engine stopped • • ON: TC and TE1 connected OFF: TC and TE1 disconnected ES–57 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Intelligent Tester Displays Test Details Control Ranges ETCS OPEN SLOW Throttle actuator ON: Throttle valve opens slowly ETCS CLOSE SLOW Throttle actuator ON: Throttle valve closes slowly ETCS OPEN FAST Throttle actuator ON: Throttle valve opens fast ETCS CLOSE FAST Throttle actuator ON: Throttle valve closes fast Control VVT (bank 1) -128 to 127 % This value added to present OCV control duty 100 %: Maximum advance -100 %: Maximum retard VVT LINEAR B1 Diagnostic Notes Test is possible when following conditions met: • Engine stopped • Shift position in P • Fully depressing accelerator pedal (APP: 59° or more) • • Engine stall or rough idle when VVT actuator operated by 100 %. Test is possible while vehicle stopped and engine idling Test is possible while vehicle stopped and engine idling VVT CTRL B1 Control VVT (bank 1) -128 to 127 % VACUUM PUMP Leak detection pump ON/OFF - VENT VALVE Vent valve ON/OFF - IAC DUTY RATIO Active IMRV (Intake Manifold Runner Valve) motor -100% to 100% FUEL CUT #1 Cylinder #1 injector fuel cut ON/OFF FUEL CUT #2 Cylinder #2 injector fuel cut ON/OFF FUEL CUT #3 Cylinder #3 injector fuel cut ON/OFF FUEL CUT #4 Cylinder #4 injector fuel cut ON/OFF COMPRESS CHECK All cylinder injector fuel cut and ignition stop ON/OFF • A130534 • • • When the duty ratio is -100% IMRV closes When the duty ratio is 100% IMRV opens Test is possible while vehicle stopped and engine idling ON: All cylinder injector fuel cut and ignition stop * HINT: *: When cranking the engine, each cylinder measures the engine rpm. In this ACTIVE TEST, the fuel and ignition of all cylinders is cut, and cranking occurs for approximately 10 seconds. Then, each cylinder measures the engine rpm. If a cylinder's engine rpm is higher than the others, that cylinder's compression pressure is compared to the others, and whether or not the compression pressure is low can be determined. 1. Warm up the engine. 2. Turn the ignition switch off. 3. Connect the intelligent tester to the DLC3. 4. Turn the ignition switch to the ON position and turn the intelligent tester on. 5. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / COMPRESS CHECK. HINT: If the results are not displayed normally, select the display items from the DATA LIST before performing the ACTIVE TEST. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / USER DATA / ENG SPEED #1 and ENG SPEED #2, ENG SPEED #3, ENG SPEED #4 (Press the YES button to change the ENG SPEED #1 to #4) and then press the ENTER button. ES ES–58 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES A130535 6. While the engine is not running, press the RIGHT or LEFT button to change the COMPRESS CHECK to ON. HINT: After performing the above procedure, the ACTIVE TEST's COMPRESS CHECK will start. Fuel injection for all cylinders is prohibited, and each cylinder's engine rpm measurement will enter standby mode. 7. Fully open the throttle. 8. Crank the engine for about 10 seconds. 9. Monitor the engine speed (ENG SPEED #1 to #4) displayed on the tester. HINT: At first, the tester's display will show each cylinder's engine rpm measurement to be extremely high. After approximately 10 seconds of engine cranking, each cylinder's engine rpm measurement will change to the actual engine rpm. NOTICE: • After the ACTIVE TEST's COMPRESS CHECK is turned ON, it will automatically turn off after 255 seconds. • When the COMPRESS CHECK test is OFF and the engine is cranked, the engine will start. • If the COMPRESS CHECK test needs to be performed after it is turned ON and performed once, press EXIT to return to the ACTIVE TEST menu screen. Then perform the COMPRESS CHECK test again. • Use a fully-charged battery. 3. SYSTEM CHECK HINT: Performing a SYSTEM CHECK enables the system, which consists of multiple actuators, to be operated without removing any parts. In addition, it can show whether or not any DTCs are set, and can detect potential malfunctions in the system. The SYSTEM CHECK can be performed with the intelligent tester. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position. (c) Turn the tester on. (d) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK. (e) Perform the SYSTEM CHECK by referring to the table below. ECM: Intelligent Tester Display Test Detail Recommended Fuel Temperature Diagnostic Note • EVAP SYS CHECK (AUTO OPERATION) Perform 5 steps in order to operate EVAP key-off monitor automatically EVAP SYS CHECK (MANUAL OPERATION) Perform 5 steps in order to operate EVAP key-off monitor manually 35°C (95°F) or less • • 35°C (95°F) or less • If no DTCs in PENDING CODE after performing this test, system functioning normally Refer to EVAP system Used to detect malfunctioning parts Refer to EVAP system 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–59 DIAGNOSTIC TROUBLE CODE CHART HINT: Parameters listed in the chart may be different than your readings depending on the type of instrument and other factors. If any DTCs are displayed during a check mode DTC check, check the circuit for the DTCs listed in the table below. For details of each DTC, refer to the page indicated. SFI SYSTEM: DTC No. Detection Item Trouble Area MIL Memory Camshaft Position "A" Actuator Circuit (Bank 1) 1. Open or short in Oil Control Valve (OCV) circuit 2. OCV 3. ECM Comes on P0011 Camshaft Position "A" - Timing OverAdvanced or System Performance (Bank 1) 1. Valve timing 2. OCV 3. OCV filter 4. Camshaft timing gear assembly 5. ECM Comes on DTC stored ES-69 P0012 Camshaft Position "A" - Timing OverRetarded (Bank 1) Same as DTC P0011 Comes on DTC stored ES-69 P0016 Crankshaft Position Camshaft Position Correlation (Bank 1 Sensor A) 1. Mechanical system (Timing chain has jumped tooth or chain stretched) 2. ECM Comes on DTC stored ES-75 P0031 Oxygen (A/F) Sensor Heater Control Circuit Low (Bank 1 Sensor 1) 1. Open in Air-Fuel Ratio (A/F) sensor heater circuit 2. A/F sensor heater (sensor 1) 3. Engine room J/B (EFI relay) 4. ECM Comes on DTC stored ES-77 P0032 Oxygen (A/F) Sensor Heater Control Circuit High (Bank 1 Sensor 1) 1. Short in A/F sensor heater circuit 2. A/F sensor heater (sensor 1) 3. Engine room J/B (EFI relay) 4. ECM Comes on DTC stored ES-77 P0037 Oxygen Sensor Heater Control Circuit Low (Bank 1 Sensor 2) 1. Open in Heated Oxygen (HO2) sensor heater circuit 2. HO2 sensor heater (sensor 2) 3. Engine room J/B (EFI relay) 4. ECM Comes on DTC stored ES-83 P0038 Oxygen Sensor Heater Control Circuit High (Bank 1 Sensor 2) 1. Short in HO2 sensor heater circuit 2. HO2 sensor heater (sensor 2) 3. Engine room J/B (EFI relay) 4. ECM Comes on DTC stored ES-83 P0010 DTC stored See page ES-65 ES ES–60 DTC No. ES 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Detection Item Trouble Area MIL Memory See page P0100 Mass or Volume Air Flow Circuit 1. Open or short in Mass Air Flow (MAF) meter circuit 2. MAF meter 3. ECM Comes on DTC stored ES-89 P0101 Mass Air Flow Circuit Range / Performance Problem 1. MAF meter 2. Air induction system 3. PCV hose connections Comes on DTC stored ES-96 P0102 Mass or Volume Air Flow Circuit Low Input 1. Open or short in MAF meter circuit 2. MAF meter 3. ECM Comes on DTC stored ES-89 P0103 Mass or Volume Air Flow Circuit High Input 1. Open or short in MAF meter circuit 2. MAF meter 3. ECM Comes on DTC stored ES-89 P0110 Intake Air Temperature Circuit Malfunction 1. Open or short in Intake Air Temperature (IAT) sensor circuit 2. IAT sensor (built into MAF meter) 3. ECM Comes on DTC stored ES-99 P0111 Intake Air Temperature Sensor Gradient Too High Mass air flow meter assembly Comes on DTC stored ES-105 P0112 Intake Air Temperature Circuit Low Input 1. Short in IAT sensor circuit 2. IAT sensor (built into MAF meter) 3. ECM Comes on DTC stored ES-99 P0113 Intake Air Temperature Circuit High Input 1. Open in IAT sensor circuit 2. IAT sensor (built into MAF meter) 3. ECM Comes on DTC stored ES-99 P0115 Engine Coolant Temperature Circuit Malfunction 1. Open or short in Engine Coolant Temperature (ECT) sensor circuit 2. ECT sensor 3. ECM Comes on DTC stored ES-108 P0116 Engine Coolant Temperature Circuit Range / Performance Problem 1. Thermostat 2. ECT sensor Comes on DTC stored ES-114 P0117 Engine Coolant Temperature Circuit Low Input 1. Short in ECT sensor circuit 2. ECT sensor 3. ECM Comes on DTC stored ES-108 P0118 Engine Coolant Temperature Circuit High Input 1. Open in ECT sensor circuit 2. ECT sensor 3. ECM Comes on DTC stored ES-108 P0120 Throttle / Pedal Position Sensor / Switch "A" Circuit Malfunction 1. Throttle Position (TP) sensor (built into throttle body) 2. ECM Comes on DTC stored ES-117 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Trouble Area MIL Memory ES–61 DTC No. Detection Item P0121 Throttle / Pedal Position Sensor / Switch "A" Circuit Range / Performance Problem TP sensor (built into throttle body) Comes on DTC stored See page ES-124 P0122 Throttle / Pedal Position Sensor / Switch "A" Circuit Low Input 1. TP sensor (built into throttle body) 2. Short in VTA1 circuit 3. Open in VC circuit 4. ECM Comes on DTC stored ES-117 P0123 Throttle / Pedal Position Sensor / Switch "A" Circuit High Input 1. TP sensor (built into throttle body) 2. Open in VTA1 circuit 3. Open in E2 circuit 4. Short between VC and VTA1 circuits 5. ECM Comes on DTC stored ES-117 P0125 Insufficient Coolant Temperature for Closed Loop Fuel Control 1. Cooling system 2. ECT sensor 3. Thermostat Comes on DTC stored ES-126 P0128 Coolant Thermostat (Coolant Temperature Below Thermostat Regulating Temperature) 1. Thermostat 2. Cooling system 3. ECT sensor 4. ECM Comes on DTC stored ES-129 P0136 Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 2) 1. Open or short in HO2 sensor (sensor 2) circuit 2. HO2 sensor (sensor 2) 3. HO2 sensor heater (sensor 2) 4. Air Fuel Ratio (A/F) sensor (sensor 1) 5. Engine room J/B (EFI relay) 6. Gas leakage from exhaust system Comes on DTC stored ES-132 P0137 Oxygen Sensor Circuit Low Voltage (Bank 1 Sensor 2) 1. Open in HO2 sensor (sensor 2) circuit 2. HO2 sensor (sensor 2) 3. HO2 sensor heater (sensor 2) 4. Engine room J/B (EFI relay) 5. Gas leakage from exhaust system Comes on DTC stored ES-132 P0138 Oxygen Sensor Circuit High Voltage (Bank 1 Sensor 2) 1. Short in HO2 sensor (sensor 2) circuit 2. HO2 sensor (sensor 2) 3. ECM internal circuit malfunction Comes on DTC stored ES-132 ES ES–62 DTC No. 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Detection Item Trouble Area MIL Memory See page P0141 Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 2) 1. Open or short in HO2 sensor heater circuit 2. HO2 sensor heater (sensor 2) 3. Engine room J/B (EFI relay) 4. ECM Comes on DTC stored ES-83 P0171 System Too Lean (Bank 1) 1. Air induction system 2. Injector blockage 3. MAF meter 4. ECT sensor 5. Fuel pressure 6. Gas leakage from exhaust system 7. Open or short in A/ F sensor (sensor 1) circuit 8. A/F sensor (sensor 1) 9. A/F sensor heater (sensor 1) 10. Engine room J/B (EFI relay) 11. A/F sensor heater and EFI relay circuits 12. PCV valve and hose 13. PCV hose connections 14. ECM Comes on DTC stored ES-150 P0172 System Too Rich (Bank 1) 1. Injector leakage or blockage 2. MAF meter 3. ECT sensor 4. Ignition system 5. Fuel pressure 6. Gas leakage from exhaust system 7. Open or short in A/ F sensor (sensor 1) circuit 8. A/F sensor (sensor 1) 9. A/F sensor heater (sensor 1) 10. Engine room J/B (EFI relay) 11. A/F sensor heater and EFI relay circuits 12. ECM Comes on DTC stored ES-150 P0220 Throttle / Pedal Position Sensor / Switch "B" Circuit 1. TP sensor (built into throttle body) 2. ECM Comes on DTC stored ES-117 P0222 Throttle / Pedal Position Sensor / Switch "B" Circuit Low Input 1. TP sensor (built into throttle body) 2. Short in VTA2 circuit 3. Open in VC circuit 4. ECM Comes on DTC stored ES-117 ES 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. Detection Item Trouble Area MIL Memory ES–63 See page P0223 Throttle / Pedal Position Sensor / Switch "B" Circuit High Input 1. TP sensor (built into throttle body) 2. Open in VTA2 circuit 3. Open in E2 circuit 4. Short between VC and VTA2 circuits 5. ECM Comes on DTC stored ES-117 P0300 Random / Multiple Cylinder Misfire Detected 1. Open or short in engine wire harness 2. Connector connection 3. Vacuum hose connection 4. Ignition system 5. Injector 6. Fuel pressure 7. MAF meter 8. ECT sensor 9. Compression pressure 10. Valve clearance 11. Valve timing 12. PCV valve and hose 13. PCV hose connections 14. Air induction system 15. ECM Comes on/Blinks *1 DTC stored ES-159 ES P0301 Cylinder 1 Misfire Detected Same as DTC P0300 Comes on/Blinks *1 DTC stored ES-159 P0302 Cylinder 2 Misfire Detected Same as DTC P0300 Comes on/Blinks *1 DTC stored ES-159 P0303 Cylinder 3 Misfire Detected Same as DTC P0300 Comes on/Blinks *1 DTC stored ES-159 P0304 Cylinder 4 Misfire Detected Same as DTC P0300 Comes on/Blinks *1 DTC stored ES-159 P0327 Knock Sensor 1 Circuit Low Input (Bank 1 or Single Sensor) 1. Short in knock sensor circuit 2. Knock sensor 3. ECM Comes on DTC stored ES-172 P0328 Knock Sensor 1 Circuit High Input (Bank 1 or Single Sensor) 1. Open in knock sensor circuit 2. Knock sensor 3. ECM Comes on DTC stored ES-172 P0335 Crankshaft Position Sensor "A" Circuit 1. Open or short in Crankshaft Position (CKP) sensor circuit 2. CKP sensor 3. CKP sensor plate 4. ECM Comes on DTC stored ES-177 P0339 Crankshaft Position Sensor "A" Circuit Intermittent Same as DTC P0335 - DTC stored ES-177 P0340 Camshaft Position Sensor "A" Circuit (Bank 1 or Single Sensor) 1. Open or short in Camshaft Position (CMP) sensor circuit 2. CMP sensor 3. Camshaft 4. Jumped tooth of timing chain 5. ECM Comes on DTC stored ES-183 ES–64 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. Detection Item Trouble Area P0351 Ignition Coil "A" Primary / Secondary Circuit 1. Ignition system 2. Open or short in IGF1 or IGT circuit (1 to 4) between ignition coil with igniter and ECM 3. No. 1 to No. 4 ignition coils with igniters 4. ECM Comes on DTC stored ES-188 P0352 Ignition Coil "B" Primary / Secondary Circuit Same as DTC P0351 Comes on DTC stored ES-188 P0353 Ignition Coil "C" Primary / Secondary Circuit Same as DTC P0351 Comes on DTC stored ES-188 P0354 Ignition Coil "D" Primary / Secondary Circuit Same as DTC P0351 Comes on DTC stored ES-188 P0420 Catalyst System Efficiency Below Threshold (Bank 1) 1. Front exhaust pipe (with Three-Way Catalytic Converter) 2. Gas leakage from exhaust system 3. A/F sensor (sensor 1) 4. HO2 sensor (sensor 2) Comes on DTC stored ES-196 P043E Evaporative Emission System Reference Orifice Clog Up 1. Canister pump module (Reference orifice, leak detection pump, vent valve) 2. Connector/wire harness (Canister pump module ECM) 3. EVAP system hose (pipe from air inlet port to canister pump module, canister filter, fuel tank vent hose) 4. ECM Comes on DTC stored ES-203 P043F Evaporative Emission System Reference Orifice High Flow Same as DTC P043E Comes on DTC stored ES-203 P0441 Evaporative Emission Control System Incorrect Purge Flow 1. Purge VSV 2. Connector/wire harness (Purge VSV ECM) 3. Canister pump module 4. Leakage from EVAP system 5. Leakage from EVAP line (Purge VSV Intake manifold) 6. ECM Comes on DTC stored ES-208 P0450 Evaporative Emission Control System Pressure Sensor / Switch 1. Canister pump module 2. EVAP system hose (pipe from air inlet port to canister pump module, canister filter, fuel tank vent hose) 3. ECM Comes on DTC stored ES-215 ES MIL Memory See page 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MIL Memory ES–65 DTC No. Detection Item Trouble Area P0451 Evaporative Emission Control System Pressure Sensor Range / Performance 1. Canister pump module 2. Connector/wire harness (Canister pump module ECM) 3. EVAP system hose (pipe from air inlet port to canister pump module, canister filter, fuel tank vent hose) 4. ECM Comes on DTC stored See page ES-215 P0452 Evaporative Emission Control System Pressure Sensor / Switch Low Input Same as DTC P0451 Comes on DTC stored ES-215 P0453 Evaporative Emission Control System Pressure Sensor / Switch High Input Same as DTC P0451 Comes on DTC stored ES-215 P0455 Evaporative Emission Control System Leak Detected (Gross Leak) 1. Fuel cap (loose) 2. Leakage from EVAP line (Canister Fuel tank) 3. Leakage from EVAP line (Purge VSV Canister) 4. Canister pump module 5. Leakage from fuel tank 6. Leakage from canister Comes on DTC stored ES-224 P0456 Evaporative Emission Control System Leak Detected (Very Small Leak) Same as DTC P0455 Comes on DTC stored ES-224 P0500 Vehicle Speed Sensor "A" 1. Open or short in speed signal circuit 2. Vehicle speed sensor 3. Combination meter 4. ECM 5. Skid control ECU Comes on DTC stored ES-229 P0504 Brake Switch "A" / "B" Correlation 1. Short in stop light switch signal circuit 2. STOP fuse 3. IGN fuse 4. Stop light switch 5. ECM - DTC stored ES-234 P0505 Idle Control System Malfunction 1. ETCS (Electronic Throttle Control System) 2. Air induction system 3. PCV hose connections 4. ECM Comes on DTC stored ES-237 ES ES–66 DTC No. 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Detection Item Trouble Area MIL Memory See page P050A Cold Start Idle Air Control System Performance 1. Throttle body assembly 2. MAF meter 3. Air induction system 4. PCV hose connections 5. VVT system 6. Air cleaner filter element 7. ECM Comes on DTC stored ES-241 P050B Cold Start Ignition Timing Performance Same as DTC P050A Comes on DTC stored ES-241 P0560 System Voltage 1. Open in back up power source circuit 2. Battery 3. Battery terminals 4. EFI No. 1 fuse 5. ECM Comes on DTC stored ES-247 P0604 Internal Control Module Random Access Memory (RAM) Error ECM Comes on DTC stored ES-251 P0606 ECM / PCM Processor ECM Comes on DTC stored ES-251 P0607 Control Module Performance ECM Comes on DTC stored ES-251 P0617 Starter Relay Circuit High 1. Park/Neutral Position (PNP) switch 2. ST relay circuit 3. Ignition switch 4. ECM Comes on DTC stored ES-253 P0630 VIN not Programmed or Mismatch - ECM / PCM ECM Comes on DTC stored ES-259 P0657 Actuator Supply Voltage Circuit / Open ECM Comes on DTC stored ES-251 P0724 Brake Switch "B" Circuit High 1. Short in stop light switch circuit 2. Stop light switch 3. ECM Comes on DTC stored ES-261 P2004 Intake Manifold Runner Control Stuck Open (Bank 1) 1. Intake manifold runner valve (IMRV) motor circuit 2. IMRV motor 3. IMRV position sensor 4. IMRV 5. ECM Comes on DTC stored ES-264 P2006 Intake Manifold Runner Control Stuck Closed (Bank 1) Same as DTC P2004 Comes on DTC stored ES-264 P2009 Intake Manifold Runner Control Circuit Low (Bank 1) 1. Open in IMRV motor circuit 2. IMRV motor 3. ECM Comes on DTC stored ES-270 P2010 Intake Manifold Runner Control Circuit High (Bank 1) 1. Short in IMRV motor circuit 2. IMRV motor 3. ECM Comes on DTC stored ES-270 ES 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. Detection Item Trouble Area MIL Memory ES–67 See page P2014 Intake Manifold Runner Position Sensor / Switch Circuit (Bank 1) 1. Open or short in IMRV position sensor circuit 2. IMRV position sensor 3. ECM Comes on DTC stored ES-275 P2016 Intake Manifold Runner Position Sensor / Switch Circuit Low (Bank 1) Same as DTC P2014 Comes on DTC stored ES-275 P2017 Intake Manifold Runner Position Sensor / Switch Circuit High (Bank 1) Same as DTC P2014 Comes on DTC stored ES-275 P2102 Throttle Actuator Control Motor Circuit Low 1. Open in throttle actuator circuit 2. Throttle actuator 3. ECM Comes on DTC stored ES-280 P2103 Throttle Actuator Control Motor Circuit High 1. Short in throttle actuator circuit 2. Throttle actuator 3. Throttle valve 4. Throttle body assembly 5. ECM Comes on DTC stored ES-280 P2111 Throttle Actuator Control System Stuck Open 1. Throttle actuator 2. Throttle body assembly 3. Throttle valve Comes on DTC stored ES-285 P2112 Throttle Actuator Control System Stuck Closed Same as DTC P2111 Comes on DTC stored ES-285 P2118 Throttle Actuator Control Motor Current Range / Performance 1. Open in ETCS power source circuit 2. Battery 3. Battery terminals 4. ETCS fuse 5. ECM Comes on DTC stored ES-288 P2119 Throttle Actuator Control Throttle Body Range / Performance 1. ETCS 2. ECM Comes on DTC stored ES-295 P2120 Throttle / Pedal Position Sensor / Switch "D" Circuit 1. Accelerator Pedal Position (APP) sensor 2. ECM Comes on DTC stored ES-298 P2121 Throttle / Pedal Position Sensor / Switch "D" Circuit Range / Performance 1. APP sensor 2. ECM Comes on DTC stored ES-305 P2122 Throttle / Pedal Position Sensor / Switch "D" Circuit Low Input 1. APP sensor 2. Open in VCP1 circuit 3. Open or ground short in VPA circuit 4. ECM Comes on DTC stored ES-298 P2123 Throttle / Pedal Position Sensor / Switch "D" Circuit High Input 1. APP sensor 2. Open in EPA circuit 3. ECM Comes on DTC stored ES-298 P2125 Throttle / Pedal Position Sensor / Switch "E" Circuit 1. APP sensor 2. ECM Comes on DTC stored ES-298 ES ES–68 DTC No. 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Detection Item Trouble Area MIL Memory See page P2127 Throttle / Pedal Position Sensor / Switch "E" Circuit Low Input 1. APP sensor 2. Open in VCP2 circuit 3. Open or ground short in VPA2 circuit 4. ECM Comes on DTC stored ES-298 P2128 Throttle / Pedal Position Sensor / Switch "E" Circuit High Input 1. APP sensor 2. Open in EPA2 circuit 3. ECM Comes on DTC stored ES-298 P2135 Throttle / Pedal Position Sensor / Switch "A" / "B" Voltage Correlation 1. Short between VTA1 and VTA2 circuits 2. TP sensor (built into throttle body) 3. ECM Comes on DTC stored ES-117 P2138 Throttle / Pedal Position Sensor / Switch "D" / "E" Voltage Correlation 1. Short between VPA and VPA2 circuits 2. APP sensor 3. ECM Comes on DTC stored ES-298 P2195 Oxygen (A/F) Sensor Signal Stuck Lean (Bank 1 Sensor 1) 1. Open or short in A/ F sensor (sensor 1) circuit 2. A/F sensor (sensor 1) 3. A/F sensor heater (sensor 1) 4. Engine room J/B (EFI relay) 5. A/F sensor heater and EFI relay circuits 6. ECM Comes on DTC stored ES-308 P2196 Oxygen (A/F) Sensor Signal Stuck Rich (Bank 1 Sensor 1) Same as DTC P2195 Comes on DTC stored ES-308 P2237 Oxygen (A/F) Sensor Pumping Current Circuit / Open (Bank 1 Sensor 1) 1. Open or short in A/ F sensor (sensor 1) circuit 2. A/F sensor (sensor 1) 3. ECM Comes on DTC stored ES-322 P2238 Oxygen (A/F) Sensor Pumping Current Circuit Low (Bank 1 Sensor 1) 1. Open or short in A/ F sensor (sensor 1) circuit 2. A/F sensor (sensor 1) 3. ECM Comes on DTC stored ES-322 P2239 Oxygen (A/F) Sensor Pumping Current Circuit High (Bank 1 Sensor 1) 1. Open or short in A/ F sensor (sensor 1) circuit 2. A/F sensor (sensor 1) 3. ECM Comes on DTC stored ES-322 P2252 Oxygen (A/F) Sensor Reference Ground Circuit Low (Bank 1 Sensor 1) 1. Open or short in A/ F sensor (sensor 1) circuit 2. A/F sensor (sensor 1) 3. ECM Comes on DTC stored ES-322 ES 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MIL Memory ES–69 DTC No. Detection Item Trouble Area P2253 Oxygen (A/F) Sensor Reference Ground Circuit High (Bank 1 Sensor 1) 1. Open or short in A/ F sensor (sensor 1) circuit 2. A/F sensor (sensor 1) 3. ECM Comes on DTC stored See page ES-322 P2401 Evaporative Emission Leak Detection Pump Stuck OFF 1. Canister pump module (Reference orifice, leak detection pump, vent valve) 2. Connector/wire harness (Canister pump module ECM) 3. EVAP system hose (pipe from air inlet port to canister pump module, canister filter, fuel tank vent hose) 4. ECM Comes on DTC stored ES-203 ES P2402 Evaporative Emission Leak Detection Pump Stuck ON Same as DTC P2401 Comes on DTC stored ES-203 P2419 Evaporative Emission System Switching Valve Control Circuit Low 1. Canister pump module (Reference orifice, leak detection pump, vent valve) 2. Connector/wire harness (Canister pump module ECM) 3. EVAP system hose (pipe from air inlet port to canister pump module, canister filter, fuel tank vent hose) 4. ECM Comes on DTC stored ES-203 P2420 Evaporative Emission System Switching Valve Control Circuit High 1. Canister pump module (Reference orifice, leak detection pump, vent valve) 2. Connector/wire harness (Canister pump module ECM) 3. ECM Comes on DTC stored ES-330 P2610 ECM / PCM Internal Engine Off Timer Performance ECM Comes on DTC stored ES-334 P2A00 A/F Sensor Circuit Slow Response (Bank 1 Sensor 1) 1. Open or short in A/ F sensor circuit 2. A/F sensor 3. ECM Comes on DTC stored ES-337 *1: Blinks when terrible misfire is detected. ES–70 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0010 Camshaft Position "A" Actuator Circuit (Bank 1) DESCRIPTION ES The Variable Valve Timing (VVT) system includes the ECM, OCV and VVT controller. The ECM sends a target duty-cycle control signal to the OCV. This control signal regulates the oil pressure applied to the VVT controller. Camshaft timing control is performed according to engine operating conditions such as the intake air volume, throttle valve position and engine coolant temperature. The ECM controls the OCV, based on the signals transmitted by several sensors. The VVT controller regulates the intake camshaft angle using oil pressure through the OCV. As a result, the relative positions of the camshaft and crankshaft are optimized, the engine torque and fuel economy improve, and the exhaust emissions decrease under overall driving conditions. The ECM detects the actual intake valve timing using signals from the camshaft and crankshaft position sensors, and performs feedback control. This is how the target intake valve timing is verified by the ECM. ECM Crankshaft Position Sensor Duty Control Target Valve Timing MAF Meter Throttle Position Sensor Feedback ECT Sensor Correction Camshaft Timing Oil Control Valve (OCV) Vehicle Speed Signal Actual Valve Timing Camshaft Position Sensor A103843E08 DTC No. P0010 DTC Detection Condition Open or short in OCV circuit (1 trip detection logic) HINT: This DTC relates to the Oil Control Valve (OCV). Trouble Area • • • Open or short in OCV circuit OCV ECM 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–71 MONITOR DESCRIPTION The ECM optimizes the valve timing using the VVT system to control the intake camshaft. The VVT system includes the ECM, the OCV and the VVT controller. The ECM sends a target duty-cycle control signal to the OCV. This control signal regulates the oil pressure supplied to the VVT controller. The VVT controller can advance or retard the intake camshaft. After the ECM sends the target duty-cycle control signal to the OCV, the ECM monitors the OCV current to establish an actual duty-cycle. The ECM determines the existence of a malfunction and sets the DTC when the actual duty-cycle ratio varies from the target duty-cycle ratio. MONITOR STRATEGY Related DTCs P0010: VVT OCV range check Required Sensors/Components (Main) VVT OCV Required Sensors/Components (Related) - Frequency of Operation Continuous Duration 1 second MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present None All of the following conditions are met - Starter OFF Ignition switch ON Time after ignition switch OFF to ON position 0.5 seconds or more TYPICAL MALFUNCTION THRESHOLDS One of the following conditions is met - A. All of the following conditions are met - Battery voltage 11 to 13 V Target duty ratio Less than 70 % Output signal duty ratio 100 % B. All of the following conditions are met - Battery voltage 13 V or more Target duty ratio Less than 80 % Output signal duty ratio 100 % C. Both of the following conditions is met - Current cut status Not cut Output signal duty ratio 3 % or less COMPONENT OPERATING RANGE VVT OCV duty ratio 3 to 100 % ES ES–72 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM C32 Camshaft Timing Oil Control Valve (OCV) 100 1 C24 123 2 C24 OC1+ OC1- ES A132330E01 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the airfuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 PERFORM ACTIVE TEST USING INTELLIGENT TESTER (OPERATE OCV) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Start the engine and turn the tester ON. Warm up the engine. On the tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VVT CTRL B1. (e) Check the engine speed while operating the Oil Control Valve (OCV) using the tester. OK Tester Operation Specified Condition OCV OFF Normal engine speed OCV ON Engine idles roughly or stalls (soon after OCV switched from OFF to ON) NG OK CHECK FOR INTERMITTENT PROBLEMS Go to step 2 ES–73 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2 INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Disconnect the C32 OCV connector. (b) Measure the resistance between the terminals of the OCV. Standard resistance: 6.9 to 7.9 Ω at 20°C (68°F) (c) Reconnect the OCV connector. NG REPLACE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY ES A095415E03 OK 3 CHECK HARNESS AND CONNECTOR (OCV - ECM) (a) Disconnect the C32 OCV connector. (b) Disconnect the C24 ECM connector. (c) Measure the resistance between the terminals of the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side: OCV Connector Tester Connection C32 OC1+ OC1Front View C24 Specified Condition C32-1 (OC1+) - C24-100 (OC1+) Below 1 Ω C32-2 (OC1-) - C24-123 (OC1-) Below 1 Ω Standard resistance (Check for short) ECM Connector Tester Connection Specified Condition C32-1 (OC1+) or C24-100 (OC1+) - Body ground 10 kΩ or higher C32-2 (OC1-) or C24-123 (OC1-) - Body ground 10 kΩ or higher (d) Reconnect the OCV connector. (e) Reconnect the ECM connector. NG OC1+ Front View OC1A106380E10 OK REPLACE ECM REPAIR OR REPLACE HARNESS OR CONNECTOR ES–74 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0011 Camshaft Position "A" - Timing Over-Advanced or System Performance (Bank 1) DTC P0012 Camshaft Position "A" - Timing Over-Retarded (Bank 1) DESCRIPTION ES The VVT system includes the ECM, Oil Control Valve (OCV) and VVT controller. The ECM sends a target duty-cycle control signal to the OCV. This control signal regulates the oil pressure applied to the VVT controller. Camshaft timing control is performed according to engine operating conditions such as the intake air volume, throttle valve position and engine coolant temperature. The ECM controls the OCV, based on the signals transmitted by several sensors. The VVT controller regulates the intake camshaft angle using oil pressure through the OCV. As a result, the relative positions of the camshaft and crankshaft are optimized, the engine torque and fuel economy improve, and the exhaust emissions decrease under overall driving conditions. The ECM detects the actual intake valve timing using signals from the camshaft and crankshaft position sensors, and performs feedback control. This is how the target intake valve timing is verified by the ECM. ECM Crankshaft Position Sensor MAF Meter Duty Control Target Valve Timing Throttle Position Sensor Feedback ECT Sensor Correction Camshaft Timing Oil Control Valve (OCV) Vehicle Speed Signal Camshaft Position Sensor Actual Valve Timing A103843E08 ES–75 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. DTC Detection Conditions Trouble Areas P0011 Advanced camshaft timing: With warm engine and engine speed of between 550 rpm and 4,000 rpm, all conditions (1), (2) and (3) are met (1 trip detection logic): 1. Difference between target and actual intake valve timings more than 5°CA (Crankshaft Angle) for 4.5 seconds 2. Current intake valve timing fixed (timing changes less than 5°CA in 5 seconds) 3. Variations in VVT controller timing more than 19°CA of maximum delayed timing (malfunction in advance timing) • • • • • Valve timing OCV OCV filter Camshaft timing gear assembly ECM P0012 Retarded camshaft timing: With warm engine and engine speed of between 550 rpm and 4,000 rpm, all conditions (1), (2) and (3) are met (2 trip detection logic): 1. Difference between target and actual intake valve timings more than 5°CA (Crankshaft Angle) for 4.5 seconds 2. Current intake valve timing fixed (timing changes less than 5°CA in 5 seconds) 3. Variations in VVT controller timing 19°CA or less of maximum delayed timing (malfunction in retarded timing) • • • • • Valve timing OCV OCV filter Camshaft timing gear assembly ECM MONITOR DESCRIPTION The ECM optimizes the intake valve timing using the VVT (Variable Valve Timing) system to control the intake camshaft. The VVT system includes the ECM, the Oil Control Valve (OCV) and the VVT controller. The ECM sends a target duty-cycle control signal to the OCV. This control signal regulates the oil pressure supplied to the VVT controller. The VVT controller can advance or retard the intake camshaft. If the difference between the target and actual intake valve timings is large, and changes in the actual intake valve timing are small, the ECM interprets this as the VVT controller stuck malfunction and sets a DTC. Example: A DTC is set when the following conditions 1, 2 and 3 are met: (a)The difference between the target and actual intake valve timings is more than 5°CA (Crankshaft Angle) and the condition continues for more than 4.5 seconds. (b)It takes 5 seconds or more to change the valve timing by 5°CA. (c) After above conditions 1 and 2 are met, the OCV is forcibly activated during 10 seconds. DTC P0011 (Advanced Cam Timing) is subject to 1 trip detection logic. DTC P0012 (Retarded Cam Timing) is subject to 2 trip detection logic. These DTCs indicate that the VVT controller cannot operate properly due to OCV malfunctions or the presence of foreign objects in the OCV. The monitor will run if all of the following conditions are met: – The engine is warm (the engine coolant temperature is 75°C (167°F) or more). – The vehicle has been driven at more than 40 mph (64 km/h) for 3 minutes. – The engine has idled for 3 minutes. MONITOR STRATEGY Related DTCs P0011: Advanced camshaft timing P0012: Retarded camshaft timing Required Sensors/Components (Main) VVT OCV and VVT Actuator Required Sensors/Components (Related) Crankshaft position sensor, camshaft position sensor and engine coolant temperature sensor Frequency of Operation Once per driving cycle Duration Within 10 seconds ES ES–76 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MIL Operation Advanced camshaft timing: Immediate Retarded camshaft timing: 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS P0100 - P0103 (MAF meter) P0115 - P0118 (ECT sensor) P0125 (Insufficient ECT for closed loop) P0335 (CKP sensor) P0340 (CMP sensor) P0351 - P0354 (Igniter) Monitor runs whenever following DTCs are not present ES Battery voltage 11 V or more Engine RPM 550 to 4,000 rpm ECT 75°C (167°F) to 100°C (212°F) TYPICAL MALFUNCTION THRESHOLDS Advanced camshaft timing: All of the following conditions are met - Crank angle between reference position and actual intake camshaft angle 67°CA or more Valve timing No change at advanced valve timing Retard camshaft timing: All of the following conditions are met - Crank angle between reference point and actual intake camshaft angle Less than 67°CA Valve timing No change at retarded valve timing If the difference between the target and actual camshaft timings is greater than the specified value, the ECM operates the VVT actuator. Then, the ECM monitors the camshaft timing change for 5 seconds. WIRING DIAGRAM Refer to DTC P0010 (See page ES-67). INSPECTION PROCEDURE NOTICE: DTC P0011 or P0012 may be set when foreign objects in the engine oil are caught in some parts of the system. The DTC will remain set even if the system returns to normal after a short time. Foreign objects are filtered out by the oil filter. HINT: • If DTC P0011 or P0012 is present, check the VVT (Variable Valve Timing) system. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P0011 OR P0012) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the tester on. ES–77 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs. Result Display (DTC Output) Proceed to P0011 or P0012 A P0011 or P0012 and other DTCs B HINT: If any DTCs other than P0011 or P0012 are output, troubleshoot those DTCs first. B GO TO DTC CHART ES A 2 PERFORM ACTIVE TEST USING INTELLIGENT TESTER (OPERATE OCV) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Start the engine and turn the tester on. Warm up the engine. On the tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VVT CTRL B1. (e) Check the engine speed while operating the Oil Control Valve (OCV) using the tester. OK Tester Operation Specified Condition OCV OFF Normal engine speed OCV ON Engine idles roughly or stalls (soon after OCV switched from OFF to ON) NG Go to step 4 OK 3 CHECK WHETHER DTC OUTPUT RECURS (DTC P0011 OR P0012) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the tester on. (c) Clear the DTCs (See page ES-38). (d) Start the engine and warm it up. (e) Switch the ECM from normal mode to check mode using the tester. (f) Drive the vehicle for more than 10 minutes. (g) Read the DTCs using the tester. OK: No DTC output. NG Go to step 4 ES–78 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK END 4 CHECK VALVE TIMING (CHECK FOR LOOSE AND JUMPED TEETH ON TIMING CHAIN) Paint Mark Paint Mark ES Timing Mark Timing Mark Groove A098172E05 (a) Remove the cylinder head cover. (b) Turn the crankshaft pulley, and align its groove with the timing mark "0" on the timing chain cover. (c) Check that the timing marks on the camshaft timing sprocket and camshaft timing gear are facing upward as shown in the illustration. If not, turn the crankshaft 1 revolution (360°), then align the marks as above. OK: Timing marks on camshaft timing gears are aligned as shown in the illustration. (d) Reinstall the cylinder head cover. NG ADJUST VALVE TIMING OK 5 INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (OCV) (a) Remove the OCV. (b) Measure the resistance between the terminals of the OCV. Standard resistance: 6.9 to 7.9 Ω at 20°C (68°F) A095415E03 (c) Apply positive battery voltage to terminal 1 and negative battery voltage to terminal 2. Check the valve operation. OK: Valve moves quickly. (d) Reinstall the OCV. Valve Moves NG A097066E01 OK REPLACE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 6 ES–79 INSPECT OIL CONTROL VALVE FILTER (a) Remove the generator. (b) Remove the OCV filter. (c) Check that the filter is not clogged. OK: Filter is not clogged. (d) Reinstall the OCV filter. (e) Reinstall the generator. OCV Filter NG CLEAN OIL CONTROL VALVE FILTER ES A098169E03 OK 7 REPLACE CAMSHAFT TIMING GEAR ASSEMBLY NEXT 8 CHECK WHETHER DTC OUTPUT RECURS (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the tester on. (c) Clear the DTCs (See page ES-38). (d) Start the engine and warm it up. (e) Switch the ECM from normal mode to check mode using the tester. (f) Drive the vehicle for more than 10 minutes. (g) Read the output DTCs using the tester. Standard: No DTC output. HINT: DTC P0011 or P0012 is output when foreign objects in engine oil are caught in some parts of the system. These codes will stay output for a short time even after the system returns to normal. These foreign objects are then captured by the oil filter, thus eliminating the source of the problem. NG OK SYSTEM OK REPLACE ECM ES–80 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0016 Crankshaft Position - Camshaft Position Correlation (Bank 1 Sensor A) DESCRIPTION In the VVT (Variable Valve Timing) system, the appropriate intake valve open and close timing is controlled by the ECM. The ECM performs intake valve control by performing the following: 1) controlling the camshaft and camshaft timing oil control valve, and operating the camshaft timing gear; and 2) changing the relative positions of the gaps between the camshaft and crankshaft. DTC No. P0016 DTC Detection Condition Trouble Area Deviation between crankshaft and camshaft position sensor signals (2 trip detection logic) ES • • Mechanical system (Timing chain has jumped tooth or chain stretched) ECM MONITOR DESCRIPTION The ECM optimizes the valve timing by using the VVT (Variable Valve Timing) system to control the intake camshaft. The VVT system includes the ECM, the Oil Control Valve (OCV) and the VVT controller. The ECM sends a target duty-cycle control signal to the OCV. This control signal regulates the oil pressure supplied to the VVT controller. The VVT controller can advance or retard the intake camshaft. The ECM calibrates the intake valve timing by setting the intake camshaft to the most retarded angle while the engine is idling. The ECM closes the OCV to retard the cam. The ECM stores this value as the VVT learning value. When the difference between the target and actual intake valve timings is 5°CA (Crankshaft Angle) or less, the ECM stores it. If the VVT learning value matches the following conditions, the ECM determines the existence of a malfunction in the VVT system, and sets the DTC. • VVT learning value: Less than 27.8°CA, or more than 48°CA. • Above condition continues for 18 seconds or more. This DTC indicates that the angle between the intake camshaft and the crankshaft is incorrect due to factors such as the timing chain having a jumped tooth. This monitor begins to run after the engine has idled for 5 minutes. MONITOR STRATEGY Related DTCs P0016: Camshaft timing misalignment at idling Required Sensors/Components VVT actuator Required Sensors/Components Camshaft position sensor, Crankshaft position sensor Frequency of Operation Once per driving cycle Duration Within 1 minute MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present P0011 (VVT system 1 - advance) P0012 (VVT system 1 - retarded) P0115 - P0118 (ECT sensor) Engine RPM 550 to 1,000 rpm TYPICAL MALFUNCTION THRESHOLDS One of the following conditions is met - VVT learning value at maximum retarded valve timing Less than 27.8°CA VVT learning value at maximum retarded valve timing More than 48°CA 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–81 WIRING DIAGRAM Refer to DTC P0335 (See page ES-177). INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the airfuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK VALVE TIMING (CHECK FOR LOOSE AND JUMPED TOOTH OF TIMING CHAIN) (See page ES-78) NG Go to step 3 NEXT Go to step 4 OK 2 3 REPLACE ECM ADJUST VALVE TIMING NEXT 4 CHECK WHETHER DTC OUTPUT RECURS NOTICE: After replacing the ECM or adjusting intake valve timing, confirm that the DTC output does not recur. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position. (c) Turn the tester on. (d) Clear the DTCs (See page ES-38). (e) Switch the ECM from normal mode to check mode using the tester (See page ES-41). (f) Start the engine and warm it up. (g) Allow the engine to idle for 1 minute or more, and then drive the vehicle for 1 minute or more. (h) Confirm that no DTC is set using the tester. OK: No DTC output NEXT END ES ES–82 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0031 Oxygen (A/F) Sensor Heater Control Circuit Low (Bank 1 Sensor 1) DTC P0032 Oxygen (A/F) Sensor Heater Control Circuit High (Bank 1 Sensor 1) HINT: • Although the DTC titles say oxygen sensor, these DTCs relate to the Air-Fuel Ratio (A/F) sensor. • Sensor 1 refers to the sensor mounted in front of the Three-Way Catalytic Converter (TWC) and located near the engine assembly. ES DESCRIPTION Refer to DTC P2195 (See page ES-308). HINT: • When either of these DTCs is set, the ECM enters fail-safe mode. The ECM turns off the A/F sensor heater in fail-safe mode. Fail-safe mode continues until the ignition switch is turned off. • The ECM provides a pulse width modulated control circuit to adjust the current through the heater. The A/F sensor heater circuit uses a relay on the B+ side of the circuit. Reference (System Diagram of Sensor 1): EFI EFI MAIN From Battery ECM A/F Sensor Heater +B A1A- HA1A HA1A A1A+ A1A+ Sensor Duty Control A1A- MREL Ground A140695E01 DTC No. DTC Detection Condition Trouble Area P0031 Air-Fuel Ratio (A/F) sensor heater current less than 0.8 A (1 trip detection logic) • • • • Open in A/F sensor heater circuit A/F sensor heater (sensor 1) Engine room J/B (EFI relay) ECM P0032 Air-Fuel Ratio (A/F) sensor heater current more than 10 A (1 trip detection logic) • • • • Short in A/F sensor heater circuit A/F sensor heater (sensor 1) Engine room J/B (EFI relay) ECM 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–83 MONITOR DESCRIPTION The ECM uses information from the Air-Fuel Ratio (A/F) sensor to regulate the air-fuel ratio and keep it close to the stoichiometric level. This maximizes the ability of the Three-Way Catalytic Converter (TWC) to purify the exhaust gases. The A/F sensor detects oxygen levels in the exhaust gas and transmits the information to the ECM. The inner surface of the sensor element is exposed to the outside air. The outer surface of the sensor element is exposed to the exhaust gas. The sensor element is made of platinum coated zirconia and includes an integrated heating element. The zirconia element generates a small voltage when there is a large difference in the oxygen concentrations between the exhaust gas and outside air. The platinum coating amplifies this voltage generation. The A/F sensor is more efficient when heated. When the exhaust gas temperature is low, the sensor cannot generate useful voltage signals without supplementary heating. The ECM regulates the supplementary heating using a duty-cycle approach to adjust the average current in the sensor heater element. If the heater current is outside the normal range, the signal transmitted by the A/F sensor becomes inaccurate, as a result, the ECM is unable to regulate air-fuel ratio properly. When the current in the A/F sensor heater is outside the normal operating range, the ECM interprets this as a malfunction in the sensor heater and sets a DTC. Example: The ECM sets DTC P0032 when the current in the A/F sensor heater is more than 10 A. Conversely, when the heater current is less than 0.8 A, DTC P0031 is set. MONITOR STRATEGY Related DTCs P0031: A/F sensor heater open/short (Low electrical current) P0032: A/F sensor heater open/short (High electrical current) Required Sensors/Components (Main) A/F sensor heater Required Sensors/Components (Related) - Frequency of Operation Continuous Duration 10 seconds MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS All: Monitor runs whenever following DTCs are not present None P0031: Battery voltage 10.5 V or more A/F sensor heater duty-cycle ratio 50 % or more Time after engine start 10 seconds or more P0032: Time after engine start 10 seconds or more TYPICAL MALFUNCTION THRESHOLDS P0031: A/F sensor heater current Less than 0.8 A P0032: A/F sensor heater current More than 10 A ES ES–84 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM COMPONENT OPERATING RANGE A/F sensor heater current 0.9 to 9.9 A WIRING DIAGRAM Refer to DTC P2195 (See page ES-312). INSPECTION PROCEDURE ES HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the airfuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 INSPECT AIR-FUEL RATIO SENSOR (HEATER RESISTANCE) Component Side: +B A/F Sensor HA1A (a) Disconnect the C15 A/F sensor connector. (b) Measure the resistance between the terminals of the A/F sensor connector. Standard resistance Sensor 1 A1A- A1A+ Tester Connection Specified Condition 1 (HA1A) - 2 (+B) 1.8 Ω to 3.4 Ω at 20°C (68°F) 1 (HA1A) - 4 (A1A-) 10 kΩ or higher (c) Reconnect the A/F sensor connector. A052607E27 NG REPLACE AIR-FUEL RATIO SENSOR OK 2 CHECK TERMINAL VOLTAGE (+B OF A/F SENSOR) (a) Disconnect the C15 A/F sensor connector. (b) Turn the ignition switch to the ON position. (c) Measure the voltage between the terminal of the A/F sensor connector and body ground. Standard voltage Wire Harness Side: A/F Sensor Connector +B C15 Tester Connection Specified Condition Sensor 1 C15-2 (+B) - Body ground 9 to 14 V (d) Reconnect the A/F sensor connector. Front View A076787E11 NG OK Go to step 5 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 3 ES–85 INSPECT ENGINE ROOM J/B (EFI RELAY) (a) Inspect the EFI MAIN fuse. (1) Remove the EFI MAIN fuse from the engine room R/B. (2) Measure the EFI MAIN fuse resistance. Standard resistance: Below 1 Ω (3) Reinstall the EFI MAIN fuse. (b) Inspect the EFI relay. (1) Remove the engine room J/B from the engine room R/B. (2) Measure the EFI relay resistance. Standard resistance Engine Room J/B: 1E Tester Connection Engine Room R/B: Specified Condition 10 kΩ or higher 1E-7 - 1E-12 Below 1 Ω (Apply battery voltage between terminals 1E-9 and 1E-11) (3) Reinstall the engine room J/B. EFI MAIN NG A138917E01 OK REPLACE ENGINE ROOM J/B ES ES–86 4 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (A/F SENSOR - EFI RELAY) (a) (b) (c) (d) Wire Harness Side: +B C15 Disconnect the C15 A/F sensor connector. Remove the engine room J/B from the engine room R/B. Disconnect the 1E engine room J/B connector. Measure the resistance between the terminals. Standard resistance (Check for open) A/F Sensor Connector Tester Connection Specified Condition C15-2 (+B) - 1E-7 (Engine room J/B) Below 1 Ω Standard resistance (Check for short) ES Engine Room J/B: Connector Side: Tester Connection Specified Condition C15-2 (+B) or 1E-7 (Engine room J/B) - Body ground 10 kΩ or higher (e) Reconnect the A/F sensor connector. (f) Reconnect the engine room J/B connector. (g) Reinstall the engine room J/B. 1E NG Engine Room R/B: A138924E01 OK CHECK ECM POWER SOURCE CIRCUIT REPAIR OR REPLACE HARNESS OR CONNECTOR ES–87 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 5 CHECK HARNESS AND CONNECTOR (A/F SENSOR - ECM) (a) Disconnect the C15 A/F sensor connector. (b) Disconnect the C24 ECM connector. (c) Measure the resistance between the terminals of the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side: A/F Sensor Connector HA1A C15 C24 Tester Connection Specified Condition C15-1 (HA1A) - C24-109 (HA1A) Below 1 Ω Standard resistance (Check for short) ECM Connector Tester Connection Specified Condition C15-1 (HA1A) or C24-109 (HA1A) - Body ground 10 kΩ or higher (d) Reconnect the A/F sensor connector. (e) Reconnect the ECM connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR HA1A A127715E07 OK 6 CHECK WHETHER DTC OUTPUT RECURS (a) (b) (c) (d) (e) (f) (g) Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Turn the tester on. Clear the DTCs (See page ES-38). Start the engine. Allow the engine to idle for 1 minute or more. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (h) Read the DTCs. Result Display (DTC Output) Proceed to No output A P0031 or P0032 B B A CHECK FOR INTERMITTENT PROBLEMS REPLACE ECM ES ES–88 ES 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0037 Oxygen Sensor Heater Control Circuit Low (Bank 1 Sensor 2) DTC P0038 Oxygen Sensor Heater Control Circuit High (Bank 1 Sensor 2) DTC P0141 Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 2) DESCRIPTION Refer to DTC P0136 (See page ES-132). HINT: • When any of these DTCs are set, the ECM enters fail-safe mode. The ECM turns off the Heated Oxygen (HO2) Sensor heater in fail-safe mode. Fail-safe mode continues until the ignition switch is turned off. • The ECM provides a pulse width modulated control circuit to adjust the current through the heater. The HO2 sensor heater circuit uses a relay on the B+ side of the circuit. Reference (System Diagram of Sensor 2): HO2 Sensor EFI from Battery EFI MAIN +B EFI NO. 3 E2 Heater Sensor ECM HT1B HT1B OX1B OX1B EX1B MREL Ground A133556E05 DTC No. DTC Detection Condition Trouble Area P0037 Heated Oxygen (HO2) sensor heater current less than 0.3 A (1 trip detection logic) • • • • Open in HO2 sensor heater circuit HO2 sensor heater (sensor 2) Engine room J/B (EFI relay) ECM P0038 Heated Oxygen (HO2) sensor heater current more than 2 A (1 trip detection logic) • • • • Short in HO2 sensor heater circuit HO2 sensor heater (sensor 2) Engine room J/B (EFI relay) ECM P0141 Cumulative heater resistance correction value exceeds threshold (2 trip detection logic) • • • • Open or short in HO2 sensor heater circuit HO2 sensor heater (sensor 2) Engine room J/B (EFI relay) ECM 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–89 MONITOR DESCRIPTION The sensing position of the Heated Oxygen (HO2) sensor has a zirconia element which is used to detect the oxygen concentration in the exhaust gas. If the zirconia element is at the appropriate temperature, and the difference between the oxygen concentrations surrounding the inside and outside surfaces of the sensor is large, the zirconia element generates voltage signals. In order to increase the oxygen concentration detecting capacity of the zirconia element, the ECM supplements the heat from the exhaust with heat from a heating element inside the sensor. Heated oxygen sensor heater range check (P0037 and P0038): The ECM monitors the current applied to the O2 sensor heater to check the heater for malfunctions. If the current is below the threshold value, the ECM determines that there is an open circuit in the heater. If the current is above the threshold value, the ECM determines that there is a short circuit in the heater. The ECM constantly monitors the current applied to the heater. If the ECM detects an open or short circuit, the ECM turns the MIL on and sets a DTC. If a malfunction is detected, the ECM cuts off the current applied to the heater. Example: The ECM sets DTC P0038 when the current in the HO2 sensor heater is more than 2 A. Conversely, when the heater current is less than 0.3 A, DTC P0037 is set. Heated oxygen sensor heater performance (P0141): After the accumulated heater ON time exceeds 100 seconds, the ECM calculates the heater resistance using the battery voltage and the current applied to the heater. If the resistance is above the threshold value, the ECM determines that there is a malfunction in the HO2 sensor heater and sets DTC P0141. MONITOR STRATEGY Related DTCs P0037: Heated oxygen sensor heater range check (Low electrical current) P0038: Heated oxygen sensor heater range check (High electrical current) P0141: Heated oxygen sensor heater performance Required Sensors/Components (Main) Heated oxygen sensor heater Required Sensors/Components (Related) - Frequency of Operation Continuous: P0037 and P0038 Once per driving cycle: P0141 Duration 1 second: P0037 and P0038 10 seconds: P0141 MIL Operation Immediate: P0037 and P0038 2 driving cycles: P0141 Sequence of Operation None TYPICAL ENABLING CONDITIONS All: Monitor runs whenever following DTCs are not present None P0037: Battery voltage 10.5 to 20 V P0038 (Condition A): Battery voltage 10.5 V or more Engine Running Starter OFF P0038 (Condition B): Battery voltage 10.5 to 20 V ES ES–90 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM P0141: All of the following conditions are met: - Battery voltage 10.5 V or more Fuel cut OFF Time after fuel cut ON to OFF 30 seconds or more Accumulated heater ON time 100 seconds or more TYPICAL MALFUNCTION THRESHOLDS P0037: Heater current ES Less than 0.3 A P0038: One of the following conditions A or B is met - A. Learned heater OFF current More than 2 A B. Heater current More than 2 A P0141: Varies with sensor element temperature (Example: More than 23 Ω) Accumulated heater resistance COMPONENT OPERATING RANGE 0.4 to 1 A (when engine idles, HO2 sensor warmed up and battery voltage 11 to 14 V) Heated Oxygen (HO2) sensor heater current WIRING DIAGRAM Refer to DTC P0136 (See page ES-139). CONFIRMATION DRIVING PATTERN These DTCs are detected when the engine idles for 110 seconds or more. INSPECTION PROCEDURE HINT: • Sensor 2 refers to the sensor mounted behind the Three-Way Catalytic Converter (TWC) and located far from the engine assembly. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 INSPECT HEATED OXYGEN SENSOR (HEATER RESISTANCE) (a) Disconnect the C22 Heated Oxygen (HO2) sensor connector. (b) Measure the resistance between the terminals of the HO2 sensor connector. Standard resistance Component Side : +B Sensor 2 E2 HT1B 2 4 1 3 Front View HO2 Sensor OX1B A115661E02 Tester Connection Specified Condition 1 (HT1B) - 2 (+B) 11 to 16 Ω at 20°C (68°F) 1 (HT1B) - 4 (E2) 10 kΩ or higher (c) Reconnect the HO2 sensor connector. ES–91 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NG REPLACE HEATED OXYGEN SENSOR OK 2 CHECK TERMINAL VOLTAGE (+B OF HO2 SENSOR) Wire Harness Side: Heated Oxygen Sensor Connector +B C22 (a) Disconnect the C22 HO2 sensor connector. (b) Turn the ignition switch to the ON position. (c) Measure the voltage between the terminal of the C22 HO2 sensor connector and body ground. Standard voltage Sensor 2 Front View Tester Connection Specified Condition C22-2 (+B) - Body ground 9 to 14 V (d) Reconnect the HO2 sensor connector. A072895E10 OK Go to step 5 NG 3 INSPECT ENGINE ROOM J/B (EFI RELAY) (See page ES-85) NG OK REPLACE ENGINE ROOM J/B ES ES–92 4 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (HO2 SENSOR - EFI RELAY) Wire Harness Side: +B C22 ES HO2 Sensor Connector Engine Room J/B: Connector Side: (a) Inspect the EFI No. 3 fuse. (1) Remove the EFI No. 3 fuse from the engine room R/ B. (2) Measure the EFI No. 3 fuse resistance. Standard resistance: Below 1 Ω (3) Reinstall the EFI No. 3 fuse. (b) Disconnect the C22 HO2 sensor connector. (c) Remove the engine room J/B from the engine room R/B. (d) Disconnect the 1E engine room J/B connector. (e) Measure the resistance between the terminals. Standard resistance (Check for open) Tester Connection Specified Condition C22-2 (+B) - 1E-6 (Engine room J/B) Below 1 Ω Standard resistance (Check for short) 1E Tester Connection Specified Condition C22-2 (+B) or 1E-6 (Engine room J/B) - Body ground 10 kΩ or higher (f) Reconnect the HO2 sensor connector. (g) Reconnect the engine room J/B connector. (h) Reinstall the engine room J/B. NG Engine Room R/B: EFI No. 3 A138925E01 OK CHECK ECM POWER SOURCE CIRCUIT REPAIR OR REPLACE HARNESS OR CONNECTOR ES–93 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 5 CHECK HARNESS AND CONNECTOR (HO2 SENSOR - ECM) (a) Disconnect the C22 HO2 sensor connector. (b) Disconnect the C24 ECM connector. (c) Measure the resistance between the terminals of the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side: HO2 Sensor Connector C22 HT1B Specified Condition C22-1 (HT1B) - C24-47 (HT1B) Below 1 Ω Standard resistance (Check for short) Front View HT1B Tester Connection C24 ECM Connector Tester Connection Specified Condition C22-1 (HT1B) or C24-47 (HT1B) - Body ground 10 kΩ or higher (d) Reconnect the HO2 sensor connector. (e) Reconnect the ECM connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR Front View A104950E11 OK 6 CHECK WHETHER DTC OUTPUT RECURS (a) (b) (c) (d) (e) (f) (g) Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Turn the tester on. Clear the DTCs (See page ES-38). Start the engine. Allow the engine to idle for 2 minutes or more. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (h) Read the DTCs. Result Display (DTC Output) Proceed to No output A P0037, P0038 and/or P0141 B B A CHECK FOR INTERMITTENT PROBLEMS REPLACE ECM ES ES–94 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0100 Mass or Volume Air Flow Circuit DTC P0102 Mass or Volume Air Flow Circuit Low Input DTC P0103 Mass or Volume Air Flow Circuit High Input DESCRIPTION ES The Mass Air Flow (MAF) meter is a sensor that measures the amount of air flowing through the throttle valve. The ECM uses this information to determine the fuel injection time and to provide the appropriate air-fuel ratio. Inside the MAF meter, there is a heated platinum wire which is exposed to the flow of intake air. By applying a specific electrical current to the wire, the ECM heats it to a given temperature. The flow of incoming air cools both the wire and an internal thermistor, affecting their resistance. To maintain a constant current value, the ECM varies the voltage applied to these components in the MAF meter. The voltage level is proportional to the airflow through the sensor, and the ECM uses it to calculate the intake air volume. The circuit is constructed so that the platinum hot wire and the temperature sensor create a bridge circuit, and the power transistor is controlled so that the potentials of A and B remain equal to maintain the predetermined temperature. HINT: When any of these DTCs are set, the ECM enters fail-safe mode. During fail-safe mode, the ignition timing is calculated by the ECM, according to the engine RPM and throttle valve position. Fail-safe mode continues until a pass condition is detected. B+ Temperature Sensor (Thermistor) Power Transistor Platinum Hot Wire (Heater) A B Output Voltage Temperature Sensor (Thermistor) Platinum Hot Wire (Heater) A122492E01 DTC No. DTC Detection Condition P0100 MAF meter voltage less than 0.2 V, or more than 4.9 V for 3 seconds (1 trip detection logic) • • • Open or short in MAF meter circuit MAF meter ECM Trouble Area P0102 MAF meter voltage less than 0.2 V for 3 seconds (1 trip detection logic) • • • Open or short in MAF meter circuit MAF meter ECM P0103 MAF meter voltage more than 4.9 V for 3 seconds (1 trip detection logic) • • • Open or short in MAF meter circuit MAF meter ECM 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–95 HINT: When any of these DTCs are set, check the air-flow rate by selecting the following menu items on the intelligent tester: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / MAF. Mass Air Flow Rate (g/sec.) Malfunctions Approximately 0.0 • • Open in Mass Air Flow (MAF) meter power source circuit Open or short in VG circuit 271.0 or more • Open in E2G circuit MONITOR DESCRIPTION If there is a defect in the MAF meter or an open or short circuit, the voltage level deviates from the normal operating range. The ECM interprets this deviation as a malfunction in the MAF meter and sets a DTC. Example: When the sensor output voltage remains less than 0.2 V, or more than 4.9 V, for more than 3 seconds, the ECM sets a DTC. If the malfunction is not repaired successfully, a DTC is set 3 seconds after the engine is next started. MONITOR STRATEGY Related DTCs P0100: MAF meter range check (Fluctuating) P0102: MAF meter range check (Low voltage) P0103: MAF meter range check (High voltage) Required Sensors/Components (Main) MAF meter Required Sensors/Components (Related) Crankshaft position sensor Frequency of Operation Continuous Duration 3 seconds MIL Operation Immediate: Engine RPM less than 4,000 rpm 2 driving cycles: Engine RPM 4,000 rpm or more Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present None TYPICAL MALFUNCTION THRESHOLDS P0100: MAF meter voltage Less than 0.2 V, or more than 4.9 V P0102: MAF meter voltage Less than 0.2 V P0103: MAF meter voltage More than 4.9 V COMPONENT OPERATING RANGE MAF meter voltage Between 0.4 V and 2.2 V ES ES–96 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM C2 Mass Air Flow Meter EFI EFI MAIN EFI No. 3 +B 3 ECM 118 VG C24 VG 5 116 E2G C24 E2G 4 FL MAIN ES 44 MREL A24 Battery A132276E01 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the airfuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 READ VALUE USING INTELLIGENT TESTER (MASS AIR FLOW RATE) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Start the engine. Turn the tester on. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / MAF. (e) Read the values displayed on the tester. Result Mass Air Flow Rate (g/sec.) Proceed to 0.0 A 271.0 or more B Between 1.0 and 270.0 (*1) C HINT: *1: The value must change when the throttle valve is open or closed with the engine running. B C Go to step 6 CHECK FOR INTERMITTENT PROBLEMS ES–97 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM A 2 INSPECT MASS AIR FLOW METER (POWER SOURCE VOLTAGE) Wire Harness Side: Front View +B (+) C2 (a) Disconnect the C2 Mass Air Flow (MAF) meter connector. (b) Turn the ignition switch to the ON position. (c) Measure the voltage between the terminal of the wire harness side connector and body ground. Standard voltage MAF Meter Connector A127724E05 Tester Connection Specified Condition C2-3 (+B) - Body ground 9 to 14 V (d) Reconnect the MAF meter connector. NG Go to step 5 OK 3 INSPECT MASS AIR FLOW METER (VG VOLTAGE) MAF Meter VG E2G +B 5 4 3 2 1 (a) Inspect output voltage. (1) Disconnect the C2 MAF meter connector. (2) Apply battery voltage across terminals +B and E2G. (3) Connect the positive (+) tester probe to terminal VG, and the negative (-) tester probe to terminal E2G. (4) Measure the voltage. Standard voltage Tester Connection Specified Condition 5 (VG) - 4 (E2G) 0.2 to 4.9 V A127786E01 (5) Reconnect the MAF meter connector. NG OK REPLACE MASS AIR FLOW METER ES ES–98 4 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (MASS AIR FLOW METER - ECM) (a) Disconnect the C2 MAF meter connector. (b) Disconnect the C24 ECM connector. (c) Measure the resistance between the terminals of the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side: MAF Meter Connector C2 Tester Connection VG E2G ES C24 Specified Condition C2-5 (VG) - C24-118 (VG) Below 1 Ω C2-4 (E2G) - C24-116 (E2G) Below 1 Ω Standard resistance (Check for short) ECM Connector Tester Connection Specified Condition C2-5 (VG) or C24-118 (VG) - Body ground 10 kΩ or higher (d) Reconnect the MAF meter connector. (e) Reconnect the ECM connector. NG E2G VG A127959E09 OK REPLACE ECM REPAIR OR REPLACE HARNESS OR CONNECTOR ES–99 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 5 CHECK HARNESS AND CONNECTOR (MASS AIR FLOW METER - ENGINE ROOM J/B) Wire Harness Side: +B C2 Engine Room J/B: MAF Meter Connector Connector Side: (a) Inspect the EFI No. 3 fuse. (1) Remove the EFI No. 3 fuse from the engine room R/ B. (2) Measure the EFI No. 3 fuse resistance. Standard resistance: Below 1 Ω (3) Reinstall the EFI No. 3 fuse. (b) Disconnect the C2 MAF meter connector. (c) Remove the engine room J/B from the engine room R/B. (d) Disconnect the 1E engine room J/B connector. (e) Measure the resistance between the terminals. Standard resistance (Check for open) Tester Connection Specified Condition C2-3 (+B) - 1E-6 Below 1 Ω Standard resistance (Check for short) 1E Tester Connection Specified Condition C2-3 (+B) or 1E-6 - Body ground 10 kΩ or higher (f) Reconnect the MAF meter connector. (g) Reconnect the engine room J/B connector. (h) Reinstall the engine room J/B. NG Engine Room R/B: EFI No. 3 A138926E01 OK CHECK ECM POWER SOURCE CIRCUIT REPAIR OR REPLACE HARNESS OR CONNECTOR ES ES–100 6 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (SENSOR GROUND) (a) Disconnect the C2 MAF meter connector. (b) Measure the resistance. Standard resistance Wire Harness Side: E2G Front View Tester Connection Specified Condition C2-4 (E2G) - Body ground Below 1 Ω (c) Reconnect the MAF meter connector. C2 OK MAF Meter Connector ES REPLACE MASS AIR FLOW METER A127724E06 NG 7 CHECK HARNESS AND CONNECTOR (MASS AIR FLOW METER - ECM) (a) Disconnect the C2 MAF meter connector. (b) Disconnect the C24 ECM connector. (c) Measure the resistance between the terminals of the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side: MAF Meter Connector C2 Tester Connection VG E2G Specified Condition C2-5 (VG) - C24-118 (VG) Below 1 Ω C2-4 (E2G) - C24-116 (E2G) Below 1 Ω Standard resistance (Check for short) C24 ECM Connector Tester Connection Specified Condition C2-5 (VG) or C24-118 (VG) - Body ground 10 kΩ or higher (d) Reconnect the MAF meter connector. (e) Reconnect the ECM connector. NG E2G VG A127959E10 OK REPLACE ECM REPAIR OR REPLACE HARNESS OR CONNECTOR ES–101 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0101 Mass Air Flow Circuit Range / Performance Problem DESCRIPTION Refer to DTC P0100 (See page ES-89). DTC No. DTC Detection Condition P0101 Conditions (a), (b), (c), (d) and (e) continue for more than 10 seconds (2 trip detection logic): (a) Engine running (b) Engine coolant temperature 70°C (158°F) or higher (c) Throttle Position (TP) sensor voltage 0.24 V or more (d) Average engine load value ratio less than 0.85, or more than 1.15 (varies with estimated engine load) Average engine load value ratio = Average engine load based on MAF meter output / Average engine load estimated from driving conditions (e) Average air-fuel ratio less than -20 %, or more than 20 % Trouble Area • • • Mass Air Flow (MAF) meter Air induction system PCV hose connections MONITOR DESCRIPTION The MAF meter is a sensor that measures the amount of air flowing through the throttle valve. The ECM uses this information to determine the fuel injection time and to provide an appropriate air-fuel ratio. Inside the MAF meter, there is a heated platinum wire which is exposed to the flow of intake air. By applying a specific electrical current to the wire, the ECM heats it to a specific temperature. The flow of incoming air cools both the wire and an internal thermistor, affecting their resistance. To maintain a constant current value, the ECM varies the voltage applied to these components of the MAF meter. The voltage level is proportional to the airflow through the sensor, and the ECM uses it to calculate the intake air volume. The ECM monitors the average engine load value ratio to check the MAF meter for malfunctions. The average engine load value ratio is obtained by comparing the average engine load calculated from the MAF meter output to the average engine load estimated from the driving conditions, such as the engine speed and the throttle opening angle. If the average engine load value ratio is below the threshold value, the ECM determines that the intake air volume is low, and if the average engine load value ratio is above the threshold value, the ECM determines that the intake air volume is high. If this is detected in 2 consecutive driving cycles, the MIL is illuminated and a DTC is set. MONITOR STRATEGY Related DTCs P0101: Mass air flow meter rationality Required Sensors/Components (Main) Mass air flow meter Required Sensors/Components (Related) Crankshaft Position (CKP) sensor, Engine Coolant Temperature (ECT) sensor and Throttle Position (TP) sensor Frequency of Operation Continuous Duration 10 seconds MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present P0115 - P0118 (ECT sensor) P0120 - P0223, P2135 (TP sensor) P0125 (Insufficient ECT for closed loop) P0335 (CKP sensor) P0340 (CMP sensor) Throttle position (TP sensor voltage) 0.24 V or more Engine Running ES ES–102 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Battery voltage 10.5 V or more Engine coolant temperature 70°C (158°F) or more IAT sensor circuit OK ECT sensor circuit OK CKP sensor circuit OK TP sensor circuit OK Canister pressure sensor circuit OK EVAP leak detection pump OK EVAP vent valve OK TYPICAL MALFUNCTION THRESHOLDS ES Averaged engine load Less than 0.85, or more than 1.23 WIRING DIAGRAM Refer to DTC P0100 (See page ES-91). CONFIRMATION DRIVING PATTERN HINT: Performing this confirmation pattern will activate the mass air flow performance monitor. Vehicle Speed Approximately 62 mph (100 km/h) Idling Time Warming Up 20 seconds or more A112632E03 1. 2. 3. 4. 5. 6. 7. Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Turn the tester on. Clear the DTCs (See page ES-38). Start the engine, and warm it up until the engine coolant temperature reaches 70°C (158°F) or higher. Drive the vehicle at approximately 62 mph (100 km/h) for 20 seconds or more. On the tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES and check if any DTCs (any pending DTCs) are set. ES–103 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the airfuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P0101) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Turn the tester on. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read the DTCs. Result Display (DTC Output) Proceed to P0101 A P0101 and other DTCs B HINT: If any DTCs other than P0101 are output, troubleshoot those DTCs first. B GO TO DTC CHART A 2 CHECK AIR INDUCTION SYSTEM (a) Check the air induction system for vacuum leakage. OK: No leakage from air induction system. NG REPAIR OR REPLACE AIR INDUCTION SYSTEM OK 3 CHECK PCV HOSE CONNECTIONS OK: PCV hose is connected correctly and is not damaged. NG OK REPLACE MASS AIR FLOW METER REPAIR OR REPLACE PCV HOSE ES ES–104 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0110 Intake Air Temperature Circuit Malfunction DTC P0112 Intake Air Temperature Circuit Low Input DTC P0113 Intake Air Temperature Circuit High Input DESCRIPTION Fig. 1 Resistance ES (kΩ) Acceptable (°C) (°F) Temperature A132329E01 The Intake Air Temperature (IAT) sensor, mounted on the Mass Air Flow (MAF) meter, monitors the IAT. The IAT sensor has a built-in thermistor with a resistance that varies according to the temperature of the intake air. When the IAT becomes low, the resistance of the thermistor increases. When the temperature becomes high, the resistance drops. These variations in resistance are transmitted to the ECM as voltage changes (see Fig. 1). The IAT sensor is powered by a 5 V supply from the THA terminal of the ECM, via resistor R. Resistor R and the IAT sensor are connected in series. When the resistance value of the IAT sensor changes, according to changes in the IAT, the voltage at terminal THA also varies. Based on this signal, the ECM increases the fuel injection volume when the engine is cold to improve driveability. HINT: When any of DTCs P0110, P0112 and P0113 are set, the ECM enters fail-safe mode. During fail-safe mode, the IAT is estimated to be 20°C (68°F) by the ECM. Fail-safe mode continues until a pass condition is detected. DTC No. DTC Detection Condition Trouble Area P0110 Open or short in IAT sensor circuit for 0.5 seconds (1 trip detection logic) • • • Open or short in IAT sensor circuit IAT sensor (built into MAF meter) ECM P0112 Short in IAT sensor circuit for 0.5 seconds (1 trip detection logic) • • • Short in IAT sensor circuit IAT sensor (built into MAF meter) ECM P0113 Open in IAT sensor circuit for 0.5 seconds (1 trip detection logic) • • • Open in IAT sensor circuit IAT sensor (built into MAF meter) ECM 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–105 HINT: When any of these DTCs are set, check the IAT by selecting the following menu items on the intelligent tester: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / INTAKE AIR. Temperature Displayed Malfunctions -40°C (-40°F) Open circuit 140°C (284°F) or higher Short circuit MONITOR DESCRIPTION The ECM monitors the sensor voltage and uses this value to calculate the IAT. When the sensor output voltage deviates from the normal operating range, the ECM interprets this as a malfunction in the IAT sensor and sets a DTC. Example: If the sensor output voltage is more than 4.91 V for 0.5 seconds or more, the ECM determines that there is an open in the IAT sensor circuit, and sets DTC P0113. Conversely, if the output voltage is less than 0.18 V for 0.5 seconds or more, the ECM determines that there is a short in the sensor circuit, and sets DTC P0112. If the malfunction is not repaired successfully, a DTC is set 0.5 seconds after the engine is next started. MONITOR STRATEGY Related DTCs P0110: IAT sensor range check (Fluctuating) P0112: IAT sensor range check (Low voltage) P0113: IAT sensor range check (High voltage) Required Sensors/Components (Main) IAT sensor Required Sensors/Components (Related) - Frequency of Operation Continuous Duration 0.5 seconds MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present None TYPICAL MALFUNCTION THRESHOLDS P0110: IAT sensor voltage Less than 0.18 V, or more than 4.91 V P0112: IAT sensor voltage [IAT] Less than 0.18 V [More than 140°C (284°F)] P0113: IAT sensor voltage [IAT] More than 4.91 V [Less than -40°C (-40°F)] COMPONENT OPERATING RANGE IAT sensor voltage [IAT] 0.18 to 4.91 V [-40°C to 140°C (-40°F to 284°F)] ES ES–106 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM C2 Intake Air Temperature Sensor (Built in Mass Air Flow Sensor) ECM 5V 65 THA 1 C24 88 E2 2 C24 R THA ETHA ES A072925E23 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the airfuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 READ OUTPUT DTC (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the intelligent tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs. Result Display (DTC Output) Proceed to P0110 A P0112 B P0113 C B Go to step 5 C Go to step 3 A 2 READ VALUE USING INTELLIGENT TESTER (INTAKE AIR TEMPERATURE) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position. (c) Turn the tester on. ES–107 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (d) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / INTAKE AIR. (e) Read the value displayed on the tester. Standard: Same as actual Intake Air Temperature (IAT). Result Temperature Displayed Proceed to -40°C (-40°F) A 140°C (284°F) or higher B Same as actual IAT C HINT: • If there is an open circuit, the intelligent tester indicates -40°C (-40°F). • If there is a short circuit, the intelligent tester indicates 140°C (284°F) or higher. B C Go to step 5 CHECK FOR INTERMITTENT PROBLEMS A 3 READ VALUE USING INTELLIGENT TESTER (CHECK FOR OPEN IN WIRE HARNESS) (a) Disconnect the C2 Mass Air Flow (MAF) meter connector. (b) Connect terminals THA and E2 of the MAF meter wire harness side connector. (c) Connect the intelligent tester to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn the tester on. (f) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / INTAKE AIR. (g) Read the value displayed on the tester. Standard value: 140°C (284°F) or higher (h) Reconnect the MAF meter connector. ECM MAF Meter THA ETHA Wire Harness Side: MAF Meter Connector NG C2 THA Go to step 4 E2 A127961E02 OK CONFIRM GOOD CONNECTION TO SENSOR. IF OK, REPLACE MASS AIR FLOW METER ES ES–108 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 4 CHECK HARNESS AND CONNECTOR (MASS AIR FLOW METER - ECM) (a) Disconnect the C2 MAF meter connector. (b) Disconnect the C24 ECM connector. (c) Measure the resistance between the terminals of the wire harness side connector. Standard resistance Wire Harness Side: MAF Meter Connector C2 ES THA E2 Specified Condition C2-1 (THA) - C24-65 (THA) Below 1 Ω C2-2 (E2) - C24-88 (ETHA) Below 1 Ω (d) Reconnect the MAF meter connector. (e) Reconnect the ECM connector. C24 ECM Connector ETHA Tester Connection NG REPAIR OR REPLACE HARNESS OR CONNECTOR THA A127959E11 OK CONFIRM GOOD CONNECTION TO ECM. IF OK, REPLACE ECM 5 READ VALUE USING INTELLIGENT TESTER (CHECK FOR SHORT IN WIRE HARNESS) MAF Meter (a) (b) (c) (d) (e) ECM THA ETHA A084869E25 Disconnect the C2 MAF meter connector. Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Turn the tester on. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / INTAKE AIR. (f) Read the value displayed on the tester. Standard value: -40°C (-40°F) (g) Reconnect the MAF meter connector. NG OK REPLACE MASS AIR FLOW METER Go to step 6 ES–109 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 6 CHECK HARNESS AND CONNECTOR (MASS AIR FLOW METER - ECM) (a) Disconnect the C2 MAF meter connector. (b) Disconnect the C24 ECM connector. (c) Measure the resistance between the terminals of the wire harness side connectors. Standard resistance Wire Harness Side: MAF Meter Connector C2 Tester Connection Specified Condition C2-1 (THA) or C24-65 (THA) - Body ground 10 kΩ or higher (d) Reconnect the MAF meter connector. (e) Reconnect the ECM connector. THA NG C24 ECM Connector THA A127959E12 OK REPLACE ECM REPAIR OR REPLACE HARNESS OR CONNECTOR ES ES–110 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0111 Intake Air Temperature Sensor Gradient Too High DESCRIPTION Fig. 1 Resistance (kΩ) ES Acceptable Temperature (°C) (°F) A067628E17 The Intake Air Temperature (IAT) sensor, mounted on the Mass Air Flow (MAF) meter, monitors the IAT. The IAT sensor has a built-in thermistor with a resistance that varies according to the temperature of the intake air. When the IAT becomes low, the resistance of the thermistor increases. When the temperature becomes high, the resistance drops. These variations in resistance are transmitted to the ECM as voltage changes (See Fig. 1). The IAT sensor is powered by a 5 V supply from the THA terminal of the ECM, via resistor R. Resistor R and the IAT sensor are connected in series. When the resistance value of the IAT sensor changes, according to changes in the IAT, the voltage at terminal THA also varies. Based on this signal, the ECM increases the fuel injection volume when the engine is cold to improve driveability. DTC No. DTC Detection Condition P0111 When either condition below is met: 1. The intake air temperature rise is large, from the previous trip warm-up to the following trip. (2 trip detection logic). 2. When the change in the intake air temperature after engine start is less than the threshold value. Trouble Area Mass air flow meter assembly MONITOR DESCRIPTION The ECM performs OBD II monitoring based on the values from the intake air temperature sensor. If there is no change of the sensor value within the normal range, the ECM will not be able to perform OBD II monitoring or will misdiagnose that there is a malfunction in the sensor. The ECM detects the stuck intake air temperature sensor value by performing monitoring after the ignition switch is turned off or the engine is started (short soak or long soak). 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–111 MONITOR STRATEGY Related DTCs P0111: Intake air temperature sensor rationality (After engine stop) P0111: Intake air temperature sensor rationality (After cold engine start) Required Sensors/Components (Main) Intake Air Temperature (IAT) sensor Required Sensors/Components (Sub) - Frequency of Operation Once per driving cycle Duration 5 hours or more MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS ES All: Monitor runs whenever following DTCs are not present None After engine stop: Time after engine start 10 seconds or more Battery voltage 10.5 V or more ECT sensor circuit OK ECT change since engine stopped Less than 180°C (356°F) ECT before engine stop 70°C (158°F) or more Time that MAF is low before engine stop 70 minutes Accumulated MAF amount before engine stop Except PZEV: 3,549 g or more PZEV: 2,314 g or more Key-off duration 30 minutes After cold engine start: Key-off duration 5 hours Time after engine start 10 seconds or more ECT sensor circuit OK ECT 70°C (158°F) or more Accumulated MAF amount Except PZEV: 3,549 g or more PZEV: 2,314 g or more One of the following conditions 1 or 2 is met: - 1. Duration while engine load is low 120 seconds or more 2. Duration while engine load is high 10 seconds or more TYPICAL MALFUNCTION THRESHOLDS After engine stop: IAT change Less than 1°C (2°F) After cold engine start: IAT change WIRING DIAGRAM Refer to DTC P0110 (See page ES-99). Less than 1°C (2°F) ES–112 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the airfuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P0111) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Turn the tester on. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read the DTCs. ES Result Display (DTC Output) Proceed to P0111 and other DTCs A P0111 B HINT: If any DTCs other than P0111 are output, troubleshoot those DTCs first. B A GO TO DTC CHART REPLACE MASS AIR FLOW METER ES–113 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0115 Engine Coolant Temperature Circuit Malfunction DTC P0117 Engine Coolant Temperature Circuit Low Input DTC P0118 Engine Coolant Temperature Circuit High Input DESCRIPTION A thermistor, whose resistance value varies according to the ECT, is built into the Engine Coolant Temperature (ECT) sensor. The structure of the sensor and its connection to the ECM are the same as those of the Intake Air Temperature (IAT) sensor. HINT: When any of DTCs P0115, P0117 and P0118 are set, the ECM enters fail-safe mode. During fail-safe mode, the ECT is estimated to be 80°C (176°F) by the ECM. Fail-safe mode continues until a pass condition is detected. DTC No. DTC Detection Condition Trouble Area P0115 Open or short in ECT sensor circuit for 0.5 seconds (1 trip detection logic) • • • Open or short in ECT sensor circuit ECT sensor ECM P0117 Short in ECT sensor circuit for 0.5 seconds (1 trip detection logic) • • • Short in ECT sensor circuit ECT sensor ECM P0118 Open in ECT sensor circuit for 0.5 seconds (1 trip detection logic) • • • Open in ECT sensor circuit ECT sensor ECM HINT: When any of these DTCs are set, check the ECT by selecting the following menu items on the intelligent tester: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / COOLANT TEMP. Temperature Displayed Malfunctions -40°C (-40°F) Open circuit 140°C (284°F) or higher Short circuit MONITOR DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to monitor the ECT. The ECT sensor has a thermistor with a resistance that varies according to the temperature of the engine coolant. When the coolant temperature becomes low, the resistance in the thermistor increases. When the temperature becomes high, the resistance drops. These variations in resistance are reflected in the output voltage from the sensor. The ECM monitors the sensor voltage and uses this value to calculate the ECT. When the sensor output voltage deviates from the normal operating range, the ECM interprets this as a fault in the ECT sensor and sets a DTC. Example: If the sensor output voltage is more than 4.91 V for 0.5 seconds or more, the ECM determines that there is an open in the ECT sensor circuit, and sets DTC P0118. Conversely, if the voltage output is less than 0.14 V for 0.5 seconds or more, the ECM determines that there is a short in the sensor circuit, and sets DTC P0117. If the malfunction is not repaired successfully, a DTC is set 0.5 seconds after the engine is next started. ES ES–114 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR STRATEGY P0115: ECT sensor range check (Fluctuating) P0117: ECT sensor range check (Low voltage) P0118: ECT sensor range check (High voltage) Related DTCs ES Required Sensors/Components (Main) ECT sensor Required Sensors/Components (Related) - Frequency of Operation Continuous Duration 0.5 seconds MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present None TYPICAL MALFUNCTION THRESHOLDS P0115: ECT sensor voltage Less than 0.14 V, or more than 4.91 V P0117: ECT sensor voltage [ECT] Less than 0.14 V [More than 140°C (284°F)] P0118: ECT sensor voltage [ECT] More than 4.91 V [Less than -40°C (-40°F)] COMPONENT OPERATING RANGE ECT sensor voltage [ECT] 0.14 to 4.91 V [-40°C to 140°C (-40°F to 284°F)] WIRING DIAGRAM C4 Engine Coolant Temperature Sensor ECM 5V 97 2 C24 96 1 C24 THW R ETHW A072925E24 ES–115 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the airfuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 READ OUTPUT DTC (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the intelligent tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs. Result Display (DTC Output) Proceed to P0115 A P0117 B P0118 C B Go to step 5 C Go to step 3 A 2 READ VALUE USING INTELLIGENT TESTER (ENGINE COOLANT TEMPERATURE) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Turn the tester on. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / COOLANT TEMP. (e) Read the value displayed on the tester. Standard value: Between 80°C and 100°C (176°F and 212°F) with warm engine. Result Temperature Displayed Proceed to -40°C (-40°F) A 140°C (284°F) or higher B Between 80°C and 100°C (176°F and 212°F) C HINT: • If there is an open circuit, the intelligent tester indicates -40°C (-40°F). • If there is a short circuit, the intelligent tester indicates 140°C (284°F) or higher. B Go to step 5 ES ES–116 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM C CHECK FOR INTERMITTENT PROBLEMS A 3 READ VALUE USING INTELLIGENT TESTER (CHECK FOR OPEN IN WIRE HARNESS) ECM ECT Sensor ES THW ETHW Wire Harness Side: ECT Sensor Connector (a) Disconnect the C4 Engine Coolant Temperature (ECT) sensor connector. (b) Connect terminals 1 and 2 of the ECT sensor connector on the wire harness side. (c) Connect the intelligent tester to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn the tester on. (f) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / COOLANT TEMP. (g) Read the value displayed on the tester. Standard value: 140°C (284°F) or higher. (h) Reconnect the ECT sensor connector. NG Go to step 4 C4 Front View A107691E20 OK CONFIRM GOOD CONNECTION TO SENSOR. IF OK, REPLACE ENGINE COOLANT TEMPERATURE SENSOR ES–117 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 4 CHECK HARNESS AND CONNECTOR (ENGINE COOLANT TEMPERATURE SENSOR ECM) (a) Disconnect the C4 ECT sensor connector. (b) Disconnect the C24 ECM connector. (c) Measure the resistance between the terminals of the wire harness side connectors. Standard resistance Wire Harness Side: E2 C4 ECT Sensor Connector THW Front View Front View Specified Condition Below 1 Ω C4-1 (E2) - C24-96 (ETHW) Below 1 Ω (d) Reconnect the ECT sensor connector. (e) Reconnect the ECM connector. C24 ECM Connector ETHW Tester Connection C4-2 (THW) - C24-97 (THW) NG REPAIR OR REPLACE HARNESS OR CONNECTOR THW A112602E24 OK CONFIRM GOOD CONNECTION TO ECM. IF OK, REPLACE ECM 5 READ VALUE USING INTELLIGENT TESTER (CHECK FOR SHORT IN WIRE HARNESS) ECT Sensor (a) (b) (c) (d) (e) ECM THW ETHW A084869E26 Disconnect the C4 ECT sensor connector. Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Turn the tester on. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / COOLANT TEMP. (f) Read the value displayed on the tester. Standard value: -40°C (-40°F) (g) Reconnect the ECT sensor connector. NG OK REPLACE ENGINE COOLANT TEMPERATURE SENSOR Go to step 6 ES ES–118 6 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (ENGINE COOLANT TEMPERATURE SENSOR ECM) (a) Disconnect the C4 ECT sensor connector. (b) Disconnect the C24 ECM connector. (c) Measure the resistance between the terminals of the wire harness side connectors. Standard resistance Wire Harness Side: C4 ECT Sensor Connector THW ES THW A112602E25 REPLACE ECM 10 kΩ or higher NG C24 ECM Connector OK Specified Condition (d) Reconnect the ECT sensor connector. (e) Reconnect the ECM connector. Front View Front View Tester Connection C4-2 (THW) or C24-97 (THW) - Body ground REPAIR OR REPLACE HARNESS OR CONNECTOR ES–119 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC Engine Coolant Temperature Circuit Range / Performance Problem P0116 DESCRIPTION Refer to DTC P0115 (See page ES-108). DTC No. DTC Detection Condition P0116 When either of following conditions is met (2 trip detection logic): • When cold engine started and engine warmed up, Engine Coolant Temperature (ECT) sensor value does not change. • After engine is warmed up, ECT sensor value does not change when engine stopped and then next cold engine start is performed. Trouble Area • • Thermostat ECT sensor MONITOR DESCRIPTION Engine coolant temperature (ECT) sensor cold start monitor When a cold engine start is performed and then the engine is warmed up, if the ECT sensor value does not change, it is determined that a malfunction has occurred. If this is detected in 2 consecutive driving cycles, the MIL is illuminated and a DTC is set. ECT sensor soak monitor After a warmed up engine is started, if the ECT sensor value does not change when the engine is stopped and then the next cold engine start is performed, it is determined that a malfunction has occurred. If this is detected in 2 consecutive driving cycles, the MIL is illuminated and a DTC is set. MONITOR STRATEGY Related DTCs P0116: Engine coolant temperature (ECT) sensor cold start monitor P0116: ECT sensor soak monitor Required Sensors/Components (Main) ECT sensor Required Sensors/Components (Related) None Frequency of Operation Once per driving cycle Duration 5 hours or more MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS ECT Sensor cold start monitor: Monitor runs whenever following DTCs are not present P0100 to P0103: Mass Air Flow (MAF) meter Battery voltage 10.5 V or more Time after engine start 1 second or more ECT at engine start Less than 60°C (140°F) IAT sensor circuit OK Soak time 5 hours or more Accumulated MAF Except PZEV: 621.76 g or more PZEV: 608 g or more Engine Running Fuel cut OFF Difference between ECT at engine start and IAT Less than 40°C (72°F) ECT Sensor soak monitor: Monitor runs whenever following DTCs not present P0100 to P0103: MAF meter P0110 to P0113: IAT sensor ES ES–120 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Battery voltage 10.5 V or more Engine Running Soak time 5 hours or more Either of the following conditions (a) or (b) is met - (a) ECT 60°C (140°F) or more (b) Accumulated MAF Except PZEV: 1,021.88 g or more PZEV: 947 g or more TYPICAL MALFUNCTION THRESHOLDS ECT Sensor cold start monitor: ECT sensor value change ES Less than 5°C (9°F) ECT Sensor soak monitor: Difference between current ECT sensor value and previous ECT sensor value when engine stopped Less than 5°C (9°F) COMPONENT OPERATING RANGE ECT ECT sensor value changes in accordance with actual ECT INSPECTION PROCEDURE HINT: • If any of DTCs P0115, P0117, P0118 or P0125 are set simultaneously with DTC P0116, the ECT sensor may have an open or a short circuit. Troubleshoot those DTCs first. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P0116) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Turn the tester on. Select the following menu items: DIAGNOSIS / ENHANCED II / DTC INFO / CURRENT CODES. (e) Read the DTCs. Result Display (DTC Output) Proceed to P0116 A P0116 and other DTCs B B GO TO DTC CHART A 2 INSPECT THERMOSTAT (a) Remove the thermostat (See page CO-12). (b) Measure the valve opening temperature of the thermostat. 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–121 Standard value: 80°C to 84°C (176°F to 183°F) HINT: In addition to the above check, confirm that the valve is completely closed when the temperature is below the standard. (c) Reinstall the thermostat (See page CO-13). NG REPLACE THERMOSTAT OK REPLACE ENGINE COOLANT TEMPERATURE SENSOR ES ES–122 ES 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0120 Throttle / Pedal Position Sensor / Switch "A" Circuit Malfunction DTC P0122 Throttle / Pedal Position Sensor / Switch "A" Circuit Low Input DTC P0123 Throttle / Pedal Position Sensor / Switch "A" Circuit High Input DTC P0220 Throttle / Pedal Position Sensor / Switch "B" Circuit DTC P0222 Throttle / Pedal Position Sensor / Switch "B" Circuit Low Input DTC P0223 Throttle / Pedal Position Sensor / Switch "B" Circuit High Input DTC P2135 Throttle / Pedal Position Sensor / Switch "A" / "B" Voltage Correlation HINT: These DTCs relate to the Throttle Position (TP) sensor. DESCRIPTION The TP sensor is mounted on the throttle body, and detects the opening angle of the throttle valve. This sensor is a non-contact type. It uses Hall-effect elements in order to yield accurate signals even in extreme driving conditions, such as at high speeds as well as very low speeds. The TP sensor has two sensor circuits which each transmits a signal, VTA1 and VTA2. VTA1 is used to detect the throttle valve angle and VTA2 is used to detect malfunctions in VTA1. The sensor signal voltages vary between 0 V and 5 V in proportion to the throttle valve opening angle, and are transmitted to the VTA terminals of the ECM. As the valve closes, the sensor output voltage decreases and as the valve opens, the sensor output voltage increases. The ECM calculates the throttle valve opening angle according to these signals and controls the throttle actuator in response to driver inputs. These signals are also used in calculations such as air-fuel ratio correction, power increase correction and fuel-cut control. ES–123 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Fail-Safe Angle Sensor Output Voltage (V) 5.0 4.8 VTA2 VTA1 2.55 2.25 Throttle Position Sensor Magnet ECM 0.93 0.69 ES 6° IC No. 1 VC E2 84° Throttle Valve Opening Angle (q) VTA1 VTA2 Usable Range 0° Note: The throttle valve opening angle detected by the sensor terminal VTA1 is expressed as a percentage. Between 10 % and 22 %: Throttle valve fully closed IC No. 2 Between 66 % and 98 %: Throttle valve fully open Magnet Approximately 19 %: Fail-safe angle (6°) A122493E04 DTC No. DTC Detection Condition P0120 Output voltage of VTA1 quickly fluctuates beyond lower and upper malfunction thresholds for 2 seconds when accelerator pedal depressed (1 trip detection logic) Trouble Area • • Throttle Position (TP) sensor (built into throttle body) ECM P0122 Output voltage of VTA1 0.2 V or less for 2 seconds when accelerator pedal depressed (1 trip detection logic) • • • • TP sensor (built into throttle body) Short in VTA1 circuit Open in VC circuit ECM P0123 Output voltage of VTA1 4.535 V or more for 2 seconds when accelerator pedal depressed (1 trip detection logic) • • • • • TP sensor (built into throttle body) Open in VTA1 circuit Open in E2 circuit Short between VC and VTA1 circuits ECM P0220 Output voltage of VTA2 quickly fluctuates beyond lower and upper malfunction thresholds for 2 seconds when accelerator pedal depressed (1 trip detection logic) • • TP sensor (built into throttle body) ECM ES–124 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. ES DTC Detection Condition Trouble Area P0222 Output voltage of VTA2 1.75 V or less for 2 seconds when accelerator pedal depressed (1 trip detection logic) • • • • TP sensor (built into throttle body) Short in VTA2 circuit Open in VC circuit ECM P0223 Output voltage of VTA2 4.8 V or more, and VTA1 between 0.2 V and 2.02 V for 2 seconds when accelerator pedal depressed (1 trip detection logic) • • • • • TP sensor (built into throttle body) Open in VTA2 circuit Open in E2 circuit Short between VC and VTA2 circuits ECM P2135 Either condition (a) or (b) is met (1 trip detection logic): (a) Difference between output voltages of VTA1 and VTA2 0.02 V or less for 0.5 seconds or more (b) Output voltage of VTA1 0.2 V or less, and VTA2 1.75 V or less, for 0.4 seconds or more • • • Short between VTA1 and VTA2 circuits TP sensor (built into throttle body) ECM HINT: • When any of these DTCs are set, check the throttle valve opening angle by selecting the following menu items on the intelligent tester: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ETCS / THROTTLE POS #1 AND THROTTLE POS #2. • THROTTLE POS #1 denotes the VTA1 signal, and THROTTLE POS #2 denotes the VTA2 signal. Reference (Normal Condition): Tester Display Accelerator Pedal Fully Released Accelerator Pedal Fully Depressed THROTTLE POS #1 0.5 to 1.1 V 3.3 to 4.9 V THROTTLE POS #2 2.1 to 3.1 V 4.6 to 5.0 V MONITOR DESCRIPTION The ECM uses the Throttle Position (TP) sensor to monitor the throttle valve opening angle. There are several checks that the ECM performs to confirm the proper operation of the TP sensor. • A specific voltage difference is expected between the sensor terminals, VTA1 and VTA2, for each throttle valve opening angle. If the difference between VTA1 and VTA2 is incorrect, the ECM interprets this as a malfunction in the sensor, and sets a DTC. • VTA1 and VTA2 each have a specific voltage range. If VTA1 or VTA2 is outside the normal operating range, the ECM interprets this as a malfunction in the sensor, and sets a DTC. • VTA1 and VTA2 should never be close to the same voltage level. If VTA1 is within 0.02 V of VTA2, the ECM determines that there is a short circuit in the sensor, and sets a DTC. If the malfunction is not repaired successfully, a DTC is set 10 seconds after the engine is next started. MONITOR STRATEGY Related DTCs P0120: Throttle position sensor 1 range check (Fluctuating) P0122: Throttle position sensor 1 range check (Low voltage) P0123: Throttle position sensor 1 range check (High voltage) P0220: Throttle position sensor 2 range check (Fluctuating) P0222: Throttle position sensor 2 range check (Low voltage) P0223: Throttle position sensor 2 range check (High voltage) P2135: Throttle position sensor range check (Correlation) Required Sensors/Components (Main) Throttle position sensor Required Sensors/Components (Related) - Frequency of Operation Continuous Duration 2 seconds: P0120, P0122, P0123, P0220, P0222 and P0223 (Accelerator pedal ON) 10 seconds: P0120, P0122, P0123, P0220, P0222 and P0223 (Accelerator pedal OFF) 0.5 seconds: P2135 Case 1 0.4 seconds: P2135 Case 2 MIL Operation Immediate Sequence of Operation None 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–125 TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present None Electronic throttle actuator power ON TYPICAL MALFUNCTION THRESHOLDS P0120: VTA1 voltage 0.2 V or less, or 4.535 V or more P0122: VTA1 voltage 0.2 V or less P0123: VTA1 voltage 4.535 V or more P0220: VTA2 voltage 1.75 V or less, or 4.8 V or more P0222: VTA2 voltage 1.75 V or less P0223: VTA2 voltage when VTA1 voltage is 0.2 V or more, and 2.02 V or less 4.8 V or more P2135 Case 1: Difference between VTA1 and VTA2 voltages 0.02 V or less P2135 Case 2: VTA1 voltage 0.2 V or less VTA2 voltage 1.75 V or less COMPONENT OPERATING RANGE VTA1 voltage 0.69 to 4.05 V VTA2 voltage 2.25 to 4.8 V FAIL-SAFE When any of these DTCs, as well as other DTCs relating to ETCS (Electronic Throttle Control System) malfunctions, are set, the ECM enters fail-safe mode. During fail-safe mode, the ECM cuts the current to the throttle actuator off, and the throttle valve is returned to a 6° throttle angle by the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing, in accordance with the accelerator pedal opening angle, to allow the vehicle to continue at a minimal speed. If the accelerator pedal is depressed gently, the vehicle can be driven slowly. Fail-safe mode continues until a pass condition is detected, and the ignition switch is then turned off. ES ES–126 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM C5 Throttle Position Sensor (Built into Throttle Body) VC VTA ES VTA2 E2 ECM 5 67 VCTA C24 6 115 VTA1 C24 4 114 VTA2 C24 3 91 ETA C24 A088199E06 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the airfuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 READ VALUE USING INTELLIGENT TESTER (THROTTLE POS #1 AND THROTTLE POS #2) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ETCS / THROTTLE POS #1 and THROTTLE POS #2. (d) Check the values displayed on the tester. Result TP#1 (VTA1) When Accelerator Pedal Released TP#2 (VTA2) When Accelerator Pedal Released TP#1 (VTA1) When Accelerator Pedal Depressed TP#2 (VTA2) When Accelerator Pedal Depressed Trouble Area 0 V to 0.2 V 0 V to 0.2 V 0 V to 0.2 V 0 V to 0.2 V VC circuit open 4.5 V to 5.0 V 4.5 V to 5.0 V 4.5 V to 5.0 V 4.5 V to 5.0 V E2 circuit open 0 V to 0.2 V, or 4.5 V to 5.0 V 2.4 V to 3.4 V (Fail-safe) 0 V to 0.2 V, or 4.5 V to 5.0 V 2.4 V to 3.4 V (Fail-safe) VTA1 circuit open or ground short 0.7 V to 1.3 V (Fail-safe) 0 V to 0.2 V, or 4.5 V to 5.0 V 0.7 V to 1.3 V (Fail-safe) 0 V to 0.2 V, or 4.5 V to 5.0 V VTA2 circuit open or ground short 0.5 V to 1.1 V 2.1 V to 3.1 V 3.3 V to 4.9 V (Not fail-safe) 4.6 V to 5.0 V (Not fail-safe) TP sensor circuit normal Proceed to A B ES–127 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: TP#1 denotes THROTTLE POS #1, and TP#2 denotes THROTTLE POS #2. B Go to step 5 A 2 CHECK HARNESS AND CONNECTOR (THROTTLE POSITION SENSOR - ECM) Wire Harness Side: C5 Throttle Body Connector (a) Disconnect the C5 throttle body connector. (b) Disconnect the C24 ECM connector. (c) Measure the resistance between the terminals of the wire harness side connectors. Standard resistance (Check for open) VTA2 E2 VTA 1 2 3 4 5 6 VC Front View VCTA C24 ECM Connector ETA VTA2 VTA1 Tester Connection Front View A107944E07 Specified Condition C5-5 (VC) - C24-67 (VCTA) Below 1 Ω C5-6 (VTA) - C24-115 (VTA1) Below 1 Ω C5-4 (VTA2) - C24-114 (VTA2) Below 1 Ω C5-3 (E2) - C24-91 (ETA) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition C5-5 (VC) or C24-67 (VCTA) - Body ground 10 kΩ or higher C5-6 (VTA) or C24-115 (VTA1) - Body ground 10 kΩ or higher C5-4 (VTA2) or C24-114 (VTA2) - Body ground 10 kΩ or higher (d) Reconnect the throttle body connector. (e) Reconnect the ECM connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 INSPECT ECM (VC VOLTAGE) Wire Harness Side: C5 Throttle Body Connector E2 VC (a) Disconnect the C5 throttle body connector. (b) Turn the ignition switch to the ON position. (c) Measure the voltage between the terminals of the throttle body connector. Standard voltage 1 2 3 4 5 6 Front View Specified Condition 4.5 to 5.5 V (d) Reconnect the throttle body connector. A107895E06 OK Tester Connection C5-5 (VC) - C5-3 (E2) NG REPLACE ECM ES ES–128 4 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM REPLACE THROTTLE BODY ASSEMBLY NEXT 5 CHECK WHETHER DTC OUTPUT RECURS (THROTTLE POSITION SENSOR DTCS) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the tester on. (c) Clear the DTCs (See page ES-38). (d) Start the engine. (e) Allow the engine to idle for 15 seconds or more. (f) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (g) Read the DTCs. ES Result Display (DTC Output) Proceed to P0120, P0122, P0123, P0220, P0222, P0223, and/or P2135 A No output B B A REPLACE ECM SYSTEM OK ES–129 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC Throttle / Pedal Position Sensor / Switch "A" Circuit Range / Performance Problem P0121 HINT: This DTC relates to the Throttle Position (TP) sensor. DESCRIPTION Refer to DTC P0120 (See page ES-117). DTC No. DTC Detection Condition P0121 Difference between VTA1 and VTA2 voltages less than 0.8 V, or more than 1.6 V for 2 seconds (1 trip detection logic) Trouble Area TP sensor (built into throttle body) MONITOR DESCRIPTION The ECM uses the TP sensor to monitor the throttle valve opening angle. This sensor transmits two signals: VTA1 and VTA2. VTA1 is used to detect the throttle opening angle and VTA2 is used to detect malfunctions in VTA1. The ECM performs several checks to confirm the proper operation of the TP sensor and VTA1. For each throttle opening angle, a specific voltage difference is expected between the outputs of VTA1 and VTA2. If the output voltage difference between the two signals deviates from the normal operating range, the ECM interprets this as a malfunction of the TP sensor. The ECM illuminates the MIL and sets the DTC. If the malfunction is not repaired successfully, the DTC is set 2 seconds after the engine is next started. MONITOR STRATEGY Related DTCs P0121: TP sensor rationality Required Sensors/Components (Main) TP sensor Required Sensors/Components (Related) - Frequency of Operation Continuous Duration Within 2 seconds MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present P0120 - P0223, P2135 (TP sensor) Either of the following conditions A or B is met - A. Ignition switch ON B. Electric throttle motor power ON TP sensor malfunction (P0120, P0122, P0123, P0220, P0222, P0223, P2135) Not detected TYPICAL MALFUNCTION THRESHOLDS Either of the following conditions A or B is met - Difference of the TP sensor voltage between VTA1 and VTA2 x 0.8 More than 1.6 V Difference of the TP sensor voltage between VTA1 and VTA2 x 0.8 Less than 0.8 V ES ES–130 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM FAIL-SAFE When this DTC, as well as other DTCs relating to ETCS (Electronic Throttle Control System) malfunctions, is set, the ECM enters fail-safe mode. During fail-safe mode, the ECM cuts the current to the throttle actuator off, and the throttle valve is returned to a 6° throttle angle by the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing, in accordance with the accelerator pedal opening angle, to allow the vehicle to continue at a minimal speed. If the accelerator pedal is depressed gently, the vehicle can be driven slowly. Fail-safe mode continues until a pass condition is detected, and the ignition switch is then turned off. INSPECTION PROCEDURE ES HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the airfuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P0121) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Turn the tester on. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read the DTCs. Result Display (DTC output) Proceed to P0121 A P0121 and other DTCs B B A REPLACE THROTTLE BODY ASSEMBLY GO TO DTC CHART ES–131 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0125 Insufficient Coolant Temperature for Closed Loop Fuel Control DESCRIPTION Refer to DTC P0115 (See page ES-108). DTC No. P0125 DTC Detection Condition Engine Coolant Temperature (ECT) does not reach closed-loop enabling temperature for 20 minutes (this period varies with engine start ECT) (2 trip detection logic) Trouble Area • • • ECT sensor Cooling system Thermostat MONITOR DESCRIPTION The resistance of the ECT sensor varies in proportion to the actual ECT. The ECT supplies a constant voltage to the sensor and monitors the signal output voltage of the sensor. The signal voltage output varies according to changes in the resistance of the sensor. After the engine is started, the ECT is monitored through this signal. If the ECT sensor indicates that the engine is not yet warm enough for closed-loop fuel control, despite a specified period of time having elapsed since the engine was started, the ECM interprets this as a malfunction in the sensor or cooling system and sets the DTC. Example: The ECT is 0°C (32°F) at engine start. After about 1 minute running time, the ECT sensor still indicates that the engine is not warm enough to begin closed-loop fuel (air-fuel ratio feedback) control. The ECM interprets this as a malfunction in the sensor or cooling system and sets the DTC. MONITOR STRATEGY Related DTCs P0125: Insufficient engine coolant temperature for closed-loop fuel control Required Sensors/Components (Main) Thermostat, cooling system Required Sensors/Components (Related) Engine coolant temperature sensor and mass air flow meter Frequency of Operation Once per driving cycle Duration Except PZEV: 62.94 seconds or more: Engine coolant temperature at engine start -8.34°C (17°F) or more 135.32 seconds or more: Engine coolant temperature at engine start -8.34 to 19.45°C (17 to -3°F) 20 minutes or more: Engine coolant temperature at engine start less than 19.45°C (-3°F) PZEV: 52.5 seconds or more: Engine coolant temperature at engine start -8.34°C (17°F) or more 97.56 seconds or more: Engine coolant temperature at engine start -8.34 to 19.45°C (17 to -3°F) 20 minutes or more: Engine coolant temperature at engine start less than 19.45°C (-3°F) MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present P0100 - P0103 (MAF meter) P0110 - P0113 (IAT sensor) P0115 - P0118 (ECT sensor) Thermostat OK ES ES–132 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TYPICAL MALFUNCTION THRESHOLDS Except PZEV: 62.94 seconds or more: Engine coolant temperature at engine start -8.34°C (17°F) or more 135.32 seconds or more: Engine coolant temperature at engine start -8.34 to 19.45°C (17 to -3°F) 20 minutes or more: Engine coolant temperature at engine start less than 19.45°C (-3°F) PZEV: 52.5 seconds or more: Engine coolant temperature at engine start -8.34°C (17°F) or more 97.56 seconds or more: Engine coolant temperature at engine start -8.34 to 19.45°C (17 to -3°F) 20 minutes or more: Engine coolant temperature at engine start less than 19.45°C (-3°F) Time until actual engine coolant temperature reaches closedloop fuel control enabling temperature ES WIRING DIAGRAM Refer to DTC P0115 (See page ES-109). INSPECTION PROCEDURE HINT: • If any of DTCs P0115, P0116, P0117 or P0118 are set simultaneously with DTC P0125, the Engine Coolant Temperature (ECT) sensor may have an open or a short circuit. Troubleshoot those DTCs first. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P0125) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Turn the tester on. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read the DTCs. Result Display (DTC Output) Proceed to P0125 A P0125 and other DTCs B HINT: If any DTCs other than P0125 are output, troubleshoot those DTCs first. B GO TO DTC CHART A 2 INSPECT THERMOSTAT (a) Remove the thermostat (See page CO-12). (b) Check the valve opening temperature of the thermostat. Standard value: 80 to 84°C (176 to 183°F) 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–133 HINT: In addition to the above check, confirm that the valve is completely closed when the temperature is below the standard. (c) Reinstall the thermostat (See page CO-13). NG REPLACE THERMOSTAT OK 3 CHECK COOLING SYSTEM (a) Check for defects in the cooling system that might cause the system to be too cold, such as abnormal radiator fan operation or any modifications. NG REPAIR OR REPLACE COOLING SYSTEM OK REPLACE ENGINE COOLANT TEMPERATURE SENSOR ES ES–134 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0128 Coolant Thermostat (Coolant Temperature Below Thermostat Regulating Temperature) HINT: This DTC relates to the thermostat. DESCRIPTION This DTC is set when the Engine Coolant Temperature (ECT) does not reach 75°C (167°F) despite sufficient engine warm-up time having elapsed. DTC No. ES P0128 DTC Detection Condition Trouble Area Conditions (a), (b) and (c) are met for 5 seconds (2 trip detection logic): (a) Cold start (b) Engine warmed up (c) ECT less than 75°C (167°F) • • • • Thermostat Cooling system ECT sensor ECM MONITOR DESCRIPTION Temperature 5 seconds Estimated ECT Threshold (75°C (167°F)) Indicated ECT Reading ECT Time DTC Set (after 2 Driving Cycles) A121605E03 The ECM estimates the ECT based on the starting temperature, engine loads, and engine speeds. The ECM then compares the estimated temperature with the actual ECT. When the estimated ECT reaches 75°C (167°F), the ECM checks the actual ECT. If the actual ECT is less than 75°C (167°F), the ECM interprets this as a malfunction in the thermostat or the engine cooling system and sets the DTC. MONITOR STRATEGY Related DTCs P0128: Coolant Thermostat Required Sensors/Components (Main) Thermostat 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Required Sensors/Components (Related) ES–135 Engine Coolant Temperature (ECT) sensor, Intake Air Temperature (IAT) sensor, Vehicle speed sensor Frequency of Operation Once per driving cycle Duration 450 seconds MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present P0010 (VVT OCV ) P0011 (VVT System 1 - Advance) P0012 (VVT System 1 - Retard) P0031, P0032 (A/F sensor heater - Sensor 1) P0100 - P0103 (MAF meter) P0110 - P0113 (IAT sensor) P0115 - P0118 (ECT sensor) P0125 (Insufficient ECT for Closed Loop) P0171, P0172 (Fuel system) P0300 - P0304 (Misfire) P0335 (CKP sensor) P0340 (CMP sensor) P0351 - P0354 (Igniter) P0500 (VSS) P2196 (A/F sensor - rationality) P2A00 (A/F sensor - slow response) Battery voltage 11 V or more Either of the following conditions 1 or 2 is met: - 1. All of the following conditions are met: - • ECT at engine start - IAT at engine start -15 to 7°C (-27 to 12.6°F) • ECT at engine start -10 to 56°C (14 to 133°F) • IAT at engine start 2. All of the following conditions are met: -10 to 56°C (14 to 133°F) - • ECT at engine start - IAT at engine start More than 7°C (12.6°F) • ECT at engine start 56°C (133°F) or less • IAT at engine start Accumulated time at 80 mph (128 km/h) or more -10°C (14°F) or more Less than 20 seconds TYPICAL MALFUNCTION THRESHOLDS Duration that both following conditions (a) and (b) are met 5 seconds or more (a) Estimated ECT 75°C (167°F) or more (b) ECT sensor output Below 75°C (167°F) INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the airfuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P0128) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position. (c) Turn the tester on. ES ES–136 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (d) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read the DTCs. Result Display (DTC Output) Proceed to P0128 A P0128 and other DTCs B HINT: If any DTCs other than P0128 are output, troubleshoot those DTCs first. B ES GO TO DTC CHART A 2 CHECK COOLING SYSTEM (a) Check for defects in the cooling system that might cause the system to be too cold, such as abnormal radiator fan operation or any modifications. NG REPAIR OR REPLACE COOLING SYSTEM OK 3 INSPECT THERMOSTAT (a) Remove the thermostat (See page CO-12). (b) Measure the valve opening temperature of the thermostat. Standard value: 80 to 84°C (176 to 183°F) HINT: In addition to the above check, confirm that the valve is completely closed when the temperature is below the standard. (c) Reinstall the thermostat (See page CO-13). NG OK REPLACE ECM REPLACE THERMOSTAT 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–137 DTC P0136 Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 2) DTC P0137 Oxygen Sensor Circuit Low Voltage (Bank 1 Sensor 2) DTC P0138 Oxygen Sensor Circuit High Voltage (Bank 1 Sensor 2) DESCRIPTION A three-way catalist converter (TWC) is used in order to convert the carbon monoxide (CO), hydrocarbons (HC), and nitrogen oxide (Nox) into less harmful substrances. To allow the TWC to function effectively, it is necessary to keep the air-fuel ratio of the engine near the stoichiometric air-fuel ratio. For the purpose of helping the ECM to deliver accurate air-fuel ratio control, a Heated Oxygen (HO2) sensor is used. The HO2 sensor is located behind the TWC, and detects the oxygen concentration in the exhaust gas. Since the sensor is integrated with the heater that heats the sensing portion, it is possible to detect the oxygen concentration even when the intake air volume is low (the exhaust gas temperature is low). When the air-fuel ratio becomes lean, the oxygen concentration in the exhaust gas is rich. The HO2 sensor informs the ECM that the post-TWC air-fuel ratio is lean (low voltage, i.e. less than 0.45 V). Conversely, when the air-fuel ratio is richer than the stoichiometric air-fuel level, the oxygen concentration in the exhaust gas becomes lean. The HO2 sensor informs the ECM that the post-TWC air-fuel ratio is rich (high voltage, i.e. more than 0.45 V). The HO2 sensor has the property of changing its output voltage drastically when the air-fuel ratio is close to the stoichiometric level. The ECM uses the supplementary information from the HO2 sensor to determine whether the air-fuel ratio after the TWC is rich or lean, and adjusts the fuel injection time accordingly. Thus, if the HO2 sensor is working improperly due to internal malfunctions, the ECM is unable to compensate for deviations in the primary air-fuel ratio control. Atmosphere PZEV: Output Voltage Ideal Air-Fuel Mixture Housing Solid Electrolyte (Zirconia Element) Platinum Electrode Heater Coating (Ceramic) Cover Richer - Air-Fuel Ratio - Leaner Exhaust Gas A088111E16 ES ES–138 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Except PZEV: Atmospheric Air Housing Output Voltage Ideal Air-fuel Mixture Platinum Electrode Solid Electrolyte (Zirconia Element) ES Heater Coating (Ceramic) Cover Richer - Air-fuel Ratio - Leaner Exhaust Gas A131740E06 DTC No. DTC Detection Condition • P0136 • • P0137 • • P0138 • Trouble Area Abnormal voltage output: During active air-fuel ratio control, following conditions (a) and (b) are met for a certain period of time (2 trip detection logic): (a) Heated Oxygen (HO2) sensor voltage does not decrease to less than 0.59 V (b) HO2 sensor voltage does not increase to more than 0.21 V Low impedance: Sensor impedance less than 5 Ω for more than 30 seconds when ECM presumes sensor to be warmed up and operating normally (2 trip detection logic) • • • • • • Open or short in HO2 sensor (sensor 2) circuit HO2 sensor (sensor 2) HO2 sensor heater (sensor 2) Air-fuel Ratio (A/F) sensor (sensor 1) Engine room J/B (EFI relay) Gas leakage from exhaust system Low voltage (open): During active air-fuel ratio control, following conditions (a) and (b) are met for a certain period of time (2 trip detection logic): (a) HO2 sensor voltage output less than 0.21 V (b) Target air-fuel ratio rich High impedance: Sensor impedance 15 kΩ or more for more than 90 seconds when ECM presumes sensor to be warmed up and operating normally (2 trip detection logic) • • • • • Open in HO2 sensor (sensor 2) circuit HO2 sensor (sensor 2) HO2 sensor heater (sensor 2) Engine room J/B (EFI relay) Gas leakage from exhaust system High voltage (short): During active air-fuel ratio control, following conditions (a) and (b) are met for a certain period of time (2 trip detection logic): (a) HO2 sensor voltage output more than 0.59 V (b) Target air-fuel ratio lean Extremely high voltage (short): HO2 sensor voltage output exceeds 1.2 V for more than 10 seconds (2 trip detection logic) • • • Short in HO2 sensor (sensor 2) circuit HO2 sensor (sensor 2) ECM internal circuit malfunction 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–139 MONITOR DESCRIPTION Active Air-Fuel Ratio Control: The ECM usually performs air-fuel ratio feedback control so that the Air-Fuel Ratio (A/F) sensor output indicates a near stoichiometric air-fuel level. This vehicle includes active air-fuel ratio control in addition to regular air-fuel ratio control. The ECM performs active air-fuel ratio control to detect any deterioration in the Three-Way Catalytic Converter (TWC) and Heated Oxygen (HO2) sensor malfunctions (refer to the diagram below). Active air-fuel ratio control is performed for approximately 15 to 20 seconds while driving with a warm engine. During active air-fuel ratio control, the air-fuel ratio is forcibly regulated to become lean or rich by the ECM. If the ECM detects a malfunction, one of the following DTCs is set: DTC P0136 (abnormal voltage output), P0137 (open circuit) and P0138 (short circuit). Abnormal Voltage Output of HO2 Sensor (DTC P0136): While the ECM is performing active air-fuel ratio control, the air-fuel ratio is forcibly regulated to become rich or lean. If the sensor is not functioning properly, the voltage output variation is small. For example, when the HO2 sensor voltage does not decrease to less than 0.21 V and does not increase to more than 0.59 V during active air-fuel ratio control, the ECM determines that the sensor voltage output is abnormal and sets DTC P0136. HO2 SENSOR CIRCUIT MALFUNCTION 15 to 20 seconds (P0136: ABNORMAL VOLTAGE) Active air-fuel ratio control Off Operation Normal 0.59 V HO2 sensor voltage Abnormal 0.21 V A115540E02 Open or Short in Heated Oxygen (HO2) Sensor Circuit (DTC P0137 or P0138): During active air-fuel ratio control, the ECM calculates the Oxygen Storage Capacity (OSC)* of the ThreeWay Catalytic Converter (TWC) by forcibly regulating the air-fuel ratio to become rich or lean. If the HO2 sensor has an open or short, or the voltage output of the sensor decreases significantly, the OSC indicates an extraordinarily high value. Even if the ECM attempts to continue regulating the air-fuel ratio to become rich or lean, the HO2 sensor output does not change. While performing active air-fuel ratio control, when the target air-fuel ratio is rich and the HO2 sensor voltage output is 0.21 V or less (lean), the ECM interprets this as an abnormally low sensor output voltage and sets DTC P0137. When the target air-fuel ratio is lean and the voltage output is 0.59 V or more (rich) during active air-fuel ratio control, the ECM determines that the sensor voltage output is abnormally high, and sets DTC P0138. HINT: DTC P0138 is also set if the HO2 sensor voltage output is more than 1.2 V for 10 seconds or more. ES ES–140 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM *: The TWC has the capability to store oxygen. The OSC and the emission purification capacity of the TWC are mutually related. The ECM determines whether the catalyst has deteriorated based on the calculated OSC value (See page ES-196). HO2 SENSOR CIRCUIT LOW VOLTAGE (P0137: OPEN) 15 to 20 seconds ES Active air-fuel ratio control Target air-fuel ratio Off Operation Normal Stoichiometric Air-Fuel Level Rich HO2 sensor voltage Abnormal Normal 0.21 V Abnormal HO2 SENSOR CIRCUIT HIGH VOLTAGE (P0138: SHORT) Operation Active air-fuel ratio control Target air-fuel ratio HO2 sensor voltage Off Stoichiometric Air-Fuel Level Lean Abnormal 0.59 V A115541E02 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–141 High or Low Impedance of Heated Oxygen (HO2) Sensor (DTC P0136 or P0137): Relationship between element temperature and impedance: (Ω) 15,000 DTC Detection Area 1,000 100 10 5 300 400 500 600 700 800 (572) (752) (932)(1,112)(1,292)(1,472) °C (°F) A076841E04 During normal air-fuel ratio feedback control, there are small variations in the exhaust gas oxygen concentration. In order to continuously monitor the slight variations in the HO2 sensor signal while the engine is running, the impedance* of the sensor is measured by the ECM. The ECM determines that there is a malfunction in the sensor when the measured impedance deviates from the standard range. *: The effective resistance in an alternating current electrical circuit. HINT: • The impedance cannot be measured using an ohmmeter. • DTC P0136 indicates the deterioration of the HO2 sensor. The ECM sets this DTC by calculating the impedance of the sensor when the typical enabling conditions are satisfied (2 driving cycles). • DTC P0137 indicates an open or short circuit in the HO2 sensor (2 driving cycles). The ECM sets this DTC when the impedance of the sensor exceeds the threshold 15 kΩ. MONITOR STRATEGY Related DTCs P0136: Heated oxygen sensor output voltage (Abnormal voltage output) P0136: Heated oxygen sensor impedance (Low) P0137: Heated oxygen sensor output voltage (Low voltage) P0137: Heated oxygen sensor impedance (High) P0138: Heated oxygen sensor output voltage (High voltage) P0138: Heated oxygen sensor output voltage (Extremely high) Required Sensors/Components (Main) Heated oxygen sensor Required Sensors/Components (Related) Crankshaft position sensor, engine coolant temperature sensor, mass air flow meter and throttle position sensor Frequency of Operation Once per driving cycle: Active air-fuel ratio control detection Continuous: Other Duration 20 seconds: Heated oxygen sensor output voltage (Abnormal voltage output, High voltage and Low voltage) 90 seconds: Heated oxygen sensor impedance (High) 30 seconds: Heated oxygen sensor impedance (Low) 10 seconds: Output voltage (Stuck high) MIL Operation 2 driving cycles Sequence of Operation None ES ES–142 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TYPICAL ENABLING CONDITIONS All: Monitor runs whenever following DTCs are not present ES P0031, P0032 (A/F Sensor heater - Sensor 1) P0037, P0038 (O2 Sensor heater - Sensor 2) P0100 - P0103 (MAF meter) P0110 - P0113 (IAT sensor) P0115 - P0118 (ECT sensor) P0120 - P0223, P2135 (TP sensor) P0125 (Insufficient ECT for Closed Loop) P0171, P0172 (Fuel system) P0300 - P0304 (Misfire) P0335 (CKP sensor) P0340 (CMP sensor) P0451 - P0456, P2401 - P2420 (EVAP system) P0500 (VSS) P2196 (A/F Sensor - rationality) P2A00 (A/F Sensor - slow response) Heated Oxygen Sensor Output Voltage (Abnormal Voltage Output, High Voltage and Low Voltage): Active air-fuel ratio control Performing Active air-fuel ratio control is performed when the following conditions are met: - Battery voltage 11 V or more Engine coolant temperature 75°C (167°F) or more Idling OFF Engine RPM Less than 4,000 rpm A/F sensor status Activated Fuel system status Closed loop Fuel cut OFF Engine load 10 to 80 % Shift position 4th (Automatic Transaxle) 3rd or more (Manual Transaxle) Heated Oxygen Sensor Impedance (Low): Battery voltage 11 V or more Estimated rear HO2 sensor temperature Less than 700°C (1,292°F) ECM monitor Completed DTC P0606 Not set Heated Oxygen Sensor Impedance (High): Battery voltage 11 V or more Estimated rear HO2 sensor temperature 450°C (842°F) or more DTC P0606 Not present Heated Oxygen Sensor Output Voltage (Extremely High): Battery voltage 11 V or more Time after engine start 2 seconds or more TYPICAL MALFUNCTION THRESHOLDS Heated Oxygen Sensor Output Voltage (Abnormal Voltage Output): Either of the following conditions is met: 1 or 2 1. All of the following conditions (a), (b) and (c) are met - (a) Commanded air-fuel ratio 14.3 or less (b) Rear HO2 sensor voltage 0.21 to 0.59 V (c) OSC (Oxygen Storage Capacity of Catalyst) 2 g or more 2. All of the following conditions (d), (e) and (f) are met - 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (d) Commanded air-fuel ratio 14.9 or more (e) Rear HO2 sensor voltage 0.21 to 0.59 V (f) OSC 2 g or more ES–143 Heated Oxygen Sensor Output Voltage (Low): All of the following conditions (a), (b) and (c) are met - (a) Commanded air-fuel ratio 14.3 or less (b) Rear HO2 sensor voltage Less than 0.21 V (c) OSC 2 g or more Heated Oxygen Sensor Output Voltage (High): All of the following conditions (a), (b) and (c) are met - (a) Commanded air-fuel ratio 14.9 or more (b) Rear HO2 sensor voltage More than 0.59 V (c) OSC 2 g or more Heated Oxygen Sensor Impedance (Low): Duration of the following condition is met 30 seconds or more Rear HO2 sensor impedance Less than 5 Ω Heated Oxygen Sensor Impedance (High): Duration of the following condition is met 90 seconds or more Rear HO2 sensor impedance 15 kΩ or more Heated Oxygen Sensor Output Voltage (Extremely High): Duration of the following condition is met 10 seconds or more Rear HO2 sensor voltage 1.2 V or more COMPONENT OPERATING RANGE Duration of the following condition is met 30 seconds or more Heated oxygen sensor voltage Varies between 0.1 and 0.9 V MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-20). ES ES–144 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM EFI ECM C15 A/F Sensor (Bank 1 Sensor 1) +B 109 C24 HA1A HA1A 2 1 (Shielded) A1A- 4 ES 112 C24 A1A+ A1A+ 3 113 C24 A1A- EFI MAIN EFI C22 HO2 Sensor No. 3 (Bank 1 Sensor 2) +B 47 C24 HT1B HT1B 2 1 (Shielded) FL MAIN E2 4 OX1B 3 64 C24 OX1B 87 C24 EX1B Battery 44 A24 MREL A134994E01 CONFIRMATION DRIVING PATTERN HINT: • This confirmation driving pattern is used in the "PERFORM CONFIRMATION DRIVING PATTERN" procedure of the following diagnostic troubleshooting procedure. • Performing this confirmation pattern will activate the Heated Oxygen (HO2) sensor monitor. (The catalyst monitor is performed simultaneously.) This is very useful for verifying the completion of the repair. 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Vehicle Speed (B) Between 40 mph and 70 mph (64 km/h and 113 km/h) ES–145 NOTICE: This test will not be completed if the vehicle is driven at absolutely constant speed such as with cruise control activated. (A) Idling ES Ignition Switch OFF Warm up 10 minutes Time (Note: Even if vehicle stops during driving pattern, test can be resumed) A115372E51 1. Connect the intelligent tester to the DLC3. A098191E02 2. 3. 4. 5. 6. 7. 8. Turn the ignition switch to the ON position. Turn the tester on. Clear the DTCs (if set) (See page ES-38). Select the following menu items: DIAGNOSIS / CARB OBD II / READINESS TESTS. Check that O2S EVAL is INCMPL (incomplete). Start the engine and warm it up. (Proceed "A") Drive the vehicle at between 40 mph and 70 mph (64 km/h and 113 km/h) for at least 10 minutes. (Proceed "B") 9. Note the state of the Readiness Tests items. Those items will change to COMPL (complete) as the O2S EVAL monitor operates. 10.On the tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES and check if any DTCs (any pending DTCs) are set. HINT: If O2S EVAL does not change to COMPL, and any pending DTCs fail to set, extend the driving time. INSPECTION PROCEDURE HINT: Sensor 2 refers to the sensor mounted behind the Three-Way Catalytic Converter (TWC) and located far from the engine assembly. HINT: Intelligent tester only: ES–146 ES 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Malfunctioning areas can be identified by performing the A/F CONTROL function provided in the ACTIVE TEST. The A/F CONTROL function can help to determine whether the Air-Fuel Ratio (A/F) sensor, Heated Oxygen (HO2) sensor and other potential trouble areas are malfunctioning. The following instructions describe how to conduct the A/F CONTROL operation using the intelligent tester. (a)Connect the intelligent tester to the DLC3. (b)Start the engine and turn the tester on. (c) Warm up the engine at an engine speed of 2,500 rpm for approximately 90 seconds. (d)On the tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/ F CONTROL. (e)Perform the A/F CONTROL operation with the engine idling (press the RIGHT or LEFT button to change the fuel injection volume). (f) Monitor the voltage outputs of the A/F and HO2 sensors (AFS B1 S1 and O2S B1 S2) displayed on the tester. HINT: • The A/F CONTROL operation lowers the fuel injection volume by 12.5 % or increases the injection volume by 25 %. • The sensors react in accordance with increases and decreases in the fuel injection volume. Standard Tester Display (Sensor) Injection Volumes Status Voltages AFS B1 S1 (A/F) +25 % Rich Less than 3.0 -12.5 % Lean More than 3.35 O2S B1 S2 (HO2) +25 % Rich More than 0.5 -12.5 % Lean Less than 0.4 NOTICE: The A/F sensor has an output delay of a few seconds and the HO2 sensor has a maximum output delay of approximately 20 seconds. Case 1 2 3 A/F Sensor (Sensor 1) Output Voltage HO2 Sensor (Sensor 2) Output Voltage Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage More than 3.35 V Less than 3.0 V Output Voltage More than 0.5 V Less than 0.4 V Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage Almost no reaction Output Voltage More than 0.5 V Less than 0.4 V Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage More than 3.35 V Less than 3.0 V Output Voltage Almost no reaction Main Suspected Trouble Areas - • • • A/F sensor A/F sensor heater A/F sensor circuit • • • HO2 sensor HO2 sensor heater HO2 sensor circuit ES–147 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Case 4 A/F Sensor (Sensor 1) Output Voltage HO2 Sensor (Sensor 2) Output Voltage Injection volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage Almost no reaction Output Voltage Almost no reaction Main Suspected Trouble Areas • • • Injector Fuel pressure Gas leakage from exhaust system (Air-fuel ratio extremely lean or rich) Following the A/F CONTROL procedure enables technicians to check and graph the voltage outputs of both the A/F and HO2 sensors. To display the graph, select the following menu items on the tester: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL / USER DATA / AFS B1 S1 and O2S B1 S2; then press the YES button and then the ENTER button followed by the F4 button. HINT: • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. • If the OX1B wire from the ECM connector is short-circuited to the +B wire, DTC P0138 will be set. 1 READ OUTPUT DTC (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs. Result Display (DTC output) Proceed to P0138 A P0137 B P0136 C B Go to step 14 C Go to step 7 A 2 READ VALUE USING INTELLIGENT TESTER (OUTPUT VOLTAGE OF HEATED OXYGEN SENSOR) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / O2S B1 S2. (d) Allow the engine to idle. (e) Read the Heated Oxygen (HO2) sensor output voltage while idling. ES ES–148 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Result HO2 Sensor Output Voltages Proceed to More than 1.2 V A Less than 1.0 V B B Go to step 5 A 3 ES CHECK HARNESS AND CONNECTOR (CHECK FOR SHORT) (a) Turn the ignition switch off and wait for 5 minutes. (b) Disconnect the C24 ECM connector. (c) Measure the resistance between the terminals. Standard resistance Wire Harness Side: C24 ECM Connector Tester Connection Specified Condition C24-47 (HT1B) - C24-64 (OX1B) 10 kΩ or higher (d) Reconnect the ECM connector. NG OX1B Go to step 4 Front View HT1B A107892E63 OK REPLACE ECM 4 INSPECT HEATED OXYGEN SENSOR (CHECK FOR SHORT) Component Side : Heated Oxygen Sensor (Sensor 2) +B HT1B 2 4 E2 (a) Disconnect the C22 HO2 sensor connector. (b) Measure the resistance. Standard resistance 1 3 Front View OX1B Tester Connection Specified Condition 1 (HT1B) - 2 (+B) 11 to 16 Ω at 20°C (68°F) 2 (+B) - 3 (OX1B) 10 kΩ or higher (c) Reconnect the HO2 sensor connector. A115661E01 NG OK REPAIR OR REPLACE HARNESS OR CONNECTOR REPLACE HEATED OXYGEN SENSOR ES–149 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 5 PERFORM CONFIRMATION DRIVING PATTERN NEXT 6 CHECK WHETHER DTC OUTPUT RECURS (DTC P0138) (a) On the intelligent tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (b) Read the DTCs. Result Display (DTC Output) Proceed to P0138 A No output B B CHECK FOR INTERMITTENT PROBLEMS A REPLACE HEATED OXYGEN SENSOR 7 READ VALUE USING INTELLIGENT TESTER (OUTPUT VOLTAGE OF HEATED OXYGEN SENSOR) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the tester on. (c) Start the engine. (d) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / O2S B1 S2. (e) After warming up the engine, run the engine at an engine speed of 2,500 rpm for 3 minutes. (f) Read the output voltage of the HO2 sensor when the engine rpm is suddenly increased. HINT: Quickly accelerate the engine to 4,000 rpm 3 times using the accelerator pedal. Standard voltage: Fluctuates between 0.4 V or less and 0.5 V or more. NG OK Go to step 14 ES ES–150 8 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PERFORM CONFIRMATION DRIVING PATTERN NEXT 9 ES CHECK WHETHER DTC OUTPUT RECURS (DTC P0136) (a) On the intelligent tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (b) Read the DTCs. Result Display (DTC Output) Proceed to P0136 A No output B B CHECK FOR INTERMITTENT PROBLEMS A 10 REPLACE HEATED OXYGEN SENSOR NEXT 11 PERFORM CONFIRMATION DRIVING PATTERN NEXT 12 CHECK WHETHER DTC OUTPUT RECURS (DTC P0136) (a) On the intelligent tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (b) Read the DTCs. Result Display (DTC Output) Proceed to P0136 A No output B B A END ES–151 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 13 PERFORM ACTIVE TEST USING INTELLIGENT TESTER (INJECTION VOLUME) Injection Volume +12 % -12 % Malfunction A/F Sensor Output Normal 3.3 V HO2 Sensor Output Malfunction 1V 0V A121606E02 (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Start the engine and turn the tester on. Warm up the engine. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / INJ VOL. (e) Change the fuel injection volume using the tester, and monitor the voltage output of Air-Fuel Ratio (A/F) and HO2 sensors displayed on the tester. HINT: • Change the fuel injection volume within the range of -12 % and +12 %. The injection volume can be changed in 1 % graduations within the range. • The A/F sensor is displayed as AFS B1 S1, and the HO2 sensor is displayed as O2S B1 S2, on the intelligent tester. Result Tester Display (Sensor) AFS B1 S1 (A/F) Voltage Variations Proceed to Alternates between more and less than 3.3 V OK Remains at more than 3.3 V NG Remains at less than 3.3 V NG HINT: A normal HO2 sensor voltage (O2S B1 S2) reacts in accordance with increases and decreases in fuel injection volumes. When the A/F sensor voltage remains at either less or more than 3.3 V despite the HO2 sensor indicating a normal reaction, the A/F sensor is malfunctioning. NG REPLACE AIR-FUEL RATIO SENSOR ES ES–152 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK CHECK AND REPAIR EXTREMELY RICH OR LEAN ACTUAL AIR-FUEL RATIO (INJECTOR, FUEL PRESSURE, GAS LEAKAGE FROM EXHAUST SYSTEM, ETC.) 14 CHECK FOR EXHAUST GAS LEAKAGE OK: No gas leakage. NG ES REPAIR OR REPLACE EXHAUST GAS LEAKAGE POINT OK 15 INSPECT HEATED OXYGEN SENSOR (HEATER RESISTANCE) (See page ES-90) NG REPLACE HEATED OXYGEN SENSOR OK 16 INSPECT ENGINE ROOM J/B (EFI RELAY) (See page ES-85) NG OK REPLACE ENGINE ROOM J/B ES–153 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 17 CHECK HARNESS AND CONNECTOR (HEATED OXYGEN SENSOR - ECM) Wire Harness Side: HO2 Sensor Connector HT1B +B (a) Disconnect the C22 HO2 sensor connector. (b) Turn the ignition switch to the ON position. (c) Measure the voltage between the +B terminal of the HO2 sensor connector and body ground. Standard voltage C22 E2 OX1B Specified Condition C22-2 (+B) - Body ground 9 to 14 V (d) Turn the ignition switch off. (e) Disconnect the C24 ECM connector. (f) Measure the resistance between the terminals of the wire harness side connectors. Standard resistance (Check for open) Front View HT1B Tester Connection C24 ECM Connector Tester Connection EX1B OX1B Specified Condition C22-1 (HT1B) - C24-47 (HT1B) Below 1 Ω C22-3 (OX1B) - C24-64 (OX1B) Below 1 Ω C22-4 (E2) - C24-87 (EX1B) Below 1 Ω Standard resistance (Check for short) Front View Tester Connection A104950E12 Specified Condition C22-1 (HT1B) or C24-47 (HT1B) - Body ground 10 kΩ or higher C22-3 (OX1B) or C24-64 (OX1B) - Body ground 10 kΩ or higher C22-4 (E2) or C24-87 (EX1B) - Body ground 10 kΩ or higher (g) Reconnect the HO2 sensor connector. (h) Reconnect the ECM connector. Reference (System Diagram of Sensor 2): HO2 Sensor EFI from Battery EFI MAIN +B EFI NO. 3 E2 Heater Sensor ECM HT1B HT1B OX1B OX1B EX1B MREL Ground A133556E05 NG REPAIR OR REPLACE HARNESS OR CONNECTOR ES ES–154 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK REPLACE HEATED OXYGEN SENSOR ES ES–155 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0171 System Too Lean (Bank 1) DTC P0172 System Too Rich (Bank 1) DESCRIPTION The fuel trim is related to the feedback compensation value, not to the basic injection time. The fuel trim consists of both the short-term and the long-term fuel trims. The short-term fuel trim is fuel compensation that is used to constantly maintain the air-fuel ratio at stoichiometric levels. The signal from the Air-Fuel Ratio (A/F) sensor indicates whether the air-fuel ratio is rich or lean compared to the stoichiometric ratio. This triggers a reduction in the fuel injection volume if the air-fuel ratio is rich and an increase in the fuel injection volume if it is lean. Factors such as individual engine differences, wear over time and changes in operating environment cause short-term fuel trim to vary from the central value. The long-term fuel trim, which controls overall fuel compensation, compensates for long-term deviations in the fuel trim from the central value caused by the short-term fuel trim compensation. If both the short-term and long-term fuel trims are lean or rich beyond predetermined values, it is interpreted as a malfunction, and the ECM illuminates the MIL and sets a DTC. DTC No. P0171 P0172 DTC Detection Condition Trouble Area With warm engine and stable air-fuel ratio feedback, fuel trim considerably in error to lean side (2 trip detection logic) • • • • • • • • • • • • • • Air induction system Injector blockage Mass Air Flow (MAF) meter Engine Coolant Temperature (ECT) sensor Fuel pressure Gas leakage from exhaust system Open or short in A/F sensor (sensor 1) circuit A/F sensor (sensor 1) A/F sensor heater (sensor 1) Engine room J/B (EFI relay) A/F sensor heater and EFI relay circuits PCV valve and hose PCV hose connections ECM With warm engine and stable air-fuel ratio feedback, fuel trim considerably in error to rich side (2 trip detection logic) • • • • • • • • • • • • Injector leakage or blockage MAF meter ECT sensor Ignition system Fuel pressure Gas leakage from exhaust system Open or short in A/F sensor (sensor 1) circuit A/F sensor (sensor 1) A/F sensor heater (sensor 1) Engine room J/B (EFI relay) A/F sensor heater and EFI relay circuits ECM HINT: • When DTC P0171 is set, the actual air-fuel ratio is on the lean side. When DTC P0172 is set, the actual air-fuel ratio is on the rich side. • If the vehicle runs out of fuel, the air-fuel ratio is lean and DTC P0171 may be set. The MIL is then illuminated. • When the total of the short-term and long-term fuel trim values is within 20 % (and the engine coolant temperature is more than 75°C [167°F]), the system is functioning normally. ES ES–156 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR DESCRIPTION Under closed-loop fuel control, fuel injection volumes that deviate from those estimated by the ECM cause changes in the long-term fuel trim compensation value. The long-term fuel trim is adjusted when there are persistent deviations in the short-term fuel trim values. Deviations from the ECM's estimated fuel injection volumes also affect the average fuel trim learning value, which is a combination of the average short-term fuel trim (fuel feedback compensation value) and the average long-term fuel trim (learning value of the air-fuel ratio). If the average fuel trim learning value exceeds the malfunction threshold, the ECM interprets this as a fault in the fuel system and sets a DTC. Example: The average fuel trim learning value is +35 % or more or -35 % or less, the ECM interprets this as a fuel system malfunction. ES Fuel Compensation Amount P0171 +35 (%) Lean Malfunction Threshold 1.35 1.0 P0172 -35 (%) Rich Malfunction Threshold 0.65 A121607E02 MONITOR STRATEGY Related DTCs P0171: Fuel trim lean P0172: Fuel trim rich Required Sensors/Components (Main) Fuel system Required Sensors/Components (Related) A/F sensor, Mass air flow meter, Crankshaft position sensor Frequency of Operation Continuous Duration Within 10 seconds MIL Operation 2 driving cycles Sequence of Operation None ES–157 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present P0010 (VVT OCV) P0011 (VVT System 1 - Advance) P0012 (VVT System 1 - Retard) P0031, P0032 (A/F sensor heater - Sensor 1) P0100 - P0103 (MAF meter) P0115 - P0118 (ECT sensor) P0120 - P0223, P2135 (TP sensor) P0125 (Insufficient ECT for Closed Loop) P0335 (CKP sensor) P0340 (CMP sensor) P0351 - P0354 (Igniter) P0500 (VSS) Fuel system status Closed loop Battery voltage 11 V or more Either of the following conditions 1 or 2 is met - 1. Engine RPM Below 1,100 rpm 2. Intake air amount per revolution 0.22 g/rev or more Catalyst monitor Not executed ES TYPICAL MALFUNCTION THRESHOLDS EVAP purge-cut Executing Either of the following conditions 1 or 2 is met - 1. Average of short-term fuel trim and long-term fuel trim 35 % or more (varies with ECT) 2. Average of short-term fuel trim and long-term fuel trim -35 % or less (varies with ECT) WIRING DIAGRAM Refer to DTC P2195 (See page ES-312). INSPECTION PROCEDURE HINT: • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. • A low A/F sensor voltage could be caused by a rich air-fuel mixture. Check for conditions that would cause the engine to run rich. • A high A/F sensor voltage could be caused by a lean air-fuel mixture. Check for conditions that would cause the engine to run lean. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P0171 OR P0172) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs. Result Display (DTC Output) Proceed to P0171 or P0172 A P0171 or P0172 and other DTCs B ES–158 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: If any DTCs other than P0171 or P0172 are output, troubleshoot those DTCs first. B GO TO DTC CHART A 2 PERFORM ACTIVE TEST USING INTELLIGENT TESTER (A/F CONTROL) (a) Connect the intelligent tester to the DLC3. (b) Start the engine and turn the tester on. (c) Warm up the engine at an engine speed of 2,500 rpm for approximately 90 seconds. (d) On the tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. (e) Perform the A/F CONTROL operation with the engine in an idling condition (press the RIGHT or LEFT button to change the fuel injection volume). (f) Monitor the output voltages of the A/F and HO2 sensors (AFS B1S1 and O2S B1S2) displayed on the tester. Result: The A/F sensor reacts in accordance with increases and decreases in the fuel injection volume: +25 % = Rich output: Less than 3.0 V -12.5 % = Lean output: More than 3.35 V NOTICE: The A/F sensor has an output delay of a few seconds and the HO2 sensor has a maximum output delay of approximately 20 seconds. ES Case 1 2 A/F Sensor (Sensor 1) Output Voltage HO2 Sensor (Sensor 2) Output Voltage Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage More than 3.35 V Less than 3.0 V Output Voltage More than 0.5 V Less than 0.4 V Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage Almost no reaction Output Voltage More than 0.5 V Less than 0.4 V Main Suspected Trouble Areas - • • • A/F sensor A/F sensor heater A/F sensor circuit ES–159 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Case A/F Sensor (Sensor 1) Output Voltage HO2 Sensor (Sensor 2) Output Voltage Extremely rich or lean actual air-fuel ratio • Injector leakage or blockage • Gas leakage from exhaust system • Fuel pressure • MAF meter • ECT sensor • Air induction system • PCV hose connections Injection Volume +25 % -12.5 % Injection volume +25 % -12.5 % 3 Main Suspected Trouble Areas Output Voltage Almost no reaction Output Voltage Almost no reaction Following the A/F CONTROL procedure enables technicians to check and graph the voltage outputs of both the A/F and HO2 sensors. To display the graph, select the following menu items on the tester: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL / USER DATA / AFS B1S1 and O2S B1S2; then press the YES button and then the ENTER button followed by the F4 button. Result Result Proceed to Case 1 C Case 2 B Case 3 A B Go to step 11 C Go to step 15 A 3 READ VALUE USING INTELLIGENT TESTER (MAF) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / MAF and COOLANT TEMP. (d) Allow the engine to idle until the COOLANT TEMP reaches 75°C (167°F) or more. (e) Read the MAF with the engine in an idling condition and at an engine speed of 2,500 rpm. Standard: MAF while engine idling: Between 1 g/sec. and 3 g/sec. (shift position: N, A/C: OFF). MAF at an engine speed of 2,500 rpm: Between 2 g/sec. and 6 g/sec. (shift position: N, A/C: OFF). NG REPLACE MASS AIR FLOW METER ES ES–160 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK 4 READ VALUE USING INTELLIGENT TESTER (COOLANT TEMP) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / COOLANT TEMP. (d) Read the COOLANT TEMP twice, when the engine is both cold and warmed up. Standard: With cold engine: Same as ambient air temperature. With warm engine: Between 75°C and 100°C (167°F and 212°F). ES NG REPLACE ENGINE COOLANT TEMPERATURE SENSOR OK 5 CHECK PCV HOSE CONNECTIONS (a) Check for PCV hose connections. OK: PCV hose is connected correctly and is not damaged. NG REPAIR OR REPLACE PCV HOSE OK 6 CHECK AIR INDUCTION SYSTEM (a) Check the air induction system for vacuum leakage. OK: No leakage from air induction system. NG REPAIR OR REPLACE AIR INDUCTION SYSTEM OK 7 CHECK FOR SPARKS AND IGNITION (See page ES-172) NG OK REPAIR OR REPLACE IGNITION SYSTEM 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 8 ES–161 CHECK FOR EXHAUST GAS LEAKAGE (a) Check for exhaust gas leakage. OK: No gas leakage. NG REPAIR OR REPLACE EXHAUST SYSTEM OK 9 CHECK FUEL PRESSURE (a) Check the fuel pressure (See page FU-9). Standard pressure: 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44.1 to 49.7 psi) NG REPAIR OR REPLACE FUEL SYSTEM OK 10 INSPECT FUEL INJECTOR (INJECTION AND VOLUME) (a) Check the injection volume (See page FU-14). Standard injection volume: 76 to 92 cm3 (4.6 to 5.6 cu in.) per 15 seconds NG REPLACE FUEL INJECTOR OK 11 INSPECT AIR-FUEL RATIO SENSOR (HEATER RESISTANCE) (See page ES-84) NG REPLACE AIR-FUEL RATIO SENSOR OK 12 INSPECT ENGINE ROOM J/B (EFI RELAY) (See page ES-85) NG REPLACE ENGINE ROOM J/B OK 13 CHECK HARNESS AND CONNECTOR (A/F SENSOR - ECM) (See page ES-325) NG OK REPAIR OR REPLACE HARNESS OR CONNECTOR ES ES–162 14 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM REPLACE AIR-FUEL RATIO SENSOR NEXT 15 PERFORM CONFIRMATION DRIVING PATTERN Vehicle Speed ES (f) Between 38 mph and 75mph (60 km/h and 120 km/h) Idling (e) Ignition Switch OFF (a), (b), (c), (d) 2 minutes 3 to 5 minutes Time A115372E52 (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the tester on. (c) Clear the DTCs (See page ES-38). (d) Switch the ECM from normal mode to check mode using the tester (See page ES-41). (e) Start the engine and warm it up with all the accessories switched OFF. (f) Drive the vehicle at between 38 mph and 75 mph (60 km/h and 120 km/h) and at an engine speed of between 1,400 rpm and 3,200 rpm for 3 to 5 minutes. HINT: If the system is still malfunctioning, the MIL will be illuminated during step (f). NOTICE: If the conditions in this test are not strictly followed, no malfunction will be detected. NEXT ES–163 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 16 CHECK WHETHER DTC OUTPUT RECURS (DTC P0171 OR P0172) (a) On the intelligent tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (b) Read the DTCs. Result Display (DTC Output) Proceed to No output A P0171 or P0172 B B A END Go to step 3 ES ES–164 ES 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0300 Random / Multiple Cylinder Misfire Detected DTC P0301 Cylinder 1 Misfire Detected DTC P0302 Cylinder 2 Misfire Detected DTC P0303 Cylinder 3 Misfire Detected DTC P0304 Cylinder 4 Misfire Detected DESCRIPTION CMP Sensor ECM CKP Sensor A093767E03 When the engine misfires, high concentrations of hydrocarbons (HC) enter the exhaust gas. Extremely high HC concentration levels can cause increases in exhaust emission levels. High concentrations of HC can also cause increases in the Three-Way Catalytic Converter (TWC) temperature, which may cause damage to the TWC. To prevent these increases in emissions and to limit the possibility of thermal damage, the ECM monitors the misfire rate. When the temperature of the TWC reaches the point of thermal degradation, the ECM blinks the MIL. To monitor misfires, the ECM uses both the Camshaft Position (CMP) sensor and the Crankshaft Position (CKP) sensor. The CMP sensor is used to identify any misfiring cylinders and the CKP sensor is used to measure variations in the crankshaft rotation speed. Misfires are counted as when the crankshaft rotation speed variations exceed predetermined thresholds. If the misfire rate exceeds the threshold level, and could cause emission deterioration, the ECM illuminates the MIL and sets a DTC. DTC No. DTC Detection Condition P0300 Simultaneous misfiring of several cylinders detected (2 trip detection logic) P0301 P0302 P0303 P0304 Misfiring of specific cylinder detected (2 trip detection logic) Trouble Area • • • • • • • • • • • • • • • Open or short in engine wire harness Connector connection Vacuum hose connections Ignition system Injector Fuel pressure Mass Air Flow (MAF) meter Engine Coolant Temperature (ECT) sensor Compression pressure Valve clearance Valve timing PCV valve and hose PCV hose connections Air induction system ECM When DTCs for misfiring cylinders are randomly set, but DTC P0300 is not set, it indicates that misfires have been detected in different cylinders at different times. DTC P0300 is only set when several misfiring cylinders are detected at the same time. 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–165 MONITOR DESCRIPTION The ECM illuminates the MIL and sets a DTC when either of the following conditions, which could cause emission deterioration, is detected (2 trip detection logic). • Within the first 1,000 crankshaft revolutions of the engine starting, an excessive misfiring rate (approximately 20 to 50 misfires per 1,000 crankshaft revolutions) occurs once. • After the first 1,000 crankshaft revolutions, an excessive misfiring rate (approximately 20 to 50 misfires per 1,000 crankshaft revolutions) occurs 4 times in sequential crankshaft revolutions. The ECM flashes the MIL and sets a DTC when either of the following conditions, which could cause Three-Way Catalytic Converter (TWC) damage, is detected (2 trip detection logic). • In every 200 crankshaft revolutions at a high engine rpm, the threshold misfiring percentage is recorded once. • In every 200 crankshaft revolutions at a normal engine rpm, the threshold misfiring percentage is recorded 3 times. MONITOR STRATEGY Related DTCs P0300: Multiple cylinder misfire P0301: Cylinder 1 misfire P0302: Cylinder 2 misfire P0303: Cylinder 3 misfire P0304: Cylinder 4 misfire Required Sensors/Components (Main) Crankshaft position sensor and camshaft position sensor Required Sensors/Components (Related) Engine coolant temperature and intake air temperature sensors and mass air flow meter Frequency of Operation Continuous Duration 1,000 crankshaft revolutions: Emission related misfire 200 crankshaft revolutions: Catalyst damaged misfire MIL Operation 2 driving cycles: Emission related misfire MIL flashes immediately: Catalyst damaged misfire Sequence of Operation None TYPICAL ENABLING CONDITIONS Misfire: Monitor runs whenever following DTCs are not present P0100 - P0103 (MAF meter) P0110 - P0113 (IAT sensor) P0115 - P0118 (ECT sensor) P0120 - P0223, P2135 (TP sensor) P0125 (Insufficient ECT for Closed Loop) P0327, P0328 (Knock sensor) P0335 (CKP sensor) P0340 (CMP sensor) P0500 (VSS) Battery voltage 8 V or more VVT system Not operated by scan tool Engine RPM 400 to 6,400 rpm Either of the following conditions (a) or (b) is met - (a) ECT at engine start More than -7°C (19°F) (b) ECT More than 20°C (68°F) Fuel cut OFF Monitor period of emission-related-misfire: First 1,000 revolutions after engine start, or Check Mode Crankshaft 1,000 revolutions Except above Crankshaft 1,000 revolutions x 4 Monitor period of catalyst-damaged-misfire (MIL blinks): All of the following conditions 1, 2 and 3 are met Crankshaft 200 revolutions 1. Driving cycles 1st ES ES–166 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2. Check mode OFF 3. Engine RPM Less than 2,600 rpm Except above (MIL blinks immediately) Crankshaft 200 revolutions x 3 TYPICAL MALFUNCTION THRESHOLDS Monitor period of emission-related-misfire: Misfire rate PZEV: 1.33 % or more Except PZEV: 1.266 % or more Monitor period of catalyst-damaged-misfire (MIL blinks): Number of misfire per 200 revolutions ES PZEV: 82 or more (varies with intake air amount and RPM) Except PZEV: 118 or more (varies with intake air amount and RPM) MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-20). WIRING DIAGRAM Wiring diagram of the ignition system. ES–167 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM C11 No. 1 Ignition Coil INJ 1 4 GND IGT1 IGF 3 85 C24 IGT1 2 C13 No. 2 Ignition Coil E23 Ignition SW 1 6 IG2 +B ECM AM2 5 4 +B GND IGT2 IGF 3 84 C24 IGT2 ES 2 C12 No. 3 Ignition Coil ST/AM2 1 4 +B GND IGT3 IGF 3 83 C24 IGT3 2 C14 No. 4 Ignition Coil FL MAIN 1 4 1 Battery C16 Noise Filter +B GND IGT4 IGF 3 2 82 C24 IGT4 81 C24 IGF1 104 C24 E1 A136157E03 Wiring diagram of the injector circuit. ES–168 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ECM C7 No. 1 Fuel Injector 108 INJ 1 E23 Ignition SW 6 IG2 AM2 #10 C9 No. 2 Fuel Injector 107 1 ES 2 C24 5 2 C24 #20 C8 No. 3 Fuel Injector 106 1 2 C24 #30 C10 No. 4 Fuel Injector 105 ST/AM2 1 2 C24 45 C24 #40 E01 FL MAIN 44 C24 E02 Battery A134997E03 CONFIRMATION DRIVING PATTERN 1. 2. 3. 4. 5. 6. Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Turn the tester on. Record the DTC(s) and freeze frame data. Using the tester, switch the ECM from normal mode to check mode (See page ES-41). Read the misfire counts of each cylinder (CYL #1 to #4) with the engine in an idling condition. If any misfire count is displayed, skip the following confirmation driving pattern. 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–169 7. Drive the vehicle several times with the conditions, such as engine rpm and engine load, shown in MISFIRE RPM and MISFIRE LOAD in the DATA LIST. HINT: In order to store misfire DTCs, it is necessary to drive the vehicle for the period of time shown in the table below, with the MISFIRE RPM and MISFIRE LOAD in the DATA LIST. Engine RPM Duration Idling 3.5 minutes or more 1,000 3 minutes or more 2,000 1.5 minutes or more 3,000 1 minute or more 8. Check whether misfires have occurred by checking for DTCs and freeze frame data. HINT: Do not turn the ignition switch off until the stored DTC(s) and freeze frame data have been recorded. When the ECM returns to normal mode (default), the stored DTC(s), freeze frame data and other data will be erased. 9. Record the DTC(s), freeze frame data and misfire counts. 10.Turn the ignition switch off and wait for at least 5 seconds. INSPECTION PROCEDURE HINT: • If any DTCs other than misfire DTCs are output, troubleshoot those DTCs first. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. • If the misfire does not recur when the vehicle is brought to the workshop, reproduce the conditions stored in the freeze frame data. • If the misfire still cannot be reproduced even though the conditions stored in the freeze frame data have been duplicated, one of the following factors is considered to be a possible cause of the problem: (a)The fuel level is low. (b)Improper fuel is used. (c) The spark plugs are dirty. (d)The problem is complex due to multiple factors. • After finishing repairs, check that no misfires occur in each cylinder (CYL #1, #2, #3 and #4). • Be sure to confirm that no misfiring cylinder DTCs are set again by conducting the confirmation driving pattern, after the repairs. • For 6 and 8 cylinder engines, the ECM intentionally does not set the specific misfiring cylinder DTCs at a high engine RPM. If misfires only occur during high engine RPM driving, only DTC P0300 is set. In the event of DTC P0300 being present, perform the following operations: (a)Clear the DTC (See page ES-38). (b)Start the engine and conduct the confirmation driving pattern. (c) Read the misfiring rates of each cylinder or DTC(s) using the tester. (d)Repair the cylinder(s) that has a high misfiring rate or is indicated by the DTC. (e)After finishing repairs, conduct the confirmation driving pattern again, in order to verify that DTC P0300 is not set. • When either SHORT FT #1 or LONG FT #1 in the freeze frame data is outside the range of +-20 %, the air-fuel ratio may be rich (-20 % or less) or lean (+20 % or more). • When the COOLANT TEMP in the freeze frame data is less than 75°C (167°F), the misfires occurred only while warming up the engine. ES ES–170 1 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO MISFIRE DTCS) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Turn the tester on. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read the DTCs. Result Display (DTC Output) ES Proceed to P0300, P0301, P0302, P0303 and/or P0304 A P0300, P0301, P0302, P0303 and/or P0304 and other DTCs B HINT: If any DTCs other than P0300, P0301, P0302, P0303 and P0304 are output, troubleshoot those DTCs first. B GO TO DTC CHART A 2 READ VALUE USING INTELLIGENT TESTER (MISFIRE RPM AND MISFIRE LOAD) (a) Connect the intelligent tester the DLC3. (b) Turn the ignition switch to the ON position and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / MISFIRE / MISFIRE RPM and MISFIRE LOAD. (d) Read and note the MISFIRE RPM and MISFIRE LOAD (engine load) values. HINT: The MISFIRE RPM and MISFIRE LOAD indicate the vehicle conditions under which the misfire occurred. NEXT 3 CHECK PCV HOSE CONNECTIONS OK: PCV hose is connected correctly and is not damaged. NG REPAIR OR REPLACE PCV HOSE OK 4 CHECK MISFIRE COUNT (CYL #1, #2, #3 AND #4) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Turn the tester on. Clear the DTCs (See page ES-38). ES–171 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (e) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / MISFIRE / CYL #1, #2, #3 and #4. (f) Allow the engine to idle. (g) Read each value for CYL #1 to #4 displayed on the tester. If no misfire counts occur in any cylinders, perform the following procedures: (1) Shift the gear selector lever to the D position. (2) Check the CYL #1 to #4. (3) If misfire counts are still not displayed, perform steps (h) and (i) and then check the misfire counts again. (h) Drive the vehicle with the MISFIRE RPM and MISFIRE LOAD noted in the "READ VALUE USING INTELLIGENT TESTER (MISFIRE RPM AND MISFIRE LOAD)" procedures above. (i) Read the CYL #1 to #4 or DTCs displayed on the tester. Result Misfire Count Proceed to Most misfires occur in only 1 or 2 cylinders A 3 cylinders or more have equal misfire counts B HINT: • If it is difficult to reproduce misfires for each cylinder, check the DATA LIST item called MISFIRE MARGIN. Try to find vehicle driving conditions that lower the MISFIRE MARGIN value. Values above 30 % are considered normal. • If the freeze frame data's record of the ECT is below 75°C (167°F), the misfire may be detected only when the engine is cold. • If the freeze frame data's record of the ENGINE RUN TIME is below 120 seconds, the misfire may be detected immediately after the engine is started. B Go to step 14 A 5 PERFORM ACTIVE TEST USING INTELLIGENT TESTER (FUEL CUT #1 TO #4) (a) Allow the engine to idle. (b) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / FUEL CUT#1 (to #4). (c) If a cylinder has a high misfire count, cut fuel to that cylinder. Compare the misfire count of the cylinder before fuel cut and after fuel cut. Result Misfire Count in Each Cylinder Proceed to Misfire count of cylinder before fuel cut and after fuel cut roughly same A Misfire count of cylinder before fuel cut lower than after fuel cut B ES ES–172 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NOTICE: This ACTIVE TEST cannot be performed while the vehicle is being driven. HINT: If the misfire count of the cylinder before and after the fuel cut are roughly the same, the cylinder is misfiring. If the misfire count of the cylinder before the fuel cut is lower than after the fuel cut, the cylinder misfires sometimes. B Go to step 11 A ES 6 CHECK SPARK PLUG (a) Remove the ignition coil and the spark plug of the misfiring cylinder. (b) Measure the spark plug electrode gap. Standard gap: 1.0 to 1.1 mm (0.039 to 0.043 in.) (c) Check the electrode for carbon deposits. Recommended spark plug: Electrode Gap A088861E01 Manufacturers Products DENSO SK20R11 NGK IFR6A11 NOTICE: If the electrode gap is larger than standard, replace the spark plug. Do not adjust the electrode gap. NG REPLACE SPARK PLUG OK 7 CHECK FOR SPARKS AND IGNITION A124396 (a) Perform a spark test. CAUTION: All ways disconnect all fuel injector connectors. NOTICE: Do not crank the engine for more than 2 seconds. (1) Remove the ignition coil from the cylinder head. (2) Install the spark plug onto the ignition coil. (3) Disconnect the 4 fuel injector connectors. (4) Attach the spark plug assembly to the cylinder head. (5) Crank the engine for less than 2 seconds and check for sparks. OK: Sparks jump across electrode gap. (6) Reconnect the 4 fuel injector connectors. (7) Install the ignition coil. NG Go to step 9 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–173 OK 8 CHECK CYLINDER COMPRESSION PRESSURE OF MISFIRING CYLINDER (a) Measure the cylinder compression pressure of the misfiring cylinder (See page EM-3). OK Go to step 10 NG CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION 9 CHANGE NORMAL SPARK PLUG AND CHECK FOR SPARKS OF MISFIRING CYLINDER (a) Change the installed spark plug with a spark plug that functions normally. (b) Perform a spark test. CAUTION: Always disconnect all fuel injector connectors. NOTICE: Do not crank the engine for more than 2 seconds. (1) Install the spark plug onto the ignition coil. (2) Disconnect the 4 fuel injector connectors. (3) Attach the spark plug assembly to the cylinder head. (4) Crank the engine for less than 2 seconds and check for sparks. OK: Sparks jump across electrode gap. (5) Reconnect the 4 fuel injector connectors. (6) Install the ignition coil. NG OK REPLACE SPARK PLUG REPLACE IGNITION COIL ASSEMBLY THEN CONFIRM THAT THERE IS NO MISFIRE ES ES–174 10 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT ECM TERMINAL OF MISFIRING CYLINDER (#10, #20, #30, AND /OR #40 VOLTAGE) Wire Harness Side: C24 ECM Connector E01 (a) Disconnect the C24 ECM connector. (b) Turn the ignition switch to the ON position. (c) Measure the voltage between the terminals of the ECM connector. Standard voltage ES Front View Tester Connection Specified Condition C24-108 (#10) - C24-45 (E01) 9 to 14 V C24-107 (#20) - C24-45 (E01) 9 to 14 V C24-106 (#30) - C24-45 (E01) 9 to 14 V C24-105 (#40) - C24-45 (E01) 9 to 14 V (d) Reconnect the ECM connector. #40 #30 #20 #10 OK Go to step 12 A107892E64 NG 11 CHECK HARNESS AND CONNECTOR (INJECTOR - ECM) (a) Disconnect the C7 to C10 injector connectors (of the misfiring cylinder). (b) Disconnect the C24 ECM connector. (c) Turn the ignition switch to the ON position. (d) Measure the resistance and voltage between the injector and the ECM connector terminals. Standard voltage Wire Harness Side: Injector Connector C7 C8 C9 C10 Front View C24 ECM Connector Cylinder Tester Connection Specified Condition No. 1 C7-1 - Ground 9 to 14 V No. 2 C9-1 - Ground 9 to 14 V No. 3 C8-1 - Ground 9 to 14 V No. 4 C10-1 - Ground 9 to 14 V Standard resistance Cylinder No. 1 #40 #30 #20 #10 Front View A106388E06 No. 2 No. 3 No. 4 Tester Connection Specified Condition C7-2 - Ground 10 kΩ or higher C7-2 - C24-108 (#10) Below 1 Ω C9-2 - Ground 10 kΩ or higher C9-2 - C24-107 (#20) Below 1 Ω C8-2 - Ground 10 kΩ or higher C8-2 - C24-106 (#30) Below 1 Ω C10-2 - Ground 10 kΩ or higher C10-2 - C24-105 (#40) Below 1 Ω (e) Reconnect the injector connector. (f) Reconnect the ECM connector. 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NG ES–175 REPAIR OR REPLACE HARNESS OR CONNECTOR OK 12 CHECK FUEL INJECTOR OF MISFIRING CYLINDER (a) Check the injector injection (whether fuel volume is high or low, and whether injection pattern is poor). NG REPLACE FUEL INJECTOR ASSEMBLY OK 13 ES CHECK VALVE CLEARANCE OF MISFIRING CYLINDER NG ADJUST VALVE CLEARANCE OK 14 CHECK AIR INDUCTION SYSTEM (a) Check the air induction system for vacuum leakage. OK: No leakage from air induction system. NG REPAIR OR REPLACE AIR INDUCTION SYSTEM OK 15 CHECK VALVE TIMING (See page ES-78) NG ADJUST VALVE TIMING OK 16 CHECK FUEL PRESSURE (a) Check the fuel pressure (See page FU-9). NG OK CHECK AND REPLACE FUEL PUMP, PRESSURE REGULATOR, FUEL PIPE LINE AND FILTER ES–176 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 17 READ VALUE USING INTELLIGENT TESTER (COOLANT TEMP) (See page ES-160) NG REPLACE ENGINE COOLANT TEMPERATURE SENSOR OK 18 READ VALUE USING INTELLIGENT TESTER (MAF) (See page ES-159) NG ES OK CHECK FOR INTERMITTENT PROBLEMS REPLACE MASS AIR FLOW METER ES–177 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0327 Knock Sensor 1 Circuit Low Input (Bank 1 or Single Sensor) DTC P0328 Knock Sensor 1 Circuit High Input (Bank 1 or Single Sensor) DESCRIPTION Flat type knock sensors (non-resonant type) have structures that can detect vibrations over a wide band of frequencies: between approximately 6 kHz and 15 kHz. Knock sensor is fitted onto the engine block to detect engine knocking. The knock sensor contains a piezoelectric element which generates a voltage when it becomes deformed. The voltage is generated when the engine block vibrates due to knocking. Any occurrence of engine knocking can be suppressed by delaying the ignition timing. DTC No. DTC Detection Condition Trouble Area P0327 Output voltage of knock sensor less than 0.5 V (1 trip detection logic) • • • P0328 Output voltage of knock sensor more than 4.5 V (1 trip detection logic) • • • Short in knock sensor circuit Knock sensor ECM Open in knock sensor circuit Knock sensor ECM HINT: When any of DTCs P0327 and P0328 are set, the ECM enters fail-safe mode. During fail-safe mode, the ignition timing is delayed to its maximum retardation. Fail-safe mode continues until the ignition switch is turned off. Reference: Inspection using an oscilloscope KNK1 Signal Waveform 1 V/ Division GND 1 ms./ Division A085286E36 The correct waveform is as shown. Items Contents Terminals KNK1 - EKNK Equipment Settings 1 V/Division 1 ms./Division Conditions Keep engine speed at 4,000 rpm with warm engine MONITOR DESCRIPTION If the output voltage transmitted by the knock sensor remains low or high for more than 1 second, the ECM interprets this as a malfunction in the sensor circuit, and sets a DTC. The monitor for DTCs P0327 and P0328 begins to run when 5 seconds have elapsed since the engine was started. If the malfunction is not repaired successfully, either DTC P0327 or P0328 is set 5 seconds after the engine is next started. ES ES–178 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR STRATEGY Related DTCs P0327: Knock sensor range check (Low voltage) P0328: Knock sensor range check (High voltage) Required Sensors/Components (Main) Knock sensor Required Sensors/Components (Related) - Frequency of Operation Continuous Duration 1 second MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS ES Monitor runs whenever following DTCs are not present None Battery voltage 10.5 V or more Time after engine start 5 seconds or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Knock Sensor Range Check (Low voltage) P0327: Knock sensor voltage Less than 0.5 V Knock Sensor Range Check (High voltage) P0328: Knock sensor voltage More than 4.5 V WIRING DIAGRAM ECM C30 Knock Sensor 1 (Shielded) 2 110 KNK1 C24 111 EKNK C24 A134998E01 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–179 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the airfuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 READ VALUE USING INTELLIGENT TESTER (KNOCK FB VAL) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Start the engine and turn the tester on. Warm up the engine. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / USER DATA / KNOCK FB VAL. (e) Read the values displayed on the tester while driving the vehicle. Standard: The values change. HINT Malfunction does not occur Knock Feedback Values change Malfunctions occur Knock Feedback Values do not change HINT: The knock feedback value change can be confirmed by running the engine with a high load, for example, by activating the air conditioning system and revving up the engine. NG OK CHECK FOR INTERMITTENT PROBLEMS Go to step 2 ES ES–180 2 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (ECM - KNOCK SENSOR) (a) Disconnect the C24 ECM connector. (b) Measure the resistance between the terminals. Standard Wire Harness Side: C24 ECM Connector Tester Connection Specified Condition C24-110 (KNK1) - C24-111 (EKNK) 120 to 280 kΩ at 20°C (68°F) (c) Reconnect the ECM connector. NG Go to step 4 ES KNK1 Front View EKNK A107892E65 OK 3 INSPECT ECM (KNK1 VOLTAGE) (a) Disconnect the C30 knock sensor connector. (b) Turn the ignition switch to the ON position. (c) Measure the voltage between the knock sensor terminals. Standard voltage Wire Harness Side: Knock Sensor Connector C30 EKNK 1 2 Front View KNK1 A105992E06 Tester Connection Specified Condition C30-2 (KNK1) - C30-1 (EKNK) 4.5 to 5.5 V (d) Reconnect the knock sensor connector. NOTICE: Fault may be intermittent. Check the wire harness and connectors carefully and retest. NG OK CHECK FOR INTERMITTENT PROBLEMS REPLACE ECM ES–181 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 4 INSPECT KNOCK SENSOR Ohmmeter Component Side: (a) Remove the knock sensor. (b) Measure the resistance between the terminals. Standard resistance Knock Sensor Tester Connection Specified Condition 2 (KNK1) - 1 (EKNK) 120 to 280 kΩ at 20°C (68°F) (c) Reinstall the knock sensor. NG A065174E15 OK REPAIR OR REPLACE HARNESS OR CONNECTOR REPLACE KNOCK SENSOR ES ES–182 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0335 Crankshaft Position Sensor "A" Circuit DTC P0339 Crankshaft Position Sensor "A" Circuit Intermittent DESCRIPTION ES The Crankshaft Position (CKP) sensor system consists of a CKP sensor plate and a pickup coil. The sensor plate has 34 teeth and is installed on the crankshaft. The pickup coil is made of wound copper wire, an iron core and magnet. The sensor plate rotates and, as each tooth passes through the pickup coil, a pulse signal is created. The pickup coil generates 34 signals per engine revolution. Based on these signals, the ECM calculates the crankshaft position and engine RPM. Using these calculations, the fuel injection time and ignition timing are controlled. DTC No. DTC Detection Condition Trouble Area P0335 When either condition below is met: • No CKP sensor signal to ECM while cranking (1 trip detection logic) • No CKP sensor signal to ECM at engine speed of 600 rpm or more (1 trip detection logic) • • • • Open or short in CKP sensor circuit CKP sensor CKP sensor plate ECM P0339 Under conditions (a), (b) and (c), no CKP sensor signal to ECM for 0.05 seconds or more (1 trip detection logic): (a) Engine speed 1,000 rpm or more (b) Starter signal OFF (c) 3 seconds or more have elapsed since starter signal switched from ON to OFF • • • • Open or short in CKP sensor circuit CKP sensor CKP sensor plate ECM Reference: Inspection using an oscilloscope. CH1 (G2+) GND CH2 (NE+) GND A063955E13 HINT: • The correct waveform is as shown. • G2+ stands for the Camshaft Position (CMP) sensor signal, and NE+ stands for the CKP sensor signal. • Grounding failure of the shielded wire may cause noise in waveforms. Items Contents Terminals CH1: G2+ - G2CH2: NE+ - NE- Equipment Settings 5 V/Division, 20 ms./Division Conditions Cranking or idling MONITOR DESCRIPTION If there is no signal from the CKP sensor despite the engine revolving, the ECM interprets this as a malfunction of the sensor. If the malfunction is not repaired successfully, a DTC is set 10 seconds after the engine is next started. 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–183 MONITOR STRATEGY Related DTCs P0335: CKP sensor range check or rationality Required Sensors/Components (Main) CKP sensor Required Sensors/Components (Related) CMP sensor Frequency of Operation Continuous Duration 3 times MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS All: Monitor runs whenever following DTCs are not present None Case 1: Time after starter OFF to ON 0.3 seconds or more Number of CMP sensor signal pulse 6 times Battery voltage 7 V or more CMP sensor circuit OK Ignition switch ON Case 2: Starter OFF Engine speed 600 rpm or more Time after starter from ON to OFF 3 seconds or more TYPICAL MALFUNCTION THRESHOLDS Case 1: Number of CKP sensor signal pulse 132 or less, and 174 or more Case 2: Engine speed signal No signal COMPONENT OPERATING RANGE CKP sensor • • CKP sensor output voltage fluctuates while crankshaft revolving 34 CKP sensor signals per crankshaft revolution ES ES–184 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM C31 Camshaft Position Sensor Intake Camshaft ES (Shielded) ECM 1 99 G2+ C24 2 98 C24 G2- C20 Crankshaft Position Sensor (Shielded) Crankshaft Position Sensor Plate 2 121 NEC24 1 122 C24 NE+ 44 C24 E02 A134999E01 INSPECTION PROCEDURE HINT: • If no problem is found through this diagnostic troubleshoot procedure, troubleshoot the engine mechanical systems. • Check the engine speed. The engine speed can be checked by using the intelligent tester. Follow the procedure below: (a)Connect the intelligent tester to the DLC3. (b)Start the engine. (c) Turn the tester on. (d)Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / ENGINE SPD. The engine speed may be indicated as zero despite the engine revolving normally. This is caused by a lack of NE signals from the Crankshaft Position (CKP) sensor. Alternatively, the engine speed may be indicated as lower than the actual engine speed if the CKP sensor output voltage is insufficient. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. ES–185 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 1 READ VALUE USING INTELLIGENT TESTER (ENGINE SPD) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Turn the tester on. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / ENGINE SPD. (e) Start the engine. (f) Read the values displayed on the tester while the engine is running. Standard: Correct values are displayed. HINT: • To check the engine speed change, display the graph on the tester. • If the engine does not start, check the engine speed while cranking. • If the engine speed indicated on the tester remains zero (0), there may be an open or short in the Crankshaft Position (CKP) sensor circuit. NG Go to step 2 OK CHECK FOR INTERMITTENT PROBLEMS 2 INSPECT CRANKSHAFT POSITION SENSOR (RESISTANCE) (a) Disconnect the C20 CKP sensor connector. (b) Measure the resistance between terminals 1 and 2. Standard resistance Component Side: Tester Connection Specified Condition 1-2 1,150 to 1,450 Ω at 20°C (68°F) (c) Reconnect the CKP sensor connector. CKP Sensor NG G037727E07 OK REPLACE CRANKSHAFT POSITION SENSOR ES ES–186 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 3 CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - ECM) (a) Disconnect the C20 CKP sensor connector. (b) Disconnect the C24 ECM connector. (c) Measure the resistance between the terminals of the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side: CKP Sensor NE+ NE- C20 ES Tester Connection Specified Condition C20-1 (NE+) - C24-122 (NE+) Below 1 Ω C20-2 (NE-) - C24-121 (NE-) Below 1 Ω Standard resistance (Check for short) C24 ECM Connector Tester Connection Specified Condition C20-1 (NE+) or C24-122 (NE+) - Body ground 10 kΩ or higher C20-2 (NE-) or C24-121 (NE-) - Body ground 10 kΩ or higher (d) Reconnect the ECM connector. (e) Reconnect the CKP sensor connector. NG NE- REPAIR OR REPLACE HARNESS OR CONNECTOR NE+ A127716E02 OK 4 CHECK SENSOR INSTALLATION (CRANKSHAFT POSITION SENSOR) (a) Check the CKP sensor installation condition. OK: Sensor is installed correctly. NG SECURELY REINSTALL SENSOR Clearance OK NG BR03795E25 OK 5 CHECK CRANKSHAFT POSITION SENSOR PLATE (TEETH OF SENSOR PLATE) (a) Check the teeth of the sensor plate. OK: Sensor plate does not have any cracks or deformation. NG REPLACE CRANKSHAFT POSITION SENSOR PLATE ES–187 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK 6 REPLACE CRANKSHAFT POSITION SENSOR NEXT 7 CHECK WHETHER DTC OUTPUT RECURS (a) (b) (c) (d) (e) (f) Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Turn the tester on. Clear the DTCs (See page ES-38). Start the engine. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (g) Read the DTCs. Result Display (DTC Output) Proceed to No output A P0335 or P0339 B HINT: If the engine does not start, replace the ECM. B A END REPLACE ECM ES ES–188 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0340 Camshaft Position Sensor "A" Circuit (Bank 1 or Single Sensor) DESCRIPTION The Camshaft Position (CMP) sensor consists of a magnet and an iron core which is wrapped with copper wire, and is installed onto the cylinder head. When the camshaft rotates, each of 3 teeth on the camshaft passes through the CMP sensor. This activates the internal magnet in the sensor, generating a voltage in the copper wire. The camshaft rotation is synchronized with the crankshaft rotation. When the crankshaft turns twice, the voltage is generated 3 times in the CMP sensor. The generated voltage in the sensor acts as a signal, allowing the ECM to locate the camshaft position. This signal is then used to control ignition timing, fuel injection timing, and the VVT system. ES DTC No. DTC Detection Condition P0340 Case 1 • No Camshaft Position (CMP) sensor signal to ECM while cranking (2 trip detection logic) Case 2 • Camshaft/Crankshaft misalignment detected at engine speed of 600 rpm or more (1 trip detection logic) Trouble Area • • • • • Open or short in CMP sensor circuit CMP sensor Camshaft Jumped tooth of timing chain ECM HINT: DTC P0340 indicates a malfunction relating to the CMP sensor (+) circuit (the wire harness between the ECM and CMP sensor, and the CMP sensor itself). Reference: Inspection using an oscilloscope CH1 (G2+) GND CH2 (NE+) GND A063955E13 HINT: • The correct waveform is as shown in the illustration. • G2+ stands for the CMP sensor signal, and NE+ stands for the Crankshaft Position (CKP) sensor signal. • Grounding failure of the shielded wire may cause noise in waveforms. Items Terminals Equipment Settings Conditions Contents CH1: G2+ - G2CH2: NE+ - NE5 V/Division, 20 ms./Division Cranking or idling MONITOR DESCRIPTION If no signal is transmitted by the CMP sensor despite the engine revolving, or the rotation of the camshaft and the crankshaft is not synchronized, the ECM interprets this as a malfunction of the sensor. If the malfunction is not repaired successfully, a DTC is set 10 seconds after the engine is next started. 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–189 MONITOR STRATEGY Related DTCs P0340: Camshaft position sensor range check P0340: Camshaft position/crankshaft position misalignment Required Sensors/Components (Main) Camshaft Position (CMP) sensor Required Sensors/Components (Related) Crankshaft Position (CKP) sensor Frequency of Operation Continuous Duration 4 seconds: CMP sensor range check 5 seconds: Camshaft position/crankshaft position misalignment MIL Operation 2 driving cycles: CMP sensor range check Immediate: Camshaft position/crankshaft position misalignment Sequence of Operation None ES TYPICAL ENABLING CONDITIONS All: Monitor runs whenever following DTCs are not present None Camshaft Position Sensor Range Check: Starter ON Minimal battery voltage while starter ON Less than 11 V Camshaft Position/Crankshaft Position Misalignment: Engine speed 600 rpm or more Starter OFF TYPICAL MALFUNCTION THRESHOLDS Camshaft Position Sensor Range Check: CMP sensor signal No signal Camshaft Position/Crankshaft Position Misalignment: Camshaft position and crankshaft position phase Misaligned COMPONENT OPERATING RANGE CMP sensor • • CMP sensor output voltage fluctuates while camshaft revolving 3 CMP sensor signals per 2 crankshaft revolutions WIRING DIAGRAM Refer to DTC P0335 (See page ES-179). INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the airfuel ratio was lean or rich, and other data from the time the malfunction occurred. ES–190 1 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT CAMSHAFT POSITION SENSOR (RESISTANCE) (a) Disconnect the C31 Camshaft Position (CMP) sensor connector. (b) Measure the resistance between terminals 1 and 2. Standard resistance Component Side: CMP Sensor Tester Connection Specified Condition 1-2 950 to 1,250 Ω (c) Reconnect the CMP sensor connector. Front View ES G037727E04 NG REPLACE CAMSHAFT POSITION SENSOR OK 2 CHECK HARNESS AND CONNECTOR (CAMSHAFT POSITION SENSOR - ECM) (a) Disconnect the C31 CMP sensor connector. (b) Disconnect the C24 ECM connector. (c) Measure the resistance between the terminals of the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side: C31 1 2 G2+ G2- CMP Sensor Connector Front View C24 ECM Connector Tester Connection Specified Condition C31-1 (G2+) - C24-99 (G2+) Below 1 Ω C31-2 (G2-) - C24-98 (G2-) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition C31-1 (G2+) or C24-99 (G2+) - Body ground 10 kΩ or higher C31-2 (G2-) or C24-98 (G2-) - Body ground 10 kΩ or higher (d) Reconnect the ECM connector. (e) Reconnect the CMP sensor connector. NG G2- G2+ Front View A106885E06 OK REPAIR OR REPLACE HARNESS OR CONNECTOR ES–191 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 3 CHECK SENSOR INSTALLATION (CAMSHAFT POSITION SENSOR) (a) Check the CMP sensor installation condition. OK: Sensor is installed correctly. NG SECURELY REINSTALL SENSOR Clearance Normal Abnormal ES BR03795E39 OK 4 CHECK VALVE TIMING (See page ES-78) NG ADJUST VALVE TIMING OK 5 CHECK CAMSHAFT (a) Check the teeth of the camshaft. OK: Camshaft teeth do not have any cracks or deformation. NG REPLACE CAMSHAFT OK 6 REPLACE CAMSHAFT POSITION SENSOR NEXT 7 CHECK WHETHER DTC OUTPUT RECURS (a) (b) (c) (d) (e) (f) Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Turn the tester on. Clear the DTCs (See page ES-38). Start the engine. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. (g) Read the DTCs. Result Display (DTC Output) Proceed to No output A ES–192 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Display (DTC Output) Proceed to P0340 B HINT: If the engine does not start, replace the ECM. B A END ES REPLACE ECM 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–193 DTC P0351 Ignition Coil "A" Primary / Secondary Circuit DTC P0352 Ignition Coil "B" Primary / Secondary Circuit DTC P0353 Ignition Coil "C" Primary / Secondary Circuit DTC P0354 Ignition Coil "D" Primary / Secondary Circuit DESCRIPTION HINT: • These DTCs indicate malfunctions relating to the primary circuit. • If DTC P0351 is set, check the No. 1 ignition coil circuit. • If DTC P0352 is set, check the No. 2 ignition coil circuit. • If DTC P0353 is set, check the No. 3 ignition coil circuit. • If DTC P0354 is set, check the No. 4 ignition coil circuit. A Direct Ignition System (DIS) is used on this vehicle. The DIS is a 1-cylinder ignition system in which each cylinder is ignited by one ignition coil and one spark plug is connected to the end of each secondary wiring. A powerful voltage, generated in the secondary wiring, is applied directly to each spark plug. The sparks of the spark plugs pass from the center electrode to the ground electrodes. The ECM determines the ignition timing and transmits the ignition (IGT) signals to each cylinder. Using the IGT signal, the ECM turns the power transistor inside the igniter on and off. The power transistor, in turn, switches on and off the current to the primary coil. When the current to the primary coil is cut off, a powerful voltage is generated in the secondary coil. This voltage is applied to the spark plugs, causing them to spark inside the cylinders. As the ECM cuts the current to the primary coil off, the igniter sends back an ignition confirmation (IGF) signal to the ECM, for each cylinder ignition. ES ES–194 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ECM From Battery Igniter No. 1 Ignition Coil IGT1 Crankshaft Position Sensor IGF1 No. 1 Spark Plug Ignition Coil ES IGT2 No. 2 Ignition Coil No. 2 Spark Plug Camshaft Position Sensor IGT3 No. 3 Ignition Coil No. 3 Spark Plug Other Sensors (Engine Coolant Temperature Sensor, Mass Air Flow Meter, Throttle Position Sensor, etc.) IGT4 No. 4 Ignition Coil TACH No. 4 Spark Plug To Tachometer A112570E02 DTC No. P0351 P0352 P0353 P0354 DTC Detection Condition No IGF signal to ECM while engine running (1 trip detection logic) Trouble Area • • • • Ignition system Open or short in IGF1 or IGT circuit (1 to 4) between ignition coil and ECM No. 1 to No. 4 ignition coils ECM 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–195 2 V/DIV. IGT Ground IGF Ground 20 ms./DIV. A093278E22 Reference: Inspection using an oscilloscope. While cranking or idling the engine, check the waveform between terminals IGT (1 to 4) and E1, and IGF1 and E1 of the ECM connector. Items Terminals Equipment Settings Conditions Contents CH1: IGT1, IGT2, IGT3, IGT4 - E1 CH2: IGF1 - E1 2 V/Division 20 ms./Division Cranking or idling ES ES–196 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR DESCRIPTION Ignition Coil IGT ECM Igniter Ignition Coil IGF ES Ignition Signal (IGT) Ignition Confirmation Signal (IGF) Normal Malfunction Circuit Open Time A115898E03 If the ECM does not receive any IGF signals despite transmitting the IGT signal, it interprets this as a fault in the igniter and sets a DTC. If the malfunction is not repaired successfully, a DTC is set 1 second after the engine is next started. MONITOR STRATEGY Related DTCs P0351: Igniter (cylinder 1) malfunction P0352: Igniter (cylinder 2) malfunction P0353: Igniter (cylinder 3) malfunction P0354: Igniter (cylinder 4) malfunction Required Sensors/Components (Main) Igniter Required Sensors/Components (Related) Crankshaft position sensor Frequency of Operation Continuous Duration 0.512 seconds MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present None Either of the following conditions A or B is met - 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM A. Engine RPM 1,500 rpm or less B. Starter OFF Either of the following conditions C or D is met - C. Both of the following conditions (a) and (b) are met - (a) Engine speed 500 rpm or less (b) Battery voltage 6 V or more D. All of the following conditions (a), (b) and (c) are met - (a) Engine speed More than 500 rpm (b) Battery voltage 10 V or more (c) Number of sparks after CPU reset 5 sparks or more ES–197 TYPICAL MALFUNCTION THRESHOLDS IGF signal ECM does not receive any IGF signal despite ECM sending IGT signal to igniter COMPONENT OPERATING RANGE IGF signal Igniter transmits IGF signal when it receives IGT signal from ECM ES ES–198 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM C11 No. 1 Ignition Coil INJ 1 4 ES GND IGT1 IGF 3 85 C24 IGT1 2 C13 No. 2 Ignition Coil E23 Ignition SW 1 6 IG2 +B ECM AM2 5 4 +B GND IGT2 IGF 3 84 C24 IGT2 2 C12 No. 3 Ignition Coil ST/AM2 1 4 +B GND IGT3 IGF 3 83 C24 IGT3 2 C14 No. 4 Ignition Coil FL MAIN 1 4 1 Battery C16 Noise Filter +B GND IGT4 IGF 3 2 82 C24 IGT4 81 C24 IGF1 104 C24 E1 A136157E03 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the airfuel ratio was lean or rich, and other data from the time the malfunction occurred. ES–199 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 1 INSPECT IGNITION COIL ASSEMBLY (POWER SOURCE) (a) Disconnect the C11 to C14 ignition coil connectors. (b) Measure the resistance between the terminals of the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side: Ignition Coil Connector C11 C12 Tester Connection Specified Condition C13 C14 C11-4 (GND) - Body ground Below 1 Ω C13-4 (GND) - Body ground Below 1 Ω C12-4 (GND) - Body ground Below 1 Ω C14-4 (GND) - Body ground Below 1 Ω +B (+) GND (-) Front View A054393E71 (c) Turn the ignition switch to the ON position. (d) Measure the voltage between the terminals of the wire harness side connectors. Standard voltage Tester Connection Specified Condition C11-1 (+B) - C11-4 (GND) 9 to 14 V C13-1 (+B) - C13-4 (GND) 9 to 14 V C12-1 (+B) - C12-4 (GND) 9 to 14 V C14-1 (+B) - C14-4 (GND) 9 to 14 V (e) Reconnect the ignition coil connectors. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 2 CHECK HARNESS AND CONNECTOR (IGNITION COIL ASSEMBLY - ECM) Wire ࠗࠣ࠾࠶࡚ࠪࡦࠦࠗ࡞#55;ゞਔ஥ࠦࡀࠢ࠲ Harness Side: Ignition Coil Connector IGF C11 C12 C13 C14 Front View IGT1 IGT2 IGT3 IGT4 ࠛࡦࠫࡦࠦࡦ࠻ࡠ࡯࡞ࠦࡦࡇࡘ࡯࠲ゞਔ஥ࠦࡀࠢ࠲ C24 ECM Connector IGT2 IGT1 Front View IGF1 IGT4 IGT3 A105983E12 (a) Disconnect the ignition coil connectors. (b) Disconnect the C24 ECM connector. (c) Measure the resistance between the terminals of the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition C11-2 (IGF) - C24-81 (IGF1) Below 1 Ω C13-2 (IGF) - C24-81 (IGF1) Below 1 Ω C12-2 (IGF) - C24-81 (IGF1) Below 1 Ω C14-2 (IGF) - C24-81 (IGF1) Below 1 Ω Standard resistance (Check for open) Tester Connection Specified Condition C11-3 (IGT1) - C24-85 (IGT1) Below 1 Ω C13-3 (IGT2) - C24-84 (IGT2) Below 1 Ω C12-3 (IGT3) - C24-83 (IGT3) Below 1 Ω C14-3 (IGT4) - C24-82 (IGT4) Below 1 Ω ES ES–200 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Standard resistance (Check for short) Tester Connection Specified Condition C11-2 (IGF) or C24-81 (IGF1) - Body ground 10 kΩ or higher C13-2 (IGF) or C24-81 (IGF1) - Body ground 10 kΩ or higher C12-2 (IGF) or C24-81 (IGF1) - Body ground 10 kΩ or higher C14-2 (IGF) or C24-81 (IGF1) - Body ground 10 kΩ or higher Standard resistance (Check for short) ES Tester Connection Specified Condition C11-3 (IGT1) or C24-85 (IGT1) - Body ground 10 kΩ or higher C13-3 (IGT2) or C24-84 (IGT2) - Body ground 10 kΩ or higher C12-3 (IGT3) or C24-83 (IGT3) - Body ground 10 kΩ or higher C14-3 (IGT4) or C24-82 (IGT4) - Body ground 10 kΩ or higher (d) Reconnect the ECM connector. (e) Reconnect the ignition coil connectors. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 CHECK WHETHER DTC OUTPUT RECURS (DTC P0351, P0352, P0353 OR P0354) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the tester on. (c) Clear the DTCs (See page ES-38). (d) Shuffle arrangement of the ignition coils (among No. 1 to No. 4 cylinders). NOTICE: Do not shuffle the connectors. (e) Perform a simulation test. (f) Check the DTCs displayed on the tester. Result Display (DTC Output) Proceed to Same DTC output A Different ignition coil DTC output B B A REPLACE ECM REPLACE IGNITION COIL ASSEMBLY ES–201 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0420 Catalyst System Efficiency Below Threshold (Bank 1) MONITOR DESCRIPTION The ECM uses the sensors mounted in front of and behind the Three-Way Catalytic Converter (TWC) to monitor its efficiency. The first sensor, the Air-Fuel Ratio (A/F) sensor, sends pre-catalyst information to the ECM. The second sensor, the Heated Oxygen (HO2) sensor, sends post-catalyst information to the ECM. In order to detect any deterioration in the TWC, the ECM calculates the Oxygen Storage Capacity (OSC) of the TWC. This calculation is based on the voltage output of the HO2 sensor while performing active airfuel ratio control, rather than the conventional detecting method, which uses the locus ratio. The OSC value is an indication of the oxygen storage capacity of the TWC. When the vehicle is being driven with a warm engine, active air-fuel ratio control is performed for approximately 15 to 20 seconds. When it is performed, the ECM deliberately sets the air-fuel ratio to lean or rich levels. If the rich-lean cycle of the HO2 sensor is long, the OSC becomes greater. There is a direct correlation between the OSCs of the HO2 sensor and the TWC. The ECM uses the OSC value to determine the state of the TWC. If any deterioration has occurred, it illuminates the MIL and sets the DTC. DTC No. P0420 DTC Detection Condition Trouble Area OSC value smaller than standard value under active air-fuel ratio control (2 trip detection logic) • • • • Front exhaust pipe (with TWC) Gas leakage from exhaust system Air-Fuel Ratio (A/F) sensor (sensor 1) Heated Oxygen (HO2) sensor (sensor 2) MONITOR STRATEGY Related DTCs P0420: Catalyst Deterioration Required Sensors/Components (Main) A/F sensor and HO2 sensor Required Sensors/Components (Related) Intake air temperature sensor, mass air flow meter, crankshaft position sensor and engine coolant temperature sensor Frequency of Operation Once per driving cycle Duration About 30 seconds MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present P0011 (VVT System 1 - Advance) P0012 (VVT System 1 - Retard) P0031, P0032 (A/F Sensor heater - Sensor 1) P0037, P0038 (O2 Sensor heater - Sensor 2) P0100 - P0103 (MAF meter) P0115 - P0118 (ECT sensor) P0120 - P0223, P2135 (TP sensor) P0125 (Insufficient ECT for Closed Loop) P0136 (O2 Sensor - Sensor 2) P0171, P0172 (Fuel system) P0300 - P0304 (Misfire) P0335 (CKP sensor) P0340 (CMP sensor) P0351 - P0354 (Igniter) P0500 (VSS) P2196 (A/F Sensor - rationality) P2A00 (A/F Sensor - slow response) Battery voltage 11 V or more Intake air temperature -10°C (14°F) or more ES ES–202 ES 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Engine coolant temperature 75°C (167°F) or more Atmospheric pressure 76 kPa (570 mmHg) or more Idling OFF Engine RPM Less than 4,000 rpm A/F sensor status Activated Fuel system status Closed loop Engine load 10 to 80 % All of the following conditions (a), (b) and (c) are met - (a) Mass air flow rate 2.5 to 50 g/sec. (b) Estimated front catalyst temperature 650 to 840°C (1,202 to 1,544°F) (c) Estimated rear catalyst temperature 400 to 770°C (752 to 1,418°F) Rear HO2 sensor heater monitor Completed Shift position 4th (Automatic transaxle) 3rd or higher (Manual transaxle) TYPICAL MALFUNCTION THRESHOLDS Oxygen Storage Capacity (OSC) of catalytic Less than 0.07 g MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-20). CONFIRMATION DRIVING PATTERN HINT: Performing this confirmation pattern will activate the catalyst monitor. This is very useful for verifying completion of a repair. Vehicle Speed (B) Between 40 mph and 70 mph (64 km/h and 113 km/h) Idling NOTICE: This test will not be completed if the vehicle is driven at absolutely constant speed such as with cruise control activated. (A) Ignition Switch OFF Warm up 10 minutes Time (Note: Even if vehicle stops during driving pattern, test can be resumed) A115372E53 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–203 1. Connect the intelligent tester to the DLC3. A076855E02 2. 3. 4. 5. Turn the ignition switch to the ON position. Turn the tester on. Clear the DTCs (if set) (See page ES-38). Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / USER DATA / CAT CMPL. 6. Check that CAT CMPL is INCMPL (incomplete). 7. Start the engine and warm it up. (Proceed to "A") 8. Drive the vehicle at between 40 mph and 70 mph (64 km/h and 113 km/h) for at least 10 minutes. (Proceed to "B") 9. Note the state of the Readiness Tests items. Those items will change to COMPL (complete) as CAT CMPL monitor operates. 10.On the tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES and check if any DTCs (any pending DTCs) are set. HINT: If CAT CMPL does not change to COMPL, and any pending DTCs fail to set, extend the driving time. CONDITIONING FOR SENSOR TESTING HINT: Perform the operation with the engine speeds and time durations described below prior to checking the waveforms of the A/F and HO2 sensors. This is in order to activate the sensors sufficiently to obtain the appropriate inspection results. Engine Speed (C) 3,000 rpm (D) 2,000 rpm Idling Ignition Switch off (D) (B) (A) Time Warming up At least 3 minutes 2 seconds Check A118003E06 ES ES–204 ES 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 1. Connect the intelligent tester to the DLC3. (Proceed to "A") 2. Start the engine and warm it up with all the accessories switched OFF, until the engine coolant temperature stabilizes. (Proceed to "B") 3. Run the engine at an engine speed of between 2,500 rpm and 3,000 rpm for at least 3 minutes. (Proceed to "C") 4. While running the engine at 3,000 rpm and 2,000 rpm alternating at 2 second intervals, check the waveforms of the A/F and HO2 sensors using the tester. (Proceed to "D") HINT: • If either voltage output of the Air-Fuel Ratio (A/F) or Heated Oxygen (HO2) sensor does not fluctuate, or there is a noise in the waveform of either sensor, the sensor may be malfunctioning. • If the voltage outputs of both the sensors remain lean or rich, the air-fuel ratio may be extremely lean or rich. In such cases, perform the following A/F CONTROL using the intelligent tester. • If the Three-Way Catalytic Converter (TWC) has deteriorated, the HO2 sensor (located behind the TWC) voltage output fluctuates up and down frequently, even under normal driving conditions (active air-fuel ratio control is not performed). Voltage output when active air-fuel ratio control not performed: Normal Catalyst Waveform of A/F Sensor in front of TWC Waveform of HO2 Sensor behind TWC Deteriorated Catalyst 3.5 V 3.0 V 1.0 V 0V 10 seconds 10 seconds A121610E02 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the airfuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P0420) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs. ES–205 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Result Display (DTC Output) Proceed to P0420 A P0420 and other DTCs B HINT: If any DTCs other than P0420 are output, troubleshoot those DTCs first. B GO TO DTC CHART A 2 ES PERFORM ACTIVE TEST USING INTELLIGENT TESTER (A/F CONTROL) (a) Connect the intelligent tester to the DLC3. (b) Start the engine and turn the tester on. (c) Warm up the engine at an engine speed of 2,500 rpm for approximately 90 seconds. (d) On the tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. (e) Perform the A/F CONTROL operation with the engine in an idling condition (press the RIGHT or LEFT button to change the fuel injection volume). (f) Monitor the voltage outputs of the A/F and HO2 sensors (AFS B1 S1 and O2S B1 S2) displayed on the tester. Result: A/F sensor reacts in accordance with increases and decreases in fuel injection volume: +25 % = Rich output: Less than 3.0 V -12.5 % = Lean output: More than 3.35 V NOTICE: The A/F sensor has an output delay of a few seconds and the HO2 sensor has a maximum output delay of approximately 20 seconds. Case A/F Sensor (Sensor 1) Output Voltage HO2 Sensor (Sensor 2) Output Voltage Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage More than 3.35 V Less than 3.0 V Output Voltage More than 0.5 V Less than 0.4 V Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage Almost no reaction Output Voltage More than 0.5 V Less than 0.4 V 1 2 Main Suspected Trouble Areas • • Catalyst Exhaust gas leakage • • • A/F sensor A/F sensor heater A/F sensor circuit ES–206 Case 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM A/F Sensor (Sensor 1) Output Voltage HO2 Sensor (Sensor 2) Output Voltage Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage More than 3.35 V Less than 3.0 V Output Voltage Almost no reaction Injection volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage Almost no reaction Output Voltage Almost no reaction Main Suspected Trouble Areas • • • 3 Extremely rich or lean actual air-fuel ratio • Injector • Fuel pressure • Gas leakage from exhaust system 4 ES HO2 sensor HO2 sensor heater HO2 sensor circuit Following the A/F CONTROL procedure enables technicians to check and graph the voltage outputs of both the A/F and HO2 sensors. To display the graph, select the following menu items on the tester: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL / USER DATA / AFS B1 S1 and O2S B1 S2; then press the YES button and then the ENTER button followed by the F4 button. Result Result Proceed to Case 1 A Case 2 B Case 3 C Case 4 D B REPLACE AIR-FUEL RATIO SENSOR C D Go to step 4 CHECK CAUSE OF EXTREMELY RICH OR LEAN ACTUAL AIR-FUEL RATIO, REPLACE FAULTY AREA AND GO TO NEXT STEP A 3 CHECK FOR EXHAUST GAS LEAKAGE OK: No gas leakage. NG REPAIR OR REPLACE EXHAUST GAS LEAKAGE POINT OK REPLACE THREE-WAY CATALYTIC CONVERTER (BOTH FRONT AND REAR CATALYSTS (FRONT EXHAUST PIPE)) 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 4 ES–207 CHECK FOR EXHAUST GAS LEAKAGE OK: No gas leakage. NG REPAIR OR REPLACE EXHAUST GAS LEAKAGE POINT OK REPLACE HEATED OXYGEN SENSOR ES ES–208 ES 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P043E Evaporative Emission System Reference Orifice Clog Up DTC P043F Evaporative Emission System Reference Orifice High Flow DTC P2401 Evaporative Emission Leak Detection Pump Stuck OFF DTC P2402 Evaporative Emission Leak Detection Pump Stuck ON DTC P2419 Evaporative Emission System Switching Valve Control Circuit Low DTC SUMMARY DTCs Monitoring Item P043E Reference orifice clogged P043F Reference orifice high-flow P2401 Leak detection pump stuck OFF P2402 Leak detection pump stuck ON P2419 Vent valve stuck closed Malfunction Detection Condition Trouble Area • P043E, P043F, P2401, P2402 and P2419 present when one of the following conditions is met during key-off EVAP monitor: • Reference orifice clogged • Reference orifice high-flow • Leak detection pump OFF malfunction • Leak detection pump ON malfunction • Vent valve ON (close) malfunction • • • Canister pump module (Reference orifice, leak detection pump, vent valve) Connector/wire harness (Canister pump module ECM) EVAP system hose (pipe from air inlet port to canister pump module, canister filter, fuel tank vent hose) ECM Detection Timing While ignition switch off Detection Logic 2 trip detection logic HINT: The reference orifice is located inside the canister pump module. DESCRIPTION The description can be found in the EVAP (Evaporative Emission) System (See page ES-346). INSPECTION PROCEDURE Refer to the EVAP System (See page ES-352). MONITOR DESCRIPTION 5 hours* after the ignition switch is turned off, the leak detection pump creates negative pressure (vacuum) in the EVAP system. The ECM monitors for leaks and actuator malfunctions based on the EVAP pressure. HINT: *: If the engine coolant temperature is not below 35°C (95°F) 5 hours after the ignition switch is turned off, the monitor check starts 2 hours later. If it is still not below 35°C (95°F) 7 hours after the ignition switch is turned off, the monitor check starts 2.5 hours later. ES–209 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Sequ ence Operations Descriptions Duration - ECM activation Activated by soak timer 5, 7 or 9.5 hours after ignition switch turned off. - A Atmospheric pressure measurement Vent valve turned OFF (vent) and EVAP system pressure measured by ECM in order to register atmospheric pressure. If pressure in EVAP system not between 76 kPa-a and 110 kPa-a (570 mmHg-a and 825 mmHg-a), ECM cancels EVAP system monitor. 10 seconds B First reference pressure measurement In order to determine reference pressure, leak detection pump creates negative pressure (vacuum) through reference orifice and then ECM checks if leak detection pump and vent valve operate normally. 60 seconds C EVAP system pressure measurement Vent valve turned ON (closed) to shut EVAP system. Negative pressure (vacuum) created in EVAP system, and EVAP system pressure then measured. Write down measured value as it will be used in leak check. If EVAP pressure does not stabilize within 15 minutes, ECM cancels EVAP system monitor. 15 minutes* D Purge VSV monitor Purge VSV opened and then EVAP system pressure measured by ECM. Large increase indicates normality. 10 seconds E Second reference pressure measurement After second reference pressure measurement, leak check performed by comparing first and second reference pressure. If stabilized system pressure higher than second reference pressure, ECM determines that EVAP system leaking. 60 seconds F Final check Atmospheric pressure measured and then monitoring result recorded by ECM. - *: If only a small amount of fuel is in the fuel tank, it takes longer for the EVAP pressure to stabilize. Operation B, E: Operation A: Atmospheric Pressure Measurement Reference Pressure Measurement Purge VSV: OFF Canister Fuel Tank OFF Vent Valve: OFF (vent) OFF (vent) Canister Pump Module Canister Pressure Sensor Canister Filter Leak Detection Pump: OFF ON Reference Orifice (0.02 inch) Operation C: EVAP System Pressure Measurement Operation D: Purge VSV Monitor ON (closed) OFF Atmospheric Pressure ON ON (closed) Negative Pressure ON ON A112612E04 ES ES–210 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM EVAP pressure during EVAP key-off monitor ON ON: Open Purge VSV OFF: Closed ON Vent Valve ON: Closed ON: Vent ON Pump EVAP Pressure ES (mmHg) 760 752 OK Malfunction 724 A B 10 seconds 60 seconds Sequence Time C Within 15 minutes D E 60 10 seconds seconds A138478E01 The leak detection pump creates negative pressure through the reference orifice. When the system is normal, the EVAP pressure is in 724 to 752 mmHg* and saturated within a minute. If not, the ECM interprets this as a malfunction. The ECM will illuminate the MIL and set DTC if this malfunction is detected in consecutive drive cycle. *: Typical valve MONITOR STRATEGY Required Sensors/Components Purge VSV and canister pump module Frequency of Operation Once per driving cycle Duration Within 2 minutes (varies with amount of fuel in tank) MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present None EVAP key-off monitor runs when all of the following conditions are met - Atmospheric pressure 70 to 110 kPa-a (525 to 825 mmHg-a) Battery voltage 10.5 V or more Vehicle speed Below 2.5 mph (4 km/h) Ignition switch off Time after key off 5, 7 or 9.5 hours EVAP pressure sensor malfunction (P0450, P0451, P0452 and P0453) Not detected EVAP canister purge valve Not operated by scan tool EVAP canister vent valve Not operated by scan tool 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM EVAP leak detection pump Not operated by scan tool Both of the following conditions are met before key off Conditions 1 and 2 1. Duration that vehicle has been driven 5 minutes or more 2. EVAP purge operation Performed ECT 4.4 to 35°C (40 to 95°F) IAT 4.4 to 35°C (40 to 95°F) ES–211 1. Key-off monitor sequence 1 to 8 1. Atmospheric pressure measurement Next sequence runs if following condition is met - Atmospheric pressure change Less than 0.3 kPa-g (2.25 mmHg-g) in 1 second 2. First reference pressure measurement Next sequence runs if all of the following conditions are met Conditions 1, 2 and 3 1. EVAP pressure just after reference pressure measurement start -1 kPa-g (-7.5 mmHg-g) or less 2. Reference pressure -4.85 to -1.057 kPa-g (-36.4 to -7.93 mmHg-g) 3. Reference pressure Saturated within 60 seconds 3. Vent valve stuck closed check Next sequence runs if following condition is met - EVAP pressure change after vent valve is ON 0.3 kPa-g (2.25 mmHg-g) or more 4. Vacuum introduction Next sequence runs if following condition is met - EVAP pressure Saturated within 15 minutes 5. EVAP canister purge valve close stuck check Next sequence runs if following condition is met - EVAP pressure change after purge valve is open 0.3 kPa-g (2.25 mmHg-g) or more 6. Second reference pressure measurement Next sequence runs if all of the following conditions are met Conditions 1, 2, 3 and 4 1. EVAP pressure just after reference pressure measurement start -1 kPa-g (-7.5 mmHg-g) or less 2. Reference pressure -4.85 to -1.057 kPa-g (-36.4 to -7.93 mmHg-g) 3. Reference pressure Saturated within 60 seconds 4. Difference between first reference pressure and second reference pressure Less than 0.5 kPa-g (3.75 mmHg-g) 7. Leak check Next sequence runs if following condition is met - EVAP pressure when vacuum introduction is complete Second reference pressure or less 8. Atmospheric pressure measurement EVAP monitor complete if following condition is met - Atmospheric pressure difference between sequence 1 and 8 Within 0.3 kPa-g (2.25 mmHg-g) TYPICAL MALFUNCTION THRESHOLDS "Saturated" indicates that the EVAP pressure change is less than 0.286 kPa-g (2.14 mmHg-g) in 60 seconds. One of the following conditions is met - EVAP pressure just after reference pressure measurement start More than -1 kPa-g (-7.5 mmHg-g) Reference pressure Less than -4.85 kPa-g (-36.4 mmHg-g) Reference pressure -1.057 kPa-g (-7.93 mmHg-g) or more Reference pressure Not saturated within 60 seconds ES ES–212 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Difference between first reference pressure and second reference pressure 0.7 kPa-g (5.25 mmHg-g) or more MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-20). ES ES–213 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC Evaporative Emission Control System Incorrect Purge Flow P0441 DTC SUMMARY DTC Monitoring Item Purge VSV (Vacuum Switching Valve) stuck open Leak detection pump creates negative pressure (vacuum) in EVAP system and EVAP system pressure measured. Reference pressure measured at start and at end of leak check. If stabilized pressure higher than [second reference pressure x 0.2], ECM determines that purge VSV stuck open. Purge VSV stuck closed After EVAP leak check performed, purge VSV turned ON (open), and atmospheric air introduced into EVAP system. Reference pressure measured at start and at end of check. If pressure does not return to near atmospheric pressure, ECM determines that purge VSV stuck closed. Purge flow While engine running, following conditions successively met: • Negative pressure not created in EVAP system when purge VSV turned ON (open) • EVAP system pressure change less than 0.5 kPa-g (3.75 mmHg-g) when vent valve turned ON (closed) • Atmospheric pressure change before and after purge flow monitor less than 0.1 kPa-g (0.75 mmHg-g) P0441 Trouble Area Detection Timing Purge VSV Connector/wire harness (Purge VSV - ECM) ECM Canister pump module Leakage from EVAP system While ignition switch off Purge VSV Connector/wire harness (Purge VSV - ECM) ECM Canister pump module Leakage from EVAP system While ignition switch off 2 trip detection logic Purge VSV Connector/wire harness (Purge VSV - ECM) Leakage from EVAP line (Purge VSV - Intake manifold) ECM While engine running 2 trip detection logic Malfunction Detection Condition • • • • • • • • • • • • • • Detection Logic 2 trip detection logic ES DESCRIPTION The description can be found in the EVAP (Evaporative Emission) System (See page ES-346). INSPECTION PROCEDURE Refer to the EVAP System (See page ES-352). MONITOR DESCRIPTION The two monitors, Key-Off and Purge Flow, are used to detect malfunctions relating to DTC P0441. The Key-Off monitor is initiated by the ECM internal timer, known as the soak timer, 5 hours* after the ignition switch is turned off. The purge flow monitor runs while the engine is running. 1. KEY-OFF MONITOR 5 hours* after the ignition switch is turned off, the leak detection pump creates negative pressure (vacuum) in the EVAP system. The ECM monitors for leaks and actuator malfunctions based on the EVAP pressure. HINT: *: If the engine coolant temperature is not below 35°C (95°F) 5 hours after the ignition switch is turned off, the monitor check starts 2 hours later. If it is still not below 35°C (95°F) 7 hours after the ignition switch is turned off, the monitor check starts 2.5 hours later. Sequ ence - Operations ECM activation Descriptions Activated by soak timer 5, 7 or 9.5 hours after ignition switch turned off. Duration - ES–214 Sequ ence ES 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Operations Descriptions Duration A Atmospheric pressure measurement Vent valve turned OFF (vent) and EVAP system pressure measured by ECM in order to register atmospheric pressure. If pressure in EVAP system not between 76 kPa-a and 110 kPa-a (570 mmHg-a and 825 mmHg-a), ECM cancels EVAP system monitor. 10 seconds B First reference pressure measurement In order to determine reference pressure, leak detection pump creates negative pressure (vacuum) through reference orifice and then ECM checks if leak detection pump and vent valve operate normally. 60 seconds C EVAP system pressure measurement Vent valve turned ON (closed) to shut EVAP system. Negative pressure (vacuum) created in EVAP system, and EVAP system pressure then measured. Write down measured value as it will be used in leak check. If EVAP pressure does not stabilize within 15 minutes, ECM cancels EVAP system monitor. 15 minutes* D Purge VSV monitor Purge VSV opened and then EVAP system pressure measured by ECM. Large increase indicates normality. 10 seconds E Second reference pressure measurement After second reference pressure measurement, leak check performed by comparing first and second reference pressure. If stabilized system pressure higher than second reference pressure, ECM determines that EVAP system leaking. 60 seconds F Final check Atmospheric pressure measured and then monitoring result recorded by ECM. - *: If only a small amount of fuel is in the fuel tank, it takes longer for the EVAP pressure to stabilize. Operation B, E: Operation A: Atmospheric Pressure Measurement Reference Pressure Measurement Purge VSV: OFF Canister Fuel Tank OFF Vent Valve: OFF (vent) OFF (vent) Canister Pump Module Canister Pressure Sensor Canister Filter Leak Detection Pump: OFF ON Reference Orifice (0.02 inch) Operation C: EVAP System Pressure Measurement Operation D: Purge VSV Monitor ON (closed) OFF Atmospheric Pressure ON ON (closed) Negative Pressure ON ON A112612E04 ES–215 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (a)Purge VSV stuck open In operation C, the leak detection pump creates negative pressure (vacuum) in the EVAP system. The EVAP system pressure is then measured by the ECM using the canister pressure sensor. If the stabilized system pressure is higher than [second reference pressure x 0.2], the ECM interprets this as the purge VSV (Vacuum Switching Valve) being stuck open. The ECM illuminates the MIL and sets the DTC (2 trip detection logic). EVAP Pressure when Purge Stuck Open: ON: Open ON Purge VSV OFF: Closed Vent Valve ON: Closed ON OFF: Vent Leak Detection Pump ON EVAP Pressure Malfunction Positive Negative First Reference Pressure Sequence Time [Second Reference Pressure] x 0.2 OK A B 10 seconds 60 seconds C Within 15 minutes D E 10 60 seconds seconds A108008E06 ES ES–216 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (b)Purge VSV stuck closed In operation D, the canister pressure sensor measures the EVAP system pressure. The pressure measurement for purge VSV monitor is begun when the purge VSV is turned ON (open) after the EVAP leak check. When the measured pressure indicates an increase of 0.3 kPa-g (2.25 mmHg-g) or more, the purge VSV is functioning normally. If the pressure does not increase, the ECM interprets this as the purge VSV being stuck closed. The ECM illuminates the MIL and sets the DTC (2 trip detection logic). EVAP Pressure when Purge VSV Stuck Closed: Purge VSV ES ON: Open ON OFF: Closed Vent Valve ON: Closed ON Leak Detection Pump OFF: Vent ON EVAP Pressure OK Positive Negative Malfunction First Reference Pressure Sequence Time C A B 10 seconds 60 seconds D Within 15 minutes E 10 60 seconds seconds A106059E06 2. PURGE FLOW MONITOR EVAP Pressure During Purge Flow Monitor: Open Purge VSV ON (Closed) Vent Valve Malfunction EVAP Pressure 0.1 kPa-g (0.75 mmHg-g) OK 0.5 kPa-g (3.75 mmHg-g) OK 1st Monitor 2nd Monitor A112640E01 The purge flow monitor consists of the two step monitors. The 1st monitor is conducted every time and the 2nd monitor is activated if necessary. 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–217 • The 1st monitor While the engine is running and the purge VSV is ON (open), the ECM monitors the purge flow by measuring the EVAP pressure change. If negative pressure is not created, the ECM begins the 2nd monitor. • The 2nd monitor The vent valve is turned ON (closed) and the EVAP pressure is then measured. If the variation in the pressure is less than 0.5 kPa-g (3.75 mmHg-g), the ECM interprets this as the purge VSV being stuck closed, and illuminates the MIL and sets DTC P0441 (2 trip detection logic). Atmospheric pressure check: In order to ensure reliable malfunction detection, the variation between the atmospheric pressures, before and after conduction of the purge flow monitor, is measured by the ECM. OBD II MONITOR SPECIFICATIONS ES 1. Key-off Monitor Monitor Strategy Required Sensors/Components Purge VSV and canister pump module Frequency of Operation Once per driving cycle Duration Within 15 minutes (varies with fuel in tank) MIL Operation 2 driving cycles Sequence of Operation None Typical Enabling Conditions EVAP key-off monitor runs when all of the following conditions are met - Atmospheric pressure 70 to 110 kPa-a (525 to 825 mmHg-a) Battery voltage 10.5 V or more Vehicle speed Below 2.5 mph (4 km/h) Ignition switch off Time after key off 5, 7 or 9.5 hours EVAP pressure sensor malfunction (P0450, P0451, P0452 and P0453) Not detected EVAP canister purge valve Not operated by scan tool EVAP canister vent valve Not operated by scan tool EVAP leak detection pump Not operated by scan tool Both of the following conditions are met before key off Conditions 1 and 2 1. Duration that vehicle has been driven 5 minutes or more 2. EVAP purge operation Performed ECT 4.4 to 35°C (40 to 95°F) IAT 4.4 to 35°C (40 to 95°F) 2. Key-off monitor sequence 1 to 8 1. Atmospheric pressure measurement Next sequence runs if following condition is met - Atmospheric pressure change Less than 0.3 kPa-g (2.25 mmHg-g) in 1 second 2. First reference pressure measurement Next sequence runs if all of the following conditions are met Conditions 1, 2 and 3 1. EVAP pressure just after reference pressure measurement start -1 kPa-g (-7.5 mmHg-g) or less 2. Reference pressure -4.85 to -1.057 kPa-g (-36.4 to -7.93 mmHg-g) 3. Reference pressure Saturated within 60 seconds 3. Vent valve stuck closed check Next sequence runs if following condition is met - EVAP pressure change after vent valve is ON 0.3 kPa-g (2.25 mmHg-g) or more ES–218 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 4. Vacuum introduction Next sequence runs if following condition is met - EVAP pressure Saturated within 15 minutes 5. EVAP canister purge valve close stuck check Next sequence runs if following condition is met - EVAP pressure change after purge valve is open 0.3 kPa-g (2.25 mmHg-g) or more 6. Second reference pressure measurement ES Next sequence runs if all of the following conditions are met Conditions 1, 2, 3 and 4 1. EVAP pressure just after reference pressure measurement start -1 kPa-g (-7.5 mmHg-g) or less 2. Reference pressure -4.85 to -1.057 kPa-g (-36.4 to -7.93 mmHg-g) 3. Reference pressure Saturated within 60 seconds 4. Difference between first reference pressure and second reference pressure Less than 0.5 kPa-g (3.75 mmHg-g) 7. Leak check Next sequence runs if following condition is met - EVAP pressure when vacuum introduction is complete Second reference pressure or less 8. Atmospheric pressure measurement EVAP monitor complete if following condition is met - Atmospheric pressure difference between sequence 1 and 8 Within 0.3 kPa-g (2.25 mmHg-g) Typical Malfunction Thresholds EVAP canister purge valve stuck open: - EVAP pressure when vacuum introduction is complete Higher than reference pressure x 0.2 EVAP canister purge valve stuck closed: - EVAP pressure change after EVAP canister purge valve is open Less than 0.3 kPa-g (2.25 mmHg-g) OBD II MONITOR SPECIFICATIONS 1. Purge Flow Monitor Monitor Strategy Required Sensors/Components Purge VSV and canister pump module Frequency of Operation Once per driving cycle Duration Within 10 minutes MIL Operation 2 driving cycles Sequence of Operation None Typical Enabling Conditions Monitor runs whenever following DTCs are not present P0011 (VVT System 1 - Advance) P0012 (VVT System 1 - Retard) P0100 - P0103 (MAF meter) P0110 - P0113 (IAT sensor) P0115 - P0118 (ECT sensor) P0120 - P0223, P2135 (TP sensor) P0125 (Insufficient ECT for Closed Loop) P0171, P0172 (Fuel system) P0300 - P0304 (Misfire) P0335 (CKP sensor) P0340 (CMP sensor) P0351 - P0354 (Igniter) P0450 - P0453 (EVAP press sensor) P0500 (VSS) Engine Running ECT 4.4°C (40°F) or more 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM IAT 4.4°C (40°F) or more EVAP pressure sensor malfunction Not detected EVAP canister purge valve Not operated by scan tool EVAP system check Not operated by scan tool Battery voltage 10 V or more Purge duty cycle 8 % or more ES–219 Typical Malfunction Thresholds Both of the following conditions are met Conditions 1 and 2 1. EVAP pressure change when purge flow is started Less than 0.1 kPa-g (0.75 mmHg-g) 2. EVAP pressure change during purge flow when EVAP pressure switching valve is ON (closed) Less than 0.5 kPa-g (3.75 mmHg-g) MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-20). ES ES–220 ES 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0450 Evaporative Emission Control System Pressure Sensor / Switch DTC P0451 Evaporative Emission Control System Pressure Sensor Range / Performance DTC P0452 Evaporative Emission Control System Pressure Sensor / Switch Low Input DTC P0453 Evaporative Emission Control System Pressure Sensor / Switch High Input DTC SUMMARY DTC Monitoring Item Malfunction Detection Condition • • P0450 Canister pressure sensor voltage fluctuation abnormal Sensor output voltage rapidly fluctuates beyond upper and lower malfunction thresholds for 0.5 seconds. • • • Canister pressure sensor noise Sensor output voltage fluctuates frequently within certain time period. • • P0451 • • Canister pressure sensor signal becomes fixed/flat Sensor output voltage does not vary within certain time period. • • • • P0452 Canister pressure sensor low input EVAP pressure less than 42.1 kPa for 0.5 seconds. Detection Timing Detection Logic EVAP monitoring (ignition off) Ignition ON position 1 trip detection logic EVAP monitoring (ignition off) Engine running 2 trip detection logic • EVAP monitoring (ignition off) 2 trip detection logic • Ignition ON position EVAP monitoring (ignition off) 1 trip detection logic Trouble Ares • • Canister pump module EVAP system hose (pipe from air inlet port to canister pump module, canister filter, fuel tank vent hose) ECM Canister pump module Connector/wire harness (Canister pump module - ECM) EVAP system hose (pipe from air inlet port to canister pump module, canister filter, fuel tank vent hose) ECM Canister pump module Connector/wire harness (Canister pump module - ECM) EVAP system hose (pipe from air inlet port to canister pump module, canister filter, fuel tank vent hose) ECM Canister pump module Connector/wire harness (Canister pump module - ECM) EVAP system hose (pipe from air inlet port to canister pump module, canister filter, fuel tank vent hose) ECM • • • • • ES–221 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC Monitoring Item Malfunction Detection Condition Trouble Ares • • P0453 Canister pressure sensor high input EVAP pressure more than 123.8 kPa for 0.5 seconds. • • Canister pump module Connector/wire harness (Canister pump module - ECM) EVAP system hose (pipe from air inlet port to canister pump module, canister filter, fuel tank vent hose) ECM • • Detection Timing Detection Logic Ignition ON position EVAP monitoring (ignition off) 1 trip detection logic HINT: The canister pressure sensor is built into the canister pump module. ES DESCRIPTION The description can be found in the EVAP (Evaporative Emission) System (See page ES-346). MONITOR DESCRIPTION Canister Pressure Sensor Specification: Malfunction Area Output Voltage 4.900 V 4.150 V Usable Range 1.425 V Malfunction Area 0.450 V 60 (450) 110 (825) kPa-a (mmHg-a) Pressure HINT: Standard atmospheric pressure is 101.3 kPa-a (760 mmHg-a) A115543E05 1. DTC P0450: Canister pressure sensor abnormal fluctuation If the canister pressure sensor output [pressure] rapidly fluctuates between less than 42.1 kPa-a (315.9 mmHg-a) and more than 123.8 kPa-a (928.4 mmHg-a), the ECM interprets this as an open or short circuit malfunction in the canister pressure sensor or its circuit, and stops the EVAP (Evaporative Emission) system monitor. The ECM then illuminates the MIL and sets the DTC (1 trip detection logic). ES–222 ES 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2. DTC P0451: Canister pressure sensor noise or fixed/flat If the canister pressure sensor voltage output fluctuates rapidly for 10 seconds, the ECM stops the EVAP system monitor. The ECM interprets this as noise from the canister pressure sensor, and stops the EVAP system monitor. The ECM then illuminates the MIL and sets the DTC. Alternatively, if the sensor voltage output does not change for 10 seconds, the ECM interprets this as the sensor being fixed/flat, and stops the monitor. The ECM then illuminates the MIL and sets the DTC. (Both the malfunctions are detected by 2 trip detection logic). 3. DTC P0452: Canister pressure sensor voltage low If the canister pressure sensor output [pressure] is below 42.1 kPa-a (315.9 mmHg-a), the ECM interprets this as an open or short circuit malfunction in the canister pressure sensor or its circuit, and stops the EVAP system monitor. The ECM then illuminates the MIL and sets the DTC (1 trip detection logic). 4. DTC P0453: Canister pressure sensor voltage high If the canister pressure sensor output [pressure] is 123.8 kPa-a (928.4 mmHg-a) or more, the ECM interprets this as an open or short circuit malfunction in the canister pressure sensor or its circuit, and stops the EVAP system monitor. The ECM then illuminates the MIL and sets the DTC (1 trip detection logic). MONITOR STRATEGY Required Sensors/Components Canister pump module Frequency of Operation Once per driving cycle: P0451 sensor fixed/flat Continuous: P0451 sensor noise, P0450, P0452 and P0453 Duration 0.5 seconds: P0450, P0452 and P0453 2 minutes: P0451 MIL Operation Immediate: P0450, P0452 and P0453 2 driving cycles: P0451 Sequence of Operation None TYPICAL ENABLING CONDITIONS P0451 (Noise monitor): Monitor runs whenever following DTCs are not present None Atmospheric pressure (absolute pressure) 70 to 110 kPa-a (525 to 825 mmHg-a) Battery voltage 10.5 V or more Intake air temperature 4.4 to 35°C (40 to 95°F) EVAP pressure sensor malfunction (P0450, P0452, 0453) Not detected Either of the following conditions A or B is met - A. Engine condition Running B. Time after key off 5, 7 or 9.5 hours P0451 (Fixed/flat monitor): Monitor runs whenever following DTCs are not present None Battery voltage 10.5 V or more Intake air temperature 4.4 to 35°C (40 to 95°F) EVAP pressure sensor malfunction (P0450, P0452, 0453) Not detected Atmospheric pressure (absolute pressure) 70 to 110 kPa-a (525 to 825 mmHg-a) Time after key off 5, 7 or 9.5 hours P0450, P0452 and P0453: Monitor runs whenever following DTCs are not present None Either of following conditions is met (a) or (b) (a) Ignition switch ON (b) Soak timer ON Battery voltage 8 V or more 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Starter ES–223 OFF TYPICAL MALFUNCTION THRESHOLDS P0450: Canister pressure sensor chattering EVAP pressure Less than 42.1 kPa-a (315.9 mmHg-a), or more than 123.8 kPa-a (928.4 mmHg-a) P0451: Canister pressure sensor noise Frequency that EVAP pressure change 0.3 kPa-g (2.25 mmHg-g) or more 10 times or more in 10 seconds P0451: Canister pressure sensor fixed/flat EVAP pressure change during reference pressure measurement Less than 0.65 kPa-g (4.88 mmHg-g) ES P0452: Canister pressure sensor low voltage EVAP pressure Less than 42.1 kPa-a (315.9 mmHg-a) P0453: Canister pressure sensor high voltage EVAP pressure More than 123.8 kPa-a (928.4 mmHg-a) ES–224 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM N17 Canister Pump Module ECM Leak Detection Pump 6 MGND M MTRB 1 34 A24 MPMP VCC 4 70 VCPP C24 VOUT 3 71 PPMP C24 2 94 EPPM C24 8 42 A24 VPMP ES Canister Pressure Sensor SGND 9 VLVB VGND Vent Valve C6 Purge VSV 1 2 49 C24 PRG EFI No. 3 FL MAIN EFI MAIN 44 MREL A24 EFI Battery A132282E01 ES–225 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE NOTICE: • When a vehicle is brought into the workshop, leave it as it is. Do not change the vehicle condition. For example, do not tighten the fuel cap. • Do not disassemble the canister pump module. • An intelligent tester is required to conduct the following diagnostic troubleshooting procedure. HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the airfuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 ES CHECK HARNESS AND CONNECTOR (CANISTER PUMP MODULE - ECM) (a) Disconnect the N17 canister pump module connector. (b) Turn the ignition switch to the ON position. (c) Measure the voltage and resistance of the canister connector. Standard Tester Connection Specified Condition N17-4 (VCC) - Body ground 4.5 to 5.5 V N17-3 (VOUT) - Body ground 4.5 to 5.5 V N17-2 (SGND) - Body ground 100 Ω or less Result Test Result Wire Harness Side: Proceed to Voltage and resistance within standard ranges A Voltage and resistance outside standard ranges B (d) Reconnect the canister pump module connector. VOUT B VCC Go to step 3 SGND N17 Canister Pump Module Connector A135029E01 A 2 REPLACE CHARCOAL CANISTER ASSEMBLY (a) Replace the canister assembly (See page EC-9). ES–226 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NOTICE: When replacing the canister, check the canister pump module interior and related pipes for water, fuel and other liquids. If liquids are present, check for disconnections and/or cracks in the following: 1) the pipe from the air inlet port to the canister pump module; 2) the canister filter; and 3) the fuel tank vent hose. Except PZEV: ES Air Inlet Port Fuel Tank Vent Hose Inspection Area* Vent Hose Vent Hose *: Check for disconnection and/or crack A132283E01 ES–227 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PZEV: Air Inlet Port ES Vent Hose Inspection Area* Fuel Tank Vent Hose Vent Hose Vent Hose *: Check for disconnection and/or crack A132284E01 NEXT 3 Go to step 5 CHECK HARNESS AND CONNECTOR (CANISTER PUMP MODULE - ECM) Wire Harness Side: VOUT VCC SGND (a) Disconnect the N17 canister pump module connector. (b) Disconnect the C24 ECM connector. (c) Measure the resistance between the terminals of the wire harness side connectors. Standard resistance (Check for open) N17 Canister Pump Module Connector Tester Connection Specified Condition N17-4 (VCC) - C24-70 (VCPP) Below 1 Ω N17-3 (VOUT) - C24-71 (PPMP) Below 1 Ω N17-2 (SGND) - C24-94 (EPPM) Below 1 Ω Standard resistance (Check for short) C24 ECM Connector Tester Connection Specified Condition N17-4 (VCC) or C24-70 (VCPP) - Body ground 10 kΩ or higher N17-3 (VOUT) or C24-71 (PPMP) - Body ground 10 kΩ or higher N17-2 (SGND) or C24-94 (EPPM) - Body ground 10 kΩ or higher (d) Reconnect the canister pump module connector. (e) Reconnect the ECM connector. VCPP EPPM PPMP A140651E01 NG REPAIR OR REPLACE HARNESS OR CONNECTOR AND GO TO STEP 5 ES–228 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK 4 REPLACE ECM (a) Replace the ECM (See page ES-432). NEXT 5 Go to step 5 CHECK WHETHER DTC OUTPUT RECURS (AFTER REPAIR) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the tester on. (c) Wait for at least 60 seconds. (d) On the tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. HINT: If no pending DTCs are displayed on the tester, the repair has been successfully completed. ES NEXT COMPLETED ES–229 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0455 Evaporative Emission Control System Leak Detected (Gross Leak) DTC P0456 Evaporative Emission Control System Leak Detected (Very Small Leak) DTC SUMMARY DTCs P0455 P0456 Monitoring Item EVAP gross leak EVAP small leak Malfunction Detection Condition Leak detection pump creates negative pressure (vacuum) in EVAP system and EVAP system pressure measured. Reference pressure measured at start and at end of leak check. If stabilized pressure higher than [second reference pressure x 0.2], ECM determines that EVAP system has large leak. Leak detection pump creates negative pressure (vacuum) in EVAP system and EVAP system pressure measured. Reference pressure measured at start and at end of leak check. If stabilized pressure higher than second reference pressure, ECM determines that EVAP system has a small leak. Trouble Area • • • • • • • • • • • • Detection Timing Detection Logic Fuel cap (loose) Leakage from EVAP line (Canister - Fuel tank) Leakage from EVAP line (Purge VSV - Canister) Canister pump module Leakage from fuel tank Leakage from canister While ignition switch off 2 trip detection logic Fuel cap (loose) Leakage from EVAP line (Canister - Fuel tank) Leakage from EVAP line (Purge VSV - Canister) Canister pump module Leakage from fuel tank Leakage from canister While ignition switch off 2 trip detection logic DESCRIPTION The description can be found in the EVAP (Evaporative Emission) System (See page ES-346). INSPECTION PROCEDURE Refer to the EVAP System (See page ES-352). MONITOR DESCRIPTION 5 hours* after the ignition switch is turned off, the leak detection pump creates negative pressure (vacuum) in the EVAP system. The ECM monitors for leaks and actuator malfunctions based on the EVAP pressure. HINT: *: If the engine coolant temperature is not below 35°C (95°F) 5 hours after the ignition switch is turned off, the monitor check starts 2 hours later. If it is still not below 35°C (95°F) 7 hours after the ignition switch is turned off, the monitor check starts 2.5 hours later. Sequ ence - Operations Descriptions Duration ECM activation Activated by soak timer 5, 7 or 9.5 hours after ignition switch turned off. A Atmospheric pressure measurement Vent valve turned OFF (vent) and EVAP system pressure measured by ECM in order to register atmospheric pressure. If pressure in EVAP system not between 76 kPa-a and 110 kPa-a (570 mmHg-a and 825 mmHg-a), ECM cancels EVAP system monitor. - 10 seconds B First reference pressure measurement In order to determine reference pressure, leak detection pump creates negative pressure (vacuum) through reference orifice and then ECM checks if leak detection pump and vent valve operate normally. 60 seconds C EVAP system pressure measurement Vent valve turned ON (closed) to shut EVAP system. Negative pressure (vacuum) created in EVAP system, and EVAP system pressure then measured. Write down measured value as it will be used in leak check. If EVAP pressure does not stabilize within 15 minutes, ECM cancels EVAP system monitor. 15 minutes* ES ES–230 Sequ ence 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Operations Descriptions Duration D Purge VSV monitor Purge VSV opened and then EVAP system pressure measured by ECM. Large increase indicates normality. 10 seconds E Second reference pressure measurement After second reference pressure measurement, leak check performed by comparing first and second reference pressure. If stabilized system pressure higher than second reference pressure, ECM determines that EVAP system leaking. 60 seconds F Final check Atmospheric pressure measured and then monitoring result recorded by ECM. - *: If only a small amount of fuel is in the fuel tank, it takes longer for the EVAP pressure to stabilize. Operation B, E: Operation A: Atmospheric Pressure Measurement ES Reference Pressure Measurement Purge VSV: OFF Canister Fuel Tank OFF Vent Valve: OFF (vent) OFF (vent) Canister Pump Module Canister Pressure Sensor Canister Filter Leak Detection Pump: OFF ON Reference Orifice (0.02 inch) Operation C: EVAP System Pressure Measurement Operation D: Purge VSV Monitor ON (closed) OFF Atmospheric Pressure ON ON (closed) Negative Pressure ON ON A112612E04 (a) P0455: EVAP gross leak In operation C, the leak detection pump creates negative pressure (vacuum) in the EVAP system and the EVAP system pressure is measured. If the stabilized system pressure is higher than [second reference pressure x 0.2] (near atmospheric pressure), the ECM determines that the EVAP system has a large leakage, illuminates the MIL and sets the DTC (2 trip detection logic). ES–231 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (b) P0456: EVAP very small leak In operation C, the leak detection pump creates negative pressure (vacuum) in the EVAP system and the EVAP system pressure is measured. If the stabilized system pressure is higher than the second reference pressure, the ECM determines that the EVAP system has a small leakage, illuminates the MIL and sets the DTC (2 trip detection logic). EVAP Pressure when EVAP System Leaks: ON: Open ON Purge VSV OFF: Closed Vent Valve ON Leak Detection Pump ON EVAP Pressure ON: Closed OFF: Vent P0455 Positive Negative P0456 First Reference Pressure [Second Reference Pressure] x 0.2 Sequence Time A 10 seconds OK C B 60 seconds Within 15 minutes D E 10 60 seconds seconds [Second Reference Pressure] A106061E05 MONITOR STRATEGY Required Sensors/Components Purge VSV and canister pump module Frequency of Operation Once per driving cycle Duration Within 15 minutes (varies with amount of fuel in tank) MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present None EVAP key-off monitor runs when all of the following conditions are met - Atmospheric pressure 70 to 110 kPa-a (525 to 825 mmHg-a) Battery voltage 10.5 V or more Vehicle speed Below 2.5 mph (4 km/h) Ignition switch off Time after key off 5, 7 or 9.5 hours EVAP pressure sensor malfunction (P0450, P0451, P0452 and P0453) Not detected EVAP canister purge valve Not operated by scan tool EVAP canister vent valve Not operated by scan tool ES ES–232 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM EVAP leak detection pump Not operated by scan tool Both of the following conditions are met before key off Conditions 1 and 2 1. Duration that vehicle has been driven 5 minutes or more 2. EVAP purge operation Performed ECT 4.4 to 35°C (40 to 95°F) IAT 4.4 to 35°C (40 to 95°F) 1. Key-off monitor sequence 1 to 8 1. Atmospheric pressure measurement Next sequence runs if following condition is met - Atmospheric pressure change Less than 0.3 kPa-g (2.25 mmHg-g) in 1 second 2. First reference pressure measurement ES Next sequence runs if all of the following conditions are met Conditions 1, 2 and 3 1. EVAP pressure just after reference pressure measurement start -1 kPa-g (-7.5 mmHg-g) or less 2. Reference pressure -4.85 to -1.057 kPa-g (-36.4 to -7.93 mmHg-g) 3. Reference pressure Saturated within 60 seconds 3. Vent valve stuck closed check Next sequence runs if following condition is met - EVAP pressure change after vent valve is ON 0.3 kPa-g (2.25 mmHg-g) or more 4. Vacuum introduction Next sequence runs if following condition is met - EVAP pressure Saturated within 15 minutes 5. EVAP canister purge valve close stuck check Next sequence runs if following condition is met - EVAP pressure change after purge valve is open 0.3 kPa-g (2.25 mmHg-g) or more 6. Second reference pressure measurement Next sequence runs if all of the following conditions are met Conditions 1, 2, 3 and 4 1. EVAP pressure just after reference pressure measurement start -1 kPa-g (-7.5 mmHg-g) or less 2. Reference pressure -4.85 to -1.057 kPa-g (-36.4 to -7.93 mmHg-g) 3. Reference pressure Saturated within 60 seconds 4. Difference between first reference pressure and second reference pressure Less than 0.5 kPa-g (3.75 mmHg-g) 7. Leak check Next sequence runs if following condition is met - EVAP pressure when vacuum introduction is complete Second reference pressure or less 8. Atmospheric pressure measurement EVAP monitor complete if following condition is met - Atmospheric pressure difference between sequence 1 and 8 Within 0.3 kPa-g (2.25 mmHg-g) TYPICAL MALFUNCTION THRESHOLDS P0455: EVAP gross leak EVAP pressure when vacuum introduction is complete Higher than reference pressure x 0.2 P0456: EVAP small leak EVAP pressure when vacuum introduction is complete Between reference pressure and reference pressure x 0.2 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–233 MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-20). ES ES–234 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0500 Vehicle Speed Sensor "A" DESCRIPTION The speed sensor detects the wheel speed and sends the appropriate signals to the skid control ECU. The skid control ECU converts these wheel speed signals into a 4-pulse signal and outputs it to the ECM via the combination meter. The ECM determines the vehicle speed based on the frequency of these pulse signals. 4-Pulse ES 4-Pulse From Wheel Speed Sensor ECM Skid Control ECU Combination Meter A115899E01 DTC No. P0500 DTC Detection Condition Trouble Area While vehicle being driven, no vehicle speed sensor signal transmitted to ECM (1 trip detection logic: Automatic transaxle) (2 trip detection logic: Manual transaxle) • • • • • Open or short in speed signal circuit Vehicle speed sensor Combination meter ECM Skid control ECU MONITOR DESCRIPTION The ECM assumes that the vehicle is being driven, when the indicated engine speed is more than 2,300 rpm and 30 seconds have elapsed since the Park/Neutral Position (PNP) switch was turned OFF. If there is no speed signal from the combination meter, despite these conditions being met, the ECM interprets this as a malfunction in the speed signal circuit. The ECM then illuminates the MIL and sets the DTC. MONITOR STRATEGY Related DTCs P0500: Vehicle speed sensor "A" pulse input error Required Sensors/Components (Main) Vehicle Speed Sensor (VSS), Combination meter and Skid control ECU Required Sensors/Components (Related) Park/Neutral Position (PNP) switch, Engine Coolant Temperature (ECT) sensor, Crankshaft Position (CKP) sensor, Throttle Position (TP) sensor and Mass Air Flow (MAF) meter Frequency of Operation Continuous Duration 2 seconds: Automatic Transaxle 8 seconds: Manual Transaxle MIL Operation Immediate: Automatic Transaxle 2 driving cycles: Manual Transaxle Sequence of Operation None 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–235 TYPICAL ENABLING CONDITIONS Automatic transmission: Monitor runs whenever following DTCs are not present P0120 - P0223, P2135 (TP sensor) Either of the following conditions (a) or (b) is met: - (a) Following conditions 1 and 2 are met: - 1. ECT and ECT sensor 20°C (68°F) or more, and sensor does not malfunction (P0115 or P0116) 2. Time after PNP switch turned OFF 10 seconds or more (b) Following conditions 1 and 2 are met: - 1. ECT and ECT sensor Less than 20°C (68°F), and sensor malfunction (P0115 or P0116) 2. Time after PNP switch turned OFF 30 seconds or more Time after ignition switch turned ON position More than 0.5 seconds Battery voltage 8 V or more Ignition switch ON Starter OFF Manual transmission: Monitor runs whenever following DTCs are not present P0100 - P0103, (MAF sensor) P0115 - P0118 (ECT sensor) P0125 (Insufficient ECT for closed loop) ECT 70°C (158°F) or more Engine PRM 2,000 rpm or more, and less than 4,500 rpm Engine Load 33.7% Battery voltage 8 V or more Starter OFF Ignition switch ON ECT sensor circuit OK MAF sensor circuit OK TYPICAL MALFUNCTION THRESHOLDS Vehicle speed sensor signal No pulse input ES ES–236 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM F2 Combination Meter Assembly Skid Control ECU 14 SI +S 12 ECM 8 A24 SPD ES A132285E01 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the airfuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK OPERATION OF SPEEDOMETER (a) Drive the vehicle and check whether the operation of the speedometer in the combination meter is normal. HINT: • The vehicle speed sensor is operating normally if the speedometer reading is normal. • If the speedometer does not operate, check it by following the procedure described in speedometer malfunction (See page ME-44). NG GO TO MALFUNCTION IN SPEEDOMETER OK 2 READ VALUE USING INTELLIGENT TESTER (VEHICLE SPD) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position. (c) Turn the tester on. ES–237 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (d) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / VEHICLE SPD. (e) Drive the vehicle. (f) Read the value displayed on the tester. OK: Vehicle speeds displayed on tester and speedometer display are equal. OK CHECK FOR INTERMITTENT PROBLEMS NG 3 ES CHECK COMBINATION METER ASSEMBLY (+S VOLTAGE) (a) Disconnect the F2 combination meter connector. (b) Turn the ignition switch to the ON position. (c) Measure the voltage between the terminal of the combination meter and body ground. Standard voltage Wire Harness Side: F2 +S Combination Meter Connector Tester Connection Specified Condition F2-12 (+S) - Body ground 4.5 to 5.5 V (d) Reconnect the combination meter connector. A132286E01 NG Go to step 5 OK 4 CHECK COMBINATION METER ASSEMBLY (SPD SIGNAL WAVEFORM) (a) Shift the transmission gear selector lever to the neutral position. (b) Jack up the vehicle. (c) Turn the ignition switch to the ON position. (d) Measure the voltage between the terminal of the combination meter and body ground while the wheel is turned slowly. Standard voltage Wire Harness Side: Combination Meter Connector F2 +S Specified Condition Voltage generated intermittently HINT: The output voltage should fluctuate up and down, similarly to the diagram, when the wheel is turned slowly. 0 to 12 V NG 0V Tester Connection F2-12 (+S) - Body ground Turn Wheel A132287E01 REPLACE COMBINATION METER ASSEMBLY ES–238 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK 5 CHECK HARNESS AND CONNECTOR (COMBINATION METER ASSEMBLY - ECM) (a) Disconnect the F2 combination meter connector. (b) Disconnect the A24 ECM connector. (c) Measure the resistance between the terminals of the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side: Combination Meter Connector Front View F2 ES Tester Connection Specified Condition F2-12 (+S) - A24-8 (SPD) Below 1 Ω Standard resistance (Check for short) +S NG A24 SPD A132288E01 OK REPLACE ECM Specified Condition 10 kΩ or higher (d) Reconnect the combination meter connector. (e) Reconnect the ECM connector. ECM Connector Front View Tester Connection F2-12 (+S) or A24-8 (SPD) - Body ground REPAIR OR REPLACE HARNESS OR CONNECTOR ES–239 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0504 Brake Switch "A" / "B" Correlation DESCRIPTION The stop light switch is a duplex system that transmits two signals: STP and ST1-. These two signals are used by the ECM to monitor whether or not the brake system is working properly. If the signals, which indicate the brake pedal is being depressed and released, are detected simultaneously, the ECM interprets this as a malfunction in the stop light switch and sets the DTC. HINT: The normal conditions are as shown in the table below. The signals can be read using the intelligent tester. Signals Brake Pedal Released In Transition Brake Pedal Depressed STP OFF ON ON ST1- ON ON OFF DTC No. DTC Detection Condition Trouble Area Conditions (a), (b) and (c) continue for 0.5 seconds or more (1 trip detection logic): (a) Ignition switch to the ON position (b) Brake pedal released (c) STP signal OFF when ST1- signal OFF P0504 ES • • • • • Short in stop light switch signal circuit STOP fuse IGN fuse Stop light switch ECM WIRING DIAGRAM E23 Ignition SW 5 AM2 A19 Stop Light SW IG2 6 IGN STOP 3 2 4 1 ECM 35 A24 ST136 A24 STP ALT ST/AM2 FL MAIN Battery A140590E01 INSPECTION PROCEDURE HINT: • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. • STP signal conditions can be checked using the intelligent tester. ES–240 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (a)Connect the intelligent tester to the DLC3. (b)Turn the ignition switch to the ON position. (c) Turn the tester on. (d)Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / STOP LIGHT SW. (e)Check the STP signal when the brake pedal is depressed and released. 1 Brake Pedal Operation Specified Condition Depressed STP signal ON Released STP signal OFF CHECK STOP LIGHT SWITCH ASSEMBLY (TERMINAL B VOLTAGE) ES (a) Disconnect the A19 stop light switch connector. (b) Turn the ignition switch to the ON position. (c) Measure the voltage between the terminals of the stop light switch connector and body ground. Standard voltage Wire Harness Side: A19 B Stop Light Switch Connector B Front View A056986E09 Tester Connection Specified Condition A19-2 (B) - Body ground 9 to 14 V A19-3 (B) - Body ground 9 to 14 V (d) Reconnect the stop light switch connector. NG Go to step 4 OK 2 INSPECT STOP LIGHT SWITCH ASSEMBLY Not Pushed Pushed 2 1 (a) Remove the stop light switch assembly. (b) Measure the resistance between the terminals. Standard resistance Tester Connection 1-2 3-4 4 3 A072924E25 Specified Condition Switch pin not pushed Below 1 Ω Switch pin pushed 10 kΩ or higher Switch pin not pushed 10 kΩ or higher Switch pin pushed Below 1 Ω (c) Reinstall the stop light switch assembly. NG OK Switch Position REPLACE STOP LIGHT SWITCH ASSEMBLY ES–241 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 3 CHECK ECM (STP AND ST1 - VOLTAGE) Brake Pedal Depressed (a) Disconnect the A24 ECM connector. (b) Turn the ignition switch to the ON position. (c) Measure the voltage between terminals ST1- and STP of the A24 ECM connector and body ground. Standard voltage Brake Pedal Released Wire Harness Side: Tester Connection Brake Pedal Operation Specified Condition A24-35 (ST1-) - Body ground Released 9 to 14 V Depressed 0 to 3 V A24-36 (STP) - Body ground Released 0 to 3 V Depressed 9 to 14 V (d) Reconnect the ECM connector. A24 ECM Connector NG REPAIR OR REPLACE HARNESS OR CONNECTOR STP ST1Front View A112585E07 OK REPLACE ECM 4 INSPECT FUSE (STOP AND IGN FUSE) (a) Remove the STOP and IGN fuses from the instrument panel J/B. (b) Measure the resistance. Standard resistance: Below 1 Ω (c) Reinstall the STOP and IGN fuses. Instrument Panel J/B: STOP NG IGN A132290E01 OK REPAIR OR REPLACE HARNESS OR CONNECTOR REPLACE FUSES (STOP AND/OR IGN FUSES) ES ES–242 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0505 Idle Control System Malfunction DESCRIPTION The idling speed is controlled by the ETCS (Electronic Throttle Control System). The ETCS is comprised of: 1) the one valve type throttle body; 2) the throttle actuator, which operates the throttle valve; 3) the Throttle Position (TP) sensor, which detects the opening angle of the throttle valve; 4) the Accelerator Pedal Position (APP) sensor, which detects the accelerator pedal position; and 5) the ECM, which controls the ETCS. Based on the target idling speed, the ECM controls the throttle actuator to provide the proper throttle valve opening angle. DTC No. ES P0505 DTC Detection Condition Idling speed continues to vary greatly from target idling speed (2 trip detection logic) Trouble Area • • • • ETCS Air induction system PCV hose connections ECM MONITOR DESCRIPTION The ECM monitors the idling speed and idling air flow volume to conduct Idle Speed Control (ISC). The ECM determines that the ISC system is malfunctioning if the following conditions are met: • The learned idling air flow volume remains at the maximum or minimum volume 5 times or more during a driving cycle. • After driving at 6.25 mph (10 km/h) or more, the actual engine idling speed varies from the target idling speed by between 100 rpm and 200 rpm, 5 times or more during a driving cycle. Example: If the actual idling speed varies from the target idling speed by more than 200 rpm* 5 times during a driving cycle, the ECM illuminates the MIL and sets the DTC. HINT: *: Threshold idling speed varies with engine load. ES–243 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Example: Idling Speed Learned Idling Air Volume Maximum Large Target Speed ES 0 Minimum Actual Idling Speed Small Time Time A121611E02 MONITOR STRATEGY Related DTCs P0505: ISC function Required Sensors/Components (Main) ETCS Required Sensors/Components (Related) Crankshaft position sensor, Engine coolant temperature sensor, and Vehicle speed sensor Frequency of Operation Once per driving cycle Duration 10 minutes MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor will run whenever these DTCs are not present None Engine Running TYPICAL MALFUNCTION THRESHOLDS Either of the following conditions 1 or 2 is met - 1. Frequency that both of the following conditions (a) and (b) are met 5 times or more (a) Engine rpm - Target engine rpm Less than -100 rpm, or more than 150 rpm (b) Vehicle condition Stop after vehicle was driven by 6.25 mph (10 km/h) or more 2. Frequency that both of the following conditions (c) and (d) are met Once (c) Engine rpm - Target engine rpm Less than -100 rpm, or more than 150 rpm (d) IAC flow rate learning value 1.3 L/sec. or less, or 6 L/sec. or more ES–244 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE HINT: • The following conditions may also cause DTC P0505 to be set: (a)The floor carpet overlapping slightly onto the accelerator pedal, causing the accelerator pedal to be slightly depressed and therefore the throttle valve position to be slightly open. (b)The accelerator pedal being not fully released. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. ES 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P0505) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Turn the tester on. Select the following the menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read the DTCs. Result Display (DTC Output) Proceed to P0505 A P0505 and other DTCs B HINT: If any DTCs other than P0505 are output, troubleshoot those DTCs first. B GO TO DTC CHART A 2 CHECK PCV HOSE CONNECTIONS OK: PCV hose is connected correctly and is not damaged. NG REPAIR OR REPLACE PCV HOSE OK 3 CHECK AIR INDUCTION SYSTEM (a) Check the air induction system for vacuum leakage. OK: No leakage from air induction system. NG OK REPAIR OR REPLACE AIR INDUCTION SYSTEM 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 4 ES–245 CHECK THROTTLE VALVE (a) Check the throttle valve condition. OK: Throttle valve is not contamainated with foreign objects and moves smoothly. NG REPLACE THROTTLE BODY ASSEMBLY OK REPLACE ECM ES ES–246 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P050A Cold Start Idle Air Control System Performance DTC P050B Cold Start Ignition Timing Performance DESCRIPTION The Electronic Throttle Control System (ETCS) controls the engine idling speed. The ETCS operates the throttle actuator to open and close the throttle valve, and adjusts the intake air amount to achieve the target idling speed. In addition, the ECM retards the ignition timing and the ETCS increases the intake air amount to quickly increase the catalyst temperature at cold start to reduce emissions. DTC No. DTC Detection Condition ES P050A P050B Trouble Area Accumulated intake air amount during 10 seconds of idling after cold start is less than threshold (2 trip detection logic) • • • • • • • Throttle body assembly Mass air flow meter Air induction system PCV hose connections VVT system Air cleaner filter element ECM Ignition timing retard value insufficient for 5 seconds or more during 10 seconds of P050A monitoring duration at cold start (2 trip detection logic) • • • • • • • Throttle body assembly Mass air flow meter Air induction system PCV hose connections VVT system Air cleaner filter element ECM MONITOR DESCRIPTION Ignition Timing Accumulated Intake Air Value Pass Detected (g) P050B Detected Advanced 5 or more P050A Detected Threshold Threshold Pass Detected 0 Retarded 10 3 Engine Start Time (Second) 3 Engine Start 10 (Second) Time A112588E01 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–247 The ECM monitors the intake air amount during idling and the ignition timing. When the Engine Coolant Temperature (ECT) is between -10°C and 50°C (14°F and 122°F), the ECM calculates the idling intake air amount for 10 seconds, beginning 3 seconds after the engine starts. When the accumulated value is below the threshold, the ECM interprets this as a malfunction in the Idle Speed Control (ISC) system at cold start. The ECM also monitors the ignition timing at cold start, and judges it to be incorrect when it is advanced to the same value for a warm engine for 5 seconds or more of the 10 second monitoring period. Example: P050A is detected when all conditions below are met (2 trip detection logic). 1. The ECT is between -10°C and 50°C (14°F and 122°F) when the engine starts. 2. The engine idles for 13 seconds after engine start. 3. The accumulated intake air amount is below the threshold. The ECM sets the DTC and illuminates the MIL 13 seconds after the engine is next started. NOTICE: When the negative battery terminal is disconnected during inspection or repairs, the ISC learning values are cleared. The ISC learning must be performed by warming up the engine and idling for 5 minutes with the ECT at 75°C (167°F) or more because DTCs cannot be detected with the ISC learning values cleared. MONITOR STRATEGY Related DTCs P050A: Idle speed control problem at cold P050B: Idle ignition timing problem at cold Required Sensors/Components (Main) Mass air flow meter Required Sensors/Components (Related) Engine Coolant Temperature (ECT) sensor, Throttle position sensor, Vehicle speed sensor Frequency of Operation Once per driving cycle Duration 10 seconds MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS P050A: Battery voltage 8 V or more Time after engine start 3 seconds or more Starter OFF ECT at engine start -10°C (14°F) or more ECT -10°C to 50°C (14°F to 122°F) Engine idling time 3 seconds or more Fuel-cut OFF Vehicle speed Less than 1.875 mph (3 km/h) Time after shift position changed (PZEV) 1 second or more Atmospheric pressure 76 kPa (570 mmHg) or more P050B: Battery voltage 8 V or more Time after engine start 3 seconds or more Starter OFF ECT at engine start -10°C (14°F) or more ECT -10°C to 50°C (14°F to 122°F) Engine idling time 3 seconds or more Fuel-cut OFF Vehicle speed Less than 1.875 mph (3 km/h) ES ES–248 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TYPICAL MALFUNCTION THRESHOLDS P050A: Manual transaxle: Less than 14.375 g Automatic transaxle (Except PZEV): Less than 13.75 g Automatic transaxle (PZEV): Less than 21.25 g Accumulated mass air flow P050B: Accumulated time when ignition timing retard is cut off 5 seconds or more INSPECTION PROCEDURE ES HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the airfuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P050A AND/OR P050B) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Turn the tester on. Select the following the menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read the DTCs. Result Display (DTC Output) Proceed to P050A and/or P050B A P050A and/or P050B and other DTCs B HINT: If any DTCs other than P050A and P050B are output, troubleshoot those DTCs first. B GO TO DTC CHART A 2 READ VALUE USING INTELLIGENT TESTER (FUEL TRIM) HINT: Calculate the total fuel trim values to check the characteristic deviation of the mass air flow meter. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position. (c) Turn the tester on. (d) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / SHORT FT #1 and LONG FT #1. (e) Read the values displayed on the tester. (f) Add together the SHORT FT #1 and LONG FT #1 values to obtain the total FUEL TRIM. 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–249 OK: Total of SHORT FT #1 and LONG FT #1 values is between -20 % and 20 %. OK Go to step 12 NG 3 PERFORM ACTIVE TEST USING INTELLIGENT TESTER (OPERATE OCV) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Start the engine and turn the tester on. Warm up the engine. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VVT CTRL B1. (e) Check the engine speed while operating the Oil Control Valve (OCV) using the tester. OK Tester Operation Specified Condition OCV OFF Normal engine speed OCV ON Engine idles roughly or stalls (soon after OCV switched from OFF to ON) NG Go to step 8 OK 4 CHECK PCV HOSE CONNECTIONS OK: PCV hose is connected correctly and is not damaged. NG Go to step 9 OK 5 CHECK AIR INDUCTION SYSTEM (a) Check the air induction system for vacuum leakage. OK: No leakage from air induction system. NG Go to step 10 OK 6 CHECK AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY (a) Visually check that the air cleaner filter element is not excessively contaminated with dirt or oil. OK: Air cleaner filter element is not excessively contaminated with dirt or oil. ES ES–250 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NG Go to step 11 OK 7 REPLACE MASS AIR FLOW METER NEXT 8 CHECK AND REPAIR VVT SYSTEM ES 9 10 NEXT Go to step 15 NEXT Go to step 15 REPAIR OR REPLACE PCV HOSE REPAIR OR REPLACE AIR INDUCTION SYSTEM NEXT 11 Go to step 15 REPLACE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY NEXT 12 Go to step 15 Go to step 15 CHECK THROTTLE VALVE (a) Check for deposits around the throttle valve and throttle valve condition. OK: No deposits around throttle valve and throttle valve moves smoothly. NG Go to step 14 NEXT Go to step 15 OK 13 14 REPLACE ECM REPAIR OR REPLACE THROTTLE BODY ASSEMBLY NEXT Go to step 15 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 15 ES–251 CHECK WHETHER DTC OUTPUT RECURS (DTC P050A AND/OR P050B) NOTICE: In this operation, the engine must be cold (the same level as the engine coolant temperature recorded in the freeze frame data). (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position. (c) Turn the tester on. (d) Clear the DTCs (See page ES-38). (e) Switch the ECM from normal mode to check mode using the tester (See page ES-41). (f) Start the engine to idle for a minute. OK: Stable fast idling. (g) Read the DTCs. OK: No DTC output. NEXT END ES ES–252 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0560 System Voltage DESCRIPTION The battery supplies electricity to the ECM even when the ignition switch is off. This power allows the ECM to store data such as DTC history, freeze frame data and fuel trim values. If the battery voltage falls below a minimum level, the memory is cleared and the ECM determines that there is a malfunction in the power supply circuit. When the engine is next started, the ECM illuminates the MIL and set the DTC. DTC No. P0560 ES DTC Detection Condition Trouble Area • • • • • Open in ECM back up power source circuit (1 trip detection logic) Open in back up power source circuit Battery Battery terminals EFI No. 1 fuse ECM HINT: If DTC P0560 is set, the ECM does not store other DTCs or the data stored in the ECM are partly erased. MONITOR STRATEGY Related DTCs P0560: ECM system voltage Required Sensors/Components (Main) ECM Required Sensors/Components (Related) - Frequency of Operation Continuous Duration 3 seconds MIL Operation Immediate (MIL illuminated after next engine start) Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present None Stand-by RAM Initialized TYPICAL MALFUNCTION THRESHOLDS ECM power source Less than 3.5 V WIRING DIAGRAM ECM FL MAIN EFI No. 1 20 A24 BATT 104 C24 E1 Battery A118508E07 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–253 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the airfuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK FUSE (EFI NO. 1 FUSE) (a) Remove the EFI No. 1 fuse from the engine room J/B. (b) Measure the resistance of the EFI No. 1 fuse. Standard resistance: Below 1 Ω (c) Reinstall the EFI No. 1 fuse. Engine Room J/B: EFI No. 1 NG A132291E01 OK REPLACE FUSE (EFI NO. 1 FUSE) ES ES–254 2 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (ECM - EFI NO. 1 FUSE, EFI NO. 1 FUSE BATTERY) (a) Check the harness and the connector between the EFI No. 1 fuse and ECM. (1) Remove the EFI No. 1 fuse from the engine room J/ B. (2) Disconnect the A24 ECM connector. (3) Measure the resistance. Standard resistance (Check for open) Engine Room J/B: EFI No. 1 Fuse ES Tester Connection Specified Condition 2 (EFI No. 1 fuse) - A24-20 (BATT) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition 2 (EFI No. 1 fuse) or A24-20 (BATT) - Body ground 10 kΩ or higher (4) Reconnect the ECM connector. (5) Reinstall the EFI No. 1 fuse. (b) Check the harness and the connector between the EFI No. 1 fuse and battery. (1) Remove the EFI No. 1 fuse from the engine room J/ B. (2) Disconnect the negative battery terminal. (3) Disconnect the positive battery terminal. (4) Measure the resistance. Standard resistance (Check for open) Tester Connection Specified Condition Battery positive terminal - 1 (EFI No. 1 fuse) Below 1 Ω Wire Harness Side: Standard resistance (Check for short) ECM Connector Tester Connection Specified Condition Battery positive terminal or 1 (EFI No. 1 fuse) - Body ground 10 kΩ or higher (5) Reconnect the positive battery terminal. (6) Reconnect the negative battery terminal. (7) Reinstall the EFI No. 1 fuse. A24 NG BATT A132292E01 REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 INSPECT BATTERY (a) Check the battery voltage. Standard voltage: 12.5 to 12.9 V at 20°C (68°F) NG REPLACE BATTERY ES–255 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK 4 CHECK BATTERY TERMINAL (a) Check that the battery terminals are not loose or corroded. OK: Battery terminals are not loose or corroded. NG REPAIR OR REPLACE BATTERY TERMINAL OK ES 5 CHECK WHETHER DTC OUTPUT RECURS (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the tester on. (c) Clear the DTCs (See page ES-38). (d) Turn the ignition switch off and turn the tester off. (e) Start the engine and turn the tester on. (f) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (g) Read the DTCs. Result Display (DTC Output) Proceed to P0560 A No output B B A REPLACE ECM CHECK FOR INTERMITTENT PROBLEMS ES–256 ES 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0604 Internal Control Module Random Access Memory (RAM) Error DTC P0606 ECM / PCM Processor DTC P0607 Control Module Performance DTC P0657 Actuator Supply Voltage Circuit / Open DESCRIPTION The ECM continuously monitors its own internal memory status, internal circuits, and output signals transmitted to the throttle actuator. This self-check ensures that the ECM is functioning properly. If any malfunction is detected, the ECM sets the appropriate DTC and illuminates the MIL. The ECM memory status is diagnosed by internal mirroring of the main CPU and the sub CPU to detect Random Access Memory (RAM) errors. The two CPUs also perform continuous mutual monitoring. The ECM illuminates the MIL and sets a DTC if: 1) outputs from the two CPUs are different or deviate from the standards, 2) the signals sent to the throttle actuator deviate from the standards, 3) a malfunction is found in the throttle actuator supply voltage, and 4) any other ECM malfunction is found. DTC No. P0604 P0606 P0607 P0657 DTC Detection Condition Trouble Area ECM internal error (1 trip detection logic) ECM MONITOR STRATEGY Related DTCs P0604: ECM RAM error P0606: ECM range check P0607: ECM CPU malfunction P0657: ETCS power supply Required Sensors/Components (Main) ECM Required Sensors/Components (Related) - Frequency of Operation Once per driving cycle: P0657 Continuous: P0604, P0606 and P0607 Duration Within 1 second MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present None TYPICAL MALFUNCTION THRESHOLDS ECM RAM errors (P0604): RAM mirror check Fail ECM CPU range check (P0606): Either of the following conditions is met: - Difference between throttle valve position of main CPU and throttle valve position of sub CPU 0.3 V or more Difference between accelerator pedal position of main CPU and accelerator pedal position of sub CPU 0.3 V or more ES–257 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ECM CPU malfunction (P0607): Either of the following conditions A or B is met - A. All of the following conditions (a), (b) and (c) are met - (a) CPU reset 1 time or more (b) Learned TP - learned APP 0.4 V or more (c) Electronic throttle actuator OFF B. CPU reset 2 times or more ETCS power supply (P0657): ETCS power supply when ignition switch turned ON position 7 V or more INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the airfuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P0604, P0606, P0607 OR P0657) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Turn the tester on. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read the DTCs. Result Display (DTC Output) Proceed to P0604, P0606, P0607 or P0657 A P0604, P0606, P0607 or P0657 and other DTCs B B A REPLACE ECM GO TO DTC CHART ES ES–258 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0617 Starter Relay Circuit High DESCRIPTION While the engine is being cranked, the positive battery voltage is applied to terminal STA of the ECM. If the ECM detects the Starter Control (STA) signal while the vehicle is being driven, it determines that there is a malfunction in the STA circuit. The ECM then illuminates the MIL and sets the DTC. This monitor runs when the vehicle is driven at 12.43 mph (20 km/h) for over 20 seconds. DTC No. DTC Detection Condition P0617 When conditions (a), (b) and (c) are met, positive (+B) battery voltage 10.5 V or more is applied to ECM for 20 seconds (1 trip detection logic) (a) Vehicle speed 12.43 mph (20 km/h) or more (b) Engine speed 1,000 rpm or more (c) STA signal ON ES Trouble Area • • • • Park/Neutral Position (PNP) switch Starter relay circuit Ignition switch ECM MONITOR STRATEGY Related DTCs P0617: Starter signal Required Sensors/Components (Main) STARTER relay, PNP switch, Clutch start switch and Ignition switch Required Sensors/Components (Related) Vehicle Speed Sensor (VSS), Crankshaft Position (CKP) sensor Frequency of Operation Continuous Duration 20 seconds MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present None Battery voltage 10.5 V or more Vehicle speed 12.43 mph (20 km/h) or more Engine speed 1,000 rpm or more TYPICAL MALFUNCTION THRESHOLDS Starter signal ON ES–259 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM (*2) Clutch Start SW 2 A22 ECM 1 A22 (*1) (*2) (*2) ES (*1) AM1 ALT 48 A24 STA (*2) E23 Ignition SW 52 C24 NSW (*1) 4 AM1 ST1 3 5 AM2 ST2 7 (*1) C1 4 Park/Neutral L B Position SW (*1) P N ST/AM2 5 Starter 1 1 C29 C3 (*2) (*1) FL MAIN 1 D1 M Battery ST 3 5 2 1 *1: Automatic Transaxle *2: Manual Transaxle A132313E04 INSPECTION PROCEDURE HINT: • The following troubleshooting flowchart is based on the premise that the engine is cranked normally. If the engine does not crank, proceed to the problem symptoms table (See page ES-27). • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 READ VALUE USING INTELLIGENT TESTER (STARTER SIGNAL) (a) Connect the intelligent tester to the DLC3. ES–260 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (b) Turn the ignition switch to the ON position and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / STARTER SIG. (d) Read the value displayed on the tester when turn the ignition switch to the ON and START positions. OK Ignition Switch Position STARTER SIG ON OFF START ON NG ES Go to step 2 OK CHECK FOR INTERMITTENT PROBLEMS 2 INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY HINT: For vehicles with the manual transaxle, proceed to step 5. (a) Disconnect the C1 PNP switch connector. (b) Measure the resistance when the transmission gear selector lever is moved to each position. Standard resistance Component Side: B(+) 2L(-) RB(+) NL(-) LL(-) DL(-) RL(-) PL(-) Gear Selector Lever Position Tester Connection Specified Condition P 2 - 6, 4 - 5 Below 1 Ω L(-) PNP Switch R 1-2 Below 1 Ω N 2 - 9, 4 - 5 Below 1 Ω D 2-7 Below 1 Ω 2 2-3 Below 1 Ω L 2-8 Below 1 Ω (c) Reconnect the PNP switch connector. A107908E01 OK Go to step 8 NG 3 REPLACE PARK/NEUTRAL POSITION SWITCH ASSEMBLY NEXT 4 READ VALUE USING INTELLIGENT TESTER (STARTER SIGNAL) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the tester on. ES–261 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / STARTER SIG. (d) Read the value displayed on the tester when turn the ignition switch to the ON and START positions. OK Ignition Switch Positions STARTER SIG ON OFF START ON NG Go to step 8 OK ES SYSTEM OK 5 INSPECT CLUTCH START SWITCH ASSEMBLY (a) Disconnect the A22 clutch start switch connector. (b) Measure the resistance between the terminals. Standard resistance Component Side: 2 1 Tester Connection Switch Condition Specified Condition 1-2 Clutch pedal released 10 kΩ or higher 1-2 Clutch pedal depressed Below 1 Ω (c) Reconnect the clutch start switch connector. A136164E01 OK Go to step 8 NG 6 REPLACE CLUTCH START SWITCH ASSEMBLY NEXT 7 READ VALUE USING INTELLIGENT TESTER (STARTER SIGNAL) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / STARTER SIG. (d) Check the value displayed on the tester when turn the ignition switch to the ON and START positions. OK Ignition Switch Position STARTER SIG ON OFF START ON ES–262 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NG Go to step 8 OK SYSTEM OK 8 INSPECT IGNITION SWITCH ASSEMBLY (a) Disconnect the E23 ignition switch connector. (b) Measure the resistance between the terminals. Standard resistance Component Side: ES A056879E35 Tester Connection Ignition Switch Position Specified Condition All Terminals LOCK 10 kΩ or higher 2-4 ACC Below 1 Ω 1 - 2 - 4, 5 - 6 ON 1 - 3 - 4, 5 - 6 - 7 START (c) Reconnect the ignition switch connector. OK Go to step 10 NG 9 REPLACE IGNITION SWITCH ASSEMBLY NEXT 10 READ VALUE USING INTELLIGENT TESTER (STARTER SIGNAL) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / STARTER SIG. (d) Check the value displayed on the tester when turn the ignition switch to the ON and START positions. OK Ignition Switch Position STARTER SIG ON OFF START ON NG OK SYSTEM OK Go to step 11 ES–263 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 11 REPAIR OR REPLACE HARNESS OR CONNECTOR (PNP SWITCH OR CLUTCH START SWITCH - STA TERMINAL OF ECM) NEXT 12 CHECK WHETHER DTC OUTPUT RECURS (a) (b) (c) (d) (e) Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Turn the tester on. Clear the DTCs (See page ES-38). Drive the vehicle at more than 12.43 mph (20 km/h) for over 20 seconds. (f) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (g) Read the DTCs. Result Display (DTC Output) Proceed to P0617 A No DTC B B A REPLACE ECM SYSTEM OK ES ES–264 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0630 VIN not Programmed or Mismatch - ECM / PCM DESCRIPTION DTC P0630 is set when the Vehicle Identification Number (VIN) is not stored in the Engine Control Module (ECM) or the input VIN is incorrect. Input the VIN with the intelligent tester. DTC No. P0630 DTC Detection Condition Trouble Area • VIN not stored in ECM • Input VIN incorrect (1 trip detection logic) ECM MONITOR STRATEGY ES Related DTCs P0630: VIN not programmed Required Sensors/Components (Main) ECM Required Sensors/Components (Related) - Frequency of Operation Continuous Duration 0.325 seconds MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS Battery voltage 8 V or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS VIN code Not programmed COMPONENT OPERATING RANGE VIN code Programmed INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the airfuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 READ CURRENT DTC (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs. ES–265 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Result Display (DTC Output) Proceed To P0630 A P0630 and other DTCs B If any DTCs other than P0630 are output, troubleshoot those DTCs first. NOTICE: If P0630 is set, the VIN must be input to the ECM using the intelligent tester. However, all DTCs are cleared automatically by the tester when the VIN is input. If DTCs other than P0630 are set, check them first. B GO TO DTC CHART A 2 INPUT VIN WITH INTELLIGENT TESTER (a) Refer to REGISTRATION (See page ES-17). NEXT END ES ES–266 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0724 Brake Switch "B" Circuit High DESCRIPTION The purpose of this circuit is to prevent the engine from stalling while driving in the lock-up condition when the brakes are suddenly applied. When the brake pedal is depressed, this switch sends a signal to the ECM. Then the ECM cancels the operation of the lock-up clutch while braking is in progress. DTC No. DTC Detection Condition Trouble Area P0724 Stop light switch remains ON even when vehicle is driven in GO (18.65 mph (30 km/h) or more) and STOP (less than 1.86 mph (3 km/h)) pattern 5 times (2 trip detection logic) • • • Short in stop light switch signal circuit Stop light switch ECM ES MONITOR DESCRIPTION This DTC indicates that the stop light switch remains ON. When the stop light switch remains ON during GO and STOP driving, the ECM interprets this as a fault in the stop light switch. Then the MIL illuminates and the ECM stores the DTC. The vehicle must be driven in GO (18.65 mph (30 km/h) or more) and STOP (less than 1.86 mph (3 km/h)) pattern 5 times in 2 driving cycles in order for the DTC to be output. MONITOR STRATEGY Related DTCs P0724: Stop light switch/Range check/Rationality Required sensors/Components Stop light switch, Vehicle speed sensor Frequency of operation Continuous Duration GO and STOP 5 times MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present None Battery voltage 8 V or more Starter OFF Ignition switch ON GO (Vehicle speed is 18.65 mph (30 km/h) or more) Once STOP (Vehicle speed is less than1.86 mph (3 km/h)) Once TYPICAL MALFUNCTION THRESHOLDS Brake switch Stuck ON ES–267 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM A19 Stop Light SW FL MAIN ALT 2 STOP 1 36 A24 STP Battery ES A140589E01 INSPECTION PROCEDURE HINT: • Using the intelligent tester's DATA LIST allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to save time. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. 1. Warm up the engine. 2. Turn the ignition switch off. 3. Connect the intelligent tester to the DLC3. 4. Turn the ignition switch to the ON position. 5. Turn the intelligent tester on. 6. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST. 7. Follow the instructions on the tester and read the DATA LIST. Item STOP LIGHT SW Measurement Item/ Range (Display) Stop light switch status/ ON or OFF Normal Condition • • Brake pedal is depressed: ON Brake pedal is released: OFF Diagnostic Note - ES–268 1 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT STOP LIGHT SWITCH Not pushed (a) Remove the stop light switch. (b) Measure the resistance between the terminals. Standard resistance Pushed Tester Connection 1-2 3-4 ES 2 1 4 3 Switch Condition Specified Condition Switch pin released Below 1 Ω Switch pin pushed in 10 kΩ or higher Switch pin released 10 kΩ or higher Switch pin pushed in Below 1 Ω (c) Reinstall the stop light switch. NG REPLACE STOP LIGHT SWITCH Stop Light Switch A115657E05 OK 2 CHECK WIRE HARNESS (ECM - BATTERY) (a) Measure the voltage of the wire harness side connector. (1) Disconnect the A24 ECM connector. (2) Measure the voltage. Standard voltage Wire Harness Side: A24 STP Tester Connection Condition Specified Condition A24-36 (STP) - Body ground Brake pedal is depressed 10 to 14 V A24-36 (STP) - Body ground Brake pedal is released Below 1 V (3) Reconnect the ECM connector. NG Front View A115671E21 OK REPLACE ECM REPAIR OR REPLACE HARNESS OR CONNECTOR ES–269 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2004 Intake Manifold Runner Control Stuck Open (Bank 1) DTC P2006 Intake Manifold Runner Control Stuck Closed (Bank 1) DESCRIPTION The intake manifold runner valve system is mounted on the intake manifold and consists of the intake manifold runner valve (IMRV), the IMRV motor and the IMRV position sensor. The IMRV motor opens and closes the IMRV using multiple gears (See page ES-270 for details). The valve position sensor detects the opening angle of the IMRV (See page ES-275 for details). The IMRV has a groove on its upper portion. When the IMRV is closed, air flows through a groove into the cylinder from the intake manifold, so that a dynamic air flow or "tumble" air flow is generated in the cylinder. The tumble air flow drastically reduces fuel deposits inside the intake air port and the combustion wall surface inside the cylinder. This improves the combustion efficiency by boosting the air-fuel mixture and air flow turbulence. The related DTCs are P2009 and P2010 (See page ES-270), and P2014, P2016 and P2017 (See page ES-275). NOTICE: Do not disassemble the IMRV and the IMRV motor. Intake Manifold Runner Valve Motor Intake Manifold Runner Valve Assembly Tumble Air Flow Groove A A A-A Intake Manifold Runner Valve Position Sensor Intake Manifold Runner Valve Intake Manifold A076833E01 ES ES–270 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM The ECM fully closes the IMRV during the first idle with the engine coolant temperature more than -10°C (14°F) and less than 60°C (140°F) and the intake air temperature is more than -10°C (14°F) before the engine is warmed up. In other condition, the ECM fully opens the IMRV. Open and closed condition for IMRV: ES Temperatures of the engine coolant and the intake air when the engine starting up Before warming up the engine When one of the following conditions is met: (a) Throttle valve opening angle is 1.5° or more. (b) Vehicle speed is 3 mph (5 km/h) or more. (c) Engine speed is 3,000 rpm or more. (d) When the shift lever is in any position other than N. Engine coolant temp. is less than -10°C (14°F) or more than 60°C 140°F) or intake air temp. is less than -10°C (14°F). OPEN OPEN OPEN Engine coolant temp. is between 10°C (14°F) and 60°C (140°F). Intake air temp. is -10°C (14°F) or more. CLOSED OPEN OPEN IMRV Operation (Normal Condition) IMRV opening angle (deg) After warming up the engine Fully open is maintained until the ignition switch is turned off 75 22 to 34 0 Half-opening angle is maintained when the engine is stopped. Fully closed by turning the ignition switch to the ON position with a cold engine (mph (km/h)) Shift lever shifted from N to D Vehicle Speed IG switch ON 0 Start the vehicle driving Engine start IG switch OFF Time A076856E02 ES–271 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM IMRV Malfunction Detection Fully open Target opening angle Closed Electricity supply (ON) Electricity supply (ON) OFF Driving Motor OFF DTC P2006 Detection timing 75° (Fully open) Normal DTC P2004 Detection timing Stuck open ES Threshold: 35° IMRV actual opening angle Threshold: 10° Stuck close Normal 0° (Fully closed) Time About 10 seconds About 10 seconds A076834E01 DTC No. DTC Detection Condition Trouble Area P2004 (Stuck open) When the IMRV opening angle is more than 10° after requesting the IMRV full close (2 trip detection logic) • • • • • IMRV motor circuit IMRV motor IMRV position sensor IMRV ECM P2006 (Stuck closed) When the IMRV opening angle is less than 35° after requesting the IMRV full open (2 trip detection logic) Same as DTC No. P2004 MONITOR STRATEGY Related DTCs P2004: IMRC Valve Stuck Open P2006: IMRC Valve Stuck Closed Required sensors/components (Main) IMRC Valve Required sensors/components (Related) IAT sensor, ECT sensor Frequency of operation Once per driving cycles Duration 10 seconds MIL operation 2 driving cycles Sequence operation None TYPICAL ENABLING CONDITIONS All: Monitor runs whenever following DTCs are not present P0110 - P0113 (IAT sensor) P0115 - P0118 (ECT sensor) ES–272 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM P2004: Battery voltage 8 V or more ECT -10°C (14°F) or more IAT -10°C (14°F) or more Ignition switch ON Command IMRC valve Closed P2006: ES Battery voltage 8 V or more Command IMRC valve Closed TYPICAL MALFUNCTION THRESHOLDS P2004: IMRC valve angle 10° or more P2006: IMRC valve angle Less than 35° COMPONENT OPERATING RANGE IMRC valve position sensor voltage 0.2 and 4.8 V ES–273 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM C33 Intake Manifold Runner Valve Assembly (Intake Air Control Valve) ECM Position Sensor VCIA 103 C24 3 Hall IC VCIA ES IACA 1 93 C24 IACA EIA 2 126 C24 EIA E1 IAC+ 5 33 A24 IAC+ IAC- 4 52 A24 IAC- DC Motor E01 E1 A132328E01 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the airfuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK WHETHER DTC OUTPUT RECURS (a) Clear the DTC (See page ES-38). (b) Start the engine. ES–274 ES 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (c) Allow the engine to idle for 20 seconds or more after running the engine at more than 3,000 rpm for 20 seconds. (d) Turn the ignition switch off. Let the engine remain stopped for 20 seconds. HINT: As running the engine to 3,000 rpm, the IMRV usually becomes fully opened. If the ignition switch is turned off under this condition, the IMRV is fully closed and then becomes half-opening angle. (e) Connect the intelligent tester to the DLC3. (f) Turn the ignition switch to the ON position. (g) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. Result Display (DTC output) Proceed to P2004 and/or P2006 are output again A No DTC output B B CHECK FOR INTERMITTENT PROBLEMS A REPLACE INTAKE MANIFOLD RUNNER VALVE ASSEMBLY ES–275 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2009 Intake Manifold Runner Control Circuit Low (Bank 1) DTC P2010 Intake Manifold Runner Control Circuit High (Bank 1) DESCRIPTION The Intake Manifold Runner Valve (IMRV) motor is driven by the ECM. The IMRV motor opens and closes the IMRV. When the current of the IMRV motor deviates from the standard range, the ECM determines that there is a malfunction. The related DTCs are P2004 and P2006 (See page ES-264), and P2014, P2016 and P2017 (See page ES-275). NOTICE: Do not disassemble the IMRV and the IMRV motor. Internal Motor with the Valve Opening Angle Sensor DC Motor Case Worm Gear Helical Gear Cushion IMRV Motor Current Position Sensor (A) 10 Detect P2010 Spur Gear (Magnet) 7 Detected DTC in 0.2 seconds 2 to 3 0.35 0 0 Pinion Gear Valve Shaft Open Duty Ratio 100 (%) Detected DTC in 0.5 seconds Detect P2009 (Closed Duty Ratio is same) A076832E01 DTC No. P2009 DTC Detection Condition Detecting open (in the motor or in the motor circuit) Condition (a) and (b) continue for 1 second: (1 trip detection logic) (a) IMRV motor output duty is 100 % (b) IMRV motor current is less than 0.35 A Trouble Area • • • Open in IMRV motor circuit IMRV motor ECM ES ES–276 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. DTC Detection Condition • P2010 • Trouble Area Detecting excess current (in the motor or in the motor circuit) Condition (a) continues for 0.2 seconds: (1 trip detection logic) (a) IMRV motor current is 10 A or more Condition (a) continues for 0.5 seconds: (1 trip detection logic) (a) IMRV motor current is 7 A or more • • • Short in IMRV motor circuit IMRV motor ECM MONITOR STRATEGY ES Related DTCs P2009: IMRC Actuator Range Check (Low Current) P2010: IMRC Actuator Range Check (High Current) Required sensors/components (Main) IMRC Valve (Actuator) Required sensors/components (Related) None Frequency of operation Continuous Duration 1 second: IMRC Actuator Range Check (Low Current) 6 times: IMRC Actuator Range Check (High Current) MIL operation Immediate Sequence operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present None Battery voltage 8 V or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS P2009: IMRC actuator current Less than 0.35 A P2010: IMRC actuator control IC current limiter port Fail COMPONENT OPERATING RANGE IMRC actuator current 0.4 to 3 A ES–277 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM C33 Intake Manifold Runner Valve Assembly (Intake Air Control Valve) ECM Position Sensor VCIA 3 Hall IC 103 C24 VCIA ES IACA 1 93 C24 IACA EIA 2 126 C24 EIA E1 IAC+ 5 33 A24 IAC+ IAC- 4 52 A24 IAC- DC Motor E01 E1 A132328E01 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the airfuel ratio was lean or rich, and other data from the time the malfunction occurred. ES–278 1 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT INTAKE MANIFOLD RUNNER VALVE ASSEMBLY (IMRV MOTOR RESISTANCE) (a) Disconnect the C33 IMRV connector. (b) Measure the motor resistance between the terminals. Standard resistance Component Side: IMRV IAC+ Tester Connection Condition Specified Condition C33-5 (IAC+) - C33-4 (IAC-) 20°C (68°F) 1 to 19 Ω IAC- NG ES REPLACE INTAKE MANIFOLD RUNNER VALVE ASSEMBLY A066037E01 OK 2 CHECK HARNESS AND CONNECTOR (IMRV MOTOR - ECM) (a) Disconnect the A24 ECM connector. (b) Disconnect the C33 IMRV motor connector. (c) Measure the resistance between the terminals of the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side: IMRV Motor Connector Tester Connection C33 IAC- Specified Condition A24-33 (IAC+) - C33-5 (IAC+) Below 1 Ω A24-52 (IAC-) - C33-4 (IAC-) Below 1 Ω Standard resistance (Check for short) IAC+ ECM Connector Tester Connection Specified Condition A24-33 (IAC+) or C33-5 (IAC+) - Body ground 10 kΩ or more A24-52 (IAC-) or C33-4 (IAC-) - Body ground 10 kΩ or more (d) Reconnect the connectors. NG A24 IAC- Front View REPAIR OR REPLACE HARNESS OR CONNECTOR IAC+ A132309E01 OK 3 CHECK WHETHER DTC OUTPUT RECURS (a) (b) (c) (d) Clear the DTC (See page ES-38). Start the engine. Run the engine at more than 3,000 rpm. Turn the ignition switch off. ES–279 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: As running the engine to 3,000 rpm, the IMRV usually becomes fully opened. If the ignition switch is turned off under this condition, the IMRV is fully closed and then becomes half-opening angle. (e) Read the DTC. Result Display (DTC output) Proceed to P2009 and/or P2010 are output again A No DTC output B B A REPLACE ECM CHECK FOR INTERMITTENT PROBLEMS ES ES–280 ES 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2014 Intake Manifold Runner Position Sensor / Switch Circuit (Bank 1) DTC P2016 Intake Manifold Runner Position Sensor / Switch Circuit Low (Bank 1) DTC P2017 Intake Manifold Runner Position Sensor / Switch Circuit High (Bank 1) DESCRIPTION HINT: This IMRV position sensor is non-contact type. The IMRV position sensor is mounted on the valve shaft axis (See page ES-264) and is used to measure the opening angle of the IMRV. Since this sensor is electronically controlled with hall elements, accurate control and reliability can be obtained. Voltage of approximately 0.6 V is applied to terminal IACA of the ECM when the IMRV is fully closed. The voltage applied to terminal IACA increases in proportion to the IMRV opening angle, approximately 3.6 V is applied to the terminal when it is fully opened. The ECM detects a malfunction in the IMRV position sensor when its voltage output deviates from the standard range. When a malfunction is detected, the ECM fully opens the IMRV using the IMRV motor until the IMRV position sensor returns to normal. The related DTCs are P2004 and P2006 (See page ES-264), and P2009 and P2010 (See page ES-270). IMRV Position Sensor Magnet ECM Hall IC Closed VCIA Detect P2017 Open 4.8 5V 3.6 IACA E1A E1 0.6 0.2 0 IMRV Position Sensor Output Voltage (V) 0 Range of operation Detect P2016 73.8 IMRV Opening Angle (deg) A076830E03 ES–281 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. DTC Detection Condition Trouble Area P2014 Condition (a) continues for 0.5 seconds: (1 trip detection logic) (a) IMRV position sensor output voltage is "0.2 V or less" or "4.8 V or more". • • • P2016 Condition (a) continues for 0.5 seconds: (1 trip detection logic) (a) IMRV position sensor output voltage is 0.2 V or less. Same as DTC No. P2014 P2017 Condition (a) continues for 0.5 seconds: (1 trip detection logic) (a) IMRV position sensor output voltage is 4.8 V or more. Same as DTC No. P2014 Open or short in IMRV position sensor circuit IMRV position sensor ECM MONITOR STRATEGY Related DTCs P2014: IMRC Valve Position Sensor Range Check (Chattering) P2016: IMRC Valve Position Sensor Range Check (Low Voltage) P2017: IMRC Valve Position Sensor Range Check (High Voltage) Required sensors/components (Main) IMRC Valve Position Sensor Required sensors/components (Related) None Frequency of operation Continuous Duration 0.5 seconds MIL operation Immediate Sequence operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present None TYPICAL MALFUNCTION THRESHOLDS P2014: IMRC valve position sensor voltage Less than 0.2 V, or more than 4.8 V P2016: IMRC valve position sensor voltage Less than 0.2 V P2017: IMRC valve position sensor voltage Less than 4.8 V COMPONENT OPERATING RANGE IMRC valve position sensor voltage 0.2 to 4.8 V ES ES–282 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM C33 Intake Manifold Runner Valve Assembly (Intake Air Control Valve) ECM Position Sensor ES VCIA 3 103 C24 VCIA IACA 1 93 C24 IACA EIA 2 126 C24 EIA Hall IC E1 IAC+ 5 33 A24 IAC+ IAC- 4 52 A24 IAC- DC Motor E01 E1 A132328E01 INSPECTION PROCEDURE HINT: If different DTCs that are related to a different system are output simultaneously while terminal E2 is used as a ground terminal, terminal E2 may be open. ES–283 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 1 CHECK HARNESS AND CONNECTOR (ECM - IMRV) (a) Disconnect the C33 IMRV connector. (b) Disconnect the C24 ECM connector. (c) Measure the resistance between the terminals of the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side: IMRV Connector IACA VCIA Tester Connection C33 EIA C33-1 (IACA) - C24-93 (IACA) Below 1 Ω C33-2 (EIA) - C24-126 (EIA) Below 1 Ω C33-3 (VCIA) - C24-103 (VCIA) Below 1 Ω Standard resistance (Check for short) ECM Connector C24 Specified Condition VCIA Tester Connection Specified Condition C33-1 (IACA) or C24-93 (IACA) - Body ground 10 kΩ or more C33-3 (VCIA) or C24-103 (VCIA) - Body ground 10 kΩ or more (d) Reconnect the connectors. NG IACA REPAIR OR REPLACE HARNESS OR CONNECTOR EIA A136168E01 OK 2 INSPECT ECM (VC VOLTAGE) (a) Disconnect the C33 IMRV connector. (b) Turn the ignition switch to the ON position. (c) Measure the voltage. Standard voltage Wire Harness Side: C33 EIA Tester Connection Specified Condition C33-1 (VCIA) - C33-2 (EIA) 4.5 to 5.5 V VCIA NG REPLACE ECM A132311E01 OK 3 REPLACE INTAKE MANIFOLD RUNNER VALVE ASSEMBLY NEXT 4 CHECK WHETHER DTC OUTPUT RECURS (a) Clear the DTC (See page ES-38). (b) Start the engine. (c) Run the engine at more than 3,000 rpm. ES ES–284 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (d) Turn the ignition switch off. HINT: As running the engine to 3,000 rpm, the IMRV usually becomes fully opened. If the ignition switch is turned off under this condition, the IMRV is fully closed and then becomes half-opening angle. (e) Turn the ignition switch to the ON position 20 seconds later. (f) Read the DTCs. Result Display (DTC output) Proceed to P2014, P2016 and/or P2017 are output again A No DTC output B ES B A REPLACE ECM SYSTEM OK ES–285 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2102 Throttle Actuator Control Motor Circuit Low DTC P2103 Throttle Actuator Control Motor Circuit High DESCRIPTION The throttle actuator is operated by the ECM and opens and closes the throttle valve using gears. The opening angle of the throttle valve is detected by the Throttle Position (TP) sensor, which is mounted on the throttle body assembly. The TP sensor provides feedback to the ECM. This feedback allows the ECM to appropriately control the throttle actuator and monitor the throttle opening angle as the ECM responds to driver inputs. HINT: This ETCS (Electronic Throttle Control System) does not use a throttle cable. DTC No. DTC Detection Condition Trouble Area P2102 Conditions (a) and (b) continue for 2.0 seconds (1 trip detection logic): (a) Throttle actuator duty ratio 80 % or more (b) Throttle actuator current 0.5 A or less • • • Open in throttle actuator circuit Throttle actuator ECM P2103 Either of following conditions is met (1 trip detection logic): • Hybrid IC diagnosis signal failure • Hybrid IC current limiter port failure • • • • • Short in throttle actuator circuit Throttle actuator Throttle valve Throttle body assembly ECM MONITOR DESCRIPTION The ECM monitors the electrical current through the electronic actuator, and detects malfunctions and open circuits in the throttle actuator based on this value. If the current is outside the standard range, the ECM determines that there is a malfunction in the throttle actuator. In addition, if the throttle valve does not function properly (for example, stuck on), the ECM determines that there is a malfunction. The ECM then illuminates the MIL and sets a DTC. Example: When the electrical current is less than 0.5 A and the throttle actuator duty ratio exceeds 80 %, the ECM interprets this as the current being outside the standard range, and illuminates the MIL and sets a DTC. If the malfunction is not repaired successfully, a DTC is set when the engine is quickly revved to a high rpm several times after the engine has idled for 5 seconds after engine start. MONITOR STRATEGY Related DTCs P2102: Throttle actuator current (low current) P2103: Throttle actuator current (high current) Required Sensors/Components (Main) Throttle actuator (throttle body) Required Sensors/Components (Related) None Frequency of Operation Continuous Duration 2 seconds: P2102 25 times or 0.6 seconds: P2103 MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present None P2102: Throttle motor ON Duty-cycle ratio to open throttle actuator 80 % or more ES ES–286 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Throttle actuator power supply 8 V or more P2103: Throttle motor ON Throttle actuator power supply 8 V or more Battery voltage 8 V or more Starter OFF TYPICAL MALFUNCTION THRESHOLDS P2102: Throttle actuator current ES Less than 0.5 A P2103: Hybrid IC current limiter port Fail FAIL-SAFE When either of these DTCs, or other DTCs relating to ETCS (Electronic Throttle Control System) malfunctions, are set, the ECM enters fail-safe mode. During fail-safe mode, the ECM cuts the current to the throttle actuator off, and the throttle valve is returned to a 6° throttle angle by the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing, in accordance with the accelerator pedal opening angle, to allow the vehicle to continue at a minimal speed. If the accelerator pedal is depressed gently, the vehicle can be driven slowly. Fail-safe mode continues until a pass condition is detected, and the ignition switch is then turned off. ES–287 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM ETCS 3 +BM A24 (Shielded) M+ 2 42 M+ C24 1 41 MC24 FL MAIN MC5 Throttle Actuator (Bulit into Throttle Body) Battery ES 63 C24 GE01 43 ME01 C24 104 C24 E1 A138928E01 INSPECTION PROCEDURE HINT: • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. • The throttle actuator current (THROTTLE MOT) and the throttle actuator duty ratio (THROTL OPN DUTY / THROTL CLS DUTY) can be read using the intelligent tester. However, the ECM shuts off the throttle actuator current when the ETCS malfunctions. ES–288 1 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT THROTTLE BODY (RESISTANCE OF THROTTLE ACTUATOR) (a) Disconnect the C5 throttle body connector. (b) Measure the resistance between terminals of the wire harness side connectors. Standard resistance Component Side: Throttle Body M+ Specified Condition 2 (M+) - 1 (M-) 0.3 to 100 Ω at 20°C (68°F) (c) Reconnect the throttle body connector. M- ES Tester Connection A059778E21 NG REPLACE THROTTLE BODY ASSEMBLY OK 2 CHECK HARNESS AND CONNECTOR (THROTTLE ACTUATOR - ECM) Wire Harness Side: C5 Throttle Body Connector (a) Disconnect the C5 throttle body connector. (b) Disconnect the C24 ECM connector. (c) Measure the resistance between the terminals of the wire harness side connector. Standard resistance (Check for open) M+ M- 1 2 3 4 5 6 Specified Condition Below 1 Ω C5-1 (M-) - C24-41 (M-) Below 1 Ω Standard resistance (Check for short) Front View C24 Tester Connection C5-2 (M+) - C24-42 (M+) ECM Connector M- Tester Connection Specified Condition C5-2 (M+) or C24-42 (M+) - Body ground 10 kΩ or higher C5-1 (M-) or C24-41 (M-) - Body ground 10 kΩ or higher (d) Reconnect the throttle body connector. (e) Reconnect the ECM connector. NG Front View REPAIR OR REPLACE HARNESS OR CONNECTOR M+ A115662E06 OK 3 INSPECT THROTTLE BODY ASSEMBLY (a) Check for foreign objects between the throttle valve and the housing. OK: No foreign objects between throttle valve and housing. NG REMOVE FOREIGN OBJECT AND CLEAN THROTTLE BODY 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–289 OK 4 INSPECT THROTTLE VALVE (a) Check if the throttle valve opens and closes smoothly. OK: Throttle valve opens and closes smoothly. NG REPLACE THROTTLE BODY ASSEMBLY OK REPLACE ECM ES ES–290 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2111 Throttle Actuator Control System - Stuck Open DTC P2112 Throttle Actuator Control System - Stuck Closed DESCRIPTION ES The throttle actuator is operated by the ECM, and opens and closes the throttle valve using gears. The opening angle of the throttle valve is detected by the Throttle Position (TP) sensor, which is mounted on the throttle body assembly. The TP sensor provides feedback to the ECM in order that it can control the throttle actuator, and therefore the throttle valve, appropriately in response to driver inputs. HINT: This ETCS (Electronic Throttle Control System) does not use a throttle cable. DTC No. DTC Detection Condition Trouble Area P2111 Throttle actuator does not close when signaled by ECM (1 trip detection logic) • • • Throttle actuator Throttle body assembly Throttle valve P2112 Throttle actuator does not open when signaled by ECM (1 trip detection logic) • • • Throttle actuator Throttle body assembly Throttle valve MONITOR DESCRIPTION The ECM determines that there is a malfunction in the ETCS when the throttle valve remains at a fixed angle despite a high drive current from the ECM. The ECM illuminates the MIL and sets a DTC. If the malfunction is not repaired successfully, a DTC is set when the accelerator pedal is fully depressed and released quickly (to fully open and close the throttle valve) after the engine is next started. MONITOR STRATEGY Related DTCs P2111: Throttle actuator stuck open P2112: Throttle actuator stuck closed Required Sensors/Components (Main) Throttle actuator Required Sensors/Components (Related) - Frequency of Operation Continuous Duration 0.5 seconds MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS All: Monitor runs whenever following DTCs are not present None P2111 (Throttle actuator stuck open): All of the following conditions are met - System guard* ON Throttle actuator current 2 A or more Duty cycle to close throttle 80 % or more * System guard is ON when the following conditions are met - Throttle actuator ON Throttle actuator duty calculation Executing Throttle position sensor Fail determined Throttle actuator current-cut operation Not executing 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Throttle actuator power supply 4 V or more Throttle actuator Fail determined ES–291 P2112 (Throttle actuator stuck closed): All of the following conditions are met - System guard* ON Throttle actuator current 2 A or more Duty cycle to open throttle 80 % or more * System guard is ON when the following conditions are met - Throttle actuator ON Throttle actuator duty calculation Executing Throttle position sensor Fail determined Throttle actuator current-cut operation Not executing Throttle actuator power supply 4 V or more Throttle actuator Fail determined TYPICAL MALFUNCTION THRESHOLDS P2111 (Throttle actuator stuck open): TP sensor voltage change No change P2112 (Throttle actuator stuck closed): TP sensor voltage change No change FAIL-SAFE When either of these DTCs, or other DTCs relating to ETCS (Electronic Throttle Control System) malfunctions, are set, the ECM enters fail-safe mode. During fail-safe mode, the ECM cuts the current to the throttle actuator off, and the throttle valve is returned to a 6° throttle angle by the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing, in accordance with the accelerator pedal opening angle, to allow the vehicle to continue at a minimal speed. If the accelerator pedal is depressed gently, the vehicle can be driven slowly. Fail-safe mode continues until a pass condition is detected, and the ignition switch is then turned off. WIRING DIAGRAM Refer to DTC P2102 (See page ES-282). INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the airfuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P2111 OR P2112) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Turn the tester on. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read the DTCs. ES ES–292 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Result Display (DTC Output) Proceed to P2111 or P2112 A P2111 or P2112 and other DTCs B HINT: If any DTCs other than P2111 or P2112 are output, troubleshoot those DTCs first. B GO TO DTC CHART A ES 2 INSPECT THROTTLE BODY ASSEMBLY (VISUALLY CHECK THROTTLE VALVE) (a) Check for contamination between the throttle valve and the housing. If necessary, clean the throttle body. And check that the throttle valve moves smoothly. OK: Throttle valve is not contaminated with foreign objects and moves smoothly. NG REPLACE THROTTLE BODY ASSEMBLY OK 3 CHECK WHETHER DTC OUTPUT RECURS (DTC P2111 OR P2112) (a) (b) (c) (d) (e) Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Turn the tester on. Clear the DTCs (See page ES-38). Start the engine, and fully depress and release the accelerator pedal quickly (to fully open and close the throttle valve). (f) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (g) Read the DTCs. Result Display (DTC Output) Proceed to No DTC A P2111 or P2112 B B A CHECK FOR INTERMITTENT PROBLEMS REPLACE ECM ES–293 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2118 Throttle Actuator Control Motor Current Range / Performance DESCRIPTION The ETCS (Electronic Throttle Control System) has a dedicated power supply circuit. The voltage (+BM) is monitored and when it is low (less than 4 V), the ECM determines that there is a malfunction in the ETCS and cuts off the current to the throttle actuator. When the voltage becomes unstable, the ETCS itself becomes unstable. For this reason, when the voltage is low, the current to the throttle actuator is cut. If repairs are made and the system returns to normal, turn the ignition switch off. The ECM then allows the current to flow to the throttle actuator so that it can be restarted. HINT: The ETCS does not use a throttle cable. ECM +B From EFI Relay ETCS From Battery Power Source Circuit for CPU +BM Throttle Actuator M+ M- Throttle Actuator Control Circuit ME01 A112629E04 DTC No. P2118 DTC Detection Condition Open in ETCS power source (+BM) circuit (1 trip detection logic) Trouble Area • • • • • Open in ETCS power source circuit Battery Battery terminals ETCS fuse ECM MONITOR DESCRIPTION The ECM monitors the battery supply voltage applied to the throttle actuator. When the power supply voltage (+BM) drops below 4 V for 0.8 seconds or more, the ECM interprets this as an open in the power supply circuit (+BM). The ECM illuminates the MIL and sets the DTC. If the malfunction is not repaired successfully, the DTC is set 5 seconds after the engine is next started. ES ES–294 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR STRATEGY Related DTCs P2118: Throttle actuator power supply Required Sensors/Components (Main) Throttle actuator, throttle valve, ETCS fuse Required Sensors/Components (Related) None Frequency of Operation Continuous Duration 0.8 seconds MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS ES Monitor runs whenever following DTCs are not present None Battery voltage 8 V or more Electronic throttle actuator power ON TYPICAL MALFUNCTION THRESHOLDS Throttle actuator power supply voltage (+BM) Less than 4 V COMPONENT OPERATING RANGE Throttle actuator power supply voltage (+BM) 9 to 14 V FAIL-SAFE When this DTC, or other DTCs relating to ETCS (Electronic Throttle Control System) malfunctions, are set, the ECM enters fail-safe mode. During fail-safe mode, the ECM cuts the current to the throttle actuator off, and the throttle valve is returned to a 6° throttle angle by the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing, in accordance with the accelerator pedal opening angle, to allow the vehicle to continue at a minimal speed. If the accelerator pedal is depressed gently, the vehicle can be driven slowly. Fail-safe mode continues until a pass condition is detected, and the ignition switch is then turned off. ES–295 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM ETCS 3 +BM A24 (Shielded) M+ 2 42 M+ C24 1 41 MC24 FL MAIN M- ES 63 C24 GE01 C5 Throttle Actuator (Bulit into Throttle Body) Battery 43 ME01 C24 104 C24 E1 A138928E01 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the airfuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 READ VALUE USING INTELLIGENT TESTER (+BM VOLTAGE) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Turn the tester on. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / +BM VOLTAGE. (e) Read the value displayed on the tester. Standard voltage: 9 to 14 V ES–296 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK Go to step 5 NG 2 CHECK FUSE (ETCS FUSE) (a) Remove the ETCS fuse from the engine room R/B. (b) Measure the ETCS fuse resistance. Standard resistance: Below 1 Ω (c) Reinstall the ETCS fuse. ES NG ETCS Engine Room R/B: A132295E01 OK REPLACE FUSE (ETCS FUSE) ES–297 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 3 CHECK HARNESS AND CONNECTOR (ECM - ETCS FUSE, ETCS FUSE - BATTERY) (a) Remove the ETCS fuse from the engine room R/B. (b) Disconnect the cable from the negative (-) battery terminal. (c) Disconnect the cable from the negative (+) battery terminal. (d) Disconnect the A24 ECM connector. (e) Measure the resistance. Standard resistance (Check for open) Engine Room R/B: ETCS Tester Connection Specified Condition 2 (ETCS fuse) - A24-3 (+BM) Below 1 Ω Positive battery terminal - 1 (ETCS fuse) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition 2 (ETCS fuse) or A24-3 (+BM) - Body ground 10 kΩ or higher Positive battery terminal or 1 (ETCS fuse) - Body ground 10 kΩ or higher (f) (g) (h) (i) Reinstall the ETCS fuse. Reconnect the cable to the positive (+) battery terminal. Reconnect the cable to the negative (-) battery terminal. Reconnect the ECM connector. NG Wire Harness Side: ECM Connector A24 +BM A132296E01 OK REPAIR OR REPLACE HARNESS OR CONNECTOR ES ES–298 4 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT ECM (+BM VOLTAGE) (a) Disconnect the A24 and C24 ECM connectors. (b) Measure the voltage between the terminals of the A24 and C24 ECM connectors. Standard voltage Wire Harness Side: C24 ECM Connector Tester Connection Specified Condition A24-3 (+BM) - C24-104 (E1) 9 to 14 V (c) Reconnect the ECM connectors. Front View ES E1 NG REPAIR OR REPLACE HARNESS OR CONNECTOR (TERMINAL E1 - BODY GROUND) A24 ECM Connector +BM Front View A106902E05 OK REPLACE ECM 5 INSPECT BATTERY (a) Check the battery voltage. Standard voltage: 12.5 to 12.9 V at 20°C (68°F) NG REPLACE BATTERY OK 6 CHECK BATTERY TERMINAL (a) Check that the battery terminals and ECM ground are not loose or corroded. OK: Battery terminals and ECM ground are not loose or corroded. NG REPAIR OR REPLACE BATTERY TERMINAL 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–299 OK CHECK FOR INTERMITTENT PROBLEMS ES ES–300 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC Throttle Actuator Control Throttle Body Range / Performance P2119 DESCRIPTION The Electronic Throttle Control System (ETCS) is composed of the throttle actuator, Throttle Position (TP) sensor, Accelerator Pedal Position (APP) sensor, and ECM. The ECM operates the throttle actuator to regulate the throttle valve in response to driver inputs. The TP sensor detects the opening angle of the throttle valve, and provides the ECM with feedback so that the throttle valve can be appropriately controlled by the ECM. DTC No. P2119 ES DTC Detection Condition Trouble Area Throttle valve opening angle continues to vary greatly from target opening angle (1 trip detection logic) • • ETCS ECM MONITOR DESCRIPTION The ECM determines the actual opening angle of the throttle valve from the TP sensor signal. The actual opening angle is compared to the target opening angle commanded by the ECM. If the difference between these two values is outside the standard range, the ECM interprets this as a malfunction in the ETCS. The ECM then illuminates the MIL and sets the DTC. If the malfunction is not repaired successfully, the DTC is set when the accelerator pedal is quickly released (to close the throttle valve) after the engine speed reaches 5,000 rpm by the accelerator pedal being fully depressed (fully open the throttle valve). MONITOR STRATEGY Related DTCs P2119: ETCS malfunction Required Sensors/Components (Main) Throttle actuator Required Sensors/Components (Related) - Frequency of Operation Continuous Duration Within 1 second MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present None System guard* ON *System guard is ON when the following conditions are met - Throttle actuator ON Throttle actuator duty calculation Executing Throttle position sensor Fail determined Throttle actuator current-cut operation Not executing Throttle actuator power supply 4 V or more Throttle actuator Fail determined TYPICAL MALFUNCTION THRESHOLDS Either of the following conditions A or B is met - A. Difference between commanded closed throttle position and current closed throttle position 0.3 V or more B. Difference between commanded open throttle position and current open throttle position 0.3 V or more ES–301 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM FAIL-SAFE When this DTC, or other DTCs relating to ETCS (Electronic Throttle Control System) malfunctions, are set, the ECM enters fail-safe mode. During fail-safe mode, the ECM cuts the current to the throttle actuator off, and the throttle valve is returned to a 6° throttle angle by the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing, in accordance with the accelerator pedal opening angle, to allow the vehicle to continue at a minimal speed. If the accelerator pedal is depressed gently, the vehicle can be driven slowly. Fail-safe mode continues until a pass condition is detected, and the ignition switch is then turned off. WIRING DIAGRAM Refer to DTC P2102 (See page ES-282). ES INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the airfuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P2119) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Turn the tester on. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read the DTCs. Result Display (DTC Output) Proceed to P2119 A P2119 and other DTCs B HINT: If any DTCs other than P2119 are output, troubleshoot those DTCs first. B GO TO DTC CHART A 2 CHECK WHETHER DTC OUTPUT RECURS (DTC P2119) (a) (b) (c) (d) (e) Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Turn the tester on. Clear the DTCs (See page ES-38). Allow the engine to idle for 15 seconds. CAUTION: Exercise extreme care and take precautions in steps (f) and (g) below. Failure to do so may result in the vehicle unexpectedly rolling away. ES–302 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (f) Securely apply the parking brake and move the gear selector lever to the D position. (g) While depressing the brake pedal securely, fully depress the accelerator pedal for 5 seconds. (h) On the tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (i) Read the DTCs. HINT: The output voltage of the throttle position sensor can be checked during step (g) using the intelligent tester. Variations in the output voltage indicate that the throttle actuator is in operation. To check the output voltage using the intelligent tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ETCS / THROTTLE POS #1. OK: No DTC output. ES NG OK CHECK FOR INTERMITTENT PROBLEMS REPLACE THROTTLE BODY ASSEMBLY 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–303 DTC P2120 Throttle / Pedal Position Sensor / Switch "D" Circuit DTC P2122 Throttle / Pedal Position Sensor / Switch "D" Circuit Low Input DTC P2123 Throttle / Pedal Position Sensor / Switch "D" Circuit High Input DTC P2125 Throttle / Pedal Position Sensor / Switch "E" Circuit DTC P2127 Throttle / Pedal Position Sensor / Switch "E" Circuit Low Input DTC P2128 Throttle / Pedal Position Sensor / Switch "E" Circuit High Input DTC P2138 Throttle / Pedal Position Sensor / Switch "D" / "E" Voltage Correlation HINT: These DTCs relate to the Accelerator Pedal Position (APP) sensor. DESCRIPTION HINT: This ETCS (Electronic Throttle Control System) does not use a throttle cable. The APP sensor is mounted on the accelerator pedal bracket and has 2 sensor circuits: VPA (main) and VPA2 (sub). This sensor is a non-contact type It uses Hall-effect elements in order to yield accurate signals even in extreme driving conditions, such as at high speeds as well as very low speeds. The voltage, which is applied to terminals VPA and VPA2 of the ECM, varies between 0 V and 5 V in proportion to the operating angle of the accelerator pedal (throttle valve). A signal from VPA indicates the actual accelerator pedal opening angle (throttle valve opening angle) and is used for engine control. A signal from VPA2 conveys the status of the VPA circuit and is used to check the APP sensor itself. The ECM monitors the actual accelerator pedal opening angle (throttle valve opening angle) through the signals from VPA and VPA2, and controls the throttle actuator according to these signals. ES ES–304 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM APP Sensor Output Voltage (V) ECM APP Sensor Magnet IC No. 1 VPA EPA ES VCPA VPA2 EPA2 IC No. 2 Magnet *1 *2 4.55 3.988 3.75 3.188 1.6 0.8 VCP2 0.29 Usable Range 0 15.9 Accelerator Pedal Turning Angle (q) *1: Accelerator Pedal Fully Released *2: Accelerator Pedal Fully Depressed A112620E03 DTC No. DTC Detection Condition Trouble Area P2120 VPA fluctuates rapidly beyond upper and lower malfunction thresholds for 0.5 seconds or more (1 trip detection logic) • • APP sensor ECM P2122 VPA 0.4 V or less for 0.5 seconds or more when accelerator pedal fully released (1 trip detection logic) • • • • APP sensor Open in VCP1 circuit Open or ground short in VPA circuit ECM P2123 VPA 4.8 V or more for 2.0 seconds or more (1 trip detection logic) • • • APP sensor Open in EPA circuit ECM P2125 VPA2 fluctuates rapidly beyond upper and lower malfunction thresholds for 0.5 seconds or more (1 trip detection logic) • • APP sensor ECM P2127 VPA2 1.2 V or less for 0.5 seconds or more when accelerator pedal fully released (1 trip detection logic) • • • • APP sensor Open in VCP2 circuit Open or ground short in VPA2 circuit ECM P2128 Conditions (a) and (b) continue for 2.0 seconds or more (1 trip detection logic): (a) VPA2 4.8 V or more (b) VPA between 0.4 V and 3.45 V • • • APP sensor Open in EPA2 circuit ECM ES–305 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. P2138 DTC Detection Condition Trouble Area Condition (a) or (b) continues for 2.0 seconds or more (1 trip detection logic): (a) Difference between VPA and VPA2 0.02 V or less (b) VPA 0.4 V or less and VPA2 1.2 V or less • • • Short between VPA and VPA2 circuits APP sensor ECM HINT: When any of these DTCs are set, check the APP sensor voltage by selecting the following menu items on the intelligent tester: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / ACCEL POS #1 and ACCEL POS #2. Trouble Areas ACCEL POS #1 When AP Released ACCEL POS #2 When AP Released ACCEL POS #1 When AP Depressed ACCEL POS #2 When AP Depressed VCP circuit open 0 to 0.2 V 0 to 0.2 V 0 to 0.2 V 0 to 0.2 V Open or ground short in VPA circuit 0 to 0.2 V 1.2 to 2.0 V 0 to 0.2 V 3.4 to 5.0 V Open or ground short in VPA2 circuit 0.5 to 1.1 V 0 to 0.2 V 2.6 to 4.5 V 0 to 0.2 V EPA circuit open 4.5 to 5.0 V 4.5 to 5.0 V 4.5 to 5.0 V 4.5 to 5.0 V Normal condition 0.5 to 1.1 V 1.2 to 2.0 V 2.6 to 4.5 V 3.4 to 5.0 V HINT: • Accelerator pedal positions are expressed as voltages. • AP denotes Accelerator Pedal. MONITOR DESCRIPTION When either output voltage of VPA or VPA2 deviates from the standard range, or the difference between the output voltages of the 2 sensor circuits is less than the threshold, the ECM determines that there is a malfunction in the APP sensor. The ECM then illuminates the MIL and sets a DTC. Example: When the output voltage of VPA drops below 0.4 V for more than 0.5 seconds when the accelerator pedal is fully depressed, DTC P2122 is set. If the malfunction is not repaired successfully, a DTC is set 2 seconds after the engine is next started. MONITOR STRATEGY Related DTCs P2120: APP sensor 1 range check (fluctuating) P2122: APP sensor 1 range check (low voltage) P2123: APP sensor 1 range check (high voltage) P2125: APP sensor 2 range check (fluctuating) P2127: APP sensor 2 range check (low voltage) P2128: APP sensor 2 range check (high voltage) P2138: APP sensor range check (correlation) Required Sensors/Components (Main) APP sensor Required Sensors/Components (Related) - Frequency of Operation Continuous Duration 0.5 seconds: P2120, P2122, P2125 and P2127 2.0 seconds: P2123, P2128 and P2138 MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present None Either of the following conditions 1 or 2 is met: - 1. Ignition switch ON 2. Throttle actuator power ON ES ES–306 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TYPICAL MALFUNCTION THRESHOLDS P2120: Either of the following conditions 1 or 2 is met: - 1. VPA voltage when VPA2 voltage is 0.04 V or more 0.4 V or less 2. VPA voltage 4.8 V or more P2122: VPA voltage when VPA2 voltage is 0.04 V or more 0.4 V or less P2123: VPA voltage 4.8 V or more P2125: ES Either of the following conditions 1 or 2 is met: - 1. VPA2 voltage when VPA voltage is 0.04 V or more 1.2 V or less 2. VPA2 voltage when VPA voltage is 0.4 to 3.45 V 4.8 V or more P2127: VPA2 voltage when VPA voltage is 0.04 V or more 1.2 V or less P2128: VPA2 voltage when VPA voltage is 0.4 to 3.45 V 4.8 V or more P2138: Either of the following conditions A or B is met: - Condition A - Difference between VPA and VPA 2 voltages 0.02 V or less Condition B - VPA voltage 0.4 V or less VPA2 voltage 1.2 V or less COMPONENT OPERATING RANGE VPA voltage 0.5 V to 4.5 V VPA2 voltage 1.2 V to 5.0 V Difference between VPA and VPA2 voltages More than 0.02 V FAIL-SAFE When any of DTCs P2120, P2121, P2122, P2123, P2125, P2127, P2128 and P2138 are set, the ECM enters fail-safe mode. If either of the 2 sensor circuit malfunctions, the ECM uses the remaining circuit to calculate the accelerator pedal position to allow the vehicle to continue driving. If both of the circuits malfunction, the ECM regards the accelerator pedal as being released. As a result, the throttle valve is closed and the engine idles. Fail-safe mode continues until a pass condition is detected, and the ignition switch is turned off. ES–307 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM A17 Accelerator Pedal Position Sensor EPA VPA VCPA EPA2 VPA2 VCP2 ECM 5 59 A24 EPA 6 55 A24 VPA 4 57 A24 2 60 A24 EPA2 3 56 A24 VPA2 1 58 VCP2 A24 VCPA ES A132297E01 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the airfuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 READ VALUE USING INTELLIGENT TESTER (ACCEL POS #1 AND ACCEL POS #2) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ETCS / ACCEL POS #1 and ACCEL POS #2. (d) Read the value displayed on the tester. Standard voltage Depressed Released FI07052E06 Accelerator Pedal Operations Released → Depressed → Released OK NG ACCEL POS #1 ACCEL POS #2 0.5 to 4.5 V 1.2 to 5.0 V Difference between ACCEL POS #1 and ACCEL POS #2 is greater than 0.02 V Difference between ACCEL POS #1 and ACCEL POS #2 is greater than 0.02 V Go to step 5 ES–308 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2 CHECK HARNESS AND CONNECTOR (ACCELERATOR PEDAL POSITION SENSOR ECM) (a) Disconnect the A17 Accelerator Pedal Position (APP) sensor connector. (b) Disconnect the A24 ECM connector. (c) Measure the resistance between the terminals of the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side: APP Sensor Connector A17 VPA2 VCPA EPA2 ES EPA VCP2 VPA 1 2 3 4 5 6 Front View A24 VPA ECM Connector VCPA VPA2 Specified Condition Below 1 Ω A17-5 (EPA) - A24-59 (EPA) Below 1 Ω A17-4 (VCPA) - A24-57 (VCPA) Below 1 Ω A17-3 (VPA2) - A24-56 (VPA2) Below 1 Ω A17-2 (EPA2) - A24-60 (EPA2) Below 1 Ω A17-1 (VCP2) - A24-58 (VCP2) Below 1 Ω Standard resistance (Check for short) EPA EPA2 VCP2 Tester Connection A17-6 (VPA) - A24-55 (VPA) Front View Tester Connection Specified Condition A17-6 (VPA) or A24-55 (VPA) - body ground 10 kΩ or higher A17-5 (EPA) or A24-59 (EPA) - body ground 10 kΩ or higher A17-4 (VCPA) or A24-57 (VCPA) - body ground 10 kΩ or higher A17-3 (VPA2) or A24-56 (VPA2) - body ground 10 kΩ or higher A17-2 (EPA2) or A24-60 (EPA2) - body ground 10 kΩ or higher A17-1 (VCP2) or A24-58 (VCP2) - body ground 10 kΩ or higher (d) Reconnect the APP sensor connector. (e) Reconnect the ECM connector. A115665E05 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 CHECK ECM (VCPA AND VCP2 VOLTAGE) (a) Disconnect the A17 APP sensor connector. (b) Turn the ignition switch to the ON position. (c) Measure the voltage between the terminals of the A17 APP sensor connector. Standard voltage Wire Harness Side: A17 APP Sensor Connector 1 2 3 4 5 6 Tester Connection Specified Condition A17-4 (VCPA) - A17-5 (EPA) 4.5 to 5.5 V A17-1 (VCP2) - A17-2 (EPA2) 4.5 to 5.5 V (d) Reconnect the APP sensor connector. VCP2 EPA2 VCPA NG EPA Front View A115666E07 REPLACE ECM ES–309 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK 4 REPLACE ACCELERATOR PEDAL ASSEMBLY NEXT 5 CHECK WHETHER DTC OUTPUT RECURS (ACCELERATOR PEDAL POSITION SENSOR DTCS) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the tester on. (c) Clear the DTCs (See page ES-38). (d) Start the engine. (e) Allow the engine to idle for 15 seconds. (f) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (g) Read the DTCs. Result Display (DTC Output) Proceed to P2120, P2122, P2123, P2125, P2127, P2128, and/or P2138 A No output B B A REPLACE ECM SYSTEM OK ES ES–310 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC Throttle / Pedal Position Sensor / Switch "D" Circuit Range / Performance P2121 DESCRIPTION HINT: Refer to DTC P2120 (See page ES-298). ES DTC No. DTC Detection Condition Trouble Area P2121 Difference between VPA and VPA2 less than 0.4 V, or more than 1.2 V for 0.5 seconds (1 trip detection logic) • • Accelerator Pedal Position (APP) sensor ECM MONITOR DESCRIPTION When the difference between the output voltages of VPA and VPA2 deviates from the standard, the ECM determines that the Accelerator Pedal Position (APP) sensor is malfunctioning. The ECM turns on the MIL and the DTC is set. MONITOR STRATEGY Related DTCs P2121: APP sensor rationality Required Sensors/Components (Main) APP sensor Required Sensors/Components (Related) - Frequency of Operation Continuous Duration 0.5 seconds MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present None Either of the following conditions 1 or 2 is met: - 1. Ignition switch ON 2. Throttle actuator power ON TYPICAL MALFUNCTION THRESHOLDS Difference between VPA voltage (learned value) and VPA2 voltage (learned value) Less than 0.4 V, or more than 1.2 V FAIL-SAFE The APP sensor has two (main and sub) sensor circuits. If a malfunction occurs in either of the sensor circuits, the ECM detects the abnormal signal voltage difference between the two sensor circuits and switches to limp mode. In limp mode, the functioning circuit is used to calculate the accelerator pedal opening angle to allow the vehicle to continue driving. If both circuits malfunction, the ECM regards the opening angle of the accelerator pedal as being fully closed. In this case, the throttle valve remains closed as if the engine is idling. If a pass condition is detected and then the ignition switch is turned off, the fail-safe operation stops and the system returns to a normal condition. WIRING DIAGRAM Refer to DTC P2120 (See page ES-302). ES–311 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the airfuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P2121) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Turn the tester on. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read the DTCs. Result Display (DTC Output) Proceed to P2121 A P2121 and other DTCs B HINT: If any DTCs other than P2121 are output, troubleshoot those DTCs first. B GO TO DTC CHART A 2 READ VALUE USING INTELLIGENT TESTER (ACCEL POS #1 AND ACCEL POS #2) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ETCS / ACCEL POS #1 and ACCEL POS #2. (d) Read the values displayed on the tester. Standard voltage Depressed Released FI07052E06 Accelerator Pedal Operations Released → Depressed → Released OK NG ACCEL POS #1 ACCEL POS #2 0.5 to 4.5 V 1.2 to 5.0 V Difference between ACCEL POS #1 and ACCEL POS #2 is greater than 0.02 V Difference between ACCEL POS #1 and ACCEL POS #2 is greater than 0.02 V CHECK FOR INTERMITTENT PROBLEMS ES ES–312 3 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM REPLACE ACCELERATOR PEDAL ASSEMBLY NEXT 4 CHECK WHETHER DTC OUTPUT RECURS (DTC P2121) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the tester on. (c) Clear the DTCs (See page ES-38). (d) Start the engine. (e) Allow the engine to idle for 15 seconds. (f) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (g) Read the DTCs. ES Result Display (DTC Output) Proceed to P2121 A No output B B A REPLACE ECM SYSTEM OK ES–313 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2195 Oxygen (A/F) Sensor Signal Stuck Lean (Bank 1 Sensor 1) DTC P2196 Oxygen (A/F) Sensor Signal Stuck Rich (Bank 1 Sensor 1) HINT: • Although the DTC titles say oxygen sensor, these DTCs relate to the Air-Fuel Ratio (A/F) sensor. • Sensor 1 refers to the sensor mounted in front of the Three-Way Catalytic Converter (TWC) and located near the engine assembly. ES DESCRIPTION The A/F sensor generates a voltage* that corresponds to the actual air-fuel ratio. This sensor voltage is used to provide the ECM with feedback so that it can control the air-fuel ratio. The ECM determines the deviation from the stoichiometric air-fuel ratio level, and regulates the fuel injection time. If the A/F sensor malfunctions, the ECM is unable to control the air-fuel ratio accurately. The A/F sensor is of the planar type and is integrated with the heater, which heats the solid electrolyte (zirconia element). This heater is controlled by the ECM. When the intake air volume is low (the exhaust gas temperature is low), a current flows into the heater to heat the sensor, in order to facilitate accurate air-fuel ratio detection. In addition, the sensor and heater portions are narrower than the conventional type. The heat generated by the heater is conducted to the solid electrolyte through the alumina, therefore the sensor activation is accelerated. A three-way catalytic converter (TWC) is used in order to convert the carbon monxide (CO), hydrocarbons (HC), and nitrogen oxide (NOX) into less harmful substances. To allow the TWC to function effectively, it is necessary to keep the air-fuel ratio of the engine near the stoichiometric air-fuel ratio. *: Value changes inside the ECM. Since the A/F sensor is the current output element, a current is converted into a voltage inside the ECM. Any measurements taken at the A/F sensor or ECM connectors will show a constant voltage. ECM Monitored A/F Sensor Voltage Alumina Heater Solid Electrolyte (Zirconia Element) Element Cover Exhaust Gas Platinum Electrode Atmospheric Air A A A-A Cross Section Air-Fuel Ratio A107164E06 ES–314 ES 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. DTC Detection Condition P2195 Conditions (a) and (b) continue for 10 seconds or more (2 trip detection logic): (a) A/F sensor voltage more than 3.8 V (b) Heated Oxygen (HO2) sensor voltage 0.15 V or more • • • • • • Open or short in A/F sensor (sensor 1) circuit A/F sensor (sensor 1) A/F sensor heater (sensor 1) Engine room J/B (EFI relay) A/F sensor heater and EFI relay circuits ECM While fuel-cut operation is performed (during vehicle deceleration), A/F sensor current 3.6 mA or more for 3 seconds (2 trip detection logic) • • A/F sensor ECM Conditions (a) and (b) continue for 10 seconds or more (2 trip detection logic): (a) A/F sensor voltage less than 2.8 V for 10 seconds (b) HO2 sensor voltage less than 0.6 V • • • • • • Open or short in A/F sensor (sensor 1) circuit A/F sensor (sensor 1) A/F sensor heater (sensor 1) Engine room J/B (EFI relay) A/F sensor heater and EFI relay circuits ECM While fuel-cut operation is performed (during vehicle deceleration), A/F sensor current less than 1.0 mA for 3 seconds (2 trip detection logic) • • A/F sensor ECM P2196 Trouble Area HINT: • When either of these DTCs is set, check the A/F sensor output voltage by selecting the following menu items on the intelligent tester: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / AFS B1 S1. • Short-term fuel trim values can also be read using the intelligent tester. • The ECM regulates the voltages at the A1A+ and A1A- terminals of the ECM to a constant level. Therefore, the A/F sensor output voltage cannot be confirmed without using the intelligent tester. • If the A/F sensor is malfunctioning, the ECM sets the DTC P2195 or P2196. MONITOR DESCRIPTION Sensor voltage detection monitor Under the air-fuel ratio feedback control, if the A/F sensor output voltage indicates rich or lean for a certain period of time, the ECM determines that there is a malfunction in the A/F sensor. The ECM illuminates the MIL and sets a DTC. Example: If the A/F sensor output voltage is less than 2.8 V (very rich condition) for 10 seconds, despite the rear HO2 sensor output voltage being less than 0.6 V, the ECM sets DTC P2196. Alternatively, if the A/F sensor output voltage is more than 3.8 V (very lean condition) for 10 seconds, despite the rear HO2 sensor output voltage being 0.15 V or more, DTC P2195 is set. Sensor current detection monitor A rich air-fuel mixture causes a low A/F sensor current, and a lean air-fuel mixture causes a high A/F sensor current. Therefore, the sensor output becomes low during acceleration, and it becomes high during deceleration with the throttle valve fully closed. The ECM monitors the A/F sensor current during fuel-cut and detects any abnormal current values. If the A/F sensor output is 3.6 mA or more for more than 3 seconds of cumulative time, the ECM interprets this as a malfunction in the A/F sensor and sets DTC P2195 (high-side stuck). If the A/F sensor output is less than 1.0 mA for more than 3 seconds of cumulative time, the ECM sets DTC P2196 (low-side stuck). ES–315 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM A/F Sensor Current Monitor: Cumulative Time "t" = t1 + t2 = 3 seconds or more ON Fuel-Cut OFF Delay (3 seconds) Delay (3 seconds) Delay (3 seconds) Sensor Current (mA) ES High Side Threshold Low Side Threshold 3 seconds or more t1 Normal Sensor Output t2 Abnormal Sensor Output Time A107165E07 MONITOR STRATEGY Related DTCs P2195: A/F sensor signal stuck lean P2196: A/F sensor signal stuck rich Required Sensors/Components (Main) A/F sensor Required Sensors/Components (Related) HO2 sensor Frequency of Operation Continuous Duration 10 seconds: Sensor voltage detection monitor 3 seconds: Sensor current detection monitor MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS All Monitor runs whenever following DTCs are not present P0031, P0032 (A/F sensor heater - Sensor 1) P0037, P0038 (O2 sensor heater - Sensor 2) P0100 - P0103 (MAF meter) P0110 - P0113 (IAT sensor) P0115 - P0118 (ECT sensor) P0120 - P0223, P2135 (TP sensor) P0125 (Insufficient ECT for Closed Loop) P0136 (O2 Sensor - Sensor 2) P0171, P0172 (Fuel system) P0300 - P0304 (Misfire) P0335 (CKP sensor) P0340 (CMP sensor) P0441 - P0456, P2401 - P2420 (EVAP system) P0500 (VSS) ES–316 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Sensor voltage detection monitor (Lean side malfunction P2195): Duration while all of the following conditions are met 2 seconds or more Rear HO2 sensor voltage 0.15 V or more Time after engine start 30 seconds or more A/F sensor status Activated Fuel system status Closed-loop Engine Running Sensor voltage detection monitor (Rich side malfunction P2196): ES Duration while all of the following conditions are met 2 seconds or more Rear HO2 sensor voltage Below 0.6 V Time after engine start 30 seconds or more A/F sensor status Activated Fuel system status Closed-loop Engine Running Sensor current detection monitor P2195 and P2196 Battery voltage 11 V or more Atmospheric pressure 76 kPa (570 mmHg) or more A/F sensor status Activated Continuous time of fuel cut 3 to 10 seconds ECT 75°C (167°F) or more TYPICAL MALFUNCTION THRESHOLDS Sensor voltage detection monitor (Lean side malfunction P2195): A/F sensor voltage More than 3.8 V Sensor voltage detection monitor (Rich side malfunction P2196): A/F sensor voltage Less than 2.8 V Sensor current detection monitor (High side malfunction P2195): A/F sensor current 3.6 mA or more Sensor current detection monitor (Low side malfunction P2196): A/F sensor current Less than 1 mA MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-20). ES–317 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM EFI ECM C15 A/F Sensor (Bank 1 Sensor 1) +B 109 C24 HA1A HA1A 2 1 (Shielded) A1A- 112 C24 A1A+ A1A+ 4 3 ES 113 C24 A1A- EFI MAIN EFI C22 HO2 Sensor No. 3 (Bank 1 Sensor 2) +B 47 C24 HT1B HT1B 2 1 (Shielded) FL MAIN E2 4 OX1B 3 64 C24 OX1B 87 C24 EX1B Battery 44 A24 MREL A134994E01 ES–318 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CONFIRMATION DRIVING PATTERN This confirmation driving pattern is used in the "PERFORM CONFIRMATION DRIVING PATTERN" procedure of the following diagnostic troubleshooting procedure. Monitor Driving Pattern 1: ECT: 75°C (167°F) or more Vehicle Speed Between 38 and 75 mph (60 and 120 km/h) Accelerator Pedal Depressed (g) (e) Idling (i) 40 mph (64 km/h) or more ES Accelerator Pedal Released (Fuel-cut) At least 3 times (j) (k) 6 mph (10 km/h) (h) Time 10 minutes or more Warming up 10 seconds 4 seconds or more or more Refer to figure below A107162E24 Driving Pattern Detail for (h) through (k): Cumulative Detection Period "t" = t1 + t2 + t3 = 3 seconds or more Reference Engine RPM Delay Detection Period t1 (i) (j) (k) 2,500 rpm 1,000 rpm Idling t2 (h) t3 Time Idling 4 seconds or more 4 seconds or more 4 seconds or more A107163E06 (a)Connect the intelligent tester to the DLC3. (b)Turn the ignition switch to the ON position. (c) Turn the tester on. (d)Clear the DTCs (See page ES-38). (e)Start the engine, and warm it up until the ECT reaches 75°C (167°F) or higher. (f) On the intelligent tester, select the following menu items to check the fuel-cut status: DIAGNOSIS / ENHANCED OBD II / DATA LIST / USER DATA / FC IDL. (g)Drive the vehicle at between 38 mph (60 km/h) and 75 mph (120 km/h) for at least 10 minutes. ES–319 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (h)Change the transmission to the 2nd gear. (i) Drive the vehicle at a proper vehicle speed to perform fuel-cut operation. (j) Accelerate the vehicle to 40 mph (64 km/h) or more by depressing the accelerator pedal for at least 10 seconds. HINT: Fuel-cut is performed when the following conditions are met: • Accelerator pedal fully is released. • Engine speed is 2,500 rpm or more (fuel injection resumes at 1,000 rpm). (k) Soon after performing step (j) above, release the accelerator pedal for at least 4 seconds without depressing the brake pedal, in order to execute fuel-cut control. (l) Allow the vehicle to decelerate until the vehicle speed declines to less than 6 mph (10 km/h). (m)Repeat steps from (h) through (k) above at least 3 times in one driving cycle. HINT: Completion of all A/F sensor monitors is required to change the value in TEST RESULT. CAUTION: Strictly observe posted speed limits, traffic laws, and road conditions when performing these driving patterns. INSPECTION PROCEDURE HINT: Intelligent tester only: Malfunctioning areas can be identified by performing the A/F CONTROL function provided in the ACTIVE TEST. The A/F CONTROL function can help to determine whether the Air-fuel Ratio (A/F) sensor, Heated Oxygen (HO2) sensor and other potential trouble areas are malfunctioning. The following instructions describe how to conduct the A/F CONTROL operation using the intelligent tester. 1. Connect the intelligent tester to the DLC3. 2. Start the engine and turn the tester on. 3. Warm up the engine at an engine speed of 2,500 rpm for approximately 90 seconds. 4. On the tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/ F CONTROL. 5. Perform the A/F CONTROL operation with the engine idling (press the RIGHT or LEFT button to change the fuel injection volume). 6. Monitor the output voltages of the A/F and HO2 sensors (AFS B1 S1 and O2S B1 S2) displayed on the tester. HINT: • The A/F CONTROL operation lowers the fuel injection volume by 12.5 % or increases the injection volume by 25%. • The sensors react in accordance with increases and decreases in the fuel injection volume. Standard Tester Display (Sensor) Injection Volume Status Voltages AFS B1 S1 (A/F) +25% Rich Less than 3.0 -12.5% Lean More than 3.35 O2S B1 S2 (HO2) +25% Rich More than 0.5 -12.5% Lean Less than 0.4 NOTICE: The A/F sensor has an output delay of a few seconds and the HO2 sensor (sensor 2) output has a maximum output delay of approximately of 20 seconds. ES ES–320 Case 1 2 ES 3 4 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM A/F Sensor (Sensor 1) Output Voltage HO2 Sensor (Sensor 2) Output Voltage Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage More than 3.35 V Less than 3.0 V Output Voltage More than 0.5 V Less than 0.4 V Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage Almost no reaction Output Voltage More than 0.5 V Less than 0.4 V Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage More than 3.35 V Less than 3.0 V Output Voltage Almost no reaction Injection volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage Almost no reaction Output Voltage Almost no reaction Main Suspected Trouble Areas - • • • A/F sensor A/F sensor heater A/F sensor circuit • • • HO2 sensor HO2 sensor heater HO2 sensor circuit • • • Injector Fuel pressure Gas leakage from exhaust system (Air-fuel ratio extremely lean or rich) Following the A/F CONTROL procedure enables technicians to check and graph the voltage outputs of both the A/F and HO2 sensors. To display the graph, select the following menu items on the tester: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL / USER DATA / AFS B1 S1 and O2S B1 S2, and press the YES button and then the ENTER button followed by the F4 button. HINT: • DTC P2A00 may be set when the air-fuel ratio is stuck rich or lean. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. • A low A/F sensor voltage could be caused by a rich air-fuel mixture. Check for conditions that would cause the engine to run rich. • A high A/F sensor voltage could be caused by a lean air-fuel mixture. Check for conditions that would cause the engine to run lean. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO P2195 OR P2196) (a) (b) (c) (d) Connect an intelligent tester to the DLC3. Turn the ignition switch to the ON position. Turn the tester on. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read the DTCs. ES–321 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Result Display (DTC Output) Proceed to P2195 or P2196 A P2195 or P2196 and other DTCs B HINT: If any DTCs relating to the A/F sensor (DTCs for the A/F sensor heater or A/F sensor admittance) are output, troubleshoot those DTCs first. B GO TO DTC CHART A ES 2 READ VALUE USING INTELLIGENT TESTER (TEST VALUE OF A/F SENSOR) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the tester on. (c) Clear the DTCs (See page ES-38). (d) Drive the vehicle in accordance with the drive pattern described in the CONFIRMATION DRIVING PATTERN. (e) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / MONITOR INFO / MONITOR STATUS. (f) Check that the status of O2S MON is COMPL. If the status is still INCMPL, drive the vehicle according to the driving pattern again. HINT: • AVAIL indicates that the component has not been monitored yet. • COMPL indicates that the component is functioning normally. • INCMPL indicates that the component is malfunctioning. (g) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / MONITOR INFO / TEST RESULT / RANGE B1 S1; then press the ENTER button. (h) Check the test value of the A/F sensor output current during fuel-cut. Result Test Value Proceed to Within normal range (1.0 mA or more, and less than 3.6 mA) A Outside normal range (Less than 1.0 mA, or 3.6 mA or more) B B Go to step 12 A 3 READ VALUE USING INTELLIGENT TESTER (OUTPUT VOLTAGE OF A/F SENSOR) (a) Connect the intelligent tester to the DLC3. (b) Start the engine. ES–322 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (c) Turn the tester on. (d) Warm up the A/F sensor at an engine speed of 2,500 rpm for 90 seconds. (e) On the tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / SNAPSHOT / MANUAL SNAPSHOT / USER DATA / AFS B1 S1 and ENGINE SPD. (f) Check the A/F sensor voltage 3 times, when the engine is in each of the following conditions: (1) While idling (for at least 30 seconds) (2) At an engine speed of approximately 2,500 rpm (without any sudden changes in engine speed) (3) Raise the engine speed to 4,000 rpm and then quickly release the accelerator pedal so that the throttle valve is fully closed. ES Standard voltage Conditions A/F Sensor Voltage Variations (1) and (2) Remains at approximately 3.3 V Between 3.1 V and 3.5 V Increases to 3.8 V or more This occurs during engine deceleration (when fuel-cut performed) (3) Reference Malfunction Condition: Normal Condition: (3) Approximately 4,000 rpm (2) Approximately 2,500 rpm (3) Approximately 4,000 rpm (2) Approximately 2,500 rpm (1) Idling (1) Idling (1) Idling Engine RPM Engine RPM A/F Sensor Voltage A/F Sensor Voltage Fuel-cut "Condition (1), (2)" Remains at approximately 3.3 V "Condition (3)" 3.8 V or more (1) Idling Fuel-cut When A/F sensor circuit is malfunctioning, voltage output does not change A107161E16 HINT: • For more information, see the diagrams below. • If the output voltage of the A/F sensor remains at approximately 3.3 V (see Malfunction Condition diagram) under any conditions, including those above, the A/F sensor may have an open circuit. (This will also happen if the A/F sensor heater has an open circuit.) ES–323 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM • If the output voltage of the A/F sensor remains at either approximately 3.8 V or more, or 2.8 V or less (see Malfunction Condition diagram) under any conditions, including those above, the A/F sensor may have a short circuit. • The ECM stops fuel injection (fuel cut) during engine deceleration. This causes a lean condition and results in a momentary increase in the A/F sensor output voltage. • The ECM must establish a closed throttle valve position learning value to perform fuel cut. If the battery terminal has been reconnected, the vehicle must be driven over 10 mph (16 km/h) to allow the ECM to learn the closed throttle valve position. • When the vehicle is driven: The output voltage of the A/F sensor may be below 2.8 V during fuel enrichment. For the vehicle, this translates to a sudden increase in speed with the accelerator pedal fully depressed when trying to overtake another vehicle. The A/F sensor is functioning normally. • The A/F sensor is a current output element; therefore, the current is converted into a voltage inside the ECM. Measuring the voltage at the connectors of the A/F sensor or ECM will show a constant voltage result. NG Go to step 9 OK 4 PERFORM CONFIRMATION DRIVING PATTERN NEXT 5 CHECK WHETHER DTC OUTPUT RECURS (DTC P2195 OR P2196) (a) Read the DTCs using the intelligent tester. (b) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. Result Display (DTC Output) Proceed to P2195 or P2196 A No output B B A END ES ES–324 6 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM REPLACE AIR-FUEL RATIO SENSOR NEXT 7 PERFORM CONFIRMATION DRIVING PATTERN NEXT ES 8 CHECK WHETHER DTC OUTPUT RECURS (DTC P2195 OR P2196) (a) Read the DTCs using the intelligent tester. (b) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. Result Display (DTC Output) Proceed to No output A P2195 or P2196 B B REPLACE ECM A END 9 INSPECT AIR-FUEL RATIO SENSOR (HEATER RESISTANCE) (See page ES-84) NG REPLACE AIR-FUEL RATIO SENSOR OK 10 INSPECT ENGINE ROOM J/B (EFI RELAY) (See page ES-85) NG OK REPLACE ENGINE ROOM J/B ES–325 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 11 CHECK HARNESS AND CONNECTOR (A/F SENSOR - ECM) (a) Disconnect the C15 A/F sensor connector. (b) Turn the ignition switch to the ON position. (c) Measure the voltage between the +B terminal of the A/F sensor connector and body ground. Standard voltage Wire Harness Side: A/F Sensor Connector HA1A +B C15 C24 Specified Condition C15-2 (+B) - Body ground 9 to 14 V (d) Turn the ignition switch off. (e) Disconnect the C24 ECM connector. (f) Measure the resistance between the terminals of the wire harness side connectors. Standard resistance (Check for open) A1A- A1A+ Tester Connection ECM Connector Tester Connection Specified Condition C15-1 (HA1A) - C24-109 (HA1A) Below 1 Ω C15-3 (A1A+) - C24-112 (A1A+) Below 1 Ω C15-4 (A1A-) - C24-113 (A1A-) Below 1 Ω Standard resistance (Check for short) A1A+ A1A- HA1A A127715E08 Tester Connection Specified Condition C15-1 (HA1A) or C24-109 (HA1A) - Body ground 10 kΩ or higher C15-3 (A1A+) or C24-112 (A1A+) - Body ground 10 kΩ or higher C15-4 (A1A-) or C24-113 (A1A-) - Body ground 10 kΩ or higher (g) Reconnect the ECM connector. (h) Reconnect the A/F sensor connector. Reference (System Diagram of Sensor 1): EFI EFI MAIN From Battery ECM A/F Sensor Heater +B A1A- HA1A HA1A A1A+ A1A+ Sensor Duty Control A1A- MREL Ground A140695E01 NG REPAIR OR REPLACE HARNESS OR CONNECTOR ES ES–326 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK 12 REPLACE AIR-FUEL RATIO SENSOR NEXT 13 PERFORM CONFIRMATION DRIVING PATTERN NEXT ES 14 CHECK WHETHER DTC OUTPUT RECURS (DTC P2195 OR P2196) (a) Read the DTCs using the intelligent tester. (b) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. Result Display (DTC Output) Proceed to No output A P2195 or P2196 B B A END REPLACE ECM 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–327 DTC P2237 Oxygen (A/F) Sensor Pumping Current Circuit / Open (Bank 1 Sensor 1) DTC P2238 Oxygen (A/F) Sensor Pumping Current Circuit Low (Bank 1 Sensor 1) DTC P2239 Oxygen (A/F) Sensor Pumping Current Circuit High (Bank 1 Sensor 1) DTC P2252 Oxygen (A/F) Sensor Reference Ground Circuit Low (Bank 1 Sensor 1) DTC P2253 Oxygen (A/F) Sensor Reference Ground Circuit High (Bank 1 Sensor 1) HINT: • Although the DTC titles say oxygen sensor, these DTCs relate to the Air-Fuel Ratio (A/F) sensor. • Sensor 1 refers to the sensor mounted in front of the Three-Way Catalytic Converter (TWC) and located near the engine assembly. DESCRIPTION These DTCs are set when there is an open or short in the A/F sensor circuit, or if A/F sensor output drops. To detect these problems, the voltage of the A/F sensor is monitored when turn the ignition switch to the ON position, and the admittance (admittance is an electrical term that indicates the ease of flow of current) is checked while driving. If the voltage of the A/F sensor is between 0.6V and 4.5V, it is considered normal. If the voltage is out of the specified range, or the admittance is less than the standard value, the ECM will determine that there is a malfunction in the A/F sensor. If the same malfunction is detected in next driving cycle, the MIL will be illuminated and a DTC will be stored. The A/F sensor, which is located between the exhaust manifold and catalyst, consists of alloyed metal elements and a heater. Depending on the engine operating conditions, the heater heats the sensor elements to activate them. Battery voltage is applied to the heater, the sensor ground is controlled by the ECM using a duty ratio. The sensor elements convert the oxygen concentration in the exhaust gas into voltage values to output. Based on the voltage, the ECM determines the air-fuel ratio and regulates the fuel injection volume depending on the air-fuel ratio and engine operating conditions. The voltage changes between 0.6V and 4.5V while the engine is running. If the air-fuel ratio is LEAN, which means the oxygen concentration in the exhaust gas is high, the voltage is high. If the air-fuel ratio is RICH, which means the oxygen concentration in the exhaust gas is low, the voltage is low. ES ES–328 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Reference (System Diagram of Sensor 1): ECM A/F Sensor EFI Heater EFI MAIN +B From Battery A1A- HA1A HA1A A1A+ A1A+ Sensor Duty Control A1A- ES MREL Ground A140695E01 A/F Sensor Voltage Alumina Heater Solid Electrolyte (Zirconia Element) Element Cover Exhaust Gas Platinum Electrode Atmospheric Air A A A-A Cross Section Air-Fuel Ratio A107164E12 DTC No. DTC Detection Condition Trouble Area P2237 Open in the circuit between terminals AF+ and AF- of the AF sensor while engine is running (2 trip detection logic) • • • Open or short in A/F sensor (sensor 1) circuit A/F sensor (sensor 1) ECM P2238 Any of the following conditions are met (2 trip detection logic) • AF sensor output drops while engine is running. • Voltage at terminal AF+ is 0.5V or less. • Voltage difference between terminals AF+ and AFis 0.1V or less. • • • Open or short in A/F sensor (sensor 1) circuit A/F sensor (sensor 1) ECM ES–329 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. DTC Detection Condition Trouble Area P2239 AF+ voltage more than 4.5 V (2 trip detection logic) • • • Open or short in A/F sensor (sensor 1) circuit A/F sensor (sensor 1) ECM P2252 AF- voltage 0.5 V or less (2 trip detection logic) • • • Open or short in A/F sensor (sensor 1) circuit A/F sensor (sensor 1) ECM P2253 AF- voltage more than 4.5 V (2 trip detection logic) • • • Open or short in A/F sensor (sensor 1) circuit A/F sensor (sensor 1) ECM MONITOR DESCRIPTION These DTCs are output when there is an open or short in the A/F sensor circuit, or if A/F sensor output drops. To detect these problems, the voltage of the A/F sensor is monitored when turn the ignition switch to the ON position, and the admittance (admittance is an electrical term that indicates the ease of flow of current) is checked while driving. If the voltage of the A/F sensor is between 0.6V and 4.5V, it is considered normal. If the voltage is out of the specified range, or the admittance is less than the standard value, the ECM will determine that there is a malfunction in the A/F sensor. If the same malfunction is detected in next driving cycle, the MIL will be illuminated and a DTC will be stored. MONITOR STRATEGY Related DTCs P2237: A/F sensor open circuit between AF+ and AFP2238: A/F sensor short circuit between AF+ and AFP2238: A/F sensor short circuit between AF+ and GND P2238: A/F sensor admittance low P2239: A/F sensor short circuit between AF+ and +B P2252: A/F sensor short circuit between AF- and GND P2253: A/F sensor short circuit between AF- and +B Required Sensors/Components (Main) A/F sensor Required Sensors/Components (Related) Engine Coolant Temperature (ECT) sensor, Crankshaft position sensor Frequency of Operation Continuous Duration 10 seconds MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present P0031, P0032 (A/F sensor heater - Sensor 1) P0100 - P0103 (MAF meter) P0110 - P0113 (IAT sensor) P0115 - P0118 (ECT sensor) P0120 - P0223, P2135 (TP sensor) P0125 (Insufficient ECT for Closed Loop) P0171, P0172 (Fuel trim) P0300 - P0304 (Misfire) P0335 (CKP sensor) P0340 (CMP sensor) P0441 - P0456, P2401 - P2420 (EVAP system) P0500 (VSS) Battery voltage 11 V or more Engine Running ECT 10°C (50°F) or more (Closed loop enabling ECT) Estimated sensor temperature 450 to 550°C (842 to 1,022°F) (for P2237) 700 to 800°C (1,292 to 1,472°F) (for P2238) Fuel-cut Not executed ES ES–330 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TYPICAL MALFUNCTION THRESHOLDS P2237: A/F sensor admittance Below 0.002 1/Ω P2238: One of the following conditions is met - 1. A/F sensor admittance Below 0.022 1/Ω 2. AF+ terminal voltage 0.5 V or less 3. Difference between AF+ and AF- terminal voltages Below 0.1 V P2239: AF+ terminal voltage ES More than 4.5 V P2252: AF- terminal voltage 0.5 V or less P2253: AF- terminal voltage More than 4.5 V COMPONENT OPERATING RANGE A/F sensor admittance 0.022 1/Ω or more AF+ terminal voltage 0.6 to 4.5 V AF- terminal voltage 0.6 to 4.5 V Difference between AF+ and AF- terminal voltages 0.1 to 0.8 V ES–331 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM EFI ECM C15 A/F Sensor (Bank 1 Sensor 1) +B 109 C24 HA1A HA1A 2 1 (Shielded) A1A- 112 C24 A1A+ A1A+ 4 3 ES 113 C24 A1A- EFI MAIN EFI C22 HO2 Sensor No. 3 (Bank 1 Sensor 2) +B 47 C24 HT1B HT1B 2 1 (Shielded) FL MAIN E2 4 OX1B 3 64 C24 OX1B 87 C24 EX1B Battery 44 A24 MREL A134994E01 INSPECTION PROCEDURE HINT: Intelligent tester only: Malfunctioning areas can be identified by performing the A/F CONTROL function provided in the ACTIVE TEST. The A/F CONTROL function can help to determine whether the Air-Fuel Ratio (A/F) sensor, Heated Oxygen (HO2) sensor and other potential trouble areas are malfunctioning. The following instructions describe how to conduct the A/F CONTROL operation using the intelligent tester. 1. Connect the intelligent tester to the DLC3. 2. Start the engine and turn the tester on. 3. Warm up the engine at an engine speed of 2,500 rpm for approximately 90 seconds. 4. On the tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/ F CONTROL. ES–332 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 5. Perform the A/F CONTROL operation with the engine idling (press the RIGHT or LEFT button to change the fuel injection volume). 6. Monitor the output voltages of the A/F and HO2 sensors (AFS B1 S1 and O2S B1 S2) displayed on the tester. HINT: • The A/F CONTROL operation lowers the fuel injection volume by 12.5 % or increases the injection volume by 25 %. • The sensors react in accordance with increases and decreases in the fuel injection volume. Standard Tester Display (Sensor) Injection Volume Status Voltages +25 % Rich Less than 3.0 -12.5 % Lean More than 3.35 +25 % Rich More than 0.5 -12.5 % Lean Less than 0.4 AFS B1 S1 (A/F) ES O2S B1 S2 (HO2) NOTICE: The A/F sensor has an output delay of a few seconds and the HO2 sensor has a maximum output delay of approximately 20 seconds. Case 1 2 3 4 A/F Sensor (Sensor 1) Output Voltage HO2 Sensor (Sensor 2) Output Voltage Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage More than 3.35 V Less than 3.0 V Output Voltage More than 0.5 V Less than 0.4 V Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage Almost no reaction Output Voltage More than 0.5 V Less than 0.4 V Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage More than 3.35 V Less than 3.0 V Output Voltage Almost no reaction Injection volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage Almost no reaction Output Voltage Almost no reaction Main Suspected Trouble Areas - • • • A/F sensor A/F sensor heater A/F sensor circuit • • • HO2 sensor HO2 sensor heater HO2 sensor circuit • • • Injector Fuel pressure Gas leakage from exhaust system (Air-fuel ratio extremely lean or rich) Following the A/F CONTROL procedure enables technicians to check and graph the output voltages of both the A/F and HO2 sensors. To display the graph, select the following menu items on the tester: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL / USER DATA / AFS B1 S1 and O2S B1 S2; then press the YES button and then the ENTER button followed by the F4 button. ES–333 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the airfuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK HARNESS AND CONNECTOR (A/F SENSOR - ECM) (a) Disconnect the C15 A/F sensor connector. (b) Disconnect the C24 ECM connector. (c) Measure the resistance between the terminals of the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side: A/F Sensor Connector HA1A Tester Connection +B C15 C24 C15-3 (A1A+) - C24-112 (A1A+) Below 1 Ω C15-4 (A1A-) - C24-113 (A1A-) Below 1 Ω Standard resistance (Check for short) A1A- A1A+ Specified Condition ECM Connector Tester Connection Specified Condition C15-3 (A1A+) or C24-112 (A1A+) - Body ground 10 kΩ or higher C15-4 (A1A-) or C24-113 (A1A-) - Body ground 10 kΩ or higher (d) Reconnect the ECM connector. (e) Reconnect the A/F sensor connector. A1A+ A1A- HA1A A127715E08 Reference (System Diagram of Sensor 1): EFI EFI MAIN From Battery ECM A/F Sensor Heater +B A1A- HA1A HA1A A1A+ A1A+ Sensor Duty Control A1A- MREL Ground A140695E01 NG REPAIR OR REPLACE HARNESS OR CONNECTOR ES ES–334 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK 2 REPLACE AIR-FUEL RATIO SENSOR NEXT 3 CHECK WHETHER DTC OUTPUT RECURS (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the tester on. (c) Clear the DTCs (See page ES-38). (d) Start the engine. (e) Allow the engine to idle for 5 minutes or more. (f) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. (g) Read pending DTCs. ES Result Display (DTC Output) Proceed to No output A P2237, P2238, P2239, P2252 or P2253 B B A END REPLACE ECM ES–335 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC Evaporative Emission System Switching Valve Control Circuit High P2420 DTC SUMMARY DTCs Monitoring Item Malfunction Detection Condition Trouble Area • P2420 Vent valve stuck open (vent) Following condition is met during key-off EVAP monitor: • EVAP pressure change when vent valve closed (ON) less than 0.3 kPag (2.25 mmHg-g) • • Canister pump module (Reference orifice, leak detection pump, vent valve) Connector/wire harness (Canister pump module ECM) ECM Detection Timing While ignition switch off Detection Logic 2 trip detection logic ES HINT: The vent valve is built into the canister pump module. DESCRIPTION The description can be found in the EVAP (Evaporative Emission) System (See page ES-346). INSPECTION PROCEDURE Refer to the EVAP System (See page ES-352). MONITOR DESCRIPTION 5 hours* after the ignition switch is turned off, the leak detection pump creates negative pressure (vacuum) in the EVAP system. The ECM monitors for leaks and actuator malfunctions based on the EVAP pressure. HINT: *: If the engine coolant temperature is not below 35°C (95°F) 5 hours after the ignition switch is turned off, the monitor check starts 2 hours later. If it is still not below 35°C (95°F) 7 hours after the ignition switch is turned off, the monitor check starts 2.5 hours later. Sequ ence - Operations Descriptions Duration ECM activation Activated by soak timer 5, 7 or 9.5 hours after ignition switch turned off. A Atmospheric pressure measurement Vent valve turned OFF (vent) and EVAP system pressure measured by ECM in order to register atmospheric pressure. If pressure in EVAP system not between 76 kPa-a and 110 kPa-a (570 mmHg-a and 825 mmHg-a), ECM cancels EVAP system monitor. - 10 seconds B First reference pressure measurement In order to determine reference pressure, leak detection pump creates negative pressure (vacuum) through reference orifice and then ECM checks if leak detection pump and vent valve operate normally. 60 seconds C EVAP system pressure measurement Vent valve turned ON (closed) to shut EVAP system. Negative pressure (vacuum) created in EVAP system, and EVAP system pressure then measured. Write down measured value as it will be used in leak check. If EVAP pressure does not stabilize within 15 minutes, ECM cancels EVAP system monitor. 15 minutes* D Purge VSV monitor Purge VSV opened and then EVAP system pressure measured by ECM. Large increase indicates normality. 10 seconds E Second reference pressure measurement After second reference pressure measurement, leak check performed by comparing first and second reference pressure. If stabilized system pressure higher than second reference pressure, ECM determines that EVAP system leaking. 60 seconds F Final check Atmospheric pressure measured and then monitoring result recorded by ECM. *: If only a small amount of fuel is in the fuel tank, it takes longer for the EVAP pressure to stabilize. - ES–336 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Operation B, E: Operation A: Atmospheric Pressure Measurement Reference Pressure Measurement Purge VSV: OFF Canister Fuel Tank OFF Vent Valve: OFF (vent) OFF (vent) Canister Pump Module ES Canister Pressure Sensor Canister Filter Leak Detection Pump: OFF ON Reference Orifice (0.02 inch) Operation C: EVAP System Pressure Measurement Operation D: Purge VSV Monitor ON (closed) OFF Atmospheric Pressure ON ON (closed) Negative Pressure ON ON A112612E04 The vent valve turns ON (closes) and the EVAP system pressure is then measured by the ECM, using the canister pressure sensor, to conduct an EVAP leak check. If the pressure does not increase when the vent valve is open, the ECM interprets this as the vent valve being stuck open. The ECM illuminates the MIL and sets the DTC. ES–337 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM EVAP Pressure when Vent Valve Stuck OFF: Purge VSV ON: Open ON OFF: Closed ON: Closed ON Vent Valve OFF: Vent Leak Detection Pump ON EVAP Pressure Positive ES Negative OK First Reference Pressure Sequence Time A 10 seconds B 60 seconds Malfunction C Within 15 minutes D 10 seconds E 60 seconds A106067E04 MONITOR STRATEGY Required Sensors/Components Purge VSV and canister pump module Frequency of Operation Once per driving cycle Duration Within 2 minutes (varies with amount of fuel in tank) MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present None EVAP key-off monitor runs when all of the following conditions are met - Atmospheric pressure 70 to 110 kPa-a (525 to 825 mmHg-a) Battery voltage 10.5 V or more Vehicle speed Below 2.5 mph (4 km/h) Ignition switch off Time after key off 5, 7 or 9.5 hours EVAP pressure sensor malfunction (P0450, P0451, P0452 and P0453) Not detected EVAP canister purge valve Not operated by scan tool EVAP canister vent valve Not operated by scan tool EVAP leak detection pump Not operated by scan tool Both of the following conditions are met before key off Conditions 1 and 2 1. Duration that vehicle has been driven 5 minutes or more 2. EVAP purge operation Performed ES–338 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ECT 4.4 to 35°C (40 to 95°F) IAT 4.4 to 35°C (40 to 95°F) 1. Key-off monitor sequence 1 to 8 1. Atmospheric pressure measurement Next sequence runs if following condition is met - Atmospheric pressure change Less than 0.3 kPa-g (2.25 mmHg-g) in 1 second 2. First reference pressure measurement ES Next sequence runs if all of the following conditions are met Conditions 1, 2 and 3 1. EVAP pressure just after reference pressure measurement start -1 kPa-g (-7.5 mmHg-g) or less 2. Reference pressure -4.85 to -1.057 kPa-g (-36.4 to -7.93 mmHg-g) 3. Reference pressure Saturated within 60 seconds 3. Vent valve stuck closed check Next sequence runs if following condition is met - EVAP pressure change after vent valve is ON 0.3 kPa-g (2.25 mmHg-g) or more 4. Vacuum introduction Next sequence runs if following condition is met - EVAP pressure Saturated within 15 minutes 5. EVAP canister purge valve close stuck check Next sequence runs if following condition is met - EVAP pressure change after purge valve is open 0.3 kPa-g (2.25 mmHg-g) or more 6. Second reference pressure measurement Next sequence runs if all of the following conditions are met Conditions 1, 2, 3 and 4 1. EVAP pressure just after reference pressure measurement start -1 kPa-g (-7.5 mmHg-g) or less 2. Reference pressure -4.85 to -1.057 kPa-g (-36.4 to -7.93 mmHg-g) 3. Reference pressure Saturated within 60 seconds 4. Difference between first reference pressure and second reference pressure Less than 0.5 kPa-g (3.75 mmHg-g) 7. Leak check Next sequence runs if following condition is met - EVAP pressure when vacuum introduction completes Second reference pressure or less 8. Atmospheric pressure measurement EVAP monitor complete if following condition is met - Atmospheric pressure difference between sequence 1 and 8 Within 0.3 kPa-g (2.25 mmHg-g) TYPICAL MALFUNCTION THRESHOLDS "Saturated" indicates that the EVAP pressure change is less than 0.286 kPa-g (2.14 mmHg-g) in 60 seconds. EVAP pressure change after EVAP canister vent valve ON Less than 0.3 kPa-g (2.25 mmHg-g) MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-20). ES–339 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC ECM / PCM Internal Engine Off Timer Performance P2610 DTC SUMMARY DTC P2610 Monitoring Item Malfunction Detection Condition Soak timer (built into ECM) ECM internal malfunction Detection Timing Trouble Area Engine running ECM Detection Logic 2 trip detection logic DESCRIPTION To ensure the accuracy of the EVAP (Evaporative Emission) monitor values, the soak timer, which is built into the ECM, measures 5 hours (+-15 minutes) from when the ignition switch is turned off, before the monitor is run. This allows the fuel to cool down, which stabilizes the EVAP pressure. When 5 hours have elapsed, the ECM turns on. ECM IGN IGSW Ignition Switch Soak Timer IC ST/AM2 EFI MAIN EFI MAIN EFI No. 2 +B MAIN MREL Battery Power Source IC Main Relay Control IC A135035E01 MONITOR DESCRIPTION 5 hours after the ignition switch is turned off, the soak timer activates the ECM to begin the EVAP system monitor. While the engine is running, the ECM monitors the synchronization of the soak timer and the CPU clock. If these two are not synchronized, the ECM interprets this as a malfunction, illuminates the MIL and sets the DTC (2 trip detection logic). MONITOR STRATEGY Required Sensors/Components ECM ES ES–340 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Frequency of Operation Once per driving cycle Duration 10 minutes MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS All: Monitor runs whenever following DTC are not present None Case 1: Engine ES Running Battery voltage 8 V or more Ignition switch ON Starter OFF Case 2: Internal engine OFF timer (elapsed time from engine stop) 10 to 300 minutes Battery voltage 8 V or more Ignition switch ON Starter OFF Case 3: Internal engine OFF timer (elapsed time from engine stop) 310 minutes or more Battery voltage 8 V or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Case 1: Soak timer measurement when ECM CPU clock counts 10 minutes Less than 7 minutes, or more than 13 minutes Case 2: ECM had the started record by internal engine OFF timer YES Case 3: ECM had the starter record by internal engine OFF timer NO INSPECTION PROCEDURE HINT: • DTC P2610 is set if an internal ECM problem is detected. Diagnostic procedures are not required. ECM replacement is necessary. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 REPLACE ECM (a) Replace the ECM (See page ES-432). NEXT 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2 ES–341 CHECK WHETHER DTC OUTPUT RECURS (a) (b) (c) (d) (e) (f) Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Turn the tester on. Clear the DTCs (See page ES-38). Start the engine and wait for 10 minutes or more. On the tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. (g) If no pending DTC is displayed, the repair has been successfully completed. NEXT END ES ES–342 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2A00 A/F Sensor Circuit Slow Response (Bank 1 Sensor 1) HINT: Sensor 1 refers to the sensor mounted in front of the Three-Way Catalytic Converter (TWC) and located near the engine assembly. DESCRIPTION Refer to DTC P2195 (See page ES-308). ES DTC No. DTC Detection Condition P2A00 Calculated value of air-fuel ratio (A/F) sensor response rate deterioration level less than threshold (2 trip detection logic) Trouble Area • • • Open or short in A/F sensor circuit A/F sensor ECM MONITOR DESCRIPTION After the engine is warmed up, the ECM performs air-fuel ratio feedback control to maintain the air-fuel ratio at the stoichiometric level. In addition, active A/F control is performed for approximately 10 seconds after the preconditions are met in order to measure the A/F sensor response rate. During active A/F control, the ECM forcibly increases and decreases the injection volume by a certain amount, based on the stoichiometric air-fuel ratio learned during normal air-fuel ratio control, and measures the A/F sensor response rate. The ECM receives a signal from the A/F sensor while performing active A/F control and uses it to calculate the A/F sensor response rate deterioration level. If the A/F sensor response rate deterioration level is less than the threshold, the ECM interprets this as a malfunction and sets the DTC. Air-Fuel Ratio Sensor Output: Approximately 10 Seconds OFF ON Active A/F Control Normal Malfunction A/F Sensor Output Increase Fuel Injection Volume Decrease A115363E03 CONFIRMATION DRIVING PATTERN HINT: Performing this confirmation pattern will activate the A/F sensor response monitor. 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–343 Vehicle Speed Between 25 and 75 mph (40 and 120 km/h) Idling (B) (A) ES Ignition Switch OFF Warming up 3 minutes Time A115372E54 1. Connect the intelligent tester to the DLC3. Tester Display G034992E01 2. 3. 4. 5. Turn the ignition switch to the ON position. Turn the tester on. Clear the DTCs (if set) (See page ES-38). Select the following menu items: DIAGNOSIS / ENHANCED OBD II / MONITOR INFO / MONITOR RESULT. 6. Check that RES RATE B1S1 is INCOMP. 7. Start the engine and warm it up. (Proceed "A") 8. Drive the vehicle at a constant speed of between 25 mph and 75 mph (40 km/h and 120 km/h) for 3 minutes. (Proceed "B") 9. Check the monitor result values on the intelligent tester by selecting the following menu items: DIAGNOSIS / ENHANCED OBD II / MONITOR INFO / TEST RESULT. 10.If the values indicated on the tester do not change, perform READINESS MONITOR DRIVE PATTERN for the A/F sensor and the heated oxygen sensor (See page ES-23). HINT: Completion of all A/F sensor monitors is required to change the value in TEST RESULT. 11.Note the value of the Monitor Result. 12.Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. 13.Check if any DTCs (any pending DTCs) are set. ES–344 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR STRATEGY Related DTCs P2A00: Air-Fuel Ratio (A/F) sensor slow response Required Sensors/Components (Main) A/F sensor Required Sensors/Components (Related) Vehicle speed sensor, Crankshaft position sensor Frequency of Operation Once per driving cycle Duration 10 to 15 seconds MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present P0031, P0032 (A/F Sensor heater - Sensor 1) P0100 - P0103 (MAF meter) P0110 - P0113 (IAT sensor) P0115 - P0118 (ECT sensor) P0120 - P0223, P2135 (TP sensor) P0125 (Insufficient ECT for Closed Loop) P0171, P0172 (Fuel system) P0300 - P0304 (Misfire) P0335 (CKP sensor) P0340 (CMP sensor) P00441 - P0456, P2401 - P2420 (EVAP system) P0500 (VSS) P2196 (A/F Sensor - rationality) Active A/F control Performing Active A/F control performed when the following conditions are met - Engine coolant temperature 75°C (167°F) or more ES Battery voltage 11 V or more Idle OFF Engine RPM Less than 4,000 rpm A/F sensor status Activated Fuel-cut OFF Engine load 10 to 70 % Shift position 2 or more Catalyst monitor Not yet Intake air amount 4 to 16 g/sec. TYPICAL MALFUNCTION THRESHOLDS Response rate deterioration level Less than 0.12 V MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-20). ES–345 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM EFI ECM C15 A/F Sensor (Bank 1 Sensor 1) +B 109 C24 HA1A HA1A 2 1 (Shielded) A1A- 112 C24 A1A+ A1A+ 4 3 ES 113 C24 A1A- EFI MAIN EFI C22 HO2 Sensor No. 3 (Bank 1 Sensor 2) +B 47 C24 HT1B HT1B 2 1 (Shielded) FL MAIN E2 4 OX1B 3 64 C24 OX1B 87 C24 EX1B Battery 44 A24 MREL A134994E01 INSPECTION PROCEDURE HINT: Intelligent tester only: Malfunctioning areas can be identified by performing the A/F CONTROL function provided in the ACTIVE TEST. The A/F CONTROL function can help to determine whether the Air-Fuel Ratio (A/F) sensor, Heated Oxygen (HO2) sensor and other potential trouble areas are malfunctioning. The following instructions describe how to conduct the A/F CONTROL operation using the intelligent tester. 1. Connect the intelligent tester to the DLC3. 2. Start the engine and turn the tester on. 3. Warm up the engine at an engine speed of 2,500 rpm for approximately 90 seconds. 4. On the tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/ F CONTROL. ES–346 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 5. Perform the A/F CONTROL operation with the engine idling (press the RIGHT or LEFT button to change the fuel injection volume). 6. Monitor the voltage outputs of the A/F and HO2 sensors (AFS B1 S1 and O2S B1 S2) displayed on the tester. HINT: • The A/F CONTROL operation lowers the fuel injection volume by 12.5% or increases the injection volume by 25 %. • The sensors react in accordance with increases and decreases in the fuel injection volume. Standard Tester Display (Sensor) Injection Volumes Status Voltages +25% Rich Less than 3.0 -12.5% Lean More than 3.35 +25% Rich More than 0.5 -12.5% Lean Less than 0.4 AFS B1 S1 (A/F) ES O2S B1 S2 (HO2) NOTICE: The A/F sensor has an output delay of a few seconds and the HO2 sensor has a maximum output delay of approximately 20 seconds. Case A/F Sensor (Sensor 1) Output Voltage HO2 Sensor (Sensor 2) Output Voltage Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage More than 3.35 V Less than 3.0 V Output Voltage More than 0.5 V Less than 0.4 V Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage Almost no reaction Output Voltage More than 0.5 V Less than 0.4 V Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage More than 3.35 V Less than 3.0 V Output Voltage Almost no reaction Injection volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage Almost no reaction Output voltage Almost no reaction Main Suspected Trouble Areas - 1 2 3 4 • • • A/F sensor A/F sensor heater A/F sensor circuit • • • HO2 sensor HO2 sensor heater HO2 sensor circuit • • • Injector Fuel pressure Gas leakage from exhaust system (Air-fuel ratio extremely lean or rich) Following the A/F CONTROL procedure enables technicians to check and graph the voltage outputs of both the A/F and HO2 sensors. To display the graph, select the following menu items on the tester: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL / USER DATA / AFS B1 S1 and O2S B1 S2; and press the YES button and then the ENTER button followed by the F4 button. HINT: • DTC P2A00 may be set when the air-fuel ratio is stuck rich or lean. ES–347 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM • A low A/F sensor voltage could be caused by a rich air-fuel mixture. Check for conditions that would cause the engine to run rich. • A high A/F sensor voltage could be caused by a lean air-fuel mixture. Check for conditions that would cause the engine to run lean. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P2A00) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Turn the tester ON. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read the DTCs. Result Display (DTC Output) Proceed to P2A00 A P2A00 and other DTCs B If any DTCs relating to the A/F sensor (DTCs for the A/F sensor heater or A/F sensor admittance) are output, troubleshoot those DTCs first. B GO TO DTC CHART A 2 INSPECT AIR-FUEL RATIO SENSOR (HEATER RESISTANCE) (See page ES-84) NG REPLACE AIR-FUEL RATIO SENSOR OK 3 CHECK HARNESS AND CONNECTOR (A/F SENSOR - ECM) (See page ES-325) NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 4 PERFORM CONFIRMATION DRIVING PATTERN NEXT 5 CHECK WHETHER DTC OUTPUT RECURS (DTC P2A00) (a) Connect the intelligent tester to the DLC3. ES ES–348 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (b) Turn the ignition switch to the ON position and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. (d) Read pending DTCs. Result Display (DTC Output) Proceed to P2A00 A No output B B ES CHECK FOR INTERMITTENT PROBLEMS A 6 REPLACE AIR-FUEL RATIO SENSOR NEXT 7 PERFORM CONFIRMATION DRIVING PATTERN NEXT 8 CHECK WHETHER DTC OUTPUT RECURS (DTC P2A00) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. (d) Read pending DTCs. Result Display (DTC Output) Proceed to No output A P2A00 B B A END REPLACE ECM 2AZ-FE ENGINE CONTROL SYSTEM – ACCELERATOR PEDAL ROD ES–435 ACCELERATOR PEDAL ROD 2AZ-FE ENGINE CONTROL SYSTEM ENGINE COMPONENTS ES 5.4 (55, 48 in.*lbf) ACCELERATOR PEDAL ROD N*m (kgf*cm, ft.*lbf) : Specified torque A135645E01 ES–436 2AZ-FE ENGINE CONTROL SYSTEM – ACCELERATOR PEDAL ROD ON-VEHICLE INSPECTION Intelligent Tester 1. ES DLC3 CAN VIM CHECK ACCELERATOR PEDAL ROD (a) Measure the voltage. (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch to the ON position. (3) Turn the intelligent tester ON. (4) Select the menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / ACCEL POS #1, ACCEL POS #2. (5) Operate the accelerator pedal, and then check that the ACCEL POS #1 and ACCEL POS #2 values are within the specifications. Standard voltage (ACCEL POS #1) Accelerator Pedal Condition C131977E05 Specified Condition Released 0.5 to 1.1 V Depressed 2.5 to 4.5 V Standard voltage (ACCEL POS #2) Accelerator Pedal Condition Specified Condition Released 1.2 to 2.0 V Depressed 3.4 to 5.0 V If the result is not as specified, check the accelerator pedal rod, wire harness or ECM. REMOVAL 1. A135676 REMOVE ACCELERATOR PEDAL ROD (a) Disconnect the accelerator pedal position sensor connector. (b) Remove the 2 bolts and accelerator pedal rod. 2AZ-FE ENGINE CONTROL SYSTEM – ACCELERATOR PEDAL ROD ES–437 INSTALLATION 1. INSTALL ACCELERATOR PEDAL ROD NOTICE: • Avoid physical shock to the accelerator pedal assembly. • Do not disassemble the accelerator pedal assembly. (a) Install the accelerator pedal rod with the 2 bolts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) (b) Connect the accelerator pedal position sensor connector. ES A135676 2AZ-FE ENGINE CONTROL SYSTEM – ECM ES–433 (c) Remove the 4 screws and ECM bracket. A135117 INSTALLATION 1. INSTALL ECM (a) Install the bracket to the ECM with the 4 screws. Torque: 3.0 N*m (30 kgf*cm, 27 in.*lbf) A135117 (b) Install the ECM with the 3 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) A135675 2. CONNECT CONNECTOR (a) Connect the 2 ECM connectors. NOTICE: When connecting the connector, make sure that dirt, water and other foreign matter does not become stuck between the connector and other part. (1) Connect the 2 ECM connectors and lower the 2 levers. NOTICE: Make sure that the 2 levers are securely lowered. 3. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (See page EM-120) 4. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See page ES-419) 5. INSTALL ENGINE COVER SUB-ASSEMBLY (See page EM-121) A126208 ES ES–434 2AZ-FE ENGINE CONTROL SYSTEM – ECM 6. ES RESET MEMORY (a) When replacing the ECM, perform the RESET MEMORY procedure (A/T initialization) (See page AX-16). ES–431 2AZ-FE ENGINE CONTROL SYSTEM – ECM ECM 2AZ-FE ENGINE CONTROL SYSTEM ENGINE COMPONENTS PURGE VSV VACUUM HOSE NO. 2 VENTILATION HOSE AIR CLEANER CAP SUB-ASSEMBLY ES AIR CLEANER CASE SUB-ASSEMBLY 9.0 (92, 80 in.*lbf) 5.0 (51, 44 in.*lbf) PURGE VSV VACUUM HOSE NO. 1 ENGINE COVER SUB-ASSEMBLY 6.5 (66, 57in.*lbf) AIR CLEANER BRACKET 8.0 (82, 71 in.*lbf) 3.0 (30, 27 in.*lbf) 3.0 (30, 27 in.*lbf) ECM N*m (kgf*cm, ft.*lbf) : Specified torque A135643E01 ES–432 2AZ-FE ENGINE CONTROL SYSTEM – ECM REMOVAL ES 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (See page EM-94) 3. REMOVE AIR CLEANER INLET ASSEMBLY (See page EM-94) 4. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-416) 5. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (See page EM-95) 6. REMOVE AIR CLEANER BRACKET (a) Remove the 2 bolts and air cleaner bracket. 7. DISCONNECT ECM CONNECTOR (a) Disconnect the 2 ECM connectors. (1) Raise the levers while pushing the locks on the levers, and disconnect the 2 ECM connectors. NOTICE: After disconnecting the connector, make sure that dirt, water and other foreign matter does not contact the connecting part of the connector. 8. REMOVE ECM (a) Remove the 3 bolts of the ECM with bracket. (b) Remove the ECM with bracket. A135673 A135674 A135675 ES–430 2AZ-FE ENGINE CONTROL SYSTEM – AIR FUEL RATIO SENSOR RELAY AIR FUEL RATIO SENSOR RELAY Engine Room R/B Unit D: INSPECTION 1. 1A 1E INSPECT AIR FUEL RATIO SENSOR RELAY (a) Using an ohmmeter, measure the resistance according to the value(s) in the table below. Standard resistance Tester connection 1E-7 - 1E-10 4 3 10 7 ES A137364E03 Specified Condition Below 1 Ω 1A-3 - 1A-4 10 kΩ or higher 1A-3 - 1A-4 Below 1 Ω (Battery voltage applied between terminals 1E-7 and 1E-10) 2AZ-FE ENGINE CONTROL SYSTEM – CIRCUIT OPENING RELAY ES–429 CIRCUIT OPENING RELAY Engine Room R/B Unit D: INSPECTION 1. 1E INSPECT CIRCUIT OPENING RELAY (a) Using an ohmmeter, measure the resistance according to the value(s) in the table below. Standard resistance Tester connection 1E-8 - 1E-12 13 12 8 7 A137364E02 Specified Condition Below 1 Ω 1E-7 - 1E-13 10 kΩ or higher 1E-7 - 1E-13 Below 1 Ω (Battery voltage applied between terminals 1E-8 and 1E-12) ES ES–428 2AZ-FE ENGINE CONTROL SYSTEM – EFI RELAY EFI RELAY Engine Room R/B Unit D: INSPECTION 1. 1E INSPECT EFI RELAY (a) Using an ohmmeter, measure the resistance according to the value(s) in the table below. Standard resistance Tester connection 12 10 9 7 ES A137364E01 Specified Condition 1E-9 - 1E-10 Below 1 Ω 1E-7 - 1E-12 10 kΩ or higher 1E-7 - 1E-12 Below 1 Ω (Battery voltage applied between terminals 1E-9 and 1E-10) ES–424 2AZ-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR REMOVAL ES 1. DISCHARGE FUEL SYSTEM PRESSURE (See page FU-12) 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 3. REMOVE NO. 1 ENGINE COVER (See page EM-94) 4. DRAIN COOLANT (See page CO-5) 5. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH (See page WW-9) 6. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH (See page WW-9) 7. REMOVE FRONT FENDER TO COWL SIDE SEAL LH (See page WW-9) 8. REMOVE FRONT FENDER TO COWL SIDE SEAL RH (See page WW-9) 9. REMOVE COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See page WW-10) 10. REMOVE WINDSHIELD WIPER MOTOR AND LINK (See page WW-10) 11. REMOVE COWL TOP PANEL OUTER SUBASSEMBLY (a) Remove the 4 bolts, 4 nuts and cowl top panel outer sub-assembly. 12. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-502) 13. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (See page EM-95) A136272 14. REMOVE THROTTLE BODY (See page ES-417) 15. DISCONNECT FUEL TUBE (See page FU-12) 16. REMOVE FUEL DELIVERY PIPE WITH INJECTOR (See page FU-13) 17. REMOVE INTAKE MANIFOLD (a) Disconnect the union to check valve hose from the brake booster. (b) Disconnect the camshaft timing oil control valve connector. (c) Remove the wire harness clamp. (d) Remove the union to check valve hose from the vacuum hose clamp. (e) Remove the 5 bolts, 2 nuts and intake manifold. A135672 2AZ-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR (f) ES–425 Remove the gasket from the intake manifold. A090130E01 18. REMOVE KNOCK SENSOR (a) Disconnect the knock sensor connector. (b) Remove the nut and knock sensor. A128922 INSPECTION 1. KNOCK CONTROL SENSOR (a) Using an ohmmeter, measure the resistance between the terminals. Standard resistance: 120 to 280 kΩ at 20°C (68°F) If the resistance is not specified, replace the sensor. A065174 INSTALLATION Upper side 1. INSTALL KNOCK SENSOR (a) Install the knock sensor with the nut. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) NOTICE: Make sure that the knock sensor is in the correct position. (b) Connect the knock sensor connector. 2. INSTALL INTAKE MANIFOLD (a) Install a new gasket into the intake manifold. 10q 10q A128924E01 New Gasket A090130E02 ES ES–426 2AZ-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR (b) Install the intake manifold with the 5 bolts and 2 nuts. Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) (c) Fit the union to check valve hose into the vacuum hose clamp. (d) Install the wire harness clamp. (e) Connect the camshaft timing oil control valve connector. (f) Connect the union to check valve hose to the brake booster. A135672 ES 3. INSTALL FUEL DELIVERY PIPE WITH INJECTOR (See page FU-15) 4. INSTALL FUEL TUBE (See page FU-16) 5. INSTALL THROTTLE BODY (See page ES-418) 6. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (See page EM-120) 7. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See page ES-419) 8. INSTALL AIR CLEANER INLET ASSEMBLY (See page EM-120) 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page EM-120) 10. ADD ENGINE COOLANT (See page CO-5) 11. CHECK FOR ENGINE COOLANT LEAKS (See page CO-1) 12. CHECK FOR FUEL LEAKS (See page FU-9) 13. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (See page EM-121) 14. INSTALL COWL TOP PANEL OUTER SUBASSEMBLY (a) Install the outer cowl top panel sub-assembly with the 4 bolts and 4 nuts. Torque: Bolt 5.0 N*m (51 kgf*cm, 44 in.*lbf) Nut 85 N*m (867 kgf*cm, 44 ft.*lbf) A136272 15. INSTALL WINDSHIELD WIPER MOTOR AND LINK (See page WW-14) 16. INSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See page WW-15) 17. INSTALL FRONT FENDER TO COWL SIDE SEAL RH (See page WW-15) 18. INSTALL FRONT FENDER TO COWL SIDE SEAL LH (See page WW-15) 19. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH (See page WW-15) 2AZ-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR ES–427 20. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH (See page WW-16) ES 2AZ-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR ES–421 KNOCK SENSOR 2AZ-FE ENGINE CONTROL SYSTEM ENGINE COMPONENTS WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH 20 (204, 15) FRONT FENDER TO COWL SIDE SEAL RH ES WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 7.5 (77, 66 in.*lbf) 85 (867, 63) FRONT FENDER TO COWL SIDE SEAL LH 5.0 (51, 44 in.*lbf) WINDSHIELD WIPER MOTOR AND LINK COWL TOP PANEL OUTER SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque A136912E05 ES–422 2AZ-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR AIR CLEANER CAP SUB-ASSEMBLY THROTTLE POSITION SENSOR CONNECTOR NO. 2 VENTILATION HOSE FUEL PIPE SUPPORT x4 PURGE LINE HOSE 30 (305, 22) PURGE VSV VACUUM HOSE THROTTLE BODY GASKET FUEL TUBE NO. 1 THROTTLE BODY HOSE 9.0 (92, 80 in.*lbf) ES WATER BY-PASS HOSE NO. 2 WATER BY-PASS HOSE 5.0 (51, 44 in.*lbf) PURGE VSV VACUUM HOSE NO. 1 ENGINE COVER SUB-ASSEMBLY AIR CLEANER CASE SUB-ASSEMBLY AIR CLEANER INLET ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A135092E01 ES–423 2AZ-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR 30 (306, 22) x2 x5 ES INTAKE MANIFOLD GASKET 20 (204, 15) KNOCK SENSOR 20 (204, 15) FUEL DELIVERY PIPE WITH INJECTOR 20 (204, 15) FUEL TUBE SPACER INSULATOR N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A135640E01 2AZ-FE ENGINE CONTROL SYSTEM – THROTTLE BODY ES–417 REMOVAL (*1) 1. DRAIN ENGINE COOLANT (See page CO-5) 2. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (See page EM-94) 3. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (a) Disconnect the mass air flow meter connector (*1). (b) Disconnect the purge VSV connector (*2). (c) Disconnect the 2 purge VSV vacuum hoses (*3). (d) Disconnect the purge line hose from the clamp (*4). (*2) (*3) (*3) (*4) ES A135666E01 (e) Disconnect the No. 2 ventilation hose from the air cleaner hose. A135667E01 (f) Lock the No. 1 air cleaner hose clamp, and then disconnect the No. 1 air cleaner hose from the throttle body. A135668 (g) Remove the 2 bolts and air cleaner cap. (h) Remove the air cleaner filter element from the air cleaner case. 4. A135669 REMOVE AIR CLEANER CASE SUB-ASSEMBLY (See page EM-95) ES–418 2AZ-FE ENGINE CONTROL SYSTEM – THROTTLE BODY 5. REMOVE THROTTLE BODY (a) Disconnect the throttle position sensor connector and wire harness clamp. A128919E01 (b) Remove the 4 bolts, and then remove the fuel pipe support and throttle body. ES A128920E01 (c) Disconnect the purge line hose from the throttle body. (d) Disconnect the water by-pass hose from the throttle body. (e) Disconnect the No. 2 water by-pass hose from the throttle body. (f) Disconnect the No. 1 throttle body hose from the throttle body. A128921E01 (g) Remove the gasket from the intake manifold. A124566 INSPECTION 1. A090372 INSPECT THROTTLE BODY ASSEMBLY (a) Using an ohmmeter, measure the resistance between the terminals. Standard resistance Symbols (terminal No.) Resistance Temperature M+ (2) - M- (1) 0.3 to 100 Ω 20°C (68°F) If the result is not as specified, replace the throttle body assembly. 2AZ-FE ENGINE CONTROL SYSTEM – THROTTLE BODY New Gasket ES–419 INSTALLATION 1. INSTALL THROTTLE BODY (a) Install a new gasket onto the intake manifold. A124566E01 (b) Connect the purge line hose to the throttle body. (c) Connect the water by-pass hose to the throttle body. (d) Connect the No. 2 water by-pass hose to the throttle body. (e) Connect the No. 1 throttle body hose to the throttle body. A128921E01 (f) Install the throttle body and fuel pipe clamp with the 4 bolts. Torque: 30 N*m (305 kgf*cm, 22 ft.*lbf) (g) Connect the fuel tube into the clamp. A128920E01 (h) Connect the throttle position sensor connector. (i) Connect the wire harness clamp. A128919E01 2. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (See page EM-120) 3. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (a) Install the air cleaner filter element onto the air cleaner case. ES ES–420 2AZ-FE ENGINE CONTROL SYSTEM – THROTTLE BODY (b) Insert the hinges. Install the air cleaner cap subassembly with the 2 bolts. ES A135670 (c) Align the matchmarks of the No. 1 air cleaner hose and throttle body, and then connect the air cleaner hose No. 1 to the throttle body and unfasten the No. 1 air cleaner hose clamp. NOTICE: Make sure that the hose clamp is at the correct angle. Unfasten (A) Side View : (A) 90q A135671E01 (d) Connect the No. 2 ventilation hose to the air cleaner hose. A135667E01 (e) (f) (g) (h) (*4) (*3) (*2) (*2) 4. INSTALL AIR CLEANER INLET ASSEMBLY (See page EM-120) 5. ADD ENGINE COOLANT (See page CO-5) (*1) A135666E02 Connect the purge line hose to the clamp (*1). Connect the 2 purge VSV vacuum hoses (*2). Connect the purge VSV connector (*3). Connect the mass air flow meter connector (*4). 2AZ-FE ENGINE CONTROL SYSTEM – THROTTLE BODY ES–421 6. CHECK FOR ENGINE COOLANT LEAKS (See page CO-1) 7. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (See page EM-121) ES 2AZ-FE ENGINE CONTROL SYSTEM – THROTTLE BODY ES–415 THROTTLE BODY 2AZ-FE ENGINE CONTROL SYSTEM ENGINE COMPONENTS AIR CLEANER CAP SUB-ASSEMBLY THROTTLE POSITION SENSOR COONECTOR NO. 2 VENTILATION HOSE FUEL PIPE SUPPORT x4 PURGE LINE HOSE 30 (305, 22) PURGE VSV VACUUM HOSE THROTTLE BODY GASKET ES FUEL TUBE NO. 1 THROTTLE BODY HOSE 9.0 (92, 80 in.*lbf) WATER BY-PASS HOSE NO. 2 WATER BY-PASS HOSE NO. 1 ENGINE COVER SUB-ASSEMBLY PURGE VSV VACUUM HOSE N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A135636E01 ES–416 2AZ-FE ENGINE CONTROL SYSTEM – THROTTLE BODY ON-VEHICLE INSPECTION 1. Intelligent Tester ES DLC3 CAN VIM G041046E29 INSPECT THROTTLE BODY ASSEMBLY (a) Listen to the throttle control motor operating sounds. (1) Turn the ignition switch to the ON position. (2) When pressing the accelerator pedal position sensor lever, listen to the running motor. Make sure that no friction noise comes from the motor. If friction noise exists, replace the throttle body assembly. (b) Inspect the throttle position sensor. (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch to the ON position. (3) Check that the MIL turns off. (4) Under CURRENT DATA, the throttle valve opening percentage (THROTTLE POS) should be within the standard range below. Standard throttle valve opening percentage: 60% or more If the percentage is less than 60%, replace the throttle body assembly. NOTICE: When checking the throttle valve opening percentage, the transmission should be in neutral. ES–414 2AZ-FE ENGINE CONTROL SYSTEM – ENGINE COOLANT TEMPERATURE SENSOR INSPECTION 1. ES INSPECT ENGINE COOLANT TEMPERATURE SENSOR (a) Using an ohmmeter, measure the resistance between the terminals. Standard resistance Condition Specified Condition 20°C (68°F) 2.32 to 2.59 kΩ 80°C (176°F) 0.310 to 0.326 kΩ If the result is not as specified, replace the sensor. NOTICE: In case of checking the water temperature sensor in the water, do not allow water to go into the terminals. After checking, dry the sensor. RESISTANCE kΩ (-4) (32) (68)(104)(140)(176)(212) TEMPERATURE °C (°F) A114776E01 INSTALLATION 1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR (a) Install a new gasket onto the engine coolant temperature sensor. (b) Using SST, install the engine coolant temperature sensor. SST 09817-33190 Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) (c) Connect the engine coolant temperature sensor connector. 2. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (See page EM-120) 3. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See page ES-419) 4. INSTALL AIR CLEANER INLET ASSEMBLY (See page EM-120) 5. ADD ENGINE COOLANT (See page CO-5) 6. CHECK FOR ENGINE COOLANT LEAKS (See page CO-1) 7. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (See page EM-121) New Gasket SST A095412E02 ES–412 2AZ-FE ENGINE CONTROL SYSTEM – ENGINE COOLANT TEMPERATURE SENSOR ENGINE COOLANT TEMPERATURE SENSOR 2AZ-FE ENGINE CONTROL SYSTEM ENGINE COMPONENTS AIR CLEANER CAP SUB-ASSEMBLY 9.0 (92, 80 in.*lbf) NO. 1 ENGINE COVER SUB-ASSEMBLY ES AIR CLEANER INLET ASSEMBLY GASKET 20 (204, 15) 5.0 (51, 44 in.*lbf) ENGINE COOLANT TEMPERATURE SENSOR 5.0 (51, 44 in.*lbf) AIR CLEANER CASE SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque A135634E01 2AZ-FE ENGINE CONTROL SYSTEM – ENGINE COOLANT TEMPERATURE SENSOR ES–413 REMOVAL Gasket SST A095412E01 1. DRAIN ENGINE COOLANT (See page CO-5) 2. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (See page EM-94) 3. REMOVE AIR CLEANER INLET ASSEMBLY (See page EM-94) 4. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-416) 5. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (See page EM-95) 6. REMOVE ENGINE COOLANT TEMPERATURE SENSOR (a) Disconnect the engine coolant temperature sensor connector. (b) Using SST, remove the engine coolant temperature sensor and gasket. SST 09817-33190 ES ES–410 2AZ-FE ENGINE CONTROL SYSTEM – CRANKSHAFT POSITION SENSOR CRANKSHAFT POSITION SENSOR 2AZ-FE ENGINE CONTROL SYSTEM ENGINE COMPONENTS V-RIBBED BELT 9.8 (100, 87 in.*lbf) 8.4 (86, 74 in.*lbf) GENERATOR ASSEMBLY ES 52 (530, 38) 21 (215, 16) 9.0 (92, 80 in.*lbf) CRANKSHAFT POSITION SENSOR FRONT FENDER APRON SEAL RH ENGINE UNDER COVER RH N*m (kgf*cm, ft.*lbf) : Specified torque A138521E01 2AZ-FE ENGINE CONTROL SYSTEM – CRANKSHAFT POSITION SENSOR ES–411 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE FRONT WHEEL RH 3. REMOVE FRONT FENDER APRON RH 4. REMOVE V-RIBBED BELT (See page EM-6) 5. REMOVE GENERATOR ASSEMBLY (See page CH-11) 6. REMOVE CRANKSHAFT POSITION SENSOR (a) Disconnect the crankshaft position sensor connector. (b) Remove the connector clamp and wire harness clamp. (c) Remove the wire harness clamp bracket from the wire harness. (d) Remove the bolt, and then remove the crankshaft position sensor. A097797 INSPECTION 1. INSPECT CRANKSHAFT POSITION SENSOR (a) Using an ohmmeter, measure the resistance between the terminals. Standard resistance Temperature Specified Condition Cold 985 to 1,600 Ω Hot 1,265 to 1,890 Ω A108285 NOTICE: "Cold" and "Hot" mean the temperature of the coils themselves. "Cold" is from -10 to 50°C (14 to 122°F) and "Hot" is from 50 to 100°C (122 to 212°F). If the resistance is not as specified, replace the sensor. INSTALLATION 1. O-Ring A095436E01 INSTALL CRANKSHAFT POSITION SENSOR (a) Apply a light coat of engine oil to the O-ring on the crankshaft position sensor. ES ES–412 2AZ-FE ENGINE CONTROL SYSTEM – CRANKSHAFT POSITION SENSOR (b) Install the crankshaft position sensor with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) (c) Connect the crankshaft position sensor connector. Wire Harness Clamp Bracket Rib ES A116845E01 2. INSTALL GENERATOR ASSEMBLY (See page CH-19) 3. INSTALL V-RIBBED BELT (See page EM-7) 4. INSTALL FRONT FENDER APRON SEAL RH 5. INSTALL FRONT WHEEL RH 6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL ES–408 2AZ-FE ENGINE CONTROL SYSTEM – CAMSHAFT POSITION SENSOR CAMSHAFT POSITION SENSOR 2AZ-FE ENGINE CONTROL SYSTEM ENGINE COMPONENTS AIR CLEANER CAP SUB-ASSEMBLY 9.0 (92, 80 in.*lbf) ES NO. 1 ENGINE COVER SUB-ASSEMBLY 9.0 (92, 80 in.*lbf) CAMSHAFT POSITION SENSOR N*m (kgf*cm, ft.*lbf) : Specified torque A135630E01 2AZ-FE ENGINE CONTROL SYSTEM – CAMSHAFT POSITION SENSOR ES–409 REMOVAL 1. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (See page EM-94) 2. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-416) 3. REMOVE CAMSHAFT POSITION SENSOR (a) Disconnect the camshaft position sensor connector. (b) Remove the bolt and camshaft position sensor. ES A124557 INSPECTION 1. INSPECT CAMSHAFT POSITION SENSOR (a) Measure the resistance of the sensor. Standard resistance Tester Connection Specified Condition 1 (G+) - 2 (G-) 835 to 1,400 Ω at Cold 1 (G+) - 2 (G-) 1,060 to 1,645 Ω at Hot NOTICE: "Cold" and "Hot" mean the temperature of the coils themselves. "Cold" is from -10 to 50°C (14 to 122 °F) and "Hot" is from 50 to 100°C (122 to 212°F). If the result is not as specified, replace the camshaft position sensor. A095265E01 INSTALLATION 1. O-Ring INSTALL CAMSHAFT POSITION SENSOR (a) Apply a light coat of engine oil to the O-ring of the sensor. NOTICE: Make sure that the O-ring is not cracked or jammed when installing it. A095434E01 (b) Install the camshaft position sensor with the bolt. Torque: 9.0 N*m (90 kgf*cm, 80 in.*lbf) (c) Connect the camshaft position sensor connector. A124557 2. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See page ES-416) 3. CHECK FOR ENGINE OIL LEAKS 4. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (See page EM-121) ES–406 2AZ-FE ENGINE CONTROL SYSTEM – CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY REMOVAL ES 1. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (See page EM-94) 2. REMOVE VACUUM HOSE CLAMP (a) Remove the bolt and disconnect the vacuum hose clamp. 3. REMOVE CLIP NUT (a) Remove the clip nut. 4. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Disconnect the camshaft timing oil control valve assembly connector. (b) Remove the bolt and camshaft timing oil control valve assembly. A135664 A135665E01 A124556 2AZ-FE ENGINE CONTROL SYSTEM – CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY ES–407 INSPECTION 1. 1 INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Resistance inspection. (1) Using an ohmmeter, measure the resistance between the terminals. Standard resistance: 6.9 to 7.9 Ω at 20°C (68°F) If necessary, replace the camshaft timing oil control valve assembly. (b) Movement inspection. (1) Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2, and check the movement of the valve. NOTICE: Confirm that the valve moves freely and does not stick in any position. If necessary, replace the camshaft timing oil control valve assembly. HINT: Accumulation of foreign objects causes subtle pressure leaks. The subtle pressure leaks will cause the camshaft to advance, and this will cause a DTC to be set. 2 Valve B001689E02 INSTALLATION New O-Ring 1. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Apply a light coat of engine oil to an O-ring of the camshaft timing oil control valve assembly sensor. A093611E01 (b) Install the camshaft timing oil control valve assembly with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) (c) Connect the camshaft timing oil control valve assembly connector. A124556 ES ES–408 2AZ-FE ENGINE CONTROL SYSTEM – CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 2. INSTALL CLIP NUT (a) Install the clip nut. 3. INSTALL VACUUM HOSE CLAMP (a) Install the vacuum hose clamp with the bolt. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 4. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (See page EM-94) A135665E01 ES A135664 ES–404 2AZ-FE ENGINE CONTROL SYSTEM – CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 2AZ-FE ENGINE CONTROL SYSTEM ENGINE COMPONENTS 9.0 (92, 80 in.*lbf) NO. 1 ENGINE COVER SUB-ASSEMBLY ES CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 9.0 (92, 80 in.*lbf) 5.0 (51, 44 in.*lbf) CLIP NUT VACUUM HOSE CLAMP N*m (kgf*cm, ft.*lbf) : Specified torque A135628E01 2AZ-FE ENGINE CONTROL SYSTEM – CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY ES–405 ON-VEHICLE INSPECTION Intelligent Tester DLC3 CAN VIM G041046E28 1. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position. (c) Start the engine and warm it up. (d) Select the intelligent tester from the ACTIVE TEST menu. (e) Check the engine speed when the OCV is operated by the intelligent tester. Standard Condition Specified Condition VVT system is OFF (OCV is OFF) Normal engine speed VVT system is ON (OCV is ON) Rough idle or engine stalled ES 2AZ-FE ENGINE CONTROL SYSTEM – MASS AIR FLOW METER ES–401 MASS AIR FLOW METER 2AZ-FE ENGINE CONTROL SYSTEM ENGINE COMPONENTS MASS AIR FLOW METER CONNECTOR ES MASS AIR FLOW METER A135626E01 ES–402 2AZ-FE ENGINE CONTROL SYSTEM – MASS AIR FLOW METER ON-VEHICLE INSPECTION NOTICE: • Perform the MAF meter inspection according to the procedures below. • Only replace the MAF meter when both the LONG FT#1 value and MAF value in the DATA LIST (with the engine stopped) are not within the normal operating range. 1. ES INSPECT MASS AIR FLOW METER (a) Perform confirmation driving pattern. (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch to the ON position. (3) Turn the tester ON. (4) Clear the DTCs (See page ES-38). (5) Start the engine and warm it up with all accessory switches OFF (until the engine coolant temperature is 75°C (167°F) or more). (6) Drive the vehicle at 50 km/h (31 mph) or more for 3 to 5 minutes (*1). (7) Allow the engine to idle for 2 minutes (*2). (8) Perform steps (*1) and (*2) at least 3 times. (Vehicle Speed) *1 *1 *1 31 mph (50 km/h) Idling Ignition switch OFF *2 *2 *2 Warming up *1: 3 minutes or more *2: 2 minutes or more A116436E19 (b) Read values using the intelligent tester (LONG FT#1). (1) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / LONG FT#1. (2) Read the values displayed on the tester. Standard value: Within -15 to +15 % If the result is not within the specified range, perform the inspection below. 2AZ-FE ENGINE CONTROL SYSTEM – MASS AIR FLOW METER ES–403 (c) Read values using the intelligent tester (MAF). NOTICE: • Turn off the engine. • Perform the inspection with the vehicle indoors and on a level surface. • Perform the inspection of the MAF meter while it is installed to the air cleaner case (installed to the vehicle). • During the test, do not use the exhaust air duct to perform suction on the exhaust pipe. (1) Turn the ignition switch to the ACC position. (2) Turn the ignition switch to the ON position (do not run the engine). (3) Turn the intelligent tester ON. (4) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / MAF. (5) Wait 30 seconds, and read the values on the intelligent tester. Standard condition: Less than 0.50 g/sec. • If the result is not as specified, replace the MAF meter. • If the result is within the specified range, inspect the cause of the extremely rich or lean air fuel ratio (See page EC-20). Intelligent Tester DLC3 CAN VIM G041046E28 REMOVAL 1. REMOVE MASS AIR FLOW METER (a) Disconnect the mass air flow meter connector. (b) Remove the 2 screws and mass air flow meter. A135663E01 INSTALLATION 1. A135663E01 INSTALL MASS AIR FLOW METER (a) Install the mass air flow meter with the 2 screws. (b) Connect the mass air flow meter connector. ES ES–402 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MIL Circuit DESCRIPTION The MIL (Malfunction Indicator Lamp) is used to indicate vehicle malfunction detected by the ECM. When the ignition switch is turned ON position, power is supplied to the MIL circuit, and the ECM provides the circuit ground which illuminates the MIL. The MIL operation can be checked visually: When the ignition switch is first turned ON position, the MIL should be illuminated and should then turn off. If the MIL remains illuminated or is not illuminated, conduct the following troubleshooting procedure using the intelligent tester. WIRING DIAGRAM ES E23 Ignition SW ECM AM2 IG2 MIL 13 F1 6 5 GAUGE No. 2 IG+ 4 F2 24 A24 CHK W Combination Meter ST/AM2 FL MAIN Battery A138929E01 INSPECTION PROCEDURE 1 CHECK THAT MIL IS ILLUMINATED (a) Perform troubleshooting in accordance with the table below. Result B Condition Proceed to MIL remains ON A MIL does not illuminate B Go to step 5 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–403 A 2 CHECK WHETHER MIL TURNS OFF (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Check if any DTCs have been stored. Note down any DTCs. (e) Clear the DTCs (See page ES-38). (f) Check if the MIL goes off. Standard: MIL goes off. OK REPAIR CIRCUITS INDICATED BY OUTPUT DTCS NG 3 CHECK HARNESS AND CONNECTOR (CHECK FOR SHORT IN WIRE HARNESS) (a) Disconnect the A24 ECM connector. (b) Turn the ignition switch to the ON position. (c) Check that the MIL is not illuminated. OK: MIL is not illuminated. (d) Reconnect the ECM connector. Wire Harness Side: A24 ECM Connector W OK Front View A115671E23 NG REPLACE ECM ES ES–404 4 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (COMBINATION METER - ECM) (a) Disconnect the A24 ECM connector. (b) Disconnect the F2 combination meter connector. (c) Measure the resistance between the terminals of the wire harness side connectors. Standard resistance (Check for short) Wire Harness Side: Combination Meter Connector CHK F2 Tester Connection Specified Condition A24-24 (W) or F2-4 (CHK) - Body ground 10 kΩ or higher (d) Reconnect the ECM connector. (e) Reconnect the combination meter connector. ES Front View OK REPAIR OR REPLACE COMBINATION METER ASSEMBLY ECM Connector A24 W Front View A132305E01 NG REPAIR OR REPLACE HARNESS OR CONNECTOR 5 CHECK THAT MIL IS ILLUMINATED (a) Check if the MIL is illuminated when the ignition switch is turned ON position. OK: MIL is illuminated. OK SYSTEM OK NG 6 CHECK THAT ENGINE STARTS (a) Turn the ignition switch to the ON position. (b) Start the engine. Result Result Proceed to Engine starts A Engine does not start* B 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–405 HINT: *: The intelligent tester cannot communicate with the ECM. B GO TO VC OUTPUT CIRCUIT A 7 INSPECT COMBINATION METER ASSEMBLY (MIL CIRCUIT) (a) Check the MIL circuit (See page ME-19). NG REPAIR OR REPLACE COMBINATION METER ASSEMBLY OK CHECK AND REPLACE HARNESS AND CONNECTOR (COMBINATION METER - ECM) ES ES–397 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Fuel Pump Control Circuit DESCRIPTION When the engine is cranked, the starter relay drive signal output from the STAR terminal of the ECM is input into the STA terminal of the ECM, and NE signal generated by the crankshaft position sensor is also input into the NE+ terminal. Thus, the ECM interprets that the engine is cranked, and turns the transistor Tr1 in the ECM internal circuit ON. The current flows to the C/OPN (Circuit Opening) relay by turning the Tr1 ON. Then, the fuel pump operates. While the NE signal is input into the ECM, when the engine is running, the ECM turns the Tr1 on continuously. ES ECM C/OPN FC IGN Tr1 M Fuel Pump IG2 ST2 AM2 EFI MAIN EFI MREL ST/AM2 Park/Neutral Start Switch NSW ST To Starter MAIN STA NE Signal NE+ Battery A135052E01 ES–398 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM E23 Ignition SW C/OPN 7 A24 FC IGN 5 AM2 IG2 6 AT/AM2 ES EFI MAIN EFI 44 A24 MREL FL MAIN N10 Fuel Pump Battery 5 M 104 C24 E1 4 A133517E02 INSPECTION PROCEDURE 1 PERFORM ACTIVE TEST USING INTELLIGENT TESTER (OPERATE C/OPN RELAY) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / FUEL PUMP / SPD. (d) Check whether the fuel pump operation sound occurs when performing the Active Test on the tester. OK: Fuel pump operating sound occurs. NG Go to step 2 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2 ES–399 CHECK ECM POWER SOURCE CIRCUIT NG REPAIR OR REPLACE ECM POWER SOURCE CIRCUIT OK 3 INSPECT ENGINE ROOM J/B (C/OPN RELAY) (a) Remove the engine room J/B from the engine room R/B. (b) Inspect the C/OPN relay. (1) Measure the C/OPN relay resistance. Standard resistance Engine Room J/B: Tester Connection Specified Condition 10 kΩ or higher 1E-7 - 1E-13 1D 1E (c) Reinstall the engine room J/B. NG Engine Room R/B: A138918E02 OK Below 1 Ω (Apply battery voltage between terminals 1D-12 and 1E-8) REPLACE ENGINE ROOM J/B ES ES–400 4 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT ECM (FC VOLTAGE) (a) Disconnect the A24 and C24 ECM connectors. (b) Measure the voltage between the terminals of the A24 and C24 ECM connectors. Standard voltage Wire Harness Side: C24 ECM Connector Tester Connection Specified Condition A24-7 (FC) - C24-104 (E1) 9 to 14 V (c) Reconnect the ECM connectors. Front View ES E1 NG REPAIR OR REPLACE HARNESS OR CONNECTOR (ECM - BATTERY) NG REPLACE FUEL PUMP A24 ECM Connector FC Front View A106902E07 OK 5 OK INSPECT FUEL PUMP ES–401 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 6 CHECK HARNESS AND CONNECTOR (C/OPN RELAY - FUEL PUMP - BODY GROUND) Wire Harness Side: N10 1 (+) 2 3 Fuel Pump Connector 4 5 (-) (a) Check the harness and the connectors between the engine room J/B and the fuel pump. (1) Remove the engine room J/B from the engine room R/B. (2) Disconnect the 1E engine room J/B connector. (3) Disconnect the N10 fuel pump connector. (4) Measure the resistance between the terminals. Standard resistance (Check for open) Engine Room J/B: Component Side: Below 1 Ω Tester Connection Specified Condition 1E-13 or N10-4 (Fuel pump) - Body ground 10 kΩ or higher (b) Check the harness and the connectors between the fuel pump and body ground. (1) Disconnect the N10 fuel pump connector. (2) Measure the resistance. Standard resistance (Check for open) Tester Connection Specified Condition N10-5 (Fuel pump) - Body ground Below 1 Ω (c) Reconnect the engine room J/B connector. (d) Reconnect the fuel pump connector. (e) Reinstall the engine room J/B. Engine Room R/B: NG A138923E01 REPLACE ECM Specified Condition Standard resistance (Check for short) 1E OK Tester Connection 1E-13 - N10-4 (Fuel pump) REPAIR OR REPLACE HARNESS OR CONNECTOR ES ES–392 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM VC Output Circuit DESCRIPTION The ECM constantly generates 5 V power from the battery voltages supplied to the +B (BATT) terminal to operate the microprocessor. The ECM also provides this power to the sensors through the VC output circuit. ECM ES From EFI MAIN Fuse From EFI MAIN Relay Throttle Position Sensor, Accelerator Pedal Position Sensor, etc. (Sensors which have IC) Engine Coolant Temperature Sensor, Intake Air Temperature Sensor, etc. BATT 5 V Constant Voltage Circuit +B Microprocessor VC R A116143E06 When the VC circuit is short-circuited, the microprocessor in the ECM and sensors that are supplied with power through the VC circuit are inactivated because the power is not supplied from the VC circuit. Under this condition, the system does not start up and the MIL does not illuminate even if the system malfunctions. HINT: Under normal conditions, the MIL is illuminated for several seconds when the ignition switch is first turned ON position. The MIL goes off when the engine is started. ES–393 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM C5 Throttle Position Sensor VC VTA VTA2 E2 5 67 VCTA C24 6 115 C24 VTA1 4 114 C24 VTA2 3 91 ETA C24 A17 Accelerator Pedal VCPA 4 Position Sensor 1 VCP2 57 VCPA A24 58 VCP2 A24 6 55 A24 VPA 3 56 A24 VPA2 5 59 EPA A24 2 60 EPA2 A24 N17 4 Canister Pressure VCC Sensor (bulit into Canister VOUT 3 Pump Module) 70 VCPP C24 2 94 EPPM C24 VPA VPA2 EPA EPA2 SGND ES 71 C24 PPMP A135050E01 INSPECTION PROCEDURE 1 CHECK MIL CONDITION (a) Check that the Malfunction Indicator Lamp (MIL) lights up when turning the ignition switch to the ON position. OK: MIL lights up. ES–394 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK SYSTEM OK NG 2 CHECK COMMUNICATION BETWEEN INTELLIGENT TESTER AND ECM (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the tester on. (c) Check for communication between the tester and ECM. Result ES Result Proceed to Communication is possible A Communication is not possible B A GO TO MIL CIRCUIT B 3 CHECK MIL (THROTTLE POSITION SENSOR) (a) Disconnect the C5 throttle body connector. (b) Turn the ignition switch to the ON position. (c) Check the MIL. Result Result Proceed to MIL illuminates A MIL does not illuminate B (d) Reconnect the throttle body connector. A REPLACE THROTTLE BODY ASSEMBLY B 4 CHECK MIL (ACCELERATOR PEDAL POSITION SENSOR) (a) Disconnect the A17 accelerator pedal position sensor connector. (b) Turn the ignition switch to the ON position. (c) Check the MIL. Result Result Proceed to MIL illuminates A MIL does not illuminate B (d) Reconnect the accelerator pedal position sensor connector. A REPLACE ACCELERATOR PEDAL ASSEMBLY ES–395 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM B 5 CHECK MIL (CANISTER PUMP MODULE) (a) Disconnect the N17 canister pump module connector. (b) Turn the ignition switch to the ON position. (c) Check the MIL. Result Result Proceed to MIL illuminates A MIL does not illuminate B (d) Reconnect the canister pump module connector. A REPLACE CHARCOAL CANISTER ASSEMBLY A135172 B 6 CHECK HARNESS AND CONNECTOR (a) Disconnect the C5 throttle body connector. (b) Disconnect the A17 accelerator pedal position sensor connector. (c) Disconnect the N17 canister pump module connector. (d) Disconnect the A24 and C24 ECM connectors. (e) Measure the resistance between the terminals of the wire harness side connectors. Standard resistance (Check for short) Wire Harness Side : C24 ECM Connector VCPP VCTA A24 Front View ECM Connector Front View VCPA A107934E14 Specified Condition C24-67 (VCTA) - Body ground 10 kΩ or higher A24-57 (VCPA) - Body ground 10 kΩ or higher A24-58 (VCP2) - Body ground 10 kΩ or higher C24-70 (VCPP) - Body ground 10 kΩ or higher (f) Reconnect the throttle body connector. (g) Reconnect the accelerator pedal position sensor connector. (h) Reconnect the canister pump module connector. (i) Reconnect the ECM connectors. NG VCP2 Tester Connection REPAIR OR REPLACE HARNESS OR CONNECTOR ES ES–396 OK REPLACE ECM ES 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–349 EVAP System RELATED DTCS DTC Monitoring Item P043E Reference orifice clogged (built into canister pump module) P043F Reference orifice high-flow (built into canister pump module) P0441 • • • P0450 Canister pressure sensor (built into canister pump module) voltage abnormal fluctuation P0451 • • P0452 Canister pressure sensor (built into canister pump module) voltage low P0453 Canister pressure sensor (built into canister pump module) voltage high P0455 EVAP gross leak P0456 EVAP small leak Purge VSV (Vacuum Switching Valve) stuck closed Purge VSV stuck open Purge flow Canister pressure sensor (built into canister pump module) noise Canister pressure sensor (built into canister pump module) signal becomes fixed/flat See page ES-203 ES-208 ES-215 ES-224 P2401 Leak detection pump stuck OFF (built into canister pump module) P2402 Leak detection pump stuck ON (built into canister pump module) P2419 Vent valve stuck closed (built into canister pump module) P2420 Vent valve stuck open (vent) (built into canister pump module) ES-330 P2610 Soak timer (built into ECM) ES-334 ES-203 If any EVAP system DTCs are set, the malfunctioning area can be determined using the table below. ES ES–350 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTCs Malfunctioning Areas P2401 P043E P0441 P0450 P0451 P0452 P0453 P0455 P0456 P2419 P2420 P2402 P043F Reference orifice clogged Reference orifice high-flow Purge VSV stuck open Purge VSV stuck closed ES Canister pressure sensor fixed output Canister pressure sensor noise Canister pressure sensor low output Canister pressure sensor high output Gross leak Small leak Leak detection pump stuck OFF Leak detection pump stuck ON Vent valve stuck closed Vent valve stuck open (vent) A106731E11 NOTICE: If the reference pressure difference between the first and second checks is greater than the specification, all the DTCs relating to the reference pressure (P043E, P043F, P2401, P2402 and P2419) are stored. ES–351 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DESCRIPTION Location of EVAP (Evaporative Emission) System: Except PZEV Purge VSV EVAP Hose (from Canister) ES EVAP Hose (to Intake Manifold) Purge Line Fuel Tank Refueling Valve Air Inlet Port Canister Fuel Cap Canister Pump Module Canister Pressure Sensor Bleeding Pipe Canister Filter Note: Leak Detection Pump Vent Valve The canister is located near the fuel tank, underneath the body. A135200E01 ES–352 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Location of EVAP (Evaporative Emission) System: PZEV Purge VSV Evap Hose (from Canister) ES Evap Hose (to Intake Manifold) Purge Line Fuel Tank Refueling Valve Air Inlet Port Canister Fuel Cap Bleeding Pipe Note: Canister Pump Module Canister Filter The canister is lecated near the fuel tank, underneath the body. Canister Pressure Sensor Leak Detection Pump Vent Valve A135201E01 ES–353 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM EVAP System Circuit: Throttle Valve Air Cleaner Intake Manifold ECM Soak Timer Canister Pump Module Purge VSV Canister Filter Canister Fuel Cap Refueling Valve ES Restrictor (0.08 inch) Cut-off Valve Roll-Over Valve Fuel Tank A122570E02 NOTICE: In this vehicle's EVAP system, turning ON the vent valve does not seal off the EVAP system. To check for leaks in the EVAP system, disconnect the air inlet vent hose and apply pressure from the atmospheric side of the canister. While the engine is running, if a predetermined condition (closed-loop, etc.) is met, the purge VSV is opened by the ECM and stored fuel vapors in the canister are purged into the intake manifold. The ECM changes the duty cycle ratio of the purge VSV to control purge flow volume. The purge flow volume is also determined by the intake manifold pressure. Atmospheric pressure is allowed into the canister through the vent valve to ensure that the purge flow is maintained when the negative pressure (vacuum) is applied to the canister. The following two monitors run to confirm the appropriate EVAP system operation. 1. Key-off monitor This monitor checks for EVAP (Evaporative Emission) system leaks and canister pump module malfunctions. The monitor starts 5 hours* after the ignition switch is turned off. At least 5 hours are required for the fuel to cool down to stabilize the EVAP pressure, thus making the EVAP system monitor more accurate. The leak detection pump creates negative pressure (vacuum) in the EVAP system and the pressure is measured. Finally, the ECM monitors for leaks from the EVAP system, and malfunctions in both the canister pump module and purge VSV, based on the EVAP pressure. HINT: *: If the engine coolant temperature is not below 35°C (95°F) 5 hours after the ignition switch is turned off, the monitor check starts 2 hours later. If it is still not below 35°C (95°F) 7 hours after the ignition switch is turned off, the monitor check starts 2.5 hours later. 2. Purge flow monitor The purge flow monitor consists of the two monitors. The 1st monitor is conducted every time and the 2nd monitor is activated if necessary. • The 1st monitor While the engine is running and the purge VSV (Vacuum Switching Valve) is ON (open), the ECM monitors the purge flow by measuring the EVAP pressure change. If negative pressure is not created, the ECM begins the 2nd monitor. ES–354 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM • The 2nd monitor The vent valve is turned OFF (open) and the EVAP pressure is measured. If the variation in the pressure is less than 0.5 kPa-g (3.75 mmHg-g), the ECM interprets this as the purge VSV being stuck closed, and illuminates the MIL and sets DTC P0441 (2 trip detection logic). Atmospheric pressure check: In order to ensure reliable malfunction detection, the variation between the atmospheric pressures, before and after conduction of the purge flow monitor, is measured by the ECM. EVAP Purge Flow: Reference Orifice (0.02 inch) Fuel Cap Refueling Valve Canister Pressure Sensor To Atmosphere ES Purge VSV (ON) Fuel Tank Canister To Intake Manifold ECM Canister Filter Vent Valve (OFF) Leak Detection Pump (OFF) Canister Pump Module Soak Timer A122571E02 Components Operations Canister Contains activated charcoal to absorb EVAP (Evaporative Emissions) generated in fuel tank. Cut-off valve Located in fuel tank. Valve floats and closes when fuel tank 100 % full. Purge VSV (Vacuum Switching Valve) Opens or closes line between canister and intake manifold. ECM uses purge VSV to control EVAP purge flow. In order to discharge EVAP absorbed by canister to intake manifold, ECM opens purge VSV. EVAP discharge volume to intake manifold controlled by purge VSV duty cycle ratio (current-carrying time) (Open: ON; Closed: OFF). Refueling valve Controls EVAP pressure from fuel tank to canister. Valve consists of diaphragm, spring and restrictor (diameter: 0.08 inch). When fuel vapor and pressure inside fuel tank increase, valve opens. While EVAP purged, valve closes and restrictor prevents large amount of vacuum from affecting pressure in fuel tank. Valve opened while refueling. Roll-over valve Located in fuel tank. Valve closed by its own weight when vehicle overturns to prevent fuel from spilling out. Soak timer Built into ECM. To ensure accurate EVAP monitor, measures 5 hours (+-15 min) after ignition switch turned off. This allows fuel to cool down, stabilizing EVAP pressure. When approximately 5 hours elapsed, ECM activates (refer to fig. 3). Canister pump module Consists of (a) to (d) below. Canister pump module cannot be disassembled. (a) Vent valve Vents and closes EVAP system. When ECM turns valve ON, EVAP system closed. When ECM turns valve OFF, EVAP system vented. Negative pressure (vacuum) created in EVAP system to check for EVAP leaks by closing purge VSV, turning on vent valve (closed) and operating leak detection pump (refer to fig. 1). (b) Canister pressure sensor Indicates pressure as voltages. ECM supplies regulated 5 V to canister pressure sensor, and uses feedback from sensor to monitor EVAP system pressure (refer to fig. 2). ES–355 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Components Operations (c) Leak detection pump Creates negative pressure (vacuum) in EVAP system for leak check. (d) Reference orifice Has opening with 0.02 inch diameter. Vacuum produced through orifice by closing purge VSV, turning off vent valve and operating leak detection pump, to monitor reference pressure. Reference pressure indicates small leak of EVAP. Canister Pump Module (fig. 1): : Airflow Condition: Purge Flow Vent Valve: OFF (vent) Condition: Leak Check To Canister Filter (Atmosphere) ES Canister Reference Orifice (0.02 inch) From Refueling Valve Canister Pressure Sensor Leak Detection Pump: OFF Vent Valve: ON (closed) Leak Detection Pump: ON A115902E04 Canister Pressure Sensor Specification (fig. 2): Malfunction Area Output Voltage 4.900 V 4.150 V Usable Range 1.425 V Malfunction Area 0.450 V 60 (450) 110 (825) Pressure kPa-a (mmHg-a) HINT: Standard atmospheric pressure is 101.3 kPa-a (760 mmHg-a) A115543E06 ES–356 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Soak Timer Circuit (fig. 3): ECM IGN IGSW Ignition Switch Soak Timer IC ST/AM2 ES EFI MAIN FL MAIN Battery EFI MAIN EFI No. 2 +B MREL Power Source IC Main Relay Control IC A135035E03 ES–357 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM N17 Canister Pump Module ECM Leak Detection Pump 6 MGND MTRB M 34 A24 MPMP 1 ES Canister Pressure Sensor VCC 4 70 VCPP C24 VOUT 3 71 PPMP C24 2 94 EPPM C24 8 42 A24 VPMP SGND 9 VLVB VGND Vent Valve C6 Purge VSV 1 2 49 C24 PRG EFI No. 3 FL MAIN EFI MAIN 44 MREL A24 EFI Battery A132282E01 INSPECTION PROCEDURE NOTICE: The intelligent tester is required to conduct the following diagnostic troubleshooting procedure. ES–358 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: • Using intelligent tester monitor results enables the EVAP (Evaporative Emission) system to be confirmed. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 ES CONFIRM DTC (a) (b) (c) (d) (e) Turn the ignition switch off and wait for 10 seconds. Turn the ignition switch to the ON position. Turn the ignition switch off and wait for 10 seconds. Connect an intelligent tester to the DLC3. Turn the ignition switch to the ON position and turn the tester on. (f) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (g) Confirm DTCs and freeze frame data. If any EVAP system DTCs are set, the malfunctioning area can be determined using the table below. NOTICE: If the reference pressure difference between the first and second checks is greater than the specification, all the DTCs relating to the reference pressure (P043E, P043F, P2401, P2402 and P2419) are stored. 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTCs Malfunctioning Areas ES–359 P2401 P043E P0441 P0450 P0451 P0452 P0453 P0455 P0456 P2419 P2420 P2402 P043F Reference orifice clogged Reference orifice high-flow Purge VSV stuck open Purge VSV stuck closed Canister pressure sensor fixed output Canister pressure sensor noise ES Canister pressure sensor low output Canister pressure sensor high output Gross leak Small leak Leak detection pump stuck OFF Leak detection pump stuck ON Vent valve stuck closed Vent valve stuck open (vent) A106731E11 NEXT 2 PERFORM EVAP SYSTEM CHECK (AUTO OPERATION) NOTICE: • The EVAP SYSTEM CHECK (AUTO OPERATION) consists of 5 steps performed automatically by the intelligent tester. It takes a maximum of approximately 18 minutes. • Do not perform the EVAP SYSTEM CHECK when the fuel tank is more than 90% full because the cut-off valve may be closed, making the fuel tank leak check unavailable. • Do not run the engine during this operation. • When the temperature of the fuel is 35°C (95°F) or more, a large amount of vapor forms and any check results become inaccurate. When performing the EVAP SYSTEM CHECK, keep the temperature below 35°C (95°F). (a) Clear the DTCs (See page ES-38). ES–360 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (b) On the tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION. (c) After the EVAP SYSTEM CHECK is completed, check for pending DTCs by selecting the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. HINT: If no pending DTCs are displayed, perform MONITOR CONFIRMATION (see "Diagnostic Help" menu). After this confirmation, check for pending DTCs. If no DTCs are displayed, the EVAP system is normal. ES NEXT 3 PERFORM EVAP SYSTEM CHECK (MANUAL OPERATION) EVAP SYSTEM CHECK ON: Open ON Purge VSV Vent Valve OFF: Closed ON: Closed ON OFF: Vent Leak Detection Pump ON EVAP Pressure Positive Gross Leak Negative First Reference Pressure Small Leak No Leak Steps Time (Reference) 1/5 2/5 10 seconds 60 seconds 3/5 Within 15 minutes [Second Reference Pressure] x 0.2 Normal Pressure 4/5 5/5 60 10 seconds seconds A106735E08 NOTICE: • In the EVAP SYSTEM CHECK (MANUAL OPERATION), perform the series of 5 EVAP SYSTEM CHECK steps manually using the intelligent tester. • Do not perform the EVAP SYSTEM CHECK when the fuel tank is more than 90% full because the cut-off valve may be closed, making the fuel tank leak check unavailable. • Do not run the engine during this operation. 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–361 • When the temperature of the fuel is 35°C (95°F) or more, a large amount of vapor forms and any check results become inaccurate. When performing the EVAP SYSTEM CHECK, keep the temperature below 35°C (95°F). (a) Clear the DTCs (See page ES-38). (b) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / MANUAL OPERATION. NEXT 4 PERFORM EVAP SYSTEM CHECK (STEP 1/5) ES ON Purge VSV ON: Open OFF: Closed Vent Valve ON: Closed ON OFF: Vent Leak Detection Pump ON Canister Pressure Sensor Noise EVAP Pressure Positive Negative First Reference Pressure Steps OK Time 1/5 10 seconds (Reference) A106736E05 (a) Check the EVAP pressure in step 1/5. Result DTCs* P0451 Test Result Suspected Trouble Area Proceed to Virtually no variation in EVAP pressure Not yet determined A EVAP pressure fluctuates by +-0.3 kPa-g (2.25 mmHg-g) or more Canister pressure sensor noise B *: These DTCs are already present in the ECM when the vehicle arrives and are confirmed in the "CONFIRM DTC" procedures above. B Go to step 29 ES–362 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM A 5 PERFORM EVAP SYSTEM CHECK (STEP 1/5 TO 2/5) ON Purge VSV OFF: Closed Vent Valve ES ON: Open ON: Closed ON Leak Detection Pump OFF: Vent ON EVAP Pressure Positive Negative Leak Detection Pump Stuck ON First Reference Pressure Steps Time (Reference) 1/5 2/5 10 seconds 60 seconds A106737E05 (a) Check the EVAP pressure in steps 1/5 and 2/5. Result DTCs* Test Results - Virtually no variation in EVAP pressure during step 1/5. Then decreases to reference pressure Not yet determined A Small difference between EVAP pressures during steps 1/5 and 2/5 Leak detection pump stuck ON B P2402 Suspected Trouble Area Proceed to *: These DTCs are already present in the ECM when the vehicle arrives and are confirmed in the "CONFIRM DTC" procedures above. HINT: The first reference pressure is the value determined in step 2/5. B A Go to step 22 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 6 ES–363 PERFORM EVAP SYSTEM CHECK (STEP 2/5) ON Purge VSV ON: Open OFF: Closed OFF: Vent Leak Detection Pump EVAP Pressure Positive ON: Closed ON Vent Valve ON ES Leak Detection Pump Stuck OFF Reference Orifice High-flow 4 seconds Negative Vent Valve Stuck Closed First Reference Pressure Standard OK Reference Orifice Clogged Steps Time (Reference) 3/5 2/5 Within 15 minutes 60 seconds A106738E05 HINT: Make a note of the pressures checked in steps (a) and (b) below. (a) Check the EVAP pressure 4 seconds after the leak detection pump is activated*. HINT: *: The leak detection pump begins to operate as step 1/5 finishes and step 2/5 starts. (b) Check the EVAP pressure again when it has stabilized. This pressure is the reference pressure. Result DTCs* Test Result Suspected Trouble Area - EVAP pressure in step (b) between -4.85 kPa-g and -1.057 kPa-g (-36.4 mmHg-g and -7.93 mmHg-g) Not yet determined A P043F and P2401 EVAP pressure in step (b) -1.057 kPa-g (-7.93 mmHg-g) or more • • B P043E EVAP pressure in step (b) below -4.85 kPa-g (36.4 mmHg-g) Reference orifice clogged C P2419 EVAP pressure in step (a) more than -1.057 kPa-g (-7.93 mmHg-g) Vent valve stuck closed D Reference orifice high-flow Leak detection pump stuck OFF Proceed to ES–364 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM *: These DTCs are already present in the ECM when the vehicle arrives and are confirmed in the "CONFIRM DTC" procedures above. B Go to step 11 C Go to step 29 D Go to step 20 A ES 7 PERFORM EVAP SYSTEM CHECK (STEP 2/5 TO 3/5) ON Purge VSV Vent Valve ON Leak Detection Pump ON ON: Open OFF: Closed ON: Closed OFF: Vent EVAP Pressure Positive Negative Vent Valve Stuck Open (vent) First Reference Pressure Steps Time 2/5 3/5 Within 15 minutes (Reference) A106739E05 (a) Check the EVAP pressure increases in step 3/5. Result DTCs* Test Result Suspected Trouble Area Proceed to EVAP pressure increases by 0.3 kPa-g (2.25 mmHg-g) or more within 10 seconds of proceeding from step 2/5 to step 3/5 Not yet determined A P2420 No variation in EVAP pressure despite proceeding from step 2/5 to step 3/5 Vent valve stuck open (vent) B P0451 No variation in EVAP pressure during steps 1/ 5 through 3/5 Canister pressure sensor malfunction fixed C - *: These DTCs are already present in the ECM when the vehicle arrives and are confirmed in the "CONFIRM DTC" procedures above. 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM B Go to step 19 C Go to step 29 ES–365 A 8 PERFORM EVAP SYSTEM CHECK (STEP 3/5) ON Purge VSV Vent Valve Leak Detection Pump ON ON: Open OFF: Closed ON: Closed OFF: Vent ON EVAP Pressure Positive Negative First Reference Pressure Steps Time (Reference) 3/5 Within 15 minutes A106740E05 (a) Wait until the EVAP pressure change is less than 0.1 kPa-g (0.75 mmHg-g) for 30 seconds. (b) Measure the EVAP pressure and record it. HINT: A few minutes are required for the EVAP pressure to become saturated. When there is little fuel in the fuel tank, it takes up to 15 minutes. NEXT ES ES–366 9 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PERFORM EVAP SYSTEM CHECK (STEP 4/5) ON Purge VSV OFF: Closed ON: Closed ON Vent Valve ES ON: Open OFF: Vent Leak Detection Pump ON EVAP Pressure OK Positive Negative Purge VSV Stuck Closed First Reference Pressure Steps 4/5 Time 10 seconds (Reference) A106741E05 (a) Check the EVAP pressure in step 4/5. Result DTCs* Test Result Suspected Trouble Area Proceed to - EVAP pressure increases by 0.3 kPa-g (2.25 mmHg-g) or more within 10 seconds of proceeding from step 3/5 to step 4/5 Not yet determined A P0441 EVAP pressure increases by 0.3 kPa-g (2.25 mmHg-g) or more within 10 seconds of proceeding from step 3/5 to step 4/5 Problems in EVAP hose between purge VSV and intake manifold B P0441 Variation in EVAP pressure less than 0.3 kPa-g (2.25 mmHg-g) for 10 seconds, after proceeding from step 3/5 to step 4/5 Purge VSV stuck closed C *: These DTCs are already present in the ECM when the vehicle arrives and are confirmed in the "CONFIRM DTC" procedures above. A B Go to step 15 C Go to step 12 ES–367 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 10 PERFORM EVAP SYSTEM CHECK (STEP 5/5) ON: Open ON Purge VSV Vent Valve OFF: Closed ON: Closed ON OFF: Vent Leak Detection Pump ES ON EVAP Pressure Positive Gross Leak [Second Reference Pressure] x 0.2 Negative First Reference Pressure Small Leak No Leak Steps 5/5 Time 60 seconds (Reference) [Second Reference Pressure] A106735E09 (a) Check the EVAP pressure in step 5/5. (b) Compare the EVAP pressure in step 3/5 and the second reference pressure (step 5/5). Result DTCs* Test Result Suspected Trouble Area Proceed to EVAP pressure (step 3/5) lower than second reference pressure (step 5/5) Not yet determined (no leakage from EVAP system) A P0441 and P0455 EVAP pressure (step 3/5) higher than [second reference pressure (step 5/5) x 0.2] • • B P0456 EVAP pressure (step 3/5) higher than second reference pressure (step 5/5) EVAP small leak - Purge VSV stuck open EVAP gross leak B *: These DTCs are already present in the ECM when the vehicle arrives and are confirmed in the "CONFIRM DTC" procedures above. A Go to step 35 B Go to step 12 ES–368 11 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PERFORM EVAP SYSTEM CHECK (STEP 3/5) ON Purge VSV Vent Valve ES OFF: Closed ON: Closed ON Leak Detection Pump ON: Open OFF: Vent ON Leak Detection Pump Stuck OFF EVAP Pressure Positive Negative Reference Orifice High-flow First Reference Pressure Steps Time 2/5 3/5 Within 15 minutes (Reference) A106742E04 (a) Check the EVAP pressure in step 3/5. Result DTCs* Test Result P043F EVAP pressure less than [reference pressure] measured at 2/5 Suspected Trouble Area Proceed to Reference orifice high-flow A P2401 EVAP pressure almost same as [reference pressure] measured at 2/5 Leak detection pump stuck OFF B *: These DTCs are already present in the ECM when the vehicle arrives and are confirmed in the "CONFIRM DTC" procedures above. HINT: The first reference pressure is the value determined in step 2/5. A Go to step 29 B Go to step 22 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 12 ES–369 PERFORM ACTIVE TEST USING INTELLIGENT TESTER (PURGE VSV) Hose (to Canister) Purge VSV A136177E01 (a) On the intelligent tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / EVAP VSV (ALONE). (b) Disconnect the hose (connected to the canister) from the purge VSV. (c) Start the engine. (d) Using the tester, turn off the purge VSV (EVAP VSV: OFF). (e) Use your finger to confirm that the purge VSV has no suction. (f) Using the tester, turn on the purge VSV (EVAP VSV: ON). (g) Use your finger to confirm that the purge VSV has suction. Result Test Result Suspected Trouble Area Proceed to No suction when purge VSV turned OFF, and suction applied when turned ON Purge VSV normal A Suction applied when purge VSV turned OFF Purge VSV stuck open B No suction when purge VSV turned ON • • C Purge VSV stuck closed Problems with EVAP hose between purge VSV and intake manifold (h) Reconnect the hose. B Go to step 14 C Go to step 15 A 13 CHECK FUEL CAP (a) Check that the fuel cap is correctly installed and confirm the fuel cap meets OEM specifications. (b) Tighten the fuel cap until a few click sounds are heard. HINT: If an EVAP tester is available, check the fuel cap using the tester. 1. Remove the fuel cap and install it onto a fuel cap adapter. 2. Connect an EVAP tester pump hose to the adapter, and pressurize the cap to 3.2 to 3.7 kPa (24 to 28 mmHg) using an EVAP tester pump. 3. Seal the adapter and wait for 2 minutes. 4. Check the pressure. If the pressure is 2 kPa (15 mmHg) or more, the fuel cap is normal. Result Test Result Fuel cap correctly installed Suspected Trouble Area Proceed to - A ES ES–370 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Test Result Suspected Trouble Area • • • Fuel cap loose Fuel cap improperly installed Defective fuel cap Fuel cap does not meet OEM specifications Proceed to B Defective fuel cap - B No fuel cap - C (c) Reinstall the fuel cap. ES 14 A Go to step 28 B Go to step 26 C Go to step 27 INSPECT DUTY VACUUM SWITCHING VALVE (PURGE VSV) Hose (to Canister) Purge VSV (a) Turn the ignition switch off. (b) Disconnect the C6 purge VSV connector. (c) Disconnect the hose (connected to the canister) from the purge VSV. (d) Start the engine. (e) Use your finger to confirm that the purge VSV has no suction. A135202E02 Result Test Result Suspected Trouble Area Proceed to No suction ECM A Suction applied Purge VSV B (f) Reconnect the purge VSV connector. (g) Reconnect the hose. 15 A Go to step 34 B Go to step 30 CHECK EVAP HOSE (PURGE VSV - INTAKE MANIFOLD) (a) Disconnect the hose (connected to the intake manifold) from the purge VSV. (b) Start the engine. (c) Use your finger to confirm that the hose has suction. Purge VSV Hose (to Intake Manifold) A135203E01 ES–371 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Result Test Result Suspected Trouble Area Proceed to Suction applied EVAP hose between purge VSV and intake manifold normal A No suction • • B Intake manifold port EVAP hose between purge VSV and intake manifold (d) Reconnect the hose. B Go to step 25 A 16 INSPECT DUTY VACUUM SWITCHING VALVE (PURGE VSV) Purge VSV A (a) Remove the purge VSV. (b) Apply the battery voltage to the terminals of the purge VSV. (c) Using an air gun, confirm that air flows from port A to port B. B A135066E01 Result Test Result Suspected Trouble Area Proceed to Air flows Purge VSV normal A No air flow Purge VSV B (d) Install the purge VSV. B Go to step 30 A 17 CHECK HARNESS AND CONNECTOR (POWER SOURCE OF PURGE VSV) (a) Disconnect the C6 purge VSV connector. (b) Turn the ignition switch to the ON position. (c) Measure the voltage between terminal 1 of the purge VSV connector and body ground. Wire Harness Side: C6 Purge VSV Connector Front View A052933E25 Result Test Result Suspected Trouble Area Proceed to 9 to 14 V Normal A Other than result above Wire harness or connectors between purge VSV and ECM B (d) Reconnect the purge VSV connector. ES ES–372 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM B Go to step 31 A 18 CHECK HARNESS AND CONNECTOR (PURGE VSV - ECM) (a) Disconnect the C24 ECM connector and the C6 purge VSV connector. (b) Measure the resistance between the terminals of the wire harness side connectors. Standard resistance Wire Harness Side: C24 ECM Connector ES PRG C6 Front View Tester Connection Specified Condition C24-49 (PRG) - C6-2 (Purge VSV) Below 1 Ω C24-49 (PRG) - Body ground 10 kΩ or higher C6-2 (Purge VSV) - Body ground 10 kΩ or higher (c) Reconnect the purge VSV connector. (d) Reconnect the ECM connector. Purge VSV Connector Front View A112616E04 OK Go to step 34 NG Go to step 31 ES–373 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 19 INSPECT CANISTER PUMP MODULE (POWER SOURCE FOR VENT VALVE) (a) (b) (c) (d) Turn the ignition switch off. Disconnect the N17 canister pump module connector. Turn the ignition switch to the ON position. Measure the voltage between the VLVB terminal of the canister pump module connector and body ground. ES Wire Harness Side: VLVB N17 Canister Pump Module Connector A135029E02 Result Test Result Suspected Trouble Area Proceed to 9 to 14 V 1. Wire harness between vent valve and ECM 2. Vent valve 3. ECM A Below 3 V Power source wire harness of vent valve B (e) Reconnect the canister pump module connector. B A Go to step 31 ES–374 20 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT CANISTER PUMP MODULE (VENT VALVE OPERATION) Canister Pump Module: VGND (-) Except PZEV: VLVB (+) (a) Turn the ignition switch off. (b) Disconnect the N17 canister pump module connector. (c) Apply the battery voltage to the VLVB and VGND terminals of the canister pump module. (d) Touch the canister pump module to confirm the vent valve operation. ES VGND (-) PZEV: VLVB (+) A135039E01 Result Test Result Suspected Trouble Areat Proceed to Operating 1. Wire harness between vent valve and ECM 2. ECM A Not operating Vent valve B (e) Reconnect the canister connector. B A Go to step 29 ES–375 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 21 CHECK HARNESS AND CONNECTOR (ECM - CANISTER PUMP MODULE) (a) Disconnect the A24 ECM connector. (b) Disconnect the N17 canister pump module connector. (c) Measure the resistance between the VPMP terminal of the ECM connector and the VGND terminal of the canister pump module connector. Wire Harness Side: A24 VPMP ECM Connector ES Front View Canister Pump Module Connector N17 1 2 3 4 5 6 7 8 9 10 Front View VGND A112621E09 Result Test Result Suspected Trouble Area Proceed to Below 1 Ω ECM A 10 kΩ or higher Wire harness between ECM and canister pump module B (d) Reconnect the ECM connector. (e) Reconnect the canister pump module connector. A Go to step 34 B Go to step 31 ES–376 22 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PERFORM ACTIVE TEST USING INTELLIGENT TESTER (VACUUM PUMP (ALONE)) (a) (b) (c) (d) Turn the ignition switch off. Disconnect the N17 canister pump module connector. Turn the ignition switch to the ON position. On the intelligent tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VACUUM PUMP. (e) Measure the voltage between MTRB terminal 1 of the canister pump module connector and body ground when the leak detection pump is turned ON and OFF using the tester. ES Wire Harness Side: MTRB N17 Canister Pump Module Connector A135029E03 Result Suspected Trouble Area Proceed to Below 3 V when OFF 9 to 14 V when ON Test Result 1. Wire harness between leak detection pump and body ground 2. Leak detection pump A Below 3 V when OFF and ON 1. Wire harness between leak detection pump and ECM 2. ECM B B A Go to step 24 ES–377 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 23 CHECK HARNESS AND CONNECTOR (CANISTER PUMP MODULE - BODY GROUND) (a) Turn the ignition switch off. (b) Disconnect the N17 canister pump module connector. (c) Measure the resistance between the MGND terminal of the canister pump module connector and body ground. ES Wire Harness Side: Canister Pump Module Connector N17 MGND A135029E04 Result Test Result Suspected Trouble Area Proceed to Below 1 Ω Leak detection pump A 10 kΩ or higher Wire harness between canister pump module and body ground B (d) Reconnect the canister pump module connector. A Go to step 29 B Go to step 31 ES–378 24 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (ECM - CANISTER PUMP MODULE) (a) (b) (c) (d) Wire Harness Side: A24 ES MPMP ECM Connector Turn the ignition switch off. Disconnect the N17 canister pump module connector. Disconnect the A24 ECM connector. Measure the resistance between the MPMP terminal of the ECM connector and the MTRB terminal of the canister pump module connector. Front View Canister Pump Module Connector 1 2 3 4 5 6 7 8 9 10 N17 MTRB Front View A112621E10 Result Test Result Suspected Trouble Area Proceed to Below 1 Ω ECM A 10 kΩ or higher Wire harness between ECM and canister pump module B (e) Reconnect the canister pump module connector. (f) Reconnect the ECM connector. 25 A Go to step 34 B Go to step 31 INSPECT INTAKE MANIFOLD (EVAP PURGE PORT) (a) (b) (c) (d) Stop the engine. Disconnect the EVAP hose from the intake manifold. Start the engine. Use your finger to confirm that the port of the intake manifold has suction. Result Test Result Suspected Trouble Area Proceed to Suction applied EVAP hose between intake manifold and purge VSV A No suction Intake manifold B (e) Reconnect the EVAP hose. A Go to step 32 B Go to step 33 ES–379 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 26 CORRECTLY REINSTALL OR REPLACE FUEL CAP HINT: • When reinstalling the fuel cap, tighten it until a few click sounds are heard. • When replacing the fuel cap, use a fuel cap that meets OEM specifications. NEXT 27 Go to step 36 REPLACE FUEL CAP ES HINT: When installing the fuel cap, tighten it until a few click sounds are heard. NEXT 28 Go to step 36 LOCATE EVAP LEAK PART Except PZEV: Canister Pump Module EVAP Pressure Tester Tool PZEV: Canister Pump Module Adapter A135204E01 (a) Disconnect the vent hose. (b) Connect the EVAP pressure tester tool to the canister pump module with the adapter. ES–380 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (c) Pressurize the EVAP system to 3.2 to 3.7 kPa (24 to 28 mmHg). (d) Apply soapy water to the piping and connecting parts of the EVAP system. (e) Look for areas where bubbles appear. This indicates the leak point. (f) Repair or replace the leak point. HINT: Disconnect the hose between the canister and the fuel tank from the canister. Block the canister side and conduct an inspection. In this way, the fuel tank can be excluded as an area suspected of causing fuel leaks. NEXT ES 29 Go to step 36 REPLACE CHARCOAL CANISTER ASSEMBLY (a) Replace the canister assembly (See page EC-9). NOTICE: When replacing the canister, check the canister pump module interior and related pipes for water, fuel and other liquids. If liquids are present, check for disconnections and/or cracks in the following: 1) the pipe from the air inlet port to the canister pump module; 2) the canister filter; and 3) the fuel tank vent hose. Except PZEV: Air Inlet Port Fuel Tank Vent Hose Inspection Area* Vent Hose Vent Hose *: Check for disconnection and/or crack A132283E01 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–381 PZEV: Air Inlet Port ES Vent Hose Inspection Area* Fuel Tank Vent Hose Vent Hose Vent Hose *: Check for disconnection and/or crack A132284E01 NEXT 30 Go to step 36 REPLACE DUTY VACUUM SWITCHING VALVE (PURGE VSV) (a) Disconnect the connector and the hoses from the purge VSV. (b) Remove the purge VSV. (c) Install a new purge VSV. (d) Reconnect the connector and hoses. Purge VSV NEXT Go to step 36 A135206E01 31 REPAIR OR REPLACE HARNESS OR CONNECTOR NEXT 32 Go to step 36 REPLACE EVAP HOSE (INTAKE MANIFOLD - PURGE VSV) NEXT Go to step 36 ES–382 33 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT INTAKE MANIFOLD (EVAP PURGE PORT) (a) Check that the EVAP purge port of the intake manifold is not clogged. If necessary, replace the intake manifold. NEXT 34 Go to step 36 REPLACE ECM (a) Replace the ECM (See page ES-432). ES NEXT 35 Go to step 36 REPAIR OR REPLACE PARTS AND COMPONENTS INDICATED BY OUTPUT DTCS (a) Repair the malfunctioning areas indicated by the DTCs that had been confirmed when the vehicle was brought in. NEXT 36 Go to step 36 PERFORM EVAP SYSTEM CHECK (AUTO OPERATION) NOTICE: • The EVAP SYSTEM CHECK (AUTO OPERATION) consists of 5 steps performed automatically by the intelligent tester. It takes a maximum of approximately 18 minutes. • Do not perform the EVAP SYSTEM CHECK when the fuel tank is more than 90% full because the cut-off valve may be closed, making the fuel tank leak check unavailable. • Do not run the engine in this step. • When the temperature of the fuel is 35°C (95°F) or more, a large amount of vapor forms and any check results become inaccurate. When performing an EVAP SYSTEM CHECK, keep the temperature below 35°C (95°F). (a) Clear the DTCs (See page ES-38). (b) On the intelligent tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION. (c) After the SYSTEM CHECK is completed, check for pending DTCs by selecting the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. HINT: If no pending DTCs are found, the repair has been successfully completed. 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–383 NEXT COMPLETED CONFIRMATION DRIVING PATTERN HINT: After a repair, check Monitor Status by performing the Key-Off Monitor Confirmation and Purge Flow Monitor Confirmation described below. 1. KEY-OFF MONITOR CONFIRMATION (a) Preconditions The monitor will not run unless: • The vehicle has been driven for 10 minutes or more (in a city area or on a freeway) • The fuel tank is less than 90 % full • The altitude is less than 8,000 ft (2,400 m) • The Engine Coolant Temperature (ECT) is between 4.4°C and 35°C (40°F and 95°F) • The Intake Air Temperature (IAT) is between 4.4°C and 35°C (40°F and 95°F) • The vehicle remains stationary (the vehicle speed is 0 mph (0 km/h)) (b) Monitor Conditions 1. Allow the engine to idle for at least 5 minutes. 2. Turn the ignition switch off and wait for 6 hours (8 or 10.5 hours). HINT: Do not start the engine until checking MONITOR STATUS. If the engine is started, the steps described above must be repeated. (c) Monitor Status 1. Connect the intelligent tester to the DLC3. 2. Turn the ignition switch to the ON position and turn the tester on. 3. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / MONITOR STATUS. 4. Check the Monitor Status displayed on the tester. HINT: If INCMP is displayed, the monitor is not complete. Make sure that the preconditions have been met, and perform the Monitor Conditions again. 2. PURGE FLOW MONITOR CONFIRMATION (P0441) HINT: Perform this monitor confirmation after the Key-Off Monitor Confirmation shows COMPL (complete). (a) Preconditions The monitor will not run unless: • The vehicle has been driven for 10 minutes or more (in a city area or on a freeway) • The ECT is between 4.4°C and 35°C (40°F and 95°F) • The IAT is between 4.4°C and 35°C (40°F and 95°F) (b) Monitor Conditions 1. Release the pressure from the fuel tank by removing and reinstalling the fuel cap. 2. Warm the engine up until the ECT reaches more than 75°C (167°F). 3. Increase the engine speed to 3,000 rpm once. 4. Allow the engine to idle and turn A/C ON for 1 minute. (c) Monitor Status 1. Turn the ignition switch off (if ON or the engine is running). 2. Connect the intelligent tester to the DLC3. 3. Turn the ignition switch to the ON position and turn the tester on. 4. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / MONITOR STATUS. 5. Check the Monitor Status displayed on the tester. HINT: If INCMP is displayed, the monitor is not complete. Make sure that the preconditions have been met, and perform the Monitor Conditions again. ES ES–384 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-20). ES ES–385 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ECM Power Source Circuit DESCRIPTION When the ignition switch is turned ON position, the battery voltage is applied to IGSW of the ECM. The output signal from the MREL terminal of the ECM causes a current to flow to the coil, closing the contacts of the engine room J/B (EFI relay) and supplying power to either terminal +B or +B2 of the ECM. WIRING DIAGRAM E23 Ignition SW ECM ST/AM2 IGN 5 AM2 EFI MAIN FL MAIN Battery IG2 6 ES 28 A24 IGSW 2 A24 +B EFI EFI No. 2 1 A24 +B2 44 A24 MREL 104 C24 E1 A132300E02 ES–386 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (ECM - BODY GROUND) (a) Disconnect the C24 ECM connector. (b) Measure the resistance. Standard resistance Wire Harness Side: C24 ECM Connector Tester Connection Specified Condition C24-104 (E1) - Body ground Below 1 Ω (c) Reconnect the ECM connector. NG ES REPAIR OR REPLACE HARNESS OR CONNECTOR E1 A107892E79 OK 2 INSPECT ENGINE ROOM J/B (EFI RELAY VOLTAGE) (a) (b) (c) (d) Engine Room J/B: Connector Side: Remove the engine room J/B from the engine room R/B. Disconnect the 1E engine room J/B connector. Turn the ignition switch to the ON position. Measure the voltage between the terminals. Standard voltage Tester Connection Specified Condition 1E-12 - Body ground 9 to 14 V (e) Reconnect the engine room J/B connector. (f) Reinstall the engine room J/B. 1E OK Engine Room R/B: A138922E01 Go to step 4 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–387 NG 3 INSPECT FUSE (EFI MAIN FUSE) EFI MAIN Engine Room R/B: (a) Inspect the EFI MAIN fuse. (1) Remove the EFI MAIN fuse from the engine room R/B. (2) Measure the EFI MAIN fuse resistance. Standard resistance: Below 1 Ω (3) Reinstall the EFI MAIN fuse. NG REPLACE FUSE (EFI MAIN FUSE) A137446E01 OK CHECK AND REPAIR HARNESS AND CONNECTOR (BATTERY - EFI RELAY) 4 INSPECT ENGINE ROOM J/B (EFI RELAY) (a) Remove the engine room J/B from the engine room R/B. (b) Inspect the EFI relay. (1) Measure the EFI relay resistance. Standard resistance Engine Room J/B: Tester Connection Specified Condition 10 kΩ or higher 1E-6 - 1E-12 1E (c) Reinstall the engine room J/B. NG Engine Room R/B: A138918E01 OK Below 1 Ω (Apply battery voltage between terminals 1E-9 and 1E-11) REPLACE ENGINE ROOM J/B ES ES–388 5 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT FUSE (EFI NO. 2 FUSE) Engine Room R/B: (a) Inspect the EFI No. 2 fuse. (1) Remove the EFI No. 2 fuse from the engine room R/ B. (2) Measure the EFI No. 2 fuse resistance. Standard resistance: Below 1 Ω (3) Reinstall the EFI No. 2 fuse. NG ES REPLACE FUSE (EFI NO. 2 FUSE) EFI No. 2 A135067E01 OK 6 CHECK HARNESS AND CONNECTOR (EFI RELAY - ECM) (a) Disconnect the A24 ECM connector. Wire Harness Side: A24 ECM Connector +B2 +B Front View A115671E24 ES–389 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (b) Remove the engine room J/B from the engine room R/B. (c) Disconnect the 1E engine room J/B connector. (d) Measure the resistance between the terminals. Standard resistance (Check for open) Engine Room J/B: Connector Side: Tester Connection Specified Condition A24-2 (+B) - 1E-6 Below 1 Ω A24-1 (+B2) - 1E-6 Below 1 Ω Standard resistance (Check for short) 1E Tester Connection Specified Condition A24-2 (+B) or 1E-6 - Body ground 10 kΩ or higher A24-1 (+B2) or 1E-6 - Body ground 10 kΩ or higher ES (e) Reconnect the ECM connector. (f) Reconnect the engine room J/B connector. (g) Reinstall the engine room J/B. NG Engine Room R/B: REPAIR OR REPLACE HARNESS OR CONNECTOR A138922E01 OK 7 INSPECT ECM (IGSW VOLTAGE) (a) Disconnect the A24 and C24 ECM connectors. (b) Turn the ignition switch to the ON position. (c) Measure the voltage between the terminals of the A24 and C24 ECM connectors. Standard voltage Wire Harness Side: C24 ECM Connector Tester Connection Specified Condition A24-28 (IGSW) - C24-104 (E1) 9 to 14 V (d) Reconnect the ECM connectors. Front View A24 OK E1 ECM Connector IGSW Front View A107934E16 Go to step 10 ES–390 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NG 8 INSPECT FUSE (IGN FUSE) (a) Remove the IGN fuse from the instrument panel J/B. (b) Measure the fuse resistance. Standard resistance: Below 1 Ω (c) Reinstall the fuse. Instrument Panel J/B: NG ES REPLACE FUSE (IGN FUSE) IGN A135169E01 OK 9 INSPECT IGNITION SWITCH ASSEMBLY (a) Disconnect the E23 ignition switch connector. (b) Measure the resistance between the terminals. Standard resistance Component Side: A056879E35 Tester Connection Ignition Switch Position Specified Condition All Terminals LOCK 10 kΩ or higher 2-4 ACC 1 - 2 - 4, 5 - 6 ON 1 - 3 - 4, 5 - 6 - 7 START Below 1 Ω (c) Reconnect the ignition switch connector. NG OK REPAIR OR REPLACE HARNESS OR CONNECTOR REPLACE IGNITION SWITCH ASSEMBLY ES–391 2AZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 10 CHECK HARNESS AND CONNECTOR (EFI RELAY - ECM, EFI RELAY - BODY GROUND) (a) Disconnect the A24 ECM connector. Wire Harness Side: A24 ECM Connector ES MREL Front View A115671E25 (b) Remove the engine room J/B from the engine room R/B. (c) Disconnect the 1E engine room J/B connector. (d) Measure the resistance between the terminals. Standard resistance (Check for open) Engine Room J/B: Connector Side: Tester Connection Specified Condition A24-44 (MREL) - 1E-9 Below 1 Ω 1E-11 - Body ground Below 1 Ω Standard resistance (Check for short) 1E Tester Connection Specified Condition A24-44 (MREL) or 1E-9 - Body ground 10 kΩ or higher (e) Reconnect the ECM connector. (f) Reconnect the engine room J/B connector. (g) Reinstall the engine room J/B. NG Engine Room R/B: A138922E01 OK REPLACE ECM REPAIR OR REPLACE HARNESS OR CONNECTOR 2AZ-FE INTAKE – INTAKE AIR CONTROL SYSTEM IT–1 INTAKE AIR CONTROL SYSTEM 2AZ-FE INTAKE ENGINE PARTS LOCATION for PZEV: INTAKE AIR CONTROL VALVE IT A135059E06 IT–2 2AZ-FE INTAKE – INTAKE AIR CONTROL SYSTEM SYSTEM DIAGRAM C33 INTAKE AIR CONTROL VALVE VCIA IACA EIA IAC+ IT IAC- ECM 3 B 103 C24 VCIA 1 B-W 93 C24 IACA 2 L 126 C24 EIA 5 W 9 CA2 L 4 G 19 CA2 W 33 A24 IAC+ A24 IAC- A135688E02 2AZ-FE INTAKE – INTAKE AIR CONTROL SYSTEM IT–3 ON-VEHICLE INSPECTION 1. (3) (4) (5) (6) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG). Turn the tester on. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / INTAKE CTL VSV1. Press the right or left button. (7) Make sure that a clicking sound is heard from the intake air control valve when current flows. If the result is not as specified, replace the intake air surge tank. Intelligent Tester DLC3 INSPECT INTAKE AIR CONTROL VALVE ASSEMBLY (a) Inspection procedure when using the intelligent tester: (1) Warm up the engine. (2) Stop the engine. CAN VIM C131977E05 IT IT–4 2AZ-FE INTAKE – INTAKE AIR CONTROL VALVE INTAKE AIR CONTROL VALVE 2AZ-FE INTAKE ENGINE COMPONENTS 9.0 (92, 80 in.*lbf) AIR CLEANER CAP SUB-ASSEMBLY NO. 1 ENGINE COVER SUB-ASSEMBLY AIR CLEANER INLET ASSEMBLY 5.0 (51, 44 in.*lbf) IT 5.0 (51, 44 in.*lbf) AIR CLEANER CASE SUB-ASSMEBLY N*m (kgf*cm, ft.*lbf) : Specified torque A128948E02 IT–5 2AZ-FE INTAKE – INTAKE AIR CONTROL VALVE FRONT WIPER ARM AND BLADE ASSEMBLY RH 20 (204, 15) FRONT FENDER TO COWL SIDE SEAL RH FRONT WIPER ARM AND BLADE ASSEMBLY LH COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 7.5 (77, 66 in.*lbf) 85 (867, 63) FRONT FENDER TO COWL SIDE SEAL LH 5.0 (51, 44 in.*lbf) WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY IT COWL TOP PANEL OUTER SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque A136912E06 IT–6 2AZ-FE INTAKE – INTAKE AIR CONTROL VALVE INTAKE AIR SURGE TANK ASSEMBLY 30 (306, 22) x2 x5 INTAKE AIR CONTROL VALVE GASKET IT FUEL INJECTOR CONNECTOR 20 (205, 15) FUEL MAIN TUBE NO. 1 DELIVERY PIPE SPACER INJECTOR VIBRATION INSULATOR N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A135660E04 2AZ-FE INTAKE – INTAKE AIR CONTROL VALVE IT–7 REMOVAL 1. REMOVE INTAKE AIR SURGE TANK ASSEMBLY HINT: (See page ES-510) 2. REMOVE INTAKE AIR CONTROL VALVE (a) Remove the intake air control valve. A135692 INSPECTION 1. 5 (IAC+) 4 (IAC-) INSPECT INTAKE AIR CONTROL VALVE (a) Inspection procedure when applying voltage between the terminals: (1) Apply battery voltage between terminals 4 (IAC+) and 5 (IAC-) of the intake air control valve. The actuator should continue to keep the valve open. IT A135693E01 INSTALLATION A135692 1. INSTALL INTAKE AIR CONTROL VALVE (a) Install the intake air control valve. 2. INSTALL INTAKE AIR SURGE TANK ASSEMBLY HINT: (See page ES-511) INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD IP–1 INSTRUMENT PANEL SAFETY PAD PRECAUTION 1. 2. Code Shape PRECAUTION FOR VEHICLE WITH SRS AIRBAG AND SEAT BELT PRETENSIONER (a) Some operations in this section may affect the SRS airbags. Prior to performing the corresponding operations, read the SRS airbag NOTICE. TABLE OF BOLT, SCREW AND NUT Size Parts No. φ=6 mm (0.24 in.) Length=20 mm (0.79 in.) 90119-06166 φ=5 mm (0.20 in.) Length=16 mm (0.63 in.) 93567-55016 φ=6 mm (0.24 in.) Length=20 mm (0.79 in.) 90159-60610 φ=5 mm (0.20 in.) Length=15 mm (0.59 in.) 90164-50034 φ=5 mm (0.20 in.) Length=20 mm (0.79 in.) 93567-15020 φ=5 mm (0.20 in.) Length=16 mm (0.63 in.) 93567-15016 φ=6 mm (0.24 in.) Length=16 mm (0.63 in.) 90119-06480 IP IP–2 Code IP INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD Shape Size Parts No. φ=6 mm (0.24 in.) Length=18 mm (0.71 in.) 90119-06428 φ=6 mm (0.24 in.) 90179-06206 φ=6 mm (0.24 in.) Length=15 mm (0.59 in.) 90119-06915 φ=8 mm (0.31 in.) Length=20 mm (0.79 in.) 91633-60820 φ=5 mm (0.20 in.) Length=16 mm (0.63 in.) 90159-50305 φ=5 mm (0.20 in.) Length=16 mm (0.63 in.) 93565-15016 φ=6 mm (0.24 in.) Length=18 mm (0.71 in.) 90080-11664 φ=5 mm (0.20 in.) Length=16 mm (0.63 in.) 90080-16097

φ=5 mm (0.20 in.) Length=22 mm (0.87 in.) 90159-A0006 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD Code Shape Size Parts No. φ=5 mm (0.20 in.) Length=15 mm (0.59 in.) 90080-16106 φ=5 mm (0.20 in.) Length=20 mm (0.79 in.) 90167-A0001 φ=6 mm (0.24 in.) Length=16 mm (0.63 in.) 90080-11717 φ=6 mm (0.24 in.) Length=16 mm (0.63 in.) 90080-11736 φ=6 mm (0.24 in.) 90080-18071 φ=8 mm (0.31 in.) Length=20 mm (0.79 in.) 90119-A0011 φ=5 mm (0.20 in.) Length=16 mm (0.63 in.) 90159-A0021 φ=5 mm (0.20 in.) Length=14 mm (0.55 in.) 90167-A0005 φ=6 mm (0.24 in.) Length=15 mm (0.59 in.) 90080-11545 IP–3 IP IP–4 Code IP INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD Shape Size Parts No. φ=6 mm (0.24 in.) 90179-06115 φ=6 mm (0.24 in.) Length=20 mm (0.79 in.) 90084-10051 φ=6 mm (0.24 in.) Length=16 mm (0.63 in.) 90080-10171 IP–5 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD COMPONENTS for TMC Made: TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY IP 2.0 (20, 18 in.*lbf) STEERING COLUMN COVER 50 (510, 37) STEERING WHEEL ASSEMBLY LOWER NO. 2 STEERING WHEEL COVER LOWER NO. 3 STEERING WHEEL COVER 8.8 (90, 78 in.*lbf) STEERING PAD N*m (kgf*cm, ft.*lbf) : Specified torque B137279E01 IP–6 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD for TMMK Made: IP TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY 2.0 (20, 18 in.*lbf) STEERING COLUMN COVER for 4 Spoke: 50 (510, 37) STEERING WHEEL ASSEMBLY LOWER NO. 2 STEERING WHEEL COVER LOWER NO. 3 STEERING WHEEL COVER STEERING PAD 8.8 (90, 78 in.*lbf) for 3 Spoke: STEERING WHEEL ASSEMBLY 50 (510, 37) LOWER NO. 2 STEERING WHEEL COVER LOWER NO. 3 STEERING WHEEL COVER STEERING PAD 8.8 (90, 78 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque B137280E01 IP–7 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD for TMC Made: COMBINATION METER ASSEMBLY IP INSTRUMENT CLUSTER FINISH PANEL without Smart Key System: LOWER INSTRUMENT PANEL FINISH PANEL with Smart Key System: NO. 1 INSTRUMENT PANEL SUB-ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL COWL SIDE TRIM SUB-ASSEMBLY LH COWL SIDE TRIM CLIP LOWER INSTRUMENT PANEL FINISH PANEL LH FRONT DOOR SCUFF PLATE LH B137281E01 IP–8 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD for TMMK Made: COMBINATION METER ASSEMBLY IP INSTRUMENT CLUSTER FINISH PANEL without Smart Key System: LOWER INSTRUMENT PANEL FINISH PANEL with Smart Key System: NO. 1 INSTRUMENT PANEL SUB-ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL COWL SIDE TRIM SUB-ASSEMBLY LH COWL SIDE TRIM CLIP or

LOWER INSTRUMENT PANEL FINISH PANEL LH FRONT DOOR SCUFF PLATE LH B137281E03 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD IP–9 for TMC Made: LOWER INSTRUMENT PANEL SUB-ASSEMBLY IP or COWL SIDE TRIM SUB-ASSEMBLY RH COWL SIDE TRIM CLIP FRONT DOOR SCUFF PLATE RH INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY B137282E01 IP–10 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD for TMMK Made: LOWER INSTRUMENT PANEL SUB-ASSEMBLY IP or

COWL SIDE TRIM SUB-ASSEMBLY RH COWL SIDE TRIM CLIP FRONT DOOR SCUFF PLATE RH INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY B137282E03 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD IP–11 NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH IP NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH for Automatic Transaxle: SHIFT LEVER KNOB SUB-ASSEMBLY FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY UPPER CONSOLE REAR PANEL SUB-ASSEMBLY for Manual Transaxle: SHIFT LEVER KNOB SUB-ASSEMBLY UPPER CONSOLE PANEL UPPER CONSOLE REAR PANEL SUB-ASSEMBLY B137283E01 IP–12 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD for TMC Made: INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY IP without Navigation System: RADIO RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY with Navigation System: NAVIGATION RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY UPPER CONSOLE PANEL SUB-ASSEMBLY B137284E01 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD IP–13 for TMMK Made: INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY IP without Navigation System: RADIO RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY with Navigation System: NAVIGATION RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY UPPER CONSOLE PANEL SUB-ASSEMBLY B137284E03 IP–14 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD for TMC Made: FRONT PILLAR GARNISH CLIP FRONT PILLAR GARNISH CLIP FRONT PILLAR GARNISH RH IP FRONT PILLAR GARNISH LH INSTRUMENT PANEL NO. 3 REGISTER ASSEMBLY INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY NO. 1 CONSOLE BOX INSERT FRONT NO. 2 CONSOLE BOX INSERT FRONT CONSOLE BOX CARPET CONSOLE BOX ASSEMBLY CONSOLE BOX POCKET Non-reusable part B137285E01 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD IP–15 for TMMK Made: FRONT PILLAR GARNISH CLIP FRONT PILLAR GARNISH CLIP FRONT PILLAR GARNISH RH IP FRONT PILLAR GARNISH LH INSTRUMENT PANEL NO. 3 REGISTER ASSEMBLY INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY NO. 1 CONSOLE BOX INSERT FRONT or or NO. 2 CONSOLE BOX INSERT FRONT CONSOLE BOX CARPET CONSOLE BOX ASSEMBLY CONSOLE BOX POCKET Non-reusable part B137285E03 IP–16 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD for TMC Made: INSTRUMENT PANEL NO. 1 SPEAKER PANEL SUB-ASSEMBLY INSTRUMENT PANEL NO. 2 SPEAKER PANEL SUB-ASSEMBLY IP NO. 1 DEFROSTER NOZZLE GARNISH for RH Side: for LH Side: FRONT NO. 2 SPEAKER ASSEMBLY FRONT NO. 2 SPEAKER ASSEMBLY or or or 20 (204, 15) or INSTRUMENT PANEL SAFETY PAD ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B137286E01 IP–17 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD for TMMK Made: INSTRUMENT PANEL NO. 1 SPEAKER PANEL SUB-ASSEMBLY INSTRUMENT PANEL NO. 2 SPEAKER PANEL SUB-ASSEMBLY IP NO. 1 DEFROSTER NOZZLE GARNISH for RH Side: for LH Side: FRONT NO. 2 SPEAKER ASSEMBLY FRONT NO. 2 SPEAKER ASSEMBLY , or , or 20 (204, 15) INSTRUMENT PANEL SAFETY PAD ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B137286E03 IP–18 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD for TMC Made: NO. 3 INSTRUMENT PANEL STAY IP GLOVE BOX LIGHT ASSEMBLY with Plasmacluster: DEFROSTER NOZZLE ASSEMBLY NO. 2 HEATER TO REGISTER DUCT PLASMACLUSTER SIDE NO. 2 DEFROSTER NOZZLE DUCT SIDE NO. 1 DEFROSTER NOZZLE DUCT NO. 3 HEATER TO REGISTER DUCT NO. 1 HEATER TO REGISTER DUCT with Navigation System: FRONT PASSENGER AIRBAG ASSEMBLY NO. 2 ANTENNA CORD SUB-ASSEMBLY NAVIGATION ANTENNA ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque 7.0 (71, 62 in.*lbf) B137288E01 IP–19 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD for TMMK Made: NO. 3 INSTRUMENT PANEL STAY NO. 3 INSTRUMENT PANEL STAY IP NO. 1 INSTRUMENT PANEL PIN GLOVE BOX LIGHT ASSEMBLY with Plasmacluster: DEFROSTER NOZZLE ASSEMBLY SIDE NO. 2 DEFROSTER NOZZLE DUCT PLASMACLUSTER NO. 2 HEATER TO REGISTER DUCT SIDE NO. 1 DEFROSTER NOZZLE DUCT NO. 3 HEATER TO REGISTER DUCT NO. 1 HEATER TO REGISTER DUCT FRONT PASSENGER AIRBAG ASSEMBLY with Navigation system: NO. 2 ANTENNA CORD SUB-ASSEMBLY NAVIGATION ANTENNA ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque 7.0 (71, 62 in.*lbf) B137287E01 IP–20 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD REMOVAL 1. PRECAUTION (See page IP-1) 2. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment (See page RS-1). 4. REMOVE LOWER NO. 3 STEERING WHEEL COVER (See page RS-349) 5. REMOVE LOWER NO. 2 STEERING WHEEL COVER (See page RS-349) 6. REMOVE STEERING PAD (See page RS-350) 7. REMOVE STEERING WHEEL ASSEMBLY (See page SR-38) 8. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-24) 9. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-25) IP 10. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (a) Remove the bolt and the screw . (b) Disconnect the hood lock control cable assembly. (c) Disengage the claw and the 9 clips. (d) Remove the air hose, disconnect the connector, and then remove the lower instrument panel finish panel LH. B133980E05 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD IP–21 11. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (a) Remove the bolt and the screw or

. (b) Disconnect the hood lock control cable assembly. (c) Disengage the claw and the 9 clips. (d) Remove the air hose, disconnect the connector, and then remove the lower instrument panel finish panel LH. IP or

B133980E02 12. REMOVE STEERING COLUMN COVER (for TMC Made) (a) Remove the 2 screws . (b) Disengage the 2 claws and remove the lower steering column cover. (c) Disengage the claw and remove the upper steering column cover. B137294E01 13. REMOVE STEERING COLUMN COVER (for TMMK Made) (a) Remove the 2 screws . (b) Disengage the 2 claws and remove the lower steering column cover. (c) Disengage the claw and remove the upper steering column cover. 14. REMOVE TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY (See page SR-39) B137294E02 IP–22 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD 15. REMOVE NO. 1 INSTRUMENT PANEL SUBASSEMBLY (a) Disengage the 3 claws and the 2 clips. (b) Disconnect the connector and remove the instrument panel sub-assembly. IP B133982 16. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (w/o Smart Key System) (a) Disengage the 2 claws and 2 clips, and then remove the lower instrument panel finish panel. B133983 17. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (w/ Smart Key System) (a) Disengage the 2 claws and 2 clips. (b) Disconnect the connector and remove the lower instrument panel finish panel. B133984 18. REMOVE INSTRUMENT CLUSTER FINISH PANEL (a) Remove the 2 clips. (b) Disengage the guide and 4 claws, and then remove the instrument cluster finish panel. Guide B133985E01 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD IP–23 19. REMOVE COMBINATION METER ASSEMBLY (for TMC Made) (a) Remove the 4 screws . (b) Disconnect each connector and remove the combination meter assembly. IP B133987E01 20. REMOVE COMBINATION METER ASSEMBLY (for TMMK Made) (a) Remove the 4 screws . (b) Disconnect each connector and remove the combination meter assembly. B133987E02 21. REMOVE FRONT DOOR SCUFF PLATE RH (See page IR-26) 22. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH (See page IR-26) 23. REMOVE INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY (a) Disengage the 4 claws. (b) Disengage the 2 guides and remove the No. 2 under cover sub-assembly. Guide B133988E01 24. REMOVE LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMC Made) (a) Remove the bolt . (b) Remove the 4 screws . (c) Disengage the 3 claws and the 3 clips. (d) Disconnect the connector and remove the lower instrument panel sub-assembly. B133992E01 IP–24 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD 25. REMOVE LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMMK Made) (a) Remove the bolt . (b) Remove the screw or

and the 3 screws . (c) Disengage the 3 claws and the 3 clips. (d) Disconnect the connector and remove the lower instrument panel sub-assembly. IP or

B133992E02 26. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle) (a) Turn the shift lever knob counterclockwise and remove the shift lever knob sub-assembly. B133990 27. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) (a) Turn the shift lever knob counterclockwise and remove the shift lever knob sub-assembly. B137272 28. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (a) Disengage the 2 clips and remove the No. 1 instrument cluster finish panel garnish. B133993 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD IP–25 29. REMOVE NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (a) Disengage the 2 clips and remove the No. 2 instrument cluster finish panel garnish. IP B133994 30. REMOVE FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (for Automatic Transaxle) (a) Disengage the 6 claws and the 3 clips, and then remove the floor shift position indicator housing subassembly. (b) with Seat Heater System: (1) Disconnect each connector. B133995 31. REMOVE UPPER CONSOLE PANEL (for Manual Transaxle) (a) Open the lid of the upper console panel. (b) Apply protective tape to the area shown in the illustration. Protective tape B137274E01 IP–26 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD (c) Using a moulding remover, disengage the 2 claws and the 5 clips, and then remove the upper console panel as shown in the illustration. IP B137275E01 32. REMOVE UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Automatic Transaxle) (a) Disengage the 3 claws and the 5 clips. (b) Disengage the clamp. (c) Disconnect the connector and remove the upper console rear panel sub-assembly. Clamp B133996E01 33. REMOVE UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Manual Transaxle) (a) Disengage the 3 claws and the 5 clips. (b) Disconnect the connector and remove the upper console rear panel sub-assembly. B137277 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD IP–27 34. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMC Made) (a) Remove the 2 screws . (b) Disengage the 4 claws. (c) Disconnect each connector and remove the upper console panel sub-assembly. IP B133997E01 35. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMMK Made) (a) Remove the 2 screws . (b) Disengage the 4 claws. (c) Disconnect each connector and remove the upper console panel sub-assembly. B133997E02 36. REMOVE INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY (a) Apply protective tape to the areas shown in the illustration. Protective tape B133998E01 IP–28 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD (b) Using a moulding remover, disengage the 3 clips. IP B133999 (c) Using a moulding remover, disengage the 4 clips. (d) Disconnect the connector and remove the instrument panel No. 2 register assembly. 37. REMOVE RADIO RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY (w/o Navigation System) (See page AV-146) 38. REMOVE NAVIGATION RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY (See page NS-195) 39. REMOVE CONSOLE BOX POCKET (a) Remove the console box pocket. B134000 40. REMOVE CONSOLE BOX CARPET (a) Remove the console box carpet. B134004 41. REMOVE CONSOLE BOX ASSEMBLY (for TMC Made) (a) Remove the 2 screws . B134002E01 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD IP–29 (b) Remove the 2 bolts and the console box assembly. IP B134003E01 42. REMOVE CONSOLE BOX ASSEMBLY (for TMMK Made) (a) Remove the 2 screws . B134002E02 (b) Remove the 2 bolts or and the console box assembly. or or B134003E02 43. REMOVE NO. 2 CONSOLE BOX INSERT FRONT (for TMC Made) (a) Remove the 3 screws . (b) Disengage the clip and remove the No. 2 console box insert front. B134005E01 IP–30 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD 44. REMOVE NO. 2 CONSOLE BOX INSERT FRONT (for TMMK Made) (a) Remove the 3 screws . (b) Disengage the clip and remove the No. 2 console box insert front. IP B134005E02 45. REMOVE NO. 1 CONSOLE BOX INSERT FRONT (for TMC Made) (a) Remove the 3 screws . (b) Disengage the clip and remove the No. 1 console box insert front. B134006E01 46. REMOVE NO. 1 CONSOLE BOX INSERT FRONT (for TMMK Made) (a) Remove the 3 screws . (b) Disengage the clip and remove the No. 1 console box insert front. 47. REMOVE FRONT PILLAR GARNISH LH (See page IR27) B134006E02 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD IP–31 48. REMOVE INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY (a) Disengage the 4 clips and remove the instrument panel No. 1 register assembly. IP B134007 49. REMOVE INSTRUMENT PANEL NO. 1 SPEAKER PANEL SUB-ASSEMBLY (a) Disengage the 6 claws and the 2 clips. (b) Disengage the 2 guides and remove the instrument panel No. 1 speaker panel sub-assembly. 50. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (for LH Side) (See page AV-156) 51. REMOVE FRONT PILLAR GARNISH RH (See page IR27) Guide B134009E01 52. REMOVE INSTRUMENT PANEL NO. 3 REGISTER ASSEMBLY (a) Disengage the 4 clips and remove the instrument panel No. 3 register assembly. B134008 IP–32 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD 53. REMOVE INSTRUMENT PANEL NO. 2 SPEAKER PANEL SUB-ASSEMBLY (a) Disengage the 6 claws and the 2 clips. (b) Disengage the 2 guides and remove the instrument panel No. 2 speaker panel sub-assembly. 54. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (for RH Side) HINT: Use the same procedures for the RH side and the LH side (See page AV-156). IP Guide B134010E01 55. REMOVE NO. 1 DEFROSTER NOZZLE GARNISH (a) Disengage the 8 clips and the 4 guides. (b) Disconnect each connector and remove the No. 1 defroster nozzle garnish. 56. DISCONNECT INSTRUMENT PANEL WIRE ASSEMBLY (See page RS-393) 57. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY (for TMC Made) (a) Disengage each clamp. (b) Disconnect each connector. (c) Remove the bolt . (d) Remove the 2 passenger airbag bolts . Guide B134011E01 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD IP–33 (e) with "Plasmacluster": (1) Disconnect the connector. IP with “Plasmacluster”: Clamp B134012E01 (f) Remove the 2 bolts or . (g) Remove the 2 nuts or . IP–34 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD (h) Disengage the 5 claws and remove the instrument panel safety pad assembly. IP or or or or B134014E01 58. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY (for TMMK Made) (a) Disengage each clamp. (b) Disconnect each connector. (c) Remove the bolt . (d) Remove the 2 passenger airbag bolts . INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD IP–35 (e) with "Plasmacluster": (1) Disconnect the connector. IP with “Plasmacluster”: Clamp B134012E02 (f) Remove the 2 bolts , or . (g) Remove the 2 nuts . IP–36 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD (h) Disengage the 5 claws and remove the instrument panel safety pad assembly. IP , or , or B134014E02 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD IP–37 59. REMOVE NO. 3 INSTRUMENT PANEL STAY (a) Disengage the claw and remove the 5 No. 3 instrument panel stays. IP B134015 DISASSEMBLY 1. REMOVE SIDE NO. 1 DEFROSTER NOZZLE DUCT (for TMC Made) (a) Remove the screw and the side No. 1 defroster nozzle duct. 2. REMOVE SIDE NO. 1 DEFROSTER NOZZLE DUCT (for TMMK Made) (a) Remove the screw and the side No. 1 defroster nozzle duct. B134016E02 B134016E01 IP–38 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD 3. REMOVE SIDE NO. 2 DEFROSTER NOZZLE DUCT (for TMC Made) (a) Remove the screw and the side No. 2 defroster nozzle duct. 4. REMOVE SIDE NO. 2 DEFROSTER NOZZLE DUCT (for TMMK Made) (a) Remove the screw and the side No. 2 defroster nozzle duct. 5. REMOVE DEFROSTER NOZZLE ASSEMBLY (for TMC Made) (a) Remove the 3 screws and the defroster nozzle assembly. 6. REMOVE DEFROSTER NOZZLE ASSEMBLY (for TMMK Made) (a) Remove the 3 screws and the defroster nozzle assembly. 7. REMOVE NO. 1 HEATER TO REGISTER DUCT (for TMC Made) (a) Remove the 3 screws and the No. 1 heater to register duct. IP B134017E02 B134017E01 B134018E02 B134018E01 B134019E02 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD 8. IP–39 REMOVE NO. 1 HEATER TO REGISTER DUCT (for TMMK Made) (a) Remove the 3 screws and the No. 1 heater to register duct. IP B134019E01 9. REMOVE NO. 3 HEATER TO REGISTER DUCT (for TMC Made) (a) Remove the 3 screws and the No. 3 heater to register duct. B134020E02 10. REMOVE NO. 3 HEATER TO REGISTER DUCT (for TMMK Made) (a) Remove the 3 screws and the No. 3 heater to register duct. B134020E01 11. REMOVE NO. 2 HEATER TO REGISTER DUCT (for TMC Made) (a) Remove the 2 screws and the No. 2 heater to register duct. B134021E02 12. REMOVE NO. 2 HEATER TO REGISTER DUCT (for TMMK Made) (a) Remove the 2 screws and the No. 2 heater to register duct. 13. REMOVE NO. 2 ANTENNA CORD SUB-ASSEMBLY (See page AV-196) 14. REMOVE NAVIGATION ANTENNA ASSEMBLY (See page NS-214) B134021E01 IP–40 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD 15. REMOVE FRONT PASSENGER AIRBAG ASSEMBLY (See page RS-395) 16. REMOVE GLOVE BOX LIGHT ASSEMBLY (a) Disengage the 2 claws and remove the glove box light assembly. 17. REMOVE PLASMACLUSTER (w/ Plasmacluster) (See page AC-276) IP B134022 18. REMOVE NO. 1 INSTRUMENT PANEL PIN (for TMMK Made) (a) Remove the 2 screws and 2 No. 1 instrument panel pins. B137271E01 REASSEMBLY B137271E01 1. INSTALL NO. 1 INSTRUMENT PANEL PIN (for TMMK Made) (a) Install the 2 No. 1 instrument panel pins with the 2 screws . 2. INSTALL PLASMACLUSTER (w/ Plasmacluster) (See page AC-276) INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD IP–41 3. INSTALL GLOVE BOX LIGHT ASSEMBLY (a) Engage the 2 claws and install the glove box light. 4. INSTALL NAVIGATION ANTENNA ASSEMBLY (See page NS-214) 5. INSTALL NO. 2 ANTENNA CORD SUB-ASSEMBLY (See page AV-210) IP B134023 6. INSTALL NO. 2 HEATER TO REGISTER DUCT (for TMC Made) (a) Install the No. 2 heater to register duct with the 2 screws . 7. INSTALL NO. 2 HEATER TO REGISTER DUCT (for TMMK Made) (a) Install the No. 2 heater to register duct with the 2 screws . 8. INSTALL NO. 3 HEATER TO REGISTER DUCT (for TMC Made) (a) Install the No. 3 heater to register duct with the 3 screws . 9. INSTALL NO. 3 HEATER TO REGISTER DUCT (for TMMK Made) (a) Install the No. 3 heater to register duct with the 3 screws . B134021E02 B134021E01 B134020E02 B134020E01 IP–42 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD 10. INSTALL NO. 1 HEATER TO REGISTER DUCT (for TMC Made) (a) Install the No. 1 heater to register duct with the 3 screws . IP B134019E02 11. INSTALL NO. 1 HEATER TO REGISTER DUCT (for TMMK Made) (a) Install the No. 1 heater to register duct with the 3 screws . B134019E01 12. INSTALL DEFROSTER NOZZLE ASSEMBLY (for TMC Made) (a) Install the defroster nozzle assembly with the 3 screws . B134018E02 13. INSTALL DEFROSTER NOZZLE ASSEMBLY (for TMMK Made) (a) Install the defroster nozzle assembly with the 3 screws . B134018E01 B134017E02 14. INSTALL SIDE NO. 2 DEFROSTER NOZZLE DUCT (for TMC Made) (a) Install the side No. 2 defroster nozzle duct with the screw . INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD IP–43 15. INSTALL SIDE NO. 2 DEFROSTER NOZZLE DUCT (for TMMK Made) (a) Install the side No. 2 defroster nozzle duct with the screw . IP B134017E01 16. INSTALL SIDE NO. 1 DEFROSTER NOZZLE DUCT (for TMC Made) (a) Install the side No. 1 defroster nozzle duct with the screw . B134016E02 17. INSTALL SIDE NO. 1 DEFROSTER NOZZLE DUCT (for TMMK Made) (a) Install the side No. 1 defroster nozzle duct with the screw . B134016E01 IP–44 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD INSTALLATION 1. INSTALL NO. 3 INSTRUMENT PANEL STAY (a) Engage the claw and install the 5 No. 3 instrument panel stays. IP B134015 2. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY (for TMC Made) (a) Engage the 5 claws. NOTICE: Do not allow the wire harness to get caught in the claws. INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD IP–45 (b) Install the 2 bolts or and 2 nuts or . IP or or or or B134014E01 (c) Engage each clamp. (d) Install the bolt . Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) (e) Install the 2 passenger airbag bolts . Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) (f) Connect each connector and install the instrument panel safety pad assembly. IP–46 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD (g) with "Plasmacluster": (1) Connect the connector. IP with “Plasmacluster”: Clamp B134012E01 3. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY (for TMMK Made) (a) Engage the 5 claws. NOTICE: Do not allow the wire harness to get caught in the claws. INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD IP–47 (b) Install the 2 bolts , or and 2 nuts . IP , or , or B134014E02 (c) Engage each clamp. (d) Install the bolt . Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) (e) Install the 2 passenger airbag bolts . Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) (f) Connect each connector and install the instrument panel safety pad assembly. IP–48 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD (g) with "Plasmacluster": (1) Connect the connector. IP with “Plasmacluster”: Clamp B134012E02 4. CONNECT INSTRUMENT PANEL WIRE ASSEMBLY (See page RS-398) INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD IP–49 5. INSTALL NO. 1 DEFROSTER NOZZLE GARNISH (a) Connect each connector. (b) Engage the 4 guides. (c) Engage the 8 clips and install the No. 1 defroster nozzle garnish. 6. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (for LH Side) (See page AV-156) IP Guide Guide B134011E01 7. INSTALL INSTRUMENT PANEL NO. 1 SPEAKER PANEL SUB-ASSEMBLY (a) Engage the 2 guides. (b) Engage the 6 claws and the 2 clips to install the instrument panel No. 1 speaker panel subassembly. 8. INSTALL INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY (a) Engage the 4 clips and install the instrument panel No. 1 register assembly. 9. INSTALL FRONT PILLAR GARNISH LH (See page IR51) B134009E01 10. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (for RH Side) HINT: Use the same procedures for the RH side and the LH side (See page AV-156). B134007 IP–50 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD 11. INSTALL INSTRUMENT PANEL NO. 2 SPEAKER PANEL SUB-ASSEMBLY (a) Engage the 2 guides. (b) Engage the 6 claws and the 2 clips to install the instrument panel No. 2 speaker panel subassembly. IP Guide B134010E01 12. INSTALL INSTRUMENT PANEL NO. 3 REGISTER ASSEMBLY (a) Engage the 4 clips and install the instrument panel No. 3 register assembly. 13. INSTALL FRONT PILLAR GARNISH RH (See page IR52) B134008 14. INSTALL NO. 1 CONSOLE BOX INSERT FRONT (for TMC Made) (a) Engage the clip. (b) Install the No. 1 console box insert front with the 3 screws . B134006E01 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD IP–51 15. INSTALL NO. 1 CONSOLE BOX INSERT FRONT (for TMMK Made) (a) Engage the clip. (b) Install the No. 1 console box insert front with the 3 screws . IP B134006E02 16. INSTALL NO. 2 CONSOLE BOX INSERT FRONT (for TMC Made) (a) Engage the clip. (b) Install the No. 2 console box insert front with the 3 screws . B134005E01 17. INSTALL NO. 2 CONSOLE BOX INSERT FRONT (for TMMK Made) (a) Engage the clip. (b) Install the No. 2 console box insert front with the 3 screws . B134005E02 IP–52 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD 18. INSTALL CONSOLE BOX ASSEMBLY (for TMC Made) (a) Install the 2 screws . IP B134002E01 (b) Install the console box assembly with the 2 bolts . B134003E01 19. INSTALL CONSOLE BOX ASSEMBLY (for TMMK Made) (a) Install the 2 screws . B134002E02 (b) Install the console box assembly with the 2 bolts or . or or B134003E02 20. INSTALL CONSOLE BOX CARPET (a) Install the console box carpet. 21. INSTALL CONSOLE BOX POCKET (a) Install the console box pocket. 22. INSTALL RADIO RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY (w/o Navigation System) (See page AV-147) B134004 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD IP–53 23. INSTALL NAVIGATION RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY (w/ Navigation System) (See page NS-196) 24. INSTALL INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY (a) Engage the 7 clips and install the instrument panel No. 2 register assembly. 25. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMC Made) (a) Connect each connector. B134001 (b) Engage the 4 claws. (c) Install the upper console panel sub-assembly with the 2 screws . 26. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMMK Made) (a) Connect each connector. B133997E01 (b) Engage the 4 claws. (c) Install the upper console panel sub-assembly with the 2 screws . B133997E02 IP IP–54 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD 27. INSTALL UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Automatic Transaxle) (a) Connect the connector and engage the clamp. (b) Engage the 3 claws and 5 clips to install the upper console rear panel sub-assembly. IP Clamp B133996E01 28. INSTALL UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Manual Transaxle) (a) Engage the 3 claws and 5 clips to install the upper console rear panel sub-assembly. 29. INSTALL FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (for Automatic Transaxle) (a) with Seat Heater System: (1) Connect each connector. B137277 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD IP–55 (b) Engage the 6 claws and the 3 clips to install the floor shift position indicator housing sub-assembly. IP B133995 30. INSTALL UPPER CONSOLE PANEL (for Manual Transaxle) (a) Engage the 2 claws and the 5 clips to install the upper console panel as shown in the illustration. B137276 31. INSTALL NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (a) Engage the 2 clips and install the No. 2 instrument cluster finish panel garnish. B133994 IP–56 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD 32. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (a) Engage the 2 clips and install the No. 1 instrument cluster finish panel garnish. IP B133993 33. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle) (a) Install the shift lever knob sub-assembly. B133991 34. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) (a) Install the shift lever knob sub-assembly. B137273 35. INSTALL LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMC Made) (a) Engage the 3 claws and 3 clips. (b) Install the 4 screws . (c) Install the lower instrument panel sub-assembly with the bolt . B133992E01 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD IP–57 36. INSTALL LOWER INSTRUMENT PANEL SUBASSEMBLY (for TMMK Made) (a) Engage the 3 claws and 3 clips. (b) Install the screw or

and 3 screws . (c) Install the lower instrument panel sub-assembly with the bolt . or

IP B133992E02 37. INSTALL INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY (a) Engage the 4 claws and 2 guides and install the instrument panel No. 2 under cover. 38. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH (See page IR-55) 39. INSTALL FRONT DOOR SCUFF PLATE RH (See page IR-55) Guide B133989E01 40. INSTALL COMBINATION METER ASSEMBLY (for TMC Made) (a) Connect each connector. (b) Install the combination meter assembly with the 4 screws . B133987E01 41. INSTALL COMBINATION METER ASSEMBLY (for TMMK Made) (a) Connect each connector. (b) Install the combination meter assembly with the 4 screws . B133987E02 IP–58 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD 42. INSTALL INSTRUMENT CLUSTER FINISH PANEL (a) Engage the guide and the 4 claws. (b) Install the instrument cluster finish panel with the 2 clips. IP Guide B133985E01 43. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/o Smart Key System) (a) Engage the 2 claws and 2 clips to install the lower instrument panel finish panel. 44. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/ Smart Key System) (a) Connect the connector. B133983 (b) Engage the 2 claws and 2 clips to install the lower instrument panel finish panel. 45. INSTALL NO. 1 INSTRUMENT PANEL SUBASSEMBLY (a) Connect the connector. B133984 (b) Engage the 3 claws and 2 clips to install the No. 1 instrument panel sub-assembly. 46. INSTALL TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY (See page SR-50) 47. ADJUST SPIRAL CABLE SUB-ASSEMBLY (See page RS-367) B133982 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD IP–59 48. INSTALL STEERING COLUMN COVER (for TMC Made) (a) Engage the claw and install the upper steering column cover. (b) Engage the 2 claws and install the lower steering column cover. (c) Install the steering column cover with the 2 screws . Torque: 2.0 N*m (20 kgf*cm, 18 in.*lbf) IP B137294E01 49. INSTALL STEERING COLUMN COVER (for TMMK Made) (a) Engage the claw and install the upper steering column cover. (b) Engage the 2 claws and install the lower steering column cover. (c) Install the steering column cover with the 2 screws . Torque: 2.0 N*m (20 kgf*cm, 18 in.*lbf) B137294E02 50. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made) (a) Install the air hose and connect the connector. (b) Engage the claw and the 9 clips. (c) Instal the instrument panel finish panel LH with the screw and bolt . B133980E05 IP–60 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD 51. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made) (a) Install the air hose and connect the connector. (b) Engage the claw and the 9 clips. (c) Instal the instrument panel finish panel LH with the screw or

and bolt . 52. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH (See page IR-54) 53. INSTALL FRONT DOOR SCUFF PLATE LH (See page IR-54) IP 54. INSTALL STEERING WHEEL ASSEMBLY (See page SR-51) 55. INSTALL STEERING PAD (See page RS-350) 56. INSTALL LOWER NO. 3 STEERING WHEEL COVER (See page RS-351) or

B133980E02 57. INSTALL LOWER NO. 2 STEERING WHEEL COVER (See page RS-352) 58. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 59. INSPECT STEERING PAD (See page RS-352) 60. INSPECT SRS WARNING LIGHT (RS-32) IP–60 INSTRUMENT PANEL – REAR CONSOLE BOX REAR CONSOLE BOX INSTRUMENT PANEL BODY COMPONENTS for Automatic Transaxle: SHIFT LEVER KNOB SUB-ASSEMBLY IP FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH UPPER CONSOLE REAR PANEL SUB-ASSEMBLY for Manual Transaxle: SHIFT LEVER KNOB SUB-ASSEMBLY NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH UPPER CONSOLE PANEL UPPER CONSOLE REAR PANEL SUB-ASSEMBLY CONSOLE BOX CARPET CONSOLE BOX POCKET CONSOLE BOX ASSEMBLY B137289E01 INSTRUMENT PANEL – REAR CONSOLE BOX IP–61 CONSOLE COMPARTMENT DOOR SUB-ASSEMBLY IP for Manual Air Conditioning System: REAR CONSOLE END PANEL SUB-ASSEMBLY for Automatic Air Conditioning System: REAR CONSOLE END PANEL SUB-ASSEMBLY B137290E01 IP–62 INSTRUMENT PANEL – REAR CONSOLE BOX REMOVAL IP 1. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-24) 2. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) (See page IP-24) 3. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-24) 4. REMOVE NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-25) 5. REMOVE FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-25) 6. REMOVE UPPER CONSOLE PANEL (for Manual Transaxle) (See page IP-25) 7. REMOVE UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Automatic Transaxle) (See page IP26) 8. REMOVE UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Manual Transaxle) (See page IP-26) 9. REMOVE CONSOLE BOX POCKET (See page IP-28) 10. REMOVE CONSOLE BOX CARPET (See page IP-28) 11. REMOVE CONSOLE BOX ASSEMBLY (a) Remove the 2 screws. B134002 (b) Remove the 2 bolts and the console box assembly. B134003 INSTRUMENT PANEL – REAR CONSOLE BOX IP–63 DISASSEMBLY 1. REMOVE REAR CONSOLE END PANEL SUBASSEMBLY (for Manual Air Conditioning System) (a) Disengage the 4 clips and remove the rear console end panel sub-assembly. IP B137268 2. REMOVE REAR CONSOLE END PANEL SUBASSEMBLY (for Automatic Air Conditioning System) (a) Disengage the 4 clips and remove the rear console end panel sub-assembly. 3. REMOVE CONSOLE COMPARTMENT DOOR SUBASSEMBLY (a) Remove the 4 screws and the console compartment door sub-assembly. B137269 B137270 REASSEMBLY 1. B137270 INSTALL CONSOLE COMPARTMENT DOOR SUBASSEMBLY (a) Install the console compartment door sub-assembly with the 4 screws. IP–64 INSTRUMENT PANEL – REAR CONSOLE BOX 2. INSTALL REAR CONSOLE END PANEL SUBASSEMBLY (for Manual Air Conditioning System) (a) Engage the 4 clips and install the rear console end panel sub-assembly. 3. INSTALL REAR CONSOLE END PANEL SUBASSEMBLY (for Automatic Air Conditioning System) (a) Engage the 4 clips and install the rear console end panel sub-assembly. IP B137268 B137269 INSTALLATION 1. INSTALL CONSOLE BOX ASSEMBLY (a) Install the 2 screws. B134002 (b) Install the console box assembly with the 2 bolts. B134003 2. INSTALL CONSOLE BOX CARPET (See page IP-51) 3. INSTALL CONSOLE BOX POCKET (See page IP-51) 4. INSTALL UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Automatic Transaxle) (See page IP53) 5. INSTALL UPPER CONSOLE REAR PANEL SUBASSEMBLY (for Manual Transaxle) (See page IP-53) INSTRUMENT PANEL – REAR CONSOLE BOX IP–65 6. INSTALL FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (See page IP-53) 7. INSTALL UPPER CONSOLE PANEL (for Manual Transaxle) (See page IP-54) 8. INSTALL NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-54) 9. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH (See page IP-55) 10. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle) (See page IP-55) 11. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) (See page IP-55) IP EX–1 2AZ-FE EXHAUST – EXHAUST PIPE EXHAUST PIPE 2AZ-FE EXHAUST ENGINE COMPONENTS HEATED OXYGEN SENSOR 44 (449, 32) GASKET FRONT EXHAUST PIPE ASSEMBLY 43 (438, 32) 33 (337, 24) REAR EXHAUST PIPE NO. 1 SUPPORT BRACKET FRONT EXHAUST PIPE NO. 1 SUPPORT BRACKET GASKET 43 (438, 32) 33 (337, 24) EXHAUST PIPE SUPPORT NO. 4 43 (438, 32) GASKET EXHAUST PIPE SUPPORT NO. 4 CENTER EXHAUST PIPE ASSEMBLY EXHAUST PIPE SUPPORT NO. 4 EXHAUST PIPE SUPPORT NO. 4 EX EXHAUST PIPE SUPPORT NO. 4 43 (438, 32) EXHAUST PIPE SUPPORT NO. 4 TAIL PIPE ASSEMBLY TAIL PIPE ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque EXHAUST PIPE SUPPORT NO. 4 Non-reusable part A135662E01 EX–2 2AZ-FE EXHAUST – EXHAUST PIPE REMOVAL 1. REMOVE TAIL PIPE ASSEMBLY (a) Remove the 2 nuts and tail pipe assembly. A135689E01 (b) Remove the gasket from the center exhaust pipe. 2. REMOVE CENTER EXHAUST PIPE ASSEMBLY (a) Remove the 2 bolts, 2 nuts and center exhaust pipe assembly. EX A135690E01 (b) Remove the gasket from the front exhaust pipe. 2AZ-FE EXHAUST – EXHAUST PIPE 3. EX–3 REMOVE FRONT EXHAUST PIPE ASSEMBLY (a) Remove the 2 nuts. A135691 (b) Remove the 2 nuts, front exhaust pipe No. 1 support bracket and front exhaust pipe assembly. (c) Remove the gasket from the exhaust manifold. 4. REMOVE HEATED OXYGEN SENSOR (See page EC24) 5. REMOVE REAR EXHAUST PIPE NO. 1 SUPPORT BRACKET (a) Remove the 2 bolts and rear support bracket. Bracket A132948E01 INSTALLATION Pipe Assembly Front 1. INSTALL REAR EXHAUST PIPE NO. 1 SUPPORT BRACKET (a) Install the rear support bracket with the 2 bolts. Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf) NOTICE: Be sure to install the bracket in the correct direction. 2. INSTALL HEATED OXYGEN SENSOR (See page EC24) 3. INSTALL FRONT EXHAUST PIPE ASSEMBLY (a) Install a new gasket onto the front exhaust pipe assembly. Bracket A060823E04 EX EX–4 2AZ-FE EXHAUST – EXHAUST PIPE (b) Install the front exhaust pipe assembly with the 2 nuts. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) A135691 (c) Install the front exhaust pipe No. 1 support bracket with the 2 nuts . Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf) 4. EX INSTALL CENTER EXHAUST PIPE ASSEMBLY (a) Install a new gasket onto the front exhaust pipe. (b) Install the center exhaust pipe assembly with the 2 bolts and 2 nuts. A135690E01 2AZ-FE EXHAUST – EXHAUST PIPE EX–5 Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 5. INSTALL TAIL PIPE ASSEMBLY (a) Install a new gasket onto the tail pipe assembly. (b) Install the tail pipe assembly with the 2 nuts. A135689E01 Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 6. CHECK FOR EXHAUST GAS LEAKS If gas is leaking, tighten the areas necessary to stop the leak. Replace the damaged parts as necessary. EX